Fisher Chevrolet 13000 series User manual

NOTE
Schedulingrevisionspreventedtheincorporationofservice
procedurereferencespertainingtothe"Z-67"bodystyle
inthisservicemanual.Duetobasicsimilarityindesign,
serviceproceduresspecifiedinthismanualforthe"Z-37"
stylecanbeutilizedwhenservicingthe"Z-67"style,with
afewexceptions.
Forbasicserviceproceduresconcerningthe"Z-67"rear
quarterwindowmechanism,foldingtopadjustment,folding
topstaypaddimensionsorfoldingtopelectricactuator,
refertothe1966FisherBodyServiceManual.TheFolding
TopTrimAssemblyoperationsarethesameasforother
seriesconvertiblesinSection13ofthis1967manual.

GENERALINFORMATION1-1
SECTION1
GENERALINFORMATION
INDEX
SubjectPage
ManualDescription1-1
Introduction1-1
Index1-1
PageandFigureNumbers1-1
ReferenceTabs1-1
Text1-1
Illustrations1-1
BodyNumberPlate1-1
ModelIdentification1-1
Introduction1-1
SubjectPage
BodyStyleNumber1-2
BodyStyleNumberSeries1-2
BodyStyleNumberSuffix1-2
BodyTypeName1-2
BodyTypeLetter1-2
WoodGrainTreatment1-3
Description1-3
Removal1-3
Installation1-3
MANUALDESCRIPTION
INTRODUCTION
Thispublicationcontainstheessentialremoval,
installation,adjustmentandmaintenancepro-
ceduresforservicingall1967FisherBodyStyles.
Thisinformationiscurrentasoftimeofpublica-
tionapproval.
INDEX
Theprecedingpagecontainsa "TableofContents'7
whichliststhesectionnumberandsubjecttitleof
eachmainbodyareasection.Thefirstpagein
eachmainbodyareasectionhasanindextothe
subjectsincludedinthatsection.Analphabetic
indexcoveringtheentiremanualislocatedin
section18.
PAGEANDFIGURENUMBERS
Allpagenumbersandfigurenumbersconsistof
twosetsofdigitsseparatedbya dash.Thedigits
precedingthedashidentifythemainbodyareasec-
tion. Thedigitsfollowingthedashrepresentthe
consecutivepagenumberorfigurenumberwithin
theparticularbodyareasection.
REFERENCETABS
Thefirstpageofeachsectionismarkedwitha
ready-referenceblacktabcorrespondingwiththe
tableofcontentspage.
TEXT
Unlessotherwisespecified,eachserviceprocedure
coversallbodystyles.Procedurescoveringspeci-
ficstylesareidentifiedbythestylenumber,body
seriesnumber,bodytypeletterorsimilardesigna-
tion. A descriptionofthesedesignationsiscovered
inthissectionunder"ModelIdentification".
ILLUSTRATIONS
Wherepossible,illustrationsareplacedinclose
proximitytotheaccompanyingtextandshouldbe
usedaspartofthetext.
BODYNUMBERPLATE
Thebodynumberplateidentifiesthebodystyle,
bodyassemblyplant,bodynumber,trimcombina-
tionnumber,paintcodeandtimebuiltcode(Fig.
1-1).OnCorvairstyles,thebodynumberplateis
attachedtotheleftsideofthemotorcompartment
crossrail.OnCadillac"C" & "D" styles,the
plateislocatedontheleftupperportionofthe
horizontalsurfaceofthecowl.Onallothercars,
theplateislocatedontheleftupperportionofthe
verticalsurfaceofthedashfirewall.
MODELIDENTIFICATION
INTRODUCTION
Duetothewidevarietyofbodystylesavailable,
certainbodystyleshavebeengroupedinthis
publicationasanaidtoidentification.Thesegroup
designationsmaybeusedindividuallyorinvarious
combinations.Anexplanationoftheprincipalcate-
goriesfollows:

1-2GENERALINFORMATION
BODYSTYLENUMBER
Thebodystylenumberconsistsoffivedigitsas
theyappearonthebodynumberplate.(Referto
previoussectionforbodynumberplatelocation.)
Thebodystylenumberisusedtoincludeorexclude
aspecificstyle(ex.on16637,use; onall
styles, exceptthe68069style,use).
BODYSTYLENUMBERSERIES
49-4doorsedanhardtop
55-4doorstationwagontwoseatwithskylight
57-2doorsportcoupehardtop
65-4doorstationwagonthreeseatwith
skylight
67-2doorconvertiblecoupe
69- 4 doorsedanwithpillarpost(somemodels
equippedwithdoorwindowframes)
80-2doorpick-updelivery
87- 2 doorsportcoupehardtop(plainback)
Thebodystylenumberseries
indicatethreepossibilities:maybeusedto
Division- firstdigitandfourzeros(ex.10000
Chevrolet;20000Pontiac).
DivisionandCarLine- firsttwodigitsand
threezeros(ex.33000OldsmobileF 85;45000
BuickLeSabre).
Division,CarLineandStyleGroup- Firstthree
digitsandtwozeros(ex.25200Catalina;25600
StarChief).
BODYSTYLENUMBERSUFFIX
Thelasttwodigitsofthebodystylenumberindi-
catebodytypeasfollows:
07-2doorsportcoupewithpillarpost
(strutback)
11-2doorsedanwithpillarpost
17-2doorsportcoupehardtop(strutback)
23-4doorsedanwithauxiliarycenterseat
33-4doorsedanwithauxiliarycenterseat
andcenterpartitionwindow
35-4doorstationwagontwoseat
37-2doorcoupehardtop
39-4doorsedanhardtop
45-4doorstationwagonthreeseat
47-2doorsportcoupehardtop
DIVISIONSERIES-i
TIMEBUILTCODE
MODELYEAR
— BODYTYPE
-ASSEMBLYPLANT
-UNITNUMBER
STCTORJCORP
65-12345FBD123456BODY
123-A A-APAINT
o
TRIMNUMBER-
)DYBYFISHERO
UPPERBODYCOLOR,
ORFOLDINGTOP
ORROOFCOVER
-LOWERBODYCOLOR
Fig. 1-1—Body NumberPlate
BODYTYPENAME
Bodytypenamesareusedforgroupclassification
asfollows(stylenumbersuffixshowninbrackets):
ClosedStyle
Twodoorsedan(11)
Twodoorsportcoupe(07)
Fourdoorsedan(69)
Limousine(23,33)
HardTop
Sportcoupehardtop(17,47,57,87)
Coupehardtop(37)
Sedanhardtop(39,49)
StationWagon
Stationwagontwoseat(35lessskylight;55
withskylight)
Stationwagonthreeseat(45lessskylight;65
withskylight)
ConvertibleCoupe(67)
SedanDelivery(80)
BODYTYPELETTER
Basicbodytypescanbeidentifiedbygenericgroup
classificationsasfollows:
"A" - Chevrolet13000Series
Pontiac23-24000Series
Oldsmobile33000Series
Buick43-44000Series
"B" - Chevrolet15-16000Series
Pontiac25-26000Series
Oldsmobile35000Series
Buick45-46000Series
"C" - Oldsmobile384-386-39800Series
Buick482-48400Series
Cadillac68000Series
"D" - Cadillac69700Series

GENERALINFORMATION1-3
"E" - Oldsmobile394-39600Series
Buick49000Series
Cadillac69300Series
"F'; - Chevrolet12000Series
"X"- Chevrolet11000Series
"Z" - Chevrolet10000Series
WOODGRAINTREATMENT
STATIONWAGONSANDSEDANDELIVERY
DESCRIPTION
Thewoodgraintransferfilmisa vinylmaterial
witha pressuresensitiveadhesivebacking.The
transfersareservicedinpre-cutpanels.
REMOVAL
Removethemoldingsfromtheaffectedpanel(see
MoldingSection17).Thetransferfilmmaythen
beremovedbyliftinganedgeandpeelingthe
materialfromthepaintedsurface.Exercisecare
soasnottodamagethepaint.
NOTE: Applicationofheattothetransferand
thepanelbymeansofa heatgunorheatlamp
willaidintheremoval.
INSTALLATION
Preparationofthesurfacetowhichthetransfer
willbeappliedisveryimportant.Incaseswhere
bodymetalrepairhasbeenmade,itisnecessary
toprimeandcolorcoattheseareastoblendwith
theundamagedsurface.Applythetransferfilmto
colorcoatedpanelsonly,nevertobaremetalor
primer.Thesurfacemustbefreeofanyimper-
fectionsthatmayhigh-lightthroughthefilm.Re-
movedirtnibsandotherforeignmaterialinthe
paintbylightsandingwith600gritsandpaper.
Thetemperatureofthebodymustbemaintainedat
amoderatelevelbetweenapproximately65and90
degrees.Toowarma bodywillcausethewood
grainfilmtostickprematurelywhiletoocoola
bodywillreducetheadhesionofthewoodgrain
film. Coolthebodypanelwithcoolwaterwhentoo
warmandheatthebodypanelwitha heatgunor
aheatlampwhentoocold.Justpriortoapplication
ofthetransferfilmcleanthepaintedsurfacewith
anon-petroleumbasevolatilecleanerandallowto
dry.
Thefollowingaretherecommendedstepsforeasy
applicationofthefilm.
1. Cutthepaperbackingtheentirewidthofthe
transferattheapproximatecenterlineofthe
filmexercisingcarenottodamagethetransfer
film.
2. Peelthepaperbackingfromonehalfofthe
film.
3. Aligntheupperedgeofthehalfofthefilmwith
thepaperbackingtotheloweredgeofthe
piercedmoldingholesmakingsurethatthe
transferiscenteredonthepanel.
4. Startingatthecenterofthetransferandusing
awaterdampenedrag,pressthathalfofthe
transferwiththebackingremovedontothe
panel.Workoutboardfromthemiddletothe
edges. Removeallairbubbles.
NOTE: Thetransfercanbepulledbackfrom
thepanelandreinstallediflargeairpockets
develop.Exercisecarenottostretchthema-
terial.Smallairbubblesmayberemovedby
piercingthefilmatthebubblewitha pinand
pressingthebubbledown.
5.Removethebackingfromtheotherhalfofthe
transfer.Applythishalfinthesamemanner
workingfromthecentertotheendandfrom
themiddletotheupperandloweredges.
6.Foldthetransferoverthedoororquarter
edgesandpresstothehemmingflanges.Ap-
plicationofheatwitha heatlamporheatgun
willaidinfoldingthetransferovertheedge.
NOTE: Ifthetransferfilmwillnotadhereto
theflange,brusha clearvinyladhesivetothe
backedgeofthefilmandreapply.
7.Reinstallthemoldings.

LUBRICATION 2-1
SECTION 2
LUBRICATION
Subject
InstrumentPanelCompartmentDoor
FrontDoorHingeHold-OpenAssembly . . . .
RearDoorHingeHold-OpenAssembly
DoorLockForkBolt and RotaryBolt
DoorLockStriker
DoorJambSwitch
DoorLockMechanism and LockParts
FrontCompartment Lid Lock
DoorWindowRegulator and Cams - Styles
withUpperFrames
DoorWindowRegulatorCams and Guides - Styl(
withoutUpperFrames
INDEX
PageSubject
2-1
2-1
2-1
2-1
2-1
2-2
2-2
2-2
2-2
2-2
DESCRIPTION
Themovablemechanicalparts ofthe body arelu-
bricated atthe factory to insureproper and quiet
operation. If additionallubrication is required, the
followingspecifiedmaterials or theirequivalents
should be used atthe locationslisted.
INSTRUMENTPANELCOMPARTMENT
DOORHINGE
Wipe off dirt and apply a sparingamount of dripless
oil tothe hingefrictionalpoints.Operatedoor and
wipe off excesslubricant.
FRONTDOORHINGEHOLD-OPEN
ASSEMBLY
Wipe off dirt and applyengine oilto pointsindicated
(Fig. 2-1).
Page
RearQuarterWindowRegulatorCams and Guides. 2-4
RearCompartment Lid Lock 2-5
RearCompartmentHinges and TorqueRods ...2-5
TailGateWindowRegulator and Cams
(StationWagon) 2-5
TailGateLockStriker(StationWagon) 2-5
TailGateHinges(StationWagon) 2-5
GasTankFillerDoorHinge 2-5
FoldingSeatLinkage 2-5
FrontSeatAdjusterMechanism 2-6
Convertible Top Linkage 2-6
I
Fig. 2-1 —FrontDoorHingeHold-OpenAssembly
Fig. 2-2 —RearDoorHingeHold-OpenAssembly
REARDOORHINGEHOLD-OPEN
ASSEMBLY
Wipe off dirt and apply a lightcoat of Lubriplate
tofrictionalpoints (Fig.2-2). Wipe off excess
lubricant.
DOORLOCKFORKBOLTAND
ROTARYBOLT
Wipe off dirt and apply a thincoat of stick-type
lubricant andoil(Fig.2-3and2-4).
DOORLOCKSTRIKER
Wipe off dirt and apply a thincoat of stick-type
lubricant totop surface of strikerteeth at areas
indicated (Fig.2-5).

2-2LUBRICATION
Fig. 2-3—DoorLockForkBoltandRotaryBolt
DOORJAMBSWITCH
Wipeoffdirtandapplya thincoatofLubriplateto
endsurfaceofswitchplungerandremoveexcess
lubricant.
DOORLOCKINGMECHANISMAND
LOCKPARTS
ApplyLubriplatetopivotpointsatendsofcon-
nectingrodsandmovingpartsoflock.
FRONTCOMPARTMENTLIDLOCK
Onfrontcompartmentlidlockapplya thincoatof
Lubriplatetocontactpointasindicated(Fig.2-6).
DOORWINDOWREGULATORAND
CAMS—STYLESWITHUPPERFRAMES
Applya coatofLubriplatetoareasindicated,(Fig.
2-7).Lubricationoffrontandreardoorswithup-
perframesistypical.
DOORWINDOWREGULATORCAMS
ANDGUIDES—STYLESWITHOUT
UPPERFRAMES
Applya coatofLubriplatetoareasindicated.(Fig.
2-8).Lubricationoffrontandreardoorswithout
upperframesistypical.
Fig. 2-4—DoorLockForkBoltandRotaryBolt
Fig. 2-5-DoorLockStriker

LUBRICATION2-3
Fig. 2-7—DoorWindowRegulatorandCams
OnStylesWithUpperFrames
Fig. 2-6—FrontCompartmentLidLock
LUBRIPLATE
LUBRIPLATE'
n
SECTIONA.A1364
Fig. 2-8—DoorWindowRegulatorandCamsOnStylesWithoutUpperFrames

2-4LUBRICATION
Fig. 2-9 —RearQuarterWindowRegulator
Cams and Guides
SECTION A-A
Fig. 2-11 —TailGateWindowRegulator and Cams
(StationWagons)
REARQUARTERWINDOWREGULATOR
CAMSANDGUIDES
Apply a coat of Lubriplate to regulator,cams and
guides.Lubricationshown is typical of points to
belubricated on otherquarterwindowregulators,
etc. (Fig.2-9).
STICKTYPELUBRICANT
Fig. 2-10—RearCompartment Lid Lock
Fig. 2-12—TailGateLockStrikerStationWagon

LUBRICATION 2-5
DRIPLESS OIL
1365
DRIPLESS OIL
2314
Fig. 2-14—Convertible Top Linkage -
(ManualTypeShown)•A"Styles
Fig. 2-13-Convertible Top Linkage - "BandC" Styles
REARCOMPARTMENTLIDLOCK
Apply a thincoat of Lubriplate to lockbolt (Fig.
2-10).
REARCOMPARTMENTHINGESAND
TORQUERODS
ApplyLubriplate andor dripless oilto frictional
points as required.Wipe off excesslubricant.
TAILGATEWINDOWREGULATORAND
CAMS(stationwagon)
ApplyLubriplate to areasindicated (Fig. 2-11).
TAILGATELOCKSTRIKER
(stationwagon)
Apply a thincoat of stick-typelubricant to surface
ofstrikerteeth.Afterlubrication,closetailgate
severaltimes and removeexcesslubricant (Fig.
2-12).
TAILGATEHINGES(stationwagon)
Apply a sparingamount of dripless oilto frictional
parts, worktailgateseveraltimes and remove ex-
cesslubricant.
GASTANKFILLERDOORHINGE
Apply a few drops of dripless oilto frictionalpoints
ofdoorhinge,workdoorseveraltimes and remove
excesslubricant.
FOLDINGSEATLINKAGE
Wipe off dirtandapply a sparingamount of dripless
oil toall frictionalareas.Worklinkageseveral
times and wipe off excesslubricant.

2-6LUBRICATION
1• DRIPLESSOIL
2- LUBRIPLATE
FRONTSEATADJUSTERMECHANISM
(ManuallyandElectricallyOperated)
Thoroughlywipeoffoldlubricant.Applya thin
coatoflubriplatetojackscrewsandtracks.Oper-
ateseattolimitsofallpositions.Applya small
amountofdriplessoiltolinkageandwipeoff
excesslubricant.
CONVERTIBLETOPLINKAGE
ApplyLubriplateordriplessoiltopointsindicated
(Fig.2-13,2-14and2-15).Wipeoffexcesslubri-
canttopreventsoilingtrim.
Fig. 2-15—ConvertibleTopLinkage- "F"Styles

UNDERBODY3-1
SECTION3
UNDERBODY
INDEX
SubjectPage
UnderbodyAlignment- Corvair
GeneralConstruction3-1
UnderbodyGeneralService3-1
AlignmentChecking
BodyTramGage3-2
ReferencePointDimensions3-2
HorizontalDimensions3-3
VerticalDimensions3-5
UnderbodyAlignment- ChevyII3-5
GeneralConstruction3-5
UnderbodyGeneralService3-6
AlignmentChecking3-7
BodyTramGage3-7
SubjectPage
PrinciplesofTramming3-7
CarPreparation3-7
TrammingSequence3-8
ReferencePointDimensions3-8
HorizontalDimensions- FrontEndSkirt. . 3-9
HorizontalDimensions- Body3-10
VerticalDimensions. . . 3-11
CowlandDashDimensions3-12
UnderbodyAlignment-"F"BodyStyles3-12
Description3-12
ReferencePointDimensions3-12
HorizontalDimensions3-12
VerticalDimensions3-14
UNDERBODYALIGNMENT
AllCorvairStyles
GENERALBODYCONSTRUCTION
Thebodydesignusedonthe10000seriesisofan
integral,allsteel,weldedconstruction,commonly
knownas"unitized"bodyconstruction.Theover-
allrigidityofthebodyisdrawnfromeachofthe
individualmetalcomponentswhich,whenwelded
together,comprisethebodyshellassembly.Panels
formingtheunderbodyareaincorporateattachment
provisionsforthepowertrainandthesuspension
systems.Thesepanels,therefore,contributethe
greatestamountofstrengthtothebodyassembly.
UNDERBODY
GENERALSERVICEINFORMATION
Theunderbodyassemblyiscomprisedofframe
siderails,framecrossrails,floorpancrossbars,
innerandouterrockerpanelsandotherfloorpanel
components.Theunderbodyisofall-weldedcon-
struction.Theslightestmisalignmentintheunder-
bodycanaffectdoor,frontcompartmentlid,and
enginecompartmentlidfits.Mostimportant,how-
ever,underbodymisalignmentcaninfluencethe
suspensionsystem,therebycausingmanyofthe
problemsthatarisefroma suspensionmisalign-
ment.Itisessential,therefore,thatunderbody
alignmentbeexacttowithin1/16"ofthespecified
dimensions.
Intheeventofcollisiondamageitisimportantthat
underbodyalignmentbethoroughlycheckedand,if
necessary,realignedinordertoaccuratelyestab-
lishsuspension,steeringandenginemountinglo-
cations.Therearemanyclassificationsoftools
thatmaybeemployedtocorrecttheaveragecolli-
siondamagesituationincludingframestraightening
machines,lighterexternalpullingequipmentand
standardbodyjacks.
Frametoolsarenotconsideredasessentialequip-
mentforaveragecollisionrepairoperations;how-
ever,therewillbemanysituationswiththis
unitizedtypeofconstructionaswithothertypesof
frameconstruction,whereframeequipmentwillbe
required.Therearealsoareasofrepairwhere,
eventhoughnotessential,frameequipmentmay
provebeneficial.
IMPORTANT:Sinceeachindividualunderbody
componentcontributesdirectlytotheover-all
strengthofthebody,itisessentialthatproper
welding,sealingandrustproofingtechniquesbe
observedduringserviceoperations.Underbody
componentsshouldberust-proofedwhenever
bodyrepairoperations,whichdestroyordamage
theoriginalrust-proofing,arecompleted.Par-
ticularlycriticalaretheenclosedboxareas.
Whenrust-proofingcriticalunderbodycom-
ponents,itisessentialthata goodqualitytypeof
airdryprimerbeused(suchascorrosionre-
sistantzincchromate).Itisnotadvisableto
usecombinationtypeofprimersurfacers.
Toassistincheckingalignmentoftheunderbody
components,repairingminorunderbodydamageor
locatingreplacementparts,thefollowingunderbody
dimensionsandalignmentcheckinginformationis
presented.

3-2UNDERBODY
llllllllllllilll
|I|I|1|I|HHH1|
CENTERDRILL
ASSHOWN
1844
Fig. 3-1-TramGageCenteringBolt
ALIGNMENTCHECKING
BodyTramGageINFORMATION
Anaccuratemethodofdeterminingthealignmentof
theunderbodyutilizesa measuringtramgage.
Thetramgagerequiredtoperformallrecom-
mendedmeasuringchecksproperlymustbecapable
ofextendingtoa lengthof102".Atleastoneofthe
verticalpointersmustbecapableofa maximum
reachof18".
DimensionsshownintheupperportionofFigure
3-2arecalculatedona horizontalplaneparallel
totheplaneoftheunderbody.Precisionmeasure-
mentscanbemadeonlyifthetramgageisalso
paralleltotheplaneoftheunderbody.Thiscan
becontrolledbysettingtheverticalpointersonthe
tramgageaccordingtothedimensionsshownin
thelowerportionofFigure3-2.
Apropertrammingtoolisessentialforanalyzing
anddeterminingtheextentofcollisionmisalign-
mentpresentinunderbodyconstruction.
Tofacilitatecenteringthetramgagepointersat
thesuspensionlocations,specialcenteringbolts
(samesizeandthreadasoriginalattachingbolts)
maybepreparedasshowninFigure3-1.Usecen-
terofbolt threaddiameterforcenteringdrill
point.Depthofdrilled-outconeshouldbethesame
forallcenteringboltsbeingusedasa "set".
UnderbodyAlignmentReference
PointDimensions—(Fig.3-2)
Dimensionstogageholesandotherunthreaded
holesaremeasuredtodeadcenteroftheholesand
RIGHTSIDE
T
LINE
Fig. 3-2—UnderbodyVerticalAlignmentRef.Points

UNDERBODY3-3
flushtotheadjacentsurfacemetal.Dimensionsto
bodyfronttiedownslotsaremeasuredtothefront
centerlineedgeoftheslot(seeFig.3-3).Dimen-
sionstoboltorboltholelocationsaremeasured
tothedeadcenterofthethreaddiameterofthe
boltorbolthole,unlessspecifiedotherwise.
Thefollowingreferencepointsarekeylocations
andshouldbeusedwhereverpossibleasa basis
forcheckingotherreferencepoints:
1. Frontsuspensionfrontattachingboltholesor
boltheads.
2. 3/4inchmastergageholeinmotorcompart-
mentsiderail-to-rockerpanelbrace.
3. Rearsuspensioncontrolarmlowerandupper
outerattachingboltholes(upperedgeofholes).
HorizontalDimensions
(Fig. 3-2)
Fig.
Ref.DimensionLocation
A33-7/8Centeroffrontbumperlower
attachingboltholes.
B24-3/8Directlybelowcenteroffront
bumperlowerattachingbolthole
andfrontsuspensionfrontat-
tachingboltheadorboltholeon
samesideofbody.
C39-1/16Directlybelowcenteroffront
bumperlowerattachingbolthole
andfrontsuspensionfrontat-
tachingboltholeorboltheadon
oppositesideofbody.
D15-7/83/4"holeinfrontcompartment
siderailandfrontsuspension
frontattachingboltholeorbolt
headonsamesideofbody.
E35-9/163/4"holeinfrontcompartment
siderailandfrontsuspension
frontattachingboltholeorbolt
headonoppositesideofbody.
F463/4"holeinfrontcompartment
siderailandbodytiedownslot
onsamesideofbody(usefront
centerofslotofsiderailmetal
-SeeFig.3-3).
G59-29/323/4"holeinfrontcompartment
siderailandbodytiedownslot
onoppositesideofbody(use
frontcenterofslotofsiderail
metal- SeeFig.3-3).
FRONTOFCAR
REFERENCEPOINT
EDGEOFRAILMETAL)
EDGEOFREINFORCEMENT
INSIDERAIL
1894
Fig. 3-3—FrontBody-TieDownSlot
Fig.
Ref.Dimension
H31-7/8
Location
Lowerinneredgeofsteering
gearreinforcementdirectlybe-
lowcenterofsteeringgearfront
attachingbolthole(Fig.3-4)and
lowerinneredgeoffrontcom-
partmentrightsideraildirectly
belowcenterofsteeringgear
idlerarmsupportlowerattach-
ingbolthole(Fig.3-5).
FRONTOFCAR
STEERINGGEAR
FRONT
STEERINGGEAR
REINFORCEMENT
REFERENCEPOINT(DIRECTLY
BELOWCENTEROFBOLT)
1896
Fig. 3-4—Ref. PointatSteeringGearReinforcement

3-4UNDERBODY
STEERING IDLER
ARMBOLT
REFERENCE POINT
(DIRECTLY BELOWBOLT)
1869
Fig.3-5—Ref.PointatSteeringIdlerArm
Location
Fig.
Ref.Dimension
I31-15/16Lowerinneredgeofsteering
gearreinforcementdirectlybe-
lowcenterofsteeringgearfront
attachingbolthole(Fig.3-4)and
frontsuspensionfrontattaching
boltholeorboltheadonop-
positesideofbody.
J31-1/32Lowerinneredgeoffrontcom-
partmentrightsideraildirectly
belowcenterofsteeringgear
idlerarmsupportlowerattach-
ingbolthole(Fig.3-5)and
frontsuspensionfrontattaching
boltholeorboltheadonop-
positesideofbody.
K27-9/16Frontsuspensionfrontattaching
boltholeorbolthead.
L45-23/32Frontsuspensionfrontattaching
boltholeorboltheadandbody
fronttiedownslotonopposite
sideofbody(usefrontcenterof
slotofsiderailmetal- See
Fig.3-3).
M96-1/8Frontsuspensionfrontattaching
boltholeorboltheadonop-
positesideofbodyand3/4"
mastergageholeinmotor
compartmentsiderail-to-
rockerpanelbrace.
N89-9/16Frontsuspensionfrontattaching
boltholeorboltheadand3/4"
mastergageholeinmotor
compartmentsiderail-to-
rockerpanelbraceonsameside
ofbody.
Fig.
Ref.Dimension
O31-3/8
40-3/16
72
58-13/32
S98-1/8
T101-3/8
U91-3/8
94-7/8
W44
Location
Frontsuspensionfrontattaching
boltholeorboltheadandbody
fronttiedownslotonsameside
ofbody(usefrontcenterofslot
ofsiderailmetal- SeeFig.
3-3).
Bodyfronttiedownslot(use
frontcenterofslotofsiderail
metal- SeeFig.3-3).
Bodyfronttiedownslot(use
frontcenterofslotofsiderail
metal- SeeFig.3-3)and3/4"
mastergageholeinmotor
compartmentsiderail-to-
rockerpanelbraceonopposite
sideofbody.
Bodyfronttiedownslot(use
frontcenterofslotofsiderail
metal- SeeFig.3-3)and3/4"
mastergageholeinmotor
compartmentsiderail-to-
rockerpanelbraceonsameside
ofbody.
Frontsuspensionfrontattaching
boltholeorboltheadandrear
suspensioncontrolarmlower
outerattachingbolthole(upper
edgeofhole)onoppositesideof
body.
Frontsuspensionfrontattaching
boltholeorboltheadandrear
suspensioncontrolarmupper
outerattachingbolthole(upper
edgeofhole)onoppositesideof
body.
Frontsuspensionfrontattaching
boltholeorboltheadandrear
suspensioncontrolarmlower
outerattachingbolthole(upper
edgeofhole)onsamesideof
body.
Frontsuspensionfrontattaching
boltholeorboltheadandrear
suspensioncontrolarmupper
outerattachingbolthole(upper
edgeofhole)onsamesideof
body.
3/4" mastergageholeinmotor
compartmentsiderail-to-
rockerpanelbrace.

UNDERBODY 3-5
Fig.
Ref.Dimension
X38-15/16
67-1/2
55-1/32
Location
Outsideedgeofmotorcompart-
mentsideraildirectlybelow
transmissionsupportupper at-
tachingbolt.
NOTE:Thisdimension is con-
stantrearward to motor
compartmentrearcrossrail.
3/4"mastergageholeinmotor
compartmentsiderail-to-
rockerpanelbrace and lower
edge of jointofmotorcompart-
mentsiderail and motor
compartmentrearcrossrailon
oppositesideofbody.
3/4"mastergageholeinmotor
compartmentsiderail-to-
rockerpanelbrace and lower
edge of jointofmotorcompart-
mentsiderail and motor
compartmentrearcrossrailon
samesideofbody.
12-9/32Frontedge of3/4" diameter
painthole.
11-19/32Lowerinneredge of steering
gearreinforcementdirectlybe-
lowcenter of frontattaching
bolthole(Fig.3-4).
Fig.
Ref.Dimension
d11-17/32
12-13/32
11-13/16
10-1/4
9-3/4
g6
6-13/16
AA41-5/32Rearbumperlowerattaching
holes.
VerticalDimensions
(Fig.3-2)
Fig.
Ref.
a
Dimension
15-3/16
Location
Center of frontbumperlower
attachingboltholes.
i
j
k
1
o-o/o
12-3/8
13-13/32
18
m15-3/32
Location
Lowerinneredgeoffrontcom-
partmentrightsideraildirectly
belowcenter of steeringidler
armsupportlowerattachingbolt
hole(Fig.3-5).
Frontsuspensionfrontattaching
hole(frontsuspensionremoved).
Frontsuspensionfrontattaching
bolt (suspensioninstalled).
Frontsuspensionrearattaching
hole(frontsuspensionremoved).
Frontsuspensionrearattaching
bolt(suspensioninstalled).
Lowersurfaceoffrontcompart-
mentsiderail at bodyfronttie
downslot(frontcenterofslot).
Fig.3-3.
3/4"mastergageholeinmotor
compartmentsiderail-to-
rockerpanelbrace.
Rearsuspensioncontrol arm
lowerouterattachingbolthole
(upperedgeofhole).
Rearsuspensioncontrol arm
upperouterattachingbolthole
(upperedgeofhole).
Transmissionsupportupperat-
tachingbolt hole or bolthead.
Lowersurface of motorcom-
partmentsiderail ata point 1
inchrearward of readedge
ofmotorcompartmentcorner
reinforcement.
Lowersurface of motorcom-
partmentsiderailadjacent to
frontedge of motorcompart-
mentrearcrossrail.
UNDERBODYALIGNMENT
Chevy II Styles
GENERALBODYCONSTRUCTION
Description
Chevy II seriesbodiesareofunitizedconstruction
withprovisions for theattachmentofanindepend-
entfrontendskirtassembly.Thefrontendskirt
assemblyincorporatesattachmentprovisions for
thefrontendsheetmetal,frontsuspensionsystem,
engineandothermechanicalcomponents.There-
movablefront end skirtassembly is covered in
detail inthe "FRONTENDSKIRTASSEMBLY"
sectionofthechassismanual.
Thebody isof integralallsteel,weldedconstruc-
tion. The over-allrigidity of thebody is drawn

3-6UNDERBODY
Fig. 3-6—Skirt-to-DashMounting
fromeachoftheindividualmetalcomponents
which,whenweldedtogether,comprisethebody
shellassembly.Panelsformingthecowlanddash
andunderbodyincorporateattachmentprovisions
forthefrontendskirtassemblyandrearsuspen-
sionsystem.Thesepanels,therefore,contribute
thegreatestamountofstrengthtothebody
assembly.
UNDERBODYGENERAL
SERVICEINFORMATION
Sinceeachindividualunderbodycomponentcon-
tributesdirectlytotheover-allstrengthofthe
body,itisessentialthatproperwelding,sealing
andrust-proofingtechniquesbeobservedduring
serviceoperations.Underbodycomponentsshould
berust-proofedwheneverbodyrepairoperations,
whichdestroyordamagetheoriginalrust-proofing,
arecompleted.Whenrust-proofingcriticalunder-
bodycomponents,itisessentialthata goodquality
typeofairdryprimerbeused(suchascorrosion
resistantzincchrornate).Itisnotadvisabletouse
combinationtypeprimersurfacers.
1840
Fig. 3-7—HorizontalandVerticalDimensions(FrontSkirtAssembly)

UNDERBODY3-7
ALIGNMENTCHECKINGPROCEDURE
Theunderbodyiscomprisedofbodydashfront
braces,bodyfloorpancrossbraces,bodycom-
partmentpansiderails,innerandouterrocker
panelsandotherfloorpanelcomponents.The
underbodyisofallweldedconstruction.Misalign-
mentintheunderbodycanaffectfrontfender,door,
rearcompartmentlidandglassopeningalignment,
stationwagontailgateandbackbodyopening
alignments.Mostimportant,however,underbody
misalignmentcaninfluencethesuspensionsystem,
therebycausingmanyoftheproblemsthatarise
froma suspensionmisalignment.Itisessential,
therefore,thatunderbodyalignmentbeexactto
within1/16"ofthespecifieddimensions.
Intheeventofcollisiondamage,itisimportant
thatunderbodyalignmentbethoroughlychecked
and,ifnecessary,realignedinordertoaccurately
establishproperdimensions.Therearemany
classificationsoftoolsthatmaybeemployedto
correcttheaveragecollisiondamagesituation
includingframestraighteningmachines,lighter
externalpullingequipmentandstandardbodyjacks.
NOTE:Minormisalignmentofthefrontend
assemblytothebodymaybecorrectedbyadding
orremovingshimsattheupperskirt-to-dash
attachingsurface.Figure3-6showsbothupper
andlowerattachmentandtheinstalledposition
oftheshims.Shimsareavailablein1/32"and
1/8"thickness.
CAUTION:Donotchangeskirtassembly-to-
dashshimminginanefforttoadjustthe
door-to-fendergaporanyothersheetmetal
appearanceitem.Theseshimsregulatethefront
endassemblyrelationshiptothebodyandshould
onlybeusedtocorrectdimensionsasshownin
Figures3-7and3-8.
Toassistincheckingalignmentoftheunderbody
components,repairingminorunderbodydamageor
locatingreplacementparts,thefollowingunderbody
dimensionsandalignmentcheckinginformationis
presented.
BodyTramGage
Anaccuratemethodofdeterminingthealignment
oftheunderbodyutilizesa measuringtramgage.
Thetramgagerequiredtoperformallrecom-
mendedmeasuringchecksproperlymustbecapable
ofextendingtoa lengthof91".Atleastoneofthe
verticalpointersmustbecapableofa maximum
reachof17".
Horizontaldimensionsshownintheupperportion
ofFigures3-7and3-8arecalculatedona plane
paralleltotheplaneoftheunderbody.Precision
measurementscanbemadeonlyifthetramgage
isproperlyadjustedsoastoremainparallel
totheplaneoftheunderbodyduringmeasuring
operations.
Apropertrammingtoolisessentialforanalyzing
anddeterminingtheextentofcollisionmisalign-
mentpresentinunderbodyconstruction.
PrinciplesofTramming
Intheupperportionof3-7and3-8allreference
locationsshownaresymmetricalaboutthecenter-
lineofthevehicle.Forexample,whenperforming
across-checkofthebodyfloorpanarea,dimen-
sion"N;;shouldmeasurethesamedistanceinboth
diagonaldirectionsofthecross-checkoperation.
Crosscheckingoperationsareusedtodetermine
therelationshipbetweentwolocationsonthe
underbody.
Tomeasurethedistanceaccuratelybetweenany
tworeferencepointsontheunderbody,twospecifi-
cationsarerequired:
a.Thehorizontaldimensionbetweenthetwo
pointstobetrammed.
b. Theverticaldimensionfromthedatumlineto
thepointstobetrammed.Asanexample,the
diagonalmeasurement(calculatedona hori-
zontalplane)betweenreferencepointsofdi-
mensionline"N",showninFigure3-8,is
7825/32inches.Thespecificationsfromthe
datumlinehavea verticalheightdifferenceof
35/16inchesbetweentheforwardlocationof
dimension"N"(atverticaldimension"e")
andtherearwardlocationofdimension"N;;
(atverticaldimension"h").Thevertical
pointerusedattheforwardlocationshould
bepositionedsoastoextend3 5/16inches
furtherfromthetrambarthanthepointer
usedattherearwardlocation.Withtheproper
settingsthetrambarwillbeona plane
paralleltothatofthebodyplane.Theexcep-
tiontothiswouldbewhenoneofthereference
locationsisincludedinthemisalignedarea;
thentheparallelplanebetweenthebodyand
thetrambarmaynotprevail.Aftercompletion
oftherepairs,thetramgageshouldbesetat
thespecifieddimensiontochecktheaccuracy
oftherepairoperation.
CarPreparation
Preparingthecarfortheunderbodyalignment
checkinvolvesthefollowing:
1. Placethecaronlevelsurface.
2. Theweightofthecarshouldbesupportedat
thewheellocations.

3-8UNDERBODY
Fig. 3-8—HorizontalandVerticalDimensions(BodyAssembly)
3.Avisualdamageinspectionshouldbemadeto
eliminateneedlessmeasuring.Obviouslydam-
agedormisalignedareascanoftenbelocated
bysight.
Tramming Sequence
Thetrammingsequencewillvarydependingupon
thenatureandlocationofthemisalignedarea.
Priortoperforminganytrammingoperation,the
accuracyofreferencepointstobeusedmustbe
determined.A measurementthatoriginatesfroma
referencepointwhichisincludedina damaged
areawillproduceuntrueresultsandconfusethe
evaluationoftheunderbodycondition.Unlikethe
conventionaltypeofframedesign,theunitizedtype
ofbodyconstructionseldomdevelopsthecondition
of"diamond''inthefloorpanareaasa resultof
frontorrearendcollisions.Therefore,underbody
alignmentcheckingcanusuallyoriginatefromthe
bodyfloorpanarea.Ifinspectionindicatesthat
theselocationshavebeendisturbedandarenot
suitableformeasuring,oneoftheundamaged
suspensionlocationsshouldbeusedasa beginning
referencepoint.Ifa raresituationshouldexist
wherealloftheselocationsarenotsuitableas
referencepoints,repairoperationsshouldbegin
withthebodyfloorpanarea.Allotherunderbody
componentsshouldbealignedprogressivelyfrom
thisarea.
UnderbodyAlignmentReferencePoint
Dimensions(Figures3-7,3-8,and3-9)
Dimensionstogageholesandotherunthreaded
holesaremeasuredtodeadcenteroftheholesand
flushtotheadjacentsurfacemetal.Dimensions
toboltorboltholelocationsaremeasuredtothe
deadcenterofthethreaddiameterofthebolt or
bolthole.
Figure3-7specifiesdimensionreferenceloca-
tionsrequiredforalignmentoffrontendskirt
assemblyandforalignmentoffrontendskirt
assemblytobodyassembly.Figure3-8specifies