washer fluid CHEVROLET CAMARO 1967 1.G Chassis Workshop Manual

LUBRICATION 0-13

LUBRICATION

INDEX

Page

Engine Crankcase Oil . 0-13

Crankcase Capacities. . 0-13

Lubrication . ,
•
o-13

SAE Viscosity Oils 0-13

Types of Oils 0-14

Maintaining Oil Level 0-14

Oil and Filter Change Intervals 0-14

Oil.
. . ...:.. 0-14

Filter o-14

Crankcase Dilution . 0-14

Automatic Control Devices to Minimize

Crankcase Dilution 0-14

Crankcase Breather Cap 0-14

Crankcase Ventilation System 0-15

Valve Type 0-15

Fuel Filter 0-15

Air Cleaner . 0-15

Polyurethane Type 0-15

Oil Wetted Paper Element Type 0-15

Battery Terminal Washers 0-15
Page

Distributor 0-15

Rear Axle and 3-Speed and Overdrive

4-Speed Transmission 0-15

Recommended Lubricants 0-15

Multi-Purpose Gear Lubricants 0-15

Lubricant Additions 0-15

Lubricant Changes 0-15

Powerglide Transmission 0-15

Turbo Hydra-Matic 0-16

Front Wheel Bearings 0-16

Manual Steering Gear . . . . 0-16

Power Steering 0-16

Air Conditioning 0-16

Brake Master Cylinder. 0-16

Parking Brake 0-16

Clutch Cross-Shaft , 0-16

Chassis Lubrication 0-16

Lubrication Diagrams . . 0-19

Body Lubrication (Chevrolet, Chevelle, Chevy n, Camaro). 0-20

Body Lubrication Points (Corvette) . 0-21

The selection of the proper lubricant and its correct

application at regular intervals does much to increase the

life and operation of all moving parts of the vehicle.

Consequently, it is important that the correct grade of

oil or grease, as noted in the following pages, be used.

ENGINE CRANKCASE OIL

Crankcase Capacity

4 Cylinder 4 qt.

6 Cylinder 4 qt.

8 Cylinder (283) 4 qt.

8 Cylinder (327) 4 qt.

8 Cylinder (350) 4 qt.

8 Cylinder (396) 4 qt.

8 Cylinder (427) Chevrolet 4 qt.

8 Cylinder (427) Corvette 5 qt.

For 4 Cyl. Add .5 qt. with filter change;

1 qt. for 6 and 8 Cyl. engines.

Lubrication

Crankcase oil should be selected to give the best per-

formance under the climatic and driving conditions in the

territory in which the vehicle is driven.

During warm or hot weather, an oil which will provide

adequate lubrication under high operating temperatures

is required.

During the colder months of the year* an oil which will

permit easy starting at the lowest atmospheric tempera-

ture likely to be encountered, should be used.

When the crankcase is drained and refilled, the crank-

case oil should be selected, not on the basis of the exist-

ing temperature at the time of the change, but on the

lowest temperature anticipated for the period during

which the oil is to be used.

Unless the crankcase oil is selected on the basis of

viscosity or fluidity of the anticipated temperature, dif-

ficulty in starting will be experienced at each sudden

drop in temperature.
SAE Viscosity Oils

SAE Viscosity Numbers indicate only the viscosity or

body of the oil, that is, whether an oil is a light or a

heavy body oil, and do not consider or include other

properties or quality factors.

The lower SAE Viscosity Numbers, such as SAE 5W

and SAE 10W which represent the light body oils, are

recommended for use during cold weather to provide

easy starting and instant lubrication. The higher SAE

Viscosity Numbers such as SAE 20 and SAE 20W, which

represents heavier body oils, are recommended for use

during warm or hot weather to provide improved oil

economy and adequate lubrication under high operating

temperatures.

Oils are available which are designed to combine the

easy starting characteristics of the lower SAE Viscosity

Number with the warm weather operating characteristics

of the higher SAE Viscosity Number. These are termed

"multi-viscosity oils," SAE 5-10W, SAE 5W-20, SAE

10W-20W, and SAE 10W-30.

The following chart will serve as a guide for the

selection of the correct SAE Viscosity Number for use

under different atmospheric temperature ranges, and

suggests the appropriate SAE Viscosity Numbers when

multi-viscosity oils are used.

Lowest Anticipated

Temperature

During Time

Oil Will Be

in Crankcase

32°F.

0°F.

Below 0°F.
Recommended

SAE Viscosity

Oils

SAE 20 or 20W

SAE 10W

SAE 5W
Recommended

SAE

Multi-

Viscosity

Oils

SAE 10W-30 .

SAE 10W-30

SAE 5W-20

SAE 30 or 10W-30 is recommended when most of the

driving is at high speeds and/or at temperatures above

90
°F.

CHEVROLET CHASSIS SERVICE MANUAL

LUBRICATION 0-15

CRANKCASE VENTILATION VALVE

VALVE TYPE

NOTE: Under prolonged dusty driving condi-

tions,
it is recommended that these operations

be performed more often. Every 12,000 miles

or 12 months the valve should be replaced.

Connecting hoses, fittings, flame arrestor and

crankcase breather cap (where used) should be

cleaned. At every oil change the system should

be tested for proper function and serviced, if

necessary.

FUEL FILTER

Replace filter element located in carburetor inlet if

flooding occurs, if engine surges during constant speed

operation (pulsating effect) or if poor performance is

experienced during acceleration or at higher speeds.

AIR CLEANER

NOTE: Under prolonged dusty driving condi-

tions,
it is recommended that these operations

be performed more often.

POLYURETHANE TYPE-

Every 12,000 miles clean element in solvent, squeeze

out solvent, then soak in engine oil and squeeze out

excess.

OIL WETTED PAPER ELEMENT TYPE-

First 12,000 miles inspect or test element; if satis-

factory, re-use element but recheck every 6,000 miles

until replaced. Element must not be washed, oiled,

tapped or cleaned with an air hose.

BATTERY TERMINAL WASHERS

Battery terminals have felt washers between top of

case and cable connections to minimize corrosive action

of battery acid. These felt washers should be saturated

with engine oil every 6,000 miles.

DISTRIBUTOR

4 and 6-Cylinder Engine—Remove distributor cap and

rotate lubricator 1/2 turn at 12,000 mile intervals. Re-

place at 24,000 mile intervals.

8-Cylinder Engine—Change cam lubricator end for end

at 12,000 mile intervals. Replace at 24,000 mile

intervals.

REAR AXLE AND 3-SPEED AND

OVERDRIVE, 4-SPEED TRANSMISSIONS

The passenger car operates under the most severe

lubrication conditions at high speed and requires a hypoid

lubricant which will meet this condition.

Recommended Lubricants

Standard Rear Axles—SAE 90 "Multi-Purpose" gear

lubricant.

Positraction Rear Axles—Use special Positraction

lubricant.
CAUTION: Straight Mineral Oil gear lubricants

must not be used in hypoid rear axles.

Transmissions—SAE 90 "Multi-Purpose" gear

lubricant.

The SAE 90 viscosity grade is recommended for year

round use. However, when extremely low temperatures

are encountered for protracted periods during the winter

months, the SAE 80 viscosity grade may be used.

"Multi-Purpose" Gear Lubricants

Gear lubricants that will satisfactorily lubricate hypoid

rear axles have been developed and are commonly re-

ferred to as ' 'Multi-Purpose" gear lubricants meeting

U.S.
Army Ord. Spec. MIL-L-2105B.

These lubricants can also be satisfactorily used in

manual transmissions.

CAUTION: With Positraction rear axles use

special Positraction lubricant.

"Multi-Purpose" gear lubricants must be manufac-

tured under carefully controlled conditions and the

lubricant manufacturer must be responsible for the

satisfactory performance of his product. His reputation

is the best indication of quality.

Lubricant Additions

The lubricant level in the axle and transmission hous-

ings should be checked periodically. (Every 6,000 miles.)

It is recommended that any additions required to bring

up the lubricant level be made using the same type lubri-

cant already in the housing.

When checking lubricant level in transmission or rear

axle the unit being cheeked should be at operating

temperature. With unit at operating temperature the

lubricant should be level with bottom of the filler plug

hole.
If the lubricant level is checked with the unit cold

the lubricant level should be 1/2 inch below the filler

plug hole.

Lubricant Changes

The rear axle lubricant does not require changing for

the life of the vehicle. If additions are needed, or when

refilling the axle after service procedures, use lubricants

described above.

POWERGLIDE TRANSMISSION

NOTE: Every 12,000 miles, it is recommended

that the Powerglide low band be adjusted as

specified in Section 7 of this manual.

Every 6,000 miles--Check fluid level on dipstick with

engine idling, selector lever in neutral position, parking

brake set and transmission at operating temperature. If

fluid level is below full mark on dip stick, adding a small

amount of Automatic Transmission Fluid, General Motors

Automatic Transmission Fluid (Part Numbers 1050568-

69,
70) is recommended. If this fluid is not obtainable,

use Automatic Transmission Fluid Type 'A' bearing the

mark AQ-ATF followed by a number and the suffix letter

'A'.
Recheck fluid level on dip stick and again add a

small amount of fluid if needed to bring level to full

mark. DO NOT OVERFILL.

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-53

Fig.
70—Wiring and Vacuum Lines—Four-Season (Camaro)

Installation

1.
Connect the expansion valve to the refrigerant pipes.

Attach the capillary bulb to the evaporator.

2.
Attach the evaporator to the- case. Attach the inlet

and outlet pipes clamps.

3.
Assemble the case halves. Insert the capillary tube

from the thermostatic switch between the fins as

shown in Figure . Attach the cover plate to the

case.

4.
Mount the unit to the dash and connect the refrigerant

lines.

5.
Evacuate and charge the system. If a new evaporator

was installed, add three fluid ounces of refrigerant

oil to the system before charging.

6. Test system operation.

Chevy II All-Weather System

Removal

Under
the Hood

1.
Purge the refrigerant from the system.

2.
Remove the refrigerant hoses from the evaporator

inlet and outlet connections extending through the

special grommet in the dash panel and into the

engine compartment.

3.
Remove the screw, nut, spacer bracket and grommet

from the outlet connection pipes.
Within the Car

4.
Remove the glove box, ash tray and ash tray

retainer.

5.
Reach through the glove box door to disconnect the

air conditioning "on" door bowden cable (fig. 75).

6. Remove the two shield attaching screws and shield

(A, fig. 76) which covers the lower right evaporator

bracket-to-blower bracket attaching screw (B, fig.

76),
then remove this screw.

7.
Behind the lower left side of ihe evaporator, remove

the evaporator bracket-to-heater distributor bracket

attaching screw (C, fig. 76).

8. Reaching through the glove box door and ash tray

openings, remove the two nuts and washers (D,

fig.
76) attaching the evaporator assembly studs to

the lower instrument panel flange and reinforcement.

9. Disconnect the drain hoses and carefully pull the

evaporator unit toward the rear of the vehicle.

10.
Disconnect wiring connectors (see fig. 77) as nec-

essary and remove the evaporator unit from the

vehicle.

Gore and/or Expansion Valve Replacement

A defective unit must be replaced since repairs should

never be made on the evaporator core. Before replacing

the core, however, check to be sure that any leaks pres-

sent are not located at the hose connections or expansion

valve connections. The following procedure assumes that

the evaporator unit has been removed from the vehicle

as outlined above.

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-57

EVAPORATOR PIPES

DISTRIBUTOR RELAY GRD.

ASSEMBLY & WASHER

EVAPORATOR ASM.
BLOWER

SHROUD

(RACKET

(PART OF

BLOWER)

Fig.
76—Evaporator Removal—All Weather

7. Disconnect the thermostatic expansion valve to evap-

orator inlet connector, remove the power element

bulb from the evaporator outlet line and carefully

move .the valve and its inlet hose away from the

evaporator case.

8. Remove the electrical connectors from the relay

and resistor terminals.

9. Remove the screws attaching the evaporator case

cover to the case. See Fig. 79. The core is bracket

mounted to the cover and the entire core and cover

assembly may now be removed from the vehicle.

10.
Remove the two cover to core bracket screws and

separate the core from the cover.

11.
Install the new core to the cover being sure that the

grommets are properly installed around the inlet

and outlet lines.

12.
Reinstall the core and cover assembly into the evap-

orator case and replace the attaching screws.
13.
Reinstall the STV and expansion valves, the equal-

izer line connection and the evaporator oil bleed line

from the STV.

NOTE:
Use all new «O" rings.

14.
Reinstall the radiator supply tank, water valve and

vacuum line, and replace the heater hoses onto the

core pipes being sure not to switch the hoses. Then

refill the radiator.

15.
Add three fluid oz. refrigerant oil after installing a

new core, evacuate and charge the system.

EXPANSION VALVE

The thermostatic expansion valve is factory adjusted

and pre-set and cannot be adjusted after installation. A

malfunctioning valve must be replaced. However, before

proceeding, check all other possible causes of the trouble.

Make certain that the power element bulb is properly

CHEVROLET CHASSIS SERVICE MANUAL

BRAKES 5-20

boss to the front brakes will not contain a check

valve and spring. .

Removal

1.
Wipe main cylinder and lines clean with a clean

cloth. Place dry cloths below main cylinder area to

absorb any fluid spillage.

2.
Disconnect hydraulic lines at main cylinder. Cover

line ends with clean lint-free material to prevent

foreign matter from entering the system.

3.
Disconnect the push rod from the brake pedal.

4.
Unbolt and remove the main cylinder from the

firewall.

5.
Remove the main cylinder mounting gasket and boot.

6. Remove the main cylinder cover and dump out the

fluid. Pump the remaining fluid from the cylinder

by depressing the push rod.

Disassembly (Fig. 32)

1.
Clamp main cylinder in a bench vice.

2.
Remove push rod retainer.

3.
Remove secondary piston stop bolt from bottom of

front fluid reservoir.

4.
Remove the snap ring retainer and primary piston

assembly. Remove the secondary piston, piston

spring, and retainer by blowing air through the stop

bolt hole. (If no air is available, a piece of wire

may be used. Bend approximately 1/4 inch of one

end into -a right angle, hook the secondary piston

and pull it out.)

5.
Position main cylinder in vice with outlet holes

facing up.

6. Drill a 13/64 inch hole through both check valve

seats.

7 Tap out both seats using a 1/4 - 20 tap.

8. Install a spare brake line tube nut in the outlet

hole.
Place a flat washer on a one inch screw

(threaded to screw into tapped hole), and thread

screw into threaded hole in tube seat. Hold the

screw to keep it from turning and back out the

tube nut. This will remove the tube seat.

9. Repeat Step 8 above on second tube seat.

10.
Remove the check valves and springs from the cavi-

ties beneath the tube seats.

11.
Remove the primary seal, primary seal protector,

and secondary seals from the secondary piston.

Remove the piston extension screw securing the

primary piston spring to the primary piston. Re-

move the spring retainer, primary seal, primary

seal protector, and secondary seal from the pri-

mary piston.

Cleaning and Inspection

1.
Remove main cylinder casting from vice and inspect

the bore for corrosion, pits, and foreign matter.

Be sure that the outlet ports are clean and free of

brass cuttings from the tube seat removal operation.

2.
Inspect the fluid reservoirs for foreign matter.

Check the bypass and compensating ports to the

cylinder bore to insure that they are not restricted.

Do not use wire to check ports.

NOTE: Before washing parts, hands must be

clean. Do not wash hands in gasoline or oil

before cleaning parts. Use soap and water only.

3.
Use Declene or equivalent to clean all metal parts

thoroughly. Immerse parts in the cleaning fluid and
brush with hair brush to remove foreign matter.

Blow out all passages, orifices, and valve holes. Air

dry the parts and place on clean paper or lint-free

clean cloth.

NOTE: Be sure to keep parts clean until re-

assembly. Rewash parts, if there is any occa-

sion to doubt cleanliness.

4.
Check pistons for scratches or other visual damage;

replace if necessary.

Assembly (Fig. 32)

Use care when reassembling the main cylinder check

valves. Improper assembly of the check valve seats

will result in distortion of the seats. If this occurs,

there will be no check valve action and a loss of brake

pedal travel will result; the pedal will have to be pumped

one or more times before actual car braking occurs.

1.
Place the main cylinder in a vice with the outlet

holes facing up. Place the check valve springs, in

the outlet holes. Be sure the springs are seated

in the bottom of the holes. Place new rubber check

valves over the springs, being careful not to dis-

place the springs from the spring seats.

2.
Place new brass tube seats in the outlet holes. Be

sure seats are not cocked as this would cause burrs

to be turned up as the tube seats are pressed in.

. Thread a spare brake line tube nut into the outlet

hole and turn the nut down until the tube seat bot-

toms.
Remove the tube nut and check the outlet hole

for loose burrs, which might have been turned up

when the tube seat was pressed down. Repeat this

process to bottom the second seat.

3.
Put new secondary seals in the two grooves in the

end of the secondary piston assembly. The seal

which is nearest the end will have its lips facing

toward that end. The seal in the second groove

should have its lips facing toward the portion of

the secondary piston which contains the small com-

pensating holes.

4.
Assemble a new primary seal protector and primary

seal over the end of the secondary piston with the

flat side of the seal seats against the seal protector,

and the protector against the flange of the piston

which contains the small compensating holes.

5.
Assemble the new secondary seal into the groove on

the push rod end of the primary piston. The lips of

this seal should face toward the small compensating

holes in the opposite end of the primary piston.

6. Assemble the new primary seal protector and pri-

mary seal on the end of-the primary piston with the

flat side of the. seal seated against the seal protector,

and the protector against the flange on the piston

which contains the compensating holes.

7.
Assemble the spring retainer in one end of the

primary piston spring and the secondary piston

stop in the other end. Place the end of the spring

over the end of the primary piston with the spring

retainer seats inside of the lips of the primary

seal.

8. Remove all cleaning liquid from the threaded hole

in the primary piston. Place the piston extension

screw down through the secondary piston stop and

the primary spring retainer and screw it into the

primary piston until it bottoms out.

9. Coat the bore of the master cylinder with clean

CHEVROLET CHASSIS SERVICE MANUAL

BRAKES 5-21

brake fluid. Coat the primary and secondary seals

on the secondary piston with clean brake fluid. Insert

the secondary piston spring retainer into the sec-

ondary piston spring. Place the retainer and spring

down over the end of the secondary piston until the

retainer locates inside of the lips of the primary

cup.

10.
Hold the master cylinder with the open end of the

bore down. Push the secondary piston into the bore

until the spring seats against the closed end of the

bore.

11.
Position the master cylinder in a vise with the

open end of the bore up. Coat the primary and

secondary seal on the primary piston with clean

brake fluid. Push the primary piston assembly,

spring end first, into the bore of the master cylinder*

Hold the piston down and snap the lock ring into

position in the small groove in the I.D. of the bore.

12.
Push the primary piston down to move the secondary

piston forward far enough to clear the stop screw

hole in the bottom of the front fluid reservoir. Install

the stop screw.

13.
Install reservoir diaphragm in the reservoir cover

and install the cover on the main cylinder. Push

bail wire into position to secure the reservoir cover.

Installation

1.
Assemble the push rod through the push rod retainer,

if it has been disassembled.

2.
Push the retainer over the end of the main cylinder.

Assemble new boot over push rod and press it down

over the push rod retainer. Slide new mounting

gasket into position.

3.
Secure .the main cylinder to the firewall with mount-

ing bolts.

4.
Connect the push rod clevis to the brake pedal with

pin and retainer.

5. Connect the brake lines to the main cylinder.

6. Fill the main cylinder reservoirs to the levels

shown in Figure 8. Bleed the brake system as out-

lined in this section.

7. K necessary, adjust the brake pedal free play as

outlined in this section.

WHEEL CYLINDER (Fig. 33)

The wheel cylinder boots should be removed from a

cylinder body only when they are visibly damaged or

leaking fluid. Wheel cylinders having torn, cut, or heat-

cracked boots should be completely overhauled.

Removal

1.
Raise vehicle and place on jack stands.

Fig.
33-Chevelle Wheel Cylinder—Exploded View

1.
Push Rod Boot 6. Spring

2.
Piston 7. Piston Cup

3. Piston Cup 8. Piston

4.
Housing 9. Push Rod Boot

5. Fluid Inlet
2.
Remove wheel and tire assembly. Back off brake

adjustment, if necessary, and remove drum.

3.
Disconnect brake system hydraulic line from

cylinder.

4.
Remove brake shoe pull back springs.

5. Remove screws securing wheel cylinder to flange

plate. Disengage cylinder push rods from brake

shoes and remove cylinder.

NOTE:
On Chevrolet, it is necessary to re-

move the anchor pin which holds the front wheel

cylinder to flange plate to remove the front

wheel cylinder.

Disassembly

1.
Remove boots from cylinder ends with pliers and

discard boots.

2.
Remove and discard pistons and cups.

Inspection and Cleaning

NOTE:
Staining is not to be confused with

corrosion. Corrosion can be identified as pits

or excessive bore roughness.

1.
Inspect cylinder bore. Check for staining and corro-

sion.
Discard cylinder if corroded.

2.
Polish any discolored or stained area with crocus

cloth by revolving the cylinder on the cloth sup-

ported by a finger. Do not slide tfce cloth in a

lengthwise manner under pressure.

NOTE:
Before washing parts, hands must be

clean. Do not wash hands in gasoline or oil

before cleaning parts. Use soap and water to

clean hands.

3.
Wash the cylinder and metal parts in Declene or

equivalent.

4.
Shake excess cleaning fluid from the cylinder-. Do

not use a rag to dry the cylinder as lint from the rag

cannot be kept from the cylinder bore surfaces.

5. Check piston for scratches or other visual damage;

replace if necessary.

Assembly (Fig. 33)

1.
Lubricate the cylinder bore and counterbore with

clean brake fluid and insert spring - expander

assembly.

2.
Install new cups with flat surfaces toward outer

ends of cylinder. Be sure cups are lint and dirt free

before insertion. Do not lubricate cups prior to

assembly.

3.
Install new Durex pistons into cylinder with flat

surfaces toward center of cylinder. Do not lubri-

cate pistons before installation.

4.
Press new boots into cylinder counterbores by hand.

Do not lubricate boots prior to installation.

Installation

1.
Position wheel cylinder to brake flange plate. Install

screws and tighten securely.

NOTE:
On Chevrolet front wheels, mount front

wheel cylinders to the brake flange plate by

installing the threaded anchor pin through the

wheel cylinder housing and tighten to 130 lb. ft.

To secure, peen over the flat washer on the

anchor pin.

CHEVROLET CHASSIS SERVICE MANUAL

BRAKES
5-31

POWER BRAKES

INDEX

General Description 5-31

Maintenance
and"
Adjustments 5-31

Inspection . ... 5_31

Lubrication 5-31

Bleeding Instructions . . . 5.31

Air Cleaner Service . . . , 5.31
Page

Component Replacement 5-31

Power Brake Cylinder ......* 5-31

Removal . . 5-31

Disassembly and Assembly See Overhaul Manual

Installation . . . . 5-31

GENERAL DESCRIPTION

The Power Brake Unit is a self-contained hydraulic

and vacuum unit, utilizing manifold vacuum and atmos-

phere pressure for its power.

This unit permits the use of a low brake pedal as well

as less pedal effort than is required with the conventional

(nonpower) hydraulic brake system. Only two external
line connections are necessary -
one
a vacuum connection

from manifold to check valve located on front shell; the

other, a hydraulic connection from the main cylinder

outlet directly into the hydraulic system. The unit is

mounted on the engine side of the fire wall and directly

connected to the brake pedal.

MAINTENANCE AND ADJUSTMENTS

INSPECTIONS

1.
Check vacuum line and vacuum line connections as

well as vacuum check valve in front shell of power

unit for possible vacuum loss.

2.
Inspect all hydraulic lines and connections at the

wheel cylinders and main cylinder for possible

hydraulic leaks.

3.
Check brake assemblies for scored drums, grease

or brake fluid on linings, worn or glazed linings,

and make necessary adjustments.

4.
Check brake fluid level in the hydraulic reser-

voirs.
The reservoirs should be filled to the levels

shown in Figure 8.

5. Check for loose mounting bolts at main cylinder and

at power section.

6. Check air cleaner filter in power piston extension

and replace filter if necessary.

7. Check brake pedal for binding and misalignment

between pedal
-and
push rod.

LUBRICATION

The power brake unit is lubricated at assembly and
needs no further lubrication other than maintaining

normal reservoir fluid level. The reservoir should be

filled as described in this section.

BLEEDING INSTRUCTIONS

The power system may be bled manually or with a

pressure bleeder as outlined in this section. Use only

GM
Supreme 11 Brake Fluid or equivalent. Do not use the

power assist while bleeding. The engine should not be

running and the vacuum reserve should be reduced to

zero by applying the brake several times before starting

the bleeding procedure.

AIR CLEANER SERVICE

Servicing of the air cleaner is recommended and the

element replaced when restriction becomes severe

enough to affect power brake response. At any other

time, if cleaning of the filter is felt necessary, it should

be shaken free of dirt or washed in soap and water and

thoroughly dried.

COMPONENT REPLACEMENT

POWER BRAKE CYLINDER

Removal

1.
Remove vacuum hose from vacuum check valve.

2.
Disconnect hydraulic lines at main cylinder.

Disconnect push rod at brake pedal assembly.

Remove nuts and lock washers securing power unit

to fire wall, and remove power unit from engine

compartment.
3.

4.

NOTE:
Chevy

to fire wall.
has a three stud attachment

Repair procedures for the power cylinder are outlined

in the Brake Section of the Overhaul Manual-for service
of the main cylinder refer to applicable portion of

"Standard Brakes" in this manual.

Installation

1.
Mount the power brake assembly in place and install

the attaching nuts and lock washers.

2.
Attach vacuum line to check valve.

3.
Secure hydraulic lines to main cylinder.

4.
Attach push rod to brake pedal assembly, and check

operation of stop light.

5. Bleed brakes as outlined in this section.

CAUTION: After replacing the unit on the vehi-

cle,
start the engine and allow vacuum to build

up before applying the brake.

CHEVROLET CHASSIS SERVICE

CLUTCH
AND
TRANSMISSIONS
7-23

Assembly (Fig.
4X)

1.
With detent spring tang projecting
up
over
the 3rd

and
4th
shifter shaft cover opening install
the
first

and second detent
cam
onto
the
detent
cam
pivot
pin.

With
the
detent spring tang projecting
up
over
the

first
and
second shifter shaft cover hole install
the

3rd
and 4th
detent
cam,

NOTE:
The 1-2
detent
cam has a
.090" greater

contour
on the
inside detent notch.

2.

3.
Install detent
cam
retaining
"C"
ring
to
pivot shaft,

and hook spring into detent
cam
notches.

Install
1-2 and 3-4
shifter shaft assemblies
in
cover

being careful
not to
damage seals. Install both shift

forks
to
shifter shaft assemblies, lifting
up on
detent
cam
to
allow forks
to
fully seat into position.

4.
Install reverse detent ball
and
spring
to
cover, then

install reverse shifter shaft assembly
to
cover.

5.
Install outer shifter levers, flat washers, lock wash-

ers
and
bolts.

Installation

1.
Shift shifter levers into neutral detent (center) posi-

tion. Position cover gasket
on
case.

2.
Carefully position side cover into place making sure

the shift forks
are
aligned with their respective

mainshaft clutch sliding sleeves.

Install cover attaching bolts
and
tighten evenly
to

specified torque.

Remove filler plug
and add
lubricant specified
in

Section
0, to
level
of
filler plug hole.
3.

4.

ALUMINUM POWERGLIDE

INDEX

Page

General
Description
7-23

Maintenance
and
Adjustments .............. 7—23

Oil
Level Check
7-23

Periodic
Oil
Change
7-24

Periodic
Low
Band Adjustment
7-24

Manual
Shift Linkage Check
and
Adjust
7-24

Floor
Shift Linkage
7-25

Floor
Mounted Control Lever
and

Bracket
Assembly
7-29

Throttle
Valve Linkage
.... 7-29

Neutral
Safety Switch
.. . 7-30

Throttle
Return Check Valve (Dashpot)
7-30

Component
Parts Replacement
7-30

Transmission
Replacement .............. 7—30
Page

Other
Service Operations
7-32

Diagnosis
7-32

Warming
Up
Transmission
7-32

Shop
Warm
Up , 7-32

Road
Warm
Up 7-32

Checking
Fluid Level
and
Condition
7-32

Manual
Linkage
7-32

Oil
Leaks
7-33

Basic
Pressure Checks
7-33

Wide
Open Throttle Upshift Pressure Check
.... 7-33

Idle
Pressure
in
Drive Range
7-33

Manual
"Low"
Range Pressure Check .......
7-33

Drive
Range Overrun (Coast) Pressure
.
.......
7-33

Powerglide
Shift Points
. . 7-35

GENERAL DESCRIPTION

The case
and
converter housing
of the two
speed alumi-

num Powerglide Transmission
is a
single case aluminum

unit. When
the
manual control
is
placed
in the
drive
po-

sition,
the
transmission automatically shifts
to low
gear

for initial vehicle movement.
As the car
gains speed
and

depending
on
load
and
throttle position,
an
automatic shift

is made
to
high gear.
A
forced downshift feature
pro-

vides
a
passing gear
by
returning
the
transmission
to low

range.

The
oil
pump assembly
is a
conventional gear type
and

the
oil
pump housing
is of the
large diameter type acting

as
the
front bulkhead
of the
transmission.
The
torque

converter
is a
conventional three element welded design

bolted
to the
engine flywheel which drives through
a
two-

speed planetary gearset.
The
high clutch assembly
is

typical
of the
designs used
in
this type transmission.
The

aluminum Powerglide uses
an
output shaft mounted
gov-
ernor which requires
a
hole through
the
output shaft.
The

reverse clutch assembly
is a
multiple disc type clutch.

The steel plates
are
splined directly
to the
case while
the

face plates
are
splined
to the
internal
or
ring gear.
The

clutch piston operates within
the
rear portion
of the
case.

The internal diameter
of the
pistoh
is
sealed to
an
integral

hub portion
of the
case rear bulkhead.
The
outside
dia-

meter
is
sealed
to a
machined portion
of the
case.
The

piston
is
hydraulically applied
and is
released
by
separate

coil springs.
The
valve body assembly
is
bolted
to the

bottom
of the
transmission case
and is
accessible
for

service
by
removing
the oil pan
assembly.
The
valve

body consists
of an
upper
and
lower body located
on
either

side
of a
transfer plate.
The
vacuum modulator
is lo-

cated
on the
left rear face
of the
transmission case.
The

modulator valve bore
is
located
in the
upper valve body.

MAINTENANCE
AND
ADJUSTMENTS

OIL LEVEL CHECK

The transmission
oil
level should
be
checked period-

ically
as
recommended
in
Section
0. Oil
should
be
added

only when level
is on or
below
the
"ADD" mark
on the dip

stick with
oil hot or at
operating temperature.
The oil

level
dip
stick
is
located
at the
right rear
of the
engine
compartment. Fill with
oil
specified
in
Section
0.

In order
to
check
oil
level accurately,
the
engine should

be idled with
the
transmission
oil hot and the
control

lever
in
neutral (N) position.

It
is
important that
the oil
level
be
maintained
no

higher than
the
"FULL" mark
on the
transmission
oil

level gauge.
DO NOT
OVERFILL,
for
when
the oil
level

CHEVROLET CHASSIS SERVICE MANUAL

STEERING 9-37

NUT

Fig.
69—Control Valve Ball Stud Seal Replacement

(Service Type)

4.
Center the ball stud, seal and clamp at opening in

adapter housing, then install spacer, bolt and nut.

Removal

1.
Raise the front of the vehicle off the floor and place

it on stands.

2.
Remove the relay rod to control valve clamp bolt.

3.
Disconnect the two pump to control valve hose cdn-

nections and allow fluid to drain into a container,
then disconnect the two remaining valve to power

cylinder hoses.

4.
Remove the retaining nut from the ball stud to pitman

arm connection and disconnect the control valve

from the pitman arm.

5. Turn the pitman arm to the right clear of the control

valve and unscrew the control valve from the relay

rod.

6. Remove the control valve from the vehicle.

Installation

1.
Install the control valve on the vehicle by reversing

the removal procedure.

2.
Reconnect the hydraulic lines, fill the system with

fluid and bleed out air using the procedure outlined

under "Maintenance and Adjustments/' Grease ball

joint.

POWER CYLINDER (Fig. 70)

Chevy II and Corvette

Removal

1.
Disconnect the two hydraulic lines connected to the

power cylinder and drain fluid into a container. Do

not reuse.

2.
Remove cotter pin, nut, retainer and grommet from

power cylinder rod attached to the frame bracket.

3.
Also remove grommet and retainer from bracket if

replacement parts are required.

1.
Snap Ring

2.
End Plug and

Lube Fitting

3.
"O" Ring
Fig.
70—Power Cylinder—Exploded View

4.
Spring

5. Spring Seat

6. Ball Stud
7. Ball Seat

8. Ball Stud Seal

9. Piston Body
10.
Piston Rod Seal

11.
Backup Washer

•12.
Scraper Element
13.
Piston Rod Scraper

14.
Snap Ring

15.
Piston Rod

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