SECTION O
INFORMATION AND LUBRICATION
CONTENTS OF THIS SECTION
Page
General Information o-l
Lubrication 0-13
GENERAL INFORMATION
Model Identification and Vehicle Dimensions
Chevrolet
Chevelle
Chevy n
Corvette
Camaro
Page
0-1
0-1
0-2
0-2
0-3
0-3
Page
Unit and Serial Numbers o-3
Engine Number o-3
Vehicle Serial Number 0r3
Keys and Locks 0-4
Pushing,Towing and Lifting 0-7
Series
Biscayne
Bel Air
Tmpala.
Impala
Super Sport
Caprice
MODEL IDENTIFICATION-CHEVROLET
Model Number
6-Cyl
15311
15369
15335
15511,
15569
15535
15545
16387
16367
16369
16339
16335
16345
16787
16767
—
—
—
—
V-8
15411
15469
15435
15611
15669
15635
15645
16487
16467
16469
16439
16435
16445
16887
16867
16647
16639
16635
16645
Description
2-Door Sedan, 6-Passenger
4-Door Sedan, 6-Passenger
4-Door Station Wagon, 2-Seat
2-Door Sedan, 6-Passenger
4-Door Sedan, 6-Passenger
4-Door Station Wagon, 2-Seat
4-Door Station Wagon, 3-Seat
2-Door Sport Coupe, 5-Passenger
2-Door Convertible, 5-Passenger
4-Door Sedan, 6-Passenger
4-Door Sport Sedan, 6-Passenger
4-Door Station Wagon, 2-Seat
4-Door Station Wagon, 3-Seat
2-Door Sport Coupe, 4-Passenger
2-Door Convertible, 4-Passenger
2-Door Custom Coupe, 5-Passenger*
4-Door Custpm Sedan, 6-Passenger
4-Door Custom Wagon, 2-Seat
4-Door Custom Wagon, 3-Seat
*4-Passenger when optional bucket front seats are specified.
VEHICLE DIMENSIONS-CHEVROLET
Pertinent dimensions for the different models are shown in the following chart.
Model
Length Overall . .
Width Overall (Body)
Height Overall
Wheelbase
Tread-Front
Tread-Rear
Curb Weight: Approximately 3543 lbs.
Sedan
213.2"
79.6"
55.4"
119.0"
62.5"
62.4"
4-Door Sedan with
2-Door
Sport Coupe
213.2"
79.6"
54.4"
119.0"
62.5"
62.4"
L-6 Engine; 3685 lbs
Convertible
Coupe
213.2"
79.6"
55.3"
119.0"
62.5"
62.4"
. with V-8 Engine.
Station
Wagon
212.4"
79.6"
56.7"
119.0"
63.5"
63.4"
CHEVROLET CHASSIS SERVICE MANUAL
GENERAL INFORMATION 0-2
MODEL IDENTIFICATION-CHEVELLE
Series
Chevelle 300
Chevelle 300
Deluxe
Malibu
Super Sport
396
Concours
Model Number
6-Cyl
13111
13169
13311
13369
13335
13569
13539
13517
13567
13535
—
13735
V-8
13211
13269
13411
13469
13435
13669
13639
13617
13667
13635
13817
13867
13835
Description
2-Door -Sedan, 6-Passenger
4-Door Sedan, 6-Passenger
2-Door Sedan, 6-Passenger
4-Door Sedan, 6-Passenger
4-Door Station Wagon, 2-Seat
4-Door Sedan, 6-Passenger
4-Door Sport Sedan, 6-Passenger
2-Door Sport Coupe, 5-Passenger*
2-Door Convertible, 5-Passenger*
4-Door Station Wagon, 2-Seat
2-tooor Sport Coupe, 5-Passenger*
2-Door Convertible, 5-Passenger*
4-Door Station Wagon, 2-Seat
*4-Passenger when optional bucket seats are specified.
EL CAMINO
13380
13580
13480
13680
2-Door
Sedan
Pickup,
3-Passenger Reg.
2-Door
Sedan
Pickup,
3-Pass. Deluxe
VEHICLE DIMENSIONS-CHEVELLE
Pertinent dimensions for the different models are shown in, the following chart.
Model
Sedan
197.0"
75.0"
54.1"
115.0"
58.0"
58.0"
2-Door
Sport Coupe
197.0"
75.0"
53.2"
115.0"
58.0"
58J0"
Convertible
Coupe
197.0"
75.0"
53.9"
115.0"
58.0"
58.0"
Station
Wagon
199.9"
75.0"
56.7"
115.0"
58.0"
58.0"
Sedan
Pickup
199.9"
75.0"
56.7"
115.0"
58.0"
58.0"
Length Overall .
Width Overall (Body)
Height Overall . . .
Wheelbase. .
Tread-Front
Tread-Rear .
Curb Weight: Approximately 3104 lbs. 4-Door Sedan with L-6 Engine 3258 lbs. with V-8 Engine.
MODEL IDENTIFICATION-CHEVY II
Series
100
NOVA
NOVA SS
Model Number
L-4
11111
11169
mmm.
—
6 Cyl.
11311
11369
11335
11569
11537
11535
11737
V-8
11411
11469
11435
11669
11637
11635
11837
Description
2-Door Sedan, 6-Passenger
4-Door Sedan, 6-Passenger
4-Door Station Wagon, 2-Seat
4-Door Sedan, 6-Passenger
2-Door Sport Coupe, 5-Passenger
4-Door Station Wagon, 2-Seat
2-Door Sport Coupe, 4-Passenger
CHEVROLET CHASSIS SERVICE MANUAL
GENERAL INFORMATION 0-3
VEHICLE DIMENSIONS-CHEVY II
Model
Length Overall
Width Overall (Body) . . . .
Height Overall
Wheelbase
Tread-Front
Tread-Rear . . .
Sedan
183.0"
71.3"
56.7"
110.0"
56.8"
56.3"
2-Door
Sport Coupe
183.0"
71.3"
54.4"
110.0"
56.8"
56.3"
Station
Wagon
187.4"
71.3"
57.6"
110.0"
56.3"
55.8"
Curb Weight: Approximately 2668 lbs. 4-Door Sedan with L-4 Engine; 2767
lbs.
with L-6 Engine; 2959lbs.
with V-8 Engine.
MODEL IDENTIFICATION-CAMARO
VEHICLE DIMENSIONS-CORVEnE
Model Number
6-Cyl
12337
12367
V-8
12437
12467
Description
2-Door Sport Coupe, 4-Passenger
2-Door Convertible, 4-Passenger
VEHICLE DIMENSIONS-CAMARO
Model
Length Overall .....
Width Overall (Body) . .
Height Overall
Wheelbase
Tread-Front
Tread-Rear
Sport Coupe
Convertible
184.7"
72.6"
50:8"
108.0"
59.0"
58.88"
Weight: Sport Coupe with L6 Engine 2908 lbs.; with
V-8 Engine 3063 lbs.
MODEL IDENTIFICATION-CORVETTE
Model
Number
19437
19467
Description
2-Door Sport Coupe, 2-Passenger
2-Door Convertible, 2-Passenger
UNIT AND SERIAL NUMBER LOCATIONS
For the convenience of servicemen when writing up
certain business papers, such as L. & M.R.'s Product
Information Reports, or reporting product failures in
any way, we are showing below the location of various
unit numbers. These unit numbers and their prefixes
and suffixes are necessary on these papers for various
reasons—such as accounting, follow-up on production,
etc.
Model
Length Overall
Width Overall (Body). . .
Height Overall.
Wheelbase
Tread-Front
Tread-Rear .
Convertible
Sport
Coupe
175.1"
69.6"
49.8"
49.6"
98.0"
56.8"
57.6"
Curb Weight: 3145 lbs. Convertible
3135 lbs. Sport Coupe
with Base V-8
The prefixes on certain units identify the plant in which
the unit was manufactured, and thereby permits proper
follow-up of the plant involved to get corrections made
when necessary.
Engine Unit Number
The engine unit number (figs. 3 and 4) shows manu-
facturing plant, month and day of manufacture, and
transmission type. A typical engine number would be
F1210FA, which would breakdown thus:
F~Manufacturing Plant (F—Flint, T—Tonawanda)
12—Month of manufacture (December)
10—Day of manufacture (tenth)
FA—Transmission and engine type
Vehicle Serial Number
A typical vehicle serial number tag (fig. 1) yields
manufacturers identity, vehicle type, model year, as-
sembly plant and production unit number when broken
down as shown in the following chart.
Manufacturer
Identity1
1
Body
Style2
5645
Model
Year8
7
Assembly
Plant*
F
Unit
Number5
100025
CHEVROLET CHASSIS SERVICE /MANUAL
SECTION 2
FRAME
INDEX
Page
General Description 2-1
Chevrolet 2-1
Cheveile '. 2-1
Repair Procedures 2-1
Page
Checking Frame Alignment 2-1
Car Preparation 2-1
Tramming Sequence 2-1
Reference Point Dimensions 2-1
GENERAL DESCRIPTION
CHEVROLET AND CHEVELLE
Frames used on Chevrolet and Cheveile lines are basi-
cally the same, consisting of full length right and left
side members joined laterally by crossmembers. Sev-
eral different frames are used in each line to meet the
various vehicle size and function requirements but the
basic shape for each line remains the same. Differences
between frames in a given line exist only in metal gauge,
part size and numbers of parts necessary to meet the
particular structural requirements of the models
involved.
CORVETTE
The Corvette frame is a rigid perimeter unit, with five
crossmembers. From the rear kick-up forward, trap-
azoidal shaped, closed side members outline and protect
the passenger compartment. At the cowl area, the side
members curve inward in a sweeping "S" shape, to pro-
vide a sturdy foundation for the engine mounts and clear-
ance for front wheel movement. From the kick-up
rearward, box-sectioned side rails provide fore and aft
support for the rear axle and suspension. Lateral sup-
port is provided by five variously shaped welded-in
crossmembers, including the front unit, which formerly
was bolted-in.
CHEVY II AND CAMARO
Underbody alignment checking procedures will be found
in the Body Service Manual.
REPAIR PROCEDURES
CHECKING FRAME ALIGNMENT
Vehicles involved in an accident of any nature which
might result in a "swayed" or "sprung" frame should
always be checked for proper frame alingment in addi-
tion to steering geometry and wheel alignment.
CAR PREPARATION
Preparing the car for the frame alignment check in-
volves the following:
1.
Place the car on level surface.
2.
The weight of the car should be supported at the
wheel locations.
3.
A visual damage inspection should be made to elim-
inate needless measuring. Obviously damaged or
misaligned areas can often be located by sight.
TRAMMING SEQUENCE
When checking a frame for alignment in case of dam-
age,
the first step is horizontal "X" checking with a
tram from similar given points on opposite side of the
frame.
Frame alignment checks on all models should be made
with the tram points set at the center of each locating
point indicated and the cross bar level to insure
accuracy.
When "X" checking any section of the frame, the
measurements should agree within 3/16". If they do not,
it means that corrections will have to be made.
If a tram gauge is not available, the "plumb bob"
method of checking may be used. To assure any degree
of accuracy when using this method, the vehicle should
be on a level floor.
By using this method, it is only necessary to have a
#
piece of cord attached to an ordinary surveyor's plumb
bob.
When measuring the distance between two points,
the free end of the cord should be placed on the reference
point allowing the plumb bob to hang on the floor. A check
mark should be made on the floor just under the tip of
the plumb bob. This operation should be repeated at all
reference points. With these points located on the floor,
they may easily be measured with a rule.
The second step is checking the vertical dimensions
from the datum plane to the points to be trammed. With
the proper settings the tram bar will be on a plane
parallel to that of the frame. The exception to this would '
be when one of the reference locations is included in the
misaligned area; then the parallel plane between the
frame and the tram bar may not prevail. After com-
pletion of the repairs, the tram gauge should be set at
the specified dimension to check the accuracy of the re-
pair operation.
ALIGNMENT REFERENCE POINT DIMENSIONS
Dimensions to holes are measured to dead center of
the holes and flush to the adjacent surface metal.
CHEVROLET CHASSIS SERVICE MANUAL
FRONT SUSPENSION 3-5
FRONT END ALIGNMENT
Front end alignment, that is alignment of the inter-
related steering components of the front suspension sys-
tem, must be correctly maintained to assure ease and
stability of steering and satisfactory tire life.
Alignment Preliminary Steps
Several different types of machines are available for
checking all the factors of front end alignment. The in-
structions furnished with each particular machine should
be followed. In all cases, however, checks should be
made with the vehicle level and at curb weight.
Since steering complaints are not always the result of
improper alignment a check should be made to see if any
of the following conditions exist. Any such conditions
should be corrected before proceeding further.
1.
Steering gear loose or improperly adjusted.
2.
Steering gear housing loose at frame.
3.
Excessive wear or play in spherical joints or steer-
ing shaft coupling.
4.
Tie rod or steering connections loose.
5.
Improper front spring heights.
6. Unbalanced or underinflated tires.
7.
Improperly adjusted wheel bearings.
8. Shock absorbers not operating properly.
Wheel alignment should always be made with the vehi-
cle rolled forward taking out any slack in the same man-
ner as when the vehicle is traveling forward.
Caster and Camber Adjustment
NOTE: Before adjusting caster and camber
angles, the front bumper should be raised and
quickly released to allow car to return to its
normal height.
Chevelle, Camaro and Corvette
Caster and camber adjustments are made by means of
shims inserted between the upper control arm inner sup-
port shaft and the support bracket attached to the frame
(fig. 6). Shims may be added, subtracted or transferred
to change the readings as follows:
Fig.
6 - Caster and Camber Adjustment - Chevelle
Typical of Corvette and Camaro
Caster - change shims at either the front or rear of
the shaft.
The addition of shims at the front bolt or removal
of shims at the rear bolt will decrease positive
caster. One shim (1/3 2") will change caster (ap-
prox.) 1/4°.
Camber - change shims at both the front and rear of
the shaft.
Adding an equal number of shims at both front and
rear of the support shaft will decrease positive cam-
ber. One shim (1/32") at each location will move
camber (approx.) 1/5° (Chevelle and Camaro); 1/6°
(Corvette).
TIGHTEN TO LOCK
ADJUSTMENT
Fig.
7 - Caster and Camber Adjustment Points - Chevrolet
CHEVROLET CHASSIS SERVICE MANUAL
FRONT SUSPENSION 3-7
CAMARO
CHEVROLET
AND
CORVETTE
LOWER
CONTROL
ARM
CHEVELLE
CHEVY
II
Fig.
9- Checking Riding Height
not the vehicle riding height is correct.
1.
Place the vehicle on a smooth, level floor and bounce
and rock the front end several times. Raise vehicle,
then allow it to settle to a normal height.
2.
Measure the following two distances (fig. 9):
a. From the floor to the center of the inner pivot of
the lower control arm. (On the Chevrolet and
Camaro, this measurement must be made at the
rear end of the pivot.)
b.
Chevrolet--Measure the distance from the floor
to the lower face of the lower steering knuckle
boss for the spherical joint on the same side of
the vehicle.
Chevelle—From the floor to the outer pivot
which is located 1/8" (.12) inboard from the ball
stud boss at the lower surface of the arm.
Chevy II--Measure the distance from the floor
to the lower ball joint seat.
Corvette—Measure the distance from the floor
to the lower face of the lower steering knuckle
boss for the spherical joint on the same side of
the vehicle.
Camaro—From the floor to the lower inboard
edge of ball seat.
3.
The difference between these two measurements
should be as outlined in the Specifications given at
the end of the book with the vehicle at curb weight
(full tank of gas, spare tire and jack in trunk, no
passengers).
4.
Measure the opposite side of the vehicle in the same
manner. The measurements for both sides should
differ no more than 1/2".
5. To correct the height, springs must be replaced.
These springs do not have flat ends and shims should
not be used.
CHEVROLET CHASSIS SERVICE MANUAL
FRONT SUSPENSION 3-9
Inspection
1.
Check bearings for cracked separators or worn or
pitted rollers and races.
2.
Check brake drum for
out-of-
round or scoring.
3.
Check fit of bearing outer cups in hub.
Repairs
Replacement of Bearing Cups
1.
Using steel bar stock, make press-out tools shown in
Figure 11.
2.
Insert removers through hub, indexing ends into slots
in hub shoulder behind bearing cup.
3.
Using a suitable extension pipe or rod, press bearing
cups from hub.
4.
Install new bearing cup in hub using Tool J-8849 on
the outer and Tool J-8850 on the inner cup (fig. 12).
Use Driver Handle J-8092 with the installers. Make
sure that the bearing cups are not cocked and are
fully seated against shoulder in hub.
Installation
1.
Pack both inner and. outer bearings using a high
melting point wheel bearing lubricant.
2.
Place inner bearing in hub, then install a new inner
bearing lip seal assembly. Seal flange should face
bearing cup.
3.
Carefully install wheel hub over steering spindle.
4.
Install outer bearing, pressing it firmly into the hub
by hand.
5.
Install spindle washer and adjusting nut. Draw up
tight and adjust wheel bearings as outlined under
"Front Wheel Bearing Adjustment".
STEERING KNUCKLE
Chevrolet, Chevelle, Camaro and Corvette—It is rec-
ommended that vehicle be raised and supported on a
twin-post hoist so that the front coil spring remains com-
pressed, yet the wheel and steering knuckle assembly re-
main accessible. If a frame hoist is used, support lower
control arm with an adjustable jackstand to safely retain
spring in its curb height position.
Chevy n— While vehicle weight is still on front wheels,
position support between upper control arm and frame
side rail (fig. 13), then raise vehicle and position adjust-
able jackstand under lower control arm.
Removal
1.
Raise vehicle and support lower control arm as noted
above.
2.
Remove hub cap, wheel hub dust cover, cotter pin,
adjusting nut and washer. Withdraw wheel and tire,
brake drum, (or, on Corvette--brake caliper and disc
and hub assembly, See Section 5) and wheel hub and
bearing assembly from steering knuckle spindle.
3.
Remove brake shoes from backing plate (except
Corvette, See Section 5) and clamp wheel cylinder.
CAUTION: Keep brake shoes clean and dry.
4.
Remove brake anchor pin and two bolts securing
brake backing plate and steering arm to steering
knuckle.
5.
Withdraw steering arm and brake backing plate from
steering knuckle. Wire backing plate to frame (fig.
13).
Do not disconnect brake line.
NOTE: Refer to Section 9 - Steering Linkage -
Tie Rod, for further steering arm service
operations.
6. Remove upper and lower ball stud cotter pins and re-
move ball stud nuts. Free steering knuckle from
ball studs by rapping steering knuckle bosses. With-
draw steering knuckle.
Installation
1.
Place steering knuckle in position and insert upper
and lower ball studs into knuckle bosses.
2.
Install ball stud nuts and tighten nut as shown in the
specifications at the end of this section.
Fig.
12 - Installing Front Hub Inner Bearing
Fig.
13 - Backing Plate Removed - Chevy II
CHEVROLET CHASSIS SERVICE MANUAL
FRONT SUSPENSION 3-11
Chevy II (Fig. 14)
Removal
1.
While vehicle weight is still on front wheels, position
support between upper control arm and frame side
rail (fig. 15).
NOTE: Bight side control arm support bracket
is illustrated in Figure 15. For left side, angled
support should be welded to reverse side of
plate.
2.
Raise vehicle and remove wheel and tire.
3.
Disconnect lower shock absorber mounting nuts, lock
washers and rubber washers from lower spring seat.
4.
Remove shock absorber upper mounting bracket
bolts.
Lift bracket and shock absorber assembly
from vehicle (fig. 16).
5.
Remove shock absorber from upper mounting bracket
and remove rubber bushings and washers.
Installation
1.
Assemble upper washer and rubber bushing to shock
absorber rod (refer to Figure 14).
2.
Assemble upper mounting bracket, bushing, washer
and nut to rod. Torque according to Specifications at
the end of this book.
3.
Install rubber washers to shock absorber lower seat
studs and insert shock absorber and upper bracket
assembly into shock absorber access hole, and posi-
tion to the lower spring seat. Install washers, nuts
and torque according to Specifications at the end of
this book.
NOTE: Shock absorber seat upper washers
must correctly pilot into spring seat.
4.
Install upper mounting bracket to spring tower and
torque nuts according to Specifications at the end of
this book.
STABILIZER BAR (FIG. 17)
Removal
1.
Raise vehicle and support both front wheels.
2.
Disconnect stabilizer bar from lower control arm.
Remove stabilizer bar brackets from the frame
(Chevrolet, Chevelle, Camaro and Corvette) or from
the front crossmember (Chevy n) and remove
stabilizer.
Fig.
16 - Removing Shock Absorber and Bracket - Chevy II
3.
Disconnect stabilizer link bolts, spacers and rubber
bushings from lower control arms.
4.
Inspect rubber stabilizer link bushings and Stabilizer
insulator bushings for aging. Replace if necessary.
Installation
1.
If new insulators
are necessary, coat stabilizer with
recommended rubber lubricant and slide frame bush-
ings into position.
2.
Insert stabilizer brackets over bushings and connect
to frame. Do not torque at this point. Connect sta-
bilizer ends to link bolts on lower control arms.
Torque bracket bolts and link nuts as shown in the
Specifications.
NOTE: Never get lubricant on outside of frame
stabilizer bar bushings or they may slip out of
brackets.
STRUT ROD (FIG. 18)
Chevrolet and Chevy II
Removal
1.
Raise vehicle to
clearance.
provide sufficient working
TYPICAL OF
CHEVROLET, CHEVELLE AND CAMARO
BRACKET LINK BOLT
CORVETTE
CHEVY H
Fig.
17- Stabilizer Bar
CHEVROLET CHASSIS SERVICE MANUAL