1967 CHEVROLET CAMARO seats

REAR SUSPENSION AND DRIVE LINE 4-34

COMPONENT PARTS REPLACEMENT (CORVETTE)

AXLE DRIVESHAFT-FIGURE 88

Removal

1.
Disconnect inboard driveshaft trunnion from side

gear yoke.

2.
Bend bolt lock tabs down and remove four bolts

securing shaft flange to spindle drive flange.

3.
Pry driveshaft out of outboard drive flange pilot

and remove by withdrawing outboard end first (fig.

89).

Repairs

1.
Remove bearing lock ring from trunnion yoke.

2.
Support turnnion yoke on a piece of 1-1/4" pipe on

arbor press bed.

3.
Using suitable socket or rod, press trunnion down

far enough to drive opposite bearing cup from yoke.

4.
Remove trunnion and press other bearing cup from

yoke, being careful not to
drop'
cup
or lose bearing

rollers.

5. Remove trunnion and yoke from other joint in a

similar manner.

3

AXLE
II 1

i

c

DRI\

c

y
'E SHAFT ^

AXLE
v

DRIVE^
SHAFT
•
Fig.
88—Axle Driveshaft
6. Remove dust seals from trunnion, clean and inspect

bearing rollers and trunnion. Relubricate bearings

with a high-melting point wheel bearing type

lubricant.

NOTE:
In addition to packing the bearings,

make sure that the lubricant reservoir at the

end of each trunnion is completely filled with

lubricant. In filling these reservoirs, pack lu-

bricant into the hole so as to fill from the .

bottom. This will prevent air pockets and en-

sure an adequate supply of lubricant.

7. Place new dust seals on trunnion, cavity of seal

toward end of trunnion - then position Tool J-21556

over end of trunnion and into cavity portion of seal.

Press seal onto trunnion until tool bottoms against

trunnion (fig. 90).

NOTE:
Installation of seal is critical to proper

sealing - use specified tool during installation

to prevent seal distortion and to assure proper

seating of seal on trunnion.

8. Partially install one bearing cup into yoke. Place

trunnion in yoke and into bearing cup. Install other

bearing cup and press both bearing cups into yoke,

being careful to keep trunnion aligned in bearing

cups.

9. Press bearing cups far enough to install lock rings,

and install lock rings.

NOTE:
It may be more convenient, if neces-

sary, to use a bench vise for removal and

installation, instead of an arbor press. In this

case, proceed with disassembly and assembly

procedure as with an arbor press.

Installation

1.
Place driveshaft inboard trunnion into side gear

yokes and assemble
"XJ"
bolts. Rotate yokes so that

trunnion seats are phased 90° apart.

2.
Install outboard drive flange into spindle drive flange

pilot, position bolt lock over bolt holes and install

four bolts. Torque bolts to specification and bend

lock tabs flat against bolt heads.

Fig. 89—Removing Driveshaft

Fig.
90—
"U"
Joint Trunnion Seal Installation

CHEVROLET CHASSIS SERVICE MANUAL

BRAKES 5-20

boss to the front brakes will not contain a check

valve and spring. .

Removal

1.
Wipe main cylinder and lines clean with a clean

cloth. Place dry cloths below main cylinder area to

absorb any fluid spillage.

2.
Disconnect hydraulic lines at main cylinder. Cover

line ends with clean lint-free material to prevent

foreign matter from entering the system.

3.
Disconnect the push rod from the brake pedal.

4.
Unbolt and remove the main cylinder from the

firewall.

5.
Remove the main cylinder mounting gasket and boot.

6. Remove the main cylinder cover and dump out the

fluid. Pump the remaining fluid from the cylinder

by depressing the push rod.

Disassembly (Fig. 32)

1.
Clamp main cylinder in a bench vice.

2.
Remove push rod retainer.

3.
Remove secondary piston stop bolt from bottom of

front fluid reservoir.

4.
Remove the snap ring retainer and primary piston

assembly. Remove the secondary piston, piston

spring, and retainer by blowing air through the stop

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

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

end into -a right angle, hook the secondary piston

and pull it out.)

5.
Position main cylinder in vice with outlet holes

facing up.

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

seats.

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

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

hole.
Place a flat washer on a one inch screw

(threaded to screw into tapped hole), and thread

screw into threaded hole in tube seat. Hold the

screw to keep it from turning and back out the

tube nut. This will remove the tube seat.

9. Repeat Step 8 above on second tube seat.

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

ties beneath the tube seats.

11.
Remove the primary seal, primary seal protector,

and secondary seals from the secondary piston.

Remove the piston extension screw securing the

primary piston spring to the primary piston. Re-

move the spring retainer, primary seal, primary

seal protector, and secondary seal from the pri-

mary piston.

Cleaning and Inspection

1.
Remove main cylinder casting from vice and inspect

the bore for corrosion, pits, and foreign matter.

Be sure that the outlet ports are clean and free of

brass cuttings from the tube seat removal operation.

2.
Inspect the fluid reservoirs for foreign matter.

Check the bypass and compensating ports to the

cylinder bore to insure that they are not restricted.

Do not use wire to check ports.

NOTE: Before washing parts, hands must be

clean. Do not wash hands in gasoline or oil

before cleaning parts. Use soap and water only.

3.
Use Declene or equivalent to clean all metal parts

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

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

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

clean cloth.

NOTE: Be sure to keep parts clean until re-

assembly. Rewash parts, if there is any occa-

sion to doubt cleanliness.

4.
Check pistons for scratches or other visual damage;

replace if necessary.

Assembly (Fig. 32)

Use care when reassembling the main cylinder check

valves. Improper assembly of the check valve seats

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

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

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

one or more times before actual car braking occurs.

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

holes facing up. Place the check valve springs, in

the outlet holes. Be sure the springs are seated

in the bottom of the holes. Place new rubber check

valves over the springs, being careful not to dis-

place the springs from the spring seats.

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

sure seats are not cocked as this would cause burrs

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

. Thread a spare brake line tube nut into the outlet

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

toms.
Remove the tube nut and check the outlet hole

for loose burrs, which might have been turned up

when the tube seat was pressed down. Repeat this

process to bottom the second seat.

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

end of the secondary piston assembly. The seal

which is nearest the end will have its lips facing

toward that end. The seal in the second groove

should have its lips facing toward the portion of

the secondary piston which contains the small com-

pensating holes.

4.
Assemble a new primary seal protector and primary

seal over the end of the secondary piston with the

flat side of the seal seats against the seal protector,

and the protector against the flange of the piston

which contains the small compensating holes.

5.
Assemble the new secondary seal into the groove on

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

this seal should face toward the small compensating

holes in the opposite end of the primary piston.

6. Assemble the new primary seal protector and pri-

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

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

and the protector against the flange on the piston

which contains the compensating holes.

7.
Assemble the spring retainer in one end of the

primary piston spring and the secondary piston

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

over the end of the primary piston with the spring

retainer seats inside of the lips of the primary

seal.

8. Remove all cleaning liquid from the threaded hole

in the primary piston. Place the piston extension

screw down through the secondary piston stop and

the primary spring retainer and screw it into the

primary piston until it bottoms out.

9. Coat the bore of the master cylinder with clean

CHEVROLET CHASSIS SERVICE MANUAL

BRAKES 5-21

brake fluid. Coat the primary and secondary seals

on the secondary piston with clean brake fluid. Insert

the secondary piston spring retainer into the sec-

ondary piston spring. Place the retainer and spring

down over the end of the secondary piston until the

retainer locates inside of the lips of the primary

cup.

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

bore down. Push the secondary piston into the bore

until the spring seats against the closed end of the

bore.

11.
Position the master cylinder in a vise with the

open end of the bore up. Coat the primary and

secondary seal on the primary piston with clean

brake fluid. Push the primary piston assembly,

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

Hold the piston down and snap the lock ring into

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

12.
Push the primary piston down to move the secondary

piston forward far enough to clear the stop screw

hole in the bottom of the front fluid reservoir. Install

the stop screw.

13.
Install reservoir diaphragm in the reservoir cover

and install the cover on the main cylinder. Push

bail wire into position to secure the reservoir cover.

Installation

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

if it has been disassembled.

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

Assemble new boot over push rod and press it down

over the push rod retainer. Slide new mounting

gasket into position.

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

ing bolts.

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

pin and retainer.

5. Connect the brake lines to the main cylinder.

6. Fill the main cylinder reservoirs to the levels

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

lined in this section.

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

outlined in this section.

WHEEL CYLINDER (Fig. 33)

The wheel cylinder boots should be removed from a

cylinder body only when they are visibly damaged or

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

cracked boots should be completely overhauled.

Removal

1.
Raise vehicle and place on jack stands.

Fig.
33-Chevelle Wheel Cylinder—Exploded View

1.
Push Rod Boot 6. Spring

2.
Piston 7. Piston Cup

3. Piston Cup 8. Piston

4.
Housing 9. Push Rod Boot

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

adjustment, if necessary, and remove drum.

3.
Disconnect brake system hydraulic line from

cylinder.

4.
Remove brake shoe pull back springs.

5. Remove screws securing wheel cylinder to flange

plate. Disengage cylinder push rods from brake

shoes and remove cylinder.

NOTE:
On Chevrolet, it is necessary to re-

move the anchor pin which holds the front wheel

cylinder to flange plate to remove the front

wheel cylinder.

Disassembly

1.
Remove boots from cylinder ends with pliers and

discard boots.

2.
Remove and discard pistons and cups.

Inspection and Cleaning

NOTE:
Staining is not to be confused with

corrosion. Corrosion can be identified as pits

or excessive bore roughness.

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

sion.
Discard cylinder if corroded.

2.
Polish any discolored or stained area with crocus

cloth by revolving the cylinder on the cloth sup-

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

lengthwise manner under pressure.

NOTE:
Before washing parts, hands must be

clean. Do not wash hands in gasoline or oil

before cleaning parts. Use soap and water to

clean hands.

3.
Wash the cylinder and metal parts in Declene or

equivalent.

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

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

cannot be kept from the cylinder bore surfaces.

5. Check piston for scratches or other visual damage;

replace if necessary.

Assembly (Fig. 33)

1.
Lubricate the cylinder bore and counterbore with

clean brake fluid and insert spring - expander

assembly.

2.
Install new cups with flat surfaces toward outer

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

before insertion. Do not lubricate cups prior to

assembly.

3.
Install new Durex pistons into cylinder with flat

surfaces toward center of cylinder. Do not lubri-

cate pistons before installation.

4.
Press new boots into cylinder counterbores by hand.

Do not lubricate boots prior to installation.

Installation

1.
Position wheel cylinder to brake flange plate. Install

screws and tighten securely.

NOTE:
On Chevrolet front wheels, mount front

wheel cylinders to the brake flange plate by

installing the threaded anchor pin through the

wheel cylinder housing and tighten to 130 lb. ft.

To secure, peen over the flat washer on the

anchor pin.

CHEVROLET CHASSIS SERVICE MANUAL

CLUTCH AND TRANSMISSIONS 7-4

5.
Install Tool J-5824 to support the clutch assembly

during removal.

NOTE: Look for "X" mark on flywheel and on

clutch cover. If MX" mark is not evident, prick

punch marks on flywheel and clutch cover for

indexing purposes during installation.

6. Loosen the clutch-to-flywheel attaching bolts evenly

1 turn at a time until spring pressure is released,

then remove the bolts, and remove clutch assembly.

Installation to Vehicle

Clean pressure plate and flywheel face. (They should

be free of oil, grease, metal deposits or burned spots).

1.
Position the clutch disc and pressure plate in relar

tive installed position and support them with align-

ment Tool J-5824.

NOTE: The driven disc on the 4 and 6 cylinder

engines is installed with the damfper springs to

the flywheel side; the V-8 is opposite, however,

THE GREASE SLINGER IS ALWAYS ON THE

TRANSMISSION SIDE.

2.
Turn clutch assembly until "X" mark on cover lines

up with "X" mark oh flywheel, then align cover bolt

holes to nearest flywheel holes.

3.
Install a bolt in every hole and tighten down evenly

and gradually until tight (to avoid possible clutch

distortion).

NOTE: Cover loads are as high as 1-1/4 tons.

4.
Remove pilot tool.

5.
Unhook clutch fork and lubricate ball socket and fork

fingers at release bearing end with a high melting

point grease such as graphite and reinstall fork on

ball stud. On Corvette models use Moly Grease.

6. Lubricate the recess on the inside of throwout bear-

ing collar and the throwout fork groove with a light

coat of graphite grease (fig. 4). On Corvette models

use Moly Grease.

7.
Install clutch fork and dust boot into clutch housing

and install throwout bearing to the throwout fork, then

install flywheel housing.

8. Install transmission as outlined in transmission

section.

9. Connect fork push rod and spring.

10.
Adjust shift linkage as outlined in transmission

section.

11.
Perform linkage adjustment for pedal free play and

check clutch release position.

CLUTCH PEDAL

The clutch pedal is the pendant-type hung from a sup-
Fig. 5 - Release Bearing Lubrication and Comparison

port brace common to the brake pedal and must be re-

moved to remove brake pedal. Refer to Section 5 for

brake and clutch pedal service procedure.

CLUTCH CROSS SHAFT (Figs. 6, 7 & 8)

Removal

1.
Remove linkage return and lower linkage springs and

disconnect clutch pedal and fork push rods from re-

spective cross shaft levers.

2.
Loosen outboard ball stud nut and slide stud out of

bracket slot.

3.
Move cross shaft outboard, and as required to clear

inboard ball stud, then merely lift out to remove

from vehicle.

Repairs

The cross shaft has nylon ball stud seats which should

be inspected for wear or damage. Also check condition

of engine bracket ball stud assembly and special anti-

rattle "O" ring. Figures 6, .7
&
8 show component parts

of cross shaft. Replace parts as necessary based on wear

or damage. Lubricate ball studs and seats with graphite

grease before reassembly.

Installation

1.
Reverse removal procedure to install.

2.
Adjust clutch linkage as previously outlined.

CHEVROLET CHASSIS SERVICE MANUAL

STEERING 9-39

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

5. Remove the power cylinder from the vehicle.

Inspection

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

replace the seals using the procedure outlined under

"Disassembly."

2.
Examine the brass fitted hose connection seats for

cracks or damage and replace if necessary.

3.
For service other than ball seat or seal replacement

and ball stud removal, replace the power cylinder.

4.
Check the frame bracket parts for wear.

Disassembly

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

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

oil.

2.
Remove the piston rod scraper and scraper element,

back up washer and piston rod seal from the rod.

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

stud seal.

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

lube fitting.

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

plug, spring, spring seat and ball stud.

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

power cylinder ball stud opening.

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

out using Tool J-8937.

Assembly

1.
Reassemble the piston rod seal components by re-

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

faces of the seal and scraper before assembly.

2.
Reverse the disassembly procedure when reassem-

bling the ball stud.

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

seated in the ring groove.

Installation

1.
Install the power cylinder on the vehicle by reversing

the removal procedure.

2.
Reconnect the two hydraulic lines, fill the system

with fluid and bleed out air using the procedure out-

lined under "Maintenance and Adjustments." Grease

ball joint.

POWER STEERING HOSES

When servicing the power steering hoses be sure to

align the hoses in their correct position as shown in

Figure 71. On Chevelle models with 396 engine, install

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

between the hose and the Delcotron or the inner fender

skirt.

It is important that the power steering hoses be in-

stalled correctly. Hoses installed out of position may be

subjected to chafing or other abuses during sharp turns.

Always make hose installations with front wheels in

straight ahead position. Do not twist hoses unneces-

sarily during installation.

CAUTION: Do not start engine with any power

steering hose disconnected.

CHEVROLET CHASSIS SERVICE MANUAL

ELECTRICAL-BODY AND CHASSIS 12-9

Fig.
15 - Headlamp Panel Actuating Motor Mounting (Corvette)'

HEADLAMP PANEL MOTOR-CORVETTE (Fig. 15)

Removal

1.
Raise hood and as a safety precaution install a bolt

through the hole in the hood support - secure bolt

with a nut.

2.
Remove positive lead from battery terminal.

3.
Disconnect motor lead wire and position it out of the

way.

4.
Turn the knurled knob at inboard end of motor until

the gear seems to turrj freely - turn the knob in one

direction until a definite drag is experienced, then

rotate knob approximately six complete turns in the

opposite direction.

NOTE:
The above step is necessary to produce

a no-load condition on the drive gear and to per-

mit separation of motor from the panel pivot

shaft.

5. Remove the retainer from groove in motor locating

stud then remove the motor-to-support retaining

screw and remove motor assembly from the vehicle.

Installation

1.
Rotate motor and headlamp panel as required to align

slot in motor with headlamp panel pivot shaft, and

install motor on shaft so that the bracket is aligned

with the locating stud.

NOTE:
It may be necessary to turn knurled

knob on end of motor to permit alignment of

motor with shaft.
Slide motor onto shaft until it seats against shaft

shoulder; then install retainer in groove on locating

stud.

Install motor-to-support retaining screw making

sure ground wire is installed between screw head and

bracket.

Connect motor lead wires, making sure that contacts

are clean and that connection is secure.

Connect positive lead battery terminal, remove bolt

from hood support, close hood and check operation of

headlamp panel.

HEADLAMP MOTOR REPLACEMENT-

CAMARO (Fig. 16)

1.
Disconnect battery ground cable and when working on

right headlamp unit, remove battery from vehicle to

gain access to housing retaining bolts.

2.
Remove bezel retaining screws and bezel.

3.
Remove headlamp cover retaining screws and cover

from door assembly.

4.
Manually open door assembly (push door toward cen-

ter of vehicle) and disconnect limit switch

connections.

5. Remove four screws retaining assembly to radiator

support (note location and number of shims, if any).

6. Rotate assembly toward center of vehicle until rear

of unit is exposed, then disconnect wiring connectors

at headlamp and motor assemblies.

7. Rotate assembly until headlamp is facing downward

and carefully remove the assembly from the vehicle

opening.

8. Remove nut attaching motor assembly to pivot arm.

9. Remove two nuts and bolts retaining motor assembly

to base plate and remove motor assembly.

CHEVROLET CHASSIS SERVICE MANUAL