17.

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PART 17-1 PAGE PART 17-3 PAGE

GENERAL BODY SERVICE .17-1 DOORS, WINDOWS, TAILGATE
AND DECK LID 17-30
PART 17-2
FRONT SHEETMET
Al, BUMPERS,
EXTERIORMOULDINGS. . . . . . . . . .17-11

PART
17.1 GENERAL BODY SERVICE

Section Page Section Page

2 Common Dust and Adjustments
Water Leaks and Repairs. ... . . .. . . .17-1 Paint Refinishing. . . . . . . . . . . . . . . . . . . .17-4
1
DiagnosisandTesting
. . .17-1 3 Cleaning and Inspection. . . . . . . . . . . . . . . .17-8
.. .17-1 Care of Wood Grain Paneling . . . . . . . . . 17-9
Types of Sealer and Application. ....... . . .17-1 4 Hoisting. . . . . . . . . . . . . . . . . . . . . .17-10
BodyAlignment
. . .17-3

DIAGNOSIS AND TESTING

DUST AND WATER LEAKS dust enters. The point of entry is 5. Center pillar trim on 4-door
Sealer locations should be consid- often deceptive in that the dust may models.
ered when checking for dust or water enter at one point, then follow the 6. Scuff plates.
leaks. The forward motion of the car passagesformed by interior trim to
After removing the trim, the loca-
creates a slight vacuum within the another point.
tion of most leaks will be readily
body, particularly if a window or Under certain conditions, water evident. The entrance of dust is usu-
ventilator is partially open. Any un- can enter the body at any point ally indicated by a pointed shaft of
sealed small opening in the lower where dust can enter. Any considera- dust or silt. Seal these leaks, and road
section of the body will permit air tion of water leakage must take into test the car on a dusty road to make
to be drawn into the body. If dust is account all points covered under sure that all leaks are sealed.
present in the air, it will follow any dust leaks.
path taken by the air from the point To determine the exact location of After the road tests, check for indi-
of entry into the passenger and lug- a dust leak, it may be necessary to cations of a dust pattern around the
gage compartments. Opening the remove the following trim from the door openings, cowl panel, lower
ventilator air ducts will equalize car: part of the quarter panel, and in the
these pressures. Dust accumulates in 1. Cowl trim panel. luggage compartment.
the rocker panel, and may eventually . Sometimes leaks can be located by
work its way to the kick-up or the 2. Quarter trim panel. putting bright lights under the car,
rear body pillar, and follow the con- 3. Rear seat back and seat cush- with the above components removed,
tour of the wheelhouse into the lug- ion. and checking the interior of the
gage compartment. 4. Luggage compartment floor body joints and weld lines. The light
To eliminate dust leakage, deter- mats, spare wheel, and side trim will show through where leaks exist.
mine the exact point at which the panel.

, cation are given under each sealer

TYPES OF SEALER and is commonly known as perma-
AND APPLICATION type. gum. It is used on spotweld holes,
around moulding clips, or between
The all-purpose sealers described CAULKING CORD AB19560-A two surfaces not properly sealed by
below have been selected for service This sealer has a plastic base with a gasket. Apply the sealer with a
use. The method and points of appli- an asbestos filler. is heavy bodied. Dutty knife.
17-2 GROUP 17 BODY, DOORSAND WINDOWS
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BODYSERVICE 17-3

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fRONT BUMPER
NOTE:UNDERBODYSIDESAND DIAGONAL DIMENSIONSMUST BE EQUAL. DIMENSIONSUNDER100"
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FIG. 2-Fairl.ane UnderbodyDimensions

TRIM CEMENT C2AZ-19C525-A ommended that silicone lubricant Rough out badly damaged areas
This cement is recommended for be applied to the upper weather- before taking measurements for
instrument panel safety cover and strips at every regular lubrication squaring up a body. If necessary,
body panel plastic water shield in- period. Its use makes the doors remove the glass from the damaged
stallation. It is also useful for repair easier to close, avoids weatherstrip area to prevent damage. In severe
or replacement of other vinyl and squeaks, retards excess weatherstrip cases reinforcement brackets and
rubber trim. wear from chafing between the other inner construction may have
door glass upper frame and the to be removed or cut to permit
RUBBER CEMENT 8A-19552-B weatherstrip, and helps to retain restoration of the outer shell and
This quick-drying, strong adhe- door window alignment by reduc- pillars without excessive strain on
sive material is designed to hold ing friction between the glass frame the parts. Straighten, install, and se-
weatherstripping on doors, bodies, and rubber weatherstrip. cure all such parts in place before
deck lids, cowl ventilators, and the attempting to align the body.
surrounding metal. Windows and BODY ALIGNMENT In cases of severe or sharp bends,
windshields which are set in rubber Servicing the unitized body should it may be necessary to use heat.
can be effectively sealed against present no unusual difficulties or Any attempt to cold-straighten a
leakage by flowing cement into the necessitate additional equipment severely bent bracket may cause
affected areas. other than that required for the ruptures of the welds and may also
Clean all grease, dirt, and old conventional frame and body repair. cause cracks in the bent part. Never
sealer from the surfaces to be ce- The application of heat and the use heat the area more than a dull red.
mented. For best results, apply a of heavy-duty jacks must be care-
medium coat of cement to both sur- fully controlled because of the dif- CHECKING BODY FOR
faces, allow it to dry until tacky, ference in the gauge of the metal MISALIGNMENT
and press both surfaces firmly to- in the sub-frame of a unitized body To align or square up a body, take
gether. and the stress points developed in a two opposite diagonal measurements
single welded unit construction. It between pillars. Use a measuring
Sll-ICON LUBRICANT is possible to pull damaged areas tram for these measurements. Take
COAZ-19553.A (JELLY) AND back into alignment with the use the measurements between reference
COAZ.19553.C (SPRAY) of light-weight jacks and hydraulic points such as crease lines or weld
This lubricant is to be used on the equipment without heating the joints which are diagonally opposite
door window weatherstrips. It is rec- metal 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 ob-
tain proper body alignment when
repairing a body that is damaged
on both sides. In these cases, hori-
zontal 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 jack-
ing 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. Horizon-
tal, vertical, and diagonal checking
points are established on all four
sides of the door opening that is
being measured.
CHECKING UNDERBODY FOR
MISALIGNMENT
The dimensions of the underbody
must be restored in the repair of
major body damage, to provide cor-
rect front and rear wheel geometry
(Figs. I, 2 and 3). All the dimen-
sions are detailed to the center line
of existing holes in the underbody
assembly. Once the frame and sus-
pension members are aligned, the
balance of the repair can be per-
formed.
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 re-
finishing materials agree on the pro-
cedure 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 re-
move 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 Chemi-
cal Division of Amchem Products,
Inc.) or Bonderite No. 34 (Distrib-
uted 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 succeed-
ing coats and color as required must
be applied according to vendor's di-
rections. Examples such as the Du-
Pont and Ditzler systems are given
as follows:
SYSTEM FOR USING DUPONT
PREPARAKOTE
1. Spray Preparakote over prop-
erly 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 care-
fully, 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 Lac-
quer as directed. Then air-dry or
force-dry until the lacquer is hard
enough to be polished.
5. Polish the lacquer as recom-
mended 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 recom-
mended 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 thick-
ness of about two mils.
3. After drying the primer surfacer
about thirty minutes, carefully sand
with No. 360 or No. 400 silicon car-
bide paper, wet or dry, so as not to
cut through the zinc dust primer
coat. Blow off and tack clean.
4. Spray matching Duracryl lac-
quers 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 resist-
ance and gloss retention in metallic
colors than the ordinary enamels.
Acrylic enamels also possess the
property of good polishability.
Following are recommended re-
pair 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 pro-
cedure consists of:
1. Remove the defect by oil sand-
ing with 600 grit paper, using water
or mineral spirits as a lubricant.
2. Apply a white or light colored
medium grit machine polishing com-
pound (Sno-Flake No. 16 or equiva-
lent) to the painted surface with a
brush.
3. Polish the entire panel surface
using an 1850 rpm wheel and a car-
pet 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 smooth-
ness of the finish on the entire car.
Repair By Repainting. Acrylic
enamels can be repaired by repaint-
ing with either conventional air dry-
ing 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 - GENERALBODY SERVICE 7-5

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 17-6 GROUP 17
both the original finish and the re-
pair 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 acry-
lic 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 thor-
ough 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 re-
pair 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 con-
tainer.
After sanding, proceed with the
application of a primer surfacer re-
duced 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 ab-
normal paint conditions that may be
encountered (Fig. 4). It is very im-
portant to identify the paint condi-
tion correctly so that the proper
repair procedure may be followed.
For each of the following paint con-
ditions described, the recommended
repair procedure will be indicated.
BLISTERING
Blistering is the formation of bub-
bles 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 in-
stances, this complaint may be con-
fused 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 be-
tween the coats, metal not properly
cleaned, or uneven temperatures
between the metal and the paint
being sprayed.
BODYI DOORSAND WINDOWS
Acrylic Enamel. Repair by re-
painting (color coat). Priming pro-
cedure must first be followed if
defect is due to poor metal prepara-
tion.
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 long-
er, 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 ex-
cessively 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 Enamel. Repair by polish-
ing.
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 condi-
tion (Color coat.)
ORANGE PEEL
Orange peel is a term used to
describe an uneven, mottled appear-
ance on the paint surface. This is
usually caused by improper thin-
ning 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 sur-
rounding 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 apply-
ing 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 ex-
cessively thin color coat, or applica-
tion 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 Thi~ i~ 11~11"l1v
 PART 17-1 GENERALBODY SERVICE 17-7

RANDOMBLISTERS PITS AND POp.UPS SCRATCHES

PATTERN BLISTERS DIRT IN PAINT CRATERS WATER SPOTTING

LINE CHECKING MILDEW THIN PAINT INDUSTRIAL FALL.DUT

CHIPPING OFF COLOR RUNS AND SAGS ORGANIC FALL-OUT

BRUISES ORANGE PEEL PEELING

CRACKING OVERSPRAY WRINKLES

N-1471-A

FIG. 4~Paint Defects

~
 17-8 GROUP 17 BODYDOORSAND WINDOWS
caused by over-application of paint
or hesitation in the stroke of the
gun.
Acrylic Enamel. Use polish re-
pair procedure.
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 re-
pair procedure for shallow penetra-
tion. Refinish panels to correct con-
ditions 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 re-
pair procedure.
WATER SPOmNG
Water spotting is evidenced by a
milky pattern where water drops
have fallen.
Acrylic Enamel. Use polish re-
pair 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 ad-
hesion 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 re-
move loose soil. Rinse well and
examine the painted surfaces for
iron base fall-out particles. If there
CLEANING AND INSPECTION
FLOOR PAN PLUGS
AND GROMMETS
The floor-pan plugs seal the vari-
ous 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
I
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 de-
tergent such as car wash compound
(COAA-19B521-A). This acid deter-
gent 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 shel-
tered area so that the work will be
kept as cool as possible to prevent
rapid evaporation of water and con-
sequent 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 solu-
tion 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
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
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 (8A-
19519-A) using a piece of heavy
toweling. Again, a thorough water
rinsing is extremely important.
Sometimes small black spots re-
main 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 vigor-
ously 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 flush-
ed 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 dam-
aged 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.
cleared periodically.
BODY MAINTENANCE
Regular body maintenance pre-
serves the car's appearance and re-
duces the cost of maintenance dur-
ing the life of the car. The follow-
ing steps are suggested as a guide
 PART 17-1- GENERALBODYSERVICE
for regular body maintenance:
1. Vacuum the interior thorough-
ly 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 gar-
nish 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 rat-
tles, 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 anti-
squeak 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 fre-
quently 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 com-
pound. 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 excel-
lent 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 plas-
tic 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 tetrachlor-
ide, body polish, battery acid, anti-
freeze, gasoline, motor oils or other
type lubricants.
Approved cleaners B8A-19523
-A, or -B, B5A-19525-A, COAZ-
19526-A or -B (soft trim cleaners),
BAF-19521-A (leather and vinyl up-
holstery 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 par-
ticles 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 serv-
iced 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 WOOD-
GRAIN 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 trans-
fer is to be applied is damaged, re-
pair 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 ad-
hesive.
4. Allow the binding coat to air-
dry 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, ap-
ply a 20% M-5412-A transfer solu-
tion to the panel. Any excess solu-
tion that runs down on adjacent
panels must be wiped off immedi-
ately.
10. Place the wet transfer on the
panel, paper side out. Adjust the
transfer to match the graining on
adjoining panels, and carefully re-
move the paper backing.
 17-10 GROUP 17 - BODY,DOORS
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 VEHICLE
The unitized body-frame construc-
tion requires special precautions and
procedures when the car is jacked
up or hoisted. In some cases, spe-
cial 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 inter-
ference, the hoist flanges should be
modified as necessary and/ or the
approach ramps built up to provide
the needed clearance.
RAIL TYPE-FREE WHEELING
HOIST
FRONT
The front adapters or hoist plates
must be carefully positioned in con-
tact with the lower suspension arms
to assure safe, accurate lifting.
REAR
The hoist adaptersmust be posi-
tioned carefully under the rear axle
to prevent damageto the shock ab-
sorberswhen 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
ANDWINDOWS
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 re-
move the air and excesssolution.
15. Allow the panel to air-dry for
post adapters must be positioned
carefully to contact the center of
the lower suspension arms (Figs. 5
and 6).
REAR
To prevent damage to the shock
absorbers, the rear forks must con-
tact the axle at points not farther
out board than one inch from the
circumference welds near the differ-
ential housing. Carefully raise the
rear post and check the position of
the fork (Figs. 5 and 6).
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 nOR IArKrnNtAr¥b~~
- --~"""---
FRONT FRAME CONTACT AREA Mll11-A
FIG. 5-Front Hoist Contact Areas
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.
least 12 square inches of underbody
area. Figs. 5 and 6 show recom-
mended contact points for the hoist
pads.
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 con-
nection. Either side of the front
end of the car may also be raised
by jack pressure on the front cross-
member, or on the crossmember
to which the stabilizer is connected.
Do not attempt to use jack pressure
on either front or rear Mustang
bumpers.
FIG. 6-Rear Hoist ContactAreas
 17-11

FRONT SHEET METAL, BUMPERS,

EXTERIOR MOULDINGS
Section Page Section Page
1 In-Car Adjustments and Repairs .17-11 Radiator Grille-Fairlane .17-12
Hood Adjustments. 17-11 Radiator Grille-Mustang .17-14
Hood Lock Adjustments-Mustang .17-11 Front Bumper-Comet, Falcon, Fairlane .17-14
Hood Lock Adjustment-Comet, Falcon, Front Bumper-Mustang .17-15
Fairlane 17-11 Rear Bumper-Falcon ..17-16
2 Removal and Installation. . . . . . . . . . . . . . . . . . . . .17-12 Rear Bumper-Comet, Fairlane. . . . . . . . . .. . .17-16
HoodHinge 17-12 Rear Bumper-Mustang .17-16
RadiatorGrille-Comet. . . . . . . . . . . . . . . . . . . .17-12 Rear Bumper Guard-Mustang... . . . . . . . . . . .17-17
RadiatorGrille-Falcon. . . . . . . . . . . . . . . . . . . .17-12 Exterior Mouldings. 17-17

HOOD ADJUSTMENTS
The hoOd is provided with fore
and aft, vertical, and side-to-side
adjustments (Fig. 1). These direc-
tions 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 pro-
vide 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 adjust-
ed 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
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 attach-
ing 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.
6. To adjust the safety catch
striker, loosen the two attaching
screws and position the catch cor-
rectly. 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 sev-
eral 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 mechan-
ism 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.

LOCK DOWEL SAFETYCATCH STRIKER HOOD LOCK

--
...'.-N1071-B --,
SAFETYCATCH
N1184-B
FIG. 1-Hood Hinge Installation
-Typical FIG. 2-Hood LockMechanism-Mustana
17-12 GROUP 17 - BODYDOORSAND WINDOWS I

REMOVAL AND INSTAllATION

HOOD HINGE grille and remove the grille orna- INSTALLATION
1. Prop the front of the hood in ment. 1. Position the grille assembly in
the open position and cover the the grille opening and loosely install
fender and cowl panel. INSTALLATION the upper retaining bolts.
2. Remove the hinge-to-hood re- 1. Position the grille ornament 2. Loosely install the lower grille-
taining bolts, the retaining bolts at on the left grille and install the re- to-center support bracket retaining
the fender apron and cowl (Fig. 1), taining nuts and washers. screw.
and remove the hinge. 2. Position the grille center panel 3. Install the end grille retaining
3. Position the hood hinge on the to the grille assembly and install screw at each headlight housing and
body and install the hinge retaining the retaining screws. tighten all bolts and screws.
bolts. 3. Position the grille assembly in 4. Install the headlight doors.
4. Adjust the hood for proper fit. the grille opening. RADIATOR GRILLE-FAIRLANE
4. Install the grille top retaining REMOVAL
RADIA TOR GRillE-COMET
screws, the grille-to-center lock sup-
REMOVAL port retaining screw and the right 1. Remove the headlight door re-
1. Remove one screw and two and left side grille retaining bolts. taining screws and remove the head-
bolts retaining the grille assembly light doors.
to the center lock support and the 2. Remove the screws retaining
RADIATOR GRillE-FALCON
right and left sides at the stone the grille assembly to the hood lock
REMOVAL support, the screws retaining the
deflector (Fig. 3).
2. Remove the four screws re- 1. Remove the headlight door re- grille to the upper grille support
taining the grille assembly to the taining screws and remove the head- brackets, and the three retaining
upper support; remove the grille light doors. screws from each end of the grille
assembly from the grille opening 2. Remove one retaining screw (Fig. 5).
and place it on a bench. from each side of the grille at the 3. Remove the grille assembly
3. Remove the eight screws re- headlight housing (Fig. 4). from the car.
taining the grille center panel to the 3. Remove the lower grille to cen- 4. Remove the three nuts retain-
grille assembly and remove the ter retaining screw (Fig. 4). ing the grille ornament and remove
panel. 4. Remove the upper grille to sup- the ornament.
4. Remove the nut and washer re- port bracket retaining screws (Fig. 5. Remove the screws retaining
taining the grille ornament to the 4) and remove the grille assembly. the upper and lower grille mould-

'GRilLE ASSEMBLy'8200

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..nllfnIN~_Ii;A~~

~R1LlE OPENINGPANEL
824~~
(f/'---

~t -..,..- j, '~v HOOD

HEAOlAMP HOUSING SEAl 3A133 J
ASSEMBLY-16612
HEAOLAMP HOUSING ASSEMBLY .
l.1 ASSEMBLY_",nn
HOOO lOCK
N 1322-0

FIG. 3-Comet Grille and Hood LockAssembly

 PART 17-2 FRONT SHEETMETAL, BUMPERS,EXTERIORMOULDINGS 17-13

N 1185- E

FIG. 4-Falcon Grilleand Hood Lock Assembly

FIG. 5-Fairlane Grille and Hood LockAssembly

17-14 GROUP 17 - BODY,DOORSANDWINDOWS

ings to the grille assembly and re-

move 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 orna-
ment retainer and retaining nuts.
3. Position the grille assembly on
the car and grille assembly retain-
ing screws
4. Install the headlight doors.

GRILLE-MUSTANG
REMOVAL
1. Open the hood.
2. Remove the four grille retain-
ing screws from the lower inner
flange of the grille.
3. Remove the four grille retain-
ing screws from the upper flange of
the grille upper center support
bracket to the hood lock hook sup-
port. N 1365- C
4. Remove the grille assembly.

INSTALLADON FIG. 6-Comet Front Bumper Installation

1. Transfer the upper center sup-
port 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 retain-
ing screws.
3. Close the hood.
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 as-
sembly retaining nuts and remove
the parking light assemblies.

INSTALLATION
1. Install the license plate on the
new bumper.
2. Install the parking light assem- N 1366. B
blies in the new bumper.
3. Install the bumper inner and
nllter ~rm~ nn the new humner usinll FIG. 7-Falcon Front BumperInstallation
 PART 17 -2 - FRONT SHEETMETAL, BUMPERS,EXTERIORMOULDING 17-15

FRONT BUMPER-MUSTANG
, .\
REMOVAL
~~

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

I\
~
,..\, ~ 1. Raise the car to provide work-

..'"
:~,~~.\\\\\\\.., l.~C~S~ ,PLA:I;E ing access.
17754 '\~~ :-""'~'\]'-~\\\"'\' BRAt"ICI=T, 17~1
2. Tape the stone deflector to pre-
\\.::~:i;;:~~~~\\\\\~ vent scratching the paint finish.
3. Remove the left and right
R,H. INNER ARM " R\~' bumper-to-fender bracket bolts from
\'~$, the fenders.
177¥
~': 4. Remove the bumper bar-to-in-
~ ner arm and the bumper bar-to-outer
~~;~!~~1~~:~1;%) arm retaining bolts from each side
~ ,~.,,! \~ \!,'I~'~."'"
---,-\",~;:,,;~,:;;;;;,';i ~1 of the bumper (Fig. 9). Remove the
"'
/8 bumper and bumper-to-fender brack-
c, . ,- et as an assembly.
IMPA~TBAR~,':
i7757 _A"" ~ INSTALLATION
~""~ ~..""" 1. Transfer the bumper-to-fender
, bracket to the new bumper.
.
BUMPER LOWER
L.
H OUTERARM
17754
2. Position the bumper on the car.
Install the bumper bar-to-inner arm
'XTENSION - 17Bd75 and the bumper bar-to-outer arm re-
.H: INNERARM
17766 taining bolts.
R 1178- B 3. Install the bumper-to-fender
bracket retaining bolts.
FIG. 8-Fairlane Front BumperInstallation 4. Remove the protective tape
from the stone deflector and lower
spacers and washers as shown in 5. Align the bumperassemblyand the car.
Figs. 6, 7 and 8. tightenthe bumperarm-to-frameside
4. Position the bumper assembly rail retaining bolts. FRONT BUMPER GUARD-
to the car and loosely install the 6. Route the parking light wiring MUSTANG
bumper arm-to-frame side rail re- through the fender aprons and con- 1. Remove the screw and washer
taining bolts. nect the wiring connectors. retaining the bumper guard to the

.
BUMPER GUARD
~~

VIFW- ""

Nl:m6-A

FIG. 9-Mustang Front BumperInstallation

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 as-
sembly 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 arm-
to-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.
.
_OWEREXTENSION-178875
FIG. 10-Falcon RearBumperInstallation
GROUP 17 BODYDOORSAND WINDOWS
I
REAR BUMPER IMPACT BAR-
COMET, FAIRLANE
REMOVAL
1. Open the luggage compart-
ment. Disconnect the license light
wiring connector and push the lic-
ense 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 re-
taining screw and washer assem-
blies.
4. Remove the lower inner arm-
to-lower back panel retaining screw
and washer assemblies (Fig. 11).
5. From inside the luggage com-
partment, 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 assembliesre-
taining 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-
N 1367. B
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 im-
pact bar.
4. Position the bumper assembly
on the car. Feed the license plate
light wire through its routing grom-
met in the lower back panel and
start one upper arm-to-body retain-
ing screw on each side.
5. Shift the bumper assembly as
necessary for proper alignment and
install the remaining bumper arm-
to-body retaining screws. Torque the
retaining screws to 25 to 38 ft-lbs
specification.
6. Install the lower bumper arm-
to-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 compart-
ment. 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 assem-
bly (Fig. 12).
3. Remove the four bumper-to-
mounting 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.
INSTALLATION
1. Position the license plate light
and bracket on the bumper and in-
stall the two retaining screws.
2. Position the bumper mounting
brackets on the bumper and install
the bumper-to-mounting bracket re-
taining bolts.
3. Connect the license light wiring
and install the spare wheel.
 PART 17-2 FRONT SHEETMETAL, BUMPERS,EXTERIORMOULDINGS 17-17

REAR BUMPERGUARD-
MUSTANG
REMOVAL
1. Open the luggage compart-
ment door and remove the spare tire
assembly to provide access to the
upper guard retaining screw and

~/f)-
- "1
\,~
--;:::::::
'.
washer.
2. From inside the luggage com-
A-":';~~ :""C~
~ ~,~ ::::r::---~'>-"
"'" partment, remove the upper guard

.. , :(~ retaining screw and washer (Fig. 12).

" 3. From beneath the car, remove
OUTERARM-1779S-6 the lower guard retaining screw and
0 ~~:~ INNER
ARM~
17A973.4"", washer (Fig. 12). Remove the
bumper guard.
" INST ALLA.TION
1. Transfer the two nuts and re-
g-
~l tainers to the new bumper guard.
%-0'
., Transfer the rubber spacers to the
LICENSE PLATE new bumper guard.
SUPPORT
BRACKET-13393 2. Position the bumper guard on
the car and install the two retaining
screws and washers.
IMPACT BAR.179Of 3. Install the spare tire assembly.
EXTERIOR MOULDINGS
Before removing the exterior
mouldings, it should be detennined
by the type of retainer used whether
N1417.B
a respective door, quarter or lug-
FIG. 11 .Comet,FairlaneRearBumperInstallation
gage compartment trim panel must
first be removed to provide access
(Figs. 13 through 31).

H 1387- A

FIG. 1 2-Mustang RearBumperInstallation

~
17-20 GROUP 17 - BODY,DOORS
ANDWINDOWS

i(tt)
. . . . -
SHOWN TYPICAL N 137,

FIG. 17-Exterior Mouldings-Comet Model 71

///

L
-w:-
~
"1~:~-;~ - II"
~
-- ---
~

---
MODELS C6GB FIGURE 1

FIG. 1 8-Exterior RearMouldings-Comet Model 71

 PART 17-2 FRONT SHEETMETAL, BUMPERS,EXTERIORMOULDINGS 17-21

A-:::~;;;;;;:;:;;;;;-;LS C6GB.54D.63C.63D.76B.76D
L~~:::::::::::::- FIGURE2
~
\
~'~:.,.~s~r ,-- ~ ,~
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MODE LS C6GB. S4A.54B.62A.63B
FIGURE 1
:::::::;::::::-
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~ L
.-:::::;:::=-
~~:::::~
MODEi,$C6QB.63E.63H-76C.76H '~~~
FIGURE 3 ,...,..~~~~::::
~
£

L---
,
~ ~

FIG. 19-Exterior Rear Moulding-Comet Models (Except71)

FIG. 20-Exterior Mouldings-Falcon

Models54A,548, 62A, 628, 62C
 17-22 GROUP 17 BODYDOORSAND WINDOWS I

""'-

,
(!r
,,\\

:~ ~~;3:::: 1(;)

~
~
0
~,=-
=~
..~I
::::::::,.
~-:::=::::-
5l!;i~

~\"--,I :::::~::::~::::?
::::::::=-~~DEL C6DB
-71A
~
~ = -..

~,,==
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(.)
-~ ~@

:;F"~ ~-=
MODELC6DB-71B

IJj
i:""' ~ ~ '"
\C~I
~~ ~
MO{)EL C6DB-71B
~ (E)
,*'
:.y
!b>"
c

:YjQ) N 1370.

FIG. 21-Exterior Mouldings-Falcon

Models71A,718

~
-~-~ ~~
~--
:!!fjj
IQ~,
i
(G') N 1~71.cl

FIG. 22-Exterior Mouldings-Falcon

Model66
~
 PART 17-2 FRONT SHEETMETAL, BUMPERS,EXTERIORMOULDINGS 17-23

~
~

~
~
~.
~""C 'c
"""""" --"
--c~

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MODELS C6DB-S4A-62A

rn! ~
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.EQ ~

, .",
N 1377. c:

FIG. 23-Exterior RearMouldings-Falcon Models54, 62, 71

7~;::::;e~

~ ~
~
.~
~
::::::::: :..

lL-
MODELSC6DB-54A-62A-66A-I;I;r_71A

~::=:;:;;:;;::~~;~::!/L"""
:~ -~-=-
'..- -1" ~r
.;~~~-:- ~ ~ ~
.
~ ~~::~:~
~ -

~. --
- c
B BB

MOOELSC6DB-S4B-62B-62C-66B-66D-71B
N 147'

FIG. 24-Exterior Front Mouldinos-Folcon Models (ALl)

~
17-24 GROUP 17-BODY, DOORSAND WINDOWS

fiG. 2!5-Exterior FrontMouldings-Fairlane

N 1381-C

FIG. 26-Exterior Mouldings-Fairlane

ModelsS4A,62A
 PART 17 -2 - FRONT SHEETMETAL, BUMPERS,EXTERIORMOULDINGS 17-25

-::::::::::::::~

- 'r- rL L.-""
.-"
,,--- --:-::~~
~~L '-
"' "'-

\\ "..,.

-
/~~.,..,...==~
./

@~
-::::::::::::::- ..-
- -::::--~~ MOOELC60B-63B

MODEL C60B-62B SHOWN

MODELS C60B-63B - 76B TYPICAL

,""

~
=&~"""'L L ..

I'-~""'-= L \.::.I
l "
..-::::::;;J

~~

tj '-:./

MODEL C608-548

~~

~
"~j
i .~

@
I ~
~ - ~:~"":,;;
'" I~

FIG. 27-Exterior Mouldings-FairlaneModels548, 628, 638, 168

~
 17-26 GROUP 17 BODY, DOORSAND WINDOWS

..;:::=:::::::::-- " "-.

I.. "

~
==-~~

,-@
I MODEL C60B.63C SHOWN
- ..,. MODEL C60B-76C TYPICAL

.1~
~ ,
j@
-- -~=~:::::::~::::::~~, '--
11!~

-::::: ~ j ~
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ill
COCCo

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Iff
MODELC60B-63D SHOWNMODEL C60B-76D TYPICAL
(B)

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'-
'"

~ ,

. i
@
~ "'L) 0
FIG. 28-Exterior Mouldinas-Fairlane
Models63(. 63D.76(. 76D

~
 PART 17-2 - FRONTSHEETMETAL,BUMPERS,
EXTERIOR
MOULDINGS 17-27

>-"
---

\\)
\l-- ~
~
--\ @.,
~
!:~ ~
,
I
:::/--
::J
v
-c::.
~

"\\;:- MOOEL C608-718

(;:;'\~
@
,-.:.,

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~ '~

£~ '-.,~ ~
'C\

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~ ~
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N 1383. C

FIG. 29-Exterior Mouldings-Fairlane

Models71

~
17-28 GROUP 17 - BODYDOORSAND WINDOWS
I

Ia

:JJ
~
MOO EL 5 S4A. 62A ::.:.= r
..L-
~

FIG. 30-Exterior RearMouldinas-Fairlane Models (ALl)

 PART 17-2 - FRONTSHEETMETAL,BUMPERS,
EXTERIOR
MOULDINGS 17-29

.,c ~
~
~
-=- :l[ -- I
t
~ ~ p

~
,
0

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FIG. 31 .ExteriorMouldinas-Mustana Models (ALL)

~
17-30

Section Page Section Page

Lock Striker Adjustment.
Door Alignment ................ 17-30 Front Door Glass-Comet, Fairlane
1
In-Car
Adjustments
and
Repairs
17-30 ModeI63,76 17-41
17-30 Front Door Window Regulator-Manual-
Vent Window Adjustment-Comet, Falcon Comet, Fairlane- Model 63, 76. . . . . . . . . . . .17-42
Door Glass Adjustment-Comet,
ExceptModels63,76 Fairlane 17-31 Front Door Window Regulator-Except
Models63,76 17-42
Front Door Glass Adjustment-Comet,
Models63,76
17-31 Front Door Rear Glass Run-Models 63, 76. .17-42
Rear Door Glass-Comet, Falcon-
Falcon, Fairlane Models 54, 71. . . . . . . . . 17-32 ModeI54 17-42
Door Glass Adjustment-Comet, Falcon, Rear Door Window Regulator. . . . . . . . . . . . . .17-42
Door Window Adjustment-Mustang. . . . .
FairlaneModels62 17-32 Quarter Glass- Model 62. . . . . . . . . . . . . . . . . . .17-43
17-32 Quarter Window Regulator-ModeI62 .17-43
Rear Door Window Adjustment-Comet, Quarter Window Regulator-Model 63 .17-43
Falcon, Fairlane. . . . . . . . . . . . . . . . . . . . . . 17-33 Quarter Window Front Guide-Model 63 .17-43
Quarter Window Adjustment-Comet, Quarter Window Rear Guide- Model 63. . . . .17-43
Falcon, Fairlane Model 62. . . . . . . . . . . . . 17-36 Rear Quarter Window Glass-Fairlane,
Quarter Window Adjustment-Comet, Comet-ModeI76 17-43
Quarter Window Adjustment-Comet,
FairlaneModeI63
17-36 Rear Quarter Window and/or Weatherstrip-
Model 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-44
Quarter Window Adjustment-Mustang.
FairlaneMode176 . . . .17-36 Windshield-Comet, Falcon, Fairlane. . . . . . . . 17-44
. .17-36 Windshield-Mustang Model 76. . . . . . . . . . . . ...~
17-47
Windshield-Mustang
Model
63,
65
Tailgate Emergency Opening Procedure.. . . . .17-36 17-ii~

Dual-Action Tailgate Adjustments. . . . . . . . . .17-37 Back Window and/or Weatherstrip-

2 Removal . .17-37
and Installation. ................. Back Window-Mustang Model 65. . . . . . . . . . 17-49
Standard
DeckLidAlignment
DeckLockAdjustment
Tailgate
Hinge
Adjustment
Comet,Falcon,Fairlane
. .17-37 17-49
. .17-37 Back Window-Mustang ModeI63 17_,(}
."-J,)
. .17-39 Inside Rear View Mirror (Bonded to
Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-39 Windshield). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-51
Front Door Lock-Except Models 63, 76.. . .17-39 Tailgate Window Regulator. . . . . . . . . . . . . . . . . 17-52
TailgateGlass
DoorLockCylinder
Front
RearDoorLock Door . .17-39 Lock-Models 63, 76 , 17-53
. .17-39 Tailgate Switch and Lock Cylinder-Power. . ...17_~d
~.
. .17-39 Tailgate Window Handle and Lock Cylinder-
Door Handle or Push Button.. . . . . . . . . . . . . .17-39 Manual. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-54
Door Vent Window Frame-Except Dual-Action Tailgate Hinges. . . . . . . . . . . . . . . . 17-55
Models 63, 76... . . . . . . . . . . . . . . . . . . . . . 7-39 Dual-Action Tailgate Locks. . . . . . . . . . . . . . . . . 17-55
Vent Window or Weatherstrip-Models Dual-Action Tailgate Torsion Bar. . . . . . . . . . . . 17-55
63, 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-41 Deck Lid Hinge or Torsion/Bar. . . . . . . . . . . . . . 17-55
Front Door Glass-Except Models 63, 76. 17-41 DeckLidLock 17_"
~.I

IN-CAR ADJUSTMENTS AND REPAIRS

DOOR ALIGNMENT striker plate for proper door closing. between the lock striker and the
The door hinges provide sufficient Do not cover up poor door adjust- lock. To check this clearance, clean
adjustment to correct most misalign- ment with striker plate adjustment. the lock jaws and the striker area,
ment conditions. Loosen the door and then apply a thin layer of dark
hinge attaching bolts and adjust the LOCK STRIKER ADJUSTMENT grease to the lock striker. As the
door so that it is centered in the door The striker pin can be adjusted door is closed and opened, a measur-
opening when closed. Then, tighten laterally and vertically as well as able pattern will result. Move the
the hinge attaching bolts. fore and aft. The lock striker should striker assembly laterally to provide
After adjustment at the hinge not be adjusted to correct door sag. a flush fit at the door and the pillar
attaching points, check the align- The lock striker should be shimmed or quarter panel.
ment between the door lock and to get the clearance shown in Fig. I
 PART 17-3 - DOORS,WINDOWS,TAILGATEAND DECKLID 17 -31

DOOR GLASS ADJUSTMENT- Tighten the screw and washer as-

COMET, FAIRLANE MODELS semblies, Y and AB securely.
63,76 5. Position the vent window as-
The door must be properly aligned sembly and vent window division
in the body opening before glass bar glass run rearward, into a posi-
adjustments are made. tion relative to the door window
1. Remove the door trim panel glass and tilt fore and aft, as re-
and peel back the watershield to pro- quired, to maintain a parallel rela-
vide access. tionship to the front body pillar.
2. Loosen screw and washer as- Tighten the screw and washer as-
semblies A, J, Z and AB, also nuts semblies A securely. The adjusted
C, E and L (Fig. 2). position of the vent window assem-
FIG. l-Door LockStriker bly should be such as to provide
3. Cycle the window to its up
Adjustment position and manually position the window travel free of binding.
window assembly inboard or out- 6. To provide a proper interfer-
VENT WINDOW ADJUST- board, as required, for proper align- ence relationship of the vent window
MENTS-COMET, FALCON ment to the outside belt weather- and the door window assemblies to
EXCEPT MODELS 63, 76 strip and tighten the screw and the top roof rail weatherstrip, tilt
washer assembliesJ. these assembliesinboard or outboard
The vent glass and/or the vent
4. Tilt the window assembly fore as required, by turning the screws,
window frame may be adjusted in
or aft as required, to obtain a par- B, D and K clockwise or counter-
various ways. With the vent glass in-
allel relationship between the top clockwise, to the desired setting and
stalled, the lower pivot spring ten-
of the window and the roof rail then tighten the nuts C, E and L
sion may be adjusted with a socket,
weatherstrip. This will position the securely. At this point, secure the
extension, and ratchet used through
rear guide assembly in correct fore vent window regulator assembly
the access hole in the door inner
panel. Adjust so that the glass will and aft alignment. Tighten nut L door vent window, by tightening the
temporarily. Turn screw G clock- screw and the washer assemblies A
stay open at highway speeds. The
door frame mounting holes are wise or counter-clockwise, as re- securely.
elongated to provide a tight fit for quired, to maintain position of the 7. When the above steps are com-
the vent window frame in the door guide assembly and tighten nut and pleted, cycle the window down un-
washer assembly H securely. At til the top of the window is flush
frame. The upper pivot mounting
holes are slotted to help provide this point, adjust the door window with the belt and position the down
a weather-proof fit of the glass frame stop assemblies up or down as re- stop assembly to the bumper door
within the vent window frame. quired, for correct engagement. window stop and secure it with the

GLASS AND CHANNEL ASS'Y. - 21400.

~-:::C"~--~"'---~--~-~ ~~,.
~~.,
:~.'-I
iii~'-1[~-.';Ii '.",.., !".,;)\ ""'0'

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f'
of;'

.;1__-

, ~
l
UPP~R.~RONTSTOP~30600
;*f\
' FRONT GLASS CHAN~EL BRACKET -23288 Q,- c; 11
LOWER STOP BRACKET - 217~

~'t:~,;;.-;;:;;.;;.~.. .:::'"'-~-~',:~'
"
,;}'
c,
I REAR GLASS CHANNEL
BRACKET - 23296

~~~,~;j~!:":::'-:'i.:'i.:::34!
~L I"I ";, " --j!..

y.
B \r,;",,- ,$""
r#~i¥~~ \",~tl
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."' ".~ REGULATOR
ASS'Y.(ELECTR1C)-23200.

\\\~ \'~-"
Co \~ 1
D
t'tJ,:
I [t]-.. ,-]"" ,,"""*
BEL T OUTSIDE WEATHERSTRIP-21452. 3' f'
'\ iJ-
i~1~,; i )Ir"J~
I ~
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,: '" ..
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D"AD"'lln"_""Ann.lrf"..,..J;.~;1_!!!
:,, ,

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A'~ :!?J " ,
:,,;~1

~~
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:",

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:" .,c,
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REOULATOR
ASS'Y.- 23200.1
STOP BUMPER -2176:
. -. '"lff' .L ,-
K
~~
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'! J
:~'/.;::::
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U!fJ17i1
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: ' ! fig
aid
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-L::~l-- ~~" d 'I!iJL Ji

EQUALIZER ARM. BRACKET -23230
!~-, """BELT INSIDEWEATHERSTRIP-21436.
. ,,'-ASSRUNRETAINERANDBRACKETASS'Y.- 223A24.5 N 1283. D

FIG. 2-Door Window Mechanism-Comet,FairlaneModels 63, 16

~
17-32 GROUP 17 - BODY,DOORSANDWINDOWS
screw and washer assembliesZ.
8. Install the watershieldand the
door trim Danel.
FRONT DOOR GLASS AD-
JUSTMENTS-COMET, FALCON
FAIRLANE MODELS 54, 71
The door trim panel must be re-
moved 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 ADJUSTMENT-
COMET, 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 as-
sembly 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 counterclock-
wise as required. Tighten ite~s D
and E securely.
3. To obtain a flush condition be-
tween 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 ad-
justed up or down at screw and
washer assemblies U. After adjust-
ment, tighten the screw and washer
assembliesU securely.
DOOR WINDOW ADJUST-
MENT -MUSTANG
1. Remove the door trim panel
and watershield.
2. With the glass and channel as-
sembly in the up position, the vent
window assembly is adjusted forward
or backward and up or down at
points A to obtain a parallel clear-
ance 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 op-
erate freely with no binding in the
door glass lockside run and retainer
assembly, but still have adequate en-
gagement 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 di-
vision 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 DOORS,WINDOWS,TAILGATEAND DECKLID 17-33

VENT WINDOW DIVISION BAR GLASS

ASSEMBLY
- 21402- 3 RUN-21660
'- L , GLASS AND CHANNEL
ASSEMBLY -21400-1
III
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i-' al-- -'~.
I.
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r' RUN RETAINER ASSEMBLY-223A24.

DIVISION BAR GLASS II: : r"j 1
I."

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~,"C~il FRONT CHANNEL
5
II"
Iljii 1 ",
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'1 "'", "
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VIEW A BRACKET -23288 II:. :1!i~ ~\!;(,!'
;""'0, ,
LOWER STOP 11//
.. I-~
-~ o~
-:':-:.: ~~,,~~~~.. ,,;

'-
J' -"~
ELECTRIC WINDDW REGULATDR
~SSEMBL Y - 23200-1
II
" ,::~~;,~:
I\ OUTSIDE BELT
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INSIDE BELT
ASSEMBLY-23200-1 EQUALIZERARMBRACKE~ ; \'!:~j WEATHERSTRIP-21436,7
ASSEMBLY
- 23230 GLASS
RUN
- ;1
22Al00-1
N1478-A

FIG. 4-Door Window Mechanism-Falcon,Comet,Fairlane-Model 62

screw and washer assemblies at glass assembly may be adjusted to tween the top edge of the glass and
point A. tilt toward the inside or outside of channel assembly and the top edge
4. To obtain tlie proper interfer- the body at points D and E. After of the vent window frame, the front
ence of the glass assembly against adjustment, tighten the screw and stop assembly is adjusted up or
the outside belt rail weatherstrip washer assembliesat points D and E. down at point F; after adjustment,
and the roof rail weatherstrip, the 5. To obtain a flush condition be- tighten the screw and washer assem-
bly 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 re-
quired at points G and H. After ad-
justment, tighten the nuts at points
G and the screw and washer assem-
bly, point H securely.

REAR DOOR WINDOW

ADJUSTMENT -COMET I
FALCON, FAIRLANE
1. Remove the door trim panel
and watershield.
2. To obtain proper alignment of
retainer and division bar assembly-
to 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 re-
quired. Tighten nut and washer as-
FIG. 5-Door Window Mechanism-Mustang sembly C securely (Fig. 6).
17-34 BODYI DOORSAND WINDOWS

FIG- 7-0llnrtpr Winrlnw Mp..hnnicm-~nl..nn (nmpt ~nirlnnp_Mnrlpll.?

 PART 17-3 DOORS,WINDOWS,TAILGATEAND DECKLID 17-35

WiNDOW ,UPPER STOP - 222A24

ASSEMBLY-'
29700.1" /; .- "'-- REAR GUIDE LOWER BRACKET EXTENSION-298A52
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ELECTRIC REGULATOR-J{)~6.7

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STOP BUMPER- 29994 ""oJ
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FIG. 8-Quarter Window Mechanism-Comet,Fairlane-Model 63

STOP UPPER BRACKET -29998 !! -..;

gUTER WEATHE~~T~.lg;-2J.932,3..",; , , WINDOW

ASSEMBLY
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LOCK PILLAR-TO-WINDOW FRAME SEAL-28182-3 ,;;' ,~
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FIG- o-aunrt~r Window M~{honi5m-(omet. Foirlone-Model 76

~
17-36 GROUP 17 BODY DOORSAND WINDOWS
3. Install the watershield and door
trim panel.
QUARTER WINDOW ADJUST-
MENT -COMET, FALCON,
FAIRLANE-MODEL 62
1. Remove the quarter trim panel
and watershield.
2. To obtain proper clearance be-
tween the quarter window assembly
and the quarter window glass run
retainer assembly, operate the win-
dow to its full down position, loosen
screw and washer assembly D, and
adjust the retainer assembly for-
ward. After adjustment, tighten the
screw and washer assembly finger
tight (Fig. 7).
3. To obtain proper clearance be-
tween the quarter window assembly
and the quarter window glass run
retainer assembly, operate the win-
dow to its full up position. Loosen
screw and washer assemblies D and
adjust the retainer assembly for-
ward. After adjustment, tighten
screw and washer assemblies D
securely.
4. Install the watershield and
quarter trim panel.
QUARTER WINDOW ADJUST-
MENT-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 quar-
ter 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 weath-
erstrip. To do this, set the quarter
window assembly into position and
temporarily secure the front guide
assembly and the rear guide assem-
bly, by tightening screw and washer
assemblies G and B finger tight.
Also secure the upper stop assem-
blies and the door window stop
bracket, by tightening the screw and
washer assemblies K, Land M or outboard as required. Tighten
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 se-
curely.
5. Cycle the quarter window as-
sembly to its down position, flush
with the top of the quarter panel.
This will locate the rear guide as-
sembly and quarter window rear
guide lower extension assembly in
its proper position.
6. Tighten screw and washer as-
semblies A and C securely. Position
the quarter window lower stop as-
sembly firmly against the bottom
edge of the quarter window assembly
and tighten screw and washer as-
semblies F securely.
7. Cycle the quarter window as-
sembly 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 ADJUST-
MENT-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 re-
quired for alignment to the front
door window and roof rail. This will
properly position the quarter win-
dow guide panel assembly. Tighten
screw and washer assemblies E se-
curely.
4. Position the upper stop assem-
blies (Fig. 9) and the quarter upper
stop brackets and tighten the retain-
ing 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 interfer-
ence fit with the roof rail weather-
strip, tilt the guide assembly inboard
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 re-
taining screw K (Fig. 9).
8. Cycle the window up and
down to recheck alignment. Then,
install the watershield and quarter
trim panel.
QUARTER WINDOW ADJUST-
MENT -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 align-
ment and interference between the
top edge of the quarter window as-
sembly and the roof rail weather-
strip, the quarter window guide as-
sembly is adjusted forward or back-
ward 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 as-
sembly at items A, finger tight.
4. To obtain the proper align-
ment and interference between the
top edges of the quarter window as-
sembly and the roof rail weather-
strip, the guide assembly may be
tilted toward the inside or outside of
body at the screw and washer as-
sembly at items A and B. After ad-
justment, tighten the screw and
washer assemblies, items A and B
securely.
5. To obtain the proper level be-
tween the quarter panel at the belt
line and top edge of the glass and
channel assembly, the quarter win-
dow stop may be adjusted up or
down as required at the screw and
washer assembly, item C. This ad-
justment is made with the window
in the down position. After adjust-
ment, 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 regu-
lator 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 re-
taining spring clip and remove the
 PART 17-3 - DOORS,WINDOWS,TAILGATEAND DECKLID 17-37

clip from the roller. Hold the tail-
gate window firmly and pry the
regulator arms off of the two rollers,
carefully lower the window into the
tailgate, then open the tailgate.
STANDARD TAILGATE HINGE
ADJUSTMENT
The tailgate can be adjusted fore to body mounting bolts.
or aft and up or down at the hinge To adjust the tailgate from side

DUAL-ACTION ,<~::::.'}~
t;j~..:~ ~====: =: :::: ::::::=
TAILGATE ADJUSTMENTS ..:'' ~:::::::

While full adjustments are pro-

vided for the dual action tailgate, no
unique methods are employed. The
following information will assist in ~~~~~~*-Ll
I I .' .. ..;~,
','l .I DOOR CHECK
locating and performing the adjust- FLOATING TAPPING PLATES
IN PILLAR PROVIDE
i.. ..,l~..'r i I
./'
ments.
The fore and aft and up and down
FORE & AFT AND UP
&DOWNADJUSTMENT
,
-I y
adjustment of the tailgate is accom- (LOOSEN SCREWS)
plished at the hinge side by means
of square holes in the body pillar,
%Q OVERSIZE HOLES IN GATE
PROVIDE LATERAL ADJUSTMENT
backed by floating tapping plates, at (LOOSEN NUTS)
the upper and lower hinge attach- r

ments (Fig. 11 and 12). I~

Lateral adjustment of the tailgate
is accomplished at the upper hinge
.i ,j
by adding or removing spacer shims
between the hinge on the body and '+'~f..
II..
the pillar. Lateral adjustment at the ,i
lower hinge is accomplished by ~' I
)y '

-
..'
means of oversize holes in the tail-
8'1
gate at the hinge on the gate attach- ;!ji{7j;~~,,=-
ment (Figs. 11 and 12).
Fore and aft and up and down
adjustment of the strikers is accom-
plished by means of square holes in
--~ ::::.::::~ ~:::::=-
the pillar backed by floating tapping
plates. Lateral adjustment is accom- VERTICAL PIVOT -,

plished by adding or removing ~-~~~-:~-

shims (Fi2. 13). FIG. 11-Lower Left Hinae Assembly
17-38 GROUP 17 BODY,DOORSAND WINDOWS

" """
#
""'"
".. '.'.1, '"
'1' '" '"'" to side in the tailgate opening, re~

UPPER "HINGF ON GATE"

UPPER
"HINGE
\ ON BODY" {.'! i$ ! i ii
I' , "
"~ "" of'"",
'l' 'Ii,.' .I!i
move the trim panel, loosen the
hinge to tailgate bolts and shift the
/.~
,.' ii!' .- . ': ',ISPACER
SHIMS tailgate as required.
-- 'f':- PROVIDE
LATERAL
..-' ' ADJUSTMENT
Q- DECK LOCK ADJUSTMENT
'/ The striker plate can be adjusted

~;V:
-_.::::,~';i/),[..:~:-:"?,{.~-::---
laterally and vertically and the lock
"" "\ can be adjusted laterally. Before ad-
\'.'. ilf"'-'~\~
T
,,\1\\ '-'-
FLOATING TAPPING justing the deck lid lock, make sure
"
, "",
"",
PLATES IN PILLAR that the deck lid is properly aligned.
/. PROVIOE FORE ANO
f'=:'
", \\\", ;\"
! ~ AFT AND UP AND To adjust the lock, loosen the
\ \'.. \\\ 'I ,:I ,/ DOWNADJUSTMENT attaching screws, move the lock as
~ \\ \" 1,-
,'\ "" , ,i.
il

/;:/
",
", ..~ , \\
-I.
Ii
(LOOSEN SCREWS) required to make good contact and
'\, \\to." '.,--~ " If tighten the attaching screws. Move
", '" \ ".LOWER HINGE ASSEMBLY
",
'"
'\'
"'" \\-11 the striker plate up or down as
;==)'
\\\ ~
"
'\ ,
'\ ,
, ,
necessary to increase or decrease
'\
"
"
"
,
,
,
,
~. the clearance between the deck lid
,\ ,
'\,
and the lower back panel.
" .
'"
\, .

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 mount-
ing bracket provide up and down
movement. Enlarged hinge mounting
bolt holes in the lid inner panel pro-
N 1480 - A
vide limited lateral movement.
FIG. 1 2-Upper Left Hinge Assembly

FIG. 13-Tailqate LockStrikerAdjustment

 PART 17-3
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 re-
placement 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 seri-
ously damaged, the whole door need
not be replaced. A replacement outer
panel is available.
INSTALLATION
1. If the hinge was removed, in-
stall 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 LOCK-
EXCEPTMODELS 63, 76
REMOVAL
1. Remove the trim panel and
position the water shield away from
the accessholes.
2. Disconnect the door lock re-
mote control link, the lock actuat-
ing rod and the lock control to
cylinder at the lock (Fig. 14). Re-
move the knob from the push but-
ton 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. Con-
nect the lock control to cylinder
rod, the lock actuating rod, and the
remote control link at the lock. In-
stall the push button.
3. Position the glass rear run in
the door. Install the retaining bolt,
adjust the rear run, and ti2hten the
DOORS,WINDOWS,TAILGATEAND DECKLID
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 re-
taining 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 water-
shield 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 re-
mote control rod and door lock
control rod at the door lock assem-
bly.
3. Remove the three screws re-
taining 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 con-
trol rod at the door lock assembly.
3. Check the operation of the
lock. If necessary, adjust the lock
striker.
4. Carefully position the water
17-39
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 re-
placed 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 re-
tainer rearward to release the cylin-
der, 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 cylin-
der 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 nec-
essary to disconnect the lock actuat-
ing 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 assem-
bly 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,
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 re-
taining 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. Sepa-
rate 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 assem-
bly 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
WINDOWS,
TAILGATE
AND DECKLID
5. Position the frame assembly on
the door and install the three retain-
ing 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 weather-
strips.
12. Install the door watershield
and trim panel.
VENT WINDOW OR WEATHER-
STRIP-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 retain-
ing nut, and remove the vent win-
dow 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 as-
sembly 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 GLASS-
EXCEPT 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 reg-
ulator 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 rol-
ler in the channel, and finally posi-
tion the run in the division bar.
S. Connect the run and bracket,
making necessary lateral adjustment.
6. Install the stop, making neces-
sary 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 retain-
ing 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 as-
sembly 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 assem-
bly in the door.
3. Position the vent window as-
sembly in the door.
4. Install the front run assembly
in the Vent division bar.
5. Snap the door belt inner weath-
erstrip 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 assem-
bly 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 assem-
bly 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-MANUAL-
COMET, FAIRLANE-MODEL
63,76
REMOVAL
1. Remove the front door trim
panel and watershield.
2. Remove the four regulator as-
sembly retaining screws.
3. Prop the window in its up posi-
tion 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 retain-
ing 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 po-
sition 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 regu-
lator 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 ad-
justing 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 tight-
en 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 retain-
ing the regulator roller channel
bracket to the lower window channel
(Fig. 3).
3. Remove the lower stop as-
sembly.
4. Remove the screw and nut re-
taining the rear run retainer and
stationary glass. Move the run re-
tainer 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 chan-
nel bracket on the window channel.
5. Install the lower window stop.
6. Install the door trim water-
shield 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,
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 re-
move it.
INSTALLATION
1. Transfer the channel, using the
tool shown in Fig. 15.
2. Position the glass in the quar-
ter 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 retain-
ing bolts, slide the regulator arm
out of the equalizer and remove the
regulator.
INSTALLATION
1. Position the regulator inside
WINDOWS,
TAilGATEAND DECKLID
the quarter panel, engage the arm in
the equalizer, and install the regula-
tor 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 low-
er glass channel and remove the
glass channel bracket. Prop the win-
dow assembly in its up position.
4. Remove the four screws retain-
ing the regulator assembly to the
quarter panel and remove the regu-
lator 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 win-
dow front guide into the glass chan-
nel rollers.
2. Install the quarter window
front guide retaining bolts and ad-
juster screw lock nut snugly.
3. Check the operation of the
glass, adjust it if necessary, and
tighten the retaining bolts and ad-
juster 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 adjust-
er 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 adjust-
er 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, COMET-
MODEL 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 chan-
nel bracket (Fig. 9) from the lower
glass channel.
4. Remove the three quarter win-
dow guide panel retaining screws.
1 7-44 GROUP
5. Raise the top assembly off the
windshield header far enough to per-
mit 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 assem-
bly and install the weatherstrip re-
taining 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. Ad-
just the upper and lower window
stops and tighten all retaining
screws.
9. Cycle the window assembly up
and down to insure proper adjust-
ment. Then, install the quarter trim
panel, rear seat back and seat cush-
ion.
REAR QUARTER WINDOW
AND/OR WEATHERSTRIP
MODEL 71
REMOVAL
1. Remove the spare tire cover
and spare tire.
2. Remove the inside lower gar-
nish 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 mould-
ing 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 weather-
strio.
INSTALLATION
1. Apply a bead of sealer around
the window opening flange.
2. Position the weatherstrip on
the glass and install the outer mould-
ing 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 mould-
ing retaining screws (Fig. 16).
7. Install the inside quarter win-
dow 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 GROUP 17 BODY,DOORSAND WINDOWS
I
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 PART 17-3
cedure for windshield glass replace-
ment. 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 weather-
strip retainers.
2. Remove the wiper arm and
blade assemblies.
3. Remove the cowl top ventilator
grille panel retaining screws and re-
move the cowl top ventilator grille
panel.
4. Remove the outside top mould-
ing retaining screws (Model 76) or
unsnap the upper moulding retainers,
(all other models), using tool T64P-
42430 R or L and remove the out-
side top moulding.
5. Remove the outside side
moulding retaining screws and re-
move 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
FIG. 19-Windshield Installation-MustangBodyTypes63, 6S
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 in-
serted 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 mould-
ing retainers on the pinchweld flange.
3. Temporarily position the glass
in the opening. Mark the center of
the glass and the cowl. Position suc-
tion 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
17-47
C4AZ-19562-A.
5. Mix two tubes of sealer as
directed in Kit C4AZ-19562-A.
6. Position the sealer in a caulk-
ing gun and apply approximately a
%6-inch bead of sealer to the inside
edge of the glass.
7. Apply approximately a %6-
inch 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 out-
side windshield mouldings (Fig. 19).
2. Using Tool T64P42430 R or
L, remove the left and right wind-
 17-48 GROUP 17 - BODY
I DOORSAND WINDOWS

shield outside side mouldings. use the draw cord to pull the lip of 6. Remove the front upper body
3. Remove the windshield wiper the weatherstrip over the window pillar weatherstrip retainer retaining
arm and blade assemblies. opening lower flange, each side screws (four) and remove the re-
4. Using Tool T64P42430 R or L, flange and then over the upper tainers.
remove the windshield outside belt flange. 7. Remove the retaining screw and
mouldings (Fig. 19). 8. Install the outside belt mould- two retaining nuts from each left and
S. Remove the windshield and ing (Fig. 19) by positioning it and right windshield outside top mould-
weatherstrip assembly by pushing snapping it over its clip retainers. ing and remove the mouldings (Fig.
outward along the inner edges of the 9. Install the outside side mould- 20, View AA).
windshield. ings by snapping them over their clip 8. Remove the two retaining
retainers. screws from each windshield outside
INSTALLA'llON 10. Install the top right and left side moulding and, using Tool
1. Remove the weatherstrip from outside side mouldings by snapping T64P42430 R or L, remove the out-
the glass. them over their clip retainers. side side mouldings.
2. Clean all old sealer from the 11. Clean the windshield and 9. Remove the windshield wiper
weatherstrip and the body opening mouldings. arm and blade assemblies.
flange. 12. Install the windshield wiper 10. Using Tool T64P42430 R or
3. Using a caulking gun, apply arm and blade assemblies. L, remove the windshield outside belt
sealer in the weatherstrip glass open- moulding.
WINDSHIELD-MUSTANG 11. Remove the windshield and
ing. MODEL 76
4. Position the weatherstrip on the weatherstrip assembly by pushing
glass and install a draw cord in the REMOVAL outward along the inner edges of the
body opening groove of the weather- 1. Lower the convertible top. windshield.
strip. 2. Remove the rear view mirror.
5. Using a caulking gun, apply a 3. Remove the four upper garnish INSTALLADON
bead of sealer all the way around the moulding retaining screws and re- 1. Remove the weatherstrip from
body opening outer flange. move the upper garnish moulding. the glass.
6. Apply rubber lubricant to the 4. Remove the sun visor bracket 2. Clean all old sealer from the
weatherstrip surface that contacts the and pivot retaining screws and re- weatherstrip and the body opening
body opening flange. move the sun visor assemblies. flange.
7. Position the windshield and 5. Remove the front upper body 3. Using a caulking gun, apply
weatherstrip assembly in the wind- pillar weatherstrips (Fig. 20). Note sealer in the weatherstrip glass open-
shield opening and, with a helper that these weatherstrips are pressed ing.
applying pressure from the outside, into their retainers. 4. Position the weatherstrip on the

DE MOU~q~G
, OUTSIDE TOP MOULDING
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PILLAR
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PILLAR UPPER
RFTAINFR WEATHERSTRIP VIEW - BB Nl388-A
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FIG. 20-Windshield Installation-MustangBodyType76

~
 PART 17-3 - DOORS,WINDOWS,TAILGATE
ANDDECKLID 17-49

glass and install a draw cord in the
body opening groove of the weather-
strip.
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 wind-
shield opening. With a helper apply-
ing pressure from the outside, use the
draw cord to pull the lip of the
weatherstrip over the window open-
ing lower flange, each side flange
and then over the upper flange.
8. Install the outside belt mould-
ing (Fig. 20) by snapping the mould-
ing over the retaining clips.
9. Install the outside side mould-
ings by snapping them over their
retaining clips and install the retain-
ing screws.
10. Position the left and right out-
side 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. 2. Using a sealer gun, apply sealer
14. Position the upper garnish in the weatherstrip glass opening.
moulding and install the garnish 3. Position the weatherstrip on the
moulding retaining screws. glass, and then install the mould-
15. Install the rear view mirror. ings in the weatherstrip.
16. Clean the windshield and 4. Insert the draw cord in the
mouldings. weatherstrip, and apply rubber lubri-
17. Install the wiper arm and cant to the weatherstrip surfaces that
blade assemblies. will contact the back window open-
ing flange.
BACK WINDOW AND/OR
5. Using a sealer gun, apply a
WEA THERSTRIP-COMET,
bead of sealer completely around the
FALCON, FAIRLANE
back window opening.
REMOVAL
6. Position the window assembly
1. Using Tool T64-P42430-R or in the body opening. With a helper
L, release the outside upper mould- applying hand pressure from the
ings (Fig. 21), from their moulding outside, use the draw cord to pull
retainers and remove the outside up- the lips of the weatherstrip over the
per mouldings. window opening flanges.
2. Using Tool T64-P42430-R or 7. Install the outside lower left
L, release the outside lower mould- and right mouldings.
ings from their moulding retainers 8. Install the outside upper left
and remove the outside lower and right mouldings.
mouldings.
9. Clean the window and mould-
3. From inside the car, loosen the
weatherstrip edges and then push mgs.
out the back window and weather- BACK WINDOW-MUSTANG
strip as an assembly. MODEL 65
4. Place the window asembly on
REMOVAL
a bench and remove the weatherstrip
from the glass. 1. Using Tool T64P42430 R or L,
remove the outside side mouldings
INSTALLATION ~nd the outside upper comer mould-
1. Clean the glass, weatherstrip mgs.
and the body opening flange. 2. Using Tool T64P42430 R or L,

CDMOULDING RETAINER LOCATIONS

I1ij'\OUTSIDE UPPER LEFT -Z
\!V Ma,JLDING,~42431

If, ) MOULDING ~

~'
"'- \:\ ~ \ \
\

';\ '!J
\

"" 11 OUTSIDE LOWER LEFT

MOULDING- 42405
'\
~' \
~ ~"~4'\ 0 MOULDING RETAI~\ER LOCATIONS
" \.
, 2

fi1\OUTSIDELOWERRIGHT \

;;:~~~~~-
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c , .,

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'"'"""0."
-~ -
I ..:::;:;:;;:--
@O
OUTSIDEUPPERRIGHT
IT4 MOULDING
R£TA.iN£R-4248i
MOULDING
;;;42430
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FIG. 21-Back Window Installation-Comet, Falcon,Fairlane

 17-50 GROUP 1 7 - BODYDOORSAND WINDOWS
I

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 open-
ing 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-
ing into position over its retaining
clips (Fig. 22).
8. Snap the outside upper mould-
ing into position over its retaining
clips (Fig. 22).
9. Snap the outside side mould-
ings into position over the retaining
clips (Fig. 22).
10. Install the outside upper cor-
ner mouldings.
11. Clean the glass and mould-
ings.
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 gar-
nish moulding upper joint cover. Re-
move the back window upper left
and right garnish moulding retaining
screws and remove the mouldings
(Fig. 23).
4. Remove the left and right vent
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 re-
move 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 pres-
sure from the inside, remove the
back window and weatherstrip
assembly.
9. Remove the weatherstrip from
the glass.
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

CORNER MOULDING MOULDING,

OUTSIDE SIDE
MOlJLDING
A- B
RETAINER

SEAI,ER
MOULDING RETAINER

OUTSIDErop
MOU'DING
CORNER
MaU' I)ING -
/'
VIEW- AA

-WEATHERSTRIP VIEW - BB
"""'-

)
I
/
~/
/ L ",:::::::::"\~

. ~ SEALER
-
MOULDING
FIG. 22-Back
~FTAINF~ Window Installation-Mustang Body Type 65
-
.
-
VIEW
-
CC
~
~
Nl:NO.A

~
 PART 17-3 DOORS,
WINDOWS,
TAILGATE
ANDDECKLID 17-51

UPPER FRONT
UPPER BACK WINDDWGARNISHMOULDING 6342324
""""""".-.r"",
- 5. Apply sealer between the
QUARTER TRIM
PANEL - 6331002
,..,u ,u..,.- COYER .6342353 weatherstrip and the outside pinch
REAR QUARTER UPPER weld flange.
,~~. 6331112
6. Apply sealer between the outer
..,~ LOWERFRONT BACK
:;.
WINOOWTRIM PANEL glass surface and the weatherstrip.
~ 6347A68 7. Snap the window exterior
LOWER FRONT mouldings into place in the follow-
ing order; left lower moulding, left
.. ..
" upper moulding, right lower mould-
ing and right upper moulding.
8. Install the upper rear left and

L
--
~J
right quarter trim panels.
9. Install the upper front left and
... right quarter trim panels.
..
-~ 10. Install the back window lower
- -UPPER REAR '" front trim panel.
<::: ~ ' -QUARTER TRIM
UPPER REAR
QUARTER TRIM 11. Install the upper rear left and
"'--MOULDING CAP
63291C12
MOULDING right quarter trim mouldings and
, 6331144
REAR QUARTER LOWER moulding cap.
\ TRIM PANEL. 6331070 12. Install the upper front left and
--
"'UPPER FRONT QUARTER right quarter trim mouldings.
TRIM MOULDING. 6331282 13. Install the back window upper
-- "-

- -.:J~ ~ LOWER FRONT QUARTER

TRIM PANEL -6331486 --- left and right garnish mouldings and
garnish moulding joint cover.
-UPPER FRONT QUARTER TRIM MOULDING CAP. 63290C86 VIEW - AA ASSEMBLED R 1289 - A 14. Clean the back window and
FIG. 23-lnterior Moulding and QuarterTrim Panel Installation- mouldings.
Mustang Body Type 63 INSIDE REAR VIEW MIRROR
-BONDED TO WINDSHIELD
body opening groove. ing. Use the pull cord to pull the lip REMOVAL
4. With the aid of an assistant, of the weatherstrip over the pinch- 1. Clean both the inside and out-
position the glass and weatherstrip weld while applying pressure to the side surfaces of the windshield in the
assembly in the body window open- glass from the outside. area of the mirror mounting bracket.

SEALER

:: ~

C342006
GLASS
IINDOW
.

\\\ VIEW AA

cf~
WEATHER STRIP
. ASSEMBLY
6342084

"-?'y

/// LOWER
.
MOULDINGS
6342404
.5
--

MOULDING RETAINERS
(22 REQUIRED)
654'143 ,"

~ SEALER

FIG. 24-Back Window Installation-Mustang Body Type 63

17-52
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 mate-
rials 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
,\
C'"cC
CC
c'"
A
-- -~-,.,)--\
A ---~..~
~-
::::
~ panel retaining screws and remove
EPOXY CATALYST
--
FIG. 2S-Bonded RearView Mirror Installation-Comet. Falcon.Fairlane
GROUP 17 - BODY,DOORS
ANDWINDOWS
outside surface of the windshield
(Fig. 25).
2. Use a good grade of Ethyl Al-
cohol to thoroughly clean the inside
glass surface bracket mounting area
and mounting bracket face. It is im-
portant that the mounting surfaces
are properly cleaned before the resin
is applied.
3. To mix the resin pour the en-
tire 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 prop-
erly 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 pos-
sible.
6. Place the mounting bracket
-A 1,.i6"-MEASURED FROM
. EDGE OF GLASS
=---
--
. the tape and install the mirror and
---
TAPE
~ 3. Remove the window regulator
""~~~~ ~~~"',.~".
R117S-A
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 infra-
red 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 pres-
sure apply the mounting surface of
the bracket to the desired inside area
of the windshield.
8. Secure the bracket to the wind-
shield 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 brack-
et 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
arm to the bracket.
TAILGATE GLASS
REMOVAL
1. Open and temporarily support
the tailgate.
2. Remove the tailgate cover
the panel.
arm roller retaining pins, disconnect
the arms from the rollers, and re-
move the rollers from the glass
channel.
4. Remove the window from the
tailgate.
INSTALLATION
1. With a glass remover tool, re-
move 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 sup-
ports and remove the temporary
support.
TAILGATE WINDOW
REGULATOR-COMET, FAIRLANE
REMOVAL
If the tailgate window regulator
mechanism should fail with the win-
dow in a partially closed or closed
FIG. 26-Tailqate and WeatherstripInstallation-Typical
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 pan-
el retaining screws and remove the
panel.
4. Remove the window regulator
arm roller retaining pins, disconnect
the arms from the rollers, and re-
move the rollers from the glass
channel.
5. Remove the tailgate window
from the tailgate and scribe the reg-
ulator 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 regu-
lator 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
R1132-B
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 pan-
el retaining screws and remove the
panel.
4. Remove the window regulator
arm roller retaining pins, disconnect
the arms from the rollers, and re-
move the rollers from the glass
channel.
5. Remove the window from the
tailgate.
6. Disconnect the motor leads
from the wiring harness in the tail-
gate.
7. Scribe the regulator mounting
location, remove the regulator re-
taining bolts, and remove the regu-
lator with the motor att~ched.
INSTALLATION
1. Do not remove the electric
regulator drive assembly for transfer
to the new regulator until the regu-
lator counterbalance spring is un-
loaded. 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 as-
sembly to the regulator. Remove and
discard the manual drive assembly.
The manual clutch and gear assem-
bly should not be removed until the
electric drive assembly is installed.
5. Install the regulator assembly
on the tailgate and align the regu-
lator 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 pan-
el to the tailgate.
11. Connect the tailgate hinge
supports and remove the temporary
support.
17 - BODY
I DOORS
AND WINDOWS
TAILGATE SWITCH AND 6. Apply Lubriplate to the glass
LOCK CYLINDER-POWER rollers.
REMOVAL 7. Clean the old sealer from the
1. Open and temporarily support tailgate cover panel and apply new
sealer.
the tailgate.
8. Install the tailgate cover panel
2. Disconnect the tailgate hinge
supports at the tailgate. to the tailgate.
9. Connect the tailgate hinge sup-
3. Remove the tailgate cover pan-
ports and remove the temporary
el retaining screws and remove the
support.
panel.
4. Remove the window regulator TAILGATE WINDOW HANDLE
arm roller retaining pins, disconnect AND LOCK CYLINDER-
the arms from the rollers, and re- MANUAL
move the rollers from the glass
REMOVAL
channel.
1. With the tailgate window in
5. Remove the window from the
the closed position, unlock the tail-
tailgate. gate handle, and rotate the handle
6. Remove the regulator.
assembly to reveal the mounting
7. Remove the nuts retaining the
lock and switch, and then remove screws (Fig. 28).
2. Remove the handle mounting
the lock and lock cylinder from the
screws, and then remove the handle
tailgate (Fig. 27). assembly and pad.
8. If the switch requires replace-
3. To remove the lock cylinder
ment, disconnect the switch wires
turn the key in the cylinder to align
from the tailgate wiring harness and
the cylinder locking pin with the ac-
remove the switch and wires.
cess hole in the handle assembly.
9. To remove the lock cylinder,
Depress the locking pin and remove
depress the lock cylinder retaining
pin, insert the key and rotate the the lock cylinder.
cylinder until the retaining pin drops,
INSTALLATION
and then remove the lock cylinder.
1. To replace the lock cylinder,
INSTALLATION transfer the O-rings, and then with
the key in the cylinder, install the
1. To install the lock cylinder, in-
lock cylinder in the handle assembly.
sert the key in the lock cylinder and
2. If the window regulator has
slide the cylinder into the retainer.
been replaced, it may be necessary
2. To install the switch assembly,
to reposition the handle assembly so
route the wiring harness through the
that it hangs in a vertical position,
tailgate to the tailgate harness switch
with the tailgate window in a closed
connector.
position. To adjust the handle posi-
3. Place the lock assembly and
tion, remove the snap ring and
gasket to the tailgate and position
socket from the window regulator
the switch to the lock assembly. It
stem, and then install the socket
may be necessary to rotate the lock
with the notch at the top.
cylinder to align the switch and the
3. Install the pad and handle as-
lock. Install the retaining nuts.
4. Install the window regulator. sembly.
5. Install the tailgate window as-
sembly into the tailgate.
TAILGATEUPPEREDGE
\
.
-"WITCH
Rl082-A
FIG. 28-Tailgate Window
FIG. 27-Tailgate Switchand RegulatorHandle Installation
Lock Installation-Typical - 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 sup-
port 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 re-
move the hinge.
4. Position the hinge to the body
and tailgate scribe marks and in-
stall 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 open-
ing). 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 re-
tainer screws.
4. Install the linkage to the lock.
Install the access cover, watershield
and trim panel.
Right Upper Lock
1. Open the tailgate (side open-
ing). Remove the tailgate trim panel,
watershield and access panel.
2. Engage the upper lock pawl to
the closed position and raise the win-
dow partially out of the gate. Re-
move 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 con-
nector 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 re-
tainer 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 tail-
gate.
9. Install the tailgate accesspanel,
watershield, and trim panel. Open
the upper lock and close the tail-
gate. 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 bell-
crank 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 as-
sembly away from the body opening.
Place the tailgate on an appropriate
stand approximately bumper high.
7. Remove the torsion bar re-
tainer bracket and remove the tor-
sion bar from the left side of the
gate. (Fig. 29).
INSTALLATION
1. Place the torsion bar in its
respective mounting position and in-
stall the torsion bar right retainer
bracket.
17-55
1. With an assistant, position the
tailgate assembly to the body open-
ing. 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 har-
ness in its original position.
5. Install the window lower stop
and lock the bellcrank assembly.
6. Lower the window in the tail-
gate to where the top edge of the
glass is even with the weatherstrip
and adjust the lower stop if neces-
sary.
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 in-
stalled.
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 re-
move the bar.
4. Position a cover under the
hinge edge of the deck lid to pre-
vent 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 par-
tially 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 attach-
ing 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 17-57

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

'" I"
N1189-A
FIG. 30-Deck Lid Torsion Bar
- Typical
the lock assembly and the door lock
extension.
2. Remove the sleeveassembly re-
taining 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