Group 17 Body, Doors And Windows

17.'

PAGE .17-1

PART 17-1 GENERAL

BODY SERVICE

PART 17-3

PAGE

DOORS, WINDOWS, TAILGATE AND DECK LID

17-30

PART 17-2 FRONT SHEETMET Al, BUMPERS, EXTERIORMOULDINGS. .

PART

17.1

. . . . . . . .17-11

GENERAL BODY SERVICE

Section DiagnosisandTesting

1

2 Common Dust

and

Adjustments Water

Leaks

and Repairs.

Types of Sealer and Application.

... . . ..

.......

BodyAlignment

DIAGNOSIS

Section

Page . . .17-1 . . .17-1 .. .17-1 . . .17-1 . . .17-3

Paint Refinishing. . . . . . . . . . . 3 Cleaning and Inspection. . . . . . . Care of Wood Grain Paneling 4 Hoisting. . . . . . . . . . . . . . . . . . . . .

Page . . . . . . . . .17-4 . . . . . . . . .17-8 . . . . . . . . . 17-9

.17-10

AND TESTING

DUST AND WATER LEAKS Sealer locations should be considered when checking for dust or water leaks. The forward motion of the car creates a slight vacuum within the body, particularly if a window or ventilator is partially open. Any unsealed small opening in the lower section of the body will permit air to be drawn into the body. If dust is present in the air, it will follow any path taken by the air from the point of entry into the passenger and luggage compartments. Opening the ventilator air ducts will equalize these pressures. Dust accumulates in

dust enters. The point of entry is often deceptive in that the dust may enter at one point, then follow the passagesformed by interior trim to another point. Under certain conditions, water can enter the body at any point where dust can enter. Any consideration of water leakage must take into account all points covered under dust leaks. To determine the exact location of a dust leak, it may be necessary to remove the following trim from the car: 1. Cowl trim panel.

.

the rocker panel, and may eventually

work its way to the kick-up or the rear body pillar, and follow the contour of the wheelhouse into the luggage compartment. To eliminate dust leakage, determine the exact point at which the

TYPES OF SEALER

2. Quarter trim panel. 3. Rear seat back and seat cushion. 4. Luggage compartment floor mats, spare wheel, and side trim panel.

,

cation are given under each sealer

AND APPLICATION

type.

The all-purpose sealers described below have been selected for service use. The method and points of appli-

CAULKING CORD AB19560-A This sealer has a plastic base with an asbestos filler. is heavy bodied.

5. Center pillar trim on 4-door models. 6. Scuff plates. After removing the trim, the location of most leaks will be readily evident. The entrance of dust is usually indicated by a pointed shaft of dust or silt. Seal these leaks, and road test the car on a dusty road to make sure that all leaks are sealed. After the road tests, check for indications of a dust pattern around the door openings, cowl panel, lower part of the quarter panel, and in the luggage compartment. Sometimes leaks can be located by putting bright lights under the car, with the above components removed, and checking the interior of the body joints and weld lines. The light will show through where leaks exist.

and is commonly known as permagum. It is used on spotweld holes, around moulding clips, or between two surfaces not properly sealed by a gasket. Apply the sealer with a Dutty knife.

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17-3

GENERAL BODYSERVICE

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FIG. 2-Fairl.ane UnderbodyDimensions TRIM CEMENT C2AZ-19C525-A This cement is recommended for instrument panel safety cover and body panel plastic water shield installation. It is also useful for repair or replacement of other vinyl and rubber trim. RUBBER CEMENT 8A-19552-B This quick-drying, strong adhesive material is designed to hold weatherstripping on doors, bodies, deck lids, cowl ventilators, and the surrounding metal. Windows and windshields which are set in rubber can be effectively sealed against leakage by flowing cement into the affected areas. Clean all grease, dirt, and old sealer from the surfaces to be cemented. For best results, apply a medium coat of cement to both surfaces, allow it to dry until tacky, and press both surfaces firmly together. Sll-ICON LUBRICANT COAZ-19553.A (JELLY) AND COAZ.19553.C (SPRAY) This lubricant is to be used on the door window weatherstrips. It is rec-

ommended that silicone lubricant be applied to the upper weatherstrips at every regular lubrication period. Its use makes the doors easier to close, avoids weatherstrip squeaks, retards excess weatherstrip wear from chafing between the door glass upper frame and the weatherstrip, and helps to retain door window alignment by reducing friction between the glass frame and rubber weatherstrip. BODY ALIGNMENT Servicing the unitized body should present no unusual difficulties or necessitate additional equipment other than that required for the conventional frame and body repair. The application of heat and the use of heavy-duty jacks must be carefully controlled because of the difference in the gauge of the metal in the sub-frame of a unitized body and the stress points developed in a single welded unit construction. It is possible to pull damaged areas back into alignment with the use of light-weight jacks and hydraulic equipment without heating the metal

Rough out badly damaged areas before taking measurements for squaring up a body. If necessary, remove the glass from the damaged area to prevent damage. In severe cases reinforcement brackets and other inner construction may have to be removed or cut to permit restoration of the outer shell and pillars without excessive strain on the parts. Straighten, install, and secure all such parts in place before attempting to align the body. In cases of severe or sharp bends, it may be necessary to use heat. Any attempt to cold-straighten a severely bent bracket may cause ruptures of the welds and may also cause cracks in the bent part. Never heat the area more than a dull red. CHECKING BODY FOR MISALIGNMENT To align or square up a body, take two opposite diagonal measurements between pillars. Use a measuring tram for these measurements. Take the measurements between reference points such as crease lines or weld joints which are diagonally opposite each other on the two pillars being

17-4

GROUP 17

measured. Since all measurements should be made from the bare metal, remove all interior trim from the checking points. In some cases, it is difficult to obtain proper body alignment when repairing a body that is damaged on both sides. In these cases, horizontal and vertical measurements can be taken from a body of the same body style. Once these basic dimensions are taken and established on the damaged body, alignment can be made by diagonal measurements taken from points on the two pillars. Do not attempt to correct any serious misalignment with one jacking operation. This is particularly true if other sections of the body also require aligning. Align each section proportionately until the proper dimensions are obtained. Door openings are checked in the same manner as the body. Horizontal, vertical, and diagonal checking points are established on all four sides of the door opening that is being measured. CHECKING UNDERBODY MISALIGNMENT

FOR

The dimensions of the underbody must be restored in the repair of major body damage, to provide correct front and rear wheel geometry (Figs. I, 2 and 3). All the dimensions are detailed to the center line of existing holes in the underbody assembly. Once the frame and suspension members are aligned, the balance of the repair can be performed. PAINT REFINISHING PAINT DAMAGES AND PROCEDURES FOR REPAIR Paint Repairs on Galvanized Metals. If for any reason it becomes necessaryto perform paint repairs on galvanized rocker panels or any other galvanized steel surfaces, care must be exercised in preparing the bare galvanized surface to properly accept paint, and the best possible paint products must be employed to insure satisfactory adhesion to the metal and to give a good color match with acceptable durability. Most of the approved paint suppliers for refinishing materials agree on the procedure for metal preparation but use different primer recommendations. The methods involving the use of DuPont Preparakote and Ditzler Zinc Dust Primer are indicated here and it is important that either one be

BODY DOORSAND WINDOWS I

employed exactly as directed. No short cuts nor any inter-mixing should be attempted. METAL PREPARATION FOR GALVANIZED STEEL 1. Strip, sand-off or otherwise remove all paint from the affected galvanized steel panel. 2. Wire-brush or steel-wool the entire metal surface and remove all grease or oil by wiping with a clean solvent. 3. Wipe the panel using a clean cloth or sponge with Lithoform No. 2 (Distributed by the Neilson Chemical Division of Amchem Products, Inc.) or Bonderite No. 34 (Distributed by Parker Rustproof). The work should be kept completely wet for at least three minutes and the metal should be thoroughly etched. If any bright metal remains the treatment should be repeated. 4. Rinse the area with clean water and blow off with compressed air.

5. The dried surface must be primed immediately. Then succeeding coats and color as required must be applied according to vendor's directions. Examples such as the DuPont and Ditzler systems are given as follows: SYSTEM FOR USING DUPONT PREPARAKOTE 1. Spray Preparakote over properly prepared metal. Force-dry with radiant heat or air-dry overnight. This primer must be dried hard enough to sand wet or dry. 2. Sand the Preparakote very carefully, preferably with No. 400 paper so as to avoid cutting through to bare metal. Blow off and tack clean. 3. Spray two coats of No. 22 clear sealer and allow to air-dry for thirty minutes. 4. Spray on matching Acrylic Lacquer as directed. Then air-dry or force-dry until the lacquer is hard enough to be polished. 5. Polish the lacquer as recommended by supplier. SYSTEM FOR USING DITZLER ZINC DUST PRIMER 1. Prime the galvanized area with DPE659 Zinc Dust Primer. This is a two-component product and the zinc must be carefully mixed with the vehicle as directed. A recommended film thickness of one mil may be recoated with a lacquer base primer surfacer such as DZL3200 in

about twenty minutes. Do not sand DPE659. 2. Spray primer surfacer DZL3200 reduced as directed to a film thickness of about two mils. 3. After drying the primer surfacer about thirty minutes, carefully sand with No. 360 or No. 400 silicon carbide paper, wet or dry, so as not to cut through the zinc dust primer coat. Blow off and tack clean. 4. Spray matching Duracryl lacquers as directed and after drying rub and polish as required. All material coatings may be force-dried. Careful manipulation is recommended. Acrylic Enamels. Acrylic enamels exhibit better hardness. mar resistance and gloss retention in metallic colors than the ordinary enamels. Acrylic enamels also possess the property of good polishability. Following are recommended repair procedures for acrylic enamels: Repair By Polishing. Repair of minor dirt or fallout, sags, mars, scratches, dry spray, overspray, and orange peel can be accomplished by machine or hand polishing or by both sanding and polishing without the necessityof repainting. Repairs of this type should apply to an entire panel while spot repairs should be attemped only in isolated areas. The suggested polish repair procedure consists of: 1. Remove the defect by oil sanding with 600 grit paper, using water or mineral spirits as a lubricant. 2. Apply a white or light colored medium grit machine polishing compound (Sno-Flake No. 16 or equivalent) to the painted surface with a brush. 3. Polish the entire panel surface using an 1850 rpm wheel and a carpet pad (approximately 518 -inch nap) or lambswool pad. 4. Buff the surface with a clean lambswool pad. Normally, acrylic enamels do not need polishing to improve their gloss; however, the foregoing procedure can be used to restore the original luster to the film after weathering, or to improve the surface smoothness of the finish on the entire car. Repair By Repainting. Acrylic enamels can be repaired by repainting with either conventional air drying or low bake enamels, or with acrylic lacquers. When repainting metallic colors, it is recommended that acrylic lacquer be used since a better color match can be obtained:

PART 7 -1

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both the original finish and the repair can be polished to provide the same luster, and the air dry acrylic repair lacquer will provide better durability in service than air dry enamels. Do not use Nitrocellulose lacquers for exterior repairs. When using anyone of the three types of repair materials over acrylic enamel, remove all traces of wax, polish or grease with a good silicone remover such as DL-60-372 I-A. It is extremely important that a thorough sanding of the original finish be accomplished using No. 400 grit paper. Care should be exercised to insure that all surfaces, including edges and areas adjacent to applied mouldings, are thoroughly sanded in order to provide adhesion of the repair top coat. Areas sanded to the base metal (cut through) should be treated with an acid cleaner such as Metalprep (distributed by Amchem Products Inc.). Follow the directions of the supplier as stated on the container. After sanding, proceed with the application of a primer surfacer reduced according to the supplier's recommendations to any bare metal spots that have been exposed. After the recommended air dry time, sand the primer surfacer with No. 400 grit paper before application of the repair material. The lacquer or enamel used should be reduced as recommended by its supplier. PAINT DEFECTS AND REPAIR PROCEDURES Listed here are some of the abnormal paint conditions that may be encountered (Fig. 4). It is very important to identify the paint condition correctly so that the proper repair procedure may be followed. For each of the following paint conditions described, the recommended repair procedure will be indicated. BLISTERING Blistering is the formation of bubbles or pin points on the surface of the finished work. Unless inspected by a magnifying glass, this condition is very hard to identify. In some instances, this complaint may be confused with dirt in the paint. To verify blistering, prick the suspected areas, and note whether a hole exists under the bubble. This condition is caused by rust, moisture, Or oil between the coats, metal not properly cleaned, or uneven temperatures between the metal and the paint being sprayed.

BODYI DOORSAND WINDOWS

Acrylic Enamel. Repair by repainting (color coat). Priming procedure must first be followed if defect is due to poor metal preparation. CHECKING Line checking has the appearance of thin, straight lines criss-crossing each other. These lines may be from one-half inch to four inches or longer, increasing in length as the finish ages. Acrylic Enamel. Refinish panel. (Color coat-primer if damaged.) CHIPPING AND STONE BRUISES Chipping occurs when the surface of the finish coat of paint has been broken by a sharp blow, and small particles of paint have flaked off. Frequently, stone bruises result in chipping. Acrylic Enamel. Refinish panel. Paint may be spotted if in isolated areas. (Prime to be bare metal.) CRACKING Cracking is evidenced by the paint curling. Frequently, cracking starts at the edge of the panel. This is caused by poor mixing of paint or by temperature changes during the various painting stages. Acrylic Enamel. Refinish panel. (Prime if both color and primer cracking.) CROW FOOTING Crow footing may be described as small lines branching off from a point in all directions and giving the appearance of a crow's foot. Crow footing is usually caused by spraying a second coat before the first coat is dry, by spraying an excessively thick coat, or by thinners which evaporate too fast. Acrylic Enamel. Refinish panel. (Color coat.) DIRT IN PAINT Patches where dirt appears are sometimes confused with blistering. To vertify the condition, prick the suspected areas, and note whether there is foreign material under the surface. Acrylic Enamel. Refinish panel. procedure will be effective in most cases. (Color coat.)

MILDEW Mildew growth which occurs alon2 radial lines is most common-

ly found in a very dark gray or black color. Acrylic ing.

Enamel. Repair by polish-

OFF-COLOR The term off-color is applied to adjacent areas on which the colors do not match. It may also appear when making spot repairs. Acrylic Enamel. Refinish panel if polishing does not correct condition (Color coat.) ORANGE PEEL Orange peel is a term used to describe an uneven, mottled appearance on the paint surface. This is usually caused by improper thinning of the paint. Acrylic Enamel. Refinish panel if polishing does not correct condition. (Color coat.) OVERSPRAY Overspray is evidenced by a rough, dull finish in the area surrounding the paint repair.

PEELING Peeling occurs when large areas of the finish or primer coat separate from the metal or prime coat. This is usually caused by wax, grease, rust or oil under the paint. Do not confuse with orange peel. PITS AND POP-UPS Pits and craters may be identified by the appearance of small round depressions in the paint. These may be caused by not allowing the first coat ot dry sufficiently before applying the second coat or from failure to remove silicone polishes before repainting. Acrylic Enamel. First use polish repair procedure refinish panel if necessary. (Color coat.) THIN PAINT The primer will show through the finish coat as a result of an excessively thin color coat, or application of the color coat before the surface is dry. Acrylic Enamel. Refinish panel. (Color coat.) RUNS AND SAGS The uneven collections of paint on the finish surface are referred to as runs and sags. The collections may appear in the form of tear drops or sagging lines. Usually these lines are quite soft and sometimes thev mav he wrinlrleti

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PART 17-1

17-7

GENERALBODY SERVICE

SCRATCHES

PITS AND POp.UPS

RANDOMBLISTERS

DIRT IN PAINT

PATTERN BLISTERS

LINE CHECKING

MILDEW

CHIPPING

OFF COLOR

BRUISES

CRACKING

CRATERS

WATER SPOTTING

THIN PAINT

INDUSTRIAL FALL.DUT

ORGANIC FALL-OUT

RUNS AND SAGS

ORANGE PEEL

OVERSPRAY

PEELING

WRINKLES N-1471-A

FIG. 4~Paint Defects

GROUP 17 BODYDOORSAND WINDOWS

17-8

I

caused by over-application of paint or hesitation in the stroke of the gun. Acrylic Enamel. pair procedure.

Use polish

re-

SCRATCHES Scratches are thin marks Or tears that may partially or completely penetrate the surface of the finish coat of paint. Acrylic Enamel. Use polish repair procedure for shallow penetration. Refinish panels to correct conditions of deep penetration. SPOT DISCOLORA nON This is evidenced by brown spots or stains on the surface. Stains or spots can be caused by road tar, acid or alkali-bearing water from the streets. Acrylic Enamel. Use polish repair procedure. WATER SPOmNG Water spotting is evidenced by a milky pattern where water drops have fallen. Acrylic Enamel. Use polish repair procedure. INDUSTRIAL FALL-OUT Industrial fall-out is the result of particles being exhausted into the air by the various processesof heavy industry, or in areas where there is a concentration of industry. Industrial fall-out particles appear to the eye as tiny rust-colored dots on the paint film and the surface will feel rough to the touch. Some of the particles have excellent adhesion and are difficult to remove. However, the following procedure has proven effective in the removal of this fall-out. 1. Wash the car with car wash compound (COAA-19B521-A) to remove loose soil. Rinse well and examine the painted surfaces for iron base fall-out particles. If there

is a significant quantity of fall-out not removed by ordinary washing, the oxalic treatment should then be used. All cracks, ledges, grooves, etc., where fall-out has accumulated should be cleaned by wiping or by air blow-off. 2. Dissolve six to eight ounces of oxalic acid (dry) in one gallon of warm water and add one or two tablespoonsful of a non-alkaline detergent such as car wash compound (COAA-19B521-A). This acid detergent solution must be prepared and kept in a clean NON-METALLIC container. Apply this solution liberally to all affected surfaces of the car with a large sponge. Use a broad wiping stroke and keep the work completely wet for about 15 minutes, or until the operator can no longer feel any surface roughness or isolated gritty particles with bare or gloved finger tip. If this is not done thoroughly, rust staining may soon redevelop. Be sure that the entire acid cleaning procedure is performed in a sheltered area so that the work will be kept as cool as possible to prevent rapid evaporation of water and consequent surface drying. Do not work in the sun. 3. Rinse with clear water. This must be done very thoroughly to prevent possible corrosion. No traces of acid should be left on any surface. Bright trim parts, particularly anodized aluminum and stainless steel, may be stained by prolonged contact with the cleaning solution. Painted areas also can be spotted by prolonged exposure. It is also important to keep the oxalic acid cleaner solution from leaking to the inside of the car because some fabrics might be bleached or discolored by the solution. If the fall-out is not completely removed or is deeply imbedded in the paint film, cleaning with the acid detergent mixture must be

repeated. This may be aided by using a fine scrub brush, possibly a nylon bristle type. Make sure that the light scrubbing required does not scratch the paint. It is sometimes helpful to briskly rub the work with a mixture of equal parts of oxalic acid cleaner and FoMoCo cleaner wax polish (8A19519-A) using a piece of heavy toweling. Again, a thorough water rinsing is extremely important. Sometimes small black spots remain after the oxalic cleaning has removed all iron based fall-out. Such deposits might be asphaltic or they might be over-spray. These usually can be removed by rubbing vigorously with a cloth saturated with a mixture of kerosene and Actusol (about five parts of kerosene to one part of Actusol). Any residue of this solvent mixture may be readily flushed off with water. ORGANIC FALL.OUT Organic fall-out may result from parking cars under trees or from the air under certain atmospheric conditions. Acrylic Enamel. Refinish damaged panels. (Color coat and primer.) INTERIOR PAINT REPAIRS The proper matching of colors can be obtained if the following procedures are carefuly adhered to: 1. Clean the surface to be painted with wax and silicone remover. 2. Feather-edge the damaged area with 400 grit wet or dry sandpaper. (Prime all areas of bare metal with M-6J-12S Primer.) 3. Mix the paint per instructions on the can and spray several light coats. Allow the paint to become tacky between coats. 4. Spray the entire area sparingly with B7A-645-S Lacquer Leveler which will blend the repaired area with existing painted surfaces.

CLEANING AND INSPECTION FLOOR PAN PLUGS AND GROMMETS The floor-pan plugs seal the various access holes. If any plugs are missing or improperly installed, a dust or water leak may result. This also applies to the grommets used on the dash panel. When dust or

water leaks are evident, these plugs and grommets should be checked for proper installation. DRAIN HOLES Drain holes or valves located on the underside of each rocker panel, quarter panel, and door should be

cleared periodically. BODY MAINTENANCE Regular body maintenance preserves the car's appearance and reduces the cost of maintenance during the life of the car. The following steps are suggested as a guide

PART 17-1- GENERALBODYSERVICE for regular body maintenance: 1. Vacuum the interior thoroughly and wash the car. 2. Check all openings for water leaks, and seal where necessary. 3. Cement all loose weatherstrips which are still usable. 4. Replace all door and deck lid weatherstrips which are unfit for service. 5. Apply silicone lubricant to the weatherstripping. 6. Replace all cracked, fogged, or chipped glass. 7. Align the hood, doors, and deck lid if necessary. 8. Inspect the windshield wiper blades and replace them if necessary. 9. Tighten the sill plate and garnish moulding screws. 10. Clean the seats, door trim panels, and headlining. 11. Touch up or paint chipped or scratched areas. 12. Drain holes located on the underside of each rocker panel, quarter panel, and door, should be cleared periodically. RATTLE ELIMINATION Most rattles are caused by a loose bolt or screw. Foreign objects such as nuts, bolts, or small pieces of body deadener in the door wells, pillars and quarter panels are often the source of rattles. Door wells can be checked by carefully striking the underside of the door with a rubber mallet. The impact made by the mallet will indicate if loose objects are in the door well. In the event that tightening the bolts and screws, located on such assemblies as the doors, hood, and deck lid does not eliminate the rattles, the trouble is probably caused by misalignment. If this is the case, follow the adjustment and alignment procedures for these assemblies. Rattles and squeaksare sometimes caused by weatherstripping and antisqueak material that has slipped out of position. Apply additional cement or other adhesive, and install the material in the proper location to eliminate this difficulty. EXTERIOR CLEANING The outside finish should be frequently washed. Never wipe the painted surface with a dry cloth. Dusting the finish when it is dry tends to rub the dust and dirt into the baked enamel, and leaves a sandpaper effect on the surface. To keep the finish bri2ht and attractive

and eliminate the necessity of using polish, wash the car whenever it has accumulated a moderate amount of dirt and road salt. The bright metal parts of the car require no special care. Periodic cleaning will preserve the beauty and life of these finishes. Wash with clear water or if the parts are very dirty use FoMoCo COAA-19B521-A compound. Using a clean soft cloth or a sponge and water, rinse and wipe the parts dry. FoMoCo Chrome Cleaner may be used sparingly to remove rust or salt corrosion from chrome plated parts. Do not scour aluminum or chrome finished parts with steel wool or polish them with products containing abrasives. A FoMoCo Polish will provide excellent protection for all bright metal parts. INTERIOR CLEANING Use a vacuum cleaner to remove dust and dirt from the upholstery or floor covering. Vinyl and woven plastic trim that is dusty can usually be cleaned with a damp cloth. Do not use cleaning materials containing kerosene, naptha, toluol, xylol 10°, lacquer thinners, cellulose acetate, butyl cellosolve, carbon tetrachloride, body polish, battery acid, antifreeze, gasoline, motor oils or other type lubricants. Approved cleaners B8A-19523 -A, or -B, B5A-19525-A, COAZ19526-A or -B (soft trim cleaners), BAF-19521-A (leather and vinyl upholstery cleaner), and CIAZ-19C507 -A (convertible back window cleaner) are available for service. Instructions for the use of these cleaners are indicated with their containers. CARE OF WOOD GRAIN PANELING WASHING Never wipe the panels or trim rails with a dry cloth. This method of cleaning tends to rub dust particles into the finished surface and leave fine scratches. Plush off all loose dirt and other elements, and wipe the body panels and rails with a sponge and plenty of cold water. If desired, a mild soap may be used. Rinse thoroughly with clear water and wipe dry. GLASS FIBER TRIM RAn. REMOVAL AND INSTALLATION The glass fiber trim rails are serviced with the wood-grain already

17-9

applied. To remove the body side trim rails, remove the cap over each trim rail screw to gain accessto the screws. Remove the screws and the trim rail assembly. When installing the body side trim rail, apply sealer (AB-19560-A) around each mounting hole. Install the cap retainer, screw and cap. APPLICATION OF WOODGRAIN TRANSFERS Wood grain transfers are available for application to the panels. The materials necessary to apply the transfers are a bonding coat (M-4584), 20% transfer solution of M-5412-A, and clear spar varnish. If the surface on which the transfer is to be applied is damaged, repair and metal finish first. 1. Mask off the area where the transfer is to be applied. 2. Prime-coat all bare metal areas, and wet-sand. 3. Spray the surface with transfer bonding coat (M-4584). This coat is the binder for the transfer adhesive. 4. Allow the binding coat to airdry for one hour, or heat-dry (1600P) for 20 minutes. 5. Lightly wet-sand the binding coat, and wipe it dry. 6. Make a paper template of the damaged area, and cut the new transfer to size, using the template as a guide. Leave about V2 inch of extra material around the edge of the transfer to allow for matching and trimming. 7. Mix a solution of 20% transfer solution M-5412-A and 80% water. This solution permits shifting of the transfer after it has been applied, so that the graining can be matched. Try a sample of the transfer and solution on an old piece of metal or fender. If the transfer cannot be pulled off after two minutes, the solution is too strong and must be diluted with more water. 8. Soak the transfer in lukewarm water for one minute to loosen the paper backing. Do not remove the backing until the transfer is applied. 9. Using a cheese cloth pad, apply a 20% M-5412-A transfer solution to the panel. Any excess solution that runs down on adjacent panels must be wiped off immediately. 10. Place the wet transfer on the panel, paper side out. Adjust the transfer to match the graining on adjoining panels, and carefully remove the paper backing.

17-10

GROUP 17 - BODY,DOORS ANDWINDOWS

11. Sponge the transfer with clean water to remove all traces of the paper backing adhesive. 12. Remove all air bubbles and wrinkles with a squeegee. 13. Wash the transfer with clear

HOISTING

water and dry with a chamois. 14. Pierce any blisters or small air bubbles as they appear, and press down the area with a finger to remove the air and excesssolution. 15. Allow the panel to air-dry for

one hour, or heat dry (160oP.) for 20 minutes. 16. When the panel is dry, spray two coats of clear spar varnish over the transfer. Do not use clear lac. quer or sheUac.

post adapters must be positioned carefully to contact the center of the lower suspension arms (Figs. 5 and 6).

least 12 square inches of underbody area. Figs. 5 and 6 show recommended contact points for the hoist pads.

REAR To prevent damage to the shock absorbers, the rear forks must contact the axle at points not farther out board than one inch from the circumference welds near the differential housing. Carefully raise the rear post and check the position of the fork (Figs. 5 and 6).

FLOOR JACK When a stationary floor jack or a roll jack is to be used, there are several specific recommended points of contact. Either side of the car may be raised at the front by jack contact at the lower arm strut connection. Either side of the front end of the car may also be raised by jack pressure on the front crossmember, or on the crossmember to which the stabilizer is connected. Do not attempt to use jack pressure on either front or rear Mustang bumpers.

VEHICLE

The unitized body-frame construction requires special precautions and procedures when the car is jacked up or hoisted. In some cases, special hoist adapters must be used as recommended by specific hoist manufacturers. Refer to the Owner's Manuals when using the jack supplied with the car. DRIVE-ON TYPE HOIST To prevent possible damages to the underbody, do not drive the car onto the drive-on type hoist without first checking for possible interference between the upright flanges of the hoist rails and the underbody. Should there be interference, the hoist flanges should be modified as necessary and/ or the approach ramps built up to provide the needed clearance.

FRAME CONTACT HOIST Frame contact hoist adapters are necessary to lift the car. The hoist adapter pads should each cover at : " 'FRONT RAIL TYPE, FORK LIFt AO~l IArKrnNtAr¥b~~

nOR

RAIL TYPE-FREE WHEELING HOIST FRONT The front adapters or hoist plates must be carefully positioned in contact with the lower suspension arms to assure safe, accurate lifting.

REAR The hoist adaptersmust be positioned carefully under the rear axle to prevent damageto the shock absorberswhen the car is raised. The hoist rails should be raised slowly and the position of the adapters checked. FORK LIFT-TWIN POST HOIST FRONT To assure safe hoisting, the front

-

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FRONT FRAME CONTACT AREA

FIG. 5-Front

Mll11-A

Hoist Contact Areas

FIG. 6-Rear Hoist ContactAreas

17-11

FRONT SHEET METAL, BUMPERS, EXTERIOR MOULDINGS Section 1 In-Car Adjustments and Repairs Hood Adjustments. Hood Lock Adjustments-Mustang Hood Lock Adjustment-Comet, Falcon, Fairlane

Page .17-11 17-11 .17-11 17-11

2 Removal and Installation. . . . . . . . . . . . . . . . . . . . .17-12

HoodHinge 17-12 RadiatorGrille-Comet. . . . . . . . . . . . . . . . . . . .17-12 RadiatorGrille-Falcon. . . . . . . . . . . . . . . . . . . .17-12

HOOD ADJUSTMENTS The hoOd is provided with fore and aft, vertical, and side-to-side adjustments (Fig. 1). These directions refer to the position of the hood when it is fully lowered. The elongated bolt slots in the hinge at the hood provide the side-to-side adjustment. The enlarged holes in the hinge at the fender apron provide both vertical and fore and aft adjustments. Hood bumpers, located on the top left and the top right surface of the radiator support, can be adjusted up and down to provide a level surface alignment of the hood panel with the front fenders HOOD LOCK ADJUSTMENTS

MUSTANG Before adjusting the hood lock

Section Page Radiator Grille-Fairlane .17-12 Radiator Grille-Mustang .17-14 Front Bumper-Comet, Falcon, Fairlane .17-14 Front Bumper-Mustang .17-15 Rear Bumper-Falcon ..17-16 Rear Bumper-Comet, Fairlane. . . . . . . . . .. . .17-16 Rear Bumper-Mustang .17-16 Rear Bumper Guard-Mustang... . . . . . . . . . . .17-17 Exterior Mouldings. 17-17

mechanism, make certain that the hood is properly aligned. The hood lock (Fig. 2) can be moved fore or aft and side to side to align it with the lock dowel. The safety catch can be adjusted to engage the hood lock catch. 1. Loosen the hood lock attaching bolts. Move the lock assembly as required to align it with the lock dowel on the hood. 2. Tighten the attaching bolts. 3. Loosen the lock nut on the hood lock dowel and turn the dowel inward to adjust the hood tighter, or outward to loosen the adjustment. Do not bend the hood lock dowel. 4. The lock dowel is adjusted correctly when the top of the hood is flush with the fenders, when locked. 5. Tighten the dowel lock nut after adjusting the lock dowel.

LOCK DOWEL

6. To adjust the safety catch striker, loosen the two attaching screws and position the catch correctly. Tighten the screws and lower the hood to make certain the safety catch striker engages the hood lock safety catch. 7. Open and close the hood several times to be certain that the lock mechanism is secure. COMET, FALCON AND F AIRLANE 1. With the hood open loosen the hood lock retaining screws (Figs. 3, 4 and 5). 2. Move the hood lock mechanism as required to align it with the lock striker. 3. Tighten the lock retaining screws. Open and close the hood several times to be sure that it latches securely.

SAFETYCATCH STRIKER

HOOD LOCK

-...'.-N1071-B

FIG. 1-Hood Hinge Installation -Typical

--,

SAFETYCATCH

FIG. 2-Hood LockMechanism-Mustana

N1184-B

GROUP 17 - BODYDOORSAND WINDOWS

17-12

I

REMOVAL AND INSTAllATION grille and remove the grille ornament.

HOOD HINGE 1. Prop the front of the hood in the open position and cover the fender and cowl panel. 2. Remove the hinge-to-hood retaining bolts, the retaining bolts at the fender apron and cowl (Fig. 1), and remove the hinge. 3. Position the hood hinge on the body and install the hinge retaining bolts. 4. Adjust the hood for proper fit.

INSTALLATION 1. Position the grille assembly in the grille opening and loosely install the upper retaining bolts. 2. Loosely install the lower grilleto-center support bracket retaining screw. 3. Install the end grille retaining screw at each headlight housing and tighten all bolts and screws. 4. Install the headlight doors.

INSTALLATION 1. Position the grille ornament on the left grille and install the retaining nuts and washers. 2. Position the grille center panel to the grille assembly and install the retaining screws. 3. Position the grille assembly in the grille opening. 4. Install the grille top retaining screws, the grille-to-center lock support retaining screw and the right and left side grille retaining bolts.

RADIA TOR GRillE-COMET REMOVAL 1. Remove one screw and two bolts retaining the grille assembly to the center lock support and the right and left sides at the stone deflector (Fig. 3). 2. Remove the four screws retaining the grille assembly to the upper support; remove the grille assembly from the grille opening and place it on a bench. 3. Remove the eight screws retaining the grille center panel to the grille assembly and remove the panel. 4. Remove the nut and washer retaining the grille ornament to the

RADIATOR GRILLE-FAIRLANE REMOVAL 1. Remove the headlight door retaining screws and remove the headlight doors. 2. Remove the screws retaining the grille assembly to the hood lock support, the screws retaining the grille to the upper grille support brackets, and the three retaining screws from each end of the grille (Fig. 5). 3. Remove the grille assembly from the car. 4. Remove the three nuts retaining the grille ornament and remove the ornament. 5. Remove the screws retaining the upper and lower grille mould-

RADIATOR GRillE-FALCON REMOVAL 1. Remove the headlight door retaining screws and remove the headlight doors. 2. Remove one retaining screw from each side of the grille at the headlight housing (Fig. 4). 3. Remove the lower grille to center retaining screw (Fig. 4). 4. Remove the upper grille to support bracket retaining screws (Fig. 4) and remove the grille assembly.

'GRilLE ASSEMBLy'8200

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PART 17-2

FRONT SHEETMETAL, BUMPERS,EXTERIORMOULDINGS

N 1185- E

FIG. 4-Falcon Grilleand Hood Lock Assembly

FIG. 5-Fairlane Grille and Hood LockAssembly

17-13

17-14

GROUP

17

- BODY,DOORSANDWINDOWS

ings to the grille assembly and remove the grille mouldings and grille moulding retainers. INSTALLATION 1. Install the upper and lower grille moulding retainers on the grille mouldings, position the grille mouldings on the grille and install the grille moulding retaining screws. 2. Position the grille ornament on the grille and install the ornament retainer and retaining nuts. 3. Position the grille assembly on the car and grille assembly retaining screws 4. Install the headlight doors. GRILLE-MUSTANG REMOVAL 1. Open the hood. 2. Remove the four grille retaining screws from the lower inner flange of the grille. 3. Remove the four grille retaining screws from the upper flange of the grille upper center support bracket to the hood lock hook support. 4. Remove the grille assembly. INSTALLADON 1. Transfer the upper center support bracket, the grille bars and ornament, and the spring nuts to the new grille assembly. 2. Position the grille assembly on the car and install the grille retaining screws. 3. Close the hood.

N 1365- C

FIG. 6-Comet Front Bumper Installation

FRONT BUMPER-COMET, FALCON, FAIRLANE REMOVAL 1. Disconnect the parking light wiring connectors and push the wires through their routing holes in the fender aprons. 2. Remove the bumper left and right inner and outer arm-to-frame side rail retaining bolts and remove the bumper assembly. (Figs. 6, 7, and 8). 3. Remove the bumper inner and outer arms from the bumper. 4. Remove the license plate. S. Remove the parking light assembly retaining nuts and remove the parking light assemblies. INSTALLATION 1. Install the license plate on the new bumper. 2. Install the parking light assemblies in the new bumper. 3. Install the bumper inner and nllter ~rm~ nn the new humner usinll

N 1366. B

FIG. 7-Falcon Front BumperInstallation

PART 17 -2 -

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R 1178- B

FIG. 8-Fairlane Front BumperInstallation spacers and washers as shown in Figs. 6, 7 and 8. 4. Position the bumper assembly to the car and loosely install the bumper arm-to-frame side rail retaining bolts.

5. Align the bumperassemblyand tightenthe bumperarm-to-frameside rail retaining bolts. 6. Route the parking light wiring through the fender aprons and connect the wiring connectors.

.

BUMPER GUARD

17-15

FRONT BUMPER-MUSTANG REMOVAL 1. Raise the car to provide working access. 2. Tape the stone deflector to prevent scratching the paint finish. 3. Remove the left and right bumper-to-fender bracket bolts from the fenders. 4. Remove the bumper bar-to-inner arm and the bumper bar-to-outer arm retaining bolts from each side of the bumper (Fig. 9). Remove the bumper and bumper-to-fender bracket as an assembly.

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11 R,W:OUTER ARM (:::~~"'~~, 17754

FRONT SHEETMETAL, BUMPERS,EXTERIORMOULDING

INSTALLATION 1. Transfer the bumper-to-fender bracket to the new bumper. 2. Position the bumper on the car. Install the bumper bar-to-inner arm and the bumper bar-to-outer arm retaining bolts. 3. Install the bumper-to-fender bracket retaining bolts. 4. Remove the protective tape from the stone deflector and lower the car. FRONT BUMPER GUARDMUSTANG 1. Remove the screw and washer retaining the bumper guard to the

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Nl:m6-A

FIG. 9-Mustang Front BumperInstallation

GROUP 17

17-16

lower frame side rail (Fig. 9). 2. Remove the screw and washer retaining the bumper-guard-to-guard upper bracket and remove the guard assembly. 3. Transfer the nut and retainer assembly and the rubber spacer to the new bumper guard (Fig. 9, View "BB"). 4. Position the bumper guard assembly on the car. 5. Install the two retaining screws and washers. REAR BUMPER-FALCON REMOVAL 1. Remove the screws retaining the license plate lamp assembly to the rear bumper. 2. Remove the rear license plate. 3. Remove the four bumper armto-frame retaining bolts (Fig. 10), and remove the bumper assembly. INSTALLATION 1. Transfer the rear bumper arms and rubber bumper to the new bumper. 2. Position the bumper assembly on the car and install the bumper arm-to-frame retaining bolts. 3. Position the license plate lamp assembly to the bumper and install the retaining bolts. 4. Install the license plate.

BODYDOORSAND WINDOWS I

REAR BUMPER IMPACT BARCOMET, FAIRLANE REMOVAL 1. Open the luggage compartment. Disconnect the license light wiring connector and push the license light wire out of its routing grommet. 2. Remove the spare tire and wheel assembly. 3. From beneath the car, remove the access covers from the lower bumper arm-to-lower back panel retaining screw and washer assemblies. 4. Remove the lower inner armto-lower back panel retaining screw and washer assemblies (Fig. 11). 5. From inside the luggage compartment, remove the upper inner arm-to-lower back panel retaining screw and washer assemblies (Fig. 11). Remove the bumper assembly from the car and place it on a bench. 6. FAIRLANE ONLY: Remove the screw and washer assembliesretaining the license plate support bracket to the impact bar (Fig. 11), and remove the license plate support bracket assembly from the impact bar. 7. Remove the rubber license sup-

port bracket-to-i~pact bar bumpers (Fig. 11). 8. Remove the bumper outer and inner arm-to-impact bar retaining bolts and spacers (Fig. 11). Remove the outer and inner arms from the impact bar. INSTALLATION 1. Insert the bumper inner and outer arm-to-impact bar retaining bolts in the impact bar. Install the spacers and the inner and outer arms on the impact bar. Torque the retaining nuts to 17 to 23 ft-lbs. 2. Install the license plate support rubber bumpers on the impact bar. 3. FAIRLANE ONLY: Install the license plate support on the impact bar. 4. Position the bumper assembly on the car. Feed the license plate light wire through its routing grommet in the lower back panel and start one upper arm-to-body retaining screw on each side. 5. Shift the bumper assembly as necessary for proper alignment and install the remaining bumper armto-body retaining screws. Torque the retaining screws to 25 to 38 ft-lbs specification. 6. Install the lower bumper armto-lower back panel retaining screw accesscovers. 7. Install the spare tire and wheel assembly. Connect the license plate light wiring connector. REAR BUMPER-MUSTANG REMOVAL 1. Open the luggage compartment. Remove the spare wheel and disconnect the license light wiring connector. 1. Remove the four bumper mounting bracket-to-body retaining bolts and remove the bumper assembly (Fig. 12). 3. Remove the four bumper-tomounting bracket retaining bolts and remove the brackets (Fig. 12). 4. Remove the two license plate light and bracket retaining screws and remove the light and bracket.

.

_OWEREXTENSION-178875

N 1367. B

FIG. 10-Falcon RearBumperInstallation

INSTALLATION 1. Position the license plate light and bracket on the bumper and install the two retaining screws. 2. Position the bumper mounting brackets on the bumper and install the bumper-to-mounting bracket retaining bolts. 3. Connect the license light wiring and install the spare wheel.

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PART 17-2

FRONT SHEETMETAL, BUMPERS,EXTERIORMOULDINGS

17-17

REAR BUMPERGUARDMUSTANG REMOVAL 1. Open

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INST ALLA.TION 1. Transfer the two nuts and retainers to the new bumper guard. Transfer the rubber spacers to the new bumper guard. 2. Position the bumper guard on the car and install the two retaining screws and washers. 3. Install the spare tire assembly. EXTERIOR MOULDINGS Before removing the exterior mouldings, it should be detennined by the type of retainer used whether a respective door, quarter or luggage compartment trim panel must first be removed to provide access (Figs. 13 through 31).

H 1387- A

FIG. 1 2-Mustang RearBumperInstallation

GROUP 17 - BODY,DOORS ANDWINDOWS

17-20

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17-21

FRONT SHEETMETAL, BUMPERS,EXTERIORMOULDINGS

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17-24

GROUP

17-BODY,

DOORSAND WINDOWS

fiG. 2!5-Exterior FrontMouldings-Fairlane

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FIG. 26-Exterior Mouldings-Fairlane ModelsS4A,62A

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17-31

Falcon, Fairlane Models 54, 71. . . . . . . . . Door Glass Adjustment-Comet, Falcon, Door Window Adjustment-Mustang. . . . .

17-32

Models63,76

FairlaneModels62

Rear Door Window Adjustment-Comet, Falcon, Fairlane. . . . . . . . . . . . . . . . . . . . . . Quarter Window Adjustment-Comet, Falcon, Fairlane Model 62. . . . . . . . . . . . . Quarter Window Adjustment-Comet, Quarter Window Adjustment-Comet, FairlaneModeI63

Quarter Window Adjustment-Mustang. FairlaneMode176

17-32 17-32 17-33 17-36 17-36

. . . .17-36

. .17-36 Tailgate Emergency Opening Procedure.. . . . .17-36 Dual-Action Tailgate Adjustments. . . . . . . . . .17-37

. .17-37 . .17-37 . .17-37 . .17-39 Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-39 Front Door Lock-Except Models 63, 76.. . .17-39 . .17-39 DoorLockCylinder . .17-39 . .17-39 Door Handle or Push Button.. . . . . . . . . . . . . .17-39 Front RearDoorLock

Door

Lock-Models

................. Adjustment

Hinge

Tailgate

Standard

DeckLidAlignment

and Installation.

DeckLockAdjustment

2 Removal

63,

63,

76... . . . . . . . . . . . . . . . . . . . . .

7-39

Vent Window or Weatherstrip-Models 63, 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Door Glass-Except Models 63, 76.

17-41 17-41

17-47 Model 76. . . . . . . . . . . . ...~ 17-ii~

Back Window and/or Weatherstrip-

Model 65. . . . . . . . . . 17-49 17-49 17_,(} Back Window-Mustang ModeI63 ."-J,) Inside Rear View Mirror (Bonded to Windshield). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-51 Back Window-Mustang

Tailgate Window Regulator.

. . . . . . . . . . . . . . . . 17-52 17-53

,

76

Door Vent Window Frame-Except Models

Windshield-Mustang

65

17-31

63,

Fairlane

ExceptModels63,76

Model

Falcon

Door Glass Adjustment-Comet,

Section Page Front Door Glass-Comet, Fairlane ModeI63,76 17-41 Front Door Window Regulator-ManualComet, Fairlane- Model 63, 76. . . . . . . . . . . .17-42 Front Door Window Regulator-Except Models63,76 17-42 Front Door Rear Glass Run-Models 63, 76. .17-42 Rear Door Glass-Comet, FalconModeI54 17-42 Rear Door Window Regulator. . . . . . . . . . . . . .17-42 Quarter Glass- Model 62. . . . . . . . . . . . . . . . . . .17-43 Quarter Window Regulator-ModeI62 .17-43 Quarter Window Regulator-Model 63 .17-43 Quarter Window Front Guide-Model 63 .17-43 Quarter Window Rear Guide- Model 63. . . . .17-43 Rear Quarter Window Glass-Fairlane, Comet-ModeI76 17-43 Rear Quarter Window and/or WeatherstripModel 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-44 Windshield-Comet, Falcon, Fairlane. . . . . . . . 17-44 Windshield-Mustang

Vent Window Adjustment-Comet,

Page 17-30 17-30 17-30

Comet,Falcon,Fairlane

................

TailgateGlass

Alignment

and

Door

Repairs

Lock Striker Adjustment. Adjustments

In-Car

1

Section

Tailgate Switch and Lock Cylinder-Power. . ...17_~d ~. Tailgate Window Handle and Lock CylinderManual. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-54 Dual-Action Tailgate Hinges. . . . . . . . . . . . . . . . 17-55 Dual-Action Tailgate Locks. . . . . . . . . . . . . . . . . 17-55 Dual-Action Tailgate Torsion Bar. . . . . . . . . . . . 17-55 Deck Lid Hinge or Torsion/Bar. . . . . . . . . . . . . . 17-55 17_" DeckLidLock ~.I

IN-CAR ADJUSTMENTS AND REPAIRS DOOR ALIGNMENT The door hinges provide sufficient adjustment to correct most misalignment conditions. Loosen the door hinge attaching bolts and adjust the door so that it is centered in the door opening when closed. Then, tighten the hinge attaching bolts. After adjustment at the hinge attaching points, check the alignment between the door lock and

striker plate for proper door closing. Do not cover up poor door adjustment with striker plate adjustment. LOCK STRIKER ADJUSTMENT The striker pin can be adjusted laterally and vertically as well as fore and aft. The lock striker should not be adjusted to correct door sag. The lock striker should be shimmed to get the clearance shown in Fig. I

between the lock striker and the lock. To check this clearance, clean the lock jaws and the striker area, and then apply a thin layer of dark grease to the lock striker. As the door is closed and opened, a measurable pattern will result. Move the striker assembly laterally to provide a flush fit at the door and the pillar or quarter panel.

~

PART 17-3 -

DOORS,WINDOWS,TAILGATEAND DECKLID

Tighten the screw and washer assemblies, Y and AB securely. 5. Position the vent window assembly and vent window division bar glass run rearward, into a position relative to the door window glass and tilt fore and aft, as required, to maintain a parallel relationship to the front body pillar. Tighten the screw and washer assemblies A securely. The adjusted position of the vent window assembly should be such as to provide window travel free of binding. 6. To provide a proper interference relationship of the vent window and the door window assemblies to the top roof rail weatherstrip, tilt these assembliesinboard or outboard as required, by turning the screws, B, D and K clockwise or counterclockwise, to the desired setting and then tighten the nuts C, E and L securely. At this point, secure the vent window regulator assembly door vent window, by tightening the screw and the washer assemblies A securely. 7. When the above steps are completed, cycle the window down until the top of the window is flush with the belt and position the down stop assembly to the bumper door window stop and secure it with the

DOOR GLASS ADJUSTMENTCOMET, FAIRLANE MODELS 63,76 The door must be properly aligned in the body opening before glass adjustments are made. 1. Remove the door trim panel and peel back the watershield to provide access. 2. Loosen screw and washer assemblies A, J, Z and AB, also nuts C, E and L (Fig. 2). 3. Cycle the window to its up position and manually position the window assembly inboard or outboard, as required, for proper alignment to the outside belt weatherstrip and tighten the screw and washer assembliesJ. 4. Tilt the window assembly fore or aft as required, to obtain a parallel relationship between the top of the window and the roof rail weatherstrip. This will position the rear guide assembly in correct fore and aft alignment. Tighten nut L temporarily. Turn screw G clockwise or counter-clockwise, as required, to maintain position of the guide assembly and tighten nut and washer assembly H securely. At this point, adjust the door window stop assemblies up or down as required, for correct engagement.

FIG. l-Door LockStriker Adjustment VENT WINDOW ADJUSTMENTS-COMET, FALCON EXCEPT MODELS 63, 76 The vent glass and/or the vent window frame may be adjusted in various ways. With the vent glass installed, the lower pivot spring tension may be adjusted with a socket, extension, and ratchet used through the access hole in the door inner panel. Adjust so that the glass will stay open at highway speeds. The door frame mounting holes are elongated to provide a tight fit for the vent window frame in the door frame. The upper pivot mounting holes are slotted to help provide a weather-proof fit of the glass frame within the vent window frame.

GLASS AND CHANNEL

17 -31

ASS'Y. - 21400.

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17-32

GROUP 17 - BODY,DOORSANDWINDOWS

screw and washer assembliesZ. 8. Install the watershieldand the door trim Danel. FRONT DOOR GLASS ADJUSTMENTS-COMET, FALCON FAIRLANE MODELS 54, 71 The door trim panel must be removed to make any of the following adjustments. Fore-and.aft adjustment for snug glass fit within the runs may be made by using suitable shim stock between the front run and the vent window division bar. The front and/or the rear run may also be shimmed at the lower attaching point(s). Vertical adjustment is possible by means of the single stop (Fig. 3). When the glass is fully lowered, the upper edge should be even with the belt line. Lateral adjustment for smooth movement of the glass within the runs can be made by moving the lower attaching points of the run (Fig. 3).

DOOR GLASS ADJUSTMENTCOMET, FALCON, FAIRLANE MODELS 62 1. Remove the door trim panel and peel back the watershield to pro-

vide access. Refer to Fig. 4 for the following adjustments. 2. To obtain proper alignment of the lockside glass run retainer assembly to the door window frame and vent window division bar with the retainer, loosen nut and washer assembly D and screw and washer assembly E. Drop the top edge of the glass and channel assembly to approximately four inches above the door outer panel belt line. Turn screw C clockwise or counterclockwise as required. Tighten ite~s D and E securely. 3. To obtain a flush condition between the top edge of the glass and channel assembly and the belt line when the window is in the down position, the stop assembly is adjusted up or down at screw and washer assemblies U. After adjustment, tighten the screw and washer assembliesU securely. DOOR WINDOW MENT -MUSTANG

ADJUST-

1. Remove the door trim panel and watershield. 2. With the glass and channel assembly in the up position, the vent window assembly is adjusted forward or backward and up or down at

points A to obtain a parallel clearance between the windshield side moulding and the forward edge of the front door vent window frame, typical of Fig. 5. Adjustment fore and aft is to be made so that the glass and channel assembly will operate freely with no binding in the door glass lockside run and retainer assembly, but still have adequate engagement of sliding glass with the vent window division bar run and bracket assembly. Tighten the screw and washer assemblies at point A sufficiently to hold the vent window in position. 3. To obtain proper alignment with the windshield outside side moulding and to obtain the proper interference between the roof rail weatherstrip and the top edge of the vent window frame, the vent window assembly may be tilted toward the inside or outside of the body by rotating the adjusting screw at point B clockwise or counterclockwise. Tighten the jam nut at point B. Then, adjust the set screw at point C until the shoulder of the screw is against the door vent window division bar lower support. Do not create any bind or distort the glass run. After adjustment, tighten the jam nut at point C. Tighten the

VI EW - FF N 1080- C

PART 17-3 VENT

WINDOW

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ASSEMBLY - 21402- 3 '-

17-33

DOORS,WINDOWS,TAILGATEAND DECKLID

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FIG. 4-Door Window Mechanism-Falcon,Comet,Fairlane-Model 62 screw and washer assemblies at point A. 4. To obtain tlie proper interference of the glass assembly against the outside belt rail weatherstrip and the roof rail weatherstrip, the

glass assembly may be adjusted to tilt toward the inside or outside of the body at points D and E. After adjustment, tighten the screw and washer assembliesat points D and E. 5. To obtain a flush condition be-

tween the top edge of the glass and channel assembly and the top edge of the vent window frame, the front stop assembly is adjusted up or down at point F; after adjustment, tighten the screw and washer assembly at point F securely. (See View AA, Fig. 5). 6. To make the top edge of the glass assembly parallel to the roof rail weatherstrip, the equalizer arm bracket and the rear stop assembly may be adjusted up or down as required at points G and H. After adjustment, tighten the nuts at points G and the screw and washer assembly, point H securely. REAR DOOR WINDOW ADJUSTMENT -COMET I FALCON, 1.

FIG. 5-Door Window Mechanism-Mustang

FAIRLANE

Remove the door trim panel

and watershield. 2. To obtain proper alignment of retainer and division bar assemblyto door- window frame, loosen nut and washer assembly C. Drop the glass and channel assembly to its down position and turn screw B clockwise or counterclockwise as required. Tighten nut and washer assembly C securely (Fig. 6).

17-34

FIG-

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17-36

GROUP 17 BODY DOORSAND WINDOWS

3. Install the watershield and door trim panel. QUARTER WINDOW ADJUSTMENT -COMET, FALCON, FAIRLANE-MODEL 62 1. Remove the quarter trim panel and watershield. 2. To obtain proper clearance between the quarter window assembly and the quarter window glass run retainer assembly, operate the window to its full down position, loosen screw and washer assembly D, and adjust the retainer assembly forward. After adjustment, tighten the screw and washer assembly finger tight (Fig. 7). 3. To obtain proper clearance between the quarter window assembly and the quarter window glass run retainer assembly, operate the window to its full up position. Loosen screw and washer assemblies D and adjust the retainer assembly forward. After adjustment, tighten screw and washer assemblies D securely. 4. Install the watershield and quarter trim panel. QUARTER WINDOW ADJUSTMENT-COMET, FAIRLANE MODEL 63 1. Remove the quarter trim panel and watershield to provide access. Refer to Fig. 8 for the following procedure. 2. Temporarily loosen screw and washer assembliesA, B, C, E, F, G, R, K, and L (Fig. 8). 3. It is necessary to obtain a 0.26 to 0.30 inch parallel dimension between the front edge of the quarter window frame and the rear edge of the door window frame as shown in view B, the 0.26 inch parallel dimension as shown in view C, and maintain height relationship of the quarter window to the door window frame and roof rail weatherstrip. To do this, set the quarter window assembly into position and temporarily secure the front guide assembly and the rear guide assembly, by tightening screw and washer assemblies G and B finger tight. Also secure the upper stop assemblies and the door window stop bracket, by tightening the screw and washer assemblies K, Land M securely. Th~ extension assembly, quarter window front guide lower bracket, is secured by tightening screw and washer assembliesE. 4. To obtain proper alignment of the quarter window assembly with

I

the door window glass and channel assembly and proper interference with the roof rail weatherstrip, tilt the front guide assembly inboard or outboard at the bottom as required. When adjustment is complete, tighten screw and washer assemblies H securely. 5. Cycle the quarter window assembly to its down position, flush with the top of the quarter panel. This will locate the rear guide assembly and quarter window rear guide lower extension assembly in its proper position. 6. Tighten screw and washer assemblies A and C securely. Position the quarter window lower stop assembly firmly against the bottom edge of the quarter window assembly and tighten screw and washer assemblies F securely. 7. Cycle the quarter window assembly to its down position and secure the front and rear guide assemblies by tightening screw and washer assembliesBand G securely. 8. Install the watershield and quarter trim panel. QUARTER WINDOW ADJUSTMENT-COMET, FAIRLANE MODEL 76 1. Remove the quarter trim panel and watershield. 2. Loosen the screw and washer assemblies A, B, E, G, K, Land M (Fig. 9). 3. Position the window fore and aft", and tilt it fore and aft as required for alignment to the front door window and roof rail. This will properly position the quarter window guide panel assembly. Tighten screw and washer assemblies E securely. 4. Position the upper stop assemblies (Fig. 9) and the quarter upper stop brackets and tighten the retaining screw and washer assemblies L and M. 5. Secure the window guide lower bracket to the guide assembly by tightening screw and washer assem'" bly G. 6. To provide alignment with the front door window and an interference fit with the roof rail weatherstrip, tilt the guide assembly inboard or outboard as required. Tighten screw and washer assemblies A and B. 7. Cycle the window to its down position so that the top of the window is flush with the belt line. Position the lower stop assembly

against the window channel and tighten the lower stop assembly retaining screw K (Fig. 9). 8. Cycle the window up and down to recheck alignment. Then, install the watershield and quarter trim panel. QUARTER WINDOW ADJUSTMENT -MUSTANG 1. Remove the rear seat cushion and seat back. 2. Remove the quarter trim panel and watershield. 3. To obtain the 0.28-inch parallel dimension between the front edge of the quarter window frame and the rear edge of the door window frame as shown in sectional view AA (Fig. 10) and to maintain a parallel alignment and interference between the top edge of the quarter window assembly and the roof rail weatherstrip, the quarter window guide assembly is adjusted forward or backward and up or down at the screw and washer assembly items A. See sectional views BB and CC (Fig. 10). Tighten the screw and washer assembly at items A, finger tight. 4. To obtain the proper alignment and interference between the top edges of the quarter window assembly and the roof rail weatherstrip, the guide assembly may be tilted toward the inside or outside of body at the screw and washer assembly at items A and B. After adjustment, tighten the screw and washer assemblies, items A and B securely. 5. To obtain the proper level between the quarter panel at the belt line and top edge of the glass and channel assembly, the quarter window stop may be adjusted up or down as required at the screw and washer assembly, item C. This adjustment is made with the window in the down position. After adjustment, tighten the screw and washer assembly, item C securely. TAILGATE EMERGENCY OPENING PROCEDURE Should failure occur on the power operated tailgate window in the up position, entry can be accomplished by disconnecting the window regulator arms from the glass assembly. Use the following procedure: Carefully insert a hooked tool or wire between the outer weatherstrip and the tailgate window. Locate the window regulator arm rollers. Insert the hooked tool into the roller retaining spring clip and remove the

PART 17-3 - DOORS,WINDOWS,TAILGATEAND DECKLID

clip from the roller. Hold the tailgate window firmly and pry the regulator arms off of the two rollers, carefully lower the window into the tailgate, then open the tailgate. DUAL-ACTION TAILGATE ADJUSTMENTS While full adjustments are provided for the dual action tailgate, no unique methods are employed. The following information will assist in locating and performing the adjustments. The fore and aft and up and down adjustment of the tailgate is accomplished at the hinge side by means of square holes in the body pillar, backed by floating tapping plates, at the upper and lower hinge attachments (Fig. 11 and 12). Lateral adjustment of the tailgate is accomplished at the upper hinge by adding or removing spacer shims between the hinge on the body and the pillar. Lateral adjustment at the lower hinge is accomplished by means of oversize holes in the tailgate at the hinge on the gate attachment (Figs. 11 and 12). Fore and aft and up and down adjustment of the strikers is accomplished by means of square holes in the pillar backed by floating tapping plates. Lateral adjustment is accomplished by adding or removing shims (Fi2. 13).

STANDARD TAILGATE HINGE ADJUSTMENT The tailgate can be adjusted fore or aft and up or down at the hinge

17-37

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FLOATING TAPPING PLATES IN PILLAR PROVIDE FORE & AFT AND UP &DOWNADJUSTMENT (LOOSEN SCREWS)

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17-38

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to side in the tailgate opening, re~ move the trim panel, loosen the hinge to tailgate bolts and shift the tailgate as required. DECK LOCK ADJUSTMENT The striker plate can be adjusted laterally and vertically and the lock can be adjusted laterally. Before adjusting the deck lid lock, make sure that the deck lid is properly aligned. To adjust the lock, loosen the attaching screws, move the lock as required to make good contact and tighten the attaching screws. Move the striker plate up or down as necessary to increase or decrease the clearance between the deck lid and the lower back panel.

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FIG. 13-Tailqate LockStrikerAdjustment

DECK LID ALIGNMENT The deck lid can be shifted fore and aft, up and down, and from side to side. Slotted holes in the lid provide fore and aft movement. Slotted hinge bolt holes in the mounting bracket provide up and down movement. Enlarged hinge mounting bolt holes in the lid inner panel provide limited lateral movement.

PART 17-3

DOORS,WINDOWS,TAILGATEAND DECKLID

17-39

REMOVAL AND INSTAllATION DOORS REMOVAL 1. Remove the door hinge-to-door attaching bolts, and remove the door. 2. If a hinge is damaged, remove the pillar attaching bolts and remove the hinge: 3. If the door is damaged, a replacement door is furnished as a sheet metal shell in prime paint. It has no hinges, trim, glass, runs, or hardware. When a door is replaced, make any needed minor repairs to the new shell, drill holes necessary for mouldings, paint the door, and transfer all usable parts. Cement the weatherstrip properly. If only a door outer panel is seriously damaged, the whole door need not be replaced. A replacement outer panel is available. INSTALLATION 1. If the hinge was removed, install it to the pillar. 2. Position the door to the hinges. Partially tighten the bolts, align the door, and tighten the bolts securely. 3. Align the door glass, glass runs, stops, regulator, and remote control. 4. Install the door water shield and the door trim.

FRONT DOOR LOCKEXCEPTMODELS 63, 76

REMOVAL 1. Remove the position the water

trim

panel

and

shield away from

the accessholes. 2. Disconnect the door lock remote control link, the lock actuating rod and the lock control to cylinder at the lock (Fig. 14). Remove the knob from the push button rod. 3. Remove the glass rear run lower retaining bolt and position the run away from the door lock. 4. Remove the lock assembly from the door. Remove the push button rod from the lock. INSTALLATION 1. Connect

the push button rod to

the lock. 2. Position the lock in the door, and install the retaining screws. Connect the lock control to cylinder rod, the lock actuating rod, and the remote control link at the lock. Install the push button. 3. Position the glass rear run in the door. Install the retaining bolt, adjust the rear run, and ti2hten the

retaining bolt. 4. Check the operation of the lock. If necessary, adjust the lock striker. 5. Carefully position the water shield to the inner panel; and install the trim panel. FRONT DOOR LOCK-

MODELS, 63,

76

REMOVAL 1. Remove the door trim panel and watershield. 2. Remove the door window glass channel bracket retaining screws. Prop the window in its up position and cycle the regulator arms to the down position. 3. Disconnect the control rods from the lock assembly (Fig. 14). 4. Remove the three screws retaining the lock assembly and remove the lock assembly from the door. INSTALLATION 1. Position the lock assembly in the door and install the three lock assembly-to-door retaining screws. 2. Connect the control rods to the lock assembly. 3. Raise the window regulator arms and bracket and install the regulator arm bracket-to-window channel retaining screws. Remove the prop used to temporarily hold the window in its up position. 4. Install the door trim watershield and the door trim panel. REAR DOOR LOCK REMOVAL 1. Remove the trim panel and position the water shield away from the access holes. 2. Disconnect the door lock remote control rod and door lock control rod at the door lock assembly. 3. Remove the three screws retaining the lock assembly to the door and remove the lock assembly from the door (Fig. 14) INSTALLATION 1. Position the lock assembly in the door, and install the retaining screws. 2. Connect the door lock remote control rod and the door lock control rod at the door lock assembly. 3. Check the operation of the lock. If necessary, adjust the lock striker. 4. Carefully position the water

shield to the inner panel, and install the trim panel. DOOR LOCK CYLINDER The key code is stamped on the lock cylinder to assist in replacing lost keys. When a lock cylinder is replaced, both door lock cylinders and the ignition lock cylinder should be replaced in a set. This will avoid carrying an extra key which will fit only one lock. 1. Remove the trim panel and position the water shield away from the access holes. 2. Disconnect the lock control to door lock cylinder rod at the lock cylinder. 3. Pull the door lock cylinder retainer rearward to release the cylinder, and remove the lock cylinder from the door. 4. Transfer the lock cylinder arm to the new lock cylinder. 5. Position the lock cylinder in the door, and install the lock cylinder retainer (Fig. 14). 6. Connect the lock control to door lock cylinder rod at the lock cylinder. 7. Carefully position the water shield to the inner panel and install the trim panel. DOOR HANDLE AND/OR PUSH BUTTON 1. Remove the door trim panel, and position the water shield away from the access holes. 2. Remove the handle retaining screw and nut, and remove the handle (Fig. 14). To remove the front door handle, it will be necessary to disconnect the lock actuating link. 3. To replace the push button remove the retaining plate screw, retaining plate, spring, push button, and rubber seal from the handle. 4. Install the push button assembly if it was removed, and install the handle assembly. Connect the lock actuating link to the door handle. 5. Carefully position the water shield to the inner panel, and install the trim panel. DOOR VENT WINDOW FRAME -EXCEPT MODELS 63, 76 1. Remove the door trim panel, trim panel lower retainer and the watershield.

FIG. 14-Door Handle and LockInstallation

PART 17-3 - DOORS, WINDOWS, TAILGATE AND DECKLID 2. Remove the inner and outer door belt line weatherstrips (view D, Fig. 4) by prying them loose from the door. 3. Remove the window lower stop and completely lower the door window. 4. Remove the front glass run adjusting bolt, lock nut and washer. 5. Remove the front glass run from the division bar retainer at the vent frame by sliding the run down and removing it from the door through the inner panel access hole. 6. Remove the three screws retaining the vent frame to the door frame. Remove the vent window assembly and place it on a bench. 7. Remove the screws retaining the upper vent pivot to the vent frame assembly. Remove the nut retaining the lower pivot bolt and remove the spring nylon bushings, washer and stop washer. 8. Remove two screws from the top of the assembly and remove the four rivets retaining the vent frame and division bar weatherstrip. Separate the frame and division bar. 9. Using a tool such as shown in Fig. 15, remove the glass. Remove the weatherseal. INSTALLATION 1. Position new weatherseal to the vent glass. 2. Lubricate the weatherseal with Ru-Glyde and seat the glass assembly in its channel. 3. Position the division bar to the vent frame. Position the vent frame and division bar weatherstrip and install the four rivets and two screws at the top of the frame. 4. Assemble the vent tension spring to the lower pivot and adjust the pivot spring tension so that the window will stay open at highway soeeds. GLASSAND CHANNEL REMOVAL TOOL (NO. 2900) AVAILABLE FROM SOMMERAND MALA GLASS MACHINE COMPANY, 5501 W. OGDEN AVENUE. CHICAGO 50. ILLINOIS

FIG. 1 S-Glass Channel Replacement

5. Position the frame assembly on the door and install the three retaining screws. 6. Position the glass front run in the door and slide it into the vent frame retainer. 7. Loosely install the front run adjusting bolt and nut. 8. Raise the window halfway and loosely install the lower glass stop. 9. Adjust the front run and tighten the retaining nut. 10. Lower the window so that the top of the glass is level with the window opening belt line. 11. Install the belt line weatherstrips. 12. Install the door watershield and trim panel. VENT WINDOW OR WEATHERSTRIP-MODELS 63, 76 REMOVAL The vent window glass may be removed and/ or installed by using the tool shown in Fig. 15. When installing new glass, use new glass tape, and apply sealer to the frame horizontal channel and to the other channel in the area of the upper pivot. 1. Remove the door trim panel and position the water shield away from the access holes. 2. Remove the front run bracket retaining bolt, and position the run out of the vent window division bar (Fig. 2). 3. Remove the door vent window assembly retaining bolts and retaining nut, and remove the vent window assembly. 4. Remove the upper pivot from the frame and remove the lower pivot spring assembly, then remove the vent window and frame. 5. Remove the weatherstrip. INSTALLATION 1. Install the weatherstrip. 2. Position the vent window and frame into the vent assembly. 3. Install the pivot and the pivot spring assembly. Adjust the spring tension so that the vent glass will stay open when the car is driven at highway speeds. 4. Position the vent window assembly in the door and install the retaining bolts and retaining nut snugly. 5. Position the front run in the vent window division bar and install the retaining bolt snugly. 6. Align the vent window and front run and tighten the retaining bolts and retaining nut.

17-41

7. Carefully position the water shield to the inner panel and install the trim panel. FRONT DOOR GLASSEXCEPT MODELS 63, 76 REMOVAL 1. Remove the trim panel and position the water shield away from the access holes. 2. After removing the stop (Fig. 4), lower the glass until the regulator arm roller is out of the glass channel. 3. Unsnap and remove the belt weatherstrips, loosen the front run attaching bolt at the mounting bracket, and remove the bracket attaching bolt from the inner panel. 4. Remove the front run from the division bar by pulling rearward on the edges of the run. 5. Remove the glass. INSTALLATION 1. Using the tool shown in Fig. 15, remove the channel from the glass. 2. Install the channel, using new glass tape. 3. Simultaneously, position the glass and run in the door, and install the belt weatherstrips. 4. Position the regulator arm roller in the channel, and finally position the run in the division bar. S. Connect the run and bracket, making necessary lateral adjustment. 6. Install the stop, making necessary adjustment. 7. Carefully position the water shield, the inner panel, and install the trim panel. FRONT DOOR GLASS-COMET, FAIRLANE-MODEL 63, 76 REMOVAL 1. Remove the door trim panel and watershield. 2. Remove the door trim panel upper retainer from the door. This provides accessto the window upper stop retaining screws. 3. Remove the window upper stops (Fig. 2). 4. Remove the vent window and division bar retaining screws and nuts (Fig. 1). s. Remove the rear guide retaining screws and nuts. Remove the rear guide from the door. 6. Remove the glass channel roller brackets from the lower window channel. 7. Lower the window assembly into the door. 8. Remove the door belt inner

17-42

GROUP 17 BODYDOORSAND WINDOWS

weatherstrip by unsnapping the weatherstrip retainer clips from the door inner panel. 9. Remove the run assembly from the vent division bar. 10. Remove the vent window assembly from the door. 11. Lift the door glass assembly up and out of the door. 12. Remove the frame from the glass. INST ALLA nON 1. Position the frame on new glass. 2. Position the door glass assembly in the door. 3. Position the vent window assembly in the door. 4. Install the front run assembly in the Vent division bar. 5. Snap the door belt inner weatherstrip and retaining clips into place on the door inner panel. 6. Raise the door glass and install the regulator channel brackets on the lower window frame. 7. Position the rear guide assembly in the door and install, but do not tighten, the retaining nuts and screws snug. 8. Position the window upper stops and install, but do not tighten, the stop retaining screws. 9. Adjust the vent window assembly to the front pillar and tighten the division bar retaining screws and nuts. 10. Adjust the rear guide and tighten the retaining nuts and screws. 11. Adjust the window upper stops and tighten the stop retaining screws. 12. Install the door trim panel upper retainer. 13. Install the door trim panel watershield and the door trim panel. FRONT DOOR WINDOW REGULATOR-MANUALCOMET, FAIRLANE-MODEL 63,76

REMOVAL 1. Remove the front door trim panel and watershield. 2. Remove the four regulator assembly retaining screws. 3. Prop the window in its up position and remove the front channel bracket from the window frame. 4. Loosen the front run retaining nut and remove the regulator from the door. The regulator arm rollers will slide out of the rear channel bracket and the equalizer arm bracket to permit removal of the re2ulator assemblv from the door.

I

INSTALLATION 1. Position the regulator assembly in the door and install the regulator arm rollers in the channel brackets. 2. Align the regulator retaining screw holes with the retaining screw holes in the door panel and install the four regulator assembly retaining screws. 3. Install the front run lower retaining nut. 4. Install the front channel bracket on the window frame. S. Install the watershield and door trim panel. FRONT DOOR WINDOW REGULATOR-EXCEPT MODELS 63, 76 REMOVAL 1. Remove the trim panel and position the water shield away from the access holes. 2. Disconnect the regulator from the glass channel roller. 3. Raise the glass by hand and secure it in the raised position. 4. Remove the regulator retaining bolts (Fig. 3) and remove the regulator through the door access hole. INSTALLATION 1. Position the regulator inside the door and install the retaining bolts snugly. 2. Lower the glass and connect the regulator. 3. Check the operation of the glass, adjust it if necessary, and tighten the retaining bolts. 4. Carefully position the water shield to the inner panel and install the trim panel. FRONT DOOR REAR GLASS RUN-MODELS 63, 76 REMOVAL 1. Remove the trim panel and position the water shield away from the accessholes. 2. Remove both window upper stop brackets from the glass lower channel. 3. Disconnect both regulator arms from the glass lower channel, and remove the rollers. Remove the glass assembly. 4. Remove the glass rear run lower retaining bolt. Remove the run upper adjusting screw lock nut. Do not disturb the position of the adjusting screw. Remove the run from the door. INSTALLATION 1. Position the rear run in the

door and install the lower retaining bolt and upper adjusting screw lock nut snugly. 2. Position the glass assembly in the door. Install the rollers in the glass lower channel, and connect both regulator arms. 3. Attach the window upper stop brackets to the lower channel. 4. Adjust the rear run and tighten the retaining bolt and nut. 5. Carefully position the water shield to the inner panel and install the trim panel.

REAR DOOR GLASS-COMETI FALCON-MODEL 54 REMOVAL 1. Remove the door trim panel and watershield. 2. Remove the two screws retaining the regulator roller channel bracket to the lower window channel (Fig. 3). 3. Remove the lower stop assembly. 4. Remove the screw and nut retaining the rear run retainer and stationary glass. Move the run retainer and glass back and down in the door. 5. Remove the door belt, outside weatherstrip. 6. Tilt the door window down and then lift it out of the door. 7. Using a tool such as shown in Fig. 15, remove the glass from the lower channel. INSTALLATION 1. Position new glass tape on the glass and, using a tool such as shown in Fig. 15, install the lower channel on the glass. 2. Position the glass and channel assembly in the door. 3. Position the rear run retainer and stationary glass assembly and install the retainer screw and nut. 4. Install the regulator roller channel bracket on the window channel. 5. Install the lower window stop. 6. Install the door trim watershield and the door trim panel. 7. Install the window outside belt weatherstrip. REAR DOOR WINDOW REGULATOR REMOVAL 1. Remove the trim panel and position the water shield away from the accessholes. 2. Disconnect the regulator from the glass channel roller. 3. Raise the glass by hand and secure it in the raised position.

PART 17-3 - DOORS, WINDOWS, TAilGATEAND DECKLID 4. Remove the regulator retaining screws and remove the regulator through the door access hole. INSTALLATION 1. Position the regulator inside the door and install the retaining screws snugly. 2. Lower the glass and connect the regulator. 3. Check the operation of the glass, adjust it if necessary, and tighten the retaining bolts. 4. Carefully position the water shield to the inner panel and install the trim panel. QUARTER GLASS-MODEL 62 REMOVAL 1. Remove the rear seat cushion and back. 2. Remove the trim panel and position the water shield away from the accesshole. 3. Remove the lower and front garnish moldings. 4. Remove the rear run. 5. Lower the window until the regulator rollers are accessible, and disconnect the front rollers from the channel. 6. Lower and tilt the glass to remove it. INSTALLATION 1. Transfer the channel, using the tool shown in Fig. 15. 2. Position the glass in the quarter panel, and connect the front rollers. 3. Install the rear run, adjusting it as necessary. 4. Install the garnish mouldings, position the water shield, and install the trim panel. 5. Install the seat cushion and back QUARTER WINDOW REGULATOR-MODEL 62 REMOVAL 1. Remove the rear seat cushion and back. 2. Remove the trim panel and position the water shield away from the accesshole. 3. Disconnect the regulator from the glass channel rollers. 4; Raise the glass by hand and secure it in the raised position. 5. Remove the regulator retaining bolts, slide the regulator arm out of the equalizer and remove the regulator. INSTALLATION 1. Position the regulator inside

the quarter panel, engage the arm in the equalizer, and install the regulator retaining bolts snugly. 2. Position the rollers in the glass channel, lower the glass and connect the regulator. 3. Check the operation of the glass, adjust it if necessary, and tighten the retaining bolts. 4. Position the water shield, and install the trim panel. 5. Install the seat cushion and back. QUARTER WINDOW REGULATOR-MODEL 63 REMOVAL 1. Remove the rear seat cushion and seat back. 2. Remove the quarter trim panel and watershield. 3. Remove the screws retaining the glass channel bracket to the lower glass channel and remove the glass channel bracket. Prop the window assembly in its up position. 4. Remove the four screws retaining the regulator assembly to the quarter panel and remove the regulator assembly. INSTALLATION 1. Position the regulator assembly in the quarter panel and install the four regulator retaining screws. 2. Remove the prop used to hold the window up and install the glass channel bracket on the glass channel. 3. Install the quarter trim panel watershield and trim panel. 4. Install the rear seat back and cushion. QUARTER WINDOW FRONT GUIDE-MODEL 63 REMOVAL 1. Remove the rear seat cushion and seat back. 2. Remove the quarter window handle, ann rest, the quarter trim panel, trim panel retainer, garnish moulding, and position the water shield away from the access hole. 3. Remove the quarter window front guide lower retaining bolts and the adjuster screw lock nut. 4. Turn the adjuster screw to its full in position. 5. With the quarter glass in the lowered position remove the quarter window front guide from the glass channel rollers. 6. Remove the quarter window front guide through the access hole with the window glass in the up position.

17-43

INSTALLATION 1. With the quarter glass in the up position, install the quarter window front guide into the glass channel rollers. 2. Install the quarter window front guide retaining bolts and adjuster screw lock nut snugly. 3. Check the operation of the glass, adjust it if necessary, and tighten the retaining bolts and adjuster screw lock nut. 4. Position the water shield and install the garnish moulding, trim panel retainer, quarter trim panel, regulator handle, and arm rest. S. Install the rear seat back and seat cushion. QUARTER WINDOW REAR GUIDE-MODEL 63 REMOVAL 1. Remove the rear seat cushion and seat back. 2. Remove the quarter window handle, arm rest, quarter trim panel, trim panel retainer and garnish moulding, and position the water shield away from the access hole. 3. Position the rear seat back panel cardboard away from the seat back panel. 4. Remove the quarter window rear guide retaining bolt and adjuster screw lock nut, and remove the rear guide. INSTALLATION 1. Position the rear guide in the quarter and install the retaining bolt and adjuster screw lock nut snugly. 2. Check the operation of the glass, adjust it if necessary, and tighten the retaining bolt and adjuster screw lock nut. 3. Install the rear seat back panel card board. 4. Position the water shield, and install the garnish moulding, trim panel retainer, trim panel, regulator handle, and arm rest. S. Install the rear seat back and seat cushion. REAR QUARTER WINDOW GLASS-FAIRLANE, COMETMODEL 76 REMOVAL 1. Remove the rear seat cushion, seat back and quarter trim panel. 2. Remove the quarter window upper stops. 3. Remove the lower glass channel bracket (Fig. 9) from the lower glass channel. 4. Remove the three quarter window guide panel retaining screws.

1 7-44

GROUP

5. Raise the top assembly off the windshield header far enough to permit clearance between the window and roof side rails. 6. Remove the window from the quarter panel. 7. Remove the retaining screw from the weatherstrip and remove the weatherstrip from the window. 8. Remove the screws retaining the window top frame and remove the frame from the glass. 9. Using a tool such as shown in Fig. 15, remove the glass from the lower and side channel. INSTALLATION 1. Using a tool such as shown in Fig. 15, install the lower and side channels on the glass. 2. Position the top frame on the glass assembly and install the frame retaining screws. 3. Position the quarter window weatherstrip on the window assembly and install the weatherstrip retaining screw. 4. Position the quarter window in the guide assembly and install the guide retaining screws snugly. 5. Install the lower glass channel bracket on the glass channel. 6. Install the window upper stops snugly.

17-BODY,

DOORSAND WINDOWS

7. Raise the top assembly and fasten the top hold-down clamps. 8. Align the window assembly to the door glass and top side rails. Adjust the upper and lower window stops and tighten all retaining screws. 9. Cycle the window assembly up and down to insure proper adjustment. Then, install the quarter trim panel, rear seat back and seat cushion. REAR QUARTER WINDOW AND/OR WEATHERSTRIP MODEL 71 REMOVAL 1. Remove the spare tire cover and spare tire. 2. Remove the inside lower garnish moulding from the wheel well area. 3. Remove the quarter window inside front garnish moulding. 4. Remove the quarter window outside front moulding (Fig. 16). 5. Working from inside the car, loosen the weatherstrip from the window opening flange, and push the window, weatherstrip and moulding assembly out of the opening. 6. Remove the moulding and weatherstrip from the glass. 7. Using solvent, remove all old

sealer from the window opening flange, the window and the weatherstrio. INSTALLATION 1. Apply a bead of sealer around the window opening flange. 2. Position the weatherstrip on the glass and install the outer moulding in the weatherstrip. 3. Install a draw cord in the weatherstrip, and apply Ru-Glyde to the weatherstrip surfaces that will contact the window opening flange. 4. Position the window assembly to the window opening and use the draw cord to pull the weatherstrip over the window opening flange. 5. Using a caulking gun, apply sealer between the outside of the glass and the weatherstrip. 6. Install the outside front moulding retaining screws (Fig. 16). 7. Install the inside quarter window front garnish mouldings. 8. Install the inside lower garnish moulding. 9. Check for water leaks, then clean the glass and mouldings. 10. Install the spare tire and cover. WINDSHIELD-COMET, FALCON, FAIRLANE Following is a generalized pro-

7-46

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PART 17-3 cedure for windshield glass replacement. Refer to Figs. 17 and 18 for Comet, Falcon or Fairlane models. On convertible models, lower the top assembly. REMOVAL 1. Model 76: Remove the pillar weatherstrips, weatherstrip retainer retaining screws and the weatherstrip retainers. 2. Remove the wiper arm and blade assemblies. 3. Remove the cowl top ventilator grille panel retaining screws and remove the cowl top ventilator grille panel. 4. Remove the outside top moulding retaining screws (Model 76) or unsnap the upper moulding retainers, (all other models), using tool T64P42430 R or L and remove the outside top moulding. 5. Remove the outside side moulding retaining screws and remove the outside side mouldings. 6. Remove the outside lower moulding retainer retaining screws. Remove the outside lower moulding and retainers. 7. Remove the sun visor and bracket assemblies. 8. Remove the interior rear view

DOORS,WINDOWS,TAilGATEAND DECKLID

mirror. On models with the rear view mirror attached to the glass do not remove the mirror bracket from the glass. 9. Remove the interior garnish mouldings. 10. With the aid of an assistant, and using a length of piano wire inserted between the seal and the flange of the window opening, cut the seal around the perimeter of the glass. 11. Remove the windshield glass. 12. Remove the remaining butyl tape seal from th.e pinchweld flange of the window ope.ning and remove the moulding retainers and spacers from the pinchweld flange. INSTALLATION 1. Clean the pinchweld flange and prime the flange. 2. Install the spacers and moulding retainers on the pinchweld flange. 3. Temporarily position the glass in the opening. Mark the center of the glass and the cowl. Position suction cups on the outside of the glass to facilitate handling. 4. Remove the glass from the opening. Clean a one inch surface around the inside outer perimeter of the glass and prime this surface with the primer supplied in Kit

FIG. 19-Windshield Installation-MustangBodyTypes63, 6S

17-47

C4AZ-19562-A. 5. Mix two tubes of sealer as directed in Kit C4AZ-19562-A. 6. Position the sealer in a caulking gun and apply approximately a %6-inch bead of sealer to the inside edge of the glass. 7. Apply approximately a %6inch bead of sealer to the pinchweld flange. 8. Position the glass in the center of the opening, using the locating marks as a guide. 9. Remove the suction cups. 10. Install the outside mouldings. Be sure that the cowl top panel seal is installed under the lower outside moulding. 11. Install the cowl top ventilator grille panel. 12. Install the windshield wiper arm and blade assemblies. 13. Install the interior garnish mouldings, rear view mirror and sun visors. WINDSHIELD-MUSTANG MODEL 63, 65 REMOVAL 1. Using Tool T64P42430 R or L, remove the top left and right outside windshield mouldings (Fig. 19). 2. Using Tool T64P42430 R or L, remove the left and right wind-

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GROUP

17-48

use the draw cord to pull the lip of the weatherstrip over the window opening lower flange, each side flange and then over the upper flange. 8. Install the outside belt moulding (Fig. 19) by positioning it and snapping it over its clip retainers. 9. Install the outside side mouldings by snapping them over their clip retainers. 10. Install the top right and left outside side mouldings by snapping them over their clip retainers. 11. Clean the windshield and mouldings. 12. Install the windshield wiper arm and blade assemblies.

shield outside side mouldings. 3. Remove the windshield wiper arm and blade assemblies. 4. Using Tool T64P42430 R or L, remove the windshield outside belt mouldings (Fig. 19). S. Remove the windshield and weatherstrip assembly by pushing outward along the inner edges of the windshield. INSTALLA'llON 1. Remove the weatherstrip from the glass. 2. Clean all old sealer from the weatherstrip and the body opening flange. 3. Using a caulking gun, apply sealer in the weatherstrip glass opening. 4. Position the weatherstrip on the glass and install a draw cord in the body opening groove of the weatherstrip. 5. Using a caulking gun, apply a bead of sealer all the way around the body opening outer flange. 6. Apply rubber lubricant to the weatherstrip surface that contacts the body opening flange. 7. Position the windshield and weatherstrip assembly in the windshield opening and, with a helper applying pressure from the outside,

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17 - BODY I DOORSAND WINDOWS

WINDSHIELD-MUSTANG MODEL 76 REMOVAL 1. Lower the convertible top. 2. Remove the rear view mirror. 3. Remove the four upper garnish moulding retaining screws and remove the upper garnish moulding. 4. Remove the sun visor bracket and pivot retaining screws and remove the sun visor assemblies. 5. Remove the front upper body pillar weatherstrips (Fig. 20). Note that these weatherstrips are pressed into their retainers.

INSTALLADON 1. Remove the weatherstrip from the glass. 2. Clean all old sealer from the weatherstrip and the body opening flange. 3. Using a caulking gun, apply sealer in the weatherstrip glass opening. 4. Position the weatherstrip on the

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6. Remove the front upper body pillar weatherstrip retainer retaining screws (four) and remove the retainers. 7. Remove the retaining screw and two retaining nuts from each left and right windshield outside top moulding and remove the mouldings (Fig. 20, View AA). 8. Remove the two retaining screws from each windshield outside side moulding and, using Tool T64P42430 R or L, remove the outside side mouldings. 9. Remove the windshield wiper arm and blade assemblies. 10. Using Tool T64P42430 R or L, remove the windshield outside belt moulding. 11. Remove the windshield and weatherstrip assembly by pushing outward along the inner edges of the windshield.

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PART 17-3 - DOORS,WINDOWS,TAILGATE ANDDECKLID glass and install a draw cord in the body opening groove of the weatherstrip. 5. Using a caulking gun, apply a bead of sealer all the way around the body opening outer flange. 6. Apply rubber lubricant to the weatherstrip surfaces that contact the body opening flange. 7. Position the windshield and weatherstrip assembly in the windshield opening. With a helper applying pressure from the outside, use the draw cord to pull the lip of the weatherstrip over the window opening lower flange, each side flange and then over the upper flange. 8. Install the outside belt moulding (Fig. 20) by snapping the moulding over the retaining clips. 9. Install the outside side mouldings by snapping them over their retaining clips and install the retaining screws. 10. Position the left and right outside top mouldings and install the retaining screws and nuts. 11. Position the left and right front upper body pillar weatherstrip retainers (Fig. 20) and install the retaining screws. 12. Install the front upper body pillar weatherstrips by pressing them securely into their retainers. 13. Install the sun visor bracket

and pivot assemblies. 14. Position the upper garnish moulding and install the garnish moulding retaining screws. 15. Install the rear view mirror. 16. Clean the windshield and mouldings. 17. Install the wiper arm and blade assemblies.

17-49

2. Using a sealer gun, apply sealer in the weatherstrip glass opening. 3. Position the weatherstrip on the glass, and then install the mouldings in the weatherstrip. 4. Insert the draw cord in the weatherstrip, and apply rubber lubricant to the weatherstrip surfaces that will contact the back window opening flange. 5. Using a sealer gun, apply a bead of sealer completely around the back window opening. 6. Position the window assembly in the body opening. With a helper applying hand pressure from the outside, use the draw cord to pull the lips of the weatherstrip over the window opening flanges. 7. Install the outside lower left and right mouldings. 8. Install the outside upper left and right mouldings. 9. Clean the window and mouldmgs.

BACK WINDOW AND/OR WEA THERSTRIP-COMET, FALCON, FAIRLANE REMOVAL 1. Using Tool T64-P42430-R or L, release the outside upper mouldings (Fig. 21), from their moulding retainers and remove the outside upper mouldings. 2. Using Tool T64-P42430-R or L, release the outside lower mouldings from their moulding retainers and remove the outside lower mouldings. 3. From inside the car, loosen the weatherstrip edges and then push out the back window and weatherstrip as an assembly. 4. Place the window asembly on a bench and remove the weatherstrip from the glass.

BACK WINDOW-MUSTANG MODEL 65 REMOVAL 1. Using Tool T64P42430 R or L, remove the outside side mouldings ~nd the outside upper comer mouldmgs. 2. Using Tool T64P42430 R or L,

INSTALLATION 1. Clean the glass, weatherstrip and the body opening flange.

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17-50

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remove the outside upper moulding and the outside lower moulding. 3. Remove the back window and weatherstrip assembly by pushing outward along the inner edges of the glass. 4. Remove the weatherstrip from the glass. INSTALLATION 1. Clean all old sealer from the weatherstrip and the body opening

flange. 2. Using a caulking gun, apply sealer in the weatherstrip glass opening groove. 3. Position the weatherstrip on the glass and install a draw cord in the weatherstrip body opening groove. 4. Using a caulking gun, apply a bead of sealer all the way around the body opening flange. 5. Apply rubber lubricant to the weatherstrip surface that contacts the body opening flange. 6. Position the window and weatherstrip assembly in the body opening and, with a helper applying pressure from the outside, use the draw cord to pull the lip of the weatherstrip over the body opening flange. 7. Snap the outside lower mould-

BACK WINDOW-MUSTANG MODEL 63 REMOVAL 1. Remove the quarter trim upper front moulding retaining screws and remove the quarter trim upper front mouldings. 2. Remove the quarter trim upper rear moulding cap retaining screw and remove the cap. Remove the quarter trim upper left and right rear moulding retaining screws and remove the mouldings. (Fig. 23). 3. Remove the back window garnish moulding upper joint cover. Remove the back window upper left and right garnish moulding retaining screws and remove the mouldings (Fig. 23). 4. Remove the left and right vent

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air extractor grille assembly (quarter trim upper front panels) retaining screws and remove the panels (Fig. 23). 5. Remove the back window lower front left and right trim panel retaining bolts and screws and remove the panels (Fig. 23). 6. Remove the quarter trim upper rear left and right panel retaining screws and remove the panels. 7. Using moulding removal Tool T64P-42006-A or B, remove the back window exterior mouldings in the following order: right upper moulding, right lower moulding, left upper moulding and left lower moulding (Fig. 24). 8. With an assistant applying pressure from the inside, remove the back window and weatherstrip assembly. 9. Remove the weatherstrip from the glass.

ing into position over its retaining clips (Fig. 22). 8. Snap the outside upper moulding into position over its retaining clips (Fig. 22). 9. Snap the outside side mouldings into position over the retaining clips (Fig. 22). 10. Install the outside upper corner mouldings. 11. Clean the glass and mouldings.

INSTALLATION 1. Clean excess old sealer from the body window opening. 2. Clean old sealer from the weatherstrip if the weatherstrip is to be re-used. 3. Position the weatherstrip on the glass and install a pull cord (l/S inch sash cord) around the weatherstrip

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FIG. 23-lnterior Moulding and QuarterTrim Panel InstallationMustang Body Type 63 body opening groove. 4. With the aid of an assistant, position the glass and weatherstrip assembly in the body window open-

17-51

DOORS, WINDOWS, TAILGATE ANDDECKLID

ing. Use the pull cord to pull the lip of the weatherstrip over the pinchweld while applying pressure to the glass from the outside.

5. Apply sealer between the weatherstrip and the outside pinch weld flange. 6. Apply sealer between the outer glass surface and the weatherstrip. 7. Snap the window exterior mouldings into place in the following order; left lower moulding, left upper moulding, right lower moulding and right upper moulding. 8. Install the upper rear left and right quarter trim panels. 9. Install the upper front left and right quarter trim panels. 10. Install the back window lower front trim panel. 11. Install the upper rear left and right quarter trim mouldings and moulding cap. 12. Install the upper front left and right quarter trim mouldings. 13. Install the back window upper left and right garnish mouldings and garnish moulding joint cover. 14. Clean the back window and mouldings. INSIDE REAR VIEW MIRROR -BONDED TO WINDSHIELD REMOVAL 1. Clean both the inside and outside surfaces of the windshield in the area of the mirror mounting bracket. SEALER

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GROUP 17 - BODY,DOORS ANDWINDOWS

17-52

outside surface of the windshield (Fig. 25). 2. Use a good grade of Ethyl Alcohol to thoroughly clean the inside glass surface bracket mounting area and mounting bracket face. It is important that the mounting surfaces are properly cleaned before the resin is applied. 3. To mix the resin pour the entire contents of the small catalyst bottle ino the large epoxy bottle (Fig. 25). 4. Stir the contents for 3 to 5 minutes. To guarantee the correct mixing ratio and resulting bond strength it is mandatory that the entire contents of both bottles are used and properly mixed. Under no circumstances should only portions of the epoxy or catalyst be used. 5. Apply the mixed resin to the bracket mounting surface. Level off the resin film as smoothly as possible. 6. Place the mounting bracket

Inspect the windshield .for stone chips and scratches. 2. Using welding putty or wet rags, insulate all chips or scratches within 12 inches of the mirror mounting bracket. 3. Apply heat to the bracket mounting area from outside the windshield with a standard 250 watt infrared bulb (heat lamp). Hold the lamp approximately 4 inches from the windshield, and rotate it in a small circle. 4. The mirror mounting bracket can be pulled off the windshield glass in approximately 8-10 minutes using the mirror as a handle. 5. Slowly remove the heat lamp. Do not remove the insulating materials until the windshield has cooled to room temperature. 6. Remove the mirror and arm from the bracket. INSTALLATION 1. Locate and mark with a wax pencil the bracket location on the

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surface upward in a vise or in a small mound of permagum or any suitable holding material that will support the mounting bracket (Pig. 25). Hold a standard 250 watt infrared lamp about 5 to 6 inches from the mounting surface of the bracket for 21/2 minutes. 7. Allow the bracket to cool for one minute. With light hand pressure apply the mounting surface of the bracket to the desired inside area of the windshield. 8. Secure the bracket to the windshield using a piece of tape about 5 inches long located just under the knob of the bracket. Apply another piece of tape in the vertical direction to firmly hold the mounting bracket in place on the windshield. 9. When the temperatures are above 67°P., the mirror and arm should not be mounted to the bracket for 8 hours, to allow the resin to properly adhere the bracket to the glass. However, the car may be used with the bracket taped in place one hour after installation. When the temperatures are below 67°P., the mirror and arm should not be mounted to the bracket for 16 hours. However, the car can be used 2 hours after the bracket has been taped in place. 10. After the bracket has had time to adhere to the glass, remove the tape and install the mirror and arm to the bracket. TAILGATE GLASS REMOVAL 1. Open and temporarily support the tailgate. 2. Remove the tailgate cover panel retaining screws and remove the panel. 3. Remove the window regulator arm roller retaining pins, disconnect the arms from the rollers, and remove the rollers from the glass channel. 4. Remove the window from the tailgate. INSTALLATION 1. With a glass remover tool, remove the glass lower retainer and channel, and weatherstrip. 2. Remove the weatherstrip from the glass lower retainer and channel assembly, and then clean the glass groove. 3. Position the weatherstrip into the glass lower channel. Install the weatherstrip and channel to the 21ass.

4. Slide the window assembly into the glass runs and connect the regulator arms and rollers to the glass lower channel. 5. Apply Lubriplate to the glass rollers. 6. Clean the old sealer from the tailgate cover panel and apply new sealer. 7. Install the tailgate cover panel to the tailgate. 8. Connect the tailgate hinge supports and remove the temporary support. TAILGATE WINDOW REGULATOR-COMET, FAIRLANE REMOVAL If the tailgate window regulator mechanism should fail with the window in a partially closed or closed

position, the tailgate can be opened by removing the window side and upper runs (Fig. 26). 1. Open and temporarily support the tailgate. 2. Disconnect the tailgate hinge supports at the tail gate. 3. Remove the tailgate cover panel retaining screws and remove the panel. 4. Remove the window regulator arm roller retaining pins, disconnect the arms from the rollers, and remove the rollers from the glass channel. 5. Remove the tailgate window from the tailgate and scribe the regulator mounting location. 6. Remove the regulator retaining bolts and remove the regulator.

INSTALLADON 1. Place the regulator manual drive spline into the handle, align the regulator, and install the regulator retaining bolts. Install the window assembly in the tailgate. 2. Clean the old sealer from the tailgate cover panel and apply new sealer. 3. Install the tailgate cover panel to the tailgate. TAILGATE WINDOW REGULATOR-POWER REMOVAL If the tailgate window regulator mechanism should fail with the window in a partially closed or closed position, the tailgate can be

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17-54

GROUP

opened by removing the window side and upper runs (Fig. 26). 1. Open and temporarily support the tailgate. 2. Disconnect the tailgate hinge supports at the tailgate. 3. Remove the tailgate cover panel retaining screws and remove the panel. 4. Remove the window regulator arm roller retaining pins, disconnect the arms from the rollers, and remove the rollers from the glass channel. 5. Remove the window from the tailgate. 6. Disconnect the motor leads from the wiring harness in the tailgate. 7. Scribe the regulator mounting location, remove the regulator retaining bolts, and remove the regulator with the motor att~ched. INSTALLATION 1. Do not remove the electric regulator drive assembly for transfer to the new regulator until the regulator counterbalance spring is unloaded. To unload the regulator counterbalance spring, place the spring in a vise so that the spring cannot unwind, disconnect the spring from the outer retaining tab, and then slowly loosen the vise jaws. 2. Remove the screws retaining the regulator drive assembly and the motor to the regulator and remove the drive assembly and motor. 3. Position the drive assembly and motor to the new regulator and install the retaining screws. 4. Drill out the rivets retaining the manual clutch and housing assembly to the regulator. Remove and discard the manual drive assembly. The manual clutch and gear assembly should not be removed until the electric drive assembly is installed. 5. Install the regulator assembly on the tailgate and align the regulator as required. 6. Connect the wiring harness to the motor and secure the harness in place with the retainer. 7. Install the window assembly into the tailgate. 8. Apply Lubriplate to the glass rollers. 9. Clean the old sealer from the tailgate cover panel and apply new sealer. 10. Install the tailgate cover panel to the tailgate. 11. Connect the tailgate hinge supports and remove the temporary support.

17 - BODY I DOORS AND WINDOWS

TAILGATE SWITCH AND LOCK CYLINDER-POWER REMOVAL 1. Open and temporarily support the tailgate. 2. Disconnect the tailgate hinge supports at the tailgate. 3. Remove the tailgate cover panel retaining screws and remove the panel. 4. Remove the window regulator arm roller retaining pins, disconnect the arms from the rollers, and remove the rollers from the glass channel. 5. Remove the window from the tailgate. 6. Remove the regulator. 7. Remove the nuts retaining the lock and switch, and then remove the lock and lock cylinder from the tailgate (Fig. 27). 8. If the switch requires replacement, disconnect the switch wires from the tailgate wiring harness and remove the switch and wires. 9. To remove the lock cylinder, depress the lock cylinder retaining pin, insert the key and rotate the cylinder until the retaining pin drops, and then remove the lock cylinder. INSTALLATION 1. To install the lock cylinder, insert the key in the lock cylinder and slide the cylinder into the retainer. 2. To install the switch assembly, route the wiring harness through the tailgate to the tailgate harness switch connector. 3. Place the lock assembly and gasket to the tailgate and position the switch to the lock assembly. It may be necessary to rotate the lock cylinder to align the switch and the lock. Install the retaining nuts. 4. Install the window regulator. 5. Install the tailgate window assembly into the tailgate.

6. Apply Lubriplate to the glass rollers. 7. Clean the old sealer from the tailgate cover panel and apply new sealer. 8. Install the tailgate cover panel to the tailgate. 9. Connect the tailgate hinge supports and remove the temporary support. TAILGATE WINDOW HANDLE AND LOCK CYLINDERMANUAL REMOVAL 1. With the tailgate window in the closed position, unlock the tailgate handle, and rotate the handle assembly to reveal the mounting screws (Fig. 28). 2. Remove the handle mounting screws, and then remove the handle assembly and pad. 3. To remove the lock cylinder turn the key in the cylinder to align the cylinder locking pin with the access hole in the handle assembly. Depress the locking pin and remove the lock cylinder. INSTALLATION 1. To replace the lock cylinder, transfer the O-rings, and then with the key in the cylinder, install the lock cylinder in the handle assembly. 2. If the window regulator has been replaced, it may be necessary to reposition the handle assembly so that it hangs in a vertical position, with the tailgate window in a closed position. To adjust the handle position, remove the snap ring and socket from the window regulator stem, and then install the socket with the notch at the top. 3. Install the pad and handle assembly.

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FIG. 28-Tailgate Window RegulatorHandle Installation - Typical

PART 17-3 DUAL-ACTION TAILGATE HINGES REMOVAL AND INSTALLATION Upper Left Hinge 1. Open the tailgate (horizontally, as a dropgate) and scribe a location mark around that part of hinge to be replaced. 2. Remove the hinge retainer screws. 3. Position the hinge to the scribe marks and install the retainer screws. Lower Left Hinge 1. Open the tailgate (horizontally, as a dropgate) and position a support under the hinge side of the gate. 2. Remove the tailgate door check. Raise the tailgate partially and remove the torsion bar retainer link from the body. 3. Scribe the hinge location on the body and the tailgate. Remove the hinge retainer screws and remove the hinge. 4. Position the hinge to the body and tailgate scribe marks and install the hinge retainer screws. 5. Close the tailgate and check for proper lower hinge alignment. Adjust the hinge if necessary. 6. Open the tailgate partially and install the torsion bar retainer link to the body. 7. Install the tailgate door check. DUAL-ACTION TAILGATE LOCKS REMOVAL AND INSTALLATION Right Lower Lock 1. Open the tailgate (side opening). Remove the tailgate trim panel, watershield and access panel. 2. Disconnect the linkage from the lock. Remove the three retaining screws and remove the lock. 3. Transfer the linkage retainer clips to the new lock. Position the lock in the gate and install the retainer screws. 4. Install the linkage to the lock. Install the access cover, watershield and trim panel. Right Upper Lock 1. Open the tailgate (side opening). Remove the tailgate trim panel, watershield and access panel. 2. Engage the upper lock pawl to the closed position and raise the window partially out of the gate. Remove the regulator arms from the window regulator channel and re:move the window assembly.

DOORS, WINDOWS, TAILGATE ANDDECKLID

3. Disconnect the linkage at the upper lock. Remove the wire connector from the upper lock safety switch. 4. Remove the right guide upper retainer bolt. Remove the three screws retaining the lock and remove the lock assembly. 5. Transfer the linkage retainer clips and the safety switch to the new lock assembly. 6. Position the lock in the gate and install the lock retainer screws. Install the window guide upper retainer bolt. 7. Connect the wire connector to the switch and connect the linkage to the lock. 8. Position the window assembly in the gate and install the regulator arms to the regulator channel. Close the lock pawl to engage the switch and lower the window into the tailgate. 9. Install the tailgate accesspanel, watershield, and trim panel. Open the upper lock and close the tailgate. Check the lock alignment to the striker. Adjust the lock striker if necessary. DUAL-ACTION TAILGA TE TORSION BAR REMOVAL 1. Remove the tailgate trim panel, watershield and accesscover. 2. Move the tailgate glass out partially by closing the right upper lock pawl and turning the key in the tailgate cylinder. 3. Remove the lock control bellcrank assembly and window lower stop. 4. Loosen the window regulator motor harness to gain slack at the tailgate-to-body location. 5. Raise the tailgate partially and remove the torsion rod retainer link from the body (2 screws). 6. With an assistant, remove the left lower hinge pivot bolt. Unlock the right lower lock, remove one check cable retainer screw from each side and move the tailgate assembly away from the body opening. Place the tailgate on an appropriate stand approximately bumper high. 7. Remove the torsion bar retainer bracket and remove the torsion bar from the left side of the gate. (Fig. 29). INSTALLATION 1. Place the torsion bar in its respective mounting position and install the torsion bar right retainer bracket.

17-55

1. With an assistant, position the tailgate assembly to the body opening. Engage the right lower lock to the striker plate. Install the left hinge pivot bolt and install the check cable retainer screws. 3. Install the torsion bar retainer link to the body. 4. Position the motor wiring harness in its original position. 5. Install the window lower stop and lock the bellcrank assembly. 6. Lower the window in the tailgate to where the top edge of the glass is even with the weatherstrip and adjust the lower stop if necessary. 7. Install the tailgate accesscover, watershield and trim panel. DECK LID HINGE OR TORSION BAR REMOVAL 1. Prop the deck lid open. 1. Mark the hinge position on the lid and on the mounting bracket for reference when a new hinge is installed. 3. U.~ing a tool T64K-44890-B pry the anchor end of the torsion bar out of its adjustment notch (Fig. 30). Lower the deck lid and from inside the luggage compartment remove the bar. 4. Position a cover under the hinge edge of the deck lid to prevent paint damage. Remove the hinge attaching bolt from the deck lid and from the mounting bracket, and remove the hinge. INSTALLATION 1. Position the hinge, and partially tighten the mounting bolts. 2. Remove the protective cover and install the torsion bar, reversing the procedure in step 3 above. The farther rearward the anchor end is twisted, the greater the tension. 3. Remove the prop and check the lid position. After any necessary adjustment, tighten the hinge attaching bolts. DECK LID LOCK 1. Unlock and open the deck lid. 2. Remove the bolts retaining the lock assembly and remove the lock. 3. Position the lock assembly to the deck lid and loosely install the retaining bolts. 4. Adjust the lock assembly and tighten the bolts. DECK LID LOCK CYLINDER REMOVAL 1. Open the deck lid and remove

17-56

GROUP 17 - BODYDOORSAND WINDOWS I

"l.,

""

R 1114-C

FIG. 29-Tailaate LockMechanism

PART 17-3

-

DOORS, WINDOWS, TAILGATE ANDDECKLID

turn the key in the cylinder VB turn clockwise from the locked position and insert the cylinder into the sleeve assembly. 2. Position the sleeve assembly

'"

I"

N1189-A

FIG. 30-Deck Lid Torsion Bar

- Typical

the lock assembly and the door lock extension. 2. Remove the sleeveassembly retaining nut, lock washer, spacer, and sleeve and cylinder (Fig. 31). 3. To remove the lock cylinder from the sleeve assembly, turn the key in the cylinder Vs turn clockwise from the locked position, depress the cylinder retaining pin, and remove the key and cylinder. INSTALLATION 1

Tn

in~t..11

th..

l~k

"vlincfer

17-57

spacer, and washer to the deck lid door and install the retaining nut. 3. Position the door lock extension, install the lock assembly and adjust it.