ECO mode CHEVROLET CAMARO 1967 1.G Chassis Owner's Manual

CLUTCH AND TRANSMISSIONS 7-14

SPEED HEAVY DUTY TRANSMISSION

(WARNER MODEL T 16)

INDEX

General Description ......

Maintenance and Adjustments

Shift Linkage Adjustment

Side Cover ........

Removal .........

Disassembly
7-14

7-14

7-14

7-14

7-14

7-14
Assembly 7-14

Installation • 7-15

Other Maintenance
&
Adjustment

Operations See 3-Speed Saginaw Section

Transmission Replacement . . . See 3-Speed Saginaw Section

GENERAL DESCRIPTION

The Borg-Warner heavy duty three speed fully syn-

chronized (all forward gears) transmission incorporates

helical gears throughout specially designed to provide

high torque capacity, and gear teeth proportion to operate

at high speeds with neither excessive heat generation nor

excessive frictional losses. Shafts, bearings, high ca-

pacity clutches and other precision parts are held to

close limits providing proper clearances necessary for

durability during extended heavy usage.

The main drive gear is supported by a heavy duty 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 heavy duty ball bearing mounted in the

front of the extension housing.

The countergear is carried on a double 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. An 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 reverse idler gear is carried on 25

roller bearings while thrust is taken on thrust washers

located between the ends of the gear and the thrust bosses

of the case.

Gear shifting is manual through shift control rods from

the shifter tube in the mast jacket to the rearward shift

lever of the side cover assembly for first and reverse

gear; and through a cross shaft assembly attached to the

forward side cover lever for second and third gear. All

three forward gears are fully synchronized. The syn-

chronizer 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. The transmission may be used as an aid

in deceleration by downshifting in sequence without

double-clutching or any gear clashing. Reverse is not

synchronized, however, it is a helical gear to insure

quiet operation.

MAINTENANCE AND ADJUSTMENTS

Refer to similar procedures under the 3-speed Saginaw

Transmission Section for—Column Mounted Shift Linkage

Adjustment, Speedometer Driven Gear and Oil Seal Re-

placement, Extension Oil Seal Replacement and Trans-

mission Replacement. ~~

Camaro and Corvette Floor Shift Linkage Adjustment

(Fig.
lc)

1.
Set Lever (L), (K) in neutral position.

2.
Move Lever Assembly (A) and Levers (C), (D) to

neutral position and insert Locating Gauge (B) into

control Lever Bracket Assembly.

3.,
Install Rod (H) with Retainer (M) on Lever (L).

4.
With two Jam Nuts (G), (E) and Swivel (F) loose on

Rod (H) insert and attach Swivel with Retainer (N)

to Lever (D).

5.
Repeat steps 3 and 4 for Rod (J) and Levers (C
&
K).

6. Remove' Locating Gauge and check shift to insure

proper operation.

SIDE COVER ASSEMBLY

Removal

1.
Drain transmission and disconnect control rod and

cross shaft from side cover levers. *

2.
Remove nine cap screws securing the transmission

side cover assembly to transmission, case and re-

move cover assembly, shifting forks, and gasket.
Disassembly (Fig. 2C) '

1.
Remove shifting forks from shift lever assemblies.

2.
Remove nut and lock washer from each shift lever

shaft.

3.
Remove outer shift levers and lightly tap shift lever

shafts from assembly.

4.
Remove two steel balls, poppet spring, interlock pin

and interlock sleeve from cover.

5.
Remove "O" ring seals from shift lever shafts.

Assembly (Fig. 2C)

1.
Install new "O" ring seals to shift lever shafts.

2.
Install low and reverse shifter shaft and plate as-

sembly to cover.

3.
Place shifter shaft and plate assembly in neutral po-

sition, middle detent, and install interlock sleeve,

ball, poppet spring and interlock pin.

4.
Install remaining poppet ball and then install second

and third shifter shaft and plate assembly.

NOTE: Installation is easiest if shifter shaft

and plate assembly passes over ball in its neu-

tral position.

5.
Check clearance between end of interlock sleeve and

shifter shaft and plate cams when one plate is in

neutral and the other is shifted into gear position.

CHEVROLET CHASSIS SERVICE MANUAL

CLUTCH AND TRANSMISSIONS 7-24

is at the full mark on the dip stick, it is just slightly be-

low the planetary gear unit. If additional oil is added,

bringing the oil level above the full mark, the planetary

unit will run in the oil, foaming and aerating the oil. This

aerated oil carried through the various oil pressure pas-

sages (low servo, reverse servo, clutch apply, converter,

etc.) may cause malfunction of the transmission assem-

bly, resulting in cavitation noise in the converter and

improper band or clutch application. Overheating may

also occur.

If the transmission is found consistently low on oil, a

thorough inspection should be made to find and correct

all external oil leaks.

PERIODIC OIL CHANGE

The transmission oil should be changed periodically as

recommended in Section 0, and whenever transmission is

to be removed from the vehicle for repairs.

1.
Run engine for one minute in neutral prior to chang-

ing.

2.
Be sure vehicle is level or raise from the rear only.

3.
Remove the oil pan drain plug and allow oil to drain

thoroughly into a pan or can.

Replace drain plug and refill with approximately two

quarts of oil specified in Section 0.

NOTE: To refill the transmission, remove dip

stick from oil filler tube and refill transmission

with oil specified in Section 0 using filler tube

and funnel J-4264. Then, after shifting into all

ranges at idle speed to fill all oil passages, the

engine should be run at 800-1000 rpm with the

transmission in Neutral until the oil warms up,

then add oil as required to raise the fluid level

to the full mark on the dip stick. Refill capacity

is approximately 2 qts.
4.

Fig.
1PG - Adjusting Low Band Using J-21848
PERIODIC LOW BAND ADJUSTMENT (Fig. 1PG)

Low band adjustment should be periodically performed

at 12,000 mile intervals, or sooner, as necessary if op-

erating performance indicates low band slippage.

1.
Raise vehicle and place selector lever in neutral.

2.
Remove protective cap from transmission adjusting

screw.

3.
a. On Corvette Models: Drop left exhaust pipe for

clearance.

b.
On Chevelle Models: To gain clearance between

underbody and transmission, it may be necessary

to remove rear mount bolts from crossmember,

and move transmission slightly toward passenger

side of vehicle. .

4.
Loosen adjusting screw lock nut 1/4 turn and hold in

this position with wrench.

5.
Using Special Tool J-21848 adjust band to 70 in. lbs.

and back off four (4) complete turns for a band which

has been in operation for 6,000 miles or more,.or

three (3) turns for one in use less than 6,000 miles.

CAUTION: Be sure to hold the adjusting screw

lock nut at 1/4 turn loose with a wrench during"

the.adjusting procedure.

6. Tighten the adjusting screw lock nut to specified

torque.

CAUTION: The amount of back-off is not an

approximate figure, it must be exact.

MANUAL SHIFT LINKAGE CHECK & ADJUST

(Column Type)

1.
The shift tube and lever assembly must be free in the

mast jacket. See Section 9 for alignment of steering

column assembly if necessary.

2.
To check for proper shift linkage adjustment, lift

the transmission selector lever towards the steering

wheel. Allow the selector lever to be positioned in

drive (D) by the transmission detent.

NOTE: Do not use the indicator pointer as a

reference to position the selected lever. When

performing linkage adjustment, pointer is ad-

justed last.

3.
Release the selector lever. The lever should be in-

hibited from engaging low range unless the lever is

lifted.

4.
Lift the selector lever towards the steering wheel,

and allow the lever to be positioned in neutral (N) by

the transmission detent.

5.
Release the selector lever. The lever should now

be inhibited from engaging reverse range unless the

lever is lifted.

6. A properly adjusted linkage will prevent the selector

lever from moving beyond both the neutral detent, and

the drive detent unless the lever is lifted to pass

over the mechanical stop in the steering column.

7.
In the event that an adjustment is required, place

the selector lever in drive (D) position as determined

by the transmission detent. See Steps 2 and 3.

8. Loosen the adjustment swivel at the cross-shaft,

and rotate the transmission lever so that it contacts

the drive stop in the steering column.

9. Tighten the swivel and recheck the adjustment. See

2 and 6.

CHEVROLET CHASSIS SERVICE MANUAL

FUEL TANK AND EXHAUST SYSTEMS
8-8

CHEVELLE

FUEL TANKS

INDEX

Page

General Description.
g.g

Component Part Replacement
8-8

Fuel Tanks
. 8-8

Fuel Lines
8-8
Metering Units (Gauge, Sending Unit)

Fuel Tank Filler Neck Caps.
. .

Fuel Tank Vent Lines
Page

8-8

8-8

8-9

GENERAL DESCRIPTION

All models
use a 20
gallon capacity (approx.) fuel tank

mounted between
the
frame rails behind
the
rear axle.

The fuel tanks
are
basically
the
same
for
sedan, 2-seat

station wagon
and
pickup models except
for
filler neck

location
and
venting
(fig. 8).

All fuel tanks
are
vented
to the
atmosphere. Sedan

model tanks have
an
external vent hose and pipe assem-

bly
(fig. 11) and use a
non-vented fuel cap. Station wagon

and pickup model tanks
are
vented through
a
hose
and

vent pipe assembly
to the
filler neck
(fig. 8)
and
use a

vented, anti-surge type
gas cap. The
fuel caps
are two

different designs conforming
to SAE
standards
and are

not interchangeable.

The filler neck assembly
on
sedan models
is a
rear

fill design located behind
the
center
bar of the
bumper.
Station wagon
and
sedan pickup model filler neck assem-

blies
are
located
in
the left rear quarter panel.

The fuel pickup pipe
is
built integrally with
the
tank

gauge, located
at the
top-front center
of
the tank.
A
fine

mesh screen
is
located
at
the bottom-end
of the
fuel pick-

up pipe
to
prevent
the
entrance
of
foreign material into

the fuel system.

The sedan fuel tanks
are
held
in
place
by
two metal

straps attached individually
to the
underbody
at
each
end.

The straps hinge
at the
forward end and secure
the
tank

at
the
rear with
an
adjustable bolt
and nut
assembly.

The station wagon
and
pickup models have
a
frame

mounted fuel tank secured with straps
to
front and rear

supports.

COMPONENT PART REPLACEMENT

FUEL TANK

Draining Tank

The absence
of a
drain plug
in the gas
tanks makes
it

necessary
to
siphon fuel from
the
tank when draining
is

needed. Refer
to the
recommended draining procedures

previously outlined under Chevrolet Models
in
this

section.

Removal
and
Installation (Sedan Models)

1.
Raise vehicle.

2.
Drain fuel tank.

3.
Disconnect fuel pickup line
and
gauge wires from

tank unit.

4.
Disconnect vent hose from tank.

5. Remove tank support straps and lower tank carefully.

6.
To
install, reverse
the
removal procedure.

Removal
and
Installation

(Station Wagon
and
Pickup)

1.
Follow Steps
1
thru
3
outlined under sedan models.

2.
Remove tank support straps.

3.
Remove frame screw attachments from
the
front

support
(fig. 8).

4.
Guide tank forward
and
remove.

5.
To
install, reverse removal procedure.

FUEL LINES

The fuel lines, extending from fuel tank toiiuelpump,

are routed
on the
underside
of the
underbody along
the

right side
of the
vehicle opposite
the
single exhaust
sys-

tem.
The
fuel lines should occasionally
be
inspected
for
leaks,
kinks,
or
dents.
If
evidence
of
dirt
is
found
in the

carburetor
or
fuel pump
on
disassembly,
the
lines should

be disconnected
and
blown
out.
Check
the
fuel tank

strainer
for
damage
or
omission. Fuel lines
are of 5/16"

diameter tubing with beaded type ends
for
connections
of

hoses.

FUEL PIPE RETAINER
CUP

Removal
and
Installation

If fuel pipes
and
retainer clips
are
removed, Tool

J-7777 should
be
used
to
install
new
retainer clips
(fig.

10).
After removal
of the old
clip from
the
frame, position

the
new
clip
in the
location
of the old
clip. Index
the

"blind rivet"
and
press hard (hand pressure should
do)

to expand rivet.

GAUGE UNIT
AND
FUEL STRAINER

Removal
and
Installation
(Fig. 11)

1.
Drain tank
to a
level below
the
unit.

2.
Disconnect fuel pickup line
and
gauge unit wire.

3.
Use
special Tool J-8950
to
remove
cam
lock.
Re-

move unit
and
rubber gasket.

CAUTION: Carefully remove unit
so as not to

damage screen
on the end of
the pipe.

4.
Clean screen
by
blowing
out
with compressed
air.

5. Reverse procedure
to
install.

FUEL TANK FILLER NECK CAPS

The fuel tank filler neck caps
are
non-vented with
an

anti-surge feature. Station wagons have vented caps.

(Refer
to
"Fuel Tank Vent Lines").

CHEVROLET CHASSIS SERVICE MANUAL

FUEL TANK
AND
EXHAUST SYSTEMS
8-13

CHEVY II

FUEL TANKS

INDEX

Page

Page

General Description.
8-13

Component Part Replacement
8-13

Fuel Tanks
8-13

Fuel Lines
8-14
Metering Units (Gauge Sending Unit)
8-13

Fuel Tank Filler- Neck Caps.
. . 8-14

Fuel Tank Vent Lines .......
8-14

GENERAL DESCRIPTION

ANTI-SQUEAK

MA'
ANTI-SQUEAK

MATERIAL

SEDANS

STATION WAGON

Fig.
15-Chevy
II
Fuel Tanks

All Chevy
II
Models have
16
gallon capacity (approx.)

fuel tanks mounted between
the
frame rails
to the
rear
of

the rear axle
(fig. 15). The
fuel tanks
are
basically
the

same
for the
passenger
car
and two-seat,
six
passenger

station wagon models. The tanks
are
held
in
place
by two

metal straps attached individually
to the
underbody
at

each
end. The
straps hinge
at the
forward
end
and secure

the tank
at the
rear with
an
adjustable bolt and nut
ad-

sembly. The tank rests against the rear compartment
pan

reinforcement.
The
two-seat station wagon
gas
tank
is

secured
to the
contour
of
forward
and
rear underbody
brackets.
The
filler neck
is
accessible
by
removal
of a

fender
gas cap at the
rear left fender location.

A fine mesh screen
is
located
at the end of the
fuel

pickup pipe
to
prevent
the
entrance
of
dirt into
the sys-

tem.
The
tank
can be
drained
by
siphoning
at the
filler

neck
or by
removing
the
gauge sending unit and siphon-

ing
at the
tank opening.

CAUTION: Care should
be
exercised
to
avoid

denting
or
puncturing
the
fuel tank when
in-

stalling
or
removing.
~

COMPONENT PART REPLACEMENT

FUEL TANKS

Draining Tank

The absence
of a
drain plug
in
the Chevy
n
Model
gas

tanks makes
it
necessary
to
siphon fuel from
the
tank

when draining
is
needed. Refer
to the
recommended

draining procedures previously outlined under Chevrolet

Models
in
this section.

Removal
and
Installation

1.
Drain fuel tank.

2.
Raise
and
support vehicle.

3.
Disconnect
the
filler neck inlet hose
and the
vent

connection
(fig. 15).

4.
Remove
the gas
tank sending gauge unit access hole

cover
on
station wagons.
5. Disconnect fuel tank gauge sending unit with special

spanner Tool J-8950, detach wire
and
fuel pickup

line
at the gas
tank.

6. Remove tank support straps and lower tank carefully.

7. Reverse procedure
to
install.

The sending units
are
located on
the top
forward
end of

the
gas
tanks.
The
fuel strainer
is
located
at the end of

these sending units.

FUEL TANK GAUGE SENDING UNIT

AND FUEL STRAINER
(Fig. 16)

Replacement

1.
Drain tank
to a
level below
the
unit.

2.
Disconnect fuel pickup line
and
gauge unit wire.

3.
Use
special Tool J-8950
to
remove
cam
lock.
Re-

move unit and rubber gasket.

CHEVROLET CHASSIS SERVICE MANUAL

STEERING
9-32

arm on frame and install mounting bolts, washers

and nuts. No washer is used on Corvette.

Install relay rod to idler arm, ^making certain seal

is on stud. Install and tighten nut.

Install cotter pin.

Refer to torque specifications at rear of manual for'

correct torque values.

Chevy II (Fig. 62}

Removal

1.
Remove cotter pin, nut and washer securing idler

arm to relay rod.

2.
Remove relay rod from idler arm.

3.
If equipped with power steering disconnect power

cylinder shaft from idler arm bracket.

4.
Remove three idler bracket to frame bolts and nuts

and remove bracket and idler arm assembly.

5.
Remove cotter pin, nut, washer and bolt securing the

idler arm to the bracket.

6. Press out the idler arm bushing for replacement.

Installation

NOTE: Installation must be done with front

wheels straight ahead or the car will lead to one

side.

1.
Install idler arm bushing, if previously removed.

NOTE: Make certain the outer sleeve of the

bushing does not protrude above surface of idler

arm.

2.
Reverse removal procedure and torque all nuts ac-

cording to specifications.

PITMAN ARM

Removal

1.
Remove cotter pin from pitman arm ball stud and

remove nut.

2.
Remove relay rod from pitman arm by tapping on

side of rod or arm in which the stud mounts with a

hammer while using a heavy hammer or similar tool

as a backing. Pull down on relay rod to remove

from stud.

3.
Remove pitman arm nut from sector shaft and mark

relation of arm position to shaft.

4.
Remove pitman arm with Tool J-6632 as shown in

Figure 2.

Installation

1.
Install pitman arm on sector shaft, lining up the

• marks made upon removal.

2.
Install sector shaft nut.

3.
Position relay rod on to pitman arm. Install nut.

Continue to tighten arm enough to align castellation

with hole in stud and install cotter pin.
STEERING ARM

If, through collision or other damage, it becomes nec-

essary to remove and replace either steering arm, pro-

ceed as follows:

Removal

1.
Remove tie rod from steering arm as outlined in this

section.

2.
Remove front wheel, hub and brake drum as a unit

by removing hub cap and dust cap, cotter pin from

spindle nut and the spindle nut. Pull assembly to-

ward outside of vehicle. If removal is difficult, it

may be necessary to back off brake adjustment to

increase brake shoe-to-drum clearance; see Hy-

draulic Brake Adjustment, Section 5. On models

with disc brakes, remove caliper and disc.

3.
With wheel and drum assembly or caliper and disc

removed, steering arm retaining bolt heads are ac-

cessible and removal of steering arm from vehicle

may be accomplished by removing retaining nuts.

Installation

1.
Place steering arm in position on vehicle and install

retaining bolts*

2.
Install nuts. Use only the special locknut listed for

this use in the Chevrolet Parts Catalog.

3.
Pack wheel bearings using a high quality wheel

bearing lubricant. Install bearings and wheel-hub-

brake drum assembly removed previously. On disc

brake models, install disc and caliper.

4.
Install keyed washer and spindle nut. Proceed as out-

lined under t{ Front Wheel Bearing Adjustment" in

Section 3.

5.
Install tie rod ball stud in steering arm. Be sure that

the dust cover is in place on ball stud.

6. Install castellated nut on ball stud, tighten securely

and install cotter pin.

7.
Following directions given in Section 3 to check cor-

nering wheel relationship and toe-in; correct as

required.

STEERING DAMPER-CORVETTE

Removal

1.
Remove bolt from damper pivot bracket at relay rod.

2.
Remove nut from damper pivot at frame bracket and

withdraw damper assembly.

Damper is serviced as a unit. Replace damper if
3.

damaged or excessively worn.

Installation

1.
Place piston rod end into frame bracket and install

retainers, bushings, and nut.

2.
Insert cylinder end pivot into relay rod bracket and

install through bolt.

CHEVROLET CHASSIS SERVICE MANUAL

STEERING
9-33

POWER STEERING

INDEX

Page

General Description
. 9-33

Maintenance
and
Adjustments
9-33

Bleeding Hydraulic System
9-33

Fluid Level
. 9-33

Adjustments
. 9-34

Power Steering Gear
. . 9-34

Pump Belt Tension
9-34
Hydraulic System Checks
9-34

Component Replacement
and
Repairs
. 9-35

Power Steering Pump.
. 9-35

Power Steering Gear
9-36

Control Valve
and
Adapter Assembly
9.35

Power Cylinder
9.37

Power Steering Hoses
9.39

GENERAL DESCRIPTION

Two types
of
power steering
are
used
for 1967.
One
is

the conventional linkage type
for
Chevy
n and
Corvette

vehicles
and the
other
is the
integral gear type
for

Chevrolet, Chevelle,
and
Camaro.
For
both types
the

hydraulic pressure
is
provided
by an
engine-driven vane-

type pump.

On
the
Chevy
n and
Corvette linkage type power steer-

ing, hydraulic pressure
is
delivered through
a
hose from

the pump
to a
valve which senses
the
requirement
for

power assistance
and
supplies
the
power cylinder
ac-

cordingly.
The
steering gear used with this power steer-

ing
is the
same basic unit used
on
manually steered

vehicles;
it is
serviced
as
outlined
in the
manual steering

part
of
this section except
for
adjustment, which
is

covered
in the
following pages.
The
steering linkage also

is serviced the same
as
manual counterparts.

The Chevrolet, Chevelle
and
Camaro integral gear type

power steering
has the
hydraulic pressure delivered

from
the
pump through two hoses
to the
steering gear.
In
the power steering gear
the
steering shaft, hydraulic

valve, worm, and rack-piston
nut are all in
line making
a

compact
and
space saving assembly.
All oil
passages
are

internal within
the
gear except
the
pressure
and
return

hoses.

The steering gear
is a
recirculating ball system
in

which steel balls
act as a
rolling thread between
the

steering worm
and
rack-piston
nut. The
rack-piston
nut

is
all one
piece
and is
geared
to the
sector
of
the piston

shaft.
The
valve
is
contained
in the
gear housing elimi-

nating
the
need
of
bolts
or
seals
to
attach
a
separate

valve housing.

The valve
is an
open-center, rotary-type three
way

valve.
The
spool
is
held
in
neutral position by means
of a

torsion
bar. The
spool
is
attached
by
means
of
the stub

shaft
to one end of the
torsion
bar
and
to the
valve body

on
the
other
end.
Twisting
of the
torsion bar allows
the

spool
to
move
in
relation
to the
valve body thereby oper-

ating
the
valve.

MAINTENANCE
AND
ADJUSTMENTS

BLEEDING HYDRAULIC SYSTEM

1.
Fill
oil
reservoir
to
proper level and
let oil
remain

undistrubed
for at
least two minutes.

2.
Start engine
and run
only
for
about
two
seconds.

3.
Add
oil if
necessary.

4.
Repeat above procedure until
oil
level remains
con-

stant after running engine.

5. Raise front
end of
vehicle
so
that wheels
are off
the

ground.

6. Increase engine speed
to
approximately
1500 rpm.

7. Turn
the
wheels
(off
ground) right
and
left, lightly

contacting
the
wheel stops.

8. Add
oil if
necessary.

9. Lower
the car and
turn wheels right and left
on the

ground.

10.
Check
oil
level and refill
as
required.

11.
If oil is
extremely foamy, allow vehicle
to
stand
a

few minutes with engine
off and
repeat above

procedure.
,

a.
Check belt tightness
and
check
for a
bent
or
loose

pulley. (Pulley should
not
wobble with engine

running.)
b.
Check
to
make sure hoses
are not
touching
any

other parts
of the car,
particularly sheet metal.

c. Check
oil
level, filling
to
proper level
if
neces-

sary, following operations
1
through
10.
This

step
and
Step
"D" are
extremely important
as

low
oil
level and/or
air in the oil are the
most

frequent causes
of
objectionable pump noise.

d. Check
the
presence
of air in the oil. If air is

present, attempt
to
bleed system
as
described
in

operations
1
through
10. If it
becomes obvious

that
the
pump will
not
bleed after
a few
trials,

proceed
as
outlined under Hydraulic System

Checks.

FLUID
LEVEL

1.
Check
oil
level
in the
reservoir
by
checking
the dip

stick when
oil is at
operating temperature.
On

Chevelle models equipped with remote reservoir,

the reservoir should
be
maintained approximately

3/4 full when
oil is at
operating temperature.

2.
Fill,
if
necessary,
to
proper level with
GM
Power

Steering Fluid
or, if
this
is not
available, automatic

CHEVROLET CHASSIS SERVICE MANUAL

STEERING 9-39

4.
Remove cotter pin, nut and ball stud at relay rod.

5. Remove the power cylinder from the vehicle.

Inspection

1.
Inspect the seals for leaks; if leaks are present,

replace the seals using the procedure outlined under

"Disassembly."

2.
Examine the brass fitted hose connection seats for

cracks or damage and replace if necessary.

3.
For service other than ball seat or seal replacement

and ball stud removal, replace the power cylinder.

4.
Check the frame bracket parts for wear.

Disassembly

1.
To remove the piston rod seal remove the snap ring;

then pull out on the rod, being careful not to spray

oil.

2.
Remove the piston rod scraper and scraper element,

back up washer and piston rod seal from the rod.

3.
At the ball stud end of the cylinder, remove the ball

stud seal.

4.
Remove the snap ring retaining the end plug with the

lube fitting.

5. Push on the end of the ball stud and remove the end

plug, spring, spring seat and ball stud.

6. Remove the "O" ring seal from the top lip of the

power cylinder ball stud opening.

7. If the ball seat is to be replaced, it must be pressed

out using Tool J-8937.

Assembly

1.
Reassemble the piston rod seal components by re-

versing the disassembly procedure. Apply a thin
coat of Lubriplate or equivalent on the inner sur-

faces of the seal and scraper before assembly.

2.
Reverse the disassembly procedure when reassem-

bling the ball stud.

3.
In each case be sure that the snap ring is securely,

seated in the ring groove.

Installation

1.
Install the power cylinder on the vehicle by reversing

the removal procedure.

2.
Reconnect the two hydraulic lines, fill the system

with fluid and bleed out air using the procedure out-

lined under "Maintenance and Adjustments." Grease

ball joint.

POWER STEERING HOSES

When servicing the power steering hoses be sure to

align the hoses in their correct position as shown in

Figure 71. On Chevelle models with 396 engine, install

the upper hose so that there is at least .6 inch clearance

between the hose and the Delcotron or the inner fender

skirt.

It is important that the power steering hoses be in-

stalled correctly. Hoses installed out of position may be

subjected to chafing or other abuses during sharp turns.

Always make hose installations with front wheels in

straight ahead position. Do not twist hoses unneces-

sarily during installation.

CAUTION: Do not start engine with any power

steering hose disconnected.

CHEVROLET CHASSIS SERVICE MANUAL

SECTION 10

WHEELS AND TIRES

INDEX

Page

General Description
10-1

Maintenance
and
Adjustments
.............. 10—1

Tires
10-1

Pressures . 10-1

Inspection 10-1

Wear 10-1

Rotation 10-4

Noise 10-4

Cleaning 10-4

Change (W/Wheels) 10-4

Wheels 10-5

Static Balancing (w/Tire) 10-5
Page

Dynamic Balancing (w/Tire) . 10-5

Run Out (w/o Tire) 10-5

Cleaning 10-5

Service Operations 10-5

Tires 10-5

Removal 10-5

Installation 10-5

Repair 10^6

Wheels . 10-6

Valve Assembly 10-6

Repair (Rim) 10-7

GENERAL DESCRIPTION

WHEELS

Chevrolet, Chevelle, Camaro, Chevy n, and Corvette

are base equipped with welded steel wheels. Five studs

with nuts fasten each wheel to the front hub or rear axle

flange. Disc brake equipped vehicles (except Chevrolet

and Corvette) require special 14 inch diameter wheels

with a revised design for clearance, Chevrolet disc brake

equipped vehicles have 15 in. diameter wheels as do all

Corvettes.

Chevrolet station wagons, Chevelle Super Sport 396,

Corvette and Camaro Super Sport 350 are base equipped

with 6 in. width wheels. All other vehicles have 5 in.

width wheels, except Chevy n 100, 300 and 500 Series

Sedans, which have 4 in. width wheels.

Do not install 6 inch width wheels or snow chains on

Chevrolets equipped with rear fender skirts.

TIRES

The factory installed tires on Chevrolet passenger

cars are selected to provide the best all around tire

performance for all normal operation. They are de-

signed to operate satisfactorily with loads up to and in-

cluding the specified full rated load capacity of the
automobile when inflated as recommended in the Vehicle

Capacity Rating and Recommended Tire Inflation Pres-

sures Table (see Specifications).

Optional Oversize and 8-Ply Rating Tires

{Chevrolet and Chevelle Only)

Oversize or 8-ply rating tires are not necessary on

passenger cars for normal requirements. However, an

extra margin of tire service is available when these

options are used at loads up to and including full rated

load.

Optional oversize 4-ply rating and/or 8-ply rating

tires are available on models as indicated in the Tire

Usage Chart (see Specifications). On some models (ex-

ample—Station Wagon), space limitations do not permit

the use of a larger size tire; hence, the 8-ply rating

tire is an available option.

In either case, these tires are applicable to extended

operation at or near full rated load or for trailer towing

when an extra margin of tire service is desired. How-

ever, use of a larger tire or an 8-ply rating tire should

not be construed as permitting an increase in the full

rated vehicle load (see Specifications).

MAINTENANCE AND ADJUSTMENTS

TIRES

Inflation Pressures

To ensure the proper tire inflation pressure for the

owners particular requirements follow the recommenda-

tions in the Vehicle Capacity Rating and Recommended

Tire Inflation Pressures Table (seeSpecifications). Keep

tires properly inflated, and check inflation pressures

periodically. This will ensure the best tire life and riding

comfort, over the full range of driving conditions.
Inspection

Every few thousand miles and at each lubrication, tires

should be checked for sharp objects or stones in the

tread. H tire is punctured, it should be repaired using

one of several repair kits available through tire manu-

facturers1 outlets.

Wear

Misalignment

This is wear due to excessive toe-in or toe-out. In

CHEVROLET CHASSIS SERVICE MANUAL

WHEELS AND TIRES 10-4

the road and it slips, grinding off the tread on the inside

half of the tire at an excessive rate. This type of tire

shows much the same appearance of tread wear as tire

wear caused by negative camber.

Second, the transfer of weight may also over-load the

outside tires so much that they are laterally distorted

resulting in excessive wear on the outside half of the

tire producing a type of wear like that caused by ex-

cessive positive camber.

Cornering wear can be most easily distinguished from

abnormal camber wear by the rounding of the outside

shoulder or edge of the tire and by the roughening of the

tread surface which denotes abrasion.

Cornering wear often produces a fin or raised portion

along the inside edge of each row in the tread pattern.

In some cases this fin is almost as pronounced as a

toe-in fin, and in others, it tapers into a row of tread

blocks to such an extent that the tire has a definite step

wear appearance.

The only remedy for cornering wear is proper in-

struction of owners.

Fig.
5 - Tire Rotatidh

Rotation

To minimize the possibility of tire noise and to equal-

ize tire wear, it is recommended that tires be inter-

changed every 6000 miles as shown in Figure 5 or more

frequently in the case of extremely heavy wear.

NOTE:
Rotate Corvette tires at 4000 miles or

sooner.

Interchanging tires will effectively prevent undue wear

on any particular tire. II tire interchanging is followed

as recommended above, all tires will have the same

number of miles in each wheel position at the end of the

fourth change. When interchanging tires, inspect for

signs of abnormal wear, bulging, etc., stones, glass, and

nails should be removed before reinstallation.

Noise

Noise caused by the normal action of tire treads on

various road surfaces is often confused with rear axle
gears or other noises in the car.

The determination of whether tires are causing the

noise complained of is relatively simple. The car should

be driven at various speeds and note taken of part

throttle, and sudden acceleration and deceleration. Axle

and exhaust noises show definite variations under these

conditions, while tire noise will remain constant. Tire

noise is, however, most pronounced at speeds of approx-

imately twenty or thirty miles per hour.

The tires may be further checked by driving the ear

over smooth pavement with the tires at normal pressure

and again over the same stretch of pavement when the

tires have been inflated to fifty pounds pressure. Reduce

the tires to normal pressure one at a time to determine

the faulty tire or tires. This high inflation pressure

should immediately be reduced to normal after test. If

the noise for which the test is being made is caused by

tires,.
it will noticeably decrease when the tire pressure

is increased, whereas axle noise should show no change

in volume.

If, on inspection, the tires on the front wheels are

found to be creating most of the noise the alignment of

the front wheels should be checked. Excessive tire noise

usually results from lower than recommended tire pres-

sure, incorrect alignment, uneven tire wear, or defective

(thumper) tire.

Cleaning

A great deal of ordinary road dirt which collects on

white sidewall tires may be sponged off with clear water

or a mild soap solution.

A good brand of whitewall tire cleaner, however, is

a quicker and more effective cleaner for removing dirt

and stains from whitewall tires and in many cases it

will remove stains and discoloration that the simpler

method of soap and water will not remove.

Under no circumstances should gasoline, kerosene or

any cleaning fluid containing a solvent derived from oil

be used to clean whitewall tires. Oil in any form is

detrimental to tire rubber and a cleaner with an oil base

will discolor or injure whitewall tires.

Change (W/Wheels)

To change the road wheels using the jack that comes

with the car, observe the following procedure:

1.
Set hand brake and block front wheels if rear wheel

is being changed.

2.
Remove hub cap or wheel disc and break wheel

mounting nuts loose.

3.
Place the jack as directed tinder, General Informa-

tion,
Section 0 and raise car until wheel clears

ground.

4.
Remove wheel mounting nuts and remove wheel from

hub or drum.

5. To replace road wheel, reverse the above instrue-

. tions. Proper torque on nuts is 55-75 ft. lbs.

torque (70-85 ft. lbs. for Corvette aluminum wheel

nuts).

CAUTION: On models equipped with discs, in-

dex the pilot hole in the disc on the valve stem.

(To insure that the anti-rotation notches in wheel

disc register on lugs in wheel rim.)

CHEVROLET CHASSIS SERVICE MANUAL

CHASSIS SHEET METAL 11-18

b.
Check and adjust front wheel alignment as out-

lined in Section 3.

c. Check and adjust headlamp aiming as outlined in

Section 12.

HOOD ASSEMBLY

Hood may be removed either with or without hinges.

To shorten aligning time, hood hinge plates may be lo-

cated by scribing a mark on hood and/or body which

outlines entire plate. See Maintenance and Adjustments -

Hood Hinge for hood adjustment procedure. Hood hinge

springs may be easily and safely removed and installed.

through the use of Tool J-9559 as follows:

1.
With hood opened only far enough to allow passage of

mechanic's arm between hood and fender, insert ends

of J-9559 (through bolt removed) between coils of

spring until barrel of tool contacts outer diameter

of spring.

2.
Open hood fully while still holding spring (with tool

installed) in hand; when hood is near fully opened

position, spring may be removed as shown in Figure

28.

3.
As soon as spring is removed, insert long bolt sup-

plied with J-9559 through holes in end of tool, pass-

ing it through spring, and install nut on bolt.

Spring may be removed from J-9559 or J-9559 may be

installed in a new spring by the following method:

1.
Place a closed 6 or 8 inch "C" clamp in a vise or

fasten it to a heavy bench top (bench should be fas-

tened to floor).

2.
Hook one end of spring in clamp and the other end

in hook of a hoist as shown in Figure 29.

3.
Stretch the spring enough to allow insertion of

J-9559. Install through bolt if spring is not to be

installed on hinge at once.

HOOD CATCH AMD LOCK (Fig. 19)

Removal

1.
Remove catch assembly as follows:

a. Remove screws retaining catch assembly to radi-

ator support.

b.
Remove screws retaining catch assembly to catch

support assembly.

c* Remove screws retaining catch assembly to grille

upper bar.

2.
Before removing hood lock plate from hood, locate

position on hood by scribing around base of lock

plate. Remove screws retaining lock plate to hood

and remove lock plate from vehicle.

Installation

1.
Install both catch and lock assemblies in reverse

order of removal procedure.

2.
Align as outlined under Maintenance and Adjust-

ments - Hood Catch.

HOOD TRIM

Crown Molding

Hood crown molding is retained by clips installed on

underside of hood. Clips may be removed by carefully

pressing them off molding mounting studs with screw

driver.
When installing a new molding, force clips onto mount-

ing studs as far as possible and then clench clips with

long-nosed pliers to eliminate gap between molding and

hood, as shown in Figure 30.

Emblem

The hood emblem is retained by four nuts which are

accessible from under the hood.

COWL VENT GRILLE

The cowl vent grille replacement procedure for Chevy

U is the same as for Chevrolet and Chevelle. Refer to

Chevrolet and Chevelle Cowl Vent Grille replacement

procedure and see Figure 16.

FRONT END ASSEMBLY

The Chevy n front end body design allows for removal

of the entire front end of the vehicle without disassembly

of front suspension of sheet metal. One man may remove

and transport the front end assembly using only a floor

jack placed under the crossmember and the vehicle front

wheels. Figure 31 illustrates the assembly in process

of removal with jack stand in position under rocker panel.

Proceed with removal
as.
follows:

Removal

1.
Remove hood assembly as outlined in this section.

2.
Remove engine assembly as outlined in Section 6.

On 4 cylinder models, replace crossmember.

3.
Raise car from floor and install jack stands as

shown in Figure 31.

4.
Remove pitman arm from steering gear as outlined

in Section 9.

5.
Remove steering gear mounting bolts from skirt

assembly.

6. Remove 4 bolts securing each skirt assembly to

lower dash brace.

7.
Remove fender-to-rocker extension mounting screws

and record shimming.

8. Remove brake hydraulic line and fuel line from right

hand skirt.

9. Position floor jack or equivalent under front cross-

member.

10.
Remove hydraulic line from main cylinder.

11.
Remove fender-to-cowl mounting screws and record

shimming.

12.
Remove upper skirt-to-dash mounting screws and

record shimming.

13.
Remove front end from vehicle as shown in Figure

31.

Inspection

If car has been involved in a collision, it is advisable

to carefully inspect cowl and dash area for damage. Pay

particular attention to welds, cage nuts, weld nuts and

skirt mounting surfaces. Cage and weld nuts may be

repaired by outright replacement (the best method), or

by the installation of spiral thread inserts. If the spiral

inserts are used, follow the instructions furnished by the

manufacturer. -

Installation

%, position front end assembly at upper dash mounts

and lower dash support, align screw holes with drift

punch and install all mounting screws and bolts

loosely; do not tighten until all screws and bolts are

started. Replace original shimming.

CHEVROLET CHASSIS SERVICE MANUAL