
SECTION
3
FRONT SUSPENSION
INDEX
Page
General Description
. . . . 3-1
Maintenance and Adjustments
3-3
Front Wheel Bearing Adjustment
3-3
Front End Alignment
3-5 .
Alignment Preliminary Steps ............
3-5
Caster
and
Camber Adjustments
. . 3-5
Chevelle, Caxnaro
and
Corvette
3-5
Chevrolet and Chevy
II 3-6
Steering Axis Inclination
3-6
Toe-in Adjustment
3-6
Cornering Wheel Relationship
3-6
Riding Heigit
and
Coil Spring Sag
3-7
Repair Procedures
3-8
Front Brake Drum (Chevrolet, Camaro, Chevelle,
Chevy E)
. . 3-8
Removal
3-8
Installation
3-8
Front Wheel Hub
3-8
Replacement
. . . . . 3-8
Replacement
of
Hub Wheel Bolts
3-8
Front Wheel Bearings
. . 3-8
Removal
3-8
Inspection
3-9
Repairs
. . 3-9
Replacement
of
Bearing Cups
3-9
Installation
3-9
Steering Knuckle
. . . 3-9
Removal
3-9
Installation
3-9
Shock Absorber
3-10
Chevrolet, Chevelle, Camaro
and
Corvette
3-10
Removal
, . 3-10
Installation
3-10
Chevy
It 3-11
Removal
3-11
Installation
3-11
Stabilizer
Bar 3-11
Removal
3-11
Installation
3-11
Strut Rod
3-11
Chevrolet and Chevy
II 3-11
Removal
3-11
Installation
3-12
Front Coil Springs
3-12
Chevrolet
3-12
Removal
3-12
Installation
3-13
Chevelle
and
Camaro
3-13
Removal
3-13
Installation
3-14
Chevy H
3-14
Removal
3-14
Spring Seat Disassembly and Assembly
3-15
Installation
3-15
Corvette
3-15
Lower Control Arm Spherical Joint
.' 3-16
Chevrolet, Chevelle, Camaro and
Corvette
3-16
Inspection
. 3-16
Chevrolet and Corvette
3-16
Removal
3-16
Installation
3-16
Page
Chevelle
and
Camaro
3-17
Removal
3-17
Installation
. . . . 3-17
Chevy
II 3-17
Inspection
. 3-17
Removal
3-17
Installation
3-17
Lube Fittings
3-18
Lower Control Arm
. . . . 3-18
Chevrolet
. 3-18
Removal
3-18
Installation
3-18
Chevelle and Camaro
3-18
Removal
3-18
Installation
3-18
Chevy H
3-18
Removal
3-18
Installation
3-19
Corvette
3-19
Removal
3-19
mstallation
3-19
Lower Control Arm Bushings
3-20
Chevrolet
3-20
Removal
3-20
Installation
3-20
Chevelle and Camaro
. 3-20
Removal
3-20
Installation
3-20
Chevy H
3-21
Removal
* 3-21
InstaEation
3-21
Cross Shaft and/or Bushings
. 3-21
Corvette
3-21
Removal
3-21
Installation
3-21
Upper Control Arm Spherical Joint
3-21
Chevrolet, Chevelle, Camaro and Corvette
..... 3-21
Inspection.
3-21
Replacement
3-21
Chevy
II 3-21
Inspection
3-21
Replacement
3-21
Lube Fittings
3-22
Upper Control Arm
3-22
Chevrolet, Chevelle, Camaro
and
Corvette
3-22
Removal
3-22
Installation
3-22
Chevy H
3-22
Removal
3-22
Installation
3-23
Upper Control Arm Cross Shaft
and/or Bushings
3-23
Chevrolet, Camaro and Chevelle
3-23
Removal
. 3-23
Installation
3-23
Chevy H
3-24
Removal
3-24
Installation
. . . 3-25
Corvette
3-25
Removal
3-25
Installation
3-25
Special Tools
3-26
Specifications
...'..'
At rear of Book
GENERAL DESCRIPTION
The 1967 Chevrolet, Chevelle, Camaro, Chevy n and
Corvette front suspension systems are basically similar,
being of the
S.L.A.
(short-long arm) type with independent
coil springs. In the Chevrolet, Chevelle, Camaro and
Corvette the springs ride on the lower control arms; in
the Chevy II the springs ride on the upper control arms.
Spherical joints connect the upper and lower arms to the
steering knuckle. Tapered roller wheel bearings are
used.
Camber angle is adjusted, on the Chevrolet and Chevy n
CHEVROLET CHASSIS SERVICE MANIM

FRONT SUSPENSION 3-18
CHEVROLET
CHEVELLE
CAMARO (TYPICAL)
CHEVY U
LOWER CONTROL ARM
CORVETTE
Fig.
30 - Lower Control Arm Attachment
2.
Raise lower control arm and insert ball stud into
steering knuckle lower boss. Install nut and insert
new cotter pin. Install stabilizer linkage.
Lube Fittings
Special self threading type lube fittings are used in the
spherical joint assemblies. If it is necessary to replace
a fitting a standard threaded type may be used. However,
replacement spherical joint assemblies are supplied less
the lube fitting. Therefore it will be necessary to install
a self threading type fitting into the untapped hole pro-
vided when replacing the entire assembly.
LOWER CONTROL ARM
Chevrolet (Fig. 30)
Removal
1.
Remove the coil spring as outlined previously.
2.
Remove lower control arm ball stud cotter pin and
loosen nut. Loosen the ball stud, then remove nut
and lower control arm.
CAUTION: Use extreme care not to damage
the seal during this operation.
Installation
1.
Insert lower control arm ball stud into the steering
boss,
install the nut and insert new cotter pin.
2.
Install the coil spring as outlined previously.
3.
Tighten nuts to torque shown in Specifications.
Chevelle and Camaro (Fig. 30)
Removal
1.
Remove the front coil spring as outlined previously.
2;
Remove the two control arm to frame and cross-
member bracket attaching bolts and lock washers.
3.
Remove the lower control arm assembly.
Installation
1.
With the control arm in place in frame and cross-
member brackets, install the front and rear attaching
bolts,
nuts and lock washers.
2.
Install the coil spring as outlined under "Front Coil
Spring - Installation".
3.
Tighten the nuts to torque shown in Specifications.
Chevy II (Fig. 30)
Removal
1.
With vehicle weight still on front wheels, install
CHEVROLET CHASSIS SERVICE MANUAL

SECTION
4
REAR SUSPENSION
AND
DRIVE LINE
CONTENTS
OF
THIS SECTION
Page
Rear Suspension
4-1
Drive Line.
. 4-26
Rear Axle ......
4-26
Propeller Shaft
and
Universal Joints
Special Tools
4-37
4-43
REAR SUSPENSION
INDEX
General Description
4-1
Chevrolet
4-1
Chevelle
4-1
Chevy
n and
Camaro
. . . . . 4-2
Corvette
. . . . . . 4-3
Maintenance
and
Adjustments ...............
4-4
Riding Height Check (Chevrolet, Camaro,
Chevelle
and
Chevy
II) 4-5
Wheel Alignment (Corvette)
4-5
Wheel Bearing Adjustment (Corvette)
4-6
Component Parts Replacement (Chevrolet, Camaro,
Chevelle
and
Chevy
JJ) 4-7
Coil Spring
4-7
Chevrolet
4-7
Removal
4-7
Installation
4-7
Chevelle
4-8
Removal
4-8
4-8
Installation
.
Leaf Spring, Spring Seat Pads, Spring
Eye
Bushings
4-9
Chevy
H 4-9
Removal
4-9
Installation
4-9
Camaro
4-10
Removal
4-10
Installation
4-11
Shock Absorber
4-11
Chevrolet
and
Chevelle
. 4-11
Removal
4-11
Installation
. . 4-12
Chevy
II 4-12
Removal
4-12
Installation
4-rl2
Camaro
4-12
Removal
. 4-12
Installation
4-12
Control
Arm . . 4-12
Chevrolet Upper
4-12
Removal
. 4-12
Page
Bushing Replacement
. 4-13
Installation
4-14
Chevrolet Lower
4-14
Removal
4-14
Bushing Replacement
4-14
Installation
. 4-15
Chevelle Upper
and
Lower.
. 4-15
Removal
4-15
Bushing Replacement
4-15
Installation
4-17
Rear Suspension
Tie Rod
(Chevrolet)
. . .
......
. . . 4-17
Removal
4-17
Bushing Replacement
4-17
Installation
4-17
Component Parts Replacement (Corvette)
. . 4-17
Wheel Spindle
and
Support
4-17
Removal
4-17
Repairs
', . 4-17
Installation
4-18
Differential Carrier Support Bracket Replacement.
. 4-20
Shock Absorber
4-20
Removal
4-20
Installation
* .... 4-20
Strut
Rod and
Bracket
4-20
Removal
4-20
Repairs
4-21
Installation
4-21
Spring
4-21
Removal
4-21
Repairs
4-22
Installation
4-22
Torque Control
Arm 4-23
Removal
4-23
Repairs
. 4-23
Installation
4-24
Suspension Crossmember
4-24
Removal
4-24
Repairs—Isolation Mount
4-25
Installation
4-25
Stabilizer Shaft Replacement
4-25
GENERAL DESCRIPTION
CHEVROLET
The link type rear suspension (fig. 1) has two lower
control arms which maintain proper axle to frame re-
lationship and also take the acceleration, drive and
braking forces. A single upper control arm on light-
duty models (or two upper control arms on heavy-duty
models and all station wagons) limits axle rotation when
drive, acceleration or braking forces are applied. Lateral
movement of the axle is restricted by the axle-to-frame
tie rod. Two full coil springs and two direct, double
acting shock absorbers are provided for additional ride
control.
CHEVELLE
The rear suspension (fig. 2) is of the four-link design
utilizing axle mounted, full coil springs and direct,
double-acting shock absorbers.
Two rubber-bushed lower control arms, stretching
slightly outboard from axle-mounted brackets to frame
side member mounted brackets, maintain fore and aft
CHEVROLET CHASSIS SERVICE MANUAL

REAR SUSPENSION
AND
DRIVE LINE
4-26
DRIVE LINE
REAR AXIE
INDEX
Page
General
Description
4-26
Chevrolet,
Camaro,
Chevelle
and
Chevy
II 4-26
Corvette
4-26
Maintenance
and
Adjustments
4-27
Lubricant
4.37
Lubricant'
Leaks
4_27
Axle Bolts
and
Wheel
Nuts
4-27
Rear Axle Noise
Diagnosis
4-29
Gear Noise
4_29
Bearing
Noise
4-29
Failure
Analysis
4^9
Hypoid
Gears
4..3Q
Differential Gears. 4_30
Bearings
....'.
4.30
Component Parts Replacement
(Chevrolet, Chevelle, Camaro and Chevy n ..... 4.30
Axle Assembly ,. . 4_30
Removal 4 30
Installation * ' 4 3Q
Axle Shaft . . . 4-31
Removal 4-31
Wheel Bolt Replacement 4-31
Oil Seal and/or Bearing Replacement. 4-31
Brake Flange Plate Replacement 4-31
Installation 4-32
Pinion Flange, Dust Deflector and/or
Oil Seal Replacement 4-32
Component Parts Replacement (Corvette) 4-34
Axle Driveshaft .- 4-34
Removal 4-34
Repairs 4-34
Installation. . 4-34
Pinion Flange, Dust Deflector and/or Oil Seal. .... 4-35
Removal 4-35
Inspection . 4-35
Installation .- 4-35
Differential Carrier 4-36
Removal 4-36
Installation 4-36
Positraction Differential Unit-On the Vehicle Check . . 4-37
\
GENERAL DESCRIPTION
CHEVROLET, CHEVELLE, CHEVY
I! AND
CAMARO
The rear axle
(fig. 72) is a
semifloating, fabricated
construction type consisting
of a
cast carrier with large
bosses
on
each
end
into which
two
welded steel tubes
are fitted.
The
carrier contains
an
overhung hypoid
pinion
and
ring gear.
The
differential
is a
two pinion
arrangement.
The axle housing
is
made up
of
two steel welded tubes
pressed into
the
crossbore
of the
cast carrier
-
each
tube
is
puddle welded
at
three places
to the
carrier.
Welded-on brackets provide attachment points
for
Chevelle springs,; shock absorbers,
and
lower control
arms.
Chevrolet models have welded-on brackets
for
control arms,
tie
rod, and shock absorbers. The housing
on Chevy II and Camaro has welded brackets
for
mounting
lower spring
pad
and shock absorber.
A
welded flange
is
provided
for
brake flange plate attachment.
The overhung hypoid drive pinion
is
supported
by
two
preloaded tapered roller bearings.
The
pinion shaft
is
sealed
by
means
of a
molded, spring loaded, rubber seal.
The seal
is
mounted
on the
pinion shaft flange which
is
splined and bolted
to
the hypoid pinion shaft.
The hypoid ring gear
is
bolted
to a
one-piece differen-
tial case which
is
supported
by two
preloaded tapered
roller bearings.
CORVETTE
The Corvette rear axle
is of the
type where
the dif-
ferential carrier housing enclosing
the
differential
and
hypoid gears
is
supported
on a
crossmember mounted
to
the chassis frame.
The
differential
is
connected through
universal joints
to the
drive shafts
and
wheels
(fig. 73).
The internal components
of the
carrier
are of
conven-
tional design, incorporating
a
hypoid gear
set
with
an
overhung pinion supported
on two
pre-loaded, tapered
roller bearing assemblies,
and a
two-pinion differential
assembly supported
on
tapered roller bearings. Pinion
mounting distance adjustments
are
made through the
use
of shims,
as are the
differential bearing pre-load
and
backlash adjustments.
The
differential side gears drive
two splined yokes which
are
retained laterally
by
snap
rings located on the yoke splined end. The yokes
are
sup-
ported on caged needle bearings pressed into
the
carrier,
adjacent
to the
differential bearings.
A
lip seal, pressed
in outboard
of
the bearings, prevents
oil
leakage and dirt
entry.
The
carrier cover
is
bolted
to the
carrier and
provides accessibility
to the
internal parts.
The
cover
incorporates two integral, reinforced mounting pads which
serve
as the
carrier attaching point
to the
suspension
crossmember,
and an
attaching point
for the
spring
center section. The filler plug
is
located on the right side
of the cover near the bolting flange.
All service operations allow carrier removal without
removing
the
carrier cover. Cover removal
is
not nec-
essary
in any of the
service procedures except
in
the
case
of
complete carrier housing replacement,
as the
carrier and cover
are
serviced
as
an assembly.
CHEVROLET CHASSIS SERVICE MANUAL

REAR SUSPENSION AND DRIVE LINE 4-33
Fig.
84—Drive Pinion Flange Removal
J-21057 for heavy-duty axle, press seal into bore
until it seats against shoulder (figs. 85 and 86).
CAUTION: Pinion oil seal flange must not bot-
tom against "carrier. Press seal into carrier
bore until it seats against internal shoulder -
do not apply unnecessary pressure after seal is
seated. To do so will destroy rubber seat ancl
distort seal. ;
11.
Position and align pinion flange on pinion shaft using
Tools J-9458 and
J-8614-1.
Tool J-9458-1 is
threaded onto pinion shaft and nut tightened against
J-9458-2 to pull flange on shaft (fig. 87). Remove
Fig.
86—Drive Pinion Flange Oil Seal
Installation (Heavy-Duty)
J-9458 after flange is seated.
NOTE: The position of the pinion and flange
was previously marked so that reinstallation
may be made with flange and pinion in same
relative position.
CAUTION: Do not attempt to hammer flange
onto pinion shaft. To do so will damage ring
gear and pinion.
12.
13.
14.
15.
Pack the cavity between end of pinion splines and
pinion flange with a non-hardening sealer (such as
Permatex Type A) prior to installing washer and
nut on pinion.
Install washer and a new self-locking nut on pinion
shaft. Tighten nut to remove end play and continue
alternately tightening in small increments and check-
ing preload with torque wrench until it is the same
as that recorded in Step 4.
Reassemble the rear universal joint, and torque
"V" bolt nuts to specifications.
Lower vehicle to floor and road test for leaks.
Fig.
85—Drive Pinion Flange Oil Seal
Installation (Light-Duty)
Fig.
87—Drive Pinion Flange Installation
CHEVROLET CHASSIS SERVICE MANUAL

REAR SUSPENSION AND DRIVE LINE 4-42
Fig.
113—Rear Suspension Special Tools (Chevrolet, Camaro, Chevelle and Chevy II)
1.
J-8614
2.
J-21057
3. J-21468
4. J-5748
5. J-21830
6. J-7574
7. J-7877
8. J-21474
9. J-9458
Companion Flange Remover—Consists of J-8614-1
Holder, J-8614-2 Nut and J-8614-3 Screw.
Drive Pinion Oil Seal Installer—Heavy-Duty Axle.
Drive Pinion Oil Seal Installer—Light Duty
Axle—Used with J-9458.
Positraction Torque Measuring Adapter.
Upper and Lower Control Arm Bushing Puller-
Consists of J-21830-2 Adapter, J-21830-4 Receiver,
J-21830-7 Bridge—Used with J-21058-6 Spacer,
and J-21830-3 Spacer.
Chevrolet Lower Control Arm Front Bushing
Remover/Installer—Consists of J-7574-4 Receiver,
J-7574-1 Remover, J-7574-2 Installer Adapter,
J-7574-3 Spacer.
Chevrolet Tie Rod Bushing Remover/Installer—Consists
of J-7877-1 Remover Adapter, J-7877-2 Bushing
Receiver, J-7877-3 Installer Adapter—Used with
j-7079-2
Handle.
Chevelle Control Arm Bushing Remover—Consists of
J-21474-5 Receiver, J-21474-1 Spacer and
J-21474-2 Adapter.
Drive Pinion Oil Seal Installer—Light Duty
Axle—Used with J-21468.
10.
J-21051 Rear Wheel Bearing and Oil Seal Installer-
Heavy Duty Axle—Used with J-7079-2.
11.
J-21491 Rear Wheel Bearing and Oil Seal Installer—Light
Duty Axle—Used with J-8092.
12.
J-2619 Rear Wheel Bearing and Oil Seal Remover (Slide
Hammer).
13.
J-8119 Rear Wheel Bearing and Oil Seal Remover—Used
with J-2619.
14.
J-21058 Upper and Lower Control Arm Puller—Consists of
J-21058-15 Screw and J-21058-8 Nut—Used
with J-21830.
15.
J-8092 Driver.Handle—Threaded Type.
16.
J-7079-2 Driver Handle—Insert Type.
17.
J-21548 Propeller Shaft "U" Joint Trunnion Seal Installer.
18.
J-21991 Chevelle Upper Control Arm Carrier- Bushing
Remover Adapter.
19.
J-5853 Torque Wrench—In. lbs.
20.
J-5810 Torque Wrench Adapter (3/4" to 3/8")
21.
J-1313 Torque Wrench—ft. lbs.
Tools Not Illustrated
J-22553 Rear Spring Front Bushing Remover/Installer Consists
of J-22553-1 Receiver, J-22553-2 Installer—Used
with J-21978-1 Receiver, J-21058-8 Nut and
J-21058-15 Puller Screw.
CHEVROLET CHASSIS SERVICE MANUAL

REAR SUSPENSION AND DRIVE LINE 4-43
Fig.
114—Rear Suspension Special Tools (Corvette)
1.
J-8111-23 Torque Control Arm Spacer Flaring Tool
2.
J-22602 Wheel Drive Spindle Remover
3.
J-9436 Wheel Drive Spindle Outer Bearing Installer
4.
J-21057 Drive Pinion Oil Seal Installer
5. J-8331 Wheel Drive Spindle Outer Bearing Remover
6.
J-7877 Strut Rod Bushing Replacement Sef
7. J-7817 Wheel Drive Spindle Bearing Cup Installer
8.
J-21548 Propeller Shaft "U" Joint Trunnion Seal Installer
9. J-21556 Axle Drive Shaft "U" Joint Trunnion Sea! Installer
10.
J-5748 Positraction Torque Measuring Adapter
11.
J-7079-2 Driver Handle (Insert Type)
12.
J-8001 Dial Indicator Set
13.
J-8092 Driver Handle (Threaded Type)
14.
J-7055-1 Torque Control Arm Bushing Installer
15.
J-8614 Rear Axle Companion Flange Holder
CHEVROLET CHASSIS SERVICE MANUAL

BRAKES 5-22
2.
Replace ail push rods and pull back springs.
3.
Connect hose or line to wheel cylinder.
NOTE:
If replacing front wheel cylinder, con-
nect hose and inspect installation as outlined in
"Hydraulic Brake Hose Replacement".
4.
Install drum and wheel.
5. Bleed brakes as outlined in this section.
ANCHOR PIN
Front Wheel
1.
Raise front of vehicle and place on jack stands.
2.
Remove wheel and drum as outlined in this section.
3.
Remove brake shoe pull back springs, link and guide
plate.
4.
Disengage anchor pin lock and remove anchor pin by
turning counterclockwise.
5. Place new lock plate on anchor pin and pass pin
through the hole in flange plate and screw into tapped
hole in spindle support.
6. Torque pin to 130 lb. ft. and lock by peening over
washer tabs.
7. Install brake shoe guide plate, link and pull back
springs.
8. Adjust brakes, install drum and wheel as outlined
in this section. Test brake operation.
Rear Wheel
Two type anchor pins are used in production for the
rear wheels. The riveted type is not serviced and if
failure or damage should occur to either the anchor
pin or flange plate, both parts will have to be replaced
and the threaded type anchor pin used.
Threaded Type
1.
Raise rear of vehicle and place on jack stands,
2.
Remove wheel and drum as outlined in this section.
3.
Remove brake shoe pull back springs, link and guide
plate.
4.
Remove anchor pin retaining nut and washer and
remove pin from flange plate.
5. Position anchor pin to flange plate, install lock
washer and nut, and torque pin to 80 lb. ft.
6. Install brake shoe guide plate, link and pull back
springs.
7. Adjust brakes and install drum and wheel as outlined
in this section.
8. Test brake operation.
BRAKE DRUMS
Front brake drums are the demountable type; that is,
they can be removed without removing the hub. Rear
brake drums are demountable and may be removed
wihtout removing the axle shaft.
A lanced "knock out" area (fig. 34) is provided in
the web of the brake drum for servicing purposes in
the event retracting of the brake shoes is required in
order to remove the drum.
A small screw driver or hooked wire may be inserted
to disengage the automatic adjuster actuating lever so
the star wheel may be turned.
Removal
1.
Raise vehicle and place on jack stand.
2.
Remove wheel and tire assembly, back off brake
adjustment and remove drum.
Inspection and Reconditioning
Whenever brake drums are removed they should be
thoroughly cleaned and inspected for cracks, scores,
deep grooves, and out-of-round. Any of these conditions
must be corrected since they can impair the efficiency
of brake operation and also can cause premature failure
of other parts.
Smooth up any slight scores by polishing with fine
emery cloth. Heavy or extensive scoring will cause
excessive brake lining wear and it will probably be
necessary to rebore in order to true up the braking
surface.
An out-of-round drum makes accurate brake shoe
adjustment impossible and is likely to cause excessive
wear of other parts of brake mechanism due to its
eccentric action.
A drum that is more than .008" out-of-round on the
diameter is unfit for service and should be rebored.
Out-of^round, as well as taper and wear can be ac-
curately measured with an inside micrometer fitted
with proper extension rods.
If drum is to be rebored for use with standard size
brake facings which are worn very little, only enough
metal should be removed to obtain a true smooth braking
surface.
If drum has to be rebored more than .020" over the
standard diameter, it should be rebored to .060" diameter
oversize and the brake facing should be replaced with
.030"
oversize facings.
A brake drum must not be rebored more than .060"
over the maximum standard diameter, since removal
of more metal will effect, dissipation of heat and may
cause distortion of drum. Chevrolet brake facing is
not furnished larger than .030" oversize and this will
not work efficiently in drums bored more than .060"
oversize.
Brake drums may be refinished either by turning or
grinding. Best brake performance is obtained by turning
drums with a very fine feed. To insure maximum lining
life,
the refinished braking surface must be smooth and
free from chatter or tool marks, and run-out must not
exceed .005" total indicator reading.
Cleaning
New brake drums in parts stock are given a light.
coating of rust proofing oil to prevent the formation of
rust on the critical braking surfaces during the time
that the drums are in storage.
This rust proofing oil must be carefully removed
before the drum is placed in service to prevent any
of this oil from getting on the brake shoe facings, which
might cause an extreme brake grab condition.
It is recommended that a suitable volatile, non-toxic,
greaseless type solvent be used to clean the oil from the
braking surface of the new brake drums before they are
•placed in service to insure the cleanest possible surface.
Gasoline or kerosene should not be used as there is
danger that a portion of the diluated oil substance may
be left on the braking surface that may later cause
difficulty.
Installation
1.
Make brake adjustment as outlined in this section.
CHEVROLET CHASSIS SERVICE MANUAL