seat adjustment CHEVROLET CAMARO 1967 1.G Chassis Workshop Manual

SECTION
IB

CORVETTE BODY

INDEX

Page

General Description . . * • •.
•
^"i1

Maintenance and Replacements 1B-1

Front End 1B-1

Adjustments IBri

Hood 1B-1

Hood Catch 1B-2

Hood Assembly . 1B-2

Front Emblems 1B-2

Vent Grilles 1B-2

Instrument Panel Tray . 1B-2

Cowl Area Trim
....................
1B-4

Rear View Mirror 1B-4

Outside 1B-4

Inside . 1B-4

Sun Visor . 1B-4

Cowl Ventilator Assembly 1B-4

Windshield ; 1B-5

Doors 1B-7

Adjustments 1B-7

Door Lock Striker 1B-7

Door Window and Vent 1B-7

Door Hinges 1B-7

Trim Panel and Inside Handles IB-11

Weatherstrip 1B-11

Door Ventilator Assembly 1B-12

19437 Model 1B-12

19467 Model 1B-13

Window Glass 1B-13

Glass Run Channel—Upper 1B-14

Window Outer Seal Assembly 1B-14

Window Inner Seal Assembly 1B-14

Glass Run Channel—Rear 1B-15

Window Regulator—Manual 1B-15

Window Regulator—Power 1B-15

Door Lock and Remote Controls 1B-16

Outer Handle . 1B-16

Lock Cylinder 1B-17

Hinges—Door Assembly . 1B-17

Rear Quarter .. . 1B-19

Door Sill and Molding . . 1B-19

Rear End . . r 1B-19

Folding Top Compartment Lid 1B-19

Adjustments . . 1B-19

1B-19
Page

Lock 1B-19

Control 1B-19

Rear Window—19437 Model 1B-21

Gas Tank Door and Rear Trim Plate.,. . . . . . . . 1B-23

Rear Filler Panel 1B-23

Spare Tire Mount 1B-23

Rugs and Interior Trim 1B-25

Cleaning Soft Trim 1B-25

Carpets and Covers—All Models 1B-26

Rear Body Trim , . 1B-26

Soft Covers 1B-26

Rigid Plastic Trim 1B-26

Garnish Moldings Plus-Headliner-19437 Model . . 1B-27

Seats 1B-27

Body Mounting 1B-27

Body Repairs . 1B-27

General Instructions . . . 1B-27

Repair Panels. 1B-28

Precautions 1B-29

Plastic Solder Kit 1B-29

Resin Kit 1B-30

Specific Repairs 1B-32

Scratched Panels-Spot Refinishing 1B-32

Dents in Panels-Surface Cracks !B-33

Cracked Panels . . 1B-35

Fractures 1B-37

Panel Replacement 1B-39

Hard Top . . 1B-41

Care and Storage 1B-41

Rear Window 1B-41

Garnish Moldings and Latches 1B-42

Headlining 1B-43

Weatherstrips and Drip Molding 1B-43

Vinyl Covering . 1B-43

Folding Top 1B-46

Care of Folding Top 1B-46

Care of Rear Window 1B-46

Adjustments 1B-48

Top Assembly, Removal and Installation 1B-49

Top Trim and Rear Window Assembly 1B-50

Frame and Linkage 1B-52

Weatherstrip 1B-52

Adding Hardtop 1B-52

Special Tools 1B-53

GENERAL DESCRIPTION

.
A
structural network
of
steel forms the backbone
of
the

Corvette body. When combined with
the
fiber-glass
re-

inforced plastic body panels,
the
steel-plastic marriage

results
in a
body with increased torsional rigidity
and

greater beaming strength.
Convertible models continue with two roof styles:
the

folding
top
and the removable hardtop. In operation, both

tops function similar to those
of
previous models. Either

top
is
standard and both
are
optional
as
determined by

the top selected
as
base equipment.

MAINTENANCE
&
REPLACEMENTS

FRONT
END

ADJUSTMENTS

(Refer to Figure
2)

Adjustments should
be
made
in
order
-
hood position

first, then catch adjustments.
Hood

The position
of the
hood
in
relation
to
the hood body

opening and the fender surfaces
is
controlled by the posi-

tion
of the
hinges and position
and
adjustment
of
catch

and bumpers.

The fore
and aft
position
of the
hood may be adjusted

CHEVROLET CHASSIS SERVICE MANUAL

CORVETTE BODY 1B-13

Fig.
30-Door Weatherstrip

3.
Remove window drive pin retaining screw.

4.
Loosen regulator support mounting screws.

5. Pull windows up and out of ventilator assembly.

19467 Model

Refer to Figure 34 for parts identification.

Removal

1.
Perform Operations 1 and 8-19437 Model-Removal.

2.
Remove ventilator assembly mounting screws and

loosen ventilator assembly mounting nut - upper.

3.
Lift ventilator assembly up and out of door pocket,

rotating so that lower bracket will pass through

window slot as shown in Figure 35.

4.
Regulator may be separated from the ventilator as-

sembly by removing window drive pin retaining

screw and regulator mounting screw.

Installation

1.
Pass lower bracket through window slot; rotate as-

sembly and align mounting holes*

2.
Install all mounting screws loosely.

3.
Roll door window up carefully making sure forward

edge of window is seated in its glass run channel.

4.
Reach through larger access opening and insert

lower mounting stud through door inner panel.

5. Tighten ventilator assembly mounting screws and

install upper and lower mounting nuts.

6. Adjust as necessary as outlined under Doors -

Adjustments - Door Windows.

Ventilator Window Assembly Replacement

Window and frame assembly may be replaced without
removing entire ventilator assembly from vehicle. Pro-

ceed as follows:

1.
Remove door trim panel as outlined in this section.

2.
Remove window drive pin retaining screw.

3.
Push down on window to disengage upper pivot pin

from frame as shown in Figure 36.

4.
Pull window assembly up and out of door.

WINDOW GLASS

Removal

1.
Remove door trim panel and access covers as out-

lined in this section.

2.
Remove ventilator assembly as outlined in this sec+

tion.
Consult write-up intended for body style

involved.

Position window so that sash retaining nuts are ac-

cessible through door inner panel and remove screws

(fig. 37).

Lower window at least 3/4 of total travel and remove
3.

4.

from door pocket as shown in Figure 38.

Installation

1.
If regulator upper guide rail has been removed from

door pocket, replace it on regulator rollers. Note

curvature of rail.

2.
Insert glass in door pocket with convex curvature to

the outside of car. Roll window regulator up until

sash bolt locations are visible through holes in inner

panel.

3.
Align holes in sash with holes in upper guide rail

and install bolts and nuts.

4.
Install ventilator assembly. Consult write-up in-

CHEVROLETCH>
SERVICE

CORVETTE BODY 1B-27

CUT OFF PAINTED

PORTION OF CARTRIDGE NOZZLE

ALONG EDGE-OF PAINT LINE

ADHESIVE CAULKING

MATERIAL

Fig.
60—Applying Caulking Material to Glass

GARNISH MOLDINGS PLUS HEADLINER-

19437 MODEL

Figure 64 illustrates installation details of garnish

moldings and headlining.

Headlining is not cemented in place.

Removal of dome lamp and garnish moldings is

necessary.
J-NUT

FILLER PANEL

BODY REAR

Fig.
61—Installing Rear Glass
Fig.
62—Gas Tank Door and Rear Trim Plate

SEATS

Removal

1.
Remove bolt retaining each forward support to floor.

2.
Fold seat back forward.

3.
Loosen two bolts retaining each seat hold-down

bracket.

4.
Move seat forward and out of brackets.

Adjustments

Height of seats is adjustable at both front and rear by

means of shims or washers.

Angle of seat backrest may be changed by adjusting

stops located on lower edge of seat back.

BODY MOUNTING

Figure 65 illustrates underbody attachment-to-frame

body mounting brackets. Shims which are shown on

rear crossmember are cemented in place.

The torque of all body mounting bolts should be checked

periodically as an aid to preventing annoying squeaks

and rattles. AH bolts shown in Figure 65 should be

torqued to 45 lbs. ft.

BODY REPAIRS

GENERAL INSTRUCTIONS

The following gives information necessary for repair

of collision damage and performance of general main-

tenance on both the 19437 and 19467 Corvette bodies.

Included here is information dealing with availability of

repair panels, general installation procedures for in-

staUing panels and repairing damage to the body.

Repair of fiber glass reinforced plastic bodies is a

relatively easy matter if a few simple precautions are

observed.

In cases where welding must be done on steel parts

which are stiU installed on body, do not allow flame or

direct welding heat to come into direct contact with

CHEVROLET CHASSIS SERVICE MANUAL

SECTION
3

FRONT SUSPENSION

INDEX

Page

General Description
. . . . 3-1

Maintenance and Adjustments
3-3

Front Wheel Bearing Adjustment
3-3

Front End Alignment
3-5 .

Alignment Preliminary Steps ............
3-5

Caster
and
Camber Adjustments
. . 3-5

Chevelle, Caxnaro
and
Corvette
3-5

Chevrolet and Chevy
II 3-6

Steering Axis Inclination
3-6

Toe-in Adjustment
3-6

Cornering Wheel Relationship
3-6

Riding Heigit
and
Coil Spring Sag
3-7

Repair Procedures
3-8

Front Brake Drum (Chevrolet, Camaro, Chevelle,

Chevy E)
. . 3-8

Removal
3-8

Installation
3-8

Front Wheel Hub
3-8

Replacement
. . . . . 3-8

Replacement
of
Hub Wheel Bolts
3-8

Front Wheel Bearings
. . 3-8

Removal
3-8

Inspection
3-9

Repairs
. . 3-9

Replacement
of
Bearing Cups
3-9

Installation
3-9

Steering Knuckle
. . . 3-9

Removal
3-9

Installation
3-9

Shock Absorber
3-10

Chevrolet, Chevelle, Camaro
and

Corvette
3-10

Removal
, . 3-10

Installation
3-10

Chevy
It 3-11

Removal
3-11

Installation
3-11

Stabilizer
Bar 3-11

Removal
3-11

Installation
3-11

Strut Rod
3-11

Chevrolet and Chevy
II 3-11

Removal
3-11

Installation
3-12

Front Coil Springs
3-12

Chevrolet
3-12

Removal
3-12

Installation
3-13

Chevelle
and
Camaro
3-13

Removal
3-13

Installation
3-14

Chevy H
3-14

Removal
3-14

Spring Seat Disassembly and Assembly
3-15

Installation
3-15

Corvette
3-15

Lower Control Arm Spherical Joint
.' 3-16

Chevrolet, Chevelle, Camaro and

Corvette
3-16

Inspection
. 3-16

Chevrolet and Corvette
3-16

Removal
3-16

Installation
3-16
Page

Chevelle
and
Camaro
3-17

Removal
3-17

Installation
. . . . 3-17

Chevy
II 3-17

Inspection
. 3-17

Removal
3-17

Installation
3-17

Lube Fittings
3-18

Lower Control Arm
. . . . 3-18

Chevrolet
. 3-18

Removal
3-18

Installation
3-18

Chevelle and Camaro
3-18

Removal
3-18

Installation
3-18

Chevy H
3-18

Removal
3-18

Installation
3-19

Corvette
3-19

Removal
3-19

mstallation
3-19

Lower Control Arm Bushings
3-20

Chevrolet
3-20

Removal
3-20

Installation
3-20

Chevelle and Camaro
. 3-20

Removal
3-20

Installation
3-20

Chevy H
3-21

Removal
* 3-21

InstaEation
3-21

Cross Shaft and/or Bushings
. 3-21

Corvette
3-21

Removal
3-21

Installation
3-21

Upper Control Arm Spherical Joint
3-21

Chevrolet, Chevelle, Camaro and Corvette
..... 3-21

Inspection.
3-21

Replacement
3-21

Chevy
II 3-21

Inspection
3-21

Replacement
3-21

Lube Fittings
3-22

Upper Control Arm
3-22

Chevrolet, Chevelle, Camaro
and
Corvette
3-22

Removal
3-22

Installation
3-22

Chevy H
3-22

Removal
3-22

Installation
3-23

Upper Control Arm Cross Shaft

and/or Bushings
3-23

Chevrolet, Camaro and Chevelle
3-23

Removal
. 3-23

Installation
3-23

Chevy H
3-24

Removal
3-24

Installation
. . . 3-25

Corvette
3-25

Removal
3-25

Installation
3-25

Special Tools
3-26

Specifications
...'..'
At rear of Book

GENERAL DESCRIPTION

The 1967 Chevrolet, Chevelle, Camaro, Chevy n and

Corvette front suspension systems are basically similar,

being of the
S.L.A.
(short-long arm) type with independent

coil springs. In the Chevrolet, Chevelle, Camaro and

Corvette the springs ride on the lower control arms; in
the Chevy II the springs ride on the upper control arms.

Spherical joints connect the upper and lower arms to the

steering knuckle. Tapered roller wheel bearings are

used.

Camber angle is adjusted, on the Chevrolet and Chevy n

CHEVROLET CHASSIS SERVICE MANIM

FRONT SUSPENSION 3-8

REPAIR PROCEDURES

Unless otherwise indicated all repair procedures will

apply to all five vehicles covered in this manual.

CAUTION: During any operations which in-

clude breaking the ball stud loose from the

knuckle boss extreme care must be used to as-

sure that the ball stud seal is not damaged or

cut. A recommended way to loosen the stud is to

place a flat bar stock against the knuckle boss

and strike the bar rather than the knuckle.

FRONT BRAKE DRUM-CHEVROLET, CAMARO,

CHEVELLE, CHEVY It

Removal

1.
Remove hub caps, partially loosen wheel nuts and

raise vehicle from floor. Remove wheel nuts and

wheel.

2.
Remove brake drum. In some cases it may be nec-

essary to back off brake adjustment because of

scored drum or unevenly worn brake linings.

3.
Check brake drum for concentricity, damaged pilot

diameter or scored braking surface. Lightly sand

braking surface and wipe clean.

Installation

1.
Install drum over hub bolts making sure alignment

dowel on drum web indexes with hole in wheel hub.

This will assure proper drum alignment with hub

bolts and hub pilot diameter.

2.
Install wheel and partially tighten wheel nuts.

3.
Re-adjust brake shoes to original setting. It may be

necessary to re-adjust brake shoes on both front

and/or rear wheels to assure balanced brake adjust-

ment. See Section 5 for brake adjustment procedure.

4.
Lower vehicle to floor, tighten hub wheel nuts and in-

stall hub cap.

FRONT WHEEL HUB

Replacement

1.
Remove hub caps, break loose the wheel stud nuts
VM" DIA. PIPE OR ARBOR

>l

INNER CUP

OUTER CUP
JL
RADIUS

e^

Fig.
10 - Pressing Front Hub Bolts (Typical)
Fig.
11 - Front Wheel Bearing Cop Removers

and raise vehicle. Remove wheel nuts, wheel and

tire and brake drum or (on Corvette) brake caliper

and brake disc.

NOTE:
On the Corvette, the hub and brake disc

are serviced as a complete assembly.

2.
Pry out hub grease cap, cotter pin, spindle nut and

washer,
and
remove hub. Do not drop wheel bearings.

3.
Reverse this procedure to install.

Replacement of Wheel Hub Bolts

It may be necessary to replace damaged wheel hub

bolts.
In this case, service the hub in the following

manner.

1.
Remove the hub bolts with a press or hammer.

These bolts are not peened into the hub. Do not

damage wheel mounting surface on hub flange.

2.
Install new serrated bolt into hole in
hub.
Tap lightly

with a hammer to start bolt serrations in hole, mak-

ing sure that bolt is square with hub flange.

3.
Press bolt into flange until head is fully seated

against hub flange (fig. 10).

FRONT WHEEL BEARINGS

Removal '

1.
Remove wheel hub as described above.

NOTE: Discard cotter pin. Install new cotter

pin when assembling.

2.
Remove outer roller bearing assembly from hub with

fingers. The inner bearing assembly will remain in

the hub and may be removed after prying out the

inner bearing lip seal assembly. Discard seal.

3.
Wash all parts thoroughly in cleaning solvent and

blow dry.

CHEVROLET CHASSIS SERVICE MANUAL

FRONT SUSPENSION 3-9

Inspection

1.
Check bearings for cracked separators or worn or

pitted rollers and races.

2.
Check brake drum for
out-of-
round or scoring.

3.
Check fit of bearing outer cups in hub.

Repairs

Replacement of Bearing Cups

1.
Using steel bar stock, make press-out tools shown in

Figure 11.

2.
Insert removers through hub, indexing ends into slots

in hub shoulder behind bearing cup.

3.
Using a suitable extension pipe or rod, press bearing

cups from hub.

4.
Install new bearing cup in hub using Tool J-8849 on

the outer and Tool J-8850 on the inner cup (fig. 12).

Use Driver Handle J-8092 with the installers. Make

sure that the bearing cups are not cocked and are

fully seated against shoulder in hub.

Installation

1.
Pack both inner and. outer bearings using a high

melting point wheel bearing lubricant.

2.
Place inner bearing in hub, then install a new inner

bearing lip seal assembly. Seal flange should face

bearing cup.

3.
Carefully install wheel hub over steering spindle.

4.
Install outer bearing, pressing it firmly into the hub

by hand.

5.
Install spindle washer and adjusting nut. Draw up

tight and adjust wheel bearings as outlined under

"Front Wheel Bearing Adjustment".

STEERING KNUCKLE

Chevrolet, Chevelle, Camaro and Corvette—It is rec-
ommended that vehicle be raised and supported on a

twin-post hoist so that the front coil spring remains com-

pressed, yet the wheel and steering knuckle assembly re-

main accessible. If a frame hoist is used, support lower

control arm with an adjustable jackstand to safely retain

spring in its curb height position.

Chevy n— While vehicle weight is still on front wheels,

position support between upper control arm and frame

side rail (fig. 13), then raise vehicle and position adjust-

able jackstand under lower control arm.

Removal

1.
Raise vehicle and support lower control arm as noted

above.

2.
Remove hub cap, wheel hub dust cover, cotter pin,

adjusting nut and washer. Withdraw wheel and tire,

brake drum, (or, on Corvette--brake caliper and disc

and hub assembly, See Section 5) and wheel hub and

bearing assembly from steering knuckle spindle.

3.
Remove brake shoes from backing plate (except

Corvette, See Section 5) and clamp wheel cylinder.

CAUTION: Keep brake shoes clean and dry.

4.
Remove brake anchor pin and two bolts securing

brake backing plate and steering arm to steering

knuckle.

5.
Withdraw steering arm and brake backing plate from

steering knuckle. Wire backing plate to frame (fig.

13).
Do not disconnect brake line.

NOTE: Refer to Section 9 - Steering Linkage -

Tie Rod, for further steering arm service

operations.

6. Remove upper and lower ball stud cotter pins and re-

move ball stud nuts. Free steering knuckle from

ball studs by rapping steering knuckle bosses. With-

draw steering knuckle.

Installation

1.
Place steering knuckle in position and insert upper

and lower ball studs into knuckle bosses.

2.
Install ball stud nuts and tighten nut as shown in the

specifications at the end of this section.

Fig.
12 - Installing Front Hub Inner Bearing
Fig.
13 - Backing Plate Removed - Chevy II

CHEVROLET CHASSIS SERVICE MANUAL

FRONT SUSPENSION ,3-13

6. Carefully lower the inner end of the control arm.

Tension on the spring will be removed before the

spring can be removed from the vehicle.

7.
Remove the spring.

Installation

1.
With the suspension set up as in Step 2 of the disas-

sembly procedure, insert a block of wood between the

upper control arm and the spring tower to keep the

arm up out of the way.

2.
Set the spring in place on the crossmember after

checking on proper positioning necessary.

3.
Install the steel bar and wood block as shown in Fig-

ure 20 and lift the control arm up until the inner

pivot cam bolt can be installed. ,

4.
Install the outer cam and loosely install the lock

washer and nut

5.
Set the cam bolt on the mark scribed during the re-

moval procedure and hold in this position while tight-

ening the nut (See specifications at the end of this

book).

6. Replace the strut rod to lower control arm nuts,

bolts and lock washers, the stabilizer bar link, the

shock absorber, the tie rod end, and the wheel and

tire.

7.
Lower vehicle to floor and install the shock absorber

upper stem retaining nut retainer and grommet.

8. Check the camber adjustment.

Chevelle and Camaro

Removal

1.
With an open end wrench hold the shock absorber up-

per stem from turning, and then, remove the upper

stem retaining nut, retainer and rubber grommet.

2.
With the car supported by the frame so that the con-

trol arms hang free, remove the wheel and tire as-

sembly (replace one wheel nut to retain the brake

drum),
shock absorber, and stabilizer bar to lower

control arm link.
4.

5.
Fig.
21 - Front Spring Removal - Chevelle & Camaro

Place a steel bar (fabricated as shown in Figure 19)

through the shock absorber mounting hole in the

lower control arm so that the notch seats over the

bottom spring coil and the bar extends outboard be-

yond the end of the control arm and slightly toward

the front of the car.

With a suitable jack or hoist lift up slightly on the

end of the bar.

Remove the lower ball stud cotter pin and attaching

nut and remove the ball stud from the knuckle.

ALTERNATE METHOD

Fig.
22 - Removing or Installing Front Coil Spring - Corvette (Typical)

CHEVROLET CHASSIS SERVICE MANUAL

SECTION
4

REAR SUSPENSION
AND
DRIVE LINE

CONTENTS
OF
THIS SECTION

Page

Rear Suspension
4-1

Drive Line.
. 4-26

Rear Axle ......
4-26
Propeller Shaft
and
Universal Joints

Special Tools
4-37

4-43

REAR SUSPENSION

INDEX

General Description
4-1

Chevrolet
4-1

Chevelle
4-1

Chevy
n and
Camaro
. . . . . 4-2

Corvette
. . . . . . 4-3

Maintenance
and
Adjustments ...............
4-4

Riding Height Check (Chevrolet, Camaro,

Chevelle
and
Chevy
II) 4-5

Wheel Alignment (Corvette)
4-5

Wheel Bearing Adjustment (Corvette)
4-6

Component Parts Replacement (Chevrolet, Camaro,

Chevelle
and
Chevy
JJ) 4-7

Coil Spring
4-7

Chevrolet
4-7

Removal
4-7

Installation
4-7

Chevelle
4-8

Removal
4-8

4-8

Installation
.

Leaf Spring, Spring Seat Pads, Spring
Eye

Bushings
4-9

Chevy
H 4-9

Removal
4-9

Installation
4-9

Camaro
4-10

Removal
4-10

Installation
4-11

Shock Absorber
4-11

Chevrolet
and
Chevelle
. 4-11

Removal
4-11

Installation
. . 4-12

Chevy
II 4-12

Removal
4-12

Installation
4-rl2

Camaro
4-12

Removal
. 4-12

Installation
4-12

Control
Arm . . 4-12

Chevrolet Upper
4-12

Removal
. 4-12
Page

Bushing Replacement
. 4-13

Installation
4-14

Chevrolet Lower
4-14

Removal
4-14

Bushing Replacement
4-14

Installation
. 4-15

Chevelle Upper
and
Lower.
. 4-15

Removal
4-15

Bushing Replacement
4-15

Installation
4-17

Rear Suspension
Tie Rod
(Chevrolet)
. . .
......
. . . 4-17

Removal
4-17

Bushing Replacement
4-17

Installation
4-17

Component Parts Replacement (Corvette)
. . 4-17

Wheel Spindle
and
Support
4-17

Removal
4-17

Repairs
', . 4-17

Installation
4-18

Differential Carrier Support Bracket Replacement.
. 4-20

Shock Absorber
4-20

Removal
4-20

Installation
* .... 4-20

Strut
Rod and
Bracket
4-20

Removal
4-20

Repairs
4-21

Installation
4-21

Spring
4-21

Removal
4-21

Repairs
4-22

Installation
4-22

Torque Control
Arm 4-23

Removal
4-23

Repairs
. 4-23

Installation
4-24

Suspension Crossmember
4-24

Removal
4-24

Repairs—Isolation Mount
4-25

Installation
4-25

Stabilizer Shaft Replacement
4-25

GENERAL DESCRIPTION

CHEVROLET

The link type rear suspension (fig. 1) has two lower

control arms which maintain proper axle to frame re-

lationship and also take the acceleration, drive and

braking forces. A single upper control arm on light-

duty models (or two upper control arms on heavy-duty

models and all station wagons) limits axle rotation when

drive, acceleration or braking forces are applied. Lateral

movement of the axle is restricted by the axle-to-frame

tie rod. Two full coil springs and two direct, double
acting shock absorbers are provided for additional ride

control.

CHEVELLE

The rear suspension (fig. 2) is of the four-link design

utilizing axle mounted, full coil springs and direct,

double-acting shock absorbers.

Two rubber-bushed lower control arms, stretching

slightly outboard from axle-mounted brackets to frame

side member mounted brackets, maintain fore and aft

CHEVROLET CHASSIS SERVICE MANUAL

REAR SUSPENSION AND DRIVE LINE 4-18

ig.
44—Rear Suspension Tie Rod Attaching Points (Chevrolet)

Bushing
Replacement

The following bushing removal procedure is effective

for both ends of the tie rod used on station wagons and

the left end of the tie rod used on all models except

station wagons.

1,
With tie rod bushing centered over Tool J-7877-2

and with tie rod supported horizontally, press or

drive bushing from rod, using Tools J-7877-1 and

J-7079-2 as shown in Figure 45.

2.
With tie rod centered over Tool J-7877-2 and rod

supported horizontally, press or drive bushing into

arm using Tools J-7877-3 and J-7079-2 as shown

in Figure 45. Tool J-7877-3 should bottom on tie

rod when bushing is fully installed.
fig.
45—Tie Rod Bushing Replacement (Chevrolet)

Installation

1.
Mount the tie rod to the axle bracket stud. Install

nut and special washer but do not tighten.

NOTE:
On the tie rod used on all models except

station wagons, place flanged portion of bushing

against attaching bracket.

2.
Install the bolt, lock washer and nut to the frame

bracket (fig. 44). Do not tighten.

NOTE:
Bolt may be installed from either

direction.

3.
Lower vehicle to floor (if raised) and bounce rear

end several times to settle bushings. Tighten af-

fected parts to specifications.

COMPONENT PARTS REPLACEMENT (CORVETTE)

WHEEL SPINDLE AND SUPPORT (Fig. 46)

Removal

Hemdve wheel drive spindle as outlined previously in

this section under "Wheel Bearing Adjustment".

Repairs

Out of 3/8" square steel bar stock, make bearing

removers and use as shown in Figure 47.

After removing deflector, spindle inner grease seal

and inner bearing race, bearing cups may be re-

moved while spindle support is still mounted to the

torque arm, by inserting remover tool and tapping

cup out. New bearing cups are installed using Tool

J-7817 cup installer and handle J-8092 (fig. 48).

To remove spindle support from torque arm, pro-

ceed as follows.

a. Disconnect parking brake cable from actuating

lever.

b.
Remove four nuts securing support to torque arm

and withdraw brake backing plate and position it

out of the way.

c. Disconnect shock absorber lower eye from strut

rod mounting shaft. It may be necessary to sup-

port spring outer end before disconnecting shock
absorber, as shock absorber has internal rebound

control.

d. Remove cotter pin and nut from strut rod mount-

ing shaft, then pull shaft from support and strut

rod.

e. Spindle support may then be removed and bearing

cups serviced as in Step 2 above.

4.
To remove drive spindle outer bearing and seal

proceed as follows.

a. Position Tool J-8331 between chamfered edge of

bearing seat and inner race of bearing (fig. 49).

Clamp Tool J-8331 in a vise and apply pressure

to unseat bearing.

CAUTION: Use extreme caution when position-

ing Tool J-8331 against machined surface of

spindle. Make sure all tool imperfections such

as nicks and burrs are removed from spindle

contact area before applying pressure to unseat

bearing.

b.
Position Tool J-8331 and spindle in an arbor

press and press bearing from spindle (fig. 50).

c. Remove outer seal and inspect for damage--re-

place if necessary. Outer seal must be placed on

spindle before outer bearing inner race and roller

CHEVROLET CHASSIS SERVICE MANUAL

REAR SUSPENSION AND DRIVE LINE 4-30

Fig.
76—Differential Gear Failure

Hypoid Gears

Hypoid gear tooth scoring (fig. 74) is caused generally

by improper break-in, incorrect lube, insufficient gear

backlash or improper 'ring/pinion gear alignment. The

scoring will progressively lead to complete erosion of

the gear tooth, or gear tooth pitting and eventual fracture

with possible attendant damage to bearings, if the initial
scoring condition is not diagnosed in time and corrected.

Hypoid gear scoring is easily recognized by its char-

acteristic loud whine in either drive, coast or under both

conditions. Another cause of hypoid tooth fracture (fig.

75) is extended overloading of the gear set which will

produce fatigue fracture, or shock loading which will

result in sudden failure.

Differential Gears

Common causes of differential gear failure are shock

loading, extended overloading leading to fatigue failure,

and overheating of gear thrust surfaces resulting from

excessive wheel spin and consequent lubrication break-

down. Overheating will lead to seizing of thrust surfaces

or tooth failure (fig. 76).

Bearings

• Failure of axle tapered roller bearings is due pri-

marily to excessive wear caused by long service or

foreign materials in the oil. The second most common

cause of bearing failure is too tight or too loose pre-

load adjustment leading to spalling and eventual failure.

This failure may also lead to hypoid gear scoring due to

the resultant misalignment of the hypoid gear set.

COMPONENT PARTS REPLACEMENT

(Chevrolet, Cheveile, Chevy II and Camaro)

AXLE ASSEMBLY

Removal

1.
Raise vehicle to a height that will permit axle as-

sembly to hang freely and position supports under

both frame side rails.

2.
Disconnect wheel cylinder inlet lines. Disconnect and

remove brake hose and brake line retaining bracket

by removing retaining bolt from carrier cover.

3.
Loosen parking brake equalizer adjusting nut and

disconnect both rear cables at frame bracket and at

control arms. See Section 5 for detail of parking

brake cable removal.

4.
Remove two trunnion bearing "U" bolts from the

rear yoke and separate rear universal joint. Wire

propeller shaft to frame side rail and tape trunnion

bearing cups.

5. Support arid secure axle assembly with an adjustable

lifting device. On Chevrolet and Cheveile models,

loosen upper and lower control arm attaching bolts

at axle housing. (On Chevrolet models, disconnect

tie rod at axle bracket.)

6. Disconnect shock absorbers at axle brackets. Refer

to Shock Absorber Removal procedures outlined in

this section.

7. On Chevrolet and Cheveile models, lower axle as-

sembly until suspension reaches end of travel, then

disconnect spring retainers and withdraw springs

from vehicle.

8. On Chevy II and Camaro models, remove four nuts

securing lower spring seat to axle housing, then

remove spring front eye bolts or spring attaching

bracket and swing spring to rear so that it does not

interfere with axle.

9. On Chevrolet and Cheveile models, disconnect upper

and lower control arm attaching bolts at axle housing*
10.
Lower axle assembly and remove from under vehicle.

Installation

1.
Place axle assembly under vehicle and raise into

position.

2.
On Chevrolet and Cheveile models, install, but do not

tighten, upper and lower control arm attaching bolts

at axle housing.

3.
On Chevrolet models, position coil springs in upper

seats so that end of spring is indexed in seat.

4.
On Chevrolet models, install lower end of spring on

axle bracket or control arm and secure by installing

retainer and bolt. Install lock washer and retainer

nut.

5. On Cheveile pry lower pigtail of spring over vertical

flange of the axle bracket spring seat.

6. On Chevy II and Camaro models, install spring seat

pads and swing springs up into spring seats on axle

housing, making sure upper seat pads are aligned in

axle housing bracket.

7. Install spring front eye bolt and tighten, then install

spring seat lower mounting bracket and retaining

nuts.

8. Raise axle assembly to allow shock absorber and tie

rod installation. Position shock absorber in axle

bracket. Torque nut as outlined in Shock Absorber

Installation procedures.

9. Install brake hose and brake line retaining bracket

to carrier and connect wheel cylinder inlet lines.

Connect parking brake cable to frame bracket and

at control arm. Adjust parking brake and bleed

brakes as outlined in Section 5.

10.
Reassemble rear universal joint to companion flange.

11.
Support vehicle at axle and remove supports from

beneath the frame side rails.

12.
Remove supports and lower vehicle to floor. Torque

all affected parts to specifications.

CHEVROLET CHASSIS SERVICE MANUAL