E Body Assembly Sequence

[floorit426]

Is there any reference material, regarding the order, in which the parts were assembled, on the line, back in the day? I'm re installing exhaust, rear suspension, differential, and fuel system, on my 'cuda, right now. This sure would be a big help. I've already have had to remove a few pieces, because they were put on ahead of other components.

Thanks

[anlauto]

Interesting question

[cuda hunter]

that is a very interesting question. 

[RUNCHARGER]

I'm pretty sure Anlauto did a post on this a few years ago on this site. Hopefully it will turn up in a search.

[EV2RTSE]

from RestoRick's website

http://www.restorick.com/tech/topic.asp?TOPIC_ID=58

[cuda hunter]

ASSEMBLY 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 I'll 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!

Rick Kreuziger

[Shoooter]

That's a great list , know wonder my car isnt finished I'm jumping all around that list haha

[anlauto]

The original question was "how the factory assembled them" not necessarily how restoration shops do it...

[PLUM72]

There is some cool assembly line photos and other information at the Hamtramck Historical site.

https://www.hamtramck-historical.com/photos-p.shtml

[R/T's 4 R/P]

RestoRick and I had gone back and forth a number of years ago on this topic and the worksheet.
The reality is, of course, there are some things that are 'dependent' on other things before they can be assembled.
You can attach the hardware for the headlight buckets without having any impact on whether you can or can't put the spare tire in the trunk---extreme example.

If you breakdown the process/project into sub-assemblies, this gets more detailed, and is maybe not what some are looking at.
For example, the engine is a whole activity all by itself, as would be the rear-end, the gauges/dash assembly, upholstery, etc.

For any of you in manufacturing environments with Assembly lines this comes under the umbrella of line-balance and takt time.  There are independent simple actions that can be done anytime.
I find that some items are highly motivating to get accomplished.  Some, while just as time consuming, seem to leave me feeling like i just spent a whole day and 'that's all i got done!'