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T O P I C R E V I E W
Posted - 02/19/2006 : 17:02:59ASSEMBLY SEQUENCE: (some variation with different body types) (from bare painted body shell) Spray radiator saddle blackout Rocker panel pinchweld blackout (if applicable) Front frame rail side blackout (if applicable)
1. trunk weatherstrip 2. body rubber bumpers 3. trunk latch mechanism 4. hood latches & release mechanisms 5. main body brake & fuel tubing 6. fuel tank & fuel hose connections 7. emissions tubes & hose connections (if applicable) 8. inner cowl insulation pad 9. firewall insulation pad 10. swing pedal(s) 11. brake booster (if applicable) 12. master cylinder 13. defroster duct 14. kick panel insulation pads 15. LH vent box (if applicable) 16. E-brake pedal assembly & front cable 17. wiper mechanism 18. wiper motor 19. heater box assembly 20. cowl vent screens (if applicable) 21. accelerator pedal & cable 22. dash assembly (completely assembled outside of car including instrument cluster, dash pad, glove box liner, radio, speaker, wiring, etc.) 23. Vent pull cables, defroster & vent cables 24. proportioning valve & metering block (if applicable) 25. firewall brake tubing 26. starter relay 27. forward lamp harness 28. engine harness 29. starter wiring 30. washer bottle & hoses 31. ballast resistor 32. voltage regulator 33. horn relay (Bbody cars) 34. horns 35. heater hoses 36. headlights 37. fender inner splash shields (front & rear of wheel) 38. rear suspension stop bumpers 39. rear seat belts (some bolt tips get undercoating) 40. rear shocks bolted in at top only & compressed 41. grille & headlight doors 42. front bumper 43. front valance (if applicable) with directionals 44. front & rear side marker lamps 45. rear bumper 46. radio antenna 47. fender emblems (if applicable) 48. rear of fender splash shields 49. undercoat wheelwells 50. exterior emblems 51. windshield & backlite stainless trim 52. windshield wiper arms & blades 53. other exterior trim 54. taillights 55. mid body/rear lamp wiring harness 56. dome lamp wiring harness 57. shoulder harness clips (if applicable) 58. rear grip strips (Bbody) 59. headliner 60. roofrail c-channels 61. roofrail weatherstrips 62. windshield & backlite moulding clips 63. windshield & backlite 64. upper control arms on body 65. fuel hose clamped on body side fuel tubing with keystone crimp clamp 66. install rear leaf springs front only 67. position rear end housing on springs 68. loosely fasten u-bolts 69. lift rear axle into position and install shackles 70. connect e-brake cables 71. connect brake line tubing & hose 72. DRIVETRAIN SUBASSEMBLE a. K-member b. engine c. carb(s) d. starter e. alternator f. fan & fan clutch g. power steering pump (if applicable) h. belts i. motor mounts j. trans & related hardware k. lower control arms l. strut rods m. center link, idler arm, tie rods n. steering box & pitman arm o. fuel pump and tubing p. fan blade q. radiator hoses
73. drop body onto drivetrain subassembly 74. connect heater hoses 75. install trans crossmember 76. install driveshaft 77. connect shift linkages 78. install z-bar (if applicable) 79. connect clutch linkage (if applicable) 80. plug in electrical connections to engine 81. position fan shroud over fan blade 82. install radiator & connect hoses 83. connect trans cooler (if applicable) 84. bolt up fan shroud 85. install torsion bars 86. install exhaust system 87. install rear valance (if applicable) 88. set car on the ground 89. install & align door and quarter glass 90. install steering column 91. install carpeting 92. install seat belts 93. install quarter interior trim panels 94. install rear seat 95. install console (if applicable) 96. install front seat(s) 97. install trunk mat 98. install spare tire 99. install bumper jack
There are many different sequences of assembly possible. Sometimes Iíll jump from one area to another depending on parts available or other road blocks. There are cases where the wrong order will give you headaches though!