ALPHABETICAL INDEX

All Passenger Cars

Step 1 tape template to fender and drill holes Fig. 181.

Step 2 insert screw driver or rod in 1 inch dia. hole and knock out rubber plug from hinge pillar.

Step 3 remove the right cowl kick panel.

Step 4 install radio antenna Fig. 181.

Step 5 insert the jack end of antenna lead-in cable into the radio and screw the antenna lead-in coupling onto the antenna firmly.

Step 6 replace the right cowl kick panel.

Radio Antenna (Manually Operated)

All Passenger Cars

Step 1 locate templates on left rear fender and drill three holes.

Step 2 attach clip and bracket Fig. 182 and insert antenna assembly through holes.

Step 3 place gasket and bezel on antenna rod and secure with cap tightly.

Step 4 attach bracket to inner panel Fig. 182 and tighten clip nut.

Step 5 remove kick panel, clamp cable Fig. 182 and route toward front of car.

Step 6 replace kick panel.

Step 7 adjust antenna trimmer located on the bottom of radio.

Radio Antenna (Electrically Operated) Installation Instructions

PASSENGER CARS

Step 1 - locate templates on right rear fender and drill three holes.

Step 2 - attach clip and bracket Fig. 183 and insert antenna assy up through drilled holes.

Step 3 - place gasket and bezel on antenna rod and secure with cap tightly.

Step 4 - attach bracket to inner panel Fig. 183 and tighten clip nut.

Step 5 -remove r. h. kick panel, route wire and cable (after cable is clamped Fig. 184) together toward front of car.

Step 6 install switch and complete cable and wire routing through main wire harness clips.

Step 7 connect all terminals, insert antenna lead-in cable jack into radio receiver and fuse into terminal block.

Step 8 adjust antenna trimmer located on bottom of radio.

Step 9 replace the kick panel.

Radio Installation Instructions

ALL PASSENGER CARS

PRELIMINARY:

Check all items against the packing slip. If any items are missing, mark them on the packing slip, fill in the dealers' name, and forward it to the zone office. Attention of the zone parts and accessories manager. After checking the tubes and vibrator to be sure they are pushed tight into the sockets. Hook the radio receiver to a 12 volt power supply and play the radio while installing the supression equipment. (A new radio that plays properly for the first 15 minutes can be assumed to be an acceptable product which should operate in a normal manner without interruption.)

Step 1 install ground straps, capacitors, and static collectors. See illustrations no. Fig. 185 Fig. 186, Fig. 187 Fig. 188, AND STEP 12.

Step 2 remove radio grille, glove box, and radio control cover from instrument panel.

Step 3 install radio speaker. Fig. 189.

Step 4 replace grille with the nuts and washers previously removed. one of these nuts is used to install the radio support brace.

Step 5 install antenna lead-in clip. (Manual Radio Only) Fig. 189.

Step 6 install radio receiver.

Step 7 install control knobs and escutcheons.

Step 8 route and connect all leads and wires as illustrated. see Fig. 190 For manual wiring or Fig. 191Fig. 192 for signal seeking wiring.

Step 9 install fuse on terminals designated "radio power" on fuse junction block under instrument panel on left hand side of dash panel. see view c.

Step 10 extend antenna full height and tune for a weak station between 800 and 1000 kc. Adjust the antenna trimmer on the bottom of the radio for maximum volume.

Step 11 replace glove compartment box.

Step 12 see sheet 4 for v-8 engine special ground straps.

Fig. 193.

Radio Antenna

All Trucks

1. Place the template on the right hand front fender as indicated in Fig. 194. CAUTION: Follow the directions given on the template. Secure the template with masking tape.
2. Select the proper hole for drilling. This is indicated on the template. See Fig. 194. Centerpunch.
3. Remove template and drill a 13/16 inch diameter hole perpendicular to the fender surface.
4. Drop the inner spacer on the antenna. See Fig. 195.
5. From under the fender, pass the antenna up through the hole just drilled. Add the gasket and the outer spacer. Install the special hex head nut and tighten to finger tightness only. CAUTION: Make sure the extension arm at the bottom of the antenna faces inboard. See Fig. 196.
6. Attach the bracket loosely to the antenna extension arm with the hex head machine screw, internal-external tooth lockwasher and hex head nut. IMPORTANT: For Series 3000 trucks, shorten the bracket before attaching as shown in Fig. 196.
7. Align the bracket flush with the baffle, as shown in Fig. 198. then tighten the screw and nut assembly securely.
8. Using the holes in the bracket as a template, (See Fig. 196) centerpunch and drill two holes with a number 28 drill through the baffle. Secure the bracket to the baffle with two tapping screws.
9. Tighten the special hex head nut on the antenna assembly securely against the outer spacer. Add the special felt washer and antenna cap nut. The assembly should now be complete as shown in Fig. 195.
10. Locate on the cowl under the front fender, the dash mat clip. Measure outboard 1-3/4 inches from dash mat clip, centerpunch, and drill a 7/16 inch hole, as shown in Fig. 197. Remove any burrs resulting from the drilling and install the rubber grommet provided.
11. Attach the antenna cable to the antenna connector and pass the cable through the grommet. Route the cable under the instrument panel, connect the cable to the radio by means of the cable plug-in jack. This is shown in Fig. 198.
12. Attach the antenna cable to the inside bottom lip of the instrument panel with the clip provided, as shown in Fig. 198.

5000 SERIES

1. Place the template on the right hand front fender, as indicated in the upper portion of Fig. 199.CAUTION: Follow the directions given on the template. Secure the template with masking tape.
2. Select the proper hole for drilling. This is indicated on the template. See upper portion of Fig. 199. Centerpunch.
3. Proceed as directed in steps 3, 4, and 5 of the 3000, 4000, and 6000 Series instructions. CAUTION: Make sure the extension arm at the bottom of the antenna faces outboard during step 5.
4. Proceed as directed in step 6 of the 3000, 4000 and 6000 Series instructions. IMPORTANT: For Series 5000 trucks, shorten the bracket before attacking as shown in Fig. 199.
5. The bracket should now rest on the inside lip of the wheel opening flange. Using the remaining hole centerpunch and drill through the flange with a No. 33 drill.
6. Use a 1/4 inch standard hex nut (this is not included in the package) as a spacer between the bracket and the wheel opening flange, and from the bottom introduce the tapping screw provided making sure that it passes through the nut and bracket. Tighten securely. See Fig. 199.
7. Tighten the hex head machine screw, internal-external tooth lockwasher and hex head nut.
8. Repeat step 9 of the 3000, 4000 and 6000 Series instructions.
9. From inside the cab locate the perforated hole on the dash mat 3-1/4 inches up from the bottom of the mat and 1-1/2 inches in from the kick panel. Remove the material along the perforations, centerpunch and drill a 1/2 inch diameter hole through the cowl. Remove any burrs resulting from the drilling.
10. From under the right hand front fender, install the grommet in the hole just drilled and route the cable through the grommet to the inside of the dash panel. Connect it to the radio by means of the radio plug-in jack.

TRUCKS

Unpack the radio receiver and check all the parts with the packing slip. If any items are missing, indicate this on the packing slip and together with the dealer name and address send the packing slip to the Zone Office to the attention of the Zone Parts and Accessories Manager.

While bench convenience is available, check the tubes and vibrator to make sure they are secured tightly in their sockets. Connect the radio to a 12-volt power supply and allow the radio to play while installing the noise suppression equipment. Radios that play for 15 minutes should give many months of uninterrupted service.

1. Remove the high tension coil wire from the distributor cap. Install the distributor suppressor and nipple in the distributor cap and connect the high tension wire to the suppressor. See Fig. 201.
2. Mount the generator capacitor (No. 1911095) on the generator with the existing screw in the generator housing and connect the lead wire to the generator armature terminal. See Fig. 201. NOTE: Do not connect the lead wire to the generator field terminal.
3. Install the ignition coil capacitor (No. 1929070) to the coil mounting bracket with the screw and lockwasher provided and attach the lead wire to the positive terminal of the coil. See Fig. 201.
4. Mount the voltage regulator capacitor (No. 1917580) under the voltage regulator mounting screw and attach the lead wire to the battery terminal on the voltage regulator. See Fig. 201.
5. Remove both front wheel hub caps. Prepare to install the front wheel static collectors by removing both grease retainers and cleaning them of any grease. Remove the grease from the center holes in the front wheel spindles and clean the holes with sand paper to assure a good electrical contact for the static collector buttons. Bend the cotter pins to give adequate clearance for the static collector buttons so they may contact properly with the wheel spindle holes.
6. Press the static collectors into the grease retainers with the collector buttons up and the planes of the buttons parallel with the open sides of the retainers. See Fig. 202. NOTE: For 5000 and 6000 Series trucks only, it will be necessary to attach the static collectors to the adapters provided. See Fig. 202.
7. Replace grease retainers and hub caps.
8. Remove the radio hole cover plate and the two button plugs from the instrument panel.
9. Attach the radio mounting brace loosely to the bracket on the plenum panel with the bolt and spring lockwasher provided. See Fig. 203.
10. Lift the radio up behind the instrument panel with the control studs pointing up, then tip the set to bring the control studs and dial through the holes in the instrument panel.
11. Attach the radio to the instrument panel at the control studs with the two special nuts provided. Fasten to finger tightness.
12. Attach the mounting brace loosely to the radio at the mounting pad with the bolt and spring lockwasher provided. See Fig. 203.
13. Level the radio with the instrument panel so that it positions with a minimum of stress at the control studs. Tighten securely the tow bolts in the mounting brace and the two special nuts on the radio control studs.
14. Place the radio control knob assemblies and felt washers on the control studs. See Fig. 203. NOTE: The control knob assembly for the left hand control stud is keyed.
15. Route the power and dial lamp lead wires from the radio through the clip on the back of the instrument cluster and through the clip on the plenum panel and down to the accessory junction block. See Fig. 200.
16. Connect the terminal on the black power lead wire to the terminal on the accessory junction block marked "RADIO". Install the fuse in the clips directly underneath. See Fig. 204.
17. Connect the terminal on the gray dial lamp lead wire to one of the terminals on the upper left hand corner of the accessory junction block. See Fig. 204.
18. Connect the capacitor (No. 7263920) to the accessory junction block with the existing screws, one wire to the bracket and the other wire to the connection in the lower left hand corner. See Fig. 204.
19. Attach the antenna lead wire clip (provided in the antenna package) to the reinforcement flange of the instrument panel placing it near the lower left hand corner of the dispatch box opening. See Fig. 200.
20. Route the antenna lead wire through the clip on the instrument panel and plug it into the connector on the right side of the radio.
21. Tape the template to the header panel keeping it flush with the edge of the header panel and centered with the dimple on the underside of the header panel. See Fig. 205. NOTE: If a rear view mirror is installed, keep the template centered with the centerline of the rear view mirror bracket.
22. Centerpunch the seven hole locations indicated on the template; that is, two center holes, four corner holes and one hole for the speaker ground wire.
23. Remove the template and drill the four corner holes and the hole for the speaker ground wire with a 1/8 inch diameter drill. See Fig. 205.
24. Cut out the two center holes with a 3-1/2 inch diameter hole saw.
25. Cut out the two triangles of metal between the two center holes.
26. Place the rubber grommet in the cut-out on the speaker shroud. See Fig. 205. NOTE: When a rear view mirror is installed, discard the grommet.
27. Feed a stiff wire up through the right hand windshield pillar and out through the speaker opening in the header panel. Attach the speaker lead wire to this wire and pull it back down through the windshield pillar. Detach the speaker lead wire from the stiff wire and plug this end of the speaker lead wire into the connector on the underside of the radio case.
28. Attach the speaker ground wire to the header panel with the screw provided.
29. Plug the speaker lead wire and the ground wire into the connectors on the speaker.
30. Attach the speaker assembly to the header panel with the four self-tapping screws provided. See Fig. 205.
31. Position the slack of the speaker lead wire along the inside of the instrument panel reinforcement flange and attach it to the antenna clip. See Fig. 200.
32. Extend the antenna to full height. Turn on the radio receiver and tune in a weak station near 800 on the dial with the volume control turned to maximum position. With a small screwdriver adjust the antenna trimmer condenser for clearest and maximum volume. NOTE: The antenna trimmer is located on the bottom of the radio receiver and is indicated by a red sticker.
33. Hang the radio operation instruction tag on one of the radio control knobs.

PASSENGER CARS

Step 1 drill a 17/32 inch dia. hole in instrument panel. Install auxiliary speaker switch. see view "a".

Step 2 disconnect speaker from transformer jack and join it to auxiliary switch wire having the connector. See Fig. 253 For manual and push button receivers or Fig. 254 For signal seeking receiver.

Step 3 attach center wire of auxiliary switch to transformer jack at point where wire was removed in step no. 2.

Step 4 route auxiliary speaker switch to auxillary speaker wire as shown. See illustration no. Fig. 253 and no. Fig. 254.

Step 5 install the auxiliary speaker as shown. See Fig. 255.

Step 6 turn radio on and put auxiliary speaker control knob in its extreme counter clock-wise position. To test, turn control in a clock-wise rotation to have the sound transfer from entirely on the front speaker to entirely on the auxiliary speaker.

Air Conditioning and Heating

8 CYLINDER PASSENGER CARS

Body front end and engine modification disconnect battery. Remove hood from hood hinges. Remove the front fender baffle to radiator support bolts. remove the horns and allow them to hang.

STEP 1 - Mount compressor support and compressor fig. 1.

STEP 2 - 35 AMP generator, part no. 1102083 and 1119002 regulator, are recommended but not in package. See Fig. 1.

STEP 3 - Replace harmonic balancer with special harmonic balancer.

STEP 4 - Replace production pulley with new pulley at the same time assembling special fan.

STEP 5 - Replace fuel line from carburetor to fuel pump. See Fig. 2.

STEP 6 - From passenger compartment remove two perforated areas from dash mat. From engine side of dash, remove the two hole covers. Retain screws and special clamps for future use. CAUTION: When Extending capillary tube make sure valve lever is in locked open Position and secured by disposable wire clip Fig. 2.

STEP 7 - Install transition piece, gasket, core and core housing Fig. 2.

STEP 8 - Install water valve Fig. 2. NOTE: Apply adhesive cement to this surface of gasket and adhere to inside surface of transition piece.

STEP 9 - Install defroster duct and distribution duct assemblies Fig. 3. NOTE: Locking clip must not be removed until capillary is clipped into position. Slide special grommet over capillary tube from water control. Slide grommet into slot on top of distribution duct and extend coil. Clip capillary tube to deflector Fig. 3.

STEP 10 - Mount condenser and horns to baffle Fig. 4. Horn brackets slide into slots on condenser mounting bracket. CAUTION: Two brown leads and one black lead are connected to "a" terminal. Dark blue lead is connected to "f" terminal.

STEP 11 - Assemble special sleeve onto transition piece, folding It back on itself half way, until evaporator is in place, then unfold Over mouth of blower Fig. 5.

STEP 12 - For mounting air outlets to instrument panel, follow instructions on templates in locating and cutting 4 inch diameter hole. Place bezel in hole and mark instrument panel for screw holes to be drilled.

STEP 13 - Install control in instrument panel and attach cables Fig. 6. NOTE: Heavier front springs for air conditioner installation recommended but not in package. For dealer installation, order under part no. 3722423. For air conditioner only. Replace 10 amp fuse in fuse junction block Fig. 7.

STEP 14 - Bolt the shut-off valves together Fig. 8 in view "a".

STEP 15 - Remove cover plate from head of compressor and install valve assembly.

STEP 16 - Loosed gage connection cap at "a" and acorn nuts "d" and "e".

STEP 17 - Run compressor at approximately 1.000 r.p.m. for two minutes and then tighten cap at "a".

STEP 18 - Stop compressor. Tightly back seat valves "d" and "e" as shown.

STEP 19 - Install acorn nuts at "d" and "e".

STEP 20 - Blow out the area with compressed air and halogen leak test shut off valves at compressor head.

It must be noted that at no time must the plate or shut off valves be removed from the compressor for a period of time to exceed 2 minutes. Failure to adhere to this condition would result in contamination of the system and lead to early failure. (The time required to perform steps one and two is less than a minute by an inexperienced operator; therefore, there should be no cause for leaving the system open for any longer period.) At no time should the compressor be operated with the valves removed.

STEP 21 - Locate, scribe and drill all holes using dimensions Fig. 9.

STEP 22 - If the car is equipped with powerglide transmission, drain and retain the transmission fluid. Remove the filler tube and transmission housing side cover. Retain the filler tube and all attaching bolts and washers. Install the new side cover, using the attaching bolts retained. Place the "o" ring in the filler tube cover opening, and install the filler tube. (Henceforth, the filler tube will act only as a vent.) Refill the transmission through the plug hole in the cover. Install the plug and gasket. Check the fluid level with the engine idling, parking brake set, transmission oil hot and control lever in "n" position. (The transmission is properly filled when the transmission oil is level with the plug opening in the cover.)

Air Conditioning Conversion

8 CYLINDER PASSENGER CARS

Body front end and engine modification disconnect battery. Remove hood from hood hinges. Remove the front fender baffle to radiator support bolts. remove the horns and allow them to hang.

STEP 1- Mount compressor support and compressor Fig. 10.

STEP 2 - 35 AMP generator, part no. 1102083 and 1119002 regulator, are recommended but not in package. See Fig. 10.

STEP 3 - Replace harmonic balancer with special harmonic balancer.

STEP 4 - Replace production pulley with new pulley at the same time assembling special fan.

STEP 5 - Replace fuel line from carburetor to fuel pump. See Fig. 10.

STEP 6 - Install transition piece, gasket, core and core housing Fig. 11.

STEP 7 - Mount condenser and horns to baffle Fig. 12. Horn brackets slide into slots on condenser mounting bracket. CAUTION: Two brown leads and one black lead are connected to "a" terminal. Dark blue lead is connected to "f" terminal.

STEP 8 - Assemble special sleeve onto transition piece, folding it back on itself half way, until evaporator is in place, then unfold over mouth of blower Fig. 13.

STEP 9 - For mounting air outlets to instrument panel, follow instructions on template in locating and cutting 4 inch diameter hole. Place bezel in hole and mark instrument panel for screw holes to be drilled.

STEP 10 - Install control in instrument panel and attach cables Fig. 14.

STEP 11- Bolt the shut-off valves together Fig. 15 in view "a".

STEP 12 - Remove cover plate from head of compressor and install Valve assembly.

STEP 13 - Loosen gage connection cap at "A" and acorn nuts "D" and "E".

STEP 14 - Run compressor at approximately 1. 000 r. p.m. for two minutes and then tighten cap at "a".

STEP15 - Stop compressor. Tightly back-seat valves d & e Fig. 15.

STEP 16 - Install acorn nuts at "d" and "e".

STEP 17 - Blow out the area with compressed air and halogen leak test shut off valves at compressor head. It must be noted that at no time must the plate or shut off valves be removed from the compressor for a period of time to exceed 2 minutes. Failure to adhere to this condition would result in contamination of the system and lead to early failure. (The time required to perform steps one and two is less than a minute by an inexperienced operator; therefore, there should be no cause for leaving the system open for any longer period.) At no time should the compressor be operated with the valves removed.

STEP 18 - Locate, scribe and drill all holes using dimensions Fig. 16. Assemble all parts Fig. 16.

STEP 19 - If the car is equipped with powerglide transmission, drain and retain the transmission fluid. Remove the filler tube and transmission housing side cover. Retain the filler tube and all attaching bolts and washers. Install the new side cover, using the attaching bolts retained. Place the "o" ring in the filler tube cover opening, and install the filler tube. (Henceforth, the filler tube will act only as a vent.) Refill the transmission through the plug hole in the cover. Install the plug and gasket. Check the fluid level with the engine idling, parking brake set, transmission oil hot and control lever in "n" position. (The transmission is properly filled when the transmission oil is level with the plug opening in the cover.)

Air Conditioning

6 CYLINDER PASSENGER CARS

Body front end and engine modification disconnect battery. Remove hood from hood hinges. Remove the front fender baffle to radiator support bolts. Remove the horns and allow them to hang.

STEP 1 - Mount support and compressor Fig. 17.

STEP 2 - 35 AMP generator, part no. 1102083 and 1119002 regulator, recommended but not in package. See Fig. 17.

STEP 3 - Replace harmonic balancer with special harmonic balancer.

STEP 4 - Couple new fan pulley to production pulley at the same time assembling special fan Fig. 17. NOTE: Remove thermostat housing, and replace heater plug with elbow and special nipple in position Fig. 17. Replace thermostat housing.

STEP 5 - From passenger compartment remove two perforated areas from dash mat. From engine side of dash, remove the two hole covers. Retain screws and special clamps for future use.

STEP 6 - Install transition piece, gasket, core and core housing Fig. 18.

STEP 7 - Install water valve Fig 18. NOTE: Apply adhesive cement to this surface of gasket and adhere to inside surface of transition piece.

STEP 8 - Install defroster duct and distribution duct assemblies Fig. 19. NOTE: Locking clip must not be removed until capillary is clipped into position. Slide special grommet over capillary tube from water control. Slide grommet into slot on top of distribution duct and extend coil. Clip capillary tube to deflector Fig. 19.

STEP 9 - Mount adapters and condenser to radiator Fig. 20. Remount horns to baffle. CAUTION: Two brown leads and one black lead are connected to "a" terminal. Dark blue lead is connected to "f" terminal.

STEP 10 - Assemble special sleeve onto transition piece, folding it back on itself half way, until evaporator is in place, then unfold over mouth of blower Fig. 21.

STEP 11 - For mounting air outlets to instrument panel, follow instructions on template in locating and cutting 4 inch diameter hole. Place bezel in hole and mark instrument panel for screw holes to be drilled.

STEP 12 - Install control in instrument panel and attach cables Fig. 22.

STEP 13 - Bolt the shut-off valves together Fig. 24 in view "a".

STEP 14 - Remove cover plate from head of compressor and install Valve assembly.

STEP 15 - Loosed gage connection cap "a" and acorn nuts "d" and "e".

STEP 16 - Run compressor at approximately 1.000 r.p.m. for two minutes and then tighten cap at "a".

STEP 17 - Stop compressor. tightly back - seat valves "d" and "e" Fig. 24.

STEP 18 - Install acorn nuts at "d" and "e".

STEP 19 - Blow out area with compressed air and halogen leak test shut off valves at compressor head. It must be noted that at no time must the plate or shut off valve be removed from the compressor for a period of time to exceed 2 minutes. Failure to adhere to this condition would result in contamination of the system and lead to early failure. (The time required to perform steps one and two is less than a minute by an inexperienced operator; therefore, there should be no cause for leaving the system open for any longer period.) At no time should the compressor be operated with the valves removed.

STEP 20 - Locate, scribe and drill all holes using dimensions Fig. 25.Assemble all parts Fig. 25.

STEP 21 - If the car is equipped with powerglide transmission, drain and retain the transmission fluid. remove the filler tube and transmission housing side cover. Retain the filler tube and all attaching bolts and washers. Install the new side cover, using the attaching bolts retained. Place the "o" ring in the filler tube cover opening, and install the filler tube. (Henceforth, the filler tube will act only as a vent.) Refill the transmission through the plug hole in the cover. Detail the plug and gasket. Check the fluid level with the engine idling, parking brake set, transmission oil hot and control lever in "n" position. (The transmission is properly filled when the transmission oil is level with the plug opening in the cover.)

Air Conditioning Conversion Installation Instructions

6 CYLINDER PASSENGER CARS

Body front end and engine modification disconnect battery. Remove hood from hood hinges. Remove the front fender raffle to radiator support bolts. Remove horns and allow them to hang.

STEP 1 - Mount support and compressor Fig. 26.

STEP 2 - 35 AMP generator part no. 1102083 and 1119002 regulator recommended but not in package. See Fig. 26.

STEP 3 - Replace harmonic balancer with special harmonic balancer.

STEP 4 - Couple new fan pulley to production pulley, at the same time assembling special fan Fig. 26. NOTE: Remove thermostat housing, and replace heater plug with elbow and special nipple in position Fig. 26. Replace thermostat housing.

STEP 5 - Install transition piece, gasket, core and core housing Fig. 27. NOTE: Apply adhesive cement to this surface of gasket and adhere to inside surface of transition piece.

STEP 6 - Mount adapters and condenser to radiator Fig. 28. Remount horns to baffle. CAUTION: Two brown leads ad one black lead are connected to "a" terminal, dark blue lead is connected to "f" terminal.

STEP 7 - Assemble special sleeve onto transition piece, folding it back on itself half way, until evaporator is in place, then unfold over mouth of blower Fig. 29.

STEP 8 - For mounting air outlets to instrument panel, follow instructions on template in bezel in hole and mark instrument panel for screw holes to be drilled.

STEP 9 - Install control in instrument panel and attach cables Fig. 30.NOTE: Heavier front springs for air conditioner Installation recommended but not on package. For dealer installation Order under part No. 3722423.

STEP 10 - Bolt the shut-off valves together Fig. 31 in view "a".

STEP 11 - Remove cover plate from head of compressor and install valve assembly.

STEP 12 - Loosen gage connection cap at "a" and acorn nuts at "d" and "e".

STEP 13 - Run compressor at approximately 1. 000 r. p. m. for two minutes and then tighten cap at "a".

STEP 14 - Stop compressor. tightly back -seat valves "d" and "e" Fig. 31.

STEP 15 - Install acorn nuts at "d" and "e".

STEP 16 - Blow out the area with compressed air and halogen leak test shut -off valves at compressor head. It must be noted that at no time must the plate or shut off valves be removed from the compressor for a period of time to exceed 2 minutes. Failure to adhere to this condition would result in contamination of the system and lead to early failure. (The time required to perform steps one and two is less than a minute by an inexperienced operator; therefore, there should be no cause for leaving the system open for any longer period.) At no time should the compressor be operated with the valves removed.

STEP 17 - Locate, scribe and drill all holes using dimensions Fig. 32. Assemble all parts Fig. 32.

STEP 18 - If the car is equipped with powerglide transmission, drain and retain the transmission fluid. Remove the filler tube and transmission housing side cover. Retain the filler tube and all attaching bolts and washers. Install the new side cover using the attaching bolts retained. Place the "o" ring in the filler tube cover opening, and install the filler tube. (Henceforth, the filler tube will act only as a vent.) Refill the transmission through the plug hole in the cover. Install the plug and gasket. Check the fluid level with the engine idling, parking brake set, transmission oil hot and control lever in "n" position. (The transmission is properly filled when the transmission oil is level with the plug opening in the cover.)

Car Heater and Defroster (Deluxe) Installation Instructions

Step 1 remove perforated portions of dash mat.

Step 2 fit distributor ends of defroster in slots provided in cowl. Attach defroster to cowl.

Step 3 install the core housing and distributor duct, securing the core housing and distributor duct together.

Step 4 assemble seal to base of water control valve. Secure cable to valve and seat the valve base on the dash and secure in place.

Step 5 slide special grommet over capillary tube from valve control. Slide grommet into slot on top of distiubutor. Clip capillary tube to deflector. (Caution: When extending capillary make sure valve lever is in locked open position and secured by disposable wire clip Fig. 114 in step 4.)

Step 6 from engine side install the core and transition assembles.

Step 7 assemble blower mounting bracket to fender and skirt. Assemble blower motor and gasket to bracket. Install sleeve between blower and transition assembly. Install air hose from takeoff tube to blower.

Step 8 drain radiator.

Step 9 remove plugs from thermostat housing and water pump and install nipples and hoses.

NOTE: Cut hose to requieted length Fig. 115.

Step 10 install control assembly in instrument panel and attach cables Fig. 116.

Step 11 install 10 amp fuse in fuse and terminal block.

Step 12 refill radiator.

Car Heater and Defroster (Recirculating) Installation Instruction

Step 1 remove perforated portions of dash mat.

Step 2 install defroster duct.

Step 3 install distributor duct.

Step 4 install heater hole cover plate to dash and attach blower motor assembly and secure to distributor duct.

Step 5 drain radiator. install nipples and hoses.

Step 6 install heater control switch.

Step 7 install 10 amp fuse in terminal and fuse block.

Step 8 refill radiator.

Fig. 117.

Heater and Defroster Installation Instructions

ALL TRUCKS

Step 1 drain radiator.

Step 2 punch holes through dash mat for insertion of studs and core pipes into dash panel. Remove glove box.

Step 3 install defroster inlets.

Step 4 remove cover plate from inlet opening. assemble blower housing unit. Apply sealer Fig. 118 In view A.

Step 5 install and adjust cable Fig. 118 In view B. ( have air inlet door in outside air position.)

Step 6 install complete unit into dash panel Fig. 118. Secure in place.

Step 7 install right and left hand defroster hoses Fig. 118.

Step 8 remove control panel dummy plate.

Step 9 install control unit (view c)

Step 10 route air inlet cable (No. 1) into location on control unit Fig. 119. Pull cable out to close inlet door. Move lever approx. 1/8 inch toward inside air position. Tighten screw holding cable wire to control lever. Move lever to inside air position without moving door crank.

Step 11 attach temperature cable (No. 2) to control unit Fig. 119. Adjust for clearance. move lever on control panel toward bottom Fig. 119 In view D. Partially tighten clamp. Return lever to 1/16 inch from top of slot and secure.

Step 12 attach and clearance adjust the defroster cable (No. 3) Fig. 119 In view F. Control panel adjustment is the same as No. 2 cable.

Step 13 plug connectors together and install in clip on heater housing Fig. 119 In view H.

Step 14 route red and gray wires through the 3 clips Fig. 119 And plug connector ends into junction lock Fig. 119 In view G. Install fuse.

FENDER SKIRT MOUNTING RACKET NOT REQUIRED 5000 SERIES

Step 1 remove plugs in thermostat and water pump housings.

Step 2 installthe long and short nipples Fig. 120.

Step 3 install hoses and secure to fender skirt Fig. 120.

7000 AND 8000 SERIES WITH AIR OVER HYDRAULIC BRAKES

Step 1 remove plugs, cut hoses, and drill for 8000 series.

Step 2 install parts Fig. 121.

9000, 10000 SERIES

Step 1 drill and install parts Fig. 122.

Step 2 fill radiator and set temperature lever for "on" position.

Heater and Defroster Installation Instructions (Recirculating)

All Trucks

Step 1 drain radiator.

Step 2 punch holes through dash mat for insertion of studs and core pipes into dash panel.

STEP 3 Install rh & lh defroster inlets Fig. 123.

Step 4 install heater housing into place in dash panel and secureFig. 123.

Step 5 install defroster hoses Fig.123.

Step 6 remove instrument panel control dummy plate.

Step 7 locate and drill hole in plate (View B).

Step 8 replace plate and assemble switch parts Fig. 124 In view B.

Step 9 install wiring hook-up as indicated in above wiring instructions.

7000 & 8000 SERIES (AIR OVER HYDRAULIC BRAKES)

Step 1 remove pipe plugs, cut hoses, and drill for 8000 series.

Step 2 install parts Fig. 125.

9000 & 10,000 SERIES

Step 1 drill and install parts Fig. 126.

Step 2 fill radiator and set temperature lever for "on" position,

3000, 4000, 5000, 6000, 7000, 8000 SERIES

Step 1 remove plugs in thermostat and water pump housing.

Step 2 install the long and short nipples Fig.127.

Step 3 install hoses and secure to fender Fig. 127.

Electrical

Pull back floor mat remove foot switch and switch plate noting orientation of terminals. File notch in plate Fig. 33, Install new foot switch using existing mounting parts. Bring amplifier harness through speedometer cable grommet in firewall assemble triple connector over three female terminals

(See Fig. 3) And attach to switch, remount switch plate and switch on toe pan. Connect red wire from switch to red wire from amplifier using connector provided. Connect extension wire assembly provided to harness removed from foot switch and route out thrugh speedometer cable grommet to connect to power relay Fig. 33 In Fig. 3. replace floor mat to cover all foot switch wiring.

TO INSTALL POWER RELAY;

Select convenient location in engine, compartment within reach of extension wire harness from harness removed from foot switch, using relay as a template, center punch and drill two 1/8 dia. holes. Attach relay with # 10 x 1/2 tapping screws provided.

TO INSTALL AMPLIFIER;

Locate hole "A" Fig. 34 and drill 3/16 dia. hole. Using amplifier as a template, locate and drill other three holes. 1/4-14 x 3/4 screws from packarge are to be used for attaching amplifier. ("dim and "hold" on amplifier cover should be toward front of car.) Locate and drill 1" dia. hole "b" as shown. Route amplifier harness back through this hole, using split grommet provided in package.

Fig. 35.

Fig. 36.

The centerline of the photo tube unit must be aimed parallel to the centerline of the car afterinstallation is made. Horizontal aim must be checked as follows: place two pieces of tape on a wall or screen at hood height Fig. 37, Place the car 25 feet back from the wall, with the centerline of the hood aimed at the right hand tape. Remove cover and replace with level from autronic eye tester. Aim over sights to left hand tape. If unit is aimed more than 4" left or right of tape, elongate one side of mounting stud hole in the instrument panel sufficiently to rotate unitfor correct aim.

Wiring Junction Block

All Passenger Cars

STEP 1 - Place wiring junction block on cowl side panel, and secure in place with the two screws furnished. Attach the wiring harness assembly connectors, and main wiring harness connectors on the junction block as directed.

STEP 2 - Attach the pink wire to the terminal on the ignition switch marked "acc. ". Fig. 51.

Block Wiring Junction Truck

ALL TRUCKS

STEP 1 - Locate and remove rectangular section (knock-out) Fig. 52 in illustration.

STEP 2 - Connect the harness wires to the junction block Fig. 52.

STEP 3 - Position the block in the cut-out Fig. 52. Coat tapping screws with windshield sealer. Secure the Junction block firmly into the dash.

STEP 4 - Route the junction block harness with the main wiring harness through clip Fig. 52.

STEP 5 - Plug the red and gray wires into the light switch Fig. 52 in the illustration and View A.

STEP 6 - If accessory terminal on the ignition switch is occupied, disconnect that connection and connect to the male connector (pig tail) on the pink wire.

STEP 7 - Connect the female terminal on the pink wire to the accessory terminal on the ignition switch.

Vibrator Horn Installation Instructions

PASSENGER CARS

Fig. 128.

Vibrator Horn

Trucks

Step 1 mount r.h. horn assembly with existing bolt for series 3000, 4000, 6000, 8000, and 10,000. See view A. for series 5000, 7000, and 9000 mount with attaching parts supplied as in view B.

Step 2 route R.H. horn wire assembly with main wiring harness extension assembly for all models.

Step 3 test installation.

Fig. 129.

Backing Lamp Installation Instructions

PASSENGER CARS, STATION WAGONS, AND SEDAN DELIVERY

PASSENGER CARS ONLY

Step 1 locate area in steering column (Fig. 130R switch mounting (manual shift only) or location of exisitng production switch. ( Atomatic Transmission)

Step 2 in manual shift cars, opening is taped. (View C) remove tape and place gear shift lever in neutral.

Step 3 locate the two holes at sides of opening. (View C)

Fig. 131.

Step 4 position the switch and install with the two wide-pitch tapping screws provided.

Step 5 plug the "V" connector of the wire assembly on the two terminals of the installed switch (view c ), Fig. 130.

NOTE: If the car is equipped with automatic transmission, simply plug the "v" connector (View D , Fig. 132) on the unused terminals of the existing combination switch Fig. 132.

Step 6 snap clip provided and Fig. 132 in view "a" near the dash end of the steering support housing. (Fig. 131)

Step 7 for either switch, run the harness upward into the clip Fig. 132 and directly to the left along the face of the dash mat to the accessory junction block (SEE Fig. 131 View B).

Step 8 position the clip provided on the top edge of kick pad near the forward end of junction block and close to the dash mat.

Step 9 place the harness into clip taking up slack.

Step 10 allow short terminal wire to hang loose for future installation and feed long wire down corner of cowl between dash mat and kick pad and under floor mat on toe pan to the floor. (Fig. 131)

Step 11 remove the door scuff plate, carpet, and wiring harness cover and route wire with body harness to rear. Locate loom so that front end extends 4 inches under the cover. (See View E, Fig. 132)

Step 12 re-assemble and route wire to deck floor pan. (Fig. 132)

Step 13 remove L. H. and R. H. existing covers in backing lamp openings.

Step 14 insert bracket through mounting hole. hook one leg in place in notch at side. pull opposite leg toward center of lamp and hook at remaining notch.

Step 15 disassemble backing lamp assembly, L. H. & R. H. Fig. 133 IN Fig. 133.

Step 16 insert wire through hole in opening of bracket and over top of reinforcement to brace Fig. 134. Secure housing to mounting bracket with the two 8-32 x 3/4 flat hd. screws provided. Complete assembly with the lens and gasket. (follow view h & i for all screw locations.)

Step 17 locate hole in left and right hand bumper brace. (Fig. 133) snap clips provided into each hole. (View G )

Step 18 locate existing plugs in floor pan. (L. H. & R. H.) Remove and install the two grommets provided.

Step 19 route L. H. & R. H. lamp wire through clips and grommets and bring out on floor pan. (Fig. 133) Remove any slack to insure clearance at exhaust pipe.

Step 20 join L. H. & R. H. wires and switch wire with "Y" connector according to View G.

Step 21 attach short terminal wire (leading off installed harness at cowl) to junction block Fig. 131 In view B, Fig. 131.

Step 22 install fuse provided and check for operation. Station wagon and sedan delivery

NOTE: Passenger car switch installation and front wiring will be identical for station wagons and sedan delivery excepting additional removal of rear floor edge mouldings.

NOTE: The following steps are for station wagon and sedan delivery only.

Step 18 after step 17 has been completed, locate and drill hole for L. H. grommet. (View K, Fig. 134) pass switch wire down through hole.

Step 19 install the small grommet. (Small Hole)

Step 20 install large clip on body anchor plate Fig. 134 in Fig. 134.

Step 21 place L. H. lamp wire into clip at bumper brace and route into body anchor plate clip Fig. 135. Route switch wire into clip. (Fig. 134) Plug both wires into "y" connector.

Step 22 install the three clips provided at equal distances along rear cross member. (Fig. 135)

Step 23 route R. H. lamp wiring in same manner as L. H. except to lead lamp wire through the three clips and plug into connector Fig. 135.

Step 24 attach short terminal wire (leading off installed harness at cowl) to junction block Fig. 131 in view B, Fig. 131.

Step 25 install fuse provided and check for operation.

Backing Lamp Installation Instructions

SUBURBAN CARRYALL, PANEL AND PICKUP TRUCKS

FOR 3-SPEED TRANSMISSIONS:

1. Attach the switch lever loosely to the gearshift lever, as shown in Fig. 136.
2. Place the template provided over the gearshift rod and on the steering gear cowl upper bracket, Fig. 136 In Fig. 136. Centerpunch and drill two 13/64 holes on the LEFT HAND side of the steering column. Attach the switch to the bracket and tighten securely. Attach the switch and bracket assembly to the steering gear cowl upper bracket by means of two 8-32 x 1/2 screws, Fig. 136 in Fig. 136.
3. Place the gearshift lever in reverse, and position the switch lever working surface directly over the switch plunger. Tighten only the switch bracket. See Fig. 136. With the gearshift lever in the REVERSE position, rotate the switch lever so that the switch plunger is depressed to 3/16-inch from the end of the switch.
4. Tighten securely in this position. Return the gear. shift lever to the NEUTRAL position. See view B, Fig. 136.
5. Select the long wire with the two connectors. Enlarge the hole in the main wiring harness grommet. From the engine compartment, route the male terminal end of this wire through the hole in the grommet into the driver's compartment. Connect this wire to the switch. Clip in place. See Fig. 136.
6. Connect the male terminal of the remaining wire to the switch, and connect the female terminal to the junction block terminal marked BACK-UP LP. Clip the wire in place. See Fig. 136.

FOR HYDRA-MATIC TRANSMISSION:

Same as 3-speed transmission installation, except the switch lever and the switch bracket are mounted on the RIGHT HAND side of the steering column. Final assembly should be Fig. 136 in view C Fig. 136.

FOR 4-SPEED TRANSMISSION:

1. Remove and retain the gearshift lever knob.
2. Remove and discard the existing gearshift levercap.
3. Attach the switch to the new cap, and install this assembly on the transmission, locking it in place. See Fig. 137.
4. Place the gearshift lever in the REVERSE position. Install the switch lever on the gearshift lever, depressing the switch plunger to 3/16 inch from end of switch. Hold in this position by tightening the set screw. Replace the gearshift lever knob. Place the gearshift lever in the neutral position. See Fig. 137.
5. Attach the two clips provided to the support bracket under the dash.
6. Repeat steps 5 and 6 of the 3-speed transmission back-up switch installation, but route the wires UNDER the floor mat. Refer to Fig. 137.

FOR ALL TRANSMISSIONS:

1. From the engine compartment, take up any slack in the switch wire. Route this wire to the rear, clipping it in place on the dash and on the frame side member along with the main wiring harness.
2. Locate the holes to be drilled in the left rear fender for attaching the backing lamp. See Fig. 138 for pickups, Fig. 139 for panels and suburban carryalls. At these locations, centerpunch and drill a 1-1/2 inch diameter hole and two 5/16 inch diameter holes. Repeat process for right rear fender.
3. Install the spring nuts over the 5/16 inch diameter holes.
4. Remove the doors, lenses and gaskets from the lamp assemblies. Pass the lamp lead wires through the 1-1/2 inch diameter holes. FOR PANELS ONLY, attach a stiff wire to the lamp lead wires, then work the wires through the grommets in the filler panels. Remove the stiff wire and pull the lamp wires through the grommets. FOR SUBURBAN CARRYALLS ONLY, repeat process; but first remove the plugs in the filler panel. Rework the left hand plug as a grommet, then re-install this reworked plug and the grommet from the kit in the filler panels.
5. Attach the pods and lamp bodies to the fenders with the topping screws provided, fitting the pods to the fender contour. Refer to Fig. 138 for pickups, Fig. 139 for panels and suburban carryalls.
6. Attach clips to the panel flanges and side members. Route the lamp lead wires through the clips and through the grommets in the rear cross member. Refer to Fig. 140 for pickups, Fig. 141 for panels and suburban carryalls.
7. Attach clips to the rear cross member. Connect the lamp lead wires to the wires loading from the dash. Take up any slack by folding and taping (or cut, splice, solder and tape the wires). Clip the wires leading from the dash in place along the side member and rear cross member. Refer to Fig. 140 for pickups, Fig. 140 for panels and suburban carryalls.
8. Install fuse in fuse block. See Fig. 136 or Fig. 136.

Passenger Cars

Step 1 locate outermost existing holes at each end of instrument panel. (main view.)

Step 2 position bracket assemblies Fig. 142 in view a and secure each with tapping screws furnished.

Step 3 install 4 clips on instrument panel reinforcement Fig. 142 in view c and route wire through clips.

Step 4 remove production wires from switches and attach to courtesy lamp connectors (View D).

Step 5 plug courtesy lamp wires into switches (View D).

Step 6 plug connector with double wires into terminal Fig. 142 on junction block (View B)

Fog Lamp Installation Instructions

ALL TRUCKS

1. Refer to Fig. 143 for the location of the two holes to be drilled in bumper for the fog lamp installation on the various models. At these points, 11/16-inch forward of the bumper rear edge, centerpunch and drill two 11/16-inch diameter holes. NOTE: On models with a radiator grille guard, locate the holes to be drilled by using the centerlines of the two existing holes in the base of the grille guard. Centerpunch at these points. Remove the grille guard and drill two 11/16-inch diameter holes. Remount the grille guard. On 8000 and 10,000 Series mount in the hole on the base of the grille guard only.
2. Attach the fog lamps loosely to the bumper in the sequence shown in Fig. 144. NOTE: Use the thick upper bracket for 3000 Series models only. Use the thin upper bracket for all other models. On all models, the lamp with the longest wire is used on the right side.
3. Route the fog lamp wires under the front edges of the fenders and through the parking lamp grommets and clips on the fender skirts and in the engine compartment. Clip the wires to the front fender flanges. Route the right hand wire through the main wiring harness clips on the radiator support. See Fig. 143
4. Connect the fog lamp wires to the double terminal wire (from the package). Route wire through the main wiring harness clips on the left hand fender skirt and through the main wiring grommet on the dash panel and into the cab interior. See Fig. 143.
5. Locate a point at the center of the horizontal centerline running through the choke and light switch. Two inches up from this point, centerpunch and drill a 13/32 inch diameter hole through the instrument panel. See Fig. 145.
6. Remove the face nut from the fog lamp switch, and from behind the instrument panel, insert the knob through the 13/32 inch diameter hole just drilled. Replace the face nut, and tighten securely.
7. Continue the routing of the wire in step 4 through the main wiring harness clip on the plenum chamber and up to the fog lamp switch. See Fig. 145.
8. Connect this wire to the terminal on the fog lamp switch marked ROAD.
9. Remove the black tail lamp wire from the main light switch. Connect it to the jumper wire on the short wire assembly from the package, making sure that the rubber sleeve covering the jumper wire terminal is in place. See Fig. 145.
10. Connect the terminal on the jumper wire to the terminal of the main light switch from which the tail lamp wire was removed. See Fig. 145.
11. Connect the eyelet terminal of the short wire assembly to the terminal on the fog lamp switch marked TAIL. See Fig. 145.
12. Connect the eyelet terminal of the remaining wire from the package to the terminal on the fog lamp switch marked BAT. Route it through the main wiring harness clip and attach it to the terminal on the junction block marked FOG LP. Install the 14 ampere fuse provided. See Fig. 145.

LAMP ALIGNING PROCEDURE

Place the truck on a level surface with a light-colored wall (or aiming screen) 25 feet ahead. Draw a horizontal line an the wall 4 inches below the level of the fog lamp centers. From inside the cab, sight through the windshield and down the center of the hood to determine the vertical center of the truck. At this point, draw a vertical line on the wall. To the right and to the left of this vertical centerline, draw another vertical line the same distance from the centerline of the truck as shown in Fig. 143. Turn on the fog lamps. Aim each lamp so the top of the beam is at the horizontal line on the wall and centered on the appropriate vertical line, as shown in Fig. 146. When the lamps have been properly aimed, tighten them in position.

Glove Compartment Light Switch Installation Instructions

1500 PASSENGER CARS AND TRUCKS

Step 1 install the light assembly in hole provided in outer edge of glove compartment opening.

Step 2 crush and remove insulator from terminal on red wire. Make sure not to distort terminal. insert terminal in switch and install bulb.

NOTE: Discard the three clips and the wire assembly in the kit. They are provided for truck installation only.

Fig. 147.

TRUCK INSTALLATION

Step 1 install the light switch assembly Fig. 148. Insert wire terminal and install bulb.

Step 2 remove existing screw, slit hole in glove compartment partition and route wire Fig. 148.

Step 3 remove the orange dome light wire from the main light switch and attach it to the male terminal of the wire assembly furnished in the kit.

Step 4 connect the female terminal of the wire assembly to the main light switch terminal from which the orange dome lamp wire was removed.

Step 5 install the three cups on the instrument panel reinforcement and route wire assembly through Fig. 148 AND VIEW "A".

Step 6 check the installation for proper operation.

Luggage Compartment Lamp Installation Instructions

PASSENGER CARS

Step 1 locate the recessed opening in the inner panel of the deck lid shown in Fig. 149 and View B.

Step 2 pass the wire assembly only, through the opening, down between the outer and inner panels and bring out through smallest opening near left hinge Fig. 149.

Step 3 mount the lamp inside the inner panel Fig. 149 in View B and attach the bracket to existing hole with the tapping screw provided.

Step 4 locate and attach the 4 cups provided, Fig. 150.

Step 5 route the wire through the clips and behind the hinge pillars.

Step 6 open the license lamp connectors and install the luggage wire connectors in their correct position Fig. 151 in View C.

Step 7 when light switch is in an "on" position, the luggage lamp light will light when deck lid is raised and go off automatically when lid is lowered.

Tail and Stop Lamp Installation Instructions

TRUCKS

Procedure for installation of a right hand tail and stop lamp on all trucks and commercials.

First, determine the model of the truck and follow the instructions for that particular model installation.

PICKUP INSTALLATION

1. Remove the two bolts, nuts and lockwashers from the front side of the right rear stake pocket.
2. Place a wiring clip on one of these bolts and attach the tail lamp bracket to the stake pocket with the lockwasher and nut in their former location. Make sure the cut-out section in the bracket is down and the bolt is in the outer hole of the stake pocket. Install the second bolt in the inner hole and with its lockwasher and nut in place, tighten both bolts securely as shown in Fig. 152.
3. Mount the tail lamp to the bracket support with the two nuts and lockwashers keeping the tail lamp drain hole at the bottom.
4. Drill an 11/32 inch hole in the right frame side rail, 1-1/2 inches down and 3/4 of an inch from the end. This hole is marked "Drill only rear hole for all pickups and platforms", as shown in Fig. 153.
5. At this hole, attach another clip for the tail lamp extension wire using the bolt, nut and lockwasher provided.
6. Install the rubber grommet in the hole in the right end of the rear cross member.
7. Route the tail lamp extension wire through the two clips and rubber grommet, then along the rear cross member to the regular tail lamp wiring harness.
8. Cut the tail lamp extension wire where it reaches the regular wiring harness, allowing enough length for splicing.
9. Match the ribbed and plain extension wires to the ribbed and plain wires of the regular tail lamp wiring harness and splice, solder and tape these connections. Clip the extension wiring to the cross member flange with the two special clips as shown in Fig. 154.

PLATFORM INSTALLATION

1. With the weld nuts facing the rear, hold the tail lamp bracket support up inside the right side slot provided in the rear rub rail. Attach the bracket support to the rear cross sill with two bolts and lockwashers at the holes provided.
2. Mount the tail lamp to the bracket support with the lockwashers and nuts provided, keeping the tail lamp drain hole to the bottom as shown in Fig. 155.
3. Drill the 11/32 inch hole in the right side member 1-1/2 inches down and 3/4 of an inch from the rear. This hole is marked " Drill only rear hole for all platforms and pickups". See Fig. 153.
4. Using this hole, attach a wiring clip on the inside of the side member with the bolt, nut and lockwasher provided.
5. Install the rubber grommet in the hole in the right end of the rear cross member.
6. Route the tail lamp extension wire up over the right side sill through the frame clip and cross member grommet. Run the wire along the front side of the rear cross member to the regular tail lamp harness at the left side as shown in Fig. 155.
7. Fasten the tail lamp extension wire on the inside of the sill using one or two of the clips and nails as required. Use 2 clips for long overhanging sill and only one for the short overhang.
8. Cut the extension wire where it reaches the regular wiring harness, allowing ample wire for splicing.
9. Match the ribbed and plain extension wires to the ribbed and plain wires of the regular tail lamp wiring harness and splice, solder and tape these connections, as Fig. 154.
10. Clip the extension wire to the rear cross member flange.

CHASSIS INSTALLATION

1. If required, drill the two 11/32 inch holes in the end of the right frame side rail according to the model of truck. See Fig. 153.
2. Fasten the tail lamp bracket support to the frame side rail with the two bolts supplied, placing the clip on the inner bolt. See Fig. 154.
3. Attach the tail lamp to the bracket support keeping the tail lamp drain hole to the bottom. See Fig. 154.
4. Install the grommet in the cross member and route the extension wire through the clip and grommet, then along the rear cross member to the regular tail lamp wiring harness. See Fig. 154.
5. Complete the wiring installation in the same manner as Pickup Instructions No. 8 and 9.

ALL PASSENGER CARS

NOTE: Check lamp after installation by lowering the hood to within eight inches of the closed position. If the light does not go off, bend the bracket downword until the lamp goes off in this position.

Fig. 156.

Under Hood Lamp

All Passenger Cars and Trucks

1. Position the underhood lamp and bracket. assembly on the hood rear reinforcement Fig. 157. NOTE: LOCATIONS FOR 6-CYLINDER AND 8-CYLINDER ENGINES Hold the lamp bracket with its shoulder fitting the corner of the box section of the hood reinforcement Use the bracket as a template to locate the hole. Remove the lamp assembly.
2. Drill a 1/8 inch hole in the reinforcement and attach the lamp with the sheet metal screw.
3. Attach the two clips with the narrow wire opening to the hood reinforcement in the location Fig. 157 and assemble the wire.
4. Route the wire through the grommet and the dash Fig. 157.
5. Attach the clip with the large wire opening to the top of the dash mat in the location Fig. 157. Run the wire through this clip to the accessory junction block, add connector, and attach it to the hood lamp terminal. Insert the fuse Fig. 157.
6. Check lamp after installation by lowering the hood to within eight inches of the closed position. If the light does not go off, bend the bracket downward until the lamp does go off in this position.

ALL PASSENGER CARS

Step 1 remove lamp from lighter retainer and remove retainer from cigarette lighter housing.

Step 2 put bezel in place, insert housing through instrument panel, and reinstall retainer on the housing and the lamp on retainer.

Step 3 route lamp wire through the main wiring harness clips to the junction block. plug connector on terminal Fig. 158 in View A.

Step 4 connect the main wiring harness red wire, with connector attached, to the terminal of the lighter housing.

Cigarette Lighter

TRUCKS

1. Remove the dummy button or the existing production lighter.
2. Remove the lamp Assembly from the lighter retainer and the retainer from the housing assembly.
3. Insert the housing through the instrument panel and reassemble the retainer Fig. 159.
4. Tighten the retainer securely against the instrument panel. Attach the lamp assembly by inserting the lamp housing tabs through the slots. (if necessary to avoid lamp installation interference, loosen the retainer, rotate the housing, and retighten the retainer with the slots in the desired position.)
5. Route the lamp wire (black) through the clip behind the dash panel, to the tail light terminal (T) on the main light switch.
6. Route the lighter wire (red) to the battery terminal on the ignition switch.
7. To operate the unit, push in the knob and heating unit assembly to the heating position. It will return to the normal position when ready for use.

All Passenger Cars

Step 1 locate with template and drill hole 3/4 inch depth into windshield molding and pillar Fig. 207.

Step 2 secure top hole in bracket, gasket and molding with tapping screw Fig. 208.

Step 3 drill bottom hole and secure bracket Fig. 208 above.

Step 4 loosen set screw, (Fig. 209>) insert drill bushing in place and tighten set screw.

Step 5 drill 1/2 inch hole, using bushing as a guide, completely through pillar and garnish molding. Remove sheet metal screw if it appears as an obstruction to contemplated drilling. Replace on completion.

Step 6 remove bushing and clean up burrs in garnish molding.

Step 7 locate and drill hole for spot lamp wire Fig. 210 above.

Step 8 remove spot lamp switch housing Fig. 211

Step 9 insert the spotlamp shaft completely through the 1/2 inch drilled hole Fig. 212 being careful to seat properly. Tighten the bracket screw securely.

Step 10 install the spacer and retainer on the shaft and secure in place by inserting and tightening the set screw provided (Fig. 213).

Step 11 re -install the switch housing on shaft.

Step 12 insert spotlamp wire through grommet into 3/16 hole and extend as shown in illustration Fig. 213 and Fig. 214. CAUTION: Do not assemble connector to spot lamp wire terminal until lamp lead has been threaded through pillar

Step 13 install double connector wire extension as shown in illustration no. Fig. 214 and Fig. 215.

Step 14 install 14 amp fuse on fuse and terminal block as shown in Fig. 215.

Step 15 check for proper operation.

Right Hand Spot Lamp

All Passenger Cars

Step 1 locate with template and drill hole 3/4 inch depth into windshield molding and pillar Fig. 216.

Step 2 secure top hole in bracket, gasket, and molding with tapping screw Fig. 217.

Step 3 drill bottom hole and secure bracket Fig. 217 above.

Step 4 loosen set screw, (Fig. 218) insert drill bushing in place and tighten set screw.

Step 5 drill 1/2 inch hole using bushing as a guide, completely through pillar and garnish molding. Remove sheet metal screw if it appears as an obstruction to contemplated drilling. Replace upon completion.

Step 6 remove bushing and clean up burrs in garnish molding.

Step 7 locate and drill hole for spotlamp wire Fig. 219 above.

Step 8 remove spotlamp switch housing Fig. 220.

Step 9 insert the spotlamp shaft completely through the 1/2 inch drilled hole Fig. 221 being careful to seat properly. Tighten the bracket screw securely.

Step 10 install the spacer and retainer on the shaft and secure in place by inserting and tightening the set screw provided. (Fig. 222)

Step 11 re-install switch housing on shaft.

Step 12 insert spotlamp wire through grommet; into 5/16 inch hole as shown in illustrations numbered Fig. 222 & 223.

Step 13 assemble connector to terminal and plug onto spotlamp terminal on junction block shown Fig. 223 Fig. 224.

Step 14 insert 14 amp fuse in receptacle marked acc. lp. as shown in Fig. 224.

Step 15 check for proper operation.

Spot Lamp Installation Instructions

TRUCKS

1. FOR 3000 SERIES ONLY: Remove the existing standard mirror and bracket from the left hand front door and-discard all parts. Coat the three 3/8 inch truss head screws provided with sealer and install them in the holes in the door panel.
2. Locate the template on the left hand hinge cover panel according to the directions given on the template. Secure with tape. See Fig. 225.
3. Centerpunch the two holes to be drilled. Remove the template.
4. Using a No. 29 (.136) drill or 9/64 inch drill, drill two holes through the hinge cover panel and plenum chamber.
5. Attach the outside mounting bracket and gasket to the hinge cover panel with the two 3/4 inch long screws provided. See Fig. 225.
6. Using the mounting bracket as a guide, drill a 1/2 inch diameter hole through the hinge cover panel and instrument panel, Fig. 225. CAUTION: Feed the drill slowly and directly in line with the bracket.
7. From inside the cab, remove any burrs resulting from this drilling.
8. On the some vertical line as the centerline of the 1/2 inch hole just drilled, measure 5/8 inch down from the bottom edge of the hole and scribe a line on the instrument panel, At this line, centerpunch and drill a 5/16 inch diameter hole through the instrument panel only. Remove any burrs resulting from this drilling. See Fig. 226.
9. Detach the handle from the spotlamp shaft by removing the screw from the left side of the handle housing and loosening the screw at the bottom of the housing. See Fig. 226.
10. Remove the screws, mounting bracket and gasket described in step 5 and retain all parts.
11. Slide the mounting bracket over the spotlamp shaft making sure that the key in the lamp arm fits snugly into the notch in the bracket. See Fig. 227.
12. Slip the bracket retaining spring over the spotlamp shaft making sure that the end of the spring having the small tang is away from the bracket. Compress the spring into the bracket until the bend in the small tang fits into the hole in the shaft. See Fig. 228.
13. Slip the gasket over the shaft and fit it to the bracket.
14. Insert the shaft end of the now unitized spotlamp and bracket through the 1/2 inch diameter hole previously drilled, and attach this assembly to the door with the two topping screws removed in step 10.
15. Remove the friction nut from the spring bracket and, from inside the cob, slip the spring bracket over the shaft and bend the arms to fit the contour of the instrument panel. See Fig. 226 Note: The long arm on the bracket should be to the right of the shaft.
16. Hold the bracket in position against the instrument panel by threading the friction nut onto the spring bracket. Tighten until the bracket is held securely in place.
17. Using the holes in the spring bracket arms as a guide, drill two holes through the instrument panel with a No. 27 (.144) drill or a 9/64 inch drill.
18. Secure the spring bracket to the instrument panel with the two 3/8 inch screws provided.
19. Re-attach the spotlamp handle on the shaft. Refer to step 9. NOTE: The handle should be positioned on the shaft 30° to the rear of the vehicle when the spotlamp is in its normal position.
20. Pass the spotlamp wire through the 5/16 inch diameter hole previously drilled in the instrument panel. Route the wire along the top of the cowl kick panel and down to the accessory junction block.
21. Fasten the spotlamp wire to the terminal on the accessory junction block marked "Spotlamp". Add a 9 ampere fuse. See Fig. 226.
22. Position the spotlamp wire so that there is just enough slack to permit the handle to be rotated freely.
23. Press the rubber grommet on the spotlamp wire into the 5 /16 inch diameter hole in the instrument panel.
24. Adjust the nut on the spring bracket to obtain the proper horizontal friction.
25. Inspect the installation for proper rigidity, seal, fit and operation. Correct, if necessary.

CHASSIS AND PLATFORM MODEL TRUCKS

Step 1 the switch housing should match the color of the steering column. The lamp housing should match the color of the fender. Paint these parts when necessary.

Step 2 remove the steering wheel, discard the hub cover and attach the cancelling cam using the hub cover screws and lockwashers.

NOTE: The prong on the cancelling cam should be on the left side. Fig. 231.

Step 3 remove the wiring clamp from the steering column and feed the wires leading from the switch, through the slots on the underside of the steering column. Fig. 231.

Step 4 screw the signal lever into the switch assembly and tighten the locking nut.

Step 5 place the switch assembly loosely on the steering column with the lever on the left side.

Step 6 replace the steering wheel in the correct straight ahead position and secure in place.

Step 7 secure the switch assembly in position with the clamping screw, keeping 1/8 inch clearance between the top of the switch housing and the bottom of the steering wheel.

Step 8 remove any slack in the switch wires,and re-attach the wiring clamp to the steering column.

Step 9 from behind the instrument panel install the signal lamp wiring harness as directed in Fig. 232.

Step 10 plug the switch wires into the 3-way connector so that the wire colors match mating harness connector. See Fig. 232.

Step11 through the hole in the main harness grommet on the dash panel, route the directional signal harness into the engine compartment. Clip in place on the front of the dash and follow the main harness to the rear of the cab.

Step 12 connect the front extension wire and route it in the clips with the main harness along the left fender skirt and across the front end.

Step 13 refer to Fig. 233 to locate the holes to be drilled in each fender, for mounting the front signal lamps. at these points, drill two 15/32 inch diameter holes.

Step 14 mount the lamps on the fenders using the parts in the sequence shown in Fig. 233. Make sure the plate reinforcements are positioned to direct the lead wires toward the grommets in the fender skirt.

Step 15 route each lamp wire through the grommet as indicated in Fig. 234.

Step 16 remove the parking lamp plug from the main harness connector at the front end, and insert the directional signal lamp wire terminal in open hole of the plug. Insert extension wire terminal in the open hole in the main harness connector, replace plug, repeat on the opposite side.

NOTE: The front installation is not intended for use alone. For the flasher to operate properly the rear lamps must be installed either at this time as follows or later by an outside body builder.

Step 17 for platform trucks mount the rear signal lamps on the wood sill. locate the bracket as shown in Fig. 235. Attach with the wood screws provided and make sure the ground wires are used. Route the wires and clip as shown in Fig. 235.

Step 18 route the lamp lead wires as far forward as they will reach. Connect the rear extension under the rear of the cab, and route to the rear in the clips with the tail and stop lamp wires. Separate the rip cord wires, and cut the black wire to the length to reach the right hand lamp wire and the white stripe wire to reach the left hand lamp wire. Solder or crimp the terminals securely. Attach the connectors and plug in the lamp wires.

Step 19 for drive-away purposes prior to mounting a body. mount the rear signal lamps as indicated in Fig. 236. Connect as described in step 18, except loop up the excess wire for cutting to the proper length later.

Step 20 for truck bodies requiring rear flush mounted signal lamp, determine the desirable left and right hand mounting location, and install as directed in step 18.

Direction Signal Lamp Installation Instructions

FOR CAMEO CARRIER, SUBURBAN CARRY ALL, AND PANEL TRUCKS

Step 1 the color of the switch housing should match the color of the steering column. Paint when necessary.

Step 2 remove the steering wheel, discard the hub cover and attach the cancelling cam using the hub cover screws and lockwashers.

NOTE: The prong on the cancelling cam should be on the left side.

Step 3 remove the wiring clamp from the steering column and feed the wires leading from the switch through the slots on the underside of the steering column Fig. 237.

Step 4 screw the signal lever into the switch assembly. tighten the locking nut.

Step 5 place the switch assembly loosely on the steering column with the lever on the left side.

Step 6 replace the steering wheel in the correct straight-ahead position and secure in place.

Step 7 secure the switch assembly in position with the clamping screw keeping 1/8 inch clearance between the top of the switch housing and the bottom of the steering wheel.

Step 8 remove any slack in the switch wires, and re-attach the wiring clamp to the steering column.

Step 9 from behind the instrument panel, install the signal lamp wiring harness as shown in Fig. 238.

Step 10 plug the switch wires into the 6-way connector so that the wire colors match the mating harness connector.

Step 11 through the hole in the main wiring harness grommet on the dash panel, route the direction signal harness into the engine compartment. clip in place on front of dash and follow main harness to rear of cab.

Step 12 connect front extension wire and route in clips with main harness along fender skirt and across front end.

Step13 remove and retain both front parking lamp lens, lens gaskets and attaching screws.

Step14 remove and substitute lamp bodies and wiring. Retain the mounting pads and attaching screws.

Step 15 install the lamp bulbs and attach the lenses.

Step 16 insert extension wire terminal in the open hole in the main harness connector and insert parking and direction signal wire plug. (View B)

Step 17 from under the rear of the cab, disconnect the tail and stop lamp wire extension from the main harness. connect this and the signal harness extension Fig. 240.

Step 18 route the signal harness extension to the rear, clipping it in place along with the tail and stop lamp wire extension assembly on the left hand frame side member Fig. 241.

Step 19 cut off signal wiring harness extension where it reaches the R. H. tail & stop lamp wires. Solder or crimp the terminals securely and insert in connector so that wire colors match those in mating connector on the R.H. TAIL & stop lamp wires.

Step 20 disconnect the R. H. tail & stop lamp extension from the L.H. tail & stop extension and connect to the extension from the front. the jumper is not used.

Fig. 242.

Direction Signal Lamp Installation Instructions

CHASSIS AND PLATFORM MODEL TRUCKS

step 1 the switch housing should match the color of the steering column. The lamp housing should match the color of the fender. Paint these parts when necessary.

Step 2 remove the steering wheel, discard the hub cover and attach the cancelling cam using the hub cover screws and lockwashers.

NOTE: The prong on the cancelling cam should be on the left side. See Fig. 243.

Step 3 remove the wiring clamp from the steering column and feed the wires leading from the switch, through the slots on the underside of the steering column. Fig. 243.

Step 4 screw the signal lever into the switch assembly and tighten the locking nut.

Step 5 place the switch assembly loosely on the steering column ith the lever on the left side.

Step 6 replace the steering wheel in the correct straight ahead position and secure in place.

Step 7 secure the switch assembly in position with the clamping screw, keeping 1/8 inch clearance between the top of the switch housing and the bottom of the steering wheel.

Step 8 remove any slack in the switch wires, and reattach the wiring clamp to the steering column.

Step 9 from behind the instrument panel install the signal lamp wiring harness as directed in Fig. 244.

Step 10 plug the switch wires into the 3 -way connector so that the wire colors match mating harness connector. SEE Fig. 244.

Step 11 through the hole in the main harness grommet on the dash panel, route the directional signal harness into the engine compartment. Clip in place on the front of the dash and follow the main harness to the rear of the cab.

Step 12 connect the front extension wire and route it in the clips with the main harness along the left fender skirt and across the front end.

Step 13 refer to Fig. 245 to locate the holes to be drilled in each fender, for mounting the front signal lamps. At these points, drill two 15/32 inch diameter holes.

Step 14 mount the lamps on the fenders using the parts in the sequence shown in Fig. 245. Make sure the plate reinforcements are positioned to direct the lead wires toward the grommets in the fender skirt.

Step 15 route each lamp wire through the grommet as indicated inFig. 246

Step 16 remove the parking lamp plug from the main harness connector at the front end, and insert the directional signal lamp wire terminal in open hole of the plug. Insert extension wire terminal in the open hole in the main harness connector, replace plug, repeat on the opposite side.

NOTE: The front installation is not intended for use alone. For the flasher to operate properly the rear lamps must be installed either at this time as follows or later by an outside body builder.

Step 17 for platform trucks mount the rear signal lamps on the wood sill. Locate the bracket as shown in Fig. 247. Attach with the wood screws provided and make sure the ground wires are used. Route the wires and clip as shown in Fig. 247.

Step 18 route the lamp lead wires as far forward as they will reach. Connect the rear extension under the rear of the cab, and route to the rear in the clips with the tail and stop lamp wires. Separate the rip cord wires, and cut the black wire to the length to reach the right hand lamp wire and the white stripe wire to reach the left hand lamp wire. Solder or crimp the terminals securely. Attach the connectors and plug in the lamp wires.

Step 19 for drive-away purposes prior to mounting a body. mount the rear signal lamps as indicated in Fig. 248. Connect as described in step 18, except loop up the excess wire for cutting to the proper length later.

Step 20 for truck bodies requiring rear flush mounted signal lamp, determine the desirable left and right hand mounting location, and install as directed in step 18.

Parking Brake Alarm Installation Instructions

PASSENGER CARS

Step 1 loosen the left hand parking brake bracket mounting screw and slide the lamp bracket slotted flange between the parking brake bracket and the lockwasher. position Fig. 249 In main view and tighten securely.

Step 2 assembly the lamp assembly through the bracket hole Fig. 249 in View C.

Step 3 install the flasher clip and flasher on the cowl kick panel Fig. 249 in the main view and View A.

Step 4 attach the lamp wire to the flasher Fig. 249. (View A.)

Step 5 apply the parking brake and attach the switch clamp on the housing Fig. 249. (View D.) with the locating key against the lower end of the housing groove, tighten securely.

Step 6 install the wire assembly connector Fig. 249 in view b. plug the opposite ends of wire assembly into the switch assembly (View D).

Step 7 plug remaining wire into flasher.

Step 8 install fuse if needed.

Parking Brake Alarm

3000 Series With Instrument Panel Hand Brake Lever

1. Centerpunch and drill a 7/8 inch hole in the instrument panel midway between and in line with the choke control and the main light switch. See Fig. 251.
2. File a 1/16 inch radius slot at the bottom center of the hole just drilled.
3. Insert the lens and housing assembly in the drilled hole, and then slip the spring over t