boot CHEVROLET CAMARO 1967 1.G Chassis User Guide

CLUTCH AND TRANSMISSIONS 7-4

5.
Install Tool J-5824 to support the clutch assembly

during removal.

NOTE: Look for "X" mark on flywheel and on

clutch cover. If MX" mark is not evident, prick

punch marks on flywheel and clutch cover for

indexing purposes during installation.

6. Loosen the clutch-to-flywheel attaching bolts evenly

1 turn at a time until spring pressure is released,

then remove the bolts, and remove clutch assembly.

Installation to Vehicle

Clean pressure plate and flywheel face. (They should

be free of oil, grease, metal deposits or burned spots).

1.
Position the clutch disc and pressure plate in relar

tive installed position and support them with align-

ment Tool J-5824.

NOTE: The driven disc on the 4 and 6 cylinder

engines is installed with the damfper springs to

the flywheel side; the V-8 is opposite, however,

THE GREASE SLINGER IS ALWAYS ON THE

TRANSMISSION SIDE.

2.
Turn clutch assembly until "X" mark on cover lines

up with "X" mark oh flywheel, then align cover bolt

holes to nearest flywheel holes.

3.
Install a bolt in every hole and tighten down evenly

and gradually until tight (to avoid possible clutch

distortion).

NOTE: Cover loads are as high as 1-1/4 tons.

4.
Remove pilot tool.

5.
Unhook clutch fork and lubricate ball socket and fork

fingers at release bearing end with a high melting

point grease such as graphite and reinstall fork on

ball stud. On Corvette models use Moly Grease.

6. Lubricate the recess on the inside of throwout bear-

ing collar and the throwout fork groove with a light

coat of graphite grease (fig. 4). On Corvette models

use Moly Grease.

7.
Install clutch fork and dust boot into clutch housing

and install throwout bearing to the throwout fork, then

install flywheel housing.

8. Install transmission as outlined in transmission

section.

9. Connect fork push rod and spring.

10.
Adjust shift linkage as outlined in transmission

section.

11.
Perform linkage adjustment for pedal free play and

check clutch release position.

CLUTCH PEDAL

The clutch pedal is the pendant-type hung from a sup-
Fig. 5 - Release Bearing Lubrication and Comparison

port brace common to the brake pedal and must be re-

moved to remove brake pedal. Refer to Section 5 for

brake and clutch pedal service procedure.

CLUTCH CROSS SHAFT (Figs. 6, 7 & 8)

Removal

1.
Remove linkage return and lower linkage springs and

disconnect clutch pedal and fork push rods from re-

spective cross shaft levers.

2.
Loosen outboard ball stud nut and slide stud out of

bracket slot.

3.
Move cross shaft outboard, and as required to clear

inboard ball stud, then merely lift out to remove

from vehicle.

Repairs

The cross shaft has nylon ball stud seats which should

be inspected for wear or damage. Also check condition

of engine bracket ball stud assembly and special anti-

rattle "O" ring. Figures 6, .7
&
8 show component parts

of cross shaft. Replace parts as necessary based on wear

or damage. Lubricate ball studs and seats with graphite

grease before reassembly.

Installation

1.
Reverse removal procedure to install.

2.
Adjust clutch linkage as previously outlined.

CHEVROLET CHASSIS SERVICE MANUAL

CLUTCH AND TRANSMISSIONS 7-9

6. Connect speedometer cable.

7. Install propeller shaft assembly.

8. Fill transmission with lubricant specified in Section

O.

CORVETTE TRANSMISSION REPLACEMENT

, 1. Disconnect battery ground cable.

2.
Pisassemble transmission shift control lever by un-

screwing ball from lever, lifting out
"T"
handle re-

turn spring and "T" handle, then remove the anti-

rattle bushings.

3.
Raise front and rear of vehicle.

4.
Insert a block of wood between the top of the dif-

ferential carrier housing and the underbody (to pre-

vent upward travel of the carrier when the carrier

front support is disconnected).

5. Disconnect the differential carrier front supportfrom

its frame bracket, by removing the nut on the under-

side of the biscuit mount.

6. Pry the carrier downward to relieve load while re-

moving the two center mounting bolts from the car-

rier front support. (To pry carrier downward insert

crowfoot end of a pry bar through the opening in the

carrier front support, hooking end of bar over top of

the center mounting bolt pad cast in the underside of

the carrier.)

7. Pivot carrier support downward for access to prop

shaft "U" joint.

8.
.
Disconnect prop shaft front and then rear "U" bolts.

9. Disconnect parking brake cable from ball socket at

idler lever located near center of underbody.

10.
Remove prop shaft by moving shaft forward.

11.
Remove heat deflectors from the right and left ex-

haust pipe.

12.
Remove left bank exhaust pipe.

13.
Remove right bank exhaust pipe and heat riser.

14.
Disassemble the transmission mount, as follows:

a. Remove the two bolts that attach rear mount

cushion to the rear mount bracket.

b.
Support engine under oil pan and raise engine to

remove load from rear mount cushion.
CAUTION: To avoid damage to oil pan, a suit-

able wide base, heavy wood platform should be

placed between the jack pad and the oil pan.

c. Remove the three transmission mount bracket-

to-
crossm ember bolts and remove mount bracket.

d. Remove the two bolts from mount pad to trans-

mission case and remove rubber mount cushion

and exhaust pipe "yoke".

15.
Disconnect transmission linkage by removing the

shift levers at the transmission side cover.

16.
Disconnect speedo cable at transmission extension.

17.
Remove transmission output shaft slip yoke.

NOTE:
The yoke is removed to avoid tearing

the heat reflecting pad on the underbody, when

the transmission is being removed.

18.
Remove two bolts to disconnect the transmission

gearshift control lever and bracket assembly from

its adapter plate on side of transmission. Lower

transmission assembly from the vehicle, letting the

gearshift lever slide down and through the dust boot

in the console.

19.
Remove transmission-to-clutch housing attaching

bolts.

20.
Slide transmission assembly rearward from clutch

and rotate transmission for access to the three flat

head machine screws in the control lever bracket

adapter plate. Remove adapter plate. Rotate trans-

mission back to the upright position.

21.
To allow room for transmission removal slowly

lower the rear of engine until the tachometer drive

cable at the distributor just clears the horizontal

ledge across the front of dash.

CAUTION: The tachometer cable can be easily

damaged by heavy contact with the dash. Slide

transmission rearward out of the clutch, then

tip front end of transmission downward and

lower the assembly from vehicle.

22.
Reinstall transmission assembly by performing above

steps in reverse order.

TRANSMISSION OVERDRIVE

INDEX

Page

General
Description 7-10

Maintenance
and Adjustments 7—10

Governor
Switch and Pinion .............. 7-10

Sun
Gear Solenoid Oil Seal and Control

Cable
Bracket 7-10

Case
Rear Oil Seal 7-10

Removal
7-10

Installation
. . . . . 7-10

Control
Shaft Lever and Oil Seal 7-10

Speedometer
Driven Gear 7-10

Electrical
Unit Checks 7-11

Overdrive
Relay . 7-11
Page

Air
Gap 7-11

Point
Opening 7-11

Closing
Voltage 7-11

Solenoid
. 7-11

Closing
Coil 7-11

Engaging
Spring . - 7-11

Ignition
Grounding Contact . 7-11

Governor
Switch 7-11

Kickdown
Switch 7-11

Diagnosis
- Overdrive 7-12

Mechanical
. 7-12

Electrical
7-13

CHEVROLET CHASSIS SERVICE MANUAL

CLUTCH
AND
TRANSMISSIONS
7-20

COMPONENT PARTS REPLACEMENT

3.

4.

5.

6.
TRANSMISSION REPLACEMENT
(EXC.
CORVETTE)

Removal From Vehicle

1.
Remove shift lever trim plate and dust boot.

Remove shift lever assembly.

Raise vehicle
to
desired working height.

Disconnect
the
speedometer cable from speedometer

driven gear fitting.
.
~
. •

Remove propeller shaft, then support engine
at the

oil
pan
rail with
a
jack
or
other suitable support

capable
of
supporting
the
engine when transmission

is removed.

Disconnect shift lever bracket assembly from exten-

sion
and
remove
all 3
transmission shifter levers

from shifter shafts, (leave linkage connected
to

levers)
and
remove bracket assembly levers
and

linkage.

Remove extension mount7 to-crossmember attaching

bolts.

Loosen transmission crossmember
and
move rear-

ward
or
remove.

Remove
the
transmission-to-clutch housing retaining

bolts
and
install two guide pins, J-1126,
in
top holes.

Slide
the
transmission straight back until
the
input

shaft
is
free
of
splines
in the
clutch disc.

Slide
the
transmission rearward
to
allow sufficient

clearance
of
input shaft
and
clutch housing. Then tilt

input shaft
end of
transmission downward and with-
8.

9.

10.

11.
draw transmission from vehicle.

installation
to
Vehicle

1.
Raise transmission
and
rotate
as
necessary-to start

input shaft into clutch disc
and
slide transmission

forward until
it
bottoms against clutch housing.
Re-

move guide pins.

2.
Install
the
transmission-to-clutch housing retaining

bolts.
Torque
all
four retaining bolts
to 50 ft. lbs.

3.
Raise engine
and
position extension mount
to
cross-

member,
and
loosely install
the
retaining bolts.

Tighten crossmember
to
frame retaining bolts.

4.
Remove temporary support from engine, and torque

the extension mount retaining bolts.

5. Install propeller shaft.

6. Install control lever bracket assembly
to
transmis-

sion extension
and
connect shifter levers
to
shifter

shafts.

7. Fill transmission
to
level
of
filler plug hole with

correct lubricant specified
in
Section
0.

8. Lower vehicle and install shift lever assembly, check

shift pattern and adjust linkage
as
required.

9. Install trim plate and dust boot.

CORVETTE TRANSMISSION REPLACEMENT

Refer
to
similar procedure under 3-Speed Corvette

Transmission.

FOUR-SPEED (SAGINAW) TRANSMISSION

INDEX

Page

General Description
7-20

Maintenance
and
Adjustments
. . 7-21

Shift Linkage Adjustment.
. 7-21

Speedometer Driven Gear
and

Oil Seal ................
(See
Muncie 4-Speed)

Side Cover
7-22
Page

Removal
. . , 7-22

Disassembly
. . 7-22

Assembly
. . . 7-22

Installation
. 7-22

Extension
Oil
Seal
(See
Muncie 4-Speed)

Transmission Replacement (See Muncie 4-Speed)

GENERAL DESCRIPTION

The Saginaw four speed fully synchronized
(all
forward

gears) transmission incorporates helical drive gears

throughout.

The main drive gear
is
supported
by a
ball bearing
at

the front
end of the
transmission case and
is
piloted
at its

front
end in an oil
impregnated bushing mounted
in the

engine crankshaft.
The
front
end of the
mainshaft
is

piloted
in a row of
roller bearings
set
into
the
hollow
end

of
the
main drive gear
and the
rear end
is
carried
by a

ball bearing mounted
in the
front
of the
extension housing.

The countergear
is
carried
on a
single
row of
rollers

at both ends while thrust
is
taken on thrust washers
lo-

cated between
the
ends
of the
gear and
the
thrust bosses

in
the
case. Ah anti-rattle plate assembly
at the
front
of

the countergear provides
a
constant spring tension
be-

tween
the
counter
and
clutch gears
to
reduce torsional

vibrations.
The
sliding reverse idler gear
is
carried
on

a bushing finish bored
in
place.
It
rotates
on a
short

idler shaft retained by
a
woodruff
key.

The synchronizer assemblies consist
of a
clutch
hub,

clutch sleeve,
two
clutch
key
springs and three energizer

clutch keys
and are
retained
as an
assembly on
the
main

shaft
by a
snap ring.
A great deal
of
similarity
and
interchangeability
now

exists between
the new 3 and
4-speed Saginaw trans-

missions.

However,
the
synchronizer assembly
at the
front
of the

mainshaft
is
used
for the
third and fourth rather than
the

second
and
third shift.
The
synchronizer assembly
at

the rear
of the
mainshaft
is
used
for the
first and second

rather than
the
first
and
reverse shift. Gear teeth
cut

in
the
first and second synchronizer sleeve (reverse gear)

distinguish
it
from
the
third
and
fourth synchronizer

sleeve.

Starting from
the
front, gears
on the
mainshaft
are

third, second
and
first rather than second, first and
re-

verse.
A
fourth blocker ring
is
used between
the 1-2

synchronizer assembly
and
first gear
on the
four-speed

transmissions.

The cover
on the new
four-speed transmission
is lo-*

cated
on the
left-hand side
of the
case.
It is
similar
to

the three-speed cover with
the
addition
of a
reverse

shifter shaft assembly, detent ball
and
detent spring.

Disassembly
and
assembly procedures
are
covered
in

this section.

CHEVROLET CHASSIS SERVICE MANUAL

FUEL TANK AND EXHAUST SYSTEMS 8-19

Fig.
22—Spare Tire Carrier Installed

6. Remove two fuel tank retaining strap bottom nuts

from forward support member located at forward

front side of tank.

7. Remove fuel tank metering unit wires (fig. 25).

8. Remove fuel pickup line and drain tank.

9. Remove gas cap, filler neck boot from the top of tank

and disconnect drain line (fig. 24).

NOTE:6
Coupe Models—Remove filler neck.

10.
Remove fuel tank support frame attachment bolts and

support.

11.
Lower tank and rotate toward the front of vehicle.

Installation (20 Gallon Tank)

NOTE:
Place hoses and wires to one side and

position anti-squeak pads to the crossmember,
END OF HOSE FLUSH

TO Va INCH BACK FROM

EDGE OF BUMPERETTE

Fig.
24-Gas Tank Filler Neck Vent Hose

cemented to the support and attached to the tank.

Replace with new pads as required.

1.
Hook retaining straps at the rear frame crossmem-

ber. (Crimp strap ends at rear frame attachment.)

NOTE:
Make certain strap ends are hooked and

anti-squeak pads are properly positioned.

2.
Slowly rotate fuel tank into position.

CAUTION: Coupe-Install filler neck after tank

is installed.

3.
Attach fuel tank support at the frame side rails.

TANK METERING UNI

WIRE CONNECTIONS

Fig.
23—Exhaust System Tail Pipe Attachment
Fig.
25—Fuel Tank Metering Unit, Wires and Lines

CHEVROLET CHASSIS SERVICE MANUAL

FUEL TANK AND EXHAUST SYSTEMS 8-20

4.
Attach the retaining straps with strap guide attached

to the fuel tank support, and secure with-the nut and

lockwasher assembly.

5. Connect the filler neck boot to the drain hose of the

tank and install boot around filler neck,

6. Connect the fuel pickup line, ground wire and make

certain that the fuel drain line is flush to 1/2" in-

board of the rear bumper opening.

7. Attach tank metering unit wires (fig. 25).

8. Replace fuel in tank. Replace gas cap.

9. Check for possible leaks.

10.
Reconnect the exhaust system by reversing the above

removal procedures (see "Exhaust System").

11.
Install spare tire carrier by securing the bolt

attachment.

12.
Install the spare tire in the tire carrier.

Removal (36 Gallon Tank)

1.
Remove cover (fig. 26).

2.
Disconnect hoses and drain tank and remove two

fittings at bottom of tank.

3.
Disconnect fuel and vent lines and wires at tank

(fig. 27).

4.
Remove straps.

installation (36 Gallon Tank)

Reverse removal procedure to install.

FUEL TANK METERING UNIT OR GAUGE

SENDING UNIT AND STRAINER

The fuel tank metering unit is located at the bottom of

the fuel tank. The fuel strainer is attached at the end of

the sending unit inside the tank.

Replacement (20 Gallon Tank)

1.
Follow fuel tank removal procedure through Step 2.

2.
Drain the tank. Disconnect the attaching wires.

3.
Remove metering unit with a fuel tank gauge unit

Spanner J-8950 (revised).

4.
'Remove metering unit and gasket.

CAUTION: Carefully remove unit so as not to

damage screen on the end of the pipe.

5. Clean strainer screen by blowing out with com-

pressed air.

6. Reverse procedure to install.

Replacement (36 Gallon Tank)

1.
Remove cover.

2.
Follow Steps 2 thru 6 as outlined under replacement

for 20 gallon tank.

FUEL LINES

20 Gallon Tank

The fuel lines are conveniently located along the out-

side of the right frame rail (fig. 28). The lines extend
Fig.
26—Gasoline Tank (36 Gallon) Compartment Cover

from the fuel tank pickup at the bottom of the tank, along

the rear frame crossmember to the right frame rail,

extending through the rail at the kickup area and along the

top inside edge of the frame to the fuel pump, Flexible

hoses are located at the fuel tank pickup and at the fuel

pump.

36 Gallon Tank

The 36 gallon tank fuel lines are routed from the bot-

tom of both sides of the tank to the right frame rail

(fig. 20).

Maintenance

CAUTION: Always drain gasoline from the

complete fuel system including carburetor, fuel

pump and all fuel lines and fuel tank if the vehi-

cle is to be stored for any great length of time.

This precaution will prevent accumulation~ol

gum formation and resultant poor engine

performance.

. The fuel lines should occasionally be inspected for

leaks,
kinks or dents, especially when work has been

done on the underside of car or after the car has been

traveling over rough or stone roads at higher speeds.

If evidence of dirt is found in the carburetor or fuel pump

at disassembly, the lines should be disconnected and

blown put. Check the fuel tank strainer for damage or

omission.

Fuel lines are beaded-type ends for connection to

hoses and flared ends for secure metal-to-metal line

connections.

CHEVROLET CHASSIS SERVICE MANUAL

STEERING 9-7

Fig.
12-Steering Coupling

3.
Disconnect transmission controls from levers at

bottom of column, if so equipped.

4.
Inside vehicle, remove trim cover or boot, pro-

tective covers, and seal from dash panel as shown

in Figure 13. On Corvette models the covers are re-

moved in the engine compartment side. Also on

Corvette models, remove screws securing escutcheon

(fig. 14) to instrument panel.

5. Disconnect Steering column harness and back-up

lamp/neutral safety switch at connector plugs.

Fig.
13—Removing or Installing Dash Panel Covers and Seal

Fig.
14—Steering Column Escutcheon—Corvette

CHEVROLET CHASSIS SERVICE MANUAL

STEERING 9-8

DIAL

UPPER COVER

FASTENER

CHEVROLET
SCREW

CHEVELLE

Fig.
15—Powerglide Indicator Connection—Chevrolet and Chevelle

6.
Chevrolet and Chevelle only:

a. Remove lower mast jacket cover (fig. 15).

b.
If vehicle is equipped with Powerglide, remove

indicator pointer wire by removing screw from

six o'clock position at bottom of mast jacket (fig.

15).
Work indicator wire out of position and

remove.

Remove instrument panel column mounting bracket

attaching hardware and remove bracket.

CAUTION: Do not allow steering column to

hang down from dash panel area or distortion to

column will result. When instrument panel

mounting bracket is removed, be sure column is

supported in its normal position.

NOTE:
The following step requires two men,

one in the driver's seat and one at engine

compartment.

8

Lift steering column upward enough to permit re-

moval of steering coupling from steering gear.

Mechanic at engine compartment can pilot column

shift levers, if so equipped, through dash panel open-

ing as column is listed. If it is necessary to leave

the vehicle at this point, place steering column in

correct mounted position and loosely install instru-

ment panel mounting bracket to support column.

9. Remove steering coupling from vehicle.

Installation

1.
Lift steering column enough to provide clearance and

loosely install steering coupling on steering gear

shaft. Be sure column is supported in its normal

mounted position at all times when not moving for

clearance. Mechanic at engine compartment can

pilot column shift levers through dash panel opening

as column is moved.

2.
Slide steering coupling into correct installed position

and install clamp bolt (fig. 12).
3.
Secure steering coupling to flanged end of steering

column with washers and nuts. Maintain coupling ad-

justment shown in Figure 16.

4.
Install instrument panel column mounting bracket.

Refer to torque specifications at rear of manual for

correct torque values.

5. Chevrolet and Chevelle only:

a. If vehicle is equipped with Powerglide, work shift

indicator pointer wire into position on column and

secure with screw at six o'clock position at bot-

tom of mast jacket (fig. 15).

b.
Install mast jacket lower cover (fig. 15).

6. Connect steering column harness at connector plug.

Connect back-up lamp/neutral safety switch plug, if

so equipped.

7. Inside vehicle, install seal, protective covers, and

trim cover or boot (fig. 13). On Corvette models the

' covers are installed in the engine compartment side.

8. Connect transmission controls to shift levers at

bottom of column if so equipped.

CHEVROLET

CHEVELLE

CORVETTE
CAMARO

Fig.
16—Steering Coupling Clearance Adjustment

CHEVROLET CHASSIS SERVICE MANUAL

STEERING 9-29

column mounting bracket, and place bracket in cor-

rect position on underside of instrument panel.

Loosely install bracket using bracket to column

mounting screws and bracket to instrument panel

washers and bolts.

NOTE: Steering shaft to gear clamp must be

tightened before column attaching bolts are

torqued. Refer to "Steering Gear-Chevy n",

installation procedure, for correct Chevy II

steering column alignment procedure.

5.
Camaro only (fig. 60):

Lay wedge shim in position on instrument panel

column mounting bracket and place bracket in cor-

rect position on underside of instrument panel.

Loosely install bracket using bracket to column

mounting screws, nuts, and washer and bolt as shown

in Figure 60.

6. Corvette only (fig. 61):

Loosely secure column mounting bracket to sup-

port plate and instrument panel with washers and

bolts.

7.
Secure flanged end of column to steering coupling

with lockwashers and nuts. On Chevy n, connect col-

umn to steering gear with clamp, clamp bolt, and

nut. On Corvette, slide steering shaft flange into

lower coupling
half,
and install upper clamp bolt

loosely; also secure support, seal and clamp loosely

at dash on engine side.

8. Tighten instrument panel mounting bracket bolts and

nuts.
Refer to torque specifications at rear of manual

for correct torque values.

9. Chevrolet only (fig. 15):

Place upper and lower mast jacket covers in po-

sition and secure covers together and to instrument

panel using nuts and screws as shown in Figure 15.

10.
Chevy H only (fig. 18):

Place lower mast jacket cover in position under

mast jacket and secure to upper cover with screws.

11.
CheveUe only (fig. 15):

Place mast jacket trim cover in position over col-

Fig.
61—Instrument Panel Mounting Bracket and

Support Plqte—Corvette
umn on underside of instrument panel and secure

with screws.

12.
Corvette only (fig. 14):

Slide escutcheon into position at instrument panel

and secure with screws. Place upper end lower

covers in position and secure with screws.

13.
On Chevrolet and CheveUe models with column

mounted powerglide controls, secure transmission

shift indicator pointer into position with set screw

(fig. 15). ,

14.
Chevrolet only (fig. 19):

a. Secure seal and cover to dash panel with screws.

b.
Place clamp assembly in position and install

clamp screw.

c. Install dash panel trim cover with mounting

screws.

15.
Chevelle only (fig. 20):

a. Secure seal and inner and outer covers to dash

panel with screws.

b.
Secure inner and outer covers together with

screws.

c. Install trim cover to dash panel with two

retainers.

16.
Chevy H only (fig. 21):

a. Secure seal, retainer, and clamp to dash panel

with screws.

b.
Install clamp screw.

c. Slide collar into position. Pinch and staple upper

tabs together.

17.
Camaro only (fig. 22):

a. Secure seal, upper cover, and lower cover to

dash panel with screws.

b.
Secure upper and lower cover together with

screws.

c. Fold rubber boot over securely against dash panel

to conceal covers.

18.
Corvette only (fig. 23):

a. Secure seal and support assembly to dash panel

on engine compartment side.

b.
Tighten clamp, washer, and clamp bolt on engine

compartment side.

19.
Connect transmission linkage to lower shift tube

levers in engine compartment, if column is so

equipped. Adjust levers as outlined in Section 7.

20.
Install steering wheel as outlined in this section.

21.
Connect directional signal, horn, back-up lamp, and

neutral start switch at wiring harness plugs. Adjust

back-up lamp, neutral start switch as outlined in

Section 12.

22.
Adjust steering gear and align and center steering

wheel as outlined in this section.

STEERING LINKAGE (Fig. 62)

TIE RODS

There are two tie rod assemblies used on all models.

Each assembly is of three piece construction, consisting

of a sleeve and two tie rod ends. The ends are threaded

into the sleeve and locked with clamps. Right and left

hand threads are provided to facilitate toe-in adjustment

and steering gear centering.

The tie rod ends are self-adjusting for wear and re-

quire no attention in service other than periodic lubrica-

tion and occasional inspection to see that ball studs are

tight. Replacement of tie rod ends should be made when

CHEVROLET CHASSIS SERVICE MANUAL

ACCESSORIES 15-12

VACUUM

(WIT

P

VACUUM Llh

, AIR SUPPt

LINES

t

SUPERLIFT F

SHOCK ABSO
OPERATED AIR COMPRESSOR

H STORAGE TANK AND

RESSURE REGULATORJV

\A

4E FROM ENG«NE^"^
/ \-HEIGHT CONTROL

•^-Z n VALVE (WITH TIME

^* DELAY MECHANISM)

EAR II

RBERS

Fig.
12 - Automatic Level Control Schematic

sure,
alternatley to opposite sides of the compressor

diaphragm.

As the compressor cycles, the reservoir air pressure

gradually increases causing a back pressure on the sec-

ond stage piston until it equals the push of pressure

against the diaphragm- At this point, a balanced condi-

tion is reached and the unit stops operating. After res-

ervoir pressure drops due to system air usage, the com-

pressor again begins to cycle and replenish the

reservoir.

Pressure balance will depend upon the prevailing mani-

fold vacuum and atmospheric pressure. Both are af-

fected by altitude above or below sea level. Balance

pressure will vary from approximately 150 to 275 psi.

NOTE: After completion of work on this sys-

tem or when servicing other parts of the car and

the system is deflated, inflate the reservoir to

140 psi or maximum pressure available through

the compressor service valve.

The PRESSURE REGULATOR VALVE is preset and

limits the reservoir outlet pressure to approximately 125

psi to avoid damage to the height control valve and Super-

lift shocks.

The HEIGHT CONTROL VALVE, which is mounted on

the frame, senses rear car height through a link attached

to the right rear upper control arm. When load is added

to the car, the overtravel lever is forced up causing an

internal lever to open the intake valve, when this valve

is open high pressure air is admitted to the Superlift

shocks. As the car raises to level, the intake valve shuts

off.

When load is removed from the car, the overtravel

lever is forced down causing the internal arm to open the

exhaust valve. As the car lowers to the level position,

the exhaust valve shuts off.

A four to eighteen second time delay mechanism, which

is built into the height control valve, prevents air trans-

fer due to normal ride movements. The overtravel

lever, which pivots around the control valve shaft, rides

off the flat side of the control valve shaft and does not

have time to. react to the rapid changes or normal ride

motions.
During changes due to loading, the time delay mecha-

nism will allow the overtravel shaft to open either the in-

take or exhaust' valve as required, since this is not a

rapid movement.

The SUPERLIFT shock absorber is essentially a con-

ventional hydraulic unit with a. pliable nylon reinforced

neoprene boot acting as an air chamber.

The unit will extend when inflated and retract when de-

flated by the control valve.

An eight to fifteen psi air pressure is maintained in the

Superlift at all times to minimize boot friction- This is

accomplished by a check valve in the exhaust fitting on

the control valve. Neither shock absorber function nor

conventional ride motions thru rear coil springs is im-

paired in the event of accidental air pressure loss. .

A combination of steel tubing and reinforced rubber

hose is used for air lines throughout the system.

-SUPERLIFT

PORT

STATION WAGON

& SEDAN

INTAKE

PORT
HAUST

PORT

Fig. 13 - Height Control Valve

AIR CHAMBER
BOOT

AIR DOME AIR PISTON

Fig. 14- Superlift Absorber

CHEVROLET CHASSIS SERVICE MANUAL

ACCESSORIES 15-14

Deflate system through service valve and disconnect

line at pressure regulator valve. Install test gauge on

regulator valve high pressure fitting.

Inflate system through service valve to maximum

available pressure.

NOTE: If available pressure is less than 140

psi,
start engine to build-up reservoir to this

pressure.

Regulated pressure should build-up to and hold

steady at 100-130 psi on test gauge.

Check regulated pressure by momentarily (not more

than one second) depressing valve core on test gauge

arid observe gauge reading.

If regulated pressure now reads less than 100 psi,

replace regulator assembly.

If regulated pressure exceeds 130 psi, replace regu-

lator assembly.

Control Valve Test

Exhaust (Superlifts Inflated)

1.
Disconnect control valve lever from link.

2.
Hold lever down in exhaust position until Superlifts

deflate or for a minimum of 18 seconds.

3.
If Superlifts deflate, perform Intake Check.

4.
If Superlifts do not deflate, remove exhaust adapter

from control valve and hold lever down as in Step 2.

Replace adapter, O-ring and filter if this deflates

Superlifts.

5.
Replace control valve if none of the above steps solve

problem.

Intake (Reservoir Pressure 125 psi Minimum)

1.
Disconnect overtravel lever from link.

2.
Hold lever up in intake position until Superlifts in-

Fig.
16 - Assembly Leak Test Preparation
flate or for a minimum of fifteen seconds.

3.
If Superlifts inflate and hold, proceed to Time Delay

Check. '•

4.
If Superlifts inflate and then leak down, perform leak

test on lines and fittings and then on Superlifts and

control valve. Repair or replace as indicated.

Time Delay Test (Reservoir Pressure 125 psi Minimum)

1.
Record rear trim height of empty car (rear bumper

to ground).

2.
Add weight equivalent to two passenger load to rear

of car. Car should begin to level in 4-18 seconds.

3.
Remove weight. After 4-18 seconds car should begin

to settle.

4.
Replace valve if time delay is not within the 4-18

seconds.

Trim Adjustment—On Car

Trim adjustment should be performed with a full fuel

tank (or the equivalent in load at the rate of 6 lbs
./gal-

lon)
,
but no other load.

Abbreviated Adjustment

1.
Fill the compressor at the service valve with the

available air line pressure.

2.
Disconnect link from height control valve lever.

Move the height control valve lever upward until air

fills the Superlifts.

3.
Move lever downward and hold until air stops escap-

ing from the exhaust port of the height control valve.

The Superlifts will now automatically hold 8 to 15

PSI.
;

4.
Let lever go to its neutral position> and loosen the

lever adjustment nut.

5.
Assemble the link to the height control valve lever

and tighten the lever adjustment nut.

NOTE: Do not move control valve lever and

overtravel body while tightening nut.

Leak Tests

Compressor, Reservoir and Regulator

1.
Remove assembly intact.

2.
Connect test gauge to regulator. Inflate reservoir

through service valve to 80-110 psi.

3.
Route an 8" rubber hose between vacuum and vent

ports,
(fig. 16).

4.
Submerge in water and observe for air leaks at:

Reservoir weld seam.

Reservoir to compressor O-ring.

Regulator to compressor O-ring.

Regulator boot-defective internal.O-rihg.

Diaphragm between first and second stage housings.

' Tightening through bolts may correct the leak.

Cover gasket and retainer screw. A few bubbles here

is not a leak. A continuous stream indicates defec-

tive compressor check valves.

Service valve.

Test gauge connections.

5.
Correct any leaks detected by either tightening

screws or replacing parts.

CHEVROLET CHASSIS SERVICE MANUAL