SECTION 1

BODY

CONTENTS OF THIS SECTION


Figure Index
General Description
Body Lubrication
Service Operations and Adjustments
Electric Regulators and Seat Adjuster
Convertible Top System
Keys and Locks
Care of Trim
Assembly Manual

Body by Fisher Service News Volume 1
Body by Fisher Service News Volume 2

Figure Index



1955 FIGURE INDEX

Fig. 1 - Transmission Cable Adjustment
Fig. 2 - Vacuum Wiper Motor
Fig. 3 - Auxiliary Drive Drums
Fig. 4 - Wiper Transmission
Fig. 5 - Cowl Side Drain Gutter
Fig. 6 - Air Intake Louver Panel
Fig. 7 - Windshield Garnish Moldings
Fig. 8 - Windshield Reveal Moldings
Fig. 9 - Convertible Reveal Moldings
Fig. 10 - Reveal Molding Clips
Fig. 11 - Loosening Windshield Channel
Fig. 12 - Windshield Body Opening Check
Fig. 13 - Windshield to Body Clearance
Fig. 14 - Windshield Drain Gutter
Fig. 15 - Convertible Reveal Molding Cutout
Fig. 16 - Cord in Pinchweld Cavity
Fig. 17 - Installing Lip of Rubber
Fig. 18 - Instrument Panel Compartment
Fig. 19 - Sedan Door Inner Panel
Fig. 20 - Sedan Door Electric Lift Inner Panel
Fig. 21 - Electric Lift Master Switch
Fig. 22 - Door Window
Fig. 23 - Door Window Adjustment
Fig. 24 - Door Window Regulator
Fig. 25 - Door Weatherstrip Installation
Fig. 26 - Front Door Weatherstrip Location
Fig. 27 - Rear Door Weatherstrip Location
Fig. 28 - Front Door Hinge Pillar Weatherstrip
Fig. 29 - Rotary Lock Parts
Fig. 30 - Rotary Lock Parts
Fig. 31 - Door Lock Remote Control
Fig. 32 - Door Lock Striker
Fig. 33 - Rotary Lock and Engagement Check
Fig. 34 - Front Door Hinge
Fig. 35 - Hinge Sealing
Fig. 36 - Door Inner Panel Seals - Four-Door Sedans
Fig. 37 - Door Inner Panel Seals - Two-Door Sedans
Fig. 38 - Body Mounting Bolts
Fig. 39 - Door to Pillar Clearances
Fig. 40 - Ventilator Regulator
Fig. 41 - Ventilator Adjustment
Fig. 42 - Ventilator Removal
Fig. 43 - Door Handle Outside Attachment
Fig. 44 - Door Handle Exploded
Fig. 45 - Door Lock Cylinder
Fig. 46 - Door Lock Cylinder Exploded
Fig. 47 - Convertible Door Inner Panel
Fig. 48 - Convertible Door Electric Lift Inner Panel
Fig. 49 - Door Weatherstrip Installation
Fig. 50 - Convertible Door Ventilator
Fig. 51 - Convertible Regulator
Fig. 52 - Convertible Door Window
Fig. 53 - Mechanical Sealing Strip
Fig. 54 - Sealing Mechanical Sealing Strip
Fig. 55 - Convertible Door Inner Panel Sealing
Fig. 56 - Rear Door Inner Panel
Fig. 57 - Rear Door Electric Lift Inner Panel
Fig. 58 - Rear Door Hinge Sealing
Fig. 59 - Rear Door Hinge Plate Sealing
Fig. 60 - Rear Door Lock and Remote Control
Fig. 61 - Adjusting Lock to Free-Wheeling
Fig. 62 - Free-Wheeling Control Rod
Fig. 63 - Rear Door Assembly
Fig. 64 - Rear Door Inner Panel Sealing
Fig. 65 - Back Window Cross Section
Fig. 66 - Back Window Sealing
Fig. 67 - Torsion Rods Cover
Fig. 68 - Disengaging Torsion Rod
Fig. 69 - Torsion Rod Adjusting Positions
Fig. 70 - Rear Compartment Lid Lock
Fig. 71 - Rear Compartment Weatherstrip
Fig. 72 - Rear Compartment Lid Hinge Shimming
Fig. 73 - Rear Compartment Bolt and Striker Check
Fig. 74 - Rear Compartment Lid Clearances
Fig. 75 - Back Window Gutter Drain
Fig. 76 - Rear Quarter Window
Fig. 77 - Rear Quarter Window Sport Coupe
Fig. 78 - Rear Quarter Window Adjustments
Fig. 79 - Rear Quarter Window Electric Regulator
Fig. 80 - Rear Quarter Window Guides
Fig. 81 - Rear Quarter Window Sealing Strip
Fig. 82 - Convertible Rear Quarter Window
Fig. 83 - Rear Quarter Window Electric Window Regulator
Fig. 84 - Front Seat Construction
Fig. 85 - Front Seat Side Panels
Fig. 86 - Front Seat Regulator Switch
Fig. 87 - Front Seat Electric Regulator
Fig. 88 - Seat Adjuster Tensioner Spring
Fig. 89 - Tilting Seat Back Removal
Fig. 90 - Seat Solid Back Removal
Fig. 91 - Seat back of Trim
Fig. 92 - Headlining Installation
Fig. 93 - Exterior Molding-Four Door Styles
Fig. 94 - Exterior Molding-Two Door Styles
Fig. 95 - Exterior Molding-Convertible Style
Fig. 96 - Exterior Molding-Sport Coupe Style
Fig. 97 - Electric Window Regulator
Fig. 98 - Wiring Diagram Electric Windows and Seat
Fig. 99 - Checking Door Switch
Fig. 100 - Checking Door Switch
Fig. 101 - Checking Switch to Motor Leads
Fig. 102 - Checking Motor Operation
Fig. 103 - Side Roof Rail Weatherstrip
Fig. 104 - Front Roof Rail Corner Brace
Fig. 105 - Sunshade Support and Handle Striker
Fig. 106 - Top Linkage Adjusting Points
Fig. 107 - Hydro-Lectric Layout
Fig. 108 - Reservoir Fill Line
Fig. 109 - Motor and Pump Removal
Fig. 110 - Lift Cylinder Removal
Fig. 111 - Checking Folding Top Switch
Fig. 112 - Checking Switch to Motor Leads
Fig. 113 - Checking Hydraulic Pressures
Fig. 114 - Adjusting Pump Pressure
Fig. 115 - Slide Bar Lock
Fig. 116 - Tumbler Requirement Diagram
Fig. 117 - Inserting Tumblers
Fig. 118 - Checking with Code
Fig. 119 - Inserting Tumbler Springs
Fig. 120 - Inserting Spring Retainer


Body Wiring Diagrams:


Fig. 122 - Convertible Wiring Diagram
Fig. 123 - Four Door Sedan Wiring Diagram
Fig. 124 - Sport Coupe Wiring Diagram
Fig. 125 - Two Door Sedan Wiring Diagram


1956 FIGURE INDEX

Fig. 1 - Transmission Cable Installation
Fig. 2 - Electric Wiper Motor
Fig. 3 - Electric Wiper Motor Switch
Fig. 4 - Cowl Ventilating System
Fig. 5 - Cowl Side Drain Gutter
Fig. 6 - Windshield Reveal Moldings
Fig. 7 - Convertible Reveal Moldings
Fig. 8 - Sealing Windshield Reveal Moldings
Fig. 10 - Sealing Front and Rear Door Weatherstrip
Fig. 11 - Caulking Lock Frame
Fig. 13 - Convertible and Sport Coupe Door Weatherstrip
Fig. 14 - Nomad Side Roof Rail Weatherstrip
Fig. 15 - Rear Door Assembly-Standard Sedan
Fig. 16 - Rear Door Inner Panel Sealing-Standard Sedan
Fig. 41 - Back Window Assembly-Standard Sedan
Fig. 42 - Back Window Reveal Moldings-Standard Sedan
Fig. 43 - Back Window Assembly-Sport Sedan
Fig. 44 - Back Window Reveal Moldings-Sport Sedan
Fig. 45 - Removing Reveal Molding
Fig. 46 - Installation of Reveal Moldings
Fig. 47 - Rear Quarter Trim-4 Door Station Wagon
Fig. 48 - Rear Quarter Window Installation-4 Door
Fig. 49 - Rear Quarter Trim-2 Door Station Wagon
Fig. 50 - Rear Quarter Window Installation-2 Door Station Wagon
Fig. 51 - Inside Side Panel Moldings-Sedan Delivery
Fig. 52 - Rear Quarter Inner Panel Sealing-All Styles
Fig. 53 - Tail Gate Assembly Removal
Fig. 54 - Sealing Tail Gate Hinge Strap
Fig. 56 - Removing Tail Gate Outside Handle
Fig. 57 - Tail Gate Lock Striker
Fig. 58 - Tail Gate Outside Handle-Nomad
Fig. 59 - Tail Gate Lock Remote and Push Button Control Assembly-Nomad
Fig. 60 - Tail Gate Lock Push Button-Exploded-Nomad
Fig. 61 - Tail Gate and Lift Gate Weatherstrips
Fig. 62 - Lift Gate Assembly Hinges
Fig. 63 - Lift Gate Window
Fig. 64 - Lift Gate Supports
Fig. 65 - Lift Gate Assembly
Fig. 66 - Lift Gate Adjustments
Fig. 68 - Lift Gate Window Installation
Fig. 69 - Lift Gate Weatherstrips
Fig. 70 - Back Door Assembly-Sedan Delivery
Fig. 85 - Exterior Moldings-Sport Sedan Style
Fig. 72 - Seat Adjuster Assembly-Sedan Delivery
Fig. 73 - Folding Seat Assembly-6 Passenger Station Wagon
Fig. 74 - Right Center Folding Seat Assembly-9 Passenger Station Wagon
Fig. 75 - Floor Board Supports
Fig. 76 - Maximum Floor Space
Fig. 77 - Left Center Folding Seat Assembly
Fig. 78 - Rear Seat Assembly
Fig. 79 - Headlining Retainer and Trim Stick
Fig. 80 - Headlining - Standard Sedan an Sport Coupe
Fig. 81 - Headlining - Station Wagon
Fig. 82 - Headlining - Nomad
Fig. 83 - Exterior Moldings - 4 Door Styles
Fig. 84 - Exterior Moldings - 2 Door and Sport Coupe Styles
Fig. 85 - Exterior Moldings - Sport Sedan Styles
Fig. 86 - Exterior Moldings - 4 Door Station Wagon
Fig. 87 - Exterior Molding - 2 Door Station Wagon
Fig. 88 - Exterior Molding - Nomad Station Wagon
Fig. 89- Sealing Front Door Ventilator Reveal Molding
Fig. 90 - Side Roof Rail Sealing
Fig. 91 - Side Roof Rail Drip Molding Scalp Installation
Fig. 92 - Rear Quarter Window Rear Reveal Molding
Fig. 93 - Rotor Type Pump Installed Behind Rear Seat
Fig. 94 - Motor and Pump Assembly-Exploded
Fig. 95 - Motor and Pump Assembly-Removal
Fig. 96 - Adapter Hose
Fig. 97 - Disassembly of Reservoir Tube
Fig. 98 - Pump Action When Raising Top
Fig. 99 - Pump Action When Lowering Top
Fig. 100 - Fluid Flow Between Rotors and Reservoir
Fig. 101 - Position of Rocker Arm When Raising Top
Fig. 102 - Position of Rocker Arm When Lowering Top
Fig. 103 - Pressure Relief Valve
Fig. 104 - Pressure Relief Valve Ball Unseated
Fig. 105 - Fluid Level in Reservoir
Fig. 106 - Checking Pump Pressure

Service Operations and Adjustments Index


General Description
Body Lubrication
Service Operations and Adjustments
Front End Assembly
Windshield Wiper Assembly
Electric Windshield Wiper
Cowl Assembly
Windshield Assembly
Instrument Panel Compartment
Door Assemblies
Sedan Front Door
Convertible and Sport Coupe Front Door
Front Door - Nomad Station Wagon
Rear Door Assemblies
Rear End Assembly
Back Window Assembly
Back Window Assembly - Sport Sedan
Rear Compartment Assembly
Adjustment
Rear Quarter Assembly
Sport Coupe Rear Quarter
Convertible Rear Quarter
Station Wagon Rear Quarter
Trim Assemblies
Front Seats
Rear Seat Assembly
Headlining
Exterior Moldings
Sedan Front and Rear Door Exterior Moldings
Sedan Rear Quarter and Rear Fender Moldings
Convertible and Sport Coupe Door Exterior Moldings
Convertible and Sport Coupe Rear Quarter and Fender Moldings
Sport Sedan Exterior Moldings
Moldings Peculiar to Station Wagon Styles
2 Door Station Wagon
4 Door Station Wagon
Nomad Station Wagon
Electric Window Assembly
Electric Window Regulator and Seat Adjuster
Electrical Unit Checks
Convertible Top
Folding Top
Adjustments
Hydro-Lectric
Trouble Diagnosis
Keys and Locks
Care of Trim

General Description

The 1956 bodies, while basically the same as in 1955, incorporate many changes and additions in service information. These changes and additions have been included in this manual where appropriate.

The 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 1956 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

Instrument Compartment Door Hinge
Lubricant.............Dripless Oil

Front Door Hold Open Clips
Lubricant.............Lubriplate or Equivalent

Door Jamb Light Switch
Lubricant.............Lubriplate or Equivalent

Door Lock Bolt Housing
Lubricant.............Stick Type Lubricant

Door Lock Striker Teeth
Lubricant.............Stick Type Lubricant

Rear Door Hinge and Hold Open
Lubricant.............Lubriplate or Equivalent

Deck Lid Hinge and Torque Rod Ends
Lubricant.............Lubriplate or Equivalent

Deck Lid Lock Bolt
Lubricant.............Lubriplate or Equivalent

Gas Filler Door Hinge
Lubricant.............Dripless Oil

Folding Top Linkage Bearing Points
Lubricant.............No. 10 Engine Oil

Side Roof Rail Mechanical Sealing Strip Gasket
Lubricant.............Silicone Emulsion

Parts to be lubricated when access to parts can be obtained.

Windshield Wiper Motor and Transmission Spools
Lubricant.............Lubriplate or equivalent

Door Lock Parts
Lubricant.............Lubriplate or equivalent

Window Regulator Rack and Cam Channels
Lubricant.............Lubriplate or equivalent

Service Operations and Adjustments

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 Assembly Removal

  1. Remove instrument panel compartment box.
  2. Adjust cables to slack position.
  3. Observe attachment of cables to auxiliary drive, then detach cables from drums. IMPORTANT: Note how the right transmission cables are crossed.
  4. Remove wiper motor from auxiliary drive assembly, then remove two screws securing drive to dash panel.

Installation

  1. Install wiper motor and auxiliary drive to dash panel and secure with attaching screws.
  2. Inside of body, attach transmission cables to auxiliary drive drums "A" and "B", Fig. 1, as follows: Attach right transmission cables to auxiliary drive drum "A" in the following sequence:
  3. Adjust cables to tensioned position.
  4. Connect wiper motor parts as required and check operation of wiper motor. Install instrument panel compartment box.

Window Wiper Transmission

Removal

  1. Remove wiper blade and arm assemblies.
  2. Remove instrument panel compartment box.
  3. Adjust wiper transmission cables to slack position.
  4. Observe attachment of transmission cables to auxiliary drive, then disconnect cables from auxiliary drive drums.
  5. On outside of body at each transmission, remove escutcheon spanner nut using tool J-5449-A. Lift escutcheon from body, disconnect washer hose and remove escutcheons.
  6. At each transmission, using tool J-5449-A, remove transmission spacer nut and remove spacer.
  7. On inside of body, pull each transmission down through cowl panel and remove from body.

Installation

  1. Install gasket to each transmission and apply medium-bodied sealer around transmission shaft to gasket surface contacting body metal.
  2. Position each transmission assembly in body, install spacer and secure in place with spacer spanner nut using tool J-5449-A.
  3. Attach transmission cables to auxiliary drive drums. (See step 2 of "Wiper Motor and Auxiliary Drive Assembly.")
  4. Connect washer hose to transmission escutcheon and secure escutcheon with chrome plated spanner nut.
  5. Reinstall wiper blade and arm assemblies. Check operation of wiper motor and transmission assembly.
  6. Reinstall instrument panel compartment box.

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.

Electric Windshield Wiper

A single electric-type wiper motor powers both wiper blades on some models. Motor is mounted under center of dash panel as shown in Fig. 2.

Wiper is controlled by knob on dash panel. Turning knob clockwise selects either "Low" or "High" speed operation of wipers.

If wipers fail to operate (engine ignition switch must be "On"), turn control knob off (counterclockwise). Free wiper blades straight out from windshield glass only. Blades may be stuck or frozen to windshield.

CAUTION: Do not attempt to move blades by hand through their normal path of operation as damage to mechanism will result.

The electrical circuit to wiper motor may also be checked. Wiring connection must be kept securely tight.

Motor Replacement

1. Disconnect wiring at terminal front of cowl then follow instructions from "Wiper Motor, Replace."


IMPORTANT: Be especially careful when removing electric windshield wiper assemblies for any reason not to lose the mounting shims used between the unit and the dash panel. If the wiper is reinstalled without using these shims, a binding condition results at the wiper motor drive resulting in either sluggish operation or complete stoppage of the unit.

Adjustments Trouble
Possible Causes
Remedy

A. Motor Unit inoperative.
1. No supply voltage at motor terminal (Ign. switch on)
1. Check automobile wiring.

2. Unit improperly grounded.
2. Ground strap of motor unit should be placed under auxiliary drive mounting screw.

Disconnect Bowden wire from motor unit and remove switch cover (Fig. 2) before proceeding with the following checks in Section A.

3. Internal motor circuits.
3. With ignition switch on, check between contact 4 and ground with voltmeter. No reading indicates internal motor open circuit. Send to United Motors Service.

4. Defective soldering field leads to switch assembly.
4. Resolder any loose connections.

5. Switch fiber cam not tripping contact 4 against contact 3. (Manually operate switch arm to turn on unit and observe action of fiber cam.)
5. Check that fiber cam is in correct position-contact 4 toggle blade is bottoming in fiber cam slot. Toggle spring in position, coil spring connected. See Fig. 3

6. Contacts 3 and 4 dirty.
6. Clean contacts with crocus cloth.


B. Hard to turn on.

1. Bowden wire kinked or bent.

1. Try removing kink or replace Bowden wire assy.

2. Switch fiber cam not sliding up over oscillating shut-off arm when unit is turned on.
2. Remove switch cover and operative unit to move oscillating arm away from switch fiber cam and polish end of switch fiber cam with crocus cloth.


C. Unit will not shut off.

1. Failure of oscillating shut-off arm to trip contact 4 away from contact 3. Poor switch adjustment oscillating arm should come up and push against lower half of the end of the switch fiber cam.
1. Adjust switch as follows:
a. Loosen switch assembly mounting screws.

b. Move switch toward oscillating arm and tighten mounting screws.

c. Test for slow, fast and park positions.


D. No fast speed.

1. Contacts 1 and 2 not opening in fast speed switch position.

1. Remove switch cover and manually move switch arm that is normally moved by the plastic slide to the high speed position-Ear on switch fiber cam should move contact 2 away from contact 1. Failure of switch to function as described may be corrected by adjusting switch as follows:
a. Loosen switch assembly mounting screws.
b. Move switch assembly toward motor section of wiper unit and tighten mounting screws.
c. Test for slow, fast and park positions.

2. Switch fiber cam slot not seated properly in contact 4 toggle blade.
2. Position fiber cam slot in toggle blade (Fig. 3).

3. Switch cover shorting on resistor terminal nearest motor.
3. Bend down resistor terminal so that it will clear cover.


E. No slow speed.

1. Contacts 1 and 2 not making contact at low speed position.
1. Check for dirty contacts and clean if necessary. If contacts 1 and 2 appear to be separated in the low speed switch position, it may be possible to bend contact No. 1 slightly so that it will make contact with contact No. 2.


F. Wiper blades not parking against lower edge of windshield when unit is turned off-jumps away from edge 30-40 degrees.

1. No slow speed.
1. See remedy in Section E above.


G. Excessive speed in high speed switch position (contacts 1 and 2 open). Normal fast speed 160-180 wipes per minute.

1. Switch assembly resistor mounting rivets loose.
1. Tighten rivets to make solid contact.

2. Resistor open.
2. Send unit to United Motors Service.


H. Excessive speed in both the low and fast speed switch positions.

1. Defective soldering of the black shunt field lead to the switch assembly.

1. Resolder black field lead to switch.

Cowl Assembly

Cowl Ventilating System


Fig. 4

The 1956 Chevrolet incorporates a ventilating system with an air intake louver panel located on top of the cowl. The air entering the cowl top ventilator louver panel flows through a duct which guides the air into the body through an opening at each cowl side duct panel. The flow of air into the body is regulated by a valve in each cowl side opening; each valve is adjusted by the use of a cable and control knob. Water entering the inlet louver panel into the duct flows down the cowl side duct panel into a drain gutter which directs the water out of the body.

Cowl Side Drain Gutter

Removal and Installation

A cowl side drain gutter is located on the right and left cowl side panel adjacent to the door opening as shown in Fig. 5.

  1. Remove three (3) screws indicated by arrows and remove gutter.
  2. To install, reverse removal procedure. Apply body caulking compound between gutter and body metal as indicated at one "1" in inset. Be sure that seal is continuous at area marked "X."

Air Intake Louver Panel

Removal and Installation

  1. Remove wiper blade and arm assemblies, transmission spanner nuts, and transmission escutcheons.
  2. Remove windshield lower reveal moldings and molding retaining clips located on louver panel (see "Windshield Reveal Moldings").
  3. Lift up hood and remove screws indicated by arrows in illustration, then remove panel from body.
  4. To install, reverse removal procedure.

Front Body Hinge Pillar Weatherstrip

The weatherstrip is located along the upper portion of the front body hinge pillar and is secured in place by four snap-in clips which are formed from a wire insert. Removal and Installation Carefully position tip of mechanically retained weatherstrip inserting tool or other suitable tool under weatherstrip at each clip location and snap clip out of the hole. To install weatherstrip, reverse the removal procedure.

Windshield Assembly - All Styles

The 1956 Chevrolet incorporates a large one-piece windshield which is retained in the windshield opening by a one-piece rubber channel.

Windshield Reveal Moldings

The sedan, sport sedan and sport coupe styles have reveal moldings of the same design. The convertible style takes a different windshield upper and side reveal molding, as shown in the accompanying illustrations.

Removal

  1. Apply masking tape on the body at areas adjacent to the windshield lower reveal moldings.
  2. Remove the wiper blade and arm assembly from each transmission.
  3. Remove the transmission escutcheon spanner nut with tool J-5449-A, then remove escutcheon from each transmission.
  4. With suitable tool, carefully slide escutcheon from the junction of the lower reveal moldings to expose clip attaching screw.
  5. Remove screw securing retaining clip under escutcheon and slide clip into either molding.
  6. On inside of body beneath instrument panel, remove nut and washer securing each windshield lower reveal molding clip located between transmission and lower corner reveal molding.
  7. Carefully slide either lower reveal molding approximately 1-1/2" toward center line of the body. NOTE: At this location, the reveal molding lower Range is cut out to permit disengagement of the lower edge of the molding from the inboard retaining clip.
  8. Disengage molding from inboard clip, then slide molding toward center line of body until end of molding disengages from outboard clip. Repeat for opposite molding.
  9. On sedan, sport sedan and sport coupe styles remove screw "A," Fig. 6, securing lower corner reveal molding, pull molding out slightly and slide corner reveal molding down and remove. On convertible styles, remove screw "A," Fig. 7, from lower comer of side reveal molding, then open door and remove three screws "C," Fig. 7, securing molding to windshield side pillar and remove molding. Repeat operation at opposite side.
  10. Remove screw "B," figs. 6 or 7, at each end of upper reveal molding. On convertible styles note how rubber channel is notched at screw locations.

NOTE: On all styles, the upper reveal molding(s) can only be removed from the windshield rubber channel after the windshield is removed from the body.

Installation

  1. To install moldings, reverse the removal procedure. Apply a medium-bodied sealer to screw holes indicated at "1" in Fig. 8. Apply sealer inside of holes as indicated at "2") in section "A-A."
  2. In addition at the windshield lower reveal moldings, apply a medium-bodied sealer around clip holes as indicated at "3."

Instrument Panel Compartment

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.

Door Assembly

SEDAN FRONT DOOR

Figure 19 and figure 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

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:

  1. On front doors, formed bend in weatherstrip should be located in the cove area of door (Fig. 26).
  2. 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).
  3. Butt joint should be located at the bottom center of the door between two clips.
  4. 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.
  5. 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.
  6. Carefully trim ends of weatherstrip to form butt joint, and install balance of clips. Make sure a complete bond is made at cemented area.
  7. Coat ends of weatherstrip with weatherstrip adhesive and form butt joint.
  8. Remove door trim assembly and access hole cover(s). Working through access holes apply medium bodied sealer over and around weatherstrip attaching clips indicated at "1" in Fig. 10. Seal all clips along door bottom and lower clip at each door pillar.
  9. Reinstall weatherstrip retaining clips and previously removed parts. Seal door inner panel as specified in "Door Inner Panel Sealing."

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

The front and rear door locks are the rotary bolt type lock and incorporate the new inter-lock feature consisting of a notch in the striker into which the rotary bolt housing extension engages. With the inter-lock feature it is very important that the lock extension engages properly in striker notch and that, where necessary, the correct striker emergency spacers are used to obtain proper engagement.

NOTE: Before installing door lock, apply a ribbon of caulking compound across the face of the lock frame approximately 3/4" above the rotary bolt housing as shown at "1" (see Fig. 11).

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. Figure 29 and figure 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-ALL STYLES

Front and rear door lock strikers incorporate the new inter-lock feature consisting of a notch in the striker into which the lock bolt housing extension engages. With the inter-lock feature it is very important that the lock extension engages properly in the striker notch and that, where necessary, the correct striker emergency spacers are used to obtain proper engagement.

Removal and Installation

  1. With pencil, scribe position of striker on body pillar.
  2. Remove three door lock striker attaching screws and remove striker and adjusting plates from pillar.
  3. To install, place striker and adjusting plates within scribe marks on pillar and tighten screws.

IMPORTANT: Whenever a door has been removed and installed, or realigned, the door SHOULD NOT be closed completely until a visual check is made to determine if the lock extension will engage in the striker notch. Where required, door lock striker emergency spacers should be installed so that door can be closed and an accurate check made to determine emergency spacer requirements.

Adjustments

  1. To adjust striker "up", "down", "in", or "out" loosen striker plate screws and shift striker and adjusting plates as required, then tighten screws.
  2. DIMENSIONAL SPECIFICATIONS FOR USE OF DOOR LOCK STRIKER EMERGENCY SPACERS.

When dimension "A" from inside face of than 3/16", install emergency spacers and proper striker teeth to center of lock extension is less length striker attaching screws as directed below. 


Dimension "A"      No. Spacers Required        Spacer Thickness     Striker Attaching  Screws* 
                                                                                                                         
3/16", to 2/8"        1                           1/16"              Original Screw 
1/8" to 1/16"         1                           1/8"               Emergency Screw
                                                                     (1/8" longer) 
1/16" to 0            1-(1/8"  Spacer)            3/16" (Total)      Emergency Screw
                      1-(1/16" Spacer)                               (1/8" longer) 
0 to 1/16"            2-(1/8" Spacers)            1/4" (Total)       Emergency Screw
Interference                                                         (1/4" longer) 
*Zinc or cadmium-plated flat head cross recess screw with countersunk washer. 
NOTE: Dimension "B" from center of lock extension to inside face of striker notch should never be less than 1/8".

Front Door Assembly

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:
  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.

Inner Panel Sealing

Some of the front door inner panel weatherseals have been changed for 1956 styles. These changes are covered below. Whenever work is performed on a door where any of the door inner panel weatherseals have been disturbed, the area must be resealed before the door trim assembly is reinstalled.

Figure 12 shows door inner panel openings which are sealed to prevent water leakage and possible damage to the door trim assembly.

  1. At both access holes apply ribbon of medium bodied sealer across top and down side flanges of access hole opening to provide seal between cover plate and door inner panel (1).
  2. Apply ribbon of medium-bodied sealer to access hole cover plate starting at point "2" above lower corners and extending downward and along edge of offset flange (2).
  3. After access hole cover plates are installed, seal lower offset corners with sealer (3).
  4. Apply sufficient body caulking compound to effect a watertight seal at:
  5. Apply waterproof tape over the following door inner panel openings.

    Front Door Adjustment

    IMPORTANT: After performing any door adjustments on a convertible or four door sedan style the door ventilator and window should be checked for proper alignment with the side roof rail weatherstrip and adjusted where required. In addition, when performing adjustment on any style do not close the door completely without making a visual check to see that the door lock extension engages in the striker notch as specified.

    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.

    Convertible and Sport Coupe Door

    figure 47 and figure 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.

    Ventilator Garnish Molding

    1. Remove door belt finishing molding and ventilator cap finishing molding.
    2. At door hinge pillar remove one screw securing-, door weatherstrip tab and two screws securing garnish molding, then carefully remove garnish molding from door assembly.
    3. To install, reverse removal procedure.

    Weatherstrips

    The front door weatherstrip is a one piece mechanically retained type with external clips formed from a wire insert extending through the length of the weatherstrip. The weatherstrip is secured to the door by snapping the weatherstrip clips into holes around the perimeter of the door. At locations "A" and "B," indicated in Fig. 13, a tab, which is an integral part of the weatherstrip, is secured to the door pillar. Along the cove area of the door the weatherstrip is cemented in place, and at location "C," a clip inserted into the weatherstrip is secured to the hinge pillar. After the weatherstrip is installed, sealer is applied through the inner panel access holes to the weatherstrip attaching clips along the bottom of the door.

    A front door hinge pillar auxiliary weatherstrip is provided to direct any water in the cove area of the hinge pillar into a drainage hole in the hinge pillar. The auxiliary weatherstrip is cemented to the door hinge pillar and has two snap-on clips at the lower portion of the weatherstrip.

    Removal

    1. Remove front door ventilator cap finishing molding.
    2. Remove screws securing weatherstrip tabs at locations "A" and "B," and weatherstrip clip at location "C" (Fig. 13).
    3. Using a mechanically retained weatherstrip inserting tool or other suitable tool, carefully position tip of tool under weatherstrip at each clip location, and snap clip out of hole.

    NOTE: At top of hinge pillar carefully remove weatherstrip from under ventilator reveal molding. At cove area of hinge pillar carefully break cement bond at same time that weatherstrip clips are being snapped from holes.

    Installation

    1. Clean off old weatherstrip cement and sealer from door.
    2. Insert tab at top of weatherstrip under ventilator reveal molding and install weatherstrip tab attaching screw at location "A" on upper hinge pillar.
    3. Apply a ribbon of approved weatherstrip cement in comer of rabbet along cove area as indicated at "1" in Fig. 13.
    4. Install weatherstrip clips into clip holes starting at upper hinge pillar and cove area. Press or roll weatherstrip along cove area to assure a good cement bond. To install clips into holes, place "V-shaped" tip of weatherstrip inserting tool on loop of clip, then push clip into hole until it snaps into position. NOTE: Do not use excessive force or strike tool when pushing clips into holes as it may distort shape of clip, resulting in improper weatherstrip retention.
    5. Install weatherstrip tab attaching screw at location "B" on lock pillar.
    6. Insert weatherstrip clip into weatherstrip, at location "C," so that prongs of clip are on top of wire insert in weatherstrip, then secure clip to hinge pillar.
    7. Remove door trim assembly and inner panel access hole covers. Working through access holes apply medium-bodied sealer over and around weatherstrip attaching clips, indicated at "2." Seal all clips along door bottom and lower clip at each door pillar.
    8. Seal and install inner panel access hole covers. Seal door inner panel as specified in "FRONT DOOR INNER PANEL SEALING." Reinstall door trim assembly and inside hardware parts. Seal and install ventilate, or cap finishing molding.

    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

    1. Medium bodied sealer


    2. Access door flange

    2. Medium bodied sealer


    3. Access door corners

    3. Medium bodied sealer


    4. Arm rest attaching holes

    4. Waterproof tape


    5. Access hole

    5. Waterproof tape


    6. Trim pad nail slots

    6. Waterproof tape


    7. Window cam attaching holes

    7. Body caulking compound


    8. Regulator attaching holes

    8. Body caulking compound


    9. Ventilator lower attaching hole

    9. Body caulking compound

    Door Lock

    The front and rear door locks are the rotary bolt type lock and incorporate the new inter-lock feature consisting of a notch in the striker into which the rotary bolt housing extension engages. With the inter-lock feature it is very important that the lock extension engages properly in the striker notch and that, where necessary, the correct striker and 'emergency spacers are used to obtain proper engagement.

    Removal and Installation

    1. Remove door window assembly and door window glass run channel.
    2. Remove remote control attaching screws and detach the remote control connecting rod from the lock assembly.
    3. With a short straight bladed screwdriver, carefully disengage door lock cylinder connecting rod from retaining clip on locking lever.
    4. To install lock assembly, reverse removal procedure.

    NOTE: Before installing door lock, apply a ribbon of caulking compound across the face of the lock frame approximately 3/4" above the rotary bolt housing as shown at "l ", Fig. 11

    Door Lock Cylinder Assembly

    The door lock cylinder assembly on convertible and sport coupe front doors is very similar to the cylinder assembly used on the front door of sport sedan styles. For service procedures, refer to page 1-18.

    Front Door-Nomad Station Wagon

    Since the Nomad front door is much the same as the Convertible and Sport Coupe front door, most service procedures will be the same as already covered in that section of either this supplement or the 1955 Passenger Car Shop Manual.

    The side roof rail weatherstrip shown here is peculiar to the Nomad Station Wagon.

    Side Roof Rail Weatherstrip

    The side roof rail weatherstrip consists of one section of a fabric covered rubber designed with a metal insert formed to the contour of the side roof rail. The weatherstrip is secured to the side roof rail with screws installed through the weatherstrip into the side roof rail.

    Removal

    1. Remove screws securing weatherstrip to side roof rail and carefully remove weatherstrip.

    Installation

    1. Clean off old sealer from weatherstrip and side roof rail.
    2. Apply bead of caulking compound along length of weatherstrip indicated at "1" in Fig. 14. Apply seal along line just outboard of attaching holes as shown at "2" in section "B-B" and "C-C."
    3. Assemble weatherstrip to side roof rail. Install attaching screws loosely, adjust weatherstrip as required, then tighten screws.
    4. Clean off excess sealer.

    Adjustments

    1. To adjust side roof rail weatherstrip inboard or outboard, loosen attaching screws and position weatherstrip as required, then tighten screws.
    2. To adjust side roof rail weatherstrip downward, loosen weatherstrip and insert waterproof shim as required between weatherstrip and side roof rail.

    Rear Door Assembly

    The manual regulator type rear door inner panel and the electric regulator type rear door inner panels are shown in figures 56 and 57 respectively. The illustrations show the location of hardware parts and their attaching points.

    1. Glass Run Channel
    2. Upper and Low Hinge Cover Plates and Hinges
    3. Locking Rod and lever
    4. Lock Remote Control
    5. Lock Remote Control Connecting Rod
    6. Lock
    7. Window Regulator
    8. Window Regulator Stationary Cam Adjusting Screws
    9. Access Hole Cover Plate
    10. Trim Pad Retainers
    11. Glass run Channel Adjusting Screw
    12. Window Control Switch Terminal Block
    13. Window Electric Regulator
    14. Electrical Conduit Opening
    15. Electric Connectors for Door Window Regulator Motor
    16. Attaching Holes for plastic Type Door Arm Rest
    17. 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

    1. Remove hinge cover plates from center pillar, clean sealer from around hinge straps and scribe location of straps on center pillar.
    2. 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.
    3. Support door and remove three upper and lower attaching bolts from hinge strap and remove door.

    Installation

    1. Clean all old sealing compound from hinge areas. Do not soil adjacent trim.
    2. 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).
    3. 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.
    4. Apply medium bodied sealer to upper and lower hinge as indicated at "A" and "B" in figure 59.
    5. Install hinge cover plates and remove excess sealer.

    Adjustment

    IMPORTANT: Whenever a door has been adjusted, the door should not be closed completely until a visual check is made to determine if the lock extension will engage in the striker notch. Where required, door lock striker emergency spacers should be installed. See "Door Lock Striker Adjustments."

    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

    1. Remove trim pad and remote control attaching screws "A" (Fig. 60).
    2. Remove remote control after disengaging connecting rod.
    3. To install, reverse this procedure.

    Rear Door Lock

    Removal and Installation

    1. Remove trim pad, access hole cover and remote control.
    2. Remove inside locking rod lever attaching screw "B" and washer, disengage lever connecting rod from clip "C" and door lock (Fig. 60).
    3. Remove glass run channel screw "D" and four lock attaching screws "E".
    4. Remove lock through access hole.
    5. 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:

    1. Pull inside locking rod knob to the "up" position and remove rear door lock upper attaching screw.
    2. Insert adjusting tool through screw hole as shown in illustration, (Fig. 61).
    3. 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 Front Channel

    Removal and Installation

    1. Lower door window and remove trim pad and access hole cover (Fig. 15). have been changed for 1956 styles. These changes are covered below. Whenever work is performed on a door where any of the door inner panel weatherseals have been disturbed, the area must be resealed before the door trim assembly is reinstalled. Fig. 16 shows the door inner panel openings which are sealed to prevent water leakage and possible damage to the door trim assembly.
    2. Remove screw "E" at lower end of channel and carefully pry channel rose-bud fasteners from retaining holes at door header.
    3. Carefully pull channel from door.
    4. 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 Upper and Rear Channel

    Removal and Installation

    1. Lower door window, remove trim pad, access hole cover and screw "D" from end of glass run channel (Fig. 15).
    2. Detach upper channel from door lock pillar, then remove rose-bud fastener from retainer at "G."
    3. Carefully pull glass run channel up through window opening.
    4. 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 Upper and Rear Channel

    1. Lower door window, remove trim pad, access hole cover and screw "D" from end of glass run channel (Fig. 15)
    2. Detach upper channel from door lock pillar, then remove rose-bud fastener from retainer at "G".
    3. Carefully pull glass run channel up through window opening.
    4. 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

    1. 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.
    2. Remove upper glass run channel and through access holes "A" and "B" remove window to sash channel cam screws.
    3. 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.
    4. To install, reverse this procedure and reseal inner panel.

    Adjustment

    1. To correct a glass tilted in the run channels, loosen stationary cam screw "C" and move stationary cam as desired (Fig. 63).
    2. 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

    1. 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.
    2. Through access holes at "A" and "B" remove window to sash channel cam screws and prop window in closed position.
    3. Remove stationary cam screws "C" and cam, disengage sash channel cam from regulator and remove sash channel cam.
    4. Remove screws "F" and carefully remove regulator.
    5. 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.

    Inner Panel Sealing

    Some of the rear door inner panel weatherseals have been changed for 1956 styles. These changes are covered below.

    Whenever work is performed on a door where any of the door inner panel weatherseals have been disturbed, the area must be resealed before the door trim assembly is reinstalled. Fig. 16 shows the door inner panel openings which are sealed to prevent water leakage and possible damage to the door trim assembly.

    Inner Panel Sealing

    1. Apply ribbon of medium-bodied sealer across top and down side flanges of access hole opening to provide seal between cover plate and door inner panel (1).
    2. Apply ribbon of medium-bodied sealer to access hole cover plate starting at point "2" above lower corner extending downward and along edge of offset flange at bottom of cover (2).
    3. After access hole cover is installed, seal lower offset corners (3).
    4. Apply sufficient body caulking compound to the following locations:
      • Window regulator attaching holes (4).
      • Door inner panel cam attaching holes (5).
      • Door trim assembly nail slots (6).
      • Arm rest attaching holes (7).
    5. Apply waterproof body tape over the following, a door inner panel openings:
      • Welding access holes (8).
      • Cam access holes (9).
      • Lock access hole (10)

    Rear End Assembly

    BACK WINDOW ASSEMBLY

    ALL STYLES BUT SPORT SEDAN

    DESCRIPTION: The back window consists of a large one-piece glass secured in the body opening by a one-piece rubber channel. Fig. 41 shows how the glass is retained by the back window reveal moldings, which consist of a one piece upper reveal, right and left lower reveal, and a right and left comer reveal escutcheon. The removal and installation of the moldings and the glass is outlined and illustrated in this section.

    Back Window Reveal Moldings

    The back window reveal moldings are secured to the body by a combination of bolt and clip assemblies and clips. Each comer reveal escutcheon is secured by one bolt and clip assembly. The upper and lower reveal moldings are retained by one of two alternate methods depending on the assembly plant option. These optional methods control the removal and installation of the moldings as described below and in Fig. 42 which shows typical sections taken through the back window glass, rubber channel and reveal molding.

    Upper Reveal Moldings

    1st Assembly Method-Molding secured by clips which allow moldings to be removed from rubber channel before removing back window. This is the standard production method.

    2nd Assembly Method -Molding secured to body by clips in rubber channel which require removal of back window in order to remove moldings from rubber channel. This method is optional, to be used only in production emergencies.

    Lower Reveal Moldings

    lst Assembly Method-Lower moldings secured to body by clips which allow moldings to be removed without removal of back window as in Method I for upper reveal. Moldings may also be held to the body opening by three screws in production emergencies in conjunction with this, method, necessitating the removal of the back window and rubber channel from the body opening before the molding can be removed.

    2nd Assembly Method-Moldings secured to body by clips in rubber channel which require removal of back window in order to remove moldings from the rubber channel.

    Removal and Installation

    See Fig. 42.

    1. Mask off the outside body surfaces around the rear window opening to protect the paint finish and place a protective covering over rear compartment lid.
    2. On sedan styles place protective covering over rear seat cushion and back and parcel shelf. On these styles no garnish molding removal is necessary. On coupe styles remove rear seat cushion and back, rear quarter belt finishing moldings, and then remove back window garnish moldings.
    3. Turn back inner lip of rubber channel and remove corner reveal escutcheon attaching nut at each side, then remove escutcheons.
    4. To remove upper reveal molding, place suitable flat-bladed tool between edge of roof panel and upper reveal molding, then carefully attempt to pry molding from body opening. NOTE: Molding should lift freely from rubber channel if installed with Clip No. 1. If optional Clip No. 2 was utilized in installation, the molding will not lift. In these cases, press upper edge of back glass out of body opening to remove molding from rubber channel.
    5. To remove the lower reveal moldings insert a flat-bladed tool between rubber channel and molding, and carefully attempt to pry molding from body opening. NOTE: Moldings installed by lst assembly method utilizing Clip No. I should readily pry loose. Moldings which do not pry loose may be attached to the body by screws in conjunction with the first assembly method, or held to the rubber channel by Clip No. 2, in conjunction with the 2nd assembly method.
    6. When lower moldings do not pry loose, remove the back glass from the body, as outlined in "Back Window." NOTE: If moldings come out with back glass assembly, remove them separately from the rubber channel. If moldings do not come out, remove molding attaching screws for complete removal of moldings from body.
    7. To install moldings, apply medium-bodied sealer around base of corner reveal molding bolt and reverse removal procedure. If lower reveal moldings were attached with screws, they must be screwed in place prior to glass installation. If lower reveal moldings and glass assembly were removed, seal window opening as specified in "Back Window."

    Back Window Glass and Rubber Channel

    Removal - Fig. 42

    1. Place protective covering over the painted surfaces below the back window and over parcel shelf. On two and four-door sedan styles cover the rear seat back and cushion. On coupe styles remove rear seat cushion and back, rear quarter belt finishing moldings, and back window garnish moldings.
    2. Remove back window corner reveal escutcheon and if possible upper reveal molding. See "Back Window Reveal Moldings." Break seal between rubber channel and pinchweld flange around perimeter of glass. On sedan styles disengage garnish rubber lip from position over headlining rear edge.
    3. From inside of body carefully push upper edge of window and channel outward until lip of rubber channel is disengaged from pinchweld flange.
    4. With aid of helper, lift complete assembly from body opening. NOTE: Because lower reveal moldings may be secured to body with screws it is necessary to lift the back window and rubber channel up and over the molding when removing them from the body opening.
    5. Place assembly on a covered bench or stand. If necessary, remove lower reveal moldings and clips from rubber channel, then remove rubber channel from glass.

    Installation

    1. Clean original sealer from back window body opening and rubber channel. Check body pinchweld flange for irregularities and correct if present. Check back window gutter and drain hoses for any obstructions and clean out if necessary.
    2. Assemble rubber channel to glass.
    3. Check reveal attaching clips for secureness at upper and lower pinchweld flange on installations utilizing Clip No. 1. When installing lower molding with Clip No. 2, be sure clips are properly secured to moldings, then apply medium-bodied sealer to clips as at "1" and install to rubber channel.
    4. Insert a strong cord into pinchweld cavity of rubber channel and bring both ends around to the bottom center of the glass. Tie ends of cord together and tape to the glass.
    5. Apply a bead of medium-bodied sealer to the base of the rubber channel, completely around its perimeter. Also apply a heavy bead of medium-bodied sealer at the rabbet (cross-section 2) of the pinchweld flange around the entire perimeter of the window opening. NOTE: In cases where upper or lower reveal molding clips of type No. 1 have been replaced, install a bead of mediumbodied sealer in the corner of the clip and connect this bead of sealer with the sealer previously applied to the corner of the back window opening rabbet.
    6. With the aid of a helper, place back window assembly into the body opening. On sedan styles, while helper is applying pressure to outside surface of glass, carefully draw large garnish lip of rubber channel over pinchweld into body.
    7. Pull ends of cord from the pinchweld cavity of the rubber channel on inside of body to seat channel over the pinchweld flange around perimeter of glass.
    8. Install reveal moldings, being sure to apply medium-bodied sealer to base of comer reveal escutcheon studs.
    9. Apply approved weatherstrip cement between glass and the outer lip of the rubber channel completely around the perimeter of the glass.
    10. Clean off excess cement and sealer. On coupe styles install garnish moldings and replace rear seat back and cushion and rear quarter belt finishing moldings. On sedan styles draw inner rubber garnish lip into position over headlining rear edge as shown in Fig. 42, and remove all protective coverings and masking tape.

    BACK Window Assembly-Sport Sedan

    The back window consists of a large, one-piece glass secured in the body opening by a one-piece rubber channel. Fig. 43 shows the glass and back window reveal moldings installed in the body. The removal and installation of the moldings and the glass is outlined and illustrated in this section. Reveal Moldings Each back window side reveal molding is secured by bolt and clip assemblies with attaching nuts on the inside of the body. See Fig. 44.

    Removal and Installation

    1. Apply masking tape to body surface adjacent to the back window upper and lower reveal moldings and place protective covering over the rear compartment lid.
    2. On inside of body, remove rear seat cushion and back, and on 2400 style, the right and left side roof rail rear finishing molding. Remove garnish moldings.
    3. At right and left corner of back window, turn back inner lip of rubber channel to expose two nuts securing the back window side reveal molding, then remove attaching nuts.
    4. Loosen rear end of side roof rail weatherstrip and remove screws securing back window side reveal molding, then carefully disengage molding from back window upper and lower reveal and side roof rail molding.
    5. Insert a suitable flat-bladed tool between upper reveal molding and panel, as shown in Fig. 45, and carefully pry molding from clips installed to pinchweld flange.
    6. Slide back window lower reveal molding escutcheon to left reveal molding, then starting at the rear end of the molding, insert flat. bladed tool between top portion of molding and channel and carefully pry each molding from dips installed to channel retainer. In addition, disengage front end of molding from slide-in clip secured to the body.
    7. To install moldings, reverse removal procedure.

    Back Window Glass

    Removal

    1. Place protective covering over rear compartment lid.
    2. On inside of body, remove rear seat cushion and back and back window garnish moldings, then carefully break seal between inner lip of rubber channel and pinchweld flange around perimeter of glass.
    3. Remove back window reveal moldings as outlined in "Back Window Reveal Moldings."
    4. From inside of body, carefully push upper edge of window and channel outward until lip of rubber channel is disengaged from pinchweld flange.
    5. With aid of helper, lift complete assembly from body opening and place on covered bench, then remove channel from glass.

    Installation

    1. Clean original sealer from back window body opening and rubber channel. Check body pinchweld flange and channel retainer for irregularities and correct if present. Check back window gutter and drain hoses for any obstructions and clean out if necessary.
    2. Check installation of clips at pinchweld flange and channel retainer. If replacing clips, apply medium-bodied sealer to opening rabbet as shown at "1" in View "A," Fig. 46.
    3. Insert strong cord into pinchweld cavity of rubber channel, tie ends together and tape them to bottom center of glass.
    4. Apply bead of medium-bodied sealer to corner of back window opening rabbet, as indicated at "2" in Section "A-A" and View "A" in Fig. 46, completely around perimeter of opening.
    5. Apply bead of medium-bodied sealer to base of rubber channel as indicated at "3" in Section "A-A" completely around perimeter of glass.
    6. With aid of helper, place back window assembly into body opening. While helper is applying pressure to outside surface of glass, carefully pull ends of string to seat lip of rubber channel over pinchweld flange and channel retainer.
    7. Install back window reveal moldings. Apply weatherstrip cement between rubber channel and glass as indicated at "4" in Section "A-A."
    8. Clean off excess cement and install previously removed parts.

    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

    1. Open lid and place protective covering over adjacent finish areas.
    2. Disconnect light wire at connector and remove wire from lid. Scribe position of hinge straps on lid inner panel .
    3. With a helper-assisting, remove bolts attaching hinge strap to lid inner panel and remove compartment lid.
    4. To install reverse this procedure, make sure hinge straps are aligned within scribe marks.

    Rear Compartment Lid Hinge

    Removal

    1. Place protective covering over paint finish at working area and place a suitable support under lid near the hinge being removed.
    2. Scribe location of hinge strap on lid inner panel, then remove strap to lid retaining bolts.
    3. Remove screws for the torsion rod cover at the left hinge (see inset Fig. 67) and remove cover.
    4. 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).
    5. Disengage torsion rod from movable portion of hinge strap and remove rod.
    6. 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

    1. Place hinge in hinge box and install pin, bend down pin retaining tab.
    2. Install hinge strap to lid within scribe marks on lid inner panel.
    3. 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.
    4. 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.
    5. Center rubber silencer at the crossover point of the torsion rods, then install rod cover to left hand hinge box.
    6. Check lid alignment in compartment opening and remove protective covering.

    Lid Lock Cylinder

    Removal and Installation

    1. Insert suitable hooked tool through inner panel of lid and pull lock cylinder retainer away from cylinder. See inset in figure 70.
    2. Remove lock cylinder and gasket from lid outer panel.
    3. To install, reverse this procedure, after sealing at cylinder opening in outer panel.

    Lid Lock

    Removal and Installation

    1. Remove lock cylinder from compartment lid.
    2. Remove lid lock and cover plate screws "B" and "C" and remove lock and cover plate assembly ( Fig. 70).
    3. 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

    1. 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

    1. Service replacement weatherstrips are longer than required, but should not be cut until weatherstrip is installed.
    2. Locate two clip holes indicated at. "A" in figure 71 near the lid lock bolt. These holes are closer together than the others.
    3. 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".
    4. Install all clips except those to be inserted into clip holes at "A".
    5. 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.
    6. 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. See 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

    1. From inside rear compartment, remove drain hose from rear quarter inner panel (Fig. 75).
    2. Remove rear seat cushion, back and back window garnish moldings.
    3. With a wide blade putty knife or some other suitable tool, carefully separate cemented parcel shelf trim from metal.
    4. Loosen the cemented upper end of drain hose at "A" and carefully remove hose from outlet (see inset).

    Installation

    1. Apply weatherstrip adhesive to sealing edges "A" of drain hose and place hose in outlet opening.
    2. From inside rear compartment draw hose down into position and insert other end of hose into opening in rear quarter panel.
    3. Remove all excess sealer and reinstall parcel shelf covering, garnish molding, rear seat back and cushion.

    Rear Quarter Assembly

    Rear Quarter Trim

    Four Door Sedan Removal and Installation

    1. Remove rear seat cushion and back.
    2. Remove rear quarter window garnish molding.
    3. Remove one drive nail from the upper rear corner of the trim panel.
    4. Swing the rear edge of the trim panel forward to expose the tacks attaching the front edge of the panel to the rear body lock pillar.
    5. Remove tacks attaching front edge of panel to lock pillar and remove panel from body.
    6. To install, reverse procedure.

    Rear Quarter Window

    Two Door Sedan

    The rear quarter window lower sash channel cam is welded to the lower sash channel in place of being attached by screws as on past styles. This change necessitates new service methods.

    Removal and Installation

    1. Operate rear quarter window to "up" position. On electric styles, disconnect positive battery cable to prevent accidental operation of window.
    2. Remove rear seat cushion and back, rear quarter window garnish molding and, when present, remove rear quarter arm rest.
    3. Remove rear quarter trim panel. NOTE: On electric styles, carefully disengage switch from switch terminal block.
    4. Remove access hole cover.
    5. Detach window front and rear guides from inner panel and disengage guides from window sash channel rollers.
    6. On electric styles, temporarily connect power supply and carefully lower window to "half-down" position, then disconnect power supply. On manual styles, lower window to "half-down" position.
    7. Rotate rear edge of window upward until window lower sash channel cam is disengaged from window regulator arm roller, then remove window from body. CAUTION: On bodies equipped with electrically powered window regulators DO NOT OPERATE REGULATOR MOTOR after window assembly is disengaged from regulator. Operation of motor with load removed may damage the unit or make it inoperative.
    8. To install, reverse removal procedure.

    Sport Coupe Rear Quarter

    Instructions and procedures covered in the 1955 shop manual remain the same except for:

    Window Sealing Strip

    Removal and Installation

    1. With the window in the down position remove the side roof rail mechanical sealing strip.
    2. Remove rear seat cushion, back, quarter belt finishing molding and side roof rail finishing molding.
    3. Remove side roof rail rear finishing moldings.
    4. Remove screws attaching inner extension and outer extension.

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

    55 VERSION

    Belt Finish Molding

    Removal and Installation

    1. Remove rear seat cushion and back, then remove retaining screws and molding.
    2. To install, reverse this procedure.

    Quarter Arm Rest

    Removal and Installation

    1. Remove rear seat cushion and back, disconnect courtesy lamp switch at left side only.
    2. Remove attaching screws and rear quarter arm rest. Lift arm rest up to clear retaining tabs.
    3. To install, reverse this procedure.

    Quarter Trim Panel

    Removal and Installation

    1. Remove quarter arm rest, belt finish molding and window regulator. On electric lift installations, disconnect switch.
    2. Remove nail from rear corner of trim panel and swing trim panel forward exposing tacks at lock pillar edge of trim.
    3. Remove tacks and trim.
    4. To install, reverse this procedure.

    Quarter Window

    Removal and Installation

    1. 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.
    2. With window in up position remove window rear guide screws "A" and remove guide(fig. 77).
    3. 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.
    4. Disengage front roller from guide channel and remove quarter window.
    5. 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

    1. Remove quarter window.
    2. Remove access hole cover and disconnect motor wire.
    3. Remove regulator attaching screws "A" and remove regulator (fig. 79).
    4. To install, reverse this procedure, then reseal access hole cover and regulator attaching screws.

    Window Guide-Rear

    Removal and Installation

    1. Remove rear seat hardware and trim.
    2. Remove access hole cover and with the window in the up position, remove attaching screws "A" ( fig. 80).
    3. Disengage rear guide from window roller and remove guide from body.
    4. To install, reverse this procedure.

    Window Guide-Front

    Removal and Installation

    1. Remove quarter window and regulator.
    2. Remove front guide screws "B" and remove guide from body through access hole (fig. 80).
    3. To install, reverse this procedure.

    Window Sealing Strip

    Removal and Installation

    1. With the window in the down position remove the side roof rail mechanical sealing strip.
    2. Remove rear seat cushion, back, quarter belt finishing molding and side roof rail finishing molding.
    3. Remove screws attaching inner extension and outer extension (fig. 81).
    4. Remove screws attaching sealing strip, pull sealing strip forward to disengage from outer molding and remove.
    5. 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

    Procedures remain the same as 1955 except for:

    Quarter Window-Electric and Manual

    Removal and Installation

    Step 5 in the Quarter Window Service procedure has been revised as shown.

    5. Disengage window lower sash channel cam from regulator arm and lift upward to remove from between quarter inner and outer panels.

    55 VERSION

    Folding Top Compartment Side Trim Panel

    Removal and Installation

    1. Remove rear seat cushion and back, on left side of body, disconnect courtesy lamp switch.
    2. Remove attaching screws and top compartment side trim panel.
    3. To install, reverse this procedure.

    Trim Panel

    Removal and Installation

    1. 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.
    2. Remove nail from rear of trim panel and swing panel out to expose tacks attaching panel to lock pillar. Remove tacks and panel.
    3. To install, reverse the removal procedure.

    Quarter Window-Electric and Manual

    Removal and Installation

    1. Remove rear seat cushion and back, then lower the folding top.
    2. Place window in the half way position, on electric models disconnect positive battery cable.
    3. 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.
    4. Remove pivot bolt "A" and disengage male hinge from female hinge (fig. 82).
    5. Temporarily connect lift power supply or reinstall quarter window handle and carefully operate window until regulator arm can be removed from the cam channel.
    6. Remove window from body, exercise caution to prevent scratching of glass on window stop. Disconnect power supply from electric lift.
    7. 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

    1. Remove rear quarter window, access hole cover and regulator attaching screws "A." On electric equipped lifts, disconnect switch (fig. 83).
    2. Remove regulator from body through access hole.
    3. To install, reverse this procedure, reseal access door and regulator holes.

    Window Guide

    Removal and Installation

    1. Remove quarter window.
    2. Remove guide screw "B" at quarter lock pillar, two upper attaching screws at "C" and center stud nut and washer at "D" (fig. 83).
    3. Remove guide assembly from window opening.
    4. To install, reverse this removal procedure.

    Station Wagon Rear Quarter

    Rear Quarter Window Garnish Moldings-4 Door

    Removal and Installation

    The garnish moldings are secured to the body with screws, and consist of a garnish molding front and rear, and a garnish molding upper and lower escutcheon. To remove moldings, remove e