SECTION 1

BODY

CONTENTS OF THIS SECTION


Figure Index
General Description
Body Lubrication
Service Operations and Adjustments
Assembly Manual

Figure Index




Fig. 1 - Vacuum Type Windshield Wiper Motor
Fig. 2 - Transmission Cable Installation
Fig. 3 - 1957 Electric Windshield Wiper
Fig. 4 - Switch Section of Wiper
Fig. 5 - Drive and Oscillating Section of Wiper
Fig. 6 - Oscillating Parts at Start of Park Cycle
Fig. 7 - Oscillating parts at Completion of Park Cycle
Fig. 8 - Park Position Circuit Diagram
Fig. 9 - Low Speed Circuit Diagram
Fig. 10 - High Speed Circuit Diagram
Fig. 11 - Breaker Arm-to-Cam Guide Clearance
Fig. 12 - Oscillating Parts - Exploded
Fig. 13 - Assembly of Drive Assembly Disc, Spring, and Pawl
Fig. 14 - Assembly of Yoke, Cam and Pin, and Drive Disc
Fig. 15 - Wiper Motor - Exploded View
Fig. 16 - Retaining Brushes with Improvised Separator
Fig. 17 - Holding Brushes with Brush Retainer Spring 5096576
Fig. 18 - Motor Case Electrical Connections
Fig. 19 - Installing Brushes in Holders
Fig. 20 - Cowl Side Drain Gutter
Fig. 21 - Instrument Panel Cover
Fig. 22 - Windshield Reveal Moldings
Fig. 23 - Convertible Reveal Moldings
Fig. 24 - Sealing Windshield Reveal Moldings
Fig. 25 - Windshield Garnish Moldings
Fig. 26 - Windshield Reveal Moldings
Fig. 27 - Reveal Molding Clips
Fig. 28 - Loosening Windshield Channel
Fig. 29 - Windshield Body Opening Check
Fig. 30 - Windshield to Body Clearance
Fig. 31 - Windshield Drain Gutter
Fig. 32 - Convertible Reveal Molding Cutout
Fig. 33 - Cord in Pinchweld Cavity
Fig. 34 - Installing Lip of Rubber
Fig. 35 - Instrument Panel Compartment
Fig. 36 - Rear View Mirror and Bracket ( Sport Sedan)
Fig. 37 - Sedan Door Inner Panel
Fig. 38 - Sedan Door Electric Lift Inner Panel
Fig. 39 - Electric Lift Master Switch
Fig. 40 - Door Window
Fig. 41 - Door Window Adjustment
Fig. 42 - Door Window Regulator
Fig. 43 - Door Weatherstrip Installation
Fig. 44 - Front Door Weatherstrip Location
Fig. 45 - Rear Door Weatherstrip Location
Fig. 46 - Sealing Front and Rear Door Weatherstrip
Fig. 47 - Front Door Water Deflector
Fig. 48 - Front Door Hinge Pillar Weatherstrip
Fig. 49 - Rotary Lock Parts
Fig. 50 - Rotary Lock Parts
Fig. 51 - Door Lock Remote Control
Fig. 52 - Caulking Lock Frame
Fig. 53 - Checking Adjustment of Door Lock Striker
Fig. 54 - Front Door Hinge
Fig. 55 - Hinge Sealing
Fig. 56 - Door Inner Panel Sealing
Fig. 57 - Door to Pillar Clearances
Fig. 58 - Body Mounting Bolts
Fig. 59 - Ventilator Regulator
Fig. 60 - Ventilator Adjustment
Fig. 61 - Ventilator Removal
Fig. 62 - Door Outside Handle Attachment
Fig. 63 - Door Handle Exploded
Fig. 64 - Door Lock Cylinder
Fig. 65 - Door Lock Cylinder Exploded
Fig. 66 - Door Lock Spring Clip
Fig. 67 - Rear Door Inner Panel
Fig. 68 - Rear Door Electric Lift Inner Panel
Fig. 69 - Rear Door Hinge Sealing
Fig. 70 - Rear Door Hinge Plate Sealing
Fig. 71 - Rear Door Lock and Remote Control
Fig. 72 - Adjusting Lock to Free-Wheeling
Fig. 73 - Free-Wheeling Control Rod
Fig. 74 - Rear Door Assembly
Fig. 75 - Rear Door Assembly - Standard Sedan
Fig. 76 - Rear Door Inner Panel Sealing - Standard Sedan
Fig. 77 - Side Roof Rail Sealing - Sport Sedan
Fig. 78 - Side Roof Rail Weatherstrip Adjustments
Fig. 79 - Front Door Inner Panel Sealing - Sport Sedan
Fig. 80 - Sealing Door Ventilator Cap Finishing Molding
Fig. 81 - Front Door Window Removal - Sport Sedan
Fig. 82 - Door Lock Removal - Front Door
Fig. 83 - Door Lock Remote Control
Fig. 84 - Front Door Lock Cylinder
Fig. 85 - Front Door Outside Handle
Fig. 86 - Rear Door Assembly and Hinges
Fig. 87 - Sealing Door Hinge
Fig. 88 - Rear Door Inner Panel Sealing - Sport Sedan
Fig. 89 - Door Lock Removal - Rear Door
Fig. 90 - Rear Door Outside Handle
Fig. 91 - Door Lock Connector Assembly
Fig. 92 - Rear Door Window and Regulator - Electric
Fig. 93 - Rear Door Window and Regulator - Manual
Fig. 94 - Rear Door Window Removal
Fig. 95 - Rear Door Window Adjustments
Fig. 96 - Rear Door Window Regulator Removal - Electric
Fig. 97 - Rear Door Window Regulator Removal - Manual
Fig. 98 - Rear Door Window Regulator Electric Motor Assembly
Fig. 99 - Rear Door Weatherstrips - Sport Sedan
Fig. 100 - Convertible Door Inner Panel
Fig. 101- Convertible Door Electric Lift Inner Panel
Fig. 102 - Convertible and Sport Coupe Door Weatherstrip
Fig. 103 - Convertible Regulator
Fig. 104 - Convertible Door Window
Fig. 105 - Mechanical Sealing Strip
Fig. 106 - Sealing Mechanical Sealing Strip
Fig. 107- Convertible Door Inner Panel Sealing
Fig. 108 - Nomad Side Roof Rail Weatherstrip
Fig. 109 - Back Window Assembly - Standard Sedan
Fig. 110 - Back Window Reveal Mouldings - Standard Sedan
Fig. 111 - Back Window Assembly - Sport Sedan
Fig. 112 - Back Window Reveal Moldings - Sport Sedan
Fig. 113 - Removing Reveal Molding
Fig. 114 - Installation of Reveal Moldings
Fig. 115 - Torsion Rods Cover
Fig. 116 - Disengaging Torsion Rod
Fig. 117 - Torsion Rod Adjusting Positions
Fig. 118 - Rear Compartment Lid Lock
Fig. 119 - Rear Compartment Weatherstrip
Fig. 120 - Rear Compartment Lid Hinge Shimming
Fig. 121 - Rear Compartment Bolt and Striker Check
Fig. 122 - Rear Compartment Lid Clearances
Fig. 123 - Back Window Gutter Drain
Fig. 124 - Rear Quarter Window Sport Coupe
Fig. 125 - Rear Quarter Window Adjustments
Fig. 126 - Rear Quarter Window Electric Regulator
Fig. 127 - Rear Quarter Window Guides
Fig. 128 - Convertible Rear Quarter Window
Fig. 129 - Rear Quarter Window Electric Window Regulator
Fig. 130 - Rear Quarter Trim - 4 Door Station Wagon
Fig. 131 - Rear Quarter Window Installation - 4 Door
Fig. 132 - Rear Quarter Trim - 2 Door Station Wagon
Fig. 133 - Rear Quarter Window Installation - 2 Door Station Wagon
Fig. 134 - Inside Side Panel Moldings - Sedan Delivery
Fig. 135 - Rear Quarter Inner Panel Sealing - All Styles
Fig. 136 - Tail Gate Assembly Removal
Fig. 137 - Sealing Tail Gate Hinge Strap
Fig. 138 - Sealing Tail Gate Hinge
Fig. 139 - Removing Tail Gate Outside Handle
Fig. 140 - Tail Gate Lock Striker
Fig. 141 - Tail Gate Outside Handle - Nomad
Fig. 142 - Tail Gate Lock Remote and Push Button Control Assembly - Nomad
Fig. 143 - Tail Gate Lock Push Button - Exploded - Nomad
Fig. 144 - Tail Gate and Lift Gate Weatherstrips
Fig. 145 - Lift Gate Assembly Hinges
Fig. 146 - Lift Gate Window
Fig. 147 - Lift Gate Supports
Fig. 148 - Lift Gate Assembly
Fig. 149 - Lift Gate Adjustments
Fig. 150 - Lift Gate Hinge
Fig. 151 - Lift Gate Window Installed
Fig. 152 - Lift Gate Weatherstrips
Fig. 153 - Back Door Assembly - Sedan Delivery
Fig. 154 - Front Seat Construction
Fig. 155 - Front Seat Side Panels - All Styles
Fig. 156 - Front Seat Regulator Switch
Fig. 157 - Front Seat Electric Regulator
Fig. 158 - Seat Adjuster Tensioner Spring
Fig. 159 - Tilting Seat Back Removal
Fig. 160 - Seat Solid Back Removal
Fig. 161 - Seat Adjuster Assembly- Sedan Delivery
Fig. 162 - Folding Seat Assembly - 6 Passenger Station Wagon
Fig. 163 - Right Center Folding Seat Assembly- 9 Passenger Station Wagon
Fig. 164 - Floor Board Supports
Fig. 165 - Maximum Floor Space
Fig. 166 - Left Center Folding Seat Assembly
Fig. 167 - Rear Seat Assembly
Fig. 168 - Headlining Retainer and Trim Stick
Fig. 169 - Headlining Installation
Fig. 170 - Headlining - Standard Sedan and Sport
Fig. 171 - Headlining - Station Wagon
Fig. 172 - Headlining - Nomad
Fig. 173 - Exterior Moldings - 1500 Series Utility Sedan
Fig. 174 - Exterior Moldings - 1500 Series Four-Door Sedan
Fig. 175 - Exterior Moldings - 2400 Series Two-Door Sedan
Fig. 176 - Exterior Moldings - 2400 Series Four Door Sedan
Fig. 177 - Exterior Moldings - 2400 Series Sport Sedan
Fig. 178 - Exterior Moldings - 2400 Series Nomad
Fig. 179 - Sealing Rear Quarter Window Exterior Moldings
Fig. 180 - Exterior Moldings - 2400 Series Convertible
Fig. 181 - Socket and Blade-Type Connectors
Fig. 182 - Electric Window Regulator
Fig. 183 - Power Window Wiring Installation
Fig. 184 - Checking Door Switch
Fig. 185 - Checking Door Switch
Fig. 186 - Checking Switch to Motor Leads
Fig. 187 - Checking Motor Operation
Fig. 188 - Side Roof Rail Weatherstrip
Fig. 189 - Front Roof Rail Corner Brace
Fig. 190 - Sunshade Support and Handle Striker
Fig. 191 - Top Linkage Adjusting Points
Fig. 192 - Rotor Type Pump Installed Behind Rear
Fig. 193 - Motor and Pump Assembly - Exploded
Fig. 194 - Motor and Pump Assembly - Removal
Fig. 195 - Adaptor Hose
Fig. 196 - Disassembly of Reservoir Tube
Fig. 197 - Pump Action When Raising Top
Fig. 198 - Pump Action When Lowering Top
Fig. 199 - Fluid Flow Between Rotor and Reservoir
Fig. 200 - Position of Rocker Arm When Raising Top
Fig. 201 - Position of Rocker Arm When Lowering Top
Fig. 202 - Fluid Level in Reservoir
Fig. 203 - Checking Pump Pressure
Fig. 204 - Slide Bar Lock
Fig. 205 - Tumbler Requirement Diagram
Fig. 206 - Inserting Tumblers
Fig. 207 - Checking With Code
Fig. 208 - Inserting Tumbler Springs
Fig. 209 - Inserting Spring Retainer
Fig. 210 - Convertible Wiring
Fig. 211 - Four Door Sedan Wiring Diagram
Fig. 212 - Sport Coupe Wiring Diagram
Fig. 213 - Two Door Sedan Wiring Diagram
Fig. 214 - Sport Sedan Wiring Diagram
Fig. 215 - Body Tools

General Description

The 1957 bodies, while basically the same as in 1955, incorporate many changes and additions. This section is not supplementary to 1955 or 1956 but is complete in itself. Service and procedures are covered on all 1957 styles.

BODY LUBRICATION

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

The following parts should be lubricated twice a year.

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

Lubrication Points
Lubricant

Instrument Compartment Door Hinge
Dripless Oil

Front Door Hold Open Clips
Lubriplate or Equivalent

Door Jamb Light Switch
Lubriplate or Equivalent

Door Lock Bolt Housing
Stick Type Lubricant

Door Lock Striker Teeth
Stick Type Lubricant

Rear Door Hinge and Hold Open
Lubriplate or Equivalent

Deck Lid Hinge and Torque Rod Ends
Lubriplate or Equivalent

Deck Lid Lock Bolt
Lubriplate or Equivalent

Gas Filler Door Hinge
Dripless Oil

Folding Top Linkage Bearing Points
No. 10 Engine Oil

Side Roof Rail Mechanical Sealing Strip (Gasket Parts to be lubricated when access to parts can be obtained.)
Silicone Emulsion

Windshield Wiper Motor and Transmission Spools
Lubriplate or equivalent

Door Lock Parts
Lubriplate or equivalent

Window Regulator Rack and Cam Channels
Lubriplate or equivalent

Service Operations and Adjustments


Cowl Assembly
Instrument panel compartment
Door Assembly
Rear End Assembly
Trim Assemblies
Electric Window Assembly
Electrical Unit Checks
Hydro-Lectric System
Keys and Locks
Care of Trim

Cowl Assembly


Vacuum Windshield Wiper Assembly
Electric Windshield Wiper Assembly
Cowl Ventilating System
Windshield Assembly-All Styles

Vacuum Windshield Wiper Assembly

See Fig. 1

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.

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 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. 2, as follows: Attach right transmission cables to auxiliary drive drum "A" in the following sequence:
    • Cable No. 1 (cable leading from top of transmission pulley) to retainer No. 1.
    • Cable No. 2 (cable leading from bottom of transmission pulley) to retainer No. 2. NOTE: Right transmission cables should "cross-over" approximately midway between the transmission and auxiliary drive.
    • Attach left transmission cables to drum "B" in the following sequence:
    • Cable No. 3 (cable leading to top of transmission pulley).
    • Cable No. 4 (cable leading from bottom of transmission pulley). NOTE: Left transmission cables do not cross over.
  3. Adjust cables to tensioned position.
  4. Connect wiper motor parts as required and check operation of wiper motor. Install instrument panel compartment box.
Windshield Wiper Transmission

The attachment of the windshield wiper transmission is the same as on past styles with the exception of an additional support and attaching nuts which secure the transmission to the underside of the upper shroud.

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.
  5. On outside of body at each transmission, remove escutcheon spanner nut and lift escutcheon from transmission.
  6. Inside body, remove transmission support attaching nuts. Then pull each transmission down through upper shroud panel and remove from body.

Installation

  1. Lubricate parts as specified.
  2. Install gasket to each transmission and apply a medium bodied sealer around transmission shaft to gasket surface contacting body metal.
  3. Position each transmission assembly in body and secure transmission support with attaching nuts to upper shroud.
  4. Attach transmission cables to auxiliary drive drums. NOTE: If new transmission is being installed, it is necessary to remove plastic collar from transmission before cables can be tensioned.
  5. Secure escutcheon with chrome plated spanner nut.
  6. Reinstall wiper blade and arm assemblies. Check operation of wiper motor and transmission assembly.
  7. Reinstall the instrument panel compartment box.
Windshield Wiper Control

Removal and Installation

  1. Remove control cable from motor assembly by loosening screw at motor.
  2. Loosen set screw in control knob at instrument panel and remove knob.
  3. Remove spanner nut with Tool 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 Assembly

The electric windshield wiper (Fig. 3) used on the 1957 Chevrolet is a 12-volt DC unit powered by an internally grounded motor containing both a series and shunt field. The armature of the motor is fitted with a worm shaft which drives the oscillating mechanism through a nylon gear.

A leaf contact-type switch enclosed within the motor housing controls the motor and has three positions; high speed, low speed, and a park, or off position. This switch is controlled by means of a nylon slider mounted externally over the switch on the motor housing which in turn is operated by a bowden cable from the dash panel.

To protect the motor from damage due to overheating, a thermal circuit breaker is built into the case at the commutator end of the motor.

Basically, the electric windshield wiper consists of the cast motor housing, electric motor, the switch mechanism, and the oscillating drive mechanism. A stamped steel case mounts the thermal circuit breaker and motor brushes and completes the encasement of the motor. Individual stamped covers are used over both the switch and oscillating drive recesses in the motor housing. The auxiliary drive mounting bracket which attaches the wiper unit to the dash panel is permanently fastened to the oscillating section cover. An oscillating drive arm is pressed onto the oscillating shaft in a fixed position and should not be removed in service.

Stopping the Wiper

With the unit operating, moving the wiper control on the instrument panel to the off, or park, position moves the nylon slider on the switch cover which moves the latch assembly switch arm (fig. 4) in the switch housing. The latch assembly switch arm is attached to the shaft of the latch assembly toggle (fig. 5), therefore switch arm movement results in like action by the latch toggle. As the spring-loaded latch assembly toggle snaps away from the oscillating drive mechanism, the latch assembly arm (fig. 5) reacts in the opposite direction, thus placing the arm in the path of the clockwise rotating drive assembly disc (fig. 5). After the latch arm contacts the ear of the drive assembly disc as shown in figure 6, the rest of the drive assembly continues to turn, tightening a spring attached to both the nylon gear (fig. 5) and the drive assembly disc. This build-up of spring tension forces the drive pin (fig. 7) to move toward the outer radius of the yoke in the drive assembly, thus increasing the arc-of-travel of the connecting rod (fig. 5). By this means, the additional angular travel required to bring the wiper blades to rest against the cowl molding is provided.

Attached to the opposite end of the oscillating shaft in the switch portion of the motor housing is the breaker arm (fig. 4). During operation of the wiper, the breaker arm oscillates freely inside the switch casting. However, once the drive pin arc-of-travel is increased as described above and as illustrated in figure 7, the oscillation range of the breaker arm (fig. 4) is altered causing the arm to hit the fiber cam and trip the contacts. This action trips contact No. 4 (fig. 4), moving it away from contact No. 3 which breaks the ground and moves No. 4 into contact No. 5 which results in a momentary short being thrown across the armature. This operation provides a dual purpose: First, the separating of contacts No. 3 and 4 breaks the circuit to the motor and finally, the closing of contacts No. 4 and 5 shorts the armature thus providing considerable braking action to overcome any coasting action of the motor when shut down. Figure 8 provides an electrical diagram of the unit with the switch contacts in their park relationship.

Starting the Wiper

Moving the switch slider (fig. 3) by means of the control located on the dash into slow speed, or the first operating position, trips the latch assembly toggle (fig. 5), knocking the latch assembly arm clear of the ear of drive assembly disc.

This releases the spring tension built up as the unit went into park, snapping the drive pin back to its original position in the yoke as shown in figure 6. By this means, the usual wiper pattern of the blade arms is re-established.

At the same time that the latch assembly toggle releases the spring tension in the drive and oscillating portion, the movement of the switch slider causes contact Nos. 1 and 2 to close and Nos. 3 and 4 to close, thus forming the wiper low speed circuit 9 .

Low Speed Circuit

In low speed and following the diagram shown in Fig. 9, contact Nos. 1 and 2 are closed and Nos. 3 and 4 are closed. From source, the current passes the circuit breaker and energizes the series field. After passing through the series field, the power is divided; part is directed to the armature and the remainder is eliminated by being diverted to ground through the shunt field, through contacts No. 1 and 2, then to contact No. 4, and finally to contact No. 3 which is grounded. In following this path, it is well to remember that current always follows the path of least resistance, therefore in low speed, no current passes through the resistor because of the more direct path to ground.

The major point to remember concerning low speed operation is that only about one-half of the power is used to drive the motor; the remainder is diverted to ground.

High Speed Circuit

Moving the wiper control on the dash panel further closes the high speed circuit (fig. 10A). For high speed operation, all contacts are open with the exception of Nos. 3 and 4 which produces the following electric flow: From the source, current flows through the circuit breaker and energizes the series field as in low speed operation. Upon leaving the series field, the current once again divides; half going directly to the armature and the remainder through the shunt field. However, with only contacts No. 3 and 4 closed, the current is forced to flow through the resistor to reach ground via the jumper to No. 4 and finally to No. 3 contact and ground. By forcing the current through the resistor, the flow through the shunt field is slowed considerably, consequently more current is forced to flow through the armature to reach ground and the motor speed is increased proportionately.

CARE, MAINTENANCE AND ADJUSTMENT

Three adjustments are required for proper functioning of the electric windshield wiper; armature and end-play adjustment, drive assembly end-play adjustment, and switch adjustment. Of these, both end-play adjustments would usually be performed either during or after complete overhaul of the unit. Drive assembly end-play is accomplished during rebuild of the unit whereas the armature end-play adjustment is made after reinstalling the wiper on the car. Loss of or incorrect switch adjustment accounts for the majority of wiper complaints, therefore it is with this adjustment that the serviceman should be most critical.

It is possible that adjustments within the switch compartment could be made with the wiper installed on car, however, due to the general inaccessibility of the wiper and its ease of removal, it is recommended that the unit be removed so that all service procedures may be made on the bench.

Switch

Adjustment

  1. Remove the switch housing cover.
  2. Move the latch assembly switch arm ( fig. 4) against the fiber cam until the switch contacts snap to the low speed position (fig.9). Further lateral movement of the latch switch arm should separate contacts Nos. 1 and 2 and hold contacts Nos. 3 and 4 closed, thus forming the high speed circuit (fig. 10).
  3. If latch assembly switch arm travel is insufficient to move the fiber cam adequately to move the contacts into their low and high speed positions, loosen the two switch mounting screws (fig. 4) and shift the switch assembly as required.
  4. When the unit is stopped, the breaker arm (fig. 4) should contact the fiber cam and move it sufficiently to snap the switch contacts into their park position (fig. 8). If the motor does not stop when the dash control is turned to the "OFF" position, the switch assembly mounting screws (fig. 4) should be again loosened and the switch shifted toward the breaker arm.

NOTE: Although seldom necessary, the breaker arm (fig. 4) may be bent toward the fiber cam if the unit cannot be stopped after shifting the switch its full limit. When the breaker arm is stopped at its park position, the minimum clearance between the arm and cam guide should be 1/32" (fig. 11).

Armature End-Play

Adjustment

  1. This adjustment is generally required only after a rebuild of the wiper but can be made at any time with the unit installed.
  2. Connect a DC ammeter in the circuit, start the electric wiper, and note the ampere draw.
  3. Tighten the armature end - play adjusting screw located in the end of the cast motor housing until a rise in the current draw is noted, then back-off adjusting screw slowly until ampere draw returns to that in (1) above. As a safety factor, back off screw an additional 1/8 turn.
  4. To lock adjustment, tighten jam nut.
Drive Assembly End-Play

Adjustment

Drive assembly end-play should be established within .005"-.008" during assembly through use of end-play washers beneath the snap ring on the portion of drive assembly shaft shown at the bottom center of figure 4.

MAJOR SERVICE OPERATIONS

As mentioned earlier, complete tear-down of the wiper assembly is seldom required as the majority of its malfunctions occur within the external controls to the wiper or within the switch housing.

The overhaul procedures are broken down into three major areas: switch assembly, oscillating and drive assembly, and motor. Both the switch and motor assemblies can be serviced without disturbing other sections of the wiper but to disassemble and assemble to the oscillating and drive portion it is also necessary to remove certain elements from the switch housing. Because of the general independence of each section of the wiper, complete disassembly, inspection, and assembly instructions are provided under the wiper component headings.

Switch

Disassembly

  1. Remove four screws securing switch cover and remove cover.
  2. Remove two switch assembly mounting screws (fig. 4) and lift out switch to extent of slack in connecting wires.
  3. Complete removal of switch assembly by placing a hot soldering iron against the three lead connections to the switch. Code the connection points to insure that the color coded wires are connected at the proper locations at assembly.
  4. Remove the switch breaker arm (fig. 4) from end of oscillating shaft by removing plastic retainer.

CAUTION: Do not remove latch assembly switch arm (fig. 4).

Cleaning and Inspection

Check all switch contacts for foreign matter or possible deformation. Contacts can be cleaned with a cloth dampened with carbon tetrachloride or small imperfections removed with emery paper. Broken contacts require replacement of the switch as an assembly.

Be especially careful to check that there is no foreign matter bridging the insulators at the base of the switch. Should any insulator be broken or oil soaked, these can be replaced by removing the two screws holding the contacts and insulators and replacing the insulators with like thicknesses of tag board or non-conducting gasket material.

Check that breaker arm fiber contact surface is in good condition.

Installation

NOTE: If work is necessary within the oscillating and drive section, delay reassembly of the switch components until that work is completed.

  1. Place breaker arm (fig. 4) in slot in oscillating shaft and secure with plastic retainer.
  2. Resolder electrical leads to switch assembly. If connection points were not coded during disassembly, hold switch assembly with fiber cam (fig. 4) downward and with switch mounting surface away from you. Then, from left to right, solder green wire to top-left terminal closest to mounting bracket, red wire to central terminal, and black wire to terminal at bottom right side or closest to the resistor side of the switch.
  3. Fasten switch assembly with two mounting screws (fig. 4) and position as required to satisfy requirements outlined under "Switch Adjustments" earlier in these pages.
  4. Reinstall switch cover and secure with four screws.
Oscillation and Drive Assembly

Disassembly

  1. Perform all operations listed under "Disassembly of Switch" except that it is not necessary to unsolder the electrical leads to the switch. The only purpose is to remove the breaker arm retainer and arm to allow removal of the oscillation shaft.
  2. Remove snap ring shown at bottom of figure 4 and any thrust washers secured by snap ring.
  3. Remove four screws and external-teeth lock washers securing oscillating and drive section cover.
  4. CHECK THAT THE LATCH ASSEMBLY IS NOT IN PARK POSITION, then carefully tap both the oscillating shaft on which the breaker arm (fig. 4) was attached and the drive assembly shaft shown at bottom center of figure 4 out of the housing from the switch compartment side with a soft drift. The latch assembly switch arm is shown in the low speed position in figure 4.
  5. To separate the oscillating mechanism from the connecting rod, remove "E" type retaining ring ( fig. 5) from drive pin and lift out oscillating mechanism.
  6. To complete the disassembly of the oscillating and drive section of the wiper, remove the snap ring (1, fig. 12) and separate the remainder of the parts (fig. 12).

NOTE: Further disassembly of the cover and linkage should not be attempted as these parts are furnished only as assemblies for service. No attempt should be made to remove the latch assembly toggle or arm (fig. 4) as these are fixed fast in the housing. If necessary, the latch spring (fig. 4) can be changed with the toggle installed.

Cleaning and Inspection

Clean all parts except the nylon gear with cleaning solvent and air-dry. Check all parts for deformations and repair or replace as necessary.

The nylon drive gear should be checked for worn or broken teeth. If either condition is present, replace the gear.

Clean the cover and connecting rod linkage of all old lubricant and check for bent parts. Replace the cover and linkage if any faults are found.

Assembly

  1. To reassemble oscillating components (fig. 12), connect spring to drive disc as follows: Position pawl (7, fig. 12) on pin in drive disc (6), then place wire spring on pawl and catch hooked end under offset end of pawl. Straight leg of spring should be then forced against side of disc center hub as shown in figure 13.
  2. Install drive disc and spring assembled in previous step on nylon gear (9, fig. 12).
  3. Place cam and drive pin (5, fig. 12) and yoke (4) on disc as shown in figure 14. Be sure drive pin is cradled in slot on yoke.
  4. To complete the assembly of the oscillation components, place end-play washers (3, fig. 12) and retaining washer (2) on lug and secure with snap ring (1). Measure total end-play within the unit with a feeler gauge and add or remove washers (3) until total end-play is .008" or less.
  5. Lubricate between yoke, cam and drive pin, disc and at all pivot points on the cover linkage with light oil. Then place a light grease coating on the armature shaft, nylon gear teeth, and on the linkage pivot points previously oiled. DO NOT GREASE TOGGLE OR ARM.
  6. Insert drive pin (fig. 5) through connecting rod and secure with "E" type retainer.
  7. Check that toggle is not in park position, then insert oscillating shaft and gear shaft through bores in housing. Tap as required to fully seat shafts.
  8. Secure cover with four screws and external teeth lock washers.
  9. Install breaker arm (fig. 4) in slot of oscillating shaft and secure with plastic retainer.
  10. Reinstall switch components as described under "Installation of Switch."
  11. Place end-play washers as required on end of gear shaft shown at bottom center of figure 4 until total end-play is approximately .010", then complete installation by installing snap ring.
Motor

Disassembly

The motor may be serviced without disturbing other sections of the wiper.

NOTE: All number references are to fig. 15.

  1. Remove two tie bolts (1) securing case (4) to housing (10).
  2. Remove end-play adjusting screw (11) and lock nut (12).
  3. Strike the steel case (4) lightly with a mallet to partially loosen it from the motor field (9) and wiper housing (10).
  4. Insert a tool through the armature adjusting screw opening and push against the end of the armature to back off the case. This will retain the armature commutator between the brushes until ready to separate armature from the case.
  5. To separate the case from the armature while still retaining the brush springs (2) and brushes (3) in place, fashion a separator similar to that illustrated in figure 16 from heavy wire and insert behind the brush leads as shown. The steel case may then be separated from the armature while being careful not to break the electrical connections. CAUTION: Be careful not to lose thrust ball (7) from commutator end of armature (8).
  6. Once the armature is removed, insert brush retainer spring No. 5096576 between ends of brushes as shown in figure 17 to prevent possibility of pulling leads out of brushes through prolonged tension by the improvised separator (fig. 16).
  7. If necessary, remove felt washer (6) and thrust disc (5) from motor case (4). Also, the armature (8) may be taken out of field (9).
  8. Because the field is pressed into the die cast housing, further disassembly of the motor section is not recommended. However, should it be necessary to free the case assembly from the field, unsolder the field leads attached to the brush holders.

Cleaning and Inspection

  1. Inspect both the field and armature for damage due to overheating such as unsoldered electrical connections.
  2. Check that brush leads are firmly attached both to the brushes and their connections at the brush holders.
  3. Check brushes for wear. If brushes are worn to within 3/16" of brush lead, or pigtail, they should be replaced.
  4. Check contacts of circuit breaker shown at top of figures fig.16 and fig. 17. Clean as required or file lightly to remove irregularities.
  5. Inspect all leads from the brush and circuit breaker plate for worn insulation or breaks. Be sure that green lead is held to base insulator by clip to prevent lead chaffing on armature.
  6. If it was determined by inspection in step 3 above that brush replacement was required, proceed as follows:
Assembly

NOTE: All number references are to fig. 15.

  1. If leads were disconnected to separate case (4) from remainder of wiper, resolder connections according to the diagram shown in figure 18.
  2. Loop a 6" to 8" length of string around the brush spring retainer 5096576 shown between the brushes in figure 17. This is used to pull out retainer after armature commutator is inserted.
  3. Insert thrust plate (5) and felt washer (4) into bushing in steel case. Put a few drops of light oil on felt washer.
  4. If removed, start armature (8) into field (9). Twisting the armature slightly will aid in getting the armature worm shaft engaged with the nylon gear in the drive and oscillating section.
  5. Using a high melting point grease, stick the 3/6" thrust ball (7) in commutator end of armature.
  6. Holding the armature slightly extended from the field by means of a tool inserted through the armature end-play adjusting screw hole, push the steel case (4) onto commutator end of the armature. Check that the armature is fully seated, then pull out the brush retaining spring (fig. 17) by means of the string attached in step 2 above.
  7. Line up the tie bolt holes in the steel case (4) with those in wiper housing (10) and push case into position. Then secure with two tie bolts (1).
  8. Install end-play adjusting screw (11) and lock nut (12) to complete assembly.
  9. After wiper is reinstalled, adjust armature end play as described earlier under "Adjustment." The nylon slider (fig. 3) should be lubricated with petroleum jelly prior to installation of the wiper.

TROUBLES AND REMEDIES

CAUTION: Disconnect unit from source of power before removing switch cover.

Trouble

Possible Causes

Remedies

A. Unit will not turn on.

1. No supply voltage at wiper unit.
1. Check wiring carefully.
2. Unit improperly grounded.
2. The wiper unit ground strap should be placed under one of the auxiliary drive mounting screws.

3. Defective soldering at switch terminals.
3. Resolder switch connections if necessary.

4. Defective motor-open field, brushes sticking.
4. Repair defective motor.

5. Contacts 3 and 4 not making contact when unit is turned on or contacts 3 and 4 dirty.
5. Bend contact 3 slightly so that it will make contact with contact No. 4. (Be sure switch is in the low or high speed position when doing this.)

6. Circuit breaker contacts dirty, defective circuit breaker.
6. Remove case and brush assembly and check circuit breaker contacts.

B. Unit will not shut off.

1. Failure of oscillating arm to trip contact 3 and 4 (fig. 4).
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. If proper adjustments cannot be obtained through steps a, b, and c, replace switch assembly.

2. Poor fit between oscillating arm and oscillating shaft slot which would allow excessive circular play of the oscillating switch arm.
2. Replace oscillating switch arm, or try staking it in position.

3. Jumper between contacts 2 and 4 ( fig. 8) shorting to ground.
3. If impossible to remove shorted condition, replace switch assembly.

C. Slow speed operation in both slow and fast switch positions.

1. Switch breaker arm which is operated by the external switch slide not opening contacts 1 and 2 (fig. 4).
1. Adjust 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.
d. If proper adjustment
cannot be obtained by steps a, b, and c, replace switch assembly.

2. Short between switch cover and switch assembly.
2. Caused by switch assembly resistor touching switch cover. Bend the resistor down so that it will
clear the cover.

3. Switch fiber cam not seated properly in slot and therefore, fails to open contacts 1 and 2.
3. Position the fiber cam in the slot and check for proper functioning.


D. Normal fast operation in both the slow and fast speed positions.

1. Speed control contacts No. 1 and 2 (fig. 4) not making contact at low speed position (resistor is in circuit in both slow and fast switch positions).
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. If the above repairs fail to correct this condition, replace the switch assembly.

E. Excessive speed in high speed positions, slow speed OK.

1. Switch assembly resistor open.
1. Replace switch assembly.

F. Excessive speed in both low and high speed positions.

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

2. Open shunt field.
2. Replace entire motor unit.

Ventilating System

Description

The 1957 Chevrolet incorporates a new ventilating system with air intakes at the forward end of the car. The air flows through air ducts and into the body through openings in each side of the dash panel. The flow of air is regulated by the same type controls used on past styles.

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. 20.

  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."
Instrument Panel Cover (All Styles Equipped with Cover)

The instrument panel cover of plastic construction is serviced as a one-piece unit. In Service the cover is secured to the instrument panel by 3M Super Weatherstrip Adhesive (Neoprene) or equivalent around the perimeter of the cover and by metal retainers along the rear edge of the cover.

Removal

  1. Cover front seat assembly.
  2. Remove windshield side and lower garnish moldings and instrument panel finishing caps.
  3. Along rear edge of instrument panel remove cover retainers.
  4. Loosen or remove instrument panel parts necessary to facilitate cover removal.
  5. Detach cemented area of cover from instrument panel and remove from car.

Installation

  1. Clean and dry cementing surface of instrument panel.
  2. Apply thin uniform coat of 3M Super Weatherstrip Adhesive (Neoprene) or equivalent to all cementing surfaces of instrument panel cover and allow to dry. See Fig. 21.
  3. Apply a heavy coat of 3M Super Weatherstrip Adhesive (Neoprene) or equivalent to the rear cementing surface of the instrument panel. Immediately following this application of adhesive, carefully position cover on instrument panel. Check alignment of cover and press rear cemented surface of cover to instrument panel firmly and evenly. See Fig. 21.
  4. Working a small area (approximately 6 inch lengths) at a time, apply 3M Super Weatherstrip Adhesive (Neoprene) or equivalent to front cementing surface of instrument panel and press cover to instrument panel firmly and evenly. See Fig. 21.
  5. Install all previously removed parts and remove protective cover from seat assembly.
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 1957 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 illustrations Fig. 22 Windshield Reveal Moldings and Fig. 23-Convertible Reveal Moldings.

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 5449, 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 l/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. 22, securing lower corner reveal molding, pull molding out slightly and slide corner reveal molding down and remove. On convertible styles, remove screw "A," fig. 23, from lower comer of side reveal molding, then open door and remove three screws "C," fig. 23, securing molding to windshield side pillar and remove molding. Repeat operation at opposite side.
  10. Remove screw "B," figs. 22 or fig. 23, 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. 24. 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."
Windshield Garnish Moldings

Removal and Installation

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

    Convertible Bodies All Other Bodies

    1. Upper Moldings 1. Side Moldings
    2. Side Moldings 2. Escutcheon
    3. Escutcheon 3. Upper Moldings
    4. Lower Moldings 4. Lower Moldings

    Figure 25 identifies the windshield garnish moldings.

    To install, reverse this procedure.
Windshield Side Pillar Finishing Molding
Sport Coupe and Bel-Air Models

Removal and Installation

  1. Remove windshield lower reveal and lower corner molding.
  2. Remove screw securing end of upper reveal, open door and remove three screws (fig. 26) from face of windshield side pillar and carefully pry off molding.
  3. To install, seal all attaching screw holes with a medium body sealer, then reverse the removal procedure.
Windshield Side Pillar Finishing Molding
Convertible Styles

Removal and Installation

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

Windshield Header Molding
Convertible Styles

Removal and Installation

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

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

Removal

  1. Place protective covering over the hood, front fenders, instrument panel and front seat assembly. On convertible models, lower the top.
  2. Remove the windshield garnish moldings and rear view mirror support.
  3. On sedans and sport coupes, remove the windshield lower and lower comer reveals. Carefully pry off escutcheon at junction of upper reveal. On convertibles, remove lower and side reveals.
  4. Remove screws attaching ends of upper reveals. Also remove lower reveal attaching clips from body (fig. 27).
  5. On the inside of the body, loosen the hp of the windshield rubber channel from the pinchweld flange along the top and at the sides by applying pressure with the palm of the hand to the edge of the glass. At the same time assist the lip of the rubber channel over the pinchweld.-flange with a flat bladed tool (fig. 28).
  6. After freeing the rubber channel, with the aid of a helper, lift the windshield from the body and place it on a covered bench.
  7. Disengage the "T" flange of the upper reveals from the rubber channel and remove moldings. NOTE: On convertible bodies a notch is cut at each end of the upper reveal molding in the windshield rubber channels.
  8. Remove rubber channel from glass.

Body Windshield Opening Check

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

  1. Check for the following conditions at the previous marked point of fracture.
    • Chipped edges on glass.
    • Irregularities in body opening.
    • Irregularities in rubber channel.
  2. Remove all sealer from flange and body around windshield opening.
  3. Check flange area for solder, weld high spots, or hardened spot-weld sealer. Remove all high spots.
  4. Check windshield glass to opening, by supporting glass with Tool 5742 (fig. 29). CAUTION: Do not strike glass against body metal. Chipped edges on the glass can lead to future breaks.
  5. With the windshield supported and centered in its opening, check the relationship of the glass to the body opening flange around the entire perimeter of the glass.
  6. Figure 30 is a cross section taken through the glass channel and body opening. Check the relationship of glass to opening as follows:
    • Inside edge of glass to body flange, at any point, dimension 3/16" to 1/4".
    • Outer edge of glass to parallel body metal at any point, dimension 5/6" to 7/16".
  7. Mark areas of body metal or flange to be reformed, remove glass and correct as necessary.
  8. Recheck windshield in its opening and if satisfactory, mark the glass and body so the glass may be accurately centered upon installation.

Installation

  1. Check the windshield drain gutter and drain hoses for obstruction. Clean if necessary. Reseal each drain hose with medium bodied sealer (fig. 31).
  2. Assemble rubber channel to glass and install upper reveal. To facilitate installation of reveal molding to channel apply a mild soap solution to rubber channel molding cavity and "T" flange of molding.
  3. On convertibles, carefully center upper reveal molding in channel, and where a new rubber channel is being used, at each end of the molding cut a notch in rubber channel at the molding attaching screw locations (fig. 32).
  4. Insert cord into pinchweld cavity of channel around the entire windshield. Tie cord loosely and tape ends to inside surface of glass (fig. 33).
  5. Apply a heavy ribbon of medium bodied sealer at the base of the pinchweld flange around the entire perimeter of the opening.
  6. Carefully place and center the windshield in the body opening with the aid of a helper.
  7. Press firmly on the outside surface of the glass and have the helper, inside the body, slowly pull the cord outward from the lower center toward each lower corner to seat the lip of the rubber channel over the flange. (fig. 34).
  8. Seal the outside lip of the rubber channel to the glass with weatherstrip adhesive.
  9. Remove all excess sealer and adhesive with mineral spirits.
  10. Reinstall moldings, sunshade supports, etc.

Instrument Panel Compartment
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. 35).
  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.

Compartment 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.
Rear View Mirror Support
Sport Sedan Models

The rear view mirror and support ( fig. 36) is located at the lower center area of the windshield opening and is secured to the instrument panel by two (2) nut and washer assemblies.

Removal and Installation

  1. Remove windshield side and lower garnish moldings.
  2. Remove two (2) attaching nuts and washers from rear view mirror support by reaching under instrument panel.
  3. Remove rear view mirror assembly from car.
  4. To install, reverse removal procedure.
All Except Sport Sedan
  1. Remove side and upper windshield garnish moldings on all models except convertible. On convertibles, remove the upper garnish moldings.
  2. Remove three screws securing mirror support and remove support.
  3. To install, reverse removal procedure.

Door Assembly


Sedan and Station Wagon Front Door Assembly
Sedan and Station Wagon Rear Door Assembly
Sport Sedan Door Assembly
Convertible and Sport Coupe Door Assembly
Nomad Station Wagon Front Door Assembly

Sedan and Station Wagon Front Door Assembly

Figures fig. 37 and fig. 38 are the sedan front door 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. Window 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. Hinge Pillar Electric Conduit
  17. Window Regulator Motor Electric Connectors
  18. Plastic Type Door Arm Rest Attaching Holes
  19. Hanger Plate for Built-In Type Door Arm Rest
Inside Handles

Removal and Installation

  1. Depress door trim and insert Tool 4614 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 in 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.
Trim Pad

Removal and Installation

  1. Remove garnish molding, inside hardware and arm rest.
  2. Remove screw from lower comers 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. 39).
  3. Remove switch from escutcheon by depressing clips with an awl at "B" and remove clips.
  4. To install, reverse this procedure.

NOTE: On all styles except the Sport Sedan, the feed stud of the master control switch should point toward front of car. On Sport Sedan styles, the stud should point toward rear of car. 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. 40). 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. 41).
  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. 42). 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 door 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 5757 under weatherstrip at the clips and carefully snap clips from retaining hole (fig. 43). Break cement seal and 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. 44).
  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. 45).
  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 44 or six in figure fig. 45, 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 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
  9. weatherstrip attaching clips indicated at "V in fig. 46. Seal all clips along door bottom and lower clip at each door pillar.
  10. Reinstall weatherstrip retaining clips and previously removed parts. Seal door inner panel as specified in "Door Inner Panel Sealing."
Front Door Water Deflectors
All Two-Door Models

A door water deflector, consisting of waterproof paper secured to the door inner panel by elastic double sided sealing tape, is provided on front doors. The deflector covers the complete door inner panel and fits into a slot along the bottom of the door inner panel. This deflects water into the bottom of the door where it can drain out the door bottom drain holes. When work is performed on a door where the water deflector has been disturbed, the deflector must be properly sealed and attached to the inner panel as specified below. When loosening or removing a door water deflector, the seal between the double sided sealing tape and water deflector should not be broken.

Removal

  1. Remove door belt finishing molding and door trim assembly.
  2. Carefully detach water deflector with attached double sided sealing tape from door inner panel. Do not remove double sided sealing tape from deflector unless it is necessary to replace the sealing tape. Use caution that dirt or foreign matter does not get on exposed surface of tape and destroy adhesive qualities of tape.

Installation

  1. Prior to installing water deflector, clean surfaces of inner panel contacted by sealing tape to insure satisfactory seal.
  2. Inspect water deflector and where necessary repair any tears or holes with waterproof body tape applied to both sides of deflector.
  3. Insert bottom edge of water deflector in slot across bottom of inner panel. Align holes in water deflector with regulator spindles and inside trim and hardware installation holes. When properly aligned press or roll edges of water deflector to inner panel to effect a watertight seal.
  4. Tape upper and lower comers of water deflector to inner panel with 2 inch strips of waterproof body tape, as indicated in Fig. 47.
  5. Install previously removed door trim and inside hardware.
Front Hinge Pillar Auxiliary Weatherstrip

Removal

  1. Remove two snap fasteners "A" with flat bladed tool, break cement seal and remove weatherstrip (fig. 48).

Installation

  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. Weatherstrip must not cover any part of drain hole.
  3. Install remainder of weatherstrip into place and firmly press weatherstrip to establish a complete bond.
  4. Remove excess adhesive.
Door Lock

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

Operation

A rotary bolt type door lock is used on all models. Figuresfig. 49 and fig. 50 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. 49). 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. 50).
  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. 51).
  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. 51).
  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 across the face of the lock frame approximately 3/4' above the rotary bolt housing as shown at "I" (see fig. 52).

Door Lock Striker-All Styles

Front and rear door lock strikers incorporate the 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 striker teeth to center of lock extension is less than 3/16", install emergency spacers and proper length striker attaching screws as directed on next page.

NOTE: Dimension "B" from center of lock extension to inside face of striker notch should never be less than 1/8". 

Dimension"A"     No. Spacers Required      Spacer Thickness      Striker Attaching 
                                                                       Screws*

3/16" to 1/8"             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-
                                                                   (1/8" 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.

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:
    • Remove screws securing electric conduit and carefully slide conduit toward front pillar exposing wire harness.
    • Detach wire harness from clips and disconnect motor leads. Disengage wiring from retaining clips and carefully pull harness from cutout in door hinge pillar.
  4. Support door and remove bolts "A" or "B" (fig. 54). 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 55, 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 1957 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 56 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 comers 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:

All window regulator attaching holes (4).

Door inner panel cam attaching holes (5).

Ventilator division channel lower attaching stud and nut (6).

Ventilator tee-shaft access hole and ventilator regulator attaching screws. (7, View "A.")

Door trim assembly nail slots (8).

On electric styles-inner flanges of switch hole cover and to upper rear corners and
across top joint of cover and inner panel. (9, View "B.")

Door arm rest attaching holes (10).

  1. Apply waterproof tape over the following door inner panel openings.

Cam access hole (11).

Lock access hole (12).

Lower hinge access hole (13).

Upper hinge access hole (14).

On electric styles-window regulator spindle hole (15).

Front Door Adjustment

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

Up or Down and In or Out

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

Up or Down and Fore or Aft

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

Should the door clearance at the body hinge and windshield pillars be parallel and fall within 1/16" to 3/16" clearances and the door at the center or lock pillar be tilted (close at the top, wide at the bottom or vice-versa) it is indicative of another type of correction, namely body shimming. In most cases, where adjustment of the doors cannot correct a door alignment problem, body shimming will be the answer. Figure 58 shows the location of all body mounting points and where shims may be added or removed to correct body alignment faults. In addition figure 57 gives the dimensional clearances of the doors at the pillars.

NOTE: 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.

Ventilator Regulator

Removal and Installation

Remove door garnish molding, trim pad and small access hole cover.

Remove screws "A" and "B" (fig. 59), disengage regulator from "Tee" shaft and lower it between door panels out through small access opening.

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. 60). 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. 61).
  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" (figure 62) 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 washer slightly and make quarter turn and remove stop washer, retainer, spring and push button and shaft (fig. 63).
  3. To install, reverse this procedure.
Lock Cylinder

Removal and Installation

  1. Pry retainer "C" out sufficiently to release cylinder (fig. 62).
  2. Remove cylinder and gasket.
  3. Remove retaining clip "A" and pawl (fig. 64).
  4. Carefully bend open four cylinder housing scalp tabs "B" and remove scalp. CAUTION: When removing scalp, hold spring loaded cylinder cap depressed with finger. Note position of springs and cap for reassembly purposes.
  5. Remove cylinder from housing. Figure 65 shows an exploded view of the door lock.
  6. To install, reverse this procedure, insert cylinder with curved edge toward lock pillar and check operation of lock cylinder.

NOTE: A redesigned spring clip is used on the door lock lovers to secure the connecting rods to the lock lovers. A slot in the spring clip provides easier disengagement of the clip thereby facilitating easier detachment of the lock connecting rods from the lock. To disengage spring clips, use a screw driver or other suitable tool to slide clip out of engagement. Figure 66 shows a door lock spring clip engaged and disengaged.

Sedan and Station Wagon Rear Door Assembly

The manual regulator type rear door inner panel and the electric regulator type rear door Fig. 66-Door Lock Spring Clip

inner panels are shown in figures 67 and figure 68 respectively. The illustrations show the location of hardware parts and their attaching points.

  1. Glass Run Channel
  2. Upper and Lower Hinge Cover Plates and Hinges
  3. Locking Rod and Lover
  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. 69).
  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 70.
  5. Install hinge cover plates and remove excess sealer.

Adjustment

To check the rear door alignment in the body opening, remove the lock striker from the body lock pillar and allow the door to hang free. Then check spacing (fig. 57) 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".

NOTE: 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."

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

Same as front door.

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. 71).
  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. 72).
  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. 73).

NOTE: Adjusting tool may be made from a 7" x 1/8" rod bent to form a right angle 3/8" from one end.

Glass Run Upper Channel

Removal and Installation

  1. Lower door window and remove trim pad and access hole cover (fig. 74).
  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 Lower Channel

Removal and Installation

  1. Lower door window, remove trim pad, access hole cover and screw "D" from end of glass run channel (fig, 74).
  2. Detach upper channel from door lock pillar, then remove rose-bud fastener from retainer at "G."
  3. Carefully pull lower 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.
Glass Run Front Channel

Removal and Installation

  1. Lower door window and remove trim pad and access hole cover (fig. 75).
  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. 75).
  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

Similar procedure as front door except that door ventilator does not have to be removed.

Adjustment

Similar to front door.

Rear Door Window Regulator

Removal and Installation

Same procedure used as for front door except that there is no division channel adjusting stud and nut.

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

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

  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 comer 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).

  1. Apply waterproof body tape over the following door inner panel openings:

Welding access holes (8).

Cam access holes (9).

Lock access hole (10).

Sport Sedan Door Assembly


Front Door Assembly
Rear Door Assembly
Center Pillar Assembly

The door section is divided into the following parts:

Special attention should be given the door lock striker adjustments and dimensional specifications for use of striker emergency spacers. Special attention should also be given to both front and rear door window adjustments to provide proper window frame contact with the side roof rail weatherstrip.

PROCEDURES FOR BOTH FRONT AND REAR DOOR

Door Belt Finishing Molding

Removal and Installation

  1. Remove inside locking rod knob.
  2. Remove screw securing each end of molding; disengage molding from clips and remove from door.
  3. To install reverse removal procedure.
Door Arm Rest

Removal and Installation

The same procedure as on the plastic type on the sedan front door.

Door Trim Assembly

Removal and Installation

The same procedure as used on the sedan front door except that the door belt finishing molding must also be removed.

Side Roof Rail Weatherstrip

The side roof rail weatherstrip is a one-piece weatherstrip, with an "L" shaped metal insert through the entire length of the weatherstrip. The weatherstrip is secured to the side roof rail by fourteen screws and to the body front pillar by one screw.

IMPORTANT: The attaching holes in the side roof rail weatherstrip are elongated to provide "in" and "out" adjustment for proper contact with the front and rear door window frames. However, the amount of adjustment is small and is not intended to correct for improper ventilator or door window alignment. It is very important that the front door ventilator and the front and rear door windows are checked and, if necessary, aligned for proper contact with the side roof rail weatherstrip.

The following procedures may be used for removing, installing and adjusting the side roof rail weatherstrip.

Removal

  1. Open both front and rear doors and lower the windows.
  2. Remove one screw securing weatherstrip at body front hinge pillar and screws securing weatherstrip to side roof rail. Carefully detach weatherstrip from sealer and remove from body.

CAUTION: Use care when removing and handling weatherstrip so as not to bond metal insert.

Installation

  1. Clean off all old sealer from weatherstrip attaching surfaces along side roof rail.
  2. As a bench operation, apply a continuous ribbon of heavy-bodied sealer (3/16" diameter) along the inboard edge of weatherstrip as indicated at "1" (fig. 77), along entire length of weatherstrip.
  3. At the front end of the weatherstrip apply a good grade of weatherstrip cement to the contacting surface of weatherstrip, indicated at "2"
  4. Position weatherstrip to side roof rail and retain in position with one attaching screw at front center and rear of weatherstrip.
  5. Install loosely all weatherstrip attaching screws.
  6. With the doors and windows closed, position weatherstrip so that an even, continuous contact is made with the window frames and tighten weatherstrip attaching screws. Clean off excess sealer and cement with mineral spirits.
  7. Lubricate. Apply a silicone rubber lubricant to surface of side roof rail weatherstrip indicated at "1" in fig. 77. Lubricant is to be applied along length of weatherstrip. In addition, apply lubricant to the top and inboard surface of the rear door window frame sash channel as indicated at "2". Apply lubricant to the upper front comer of the frame extending from the forward edge rearward for a distance of seven inches.

Adjustments

  1. The attaching holes in the side roof rail weatherstrip are elongated to provide "in" and "out" adjustment for proper contact with the front and rear door window frames as shown in fig. 78. To adjust weatherstrip, loosen attaching screws along area requiring adjustment, move weatherstrip "in" or "out" as required and retighten screws. NOTE: The amount of "in" and "out" weatherstrip adjustment is small and is not intended to correct for improper ventilator or door window alignment. If proper weatherstrip contact cannot be obtained through the "in" and "out" weatherstrip adjustment, the door ventilator and/or windows must be aligned to obtain the proper weatherstrip contact.
  2. The side roof rail weatherstrip can also be shimmed downward to provide proper contact with the ventilator frame and door glass frame. To perform this operation, detach weatherstrip from side roof rail sufficiently to install tapered waterproof shims between the weatherstrip and the side roof rail. DO NOT BEND THE INTEGRAL METAL INSERT. Shims should be securely cemented to side roof rail, and specified sealer should be re-applied to weatherstrip in affected area.

CAUTION: Shims should be well tapered and long enough to provide a continuous sealing surface along the length of the weatherstrip. Shims which are not tapered or too short may cause irregularities in the sealing surface.

Front Door Assembly

Assembly and Hinges

The front door hinges are the swing-out type with an integral door check and hold open, similar to the sport coupe. The hinges are attached to the front body hinge pillar and to the door assembly with bolts, cage nuts and anchor plates. Either of two methods may be used to remove the door from the body.

  1. The door and hinges can be removed as an assembly from the body hinge pillar.
  2. The door can be removed from the hinge straps.

Adjustment

Door adjustments are provided through the use of floating cage nuts and anchor plates in the door and adjacent hinge pillar. When checking the door for misalignment, remove the door lock striker from the body pillar to allow the door to hang free on its hinges.

IMPORTANT: After performing any door adjustments the front door ventilator and window should be checked for proper alignment with the side roof rail weatherstrip and adjusted, where required. In addition the door lock extension-to striker engagement should be checked and adjusted, if necessary.

Inner Panel Sealing

Fig. 79 shows the front door inner panel areas which must be sealed to prevent entrance of water and possible damage to interior trim. Whenever any work is performed on the door where the weatherseal has been disturbed, the area must be resealed before the door trim assembly is reinstalled.

Sealing Operations

  1. Apply a ribbon (approximately 3/16" diameter) of medium-bodied sealer across the top and down the side flanges to a point 1/2"' beyond the access hole cover offset line to Provide a seal between cover and inner panel.
  2. Apply a ribbon of medium-bodied sealer to the contacting surface of access hole cover at the lower corners.
  3. After access hole cover is installed, seal lower comers of cover, at offset, with body caulking compound.
  4. Apply body caulking compound at the following locations (fig. 79):

Over the window regulator attaching holes (1).

Over the window cam attaching holes (2).

Over the ventilator division channel lower attaching hole (3).

Over trim assembly nail slots (4).

Over the wiring clip attaching hole (5).

Over the arm rest attaching holes (6).

  1. Apply waterproof body tape at the following locations:

Over both lower and upper hinge access hole (7).

Over the window cam access hole (8).

Over the manual window regulator spindle hole (9).

Over the door lock remote control connecting rod clip attaching hole-apply before
installing clip (10).

On styles equipped with electrically operated window regulators apply body caulking compound in the upper rear corners, across the top and clown the side joints of switch hole cover and inner panel. Sealer to be worked into openings to insure proper seal (11).

Apply a sufficient amount of body caulking compound to block off the ventilator tee shaft access hole (12).

Apply body caulking compound over ventilator regulator attaching holes (13).

Apply waterproof body tape over access hole (14).

Door Ventilator Cap Finishing Molding

Removal and Installation

  1. At top of ventilator remove two screws securing cap finishing molding and remove molding from ventilator.
  2. Before installing cap finishing molding apply a ribbon (1/4" in diameter) of body caulking compound from the front edge of the molding to a point rearward of the attaching hole then outboard to the outer flange as shown in fig. 80. Make sure window glass bumper assembly is properly fastened at top of ventilator division channel, then install cap finishing molding.

After installation, clean off excess sealer and make sure bumper assembly is properly positioned in finishing molding.

Door Window (Manual and Electric)

Removal and Installation

The procedure used is the same as the Sport Coupe front door except that the belt finishing molding does not apply.

Adjustments

Adjustment procedure is similar to that used on the Sport Coupe.

Door Locking Mechanisms

The operation of the front door locks on the sport sedan styles is the same as on other sedan styles; however, due to the new center pillar design the lock is located lower in the door requiring connecting rods from the door outside handle and lock cylinder assemblies.

Door Lock Spring Clip

Similar to that used on Sedan front doors.

Door Lock

Removal

Similar procedure to that which is used on Sedan front doors.

Door Outside Handle

The door outside handle is equipped with a bell crank lever which actuates the lock lever by means of a connecting rod. An adjusting nut is provided at the lower end of the outside handle connecting rod to provide adjustment for proper contact of the handle push button shaft with the bell crank.

Removal and Installation

  1. Raise door window. Remove door trim assembly and large access hole cover.
  2. See fig. 82. Through access hole detach outside handle connecting rod adjusting nut "C" from lock lever. To detach adjusting nut from lock, insert a screw driver between connecting rod and lock lever, then snap rod and adjusting nut from spring clip on lock lever.
  3. Through access holes "H," fig. 83, remove handle attaching screws, then remove handle and gaskets with attached connecting rod from door. As a bench operation remove connecting rod from handle.
  4. To install, reverse removal procedure. Before attaching the outside handle connecting rod adjusting nut "C," fig. 82, to lock lever, adjust nut so that door handle bell crank just contacts handle push button shaft, then attach adjusting nut to lock lever.

Check operation of outside handle before installing access hole cover, door trim assembly and hardware parts. Seal door inner panel as specified in "FRONT DOOR INNER PANEL SEALING".

Door Lock Cylinder

The front door lock cylinder operation differs from cylinders on other models in that the cylinder actuates the door lock by means of a connecting rod.

Removal and Installation

  1. Raise door window. Remove door trim assembly and large access hole cover.
  2. Through large access hole detach lock cylinder connecting rod "D" from lock lever (fig. 82). To detach connecting rod, insert a screw driver between connecting rod and lock lever, then snap rod from spring clip on lock lever.
  3. With a suitable tool pry out retaining clip "I", shown in fig. 83, sufficiently to allow removal of lock cylinder with attached connecting rod from the door.
  4. Door lock cylinder connecting rod may be removed from lock as a bench operation.
  5. To install, reverse removal procedure. Check operation of lock cylinder and lock before installing access hole cover, door trim assembly and hardware parts. Seal door inner panel as specified in "DOOR INNER PANEL SEALING".
Door Lock Cylinder

Disassembly and Assembly

  1. Remove cylinder assembly from door.
  2. Remove door lock spring clip and pawl.
  3. Carefully bend open four cylinder housing scalp tabs and remove scalp. NOTE: While removing scalp, hold cylinder cap, which is under tension from cap springs, depressed with finger. After scalp is removed, observe position of spring and cap so they can be reinstalled in same relative positions. See fig. 84.
  4. Remove cylinder from cylinder housing.
  5. To install, reverse removal procedure.
Door Outside Handle

Disassembly and Assembly (fig. 85)

  1. Remove front door outside handle, as previously described.
  2. Depress retainer sufficiently to turn bell crank lever and support one quarter turn. Remove bell crank lever and support, retainer, spring, push button and shaft and sealing ring from handle
  3. To install, reverse disassembly procedure.
Door Inside Locking Rod and Knob

Removal and Installation

  1. Raise door window. Remove door trim assembly and large access hole cover.
  2. Through access hole detach inside lock rod "E," indicated in fig. 82 from lock lever and remove rod from door.
  3. To install inside locking rod, reverse removal procedure. Seal door inner panel as specified in "FRONT DOOR INNER PANEL SEALING".
Door Lock Remote Control and Connecting Rod

Removal and Installation

  1. Raise door window and remove door trim assembly.
  2. Remove lock remote control attaching screws "A," indicated in fig. 83; detach remote control from connecting rod and remove from door.
  3. To remove door lock remote control connecting rod, remove large access hole cover, then through access hole detach connecting rod from lock at "F," fig. 82, and from clip at location "J," shown in fig. 83, and remove rod from door.
  4. To install, reverse removal procedure. If large access hole cover has been removed, seal cover and door inner panel as specified in "DOOR INNER PANEL SEALING".
Weatherstrips

Sport Sedan front door weatherstrip and hinge pillar auxiliary weatherstrip procedures are the same as previously outlined under "CONVERTIBLE AND SPORT COUPE DOOR" in this manual.

Rear Door Assembly

Removal and installation procedures are illustrated in fig. 86. Particular attention should be given the rear door window adjustments to provide proper window frame contact with the side roof rail weatherstrip, and to the door lock striker adjustments and dimensional specifications for use of striker emergency spacers.

Door Assembly and Hinges

The rear door assembly is attached to the body center pillar with two butt type hinges. The lower hinge, which has an integral type door check and hold open, is secured with three screws to an anchor plate at both the. door hinge pillar and center pillar. The upper hinge is secured with three screws to an anchor plate at the door hinge pillar and with three screws to an upper support at the center pillar.

Removal

Either of the following two methods can be used to remove the door from the body.

  1. Operate window to down position.
  2. Clean off excess sealer from around each hinge strap and scribe hin