SECTION 11

CHASSIS SHEET METAL

CONTENTS OF THIS SECTION

The fenders, grille and surrounding sheet metal form an integrated frame work, which is attached to the body fig. 1 and mounted at a central rubber insulated point on the front cross member of the chassis frame. A heavy ribbed, deep drawn two piece welded skirt forms a box structure with the fender and filler skirt.

New this year are the ventilation ducts located in either fender, extending through the fender skirt and attaching to the body. These ducts, which gather air from just above the headlamps, are composed of two sections. The first section attaches at the opening above the headlamp and extends, by way of a rubber seal, through the fender skirt. This section includes the drain hole. The second section fits into the rear of the first section, and is supported by a brace to the fender skirt at the front and by three screws to the firewall at the rear. This section, on either side, includes the damper for shutting off the flow of air, and, on the right side of the vehicle, also includes the passage supplying air to the heater or air conditioning system.

Three widely spaced cross members maintain alignment and rigidity across the front and connects the fender skirts and fender filler skirts; a reinforcement spans the grille header line; and a fender-to-fender "U" channel tie bar is riveted through gussets to the radiator core support side channels and serves as the main cross beam supporting the front end structure.

The radiator core support is center mounted to an angle bracket which is welded to the integral front suspension cross member. This type of mounting eliminates the separate radiator support cross member and serves as a base for the filler panel center support.

The one piece hood has the lock support bracket attached to the hood front flange and to the hood front reinforcement bar. Two hood panel braces attached to the front part of the lock support bracket extend diagonally across the front comers of the hood to the ends of the front reinforcement. This arrangement of parts adds considerable stiffness to the front portion of the hood. A center brace assembly extends from the hood front reinforcement to the rear reinforcement and is bolted at both front and rear reinforcements. This center support adds strength to the center portion of the hood as well as providing support for the center of the hood filler panel which spans the arch of the hood.

A newly designed full lift hood hinge assures simultaneous hinge action, easy operation and positive hold-open. The spring counterbalanced hood opens fully with very little effort as soon as it is unlocked fig. 2.

A hood safety catch and self-locking mechanism virtually eliminates the unlocked hood danger. The safety catch and the hood catch are pivoted through a hole in the lower lock plate. This prohibits any sliding action of the safety catch. The lock permits only a downward movement of the hood while the car is in motion and provides positive locking at all intermediate positions down to the completely closed position.

Service Operations

Hood Assembly

Hood Hinge
Hood Lock and Lock Plate
Hood Nameplate
Hood Lacing
Hood Assembly
Hood Adjustment
Hood Filler Panel
Hood Front and Rear Reinforcement
Hood Bumpers

Hood Hinge

Removal

1. Prop the hood in the extreme open position and place protective covering over cowl panel and fenders.
2. Scribe position of hood hinge on hood rear reinforcement and remove the two bolts.
3. Scribe position of hinge attachment on cowl wall. From within car, remove two bolts attaching hinge to cowl wall.
4. Remove bolt and retainer attaching hinge to fender flange.
5. From under hood, remove last bolt holding hinge to cowl wall and remove hinge.

Installation

1. Seal hinge attaching holes at cowl wall with body caulking compound.
2. First install upper bolt (from hood side) loosely.
3. Install two bolts attaching hinge to hood rear reinforcement, first aligning with scribe marks.
4. Close hood and align flush with cowl and fenders.
5. Install remaining two bolts from inside and tighten.
6. Raise hood and tighten top mounting bolt.
7. Replace and tighten bolt and retainer holding hinge to fender assembly.
8. Remove protective coverings.

The hood lock, fig. 3, is attached to the lock support bracket by two bolts and a sheet metal screw. The locking plate is attached to the grille reinforcement by two bolts and to the spacer assembly by one bolt. The locking plate bolt holes are slotted to provide a lateral adjustment of the locking plate.

Hood Air Scoop Assembly

Both air scoop assemblies located on the hood are removed and replaced in the same manner (fig. 4).

Removal

1. From underside of hood, remove the nut and screw holding the air scoop assembly, insert assembly and bracket.
2. Remove the two screws and lock washers attaching the bracket to the back of the air scoop assembly and retaining the insert assembly.

Installation

1. Attach screws and lock washers attaching insert and bracket to air scoop assembly.
2. Install in place and attach the screw and nut holding assembly in place.

The hood name plate is attached to the hood with four special spring nuts.

Hood Lacing

Hood Lacing The hood lacing is retained by spread snap clips which are inserted into holes provided in the top of the cowl.

Hood Assembly

Removal

1. Prop the hood in the open position, fig. 5, then place protective covering at top of cowl and on fenders.
2. Scribe position of hinge attachment on hood rear reinforcement.
3. Carefully remove attaching bolts at hinge to hood. Care must be used to prevent hood from dropping and damaging surrounding parts.
4. Remove hood from vehicle.

Installation

1. Protect top of hood and fenders with covering.
2. Place hood in position over hinges and loosely install bolts.
3. Prop hood in open position, and place hinge to hood attaching plate within scribe marks and tighten bolts.
4. Adjust if necessary. Remove prop and protective covering.

Hood Adjustment

Vertical adjustment of the hood is provided through slotted holes at the cowl attaching point. Longitudinal adjustments are provided through slotted holes at the hinge to hood attaching point.

Hood Filler Panel

The hood filler panel is attached with nuts and lock washers to studs in the hood flange, on each side of the hood, and in the channel reinforcement in the center of the hood. Also, the panel is attached by a screw at each end through the flange of the hood. A seal is provided between the filler panel and the hood.

Hood Front and Rear Reinforcements

The hood rear reinforcement is welded to the rear hood flange and is provided with an antisqueak pad at the center of the hood.

The hood front reinforcement spans the hood just ahead of the hood filler panel and provides a place to bolt the lock support bracket and hood panel braces. This serves to stiffen the hood.

A center brace assembly is attached to the front and rear reinforcements by means of bolts and lock washers.

Hood Bumpers

A stationary hood bumper is located on each side of the hood at the fender to fender skirt attaching flange. In addition, two adjustable bumpers are provided on each side at the front corners of the hood.

Radiator Grille and Baffles

Grille Center Bar
Parking Lamps
Grille
Grille Filler Panel

Front Fender Shield Extension and Baffle Assembly Shield Assembly

Removal

1. Remove eight stamp nuts and two spin nuts attaching center bar to radiator grille (fig. 6).
2. Remove stamp nut attaching center bar to center spacer.
3. Lift off center bar and unplug electrical connections.

Installation

1. Replace electrical connections.
2. Replace spacer bar and install all spin nuts and stamp nuts.

Removal

1. From rear of center bar remove stamp nuts from lamp assembly and remove assembly. Lens may be removed for bulb replacement by removing two screws at front of lens (fig. 7).

Installation

1. Reverse the removal procedure for installation.

Removal

1. Remove center bar (see above).
2. Remove the eight screws attaching the grille screen to the filler panel (fig. 8).
3. Remove the six screws attaching the grille screen to the fender tie bar.
4. From each side, remove screw attaching grille to the fender flange.
5. From the front of the car, remove the grille.

Installation

1. Set the grille in place and replace all screws and bolts. Replace center bar.

Fig. 9

Removal

1. Remove the front bumper.
2. Remove two bolts attaching center spacer assembly to filler panel.
3. Remove screw attaching each outer spacer assembly to filler panel.
4. Remove eight screws attaching radiator grille to filler panel.
5. Remove the six screws at each side attaching the filler panel to the skirt filler assembly, skirt assembly and baffle.
6. Remove the bolt attaching the filler panel support assembly to the radiator support assembly.
7. From each side, remove the bolt and washer attaching the filler panel and rubber seal to the fender flange.
8. Remove filler panel.

Installation

1. Hold filler panel in place and install, on each side, the bolt and washer attaching filler panel and rubber seal to the fender flange. It is important that the washer be installed to prevent twisting of the rubber seal.
2. Replace the filler panel to radiator support bolt.
3. Replace the six screws, on each side, attaching the filler panel support to the rest of the sheet metal.
4. Replace the eight screws holding the grille to filler panel, the screw attaching the outer spacer to the filler panel, and the two bolts attaching the center spacer to the filler panel.

Removal

1. From beneath fender remove two screws attaching shield to fender skirt. 'The front screw also attaches the baffle to the fender skirt.
2. Under hood, remove two screws attaching radiator support assembly to shield and one screw attaching the baffle to the shield.

Baffle Assembly Removal

Fig. 10

1. From beneath fender, remove four screws attaching fender skirt to baffle. The bottom screw will be already removed if the shield has been removed.
2. From beneath hood, remove the four bolts attaching baffle to radiator support assembly. The top bolt also supports the horn, which should be carefully laid aside. If the shield has been removed, the lower bolt will have been already removed.
3. Remove two screws attaching baffle to radiator tie bar assembly.
4. Remove baffle assembly. Installation The baffle and shield may be installed, either singly or as a unit, by reversing the removal procedures.

Tie Bar and Radiator Support
Bumper Bracket
Front Fender
Front Fender and Skirt
Front End Sheet Metal
Front End Sheet Metal Adjustment

Tie Bar and Radiator Support

The radiator support is riveted to the tie bar and with the radiator may be removed as an assembly from the vehicle without disturbing the front end sheet metal. The attachment of the radiator core to the radiator support varies with the six and eight cylinder engine. The six cylinder engine radiator core is mounted in front of the tie bar and the eight cylinder engine has the core mounted in back of the tie bar.

Removal

1. Raise the hood and disconnect upper and lower radiator hoses at the radiator and drain radiator. Remove oil cooler lines from base of radiator on Powerglide and Turboglide models.
2. Install screws attaching horn and baffle to radiator to support. Remove radiator core. NOTE: Each radiator core may or may not be shimmed. Check location of shims for installation purposes.
3. Remove the two bolts, at each side, attaching tie bar to fender skirt. Also remove two baffle to tie bar upper screws. NOTE: The tie bar is shimmed at the fender skirt attaching point. Check location and number of shims at attaching point (fig. 11).
4. Remove four screws from each side, attaching baffle to radiator support. NOTE: Upper bolt at each baffle also retains horns to radiator support. Lay horns out of way.
5. From beneath vehicle, straighten out tabs of lock plate and remove nuts from support bolts.
6. Remove lock plate, two plates and cushion, then remove radiator core support and tie bar from vehicle. CAUTION: A pad and shims are inserted between the radiator core support and front cross member. Note the number of shims for installation purposes.

Installation

1. Place shims and cushion on front cross member and position radiator core support and tie bar in place. From under vehicle install plates, cushion, lock plate and nuts and torque nuts to 9 to 11 foot lbs. and lock in place with lock plate tabs.
2. Install screws attaching horn and baffle to radiator support and tie bar.
3. Replace shims and install bolts attaching tie bar to fender skirt. NOTE: Check anti-squeak in this area before installation and replace if necessary.
4. Position radiator core in support with proper shims at bolt locations. Install bolts loosely.
5. Shift position of radiator in support, allowing 3/4" clearance between radiator core and engine fan. Tighten bolts. NOTE: Slotted radiator support frame attaching holes allow movement of the core for engine fan to core clearance. A compensating adjustment through oversize holes in the frame bracket, may be necessary at the radiator support to chassis frame attachment to acquire the 3/4" core to fan clearance.
6. Connect the upper and lower radiator hoses. Replace oil cooler lines to base of radiator on Powerglide and Turboglide models and refill radiator.

Fig. 12

Removal

1. Under fender, remove the two bumper bracket to fender flange attaching bolts.
2. Remove the front bumper rear brace at frame and bumper bracket.
3. Remove bumper bracket assembly.

Installation

1. Install bracket to fender flange mounting bolts.
2. Install rear brace and bolts attaching it to frame and bumper bracket.

Fig. 13 and Fig. 14

Removal

1. Remove four screws attaching headlamp door assembly to fender.
2. Remove four screws attaching headlamp housing to fender and front air duct. NOTE: The headlamp ground wire is attached to one of these screws.
3. Remove the four screws attaching the front of the front air duct to the fender.
4. From beneath hood, remove the two screws attaching the radiator tie bar to the fender and fender skirt.
5. Remove the three sheet metal screws attaching fender to fender flange. If heater is present, remove the two screws attaching the blower bracket to the fender flange.
6. Beneath fender, remove the two bolts attaching the bumper bracket to the fender flange.
7. Remove three stamp nuts attaching the outer grille bar to the fender flange and filler skirt assembly. From in front of the fender, remove the outer grille bar.
8. Still beneath fender, remove the bolt attaching the grille tie bar to the fender, fender skirt and skirt filler assemblies.
9. Remove the skirt to fender screw located on that part of the skirt facing the front of the vehicle and on the engine side of the air duct.
10. Remove the fender to skirt brace screw.
11. Remove the skirt to fender screw at the lower rear corner of the fender.
12. Remove the screw and tab attaching the lower front corner of the fender to the filler panel.
13. Remove the fender to cowl and fender to side rail bolts. Note the number and location of any shims present.
14. Remove fender. Front air duct may be pulled from rear air duct as fender is removed and may be removed from fender. Fold the rubber sleeve (at joint of front and rear air duct) back on front duct.

Installation

1. Attach the front air duct and, making sure the air duct extends through the hole in the fender skirt and fits properly into the rear air duct, place the fender in position and loosely install the fender to cowl and fender to side rail bolts and shims. Be sure to pull the rubber sleeve (at joint of front and rear air ducts) into place to insure a complete seal.
2. Install the screw and tab attaching the filler panel to the fender, the skirt to fender screw at the lower rear of the fender, the fender to skirt brace screw and the fender skirt to fender screw located inboard from the front air duct.
3. Replace bolt attaching the fender and fender skirt to the grille tie bar.
4. Replace the grille outer bar and install three stamp nuts securing bar. Install two bumper bracket to fender flange bolts.
5. Install three screws attaching fender flange to skirt. If heater is present, also install two screws attaching blower bracket to fender flange.
6. Install two bolts attaching radiator tie bar to fender flange.
7. Install the four screws attaching the front air duct to the fender and then the four screws attaching the headlamp housing to the front air duct and fender. NOTE: Be sure to connect the headlamp ground wire.
8. Install the headlamp door assembly to the fender.
9. Tighten down all bolts and screws.

Fig. 13 and Fig. 14

Removal

NOTE: Certain locations have shims specified as required for adjusting purposes. Therefore shims should be replaced as removed at these locations upon installation. In addition, check condition of all seals, Raps and antisqueak strips at fender attaching points.

1. If left fender and skirt is being removed, disconnect positive cable from battery. To remove right fender and skirt the battery must be removed and, from beneath the fender, the two screws attaching the battery support assembly to the fender skirt must be removed. In addition unclip all hoses and wiring found on the fender skirt to be removed. Disconnect headlamp wiring at connector.
2. From beneath fender, remove two screws attaching fender flange to bumper bracket.
3. Remove the screw and tab at lower front of fender attaching filler panel to skirt filler assembly and fender flange.
4. Remove three cap nuts attaching outer grille bar to fender and filler skirt assembly and remove the outer bar assembly.
5. Remove the two screws attaching the grille tie bar to the skirt and fender flange.
6. Remove one screw attaching skirt filler assembly to fender skirt and filler panel, two screws attaching fender skirt to filler panel and two screws attaching fender skirt to engine shield.
7. Remove three screws attaching fender skirt to baffle.
8. Remove two screws attaching the fender skirt to the dash leg support assembly.
9. Under the hood, remove the screw attaching the fender skirt to the skirt filler assembly.
10. From under hood, remove two bolts attaching the radiator tie bar to the fender flange.
11. On the right fender, if the heater is installed, remove the three screws attaching the blower motor to the blower bracket. If desired, the bracket may also be removed by taking out four screws, two at the fender flange and two at the fender skirt.
12. From within vehicle, remove three screws attaching rear air duct to dash panel.
13. Remove fender to cowl and fender and fender to side rail bolts, noting number and location of any shims present.
14. Remove fender skirt.
15. Headlamp and front air duct may be removed as described under "Front Fender -Removal". The rear air duct will remain in place, attached to the fender skirt by a screw, and may be removed if desired.

Installation

1. Replace headlamp, front air duct and rear air duct (if removed) in fender.
2. Carefully replace fender and skirt assembly, making sure that the front air duct fits properly with the rear air duct.
3. Loosely install the fender to cowl and fender to side rail bolts, replacing the shims noted when these bolts were removed.
4. Replace the three screws attaching the rear air duct to dash panel.
5. Replace the screw and tab attaching the filler panel to the lower front comer of the fender and skirt filler assembly.
6. Replace the outer grille bar assembly and from beneath vehicle install the three cap nuts attaching the grille bar to the fender flange and skirt filler assembly.
7. Still beneath the vehicle, replace bolts attaching the bumper bracket to the fender flange, and two screws attaching the grille tie bar to fender skirt, one screw attaching skirt filler assembly to filler panel and fender skirt, two screws attaching fender skirt to filler panel, two screws attaching fender skirt to engine shield, and three screws attaching fender skirt to baffle assembly.
8. Replace two screws attaching the fender skirt to the dash leg support.
9. Under hood, replace the screw attaching the fender skirt to the skirt filler assembly.
10. Replace blower bracket, if removed, and blower motor.
11. Tighten all bolts and screws.

Fig. 14

Removal

1. Place protective covering over cowl and door panels and remove hood.
2. Disconnect the front end wiring harness at the dash connector. Remove battery to reduce weight.
3. Drain the radiator and disconnect upper and lower radiator hoses, and on Powerglide and Turboglide models disconnect the coolant lines leading to the base of the radiator core. NOTE: To lessen the weight of the front end sheet metal assembly, the radiator may be removed at this point if desired.
4. Remove three screws attaching heater blower to the blower bracket assembly. If desired the blower bracket may be removed by taking out two screws attaching it to the fender flange and two screws attaching it to the fender skirt.
5. From within car, remove three screws on each side attaching rear of rear air duct to dash panel.
6. Remove fender to cowl and fender to side rail bolts, observing the location and number of shims, from each side of vehicle.
7. Remove two screws, from under fender, attaching fender skirt to dash leg support.
8. Under front of vehicle, remove the nuts attaching tie bar and radiator support assembly to frame cross member bracket. Note shim plate and cushion arrangement at this point for installation arrangement.
9. Remove front bumper to bumper bracket bolt at each side of vehicle.
10. Remove three bolts, on each side, attaching bumper supports to frame.
11. Remove front end sheet metal from vehicle.

Installation

1. Tape cushion and shims in place at radiator support to frame cross member attaching point. Place protective covering over doors and cowl.
2. Check all anti-squeak and replace where necessary. Check flaps on fender skirt and replace where necessary.
3. Position front end sheet metal on vehicle. Make sure radiator support to cross member bolts are through frame holes.
4. Loosely install cushion plates, lock plate and nuts to radiator support bolts.
5. Loosely install fender to cowl and fender to body side rail bolts, replacing shims and washers as disassembled.
6. Install fender skirt to dash leg support bolts.
7. Replace the blower bracket assembly, if removed, and the blower motor.
8. From within vehicle, replace three screws attaching the rear of both rear air ducts to the dash panel.
9. Remove the screws attaching the engine shield to the fender skirt and the radiator support assembly.
10. Align sheet metal with door and cowl, then tighten bolts at fender to cowl, fender to body side rail and frame to radiator support.
11. Replace bumper and make all wiring connections.
12. Install radiator to radiator support, hook up all hose and cooler line connections and refill radiator.
13. Replace bumper.
14. Install hood, remove coverings and check alignment of hood and doors with front end sheet metal. If further alignment is needed see the following paragraphs.

The front end sheet metal is provided with four adjusting points (fig. 15). The fender to cowl attaching point allows through shimming an up or down adjustment at the rear. The fender to body side rail allows a lateral adjustment at the rear through shimming. In addition, shimming at the radiator support to chassis frame cross member provides an up or down adjustment of the front of the sheet metal. Oversize holes at this location also provide a fore or aft and lateral adjustment. Further lateral adjustment is available for the front of the fenders by shimming at the tie bar to fender attaching points. To adjust, loosen bolts and nuts on one or both sides, depending on the needed adjustment, shim at the described locations and retighten bolts.