Lincoln Continental Shop Manual

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GROUP INDEX
•
LUIRICAt1Ql4 CHAitTS '.~·.,,w:n
~- _·E:U
SERVICE DEPARTMENT
SPECIAL SERVICE TOOLS ··&&
FORD DIVISION
~MOTOR COMPANY (001)
INDEX 1m
FIRST PRINTING ~SEPTEMBER, : ·;6J SPECIFICATIONS AT END OF EACH GROUP
©1963 FORD MOTOR COMPANY, DEARBORN~ MICHIGAN
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FOREWORD
This shop manual provides the Service Technician with com-
plete information for the proper servicing of the 1964
Lincoln Continental.
The information is grouped according to the type of work
being performed, such as diagnosis and testing, frequently
performed adjustments and repairs, in-vehicle adjustments,
overhaul, etc. Specifications and recommended special tools
are included.
Refer to the opposite page for important vehicle identifica-
tion data.
The descriptions and specifications' in this manual were in
effect at the time this manual was approved for printing. The
Ford Motor Company reserves the right to discontinue models
at any time, or cha/zge specifications or design, without notice
and without incurring obligation.
SERVICE DEPARTMENT
FORD MOTOR COMPANY

(003} LINCOLN-CONTINENTAL IDENTIFICATION 3
LINCOLN-CONTINENTAL IDENTIFICATION
LIGHT SILVER BLUE METALLIC CRINKLE LEATHER
DAY OF MONTH CONVENTIONAL 2 891 RATIO AXlE
1964 MODEL YEAR - - - " CONSKUTiVE UNIT NUMBER

PRODUCED AT WIXOM PlANT ENGINE 430 CID 4V CARBURETOR
BODY SERIAL CODE
IDENTIFlCA TION
N1200-B
FIG. 1-1964 Lincoln-Continental Warranty Plate
Figure 1 illustrates the 1964 Lincoln-Continental Warranty Plate. The 29H. 29th Day August
Warranty Plate is located on the rear (lock) face of the left front door. 11 .. Boston District
The official Vehicle Identification Number for title or registration purposes I. 2.89:1 Axle Ratio
is located on the right front fender apron above the upper suspension arm 4.. Twin Range Turbo-Drive Transmission
opening (Fig. 2). Do not use the "Warranty Number" on the Warranty plate
for title or registration purposes. BODY
53A ... . 4- Door Sedan
74-A ... . 4-Door Convertible
COLOR
Two-tone paint codes use the same symbols as the single colors except that
two symbols are used. The lower body color code will appear first in the
Warranty Plate Paint Color Space.
If a special paint is used, the paint color space will not be stamped.
*M-30-J
Code Number Color Sales Name
A. .1724. Black. . Black Satin
C... . .1620. Dark Gray Metallic.. Princeton Gray
E. .. 1446 . . Silver Blue Metallic.. . Silver Blue
F .1226. Light Blue. . Powder Blue
G... 1636. Buff Buckskin
H. . .1544 Nocturne Blue Metallic ... Nocturne Blue
J.. .1515 . Red . Fiesta Red
FIG. 2-Vehide M.. .1619 .White . Arctic White
Identification Nvntber Location N.. 921 Platinum.. Platinum
0. 1629 Light Green Metallic. . . Silver Green
Q 1624 Medium Blue Metallic. Huron Blue
VEHICLE DATA R... 1633. Yellow EncinoYellow
S.. .1453 Dark Green Metallic... . Highlander Green
Example (fig. 1): T. 1631 light Beige Metallic . . . Desert Sand
U .1070. Med. Turquoise Metallic . Regal Turquoise
(74A W 81 29H 11 4) W.. 1555. . Pink Metallic.. . Rose
74A .. 4-Door Convertible )(. 1632 Maroon Metallic. Royal Maroon
w Rose 2:.. 1630 Medium Beige Metallic. Silver Sand
81. light Silver Blue Metallic Crinkle Leather *"M-32-J" Acrylic Paint Alternate with "M-30-J"

4 LINCOLN-CONTINENTAL IDENTIFICATION (004)
TRIM DSO
Deviation trim sets will use existing trim codes plus 2 suffix. A trim code Domestic Special Orders, Foreign Special Orders, and Pre-Approved Special
with a numeral suffix is not serviced, while a trim code with an alphabetical Orders have the complete order number recorded in this space. Also to
suffix is serviced. appear in this space is the two-digit code number of the District which
CODE TRIM SCHEMES ordered the unit. If the unit is regular production, only the District code
number appears.
Motif Cloth and Crinkle leather
(Bench-Biscuit)
20 ........................ Rose Beige and Rose Beige DISTRICT CODE
22. . . . . . ................ Blue and Blue Code District Code District
27 ........................ Turquoise and Turquoise 11 ...................... Boston 34 ..................... Detroit
(Bench-Pleated) 12 .. , .............. Philadelphia 41. .................... Chicago
70. . . . . . ......... Rose Beige and Light Rose Beige D/L 13 .................... New York 44 .................... St. louis
71. . . . . . . . . . . .
. ..... Silver Blue and Light Silver Blue Metallic 14 .................. Washington 45 .................. Twin Cities
72 ........................ Blue and Light Blue D/L 21 ...................... Atlanta 51 ..................... Denver
74 ........................ Beige and Pearl Beige 22 ....................... Dallas 52 ................. los Angeles
76 ........................ Black and White 24 ................. .Jacksonville 53 .................... Oakland
77.. . ................ Tmquoise and Light Turquoise 0/L 25 .................... Memphis 54 ..................... Seattle
Broad Cloth (Bench-Pleated) 31 ...................... Buffalo 81. ............. Ford of Canada
31. . . ................ Medium Silver Blue 32 .................... Cincinnati 84 ......... Home Office Reserve
Versailles Cloth and Crinkle leather 33 .................... Cleveland 90-99 ................... Export
(Bucket-Biscuit)
44. . . . . . . . . . . . . . . . ....... Beige and Beige AXLE
46 ........................ Black and Black Anumber designates a conventional axle, while a letter designates an Equa-
51. . .............. Silver Blue and Light Silver Blue Metallic lock differential.
(Bench-Biscuit) Code Ratio
61. . .............. Silver Blue and Light Silver Blue Metallic 1............................. ·.. ·.......................... 2.89:1
64 ........................ Beige and Beige 3................... ·...................................... 3.11:1
66 ........................ Black and Black A.... : ................. ~ .................................. 2.89:1
Crinkle leather
(Bucket-Biscuit) TRANSMISSION
50 ........................ Rose Beige The numeral "4" indicates a dual-range automatic transmission.
51. . . . . . . . . . . . . . . . ....... Silver Blue
52............. . ...... Blue VEHICLE WARRANTY NUMBER
54... . . Beige
Example (Fig. 1): 4Y 86N 400001
55..... . .... Red
56..... . ....... Black 4........................ 1964 Model Year
57... . . .... Turquoise Y........................ Wixom Assembly Plant
58 ........................ Burgundy 86 ....................... 4-Door Convertible
59... . ....... Palomino N........................ 8-Cylinder 430 Cubic Inch Engine
(Bench- Pleated) 400001 ................... First Unit Built (Consecutive Unit Number)
80. . . .. . ................ Light Rose Beige Metallic
81. . . . . . . . . . . ........... Light Silver Blue Metallic MODEL YEAR
82 ........................ light Blue 0/L The numeral "4" designates 1964
84 ................. ·....... Pearl Beige
85 ........................ Red ASSEMBLY PLANT
86 ........................ Black Code Assembly Plant
87 ........................ light Turquoise D/L S ..................................................... Pilot Plant
88. . . . . . . ........ Burgundy Y........................................................ Wixom
DATE MODEL
The code letters for the month are preceded by a numeral to show the day The model code number identifies the product line series and the particular
of the month when the car was completed. The second year code letters body style: the first of the two digits shows the product line, and the second
are to be used if 1964 model production exceeds 12 months. digit shows the body style.
First Second Code Body Type
Month Model Year Model Year
82 ...................... . .............. .4-0oor Sedan
January... . .................. A....... .N
86........ .. ....... .. .............. .4-Door Convertible
February.. . .................. B.............. P
March........ . .............. C.............. Q
April............. . ............... D.............. R ENGINE
May.......................... .E.... . .... S Code
June............. . ................ F....... . .... T N......... . ...... 8-Cylinder 430 Cubic Inch 4-V Carburetor
July........... .. ................... G............ U 7.......... .. . .... 8-Cylinder 430 Cubic Inch 4-V Carburetor
August .................... ~ ........... H.............. V (low Compression)
September. .. . . .. . ... J.. ............. W
October . . . . . . . . . K.............. X CONSECUTIVE UNIT NUMBER
November.... .l....... .. Y The assembly plant, with each model year, begins with consecutive unit
December. . .. .. .. . ... . M.............. Z number 400001 and continues on for each car built.

. (005) 2-1
GROUP
2
PART 2-1
GENERAL BRAKE SERVICE .
PART 2-2
PAGE
. . 2-1
PART 2-3
SPECIFICATIONS
PAGE
. . 2-20
•
BRAKE SYSTEM .. " ... . 2-6
PART GENERAL BRAKE SERVICE

2-1
Section Page Section Page
1 Diagnosis and Testing ....... . ......... " . 2-1 3 Cleaning and Inspection ................... 2-5
2 Common Adjustments and Repa1r' ....... 2-4
II DIAGNOSIS AND TESTING
PRELIMINARY TESTS foot pressure and less pressure will ROAD TEST
be required to hold the pedal in the
1. Check the fluid level in the appiied position. If no action is felt, The car should be road tested
master cylinder, and add FoMoCo the vacuum booster system is not only if the brakes will safely stop
heavy-duty brake fluid if required. functioning. Follow the procedures the car. Apply the brakes at a speed
2. Push the brake pedal down as in the "Booster Diagnosis Guide." of 25-30 mph to check for the exist-
far as it will go while the car is ence of the trouble symptoms listed
4. With the engine shut off, ex-
standing still and the engine is run- in Table 1, with the exception of
haust all vacuum in the system.
ning. If the pedal travels more than those resolved in the preliminary
Depress the brake pedal and hold
haJfway between the released posi- tests and brake chatter. To check
it in the applied position. If the
tion and the floor, check the brake for brake chatter or surge, apply
pedal gradually falls away under this
adjustment and the automatic ad- the brakes lightly from approxi-
justers. pressure, the hydraulic system is
leaking. Check all tubing hoses, wheel mately 50 mph. For each of the
To check adjuster operation, fol- cylinders and connections for leaks. symptoms encountered, check and
low the procedure described under eliminate the causes which are also
"Brake Shoe Adjustments" in Part If the brake pedal movement feels listed in Table 1.
2-2, Section 2. spongy, bleed the hydraulic system
Make several reverse brake stops to remove air from the lines and If the causes of noisy or grabbing
to ensure uniform adjustment at all cylinder. See "Hydraulic System brakes listed in Table 1 have been
wheels. Bleeding", Section 2. Also, check for checked and eliminated and the
leaks or insufficient fluid . brakes still grab, follow the appli-
3. With the transmission in neu-
tral, stop the engine and apply the 5. Should one of the brakes be cable procedures in the "Booster
parking brake. Depress the service locked and the car must: be moved, Diagnosis Guide."
brake pedal several times to exhaust open the brake cylinder bleeder
all vacuum in the system. Then, de- screw long enough to let out a few If the brakes fail to release or if
press the pedal and hold it in the drops of brake fluid. This bleeding the pedal is slow in returning, fol-
applied position. Start the engine. 1f operation will release the brakes, low the applicable procedures in-
the vacuum system is operating, the but it will not correct the cause of dicated in the "Booster Diagnosis
pedal will tend to fall away under the trouble. Guide."

2-2 GROUP 2-BRAKES (006)
BRAKE BOOSTER TROUBLE DIAGNOSIS GUIDE
If the preliminary tests show that from the car as described in Part
the unit is not operating, remove 2-2, Section 3. Refer to "Disassem-
the hose from the power unit and bly of Booster Unit," Part 2-2, Sec-
check the vacuum source by placing tion 4 for the internal checks that
a thumb over the }lose. Remove the follow. Remove the booster body
thumb and note the volume of suc- from the end plate, and inspect the
tion (gulp of air). In case of little internal vacuum hose to see that it
or no suction, check the reserve tank, is properly installed and is not re-
BOOSTER INOPERATIVE stricted. If the hose is faulty, replace
vacuum check valve, and fittings for
vacuum leaks. If no trouble is found it. Also, be sure the inside of the
body is clean. Inspect the booster
in the vacuum source, install the
piston for faulty packing and replace
hose, making sure there are no kinks, if necessary. Inspect the piston plate
and check the power unit. attaching bolts for looseness and a
Check the air cleaner to make consequent vacuum leak. Tighten if
sure that it is clean and free of necessary. Also check the piston to
restrictions. Remove the booster unit make sure it is not jammed.
This condition may result from a touched up lightly with crocus cloth.
clogged booster air cleaner or im- Do not oil. Replace if necessary.
proper master cylinder push rod ad- If the return spring is broken,
justment. Refer to "Disassembly of weak, or distorted, it should be re-
Booster Unit," Part 2-2, Section 4 placed. The booster piston must be
for checking internal causes. Intern- disassembled to locate and correct
SLOW BRAKE PEDAL RETURN al causes may be a restricted air the cause of a sticking poppet valve.
(OR FAIL TO RELEASE) passage, sticky valve plunger, broken If the poppet valve appears faulty,
valve return spring, or the atmos- it should be replaced. Inspect the
pheric poppet valve stuck in a closed vacuum check valve for faulty op-
position. The air passages should be eration. Be sure that the booster
checked for restrictions and blown piston is free to move in its normal
out. The valve plunger may be stroke.
This condition may result from a Refer to "Disassembly of Booster

broken poppet spring or a sticking Unit" in Part 2-2, Section 4. If the
poppet valve. Remove the booster poppet return spring is broken, weak
GRABBING BRAKES unit from the car as described in or disturbed, replace it. If the pop-
Part 2-2, Section 3. Remove the pet valve appears worn or bent, it
booster body from the end plate, should be replaced.
and disassemble the booster piston.

(007) PART 2-1 -GENERAL BRAKE SERVICE 2-3
TABLE 1 -Brake Trouble Symptoms and Possible Causes

Trouble Symptoms
~T
~
(/)
>.
~ ~
0 0.
>
ro Cl.
0 0()
Possible Causes of M
'
..:L
U":
~ ..... c -<
Oil
- .b II) :.0
2 c:::
-
0 t....
ro :;:; cII) .:::: .D 0
a
t.... c~ ~ ~ ro z
Trouhlc Symptoms 0 ~
'"0 s ~
'"0
0:
::::l
'"0
>
II)
-< 1-.
u ::r;, ..;:.G 0 0
..:.::
~
II)
~
'"0
v
II)
0... ~./) u
...c
'.> ..c:
u u
-~ 0
r:: 1-. :5 .:d ..... 0
:ls e
co
0... >.
0[) Q.. ~
i/)
II) i/)
0
0
Vl
II)
0~ 0
>,II)
(/) (/)
~
~ § II) ..::.:! u
u :§w: .;.:: g] r/l..;:.G ..;:.G
;1 ro 0.
1-.
~ c e >< uo
ro
Q;5 ...c~
·0- '-'
C':l C':l
1-.
6 -< ::r: Vl u 0 co :..w Q.. ..... e~:~O:: ZCl:l CQ
---i
I
Mechanical Resistance at Pedal or Sr'. t" X X
1----
Brake Line Rcstridcd X X X X
~----
Leaks or Insufficient Fluid I

-------+ X X X X
Improper Tirr Pressure

________J X X
1mproperly Adjusted or Worn Whee' ikaring: ! X X

-~----~-----
Distorted or Improperly Adjusted Br.,
Faulty Retracting Spring

----·- ----tl
l' Shoe X X X X X X X
-t
X X
Drum Out of Round X X X
Lining Glazed or Worn X X X X X X X

-----~--
Oil or Grease on lining I X X X X X X
Loose Carrier Plate

-~
---- ----
X X X
Loose Lining
Scored Drum
--------~
Dirt on Drum-Lining Surface

--1
_____ ______
, '
X
X X
X
-~------~---
Faulty Brake Cylinder X X X X

--1--
Dirty Brake Fluid X X X X

-- ----------------- - ------------
Faulty Master Cylmdcr X X X X
-~------ ·---·---
Air in Hydraulic System
Self Adjusters Not Operating

--- ~~--~-----
---1
-~~----- ·- ---·--~-
X X
X
X
X
X
Insufficient Shoe-to-Carncr Plate Lur~ricatwn X X X

r---·-------- ~-----~-~~--
Tire Tread Worn X

--------~---
Poor Lining to Drum Contact X
r t--
------------
Loose Front Suspcnsi,,n X

c--------~-------
~-- !------ ------ - - - --
i
"Threads'' J .eft h Drum Tun, in!.! ·I l'ul!' ....
-i-
Shoe" S1dcv. a\< X
~-
c---------------------- --
Cracked Drum X

EJ COMMON ADJUSTMENTS AND REPAIRS ..

PARKING BRAKE mains in the original unit. How- # 15 OR # 16 U.S.S. GAUGE SHEET STEEl
LINKAGE ADJUSTMENT ever, when a new push rod is used, I• 2·~------~~
or the push rod assembly is trans- i--r--ii
Check the parking brake cables
ferred to another unit, the distance
when the brakes are fully released.
from the end of the adjustment
If the cables are loose, adjust them
screw to the mounting surface of
as follows:
the booster body should be checked.
1. Fully release the parking brake Use either a micrometer depth gauge
pedal by pushing down on the man-
to a dimension of 1.200 inch or a
ual release lever. height gauge as shown in Fig. 1.
2. Raise the car. The details for making a height H1087-B
3. Loosen the adjusting nut on gauge are given in Fig. 2.
the equalizer rod, then turn the lock After assembly of the master cyl- FIG. 2-Push Rod Gauge
nut in front of the equalizer several inder to the power section, the piston Dimensions
turns forward (Fig. 15, Part 2-2, cup in the hydraulic cylinder should
Section 3). just clear the compensating port hole with clean brake fluid, and loosen
4. Depress the parking brake pedal when the unit is in the fully released the bleeder fitting approximately 3A
slowly until the initial locking posi- position. This can be checked by turn.
tion is obtained. placing a few drops of brake fluid 3. Push the brake pedal down
5. Turn the adjusting nut forward over the compensating port and ap- slowly through its full travel. Close
against the equalizer until approxi- plying light air pressure to the out- the bleeder fitting, then return the
mately 100 lbs. of force at the output port of the master cylinder. If .pedal to the fully-released position.
side diameter of the tire is required air bubbles appear, the port is open. Repeat this operation until air bub-
to turn the rear wheels. If the primary piston cup overlaps bles cease to appear at the sub-
6. Tighten the lock nut against the compensating port, there will be merged end of the tube.
the equalizer. no flow of air through the compen- 4. When the fluid is completely
7. Release the parking brake, and sating port. If this condition exists, free of air bubbles, close the bleeder
check to make sure that the brake the adjustment screw should be fitting and remove the drain tube.
shoes return to the fully released turned into the push rod a slight 5. Repeat this procedure at each
position. amount or until the compensating brake wheel cylinder in order: left
8. Depress the parking brake pedal port is open. rear, right front, and left front. Re-
with 100 lbs. of pedal force. fill the master cylinder reservoir af-
9. Release the parking brake again, HYDRAULIC SYSTEM BLEEDING ter each brake cylinder is bled and
and check as in step 7. when the bleeding operation is com-
When any part of the hydraulic pleted. The fluid level should be
10. If the rear brakes do not fully
system has been disconnected for within Vs -inch of the top of the
release, check the cables for kinks repair or replacement, air may get
or binds. Free the cables as required. reservoir.
into the lines and cause spongy pedal
action. Bleed the hydraulic system
MASTER CYLINDER PUSH after it has been properly connected PRESSURE BLEEDING
ROD ADJUSTMENT· to be sure that all air is expelled Bleed the longest lines first. Never
from the brake cylinders and lines. use brake fluid which has been
The push rod is designed with a The hydraulic system can be bled drained from the hydraulic sys-
self-locking adjustment screw to pro- manually or with pressure bleeding tem.
vide the correct relationship between equipment. The bleeder tank should contain
the booster piston and the master enough new heavy-duty brake fluid
cylinder piston. The adjustment to complete the bleeding operation,
screw is set to the correct height at MANUAL BLEEDING
and it should be charged with 10-
the time of the original assembly of Bleed the longest lines first. Keep 30 pounds of air pressure.
the power unit. Under normal serv- the master cylinder reservoir filled 1. Clean all dirt from the master
ice the adjustment screw does not with new heavy-duty brake fluid dur- cylinder reservoir cap.
require any further attention pro- ing the bleeding operation. 2. Remove the master cylinder
viding the push rod assembly re- Never use the brake fluid which reservoir cap, install an adapter cap
has been drained from the hy- to the reservoir, and attach the
draulic system. bleeder tank hose to the fitting on
1. Position a 3/s -inch box wrench the adapter cap.
on the bleeder fitting on the right Adapter cap 2162 can be used,
rear brake wheel cylinder. Attach or an adapter cap can be fabricated
a rubber drain tube to the bleeder by cutting a hole in the center of a
fitting. The end of the tube should filler cap and soldering a fitting at
fit snugly around the bleeder fit- the hole.
ting. 3. Position a Vs -inch box wrench
2. Submerge the free end of the on the bleeder fitting on the right
FIG. 1-Push Rod Adiustment tube in a container partially filled rear brake wheel cylinder. Attach a

(009) PART 2-1-GENERAl BRAKE SERVICE 2-5
rubber drain tube to the bleeder fit- 'vith clean brake fluid, and loosen 8. When the bleeding operation
ting. The end of the tube should 1 he bleeder fitting. is completed, close the bleeder tank
fit snugly around the bleeder fit- (). When air bubbles cease to ap- valve and remove the tank hose
ting. pear in the fluid at the submerged from the adapter fitting.
4. Open the valve on the bleeder end of the drain tube, close the
tank to admit pressurized brake bleeder fitting and remove the tube. 9. Remove the adapter cap, .refill
fluid to the master cylinder reservoir. 7. Repeat this procedure at each the master cylinder reservoir to with-
5. Submerge the free end of the hrake wheel cylinder in order: left in 3,/s inch from the top of the
tube in a container partially filled rear, right front, and left front. reservoir, and install the filler cap.
EJ CLEANING AND INSPECTION

BRAKE ASSEMBLY 'he springs show any loss of load or booster is shown in Fig. 3.
-.:hange in free length indicating over- After disassembly, immerse all
1. Remove the wheel from the ~1eating, replacement of the retract-
drum, then remove the drum as metal parts in a suitable solvent.
mg and hold down springs is neces- Use only alcohol on rubber parts or
outlined in Part 2-2, Section 2. Wash
-;ary. Overheated springs lose their parts containing rubber. After the
all the parts except the brake shoes
pull and could cause the new lin-
in a cleaning fluid and dry w.ith com- parts have been thoroughly cleaned
ing to wear prematurely if they
pressed air. and rinsed in cleaning solvent, the
are not replaced.
2. Brush all dust from the back- 5. If the car has 40,000 or more metal parts which come in contact
ing plates and interior of the brake miles of operation, or signs of ex- with hydraulic brake fluid or rub-
drums. treme overheating are present when ber parts should be rewashed in clean
3. Inspect the brake shoes for ex- relining brakes, the wheel cylinders alcohol before assembly. Use an air
cessive lining wear or shoe damage. should be disassembled and inspect- hose to blow dirt and cleaning fluid
If the lining is worn to within 1~1~ ed for wear and dirt in the cylinder. from the recesses and internal pas-
inch of the rivet heads or if the fhe cylinder cups should be replaced sages. When overhauling a power
shoes are damaged, they must he ! hus avoiding future problems. booster, use all parts furnished in
replaced. Replace any lining that has (). Inspect all other brake parts the repair kit. Discard all old rub-
been oil saturated. Replace lining and replace any that are worn or ber parts.
in axle sets. Prior to replacement damaged. Inspect all other parts for dam-
of lining, the drum diameter should 7. Inspect: the brake drums and, age or excessive wear. Replace dam-
be checked to determine if oversize 1f necessary, refinish. Refer to Part aged or excessively worn parts. If
linings must be installed. 2-2, Section 4 for refinishing. the inside of the booster body is
4. Check the condition of the rusted or corroded, polish it with
brake shoes, retracting springs, and BOOSTER UNIT steel wool or fine emery cloth. Re-
drum for signs of overheating. If A disassembled view of the brake place the body shell when scored.
EXPANDER AND PI
8 SELF-TAPPING SCREWS
PISTON PACKING
-_J~
MASTER CYliNDER
PUSH ROD __ / RUBBER BOOT
REACTION
DISC
-- J-
......
GASKET
-........ .....
(.
__
RING
VACUUM TUBE
AND PLATE
PLATE
VACUUM HOSE
BOOSTER BODY POPPET Rf TURN SPRING H12412-A
FIG. 3-Booster Unit Disassembled

2-6 (010}
PART BRAKE SYSTEM

2·2
1 Description and Operation ................. 2-6 3 Removal and Installation .................. 2-13
2 In-Car Adjustments and Repairs ............. 2-8 4 Major Repair Operations .................. 2-16
D DESCRIPTION AND OPERATION

HYDRAULIC SELF-ADJUSTING ism consists of a cable, cable guide, ing the drum forces the upper end
BRAKE SYSTEM adjusting lever, and adjuster spring of the primary shoe against the
(Fig. 1). The cable is hooked over anchor pin. The action of the wheel
The hydraulic brake system on the anchor pin at the top and is con- cylinder moves the upper end of the
the 1964 Lincoln employs single nected to the lever at the bottom. secondary shoe away from the an-
anchor, internal expanding and self- The cable is connectd to the second- chor pin. The movement of the sec-
adjusting brake assemblies which ary brake shoe by means of the cable ondary shoe causes the cable to pull
are powered by a vacuum booster guide. The adjuster spring is hooked the adjusting lever upward and
as standard equipment. to the primary brake shoe and to the against the end of a tooth on the ad-
The master cylinder converts phys- lever. The automatic adjuster oper- justing screw star wheel. The up-
ical force from the brake pedal and ates only when the brakes are ap- ward travel of the lever increases as
booster into hydraulic pressure plied while the car is moving rear- lining wear increases. When the
against the pistons in the wheel cylin- ward and only when the secondary lever can move upward far enough,
ders. The wheel cylinder pistons in shoe is free to move toward the it passes over the end of the tooth
turn convert hydraulic pressure back drum beyond a predetermined point. and engages the tooth. When the
into physical force at the brake With the car moving rearward and brakes are released, the adjusting
shoes. the brakes applied, the "wrap- spring pulls the lever downward
The self-adjusting brake mechan- around" action of the shoes follow- causing the star wheel to tum and
REAR
BRAKE
H1278-A
FIG •. 1-Lincoln Self-Adiusting Bralc:e Assemblies

(011) PART 2-2-BRAKE SYSTEM 2-7
t
MANUAL RELEASE
HANDLE
D ATMOSPHERIC PRESSURE
DvAcuuM
§ HYDRAULIC FLUID
H1067-C
H1292-A
FIG. 2-Booster in Released Position FIG. 4-Parking Brake
Control Assembly
expand the shoes. The star wheel is BOOSTER SYSTEM
turned one tooth at a time as the The booster assembly (Figs. 2 and The chamber in back of the boost-
linings progressively wear. 3) is mounted on the engine side er piston is at all times open to at-
With the car moving forward and of the dash panel. A vacuum reser- mospheric pressure through an air
the brakes applied, the secondary voir, mounted on the left front fen- cleaner. When the pedal is in the
shoe is against the anchor pin and der splash shield, gets its vacuum released position, the valve return
the primary shoe is moved toward from the engine intake manifold. spring holds the valve operating rod
the drum. Therefore, the adjuster When the engine is stopped, a check and plunger back against the piston
does not operate. valve traps vacuum in the reservoir. rear plate leaving the atmospheric
The vacuum reservoir maintains port open and the vacuum port
The rear brake assembly is basic-
enough vacuum (after the engine has closed (Fig. 2) . The atmospheric
ally the same as the front brake. The
stopped) for several power-assisted pressure in the rear chamber is free
conventional parking brake lever,
brake applications. Should the power to pass through the open· atmospheric
link, and spring are used in the rear
unit fail, the car can still be braked, port of the valve and the porting in
brake.
although greater pedal pressure by the piston to the chamber area in
The anchor pins on all brakes are the driver will be necessary for a front of the piston. The booster pis-
fixed and non-adjustable. given application. ton is, therefore, balanced in atmos-
phere (atmospheric pressure on both
sides) and does not move.
VACUUM PORT
(OPEN)
ATMOSPHERIC
PORT
(CLOSED)
~ HYDRAULIC FLUID
D HYDRAULIC FLUID PRESSURE
H1077-C
FIG. 5-Parking Brake
FIG. 3-Booster in Applied Position Locking and Release Mechanism

PARKING BRAKES the ramp is such that the roller will

ride on the ramp as the pedal is de-
An independent foot- operated pressed; however, when the applying
parking brake control actuates the motion stops and the pedal starts to
rear wheel brake shoes through a release, the roller becomes wedged
cable linkage. The operating cable is
between the friction block and the
routed from the parking brake con-
ramp thus locking the brakes in the
trol assembly to the equalizer lever
applied position. Since the roller is
TO ENGINE which is attached to the equalizer
MANIFOLD mounted in the release lever, a slight
VACUUM
assembly. The rear brake cables con- movement of the release ·lever will
===• nect the equalizer assembly to the

parking brake lever at each rear sec-
ondary shoe (Figs. 15 and 17).
force the roller out of its wedged
position allowing the brakes to re-
lease. The release lever is actuated
VACUUM When the pedal is depressed the automatically by the vacuum control
JUNCTION BLOCK H1286·A secondary brake shoes are forced or by the manual release handle
against the rear brake drums. The
FIG. 6- Vacuum pedal is held in the applied position
which is connected to the lever.
Connections for Automatic by the wedging action of a steel The vacuum power unit with
roller between a friction block and mounting bracket is riveted to the
Parking Brake Release control assembly. The vacuum act-
a ramp in the control assembly
(Fig. 4). uated piston within the unit is con-
As the brake pedal is depressed nected by a link to the upper end of
A vacuum power unit will release
(Fig. 3 ), the valve operating rod and the release handle which actuates the
the parking brakes automatically
plunger move forward against the when the transmission selector lever release lever to move the steel roller
poppet valve to close the atmospheric is moved into any drive position with out of the locked position (Figs. 4
port. Further travel of the rod and the engine running. The brakes will and 5). The lower end of the release
plunger moves the poppet away from not release automatically, however, handle extends out for alternate
the vacuum seat to open the vacuum when the selector lever is in the manual release in the event of a
neutral or park position with the vacuum power failure or for optional
port and establish direct connection
engine running, or in any position manual release at any time.
between the intake manifold (or res-
ervoir) through the porting in the with the engine off. Hoses connect the power unit and
The parking brake control assem- the engine manifold to a vacuum re-
valve and piston to the forward
bly is mounted to a bracket on the lease valve in the transmission neu-
chamber. As vacuum removes air tral switch( Figs. 4 and 6). Moving
dash panel to the left of the steering
from the forward chamber, atmos- the transmission selector lever into
column (Fig. 15). The pedal assem-
pheric pressure behind the booster bly pivots on the stationary pedal any drive position with the engine
piston exerts the force against the mount (Fig. 4). A steel roller and running will open the release valve
hydraulic push rod and piston that friction block are assembled to the to connect engine manifold vacuum
supplies the power assist. The amount upper end of the pedal. A steel to one side of the actuating piston
of assist supplied by the power unit ramp is atta£;hed to the pedal mount in the power unit. The pressure dif-
is always directly proportional to the in such manner that the roller is ferential thus created will cause the
amount of pressure being supplied positioned between the friction block piston and link to pull the man-
to the pedal. Gradual application of and the ramp (Fig. 5). The angle ual release handle which, in turn,
the brakes is thus possible. of the friction block with respect to actuates the release lever.
EJ IN-CAR ADJUSTMENTS AND REPAIRS

BRAKE SHOE ADJUSTMENTS normal room temperature when ad- 2. Remove the adjusting hole
justing the brake shoes. If the shoes cover from the backing plate and,
The car should be in a raised posi- are adjusted when the drurns are hot from the backing plate side, turn
tion with the wheels off the floor. and expanded, the shoes may drag the adjusting screw upward to ex-
If the car is raised on a frame- pand the shoes (Fig. 7). Expand the
when the drums are cool and con-
contact hoist, disconnect the park- tracted. shoes until a slight drag is felt when
ing brake cables to prevent the 1. After the shoes have been in- the drum is rotated.
rear brakes from being partially stalled or the adjusting screw has 3. Remove the drum. Mark the
applied due to rear axle and spring been turned, install the drum. Be tooth on the star wheel where the
sag on the hoist. sure that all excess grease, oil, and lever contacts the adjusting screw.
The hydraulic service brakes are other foreign material are wiped off While holding the adjusting lever out
self-adjusting and require a manual the backing plate and drum. of engagement with the adjusting
adjustment only after the brake shoes Before installing the brake drum screw, back off the adjusting screw
have been relined, replaced, or when on the front wheel spindle, wipe the with a 3A turn with the fingers. If
the length of the adjusting screw has spindle completely free of grease. finger movement will not turn the
been changed while performing some Install the drum carefully so that screw, free it up; otherwise, the self-
other service operation. the grease seal retainers within the adjusting lever will not turn the
The brake drums should be at hub will not be damaged. screw. Lubricate the screw with a

back into position. Remove the

wheel bearing and withdraw the
brake drum.
If the brake drum will not come
off easily, insert a narrow screw-
driver through the brake adjusting
hole in the backing plate, and dis-
engage the adjusting lever from
the adjusting screw. While thus
holding the adjusting lever away
from the adjusting screw, back off
the adjusting screw with the brake
adjusting tool2018-A (Fig. 8). Back
MOVE HANDLE
off the adjustment only if the drum UPWARDS
cannot be removed easily. Be very
careful not to burr, chip, or dam- H1144-A
H1315-A agE~ the notches in the adjusting
screw; otherwise, the self-adjusting FIG. 8-Bac:king off
mechanism will not function prop- Brake Adiustment
FIG. 7-Expanding Brake Shoes erly. If the adjustment was changed,
make sure that the adjuster lever
justing lever away from the adjust-
thin uniform coating of Stanolube~ seal'> properly in the shoe web.
ing screw, back off the adjusting
HD Molv Grease-Grade 2. screw with the brake adjusting tool
Any other adjustment procedure INSTALLATION (Fig. 8).
may cause damage to the adjusting 1. lf the drum is being replaced, Back off the adjustment only if
screw with consequent self-ad- remove the protective coating from the drum cannot be removed
juster problems. the new drum with carburetor de- easily. Be very careful not to burr,
4. Apply a small quantity of high- greaser. Install new bearings and a chip, or damage the notches in the
temperature grease to the points grease retainer. Soak the new grease adjusting screw; otherwise, the
where the shoes contact the backing retainer in light engine oil at least self-adjusting mechanism will not
plate, being careful not to get the 30 minutes before installation. Pack function properly.
lubricant on the linings. Install the the wheel bearings, install the inner
drum. bearing cone and roller assembly in INSTALLATION
On front wheels, install the wheel the inner cup, and install the new 1. Remove the protective coating
outer bearing, washer, and adjusting grease retainer. See Part 3-1, Sec- from a new drum with carburetor
nut, then adjust the wheel bearings tion 2 . degreaser.
as outlined in Part 3-1, Section 2. lf the original drum is being in- 2. Place the drum over the brake
On rear wheels, install the three stalled, make sure that the grease in assembly and into position. Install
Tinnerman nuts and tighten securely. the hub is clean and adequate. the three Tinnerman nuts and tighten
5. Install the wheel on the drum 2. Install the drum assembly, outer securely.
and tighten the mounting nuts to wheel bearing, washer and adjusting 3. Install the wheel. If the adjust-
specification. nut. ment was backed off, adjust the
6. Install the adjusting hole cover 3. Adjust the wheel bearing as brake as outlined under "Brake Shoe
on the brake backing plate. outlined in Part 3-1, Section 2, then Adjustments".
7. When adjusting the rear brake install the nut lock, cotter pin and
shoes, check the parking brake the grease cap. BRAKE SHOES AND
cables for proper adjustment. Make ,t Install the wheel and hub cap. ADJUSTING SCREW
sure that the equalizer lever oper- If the adjustment was backed off, REMOVAL
ates freely. adjust the brake as outlined under
8. After the brake shoes have been 1. With the wheel and drum re-
''Brake Shoe Adjustment".
properly adjusted, check the oper- moved, install a clamp over the ends
ation of the brakes. REAR BRAKE DRUM
FRONT BRAKE DRUM REMOVAL
REMOVAL 1. Raise the car so that the wheel

is dear of the floor.
1. Raise the car w that the wheel 2. Remove the hub cap and wheel.
is clear of the floor. Remove the three Tinncrman nuts
2. Remove the hub cab, and re- and remove the brake drum.
move the wheel from the drum. Re- If the brake drum will not come
move the bearing dust cap, cotter off, insert a narrow screwdriver T
pin, nut lock, adjusting nut, and through the brake adjusting hole in LM-119 H1281-A
washer. the hacking plate, and disengage the
3. Pull the brake drum approxi- adJusting lever from the adjusting FIG. 9-Retrading
mately two inches outward and push screw. While thus holding the ad- Spring Removal

of the brake cylinder as shown in time the automatic adjusting

Fig. 9. mechanism operated. To prevent
2. Contract the shoes as follows: installation on the wrong side of the
a. Disengage the adjusting lever car, the socket end of the adjusting
from the adjusting screw by pulling screw is stamped with an R or L
backward on the adjusting lever (Fig. 11). The adjusting pivot nuts
(Fig. 1). can be distinguished by the number
b. Move the outboard side of the of grooves machined around the
adjusting screw upward and back off body of the nut. Two grooves indi-
the pivot nut and as far as it will go. cate a right hand nut; one groove
3. Pull the adjusting lever, cable indicates a left hand nut.
and automatic adjuster spring down H1280-A 11. Place the adjusting socket on
and toward the rear to unhook the the screw and install this assembly
pivot hook from the large hole in the FIG. 10-Retrading between the shoe ends with the ad-
secondary shoe web. Do not attempt Spring Installation justing screw toothed wheel nearest
to pry the pivot hook out of the the secondary shoe.
hole. anchor pin with the crimped side 12. Hook the cable hook into the
4. Remove the automatic adjuster toward the backing plate. hole in the adjusting lever. The ad-
spring and adjusting lever (Fig. 1). 7. Install the cable guide on the justing levers are stamped with an
5. Remove the primary shoe to secondary shoe web with the flanged R or L to indicate their installation
anchor spring with the tool shown in hole fitted into the hole in the sec- on a right or left hand brake assem-
Fig. 9. With the same tool, remove ondary shoe web. Thread the cable bly (Fig. 11).
the secondary shoe to anchor spring around the cable guide groove (Fig. 13. Position the hooked end of the
and unhook the cable eye from the 1). adjuster spring completely into the
anchor pin. It is imperative that the cable large hole in the primary shoe web.
6. Remove the anchor pin plate be positioned in this groove and The last coil of the spring should
and the anti-rattle clip. - not between the guide and the shoe be at the edge of the hole. Connect
7. Remove the cable guide from web. the loop end of the spring to the
the secondary shoe (Fig. 1). 8. Install the secondary shoe to adjuster lever hole (Fig. 1).
8. Remove the shoe hold down anchor spring (Fig. 10). 14. Pull the adjuster lever, cable
springs, shoes, adjusting screw, pivot 9. Install the primary shoe to an- and automatic adjuster spring down
nut, and socket. chor spring with the tool shown in and toward the rear to engage the
9. On rear brakes, remove the Fig. 10. pivot hook in the large hole in the
parking brake link and spring. Dis- Be certain that the cable eye is secondary shoe web (Fig. 1).
connect the parking brake cable not cocked or binding on the an- 15. After installation, check the
from the parking brake lever. chor pin when installed. All parts action of the adjuster by pulling the
10. After removing the rear brake should be flat on the anchor pin. section of the cable between the
secondary shoe, disassemble the Remove the brake cylinder clamp. cable guide and the adjusting lever
parking brake lever from the shoe 10. Apply high-temperature grease toward the secondary shoe web far
by removing the retaining clip and ( Stanalube-HD Moly Grease-Grade enough to lift the lever past a tooth
spring washer (Fig. 1). 2) to the threads and the socket end on the adjusting screw wheel. The
of the adjusting screw. Turn the ad- lever should snap into position be-
INSTALLATION justing screw into the adjusting pivot hind the next tooth, and release of
nut to the limit of the threads and the cable should cause the adjuster
1. Back off the parking brake ad- spring to return the lever to its 9rigi-
then back off 112 turn.
justment. nal position. This return action of
Interchanging the brake shoe
2. Before installing the rear brake the lever will turn the adjusting screw
adjusting screw assemblies from
shoes, assemble the parking brake one tooth.
one side of the car to the other
lever to the secondary shoe and If pulling the cable does not pro-
would cause the brake shoes to
secure with the spring washer and duce the action described, or if the
retract rather than expand each
retaining clip. lever action is sluggish instead of
3. Apply a light coating of high- positive and sharp, check the posi-
temperature grease at the points tion of the lever on the adjusting
where the brake shoes contact the screw toothed wheel. With the brake
backing plate. in a vertical position (anchor at the
4. Position the brake shoes on the top) , the lever should contact the
backing plate and secure the assem- adjusting wheel o/J.r. inch ( ± %2 inch)
bly with the hold down springs. On above the centerline of the screw.
the rear brake, install the parking If the contact point is below this
brake link and spring. Connect the centerline, the lever will not lock on
parking brake cable to the parking the teeth in the adjusting screw wheel,
brake lever (Fig. 1). and the screw will not be turned as
5. Install the anti-rattle clip and the lever is actuated by the cable.
the anchor pin plate on the anchor To determine the cause of this
pin. FIG. 11-Adiusting condition:
6. Place the cable eye over the Screws and Lever Identification a. Check the cable end fittings.

L ~·.~(.0 BLEEDER VALVE

4. Remove the brake cylinder re-
PISTON /
taining bolts and lock washers and
T
remove the cylinder. Remove the
BOOT clamp from the cylinder.
\ PlST\
- ·~I
I
, ·. ~.~•c&:J
"'' t .:..· I c'!' J"
INSTALLATION
Wipe the end(s) of the hydraulic
1
LINK CUP CYLINDER SPRING BOOT H1295-A
line to remove any foreign matter
before making connections.
1. To install a front cylinder:
a. Insert the front cylinder into
FIG. 12-Wheel Cylinder the opening on the backing
plate with the inlet toward
The cable should completely fill or 0.003 inch beyond its original di- the rear of the car. Install
extend slightly beyond the crimped ameter. the retaining bolts and lock
section of the fittings. If it does not 4. Check the bleeder hole to be washers.
meet this specification, possible dam- sure that it is open. b. Install a new copper gasket
age is indicated and the cable assem- over the hose fitting. Screw
bly should be replaced. ASSEMBLY the hose assembly into the
b. Check the cable length. The cylinder.
cable should measure 11 'h inches 1. Apply a coating of heavy-duty
brake fluid to all internal parts. c. Engage the opposite end of
( ± lko~ inch) from the end of the
2. Thread the bleeder screw into the hose to the bracket on
cable anchor to the end of the cable
the cylinder and tighten securely. the frame, install the horse-
hook.
3. Insert the return spring, cups, shoe-type retaining clip, and
c. Check the cable guide for dam-
and pistons into their respective posi- connect the brake tube to
age. The cable groove should be
tions in the cylinder bore (Fig. 12). the hose with the tube fitting
parallel to the shoe web, and the
Place a boot over each end of the nut. Tighten the nut to
body of the guide should lie flat
cylinder. specification.
against the web. Replace the guide
if it shows damage. 2. To install a rear cylinder:
d. Check the pivot hook on the WHEEL CYLINDER a. Place the rear wheel cylin-
lever. The hook surfaces should be REPLACEMENT der into position. Enter the
square with the body of the lever tubing into the cylinder, and
for proper pivoting. Replace the REMOVAL
start the tube fitting nut into
lever if the hook shows damage. 1. With the wheel in a raised posi- the threads of the cylinder.
e. See that the adjusting screw tion, remove the wheel and the drum. b. Secure the cylinder to the
socket is properly seated in the notch 2. Remove the brake shoe assem- backing plate by installing
in the shoe web. blies following procedures outlined the retaining bolts and lock
in this section. washers.
WHEEL CYLINDER REPAIR 3. Disconnect the brake line from c. Tighten the tube fitting nut
the brake cylinder. Be sure the en- to specification.
DISASSEMBLY gine is stopped and there is no
3. Install the links in the ends of
V Remove the links and the rub- vacuum in the booster system be- the brake cylinder, install the shoe
ber boots from the ends of the brake fore disconnecting the hydraulic
and adjuster assemblies, and adjust
cylinder. Remove the pistons, cups, lines. the shoes as outlined in this section.
and return spring from the cylinder To disconnect the hose at a front
4. Install the brake drum and
bore (Fig. 12). cylinder, loosen the tube fitting that
wheel, and bleed the brakes as out-
2. Remove the bleeder screw from connects the opposite end of the hose
lined in Part 2-1, Section 2.
the cylinder. to the brake tube at a bracket on
the frame. Remove the horseshoe-
type retaining clip from the hose and BRAKE BACKING PLATE
INSPECTION REPLACEMENT
bracket, disengage the hose from the
1. Wash all parts in clean de- bracket, then unscrew the entire hose REMOVAL
natured alcohol. 1f alcohol is not assembly from the front brake cylin-
available, use specified brake fluid. der. 1. Remove the wheel and brake
Dry with compressed air. At a rear cylinder, unscrew the drum. Disconnect the brake line
2. Check all internal parts for ex- tube fitting that connects the tube to from the brake cylinder.
cessive wear or damage. If any of the cylinder. Do not pull the metal 2. Remove the brake shoe and ad-
the internal parts require replac- tube away from the cylinder. Pull- juster assemblies and the wheel cylin-
ing, allshould be replaced. ing the tube out of the cylinder der as outlined in this section. On
3. Inspect the cylmder bore for connection will bend the metal the rear wheels, disconnect the park-
score marks or rust. lf either con- tube and make installation diffi- ing brake lever from the cable.
dition is present, the cylinder bore cult. The tube will separate from 3. If the rear backing plate is be-
must be honed. However, the cylin- the cylinder when the cylinder is re- ing replaced, rotate the axle shaft
der should not be honed more than moved from the backing plate. so that the hole in the axle shaft

2-12 GROUP 2--BRAKES (016)
~~FRONT END
RETAININTcup--j';\HOSE
TOMAINJ~~ ~BRACKET
)
H1289-A
FIG. 13-Service Brake System

flange lines up with the backing plate 3. Install the brake shoe and ad- All brake tubing should be flared
retaining nuts, and remove the nuts. juster assemblies as outlined in this properly to provide good leak-proof
Pull the axle shaft assembly out of section. On a rear brake, connect the connections. Clean the brake tubing
the housing with tool 4235C and a parking brake cable to the lever. In- by flushing with clean denatured
slide hammer (Par.t 4-2), then re- stall the brake drum and wheel. alcohol before installation.
move the backing plate. 4. Adjust the brake shoes and When connecting a tube to a hose,
If the front backing plate is being bleed the brake system as outlined tube connector, or brake cylinder,
replaced, remove the bolts and nuts in this section. tighten the tube fitting nut to the
that secure the plate to the front specified torque with Milbar tool
wheel spindle and remove the plate. HYDRAULIC Ll NES 1112-144 or equivalent.
Steel tubing is used throughout
INSTALLATION BRAKE HOSE REPLACEMENT
the brake system with the exception
1. Position a new rear backing of the flexible hoses at the front A flexible brake hose should be
plate on the retaining bolts in the wheels and at the rear axle housing replaced if it shows signs of soften-
axle housing flange. Insert the axle brake tube connector (Fig. 13). ing, cracking, or other damage.
shaft into the housing so that the Always bleed the entire system When installing a new front brake
splines engage the differential side after any hose or line replacement. hose, position the hose to avoid con-
gear with the bearing retainer sliding tact with other chassis parts. Place a
onto the retaining bolts and against BRAKE TUBE REPLACEMENT new copper gasket over the hose
the backing plate. Install the retain- If a section of the brake tubing fitting and screw the hose assembly
ing nuts through the access hole in becomes damaged, the entire section into the front brake cylinder. Engage
the axle shaft flange. should be replaced with tubing of the opposite end of the hose to the
Position a new front backing plate the same type, size, shape, and bracket on the frame so that the
to the wheel spindle and' install the length. Copper tubing should not hose is ¥s -% inch from the lower
retaining bolts and nuts. be used in a hydraulic system. flange of the No. 2 cross member
2. Install the wheel cylinder and When bending brake tubing to fit with the suspension at normal posi-
connect the brake line as outlined in underbody or rear axle contours, be tion (Fig. J 3). Install the horse-
this section. careful not to kink or crack the tube. shoe-type retaining clip, and connect

(017) PART 2-2- BRAKE SYSTEM 2-13
the tube to the hose with the tube Place a new gasket over the rear that the hose bends are in a plane
fitting nut. hose fitting and screw the hose as- between the bracket and connector.
A rear brake hose should be in- sembly into the rear brake tube con- Install the horseshoe-type retaining
stalled so that it does not touch the nector. Engage the front end of the clip, and connect the tube to the
muffler outlet pipe or shock absorber. hose to the bracket on the frame so hose with the tube fitting nut.
El REMOVAL AND INSTALLATION

MASTER CYLINDER tamed against the reaction disc and panel. Disconnect the light and wire
there is no air pocket between the (plug-in connector) from the control
REMOVAL end of the push rod and the reaction lead.
1. Disconnect the battery ground disc. 4. Remove the C-washer that re-
cable. :t Before proceeding with the in- tains the brake pedal to booster push
2. Remove the hydraulic line out- stallation, check the distance from rod (Fig. 16), and disconnect the
let fitting from the master cylinder. the outer end of the push rod to the rod from the pedal. Remove the
3. Disconnect the stop light switch master cylinder mounting surface at nylon bushings from the rod.
wires. It is not necessary to remove the end of the vacuum cylinder 5. Loosen the hood release handle-
the stop light switch. (Part 2-1, Fig. 1). This dimension to-bracket lock nut, and remove the
4. Remove the two nuts and lock should be from 1.175 to 1.180 inch release handle and cable assembly
washers that secure the master cylin- measured metal to metal. If the push from the bracket to obtain clearance
der to the booster unit (Fig. 14). rod dimension is not correct, see for removing the booster retaining
Separate the master cylinder from "Master Cylinder Push Rod Adjust- nuts.
the booster unit and make sure that ment", Part 2-1, Section 2. 6. Remove the five retaining nuts
the master cylinder does not rest on 4. When the push rod adjustment from the booster mounting studs at
the push rod. is correct, replace the rubber seal in the passenger side of the dash panel.
5. Remove the rubber seal from the groove at the end of the master 7. From under the hood, discon~
the outer groove at the end of the cylinder. nect the vacuum hose from the
master cylinder. 5. Position the master cylinder booster and remove the booster as-
6. Remove the push rod from the over the push rod onto the two studs sembly.
power unit. Do not disturb the ad- that are integral with the booster
justing screw. body. INSTALLATION
6. Install the attaching nuts and
lock washers and torque the nuts to 1. Install the booster assembly on
INSTALLATION specifications. the engine side of the dash panel.
1. Apply a light coating of lubri- 7. Replace the stop 1ight switch The mounting studs and valve rod
cant COAZ-19584-A to the piston wires. go through the holes in the dash
end of the hydraulic push rod and 8. Install the master cylinder hy- paneL
guide the piston end of the push rod draulic line outlet fitting. 2. Connect the vacuum hose to
into the center bore of the booster 9. Bleed the brake system. Fill the the booster. A new clamp will be
piston. ma<>ter cylinder to V<l-lh inch from required.
2. Twist the push rod to make cer- the top of the filler opening. Replace 3. From inside the car, install the
tain the rnd of the piston is bot- the filler cap and gasket. booster retaining nuts on the mount-
10. Connect the battery ground ing studs and torque them to specifi-
cable. cations.
4. Install the nylon bushings in
BOOSTER UNIT the eye of the push rod. Use grease
to lubricate the bushings.
REMOVAL 5. Connect the push rod to the
1. Disconnect the battery ground brake pedal assembly and secure
cable. with the C-washer (Fig. 16).
2. Remove the three retaining 6. Position the hood release handle
bolts, nut and washer, and remove and cable assembly in the bracket at
the two left side fender apron··to- the bottom of the instrument panel,
cowl braces for access (Fig. 14). and tighten the lock nut.
3. From inside the car, remove 7. Position the lower outer exten-
the six retaining screws and the in- sion assembly to the underside of
strument panel lower outer extension the instrument panel and secure with
from the underside of the instru- six attaching screws.
ment panel. On cars equipped with a speed
Before removing the lower outer control, connect the light and wire
extension from cars equipped with (plug-in connector) to the control
:1 speed control, remove the control head. M aunt the control head to the
FIG. 14-Master Cylinder head (two retaining screws) from underside of the instrument panel
ond Booster Installation the underside of the instrument and secure with two screws.

and secure with the clevis pin and

cotter pin (Fig. 15).
2. Connect the hose to the vacuum
power unit.
3. Position the parking brake con-
trol assembly to the mounting brack-
et on the dash panel, and install the
mounting screws.
4. Connect the support rod to the
parking brake control assembly and
to the service brake pedal support
bracket.
\
5. From underneath the car, con-
""' nect the ball end of the operating

cable to the equalizer lever.
PARKING BRAKE 6. Adjust the parking brake link-
CONTROL ASSEMBLY
age.
7. Check the operation of the
automatic release.
MOUNTING BRACKET PARKING BRAKE VACUUM

POWER UNIT
H1287-A
REMOVAL
FIG. 15-Parking Brake Control and Linkage Connections 1. Remove the parking brake con-
trol assembly from the car as de-
8. Connect the vacuum hose to 2. Disconnect and remove the sup- scribed under "Removal" in the
the booster and secure with the hose port rod from the parking brake foregoing procedure.
clamp. control assembly and the service 2. Drill out or grind off the two
9. Install the two left side fender brake pedal support bracket (Fig. rivets that retain the vacuum power
apron-to-cowl braces and secure in 15). unit to the parking brake control
place with the three retaining bolts, 3. Remove the control assembly- assembly.
nut, and washer. to-mounting bracket screws. 3. Drill out or grind off the rivet
10. Connect the battery ground 4. Disconnect the hose from the that connects the vacuum piston link
cable. vacuum power unit. to the release lever, and remove the
11. Bleed the brakes as detailed 5. With the parking brake in the power unit.
in Part 2-1, Section 2. fully released position, remove the
cotter pin and clevis pin. INSTALLATION
VACUUM RESERVOIR 6. Disconnect the operating cable
from the clevis, and remove the con- 1. Position the vacuum power unit
REMOVAL trol assembly. on the parking brake control as-
1. Raise the front of the car. sembly and secure with two round
2. Loosen the clamp and discon- INSTALLATION head bolts and nuts.
nect the vacuum hose at the reservoir 1. Attach the parking brake cable 2. Connect the vacuum piston link
fitting. to the clevis on the control assembly to the release 1ever with a sho~lder
3. Remove the two reservoir
bracket retaining screws and remove
the reservoir.
INSTALLATION
1. Position the reservoir, and se-
cure it with the two bracket retaining
screws.
2. Install the hose and new clamp
on the reservoir fitting and tighten
the clamp.
3. Lower the front of the car.
PARKING BRAKE
CONTROL ASSEMBLY
REMOVAL
1. Disconnect the parking brake H1290-A
cable from the equalizer lever under-
neath .rhe car (Figs. 15 and 17). FIG. 16-Brake Pedal and Related Parts

bolt nut and wave washer. The wave 2. From inside the car, remove Remove the pivot bolt and the brake
washer is positioned on the shoulder the six retaining screws and the in- pedal assembly from the support
bolt between the vacuum piston link strument panel lower outer extension bracket.
and the release lever. The link and from the underside of the instrument
release lever must pivot freely. panel.
INSTALLATION
3. Install the parking brake con- Before removing the lower outer
trol assembly in the car as described extension from cars equipped with a 1. Position the brake pedal assem-
under "Installation" in the fore- speed control, remove the control bly in the support bracket and install
going procedure. head (two retaining screws) from the pivot bolt and nut. Install the
4. Test the lock and automatic the underside of the instrument air conditioning icing switch, motor
release operations of the parking panel. Disconnect the light and wire and bracket assembly on cars so
brake control assembly with the (plug-in connector) from the con- equipped.
engine running in all the transmission trol lead. 2. Install the nylon bushings in the
selector lever positions. With the 3. Remove the C-washer that re- eye of the push rod. Lubricate the
engine running, the parking brake tains the push rod to the brake pedal bushings. Connect the push rod to
should remain engaged in neutral or assembly (Fig. 16), and disconnect the brake pedal assembly and secure
park and should release in any drive the rod from the pedal. Remove the with the C-washer (Fig. 16).
position. bushings from the rod. 3. Position the hood release
4. Remove the nut from the brake handle and cable assembly in the
BRAKE PEDAL pedal pivot bolt. bracket at the bottom of the instru-
REMOVAL 5. On cars equipped with air con- ment panel, and tighten the lock nut.
1. Disconnect the battery ground ditioning, remove the air condition- 4. Position the lower outer ex-
cable. ing icing switch, motor and bracket. tension assembly to the underside of
ARMOR EXTENDS FORWARD OF CLAMP

l 5fs II lf4 , ON RIGHT SIDE
2 Ya 11 :j~ 1
/4 " ON LEFT ~
EQUAliZER-TO-REAR
-----
HORSE SHOE CLIP
'EQUALIZER-TO-CONTROL CABLE STOP
H1288-A
FIG. 17 -Parking Brake System

the instrument panel and secure with with .the horseshoe-type retaining 6. Working on the wheel side of
six attaching screws. clip (Fig. 15). the backing plate (Fig. 1), compress
On cars equipped with a speed 2. Install the underbody support the prongs on the cable retainer so
control, connect the light and wire plate. that they can pass through the hole
(plug-in connector) to the control 3. Position the cable and retaining in the backing plate. Draw the cable
head. Mount the control head to clamps at the underbody and mount- retainer out of the hole.
the underside of the instrument panel ing bracket, then install the clamp 7. With the spring tension off the
and secure with two screws. retaining bolts (Fig. 15). parking brake lever, lift the cable
5. Connect the battery ground 4. Install the left front fender out of the slot in the lever and re-
cable. splash shield. move it through the backing plate
6. Start the engine and apply the 5. Attach the parking brake cable hole.
brakes to make sure that they are to the clevis on the control assembly
operating properly. and secure with the clevis pin and INSTALLATION
cotter pin (Fig. 15).
6. Connect the hose to the vacuum 1. Pull enough of the cable through
PARKING BRAKE EQUALIZER TO power unit. the housing so that the end of the
CONTROL ASSEMBLY CABLE 7. Position the parking brake con- cable may be inserted through the
trol assembly to the mounting backing plate hole from the inner
REMOVAL
bracket on the dash panel, and inside and engaged with the slot in
1. Disconnect the parking brake stall the mounting screws. the parking brake lever. ·
cable from the equalizer lever un- 8. Connect the support rod to the 2. Pulling the excess slack from
derneath the car (Figs. 15 and 17). parking brake control assembly and the cable, insert the cable housing
2. Disconnect and remove the to the service brake pedal support into the backing plate access hole
support rod from the parking brake bracket. so that the retainer prongs expand
control assembly and the service 9. From underneath the car, con- (Fig. 1).
brake pedal support bracket (Fig. nect the ball end of the operating 3. Position the cable to the under-
15). cable to the equalizer lever. body and install the retaining clamp
3. Remove the control assembly- 10. Adjust the parking brake link- so that the cable conduit armor ex-
to-mounting bracket screws. age. tends forward of the clamp as shown
4. Disconnect the hose from the 11. Check the operation of the in Fig. 17. Insta1l the clamp retain-
vacuum power unit. automatic release. ing nuts.
4. Hook the cable housing to the
5. With the parking brake in the
retainer at the spring U-bolt.
fully released position, remove the PARKING BRAKE EQUALIZER TO 5. Engage the forward end of the
cotter pin and clevis pin. REAR WHEEL CABLE cable housing with the frame
6. Disconnect the operating cable
REMOVAL bracket and secure with the horse-
from the clevis, and remove the con- shoe-type clip.
trol assembly. 1. Raise the car and remove the 6. While holding the adjustable
7. Remove the left front fender hub cap and wheel. cable stop against the cable housing
splash shield. 2. Remove the three Tinnerman end, pull the cable through the hous-
8. Remove the retaining bolts and nuts that hold the brake drum in ing until there is a distance of five
cable clamps (Fig. 15). place, and remove the drum. inches between the two stops as
9. Remove the underbody support 3. Loosen the equalizer rod ad- shown in Fig. 17. Crimp the adjust-
plate. justing nut and disconnect the cable able stop against the cable to hold
10. Remove the horseshoe-type re- from the equalizer (Fig. 15). this dimension.
taining clip at the cable bracket, and 4. Remove the horseshoe-type clip 7. Insert the ball end of the cable
disengage the cable from the bracket that retains the cable housing to the into the equalizer.
(Fig. 15) . Remove the cable. body bracket and pull the cable and 8. Install the rear drum. Tighten
housing out of the bracket (Fig. 17) . the three Tinnerman nuts that retain
INSTALLATION 5. Remove the clamp retaining the drum and install the wheel and
nuts and the cable clamp. Disengage hub cap.
1. Engage the parking brake cable the cable housing from the hook-type 9. Adjust the parking brake link-
housing with the bracket and secure retainer at the spring U-bolt. age as outlined in Part 2-1, Section 2.
EJ MAJOR REPAIR OPERATIONS

BRAKE DRUM REFINISHING and true up the drum. The refinished size linings must be installed.
diameter must not exceed 0.060 inch After a drum is turned down,
Minor scores on a brake drum
oversize ( 11.15 0 inches) . wipe the refinished surface with a
can be removed with a fine emery
cloth. A drum that is e«cessively If the drum diameter is less than cloth soaked in clean, denatured al-
scored or shows a total indicator 0.030 inch oversize ( 11.120 inches) cohol. If one drum is turned down,
runout of over 0.007 inch should after refinishing, standard linings the opposite drum on the same axle
be turned down. Remove only must be installed. If the drum dia- should also be cut down to the same
enough stock to eliminate the scores meter is 11.120-11.150 inches, oversize.

(021) PART 2-2-BRAKE SYSTEM 2-17 •.
gasket. Pour out any brake fluid that

may remain in the cylinder or res~
FILLER CAP ervoir.
2. Remove the stop light switch
and the brake line fitting from the
GASKET forward end of the cylinder (Fig.
18).
3. Remove the snap ring from the
SEAl SNAP\RING
bore at the rear of the cylinder with
tool 33621 (Fig. 19).
VALVE
f<l·~f~\'ir:'/ ,.··
f') {\
~~~
·r
, ..
~(\(A
Jf!·
tf!.
. ' \ ;·
PISTON
I ..
0-RING
4. Remove the piston assembly,
cup, and the spring and check valve
assembly from the cylinder bore.
Remove the 0-ring from the piston.
CUP CLEANING, INSPECTION,

SPRING AND REPAIRS
L tt~·'
5 ~. -----·WASHER 1. Clean all master cylinder parts
~NUT in clean, denatured alcohol, and in~
spect the parts for wear or damage,
H1279-A
replacing them as required. When
using a master cylinder repair kit,
FIG. 18-Brake Master Cylinder Disassembled install all the parts supplied.
2. Check the ports and vents in
BRAKE SHOE RELINING shoe. Starting in the center, insert the master cylinder to make sure
and secure the rivets, working al- that all are open and free of foreign
Brake linings that are worn to ternately towards each end. Install matter.
within Ys2 inch of the rivet or have all parts supplied in the kit. nen- 3. Check the ports in the piston
been saturated with grease or oil uine Lincoln replacement linings to make sure that they are open and
should be replaced. Failure to re~ are ground and no further grind- free of foreign material.
place worn linings will result in a ing is required. 4. Inspect the cylinder walls for
scored drum. When it is necessary 4. Check the clearance between scores or rust, and recondition them
to replace linings, they must also the shoe and lining. The lining must if necessary. Hone the cylinder
be replaced on the wheel on the scat tightly against the shoe with not walls no more than necessary
opposite side of the car. more than 0.005-inch clearance be- (0.003 inch maximum). Oversize
Inspect brake shoes for distortion. tween any two rivets. pistons and cups are not available
cracks, or looseness. If this condi- for excessively honed cylinders.
tion exists, the shoe should be dis- MASTER CYLINDER 5. Remove any burrs or loose
carded. Do not repair a defective DISASSEMBLY metal that may have resulted from
brake shoe. 1. Clean the outside of the cyl- the honing operation, and clean the
1. Wash the brake shoes thor~ inder, and remove the filler cap and cylinder with denatured alcohol.
oughly in a clean solvent. Remove
all burrs or rough spots from the RETURN SPRING
shoes.
2. Check the inside diameter of
the brake drum. If the diameter is
less than 11.120 inches, standard
linings may be installed. If the dia-
meter is 11.120-11.150 inches, over-
size linings should be installed.
3. Position the new lining on the
FILTER ASSEMBLY
END PLATE
H1293-A
FIG. 19-Removing Snap H1291-A
Ring from Master Cylinder FIG. 20-End Plate and Piston Removed

ASSEMBLY
PLATE
1. Dip all parts except the master
cylinder body in clean FoMoCo
heavy-duty brake fluid. PISTON FRONT PLATE
2. Install the brake line fitting
~·~;~v·~:~r
and the stop light switch on the
cylinder and tighten them securely.
3. Install the 0-ring on the pis-
ton. Install the spring, seal, and
SPRING~
check valve assembly, seal, cup, and
piston in the cylinder bore (Fig. 18).
4. Install the snap ring in the rear
end of the bore (Fig. 19). VAlVE PlUNGER
RETAINER\
DIAPHRAGM
DISASSEMBLY OF VALVE OPERA TJNG ROD
BOOSTER UNIT
When overhauling the assembly,
always use a repair kit. If replace- REACTION DISC
ment of the piston packing or dia-
phragm is necessary, use a piston
packing and diaphragm kit.
H1294-A
REMOVAL OF END PLATE,
AIR CLEANER AND
FIG. 22-Piston and Valve Disassembled
BOOSTER PISTON
4. Slide the vacuum hose from 3. Remove the rubber reaction
1. Disengage the rubber boot from the booster piston and from the disc from the piston front plate. If
the scalloped flange of the end plate, vacuum tube on the inside of the necessary, use a piece of rod having
and slide the boot back on the push end plate. Separate the end plate a smooth flat end to push the re-
rod. from the booster piston assembly by action disc out of the piston plate.
2. Scribe alignment marks across sliding the valve rod and rubber 4. Disengage the rubber dust
the end plate and booster body. Re- boot through the hole in the end guard from the shoulder on the
move six of the eight end plate at- plate (Fig. 20). pisttm rear plate. Slide the guard
taching screws, leaving two opposite 5. Remove the screws, vacuum bat:k on the valve rod so that the
screws~ Press down on the end plate tube and plate, and gasket from the plunger can be pushed far enough
while removing the remaining two end plate. Remove the attaching off its seat for cleaning and inspec-
screws to prevent the piston return screws, air filter cover, and air filter tion.
spring from expanding. from the end plate (Part 2-1. Fig. 3 l. Do not separate the valve operat-
3. Scribe across the face of the ing rod from the valve plunger un-
piston to register with the mark on less it is necessary to replace faulty
REMOVAL OF FELT RETAINER.
the end plate; then, remove the end or damaged parts. To replace either
FELT, AND EXPANDER RING
plate with the booster piston and the valve operating rod or valve
piston return spring. 1. Spring the felt retaining ring plunger, hold the assembly with the
sufficiently to disengage the ring valve plunger down and inject al.co-
from the grooves in the bosses ,m hol in the valve plunger through the
the piston rear plate (Fig. 21). opening around the valve rod to wet'
2. Remove the piston felt and the rubber lock in the plunger, then
expander ring from the piston as- drive or pry the valve plunger off
sembly (Part 2-1, Fig. 3). the valve rod.
With the plunger separated from
DISASSEMBLY OF BOOSTER the rod, pull the rod out from the
PISTON AND VALVE rear side of the piston plate; then
slide the dust guard and rubber boot
1. Remove the six bolts and lock from the ball end of the rod (Fig.
washers from the piston front plate. 22).
Lift off the piston rear plate, valve
rod, and plunger assembly. Remove ASSEMBLY OF BOOSTER UNIT
the leather piston packjng from the
piston front plate. ASSEMBLY OF BOOSTER
2. Remove the valve return spring. PISTON AND VALVE
poppet and diaphragm assembly, 1. If the valve operating rod and
poppet spring, and diaphragm sup- the valve plunger were separated,
port plate. Separate the poppet spring slide the rubber boot and the dust
FIG. 21-Retaining retainer and the poppet diaphragm guard over the ball end of the rod.
Ring Removal from the poppet I Fig. 22). Insert the rod through the hole in

(023) PART 2-2- BRAKE SYSTEM 2-19
the piston rear plate from the rear ASSEMBLY OF BOOSTER

side (Fig. 22). Dip the valve plunger BODY, PISTON, AND
in alcohol and assemble it to the END PLATE
ball end of the valve operating rod.
Make certain that the ball end of I. Attach the hose to the tube of
the rod is locked in place in the the vacuum piston and align the
valve plunger. It may be necessary hose to lay flat against tl-1e piston.
to tap the end of the rod to seat the 2. Apply a thin coat of booster
ball end of the rod in the valve body oil to the bore of the booster
plunger. body.
2. While holding the valve plunger 3. Saturate the air filter felt with
firmly in its seat in the front side booster body oil.
of the plate, assemble the rubber 4. Assemble the air filter and
dust guard over the shoulder on the FELT EXPANDER RING
cover to the end plate with attach-
rear side of the piston plate. H1085-B
ing screws (Fig. 20).
3. Clamp the valve operating rod
in a vise with the piston rear plate
FIG. 23-Felt and 5. Insert the short end of the
up. Lay the leather piston packing Expander Ring Installation vacuum tube through the gasket, and
install the tube, gasket, and plate
on the rear plate with tht~ lip of the assembly to the end plate. Secure
leather over the edge of the plate. piston plate bolts and Jock washers.
Leave the bolts loose. with attaching screws (Part 2-1,
4. Install the valve return spring Fig. 3).
over the end of the valve plunger. 12. Insert the rubber reaction disc
5. Assemble the poppet dia- into the recess ·at the center of the 6. Jnstall the end plate over the
phragm over the end of the poppet piston front plate. valve operating rod and pull the
(Fig. 22). Make certain that the Use care not to lose the reaction rubber boot through the hole in the
diaphragm is in the recess of the disc out of the piston before the end plate at the same time (Fig. 20).
poppet. push rod is installed. Attach the vacuum hose to the tube
inside of the end plate.
6. Press the poppet spring retainer
over the end of the poppet into the ASSEMBLY OF EXPANDER Before proceeding further, make
relief of the diaphragm. RING, FELT, AND RETAINER certain that the reaction disc is in
7. Assemble the poppet and dia- place in front of the piston plate.
I. Turn the piston assembly upside
phragm assembly over the valve re- down and assemble the expander 7. Center the small diameter end
turn spring and into the recess of ring against the inside lip of the of the piston return spring in the
the piston rear plate. leather packing as shown in Fig. 23. booster body. Center the piston on
8. Install the diaphragm plate in 2. Saturate the felt with booster the spring and align the scribe
the recess of the diaphragm. body oil and assemble it in the ex- marks on the piston, the booster
9. Insta11 the poppet spring over pander ring. body, and end plate. Compress the
the shoulder of the retainer. :;. Assemble the retainer ring over spring and install two attaching
10. Center the poppet spring on the bosses on the piston rear plate screws at opposite sides to hold the
the piston front plate. Align and as- making certain that the retainer is end plate and booster body together.
semble the piston front plate to the anchored in all six grooves of the Install the balance of the screws and
piston rear plate. piston plate. Securely tighten the tighten all screws uniformly.
, 11. Hold the piston front and rear six cap screws in the piston front 8. Assemble the rubber boot over
plates together and install the six plate. the scalloped flange of the end plate.

2-20 (024)
PART SPECIFICATIONS
2-3
DIMENSIONS-In Inches
Drum Wheel Master
Drum Maximum lining length lining Width lining Thickness Cylinder
Brake Inside Cylinder
Boring Primary Bore Bore
Diameter limit Secondary Primary Secondary Primary Secondary Diameter Diameter
1%z
Front (1.094)
Rear
11.090 11.150 9.39 12.21 3 3 0.320 0.320
I~
*
(0.875)
(0.938)
BRAKE CHECK AND ADJUSTMENTS

Type of Check or Adjustment Specification
, ...
Drum Diameter Brake lining Required

11.090-11.120 inch Standard
Brake Shoe Repair 11,120-11.150 inch Oversize
Maximum Brake Lining Clearance (Midway between Rlvets)-0.005 inch
Maximum Lining Wear limit (From Top of Rivets)- 1132 inch
Master Cylinder Hydraulic Master Cylinder Bore Maximum Honed Diameter-0.878 inch
Power Unit Push Rod Adjustment-1.200 inch
Drum Out-of-Round Refinish if Total Indicator Runout Exceeds 0.007 inch
Self-Adjustment Cable Length End of Cable Anchor to End of Cable Hook-llYs inch ± lfs.
fi'ORQUE LIMITS
Description Foot-Pounds
Parking Brake Control Assembly Mounting Bolts 15-19
Master Cylinder to Booster Body 22-28
Booster to Dash Panel 15-25
Brake Tube Fitting :Nuts at Master Cylinder, Rear Wheel Cylinders, and at all Connectors 70 in.-lbs.
(Max.)
Brake Tube Fitting Nuts at Brake Hoses 110 in.-lbs.
(Max.)
FRONT BRAKES
Wheel to Hub and Drum Assembly Nuts 75-110
Front Wheel to Spindle Nut While Rotating Wheel 17-25
Brake Backing Plate to Spindle Nuts I Upper 25-35
J Lower 70-95
Wheel Cylinder to Backing Plate 10-20
REAR BRAKES
Drum to Axle Shaft Flange Speed Nut Hand Push Fit
Whee] to Drum and Axle Shaft Flange Nuts 75-110
Rear Wheel Bearing Retainer Plate and Brake Backing Plate to Axle Housing Flange Nuts 30-45
Wheel Cylinder to Backing Plate 10-20
Brake Fluid-M3833-D
Brake Shoe Adjusting Screw Lubricant-Stanolube-HD Moly Grease-Grade 2

(025) 3-1
GROUP
3
PART 3-1 PAGE PART3~ PAGE
SUSPENSION, STEERING, WHEELS AND STEERING .................... 3-15
TIRES GENERAL SERVICE ....... 3-1
PART 3-4
I
PART 3-2 WHEELS AND TIRES .............. 3-28
SUSPENSION ................... 3-7
PART 3-5
SPECIFICATIONS ................ 3-32
PART SUSPENSION, STEERING, WHEELS

3-1 AND TIRES GENERAL SERVICE
1 Diagnosis and Testing . . . . . . . . . . ......... 3-1 3 Cleaning and Inspection ................... 3-4
2 Common Adjustments and Repair,, ............ 3-3
D DIAGNOSIS AND TESTING

Table 1 lists various suspension, dip stick. Do not overfill the reser- FLUID PRESSURE TEST
steering, and wheel and tire trouble voir.
A fluid pressure test will show
symptoms and their possible causes.
CHECK FOR FLUID LEAKS whether the pump or some other
The possible causes are listed in the
With the engine idling, turn the unit in the power steering system is
table in the order in which they
steering wheel from stop to stop causing trouble in the system.
should be checked. For example,
refer to the fourth trouble symptom several times. Check all possible The pressure testing gauge set,
in Table 1, "Hard Turning When leakage points. Tighten all loose fit- tool 3500-E, requires modification to
Stationary." When checking the pos- tings, and replace any damaged lines make it adaptable for installation in
sible causis, check item 1 (tire pres- or defective seats. the power steering hydraulic system.
sure) and item 2 (tire size) before The parts required and the modifi-
CHECK TURNING EFFORT
proceeding with items 11, 16, and 20 cation procedure are as follows:
as indicated. With the front wheels properly
aligned and tire pressures correct, a. Power Steering Pressure Line
check the effort required to turn the Cl VV-3A719-A or subsequent
PRELIMINARY CHECKS
steering wheel. lines released for this applica-
The following preliminary checks 1. With the car on dry concrete, cation. (Refer to the appropri-
should always be made before per- set 1he parking brakes. ate Parts Catalog.)
forming any trouble shooting oper-
2. With the engine warmed up and b. Inverted Flare Connector ( ¥s
ations. Also, see Table 1.
running at idle speed, turn the steer- inch O.D. Tube x 14 inch Pipe
ing wheel to the left and right several Thread).
CHECK FLUID LEVEL times to warm the fluid.
Run the engine until the fluid is 3. Remove the steering wheel hub c. Tnverted Flare Connector ( %r.
at normal operating temperature. cap assembly. Attach a torque inch O.D. tube x Y4 inch Pipe
Then turn the steering wheel all the wrench to the steering wheel nut. Thread).
way to the left and right several Measure the pull required to turn
times, and shut off the engine. d. Flared Tube Female Coupling
the wheel at least one complete (% inch O.D. Tube x % inch
Check the fluid level in the reser- revolution in both directions. The Pipe Thread).
voir. 1f the level is low. add enough steering effort should not exceed
automatic transmission fluid to raise 5 lhs. pull at the steering wheel rim. The connectors and the cou-
the level to a point one inch from lf a torque wrench is used, re-chec~k pling are standard-type fittings
the top, or to the F mark on the nut torque after test. and can be purchased locally.

3-2 GROUP 3-SUSPENSION, STEERING, WHEELS AND TIRES (026}
TABLE 1-Trouble Symptoms and Possible Causes

~
c:
"'
-~
~
<t:
e
1-
Q; 0.0
0
~
0
"'~
,_ e
CL.
"'
~
0 ~ ·c; 3: c:
(1)
., -l
"'0
(f)
~
c: z
c:
0
0.
E
~
(1)
~
i-=
E
c:
-~
_, 0~ e ~
U) ·~ >
Ill 0 c: 1- Q;
(f)
E
0
(.)
m
"5
.......... ~
(1) (1)
-c Q.) -c Q.)
"0
cat- c: ..s::: ~ (i) c: 0 ::::1 0::: t>O Q)
0::
:;)A. OD OD
"' 3: ::::
(/)
Q.)
..s:::
Q.)
"0 "'
3:
0::: 1-
c:: 0 ~ Q.)
..t:: ..s:::
c:
0
·;n
0~
... .,
~>-
·~ ·= ·=
Q;
OD
Q;
OD
c:
'§
"0
c::
3:
0
(/5
~
~
-c
0
>.
0
-;;;
0
CL.
0
0 3:
Q.)
1:10
::::1
0
c:
~
~
"' (/5
"'3: Q) c:: ~
~
~ 0:::
~ 0
Ci) Ci) :::: OD ::I 0
>. ~
Ci) 1-
-o ·=
Q;
E' .s
E
£ (/)
>.
o-
(/) ~
:0 0 <a 0 ::::1
U')
"E ci> "E ~

~
-c ~ c::
0
~ ~
:2 :5 -c c:: ~
POSSIBLE CAUSES OF TROUBLE 0
-l "'
:X:: ::X: U5 U') CL. (/5
0
CJ:l i-= co ..0
<t: U') "'
::X:
Q)
0:::
1. Incorrect Tire Pressure X X X X X X X X X X X

2. Tire Sizes Not Uniform X X X X X X X
3. Overloaded or Unevenly Loaded Vehicle X X X X

4. Power Steering Fluid Level Low-Leak X X X X
5. Sagging or Broken Spring X X X X X X X
6. Rear Spring Tie Bolt Off Center X X X

I I
7. Broken Rear Spring Tie Bolts X X X X X X X
8. Rear Spring Front Hanger Mislocated I X I X X
9. Bent Spindle Arm X X X X
10. Bent Spindle X X X X

I
11. Lack of Lubrication X X X X
I X X I
12. Air in Power Steering System X X X X
13. Obstruction in Power Steering Lines X X X
I
14. Loose or Weak Shock Absorber X X I X X X X
I
• 15. Loose or Worn Suspension Arm Bushings X X
I X X
16. Binding Front Suspension Ball Joints or Steering Linkage X X X X i X

I
X
17. Loose, Worn, or Damaged Steering Linkage or Connections X X X X X X X .

18. Loose Steering Gear Mountings X X X X X
19. Insufficient Steering Pump Pressure X X X

20. Incorrect Steering Gear Adjustment X X X X X X X X X X
21. Incorrect Brake Adjustment X X X X
22. Incorrect Front Wheel Bearing Adjustment X X X X X X X

X
23. Wheel Out of Balance X I X X I
24. Incorrect Front Wheel Alignment X X X X X X X X

25. Out-of-Round Wheel or Brake Drum X X X
I
26. Frarne or Underbody Out of Alignment X X X
I
27. Bent Rear Axle Housing X X X X
28. Excessive Wear of Power Steering Pump Internal Parts X X
29. Steering Gear Valve Spool Binding or Out of Adjustment
I 1 X X X X
30. Obstruction Within Steering Gear X X X X

{027) PART 3-1-SUSPENSION, STEERING, WHEELS AND TIRES GENERAL SERVICE 3-3
full right and full left turn positions

and observe the gauge readings.
CAUTION: Hold the wheels in
this position only long enough to
obtain an accurate reading.
The gauge should read between
1120 and 1250 psi. If the pressure is
less than 1120 psi, close the valve at
the gauge and note the pump pres-
sure. If it is low with the valve
closed, it indicates that the pump is
not operating properly. If the pres-
sure goes up with the valve closed,
it indicates that the low pressure in
the system must be due to internal
FIG. 1-Modified FIG. 2-Pressure leakage in the power unit, providing
Pressure Gauge Assembly Testing Gauge Installation all connections are tight.
4. Remove the pressure testing
e. To modify tool 3500-E, remove 1. To check the pump pressure, gauge set, and connect the pressure
disconnect the pressure line (upper line at the steering gear. FiJI and
the hose from the hand shut-off
line) at the steering gear. Connect bleed the system.
valve block. Install the 3fs inch
the modified pressure-testing gauge
x V-4 inch inverted flare VALVE SPOOL CENTERING
assembly, tool 3500-E, between the CHECK
connector in the valve block,
pressure line from the pump and the
and assemble the pressure line, The valve spool centering check
steering gear. (See Fig. 2.)
C1VV-3A719-A (or subse- requires the use of the modified pres-
2. Make sure the hand-valve at the sure testing gauge set, tool 3500-E.
quently released line) to the gauge is fully opened. Start the en- The parts required and the modifica-
connector (Fig. 1). Assemble gine and cycle the steering gear from tion procedure are outlined above.
the 3/s x V-4 inch coupling and stop to stop until the gear housing For the complete Valve Spool Cen-
the ~6-inch connector to the is warm. Check the fluid level in the tering procedure, refer to Part 3-3,
free end of the hose leading to reservoir and add fluid, if necessary. Section 4, "Assembly of Steering
the pressure gauge. 3. Turn the steering wheel to the Gear."
EJ COMMON ADJUSTMENTS AND REPAIRS

WHEEL ALIGNMENT the rear bolt, will change castt~r in shaft will change the camber 1;4 o.
ADJUSTMENTS the negative direction. Outboard Inboard movement will change the
After front wheel alignment fac- movement of the front bolt, or in- camber in the negative direction.
tors have been checked, make the board movement of the rear bolt, Outboard movement will change the
necessary adjustments. Do not at- will change caster in the positive camber in the positive direction.
tempt to adjust front wheel align- direction. 3. When the camber is correct,
ment by bending the suspension 3. When the caster is correct, torque the shaft retaining bolts to
or steering parts. torque the shaft retaining bolts to specification and recheck the camber
specification and recheck the caster and caster to insure the readings have
CASTER and camber to insure the readings not changed.
1. Position the car on a level floor have not changed.
or on runway-type wheel alignment TOE-IN AND STEERING WHEEL
equipment. Position a suitable gauge CAMBER ALIGNMENT ADJUSTMENTS
on the front wheels and check the 1. With the car on runway-type TOE-IN
caster angle. Correct caster is nega- wheel alignment equipment, or on
tive 3_4 o to negative 2 114 o. Maximum a level floor, position a suitable gauge Toe-in is adjusted by means of the
difference between wheels should not on the wheels and check the camber sleeve at the outer end of each
exceed 1h o with 1;4 o preferred. angle. Correct camber is oo to posi- spindle connecting rod. The toe-in
2. To adjust caster, raise the hood. tive ~ o. Maximum differenC4;! be- specification is ~~r; inch to :Yt~; inch.
Loosen the bolts that secure the up- tween wheels should not exceed 1/2 o 1. Set the front wheels in the
per suspension arm shaft to the with 1/4 o preferred. straight-ahead position. To be sure
frame member and, with the aid ot 2. To adjust camber, raise the the wheels are straight-ahead, push
a pry bar, move the shaft in or out, hood. Loosen the bolts that secure the car backward about six feet;
as required. A movement of approxi the upper suspension arm shaft to then, pull it forward about three feet.
mately %~ inch at either the front the frame member and, with the aid The last movement of the car must
or rear bolt location will change the of a pry bar. move the shaft in or he forward to position the wheels
caster 1/2 o. Inboard movement of the out, as required. A movement of properly.
front bolt, or outboard movement ot approximately ::,;4 inch of the entire 2. Remove the cap from the steer~

3-4 GROUP 3-SUSPENSION, STEERING, WHEELS AND TIRES (028)
TURN DOWNWARD TO TURN TURN UPWARD TO downward the same number of turns
INCREASE ROD LENGTH TURN UPWARD DOWNWARD INCREASE ROD LENGTH to move the steering wheel spokes to
TO DECREASE TO D£CREASE ~ their normal position. If the wheel is
llJ»~NG;
Ciict~
turned clockwise from its normal
position, turn both sleeves upward
(viewed from the rear). If the wheel
is turned counterclockwise, turn both
LEn-HAND SLEEVE RIGHT·HAND SLEEVE F1 037.a sleeves downward (viewed from the
FIG. 3-Spindle Connecting Rod Adiustments rear).
3. Tighten the sleeve clamp bolts
ing wheel hub by pressing downward clamp bolts to specification. To pre· to specified torque.
and turning the cap to the left. Make vent interference, both bolts should
TURNING ANGLE
sure the alignment mark on the hub be in a vertical position on the rear
of the steering wheel is lined up with side of the sleeve and the clamps The angular relationship of one
the mark on the end of the steering should not project beyond the front wheel to the other must change
shaft. The mark on the end of the ends of the sleeve. as the vehicle makes a turn. The
shaft indicates the high-point of the turning angle o( an outside wheel
steering gear. With the front wheels STEERING WHEEL SPOKE should be 17o 42' when the inside
straight-ahead, the alignment marks POSITION wheel is turned 20°. If the turning
should be vertical and the steering When the steering gear is on the angle does not check to these sped-
wheel spokes should be in their high-point, the front wheels should cations, crosswear of tires will result.
normal position. If repositioning is be in the straight-ahead position and Bent parts are generally the cause
required, refer to STEERING the steering wheel spokes should be of an incorrect turning angle.
WHEEL SPOKE POSITION ad- in their normal position. The marks
justment procedure which follows. on the end of the steering shaft and THEORETICAL KING PIN
3. To adjust toe-in, loosen the two on the hub of the steering wheel INCLINATION
clamps on each spindle connecting should also be lined up and in a Theoretical king pin inclination is
rod sleeve. Lengthen or shorten both vertical position. If necessary, the the tilt of the top of the spindle to-
spindle connecting . rods an equal spokes can be repositioned without ward the centerline of the car. King
amount to obtain the correct toe-in. changing the toe-in setting (Fig. 4) . pin inclination is merely a theoretical
Lengthening both rods increases toe- 1. Loosen the clamps on both value as the desired inclination is
in. Shortening both rods decreases spindle connecting rod sleeves (Fig. built into a car at the time of manu-
toe-in (Fig. 3). 3). facture and cannot be adjusted. Un-
4. Torque the adjusting sleeve 2. Turn both sleeves upward or less related parts are bent, the angle
will be 7o when the camber angle
WHEN TOE·IN IS CORRECT: TURN BOTH is positive 314 o.
TURN BOTH CONNECTING CONNECTING ROO
ROD SLEEVES UPWARD SLEEVES DOWNWARD
TO ADJUST SPOKE TO ADJUST SPOKE WHEEL INSPECTION
POSITION POSITION
Wheel hub nuts should be in-
spected and tightened to specifica-
tion during pre-delivery inspection.
Loose wheel hub nuts may cause
shimmy and vibration. Elongated
stud holes in the wheels may also re-
sult from loose hub nuts.
Keep the wheels and hubs clean.
Stones wedged between the wheel
and drum, and lumps of mud or
WHEN TOE-IN IS
grease can unbalance a wheel and
NOT CORRECT: ----l~~-__, tire.
LENGTHEN LEFT ROD TO SHORTEN LEFT ROO TO Check for damage that would
INCREASE TOE-IN DECREASE TOE-IN
affect the runout of the wheels.
SHORTEN RIGHT ROD TO LENGTHEN RIGHT ROD
DECREASE TOE-IN TO INCREASE TOE-IN
Wobble or shimmy caused by a
damaged wheel will eventually
ADJUST BOTH RODS EQUALLY TO MAINTAIN NORMAL $POKE POSITION damage the wheel bearings. Inspect
the wheel rims for dents that could
FIG. 4- Toe-In and Steering Wheel Spoke Alignment Adiustments permit air to leak from the tires.

FRONT END GENERAL alignment checks should be per- equipment, portable equipment may
INSPECTION formed on stationary wheel aligning be used and the work may be per-
Whenever possible, front wheel equipment. In, the absence of such formed on a level floor. The floor

(029) PART 3-1- SUSPENSION, STEERING, WHEELS AND TIRES GENERAL SERVICE 3-5
area should be level within 1;4 inch

from front to rear of the car and
within ~/s inch from side to side. It
might be well, if portable equipment
is used frequently, to mark off a
known level area on the shop floor.
Prior to checking or setting the
front wheel alignment, be sure all
front suspension and steering sys-
tem nuts and bolts are properly
torqued. It is especially important to POINT ON UNDERSIDE:
have the drag strut nut and the upper OF CROSSMEMBER
arm shaft bolts tightened to the POCKET
proper torque specification, as a loose

nut or bolt can directly affect the
caster or camber reading. The items
which follow also should be checked
and, if necessary, corrected before
aligning the wheels.
1. Be sure the tires arc inflated to
the proper pressure at all four wheels.
2. Be sure the front wheel bearings
are adjusted properly and that the
THRU
wheels turn freely. JOINT
3. Check the shock absorbers for
leaks. Replace the shock absorbers
if necessary.
4. Check for looseness at the tie-·
rod ends. Looseness can affect the F1217-A
toe-in readings and adjustment. To
inspect the front suspension for
looseness or wear, it will be necessary
FIG. 7-Front Suspension Riding Height Measurement
to raise the car.
5. Be sure the wheels are balanced. wheel tilts outward, camber is posi-
CAUTION: Do not raise the car
6. Check the runout of each front tive. If a wheel tilts inward, camber
by means of the lower suspension
wheel and tire using a dial indicator is negative (Fig. 6).
arms. This will release the tension
against the rim outer band. If the
on the lower ball joints. TOE-IN
runout exceeds 1/s inch, correction
may be made by rotating the wheel Toe-in is the turning inward of the
CHALK MARK IN THIS POSITION on the drum. When the minimum front wheels, so that they are closer
WHEN CHECKING TOE-IN AND TOE-OUT runout has been obtained, mark the together at the front than at the rear.
ON TURNS
point of greatest runout so the whee Is
BALL JOINT INSPECTION
can be positioned as shown in Fig.
5 when checking the front end align- LOWER ARM
ment. Hold a piece of chalk against 1. Raise the front of the car.
the wheel rim or the tire sidewall 2. Adjust wheel bearing to no
while spinning the wheel. The chalk end play (see Part 3-4 for bearing
will mark the rim or tire at the point adjustment procedure).
of greatest runout. 3. Attach a dial indicator to the
lower arm. Position the indicator
WHEEL ALIGNMENT
DEFINITIONS POSITIVE
An understanding of the factors
involved in wheel alignment is neces-
sary, before an accurate job of align-
_.!
I:
w CAMBER
NEGATIVE-, i
CASTER ~Lj
~POSITIVE
CASTER
ment can be performed.

3.~G OF TIRE ~:;;.----·
·~+ _ '
CHALK MARK IN THIS POSITION CASTER 1 •:, \

l.u*-~~-- . ~ .-~.)+ +-
WHEN CHECKING CASTER AND CAMBER 'l.i
I : ( \
Caster is the forward or rearward
~'1111 ...... \ ~.w;
LOCATION OF POINT OF GREATEST tilt of the top of the wheel spindle.
LATERAL RUN-OUT ON FRONT
WHEElS WHEN CHECKING If the spindle tilts to the rear, caster ~~ ,, ~ ~ ' ./
ALIGNMENT FACTORS is positive. If the spindle tilts to the

front, caster is negative (Fig. 6).
CAM~Ek FRONT OF
CAR
~
ANGLE
F1215-A F1216-A
CAMBER
FIG. 5-Front Wheel Camber is the amount the front FIG. 6-Caster and
Position for Che(king Alignment wht::els are tilted at the top. lf a Camber Angles

3-6 GROUP 3-SUSPENSION, STEERING, WHEELS AND TIRES {030)
2. Raise the front bumper at the

center about one inch and release
very slowly. Again measure and re-
DiMENSION D FROM AXLE HOUSING
TO SURFACE ON SIDE MEMBER cord the readings obtained on each
IMMEDIATELY BEHIND AXLE BUMPER. side of the car as in Step 1.
3. Average the two readings ob-
tained on each side of the car to
obtain the true riding height. The
difference between one side of the car
and the other should not be more
than Y2 inch.
REAR SUSPENSION
1. To measure the riding height,
push downward on the center of the
rear bumper about one inch and
release it slowly. Measure between
the points shown in Fig. 8.
2. Raise the rear bumper at the
center about one inch and release it
slowly. Again measure the riding
height. The average of the two meas-
urements is the true riding height.
The riding height specifications are
shown in Fig. 8.
F1218-A POWER STEERING PUMP

CLEANING AND INSPECTION
FIG. 8-Rear Suspension Riding Height Measurement
1. Wash all parts in clean solvent,
and dry them with clean cloths or
plunger on the wheel rim at the over several thousand miles usage due compressed air.
bottom of the tire. to mud deposits on the underbody. 2. Inspect the rotor shaft for wear,
4. Grasp the tire at the top and This weight increase can account for scoring, nicks, or burrs. Replace the
bottom, and slowly move the tire in a noticeable reduction in riding shaft if it is damaged or if the inner
and out, noting the reading on the height. Therefore, excessive accumu- keyway is damaged.
dial indicator. lations of mud should be removed
before checking the riding height. 3. I nspcct the rotor, rollers, and
5. If the reading exceeds 0.250 the cam ring for wear or scoring.
inch, replace the ball joint (refer to Before checking the front or rear 4. Make sure the inner faces of
Part 3-2, Section 2, for the replace- curb weight suspension riding height, the cover and the housing are free
ment procedure). perform the following steps: of paint, nicks, or burrs. Check all
UPPER ARl\'1 1. Position the vehicle on a smooth, oil passages for restrictions.
level floor. 5. Inspect the valving surfaces
Refer to Part 3-2, Section 2, for
the procedure required to disconnect 2. Inflate all tires to 24 psi. The (areas where the rotor and rollers
the ball joint from the spindle prior fuel tank should be full. Any loading contact) for wear or scoring. Replace
to checking ball joint stud rotating must be removed from the passen- the pressure plate or the cover if
torque. ger and luggage compartments. worn or scored. Inspect the bushing
in the pressure plate for wear or
RIDING HEIGHT MEASUREMENT
:t Place the front seat in its rear- scoring, and replace the plate if
most position. necessary.
In cases of vehicle riding height
complaints, accurate measurements 6. Inspect the control valve for
of the front and rear suspension wiil FRONT SUSPENSION scores, nicks, or burred edges. Re-
be necessary to determine which 1. Push the front bumper down- place the valve if damaged. Do not
-.pring should be replaced, if any. ward at the center about one inch. disassemble the valve. Check the
Some riding height variation between Release very slowly so that suspen- valve for free movement in the
similar models must be expected due sion friction stops the car. Measure housing bore.
to the weight of optional accessories. between the points shown in Fig. 7. 7. Inspect the tube seat in the
rn addition, a vehicle in customer Measure and record the reading ob- housing. If damaged, remove it with
usage can gain 100 or more pounds tained on each side of the car. an E-Z-Out and install a new scat.

(031) 3-7
PART SUSPENSION
Section Page
1 Description and Operation .................. 3-7
2 In-Car Adjustments and Repairs ............. 3-7
3-2 3 Removal and Installation ................... 3-9

4 Major Repair Operations .................. 3-13

FRONT SUSPENSION
The front wheel suspension is a
ball joint type utilizing coil springs
and double acting shock absorbers.
Fore and aft movement of each front
wheel is controlled by a non-adjust-
able type stabilizing strut (drag strut)
connected to the suspension lower
arm and to a point forward on the
number one crossmember (Fig. 1 ) .
A single rubber-cored bushing is used
at the inner end of the suspension
lower arm. Caster and camber are
adjusted without the use of shims.
Adjustment is accomplished by move-
ment of the serrated upper arm shaft.
REAR SUSPENSION
The major components of the rear F1219-A
suspension system are the leaf springs
which are mounted to the underbody FIG. 1-Front Suspension
(Hotchkiss Design) and the restrict-
ed, double-acting, telescopic-type mounting pads are provided for attached to the crossmember by a
shock absorbers (Fig. 2).
spring-to-axle alignment. mounting plate. The shock absorber
The springs are insulated from the
axle with rubber-lined clamps and The rear shock absorbers are the lower end is stud mounted to a
attached to the axle with U-bolts. direct-acting type which have an in- bracket welded to the forward side
Laterally slotted holes in the axle tegral stud at the upper end and are of the axle housing.

BALL JOINT REPLACEMENT 6. Place a jack under the spring nut to line up the cotter pin hole.
pocket in the lower arm, and raise Install the cotter pin.
The lower ball joint is riveted to
the arm slightly. Place a support 11. Install the brake backing plate,
the lower arm whereas the upper ball
stand under the lower arm as a safety and tighten the retaining nuts to
joint is bolted to the upper arm.
precaution. specified torque.
When replacing a ball joint, use all
the parts supplied in the kit. 7. Remove the nut from the ball 12. Install the hub and drum and
joint stud. Raise the upper arm and the wheel and tire. Torque the wheel
LOWER ARM spindle until the spindle clears the nuts to specification.
ball stud. Prop the upper arm in the 13. Adjust the wheel bearings, and
1. Raise the car. Place a support
raised position. lower the car.
under each rail to the rear of the
8. Remove the ball joint rivet
lower arm in the lifting pad area.
heads with a chisel. Punch the re- UPPER ARM
2. Remove the wheel and tire, then maining portion of the rivets from
remove the hub and drum. the holes, and remove joint. 1. Place a jack under the outer end
3. Remove the brake backing 9. Install' the new joint using 1the of the lower arm, and raise the arm.
plate, and wire it to the underbody parts supplied in the kit. Torque 1the Place a support stand under the side
to prevent damage to the brake hose. nuts to specification. Make sure the rail in the lifting pad area.
4. Remove the cotter pin from the joint is completely filled with the 2. Remove the wheel and tire.
lower ball stud, anc loosen the nut specified lubricant. 3. Remove the cotter pin from the
one to two turns. 10. Lower the upper arm while upper ball stud, and loosen the nut
5. Using a brass hammer, tap the guiding the spindle over the ball stud. one to two turns.
spindle until the ball stud pops loose Install the stud nut and tighten it to 4. Pry the arm upward and, using
against the nut. specification. Continue to tighten the a brass hammer, tap the spindle at

GROUP 3 -SUSPENSION, STEERING, WHEELS AND TIRES
INSULATOR
SPRING ASSEMBLY
BUSHING
RETAINER
f1220-A
FIG. . Components
2-Rear Suspension

(033) PART 3-2-SUSPENSION 3-9
the stud boss until the ball stud rotate the ball joint stud. If the specified lubricant.
loosens against the nut. Remove the torque is found to be less than 12 9. Guide the ball JOint stud into
nut. in-lbs, replace the ball joint. the spindle. Install the stud nut and
5. Raise the upper arm to free the 7. Remove the ball joint retaining torque it to specification. Continue
ball stud from the spindle. Wire the nuts and bolts, and remove the joint. to tighten the nut to line up the cot-
upper end of the spindle to the under- 8. Install the new joint using the ter pin hole. Install the cotter•pin.
body to prevent damage to the brake parts supplied in the kit. Torque the 10. Install the wheel and tire.
hose. nuts to specification. Make sure the Torque the wheel nuts to specifica-
6. Check the torque required to joint is completely filled with the tion.

FRONT WHEEL SPINDLE and nuts, and tighten to specifi<:a- the crossmember; otherwise, the
tions (Fig. 3). upper attachment could be loose
REMOVAL 4. Install the wheel, hub and and noisy.
·1. Raise the car. Place a support drum, and adjust the wheel bearing.
under each side rail to the rear of the 5. Lubricate the steering stop on FRONT SPRING AND
lower arm in the lifting pad area. the lower arm and the mating flat LOWER ARM
on the spindle with specified lubri-
2. Remove the wheel and tire, then cant. REMOVAL
remove the hub and drum. 6. Remove the safety stands, lower
3. Remove the brake backing the car and check camber, caster and 1. Raise the vehicle. Place a sup-
plate, and wire it to the underbody toe-in. port under each underbody side rail
to prevent damage to the brake hose. to the rear of the lower arm in the
lifting pad area. Refer to Fig. 3.
4. Disconnect the spindle arm con- FRONT SHOCK ABSORBER
2. Remove the wheel and tire as-
necting rod from the spindle arm REMOVAL sembly; then, remove the hub and
with tool 3290-C. See Fig. 3, drum.
5. Remove the cotter pins from 1.. Remove the stud nut at the upper 3. Loosen the brake backing plate
both ball joint stud nuts. Loosen the eye of the shock absorber. Remove to provide clearance at the end of
nuts one to two turns. the upper eye stud bracket to cross- the arm when it is lowered.
member retaining bolt and remove 4. Remove the shock absorber.
6. Using a brass hammer. tap the the stud bracket. Refer to Fig. 3.
spindle at the lower ball joint until 5. Disconnect the stabilizing strut
2 . Remove the bolts which retain (drag strut) from the lower arm.
the ball stud pops loose against the
the shock absorber to the suspension 6. Disconnect the stabilizer bar
nut. Pry upward on the upper arm,
lower arm. Lower, and remove the from the suspension arm.
and tap the spindle at the upper ball
shock absorber. 7. Remove the cotter pin from the
joint until the ball stud loosens 3.. Examine the shock absorber
against the nut. slotted nut attaching the lower ball
unit and rubber bushings. Replace joint to the end of the spindle boss.
7. Place a jack under the outer parts that are defective, deteriorate~d, Loosen the nut one to two turns.
end of the lower arm, and raise the or worn. 8. Using a brass hammer, tap the
arm several inches. Remove both
spindle until the ball stud pops loose
ball stud nuts, and remove the INSTALLATION against the nut.
spindle.
9. Place a jack under the outer
1. Fully extend the shock absorber
end of the lower arm and raise the
and position it inside the coil spring.
INSTALLATION arm several inches.
Connect the lower end of the shock
10. Install the spring compressor
1. Position the new spindle onto absorber to the suspension lower arm.
tool 5310-A (Fig. 4) inside the
the upper and lower ball joint studs, Torque the retaining nuts to specifi-
spring with the jaws of the tool to-
install the stud nuts and tighten the cation.
ward the center of the car.
nuts to specifications. Continue to 2. Insert the upper bracket stud
11. Remove the nut from the ball
tighten both nuts until the cotter through the bushing in the shock joint stud. Lower the jack until the
pin holes line up with the slots, then absorber upper eye. Install the stud
spindle and spring are free, and
install new cotter pins. bracket to crossmember retaining
remove the spring and insulators.
bolt. Do not tighten the bolt at this
2. Connect the spindle connecting 12. Remove the lower arm to
time.
rod to the spindle arm. Install the crossmember nut, bolt, washers, and
3. Install the upper eye bracket
retaining nut and tighten the nui spacer, then remove the arm.
stud nut. Torque the nut to specifi-
to specification. Continue to tighten cation.
the nut until the cotter pin hole lines INSTALLATION
4. Torque the stud bracket to
up with the slot, then install a new
crossmember retaining holt to specitfi- 1. Connect the inner end of the
cotter pin.
cation. The shock absorber upper lower arm to the underbody cross-
3. Assemble the brake carrier eye stud nut must be tightened to member. Do not tighten the retain-
plate, gaskets and dust shield to the compress the rubber bushing ing nut at this time. Refer to Fig.
spindle. Install the retaining holt.;; before the stud bracket is bolted to 3.

3-10 GROUP 3-SUSPENSION, STEERING, WHEELS AND TIRES (03~)
SHOCK ABSORBER
STABILIZER BAR
WA:::-ifNSUL~
INSULATOR;
I
INSULATOR
WASHER
\
\ SPACER
WASHER
SCREW--4
F1221-A
FIG. 9-Front Suspension Components

2. Place a jack under the outer end cotter pin hole. Install a new cotter
of the arm. pin.
3. Tape the upper and lower spring 4. Install the wheel and tire, and
insulators to the spring. torque the wheel nuts to specification.
4. Compress the coil spring with 5. With the front end weight of the
tool 5310-A (Fig. 4) and place the car on the wheels, torque the bolts at
spring and insulators in position. Be the ends of the upper arm shaft to
sure both ends of the spring are specification if the bushings were
properly seated, and raise the arm. f1222-A replaced.
Guide the spindle boss over the ball 6. Check the front wheel align-
joint stud. FIG. 4-Coil Spring ment.
5. Install the ball joint stud retain- Compressed for Installation REAR SHOCK ABSORBER
ing nut and torque it to specification.
Continue tightening the nut to line REMOVAL
up the cotter pin hole. Install a new INSTALLATION 1. Lift the car and place support
cotter pin. stands under the axle housing. Posi-
1. Position the upper arm shaft on
6. Connect the stabilizer bar to the tion the car with a hoist to relieve
the underbody member. Line up 1the
lower arm. Torque the nut to speci- tension on the shock absorbers.
shaft with the marks made before
fication. 2. Remove the screws that retain
removal of the arm.
7. Connect the drag strut to the the shock absorber mGUnting plate
lower arm. Torque the nuts to speci- 2. Install the retaining bolts and to the crossmember (Fig. 6).
fication. lock washers. Fabricate a tool as 3. Remove the retaining nut and
8. Install the shock absorber. shown in Fig. 5 to hold the nut in washers from the lower end of the
place while starting the retaining shock absorber.
9. Tighten the brake backing plate
bolt into the nut. Remove the tool, 4. Remove the shock absorber.
retaining nuts to specification.
then tighten the retaining bolts to 5. Remove the nut, outer washer,
10. Install the hub and drum, and
specification. and insulator that retain the shock
the wheel and tire assembly. Torque
the wheel nuts to specification. Ad- 3. Guide the ball joint stud into 1the absorber to the mounting plate; then
just the wheel bearings. Remove the spindle. Install the retaining nut and remove the plate.
support stands. torque it to specification. Continue 6. Inspect the shock absorber for
tightening the nut to line up the damage or leaks. If the bushing must
11. With the front end weight of
the car on the wheels, torque the
lower arm to crossmember bolt re-
taining nut to specification.
UPPER ARM
REMOVAL
1. Place a jack under the outer
end of the suspension lower arm and J; 16" GAUGE -
raise the arm. Refer to Fig. 3. STEEl !REFERENCE)
3"
i2. Remove the wheel and tire as-
sembly.
3. Remove the cotter pin from the
upper ball joint stud. Loosen the nut
one or two turns. Pry upward on the
upper arm and, using a brass ham-
mer, tap the spindle at the stud boss
until the ball joint stud loosens
against the nut. Remove the nut.
4. Raise the upper arm to free the
ball joint stud from the spindle. Wire
the upper end of the spindle to the
underbody to prevent damage to
the brake hose.
5. Mark the position of the upper
arm shaft on the underbody member
to facilitate making caster and cam-
ber adjustments after installation of
the upper arm.
6. Remove the suspension upper
arm-to-underbody retaining bolts, F1223-A
lock washers, and retaining nuts.
Then remove the upper arm. FIG. S-Upper Arm Shaft Installation Tool

stands under the sidemembers on

LOCK NUT the rear of each rear spring hanger.
2. Lower the rear axle slightly to
reduce some of the spring load; then,
remove the spring U-bolts.
3. Remove the nut and front
mounting bolt. Refer to Fig. 2.
4. Remove the rear shackle nuts
q -~~MOUNTING PLATE
and mounting plate. Remove the
lower, inner insulator. Remove the
spring. If the rear shackle insula-
~INSULATOR tors are to be replaced, it will be
necessary to remove the rear
WELDED NUT , hanger assembly. (Hanger attach-
~
ing bolts must be torqued to speci-
fication when reinstalled.)
SCREW ~
RETAINING-._ ...... .
5. Remove the insulators from the
spring.
6. Examine all parts for· wear or
SHOCK ABSORBER damage. Note the condition of the
spring center bolt.
7. The spring center bolt can be
replaced by clamping the spring in a
vise, thus keeping the spring com-
pressed during bolt removal and in-
stallation.
INSTALLATION
LOCK WASHER
1. Install the spring to the rear
shackle assembly with the insulators
F1224-A in position. Do not tighten the nuts
at this time. Refer to Fig. 2.
FIG. 6-Reor Shock Absorber Mounting 2. Attach the spring to the front
hanger with the insulators in posi-
be replaced, the operation may be LOWER MOUNTING STUD tion. Do not tighten the nut at
performed without the use of special REPLACEMENT this time.
tools. Wet the rubber bushing with 3. Place the insulator and retainers
brake fluid and press it into the If the shock absorber mounting in position on the spring.
shock absorber eye by hand. Re- stud is damaged, replace the stud as 4. Lower the axle housing onto the
place the insulators if they appear follows:
insulator and retainer assembly.
worn or damaged. 1. Cut off the old stud as close to
CAUTION: If a wedge was
the bracket as possible.
located between the upper retain-
2. Grind off the weld at both ends
er and mounting pad, reinstall the
INSTALLATION of the stud and bracket face.
same thickness wedge with the
3. Drive out the balance of the
1. Place the inner washer and in- taper in the original direction.
stud with a brass drift. Do not en-
sulator on the upper (stud) end of Raise the axle until the spring is
enlarge the hole in the bracket.
the shock absorber (Fig. 6). approximately horizontal with the
4. Remove any weld remaining on
2. Install 'the mounting plate, outer the sides of the bracket.
floor.
insulator, washer and nut on the 5. Attach the service stud to the 5. Install the lower insulator re-
stud. Torque the nut to specification. axle housing bracket with a nut. tainer and U-bolts. Do not tighten
3. Attach the mounting plate and Torque the nut to specification. the U-bolt nuts at this time. Torque
shock absorber to the crossmcmber the rear shackle nuts to specification.
6. Stake the nut to prevent loosen-
with the retammg screws and ing. 6. Torque the front shackle nut to
washers. Torque the screws to speci- specification.
fication. 7. Tighten the U-bolt nuts evenly
4. Connect the lower end of the REAR SPRING to the specified torque.
shock absorber to the mounting stud REMOVAL 8. Make sure the lower insulator
with the washers and retaining nut. retainer contacts the upper re-
Torque the nut to specification. 1. Raise the car and place support tainer.


LOWER ARM OVERHAUL-
ARM REMOVED
Inspect the lower arm, bushings
and pivot bolt for cracks, bends,
wear or other damage. Replace the
arm if necessary.
Install the nut on the ball joint
stud, and turn the stud in the ball
joint with a torque wrench to check
rotating torque. If the turning effort
is not within specifications, replace
the ball joint.
Note: Do not wash the ball joint
with solvent. The solvent may at-
tack parts within the joint.
FIG. 10-Removing
BALL JOINT REPLACEMENT
Upper Arm Rear Bushing
See Section 2 for the complete in-
car ball joint replacement procedure. Note: Do not wash the ball joint
Refer to Section 3 for the lower with solvent. The solvent may
arm removal procedure. FIG. 8-lnstalling attack parts within the joint.
1. To remove the ball joint, if it Lower Arm Bushing
requires replacement, remove the BBSHING AND INNER SHAFT
rivet heads with a chisel. Punch the REPLACEMENT
instal! the new joint using the parts
remaining portion of the rivets from 'Wpplicd in the hall joint kit. Torque Always replace both upper arm
the holes. the nuts to specification. Make sure bushings, if either bushing is worn
2. Press the bushings out of the the joint is completely filled with the or damaged. Install only new bush-
arm with tool 3069--dctails H, AA, ~pccil1ed lubricant. ings when replacing the inner shaft.
and AA2 (Fig. 7). Refer to Section 3 for the upper
3. Apply silicone or liquid soap to UPPER ARM OVERHAUL- arm removal procedure.
the shell of the new hushing. Place ARM REMOVED 1. Remove the bolts, lockwashers,
the bushing in the arm with the ln~pe<.:t the upper arm and the and cup washers from the ends of the
flange end (large end) of the hush- inner shaft for cracks, bends or upper arm shaft.
ing at the front of the arm. nthcr damage. Replace the parts as 2. Assemble the remover, tool
4. Press the hushing into the arm r-equired. 3044-LA, to the shaft at the front
until the shoulder on the bushing Replacement arms come with th~ hushing. Press the bushing out of
shell seats against the arm. Use tool bushings, inner shaft, and ball joint the arm using the support cup, tool
3069-details H, AA2, and M5 (Fig. installed. If the original arm is to 3069-H, and the remover tool 3044-
8). he used, these components should AB3 (fig. 9).
5. Tf the hall joint was removed, be replaced on the bench. 3. Remove the shaft and rear
bushing inner cup \Vasher.
4. Remove the upper arm rear
bushing using the support cup, tool
3069-H, and the remover, tool 3069-
L (Fig. 10).
Toof-3069-H
F1225-A F1229-A
FIG. 7-Removing FIG.9-Removing Upper FIG. 11-Upper Arm,

Lower Arm Bushing Arm Front Bushing Shaft, and Bushing Assembly

the front end weight of the car is

on the wheels.
CAUTION: These bolts are made
of a special material. Use only the
specified bolt if replacement is
necessary.
BALL JOINT REPLACEMENT

Check the ball joint stud rotating
torque as detailed in Section 2. If
the turning effort is not within speci-
fications, or the ball joint shows
signs of wear or damage; then fol-
low the ball joint replacement proce-
FIG. 12-lnstalling dure as outlined in Section 2. FIG. 13-lnstalling
Upper Arm Rear Bushing Upper Arm Front Bushing
REAR SPRING OVERHAUL-
5. Both upper arm bushings are SPRING REMOVED place parts where necessary (Fig. 2).
pressed into the arm from the out- FRONT HANGER ASSEMBLY If the rear shackle bushings are
side toward the inside of the arm. To to be replaced, it will be necessary
facilitate installation, use silicone or If the front hanger or bushings are to remove the rear hanger assem-
liquid soap as a lubricant. See Fig. to be replaced, proceed as follows. bly. Torque the hanger attaching
11 for proper assembly of the shaft 1. Remove the nut and lock washer bolts to specification when re-
and bushings. from the spring front mounting bolt installed.
6. Press the upper arm rear bush- (Fig. 2).
ing into the arm using the support 2. Tap the spring mounting bolt SPRING LEAVES AND
cup, tool 3069-H, and the replacer, out of the bushing and hanger, then TIE-BOLT
tool 3068 (Fig. 12). Press the bush- separate the hanger from the spring.
ing in until the shoulder stop is Remove the bushings. Check for broken spring leaves.
reached. 3. Position the bushings in the Inspect the anti-squeak inserts be-
7. With the rear bushing cup front eye of the spring. Assemble tween the leaves, and replace them
washer on the shaft, insert the end the front hanger to the spring eye if they are worn. The spring leaves
of the shaft into the rear bushing. an-d install the spring mounting bolt must be dry and free of oil and
Press the front bushing onto the shaft through the hanger, bushings, and dirt before new inserts are in-
and into the arm using the replacer, spring eye as shown in Fig. 2. stalled.
tool 3068 (Fig. 13). Bottom the 4. Install the lockwasher and nut Inspect the spring clips for worn
bushing flange against the flange in on the mounting bolt and tighten to or damaged threads (Fig. 2). Check
the arm. the specified torque. the spring dip plate and insulator
8. Install the cup washers, lock- retainers for distortion.
washers, and bolts at the ends of If the spring center tie-bolt re-
REAR SHACKLE AND
the upper arm shaft. Do not tighten quires replacement, clamp the spring
HANGER ASSEMBLY
the bolts at this time. These must in a vise to keep the spring com-
be tightened after the arm assem- Inspect the rear shackle, bushings, pressed during bolt remo-..al and
bly has been installed, and when and studs for wear or damage. Re- installation.

(039) 3-15
PART STEERING
Section
1
2
Page
Description and Operation ................. 3-15
In-Car Adjustments and Repairs ............ 3-17
3-3 3
4
Removal and Installation .................. 3-20
Major Repair Operations .................. 3-21
II DESCRIPTION AND OPERATION
HYDRO-WIPE
ASSEMBLY
---r-i
EAR
FIG. 1-Power Steering System G1198-A
POWER STEERING SYSTEM obtains its operating oil pressure The power cylinder is an integral
The power steering system includes f;·u;n the rpw,:· steering hydraulic part of the gear housing. This piston
the crankshaft-driven pump, the tor- ·;v<-.tc-ln. is double acting, in that fluid pres-
sion bar type steering gear, a fluid sure may be applied to either side of
reservoir, pressure and return lines, TORSION BAR STEERING GEAR the piston. The one-piece piston and
and the steering linkage (Fig. 1). power rack is meshed to the sector
The power steering unit is a
The basic pump consists of a hous- shaft.
torsion-bar type of hydraulic assisH~d
ing and cover, a rotor and rollers system. This system furnishes power The operation of the hydraulic
wHich rotate within a cam ring, and to reduce the amount of turning control valve is governed by the
a pressure plate. A flow control valve effort required at the steering wheel. twisting of .a torsion bar. All effort
in the pump housing governs the flow It also reduces road shock and vibra- applied to the steering wheel is trans-
of fluid. Maximum pump pressure is tions. mitted directly through the torsion
controlled by a relief valve inside
The torsion bar power steering bar to the ball nut and worm assem-
the flow control valve.
unit includes a rack and piston, and bly. Any resistance to the turning of
The major details of the power a worm and ball nut assembly which the front wheels results in twisting
steering gear are the sector shaft, is meshed to the gear on the steering of the bar. The twisting of the bar
ball nut and worm shaft, torsion bar sector shaft. The unit also includes increases as the front wheel turning
and control valve, and the power a hydraulic valve, valve sleeve, and effort increases. The control valve
cylinder and piston. These details all torsion bar assembly which are spool, actuated by the twisting of
are contained within a one-piece mounted on the end of the worm the torsion bar, directs fluid to the
housing. shaft and operated by the twisting side of the piston where hydraulic
The movement of the control valve action of the torsion bar. assist is required.
depends upon the twisting of the The torsion-bar type of power The lower end of the torsion bar
torsion bar. The resistance of the steering gear is designed with all is splined to the lower end of the
front wheels to being turned governs components in one housing (Fig. 2). inside diameter of the worm shaft.
the amount of torsion bar twist. As This makes possible internal fluid The upper end of the worm shaft is
the torsion bar twiqs, the control passages between the valve and cyl- coarsely splined to the inside diam-
valve moves to direct fluid under inder. thus eliminating all external eter of the torsion bar and input
pressure in the side of the piston lines and hoses, except the pressure shaft assembly upper end. This
which requires power assist. and return hoses hetween the pump spline fit is sufficiently loose so that
The windshield wiper svstcrn and gear assembly. the upper end of the torsion har

HORN GROUND WIRE STRAIGHT -AHEAD POSITION

CONNECTION
When the power unit is not assist-
ing in the steering effort, the valve
spool is in the neutral (straight-
ahead) position (Fig. 4). The fluid
flows from the pump, through the
open-center valve, and returns to the
pump through the worm bearing.
Therefore, no area of the valve spool
or steering gear is under high pres-
sure in this position. The amount of
pressure in neutral position is ap-
proximately 30 psi at normal opera-
ting temperatures.
The pump has no influence on the
valve spool, but the spool, housing,
and power cylinder are full of fluid
at all times when the pump- operates.
RIGHT TURN
When the steering wheel is turned
to the right, the ball nut on the worm
resists being turned due to load on
the sector shaft from the front end
weight of the vehicle. Thus the tor-
sion bar will start to twist (Fig. 4).
For a right turn the valve spool
moves up, allowing fluid from the
SECTOR--- pump to enter against the upper side
SHAFT of the power piston. The fluid on the
lower side of the piston is free to
return through the valve to the pump.
G1087-B Therefore, the power assist is to the
upper side of the piston, pushing it
FIG. 2-Power Steering Gear downward and providing assist in
turning of the sector shaft.
and input shaft assembly can twist
in the actuator, and thus move it
up and down. This movement results
from a short length of helical splines
on the inside diameter of the actua-
tor which engage the outside diam-
eter of the input shaft. The actuator
is held in the spool by a snap ring.
Therefore, as the torsion bar twists,
its radial motion is transferred into
axial motion hy helical threads. Thus,
the valve spool is moved off center,
and fluid is directed to one side of
the piston or the other (Fig. 3).
The restricting of the fluid flow
to one side of the piston increases
the fluid pressure proportionately to
the reaction of turning the front
wheels.
The resistance of the torsion har
gives the driver a feel of the road
at all times. The more •he torsion
bar twists, the greater the feel of
the road and at the same time the
driver is receiving a greater power
assist in steering. FIG. 3- Valve Detail

(041) PART 3-3-STEERING 3-17
LEFT TURN STRAIGHT RIGHT TURN

G1114-B
FIG. 4-Power Flows
LEFT TURN PUMP

If the steering wheel is turned to The roller-type hydraulic pump,
the left, it will cause a similar action driven by the crankshaft, draws auto-
but in the opposite direction (Fig. matic transmission fluid from the
4). The torsion bar twists to the left reservoir and provides fluid pressure
moving the valve spool downward, for the system. Steering gear lubri-
allowing fluid from the pump to cation is also provided by the same
SERIAL NUMBER fluid from the reservoir. Within the
enter against the lower side of the OR DATE CODE pump itself is a flow-control and
power piston. The fluid on the upper
pressure-relief valve which governs
side of the piston is free to return the pressures within the steering sys-
through the valve to the pump.
Therefore, the power assist is to the
FIG. 5-Steering Gear tem according to the varying condi-
Identification Tag tions of operation. After fluid has
lower side of the piston, pushing it passed from the gear, it returns to
upward. The instant the driver stops the reservoir.
applying steering effort to the steer- spool returning to neutral position, An identification tag is attached to
ing wheel the valve spool is returned the torsion bar straightening also machined pad on top of the steering
to its neutral position by the unwind- helps to return the wheels to the gear housing (Fig. 5) with a self-
ing of the tbrsion bar. \Vith the valve <>traight-ahead position. tapping screw.

STEERING WHEEL SPOKE STEERING COLUMN UPPER
POSITION BEARING REPLACEMENT
See Part 3-1, Section 2, for this
adjustment.
REMOVAL
1. Disconnect the battery ground
STEERING WHEEL REPLACEMENT cable.
1. Remove the hub cap from the 2. Loosen the Allen head screw
steering wheel. that secures the flexible coupling to
2. Remove the steering wheel nut, the steering shaft.
and then remove the steering wheel 3. Remove the steering wheel.
as shown in Fig. 6. 4. Remove the turn signal lever
3. Transfer all serviceable parts from the column.
to the new steering wheel. 5. Remove the horn wire and turn
4. Position the steering wheel on FIG. 6-Removing G1199-A, signal switch attaching screws (Fig.
the shaft so that the alignment mark Steering Wheel 7). Lift the switch and horn wire
on the hub of the wheel is adjacent from the flange and place them to
to the one on the shaft. Install and the nut securely. one side.
torque the nut to specification. Stake 5. Install the hub cap. 6. Remove the upper bearing re-

STEERING SHAFT
NEUTRAL SWITCH AND LEVER
FIG. 7-Steering Column and Selector Lever Tube Details G1200-A
tainer attaching screws and remove 10. Connect the battery ground 3. Remove the cap from the steer-
the retainer. cable. ing wheel hub. Press downward on
7. Install the steering wheel at- 11. Check the turn signal operation the cap and turn counterclockwise.
taching nut on the steering shaft. and the horn. Remove the steering wheel as shown
8. Grasp the nut and pull the in Fig. 6.
shaft from the column. STEERING COLUMN AND 4. Disconnect the wires at the
9. Remove the upper bearing snap SELECTOR TUBE REPLACEMENT steering column. Remove the screws
ring and pull the bearing off the shaft. REMOVAL that hold the wire access cover to
10. Remove the rubber insulator 1. Disconnect the battery. the underside of the column. Slide
from the bearing. 2. Disconnect the rod from the the cover toward the steering wheel
lever at the lower end of the selector to remove it (Fig. 7) .
INSTALLATION 5. Remove the screws that hold the
tube. Loosen the clamp bolt that
1. Pack the bearing with Lubri- locks the flexible coupling to the column cover plate to the dash panel.
plate. steering shaft. 6. Remove the column-to-instru-
2. Install the rubber insulator on ment panel bracket clamp. Remove
the bearing (Fig. 7). the column.
3. Install the bearing and upper
snap ring on the shaft. INSTALLATION
4. Position the shaft and bearing
in the column making sure that the 1. Position the steering column.
flat on the lower end of the shaft Install the column-to-instrument
enters the flex coupling. panel bracket clamp.
5. Position the bearing retainer on 2. Fasten the column. cover plate
the flange and secure it with the to the dash panel.
attaching screws. 3. Connect the wires at the steer-
6. Secure the turn signal switch ing column. Install the wire access
and the horn wire to the flange. cover.
7. Install the turn signAl lever. 4. Align the steering shaft and
8. Install the steering wheel. steering wheel hub index marks and
9. Secure the steering shaft to the install the steering wheel. Torque
flex coupling with the Allen head FIG. 8-Pressing Out G1201-A the retaining nut to specification and
screw. Ball Stud stake securely.

GROUND WIRE ~
ATTACHING SCREW-·,l
SLEEVE ALIGNMENT _J.;=:--LOCKWASHER

BOLT t
IDLER ARM
AND
BRACKET ASSEMBLY
~CLAMP BOLT {2)
GEAR ASSEMBLY
'i~r=-.=~
•I
,, :: 5~
.. ~ '~:.~~~~
SPINDLt ARM
/'"
STEERING GEAR
CONNECTI~IG ROD MOUNTING BOLT
Gl 161-B
FIG. 9-Components of Steering Linkage

5. Install the steering wheel hub INSTALLATION turn the steering wheel in both di-
cap. rections as required to discharge the
l. Install the seal over the ball stud fluid from the gear.
6. Connect the shift rod to the of the center link, then assemble the
lever at the lower end of the selector 3. Working from under the car,
connecting link to the idler arm and
tube. disconnect the Pitman arm from the
torque the ball stud retaining nut to
7. Tighten the clamp bolt which steering gear.
specification. Install the cotter pin.
locks the flexible coupling to the 4. Remove the hub cap from the
2. Install new ball stud seals and
steering shaft. steering wheel. ·
assemble the connecting rod ball
8. Connect the battery. studs to the spindles. Torque the stud 5. Attach an inch-lb torque wrench
retaining nuts to specification and to the steering wheel attaching nut
install the cotter pins. (Fig. 10).
STEERING LINKAGE 6. Measure the force required to
3. Attach the idler arm bracket
R~PLACEMENT to the body sidemember with the move the worm shaft approximately
mounting bolts and tighten the nuts 20° away from the stop.
REMOVAL to the specified torque. 7. If reading is not within 6-8 in-
4. Jnstall the connecting link ball lbs, loosen the adjuster lock nut and
1. Remove the cotter pins and
stud seal on the ball stud, then as- turn the bearing adjuster to obtain
nuts from the ball studs in the spindle
semble the connecting link ball stud the proper reading. Tighten the lock
arms and the steering gear (Pitman)
to the steering arm. Torque the stud nut, making sure the adjuster does
arm. Install the thread protector on
retaining nut to specification and in- not turn. Re-check pre-load.
the ball stud as shown in the inset in
Fig. 8. Install the remover detail stall the cotter pin.
making sure the end of the slot in 5. Make certain all the ball joints
the tool is against the ball stud. Press are full of lubricant.
the ball stud from the arm. Because 6. Check toe-in and steering wheel
of the special design of the ball spoke position.
stud seals, a wedge type ball stud
separator must not be used. STEERING GEAR
2. Remove the nuts and bolts Worm Bearing Preload and
that attach the idler arm bracket to St~ctor Mesh Adjustment.
the sidemember, and remove the 1. Remove the fluid from the
linkage. power steering reservoir with a
3. To disassemble the linkage use suction gun.
tool 3290-C to press the ball stud 2. Disconnect the fluid return line
out of the steering connecting link from the reservoir. Place the end FIG. 10-Checking G1202-A
and the idler arm (Fig. 9). of the return line in a container and Steering Gear Pre-load

3-20 GROUP 3-SUSPEN,SION, STEERING, WHEELS AND TIRES (044)
9. Rotate the steering gear to the AIR BLEEDING

left stop. Using an inch-pound torque
wrench, back it off at a constant pull, Air in the system (shown by
reading the torque at exact mechani- bubbles in the fluid) should be
cal center. purged. Furthermore, the power steer-
Rotate the gear to the right stop ing system should be purged after
and take the reading in the opposite any part of it has been opened to the
direction. atmosphere or disconnected for repair
If two slightly different readings or replacement.
are obtained, the larger should be 1. Run the engine at idle speed.
recorded as total on-center meshload. Check the fluid level in the pump
10. If total over-center meshload reservoir. If necessary, add the speci-
is not within 15-17 in-lbs, loosen the fied automatic transmission fluid to
sector adjuster lock nut (Fig. 11)
bring the level to the "F" mark on
and turn the adjuster screw to obtain
proper adjustment. the dipstick.
FIG. 11-Pre-load and NOTE: ¥1.6 turn of the adjuster will 2. Turn on the windshield wipers.
Mesh Load Adiustments increase the meshload approximately Rotate the steering wheel from stop
8. Locate the mechanical center 2 in-lbs. to stop several times to bleed the
of the steering gear by rotating the Tighten the adjuster lock nut mak- air from the system. Do not hold the
steering wheel right or left to the ing sure the adjusting screw does not wheels against the stops. Recheck
stop, then back it off 13.4 turns. turn. Re-check the meshload. the fluid level in the reservoir.
EJ REMOVAL AND INSTALLATION

STEERING GEAR pressure and the return line to the
steering gear.
REMOVAL 9. Connect the horn ground wire
1. Disconnect the pressure line to the sleeve alignment bolt. Install
and the return line from the steering and torque the flexible coupling re-
gear housing. Plug the openings and taining bolt to specification.
cap the lines. 10. Fill the fluid reservoir and start
2. Disconnect the horn ground the engine. Cycle the steering wheel,
wire from the sleeve alignment bolt. with the windshield wipers operating,
Remove the bolt that secures the and check for oil leaks. Do not hold
flexible coupling to the steering gear the wheels against their stops and
worm shaft (Fig. 9). cause the fluid to overheat.
3. Raise the car. Remove the trans- 11. If the gear has been over-
mission linkage splash shield. hauled, adjust the position of valve
4. Remove the exhaust manifold to spool as detailed in "Assembly of
resonator pipe, and remove the front FIG. 12-Removing G1204-A Steering Gear," Section 4.
end crossmember. Pitman Arm
5. Remove the Pitman arm from PUMP RESERVOIR-WITHOOT
the sector shaft as shown in Fig. 12. AIR CONDITIONING
6. Remove the transmission link- 2. Center the gear by turning the
age rods from the equalizer shaft. worm shaft to either stop, then, turn REMOVAL
Force the shaft outward. This corn- it back approximately two turns. 1. Remove the reservoir cover and
presses a spring within the shaft 3. Center the steering wheel and gasket. Withdraw the fluid with a
which frees it from the inner ball insert the input shaft in the flexible suction gun.
joint. coupling. Secure the steering gear 2. Remove the reservoir bracket
7. Loosen (or remove) the retain- to the body member with the at- to cylinder block upper cap screw
ing bolts at the lower edge of the taching bolts. Torque the bolts to and the lower cap screw and spacer.
fender splash shield to obtain clear- specification. 3. Disconnect the reservoir inlet
ance; then remove the gear housing- 4. Position the Pitman arm on the line and the outlet line at the reser-
to-body member mounting bolts. sector shaft and secure it with a lock voir, and remove the reservoir.
8. Pull the steering gear from the washer and nut. Torque the nut to
specification. INSTALLATION
flexible coupling.
5. Position the equalizer shaft and 1. Connect the reservoir to pump
install the transmission linkage rods. line (outlet line) at the reservoir,
INSTALLATION 6. Install the manifold-to-resonator but do not tighten the clamp.
1. If a new gear is being installed, pipe. 2. Attach the reservoir and hracket
transfer the insulators from the old 7. Attach the front crossmember to the cylinder block with the upper
gear to the new one. if they are in a and the splash shield lower edge. cap screw and the lower cap screw
serviceable condition. 8. Lower the car. Connect the and spacer. Tighten the cap screws.

3. Tighten the outlet line clamp at INSTALLATION drive key.

the reservoir. Connect the reservoir 1. Position the reservoir in the 7. Disconnect the pump inlet line
inlet line to the reservoir. engine compartment. Loosely attach at the pump, and plug the end of
4. Fill the reservoir with the speci- the reservoir and bracket to the cyl- the line to prevent the loss of fluid.
fied automatic transmission fluid. inder block with the upper cap screw. DisconneCt the pump pressure line
Run the engine, and bleed the svs- 2. Install the fan shroud, then at the pump.
tem by cycling the steering g~ar raise the front of the car. 8. Remove the pump to engine
with the windshield wipers turned ~1. Connect the reservoir to pump front cover cap screws, and remove
on. Check for leaks, and recheck the line (outlet line) at the reservoir. the pump. Remove the seal from the
fluid level. 4. Install the reservoir bracket to front cover.
cylinder block lower cap screw and
PUMP RESERVOIR-WITH AIR spacer. Tighten both the upper and INSTALLATION
CONDITIONING the lower cap screws. 1. Install a new seal on the engine
5. Connect the reservoir inlet line front cover.
REMOVAL at the reservoir. Install the clamps 2. Align the slot in the pump rotor
1. Raise the front of the car. Re- on both lines. Lower the car, and shaft with the drive key in the crank-
move the reservoir to pump line install the reservoir cover and retain- shaft, and slide the pump onto the
(outlet line) clamp at the reservoir, ing nut. shaft. Install the pump to engine
but do not disconnect the line at 6. Fill the reservoir with the spec:i- front cover cap screws. Torque the
this time. fied automatic transmission fluid. cap screws to specification.
2. Disconnect the reservoir inlet Run the engine, and bleed the sys- 3. Connect the pump inlet line and
line at the reservoir. tem by cycling the steering gear with the pressure line.
the windshield wipers turned on. 4. Install the damper drive key,
3. Remove the reservoir bracket
Check for leaks, and recheck the damper, washer and bolt. Torque
to the cylinder block upper cap
fluid level. the bolt to specification.
screw. Support the reservoir and
5. Install the fan, pulley, and
remove the lower cap screw and POWER STEERING PUMP spacer. Install the generator drive
spacer. REMOVAL belts. Adjust the belt tension, and
4. \Vith a drain pan under the 1. Open the hood, and install tighten the adjusting and support
reservoir, disconnect the outlet line fender covers. bracket bolts.
hose from the reservoir tube and 2. If the car is equipped with air 6. If the car is equipped with air
allow the fluid to drain. conditioning, loosen the compressor conditioning, install the compressor
5. Remove the reservoir cover readjusting and support bracket bolits drive belt. Adjust the belt tension,
taining nut and the cover. Position and remm'e the drive belt. and tighten the adjusting and support
the cover and the reservoir out of 3. Loosen the generator adjusting bracket bolts.
the way and allow them to rest in and support bracket bolts, and re- 7. Run the engine at idle speed,
the engine compartment. move the drive belts. and check the fluid level in the reser-
6. Lower the front of the car. Re- 4. Remove the fan, pulley, and voir. If required, add the specified
move the fan shroud. spacer. automatic transmission fluid. Turn
7. Remove the reservoir and the 5. Raise the car. on the windshield wipers. Rotate the
cover by manipulating them through 6. Remove the crankshaft damper steering wheel from stop to stop
the opening between the radiator and bolt and washer. Remove the damper several times to bleed the air from
the compressor drive belt. with tool 6306-AG. Remove the the system. Recheck the fluid level.
a MAJOR REPAIR OPERATIONS

STEERING GEAR DISASSEMBLY piston rack as follows:
Use only parts specified for the a. Position a dial indicator against
Lincoln steering gear. the piston. Locate the dial in-
1. Drain the hydraulic fluid from dicator shaft on the machined
the ports, and thoroughly clean the surface at the outside diameter
exterior of the unit with a suitable of the piston, and set it at zero
solvent. (Fig. 14).
2. Mount the unit for disassembly b. While holding the sector shaft
on a stand adapter or in a vise. firmly, push the piston by hand
3. After removing the cylinder as far as it will go first in one
plug snap ring, use compressed air directon and then the other, to
to remove the cylinder plug from the obtain total deflection of the
piston rack bore. needle (Fig. 14). Note the in-
4. After removing the snap ring, dicator reading.
remove the cylinder cap from the c. The backlash should not exceed
piston bore (Fig. 13) . Remove the .004 inch. If the backlash is
cylinder cap 0-ring. excessive, install a new piston
5. Check the amount of backlash FIG. 13-Removing or sector shaft as required when
between the sector gear and the Cylinder Cap Snap Ring assembling the gear.

VALVE
SPOOL G1098-A
FIG. 18-Removing
Torsion Bar and Sleeve
3. Remove the torsion bar, valve

spool, actuator, seal, bearing and race
FIG. 16-Removing from the worm shaft (Fig. 19). Tap
Sector Shaft
FIG. 14-checking the end of the torsion bar with a
soft-faced hammer, if necessary. The
Piston Backlash 11. Remove the bearing adjuster valve spool and the actuator as-
lock nut and the bearing adjuster. sembly are spring-loaded. Discard
6. Turn the worm shaft all the way 12. Remove the torsion bar and the lower bearing race seal. Separate
to the stop and back it off about one sleeve assembly (Fig. 18) by lightly the valve spool and the actuator as-
and three-quarters turns, using the tapping on the lower end of the sembly from the torsion bar by turn-
tool shown in Fig. 15. torsion bar with a soft-faced hammer. ing the valve spool and actuator
7. Loosen the sector shaft ad- 13. Remove the sector shaft oil while turning the torsion bar.
justing screw lock nut and adjusting seal retaining snap ring (Fig. 21). 4. Remove the valve spool snap
screw. Remove the cap screws that Remove the outer seal with tool ring. Remove the valve spool from
attach the steering gear housing 1175-AE, then remove the spacer. the actuator.
cover to the housing. Tap on the Remove the inner seal with tool
lower end of the sector shaft with 1175-AE. 5. Check the ball nut assembly for
a soft-faced hammer until the sector evidence of binding or rough spots
shaft and cover can be removed TORSION BAR AND in the assembly itself. Do not dis-
(Fig. 16). Remove and discard the SLEEVE DISASSEMBLY assemble unless there is evidence
housing cover gasket and cover bolts 1. Position the ball nut assembly of binding or rough spots. Be sure,
(not re-usable). Slide the cover to in a vise. Use a clean cloth in the however, that there is sufficient lu-
one side to release the adjusting vise to protect the ball nut assembly. brication throughout the ball nut.
screw from the sector shaft, and re- Remove the valve spool sleeve from The ball nut is not preloaded and
move the adjusting screw from the the torsion bar assembly (Fig. 21). should move freely throughout the
cover. Remove the 0-ring from the sleeve. entire travel. Do not rotate the
8. Push the piston out of the hous- 2. Remove the valve spool adjuster ball nut against the end of the
ing. Remove the piston 0-ring. Re- lock nut from the lower end of the worm shaft as damage will result.
move the piston rack bore 0-ring as torsion bar. Remove the valve spool To disassemble the ball nut proceed
shown in Fig. 17. adjuster from the torsion bar. as follows.
9. Loosen the valve sleeve align- 6. Remove the ball nut guide re-
ment bolt. tainer and the ball guides. Turn the
10. Remove the valve adjuster nut over and remove the balls by
cap and remove the 0-ring from the rotating the worm shaft from side
cap. to side. Catch the balls in a clean pan
or a clean cloth. Remove the ball
nut from the worm shaft. Note the
position of the ball nut on the
worm shaft (Fig. 22).
7. Wash all parts in clean solvent
and dry them with compressed air.
8. Inspect the worm and ball nut
grooves, and all of the balls for wear
or scoring. If either the worm or
ball nut needs replacing, both must
be replaced as a matched assembly.
Inspect the ball nut teeth for pitting,
wear or scoring.
FIG. 17-Removing 9. Make certain that the ball re-
FIG. 15-Pre-load Check Piston 0-Ring turn guide ends are not damaged.

/ / - -...., HOUSING COVER~

I \
: SECTOR 1
~ SHAFT 1
V
DJUSTING\ SPRING
REW I
'II I
I I
\
\
, __ I / I
I
SECTOR SHAFT
.,..- ......
{/ '\
I I TUBE
I I
LOCK NUT
I I
I I
I I
I I
I 1....-:.·-~'".IXI'.l
\ ,_.,.. )
OUTER RACE SEAL
/ .,
I \
I I
I
I
I
I
I
I
I
I
VALVE SPOOL
ADJUSTER
\
'
__ ., I
I
I
~SNAP RING
OUTER SEAL
(UP)
G1086-C
FIG. 19-Power Steering Gear Disassembled

TORSION BAR AND SLEEVE Align the ball return guide holes over the balls. While holding the
ASSEMBLY with the worm groove. Count 31 two halves together, push the guide
balls (one half the number of balls) into the guide holes in the ball nut.
1. Slide the ball nut over the worm.
into a suitable container This is the If the guide does not push all the
See Fig. 22 for the correct position.
number of balls required to fill one
circuit. Drop 21 of these balls into
one guide hole to fill the one cir-
cuit in the ball nut. It may be nec-
essary to oscillate the shaft slightly
to circulate the balls. Make sure
that none of the balls come out
the other end of the circuit and
enter the worm groove between the
two circuits.
2. Coat the groove of one-half of
a return guide with clean oil-soluble
FIG. 20-Removing grease and place 10 balls in the guide. FIG. 21-Removing
Valve Spool Sleeve Place the other half of the guide Volve Spool Adjuster

GROUP 3-SUSPENSION, ,STEERING, WHEELS AND TIRES (048)
FIG. 22-Ball Nut

Position
way down easily, tap it lightly with
a soft-faced hammer to seat it. Fill
the second circuit in the same man-
ner and then attach the guide clamp
with the lockwashers and retaining
screws.
3. Inspect the torsion bar splines FIG. 24-lnstalling Torsion Bar
for nicks, pitting, wear or scoring.
Make sure the blind spline on the ing, using the tools shown in Fig. and the actuator on the torsion bar.
torsion bar lines up with the punch 23. Turn the lower end of the shaft so
dot on the upper end of the as- that the two identifying punch marks
6. Install the bearing in the sleeve,
sembly (large splined end). If they are aligned (Fig. 24). Hold the as-
using the tool shown in Fig. 23. The
do not line up, replace the torsion sembly together and insert the tor-
bearing must be pressed in so that
bar assembly. sion bar into the worm shaft, aligning
there is 0.035-0.045-inch between
4. Check the fit of the actuator the upper surface of the bearing the blind spline on the torsion bar
on the torsion bar assembly, with the and the seal seat surface of the with the end of the spiral groove on
spring in place. Hold the torsion bar sleeve. To install the seal, use the the lower end of the worm and
while turning the actuator. When the tool shown in Fig. 23. Install the shaft. The torsion bar assembly is
actuator is released, the spring should snap ring and check bearing rotation. properly installed when the valve
cause the actuator to pop off the spool bottoms against the upper
7. Lubricate the parts with auto-
threads. If it does not pop off, re- hearing and race.
matic transmission fluid.
place the spring and check the gear 11. Hold the lower bearing, race
teeth for burrs. If there are any 8. Check the fit of the upper bear-
ing race to insure that it is a slip and seal in position on the worm
burrs that cannot be removed, re- shaft and install the valve spool ad-
place the defective parts. fit in the sleeve. Install the bearing
race and bearing on the worm shaft. juster on the torsion bar, but do
5. Check the sleeve ball bearing not tighten. Install the lock nut. Lu-
for freedom of rotation. If the bear- 9. Install the valve spool on the
bricate the lip of the input shaft seal
ing is satisfactory, remove the snap actuator and retain with a new snap
with automatic transmission fluid.
ring and replace the oil seal. If the ring. Check the valve spool for free
12. Install the valve sleeve over
bearing must be replaced, remove rotation.
the valve spool so that the upper
the seal, and then remove the bear- 10. Install the torsion bar spring bearing outer race is seated in the
recess of the sleeve. Install a new
0-ring seal on the sleeve.
ASSEMBLY OF STEERING
GEAR
Refer to Fig. 19.
1. Align the slot in the sleeve with
the lock screw in the housing, and
install the torsion bar and sleeve
assembly in the housing. Be sure
that the seal and the lower bearing
outer race are properly seated.
Tap on the sleeve until it bottoms.
Torque the lock screw to 15-20
ft-lbs. The lock screw and the brass
washer must be seated against the
housing when they are properly
installed.
2. Install the bearing adjuster and
lock nut.
3. Install the valve spool center-
FIG. 23-Replacing Sleeve Seal and Bearing ing wrench (Fig. 25) on the valve

(049} PART 3-3- STEERING 3-25
5.. Install a new 0-ring in the

SOCKET
piston rack bore of the housing, and
lubricate the parts.
6. Carefully hone the edges of the
piston rack teeth with a hand stone
to prevent cutting the piston rack
bore 0-ring during installation.
7. Install a new 0-ring on the
piston and install the piston in the
housing. Lubricate the parts thor-
oughly and rotate the piston while
inserting it. Align the center rack
teeth with the sector bore in the
housing.
8. Grease the sector shaft splines
and install the shaft. Make sure FIG.27-Pressure G1206-A
FIG. 25-Valve Spool G1205-A
that the sector shaft is centered by Gauge Installed
Preliminary Centering rotating the worm shaft. Count the
turns from one stop to the other. T62B-3576-A as shown in Fig. 26.
spool adjuster, and locate the valve There should be at least 3V:z turns. The long flange of the adapter
spool so that the valley between the If there are fewer than 3 V:z turns, should press against the seal.
lands can be seen through the pres- remove the sector shaft and install 10. Install the metal spacer against
sure port. Lock the adjuster with the correctly. the inner seal, then position the sec-
lock nut, as shown in Fig. 25. This 9. Po~ition the sector shaft inner tor shaft outer seal with the sealing
is only a preliminary adjustment. seal in the steering gear housing with lip facing inward against the spacer.
4. Center the ball nut with the the rubber sealing lip facing inward. Seat the seal with the tool and adapt-
centerline of the sector shaft open- Seat the seal in the housing with er (Fig. 26). The short flange of
ing. tool T61B-3576-A and adapter the adapter should press against
the outer seal.
11. Install the seal retammg snap
INNER SEAL INSTALLATION ring. If the outer seal has blocked
LONG INSTALLATION off the snap ring retaining groove
FLANGE in the casting, tap the tool and
INWARD
adapter against the snap ring so that
the snap ring will seat into the
groove of the casting.
12. Install the sector shaft adjust-
ing screw with the proper shim to
obtain proper clearance ( 0.002).
Shims are available in thicknesses of
0.063, 0.065, 0.067 and 0.069. Place
the housing cover, with a new gasket
in place, over the adjusting screw,
and turn the screw until the cover is
seated. Install new cover attaching
screws, and torque them to specifi-
cation.
13. Adjust the worm bearing pre-
load and the sector mesh as detailed
in Section 2. This adjustment can
he accomplished with the steering
gear out of the car by attaching a
34 -inch socket ( 12 point) and an
in-lb torque wrench to the input

Adapter-T628-357 6-A
shaft instead of the steering wheel
attaching nut.
14. Check the piston rack back-
lash as detailed under "Steering Gear
Disassemhly" in this Section.
15. Install a new cylinder plug
0-ring and the cylinder plug in
the piston rack bore. Secure the cylin-
der plug with a snap ring.
16. Install a new cylinder cap
0-ring in the piston bore, then in-
FIG. 26-lnstalling Sedor Shaft Oil Seals stall the cylinder cap and snap ring.
FORD MOTOR CO.-Lincoln Continental-Group 3-A-P 2970--3-8-28-63

22. Using an inch-pound torque steering pump. Foreign matter picked

wrench with a %-inch socket at the up on working parts may cause dam-
input shaft, rotate the gear to the age or failure of the unit. Clean con-
left stop, adding sufficient torque to tainers should be used for parts.
the torque wrench to simultaneously 1. Drain the fluid from the pump.
obtain 300 psi on the pressure gauge, Remove the pump cover to housing
and the required torque on the cap screws (Fig. 29) . Place the
torque wrench gauge. pump on the bench, cover side down.
Repeat this process again in the Lift the housing from the cover.
opposite direction. 2. Remove the large and the small
The torque required to obtain a 0-rings from the pump cover. Re-
gauge reading of 300 psi in both move the 0-ring from the pressure
directions should not differ more plate hub.
than 3 inch-pounds. 3. Remove the pressure plate to
FIG. 28-Adiusting G1207-A 23. If the torque wrench reading
is more than 3 inch-pounds between
cover screws, and remove the plate.
Lift the cam ring off the dowel pins.
Centering Spool the right and left turns, loosen the 4. Remove the rollers. Lift the
17. To adjust the centering spool, valve spool adjuster lock nut and rotor off the shaft, and remove the
connect a 0-2000 psi pressure gauge rotate the adjuster in the direction drive key from the shaft. Remove the
between the car pump pressure line of the low reading (Fig. 28) . Only a dowel pins from the cover.
and the inlet port (upper hole) in slight movement of the adjuster is 5. Remove the rotor shaft from
the gear (Fig. 27). required to move the valve spool. the cover. Do not remove the snap
18. Connect the return hose to the Tighten the adjuster lock nut before ring from the shaft unless it, or
outlet port (lower hole) in the gear. each reading is made. the shaft, is damaged.
19. Make certain that the gauge 24. Install the steering gear in the 6. Pry the rotor shaft seals out of
hand valve is in the fully open posi- car. the cover and the housing.
tion. 25. Recheck the torque in both 7. Do not disturb the control
20. Fill the power steering pump directions as in step No. 22. If the valve unless diagnosis indicated a
reservoir to the correct level with readings are within 3 inch-pounds control valve problem or foreign
the specified fluid. of each other, install the adjuster matter in the valve. To remove the
21. Start the engine and cycle the cap. Disconnect the test gauge. valve, drive the roll pin out of the
steering gear from stop-to-stop until POWER STEERING PUMP housing. Remove the plug and
the fluid reaches normal operating DISASSEMBLY 0-ring, control valve, and the
temperature. Recheck the reservoir A clean working area should be spring. If the plug or valve is stuck,
and add fluid as necessary. used when overhauling the power tap the end of the housing on a piece
SOL T (7)
~-
I ---
0
\ COVER SEAL
1 RETAINER RING
SCREW (2}
FIG. 29-Power Steering Pump 61201-A

FIG. 32-lnstalling G12.11
Rotor Shaft in Cover

1. Install the control valve spring
in the housing. Install the valve with
the small sensing hole in the end of FIG. 33-Cam Ring G1212
the valve toward the spring. Install Installation
a new 0-ring on the plug. The
plug 0-ring is lJs inch smaller terbored side of the rotor toward the
in diameter than the bypass
FIG. 3D-Preparation G1209-A
0-ring. Make sure the proper
cover so that it goes over the snap
ring.
for Installing Rotor Shaft Seals 0-ring is used. Install the plug 5. Place the cam ring on the dowel
and a new roll pin (Fig. 29). pins with the chamfered edge up-
of wood or tap it with a soft-faced 2. The rotor shaft oil seals are inward (Fig. 33). Place the rollers in
hammer. Remove the 0-ring from stalled in the cover and the housing the rotor.
the plug. with tool 3583-J, which consists of a 6. Place the pressure plate on the
driver and an adapter. The proced- dowel pins. Install and tighten the
POWER STEERING PUMP ure is as follows: screws to 20 in-lbs torque. Install
ASSEMBLY a. Support the cover on wood the 0-ring on the pressure plate
Apply automatic transmission fluid blocks (Fig. 30) to provide tool hub. Install 0-rings in the groove
to all parts as they are assembled. clearance. Use clean blocks at the oil bypass hole and around the
Always use new seals and 0-rings. that will not nick or damage cam ring (Fig. 34) .
the inner face of the cov,~r. 7. Place the tool shown in Fig. 32
b. Start the seal (metal shell up- in the rotor shaft to prevent damage
ward) squarely into the bore to the oil seal, then install the hous-
with finger pressure. Place the ing on the cover. Install and torque
adapter on the driver with the the cap screws to 15-20-ft-lbs.
square corner of the adapter
toward the seal (Fig. 30).
Drive the seal into the cover, as
shown in Fig. 31 until it bot-
toms.
Driving the seal beyond this
point can damage it. Install
the seal in the pump housing in
the same manner.
3. Install the rotor shaft in the
cover as shown in Fig. 32 to prevent
damage to the seal.
4. Install the dowel pins in the
covt:~r. Place the rotor drive key in
the shaft. Install the rotor on the
FIG. 31-lnstalling G1210
shaft with the drive key groove FIG. 34-0-Ring G1213
Rotor Shaft Seal aligned with the key and the coun- Installation

3-28 (052)
PART WHEELS AND TIRES

~~
1
2
Description and Operation ................. 3-28
In-Car Adjustments and Repairs ............ 3-28
p~
3-4 3
4
Removal and Installation .................. 3-29
Major Repair Operations .................. 3-29

FRONT WHEEL ASSEMBLY cotter pin (Fig. 1). The front wheel shaft flange studs and is held against
assemblies rotate freely on their the hub and drum by the wheel nuts.
Each front wheel and tire assem- respective spindles and are driven by The rear wheel bearing is pressed
bly is bolted to its respective front the motion of the car. onto the axle shaft just inside the
hub and brake drum assembly. Two shaft flange, and the entire assembly
opposed, tapered roller bearings are is retained to the rear axle housing
REAR WHEEL ASSEMBLY
installed in each hub. A grease re- by the bearing retainer plate which
tainer is installed at the inner end of The rear wheel hub and brake is bolted to the housing flange.
the hub to prevent lubricant from drum assembly is retained to studs The inner end of each axle shaft
leaking into the drum. The entire on the rear axle shaft flange by three is splined to the engine powered
assembly is retained to its spindle speed nuts. The wheel and tire as- differential. The rear wheels are,
by the adjusting nut, nut lock and sembly mounts on the same rear axle therefore, driven by the engine.

FRONT WHEEL BEARING HUB AND BRAKE
ADJUSTMENT DRUM ASSEMBLY
The front wheel bearings should

be adjusted if the wheel is loose on ADJUSTING
NUT
the spindle or if the wheel does not
rotate freely. The following pro-
cedure will bring the end play to
specification. GREASE
CAP
1. Raise the car until the wheel
and tire clear the floor.
2. Pry off the wheel cover and
remove the grease cap (Fig. 1) from
the hub.
WHEEL
3. Wipe the excess grease from the ASSEMBLY
end of the spindle, and remove the
adjusting nut cotter pin and nut lock. F1056-C
4. While rotating the wheel, hub,
and drum assembly, torque the ad- FIG. 1-Front Hub, Bearings & Grease Retainer
justing nut to 15-20 ft-lbs to seat the
bearings (Fig. 2) . next castellation on the nut lock around the castellated flange of the
5. Locate the nut lock on the ad- aligns with the cotter pin hole in nut lock (Fig. 2).
justing nut so that the castellations the spindle. 8. Check the front wheel rotation.
on the lock are aligned with the 7. Install a new cotter pin, and If the wheel rotates properly, install
cotter pin hole in the spindle. bend the ends of the cotter pin the grease cap and the hub cap or
6. Back off both the adjusting nut
and the nut lock together until the
I~, \~
;t~j~
~ ~ WITH DRUM AND WHEEL
ROTATING, TORQUE THE INSTAll LOCK ON NUT SO THAT
BACK OFF NUT AND NUT
LOCK ONE CASTELLATION
F1 019-A ADJUSTING CASTELLATIONS ARE AliGNED
INSTAll COTTER PIN.
NUT TO 15-20ft. lbs. WITH COTTER PIN HOLE.
F1138-A
FIG. 3- Tire Cross-
Switc'bing Diagram FIG. 2-Front Wheel Bearing Adiustment

(053) PART 3-4-WHEEtS AND TIRES 3-29
wheel cover. lf the wheel still rotates TIRE ROTATION Fig. 3. See Group 19 for the speci-
roughly or noisily, clean or replace For longer tire life, all five tires fied intervals.
the bearings and cups as required. should be cross-switched as shown in

WHEEL AND TIRE ASSEMBLY wheel downward, and insert two ing band over the tire (Fig. 5). If a
tire irons about 8 inches apart be- mounting band is not available, tie
REMOVAL tween the tire inner bead and the a tourniquet of heavy cord around
1. Pry off the wheel hub cap or back side of the wheel rim. Use only the circumference of the tire. Tighten
cover. Loosen but do not remove the tire irons with rounded edges or the cord with a tire iron. Center the
wheel hub .nuts. irons designed for demounting tire on the wheel with a rubber
2. Raise the car until the wheel tubeless tires. mallet.
and tire clear the floor. 4. Leave one tire iron in position, 5. Give the tire a few quick bursts
and pry the rest of the bead over of air to seat the beads properly,
3. Remove the wheel hub nuts
the rim with the other iron. Take then inflate the tire to 40 pounds
from the bolts, and pull the wheel
small "bites" with the iron around pressure. Check to see that the bead
and tire assembly from the hub and
the tire in order to avoid damaging positioning rings (outer rings near
drum.
the sealing surface of the tire bead. the side walls) are evenly visible
5. Stand the wheel and tire up- just above the rim flanges all the way
DEMOUNTING TIRE FROM right with the tire outer bead in the around the tire. If the rings are not
WHEEL drop center well at the bottom of even, deflate the tire completely and
The tire can be demounted on a the wheel. Insert the tire iron be- inflate it again.
mounting machine. Be sure that tween the bead and the edge of the 6. When the rings are properly
the outer side of the wheel is wheel rim, and pry the wheel out positioned, deflate the tire to the
positioned downward. If tire irons of the tire. recommended pressure.
are used follow the procedure given MOUNTING TffiE TO WHEEL
here. INSTALLATION
1. If a used tire is being installed
1. Remove the valve cap and core, remove all dirt from the tire. 1. Clean all dirt from the hub and
and deflate the tire completely. If a tire is being mounted to the drum.
2. With a bead loosening tool, original wheel, clean the rim with
break loose the tire side walls from emery cloth or fine steel wool. Check
the wheel (Fig. 4). the rim for dents.
3. Position the outer side of the If a new wheel is being installed,
coat a new valve with RUGLYDE
or similar rubber lubricant and posi-
tion the valve to the new wheel. Use
a rubber hammer or a valve replac-
ing tool to seat the valve firmly
against the inside of the rim. Fl 021-A
2. Apply RUGLYDE or a similar
rubber lubricant to the sealing sur- FIG. 5- Tubeless Tire
face on both tire beads. With the Mounting Band
outer side of the wheel down, pry
the beads over the wheel rim with 2. Position the wheel and tire as-
two tire irons. Do not use a ham- sembly on the hub and drum. Install
mer or mallet to force the beads the wheel hub nuts and tighten them
over the rim. alternately in order to draw the
F1058-A 3. Align the balance mark on the wheel evenly against the hub and
tire with the valve on the wheel. drum.
FIG. 4-Bead Loosening 4. Hold the beads against the rim 3. Lower the car to the floor, and
Tool flanges by positioning a tire mount- torque the hub nuts to specification.
E] MAJOR REPAIR OPERATIONS

FRONT WHEEL GREASE SEAL ings should be cleaned, inspected, and tire clear the floor.
AND BEARING REPLACEMENT and repacked. If the bearing cups or
AND/OR REPACKING the cone and roller assemblies are 2. Insert a narrow screwdriver
worn or damaged, they should be through the brake adjusting hole at
If bearing adjustment will !lOt the inner side of the brake adjusting
rc:placed.
eliminate looseness or rough and plate, and disengage the adjusting
noisy operation, the hub and bear- 1. Raise the car until the wheel lever from the adjusting screw. While

3-30 GROUP 3-SUSPENSION, STEERING, WHEELS AND TIRES {054)
FIG. 8-Front Wheel Bearing Cup Installation

the spindle. Remove the outer bear- 8. Thoroughly clean the spindle
ing cone and roller assembly (Fig. and the inside of the hub with sol-
1 ). vent to remove all old lubricant.
4. Pull the wheel, hub, and drum Cover the spindle with a clean
assembly off the wheel spindle. cloth, and brush all loose dust and
5. Remove the grease retainer dirt from the brake assembly. To
(Fig. 6) and the inner bearing cone prevent getting dirt on the spindle,
and roller assembly from the hub. carefully remove the cloth from
6. Clean the lubricant off the the spindle.
inner and outer bearing cups with 9. If the inner and/or outer bear-
solvent and inspect the cups for ing cup(s) were removed, install the
scratches, pits, excessive wear, and replacement cup(s) in the hub with
other damage. If the cups are worn the tools shown in Fig. 8. Be sure
FIG. &-Removing or damaged, remove them with the to seat the cups properly in the
Grease Retainer tools shown in Fig. 7. hub.
7. Soak a new grease retainer in 10. Pack the inside of the hub
holding the adjusting lever away light engine oil at least 30 minutes with specified wheel bearing grease.
from the screw, back off the adjust- before installation. Thoroughly clean Add lubricant to the hub only until
ing screw with the brake adjusting the inner and outer bearing cones the grease is flush with the inside
tool. Be very careful not to burr, and rollers with solvent, and dry diameter of both bearing cups.
chip, or damage the notches in the them thoroughly. Do not spin the 11. Pack the bearing cone and
adjusting screw; otherwise the bearings dry with compressed air. roller assemblies with wheel bearing
self-adjusting mechanism will not Inspect the cones and rollers for grease. A bearing packer is desirable
function properly. wear or damage, and replace them for this operation. If a packer is not
3. Remove the wheel cover or hub if necessary. The cone and roller as- available, work as much lubricant
cap. Remove the grease cap from the semblies and the bearing cups should as possible between the rollers and
hub. Remove the cotter pin, nut lock, be replaced as a set if damage to cages. Lubricate the cone surfaces
adjusting nut, and flat washer from either is encountered. with grease.
12. Place the inner bearing cone
FIG. 9-Grease
FIG. 7-front Wheel Bearing Cup Removal Retainer Installation

(055) PART 3-4-WHEELS AND TIRES 3-31
and roller assembly in the inner cup, ings before repacking with new bearing cone and roller assembly in
and install the new grease retainer grease. the inner bearing cup. Install the
with the tool shown in Fig. 9. Be grease retainer.
sure the retainer is properly FRONT HUB AND DRUM 5. Install the new hub and drum
seated. ASSEMBLY REPLACEMENT assembly to the wheel spindle. Keep
the hub centered on the spindle to
13. Install the wheel, hub, and When the hub and drum assembly prevent damage to the grease re-
drum assembly on the wheel spindle. is replaced, new bearings, cups, and tainer.
Keep the hub centered on the grease retainer must be installed in 6. Install the outer bearing cone
spindle to prevent damage to the the new assembly. The new grease and roller assembly and the flat
grease retainer or the spindle retainer should be soaked in light washer on the spindle, then install
threads. engine oil at least 30 minutes before the adjusting nut.
14. Install the outer bearing cone installation. 7. Position the wheel and tire as-
and roller assembly and the flat 1. Raise the car until the wheel sembly on the new hub and drum
washer on the spindle, then install and tire clear the floor. Pry off the assembly. Install the wheel hub nuts
the adjusting nut. hub cap or wheel cover, and remove and tighten them alternately in order
the wheel and tire assembly from to draw the wheel evenly against the
15. Adjust the wheel bearings as the hub and drum assembly. hub and drum.
outlined in Section 2, and install a 2. Back off the brake shoe and re- 8. Adjust the wheel bearings as
new cotter pin. Bend the ends of the move the old hub and drum assem- outlined in Section 2, and install a
cotter pin around the castellations of bly from the wheel spindle. new cotter pin. Bend the ends of the
the nut lock to prevent interference 3. Remove the protective coating cotter pin around the castellations of
with the radio static collector in the from the new hub and drum with the nut lock to prevent interference
grease cap. Install the grease cap. carburetor degreaser. Install new with the radio static collector in the
16. Adjust the brake shoes. Install inner and outer bearing cups in the grease cap. Install the grease cap.
the wheel cover. new hub with the tool shown in 9. Adjust the brake shoes as out-
Fig. 8. Be sure to seat the cups lined in Part 2-2, Section 2.
NOTE: All old grease should be properly in the hub. 10. Install the hub cap or wheel
completely cleaned from the bear- 4. Grease and install the inner cover.

3-32 (056)
PART SPECIFICATIONS
3-5
TIRES REAR SUSPENSION TORQUE LIMITS
Inflation Pressure (P.S.I.} (Cold} 24 Description Ft-lbs
Size 9.15 X 15 Rear Shock Absorber to Axle 30-40
Rear Shock Absorber Bracket to Crossmember 17-25
Rear Shock Absorber Stud to Rear Axle (Service Only) 65-80
Rear Spring to Shackle 16-22
Rear Spring Front Bracket to Sidemember 50-90
FRONT WHEEL ALIGNMENT
Rear Spring front Eye Bolt (Front Shackle Nut) 50-70
Caster (Degrees) (Within W one Side of Car to Rear Spring Leaves Retaining Bolt 40-50
Other, Y4 o preferred) -% 0 to -2Y4° Rear Spring U- Bolts 50-60
Camber (Degrees) (Within Ylo One Side of Car to Shackle to Mounting Hanger 16-22
Other, \.i o Preferred) oo to Plus% o Shackle Mounting Hanger to Side Rail 40-62
Kingpin Inclination-Theoretical (at +% ocamber) 70
Angle of Outside Wheel When Inside Wheel is at zoo 17° 42'

STEERING CHECKS AND ADJUSTMENTS
Riding Height:
Allowable Difference-One Side of Car to Other Yz
-- Description
Toe-In Sector Shaft Mesh-Total Center Mesh
Maximum 3!J6 in-lbs
Load (Measure with torque wrench at
Minimum 1J16 mechanical center) 15-17
Tread Rear-61.0 Front-62.1 Worm Bearing Pre-Load in-lbs
(Measure with torque wrench zoo off either stop) 6-8
Turning Circle (Feet) (Curb to Curb to Outside of Tire) 45.7 Piston Backlash (Maximum) 0.004
Ratios:
Overall 20.5:1
Steering Gear 17.0:1
Steering Whee!:
FRONT SUSPENSION TORQUE LIMITS Diameter 16
Number of Turns(Full Left to Right) 3%-4
Description Ft-lbs Thrust Screw to Sector Slot
Brake Backing Plate to Spindle-Upper 25-35 Clearance (Maximum) 0.002
-Lower 70-95 Fluid (M2C33-C-O) I C1AZ-19582
Front Wheel Spindle Nut (Back off one Slot
after Torque Check) 15-20
Jounce Bumper to Drag Strut 22-28
STEERING TORQUE LIMITS
lower Ball Joint to lower Arm 22-28
Description Ft-lbs
lower Suspension Arm to No. 2 Crossmember 110-140 !
Gear Cover to Gear Housing lS-22
Shock Absorber Bracket to No. 2 Crossmember 20-30 Control Valve Spool Lock Nut 5-9 0
Shock Absorber to Lower Suspension Arm 20-30 Control Valve Spool Adjuster Cap 10-15
Mesh Load Adjusting Screw Lock Nut 25-30
Shock Absorber to Shock Bracket Stud 40-55 Sleeve Adjusting Lock Nut 60-80
Spindle Arm Connecting Rod Ball Stud Ball Return Guide Clamp Screw 18-36
to Spindle Arm I 40-55 Pressure Line to Gear 10-15
Spindle Connecting Rod Adjusting Sleeve Clamp Nut Return Line to Gear 20-30
22-28
- Connecting Link Ball Stud to Idler Arm 40-55
Spindle to Lower Ball Joint Stud 70-90 Connecting Link Ball Stud to Pitman Arm 40-55
--
Spindle to Upper Ball Joint Stud 55-75 Crankshaft Damper Attaching Bolt 75-90
Gear Housing to Sidemember 35-50
Stabilizer Bar to Lower Suspension Arm 8-13 20-30
Idler Arm Bracket to Sidemember
Upper Arm Bushings to Shaft 70-90 Lock Screw to Sleeve 15-20
Pitman Arm to Shaft 100-130
Upper Ball Joint to Upper Arm 21-29
Pump to Engine Front Cover 8-11
Upper Arm Shaft to No. 2 Crossmember 100-125 Spindle Arm Connecting Rod Ball Stud to
Connecting Link 40-55
Wheel Nuts 75-110
Spindle Arm Connecting Rod Ball Stud to
Ball ioint Stud Torque Check 12 in-lbs Spindle Arm 40-55
(Minimum Acceptable Torque Required to Steering Wheel Nut* 18-24
Turn the Ball Joint Stud) *Stake nut after tightening.

4-1
GROUP
4
PART 4-1 PAGE PART 4-3 'PAGE
GENERAL AXLE SERVICE ... 4-1 SPECIFICATIONS .. 4-19
PART 4-2
REAR AXLE ........ 4-6
I
PART GENERAL AXLE SERVICE
4-1
1 Diagnosis and Testing . . . . . . . . . ........... 4-1 3 Cleaning and Inspection ................... 4-4
2 Common Adjustments and Repa1rs .......... 4-2

Certain rear axle trouble symptoms parts of the car. For this reason, repairing, or replacing any of the
are also common to the engine, drive be sure that the cause of the trouble axle parts.
line, transmission, tires, and other is in the rear axle before adjusting,
REAR AXLE TROUBLE DIAGNOSIS GUIDE
Since gears are in mesh, som(~ when the car is coasting at low
rear axle noise is normal. However, speeds, and it usually stops when
excessive noise often indicates the the brakes are gently applied. To
beginning of other troubles in the find the noisy bearing, jack up each
axle. wheel and check each bearing for
A road test can help determine roughness while the wheel is rotat-
whether the noise is being caused by ing, provided that the car is equipped
trouble in the rear axle or in other with a conventional differential.
parts of the car. Before road-test- If all possible external sources
ing the car, make sure that the tire of noise have been checked and
pressures and the rear axle lubri- eliminated, and the noise still exists,
cant level are normal. Then drive road-test the rear axle under all four
the (~ar far enough to warm the driving conditions:
axle lubricant to its normal oper- 1. Drive: Higher than normal
EXCESSIVE REAR AXLE ating temperature. road-load power, where the speed
NOISE With the car stopped and the gradually increases on level road
transmission in neutral, run the en- acceleration.
(ALL REAR AXLES)
gine at various speeds. If the noise 2. Cruise: Constant speed opera-
still exists during this test, it prob- tion at normal road speeds.
ably comes from the engine or the 3. Float: Using only enough
exhaust system. throttle to keep the car from driving
To determine if the noise is being the engine. Car will slow down (very
caused by the rear axle or the tires, little load on rear axle gears) .
drive the car over several different 4. Coast: Throttle closed - engine
types of road surfaces. Smooth as- is braking the car. (Load is on the
phalt or black-top roads minimize tire coast side of the gear set.)
noises. Tire noises may be eliminated Any noise produced by the side-
hy cross-switching the tires. Snow gears and pinions .in the differential
tires often cause noises not heard case will be most pronounced on
with conventional tires. turns. A continuous whine under a
Noise caused by a worn or dam- light load between 20 and 35 miles
,_________________.~..1_ aged wheel bearing is often loudest per hour indicates rough or brin-
CONTINUED ON NEXT PAGE

4-2 GROUP 4-REAR AXLE (058)
REAR AXLE TROUBLE DIAGNOSIS GUIDE (Continued)
EXCESSIVE REAR AXLE nelled pinion bearings. If the tone rough and irregular; worn, rough or
NOISE of drive, coast and float noise differs loose differential or pinion shaft bear-
(ALL REAR AXLES) with speed and if the noise is very ings are indicated.
Excessive backlash in the axle tween the drive pinion and drive
EXCESSIVE REAR AXLE driving parts may be caused by gear, excessive backlash in the dif-
BACKLASH worn axle shaft splines, loose axle ferential gears, or bearings which
(ALL REAR AXLES) shaft flange nuts, loose U-joint flange are worn or out of adjustment.
mountings, excessive backlash be-
Before removing the "Directed cant that did not drain. Flushing
Power" differential for overhaul, the unit with solvents is not rec-
change the lubricant as described ommended due to the undesirable
in the following procedure and op- effect the solvents may have on
erate the car for 200 miles. the new lubricant.
1. Operate the vehicle enough to 6. Clean the gasket surfaces_. In-
thoroughly warm the rear axle lu- stall a new gasket, and install the
DIFFERENTIAL CHATTERS bricant. cover and bolts.
(DIRECTED POWER ONLY) 2. Thoroughly clean the area 7. Torque the cover bolts to spec-
around the rear axle housing cover. ifications.
3. Remove the housing cover bolts 8. Refill with the specified lubri-
and cover. Drain the lubricant. cant.
4. Rotate the wheels by hand to If the chatter is still evident after
allow the lubricant in the unit to 200 miles of operation, remove and
drain. overhaul the "Directed Power" dif-
5. Syphon or wipe out all lubri- ferential.
The pulling power of each rear required to apply the clutch at the
wheel should be tested separately. poor traction wheel. Now, the car
Place one wheel on good traction should move. Turn the car around
such as dry cement and the other and test the opposite wheel. If either
wheel on ice, snow, mud, gravel, or wheel continues to spin even with
AXLE WILL NOT DRIVE grease. Try to drive the car either the light brake application, remove
WITH POOR TRACTION AT forward or backward. To avoid and overhaul the differential.
ONE WHEEL "break-away" of the good traction Do not test the "Directed Power"
(DIRECTED POWER ONLY) wheel, apply the throttle lightly. If differential while one wheel is on
the car does not move and the poor a jack. The unit could cause the
traction wheel spins, the parking car to jump off the jack. This could
brake should be applied to cause a also occur during "on car" rear
slight drag. This light brake applica- wheel balancing. Wheels should,
tion should provide the resistance therefore, be balanced off the car.

PINION AND RING GEAR the carrier housing to locate the be adjusted away from or toward the
TOOTH CONTACT ADJUSTMENT pinion for correct contact with the pinion to increase or decrease back-
Two separate adjustments affect ring gear. The original factory in- lash between the gears. The shims
pinion and ring gear tooth contact. stalled shim pack is of the correcf installed behind the differential side
They are pinion location and back- thickness for a given original carrier bearings locate the differential case
lash (Fig. 1 ) . Painting the ring gear and gear set assembly. In service, and ring gear assembly in the car-
teeth with marking compound and shims should be added or removed rier housing. To increase the back-
rolling a pattern, as described under from the original pack only as in- lash between the ring gear and pin-
"Inspection Before Disassembly of dicated by the tooth pattern check ion (move ring gear away from
Carrier" in Section 3, will indicate (Fig. 2) . Adding shims moves the pinion), remove the necessary shims
what adjustments should be made pinion toward the ring gear~ remov- from behind the bearing on the ring
on a particular gear set. ing shims moves the pinion away gear side of the differential case
from the gear (Fig. 1 ) . and install them behind the bearing
PINION LOCATION
on the pinion side of the case (Fig.
Individual differences in machin- BACKLASH BETWEEN RING 1). To decrease backlash (move ring
ing the carrier housing and the gear GEAR AND PINION gear toward pinion), remove the
set require a shim pack between The tooth pattern check also in- necessary shims from behind the
the pinion rear bearing cup and dicates whether the ring gear should bearing on the pjnion side of the

(059) PART 4-1-GENERAL AXLE SERVICE 4-3
case and install them behind the

bearing on the ring gear side of the
case.
PINION BEARING PRELOAD
Any load applied to the pinion
exerts a great amount of end thrust BEARING PRELOAD
on the pinion shaft. On pull (engine SHIM PACK
driving rear wheels), the pinion tends

to "walk" away from the ring gear,
and the rear bearing takes the thrust
(Fig. 1). On coast (rear wheels driv-
ing engine), the pinion tends to
"walk" toward the ring gear, and the
front bearing takes the thrust. lf
this end-play or "walk" were al-
lowed, pinion and ring gear tooth
contact would change every time
the end thrust on the pinion
changed. The ptmon, therefore,
must be held firmly in one place
(zero end play) to maintain cor-
rect tooth contact.
I
Any change in the pinion locating
shim pack requires a corresponding
change in the bearing preload shim -t--~~~;;~~~~--~~~~~c~ iBACKLASH
pack (Fig. 1 ) . The bearing cups are
fixed in the housing and the cones
are fixed to the pinion shaft; there-
fore, if the rear bearing cup position
were changed by adding or removing
shims, not only would the pinion
shaft move in or out, but the cones
moving with the shaft would move
into or out of their cups to increase
or decrease tension. The preload 11408-A
shim pack must be changed to com-
pensate for this change of bearing FIG. 1-Pinion and Ring Gear Tooth Contact Adiustments
For example, if a 0.002mcl")

cone tension against the cups.
"~g,c;:t•
TOE
r~ HEEl
{LARGE END
OF TOOTH)
{cl HEEL CONTACT
{a) TOE CONTACT {B) CORRECT CONTACT TO CORRECT -DECREASE BACKLASH,
MOVE RING GEAR TOWARD PINION
TO CORRECT -INCREASE BACKLASH,
MOVE RING GEAR AWAY FROM PINION
d)
(e) CONTACT AT BASE OF TOOTH

TO CORRECT -MOVE PINION AWAY
FROM RING GEAR, THEN ESTABLISH
CORRECT BACKLASH.
{d) CONTACT AT EDGE OF TOOTH
TO CORRECT -MOVE PINION "IN" NOTE Contact patlerns {a), (c}, (d) and (e) ind1cate Incorrect placement of slums and w1ll result ;,. noise ond gear failure.
TOWARD RING GEAR, THEN ESTABLISH Pattern (b) shows Cort'flcf contact pattern. The above ring gear tooth contact potlerns would be made under LooJ
CORRECT BACKLASH. cond1tions only (actual operation). Do 110t attempt to check a new installation for correct contact under No LooJ con-
dlfions TOOTH CONTACT WILL BE CORRECT AS SHOWN AT (B) If SHIMS HAVE BEEN PROPERlY INSTAllED.
FIG. 2- Tooth Contact Pattern Check E1417-A

were removed from the locating Similarly, if a 0.002-inch shim tension and restore original preload.
shim pack to move the pinion 0.002 were added to the locating shim
inch farther away from the ring pack to move the pinion 0.002 inch DETERMINING THE SHIM
gear, the rear bearing cup would closer to the ring gear, the rear bear- PACKS
move closer to the front bearing cup ing cup would move farther away To make any of the foregoing ad-
by 0.002 inch. As the pinion shaft from the front bearing cup by 0.002 justments, the differential case, drive
and rear bearing cone shifted with inch. As the pinion shaft and rear pinion, and pinion bearings will have
the rear bearing cup, the front bear- bearing cone shifted rearward with to be removed from the housing as
ing cone would move 0.002 inch out the rear bearing cup, the front bear- outlined under "Disassembly" in
of its cup thus decreasing preload. ing cone would move 0.002 inch Part 4-2. The correct thickness for
A 0.002-inch shim, therefore, must farther into its cup thus increasing the four shim packs shown in Fig.
be removed from the preload shim tension. A 0.002-inch shim, there- 1 can then be determined by follow-
pack also so that the front bearing fore, must be added to the pre- ing the "Installation of Pinion, Bear-
cone can move the 0.002 inch back load shim pack also so that the front ings, and Differential Case" proce-
into its cup to restore the original bearing cone will move the 0.002 dure outlined under "Assembly" in
preload. inch out of its cup to relieve the Part 4-2.

INSPECTION BEFORE Backlash should be within specifica- Too/-.4201·C
DISASSEMBLY OF CARRIER tions.
5. If no obvious defect is noted,
The differential carrier should be check the gear tooth contact. Paint
inspected before any parts are re- the gear teeth with suitable gear
moved from it. The checks given marking compound, such as a paste
in the following procedure can help made with dry red lead and oil. A
to find the cause of the trouble and mixture that is too wet will run and
to determine the corrections needed. smear. Too dry a mixture cannot
1. Place the housing assembly in a be pressed out from between the
holding fixture, tool 4005 as shown teeth. Wrap a cloth or rope around
in Fig. 3. the drive pinion flange to act as a
2. Thoroughly clean the housing brake. Rotate the ring gear back
and cover assembly, and then remove and forth (use a box wrench on the
the cover-to-housing bolts. ring gear attaching bolts for a lever)
until a clear tooth contact pattern is
FIG. 5-Ring Gear Runout Check
3. Using a suitable solvent, clean
the lubricant from the internal work- obtained. ring gear, as shown in Fig. 5. With
ing parts and visually inspect the Certain types of gear tooth contact the indicator at zero setting, revolve
parts for wear or damage. Rotate patterns on the drive gear indicate the ring gear one revolution and
the gears to see if there is any rough- incorrect adjustment. Noise caused note the total runout. If the total
ness which would indicate defective by incorrect adjustment can often indicator reading exceeds specifica-
bearings or chipped gears. Check the be corrected by readjusting the gears tions, it may indicate a loose ring
gear teeth for scoring or signs of as outlined in Section 2. Typical gear or a sprung differential case
patterns and the necessary correc- or housing. Disassemble the carrier
abnormal wear.
tions are shown in Fig. 2. and replace necessary parts as in-
4. Set up a dial indicator (Fig. 4), 6. Gear tooth runout can some-
and check the backlash between the dicated in Part 4-2, Section 4.
times be detected by an erratic pat- 7. Check the clearance between
drive gear and pinion at four equally tern on the teeth. However, a dial
spaced points around the drive gear. the side bearing caps and bearing
indicator should be used to measure cups. If the clearance is 0.003 inch
the runout of the back face of the or more, it could indicate that the
bearing is turning in the housing.
Visually check to determine that
the cap is properly seated against its
mating surface on the housing. If
the clearance exists with the cap
properly seated and the bolts prop-
erly torqued, check the mating sur-
faces of the housing and caps for
damage. Replace the housing andior
caps as necessary.
INSPECTION AFTER
DISASSEMBLY
FIG. 3-Axle Housing Thoroughly clean all parts (Fig.
AssenJbly in Holding Fixture FIG. 4-Backlash Check 6) except wheel bearings in clean sol-

(061)' PART 4-1-GENERAL AXLE SERVICE 4-5
THRUST WASHER~ i' NIONS fj

.-.·-.~t:J-:;~~, ~-- (({QI;-THRUST ~
~~ ~-, "~~'/
SIDE GEAR , WASHER
THRUST WASHER----\(.,!,~~)~ '-/~ ~~(()) SIDE GEAR y BUMPER

,} -~ PINION )HAFT ~ ~1
THRUST WASHER SH\IM SIDE BEARING ~~
~ ~b~~©~~ ~"
BRACKET
__. SHIM /~ ~J-
CUP ~
'W~ T =vt"'h,, ~SPACERS
I
~.IDE BEARINGrrREAR CONE AND ROUER ASSEMBLY
REAR BEARING CUP :
SHIM ~ BEARING CAP 1
~ I~ !J~·/.. :
SHAFT AND BEARING Q ~~!lt~.
i!lYi ',\ \,..,~. . v -=--
WHEEl BEARING SHIM__.....\Q; '
RHAINER ---~ ~~~~ ~IFRONT BEARING CUP
~ -- ~ SLINGER
'.£..~~~~-',.....,~~ ~~ ;;r:~F~~~::lV
BOLT
•-
FRONT CONE AND ROLLER ASSEMBLY y f!!J~~'
GASKET '
"U" JOINT FLANGE ~()
PINION SHAFT NUT El _A
390
FIG. 6-Rear Axle Disassembled
vent, and dry them \\iith compressed wear patterns. Pinion cups must he bearing bores are smooth and that
air. Inspect the parts for defects. solidly seated. Check by attempting the threaded holes are not damaged.
Clean the inside of the carrier before to insert a 0.00 15-inch feeler he- Remove any nicks or burrs from the
rebuilding it. When a scored gear tween these cups and the bottoms of mating surfaces of the carrier hous-
set is replaced, the axle housing their bores. ing.
should be washed thoroughly and When operated in the cups, cone
steam cleaned. This should be done and roller assemblies must turn witth- DIFFERENTIAL CASE
only after the axle shafts, wheel out roughness. Examine the roller Make sure that the hubs where
bearings, and seals arc removed from ends for wear. Stepwear on the roller the bearings mount are smooth.
the housing. Inspect individual parts ends indicates the hearings were not Carefully examine the differential
as outlined beiow. preloaded properly or the rollers case bearing shoulders, which may
were slightly misaligned. have been damaged when the bear-
GEARS If inspection reveals either a de- ings were removed. The bearing as-
Examine the pinion and ring gear fective cup or a defective cone and semblies will fail if they do not seat
teeth for scoring or excessive wear. rol ier assembly both parts should be firmly against the shoulders. Check
The pattern taken before disassembly replaced to avoid early failure. the fit (free rotation) of the differ-
should be helpful in judging if gc.1rs lJ-.JOINT FLANGE ential side gears in their counter-
can he re-used. \Vorn gears cannot hores.
be rebuilt to correct a noisy concli- He sure that the ears of the flange
tion. Gear scoring is the result 0f have not heen damaged in removing DIRECTED POWER
excessive loading or the usc of in- the drive shaft or in removing the DIF'FERENTIAL
correct lubricant. Scored gears can- flange from the axle. The end of the Inspect all parts, particularly the
not be re-used. flange that contacts the oil slinger as spring plates and discs, the clutch
Examine the teeth and thrust sur- well as the flat surface of the pinion plates and discs, the plate surfaces
faces of the differential gears. Wear nut counterhore must he smooth. of the case halves, and the side gear
of splines, thrust surfaces. o.Jr thrust Polish these surfaces if necessary. rings for excessive wear or scoring
washers can contribute tn cxces-;ivt' Roughness aggravates backlash (Part 4-2, Fig. 23). Replace any
drive line backlash. noises, and causes wear of the parts that arc worn or damaged.
slinger and pinion nut with a result- If one or more of the plates or
BEARING CUPS AND CONE <~nt loss in pinion hearing preload.
AND ROLLER ASSEMBLIES discs in a clutch pack on one of
CARRIER HOUSING the sides need replacing, the entire
Check the hearing cups for nngs, stack of plates and discs on th~t
scores, galling, or excessively worn Make sure· that the differential side should be replaced.

4-6 (062}
PART REAR AXLE

4-2
1 Description and Operation .................. 4-6 3 Removal and Installation ................. .4-10
2 In-Car Adjustment and Repair ............... 4-8 4 Major Repair Operations ................. .4-11
a DESCRIPTION AND OPERATION
REAR WHEa BEARING
E1410-A
FIG. 1-Rear Axle Assembly
CONVENTIONAL AXLE in the forward side of the carrier which are retained in the housing
housing. Pinion locating shims, in- by removable caps. Shims, installed
DESCRIPTION stalled between the rear bearing between each differential side bear-
cup and the cup seat, control the ing and the shoulder on the case,
The rear axle is of the integral drive pinion depth adjustment. The perform three functions: they take
carrier-housing, hypoid gear type, in pinion bearing preload is controlled up the differential case side clear-
which the centerline of the drive by shims located between the pin- ance; they adjust the backlash be-
pinion is mounted below the center- ion front bearing and the shoulder tween ring gear and pinion; and
line of the ring gear (Fig.' 1). on the drive pinion shaft. they establish differential side bear-
The integral pinion gear and shaft The differential case assembly is ing preload.
is supported by two opposed tapered supported by two opposed tapered A cover on the rear of the carrier
roller bearings which are assembled roller (side) bearings and cups, housing provides access for inspec-

(063) PART 4-2-REAR AXLE: 4-7
tion, removal and installation of the has an identical clutch assembly the opposite side of their "V" ramps
differential assembly and drive pin- which connects one of the axle shafts and will again be forced apart to
ion. A metal tag, stamped with the directly to the case half as driving apply against the clutch packs. There-
gear ratio plus the number of teeth conditions demand. Each clutch fore, since the ramps are "V" shaped,
on the ring gear and pinion, is se- pack consists of five steel platt~s set the clutches will apply during either
cured to the housing by one of the between the case and the side gear forward or reverse operation. Like-
cover bolts. ring. The two outer plates and the wise, the clutches will apply whether
center plate are locked to the. dif- the power flow is from the differen-
Cars equipped with "Directed ferential case half by external lugs. tial case to the axle shafts, or from
Power" differential assemblies will The remaining two plates (discs) the axle shaft to the differential case.
have an additional metal tag iden- have internal spline teeth which lock
tification attached to one of the to the splined hub on the side gear The amount of compression on
cover bolts.
ring. The external lug plate and the the clutch plates will be proportion-
Ball bearing assemblies (rear spline disc plate that are located next ate to the load applied to the dif-
wheel bearings) are pressed onto to the case half are spring plates, ferential case and the resistance to
the outer ends of the axle shafts and which are installed with the convex turning offered by each mate shaft.
set in the outer ends of the axle hous- (bowed) side against the case. The For example, if the car is driven
ing. These bearings support the semi- side gear ring is internally splined straight ahead and the traction or
floating axle shafts at the outer ends. to the axle shaft and acts as a pres- load on both wheels is equal, both
The inner ends of the shafts spline sure plate against the clutch pack. mate shafts will give equal resistance
to the differential side gears. Bearing to the rotating differential case and
retainer plates hold the shafts in the Unlike the single pinion shaft of will thus bear against their respective
housing. The axle shafts are equal the conventional unit, the two pin- ramps with equal force. This equal
in length and arc, therefore, inter- ion mate shafts are not rigidly at- movement of the mate shafts will
changeable. tached to the differential case, nor cause them to exert equal pressure
are they attached to each other. At against both right and left-hand
both ends of the mate shafts, there clutch packs. Both axle shafts will,
OPERATION are two flat surfaces so arranged that therefore, be locked directly to the
they form a "V" which mates with case with equal force.
The rear axle drive pinion receives corresponding "V" shaped surfaces
its power from the engine through (ramps) cut in the shaft openings of Clutch application prevents mo-
the transmission and drive shaft. the differential case. mentary spinning of one of the
The pinion gear rotates the differen-
wheels when it leaves the road be-
tial case through engagement with
cause of a bump, or encounters poor
the drive gear, which is bolted to
OPERATION traction because of a slippery road.
the case outer flange. Inside the
Under these conditions, even though
case, two different pinion gears are
The "Directed Power" axle has a the traction load is relieved on the
mounted on the differential pinion
power flow identical to the conven- one wheel, the acceleration load is
shaft which is pinned to the case.
tional rear axle, plus a more direct simultaneously applied to the dif-
These pinion gears are engaged with
power flow which automatically takes ferential case as the engine tries
the side gears, to which the axle
effect as driving conditions demand. to spin the wheel.
shafts are splined. Therefore, as the
differential case turns, it rotates the This more direct power flow is from
axle shafts and rear wheels. When the differential case to each axle When the rear axle is in a turn,
shaft through clutches. the appropriate clutch releases auto-
it is necessary for one wheel and
matically to allow normal differ-
axle shaft to rotate faster than the
The mate shafts are assembkd in ential operation as required. In the
other, the faster turning side gear
the case with enough clearance so straight ahead position, the differ-
causes the pinions to roll on the
that when the case tries to rotate ential case is driving both wheels
slower turning side gear to allo"'
differential action between the two the mate shafts and the mate shafts and thus applies an equal load
axle shafts. resist rotation, they will be forced to against both mate shafts. Since both
hear against one side of their "V" mate shafts offer resistance to this
ramps. Since the two "V" ramps load, both clutches are applied. On
"DIRECTED POWER" AXLE of one mate shaft point in a di- a turn, however, the outside wheel
rection opposite to that of the two turns faster than the inside wheel.
DESCRIPTION "'V" ramps of the other mate shaft, The outside wheel, instead of being
The "Directed Power" axle is the the two shafts with their pinions driven by the case, now tends to
same as the conventional axle with will be forced apart as they resist drive the case. With the power thus
respect to the ring gear and pinion. rotation. This mate shaft movement relieved, the differential case releases
the bearings, the housing, and the compresses the clutch pack through its load against the outside wheel
axle shafts. The difference is in the the pinion gears and side gear rings. mate shaft which, in turn, releases
differential assembly. its pressure against the outside
When the differential case rotates wheel clutch pack. With the clutch
The differential is of a two-piece in the opposite direction, the mate released, normal differential action
case design (Fig. 23). Each case halt shafts will be forced to bear against will take effect.

4-8 GROUP 4-REAR AXLE {064)
EJ IN-CAR ADJUSTMENT AND REPAIR

REAR AXLE SHAFT, WHEEL
BEARING, AND OIL SEAL
REPLACEMENT
The rear axle shafts, wheel bear-
ings and oil seals can be replaced
without removing the axle assembly
from the car.
1. Remove the wheel and tire from
the brake drum.
2. Remove the Tinnerman nuts
that secure the brake drum to the FIG. 3-Axle Shaft Removal
axle shaft flange, and then remove
the drum from the flange. 11. Press on a new wheel bearing
3. Working through the hole pro- retainer ring with tool 4621-A. Do
vided in the axle shaft flange, re- not attempt to press on both the
move the nuts that secure the wheel wheel bearing and retainer ring
bearing retainer to the axle housing at the same time.
(Fig. 2). 12. Whenever a rear axle shaft
4. Pull the axle shaft assembly out is removed, the oil seal must be
replaced. Remove the seal with the
of the axle housing (Fig. 3). InstaJI
one nut to hold the brake backing tool shown in Fig. 13. FIG.5-Rear Wheel Bearing
plate in place after the axle shaft 13. Soak new seals in SAE 10 oil Removal
is removed. for 1/2 hour before use. Install the
5. Check the bearing for smooth new seal with tool 4245-B as shown 15. Install the bearing retainer
free rotation. Check the axle shaft in Fig. 14. Wipe a small amount of plate and the nuts that secure it.
splines for burrs, wear or damage. an oil resistant sealer on the outer Torque the nuts to specification
Replace worn or damaged parts. edge of the seal before it is installed. (Fig. 2).
6. If the rear wheel bearing is to Do not put sealer on the sealing 16. Install the brake drum and the
be replaced, loosen the inner r~tainer lip. Install the seal with its sealing drum retaining nuts.
ring by nicking it deeply with a cold tips toward the axle housing. 17. Install the wheel and tire on
chisel in several places (Fig. 4). It 14. Place a new gasket on each the drum.
will then slide off easily. side of the brake backing plate,
DRIVE PINION OIL SEAL
7. Press the bearing from the axle and then carefully slide the axle shaft
REPLACEMENT
shaft with the tool shown in Fig. 5. into the housing so that the rough
8. Inspect the machined surface forging of the shaft will not damage The drive pinion oil seal can be
of the axle shaft and the axle hous- the oil seal. Start the axle splines replaced without removing the rear
ing for rough spots or other irregu- into the side gear, and push the axle assembly from the car. Soak the
larities which would affect the seal- shaft in until the bearing bottoms in new seal in SAE 10 oil for 1/~ hour
ing action of the oil seal. Carefu11y the housing. before use.
remove any burrs or rough spots. 1. Raise the car on a hoist, or the
9. Lightly coat the wheel bearing rear of the car on a suitable jack.
bores with baH joint grease.
10. Place the retainer plate on the
axle shaft, and press the wheel bear-
ing on the shaft with tool 4621-A as
shown in Fig. 6.
FIG. 2-Wheel Bearing Retainer FIG. 4- Wheel Bearing Retainer FIG. 6-Rear Wheel Bearing
Plate ~emoval or Installation Ring Removal Installation

(065) PART 4-2-REAR AXLE 4-9
Tooi-1175-AE Tooi-4858-B
FIG. 9-Pinion Shaft Oil Seal

Removal
to avoid dropping the loose uni- FIG. 11-U-Joint Flange
versal joint hearing cups. Slide the Installation on Car
drive shaft forward, and remove
it from the transmission extension 10. Inspect the parts. Replace any
FIG. 7-Pinion Shaft Nut Removal housing. Install tool 7657-J in the that are worn or damaged.
or Installation-Axle in Cor transmission housing to prevent leak-
age. 11. Clean the pinion oil seal seat.
5. While holding the flange with Coat the outer edge of the new seal
2. Remove the retaining bolts and tool 4851-K, remove the pinion shaft with a small amount of oil resistant
washers, and then remove the bump- nut (Fig. 7). sealer. Do not put sealer on the
er, bracket, and spacers from the 6. Clean the carrier-housing around sealing lip. Drive the seal into the
housing. the oil seal. Place a drain pan under housing, using the tool shown in
3. To maintain proper drive line the seal, or raise the front of the Fig. 10.
balance, the drive shaft should he car· higher than the rear. 12. Start a new dust deflector over
installed in its original position. To 7. The U-joint flange removing the U-joint flange and drive the de-
insure proper installation at assem- tool 4858-D must be modified to fit flector into position on the flange
bly, make scribe marks on the drive the larger 1961-64 U-joint flange. as shown in Fig. 38.
shaft rear end yoke and the axle This can be easily accomplished by 13. Coat the inside of the U-joint
U-joint flange (Fig. 12). Also, make drilling two additional :Ys ··inch diam- flange with specified lubricant, and
chalk marks on the drive shaft front eter holes through the flat plate press the flange into position with
slip yoke and the transmission ex- portions of the tool to correspond to tool 4858-B as shown in Fig. 11.
tension housing. the opposing diagonal holes in the
4. Disconnect the rear end of the flange. See Fig. 8 for drilling di- 14. Remove the flange installing
drive shaft by removing the U-joint tool, and install the pinion shaft
mensions.
bearing caps that hold the spider to 8. Use reworked tool 4858-D to re- washer and nut. While holding the
the axle U-joint flange. Be careful move the U-joint flange from the flange with the tool shown in Fig.
7, torque the pinion shaft nut to
drive pinion, as shown in Fig. 8. Re-
move the dust deflector if damaged. specifications.
Tooi-4858-D Modified
9. Remove the pinion shaft seal 15. Remove tool 7657-J from the
assembly using tool 1175-AE, as transmission extension housing. In-
shown in Fig. 9. stall the drive shaft to the transmis-
Too/.-4676
FIG.8-U-Joint Flange Removal FIG. 10-Pinion Shaft Oil Seal FIG. 12-Drive Shaft-to-Axle
-Axle in Car Installation U-Joint Flange Connection

sion, so that the chalk marks on flange during the removal procedure 17. Install the spacers, bumper
the slip yoke and the transmission (Fig. 12). Connect the shaft to the bracket, and bumper on the hous-
extension housing are aligned. flange by installing the U-joint bearing, and secure with the retaining
16. Position the drive shaft to the ing caps that hold the spider to the bolts and lockwashers.
axle U-joint flange, aligning the flange. Install the bearing cap re- 18. Check the lubricant level, and
scribe marks made on the drive shaft taining bolts and torque to specifica- add whatever amount of specified
rear end yoke and the axle U-joint tions. lubricant is necessary. Lower the car.

REAR AXLE HOUSING sorbers from the mounting studs on Position the bolts in the replacement
ASSEMBLY the axle housing. housing flanges.
12. Remove the brake line-to-axle 2. Soak two new rear wheel bear-
REMOVAL housing retaining clips and the re- ing oil seals in SAE 10 oil for ~
1. Raise the car on a hoist or the taining bolt holding the junction hour before installation. Wipe a
rear of the car on a suitable jack. block to the axle housing. small amount of an oil resistant
Place a jack stand under each side, 13. Remove the parking brake sealer on the outer edge of each
at the rear of the spring hangers. cable retainers from the U-bolts. Do
seal before it is installed. not put
2. Lower the car until the weight 14. Remove the brake backing sealer on the sealing lip. Install
is supported by the jack stands. plates and wire them to the under- the oil seals in the ends of the rear
body. Do not disconnect the brake axle housing with the sealing lip
3. Drain the axle housing by
lines. toward the housing (Fig. 14).
loosening the rear cover bolts.
15. Remove the axle U-bolt re- 3. Position the rear axle housing
4. Remove the retaining bolts and on the rear springs. Position the
taining nuts.
washers, and remove the bumper, spring center mounting upper and
16. Remove the U-bolts, the spring
bracket and spacers from the hous- lower insulators and retainers, the
center mounting, insulator retainers
ing. shim wedge, and the U-bolts.
and the insulators.
5. To maintain proper drive line 4. Install the U-bolt retaining nuts
17. Remove the axle housing as-
balance, the drive shaft should be and torque to specifications. Make
sembly.
installed in its original position. To sure that the spring lower insulator
insure proper installation at assem- INSTALLATION contacts the upper retainer.
bly, make scribe marks on the drive 5. Install the brake backing plates
shaft rear end yoke and the axle 1. Clean the axle housing and
shafts using kerosene and swabs. To with new gaskets on the axle hous-
U-joint flange (Fig. 12). Also, make ing flanges.
chalk marks on the drive shaft front avoid contamination of the grease
in the sealed ball bearings, do not 6. Connect the parking brake
slip yoke and the transmission ex- cables to the U-bolts with the hook
tension housing. allow any quantity of solvent di-
rectly on the wheel bearings. type retainers.
6. Disconnect the rear end of the 7. Install the junction block on
If the axle housing is being re-
drive shaft by removing the two the axle housing and secure with
placed, disassemble the drive pinion
U-joint bearing caps that hold the the retaining bolt. Position the brake
and differential case assembly from
spider to the axle U-joint flange. Be line to the axle housing, and secure
the old housing and assemble them
careful to avoid dropping the loose with the retaining clips.
in the replacement housing as des-
universal joint bearing cups. Slide 8. Raise the rear axle housing and
scribed in Part 2-2, Section 4. Re-
the drive shaft forward, and remove springs enough to allow connecting
move the bolts that retain the brake
it from the transmission extension the rear shock absorbers to the
backing plate and wheel bearing re-
housing. Install tool 7657-J in the
tainer from the old housing flanges.
transmission housing to prevent leak-
age.
7. Remove the two rear wheel and
tire assemblies.
8. Remove the Tinnerman nuts
that secure each brake drum to the
axle shaft flange, and then remove
the drum from the flange.
9. Working through the hole pro-
vided in each axle shaft flange (Fig.
2), remove the nuts that secure the
wheel bearing retainer to the axle
housing. Pull each axle shaft and
hearing assembly out of the axle
housing using the tool ~hown in
Fig. 3. E1406-A
10. Remove both wheel hearing oil
seals (Fig. 13). FIG. 13-Rear Wheel Bearing FIG. 14-Rear Wheel Bearing
11. Disconnect the rear shock ah- Oil Seal Removal Oil Seal Installation

mounting studs on the axle housing. ll. Install the brake drums and flange during the removal procedure
Install the washers and nuts on the the ( Tinnerman) drum retaining (Fig. 12). Connect the shaft to the
studs and torque to specifications. nuts. flange by installing the U-joint bear-
9. Install the two axle shaft assem- 12. Install the wheel and tire as- ing caps that hold the spider to the
blies in the axle housing. Carefully semblies on the drums. flange. Install the bearing cap re-
slide each axle shaft into the housing 13. Remove tool 7657-J from the taining bolts, and torque to specifica-
so that the rough forging of the shaft transmission extension housing. In- tions.
will not damage the oil seal. Start stall the drive shaft to the transmis-
the axle splines into the side gear, sion, so that the chalk marks on 15. Install the spacers, bumper
and push the shaft in until the bear- the slip yoke and the transmission bracket, and bumper on the housing
ing bottoms in the housing. extension housing are aligned. and secure with the retaining bolts
10. Install the bearing retainer 14. Position the drive shaft on the and lock washers.
plates and the nuts that secure them. axle U-joint flange, aligning the 16. Fill the rear axle with specified
Torque the nuts to specifications scribe marks made on the drive shaft lubricant. Remove the jack stands
(Fig. 2). rear end yoke and the axle U-joint and lower the car.
~~ MAJOR REPAIR OPERATIONS

DISASSEMBLY with its respective bearing for
ClAMP SCREW Carrier Spreader 4000-C
proper assembly.
Mount the' axle housing in the 4. Remove the spreader tool, and
holding fixture tool 4005 (Fig. 3, turn the housing in the holding fix-
Part 4-1), and perform the "Inspec- ture so that the drive pinion shaft
tion Before Disassembly of Carrier" is in a vertical position. Remove
as explained in Part 4-1, Section 3. the nut from the pinion shaft as
Then disa~semble the carrier as out- shown in Fig. 17.
lined in the following procedures. 5. Remove the U-joint flange from
REMOVAL OF the pinion shaft using the modified
DIFFERENTIAL CASE, tool shown in Fig. 8.
PINION, AND BEARINGS 6. Turn the housing in the hold-
ing fixture so that the drive pinion
1. Remove the attaching bolts and is in a horizontal position, and then
the differential side bearing caps remove the pinion shaft oil seal with
(Fig. 15). Note the identification the tool shown in Fig. 9. Lift out
marks stamped on the bearings and the gasket and slinger.
housing for proper assembly.
2. Install the carrier spreader so
FIG. 16-Spreading Carrier 7. Turn tool 4201 onto the pinion
Housing shaft threads and drive against the
that the dowels on the tool enter tool until the pinion shaft and rear
the openings in the housing (Fig. the housing until the differential as- bearing are loosened from the hous-
16). Tighten the hold-down clamp sembly can be forced out with a pry ing (Fig. 18). Remove the tool from
screws. bar or long screwdriver. Do not the pinion shaft, withdraw the pin-
1 3. Release the wing nuts on the spread the housing more than ion and rear bearing assembly from
holding fixture, and spread the car- 0.020 inch to remove the differen- the rear of the housing, and remove
rier housing by rotating the turn- tial. Loosen the spreader turn- the front bearing and preload shims
buckle on the spreading tool. Spread buckle immediately after lifting from the front of the housing. Tie
out the differential assembly to all the shims together for assem-
BEARING CAP LOCATING MARKS prevent springing the housin~~· bly. Record the thickness of the
___ u
BOT LEITERS HORIZONTAl f-:._", Place each differential bearing cup shims in case they should be lost.
E1352-A E1383-A
FIG. 15-Differential Bearing FIG. 17 -Pinion Shaft Nut FIG. 18-Pinion and Bearing
Cap Locating Marks Removal Assembly Removal

CONVENTIONAL CASE
MARKINGS
DIFFERENTIAL CASE
DISASSEMBLY
1. Position the differential case in
the holding fixture, locate the fingers
of the puller tool in the cast recesses
of the differential case, and pull one
of the differential side bearings (Fig.
21). Tie the shims together for
assembly and label "ring gear
side" or "pinion side." Record the
thickness of the shims in case they
should be lost. E1392-A
- 2. Reverse the differential case in
the holding fixture, and remove the
second side bearing and shim pack FIG. 22-Aiignment Marks for
as dir~ted in step 1. Proper Assembly
3. Remove the ring gear-to-differ-
ential case bolts, and remove the 3. Place the assembly in holding
gear from the case. fixture 4205-B shown in Fig. 21. If
FIG. 19-Pinion Rear Bearing 4. With a punch, drive out the dif- the side bearings and/ or ring gear
Cup Removal ferential pinion shaft lock pin. Re- do not require replacement, skip
move the differential pinion shaft, steps 4 and/or 5 and proceed with
pinions, and thrust washers. Remove step 6.
8. Remove the pinion rear bearing the side gears and thrust washers. 4. Using the puller tool shown in
cup as shown in Fig. 19. Remove the Refer to Fig. 6, Part 4-1. Fig. 21, remove one of the differen-
pinion locating shims and tie them tial side bearings. Tie the shims
together. Record the thickness of "DffiECTED POWER" together for assembly, and label
the shims in case they should be DIFFERENTIAL CASE "Ring Gear Side" or "Pinion Side."
lost. DISASSEMBLY Record the thickness of the shims
9. With the forward end of the 1. Mark the differential case in case they should be lost. Re-
housing up, remove the pinion front halves for correct alignment at as- verse the differential case in the fix-
bearing cup (Fig. 20). sembly. See the "Case Markings" in ture, and repeat the procedure for
10. If necessary, the pinion rear Fig. 22. the opposite side bearing and shims.
bearing may be pressed off the drive 2. Mark one end of each mate 5. Remove the ring gear-to-differ-
pinion. Use tool 4621-BA. shaft exactly as shown in Fig. 22 so ential case bolts and remove the
that the "V" shaped end of each gear from the case.
If inspection before disassembly 6. Loosen but do not remove the
showed excessive ring gear runout, shaft will match the same "V" ramp
in the case when the unit is assem- eight bolts that hold the differen-
do not proceed to the disassembly tial case halves together. Remove
of the differential case at this bled.
the differential case from the holding
point. First, determine which parts fixture and set the case on the bench
should be replaced (differential case, with the ring gear half of the case
bearings, or ring gear) as explained down as in Fig. 22.
under "Parts Repair or Replacement" 7. Remove the case attachin~bolts
in this section. and the cover half of the case. Re-
move the upper clutch plates a;d
discs, side gear ring, side gear, and
upper mate shaft and pinions (Fig.
23). Keep these parts with the cover
half of the case so that they will
be installed in their original posi-
tions during assembly.
8. Remove the corresponding parts
from the ring gear half of the case
(Fig. 23), and keep the parts with
the ring gear half for proper assem-
bly.
PARTS REPAIR OR
REPLACEMENT
Clean and inspect all the parts as
outlined in Part 4-1, Section 3. Be-
fore assembling the rear axle, repair
FIG. 20-Pinion Front Bearing FIG. 21-Differential Bearing or replace all parts as indicated by
Cup R~emoval Removal the inspection.

FRICTION CLUTCH PLATE FRICTION CLUTCH PLATE
DIFFERENTIAL PINION (MATE)

SPRING DISC SHAFTS AND PINIONS SPRING DISC
CASE DIFFERENTIAL CASE

RING GEAR FLANGE HALF COVER HALF
E1391-A
FIG. 23- "Directed Power" Differential-Disassembled

The principal replacement opera- shown under the new pinion shim axle as a matched set (never sep-
tions are covered in the following adjustment number and in line with arately). Be sure that the same
procedures. All other repair or re- the old pinion number is the amount matching number appears on both
placement operations are performed of change that should be made to the drive pinion and the ring gear.
during "Cleaning and Inspection" the original shim thickness. Note the number "666F" in Fig. 24.
Part 4-1, Section 3, or during the If the old pinion is marked +4, 4. Start the rear bearing on the
"Assembly" procedures in this sec- for example, and the new pinion is drive pinion with its tapered end up,
tion. marked -2, the table indicates that then press the bearing on the pinion
0.006 inch of shim stock should be
DRIVE PINION AND RING added to the original shim pack.
GEAR SET If the original shim pack was lost
or if a new axle housing is being in-
When replacing a ring gear and stalled, substitute a nominal 0.030
pinion, note that the original factory inch shim for the original, and re-
insta\led (pinion locating) shim is o1 peat the foregoing steps for a trial
the correct thickness to adjust for huild-up. If any further shim change
individual variations in both the car-- is necessary, it will be indicated in
rier housing dimension and in the the tooth pattern check.
original gear set dimension. There- A new ring gear and pinion
fore, to select the correct shim thick- should always be installed in an
ness for the new gear set to he in-
stalled, follow these steps:
1. Measure the thickness of the
original pinion locating shim with
a micrometer.
2. Note the shim adjustment num-
ber on both the old pinion and the
new pinion. Each pinion gear is
marked with an adju~tmcnt number
such as the ·~·I marking in Fig. 24.
3. Refer to the tahle in Part 4-3
for the correct amount of shim thick- FIG.24-Pinion and Ring Gear FIG. 25-Pinion Rear Bearing
ness change. The amount that is Markings Installation

shaft as shown in Fig. 25. Use ASSEMBLY

a 0.0015-inch feeler gauge between
CONVENTIONAL
the bearing and the pinion gear to
DIFFERENTIAL CASE
be sure that the bearing is fully
ASSEMBLY
seated.
5. After determining the correct 1. Place a thrust washer over
shim thickness and insta11ing the each pinion and side gear. Assemble
rear bearing as explained in the fore- the pinion and side gears in the
going steps, install the new pinion differential case and secure them
and ring gear as outlined under "As- with the pinion shaft (Fig. 6, Part
sembly." 4-1). Lubricate all differential
parts liberally with axle lubricant
DIFFERENTIAL CASE, during assembly.
BEARINGS, AND RING GEAR 2. Slide the side gears and thrust
washers tightly against the pinion
If the ring gear runout check be- gear. Then, using a feeler ribbon,
fore disassembly exceeded specifi- check the clearance between the case
cations, the condition may be caused and the thrust washers. If the clear-
by a warped ring gear, a defective ance exceeds 0.015 inch, new thrust
case, or by excessively worn differ- washers must be installed.
ential side bearings. 3. Align the lock pin hole in the
To determine the cause of exces- pinion shaft with the hole in the case FIG. 28- Assembly of Differential
sive runout proceed as follows: and install the lock pin. Peen the Case Halves
1. Remove the ring gear from the case metal over the lock pin.
4. Place the differential case as- plates and discs to the side gear that
case, and install the case back in the pertains to the cover half of the case.
housing with side bearings and cups sembly in a holding fixture, tool
4205-B. Install the ring gear and Follow the same order of assembly
still installed. as in the foregoing step.
secure it with bolts. Torque the bolts
2. Check the runout of the case 3. Hold each differential case half
to specifications.
flange with a dial indicator. If the on its side and install the pertinent
runout does not now exceed speci- "DIRECTED POWER" side gear ring with plates and discs
fications, install a new ring gear to DIFFERENTIAL assembled. Make sure that the
the case during assembly. If the run- CASE ASSEMBLY dutch plate lugs are aligned and
out still exceeds specifications, the that they enter the slots in the case
ring gear is true and the trouble is 1. Select the side gear ring and
(Fig. 27). The side gear ring will
due to either a defective case or the clutch pack that pertains to the
rotate with a slight drag when
worn bearings. Continue with steps ring gear half of the differential
properly seated in the case.
3 through 5. case (Fig. 26). Assemble to the side
4. With the ring gear half of the
gear ring in order: a flat clutch
3. Remove the differential case case in an upright position, as in
plate (with external lugs), a clutch
from the carrier housing and re- Fig. 28, place the proper side
disc (with internal splines), a clutch
move the side bearings from the gear on the side gear ring. Place the
plate, the spring disc (with convex
case, using the tool shown in Fig. 21. lower (ring gear half) mate shaft
side toward the case), and the
4. Press new bearings on the case and pinions on the side gear ring
spring plate (with convex side to-
hubs with tool 4222-H, and again so that the locating marks on the
ward the case) .
install the differential case assembly 2. Assemble the remaining clutch
in the housing without the ring gear.
5. Check the case runout again
with the new bearings. If the runout
is now within specifications, the old
bearings were excessively worn. Use
' J·.·/·/
new bearings for assembly. If the
runout is still excessive, the case is
defective and should be replaced.
E1396-A
FIG. 26-Positioning of Parts for FIG. 27 -Installation of Side Gear FIG. 29-Spline Alignment of Side
Assembly Ring, Discs, and Plates in Case Gear and Side Gear Ring

(071) PART 4-2- REAR AXLE 4-15
mate shaft are aligned with the cor-

responding marks on the case. Posi-
tion the upper (cover half) mate
shaft and pinions with marks aligned,
and set the cover half side gear on
top of the four pinions (Fig. 28).
5. While holding the side gear and
clutch pack in the cover half of the
case, install the cover half on the
ring gear half so that the locating
marks on each differential case half
are in alignment (Fig. 28).
6. Install the differential case bolts
and turn them in a few threads.
7. Align the splines of the side
gears and side gear rings by insert-
ing the axle shaft on each side of
the case. Be sure the shaft goes all
the way in to engage both side gear
and side gear ring splines (Fig.
29).
8. With the axle shafts in posi-
tion, torque the differential case
bolts evenly and alternately to speci-
FIG. 31-Pinion Rear Bearing
fications. Cup Installation
9. Remove the axle shafts and
front end is down. Place dummy
check for proper assembly. If the
bearings (tool 4205-C) on the dif-
differential has been properly as-
ferential case hubs, and instaH the
sembled, each mate shaft should
be tight in its ramp; or, if there is case in the housing.
(b) Install the bearing caps in
clearance between the shaft and
the ramp, the clearance should be their correct position as indicated
equal at all four mate shaft ends.
by the identification marks, and in- FIG. 32-Pinion Front Bearing
stall the cap retaining bolts finger Cup Installation
INSTALLATION OF PINION, tight.
BEARINGS, AND (c) Set up a dial indicator with 3. Turn the front end of the axle
DIFFERENTIAL CASE its contact point against the back housing up, and install the front
face of the ring gear as shown in bearing cup (Fig. 32)!
1. Before installing the pinion and Fig. 30. Grasp both sides of the 4. The rear face of the pinion
bearings, measure the differential rmg gear firmly as shown, and gear (either new or old) should be
case side clearance as outlined in the with a steady pressure move the en- lightly stoned to remove any ir-
following steps. tire differential assembly in one di- regularities or burrs before at-
(a) Turn the axle housing as- rection to the limit of its travel. tempting a pinion gear depth
sembly in the fixture so that the Adjust the indicator to zero. reading.
\
(d) In the same manner, move Turn the housing to a horizontal
the differential assembly as far as it
will go in the opposite dire(:;tion.
Note the reading on the dial indi-
cator. This reading indicates the
amount of shims needed behind the
differential side bearings to take up
the total clearance between the
hearing caps and the case. Record
this reading for use later in the
assembly procedure.
(e) Remove the differential case
from the housing, and remove the
dial indicator and dummy bearings.
2. Install the pinion locating shim
pack, and then install the rear bear-
ing cup (Fig. 31). If the original
ring gear and pinion is being in-
stalled, usc the original shim pack.
If a new gear set is being installed,
usc a corrected shim pack as ex-
FIG. 30-Measuring Differential plained under ''Parts Replacement FIG. 33-Drive Pinion and Bearing
Case Side Clearance and Repair"" in this section. Assembly Installation

FIG. 34-Measuring Pinion

Bearing Preload
position, and install the drive pinion
and rear bearing assembly by in·
serting it from the rear side of the
housing. Install the front bearing
(without preload shims) and tool
4858-B on the pinion shaft, then
turn the housing to an upright posi-
tion. Draw these parts together in
the housing by turning the nut on
the tool (Fig. 33).
5. Tighten the nut on tool 4858-B
until the torque required to rotate
the drive pinion in the housing is
15 in-lbs as shown on the torque
indicator (Fig. 34).
6. To verify the selection of the
pinion locating shim, measure the
pinion depth as outlined in the fol-
lowing steps:
(a) Check the micrometer accu-
racy of the pinion depth gauge (tool
4020-B). The zero setting on the
FIG. 36-Measuring Pinion Depth

THIMBLE AlLEN SCREW
barrel should coincide with the l- ing caps and bolts. Torque the bolts
inch mark on the thimble (Fig. 35). to specifications. Attach the anvil
If the micrometer adjustment is out clamp assembly to the differential
0.003 inch or more, loosen the Allen housing. The anvil clamp should be
screw and turn the barrel until the positioned, as shown, with the em-
zero mark reaches the l-inch mark bossed letters facing downward.
on the thimble. When the adjustment Place the anvil block on the pinion,
is set, tighten the Allen screw. For as shown. Tighten the clamping
errors smaller than 0.003 inch turn screw against the anvil block.
the barrel with the spanner wrench (d) Refer to the calibration chart
until the error is corrected. in Table 1 to determine the correct
ANVIl (b) Remove the outer lock rings shim thickness for the pinion that
GAUGE SHAFT RESTING from the gauge shaft (Fig. 35). is instaiied. Check the pinion mark-
~NANVIl Position the aligning bushings as ing (Fig. 24). The micrometer
E1400-A shown in the insert in Fig. 36. reading shown in the calibration
(c) Install the gauge shaft and chart under the pinion marking of
FIG. 35-Pinion Depth Gauge micrometer assembly in the housing the pinion being used indicates the
Adius~menf as shown in Fig. 36. Install the bear· correct shim thickness.

TABLE 1-Calibration Chart (Gauge 4020-B)

inion
Marking +10 +9 +8 +7 +6 +5 +4 +3 +2 +1 0 -1 -2 -3 -4 -5 ~
*Micrometer
Reading .865 .866 .867 .868 .869 .870 .871 .872 .873 .874 .875 .876 .877 .878 .879 .880
*Allowable Tolerance: ±0.001 inch.
(e) Turn the micrometer thimble cup (Fig. 31), then install the pinion
until the spindle just contacts the and bearing assembly in the housing
anvil of the gauge tool, and take (Fig. 33).
the micrometer readings. (Figs. 35 8. If shims were installed or n~
and 36.) If the micrometer reading moved, recheck the pinion depth
varies more than 0.001 inch from as outlined in step 6.
the specifications in the calibration 9. Establish the pinion bearing
chart, the pinion shim pack will re- preload as outlined in the following
quire an adjustment. If the microm- steps.
eter reading obtained is greater than (a) With the drive pinion set at
that specified in the chart, it will be its correct depth, remove the pinion
necessary to remove 0.00 l inch in and the pinion front bearing (Fig.
shim stock for each 0.001 inch dif- 18).
ference between the micrometer (b) Install the drive pinion again,
reading and that specified in the and place the bearing preload shims
chart. over the forward end of the pinion
Conversely, if the micrometer shaft. If the pinion location shim
reading is Jess than that specified in pack behind the rear bearing cup
the chart, it will require the instaHa- was not changed, install the original
tion of 0.001 inch in shim stock for preload shim pack. If the pinion FIG. 38-U-Joint Flange
each 0.001 inch difference between location shim pack was changed, Deflector Installation
the micrometer reading and that add or subtract the same number
specified in the chart. of shims from the preload pack as flange (Fig. 38). Start the com-
7. Remove the gauge tool. If the was added or subtracted from the panion flange over the drive pinion
micrometer reading was within speci- pinion location pack. and press the flange into position as
fications, proceed with step 9. If shown in Fig. 39.
(c) Start the front bearing over
shim adjustment is required, remove the shaft with its tapered end down. 14. Install the washer and lock
the pinion and rear bearing assem- Press the bearing on the shaft with nut on the pinion shaft. While hold-
bly (Fig. 18). Then remove the the tool shown in Fig. 33. Using ing the flange with the tool shown
pinion rear bearing cup. (Fig. 19). tool 4858-G, torque the nut on the in Fig. 17, torque the nut to speci-
When adding or removing shims, fications.
tool to 200-220 ft-lbs (Fig. 37).
measure each shim separately. (d) With the pinion shaft in a 15. Refer back to the reading re-
Check the bearing bore for burrs vertical position, and using tool corded in step 1. This reading (taken
or upset metal. If any is present, 4209 as shown in Fig. 34 check before the pinion was installed) rep-
it must be removed. Make sure the torque required to rotate the resents the total clearance between
that the bearing cup and shim drive pinion. Correct preload will the differential side bearing cups and
pack are fully seated in the bore. be obtained when the torque re- the case. Perform the following steps
Install the pinion rear bearing quired to rotate the pinion is as for determining the number of shims
specified in Part 4-3. required at each bearing to take up
(e) If the torque is less than the
minimum specified, remove the front
pinion bearing and remove shims.
If the torque exceeds the maximum Tooi-4858-B
specified, install shims. Install the
front bearing again, and recheck the
preload.
10. Place the oil slinger over the
drive pinion and against the bearing
with its concave side up (Part 4-1,
Fig. 6).
11. Install the oil slinger gasket.
12. Start the new seal over the
drive pinion with the sealing edge
pointing down; then, using the tool
shown in Fig. 10, drive the seal
into position.
13. Start a new seal deflector over
FIG. 37 -Establishing Pinion the companion flange and drive FIG. 39-U-Joint Flange
Bearing Preload the deflector into position on lthe Installation-On Bench

16. Remove the dial indicator,

bearing caps and differential case
from the housing. Remove the
dummy bearings from the differ-
ential case.
17. Install the required number
of shims on the bearing case. Using
tool 4222-H, press the side bearings
on the case.
18. Attach the spreader tool to
the housing, as shown in Fig.
16, making certain the dowels
on the tool enter the openings
in the housing. Spread the housing
enough to permit installation of the
differential case and bearing as-
sembly. Do not spread the housing
more than 0.020 inch.
19. Install the bearing · caps in
their respective positions as indi-
cated by the markings on the caps
CLEARANCE .032"
and housing (Fig. 15). Remove the
+ PRELOAD .015" spreader. Place some sealing com-
pound on the bearing cap bolts.
.038w SHIM -~~ Install and torque the bolts to
PACK specifications.
E1243-B
20. With the dial indicator at-
FIG. 40-Differential Bearing Preload and Ring Gear Backlash Adiustment tached to the housing, as shown in
Fig. 4, Part 4-1, check the backlash
between the ring gear and pinion at
the clearance and establish preload the previously recorded total read- four equally spaced points around
and backlash: ing to obtain the amount of shims the ring gear.
(a) Place the dummy bearings necessary to take up the clearance
(tool 4205-C) on the differential between the bearing cup and the The backlash should not be less
hubs, and again install the differ- case at the pinion side of the dif- than 0.003 inch or exceed 0.008
ential assembly in the housing (this ferential. Increase this pinion side inch, and must not vary more than
time with the pinion installed). In- shim pack by an additional 0.015 0.002 inch between the positions
stall the bearing caps in their proper inch in order to provide correct bear- checked.
positions. Install and tighten the re- ing preload and backlash. 21. Attach a dial indicator to the
taining bolts finger tight. Install the EXAMPLE (Fig. 40): differential housing as shown in
dial indicator with the contact point Total Clearance Fig. 5, Part 4-1. With the indicator
against the back face of the ring previously recorded ... 0.070 inch set at "zero", revolve the ring gear
gear as shown in Fig. 30. Move Less reading in foregoing at least one revolution and check
the differential and ring gear as- step (a) the total ring gear runout. The total
sembly tight against the pinion (Amount of shims indicator reading, or runout, should
gear, and then set the dial indicator necessary to take not exceed 0.006 inch.
to zero. Move the differential and up clearance at ring 22. Make a final tooth contact
ring gear assembly away from the gear side) ........ 0.038 inch pattern check.
pinion as far as possible, and note Shims necessary to take
the reading. up clearance at 23. Install the gasket and differ-
(b) This reading indicates the pinion side . . ........ 0.032 inch ential cover with the gear identifi-
amount of shims necessary to take Plus 0.015 inch shims for cation ta~ beneath one of the cover
up the clearance between the bear- preload and backlash .. 0.015 inch bolts. Torque the bolts to specifi-
ing cup and the case at the ring Total amount of cations.
gear side of the differential as- shims at 24. Refill the axle with specified
sembly. Subtract this reading from pinion side ........ 0.047 inch lubricant.

(07~) 4-19
PART SPECIFICATIONS
4-3
REAR AXLE TORQUE LIMITS (Ft-lbs)
ADJUSTMENTS Differential Bearing Cap Retaining Bolts 70-90

--------
Description Inches
Ring Gear to Differential Case 50-60
Backlash Between Ring Gear and Pinion 0.003-0.008 -·
---···-------~-- -------··------ "Directed Power" Differential Case Half Retaining Bolts 35-45
Maximum Backlash Variation Between Teeth 0.002 r--------------
--- -- --------- Carrier Rear Cover Retaining Bolts 15-25
f-·
Maximum Runout of Backface of
Ring Gear as Assembled 0.006 Bumper Bracket to Carrier Housing Retaining Bolts 20-30
--------- f--
Nominal Pinion Locating Shim 0.030 U-Joint Flange to Drive Pinion Shaft Nut 200-220
-- -- r-----·
Available Pinion Locating Shims (Inches) 0.0025, 0.0035, Drive Shaft to Axle U-Joint Flange (Bearing Cap Bolts) 15-20
0.0045, 0.0055, 0.009, r-----·
0.011, 0 . 027, and 0.033 Minimum Pinion Nut Torque
------- -------- Required to Obtain Correct Pinion Bearing Preload 200-220
Available Pinion Bearing 0.003, 0.005, f-·------------ --
Preload Shims 0.010 and 0.030 Rear Spring U-Bolt Nuts 50-60
-- 1--------
Maximum Carrier Housing Spread 0.020 Rear Wheel Bearing Retainer Plate to Axle Housing 50-65
f--
Rear Shock Absorber to Axle Mounting Stud Nuts 30-40
PINION AND DRIVE GEAR IDENTIFICATION
Number of Teeth PINION BEARING PRELOAD ADJUSTMENT
Ratio r---- ·---~- ---------1
Ring Gear Pinion Inch
ll escripti on
2.89:1 55 19
Pounds
1---------------- ----r------- --I-----~--
With Se!al (New Bearings) 22-24
3.11 :1 59 19 -----------~·-
With Seal (Old Bearings) 12-16

------
LUBRICANT Without Seal (New Bearings) 18-20
,.--
Capacity 4.8 Pints Without Seal (Old Bearings) 8-12
\
DRIVE PINION ADJUSTING SHIM THICKNESS CHANGES (Inches)
New Pinion Marking

Old Pinion
Marking I
-4 -3 -2 -1 0 +1 +2 +3 +4
l
+4 +0.008
-------
- +0.007 _J. I
+0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 : +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001

+------
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002
f-------- --··- f - - - - - - ~-----f--·
+I +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003

-----
0 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004

---·
-1 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005

--~-
-2 +0.002 +0.001 I 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006

. r--------- --- -+ -- --~--·--
--
-3 +0.001 o I -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
--~--t ---- ---------~--
1--·
-4 0 -0.001 -0.002 -0.006

I -0.003 -0.004 -0.005 -0.007 -0.008

(076) .
1f[X)0~ (¥>~@§
0~]'§~]'0@~~{1,{1,\1
§{1,~~~

(077) 5-l
GROUP
5
PART DRIVE LINE
5-1
1 Description ................. . .......... 5-1 3 Removal and Installation ................... 5-2
•
2 Diagnosis and Testing .......... . .......... 5-2 4 Major Repair Operations ................... 5-2
II DESCRIPTION
The drive shaft assembly is a with a centering ball supported by
Hotchkiss type which incorporates roller bearings. The ball, socket, and
two universal joints, a centering bearings are lubricated through a
socket yoke, and a center yoke at special fitting in the yoke.
the transmission end of the shaft The slip yoke at the front univer-
(Fig. 1). A single universal joint is sal joint contains two caged needle
used at the rear axle end of the shaft. hearing assemblies which operate in
The three universal joints are of two grooves in the transmission out-
the needle bearing type and are
equipped with lubrication plugs. Fig.
put shaft. Torque from the output
shaft is transmitted through the
FIG. 2-Lubri,otion Tool
2 illustrates the special needle nose needle bearings to the slip yoke. The sion. When applying undercoat,
quick disconnect fitting that is re- slip yoke also is free to move fore cover the drive shaft. An accumu-
quired to lubricate the drive shaft. and aft on the output shaft to lation of undercoat on the drive
The centering socket yoke, which compensate for movement of the shaft may cause it to become un-
forms part of the front universal rear axle. The needle bearings are balanced. Vibration can cause ex-
joint, consists of a yoke and socket lubricated by fluid in the transmis- cessive wear of drive line parts.
@>--SNAP RING
BEARING
LUBRICATION
-·--B FITTING
~
BEARING
SEAL -----o DRIVE SHAFT
RING~
PLUG-~
SNAP PLU\G
BEARING~
CENTER YOKE
SEAL t €)
'
CENTERING SOCKET YOKE
SPIDER
E1423-A
FIG. 1-Drive Shaft Disassembled

5-2 GROUP 5-DRIVE LINE (078}
EJ DIAGNOSIS AND TESTING

DRIVE LINE BALANCE or a change in shimming is required,
If detailed parts of the drive shaft check the pinion nose angle as re-
are replaced and shaft vibration is lated to the rear riding height of the
encountered after installation, dis- car. The procedure for checking the
connect the shaft at the slip yoke. riding height is outlined under "Rid-
Rotate the slip yoke and transmission ing Height Measurement" in Steer-
output shaft 180 degrees; then, re- ing, Group 3, Part 3-1. Pinion nose
connect the shaft to the slip yoke. angle will vary with different rid-
If the vibration persists, disconnect ing heights. After checking and
the shaft at the rear axle companion recording the rear riding height,
flange. Rotate the flange and drive check the pinion nose angle as
pinion 180 degrees and reconnect follows:
1. Place the car on a known level
FIG. 3-Cheddng Pinion
the shaft to the flange.
surface, such as a drive-on front
Nose Angle-Typical
DRIVE LINE ANGLE CHECK suspension alignment fixture, which not compare to the related riding
Vibration or "shudder" which is will allow access to the rear axle height, remove the "U'' bolt nuts.
noticeable either on fast acceleration pinion nose. Install the appropriate wedges be-
or when coasting, using the engine 2. With a protractor and plumb tween each spring insulator upper
for a brake, may be caused by the line, measure the pinion nose angle, retainer and the axle housing mount-
rear axle housing being loose on the as shown in Fig. 3. To make this ing pad.
rear springs or by excessive drive tool, obtain a common protractor 5. Install and torque the "U" bolt
line angles. If the rear axle "U" and drill a small hole at the exact nuts to 50-60 ft-lbs.
bolts are loose, torque the nuts to center of the base (0°) line. Insert TABLE 1
50-60 ft-lbs. a short length of thread or fine *Pinion Nose
Drive line angles may be corrected fishing line through the drilled hole Riding Height Angle
by tilting the rear axle pinion nose and attach a weight to act as a
plumb bob. 6 inches 4°Down
up or down as required. Tapered 3Y2 o Down
3. Compare the riding measure- 7 inches
shims (wedges) are available in three 3o Down
ment and the pinion nose angle 8 inches
angles: Y2 , 1, arid 1Y2 degrees with 2Y2o Down
reading with those shown in Table 1. 9 inches
no more than one wedge to be used
on a side. To determine if shimming 4. If the pinion nose angle does *Tolerance ± ~ o

REMOVAL bolts and caps attaching the rear rear universal joint with the one on
universal joint to the differential the companion flange and install the
To maintain proper drive line bal- drive pinion companion flange. Do caps, bolts, lock washers and nuts.
ance, mark the drive shaft, universal not drop the loose bearing cups. 2. Torque the bolts to 15-18 ft-
joints, slip yoke, and companion 4. Remove the shaft assembly. lbs.
flange before removing the shaft as- 5. Pull the slip yoke off the trans- 3. Install the bearing assemblies
sembly, so it can be ·reinstalled in its mission output shaft. Install Tool by snapping them over the spline
original position. 7657-J in the transmission extension teeth using a hammer handle.
1. To remove the drive shaft as- housing to prevent fluid loss. 4. Slide the slip yoke into place on
sembly, remove the cap screws or 6. Using a long screwdriver, snap the transmission output shaft.
attaching bolts attaching the slip the two roller bearing assemblies off 5. Align the index marks on the
yoke to the front universal joint. the spline teeth inside the slip yoke. front U-joint with the one on the
2. Push the slip yoke forward on slip yoke.
the transmission output shaft and 6. Install the cap screws or attach-
INSTALLATION
lower the front of the drive shaft. ing bolts and lock washers. Tighten
3. Remove the nuts, lock washers, 1. Align the index marks on the them to 15-18 ft-lbs.
IJ MAJOR REPAIR OPERATIONS

DISASSEMBLY 2. Remove the lubrication plugs. or a socket about one inch in di-
Apply pressure on the centering ameter. As a receiver tool, use a sec-
1. Mark the position of the spid- socket yoke, and remove one bear- tion of pipe or a socket with an
ers, the center yoke, and the centering cup, as shown in Fig. 4. Remove inside diameter of about 1114 inches.
ing socket yoke as related to the the opposite bearing cup in the same Clamp these details and the center
yoke which is welded to the front manner. yoke in a vise, as shown in Fig. 5.
of the drive shaft tube. The spiders 3. Remove the snap rings which 4. Close the vise to press the bear-
must be assembled with the lubri- retain the bearing cups in the front ing cup approximately % inch out
cation plugs in their original posi- of the center yoke. As a remover of the center yoke and into the re-
tion to provide proper clearance. tool, use a piece of round bar stock ceiver. The bearing cup cannot be

(079) PART 5-1-DRIVE LINE 5-3
FIG. 4-Removing Bear-

ing Cup from Centering Socket Yoke
pressed out of the yoke more than
approximately % inch without
causing damage. FIG. 8-Removing
5. Tightly clamp the exposed bear- Center Socket Yoke
ing cup in the vise and drive the
yoke from the cup using a brass cup into the yoke far enough to in-
drift, as shown in Fig. 6. stall the snap ring. Install the snap
6. Using the same removing tools, ring in the opposite side of the yoke.
press on the exposed spider end to FIG. &-Removing Make certain both snap rings are
press the opposite bearing cup ap- Bearing Cup from Center Yoke properly seated. Install the lubrica-
proximately % inch out of the yoke tion fitting.
(Fig. 7). Remove the bearing cup retaining 3. To assemble the front universal
7. Remove the loose spider, and snap rings. joints, position the spider in the
remove the exposed bearing cup us- 13. With the same tools that were drive shaft yoke. Make sure the
ing a brass drift, as shown in Fig. 5. used to remove the front universal lubrication plugs will be in the
8. Pull the centering socket yoke joint bearing cups, press one bearing same position as originally in-
assembly off the centering stud, as out of the yoke. stalled. Press in the bearing cups and
shown in Fig. 8. Remove the rubber 14. Change the position of the seals. Install the snap rings.
seal from the centering ball stud. tools and press on the exposed spider 4. Position the center yoke over
9. Remove the snap rings from the end until the opposite bearing cup the spider ends and press in the
rear of the center yoke and the drive is free. Remove the spider. bearing cups and seals. Install the
shaft yoke. 15. Clean those parts which are to snap rings.
10. Partially press a bearing cup be re-used with a suitable cleaning 5. Install a new seal on the center-
out of the drive shaft yoke, as shown solvent. When replacement parts are ing ball stud. Position the centering
in Fig. 9. Stop the pressing oper- available in a repair kit, install all socket yoke on the stud.
ation when the inside of the center the parts supplied in the kit. If the 6. Place the front spider (with the
yoke almost contacts the slinger drive shaft is damaged, replace the lubrication fitting hole properly posi-
ring at the front of the drive shaft complete drive shaft assembly to be tioned) in the center yoke. Press in
yoke; otherwise, the ring can be assured of a balanced assembly. the bearing cups and seals, and in-
distorted. The arrow in Fig. 9. indi- stall the snap rings.
cates the interference point. Clamp ASSEMBLY 7. Apply pressure on the centering
the exposed bearing cup in the vise 1. To assemble the rear universal socket yoke and install the remain-
and drive the yoke from the cup. joint, start a new bearing cup and ing bearing cup and seals.
Remove the opposite bearing cup seal in the yoke. Insert the spider 8. Install the plugs and lubricate
from the drive shaft yoke in the and press the bearing cup approxi- the front and rear joints and the
same manner. mately 1;4. inch below flush with the centering yoke.
11. Remove the remaining bearing yoke.
cups from the center yoke and re- 2. Start a new bearing cup and
move the spider. seal over the opposite spider journal
12. Remove the lubrication fitting and into the yoke. Press the bearing
from the rear universal .ioint spider
INTERFERENCE
POINT
FIG. 7-Partially
FIG. 5-Partially Remov- Removing Second Bearing Cup FIG. 9-Bearing Cup
ing Bearing Cup from Center Yoke from Center Yoke Removal and Interference Point

(080)
1f{}=00~ [p~@§
0~1r§~1r0@~~[1[1 \'?
§[1~~~

7-1
GROUP
7
PART 7-1 PAGE PART 7-3 PAGE
GENERAL TRANSMISSION SERVICE .... 7-1 SPECIFICATIONS . . 7-39
PART 7-2
TURBO-DRIVE
AUTOMATIC TRANSMISSION . . . . . 7-13
PART GENERAL
TRANSMISSION
~ti~
Diagnosis and Testing ..................... 7-1
h~
7-1 SERVICE
2 Common Adjustments and Repairs ........... 7-8
3 Cleaning and Inspection ................... 7-8

I
The following preliminary checks The cooler can be further checked or if the fluid in the oil cooler leaks
should be made on the transmission for leaks by disconnecting the lines into the engine coolant system. A
before proceeding with any other at the cooler fittings and applying black light, however, must be used
diagnosis checks. 5 psi air pressure to the fittings. If with the fluorescent dye solution.
the cooler is leaking and will not
TRANSMISSION FLUID
hold this pressure, the radiator must CONVERTER AREA OIL LEAKAGE
LEVEL CHECK
be replaced. The cooler cannot be
Check the transmission fluid level. In diagnosing and correcting fluid
replaced separately.
Low fluid level can affect the oper- leaks in the front pump and con-
If leakage is found at either the verter area, the following procedures
ation of the transmission,. and may transmission throttle lever (kickdown
indicate fluid leaks that could cause are to be used to facilitate locating
lever) shaft or the manual lever the exact cause of oil leakage. Leak-
transmission damage. shaft, replace either or both seals.
A fluid level that is too high will age at the front of the transmission, as
Inspect the pipe plugs in the evidenced by oil around the con-
cause the fluid to become aerated. transmission case. If a plug shows
Aerated fluid will cause a low control verter housing, may have several
leakage, torque the plug to specifi- sources. By careful observation, it
pressure, and the aerated fluid may cation. If tightening does not stop
be forced out the vent at the front of is possible, in many instances, to
the leak, replace the plug. pinpoint the source of the leak before
the transmission case.
When converter drain plugs leak, removing the transmission from the
TRANSMISSION FLUID remove the two drain plugs with a car. The paths the fluid takes to reach
LEAKAGE CHECKS sixpoint wrench. Coat the threads the bottom of the converter housing
Check the speedometer cable con- with FoMoCo Perfect Seal Sealing are shown in Fig. 1. Figure 2 shows
nection at the transmission for oil Compound or its equivalent, and in- the location of the hole in the front
leakage. Check the governor inspec- stall the plugs. Torque the drain of the case that can cause oil leakage
tion plate for leakage. Install a new plugs to specification. Fluid leakage at the converter area, if the trans-
gasket if needed. Leakage at the oil from the converter housing may be mission oil level is too high. Check
pan gasket often can be stopped by caused by engine oil leaking past the oil lev.el first, then check the fol-
tightening the attaching bolts to the the rear main hearing or from oil lowing items:
proper torque. If necessary, replace gallery plugs, or power steering oil 1. Fluid that leaks by the seal lip
the gasket. leakage from the steering or will tend to move along the drive hub
Check the fluid filler tube connec- hydro-wipe system. Be sure to and onto the back of the impeller
tion at the transmission. Check the determine the exact cause of the housing. Except in the case of a total
fluid lines and fittings between the leak before repair procedures are seal failure, fluid leakage by the lip
transmission and the cooler in the started. of the seal will be deposited on the
radiator tank for leakage, looseness, Oil-soluble aniline or fluorescent inside of the converter housing only,
wear, or damage. If leakage cannot dyes premixed at the rate of 1h tea- near the outside diameter of the
be stopped by tightening a fitting, re- spoon of dye powder to 1h pint of housing (Fig. 1).
place the leaking parts. transmission fluid have proved help- 2. Fluid leakage by the outside
Check the engine coolant in the ful in locating the source of the diameter of the seal and front pump
radiator. If transmission fluid is fluid leakage. Such dyes may be used body will follow the same path as
present in the coolant, tht~ cooler in to determine whether an engine oil shown in Fig. 1.
the radiator tank is probably leaking. or transmission fluid 1eak is present, 3. Fluid that leaks by a front pump

7-2 GROUP 7-AUTOMATIC TRANSMISSION (082}
to case bolt will be deposited on the

inside of the converter housing only.
Fluid will not be deposited on the
back of the converter (Fig. 1).
4. Leakage by the front pump to
case gasket may cause fluid to be
deposited inside the converter hous-
ing, or it may seep down between the
front of the case and converter hous-
ing. Fluid on the front of the case,
above the pan gasket, is evidence that
Til
the front pump to case gasket could
be leaking. [ I
5. Fluid leakage from the con-
verter drain plugs will appear at the
I
outside diameter of the converter on CRANKSHAFT
the back face of the flywheel, and in
the converter housing only, near the FRONT PUMP SEAL LEAK
flywheel (Fig. 1).
6. Engine leaks are sometimes im-
properly diagnosed as front pump
r
seal leaks.
The following leakage areas
should also be checked to deter-
mine if other oil leakage is causing
the problem.
1. Leakage at the rocker arm cover
(valley cover) may allow oil to flow
over the converter housing or seep
down between the- converter housing
and engine block causing oil to be
present in or at the bottom of the
converter housing.
2. Oil gallery plug leaks will allow
oil to flow down the rear face of the
block to the bottom of the converter
housing.
3. Leakage by the crankshaft seal
will work back to the flywheel, and
from there into the converter housing
(Fig. 1).
Oil leakage from other areas such CONVERTER DRAIN PlUG LEAK D1311-A
as the power steering or from the
hydro-wipe motor, lines or connec-
tions, forward of the transmission, FIG. 1-Converter Area Oil Leakage Checks
could cause oil to be present around
the converter housing due to blow since road draft may cause power the transmission reaches operating
back or road draft. steering fluid to be present on the temperature. Observe the back of
The following procedure should transmission. the block and the top of the con-
be used to determine what is caus- 2. Remove the lower converter verter housing for evidence of oil
ing the oil leakage before any re- housing cover. Clean off any fluid leakage. Raise the car on a hoist and
pairs are made: from the top and bottom of the con- run the engine at fast idle, then at
1. Remove the transmission dip- verter housing, front of the trans- engine idle, and occasionally shift to
stick and note the color of the fluid. mission case, and rear face of the the drive and reverse ranges to in-
Original factory fill fluid is dyed red engine and engine oil pan. Clean crease pressures within the trans-
to aid in determining if leakage is by washing with suitable non-flam- mission. Observe the front of the fly-
from the engine or transmission. Un- mable solvent, and blow dry with wheel, back of the block, inside the
less a considerable amount of "make- compressed air. converter housing and the front of
up" fluid has been added, or the 3. Wash out the converter housing, the transmission case. Run the engine
fluid has been changed, the red color the front of the flywheel, and the until oil leakage is evident and the
should assist in pinpointing the leak. converter drain plugs. The converter probable source of leakage can be
Fluid used in the power steering and housing may be washed out using determined.
hydro-wipe system is also dyed red. cleaning solvent and a squirt type oil CONVERTER LEAKAGE CHECK
This source of leakage should be can. Blow all washer areas dry with If there are indications that the
eliminated, if present, before per- compressed air. welds on the torque converter hous-
forming work on the transmission 4. Start and run the engine until ing are leaking, the following check

(083) PART 7-1- GENERAL TRANSMISSION SERVICE 7-3
¥32" STEEL PLATE ~ HEX. HEAD SCREW
DISHED OR
o/a" X 1%",
DRILL TO SUIT
!!!!!" 3
/8" -24 X V2
FLAT WASHER
1 JA" O.D., 1 ~" I.D. HEX. NUT %"-24
WELD
TOGETHER
SECTION
VIEW FROM A-A
FRONT (REVOLVED) D 1360-A
RUBBER PLUG
1 V2" DIA. X 2"
FIG. 2- Transmission LONG V2"
Vent at Front of Transmission Case SPACER-
B2Q-9438-A
HOLE THRU
APPROXIMATElY
40 DUROMETER STANDARD BOLT
should be made before the unit is PLUG V2"- 13 X 4 V2"
replaced. A leak checking tool (Fig. LONG SQUARE
CHAIN, 10" lONG THREAD END
3) can be made from standard parts. WElD TOGETHER
REMOVE HEAD
1. Install the plug in the converter SECURElY -MUST
AND WELD TO
NOT LEAK
(Fig. 4) and expand it by tightening WASHER
the wing nut. Attach the safety
STANDARD FITIING-
chains. 87971-S
2. Install the air valve in one of VALVE 01067-A
the drain plug threads.
3. Introduce air pressure into the FIG. 3-Converter Leak Checking Tool
converter housing. Check the pres-
sure with a tire gauge and adjust it and kickdown) should occur within the vacuum gauge reading is lower
to 20 psi. the road speed limits given in the than 18.0 inches, an engine or
4. Place the converter in a tank of Specification Section of Group 7. vacuum line problem is indicated.
water. Observe the weld areas for Automatic Shifts (Control Pres- Repair as necessary.
bubbles. If no bubbles are observed, sure and Diaphragm Unit Checks). The transmission control pressure
it may be assumed that the welds are If the automatic shifts do not occur should agree with the control pres-
not leaking. within limits, the following procedure sures as outlined in the Specification
ENGINE IDLE SPEED CHECK is suggested to separate engine, trans- Section of Group 7. If transmission
Check and, if necessary, adjust the mission, linkage, and diaphragm unit control pressure is within limits, shift
engine idle speed, using the proce- troubles: the transmission into D 1 or D2 and
dure given in Group 10. 1. Attach a tachometer to the firmly apply the service brakes. Ad-
If the idle speed is too low, the
engine and a vacuum gauge to the vance the throttle until the engine
engine will run roughly. An idle transmission vacuum line, at the vacuum gauge reading falls below
speed that is too high will cause transmission. 16-13.7 inches. As the vacuum gauge
the car to creep, have harsh engage- 2. Attach a pressure gauge to the reading passes through the 16-13.7
ments and harsh closed throttle control pressure outlet at the left inches range, transmission control
downshifts. side of the transmission. pressure should start to rise and con-
3. Firmly apply the parking brake
\
MANUAL LINKAGE CHECKS and start the engine.
Correct manual linkage adjustment 4. Adjust the engine idle speed to
is necessary to position the manual the specified rpm in Dl or D2. If
valve for proper fluid pressure direc- the engine idle speed cannot be
tion to the different transmission brought within limits by adjustment
components. Improperly adjusted at the carburetor idle adjustment
manual linkage may c:ause cross- screw, check the throttle and down-
leakage and subsequent transmission shift linkage for a binding condition.
failure. Refer to Linkage Adjust- If the linkage is satisfactory, check
ments in this Group of the manual for vacuum leaks in the transmission
for detailed manual linkage adjust- diaphragm unit and its connecting
ment procedure. tubes and hoses. Check all other
vacuum operated units (such as the
CONTROL PRESSURE, VACUUM power brake or distributor advance
DIAPHRAGM UNIT, AND
DOWNSHIFT LINKAGE
diaphragm) for vacuum leaks.
5. At engine idle speed, read the
~-. :> ~Tire Pressure Gauge
When the vacuum diaphragm unit engine vacuum gauge and the trans- 01068-A
is operating properly and the down- mission control pressure gauge.
shift linkage is adjusted properly, all The engine vacuum gauge should FIG. 4-Converter Leak
the transmission shifts (automatic read a minimum of 18.0 inches. If Checking Tool Installation

7-4 GROUP 7-AUTOMATIC TRANSMISSION (084)
tinue to rise with throttle opening, pressure regulator and control valve
until maximum control pressure for body.
stall in 01 and D2 is obtained. When
the selector lever is shifted into R KICKDOWN SHIFTS
or L and the engine rpm is increased, With the linkage properly ad·
control pressure should rise immedi- justed the transmission still might
ately and reach its maximum before not downshift when it is road-tested
engine speed reaches stall rpm. If because of an improperly adjusted
the vacuum and pressure gauge read- or bent downshift control rod. Check
ings follow the pattern described for restricted transmission throttle
above, the diaphragm unit and trans- lever travel at the transmission or
mission control pressure regulation kickdown rod.
system are operating properly.
If transmission control pressure at STALL TEST
idle is too low, too high, fails to rise The stall test is made in D 1, 02,
with throttle opening, or is extremely Ll, L, orR (at full throttle only) to
erratic, follow the procedure given
under the following appropriate head- FIG. 5- Testing Trans- determine if the bands and clutches
are holding properly. While making
ing. mission Va,uum Unit for Leakage this test, do not hold the throttle
CONTROL PRESSURE IS LOW open for more than five seconds at
trol rod. When the hose is removed, a time. Then move the selector lever
If control pressure at engine idle the internal spring of the vacuum
is low in all selector lever positions, to N for about one minute and run
unit should push the control rod out- the engine at fast idle to cool the
trouble other than the diaphragm ward.
unit is indicated. converter before making the next
Transmission control pressure in R CONTROL PRESSURE DOES test.
is regulated entirely by the control NOT RISE WITH THROTTLE Connect a tachometer, and start
pressure regulator valve and its OPENING the engine to allow it to reach its
spring. When control pressure at en- If transmission control pressure normal temperature. Apply both the
gine idle is low in all ranges, check does not rise in D 1 and D2 as engine parking and service brakes.
for excessive leakage in the front oil vacuum falls below 16-13.7 inches, With the selector lever at D2,
pump, case, pressure regulator and check the transmission's pressure rise press the accelerator to the floor.
control valve body. capacity by shifting to R. In this Note the engine speed. Stall speeds
position, maximum control pressure are given in the Specification Section
CONTROL PRESSURE IS HIGH should be obtained at not more than of Group 7.
If transmission control pressure at engine stall rpm. In D 1 (car standing still), the
engine idle is too high in Dl, D2 If pressure rise is normal in R, re- front clutch and the one-way clutch
and L, the trouble may be in the dia- move the hose from the diaphragm are engaged at all accelerator pedal
phragm vacuum unit or its connect- unit and check the hose and tubes positions.
ing tubes and hoses. In D2 (car standing still), the
as given above. If the vacuum read-
With the engine idling, disconnect front clutch and front band are en~
ing at the diaphragm end of the hose
the hose from the diaphragm unit gaged at all accelerator pedal posi-
is 18 in. Hg or greater, check the
and check the engine manifold diaphragm unit and again check for tions.
vacuum. Hold a thumb over the end In L, the front clutch and rear
a pressure rise with the throttle open-
of the hose and check for vacuum. band are applied.
ing in 01 and D2. If control pres-
If the engine speeds up when the In R, the rear clutch and ..rear
sure does not rise now, the trouble
hose is disconnected and slows down band are applied.
is in the transmission hydraulic cir-
as the thumb is held against the end If the engine speed exceeds the
cuits. Check for excessive leakage
of the hose, the vacuum hose is maximum limits, release the accel-
in those components which have con-
capable of holding vacuum. erator immediately because clutch
trol pressure in them in 01 and 02
To check the vacuum unit for dia- or band slippage is indicated.
but do not have control pressure in
phragm leakage, remove the vacuum The band or clutch that is causing
them in R.
unit from the transmission. Use a the slippage can be found by testing
distributor tester equipped with a CONTROL PRESSURE IS in another selector lever position.
vacuum pump (Fig. 5). Set the EXTREMELY ERRATIC For example, should the transmis-
regulator knob so the vacuum gauge If transmission control pressure is sion slip in D 1 (low gear) but not
reads 18 inches with the end of the extremely erratic in D 1 and D2, in D2 (intermediate gear) the prob-
vacuum hose blocked to obtain a check the diaphragm unit tubes, able cause is the planet one-way
maximum vacuum reading of 18 in. hoses, and diaphragm push rod as clutch.
Hg. given under Control Pressure Is
Then, connect the vacuum hose to High. If the vacuum source is satis- PERFORMANCE CHECKS
the transmission vacuum unit. If the factory, check the diaphragm unit Performance checks should b~
vacuum gauge still reads 18 inches, and repeat the tests for transmission made only after all preliminary
the vacuum unit diaphragm is not control pressure. If control pressure checks have been completed. If an
leaking. As the hose is removed from is still extremely erratic, the trouble unsatisfactory operating condition is
the transmission vacuum unit, hold is in the transmission hydraulic regu- found during these checks, stop the
one finger over the end of the con- lating circuits. Clean and inspect the checks and proceed to the final

(085) PART 7- 1 -GENERAL TRANSMISSION SERVICE 7-5
diagnosis and correction of the SHIFT POINT CHECKS conditions.

trouble. Partial-throttle downshifts in Dl
Check the light throttle upshifts
INITIAL ENGAGEMENT in D I . The transmission should start may be checked by using the service
CHECKS in first gear and shift to second and brakes as a load. With the transmis-
Initial engagement checks are then shift to third within the shift sion in third gear, D 1, and car speed
made to determine if initial band points as outlined in the Specifica- at about 30 mph, depress and hold
and clutch engagements are correct. tion Section of Group 7. the accelerator· at a half-throttle posi-
Run the engine until the normal While the transmission is in third tion. At the same time, apply the
operating temperature is reached. gear, depress the accelerator pedal service brakes to the point that road
With the engine at the correct idle through the detent (to the floor) speed is slowly reduced. The third
speed, shift the selector lever from position. The transmission should to second and then second to first
N to D2, and from N to Dl. Ob- shift from third to second or third shifts should occur as road speed
serve the initial band and clutch to first, depending on the car speed decreases.
engagements. Band and clutch en- as outlined in the Specification Sec- When the selector lever is at D2,
gagements should be smooth in all tion of Group 7. the transmission can operate only in
positions. Rough initial engagements Check the closed throttle down- second and third gears. Shift points
in Dl, D2, L or R are caused by shift from third to first by coasting for second to third and third to sec-
high engine idle speed, bands out down from about 30 mph in third ond are the same in both D2 and
of adjustment, high control pressure, gear. The shift should occur within Dl.
and faulty operation of the vacuum the limits given in the Specification If the transmission is in third gear
unit, pressure regulator valve or Section of Group 7. A 3-2-1 shift and road speed is above about 30
main control valve. may be experienced under certain mph, the transmission should shift
CONVERTER FILL
OIL RETURN FROM COOU' LINE PRESSURE TO
TO PRESSURE REGULATOR OUTSIDE OF CASE
FOR PRESSURE TEST
FRONT
SERVO #?
RElEASE
···~
APPLY AND RELEA ,t
TOP VIEW 81317-A
FIG. 6- Transmission Case Hydraulic Passages

to second gear when the selector REAR CLUTCH

lever is moved from D2 or D 1 to Apply air pressure to the rear
L. When the same manual shift is passage (Fig. 6). A dull thud indi-
made below about 25 mph, the trans- cates that the rear clutch piston has
mission will shift from second or moved to the applied position. If no
third to first. This check will deter- noise is heard, place the finger tips
mine if the governor pressure and on the rear drum and again apply
shift control valves are functioning air pressure to detect movement of
properly. the piston.
CONVERTER CHECK FRONT SERVO
When the stall test speeds are low Hold the air nozzle in the front
and the engine is properly tuned, servo apply hole (Fig. 6). Operation
converter stator clutch problems are of the front servo is indicated by a
indicated. A road test must be per- tightening of the front band around
formed to determine the exact cause the drum. Continue to apply air pres-
of the trouble. sure to the front servo apply hole,
If the stall test speeds are 300 to and introduce air pressure into the
400 rpm below the values shown front servo release hole. Hold a
in the Specification Section of Group
7, and the car cruises properly but
FIG. 7-Governor Valve cloth over the release tube while
applying the servo to catch the
has very poor acceleration, the stator cated by introducing air pressure spray from the release tube. The
clutch is slipping. into the transmission case passages front servo should release the band
Remove the converter and check leading to the clutches, rear servo, against the apply pressure.
the stator clutch as described in and governor, and into the front REAR SERVO
"Cleaning and Inspection," Part 7-1. servo apply and release pressure Apply air pressure to the rear
If the stall test speeds are 300 to holes (Fig. 6). servo apply passage (Fig. 6). The
400 rpm below the values, and the rear band should tighten around the
car drags at cruising speeds and has FRONT CLUTCH drum if the rear servo is operating
poor acceleration, the stator clutch Apply air pressure to the trans- properly.
is installed backwards. mission case front clutch passage During the above air pressure
When the stall test shows normal (Fig. 6). A dull thud can be heard checks, if the servo does not operate,
speeds and the acceleration is good, when the clutch piston is applied. disassemble, clean, and inspect the
but the car drags at cruising speeds, If no noise is heard, place the finger servo parts to locate the source of
the difficulty is due to a seized stator tips on the drum and again apply the trouble.
assembly. If the stator is defective, air pressure to the front clutch pas- If air pressure applied to either of
replace the converter. sage. Movement of the piston can the clutch passages faiJs to operate a
AIR PRESSURE CHECKS be felt as the clutch is applied. clutch or operates both clutches at
A "NO DRIVE" condition can once, remove the clutch units and with
GOVERNOR air pressure, check the fluid passages
exist, even with correct transmission
fluid pressure, because of inoperative Remove the governor inspection at the output shaft aluminum sleeve
clutches or bands. The inoperative cover from the extension housing. for correct indexing with the shaft
units can be located through a series Apply air pressure to the front clutch holes. Check the primary sun gear
of checks by substituting air pressure passage, listen for a sharp noise, and shaft assembly passages with air pres-
for the fluid pressure to determine watch to see if the governor weight sure to detect obstructions (Fig. 8).
the location of the malfunction. snaps inward (Fig. 7). Inward weight If the output shaft and primary
When the selector lever is at D2, movement indicates correct governor sun gear shaft passages are clear,
a "NO DRIVE" condition may be valve operation. remove the clutch assemblies, and
caused by an inoperative front
clutch. A "NO DRIVE" condition # 1 CONTROL PRESSURE
at Dl may be caused by an inoper- TO FRONT CLUTCH AND
GOVERNOR
ative front clutch or one-way clutch.
When there is NO DRIVE in L, the
difficulty could be caused by im-
proper functioning of the front
clutch. Failure to drive in reverse
range could be caused by a mal-
function of the rear clutch or rear
hand. Erratic shift points could be
caused by a malfunction of the gov-
ernor.
To make the air pressur~ checks, #2 CONTROL
drain the transmission fluid, then PRESSURE TO REAR
CLUTCH
remove the oil pan, the control valve D1022-A
assembly and necessary oil tubes.
The inoperative units can be lo- FIG. 8-0utput and Primary Sun Gear Shafts Fluid Passages

(087) PART 7-1- GENERAL TRANSMISSION SERVICE 7-7
clean and inspect the malfunction- that may be found and gives the letter symbols for each item are ex-
ing clutch to locate the trouble. items that should be checked to find plained in the key. If items A, B,
the cause of the trouble. C, K, and the stall test have already
DIAGNOSIS GUIDE The items to check are arranged been checked during preliminary
The Diagnosis Guide lists the in a logical sequence which should checks and adjustments, they need
most common trouble symptoms be followed for quickest results. The not be repeated.
DIAGNOSIS GUIDE
Items to Check
Trouble Symptom i Transmission Transmission
out of car
Probable Trouble Sources
in car
Rough Initial Engagement in Dl or D2 KBWFE A. Fluid Level
-
1-2 or 2-3 Shift Points 1ncorrect ABCDWEL B. Vacuum Diaphragm Unit or Tubes
rj
c. Manual Linkage
Rough 2-3 Shift BGFE
D. Governor
Engine Overspeeds on 2-3 Shift I BGEF r -
i
-- E. Valve Body
No. 1-2 or 2-3 Shift i DECG b c fj
i F. Pressure Regulator
No. 3-1 Shift I KBE G. Front Band
No Forced Downshifts l LWE H. Rear Band
__l -
Runaway Engine on Forced Downshift J GFE cj I. Rear Servo (Air Check)
I J. Front Servo (Air Check)
Rough 3-2 or 3-1 Shift at
Closed Throttle KBE K. Engine Idle Speed
Creeps Excessively in D 1 or D2
----
1- K L. Downshift Linkage
Slips or Chatters in First Gear, D I

I
I ABWFE a c fi M. Converter Drain Plugs
i
- N. Oil Pan Gasket, Drain Plug or Tube
Slips or Chatters in Second Gear I ABGWFE a cj -
-------- l
0. Oil Cooler and Connections
Slips or Chatters in R I
!
AHWFEI b cf -
P. Manual or Throttle Lever Shaft Seal
No Drive in Dl
- l CE i
Q. Vs-inch Pipe Plug in Side of Case
No Drive in D2 t
GER acf R. Perform Air Pressure Check
i
I
No Drive in L CHIER cf s. Extension Housing to Case Gaskets and
Lock Washers
No Drive in R HIER bcf
T. Center Support Bolt Lock Washers
No Drive in Any Selector Lever
Position ACWFER c U. Extension Housing Rear Oil Seal
+---- v. Governor Inspection Cover Gasket
Lockup in Dl CIJ bgc
w. Perform Control Pressure Check
t:
Lockup in D2 CHI bgci
X. Speedometer Driven Gear Adapter Seal
Lockup in L GJE bgc
a. Front Clutch
I
Lockup in R G a g cj b. Rear Clutch
-+---
Parking Lock Binds or Does Not Hold
-+-------
c g c. Leakage in Hydraulic System
Engine Does Not Start by Pushing Car ',
ACFE ec d. Front Pump
Transmission Overheats
- +-- e. Rear Pump
OF n
+---- f. Fluid Distributor Sleeve in Output Shaft
Maximum Speed Too Low, I
Poor Acceleration i n g. Parking Linkage

I h. Planetary Assembly
Transmission Noisy in N F ad
Transmission Noisy in First,
~ I
I. Planetary One-Way Clutch
Second, Third, or Reverse Gear I F habd j. Engine Rear Oil Seal
I
Transmission Noisy in P F d m. Front Pump Oil Seal
I
Transmission Noisy During Coast at r n. Converter One-Way Clutch

20-30 mph inN, Engine Stopped e p. Front Pump to Case Gasket
Fluid Leak iMNOPQSTUVX jmp r. Rear Clutch Piston Air Bleed Valve


TRANSMISSION FLUID If a major failure has occurred fluid to the transmission to raise the
LEVEL CHECK within the transmission such as a level to the F (full) mark on the
clutch, band, bearing, etc., the trans- dipstick. Do not overfill the trans-
The transmission fluid level should mission will have to be removed for mission.
be checked using the following pro- service. At this time the converter
cedure: must be thoroughly flushed to re-
1. Make sure that the car is stand- OIL COOLER
move any dirt.
ing level. Then firmly apply the FLUSHING PROCEDURE
When filling a dry transmission
parking brake. and converter, install 6 quarts of When a clutch or band failure or
2. Run the engine at normal idle fluid. Start the engine; shift the other internal trouble has occurred
speed. If the transmission fluid is selector lever as in step 5 below; in the transmission, any metal par-
cold, run the engine at fast idle check and add fluid as necessary. ticles or clutch plate or band ma-
speed (about 1200 rpm) until the
Following is the procedure for terial that may have been carried
fluid reaches its normal operating
partial drain and refill due to minor into the cooler should be removed
temperature. When the fluid is warm,
repairs. from the system by flushing the
slow the engine down to normal idle
1. Remove the reinforcement plate cooler before the transmission is put
speed.
and loosen the oil pan bolts. When back into service.
3. Shift the selector lever through
the fluid has stopped draining from 1. Disconnect the fluid return line
all positions, and place the lever at from the rear of the transmission.
P. Do not turn off the engine during the transmission, remove and thor-
oughly clean the oil pan. Discard the 2. Start the engine and drain about
the fluid level checks. two quarts of fluid from the cooler
4. Clean all dirt from the trans- oil pan gasket. Remove the con-
verter drain plugs. After the con- into a pan. Discard the drained fluid.
mission fluid dipstick cap before re- If there i:; no fluid flow or the fluid
moving the dipstick from the filler verter has drained, install the plugs.
Place a new gasket on the oil pan, does not flow freely from the return
tube. line, shut off the engine and discon-
5. Pull the dipstick out of the and install the filter-type screen and
pan on the transmission. nect both lines at the cooler and
tube, wipe it clean, and push it all
transmission.
the way back into the tube. 2. Install the oil pan, and tighten
3. Use an air hose (with not more
6. Pull the dipstick out of the the pan retaining bolts to specifica- than 100 psi air pressure) to reverse
tube again, and check the fluid level. tions. Install the reinforcement plate flush the lines and the cooler.
If necessary, add enough fluid to the under the oil pan. 4. Connect both lines at the cooler,
transmission through the filler tube 3. Add about 6 quarts of fluid to and the pressure line at the trans-
to raise the fluid level to the F the transmission through the filler mission.
(Full) mark on the dipstick. Do not tube. 5. Start the engine and check the
overfill the transmission. 4. Run the engine at idle speed fluid flow. If the fluid flows freely,
for about two minutes, then run the connect the return line at the trans-
TRANSMISSION FLUID engine at fast idle speed (about 1200 mission and fill the transmission with
rpm) until it reaches its normal op- new fluid to the specified level. If
DRAIN AND REFILL erating temperature. Do not race there is no fluid flow or if the flow
Normal maintenance and lubrica- the engine. is restricted, replace the radiator. Do
tion requirements do not necessitate 5. Shift the selector lever through not attempt to correct cooler or
periodic automatic transmission fluid all the positions, place it at P, and cooling line leaks by closing off
changes. check the fluid level. Add enough the lines.

Clean all parts with suitable sol- tilt the converter in all directions to TURBINE AND STATOR
vent and use moisture free air to drain as much fluid as possible. END PLAY CHECK
dry off all the parts and clean out 2. Install the drain plugs and fill 1. Insert the tool into the con-
oil passages. the converter through the pump verter pump drive hub until it bot-
drive hub with a Jight-body oil such toms (Fig. 9).
CONVERTER CLEANING as kerosene, or a cleaning solvent 2. Install the guide over the con-
The converter cannot be disas- suitable for transmission cleaning. verter pump drive hub.
sembled for cleaning. If there is 3. Install the tool shown in Fig. 9 3. Expand the split fiber bushing
reason to believe that the converter in the converter. Expand the bush- in the turbine spline by tightening
has an excessive amount of foreign ing in the turbine spline. Rotate the the adjusting nut. Tighten the ad-
material in it, the following cleaning tool to circulate the fluid in the justing nut until the tool is securely
procedure should be used: converter. locked to the spline.
1. With the converter on the 4. Remove both drain plugs and 4. Attach a dial indicator to the
benctJ., remove both drain plugs and thoroughly drain the converter. tool (Fig. 9). Position the indicator

(089) PART 7-1 -GENERAL TRANSMISSION SERVICE 7-9
CONVERTER END PLAY CHECK
Tool M-105-f~J(t J/s
____ / .. .. <::~---~---
-~-~- .• •.•
;,.._,;;,,~~~~---'.
_:ggs_
( ' ...
_z~. j
CHECKING ONE-WAY CLUTCH
FIG. 9- Typical Converter Checking Tool

button on a converter pump drive and hold a 10 ft-lb torque, replace should rotate freely without any
hub lug, and set the dial face at 0 the converter unit. signs of interference or scraping
(zero). within the converter assembly.
STATOR TO IMPELLER 4. If there is an indication of
5. Lift the tool upward as far as
INTERFERENCE CHECK scraping, the trailing edges of the
it will go and note the indicator
1. Position the front pump assem- stator blades may be interfering with
reading. The indicator reading is the
total end play which the turbine bly on a bench with the spline end the leading edges of the impeller
and stator share. If the total end of the stator shaft pointing up (Fig. blades. In such cases, replace the
10). converter.
play exceeds the limits as outlined
in the Specification Section of Group 2. Mount a converter on the pump
7, replace the converter unit. so that the splines on the one-way
STATOR TO TURBINE
clutch inner race engage the mating
splines of the stator support, and the INTERFERENCE CHECK
STATOR ONE-WAY
CLUTCH CHECK converter hub engages the pump 1. Position the converter on the
drive gear. bench front side down.
1. Loo~en the adjusting nut to free 3. While holding the pump sta- 2. Install a front pump assembly
the split bushing, and then remove tionary, try to rotate the converter
the tool from the converter. counterclockwise. The converter
2. Install the stator outer race
holding tool in one of the openings
in the stamped thrust washer pro-
vided in the stator (Fig. 9).
3. Insert the tool in the converter
pump drive hub. As the tool enters
the converter, the pins will engage
the stator clutch inner race spline.
4. Place a torque wrench on the
tool (Fig. 9). The tool (and stator
inner race) should turn freely clock-
wise (from the pump drive hub side
of the converter). It should lock up
and hold a 10 ft-lb pull when the
wrench is turned counterclockwise. FRONT PUMP AND STATOR
SUPPORT SHAFT
Try the clutch for lockup and hold D1065-A
in at least five different locations
around the converter. FIG. 10-Stator to FIG. 11-Stator to Turbine
5. If the clutch fails to lock-up Impeller Interference Check Interference Check

to engage the mating splines of the 5. Inspect the external parking

stator support and stator, and pump gear teeth for damage and the speed-
drive gear lugs. ometer drive gear teeth for burrs.
3. Install the input shaft, engaging 6. If either the output shaft or
the splines with the turbine hub ring gear has been replaced, place
(Fig. 11). the assembled unit with the gear face
4. While holding the pump station- down on the bench, push the shaft
ary, attempt to rotate the turbine downward, and check the clearance
with the input shaft. The turbine between the top of the snap ring and
should rotate freely in both directions its groove (Fig. 13) . If this clear-
without any signs of interference or ance exceeds 0.002 inch, replace the
scraping noise. snap ring with a thicker ring to re-
5. If interference exists, the stator duce the clearance to less than 0.002
front thrust washer may be worn inch. Selective snap rings are avail-
allowing the stator to hit the turbine. able in several thicknesses for this
In such cases, the converter must
be replaced.
purpose.
7. Inspect the primary sun gear
FIG. 13-Checking Output
for broken or worn teeth. Inspect Shaft Snap Ring
OUTPUT SHAFT AND PRIMARY all thrust surfaces and journals for
SUN GEAR SHAFT scores. Check all fluid passages (Fig. 3. Inspect the one-way,. clutch
1. Inspect the thrust surfaces and 14) for obstructions and leakage. sprags and springs for excessive wear
journals for scores. Inspect the in- Inspect the seal ring grooves for or damage.
ternal gear for broken or worn burrs.
teeth. 8. Inspect the sun gear shaft EXTENSION HOUSING
2. Inspect the aluminum sleeve for splines for burrs and wear. Check 1. Inspect the housing for cracks.
scores or leakage. Inspect the ring the front clutch lubrication valve Inspect the gasket surface for burrs
grooves for burrs. for free movement. or warpage. Check for leakage
3. Inspect the keyway and drive 9. Check the fit of the seal rings around the governor inspection cover
ball pocket for wear. in the grooves of the shaft. The and gasket. If leakage is found, in-
4. Inspect the output shaft sleeve rings should enter the grooves freely stall a new gasket.
for alignment with the governor without bind. 2. Inspect the bushing for scores
drive ball (Fig. 12). 10. Check the fit of the seal rings or wear.
in their respective bores. A clear- 3. Inspect the rear seal for hard-
GOVERNOR ance of 0.002-0.009 inch should ness, cracks, or wear. If the seal
DRIVE BALL exist between the ends of the rings. shows wear or deterioration, replace
POCKET
11. Install the seal rings on the the seals.
shaft, and check for free movement Inspect the seal counterbore and
in the grooves. remove all burrs and scores with
crocus cloth.
DISTRIBUTOR SLEEVE
1. Inspect the distributor sleeve REAR CLUTCH
for scores or excessive ring wear.
Inspect the distributor sleeve pas- 1. Inspect the drum band surface,
sages for obstructions. the bushing, and thrust surfaces for
2. Check the fit of the fluid tubes scores. Minor scores may be re-
in the distributor. moved with crocus cloth. Badly
scored parts must be replaced.
·PINION CARRIER, ONE-WAY 2. Inspect the needle bearing for
CLUTCH AND CENTER SUPPORT worn rollers. Inspect the clutch pis-
1. Inspect the clutch outer race, ton bore and the piston inner and
inner race, band surface, pinion outer bearing surfaces for scores.
gears, bearings, and thrust washer Check the air bleed ball valve in
(Fig. 15) for roughness. the clutch piston for free move-
2. Inspect the center support bush- ment. Check the orifice to make sure
ing for roughness. it is not plugged.
Dl 508-A
FIG. 12-Correct Position
of Output Shaft Sleeve FIG. 14-Cross-Sedion of Primary Sun Gear Shaft

(091} PART 7-1 -GENERAL TRANSMISSION SERVICE 7-11
ONE-WAY CLUTCH PINION CARRIER 4. Check all fluid passages for ob-
INNER RACE
structions, and check mating sur-
faces and gasket surfaces of the
pump body and cover for burrs.
5. Inspect the pump cover bear-
ing surface for scores. Minor burrs
or scores may be removed with
crocus cloth.
6. If any pump parts, other than
the pump cover, are defective, re-
place the pump as a unit. The pump
cover can be replaced separately.
ONE-WAY CLUTCH
PRESSURE REGULATOR
OUTER RACE 1. Inspect the regulator body and
PINION CARRIER
SUPPORT BUSHING
cover mating surface for burrs.
01037-B
2. Check all fluid passages for
obstructions.
FIG. 15-Pinion Carrier, One-Way Clutth and Center Support 3. Inspect the control pressure and
converter pressure valves and bores
3. Check the fluid passages for does not slide freely on the serra- for burrs and scores. Remove all
obstructions. All fluid passages must tions or that is not fiat. Front clutch burrs carefully with crocus cloth.
be clean and free of obstructions. plates differ in friction character- 4. Check free movement of the
4. Inspect the clutch plates for istics from the rear clutch plates valves in their bores. The valves
scores, and check the plates for fit and are not interchangeable. should fall freely into the bores when
on the clutch hub serrations. Replace 6. Check the clutch hub thrust both the valve and bore are dry.
all plates that are badly scored or surfaces for scores and the clutch 5. Inspect the valve springs and
do not fit freely in the hub serra- hub splines for wear. spacers for distortion.
tions. Front clutch plates differ in 7. Inspect the turbine shaft bear- 6. Check the lube circuit check
friction characteristics from rear ing surfaces for scores. If excessive ball and spring for defects.
clutch plates and are not inter- clearance or scores are found, dis-
changeable. card the unit. VALVE BODY
5. Inspect the dutch pressure 8. Check the splines on the turbine
plate for scores on the clutch plate 1. Inspect all valve and plug bores
shaft for wear and replace them if
bearing surface. Check the clutch for scores. Check all fluid passages
they are excessively worn. Inspect
release spring for distortion. for obstructions. Inspect the check
the bushing in the turbine shaft for
valve for free movement. Inspect all
scores.
mating surfaces for burrs or distor-
FRONT CLUTCH tion. Inspect all plugs and valves for
1. Inspect the clutch cylinder FRONT PUMP
thrust surfaces, piston bore, and 1. Inspect the mating surfaces of
clutch plate serrations for scores or the pump body and cover for burrs.
burrs. Minor scores or burrs may be 2. Inspect the drive and driven
removed with crocus cloth. Replace gear bearing surface for scores, and
the clutch cylinder if it is badly check the gear teeth for burrs. In-
scored or damaged. spect the stator support splines for
2. Check the fluid passage in the burrs and wear.
clutch cylinder for obstructions. 3. Check the fluid passages for
Clean out all fluid passages. Inspect obstructions.
the clutch piston for scores and re- 4. If any parts other than the
place if necessary. stator support are found defective,
Inspect the piston check ball for replace the pump as a unit. Minor
freedom of movement and proper burrs and scores may be removed
seating (Fig. 16). with crocus cloth. The stator sup-
3. Check the clutch release spring port is serviced separately.
for distortion and cracks. Replace
the spring if it is distorted or
REAR PUMP
cracked.
4. Inspect the composition clutch 1. Remove the drive and driven
plates and the steel clutch plates and gears from the pump body.
the- clutch pressure plate for scored 2. Inspect the gear pockets and
bearing surfaces. Replace all parts the crescent of the pump body for
that are deeply scored. scores or pitting.
5. Check the clutch plates for 3. Inspect the inner bushing and
flatness and fit on the clutch hub the drive and driven gear bearing FIG. 16-Front Clutth
serrations. Discard any plate that surfaces for scores. Piston Check Valve

burrs and scores. Crocus cloth can weight for burrs and distortion. Mat- stem for scores. Inspect the actuat-
be used to polish valves and plugs ing surfaces must be smooth and ing lever socket for scores and wear.
if care is taken to avoid rounding flat. Check the actuating lever and shaft
the sharp edges of the valves and for wear.
plugs. FRONT SERVO 4. Inspect the band and the struts
2. Inspect all springs for distor- for distortion. Inspect the band ends
tion. Check all valves and plugs for 1. Inspect the servo casting area for cracks.
free movement in their respective of the case for cracks and the piston 5. Inspect the servo spring for
bores. Valves and plugs, when dry, bore and the servo piston for scores. distortion.
must fall from their own weight in Check fluid passages for obstruc- 6. Inspect the servo band lining
their respective bores. tions. for excessive wear and bonding to
3. Roll the manual valve on a flat 2. Check the actuating lever for the metal band. The band should be
surface to check it for a bent con- free movement, and inspect it for replaced if worn to a point where
dition. wear. the grooves are not clearly evident.
3. Check the servo spring and
servo band strut for distortion.
GOVERNOR CASE
1. Inspect the governor valve and REAR SERVO Inspect the case for cracks and
bore for scores. Minor scores may stripped threads. Inspect the gasket
be removed with crocus cloth. Re- 1. Inspect the servo casting area surfaces and mating surfaces for
place the governor if the valve or of the case for cracks and the piston burrs. Check the vent at the front
body is deeply scored. bore for scores. of the case for obstructions, and
2. Check for free movement of 2. Check the fluid passages for check all fluid passages for obstruc-
the valve in the bore. Inspect fluid obstructions. Check the orifice in tions and leakage (Fig. 6).
passages in the valve body and coun- the servo piston for dirt. Inspect the Inspect the case bushing and
terweight for obstructions. All fluid check valve in the servo piston for center support bushing for scores.
passages must be clean. freedom of movement and proper Inspect the torsion lever pin for
3. Inspect the mating surfaces of seating. wear. Check all parking linkage parts
the governor body and counter- 3. Inspect the accumulator piston for wear or damage.

(093) 7-13
PART TURBO-DRIVE AUTOMATIC TRANSMISSION

7-2
Section Page Section • Page
1 Description and Operation .... ......... 7-13 3 Removal and Installation .................. 7-27
2 In-Car Adjustments and Repairs . . ........ 7-21 4 Major Repair Operations .................. 7-28

DESCRIPTION identifies the transmtsston model the transmission model identification
used. The tag attached by one oil is not changed.
The Turbo-Drive transmission
(Fig. 1) has a hydraulic torque con- pan bolt includes the mode] prefix
verter combined with a hydraulically and suffix, as well as the service PRINCIPLES OF OPERATION
controlled automatic planetary gear identification number, and serial
train. A conventional selector lever number. TO START THE ENGINE
and quadrant is used to obtain the The service identification number Move the transmission selector
desired gear ratio. indicates changes to service parts lever to either the Neutral (N) or
The identification tag (Fig. 2) which affect interchangeability when Park (P) position. These are the
INTERNAL
RING GEAR PRIMARY SUN GEAR
REAR PUMP
DISTRIBUTOR
SLEEVE
D1323-A
FIG. 1- Turbo-Drive Transmission

7-14 GROUP 7 -AUTOMATI_C TRANSMISSION (094)
gine. If "rocking" at medium

TRANSMISSION MODEL
throttle will not provide traction,
have the car pulled from its stuck
position to prevent overheating
the transmission.
1. Towing. If the transmission is
in working order, the car may be
towed for short distances (less than
12 miles) at a speed no higher than
40 mph with the selector lever set
at N. If the transmission is inoper-
ative, the drive shaft should be dis-
SERIAL NO.
connected before towing, or the rear
01324-A of the car raised by the tow truck.
If the rear of the car is raised a
FIG. 2- Transmission Identification Tag locking device should be instalied
on the steering wheel to keep the
front wheels in a straight-ahead
only selector lever settings at which the rear wheels in D2 will minimize
position.
the engine will start. To actuate the rear wheel spin and provide better
starter, insert the ignition key and control of the vehicle. The selector
turn it fully to the right. lever can be alternated between D 1 TORQUE CONVERTER
and D2 positions at any road speed. OPERATION
TO ENGAGE THE 3. Low (L). The L position is
provided for extra pulling power and The hydraulic torque converter
TRANSMISSION
~ngine b:aking. Extra pulling power
(Fig. 3) consists of an impeller
The transmission is engaged when IS sometimes needed when driving
(pump), a turbine, and a stator.
one of the following positions in the through deep sand, mud, or snow All these parts are enclosed and
quadrant is selected: and wh~n. climbing steep grades. operate in a fluid-filled housing .
. 1. Drive (Dl Large Dot).Dl posi- When dnvmg from a standing start, When the engine is running, the
tion should be used for most normal the. transmission will not upshift into fluid in the torque converter flows
driving. This driving range features a htgher gear while the selector lever from the impeller to the turbine and
maximum performance, economy is in the L position. Therefore to back to the impeller through the
and flexibility by incorporating an avoid imposing unnecessary s;ress stator. This flow produces a maxi-
automatic low gear start. The trans- on the engine and prevent overheat- mum torque increase of about 2
mission automatically shifts from ing the transmission, the car should to 1 when the turbine is stalled.
low to intermediate then to high not be driven in low gear for ex- When enough torque is developed
gear. To obtain maximum accelera- tended periods of time or at con- by the impeller, the turbine begins to
tion from a standstill, press the ac- tinuous speeds in excess of 25 mph. rotate, turning the turbine shaft.
celerator to the floor and the car The converter torque multiplica-
. To o?tain maximum engine brak-
will move forward under wide open tion gradually tapers off as turbine
mg, shtft to the L position when
throttle. speed approaches impeller speed, and
descending steep grades. The trans-
With the accelerator all the way
mission will automatically shift to
down to the floor, the transmission
intermediate gear at speeds above
will shift from low to intermediate
approximately 25 mph. When the
gear at approximately 45 mph and
car speed drops below approximately
then into high gear at approximately
25 mph, the transmission will auto-
70 mph.
matically shift to, and remain in,
For fast acceleration while driv-
low gear. Move the selector lever
ing in high gear, press the accelera-
back to D 1 or D2 position and the
tor to the floor. The transmission
transmission wi11 resume normal au-
will automatically downshift from
tomatic shift operation.
high to intermediate at any speed
between approximately 30 to 70 mph 4. Reverse (R). Use the R position
and into low gear at speeds below to back up the car. Bring the car to
approximately 30 mph. Release the a complete stop before moving the
accelerator and the transmission will selector to R.
automatically upshift to intermed- 5. Park (P). Bring the car to a
iate or high gear depending upon complete standstill. Set the selector
car speed and accelerator position. in P. position and, as an added pre-
2. Drive (D2 Small Dot). The D2 cautiOn, set the parking brake.
position provides intermediate gear 6. "Rocking" the Car. Move the
starts with a single shift into high selector lever back and forth be-
gear. .This range is desir'able for tween R and L with the accelerator
smooth gentle starts, as well as driv- pedal depressed slightly to increase
ing under slippery road conditions. engine speed and provide traction. FIG. 3-Cross-Section of
The smooth transition of power to CAUTION: Do not race the en- Typical Torque Converter

(095) PART 7-2- TURBO-DRIVE AUTOMATIC TRANSMISSION 7-15
it becomes 1 to 1 when the turbine

is being driven at 9 I 10 impeller
speed. This is known as the "coup-
ling point."
When the turbine is rotating at
less than 9I 10 impeller speed, the
converter is multiplying torque. The
fluid leaving the turbine blades
strikes the front face of the stator
blades. These blades are held station-
ary by the action of a one-way
clutch (Fig. 3) as long as the fluid
is directed against the front face of
the blades.
When the turbine rotates faster
than 9110 impeller speed the con-
verter no longer multiplies torque.
The fluid is directed against the back
face of the stator blades. As the
one-way clutch permits the stator
to rotate only in the direction of im-
peller rotation, the stator begins to
turn with the impeller and turbine.
The converter operates as an effi- 01006-A
cient fluid coupling as long as the FIG. 4-Planetary Gear Train
turbine speed remains greater than
9 I 10 impeller speed.
A constant flow of fluid into and piston to permit fluid exhaust when and the other end is connected to the
out of the converter is maintained. the piston is in its released position. front servo.
Some of the fluid coming out of the J n neutral, the front dutch drum Fluid pressure moves the front
converter is forced through a trans- and steel plates are being driven by servo piston against the inner end of
mission oil cooler unit located in the the turbine shaft while the bronze the front servo actuating lever. Force
radiator tank. plates are stationary. In reverse, the is transmitted through a strut be-
clutch is not applied. tween the outer end of the lever and
OPERATION OF PLANETARY the end of the band to tighten the
GEAR TRAIN, CLUTCHES, REAR CLUTCH band around the rear clutch drum.
BANDS AND SERVOS Under certain conditions, the servo
The rear clutch (Fig. 5) is oper- is released by directing fluid pressure
PLANETARY GEAR TRAIN ated by fluid pressure against the to the opposite side of- the piston,
clutch piston. Movement of the pis- assisted by release spring force.
The planetary gear train consists ton compresses the release spring
of a primary sun gear, secondary sun and locks the multiple-disc clutch. REAR BAND AND SERVO
gear, primary and secondary pinions The rear clutch drive plates are
which are held in a common carrier, splined to the front clutch drum and The rear band fits around the
and an internal gear to which the the driven plates are connected to planetary gear drum. One end of
transmission output shaft is attached the rear clutch drum and secondary the band contacts the end of the
(Fig. 4). sun gear. When the rear clutch is band adjusting screw, and the other
applied (in the reverse and third
REAR ClUTCH DRUM
FRONT CLUTCH gear ratios) the secondary sun gear
is driven. The piston is returned to
The front clutch drive plates (Fig. the released position by the release
5) are connected to the turbine spring (Fig. 5).
shaft through the front clutch drum. In neutral, the rear clutch bronze
The driven plates are connected to plates are being driven while the
the primary sun gear shaft. steel plates are free. In second gear,
The front clutch is operated by the bronze plates are driven, but the
fluid pressure against the clutch pis- steel plates are held stationary. In
ton. The piston moves against a disc first gear, the bronze plates are driv-
spring which acts as a lever to lock en clockwise at engine speed while
the drive and driven plates together. the steel plates are driven counter-
Whe~ the clutch is applied, the pri-
clockwise.
mary sun gear is locked to and driven
by the turbine shaft. The piston is
returned to the release position by FRONT BAND AND SERVO
DRIVE PlATES D1007-A
the disc spring when the fluid pres- One end of the front band, which
sure is removed (Fig. 5). A check encircles the rear clutch drum, is FIG. 5- Typical Front and
ball is installed in the front clutch anchored to the transmission case,. Rear Clutches

end connects to the rear servo. from the spring force of the rear lowing the check valve to close.
Two rear servo pistons apply the band and whatever friction is in When the check valve closes, the
rear band. The small (fast-acting) the servo lever and band struts. fluid in the small piston is trapped,
piston, which is in direct contact with At a low apply pressure and small and the apply force of the large pis-
the servo lever, is located inside the volume of fluid flow, the small piston ton is added to that of the small pis-
large piston. moves and tightens the rear band ton. ·
Fluid pressure against the large on the pinion carrier. With full band application, the
piston flows through a check valve When the apply pressure builds trapped fluid can bleed out through
to work against the small piston, up to about 10 psi, the large piston an orifice, allowing the small piston
which has low pressure resistance moves against its return spring, al- to bottom on the large piston.
REAR BAND
APPLIED
FRONT BAND
RELEASED
NEUTRAL FIRST GEAR, L
REAR BAND FRONT BAND

RELEASED APPLIED
- -
REAR CLUTCH
FIRST GEAR, 01 RELEASED SECOND GEAR
REAR BAND
REAR CLUTCH APPLIED
APPLIED
FRONT BAND
REAR BAND POWER FLOW . . .
THIRD GEAR REVERSE GEAR RELEASED
RELEASED
ROTATION
01136-A
FIG. 6- Typital Power Flow-Eath Gear Ratio

TABLE 1-Gear Ratios justed to engine torque, road speed,

and selector lever position.
Selector Lever Clutch Band Gear To accomplish this, compensator
Gear Ratio
Position Applied Applied pressure under various conditions is
Neutral N
- - !-------
None None - --
adjusted by throttle pressure (engine
torque), governor pressure (road
First Dl or L Front Rear* 2.37:1 speed), or selector lever position.
f-------- 1--~~------ 1------- ---
Second Dl or D2 Front Front 1.48:1 Compensator pressure, in turn, ad-
---- ---- ~--- -~-·-----
justs control pressure by positioning
Third Dl or D2 Front <1nd Rear None 1:1 the control pressure regulator valve.
-- r------~-- -~-- --------
Reverse R R~ar Rear 1.84:1
CONVERTER PRESSURE
*In first gear Dl, the planet carrier 1s held against rotation by the one-
way clutch. Like control pressure, converter
pressure is regulated by the converter
POWER FLOWS-EACH gether and driven as a unit (Fig. 6). pressure regulator valve spring and
GEAR RATIO Therefore, the pinions cannot rotate is adjusted to driving conditions by
and the entire planetary train re- compensator pressure and selector
Table 1 lists the ratios obtained
volves as a unit, which causes the lever positions.
through the various power flows.
output shaft to rotate at the same
speed as the turbine shaft. THROTTLE PRESSURE
POWER FLOW- NEUTRAL
When the transmission is in neu- POWER FLOW -REVERSE Throttle pressure adjusts the trans-
tral (Fig. 6), no gears are held or Reverse gear is obtained by driv- mission operation to engine torque.
driven, and no power is transmitted ing the secondary sun gear and hold- Throttle pressure is produced from
to the output shaft. ing the pinion carrier (Fig. 6). The control pressure by the throttle valve.
secondary pinions drive the internal The throttle valve is controlled by a
POWER FLOW - FIRST GEAR, L gear in the reverse direction. The spring-loaded vacuum diaphragm
primary sun gear and the primary unit mounted on the rear of the
In first gear when the selector pinions rotate freely and have no transmission case. Throttle pressure
lever is at L, the primary sun gear effect on the gear train. is regulated only when the front
is driven and the pinion carrier is clutch is on. Because, from the front
held by the rear band (Fig. 6). POWER FLOW -- clutch circuit, control pressure is
Power is transmitted to the primary PARK POSITION directed to the throttle valve to pro-
pinions, the secondary pinions, and When the selector lever is in the duce throttle pressure.
the internal gear, driving the internal P position, the parking pawl en- The vacuum diaphragm is actuated
gear in the same direction as the gages the external teeth on the in- by the engine intake manifold vac-
primary sun gear. The secondary uum, working against spring pres-
ternal gear to Jock the internal gear
sun gear turns free in the reverse sure. When the vacuum is higher
and output shaft to the case. This
direction and has no effect on the than 16 in. Hg, the diaphragm moves
locks the rear wheels to prevent
gear train. against spring pressure and moves
movement of the car.
the push rod away from the throttle
POWER FLOW-FIRST GEAR, Dl OPERATION OF HYDRAULIC valve to cut off the throttle pressure
CONTROL SYSTEM regulation. As the engine rpm is
In first gear at the D I selector
lever position, the pinion carrier is PRESSURE PUMPS advanced, manifold vacuum will fall
held against rotation by the one-way below 16 in. Hg. As the vacuum
The front pump, driven by the drops, the spring-loaded diaphragm
clutch instead of by the rear band converter impeller, can deliver fluid
(Fig. 6). First gear in D 1 is the moves the push rod to open the
pressure to the hydraulic control throttle valve and regulates the
only gear that uses the one-way system whenever the engine is run-
dutch only to hold the pinion car- throttle pressure in relationship to
ning (Fig. 7). The rear pump, driv- the changes in manifold vacuum.
rier.
en by the transmission output shaft,
delivers fluid pressure to the con-
POWER FLOW- SECOND GEAR THROTTLE PRESSURE
trol system when the car moves for-
ward. BOOST VALVE
Second gear ratio is obtained by
driving the primary sun gear and Both pumps deliver fluid pressure To compensate for the slight mani-
holding the secondary sun gear to the control pressure regulator and fold vacuum changes with throttle
(Fig. 6). The primary pinions drive control valve body. A regulated con- movements beyond about 50° car-
the secondary pinions, causing them trol pressure is available at the con- buretor valve opening, a throttle pres-
to "walk" around the secondary sun trol valve body whenever the engine sure boost valve comes into opera-
gear, rotating the internal gear and is running. tion. At about 51 psi throttle pressure
output shaft. CONTROL PRESSURE AND the spring-loaded boost valve (Fig.
7) comes into a balance position.
COMPENSATOR PRESSURE
POWER_ FLOW- THIRD GEAR Throttle pressure below 51 psi can-
Control pressure is regulated by not move the boost valve against
In third gear, the primary and the spring-loaded control pressure spring force plus throttle pressure
secondary sun gears arc locked to- regulator valve (Fig. 7). It is ad- force acting at the boost valve. Be-

7-18 GROUP .7- AUTOMATIC TRANSMISSION (098)
REAR
PUMP
REAR PUMP
CHECK VALVE
LUBE CIRCUIT ~===================::rTHROTTLE BOOST VALVE
01326-A
FIG. 7-Vatuum Controlled-Main Control, Hydraulit Circuit

. (099) PART 7-2-TURBO-DRIVE AUTOMATIC TRANSMISSION 7-19
low 51 psi, therefore, throttle pres- THROTTLE REDUCING VALVE DOWNSHIFT VALVE
sure will flow through the boost valve Before throttle pressure or boosted
without interference. The downshift valve is in the con-
throttle pressure is admitted to the trol valve upper body. The inner
Throttle pressures above 51 psi face of the 2-3 shift valve and 1-2 downshift lever contacts one end of
will move the boost valve to the right shift valve, it must open a passage the spring-loaded downshift valve.
(Fig. 7). This movement will first past the spring-loaded valve (Fig. 7). Control pressure is directed to a
cut off throttle pressure flow to the Approximately 20 psi throttle pres- land of the valve. Linkage is con-
shift valves and coasting control sure is required to move the valve nected between the accelerator pedal
valve, and it will then open a pas- against its spring far enough to open and downshift lever. The downshift
sage to permit control pressure to the passage. Once past the valve, valve is moved to open a passage
enter the throttle pressure circuit. The throttle pressure will work on the to direct control pressure to the shift
new boosted throttle pressure is di- spring end of the plug and exert a valves and the inhibitor valve when
rected to the shift valves and the force to cut off throttle pressure flow the accelerator pedal is depressed
coasting control valve. Throttle pres- past the valve. In this case, the valve through the detent (Fig. 7).
sure will continue to work against becomes a balanced valve wherein
the end of the boost valve. For each the valve is balanced between
pound of increase in throttle pres- 3-2 KICKDOWN CONTROL
throttle pressure force on the one VALVE
sure (above 51 psi), the boosted end and spring force plus throttle
throttle pressure will increase about pressure force on the other end. The The 3-2 kickdown control valve
three pounds. pressure past the valve will, there- operates in the front servo release
fore, be reduced. pressure' passage between the 2-3
GOVERNOR PRESSURE shift valve and the front servo. A
2-3 SHIFT VALVE check valve is installed parallel with
Governor pressure is produced the kickdown control valve in the
from control pressure from the front The 2-3 shift valve controls the
same passage so that release pressure
clutch circuit by the valve in the 2-3 upshift and the 3-2 downshift.
flow to the servo by-passes it.
governor body which rotates at out- The valve is held in its closed posi-
tion by springs. It is opened by The kickdown valve controls the
put shaft speed. rate of front servo release pressure
governor pressure acting on the end
The governor valve is a balanced exhaust (flow from the servo), and
of the valve. Under various driving
valve. It is balanced between centrif- thereby the rate of front band ap-
conditions, governor pressure is
ugal force acting on the governor plication.
opposed by spring force plus throttle
valve plus governor spring force and The 3-2 kickdown control valve
or boosted throttle pressures, and
governor pressure force (Fig. 7). eliminates the possibility of a run-
control pressure.
Governor pressure is, therefore, pro- away condition in the transmission
portional to road speed. during a 3-2 kickdown at low car
INHIBITOR VALVE
speeds (about 25 mph). It also elimi-
TRANSITION VALVE The inhibitor valve prevents a 2-1 nates the possibility of a tie-up during
downshift, either manual or kick- the same shift at higher speeds (50
The transition valve controls the down, at excessive road speeds. mph and more) .
front servo apply pressure flow. The inhibitor valve is held in its
In the D 1 range, the transition open position by a spring. It is closed REVERSE SHUTTLE VALVE
valve blocks front servo apply pres- by governor pressure. Under various
suite flow until the 1-2 valve is closed driving conditions, governor pres- When the transmission is shifted
by governor pressure. sure is opposed by spring force plus to reverse, rear servo apply pressure
In the D2 range, the transition control pressure. is directed to the reverse shuttle valve
valve permits front servo apply pres- (Fig. 7) . In addition, rear clutch
sure to flow through it at all times. 3-2 COASTING CONTROL apply pressure is also directed to the
VALVE reverse shuttle valve where it acts
on the area provided by the differ-
1-2 SHIFT VALVE The 3-2 coasting control valve. ence in the diameters of the lands
operates in the front servo release of the valve. As the rear clutch is
The 1-2 shift valve controls the passage. applied, pressure builds up in this
1-2 upshift in the Dl range. On the During a 3-2 closed-throttle down .. circuit until the pressure force on the
2-1 downshift, either manual (shift shift in D2 range, the valve is posi .. valve provided by rear clutch apply
to L) or kickdown, the 1-2 shift tioned by its spring so that front pressure overcomes the reverse
valve controls the shift only within servo release pressure must exhaust shuttle valve spring force. At this
the road speed range permitted by slowly through an orifice. This slow point the valve moves against spring
the inhibitor valve. exhaust of release pressure provides force, blocking the rear servo ex-
The 1-2 valve is held in its open a slow front band application. haust passage and allowing rear
position by a spring. It is closed by During a partial-to-full-throttle servo apply pressure to pass through
governor pressure. Under various 3-2 downshift, the 3-2 coasting con- the shuttle valve and apply the rear
driving conditions, governor pres- trol valve is positioned by throttle servo and band. In this manner, the
sure is opposed by spring force plus pressure or boosted throttle pressure rear band application is timed with
reduced throttle and reduced boosted so that front servo release pressure the rear clutch application when re-
throttle pressures, and control pres- can exhaust rapidly to provide a verse ratio is selected.
sure. rapid front band application. In Park position, rear servo apply

7-20 GR,OUP 7-AUTOMATIC TRANSMISSION (100)
pressure is directed to the reverse shuttle valve. The second passage ates in second gear. Control pres-
shuttle valve. The shuttle valve spring admits control pressure to apply the sure is directed to the reverse
holds the valve in the position which front clutch and supply the gover- shuttle valve to position the valve,
blocks the pressure from passing nor and transition valve. The front preventing the reverse servo from
through the valve, and the rear servo clutch circuit also directs control being applied.
is not applied. The position of the pressure to the throttle and com-
valve opens the rear servo apply pensator valves. Control pressure is HYDRAULIC CONTROL
passage to exhaust. now regulated by road speed and SYSTEM- D2, THffiD GEAR
In D 1 and D2 ranges, the pres· the rate the car is accelerated. The
sure to the 2~3 shift valve is directed third passage directs control pres~ D2 range third gear operation is
to the spring end of the reverse sure to flow through the 1-2 shift the same as D 1 range, third gear
shuttle valve. Force on the valve valve and inhibitor valve and close except that the closed throttle down-
provided by Dl or D2 pressure plus the transition valve. shift is from third to second in D2
spring force, will hold the valve in With the front clutch applied, the instead of from third to first as in
the closed position, even when front primary sun gear tries to drive the Dl.
clutch apply and rear clutch apply pinion carrier in a counterclockwise
are fed to the valve. This prevents direction. Counterclockwise rotation HYDRAULIC CONTROL
the rear servo from being applied at the pinion carrier is prevented by SYSTEM- Dl AND D2 RANGES,
in Dl or D2. the one~way clutch. With the front 3-2. KICKDOWN
When the transmission is shifted clutch applied and the pinion car-
When the accelerator pedal is de-
to manual low, the Dl or D2 control rier held, the transmission is in
pressed through the detent, the down-
pressure that was under the reverse first gear.
shift valve opens a passage that ad-
shuttle valve is exhausted at the mits control pressure behind the
manual valve. The front clutch apply HYDRAULIC CONTROL throttle reducing valve to oppose
pressure forces the shuttle valve SYSTEM - Dl, SECOND GEAR governor pressure. If the transmis-
against the spring force, opening sion is in high and road speed is
the valve. If car speed is below the The 1-2 shift occurs when gover-
nor pressure force on the 1-2 shift below the 3-2 inhibitor point, the
low inhibitor point, or if the car is 2-3 shift valve will be forced closed
stopped, the rear servo apply oil is valve overcomes throttle pressure
and spring forces. The 1-2 shift valve against governor pressure. When the
present at the shuttle valve and will 2-3 shift valve closes, control pres-
apply the rear servo as soon as the moves inward, exhausting the fluid
which holds the transition valve sure which has been applying the
shuttle valve moves. If the car speed rear clutch and releasing the front
is above the inhibitor point, rear closed. The transition valve opens
and admits control pressure to apply band is exhausted. The apply pres-
servo apply pressure will be cut off sure that was in the front servo in
at the inhibitor valve. the front band.
The front clutch remains on, and third gear is now free to apply the
the front band applies to put the front band. As soon as the front
HYDRAULIC CONTROL band applies, the transmission is in
transmission in second gear.
SYSTEM- NEUTRAL second gear.
The manual valve at N selector HYDRAULIC CONTROL
lever position blocks the fluid flow SYSTEM - Dl, THIRD GEAR HYDRAULIC CONTROL
to both clutches and both bands. SYSTEM- L, FIRST GEAR
With no fluid pressure in the clutches The 2-3 shift occurs when gover-
or servos, the clutches and bands are nor pressure force overcomes spring In L range, first gear, control pres-
released by spring pressure, prevent- and throttle pressure force at the sure is directed by the manual valve
ing power from being transmitted to 2-3 shift valve. When the shift valve to apply the front clutch and,.. rear
the transmission output shaft. With- opens, control pressure flows through band. The front clutch is applied
out control pressure in the front it to apply the rear clutch and re- with the same circuits as in D 1 and
clutch circuit, the throttle valve and lease the front band. With both D2. To apply the rear band, the
compensator valves do not receive clutches applied, the transmission is front clutch apply pressure positions
control pressure. in third gear. Control pressure is the reverse shuttle valve to allow
Neutral operation of the trans- directed to the reverse shuttle valve control pressure to pass through the
mission regulates control pressure to position the valve to prevent the valley of the reverse shuttle valve.
and maintains a full torque con- reverse servo from being applied. When the transmission is operating
verter, lubricates the transmission, in high gear and the selector lever is
and maintains a flow of fluid through moved to L, the control pressure
HYDRAULIC CONTROL used in D 1 and D2 at the bottom
the cooling system. SYSTEM- D2, SECOND GEAR of the reverse shuttle valve is ex-
When the manual valve is at the hausted at the manual valve. The
HYDRAULIC CONTROL front clutch apply circuit acting on
D2 selector lever position, control
SYSTEM- Dl, FIRST GEAR the end of the reverse shuttle valve
pressure to the 1-2 shift valve is
When the selector lever is moved cut off. This condition permits con~ moves the valve against the spring
from N to D 1, the manual valve trol pressure to flow through the opening the circuit to apply the
opens three passages to control pres- transition valve to apply the front rear band. The operation of the in-
sure. From left to right, the first pas- band. hibitor vaive controls the pressure
sage directs control pressure to With the front clutch and the front in the circuit to apply the rear band.
supply the 2-3 valve and reverse band applied, the transmission oper- When the manual valve is in the

{101) PART 7-2- TURBO-DRIVE AUTOMATIC TRANSMISSION 7-21
L posttlon, control pressure is di- clutch. The same circuit is directed of the valve into the lubrication cir-
rected to the 1-2 and 2-3 shift valves to the reverse shuttle valve. This cuit (Fig. 8).
to hydraulically lock these valves in positions the valve to open the cir- A regulating check valve in the
position. The governor pressure can- cuit to apply the rear servo and rear regulator body will limit lube pres-
not move the shift valves against the band (Fig. 7). sure to 15 psi (nominal). If pres-
control pressure, therefore automat- sure exceeds 15 psi, the check•valve
ic shifts from low gear are elimi- ball will unseat and excess fluid will
PRESSURE REGULATOR
nated (Fig. 7). be returned to the front pump intake·
To insure adequate cooling, trans- port. The check valve will insure an
mission fluid which is returned from adequate flow of fluid through the
HYDRAULIC CONTROL converter and cooler once the de-
the converter first passes through the
SYSTEM- R, REVERSE GEAR
oil cooler. From there, it is directed mand for lube oil flow has been
When the manual valve is shifted to the lower end and valley of the satisfied.
into the reverse position, control converter pressure regulator valve. If, at high engine rpm, pump out-
pressure is directed from the manual When the converter fill and converter put exceeds the demand for convert-
valve to apply the rear clutch and return pressure - build-up is high er fill, the converter pressure regu-
rear band. The rear clutch circuit is enough, the converter pressure regulator valve will be moved further to
directed through the upper valley of lator valve will move to allow cooler by-pass excess front pump output
the 2-3 shift valve to apply the rear fluid to pass through the lower valley back to the front pump inlet port.
CONVERTER PRESSURE
REGULA TOR VAlVE :..
~~
SEPARATOR PLATE
FRONT PUMP
CHECK VALVE
AND SPRING
~ lOCK RING-~-)
BAll SEAT-lie
BAll-O
:?
LUBRICATION
SPRING ,.~ CIRCUIT
CHECK VALVE
!1
:fi
CONTROL PRESSURE CONTROL PRESSURE
RETAINER
~ ,~
-.
~ Vdt_E.ST.OP«···:·IJ·;.·~_G:r;:.i(iii·~-w.-_-J
~~
~ +
CONVERl fR PRESSURE
REGULATOR SPRING
= '
c:Q
RETAINER
~ .lr;;llllt
' ..,
CONVERTER PRESSURE
REGUlATOR VALVE
c, .. '
T.
01325-A
FIG. 8-Pressure Regulator

LINKAGE ADJUSTMENTS ENGINE IDLE SPEED CHECK temperature.
Linkage adjustments must be made If the car has air conditioning, 3. Connect a tachometer and place
in the following sequence: turn the system off before adjust- the selector lever in D2 or Dl.
1. Adjust the engine idle speed. ing the engine idle speed. 4. With the carburetor fast idle
2. Adjust the accelerator pedal 1. Apply the parking brake and cam tripped, the engine idle speed
height. place the selector lever in N. should be within specifications in
3. Adjust the downshift rod. 2. Run the engine at idle speed drive range. (Refer to Carburetor
4. Adjust the manual linkage. until it reaches normal operating Idle Speed and Anti-Stall Dashpot

ACCELERATOR
RETURN SPRING
····--
1,..,...- -
1
D1318-A
FIG. 9-Typical Unkage Adiustments

Adjustments in Group 10 for details crank is up against the stop pin on Slide the spring clip over the end of
regarding the location and adjust- the inner mounting bracket on the the rod to lock the rod to the ball-
ment procedure.) bellcrank assembly (Fig. 9). stud. Tighten the lock nut securely.
ACCELERATOR PEDAL 2. Pull upward and hold the down- Be sure the bellcrank outer bracket
HEIGHT CHECK shift rod against the transmision in- remains against the stop pin. U it is
1. The pedal height adjustment ternal stop. Adjust the length of the not against the pin, lengthen the
must be made only at the accelera- rod until the hole in the rod is downshift rod one additional turn.
tor connecting link (Fig. 9) . aligned with the ballstud on the bell- If the downshift rod is adjusted
2. With the engine turned off, crank assembly. too long, the transmission will not
measure the distance from the top 3. Lengthen the downshift rod one upshift because the downshift
of the accelerator pedal to the carpet. turn and position it on the ballstud. valve is opened to line pressure.
This measurement should be ap- BOnOM VIEW OF SWITCH TOP VIEW OF SWITCH
proximately 3% inches. This is a
nominal measurement only. Fur-
ther adjustment may be required
· after road test if the kickdown
operation is not functioning prop-
erly.
3. Depress the accelerator pedal
and check for detent feel and kick-
down action of the bellcrank. Ad-
just the accelerator pedal height, as
required, to achieve proper oper-
ation of the downshift rod. Check
the kickdown operation when the
car is road tested.
DOWNSHIFT ROD
1. Loosen the lock nut on the
downshift rod. Disconnect the rod
from the ballstud on the bellcrank
assembl.y by sliding the spring clip off
the end of the rod. ~ake sure the
movable outer bracket on the bell- FIG. 10-Starter Neutral Switch Location

( to3) _ _ _ _ _ _P_A_R_T_7_-_2_-_T_UR_B_O-_DR_IV_E_A_UT_O_M_AT_IC_T_RA_N_SM_IS_S_IO_N_ _ _ _ _ _7_-2_3
MANUAL LINKAGE mission manual lever. Lengthen the selector lever positions. The circuit
link one-half additional turn and must be open in all drive positions
1. If the car has a movable steer- connect it to the transmission shift and closed only in park and neu-
ing column, position the column in lever. tral. (The starter should engage only
the uppermost position. With the 5. Check the selector lever through in park and neutral).
engine turned off, place the selector all positions to assure correct link- 2. To adjust the switch, loosen the
lever against the stop in the D 1 age adjustment. retaining screws that locate the switch
position. Raise the car. Remove the Do not make compensating ad- on the steering column (Fig. 10).
linkage splash shield. justments in the manual control
2. Disconnect the adjustable link 3. Place the transmission selector
linkage to overcome misalignment lever firmly against the stop of the
from the transmission manual shift of the selector lever indicator or
lever on the transmission (Fig. 9). neutral detent position.
the starter neutral switch. Adjust- 4. Rotate the switch actuating lever
3. Be sure that the transmission ment or necessary corrections must
shift lever is fully engaged in the until the gauge pin (no. 43 drill)
be made to these components with- can be inserted into the gauge pin
second detent from the bottom D 1. out disturbing the correct manual
The bottom detent is low (L). holes (Fig. 10).
linkage adjustment. 5. Tighten the 2 switch retaining
4. Loosen the lock nut on the
adjustable link (Fig. 9). Pull down- screws and remove the gauge pin.
ward on the link to hold the selec- STARTER NEUTRAL SWITCH 6. Check the operation of the
tor lever against the stop. Lengthen ADJUSTMENT switch in each selector lever posi-
or shorten the link by rotating the 1. With the manual linkage prop- tion. The starter should engage in
lower end until the hole in the link erly adjusted, check the starter en- only the neutral and park detent
aligns with the stud on the trans- gagement circuit in all transmission positions. Whenever the manual
EXTERNAL
FRONT BAND
ADJUSTMENT
CONVERTER RETURN
PRESSURE: TO OIL
COOLER
EXTERNAL
REAR BAND
ADJUSTMENT
COOLED OIL RETURN

FROM OIL COOLER
~-~~ TO PRESSURE
REGULATOR
FRONT SERVO
IN CASE
01328-A
FIG. 11-External Transmission Components

EXTENSION HOUSING
FIG. 14-Governor In
Extension Housing
torque), loosen the screw and re-
tighten until the wrench overruns.
4. Back off the adjusting screw
1~ turns. Severe damage may re-
sult if the adjusting screw is not
backed oft exactly 1~ turns.
5. Hold the adjusting screw sta-
tionary, and tighten the adjusting
screw lock nut to approximately
FIG. 12-Front Band Adjustment 35-40 ft-lbs.
linkage is adjusted, the starter threads. Loosen the adjusting screw
GOVERNOR REPLACEMENT
neutral switch should be checked lock nut.
and, if necessary, adjusted. 3. Tighten the adjusting screw with 1. Raise the car so that the trans-
tool 7345 until the tool handle mission extension housing is acces-
"breaks" over center. If the adjust- sible.
FRONT BAND ADJUSTMENT
ing screw is tighter than wrench 2. Remove the inspection cover
The front band is adjusted ex- capacity (10 ft-Ibs torque), loosen from the governor assembly hole in
ternally. The adjusting screw is the adjusting screw and re-tighten the extension housing.
threaded through the left front side the screw. 3. Rotate the drive shaft until the
of the transmission case (Fig. 11). 4. Back the adjusting screw off ex- governor is in line with the inspec-
Tools 7345 and 7345-L are required actly 3 turns. tion hole in the extension housjng.
to adjust the front band (Fig. 12). Severe damage may result if the
4. Remove the two governor valve
1. Raise the ~ar. Remove the adjusting screw is not backed off
body retaining bolts and governor
transmission linkage splash shield. exactly 3 complete turns.
from the counterweight (Fig. 14).
2. Remove all dirt from the adjust- 5. Hold the adjusting screw sta-
tionary and tighten the lock nut to Do not drop any parts into the
ing screw threads, then oil the
35-40 ft-lbs. extension housing.
5. If the removed governor can be
REAR BAND ADJUSTMENT cleaned, make sure all parts are thor-
oughly clean and lubricated and the
1. Fold back the floor mat to ex- governor valve moves freely within
pose the right side of the floor pan. the valve body before the valve body
2. Remove the access hole cover is assembled to the counterweight.
from the floor pan. Remove all dirt
from the adjusting screw threads, 6. Lubricate the new governor
then oil the threads (Fig. 13). valve parts with clean transmission
3. Loosen the rear band adjusting fluid. The valve must move freely in
screw lock nut with tool 7195-C, as the valve body bore.
shown in Fig. 13. Using the T-handle 7. Install the governor valve as-
on the tool, tighten the adjusting sembly to the counterweight so that
Tooi-7195-C screw until the wrench over-runs. If the valve body cover is faced toward
the screw is found to be tighter the rear of the car. Torque the two
FIG .•13- Rear Band Adiustment than wrench capacity (10 ft-lbs attaching bolts to specifications.

(105) PART 7-2-TURBO-DRIVE AUTOMATIC TRANSMISSION
MAIN PRESSURE TUBE FROM

PRESSURE REGUlATOR PRESSURE REGULATOR
TO VALVE BODY
REAR SERVO
LUBRICATION
REAR PUMP
TO VALVE BODY
REAR SERVO APPLY
AND RELt:ASE REAR CLUTCH
01330-A
FIG. 15-Hydraulic Pressure Tubes

OIL PAN AND/OR CONTROL Re-use the fluid only if it is in 5. Remove the compensator tube
VALVE BODY REPLACEMENT good condition. from the valve body to pressure
1. Raise the car so that the trans- 2. Remove the oil pan, gasket, and regulator.
mission oil pan is accessible. Remove oil filter type screen. During the 6. Remove the rear pump to valve
the reinforcem~nt plate under the following operations, care must be body pressure tube.
transmission oil pan. taken to avoid bending or damag- 7. Remove the rear servo apply
ing the oil tubes (Fig. 15). and release tube.
By loosening the oil pan bolts,
8. Remove the three short tubes
drain the fluid from the transmis- 3. Remove the front servo apply
which direct front clutch, rear
sion. If the same fluid is to be used and release tube.
clutch, and governor pressure be-
again in the transmission, filter the 4. Remove the main pressure tube tween the valve body and the trans-
fluid through a 100-mesh screen as from the pressure regulator to the mission case.
it drainS from the transmission. main control valve. 9. Remove the throttle valve vac-

D1320-A
FIG. 17-Extension
Housing Seal & Bushing Removal
place during the parking pawl re-
placement procedure.
2. Raise the car on the hoist and
support the front of the transmission
with an adjustable jack stand and
drain the transmission fluid from the
oil pan.
3. Mark the drive shaft with the
location of the axle companion
flange. Remove the two U-bolts hold-
ing the drive shaft to the companion
flange; then, remove the drive shaft.
4. Remove the reinforcement plate
under the transmission oil pan. Re-
move the oil pan and oil filter type
screen. Remove the parking brake
equalizer bar retracting spring and
disconnect the parking brake cable
and equalizer assembly.
5. Remove the three short · tubes
from the main control valve that
direct rear clutch, front clutch, and
governor return pressure to the case.
6. Remove the crossmember at
FIG. 16-Va,uum Unit Removal or Installation the extension housing and remove
the extension housing.
uum diaphragm assembly and throttle and vacuum unit (Fig. 15), use the 7. With a soft hammer tap the
control valve rod. following procedure to remove and distributor and rear pump to move
10. Remove the main control replace the pressure regulator. the distributor back until the rear
valve assembly attaching bolts; then, 1. Remove the pressure regulator clutch, front clutch, and governor
remove the assembly by lifting it spring retainer, springs and spacers. return tubes are removed from the
from the mounting pad on the case. 2. Remove the pressure regulator case.
Hold the manual valve in place as assembly attaching bolts, and then, 8. Remove the output shaft and
the assembly is removed. remove the assembly. rear pump as an assembly.
11. To install the control valve
3. To assemble the pressure regula- 9. Remove the end of the toggle
body, reverse the above removal pro-
tor assembly, reverse the above pro- return spring from the toggle lever
cedure, torquing the retaining bolts
cedures and torque the retaining
to specifications. Make sure the vac- Tooi-7657-J
uum unit and control rod are prop- bolts to specifications.
erly assembled before the oil pan
is assembled (Fig. 16). PARKING PAWL REPLACEMENT
1. Loosen the lock nut on the rear
PRESSURE REGULATOR band adjustment stud. Tighten the
REPLACEMENT stud with tool 7195-C (Fig. 13)
• until the tool handle overruns. Do D1321-A
With the lubricating tube and the
same detail parts removed as outlined not back off the adjusting screw.
under Control Valve Body Removal, This will hold the planet carrier, FIG. 18-Exterrsion
except for the control valve body front and rear clutch assemblies in Housing Seal & Bushing Installation

(107) PART 7-2-TURBO-DRIVE AUTOMATIC TRANSMISSION 7-27
pin, and remove the 0.328 diameter EXTENSION HOUSING OIL SEAL oil seal using tool1175-AE (Fig. 17).
washer and pin. AND BUSHING REPLACEMENT After removing the oil seal, the bush-
10. Remove the parking pawl sup- ing can be removed with tool 7000-
port pin with a magnet. 1. Raise the car and mark the
AG (Fig. 17).
11. Remove the parking pawl parts. drive shaft for proper replacement.
12. To assemble the new parking Remove the drive shaft and position 3. Install a new bushing using tool
pawl, reverse the above procedure the parking brake equalizer and cables 7657-J with the adapter ring detail
using new gaskets. Reset the rear to obtain free access to the transmis- of the tool. Install a new oil seal
band and fill the transmission with sion extension housing. using tool 7657-J without the adap-
fluid. 2. Remove the extension housing ter ring (Fig. 18) .

When removing the transmission,
it is necessary to remove the com-
plete transmission and converter
housing assembly as one unit. The
transmission gear box and converter
housing cannot be separated while
in the car. One additional converter
housing to transmission case bolt is
located behind the converter assem-
bly where it is not accessible until
after the converter has been re-
moved (Fig. 19).
REMOVAL
1. Raise the hood. Remove the 01332-A FIG. 21-Positioning
converter housing to engine upper Transmission on Jack
bolts and remove the power box FIG. 19-lnternal Bolt-
cover. Connect a starter remote con- Retaining Converter Housing to Case 10. Disconnect the oil cooler lines
trol lead to the battery terminal. At- at the transmission and radiator and
tach the other remote control lead 7. Remove the engine stabilizer remove the tubes (Fig. 20).
to the small terminal which has a bar installation from the converter
housing. 11. Position the transmission jack
red and blue wire at the power box.
8. Remove the converter to fly- (7000EHJ with Adapter Kit 7000-
Place the transmission in neutral,
whee) retaining nuts. As the con- EG and Bracket Kit 7000-LC) un-
N.
verter is rotated, remove the con- der the transmission and raise the
2. Raise the car and remove the transmission slightly (Fig. 21).
reinforcement plate from under the verter drain plugs and drain the
transmission oil pan. Drain the fluid fluid from the converter. Use the 12. Remove the rear support
frqm the transmission by loosening starter remote control to turn the ( crossmember) to transmission ex-
the oil pan bolts. Remove the con- flywheel. tension housing nuts. Remove the
verter access cover from the front 9. Turn the front wheels fully to crossmember bracket to underbody
of the converter housing; then, re- the right and remove the starter bolts and remove the crossmember
move the transmission linkage splash motor. and brackets.
shield. Disconnect the oil filler tube.
3. Disconnect the drive shaft at
the differential pinion shaft flange.
Remove the drive shaft. Mark the
rear universal joint and the pin-
ion flange before removing the
drive shaft so that it can be in-
~ \-:··
stalled in the same position.
, ''5l-~,~
4. Remove the parking brake
equalizer bar retracting spring. Dis-
connect the parking brake cables
and equalizer assembly.
5.- Disconnect the downshift rod TRANSMISSION OIL
and the necessary manual shift link- COOLANT liNES
age parts at the transmission levers.
6. Disconnect the vacuum line
hose at the vacuum diaphragm. Dis- 01322-A
connect the speedometer cable at the
transmission. FIG. 20-0il Coolant Line Routing

13. Detach the vacuum line at the izer assembly between the transmis- 10. Connect the downshift rod
converter housing. sion and the underbody, and then, and the manual shift linkage at the
14. Remove the manual linkage the engine stabilizer bar to the con- transmission. Adjust the manual shift
equalizer assembly mounted between verter housing. linkage.
the transmission and the underbody. 4. Connect the vacuum line to the 11. Position the starter motor seal
15. Remove the remammg con~ vacuum diaphragm. and install the starter motor. Con-
verter housing to engine retaining 5. Install the speedometer cable nect the starter motor cable.
bolts. and drive gear in the extension hous- 12. Install the converter housing
16. Move the transmission and ing. to the engine. Torque all converter
converter assembly to the rear and 6. Install the crossmember and housing retaining bolts to specifica-
remove it from under the car. body brackets. Torque the cross- tions.
member to underbody bolts and the 13. Connect the oil cooler lines
body bracket bolts. and install the underbody reinforce-
INSTALLATION
7. Lower the transmission. Install ment plate. Torque the plate bolts
1. With the transmission on the the crossmember to rear support re- to specifications.
jack (Fig. 21), raise the transmis~ taining nuts. Torque the nuts to 14. Install the converter to fly-
sion and converter assembly into po- specifications. wheel retaining nuts and washers.
sition. Align the converter with the 8. Install the drive shaft in the Torque the nuts to specifications.
flywheel and the converter housing position previously marked. Torque 15. Install the transmission link-
with the engine dowel pins. the rear universal joint U-bolts to age splash shield.
2. Install the converter housing to specifications. 16. Lower the car. Install the con-
engine lower bolts and tighten the 9. Install the parking brake equal~ verter housing to engine upper bolts
bolts snugly. Attach the vacuum line izer and cable assembly. Install the and torque the bolts to specifications.
support to the converter housing. parking brake equalizer retracting Fill the transmission. Check the ad-
3. Install the manual linkage equal- spring. justment of the downshift linkage.

DISASSEMBLY taken to avoid bending or damag-
NUT-%-16 (2 REQ'D) ing the oil tubes (Fig. 15).
The following procedure covers 3. Remove the front servo apply
the bench disassembly and assembly and release tube.
of the transmission, after the unit 4. Remove the main pressure tube
has been removed from the car. from the pressure regulator to the
main control valve (Fig. 15).
CONVERTER AND
5. Remove the compensator tube
CONVERTER HOUSING
from the valve body to the pressure
1. Hold the converter assembly regulator.
with both hands and pull the con- 6. Remove the rear pump to valve
verter directly forward. To prevent body pressure tube.
damage to the front pump seal, do WASHER-%
TRANSMISSION HOLDING
FLAT (REQ'D) 7. Remove the rear servo apply
not rock the converter assembly from ST AND-7000-CJ
01335-A
and release tube.
side to side. 8. Remove the three short tubes
2. Remove the one bolt which which direct front clutch, rear chltch,
holds the converter housing to the FIG. 23-Adapting Holding and governor pressure between tQ.e
transmission case from inside the Fixture for Transmission valve body and transmission case.
converter housing (Fig. 19). 9. Remove the lubricating tube.
3. Remove the five bolts which
TRANSMISSION CASE SIDEVIEW hold the converter housing to the
ASSEMBLy CONVERTER ~1p transmission case. Remove the con-
HOUSING d J\ verter housing vent baffle (Fig. 22).
Remove the converter housing and
gasket.
\ TRANSMISSION
SUB~ ASSEMBLIES
1. Place the transmission in Hold-

ing Fixture 7000-CJ, using two %-16
x 4 inch bolts and %-16 nuts to se-
cure it to the holding fixture (Fig.
01334-A 23).
2. Remove the oil pan, gasket, and
FIG. 22-Converter oil filter type screen. During the FIG. 24-checking
Housing Vent Baffle
~
following operations, care must be Transmission End Play

28. Expand the rear band with

snap ring pliers and use the actuat-
BEARING RACE
ing lever strut as a spacer to hold
the rear band in the spread position.
Slide the clutch assemblies, center
support and planet carrier out of' the
rear of the case (Fig. 26).
29. Place the clutch assemblies,
center support, and planet carrier in
the Holding Fixture tool No.
77530-A (Fig. 27).
30. Remove and separate the
clutch assemblies. Separate the planet
carrier from the center support (Fig.
28). Place the rear clutch and pri-
D1337-A mary sun gear into Holding Fixture
77530-A.
FIG. 25-0utput Shaft 31. Remove the bronze and steel
Thrust Washer & Race thrust washers from the clutch as-
sembly.
10. Remove the throttle valve 32. Remove the oil seal rings from
vacuum diaphragm assembly and the primary sun gear shaft, and re-
throttle control valve rod. move the rear clutch from the sun
11. Remove the main control valve gear shaft (Fig. 29). Remove the
assembly attaching bolts; then, re- rear clutch seal rings from the sun
move the assembly by lifting it from gear shaft and the thrust washer be-
the mounting pad on the case. Hold tween the rear clutch and primary
the manual valve in place as the FIG. 27 -Gear Train sun gear.
assembly is removed. Positioned In Holding Fixture 33. With a screwdriver, remove
12. Remove the pressure regulator the front clutch snap ring which
spring retainer and springs. 18. Remove the distributor sleeve holds the turbine shaft to the front
13. Remove the pressure regulator retaining snap ring. clutch hub. Remove the turbine
assembly attaching bolts, and then, 19. Remove the distributor sleeve shaft. Remove the front clutch plates
remove the assembly. and tubes from the output shaft by and internal hub. With an arbor
14. Loosen the front and rear tapping with a soft-faced hammer press and tool 77 5 65 remove the
band adjusting studs several turns. on the sleeve. Do not bend or dis- Belleville spring and snap ring (Fig.
15. Check transmission end play. tort the tubes. Remove the four oil 30) and with an air hose and tool
seal rings and spacer washer from No. 7000DE, remove the piston.
(The specified limits are 0.0 I 0 to
0.029 inch.) Use Dial Indicator the output shaft. 34. Remove the rear clutch pres-
4201-C and Dial Indicator Support 20. Remove the governor snap sure plate snap ring and rear clutch
Fixture 77067 (Fig. 24). nng and remove the governor from plates. With an arbor press and tool
the output shaft. Remove the gov- 77 515-A, compress the rear clutch
16. Remove the front pump at-
ernor drive ball. spring, remove the snap ring spring
taching bolt; and remove the pump 21. Remove the rear pump from retainer and release the spring (Fig.
from the case. Remove the front
.
the cast::, and remove the extension 31). With an air bose and tool No.
pump to transmission case gasket. housing pump gaskets. Remove the 7000DE, remove the piston.
17. To remove the extension hous- rear pump discharge port "0" ring
ing seal and bushing, if necessary,
35. When assembling the clutch-
from the case.
refer to In-Car Adjustments and! Re- 22. Remove the output shaft
pairs. Remove the extension housing :Jl
needle bearing type rear thrust
P
bolts and pull the housing away washer from the rear pump. Remove
from the transmission case and off the bearing race (Fig. 25). .'
the output shaft. 23. Hold the planet assembly for-
~ .1.rd and remove the output shaft.
24. Remove the output shaft front
thrust washer.
25. Remove the two oil seal rings
fr• \ffi the front clutch sun gear shaft.
26. Using a brass drift, tap the
rear band actuating lever shaft out
A8
013:18-A
thwugh the rear of the case.
:~1. Remove the rear band actuat-
in~~ lever, strut, and rear band anchor
> 01341-A
FIG. 26-Removing sllut. Remove the center support FIG. 29-Removing Rear
Transmission Gear Train r., 'Its. Clutch From Primary Sun Gear Shaft

7-30 GROUP 7 -AUTOMATIC TRANSMISSION {110)
FRONT CLUTCH
FRONT CLUTCH HUB
FRONT CLUTCH DRUM

AND PISTON
PRESSURE PLATE
REAR CLUTCH
BRONZE THRUST WASHER
SNAP RING
STEEL THRUST· WASHER

PLANET CARRIER
PRIMARY SUN GEAR SHAFT
PLANETARY AND OUTPUT SHAFT
D-1340A
FIG. 28-Ciutch and Gear Train-Explode

tainer holding the tool so that the

compressed return spring does not
release too quickly.
39. Remove the rear servo spring
retainer, spring, and piston from the
case. Remove the accumulator pis-
ton, check valve, spring and 0-ring
(Fig. 33).
40. Remove the front servo cover
with a screwdriver.
41. Apply thumb pressure on the
front servo piston and remove the
front servo piston retainer snap ring
FIG. 3D-Removing and piston assembly (Fig. 34). FIG. 32-Removing Rear
Belleville Spring Snap Ring Servo Snap Ring
es and gear train, reverse the 42. Remove the front servo piston
above procedure. assembly and return spring. Dis-
36. Remove the rear band through assemble the pistons and 0-rings
the bottom of the case. (Fig. 35).
37. Remove the front band, anchor 43. Drive out the front band actu-
strut and actuating lever strut from ating lever shaft access hole plug on
the case. the front face of the case near the
38. To remove the rear servo as- front pump.
sembly, hold and compress the spring
44. Remove the front servo actu-
retainer with a large "C" clamp or a
valve spring compressing tool (No. ating lever retainer clip (Fig. 36).
7513-EE) as the snap ring is re- Remove the actuating lever shaft
moved (Fig. 32). After the snap FIG. 31-Removing Spring through the hole in the front face of
ring has been removed, release the Retainer Snap Ring from Rear the case. Remove the front servo
pressure slowly on the spring re- Clutch actuating lever.
RETAINER ACCUMUlATOR
Plsro 'TN (
I
PISTON SEAL ·•
1
_\ CHECK
VALVE SPRING
SNAP RING RETURN SPRING
01345-A
FIG. 33-Rear Servo Assembly

7-32 GROUP 7- AUTOMATIC TRANSMISSION (112}
SNAP RING be coated with petroleum jelly to

facilitate assembly. Always install
new gaskets when assembling parts
of the transmission.
Tighten all bolts and screws to the
recommended torque. Refer to Part
7-1 for cleaning and inspection pro-
cedures.
FIG. 37 -Front Pump
FRONT PUMP Disassembled
1. Remove the stator support at-
taching screws and remove the stator 2. Remove the drive and driven
support. Mark the top surface of the gears from the pump body.
pump driven gear with Prussian blue 3. Refer to Fig. 37 for a disassem-
FIG. 34-Removing Front to assure correct assembly. Do not bled view of the front pump. Inspect
Servo Snap Ring scratch the pump gears. the pump body housing, drive gear
bushing, gear pockets, and crescent
PARTS REPAIR for scores.
AND REPLACEMENT 4. Inspect the mating surfaces of
the pump body and cover for burrs.
During the repair of the sub-
assemblies, certain general instruc- 5. Inspect the drive and driven
tions which apply to all units of the gear bearing surface for scores, and
transmission must be followed. These check the gear teeth for burrs. In-
instructions are given here to avoid spect the stator support splines for
unnecessary repetition. burrs and wear.
Handle all transmission parts care- 6. Check the fluid passages for ob-
fully to avoid nicking or burring the structions.
bearing or mating surfaces. 7. If any parts other than the
Lubricate all internal parts of the stator support are found defective,
transmission with transmission fluid replace the pump as a unit. Minor
before assembly. Do not use any burrs and scores may be removed
other lubricants. FIG. 36-Removing Front with crocus cloth. The stator support
Gaskets and thrust washers may Servo Actuating Lever Retainer Clip is serviced separately.
01347-A
FIG~ 35-Front Servo Assembly

' ( 113) PART 7-2- TURBO-DRIVE AUTOMATIC TRANSMISSION 7-33
~--~,::Z~I=A
valve and spring from the regulator
cover (Fig. 8).
4. Wash all parts thoroughly in
clean solvent and blow dry with
""" ·\.~ moisture-free compressed air.
··--ifl203-B 5. Inspect the regulator body- and
cover mating surfaces for burrs.
FIG. 38-Removing Front 6. Check all fluid passages for
obstructions.
Pump Seal
7. Inspect the control pressure
and converter pressure valves and
8. Bolt the front pump to the
bores for burrs and scores. Remove
transmission case with capscrews.
all burrs carefully with crocus cloth.
9. Install the oil seal remover with
tool 1175AE shown in Fig. 38. Then 8. Check the free movement of
pulJ the front seal from the pump the valves in their bores. Each valve
body. The front seal is %-inch FIG. 40-Rear Pump should fall freely into its bore when
thick. both the valve and bore are dry.
10. Clean the pump body counter- to the pump body, and remove the 9. Inspect the valve springs for
bore. Then inspect the bore for cover. Mark the top face of the pump distortion. Remove the lubricating
rough spots. Smooth up the counter- drive and driven gear with Prussian check ball lock ring, ball seat, ball
bore with crocus cloth. blue to assure correct installation of and spring. After checking or repair-
11. Remove the pump body from the gears at assembly (Fig. 40). Do ing parts, assemble the parts in the
the transmission case. not scratch or punch marks on the reverse order of removal.
12. Coat the outer diameter of a pump gears. 10. Position the check valve spring
new seal with FoMoCo Sealing 2. Remove the drive and driven and valve in the regulator cover.
Compound, or its equivalent. Then t:cars from the pump body. 11. Position the separator plate on
position the seal in the pump body. 3. Inspect the gear pockets and the regulator cover.
Drive the seal into the pump body t r1e crescent of the pump body for 12. Position the regulator cover
with the tool shown in Fig. 39 until ~dlres or pitting. and separator plate on the regulator
the seal is firmly seated in the body. '1. lnspect the inner bushing and body, and install the attaching
13. Place the pump driven gear in the drive and driven gear bearing screws. Torque the screws to specifi-
the pump body with the mark on the \li rfaccs for scores.
cation.
gear facing upward. Install the drive 5. Check all fluid passages for ob- 13. Insert the valves in the pres-
gear in the pump body. sure regulator body.
"' ructions, and check the mating sur-
14. Install the stator support, at- f <tees and gasket surfaces of the
taching screws, and lock washers. pump body and cover for burrs. CONTROL VALVE BODY
Check the pump for free movement 6. Inspect the pump cover bear- During the disassembly of the con-
of the gears. ing surface for scores. Minor burrs trol valve assembly, avoid damage to
REAR PUMP llr scores may be removed with valve parts and keep the valve parts
C 1 •XUS cloth. clean. Place the valve assembly on a
1. Remove the screws and lock
washers which secure the pump cover 7. If any pump parts, other than clean shop towel while performing
the pump cover, are defective, re- the disassembly operation. Do not
place the pump as a unit. The pump separate the upper and lower valve
cover can he replaced separately. / bodies and cover until after the
S. Place the pump driven gear in valves have been removed.
t ht: pump body with the mark
(placed on the gear at disassembly) Disassembly
f:1ving upward.
9. Jnstall the drive gear in the i. Remove the manual valve (Fig.
p11ITip body with the mark facing 41).
upward. Install the pump cover, at- 2. Remove the throttle valve body
taching screws, and lock washers. and the separator plate. Remove the
I urque the screws to specification. throttle valve.
10. Check the pump for free 3. Remove one screw attaching
movement of the gear. the separator plate to the ]ower valve
body. Remove the upper body front
PRESSURE REGULATOR plate. The plate is spring-loaded.
Apply pressure to the plate while
fi Remove the valves from the removing the attaching screws.
re;c~ulator body. 4. Remove the compensator sleeve
::!. Remove the regulator body and plug, and remove the compensa-
C(l\ cr attaching screws, and remove tor valve springs. Remove the com-
th•' cover. pensator valve.
FIG. 39-lnstalling Front :t Remove the separator plate. 5. Remove the throttle boost valve
Pump Seal Then remove the front pump check and spring.

I -------------~G~R~O~U~P~7~A~UT~O~M~AT~IC~T~RA~N=SM=IS=SI=ON~____________(_n_
7-34_ 4_)
' 1 ' 1
LOWER BODY
~-- SIDE PLATE
INHIBITOR VALVE
AND SPRING
<:::::lII 1-2 SHIFT VALVE
AND SPRING
SEPARATOR PLATE
~
LOWER
BODY
SIDE PLATE
FRONT SERVO
RELEASE CHECK 3-2 KICK DOWN CONTROL
BAll AN:~ 7VE AND SPRING RETAINER
a- REVERSE
SHUTILE
VALVE
CONTROL VALVE
3-2 COASTir(jj\,
~
SEPARATOR
PLATE
THROTILE REDUCING
VALVE
AND SPRING
j 3-2 COASTING CONTROL

VALVE SPRING AND RETAINER
LOWER BODY
" - - - E N D PLATE
AA &A
UPPER VALVE BODY
AND REAR PLATE
COMPENSATOR
CUT -BACK PLUG
01350-A
FIG. 41-Main Control Valve Body-Exploded View

(115) PART 7-2-TURBO-DRIVE AUTOMATIC TRANSMISSION 7-35
6. Remove the downshift valve Assembly

and spring.
7. Remove the upper valve body 1. Arrange all parts in their cor-
rect positions. Rotate the valves and
rear plate.
8. Remove the compensator cut- plugs when inserting them in their
back valve. bores to avoid shearing of soft body
castings (Fig. 41 ) .
9. Remove the lower body side
plate. The plate is spring-loaded. 2. Position the separator plate on
Apply pressure to the plate while the upper body.
removing the attaching screws. 3. Be sure that the rear pump
10. Remove the 1-2 shift valve check valve spring, valve, and seat
and spring. Remove the inhibitor in the lower body are correctly in~
valve and spring. stalled. Position the lower body on
11. Remove the two screws attach- the upper body, and start but do not
ing the separator plate to the cover. tighten the attaching screw.
Remove the lower body end plate. 4. Position the cover and separator
The end plate is spring-loaded. plate on the lower body and start
Apply pressure to the plate while the four through bolts.
removing the attaching screws. 5. Align the separator with the
12. Remove the reverse shuttle D1052-A
upper and lower valve body attach-
valve and spring. ing bolt holes. Install and torque the
13. Remove the 2-3 delay and FIG. 42-Governor four valve body bolts to specification.
throttle reducing valve sleeve, the Excessive tightening of these bolts
throttle reducing valve, spring, and trol valve spring retainer from the may distort the valve bodies, caus-
the 2-3 shift delay valve. Remove the cover. Remove the spring and valve. ing valves or plugs to stick.
2-3 shift valve spring and valve. 18. Remove the through bolts and 6. Install the 3-2 kickdown control
14. Remove the transition valve. screws. Then separate the bodies. valve and spring, and the check ball
15. Remove the plate (Fig. 41) and spring in the cover. Install the
from the valve body cover. 19. Inspect the rear pump check plate.
16. Remove the check ball spring valve for freedom of movement. This 7. Install the 3-2 coasting control
and check ball. Remove the 3-2 valve seat in the lower body is staked valve, spring, and spring retainer in
kickdown control valve spring and for a firm fit and should not be re- the cover.
valve. moved unless a new one is to be 8. Install the transition valve in
17. Remove the 3-2 coasting con- installed. the lower body.
SUPPORT PIN
TOGGLE OPERATING
LEVER SUPPORT PIN
FIG. 43-Manual and Parking Pawl Linkage

7-36 GROUP 7-AUTOMATIC TRANSMISSION ,(116)
stall the throttle valve body. Install

the three attaching .screws.
19. Install four screws attaching
the cover to the lower body, two
screws attaching the separator plate
to the upper body, and one screw
attaching the separator plate to the
lower body. Torque the cover and
body screws to specification.
20. Install the manual valve.
l" J.D. PIPE

OR SOCKET
FIG. 44-Removing FIG. 48-lnstalling

Parking Pawl Toggle Pin Lubrication Tube
9. Install the 2-3 shift valve and the valve body and counterweight for
spring. Install the 2-3 shift delay burrs and distortion. Mating surfaces
valve and the spring and throttle re- must be smooth and flat.
ducing valve in the sleeve. Slide the 7. Install the governor valve and
sleeve and valve into position in the spring assembly in the bore of the
lower body. valve body. Install the washer, sleeve,
10. Install the reverse shuttle valve and plug. Make sure the three points
and spring. Install the lower body on the end of the sleeve seat in the
end plate. FIG. 46-lnstalling Front slots in the washer.
11. Install the inhibitor valve Servo Cover 8. Install the body on the counter-
spring and valve in the lower body. weight. Make sure the fluid pas-
12. Install the 1-2 shift valve GOVERNOR sages in the body and the counter-
spring and valve. Install the lower weight are aligned.
body side plate. 1. Remove the governor valve 9. Position the valve body cover
body cover. on the body, and install the screws.
13. Install the compensator cut-
2. Remove the valve body from
back valve in the upper body. Install
the counterweight.
the upper body rear plate.
3. Remove the plug, sleeve, washer,
14. Install the downshift valve and valve from the body (Fig. 42).
spring and valve. 4. Inspect the governor valve and
15. Install the throttle boost valve bore for scores. Minor scores may be
and spring. removed with crocus cloth. Replace
16. Install the compensator valve, the governor if the valve or body is
inner and outer compensator springs, deeply scored.
and the compensator sleeve and plug. 5. Check for free movement of
17. Position the front plate. Apply the valve in the bore. Inspect fluid
pressure to the plate while installing passages in the valve body and
the two attaching screws. counterweight for obstructions. All
REAR FRONT CLUTCH GOVERNOR
18. Install the throttle valve in the fluid passages must be clean. CLUTCH AND GOVERNOR RETURN
throttle valve body. Position the 6. Inspect the mating surfaces of
separator on the upper body and in-
FIG. 49-lnstalling Rear 01354-A
Clutch, Front Clutch, and Governor
Tubes
MANUAL AND PARKING
PAWL LINKAGE
DISASSEMBLY
1. Detach the parking pawl toggle
operating rod from the manual de-
tent lever and parking pawl toggle
operating lever assembly (Fig. 43).
y 2. Remove throttle control inner
01351-A .. 01056-B
lever nut, inner lever, outer lever,
manual valve detent lever nut, de-
FIG. 45-lnstalling Front FIG. 47 -One-Way Clutch tent lever, ball, spring and outer lever
Servo Piston Installation on Center Support from the case.

(117} PART 7-2- TURBO-DRIVE AUTOMATIC TRANSMISSION 7-37
FIG. 50-Installing Rear FIG.52-Installing FIG. 53-Installing Main

Servo Apply and Release Tube Compensator Tube Pressure Tube
3. To remove the parking pawl lects, all mating surfac:es should be squarely on top of the one-way
toggle lever support pin from the 1 ubricated with clean transmission clutch. With the end of a screw-
back face of the case, a special tool fluid before they are assembled. driver, position all the cams of the
must be adapted (Fig. 44). A piece 1. Assemble the front servo assem- one-way clutch to enter the carrier,
of pipe approximately 1 inch long hJy into the case using new oil rings. then rotate the planet carrier to in-
by 1 inch I.D., or a suitable socket l nstall the front servo release spring stall it.
can be used with a 5 I 16-18 x 31;2 ~~nd piston assembly in the front 10. Assemble the planet and center
inch bolt, nut and washer as a pin ,,·rvo bore in the case. Compress the support assembly to the front and
pulling tool. When the pin is re- l r(mt servo piston metal-type oil rear clutch assembly. Make sure that
placed, make sure that it is flush nng while installing the piston as- the thrust washers between the clutch
with the back face of case. If the ..,~·mbly (Fig. 45). assemblies are properly positioned
pin is pressed in too far, the park- 2. Apply pressure to the front and the needle bearing thrust washer
ing pawl lever will bind and not ..,,_Tvo retainer and install the retainer and race is positioned between the
release. -,nap ring (Fig. 34). planet assembly and front clutch
4. Remove the parking pawll sup- 3. Install the seal on the front sun gear.
port pin and parking pawl assembly -.,_-rvo cover and press the cover into
11. Install the two oil seal rings
from the case. piace in its bore in the case. Do not
on the end of the sun gear shaft and
5. Remove the parking pawl 1toggle damage the rubber seal on the cover
the output shaft front thrust washer
operating lever retaining clip from ! Fig. 46).
on the planet assembly. Now, as-
the support pin; then, remove the 4. Using new oil rirtgs, assemble
semble the output shaft to the gear
lever. Tap out the toggle operating r he rear servo piston. Install the rear
train .
lever support pin using a brass drift ... ervo piston assembly in its bore in
to drive the pin into the case. the transmission case. Position the 12. Install the complete gear train
6. Remove the manual control -.pring on the piston and the retainer (clutches, center support, planet
lever oil seal from the case. 'Hl the spring (Fig. 3 3).
carrier and output shaft) in the case
7. To assemble, reverse the above 5. Compress the rear servo piston (Fig. 26). Make sure that the input
procedure. • \('ring retainer and install the snap shaft thrust washer tangs stay posi-
r1ng (Fig. 32). tioned in the slots in the front of
ASSEMBLY the case. The center support can
6. Install the front band in the
After all the parts have been care- only be positioned one way to line
',!SC.
fully cleaned and inspected for de- up the bolt holes.
7. Install the rear band in the case.
xpand the rear band, using the
I="
~H:tuating lever strut as a spacer to
hold the band in the expanded posi-
llon.
8. Install the input shaft thrust
washer in the case. Make sure that
the tangs on the washer hold it in
place as the gear train is assembled.
9. On the bench, assemble the
planet one-way clutch, center sup-
port, and planet carrier. The one-
V\ ay clutch is assembled with drag
"'rips toward the front of the center

"''ppon (Fig. 47). Check the action
t '1 the one-way clutch after the one-
FIG 51-Installing Rear \A ay clutch is installed on the center
FIG. 54-Installing Front
Pump Pressure Tube ..,11pport. Position the planet carrier Servo Apply and Release Tubes

13. Install the center support bolts 23. Install the distributor sleeve 31. Install the main control valve
and washers. Torque the bolts to with tubes assembled, on the output assembly. Position the assembly so
specifications. shaft, with the I.D. chamfer toward that maximum contact is obtained
14. Remove the spacer from the the front of the transmission. between the manual valve and detent
rear band. Install the rear band 24. Guide the distributor tubes lever when it is placed in each detent
anchor strut and position the band into the transmission case as the dis- position. The manual valve should
on the strut. Make sure the slot in tributor is moved forward over the not bind in the casting as the detent
the strut and the pin in the band oil rings and against the spacer lever is moved to each detent posi-
are in alignment. washer. tion.
15. Position the rear band actuat- 25. Install the distributor sleeve 32. Install the throttle control
ing lever and strut in the case and retaining snap ring. valve rod and throttle valve control
install the rear band actuating lever 26. Install the extension housing diaphragm assembly.
shaft. and extension housing bolts and 33. Install the hydraulic pressure
16. Install the front band actuat- washers. Torque the bolts to specifi- tubes in the following order, making
ing lever, pin and retaining clips. cations. sure that the tubes are set firmly in
Insert the metal plug in the case at 27. Install a new front pump gas- place to eliminate any hydraulic
the lever pin hole. Install the front ket, front pump and bolts. Torque leakage. First install the lubricating
band actuating and anchor struts. the bolts to specifications. tube (Fig. 48) , then the rear clutch,
17. Check to see if the rear pump front clutch and governor return
drive gear key is in the output shaft. 28. Check transmission end play tubes (Fig. 49). Next install the rear
Install the rear pump discharge port (Fig. 24). (The specified end play servo apply and release tube (Fig.
"0" ring in the case. limit is 0.010 to 0.029 inch.) If end 50). Then the rear pump pressure
18. Position the output shaft play is not within specification, re- tube (Fig. 51) and compensator tube
needle bearing type thrust washer place the selective fit output shaft (Fig. 52). Install the main pressure
on the output shaft and the race into thrust washer in front of the output tube (Fig. 53) and the front servo
the front of the rear pump. Install shaft. apply and release tubes (Fig. 54).
the case to pump gasket on the 29. Adjust the front and rear 34. Install the seal on the front
pump. bands. For the front band, back off pump inlet tube on the screen and
19. Install the rear pump on the the stud 3 turns after the tool over- install the screen.
output shaft. The keyway of the runs, using tool No. 7345 and 35. Install the oil pan gasket and
drive gear and key on the output 7345-L. Then tighten the lock nut to oil pan. Torque the oil pan retaining
shaft will have to be in alignment. specifications. For the rear band, bolts to specifications.
20. Install the governor drive ball, back off 1:Y2 turns with tool No. 36. Remove the transmission from
governor and snap ring on the output 7195-C after the tool overruns; then, the holding fixture.
shaft. tighten the lock nut to specifications. 37. Install the converter housing
21. Install the spacer washer and (Refer to In-Car Adjustments and gasket, housing and vent baffle. In-
four oil seal rings on the output Repairs for Band Adjustment pro- stall the one internal bolt retaining
shaft. cedures.) the converter to the case. Torque all
22. Install the rear pump to exten- 30. Install the pressure regulator bolts to specifications.
sion housing gasket on the rear assembly springs, spacers and retain- 38. Install the converter in the
pump. er. Torque the bolts to specifiactions. front pump.

(119) 7-39
PART SPECIFICATIONS
7-3
CONTROL PRESSURE RANGES TRANSMISSION GEAR RATIOS
Manifold Engine Gauge Selector
Vacuum Speed Selector Reading Clutch Band Gear
Gear lever Applied
HG (Inches) RPM Position PSI Applied Ratio
Position
16 Idle 01-02 57-77
Minimum P-R-N 57-213 Neutral N None None -
Pressure -- First D1 Front Rear# 2.37:1
16 to 13.7 As Required Dl-D2-L
Starts Rising Second Dl or D2 Front Front 1.48:1
1.5 Stall Dl-02-L -----rsl-176 --
Front
or less 1550-1750 R 201-213 Third D1 or D2 None 1.1:1
and Rear
Reverse R Rear Rear 1.84:1
TORQUE SPECIFICATIONS #In first gear Dl, the planet earner IS held against rotation by the one-way
FOOT clutch.
APPLICATION DESCRIPTION
POUNDS
Band Adjustment Stop to Case Nut-Yz -20 light Hex Jam 35-40
-- SJALL SPEEDS
Case to Converter Housing Bolt--1i6·14 x 1% Hex- Hd. 35-40 Selector
Clutch Band Engine
Converter Drain Plug Plug-- Ys -27 Dry Seal Taper Thd. 15-28 Lever Applied Applied RPM
Converter Housing to Case Bolt--1id4 x Ys Self l~ocking 35-45 Position
Diaphragm Assy. to Case Diaphragm Assy.-T.V. Control 20-30 D2 Front Front
Extension Assy. to Case Bolt--%-16 x 314 Hex- Hd. 28-38 01 Front One-Way Clutch 1550-1750
Front Pump Assy. to Case Bolt--7"16-18 X 2 Hex Hd. 17-22 L Front Rear
Front Servo Rei. Piston to Pin Screw & L/W. Assy- R Rear Rear
#10-32 x Ya Pan Hd *20-30
Governor Body to Counterweight Screw-14 -20 1Y2 Fill Hd. *50-60 Converter Stall Ratio ... .......... ............................ 2.1:1
Governor Cover to Body Screw-#10-24 x Ya Flat Hd. *20-30
Governor Insp. Cover to Ext. Screw-14 -20 x Yz Fili Hd. *50-60 LUBRICANT REFILL CAPACITY
Inner T.V. Lever to Shaft Nut--7"16·24 Hex lock 17-20
Type of lubricant Approximate Capacity
Main Control Valve Assy. Screw-#10-24 x .44 *20-30
Components Screw-#10-24 x % *20-30 Ford Automatic Transmission Fluid
12 Qts., 21 oz.
Screw-#10-24 x% *20-30 ClAZ-19582-A
Screw-#10-24 x 1i6 *20-30
Screw-#10-24 x 1.31 *20-30
Main Control Valve to Case Bolt--14-20 x 1% Hex-Hd. 8-10
CHECKS AND ADJUSTMENTS
Manual Control Lever to Shaft Nut--~6-24 Hex Lock 35-40 Operation Specification
-------~
Oil Pan to Case Bolt·- 51id8 x% Hex Hd. 10-13 Transmission End Play Check 0.010-0.029 inch
Oil Pres. Reg. Cover to Body Screw &L/W. Assy-#10-24 x% *20-30 Selective Thrust Washers
Available:
Planetary Support to Case Screw-Planetary Support 0.063-0.061 inch, 0.069-0.067 inch
Locating 20-25 I
0.076-0.074 inch, 0.083-0.081 inch

Pressure Gauge Tap Plug-Ys -27 Dry Sea I-T aper Thd. 7-18
Turbine and Stator End Play Check 0.060 inch (maximum)
Pressure Regulator to Case Screw-~6-18 x Ys Hex Hd. 17-22
Front Band Adjustment Adjust screw to 10 ft-lbs
Rear Oil Pump Cover to Body Screw-Y4 -20 x% Pan Hd. *80-90 (Use Y4 -inch spacer between torque, and back off three
Screw-#10-24 x % Pan Hd. *25-35 adjustment screw and servo full turns
---.-----~-:-:-
Stator Support to Pump Body Screw-#10-24 x% Flat Hd. *25-35 piston stem)
Upper to Lower Valve Body Bolt-Y4 -20 x 2Yz He-K. Hd. 4-6 Rear Band Adjustment Adjust screw to 10 tt-lbs
*Inch-Pounds. torque, and back off 1Yz turns;
lock nut to 35-40 tt-lbs
Primary Sun Gear Shaft Ring End
CLUTCH PLATE APPLICATION Gap Check 0.002-0.009 inch
FRONT CLUTCH REAR ClUTCH Accelerator Pedal Height Adjustment 3% inches above floor mat
Steel Composition Steel Rear Clutch Steel Plate Coning
Plates
4
II Plates
5
Plates
5
Composition
Plates
5
Clearance Check
Output Shaft to Fluid Distributor
0.010 inch (maximum)
Seal Ring End Gap 0.001 to 0.006 inch
TRANSMISSION SHIFT POINTS (APPROXIMATE)

Manual
Shift
Automatic Shift Speeds (mph) Speeds
(mph)
01 01 or 02 01 01 or 02 01 02 L
1·2 1-2 2-3 2-3 3-1 3·2 2·1 3-2 2·1
Minimum Maximum Minimum Maximum Minimum Maximum Maximum Minimum
Throttle Throttle Throttle Throttle Throttle Throttle Throttle Throttle
8-11 41-50 12-25 68-81 7-9 63-75 21-33 7-12 19-28

UlUJ
~~®§
11fXJO@
0~11§~110@~~~~\1
®~~~~

(121) 8-1
GROUP
a
GENERAL ENGINE SERVICE . . . . . . . . 8-1 SPECIFICATIONS . 8-53
PART 8-2
430 V-8 ENGINE ................. 8-18
PART GENERAL ENGINE SERVICE

&ct~
8-1 hp Section Page
1 Diagnosis and Testing. . . . . . . . . . . . . . . . . . . . 8-1 2 Common Adjustments and Repairs (Continued)
2 Common Adjustments and Repair~............ 8-9 Camshaft ............................... 8-11
Valve Clearance .......................... 8-9 Crankshaft ............................. 8-11 •
Valve Rocker Arm Shaft Assembl.y .......... 8-10 Pistons, Pins and Rings .................... 8-11
Push Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-10 Cylinder Block .......................... 8-12
Cylinder Heads . . . . . . . . . . . . . . . ......... 8-10 3 Cleaning and Inspection ................... 8-13
Valves . . . . . . . . . . . . . . . . . . . . . . ............ 8-11
This part covers engine diagnosis, inspection procedures are covered. pair procedures, refer to the perti-
testing, adjustment and repair proce- For engine removal, disassembly, nent part of this group.
dures. In addition, the cleaning and assembly, installation and major re-

DIAGNOSIS that could be at fault are listed in items that affect acceleration are
order of their probable occurrence. listed. Check all these items before
Engine performance complaints
usually fall under one of the basic Check the items in the order listed. proceeding to the next probable
headings listed in the "Diagnosis For example, under "Poor Accelera- cause.
Guide." When a particular trouble tion," the ignition system is listed For diagnosis of transistor igni-
can not be traced to a definite cause as a probable cause of the trouble. tion system malfunctions, refer to
by a simpie check, the possible items All the conventional ignition system Group 9.
DIAGNOSIS GUIDE
The cause of this trouble is usually the cylinders. Remove the cylinder
in the starting system (Group 14) . head(s) and inspect the gasket(s)
If the starting system is not at and/ or head ( s) for cracks. Exam-
ENGINE WILL fault, check for a hydrostatic lock ine the cylinder block for cracks.
or a seized engine as follows: If the engine does not crank with
NOT CRANK
Remove the spark plugs, then at- the plugs removed, remove the oil
tempt to crank the engine with the pan and check for displaced bearing
starter. If the engine cranks, it indi- inserts or seized pistons.
cates that water is leaking into
Check the fuel supply. If there is To determine which system is at

ENGINE CRANKS sufficient fuel in the tank and the fault, perform the foiiowing test:
NORMALLY, BUT WILL proper starting procedure is used, Disconnect a spark plug wire.
NOT START the cause of the trouble probably Check the spark intensity at the end
lies in either the ignition or the fuel of the wire by installing a terminal
system. adapter in the terminal of the wire to

8-2 GROUP 8-ENGINE (122)
DIAGNOSIS GUIDE {Continued)
be checked. Then hold the adapter The choke plate and linkage for
approximately %s inch from the ex- binding.
haust manifold and crank the engine. The fast idle cam for binding.
Thermostatic spring housing ad-
IF THERE IS NO SPARK justment.
OR A WEAK SPARK
AT THE SPARK PLUGS
FUEL SUPPLY AT THE
The cause of the trouble is in the CARBURETOR
ignition system.
To determine if the cause of the Work the throttle by hand several
trouble is in the primary or the times. Each time the throttle is
secondary circuit, remove the coil actuated, fuel should spurt from
high tension lead from the top of the accelerating pump discharge
the distributor, and hold it approxi- nozzle(s).
mately 3/16 inch from the cylinder If fuel is discharged by the ac-
head. With the ignition on, crank celerating pump, the engine is prob-
the engine and check for a spark. ably flooded, or there is W(!ter in
If the spark at the coil high ten- the fuel system, or an engine me-
sion lead is good, the cause of the chanical item is at fault.
trouble is probably in the distributor If fuel is not discharged by the
cap, rotor or spark plug wires. accelerating pump, disconnect the
ENGINE CRANKS If there is no spark or a weak carburetor fuel inlet line at the
NORMALLY, BUT WILL spark at the coil high tension lead, carburetor. Use a suitable container
NOT START (Continued} the cause of the trouble is probably to catch the fuel. Crank the engine
in the primary circuit, coil to dis- to see if fuel is reaching the car-
tributor high tension lead, or the buretor.
coil. If fuel is not reaching the car-
buretor, check:
IF THERE IS A The fuel filter.
GOOD SPARK AT The fuel pump.
THE SPARK PLUGS The carburetor fuel inlet line for
Check the spark plugs. If the obstructions.
spark plugs are not at fault, check The fuel pump flexible inlet line
the following items: for a collapsed condition.
The fuel tank line for obstructions.
AUTOMATIC CHOKE The fuel tank vented cap.
Check the position of the choke If fuel is reaching the carburetor,
plate. If the engine is hot, the plate check:
should be open. If the plate is not The fuel inlet system including the
open, the engine will load up due to fuel inlet needle and seat assembly
the excessively rich mixture and will and the float assembly.
not start. If the engine is cold, the Check for dirt in the carburetor
plate should be closed. If the plate is which will not allow fuel to enter
not operating properly, check the fol- or be discharged from the idle sys-
lowing items: tem.
FUEL SYSTEM Incorrect throttle linkage adjust-

ment.
Idle fuel mixture needles not prop- Clogged air bleeds or idle passages.
erly adjusted. Restricted fuel tank vented cap or
Engine idle speed set too low. fuel lines.
The choke not operating properly. Incorrect fast (cold) idle screw
Float setting incorrect. adjustment.
ENGINE STARTS, BUT Fuel inlet system not operating
FAILS TO KEEP RUNNING properly. IGNITION SYSTEM
Dirt or water in the fuel lines or Breaker points not properly ad-
in the fuel filter. justed.
Carburetor icing. Defective spark plugs.
Fuel pump defective. Leakage in the high tension wiring.
Check for dirt in the carburetor Defective ignition resistor.
not allowing fuel to enter or be dis- Open circuit in primary resistance
charged from the idle system. wire.

(123) PART 8-1-GENERAL ENGINE SERVICE 8-3
DIAGNOSIS GUIDE (Continued)
Determine if the miss is steady or Dirt or water in the fuel lines or

erratic and at what speed the miss carburetor.
occurs by operating the engine at Restricted fuel filter.
various speeds under load.
COOLING SYSTEM
MISSES STEADILY AT
ALL SPEEDS Check the cooling system for in-
ternal leakage and/ or for a condi-
Isolate the miss by operating the tion that prevents the engine from
engine with one cylinder not firing. reaching normal operating tempera-
This is done by operating the engine ture.
with the ignition wire removed from
one spark plug at a time, until all cyl- ENGINE
inders have been checked. Ground Perform a manifold vacuum test or
the spark plug wire removed. a compression test to determine
If the engine speed changes when which mechanical component of the
a particular cylinder is shorted out, engine is at fault.
that cylinder was delivering power
before being shorted out. If no MISSES AT IDLE ONLY
change in the engine operation is
evide:nt, the miss was caused by that FUEL SYSTEM
cylinder not delivering power before Idle fuel mixture needles not prop-
being shorted out. In this case, check erly adjusted.
the:
IGNITION SYSTEM IGNITION SYSTEM
If the miss is isolated in a par-

Defective coil, condenser, breaker
ticular cylinder, perform a spark test points, rotor, ignition, wiring or
on the ignition lead of that cylinder. spark plugs.
If a good spark does not occur, Excessive play in the distributor
the trouble is in the secondary cir- shaft.
ENGINE RUNS, BUT cuit of the system. Check the spark Worn distributor cam.
MISSES plug wire and the distributor cap.
If a good spark occurs, check the
ENGINE
spark plug. If the spark plug is not Perform a manifold vacuum test or
at fault, a mechanical component a compression test to petermine
of the engine is probably at fault. which mechanical component of the
engine is at fault.
ENGINE
Perform a manifold vacuum test MISSES AT HIGH SPEED ONLY
or a compression test to determine FUEL SYSTEM
which mechanical component of the
engine is at fault. Low or erratic fuel pump pressure.
Fuel inlet system not operating
MISSES ERRATICALLY properly.
AT ALL SPEEDS Restricted fuel filter.
EXHAUST SYSTEM High-speed system restricted, clog-
ged, or damaged.
Exhaust system restricted. Positive crankcase ventilation sys-
IGNITION SYSTEM tem restricted or valve not operating
properly.
Breaker points not properly ad- Metering rod piston stuck in down
justed. position.
Defective breaker points, con-
denser, secondary wiring, coil, or COOLING SYSTEM
spark plugs.
High tension leakage across the Engine overheating.
coil, rotor, or distributor cap.
ENGINE
FUEL SYSTEM Perform a manifold vacuum test
Float setting incorrect. or a compression test to determine
Fuel inlet system not operating which mechanical component of the
propt:rly. engine is at fault.

8-4 GROUP 8-ENGINE {124)
FUEL SYSTEM IGNITION SYSTEM

Engine idle speed set too low. Improperly adjusted or defective
Idle fuel mixture needles not prop- breaker points.
erly adjusted. Fouled or improperly adjusted
Float setting incorrect. spark plugs.
Air leaks between the carburetor, Incorrect ignition timing.
spacer, and the manifold and/or
fittings. Spark plug misfiring.
Fuel leakage at the carburetor fuel
bowls.
Idle fuel system air bleeds or fuel ENGINE
ROUGH ENGINE IDLE passages restricted. Loose engine mounting bolts to
Fuel bleeding from the accelerat- worn insulator.
ing pump discharge nozzles. Cylinder head bolts not properly
Secondary throttle plates not clos- torqued.
ing.
Improper secondary throttle plate Positive crankcase ventilation regu-
stop adjustment. lator valve defective or a restricted
Idle compensator malfunctioning. tube.
Coolant thermostat defective. Worn camshaft lobes.
Leaking fuel pump, lines, or fit- Perform a manifold vacuum test
tings. and/ or compression test to deter-
Carburetor hot and cold air valve mine which mechanical component
malfunctioning. is at fault.
IGNITION SYSTEM Restriction in the fuel line or a

leak.
Incorrect ignition timing. Incorrectly installed accelerator
Fouled or improperly adjusted pump link.
spark plugs. Leaky gaskets, or accelerating
Improperly adjusted or defective pump plunger.
breaker points. Dirt or corrosion in accelerating
Distributor not advancing prop- system.
erly. Distributor vacuum passages in
Broken distributor spring. the carburetor blocked.
Restricted fuel filter.
FUEL SYSTEM
Inoperative accelerating pump in- BRAKES
POOR ACCELERATION let ball check. Improper adjustment - too tight.
Inoperative accelerating pump dis-
charge ball check. TRANSMISSION
Accelerating pump plunger de-
fective. Improper regulation of line pres-
Float setting incorrect. sure.
Throttle linkage not properly ad- Improper band adjustment.
justed. Converter one-way clutch.
Accelerating pump stroke not
properly adjusted. ENGINE
Defective fuel pump and/ or push Perform a manifold vacuum test
rod. and/ or compression test to determine
Automatic choke malfunction. which mechanical component of the
Restricted fuel tank vented cap. engine is at fault.
FUEL SYSTEM Metering rod piston stuck in down

position.
ENGINE DOES NOT Restricted air cleaner. Secondary throttle plates not
DEVELOP FULL POWER, Restricted fuel filter. opening.
OR HAS POOR HIGH Clogged or undersize main jets Fuel pump pressure and volume
SPEED PERFORMANCE and/ or low float setting. incorrect.
Clogged or undersize secondary Distributor vacuum passage in
jets. the carburetor blocked.
CONTINUED ON NEXT PAGE:

FUEL SYSTEM (Continllled) COOLING SYSTEM

Automatic choke malfunction or
Improperly adjusted. Thermostats inoperative or incor-
rect heat range.
IGNITION SYSTEM Check the cooling system for inter-
nal leakage and/ or for a condition
Ignition timing not properly ad- that prevents the engine from reach-
justed . ing normal operating temperature.
Defective coil, condenser, or
ENGINE DOES NOT rotor. ENGINE
DEVELOP FULL POWER, Distributor not advancing prop-
OR HAS POOR HIGH Positive crankcase ventilation valve
erly.
SPEED PERFORMANCE not operating properly.
Excessive play in the distributor Perform a manifold vacuum test
(Continued) shaft. or a compression test to determine
Distributor cam worn. which mechanical component of the
Fouled or improperly adjusted engine is at fault.
spark plugs, or spark plugs of incor- One or more camshaft lobes worn
rect heat range. beyond wear limit.
Improperly adjusted or defective
breaker points. TRANSMISSION
EXHAUST SYSTEM Improper band adjustment or

transmission malfunction. Perform an
Restriction in exhaust system. engine stall test.
Dete:rmine the actual fuel con- FINAL CHECKS

sumption with test equipment in-
stalled in the car. FUEL SYSTEM
If the test indicates that the fuel Check:
consumption is not excessive, dem- Fuel pump pressure and volume.
onstrate to the owner how improper Engine idle speed.
driving habits will affect fuel con- Idle fuel mixture needles for prop-
sumption. er adjustment.
lf the test indicates that the fuel Automatic choke for proper op-
consumption is excessive, make a eration.
preliminary check of the following Fast idle speed screw for proper
items before proceeding to the fuel adjustment.
and ignition systems. Accelerating pump stroke ad-
justment.
PRELIMINARY CHECKS Anti-sta11 dashpot for proper ad-
CHASSIS ITEMS justment.
Air cleaner for restrictions.
Check: Float setting or fuel level.
EXCESSIVE FUEL
Tires for proper pressure. Jets for wear and/or damage.
CONSUMPTION
Front wheel alignment. Metering rod piston operation.
Brake adjustment. Air bleeds for obstructions.
:EXHAUST SYSTEM Accelerating pump discharge noz-
zles for siphoning.
System restricted. Accelerator linkage for binds.
ODOMETER Choke adjustment.
Check calibration. IGNITION SYSTEM
IGNITION SYSTEM Check:
Spark plug condition and adjust-
Check: ment.
Distributor breaker points. Distributor spark advance opera-
Tgnition timing. tion.
Ignition timing.
ENGINE
Positive crankcase ventilation regu- ENGINE
lator valve defective or restricted Perform a manifold vacuum test or
tuhes. an engine compression test to deter-


ENGINE (Continued) TRANSMISSION
mine which mechanical component Check the band adjustment and
EXCESSIVE FUEL of the engine is at fault. perform a stall test.
CONSUMPTION
(Continued) COOLING SYSTEM
Check thermostat operation and
heat range.
TEMPERATURE SENDING Cooling system leaks.

UNIT AND GAUGE Drive belt tension incorrect.
Unit or gauge defective (not in- Radiator fins obstructed.
dicating correct temperature), or Thermostats defective or of incor-
constant voltage regulator defective. rect heat range.
Thermostats improperly installed.
ENGINE Cooling system passages blocked.
Cylinder head bolts not properly Water pump inoperative.
torqued causing coolant loss. Faulty fan drive.
ENGINE OVERHEATS Incorrect valve clearance.
Low oil level or incorrect viscos- IGNITION SYSTEM
ity oil used. Incorrect ignition timing.
Perform an engine manifold vac-
uum test and/or compression test EXHAUST SYSTEM
to determine which mechanical com-
ponent of the engine is at fault. Restrictions in system.
COOLING SYSTEM BRAKES

Insufficient coolant. Brakes too tight.
COOLING SYSTEM ENGINE

Leaking radiator. Cylinder head gasket defective.
Loose or damaged hose connec- Intake manifold to cylinder head
tions. gasket defective.
Water pump leaking. Cylinder head or intake manifold
LOSS OF COOLANT Radiator pressure cap defective. bolts not properly torqued.
Overheating. Cylinder block core plugs leaking.
Temperature sending unit leaking.
Cracked cylinder head or block,
or warped cylinder head or block
gasket surface.
TEMPERATURE SENDING COOLING SYSTEM

ENGINE FAILS TO REACH UNIT AND GAUGE
Thermostats inoperative or of in-
NORMAL OPERATING
Unit or gauge defective (not indi- correct heat range.
TEMPERATURE
cating correct temperature) or con-
stant voltage regulator defective.
A noisy hydraulic valve lifter can exhaust valve until the noisy lift-
be located by operating the engine at er(s) has been located.
idle speed and placing a finger on the The most common causes of hy-
face of the valve spring retainer. If draulic valve lifter troubles are dirt,
the lifter is not functioning prop- gum, varnish, carbon deposits and
erly, a shock will be felt when the air bubbles.
valve seats. Dirt in the lifter assembly can
NOISY HYDRAULIC Another method of identifying a prevent the disc valve from seating,
VALVE LIFTER noisy lifter is by the use of a piece or it may become lodged between
of hose. With the engine operating the plunger and body surfaces. In
at idle speed, place one end of the either case, the lifter becomes inop-
hose near the end of the valve stem erative due to failure to "pump-up,"
and the other end to the ear and or because the internal parts are no
listen for a metallic noise. Repeat longer free to function properly.
this procedure on each intake and When dirt is found to be respon-

(127) PART 8-1- GENERAL ENGINE SERVICE 8-7
sible for lifter malfunction, remove the engine and remove the oil pres-
the lifter assembly and thoroughly sure sending unit. Install a fitting in
clean it. Recommended engine oil this opening with a petcock-type
and filter change intervals should be valve that will permit attachment of
followed to minimize lifter prob- a ~- to %-inch diameter hose of
lems caused by dirt (Group 19). sufficient length to direct the oil dis-
Deposits of gum and varnish charge into the oil filler pipe. Close
cause similar conditions to exist the valve.
which may result in lifter malfunc- Start the engine and operate it at
tion.. If these conditions are found approximately 500 rpm for a mini-
to be present, the lifter should be mum of five minutes; then, open the
disassembled and cleaned in solvent valve slightly to permit a steady
to remove all traces of deposits. discharge of oil. Check the oil flow.
NOISY HYDRAULIC Air bubbles in the lubricating oil, Increase the engine speed to ap-
VALVE LIFTER caused by an excessively high or proximately 1000 rpm and check for
(Continued) low oil level, may likewise cause air bubbles in the oil. To facilitate
lifter malfunction. A damaged oil checking for air bubbles, direct
pick-up tube may allow air to be the oil flow over white paper or
drawn into the lubricating system. through a piece of transparent
Check for engine oil aeration as tube. The engine should not be
follows: operated at excessive speeds or
Check the engine oil level to be for extended periods with the oil
sure it is within specification and bleed attached.
correct as required. Be sure the If oil aeration is evident, remove
correct engine oil dipstick is be- the oil pan for further test and/ or
ing used. inspection of the oil pump intake
Operate the engine at approxi- system. Perform corrective action as
mately 1200 rpm until normal oper- required to remove air from the
ating temperature is reached. Stop lubricating oil.
TESTING lobes are within specifications, re~

move the dial indicator assembly and
CAMSHAFT LOBE LIFT holding fixture.
This procedure is similar to that 7. Remove the auxiliary starter
used for checking valve timing. switch. Install the rocker arm and
Check the lift of each lobe in con- shaft assemblies and related parts.
secutive order and make a note
of the readings.
MANIFOLD VACUUM TEST
1. Remove the valve rocker arm
and shaft assemblies from the cyl- A manifold vacuum test aids in
ilider heads. determining the condition of an en-
2. Install a dial indicator on the gine and also in helping to locate the
cylinder head (Fig. 1 ) . Make sure cause of poor engine performance.
the push rod is in the valve lifter To check manifold vacuum:
socket and the actuating point of 1. Operate the engine until nor-
the indicator is in the same plane mal operating temperature is reached.
as the push rod movement.
2. Connect an accurate, sensitive
3. Install an auxiliary starter
vacuum gauge to the vacuum fitting
switch. "Bump" the engine over un-
located on the left side of the mani-
til the valve lifter rests on the base
fold below the carburetor spacer.
circle of the cam. At this point the
push rod is in its lowest position.
FIG. 1-Checking 3. Operate the engine at the rec-
On an engine equipped with Camshaft Lobe Lift ommended idle rpm, with the trans-
transistor ignition, refer to Group mission selector lever in neutral.
9 for the procedure on installing cator reads zero. This is a check 4. Check the vacuum reading on
an auxiliary starter switch. on the accuracy of the original in- the gauge.
4. Set the dial indicator on zero. dicator reading. Test Conclusions. Manifold vac-
then "bump" the crankshaft over 5. If the camshaft reading on any uum is affected by carburetor adjust-
until the push rod is in its fully lobe is below specified wear limits, ment, valve timing, ignition timing,
raised position. Note the total lift the camshaft and the tappets operat- condition of the positive crankcase
recorded on the indicator. Continue ing on the worn lobes must be re- ventilation system, the condition of
to rotate the camshaft with the aux- placed. the valves, cylinder compression and
iliary starter switch until the indi- 6. If the camshaft readings for all leakage of the manifold, carburetor,

carburetor spacer, or cylinder head and choke plate in the wide open checked before condemning the rings
gaskets. position. or valves.
Because abnormal gauge readings 4. Install a compression gauge in To determine whether the rings or
may indicate that more than one of No. 1 cylinder. the valves are at fault, squirt the
the above factors are at fault, exer- equivalent of a tablespoon of heavy
cise caution in analyzing an abnor- 5. Using an auxiliary starter oil into the combustion chamber.
mal reading. For example, if the switch, crank the engine a minimum Crank the engine to distribute the oil
vacuum is low, the correction of one of five pumping strokes and record and repeat the compression test. The
item may increase the vacuum enough the highest reading. On engines oil will temporarily seal leakage past
to indicate that the trouble has been equipped with transistor ignition, the rings. If approximately the same
corrected. It is important, therefore, refer to Group 9 for the procedure reading is obtained, the rings are
that each cause of an abnormal read- on installing an auxiliary starter satisfactory, but the valves are leak-
ing be investigated and further tests switch. Note the number of coming. If the compression has increased
be conducted where necessary in pression strokes required to obtain 10 pounds or more over the original
order to arrive at the correct diag- the highest reading. reading, there is leakage past the
nosis of the trouble. 6. Repeat the test on each cylin- rings.
Table 1 lists various types of read- der, cranking the engine the same During a compression test, if the
ings and their possible causes. number of times for each cylinder as pressure fails to climb steadily and
Allowance should be made for the was required to obtain the highest remains the same during the first two
effect of altitude on the gauge read- reading on the No. 1 cylinder. successive strokes, but climbs higher
ing. The engine vacuum will decrease Test Conclusions. A variation of on the succeeding strokes, or fails to
with an increase in altitude. ± 20 psi from specified pressure is climb during the entire test, it indi-
cates a sticking valve.
TABLE 1-Manifold Vacuum Gauge Readings
HYDRAULIC VALVE
LIFTER TESTS
Gauge Reading Engine Condition
Dirt, deposits of gum and varnish
18 inches or over Normal. and air bubbles in the lubricating
Low and steady. Loss of power in all cylinders caused pos- oil can cause hydraulic valve lifter
sibly by late ignition or valve timing, or loss failure or malfunction.
of compression due to leakage around the Dirt, gum and varnish can keep
piston rings. a check valve from seating and
cause a loss of hydraulic pressure.
Very low. Manifold, carburetor, spacer or cylinder An open valve disc will cause the
head gasket leak. plunger to force oil back into the
valve lifter reservoir during the time
Needle fluctuates steadily A partial or complete loss of power in one
I as speed increases. or more cylinders caused by a leaking valve,
the push rod is being lifted to force
the valve from its seat.
cylinder head or intake manifold gasket Air bubbles in the lubricating sys-
leak, a defect in the ignition system or a tem can be caused by too much oil
weak valve spring. in the system or too low an oil level.
Air may also be drawn into the lub-
Gradual drop in reading at Excessive back pressure in the exhaust
ricating system through an opening
engine idle. system.
in a damaged oil pick-up tube. Air
Intermittent fluctuation. An occasional loss of power possibly caused in the hydraulic system can oause
by a defect in the ignition system or a a loss of hydraulic pressure.
sticking valve. Assembled valve lifters can be
tested with tool-6500-E to check the
Slow fluctuation or drift- Improper idle mixture adjustment or carbure- leak down rate. The leak down rate
ing of the needle. tor, spacer or intake manifold gasket leak. specification (for gauging purposes)
is 10-100 seconds at 50 lbs. load.
COMPRESSION TEST satisfactory. However, the compres- Plunger travel is 0.125 inch. Test the
sion of all cylinders should be uni- valve lifters as follows:
1. Be sure the crankcase oil is at form within 10 psi. 1. Place the valve lifter in the
the proper level. A reading of more than the allow- tester, with the plunger facing up-
2. Be sure the battery is properly able tolerance above normal indi- ward. Pour hydraulic tester fluid into
charged. Operate the engine for a cates excessive deposits in the cyl- the cup to a level that will cover
minimum of 30 minutes at 1200 rpm inder. the valve lifter assembly. The fluid
or until the engine is at normal oper- A reading of more than the allow- can he purchased from the manu-
ating temperature. Turn the ignition able tolerance below normal indi- facturer of the tester. Do not use
switch off, then remove all the spark cates leakage at the cylinder head kerosene, for it will not provide
plugs. Remove the coil high tension gasket, piston rings or valves. an accurate test.
lead from the distributor cap and A low, even compression in two 2. Place a ~lia-inch steel hall in
coil. adjacent cylinders indicates a cylin- the plunger cup (Fig. 2).
3. Set the primary throttle plates der head gasket leak. This should be 3. Adjust the length of the ram

for the pointer to travel from the

"Start Timing" to the "Stop Timing"
marks of the tester (Fig. 5).
6. A valve lifter that is satisfactory
must take at least 10 seconds, but not
more than 100 seconds, to leak down.
7. If the valve lifter is not within
specifications, disassemble the lifter
and clean and inspect it as outlined
in Section 3. Assemble the lifter and
test the lifter again. If it does not
meet specifications, replace it with a
new lifter. Always test a new lifter
A1894-A before installing it in the engine.
8. Remove the fluid from the cup FIG. 4-0perate Plunger
FIG. 2-Piacing Steel and bleed the fluid from the lifter Until Air Bubbles Disappear
Ball in Valve Lifter Plunger by depressing the plunger up and
down (Fig. 4). This step will aid tion remains when the good regula-
so that the pointer is in line with in depressing the lifter plunger tor valve is installed, the crankcase
the starting mark when the ram con- when checking the valve clearance. ventilation system is not at fault.
tacts the valve lifter plunger(Fig. 3). Further engine component diagnosis
4. Work the valve lifter plunger POSITIVE CRANKCASE will have to be conducted to find
up and down until the lifter fills VENTILATION SYSTJ<:M TEST the malfunction.
with fluid and all traces of air bub- A malfunctioning positive crank- If the idle condition is found to be
bles have disappeared (Fig. 4). case ventilation system may be indi- satisfactory, refer to Section 3 of this
5. Allow the ram and weight to cated by loping or rough engine idle. Part for the cleaning procedure.
force the valve lifter plunger down- Do not attempt to compensate for
ward. Measure the exact time it takes this idle condition by disconnecting
the crankcase ventilation system and
making carburetor adjustments. The
removal of the crankcase ventilation
system from the engine will adversely
affect the fuel economy and engine
ventilation with resultant shortening
of engine life.
To determine whether the loping
or rough idle condition is caused by
a malfunctioning crankcase ventila-
tion system, clean the ventilation sys-
tem components, and install a known
good regulator valve in the ventila-
tion system .
Start the engine and compare the
engine idle condition to the prior idle
FIG.3_:Adiusting the condition. FIG.5-Checking Leak-
Ram Length If the loping or rough idle condi- Down Rate

VALVE CLEARANCE this clearance to the point that, if not 3. Position the hydraulic lifter
A 0.060-inch shorter push rod compensated for, the hydraulic valve compressor tool on the rocker arm
lifter will cease to function. and slowly apply pressure to bleed
(color coded white) or a 0.060-inch
To determine whether a shorter or down the hydraulic lifter until the
longer push rod (color coded yel-
a longer push rod is necessary, make plunger is completely bottomed
low) are available for service to pro- the following check: (Fig. 6). Hold the lifter in the fully
vide a means of compensating for 1. Disconnect the coil high tension collapsed position, and check the
dimensional changes in the valve lead and starter relay leads, and clearance between the valve stem
mechanism. Valve stem to valve install an auxiliary starter switch. and the rocker arm of the valve
rocker arm clearance should be On engines equipped with tran- being checked.
within specifications with the hy- sistor ignition, refer to Group 9 4. Check the clearance with 0.078
draulic lifter completely collapsed for the procedure on installing an and 0.218-inch feeler gauges.
(refer to Part 8-3). Repeated valve auxiliary starter switch. If the 0.078-inch feeler gauge en-
reconditioning operations (valve and 1 2. Position the crankshaft as out- ters, a standard length push rod may
or valve seat refacing) will decrease 1ined in steps 5 and 6. be used.

assembly, the engine should not be TO REMOVE STOCK TO REMOVE STOCK

cranked or rotated until the hy- FROM TOPOF SEAT, FROM BOTTOM OF
USE 30° WHEEL SEAT, USE 60° WHEEL
draulic lifters have had an opportun-
ity to leak down to their normal
operating position. The leak down
rate can be accelerated by using the
tool shown in Fig. 6 on the valve
rocker arm and applying pressure in
a direction to collapse the lifter.
VALVE ROCKER ARM

SHAFT ASSEMBLY
Dress up minor surface defects on
the rocker arm shaft and in the
rocker arm bore with a hone.
If the pad at the valve end of the
FIG. &-Checking Valve rocker arm has a grooved radius, re-
Clearance place the rocker arm. Do not at- FIG. 8- Valve Seat
tempt to true this surface by Refacing
If the 0.078-inch gauge does not grinding.
enter, replace the standard push rod REAMING VALVE GUIDES
with a 0.060-inch shorter service PUSH RODS
If it becomes necessary to ream a
push rod. Following the procedures in Part valve guide (Fig. 7) to install a valve
If the 0.218-inch feeler gauge en- 8-1, Section 3, under "Push Rod In- with an oversize stem, a reaming kit
ters, the operating range of the lifter spection," check the push rods for is available which contains the fol-
is excessive. This indicates that the straightness. lowing reamer and pilot combina-
incorrect push rod has been installed If the runout exceeds the maxi- tions: a 0.003-inch O.S. reamer with
or severe wear has occurred at the mum limit at any point, discard the a standard diameter pilot, a 0.015-
push rod ends, rocker arm, or valve rod. Do not attempt to straighten inch O.S. reamer with a 0.003-inch
stem. In this case, it will be necessary push rods. O.S. pilot, and a 0.030-inch reamer
to determine the area of discrepancy with a 0.015-inch O.S. pilot.
and the incorrect or defective part(s) CYLINDER HEADS When going from a standard size
should be replaced. valve to an oversize valve, .always
If all the valve train components Replace the head if it is cracked.
Do not plane or grind more than use the reamers in sequence. Always
except the push rod are within reface the valve seat after the
limits, install a 0.060-inch longer 0.010 inch from the cylinder head
gasket surface. Remove all burrs or valve guide has been reamed.
push rod.
5. Rotate the crankshaft until No. scratches with an oil stone.
REFACING VALVE SEATS
1 piston is on TDC at the end of the
compression stroke. With No. 1 pis- Refacing of the valve seats should
ton on TDC, check the following be closely coordinated with the re-
valves: facing of the valve face so that the
No.1 Intake No. 1 Exhaust Reamer Kit
finished seat will match the valve
No.3 Intake No.4 Exhaust 6085-H-1 Standard Size face and be centered. This is import-
No.7 Intake No. 5 Exhaust ant so that the valve and seat will
No.8 Intake No. 8 Exhaust have a good compression-tight fit.
6. Position No. 6 piston on TDC Be sure that the refacer grinding
and check the following valves: wheels are properly dressed.
Grind the valve seats to a true 45o
No. 2 Intake No. 2 Exhaust angle (Fig. 8). Remove only enough
No. 4 Intake No. 3 Exhaust stock to clean up pits, grooves, or to
No.5 Intake No.6 Exhaust correct the valve seat runout. After
No. 6 Intake No. 7 Exhaust the seat has been refaced, measure
When compressing the valve the seat width (Fig. 8). Narrow the
spring to remove push rods, be seat, if necessary, to bring it within
sure the piston in the individual limits.
cylinder is below TDC to avoid If the valve seat width exceeds
contact between the valve and the the maximum limit, remove enough
piston. stock from the top edge and/or
To replace a push rod, it will be bottom edge of the seat to redu'\:.e
necessary to remove the valv~ rocker the width to specifications (Fig. 8).
arm shaft assembly, following the A1906-A On the valve seats, use a 60o angle
procedures in Part 2, Section 2. grinding wheel to remove stock from
Upon replacement of a valve push FIG. 7-Reaming Valve the bottom of the seats (raise the
rod and/ or valve rocker arm shaft Guides seats) and use a 30° angle wheel to

remove stock from the top of the ream the valve guide for the next When a piston has been fitted,
seats (lower the seats) . oversize valve stem. Valves with mark it for assembly in the cylin-
The finished valve seat should oversize stem diameters of 0.003, der to which it was fitted.
contact the approximate center of 0.015, and 0.030 inch are available If the taper and out-of-round con-
the valve face. It is good practice to for service. Always reface the ditions of the cylinder bore are with-
determine where the valve seat con- valve seat after the valve guide in limits, new piston rings will give
tacts the face. To do this, coat the has been reamed. Refer to "Ream- satisfactory service provided the pis-
seat with Prussian blue, then set ing Valves Guides." ton clearance in the cylinder bore is
the valve in place. Rotate the valve within limits. If the new rings are to
with light pressure. If the blue is CAMSHAFT be installed in a used cylinder that
transferred to the center of the has not been refinished, remove the
valve face, the contact is satisfac- Remove light scuffs, scores, or cylinder wall "glaze."
tory. If the blue is transferred to nicks from the camshaft machined
the top edge of the valve face, surfaces with a smooth oil stone. To fit a piston:
lower the valve seat. If the blue is 1. Calculate the size piston to be
transferred to the bottom edge of CRANKSHAFT used by taking a cylinder bore check
the valve face, raise the valve seat. Dress minor imperfections with an (Fig. 23).
oil stone. Reface severely marred 2. Select the proper size piston to
VALVES journals. provide the desired clearance (Fig.
If the journals exceed the wear 9).
Valve defects, such as minor pits,
grooves, etc., may be removed by re- limit, they should be refinished to 3. Make sure the piston and cyl-
facing the valves. Discard valves that size for the next undersize bearing. inder block are at room temprature
(70°F). After any refinishing op-
are severely damaged, or if the face
runout or stem clearance exceed spe- REFINISHING JOURNALS eration, allow the cylinder bore to
cool and make sure the piston and
cifications. Refinish the journal to give the
Discard any defective part of the bore are clean and dry before the
proper clearance with the next under- piston fit is checked.
valve assembly. size bearing. If the journal wil1 not
4. Attach a tension scale to the
"clean up" to give the proper clear-
REFACING VALVES end of a feeler gauge ribbon that is
ance with the maximum undersize
free of dents or burrs. The feeler
bearing available, replace the crank-
The valve refacing operation ribbon should be 1h -inch wide and
shaft.
should be closely coordinated with of one of the thicknesses listed in
Always reproduce the same jour- Fig. 9.
the valve seat refacing operation so
nal shoulder radius that existed
that the finished angles of the valve 5. Position the ribbon in the cyl-
originally. Too small a radius will
face and of the valve seat will pro- inder bore so that it extends the ·
result in fatigue failure of the crank-
vide a compression-tight fit. Be sure entire length of the piston at 90°
shaft. Too large a radius will result
that the refacer grinding wheels are from the piston pin location.
in bearing failure due to radius ride
properly dressed. 6. Invert the piston· and install it
of the bearing.
If the valve face runout is exces- in the bore so that the end of the
After refinishing the journals,
sive and/or to remove pits and piston is about llh inches below the
chamfer the oil holes, then polish
grooves, reface the valves to a true top of the cylinder block and the
the journal with a No. 320 grit
44 ° angle. Remove only enough piston pin is parallel to the crank-
polishing cloth and engine oil.
stock to correct the runout or to shaft axis.
Crocus cloth may be used also as a
clean up the pits and grooves. If the
polishing agent. 7. Hold the piston and slowly pull
edge of the valve head is less than
the scale in a straight line with the
%2 inch after grinding, replace the
PISTONS, PINS AND RINGS ribbon, noting the pull required to
valve as the valve will run too hot in
remove the feeler ribbon (Fig. 10).
the engine. The interference fit of FITTING PISTONS Compare the required pull with
the valve and seat should not be
Pistons are available for service in Fig. 9 to determine the piston clear-
lapped out.
standard sizes and 0.020 and 0.030 ance.
Remove all grooves or score
marks from the end of the valve inch oversizes. The standard size pis-
stem, then chamfer as necessary. tons are color coded on the dome as FITTING PISTON RINGS
Do not remove more than 0.010 follows: red, 4.2977-4.2983 inch;
blue, 4.2989-4.2995 inch. 1. Select the proper ring set for
inch from the stem. the size piston to be used.
If the valve and/or valve seat has If the piston clearance is greater
than the maximum limit, recheck 2. Position the ring in the cylinder
been refaced, it will be necessary to
calculations to be sure that the prop- bore in which it is going to be used.
check the clearance between the
rocker arm pad and the valve stem er size piston has been selected, 3. Push the ring down into the
with the valve train assembly in- check for a damaged piston, then bore area where normal ring wear is
stalled in the engine. try a new piston. not encountered.
If the clearance is less than the 4. Use the head of a piston to
minimum limit, recheck calculations position the ring in the bore so that
SELECT FITTING VALVES
before trying another piston. If none the ring is square with the cylinder
If the valve stem to valve guide can be fitted, refinish the cylinder for wall. Use caution to avoid damage
clearance exceeds the wear limit, the size piston available. to the ring or cylinder bore.

PISTON CLEARANCE
RIBBON RIBBON RIBBON RIBBON
0.001_5 THICK 0.002 THICK 0.0035 THICK 0.006 THICK
& 0.500 WIDE & 0.500 WIDE & 0.500 WIDE & 0.500 WIDE
Ribbon Clear- Ribbon Clear- Ribbon Clear- Ribbon Clear-
Pull ance Pull ance Pull ance Pull ance.
Lbs. Inches Lbs. Inches Lbs. Inches Lbs. ,Inches
13 - 13 - 13 0.0012 13 0.9038
12 ·- 12 - 12 0.0014 12 0.0040
11 - 11 - 11 0.0016 11 0.0041
10 - 10 - 10 0.0018 10 0,0043
9 - 9 0.0002 '9 0.0021 9 0.0045
8 - 8 0.0005 8 0.0023 8 0.0041
7 0.0002 7 0.0007 7 0.0025' 7 ~.0049 PISTON RING A1928-A
6 0.0004 6 0.0010 6 0.0027 6 0.0050
5 0.0007 5 0.0012 5 0.0030 5 0.0057
FIG. 11-Piston Ring
4 0.0009 4 0.0015 4 0.0032 4 0.0059/
Gap
3 0.0012 3 0.0017 3 0.0033 3 0.0060
without upsetting engine balance.
2 0.0015 2 0.0020 ~ 0.0036 2 0.0062 Refinish the cylinder with the
1 0.0017 1 0.0022 1 0.0038 1 0.0063 most wear first to determine the
0 0.0020 0 0.0025 0 0.0040 0 '0.0065 maximum oversize. If the cylinder
A1930·A
will not clean up when refinished
for the maximum oversize piston rec-
FIG. 9-Piston Clearance Chart ommended, replace the block.
Refinish the cylinder to within ap-
5. Measure the gap between the proximately 0.0015 inch of the re-
FITTING PISTON PINS
ends of the ring with a feeler gauge quired oversize diameter. This will
(Fig. 11). If the ring gap is less than The piston pin to piston fit must allow enough stock for the final step
the recommended lower limit, try be checked during assembly of the of honing so that the correct surface
another ring or set. piston to the connecting rod. finish and pattern are obtained. Use
clean sharp hones of No. 220-280
6. Check the ring side clearance
grit for this operation.
of the compression rings with a feeler CYLINDER BLOCK
For the proper use of the re-
gauge inserted between the ring and
REFINISHING finishing equipment, follow the in-
its lower land (Fig. 12). The gauge
CYLINDER WALLS structions of the manufacturer. Only
should slide freely around the entire
experienced personnel should be al-
ring circumference without binding.
Honing is recommended for refin- lowed to perform this work.
Any wear that occurs will form a step
ishing cylinder walls only when the After the final operation in either
at the inner portion of the lower land.
walls have minor imperfections, such of the two refinishing methods de-
If the lower lands have high steps
as light scuffs, scratches, etc. The scribed and prior to checking the
the piston should be replaced. '
grade of hone to be used is deter- piston fit, thoroughly wash the cyl-
;t-,.,.,·~--- mined by the amount of metal to be inder walls with solvent to remove
removed. Follow the instructions of all abrasive particles, then thoroughly
the hone manufacturer. If coarse dry the walls. Check the piston fit ..
stones are used to start the honing Mark the pistons to correspond to
operation, leave enough material so Feeler Gauge
that all hone marks can be removed
with the finishing hone which is used
to obtain the proper piston clearance.
Cylinder walls that are severely
marred and/ or worn beyond the
specified limits should be refinished.
Before any cylinder is refinished all
main bearing caps must be in piace
and tightened to the proper torque
so that the crankshaft bearing bores
will not become distorted from the
refinishing operation.
. Refinish only the cylinder or cyl-
mders that require it. All pistons
are the same weight, both stand-
FIG. 10-Checking ard and oversize; therefore, var- FIG. 12-Ring Side
Piston pearance ious sizes of pistons can be used Clearance

the cylinders in which they are to completed and all pistons fitted, thor- bores, oil passages, cylinder head bolt
be installed. When the refinishing of oughly clean the entire block to re- holes, etc. Coat the cylinder walls·
all cylinders that require it has been move all particles from the bearing with oil.

INTAKE MANIFOLD bore for nicks, scratches, scores, or
scuffs.
CLEANING Inspect the pad at the valve end
Remove all gasket material from of the rocker arms for indications
the machined surfaces of the mani- of scuffing or abnormal wear. If the
fold. Clean the manifold in a suitable pad is grooved, replace the rocker
solvent, and dry it with compressed arm. Do not attempt to true this
air. surface by grinding.
Check for broken locating springs.
INSPECTION CD @ CHECK DIAGONA-LLY
Inspect the manifold for blocked PUSH RODS {i) CHECK ACROSS CENTER
or restricted passages, cracks, sand A1903-A

INSPECTION
holes, improperly machined or dam-
aged surfaces, or breakage. Replace
Check the ends of the push rods
for nicks, grooves, roughness, or ex-
FIG. 14-Cylinder Head
the studs if they are stripped. Re- cessive wear. Flatness
place the manifold if it is damaged The push rods can be visually
beyond repair. checked for straightness while they Cylinder Head Flatness. Check
Remove all filings and foreign are installed in the engine by rotat- the flatness of the cylinder head
matter that may have entered the ing them with the valve closed. gasket surface (Fig. 14).
manifold as a result of repairs. They also can be checked with a Valve Seat Runout. Check the
EXHAUST MANIFOLDS dial indicator (Fig. 13) . valve seat runout with an accurate
gauge (Fig. 15). Follow the instruc-
CLEANING CYLINDER HEADS tions of the gauge manufacturer. If
Remove all gasket material from CLEANING the runout exceeds the wear limit,
the manifolds. reface the valve and valve seat.
With the valves installed to pro- Valve Seat Width. Measure the
On the right exhaust manifold, tect the valve seats, remove deposits
clean the automatic choke heat valve seat width with a valve seat
from the combustion chambers and scale. Reface the valve seats if the
chamber (stove) . Make sure the air valve heads with a scraper and a
inlet passage is completely open and width is not within specifications.
wire brush. Be careful not to dam- Valve. The critical inspection
the cover does not leak. Blow out age the cylinder head gasket sur-
the automatic choke air heat tube points and tolerances of the valves
face. After the valves are removed, are illustrated in Fig. 16.
and air inlet tube with compressed clean the valve guide bores with
air. Inspect the valve face and the
valve guide cleaning tool 6085-HI. edge of the valve head for pits,
INSPECTION Use cleaning solvent to remove dirt, grooves, scores, or other defects.
grease, and other deposits. Inspect the stem for a bent condition
Inspect the manifold for sand Remove all deposits from the
holes, cracks, restricted passages and and the end of the stem for grooves
valves with a fine wire brush or buff- or scores. Check the valve head for
improperly machined surfaces. Re- ing wheel.
place stripped or broken bolts and signs of burning, erosion, warpage
studs. INSPECTION and cracking. Defects, such as minor
Check all water passages to make pits, grooves, etc., may be removed.
VALVE ROCKER ARM Discard valves that are severely
certain they are open. Examine the
SHAFT ASSEMBLY damaged.
cylinder head for water leaks or
cracks in the exhaust or inlet ports, Inspect the valve springs, valve
CLEANING
spring retainers, locks and sleeves
Clean all the parts thoroughly. or around the valve seats. Check the
for defects. Discard any visual1y de-
Make sure all oil passages are open. cylinder head gasket surfaces for
fective parts.
If necessary, remove the plugs from
burrs and nicks. Replace the head if
Valve Face Runout. The valve
both ends of the rocker arm shaft to it is cracked.
face runout should not exceed the
thoroughly clean the shaft passages. wear limit specified in Part 8-3. If
the runout exceeds the wear limit,
INSPECTION the valve should be replaced or re-
Check the clearance between each faced as outlined under "Refacing
rocker arm and the shaft by checking Valves" in this section.
the ID of the rocker arm bore and Valve Stem Clearance. Check
the OD of the shaft. If the clear- the valve stem to valve guide clear-
ance between any rocker arm and the Holding Fixture A1003-A ance of each valve in its respective
shaft exceeds the wear limit, replace valve guide with the tool shown in
the shaft and/or the rocker arm. In- FIG. 13-Push Rod Fig. 17 or its equivalent.
spect the shaft and the rocker arm Runout Install tool 6505-F on the valve

CLEANING
Thoroughly clean all the parts in
clean solvent and wipe them with a
clean, lint-free cloth.
INSPECTION
Inspect the parts and discard the
entire lifter assembly if any part
shows signs of pitting, scoring, gall-
ing, or evidence of non-rotation. Re-
place the entire assembly if the
A1904-A plunger is not free in the body. The
plunger should drop to the bottom
FIG. 15-Valve Seat of the body by its own weight.
Runout Assemble the lifter assembly and
FIG. 17-Valve Stem check for freeness of operation by
stem until it is fully seated and
Clearance pressing down on the push rod cup.
The lifters can also be checked with
tighten the knurled set screw firmly. a hydraulic tester to test the leak
Permit the valve to drop away from tions, it is recommended that the
spring be replaced. down rate. Follow the instructions of
its seat until the tool contacts the the test unit manufacturer or the
upper surface of the valve guide. Valve Spring Squareness. Ex- procedures in Part 8-1, Section 1.
Position the dial indicator with its amine the valve springs. Discard
fiat tip against the center portion of any that show rust, pit marks, and a TIMING CHAIN
the tool's spherical section at approxi- cracked or broken condition. Check AND SPROCKETS
mately 90° to the valve stem. In each spring for squareness, using a
sleet square and a surface plate (Fig. CLEANING AND INSPECTION
order to find actual valve stem clear-
ance the tool should be moved back 19) . Stand the spring and square on Clean all parts in solvent and dry
and forth at a right angle. Take a end on the surface plate. Slide the them with compressed air. Inspect
reading on the dial indicator without spring up to the square. Revolve the the chain for broken links and the
removing the tool from the valve spring slowly and observe the space sprockets for cracks, and worn or
guide upper surface. Divide the read- between the top coil of the spring damaged teeth. Replace all the com-
ing by two, the division factor for and the square. If the spring is out ponents of the timing chain and
the tool. of square more than %4 inch, replace sprocket assembly if any one item
it. needs replacement.
Valve Spring Pressure. Check
the pressure of each valve spring with CAMSHAFT
tool 6513-DD (LM-106) as shown HYDRAULIC VALVE LIFTERS
in Fig. 18. Set the knob on the cali- CLEANING AND INSPECTION
brated screw to the compressed The lifter assemblies should be Clean the camshaft in solvent and
length of the valve spring. Pull the kept in proper sequence so that they wipe dry. Inspect the camshaft lobes
torque wrench until a click is heard. can be installed in their original for scoring and signs of abnormal
Multiply the reading on the torque position. Inspect and test each lifter wear. Lobe wear characteristics may
wrench by two. The answer obtained separately so as not to intermix the result in pitting in the general area of
is the pressure exerted by the springs. internal parts. If any part of the the lobe toe. This pitting is not detri-
If the spring is not within specifica- lifter assembly needs replacing, re- mental to the operation of the cam-
place the entire assembly.
CHECK FOR APPLY TORQUE UNTIL CLICK
BENT STEM IS HEARD. READ Torque Wrench
AND MULTIPLY READING
BY TWO (2)
FOR DIMENSIONS,
REFER TO
SPECIFICATIONS VALVE
FACE
ANGLE
Tooi-6513-DD A 1911-A A1910-A
FIG. 16-Critical Valve FIG. 18-Checking Valve FIG. 19-Checking Valve

Tolerances Spring Tens ion Spring Squareness

. {135) PART 8-1-GENERAL ENGIN£ St~ 8-15
A VS B
C VS D
= VERTICAL TAPER
=
HORIZONTAL TAPER
A VS C AND B VS D =
OUT-OF-ROUND
CHECK FOR OUT-Of-ROUND AT
EACH END OF JOURNAL
I
I
\
\
' ' .... -....e--' RADIUS RIDE FATIGUE FAILURE

A1021-A
FIG. 20-Crankshaft FIG. 22-Typical Bearing Failures

Journal Measurements
rod bore and the back of the inserts. instructions of the fixture manufac-
shaft, therefore, the camshaft should Do not use a caustic cleaning solu- turer. If the bend and/or twist is ex-
not be replaced until the lobe lift tion. Blow out all passages with cessive, the connecting rod should be
loss has exceeded 0.005 inch. straightened or replaced.
compressed air.
The lift of camshaft lobes can be
checked with the camshaft installed INSPECTION PISTONS, PINS AND RINGS
in the engine or on centers. Refer to
"Camshaft Lobe Lift." The connecting rods and related CLEANING
Check the distributor drive gear parts should be carefully inspected Remove deposits from the piston
for broken or chipped teeth. and checked for conformance to surfaces. Clean gum or varnish from
specifications. Various forms of en- the piston skirt, piston pins, and rings
CRANKSHAFT gine wear caused by these parts can with solvent. Do not use a caustic
be readily identified. cleaning solution or a wire brush
CLEANING
A shiny surface on the pin boss to clean pistons. Clean the ring
Handle the crankshaft with care side of the piston usually indicates grooves with a ring groove cleaner
to avoid possible fractures or dam- that a connecting rod is bent or the (Fig. 21). Make sure the oil ring
age to the finished surfaces. Clean piston pin hole is not in proper re- slots (or holes) are clean.
the crankshaft with solvent, then lation to the piston skirt and ring
blow out all oil passages with com- grooves. INSPECTION
pressed air. Abnormal connecting rod bear-
Carefully inspect th~ pistons for
INSPECTION ing wear can be caused by either a
fractures at the ring lands, skirts,
bent connecting rod, an improperly
Inspect main and connecting rod and pin bosses, and for scuffed,
machined crankpin, or a tapered rough, or scored skirts. If the lower
journals for cracks, scratches, grooves, connecting rod bore.
or scores. inner portions of the ring grooves
Twisted connecting rods will not have high steps, replace the piston.
Measure the diameter of each create an easily identifiable wear
jqurnal in at least four places to The step will interfere with ring
pattern, but badly twisted rods will operation and cause excessive ring
determine out-of-round, taper, or un- disturb the action of the entire pis-
dersize condition (Fig. 20). side clearance.
ton, rings, and connecing rod as- Spongy, eroded areas near the
CONNECTING RODS sembly and may be the cause of edge of the top of the piston are
excessive oil consumption. usually caused by detonation, or
CLEANING Inspect the connecting rods for pre-ignition. A shiny surface on the
Remove the bearings from the rod signs of fractures and the bearing thrust surface of the piston, offset
and cap. Identify the bearings if they bores for out-of-round and taper. from the centerline between the pis-
are to be used again. Clean the con- If the bore exceeds the recom- ton pin holes, can be caused by a
necting rod in solvent, including the mended limits and/or if the con- bent connecting rod. Replace pis-
necting rod is fractured, it should tons that show signs of excessive
be replaced. wear, wavy ring lands, fractures,
Check the piston pin to connect- and/ or damage from detonation or
ing rod bushing clearance. Replace pre-ignition.
the connecting rod if the bushing is Check the piston to cylinder bore
so worn that it can not be reamed or clearance with a tension scale and
honed for an oversize pin. ribbon, following the procedure un-
Replace defective connecting rod der "Fitting Pistons." Check the ring
nuts and bolts. side clearance following the proce-
After the connecting rods are as- dure under "Fitting Piston Rings" in
sembled to the piston, check the con- Section 2.
FIG. 21-Cieaning Ring necting rods for bend or twist on a If piston pins show signs of frac-
Grooves suitable alignment fixture. Follow the ture or etching and/or wear, replace

~
both the piston and pin assembly. scored and/ or when out-of-round
Check the piston pin fit in the piston and/ or taper exceed the wear limits.
and rod during assembly of the rod, If the cylinder walls have minor
piston and pin. surface imperfections, but the out-
Replace all rings that are scored, of-round and taper are within limits,
chipped, or cracked. Check the end it may be possible to remove the
gap and side clearance. It is good imperfections by honing the cylinder
practice to always install new rings walls and installing new service pis-
when overhauling the engine. Rings ton rings providing the piston clear-
should not be transferred from one ance is within limits. Use the finest
piston to another regardless of grade of honing stone for this oper-
mileage. ation.
MAIN AND CONNECTING
ROD BEARINGS OIL PAN
CLEANING
FIG. 24-0uter Race to CLEANING
Clean the bearing inserts and caps
Housing Clearance
Scrape any dirt or metal particles
thoroughly in solvent, and dry with from the inside of the pan. Scrape
compressed air. Do not scrape gum from all machined surfaces. Remove all old gasket material from the gas-
or varnish deposits from bearing all pipe plugs which seal oil pas- ket surface. Wash the pan in a sol-
shells. sages, then clean out all the pas- vent and dry it thoroughly. Be sure
sages. Blow out all passages, bolt all foreign particles are removed
INSPECTION holes, etc. with compressed air. from below the baffle plate.
Inspect each bearing carefully. Make sure the threads in the cyl-
Bearings that have a scored, chipped, inder head bolt holes are clean. Dirt
in the threads may cause binding INSPECTION
or worn surface should be repJaced.
Typical examples of bearing failures and result in a false torque reading. Check the pan for cracks, holes,
and their causes are shown in Fig. Use a tap to true-up threads and to damaged drain plug threads, a loose
22. The copper lead bearing base remove any deposits. baffle, and a nicked or warped gas-
may be visible through the bearing ket surface.
overlay. This does not mean that the INSPECTION Repair any damage, or replace
bearing is worn. Do not replace the After the block has been thoroughly the pan if repairs can not be made.
bearing if the bearing clearance is cleaned, make a check for cracks.
within recommended limits. Check Minute cracks not visible to the OIL PUMP
the clearance of bearings that appear naked eye may be detected by coat-
to be satisfactory with Plastigage. Fit ing the suspected area with a mix- CLEANING
new bearings following the recom- ture of 25% kerosene and 7 5% light Wash all parts in a solvent and
mended procedure (Part 8-2). motor oil. Wipe the part dry and dry them thoroughly with com-
immediately apply a coating of zinc pressed air. Use a brush to clean the
CYLINDER BLOCK
oxide dissolved in wood alcohol. If inside of the pump housing and the
CLEANING cracks are present, the coating will pressure relief valve chamber. Be
Thoroughly clean the block in become discolored at the defective sure all dirt and metal particles
solvent. Remove old gasket material area. Replace the block if it is are removed.
cracked.
-CENTER LINE OF ENGINE-.. A
Check all machined gasket sur-
AT INSPECTION
RIGHT
faces for burrs, nicks, scratches, and
ANGLE scores. Remove minor imperfections Refer to the specifications for
TO with an oil stone. Check the flatness clearances and wear limits.
CENTER of the cylinder block gasket surface Check the inside of the pump hous-
LINE OF following the procedure and specifi- ing and the outer race and rotor for
ENGINE cations recommended for the cyl- damage or excessive wear.
B inder head. Check the mating surface of the
PARALLEL
Replace all expansion-type plugs pump cover for wear. If the cover
TO
that show evidence of leakage.
CENTER Straight Edge .., , 1
Inspect the cylinder walls for scor-
~~-~"
LINE OF
ENGINE ing, roughness, or other signs of
1. OUT-OF-ROUND= DIFFERENCE BETWEEN wear. Check the cylinder bore for
A AND B out-of-round and taper. Measure the
2. TAPER= DIFFERENCE BETWEEN THE A
MEASUREMENT AT TOP OF
CYLINDER BORE AND THE A
bore with an accurate gauge follow-
ing the instructions of the manufac-
'
\}1 ,~,J
~
turer. Measure the diameter of each
MEASUREMENT AT BOTTOM OF
cylinder bore at the top, middle, and
CYLINDER BORE ·A1025-A Al921-A
bottom with the gauge placed at
right angles and parallel to the
FIG. 23-Cylinder Bore centerline of the engine (Fig. 23). FIG. 25-Measuring
Out-of"Round and Taper Refinish cylinders that are deeply Rotor End Play

mating surface is worn, scored, or housing bearing. CLEANING

grooved, replace the cover. Inspect the relief valve spring for
Measure the outer race to hous- a collapsed or worn condition. The breather cap located on the
ing clearance (Fig. 24). Check the relief valve spring ten- oil filter tube should be replaced at
With the rotor assembly installed sion. If the spring tension is not with- the proper mileage interval. Do not
in the housing, place a straight edge in specifications and/ or the spring is clean the breather cap. •
over the rotor assembly and the hous- defective, replace the spring. At the recommended interval, re-
ing. Measure the rotor end play Check the relief valve piston for move the crankcase ventilation regu-
clearance between the straight edge scores and free operation in the bor.e. lator valve, tube, hose connections,
and the rotor and outer race (Fig. Check the relief valve to body clear- outlet adapter and oil separator ele-
25). ance. The relief valve should have a ment. Clean the valve, element, tube
If the clearance between the hous- snug fit and should slide freely in and outlet adapter in clean carbure-
ing and outer race and the rotor end the bore. Clean the valve and bore tor solvent and dry them with com-
play are not within specifications, with fine crocus cloth if a slight re- pressed air. Clean the rubber hose
replace the outer race and rotor, or striction is felt. connections with a low-volatility,
the oil pump assembly. The outer petroleum-base solvent and dry them
race, shaft and rotor are replace- with compressed air.
CRANKCASE VENTILATION
able only as an assembly. SYSTEM MAINTENANCE
Check the drive shaft to housing
bearing clearance by measuring the Refer to Group 19 for the correct
OD of the shaft and the ID of the mileage interval for maintenance.

(138)
8-18
PART 430 V-8 ENGINE

8-2
1 Description and Operation ................ 8-18 2 In-Car Adjustments and Repairs (Continued)
2 In-Car Adjustments and Repairs ............ 8-23 Camshaft Rear Bearing Bore Plug
Engine Supports ....................... 8-23 Replacement ........................ 8-36
Intake Manifold ....................... 8-24 Main and Connecting Rod Bearing
Replacement ........................ 8-36
Exhaust Manifold ...................... 8-25
Piston and Connecting Rod Assembly ..... 8-38
Valve Push Rod Chamber Cover ......... 8-26
Flywheel ............................. 8-41
Valve Rocker Arm Cover ............... 8-26
Oil Filter and Adapter .................. 8-41
Valve Rocker Arms, Shafts and Push Rods 8-26
Oil Pan . . . . . . . . . . . ................... 8-41
Hydraulic Valve Lifters ................, . 8-27
Oil Pump ............................. 8-42
Positive Crankcase Ventilation System ..... 8-28
Oil Filler Pipe and Cap ................. 8-43
Cylinder Heads ........................ 8-29
3 Engine Removal and Installation ........... 8-43
Valve Spring, Retainer and Stem Seal
Replacement ........................ 8-31 4 Major Repair Operations .................. 8-46
Crankshaft Damper .................... 8-32 Crankshaft . . . . . . . . . . . . . . . . . . . . . ...... 8-46
Cylinder Front Cover .................. 8-33 Camshaft Bearing Replacement ........... 8-48
Timing Chain, Camshaft and Engine Disassembly .................... 8-49
Crankshaft Sprockets ................. 8-34 Cylinder Block Plugs and Fitings ......... 8-50
Camshaft ............................. 8-35 Engine Assembly ...................... 8-50

The 430 V-8 engine (Figs. 1, 2 CYLINDER HEADS machining the top of each cylinder
and 3) has a 4.300-inch bore and a The cylinder head assemblies have bank on a 1oo angle to the piston
3. 700-inch stroke. It has a total pis- a flat machined surface and contain (Fig. 3).
ton displacement of 430 cubic inches the valves, springs and related parts. The pistons are of a step design.
and a compression ratio of 10.1 : 1. The valve guides are an integral part Two raised projections on the dome
The warranty plate identification of the cylinder head. of the piston prevent damage to the
symbol for the engine is "H". The front to rear valve arrange- piston or valves if contact (valve
ment for the cylinder heads (Fig. float) should occur.
MANIFOLDS 4) is as follows; right bank I-E-I-E- Slotted openings in the piston are
The four-venturi manifold is of the I-E-I-E, and left bank E-I-E-I-E- parallel with the level of the oil
water-jacketed design. A wide layer I-E-1. control ring. These openings reduce
of water constantly circulates within heat build-up between the cylinder
a chamber located below the intake CYLINDER BLOCK wall and piston body. The openings
air passages which allows close con- The cylinders are numbered from also allow trapped oil to return
trol of intake manifold temperatures. front to rear, on the right bank 1, 2, rapidly to the crankcase. The slot
The intake manifold port arrange- 3 and 4 and on the left bank 5, 6, 7 openings also work jointly with oil
ment is shown in Fig. 4. The four and 8. For easy reference, each cylin- passages drilled through the pin
fuel-air intake ports of the manifold der number is embossed on the in- bosses of the piston. Oil from the
are positioned in a manner that take manifold and is located directly cylinder walls, received through the
places the carburetor primary barrels over the cylinder bores. piston openings, lubricates the piston
in the center of the intake manifold. The cylinder firing order is 1-5-4- pins, then drains into the crankcase.
The secondary barrels are located 2-6-3-7-8. This information is em- The oil control ring (lower ring)
off-center toward the rear. The cen- bossed on the top surface of the in- has two chrome-plated steel rails
trally located primary barrels pro- take manifold. which contain the self-expanding
vide uniform fuel-air distribution to The cylinder block is cast in one spacer. The spacer has ample open-
all cylinders. piece with cored passages for cooling ings for positive oil control.
The exhaust manifolds are secured the entire length of the cylinder The second compression ring is
to the cylinder heads. An' air inlet barrels. phosphate-coated and has a scraper
duct and shroud assembly is posi- Each cylinder has an angle wedge groove. The top compression ring
tioned on the left exhaust manifold combustion chamber at the top of has a chrome-plated face to resist
and directs warm air into the air the cylinder bore. The combustion abrasive wear, scoring and scuffing.
cleaner and carburetor. chambers-in-block are formed by The piston pins have an interfer-

(139) PART 8-2-430 V-8 ENGINE 8-19
A1916-A
FIG. 1-~ Left Front View FIG. 2-~ Right Front Sectional View
ence fit within the connecting rod. fit main bearing inserts. The center the front of the camshaft.
The lower end of the connecting bearing (No. 3) absorbs crankshaft The fuel pump, which is mounted
rods contain the locking-type, selec- end thrust. on the cylinder block front cover, is
tive-fit connecting rod bearing in- The distributor is mounted on the operated by a push rod and an eccen-
serts. tric cam which is secured to the
front of the cylinder block in a left
The crankshaft is supported within of-center position. The distributor is camshaft.
A crankcase oil filler tube is
the cylinder block by five selective driven by a helical gear located on
pressed into the right front-side of
the cylinder block. A disposable-
type oil filler tube cap, containing
an air filter element, is inserted onto
the tube.
VALVE TRAIN
The intake valves are free rotating.
Valve retainers (rotators) are used
on all exhaust valve assemblies to en-
sure positive rotation at low rpm.
Alternating pressure on the spring
EXHAUST PORT_S
INTAKE PORTS A1919-A
FIG. 4-lntake Manifold

FIG. 3-Front Sedional View and Cylinder Head Valve Ports

GROUP 8-ENGINE (140)
8-20
VALVE OPEN VALVE CLOSED
A1245-B
FIG. 5- Typi,al Hydrauli' Valve FIG. 6-Lubri,ation System

Lifter Operation
and washer, located within the rota- The camshaft is driven by the compression chamber, the disc valve
tor, causes a constant speed rotation. crankshaft sprocket, timing chain, moves off its seat and permits oil to
The valve rotator eliminates the need and timing gear that has nylon teeth. flow from the supply chamber to the
for a conventional valve spring re- The timing gear and camshaft eccen- compression chamber. When the
tainer and sleeve for the exhaust tric is bolted to the camshaft. compression chamber becomes filled
valves. Hydraulic ·valve lifters are used in with oil, the pressures in the two
The push rods have a radius at the engine. The valve lifters are chambers are equalized. The oil flow
each end and are oil cushioned at the housed in bores located in the cylin- ceases and the disc valve spring seats
rocker arm and valve lifter. der block valve lifter chamber. The the disc valve and closes the disc
The heavy gauge valve springs valve lifters operate directly on the valve port.
are color coded for identification camshaft lobes, thereby transmitting As the camshaft rotates, the lifter
purposes. the thrust of the camshaft lobes, by assembly is raised by the camshaft
The rocker arms are a non-adjust- the means of hydraulic pressure, to lobe. This increases the push rod
ing type. Each rocker arm and shaft the push rods which actuate the force against the lifter plunger and
assembly is held in position on the valve train. Figure 5 shows the vari- hydraulic pressure immediately
cylinder head by four rocker arm ous components and operation of a builds up in the compression cham-
supports and retaining bolts. The hydraulic valve lifter. ber until it acts as a solid member
valve rocker arm covers and gaskets When either an exhaust valve or of the valve operating mechanism.
are held in position by bolts, and an intake valve is closed, the actuat- The lifter then becomes a hydraulic
reinforcements (washers), located ing valve lifter is on the base circle ram which forces the valve in the
around the cover rim. A comb-type (lowest position) of the camshaft cylinder head to open. During this
bracket is located on the top of each lobe. period, a slight leakage of oil past
cover for positive alignment of the When the valve lifter is in this the plunger occurs (calibrated leak
spark plug high tension wiring. position, the lifter plunger spring down rate).
The camshaft is supported by five expands. This action forces the lifter As the high point of the camshaft
replaceable bearing inserts. The in- plunger and valve push rod upward, lobe rotates and passes by the foot
side diameters of the bearings are of forcing the valve end of the rocker of the valve lifter, the valve in the
a step design. The largest inside arm to maintain solid contact with cylinder head seats and the valve
diameter is found in the front bear- the valve (zero valve lash). In this lifter assembly is forced downward.
ing. The inside diameters of the position, the oil hole in the lifter Reduced force on the lifter plunger
bearings decrease 0.015 inch in size body and plunger is indexed with at this time relieves the pressure on
per bearing, from the front bearing the oil gallery in the cylinder block. the lifter plunger and it is free to
toward the rear. As the lifter plunger moves up- be moved upward by the plunger
The camshaft is also of step de- ward, the volume of the compression spring. This action allows oil to flow
sign, the largest journal 'outside chamber is increased, resulting in once again through the indexed oil
diameter is found at the front jour- reduced oil pressure in the compres- holes in the lifter body and plunger.
nal. The journals, from the front to sion chamber. Therefore, to equalize The operating cycle is completed
rear, decrease 0.015 inch in size per the resulting pressure differential be- for each revolution of the camshaft.
journal. tween the supply chamber and the Zero clearance (lash) in the valve

(141) PART 8-2-430 V-8 ENGINE 8-21
train mechanism is maintained at all in the block to a connecting passage through a hole in the front wall of
times by the hydraulic force and leading to the crankshaft main bear- the cylinder block into the timing
expansion of the plunger spring ings. chamber and downward into the
between the lifter body and plunger. The connecting rod bearings re- crankcase.
ceive their lubrication through pas- Air flows from the push rod cham-
LUBRICATION SYSTEM sages drilled from the crankshaft ber, through holes in the chamber
A pressure lubricating system em- main bearing journals to the crank- valley, into the crankcase. It then
ploying a full-flow oil filter is used pins of the crankshaft. The cylinder rises upward, through holes in the
in the engine (Fig. 6) . walls are lubricated by oil sprayed rear of the engine, into the rear of
The rotor-type oil pump, mounted from a slot or groove between the the push rod chamber valley where
inside the oil pan on the lower-left connecting rod and cap. When the a filtering element separates oil from
corner of the cylinder block is driven hole in the connecting rod lines up the gaseous air vapors. The air and
by the distributor through an inter- with the hole in the crankpin, oil is vapor by-products are then directed
mediate shaft. Thus, the oil pump sprayed onto the cylinder wall that into the intake manifold through the
and distributor are driven at cam- is opposite the one in which the rod carburetor spacer.
shaft speed. is operating. The air is directed into the intake
The oil is received from the oil A reservoir traps oil at the valve manifold through a spring-loaded
pan sump by means of an oil pick- lifter bore bosses. Thus, oil is avail- regulator valve, an exhaust tube and
up screen and tube assembly which able for lifter lubrication as soon as the carburetor spacer (Fig. 7). The
directs the oil to the oil pump. A the engine starts. This oil then drains amount of regulator valve opening or
spring-loaded relief valve in the oil through three narrow drain holes in restriction is governed by intake
pump controls the oil pressure of the valve chamber floor. manifold vacuum pressure (Fig. 7).
the system. When the pressure ex- The rocker arm assemblies receive At low intake manifold vacuum
ceeds specifications, oil is released their oil from the main oil gallery pressure (high engine speed), the
by the relief valve and is directed through a passage in the block that regulator valve opens to the position
back to the intake side of the pump. lines up with a hole in the cylinder which allows the greatest air-vapor
The oil leaves the pump directly head. The hole directs the oil through flow into the intake manifold (Fig.
through a passage in the block which the No. 1 rocker shaft support on 7, View "A"). This action allows
directs the oil to the oil filter adapter the right bank and No. 2 support on the greatest combustion of undesir-
mounted at the front lower-left hand the left bank, into the rocker shafts. able engine vapors.
corner of the block. The oil then The oil in the rocker shafts is di- At high intake manifold vacuum
travels through a passage in the oil rected through small holes to each (idle speed), the valve closes and
filter adapter to the oil filter assem- rocker arm. Thus lubricating the restricts the flow of ventilating air
bly. valve and the ball joint end of the and vapors into the richer air-fuel
The oil filter is the full-flow type. push rods. mixture present in the induction sys-
This means that the oil delivered The oil returns from the valve tem at this time (Fig. 7, View "B").
by the oil pump is directed imme- chamber of the cylinder head to the Figure 7, View "C" shows a view
diately into the filter where it is push rod chamber through holes proof the valve when vacuum pull is in
filtered before entering the main oil vided at the lower front and rear the intermediate stage.
gallery for circulation throughout the corners of the cylinder heads. The inter-relationship between vac-
engine. The oil filter assembly also Oil drains from the front cam uum pull and valve spring force
has an anti-drainback valve to assure bearing to the thrust face of the positions the valve in a manner that
htbricant to all bearings upon engine camshaft sprocket that rides against provides the best air-fuel mixture
start. the front cylinder block surface. The and engine ventilation under all oper-
The filter bypass valve, located rotation of the camshaft sprocket ating conditions. Restricted ventilat-
inside the oil filter, operates only and an oil slinger sprays the oil on ing air and vapors are constantly
when the filter flow is restricted be- the timing chain and crankshaft recirculated within the engine
cause of dirt or other foreign mate- sprocket. until demanded by the regulator
rials. When the bypass valve is open, valve.
that portion of the oil flowing POSITIVE CRANKCASE
VENTILATION SYSTEM COOLING SYSTEM
through the bypass valve does not
travel through the filtering material Ventilating air enters the engine The coolant is drawn from the
but is supplied directly to the main through the oil filler cap located at bottom of the radiator by the water
oil passage. the right front-side of the cylinder pump which delivers the coolant to
The oil from the oil filter is then block.. The filler cap contains a filter- the cylinder block, cylinder heads
directed through an oil passage in ing element which filters the incom- and intake manifold (Fig. 8). The
the block to the main oil gallery ing air. three progressive stages of engine
that is located in the center of the From the filler cap, the filtered air warm-up and cooling are shown in
chamber floor. From the main oil flows into the front section of the Fig. 9.
gaTiery the oil. is fed to each cam valve push rod chamber. The venti-
bearing through drilled passages in lating air is then directed by a baffle STAGE 1
the block. In this manner, the bear- upward through the push rod holes At low ambient temperatures or
ings provide continuous oiling of the in the cylinder heads into both rocker initial starting of the engine, the
camshaft journals. Oil flow to the arm chambers, returning in the same water pump discharges the engine
crankshaft is directed hy means of a manner at the rear of the push rod coolant through each of its "legs" to
groove in the camshaft bearing bores chamber. The baffle also directs air both sides of the cylinder block (at

FIG. 7-Positive Crankcase Ventilation System

the front face) and into diverters assure limited circulation and to Simultaneously, the intake manifold
(passageways) which direct the cool- minimize pressure build-up. temperature will rise quicker and
ant upwards into each cylinder head. Thermostats (A), (B) and (C) contribute to better vaporization of'
The coolant then flows to the rear of shown in Fig. 9 are closed. This the engine fuel.
each cylinder head and into the in- circulation of the engine coolant dur-
take manifold. From there, the cooling "Stage 1" continues to take place STAGE 2
ant flows to the front of the intake until the coolant reaches 13r-14r The flow of the engine coolant
manifold, out through the bypass F. temperature. Thus, cooling is first described in "Stage 1" remains in
connection and back into the water provided to those engine components effect during the additional flow of
pump. The bypass system is used to which rise fastest in temperature. engine coolant provided in "Stage 2".
BLOO: CYLINDER INTAKE CYLINDER BLOCK
(RIGHT BANKI HEAD MANIFOLD HEAD !LEFT BANK!
BLOCK CYLINDER INTAKC CYLINDER BLOO:

(RIGHT BANKI HEAD MANIFOLD HEAD (LEFT BANK)
BLOCK CYLINDER INTAKE CYLINDER BLOCK

(RIGHT BANKI HEAD MANIFOLD HEAD !lEFT BANKI
A1925-A A1926-A
FIG. 8-Cooling System FIG. 9-Cooling System Stages

(143) PART 8-2-430 V-8 ENGINE 8-23 .'
In addition to the water pump ward from the cylinder block, starts to open and directs the flow of
"legs" aligning with the openings in through mating passageways and engine coolant out of the intake
the face ends of the cylinder block into the cylinder heads where it is manifold water outlet port and into
for directing engine coolant into the routed through "Stage 1". the coolant supply tank. The engine
cylinder heads, each "leg" also covers coolant is then directed into the radi- ·
an opening into the cylinder block STAGE 3 ator by a hose. The coolant then flows
which includes small thermostats (B) out of the outlet connection at the
and (C) as shown in Fig. 9. When The flow of the engine coolant bottom of the radiator, thro~gh a
the engine coolant in circulation dur- described in "Stage 1" and "Stage 2" hose, and into .the inlet of the water
ing "Stage 1" reaches 137°-142°F. remains in effect during the addi- pump. At a temperature of 182°F.
temperature, the thermostats (B) tional flow of engine coolant pro- or above (low temperature thermo-
and (C) start to open and direct the vided in "Stage 3". stat) and 212°F. or above (high
flow of engine coolant through each When the engine coolant in circu- temperature thermostat), the ther-
side of the cylinder block to provide lation reaches 155°-l62°F. (low tem- mostat is fully open and the en-
the required cooling throughout the perature thermostat) or 185°-l92°F. gine coolant is completely recircu-
cylinder block. The thermostats are (high temperature thermostat) tem- lated by the water pump through
fully open at 162°F. temperature. perature, thermostat (A) located at all three stages of circulation to
The engine coolant then rises up- the front end of the intake manifold provide complete engine cooling.

ENGINE SUPPORTS support, and an engine lateral re- Removal
strictor is located on the right side
The front supports are located on of the transmission converter hous- 1. Block the rear wheels and set
each side of the crankcase and the ing (Fig. 10). the parking brake. Raise the front
rear support is located at the trans- of the car with a floor jack and in-
mission extension housing (Fig. 10) . ENGINE FRONT SUPPORT stall safety stands.
An engine rear support reinforce- The procedures given apply to 2. Disconnect the starter cable and
ment is located forward of the rear either a right or· left installation. remove the starter.
BOLT~
INSULATORE·~c:.!,PJ_
.. -; ;
h ',
ADAPTER. PLATE~:.::;::/
WASHER~ ~3 . ..§{ij).·
/·~BOLT?i{ili
. .._BOLT
NUT~
~ NUT
WASHER / LOCK WASHERS
I
~/ ENGINE
ENGINE FRONT SUPPORT- NUT ~<' FRONT SUPPORT-
\ ALL EXCEPT CONVERTIBLE "'{j~ CONVERTIBLE ONLY NUT
ENGINE LATERAL RESTRICTOR
RETAINER
1'\~UPPER RETAINER
~J~.........---LOCK WASHER
INSULA~t. ~?BOLTS
_- ~1-f~~y SUPPORT
~1...!--j-/UpPER RETAINER <$>

RBN~PER INSUlATOR
LOCK
~'i." k B R A C L : : E R INSUIATO'
Y :~ ~- ~
ENGINE
WASHER f' f &~LOWER RETAINER
REAR SUPPORT
REINFORCEMENT
NUT fit h ·-.., '-lcl-~.. ;:;-.;_ ·. LOCK WASHER
~. Y.- P0."""1Z'~.... "{
~I~ ~ ~ ~::X: ....__BOLT
NUT--..;~ WASHERS ·
ENGINE REAR SUPPORT A1829-A
FIG. 10-Engine Front and Rear Supports

3. Remove the nuts and washers brackets to the underbody side mem- ASSEMBLY
which secure the engine front sup- ber. Remove the brackets.
1. Install the head of the large
port insulators to the underbody side
Installation restrictor rod in a vise.
member.
1. If the support brackets were re- 2. Assemble the restrictor parts
4. Place a jack under the front
edge of the oil pan. Position a block moved, position the support brackets over the rod as shown in Fig. 10.
to the underbody side member and Make certain that the lips of the
of wood between the jack and the
install the bolts and washers. Torque rubber bushings are properly
front edge of the oil pan. Raise the
the bolts to specifications. seated in the bores of the inner
front of the engine about 2 inches
2. Position the retainers to the and outer restrictor brackets.
to allow clearance for removal of
transmission extension housing and 3. Torque the retaining nut to
the insulators.
install the bolts and lock washers. specifications. Remove the assembly
5. Remove the bolts securing each
Torque the bolts to specifications. from the vise.
support insulator (and adapter plate
on convertibles) to the cylinder Excessive torque can cause a noise
block. Replace the insulator on one or vibration condition. INTAKE MANIFOLD
side before proceeding to the other 3. Position the engine rear support
insulators to the transmission retain- REMOVAL
support insulator.
ers and install the bolts, washers and 1. Open the hood and install fen-
Installation nuts. Torque the bolts to specifica- der covers. Drain the cooling system
tions. at the radiator and cylinder block.
1. Position the support insulator 4. Position the support to the 2. Remove the carburetor air
(and adapter plate on convertibles) underbody side member brackets and cleaner and air inlet duct assembly.
to the cylinder block. Install and the reinforcements to the support. As a safety measure, remove the
torque the retaining bolts to specifi- Lower the transmission. Install the ground cable from the battery.
cations. lock washers and nuts securing the 3. Disconnect the heater inlet
2. Lower the front of the engine reinforcements and insulators to the hoses at the connector fittings located
and guide it as necessary to make supports. Torque the nuts to specifi- at the rear of the intake manifold.
certain that the engine front support cations. Disconnect the automatic choke
bracket studs enter the holes in the 5. Install the bolts, retainers, insu- coolant return hose from the coolant
underbody side member. Remove the lators, washers and nuts that secure return line of the heater.
floor jack and wood block. the support to the underbody side 4. Remove the retaining nut and
3. Insta11 the insulator stud mount- member brackets. Torque the nuts to washer securing the positive crank-
ing nuts and washers. Torque the specifications. case ventilation tube bracket to the
nuts to specifications. 6. Remove the transmission sup- intake manifold. Disconnect the ven-
4. Install the starter and connect port jack. Lower the car and release tilation tube and the adapter con-
the starter cable. the parking brakes. necting hose from the engine.
5. Raise the front of the car and 5. Remove the right-bank spark
remove the safety stands. Lower the ENGINE LATERAL RESTRICTOR plug wires from the spark plugs and
car. REMOVAL the rocker arm cover.
6. Remove the rear wheel blocks 6. Remove the radiator upper hose
1. Remove the bolts. securing the
and release the parking brake. from the radiator and supply tank.
restrictor outer bracket to the under-
body side rail. 7. Disconnect the heat tempera~
ENGINE REAR SUPPORT
2. Remove the bolt securing the ture sending unit wire, and the coil
Removal restrictor inner bracket to the con- primary and secondary wires from
verter housing. Remove the lateral their respective units.
1. Set the parking brakes and restrictor unit from the car. 8. Disconnect the accelerator li~k
raise the car. Position a transmission
support jack under the transmission. INSTALLATION age at the accelerator shaft assembly ·
2. Remove the nuts, bolts, wash-
(bell crank) .
1. Position the lateral restrictor 9. On a car with an air condi-
ers, retainers and insulators that unit in the car, with the outer brack-
secure the support to the underbody tioner, disconnect the wire from the
et resting on the underbody side fast idle solenoid.
side member brackets. rail (Fig. 10).
3. Remove the nuts and washers 10. Disconnect the heater outlet
2. Insert the inner bracket dowel
that secure the reinforcements and hoses from the "Y" tube connection.
pin into the converter housing. In-
insulators to the support. Raise the stall the inner bracket mounting bolt 11. Remove the two retaining
transmission slightly and remove the and torque it to specifications. bolts securing the radiator supply
support and reinforcements. 3. InstaU the outer bracket retain- tank to the intake manifold. Remove
4. Remove the bolts, nuts and ing bolts and torque them to specifi- the retaining bolt securing the engine
washers securing the engine support cations. ground strap, battery ground cable,
insulators to the transmission retain- and the supply tank brace to the
er. Remove the engine support insu- DISASSEMBLY water pump.
lators. 1. Remove the restrictor rod 12. Remove the wires from the
5. Remove the mounting bolts, retaining nut and disassemble the spark plugs and rocker arm cover
washers and retainers from the trans- restrictor unit (Fig. 10). on the left cylinder bank. Remove
mission extension housing. 2. Clean the parts in solvent. the distributor cap and wires as a
6. If necessary, remove the bolts Replace all parts that are worn or unit.
and waBhers retaining the support damaged beyond repair. 13. Disconnect the vacuum hoses

(145) PART 8-2-430 V-8 ENGINE 8-25
from the tube leading into the intake manifold fitting located below the
manifold fitting. carburetor.
14. Disconnect the fuel inlet 1ine 13. Install the positive crankcase
at the carburetor and fuel filter. Dis- ventilation tube ~d hose. Install the
connect the vacuum line from the tube on the mounting bracket, lo-
distributor diaphragm and carbure- cated on the inta~e manifold, a.nd
tor. tighten the retaining clamp.
15. Loosen the clamp and discon- 14. Connect the heater outlet hoses
nect the coolant bypass hose at the and automatic choke coolant supply
wa.ter pump. hose to the fitting located on the in-
16. On a car with an air condi- take manifold and tighten the retain-
tioner, remove the compressor sup- ing clamps.
port bracket. 15. Connect the automatic choke
17. Remove the intake manifold coolant return hose to the heater
mounting bolts, clamps and washers. return line and tighten the clamp.
With assistance, remove the intake 16. Connect the radiator inlet hose
manifold assembly. to the radiator and supply tank.
18. If the manifold is to be dis- Tighten the retaining clamps.
assembled, remove the bypass hose 17. Install the wiring loom in the
and clamps, bypass tube, carburetor clips located on the right bank rocker
gaskets and spacer, fuel lines, vac- arm cover. Install the ignition coil
uum lines, transmission carburetor primary and secondary wires, tem-
linkage, temperature sending unit, perature sending unit wire, and the
vacuum inlet line fitting and heater oil pressure sending unit wire,
outlet elbow fitting. Discard all gas- A1830·A 18. On a car with an air condi-
kets. tioner, connect the lead wire to the

FIG. 11-lntake Manifold fast idle solenoid.
Bolt Torque Sequen'e 19. Install the distributor cap and
Refer to Part 8-1, Section 3 for spark plug wires as a unit. Install
the cleaning and inspection proced- the wires on the rocker arm cover
bolts in sequence to specifications as and the spark plugs.
ures. shown in Fig. 11. 20. Install the battery ground cable
INSTALLATION 6. On a car with an air conditioner, on the battery. Close the radiator
install the compressor support brack- drain cock and the cylinder block
1. If the intake manifold was dis- et and tighten the mounting bolts drain plugs. Fill the cooling system.
assembled, install the bypass hose anJ nuts. Start the engine; bleed the cooling
and clamp, bypass tube, temperature
7. Coat one side of a new coolant system and fill it to its required level.
sending unit and the heater outlet
supply tank mounting gasket with 21. Check and adjust the initial
elbow fitting, using water-resistant
water-resistant sealer and install it on timing, if necessary. Adjust the car-
sealer. Install the vacuum inlet line
the supply tank. Insert the thermo- buretor fuel and idle mixture ad- ..
fitting, transmission carburetor link-
stat into the manifold. justments. Adjust the transmission
age, vacuum lines and fuel lines. In-
8. Install the coolant supply tank linkage.
stall the carburetor spacer and new
and coil as a unit on the intake mani- 22. Check the engine for vacuum,
gaskets.
fold and loosely install the mounting fuel, coolant and oil leakage.
2. Clean the mating surfaces of
bolts. 23. Install the fresh air inlet duct
the intake manifold and cylinder
assembly on the exhaust manifold.
heads. 9. Secure the supply tank bracket,
Install the air cleaner.
3. Install the intake manifold gas- engine ground strap, and battery
24. Remove the fender covers.
kets on the respective cylinder heads, ground cable to the water pump and
Close the hood.
with the word FRONT (imprinted torque the mounting bolt to specifica-
on the gaskets) facing toward the tions. Torque the coolant supply
front of the engine. To keep the gas- tank mounting bolts to specifications. EXHAUST MANIFOLD
kets temporarily in position, install Connect the overflow hose to the REMOVAL
manifold clamp bolts in the cylinder supply tank.
heads. The intake manifold gas- 1. Remove the air cleaner and air
LO. Connect the fuel line to the
kets are interchangeable from one inlet duct assembly. Block the rear
carburetor and filter. Connect the
cylinder bank to the other. wheels and set the parking brake.
vacuum line to the carburetor and
4. With assistance, lift the intake Raise the front of the car with a
distributor.
manifold and insert the bypass hose floor jack and install safety stands.
over the water pump inlet tube; then, 11. Connect the heater outlet hoses 2. Disconnect the exhaust mani-
position the manifold on the cylin- io the return line and tighten the fold(s) at the resonator inlet pipe(s).
der heads. Make certain the gasket clamps. Connect the accelerator link- 3. Remove the nuts and washers
holes are properly aligned. age to the accelerator shaft assembly which secure the engine front sup-
5. Remove the gasket locating (hell crank). port insulators to the underbody side
bolts. Install the intake manifold 12. Connect the transmission vac- members.
mounting bolts, clamps, studs, nuts uum hose to the vacuum line. Con- 4. Place a jack under the front
and washers. Torque the mounting nect the vacuum hoses to the intake ·edge of the oil pan. Position a block

of wood between the jack and the serve the position of the distribu- VALVE ROCKER ARM COVER
front edge of the oil pan. Raise the tor rotor.
3. Remove the intake manifold, REMOVAL
front of the engine about 2 inches to
allow clearance for removal of the following the procedure under "In- 1. Remove the air cleaner.
exhaust manifold. Position 2-inch take Manifold Removal." 2. Disconnect the spark plug wires
wood blocks between the front sup- 4. Remove the clamp securing the at the spark plugs. Remove the wires
port insulators and underbody side distributor to the cylinder block. from the bracket on the valve rocker
members. Remove the jack and wood Scribe a line on the distributor hous- arm cover(s) and position the wires
block. ing directly opposite the tip of the out of the way.
5. Bend the lock tabs and remove rotor, for installation purpose. To remove the left rocker arm
the exhaust manifold lower retaining 5. Remove the distributor from cover, remove the air inlet duct as-
bolts. Remove the safety stands and the cylinder block and valve push sembly from the exhaust manifold.
lower the car. rod chamber cover. Observe the Move the heater hoses inward to al-
6. Bend the lock tabs and remove distance the rotor turns as the dis- low room for removal of the rocker
the exhaust manifold upper retaining tributor is removed. This will be arm cover.
nuts, manifold(s) and gasket(s). very helpful when the distributor 3. Remove the valve rocker arm
is installed, for the mating teeth cover(s) and gasket(s).
of the helical gears will turn the
Refer to Part 8-1, Section 3 for distributor shaft. INSTALLATION
the cleaning and inspection proce- 6. Clean the top of the valve push
dures. rod chamber cover to prevent dirt 1. Clean the valve rocker arm
from falling into the chamber. Re- cover ( s) . Apply oil-resistant sealer
INSTALLATION to one side of new cover gasket( s).
move the cover.
1. Clean the surfaces of the ex- Lay the cemented side of the gask-
haust manifold ( s) and cylinder INSTALLATION et(s) in place in the cover(s).
head(s). Apply a light film of graph- 2. Position the cover(s) on the
ite grease to the exhaust manifold 1. Install a new gasket on the cylinder head ( s) . Make sure the
and cylinder head port areas. valve push rod chamber cover. Use gasket seats evenly all around the
2. Position the exhaust mani- an oil-resistant sealer on the gasket. head. Install the bolts (and the wire
fold(s) and gasket(s) to the cylinder 2. With the gasket in position, loom clamps on the left cover) . The
head(s). Install the lock tabs and lower the front of the cover into cover is tightened in two steps. First,
upper retaining nuts. Torque the reposition. Make certain that the rub- torque the bolts to specifications.
taining nuts to specifications and ber grommet in the cover is not dis- Two minutes later, torque the bolts
bend the lock tabs. lodged by the distributor clamp stud. to the same specifications.
3. Raise the car and install safety Torque the mounting bolts to speci- If the left cover was removed, in-
stands. Install the lower retaining fications. Torque the center end stall the air inlet duct assembly.
bolts and lock tabs. Torque the re- bolts first. 3. Connect the spark plug wires.
taining bolts to specifications and 3. With the No. 1 piston on TDC Install the air cleaner.
bend the lock tabs. of the compression stroke, set the
4. Raise the front of the engine distributor rotor in position to fire VALVE ROCKER ARMS,
and remove the wood blocks from No. 1 cylinder. (The rotor tip will SHAFTS AND PUSH RODS
between the front support insulators be aligned with the previously scribed
and underbody side members. Lower mark on the distributor housing.) REMOVAL
the engine and install the front sup- 4. Turn the rotor counterclock-
port insulator nuts and washers. 1. Remove the valve rocker arm
wise a distance equal to the amount cover(s), following the procedures
Torque the nuts to specifications. observed during the distributor re-
5. Position the resonator inlet under "Valve Rocker Arm Cover
moval procedure (approximately Vs
pipe(s) to the exhaust manifold(s) turn). Removal."
and install the retaining nuts. Torque 2. Loosen the four rocker arm
5. Install the distributor. The shaft support mounting bolts evenly and
the nuts to specifications. and rotor will turn clockwise as the
6. Remove the safety stands and alternately, two turns at a time, until
distributor gear meshes with the cam- spring tension is removed. Remove
lower the car. Remove the rear wheel shaft gear. Check the position of the
blocks and release the parking brake. the mounting bolts and washers. Lift
rotor with the scribed mark on the the rocker arm assembly from the
7. Start the engine and check for distributor housing.
exhaust leaks. Install the air cleaner cylinder head.
6. If the installation is correct and 3. Remove the push rods from the
and air inlet duct assembly. the distributor is properly seated, cylinder head. Index the push rods
VALVE PUSH ROD install the distributor clamp, nut and to the bore from which they were
CHAMBER COVER lock washer. Final timing of the removed, for inspection and re-
distrihutor must be made after placement purposes.
REMOVAL the engine is operating in the car.
1. Remove the high tension lead 7. Install the intake manifold, fol-
wires from the coil t~rminal. Con- INSTALLATION
lowing the procedure under "Intake
nect an auxiliary starter switch to Manifold InstaJiation." 1. Lubricate each valve stem foot
the starter relay. 8. Remove the auxiliary starter and the rocker arm pad with Lubri-
2. Position the No. 1 piston on switch and connect the high tension plate.
TDC of the compression stroke. Ob- lead wires at the coil terminal. 2. Position the rocker arm and

(147) PART 8-2-430 V-8 ENGINE 8-27.
shaft assembly on the cylinder head. 2. Remove the rocker arms,

Install the mounting bolts, lock wash- springs and supports from the shaft.
ers and flat washers. Tighten the Keep the parts in order so that
screws until they are slightly en- they may be replaced in their
gaged in the cylinder head. original position if they are in
3. Install the push rods on their satisfactory condition.
hydraulic lifter seats. Make certain 3. If it is necessary to remove the
that they are installed in the lift- plugs from each end of the shaft,
ers from which they were re- drill or pierce one plug. Insert a
moved. steel rod through the plug and knock
4. Seat the ends of the push rod" out the plug on the opposite end.
in the rocker arm ball sockets. Working from the open end, knock
5. Tighten the rocker arm mount- out the remaining plug.
ing bolts evenly and alternately, two NOTCH A1832-A
turns at a time, until they are snug. CI.. EANING AND INSPECTION
Torque the mounting bolts to speci-
fications. Refer to Part 8-1, Section 3, for FIG. 13-Rocker Arms
6. Check the valve clearances and the cleaning and inspection proce- and Shaft Installed- Left Bank
correct, if .necessary (Part 8-1, Sec- dures.
tion 2). which they are to be installed.
7. Install the valve rocker arm REPAIRS When the right bank rocker arm
cover(s), following the procedure and shaft is completely assembled,
under "Valve Rocker Arm Cover Refer to Part 8-1, Section 2, for the identification notch on the
Installation." the repair procedures. shaft must be facing downward
and toward the front of the en-
DISASSEMBLY ASSEMBLY gine. The left bank rocker arm
The valve mechanism and related To ensure proper valve train and shaft must be assembled so
parts are shown in Fig. 12. lubrication, it is necessary that that the identification notch on
1. Remove the cotter pins, flat the valve rocker arm shafts and the shaft faces downward and to-
washers and spring washer from the valve rocker arms be assembled ward the rear of the engine (Fig.
f!nds of the shaft. correctly for the cylinder bank on 13).
1. Oil all moving parts with en-
gine oil. Apply Lubriplate to the
rocker arm pads and the tips of the
valve stems.
2. If the plugs were removed
from the ends of the shaft, use a
blunt tool or large diameter pin
punch and install a plug, cup-side
out, in each end of the rocker arm
shaft.
3. Install a cotter pin, flat washer
and spring washer on one end of the
shaft. Install the rocker arms, sup-
ports, support bolts and lock wash-
ers, and the springs (Fig. 12).
4. Complete the assembly opera-
tion by installing the remaining
spring washer, flat washer and cot-
ter pin. Make certain the rocker
arms are installed correctly for
the respective cylinder bank upon
which they are to be installed (Fig.
13).
HYDRAULIC VALVE LIFTERS

REMOVAL
1. Remove the valve push rod
chamber cover and related parts, fol-
lowing the procedure under "Valve
Push Rod Chamber Cover Removal."
2. Remove the valve rocker arm
VALVE SPRING A1831-A covers, following the procedure
under "Valve Rocker Arm Cover
FIG. 12-Valve Mechanism and Related Parts Removal."

8-28 GROUP 8-ENGINE (148}
3. Loosen the rocker arm and SPRING

shaft assembly mounting bolts evenly
and alternately, two turns at a time,
until all spring tension is removed.
Remove the mounting bolts and
VALVE DISC RETAINER/.
VALVE DISC
LO/Ck RING \
I
' "
~\
-1fP ~~y
rocker arm assemblies from the
cylinder head as a unit.
4. Remove the valve push rods
from the cylinder heads. Remove
""'
. .
'jj
, I'J"
~ r;;
·~PLUNGER
.,PUSH ROD CUP
~SPRING
Tool
the hydraulic lifters from the cylin-
NOTE: PLUNGER AND BODY ARE MATCHED
der block. Index the push rods and
SELECTIVE FIT SETS. DO NOT
lifters to the bores from which MISMATE PAIRS.
they are removed, for inspection A1835-A
and replacement purposes (Fig.
14). FIG. 15-Hydraulic Valve
Lifter Assembly
INSTALLATION
1. Insert the lifters into the bores
spected, tested and assembled sep- FIG. 17-Lock Ring
arately to prevent the mixing of Installation
from which they were removed. Coat internal parts. Each assembly is a
the outside of the lifters with engine matched set. Mixing of the parts
oil before installation. 3. Place the lifter body over the
can cause improper valve lifter
2. Install the push rods and the assemblies and push it down over
operation. Soak all the lifters in the plunger. Pick the assemb1y up
rocker arm and shaft assemblies, fol- solvent prior to disassembling
-lowing steps 1 through 5 under (still upside down) and push the
them. plunger and push rod cup into the
"Valve Rocker Arms, Shafts and 1. Remove the lock ring from the
Push Rods Installation." body. Turn the assembly right side
lifter body with needle nose pliers. up. Install the lock ring as shown in
3 Check valve clearances and cor- Remove the push rod cup.
rect, if necessary (Part 8-1, Section Fig. 17.
2. Remove the plunger with a
2). 4. Test the hydraulic lifter (Part
lifter plunger remover (Fig. 16). 8-1, Section 1).
4. Coat new valve rocker arm 3. Remove the valve disc, small
cover gaskets with an oil-resistant spring, disc retainer and plunger POSITIVE CRANKCASE
sealer. Install the rocker arm cover, spring. VENTILATION SYSTEM
reinforcements and bolts. Torque
the mounting bolts to specifications. CLEANING AND INSPECTION The positive crankcase ventilation
5. Install the valve push rod cham- system components are shown in
Refer to Part 8-1, Section 3 for Fig. 18.
ber cover and related parts, follow- 'the cleaning and inspection proce-
ing the procedure under "Valve Push dures. REMOVAL
Rod Chamber Cover Installation."
ASSEMBLY 1. Remove the air cleaner.
DISSASSEMBLY 2. Loosen the clamp securing the
1. Place the push rod cup, upside hose to the regulator valve. Remove
A disassembled view of an hydrau- down, on the bench. Place the the hose and clamp. Remove the
lic valve lifter is shown in Fig. 15 plunger on the push rod cup. regulator valve from the ventilation
for reference purposes during dis- 2. Place the valve disc, small tube fitting.
assembly and assembly operations. spring, and the retainer ~n the 3. Loosen the clamps securing the
Each hydraulic valve lifter m~st plunger. Place the large spnng on hose to the ventilation tube and car- .
be disassembled, cleaned, m· the valve disc retainer.
VALVE LIFTERS
FIG. 14-Hydrauli' Valve FIG. 16-Lifter Plunger FIG. 18-Positive

Lifter Removal or Installation Removal Crankcase Ventilation System

{149)
PART 8-2-430 V-8 ENGINE 8-29
buretor spacer. Remove the hose and
clamps. sealer to both sides of a new gasket.
4. Loosen the ventilation tube Install the cylinder head gasket(s)
bracket retaining nuts and washers, over the cylinder block dowels.
then slide the ventilation tube out. Cylinder head gaskets can be used
5. Remove the retaining bolts
on either cylinder bank. Make cer-
tain the word "TOP" (stamped on
securing the outlet adapter to the
the gasket) is facing upward. Also,
valve push rod chamber cover. Re-
make certain the gasket oil hole
move the outlet adapter, gasket and
aligns with the oil passage in the
oil separator element.
cylinder block.
A1838-A 6. Install the cylinder head ( s)
over the dowels, while guiding the
Refer to Part 8-1, Section 3 for FIG. 19-Cylinder Head exhaust manifold studs into the reso-
the cleaning and inspection proce- Holding Fixtures nator inlet pipe connection.
dures. 7. On a car with an air condi-
INSTALLATION inder head, disconnect the transmis- tioner install the compressor mount-
sion oil filler pipe bracket at the ex- ing bracket on the compressor.
1. Install the oil separator element haust manifold. Remove the horns 8. Install the cylinder head mount-
in the valve push rod chamber cover. and bracket assembly from the ing bolts and washers. Tighten the
Make certain the screen is positioned fender apron. cylinder head bolts in sequence (Fig.
snugly around the edges of the open- 7. Remove the cylinder head 20), using 3 cold torque applica-
ing. mounting bolts. Lift the cylinder tions. First, torque the bolts to 95
2. Coat a new outlet adapter gas- head assembly (with the exhaust ft-lbs, then torque them to 115 ft-lbs
ket with oil-resistant sealer and posi- manifold attached) off the two lo- and finally to 135 ft-lbs.
tion it on the push rod chamber cating dowels on each bank of the 9. On the right bank cylinder
cover. Position the outlet. adapter on cylinder block. Remove the cylin- head, install the oil filler pipe bracket
the cover and install the retaining der head gaskets. Never pry be- on the exhaust manifold. Torque the
bolts. tween the cylinder heads and cyl- retaining nut to specifications. Bend
3. Slide the ventilation tube brack- inder block when removing the the washer tab. Install the horns and
ets under the retaining washers and heads. This can cause damage to bracket assembly on the fender ap-
nuts. Tighten the nuts. Install the the machined surfaces.
regulator valve in the ventilation tube 8. If disassembly or machining of
fitting. the cylinder head is required, remove
4. Install the hose and damp on the exhaust manifold, steel gasket
the outlet adapter and regulator and valve rocker arm assembly. In-
valve. Position and tighten the clamp. stall cylinder head holding fixtures
5. Install the hose and clamps on on the cylinder heads (Fig. 19). Use
the carburetor and ventilation tube. four intake manifold mounting bolts
6. Install the air cleaner. to attach the tools to the cylinder
heads. These tools have been de-
CYLINDER HEADS signed to allow easy handling of
Due to engine compartment clear- the cylinder heads during all work
ance factors, it is necessary to re- operations.
move the exhaust manifold and cyl-
inder head !ls a unit from each cyl- INSTALI.-ATION
inder bank. 1. Clean the cylinder head and
cylinder block gasket surfaces.
REMOVAL 2. If the cylinder head was re-
1. Raise the hood. Remove the moved for a cylinder head gasket
ground cable from the battery. replacement, check the flatness of
2. Raise the front of the car with the cylinder head and block gasket
a jack. Install safety support stands. surfaces (Part 8-1).
Disconnect the resonator inlet pipe(s) 3. Remove the cylinder head hold-
from the exhaust manifold ( s) . ing fixtures from the cylinder heads.
3. Remove the valve push rod 4. Coat the exhaust manifold and
chamber cover from the engine, fol- cylinder head port areas with a light
lowing the procedure under "Valve film of graphite grease. Install the
Push Rod Chamber Cover Removal." exhaust manifold and steel gasket on
4. Remove the valve rocker arm the cylinder head. Install lock wash-
cover(s) and gasket(s) from the cyl- ers on the two lower, center mount-
inder head ( s) . mg bolts. Install locking tab-type
5. On a car with an air condi- washers on the remaining bolts and
tioner, disconnect the compressor studs. Torque the mounting bolts and A1839-A
mounting bracket at the cylinder nuts to specifications. Bend the wash-
head. er locking tabs. FIG. 20-Cylinder Head
6. To remove the right bank cyl- 5. Apply cylinder head gasket Bolt Torque Sequence

:l'i£:~~~:·;;,., .
ron. Connect the lead wires to the
horns.
10. Secure the resonator inlet
pipe(s) to the exhaust manifold(s). a-·----~~~~-- ....,:- .....
,·rt!···-::·..
Torque the mounting nuts to specifi-
cations.
11. Close the radiator drain cock.
Install the cylinder block drain plugs.
Lower the car.
12. Lubricate each valve stem foot
and rocker arm pad with Lubriplate,
re-·' .~...tii">· ,. ~~
>?
. .. •• •••• ···.) i1 :
then position the rocker arm and 1
shaft assembly on the cylinder head.
Install the mounting bolts, lock wash-
. ·--~-:::::~~s~~~.
ers and fiat washers. Tighten the
bolts until they are slightly engaged
in the cylinder head.
13. Install the push rods in the
cylinder block, making sure they are
properly seated in the hydraulic
valve lifters ·from which they were
removed. Seat the ends of the push
rods in the rocker arm ball sockets.
14. Tighten the rocker arm shaft
support mounting bolts, evenly and
alternately, two turns at a time until
they are snug. Torque the bolts to
specifications.
15. Install the spark plugs in the
cylinder head(s), using a 1 %6 inch
spark plug deep socket tool. Torque
the spark plugs to specifications.
Due to the angle at which the
spark plugs are installed, care
must be exercised to prevent
breaking during installation.
16. Check the valve clearances
and correct, if necessary (Part 8-1,
Section 2).
17. Install the valve rocker arm I
chamber cover and gasket on the I
cylinder head ( s) . Install the bolts v1
and reinforcements. Torque the bolts
to specifications.
18. Install the valve push rod ~WASHER
chamber cover, intake manifold, and
related parts, following the procedure ~SCREW
under "Valve Push Rod Chamber EXHAUST VALVE A1840-A
Cover Installation."
FIG. 21-Cylinder Head and Related Parts
DISASSEMBLY
The cylinder head and related parts 5. Repeat steps 1 through 4 for seat refacing, cylinder head flatness
are shown in Fig. 21. the remaining valves. Keep the checks, etc., are covered in Part 8-1,
1. Clean carbon deposits from the valves and their related parts to- Section 2.
cylinder head and valve heads before gether so that they may be in-
removing the valves. stalled in their respective positions ASSEMBLY
2. Compress the valve springs in the cylinder head if inspection
(Fig. 22). Tap the retainer gently proves satisfactory. 1. Lubricate the valve stems and
with a soft hammer and remove the valve guides with engine oil.
valve retainer locks. CLEANING AND INSPECTION 2. Install the intake and exhaust
3. Remove the intake valve spring Refer to Part 8-1, Section 3 for the valves in their respective guides. In-
.retainer, inner sleeve, valve spring, cleaning and inspection procedures. stall new valve stem seals, valve
valve seal and intake valve. spring assemblies, valve spring re-
4. Remove the exhaust valve re- REPAIRS tainers and sleeves over the intake
tainer (rotator) , valve spring, valve Cylinder head repair procedures valves. Install new valve stem seals
seal and exhaust valve. and checks such as valve and valve over the exhaust valves, then install

(151) PART 8-2-430 V-8 ENGINE 8-31
FIG. 24-Measuring
Intake Valve Spring
Assembled Height
FIG. 22-Compressing FIG. 26-lnstallation
Valve Spring-On Bench ured is less than specified, additional of Air Adapter Tool
dimensional checks should be made in Spark Plug Hole
the spring and valve retainer ( roof all components affecting the spring
tator). height. 2. Remove the applicable spark
3. Compress the valve spring and VALVE SPRING, RETAINER AND plug. Remove the high tension lead
install the valve retainer locks (Fig. STEM SEAL REPLACEMENT wire from the coil terminal. Connect
22) . Release the valve spring com- an auxiliary starter switch to the
pressor slowly and check the position The operation of the exhaust valve starter relay. Crank the engine until
of the valve retainer locks. Strike the rotators can only be checked with the piston of the affected cylinder is
end of the valve stem with a fiber the engine running. on the power stroke.
mallet to make certain the retainer With the valve rocker arm cover 3. Loosen the rocker arm support
locks are properly installed. Repeat removed, place an index mark on mounting bolts evenly and alter-
the operation for the remaining each rotator. Start the engine. If nately, two turns at a time, until
valves. the rotators are operating correctly, the valve spring tension has been
4:. Use dividers to measure the the index mark will revolve at an released. Remove the push rod(s)
assembled height from the surface even rate. If no movement or erratic of the valve(s) to be serviced.
of the cylinder head spring pad to movement is noted, the rotator must 4. Tighten the rocker arm support
the underside of the intake valve be replaced. Excessive wear at one mounting bolts evenly and alter-
spring retainer or the exhaust valve spot on the tip of the exhaust nately, two turns at a time, until
rotator (Figs. 23 or 24). valve stem is also an indication they are snug.
of rotator failure. 5. Install an air adapter in the
5. If the measured dimension is
Broken valve springs, or defective spark plug hole and connect the
greater than specified, install the
valve stem seals and rotators may be air supply hose to the adapter (Fig.
necessary spacer or spacers (maxi-
replaced without the need of remov- 26) . Air pressure may turn the
mum of two) between the cylinder
ing the cylinder head, providing dam- crankshaft until the piston reaches
head spring pad and the valve spring
age to the valve or valve seat has not the bottom of its stroke.
to bring the assembled height to the
occurred. 6. Compress the valve spring and
specified dimension (Fig. 25). Do
1. Remove the valve rocker arm remove the valve retaining locks
not use spacers unless necessary.
cover( s), following the procedure
The use of spacers in excess of
under "Valve Rocker Arm Cover
recommendations will result in
Removal."
overstressing of the valve springs.
6. If the dimension when meas-
A1842-A
Tool 6513-J
A1846-A
FIG. 23-Measuring
Exhaust Valve Spring FIG. 25- Valve Spring FIG. 27 -Compressing
Assembled Height Spacer Installation Valve Spring-In-Chassis

from the valve (Fig. 27). H air port mounting bolts evenly and al-
pressure fails to hold the valve in ternately, two turns at a time, until
the closed position during this spring tension is removed. Apply
operation, it can be presumed that Lubriplate to both ends of the push
the valve is not seating or is dam- rod. Position the valve push rod
aged. If this condition occurs, re- within the rocker arm socket and the
move the cylinder head for fur- valve lifter tappet seat.
ther inspection. 17. Tighten the rocker arm shaft
7. Remove the valve spring and support mounting bolts evenly and
related parts. Remove the valve stem alternately, two turns at a time, until
seal. If air pressure has forced the they are snug. Torque the bolts to
piston to the bottom of the cylin- specifications.
der, any removal of air pressure 18. Remove the auxiliary starter
will allow the valve(s) to fall into switch. Install the high tension lead
the cylinder. A rubber band, tape wire in the ignition coil terminal.
or string wrapped around the end 19. Install the spark plug wires.
of the valve stem will prevent this Check the valve clearances and cor-
and will still allow enough travel rect, if necessary (Part 8-1, Section
to check the valve for binds. 2).
20. Start the engine and check to A1848-A
8. Inspect the valve stem for dam-
age. Rotate the valve and check the make certain that the exhaust valve
valve stem tip for eccentric move- retainers (rotators) are operating in FIG.29-Crankshaft
ment during rotation. Move the the proper manner. Damper Installation
valve up and down through normal 21. Install the valve rocker arm
travel in the valve guide and check cover( s), following the procedure bracket and support bracket bolts.
the stem for binds. If the valve under "Valve Rocker Arm Cover Push the compressor inward toward
has been damaged, it will be nec- Installation." the engine and remove the compres-
essary to remove the cylinder sor drive belt.
head for repairs as outlined in CRANKSHAFT DAMPER 4. Remove the fan assembly, spac-
Part 8-1, Section 2. REMOVAL er and the mounting bolts as a unit
9. If the condition of the valve from the water pump pulley.
proved satisfactory, hold the valve in 1. Open the hood and install fen- 5. Raise the vehicle. Remove the
the closed position and apply the air der covers. Remove the ground cable crankshaft damper retaining bolt and
pressure within the cylinder. from the battery. washer. Install the puller on the
10. Inspect the valve stem seal for 2. Loosen the alternator adjusting damper and remove the crankshaft
a cracked, torn, or brittle condition, bracket and mounting bracket bolts. damper (Fig. 28). Remove the
and replace it if necessary. Install Pull the alternator inward toward the Woodruff key, if necessary.
the seal on the valve stem. engine and remove the water pump-
11. Install the intake valve spring alternator drive belts. INSTALLATION
retainer and sleeve over the intake 3. On a car with an air conditioner, 1. Install the Woodruff key in the
valve stem. loosen the bolts securing the fan
crankshaft if it was removed. Install
12. Install the exhaust valve drive clutch and compressor drive
the crankshaft damper with the slot
spring, and retainer (rotator) over pulley to the water pump pulley.
aligned with the Woodruff key in the
the exhaust valve stem. Remove the fan drive clutch and fin
crankshaft.
13. Compress the spring (Fig. 27) assembly, and the compressor drive
2. Drive the damper onto the
and install the valve retainer locks. pulley from the vehicle as a unit.
crankshaft until it seats against the
Tap the valve stem tip with a soft Loosen the compressor adjusting
power steering pump (Fig. 29) . In-
mallet to make certain that the re- stall the washer and retaining bolt.
tainer locks are properly seated. Torque the bolt to specifications.
14. Check the valve spring as- 3. Install the fan-alternator drive
sembled height to make certain that belts on their respective pulley
it is within specifications (Figs. 23 sheaves. Adjust the alternator to ob-
and 24). If the assembled height ex- tain the specified belt tension and
ceeds specifications, install the nec- tighten the generator adjusting brack-
essary spacer or spacers to bring the et and mounting bracket bolts.
height within specifications (Fig. 4. On a car with an air condi-
26). Do not install spacers, unless tioner, install the compressor drive
necessary. Use of spacers in excess pulley and the fan drive clutch and
of recommendations will result in fan assembly on the water pump
overstressing the valve springs pulley as a unit.
and overloading the camshaft Install the compressor drive bett.
lobes which could lead to spring Adjust the compressor to obtain the
breakage or worn camshaft lobes. specified belt tension and tighten the
15. Remove the air line and mounting bolts. Tighten the compres-
adapter and install the spark plug. FIG.28-Crankshaft sor adjusting bracket bolts.
16: Loosen the rocker arm sup- Damper Removal 5. Lower the vehicle. Install the

(153) PART 8-2-430 V-8 ENGINE 8-33
battery ground cable on the battery. 13. Remove the crankshaft damper washer and torque the bolt to speci-
Remove the fender covers and close Woodruff key from the crankshaft. fications.
the hood. Remove the power steering pump. 5. Coat new water pump gaskets
14. Remove the heat shield from with water-resistant sealer. Install the
CYLINDER FRONT COVER
the fuel pump. Disconnect the fuel gaskets, water pump, oil level dip~
REMOVAL lines at the fuel pump and fuel filter. stick tube bracket, and power steer-
1. Open the hood and install Remove the fuel pump; then, re- ing reservoir mounting bracket.
fender covers. move the cup-type plug from the Torque the water pump mounting
2. Drain the cooling system (open top of the cylinder front cover with bolts to specifications. Torque the
the radiator drain cock and remove the use of a long punch. Remove the power steering pump reservoir brack-
the cylinder block drain plugs). fuel pump push rod. et mounting bolts to specifications.
3. Disconnect the overflow hose 15. Raise the front of the car and Tighten the bypass hose clamp.
from the coolant supply tank. Dis- instaJI safety support stands. Remove 6. Install the fuel pump push rod
connect the primary and secondary the bolts securing the cylinder front in the cylinder front cover. Install a
wires from the ignition coil. cover to the oil pan and the cylinder new cup-type plug in. the top of the
4. Remove the bolt securing the block. cover.
supply tank brace, engine ground 16. Carefully remove the cylinder 7. Coat a new fuel pump gasket
strap, and battery ground cable to front cover. If the oil pan gasket with an oil-resistant sealer. Install
the water pump. Disconnect the rais damaged during the removal of the gasket and fuel pump on the
diator inlet hose from the coolant the cylinder front cover, it will cylinder front cover and torque the
tank and the radiator. he necessary to replace it before mounting bolts to specifications. Con-
5. Remove the supply tank, ther- installing the cylinder front cover. nect the fuel vapor line to the fuel
mostat and gasket. pump. Install the fuel pump shield.
CLEANING AND INSPECTION 8. Install the thermostat in the in-
6. Loosen the coolant bypass hose
clamp at the water pump. Refer to Part 8-1, Section 3 for take manifold. Coat a new supply
7. On a car with an air condi- the cleaning and inspection proce- tank mounting gasket with water-re-
tioner, loosen the compressor sup- dures. sistant sealer. Install the supply tank
port bracket and adjusting bracket on the intake manifold. Install the
bolts. Push the compressor inward INSTALLATION engine ground strap and battery
toward the engine and remove the 1. Coat the oil pan gasket (if it ground cable on the supply tank
drive belt. Remove the fan drive was not replaced) and the cylinder brace; then, torque the water pump
clutch and fan assmbly, and the com- front cover gasket with an oil-re- mounting bolt to specifications.
pressor drive pulley as a unit. sistant sealer. Place an extra daub Torque the supply tank to intake
8. Loosen the alternator adjusting of sealer at the point where the two manifold mounting bolts to specifica-
bracket and mounting bracket bolts. gaskets meet. Install the gasket on tions.
Push the alternator inward toward the cylinder front cover; then, in- 9. Connect the ignition coil pri-
the engine and remove the fan-alter- stall the cover, coolant overflow hose mary and secondary wires to the coil
nator drive belts. Remove the fan clip, timing pointer, power steering terminals. Connect the overflow hose
blade assembly, spacer, and mounting hose bracket, and the mounting bolts to the supply tank.
bolts from the water pump pulJey on the cylinder block. Tighten the 10. Install the fan-alternator drive
as a unit. bolts finger-tight. belts. Adjust the alternator to obtain
9. Disconnect the radiator outlet 2. Install the oil pan to cylinder the specified drive belt tension and
hose at the water pump. Remove the front cover reinforcements and tighten the generator adjusting brack-
bolt securing the oil dipstick tube mounting bolts. Torque the bolts to et bolt. Tighten the alternator mount-
bracket to the water pump. Remove specifications. Torque the cylinder ing bolts. Connect the radiator outlet
the power steering reservoir bracket front cover mounting bolts to speci- hose to the water pump and radiator.
mounting bolt from the water pump fications. Close the radiator drain cock.
and loosen the remaining reservoir 3. Make certain the power steer- 11. On a car with an air condi-
bracket mounting bolts to allow ing pump rubber insulators are tioner, install the compressor drive
cJearance for removal of the water installed properly. Carefully install pulley, fan clutch drive, and fan as-
pump. the power steering pump on the sembly in the engine compartment
10. Remove the water pump from crankshaft, making certain the lips as a unit. Install the compressor
the cylinder block. of the cylinder front cover seal main- drive pulley, fan clutch drive and
11. Remove the crankshaft damper tain proper contact with the power fan assembly on the water pump
mounting bolt and washer. Remove steering pump. Install the retaining pulley as a unit and tighten the
the crankshaft damper (Fig. 28). bolts and washers and torque the mounting bolts.
12. Disconnect the power steering bolts to specifications. Connect the Install the compressor drive belt
high and low pressure lines at the inlet and outlet lines to the power on the compressor clutch and drive
power steering pump and immedi- steering pump. Tighten the power pulley. Adjust the compressor to ob-
ately plug the lines to prevent fluid steering hose clamp. tain the specified drive belt tension.
drainage. Remove the retaining bolts 4. Install the Woodruff key in the 12. Install the fan and spacer on
securing the power steering pump crankshaft. Install and press the the water pump pulley and torque
reservoir mounting bracket to the crankshaft damper on the crankshaft the mounting bolts to specifications.
cylinder front cover. Loosen the until it is seated against the power 13. Connect the radiator inlet hose
clamp securing the high pressure steering pump coupler shaft (Fig. to the radiator and supply tank. In-
line to the bracket. 29). Install the retaining bolt and stall the cylinder block drain plugs.

14. Fill the cooling system to the

required level.
15. Fill the power steering pump
reservoir to the required oil level.
16. Fill the crankcase with the
proper type and grade of oil to bring
it up to the required level.
17. Start the engine and check the
oil pump pressure at the instrument
panel indicator. Run the engine until
normal operating temperature is
reached.
18. While the engine is operating,
check for oil, fuel and water leak-
age. Remove the fender covers and
close the hood.
FIG. 33-Crankshaft
TIMING CHAIN, CAMSHAFT Spro,ket Removal
AND CRANKSHAFT SPROCKETS TIMING MARKS
A1849-A
REMOVAL CLEANING AND INSPECTION
1. Remove the cylinder front FIG. 31-Aiignment of Refer to Part 8-1, Section 3 for
cover, following the procedures under Timing Marks
"Cylinder Front Cover Removal." the cleaning and inspection proce-
Remove the oil slinger from the dures.
If the deflection exceeds ¥2 inch,
crankshaft.
replace the timing chain and/or INSTALLATION
2. Rotate the crankshaft in a clock-
sprockets.
wise direction (as viewed from the 1. Install the Woodruff key in the
front) to take up the slack on the 5. Rotate the crankshaft and align crankshaft. Install the crankshaft
left side of the chain. the timing marks of the crankshaft sprocket (Fig. 34) with the timing
3. Establish a reference point on and camshaft sprockets (Fig. 31). mark facing the front of the car.
the block and measure from this 2. Position the timing chain
point to the chain (Fig. 30). 6. Remove the lock plate, fuel around the camshaft sprocket. Align
4. Rotate the crankshaft in the pump eccentric, drive bushing and the timing mark on the camshaft
opposite direction to take up the wear plate from the camshaft. sprocket with the mark on the crank-
slack on the right side of the chain. 7. Remove the camshaft sprocket shaft sprocket (Fig. 32).
Force the left side of the chain out and timing chain as a unit (Fig. 32). 3. Position the camshaft sprocket
with the fingers and measure the on the camshaft (Fig. 32). Install
distance between the reference point 8. Remove the crankshaft sprock- the wear plate, fuel pump eccentric
and the chain. The deflection is the et (Fig. 33). Remove the Woodruff sleeve, drive bushing, lock plate
difference between the two measure- key. and mounting bolts. The timing
ments. marks must be adjacent and on
the same vertical centerline (Fig.
TAKE UP SLACK ON LEFT SIDE. ESTABLISH
31). If the timing marks are not
A REFERENCE POINT AND MEASURE
DISTANCE A. TAKE UP SLACK ON
positioned as shown in the illus-
RIGHT SIDE AND FORCE LEFT SIDE tration, remove the camshaft
OUT WITH THE FINGERS AND MEASURE sprocket and timing chain; then,
DISTANCE B. DEFLECTION IS A MINUS B. install the units correctly.
4. Make sure the drive bushing is
MARKS A 1 850-A
Rl
OF CHAIN A l 853 .A
FIG. 32-Camshaft
FIG. 30-Timing Chain Spro,ket and Timing Chain FIG. 34-Crankshaft
Deftection Removal or Installation Spro,ket Installation

(155) PART 8-2-430 V-8 ENGINE 8-35
REAR BEARING plate by following steps 2 thru 6
CEN:: R ,:::::EDIA~ARIN~ under "Timing Chain, Camshaft and

Crankshaft Sprockets Installation. ••
3. Coat the hydraulic lifters and
lifter bores with engine oil. Insert
the lifters into the bores from which
they were removed.
4. Install the cylinder front cover,
following steps 1 thru 7 under
"Cylinder Front Cover Installation."
5. Install the fan-alternator drive
FUEl PUMP PUSH ROD
belts. Adjust the alternator to obtain
the specified drive belt tension.
/W~RPWE
Tighten the alternator adjusting
bracket bolt. Tighten the alternator
mounting bolts.
\1
6. Install the fan blade and spacer
on the water pump pulley and torque
the mounting bolts to specifications.
7. On a car with an air condi-
tioner, install the compressor drive
:\CK~~
puiley and the fan drive clutch
and fan assembly on the water pump
TIMING CHAIN pulley as a unit. Install the compres-
sor drive belt on the compressor
clutch and drive pulley. Adjust the
DRIVE BUSHING compressor to obtain the specified
BOLT drive belt tension. Tighten the com-
pressor adjusting bracket bolts.
A1854-A
Position the condenser in the en-
gine compartment.
FIG. 35-Camshaft and Related Parts 8. Close the radiator drain cock.
Position the radiator in the engine
properly seated over the fuel pump 5. Remove the radiator, follow- compartment.
eccentric; then, torque the camshaft ing the applicable steps under "Radia- 9. On a car with an air condi-
sprocket retaining bolts to specifica- tor Removal" in Part 11-3, Section 2. tioner, secure the condenser to the
tions. 6. On a car with an air condi- lower support of the radiator.
5. Install the oil slinger on the tioner, carefully lift the condenser 10. Secure the air deflector to the
crankshaft, with the concave side of out of the engine compartment (with upper radiator support.
the slinger facing the rear of the the lines still attached) and rest it 11. Place the radiator insulators
engine. on the left front fender. between the radiator support bracket
6. Install the cylinder front cover, 7. Remove the camshaft from the and the underbody. Make certain
following the procedure under "Cyl- cylinder block. Use care to prevent they are aligned with the mounting
inder 1Front Cover Installation." damage to the camshaft bearing bolt holes. Install the .radiator upper
!-.urfaces. and lower mounting bolts.
CAMSHAFT
CLEANING AND INSPECTION 12. Connect the lower hose to the
The camshaft and related parts are
radiator and water pump. Secure the
shown in Fig. 35. Refer to Part 8-1, Section 3 for fuel and vapor line bracket to the
the cleaning and inspection proce- radiator.
REMOVAL dures.
1. Raise the hood and mask the 13. Install the valve push rod
hood edges to protect the finish. In- REPAIRS chamber cover and the distributor,
stall fender covers. Refer to Part 8-1, Section 2 for the following steps 1 thru 6 under "Valve
2. Remove the hood assembly. If repair procedures. Push Rod Chamber Cover Installa-
the hood is properly aligned, index tion."
the hood hinge to the hood for INSTALLATION 14. Install the push rods and the
installation purposes before re- 1. Lubricate the camshaft journals valve rocker arm assemblies, follow-
moving it from the car. and Jobes with engine oil. Install ing steps thru 5 under "Valve
3. Remove the hydraulic valve the camshaft. Use care to prevent Rocker Arms, Shafts and Push Rod
lifters from the engine, following the lobes and journals from dam- Installation."
the procedures under "Hydraulic aging the camshaft bearings. Care 15. Install the intake manifold and
Valve Lifter Removal." must also be used to prevent the related engine parts, following steps
4. Remove the timing chain and camshaft. from dislodging the rear 2 thru 17 and 19 and 21 under
camshaft sprocket, following steps camshaft bearing plug. "Intake Manifold Instailation."
1 thru 4 under "Timing Chain, Cam- 2. Install the timing chain cam- 16. Check the valve clearances and
shaft and Crankshaft Sprockets Re- ,haft sprocket, wear plate, fuel pump correct, if necessary (Part 8-1, Sec-
moval." ..:ccenlric, drive bushing and lock tion 2).

17. Install the wiring loom in the MAIN AND CONNECTING ROD 3. Remove the main bearing cap
clips located on the right bank rocker BEARING REPLACEMENT to which new bearings are to be in-
arm cover. Install the ignition coil It is necessary to check the condi- stalled. Remove the upper bearing
primary and secondary wires, tem- tion of all crankshaft main and con- insert with tool 6331-E. Insert the
perature sending unit wire, and the necting rod journals before replace- tool into the crankshaft oil hole
oil pressure sending unit wire. ment procedures are performed. (Fig. 36) and rotate the crankshaft
18. Install the distributor cap and If a crankshaft has journals that in the direction of normal rotation
spark plug wires as a unit. Install are damaged or worn below specifi- (clockwise). Use tool 6331-E with
the spark plug wires on the rocker cations, the crankshaft must be re- care. to avoid damage to the bear-
arm covers and spark plugs. moved from the engine for grinding ing insert.
19. Fill the crankcase to the re- or replacement purposes. It will be 4. Clean and inspect each bear-
quired level with the proper type and necessary to remove the engine from ing insert carefully. Bearings that
grade of lubricant. the car and disassemble it to replace have a scored, chipped or worn sur-
20. Add fluid to the power steering the crankshaft. face will have to be replaced (Part
reservoir to bring the fluid up to The standard main and connect- 8-1, Section 3) . Dirt or other for-
the required level. ing rod bearing inserts are a selec- eign material under a bearing
21. Start the engine. Check the tive fit and do not require line ream- insert may have distorted the
oil pressure at the instrument panel ing to size upon installation. Do not bearing. Sound judgment and
indicator. Check for oil and coolant file or lap bearing caps and webs proper inspections are necessary
leaks. or use shims to obtain the proper when diagnosing bearing failures.
22. Run the engine until normal bearing clearance. 5. Clean and inspect the main
operating temperature is indicated Selective fit bearings are available bearing journals for cracks,
and perform or check the following for service in two standard sizes scratches, grooves, or score marks.
items: only. Each size carries a different suf- Dress minor imperfections care-
Check for fuel, oil, coolant and fix to the part number. They can be fully with a fine oil stone. If the
vacuum leakage. identified by a daub of red or blue journal is damaged it will have
Check and adjust the ~nitial tim- color dye. Red marked bearing in- to be ground to size for the next
ing. serts decrease the clearance. undersize service bearing.
Perform carburetor idle and mix- Undersize bearings which are not
ture adjustments. 6. Check the main bearing journal
selective fit are available for use on for an out-of-round condition with
Perform transmission linkage ad- journals that are undersize or have
justments, if necessary. a dial indicator (tool 6565) and hold-
been reground. ing fixture (tool 4201-D). Secure
tioner, adjust the fast idle control tool 4201-D to the oil pan rail with
MAIN BEARING an oil pan mounting bolt. (Fig. 37).
linkage. REPLACEMENT
24. Install the hood assembly and Position the dial indicator on "0".
adjust it, if necessary. Remove the Check and replace one bearing Revolve the crankshaft and check
masking tape from the hood. at a time, leaving the other bear- the indicator reading. If out-of-round
25. Install the carburetor fresh air ing caps securely attached to the exceeds specifications, the crankshaft
inlet duct assembly on the exhaust cylinder block. must be replaced.
manifold. Install the carburetor air 1. Remove the spark plugs. Re- 7. Wipe oil and dirt from all con-
cleaner. move the high tension lead wire tacting surfaces of the crankshaft,
26. Remove the fender covers. from the coil terminal. Connect the bearing inserts and bearing caps.
Close the hood and road test the auxiliary starter switch to the starter 8. When replacing standard
car. relay. bearings with new bearings, it is
2. Drain the crankcase and re-
CAMSHAFT REAR BEARING BORE move the oil pan and oil pump.
PLUG REPLACEMENT
1. Remove the flywheel, follow-
ing the procedure under "Flywheel
Removal."
2. Drill a 1f2 inch hole in the
center of the camshaft rear bearing
bore plug.
3. Remove the plug with the
clutch pilot bearing remover (tool
7600-E).
4. Clean the plug bore recess
thoroughly.
5. Coat the bore with an oil-re-
sistant sealer. Position the plug in
the bore with the flange facing the
Tool 6331-E A1857-A
front of the engine. Drive the plug
inward until it is seated.
6. Install the flywheel, following FIG. 36-Upper Main FIG. 37 -Checking
the procedure under "Flywheel In- Bearing Insert Removal Crankshaft Journal for
stallation." or Installation Out-of-Round Condition

(157) PART 8-2-430 V-8 ENGINE 8-37
recommended that two blue bear- the lower insert, but do not disturb 13. Repeat the procedure for the
ing inserts be used first to obtain the Plastigage. Compare the width remaining main bearings which re-
the proper clearance. Make cer- of the flattened Plastigage at its wid- quire replacement.
tain the oil holes are clear. Install est point with the scale printed on 14. If the rear main bearing is to
the upper half of the bearing insert 1he Plastigage envelope to obtain be replaced, remove the rear main
over the crankshaft on the locking the minimum bearing clearance (Fig. bearing cap. Remove and discard.the
tang side of the crankshaft main ~ 8). Check the Plastigage at its nar- rear seal and side seals.
bearing web and rotate the insert rowest point to obtain the maximum 15. Clean the rear journal oil seal
into position as far as possible, then bearing clearance. The difference be- groove.
use tool 6331-E to fully seat the in- tween the minimum and maximum 16. Install a new rear journal oil
sert (Fig. 36). hearing clearance is the taper of the seal in the rear main bearing cap
9. Support the weight of the Journal. (Fig. 3 9). After installation, cut the
crankshaft with a small jack posi- If the taper or out-of-round spe- ends of the seals flush (Fig. 40).
tioned to bear against the crankshaft cification exceeds the allowable lim- 17. Apply a thin coating of oil-
counterweight adjoining the bearing Its, the crankshaft must be removed resistant sealer to the rear main
which is being checked for clear- and the journal ground to size for the bearing cap at the rear of the top
ance. Crankshaft support is nec- next undersize bearing. mating surface. Do not apply sealer
essary when checking main bear- If the bearing clearance is greater to the area forward of the side
ing clearances in order to prevent than the specified limit, it will be seal groove. Install the rear main
the crankshaft weight from com- necessary to remove the crankshaft bearing cap. Torque the cap bolts
pressing the Plastigage, which 'md grind the journal to size for the to specifications.
would provide an incorrect read- next undersize bearing. 18. Dip the side seals in light
ing. If the clearance is less than the engine oil, then immediately install
~pecified limit, try two red bearing them in the grooves. Do not use
10. Place a piece of Plastigage,
the full width of the bearing surface inserts or a combination of red and sealer on the side seals. The seals
on the crankshaft journal, about ~ hlue, depending on the condition. are designed to expand when
inch off-center (Fig. 38). Place the Any combination of the standard dipped in oil. Using sealer may
lower bearing insert in the cap. In- red and/ or blue bearing inserts retard this expansion. It may be
stall the bearing insert and cap. may be used to obtain the desired necessary to tap the seals into place
Torque the bolts to specifications. results. for the last 1f2 inch of travel. Do not
Do not rotate the crankshaft while 12. Aftt"!r each bearing has been cut the seal projecting ends.
making checks with Plastigage. checked and found to be satisfactory, 19. Check the retainer side seals
apply a light coating of engine oil to for leaks by squirting a few drops
11. Remove the bearing c:ap and
the bearing and journal, then install of oil into the parting lines between
PLACE Plostigoge FULL the lower bearing insert and cap. the rear main bearing cap and the
WIDTH OF JOURNAl Tighten the retaining bolts to 95-105 cylinder block from the outside.
ABOUT 1,4 INCH
tt-lbs torque. Blow compressed air against the
OFF-CENTER
seals from the inside of the block.
If air bubbles appear in the oil, it
indicates possible oil leakage. This
test should not be performed on
newly installed seals until suffi-
cient time has been allowed for
the seals to expand into the seal
grooves.
CHECK WIDTH
OF Plostigoge
0.002"
CLEARANCE
- ~·-··:·'
'
' '
''<.· .l1.·'·/··.·
...·. .·.. ~.:
MEASURING Plastigoge
A1863-A A1855-A A18S6-A
fiG. 38-Checking FIG. 39-Seal to Rear FIG. 40-Cutting Rear

Bearing Clearance Bearing Cap Installation Bearing Cap Seal

20. Install the oil pump and inter- 8. Install the upper bearing on the to specifications. Check the connect-
mediate shaft, by following steps 1 rod. Make certain the locking tang ing rod side clearance with a feeler
and 2 under "Oil Pump Installation." of the bearing is properly located. gauge (Fig. 41).
21. Install the oil pan, by follow- Pull the rod assembly into firm con- 12. Follow steps 20 thru 23 under
ing steps 1 thru 9 under "Oil Pan tact with the crankshaft journal. "Main Bearing Replacement."
Installation." 9. Install the lower bearing insert
22. Remove the auxiliary starter in the connecting rod cap. Place a CLEANING AND INSPECTION
switch. Insert the high tension lead piece of Plastigage on the bearing Refer to Part 8-1, Section 3 for
wire in the coil. Install the spark surface, the full width of the bear- the cleaning and inspection proce-
plugs and torque them to specifica- ing, about ~ inch off-center (Fig. dures.
tions. Install the spark plug wires. 38). Install the cap and torque the PISTON AND CONNECTING
23. Start the engine and check mounting nuts to specifications. Do ROD ASSEMBLY
the oil pressure at the instrument not rotate the crankshaft while
panel indicator. While the engine is the Plastigage is in place. REMOVAL
running, check for oil leakage. 10. Remove the bearing cap. Com- 1. Remove the intake manifold,
pare the width of the flattened Plasti- valve push rod chamber cover, cyl-
CONNECTING ROD gage at its widest point with the scale inder head(s) and related parts, fol-
BEARING REPLACEMENT printed on the Plastigage envelope. lowing the procedure under "Cylinder
Check and replace one bearing at This is the minimum bearing clear- Head Removal."
a time, leaving the other connecting ance (Fig. 38). Check the Plastigage 2. Remove the oil pan, following
rods securely attached to the journals. at its narrowest point to obtain the the procedure under "Oil Pan Re-
1. Follow steps 1 and 2 under maximum bearing clearance. The moval."
"Main Bearing Replacement." difference between the minimum and 3. Remove the oil pump, inlet
2. Rotate the crankshaft to posi- maximum bearing clearance is the tube and intermediate shaft, follow-
tion the connecting rod journal at taper of the journal. ing the procedure under "Oil Pump
BDC for removal of the connecting If the taper exceeds the specified Removal."
rod bearing caps and inserts. limit, the crankshaft must be re- 4. Prior to removing pistons, re-
3. Remove the mounting nuts, moved and the journal ground to size move the ridge from each cylinder
bearing cap and lower bearing insert. for the next undersize bearing. bore as follows:
Push the connecting rod and piston If the clearance is greater than the Revolve the crankshaft until the
up into the cylinder bore with a specified limit, it will be necessary to piston to be removed is at BDC. In-
wooden hammer handle. Remove the remove the crankshaft and grind the sert a clean cloth into the bore to
upper bearing insert. journal to size for the next undersize prevent chips and carbon from fall-
4. Examine the bearing inserts. bearing. ing onto the pistons and rings. Re-
Bearings that have a scored, chipped, If the clearance is less than the move the cylinder bore ridge with
grooved, or worn surface must be ~pccified limit, try two red bearing cylinder ridge reamer tool 6011-E
replaced (Part 8-1, Section 2). Dirt inserts or a combination of red and as shown in Fig. 42 (adapter tool
or other foreign material under a blue, depending on the condition. 6011-F can be used to up-date cyl-
bearing insert may have distorted Any combination of the standard inder ridge reamer tool 60 11-A). Re-
the bearing. Sound judgment and red and/ or blue bearing inserts move the cloth. Wipe the cylinder
proper inspections are necessary may be used. bore clean.
when diagnosing bearing failures. 11. Lubricate the connecting rod 5. Rotate the crankshaft until the
5. If the wear pattern on the con- bearings with engine oil and torque piston to be removed is at BDC.
necting rod bearing indicates a radius the connecting rod cap retaining nuts Remove the connecting rod bearing
ride, inspect the crankshaft journal cap and bearing inser.ts. Push the
for the cause of the trouble. connecting rod and piston out of
If the crankshaft is the cause of the cylinder bore with a wooden
failure, it must be removed from the hammer handle. Use care to prevent
engine to be ground to fit the next striking of the cylinder bore with
undersize bearing. the connecting rod. If the cylin-
If bearing failure is due to a bent inder bore is scored or nicked
connecting rod, remove the connect- while removing the assembly, it
ing rod and piston assembly and will have to be honed or bored
check the connecting rod aligments. to repair the damage.
6. Inspect the connecting rod Install the bearing inserts and
journal for cracks, scratches, burrs, connecting rod cap on the connect-
grooves or score marks. Carefully ing rod from which they were re-
dress minor imperfections with a moved. The numbered side of the
fine oil stone. Remove the crankshaft rod and cap should match. Each
if it is damaged beyond repair and assembly is numbered so that it
grind the journal to fit the next un- can be installed in the cylinder
dersize bearing (Part 8-\, Section 2). bore from which it was removed,
7. ct'ean oil, dirt and foreign ma- if inspection proves their condi-
terial from the connecting rod jour- tion to be satisfactory.
nal, connecting rod, bearing cap and FIG. 41-Conneding INSTALLATION
bearings. Rod Side Clearance 1. Remove the bearing cap and

(159) PART 8-2-430 V-8 ENGINE 8-39
A1866-A
FIG. 42-Removing Cylinder Ridge FIG. 43-Piston Installation

bearing insert from the connecting ......._Arbor Press age to the bore may require hon-
rod of the piston to be installed. ing of the cylinder and refitting
2. Coat the cylinder bores, pistons, of the piston to correct the con-
rings and piston pins with engine oil. dition.
Tool 6735-F
Check the piston ring gaps to make 5. Push the piston assembly into
certain they are properly spaced the cylinder bore by applying pres-
(Fig. 52). sure on the piston with a wooden
hammer handle (Fig. 43). Do not
3. Install the piston and connect-
hammer on the piston dome. Hand
ing rod assembly in the cylinder
pressure will immediately indicate
bore from which it was removed, or
any condition that hinders piston
to which it was fitted. Revolve the
installation. Steps can then be
crankshaft to position the connect-
taken to remedy the .condition be-
ing rod journal at BDC. Install pis-
fore damage occurs.
ton ring compressor tool 6149-E
over the piston assembly. Make cer- 6. Apply a light coat of engine
tain the notches on the edge of the oil to the journals and bearing inserts.
t~
tool face toward the top of the Install the upper bearing insert in
piston. The wrench and turning the connecting rod. Pull the rod
screw must be positioned toward
Detail-2 Detail-3 Detail- 7 downward until the upper bearing
seats on the connecting rod journal.
Install the lower insert in the con-
A1869-A
FIG. 45-Piston Pin

Removal- Arbor Press
the inside of the "V" in the cyl-
inder block. The arrow on the
head of the piston must face
toward the front of the engine,
with the numbered side of the
rod facing toward the outside of
the cylinder block (Fig. 43).
4. Insert the piston assembly and
the compressor tool in the cylinder
bore (Fig. 43). Use care to pre-
A1867-A vent the connecting rod or bolts A1870-A
from striking the cylinder bores

FIG. 44-Piston Ring or the connecting rod journals FIG. 46-Piston Pin
Removal or Installation when installing the pistons. Dam- Removal- Manual

8-40 GROUP 8-ENGINE (160) $
necting rod cap. Install the cap and PISTON related parts are shown in Fig. 47.
insert on the connecting rod so that 1. Position the connecting rod to
the numbered side of the rod and the piston as shown in Fig. 48. Make
cap match. Install the attaching nuts certain the piston identification
and tighten them until they are snug. arrow and connecting rod num-
7. Check the fit of the connecting bered side is positioned correctly
rod bearings, following the procedure for installation of the piston in the
under "Connecting Rod Bearings proper cylinder and cylinder bank.
Replacement." ···~ BOLT 2. Press the piston pin through
8. Install the oil pump and inter- the piston and connecting rod until
mediate shaft, following the proce- it extends Y-l inch beyond the piston
dure under "Oil Pump Installation." ·. NUT boss (Fig. 49 or 50).
9. Install the oil pan, following 3. Use details 1, 2, 3, 4 and 5 of
RODB<ARING~.
steps 1 thru 8 under "Oil Pan In- tool 6135-F and install the piston,
stallation." piston pin and connecting rod assem-
10. Close the radiator drain cock. bly in a vise as shown in Fig. 51. In-
Install the cylinder block drain plugs. stall a torque wrench on the nut.
Lower the car. CAP~·
Observe the torque wrench reading
11. Install the exhaust manifold while tightening the nut until detail
and cylinder head assembly, follow- A1871-A
2 has seated against detail 1. A mini-
ing steps 3 thru 16 under "Exhaust
Manifold and Cylinder Head Install- FIG. 47-Piston, mum torque limit specification of
20 ft.-lbs is required to fully seat the
ation." Connecting Rod and Related Parts pin. Remove the tools.
12. Install the valve push rod 4. If the minimum torque read-
chamber cover, following steps 1 3. Clean the piston ring grooves.
4. Disassemble the piston, piston ing is less than 20 ft-lbs, remove
thru 6 under "Valve Push Rod the piston pin as shown in Fig. 45
Chamber Cover Installation." pin and connecting rod (Fig. 45 or
46) . Each piston and connecting or 46, and replace the connecting
13. Install the intake manifold rod. The piston pin bore of the
and related parts, following steps 2 rod should be numbered so that
they can be installed in the cyl- new connecting rod must be
thru 22 under "Intake Manifold In- checked to make certain it is
stallation/' inder bore from which they were
removed, if inspection proves their within specifications. Check the
14. Install the ground cable on diameter of the piston pin to make
the battery. Fill the cooling system condition to be satisfactory.
certain it is within specifications.
with coolant to the required level. Fill CLEANING AND INSPECTION If the piston pin is not within
the crankcase to its required level specifications, replace the piston
with the proper type and grade of Refer to Part 8-1, Section 3 for
the cleaning and inspection pro- and pin assembly. Check the fit of
lubricant.
cedures. the new piston in the cylinder bore
15. Start the engine. Check the
before assembling the piston and
oil pressure at the instrument panel REPAIRS piston pin to the connecting rod.
indicator. Check for oil, coolant, Refer to Part 8-1, Section 2 for
fuel and vacuum leaks. 5. After the rods are assembled to
the repair procedures. the pistons, the complete assembly
16. Check and adjust the initial
timing. Adjust the carburetor fuel ASSEMBLY should be checked with a connecting
and idle mixture adjustments. Adjust The piston, connecting rod and
the transmission linkage.
NUMBERED SIDE NUMBERED SIDE
On a car with an air conditioner,
OF ROD OF ROD
adjust the fast idle control linkage.
17. Add the additional coolant t
FRONT
+
FRONT
needed to fill the cooling system to LEFT RIGHT
BANK BANK
its required level while bleeding air
from the cooling system.
18. Install the air cleaner and the
air inlet duct assembly. Remove the
fender covers. Close the hood and
road test the car.
r = T o o l 61;5-F
DISASSEMBLY
l
1. Remove the bearing inserts
from each connecting rod. Index POSITION OIL SQUIRT HOLE INWARD WITH
PISTON IDENTIFICATION ARROW FORWARD
t
Detail-3
==t ··r-· Detai/-2
=;-
Detail-1
the bearings so that they may be TOWARD FRONT OF ENGINE. CAUTiON: PISTON PIN
installed in the connecting rod and
~·
PISTONS ARE NOT INTERCHANGEABLE
cap from which they were re- FROM ONE CYLINDER BANK TO THE OTHER. PISTON PIN AND __...,.
A 1872-A CONNECTING ROD ASSEMBLY 't
moved, if inspection proves their A1873-A
condition to be satisfactory.
2. Remove the piston rings from FIG. 48-Connecting FIG. 49-Piston Pin
the piston (Fig. 44). Rod and Piston Assembly Installation-Arbor Press

(161) PART 8-2-430 V-8 ENGINE 8-41
OIL RING SPACER the cleaning and inspection pro-

cedures.
INSTALLATION
1. Install the reinforcing piate on
the flywheel and align the index
marks. Install the reinforcins plate
\
..lit:' 6135~ l += 1
and flywheel on the crankshaft as a
unit. Install the mounting bolts and
it
f De~U-29Delat
0
; torque them to specifications.
Deti/-3
PISTON PIN
T Deloil- 1
Detai/-5
) 2. Install the starter motor and
transmission assembly in the car
(Part 7-2).
NNECTING ROD
ASSEMBLY OIL FILTER AND ADAPTER
,, A 1874-A The Rotunda oil filter and adapter
assembly is shown in Fig. 53.
FIG. 50-Piston Pin REMOVAL
Installation- Manual 1. Raise the car. Place a drip pan
rod alignment fixture tool or other

FIG. 52-Piston Ring under the filter assembly.
2. Turn the filter counterclockwise
suitable aligning equipment. Since
Gap Spacing and remove it from the adapter. Dis-
many makes are in use, it is recom- 9. Be sure the bearing inserts and connect the oil pressure sending unit
mended that the tool manufacturer's the bearing bore in the connecting lead wire. Remove the sending unit.
instructions be followed to assure rod and cap are clean. Foreign ma- 3. Remove the bolts securing the
that the rod is not bent or twisted terial under the inserts may distort adapter to the cylinder block. Re-
beyond the specified limits. the bearing and cause a failure. move the adapter and gasket.
6. Check the piston ring gap and 10. Lubricate all parts with light INSTALLATION
side clearance (Part 8-1, Section 2) . engine oil. Install the bearing inserts
7. Install the rings on the pistons 1. Clean the gasket surfaces at
in the connecting rod and cap with the cylinder block and adapter. Coat
from which they were removed or to the tangs fitting in the slots pro-
which they were fitted (Fig. 44). The a new adapter gasket with an oil-
vided. resistant sealer and position it on the
lower compression ring must be as-
sembled with the outside counter- FLYWHEEL cylinder block.
bore down with respect to the dome 2. Install the adapter on the cyl-
REMOVAL inder block and torque the mounting
of the piston.
8. When spacing the ring gaps on 1. Remove the automatic trans- bolts to specifications.
the piston, the oil ring spacer ex- mission from the car (Part 7-2). 3. Install the oil pressure sending
pander gap "A" must be opposite 2. Index the flywheel reinforcing unit in the adapter. Connect the lead
from the raised projections on the plate to the flywheel for installat~on wire to the sending unit.
dome of the piston with the oil ring purposes. Remove the mountmg 4. Coat the gasket on the filter
segment gaps "B" staggered one i~ch bolts, reinforcing plate and flywheel with a light film of oil. Screw the
to each side (Fig. 52). CompressiOn from the crankshaft. filter onto the adapter until it is
ring gaps "C" are to be 150° on snug; then, advance it 1,4 turn. Do
each side· of the oil ring expander not overtighten the filter.
Refer to Part 8-1, Section 3 for 5. Remove the drip pan and lower
gap (Fig. 52).
SCREW'-.s ADAPTER ASSEMBLY the car.
WASHER........_, 6. Start the engine. Operate the
WASHER~ engine at fast idle and check for oil
leakage.
7. Fill the crankcase to its re-
quired level with the proper type and
grade of lubricant.
OIL PAN
REMOVAL
1. Raise the hood and install fen-
der covers. Remove the oil level dip-
stick.
2. Revolve the crankshaft to posi-
OIL FILTER ASSEMBLY
tion the No. 1 piston 15° BTDC for
oil pan clearance purposes. (Refer
A1877-A
to the position of the rotor and/or
FIG. 51-checking crankshaft damper timing marks.)
Interference Torque Required FIG. 53-Rotunda Oil 3. Set the parking brake. Raise
to Seat Piston Pin Filter and Adapter the car.

is properly aligned; then, install the

mounting bolts and reinforcements.
Torque the bolts to specifications.
Install the oil pan drain plug and
torque it to specifications.
6. Position the floor jack and a
block of wood under the leading
edge of the oil pan; raise the engine
and remove the blocks from beneath
the insulators. Lower the engine and
FIG. 54-0il Inlet Tube remove the jack. Torque the insula-
tor to underbody side member nuts
and Sc:reen Mounting Bolts to specifications. A1880-A
7. Lower the car. Install the oil
4. Drain the lubricant from the level dipstick and oil filter. Fill the
crankcase. crankcase to the required level with FIG. 56-Relief Valve
5. To allow clearance for removal the proper grade and type of lubri- Plug Removal
of the oil pan, remove the engine cant.
front support insulator to underbody 8. Start the engine and check the of oil pressure and extensive en-
side member retaining nuts. Install oil pump pressure by observing the gine damage.
a block of wood on a floor jack and oil pressure indicator on the instru- 3. Install the oil pan and related
position the jack under the front ment panel. parts following the procedure under
leading edge of the oil pan. Raise 9. With the engine running, check "Oil Pan Installation."
the engine approximately 1Y4 inches for oil leaks.
and insert a 11h inch block of wood DISASSEMBLY
10. Remove the fender covers and 1. Remove the four screws and
between the insulators and the under- close the hood.
body side members. Remove the washers securing the oil pump cover
floor jack. OIL PUMP to the oil pump.
6. Remove the oil pan mounting REMOVAL 2. Remove the oil pump outer
bolts and reinforcements (washers). 1. Remove the oil pan, following rotor and rotor shaft assembly from
Free the oil pan from the cylinder the procedure under "Oil Pan In- the oil pump housing.
block. Remove the two mounting stallation." 3. Scrape the stake marks which
bolts securing the oil pump pick-up 2. Remove the oil pump assembly, secure the relief valve plug in the
tube and screen assembly to the oil gasket and distributor intermediate oil pump housing (Fig. 55). To re-
pump, and allow the tube and screen shaft from the cylinder block. move the plug, insert a self-tapping
to drop into the oil pan (Fig. 54). screw in the old relief hole and pry
Remove the oil pan. INSTALLATION it from the oil pump housing (Fig.
1. Install the distributor ·inter- 56). Use care to prevent loss of
CLEANING AND INSPECTION mediate shaft in the oil pump rotor the relief valve spring while per-
Refer to Part 8-1, Section 3 for shaft. Apply oil-resistant sealer to a forming this operation.
the cleaning and inspection pro- new oil· pump mounting gasket and 4. Remove the spring and relief
cedures. install the gasket on the oil pump. valve from the oil pump housing.
2. Insert the intermediate shaft
INSTALLATION CLEANING AND INSPECTION
into position in the distributor shaft
1. Coat a new oil pan gasket with hex bore. Make certain it is prop- Refer to Part 8-1, Section 3 for
oil-resistant sealer and install it on erly seated. Secure the oil pump to
the cylinder block. GASKET~
the cylinder block and torque the
SPR::USING~~~
2. Coat a new oil pick-up tube screws to specifications. Make cer-
mounting gasket with oil-resistant VALVE
tain the gasket is properly in-
sealer and install the gasket on the stalled. Oil leakage can cause loss
oil pick-up tube and screen assembly.
3. Install the oil inlet tube and
screen assembly loosely on the oil
SCREEN AND
COVER ASSEMBLY)
\
1' ':• ,,;r
pump with the upper mounting bolt
and washer.
4. Position the oil pan on the
crossmember. Swing the oil inlet tube
.\"":0;~::.· ;;·.
PLUG ~ H !:''
forward and install the inlet tube
lower mounting bolt and lock washer. "\\ GASK":TER ROTOR-"\. ;J..•"'''.'.·.
lf!/llll"'J
Make certain the inlet tube gasket
is seated properly. A leak can
cause loss of the oil pressure and
\
BOLT '
LOCK WASHER
COVER~
LOCK WASHER__.--·;
cause extensive engine damage. BOlT___--'
Torque the upper and lowtr mount- Al83"1-A
ing bolts to specifications.
5. Position the oil pan on the cyl- FIG. 55-Relief Valve FIG. 57-0il Pump
inder block. Make certain the gasket Stake Marks Assembly

(163) PART 8-2-430 V-8 ENGINE 8-43
the cleaning and inspection pro- 2. Install the outer rotor and rotor oil filler pipe bracket to the intake
cedures. shaft in the housing assembly. Fill manifold.
the housing with engine oil for prim- 2. Carefully pry the filler pipe out
ASSEMBLY ing purposes. of the cylinder block. Clean the filler
3. Install the plate, using four lock pipe with solvent.
The oil pump assembly is shown
washers and screws. Torque the INSTALLATION
in Fig. 57. screws to specifications.
1. Install the relief valve, spring 1. To replace the filler pipe, tap
and relief valve plug in the oil pump it into the cylinder block with a soft
housing. Press the plug inward until OIL FILLER PIPE AND CAP mallet until it seats.
it seats; then, stake it in place. The REMOVAL 2. Secure the oil filler pipe bracket
relief hole in the plug must not to the intake manifold and torque
be~ covered or obstructed. 1. Remove the bolt securing the the mounting bolt to specifications.
EJ ENGINE REMOVAL AND INSTALLATION

The engine removal and installa- edges of the hood, fenders and cowl 3. Drain the cooling system at the
tion procedures are for the engine to protect the paint. Place fender radiator and cylinder block. Drain
only, without the transmission at- covers on the fenders. the crankcase.
tached. A typical engine installation 2. Set the parking brake and raise 4. Remove the hood asembly. If
is shown in Fig. 58. the hood is properly aligned, index
the car. Install support stands be-
the hood to the hinge for installa-
REMOVAL neath the underbody front cross tion purposes.
1. Raise the hood and mask the member. 5. Remove the carburetor air
cleaner and air inlet duct assembly.
Disconnect the battery ground cable
from the battery.
6. Remove the radiator inlet hose
from the radiator and supply tank.
7. Disconnect the heater inlet
hoses at the intake manifold and set
the hoses to one side at the rear
of the engine. Disconnect the heater
to water pump hose at the "Y" out-
let tube connection. Disconnect the
power brake vacuum booster line
from the intake manifold connection
and position it to one side at the
rear of the engine.
8. Disconnect the heater vacuum
hose from the intake manifold fitting.
9. Disconnect the automatic trans-
mission vacuum line at the intake
manifold.
10. Remove the transmission filler
tube slotted bracket from the right
rear exhaust manifold mounting stud.
11. Disconnect the battery ground
strap at the cylinder block.
12. Disconnect the primary wires
at the coil. Disconnect the wires from
the temperature sending unit and the
fast idle solenoid (cars equipped with
air conditioning).
13. Disconnect the lead wire from
the oil pressure sending unit. Remove
the wiring loom from the retaining
clips located on the valve rocker arm
cover and position it at the rear of
the engine.
14. Disconnect the transmission
fluid inlet hose connection at the
radiator. Disconnect the transmission
fluid outlet hose connection at the
FIG. 58- Typical Engine Installation outlet line. Remove the transmission

fluid filter from the underbody side pipes from the exhaust manifolds. the fabricated lifting eyes in the
member (if the car is so equipped) . 24. Remove the clamp securing cylinder head and tighten them fin-
Cover the openings of all the con- the power steering pump outlet line ger-tight. Install the engine hoisting
nections to prevent the entrance of to the mounting bracket. Disconnect sling (tool 6000-BA) on a hoist and
foreign material. the power steering outlet line from insert the hooks through the lifting
15. Remove the fuel inlet hose the power steering pump. Drain the eyes (Fig. 59).
mounting bracket from the radiator. fluid into a clean container. 2. Install the cylinder block drain
Remove the heat shield from the fuel 25. Remove the nuts and washers plugs. Raise the hoist to support the
pump. Disconnect the fuel inlet hose which secure the engine front sup- weight of the engine. Remove the
and vapor outlet hose from the fuel port insulators to the underbody side engine from the repair stand.
pump. members. 3. Install the alternator and mount-
16. On a car with an air condi- 26. Remove the bolts securing the ing bracket on the engine as a unit.
tioner, remove the fan drive clutch starter to the converter housing. Re- Install the water pump pulley-alter-
to water pump pulley retaining bolts. move the starter and dust seal. nator pulley drive belts. Adjust the
Remove the fan drive clutch, fan 27. Disconnect the lead wires from belts to obtain the specified belt
and compressor pulley from the car the alternator. Remove the trans- tension.
as a unit. mission oil cooler inlet and outlet 4. Align the converter to flywheel
17. Remove the fan blade assem- transfer line retaining clip from the mounting studs with the mounting
bly and spacer from the water pump cylinder block. bores in the flywheel.
pulley. 28. Revolve the flywheel and re- 5. Install the engine in the car,
18. Disconnect the radiator outlet move the flywheel to converter re- making certain the converter studs
hose at the water pump. taining nuts. are seated in their respective flywheel
19. On a car with an air condi- 29. Remove the engine lateral bores. Install the lower converter
tioner, remove the radiator lower restrictor from the converter hous- housing to cylinder block mounting
mounting bolts. Remove the bolts ing. Remove the lower converter bolts and torque them to specifica-
securing the radiator to the conden- housing to cylinder block retaining tions. Install the engine lateral re-
ser. Remove the bolts securing the bolts. strictor assembly on the converter
radiator to the radiator suppoit. Re- 30. Install a transmission support and the underbody side rail. Torque
move the radiator. jack under the transmission. the lateral restrictor bracket to con-
Disconnect the compressor clutch 31. Remove the upper converter verter mounting bolt to specifica-
wire at the bullet connector. Remove to cylinder block retaining bolts. tions. Torque the outer bracket
the compressor support bracket. 32. On a car with an air condi- mounting bolts to specifications.
Remove the compressor high and tioner, remove the compressor sup- 6. Install the insulator to under-
low pressure service valve caps and port bracket from the cylinder head body side member retaining nuts
"front seat" the high and low pres- and the intake manifold. and washers. Torque the nuts to
sure service valves. 33. Screw engine lifting eyes (tool specifications.
Loosen the manifold gauge port 6000-K) into the exhaust manifolds 7. Remove the lifting eyes, chains
caps slightly and slowly bleed the (Fig. 59). and sling from the engine. Install the
refrigerant from the compressor. 34. Remove the lower front mount- lower front cylinder head mounting
Tighten the port caps when all the ing bolt from each cylinder head. bolts and torque them to specifica-
refrigerant has been bled. Install fabricated lifting eyes and tions.
Remove the high and low pressure secure them to the cylinder heads 8. Remove the transmission sup-
service valves and muffler assembly finger-tight. Install two fabricated port jack. Using four nuts and lock
from the compressor. Cover all open- lifting chains and hooks on the upper washers, secure the converter to the
ings of the compressor and service chain links that are secured to the flywheel and torque the nuts to speci-
valves tightly with tape to prevent lifting bar of tool 6000-B. Insta11 fications. •
condensation. Position the service the engine hoisting sling (tool 9. Install the starter assembly,
valves and lines against the fender 6000-BA) on a hoist and insert the starter cable, dust seal and starter
apron for engine clearance purposes. lifting hooks through the lifting eyes cable mounting bracket. Tighten the
Disconnect the fast idle control (Fig. 59). Fabricate the lifting mounting bolts. Connect the starter
rod at the accelerator shaft (bell chain, hook and bracket assemblies cable to the starter.
crank) assembly. as shown in Fig. 60. 10. Connect the resonator inlet
20. Remove the radiator lower 35. With assistance, remove the pipes to the exhaust manifolds and
mounting bolts. Remove the bolts engine from the car. Guide the en- torque the mounting nuts to specifi-
securing the nk!iator to the radiator gine carefully to prevent damage. cations.
suoport. Remove the radiator. 36. Remove the fan - alternator 11. Install the converter access
21. Disconnect the transmission drive belts. Remove the alternator plate and tighten the mounting bolts.
and accelerator linkage at the accel- and mounting bracket as a unit from Install the transmission splash shield
erator shaft assembly (bell crank). the engine prior to installing the and tighten the mounting bolts.
Secure the linkage to the dash panel engine on the work stand. 12. Install the transmission oil
for engine clearance purposes. inlet and outlet transfer lines and
22. Remove the access cover from INSTALLATION bracket as a unit on the cylinder
the converter housing. Remove the 1. Screw engine lifting eyes (tool block and tighten the mounting bolt.
underbody splash shield located at 6000-K) into the exhaust manifolds. 13. Connect the lead wires to the
the lower front of the transmission. Remove the lower front mounting alternator.
23. Remove the resonator inlet bolt from each cylinder head. Install 14. Connect the power steering

(165) PART 8-2-430 Y-8 ENGINE 8-45
WELD THE 1f2" CHAIN

BOLT-EYES TO THE
RESPECTIVE CYLINDER
HEAD BOLTS I
~Y2" ~\
.r..
WELDING<._o ·. EYE-BOLT
POINTS ~ ~ !CUT-Off)
~
/
CYLINDER HEAD BOLT 1f2"
CONNECTING LINK
o/16" HOOK
A1883-A
FIG. 59-Engine Lifting Tools Installed FIG. 60-lnstruc:tions for Fabricating

Engine Lifting Eyes & Chains
pump outlet line to the power steer~ bly in the retammg clips. Connect hose to the water pump and tighten
ing pump. Install the clamp on the the temperature sending unit, coil the retaining clamp.
power steering pump outlet line and and oil pressure sending unit wires 26. Connect the transmission inlet
secure the line to the mounting to their respective units. and outlet lines to the radiator. Con-
bracket. 22. On a car with an air condi- nect the transmission oil filter inlet
15. Install the three upper con- tioner, connect the lead wire to the hose to the filter and tighten the
verter housing to cylinder block fast idle solenoid. clamp.
mounting bolts and lock washers and Install the low pressure valve 27. On a car with an air condi-
torque them to specifications. screen. Using two new gaskets be- tioner, install the fan drive clutch
16. Install the transmission oil tween the service valves and the and fan assembly, compressor drive
filler tube mounting bracket on the compressor to prevent leaks, secure pulley, mounting bolts, and washers
right exhaust manifold. Torque the the service valves to the compressor as a unit on the water pllmp pulley.
exhaust manifold mounting bolt to and torque the retaining screws to Tighten the mounting bolts.
specifications. Bend the locking tab specifications. Purge the compres- Install the compressor drive belt
of the washer. Connect the battery sor. and adjust the compressor to obtain
ground strap to the cylinder block. Connect the air conditioner clutch the specified belt tension. Tighten
17. Connect the vacuum hoses to lead wire to the bullet connector. the compressor adjusting bracket and
the intake manifold fitting. 23. Install the transmission fluid support bracket bolts.
18. Connect the heater outlet hose filter (if the car is so equipped) on 28. Install the fan blade and spacer
"Y" connecting tube to the water the underbody side member. Connect on the water pump pulley and torque
pump inlet hose. Tighten the clamp. the inlet line to the lower filter hose the mounting bolts to specifications.
Connect the heater inlet hoses to the and tighten the clamp. Connect the fuel inlet hose and the
intake manifold connector. Tighten 24. Tighten the radiator drain cock vapor outlet hose to the fuel pump.
the hose clamps; then, gather the and position the radiator in the en- Install the fuel pump heat shield.
vacuum hoses and the heater inlet gine compartment. Install the lowt~r
and outlet hoses together and in~ radiator to the condenser (if the 29. Install the fuel inlet hose and
stall the retaining band. vehicle is so equipped) mounting bracket on the radiator and tighten
19. Connect the accelerator linkage holts. Install the insulators under the mounting bolts.
to the accelerator shaft assembly the radiator; then, loosely install the 30. Connect the upper radiator
(bell crank). radiator lower mounting bolts. Align inlet hose to the radiator and the
20. On a car with an air condi- the radiator and condenser uppt~r supply tank. Tighten the hose clamps.
tioner, connect the fast idle control mounting bolt holes to the mounting Connect the battery ground strap at
rod to the accelerator shaft assembly holes in the air deflector. Install and the battery.
(hell crank). tighten all mounting bolts. 31. Fill the cooling system to its
21. Instal\ the wiring loom asscm- 25. Connect the radiator outlet required level. Add fluid to the power

steering reservoir to bring it up to and perform or check the following 35. On a car with an air condi-
the required level. items: tioner, check the air conditioner sys-
32. Fill the crankcase to the re- Check for oil, coolant and vacuum tem and charge it as necessary.
quired level with the proper grade leaks.
36. Install the carburetor air clean-
and type of lubricant. Adjust and check the initial and
er and duct assembly. Install the hood
33. Start the engine and check the advance timing.
assembly and adjust it, if necessary.
oil pressure at the instrument panel Perform carburetor idle and fuel
Remove the masking tape from the
indicator. mixture adjustments.
hood, fender and cowl.
34. Run the engine until normal Perform carburetor, accelerator
operating temperature is indicated and transmission linkage adjustments. 37. Road test the car.

To perform the operations in this move the water pump and fan as an Crankshaft Sprockets Removal."
section, it will be necessary to re- assembly. 7. Crank the engine until the tim-
move the engine from the car and 3. Remove the crankshaft damper ing marks on the sprockets are posi-
install it on a work stand. mounting bolt and washer. Install tioned as shown in Fig. 31: Remove
the puller on the damper and remove the lock plate, fuel pump eccentric,
CRANKSHAFT the damper (Fig. 28). Remove the drive bushing and wear plate. Re-
The crankshaft and related parts Woodruff key. move the camshaft sprocket and tim-
are shown in Fig. 61. 4. Remove the power steering ing chain as a unit.
pump and reservoir. 8. Remove the crankshaft sprocket
REMOVAL 5. Remove the cylinder front cover, (Fig. 33).
1. Remove the alternator and timing pointer, oil level dipstick tube 9. Invert the engine on the work
bracket. Remove the spark plugs to and the cover mounting gasket. Re- stand. Remove the flywheel. Remove
allow easy rotation of the crankshaft. move the crankshaft front oil slinger. the oil pan and gasket. Remove the
2. Disconnect the fuel inlet line 6. Check the timing chain deflec- oil pump.
at the carburetor. Remove the fuel tion, following steps 2, 3 and 4 un- 10. Make sure all bearing caps
pump and fuel pump push rod. Re- der "Timing Chain, Camshaft and (main and connecting rod) are
DAMPER
~-SEAL
~'
WOODRUFF
t WASHER
KEY
SCREW
MAIN BEARING CAPS

TIMING CHAIN
SCREWi
A1885-A
FIG. 61-Crankshaft and Related Parts

(167) PART 8-2-430 V-8 ENGINE 8-47 .I
marked so that they can be in- 12. Pry the crankshaft forward
stalled in their original locations. against the thrust surface of the
Remove the connecting rod bearing upper half of the bearing (Fig. 64).
caps. Turn the crankshaft until the 13. Hold the crankshaft forward
connecting rod from which the cap and pry the thrust bearing cap to the
is being removed is down and remove rear (Fig. 64). This will align the
the cap. Push the connecting rod and thrust surfaces of both halves of the
piston assembly up into the cylinder bearing.
11. Remove the main bearing caps. 14. Retain the forward pressure
12. Carefully lift the crankshaft on the crankshaft. Tighten the cap
out of the block so that the thrust bolts to specifications (Fig. 64).
bearing surfaces are not damaged. 15. Force the crankshaft toward
Handle the crankshaft with care the rear of the engine.
to avoid possible fracture or dam- 16. Install a dial indicator so that
age to the finished surfaces. the contact point rests against the
crankshaft flange and the indicator
CLEANING AND INSPECTION axis is parallel to the crankshaft axis
Refer to Part 8-1, Section 3 for (Fig. 65).
the cleaning and inspection proce- 17. Zero the dial indicator. Push
dures. FIG. 63-Cutting Rear the crankshaft forward and note the
Main Bearing Seal in Cylinder Block reading on the dial.
REPAIRS 18. If the end play exceeds the
To finish journals, dress minor 5. Place the upper main bearing wear limit, replace the thrust bear-
imperfections, etc., refer to Part 8-1, inserts in position in the bores with ing. If the end play is less than the
Section 2. the tang fitting in the slot provided. minimum limit, inspect the thrust
6. Install the lower main bearing bearing faces for scratches, burrs,
INSTALLATION nicks, or dirt. If the thrust faces are
inserts in the bearing caps.
1. Remove the rear journal oil 7. Install a new rear journal oil not defective or dirty, they probably
seal from the block and rear main seal in the block (Fig. 62) . After were not aligned properly. Install the
bearing cap. Remove the rear main installation, cut the ends of the thrust bearing and align the faces
bearing cap to block side seals. seals flush (Fig. 63). It is very im- following the recommended proce-
2. Remove the main bearing in portant that the seal be cut flush dure (steps 11, 12, 13 and 14), then
serts from the block and bearing with the surface of the cylinder check the end play.
caps. block. This prevents rough edges 19. Install new bearing inserts in
3. Remove the connecting rod which may project from the the connecting rods and caps. Check
bearing inserts from the connecting groove and lodge between the the clearance of each bearing fo11ow-
rods and caps. bearing cap and cylinder block. ing the procedure under "Main Bear-
4. If the crankshaft main bearing 8. Carefully lower the crankshaft ing Replacement."
journals have been refinished to a into place. Be careful not to dam- 20. After the connecting rod bear-
definite undersize, install the correct age the bearing surfaces. Install ings have been fitted, apply a light
undersize bearings. Be sure the bear- the Woodruff key in th.e crankshaft. coat of engine oil to the journals and
ing inserts and bearing bores arc Install the crankshaft sprocket (Fig. bearings.
clean. Foreign material under the in- 34) with the timing mark facing the 21. Turn the crankshaft throw to
{ serts may distort the bearing and front of the car. the bottom of its stroke. Push the
cause a failure. 9. Check the clearance of each piston all the way down until the rod
main bearing as follows: bearing seats on the crankshaft
Place a piece of Plastigage on the journal.
crankshaft journal the full width of 22. Install the connecting rod cap.
the journal and about 1;4 inch off- Torque the nuts to specifications.
center. Follow steps 10 and 11 under 23. After the piston and connect-
"Main Bearing Replacement." ing rod assemblies have been in-
10. After the bearings have been stalled, check the side clearance be-
fitted, apply a light coat of engine tween the connecting rods on each
oil to the journals and bearings. In- connecting rod crankshaft journal
stall new seals in the rear main bear- (Fig. 41).
ing cap and install the rear main 24. Clean the oil pan, oil pump
bearing cap by following steps 15 and oil pump screen. InstaJI the oil
thru 19 under "Main Bearing Re- pump and oil pan.
placement." Install all the bearing 25. Position the flywheel on the
caps, except the thrust bearing cap crankshaft. Install the retaining bolts.
(No. 3 bearing). Be sure that the Torque the bolts to specifications.
main bearing caps are installed in 26. Invert the engine on the work
Too/-6701 -B A 1886-A their original locations. Torque the stand. Install the timing chain, cam-
hearing cap bolts to specifications. shaft sprocket, wear plate, fuel pump
FIG. 62-lnstalling Rear 11. Install the thrust bearing cap eccentric, drive bushing and lock
Main Bearing Seal in Cylinder Block with the bolts finger-tight. plate by following steps 2 thru 4 un-

8-48 GROUP I-ENGINE (168)
PRY BACKWARD
PRY CRANKSHAFT FORWARD PRY CAP BACKWARD TIGHTEN CAP

A1888-A
FIG. 64-Thrust Bearing Alignment

der "Timing Chain, Camshaft and stall the fuel pump shield. ing. The camshaft bearing inside di-
Crankshaft Sprockets Installation." 32. Connect the fuel inlet line at ameters decrease in size from the
27. Install the oil slinger on the the carburetor. Install the generator front of the engine toward the rear
crankshaft, with the concave side of and bracket. Install the spark plugs. (refer to Part 8-3).
the slinger facing the rear of the 33. Install the engine in the car. 1. Remove the camshaft, the fly-
engine. wheel and the crankshaft. Push the
28. Install the cylinder front cover, CAMSHAFT BEARING pistons to the top of the cylinders.
power steering pump and reservoir, REPLACEMENT 2. Remove the camshaft bearing
and crankshaft damper following Camshaft bearings are prefinished bore plug from the rear of the cylin-
steps 1 thru 4 under "Cylinder Front to size for standard and undersize der block, with the shaft of tool
Cover Installation." camshaft bearing journals. The bear- 6261-F or a long rod.
29. Coat new water pump gaskets ings are not interchangeable from 3. Remove the camshaft bearings
with water-resistant sealer. Install the one cylinder block bore to another. (Fig. 66).
gaskets, water pump, oil level dip- They must be installed in the bore 4. Clean the camshaft rear bear-
stick tube bracket, and power steer- designated by the number stamped ing bore plug recess thoroughly.
ing reservoir mounting bracket. on the outside diameter of each bear- Clean and inspect the camshaft bear-
Torque the water pump mounting
bolts to specifications. Torque the
power steering pump reservoir
bracket mounting bolts to specifica-
tions. Tighten the bypass hose clamp.
30. Install the fuel pump push rod
in the cylinder front cover. Install a
new cup-type plug in the top of the
cover.
31. Coat a new fuel pump gasket
with an oil-resistant sealer. Install the
gasket and fuel pump on the cylinder
front cover and torque the mounting
bolts to specifications. Connect the
fuel vapor line to the fuel pump. In-
Adapter Set,
Tooi-6261-AC
/Clamp
;'!.J
FIG. 65-Crankshaft Clamp A1890-A
End Pia~ FIG. 66-Camshoft Bearing Removal and Installation

(169) PART 8-2-430 V-8 ENGINE
INSTAll FRONT BEARING 0 005-0.020 INCH the cylinder front cover. Remove the
BElOW FRONT FACE OF BLOCK
15. Remove the spark plugs from
access plug from the cylinder front the cylinder heads with a spark plug
cover, and remove the fuel pump deep socket wrench. Due to the in-
push rod. stallation angles of the spark plugs,
5. Remove the wires from the coil. care must be used to prevent
Remove the overflow hose from the breakage.
supply tank. Remove the mounting 16. Loosen the four rocker arm
bolts securing the coolant supply support bolts on each cylinder bank,
tank and brace to the intake mani- evenly and alternately, two turns
fold and water pump. Remove the at a time until valve spring tension
supply tank, coil, thermostat and is removed. Remove the rocker arm
gasket from the engine. assemblies from the cylinder heads.
6. On a car with an air condi- 17. Remove the valve push rods
FACING DOWNWARD tioner, remove the bolts securing from the cylinder heads. Retain the
A1891-A
the compressor mounting bracket to push rods in their order of re-
the cyJinder block. Remove the com-
FIG. 67 -Camshaft pressor and bracket assembly.
moval for inspection and replace-
ment purposes.
Front Bearing Measurement 7. Loosen the clamp securing the 18. Remove the cylinder head
bypass hose to the intake manifold. mounting bolts. Secure the cylinder
ing bores of the cylinder block Remove the water pump mounting head holding fixtures to the cylinder
Make certain the oil holes and bolts. Remove the water pump as- head with intake manifold mount-
grooves are open and the cylinder sembly and the oil dipstick tube ing bolts (Fig. 19). All cylinder
bore webs are not nicked, cracked. bracket. head work operations can be per-
or broken. 8. Remove the bolt securing the formed with the fixtures in place.
5. Install new camshaft bearings crankcase oil filler tube bracket to 19. Lift the cylinder heads off the
(Fig. 66). The notch on No. 1 bear- the intake manifold. Remove the oil cylinder block locating dowels and
ing must face toward the front of the filler tube and ventilation cap assem- the cylinder block. Remove the
engine with the notch downward bly from the cylinder block. Remove gaskets. Never pry between the
toward the bottom of the cylinder the oil level dipstick. cylinder heads and cylinder block.
block. The No. 1 bearing must be 9. Remove the exhaust manifolds This may cause damage to the
at least 0.005 to 0.020 inch below and steel gaskets from the cylinder finished surfaces.
the front face edge of the cylinder heads. 20. Remove the hydraulic valve
block bearing bore (Fig. 67). Bear- 10. Remove the clamp securing lifters. Index the lifters so that they
ings numbered 2, 3, 4 and 5 mus1 the ventilation tube to the mounting can be installed in their original
be installed with the split in the bracket at the left rear of the intake bores if inspection reveals a satis-
bearing facing upward toward the manifold. Remove the screw secur- factory condition.
top of the cylinder block. ing the ventilation regulator valve 21. Index the flywheel and back-
6. Coat the edges of a new cam- fitting to the intake manifold. Dis- up plate to the crankshaft flange for
shaft bearing bore plug with an oil- connect the rubber hoses from the installation purposes. Remove the fly-
resistant sealer. Install the plug with carburetor spacer and the adapter wheel and plate from the crankshaft.
the cup-side facing inward. Drive plate located on the valve push rod 22. Remove the crankshaft damp-
the plug in with a block of wood chamber cover. Remove the ventila- er mounting bolt and washer from
until it is flush or slightly below the tion tube, hoses, regulator valve and the crankshaft. Remove the crank-
surface of the cylinder block. fitting from the engine as a unit. shaft damper (Fig. 28). Remove the
7. Install the camshaft, crankshaft, 11. Remove the distributor retain- Woodruff key.
flywheel and related parts. Install the ing clamp and nut. Pull the distribu- 23. Remove the power steering
engine in the car. tor gently from the cylinder block. pump and reservoir.
Notice the distance the rotor turns 24. Remove the cylinder block
ENGINE DISASSEMBLY as the distributor is removed. This front cover, timing pointer, oil level
1. Install the engine on an engine will be helpful when the distribu- dipstick tube and the cover mount-
repair stand. Use the special steel tor is installed, for the mating of ing gasket. Remove the oil slinger.
bolts provided with the engine the helical gears will turn the dis- 25. Remove the wear plate, fuel
stand adapter when mounting the tributor shaft. pump eccentric, drive bushing and
engine on the repair stand. 12. Remove the intake manifold lock plate from the camshaft. Re-
2. Make certain that all oil and mounting bolt clamps, ventilation move the camshaft sprocket and tim-
coolant has been drained from the bracket and retaining nut. Remove ing chain as a unit.
engine. the intake manifold, carburetor and 26. Remove the crankshaft sprock-
3. Remove the spark plug wires related parts as a unit. Remove the et (Fig. 33). Remove the Woodruff
from the rocker arm covers and mounting gaskets from the cylinder key.
spark plugs. Remove the distribuior head. 27. Turn the cylinder block to a
cap and spark plug wires as a unit. 13. Remove the valve rocker arm vertical position, front end facing
Disconnect the fuel line at the car- covers and gaskets from the cylinder upward.
buretor and the fuel filter. Discon- heads. 28. Remove the engine oil filter,
nect the vacuum lines from the dis- 14. Clean the valve push rod adapter and gasket. Remove the oil
tributor and carburetor . chamber cover. Remove the valve pan and gasket.
4. Remove the fuel pump from push rod chamber cover and gasket. 29. Remove the oil pump and in-

let screen assembly, intermediate

shaft and the oil pump mounting
·gasket from the cylinder block.
30. Remove the camshaft from
the cylinder block. Use care to pre-
vent damage to the camshaft bear-
ings.
31. Remove the cylinder ridge
from the top of the cylinder bores
(Fig. 42) . Always insert a clean
cloth in the cylinder bore to catch
all metal chips and shavings. Re-
move the cloth and wipe the bore
clean before removing the piston.
32. Rotate the crankshaft until the
piston to be removed is at BDC.
Remove the connecting rod bearing
cap and bearing inserts. Push the
connecting rod and piston out of the
cylinder bore with a wooden ham-
mer handle. Use care to prevent
the connecting rod from striking
and damaging the cylinder bore.
Place the bearing caps and inserts
on the connecting rods so that the
numbered sides match. The assem-
blies are numbered so that they
can be installed in their respective
cylinders if inspection reveals a
satisfactory condithm.
Repeat the procedure for the re-
maining cylinders.
33. Turn the cylinder block so
that the bottom faces upward. Re-
move the main bearing caps and
lower inserts. Remove the crankshaft
and upper bearing inserts. Keep all
main bearing caps and inserts in
their order of removal, for inspec- A1892-A
tion and installation purposes.
34. Remove the rear oil seal and FIG. 68-Cylinder Block Plugs and FiHings
side seals from the rear main bearing
cap and the cylinder block. spect the cylinder block plug bore. moved because of wear or damage
35. If it is necessary to replace the Coat the edges of the plug with (Fig. 66). To install camshaft bear-
camshaft bearings, refer to "Cam- suitable sealing compound (oil or ings, refer to "Camshaft Bearing
shaft Bearing Replacement" in this water-resistant) and drive it into Replacement" in this section of the
section of the manual for the proper the cylinder block until it is seated. manual.
procedure. This operation should 2. To replace a small expansion 3. Install a new rear crankshaft
only be performed after inspec- plug, drill a 11'4 -inch hole in the main bearing oil seal in the cylinder
tion of the cylinder block has been center of the plug and pry it out block (Figs. 62 and 63).
completed. with a small pin punch. Clean and 4. Place the upper main bearing
inspect the cylinder block plug bore. inserts into position in the cylinder
CYLINDER BLOCK PLUGS block bore, with the tang of the bear-
Coat the edges of the plug with
AND FITTINGS ings in the slot provided. Lubricate
suitable sealing compound (oil or
The location of various cylinder water-resistant) and drive it into the bearings lightly with engine oil.
block plugs and fittings used in the the cylinder block until it is seated. If the crankshaft main journals
cylinder block are shown in Fig. 68. have been reground to a definite
ENGINE ASSEMBLY undersize install the correct under-
EXPANSION PLUG 1. Turn the cylinder block on the size bearing inserts to fit the
REPLACEMENT repair stand so that the bottom faces journals.
1. To replace a large expansion upward. Coat the cylinder block 5. Carefully install the crankshaft.
plug, drill a lh -inch hole ~n the drain plugs with water- resistant Install the lower main bearing in-
center of the plug. Remove the plug sealer and install them in the cylin- serts, and main bearing caps. Make
with a clutch pilot bearing remover der block. certain that they are installed in
(tool 7600-E) or pry it out with 2. Install new camshaft bearings their original position. Torque the
a large drift punch. Clean and in- if the original bearings were re- mounting holts to specifications.

(171)
PART 8-2-430 V-8 ENGINE 8-51
6. Check the clearance of the main cylinders is at BDC during the in- moved. Make certain they are prop-
bearings, following the procedure stallation procedure. erly seated in the hydraulic valve
under "Main Bearing Replacement." 12. Check the fit of the connecting lifters.
7. Check the crankshaft end play rod bearings, following the proce- 24. Position the rocker arm and
(Fig. 65). Force the crankshaft for- dure under "Connecting Rod Bear- shaft assemblies on the cylinder
ward as far as possible and release ing Replacement." heads. Install washers on the bolts.
it. Connect a dial indicator so that 13. Coat the camshaft journals Insert the bolts through the rocker
the contact point rests against the and bearings with engine oil. Install arm shaft supports and tighten them
crankshaft flange. Set the indicator the camshaft. Use care to prevent until they are slightly engaged in
at zero, then force the crankshaft the camshaft from damaging the the cylinder heads.
toward the rear and release it. End bearings or dislodging the rear Seat the end of the push rods in
play limits should not exceed speci- camshaft bearing plug. the rocker arm ball sockets. Make
fications. 14. Install the timing chain, cam- certain the push rods are properly
8. Turn the cylinder block to a shaft and crankshaft sprockets, wear seated in the hydraulic valve
vertical position with the front end plate, fuel pump eccentric, drive lifters.
facing upward. bushing, lock plate and the oil sling·- Tighten the rocker arm shaft sup-
9. Rotate the crankshaft to posi- er, following steps 1 thru 5 under port mounting bolts on each cylinder
tion the connecting rod journal for ''Timing Chain, Camshaft and Crank- bank evenly and alternately, two
No. 1 cylinder at BDC. Coat all the shaft Sprockets." turns at a time, until they are snug.
cylinder bores, crankshaft journals, 15. Coat a new cylinder front Torque the mounting bolts to speci-
pistons, pins and piston rings with cover gasket with an oil-resistant fications.
engine oil. Make certain the piston sealer and position it on the cylinder 25. Check the valve clearances
ring gaps are spaced properly (Fig. block. Install the cylinder front and correct if necessary (Part 8-1,
52). cover assembly, coolant overflow Section 2).
10. Install the piston assemblies, hose clip, and timing pointer. Torque 26. Coat a new valve push rod
Nos. 1 and 5, in the cylinder block the mounting bolts to specifications. chamber cover gasket with an oil-
as follows: 16. Install the power steering resistant sealer and position it on the
Install the piston ring compressor pump on the crankshaft. Torque the cylinder block and cylinder head.
on the piston, and tighten the screw. pump to cylinder front cover mount- Install the chamber cover and torque
Make certain that the notches on ing bolts to specifications. the mounting bolts to specifications.
the edge of the tool face upward 17. Install the Woodruff key in the Torque the center end bolts first.
toward the top of the piston, with crankshaft. Position the crankshaft 27. Install the crankcase oil filler
the wrench and turning screw damper on the crankshaft. MakE~ tube in the cy1inder block.
positioned toward the inside of the certain the keyway is aligned with 28. Position new intake manifold
"V" in the cylinder block (Fig. the Woodruff key in the crank- gaskets on the cylinder heads, with
43). shaft. Press the damper onto the the word "FRONT" (located on the
Install the piston assembly in the crankshaft until it seats against the gasket) facing toward the front of
cylinder bore to which it was fitted. power steering pump as shown in the engine.
The arrow on the dome of the pis- Fig. 29. Install the damper retaining 29. Carefully install the intake
ton must face toward the front bolt and washer. Torque the bolt to manifold. Make certain the gasket
of the engine with the numbered specifications. is positioned correctly. Install the
side of the rod facing outward 18. Rotate the engine so that the retaining clamps, crankcase oil filler
toward the side of the cylinder top of the cylinder block faces up- tube bracket and the mounting bolts.
blo~k. When installing the piston ward. Torque the mounting bolts in .se-
assemblies, use care to prevent the 19. Lubricate the hydraulic valve quence (Fig. 11 ) to specifications.
connecting rod bolts from striking lifters and install them in the bores 30. Connect the previously assem-
the crankshaft journal. Do not from which they were removed. bled crankcase ventilation tube, rub-
hammer on the dome of the piston 20. Position the new cylinder head ber hoses, clamps, regulator valve
when installing the assembly in gaskets over the cylinder block dow- and fitting to the carburetor and
the cylinder bore. Apply an even els. Cylinder head gaskets are in- adapter. Adjust the assembly to posi-
pressure with a wooden hammer terchangeable for use on either tion it properly and tighten the hose
handle. By applying an even pres- cylinder bank. The word "TOP" clamps.
sure on the piston, any obstruc- (stamped on the J!asket) must al- 31. Secure the bracket of the regu-
tion will be immediately noted. ways face upward when the gas- lator valve fitting to the intake mani-
The piston can then be removed, kets are installed. fold. Secure the ventilation tube to
checked and installed correctly. 21. Carefully install the cylinder the mounting bracket.
Install the selective-fit connecting head assemblies. Remove the cylin- 32. Coat the valve rocker arm
rod hearings and caps. The num- der head holding fixtures from the cover gaskets with an oil-resistant
bered side of the cap must match cylinder heads. sealer. Install the rocker arm cover
and _be on the numbered side 22. Install the cylinder head and gasket on the cylinder head and
of the rod. Install the retaining nuts mounting bolts. Tighten the cylinder torque the mounting bolts to specifi-
and tighten them until they are snug. head bolts to specifications by mak- cations.
11. To install the remaining piston ing three cold torque applications 33. Rotate the crankshaft to posi-
assemblies, repeat step 10. Always as shown in Fig. 20. tion the No. 1 piston on TDC of
rotate the crankshaft so that the 23. Install the push rods in the the compression stroke. Hold a
crankshaft journal for eaeh set of hare<; from which they were re- thumb over the spark plug hole

to determine the compression then, torque the mounting bolts to 46. Coat new water pump gaskets
stroke. Also, observe the position specifications. with an oil-resistant sealer and in-
of the timing marks on the crank- 39. Coat a new oil pan gasket stall them on the cylinder block. In-
shaft damper. . with oil-resistant sealer and install it stall the water pump, oil dipstick
Set the distributor rotor in position on the cylinder block. Install the oil tube bracket and the power steering
to fire the No. 1 cylinder spark plug, pan, reinforcements and mounting reservoir mounting bracket. Torque
with the points just breaking. Mark bolts. Torque the mounting bolts to the water pump mounting bolts to
this location by scribing a line on specifications. specifications. Tighten the bypass
the distributor housing. Turn the 40. Turn the engine so that the hose clamps.
rotor counterclockwise a distance top faces upward. 47. Install the power steering
equal to the amount observed dur- 41. Connect the vacuum line to the pump reservoir bracket lower mount-
ing the disassembly procedure ( ap- carburetor and the distributor. Con- ing bolt and torque it to specifica-
proximately 1/s turn). Install the dis- nect the fuel line to the carburetor tions. Connect the rubber hose to the
tributor. The shaft and rotor will and the fuel filter. power steering pump and reservoir.
turn clockwise as the distributor 42. Install the distributor cap and Tighten the clamps.
gear meshes with the camshaft the spark plug wires as a unit onto 48. On a car with an air condi-
gear. the distributor. Install the spark plug tioner, install the air conditioning
Check the position of the rotor wires on the valve rocker arm cover compressor and mounting bracket
with the scribed line on the housing. bracket and the spark plugs. Only assembly on the cylinder block.
If the installation is correct, install the No. 1 position is marked on Tighten the mounting bolts.
the distributor clamp, nut and lock the distributor cap. The distributor
washer. Final timing of the dis- 49. Install the thermostat in the
rotor rotates counterclockwise;
tributor must be made after the therefore, connect the wires in the intake manifold. Make certain the
engine is operating in the car. thermostat is positioned correctly
firing sequence of 1-5-4-2-6-3-7-8
34. Install the spark plugs and following this counterclockwise as noted on the front of the ther-
torque them to specifications. Due mostat.
rotation. Position the No. 7 and 8
to the spark plug installation angle, wires correctly on the cover brack- 50. Coat a new supply tank mount-
use care to prevent breakage. et to prevent inductance. ing gasket with water-resistant sealer
35. Insert the fuel pump push rod 43. Install the oil filter adapter and position it on the intake mani-
into the bore of the cylinder front and a new gasket on the cylinder fold. Remove the water pump right-
cover. Install an access plug in the block. Torque the mounting bolts to upper mounting bolt.
top of the cover. specifications. Install the oil pressure 51. Install the coolant supply tank
36. Coat a new fuel pump gas- sending unit in the oil filter adapter. and ignition coil as a unit on the
ket with an oil-resistant sealer. Install Coat the engine oil filter gasket with intake manifold and torque the
the gasket and fuel pump on the a light film of oil and turn the filter mounting bolts to specifications. In-
cylinder front cover. Torque the until it is snug; then, advance the sert the water pump mounting bolt
mounting bolts to specifications. filter ~ turn. Do not overtighten through the bracket and torque it to
37. Turn the engine so that the the filter. specifications.
bottom faces upward. 44. Insert two new cylinder block 52. Connect the overflow hose to
38. Insert the distributor interme- thermostats into the cylinder block, the supply tank and insert it through
diate shaft into the oil pump. Coat a with the thermostat bulbs facing in- the retaining clip.
new oil pump mounting gasket with ward. 53. Install the flywheel and back-
an oil-resistant sealer and position 45. Install the coolant bypass hose ing plate on the rear crankshaft
it on the cylinder block. Install the and clamps on the intake manifold flange. Torque the mounting bolts to
oil pump and inlet screen assembly; as a unit. specifications.

{173) PART 8-3-SPECIFICATIONS 8-53
PART SPECIFICATIONS
8-3
NOTE: All specifications are given in inches unless otherwise noted.
GENERAL ENGINE VALVE MECHANISM

MODEL PREFIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EDJ VALVE CLEARANCE* . . . . . . . . . . . . . . . . . . . . . • . . 0.078-0.178
~--------------------------------------------~ *Clearance specified is obtained at the valve stem tip with
PISTON DISPLACEMENT-Cubic Inches . . . . . . . . . . . . . . 430 the hydraulic valve lifter co!lapsed.
COMPRESSION RATIO . . . . . . . . . . . . . . . . . . . . . . . . 10.1:1 VALVE STEM DIAMETER
r---------------------------------------------~ Standard
BRAKE HORSEPOWER @ Specified rpm. . .... 320 @ 4600
Intake (Coded Red) ................ 0.3712-0.3717
TORQUE-ft-lbs @ Specified rpm . . . . . . ..... 465 @ 2600 (Coded Green) ............. 0.3717-0.3722
Exhaust (Coded Red) ............... 0.3701-0.3705
BORE AND STROKE . . . . . . . . . . . . . . . . . . . ..... 430 x 3.70 (Coded Green) .............. 0.3705-0.3709
0.003 Oversize
COMPRESSION PRESSURE-Sea Level Intake ............................. 0.3742-0.3752
@ Cranking Speed . . . . . . . . . . . . . . . . ...... 160-200 Exhaust ........................... 0.3731-0.3739
COMPRESSION PRESSURE TOLERANCE 0.015 Oversize
Intake .............................. 0.3862-0.3872
I
BETWEEN CYLINDERS - Allowable psi . . . . . . . . . . . . 20
Exhaust ........................... 0.3 851-0.3859
TAXABLE HORSEPOWER . . . . . . . . . . . . - . . . ......... 59.17 0.030 Oversize
Intake ............................. 0.4012-0.4022
I
~---------------------------------------------~
FIRING ORDER . . . . . . . . . . . . . . . . . . . . . . .1-5-4-2-6-3-7-8 Exhaust ........................... 0.4001-0.40091
~-------------------------------1
VALVE ARRANGEMENT-Front to Rear I
VALVE STEM TO VALVE GUIDE CLEARANCE
Intake ............. 0.0008-0.0018-Wear Limit 0.0045
Right Bank . . . . . . . . . . . . . . . . . . . . . . . I-E-I-E-1-E-I-E
Left Bank . . . . . . . . . . . . . . . . . . . . . . . . .E-I-E-I-E-1-E-I Exhaust ... ...... 0.0020-0.0030-Wear Limit 0.0055
ENGINE IDLE RPM* VALVE HEAD DIAMETER

Transmission in Drive Range ....... 450-475 Intake ............................... 1.955-1.970
*If equipped with an air conditioner, the air .:-onditioner should Exhaust ............................. 1.645-1.660
be operated for at least 20 minutes before setting the idle speed.
VALVE FACE .ANGLE
ENGINE IDLE MANIFOLD VACUUM-Minimum Inches Intake and Exhaust .......................... 44°
of Mercury @ Specified Engine Neutral
Idle rpm-Sea Level . . . . . . . . . . . . . . . . . . . . . . . . . . 18 VALVE FACE RUNOUT- MAXIMUM
Intake ................................... 0.0015
INITIAL IGNITION TIMING-BTDC* .... _ . . . . . . . . . . . 6° Exhaust ................................. 0.0020
*If the individual requirements of the car and/or the use of sub-
standard fuels dictate, the initial timing may have to be retarded VALVE SPRING APPROXIMATE FREE LENGTH . . . . . . . . . . 1.88
from the recommended setting to eliminate detonation (spark
knock). Jf•retarding is necessary, it should be done progressively VALVE SPRING MAXIMUM OUT-OF-SQUARE . . . . . . . . . . . . %4
and not to exceed 2°BTDC.
VALVE SPRING PRESSURE (Lbs) @ SPECIFIED LENGTH
CRANKCASE OIL CAPACITY* Intake and Exhaust .................. . 65-75@ 1.640
U.S. Measure . . . . . . . . . . . . . . . . . . . . . . ..... 6 Quarts Wear Limit 59 @ 1.640
Imperial Measure . . . . . . . . . . . . . . . . . . ..... 5 Quarts 179-199 @ 1.230
*Includes one quart required with oil filter replacement. Wear Limit 162@ 1.230
OIL PRESSURE-psi hot @ 2000 rpm . . . . . . . . . . . . 35-55 VALVE SPRING ASSEMBLED HEIGHT
Pad to Underside of Retainer or Rotator ...... 1% -12Jh2
CYLINDER HEAD VALVE PUSH ROD RUNOUT- MAXIMUM ............ 0.025
GASKET SURFACE FLATNESS VALVE LIFTER STANDARD DIAMETER . . . . . . . . 0.8742-0.8745

0.003 inch in any 6 inches or 0.006 inch overall.
- VALVE LIFTER TO LIFTER BORE CLEARANCE .... 0.0005-0.0018
VALVE GUIDE BORE STANDARD DIAMETER Wear Limit 0.005
Intake and Exhaust (Coded Red) .. 0.3725-0.3730
(Coded Green) .. - - . 0.3 730-0.3 735 VALVE LIFTER LEAK DOWN RATE . . . . . . . . . . 10-100 Seconds
VALVE SEAT WIDTH ROCKER ARM TO ROCKER SHAFT CLEARANCE .. 0.0025-0.0050

Wear Limit 0.006
Intake and Exhaust • • 0 • ~ • • • • • ~ • • • • • ... 0.070-0.090
·-·
ROCKER ARM SHAFT OUTSI'DE DIAMETER ...... 0.839-0.840
VALVE SEAT ANGLE
Intake and Exhaust .... ' ............ .......... 45° ROCKER SHAFT BORE DIAMETER .......... 0.8425-0.8440
--
VALVE SEAT RUNOUT ••••••••••• 0. 0 ••• ......... 0.002 ROCKER ARM LIFT RATIO ....................... 1.76:1

CAMSHAFT AND TIMING CHAIN CRANKSHAFT MAIN BEARINGS

CAMSHAFT END PLAY ...................... Restrained JOURNAL CLEARANCE ...•.•..•••.•.•..•.• 0.0008-0.0024
CAMSHAFT JOURNAL STANDARD DIAMETER WALL THICKNESS
No. 1 ............................... 2.3243-2.3248 Coded Red .......................... 0.0953-0.0956
No. 2 ............................... 2.3093-2.3098 Coded Blue .......................... 0.0959-0.0962
No. 3 ............................... 2.2943-2.2948 0.002 Undersize ....................... 0.0966-0.0971
No. 4 ............................... 2.2793-2.2798
No. 5 . .............................. 2.6243-2.2648
CAMSHAFT JOURNAL MAXIMUM OUT-OF-ROUND .... 0.0005
........ 0.005
CONNECTING ROD
CAMSHAFT JOURNAL RUNOUT- MAXIMUM
CAMSHAFT JOURNAL TO PISTON PIN BORE INSIDE DIAMETER

BEARING CLEARANCE .................. 0.0012-0.0027 Standard ............................. 0.9736-0.9741
Wear Limit 0.005
BEARING BORE DIAMETER
CAMSHAFT LOBE LIFT
Coded Red ........................... 2. 7522-2.7526
Intake and Exhaust .......................... 0.2316 Coded Blue .......................... 2.7526-2.7530
Wear Limit 0.2266
MAXIMUM ALLOWABLE LOBE LIFT LOSS BEARING BORE OUT-OF-ROUND AND
Intake and Exhaust .......................... 0.005 TAPER-Maximum ......................... :.0.0004
VALVE LIFTER LIFT CENTER-TO-CENTER LENGTH .................. 6.599-6.601
Intake (Opens) ................... 0.002 @ 22 o BTDC
Intake (Closes) .................. 0.005 @ 68 o ABDC TWIST TOTAL DIFFERENCE-Maximum .............. 0.008
Exhaust (Opens) ................ 0.002@ 63° BBDC
Exhaust (Closes) ................ 0.005@ 27° ATDC BENO TOTAL DIFFERENCE-Maximum .............. 0.004
TIMING CHAIN DEFLECTION ........................ 0.5 CONNECTING ROD ASSEMBLY-Assembled
to Crankshaft Side Clearance ............ 0.005-0.015
SPROCKET CONTACT FACE RUNOUT
Maximum Wear Liimt 0.018
.................................. 0.004
ASSEMBLE•D SPROCKET CONTACT FACE RUNOUT
Maximum ... .- .............................. 0.008
CONNECTING ROD BEARINGS
BEARING TO CRANKSHAFT CLEARANCE •.••.. 0.0007-0.0020
CAMSHAFT BEARINGS
INSIDE DIAMETER WALL THICKNESS
No. 1 ................................. 2.326-2.327 Coded Red .......................... 0.0755-0.0758
No. 2 ................................. 2.311-2.312 Coded Blue .......................... 0.0761-0.0764
No. 3 ................................. 2.296-2.297 0.002 Undersize ....................... 0.0767-0.0772
No. 4 ................................. 2.281-2.282
No. 5 ................................. 2.266-2.267
LOCATION IN RELATION TO FRONT FACE OF BLOCK PISTON
CAM BEARING BORE-NO. 1 BEARING ONLY-
BELOW . . . . . . • . . . . . . . . . . . . . . . . . . . • • . . • . 0.005-0.020 PISTON DIAMETER
Coded Red ........................... 4.2983-4.2989
Coded Blue .......................... 4.2995-4.3001
0.003 Oversize ........................ 4.3007-4.3013
CRANKSHAFT
MAIN BEARING JOURNAL STANDARD DIAMETER PISTON TO BORE CLEARANCE-1;4 INCH
Coded Red ........................... 2.9000-2.9003 From Bottom of Skirt .................. 0.0011-0.0029
Coded Blue .......................... 2.8994-2.8997 Wear Limit 0.006
MAIN BEARING JOURNAL MAXIMUM RUNOUT ....... 0.002 PISTON PIN BORE DIAMETER .............. 0.9752-0.9755
Wear Limit 0.003
RING GROOVE WIDTH
CONNECTING ROD AND MAIN BEARING JOURNAL
MAXIMUM OUT-OF-ROUND ................... 0.0004 Upper Compression Ring ............... 0.0795-0.0805
Lower Compression Ring .............. 0.09 50-0.0960
CONNECTING ROD AND MAIN BEARING Oil Ring ............................... 0.188-0.189
JOURNAL TAPER . . . . . . . . . . . . . . . . . . . . . . 0.0005 per inch
THRUST BEARING JOURNAL LENGTH ....•..••. 1.124-1.126
MAIN BEARING JOURNAL THRUST FACE RUNOUT ...... 0.001 PISTON PIN
CONNECTING ROD JOURNAL OIAMETER PISTON PIN DIAMETER-Standard ........... 0.9749-0.9752
Coded Red .......................... 2.5998-2.6001
Coded Blue .......................... 2.5992-2.5995 PISTON PIN LENGTH ...................... 3.480-3.500
CRANKSHAFT FREE END PLAY .............. 0.004-0.008 PISTON PIN TO PISTON CLEARANCE ........ 0.0002-0.0004
Wear Limit 0.012 Wear Limit 0.0008
ASSEMBLED SPROCKET FACE RUNOUT-Maximum .... 0.006
TORQUE REQUIRE'D TO FULLY SEAT
SPROCKET CONTACT FACE RUN OUT -Maximum ...... 0.001 PIN-Minimum (Ft-lbs) ........................... 20

(175) PART 8-3-SPECIFICATIONS 8-55
PISTON RINGS TORQUE LIMITS (Ft-lbs) (Continued)

RING WIDTH MANIFOLDS TO CYLINDER HEAD
Upper Compression Ring ••••••• 0 •• ... 0.077 4-0.0781 Intake ...................................... 25-28
Lower Compression Ring •• 0 •• 0 •••• .. 0.0930-0.0940 Exhaust ..................................... 15-21
-
RING SIDE CLEARANCE FLYWHEEL TO CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . 75-85
Upper Compression Ring •• 0 ••••••• ... 0.0014-0.0031
Wear Limit 0.006 OIL PUMP TO CYLINDER BLOCK . . . . . . . . . . . . . . . . . . 23-28
Lower Compression Ring ......... ..... 0.00 1-0.003
OIL PUMP COVER PLATE . . . . . . . . . . . . . . . . . . . . . . . . 7.5-8.5
Wear Limit 0.006
Oil Ring 0 •• 0. 0 0 0 •••••••• 0 •••• 0 •• .......... Snug OIL FILTER ANGLE ADAPTER TO CYLINDER BLOCK ... . 10-13
RING GAP WIDTH-Standard Bore OIL PAN DRAIN PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . 15-20
Upper and Lower Compression Rings .... 0.015-0.025
Oil Ring (Steel Rail) ..... 0.025-0.038 ••••• 0 ......... VALVE PUSH ROD CHAMBER COVER .............. 3.5-5.0
POWER STEERING PUMP TO CYLINDER FRONT COVER . . 10-13
CYLINDER BLOCK CYLINDER FRONT COVER . . . . . . . . . . . . . . . . . . . . . . . . 10-13

CYLINDER BORE DIAMETER WATER OUTLET HOUSING . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Standard • • • • • 0 0 •••••• 0 ••••••• ... ... 4.3000-4.3024
0.003 Oversize •••••• 0 0 ••••••••••• . .. 4.3024-4.3036 WATER PUMP TO CYLINDER BLOCK . . . . . . . . . . . . . . . . 23-28
CYLINDER BORE OUT-OF-ROUND-Maximum . ....... 0.001 CAMSHAFT SPROCKET TO CAMSHAFT . . . . . . . . . . . . . . 12-15

Wear Limit 0.005
--· DAMPER TO CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . 75-90
CYLINDER BORE TAPER •••••• 0 ••••••• .......... 0.001
Wear Limit 0.010 CONNECTING ROD NUTS . . . . . . . . . . . . . . . . . . . . . . . . 40-45
-
HEAD GASKET SURFACE FLATNESS VALVE ROCKER ARM COVER . . . . . . . . . . . . . . . . . . . . 2.5-4.0
0.003 inch in any 6 inches or 0.006 inch overall.
VALVE ROCKER SHAFT SUPPORT TO CYLINDER HEAD . .45-50
OIL PUMP FUEL PUMP TO CYLINDER FRONT COVER .......... 23-28
ENGINE SUPPORTS
RELIEF VALVE SPRING TENSION-
Lbs @ Specified Length ........... 9 0-9.6 @ 1.53 inches Front Support Insulator to Engine .............. 45-65
Front Support Insulator to Underbody
RELIEF VALVE CLEARANCE .......... ... 0.0015-0.0029 Side Member .............................. 45-60
- ·-- Front Support Insulator to Support Bracket on
DRIVE SHAFT TO HOUSING BEARING
Underbody Side Member (Convertibles Only) . .45-65
CLEARANCE • 0. 0. 0 ••••••• 0. 0 •••••• .... 0.0015-0.0029
Rear Support Bracket to Body Extensions ........ 20-30
ROTOR ASSEMBLY END CLEARANCE .. ... 0.0011-0.0041 Rear Support Insulators to Transmission
Extension Housing ......................... 20-30
OUTER RACE TO HOUSING RADIAL CLEARANCE . . 0.006-0.012 Rear Support, Insulators and Retainers to ·
OIL PICK-UP TUBE TO OIL PUMP ...... ........... l0-13 Rear Support Bracket ...................... 10-18
Rear Support Insulator Assembly to
Rear Support .............................. 30-45
TORQUE LIMITS (ft-lbs) ENGINE LATERAL RESTRICTOR
Lateral Restrictor Outer Bracket to
MAIN BEARING CAP BOLTS-Oiled Threads ........ 95-105 Underbody Side Member .................... 21-29
-
~YLINDER HEAD BOLTS ••• - •• 0 •••••• ......... 125-135 Lateral Restrictor Inner Bracket to
Transmission Converter Housing ............ 40-50
OIL PAN TO CYLINDER BLOCK 0 •••••• ............ 4-6 Lateral Restrictor Compression Nut ............. 20-30
STANDARD TORQUE LIMITS FOR VARIOUS SIZE BOLTS
CAUTION: Special torque limits listt>d in the preceding tables should be used in preference to these standard limits
wherever they apply.
Size (Inches) ;4-20

1
lA-28 o/t6-18 'Vln-24 %-16 %-24
·-
Torq_ue (Foot-Pounds) 6-9 6-9 12-15 15-18 23-28 30-35
Size (Inches) "?'io-14 %o-20 1/z-13 lh-20 o/tr,-18 %-18
Torque (Foot-Pounds) 45-50 50-60 60-70 70-80 85-95 130-145

(176)
lJG=OO&) [¥>&®§
O~lJ§~lYO@~&f1f1'l?
®f1&~~

(177) 9-1
GROUP
9
GENERAL IGNITION SYSTEM SERVICE .. 9-1 SPECIFICATIONS ..... 9-27
PART 9-2
DUAL ADVANCE DISTRIBUTORS ..... 9-22
PART GENERAL IGNITION SYSTEM SERVICE

9-1
1 Diagnosis and Testing ........... . . ....... 9-1 3 Cleaning and Inspection ................... 9-21
2 Common Adjustments and Repairs . . ...... 9-17

GENERAL INFORMATION
CONVENTIONAL IGNITION
SYSTEM
The ignition system consists of a
+ BATTERY
•
primary (low voltage) and a second-
ary (high voltage) circuit (Fig. 1).
The primary circuit consists of BATTERY
the:
1. Battery.
2. Ignition switch.
3. Primary circuit resistance wire.
4. Primary windings of the igni-
tion coil.
5. Breaker points.
6. Condenser.
The secondary circuit consists of
the: •
1. Secondary windings of the igni-
tion coil.
2. Distributor rotor.
3. Distributor cap. 81290..C
4. High tension wires.
5. Spark plugs. FIG. 1-Typical Ignition Circuit
When the breaker points are
closed, the primary or low voltage the distributor cap where the rotor transistor system is designed to draw
current flows from the battery distributes it to one of the spark plug 12 amperes peak current, or approxi-
through the ignition switch to the terminals in the distributor cap. This mately 5.5 amperes average current,
primary windings in the coil, then process is repeated for every power as indicated on an ammeter, in order
to ground through the closed breaker stroke of the engine. to provide high spark plug voltage
points. When the breaker points at the higher engine speeds.
TRANSISTOR IGNITION The transistor in the system acts
open, the magnetic field built up in
SYSTEM as a heavy duty switch or relay. It
the primary windings of the coil
moves through the secondary wind- The permatuned transistor igni- is similar in action to a horn relay,
ings of the coil producing high volt- tion system is available on the 430 except that it has no moving parts,
age current. High voltage current V -8 engine. Figure 2 shows a sche- and thus acts with very little time
is produced each time the breaker matic of the transistor ignition sys- lag. The transistor is connected be-
points open. The high voltage flows tem. tween the battery and the coil, and
through the coil high tension lead to The ignition coil primary in the is used to make and break the coil

9-2 GROUP 9-IGNITION SYSTEM {178)
COLD START RfLAY Red-Green Stripe
8rown
Blue
-,
....,.___...__, I
2MFD
I
II
T
DISTRIBUTOR
BATTERY Green '= r-AMPLIFIER
J IGNITION COIL
Green
11717-C
FIG. 2- Transistor Ignition System Schematic

primary circuit. connect a tachometer or other test
The distributor controls the transis- equipment into the circuit. Do not
tor. The 8-ohm resistor, connected connect test equipment into the
between the distributor and the tran- circuit in any other manner, or
sistor (in the wiring harness), limits readings will be inaccurate and
the transistor control current (and damage may occur to the transis-
distributor point current) to 0.5 am- tor, or change its operating char-
pere. The low distributor point cur- acteristics.
rent eliminates pitting and gives long Connect the tachometer red lead
distributor point life. to the tachometer block red terminal
The distributor condenser has been and black lead to the black terminal.
increased in value to 2 mfd, and is
located in the amplifier assembly. As TROUBLE ISOLATION
81844-B
in the standard ignition circuit, it CONVENTIONAL IGNITION
absorbs high inductive energy during
initial distributor point opening.
FIG. 3-Amplifier SYSTEM
Assembly
However, it no longer has any effect Ignition system troubles are caused
on the distributor points as the tran- by the application of external devices by a failure in the primary I or the
sistor effectively isolates the points other than normal testing equipment. secondary circuit or incorrect igni-
from the coil. The cold start relay contacts are tion timing. If an engine trouble
The amplifier assembly (Fig. 3) is normally closed and they are con- has been traced to the ignition sys-
mounted under an insulated cover on nected into the circuit only during tem from the "Engine Trouble Diag-
the left front fender inner panel. the start cycle. When the starter nosis Guide", the trouble can be
A ceramic ballast resistor is relay is closed, the cold start relay is found by performing an ignition sys-
mounted with the amplifier, a tach- actuated and opens its contacts. If, tem test on a scope or by further
ometer connector block is mounted during starting, the available voltage isolating the trouble to the primary
on the firewall and a cold start relay drops below 10.5 volts, the relay or secondary circuit as follows:
is mounted on the righ~ front fender contacts close, thus by-passing the 1. Remove the coil high tension
in the engine compartment. 0.33-ohm resistor in the ballast re- lead from the distributor cap.
A 2-ampere fuse in the collector sistor block, and applying full avail- 2. Hold the high tension lead ap-
to tachometer block lead prevents able voltage to the system. proximately =YJn inch from the cylin-
the transistor from being damaged The tachometer block is used to der head.

(179) PART 9-1-GENERAL IGNITION SYSTEM SERVICE 9-~
3. With the ignition switch on, or energy loss in the secondary cir-
crank the engine and check for a cuit can be caused by:
spark. 1. Fouled or improperly adjusted
If the spark is good, the trouble spark plugs.
lies in the secondary circuit. 2. Defective high voltage wiring.
If there is no spark or a weak 3. High voltage leakage across the
spark, the trouble is in the primary coil, distributor cap or rotor.
circuit, coil to distributor high ten-
sion lead or the coil. PRIMARY CIRCUIT TESTS
Primary Circuit. A breakdown or CONVENTIONAL
energy loss in the primary circuit IGNITION SYSTEM
can be caused by: A complete test of the primary
1. Defective primary wiring. circuit consists of checking the cir-
2. Burned or improperly adjusted cuit from the battery to the coil, the
breaker points. circuit from the coil to ground, and
3. A defective coil. the starting ignition circuit.
4. A defective condenser. Excessive voltage drop in the
Secondary Circuit. A breakdown primary circuit will reduce the sec-
or energy loss in the secondary cir- ondary output of the ignition coil,
cuit can be caused by: resulting in hard starting and poor
1. Fouled or improperly adjusted performance.
spark plugs. Battery to Coil Test 12001-A
2. Def~ctive high tension wiring.
3. High tension leakage across the PROCEDURE
coil, distributor cap or rotor. 1. Connect the voltmeter leads as
FIG. 5-BaHery to Coil
Test-Sun Tester
shown in Figs. 4 and 5.
TRANSISTOR IGNITION 2. Install a jumper wire from the
SYSTEM distributor terminal of the coil to If the voltmeter reading is greater
a good ground on the distributor than 6.9 volts, check the following:
Do not use any testing proced- housing. 1. The battery and cables for loose
ures or conventional short cuts 3. Turn the lights and accessories connections or corrosion.
other than those listed below, or off. 2. The primary wiring for worn
extensive damage can result to the 4. Turn the ignition switch on. insulation, broken strands, and loose
system. or corroded terminals.
Ignition troubles are caused by a RESULTS. If the voltmeter read- 3. The resistance wire for defects.
failure in the primary or secondary ing is 6.9 volts or less, the primary 4. The relay to ignition switch for
circuit, or incorrect ignition timing. circuit from the battery to the coil defects. ·
Isolate the trouble as follows: is satisfactory.
1. Remove the coil high tension Ignition Switch Test
lead from the distributor cap. PROCEDURE
2. Hold the high tension lead
1. Connect the voltmeter leads as
approximately % inch from the
1 shown in Figs. 6 and 7.
cylinder head or good ground.
2. Install a jumper wire from the
3. With the ignition switch on,
distributor terminal of the coil to a
crank the engine and check for a
good ground on the distributor body.
spark. The engine may be cranked
3. Turn all of the accessories and
by the conventional method of run-
lights off.
ning a jumper wire from the battery
4. Turn the ignition switch on.
positive terminal to the "S" terminal
of the starter relay, after discon- RESULTS. If the voltmeter read-
necting the red and blue lead at ing is 0.3 volt or less, the ignition
the relay. switch and the relay to switch wire
If the spark is good, the trouble are satisfactory.
lies in the secondary (high voltage) If the voltmeter reading is greater
circuit. If there is no spark or a than 0.3 volt, either the ignition
weak spark, the trouble is in the switch and/ or the wire are defective.
primary (low voltage) circuit.
Resistance Wire Test
Primary Circuit. A breakdown
ot energy loss in the primary circuit PROCEDURE
can be caused by: 1. Connect the voltmeter leads as
1. Defective primary wiring. shown in Figs. 8 and 9.
2. Improperly adjusted, contami- 82000-A 2. Install a jumper wire from the
nated or defective distributor points. distributor terminal of the coil to a
3. Defective amplifier assembly. FIG. 4-Battery to Coil good ground on the distributor hous-
Secondary Circuit. A breakdown Test-Rotunda Tester ing.

9-4 GROUP 9-IGNITION SYSTEM {180}
82002-A 82004-A 82006-A
FIG. &-Ignition Switch FIG. 8-Resistance Wire FIG. 10-Starting Ignition

Test-Rotunda Tester Test-Rotunda Tester Circuit Test-Rotunda Tester
3. Turn all of the accessories and Starting Ignition Circuit Test ignition switch at the solenoid while
lights off. ' observing the voltage drop.
PROCEDURE
4. Turn the ignition switch on. RESULTS. If the voltage drop
1. Connect the voltmeter leads as
RESULTS. If the voltmeter read- shown in Figs. 10 and 11. is 0.1 volt or less, the starting igni-
ing is 6.6 volts or less, the resistance tion circuit is satisfactory.
2. Disconnect and ground the coil
wire is satisfactory. to distributor high tension lead at the If the voltage drop is greater than
If the voltmeter reading is greater distributor. 0.1 volt, clean and tighten the termi-
than 6.6 volts, replace the resistance 3. With the ignition switch off, nals in the circuit or replace the
wire. crank the engine by jumping the wiring as necessary.
~ ~ --
1-
-- - _.,..
' .
- ~ :~·
~"" ,. ~·" ~ ,f
82003-A 82005-A 82007-A
·fIG. 7-Ignition Switch FIG. 9-Resisfance Wire FIG. 11-Starting Ignition

Test- Svn Tester Test-Sun Tester (if(uit Test-Sun Tester

(181) PART 9-1-GENERAL IGNITION SYSTEM SERVICE 9-5
Coil to Ground Test ing is 0.1 volt or less, the primary 2. The movable breaker point and
circuit from coil to ground is satis- the breaker plate.
PROCEDURE factory. 3. The breaker plate and the dis-
1. Connect the voltmeter leads as If the voltmeter reading is greater tributor housing.
shown in Figs. 12 and 13. than 0.1 volt, test the voltage drop 4. The distributor housing. and
2. Close the breaker points. of each of the following: engine ground.
3. Tum all lights and accessories 1. Coil to distributor primary
off. wire. Breaker Points. The breaker
4. Turn the ignition switch on.
CONDITION CAUSED BY
RESULTS. If the voltmeter read-
Any discoloration other than a frosted slate

grey shall be considered as burned points.
Incorrect alignment.
Incorrect voltage regulator setting.
Radio condenser installed to the distributor
side of the coil.
Ignition condenser of improper capacity.
Extended operation of the engine at speeds
EXCESSIVE METAL
TRANSFER OR PiniNG other than normal.
81443-8
FIG. 14-Breaker Point lnspedion

NO SPARK AT COIL
0
WITH IGNITION ON AND COLD START RELAY DISCONNECTED,
CONNECT DWELL METER TO TACH BLOCK AND CRANK ENGINE
¢
o• DWELL
0
o• TO 45° DWELL
0
45° DWELL
FIG. 12-Coil to Ground
Test-Rotunda Tester 1. POINTS ARE CONTAMINATED TROUBLE 1. NO POWER FROM IGNITION
OR ARE NOT CLOSING. IS NOT IN SWITCH.
2. OPEN CIRCUIT IN DISTRIBUTOR TRANSISTOR 2. POINTS ARE NOT OPENING.
LEAD TO AMPLIFIER. CIRCUIT 3. AMPLIFIER IS MALFUNCTIONING.
DISCONNECT DISTRIBUTOR LEAD AND CRANK ENGINE

I
o• DWELL 45° DWELL

0
POINTS ARE NOT OPENING I 1. NO POWER FROM IGNITION SWITCH.
2. AMPLIFIER IS MALFUNCTIONING.
CONNECT DISTRIBUTOR LEAD. CONNECT VOLTMETER

TO RED TERMINAL OF TACH BLOCK
AND TO GROUND. CRANK ENGINE.
I
NO VOLTAGE STEADY VOLTAGE

Q
I NO POWER FROM IGNITION SWITCH I
81890-A
FIG. 13-Coil to Ground
Test-Sun Tester FIG. 15-Transistor Ignition System Test Procedures

9-6 GROUP 9-IGNITION SYSTEM (182)
point assembly consists of the sta- not opening. If 45 o dwell is indi- wires connecting the distributor cap
tionary point bracket assembly, cated, the amplifier is malfunctioning to the spark plugs and the wire con-
breaker arm and the primary wire or there is no power from the ig- necting the center terminal of the
terminal. nition switch. distributor cap to the center terminal
Breaker points should be inspected, Use a voltmeter or test light to of the ignition coil.
cleaned and adjusted as necessary. determine if the transistor (amplifier These wires are the radio resist-
Breaker points can be cleaned with assembly) is at fault. Connect the ance-type which filter out the high
chloroform and a stiff bristle brush. voltmeter to the red-green lead termi- frequency electrical impulses that
Replace the breaker point assembly nal of the ballast resistor and to are the source of ignition noise inter-
. if the contacts are badly burned or ground. Crank the engine. ference. The resistance of each wire
excessive metal transfer between the If a steady indication of voltage should not exceed 24,500 ohms.
points is evident (Fig. 14). Metal is obtained, the trouble is in the When checking the resistance of
transfer is considered excessive when amplifier. Absence of any voltage the wires for setting ignition tim-
it equals or exceeds the gap setting. indication on the voltmeter shows ing, do not puncture the wires
there is an open circuit, or no power with a probe. The probe may cause
Coil. The coil should be tested between the ignition switch and the a separation in the conductor.
following the instructions under amplifier. The ballast resistor could At regular intervals, clean and
"Ignition System Tests". be defective. Replace it with a known inspect the wires for cracked insula-
Condenser. The condenser should good ballast resistor, and repeat the tion and loose terminals ..Repair or
also be tested following the instruc- test. replace the wires as required. A
tions under "Ignition System Tests". If the test procedure indicates a spark plug wire set is available for
defective amplifier, replace it with a service.
TRANSISTOR known good amplifier, and proceed When removing the wires from
IGNITION SYSTEM as follows: the spark plugs, grasp the moulded
Connect the distributor high ten- cap only. Do not pull on the wire
When diagnosis procedures isolate sion lead at the bullet connector. because the wire connection inside
trouble to the primary circuit, make Then, with the cold start relay dis- the cap may become separated or
the following tests to locate the de- connected and the dwell meter con- the weather seal may be damaged.
fective items. Do not use any other nected to the tachometer block,
procedure, conventional short cut, Spark Intensity
crank the engine and observe the
or connect test equipment in any indicated dwell. A reading between 1. Disconnect a spark plug wire.
other manner than that described oo and 45° indicates satisfactory
or extensive damage can be caused Check the spark intensity of one
ignition; thus, the amplifier is at wire at a time.
to the transistor ignition system. fault.
Figure 15 shows the transistor igni- 2. Install a terminal adapter in
If the dwell reading is still 45a, the terminal of the wire to be
tion system tests in outline form. the wiring from the amplifier through
Disconnect the cold start relay. checked. Hold the adapter approxi-
the ballast resistor to the coil is de- mately %ti inch from the exhaust
Connect a dwell meter to the tachom- fective. Replace the defective item.
eter block. Connect the black lead manifold and crank the engine, using
to the black terminal and the red a remote starter switch. The spark
SECONDARY CIRCUIT TESTS
lead to the red terminal. Turn the should jump the gap regularly.
ignition on and crank the engine. The following procedure is used 3. If the spark intensity of all the
Observe the dwell meter reading. on both ignition systems. wires is satisfactory, the coil, con-
oo Dwell. A dwell reading of oa denser, rotor, distributor cap and
PRELIMINARY CHECKS the secondary wires are probably
indicates:
1. The distributor points are con- 1. Remove the coil to distributor satisfactory.
high tension lead and the spark plug If the spark is good at only some
taminated or are not closing.
oo to 45° Dwell. A dwell reading wires from the distributor cap and wires, perform a high resistance test
between oo and 45° indicates: from the spark plugs. Inspect the of the faulty leads.
terminals for looseness and corro- If the spark is equal at all wires,
1. The transistor and the primary
circuit are functioning properly. sion. Inspect the wires for breaks but weak or intermittent, make a
2. The trouble could be in the and cracked insulation. Replace all high resistance check of the coil,
secondary circuit. defective wiring. distributor cap and the coil to dis-
45° Dwell. A dwell reading of 2. Clean the inside of the distribu- tributor high tension wire. Follow
45° indicates: tor cap, and inspect it for cracks, the instructions of the test set manu-
1. No power from the ignition burned contacts, permanent carbon facturer when making the tests.
switch. tracks or a defective center carbon On the transistor ignition, do
2. The distributor points are brush electrode. Remove dirt or cor- not test the coil on a coil tester,
closed and not opening. rosion from the sockets. Replace the as inconclusive results will be ob-
3. Defective amplifier assembly. cap if it is defective. tained due to the very low coil
To determine which of the three 3. Inspect the rotor for cracks or primary inductance. Substitute a
items listed are causing the trouble defects. Replace the rotor if it is known good coil and perform the
proceed as follows: ~ defective. primary circuit tests.
Disconnect the distributor lead at SECONDARY (HIGH TENSION) SPARK PLUGS
the bullet connector, and crank the WIRES
engine. If the dwell meter indicates Clean, inspect and gap the plugs
oo dwell, the distributor points are The secondary wires include the following the instructions in Sections

(183) PART 9-1- GENERAL IGNITION SYSTEM SERVICE 9-7
2 and 3. After the proper gap is ob-

tained, check the plugs on a testing
machine. Compare the sparking effi-
ciency of the cleaned and gapped
plug with a new plug. Replace the
plug if it fails to meet 70% of the
new plug performance. PLUG
Test the plugs for compression LINE
leakage at the insulator seal. Apply SEC 15 KV

a coating of oil to the shoulder of PRie
• • • 30 KV
50 40 30 2f D..:::~~
the plug where the insulator projects 1 1 1 Ofh • • Tllll18
4(0 3(5 30 2 5 2 0 1 5 aCYL. LIGHT
through the shell, and to the top of TEST
the plug, where the center electrode SELECTOR
and terminal project from the insu-
lator. Place the spark plug under
pressure with the tester's high ten- 0
sion wire removed from the spark
plug. Leakage is indicated by air
bubbling through the oil. If the test
indicates compression leakage, re-
place the plug. If the plug is satis-
factory, wipe it clean.
IGNITION TIMING
Incorrect ignition timing can be
caused by:
1. Timing incorrectly adjusted.
2. Distributor bushing and / or
shaft worn, or a bent distributor
shaft.
3. Defective vacuum advance sys-
tem.
4. Defective centrifugal advance.
IGNITION SYSTEM TESTS-
ROTUNDA TESTERS
TEST CONNECTIONS-RE-235,
RE-651, AND RE-881
The test connections for the RE-
235 tester are shown in Fig. 16, the 11991-A
test connections for the RE-651
te~ter are shown in Fig. 17, and the FIG. 16-Rotundo RE-235 Test Connedions
test connections for the RE-8 81
tester are shown in Fig. 18. 6. If the engine timing is to be distributor.
1. With the tester turned off, plug checked, plug the timing light into 2. Turn the volts switch to the
the power plug into a proper AC its socket. point resistance (PT. RES.) posi-
outlet. The following steps pertain to the tion. The points should be closed for
2. Connect the green lead to the RE-651 and RE-881 testers only. this test. If the breaker points are
distributor terminal of the coil. 7. Disconnect the battery wire open, the meter will read the battery
On a car equipped with a from the regulator and place it in voltage ( 0 to 40 scale).
transistor ignition, connect this the knob end of the 100 ampere 3. "Bump" the starter with the
green lead to the terminal on the shunt. starter switch until the voltmeter
red side of the tachometer block. 8. Place the spade terminal from pointer decreases to the lowest read-
3. Remove the No. 1 plug wire the 100 ampere shunt and the yellow ing in the black zone. On a car
from the distributor cap, place the lead on the battery terminal of the equipped with a transistor igni-
blue pickup in the cap and place the voltage regulator. tion, this bumping is done by
plug wire in the pickup. 9. Turn the ground polarity switch jumping between the "S" terminal
4. Now connect the black lead to to the minus position. On the RE-881 of the solenoid and the battery
a good ground. tester, turn the volts switch to the 20 with the ignition switch off and
If the car has a transistor igni- volt position. the coil lead (brown wire) discon-
tion, connect the black lead to the POINT RESISTANCE TEST nected from the solenoid.
terminal on the black side of the 4. Depress the PT. RES. push-
tachometer block. RE-651 Tester button.
5. Clip the red pickup over the 1. Remove and ground the high 5. The voltmeter pointer should
coil-to-distributor high tension wire. tension wire from the center of the read within the 12V area as shown

~'1.~~,.
~ ~
. ~·
,.
110 40 )0 20 lleYL.
40 M :10 :tilt .20 111 ICVL.
YOll -ANa ,...

• • • • • •
AMP TIMING SIC. 151¥ JOIY
--
• •• •
A.-a MIAOI I._D
1
115 V.A.C.
I -~ • •
Pt. liS. l.l'.M.
ENGINE CONNECTIONS
GROUND
-Ji+
I' POLARITY
ANY GOOD GROUND
COIL
BATTERY
81992-A
FIG. 17 -Rotunda RE-651 Test Connections

in black on the meter dial. If not, a car equipped with a transistor IGNITION TIMING
check for incorrect breaker point ignition system, the starter is Disconnect the vacuum line. If
spring tension or for burned or pitted bumped by jumping between the necessary, clean and mark the de-
points. "S" terminal of the solenoid and
sired timing mark.
6. Connect the high tension wire the battery, with the ignition
to the distributor. switch oft and the coil lead (brown RE-235 Tester
wire) disconnected from the sole-
RE-881 Tester noid. 1. Start the engine and allow it
to warm up.
1. Remove and ground the high 3. The voltmeter pointer should 2. Operate the engine at the speci-
tension wire from the center of the read in the black OK PT. RES. area. fied idle speed and point the timing
distributor. If it doesn't, check for improper light toward the pointer. The de-
2. "Bump" the starter with the breaker point spring tension or for sired timing mark should line up
starter switch to close the breaker burned or pitted points. with the pointer. If it doesn't, loosen
points. This will be indicated by the 4. Connect the high tension wire the distributor hold down bolt and
lowest reading on the voltmeter. On teo the distributor. rotate the distributor until the mark

15 30
KV KV
." .
-·-~..
25
&
--·---
.
--~---
--~.. M
.. ~"
·~
10
A 20
-~·---.
:~ -·==::.7= ::
.
: -
.~---~
---::-___:_::_
·:
__ -:,
-___
PLUG
LINE
15
iiYf:t: : 5
8 10
c D 5
.,,...,
I K.,o I fr I -j 1 1 DWELL ..... 0
~ I""J5 io 1~
1
.}5 20 8CVL.
81994 -A
FIG. 19-Normal
• Superimposed Primary Pattern
....
··~·_i -/,. . "i-.----
-·
1000 rpm, turn the test selector
-·UIIT
- ~-.....-
.. , .. w.
rn.
- +
........
switch to the primary (PRI.) posi-
tion.
2. ·Adjust the parade control to
position the left end of the pattern
at the left vertical line on the screen.
3. Adjust the expand control so
that the right end of the pattern is
at the right vertical line on the
screen.
RE-651 TESTER
1. Turn the rpm selector to the
5000 position. Start the engine and
adjust it to 1000 rpm.
2. Depress the PRI pushbutton on
the console panel.
3. Adjust the parade and expand
controls to position the left end of
the pattern at the left vertical line
on the screen and the right end of
the pattern at the right vertical line
on the screen.
RE-881 TESTER. The test pro-
cedure for the RE-8 81 is the same
81993-A as the test procedure for the RE-651
except for the setting of the rpm
FIG. 18-Rotunda RE-881 Test Connedions selector. For the RE-881 tester, the
rpm selector is turned to the 1600
lines up with the pointer. Now tributor hold down bolt and rotate position.
tighten the hold down bolt and check the distributor until the desired tim- Results. A normal test pattern is
the timing. ing mark and pointer line up. Tighten shown in Fig. 19.
the distributor hold down bolt and Point A indicates the spark plug
RE-651 Tester
check the timing. line which is the time when the
1. Turn the rpm selector to the points open. At B, the coil energy is
RE-881 Tester. The method of
1000 position. used up sufficiently so that the plug
testing is the same as the RE-651
2. Depress the advance timing no longer fires and only the energy
tester with the exception of Step 1
pushbutton. stored in the breaker point condenser
which should (for the RE-881) read
3. Start the engine and allow it to remains. This coil/condenser oscilla-
''turn the rpm selector to the 800
warm up. tion which is indicated in the pattern
position."
4. Operate the engine at the speci- between B and C is completely used
fied idle speed. SUPERIMPOSED PRIMARY up at C which is the points close
5. Turn the advance knob until PATTERN mark. The portion of the pattern
the ignition advance meter reads 0°. between C and D is the points close
6. Point the timing light toward Procedure time, which is cam angle or dwell
the timing pointer. The desired tim~ time. At D, the points again open
RE-235 TESTER
ing mark should line up with the and the firing cycle repeats.
pointer. If it doesn't, loosen the dis- 1. With the engine running at If points A and C are below the

horizontal 0 line, the battery polar- 2. Adjust the parade and expand 1!S
KV
30
Kv
ity is incorrect. This could be caused controls so that the left end of the A 25
by a battery that is either installed pattern is at the left vertical line on
incorrectly or improperly charged, the screen and the right end of the 10 20
causing a polarity reversal. pattern is at the right vertical line PLUI3

15
U"'E
If the firing line is not below the on the screen. .tc.
0 line and there are no oscillations 5 10
at point C, there is an open circuit

RE-651 AND RE-881 TESTERS.
The procedure is the same as the
I 1 .£
at the coil high tension tower. This procedure for the primary (super- ~ ~0 ..1. 4,0_.._30_._'20 GCYL. \
could be caused by a broken wire ,..3~
0
inside the coil tower, or a broken

imposed) pattern except the SEC. ~ ds do 1~ 8CYL.
pushbutton is depressed instead of \Q.•
center contact on the distributor the PRI pushbutton.
rotor. 81995-A
If the dwell time is too short, the Results. A normal test pattern is
breaker points are incorrectly set shown in Fig. 20. FIG. 21-15 KV PaHern
(the larger the gap, the smaller the Point A is the points open time.
dwell). The height of the pattern at point A If point 0 1 is varying erratically,
If point A is at a reduced height, indicates the high tension voltage the distributor is badly worn. If this
and the distance to B is short or non- required to overcome the spark plug variation is definite instead of erratic,
existent, and the oscillations at point gap resistance. the advance mechanism· in the dis-
C are reduced in height, there is a Point B is the plug firing line. tributor is defective.
Notice that this portion of the pat- If the dwell line between points
15
KV
30
KV
tern is quite thick. Remember that Dl and E is not the smooth line
'25
this pattern is actually 8 firing pat- shown, there is a loose connection in
1A terns superimposed one on top of the the primary circuit. Check the pri-
10 '20 other. This increase in thickness of mary circuit for loose connections,
LUG
15
the pattern at B is caused by slight damaged wires or a defective starter
IN IE
variations in the plug gap, distributor switch.
5 10 rotor gap and slight differences in
D the resistance of the individual spark 15 KV PATTERN
5
8 s,o ll 4 ~CY plug circuits.
J I 0 I '210
0 The pattern area between points Procedure
~3 ~ 3 ~ 2 5~'2~
1
f4 f5 ~CYLJ C and D shows the coil/condenser RE-235 TESTER. With the engine
oscillations to be correct. No point operating at 1000 rpm, turn the test
11996-A bounce at D indicates correct break- selector switch to the 15 KV posi-
er point spring tension. tion. Adjust the expand and parade
FIG. 20-Normal The few so called damped oscilla- controls to produce the pattern
Superimposed Secondary Pattern tions appearing at Dare normal and shown in Fig. 21.
are caused by the surge of current
through the coil primary winding RE-651 TESTER. With the rpm
high resistance in the coil primary selector at the 5000 position and the
circuit. This could be caused by a when the breaker points first close.
This current levels off and de- engine operating at 1000 rpm, de-
fouled plug, defective ignition switch, press the 15 KV pushbutton. Adjust
or a bad wire or connection. If the creases slightly toward the points
open position at E as indicated by the expand and parade controls to
scope pattern is still the same after produce the pattern shown in Fig. 21.
the above ignition parts have been the slight downward slope of the
checked and proven· satisfactory, run curve at about the 15° mark on the RE-881 TESTER. With the rpm
the 15 KV test to check for a gasket cam angle scale. selector at the 1600 position and the
leak or a lean fuel mixture. To observe the coil/condenser engine operating at 1000 rpm, de-
If point A is at a greatly reduced oscillations and the damped oscilla- press the 15 KV pushbutton. Adjust
height and there are no oscillations tions at D 1 in greater detail, adjust the expand and parade controls to
at point B, the coil has a defective the expand control so that the pat- produce the pattern shown in Fig. 21.
primary winding or the condenser tern area between point C and D 1
nearly fills the screen. Results. A normal 15 KV pattern
has an excessive series resistance.
If there is erratic action at points is shown in Fig. 21. The spark plug
If there is a variation at points C
C and D, and there is a blotch line (A) for the No. 1 spark plug
and D, the cam lobes are uneven,
above point E, the breaker points are is on the extreme right hand side of
the distributor shaft is bent, or the
burned or badly pitted. the screen. The remainder of the No.
distributor bushings are worn.
If the length of B is reduced and 1 firing pattern is on the left side of
SUPERIMPOSED SECONDARY the pattern between C and D is not the screen. The remainder of the
PATTERN superimposed, there is a series gap patterns are shown from left to right
Procedure in the coil high tension tower or in their firing order.
wire. With the exception of the No. 1
RE-235 TESTER If the line at B is sloping down- spark plug line (which should be
1. With the engine running at ward greatly (resistor plugs will shorter than the others), the pat-
1000 rpm, turn the test selector cause a slight slope), there is a high terns should be similar. If one of the
switch to the secondary (SEC.) posi- resistance in the spark plug wires, patterns differs from the others, ad-
tion. distributor cap or rotor. just the expand and parade controls

PART 9-1-GENERAL IGNITION SYSTEM SERVICE 9-11
~--------------------~30
KV
+-----------------------+25
+-----------------------+20
~------------------~~+15
'-~-+--+-~--+--+--~LI-NE_l~;
..... ,10
11997-A 0 0 0 0 0
FIG. 22-30 KV Pattern

until that pattern fills the screen in
the same manner as in the secondary
test (Fig. 20).
COIL WIRE REMOVED
The following list of symptoms
will refer to Fig. 20.
If the points open line (A) is
higher than the rest and the plug
firing line (B) is sloped downward
at an unusually large slope, there is NO.1
excessive resistance in the high ten-
sion wire to that cylinder or in the
distributor cap.
If the points open line (A) is low
and the firing line (B) is long and
nearly straight, the spark plug is
shorted out.
If the points open line (A) is low
and the firing line (B) is long and
wide, the spark plug gap is out of
adjustment.
If there are no oscillations at
points C or D, the coil primary
windings are partially shorted. FIG. 23-Sun 900 Tester Connections
If the points open line (A) and
the oscillations at point D are both the 30 KV pushbutton. Adjust the a fouled or improperly gapped spark
displaced to the right on all cylin- expand and parade controls to pro- plug or for very low compression.
ders, check the breaker points. duce the pattern shown in Fig. 22. Remove the high tension wire at
I~ all of the points open lines (A)
the distributor cap for any plug
Results. A normal 30 KV pattern except No. 1. Notice the change
are at varied heights, check the idle is shown in Fig. 22. The spark plug
adjustment of the carburetor (always between the average points open line
line (A) for the No. 1 spark plug and the points open line of the
adjust the idle mixture on the rich is on the extreme right hand side of
side). cylinder with the high tension wire
the screen. The remainder of the removed. This height difference is
30 KV PATTERN "l' o. 1 firing pattern is on the left
the coil reserve. The coil reserve
side of the screen. The remainder of should be at least 30% of the maxi-
Procedure the patterns are shown from left to mum output. If it is less than 30%,
RE-235 TESTER. With the engine right in their firing order. replace the coil.
running at 600 rpm, turn the test Notice the average height of the Remove and do not ground one
selector switch to the 30 KV posi- solid part of the points open line. spark plug wire at the spark plug.
tion. Adjust the expand and parade lncrease the speed of the engine and If a plug firing line shows up on the
controls to produce the pattern notice the height of the dotted lines. scope for that cylinder, check the
shown in Fig. 22. The difference is the required igni- plug wire and distributor cap for
tion output under load. The maxi- bad insulation.
RE-651 TESTER. With the rpm mum output should be between 13.5
selector at the 5000 position and the wd 15 KV. IGNITION SYSTEM TESTS-
engine operating at 600 rpm, depress If the maximum for one or more SUN 900 TESTER
the 30 KV pushbutton. Adjust the
uf the plugs is above 15 KV, check TEST CONNECTIONS
expand and parade controls to pro-
the complete circuit ( s) of the
duce the pattern shown in Fig. 22.
plug(sl for any trouble that would Most of the ignition system can
RE-881 TESTER. With the rpm cause this resistance. If the maxi- be tested by using the Sun 900 Scope
selector at the 1600 position and the mum docs not increase during the Motor Tester. Make the connections
engine operating at 600 rpm, depress increase in engine speed, check for as follows (Fig. 23).

1. Plug the power cord into a 14. Turn the scope display selector obtained (an unusual point open
proper outlet. to the SCOPE CHECK position and signal is one that does not form a
2. Turn the AC master switch to adjust the horizontal and vertical firing line that is straight up and
the ON position. knobs until the trace appears on the down) , check for dirty or burned
3. Turn the Tach-Dwell selector ZERO (0) line (allow about 30 points, or high series resistance.
switch to the calibrator (CAL.) posi- seconds for warm-up before adjust-
tion and adjust the dwell calibrator ment). COIL
until the meter pointer reads on the Polarity
SET LINE. CRANKING VOLTAGE
4. Turn the Tach - Dwell rpm 1. With the tester connected, turn 1. Remove the jumper lead from
switch to the 5000 position. the ignition switch ON. Make sure the distributor to ground, if it is
5. Connect the Tach-Dwell leads; that the transmission is in neutral still connected.
connect the RED insulator lead to and that the parking brake is set. 2. Insert the coil high tension lead
the primary distributor lead at the 2. Crank the engine, observe the into the scope pattern pickup.
coil. Connect the BLACK insulator speed and note the reading on the 3. Adjust the engine speed to 1200
lead to a good ground. voltmeter. rpm.
On a car equipped with a tran- If the meter reads less than the 4. Turn the scope display selector
sistor ignition system, connect the specified voltage, check for the fol- to the ALL CYLINDERS position,
RED insulator lead to the RED lowing: weak battery, defective and adjust the pattern length control
side of the tachometer block and cables, connections, switch, starter, until all cylinders appear between the
the BLACK insulator lead to the by-pass circuit, or ignition circuit to vertical lines on both sides of the
BLACK side of the tachometer coil. screen.
block. If the speed is uneven or slow, 5. Rotate the pattern shift con-
6. Connect the trigger pickup into the engine or starting circuit is trol counterclockwise until the last
the circuit of the first spark plug defective. pattern on the screen appears com-
in the firing order. _ plete.
7. Turn the Voltage Leakage unit
BREAKER POINTS 6. Observe the patterns, noting if
control counterclockwise to the 1. With the motor tester con- they are upright or inverted (Fig.
TIMING position. nected, turn the scope display selec- 24).
8. Connect a jumper lead from tor to the INDIVIDUAL CYLIN- If they are inverted, check for the
the distributor primary to a good DER position. scope ground polarity switch in the
ground. 2. Remove the jumper lead from MINUS (-) position, battery polar-
9. Set the Voltage Leakage switch the distributor to ground. ity reversed, coil improperly con-
to the 20 V position. 3. Insert the coil high tension wire nected, or incorrect coil.
10. Connect the Voltage Leakage into the scope pattern pickup. Primary and Secondary Tests.
test leads; the RED lead is connected 4. Operate the engine at 1200 To check the coil for shorted or
to the battery side of the coil and rpm. open windings and for primary or
the BLACK lead is connected to a 5. Observe the point open and secondary resistance, calibrate the
good ground. point close signals (Fig. 24). If an Condenser-Coil Unit as follows:
11. Remove the high tension wire unusual point close signal is ob- 1. Turn the AC switch to ON.
from the coil and leave the wire tained (an unusual point close signal 2. Set the Condenser-Coil Unit
disconnected. is one that does not have a short selector switch at the OHMS posi-
12. Insert the scope pattern pick- straight downward line followed by tion.
up into the coil tower and attach a series of closely grouped rapidly 3. Set the Condenser-Coil ohms
the ground clip to a good ground. diminishing oscillations) , check for switch to the desired range:
13. Set the scope ground polarity poor point contact, misaligned 4. Connect the test leads together.
switch to the POSITIVE ( +) posi- points, or weak point spring tension. 5. Adjust the Condenser-Coil cali-
tion. If an unusual point open signal is brator until the meter pointer reads
B ZERO on the ohms scale.
6. Disconnect the test leads.
7. Disconnect all leads from the
coil.
SHORTED OR OPEN WIND-
ZERO INGS.
LINE
1. Calibrate the Condenser-Coil
Unit (the ohm switch should be in
the OHMS position).
2. Connect the test lead, one to
each coil primary terminal. Observe
the polarity.
3. Insert the coil pickup into the
FIRING INTERMEDIATE
SECTION SECTION
DWEll SECTION secondary tower of the coil and con-
81727-A nect the ground lead of the pickup to
a good ground.
FIG. 24- Typical Scope Pattern 4. Turn the Condenser-Coil Unit

(189) PART 9-1-GENERALIGNITION SYSTEM SERVICE 9-13
2. Insert the coil high tension lead

NORMAL SHORTED WINDINGS OPEN WINDINGS into the scope pickup.
3. Adjust the engine speed to
1200 rpm.
4. Turn the scope display selector
to the ALL CYLINDERS position,
and adjust the pattern length control
until all of the cylinders appear be-
tween the vertical lines on the screen.
5. Rotate the pattern shift control
counterclockwise until the last pat-
tern on the screen appears complete.
6. Observe the height of each fir-
FIG. 25-Coil Test Patterns ing line, on the scope, and compare
for uniformity and height (Fig. 24).
selector switch to the COIL TEST tion, the meter should read in the If the firing voltages are uniform,
position and observe the wave pat- black bar at the right end of the but high, check for worn spark plugs,
tern visible on the coil test scope. scale. late ignition timing, lean fuel mix-
Refer to Fig. 25 for checking the 3. Move the condenser pigtail. If ture, too large a rotor gap, or a
data obtained. a deflection of the meter is noted, break in the coil wire.
the pigtail is making poor contact If the firing voltages are uneven,
PRIMARY RESISTANCE and the condenser should be replaced. check for worn spark plugs, uneven
1. Calibrate the Condenser-Coil If the reading is outside the black compression, breaks in spark plug
Unit (set the ohm switch to the bar, move the grounded lead to the wires, or a cocked or worn distribu-
OHMS position.) body of the condenser. If the read- tor cap.
2. Connect the test leads, one to ing improves, the condenser is not
each primary terminal of the coil. properly grounded to the distributor AVAILABLE VOLTAGE
3. Observe the meter reading and housing. 1. Make the same connections and
compare it with specifications. adjustments as for the firing voltage
Capacity
test above.
SECONDARY RESISTANCE 1. Turn the condenser test switch 2. Disconnect a spark plug wire
1. With the ohm switch set at the to the CAPA CITY position. with a pair of insulated pliers.
OHMS x 1000 position, calibrate the 2. Read the red scale of the meter 3. Hold the wire away from a
Condenser-Coil Unit. ( 0.5) for the microfarad capacity of ground and notice the upward extent
2. Install the coil pickup test lead the condenser being tested. of the pattern on the scope.
in the tower of the coil. 3. Refer to the specifications for If the available voltage is less than
3. Connect the ohmmeter test the recommended condenser capa- 20 KV, check for excessive resistance
leads, one to either primary terminal city. in the primary circuit, low primary
and the other to the open (pigtail) If the readings are not within input voltage, defective coil, dwell
end of the coil pickup test lead. specifications replace the condenser. less than specified, or defective
4. Observe the meter reading and secondary insulation.
Leakage
compare it with specifications.
1. Turn the condenser test switch SECONDARY INSULATION
If the meter reading exceeds
20,000 ohms, the secondary winding to the LEAKAGE position. 1. Continue with the same con-
is open. 2. The meter should now read in nections and adjustments as in the
the black bar at the left end of the last two tests.
CONDENSER scale if the condenser leakage is sat- 2. Observe the downward extent
For the condenser tests, calibrate isfactory. of the pattern of the spark plug with
the Condenser-Coil Unit as follows: If the meter pointer reads outside the wire removed.
1. Set the selector switch to the the black bar, the condenser insula- 3. Connect the spark plug wire.
CONDENSER position. tion is leaking and the condenser 4. Perform this test on all of the
2. Connect the test leads together. should be replaced. cylinders (trigger cylinder may be
3. After allowing approximately NOTE: If the condenser does not tested in the SCOPE CHECK posi-
one minute for the tester to warm meet specifications while mounted in tion).
up, adjust the calibrator until the the distributor, remove the condenser lf the lower extent is not at least
meter pointer reads on the set line and retest it. The same procedure is half the size of the upper extent,
at the right end of the meter scale. followed as above. If the condenser check for insulation leakage in the
Do not change this setting during tests bad in the distributor, but tests coil, coil tower, rotor, coil wire, dis-
the tests. good when removed, there is a short tributor cap, or spark plug wire.
or ground in the distributor primary
Resistance SECONDARY RESISTANCE
circuit. Inspect the insulation of the
1. Connect the test leads, one to distributor primary terminal and the 1. The connections and adjust-
the primary terminal of the distribu- internal circuit of the distributor. ments for this test are the same as
tor and the other to a ground on the for the last three tests, except for
distributor body. FIRING VOLTAGE the scope display selector switch
2. With the condenser test switch 1. Remove the jumper from the which is now placed in the ALL
in the SERIES RESISTANCE posi- distributor to ground. CYLINDERS position.

2. Observe and compare the spark To check the diaphragm for leak- engine.
line (Fig. 24) of the patterns for age: 2. Place the distributor in the
length, height, angle and oscillations. 1. Remove the vacuum line from holding tool and clamp it in a vise.
If all cylinders are affected, check the distributor. Adjust the vacuum 3. Push the distributor shaft up-
for high resistance in the coil tower, pressure of a distributor tester to its ward as far as it will go, then check
coil wire, rotor, or distributor cap maximum position. Hold your hand the end play with a feeler gauge
tower; also check for an accumula- over the end of the tester's vacuum placed between the collar and the
tion of deposits on the spark plugs, hose and note the maximum reading distributor base. The end play should
or poor contact between the rotor obtained. Do not exceed 25 inches be within the specified limits.
and distributor cap. Hg. If the shaft end play is not to
If one or more cylinders are 2. If the maximum reading is 25 specifications, check the location of
affected, check for high resistance in inches Hg or less, connect the tester's the distributor shaft collar.
the distributor cap tower, spark plug vacuum line to the vacuum fitting on
wires, or spark plugs. the diaphragm without changing DISTRIBUTOR TESTS-
any of the adjustments. The maxi- ROTUNDA RE-1416 TESTER
SPARK PLUGS
mum gauge reading should not be MOUNTING DISTRIBUTOR
To test the spark plugs on the car, less than it was in step 1. If it is
connect the motor tester in the same less, the diaphragm is leaking and 1. Clamp the distributor securely
manner as for the firing voltage test. should be replaced. in the distributor support arm clamp
1. Tum the display selector switch so that it will not turn in its mount-
to the ALL CYLINDERS position; DISTRIBUTOR BREAKER PLATE ing.
rotate the pattern shift control in the
WEAR 2. Loosen the hand-operated lock-
FULL CLOCKWISE position. A worn breaker plate will cause ing screw on the side of the distributor
2. Momentarily accelerate the en- the breaker point gap and contact support arm and adjust the support
gine to about 2000 rpm and return dwell to change as engine speed and arm column up or down by turning
to 1200 rpm. load conditions are varied. Mount the crank on the knob at the top of the
3. Observe the rise of the firing the distributor in a distributor tester column until the distributor shaft or
lines during the momentary engine following the instructions in this sec- adapter shaft can be securely
acceleration. tion of the manual. fastened in the driving chuck. Use
If one or more of the firing lines adapter shafts provided when driv-
is higher than the others, check for ing distributors having short shafts.
wide plug gap, open spark plug re- 3. Securely tighten the drive chuck
sistor wire, or badly deteriorated to the distributor drive shaft by
electrodes. means of the chuck key, attached by
If one or more of the firing lines a chain to the Syncrograph
is lower than the others, check for 4. Rotate the drive chuck by hand
spark plug fouling, flashover, or to make sure the distributor shaft
cracked insulators. turns freely and then tighten the
locking screw on the distributor sup-
DISTRIBUTOR DIAPHRAGM port arm.
LEAKAGE AND FREENESS 5. Connect the Syncrograph test
OF OPERATION lead to the primary or distributor-
transistor lead wire of the distributor.
These tests can be made with the
distributor installed on the engine. Since the transistor ignition distrib-
B1990-A utor does not have a condenser, it
The tests are sufficient for an engine
tune-up. However, if there are indi- will be necessary to install one in
cations that the spark advance is not FIG. 26- Testing the circuit of the tester (Fig 26) .
functioning properly, remove the Transistor Ignition Distributor BREAKER POINT RESISTANCE
distributor from the engine and
check it on a distributor test set Adjust the test to oo advance, 1. Turn the test selector to POINT
following the instructions under 0 inches vacuum, and 1000 rpm. Ad- RES. position.
"Distributor Spark Advance." just the dwell angle to 26°. Apply 2. Revolve the chuck by hand until
Check the vacuum advance mech- vacuum to the distributor diaphragm the distributor breaker points are
anism for freeness of operation by and increase it very slowly while ob- closed.
manually rotating the breaker plate serving the indicated dwell angle. 3. The meter pointer on the cam
in the direction of rotation. Do not The maximum dwell angle variation angle meter should read in the 0 K
rotate the plate by pushing on the should not exceed 6° when going zone at the left side of the meter
condenser or the breaker points. from zero to maximum vacuum at scale If the meter pointer does not
Use a hook or other suitable in- constant rpm. If the dwell angle fall in the OK zone, there is excessive
strument to rotate the plate. The variation exceeds this limit, there is resistance caused by a faulty contact
breaker plate should turn without excessive wear at the stationary sub- across the distributor points, a faulty
binding and return to its original plate pin or the diaphragm rod is primary lead or a poorly grounded
position when released. If the break- bent or distorted. base plate. A faulty contact across the
er plate binds, remove the plate. distributor points indicates improper
Clean, inspect and lubricate it as de- DISTRIBUTOR SHAFT END PLAY spring tension or burned or pitted
scribed for the particular distributor. 1. Remove the distributor from the points

{191) PART 9-1-GENERAL IGNITION SYSTEM SERVICE 9-15
INSULATION AND LEAKAGE the adjustment control so that the wise) and slowly increase the rpm to
zero degree mark on the scale is the setting specified for the first ad-
1. Turn the test selector to the opposite one of the neon flashes. The vance reading listed in the specifica-
cam angle position and revolve the balance of all the flashes should come tions.
chuck by hand until the distributor within 1o, plus or minus, evenly If the correct advance is not indi-
breaker contacts are open around the protractor scale. A larger cated at this rpm, stop the distributor
2. The cam angle meter should variation than 1 o or erratic or wan- and bend one spring adjustment
show a zero reading. If a zero read- dering flashes may be caused by a bracket to change its tension (Fig.
ing is not obtained, a short circuit to worn cam or distributor shaft or a 27). Bend the adjustment bracket
ground exists bent distributor shaft. away from the distributor shaft to
A short could be caused by poor decrease advance (increase spring
primary or distributor-transistor lead DWELL ANGLE tension) and toward the shaft to
wire insulation, a shorted condenser 1. Tum the cylinder selector to increase advance (decrease spring
or a short between the breaker arm the figure corresponding to the num- tension). After the adjustment is
and breaker plate ber of lobes on the cam of the dis- made, identify the bracket.
MECHANICAL OPERATION tributor being tested. 3. After an adjustment has been
2. Tum the test selector switch to made to one spring, check the mini-
1. Turn the test selector to the the cam angle position and operate mum advance point again.
SYNCHRO. position and check to the distributor at approximately 1000 4. Operate the distributor at the
make sure the drive chuck is securely engine rpm. specified rpm to give an advance just
tightened on the distributor shaft. 3. Adjust the distributor breaker below the maximum. If this advance
2. Turn the motor control switch point gap to the dwell angle shown is not to specifications, stop the dis-
to the left to correspond with the in the specifications. tributor and bend the other spring
direction of rotation, as listed in the bracket to give the correct advance.
rotation column of the distributor DISTRIBUTOR SPARK 5. Check the advance at all rpm
specifications. ADVANCE settings listed in the specifications.
If it is necessary to reverse the The spark advance is checked to Operate the distributor both up and
rotation of the drive motor, turn determine if the ignition timing ad- down the rpm range.
the motor control switch to the vances in proper relation to engine
OFF position and allow the chuck Vacuum Advance
speed and load.
to come to a complete stop before 1. Check the contact dwell. If the 1. Connect the test set vacuum
reversing the switch. contact dwell or the breaker point line to the fitting on the diaphragm
3. Adjust the rpm control to vary gap is not within specifications, ad- and turn the vacuum supply switch
the distributor speed between 400 just the breaker points. on.
and 4000 engine rpm or at the maxi- 2. Check the breaker arm spring 2. Set the test set to oo advance,
mum speed of the engine on which tension and adjust it if necessary. 0 vacuum, and at 1000 rpm.
the distributor is used. Erratic or 3. Check the advance at the first
thin faint flashes of light preceding vacuum setting given in the speci-
the regular flashes as the speed of fications.
rotation is increased can be due to 4. If the advance is incorrect,
weak breaker arm spring tension or change the calibration washers be-
binding of the breaker arm on the tween the vacuum chamber spring
pivot pin and nut (Fig. 28). After installing
1· Operate the distributor at ap- or removing the washers, position
proximately 2500 engine rpm. the gasket in place and tighten the
5. Move the protractor scale with nut. The addition of a washer will
decrease advance and the removal
SPACING WASHERS 82011-A of a washer will increase advance.
5. After one vacuum setting has
FIG. 28- Vacuum been adjusted, the others should be
Advance Adiustment checked. Do not change the original
rpm setting when going to a dif-
ferent vacuum setting. If the other
The dual advance distributor has
settings are not within limits, it in-
two independently operated spark
dicates incorrect spring tension, leak-
advance systems. Each system is ad-
age in the vacuum chamber and/ or
justed separately. Adjust the cen-
line, or the wrong fiber stop has been
trifugal advance before adjusting
installed in the vacuum chamber of
the vacuum advance.
the diaphragm housing.
Centrifugal Advance
DISTRIBUTOR TESTS-
1. Do not connect the test set vac- ROTUNDA RE-236 TESTER
uum line to the diaphragm. Set the
Screwdriver 82010-A test set to oo advance and the initial MOUNTING DISTRIBUTOR
rpm setting listed in the specifications. 1. Adjust the distributor support
FIG. 27 -Centrifugal 2. Operate the distributor in the arm in relation to the distributor
Advance Adiustment direction of rotation ( counterclock- shaft length.

2. Set the distributor in the sup- gap is not within specifications, ad- been adjusted, the others should be
port arm and enter the lower end just the breaker points. checked. Do not change the orig-
of the distributor shaft in the Syn- 2. Check the breaker arm spring inal rpm setting when going to a
crograph chuck. tension and adjust it, if necessary. different vacuum setting. If the
3. Tighten the chuck on the dis- The dual advance distributor has other settings are not within limits,
tributor shaft, using the wrench lo- two independently operated spark there is -incorrect spring tension,
cated near the support arm column. advance systems. Each system is ad- leakage in the vacuum chamber and/
4. Align the distributor shaft by justed separately. Adjust the cen- or line, or the wrong fiber stop has
shifting the support arm and distrib- trifugal advance bef01·e adjusting been installed in the vacuum cham-
utor, then tighten the clamp screw. the vacuum advance. ber of the diaphragm housing.
5. Clamp the distributor securely
in the distributor support arm clamp Centrifugal Advance DISTRIBUTOR TESTS-
so that it will nqt tum in its mount- SUN DT-600 TESTER
1. Do not connect the test set
ing. vacuum line to the diaphragm. Set MOUNTING
MECHANICAL OPERATION the test set to oo advance and the
1. Using the elevation crank, raise
initial rpm setting listed in the speci-
1. Turn the OFF, SET, CAM, the clamp arms high enough to per-
fications.
mit the shaft of the distributor to
SYNC. switch to SET. 2. Operate the distributor in the
clear the drive chuck.
2. Adjust the SET TACH control direction of rotation ( counterclock-
2. Position the distributor in the
so the tachometer pointer is on the wise) and slowly increase the rpm
clamp with the vacuum diaphragm
SET line. to the setting specified for the first
pointing toward the right. Tighten
3. Turn the OFF, SET, CAM, advance reading listed in the speci-
the clamp arms securely around the
SYNC. switch to SYNC. position. fications.
distributor body. Install the proper
4. Tum the MOTOR switch to the If the correct advance is not indi-
adapter to the vacuum diaphragm.
LEFT position. cated at this rpm, stop the distrib-
3. Lower the distributor with the
5. Adjust the speed control to vary utor and bend one spring adjust-
elevation crank until the gear or
the distributor speed between 400 ment bracket to change its tension
% inch of the tip of the distributor
and 4000 engine rpm, or at the max- (Fig. 27). Bend the adjustment
shaft enters the drive chuck, or until
imum speed of the engine on which bracket away from the distributor
the shaft engages the adapter if an
the distributor is used. Erratic or shaft to decrease advance (increase
adapter is being used. Do not bot-
thin faint flashes of light preceding spring tension) and toward the shaft
tom the distributor shaft in the
the regular flashes as the speed of to increase advance (decrease spring
chuck.
rotation is increased can be due to tension). After the adjustment is
4. Tighten the chuck. Do not try
weak breaker arm spring tension or made, identify the bracket.
to raise or lower the distributor
binding of the breaker arm on the 3. After an adjustment has been
after the chuck has been tightened.
pivot pin. made to one spring, check the mini-
6. Operate the distributor at ap- mum advance point again. CONDENSER TESTING
proximately 2500 engine rpm and 4. Operate the distributor at the
move the protractor scale so that the specified rpm to give an advance just Condensers should be tested for
zero degree mark on the scale is op- below the maximum. If this advance series resistance, capacity and leak-
posite one of the neon flashes. The is not to specifications, stop the dis- age. The preparation procedure is
balance of all the flashes should tributor and bend the other spring as follows:
come within 1 o, plus or minus, even- bracket to give the correct advance. 1. Trip the motor switch to the
ly around the protractor scale. A 5. Check the advance at all rpm proper position for the rotation of
variation larger than 1 o or erratic or settings listed in the specifications. the distributor being tested.
wandering flashes may be caused by Operate tpe distributor both up and 2. Turn the condenser test -selec-
a worn cam or distributor shaft or down the rpm range. tor switch to the SERIES RESIST-
a bent distributor shaft. ANCE position and connect the con-
Vacuum Advance denser test leads to·gethet.
DWELL ANGLE 3. Turn the condenser calibrate
1. Connect the test set vacuum control clockwise from the OFF po-
1. Turn the OFF, SET, CAM, line to the fitting on the diaphragm. sition.
SYNC. switch to the CAM position. 2. Set the test set to oo advance, 4. Allow the tester to warm up for
Operate the distributor at about 1000 0 vacuum, and at 1000 rpm. approximately 30 seconds and then
rptn. 3. Check the advance at the first adjust the calibrate control until the
2. Adjust the breaker point gap vacuum setting given in the speci- condenser meter reads on the SET
until the cam angle is to specifica- fications. LINE.
tions. 4. If the advance is incorrect, 5. Rotate the distributor shaft until
change the calibration washers be- the cam holds the breaker points
DISTRIBUTOR SPARK
tween the vacuum chamber spring open.
ADVANCE
and nut (Fig. 28) . After installing 6. Separate the test leads and con-
The spark advance is checked to or removing the washers, position the nect one to the distributor primary
determine if the ignition timing ad- gasket and tighten the nut. The lead and the other to the distributor
vances in proper relation to engine addition of a washer will decrease body.
speed and load. advance and the removal of a
1. Check the contact dwell. If the washer will increase advance. Series Resistance. Turn the con-
contact dwell or the breaker point 5. After one vacuum setting has denser test selector switch to the

SERIES RESISTANCE position. CAM LOBE ACCURACY wise) and slowly increase the rpm to
The condenser meter should read in 1. Connect the test leads following the setting specified for the first ad-
the black bar on the right end of the the directions in the distributor re- vance reading listed in the specifi-
scale. sistance test. cations.
2. Turn the tachometer dwell If the correct advance is not ·indi-
Capacity. Turn the condenser test cated at this rpm, stop the distributor
selector switch to the CAPACITY switch to the 8 position.
3. Adjust the distributor speed to
and bend one spring adjustment
position. The condenser meter will bracket to change its tension (Fig.
1000 rpm.
now read the capacity in microfarads. 27). Bend the adjustment bracket
4. Rotate the degree ring of the
Compare this reading with specifi- tester until the ZERO on the ring away from the distributor shaft to
cations. lines up with one of the flashes. decrease advance (increase spring
5. Observe the positions of the re- tension) and toward the shaft to
Leakage. Turn the condenser test increase advance (decrease spring
selector switch to the LEAKAGE maining flashes. If the flashes are not
evenly spaced (within ± 1 o), check tension). After the adjustment is
position. The condenser meter should made, identify the bracket.
read in the black bar at the left of for a worn cam, worn distributor
3. Mter an adjustment has been
the scale. shaft or a bent distributor shaft.
made to one spring, check the mini-
Turn the test selector switch to DWELL ANGLE mum advance point again.
the SERIES RESISTANCE position This test has the same connections 4. Operate the distributor at the
and turn OFF the condenser cali- as the preceding test, therefore they specified rpm to give an advance just
brator before disconnecting the test can be done at the same time. below the maximum. If this advance
leads. Adjust the speed to 200 rpm and is not to specifications, stop the dis-
DISTRffiUTOR RESISTANCE notice the dwell reading. If it is not tributor and bend the other spring
within specifications, adjust the bracket to give the correct advance.
1. With the motor switch in the points until the proper dwell is ob- 5. Check the advance at all rpm
proper position for the rotation of tained. Now increase the speed and settings listed in the specifications.
the distributor being tested and the check the dwell reading. If the read- Operate the distributor both up and
speed set at ZERO rpm, clip the ing changes more than two degrees, down the rpm range.
tester's distributor and ground lead check for a worn distributor shaft Vacuum Advance
together. or worn bushings.
1. Connect the test set vacuum
2. Set the tachometer dwell selec- DISTRIBUTOR SPARK line to the fitting on the diaphragm.
tor switch to the CALIBRATE po- ADVANCE 2. Set the test set to oo advance,
sition and adjust the dwell regulator
The spark advance is checked to 0 vacuum, and at 1000 rpm.
until the dwell meter reads on the
SET LINE. determine if the ignition timing ad- 3. Check the advance at the first
vances in proper relation to engine vacuum setting given in the specifi-
3. Separate the leads and connect cations.
the tester's distributor lead to the speed and load.
1. Check the contact dwell. If the 4. If the advance is incorrect,
distributor primary or distributor- change the calibration washers be-
transistor lead. Since the transistor contact dwell or the breaker point
gap is not within specifications, ad- tween the vacuum chamber spring
ignition distributor does not have and nut (Fig. 28). After installing or
a condenser, it will be necessary just the breaker points.
2. Check the breaker arm spring removing the washers, position the
to incorporate one in the test cir- gasket and tighten the nut. The ad-
cuit (Fig. 26). The tester ground tension and adjust it if necessary.
The dual advance distributor has dition of a washer will decrease
lead should now be connected to the the advance and the removal of a
distributol body. two independently operated spark
advance systems. Each system is ad- washer will increase the advance.
4. Rotate the chuck by hand until justed separately. Adjust the cen- 5. After one vacuum setting has
the points are closed. The dwell trifugal advance before adjusting been adjusted, the others should be
meter should. read in the black bar the vacuum advance. checked. Do not change the orig-
at the right end of the scale. inal rpm setting when going to a
If it does not read in the black Centrifugal Advance different vacuum setting. · If the
bar, move the tester's distributor wire 1. Do not connect the test set vac- other settings are not within limits,
step by step through the circuit to- uum line to the diaphragm. Set the it indicates incorrect spring tension,
ward the ground. When there is a test set to oo advance and the initial leakage in the vacuum chamber and/
measurable difference between two rpm setting listed in the specifications. or line, or the wrong fiber stop has
points, check that area for the cause 2. Operate the distributor in the been installed in the vacuum cham-
of the resistance. direction of rotation ( counterclock- ber of the diaphragm housing.

BREAKER POINTS feeler gauge, scope or a dwell meter. cam until the rubbing block rests on
To adjust the breaker points with the peak of a earn lobe.
ADJUSTMENT a feeler gauge: If the car is equipped with a
New Breaker Points. New break- 1. Check and adjust breaker point transistor ignition and the start-
er points can be adjusted with a alignment. Rotate the distributor er is going to be tapped to place

Feeler Gauge
LESS TENSION
12013-A
BEND STATIONARY BRACKET

· 82012-A
FIG. 33-Adiusting
Spring Tens ion
FIG. 29-Adiusting New FIG. 31-Aiigning
Breaker Point Gop Breaker Points ALIGNMENT
The vented-type breaker points
the breaker point assembly on the set the contact dwell to the low set- must be accurately aligned and strike
peak of the cam, proceed as fol- ting. New points must be set to the squarely in order to realize the full
lows: connect a jumper between low dwell as the rubbing block will advantages provided by this design,
the "S" terminal of the solenoid wear down slightly while seating to · and assure normal breaker point life.
and the battery with the ignition the cam. Any misalignment of the breaker
switch off and the coil lead (brown point surfaces will cause premature
wire) disconnected from the sole- Used Breaker Points. If the gap wear, overheating and pitting.
noid. of used breaker points is being 1. Turn the cam so that the break-
2. Insert the correct blade of a checked, use a scope or dwell meter er points are closed and check the
clean feeler gauge between the break- to test the contact dwell. It is not alignment of the points (Fig. 30).
er points (Fig. 29). The gap should advisable to use a feeler gauge to If the car has a transistor igni-
be set to the larger opening because adjust or to check the gap of used tion system, refer to the adjust-
the rubbing block will wear down breaker points because the roughness ment of new breaker points for
slightly while seating to the cam. of the points makes an accurate gap the proper starter tapping pro-
3. Apply a light film of distributor reading or setting impossible. Clean cedure.
cam lubricant to the cam when new the breaker points. Check the con- 2. Align the breaker points to
points are installed. Do not use en- tact dwell following the instructions make full face contact by bending
gine oil to lubricate the distributor under "Ignition System Tests". The the stationary breaker point bracket
cam. contact dwell should be to specifica- (Fig. 31). Do not bend the breaker
4. Set the ignition timing. tions. Check and adjust the ignition arm.
If a scope or a dwell meter is used timing. 3. After the breaker points have
to adjust new points, be sure the been properly aligned, adjust the
points are in proper alignment. Also, breaker point gap or dwell.
CAREA
ONTACT@
CENTERED ()
CORRECT
ALIGNMENT
CONTACT@
AREA NOT
CENTERED
MISALIGNMENT
OF C E N T E R @
CONTACT
AREA NOT
CENTERED
ISALIGNMENT F
OF POINT FACES 81019-A
FIG. 30-Breoker Point FIG. 32-chec:king

Alignment Breaker Point Spring Tension FIG. 34-Timing Marks

ADJUSTING SPRING TENSION IGNITION TIMING

Correct breaker point spring ten- TIMING MARK LOCATIONS
sion is essential to proper engine
operation and normal breaker point The crankshaft damper (Fig. 34)
life. If the spring tension is too has 15 timing marks ranging from
great, rapid wear of the breaker arm top dead center (TDC) to 30° be-
rubbing block will result, causing the fore top dead center (BTDC). Refer
breaker point gap to close up and to specifications for the correct igni-
retard the spark timing. If the spring tion timing.
tension is too weak, the breaker arm ADJUSTMENT
will flutter at high engine rpm re-
sulting in an engine miss. The procedure for adjusting the
To check the spring tension, place ignition timing is covered under
the hooked end of the spring tension "Ignition System Tests".
gauge over the movable breaker FIG. 36-Gapping
SPARK PLUG WIRE Spark Plugs
point. Pull the gauge at a right
REPLACEMENT
angle (90°) to the movable arm
until the breaker points just start to When removing the wires from the in the firing order ( 1-5-4-2-6-3-7-8)
open (Fig. 32). If the tension is not spark plugs, grasp the moulded cap starting at the No. 1 socket. Cylin-
within specifications, adjust the spring only. Do not pull on the wire because ders are numbered from front to rear;
tension. the wire connection inside the cap right bank 1-2-3-4, left bank 5-6-7-8.
2. Remove the brackets from the
old spark plug wire set and install
them on the new set in the same
relative position. Install the wires in
the brackets on the valve rocker arm
covers (Fig. 35). Connect the wires
to the proper spark plugs. Install the
coil high tension lead. Be sure the
No. 7 spark plug wire is positioned
in the bracket as shown in Fig. 35.
SPARK PLUGS
REMOVAL
1. Remove the wire from each
spark plug by grasping the moulded
cap of the wire only. Do not pull on
the wire because the wire connec-
tion inside the cap may become
separated or the weather seal may
be damaged.
2. Clean the area around each
FIG. 35-lgnition Wiring spark plug port with compressed air,
then remove the spark plugs.
To adjust the spring tension (Fig. may become separated or the weather
33): seal may be damaged. ADJUSTMENT
1. Disconnect the primary or dis- A typical ignition wiring installa- Set the spark plug gap by bending
tributor-transistor lead wire, and the tion is shown in Fig. 35. the ground electrode (Fig. 36).
condenser lead if so equipped, at the
breaker point assembly primary ter- REMOVAL INSTALLATION
minal. 1. Disconnect the wires from the
2. Loosen the nut holding the spark plugs and distributor cap. 1. Install the spark plugs and
spring in position. Move the spring 2. Pull the wires from the brackets torque each plug to 15-20 ft-lbs.
toward the breaker arm pivot to on the valve rocker arm covers and When a new spark plug is installed
decrease tension and in the op- remove the wires. in a new replacement cylinder head,
posite direction to increase tension. 3. Remove the coil high tension torque the plug to 20-30 ft-lbs.
3. Tighten the lock nut, then check lead. 2. Connect the spark plug wires.
spring tension. Repeat the adjustment Push all weather seals into position.
until_ the specified spring tension is lNSTALLATION
RESISTANCE WIRE
obtained. 1. Insert each wire in the proper REPLACEMENT
4. Install the primary or distrib- socket of the distributor cap. Be sure
utor-transistor lead wire, and the con- the wires are forced all the way down The primary resistance wire is
denser lead (if so equipped) , with into their sockets. The No. 1 socket checked for excessive resistance as
the lock washer and tighten the nut is identified on the cap. Install the outlined under "Resistance Wire
securely. wires in a counterclockwise direction Test".

9-20 GROUP 9-IGNITION SYSTEM {196)
CONDITION IDENTIFICATION CAUSED BY
Wet, sludgy deposits. Excessive oil entering combustion

chamber through worn rings and
pistons, excessive clearance between
valve guides and stems, or worn or
loose bearings.
Dry, black, fluffy de- Incomplete combustion caused by too

posits. rich a fuel-air mixture or by a defec-
tive coil, breaker points or ignition
cable.
White, burned, or Inefficient engine cooling, or engine

blistered insulator overheating caused by improper igni-
nose and eroded elec- tion timing, wrong type of fuel, loose
FIG. 37- Cleaning Plug trodes. spark plugs, or too hot a plug, low
Electrode fuel pump pressure.
To replace the resistance wire:

1. Remove the instrument panel
lower covers. Rusty brown to gray- Regular or unleaded gasoline.
2. Disconnect the resistance wire ish-tan powder deposit
(pink or black) from the multiple and minor electrode
molded connector at the Power Box. erosion.
This connector is the second from
the top of the Power Box, and the
pink or black resistance wire plugs CONDITIONS
into the upper right corner of the
~
connector. White, powdery de- Highly leaded gasolines.
posits.
3. Cut off the old resistance wire
at the point where it enters the main
( 1440 1) wiring loom.
4. Connect the replacement (pink
NORMAL
or black) wire to the multiple con-
CONDITIONS
nector at the Power Box.
5. Route the replacement wire as
d
Hard, baked on black Too cold a plug. Weak ignition, de-
straight as possible under the instru- carbon. fective fuel pump, dirty air cleaner,
ment panel, to the connector near the too rich a fuel mixture.
ignition switch.
6. Disconnect the old wire at the
quick disconnect (red wire with green CARBON
connector) near the ignition switch FOULING
and connect the replacement wire.
7. Cut off the old resistance wire Hard and scratchy Formed when fine sand particles com-
where it enters the main wiring loom. bine with anti-knock compounds in
8. Tape the replacement wire to the fuel. Most common industry
the main wiring loom. areas. The plugs cannot be cleaned.
~
Deposits, accumulated after a long
period of misfiring, suddenly loosened
when normal combustion chamber
deposits are restored after new p\ugs
are installed. During a high speed
SPLASHED run these deposits are thrown into
FOULING the plug.
81005-E
FIG. 38-Spark Plug Inspection


SPARK PLUGS DISTRIBUTORS Inspect the distributor cam lobes
for scoring and signs of wear. If any
Clean the plugs on a sand blast Soak all parts of the distributor lobe is scored or worn, replace· the
cleaner, following the manufacturer's assembly (except the condenser, cam assembly. •
instructions. Do not prolong the use breaker point assembly, lubricating Inspect the breaker plate assembly
of the abrasive blast as it will erode wick, vacuum diaphragm, distributor for signs of distortion. In addition,
the insulator. Remove carbon and base oil seal, and electrical wiring) inspect the stationary sub-plate for
other deposits from the threads with in a mild cleaning solvent or mineral worn nylon contact buttons. Replace
a stiff wire brush. Any deposits will spirits. Do not use a harsh cleaning the breaker plate assembly if it is de-
retard the heat flow from the plug to solution. Wipe all parts that can not fective.
the cylinder head causing spark plug be immersed in a solvent with a clean The breaker point assembly and
overheating and pre-ignition. dry cloth. condenser (if so equipped) should
Clean the electrode surfaces with After foreign deposits have been be replaced whenever the distributor
a small file (Fig. 37) . Dress the elec- loosened by soaking, scrub the parts is overhauled.
trodes to secure flat parallel surfaces with a soft bristle brush. Do not use Inspect all electrical wiring for
on both the center and side electrode. a wire brush, file, or other abrasive fraying, breaks, etc., and replace any
After cleaning, examine the plug object. Dry the parts with compressed that are not in good condition.
carefully for cracked or broken in- air. Check the distributor base for
sulators, badly pitted electrodes, and Examine the bushing surface of cracks or other damage.
other signs of failure. Replace as re- the distributor shaft and the bushing Check the diaphragm housing,
quired. for wear. The dual advance distrib- bracket and rod for damage. Check
Examine the firing ends of the utor has one bushing. The minimum the vacuum line fitting for stripped
spark plugs, noting the type of de- allowable shaft diameter at the bush- threads or other damage. Test the
posits and the degree of electrode ing is 0.4675 inch and the maximum vacuum fittings, case and diaphragm
erosion. Refer to Fig. 38 for the vari- allowable inside diameter of the bush- for leakage as explained under "Dis-
ous types of spark plug fouling and ing is 0.4690 inch. Replace worn tributor Tests". Replace all defective
their causes. parts. parts.

9-22 (198)
PART DUAL ADVANCE DISTRIBUTORS

9-2
1 Description and Operation ................ 9-22 3 Removal and Installation ................. 9-23
2 In-Car Adjustments and Repairs ........... 9-22 4 Major Repair Operations .................. 9-24

The dual advance distributor (Fig. weights. The slots determine the move against the tension of the
1) has two independently operated maximum amount of advance, and spring. This action causes the mov-
spark advance systems. A centrifugal the rate of advance is controlled by able breaker plate to pivot on the
advance mechanism is located below calibrated springs. stationary sub-plate. The breaker
the stationary sub-plate assembly and The vacuum advance mechanism point rubbing block, which is posi-
a vacuum operated spark control tioned on the opposite side of the
has a spring-loaded diaphragm which
cam from the pivot pin, then moves
diaphragm is located on the side of is connected to the breaker plate. against distributor rotation and ad-
the distributor base. As speed in- The spring-loaded side of the dia- vances the spark timing. As the mov-
creases, the centrifugal weights cause phragm is airtight and is connected able breaker plate is rotated from
the cam to advance or move ahead through a vacuum line to the carbu- retard position to full advance posi-
with respect to the distributor drive retor throttle bore. When the throttle tion, the dwell decreases slightly.
shaft. The weights turn the cam by plates open, the distributor vacuum This is because the breaker point
means of a stop plate that has two passage is exposed to manifold vac- rubbing block and the cam rotate on
slots, which fit over pins in the uum, which causes the diaphragm to different axes.
~
'SPRING
WEIGHT
LUBRICATING WICK
11380·1
FIG. 1-Typical Dual Advance Distributor

DISASSEMBLY lead from the quick disconnect. Un- 2. Loosen the nut and pull the
snap the distributor cap retaining vacuum line out of the diaphragm
REMOVAL OF COMPONENTS clips, lift the distributor cap off the assembly.
1. Remove the primary wire from distributor housing, and position the 3. Lift the rotor off the cam.
the coil or the· distributor-transistor cap out of the way. 4. Remove the spring clip securing

(199) PART 9-2-DUAL ADVANCE DISTRIBUTORS 9-23
the diaphragm link to the movable ASSEMBLY assembly in the distributor housing
breaker plate. Disconnect the dia- and secure in place on the sub-plate
phragm assembly from the distribu- DIAPHRAGM AND BREAKER by installing the washers and re-
tor housing. Lift the diaphragm link PLATE ASSEMBLY tainer. Be sure the protruding
off the pin and remove the dia- 1. Install the breaker point as- edges of the spring washer are
phragm assembly. sembly on the breaker plate. Position facing upward.
5. Working from the inside of the a new condenser (if so equipped) 5. Attach the ground wire to the
distributor, remove the primary (or and secure it in place with the re- breaker point attaching screw far-
distributor-transistor lead) wire by taining screw. thest from the breaker point adjust-
pulling it through the opening in the 2. Install the stop, return spring ment slot. Working from inside the
distributor. and calibration washers, then posi- distributor housing, pass the primary
6. Remove the two retaining tion a new gasket on the vacuum or distributor-transistor lead wire
screws and lift the entire breaker connection. Install and tighten the assembly through the opening in the
plate assembly out of the distributor vacuum connection. distributor body. From outside the
housing. distributor, pull the wire through the
7. Lift the lubricating wick out of INSTALLATION OF opening until the locating stop is
the cam. Using needle nose pliers, COMPONENTS flush with the inside of the distribu-
remove the cam retainer and lift the tor.
1. Install the weights in the hous- 6. Connect the condenser wire (if
cam off the distributor shaft. ing, then install the distributor weight
8. Lift the upper thrust washer off so equipped) and the primary or dis-
springs on the adjusting brackets tributor-transistor lead wire to the
the distributor shaft. Carefully un- from which they were removed. In-
hook and remove the distributor breaker points.
stall the upper thrust washer on the 7. Position the diaphragm assem-
weight springs. Mark each spring distributor shaft.
and the adjusting bracket to which bly and hook the diaphragm link
2. Fill the grooves in the upper over the pin on the breaker plate.
it is attached. Lift the weights out portion of the distributor shaft with
of the housing. Install the diaphragm assembly re-
distributor cam lubricant. Position taining screws. Secure the diaphragm
DIAPHRAGM AND BREAKER the cam on the distributor shaft and link with a spring retainer.
PLATE ASSEMBLY install the cam retainer. Apply a 8. Adjust the breaker point spring
light film of distributor cam lubri- tension, align the breaker points and
1. Remove the vacuum connection cant to the cam lobes. Install the adjust the breaker point gap. Check
and gasket, then remove the calibrat- wick in the cam assembly. Saturate the breaker point dwell and resist-
ing washers, return spring and stop. the wick with SAE 1OW engine oil. ance. Check the centrifugal and
2. Remove the retaining screw and 3. Position the stationary sub- vacuum advance (refer to "Dis-
lift the condenser (if so equipped) plate in the distributor. Install one tributor Tests").
off the breaker plate (Fig. 1) . end of the ground wire under the 9. Install the rotor and distributor
3. Remove the retainer and wash- plate retaining screw closest to the cap.
ers securing the movable breaker diaphragm mounting flange. 10. Connect the primary or dis-
plate to the stationary sub-plate. 4. Position the entire breaker plate tributor-transistor wir"e.
\EJ REMOVAL AND INSTALLATION
REMOVAL INSTALLATION
1. On a conventional ignition sys- The distributor installation is
tem, disconnect the primary wire at shown in Fig. 2.
the coil. On a transistor ignition 1. If the crankshaft was rotated
system, disconnect the distributor- while the distributor was removed
transistor lead from the quick dis- from the engine, it will be necessary
connect. Disconnect the vacuum ad- to time the engine. Rotate the crank-
vance line at the distributor. Re- shaft until No. 1 piston is on TDC
move the distributor cap. (after the compression stroke) . Align
2. Scribe a mark on the distribu-
the TDC mark on the timing pointer
tor body and engine block indicating
the position of the body in the block, with the timing pin on the crank-
and scribe another mark on the dis- shaft damper. Position the distribu-
tributor body indicating the position tor in the block with the rotor at
of the rotor. These marks can be the No. 1 firing position.
used as guides when installing the Make sure the oil pump inter-
distributor in a correctly timed en- mediate shaft properly engages the FIG. 2-Distributor
gine. distributor shaft. It may be neces- Installation
3. Remove the distributor hold sary to crank the engine with the
down cap screw and clamp. Lift the starter, after the distributor drive to engage the oil pump intermedi-
distributor out of the block. gear is partially engaged, in order ate shaft.

Install, but do not tighten, the the mark previously scribed on the coil. On a transistor ignition system,
retaining clamp and screw. Rotate distributor body, and the marks on connect the distributor-transistor lead
the distributor body counterclock- the distributor body and engine block to the quick disconnect.
wise until the breaker points are just in alignment. Install the retaining 5. Check the ignition timing with
starting to open. Tighten the clamp. clamp. a timing light and adjust if neces-
2. If the crankshaft has not been 3. Install the distributor cap. sary. Connect the vacuum line, and
rotated, position the distributor in 4. On a conventional ignition sys- check the advance with the timing
the block with the rotor aligned with tem, connect the primary wire to the light when the engine is accelerated.

BENCH DISASSEMBLY
Drift _ _...,_.Ill
1. Remove the distributor and Arbor
place it in a vise. Press Ram
2. Remove the rotor. Remove the
spring clip securing the diaphragm
link to the movable breaker plate.
Disconnect the diaphragm assembly
from the distributor base.
3. Lift the diaphragm link off the
pin and remove the diaphragm as-
sembly.
4. Disconnect the primary or dis-
tributor-transistor lead wire ana .the FIG. 4-Gear Removal
condenser wire (if so equipped)
from the breaker point terminal. 12. Carefully unhook and remove
5. Working from the inside of the the distributor weight springs. Mark
distributor, remove the primary or each spring, bracket and adjusting
distributor-transistor lead wire by post to which it is attached.
pulling it through the opening in the 13. Remove the weights.
distributor. 14. Remove the distributor cap
6. Remove the condenser (if so clamps.
equipped). 15. If the gear and shaft are to
7. Remove the breaker point as- be used again, mark the gear and
sembly. shaft so that the pin holes can be
8. Remove the lubricating wick. easily aligned for assembly. Re-
Using needle nose pliers, remove the move the gear roll pin (Fig. 3), then
cam retainer. remove the gear (Fig. 4).
16. Remove the shaft coJlar roll
9. Remove the movable breaker
plate spring retainer and washers. pin (Fig. 5). FIG. 6-Shaft Removal
10. Remove the stationary sub- 17. Invert the distributor and place
it on a support plate in a position BENCH ASSEMBLY
plate retaining screws. Remove the
sub-plate, breaker plate and cam as that will allow the distributor shaft ORIGINAL SHAFT AND GEAR
an assembly. to clear the support plate, and press
the shaft out of the collar and the 1. Oil the new bushing, and install
11. Remove the upper thrust distributor housing (Fig. 6). it on the bushing replacer tool. In-
washer. stall the bushing (Fig. 8). When the
18. Remove the distributor shaft
bushing (Fig. 7) . Remove the oil tool bottoms against the distributor
seal from the distributor housing. base, the bushing will be installed
to the correct depth.
2. Burnish the bushing to the
proper size (Fig. 9).
3. Oil the shaft and slide it into
the distributor body.
4. Place the collar in position on
the shaft and align the holes in the
Tooi-T52L-l 2131-C
collar and shaft, then install a new
pin (Fig. 10). Install the distributor
B1036-A cap clamps.
5. Check the shaft end play with
FIG. 3-Gear Pin FIG. 5-Collar Retaining a feeler gauge placed between the
Removal or Installation Pin Removal or Installation co1Iar and the base of the distributor.

(201) PART 9 _2 _DUAL ADVANCE DISTRIBUTORS 9-25
3-A
FIG. 9-Burnishing
Bushing
8. Remove the (.listributor ~r?m
the press. Install the gear retammg
pin (Fig. 3). . . .
9. Position the distributor ~ a
vise. Fill the grooves in the we1g~t
FIG. 11-Cam Installation
pivot pin with distributor cam lubn-
plate retaining screw closest to t~e
cant. .
diaphragm mounting flange (Ftg.
10. Position the weights in the dis- 13).
tributor.
11. Install the weight springs. Be 17. Position the movable breaker
sure the proper weight, spring and plate in the distribut'?r. In~tall the
fIG. 7- Bushing Removal adjustment bracket are assembled spring washer on the p1vot pm. Place
together. the flat washer on the spring washer.
12. Install the upper thrust washer. Be sure the protruding edges of the
If the end play is not within specifi-
13. Fill the grooves in the up~er spring washer are facing upward. In-
cations, replace the shaft and gear. stall the retainer.
6. Attach the distributor shaft sup- portion of the distributor shaft With
porting tool to the distributor. Tight- a distributor cam lubricant. 18. Install a new breaker point as-
en the backing screw in the tool 14. Install the cam assembly (Fig. sembly. Install the ground wire on
enough to remove all shaft end play 11 ) . Be sure that the slots in the cam the breaker point attaching screw
7. Install the assembly in a press. engage the pins in the weights. furthest from the breaker point ad~
Press the gear on the shaft (Fig. 10). 15. Install the cam retainer. Apply justment slot.
using the marks made on the gear a light film of cam lubricant to the 19. Install a new condenser (if so
and shaft as guides to align the pin cam lobes. Saturate the wick with equipped).
holes. SAE 1OW engine oil. Install the 20. Working from the inside to
wick in the earn assembly. The the outside of the distributor hous-
weights, springs and cam are shown ing, pass the primary or distributor-
installed in Fig. 12. transistor lead wire assembly through
16. Position the stationary sub- the opening in the distributor. Pull
plate in the distributor. Install one the wire through the opening until
end of the ground wire under the the locating stop is flush with the
PRESS ON inside of the distributor.
DISTRIBUTOR
BASE Tooi-T57L-12390-A
21. Connect the condenser wire, if
Detail 3 so equipped, and the primary or dis-
81044-A
FIG. 8-Bushing FIG. 10-0riginal Shaft
Installation
and Gear Installation
FIG. 12-Weights,
Springs and Com Installed

GROUP 9-IGNITION SYSTEM (202)
NEW SHAFT AND GEAR

The shaft and gear are replaced
as an assembly. One part should not
be replaced without replacing the
other. Refer to Fig. 1 for the correct
location of the parts.
1. Follow steps 1, 2 and 3 under
"Installing Original Shaft and Gear."
2. Attach the distributor shaft sup-
porJ:ing tool to the distributor and TIGHTEN SCREW
install the assembly in a vise. InM ENOUGH TO
REMOVE All
sert a 0.002-inch feeler gauge be- SHAFT END PLAY
tween the backing screw and the
shaft. Tighten the backing screw on
the tool enough to remove all shaft
FIG. 13-Sub-Piate end play. Remove the feeler gauge
Installation and allow the shaft to rest on the
backing screw. Slide the collar on 81387-8
tributorMtransistor lead wire to the the shaft. While holding the collar
breaker points. in place against the distributor base
{Fig. 14), drill a Vs -inch hole
FIG. 14-New Shaft ancl
22. Position the diaphragm assemM Gear Installation
bly and hook the diaphragm link through the shaft using the access
over the pin on the breaker plate. opening in the collar as a pilot.
5. Remove the distributor from
Install the diaphragm assembly re- 3. Position the gear on the end the press and remove the support
taining screws. Secure the diaphragm of the shaft. Install the assembly in tool. Install the collar retaining pin
link with a spring retainer. Install a press. (Fig. 5) and the gear retaining pin
the oil seal. 4. With the backing screw on the (Fig. 3).
23. Refer to Part 9-1 and make the support tool tightened enough to re- 6. Complete the assembly by fol-
following adjustments: move all end play, press the gear on lowing steps 8 thru 23 under "In-
Breaker point spdng tension. the shaft to the specified distance stalling Original Shaft and Gear."
Align the breaker points and ad- from the bottom face of the gear to
just the gap. the bottom face of the distributor
Check the breaker point dwell and mounting flange (Fig. 14). Drill a
resistance. Vs Minch hole through the shaft using
Centrifugal and vacuum advance. the hole in the gear as a pilot.

(203)
PART SPECIFICATIONS
9-3
DISTRIBUTOR ADVANCE CHARACTERISTICS (Continued)
GENERAL VACUUM ADVANCE. Set the test stand to oo at 1000 rpm

and 0 inches of vacuum.
Conventional Ignition System Distributor Advance Vacuum {Inches
(rpm) (Degrees) of Mercury)
Breaker Arm Spring Tension (Ounces) ......... 17-20
1000 Y2-3Y2 8
Contact Spacing (Inches) . . . . . . . . . . . . .. 0.014-0.018 1000 2;6-5;6 10
Dwell Angle at Idle Speed . . . . . . . . . . . .... 26°-28;6 o 1000 4-7 12
1000 41h-7;6 20
Transistor Ignition System Maximum Advance Limit ........................ 7;6 0
Breaker Arm Spring Tension (Ounces) ......... 19-21

Contact Spacing (Inches) ............... 0.019-0.021 Transistor Ignition System (Distributor
Dwell Angle at Idle Speed . . . . . . . . . . . ...... 22°-24° No. C4VF-12127-C)
CENTRIFUGAL ADVANCE. Set the test stand to oo at
250 rpm and 0 inches of vacuum.
DIMENSIONS
Distributor Advance Vacuum (Inches
Shaft End Play With Distributor 500 11;4 -2Y4 0
600 2%-3% 0
Removed (Inches) . . . . . . . . . . . . . . . . . . ... 0.022-0.030 800 4-5 0
Gear Location Dimension, From Bottom of Gear 1600 6%-81;4 0
2000 8Y4-9% 0
to Bottom of Mounting Rib (Inches) . . ... 3.071-3.077 Maximum Advance Limit ............... Not applicable
CONDENSER
Capacity (Microfarads) ...............

Maximum Leakage (Megohms) ...... .
a._M_a_x_im_um
__Se_r_i_es_R_e_s_is-ta_n_c_e_(o_h_m_s_)_
3
.._._ 1
VACUUM ADVANCE. Set the test stand to oo at 1000 rpm
and 0 inches of vacuum.
Distributor
(rpm)
1000
1000
1000
Advance
(Degrees)
1h-3;6
2Y2-5;6
4-7
Vacuum (Inches
of Mercury)
8
10
12
1000 4Y2-7Y2 20
Maximum Advance Limit ........................ 7lh0
IGNITION TIMING
Recommended Setting* . . . . . . . . . . . . . . . ...... 6 o BTDC SPARK PLUGS

*If the individual requirements of the car and/or if sub-
standard fuels dictate, the initial timing may have to be
retarded from the recommended setting to eliminate detona- Type ............................... Auto Lite BF-42
ltion (spark knock) . If retarding is necessary it should be Size ........................................ 18 mm.
done progressively and not to exceed 2" BTDC. Gap (Inches)
Conventional Ignition System ............. 0.032-0.036
Transistor Ignition System ................ 0.028-0.032
Torque (F~Ibs) .............................. 15-20*
ADVANCE CHARACTERISTICS *When a new spark plug is installed in a new replacement
cylinder head, torque the spark plugs to 20-30 ft-lbs.
Note: The advance characteristics that are given apply to
the distributor number as stamped on the distrib-
utor housing or on a plate attached to the distrib-
utor housing. COIL
Conventional Ignition System

Conventional Ignition System (Distributor
No. C4VF-12127-B) Primary Resistance (Ohms)* ........ 1.40-1.54 (75° F.)
Secondary Resistance (Ohms) ...... 8000-8800 (75° F.)
CENTRIFUGAL ADVANCE. Set the tt:st stand to oo at Amperage Draw
250 rpm and 0 inches of vacuum. Engine Stopped .............................. 4.5
Engine Idling ................................ 2.5
Distributor Advance Vacuum (Inches *Primary Circuit Resistor ........... 1.30-1.40 (75° F.)
500 l1.4-2Y4 0 Transistor Ignition System
600 2%-3% 0 Primary Resistance (Ohms)* ........ 7.00-9.00 (75o F.)
Secondary Resistance (Ohms) ...... 5000-7000 (75° F.)
800 4-5 0
Amperage Draw
1600 6%-8% 0 Engine Cranking ............................. 4.0
2000 8%-9 3/<i 0 Engine Idling ................................ 5.0
Maximum Advance Limit ... Not applicable *Primary Circuit Resistor .......... 7.00-9.00 (75° F.)

(204)
lJ(X]O@ (¥>~®§
O~lJ§~lJ0@~~[1J1 \'7
§(S~~~

10-1
GROUP
10
GENERAL FUEL SYSTEM SERVICE .. 10-1 FUEL PUMP AND VAPOR DISCHARGE
VALVE . . . . . . . . . . . . . . . . . . . . 10-27
PART 10-2 PART 10-5
CARTER CARBURETOR . . . . . . . . . . . I 0-11
FUEL TANK AND LINES . . . . . . . . . . 1 0-31
PART 10·3 PART 10-6
AIR CLEANER AND AIR DUCT ..... 1 0-25 SPECIFICATIONS . . . . . . . . . . . . . . . 1 0-34
PART GENERAL FUEL SYSTEM SERVICE

10-1
1 Diagnosis and Testing . . . . . . . . . . ......... 10-1 3 Cleaning and Inspection .................. 10-9
2 Common Adjustments and Repair-; .......... 10-5
II DIAGNOSIS AND TESTING I

FUEL TANK, LINES AND FILTER VAPOR DISCHARGE VALVE bleed and can be disregarded when
Test. To check whether the valve making the test.
Water and dirt that accumulate
If a considerable amount of fuel
in the fuel tank can cause a restricted is open or closed, operate the engine,
and disconnect the vapor return line is being discharged, the valve is
fuel line or filter and malfunction
at the fuel pump adapter connection. open. This condition may be due
of the vapor discharge valve, fuel to the high temperature of the fuel
pump, or carburetor. Condensation, Guard against any fuel spillage by
using a container to collect any within the pump or to the valve
which is the greatest source of water stem sticking in the open position.
entering the fuel tank, is formed by fuel that is discharged during the
check (Fig. 1). In either instance, steps must be
moisture in the air when it strikes taken to close the valve, either by
the cold interior walls of the fuel If only a small amount of fuel is cooling the fuel pump or, if the
tank. being discharged at the adapter ori- valve is stuck open, cleaning or re-
Leakage in the fuel inlet line can fice, the valve is closed. The dis- placing the valve assembly.
cause low vacuum, pressure and vol- charged fuel (approximately four If it is desired, a suitable cap or
ume conditions, and loss of fueL ounces in 100 seconds) is passing plug may be placed in the vapor dis-
A restricted fuel tank vent, located through the pressure leak-down charge outlet while performing the
in the filler cap, can cause low fuel fuel pump tests. If a cap or plug is
pump pressure and volume which
not used, connect the vapor return
may, in some instances, result in
line to the adapter.
collapsed inlet line hoses or a col-
lapsed fuel tank.
FUEL PUMP
VAPOR DISCHARGE VALVE Incorrect fuel pump pressure and
AND FUEL PUMP low volume (flow rate) are the two
Fuel pump static pressure and most likely fuel pump troubles that
flow capacity specifications for the will affect engine performance. Low
fuel pump take into consideration pressure will cause a lean mixture at
the effect of the thermostatic vapor high speeds and excessive pressure
discharge valve on these functions; will cause high fuel consumption and
therefore, all checks of static pres- carburetor flooding. Low volume will
sure and flow capacity must be taken cause fuel starvation at high speeds.
with the thermostatic valve in the Two tests: fuel pump static pres-
closed (cold) position to prevent FIG. 1-Vapor sure and fuel volume are necessary
condemnation of a good pump. Discharge Valve Test to determine that the fuel pump is

10-2 GROUP 10-FUEL SYSTEM (206)
FUEL OUTLET PRESSURE

in satisfactory condition. HOSE a flexible fuel outlet hose (Fig. 2)
GAUGE
If both the fuel pump volume and
pressure are within specifications, the
pump and lines are in satisfactory
" between the carburetor inlet connec-
tor and the fuel inlet line connector.
3. Position the flexible fuel outlet
condition and a vacuum test is not hose so that the fuel can be expelled
required. into a suitable container (Fig. 2) for
If the pump volume is low, but the capacity (volume) test.
the pressure is within specifications, 4. Operate the engine. Vent the
a test must be made with the filter system into the container by opening
removed. If the pump volume meets the hose restrictor momentarily be-
specifications with the filter removed, fore taking a pressure reading.
replace the filter. If the pump vol· 5. Operate the engine at 500 rpm.
FUEL
ume is still below specifications with CONTAINER
After the pressure has stabilized, it
the filter removed, repeat the test, 81936-A should be to specification.
with an auxiliary fuel supply source. Capacity Volume Test. Perform
If the pump still does not meet speci- FIG. 2-Fuel Pump this test only when the fuel pump
fications, replace the pump. If the Pressure and Capacity Tests pressure is within specifications.
pump does meet specifications, there 1. Operate the engine at 500 rpm.
is a restriction in the fuel supply performing the tests. A clogged or 2. Open the hose restrictor and
from the tank or the tank is not vent- restricted filter is often the cause expel the fuel into the container
ing properly. of fuel system malfunction. (Fig. 2) , while observing the time
The tests are performed with the required to expel one pint; then, close
fuel pump installed on the engine. Pressure Test the hose restrictor. One pint of fuel
Make certain the replaceable fuel 1. Remove the air cleaner. Dis- should be expelled within the spe-
filter element has been changed connect the fuel inlet line at the cified time limit.
within the recommended mainte- carburetor. Use care to prevent 3. Remove the test equipment and
nance mileage interval. When in combustion due to fuel spillage. connect the fuel inlet line to the
doubt, install a new filter prior to 2. Connect a pressure gauge, and carburetor.
FUEL PUMP, TANK AND LINES DIAGNOSIS GUIDE
Diaphragm stretched or leaking. Fuel line cracked or broken.

Fuel pump diaphragm spring Fuel pump valves improperly seat-
weak. ed.
Rocker arm worn. Dirt in fuel tank and/or lines.
LOW FUEL PUMP PRESSURE Excessive clearance between rocker Fuel tank vent (filler cap) re-
OR VOLUME arm and fuel pump link. stricted.
Fuel pump push rod and/or ec- Diaphragm ruptured.
centric worn or undersized. Vapor discharge valve malfunc~
Fittings loose or cracked. tioning.
Fuel filter clogged. Main body retaining screws loose.
Diaphragm spring too strong or tioning.

improper spring. Pump link has no free play
HIGH FUEL PUMP PRESSURE
Diaphragm surface too tight (frozen).
OR VOLUME
( overtensioned) . Diaphragm vent (breather hole)
Vapor discharge valve malfunc- plugged or missing.
Diaphragm stretched or leaking. er arm and fuel pump link.

Fuel pump springs weak. Fuel pump push rod and/or ec-
Fuel pump valves improperly centric worn or undersized.
LOW FUEL PUMP VACUUM seated. Vapor discharge valve malfunc-
Diaphragm ruptured. tioning.
Rocker arm worn. Main body retaining screws loose.
Excessive clearance between rock-
LOW FUEL PUMP VOLUME

Fuel filter clogged. Restriction in fuel supply line to
WITH NORMAL PRESSURE Fuel pump to carburetor inlet tube fuel pump.
obstructed, crimped, or leaks.
Main body retaining screws loose. Threads on fittings stripped.

FUEL PUMP LEAKS FUEL Diaphragm defective. Body cracked.
Fittings loose.
FUEL PUMP LEAKS OIL Fuel pump retaining bolts loose. Mounting gasket defective.

(207} PART 10-1- GENERAL FUEL SYSTEM 10-3
FUEL PUMP, TANK AND LINES DIAGNOSIS GUIDE (Continued}
Rocker arm, eccentric or push rod Rocker arm spring weak or

FUEL PUMP NOISE worn. broken.
Mounting bolts loose.
FUEL TANK AND/OR INLET Fuel tank vent in filler cap ob-
LINE HOSES COLLAPSED structed.
AIR DUCT 8. If the valve plate moves freely, felt by finger application and the
replace the thermostat and spring engine rpm will decrease. If the
1. Place the air duct assembly in assembly. Retest the HEAT-ON and engine rpm does not decrease or no
a container of cool water (below the REAT -OFF temperatures. suction is indicated at the inlet tube,
75o F.). Be sure that the thermostat 9. If the valve does not operate the fast idle solenoid is malfunction-
is covered by the water. correctly, adjust the thermostat rod. ing and further tests are required.
2. Place a thermometer in the water By increasing the rod length, the 3. Check for current at the sole-
and observe the temperature. valve plate will be moved toward noid terminals with the appropriate
3. With the water temperature at the HEAT-OFF position. By de- meter. If no current is present, check
75o F. or below, the valve should be creasing the rod length, the valve the air conditioner electrical sys-
in the HEAT-ON position. plate will be moved toward the tem for the cause of the malfunc-
4. Using a hot plate or other suit- REAT-ON position. tion. If current is present, remove
able device, heat the water slowly. the solenoid and check the solenoid
5. When the water temperature CARBURETOR valve and seat for damage. If the
reaches 85° F., the valve should Dirt accumulation in the fuel and seat is damaged, replace the entire
start to open. If the valve does not air passages, improper idle adjust- assembly. If the valve is damaged,
start to open at this time, stabilize ments, and improper fuel level are replace the valve only. If both the
the water temperature at 85° F. the major sources of carburetor valve and seat are undamaged and
for eight minutes before condemn- troubles. the unit is free of dirt, replace the
ing the unit. solenoid.
6. When the water temperature TESTS
reaches 100° F. or higher, the valve Idle Speed-Up Control Accelerating Pump Discharge
should be in the full HEAT-OFF 1. Remove the air cleaner. Operate 1. Remove the air cleaner.
position. the engine and the air conditioner. 2. Open the primary throttle plates
7. If the operation of the valve 2. Place a finger on the air passage and observe the fuel flow from the
is unsatisfactory, remove the ther- inlet tube projecting through the air accelerating pump discharge nozzles.
mostat and spring assembly and horn. If the idle speed-up control If the system is operating correctly,
check the valve plate shaft for bind- unit is operating correctly, the pull a quick steady stream of fuel will
ing. of vacuum will be sufficient to be flow from the discharge nozzles.
CARBURETOR DIAGNOSIS GUIDE
High fuel level. Leaking carburetor float.

Loose fuel inlet needle valve seat Float tab surface rough.
or seat gasket damaged or missing. Dirt or foreign material in fuel
FLOODING
Excessive fuel pump pressure. holds float needle valve open.
Sticking and/or restricted float op- Worn needle valve and seat.
eration.
Incorrect starting procedure. adjustment.

Automatic choke malfunction. Fuel filter or supply lines restricted
Incorrect choke linkage adjust- with dirt, water, or ice.
HARD STARTING ment. Carburetor leaking and/ or flood-
Incorrect fast idle adjustment. ing.
High carburetor fuel level. Insufficient fuel supply to carbure-
Incorrect accelerator pump stroke tor.
Improperly adjusted or defective Carburetor air, hot and cold valve

carburetor dashpot. malfunctioning.
Engine idle speed too slow. Dirt, water, or ice in fuel filter.
Incorrect idle fuel mixture.
STALLING (ENGINE HOT) Fuel tank vented cap restricted.
Insufficient fuel supply to carbure-
tor. Fuel lines restricted or leaking air.
Coolant control thermostat defec- Carburetor icing (cold, wet, or
tive. humid weather).

GROUP 10-FUEL SYSTEM (208)
CARBURETOR DIAGNOSIS GUIDE {Continued)
Excessive looseness of throttle Leaking · intake manifold and/or

STALLING (ENGINE HOT) shaft in bores of throttle body. gaskets.
(Continued) Incorrect throttle linkage adjust· Idle compensator malfunctioning.
ment to carburetor. Defective idle speed-up control.
Clogged air bleeds or idle passages. (air conditioner equipped cars).
Incorrect fast (cold) idle screw ad- Dirt, water, or ice in fuel filter.
justment. Incorrect idle fuel mixture.
Automatic choke malfunction. Fuel tank vented cap or fuel lines
STALLING (ENGINE COLD)
Defective fuel pump and/or worn restricted.
push rod. Defective idle speed-up control
(air conditioner equipped cars) .
Engine idle speed too slow. malfunctioning.

Incorrect idle air-fuel mixture. Incorrect or creeping carburetor
Foreign material obstructing idle fuel level.
fuel and/ or air system. Throttle plates and/ or throttle
ROUGH ENGINE IDLE Fresh air leakage into engine in- shaft bent or damaged. Throttle
duction system. plates misaligned.
Coolant control thermostat defec- Idle compensator malfunctioning.
tive. Positive crankcase ventilation sys-
Carburetor air, hot and cold valve tem malfunctioning.
Restricted fuel tank vented cap. inlet and/or discharge check valves.
Restriction in fuel line or air leak. Dirt, water, or ice in fuel filter.
Carburetor fuel level low. Accelerator pump plunger defec-
Dirt or restriction in accelerator tive.
ACCELERATION POOR pump system. Defective fuel pump and/or push
Inoperative pump inlet check. rod.
Accelerator pump link incorrectly Automatic choke malfunctioning.
installed. Carburetor air, hot and cold valve
Poor seating of accelerator pump malfunctioning.
Fast idle screw contacting low step Improperly adjusted or defective

of cam at curb idle. carburetor dashpot.
Incorrect throttle linkage adjust· Incorrectly installed throttle plates.
ment to carburetor. Idle compensator malfunctioning.
INCONSISTENT ENGINE Binding or sticking throttle linkage Positive crankcase ventilation sys-
IDLE SPEED or accelerator pedal. tem malfunctioning.
Sticking carburetor throttle shaft. Defective idle speed-up control
Excessive looseness of throttle (air conditioner equipped cars) .
shaft in bores of throttle body.
Thermostatic choke setting too Choke plate misaligned in air horn;

rich. binding.
AUTOMATIC CHOKE SLOW
Choke linkage sticking or binding. Defective coolant thermostat.
WARM-UP, ON TOO OFTEN
Incorrect choke linkage adjust- Restricted coolant line.
ment.
SEVERE TRANSMISSION Carburetor fast idle speed setting Throttle operating on starting step
ENGAGEMENT AFTER COLD too high. (highest step) of fast idle cam.
ENGINE START
Clogged main jets. Clogged filter screen.

SURGING (CRUISING SPEEDS Undersize main jets. Distributor vacuum passage
TO TOP SPEEDS) Low fuel level or float setting. clogged.
Low fuel pump pressure or volume.
Low fuel pump volume. Improper size or obstructed main

Low fuel level or float setting. jets.
REDUCED TOP SPEED Distributor advance malfunction- Faulty choke operation.
ing. Metering rod operating piston mal-
functioning.

(209) PART 10-1- GENERAL FUEL SYSTEM 10-5

CARBURETOR BENCH TO ADJUST, BEND
ADJUSTMENTS FLOAT ARM WITH
All carburetor adjustments except

the idle fuel mixture and the idle
speed adjustments can be made with
the carburetor removed from the car.
All adjustments except the float
adjustments, the bench fast idle speed
adjustment and the secondary throttle
lever adjustment can be made with
the carburetor mounted on the
engine.
In the process of rebuilding a car-
buretor, the bench adjustments
should be made in the following 81939-A
sequence:
FIG. 4-Fioat SeHing
FLOAT ADJUSTMENTS
I•'Ioat Setting 2. Bend the stop tab on the float
There are three adjustments that 1. With the air horn inverted, the bracket, as necessary, to adjust the
should be made on each float and air horn gasket in place, and the fuel drop.
lever assembly. The adjustments are inlet needle seated, check the clear-
made in the following order: ance between the end of each float ACCELERATOR PUMP
and the air horn gasket (Fig. 4). ADJUSTMENTS
Float Alignment
The clearance should be within spt!ci- Operating Rod
1. Sight down the side of each
float shell to determine if the side of fication. 1. With the accelerator pump op-
the float is parallel to the outer edge 2. Bend the float arm up to in- erating rod in the top hole (long
of the air hom casting (Fig. 3). crease the clearance or down to de- pump stroke) of the pump arm and
2. To adjust float alignment, bend crease the clearance (Fig. 4). Apply the throttle plates closed, measure
the float lever by applying pressure only enough pressure to bend the the distance from the top surface of
to the end of the float shell with the float arm. the air horn to the top of the plunger
fingers while supporting the float Float Drop shaft (Fig. 6) . The distance should
lever with the thumb to prevent dam- 1. With the air horn held in an
be within specification.
age to the float. Apply only enough 2. To adjust the distance, bend
upright position, measure the dis-
pressure to btmd the float lever. the accelerator pump operating rod
tance between the top of each float
3. After aligning the float, remove at the existing lower bend, as neces-
and the air horn gasket at the free-
as much clearance as possible be- end of each float (Fig. 5). The sary (Fig. 6).
tween the arms of the float lever and distance should be within specifica- Pump Stroke. The accelerator
the lugs on the air horn by bending tion. pump stroke adjustment compensates
the float.Iever. The arms of the float
lever should operate freely and be as
parallel to the inner surfaces of the
lugs on the air horn as possible.
TO ADJUST,
BEND FLOAT
LEVER
81938-A
FIG. 3-Fioat Alignment FIG. 5-Fioat Drop

ONE NOTCH RICH

THIS DISTANCE
FIG. &-Automatic
Choke Adiustment
AUTOMATIC CHOKE
ADJUSTMENT
Refer to step 4 of "Choke and
Countershaft Linkage Adjustment"
for the proper adjustment location
(Fig. 8).
TO ADJUST, BEND HERE AS NECESSARY 81941-A
FAST IDLE LINKAGE
ADJUSTMENT
FIG. &-Accelerating Pump Adiustment Fast Idle Cam. Hold the choke
plate tightly closed; the center index
for the fuel needs of the engine dur- 4. Install the heat baffle, gasket, mark on the fast idle cam should be
ing extremes of hot or cold tempera- and the thermostatic coil housing as- opposite the center of the fast idle
ture. Insert the accelerator pump op- sembly. Be sure the thermostatic screw (Fig. 9). If adjustment is re-
erating rod into the appropriate hole coil engages in the slot of the quired, bend the fast idle cam con-
in the pump arm for the climate in choke piston lever. Install the re- nector rod at the existing bend (Fig.
which the car is to be driven (Fig. taining screws loosely, then index 9).
6). the thermostatic coil housing mark Fast Idle Speed Adjustment -
CHOKE AND COUNTERSHAFT with the mid-position mark on the Bench Only. With the choke plate
LINKAGE ADJUSTMENT choke housing (Fig. 8). tightly closed, and the fast idle ad-
1. Bend a 0.026 inch wire gauge
(tool 9597) at a 90° angle, approxi-
mately Vs inch from its end.
2. Block the throttle about half-
open so the fast idle cam does not
contact the adjusting screw. Loosen
the choke countershaft lever clamp
screw. Insert the bent end of the
wire gauge into the choke housing
piston bore so that it is between the
top edge of the slot in the choke
piston cylinder and the bottom of the
slot in the choke piston (Fig. 7).
Hold the wire gauge in place by ex-
erting light pressure on the counter-
shaft lever.
3. Insert the specified size drill or
gauge (Fig. 7) between the upper
edge of the choke plate and tpe inner
wall of the air horn. Hold the choke
plate against the drill or gauge and
tighten the clamp screw on the 81942-A
countershaft lever. Remove the
gauges. FIG. 1-Choke Piston Lever Adiustment

(211) PART 10-1-GENERAL FUEL SYSTEM 10-7 ,I
TO ADJUST, BEND ROD WITH Tool-
FIG. 11-Unloader
Adiustment
UNLOADER ADJUSTMENT
1. With the throttle wide open,
there should be the specified clear-
81944-A ance (tool 9545) between the upper
edge of the choke plate and the wall
FIG. 9-Fast Idle Cam Adiustment of the air horn (Fig. 11).
2. To adjust, bend the unloader
justing screw resting on the fast idle side opposite the idle port (Fig. 10). arm on the throttle lever (Fig. 11).
cam at the center index mark, there To adjust the clearance, turn the: fast
should be the specified clearance idle screw clockwise to increase the
(tool 9597) between the primary clearance and counterclockwise to ANTI-STALL DASHPOT
plate and the throttle bore at the decrease. ADJUSTMENT
1. With the primary throttle plates
closed to their normal curb idle posi-
tion, there should be the specified
clearance between the dasbpot Plung-
er operating lever and the top sur-
face of the air born (Fig. 12). To
adjust the clearance, bend the dash-
pot lever in the area between the
lever arm base and the dasbpot
plunger (Fig. 12).
2. With the primary throttle plates
wide open, there should be the speci-
fied clearance between the dashpot
plunger operating lever and the top
surface of the air born (Fig. 12). To
adjust, bend the stop tang on the
opposite side of the lever arm (Fig.
12).
SECONDARY THROTTLE
LEVER ADJUSTMENT -
BENCH ONLY
1. Block the choke plate open.
2. Open the primary throttle plates
until there is the specified distance
(Fig. 13) between the lower edge of
the throttle plate and the throttle
FIG. 10-Fast Idle Speed Bench Adiustment bore (side opposite the idle port).

AT CLOSED THROTTLE, THIS DIMENSION SHOULD BE Ya INCH.
At this point, the secondary throttle

plate should just start to open. To
adjust, bend the throttle operating
rod at the existing bend (Fig. 13).
3. When both the primary and
secondary throttle plates are com-
pletely closed, there should be the
specified clearance (tool 9597-B)
between the positive closing shoes on
the primary and secondary throttle
levers (Fig. 14). To adjust, bend the
shoe on the secondary throttle lever
(Fig. 14).
SECONDARY THROTTLE
LOCKOUT ADJUSTMENT TO ADJUST, BEND LEVER TANG WITH Tooi-9564-A
1. Open the throttle plates slightly,

then manually open and close the
choke plate. As the fast idle cam
moves the lockout plate, the tang on
the secondary throttle lever should
freely engage in the notch (Fig. 15).
2. To adjust the secondary throttle
lever, bend the lever tang as required
(Fig. 15).
3. Hold the lockout plate to the
left and tight against the stop on
the main body casting (secondary
throttle plates partially open). The
clearance (Fig. 16) between the tang AT WIDE OPEN THROTTLE THIS
DIMENSION SHOULD BE ¥!6 INCH.
on the secondary throttle lever and AIR HORN
81947-A
the ramp on the lockout plate should
be within specification.
4. To adjust the clearance, bend
FIG. 12-Anti-Stall Dashpot Adiustment
the arm at the slot on the lockout
plate, as required (Fig. 16).
IDLE FUEL MIXTURE AND

IDLE SPEED ADJUSTMENTS-
ON THE CAR
The idle fuel mixture and idle
speed adjustments are performed
with the carburetor installed on the
engine. Refer to Part 2, Section 2
for the proper procedure.
THROTTLE LINKAGE
ADJUSTMENTS - ON THE CAR
The throttle linkage adjustments
for the Turb-O-Drive transmission
are covered in Group 7.
FUEL FILTER REPLACEMENT

A replaceable fuel filter is located
between the fuel pump and the car-
BEND HERE TO ADJUST-
buretor fuel inlet line (Fig. 17). Re- USE Tool-99798
place the eletnent if it becomes 81948-A
clogged, and also at the recommend·
ed main.tenance mileage interval. FIG. 13-Secondary Throttle Plate Adiustment

PART 10-1 -GENERAL FUEL SYSTEM 10-9
(213}
FIG. 17 -Fuel Filter

MAINTENANCE
Refer to Group 19 for the recom-
mended maintenance mileage inter-
FIG. 14-Primary and Se,ondary Closing Shoe Clearan(e val.
REPLACEMENT
1. Disconnect the fuel line from

the filter. Unscrew the filter from the
fuel pump.
2. Screw the new filter into the
0
-.---4'--~-----------
fuel pump. Do not over-tighten it.
Connect the fuel line to the fuel
LOCKOUT BEND TO PROVI filter. Use a wrench on the filter
PLATE SPECIFIED CLEARANCE B 19 51 ··A connection to prevent it from turn-
PLATE THROTTLE LEVER 81950-A ing when connecting the line.
FIG. 16-se,ondary 3. Operate the engine and check
FIG.15-se,ondary Throttle Lever Tang to Lo,kout the fuel line and filter connections
Throttle Lever Adiustment Plate Clearan(e Adiustment for leaks.

Rinse the parts in kerosene to re- bore for excessive looseness or bind-
CARBURETOR move all traces of the cleaning sol- ing and check the throttle plate(s)
Dirt, guln, water or carbon con- vent, then dry them with compressed for burrs which prevent proper Clos-
tamination in the carburetor or the air. Wipe all parts that cannot be ure. 1f the throttle shafts are exces-
exterior moving parts of a carburetor immersed in solvent with a clean, sively loose or bind in the main
are often responsible for unsatisfac- soft, dry cloth. Do not use com* body, or the plates prevent proper
tory performance. For this reason, pressed air to dry these parts. Be closure, replace or repair the com-
efficient carburetion depends upon sure all dirt, gum, carbon, and other ponent parts.
careful cleaning and inspection. foreign matter are removed from all Inspect the main body, air horn,
The cleaning and inspection of parts. nozzle bars and booster venturi as-
only those parts not included in the Force compressed air through all semblies, choke housing and thermo.:
carburetor overhaul repair kit are passages of the carburetor. Do not static spring housing, and the throttle
covered here. All gaskets and parts use a wire brush to clean any parts body for cracks.
included in the repair kit should or a drill or wire to clean out any Check the metal floats for leaks
be installed when the carburetor is openings or passages in the car- by holding them under water that
assembled and the old gaskets and buretor. A drill or wire may en- has been heated to just below the
parts should be discarded. large the hole or passage, changing boiling point. Bubbles will appear if
Wash all the carburetor parts (ex- the calibration of the carburetor. there is a leak. lf a float leaks, re-
cept the fast idle solenoid and poppet Check the choke shaft for grooves, place it. Replace the float if the arm
valve, accelerating pump plunger. wear, and excessive looseness or needle contact surface is grooved.
and the anti-stall dash pot plunger) binding. Inspect the choke plate for If the floats arc serviceable, polish
in clean commercial c;uhuretor clean- nicked edges and the choke plate the needle contact surface of the
ing solvent. If a commercial solvent valve for ease of operation, and free arm. Replace the float shafts if they
is not available, lacquer thinner or them if necessary. are worn.
denatured alcohol may be used. Check the throttle shaft(s) in its Replace all screws and nuts that

have stripped threads. Replace all Rinse the valve assembly in kero- There are two alternate procedures
distorted or broken springs. sene to remove all traces of the that can be used to clean the air
Inspect all gasket mating surfaces cleaning solvent, then dry it with filter element. One method is per-
for nicks and burrs. Repair or re- compressed air. Be sure all dirt, formed with the use of compressed
place any parts that have a damaged carbon, and other foreign matter air. The other is performed by
gasket surface. are removed from the part. tapping the element on a smooth
Manually move the vapor valve horizontal surface.
Inspect the idle tubes in each noz-
zle bar assembly. If they are plugged, stem back and forth to verify that Compressed Air Method. Direct
bent, or broken, replace the booster there is no sticking of the valve stem a stream of compressed air through
venturi and nozzle bar assembly. in its guide. If a sticking or binding the element in the direction opposite
condition exists, and it cannot be that of the intake air flow, that is
Check the remaining internal com- eliminated by flushing the assembly from the inside outward. Extreme
ponents of the carburetor and re- in solvent, the valve assembly must care must be exercised to prevent
place any that are bent, worn, crack- be replaced. The valve unit should rupture of the element material.
ed or restricted. not be disassembled in an attempt Tapping Method. Hold the ele-
to clean it as the adjustment of ment in a vertical position and tap
FUEL PUMP the thermostatic setting is critical, it lightly against a smooth, horizon-
Clean the pump body and the and the unit is permanently sealed tal surface to shake the dust and
cover in solvent. Blow out all cover at the time of manufacture. dirt out. Do not deform the ele-
passages. Inspect the body and cover ment or damage the gasket sur-
for cracks or damage and replace AIR CLEANER faces by tapping too hard. Rotate
them if necessary. Inspect the staked MAINTENANCE the filter after each tap until the
areas around the valve and seal Refer to Group 19 for the recom- entire outer surface has been cleaned.
counterbores for high spots which mended air cleaner assembly mainte- Inspection. Hold the filter in front
may cause distortion of the new nance mileage interval. of a back-up light and carefully in-
parts upon installation. Remove a1l spect it for any splits or cracks. If
high spots. Inspect the mounting REMOVAL AND the filter is split or cracked, replace
flange for distortion. Replace the INSTALLATION it.
pump body or lap the distorted Refer to Part 10-3 for the air
flange, if necessary. cleaner assembly removal and instal- BODY AND COVER
lation procedures. Clean the air cleaner body and
VAPOR DISCHARGE VALVE cover with a solvent or compressed
Thoroughly flush the valve as- FILTER ELEMENT air. Wipe the air cleaner dry if a sol-
sembly in clean commercial car- The filter element must never be vent is used. Inspect the air cleaner
buretor cleaning solvent. If a com- cleaned with a solvent or cleaning body and cover for distortion or
mercial solvent is not available, lac- solution. Also, oil must not be damage at the gasket mating sur-
quer thinner or denatured alcohol added to the surfaces of the filter faces. Replace the cover or body if
may be used. element or air cleaner body. they are damaged beyond repair.

(215) PART 10-2-CARTER CARBURETOR 10-11
PART CARTER CARBURETOR

10-2
1 Description and Operation ..... ......... 10-11 3 Removal and Installation .................. 10-19
2 In-Car Adjustments and Repairs. .... 10-18 4 Major Repair Operations ................ 10-19

DESCRIPTION OPERATION and secondary high speed system.
FUEL INLET SYSTEM Each system has a fuel bowl, an
The Carter carburetor is a 4-bar-
rel, downdraft carburetor. A green- There are two separate fuel inlet inlet needle and seat assembly, float
colored code tag, fastened to one systems. Each system supplies fuel assembly and a fuel baffle plate (Fig.
of the air horn attaching screws to a low speed system, and a primary 4) . The fuel enters through the fuel
indicates the carburetor part num-
ber, change letter and build date. An
additional red-colored tag identifies
a unit that is calibrated for high
altitude operation.
The carburetor has two main as-
semblies. They are the air horn and
main body (Figs. 1, 2 and 3).
The air horn assembly, which
serves as the main body cover, con-
tains the choke plate, the fuel inlet,
the float assemblies and the Vac-
umeter (metering rods).
The main body contains the pri-
mary and secondary throttle plates,
the secondary auxiliary throttle
plates, the booster venturis, the hot
idle compensator, the anti-stall dash-
pot plunger assembly, accelerator COUNTERSHAFT lEVER 81953-A
pump assembly, the fuel bowls, bal-
ance passage, and. the fuel passages. FIG. 1-Carter 4-Barrel Carburetor-Right Rear ~ View
The automatic choke housing is
mounted on the main body. Air con- CHOKE PLATE LINK
ditioner equipped cars ~ontain an
idle speed-up control which is
mounted on the main body.
The carburetor has a low speed
(idle fuel system), an accelerating
pump system, a primary high speed
system (primary fuel system), and
a secondary high speed system (sec- FUEL INLET
ondary main fuel system). In addi-
tion, an automatic choke system pro-
vides the correct mixture necessary
for cold engine starting and warm
up. Vacuum operated metering
rods (Vacumeters) in the main
metering jets control the amount
of fuel admitted to the nozzle. An
internal anti-stall hydraulic dashpot
prevents stalling on quick decelera-
FAST IDLE
tion by slowing the closing of the
ADJUSTING SCREW
throttle plates. A fuel inlet system
provides the various fuel metering 81954-A
systems with a constant supply of
fuel. FIG. 2-Carter 4-Barrel Carburetor-Left Rear~ View

CHOKE VACUUM PASSAGE A combination internal and ex-

AND RESTRICTION CHOKE
HOT AIR PASSAGE ternal venting system vents the fuel
bowls internally into the air cleaner
and externally to the outside of
the carburetor. An internal vent is
located at the outside edge of each
Vacumeter tower. An external vent
is drilled into each internal vent pas-
sage just below. the air cleaner
mounting flange.
A balance passage in the main
body connects the fuel bowls. This
passage balances the fuel level be-
tween the two fuel bowls.
THERMOSTATIC CHOKE
The choke control mechanism
(Figs. 6 and 7) is controlled by
engine heated coolant. The heated
coolant is obtained from the heater
hose inlet fitting, located on the in-
take manifold. The coolant flows
PRIMARY THROTTLE through an inlet hose to the gasket
mounted water jacket that surrounds
81955-A the choke thermostatic-spring coil
housing. The coolant is then routed
FIG. 3-Carter 4-Barrel Carburetor-Bottom View through a return hose to the heater
return 1ine connection.
inlet fitting. A drilled passage through bly which rises and falls with the fuel Engine coolant does not contact
the air horn assembly connects both level. When the fuel in the fuel bowl the choke control mechanism. Only
fuel bowls. reaches a pre-set level, the float raises heat, radiated from within the cool-
The amount of fuel entering either the fuel inlet needle to a position ant jacket, affects the spring coil.
fuel bowl is regulated by the dis- where is restricts the flow of fuel, When the engine is cold, tension of
tance the fuel inlet needle is lowered admitting only enough fuel to re- the spring holds the choke plate
off its seat and by fuel pump pres- place that being used. closed. Conversely, when the engine
sure. Movement of the fuel inlet The fuel inlet needle seats are and coolant water warms, radiated
needle in relation to its seat is con- installed at an angle to provide heat is absorbed by the bimetal
trolled by the float and lever assem- seating of the needles (Fig. 5). spring; the thermostatic spring loses
its tension gradually until the choke
plate reaches full-open position.
The use of engine coolant to con-
trol the automatic choke results in
an air-fuel mixture that accurately
matches ·the engine requirements.
Water in the jacket loses its ·heat
slowly and delays activation of the
choke during short stop operations.
A choke countershaft, located over
the secondary barrels, connects the
choke linkage to the choke plate
(Fig. 6). When the engine is cold,
tension of the thermostatic coil holds
the choke plate closed. When the
engine is started, air velocity against
the offset choke plate causes it to
open slightly against the thermostatic
coil tension. Intake manifold vac-
uum, applied to the choke piston,
also pulls the piston downward,
opening the choke plate to a pre-
determined position. The choke plate
assumes a position where tension of
+-FUEL
~AIR CONDITIONER the thermostatic spring is balanced
FAST IDLE SOLENOID
81956-A by the pull of vacuum on the piston
and the force of air velocity on the
FIG. '4-Fuellnlet System choke plate. Enough air i~ drawn

around the choke plate to enable

the engine to operate and prevent
flooding.
As the engine starts to operate, INLET NEEDLE SEAT
the choke operating piston is pulled

downward by manifold vacuum. The
piston initial pulldown travel is lim-
ited by a vacuum bypass slot in the
piston cylinder wall (Fig. 7). When
the top of the piston reaches the top
FUEL INLET NEEDLE
of the vacuum slot, the vacuum pull
becomes ineffective due to air that
bleeds in through the slot in the
piston. The choke plate will then
be pulled open a definite distance,
but no farther. The air from the
choke piston cylinder is exhausted
through a passage in the base of 81957-A
the carburetor flange, into the left

primary barrel and across the edge FIG. 5-Fioat Assembly
of each primary throttle plate.
As the engine warms up, the ten- provided to supply fuel for idle-speed air adjusting screw.
sion of the bimetai, thermostatic-coil and early part-throttle operation. Air At idle and part throttle operation,
gradually decre,ases as the tempera- bleeds, restrictions, and adjustments the throttle plates are almost closed.
ture of the coolant in the water are provided to control and me:ter This produces strong manifold vac-
jacket rises. This action gradually the fuel-air mixture. The air flow uum below the throttle plates which
allows the choke plate to open. required for minimum idle speed creates a great enough difference in
When the engine reaches its nor- operation is controlled by an idle pressure between the fuel bowls and
mal operating temperature, the ther-
COVER
mostatic-coil spring exerts tension on COOLANT INLET
the choke plate, forcing it to the
full-open position.
If the engine is accelerated during LINK
the engine warm-up period, the cor-
responding drop in manifold vac-
uum applied to the choke piston al-
lows the thermostatic coil to momen-
tarily, partially close the choke plate.
This action provides a richer air-
fuel mixture.
UNLOADER
If during the starting period the
engine becomes flooded, the choke
plate max be opened manually to
clean out excessive fuel in the intake
manifold. This is accomplished by
fully depressing the accelerator pedal
and engaging the starter. The un-
Ioader projection on the throttle
lever contacts the unloader lug on
the fast idle cam and in turn par-
tially opens the choke plate.
During the warm-up period, It IS
necessary to provide a fast idle speed
to prevent engine stalling. This is PRIMARY
accomplished by a fast idle cam con-
ASSEMBLY
nected to the choke countershaft.
The fast idle adjusting screw on the FAST IDLE
throttle lever contacts the fast idle ROD
cam and prevents the throttle plates SECONDARY
from returning to a normal warm THROTTLE SHAFT
engine idle position while the auto- CHOKE LOCKOUT OF
matic choke is in operation. SECONDARY THROTTLE SHAFT
LOW SPEED (IDLE) 81958-A
FUEL SYSTEM
A low speed system (Fig. 8) is FIG. 6- Thermostati' Choke Unit and Linkage

THERMOSTATIC idle operation and when the engine

SPRING
is stopped.
From the low speed jet, the air
and fuel flows through an econo-
mizer passage (restriction) . After
leaving the restriction, air is bled
into the mixture from an additional
air bleed. The mixture then flows
down a vertical passage to the idle
passage in the main body, then to
the upper and lower discharge ports.
The upper discharge is a vertical
slot-type port which is located so that
the upper portion is above the
throttle plate at idle. The throttle
plates are milled at the location of
the upper discharge ports so that a
small portion of the port is exposed
to manifold vacuum at curb idle.
At curb idle, the upper portion of
the port acts as an additional air
bleed. The lower discharge port is
exposed to manifold vacuum at all
~VACUUM 11959-A
times.
The idle speed is adjusted by
FIG. 7-Choke System turning the idle air adjusting screw
(air control valve) to admit more or
the idle discharge ports to operate through a short diagonal passage less air, as required, below the
the low speed or idle fuel system to the low speed jet which meters throttle plates (Fig. 8). In other
(Fig. 8). The low speed system is the fuel for idle and part throttle words, it bypasses the primary
located in the primary barrel (Fig. operation. The fuel flows up the throttle plates. It is particularly
9). low speed jet where it is mixed with important that the idle speed and
Fuel is forced from the fuel bowl metered air from the bypass air mixture adjustments are adjusted
through the main jet to the bottom bleed. The bypass air bleed acts as at the same time. Opening the air
of the main well. From here it flows an anti-siphoning device during off- valve to increase the idle speed
leans the mixture, thus requiring
that the mixture screws also be
turned outward to provide addi-
tional fuel.
As the throttle is opened, a larger
portion of the upper discharge port
is exposed to manifold vacuum and a
correspondingly larger quantity of
fuel is discharged into the air
stream. Further opening of the
throttle plate results in a decrease
in manifold vacuum and a decrease
in the amount of idle fuel discharged.
As the idle fuel tapers off, the main
metering circuit begins discharging
fuel.
A thermostatically controlled hot
idle compensator is located in the
web between the secondary booster
venturis (Fig. 10). At carburetor air
high inlet temperatures, the hot idle
compensator will open and allow
additional air to bypass the throttle
plates and be exhausted directly into
the intake manifold. This improves
idle stability and minimizes the ef-
fect of fuel vaporation due to high
+VACUUM
81960-A
under-hood temperatures. It is nec-
essary that the valve be shut when
FIG. 8-Low Speed System adjusting the curb idle speed.

(219) PART 10-2- CARTER CARBURETOR 10-15:
IDLE SPEED-UP CONTROL-

WITH AIR CONDITIONING
On vehicles equipped with an air
conditioner, a mechanism is used to
increase the engine idle speed suffi-
ciently to overcome the additional
torque load incurred when the air
conditioner unit is on. This device
is an electrical solenoid switch which
operates an air valve in an external
bypass system of the carburetor, to
increase air flow below the throttle
plates (Fig. 10).
The idle speed-up valve oper-
ates only when the air conditioner
unit clutch is engaged. The solenoid
is not affected by throttle position or
manifold vacuum; it is controlled
solely by the clutch. It is not nec-
essary to operate the air condition-
ing system when adjusting the
curb idle speed.
ACCELERATING PUMP
SYSTEM IDLE MIXTURE ADJUSTING NEEDLE 81961-A
The accelerating pump system, lo- FIG. 9-Low Speed Idle Mixture System
cated in the primary side, provides
a measured amount of fuel neces-
sary for smooth engine operation on
acceleration at low speeds (Fig. 11).
When the throttle is closed, the
pump plunger moves upward in its SPEED-UP AIR PASSAGE
cylinder and fuel is drawn into the
pump cylinder through the intake
check valve. The discharge check
needle valve is seated at this time
to prevent air from being drawn into
the cylinder. When the throttle is
opened, the pump plunger moves
downward, forcing the fuel out
through the discharge passage. The
fuel is forced through a diagonal
passage to the discharge needle. The
force of the fuel unseats the needle
and fuel is free to flow through a
restriction into the discharge nozzles.
When the plunger moves downward,
the intake check valve is closed, pre-
venting fuel from being forced back
into the bowl.
At high speed, accelerating pump
discharge is not necessary for smooth
acceleration. When the throttle plates
are opened a predetermined amount,
the accelerating plunger bottoms in
the cylinder, eliminating discharge.
During high speed operation, a
vacuum exists at the discharge noz-
zles. To prevent fuel from being
drawn through the system, the dis-
charge nozzles are vented by a cavity
¢AIR
between the pump restrictions and
discharge nozzles. This allows air 81962-A
instead of fuel to be drawn through
the discharge nozzles. FIG. 10-ldle Speed-Up System

10-16 GROUP 10-FUEL SYSTEM {220)
PISTON
VACUUM
PICK-UP
81964-A
FIG.12-Vacumeter-
PUMP RETURN Metering Rods
SPRING
During part throttle operation,

manifold vacuum pulls the piston
81963-A and rod assembly down, holding the
large diameter of the metering rod
FIG. 11-Auelerating Pump System in the main metering jet. This is
true at all times when the vacuum
HIGH SPEED SYSTEM amount of fuel admitted to the noz- under the piston is strong enough
zles. The position of the metering to overcome the tension of the
Primary Side. The position of the rod is controlled by manifold vacuum Vacumeter piston spring. Fuel is
metering rod (Vacumeter) in the applied to the Vacumeter piston then metered around the large di-
main metering jet controls the (Fig. 12). ameter of the metering rod in the jet.
Under any operating condition
where the tension of the spring over-
comes the pull of vacuum under the
piston, the metering rod will move
up so that its smaller diameter or
power step is in the jet. This allows
more fuel to flow through the jet.
As engine speed increases, the air
passing through the booster venturi
creates a vacuum. The amount of
vacuum is determined by the air.:
flow through the venturi, which in
turn is regulated by the speed of the
engine. The difference in pressure
between the venturi and fuel bowl
causes fuel to flow through the pri-
mary high speed circuit (Fig. 13).
At a predetermined venturi vac-
uum, fuel flows from the fuel bowl,
through the primary high speed jet
MAIN into the bottom of the main well.
The fuel moves up the main well
tube, past air bleed holes. Filtered
~FUEL air from the high speed air bleed
enters the fuel flow in the main well
~FUEL-AIR tube through holes in the side of
the tube.
¢:"=JAIR
81965-A The fuel and air mixture con-
tinues up the main well tube and is
FIG. 1·3-Primory High Speed System discharged into the booster venturi

where it is atomized and mixed with

the air flowing through the car-
buretor. The high speed air bleed
also acts as an anti-percolating vent
when a hot engine is stopped or at
idling speed. This helps to vent fuel
vapors in the main well before the
pressure is sufficient to push fuel out
of the nozzles, into the intake mani-
fold.
The throttle plates control the
amount of fuel-air mixture admitted
to the intake manifold, regulating
the speed and power of the engine.
An air bleed is also located under
the strut of each primary booster ~FUEL
venturi assembly. The air bleed con-
~FUEL-AIR
nects to the main discharge nozzle
passage and smooths out the flow of ~AIR 81966-A
fuel. The air that is bled into the
passage is proportional to the vacu-
um at the nozzle. FIG. 14-Secondory High Speed System
Secondary Side. To provide suf-
begin to open and are moved through the main secondary dis-
ficient fuel-air mixture to operate
slightly beyond each transition hole, charge nozzles. The fuel flows up
the engine at maximum power, the
fuel is drawn from the transition the secondary main we11 tube. Air is
mixture supplied by the primary
hole by venturi vacuum. The fuel introduced from the secondary high-
stage of the carburetor is supple-
flows from the fuel bowl, through speed air bleed through holes in the
mented by an additional quantity
the secondary high-speed jet into the side of the tube. The fuel and air
of fuel-air mixture from the second-
transition fuel tube. The fuel flows are discharged into the main second-
ary high-speed system (Fig. 14).
up the tube where air is introduced ary discharge nozzles. The high-speed
The secondary throttle plates are through the transition discharge air air bleed also acts as an anti-
mechanically connected to the pri- bleed. The fuel and air are then dis- percolator vent when a hot engine is
mary throttle shaft. Secondary auxil- charged through the transition holes. stopped or at idling speed. This will
iary throttle plates arc located above As the auxiliary plates are opened help vent fuel vapor pressure in the
the secondary throttle plates, just still further, fuel is discharged high-speed system before it is suffi-
below the secondary booster venturis.
INLET PORT INTAKE BALL CHECK VALVE SEAT
A counterweight is located on each
end of the auxiliary throttle plate
shaft. The auxiliary throttle plates
start to open when the air pressure
on top of the plates is great enough
to overcome the effect of the coun-
terweights,.
When the primary throttle plates
are 34 full throttle and the choke
plate is open, the secondary throttle
plates start to open. The secondary
side of the carburetor does not start
to discharge fuel until the auxiliary
throttle plates start to open. The
amount of opening achieved by the
off-set auxiliary throttle plates is
controlled by the air velocity through
the secondary barrels.
A secondary throttle lockout lever
is located on the right side of the
carburetor. The lever prevents the
secondary throttle plates from open-
ing until the choke plate is open.
This improves cold engine drive-
away at wide open throttle.
Two transition holes are located
in each secondary booster venturi, PLUNGER SPRING
81967-A
just above the auxiliary throttle
plates. As the auxiliary throttle plates FIG. 15-Anti-Stoll Doshpot

10-18 GROUP 10-FUEL SYSTEM (222) .
cient to push fuel out of the nozzles. ANTI-STALL DASHPOT ing fuel above the plunger to fill
Fuel flow from the transition holes the cylinder below the plunger. When
tapers off as the fuel is discharged An internal hydraulic anti-stall
dashpot is incorporated in the car- the throttle is closed, the plunger is
through the secondary nozzles.
When the primary throttle plates buretor (Fig. 15) to slow the closing pushed downward. The intake ball
begin to close on deceleration, the of the throttle plates to idle position. check valve is closed and fuel below
secondary plates close mechanically. When the throttle is opened, the the plunger is forced through a small
The auxiliary secondary throttle anti-stall dashpot plunger spring restriction, delaying the downward
plates are closed by counterweights, pushes the plunger upward. The in- movement of the plunger and clos-
located on the ends of the shaft. take ball check valve opens, allowing of the throttle plates.

All carburetor adjustments except If one of the idle adjustments is INITIAL IDLE SPEED AND
the float adjustments, the bench fast changed, the other idle adjustments MIXTURE SETTINGS
idle speed adjustment and the sec- may also be affected. It is necessary 1. Make an initial idle fuel mix-
ondary throttle lever adjustment can that the adjustments be made in the ture adjustment, if necessary, by
be made with the carburetor mounted turning both screws inward until
order listed, and all of the idle ad-
on the engine. Refer to Part 10-1, they · lightly touch their seat; then,
justments that follow the one being
Section 1, for "Carter Carburetor back them outward 1V2 to 2V2 turns.
Bench Adjustments." made must be checked:
2. Make an initial idle air mixture
1. Idle Mixture Adjustment. adjustment, if necessary, by turning
IDLE FUEL MIXTURE AND 2. Hot Idle rpm Adjustment.
IDLE SPEED ADJUSTMENTS the idle air mixture screw inward
3. Fast Idle rpm Adjustment. until it lightly touches its seat, then
The idle fuel mixture is controlled turn it open 3 V2 turns.
by the idle mixture adjusting screws When setting the engine idle speed
(Fig. 16). Turn the screws inward to on vehicles equipped with an air con- HOT IDLE RPM ADJUSTMENT
lean the mixture, and outward to ditioner, the air conditioner should 1. Run the engine until it reaches
enrich the mixture supplied to the be turned off and the air cleaner re- normal operating temperature. If
intake manifold. moved. If the . air conditioner is the engine is cold, it should be run
The idle. speed (air) adjustment turned on (with the air cleaner for approximately one-half hour at
screw (Fig. 16) is used to adjust idle removed), a slight roughness of the 1200 rpm to stabilize the tempera-
speed. Turn the screw outward to ture.
increase speed. Conversely, turn the engine idle may be noted. This 2. Allow the throttle to drop back
screw inward to decrease speed. may be disregarded, since the air to the normal idle speed position.
Turning the screw outward leans cleaner traps vapor and allows Attach a tachometer to the engine.
the mixture, thus requiring an adjust- them to enrich the mixture to Remove the vacuum line from the
ment at the idle mixture screws. again regain a smooth idle. vacuum power unit of the automatic
ACCELERATING PUMP STROKE ADJUSTMENT vacuum release parking brake as-
sembly and plug the vacuum line.
Set the parking brake. It is neces-
sary to inactivate the vacuum
power unit to keep the parking
brake engaged during the adjust-
ment procedures.
3. Place a small weight on the idle
compensator spring to hold the com-
pensator closed. If the compensator
is open, because of high underhood
temperatures, the idle speed ad-
justment would be incorrect when
the compensator closes.
4. Adjust the idle speed and mix-
ture screws (Fig. 16) to obtain the
specified engine idle speed with the
transmission selector in DRIVE posi-
tion. The final mixture setting
should be slightly on the rich side.
5. Remove the weight from the
compensator spring.
FAST IDLE SPEED
81968-A FAST IDLE RPM ADJUSTMENT
This adjustment is made only after
FIG. 16-ldle Fuel Mixture, Idle Speed and Accelerator the engine has been run for thirty
Pump Stroke Adiustment minutes at 1200 rpm.

1. With the engine at a stabilized, 2. Remove the tachometer. Turn THROTTLE LINKAGE
normal operating temperature and off the engine. Connect the vacuum
the fast idle screw resting on the ADJUSTMENTS
lowest (slowest) step of the cam, ad- line to the vacuum power unit of
just the fast idle screw (Fig. 16) to the vacuum release parking brake The throttle linkage adjustments
obtain the specified fast idle rpm assembly. for the Turb-O-Drive transmission
with the transmission in DRIVE are covered in Group 7.
range. 3. Install the air cleaner assembly.

REMOVAL lever assembly. Disconnect the throt- flange, snug the nuts; then, alter-
Flooding, stumble on acceleration, tle spring and the transmission con- nately tighten each mounting nut in
and other performance complaints trol (kickdown) spring from their a criss-cross pattern. Torque each
are, in many instances, caused by the retaining bracket. nut to specification.
presence of dirt, water, or other 6. Remove the carburetor retain- 5. Connect the emission reduction
foreign matter in the carburetor. To ing nuts; then, remove the throttle system inlet hose to the carburetor
aid in diagnosing the cause of com- spring bracket, carburetor, upper and spacer and tighten the clamp. Tight-
plaint, the carburetor should be care- lower gaskets, and the spacer. When- en the fuel line and distributor vac-
fully removed from the engine with- ever the carburetor is removed uum advance line connections at the
out removing the fuel from the from the engine, care must be ex- carburetor.
bowls. The contents of the bowl may ercised to prevent damage to th•~ 6. Attach the throttle control shaft
then be examined for contamination throttle plates. The lower edges of rod to the throttle lever and secure
as the carburetor is disassembled. the primary throttle plates project it with a retaining clip. Install the
1. Remove the carburetor air below the carburetor body when· throttle spring and the transmission
cleaner. Remove the radiator coolant ever they are open. control (kick-down) spring on the
supply tank cap to depressurize the INSTALLATION retaining bracket.
cooling system. 7. Connect the automatic choke
1. Make certain all old gaskelt
2. Carefully remove the inlet and material has been removed from the coolant inlet and outlet hoses, then
outlet hoses from the automatic carburetor base, spacer, and the in·· tighten the retaining clamps.
choke and plug each line with a %G- take manifold flange. 8. On cars equipped with an air
inch bolt to prevent loss of coolant. 2. Install the new carburetor lower conditioner, connect the compressor
3. Disconnect the distributor ad- gasket, spacer, and new upper gasket clutch lead wire to the fast idle
vance vacuum line, and the fuel inlet on the intake manifold. Do not use' so)enoid.
line from the carburetor. Disconnect sealer or any form of sealing com- 9. Install the cap on the radiator
the emission reduction system hose at pound on the gasket. coolant supply tank.
the carburetor spacer inlet tube. 3. Position the carburetor on the 10. Refer to Part 1, Section 2 and
4. On cars equipped with an air manifold. Loosely connect the fuel Part 2, Section 2 of the manual for
conditioner, disconnect the com- line, and distributor vacuum advance the carburetor bench adjustments
pressor clutch lead wire from the line to the carburetor. and the in-the-car adjustments. Ad-
fast idle solenoid. 4. Install the throttle spring brack- just the automatic choke, idle fuel
5. Disconnect the throttle control et and the carburetor retaining nuts. mixture, idle (hot) rpm, fast idle
rod and retaining clip from the car- To prevent leakage, distortion, or rpm, and dashpot.
buretor throttle shaft and control damage to the carburetor body 11. Install the air cleaner assembly.
IJ MAJOR REPAIR OPERATIONS

DISASSEMBLY certain components of the carbu- connect the fast-idle connector rod
:retor may be serviced without a at the inner-countcrshaft ]eyer, and
To facilitate working on the car-
complete disassembly of the entire disconnect the accelerating pump
buretor, and to prevent damage to
unit. Refer to Fig. 17 for parts iden- operating rod at the accelerating
the throttle plates, install carburetor
1ification. pump arm.
legs on the base. If legs are unavail-
able, install four 'YtG x 21;2 inch bolts AIR HORN 4. On cars equipped with an air
and 8 nuts; install nuts on the bolts, 1. Remove the air cleaner anchor conditioner, loosen the fitting that
above and below the carburetor base. •;crew. Remove the Vacumeter as- secures the vacuum inlet tube to the
Use a separate container for the ,;emblies. idle speed-up control housing.
component parts of the various as- 2. From the automatic choke side 5. Remove the 10 retaining screws,
semblies, to facilitate cleaning, in- nf the carburetor, remove the anti- then remove the air horn from the
spection, and assembly. -.tall dashpot outer arm, anti-stall main body. To avoid bending the
The following is a step-by-step se- dashpot inner operating arm, and floats, be sure the bowl cover gas-
quence of operations for completely the choke countershaft lever. ket does not stick to the air horn
overhauling the carburetor. However, 3. From the fuel inlet side, dis- casting and catch onto the floats.

PISTON SPRING
SECONDARY AUXILIARY
THROTTLE PLATES
PRIMARY----
BOOSTER VENTURI
GASKETS USED ON AIR CONDITIONER

~~~~lj:J EQUIPPED CARS, ONLY
. . ACCELERATING PUMP
DISCHARGE ASSEMBLY
SECONDARY MAIN JETS

'"'··
FITTING:~... ~,...~ ;OLE,.-010
\IDLE
'/. •
J s~~Pv~p
GASKET
HOUSING
ACCELERATING PUMP PLUNGER
SECONDARY THROTTLE SHAFT
-----.--SECONDARY
THROTTlE PLATES
(rp
SCREW----~
v
IDLE SPEED ADJUSTING
SECONDARY THROTTLE
SPRINGS PLATE LOCKOUT LEVER
_____
FAST IDLE SCREW
,
81969-A
FIG: 17 -Carter Carburetor Assembly

6. Remove the accelerating pump

plunger, the floats, the fuel inlet
needle and seat assemblies and gas-
kets; then, remove the air horn gas-
ket. The needles and seats arc
matched assemblies. If they are to
be used again, be sure the correct
needle is kept with its seat.
7. Remove the fuel inlet fitting
and gasket. Under normal service,
the carburetor air horn may be
cleaned without further disassem-
bly. If complete disassembly is
necessary, proceed with the fol-
lowing steps:
8. Remove the choke plate con-
nector link, then slide the choke
plate countershaft out of the air
horn assembly.
9. Do not disassemble the choke
countershaft and choke plates unless
they have to be replaced. If replace- SCRIBER SCRIBE LINES AND IDENTIFICATION MARKS
ment is required, remove the stake
marks from the choke plate screws,
then remove the screws and choke FIG. 18-Throttle Plate Removal
plates. Slide the choke shaft (coun-
tershaft) out of the air horn assembly. CONNECTOR LINK
MAIN BODY
spring, and the anti-stall dashpot
piston and spring. Check the fuc]
in the bowl for contamination by
dirt, water, gum, or other foreign
matter. A magnet swept around
the bowl will pick up iron oxide
dust which may have contributed
to float inlet needle and seat leaks.
Drain the fuel from the howl.
2. Remove the primary booster
venturi assemblies and gaskets. Do
not attempt to disassemble the INNER COUNTERSHAFT LEVER
81971-A
venturis, Remove the accelerating
pump discharge nozzle assembly.
gasket, and discharge needle.
FIG. 19-Choke Plate and Shaft Installation
3. Remove the hot idle compen-
sator and the secondary booster vcn-
turis. Do not attempt to disassem-
ble the venturis.
4. Lift the secondary auxiliary
throttle plates out of the main body.
5. Remove the primary and sec-
ondary main jets with the use of tool
9510-G ( Y4 inch screwdriver bit).
Primary jets have larger openings
than secondary jets. Never mix
these parts.
inlet check valve from the left-fuel
bowl.
7. Remove the fuel bowl batnes.
8. Remove the idle mixture adjust
ing needles and springs. Remove the
idle speed ~djusting screw and
spring. FIG. 20-Fuellnlet Needle, Seats, and Float Installed

and that no foreign material has ad-

hered to the gaskets.
The carburetor parts have either
a "C" enclosed in a circle or a nu-
meral stamped on them. When the
parts are installed, these identifica-
tion marks always face toward the
top or toward the outside of the
carburetor, depending upon where
the part is installed.
During assembly of the carbure-
tor, certain adjustments are required.
The details of these adjustments are
covered in Part 1, Section 2, "Car-
buretor Bench Adjustments".
AIR HORN
1. Slide the choke plate shaft into
the air horn. Position the choke plate
on the shaft with the identification
"C" facing up. Install the screws.
FIG. 21-Positioning Primary Throttle Plates Stake the retaining screws with the
use of Tool 9586.
9. Air conditioner equipped cars, sembly may be cleaned without 2. Slide the countershaft inside
remove the fast idle speed-up valve further disassembly. If complete lever on the shaft so that the identi-
and solenoid assembly. It is not disassembly is necessary, perform fication "C" is to the outside.
necessary to disassemble the fast idle the remaining operations. 3. Slide the countershaft in the
speed-up valve and solenoid unless 13. Remove the throttle connect- air horn from the fuel inlet side.
a malfunction exists. If a malfunc- ing rod. 4. Connect the choke plate con-
tion exists, remove the solenoid from 14. Remove the primary throttle nector link to the choke plate and
the valve. Note the position of the shaft arm retaining screw, spacer, to the countershaft center lever, then
poppet valve and spring for as- outer arm, inner arm, and spring. install the lever on the countershaft
sembly purposes. 15. Remove the secondary throttle (Fig. 19).
10. Remove the water jacket and operating lever screw and spacer. 5. Install the fuel inlet gasket and
thermostatic spring housing as a unit. 16. Remove the secondary throttle fitting.
Remove the spring housing gasket operating lever and spring. 6. Place a new air horn gasket on
and the heat baffle. Disassemble the 17. Remove the fast idle cam and the air horn (Fig. 20), then install
water jacket, gasket, and thermo- connector rod, and the secondary the fuel inlet needle seats, gaskets,
static spring housing only if the throttle plate lock-out lever. and needles. Install the fuel inlet
jacket gasket requires replace- 18. Remove the accelerating pump needles in their matched seats. Do
ment, or the jacket requires clean- operating rod and the fast idle ad- not install the left needle in the
ing. To remove the special screw, justing screw. right seat or vice versa. Inlet
slot out the center portion of a 19. If it is necessary to remove needles and seats are matched as-
suitable size screwdriver blade. the throttle plates, lightly scribe the semblies. Install the floats on the
11. Remove the choke housing primary and secondary throttle plates same side of the carburetor from
from the main body. along the throttle shaft and mark the which they were removed; then, refer
12. Remove the choke connector plates and their corresponding bore to Part 10-1 , Section 2, "Carburetor
rod from the choke housing shaft, with a number or letter for proper Bench Adjustments" and adjust the
then remove the shaft, and piston installation (Fig. 18). File the stake float alignment, float setting, and
and lever assembly. Under normal marks from the retaining screws, float drop.
service, the carburetor body as- then remove the screws and remove
the throttle plates. Do not scratch MAIN BODY
the edge of the plates or walls of 1. If the throttle shaft and plates
the barrels. Remove the throttle have been removed, slide the pri-
shafts. mary and secondary shafts into the
main body. If the original throttle
PARTS REPAIR OR plates are being installed, place
REPLACEMENT each plate in the same bore from
which it was removed. Refer to the
Clean and inspect the carburetor lines scribed on each throttle plate
component parts. Refer to Part 10-1, and install the plates in their proper
r -oPERATINy LEVER
SECONDARY THROTTLE
Section 3 for the proper procedure.
Replace all worn or damaged parts.
location with the screws snug, but
not tight.
RETURN SPRING 81974-A 2. Hold the secondary throttle
ASSEMBLY
plates tightly closed, and tap both
FIG. 22-Secondary Make sure all holes in the new plates with a screwdriver handle.
Throttle Return Spring Installed gaskets have been properly punched When the plates are correctly seated,

OVER-RIDE SPRING DOG LEVER OUTER ARM

81975-A
FIG. 23-Secondary Over-Ride Spring Installed

tighten the attaching screws, then 11. Position the spacer on the pri- taching screws. The thermostatic
stake them. mary throttle shaft. Install the re- spring housing and related parts
3. Place a 0.003 inch thick by taining screw. are installed after the choke coun-
Ys inch wide piece of shim stock 12. Position the secondary throttle tershaft linkage is adjusted.
between each primary throttle plate connector rod in the secondary op- 16. Install the primary, and sec-
and the bore at the idle transfer erating lever and the primary throttle ondary jets, and the accelerating
slot (Fig. 21). Hold the plates firmly shaft inner arm, with the retaining pump inlet check valve.
against the feeler stock and tighten grooves to the outside. Install the 17. Install the fuel bowl baffie
the retaining screws. Stake the retainers. plates with the identification "C"
screws. 13. Position the choke piston and toward the front of the carburetor
4. Install the secondary throttle lever assembly in the choke housing. and the cut-out portion facing up-
plate lock-out lever on the boss on Slide the choke lever and shaft into ward.
the main body with the identification the choke housing and position the
"C" to the outside and the slot in 18. Position the primary booster
piston lever on the shaft. Install the venturi gaskets in the main body.
the lever engaging the tang on the retaining screw.
secondary throttle shaft lever. The primary gaskets are interchange-
5. Install the fast idle cam with 14. Install the curved end of the able from side to side.- Position the
the steps toward the fast idle screw. choke connector rod in the choke booster venturis in the main body
6. Position the secondary throttle housing lever with the upset end with the high speed air bleed tube
return S(!~ing on the shaft, straight away from the choke housing. to the inside. A cut-out notch on
tang end against the carburetor and 15. Install a new gasket in the each booster venturi mates with a
underneath the stop (Fig. 22) . recess in the choke housing vacuum step in the main body. The primary
~ • 0
7. Position the secondary throttle passage. Position the choke housing booster venturi assemblies are not
operating lever on the shaft, with on the main body and install the at- interchangeable from side to side.
the curved shoe portion up. Wind RETAINER METERING ROD
the secondary throttle return spring
clockwise. Catch the bent tang end
over the lug of the secondary throttle
operating lever (Fig. 22).
8. Install the secondary throttle
lever spacer and screw.
9. Position the secondary over-
ride spring in the primary throttle
shaft inner arm. Slide the assembly
on the primary throttle shaft (Fig.
23).
10. Invert the carburetor and posi-
tion the throttle shaft dog lever on
the -primary throttle shaft and hook
the inside tang of the spring in the
groove on the lever arm (Fig. 23).
Hook the primary throttle shaft
outer arm on the outside tang of 81976-A
the spring and position the arm on
the primary throttle shaft (Fig. 23). FIG. 24-Va(umeter (Metering Rod} Installation

10-24 GROUP 10-FUEL SYSTEM (228}
DASHPOT INNER ARM 23. Place the accelerating pump tacting the dashpot plunger. Install
spring in the accelerating pump the retainer.
chamber (on left side of carbu-
31. Install the dashpot connector
retor). The accelerating pump
rod on the dashpot outer lever and
spring is shorter than the anti-stall the primary throttle shaft outer lever.
dashpot spring. A new accelerating The long angular portion of the rod
pump spring can be identified by is to the top and the ends of the
its red color. Place the accelerating rod face the carburetor. Install the
pump plunger over the spring. retainers.
24. Place the anti-stall dashpot 32. Connect the choke connector
spring in the dash pot chamber (on rod to the countershaft lever. Slide
right side of carburetor) . Place the
FIG. 25-Dashpot Arms dashpot plunger on the spring.
the countershaft lever on the coun-
tershaft with the "C" identification
Installation 25. Install the idle adjusting facing outward. While working on
needles and springs. Tum each the other end of the countershaft
Install the retaining screws. needle inward gently with the fingers lever, be sure the tang on the coun-
19. Position the secondary auxil- until it touches the seat, then back tershaft outer lever is over the tang
iary throttle shaft with the identifica- it out 11;2 -21;2 turns. on the countershaft inner lever (Fig.
tion "C" on the plates facing upward. 26). Tighten the countershaft lever
20. Position the secondary booster 26. Install the idle speed adjusting
screw and spring. Do not tighten. snug, but not tight.
venturi gaskets in the main body. 33. Install the fast idle cam con-
The secondary gaskets are inter- Turn the screw until it lightly touches
its seat; then, turn it outward 31;2 nector rod in the fast idle cam and
changeable from side to side. Place the countershaft inner lever. Install
turns.
the secondary booster venturis in the the retainer at the countershaft inner
main body. A drop-out notch on 27. Carefully position the air horn lever end of the rod.
each secondary booster venturi mates on the main body. Be sure the anti-
with a step in the main body. The stall dashpot plunger stem, the ac- 34. Position the accelerating pump
secondary booster venturi assem- celerating pump stem, and the arm on the boss on the air hom and
blies are not interchangeable from primary booster venturi air bleed install the retaining screw.
side to side. Install the retaining tubes enter their respective holes 35. Insert the retainer end of the
screws. in the air horn. Be sure that the accelerating pump connector link in
21. Position the hot idle compen- upper baffle plates are on the float the accelerating pump arm and the
sator in place between the secondary side of the lower baffle plates when other end of the link in the acceler-
booster venturis: Install the hot idle the air horn is positioned on the ating pump plunger. Install the re-
compensator. main body. tainer.
22. Drop the accelerating pump 28. Install the identification tag(s), 36. Install the accelerating pump
discharge needle into its passage, then retaining screws and lockwashers. operating rod in the throttle lever
install the gasket and pump dis- Install the two longest screws at the and install the retainer. Install the
charge nozzle assembly. center retaining screw hole loca- other end of the rod in the top hole
tions. Tighten the screws evenly, of the accelerating pump arm.
working from the center toward the 37. On air conditioner equipped
outside. cars, install the vacuum inlet tube
and fitting, as a unit, in the air hom.
29. Place the springs in the Vacu- Install the idle speed-up valve that
meter pistons, then place the pistons was disassembled, install the po.ppet
and metering rods in their chambers valve and spring in the housing; then
(Fig. 24). Install the Vacumeter cov- place the gasket in position and in-
ers. Do not force the metering rods stall the solenoid.
into position.
30. Place one leg of the dashpot BENCH ADJUSTMENTS
outer arm in between the two legs All carburetor adjustments except
of the dashpot inner arm and slide the idle fuel mixture and the idle
them into position on the air horn speed adjustments can be made with
(Fig. 25). The identification "C" on the carburetor removed from the
FIG. 26-Countershaft both parts should be to the outside car. Refer to Part 1, Section 2 for
Lever Installation and the inner dashpot arm lever con- the "Carburetor Bench Adjustments".

·(229)
PART AIR CLEANER AND AIR DUCT

10-3
1 Description and Operation ........... 10-25 3 Major Repair Operations ................. 10-26
2 Removal and Installation .......... 10-26

DESCRIPTION
The engine is equipped with a
dry-type carburetor air cleaner as-
sembly and thermostatically con-
trolled carburetor air inlet dust as-
sembly (Fig. 1).
The air cleaner body is mounted
on a sealing gasket located on the
carburetor air horn. The air cleaner
assembly is retained on the engine
by a stud in the carburetor body and
a wing nut above the filter cover.
The replaceable filter element assem- DUCT AND VAlVE ASSEMBLY
bly consists of pleated filter paper
encased in a wire mesh screen, with
integral plastic gaskets located on the THERMOSTAT ROD AND SPRING
top and bottom of the element. The
gaskets prevent entry of dirt and un-
filtered air into the engine.
The thermostatically controlled air
inlet duct and shroud assembly is
attached to the air cleaner body with <!:=J WARM AIR
a wing nut. The shroud is positioned
on the left exhaust manifold. The air ~ ENGINE COMPARTMENT AIR
inlet duct control mechanism consists
of a valve plate, thermostat, adjust- 81979-A
able thermostat rod, two springs and
a retaining clip. FIG. l-Air Inlet Duct and Air Cleaner-Sectional View
VALVE PLATE THERMOSTATIC
VALVE PLATE SPRING VALVE PlATE CLOSED OPEN BULB
OPERATION
AIR CLEANER.
The air received from the air duct
passes through a silencing chamber
in the air cleaner body and then
through the filter element. After
leaving the filter element, the air
is deflected down into the carburetor.
Dust particles and other foreign ma-
terials are trapped in the filter ele-
ment as the air rushes through it.
AIR DUCT
The temperature of the air enter-
ing the air cleaner is thermostatically
controlled by the carburetor air duct
assembly (Figs. 1 and 2). Air from
the engine compartment, or heated
HEAT ON WARM AIR PASSAGE HEAT OFF !1227-B
air from a shroud around the ex-
haust manifold, is available 1o the
engine. FIG. 2-Air Inlet Duct Installed

A thermostatic bulb in the air duct the air duct is less than 75o F., the 85° F., the thermostat starts to ex-
is exposed to the incoming air. A thermostat is in the retracted posi- pand and pulls the valve plate down.
spring-loaded valve plate is con- tion and the valve plate is held in the This allows cooler air from the en-
nected to the thermostatic bulb up position (heat-on) by the valve gine compartment to enter the air
through linkage. The valve plate plate spring, thus shutting off the
air from the engine compartment cleaner. When the temperature of the
spring holds the valve in the closed
position (heat-on) until the ther- (Fig. 2). All air is then drawn from air reaches approximately 105° F.,
mostatic bulb overcomes the valve the shroud around the exhaust mani- the valve plate will be in the down
tension. fold. position (heat-off) so that only en-
During the engine warm-up period As the temperature of the air pass- gine compartment air is allowed to
when the air temperature entering ing the thermostatic bulb approaches enter the air cleaner.

AIR CLEANER spection procedure. Replace all worn 3. Remove the wing bolt securing
or damaged parts. the air duct assembly to the air
FILTER MAINTENANCE cleaner and separate the air duct
INSTALLATION from the air cleaner.
Refer to Group 19 for the recom- 4. Remove the air cleaner cover
mended maintenance mileage inter- 1. Install a new air cleaner mount- and filter element.
val. ing gasket on the carburetor, if
necessary. Install the air cleaner body DIAGNOSIS AND TESTING
REMOVAL on the carburetor so that the word
1. Remove the wing nuts retaining "FRONT" faces the front of the car. Refer to Part 10-1, Section 1 for
the air cleaner assembly to the car- the air duct testing procedures.
2. Place the element in the air
buretor and the air duct (Fig. 1). cleaner body. Make sure the ele-
2. Remove the air cleaner assem- INSTALLATION
ment gasket is properly seated.
bly from the carburetor. To prevent Install the cover and connect the 1. Center the air duct shroud on
dirt from entering the carburetor, air duct to the air cleaner. Tighten the exhaust manifold and push it into
the filter element must never be place. Use care to prevent damage
the retaining wing nuts.
removed when the air cleaner body to the spark plug ignition wires.
is mounted on the carburetor.
AIR DUCT 2. Install the valve assembly on
3. Remove the cover and filter the air duct.
element. Discard the air cleaner REMOVAL 3. Carefully place the air cleaner
mounting gasket on the carburetor
1. Remove the wing nut securing body on the carburetor. Check the
if it is excessively worn or damaged.
alignment of the valve assembly to
the air cleaner to the carburetor
the air cleaner and tighten the wing
PARTS REPAIR OR (Fig. 1).
nut securing the valve assembly to
REPLACEMENT 2. Carefully lift the air cleaner the air cleaner.
Refer to Part 10-1, Section 3 for and air duct as an assembly from 4. Install the air cleaner filter ele~
the recommended cleaning and in- the engine. ment and cover.

AIR DUCT valve plate, and disconnect the rod bend the tabs to hold the thermostat
from the plate. Slide the thermostat and spring assembly in place.
DIAGNOSIS AND TESTING rod assembly from the thermostat 2. Insert the thermostat rod assem~
It is necessary to test the air duct and remove the rod from the air bly through the air duct into the ther-
prior to disassembling the unit. Refer duct.
mostat and spring assembly. Con-
to "Air Duct" in Part 10-1, Sec~ 3. Carefully bend up the tabs hold-
tion 1. ing the thermostat and spring assem- nect the opposite end of the rod to
bly in the air duct. Remove the ther~ the valve plate. Secure the rod to
DISASSEMBLY mostat and spring assembly. the plate with the retainer.
1. Disconnect the valve plate spring 3. Test the air duct and adjust
(Fig. 1). ASSEMBLY it, as necessary. Refer to "Air Duct"
2. Remove the retainer securing 1. Place the thermostat and spring in Part 10-1, Section 1 for the
the thermostat rod assemb}ly to the assembly in the air duct and carefully proper procedure.

(231} 10-27_,
PART FUEL PUMP AND VAPOR DISCHARGE VALVE

10-4
1 Description and Operation .......... 10-27 3 Major Repair Operations ................. 10-29
2 Removal and Installation . . . . . . . ......... 10-28

HEAT SHIELD
DESCRIPTION
The fuel pump (Fig. 1) is mount-
ed on the upper-portion of the cyl-
inder front cover.
A vapor discharge valve and re-
turn line adapter assembly (Fig. 1)
are contained within the fuel re-
turn port of the pump body. The
in-line replaceable fuel filter is con-
nected directly to the fuel outlet port
in the pulsator cover.
A heat shield (Fig. 1) is mounted
on the pump body and is retained
by three studs, nuts and washers.
OPERATION
FUEL PUMP
The fuel pump (Fig. 2) is me-
chanically actuated by the fuel
pump rocker arm, a push rod and
an eccentric sleeve mounted on the
front of the camshaft.
The flexible fuel pump diaphragm
is operated by a combination of
FIG. 1-Fuel Pump and Vapor Discharge Valve
rocker arm action and calibrated
diaphragm spring tension. buretor. Fuel is delivered to the pump pulsations on the carburetor
On the fuel intake stroke, the carburetor only when the fuel fuel inlet needle.
camshaft eccentric raises the rocker inlet valve in the carburetor is A relief vent is located in the
~rm push rod and causes the rocker open. The carburetor inlet valve main body below the diaphragm.
arm to pull the. fuel pump diaphragm is closed by pressure of fuel on the The vent prevents air pressure build
against the diaphragm spring pres- float when the specified fuel level up below the diaphragm.
sure. This action draws fuel through in the carburetor float chamber VAPOR DISCHARGE VALVE
the intake valve into the pump is reached. Hot vapors, which may form in
chamber and closes the outlet valve. The fuel pump rocker arm serves the pump due to atmospheric and
At the same time, fuel is drawn only to pull the diaphragm against engine operating conditions, are re-
from the fuel tank through the fuel the diaphragm spring pressure dur- leased from the fuel pump and re-
intake line to replace the fuel drawn ing the fuel inlet stroke. When there turned to the fuel tank by means
into the chamber. is no demand for fuel from the of the vapor discharge valve and
As the camshaft eccentric con- carburetor, the diaphragm spring adapter (Fig. 2) and a fuel return
tinues to rotate, the rocker arm tension is not strong enough to force line.
relieves the pressure on the dia- the diaphragm upward against the When the hot vapors reach a pre-
phragm spring and allows the spring fuel pressure built up in the inlet determined temperature within the
to move the diaphragm toward the chamber of the pump. Thus, the up pump, the calibrated thermostatic
inlet and outlet valves, against the and down rocker arm action con- spring gradually expands and moves
pressure of the fuel built up in the tinues, but the diaphragm remains the valve plunger stem off of the
fuel inlet chamber. This action stationary until pressure against the orifice in the valve seat insert. This
causes the pump inlet valve to carburetor float is relieved by a de- allows a metered flow of fuel and
close and opens the outlet valve. The mand for fuel at the carburetor. vapors through the orifice, adapter,
fuel is then forced through the pump The pulsator diaphragm in the and return line into the tank.
outlet to the fuel filter and car- fuel pump dampens the effect of fuel As fuel and vapors within the

FUEL INLET FROM FUEL TANK PULSATOR DIAPHRAGM
RETURN TO FUEL TANK
ALVE PLUNGER STEM
• FUEL VAPOR
<!=J FUEl MAIN VALVE BODY AND STEM GUIDE

VAPOR DISCHARGE VALVE
81982-A
FIG. 2-Fuel Pump and Vapor Discharge Valve-Sectional View

fuel pump cool, the thermostatic restricts the flow of fuel and vapors vapor discharge valve when it"' is
spring gradually retracts; thus, seat- into the fuel tank. A positive flow closed. This prevents a pressure
ing the valve plunger in the orifice of fuel and vapors is provided build-up in the pump due to heat
of the valve seat insert. This action through the leak down bleed in the after the engine is stopped.

FUEL PUMP retaining screws securing the fuel shield. If inspection or replacement
pump to the cylinder front cover. of the fuel pump push rod is re-
TESTS 3. Using an auxiliary starter quired, remove the access cover
Fuel pump tests are covered in switch, crank the engine until the from the cylinder front cover, and
Part 10-1, Section 1. fuel pump eccentric on the camshaft remove the push rod.
is in a position which applies the
REMOVAL least tension on the fuel pump rock- INSTALLATION
1. Remove the hose clamps and er arm. Remove the retaining screws 1. Remove all gasket material
fuel ·line hoses from the inlet and and fuel pump. Discard the mount- from the cylinder front cover and
vapor discharge connections. Dis- ing gasket. fuel pump mounting flange.
connect the fuel filter from the car- 4. If the fuel pump is to be re- 2. If a new fuel pump is to be in-
buretor fuel inlet line. placed, remove the heat shield re- stalled, install the adapter and vapor
2. Loosen, but do not remove, the taining nuts and remove the heat discharge valve in the pump body.

(233) PART 10-4-FUEL PUMP AND VAPOR DISCHARGE VALVE 10-29
Install the heat shield and tighten retaining screws and torque them disconnect the fuel line hose from the
the retaining nuts. If the fuel pump to specification. vapor discharge valve connection.
push rod was removed, install the rod 5. Connect the fuel line hoses to 2. Remove the vapor discharge
on the eccentric sleeve, and install the fuel inlet and vapor discharge valve from the pump body (Fig. 3).
the access cover on the cylinder connections. Connect the fuel filter
front cover. to the fuel pump. Do not over- INSTALLATION
3. Apply sealer to both sides of a tighten it. Connect the fuel line 1. Install the vapor discharg~ valve
new gasket. Position the gasket on the ro the fuel filter. in the adapter port of the fuel pump
fuel pump flange, and hold the fuel 6. Operate the engine and check body.
pump in position on the cylinder for leaks. 2. Connect the fuel line hose to
front cover. Make sure the rocker the adapter and tighten the retain-
VAPOR DISCHARGE VALVE
arm -is riding on the push rod. ing clamp.
4. Press the pump tight against REMOVAL 3. Operate the engine and check
the cylinder front cover. Install the 1. Remove the hose clamp and for leaks.

FUEL PUMP
DISASSEMBLY
1. Remove the heat shield retain- -, ~PULSATOR CHAMBER COVER
ing nuts and the heat shield from
the fuel pump {Fig. 3).
2. Unscrew the vapor discharge
valve from the pump body. ! ,----- PULSATOR DIAPHRAGM
'(---~
3. Scribe identification marks on
the main body, fuel pump body and
HEAT SHIELD
STUD AND NUT~~~ SCREW AND LOCKWASHER
!/
~
~-
pulsator chamber cover (Fig. 4) so LOCKWASHER _.Ar (~ @
~~LVE --~-~~UPPER
that these parts may be assembled VAPOR _ !7 .
in their original position. DISCHARGE BODY
4. Remove the retaining screws
that secure the main body to the
pump body and separate the bod-
~/ psCREW AND LOCKWASHER
ies. Remove the screws retaining

the pulsator chamber cover to the
pump body. Separate the cover and
body, and note the position of the
pulsator diaphragm so that it may be
assembled in its proper position. FUEL FILTER
Do not remove the fuel valves
ROCKER ARM SHAFT
from the valve housing. The valves
~~RETAINING
and housing are replaced as an
assembly.
5. Remove the rocker arm return
spring. PLUG
6. Remove the rocker arm pin
ROCKER ARM
seal plug (Fig. 5). 1;', RETURN SPRING
7. Press the fuel pump diaphragm ~ \!"
i: ~
I
into the fuel pump body to release ·_,,_~ ~
ROCKERAR~
the tension on the rocker arm and
allow the rocker arm pin to fall out.
If the pin does not come out freely,
use needle nose pliers (Fig. 6).
_ _. . . -~
8. Press the diaphragm into the
fuel pump body and pull the rocker
arm out to unhook the rod from PUSH ROD
~
the rocker arm link (Fig. 7).
9. Remove the fuel pump dia-
phragm assembly. Do not disassem- 81983-A
ble it. The diaphragm and spring
are serviced as an assembly. FIG. 3-Fuel Pump, Vapor Return Valve, and Filter

noted on disassembly (opening in

the diaphragm over the fuel inlet
chamber).
6. Position the cover on the valve
housing, aligning the scribed lines
on the cover with the line on the
81984-A FIG. 7-Fuel Pump

Diaphragm Removal or Installation
FIG. 4-scribe
Marked Fuel Pump fuel pump body. Install the valve
81233-C
body screws and nuts finger tight.
PARTS REPAIR OR
REPLACEMENT
FIG. 5-Rocker Arm Be sure the diaphragm ·extends
Pin Seal Plug Removal evenly around the edge of the
Clean and inspect the fuel pump
component parts. Refer to Part 10-1,
Section 3 for the proper procedure. valve housing. Be sure the pulsator
diaphragm extends evenly around
Replace all worn or damaged parts.
the edge of the cover. Install and
ASSEMBLY tighten the valve housing to cover
retaining screws.
1. Position the fuel pump dia-
phragm assembly into the main body; 7. Align the scribe line on the
then, apply pressure on the dia- valve housing and the line on the
phragm spring so that the rocker
arm can be hooked on the rod
(Fig. 7).
2. Align the rocker arm pin holes
by applying slight pressure on the
diaphragm spring; then, install the FIG. 8-Staking Shaft
rocker arm pin (Fig. 6). Retainer Plug
3. Install new rocker arm pin seal
plugs and seat the plugs securely valve housing. Tighten the retain-
(Fig. 8). ing screws and nuts.
4. Position the rocker arm return 8. Install the vapor discharge valve
spring on the boss in the main body. in the adapter port of the valve hous-
Compress the spring and slip it over ing.
the tang on the rocker arm. 9. Install the heat shield on the
5. Place a new pulsator diaphragm FIG. &-Rocker Arm fuel pump and tighten the retaining
on the valve housing in the position Pin Removal or Installation nuts.

(235) 10-31
PART FUEL TANK AND LINES

10-5
Section Page ~ti~ hp
1 Description and Operation ..... . ....... 10-31 2 Removal and Installation ................. 10-31

All Lincoln Continental models are are attached to lines which enter the The filler pipe is sealed at the tank
equipped with a 24-gallon fuel tank fuel tank through the fuel sender with an 0-ring.
(Fig. 1). The tank is held in a ver- unit assembly (Fig. 1). A filter is
Two lines, a fuel supply line and
tical position by two steel straps. An located in the tank, on the fuel send-
a vapor return line, with connecting
insulating pad is positioned between er unit pick-up tube. This filter dot~s
hoses and clamps, make up the fuel
the top of the tank and the underside not require servicing.
line system.
of the luggage compartment floor The fuel tank filJer pipe opening
pan and also between the rear ver- is located behind a door in the left- These two lines are routed to-
tical wall of the tank and front wall rear quarter panel, just above and gether from the tank, passing beneath
of the spare tire well. rearward of the wheel housing open- the left side of the underbody, then
The fuel sender unit is located on ing. The tank is vented through the under the left fender and through the
the front side of the tank. It is ac- fuel filler pipe cap. The filler pipe forward part of the fender apron.
cessible from underneath the car. is attached to the filler pipe housing All segments of the fuel lines are re-
The fuel line and vapor return line of the quarter panel with a gasket placeable. However, only the dam-
both fasten to connecting hoses that between the pipe flange and housing. aged segments are usually replaced.

FILLER PIPE 2. Position the filler pipe and ro- 6. Remove the tank and discard
tate the pipe into the fuel tank with the filler pipe opening 0-ring seal.
REMOVAL
the fabricated tool. Make certain If the fuel tank is to be replaced,
In some instances, removal of the the 0-ring seal is properly seated. remove the fuel gauge sending unit
fuel filler pipe may prove difficult. Install and tighten the filler pipe . and discard the gasket. Note the
A fuel tank filler pipe removal or retaining screws. position of the insulating pad and
installation tool can be fabricated 3. Fill the fuel tank and install the insulation between the tank
locally from standard steel shapes the filler cap. Check for fuel leaks. and retaining straps.
that are readily available. Figure 2
outlines instructions for fabricating FUEL TANK INSTALLATION
the tool.
~ 1. Partially drain the fuel tank to
REMOVAL
1. If the retaining strap(s) re-
a level below the filler pipe connec- 1. Remove the fuel tank filler cap quired replacement, install the flanged
tion in the tank (Fig. 1 ) . (Fig. 1). Drain the fuel in the tank end ( s) of the new strap ( s) in the
2. Remove the retaining screws se- into a suitable container with a slot ( s) of the underbody member
curing the filler pipe to the filler pipe siphon. (Fig. 1) . If necessary, properly posi-
housing. Insert the fabricated filler 2. Raise the front of the car and tion the tank insulating pad.
pipe removal tool in the filler pipe keep the rear wheels lowered. Dis- 2. If a new tank is to be installed,
opening. Rotate the filler pipe with connect the rear shock absorbers at adhere new insulating pressure-sensi-
the removal tool and pull it outward the top. tive black tape, of the specified width
to remove it from the fuel tank and 3. Remove fuel sender unit wire and length, to the sides of the fuel
housing. and ground wire, low fuel level tank. Install the fuel gauge sending
3. Remove and discard the 0-ring device wire, fuel line and vapor re- unit and new gasket on the tank.
seal located in the filler pipe open- turn line from the sender unit. 3. Install a new 0-ring in the
ing of the fuel tank. Replace the 4. Remove the filler pipe to fill filler pipe opening of the tank. Posi-
filler pipe mounting gasket if it is pipe housing retaining screws. Ro- tion the mounting gasket on the
worn or damaged. tate the filler pipe with the fabricated filler pipe. Insert the filler pipe into
tool and pull it outward to remove the filler pipe housing. Carefully posi-
INSTALLATION it from the fuel tank and housing. tion the tank on the retaining straps
1. Install a new 0-ring seal in the 5. Loosen the nuts and release the and hook the strap bolts in the slots
fuel tank (Fig. 1) . Install a new tank retaining strap bolts (hooks) of the underbody member. Align the
gasket, if necessary, on the filler pipe from the slotted underbody member tank and filler pipe and tighten the
mounting flange. at the front of the fuel tank. tank strap bolt retaining nuts.

REAR VIEW OF STRAP ATTACHMENT
FIG. 1-Fuel System Installation

(237) PART 10-5-FUEL TANK AND LINES 10-33
r- ~~______..,.1
4
1
Ya" DRILL THRU
-1lT
.
c:-----~
;
I
Ys :).D.
Tubing o< Steel Rod
12"
%no.D.
Tubing Steel Rod
t
STEEL
i 81987-A
~"
FIG. 3-Fuel Line

Tube Die
gauge sender unit and the fuel pump.

Remove ·the lines from the holding
clips along the underbody. Remove
all damaged hose sections and tube
sections.
INSTALLATION
1. Cut a new section of tubing to
82031-A
approximately the same length as the
section to be replaced. Allow extra
FIG. 2-Fuel Tank Filler Pipe Puller-Fabricated length for flaring the ends of the
tubing. Square the ends of the cut
and hose material of the specified tubing with a file.
4. Position the filler pipe and ro-
tate it into the tank with the fabri- •ilze (Fig. 2), available at dealerships. 2. Ream the inside edges of the
cated tool. Make certain the 0-ring A damaged section of tubing long- cut tubing with the reamer blade on
is properly seated in the fuel tank :~ r than 12 inches can be cut out of the tube cutter. Be sure metal chips
opening. Install and tighten the the existing line and replaced by a arc removed from inside the
filler pipe retaining screws. ,,xm1parable service tubing section, tube(s). Flare the ends of the cut
5. Connect the sender unit wire, ·;pliccd into the line by means of tubing, as required, with a standard
ground wire, low fuel level device .,:on nect ing hoses and retaining clamps. tube flaring kit and tool T62P-9A-
wire, fuel line and vapor return line A damaged section of tubing 274-A (Fig. 3).
to the sender unit. Install the shock .,,orter than 12 inches can be cut 3. Bend the tube section to con-
absorbers and torque the retaining .Jut of the line and replaced by a form to the contour of the original
nuts to specification. !ength of service hose and two re- tube. Cut an ample length of hose to
6. Lower the car. Fill the fuel tank caining clamps. All replacement form a coupling between the flared
and install the filler cap. Check for hoses must be cut to a length that ends of the fuel lines. Connect the
fuel leaks. will ensure proper clamp reten- hose couplings to the tubing and in-
tion beyond the flared ends of the stall the retaining clamps.
FUEL LINES eonnecting tubing.
4. Position the lines in the under-
The various fuel lines are not body clips and tighten the clips. Con-
REMOVAL
serviced as assemblies. They must nect the lines to the fuel gauge
be cut, squared and formed out of l. Drain the fuel from the tank. sender unit and the fuel pump. Fill
rolls of fuel system service tubing 2. Disconnect the lines at the fuel the tank and check for leaks.

PART FUEL SYSTEM SPECIFICATIONS

10-6
FUEL PUMP CARBURETOR (Continued)
VACUUM -Minimum {Inches of Mercury) at Anti-stall Dashpot Clearance ... %s inch between dashpot
500 Engine rpm .............................. 6.0 operating lever and air
horn with throttle wide
FUEL PUMP STATIC PRESSURE- psi at open, 1.4 inch with
500 Engine rpm .......................... . 4.5-6.5 throttle closed.
Initial Idle Mixture Adjustment ...... 1Y2 turns open.
MINIMUM FUEL PUMP VOLUME - Flow at Fast Idle Adjustment- Choke Plate Closed
500 Engine rpm .... , ........... 1 pint in 20 seconds Bench ............ 0.026 clearance between primary
throttle plate and bore (opposite
ECCENTRIC TOTAL LIFT .................... 0.234-0.260 idle port) with fast idle screw rest-
ing on center index mark on cam.
PUSH ROD In Vehicle .......... 675-700 in drive with fast idle
Diameter ............................. 0.374-0.376 screw resting on cepter index
Clearance to Bearing .................. 0.002-0.006 mark on cam.
Engine Idle rpm
Transmission In Drive ................... .450-575
Accelerating Pump Adjustment
From top of air horn to top of plunger shaft
CARBURETOR with pump operating rod in top hole ....... 17/32
CARTER FOUR-BARREL CARBURETOR Pump Operating Rod and Throttle Return
Spring Settings
The basic part number of the carburetor is 9510. The part Summer or winter ................ Appropriate hole.
number prefix and suffix appears on the identification tag
mounted on the air hom. Power System Manifold Vacuum Limits -
Inches of Mercury ........................... 4-6
Main Metering Jet and Metering Rod Identification No.
Main Metering Jets
0-5,000 feet ............................. 120-164 FUEL TANK CAPACITY
5,000-10,000 feet ......................... 120-164
Secondary Main Metering Jet U.S. MEASURE .............................. 24 gallons
0-5,000 feet ............................. 120-158 IMPERIAL MEASURE ......................... 20 gallons
5,000-10,000 ............................. 120-158
Metering Rods
Inch- Foot-
0-5,000 feet .............................. 16-225 TORQUE SPECIFICATIONS Pounds Pounds
5,000 feet ................................ 16-227
Air Horn Attaching Screw and Washer ..... 25-30
Secondary Throttle Lever Adjustment:
Lower edge of primary throttle plates to Booster Venturi Attaching Screw
throttle bore clearance ................... 29164 and Washer ........................ 15-20
Primary and secondary throttle lever closing Choke Cover Housing Attaching Screw ..... 15-20
shoe clearance ...................... 0.010-0.030
Secondary Throttle Lock Out Adjustment: Choke Plate Attaching Screw ...•......... 3-6
Secondary throttle to lever to ramp on lockout Fast Idle Cam Attaching Screw ........... 50-60
plate clearance ..................... 0.015-0.040
Dry Float Setting Carburetor Mounting Flange Nuts ......... 12-15
?1s inch between top of float and surface of gasket, Fuel Inlet Needle Seat .................. .45-60
air horn inverted. Allowable tolerance plus %4 •
Venturi Size- Diameter Metering Rod Jet ...................... 30-40
Primary .................................... 1%6 Throttle Plate Attaching Screw ............ 8-15
Secondary .................................. 1~u
Choke Thermostatic Spring Housing Initial Setting Fuel Inlet Fitting ...................... 180-215
Number of notches rich ....................... 1 Fuel Pump to Cylinder Front Cover ........ 23-28

(239)
11-1
GROUP
11
GENERAL COOLING SYSTEM SERVICE .. 11-1 FAN DRIVE CLUTCH .. 11-9
PART 11-2 PART 11·5
WATER PUMP . . . . . . . . . . . . . .... 11-5 SPECIFICATIONS ... . 11-10
PART 11·3
RADIATOR, SUPPLY TANK AND
THERMOSTATS ................. 11-7
PART GENERAL COOLING SYSTEM SERVICE

11-1
~~ hp Section Page
Diagnosis and Testing . . . . . . . . . . . . . . ...... 11-1 3 Common Adjustments and Repairs .......... 11-3
2 Maintenance . . . . . . . . . . . . . . . . . . . . ...... 11-2 4 Cleaning and Inspection . . . . . . . . . .......... 11-4
II
•
DIAGNOSIS AND TESTING
DIAGNOSIS Coolant loss may also be caused by the oil level dipstick could be an ·in-
internal leakage due to a defective dication of internal leakage.
Engine overheating and slow en- cylinder head gasket, improper tight- Rust and scale that form in the
gine warm-up are the two engine ening of the cylinder head bolts, or engine coolant passages are carried
troubles most commonly attributed a warped cylinder head or cylinder into the radiator passages by the cir-
to the cooling system. block gasket surface. culation of the coolant. This clogs
Loss of coolant, thermostat stuck Internal leakage can be detected the radiator passages and causes over-
in the closed position, or the accu- hy operating the engine at fast idle heating. Rust can be detected by the
mulation of rust and scale in the sys- and looking for the formation of appearance of the coolant. If the
tem are the main causes of overheat- bubbles in the radiator supply tank. coolant has a rusty or muddy appear-
ing. Coolant loss may be caused by Oil in the radiator supply tank may ance, rust is present.
external leakage at the radiator, ra- indicate leakage in the engine block A defective thermostat that re-
diator supply tank, water pump, hose ur a leak in the automatic transmis- mains open will cause slow engine
conluections, heater and core plugs. sion oil cooler. Water formation on warm-up.
DIAGNOSIS GUIDE
Insufficient coolant. Cooling system passages blocked
Belt tension incorrect. by rust, scale, or other foreign matter.
ENGINE OVERHEATS Radiator fins obstructed. Water pump inoperative.
Thermostat stuck closed. Faulty fan drive clutch.
Thermostat stuck open, or of in- tive (causing gauge to indicate low

ENGINE FAILS correct heat range. engine temperature) .
TO REACH NORMAL Temperature sending unit defec- Temperature gauge defective (not
OPERATING TEMPERATURE indicating true engine temperature).
Leaking radiator or radiator sup- head bolts.

ply tank. Cylinder block core plugs leaking.
Loose or damaged hose connec- Cracked cylinder head or block,
LOSS OF COOLANT tions. or warped cylinder head or block
Water pump leaking. gasket surface.
Cylinder head gasket defective. Radiator pressure cap defective or
Improper tightening of cylinder wrong type.

11-2 GROUP 11-COOUNG SYSTEM (240)
TESTING BI-METAL low the procedure for the main

SPRING thermostat test.
COOLING SYSTEM
PRESSURE TEST FAN DRIVE CLUTCH TEST
It is recommended that a cooling The recommended testing proce-
system pressure test gauge be used dure for the fan drive clutch (Fig. 1)
to properly test the system for: is as follows:
1. Blown or leaking cooling system 1. The viscosity of the silicone oil
sealing gaskets. within the drive chamber of the unit
2. Internal or external coolant directly affects its drive characteris-
leakage. tics. Therefore, the unit should not
3. Pressure cap malfunction. be cold when tested. When ambient
Many types of pressure gauges are air temperatures are below 65° F,
available for use. Therefore, it is operate the engine at approximately
recommended that the gauge manu- 1000 rpm for 20 minutes. This should
facturer's instructions be followed produce the desired temperatures
when performing the test. Never within the unit. However, regardless
exceed the rated pressure indi- of the ambient air temperature,
cated on the pressure cap when the unit must be operated for at
performing the pressure test. least 5 minutes prior to testing.
81932-A 2. Run the engine at approximately
THERMOSTAT TESTS
1000 rpm until normal operating
Main Thermostat. Remove the FIG. 1-Power Booster Fan Drive temperature is reached. This process
thermostat and immerse it in boiling Clutch can be speeded up by blocking off
water. Replace the thermostat if it the front of the radiator with card-
does not open more than lA inch. tions on the perimeter of the valve board.
If the problem being investigated may be detected. This should be con- 3. Stop the engine and, using a
is insufficient heat, the thermostat sidered normal. cloth to protect the hand, immedi-
should be checked for leakage. This Cylinder Block Thermostats. It ately check the effort required to
may be done by holding the thermo- is impossible to check the operation turn the cooling fan. If considerable
stat up to a lighted background. of used cylinder block thermostats effort is required, it can be assumed
Light leakage around the thermostat due to the distortion that occurs to that the coupling is operating satis-
valve (thermostat at room tempera- the units during their removal from factorily. If very little effort is re-
ture) is unacceptable and the thermo- the cylinder block. Do not attempt quired to turn the fan, it is an
stat should be replaced. It is possible, to repair them. Install new thermo- indication that the coupling is not
on some thermostats, that a slight stats. operating properly and it should be
leakage of light at one or two loca- If new thermostats are tested, fol- replaced.
EJ MAINTENANCE
COOLANT 50-50 concentrate should be 2. Clean or flush the cooling sys-
avoided to prevent possible over- tem, if required.
Correct coolant level is essential heating during warm weather. Do
for maximum circulation and ade- 3. To fill the cooling system:
not mix permanent-type anti- Close the radiator drain cock and
quate · cooling. In addition, for the
freeze with the methanol type. install the cylinder block drain*plugs.
cooling system to perform its func-
tion, it must receive proper care. In areas where protection to -35° Move the heater control dial in-
This includes keeping the radiator F is not required, but some protec- dicator clockwise to the "MAX"
fins clean and a periodic inspection tion is necessary, refer to the coolant heat zone.
of the cooling system for leakage. mixture chart on the Ford Rotunda Fill the system with coolant to a
Use care when removing the coolant can for the recommended point one inch below the bottom of
radiator cap to avoid injury from mixture proportions. the supply tank filler neck.
escaping steam or hot water. A standard ethylene glycol hydrom- Install the pressure cap and turn it
In production, the cooling system eter can be used to check the pro- clockwise until the first stop is
is filled with a new long-life coolant. tection level of the long-life coolant. reached. This will allow the cooling
This coolant protects to -35° F. It Refer to Group 19 for the recom- system to vent entrapped air into
will not be necessary to provide mended cooling system drain in- the atmosphere. Do not tighten the
special anti-freeze protection except terval. cap fully.
in areas where temperatures fall Operate the engine until normal
below this level. For year round pro- DRAINING AND FILLING operating temperatures are reached.
tection from corrosion and over~ THE COOLING SYSTEM After the initial fill, the coolant
heating, and for low-temperature level drops due to the displace-
protection to -35° F, all coolant 1. Remove the radiator cap. Open ment of entrapped air. Add more
added should be a mixture of 50% the radiator drain cock and remove coolant to fill the supply tank to the
Ford Rotunda coolant concentrate the cylinder block drain plugs to required level. Tighten the pressure
and water. Use of greater than a drain the cooling system. cap.

(241) PART 11-1- GENERAL COOLING SYSTEM SERVICE 11-3
4. Check the cooling system for FAN DRIVE BELTS fications. Also, check for misaligned
leakage. Move the heater control dial pulleys. If the drive belts are worn
indicator to the "MIN" heat zone. If the fan drive belts are noisy, or frayed, replace them following the
Turn the ignition key to the "OFF" check the tension of the belts to procedures in Part 11-1, Section 3.
position. make certain they are within speci-

ADJUSTMENTS mounting bolts. Move the air com-
pressor toward the engine and re-
DRIVE BELTS move the compressor drive belt.
2. Remove the alternator .splash
The belts must be properly ad- shield. Loosen the alternator mount-
justed at all times. Loose belts cause ing bolts and adjusting bracket bolts.
improper fan, water pump and alter- 3. Move the alternator toward the
nator operation. A belt that is too engine, and remove the fan drive
tight places a severe strain on the belts. ·
water pump and the alternator 4. Install the fan drive belts on
bearings. the water pump pulley, crankshaft
Properly tensioned drive belts damper and alternator pulley. Ad-
minimize noise and also prolong the just the belt tension to specifications,
service life of the belt. Therefore, it and tighten the alternator mounting
bolts and adjusting bracket bolts.
is recommended that a belt tension FIG. 2-Fan Drive Belt Tension 5. On a car with an air conditioner,
gauge be used to check and adjust Adiustment
the belt tension (Fig. 2). Any belt install the air compressor drive belt
that has operated for a minimum on the water pump pulley and the
of 10 minutes is considered a used 5. New beJt(s): Operate the engine air compressor clutch. Adjust the
belt, and when adjusted, it must for ten minutes, then check th4~ drive belt tension to specifications,
be adjusted to the reset tension tension of the belts to make certain and tighten the air compressor to
shown in the specifications. that they are within the reset speci- bracket mounting bolts.
fications. Adjust the belts, if required. 6. Install the alternator splash
Belt Tension 6. Install the alternator splash shield.
1. Remove the alternator splash shield.
shield. Loosen the alternator mount-
ing bolts. RADIATOR HOSE
REPAIRS REPLACEMENT
2. Loosen the alternator adjusting
bracket bolt. FAN REPLACEMENT
3. Install the belt tension gauge The radiator hoses should be
on the fan drive belts. Move the Removal replaced whenever they become
alternator toward or away from the cracked, rotted, or have a tendency
1. Remove the ground cable from to collapse.
engine unul the specified belt tension the battery.
is obtai·1ed. Remove the gauge. 1. Drain the radiator. Loosen the
2. Loosen the bolts securing the damps on each end of the hose to
Tighten the alternator adjusting fan blades and spacer to the water
bracket bolt; then tighten the alter- be removed. Slide the clamps in
pump pulley. Remove the fan, spacer, toward the center of the hose.
nator mounting bolts. and mounting bolts as a unit.
Install the tension gauge and check 2. Slide the hose(s) off the radiator
On a car with an air conditioner,
the belt tension. connection(s). Remove the upper
loosen the bolts securing the fan
4. On a car with an air condi- hose from the supply tank. Remove
drive clutch to the water pump
tioner, remove the bolts securing the lower hose from the water pump.
pulley. Remove the fan, drive clutch
the compressor to the support and mounting bolts as a unit. 3. Position the hose clamps on the
bracket that is attached to the cylin- center of the radiator hose( s). In-
der head. Loosen the bolts securing Installation stall the hose(s) on the respective
the compressor to the compressor connections and tighten the clamps
1. Position the spacer (or drive firmly. Make sure the clamps are
mounting bracket. clutch) and fan on the water pump
Install the tension gauge on the located beyond the bead on the
pulley and install the mounting connections.
compressor clutch drive belt. Move bolts. Tighten the bolts.
the compressor toward or away from 4. Fill the radiator to the required
2. Connect the ground cable to the level with coolant. Start the engine
the engine until the specified belt
battery. and check for coolant leaks. Check
tension is obtained. Remove the
gauge. Tighten the compressor to for proper coolant level after the
FAN BELT REPLACEMENT engine has reached normal operating
support bracket bolts. Install the
tension gauge and check the belt 1. On a car with an air conditioner, temperature. Add coolant as re-
tension. loosen the air compressor to bracket quired.

11-4 GROUP 11-COOLING SYSTEM (242)

COOLING SYSTEM WATER BY-PASS PLUG If a power flushing machine is
FLUSHING PROCEDURES used, a ''T" adapter (part of the
flushing equipment) must be at-
The design of the cooling system tached to the cylinder block as shown
requires that specific steps be taken in Fig. 3.
to reverse flush the engine. Engine Perform the power flushing proce-
cooling system thermostats open in dure as follows:
the direction of coolant flow. Due 1. Perform Steps 1 through 4 of
to this factor, it will be necessary to the "Reverse Flushing Procedure".
remove all thermostats to prevent 2. Install a "T" connection on the
back-pressure. cylinder block as shown in Fig. 3.
The water pump must be removed 3. Flush the engine until the water
to reach the cylinder block thermo- or solvent runs clean.
stat. Due to this condition, it is "T" Adapter to Flushing Machine
4. Remove the flushing machine
(Used with Power Flushing Equipment) _A
more practical to reverse flush the 81921 connections. Perform Steps 6
engine separately from the radiator. through 9 of the "Reverse Flushing
FIG. 3-Reverse Flushing Procedure". ·
REVERSE FLUSHING Procedures
PROCEDURE RADIATOR FLUSHING
7. Install the cylinder block ther- PROCEDURE
1. Remove the water pump. (Refer
to "Water Pump Removal" in Part mostats. (Refer to "Cylinder Block 1. Attach the pressure gun to the
11-2 for the proper procedure.) Thermostats Installation" in Part 11-3 upper radiator hose connection.
2. Remove the cylinder block for the proper procedure.) 2. Attach an outlet hose to the
thermostats. (Refer to "Cylinder 8. Install the water pump. (Refer radiator lower hose connection.
Block Thermostats Removal" in to "Water Pump Installation" in 3. Flush the radiator until the
Part 11-3 for the proper procedure.) Part 11-2 for the proper procedure.) water or solvent runs clean. Do not
3. Remove the coolant supply tank 9. Install the coolant supply tank use pressures in excess of 12 psi
and thermostat. (Refer to "Radiator and thermostat. (Refer to "Radiator when flushing the radiator.
Supply Tank and Thermostat Re- Supply Tank and Thermostat In-
moval" in Part 11-3 for the proper stallation" in Part 11-3 for the WATER PUMP
procedure.) proper procedure.)
1. Clean the gasket mounting sur-
4. Plug the coolant bypass tube. faces of the water pump and cylinder
POWER FLUSHING
Connect a water pressure gun attach- block.
PROCEDURE
ment to the intake manifold as illus- 2. Clean and inspect the seal seat-
trated in Fig. 3. Modern cooling system power ing surface of the water pump.
5. Flush the cylinder block until flushing equipment uses rust remov- 3. Clean the pump housing and
the system is clean. Remove the pres- ing solvents. Most equipment has inspect it for cracks, sand holes, im-
sure gun attachment. sight glasses to observe and deter- proper machining, and damaged
6. Clean the gasket surfaces of the mine when the system is clean. Power surfaces. If the water pump housing
water pump, cylinder block, coolant flushing is more efficient than the is damaged beyond repair, replace
supply tank and the intake manifold. reverse flushing method. the complete water pump.

(243)
11-5
PART WATER PUMP

11-2
1 Description and Operation . . . . . . . . . . ...... 11-5 3 Major Repair Operations .................. 11-5
2 Removal and Installation . . . . . . . . . . . ...... 11-5

The water pump is a centrifugal- and draws coolant from the radiator from the pump impeller, equally to
type with a cast iron impeller. The when the thermostat in the intake both cylinder banks.
impeller shaft is supported by a manifold is open. A bypass port on
double-row, sealed ball bearing that The water pump pulley is pressed
the water pump is connected to the a specified distance onto the water
is permanently lubricated. It re-
intake manifold to draw coolant pump shaft. The puliey is driven by
quires no additional lubrication.
The water pump is mounted on from it when the thermostat is closed, the crankshaft damper through two
the front of the cylinder block. The bypassing the radiator. V-belts. The water pump pulley
inlet port of the water pump is con- The water pump has two outlet mounts the cooling fan and spacer
nected to the radiator left side tank ports to distribute the coolant flow, (or fan drive clutch).

REMOVAL 7. Remove the water pump retain- the pulley sheaves. Close the radiator
ing bolts. Position the oil dipstick drain cock.
1. Remove the ground cable from
tube bracket and power steering 6. Adjust the alternator to obtain
the battery. Drain the cooling system. the specified belt tension. Tighten
pump bracket to allow clearance for
2. On a car with an air condi- removal of the water pump. Remove the alternator adjusting bracket bolt.
tioner, remove the power booster the water pump and mounting Tighten the alternator mounting
fan clutch, fan blade and compressor gaskets. bolts. Install the alternator splash
drive pulley. (Refer to "Fan Drive shield.
Clutch Removal" in Part 11-4 for the INSTALLATION 7. On a car with an air condi-
proper procedure.) Remove the radi- 1. Coat two new water pump tioner, install the compressor drive
ator supply tank. (Refer to "Radiator gaskets with water-resistant sealer. pulley, fan drive clutch and fan as-
Supply Tank and Thermostat Re- Install the gaskets on the water sembly and compressor ·drive belt.
moval" in Part 11-3 for the proper pump. Install the radiator supply tank, igni-
procedure) . 2. Insert the water pump bypass tion coil, overflow hose and the
3. If the vehicle is equipped with tube into the bypass hose. Make cer- radiator inlet hose. Refer to "Radia-
standard cooling components, remove tain the retaining clamp is on the tor Supply Tank and Thermostat
the, fan and spacer. (Refer to "Fan hose. Position the water pump and Installation" in Part 11-3 for the
Removal" in Part 11-1 for the proper gaskets on the cylinder block. proper installation procedure. Fill
removal procedure). 3. Position the oil dipstick tube the cooling system to the required
4. Loosen the clamp securing the bracket, power steering reservoir level. Start the engine and check for
bypass hose to the water pump. bracket, and alternator adjusting coolant leakage. Refer to "Fan Drive
5. Remove the alternator splash bracket on the water pump. Install Clutch Installation" in Part 11-4 for
shield. Loosen the alternator adjust- the water pump mounting bolts and the proper installation procedure.
ing bracket and mounting bracket torque them to specifications. 8. If the vehicle is equipped with
bolts. Push the alternator inward 4. Connect the heater outlet hose standard cooling components, install
and remove the drive belts. to the water pump fitting. Tighten the fan and spacer. Fill the cooling
6. Disconnect the radiator outlet the bypass hose clamp. system to the required level. Start the
hose at the water pump. Disconnect 5. Connect the radiator outlet hose engine and check for leakage. Refer
the heater hose at the water pump to the water pump. Install the water to "Fan Installation" in Part 11-1 for
fitting. pump and alternator drive belts on the proper installation procedure.

a unit (Fig. 6). Discard the shaft
DISASSEMBLY pulley with the use of steering wheel
The water pump assembly is shown remover tool 3600-AA as shown in and bearing assembly.
in Fig. 4. Fig. 5. CLEANING AND INSPECTION
1. Remove the impeller cover 3. Install the water pump on an Refer to Part 11-1, Section 4 for
plate and gasket. arbor press and press out the im- the cleaning and inspection proce-
2. Remove the water pump drive peller, seal and shaft and bearing as dures.

PUMP BODY
GASKET
l
•t
SEAL
~A
~
• •
FIG. 9-Water Pump Impeller

Installation
tool 8501-DD-18 over the seal and
press the seal inward until it seats
FIG. 4-Water Pump and Pulley (Fig. 8).
3. Position the water pump as-
sembly on an arbor press with the
pulley mounting end of the shaft and
bearing assembly resting on a steel
plate. Carefully press the impeller
onto the shaft until the rear face of
the impeller sets 0.105 to 0.115 inch
below the cover mounting face of
the water pump. Check the dimen-
sion, using a straight edge and a
feeler gauge (Fig. 9).
4. Position the water pump on an
arbor press with a steel block sup-
porting the shaft and bearing assem-
bly at the impeller mounting end.
Position the water pump pulley on
FIG. 5-Water Pump Pulley the shaft and press the pulley onto
Removal the shaft until a dimension of 7%2
ASSEMBLY inch is obtained between the front
When assembling the water pump, 81922-A face of the pulley and the mounting
face of the water pump "legs" (Fig.
always use new gaskets, seal, shaft
and bearing assem,bly, and impeller.
FIG. 7-lnstalling Water Pump 10).
1. Support the water pump on an
Shaft and Bearing 5. Coat the water pump cover
arbor press (Fig. 7). Position the and slinger assembly into the water gasket with a water-resistant; non-
shaft and bearing assembly in the pump housing until the bearing is hardening sealing compound. Install
water pump with the slinger facing flush with the hub edge of the hous- the gasket and cover. Tighten the
downward. Press the shaft, bearing ing. mounting bolts.
2. Support the water pump hous-
ing on its hub edge and insert the
seal assembly over the shaft with the
brass flange of the seal facing up-
1.00" Bar Steele ward. Place the recessed end of the
·- 81925-A
FIG. 6-Shaft and Bearing, Seal FIG. 8-Water Pump Seal FIG. 10-Water Pump Pulley
and Impeller Removal Installation Installation

{245) 11-7
PART RADIATOR, SUPPLY TANK AND

11-3 THERMOSTATS

1 Description and Operation . . . . . . ........ 11-7 2 Removal and Installation ................. 11-8

RADIATOR Two header tanks, one on each The radiator drain cock is located
side of the radiator (Fig. 11 ) , pro- at the lower rear of the radiator right
A cellular-tubular, crossftow radi- vide uniform distribution of the cool- side header tank. Cylinder block
ator (Fig. 11) is used in all car ant to the crossflow tubes. A heat drain plugs are located on each bank
models. An extra-cooling radiator is exchanger located within the left of the cylinder block.
available as optional equipment to side header tank of the radiator pro-
satisfy climatic and extra cooling vides means of cooling the transmis- SUPPLY TANK
requirements. Extra-cooling radiators sion fluid. Inlet and outlet fittings are
are standard equipment on air con- provided at the rear of the radiator A radiator supply tank (Fig. 11)
ditioner-equipped cars. left side header tank (Fig. 11). is provided on all models to control
surging of the coolant. The supply
tank is mounted to the intake mani-
fold coolant outlet port which con-
tains the main thermostat. The sup-
ply tank mounting bracket is secured
TRANSMISSION COOLER LINES to the water pump. A radiator rub-
ber inlet hose connects the supply
tank and the right side header tank
of the radiator.
An overflow hose is connected to
the supply tank and is secured to the
cylinder front cover by means of a
clip. The ignition coil is secured to
the underside of the supply tank by
a clamp and bracket.
THERMOSTATS
A standard, high-temperature ther-
mostat is located in the intake mani-
fold coolant outlet. When non-per-
manent-type anti-freeze is to be
used in the coo!ing system, the
high-temperature· thermostat must
be removed and replaced by a low-
temperature thermostat to elimi-
nate the possibility of the cooling
system boiling off the anti-freeze.
Also, two thermostats are located in
the front face of the cylinder block,
one in each cylinder bank (Fig. 12).
POWER BOOSTER FAN CLUTCH

(WITH AIR CONDITIONING)
8193,3-A
FIG. 11-Radiator and Supply Tank FIG. 12- Thermostat Locations

B REMOVAL AND INSTALLATION

RADIATOR lines and the radiator inlet hose. 4. Position the supply tank on the
Tighten the hose clamps. intake manifold and loosely install
REMOVAL
6. Install the fuel line bracket on the mounting bolts. Position the sup-
1. Raise the front of the car. Open the radiator. ply tank brace, engine ground straps
the radiator drain cock and drain the 7. Lower the car. Fill the cooling and battery ground cable on the
cooling system. system to its required level. Start water pump. Install the mounting
2. Disconnect and remove the the engine and check for leakage. bolt and torque it to specifications.
radiator inlet hose. Disconnect the Torque the supply tank mounting
RADIATOR SUPPLY TANK
transmission fluid inlet and outlet bolts to specifications.
AND THERMOSTAT
lines at the radiator. Plug the lines 5. Connect the overflow hose to
to prevent drainage and the en- REMOVAL the supply tank. Connect the radi-
trance of foreign material. ator inlet hose to the supply tank and
3. Disconnect the radiator outlet 1. Disconnect the battery ground radiator. Tighten the hose clamps.
hose at the water pump. cable at the battery. 6. Connect the primary and sec-
4. Remove the three radiator lower 2. Remove the pressure cap from ondary wires to the ignition coil.
mounting bolts. the radiator supply tank. Drain the Close the radiator drain cock. Con-
5. On a car with an air condi- cooling system to below the supply nect the battery ground cable to the
tioner, remove the two condenser to tank level. battery.
radiator lower mounting bolts. 3. Disconnect the overflow hose 7. Fill the supply tank to its re-
6. Remove the radiator support from the radiator supply tank. Re- quired level with coolant and install
shield. Disconnect the fuel line move the water pump mounting bolt the pressure cap. Start the engine
bracket from the radiator. Remove securing the supply tank brace, en- and check for coolant leakage.
the radiator from the car. Use care gine ground strap and battery ground
to prevent radiator damage. cable to the water pump. CYLINDER BLOCK
4. Disconnect the radiator inlet THERMOSTATS
INSTALLATION hose from the radiator and supply
tank. REMOVAL
1. Close the radiator drain cock
and position the radiator in the car. 5. Disconnect the primary and 1. Remove the water pump, fol-
secondary wires from the ignition lowing the procedures in Part 11-2,
coil. "Water Pump Removal".
tioner, install the condenser and
6. Remove the retaining bolts 2. Pry the thermostats from the
radiator support shield on the radi-
securing the radiator supply tank to cylinder block with a screwdriver or
ator and insert the three mounting
the intake manifold. Remove the thin blade chisel. It is impossible to
bolts. Do not tighten the bolts. In-
tank, gasket and thermostat. Remove check used thermostats due to the
stall the two condenser lower mount-
the ignition coil from the supply damage that occurs to the units
ing bolts. Tighten the condenser
tank. during their removal. Do not at-
upper and lower mounting bolts.
3. Install the radiator support tempt to repair them. Install new
INSTALLATION thermostats.
shield on the radiator and loosely in-
stall the three mounting bolts. 1. Install the thermostat in the INSTALLATION
4. Position the radiator insulators intake manifold with the copper
between the radiator support brack- pellet or element towards the en- 1. Clean the thermostat bores to
ets and the car underbody. Make gine. It is important that the ther- remove rust and foreign material.
certain they are aligned with the mostat be positioned correctly in 2. Install the thermostats with the
mounting bolt holes. Install the the intake manifold. If it is im- temperature bulb located inside of
radiator lower bolts. Tighten the properly positioned, it will cause the cylinder block.
radiator lower and upper mounting a retarded flow of coolant. 3. Carefully tap the thermostats
bolts. Secure the radiator support 2. Coat the radiator supply tank into position in the cylinder block.
shield to the car body upper support gasket with water-resistant sealer and A void damaging the thermostats
panel and tighten the five mounting install it on the intake manifold. during this operation.
bolts. 3. Install the ignition coil in the 4. Install the water pump, follow-
5. Install the radiator outlet hose, supply tank mounting bracket and ing the procedures in Part 11-2,
transmission fluid inlet and outlet tighten the clamp. "Water Pump Installation".

(241) 11-9
PART FAN DRIVE CLUTCH

11-4
1 Description and Operation ......... 11-9 2 Removal and Installation .................. 11-9
a DESCRIPTION AND OPERATION

Air-conditioner-equipped vehicles change. The unit also increases us- located within the chamber cause
contain a fan drive clutch assembly, able engine horsepower during high sufficient friction buildup to rotate
a six-bladed fan, a compressor drive speed operation. the housing and mounted fan. Con-
pulley, and a compressor clutch The fan drive clutch is controlled versely, a decrease in underhood
drive belt. by a heat-sensitive, bi-metal spring temperatures allows the heat-sensi-
The six-bladed fan is mounted at located on the clutch front cover. As tive spring to close the valve and
the rear of the fan drive clutch. The underhood temperatures increase, permits the return of the oil to the
clutch assembly and compressor this spring expands, causing a plate reservoir section of the unit. As the
drive pulley are secured to the water within the unit to uncover an open- drive chamber empties, the drive
pump drive pulley with four cap- ing between the oil reservoir and plate rotates freely and the fan no
screws. drive chambers. Centrifugal force longer receives torque from the en-
The fan drive clutch and fan as- of the drive chamber, as it revolves gine. The unit permits slippage so
sembly is regulated by underhood at water pump pulley speed, causes that some fan rotation will be ex-
temperatures to control the fan rpm the fluid to enter the drive chamber. perienced, even under low tem-
as engine cooling requirements Lands and grooves in the drive plat1e perature operation.

The fan drive clutch assembly is drive pulley to the water pump pul- 2. Install the clutch assembly and
serviced only as a unit. If malfunc- ley. Remove the fan drive clutch, fan compressor drive pulley on the water
tion occurs, the unit must be re- and pulley as a unit. pump pulley and tighten the mount-
placed. 4. Remove the four capscrews and ing bolts.
REMOVAL disassemble the fan from the fan 3. Install the compressor drive
drive clutch. belt on the compressor clutch and
1. Disconnect the ground cable at
t~e battery. CLEANING AND INSPECTION the drive pulley. Adjust the compres-
1
2. Loosen the compressor support Refer to Part 11-1, Section 4 for sor to obtain the specified belt ten-
bracket bolts and adjusting bracket the cleaning and inspection proce- sion and tighten the compressor to
bolts. Move the compressor inward dures. mounting bracket attaching bolts.
toward the engine. Remove the com- Tighten the support bracket bolts:
pressor drive belt. INSTALLATION 4. Connect the ground cable to
3. Remove the four bolts securing 1. Install the fan on the fan drive the battery. Remove the fender cov-
the fan drive clutch and compressor clutch and tighten the capscrews. ers and close the hood.

11-10
(248)
PART SPECIFICATIONS
11-5
COOLING FAN THERMOSTATS
OUTSIDE NO. OF MAIN THERMOSTATS

DIAMETER BLADES
Standard . . . . . . . . . . . . . . . . . . . 17.50 inches 4 Low Temperature

Air Conditioner-Equipped 18.25 inches 5 Opens op ....................... 155°-162°
Fully Open °F ........................ 182°
WATER PUMP High Temperature
WATER PUMP DRIVE ARRANGEMENT

Opens op ....................... 185°-192°
Fully Open °F ....................... 212°
Dual belts drive water pump, fan and alternator
CYLINDER BLOCK THERMOSTATS
WATER PUMP PULLEY TO ENGINE RATIO
Opens op ....................... 137°-142°
Extra Cooling (With Air Conditioning) .... 1.25:1
Fully Open °F ........................ 162°
Standard Cooling .....-.· ................ 1.25:1
WATER PUMP ASSEMBLY DIMENSIONS TORQUE VALUES

Front Face of Pulley Hub to NOTE: All specifications are given in ft-lbs unless
Pump Housing Face ................ 7.094 inches otherwise noted.
Impeller to Housing Clearance .. 0.105-0.115 inches
Water Pump to Cylinder Block .............. 23-28
Water Outlet Housing ..................... 12-15
DRIVE BELT TENSION
Fan and Pulley to Pulley Hub ............... 10-15
BETWEEN ALTERNATOR AND WATER PUMP PULLEY Radiator Lower Attachment ................. 10-15
Radiator Supply Tank to Engine ............ 20-28
New-Front .......................... 110-135
Radiator Support to Air Deflector ........... 10-15
Rear .......................... 105-140
Transmission Oil Cooler Hose Tube
*Used-Front .......................... 90-110 to Radiator .............................. 18-25
Rear ........................... 85-115 Transmission Oil Cooler Hose Fitting
to Radiator .............................. 10-12
BETWEEN WATER PUMP AND AIR COMPRESSOR PULLEY Radiator Hose Clamps to Radiator
New ................................ 120-150 and Engine ......................... ~ .... 1.0-2.5
*Used ................................ 90-120 Transmission Oil Cooler Tubes
Hose Clamps ........................ 15-20 in-lbs
*Belt operated for a minimum of 10 minutes is con-
sidered a used belt.
COOLING SYSTEM CAPACITY
Approximate Capacity
(Quarts)
Cooling System
u.s. Imperial
Measure Measure
~-
Standard 21 17lh

(249) 12-1
GROUP
12
EXHAUST SYSTEM .12-1 SPECIFICATIONS .. 12-5
PART EXHAUST SYSTEM

12-1
1 Description . . . . . . . . . , . . . . . . . . . . . . . . . . . .. 12-1 3 Removal and Installation .................. 12-3
2 In-Car Adjustments and Repairs . . . . ...... 12-1
II DESCRIPTION
A dual exhaust system (Fig. 1) contain an integral inlet extension ing nuts. The connecting flanges of
is used on all Lincoln Continental pipe and an outlet pipe. The muffler the resonator and muffler pipes are
Models. The system consists of a and pipe assemblies are one-piece sealed by means of gaskets and are
separate resonator inlet pipe, reso- units and are serviced as such. secured with bolts and nuts.
nator assembly and muffler assembly The right and left resonator cross- Hinge-type, insulated, hanger and
for each exhaust manifold. over pipes are connected to each support bracket assemblies are se-
•
The right and left resonators con- other and are secured by a U-bolt cured to the welded integral mount-
tain an integral inlet extension pipe, and clamp. The ball-type ends of the ing flanges on the rear of the reso-
outlet extension pipe and crossover right and left resonator inlet pipes nators. The muffler outlet pipes are
pipe. The resonator assemblies are tl1 into the exhaust manifold outlet. secured to the rear hinge-type ex-
one-piece units, and are serviced as The resonator inlet pipe flanges are haust system support bracket as-
such. secured to the exhaust manifold semblies by means of retaining clamp
The right and left exhaust mufflers t1anges by means of studs and retain- brackets.
B IN7CAR ADJUSTMENTS AND REPAIRS

The exhaust system must be free EXHAUST SYSTEM ALIGNMENT manifolds. If necessary, disconnect
of leakage, binds, grounding and The exhaust system components the resonator inlet pipe(s), and turn
excessive vibration. and clearance specifications are the studs inward or outward to ob-
Exhaust system vibration, ground- shown in Figs. 1 and 2. Perform tain the specified length.
ing, or binds are usually caused by: the following procedure to adjust and 4. Tighten the retaining nuts at the
loose, broken or improperly aligned neutralize the exhaust system compo- right and left inlet pipe to manifold
clamps or brackets; improper in- nents: flanges, evenly and alternately, to
stallation of the resonator inlet pipe 1. Raise the car. Loosen the re- obtain the specified distance from
flange on the exhaust manifold out- taining nuts securing the muffler out- the bottoms of the inlet pipe flanges
let flange, or improperly connected let pipe lower clamp brackets to the to the tips of the mounting studs.
resonator crossover pipes. Any of hinge bracket assemblies. Loosen the Progressively tighten the retaining
the aforementioned conditions may retaining nuts and bolts securing the nuts to the specified torque.
cause changes to the clearances of upper clamp brackets to the lower 5. Adjust the resonator crossover
the exhaust system components (Fig. cl~mp brackets. pipes at their connection to obtain
2). If any of these conditions exist, :~. Loosen the retaining nuts and the specified distance at the con-
the clearance of the exhaust system holts securing the resonator hinge necting flanges of the resonator inlet
components must be checked, ad- brackets to the plate brackets. Loosen pipes, and the specified clearances
justed and neutralized (strain re- the resonator crossover pipe retain- for the resonator inlet pipes and
lieved), or replaced to make cer- in~: clamp. resonators. Torque the resonator
tain the specified clearances are :L Check the assembled length of crossover pipe clamp retaining nuts
maintained. th,_: mounting studs in the exhaust to specification; then torque the reso-

Q
"'
0
c.,.
-
N
FIG. 1-Lincoln Continental Exhaust System -·

~

(251) PART 12-1-EXHAUST SYSTEM 12-3
nator hinge-bracket to pipe bracket bracket retaining bolts and nuts to of the lower clamp brackets to spe-
retaining nuts and bolts to specifi- specification. Check the clearance cification.
cation. of the resonator outlet pipes, muffler 7. Lower the car. Check the ex-
6. Torque the right and left outlet inlet extension pipes and the mufflers. haust system for leaks, grounding or
pipe hinge bracket to lower clamp Torque the retaining bolts and nuts excessive vibration.

The replacement procedures given RESONATOR necting flanges of the resonator in-
apply to all Lincoln Continental REMOVAL let pipes, and torque the retaining
Models and to both right and left as- clamp nuts to specification.
semblies of the dual exhaust system, 1. Raise the car at the rear under-
body side members. This will allow 5. Check the clearances of the ex-
except as noted. Refer to Figs. 1 haust system components. Adjust
and 2 for views of the exhaust sys- the rear suspension to hang down-
ward of its own weight to provide and neutralize the exhaust system,
tem components and their clearance if necessary.
specifications. clearance for removal of the reso-
nator assembly. 6. Lower the car.
2. Remove the retaining bolts se- EXHAUST MUFFLER
RESONATOR INLET PIPE curing the resonator inlet pipe and
gasket to the resonator inlet exten- REMOVAL
REMOVAL
sion pipe. Discard the gasket. Re- 1. Raise the car. Remove the bolts
1. Raise the car. To remove the left- move the bolts securing the resonator
hand resonator inlet pipe, remove securing the resonator outlet exten-
outlet pipe and gasket to the muffler sion pipe and gasket to the muffier
the transmission linkage splash inlet extension pipe. Discard the
shield. inlet extension pipe. Discard the
gasket. gasket.
2. Remove the retaining nuts se- 3. Remove the retaining clamp 2. Remove the retaining bolt se-
curing the inlet pipe to the exhaust from the resonator crossover pipe. curing the outlet pipe lower clamp
manifold. Remove the bolts and Remove the nuts securing the resona- bracket to the hinge-bracket assem-
nuts securing the resonator inlet pipe tor bracket to the plate. bly. Remove the outlet pipe retain-
to the resonator inlet pipe extension; ing clamp brackets and the muffier
remove the resonator inlet pipe, and 4. Disconnect the crossover pipe,
and remove the resonator and mount- assembly as a unit. Remove the
discard the mounting gasket. upper and lower clamp brackets. In-
ing bracket as a unit. Remove the
hinge-bracket assembly and insula- spect the clamp brackets and hinge-
INSTALLATION tor from the resonator, and replace b~acket, and replace any damaged or
any damaged or worn parts. worn parts.
1. Clean the mounting surfaces of
the exhaust manifold and the inlet INSTALLATION INSTALLATION
pipes. Position the resonator inlet
pipe flange on the studs of the ex- 1. Clean the mounting surfaces of 1. Clean the mounting flanges of
haust manifold, and loosely install the crossover pipes, resonator inlet the resonator outlet extension pipe
the1 retaining nuts. Position a new and outlet pipes, and the muffler and the muffler inlet extension pipe.
gasket between the flanges of the inlet extension pipe. Install the in- Position the upper and lower clamp
resonator inlet pipes, and loosely insulator and hinge-bracket assembly brackets on the muffler outlet pipe,
stall the retaining nuts and bolts. on the resonator flange and torque and loosely install the retaining bolt
the mounting bolts to specification. and nut.
2. Tighten the inlet pipe to mani-
fold flange retaining nuts, equally 2. Position the retaining clamp on 2. Position the muffler and clamp
and alternately, to obtain the spe- the crossover pipe. Install the reso- bracket on the hanger assembly. In-
cified distance from the bottom of nator in the car and connect the stall the lower clamp bracket on the
the inlet pipe flanges to the tips of resonator crossover pipe. Install the hinge-bracket assembly. Install and
the mounting studs. Tighten the re- plate brackets on the plate and torque the clamp bracket retaining
taining nuts, equally and alternately torque the retaining nuts to specifica- bolt and nut to specification.
to the specified torque. tion. 3. Install a new gasket, muffler
3. Position the resonator inlet ex- inlet pipe extension and retaining
3. Torque the resonator inlet pipe bolts on the resonator outlet extension
tension pipe and gasket on the inlet
to resonator inlet extension pipe re- pipe, and torque the retaining bolt
pipe, and torque the retaining bolts
taining bolts to specification. Check and nut to specification.
and nuts to specification. Position
the resonator inlet pipe clearance.
the resonator outlet pipe and gasket 4. Check the clearance of the
Adjust and neutralize the exhaust
on the muffler inlet extension pipe resonator outlet extension pipe, muf-
system, if necessary.
and torque the retaining bolts to fler inlet extension pipe and the
If the left-hand resonator inlet specification. muffler. Torque the outlet pipe lower
pipe was removed, install the trans- clamp bracket retaining bolt and nut
4. Adjust the resonator crossover
mission linkage splash shield. pipes at their connection to obtain to specification.
4. Lower the car. the specified distance at the con- 5. Lower the car.

..
~
I
rT'I
><
. :c
>
c:
VI
-1
VI
-<
....
VI
rT'I
:I:
. A1859-A -
N
-
c.n
N
FIG. 2-Lincoln Continental Exhaust System Clearance Dimensions

(253) 12-5
PART SPECIFICATIONS
12-2
TORQUE LIMITS Ft·lbs
Resonator Inlet Pipe to Exhaust Manifold 17-25

·-·
Resonator Inlet Pipe Flanges 12-22

·-
Resonator to Hinge-Bracket 12-22
·-
Resonator Hinge-Bracket to Plate Bracket 12-22
·-
Resonator Plate to Plate Bracket 12-22

·-
Muffler Upper Clamp Plate to Hinge-Bracket 12-22

·-
Muffler Hinge-Bracket to Lower Clamp Bracket 12-22
Muffler Upper Clamp Bracket to Lower Clamp Bracket 12-22

-

(254)
lf(M]O&)
fP&®~
O~lf~~lf0@~&l1l1\"?
®l1&~~

(255) 13-1
GROUP
13
GENERAl CHARGING SYSTEM REGUlATOR .. 13-11
SERVICE . . . . . . . . . . . . . . . . . .. 13·1
PART 13-2 PART 13-4
ALTERN ATOR . . . . . . . . . . . . . . . . . . 13-8 SPECIFICATIONS ............... 13-13
PART GENERAL CHARGING SYSTEM SERVICE

13-1
1 Diagnosis and Testing . . . . . . . . . . . ....... 13-1 3 Cleaning :and Inspection ................. 13-7
2 Common Adjustments and Repairs ........ 13-7

TROUBLE DIAGNOSIS GUIDE
Indications of a battery low in is at fault. If the output is normal

charge are slow cranking, hard start- or greater than the rating of the al-
ing, and headlights dim at engine idle ternator, proceed with an alternator
speed. Causes are: regulator test under the heading "Test
•
I. The alternator belt worn, or Alter.nator Regulator." If the output
loose and slipping over the pulley. is low proceed as follows: -
2. The battery in such poor con-
dition that it will not hold or take a ALTERNATOR OUTPUT LOW
charge.
3. The alternator not producing Connect a heavy jumper wire from
its rated output. the battery ground post to the alter-
4.. Regulator unit out of adjust- nator ground terminal. Repeat the
ment, and excessive resistance in the alternator output test. If the output
alternator-to-battery circuit or in the now reaches or exceeds rated output,
battt::ry-to-ground circuit. either the alternator or the battery is
BATTERY LOW IN CHARGE First chock the alternator belt ad- not properly grounded to the engine
justment and condition. frame. Replace the battery-to-ground
cable if it is corroded or partially
RECHARGE OR REPLACE broken. Clean the cable connections
BATTERY at the battery and engine, and tighten
the connections. Tighten the alter-
Perform a battery Before Charge nator mounting bolts.
Test (page 13-6). Replace the bat-
tery if the test indicates it is worn If the alternator output is still less
out or under capacity. If the battery than normal, the alternator output
capacity is normal, proceed as fol- could be low due to an open or short
lows• circuit in the field, stator, brushes, or
brush holders, or the brushes can be
worn too short or may be sticking in
TEST ALTERNATOR OUTPUT
the brush holder and not making
Test the alternator output (page good contact on the slip rings. Re-
13-2: to determine if the alternator move the alternator for repair.

13-2 GROUP 13-CHARGING SYSTEM (256)
TROUBLE DIAGNOSIS GUIDE (Continued)
TEST CIR(UIT RESISTANCE TEST ALTERNATOR REGULATOR

If the alternator output is normal, If the circuit resistance is normal,
check the external circuit to deter- test the regulator to determine if it is
mine the circuit resistance (page properly adjusted.
13-6). After checking both regulator
RESISTANCE EXCESSIVE units, adjust or replace the regulator
as necessary. If the regulator is not
If the resistance (voltage drop) is at fault, the battery is low in charge
BATTERY LOW IN CHARGE greater than that specified for the due to improper operation such as:
(Continued) car, locate the trouble by perform-
ing a complete external circuit re- 1. Excessive use of accessories.
sistance test (page 13-6) . Repair or 2. Short trips.
replace the defective part. 3. Accidental discharge of battery.
RESISTANCE NORMAL 4. Incorrect engine lubricant for
If the resistance (voltage drop) is ambient temperature encountered.
equal to or less than that specified 5. Regulator calibration set too
for the car, test the alternator regu- close to low limit for vehicle operat-
lator. ing conditions.
Indications of a high charging rate 1. Make certain that all connec-

are: tions, including the regulator ground,
1. Lights and fuses burn out re- are tight.
peatedly. 2. Check the voltage limiter. If the
2. Battery requires too frequent voltage limit is high, check the con-
HIGH CHARGING RATE refilling. tacts and replace the regulator if the
3. The ignition contacts have a contacts are burned.
short life.
To determine the possible cause of 3. If the contacts are in good con-
the high charging rate, check the dition, adjust the regulator to the
following items: specified limits (page 13-11).
ALTERNATOR TESTS
Figure 1 shows the alternator
charging circuit schematic. Figure
2 shows the alternator output con-
nector block.
BAITERY TERMINAL
OF STARTER RELAY
NOT USED
WITH AMMETER'6
,------,
I I
ALTERNATOR OUTPUT TEST I I
When an alternator output test is I I
conducted off the car, a test bench I ·I
must be used. Follow the procedure
given by the test bench equipment
~-o-~I.......J I
manufacturer. When the alternator I
o-----o---:-1---J II
is removed from the car for this
purpose, always disconnect a bat-
tery cable, as the alternator output F
I I
connector is connected to the bat- I I
tery at all times.
To test the output of the alterna-
I I
tor on the car, proceed as follows: L ::h_I!~LATOR _ _ j
1. Charge the battery if necessary.
Make the connections as shown in
Fig. 3. Be sure that the Generator FIELD TERMINAL
Field Control is in the OPEN posi-
tion at the start of this test.
2. Close the battery adapter switch.
Start the engine, then open the bat- J1205-A
tery adapter switch. All electrical
accessories including door operated FIG. 1-Aiternotor System Schematic

(257) PART 13-1-GENERAL CHARGING SYSTEM SERVICE
2500 rpm. Do not exceed this position. Maintain 2500 rpm engine
speed. speed.
4. Adjust the Generator Field 6. Adjust the Generator Field Con-
Control until the voltmeter reads trol and the LOAD control, main-
exactly 15 volts. Observe the am- taining a voltmeter reading of 15
meter reading. Add 5 amperes to this volts maximum, until the Gen·erator
reading to obtain total alternator out- Field Control is at its maximum
put. The 5 ampere factor represents clockwise position.
the field current and the ignition sys- 7. Readjust the LOAD control un-
tem current, and must be added til the voltmeter reads exactly 15
to the ammeter reading as these cur- volts. Observe the ammeter reading.
rents are not indicated on the am- Add 5 amperes to this reading to
meter. Make this test in the short- obtain total alternator output.
est possible time and do not ex-
ceed 2500 engine rpm. 8. Stop the engine, return the Gen-
erator Field Control to the OPEN
If the battery was fully charged, it position and disconnect the test
might not be possible to obtain max- equipment.
imum current output. If specified
An output of two to five amperes
FIG. 2-Aiternator current is not obtained, make the
following test before condemning the below specifications usually indicates
Electrical Connections alternator: an open diode rectifier. An output
of approximately 10 amperes below
interior lights must be turned off. 5. Turn the Generator Field Con- specifications usually indicates a
3. Gradually increase the engine trol to the OPEN position. Rotate shorted diode rectifier. An alternator
speed to a tachometer reading of the tester control knob to the LOAD with a shorted diode will usually
GENERATOR
FIELD CONTROL
SET AT OPEN
POSITION
(MAXIMUM
COUNTER-
CLOCKWISE)
J1233-B J1224-B
FIG. 3-Aiternator Output Test FIG. 4-Field Open or Short Circuit Test

13-4 13-CHARGING SYSTEM
whine, wh'lC h '11

WI be mo8 t notice-
able at idle speed. .
DIODE TEST
To test the ..
~e connectio:.os:~ve diodes, make
ontact th own in F
lead. Makee probe to each •g: 5.
probe i . sure that the . diode
the s .sharp and tb . tip of the
T varmsh at the di adt It penetrates
0
the o test the negative ed' termina.1
Fou::n~~ions ·~·~.make
dio~ame f~·
shown
positive procedure as th6.
Good . es. r e
on the meter
diodes · will . be mdicated
.
~ps or moC:n F~gs. 5 and 6 ~
Within 2 scale d'lVlSIOns)
a.n. readings alike
FIELD OPEN .
CIRCUIT TES~R SHORT
Make
Fig. the connections as sh
4. Th .
a · e norm 1 own m
s mdicated
be 2 b a current
Y the amm
d raw,
FIG 5
. -Positive Diode Test
J1211-A
ther."9i;3ii!u:"'peres t~·~~~ould
or no cuatrrent flow's. the
If
VAT-20-8 or EquJvolent
.
BAnERY
J1229-B J1225-B
FIG. 1-Field Re1ay Test FIG. 8- Voltage Limiter Test

(259) PART 13-1- GENERAL CHARGING SYSTEM SERVICE 13-5
ALURNATOR
J1227-B
FIG. 9-Voltage Drop Test-Alternator to FIG. 10-Vohage Drop Test-Alternator

Battery Positive Terminal to Battery Grc»und Terminal
field has a high resistance or is open, shown in Fig. 7. Slowly rotate the: Make the test connections as
o~ the brushes are not making proper field resistance control clockwise: shown in Fig. 8. Turn all acces-
contact with the slip rings. A current from the OPEN position until the: sories off, including door operated
flow considerably higher than that field relay contacts close. Observe dome lights. Close the battery
specified above, indicates shorted or the voltmeter reading at the moment: adapter switch, start the engine, then
grounded turns. If the test shows that that the relay closes. This is the relay open the adapter switch. Attach the
the field is shorted and the field closing voltage. If the relay closes voltage regulation thermometer to
brush assembly is not at fault, the immediately, even with the field re- the regulator cover. Operate the
entire rotor must be replaced. sistance close to the OPEN position, engine at 2000 rpm for 5 minutes.
use a 6-volt battery for this test. If Turn the master control to the
REGULATOR AND CIRCUIT the closing voltage is not to specifi- DIRECT position. If the ammeter
TESTS cations, adjust the relay. indicates more than 10 amperes, stop
the engine, remove the battery cables
The tests presented are outlined
and charge the battery.
for on-the-car operation. Be sure VOLTAGE LIMITER TEST
When the battery is charged, and
that the regulator is at "normal"
For test purposes, the lower stage the voltage regulator has been tem-
operating temperature (equivalent to
(armature vibrating on the lower perature stabilized, rotate the master
the temperature after 20 minutes of
contact) regulation is used. Voltage control to the 14 -OHM position, the
operation on the car with the hood
down). limiter calibration tests must be made ammeter should indicate approxi-
with the regulator cover in place and mately 2 amperes.
FIELD RELAY TEST the regulator at "normal" operating Cycle the regulator as follows:
temperature (equivalent to the tem- Stop the engine, close the adapter
Disconnect the regulator terminal perature after 20 minutes of oper- switch, start the engine, and open
plug, and remove the regulator 1tion on the car with a 10 ampere the adapter switch. Allow the battery
cover. Make the connections as oad). to normalize for a short time, then

13-6 GROUP 13-CHARGING SYSTEM (260)·
read the voltmeter. Read the ther- shown in Fig. 9. Tum off all elec- facturer when using such combined
mometer, and compare the voltmeter trical accessories, and lights. Close equipment.
reading with the voltage given in the battery adapter switch, start the Hydrogen and oxygen gases are
Table 1 for the ambient tempera- engine, then open the battery adapter produced in the course of normal
ture indicated on the thermometer. If switch. Slowly increase the engine battery operation. This gas mix-
the regulated voltage is not within speed until the ammeter reads 20 ture can explode if flames or
specifications, make a voltage limiter amperes. Note the voltmeter reading sparks are brought near the vent
adjustment. After each adjustment, at this point. The voltage reading openings of the battery. The sul-
be sure to cycle the regulator before should be no greater than 0. 7 volt. phuric acid in the battery elec-
each reading. The readings must be Alternator to Battery Ground trolyte can cause a serious burn
made with the cover in place. Terminal. Make the connections as if spilled on the skin or spattered
shown in Fig. 10. Close the battery in the eyes. It should be flushed
TABLE 1-Voltage Limiter Setting adapter switch, start the engine and away immediately with large
open the adapter switch. Slowly in- quantities of clear water.
Versus Ambient Air Temperature crease the engine speed until the
Voltage ammeter reads 20 amperes. The volt- BEFORE CHARGE TESTS
Ambient Air Regulation age indicated on the voltmeter should
Temperature op Setting (Volts) be less than 0.1 volt. Battery Capacity Test. A high-
rate discharge tester in conjunction
50 14.3-15.1 BATTERY TESTS AND with a voltmeter is used for this test.
75 14.1-14.9 CONCLUSIONS If the battery solution is not within
100 13.9-14.7 60° F. to 100° F., let it stand until
125 13.8-14.6 Tests are made on a battery to warm before making this test. Add
150 13.6-14.4 determine the state of charge and water if necessary to bring the bat-
175 13.5-14.3 also the condition. The ultimate re- tery solution to the proper lever. Fill
sult of these tests is to show that the only to the narrow ring near the
battery is good, needs recharging, or bottom of each vent well. Fig. 11
CffiCUIT RESISTANCE TESTS must be replaced. shows the battery capacity test in
If a battery has failed, is low in outline form.
For the purpose of this test, the charge, or requires water frequently,
resistance values of the circuits have 1. Connect the high-rate discharge
good service demands that the rea- tester and the appropriate voltmeter
been converted to voltage drop read- son for this condition be found. It
ings for a current flow of 20 to the battery terminals.
may be necessary to follow trouble 2. Adjust the discharge tester to
amperes. If the battery is fully shooting procedures to locate the
charged disconnect the regulator and draw three times the ampere hour
cause of the trouble (Section 1 in rating of the battery (an 80-ampere
run a jumper from the A+ terminal this part).
to the F terminal of the cable con- hour battery should be tested at a
Some battery test equipment com- 240-ampere load). After 15 seconds
nector, before making the tests. bines the necessary instruments and and with the battery still under load,
Alternator to Battery Positive controls in a single unit. Be sure to read the battery terminal voltage.
Terminal. Make the connections as follow the directions of the manu- The voltmeter clips must contact
BATTERY CAPACITY TEST
the battery posts and not the high-
ADJUST RESISTANCE UNTIL AMMETER READS 3 TIMES AMPERE-HOUR rate discharge tester clips. Unless
RATING OF BATTERY. HOLD FOR 15 SECONDS AND NOTE VOLTAGE. this is done the actual battery ter-
minal voltage will not be indicated.
3. If the terminal voltage is 9.6
VOLTAGE OVER 9.6 VOLTAGE LESS THAN 9.6 volts or more, the battery has good
output capacity and will accept a
CHECK SPECIFIC GRAVITY. CHARGE BATTERY, HIGH RATE CHARGE FOR 3 MINUTES.
IF LOW. OTHERWISE BATTERY IS O.K.
normal charge. Test the specific grav-
TEST INDIVIDUAL CELL VOLTAGE WHILE
CHARGING AT 30 AMPERES
ity if water has not been recently
added, and recharge if necessary.
4. If the terminal voltage is below
CELL VOLTAGE EVEN,
9.6 volts, make a test charge on the
CELL VOlTAGE UNEVEN,
WITHIN 0.1 VOLT MORE THAN 0.1 VOlT
battery.
Battery Test Charge. The condi-
CHECK TOTAL BATTERY VOLTAGE,
tion of a discharged battery may be
CHARGER OPERATING AT 30 AMPERES tested by passing current through it.
1. Connect a fast charger to the
battery and charge the battery for 3
TOTAL VOlTAGE TOTAl VOLTAGE
minutes at a rate of 30 amperes.
LESS THAN 15.5 MORE THAN 15.5 2. After 3 minutes of fast charge,
I and with the fast charger stiH oper-
I CHARGE BATTERY I BATTERY SULPHATED-LOW RATE CHARGE ating, test the individual cell voltages
MAY SALVAGE. TEST AGAIN AFTER CHARGE of the battery.
J1039-C
3. If the cell voltages vary more
Fl G. .11- Battery Capadty Test Outline than 0.1 volt, rcpJace the batter-y. If

(261) PART 13-1-GENERAL CHARGING SYSTEM SERVICE 13-7
the cell voltages are even within 0.1 below 9.6 volts, replace the battery. Fast charging. Follow the instruc-
volt, test the total battery voltage Battery charge tests. Battery tions of the fast charger manufac-
(charger still operating) . charge may be tested by measuring turer, as fast chargers vary slightly
4. If the total battery voltage is the battery electrolyte solution spe:- with different manufacturers.
now under 15.5 volts, the battery is cific gravity (hydrometer) or by Test the battery cells for specific
satisfactory and may be safely fast measuring the voltage of the bat- gravity. Then, fast charge the bllttery
.charged (see Specifications in this tery cells on open circuit (no cur- at 30 to 40 amperes maximum for
group). Always follow the fast rent flow) with a battery charg4~ the length of time shown in the
charge with sufficient slow charge tester (open circuit voltage tester). Specifications (in this group) , cor-
to bring the battery to a full A discharged 12-volt battery can responding to the specific gravity
charge. freeze during cold weather. Th4~ condition of the battery.
5. If the total battery voltage is Specifications (in this group),
over 15.5 volts, the battery is prob- Slow charging. Always follow a
show the. temperatures at which fast charge with a slow charge at 3
ably sulphat~d. Place the battery on batteries of various specific gravi··
continued slow charge. amperes for 12-volt batteries of less
ties will begin to freeze. than 70-ampere-hour capacity. Bat-
teries of 70-ampere-hour capacity or
AFTER CHARGE TESTS higher require a 4-ampere slow
BATTERY CHARGING
When the battery is fully charged charge. Continue the slow charge
(check with a hydrometer or battery A battery that is not sulphated until the battery is fully charged.
charge tester) make a capacity test. may be charged by either a fast A battery is considered fully charged
If the terminal voltage is 9.6 volts charging or slow charging method. when the specific gravity readings of
or above, place the battery back in \1ost fast charge units may be ad- all the cells, taken at hourly intervals,
service. If the terminal voltage is justed for making a slow charge. do not increase over a 3-hour period.

BELT ADJUSTMENT 2. Apply pressure on the alternator tool T63L-8620-A. Adjust the belt
front housing only and tighten the for specified tension.
1. Loosen the alternator mounting d.djusting arm to alternator bolt. 4. Tighten all mounting bolts.
bolt and the adjusting arm bolts. 3. Check the belt tension using

ALTERNATOR or roughness as was made for the insulation. Resolder poor connec-
front bearing. Inspect the rollers and tions. Replace parts that show
1. The rotor, stator, and bearings
cage for damage. Replace the bear- burned insulation.
must not be cleaned with solvent.
1ng if these conditions exist, or if the 7. Check the slip rings for nicks
Wipe these parts off with a clean
I ubricant is lost or contaminated. and surface roughness. Nicks and
doth. 4. Check both the front and rear scratches may be removed by turn-
2. Rotate ·the front bearing on the housings for cracks. Check the front ing down the _slip rings. Do not go
drive shaft. Check for any scraping housing for stripped threads in the beyond the minimum diameter limit
noise, looseness or roughness that mounting ear. Replace defective of 1.22 inches.
will indicate that the bearing is ex- housings.
cessively worn. As the bearing is be- 5. A pulley is not suitable for re- If the slip rings are badly damaged,
ing rotated, look for any lubricant use if more than % of the shaft the entire rotor will have to be re-
leakage. If any of these conditions il·~ngth will enter the pulley bore with
placed, as they are serviced as a
exist, replace the bearing. r tght pressure. Replace any pulley
complete assembly.
3. Place the rear end bearing on that is bent out of shape. 8. Replace any parts that are
the slip-ring end of the shaft and 6. Check all wire leads on both the burned or cracked. Replace brushes
rotate the bearing on the shaft. Make .,tator and rotor assemblies for loose and brush springs that are not to
the same check for noise, looseness •.;oldered connections, and for burned specification.

13-8 (262)
PART ALTERNATOR
Section Page
1 Description and Operation ................ 13-8
2 In-Car Adjustment and Repair ............. 13-8
13-2 3 Removal and Installation .................. 13-8

4 Major Repair Operations .................. 13-8

The charging system is a negative The mechanical construction of the (Fig. 2).
(-) ground system, and consists of alternator differs from a generator The alternator produces power
an alternator, a regulator, a storage in that the field rotates, and the in the form of alternating current.
battery and associated wiring. generating windings are stationary. The alternating current is rectified
An alternator with an integral
pulley and cooling-fan assembly is Energy is supplied from the system to direct current by six diodes (Fig.
belt driven from the engine. The to the rotating field through two 2) for use in charging the battery
alternator mounting is shown in Fig. brushes to two slip rings. The slip and supplying power to the elec-
1. rings are mounted on the rotor shaft trical system.

BELT ADJUSTMENT 2. Apply pressure on the alterna- tool T63L-8620-A. Adjust the belt
tor front housing only and tighten for specified tension.
1. Loosen the alternator mounting the adjusting arm to alternator bolt. 4. Tighten all mounting bolts.
bolt and the adjusting arm bolts. 3. Check the belt tension using

REMOVAL harness plug. Position the alternator
to the engine, and install the alterna-
1. Disconnect the battery ground tor mounting bolt finger-tight (Fig.
cable. 1).
2. Remove the shield (Fig. 1). 2. Install the adjustment arm to

alternator bolt.
3. Loosen the alternator mounting
bolts and remove the adjustment arm 3. Adjust the belt tension using
to alternator bolt. tool T63L-8620-A. Apply pressure
on the alternator front housing only.
4. Disengage the alternator belt. Tighten the adjusting arm bolts and
Remove the alternator mounting bolt, the mounting bolt.
disconnect the alternator cable and
remove the alternator. 4. Position the shield over the ad-
justing arm and install the attaching
ADJUSTMENT bolts.
BRACKET
INSTALLATION J1228-B
5. Connect the battery ground
1. Attach the alternator wiring FIG. 1-Aiternator Mounting cable.

DISASSEMBLY the slip rings (Fig. 3). 4. Remove the nuts from the rec-
2. Remove the three housing tifier to brush end housing mounting
1. Mark both end housings with
through bolts. studs, and remove the brush end
a scribe mark for assembly. Reach
through a ventilation slot, raise both housing. Remove the two spacer
3. Separate the drive end housing
brushes off the slip rings, and install sleeves from the rectifier plate studs.
and rotor from the stator and brush
a short length of Y8 -inch rod or stiff end housing. Make certain that the 5. If replacement is necessary,
wire through the hole in the brush brushes do not contact the greasy press the bearing from the brush end
end housing, to hold the brushes off rotor shaft. housing (Fig. 4) .

(263) PART 13-2-ALTERNATOR 13-9
BEARING RETAINER BRUSH AND RECTIFIER ASSEMBLY THROUGH BOLTS

PULLEY FAN
BRUSH END HOUSING

J1166-B
FIG. 2-Disassembled Alternator

Ya INCH Rod OR Stiff Wire
FIG. 3-Retrading
Alternator Brushes
6. Remove the terminal spacer
from the studs and unsolder the neu-
tral wire from the spacer block neu-
tral terminal.
FIG. 4-Rear Bearing
7. If the brushes are being re-
Replacement
placed, straighten the field brush
tenbinal blade locking tabs, with a 12. If the bearing is being re- fl G. 5- Soldering Diode Leads
pair of pliers, and remove the placed, puJl the bearing using a bear-
terminal blade from the terminal trig puller (Fig. 7). Remove the
spacer block. Remove the brushes hearing retainer and spacer. It will
and holders from the assembly. not be necessary to remove the stop-
8. If either · diode plate is being ring, unless it has been damaged.
replaced, carefully unsolder the leads
PARTS REPAIR OR
from the diodes (Fig. 5). Use only
REPLACEMENT
a 100-watt soldering iron. Leave the
soldering iron in contact with the Nicks and scratches may be re-
diode terminals only long enough moved from the rotor slip rings by
to remove the wires. Both pliers are turning down the slip rings. Do not
used as temporary heat sinks in go beyond the minimum diameter
order to protect the diodes. Excess Iimit of 1.22 inches. If the slip rings
heat can damage a good diode. are badly damaged, the entire rotor
9. Remove the three insulated di- rnust be replaced as it is serviced as
ode plate screws and the insulators, .111 assembly. All other assemblies are
and separate the diode plates. t 0 be replaced rather than repaired.
10. Remove the drive pulley (Fig.
6). ASSEMBLY
11. Remove the three screws that 1. If the stop-ring on the drive
hold the drive end bearing retainer, ·,haft was damaged, install a new
and remove the drive end housing. ~top-ring. Push the new ring on the FIG. 6-Pulley Removal

that the open end of the bearing is

flush with the inner surface of the
housing boss (Fig. 4). Allow space
under the outer end of the bearing
during installation.
12. Place the rectifier plate and
stator assembly in the brush end
housing and mount the rectifier
plates to the housing.
13. Retract the brushes and insert
a short length of Vs -inch rod or stiff
wire through the hole in the brush
end housing to hold the brushes in
~~~~~~~~~~~~~~~~~~r;J~1165·A the retracted position (Fig. 10).
14. Wipe clean the brush end bear-
FIG. 8-Pulley Installation ing surface of the rotor shaft.
J1206·A
FIG- 7-Front Bearing Removal FIG. 9-Stator, Heat Sink, and Terminal Spacer Block Assembly
shaft and into the groove. Do not time. Place a 1,4 -inch thick wood 15. Position the brush end housing
open the ring with snap-ring pliers. spacer between the stator coils and and stator assembly over the rotor
2. Position the drive end bearing the rectifier plate, to obtain proper and align the scribe marks made
spacer on the drive shaft against the lead wire position. Solder the wire during disassembly. Seat the ma-
stop-ring, and position the bearing leads to the diodes as shown in Fig. chined portion of the stator core into
retainer on the shaft with the flat 5 in order to avoid excessive heat to the step in the front and rear hous-
surface of the retainer outward. the diode. Use only a 100-watt iron. ings. Install the housing through bolts.
3. Putting pressure on the inner 7. Insert the new field brush ter- Remove the brush retracting rod.
race only, press the new bearing onto minal blade into the slot in the ter-
the shaft until it contacts the spacer. minal spacer block, with the brush
4. Place the drive end housing over pigtail extending toward the brush
the shaft, with the bearing positioned holder pivots (Fig. 9).
in the front housing cavity. Install 8. Install the brush holders and
the bearing retainer mounting screws. brush spring on the terminal spacer
5. Press the pulley onto the shaft block, then position the brushes in
until the hub just touches the inner the brush holders (Fig. 9).
race of the front bearing (Fig. 8). 9. Solder the neutral wire to the
A new pulley must be installed if neutral terminal. Position the termi-
more than lf4 of the shaft length nal spacer block assembly on the rec-
will enter the old pulley bore with tifier plate mounting studs, with the
light pressure. ground brush lug over the mounting
6. If a new diode plate is being in- stud farthest from the output termi-
stalled, mount the two plates togeth- nal as shown in Fig. 9. Tighten the
er so that they are insulated from diode plate assembly screws.
each other (insulating spacer between 10. Place the spacers on the recti- J1207-A
the plates and cupped insulator un- fier mounting studs farthest from the
der the screw head) as shown in Fig. terminal block (Fig. 9). FIG. 10-Brushes
9. Do not tighten the screws at this 11. Install the brush end bearing so Retracted for Assembly

(265)
13-11
PART REGULATOR
Section Page
1 Description and Operation ............... 13-11
2 In-Car Adjustment and Repair ............. 13-11
13-3 3 Removal and Installation ................. 13-12

The alternator regulator is com-
posed of two control units, a field
relay and a voltage limiter, mounted
as an assembly (Fig. 1). Because
the reverse current through the rec-
tifier is small, a reverse current cut-
out relay is not needed. The alter-
nator is self current limiting, thus a
current limiter is not needed.
FIELD RELAY
The field relay serves to connect
the battery and alternator output to
the field circuit when the engine is
running (Fig. 1, Part 13-1). When
the ignition switch is dosed, the field
relay is energized. Closing of the BATIERY TERMINAL FOR
FIElD SUPPLY VOLTAGE J1214-B
relay contacts, connects the battery
and alternator output to the field
through the voltage limiter contacts.
FIG. 1-Aiternator Regulator
tern voltage is applied to the field armature vibrates on the upper con-
VOLTAGE LIMITER
and maximum field current will flow. tact. At high engine speed and light
The temperature compensated vol- When the limiter armature floats or no load, the armature vibrates
tage limiter is a double contact unit. between the contacts, field current on the lower contact.
Limiting is accomplished by control- is reduced by flowing through the A 50-ohm resistor is connected
ling the amount of current supplied field resistor. When the limiter lower from the field terminal to ground to
to the rotating field. contacts are closed, zero current absorb electrical surges in the alter-
When the upper contacts are flows to the field. At low engine nator circuits as the voltage limiter
closed (Fig. 1, Part 13-1), full sys- spred and with a load applied, the armature vibrates on the contacts.

REGULATOR ADJUSTMENTS
Erratic operation of the regulator, GAP ADJUSTMENTS VOLTAGE ADJUSTMENTS
indicated by erratic movement of the
voltmeter during a voltage limiter
test, may be caused by dirty or pitted
regulator contacts. Use a very fine
abrasive paper such as silicon car-
bide, 400 grade, to clean the field re-
lay and the voltage limiter contacts.
Wear off the sharp edges of the abra-
sive by rubbing it against another
piece of abrasive paper. Fold the
abrasive paper over and pull the BEND ADJUSTING ARM
paper through the contacts to clean DOWN TO INCREASE
VOLTAGE LIMIT
them. Keep all oil or grease from BEND AR:M UP TO
USTING ARM DOWN
contacting the points. Do not use CORE GAP DECREASE
TO INCREASE CLOSING
VOLTAGE LIMIT VOLTAGE. BEND ARM UP TO
ADJUSTING SlOTS
compressed air to clean the regulator. DECREASE CLOSING VOLTAGE J1217-B
When adjusting the gap spacing usc
only hospital clean feeler gauges. FIG. 2-Regulator Adiustments

REGULATOR GAP contacts closed. Loosen the center (Fig. 2). To increase the- closing
ADJUSTMENTS lock screw ~ tum. Use a screwdriver voltage, bend the spring arm down.
blade in the adjustment slot under To decrease the closing voltage, bend
The difference between the upper the lock screw. Adjust the core gap the spring arm up.
stage and lower stage regulation (0.3 for 0.045 to 0.052-inch clearance be-
volt) , is determined by the voltage The voltage limit is adjusted by
tween the armature and the core at bending the voltage limiter spring
limiter point and core gaps. Make the edge of the core closest to the
the gap adjustments with the regu- arm (Fig. 2). To increase the volt-
contact points. Tighten the lock age setting, bend the adjusting arm
lator removed from the car. screw and recheck the core gap.
Adjust the point gap first. Loosen downward. To decrease the voltage
the left side screw Y4 turn. Use setting, bend the adjusting arm up-
REGULATOR VOLTAGE ward.
a screwdriver blade in the adjust-
ADJUSTMENTS
ment slot above the lock screw. Ad- Before setting the voltage and
just the upper contact until there is Final adjustment of the regulator before making a final voltage test,
0.010 to 0.015-inch gap between the must be made with the regulator at the alternator speed must be re-
lower contacts. Tighten the lock normal operating temperature. duced to zero and the ignition
screw and recheck the contact gap. The field relay closing voltage is switch opened momentarily, to
Adjust the core gap with the upper adjusted by bending the spring arm cycle the regulator.

1. Remove the battery ground 4. Attach the cable disconnect to ground wire lug, an external tooth
cable. the new regulator. lock washer, then the regulator base.
2. Remove the regulator mounting 5. Mount the regulator to the 6. Connect the battery ground
screws. radiator left air deflector. The bot- cable, and test the system for proper
3. Remove the cable disconnect tom mounting screw mounts through voltage regulation.
from the regulator. the radio condenser bracket, the

(267) 13-13
PART SPECIFICATIONS
13-4
ALTERNATOR
- Rated Brushes
Field Cut-In Belt Belt
Vendor Amperes Watts Current Speed Output
(@ 15V) (@ 15V) (Amps.@ (Alternator Speed Width Tension Number Original Wear Spring
12V 75°F.) rpm)x (Alternator (Inches) (Pounds)t Used Length Limit Tension
rpm)* (Inches) (Inches) (Ounces)
Ford 40 600 2.9-3.1 950 6500 Hot % 80-110 2 % % 7 to 12
3700 Cold
------ ---- -----
Ford 42 630 2.9-3.1 850 6500 Hot % 80-110 2 % % 7 to 12
3500 Cold
. .
*To find the equivalent engme rpm, d1v1de the alternator pulley diameter by the crankshaft pulley dtameter and then multiply by the alternator rpm .
tUsed Belt. New Belt 110-140. A used belt is one that has been in operation for more than 10 minutes.
Minimum slip-ring turn-down diameter 1.22 inches.
REGULATOR
Voltage limiter Field Relay
Vendor Current Voltage

Rating Contact Air Contact Air Closing
Regulation Gap Gap Gap Volts
Gap
(Inches) (Inches) (Inches) (Inches) @ 75° F
Ford Used with both 40- and 14.1 to 14.7 0.010 to 0.015 0.045 to 0.052 0.015 to 0.022 0.022 to 0.030 3-4
42-ampere alternators
*F1eld Relay Closmg Volts 3-4.
BATTERY
Filler Cap Color Number of Plates Ampere Hours
Black 78 80
BAnERY FREEZING TEMPERATURES

\
Specific Gravity Freezing Temp.
1.280 -90' r
1.250 -62'
1.200 -16 !·
1.150 + 5[
1.110
I +19 ~
-
VOLTAGE REGULATION SETTING

-
Ambient Standard Ford
Temperature Alternator
CF. Regulator
25 14.4-t; J
50 14.3-lU
75 14.1-lU
100 13.9-14)
125 13.8-1~ ~
150 13.6-1~ )
175 135-1~ l
-

(268)
lJ(X]Og) ~~®§
O~tr§~trO@~&~~ l?
®~&~~

GROUP
14
GENERAL STARTING SYSTEM SERVICE. 14-1 SPECIFICATIONS . . 14-8
PART 14-2
STARTER ...... 14-6
PART GENERAL STARTING SYSTEM SERVICE

14-1
1 Diagnosis and Testing . . . . . . . . . . ......... 14-1 3 Cleaning and Inspection ................... 14-5
2 Common Adjustments and Repair~ .......... 14-4

If the engine cranks but will not be seized or the starter may be a complete diagnosis.
start, the trouble is in the engine faulty. If the engine cranks but can- Do not push or tow the car for
(fuel, or ignition system) and not not be started with a booster ·battery more than 12 miles, without rais-
in the starting system. If the engine connected, attempt to start it by ing the rear wheels off the ground,
will not crank even with a booster pushing the car. lf it will not start, or disconnecting the driveshaft.
battery connected, engine parts may push or tow the car to the shop for
STARTER TROUBLE DIAGNOSIS GUIDE
1. The battery may be discharged.

2. The ignition switch, starter neu-
transmission lever in the N or P posi-
tion.
I
lr al switch or starter relay may be 2. With a fully charged battery,
moperative. operate the starter switch to crank
3. The circuit may be open or con- the engine. If the engine will not
I a in high resistance. crank and the relay does not click,
connect a jumper lead from the bat-
CHECK BATTERY tery terminal of the relay to the
Perform a Battery Capacity Test starter switch terminal of the relay
l Group 13, Part 1, Page 6). If the (Fig. 1, connection 1). If the en-
ENGINE WILL NOT CRANK b.1ttery does not test as having good gine does not crank, the starter relay
AND STARTER RELAY capacity, make a Battery Test Charge is probably defective.
DOES NOT CLICK ( Group 13, Part 1, Page 6). Replace 3. If the engine cranks in step 2,
the battery if the test indicates that remove the quick disconnect from
ir is worn out or under capacity. the starter neutral switch which is
located on the-steering column under
CHECK STARTER RELAY the instrument panel. Connect a
1. Disconnect and ground the jumper wire between the quick dis-
h Lgh tension lead from the spark coil connect terminals that are connected
sn that the engine cannot start. On to the two red-blue stripe wires.
cars with a transistor ignition, also Operate the starter switch to crank
disconnect the brown wire from the the engine.
starter relay I terminal. Place the 4. If the engine cranks in Step 3,

14-2 GROUP 14-STARTING SYSTEM {270)
STARTER TROUBLE DIAGNOSIS GUIDE (Continued)
the starter neutral switch is defective terminal of the starter relay is loose
or out of adjustment. or broken.
ENGINE WILL NOT CRANK The ignition switch starter ter-
5. If the engine does not crank in
AND STARTER RELAY minal is defective.
Step 3, there are three possible de-
DOES NOT CLICK The wire from the starter switch
fects:
(Continued) to the automatic transmission neutral
The wire from the battery terminal switch or from the neutral switch to
of the ignition switch to the battery the starter relay is loose or broken.
If the relay clicks when the igni- for burred or worn teeth. Examine
tion switch is operated, connect a the teeth on the flywheel ring gear
heavy jumper from the relay battery for burrs and wear. Replace the
terminal to the relay starter motor pinion or the flywheel ring gear if
terminal (Fig. 2, connection 2). If they are worn or damaged.
the engine cranks, replace the relay. If the starter drive is not locked,
If the engine does not crank, observe remove the starter from the engine,
the spark when connecting and dis- and perform the no-load current test.
connecting the jumper. If there is a The starter should run freely.
heavy spark, see Check Engine and If the current reading at no-load
Starter Drive below. If the spark is speed is below specifications, the
weak or if there is no spark at all, starter has high resistance and should
proceed as follows: be repaired.
If the current reading is above
normal, and the starter is running
CHECK CABLES AND
slower than it should at no-load, it
CONNECTIONS
is probably due to tight or defective
If the spark at the relay is weak bearings, a bent shaft, or the arma-
ENGINE WILL -NOT CRANK when the jumper is connected, in- ture rubbing the field poles. A shorted
BUT STARTER RELAY spect the battery starter cables for coil in the starter also causes the cur-
CLICKS corrosion and broken conductors. rent reading to be high. Disassemble
Check the ground cable to see if it the starter and determine the cause.
is broken or badly corroded. Inspect Repair it if possible, or replace the
all cable connections. Clean and starter.
tighten them if necessary. Replace If the no-load current reading of
any broken or frayed cables. If the the starter is normal, install the
engine still will not crank, the starter and remove all the spark
trouble is in the starter, and it must plugs, and attempt to crank the
be repaired or replaced. engine with the starter.
If the engine cranks with the spark
plugs removed, water has probably
CHECK ENGINE AND
leaked into the cylinders causing a
STARTER DRIVE
hydrostatic lock. The cylinder heads
If a heavy spark is obtained when must be removed, and the cause of
the jumper wire is connected, loosen internal coolant leakage eliminated.
the starter mounting bolts to free the If the engine will still not crank,
starter pinion. the engine is seized and cannot be
If the starter drive is locked, returned by the starter. Disassemble the
move the starter from the engine, engine and repair or replace the de-
and examine the starter drive pinion fective parts.
If the starter spins but will not starter shaft, or is broken.

STARTER SPINS BUT DOES
crank the engine, the starter drive is Clean or repair the starter drive
NOT CRANK THE ENGINE
worn or dirty and is sticking on the as required.
Several causes inay result in this 4. The engine may have excessive
symptom: friction.
1. The battery may be low in
ENGINE CRANKS SLOWLY charge. CHECK BATTERY
2. There may be excessive resist-
ance in the starter circuit. Test the state of charge of the bat-
3. The starter may be faulty. tery. If the battery is discharged, re-

·(271) PART 14-1-GENERAL STARTING SYSTEM SERVICE 14-3
STARTER TROUBLE DIAGNOSIS GUIDE {Continued)
charge the battery, and check the tery to ground cable, clean and
starter relay for possible internal tighten the cable connections. Re-
shorts to ground that may have check the voltage drop. If it is still
caused the battery to discharge. Per- excessive, replace the cables.
form a Battery Capacity Test (Group To correct excessive resistance of
13 . Part 1, Page 6) . If the battery the starter relay contacts, replace the
does not test as having good capacity, starter relay.
make a Battery Test Charge (Group
13. Part 1, Page 6). VOLTAGE DROP (RESISTANCE)
Replace the battery if the test indi- NORMAL
cates it to be worn out or under
capacity. If the voltage drop (resistance) is
ENGINE CRANKS SLOWLY
normal, make a starter load test. If
CHECK EXTERNAL CIRCUIT the starter current is below specifi-
{Continued)
VOLTAGE DROP cations, proceed as follows:
If the battery was fully charged Cranking Current Low. Remove
in the previous test, test the starter the starter from the engine, and re-
cranking circuit voltage drop. The pair or replace it.
voltage drop will be either excessive Cranking Current Normal or
or normal. High. Test the starter current draw
at no-load. If the no-load current
VOLTAGE DROP (RESISTANCE) draw is above or below specifications,
EXCESSIVE repair or replace the starter.
Locate the exact part of the cir- If the current draw at no-load is
cuit with the excessive resistance. normal, the starter is not at fault.
To correct excessive resistance in The engine has excessive friction,
the battery to starter relay cable, and the cause must be determined.
starter relay to starter cable or bat- Repair or replace faulty parts.
1---1~
BATTER; .l.
TO
IGNITION
COIL
STARTER FIG. 2-Starter Load Test
--------AUTOMATIC
FIG. 3-Starter No-Load Test
TRANSMISSION STARTER LOAD TEST
STARTER NEUTRAL SWITCH from the spark coil, and by connect-
( Connect the test equipment as ing a jumper from the battery termi-
shown in Fig. 2. Be sure that no cur- nal of the starter relay to the ignition
~------STARTER rent is flowing through the ammeter
+ SWITCH
ION IGNITION SWITCH) and heavy-duty carbon pile rheostat
portion of the circuit (rheostat at
switch terminal of the relay.
Stop cranking the engine, and re-
maximum resistance). duce the resistance of the carbon pile
TO BATTERY Crank the engine with the ignition until the voltmeter indicates the same
J1084-E OFF, and determine the exact read- reading as that obtained while the
ing on the voltmeter. This test is starter cranked the engine. The am-
FIG. 1-Starting Control accomplished by disconnecting and meter will indicate the starter current
Orcuit Test grounding the high tension lead draw under load. This reading should

14-4 GROUP 14-STARTING SYSTEM (272)
DO NOT CONNECT
. ..
LEAD TO BEARING
~1~---
SURFACE
FIG. &-Starter Cranking

Circuit Test
FIG. 4-Armature FIG. 5-Field Grounded nections as shown in Fig. 6. Crank
Grounded Circuit Test Circuit Test the engine with the ignition OFF.
This is accomplished by disconnect-
be 250 amperes maximum with the ing. The spot burned on the commu- ing and grounding the high tension
engine at normal operating tempera- tator is caused by an arc formed lead from the spark coil and by con-
ture. every time the commutator segment necting a jumper from the battery
connected to the open-circuit wind- terminal of the starter relay to the
STARTER NO-LOAD TEST ing passes under a brush. ignition switch terminal of the relay.
The voltage drop in the circuit will
The starter no-load test will un- ARMATURE AND FJELD be indicated by the voltmeter ( 0 to 1
cover such faults as open or shorted GROUNDED CIRCUIT TEST- volt range). Maximum allowable vol-
windings, rubbing armature, and
ON TEST BENCH tage drop should be:
bent armature shaft. The starter can
1. With the voltmeter negative
be tested, at no-load, on the test This test will determine if the wind-
ing insulation has failed, permitting lead connected to the starter terminal
bench only.
and the positive lead connected to
Make the test connections as a conductor to touch the frame or
the battery positive terminal ..... .
shown in Fig. 3. The starter will armature core.
To determine if the armature 0.5 volts.
run at no-load, and the current draw
indicated on the ammeter should be windings are grounded, make the 2. With the voltmeter negative
70 amperes maximum at 12 volts. connections as shown in Fig. 4. If lead connected to the battery ter-
It is advisable to use an ammeter the voltmeter indicates any voltage, minal of the starter relay and the
with a maximum scale reading of the windings are grounded. positive lead connected to the posi-
500 amperes for this test, as the tive terminal of the battery ..... .
Grounded field windings can be
current necessary to operate the detected by making the connections 0.1 volt.
movable pole shoe is considerably as shown in Fig. 5. If the voltmeter 3. With the voltmeter negative
higher than the steady state no-load indicates any voltage, the field wind- lead connected to the starter terminal
current draw. ings are grounded. of the starter relay and the positive
lead connected to the positive ter-
minal of the battery ...... 0.3 volt.
ARMATURE OPEN CIRCUIT STARTER CRANKING
TEST-ON TEST BENCH 4. With the voltmeter negative
CIRCUIT TEST
lead connected to the negative ter-
An open circuit armature may Excessive resistance in the starter minal of the battery and the positive
sometimes be detected by examining circuit can be determined from the lead connected to the engine ground
the commutator for evidence of bum- results of this test. Make the test con- ...... 0.1 volt.
B COMMON ADJUSTMENTS AND REPAIRS

STARTER DRIVE REPLACEMENT housing and the starter drive actuat- 5. Apply a thin coating of Lubri-
ing lever return spring. plate 777 on the armature shaft
The starter drive is shown in Fig. splines. Install the drive gear assem-
3. Remove the pivot pin retaining
7. the starter drive actuating lever and bly on the armature shaft and install
1. Loosen and remove the brush remove the lever. a new stop ring.
cover band and the starter drive actu- 4. Remove the drive gear stop ring 6. Position the starter gear actuat-
ating lever cover. retainer and stop ring from the end ing lever on the starter frame and in-
2. Loosen the through bolts enough of the armature shaft and remove stall the retaining pivot pin. Be sure
to allow removal of the drive gear the drive gear assembly. that the actuating lever properly

{273) PART 14-1 -GENERAL STARTING SYSTEM SERVICE 14-5 •.
engages the starter drive assembly. brush nearest the starter terminal 19. Check the starter no-load am-
7. Install a new retaining clip re- from the brush terminal block, as perage draw.
tainer. Position the starter drive actu- close to the lead terminal as pos-
ating return spring and drive gear sible). ARMATURE REPLACEMENT
housing to the starter frame, and 7. Unsolder (or cut) the insulated
then tighten the through bolts to brush leads from the field coils, as 1. Loosen the brush cover band
specification. close to the field connection point as retaining screw and remove !'be brush
possible. cover band and the starter drive actu-
8. Position the starter drive actu-
ating lever cover and brush cover 8. Clean and inspect the starter ating lever cover (Fig. 3). Remove
motor. the brushes from their holders.
band with gasket on the starter.
Tighten the brush cover band retain- 9. Replace the brush end plate if 2. Remove the through bolts, start-
the insulator between the field holder er drive gear housing, and the
ing screw.
brush and the end plate is cracked starter drive actuating lever return
or broken. spring.
BRUSH REPLACEMENT 3. Remove the pivot pin retaining
10. Solder the new field brushes
Replace the starter brushes when to the field coils using rosin core the starter gear actuating lever and
they are worn to half size. Always solder (Fig. 5). Use a 300-watt iron. remove the lever.
install a complete set of new brushes. 11. Install the ground brush leads 4. Remove the armature. If the
1. Loosen and remove the brush to the frame with the retaining starter drive gear assembly is being
cover band and starter drive actuat- screws. re-used, remove the stop ring retainer
and stop ring from the end of the
ing lever cover. Remove the brushes 12. Clean the commutator with
from their holders. armature shaft and remove the as-
#00 or #000 sandpaper.
sembly.
2. Remove the two through bolts 13. Position the brush end plate 5. Place the starter drive gear as-
from the starter frame. to the starter frame, with the end sembly on the new armature with a
3. Remove the drive gear housing, plate boss in the frame slot. new stop ring.
and the actuating lever return spring. 14. Position the fiber washer on 6. Install the fiber thrust washer
4. Remove the starter drive actu- the commutator end of the armature on the commutator end of the arm-
ating lever pivot retaining pin and shaft and install the armature in the ature shaft and install the armature.
lever, and remove the armature. starter frame. 7. Position the starter gear actu-
5. Remove the brush end plate. 15. Install the starter drive gear ating lever to the frame and drive
6. Remove the ground brush re- actuating lever to the frame and gear assembly and install the retain-
taining screws from the frame and starter drive assembly, and install the ing pivot pin.
remove the brushes (cut the ground pivot pin. 8. Position the starter drive actu-
16. Position the return spring on ating lever return spring, starter
the actuating lever and the drive gt:ar drive gear housing, and brush plate
housing to the starter frame. Install to the starter frame, and then install
the through bolts and tighten to spe- and tighten the through bolts to spe-
cified torque. Be sure that the snap cification. Be sure that the stop ring
ring retainer is seated properly in retainer is seated properly in the
the drive gear housing. drive gear housing.
17. Install the commutator brush- 9. Place the brushes in their hold-
es in the brush holders. Center the ers, and center the brush springs on
brush springs on the brushes. the brushes.
18. Position the actuating lever 10. Position the actuating lever
cover and the brush cover band with cover and brush cover band, with
gasket on the starter. Tighten the gasket, and then tighten the retain-
FIG. 7-Starter Drive band retaining screw. ing screw.
El CLEANING AND INSPECTION

1. Wipe the field coils, armature, 4. Inspect the armature shaft and
armature shaft, and drive with a bearings for scoring and excessive
clean cloth. Wash all other parts in wear.
solvent and dry the parts.
5. Check the brush holders for
2. Check the field coils for con- broken springs and the insulated
tinuity. Check the armature for brush holders for shorts to ground.
grounds and open circuits.
6. Check the brush spring tension.
3. Check the commutator runout It should be 45 ounces minimum.
(Fig. 8) and, if necessary, turn Replace the springs if the tension is
down the commutator. FIG. 8-Commutator Runout Chetk not within limits.

14-6 (274)
PART STARTER
Section Page
1 Description and Operation ................. 14-6
2 Removal and Installation .................. 14-6
14-2 3 Major Repair Operations .................. 14-6

rectly to ground through a set of
contacts (Fig. 2). When the starter 1---1~
is first connected to the battery a BATTERY.- !-
large current flows through the
grounded field coil, actuating a mov-
able pole shoe. The pole shoe is
attached to the starter drive actuat- STARTER RELAY
ing lever and thus the drive is forced
into engagement with the flywheel.
STARTING MOTOR
When the movable pole shoe is
J1232-A
fully seated, it opens the field coil
FIG. 1-Starter Mounting grounding contacts and the starter is
then in normal operation. A holding
The function of the starting system coil is used to maintain the movable
is to crank the engine at a high pole shoe in the fully seated position,
enough speed to permit it to start. during the time that the starter is STARTER
The system includesthe starter motor turning the engine. Red-Blue Stripe
and drive, the battery, a remote con- ---AUTOMATIC
trol starter switch, and heavy circuit A starter neutral switch, in the TRANSMISSION ONLY
STARTER NEUTRAL SWITCH
starter control circuit, prevents oper- CLOSED WITH SELECTOR IN
wiring.
r
ation of the starter if the selector NOR P POSITION
The starter mounting is shown in Red-Blue Stripe
lever is not in the N (neutral) or P
---STARTER SWITCH
Fig. 1. Figure 2 shows the starter (park) position. (ON IGNITION SWITCH)
circuit schematic.
The starter utilizes an integral TO BATTERY TERMINAL OF
GENERATOR REGULATOR J1083.c;
positive-engagement drive (Fig. 3).
When the starter is not in use, one FIG. 2-Starting Circuit
of the field coils is connected di- Schematic

1. Disconnect the starter cable at the flywheel housing, and start the 3. Snug all bolts and then tighten
the starter terminal, remove the mounting bolts. The cable support to 15 to 20 fqot-pounds torque,
starter mounting bolts, then remove bracket is mounted under the starter tightening the middle bolt first. Con-
the starter assembly. upper mounting bolt (Fig. 1). nect the starter cable.
2. Position the starter assembly to

Use the following procedure when retaining screw and remove the brush starter drive actuating lever return
it becomes necessary to completely cover band and the starter drive actu- spring.
overhaul the starter. Fig. 3 illus- ating lever cover. Observe the lead 3. Remove the pivot pin retaining
trates a partially disassembled starter. dress for assembly and then remove the starter gear actuating lever and
the commutator brushes from the remove the lever and the armature.
DISASSEMBLY brush holders. 4. Remove the stop ring retainer.
2. Remove the through bolts, Remove and discard the stop ring
1. Loosen the brush cover band starter drive gear housing, and the retaining the starter drive gear to the

(275) PART 14-2-STARTER 14-7
end of the armature shaft, and re-
~iNDP~IT
DRIVE GEAR
move the starter drive gear assembly. HOUSING
5. Remove the brush end plate. STARTER FRAME
6. Remove the two screws retain-
ing the ground brushes to the frame.
1. On the field coil that operates
\
the starter drive gear actuating lever,
bend the tab up on the field retainer
and remove the field coil retainer.
BRUSH COVER BAND
8. Remove the three coil retain-
ing screws, using tool 10044-A and
an arbor press (Fig. 4). The arbor
press prevents the wrench from slip-
ping out of the screw. Unsolder the
field coil leads from the terminal
screw, and remove the pole shoes and
coils from the frame. Use a 300-watt
iron.
9. Remove the starter terminal J1089-C
nut, washer, insulator and terminal
from the starter frame. Remove any FIG. 3-Disossembled Starter
excess solder from the terminal slot.
plate to the frame, with the end plate to specification. Do not pinch the
PARTS REPAIR OR boss in the frame slot. brush leads between the brush
REPLACEMENT 9. Apply a thin coating of Lubri- plate and the frame. Be sure that
platc 777 on the armature shaft the stop ring retainer is seated prop-
Nicks and scratches may be re- splines. Install the starter motor drive erly in the drive gear housing.
moved from the commutator by turn- gear assembly to the armature shaft 13. Install the brushes in the brush
ing it down. All other assemblies and install a new retaining stop ring. holders. Be sure to center the brush
are to be replaced rather than re- Install the stop ring retainer. springs on the brushes.
paired. 10. Position the fiber thrust wash- 14. Position the drive gear actu-
t:r on the commutator end of the ating lever cover on the starter and
ASSEMBLY armature shaft and position the arm- install the brush cover band with a
~~ture in the starter frame. gasket. Tighten the band retaining
1. Install the starter terminal, in- screw.
sulator, washers, and retaining nut in 11. Position the starter drive gear
actuating lever to the frame and 15. Check the starter no-load am-
the frame (Fig. 5). Be sure to posi- perage draw.
tion the slot in the screw perpendicu- starter drive assembly, and install the
lar to the frame end surface. l''ivot pin.
2. Position the coils and pole 12. Position the starter drive actu-
pieces, with the coil leads in the ter- ,tting lever return spring and the
minal screw slot, and then install the drive gear housing to the frame and
retaining screws. As the pole shoe l!lstall and tighten the through bolts
~crews are tightened, strike the frame
several sharp blows with a soft-faced
hammer to seat and align the pole
shoes, then stake the screws.
3. Install the solenoid coil and re-
tainer and bend the tabs to retain the
coils to the frame.
4. Solder the field coils and sole-
noid wire to the starter terminal using
rosin core solder. Use a 300-watt
rron.
5. Check for continuity and
grounds in the assembled coils.
6. Position the solenoid coil ground
terminal over the nearest ground
screw hole.
7. Posttion the ground brushes to BE SURE TO SEAT DRIVE HEAD
the starter frame and install the re- IN SCREW SOCKET J1059-B J1092·C
taining screws (Fig. 5).
8. Position the starter hrush end FIG. 4-Pole Shoe Screw Removal FIG. 5-Field Coil Assembly

14-8 (276)
PART SPECIFICATIONS
14-3
STARTERS
Current Draw Normal Engine Minimum Brushes
Under Normal Cranking Stall Torque Maximum No Load Wear Brush Spring
Vendor Load Speed @ 5 Volts Load (Amperes) Mfg. Length Limit Tension
(Amperes) (rpm) (foot Pounds) (Amperes) (Inches) (Inches) (Ounces)
Ford Positive Engagement 250 250-290 15.5 670 70 0.5 0.25 40
4.5 inch Diameter
Maxrmum Commutator Run-Out m Inches rs 0.005.
Maximum starting circuit voltage drop (battery+ terminal to starter terminal)@ normal engine temperature, 0.5 volt.

(277)
GROUP
15
GENERAl liGHTING SYSTEM, INSTRUMENTS . 15-12
HORNS, AND INSTRUMENTS SERVICE .. 15-1
PART 15-5
PART 15-2 SPECIFIICA TIONS . . . . . . . . . . . . . . . 15-18
liGHTING SYSTEM AND HORNS ..... 15-5
PART 15-3
SWITCHES, CIRCUIT BREAKERS
AND FUSES . . . . . . . . . . . . ..... 15-10
PART GENERAL LIGHTING SYSTEM, HORNS,

15-1 AND INSTRUMENTS SERVICE

1 Diagnosis and Testing ' .......... 15-1 2 Common Adjustments and Repairs .......... 15-4
LIGHT TROUBLE DIAGNOSIS GUIDE
1. Loose battery cable. 5. Loose or broken wire to the

2. Loose quick disconnect or brok· bulbs.
en wire from the battery to the head·· 6. Defective beam selector switch.
ALL HEADLIGHTS DO light switch. 7. All headlight bulbs burned out.
NOT LIGHT 3. Defective headlight switch. This may be caused by a defective or
4. Disconnected or broken win: improperly adjusted alternator vo1t-
from the headlight switch to the age regulator (Group 13).
beam selector switch.
I
INDIVIDUAL LIGHTS DO 1. Burned out bulb. bulb.
NOT LIGHT 2. I .oosc or broken wires to the 3. Poor ground.
j 1. Loose or corroded electrical 3. Improperly adjusted or defec-

LIGHTS BURN OUT ! connections. tive alternator voltage regulator
REPEATEDLY I 2. Excessive vibration. (Group 13).
l
INSTRUMENT TROUBLE DIAGNOSIS GUIDE
1. Loose or broken wire from the 4. Defective constant voltage reg-

constant voltage regulator to the fuel ulator (Part 15-4).
g<mgc. 5. Defective fuel tank sending
FUEL GAUGE ERRATIC 2. Defective fuel gauge (Part 15·· unit.
OR INOPERATIVE -+). 6. Defective radio suppression
3. Loose, broken, or shorted wire choke.
from fuel gauge to the fuel tank 7. Poor ground between fuel tank
-;ending unit. and body.

15-2 GROUP 15-LIGHTING SYSTEM, HORNS, AND INSTRUMENTS (278)
INSTRUMENT TROUBLE DIAGNOSIS GUIDE (Continued)
1. Loose or broken wire from perature gauge.

constant voltage regulator to the tem- 4. Defective temperature sending
perature gauge. unit.
TEMPERATURE GAUGE 2. Defective temperature gauge 5. Defective constant voltage regu-
ERRATIC OR INOPERATIVE (Part 15-4). lator (Part 15-4).
3. Loose or broken wire from the 6. Defective radio suppression
temperature sending unit to the tern- choke.
1. Loose or corroded constant volt- to the constant voltage regulator.

FUEL, TEMPERATURE, AND age regulator ground. 4. Defective ignition switch.
OIL PRESSURE GAUGES 2. Defective constant voltage regu- 5. Defective radio suppression
ERRATIC lator (Part 15-4). choke.
3. Broken or loose wire from or
1. Loose or broken wire from the (Part 15-4).

constant voltage regulator to the oil 4. Defective oil pressure sending
OIL PRESSURE INDICATOR pressure gauge. unit (Part 15-4).
GAUGE INOPERATIVE 2; Grounded or broken wire from 5. Defective radio suppression
the oil pressure sending unit. choke.
3. Defective oil pressure gauge
1. Defective charge indicator gauge 3. Alternator system malfunction

CHARGE INDICATOR GAUGE (Part 15-4). (Group 13).
INOPERATIVE 2. Loose or broken wires.
HORN TROUBLE DIAGNOSIS GUIDE
1. Loose connections at horn but- 4. Inoperative relay.

ton contact. 5. Horns defective or out of ad-
2. Open wire (blue-yellow stripe) justment.
HORNS DO NOT SOUND from horn relay to horn button. 6. Open wire (yellow-green stripe)
3. Open wire (yellow) from bat- from horn relay to high or low-pitch
tery to horn relay. horn.
ONE HORN FAILS 1. Broken or loose wire to the 2. Horn defective or out of ad-
TO OPERATE horn. justment.
HORNS OPERATE 1. Shorted wire to horn button 2. Shorted relay.

CONTINUOUSLY (blue-yellow stripe).
TURN INDICATOR TROUBLE DIAGNOSIS GUIDE
1. Burned out fuse. 5. Defective turn indicator switch.

2. Loose or broken wire from ig- 6. Broken, shorted, or loose wires
TURN INDICATOR LIGHTS nition switch to flasher. from switch to lights.
INOPERATIVE 3. Defective flasher. 7. Burned out bulbs, or loose
4. Loose or broken wire from sockets.
flasher to turn indicator switch.
1. Loose, broken, or shorted wires 3. Defective flasher.

TURN INDICATOR LIGHTS from switch to light. 4. Burned out bulb.
OPERATE INCORRECTLY 2. Defective indicator switch.
F
TURN INDICATOR 1. Cam improperly positioned on 2. Coil spring on switch plate as-
CANCELS IMPROPERLY steering wheel hub. sembly loose or weak.

(279) PART 15-1-GENERAL LIGHTING SYSTEM, HORNS, j~ND INSTRUMENTS SERVICE 15-3
WINDSHIELD WIPER TROUBLE HEADLIGHT AND BEAM If the headlights operate only with
DIAGNOSIS GUIDE SELECTOR SWITCH TESTS the beam selector switch in one posi-
tion, the switch or the wiring from
lf, at any time, the power steering The following tests may be made the switch to the headlight is defec-
pump is working properly and the to determine whether a headlight tive. Substitute a known good switch
windshield wipers are not: switch or a beam selector switch is for the suspected switch to determine
1. Check the control cable from defective: whether the switch or the wiring is
the instrument panel to the wiper Set the headlight switch to the at fault.
motor. headlight position, and operate the
2. Check the wiper for binding. beam selector switch. If none of the CONSTANT VOLTAGE
3. If the control cable is function- headlights turn on when the beam REGULATOR TEST
ing properly, and no binding condi- selector switch is operated, yet the Turn the ignition switch ON.
tion exists, and the windshield wipers instrument panel lights operate, the Check for voltage at the gauge feed
are still not functioning properly, headlight switch or the red-yellow wire (black with green stripe) at one
replace the wiper motor. stripe wire from the headlight switch of the gauges. The voltage should
to the beam selector switch is prob- oscillate between zero and about 10
TESTING ably defective. Substitute a known volts. If it does not, the constant
good switch for the suspected switch voltage regulator is defective, the
HORN TEST radio suppression choke is defective,
to determine whether the switch or
The only test necessary on the the wiring is at fault. or there is a short to ground be-
horns is for current draw. The cur- tween the voltage regulator and the
rent adjustment also adjusts the tone NEGATIVE LEAD
gauges.
of the horn. If the gauge unit is inaccurate or
Current Draw Test. Connect a does not indicate, replace it with a
voltmeter and ammeter to the horn new unit. If the gauge unit still is er-
and to a voltage supply as shown in ratic in its operation, the sending unit
Fig. 1. The normal current draw for or wiring to the sending unit is faulty.
the horns at 12 volts is 9.0-10.0 am- If the fuel gauge, the tempera-
peres. ture gauge, and the oil pressure
Always connect the positive bat- JUMPER WIRE
gauge indicate improperly and in
tery lead to the horn terminal as the same direction, the constant
shown in Fig. 1. If this is not done, FIG. 1-Horn Current voltage regulator could be defec-
damage may result to the horn. Draw Test tive, as it supplies the three gauges.
TO BAllERY + TERMINAL
SPLICE IN 14290
THERMISTOR ASSEMBLY
Black-Yellow Yellow
SPLICE IN 14401
Red-Blue
GROUND TO
IGNITION SWITCH / TO RESISTANCE WIRE IN
FLOOR PAN
FUEL-TANK SENDING UNIT
(REAR)
TO FUEL GUAGE
K1464-A
FIG. 2-Low Fuel Level Warning System Schematic

15-4 GROUP 15-LIGHTING SYSTEM, HORNS, AND INSTRUMENTS (280}
FUEL GAUGE AND FUEL warning light lights, replace the send- engine to determine if the gauge
LEVEL SENDING UNIT TEST er assembly. If the warning light does registers oil pressure. If the reading
not light, replace the relay. Figure 4, is obtained, check the sending unit
Disconnect the wire from the fuel
Part 15-4 shows the location of the to gauge wire. If the wire is not
level sending unit and connect it to a
thermistor terminal with the fuel broken and all connections are tight,
known good sending unit. Connect a
level sender mounted in the tank. replace the sending unit (Fig. 5,
jumper wire from the sending unit
Part 15-4).
mounting plate to the car frame. TEMPERATURE GAUGE TEST
Raise the float arm to the upper With the ignition switch in the off AMMETER TEST
stop; with the arm in this position, position, connect the terminals of To test the ammeter, turn the
the instrument panel gauge should two, series connected, flashlight cells headlights ON with the engine
read full. Lower the float arm to the to the gauge terminals. The three stopped. The meter pointer should
bottom stop; the gauge should then volts should cause the gauge to read move toward the "D" or discharge
read empty. approximately full scale. scale. If no movement of the needle
If the gauge reads properly, the is observed, check the loop on the
sending unit in the gas tank is defec- TEMPERATURE SENDING rear of the meter housing to see if
tive. UNIT TEST the battery to circuit breaker wire
If the gauge unit still indicates The sending unit can be tested by passes inside the loop. If the wire is
improperly or is erratic in its oper- first making a temperature gauge in the loop, and the meter does not
ation, the gauge unit or the wiring test to check the accuracy of the indicate a discharge, the meter is in-
to the gauge unit is faulty, repair gauge. Start the engine and allow it operative. If the meter pointer
the wire or replace the gauge unit. to warm up to normal temperature. moves toward the "C" or charge
LOW FUEL LEVEL WARNING If no reading is indicated on the scale when the headlights are
SYSTEM TEST gauge, check the sending unit to turned ON, the wire passes through
gauge wire by removing the wire the loop in the wrong direction or
The low fuel warning system cir- from the sending unit and momen- the battery is reversed. Feed the
cuit diagram is shown in Fig. 2. The tarily grounding the wire. If the wire through in the opposite direc-
warning light circuit is tested each gauge still does not indicate, the wire tion to correct this condition after
time the ignition switch is turned to is defective. Repair or replace the checking first to make sure that
the start position. When the switch wire. If the gauge now indicates, the the battery is not reversed.
is turned from ON to START, the sending unit is faulty.
warning light is illuminated. This SPEEDOMETER AND
proves that both the circuit and the OIL PRESSURE INDICATOR ODOMETER TESTS
light are functioning properly. GAUGE TEST To test the odometer accuracy,
In the event of system failure, Perform the same test as that de- drive the car over a "measured
make the following tests: scribed for the temperature gauge. mile." Speedometer accuracy can be
1. Check to see that the bulb lights The oil gauge pointer should read checked by comparing the speed-
with the ignition switch in the start approximately full scale. ometer in question against one known
position. to be accurate, while two ·cars are
2. Check for loose connections. OIL PRESSURE SENDING moving at the same speed, or by tim-
3. Turn the ignition switch to the UNIT TEST ing the car on a "measured mile."
ACC or ON position. Disconnect the The sending unit can be tested by Specifications, Part 15-5 shows
wiring at the fuel level sender assem- making a gauge unit test to deter- the proper speedometer gears to use
bly and ground the relay thermistor mine whether the gauge unit is good. for various rear axle and tire size
lead (green-black stripe). If the If the gauge unit is good, start the combinations.

WINDSHIELD WIPER HORN ADJUSTMENT
ADJUSTMENT Adjustment. Tone and current are
The control cable is adjusted by adjusted by changing the contact
means of the control cable adjust- tension (Fig. 3). Connect the horn
ment screw (Fig. 7, Part 15-4). Ad- as shown in Fig. I. Turn the self
just the control cable so that the locking tone-adjusting nut until the
control lever on the instrument panel current is within the limits for the
moves the valve control lever on the horn being adjusted. Replace the
motor from off to full on. An ad- cover and recheck the current draw.
justment screw is also provided in the
wiper vacuum control line to regu-
late the length of time the wiper
motor will operate after the wind-
shield washer button is released.
FIG. 3-Horn
Adiustmenf

(281) PART 15-2-LIGHTING SYSTEM AND HORNS 15-5
PART LIGHTING SYSTEM AND HORNS

15-2
Section Page Section .. Page
1 Description and Operation ......... 15-5 3 Removal and Installation .................. 15-5
2 In-Car Adjustments and Repairs . . ........ 15-5

HEADLIGHTS have only one filament and are used beams. The red wire with a black
for highway driving along with the stripe supplies the low beam fila-
Four sealed-beam headlights are high beams of the No. 2 headlights. ments. The black wire with a yellow
used. The two outboard lights have Locating tabs molded in the glass stripe supplies the parking lights
two filaments each for low beam and allow the mounting of the No. 1 (Fig. 1 ).
high beam, and arc marked by a lights in the inboard headlight sup-
numeral "2" molded in the glass lens. port frames only. A conventional HORNS
Locating tabs molded in the glass beam selector switch is located on the
allow the mounting of the No. 2 floor board near the left. The Lincoln is equipped with a
lights in the outboard headlight sup- Quick disconnect terminals are pair of tuned horns controlled by a
port frames only. The low beams are provided ai the left and right of the relay. The horn button closes the
used for city driving, when meeting radiator support assembly. The termi- relay contacts, completing the circuit
oncoming traffic on the highway, and nals are color coded. Like colored to the horns. One of the horns has a
for No. 2 headlight alignment. terminals are connected together. high-pitched tone; the other has a
The inboard headlights with a The green wire with a black stripe low-pitched tone. The horn circuit
numeral "1" molded in the glass lens supplies current to the headlight high is shown in Figure 1.

HEADLIGHT ALIGNMENT mension "B," upper diagram Fig. 3) mension ·'B" for the No. 2 lights is
to the 20-inch reference line ob- the same as ''B" for the No. l lights,
All headlight adjustments should tained by sighting over the uprights. dimension "A" is as measured on the
be made with a half-full fuel tank Draw a horizontal line two inches car. Note that the line of adjust-
plus or minus one gallon, with a below, and parallel to, the head- ment of the No. 2 lights is the
person seated in the driver's seat. light horizontal centerline. Then draw horizontal centerline of the No. 2
the car unloaded and the trunk the headlight vertical centerlines on lights. Turn the headlights to low
empty except for the spare tire and the screen as measured on the car beam and adjust each No. 2 light
jacking equipment, aTtd recommend- (dimension ''A," upper diagram Fig. as shown in Fig. 3.
ed pressura in all tires. Before each 3). Each headlight is adjusted by
adjustment, bounce the car by push- means of two screws located under
ing on the center of both the front NO. 1 HEADLIGHT the headlight trim ring as shown in
and rear bumpers, to level the car. ADJUSTMENT (INNER LIGHTS) Fig. 4. Always bring each beam into
To align the No. 1 headlights (in- Adjust each No. I headlight (inner final position by turning the adjusting
board lights) by means of a wall light) beam as shown in Fig. 3. screws clockwise so that the head-
screen, select a level portion of the Cover the No. 2 lights when mak- lights will be held against the tension
shop floor. Lay out the floor and wall ing this adjustment. springs when the operation is com-
as shown in Fig. 2. pleted.
Establish the headlight horizontal NO. 2 HEADLIGHT ADJUST- Some states may not approve of
centerline by substracting 20 inches MENT (OUTER LIGHTS) the 2-inch dimension for the No. 1
from the actual measured height of To align the No. 2 headlights headlights. Check the applicable
the headlight lens center from the (outer lights), a different wall chart state law, as a 3-inch dimension
floor and adding this dimension ( di- (lower diagram Fig. 3) is used. Di- may be required.

HEADLIGHTS (Fig. 4), rotate the retaining ring 4. Plug in the new bulb, and place
Cl)Uilterclockwise, anJ remove it. it in position, making sure that the
1. Remove the retaining screws 3. The headlight bulb may now be locating tabs are placed in the posi-
and headlight trim nng. pulled forward far enough to discon- tioning slots.
2. Loosen the retaining ring snew~ nect the wiring assembly plug. 5. Install the headlight bulb rc-

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1 (JUNCTION BLOCK I
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TURN-SIGNAL SWITCH
BACKUP
LIGHT
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RIGHT POSITION LEFT POSITION ....
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PARKING POSITION
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fIG. 1- Exterior Lighting, Turn Signals, Horns and Backup Lights K1457·A
-
N

(283) PART 15-2-LIGHTING SYSTEM AND HORNS 15-7
tammg ring, rotating it clockwise

under the screws, and tighten the
screws.
6. Place the trim ring into posi·
tion, and install the retaining screws.
PARKING LIGHT
To replace the bulb in the parking
» /
light, remove the retaining screws,
2s FEET lens, and bulb (Fig. 5). After the
----····~AXL~...
bulb is replaced, install the lens and
retaining screws.
PLACE WHERE CENTERLINE OF FRONT
WOULD BE. WITH VEHICLE IN POSITION
~7..-", --......_
PlACE WHERE CENrERLINE OF REAR AXlE
WOUlD BE. WITH VEHICLE IN POSITION K1086-C:
FIG. 2-Fioor and Wall Layout

I DIMENSIOt-. ''A"-----
LINE OF ADJUSTMENT _...~ <t OF VEHICLE HORIZONTAL ¢_

v· OFHEAr:;-
i\ ~ ~
J, V'
"8"
l FIG. 5-Parking Light

<( OF LEFT NO. I - t
20" liNE
-.. <( OF RIGHT NO. I
HEADliGHT HEADLIGHT TAIL AND STOP LIGHT
I To replace the bulb, pull the lug-
NO. 1 LIGHT HIGH BEAM DIAGRAM
HEADLIGHTS 25 FEET gage compartment rear liner board
FROM WALL
I DIMENSION' ''A" away from the light body and remove
I the bulb.
LINE OF ADJUSTMENT
<t OF LEFT NO. 2 - . -<t OF RIGHT NO.2
HEADLIGHT
AND HORIZONTAL HEADLIGHT BACK-UP LIGHTS
<t OF HEADLIGHTS
To replace the bulb, remove the
·- .~ two lens retaining screws and remove
t
"B''' the lens.
l ·-
LICENSE PLATE LIGHT
~ :-2"
--·- <t OF VEHICLE 20"~1NE The license plate light is shown
disassembled in Fig. 6.
I. Disconnect the light wire from
NO. 2 LIGHT LOW BEAM DIAGRAM
K1192-C
the bullet connector.
2. Remove the license plate.
FIG. 3-Headlight Wall Screens 3. Remove the two light bracket
retaining screws and remove the light
VERTICAL ADJUSTIN1G SCRE
assembly.
4. Remove two lens retaining
screws and remove the light shield,
HOUSING AND SOCKET ASSEMBLY iJ?'

GASKET ........... ~
LENS~c:E_
LIGHT t~Q~ GASKE:ULB
-~~BRACKET
cu K1469·A
K1302-B
FIG. 6-Disassembled
FIG. 4-Headlight Adiustment License Plate Light

...
Ut
Co
REAR VIEW
-•
~
fl G. 7-Instrument Panel Lights and Wiring K1455-A -

(285) PART 15-2-LIGHTING SYSTEM A.ND HORNS 15-9
------------------------------
lens and socket from the bracket. 2. Replace the bulb. to check the lock cylinder operation.
5. Remove the bulb from the 3. Position the lock washer be- 9. Connect the battery.
socket. tween the bracket and the rear deck
lid and install the bracket and light HORNS
INSTRUMENT LIGHTS assembly with the retaining screw.
The horns are mounted to the
The instrument panel lights and right front fender apron in the en-
wiring are shown in Fig. 7. LOW FUEL WARNING LIGHT gine compartment. Disconnect the
1. Disconnect the battery. horn wire from the terminal. Remove
2. Remove the radio control knobs 1. Remove the lower instrumc~nt
the horn bracket to fender apron re-
and remove the radio control lock panel.
taining screws and remove the horns.
nuts and washers. 2. Remove the fuel gauge, but do
To install, place the horns in posi-
3. Remove the knobs from the not remove the gauge from the dual
tion and install the retaining screws.
heater and air conditioner controls gauge mounting plate.
Install the horn wire.
and the heater and air conditioner 3. Remove the light bulb from the
blower switch. instrument panel at the fuel gauge HORN RING
4. Remove the 10 screws retaining mounting area.
the center instrument panel bezel 4. Install the new light bulb in the 1. Disconnect the battery.
and remove the bezeL instrument panel. 2. Remove the center steering
5. Replace the light bulb. 5. Install the fuel gauge. wheel cover.
6. Position the center instrument 6. Install the lower instrument 3. Remove the two retaining screws
panel bezel and install th~ I 0 retain- panel. in the center of the steering wheel
ing screws. and the one screw retaining the three
7. Install the knobs on the heater IGNITION SWITCH LIGHT horn wires.
and air conditioner controls and the 4. Remove the three screws under
heater and air conditioner blower 1. Disconnect the battery. the steering wheel which retain the
switch. 2. Turn the ignition key to the horn ring and remove the horn ring.
8. Install the washers and lock nuts accessory position. Slightly depress 5. Position the horn ring and in-
in the radio control parts. the pin shown in Fig. 5, Part 15·-3, stall the three retaining screws under
9. Install the radio control knobs. turn the key counterclockwise and the steering wheel.
10. Connect the battery. pull the key and lock cylinder out 6. Install the two retaining screws
of the switch assembly. in the center of the steering wheel,
ASH TRAY LIGHTS 3. Press in on the rear of the and the one screw retaining the
switch to depress the spring and ro- three horn wires.
Ash tray lights arc provided with tate the swtich Vs turn counterclock- 7. Install the center steering wheel
the ash trays on the instrument panel wise (as viewed from the terminal cover.
and in the rear compartment. To end). Remove the switch from the 8. Connect the battery.
replace the bulb, remove the ash iower instrument panel.
tray. 4. Remove the light and bracket HORN RELAY
a.;;scmbly from the underside of the
GLOVE COMPARTMENT LIGHT instrument panel for accessibility. The horn relay is mounted on the
5. Replace the light bulb. right-hand cowl side panel.
The glove compartment light is
6. Position the switch to the light 1. Disconnect the battery ground
located in the upper left corner of
and bracket assembly. cable from the battery.
the glove box. To replace the bulb,
7. Place the switch in the switch 2. Remove the six bolts retaining
remove tlJe two retaining screws and
opening, press the switch toward the the stone shield to the right front
remove the bulb-type lens.
instrument panel, and rotate the fender and remove the stone shield.
MAP LIGHT switch 1/x turn to lock it in position. 3. Disconnect the wire connector
8. Turn the key in the lock cylin- from the relay.
The map light is shown in Fig. 8. der to the accessory position. Place 4. Remove the three screws hold-
To replace the bulb, remove the two the lock and key in the ignition ing the relay mounting bracket and
lens retaining screws and remove switch, depress the pin slightly (Fig. pull out the bracket and relay.
the lens. 5, Part 15-3), and turn the key 5. Remove the nut and bolt retain-
counterclockwise. Push the lock cyl- ing the horn relay to the mounting
COURTESY LIGHTS bracket and remove the relay.
inder into the switch. Turn the key
6. Position the relay to the mount-
Courtesy lights arc located on the
ing bracket and install the bolt and
right and left rear quarter trim panel.
nut.
Remove the bezel from the trim
7. Position the relay and bracket
panel to replace the bulb.
assembly and install the three retain-
LUGGAGE COMPARTMENT ing screws.
LIGHT 8. Connect the wire connector to
the relay.
1. Remove the screw retaining the 9. Position the stone shield under
bracket and light assembly to the the fender and install the six retain-
rear deck lid. Remove the bracket ing bolts.
and light assembly and the lock 10. Connect the battery and check
washer. FIG. 8-Map Light the operation of the horn.

15-10 GROUP 15-LIGHTING SYSTEM, HORNS, AND INSTRUMENTS (286)
PART SWITCHES, CIRCUIT BREAKERS AND FUSES

15-3
l Description and Operation ................ 15-10 2 Removal and Installation ................. 15-10

HEADLIGHT SWITCH It is accessible by removing the cigar lighter, radio, turn signal, elec-
cover plate. The panel contains the trically operated antenna, and back-
A combination headlight switch,
following fuses: Instrument lights, up lights. Fuse values and locations
courtesy light switch and circuit
speed control, clock, interior lights, are shown in Fig. 2.
breaker is used (Fig. 1). The circuit
breaker protects the headlight circuit.
FUSES
The fuse panel is mounted in the
left side of the glove compartment.
7.5 AMP. TURN SIGNAL 2 AMP. CLOCK
:lt------re::::!~-15 AMP. CIGAR LIGHTER

(FRONT)
15 AMP. CIGAR LIGHTER
(REAR)
7.5 AMP. BACK-UP LIGHT 14 AMP. INTERIOR LIGHTS
10 AMP. ELECTRICAL ANTENNA
14 AMP. SPEED CONTROL
FIG. 1-Headlight K1472·A
Switch FIG. 2-Fuse Panel
B REMOVAL AND INSTALLATION

Before removing any switch, dis- HEADLIGHT BEAM SELECTOR pin shown in Fig. 5, turn the key
connect the battery ground cable SWITCH counterclockwise, and pull the key
from the battery. and lock cylinder out of the switch
Lay the floor mat back from the assembly. If only the Jock cylinder
HEADLIGHT SWITCH area of the switch and remove the is to be replaced, proceed to Step 8.
mounting screws (Fig. 3). Discon- 3. Press in on the rear of the
1. Remove the control knob and nect the wire terminal block from
shaft by pressing the knob release switch to depress the spring, and
the switch. rotate the switch YH turn counter-
button on the switch housing. To install, connect the terminal
2. Remove the bezel screw from clockwise (as viewed from the ter-
block to the switch and install the minal end). Remove the switch from
the switch and remove the switch
switch to the floor. Replace the floor the lower instrument panel.
from the lower instrument panel. mat.
3. Disconnect the electrical con- 4. Remove the nut and the two
nector from the rear of the switch STOP LIGHT SWITCH leads from the accessory terminal of
and remove the switch. the switch.
4. Connect the electrical connector Disconnect the wires from the 5. Remove the plug connector
to the switch. bullet connectors and unscrew the from the switch and remove the
5. Position the switch in the lower switch from the brake master cyl- switch.
instrument panel and secure with the inder (Fig. 4}. 6. Connect the plug connector to
bezel screw. the switch and install the two leads
IGNITION SWITCH AND to the accessory terminal with the
6. Install the control knob and LOCK CYLINDER
shaft by inserting it all 'the way retaining nut.
into the switch until a distinct click 1. Disconnect the negative cable 7. Place the switch in the switch
is heard. In some cases, it may be from the battery. opening, press the switch toward
necessary to rotate the shaft until it 2. Turn the ignition key to the ac- the instrument panel and rotate YK
engages. cessory position. Slightly depress the turn to lock in position.

(287) PART 15-3-SWITCHES, CIRCUIT BREAKERS AND FUSES 15-11
8. If a new lock cylinder is to he 9. Connect the battery cable and 2. Disconnect the wires from the
installed, insert the key in the cyl- check the ignition switch operation. switch and remove the switch from
inder and turn the key to the ac- the retaining clip.
cessory position. Place the lock and
MAP LIGHT SWITCH OR
ANTENNA SWITCH GLOVE COMPARTMENT
key in the ignition switch, depres~
LIGHT SWITCH
the pin slightly (Fig. 5). and turn 1. Remove two retaining screws
the key counterclockwise. Push the from the trim plate and remove tlhe Pull the switch from the retain-
lock cylinder into the switch. Turn plate. ing flange in the glove compartment
the key to check the lock cylinder and disconnect the wires.
operation.
FIG. 5-lgnition
~~ Switch and Lock
FIG. 3-Headlight Beam FIG. 4-stop Light
Selector Switch Switch

15-12 GROUP 15- LIGHTING SYSTEM, HORNS, AND INSTRUMENTS (288)
PART INSTRUMENTS
15-4
1 Description and Operation ................ 15-12 3 Removal and Installation ................. 15-14
2 In-Car Adjustments and Repairs ........... 15-14

All of the instruments are elec- of 5.0 volts at the gauge terminals. warning light will light just before
trically operated except the speedom- The regulator is temperature com- the fuel gauge pointer indicates
eter. Illumination is provided by pensated for all expected ambient empty and/ or when there are ap-
lights controlled by a rheostat on the (surrounding air) temperatures. proximately three gallons of fuel
lighting switch. A front view of the in the tank.
instrument panel is shown in Fig. 1. FUEL GAUGE
A thermistor assembly (Fig. 4),
The fuel gauge consists of a send- attached to the fuel sender outlet
GAUGES ing unit, located on the gas tank, and tube, is kept cool when covered by
a remote register unit (fuel gauge) gasoline. When the fuel level drops
The gauges and lights are shown mounted in the instrument cluster. low enough to expose the thermistor
in Fig. 7, Part 15-2. Figure 2 shows The remote register unit pointer is to air, the thermistor heats up. The
the gauge circuits. The upper por- controlled by a bimetallic arm and thermistor resistance then drops and
tion of the instrument cluster con- heating coil. The sending unit is a allows current to flow through a
tains the speedometer, trip odometer, rheostat that varies its resistance de- warning signal relay. The relay con-
turn signal indicators, and the high- pending on the amount of fuel in the tacts then close to light the warning
beam indicator. The lower portion tank. The fuel gauge circuit is shown light. The low fuel level warning
of the cluster contains the fuel gauge, in Fig. 2. system circuit is shown in Fig. 2.
oil pressure gauge, ammeter, and
temperature gauge. LOW FUEL LEVEL TEMPERATURE GAUGE
A constant voltage regulator main- WARNING SYSTEM
The temperature gauge consists of
tains a constant voltage supply to The low fuel level warning sys- a sending unit mounted in the cyl-
the fuel gauge, oil pressure gauge, tem consists of the fuel level sending inder head, and a remote register
and temperature gauge circuits. unit located on the fuel tank, the unit, (temperature gauge) mounted
The constant voltage regulator warning relay, and the warning light in the instrument cluster. The prin-
(Fig. 3), maintains an average value incorporated in the fuel gauge. The ciple of operation is similar to the
fuel gauge except that the resistance
of the sending unit is varied by en-
gine temperature. The temperature
gauge circuit is shown in Fig. 2.
OIL PRESSURE INDICATOR
GAUGE
A meter-type oil pressure gauge
is used. The gauge consists of a send-
ing unit on the engine and a remote
register unit in the instrument cluster.
The meter-type gauge circuit is
shown in Fig. 2.
CHARGE INDICATOR GAUGE
The charge indicator used is a
magnetic-loop type ammeter.
TURN INDICATOR
Fig. 1, Part 15-2 shows the turn
indicator wiring diagram.
SPEEDOMETER
The speedometer is connected to
the output shaft of the transmission
by means of a flexible shaft, and a
FIG. 1-lnstrument Panel

TO BAITERY -~
+TERMINAl
...
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I
~
I
z
V'l
-4
:::0
COURTESY liGHT c::
SPliCE IN !READING) 3::
!
L
I"T1
:z:
Black-Blue
fV-- ---~'COURTESY-liGHT SWITCH

-4
V'l
Green- Yellow
HEATER liGHT
White
...
FIG. 2-lnterior Lighting, Gauges, and Heater Schematic
K1456-A
"'w
I

15-14 GROUP 15-LIGHTING SYSTEM, HORNS, AND INSTRUMENTS {290)
COVER HEATING COIL

GROUND
traveled in miles and tenths of a
\ mile.
CLOCK
Adjustment of the clock is auto·
matic. If the clock runs slow or fast,
merely reset the clock to the proper
time. This action adjusts the clock
automatically.
The clock fuse is located on the
fuse panel in the glove compartment.
WINDSHIELD WIPER
The windshield wiper motor is hy-
draulically operated. The hydraulic
power for the motor is obtained from ~W~I LO~l~~\NLJYEL
FIG. 3-Constant the power steering unit. The wind- ~c.·"''7--THERMISTOR
ASSEMBLY
Voltage Regulator shield wiper system incorporates the
pressure regulator valve as part of ~---SCREEN
drive gear located inside the trans- the motor assembly (Fig. 7). The
mission. The flexible shaft drives the hydraulic fluid flows from the pump K1465·A
speedometer which registers speed in to the steering gear, to the wind-
miles per hour and also drives an shield wiper motor, to the reservoir FIG. 4-Fuel Level
odometer which records distance and back to the pump. Warning Sender Assembly

WINDSHIELD WIPER BLADE
shield wipers on and then off to gine. Install the wiper blades so they
ADJUSTMENT
bring the wiper pivot shafts to their lie flat against the lower edge of
Start the engine. Turn the wind- proper park position. Stop the en· the windshield.

LOWER INSTRUMENT PANEL 10. Remove the seven screws from but do not disconnect the wires.
the upper edge of the lower instru· 18. Remove the headlight switch
1. Disconnect the battery. ment panel. from the lower instrument panel, but
2. Remove the control knobs from do not disconnect the wires.
11. Remove the two jam nuts and
the heater and air conditioner con-
disconnect the speedometer trip re- 19. Remove the control knob from
trols, the heater and air conditioner
set and the clock reset control cables the windshield wiper control lever.
blower switch, and the radio controls.
from the lower edge of the lower 20. Remove the two retaining nuts
3. Remove the radio control lock instrument panel. from the windshield wiper control
nuts and washers.
12. Remove the two retaining bezel and remove the windshield
4. Remove the 10 screws retaining wiper and washer control assembly
screws and remove the hood lock
the instrument panel bezel to the from the lower instrument panel.
release control handle and bracket
instrument panel. Remove the bezel
from the lower instrument panel. 21. Remove the two bolts securing
from the panel and from the car.
13. Remove the speed control head the lower instrument panel to the
5. Remove the finish moulding inner cowl panel at the right and
from the upper edge of the lower and mounting bracket from the low-
er instrument panel. left side.
instrument panel.
14. Remove the cover plate from 22. Remove the ash receptacle and
6. Remove the three screws retain-
the fuse block in the glove compart- disconnect the ash tray light and
ing the trim collar at the steering col-
ment and remove the two screws re- cigar lighter leads.
umn and remove the trim collar.
7. Remove the two retaining screws taining the fuse block to the lower 23. Remove the lower instrument
at the right and left lower instrument instrument panel. panel from the car.
panel end plates. 15. Disconnect the glove compart- 24. Position the lower instrument
8. Remove the two screws retain- ment courtesy light. panel in the car.
ing the plate over the steering col- 16. Disconnect the rear deck lid 25. Install the headlight switch in
umn and remove the plate. lock release control handle. the lower instrument panel.
9. Remove the lock cylinder from 17. Remove the ignition switch 26. Position the windshield wiper
the ignition switch. from the lower instrument panel, and washer control assembly in the

{291) PART 15-4-INSTRUMENTS 15-15
lower instrument panel and install The fuel gauge and oil pressure FUEL SENDING UNIT
the two bezel retaining nuts. gauge are mounted on a single
27. Install the control knob on mounting plate. The charge indicator 1. Raise the car on a hoist.
the windshield wiper control lever. gauge and temperature gauge are 2. Drain the fuel from the tank.
also mounted on a single mounting 3. Disconnect the wires from the
28. Install the ignition switch on
plate. sending unit.
the lower instrument panel. Install
The replacement procedure given 4. Disconnect the fuel lines from
the lock cylinder in the ignition
tor the fuel gauge applies to all the the sending unit.
switch.
gauges except that only the gauge to 5. Remove any dirt that has col-
29. Connect the cigar lighter and
he replaced is removed from its lected around the sending unit so
ash tray light leads and install the
mounting plate. Figure 7, Part 15-2 that it will not enter the tank.
ash receptacle (Fig. 7, Part 15-2).
shows the wiring connections to the 6. Remove the sending unit and
30. Install the fuse block on the gasket from the tank.
lower instrument panel with the two various gauges.
7. Clean the sending unit mount-
retaining screws. Install the fuse ing surface at the fuel tank.
block cover plate. CONSTANT VOLTAGE 8. Install the sending unit with a
31. Connect the glove compart- REGULATOR new gasket.
ment courtesy light. 9. Connect the· wires and the fuel
32. Install the rear deck lid lock 1. Disconnect the battery.
lines.
release control handle. 2. Remove the two screws, retain- 10. Lower the car.
33. Install the lower instrument ing the left air duct grille and re- 11. Fill the fuel tank with the fuel
panel on the center panel with seven move the grille. removed.
screws at the upper edge, two screws 3. Disconnect the wires from the 12. Check the operation of the
at each end plate, and two bolts at constant voltage regulator. fuel gauge, the low fuel warning
the inner cowl panel. ·1. Loosen the one regulator re- light, and check for leaks.
34. Install the trim collar on the taining screw and remove the regu-
steering column with the three re- lator. TEMPERATURE GAUGE
taining screws. !i. Position the constant voltage
35. Install the plate over the steer- r.:·gulator and tighten the retaining To replace the temperature gauge,
ing column with the two retaining screw. follow the procedure given for the
screws. 6. Connect the wires to the regu- fuel gauge.
36. Connect the speedometer trip lator. Make sure that the radio sup-
reset and clock reset control cables pression choke is connected to the TEMPERATURE SENDING
to the lower instrument panel with in put side of the regulator. UNIT
the two jam nuts. 7. Position the air duct grille and
install the two retaining screws. 1. Disconnect the temperature
37. Install the hood lock release
8. Connect the battery and check sending unit wire from the sending
control handle and bracket on the
the operation of the gauges. unit.
lower instrument panel with the two
2. Prepare the new temperature
retaining screws.
sending unit for installation by ap-
38. Install the speed control head FCEL GAUGE plying a small amount of water re-
and mounting bracket on the lower sistant sealer to the threads.
instrument panel. I. Remove the lower instrument 3. Remove the temperature send-
39{ Position the instrument panel panel. ing unit from the cylinder head and
bezel on the instrument panel and 2. Disconnect the electrical con- immediately install the new tempera-
install the 10 retaining screws. nections from the fuel gauge and oil ture sending unit.
40. Install the finish moulding on pressure gauge. 4. Connect the wire to the tem:-
the upper edge of the lower instru- :t Remove the three retaining perature sending unit.
ment panel. screws and remove the dual gauge 5. Start the engine and check the
41. Install the control knobs on mounting plate and gauges from the sending unit operation.
the heater and air conditioner con- instrument panel.
trols and the heater and air condi- 4. Remove the two nuts from the OIL PRESSURE GAUGE
tioner blower switch. terminal studs and remove the fuel
42. Install the washers and lock gauge from the mounting plate. To replace the oil pressure gauge,
nuts on the radio control posts. S. Position the fuel gauge on the follow the procedure given for the
43. Install the radio control knobs. mounting plate and install the two fuel gauge.
44. Connect the battery and check nuh.
the operations of all gauges, lights, 6. Position the dual gauge mount- OIL PRESSURE
and signals. in~~ plate and gauges to the instru- SENDING UNIT
ment panel and install the three
rcL1ining screws. The oil pressure sending unit is
GAUGES mounted on top of the oil filter
7. Connect the electrical connec-
To replace the fuel gauge, oil tor" to the fuel gauge and oil pressure (Fig. 5).
pressure gauge, charge indicator gauge terminal studs. 1. Disconnect the oil pressure
gauge, and temperature gauge, it is 8. Install the lower instrument
sending unit wire from the unit.
necessary to remove the lower in- 2. Remove the sending unit from
panel.
strument panel. the oil filter.

15-16 GROUP 15- LIGHTING SYSTEM, HORNS, AND INSTRUMENTS (292)
3. Apply conductive sealing com- TURN INDICATOR FLASHER

pound to the threads of the new
sending unit and install the unit to The turn indicator flasher is lo-
the oil filter. cated at the lower edge of the instru-
4. Connect the wire to the sending ment panel to the right of the
unit. speedometer trip reset. To replace
5. Check the operation of the unit. the flasher, pull the flasher from its
retaining clip and disconnect the
CHARGE INDICATOR GAUGE wires from the terminals.
To replace the charge indicator SPEEDOMETER

gauge, follow the procedure given SPEEDOMETER CABLE K1029-A
for the fuel gauge. 1. Disconnect the battery.
2. Remove the heater, air condi- FIG. &-Speedometer
TURN INDICATOR tioner, and radio control knobs. Cable Mounting
3. Remove the radio control lock
To remove the turn indicator
nuts and washers. Wipe off all of the old lubricant.
switch, the steering wheel must first
be removed. 4. Remove the two screws retain- Lubricate the new cable with cable
1. Unscrew the turn signal switch ing the plate over the steering column lubricant BSA-19581-A (do not over
lever from the steering column. and remove the plate. lubricate), insert it all the way into
2. Remove the switch mounting 5. Remove the l 0 screws retaining the housing, and twist it slightly
bracket screws, and remove the the instrument panel bezel to the to make sure that the squared drive
switch and bracket from the steering instrument panel and remove the is engaged in the speedometer driven
column. bezel. gear. If a speedometer cable is
3. Remove the conical tension 6. Remove the jam nut and discon- broken, it will be necessary to dis-
spring and remove the switch actu- nect the speedometer trip reset con- connect both ends of the cable
ating arm. trol cable from the lower edge of housing in order to remove the
4. Disconnect the switch wires the lower instrument panel. broken sections. Tighten the mount-
from the bullet connectors. Remove 7. Remove the seven screws re~ ing bolt to 20-25 foot-pounds torque
the access plate at the steering col- taining the speedometer to the instru- (Fig. 6).
umn, remove the switch to mount- ment panel. Position the speedometer The speedometer driven gear is
ing bracket screws, and remove the out of the instrument panel, discon- held on to the speedometer cable
switch and wires. nect the speedometer cable, and re- housing by a retainer clip. When re-
When installing the new switch, move the speedometer and trip reset placing the driven gear, make certain
make certain that the cancelling cam control cable as a unit. that the gear is secure by placing the
on the steering wheel makes contact 8. Connect the speedometer cable gear in position before inserting the
with the cancelling pawls on the to the new speedometer. retainer clip through the gear slots.
switch. The clearance between the 9. Position the speedometer and
steering wheel hub and the steering trip reset control cable assembly CLOCK
shaft housing flange should not be in the instrument panel and install
more than ~':in inch for proper switch the seven speedometer retaining 1. Remove the heater, air condi-
cancelling. Reposition the steering screws. tioner, and radio control knobs.
shaft housing if necessary. 10. Connect the trip reset control 2. Remove the radio control lock
cable to the lower instrument panel nuts and washers.
with the jam nut. 3. Remove the two screw~ retain-
11. Position the instrument panel ing the plate over the steering· col-
bezel on the instrument panel and umn and remove the plate.
install the 10 retaining screws. 4. Remove the 10 screws retaining
12. Position the plate over the the instrument panel bezel to the in-·
steering column and install the two strument panel and remove the bezel.
retaining screws. 5. Remove the jam nut. and dis-
13. Install the heater and air condi- connect the clock reset control cable
tioner control knobs. from the lower edge of the lower
14. Install the washers and lock instrument panel.
nuts to the radio control posts. 6. Remove the four screws retain-
15. Install the radio control knobs. ing the clock to the instrument panel.
16. Connect the battery. Disconnect the clock wires and re-
move the clock and reset control
cable as a unit.
SPEEDOMETER CABLE
REPLACEMENT 7. Transfer the reset control cable
to the new clock.
To replace the speedometer drive 8. Position the clock and cable to
cable, disconnect the cable housing the instrument panel. Connect the
FIG. 5-0il Pressure from the speedometer, and pull the clock wires and install the four clock
Sehding Unit cable out of the housing. retaining screws.

(293) PART 15-4-INSTRUMENTS 15-17
9. Connect the reset control cable \HPER CONTROL ment panel.

to the lower instrument panel with 21. Install the trim collar on the
1. Disconnect the battery.
the jam nut. steering column with the three re-
2. Remove the three screws retain-
10. Position the instrument panel taining screws.
mg the trim collar to the steering
bezel to the instrument panel and 22. Connect the battery.
column. and remove the trim collar.
install the 10 retaining screws. 3. Remove the two screws from WIPER PIVOT SHAFT
11. Position the plate over the the left end plate of the lower in- AND LINK
steering column and install the two -..t rument panel.
retaining screws. 4. Remove the finish moulding Right Pivot Shaft
12. Install the heater and air condi- t rom the upper edge of the lower 1. Remove the 11 screws securing
tioner control knobs. wstrumcnt panel. the top cowl grille and screen. Dis-
13. Install the washers and lock 5. Remove three screws from the connect the windshield washer vac-
nuts to the radio control posts. lop of the lower instrument panel uum hoses and remove the top cowl
14. Install the radio control knobs. t,., gain access to the wiper control grille and screen.
~tssembly.
2. Remove the clip retaining the
6. Remove the control knob from left pivot shaft link to the wiper
WINDSHIELD WIPER
the windshield wiper control lever. motor. Position the link to the left.
WIPER MOTOR 7. Remove the two vacuum hoses 3. Remove the clip from the right
t rom the windshield washer control. pivot. Remove the two bolts and nut
1. Remove the two windshield 8. Remove the two retaining screws retaining the right pivot and remove
wiper mounting bolts and slide the .111d remove the windshield washer the pivot.
motor out of the mounting bracket ,_tJntrol valve from the windshield 4. Position the new right pivot.
(Fig. 7). '"' 1per control assembly. Start the two retaining bolts and the
2. Disconnect the two hydraulic 9. Remove the two retaining nut.
lines from the motor. Loosen the •;crews and remove the windshield 5. Position the left pivot shaft link
control cable set screw. ,., iper control from the lower in- to the motor and install the retain-
3. Remove the windshield washer ··1 rument panel.
ing clip.
vacuum hoses and remove the motor. 10. Remove the two retaining nuts 6. Tighten the two retaining bolts
4. Transfer the two brass fittings tnd remove the bezel from the and the nuL
to the motor, using sealing com- ~~ indshield wiper control. 7. Position the screen on the cowl,
pound on the fittings. 11. Working in the engine com- and position the cowl grille. Connect
5. Position the new motor. Posi- ;)<Utment, loosen the wiper control the windshield washer vacuum hoses.
tion the control cable and tighten ::able set screw and remove the con- 8. Install the 11 screws securing
the set screw. t ml cahle from the wiper motor.
the grille and screen.
6. Connect the windshield washer 12. Tie a wire to the wiper control Left Pivot Shaft and )_..ink
vacuum hoses. Connect both hy- ~:ahle. Working in the passenger
draulic lines so they are snug. ,:~)mpartment, pull the control cable
1. Remove the 11 screws securing
1 hrough the firewall until the wire
the top cowl grille and screen. Dis-
7. Position the motor in the mount-
11ed to the cable is accessible. Re- connect the windshield washer vac-
ing bracket. Install the right-hand
move the wire from the cable. uum hoses and remove the top cowl
retaining bolt and then install the
grille and screen.
left-hand retaining bolt. 13. Tie the wire to the new control
2. Remove the clip retaining the
8. Tighten the hydraulic lines at ...:able. From the engine compart-
link to the wiper motor and position
the motor.. 'T1ent, pull the wire and cable
the link out of the way.
9. Start the engine and check for through the firewall. Remove the
3. Remove the clip from the right
leaks. wire from the cable.
pivot. Remove the two bolts and nut
10. Check the power steering fluid 14. Install the control cable on
retaining the left pivot, and remove
and add fluid if necessary. the wiper motor and tighten the
the pivot and link assembly.
~et screw.
4. Position the new left pivot and
REGULATOR VALVE 15. Install the windshield washer link assembly. Loosen the two bolts
I
control valve on the windshield wip- and nut retaining the right pivot.
er control with the two retaining
NOTE: It is necessary to loosen
-.crews.
the right pivot to install the link
16. l nstall the windshield wiper on the pivot. Position the link on the
and washer control assembly on the pivot and install the retaining clip.
l~)wer instrument panel with the two
Tighten the two belts and nut retain-
retaining screws. ing the right pivot.
17. Install the control knob on the 5. With the left pivot and link in
windshield wiper control lever. oosition. install the two retaining
~ 18. lnstall the three screws in the bolts and nut. Install the retaining
/ 1op of the lower instrument panel. clip at the motor.
CONTROL CABLE ADJUSTMENT K1467-A
19. Instal\ the two screws in the 6. Position the screen on the cowl,
eft end plate of the lower instru- and position the cowl grille. Connect
FIG. 7-Windshield !lent panel. the ~indshield washer vacuum hoses.
Wiper Motor and Pressure 20. Install the finish moulding on 7. Install the 11 screws securing
Regulator he upper edge of the lower instru- the grille and screen.

15-18 (294)
PART SPECIFICATIONS
15-5
BULB CHART INSTRUMENT VOLTAGE
Unit Candle Power Average Voltage at Fuel and Temperature Gauge Terminals 5 Volts
or Wattage Trade No.
Headlight-No. I (Inner) 37.5 w 4001
Headlight-No. 2 (Outer) 37.5/50 w 4002
HORN CURRENT DRAW
Front Turn Signal/Parking
Rear Turn Signal & Stop/Tail
32/4 c.p.
32/4 c.p.
1157
1157
I All 9.0-10.0 Amperes at 12 Volts J
Stop/Tail Only
license Plate 4 c.p. 1155 TURN INDICATOR
Back-Up Lights 21 c.p. 1141
Engine Compartment Light 15 c.p. 93 Current Draw at 12 Volts 0-4 Amperes f
Luggage Compartment 6 c.p. 631
Dome Light 15 c.p. 1003
Instrument Panel Indicators:
Hi Beam 2 c.p. 1895
Oil Pressure 2 c.p. 1003
Generator 2 c.p. 1895
Turn Signal 2 c.p. 1895
Parking Brake Warning 2 c.p. 1895
Illumination:
Speedometer 2 c.p. 158
Cluster 2 c.p. 1895
Ash Receptacle/Gtove Compartment 1.5 c.p. 1445
Cigarette Lighter Socket & W/S Wiper
Heater Control 2 c.p. 158
Heater & A/C Control
Clock 2 c.p. 158
Ignition Key & Lighting Switch
Radio Dial 2 c.p. 1891
Courtesy and/or Map (Door Mounted) 6 c.p. 631
Automatic Transmission Control 15 c.p. 1003
CIRCUIT PROTECTION
Circuit Protective Device Location
Interior Lights & Glove Box Lights SFE 14 Fuse Behind Glove Box Door Plate
Clock 1AG-2 or AGA-2 Fuse Fuse Panel in Glove Box
Cigar Lighter (Socket) Reset Circuit Breaker On Back of Cigar Lighter Socket
Cigar lighter Circuit 3AG-15 or AGC-15 Fuse Fuse Panel in Glove Box
Back-Up Lights & Windshield Washer Pump SFE-7.5 Fuse Fuse Panel in Glove Box
Headlights 18 Amp. Circuit Breaker Incorporated in lighting Switch
Auxiliary Lights (Park, Tail, Dash, Stop & Interior)
Turn Signals SFE 7.5 Fuse Fuse Panel in Glove Box
Radio SFE 7.5 Fuse Fuse Panel in Glove Box
Rear Door Opening Warning Circuit Speed Control SFE 14 Fuse
Heat Blower Circuit Breaker Fuse Panel in Glove Box
Power Seats 30 Amp. Circurt Breaker Fuse Panel in Glove Box
Power Windows Control Circuit 20 Amp. Circuit Breaker
Power Windows Power Circuit SFE 14 Fuse Fuse Panel in Glove Box
Electric Antenna 3AG-10 Behind Glove Box Door Access Plate
Air Conditioning Circuit Breaker Fuse Panel in Glove Box
Automatic Headlight Dimmer SFE 4 Fuse At Amplifier Unit
Convertible Top Control
Power Circuit 50 Amp. Circuit Breaker On R.H. Cowl Side Panel
f
Control Circuit 10 Amp. Circuit Breaker Fuse Panel in Glove Box
Ground Circuit
luggage Compartment Lock Motor 15 Amp. Circuit Breaker On Top Control Relay Mounting Panel
Upper Back Panel Motor 15 Amp. Circuit Breaker On Top Control Relay Mounting Panel
Instrument Panel Rheostat SFE 6 Fuse Fuse Panel in Glove Box

(295) 16-1
GROUP
16
GENERAL VENTILATING, HEATING, RADIO ... . .......... 16-21
AND ACCESSORIES SERVICE . . .. 16-1
PART 16-5
PART 16-2 SPEED CONTROL . . . . . . . . . . . . . . . 16-25
VENTILATING AND HEATING . 16-11
PART 16-6
PART 16-3 AUTOMATIC HEADLIGHT DIMMER ... 16-27
AIR CONDITIONING . . . . . . . 16-13
PART 16-7
SPECIFICATIONS . . . . . . . . . . . . . . . 16-30
PART GENERAL VENTILATING, HEATING,

16-1 AND ACCESSORIES SERVICE
1 Diagnosis and Testing ......... . ........ 16-1 3 Cleaning and Inspection .................. 16-9
2 Common Adjustments and Repairs ....... 16-9

VENTILATING AND HEATING TROUBLE DIAGNOSIS GUIDE
1. Burned out fuse or loose wires 8. A kinked, clogged, or collapsed

to the heater blower. water hose.
2. Defective motor ground. 9.· Improperly connecte5l heater
:':.Fan loose on motor shaft or hoses.
INSUFFICIENT OR NO HEAT motor stalled. 10. Plugged heater core(s).
4. Defective heater blower switch. 11. Improperly installed engine
~i. Defective blower motor. thermostat.
6. Defective thermostat. 12. Air leaks in the ventilation
\ ~·. Defective water control valve. system.
·-
•
I. Improperly adjusted defroster 4. Plugged or loose defroster noz-
INSUFFICIENT OR NO air duct doors. zle.
DEFROSTING 2. Disconnected defroster hose. 5. Obstructed defroster openings
:~. Binding defroster door(s). at windshield.
-
TOO MUCH HEAT l. Defective water control valve. 2. Malfunctioning thermostat.
AIR CONDITIONING TROUBLE DIAGNOSIS GUIDE
l. Inoperative magnetic clutch. 8. Suction pressure low, discharge

~~-
Inoperative blower. pressure OK.
::. Obstructed air passages. 9. Suction pressure high, dis-
4. Complete loss of charge (no charge pressure OK.
INSUFFICIENT OR NO bubbles in sight glass at system 10. Discharge pressure low, suc-
C-oOLING start up). tion pressure high.
.}. Partial loss of charge (con- 11. Compressor defective, or loose
tinuous hubbies in sight glass after compressor belt.
start up). 12. Vacuum lines kinked, clogged,
fi. Service valves improperly set. loose, or off.
7. Inoperative servo. 13. Thermostat defective.

16-2· GROUP 16-VENTILATING, HEATING, AND ACCESSORIES (296)
AIR CONDITIONING TROUBLE DIAGNOSIS GUIDE (Continued)
14. Clutch lead disconnected or stays open or closed.

INSUFFICIENT OR NO broken. 16. Plugs left in compressor under
COOLING (Continued) 15. Expansion valve inoperative, service valve.
1. Loose, torn, or misaligned belt. parts in compressor.

NOISY COMPRESSOR 2. Loose, or slipping clutch. 4. Compressor loose on bracket.
3. Foreign material or damaged
1. Broken or loose mounting 2. Loose clutch.

COMPRESSOR VIBRATION
bracket. 3. Loose belt.
RADIO TROUBLE DIAGNOSIS GUIDE
1. Burned out fuse. tive speaker.

2. Reversed battery polarity. Be sure that proper voltage is avail-
NO RECEPTION
3. Defective antenna or lead. able at the set, then substitute the
4. Shorted speaker lead or defec- known good antenna and speaker.
NOISY RECEPTION-ENGINE NOT 3. Receiver not properly grounded

RUNNING to instrument panel.
1. Loose connections.
NOISY RECEPTION-CAR IN MOTION
NOISY OR ERRATIC NOISY RECEPTION-ENGINE RUNNING 1. Loose or broken lead-in cable.
~ECEPTION 1. Defective suppression equip- 2. Loose or defective radio an-
ment. tenna.
2. Suppression condensers not 3. Defective wheel static col-
properly grounded. lectors.
1. Voice coil rubbing on center 3. Foreign material on cone.

DISTORTED OR GARBLED pole piece of speaker magnet (either 4. Bent or twisted speaker mount-
SOUND front or rear speaker). in g.
2. Torn speaker cone.
1. Beyond normal reception dis- ception is poor be sure that antenna

WEAK RECEPTION tance from station ( FM only). is at 30-32 inch height before trying ·
2. Defective antenna. If FM re- a new antenna.
NO SOUND FROM 1. One speaker defective. tive. Operate fader to determine

ONE SPEAKER 2. Wiring to dead speaker defec- speaker at fault.
ELECTRIC ANTENNA TROUBLE DIAGNOSIS GUIDE
MOTOR DOES NOT 1. Burned out fuse. 3. Poor ground.

OPERATE 2. Defective switch or wiring. 4. Defective motor.
MOTOR OPERATES IN ONLY 1. Defective switch or wiring.

ONE DIRECTION 2. Defective motor.
MOTOR RUNS BUT WANDS 1. Bent or corroded wands.

DO NOT MOVE 2. Defective drive assembly.
SPEED CONTROL TROUBLE DIAGNOSIS GUIDE
BLOWING FUSES 1. Short or ground in the wiring circuit (Fig. 1).
1. Accelerator linkage is broken 3. Blown fuse. Fuse block is ac-

NO SPEED CONTROL or disconnected. cessible through left side of glove box.
RESPONSE 2. Drive cable broken or dis- 4. Loose connections or broken
connected. wires (internal or external).
CONTINUED ON NEXl PAG'£:

(297} PART 16-1-GENERAL VENTILATING, HEATING, AND ACCESSORIES SERVICE 16-3
SPEED CONTROL TROUBLE DIAGNOSIS GUIDE (Continued)

-
CONSTANT PRESSURE ON 1 Blown fuse. 4. Inoperative motor or locked
ACCELERATOR PEDAL ~:.No current at No. 2 Terminal. drive screw.
REGARDLESS OF SELECTOR
SETTING
:L Control cable is improperly
ad1usted. .
AUTOMATIC CONTROL DOES
No current at No. 3 Terminal. 2. Brake release switch improperly
NOT ENGAGE WHEN THE SLIDE 1.
adjusted.
SWITCH IS MOVED TO LOCK
·-
AUTOMATIC CONTROL
REMAINS ENGAGED WHEN l. Brake switch improperly ad- 2. Inoperative brake switch.
THE BRAKE PEDAL IS justed.
DEPRESSED
-
l. Speedometer cable or drive 3. Improper accelerator linkage
PULSATING ACCELERATOR
PEDAL
car•le kinked. adjustment.
~~. Lack of lubrication on cables.
-
CARBURETOR DOES NOT Jl. Improper carburetor or accel-
RETURN TO NORMAL IDLE era1 or linkage adjustment.
-·
SPEEDOMETER DOES NOT ll. Speedometer drive gear in the transmission to the power unit.
REGISTER OR THE UNIT transmission damaged. 3. Broken speedometer cable.
DOES NOT OPERATE :~. Broken drive cable from the 4. Defective speedometer.
·-
I. Cables bent or kinked. 3. Noisy speedometer head.
SPEEDOMETER NOISE
1 " Lack of cable lubrication.
"'
r - - - - - - - - - T o BATTERY (+I TERMINAL LOCATED IN

Orange-Whit·e FUSE PANEL' :---1
..---__..BI-.ac.,.k_ _ -l:.~v- STARTER RELAY

~------------------------------------~ ~
I
:
I
J-r~-~3
I o I
o:
1
Green- Violet
14 AMP. FUSE
Black-OrangE!
• Red
Yellow
SPLICE IN 14401
Black- Orange
HOLDING SWITCH
K-1533-A
FIG. 1-Wiring Diagram

16-4 GROUP 16-VENTILATING, HEATING, AND ACCESSORIES (298)
~RIVER CONTRft fore the lights are dimmed, turn the

knob clockwise to increase the sensi-
tivity and the lights will dim sooner.
Turn the knob the other way, and
wiper blade one or two notches to
assure clear vision.
If the unit doesn't switch to upper
beam immediately after the ap-
the lights will hold on the upper beam proaching car passes, it may simply
longer. be out of adjustment. To correct
DECREASE INCREASE Some perfectly normal road condi- the situation, follow the procedure
SENSITIVITY SENSITIVITY
tions, such as snow or fog, will cause for sensitivity and aim adjustment.
,g~'gN~
the headlights to dim even if another
car is not approaching. This is a TESTING VENTILATING
plus factor for the driver. It is far AND HEATING
safer to drive on low beam through
rain, snow and fog. Use the following procedure to
NORMAL check for malfunction of the heater
SENSITIVITY K1534-A Side lighting may cause the lights vacuum system. The procedure will
to dim. Light objects such as white determine if there are leaks, pinched
FIG. 2-Driver Control Knob picket fences, flashing traffic lights, lines or lines not connected.
billboards, and distant cars in hilly 1. Insert a vacuum ga:uge in the
AUTOMATIC HEADLIGHT country may trigger the unit. This vacuum supply line (black line) near
DIMMER high degree of sensitivity is necessary the dash connector block (See Fig.
in order for the unit to do its job 3).
DIAGNOSIS TIPS properly.
2. Set the regulator lever at the
If the headlights dim at the wrong Brightly-lighted areas (gas stations, MAX position. Set the vents-heater
distance occasionally, the car prob- intersections, or lighted streets, etc.) lever at the OFF position.
ably has been meeting cars with will dim the lights. 3. Start the engine and run it until
badly aimed headlights. at least 16 inches of vacuum is ob-
Snow or dirt on the windshield
Repeated dimming at the wrong may block the phototube. Sometimes tained. Stop the engine.
distance may be caused by the adjust- wiper blades in front of the unit 4. Record the vacuum reading. If
ment of the sensitivity control knob may block its vision. This reduces this reading decreases steadily, there
(Fig. 2). sensitivity and can cause cycling. It is a leak in the check valve or the
If oncoming cars are blinking be- may be necessary to lower the right- vacuum system from the check valve
CHART 1-Heater Vacuum Line Operation (Regulator Lever at MAX)

Amount Air Door Position
Vents-Heater Vacuum
Of Vacuum (Doors with no vacuum
Lever Position To Line
In Line applied are closed)*
Black-Blue Stripe 14 Inches Outside Air Closed

R-L Black-Green Stripe Mercury Left Vent Open
Black-Orange Stripe Minimum Right Vent Open

R Black-Orange Stripe Mercury
Right Vent Open
Minimum

L Black-Green Stripe Mercury Left Vent Open
Minimum
14 Inches
OFF Black-Blue Stripe Mercury Outside Air Closed
Minimum
Black-Red Stripe 14 Inches Outside Air Open

HEAT Black-Brown Stripe Mercury Heater Water Valve Open
Minimum
F Black-White Stripe 14 Inches Defroster Open

DE-ICE Black-Red Stripe Mercury Outside Air Open
Black-Brown Stripe Minimum Heater Water Valve Open
*Some air is bled by the defrost-heat door in both closed positions.

(299) PART 16-1- GENERAL VENTILATING, HEATING, AND ACCESSORIES SERVICE 16-5
to the vents-heater control (Refer CHART 2-Vacuum Drop vs. Vents-Heater Lever Position
to Fig. 3).
Vents-Heater Vacuum Drop
5. Move the vents-heater control Lever Movement Inches of Mercury
lever to the positions shown in Chart
2, observe the drop in vacuum on OFF to HEAT 0.75-3.0
the gauge. Repeat steps 3 and 4 be- 0.25-2.5
HEAT to DE-ICE
tween each lever movement to bring
DE-ICE to HEAT 0-1.5
the vacuum back to 16 inches.
HEAT to OFF 0.5-3.0
6. If any vacuum drop is Jess than OFF to L 0.25-2.0
indicated, check for pinched lines,
L toR 0.25-2.0
plugged lines, plugged fittings, or
R to R-L 0.25-2.0
partial cycle due to a binding door.
If any vacuum drop is greater than
that indicated, check for leaks, lines
not connected, or defective compo- leaks, pinched lines or lines not con- 4. Record the vacuum reading. If
nents. nected. this reading decreases steadily, there
If a single vacuum actuator is mal- is a leak in the check valve or the
1. Insert a vacuum gauge in the
functioning, check the vacuum at vacuum system from the check valve
vacuum supply line (black line) near
the actuator (Chart 1 ) . If the vac- to the vents-heater control (Refer to
:he dash connector block (Refer to
uum is within limits, the actuator Fig. 4).
Fig. 4).
is defective or the door is hinding.
2. Set the regulator lever at the 5. Move the vents-heater control
AIR CONDITIONING MAX position. Set the vents-heater lever to the positions shown in Chart
Use the following procedure to lever at the OFF position. 4, observe the drop in vacuum on the
check for malfunction of the heater- 3. Start the engine and run it until gauge. Repeat steps 3 and 4 between
air conditioner vacuum system. The ..tt least 16 inches of vacuum is ob- each lever movement to bring the
procedure will determine if there are tained. Stop the engine. vacuum back to 16 inches.
TO CARBURETOR VACUUM
RESERVOIR.
TANK
TUBING COLOR CODE
B-BR BLACK-BROWN
STRIPE
B BLACK
B-BL BLACK-BLUE STRIPE
( B-R BLACK-RED STRIPE
GR GRAY
B-0 BLACK-ORANGE STRIPE
B-G BLACK-GREEN STRIPE
B- W BLACK- WHITE-STRIPE
DASH-CONNECTOR
BLOCK RIGHT VENT
DUCT
CONNECTOR
K1377-B
FIG. 3-Heater-Va,uum Line Connedions

TUBING COLOR CODE

B-GR-BlACK-GRAY STRIPE TO CARBURETOR
VACUUM RESERVE
B-R-BLACK-RED STRIPE
TANK
B-BL-BLACK-BLUE STRIPE
B-BR-BLACK-BROWN STRIPE
B-BLACK
B-G-BLACK-GREEN STRIPE B FRESH AIR BLEED CRANK
B-0-BLACK-ORANGE STRIPE
B- W -BLACK- WHITE STRIPE
B-P-BLACK-PINK STRIPE FRESH AIR
B-T-BLACK-TAN STRIPE DOOR
B-Y-BLACK-YELLOW B-BR
DASH CONNECTOR•
BLOCK :
,j~d~~~~~B~-~P~~~~~~~§~~~F=3:1--"
B-W--__.
RIGHT VENT
DUCT
..rt:===+~l-+=~:--t-i :::5Jl__ ASSEMBLY

EVAPORATOR
'--=i~~+-.-:=.1
"T" CONNECTOR_..,..____ "T" CONNECTOR

EVAPORATOR SHUTTER
THERMOSTATIC SWITCH
~--<;---r- VENT (VACUUM EXHAUST)
B-G REGULATOR f'~~~--------B-0--------------------~

CONTROL
I B-G
I K-1384-B
FIG. 4-Heater-Air Conditioner-Vacuum Line Connections
CHART 3-Heater-Air Conditioner Vacuum Line Installation (Regulator Lever at MAX)

A/C Vents- Amount
heater Vacuum of Air Door Positions
Lever To Vacuum (All Doors or Valves not
Position Line In Line indicated are closed)
Black-Blue Stripe 14 Inches Outside Air Closed, Evaporator Shutters Open

REC Black-Pink Stripe Mercury Outside Air Bleed Closed
Black-Yellow Stripe Minimum Thermostatic Switch Operating
FRESH Black-White Stripe Mercury Outside- Air Bleed Open
Black-Yellow Stripe Minimum Thermostatic Switch Operating .
Black-Blue Stripe Outside Air Closed, Evaporator Shutters Open
Black-Pink Stripe 14 Inches Outside Air Bleed Closed
R-L Mercury
Black-Green Stripe Left Vent Open
R Black-Pink Stripe Mercury Outside Air Bleed Closed
L Black-Pink Stripe Mercury Outside Air Bleed Closed
Black-Green Stripe Minimum Left Vent Open
14 Inches
Black-Blue Stripe Outside Air Closed, Evaporator Shutters Open
OFF Mercury
Black-Pink Stripe Outside Air Bleed Closed
Minimum
Black-Brown Stripe 14 Inches Heater Water Valve Open
HEAT Black-Red Stripe Mercury Outside Air Open, Evaporator Shutters Closed
Black-Tan Stripe Minimum Toe Board Heat Open
14 Inches
Black-Brown Stripe Heater Water Valve Open
DE-ICE Mercury
Black-Red Stripe Outside Air Open, Evaporator Shutters Closed
Minimum

(301} PART 16-1-GENERAL VENTILATING, HEATING, AND ACCESSORIES SERVICE 16-7
CHART 4- Va(uum Drop vs. Vents-Heater Lever Position moving small traces of refrigerant
vapor.
Vents-Heater Vacuum Drop
Lever Movement Inches of Mercury SPEED CONTROL
DE-ICE to HEAT 0.25-2.5 PERFORMANCE CHECKS •
HEAT to OFF 2.5-5.5 After servicing the speed control

unit, the car should be road tested
OFF to L 0.25-2.0
for proper operation of the speed
L toR 0.25-2.0
control in both the manual and auto-
R to R-L 0.25-2.0 matic control positions. The speed
R-L to FRESH 0.5-3.0 control unit cannot be tested with
FRESH to REC 0.25-2.5 the car on a hoist or jack.
MANUAL OPERATION
6. If any vacuum drop is less than Hold the open end of the hose at 1. Set the selector dial for any
indicated, check for pinched lines, each suspected leak point for two or desired speed.
plugged lines, plugged fittings, or par- three seconds. The flame will nor·· 2. With the car in motion, a resist-
tial cycle due to a binding door. mally be almost colorless. The slight·· ance should be felt at the accelerator
If any vacuum is greater than that est leak will be indicated by a bright pedal when the pre-selected speed
indicated, check for leaks, lines not color to the flame. Be sure to check is reached.
connected, or defective components. the manifold gauge set and hoses for
leaks as well as the rest of the sys-· 3. Drive while holding the accel-
If a single vacuum actuator is mal- erator pedal against the back pres-
functioning, check the vacuum at the tern.
sure. The car should maintain a con-
actuator (Chart 3). If the vacuum stant speed at the selected setting even
If the surrounding air is per-·
is within limits, the actuator is de- when traveling up or down hills.
fective or the door is binding. meated with refrigerant gas, the
leak detector will indicate this gas 4. Push through the accelerator
all the time. Good ventilation is resistance to increase car speed
CHECKING FOR LEAKS
necessary to prevent this situa- above the speed control selector set-
Attach the manifold gauge set tion. A fan, even in a well venti- ting. The resistance should continue
(Fig. 5). Leave both manifold gauge lated area, is very helpful in reat all speeds above the pre-set speed.
valves at the maximum clock wise
position. Set both service valves at
the center position. Both gauges should
now show approximately 60 to 80
pounds prEJssure at 7 5o F. lf very
little or no pressure is indicated, leave
the vacuum pump valve closed, open
the Refrigerant-12 tank valve, and
set the low pressure manifold gauge
valve to the counterclockwise posi-
tion. This opens the system to tank
pressure.
Check all connections, and the
compressor shaft seal for leaks, using
a flame type leak detector (Fig. 6).
Follow the directions with the leak
detector. The smaller the flame the
more sensitive it is to leaks. There-
fore to insure accurate leak indica-
tion keep the flame as small as
TO LOW
possible. The copper element must be SERVICE VALVE
K1543-A
red hot. If it is burned away, replace
the element. FIG. 5-Manifold Gauge Set

5. Check to see if the selected car

speed can be increased or decreased
at any time by turning the selector
dial. The accelerator pedal must be
held against the back pressure dur-
ing this test.
AUTOMATIC OPERATION
Before road testing the car for

automatic operation, the speed con-
trol system should be tested for can-
cellation when the brake pedal is
depressed.
1. Turn the igmt10n switch to the
FIG. 6- Testing for Leaks ACC position.
2. Press the accelerator pedal to
the floor. Push the slide switch to
LOCK.
TURN ON HEADLAMPS, AND LET UNIT WARM-UP FOR ABOUT 3. Release the slide switch, and
30 SECONDS. COVER THE PHOTOTUIE UNIT WITH A DARK
CLOTH. OPERATE FOOTSWITCH. accelerator pedal. The speed control
should hold the accelerator pedal in
the full throttle position.
4. Depress the brake pedal 14-
inch. The accelerator pedal should
IF HEADlAMPS STAY ON LOWER BEAM, POSITION AMPLIFIER
''HOLD" CONTROL IN APPROXIMATE CENTEROF ITS TRAVEL. return to the normal position.
THIS WILL ELIMINATE THE POSSIBILTY OF LOCKING HEAD-
LAMPS ON LOW BEAM DUE TO COMPLETE MISADJUSTMENT.
IF HEAOLAMPS REMAIN ON LOWER BEAM WHEN PHOTO.
5. Road test the car and set the
TUBE IS AGAIN COVERED, CHECK THE FOLLOWING. selector knob to any desired speed.
6. When the pre-set speed is
reached, hold the accelerator pedal
against the resistance and push the
DISCONNECT THE PHOTOTUII UNIT HARNESS FROM THE slide switch to LOCK. The car should
AMPLIFIER- OPERATE FOOTSWITCH.
now be automatically controlled and
maintain the selected speed.
7. Test to see if the speed can be
increased or decreased by turning
the dial.
If HEADLAMPS REMAIN ON LOWER BEAM, TROUBLE IS IN
AMPLIFIER UNIT OR FOOTSWITCH. 8. Again test to see if the auto-
matic speed control cancels by lightly
depressing the brake pedal or by
turning the ignition switch to the
OFF position. It is not necessary
to change the speed setting when
INSTAU A NEW FOOTSWITCH. OPERATE FOOTSWITCH.
re-engaging the automatic speed
control. It can only be engaged
when the selected speed is reached
and the accelerator pedal is held
against the resistance pressure
IF HEADLAMPS REMAIN ON LOW BEAM, REMOVE THE
IF HEADLAMPS SWITCH FROM LOWER BEf.M TO
UPPER BEAM, TROUBLE WAS IN FOOTSWITCH. AMPLIFIER ONLY FOR REPAIR.
when the slide switch is pushed
to LOCK.
Kl 540-A
9. Disengage the unit by moving
FIG. 1- Trouble Shooting-Locked on Low Beam the switch to the OFF position.

(303) PART 16-1-GENERAL VENTILATING, HEATING, AND ACCESSORIES SERVICE 16-9
AUTOMATIC HEADLIGHT LOCKED ON IIIPPU HAM
DIMMER
PRELIMINARY TEST
1. Turn the headlamps to the full
ON position. (Allow about 30 sec-
onds for the headlight dimmer to
warm up.) With the car in a lighted
area, the lights should be on low-
beam regardless of the position of
the foot switch. (If upper-beam is
obtained in one position of the foot ·; HEAOlAMPS SWITCH TO LOWER BEAM,
switch, check the fuse.) rROUBLE IS IN PHOTOTUBE UNIT. REMOVE
BOTH THE PHOTOTUBE AND AMPLIFIER
[ I'OR REPAIR.
2. Depress the foot switch about ------------------~
Yx -inch to the detent. The lights
should change to the upper-beam
and then change back to the lower-
beam when the foot switch is re-
leased, if the foot switch is in the
Automatic position. If not. cycle
the foot switch to obtain the auto-
IF OPERATION OF SOTH UPPER AND LOWER
matic position. BEAM IS OBTAINED, TROUBLE IS IN AMPLIFIER
UNIT. REMOVE ONLY THE AMPLIFIER FOR
REPAIR.
3. Place a hand or a dark cloth
over the phototube unit. The lights
should switch to the upper-beam.
Remove the cloth or hand. The lights NOOVU.RIDI
should change back to the lower-
beam. (The unit will not go to upper-
beam if the phototubc unit tempera- PLACE FOOTSWITCH IN AUTOMATIC POSJnON,
ture is above 90° F. Therefore, check UNCOVER THE PHOTOTUBE UNIT. DISCONNECT
AND GROUND THE RED WIRE AT THE FOOT-
to see if the phototube is hot. If it SWITCH
is, allow it to cool and repeat the

above checks.)
If the headlights operate as ex-
plained in steps 1, 2, and 3, the de-
vice should operate correctly with
the proper aiming and sensitivity ad-
justments. If the lights do not operate K1541-A.
as described in the above steps, refer
to Figs. 7 and 8. FIG. 8- Trouble Shooting-Lotked on Upper Beam or No Over-Ride
EJ COMMON ADJUSTMENTS AND REPAIRS (NOT APPLICABLE)
SEE IN-CAR ADJUSTMENTS

AND REPAIRS (PART 16-2)

VENTILATING AND HEATING i:--. removed, make certain the cable key in the shaft.
cl.m1p and the battery terminal post When the compressor is disassem-
When installing a new vents-heater '' r,. clean and dry before assembly. bled, completely clean all gasket sur-
valve or a regulator valve, inspect for faces of shreds and foreign objects.
dirt cllld foreign objects. Aho, check AIR CONDITIONING If the compressor shaft seal is
to be sure the vacuum hoses arc On a compressor dutch installa- being replaced, inspect the compres-
clean and not pinched or cracked. tliln, carefully remove any burrs or sor internally and clean out dirt or
Be sure the pointer is not bent or d 1 rt that may be on the compressor chips as required.
rubbing. skdt. The shaft must he dry and Sec also ventilating and heating,
Whenever the battery ground cable t~r rghtly polished. Then install the this section.

insert a flattened I/s -inch diameter

rod (Fig. 10) in the oil filler hole
until it bottoms. The rod should show
%-inch of oil. This is equivalent to
NOTE:
9 ounces of oil. It may be necessary
OIL TO BE CHECKED WITH
to rotate the compressor crankshaft KEYWAY IN SHAFT FACING
slightly (by hand) so that the dip rod THE HEAD OF THE COMPRESSOR
will clear the crankshaft. If addi-
tional oil is needed in the compressor,
add Suniso 5 or Capella E refrigera-
tor compressor oil, or equivalent.
If more than Vs -inch of oil is in-
dicated, as might happen if a new
compressor is installed and oil al-
ready in the system is pumped back
to the compressor, draw out the ex-
cess oil until the proper quantity is
K1544-A indicated.
Replace the oil filler plug, and
FIG. 9-Checking then evacuate and connect the com-
Compressor Oil Level pressor back into the system. Be sure
to check the compressor filler open-
COMPRESSOR OIL LEVEL ing for leaks.
CHECK
Under normal conditions, when the CHECKING SYSTEM
air cooling system is operating sat- PRESSURES
isfactorily, the compressor oil level
need not be checked. There is no
The pressures developed on the
high pressure and low pressure side
FIG. 10-Compressor
place for the oil to go except in- of the compressor indicate whether Oil Level Dip Sti'k
side the scaled system. When the car or not the system is operating prop-
is first started, some of the oil will erly. give higher system pressures. The
he pumped into the rest of the sys- lowest figures given are for an am-
Attach the manifold gauge set
tem. After 15 minutes of operation, bient (surrounding air) temperature
(Fig. 5). It will not be necessary to
most of the oil is returned to the of 75o F., 50% relative humidity.
attach the Refrigerant-12 tank unless
compressor crankcase.
Check the compressor oil level refrigerant is to be added to the sys- The low pressure gauge should in-
tem. Set both manifold gauge valves dicate a pressure of from 12-50
only if a portion of the refrigerant
at the maximum clockwise, or closed, pounds. The high pressure gauge
system is being replaced, or if
position. Set both service valves at should indicate a pressure six or
there was a leak in the system
the center position. seven times the low pressure, or 80-
and the refrigerant is being re-
Check the system pressures with 300 pounds.
placed.
Check the oil after the system has the engine running at 1500 rpm, all At idle speed and a surrounding
been charged and has been operating controls set for maximum cooling, air temperature of 100°-110° F.,
at an engine speed of 1500 rpm for and the front of the car at least the high pressure may go as high
15 minutes in 60° F. surrounding air five feet from any wall. as 300 pounds or more. If ·it be-
temperature or above. Turn off the The actual pressures indicated on comes necessary to operate the air
engine, and isolate the compressor. the gauges wi1l depend on the temp- conditioner under these conditions,
(See In-Car Adjustments and Repairs. erature of the surrounding air and keep the high pressure down with
Part 16-2.) Remove the oil fi11er the humidity. Higher air tempera- a fan directed at the condenser and
plug from the compressor (Fig. 9), tures along with low humidity, will radiator.

(305) 16-11
PART VENTILATING AND HEATING

16-2
1 Description and Operation ......... 16-11 3 Removal and Installation ................. 16-11
2 In-Car Adjustments and Repairs. . . ........ 16-11

The heater control system incorpo- COWL OUTSIDE AIR INLET
rates two levers. The upper, or regu-
lator lever, controls the heat telil.-
perature and ventilation quantity DOOR CONTROL
from minimum to maximum. The
vents-heater lever controls the air
duct doors for outside air, heated
air and defrosting. A 4-position
INLET DOOR
blower control switch is used to give
three blower speeds for low, medium
and high volumes of air for heating
and defrosting. Fig. 1 shows the
heater installation. Some air is bled
by the defrost-heat door in both
closed positions.
A wiring diagram covering both
heating and air conditioning is shown
in Fig. 13, Part 16-3.
HEATER CORE AND WATER K1372-B

TEMPERATURE CONTROL
FIG. 1-Heater Installation
The water temperature control sys-
tem consists of a thermostat and a In operation, when the regulator the water valve, thus regulating the
water control valve. lever on the instrument panel is flow of water through the heater
The thermostat is mounted on the moved to the right for heat, vacuum core.
heater blower case and is subjected is applied to the thermostat, setting The vents-heater lever controls vac-
to discharged heater air. The Dole- the sensing element for the desired uum to the vacuum actuators to op-
type water control valve is mounted temperature. This in turn controls erate the various vent and heater
outside the heater blower case. the amount of vacuum directed to doors.

VACUUM ACTUATORS preloaded for about a 1/s -inch travel BRACKET ADJUSTMENT
of the actuator connecting link, with 1. Loosen the two vacuum motor
The vacuum actuators are adjust-
no vacuum applied. attaching screws or nuts.
able for proper air door operation.
2. Move the motor until the pre-
With no vacuum applied, adjust the Adjust the fresh air door actuator load indicator is flush with the motor
right and left fresh air vent actuators so that the door is completely closed body. The damper must be in its nor-
and the defroster actuator so that the (door arm in maximum clockwise mal position with no vacuum applied.
vent doors and defroster outlet door position) when the vents-heater lever 3. Tighten the two bracket attach-
are closed. Make these adjustments is at the OFF position (engine run- ing screws or nuts and check the
so that the actuator return spring is ning). operation of the motor.

HEATER CORE 2. Stop the engine and drain the 4. Remove the heater core mount-
coolant. Disconnect the heater core ing screws and remove the core.
REMOVAL
1. Start the engine and set the hoses. INSTALLATION
heater controls for maximum heat, 3. Remove the front cover of the 1. Place the new core in position
to open the heater water valve. heater core housing (Fig. 2). with the sponge rubber seals on each

VENTS-HEATER VALVE REGULATOR VALVE

Remove the front casting and the
REMOVAL
dial. Then remove the mounting
1. Disconnect the battery ground screws and control knobs, disconnect
cable. the vacuum hoses and remove the
2. Remove the mounting screws regulator valve.
and control knobs, and remove the
front casting and the dial. BLOWER MOTOR
..: 3. Remove the plate assembly. The blower motor, mounted in the
4. Remove the vents-heater valve blower housing on the engine side
FIG. 2-Heater Core Removal and the vacuum lines. of the dash, can be removed by dis-
connecting the motor connecting
heater core inlet tube. Install the INSTALLATION wires and ventilation tube and by re-
mounting screws. moving the mounting nuts and
2. Connect the heater core hoses. 1. Install the vacuum lines on a
new vents-heater valve, and install screws. The heater blower wiring cir-
The hose from the water valve con- cuit is shown in Fig. 3.
nects to the heater core lower inlet the valve.
pipe. 2. Install the plate assembly and
its mounting screws. BLOWER SWITCH
3. Fill the cooling system. Bleed
the system at the upper heater core 3. Install the front casting and Disconnect the battery ground
inlet pipe. dial, the mounting screws, and the cable. Remove the front casting and
4. Check for leaks. Then install control knobs. dial. Remove the plate assembly. Dis-
the core housing front cover. Check 4. Connect the battery ground connect the switch wires, and remove
the heater operation. cable. the switch.
LOCATED IN HORN
RELAY MOUNTING PLATE
, . . - - - - - - - - - T O BATIERY l+l TERMINAL r _ _/__,
20 AMP CIRCUIT BREAKER
HEATER BLOWER MOTOR
Black-Green
Black
Orange-Black
6"
I
Black
Brown
GROUND TO
FENDER APRON l.H.
~
LO POSITION
IGNITION SWITCH [QJ

MED. POSITION
HEATER SWITCH
HEATER SWITCH
Brown
K1553-A
FIG. 3-Heater Blower Wiring Circuit

(307) 16-13
PART AIR CONDITIONING

16-3
1 Description and Operation ........ 16-13 3 Removal and Installation ................. 16-16
2 In-Car Adjustments and Repairs. . . . ....... 16-14

The combined heater-air condi-
tioner incorporates two control levers. DOOR
The regulator lever controls both
heating and cooling temperature and
ventilation quantity, from minimum
to maximum. The vents-heater lever
controls the air duct doors for fresh
AIR OUTLET REGISTER
air, heated air, defrosting, cooled
recirculated air, and cooled fresh air.
The cooled fresh air is part recircu-
lated and part fresh. A 4-position
blower control switch is used to give
three blower speeds for low, medium
and high volumes of air for heating,
defrosting, and cooling. Fig. 1 shows
the heater-air conditioner installation.
Some air is bled by the defrost
doors and the toe-board heat door
when they are in their closed posi-
tions.
A wiring diagram covering both
heating and air conditioning is shown HEATER THERMOSTAT
(Fig. 13) at the end of this part of
the manual.
K1368-B
RECEIVER UNIT
The air cooling system stores the FIG. 1-Heater-Air Conditioner Installed
liquid Refrigerant-12 under pressure
in a combination receiver and dehy- ible hose to the evaporator (cooling orator outlet temperature and outlet
drator. The pressure in the receiver unit) where it is allowed to evapo- pressure.
normally varies from about 80 to rate at a reduced pressure. The evap- The restricting effect of the expan-
300 psi, depending on the surround- orator assembly is mounted on the sion valve at the evaporator causes a
ing air temperature and compressor passenger compartment side of the low pressure on the low pressure side
speed. The receiver and condenser dash. of the system of 12-50 psi, depending
comes charged and marked with the on the surrounding air temperature
total weight, so that any leak, indi- EXPANSION VALVE and compressor speed.
cated by a loss in weight, can be The rate of refrigerant evapora-
detected before assembly. tion is controlled by an expansion
The dehydrator removes any traces valve (Fig. 2) which allows only
of moisture that may have accumu- enough refrigerant to flow into the
lated in the system. Even small evaporator to keep the evaporator
amounts of moisture will cause an operating efficiently, depending on its
air cooling unit to malfunction. A heat load.
fusible plug is screwed into the re- The expansion valve consists of
ceiver. This will release the refriger- the valve and a temperature sensing
ant before the refrigerant tempera- capillary tube and bulb. The bulb
tur~ exceeds 212 o F. is clamped to the outlet pipe of the
evaporator. Thus, the valve is con-
EVAPORATOR UNIT
trolled by evaporator outlet tempera-
When the cooling system is in op- ture. An internal equalizer applies
eration, the liquid Refrigerant-12 evaporator outlet pressure to one side
flows from the combination receiver of the valve diaphragm. Thus, the FIG. 2-Expansion Valve
and dehydrator unit through a flex- valve is controlled by both evap- and Liquid Sight Glass

gas at a pressure of 12-50 psi), is the operation of the compressor by

pumped by the compressor located controlling the compressor magnetic
on the engine (Fig. 3), into the top clutch. The temperature sensing tube
of the condenser located in front of of the switch is placed in contact with
the radiator. the evaporator fins.
The compressor maintains a pres- When the temperature of the evap-
sure on its high pressure side of from orator becomes too cold, the thermo-
80-300 psi, depending on the sur- static switch opens the magnetic
rounding air temperature and com- clutch electrical circuit, disconnecting
pressor speed. the compressor from the engine.
As the now heated and compressed When the temperature of the evap-
refrigerant gas flows down through orator rises to the upper limit at
the condenser, it is cooled by air pass- which the thermostatic switch is set,
ing between the sections of the con- the thermostatic switch closes and
denser, and the cooled, compressed energizes the magnetic clutch. This
refrigerant gas condenses to liquid connects the compressor to the en-
FIG. 3-Compressor Installed refrigerant which then flows into the gine and cooling action begins again.
receiver. Before the liquid refriger- When the ignition switch is off,
ant flows on to the expansion valve, or the cooling control thermostatic
LIQUID SIGHT GLASS
it makes one more pass across the switch is in the off position, the mag-
A liquid sight glass is mounted in bottom of the condenser where it is netic clutch is not energized, and
the expansion valve (Fig. 2). The further cooled. the cooling system can not operate.
sight glass is used to check whether When the ignition switch is on
or not there is enough liquid refrig- MAGNETIC CLUTCH (engine running), and the cooling
erant in the system. Foam seen in To control the amount of cooling control is in the cooling range, the
the sight glass while the compressor that the system produces, the com- magnetic clutch is energized, the
is operating, is an indication of loss pressor is electrically cut in and compressor is connected to the en-
of refrigerant. See "Diagnosis and out of operation by the use of a mag- gine, and the cooling system is in
Testing," Part 16-1. netic clutch pulley mounted on the operation.
compressor crankshaft. The magnetic The thermostatic switch may be
COMPRESSOR UNIT clutch is controlled by a thermostatic adjusted to maintain an average
The evaporated refrigerant leaving switch which has its temperature evaporator temperature of from 30°-
w
the evaporator (now in the form of a sensing tube inserted in the fins of 600 F. (Fig. 5). The thermostatic
the evaporator core. switch operating differential tempera-
ture at any one setting is 6° F. The
SERVICE VAL YES switch is controlled by the regulator
~ERVICE
TEFLON SEALS The service valves on the compres- control.
VALVES
sor are used to test and service the
cooling system (Fig. 4). The high
pressure service valve, mounted at
the outlet to the compressor, allows
access to the high pressure side of the
system for attaching a pressure
gauge, or a servicing hose.
The low pressure valve, mounted
at the inlet to the compressor, allows
access to the low pressure side of the
system for attaching a pressure gauge,
or a servicing hose.
Both service valves may be used
to shut off the rest of the system
from the compressor during compres-
K1549-A
sor service.
K1518-A
FIG. 4-Compressor THERMOSTATIC SWITCH
Service Valves Removed The thermostatic switch controls FIG. 5- Thermostatic Switch

VACUUM ACTUATORS turn springs are prcloaded for about so that the door is completely closed
1/H inch travel of the actuator con- (door arm maximum clockwise posi-
The vacuum actuators (Fig. 2),
are adjustable for proper air door necting links, with no vacuum ap- tion) when the vents-heater lever is
operation. The single acting actuators plied. at the OFF position (engine run-
are adjusted so that the actuator re- Adjust the fresh air door actuator ning).

(309) PART 16-3-AIR CONDITIONING 16-15
To discharge the system, connect

the manifold gauge set to the system
(Fig. 5, Part 16-1). Do not connect
the manifold center connection hoses
to the Refrigerant-12 tank, or vac-
uum pump. Place the open end of
these hoses in a garage exhaust out-
let. Set the high pressure manifold
gauge valve at the maximum counter-
clockwise or open position. Open the
high pressure service valve a slight
amount (Fig. 7), and allow the re-
frigerant to discharge slowly from
the system.
Do not allow the refrigerant to
rush out, as the oil in the compres-
sor will be forced out along with it.
CHARGING THE SYSTEM

The procedure for charging de-
FIG. 6- Low Pressure pends on whether a partial charge or FIG. 7-High Pressure
Service Valve Gouge Port a complete charge is being made. Service Valve Gauge Port
When a complete charge is to be
Adjust the fresh air bleed crank made, check for leaks first (See gauge reads at least 25 inches, and as
so that the fresh air door is com- "Diagnosis and Testing," Part 16-1 ) ,
close to 30 inches of vacuum as pos-
pletely closed when the vents-heater then release the pressure and evac:u-
sible. Continue vacuum pump opera-
lever is at the OFF position (engine ate the system.
tion for 20 to 30 minutes to boil any
running). moisture out of the system. Close the
EVACUATING THE SYSTEM
Adjust the evaporator shutter so pump valve. Turn off the pump.
that the shutter is completely open Attach the manifold gauge set, a
when the vents-heater control is at tank of Refrigerant-12 and a vacuum
pump to the system (Fig. 8). Make MAKING A PARTIAL CHARGE
the REC position. Also see bracket
adjustment instructions under ''Venti- certain that the Refrigerant-12 tank Attach the manifold gauge set.
lating and Heating." valve is tightly closed. Set both serv- Open both manifold valves. Close
ice valves to the mid-position. Open the vacuum pump valve. Open the
both manifold valves (Fig. 8). Re- Regfrigerant-12 tank valve. Purge
ISOLATING THE COMPRESSOR
lease any pressure in the system. the air from the high pressure hose
To isolate the compressor from the Open the vacuum pump valve and by loosening the high pressure hose
system, turn both the high and the run the pump until the low pressure at the service valve for a few sec-
low pressure service valves to the ex-
treme clockwise position (Figs. 6 and LOW PRESSURE SERVICE VALVE CENTERED
7). Loosen the cap on the high

pressure service valve gauge port,
and allo~ the gas to escape until the
compressor is relieved of refrigerant
pressure.
Loosen the cap a small amount
only, and do not remove it until
the pressure is completely relieved.
To connect the compressor back
into the system, evacuate the com-
pressor at the high pressure service
valve gauge port, close the vacuum
pump valve, turn both service valves
to the maximum counterclockwise
position, and cap the high pressure
service valve gauge port and service
valve stems.
DISCHARGING THE SYSTEM

Discharge the refrigerant from the
system. except the compressor. be~ HIGH PRESSURE VALVE CLOSED K1545-A
fore replacing any part of the sys-
tem. FIG. 8-Evacuating the System

onds. Tighten the connections and VALVE OPEN ONE TURN

set the high pressure manifold gauge
valve at the maximum clockwise
position. Loosen the low pressure
gauge hose slightly at the low pres-
sure service valve, for a few seconds,
to purge the air from the hose. Tight-
en the connection. Set both service
Refrigerant T
valves at the center position (Fig. 9).
Run the engine at 1500 rpm with
all controls at the maximum cold
position. Charge the system until all
foam disappears from the sight glass,
then add 1;2 -pound of Refrigerant-12.
Shut the Refrigerant-12 tank valve.
It may be necessary to place the
Refrigerant-12 tank in a container
of hot water at about 150° F. to force
the gas from the tank during charg-
ing.
Never heat the Refrigerant-12
tank with a torch. A dangerous
explosion may result.
Set both service valves at the maxi-
mum counterclockwise position. Re-
move the gauge set, and cap the serv-
ice valve gauge ports and valve stem.
MAKING A COMPLETE CHARGE

Check for leaks first (See "Diag-
nosis and Testing," Part 16-1), re-
lease the pressure, then evacuate the
system. Leave both service valves at FIG. 9-Charging the Air Conditioning System
the mid-position and the vacuum
pump valve closed. Leave the low After the proper charge has been ating and charging the system as
pressure manifold gauge valve at the made, close the Refrigerant-12 tank previously given.
maximum counterclockwise or open valve, and check the system pres- For charging, attach a one pound
position. Set the high pressure mani- sures for proper operation. Set both can of Refrigerant-12 to the special
fold gauge valve at the maximum service valves at the maximum coun- valve, and open the valve. Keep the
clockwise or closed position. Set all terclockwise position. Remove the can in an upright position. When
controls to the maximum cold posi- gauge set, and cap the service valve the can is empty (no frost showing) ,
tion. gauge ports and valve stems. close the valve, remove the empty
Open the Refrigerant-12 tank can, attach a new one, and open
valve. Run the engine at 1500 rpm. CHARGING FROM SMALL the valve again.
Charge the system until 2V:z-pounds CONTAINERS Allow only Yz of the third can of
of refrigerant have been weighed refrigerant to be pumped into the
into it. During the charging, the high Refrigerant-12 is available in one system by closing the valve at the
pressure may build up to an exces- pound cans. A scale is not necessary can when the frost line has reached
sive value. This can be caused by if these small containers are used V:z way down the can. The system
an overcharge of refrigerant, or an instead of a tank. will then have been charged with
overheated engine, in combination Attach the hose, that would nor- 2112 -pounds of refrigerant.
with high surrounding temperatures. mally go to the large tank, to the Check the system pressures, set
Never allow the high pressure to special valve that is provided for the both service valves at the maximum
exceed 240-pounds while charging. small cans. Close the valve (maxi- counterclockwise position. Remove
Stop the engine, determine the cause, mum clockwise position) and follow the gauge set, and cap the service
and correct it. the procedure for leak testing, evacu- valve gauge ports and valve stems.

AIR CONDITIONING plosive, noninflammable, noncorro- teet the parts involved and the person
sive, has practically no odor, and is who is working on the unit.
SAFETY PRECAUTIONS
heavier than air. Although it is clas- Use only Refrigerant-12.
Refrigerant- I 2, which is used in sified as a safe refrigerant, certain At normal atmospheric pressures
the air conditioner system, is nonex- precautions must be observed to pro- and temperatures, liquid Refrigerant-

(311) PART 16-3- AIR CONDITIONING 16-17
12 evaporates so quickly that it tends gas into the cooling unit, always 13. Disconnect the right and left
to freeze anything that it contacts. keep the tank in an upright position. defroster hoses at the evaporator.
For this reason, extreme care must If the tank is on its side or upside 14. Disconnect the right and left
be taken to prevent any liquid re- down, liquid Refrigerant-12 will register hoses at the evaporator.
frigerant from coming in contact enter the system and damage the 15. Disconnect both center register
with the skin and especially the eyes. compressor. In surrounding air hoses at the instrument panel.
Refrigerant-12 is readily absorbed temperatures above 90°F., pro- 16. Remove five screws just back
by most types of oil. It is therefore longed engine idle will result in of windshield.
recommended that a bottle of sterile excessively high compressor pres- 17. Remove four vertical bolts,
mineral oil and a quantity of weak sures. two at steering column, the other
boric acid solution be kept nearby two at outer ends of instrument
when servicing the air conditioning EVAPORATOR panel.
system. Should any liquid refrigerant 18. Pull instrument panel back to
REMOVAL allow clearance for removal of evap-
get into the eyes, use a few drops of
mineral oil to wash them out, and 1. Disconnect the battery ground orator.
then wash the eyes clean with the cable. 19. Remove evaporator mounting
weak boric acid solution. Seek a 2. Remove the carburetor air screws and remove the evaporator.
doctor's aid immediately even though cleaner.
3. Discharge the refrigerant into INSTALLATION
irritation may have ceased.
Always wear safety goggles when the garage exhaust system. 1. Position the evaporator to the
servicing any part of the refriger- 4. Disconnect the refrigerant lines dash and drive the mounting screws.
ating system. from the evaporator, and remove the 2. Reposition instrument panel
The Refrigerant-12 in the system is expansion valve (Fig. 10). and install the four vertical bolts.
always under pressure. Because the 5. Disconect the vacuum lines 3. Drive the five screws which
system is tightly sealed, heat applied at the junction block. attach the instrument panel just back
to any part would cause this pressure 6. Disconnect the wires from the of the windshield.
to build up excessively. thermostatic switch. 4. Connect both center register
To avoid a dangerous explosion, 7. Remove the instrument panel hoses to the instrument panel.
never weld, use a blow torch, insulation board (See Group 15). 5. Connect the right and left reg-
solder, steam clean, bake body 8. Remove the sun visor mount- ister hoses to the evaporator.
finishes, or use any excessive ing brackets. 6. Connect the right and left de-
amount of heat on, or in the imme- 9. Remove the corner post garnish froster hoses to the evaporator.
diate area of, any part of the air moulding. 7. Position the upper section of
cooling system or refrigerant sup- 10. Remove the five screws re- the instrument panel such that the
ply tank, while they are closed taining the upper section of the phototubes unit plug can be con-
to the atmosphere whether filled instrument panel. Carefully lift the nected to the amplifier, and make the
with refrigerant or not. rear end of the panel and slide it connection.
away from the windshield. 8. Carefully slide the panel to the
The liquid refrigerant evaporates
11. Disconnect the phototube unit correct position and drive the five
so rapidly that the resulting refriger-
plug from the amplifier of the auto- retaining screws.
ant gas will displace the air sur-
matic headlight dimmer. 9. Install the instrument panel in-
rounding the area where the refrig-
12. Remove the upper panel. sulation board (See Group 15).
erant is released. To prevent possible
suffocation in enclosed areas, always
RECIRCULATING DOOR
discharge the refrigerant from an air EXPANSION VALVE WINDSHIELD WIPER MOTOR
cooling system into the garage ex-
haust collector. Always maintain
good ventilation surrounding the
work area. If the car is to be under-
coated, make certain that the un-
dercoating does not plug the
evaporator drain tubes.
Although Refrigerant-12 gas, un-
der normal conditions, is non-poison-
ous, the discharge of refrigerant
gas near an open flame can produce
a very poisonous gas. This gas will
also attack all bright metal surfaces.
This poisonous gas is generated in
small quantities when the flame-type
leak detector is used. A void inhaling
the fumes from the leak detector.
Make certain that Refrigerant-12
is both stored and installed in
accordance with all state and local AIR BLEED DOOR VACUUM ACTUATOR TO RECEIVER K1359-B
ordinances.
When admitting Refrigerant - 12 FIG. 10-Evoporotor Refrigerant Line Connections

16-18 GROUP 16~VENTILATING, HEATING, AND ACCESSORIES (312)
COMPRESSOR INSTALLATION
REMOVAL Before installing the compressor,
see Cleaning and Inspection - Air
1. Isolate the compressor (See In- Conditioning (Part 16-1).
Car Adjustments and Repairs) and 1. Mount the clutch on the shaft
disconnect the two service valves and and install the mounting screw and
hoses from the compressor (Fig. washer, finger-tight.
4).
2. Place the compressor on the
2. Energize the clutch and loosen mounting bracket and install the four
and remove the clutch mounting mounting bolts, finger-tight.
bolt. 3. Connect the clutch wire, ener-
3. Install a % -11 inch bolt in the gize the clutch and torque the clutch
clutch drive shaft hole. With the mounting bolt to specifications. If
clutch still energized, tighten the bolt the new compressor was shipped
to loosen the clutch from the shaft. with a bolt and washer in the end
Disconnect the clutch wire at the of the crankshaft, remove and dis-
K1385-B bullet connector. card the bolt and use a bolt with a
nylon insert in it.
FIG. 11-Evaporator 4. Loosen the muffler bracket at-
taching bolt, located below the 4. Install and adjust the drive belt,
Shutter Actuator muffler. and tighten the mounting bolts to
specifications. Do not exceed torque
10. Connect the wires to the ther- 5. Loosen the compressor mount- specifications as misalignment can
mostatic switch. ing bolts. Slide the compressor result.
toward the center of the engine, 5. Install the service valves on
ll. Connect the vacuum lines at remove the drive belt and the clutch,
the junction block. the compressor using new gaskets.
and then remove the mounting bolts
12. Install the expansion -valve Tighten the service valve flared nuts
and the compressor.
and connect the refrigerant lines. to specifications. Do not over-tight-
13. Charge the system. (See In- 6. With the compressor on the en the flared nuts. The new ROTO-
Car Adjustments and Repairs.) As work bench, remove the key from LOK service valves can be rotated
there will 'be no pressure in the sys- the shaft. slightly on their seat without
tem to begin with, be sure to check
SERVICE VALVE GASKET
for leaks after charging the system.
14. Install the carburetor air
cleaner. SERVICE VALVE
cable.
16. Operate and test the air condi- CYLINDER HEAD
tioner.
PLATE-TO-HEAD GASKET
EVAPORATOR CORE
Remove the evaporator assembly
from the car, and remove the air
deflector plate. Disconnect the evap-
orator shutter vacuum actuator and
remove the evaporator shutter. Re-
move the evaporator core mounting PLATE-TO-BODY GASKET
screws and remove the evaporator
core.
Install the new core in the hous- CRANKCASE BODY
ing. Install the evaporator shutters

and connect the actuator arm. In-
stall the air deflector, and insta11
the evaporator assembly in the car.
EVAPORATOR
SHUTTER ACTUATOR BASE PLATE GASKET
The evaporator shutter vacuum

actuator is mounted inside the evapo-
rator housing (Fig. 11). To remove
and install, remove the blower hous-
ing and the access plate on the
engine side of the dash panel. FIG. 12- York Compressor Assembly

(313) PART 16-3- AIR CONDITIONING 16-19
breaking the high pressure seal. valve plate from the top of the com- Installation
This is not an indication of a loose pressor body (Fig. 12). Do not tap
valve. or hit the aluminum head with any 1. Starting with the valve plate
6. Tighten the muffler bracket at- hard tool, as damage could result. gasket, assemble the parts in the
taching bolt. order shown in Fig. 12. Insert the
3. Remove and discard all gaskets, cylinder head bolts carefully to
7. Leak test the compressor, then
evacuate it and connect it hack into and be sure to clean gasket shreds avoid damaging the gaskets .• Before
from all gasket surfaces. assembly, apply a film of new re-
the system.
8. Check the oil level in the com- frigeration oil to both sides of both
4. Examine the cylinders and top
pressor and add or remove oil if gaskets.
of the pistons, particularly in case
necessary. Sec Cleaning and Inspec- of valve breakage. If there are score 2. Tighten all bolts finger tight,
tion, Part 16-1. and then torque the bolts a quarter
marks, replace the compressor as-
turn at a time to specifications. Do
sembly.
this by tightening the service valve
COMPRESSOR COMPONENTS 5. lf the cylinders and pistons are bolts first. Then tighten the remain-
All compressor removal and instal- in good condition, check the valve ing bolts in a sequence so those diag-
lation operations, except belt re- plate and valve leaves for damage. onally opposite are evenly drawn to
placement, can be performed only If the valve assembly is in good the required torque.
after the unit has been isolated from condition, it can be used again. If 3. Connect the compressor into
the rest of the system. Sec In-Car the valve plate is damaged, install the system.
Adjustments and Repairs. the entire replacement kit which 4. Check the oil level in the com-
includes the valve plate, valve pressor, and add or remove oil if
leaves, and the two gaskets (Fig. necessary. See Cleaning and Inspec-
VALVE PLATE 12). tion, Part 16-1.
Removal 6. When the valve plate assembly BELT
is re-used, wash it in clean solvent REMOVAL AND
1. Isolate the compressor and dis-
and dry in dry air. INSTALLATION
connect the service valves. Remove
the twelve head bolts. 7. Check the oil for dirt. If the 1. Loosen the four compressor
2. Remove the cylinder head and system is not clean, replace the oil. mounting bo1ts, and slide the com-
r - - - - - . . - . - - T O BATTERY ( i) TERMINAL
~SlARTER RElAY
Orange ll!ack
Black 20 AMP
\ BLOWER MOTOR CIRCUIT BREAKER
\ LOCATED IN
AMMETER FUSE PANEL
J~
Black
Black
GROUND TO
FENDER APRON
L.H.
Black
HEATER SWITCH IN
Black LO POSITION
Green
A/C SWITCH IN
SPLICE OFF POSITION
Red-Black
~
~
~
~
HEATER A/C
SWITCH
Green HEATER SWITCH IN
MEDIUM POSITION
HEATER A/C SWITCH A/C SWITCH IN
Black Black OFF POSITION
BLUE CONNECTOR Brown
K-1517-A
FIG. 13-Wiring Diagram Heater and Air Conditioner

pressor toward the center of the car 2. Remove the clutch and remove 3. Torque the bolts to specifica-
to remove the belt. the Woodruff key. tions.
2. Place the new belt in p·osition, 3. Remove the seal plate bolts, 4. Make certain that there are
and slide the compressor toward the and remove the plate and gasket. Do no burrs or dirt on the compressor
outside of the car and tighten the not mar the sealing surfaces, or the shaft. Then install the key, the belt,
four mounting bolts. polished shaft surface. and the clutch.
3. Adjust the belt tension to 4. Remove the carbon seal ring 5. Install the new base plate gas-
specifications. and seal housing assembly from the ket and install the base plate. Add
crankshaft. A disassembled view of new compressor oil to specifications.
CLUTCH See Cleaning and Inspection, Part
the crankshaft seal assembly is in-
REMOVAL AND cluded in Fig. 12. 16-1.
INSTALLATION 6. Install the compressor.
5. Remove the base plate and in- 7. Adjust the belt tension to speci-
1. Energize the clutch and loosen spect internal compressor for for-
and remove the clutch mounting fications.
eign particles. Clean out as required.
bolts. 6. Clean all old gasket material
2. Install a S/s -11 inch bolt in the HEATER CORE, REGULATOR
from the seal plate and the compres- VALVE, AND VENTS-
clutch drive shaft hole. With the sor. Make certain that the shaft, HEATER VALVE
clutch still energized, tighten the bolt the seal plate and the compressor
to loosen the clutch from the shaft, For removal and installation, fol-
gasket surfaces are completely clean
then remove the magnetic clutch. before installing the new seal. low the procedures given in the
3. Install the clutch, the dutch heater section of this manual.
mounting bolt, and the washer.
INSTALLATION BLOWER MOTOR
4. Energize the clutch, and torque
the bolt to specifications. 1. Lubricate the new shaft seal The blower motor is mounted in
parts in clean compressor oil. Posi- the blower housing on the engine
CRANKSHAFT SEAL
tion the seal assembly on the crank- compartment side of the dash (Fig. 1).
REMOVAL shaft, with the carbon ring toward The motor is removed by disconnect-
1. Isolate the compressor, and the seal plate. ing the motor connecting wires and
remove from the car. See In-Car 2. Position the new gasket on the ventilation tube, then removing the
Adjustments and Repairs. compressor and install the seal plate. mounting nuts and screws.

(315) 16-21
PART RADIO
Section Page
1 Description and Operation ................ 16-21
2 In-Car Adjustments and Repairs ............ 16-21
16-4 3 Removal and Installation ................. 16-21

An AM and an AM/FM radio are antenna is mounted on the right front speaker are used. Figs. 1 and
available for 1964. Both radios have fender. The antenna switch is located 3 show the radio schematic diagrams.
push button tuning as well as man- under the rear edge center of the
ual tuning. An electrically operated crash pad. A rear seat speaker and a

PUSH BUTTON ing knob. The station is correctly buttons that shift from the correct
ADJUSTMENT tuned in when the clearest tone is tuning point.
heard. Carefully push the button in On the AM/FM radio push one
Turn the radio on. Pull out the all the way, then release it. AM button all the way in before ad-
desired push button and reduce the Adjust the remaining buttons and justing the AM buttons. Push one
volume to a low value. Tune in the check all the positions for repeat ac- FM button all the way in before
desired station with the manual tun- curacy. Repeat the procedure for any adjusting the FM buttons.
EIREMOVAL AND INSTALLATION

RADIO power lead and antenna lead to the 5. Place the upper front instru-
radio and insert the radio into the ment panel in position, connect the
REMOVAL instrument panel. photo tube lead and insta11 the panel
1. Disconnect the battery ground 2. Install the upper mounting bolt mounting screws.
cable. to the radio through the upper in- 6. Install the center instrument
2. Remove the radio control strument panel. panel bezel.
knobs, and the heater control knobs. 3. Install the mounting plate on 7. Install the heater and radio con-
3. Remove the 7 upper screws from the face of the radio and the in- trol knobs.
the instrument panel reinforcement strument panel. 8. Install the right and left wind-
bracket. Remove the 5 upper instru- 4. Connect the battery and check shield pillar garnish mouldings, and
ment panel bezel mounting screws the operation of the radio. the right and left sun visors.
and remove the reinforcement brack-
tft. Remove the 5 lower instrument
panel bezel mounting screws, and RED
remove the bezel.
4. Remove the right and left sun
visors, and the right and left wind-
shield pillar garnish mouldings.
5. Remove the retaining screws
from the upper front instrument
panel. Lift the panel and disconnect
the photo tube lead at the quick dis-
connect and remove the upper panel. GREEN
(DOWN
6. Remove the radio support I
mounting bolt from the upper panel :
area. Remove the radio mounting i
plate at the face of the radio. I
~ I
7. Pull the radio out of the in- \ J
strument panel and disconnect the

antenna lead, speaker lead and
power lead and remove the radio
\.\:-~
',"\ ', \
(Fig. 4). ',·<._:j:-.:~~---
~ --......-r
INSTALLATION K1387-B
1. Connect the speaker lead, FIG. 1-Antenna Installation

6UV @ 1OOOKC FOR 1.5UV @ 1OOOKC FOR 25UV @ 262:5KC FOR 1200UV @ 262.5KC FOR .003V@ TOP OF VOLUME
I WATT OUTPUT OF 1 WATT OUTPUT OF 1 WATT OUTPUT OF 1 WATT OUTPUT OF CONTROL @400 CYCLES
400 CYCLE OUTPUT. 400 CYCLE OUTPUT. 400 CYCLE OUTPUT. 400 CYCLE OUTPUT. FOR 1 WATT OUTPUT.
I V2
2SA72
CONY
V3
2SA72
lF AMP
V4
M54
DRIVER
el.SK
Q
~
0
C5
1MF ClO (lJ
.,
c
250 ~
NOM 0'
<
I
'""
:z:
-t
;:::
>
-t
z
...en
-- --~t1E6
---{ ~\1 :::c
FRONT '""
>
SPEAKER ::::!
:z:
. en
.
NOTES:
CAPACITORS-UNLESS OTHERWISE SPECIFIED
DECIMAL VA LUES IN MF ALL OTHERS liN MMF
VOLTAGES-MEASURED FROM POINT INDICATED
TO CHASSIS WITH A VTVM.
± 1O% NO SIGNAL INPUT.
CD~®
e THE EXACT VALUE TO BE DETERMINED BY
PRODUCTION PROCESS. REPLACE WITH THE ®~({)
DUAL
CAUTION
"A" LEAD MUST BE CONNECTED TO
SAME VALUE OF THE ORIGINAL PART. TRIMMER POSITIVE(+) SIDE OF POWER SUPPLY.
TUNING RANGE-540 TO 1610 KC INPUT RADIO WILL NOT OPERATE AND DAMAGE
VOLTAGE-l4.4V DC IF FREQ-262.5 KC. TO COMPONENTS WILL RESULT IF
CONNECTED OTHERWISE.
K1421-B -
w
-
"""
en

..,.,
C":)
(A) FM
-
w
.....
.....,
I ANTQ•
:s:- AM
;: ANTQ•
.,I
*C2 *C5
i:
:=a
Cl
CP-
c;·
""
"'CD:::r
-
5I
Cl
;:::·
L3
2UH
SID C22 ::D R14

05UF.,. 470K
C23
60 NOM
AM FM
0
SIF
NO UNGROUNDED AC POWERED TEST

EQUIPMENT SHOULD EVER BE USED.
* 10% K1423-A

ANTENNA antenna to fender retaining nut. the new speaker in position and in-
7. Connect the motor wiring con- stall the mounting screws.
1. Remove the right front fender
nector, and the antenna lead-in. 6. Check for correct speaker oper-
rear splash shield. ation.
2. Disconnect the antenna lead- 8. Test the antenna operation.
in from the antenna. Disconnect the 9. Install the fender splash shield. 7. Place the upper front instrument
antenna motor wiring connector panel in position, connect the photo
tube lead and install the panel
(Fig. t). FRONT SPEAKER
mounting screws.
3. Remove the antenna to fender
top retaining nut, stanchion and gas- 1. Remove the ten center instru- 8. Install the center instrument
ment panel bezel mounting screws panel bezel, the right and left wind-
ket.
and the bezel. shield pillar garnish mouldings, and
4. Remove the motor support
bracket retaining screws. Remove 2. Remove the right and left sun the right and left sun visors.
the antenna assembly through the visors and the right and left wind-
splash shield opening. shield pillar garnish mouldings.
3. Remove the retaining screws REAR SEAT SPEAKER
5. TO INSTALL: Place the an-
tenna in position and install the· an- from the upper front instrument To remove the rear seat speaker
tenna to fender mounting gasket, panel. Lift the panel and disconnect on convertible cars, first remove the
stanchion and retaining nut. Install the photo tube lead at the quick dis- rear seats, the quarter trim panel and
the retaining nut just tight enough connect and remove the upper panel. the package tray. The speaker is then
to permit alignment of the motor 4. Remove the speaker mounting accessible for replacement. On the
support bracket retaining screws. screws, disconnect the speaker lead sedan, it is only necessary to remove
6. Tighten the motor support and remove the speaker. the spare tire for access to the rear
mounting screws; then, tighten the 5. Connect the speaker lead, place seat speaker.
FIG. 4-Radio Receiver Installation

{319) 16-25
PART SPEED CONTROL

16-5
1 Description and Operation ..... ......... 16-25 3 Removal and Instaiiation ................. 16-26
2 In-Car Adjustments and Repairs. . ........ 16-25

The speed control unit is governed ture can be put into operation by spring. When the pre-selected road
directly by car speed. A conventional moving the slide switch to the lock speed is reached a reaction pressure
speedometer drive cable, connected position (it will return to the ON is felt on the accelerator pedal.
to the input shaft at the bottom of position when released), when a When the car tends to go slower
the control unit, drives a spring pre-selected speed is reached and than the pre-selected speed, as would
loaded governor in the control unit the accelerator pedal is held against be the case in going up a hill, the
and at the same time drives a second the reaction pressure. action of the governor weights causes
cable which extends to the speed- The speed control will now oper- the contact arm to contact motor
ometer head by means of a 1 : 1 gear ate automatically without the need point No. 1. The motor now rotates
set. The spring loading of the gov- of foot pressure on the accelerator in the opposite direction; thus, the
ernor is varied and controlled by pedal. The control unit motor will magnet assembly moves to allow the
turning the selector knob located advance or retract the acceleration throttle to be opened, to maintain
on the instrument panel. For ex- pedal to maintain the pre-selected the pre-selected speed.
ample, with the selector knob set at speed. The speed of the vehicle may When the car travels downhill, it
50 mph the tension in the governor be increased or decreased by turning tends to travel faster than the pre-
spring is such that when the car the selector dial while the speed selected speed. The resulting action
speed reaches 50 mph the force of control is operating automatically. of the governor weights moves the
rotation of the governor weights is
The automatic feature is released contact arm to motor point No. 2,
balanced by the governor spring ten-
by depressing the brake pedal within causing the motor to rotate the drive
sion.
the first 1A -inch of travel, moving screw and move the magnet to close
When the speed control unit is the throttle.
the slide switch to the OFF position,
used as a mechanical speed reminder
or by turning the ignition switch
device, a resistance or back pressure
to the OFF position. Any of these
is felt at the accelerator pedal at
operations breaks the electrical cir-
and above the speed selected on the
cuit and the unit returns to manual
selector dial.
control.
The position of the back pressure
point will vary with the road grade. Inside the control unit, an activa-
tor assembly riding up and down on
The car speed can be increased a shaft, moves the contact arm be-
ai any time by pushing the accelera- tween motor points Nos. 1 and 2,
tor through the back pressure. Re- located on the magnet assembly.
lease the pressure on the accelerator Electrical contact between the point
pedal and the car will slow down on the contact arm and either motor
normally. point activates a 12-volt reversible
Turn the selector dial higher or motor that rotates a drive screw.
lower to increase or decrease the When the drive screw rotates, a nut
speed setting. Back pressure will on the screw moves the entire mag-
always be felt when selected speed net assembly to the position where
is reached. equilibrium is reached between the FIG. 1-Speed Control
The automatic speed control fea- governor weights and the governor Unit-Cover Removed

LINKAGE gauge bolt and hold the exterior arm thickness, two inches long.
1. Remove the cotter key from securely against the gauge pin (Fig. 4. Adjust the swivel on the throt-
the accelerator linkage and pull the 2). tle linkage until the linkage will as-
linkage from the exterior arm. The gauge toot is supplied in Speed semble to the exterior arm.
2. Start and run the engine until Control Kits. However, if the gauge 5. Replace the linkage and cotter
it operates at a slow idle. tool is not available, use a piece of pin.
3. Insert the gauge sleeve over the .;),,-inch I.D. tubing of ~~n-inch walt 6. Remove the gauge sleeve.

shield, making certain that the fer- 12 Volt Test Lamp

rule at the end of the cable is free in
the bottom of the dust shield.
4. Reinsert the ferrule in the dust
shield. Push in lightly on the control
cable until it stops. Do not force
the cable beyond this position.
5. Again check the selector dial in
order to make certain it is at its low
setting.
6. Again push on the control cable
until it stops. While holding the cable
in this position, tighten the screw
on the dust shield securely.
TERMINAL NO. 1 K1532·A
BRAKE PEDAL RELEASE SWITCH
1. Turn the ignition switch to the
FIG. 3-Checking Brake
FIG. 2-Gauge Tool Installed ACC position. and speed control Release Switch Adiustment
slide switch to the OFF position. 6. With the switch installed and
2. Place a 12-volt test lamp be- the lamp on, depress the brake pedal
CONTROL CABLE
tween terminal No. 1 and ground to determine if the lamp goes out
1. Rotate the selector dial toward (Fig. 3). The test lamp should be on. within the first 1.4 -inch of pedal
its low setting, as far as it will turn 3. If the lamp is out, check for a travel.
without forcing. blown fuse. 7. If the lamp fails to go out dur-
2. Loosen the screw on the dust 4. If the lamp fails to go on when ing the first 14 -inch of travel, loosen
shield. This screw retains the control the fuse is good, test the switch for the switch adjusting nuts and reposi-
cable in the bottom of the dust proper operation. tion the switch so the lamp goes out
shield. 5. If the switch is good, inspect during the first 1.4 -inch of brake
3. After loosening the screw, pull the wiring for broken wires or loose pedal travel. Tighten the adjusting
the control cable out of the dust connections (Fig. 3). nuts to specifications.

CONTROL UNIT INSTALLATION counterclockwise and remove it from
1. Position the power unit on its the control unit.
Whenever a faulty power unit is mounting bracket and secure to the 3. Remove the dust shield from
removed, the car can be driven with bracket with two bolts. the cable.
the speedometer operating, by re- 2. Connect the accelerator linkage 4. From inside the car, remove
moving the power unit cables from to the locking arm on the power unit the slide switch button, which will
the speedometer and transmission, and adjust the linkage as described pull straight out.
and by installing a standard speed- in this section of the manual (In-Car 5. Remove the two nuts which at-
ometer cable and housing assembly Adjustments and Repairs). tach the assembly to the instrument
between the transmission and speed- 3. Install the ball end of the Bow- panel.
ometer. den cable in the socket on the power 6. Remove the selector assembly
REMOVAL unit. from the instrument panel.
1. Disconnect the multiple electric 4. Install the dust shield in the 7. Disconnect the selector wires
connector at the power unit. housing. The dust shield has bayonet and remove the complete assembly.
type retention. Push in and tum INSTALLATION
2. Disconnect the drive cable and clockwise. Do not tighten the set 1. Position the cable through the
the speedometer cable from the screw on the end of the dust dash, and connect the selector wires.
power unit. shield until the control cable is 2. Assemble the selector assembly
3. Loosen the set screw at the properly adjusted. to the instrument panel, and assem-
lower end of the dust shield. 5. Adjust the control cable as de- ble the two nuts which attach it.
4. Remove the dust shield from scribed under In-Car Adjustments 3. Install the slide switch lever
the housing. Then slide the dust and Repairs. button.
shield down the cable and slip the 6. Connect the drive cable and 4. Position the dust shield on the
ball end of the Bowden cable out of speedometer cable to the power unit. cable.
its socket. 7. Connect the multiple electric 5. Insert the dust shield in the
5. Disconnect the accelerator link- connector at the power unit. housing and turn the shield ~ turn
age from the exterior arm plate on clockwise to properly retain the dust
the power unit. SELECTOR ASSEMBLY shield. Do not tighten the set screw
6. Remove the two bolts securing AND CABLE REMOVAL on the end of the dust shield until
the power unit to its mounting 1. Open the hood and loosen the the control cable has been properly
bracket and remove the power unit, cable retaining lock screw at the bot- adjusted. Adjust the control cable.
leaving the mounting bracket at- tom of the dust shield. (See I n-Car Adjustments and Re-
tached to the fender dust shield. 2. Rotate the dust shield 1,4 turn pairs.)

{321) 16-27
PART AUTOMATIC HEADLIGHT DIMMER

16-6
1 Description and Operation ......... 16-27 3 Removal and Installation ................ 16-29
2 In-Car Adjustments and Repairs. . . ........ 16-28

A detent position is provided in the
center of the control range for normal
sensitivity as adjusted at the factory.
When the control is in detent posi-
tion, the knob pointer should be
pointing up. Rotating the knob clock-
wise (the word FAR moves down),
increases sensitivity. In this position,
the headlight dimmer will switch the
headlights to lower beam when an
approaching car is farther away than
normal. Rotating the control counter-
clockwise (the word NEAR moves
down), decreases the sensitivity, thus
allowing an approaching car to ap-
proach nearer before switching
occurs.
PHOTOTUBE UNIT
The phototube unit uses a single-
stage phototube for sensing light, and
is mounted on the top-center of the
instrument panel upper-cover. The
lens picks up light from approaching
headlights and focuses it through a
filter and mask onto the phototube.
The phototube converts the light into
an electrical signal that can be used
by the amplifier unit.
FIG. 1-.Automatic Head Light Dimmer Installation AMPLIFIER UNIT
The automatic headlight dimmer, The amplifier unit supplies voltage

proper distance, light from its head-
which automatically switches the to the phototube unit and operates
lights, striking the phototube unit, the integral power relay in response
headlight beam in response to light causes the headlights to dim or switch
from an approaching car, consists of to a signal from the phototube unit.
to lower beam. At this time, if the The unit is located at the left hand
three individual units: a phototube approaching car's headlights were on
unit, an amplifier unit, and a combi- side cowl (Fig. 1).
upper beam, the driver would nor- A heavy duty power relay, with
nation dimmer over-ride-type foot mally switch to lower-beam, which
swtich (Fig. 1). special alloy contacts for switching
would greatly reduce the amount of the headlights between upper and
Headlights are automaticaHy con- light striking the phototube unit. The lower beam, is located above the
trolled only in one position of the automatic headlight dimmer is de- amplifier unit.
foot switch. Headlights change from signed to maintain or hold its vehicle
automatic operation to full time headlights on a lower beam, even FOOT CONTROL SWITCH
lower. . beam when the foot switch is with this reduction in light. When
The foot switch is a special dim-
fu11y depressed. To obtain momen- light is removed from the phototube
mer over-ride type that provides
tary highway upper-beam for signal- unit, the headlights switch back to
either Automatic or Low-Beam con-
ing oncoming drivers, when using upper-beam.
trol of the headlights. It also acts
automatic control, or for checking A sensitivity control knob, located as an over-ride for obtaining an
automatic position of the foot switch. at the back of the phototube unit, over-riding high-beam when in
depress the foot switch about :Ys inch (Fig. 2 Part 16-1), gives the driver
to a detent. Automatic position. The over-ride
a limited range of control over the section of the foot switch functions
When a car approaches within a sensitivity of the headlight dimmer. only when the switch is in Auto-

matic position. A slight downward matic posrtton of the foot switch. foot switch, the automatic headlight
pressure on top of the switch to Street lights, encountered in the city, dimmer is not an active part of the
a detent provides upper-beam, re- are usually sufficient to maintain the headlight circuit. However, it is not
gardless of light on the phototube vehicle headlights on lower-beam; turned off. It continues to function
unit. This arrangement permits sig- however, the upper-beam may be ob- as long as the headlights are turned
naling the approaching driver if he tained when needed by holding foot on and is ready to provide automatic
fails to switch to lower-beam and pressure in the over-ride position. control whenever the foot switch is
also provides a simple test for Auto- In the lower-beam position of the returned to the Automatic position.

Be certain that headlights and Adjust the aiming dial until the cor- 3. Turn the dim-hold switch mo-
windshield are free of snow and dirt responding number is under the mentarily to the Dim position to
for proper operation of the auto- pointer. switch the lights to lower-beam, then
matic headlight dimmer. 6. Adjust the vertical aim screw switch back to the Hold position.
on the phototube unit until the bub- If the lights do not switch to lower-
PHOTOTUBE UNIT VERTICAL ble is centered in the level. beam, the amplifier dim -control
AIMING PROCEDURE must be turned completely clock-
. The phototube unit must be accu- HOLD AND DIM SENSITIVITY wise and then readjusted after
rately aimed vertically. If the unit is ADJUSTMENTS ON CAR Hold adjustment is correct.
aimed too low, back reflections from Hold sensitivity must be prop- 4. Adjust the intensity control
the headlights which are being con- erly adjusted before adjusting Dim slowly counterclockwise until the
trolled, will lock the amplifier on sensitivity. The phototube unit meter pointer is on the Hold sensitiv-
lower-beam. However, the unit must must be covered with a black cloth ity adjustment line.
be aimed as low as possible to pro- during adjustments. Adjustments 5. Turn the amplifier Hold control
vide maximum tolerance for car should be made with the phototube slowly counterclockwise, just to the
loading. unit temperature below 90°. If the point where the headlights switch to
1. Phototube unit vertical aiming car has been in the sun immedi- upper-beam. Do not go beyond this
should be done with the car un- ately prior to checking, allow it to setting.
loaded, trunk empty except for spare cool in a covered place for approxi- 6. Turn the intensity control all
tire, gas tank at least half full, and mately one hour before the ad- the way clockwise.
with tires at the correct pressure. justment is actually made. 7. Tum the Dim-Hold switch to
2. Locate the car on a level floor Dim position and back to Hold posi-
(level within 1.4 inch fore and aft of PREPARATION FOR tion to obtain a lower beam.
the car). ADJUSTMENT
3. Rock the car sideways to equal- 8. Slowly turn the intensity control
1. Set the driver control to the counterclockwise just to the point
ize the springs.
4. Install the aiming device, part Detent position. where headlamps switch to upper-
of the tester on the phototube unit 2. Install the tester lamp (Fig. 3). beam. The meter pointer should now
(Fig. 2) . The three-points on the Cover the tester lamp and phototube read in the green. Hold sensitivity
aiming device must be resting on with the black cloth furnished. range on the meter scale (Fig. 3).
top of the phototube unit, and the 3. Start the engine and operate it If not, return to step 1 and repeat
aiming device must be touching at fast idle while making adjust- all steps.
the front of the phototube unit. ments.
5. Observe the number stamped 4. Turn the headlights on and wait Tester
on the driver control knob rear face. at least five minutes for the ampli- lamp
fier unit to stabilize. Place the foot
switch in the Automatic position.
AIMING DIAL 5. Turn the zero corrector, on the
face of the meter, until the meter
pointer is on the zero set line.
6. Turn the tester intensity control
counterclockwise.
7. Connect the battery leads of the
tester to the battery terminals. (Red
lead to the positive terminal and
black lead to the negative terminal.)
HOLD SENSITIVITY
ADJUSTMENT Aiming Device, Model
No. 6-J· J-8674 K1536-A
1. Rotate the amplifier Hold com-
VERTICAL AIM SCREW pletely clockwise.
2. Rotate the tester intensity con- FIG. 3-Dim and Hold
FIG. 2- Vertical Aiming Device trol all the way clockwise. Sensitivity Tester

(323) PART 16-6-AUTOMATIC HEADLIGHT DIMMER 16-29 • 1
DIM SENSITIVITY 4. Adjust the tester intensity con- 8. Slowly rotate the tester intensity
ADJUSTMENT trol until the meter pointer is at the control clockwise just to the point
Dim sensitivity adjustment line. where the headlamps switch to upper
Dim sensitivity should not be
adjusted until after Hold sensitiv- 5. Slowly rotate the amplifier Dim beam. The meter pointer should now
ity is properly adjusted. control clockwise, just to the point read in the green Dim sensitivity
1. Rotate the amplifier Dim con- where the headlights switch to lower- range on the meter scale. If not, re-
trol completely counterclockwise. beam. Do not go beyond this turn to step 1 and repeat all steps.
2. Rotate the tester intensity con- setting.
6. Rotate the tester intensity con- 9. If the adjustment is correct,
trol completely counterclockwise. turn off the headlights and discon-
3. Momentarily turn the Dim-Hold trol completely counterclockwise.
nect the tester.
switch on the tester to Hold, then 7. Turn the Dim-Hold switch to
back to the Dim position to obtain Hold, then back to Dim to obtain 10. Remove the tester lamp from
upper-beam. the upper beam. the Phototube Unit.

If the automatic headlight dimmer 2. Position the top panel and 4. Connect the negative (ground)
malfunctions and cannot be removed phototube to permit connecting cable to the battery.
for repair immediately, manual oper- the phototube plug to the amplifier 5. Check the Dim and Hold sensi-
ation of the headlights may be ob- harness. Then make the connection, tivity adjustments (See In-Car Ad-
tained at the foot switch, in most pushing plug down through hole in justments and Repairs). If the car
cases, by removing the fuse from speaker mounting plate. is to be driven without the auto-
the fuse holder. The fuse holder is 3. Carefully position the top panel matic headlight dimmer, install a
located in the amplifier wiring har- and drive in the retaining screws. standard foot switch and connect
ness, just a few inches from the 4. Replace garnish moldings on the car headlight harness to it.
amplifier unit. windshield pillars.
Should the car have to be driven 5. Connect the negative (ground) FOOT DIMMER SWITCH
with the amplifier removed, manual cable to the battery.
operation of the foot switch may be 6. Check the aim and sensitivity REMOVAL
obtained by replacing the dimmer adjustments (See In-Car Adjust-
1. Disconnect the negative
over-ride type foot switch with a ments and Repairs).
(ground) cable from the battery.
standard foot switch, and plugging
(Very important.)
the standard car wiring to it. AMPLIFIER UNIT AND HARNESS 2. Position the left side of the floor
REMOVAL mat back away from tpe area of the
PHOTOTUBE switch.
1. Disconnect the negative
REMOVAL 3. Remove two screws attaching
the switch to the floor pan. Lift the
1. Disconnect the negative 2. Remove the left hand cowl
switch from the floor pan.
(ground) cable from the battery. trim panel.
2. Remove the screws retaining 4. Disconnect the wiring connect-
3. Disconnect the amplifier wiring
fue upper section of the instrument ors from the switch.
harness from the relay (above ampli-
panel. fier), from the foot switch, and from
3. Remove garnish molding from the headlight wiring harness. INSTALLATION
windshield pillars. 4. Remove the two amplifier unit 1. Connect the wiring conneCtors
4. Carefully lift up the rear end mounting screws. Lower the ampli- to the switch.
of the panel and pull away from the fier and disconnect the phototube to 2. Position the switch on the floor
windshield. ampiifier cable. pan, and drive in the two mounting
5. Disconnect the phototube unit screws.
plug from the amplifier harness. Re- INSTALLATION 3. Position the floor mat in the
move the top panel and phototube 1. Connect the phototube to ampli- area of the switch.
unit. fier cable, position the amplifier, and 4. Connect the negative (ground)
6. Remove the phototube unit drive in the mounting screws. cable to the battery. Should installa-
from the top panel. 2. Connect the amplifier unit to tion of a standard foot switch be
the relay, to the foot switch, and to necessary, remove the left side
INSTALLATION the headlight wiring harness. cowl trim panel, and connect the
1. Install the phototube unit on 3. Install the left hand cowl trim car headlight wiring harness to
the top panel. panel. the foot switch.

16-30 GRO.UP 16~VENTILATING, HEATING AND ACCESSORIES (324)
PART SPECIFICATIONS
16-7
BLOWER MOTOR CURRENT DRAW DRIVEN BELT TENSION
At low Speed 2-3 Amperes at 12 volts Between Fan Pulley and Air Conditioner Compressor
All Engines ....................... New 120-150
At Medium Speed 3-4 Amperes at 12 volts Used':' 90-120
"'Belt operated for a minimum of I 0 minutes is considered

At High Speed 4-6 Amperes at 12 volts a used belt.
AIR CONDITIONING COMPRESSOR SPEED CONTROL
Location Torque (ft-lbs) BRAKE PEDAL RELEASE SWITCH

Adjustment Nut Torque ............ 48-60 pound-inches
Base Plate 7-11
Rear Cover Plate 7-10

RADIO
Cylinder Head 14-18
Radio Current Draw .......... 1 ampere max. @ 12 volts
Front Seal Plate 13-17 Antenna Current Draw ............ 8 amperes@ 12 volts
Service Valve (Rota lock) 35 Max.
Mounting Bolt 14-17
Oil Filler Plug 18-22
Clutch Mounting 15-22
Oil Level: Vertical Mount Ya Inch Minimum. Use Suniso lfJI5 or Capella E.

(325) 17-1
GROUP
17
GENERAL BODY SERVICE . . . . . . . . . . 17-1 DOORS, WINDOWS, AND DECK LID .. 17-17
PART 17-2
FRONT SHEET METAL, BUMPERS,
EXTERIOR MOULDINGS ... 17-12
PART GENERAL BODY SERVICE

17-1
1 Common Adjustments and Repairs ....... 17-1 3 Hoisting Procedures ..................... 17-10
2 Cleaning and Inspection ......... . . . . . .. . 17-10
COMMON ADJUSTMENTS AND REPAIRS

TYPES OF SEALER AND <tnd is commonly known as "perma- wax, tars, oils, grease, caulk and
APPLICATION gum" has a plastic base with an sealer. When desired, it can be used
asbestos filler. It is used on spotweld to thin caulk and sealer. It is harm-
The all-purpose sealers described
holes around moulding clips or be- less to cured paint, but useful in
as follows are for service use. The
tween two surfaces not properly seal- new car pre-delivery. It is important
method and points of application are
..:d by a gasket. Apply this sealer to prevent either of these cleaners
given under each sealer type. Also,
with a putty knife. from contacting vinyl or leather.
refer to Figs. 1 through 4 for sealer
application.
CEMENT C2AZ-19C525-A
SILICONE LUBRICANT COAZ-
BODY SEALER BSA-19562-A This cement is recommended for 19553-A (JELLY) AND COAZ-
This fast drying, white sealer mstrument panel safety cover and 19553-B (SPRAY)
which remains semi-elastic will not body panel plastic water shieid in-
This lubricant is to be used on
run. It is easily cleaned up with a stallation. lt is also useful for repair
the door window weatherstrips. It is
dry cloth; however, if necessary, ap- c•r replacement or other vinyl and
recommended that silicone lubricant
ply a solvent. This sealer, which pro- rubber trim. be applied to the upper weatherstrips
vides an ex.cellent surface for paint,
at every regular lubrication period.
is used for all seam sealing jobs such RUBBER CEMENT SA-19552-B Its uses makes the doors easier to
as those that are found in the floor
This quick-drying, strong adhesive close, avoids weatherstrip ·squeaks,
pan, wheelhouse, dash panel, rocker
•
material is designed to hold weather- retards excess weatherstrip wear from
panel, door opening, quarter panel,
'>lripping on doors, bodies, deck lids, chafing between the door glass upper
or drip rail. It is also used to seal
cowl ventilators, and the surrounding frame and weatherstrip, and helps to
trim panel and outside moulding clip
metal. Windows and windshields retain door window alignment by re-
holes while windshield and back
which are set in rubber can be effec- ducing friction between the glass
window installation is still another
t 1vely sealed against leakage by flow- frame and rubber weatherstrip.
use.
mg cement into affected areas.
BLACK CAULK AND SEALER Clean all grease, dirt, and old
B6A-19563-A ~·~aler from the surfaces to be
BODY MAINTENANCE
The combination black caulk and •.:emented. For best results, apply a Regular body maintenance pre-
sealer is of the same composition as medium coat of cement to both sur- serves the car's appearance and re-
body sealer and is used in the same f.1ces, allow it to dry until tacky, duces the cost of maintenance during
areas. The color is gloss black instead .:md press both surfat.:es firmly to- the life of the car. The following
of white; however. this sealer is to be .sether. steps are suggested as a guide for
used with dark colored paints or in regular body maintenance.
areas that are not visible. CLEANING SOLVENT 1. Vacuum the interior thoroughly
B7A-19526-A or B7A-19521-A and wash the car.
BODY SEALER AB-19560-A This general clean-up solvent 2. Check all openings for water
This sealer which is heavy bodied •.:leans off new or old cement smears, leaks, and seal where necessary.

17-2 GROUP 17-BODY, DOORS AND WINDOWS (326)
.
rl
'li!'
--:::_":::::"1~
r"'~. d
,
\
,
.... ~....\.,...
I
,ttPIII;.--
. ========:::.-========-·
------ -------- --
.- ··-~:: .·~~;~
I ;;
II
VIEW-BB
b.,. ' · ·· ..ll/.~

lfl. I~ .r•\ \ ~~:~;;., /
I
VIEW-CC
I I I ' I ~---
(_ .~!;;;;J
I I
••J-- : I1 I f
·====-----====----1'11
~ I
II
I
I
VIEW-AA
M1104-A
FIG. 1-Sealer Application-Front Floor Pan, Cowl Side and Dash Panel

(327) PART 17-1-GENERAL BODY SERVICE 17-3
FIG. 2-Sealer Application-Roof and Upper Body
3. Cement all loose weatherstrips ventional frame and body repair. CHECKING BODY FOR
which are still usable. rhe application of heat and the use MISALIGNMENT
4. Replace all door and deck lid of heavy-duty jacks must be carefully To align or square up a body, take
weatherstrips which are unfit for controlled because of the difference two opposite diagonal measurements
service. 111 the gauge of the metal in the
between pillars. Use a measuring
5. Apply silicone lubricant to the sub-frame of a unitized body and the tram for these measurements. Take
weatherstripping. stress points developed in a single the measurements between reference
welded unit construction. It is pos- points such as crease lines or weld
6. Replace all cracked, fogged, or sible to pull damaged areas back into
chig>ped glass. joints which are diagonally opposite
alignment with the use of light- each other on the two pillars being
7. Align hood, doors, and deck lid weight jacks and hydraulic equip-
if necessary. measured. Since all measurements
ment without heating the metal. should be made from the bare metal.
8. Inspect windshield wiper blades Rough out badly damaged areas remove all interior trim from the
and replace if necessary. before taking measurements for checking points.
9. Tighten sill plate and garnish ~quaring up a body. If necessary, re- ln some cases, it is difficult to ob-
moulding screws. :rnove the glass from the damaged tain proper body alignment when re-
10. Clean the seats, door trim area to prevent damage to the glass. pairing a body that is damaged on
panels, and headlining. In severe cases, reinforcement brack- both sides. In these cases, horizontal
11. Touch-up or paint chipped or ets and other inner construction may and vertical measurements can be
scratched areas. have to be removed or cut to permit taken from a body of the same body
restoration of the outer shell and style. Once these basic dimensions
12. Drain valves located on the
pillars without excessive strain on the are taken and established on the
underside of each rocker panel,
parts. Straighten, install, and secure damaged body, alignment can be
quarter panel and door, should be
all such parts in place before at- made by diagonal measurements
cleared periodically.
tempting to align the body. taken from points on the two pillars.
In cases of severe or sharp bends, Do not attempt to correct any seri-
BODY ALIGNMENT It may be necessary to use heat. Any ous misalignment with one jacking
attempt to cold-straighten a severely operation. This is particularly true
Servicing the unitized body should bent bracket may cause ruptures of if other sections of the body also
not present any unusual difficulties the welds and may also cause cracks require aligning. Align each section
or necessitate additional equipment m the bent part. Never heat the area proportionately until the proper di-
other than that required for the con- rnore than a dull red. mensions are obtained.

~
TO FRONT OF BODY
~
..........
VIEW-DO
VIEW 88
ASSEMBLED
M1106-A
FIG: 3-Sealer Appli,ation-Side and Center Floor Pan

{329) PART 17-1- GENERAL BODY SERVICE 17-5
LEFT SIDE OF BODY

~ I l
RIGHT SIDE OF BODY
t~, ·, ,
"
L------1
~~~.:;L.~\ \ -~ ~ \1 \>\
p ~~~~~{~?~--
.
-~=·~:-~.-.•
~
\·,.
·• ~
VIEW AA VI~W BB VIEW DD

MODEL-7 4 ONLY MODEl 7 4 ONLY
\
\
. ~:~~~~~~-~~~~~~~~~~~~~~~~~~~
\ .. - ~~ r.~--.
-l~:~~-~~i1;o~~~~i-
\
VIEW AA VIEW AA
MODEL-53 MODEL-74
<::~=~/
·::;~~
\~\
..
VIEW BB j~'- \\......·.
ccf~l
VIEW DD
VIEW
M1107-A
FIG. 4-Sealer Appli(afion-Rear Floor Pan and Body Rear

17-6 GROUP 17- BODY, DOORS AND WINDOWS (330)
FIG. 5-Underbody Dimensions

Door openings are checked in the ucts must be employed to insure 2. The work should be kept com-
same manner as the body. Horizon- satisfactory adhesion to the metal pletely wet for at least three minutes
tal, vertical, and diagonal checking and to give a good color match with and the metal should be thoroughly
points are established on all four acceptable durability. The methods etched. If any bright metal remains,
sides of the door opening that is involving the use of duPont Prepara- the treatment should be repeated.
being measured. kote and Ditzler Zinc Dust Primer 4. Rinse the area with clean water
CHECKING UNDERBODY FOR are indicated here and it is important and blow off with compressed air.
MISALIGNMENT that either one be employed exactly 5. The dried surface must be
The dimensions of the underbody as directed. No short cuts nor any primed immediately. Then succeed-
must be restored in the repair of inter-mixing should be attempted. ing coats and color as required must
major body damage in order to pro- Some operators in performing be applied according to the supplier's
vide correct front and rear wheel rocker panel repairs prefer to grind directions.
geometry. Dimensions (Fig. 5) are down the entire panel thus removing PAINT REFINISHING
detailed to the center line of existing the zinc coating (galvanizing) com- Acrylic Enamels. Acrylic enamels
holes in the underbody assembly. pletely. This, of course, involves exhibit better hardness, mar resist-
Once the frame and suspension mem- some paint removal on adjacent ance and gloss retention in metallic
bers are aligned, the balance of the panels which somewhat complicates colors than the ordinary enamels.
repair can be performed. the repair job. Acrylic enamels also possess the
Metal Preparation for Galvan- property of good polishability.
PAINT DAMAGE AND REPAIR ized Steel Following are recommended re-
PAINT REPAIRS ON 1. Strip, sand-off or otherwise repair procedures for acrylic enamels:
GALVANIZED METALS. move all paint from the affected gal- REPAIR BY POLISHING. Repair
If for any reason it becomes neces- vanized steel panel. of minor dirt or fallout, sags, mars,
sary to perform paint repairs on 2. Wire-brush or steel-wool the en- scratches, dry spray, overspray, and
galvanized rocker panels or any other tire metal surface and remove all orange peel can be accomplished by
galvanized steel surfaces, care must grease or oil by wiping with a clean machine or hand polishing or by
be exercised in preparing the bare solvent. both sanding and polishing without
galvanized surface to properly accept 3. Wipe the panel using a clean the necessity of repainting. Repairs
paint. The best possible paint prod- cloth or sponge with Lithofoam No. of this type should apply to an en-

{331) PART 17-1-GENERAL BODY SERVICE 17-7
tire panel while spot repairs should so that the proper repair procedure
be attempted only in isolated areas. may be followed. For each of the
The suggested polish repair pro- following paint conditions described,
cedure consists of: the recommended repair procedure
1. ·Remove the defect by oil sand- will be indicated.
ing with 600 grit paper. Blistering. Blistering is the forma-
2. Apply a white or light colored tion of bubbles or pin points on
medium grit machine polishing com- the surface of the finished work
pound (Sno-Flake No. 16 or equiva-
lent) to the painted surface with a
(Figs. 6 and 7). Unless inspected
by a magnifying glass, this condition
FIG. 10 FIG. 11
brush. is very hard to identify. In some in-
Bruises Cracking
3. Polish the entire panel surface stances, this complaint may be con-
using an 1850 rpm wheel and a car- fused with dirt in the paint. To verify Cracking. Cracking is evidenced
pet pad (approximately o/s" nap) blistering, prick the suspected areas, by the paint curling. Frequently,
or lambswool pad. and note whether a hole exists under cracking starts at the edge of the
4. Buff the surface with a clean the bubble. This condition is caused panel (Fig. 1 1). This is caused by
lambswool pad. by rust, moisture, or oil between the poor mixing of paint or by tempera-
Normally, acrylic enamels do not coats, metal not properly cleaned, or ture changes during the various
need polishing to improve their gloss; uneven temperatures between the painting stages.
however, the foregoing procedure metal and the paint being sprayed. Acrylic Enamel - Refinish panel.
can be used to restore the original Acrylic Enamel - Repair by re- (Prime if both color and primer
luster to the film after weathering, painting (color coat). cracking.)
or to improve the surface smoothness Crow Footing. Crow footing may
of the finish on the entire car. be described as small lines branch-
Repair By Repainting. Acrylic ing off from a point in all directions
enamels can be repaired by repaint- and giving the appearance of a
ing with either conventional air dry- crow's foot (Fig. 12). Crow footing
ing or low bake enamels, or with is usually caused by spraying a sec-
acrylic lacquers. When repainting ond coat before the first coat is dry,
metallic colors, it is recommended by spraying an excessively thick coat,
that acrylic lacquer be used since a or by thinners which evaporate too
better color match can be obtained; fast.
both the original finish and the re-
pair can be polished to provide the
FIG. 6 FIG. 7 Acrylic Enamel - Refinish panel.
Random Blisters Pattern Blisters (Color coat.)
same luster, and the air dry acrylic
Dirt in Paint. Patches where dirt
repair lacquer will provide better
appears (Fig. 13) are sometimes
durability in service than air dry Checking. "Line checking" has the
confused with blistering. To verify
enamels. appearance of thin, straight Jines
the condition, prick the suspected
When using any one of the three criss-crossing each other (Fig. 8).
areas, and note whether there is for-
types of repair materials over acrylic These lines may be from one-half
eign material under the surface.
enamel, it is extremely important inch to four inches or longer, in-
that a thorough sanding of the orig- creasing in length as the finish ages. Acrylic Enamel-Polish repair pro-
inal finish be accomplished using Acrylic Enamels-Refinish panel. cedure will be effective in most cases.
#4J()O grit paper. Care should be ex- (Color coat-primer if damaged.) (Color coat.)
ercised to insure that all surfaces, Mildew. Mildew growth, which oc-
including edges and areas adjacent Chipping and Stone Bruises. curs along radial lines, (Fig. 14) is
to applied mouldings, are thoroughly Chipping occurs when the surface of most commonly found in a very
sanded in order to provide adhesion the finish coat of paint has been dark gray or black color.
of the repair top coat. broken by a sharp blow, and small Acrylic Enamel-Repair by polish-
After sanding, proceed with the particles of paint have flaked off (Fig. ing.
application of a primer surfacer re- 9). Frequently, stone bruises result
Off-Color. The term off-color is
duced according to the supplier's in chipping (Fig. 10). applied to adjacent areas on which
recommendations to any bare metal Acrylic Enamel - Refinish panel. the colors do not match (Fig. 15).
spots that have been exposed. After Paint may be spotted if in isolated It may also appear when making spot
the recommended air dry time, sand areas. (Prime it to bare metal.) repairs.
the primer surfacer with #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 - :.: -~'
----....,..,~~ M100S-A
'
••
... M1009-A
. :. '
-~_..
.. ,. -~ M1012-A
__
Listed here are some of the ab-
normal paint conditions that may be
encountered. It is very important to FIG. 8 FIG. 9 FIG. 12 FIG. 13
identify the paint condition correctly Line Checking Chipping Crow Footing Dirt in Paint

: .~
;. • • .••
~ .. ' .• ·"!
-. -~
>: r.lr:.: 'tt~·
1.~.~.:·.'.: :· .. :.
·>';_··
.....
.~ .. ·,.
·.·....... :,.
. .; -
111111 M,02~~~
FIG. 14 FIG.15 FIG. 20 FIG. 21 FIG. 26 FIG. 27
Mildew Off Color Craters Primer Shows Industrial Organic Fall-Out
Fall-Out
Acrylic Enamel-Refinish panel if repainting.
polishing does not correct condition. Acrylic Enamel-First use polish of deep penetration.
(Color coat.) repair procedure, refinish panel if Spot Discoloration. This is evi-
Orange Peel. Orange peel is a necessary. (Color coat.) denced by brown spots or stains on
term used to describe an uneven, Primer Shows. The primer will the surface. Stains or spots can be
mottled appearance on the paint sur- show through the finish coat as a re- caused by road tar, acid or alkali-
face (Fig. 16). This is usually caused sult of an excessively thin color coat, bearing water from the streets.
by improper thinning of the paint. or application of the color coat be- Acrylic Enamel-Use polish repair
Acrylic En~mel-Repair by polish- fore the surface is dry (Fig. 21). procedure.
ing. Acrylic Enamel - Refinish panel.
Overspray. Overspray is evidenced (Color coat.) Water Spotting. Water spotting is
by a rough, dull finish in the area Runs, Sags and Wrinkles. The evidenced by a milky pattern where
surrounding the paint repair (Fig. uneven collections of paint on the water drops have fallen (Fig. 25).
17). finish surface are referred to as runs Acrylic Enamel-Use polish repair
or sags (Fig. 22). The collections procedure.
may appear in the form of tear drops Industrial Fall-Out. Industrial
or sagging lines. Usually these lines fall-out is the result of particles being
are quite soft and sometimes they exhausted into the air by the various
may be wrinkled (Fig. 23). This is processes of heavy industry, or in
usually caused by over-application of areas where there is a concentration
paint or hesitation in the stroke of of industry.
the gun. Industrial fall-out particles appear
Acrylic Enamel-Use polish repair to the eye as tiny rust-colored dots
procedure. on the paint film and the surface
will feel rough to the touch (Fig.
\.~.~•~. ~•. .~,. '.~,.~.l~t~ :-:~;.~1~

26). Some of the particles have ex-
FIG. 16 FIG. 17 cellent adhesion and are difficult to
Orange Peel Overspray
M1(·,~~·
remove. However, the following pro-
.~: -'~J
cedure has proven effective in the re-
Peeling. Peeling occurs when large moval of this fall-out:
areas of the finish or primer coat 1. Wash the car with car wash
separate from the metal or prime compound (COAA-19B521-A) tore-
coat (Fig. 18). This is usually caused M1022-A • . M1023-A
move loose dirt. Rinse well and
by wax, grease, rust, or oil under examine painted surfaces for iron
the paint. Do not confuse with FIG. 22 FIG. 23 base fall-out particles. If there is a
orange peel. Runs and Sags Wrinkles significant quantity of fall-out not
Pits and Craters. Pits and craters removed by ordinary washing, the
may be identified by the appearance Scratches. Scratches are thin oxalic treatment should then be
of small round depressions in the marks or tears that may partially used. All cracks, ledges, grooves,
paint (Figs. 19 and 20). These may or completely penetrate the surface etc., where fall-out has accumulated,
be caused by not allowing the first of the finish coat of paint (Fig. 24). should be cleaned by wiping or by
coat to dry sufficiently before apply- Acrylic Enamel-Use polish repair air blow-off.
ina the second coat or from failure procedure for shallow penetration. 2. Dissolve six to eight ounces of
to~ remove silicone polishes before Refinish panels to correct conditions oxalic acid (dry) in one gallon of
warm water and add one to two
tablespoonsful of a non-alkaline de-
tergent such as car wash compound
(COAA-19B521-A). This acid deter-
. tt ..• J :: ua gent solution must be prepared and
kept in a clean non-metallic con-
tainer.
---M1019-A M1024-.A M1025-.A Apply this solution liberally to
all affected surfaces of the car with
FIG. 18 FIG. 19 FIG. 24 FIG. 25 a large sponge. Use a broad wiping
Pecki~g Pits Snatches Water Spotting stroke and keep the work completely

{333) PART 17-1 -GENERAL BODY SERVICE 17-9
wet for about 15 minutes, or until using a fine scrub brush, possibly 1. Clean· the surface to be painted
the operator can no longer feel any a nylon bristle type. Make sure with wax and silicone remover.
surface roughness or even isolated that the light scrubbing required 2. Feather-edge the damaged areas
gritty particles with bare or gloved does not scratch the paint. It is with No. 400 grit wet or dry sand-
finger tips. If this is not done thor- sometimes helpful to briskly rub paper. (Prime all the areas of the
oughly, rust staining may soon re- the work with a mixture of equal bare metal with M-6J-12S Primer.)
develop. Be sure that the entire acid parts of oxalic acid cleaner and 3. Mix the paint according to the
cleaning procedure is performed in Ji'oMoCo cleaner wax polish (SA- instructions on the can and spray
a sheltered area so that the work 19519-A) using a piece of heavy several light coats. Allow the paint
will be kept as cool as possible to toweling. Again, a thorough water to become tacky between coats.
prevent rapid evaporation of water rinsing is extremely important. 4. Spray the entire area sparingly
and consequent surface drying. Do Sometimes small black spots re- with Lacquer Leveler ( 87 A-645-S)
not work in the sun. main after the oxalic cleaning has which will blend the repaired area
3. Rinse with clear water. This removed all iron based fall-out. Such with existing painted surfaces.
must be done very thoroughly to deposits might be asphaltic or they
prevent possible corrosion. might be over-spray. These usually RATTLE ELIMINATION
No traces of acid should be left can be removed by rubbing vigor- Most rattles are caused by loose
on any surface. Bright trim parts, ously with a cloth saturated with a bolts or screws. Foreign objects such
particularly anodized aluminum rnixturc of kerosene and Actusol as nuts, bolts, or small pieces of body
and stainless steel, may be stained ( about five parts of kerosene to one deadener in the door well, pillars,
by prolonged contact with the part of Actusol). Any residue of this and quarter panels are often the
cleaning solution. Painted areas -;ulvent mixture may be readily flush- source of rattles. Door wells can be
also can be spotted by prolonged (d off with water. checked by carefully striking the un-
exposure. It is also important to Organic Fall-Out. Organic fall-out derside of the door with a rubber
keep the oxalic acid cleaner solu- may result from parking cars under mallet. The impact made by the mal-
tion from leaking to the inside of trees or from the air under certain let will indicate if loose objects are
the car because some fabrics might :ttmospheric conditions (Fig. 27). in the door well.
be bleached or discolored by the Acrylic Enamel-Refinish damaged In the event that tightening the
solution. panels. (Color coat and primer.) bolts and screws, located on such
If the fall-out is not completely assemblies as the doors, hood, and
removed or is deeply imbedded in I~TERIOR PAINT REPAIRS deck lid, does not eliminate the rat-
the paint film, cleaning with the The proper matching of colors can tles, the trouble is probably caused
acid detergent mixture must be he obtained if the below procedures by misalignment. If this is the case,
repeated. This may be aided by are carefully followed. follow the adjustment and alignment
REAR DOOR SCUFF

PAD ASSEMBLY
N1254-B
FIG. 28-Scuff Plates and Pads-Installation

GROUP 17-BODY, DOORS AND WINDOWS (334)
procedures for these assemblies. of position. Apply additional cement SCUFF PLATES AND PADS
Rattles and squeaks are sometimes or another adhesive and install the For the proper method of remov-
caused by weatherstripping and anti- material in the proper location to ing or installing and sealing the scuff
squeak material that has slipped out eliminate this difficulty. plates and pads, see Fig. 28.

FLOOR PAN PLUGS AND dust enters. As explained above, the Dusting the finish when it is dry
GROMMETS point of entry is often deceptive in tends to rub the dust and dirt into
Many plugs and grommets are that the dust may enter at one point the baked enamel, thus leaving a sand-
used in the floor pan and dash panel. then follow the passages, formed by paper effect on the surface. To keep
The floor pan plugs seal the various interior trim, to another point. the finish bright and attractive while
body access holes. If any plugs are Under certain conditions, water eliminating the necessity of using
missing or improperly installed, a can enter the body at any point where polish, wash the car whenever it has
dust or water leak may. result. This dirt or dust can enter. Any consider- accumulated a moderate amount of
also applies to the grommets used on ation of water leakage must take dirt and road salt.
the dash panel. When dust or· water into account all points covered under The bright metal parts of the car
leaks are evident, these plugs and dust leaks. require no special car~ Periodic
grommets should be checked for To determine the exact location cleaning will preserve the beauty and
proper installation. of a dust leak, remove the following life of these finishes. Wash with clear
trim from the car: water or if the parts are very dirty
DRAIN VALVES
1. Cowl trim panel. use FoMoCo COAA-19B521-A com-
Drain valves located on the under- 2. Quarter trim panel. pound. Using a clean, soft cloth or a
side of each rocker panel, quarter sponge and water, rinse and wipe the
3. Rear seat back and seat cush-
panel, and door, should be cleared ion. parts dry. FoMoCo Chrome Cleaner
periodically. 4. Luggage compartment floor may be used sparingly to remove rust
DUST AND WATER LEAKS mats, spare wheel, and side trim or salt corrosion from chrome plated
Sealer locations should be consid- panel. parts. Do not scour aluminum or
ered when checking for dust or water 5. Center pillar trim. chrome finished parts with steel wool
leaks. It should be remembered that 6. Scuff plates. or polish them with products contain-
the forward motion of the car creates After removing the trim, the loca- ing abrasives. A FoMoCo polish will
a slight vacuum within the body, tion of most leaks will be readily provide excellent protection for all
particularly if a window or ventilator evident. Seal these leaks and road bright metal parts.
is partiaUy open. Any unsealed crev- test the car on a dust road to make
ice or small opening in the lower sure all leaks are sealed. The entrance INTERIOR CLEANING
section of the body will permit air of dust is usually indicated by a Use a vacuum cleaner to remove
to be drawn into the body. If dust is pointed shaft of dust or silt at the dust and dirt from all upholstery
present in the air, it will follow any point of entrance. or floor covering. Vinyl and woven
path taken by the air from the point After the road test, check for in- plastic trim that is dusty can usually
of entry into the passenger and lug- dications of a dust pattern around be cleaned with a damp cloth. Do
gage compartments. Opening the the door openings, cowl panel, lower not use cleaning materials con-
ventilator air ducts will equalize these part of the quarter panel, and in the taining kerosene, naphtha, toluol,
pressures. Dust may work its way luggage compartment. xylol 10o, lacquer thinners, cellu-
into the hollow, box-type, rocker Sometimes leaks can be located by lose acetate, butyl cellosolve, car-
panel which extends along the edge putting bright lights under the car, bon tetrachloride, body polish,
of the floor below the doors. Dust with the above components removed, battery acid, anti-freeze, gasoline,
that accumulates in the rocker panel, and checking the interior of the body motor oils or other type lubricants.
may eventually work its way to the joints and weld lines. The light will Approved cleaners BSA-19523-A
kick-up or the rear body pillar, and show through where leaks exist. or BSA-19525-A, COAZ-19526-A or
thus, follows the contour of the B, (soft trim cleaners) and C1AZ-
wheelhouse into the luggage com- EXTERIOR CLEANING 19C507-A (convertible back window
partment. The outside finish should be fre- cleaner) are available for service.
To eliminate dust leakage, deter- quently washed. Never wipe the Instructions for the use of these clean-
mine the exact point at which the painted surfaces with a dry cloth. ers are included on their containers.
EJ HOISTING PROCEDURES
Special precautions are necessary will result in unsafe hoisting and/or driving the car onto the hoist so that
when hoisting due to the design of possible damage to the car. the upright flanges of the hoist do
no contact the underbody of the car.
the front and rear suspension and
Approach ramps should be built up
the unitized body frame construction. DRIVE-ON HOIST
slightly if the angle of approach is
Failure to follow these instructions Care should be exercised while too steep.

(335) PART 17-1- GENERAL BODY SERVICE 17-11
RAIL TYPE (FREE WHEELING) and minimize the possibility of dam-

AND FORK LIFT (TWIN POST) age to the car.
HOISTS
The rear post fork, if not adjust- FLOOR JACK
able for width, may require special Do not attempt to raise one entire
adapters to avoid damaging the rear side of the car by placing a jack mid-
shock absorbers and also the for- way between the front and rear
ward side of the fuel tank. The front wheels. This procedure may result
post may require special adapters in in permanent damage to the car.
order to fully encompass the wider Each front wheel can be raised
lower suspension arms. independently by placing a floor jack
under the spring seat pocket in the
FRAME CONTACT HOIST lower suspension arm.
Particular care must be exercised Each rear wheel can be raised in-
when raising the car on frame con- dependently by placing a floor jack
tact hoists. Specific underbody areas, under the rear axle housing. FIG. 29- Towing
which will sustain the weight of the Do not lift both front or rear Sling-Typical
car, are designated as hoisting areas. wheels by the bumpers since damage
The length of the car may make it to the bumpers or fuel tank can chain assembly is to be attached to
necessary to use special adapters in result. the rear of the lower arm, then the
order to reach these safe hoisting chain in the hooks is to be adjusted
areas. The special adapters, if neces- BUMPER JACK so that the belt material will wrap
sary, are available from the various Bumper jack locating notches are around the bumper bar. The front
hoist manufacturers. Any deviation provided on 'he underside edge of end may be lifted as high as neces-
from the fo1Iowing instructions may the front and rear bumpers. The sary within the limits of rear bumper
result in damage to the underbody protruding end of the bumper jack clearance with the ground (Fig. 29).
and/ or sheet metal. hook should be positioned under The car may be raised and towed
The lifting areas at the front of these notches to assure slip-proof from the rear end using the rear axle
the car are designated by corrugated 1acking. The transmission shift lever as attaching locations for the sling
metal plates. should be positioned in Park, the hooks. Place the chain hooks on the
The lifting areas at the rear of the parking brake set, and the wheels outer ends of the rear axle housing,
car are located at the edges of the blocked to prevent the car from roll- between the wheels and spring seat.
underbody forward of the front edge mg. Place a 4 foot length of 4 inch square
of the rear wheel opening cover wood on the lifting sling and, as the
panel. The rear hoist pads or adapter TOWING car is being raised, position the length
arms must be positioned in this area. Lifting and towing require the use of wood so that it contacts the rear
of a towing and lifting device, other cross member and side rails at the
JACKING INSTRUCTIONS than a bumper bar and/or attaching rear of the fuel tank. This prevents
When jacking up the car for tire brackets. A universal towing sling damage to the fuel tank. When tow-
changing or any other reason, spe- of the type pictured in Fig. 29 can ing the car with the rear end raised,
cific areas and methods must be he used. a locking device must be used on the
utilized. Adherence to the following When towing from the front end steering wheel to keep the front
ins~ructions will assure safe jacking of the car, the large hook on the wheels in a straight-ahead position.

17-12 GROUP 17-BODY, DOORS AND WINDOWS {336)
PART FRONT SHEET METAL, BUMPERS, AND

EXTERIOR MOULDINGS
17·2
~ti~ p~ Section Page
1 In-Car Adjustments and Repairs ........... 17-12 2 Removal and Installation ................. 17-12
D IN-CAR ADJUSTMENTS AND REPAIRS

UP OR DOWN
HOOD
Adjustments can be made at the
hood hinges and at the hood lock
hook (Figs. 1 and 2).
The hood mounting holes in the
hinges are slotted to provide fore
or aft adjustment; also, to provide
up or down movement at the front
of the hood panel.
To maintain a flush surface be-
tween the hood and the cowl, the lock
hook can be raised or lowered. Also,
adjustable rubber bumpers -are lo- FORE OR AFT UP OR DOWN R1231-A
cated at each side of the cowl panel
to maintain a flush surface between FIG. 1-Hood Hinge FIG. 2-Hood Lock
the hood and fenders. Adiustment Adiustment

FRONT BUMPER BAR 2. Remove the hinge-to-panel re- HOOD LATCH-CONTROL
EXTENSION taining cap screws and, with a helper, CABLE
1. Remove the two extension to remove the hood panel.
REMOVAL
bumper and mounting bracket re- 3. To install, position the hood
taining cap screws (Fig. 3). panel on the hinges and install the 1. Disconnect the cable from the
2. Remove the extension. hinge-to-panel retaining cap screws. hood latch.
3. To install, align the extension Check hood panel alignment. 2. Remove the left inside vent as-
on the impact bar and install the sembly retaining bolts and remove
retaining cap screws. the vent assembly.
HOOD HINGES 3. Disconnect the cable from the
FRONT IMPACT BAR instrument panel bracket.
REMOVAL 4. Remove the screws retaining
1. Remove the impact bar exten-
1. Remove the hood panel. the cable to the dash panel and re-
sions.
move the cable.
2. Remove the lower stone shield. 2. Remove the grille assembly.
3. Disconnect the parking lamp 3. With Tool T64N-16A605-A, re- INSTALLATION
wires and remove the wires from move both hinge torsion rods. 1. Transfer the retaining nut and
their retaining clips. 4. Remove the hinge retaining retaining clips to the new cable.
4. Remove the four impact bar to screws and washers and remove the 2. Route the cable through the
mounting bracket bolts, nuts and hinges. dash panel to the hood lock.
washers (Fig. 3). 3. Connect the cable to the instru-
5. Remove the impact bar assem- ment panel bracket.
bly. INSTALLATION 4. Install the retaining screws in
6. To install, transfer the parking the dash retaining clip.
lamps and license to the new bumper; 1. To install, position the hinges 5. Install the left vent assembly.
then, reverse the removal procedure. and install the retaining screws and 6. Connect the cable to the hood
washers. lock.
HOOD PANEL 2. Using tpol T64N-16A605-A, in-
stall the hinge torsion rods. HOOD HINGE TORSION ROD
1. To maintain proper hood align-
ment, scribe a line on the hood panel 3. Install the grille assembly. REMOVAL
arou~d the hood hinge. 4. Install and align the hood panel. 1. Remove the headlamp doors

(337) PART 17-2-FRONT SHEET METAL, BUMPERS, AND EXTERIOR MOULDINGS 17-13
R.H. MOUNTING BRACKET

R.H. BAR EXTENSION
LOWER STONE
'$) li;
~
$@)
.
DEFLECTOR
, I
L.H. MOUNTING
BRACKET
IMPACT BAR
N1220-B
FIG. 3-Front Bumper Installation

and headlamp retaining rings. 3. Remove both bumper bar ex- bracket retaining screws.
2. Remove the lower stone de- tensions. 5. Remove the rubber fender mud
flector. 4. Remove the grille inner support deflectors. Remove both grille end
R. H. GRILLE
OUTER SUPPORT
HEADLAMP HOUSING
ASSEMBLIES GRILLE CENTER
SUPPORT
l
\b, L H. GRILLE
OUTER
SUPPORT
N 1237-B
FIG. 4-Radiator Grille Installation

support bracket retaining screws and bracket (Fig. 4). 8. Tighten the grille-to-center sup-
remove the grille assembly. 8. Remove one retaining cap screw port retaining cap screws.
6. Remove the grille outer support from each outer upper grille sup- 9. Tighten the grille to outer sup-
bracket retaining screws and move port bracket (Fig. 4). This cap port retaining cap screws.
the brackets toward the grille center screw is near the outer headlamp 10. Tighten the grille - to - outer
support. and can be removed with the use of bracket retaining cap screws.
7. Prop the hood securely open. a distributor clamp nut removal 11. Install the bumper bar exten-
8. Remove the torsion rods, using wrench or similar tool. sions.
Tool T64N-16A605-A. 9. Remove the grille assemblies. 12. Install the lower stone de-
flector.
INSTALLATION 13. Install the headlamps and re-
INSTALLATION
1. Transfer all hardware to the taining rings.
1. Using Tool T64N-16A605-A, new grille assemblies. 14. Install the headlamp doors.
install new torsion rods. 2. Place the grille assemblies on
2. Install the grille outer support a bench and install the left-hand-to- REAR BUMPER
brackets. right-hand grille retaining cap screws. 1. Working under the car, remove
3. Position the grille assembly and 3. Position the grille assembly on the nuts and bolts securing the center
loosely install the grille end support the center support bracket and section of impact bar to the rear
bracket retaining screws. loosely install the grille-to-support bumper mounting brackets:
4. Install the grille inner support retaining cap screws. 2. Open the luggage compartment
bracket retaining screws and tighten 4. Loosely install the grille-to- door and remove the lining board
the grille end support retaining outer support retaining cap screws. from the lower back panel. Discon-
screws. 5. Loosely install the grille-to-outer nect the back-up lamp wires and
5. Install the rubber fender mud lower support bracket retaining cap remove the dome shaped back-up
deflectors. screws. lamp housing covers.
6. Install the bumper impact bar 6. Loosely install the grille-to- 3. Remove the bolts (model 53)
extensions. outer upper support bracket retain- or nuts (model 74) securing the
7. Install the lower stone deflector. ing cap screws. center section of the bumper impact
8. Install the headlamps, headlamp 7. Align the grille assembly in the bar to the lower back panel (Fig. 5).
retaining rings and the headlamp grille opening. 4. Slowly lower the bumper
doors.
COWL TOP VENTILATION

GRILLE AND SCREEN
1. Remove the windshield wiper
arms and blades.
2. Remove the vent grille retain-
ing screws (Fig. 12, Part 17-3).
3. Raise the ventilation grille and
disconnect the washer hoses.
4. Remove the ventilation grille
and screen from the car.
5. To install, reverse the removal
procedure.
RADIATOR GRILLE
REMOVAL
1. Remove the headlamp doors.
2. Remove the headlamp retaining
rings and remove the headlamps.
3. Remove the lower stone de-
flector (Fig. 3).
4. Remove the retaining cap screws
from the center support bracket of
the grille assembly (Fig. 4).
5. Remove hoth the left and right
humper har extension retaining cap
screws and remove the extensions
(Fig. 3). ~
6. Remove the cap screws from
R1225-A
each grille outer support.
7. Remove one retaining cap screw
from each outer lower grille support FIG. 5-Rear Bumper Installation

(339) PART 17 -2-FRONT SHEET METAL, BUMPERS, AND EXTERIOR MOULDINGS 17-15
~' ~ ~~/···
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®~ ffi','U ""· . ·, )
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-~ ~ · .·;It~ /'$-./~ · . · ·.~
.J\
- 'l..- · -'.< ·.
· .,· ·.
,/ . f?" K .. . _
···>>·v·.,.·,·.··
.· ,· ·,.· .· .·. · ·.,· . . · .....
..-/ - . ·.···.~~ ·_
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CD ® CD~~
·~· .·.·.· .· ·.· · ·.·.·
~~} ~·.········~~
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•... ·.•... ·.··.·.· ..·...··•···.·..··.···· .... ·.·..· .
.. · · . ·..
~~
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'>~
-~~
®
1~,·
.
~
0 N1213-B
FIG. &-Exterior Moulding Installation

assembly to gain access to the license just the position of the bumper be- moulding, it should be determined
lamp wire. Disconnect the wire. fore tightening the bolts. by the type of moulding retainer
5. The individual parts of the used whether the respective door
bumper assembly are bolted together trim, quarter trim, or luggage com-
EXTERIOR MOULDINGS
and can be replaced as necessary partment trim should be removed.
(Fig. 5). Figure 6 shows the various methods Bolt-on moulding retainers may
6. To install the bumper assembly, of retaining the body outside mould- require removal of the trim panel
reverse the removal procedure. Ad- ings. Before removing any outside before removing the moulding.

(341)
PART DOORS, WINDOWS AND DECK LID

17-3
1 Diagnosis and Testing . . . . . . . . . . . . ....... 17-17 3 Removal and Installation .................. 17-26
2 In-Car Adjustments and Repairs . . . ....... 17-23

VACUUM DOOR LOCK ponent provides easy identification phragms may be damaged.
for proper installation (Fig. 1). Perform all the vacuum locking
The vacuum hoses are color-coded Under no circumstances should system checks with the engine run-
and the corresponding color mark- air pressure be applied to the vac- ning.
ing at the connections of each com- uum system as the actuator dia-

l. Check for vacuum at the mani- 3. Check vacuum to the control
fold, the check valve, and/or the valve by disconnecting the 14 -inch
reservoir. This can be accomplished green supply hose at the control
COMPLETE SYSTEM hy removing the hose from each com- valve. If vacuum is not present, the
INOPERATIVE ponent and attaching it to a vacuum hose is damaged, obstructed, or not
gauge. (Six to eight inches of vacuum properly installed. If vacuum is
will actuate the locks.) present, connect the hose to the
2. To gain access to the control nozzle from which it was removed.
valve, remove the glove compartment.
1. With all doors unlocked, re- valve. Check for vacuum at the red
ALL DOORS WILL NOT LOCK move the %2-inch red hose and the hose nozzle on the control valve. If
t;~; -inch green hose from the control no vacuum is present, the control
~--------------------------~----
VACUUM CONTROL
VALVE ASSEMBlY
RESERVOIR
ASSEMBLY
GREEN
RED
YELLOW
VACUUM LOCK DOOR LOCK
SOURCE ACTUATOR
ASSiBLY
CHECK VALVE
ASSEMBLY
I
LEFT FRONT
I
LEFT REAR
SELECTOR VAlVE
INSTRUMENT PANEL
ORANGE-UNLOCK
FIG. 1-Vacuum-Operated Door Locking System R1232-A

GROUP 17-BODY, DOORS AND WINDOWS (342)
valve is faulty. If vacuum is present, 2. Remove the 1.4 -inch green and
use a jumper hose and connect the two yellow hoses from the control
red nozzle to the green nozzle of valve.
ALL DOORS WILL NOT LOCK the control valve. Connect the yellow hoses to the
(Continued) If the doors lock, the problem is green hose using a jumper tube ( ~
in the selector valve or the red inch copper or steel tubing) . If the
and/ or green hoses connected to the doors lock, the control valve is
selector valve. faulty.
1. With all doors locked, remove valve or the red and/ or white hoses
the %2-inch red hose and the ~-inch connected to the selector valve.
white hose from the control valve. 2. Remove the lJ4 -inch green hose
If no vacuum is present, the control and two orange hoses from the con-
ALL DOORS WILL NOT valve is faulty. If vacuum is present, trol valve. Connect the orange hoses
UNLOCK use a jumper hose and connect the to the green hose using a jumper tube
red nozzle to the white nozzle of ( lJ4 -inch copper or steel tubing) . If
the control valve. If the doors un- the doors unlock, the control valve is
lock, the problem is in the selector faulty.
1. Remove the cowl trim panel 3. If a rear door is inoperative,

and disconnect the yellow (locking) remove the rear seat cushion and
or orange (unlocking) hose from its back. Disconnect the yellow (lock-
respective tee. If vacuum is not ing) or orange (unlocking) hose at
present at the hoses connected to the nipple located in the quarter
the control valve when the selector panel. If vacuum is not present at
valve is operated, the control valve the hoses when the selector valve is
or the hoses from the valve are operated, the difficulty is in the hose
faulty. from the tee behind the cowl trim
ONE OR MORE LOCKS ARE panel or in the tee. If vacuum is
INOPERATIVE 2. If a front door lock is inopera- present, proceed with step "D".
tive, remove the door trim panel and 4. Remove the rear door trim
access cover. Disconnect the yellow panel and access cover. Disconnect
(locking) or orange (unlocking) the yellow (locking) or orange ( un-
hose from the actuator. If vacuum locking) hose from the actuator. If
is present at the hoses when the vacuum is present at the hoses when
selector valve is operated, the actua- the selector valve is operated, the dif-
tor or the components of the locking ficulty is in the actuator or the com-
mechanism are faulty. ponents of the locking mechanism.
POWER WINDOWS the rear window will automatically A single-pole, double-throw switch
close after its respective door is is located on the arm rest on each
The front door window circuits on closed (Figs. 11-6 and 11-7). right front, right rear and left rear
the sedan and convertible models are A master control switch is mounted door for individual passenger con-
identical. The rear door window cir- on the left front door arm rest panel. trol of the door windows. A single-
cuits on sedan models (53A) are The panel consists of a single-pole, pole, double-throw switch is also
similar in design and operation to double-throw control switch for each mounted on the right front door arm
past models. The rear door window of the windows and also a safety rest for vent window control.
circuit on convertible models (74A) lock-out switch. The lock-out switch A reversible motor which has an
incorporates additional switches enables the driver to prevent the integral circuit breaker (to ground)
which automatically cause the rear operation of all window switches is located in each door. The main,
window to partially lower when its except those on the master control or power feed, 20-ampere circuit
respective rear door is opened; also, panel. breaker is located on the fuse panel.
ONE WINDOW OPERATES IN One winding in motor open or nect the switch. Insert a probe or
ONE DIRECTION ONLY shorted. arcless terminal jumper between the
THROUGH EITHER SWITCH If this condition prevails, remove armature slot of the "quick-discon-
CIRCUIT either switch assembly and disconnect" and the respective field slot of

Black
-
Brown
TO BATTERY G 2 0 AMP CIRCUIT BREAKER WHITE Black L'\,
r
~J}:..'.
·• (+)TERMINAL (LOCATED ON HORN RELAY CONNECTOR TO COURTESY liGHT GROUND Jl' '1.
MOUNTING PLATE) Black ·Slack-White
II Yellow-Brown.,=~:~~~~:~ ~ CURR~T·L~MITER ~
-
;·······---,...:....STARTER •White SPllcr;;;'
~-- RELAY ~ I I Rod-Slue ..J~h;.lgii.QJ:~ -alack FRONT-DOOR ~ 14632 ~-~LA-,
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w
1\~~9( ~.--~ ~
1
WINDOW REGULATOR
~ ~ ..-r=l~ ~ ·:ft::
«<
Block -. L Block- Mo;oR

1
I B
.~ 9 ~~ L -~ \ (~v;;R~~~~~~~~s1noNl .r.J~~=~:~i~~-
-----~--.
WINDOW-REGULATOR
sPliCE IN
., 14A005 - WINDOW-REGULATOR
SWITCH ~
~ I REAR-DOOR r~==~;====ii===~'~~'U~I~~-~~8l~u·~~~i;{i~B~Iuo:::-~i
Reel-Yellow -~
:
I Black Block
r
SAFETY RELAY I k
i '
: "\.,
ve:e6~~~~W
~
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WINDOW
RE~~\~~R
:_::::_fo~i::f5?t-· 1--
F\.:-..:if:...~<::;'"<.I...I~A::-=l---1-
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Soc Rod-Blue' 'Rod-Violet IRod-Whitel
- 1 I MOTOR f?.ml ~~
~
r-1- MOTOR ~
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0
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1
1 D WHITE CONNECTOR GROUND Yellow r'7:\. _ _ 1 uo
Rod-Yellow r I \~ Reel- 10 AMP
Y•li w 8 1 1 r+-f.t-f-+------+-++---::::::;..:.:::~;rrt:iJ1 Rod-White Violet CIRCUIT
(~I White-.--~~ J ~ Yell~r:;;:~:.._ +,q...+f-----++-~ I ~--- . i ~A~N~~~-~~~~

1
- o rown I -I - =;::Blue .... __ BR/KER

~~ ~· If ~~
Ir
__ _ 1 Yellow-V1olet ·
:;;BI:k~~~=f.Ll.,. ~>---WINDOW-REGULATOR ~- r
1
y 11 Orange MOTOR GROUND -
Red CON~Efc:TOR 8/ue---:~e//owBrown eow- c c - ~~·~i~:lE- S~L~~~t<t-IHH-....:::Reei:::;..;·V.,:::io::::let:._f--~rr--.,__ :~WINDOW-DOWN ___ \\Yellow

( , c, ~ Red Brown--- I -~ Yo/tow Block Orange \. 1,' '-, . ' ~-· '' RELAy REAR DOOR WINDOW
';';~
1 .....~~..,:8:.:,:;ro::::;w~n8::::1u~e++-+--I--R-eei':'"-W~ht_e_+-~'~~~-J-l:!i-J-__jl
j Red ti
,=
=
YetlowB/ue _ _,. Reel-Block
Reel-Black
1 ~·~ ~:~:::-
'- REGULATORM0101<
---._Red-While
~~:a_~.C~;~ni~AOOS CO~~~i~R- WIND:el:~~:lock-,...--rQctt.J~~-~~ Ye~::nge..,.J Yellow-Vio~et ;~:

tl~
1
SPLICE IN
14AJ03
Rod-Blue ~ ~
/
~\.-
White
-"-f-l:fSPliCE IN
V
14 631 CUTOFFSWITC!i !
-
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SPLICEIN
14632
.....J
-----,---'
"',
/ _ .
,_Block
~ow-
Yell
r.
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BLUECONNECTOR
V Yellow-Brown ~,·.lf=,
- • --ji ~~v
- v,.,..... =, 1/ f-White SPLICE :hi:~632""'v ·-,--\\,._;:B;,;:ro:::.:wn~-8:::;1u:;;,e+-f---'
Jl..._O+-f.,
, Yellow
---_t ~.r
f -1- ~
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1
CURRENT·SENSING
RELAY f.-Orange
v.;+: ~
Yellow-Violet I 1 Ye....:llo..::w:;:;-V;..io-let-~ -1- - ,.._DOOR-WINDOW
V
- -1 ...__ __,/_ _
/
V_. J./ \ /
:'
TO ACC. TERMINAL BROWN Rod-Violet I I REGULATOR RELAY PANEL
IGNITION SWITCH CONNECTOR ....- ~
Rod.-~Biue : : :':1,'. WINDOW-DOWN STOP \ WINDOW-ACTUATOR SWITCH! y II Bl if-Red-Wh 1te
';!';'~ ~ow-uo---l~--·I
1
',,. l:.JW SWITCH WINDOW•STOPSWITCH {DOOR-CLOSEDPOSITION) J
~\ ~ -;;~ .'J:_")--1- ~ ~CURREN:~LSA~SING
1
Rod-Blue @QJ
Red-Blue~!'----.,. ~Pt'' \m:ir:~f.o. . . J~t c6~~L~'foRWINDOW·t)}Ur--~~,_., Rod-White Yellow Black ~ .. I" i BlUE CONNECTOR
~ I ' ""'-lR
Rod-Black CUT OFF ,_I' Green Yellow-Blue .j Yellow :~ ~:~E;j:~~-1""'::::::::::::::_-:_-..._- ..
l'
1 ::
WINDOW REGULATOR
Yellow-Block
I ""'-,RED
SWITCH ~~ ,~ -@ @r-ET--
~ ~-:-"""'+~O'::'nge
~t:=:t3:@ ©J-:i0-,
.J
SWITCH POSITIONS Rod-Violet "- i CONNECTOR __ ..J Brown-Biuo
1
I tl ~ ;~~;,~::·
,..-~~-4+-...:::;::;:::.;,;;;;.-1-+--+---+--+--' "' '-...,ORANGE WIN~g~-~~~fc~ ~Red
VIolet s~~~~~N\ -
..1.
.J
u~ I 10 AMP CIRCU71T
BREAKER
DOWN UP OR J, N Yellow- Violet CONNECTOR Yellow-Blue " '\'\"J I f) I WINDOW-DOWN
iT 6 u t! ;,;r I~ r Rod-Blue~ I
OR OPEN
~
UP OR
CLOSED
DOWN /~~~~ I'

rqfr-- f-t~~MASTER-CONTROL
: , , I , :
10 6J 1------- SPLICE IN SWITCH

BY-PASS SWITCH
{DOOR-OPtJEN
POSITION)
rm~
: r++-+-t---f-+---+-1..;...1
-r-~ Wl~~~6"i'gt?~~10R
I RELAY
WIND~~R:e~~~TOR
---+-'--M-0-TO_R_o;,;.r;,;.on.:;g•~H ~~
:
Rod- Violet
7
14R~~~Yellow ~ -.~~-u-
I
L__
CLOSED OR OPEN I I - [._/
""
61 .l'o
REAR-DOOR
I
!/WINDOW-UP RElAY
1
WINDOW- :;~~ Rf~~~o;~R 1/ f-)- Orange - T f: Reel- While Bl
'"a.•.~ ",~:::• ~ ~ ~'~'& ""~U~ ,__ ' A-++--1-___;~-++__.,.;\~~.\ ~ ~~~~~~~EN

1
-~ey ~~- : B:Iow ck'~;:

: TO /ow Vue
Orange- I '" '-'"' • : .:·; I RELAY
\
~ .....- Red- Violet Black
!
:MJ'~O}T~AO~TR~R 8lack- White ?~:~:- r-~ S~Ll~;~Nk_9-t:±:±:t:::t:=~~:t=CU~R~RE~N=T-3:.....,;.1 :R:od
_i·_B=Iu:e ~:~~~re~~~~-~cY1eU~
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1
REGULATOR Black Black liMITER Blue
-Rod- Yellow )4- ~~t?~D I -......r --v-- : Black Block RELAY \ ~-!"[\ Brown ~-:-~ ~!51- Slue
_
,.---
1 COURTESY liGHT
_,--TO
GROUND Black ~ FRONT-DOOR WIN:row Yellow-Blue
........_
...._
j_ I :
,,
Block '""---~ •.
I -
------
-~a---
:~~ -~~- ~-oo~~==~OR -~~=~~~-i~~R~eel~~~~~·=~~~t:::~~-1-4-~-2-~-~=~'~~~~~~~SJ~~~k====~~--!h~II~-~-B~~~e
::,.SPliCEIN
T •=:
ellow-Orange WHITE ~...-_ _ _ _ _ _ __;,W;.:.;h::,:ite;..__ _ _ _ _ _ _~...l""'-':"~~-:~ ~- . .L. \ White Brown
GREEN CONNECTOR Reel- Yellow
CONNECTOR
FIG. 2-Power Window Circuit R1240·A

17-20 GROUP 17- BODY, DOORS AND WINDOWS {344)
the inoperative circuit; then connect the field winding in the motor is
ONE WINDOW OPERATES IN the leads of the continuity test lamp open or the circuit wiring is open.
ONE DIRECTION ONLY beween the battery slot and the arm- If the test lamp lights and the circuit
THROUGH EITHER SWITCH ature slot. If the window will not is inoperative, motor winding or cir-
CIRCUIT (Continued) operate and the light does not go on, cuit wiring is shorted.
Defective switch or open wiring. minal jumper between the armature

To check this type of problem, slot of the "quick-disconnect" and
proceed as follows: the respective field slot of the inop-
WINDOW OPERATES IN erative circuit; then connect the leads
1. Remove the inoperative switch of the continuity test lamp between
BOTH DIRECTIONS THROUGH
assembly and disconnect the switch. the battery slot and the armature
ONE SWITCH CIRCUIT ONLY
Substitute a known good switch and slot. If the motor operates and the
test. test lamp lights, the defect is in the
2. Insert a probe or' arcless ter- switch or the circuit wiring is open.
1. Motor armature and/or wind- winding. If the motor will not oper-
ings or circuit wiring is open or ate and the lamp does not light, the
shorted. armature in the motor is open or
2. Circuit breaker is improperly the armature circuit wiring is open.
grounded or defective. The following If the test lamp lights and the circuit
ONE WINDOW WILL NOT steps will help to locate the source is inoperative, the motor armature
OPERATE IN EITHER of trouble: or armature circuit wiring is shorted
DIRECTION THROUGH EITHER a. Remove the switch assembly or the field winding and/or wiring
SWITCH CIRCUIT and disconnect the switch. Connect is open or shorted.
the leads of a continuity test lamp b. If the continuity is indicated
between the battery slot and the at the battery slot by grounding the
armature slot of the "quick-discon- test lamp probe, but is not indicated
nect". Connect a jumper wire be- at any of the other slots, check the
tween the battery slot and either field ground wire connection.
20-ampere circuit breaker is de- Insert one probe of the test lamp
fective. in the battery slot of the "quick-
disconnect" and the other probe to
ALL WINDOWS WILL NOT To check the continuity of this the ground on the car to check the
OPERATE IN EITHER circuit and the operation of the 20- continuity at the battery slot. If con-
DIRECTION ampere circuit breaker, remove the tinuity is not indicated at this point,
master control switch panel assem- substitute a known good 20-ampere
bly and disconnect the left front door circuit breaker with jumper leads in
window switch "quick-disconnect". the circuit and retest.
POWER VENT WINDOW The power window schematic dia- guide during the trouble shooting
phragm should also be used as a procedure (Fig. 2).
One field winding in the motor has field positions of the switch. Proceed
an open circuit, or is shorted. with the test to the disconnect ter-
ONE WINDOW OPERATES minal at the inoperative vent motor
IN ONE DIRECTION ONLY, Remove the vent window switch and check for voltage at the con-
THROUGH EITHER SWITCH assembly from the door arm rest. nector. If voltage is indicated at the
CIRCUIT Actuate. the switch, and with a volt- motor disconnect (field and arma-
meter or test lamp, determine if volt- ture positions), the motor assembly
age is present at the armature and is defective and should be replaced.
Defective switch or open wiring. test. If the circuit is inoperative,

ONE WINDOW OPERATES IN Remove the inoperative switch as,.. check for an open circuit between
BOTH DIRECTIONS, THROUGH sembly and disconnect the switch. the disconnect at the switch and the
ONE SWITCH CIRCUIT ONLY Substitute a known good switch and disconnect to motor.

-
~
- - - - - T O BATTERY
20 AMP CIRCUIT £R'EAKER (LOCATED ON HORN RELAY MOUNTING PLATE)
Yellow-Blue
BLUE CONNECTOR
WINDOW ACTUATOR SWITCH
(DOOR- CLOSED POSITION) -
U'1
( +) TERMINAl
Oronge
WINDOW-STOP
SWITCH
SPLICE IN 14633 Black
~~·~~~~,
Black
Black
REAR-DOOR WINDOW
REGULATOR SWITCH
CURRENT SENSING
RELAY
CURRENT lfMITER Yeffow-Biue

RELAY
\
--BY-PASS SWITCH
(DOOR-OPEN POSITION)
Brown
P1115-B
FIG. 3-Automatic Rear Door Window Circuit

R1233-A
FIG. 4- Vacuum Luggage Compartment Lock

(347) PART 17-3- DOORS, WINDOWS AND DECK LID 17-23
ONE WINDOW WILL NOT Open circuit or defective motor. motor. If voltage is present, the
OPERATE IN EITHER motor is defective or the wiring leads
DIRECTION THROUGH EITHER Check for voltage indication at between the disconnect and the
SWITCH the disconnect to the inoperative vent motor are open.
BOTH WINDOWS WILL NOT

The 20-ampere circuit breaker is slot of the disconnect. If voltage is
defective. not indicated at this point, substitute
OPERATE IN EITHER
DIRECTION
Remove the master control switch a known good 20-ampere circuit
and check for voltage at the battery breaker in the circuit and retest.
AUTOMATIC REAR DOOR the window-actuator switch, the flows through the current sensing
WINDOWS (MODEL 74A) window-up cut-off switch, the up- relay control winding and opens
OPERATION relay winding, the current-limiter the contacts, thus preventing en-
relay contacts, the motor circuit ergizing of both the up and down
WINDOW-DOWN CIRCUIT breaker, and the closed bypass fields of the motor at the same time.
switch to ground. The current-limiter If the window has been lowered
1. When opening a rear door, the relay contact points are closed and
window-actuator switch is operated more than seven inches, the window-
remain closed until the door is shut up cut-off switch is actuated and the
and the switch contacts are reposi- and the window is all the way up.
tioned. This action opens the up- switch contacts are open. Thus, the
However, the window does not go up-relay circuit is open and prevents
travel field circuit of the motor, doses up until the door is shut because
the feed circuit to the control wind- the automatic up movement of the
the position of the window-actuator window until the door is closed.
ing of the window-down relay, and switch (with the door open) leaves
closes the feed circuit to the window- 3. Approximately 1;4 inch before
the motor up-field feed circuit open.
up cut-off switch (Fig. 3). the window reaches the closed posi-
2. To complete the down move- As soon as the up-relay contacts tion, it actuates the current-limiter
ment of the window, current flows are closed, a lock-in circuit is estab- relay bypass switch. The bypass
through the window-actuator switch, lished which will continue to ener- switch circuit is provided to prevent
the window-down stop switch (win- gize the up-relay coil after the win- the current-limiter relay from cutting
dow travel limit switch), the down- dow-actuator switch contacts are out if the window motor requires
relay windings and through the cur- repositioned upon closing the door. above normal operating current be-
rent-sensing relay contacts to ground. This lock-in circuit permits current fore it reaches the full up position.
flow through the up-relay contacts, 4. With the bypass switch circuit
3. When the down-relay contacts the window-up cut-off switch, the
close, the current flows from the open, the motor current-limiter relay
up-relay coil windings, the current- coil carries the full motor current. As
battery, through the down-relay con- limiter relay contacts, the motor cir-
tacts, the motor-down field, the motor soon as the window reaches its up-
cuit breaker, and the bypass switch ward limit, the motor stalls and the
armature and circuit breaker, and the to ground.
dosed bypass switch to ground. The stall current is sufficient to open the
motor is energized and the window 2. When the door is dosed, the current-limiter relay contacts. This
is lowered. window-actuator switch plunger is opens the ground circuit of the up-
1 depressed which repositions the relay coil windings and the complete
4. After the window travels down
switch contacts and completes the up circuit becomes inactive.
approximately six inches, the win-
circuit from the battery through the If the conventional power win-
dow-down stop switch is actuated
and its contacts are opened. This window-up relay contacts, the coil dows are operating properly and the
now opens the down-relay circuit, windings of the current sensing re- automatic system is inoperative~ the
lay, the window actuator switch, the motor, manual switch, bypass switch
and the downward movement of the
up-field of the motor, the motor arm- and 20-ampere circuit breaker are
window stops.
ature and circuit breaker, and the not defective.
bypass switch to ground. The motor If both systems are inoperative,
WINDOW-UP CIRCUIT operates and closes the window. the conventional circuit should be
1. When the window is lowered, The current-sensing relay con- checked first as the systems have
the window-up cut-off switch is tacts are in series with the win- common motor 10- and 20-ampere
closed providing power to the control dow-down relay control winding circuit breakers.
winding of the window-up relay. to ground. When the window is Following is a trouble diagnosis
This permits current to flow through being raised, the motor current guide.
1. 10- or 20-ampere circuit break- 4. Window-down stop switch.

WINDOW WILL NOT GO er. 5. Motor-down field winding.
DOWN 2. Window actuator switch. 6. Current-sensing relay.
3. Window-down relay. 7. Open circuit in wiring.

TROUBLE DIAGNOSIS GUIDE {Continued)
WINDOW CONTINUES ALL 1. Broken spring on the stop 2. Window-down stop switch.
THE WAY DOWN switch actuator lever. 3. Down relay.
1. 10- or 20-ampere circuit break- 3. Motor up-field winding.

WINDOW WILL NOT RETURN er. 4. Window-up cut-off switch.
TO UP POSITION 2. Window-up relay. 5. Window-actuator switch.
WINDOW CLOSES...;.MOTOR 1. Current-limiter 'relay. 2. Bypass switch. (Improper ad-

CONTINUES TO OPERATE justment or shorted contacts.)
WINDOW MOVES UP ONLY 2. Sta11ed motor due to tight win-

A SHORT DISTANCE AFTER 1. Bypass switch.
dow channels.
DOOR IS CLOSED
VACUUM CONTROLLED ing or disconnected hoses, are usual .. If vacuum is present, connect the
LUGGAGE COMPARTMENT ly detected very easily by listening hose to the valve nozzle.
DOOR LOCI( for air leaks, and can be corrected 3. Disconnect the hose from the
without excessive checking. Under right hand nozzle of the control valve
The vacuum source for this sys- no circumstances should air pres-
tem is obtained from the vacuum in the glove compartment. Touch a
sure be applied to the system as finger to the end of the nozzle and
door lock system through a tee con- serious damage to the actuator
nection at the distributor supply line. operate the valve. If vacuum is not
diaphragm will result. If the sys- present, the difficulty is in the control
The system is used to unlock the tem is inoperative, the sequence
luggage compartment door from the valve. Connect the hose if vacuum
for determining the malfunction is present.
interior of the car (Fig. 4). should start at the vacuum source
The principal components of the while the engine is running. The 4. Unlock the luggage compart-
system are a control valve assembly procedure is as follows: ment door with a key. Disconnect
and a door lock actuator assembly. the hose at the actuator. With some-
The control valve, through which the 1, Listen for obvious air leaks. one operating the control valve in the
vacuum is routed, is located in the 2. Check the vacuum control valve glove compartment, touch a finger
glove compartment. The actuator, lo- in the glove box by disconnecting to the end of the hose. If vacuum is
cated in the luggage compartment, is the hose from the left hand nozzle of not present, the difficulty is in the
a vacuum motor consisting of a dia- the valve and touching a finger to hose from the control valve to the
phragm with a rod attached to oper- the end of the hose. If vacuum is not actuator. If, however, vacuum is
ate the door mechanism. present, the difficulty is at the source present, the difficulty is in the actua-
Minor malfunctions, such as leak- from the vacuum door lock system. tor assembly,

WINDOW BYPASS SWITCH switch in the door. a %2-inch parallel clearance between
8. Connect the switch lead wires. the windshield outside, side mould-
1. Lower the window to the down Be sure that the wires are routed ing and the forward edge of the vent
position. through the three retaining clips. window frame, as shown in Sectional
2. Disconnect the negative View "AA" of Fig. 5.
cable and check the operation of the 4. Temporarily tighten the adjust-
3. Remove the trim panel from
window. ing screws at points "A".
the door.
10. Install the door trim panel.
4. Mark the position of the win- 5. Loosen the jam nut at point
dow~up stop bracket. "B."
5. Remove the window-up stop WINDOWS
6. Tilt the vent assembly toward
and bypass switch from the door as FRONT DOOR AND VENT the inside or outside of the body by
an assembly. rotating the adjusting screw at point
6. Adjust the switch so that the (Refer to Figs. 5 and 6) .
"B" clockwise or counterclockwise,
threaded portion of the switch is 1. Remove the door trim panel. as required. This adjustment is pro-
flush with the lower surface of the 2. For the vent window, loosen vided to obtain alignment with the
window stop bracket. The threaded the adjusting screws at points "A". windshield outside, side moulding
part must not protrude beyond the 3. Adjust the vent assembly for- and proper sealing between the roof
bracket. ward or backward and up or down, rail weatherstrip and top edges of
7. Install the window stop and as required, to obtain approximately the vent window frame.

{349) PART 17-3- DOORS, WINDOWS AND DECK LID 17-25
7. Cycle the glass and channel the glass and channel assembly in as necessary. Tighten the screw and
assembly to the down position. the up position. After adjustment, washer assemblies at points "H".
8. Loosen the jam nut at point tighten the jam nuts at points "B" 18. To provide a flush condition
"C". Adjust the vent window glass and "C". Tighten the screw and between the top edge of the glass
forward or backward at point "C", washer assemblies at points "A" and and channel assembly and the door
as required, so that the glass run is "E". outer panel at the belt line, loosen
parallel to the front edge of the glass 15. To obtain parallel alignment the lower stop retaining scr~w and
and channel assembly. between the top edge of the glass washer assemblies at point "J" and
9. Cycle the glass assembly up and and channel assembly and the bottom adjust the lower stop assembly up
down to determine whether or not a edge of the. roof rail weatherstrip, or down, as required. After adjust-
binding condition exists between the loosen the equalizer arm bracket re- ment, tighten the screw and washer
glass and ·channel assembly and the taining screws at points "F". Move assembly at point "J".
vent window run assembly. the equalizer arm bracket up or 19. Tighten the screw and washer
10. Adjust the lower portion of down, as required, then tighten the assembly at point "J" after all adjust-
the vent window run toward the in- screw and washer assemblies at points ments have been completed. The
side or outside of the body, as nec- "F". The glass and channel assembly window mechanism must be adjusted
essary, by rotating the adjusting must be in the up position for this to operate with a current draw not
screw at point "C" clockwise or adjustment. to exceed 20 amperes at 12 volts
counterclockwise. After adjustment, 16. To align the upper stop assem- when the windows are individually
temporarily tighten the jam nuts at blies with the stop brackets on the operated.
points "B" and "C". window channel, loosen the screws
11. For the glass and channel as- at points "G" and move the stop REAR DOOR WINDOW
sembly, cycle the glass to the up assemblies in or out, as required, 1. To obtain the proper tension
position and loosen the screw and then tighten screws "G". between the front and rear guide
washer at point "D". 17. To provide a flush condition assemblies and the window assembly,
12. Adjust the glass lockside run between the top edge of the glass rotate the adjusting screws at points
and retainer assembly forward or and channel assembly and the top "A" and "B" clockwise or counter-
backward to obtain proper clearance edge of the vent window frame, clockwise as required. The window
between the front edges of the glass loosen the upper stop retaining screw must be in the up position. After ad-
and channel and the run assembly of and washer assemblies at points "H". justment, temporarily tighten the jam
the vent window glass division bar. Adjust the upper stops up or down, nuts at points "A" and "B".
With the glass assembly in the down
position, readjust the run and re-
tainer assembly forward or backward
at point "D" to obtain proper clear-
ance between the front edge of the
glass and channel assembly and the
run assembly portion of the vent
window assembly.
13. Tilt the run and retainer toward
the inside or outside of the body, as
necessary, at point "D" to obtain
proper alignment between the top
edges of the glass and channel as-
sembly and the outside belt weather-
strip assembly. After adjustment,
tighten the screw and washer at point
"D".
14. With the glass and channel
assembly in the down position, tilt
the lockside run and retainer assem-
bly toward the inside or outside of
the body at point "E" to obtain par-
allel alignment between the rear edge
of the glass and channel assembly
and the lockside run and retainer
assembly. After adjustment, tempor-
arily tighten the screw and washer
assembly at point "E". To obtain the
proper alignment or seal between
the top edge of the glass and channel
assembly and the roof rail weather-
strip, readjust the front and rear glass
run assemblies at points "C" and "E"
simultaneously toward the inside or
outside of the body, as required, with FIG. 5-Front Door Window Adiustment

GLASS AND
CHANNEL
-~:=~=~==~==:==~=~==~==========:::r~~::::-
VENT WINDOW _ _.......,.,~.
REGULATOR
ASSEMSLY
SECTIONAL
Vlf.W-AA
SECTIONAL
VIEW-CC
REGULATOR\ EQUALIZER
-...:--...!Lo~~__.~,~~:,.-~,:.AIRMBRACKET ASSEMBLY
-()
-
-
~
Rl239-A
FIG. &-front Door Window Methanism

{351) PART 17-3-DOORS, WINDOWS AND DECK LID 17-27
7. To obtain a flush condition be-

tween the top edge of the window
and the door outer panel at the belt-
line, adjust the lower stop up or
down at point "H", as required. After
adjustment, tighten the screw at point -:-
"H".
The window mechanism must be
adjusted to operate with a current
RETAINER draw not to exceed 12 amperes.
VIEW AA
FRONT AND REAR DOOR

HINGES
When adjusting the door for cor-
rect alignment, remove the door lock
striker plate to permit the door to
REAR RUN hang free on its hinges. When prop-
erly adjusted, the door should be
centered in the door opening.
If the contour of the door does
not require correction, the door can
be aligned by adjustments provided
at the door hinges. The front doors
can be adjusted fore or aft and up
or down at the door end of the
hinges by loosening the cap screws
which are threaded into floating-type
tapping plates. The door can be ad-
justed in or out at the front body
FRONT RUN pillar end of the hinges by loosening
the cap screws and moving the door
to the proper position (Fig. 9).
FIG. 7-Rear Door Window Adiustment The rear doors can be adjusted
up or down and in or out at the
2. To obtain proper clearance be- dow for Model 74 in the same man- door end of the hinges by loosening
tween the front edge of the window ner. After adjustment, tighten the . the cap screws which are threaded
assembly and the rear edge of the nuts at points "C" securely. The into floating-type tapping plates. To
center pillar for Model 53, or be- window must be in the up position adjust the rear doors fore or aft, it
tween the front edge of the rear win- for these adjustments. is necessary to remove the door trim
dow and rear edge of the front 4. To obtain the proper alignment panel to gain access to the ooor end
window on Model 74, proceed as between the top and rear edge of the of the hinges (Fig. 10). When ad-
follows with the window in the up window and the roof side rail wea- justing the doors, loosen the cap-
~osition. Adjust the front run for- therstrip, adjust the front and rear screws just enough to maintain a
ward or backward at point "A". run assemblies toward the inside or slight drag.
After adjustment, temporarily tighten outside of the body at points "D"
the jam nut at point "A". and "E", as necessary. After adjust- DOOR LOCK STRIKER
3. To obtain a parallel alignment ment, tighten the screw and washer ADJUSTMENT
between the top edge of the window assemblies at points "D" and "E"
and the bottom edge of the roof edge and tighten the nuts at points "C". The striker pin can be adjusted
rail weatherstrip, tilt the equalizer 5. Adjust the upper stops up or laterally, vertically and fore and aft.
arm bracket assembly up or down at down as necessary to control window Loosen the striker retaining screws
points "C", as required. Vertical upward travel by loosening the screws and move the assembly in the re-
alignment is also obtained between at points "G". After adjustment, quired direction. Then, tighten the
the front edge of the rear door win- tighten the screws at points "G". retainer screws and check alignment.
dow and the rear edge of the center 6. The dovetail is adjusted toward To get the proper striker pin-to-
pillar for Model 53, or between the the inside or outside of the body door lock clearance shown in Fig.
front edge of the rear door window and the dovetail retainer up or down 11, add or remove shims between
and the rear edge of the front win- to align with striker at points "F". the striker plate and body pillar.
EJREMOVAL AND INSTALLATION

WINDSHIELD 2. Remove the windshield inside 4. Remove the front upper body
REMOVAL side mouldings. pillar weatherstrip retainers.
1. Remove the sun visor assem- 3. Remove the front upper body 5. Remove the roof drip side front
blies. pillar weatherstrips (Model 74). mouldings (Figs. 12 and 13).

UPPER STOP
RETAINER
REAR
GUIDE
Q
:a
0
c
VIEW CC
..
"11
'I
I
CICJ
0
REAR c
GUIDE ...-<
PIN
PLATE
BRACKET
ASSEMBLY
FIG. 8-Rear Door Window Mechanism

R1238-A --
w
U'l
N

(353) PART 17-3-DOORS, WINDOWS AND DECK LID 17-29
12. Remove the wiper blade and LOCK STRIKER

arm assemblies.
13. Remove the cowl top grille as-
-;embly and disconnect the wind-
shield washer hoses.
14. With a helper, push the wind-
shield, weatherstrip and outside lower
moulding assembly out of the wind-
shield opening and place on a bench.
15. Remove the outside lower
moulding from the weatherstrip and
remove the weatherstrip from the
glass. FIG. 11-Lock
16. Clean old sealer from the Striker Adiustment
weatherstrip and from the wind-
shield opening. 15. Transfer the inside rear view
miror (if removed) to the new glass.
INSTALLATION 16. Clean the windshield glass,
weatherstrip and mouldings.
1. Apply sealer to the glass groove
of the weatherstrip. INSIDE REAR VIEW MIRROR
2. Position the weatherstrip on the REMOVAL
UP
AND DOWN ADJUSTMENTS R1228-A glass, install the lower moulding in
the weatherstrip and install a 1/s -inch 1. Clean both the inside and out-
side surfaces of the windshield in the
FIG. 9-Front Door '\ash cord around the outer perimeter
of the weatherstrip in its body flange area of the mirror mounting bracket.
Hinge Adiustments groove (Fig. 14). Inspect the windshield for stone chips
3. Apply scaler to the windshield and scratches.
6. Remove the windshield outside opening pinchweld flange. 2. Using welding putty or wet rags,
upper corner mouldings (Fig. 12). 4. Apply lubricant (liquid soap or insulate all chips or scratches within
7. Remove the windshield outside Ru-Glyde) to the weatherstrip where 12 inches of the mirror mounting
side mouldings (Figs. 12 and 13). 1t contacts the pinchweld flange. bracket.
5. With the aid of a helper, care- 3. Apply heat to the bracket mount-
8. Remove the windshield outside ing area from outside the windshield
top moulding. fully position the windshield in the
opening. with a standard 250-watt infrared
9. Remove the windshield inside 6. Pull the inside lip of the weather- bulb (heat lamp) . Hold the lamp ap-
top moulding and visor retaining strip over the flange by pulling the proximately four inches from the
screws. sash cord. Pull the sash cord in the windshield while rotating it in a small
10. Remove the windshield inside same general plane as the glass. Pull circle.
side mouldings. the sash cord to the bottom corner 4. The mirror mounting bracket
of one side and then pull the other can be pulled off the windshield glass
11. Remove the instrument panel in approximately eight to ten min-
sash cord to the bottom of the other
front upper finish panel. utes, using the mirror as a handle.
side. Do not pull one sash cord all
IN AND OUT UP AND DOWN ADJUSTMENTS the way around the perimeter of 5. Slowly remove the heat lamp.
the glass. While pulling the sash Do not remove the insulating ma-
cord, gently bump the outside of the terials until the windshield has
windshield with a soft rubber mallet. cooled to room temperature.
7. Install the cowl top grille and 6. Remove the mirror ·and arm
connect the windshield washer hoses. from the bracket.
8. Install the wiper blade and arm
INSTALLATION
assemblies.
9. Install the instrument panel 1. Locate and mark with a wax
front finish panel. pencil the bracket location on the
10. Install the windshield inside outside surface of the windshield
side mouldings. (Fig. 15).
11. Install the inside top mould- 2. Use a good grade of "ethyl al-
ing and sun visor retainers. cohol" to thoroughly clean the inside
12. Install the windshield outside glass surfare bracket mounting area
side mouldings, outside top moulding and mounting bracket face. It is im-
and the outside upper corner mould- portant that the mounting surfaces
ings. are properly cleaned before the resin
13. Install the roof drip side front is applied.
mouldings, front upper body pillar 3. To mix the resin pour the entire
weatherstrip retainers and front up- contents of the small catalyst bottle
FIG. 10-Rear Door per body pillar weatherstrips. into the large epoxy bottle (Fig. 15).
Hinge Adiustments 14. Install the sun visors. 4. Properly stir the contents for

17-30 GROUP 17- BODY, DOORS AND WINDOWS (354)
FIG. 12-Windshield and Exterior Mouldings-Model74

three to five minutes to mix the cata- and resulting bond strength, it is together. Under no circumstances
lyst and epoxy into resin form. To mandatory that the entire contents should only a portion of the epoxy
guarantee the correct mixing ratio of both bottles are properly mixed or catalyst be used.
OUTSIDE TOP MOULDING
SEALER
WINDSHIELD
P MOULDING
RETAINING CLIPS
VIEW-cc''f'
VJEW-EE
R1236-A
FIG. 13-Windshield and Exterior Mouldings-Model 53

FRONT DOOR LOCK

CORD REMOVAL
1. Remove the door trim panel
and water shield.
2. Remove the window rear run
access covers from the door outer
edge.
3. Remove the rear run retaining
screws and remove the rear run from
the door.
4. Disconnect the door lock re-
mote control rod (remote control
link) from the door lock assembly.
5. Disconnect the outside door
handle button-to-lock rod (door lock
Va" SASH CORD actuating rod) from the lock assem-
bly (Fig. 16).
R1235-A
6. Remove the door lock vacuum
control retaining screws and discon-
nect the vacuum control rod from
FIG. 14-Windshield Prepared for Installation the lock assembly.
10. After the bracket has had time 7. Disconnect the lock cylinder-
5. Apply the mixed resin to the to-lock assembly rod from the lock
bracket mounting surface. Level off to adhere to the glass, remove the
tape and install the mirror and arm assembly.
the resin film as smoothly as possible. 8. Remove the lock assembly re-
to the bracket.
6. Place the mounting bracket sur-
face upward in a vise or in a small
mound of permagum or any suitable
holding material that will support the
mounting bracket as shown in Fig.
15. Hold a standard 250-watt infra-
red lamp about five to six inches from
the mounting surface of the bracket
for two and one-half minutes (Fig.
15).
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
five inches long located just under
the knob of the bracket (Fig. 15) .
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° F., the mirror and arm
should not be mounted for eight
hours, to allow the resin to properly
adhere the bracket to the glass. How-
ever, the car may be used with the
bracket taped in place one hour after
installation.
When the temperatures are below SECTIONAL VIEW AA
EPOXY CATALYST
67° F., the mirror and arm should MIRROR ASSEMBLY
not be mounted to the bracket for
16 hours, but the car can be used R1174-B
two hours after the bracket has been
taped in place. FIG. 15-Bonded Windshield Rear View Mirror Installation

17-32 GROUP 17-BODY, DOORS AND WINDOWS {356)
LOCK ACTUATING
ROD ASSEMBLY
HANDLE ASSEMBLY
VIEW AA
ASSEMBLED
GROMMET
PUSH BUTION
ROD
VIEW CC
LOCK CYLINDER LOCK CYLINDER
ASSEMBLY RETAINER
R1227-A
FIG. 16-Door Handles and Locks
taining screws and remove the lock VENT WINDOW MOTOR INSTALLATION
assembly and push button rod.
1. Remove the door trim panel 1. Slide the rollers on the window
INSTALLATION and water shield. lower channel guides.
1. Transfer the push button rod 2. Disconnect the leads from the 2. Position the window in the door
and plastic retainers to the new lock vent window motor. opening; then, align the rollers with
assembly. 3. Remove the vent window motor the regulator arm pivots.
2. Position the lock assembly in and bracket to door panel retaining 3. Press the pivots into the rollers
screws (Fig. 6). until the retainers snap into the
the door and install the retaining
screws. 4. Remove the vent window motor grooves.
3. Connect the lock cylinder-to- and bracket from the door area. 4. Position the rear window run,
lock assembly rod to the lock as- 5. To install the motor, reverse the install the window stops, and adjust
sembly. removal procedure. the run as necessary. Install the rear
4. Connect the outside door han- FRONT DOOR WINDOW run access covers.
dle push button-to-lock rod to the 5. Replace the water shield and
lock assembly. REMOVAL trim panel.
5. Connect the lock control-to-lock 1. Remove the trim panel and water
cylinder rod to the lock assembly. shield. WINDOW REGULATOR MOTOR
6. Connect the remote control rod 2. Remove the window upper stops.
to the lock ass~mbly. 3. Remove rear run access covers. 1. Remove the trim panel and
7. Connect the vacuum control rod 4. Remove the window rear run water shield.
to the lock assembly and install the retaining bolts and position the run 2. With the window in the up posi-
vacuum control retaining screws. in the bottom of the door. tion, remove the motor bracket re-
8. Position the door glass rear run 5. Remove the retainers that secure taining screw and remove the nuts
in the door. Install the retaining the window channel rollers to the attaching the motor to the regulator.
screws and adjust the run assembly. regulator arms and remove the Disconnect the wiring, and remove
9. Install the rear run access cover. rollers. the motor and coupling.
10. Install the door trim panel and 6. Lift the window out through 3. To install, reverse the removal
handles. the window opening. procedure.

VENT WINDOW FRAME 5. Connect the motor lead wires 5. Disconnect the door lock warn-
1. Remove the trim panel and and install the wiring retaining clips. ing light switch lead wires.
water shield. 6. Install the water shield and door 6. Remove the screws securing the
2. Remove the vent window motor. trim panel. door lock to the door and remove the
3. Loosen the vent window weath- lock assembly and rods.
erstrip from the front of the vent FRONT DOOR VENT WINDOW 7. Transfer the push butwn rod,
window assembly. FRAME AND DIVISION BAR door handle rod and the warning
4. Remove the lower stop bumper. light switch to the new lock assem-
1. Remove the door trim panel bly.
5. Remove the vent window as- and water shield.
sembly upper attaching screw. 8. To install the lock assembly,
2. Remove the vent window motor. reverse the removal procedure.
6. Remove the lock nut from the 3. Remove the retaining screw
vent window assembly adjusting from the front of the door weather- REAR WINDOW REGULATOR
screw. strip and remove the weatherstrip
7. Remove the lower adjusting MOTOR
from the vent frame assembly.
screw and lock nut from the bottom 4. Remove the two lock nuts and 1. Remove the trim panel and
of the division bar. screw retaining the vent assembly to water shield.
8. With the door window down, the door. 2. Remove the nuts securing the
remove the vent window assembly 5. Tilt the vent assembly in the motor to the regulator and the motor-
from the door and the front run. door and remove the front run; then, to-door bracket screw. Disconnect
9. Remove the vent window glass remove the vent assembly. the wiring and remove the motor.
lower pivot bushing assembly. 6. Remove the two vent window 3. To install, reverse the removal
10. Remove the vent window glass lower bushing retaining screws and procedure.
and frame from the vent window remove the bushing.
assembly. 7. Remove the vent glass and REAR DOOR WINDOW
11. Remove the vent window glass frame from the vent assembly. 1. Remove the door trim panel and
from the vent window frame. 8. Remove the vent window weath- water shield.
12. To install, reverse the removal erstrip from the vent window frame 2. Remove the window upper
procedure. and division bar. stops.
9. To install, reverse the removal 3. Remove the window lower stop.
FRONT DOOR WINDOW procedure. 4. Disconnect the regulator arms
REGULATOR from the !ower window channel and
REAR DOOR OUTSIDE HANDLE lower the window to the bottom of
REMOVAL
the door.
1. Remove the door trim panel and 1. Remove the trim panel and 5. Remove the door window outer
water shield. water shield. belt weatherstrip and stabilizer as-
2. Disconnect the regulator arms 2. Raise the window to its closed semblies.
from the lower glass channel. position. 6. On the convertible door window
3. Position the glass assembly to 3. Remove the screw and nut that remove the rear door window control
the top of its opening and prop it in secures the handle to the door panel. switch trigger pin from the lower
place. 4. Position the handle away from window frame.
4. Disconnect the motor wiring the door and disconnect the handle- 7. Remove the rear window assem-
connector, remove the wire retaining to·lock rod. Remove the handle and bly from the door (Fig. 8).
clip, and remove the motor bracket pads. 8. Remove the upper frame from
retaining screw. 5. To instal1, connect the lock rod the glass and remove the glass from
5. Remove the four regulator reat the handle; then, position the door the lower glass channel.
taining screws. Remove the regulator handle and pads on the door. Install 9. To install reverse the removal
and motor assembly from the door. the attaching screw and nut. Check procedure.
6. Hold the regulator assembly the pushbutton for proper clearance
in a vise and remove the motor as- between the release pin and the re- REAR DOOR WINDOW
sembly. lease lever arm on the door lock as- REGULATOR
sembly.
6. Install the water shield and 1. Remove the door trim and
INSTALLATION water shield.
trim panel.
1. Preload the replacement regu- 2. Disconnect the regulator arms
lator assembly to the correct position. from the lower window· channel and
REAR DOOR LOCK
Hold the regulator in a vise and in- prop the window IN THE UP POSI-
stall the motor on the regulator. 1. Remove the trim panel and TION.
2. Transfer the glass channel roll- water shield. 3. Disconnect the motor wiring
ers to the new regulator. 2. Disconnect the remote control connector, remove the wiring re-
3. Position the regulator and mo- rod at the door lock. taining clip and remove the motor
tor assembly in the door. Install the 3. Remove the screws securing the bracket retaining screw.
regulator retaining screws and the door lock vacuum control to the 4. Remove the four regulator re-
motor bracket retaining screw. door and disconnect the control rod taining bolts and remove the regu-
4. Connect the regulator arms from the door lock. lator and motor assembly from the
(and rollers) to the lower giass chan- 4. Disconnect the door outside door. The regulator arms must be
nel (Fig. 6). handle rod at the handle. in thE: down position.

5. Hold the regulator in a vise and the door for hinge replacement. tears. Replace the weatherstrip if
remove the motor assembly. 6. To remove the lower hinge, re- necessary.
6. Preload the replacement regula- move two cap screws and one nut 9. Remove all old sealer from the
tor to the correct position. Hold the securing the lower hinge to the body window opening pinchweld flanges.
regulator in a vise and install the and remove the hinge.
motor assembly on the regulator. 7. To remove the top hinge, re- INSTALLATION
7. To install, reverse the removal move the two cap screws securing
procedure. the top hinge to the body and remove 1. Apply an even bead of sealer in
the hinge. the weatherstrip window opening
8. To install, reverse the removal groove.
REMOTE CONTROL
procedure. 2. Position the weatherstrip on the
1. Remove the door trim panel and glass. Place masking tape at intervals
water shield. to retain the weatherstrip to the
2. Remove three remote control BACK WINDOW AND/OR glass.
mounting screws, disconnect the re- WEATHERSTRIP 3. Clean off any excess sealer from
mote control rod and remove the the inside of the glass and weather-
REMOVAL
remote control from the door. strip.
3. To install, reverse the removal 1. Remove the two back window 4. Place two lengths of Ys -inch
procedure. outside mouldings and the two out- sash cord in the body flange. groove
side lower mouldings (Fig. 17). of the weatherstrip so that the cord
2. Remove the back window left ends overlap each other approxi-
REAR DOOR HINGES-
side garnish moulding. mately 12 inches at the upper and
UPPER AND LOWER
3. Remove the back window right lower center of the glass. Tape the
1. Remove the trim panel and side garnish moulding. cord ends temporarily to the inside
water shield. of the glass.
2. Remove the courtesy light switch 4. Remove the back window lower
5. Apply an even bead of sealer
garnish moulding.
and bracket. all the way around the edge of the
3. Remove three cap screws secur- 5. Free up the inside lip of the body opening pinchweld flange (Fig.
ing the lower hinge to the door. weatherstrip. 17). Position the moulding retainers
4. Remove three cap screws secur- 6. With a helper, remove the win- as shown in Fig. 17.
ing the top hinge to the door. dow and weatherstrip as an assembly. 6. With a helper, place the window
5. Position the door off the hinge 7. Remove the weatherstrip from assembly in the window opening.
and place it on a low bench or box the glass. 7. Pull the inner lip of the weath-
by the car. It is not necessary to 8. Clean the weatherstrip thor- erstrip over the pinchweld flange.
remove the wire harness from oughly and inspect it for cracks or This is accomplished by pulling the
R1257-A
FIG. 17-Back Window and Exterior Mouldings

(359} PART 17-3-DOORS, WINDOWS AND DECK LID 17-35
the upper back panel and quarter

panels.
2. Disconnect the lamp wiring.
3. Remove the four cap screws
which secure the hinges to the door
and remove the door.
4. To install, position the door on
the hinges. Install the four cap screws
just tight enough to permit the door
to be shifted, if necessary, for proper
alignment; then, tighten the cap
screws. Connect the lamp wire.
HINGES-MODEL 53
1. Prop the luggage compartment

door open.
2. Loosen the torsion rod tension
bolts until all tension is relieved from
the torsion rods (Fig. 19).
LOCK STRIKER 3. Remove the torsion rods from
SLEEVE AND ~SHIELD the hinge.
CYLINDER ASSEMBLY
~ 4. Remove three cap screws and
N1212-B remove the hinge from the car. For
the left hand hinge removal, the
FIG. 18-Luggage Compartment Lock Mechanism left quarter wheelhouse trim cover
assembly has to be removed.
two bottom sash cords out to the 2. Remove two screws and remove 5. To install, reverse the removal
corners of the glass and then pulling the door lock access cover plate (Fig. procedure.
out the two top cords the remaining 18).
way around the glass while a helper 3. Disconnect the latch rod from
applies pressure from the outside. the lock cylinder shaft.
8. Remove the strips of tape that 4. Remove the lock cylinder re-
temporarily held the weatherstrip in taining nut and spacer from the lock
place. cylinder housing.
9. Install the inside garnish mould- 5. Pull the lock cylinder and pad
ings. from the door.
10. Install the outside and lower 6. Insert the key in the lock cyl-
mouldings. inder. Depress the plunger retaining
11. Clean the glass and mouldings the lock cylinder in the housing and
and test for water leaks. remove the lock cylinder.
7. To install, reverse the removal
LUGGAGE COMPARTMENT procedure and check the operation HINGE ASSEMBLY
N1380~A
of the lock .
LOCK CYLINDER
DOOR-MODEL 53
FIG. 19-Luggage
1. Open the luggage compartment Compartment Door Hinge
door. 1. Lay a protective covering over Torsion Rods

(360)
'if{}{]O~ fP&®§
0~1r§~1r0@~&0:,0:,\1
§0:,&~~

(361) 18-1
GROUP
18
INTERIOR TRIM ........... . . .. 18-1 CONVERTIBLE TOP . 18-11
PART 18-2
SEATS ....................... 18-5
PART INTERIOR TRIM Section Page
18-1 1 Removal and Installation .................. 18-1
D REMOVAL AND INSTALLATION

DOOR TRIM PANEL 2. Remove the door pull handle. and disconnect the electrical wires.
Basically all door panels are re- :t Remove the door lock control 6. Remove the inside door handle
tained in the same manner. In view Knob. lower half.
of this, one removal and installation 4. Remove the inside door handle 7. Remove the trim panel retain-
procedure will cover all models. upper half. ing screws.
1. Remove the trim panel front 5. Remove the door arm rest win- 8. Lift the trim panel away from
support cover (front only) . dow regulator switch plate housing the door, disconnect the courtesy
TAPE
WATER SHIELD
REAR DOOR
WATER SHIELD •
VIEW AA VIEW BB SECTIONAL VIEW BB SECTIONAL VIEW CC
FOR LEFT HAND SIDE ONLY ALTERNATE
R1249-A
FIG. 1-Door Water Shields

18-2 GROUP 18-TRIM, SEATS, AND CONVERTIBLE TOP (362)
INSIDE WEATHERSTRIP
ASSEMBLY -DOOR GLASS
AT BELT
PE
ARM REST
UPPER COVER
ARM REST
LOWER COVER
.... '~' FINISH PANEL
, ~:: .~c~~, ~,e-~~!'

ARM REST
SUPPORT
~: :< ; ./• .
ASSEMBLY
ARM REST
MOULDING
ARM REST'>'
ORNAMENT
SECTION BB
R1250-A
FIG. 2-Door Trim Panel

(363) PART 18-1-INTERIOR TRIM 18-3
lamp wire and carefully position the 11. Remove the headlining bows staple the headlining to the roof
water shield away from the inner from the header and remove from panel side retainer strips.
panel (Figs. 1 and 2). the car (Fig. 3). 7. Trim the headlining edges ap-
9. To install, reverse the removal 12. Remove the protruding and proximately 1.4 inch below the re-
procedure. loose staples from the retainer strips. tainer strips.
Flatten the remaining staples in the 8. Cut openings in the headlining
HEADLINING retainer strips. for the roof side quarter lamp as-
REMOVAL semblies and install the lamps.
INSTALLATION 9. Install the quarter belt rear
1. Open the doors and cover the mouldings, back window garnish
seats. 1. Transfer the roof bows from mouldings and the roof side inside
2. Remove the sun visors and the old headlining to the new. Be rear mouldings.
bracket assemblies. sure number 1 bow from the old 10. Install the windshield upper
3. Remove the windshield upper headlining goes into the new head- garnish moulding, the windshield side
garnish moulding. lining at the number 1 listing; garnish mouldings, sun visor and
4. Remove the windshield side number 2 bow goes into the num- bracket assemblies, roof inside front
garnish mouldings. ber 2 listing, etc. mouldings and the coat hangers.
5. Remove the coat hangers and 2. Starting at the rear, position 11. Steam the headlining. If the
roof inside front moulding. the new headlining in the car, and in- car is equipped with a vinyl head-
6. Remove the roof inside rear sert the roof bows into the header. lining, it is necessary to steam the
moulding. 3. Smooth out the wrinkles and headlining on the fabric-covered
7. Remove the back window side center the headlining at the wind- side.
and upper garnish mouldings. shield. 12. Remove the covers and close
8. Remove the quarter belt rear 4. Staple the headlining to the the doors.
mouldings. retainer strip at the windshield. INSTRUMENT PANEL PAD
9. Remove the roof side quarter 5. Center the headlining at the 1. Open the doors and cover the
lamp assemblies. rear window and staple the head- seats.
10. Starting at the rear, remove lining to the retainer strip at the back 2. Disconnect the battery cable.
the headlining from the retainer window. 3. Remove the radio control knobs
strips. 6. Smooth out the wrinkles, and and radio retaining nuts.
c
"' SIDE
FRONT
TACKING STRIP
HEADLINING SUPPORT CORNER
RETAINER TACKING STRIP
II
', I[
';:_,,... ..
;,~.·.-.~~]
..
SECTIONAL
SlDE REAR VIEW DO TAPE
RETAINER
R1251-A
FIG. 3-Headlining Installation

18-4 ,GROUP 18-TRIM, SEATS, AND CONVERTIBLE TOP (364)
4. Remove the heater control front upper finish panel. assembly to instrument panel retain-
knobs. 10. Remove the cowl side kick ing nuts, position the cluster assem-
5. Remove the steering column pads. bly away from the instrument panel,
upper collar at the instrument panel. 11. Remove the clock adjustment disconnect the cables, hoses, and
6. Remove the instrument panel shaft lock nut at the lower instru- wires from the cluster assembly, and
cluster bezel assembly. ment panel. remove the cluster assembly.
7. Remove the sun visor and 12. Remove the hood control cable 15. Remove the instrument panel
bracket assemblies. from the lower instrument panel. pad retaining screws and remove the
8. Remove the windshield side gar- 13. Remove the instrument panel pad (Fig. 4).
nish mouldings. to cowl side panel retaining screws. 16. To install, reverse the removal
9. Remove the instrument panel 14. Remove the instrument cluster procedure.
AA
SECTIONAL
VIEW AA
ASSEMBLED
FIG. 4-lnstrument Panel Pad Installation ' R1252-A

(365) 18-5
PART SEATS
Section Page
1 Power Seat ............................. 18-1
18-2 2 Rear Seat .............................. 18-10
D POWER SEAT
DESCRIPTION tion of the seat. The rear switch power to the respective driven mech-
controls the vertical movement, or anisms of the seat through drive
The six-way power seat provides tilt of the rear portion of the seat. cables. The forward solenoid oper-
horizontal, vertical, and tilting ad- The center switch controls both hori- ates the rear vertical seat drive assem-
justments. The seat is driven by a zontal and vertical movement of the blies. The center solenoid operates
single motor through a transmission seat. These switches control the op- the front vertical drive assemblies.
and six flexible drive cables encased eration of three solenoids through The horizontal seat screw jacks are
in housings (Fig. 1). relays with the exception of horizon- operated by the rear solenoid.
tal movement, which is controlled
The control switches are mounted Both the control and power cir-
directly by switch (Fig. 2).
on the left seat side shield. The for- cuits are protected by a common 20-
ward switch controls the vertical The solenoids engage the trans- ampere circuit breaker mounted on
movement, or tilt, of the front por- mission gears, transmitting driving the starting motor relay.
REAR TILT SWITCH
-r i
ADJUSTER
O PIVOTSTUD
e LOCKNUT
HORIZONTAL DRIVE GEAR

LOCK NUT
N1320-A
FIG. 1-Six-Way Power Seat-Disassembled

...
00
I
TO BATTERY I+) TERMINAL o-.
Black- While
o------BI-oc-k------~=r==~~~~~-=~~~6/a~c~k~------------------------------,
GROUND TO
FRONT FLOOR PAN
8/ack.White
SEAT-TRACK SOLENOID
(FRONT-VERTICAL)
GREEN
CONNECTOR
SEAT-REGULATOR
CONTROL MOTOR Q
;a
0
c
SPLICE IN 14289
Black-WhHo
-a
Red
Yellow
®19>
O
WHITE
CONNECTOR
Brown
Blue
~ White
SEAT-REGULATOR RElAY
{SOLENOID) SEAT-TRACK SOLENOID
{HORIZONTAl)
RED CONNECTOR
Gree
UP
POSITIONS:
FORWARD
~
BACKWARD
-----UP
-*-·-DOWN
DOWN
ACTION DIAGRAM FOR

SEAT-REGUlATOR CONTROl
-~
SEAT-REGULATOR CONTROL
SWITCH AND HOUSING SWITCH AND HOUSING
16-WAY)
FIG. 2-Six-Way Power Seat Circuit R1187·1 -

(367) PART 18-2-SEATS 18-7
FRONT SEAT
BACK ASSEMBLY
SIDE SHIELD
FRONT SUPPORT
PAD ASSEMBLY
R1253-A
FIG. 3-Front Seat Back Assembly and Installation

GROUP 18-TRIM, SEATS, AND CONVERTIBLE TOP (368)
MOTOR OPERATES, BUT 1. Defective shaft or coupling be- mission.

THERE IS NO SEAT tween motor and transmission. 3. Solenoid relay not energizing
MOVEMENT 2. Solenoid not engaging trans- the solenoid.
1. Defective (20-ampere) circuit 4. Broken wire or loose connec-

breaker. tion.
MOTOR DOES NOT OPERATE
2. Defective motor relay. 5. Defective motor.
3. Defective seat control switch.
1. Appropriate solenoid not oper- 5. Broken or binding mechanical

ating. drive system.
SEAT WILL NOT MOVE IN
2. Transmission binding. 6. Broken, worn or loose connec-
ONE DIRECTION
3. Seat control switch inoperative. tion.
4. Broken flexible drive shaft.
REMOVAL AND INSTALLATION

FRONT SEAT CUSHION SPRING
SEAT REMOVAL
-.Jr···~·..,~·-="''f~ii.'j
1. Disconnect the ground cable ' •· ~~ I')t i
from the battery.
2. Remove the nut and washer
from the front end of each seat
actuator.
3. Remove the cap screw and lock
washer from the rear of each seat
actuator.
'IF'::;'S;;;~~
4. Remove the nut and washer
that secures the motor mounting
bracket to the floor pan. SASE SIDE FILLER
..._,..... PAD
1., FRONT AND SIDE PAD
5. Disconnect the main harness
A-HOG RING- 12 REQUIRED
from the wire leading to the 20- B-HOG RING-29 REQUIRED
ampere circuit breaker (Fig. 1). C-HOG RINGS- 11 REQUIRED ALONG
6. With a helper, lift the seat and BOLSTER WIRE DEPRESSION
regulator from the car. D-HOG RING-3 REQUIRED
7. Remove the four cap screws E-HOG RING-25 REQUIRED ALONG
BOLSTER, SEE VIEW "AA"
and washers that secure the seat to F-HOG RING-35 REQUIRED ALONG
the actuators. FRONT AND SIDES
G-HOG RING-20 REQUIRED ALONG
MOTOR INSIDE LISTING AT REAR EDGE
1. Disconnect the motor leads from H-HOG RING-3 REQUIRED ALONG BOLSTER WIRE
REAR CENTER CARPET LISTING
the four connectors (Fig. 1). J-HOG RING-7 REQUIRED ALONG
2. Remove the two nuts and lock EACH REAR END CARPET LISTING
washers that secure the motor to the K-HOG RING-ONE REQUIRED ALONG
mounting bracket. EACH SIDE FACING
3. Slide the motor out of the
shaft coupling and off the mounting
bracket.
4. Slide the motor shaft into the
coupling and the studs into the
mounting bracket. SPRING BOLSTER
WIRE
5. Secure the motor to the mount-
ing bracket with two lock washers
and nuts.
6. Connect the motor leads to their
respective connectors.
RELAY
REAR CENTER WIRE
1. Disconnect the connector from
R1254-A
the seat regulator relay and from the
motor control relay (Fig. 1). FIG. 4-Front Seat Cushion Assembly
2. Remove the two sheet metal

{369) PART 18-2-SEATS 18-9
SEAT INSTALLATION
1. Secure the seat to the regulator
with four attaching screws.
2. With a helper, carefully posi-
tion the seat and regulator in the car.
3. Secure the motor mounting
bracket to the floor pan with a nut
and washer.
4. Secure each seat actuator ( regu-
lator) to the floor pan with a cap
screw, two washers and a nut.
5. Connect the main harness to the
harness leading to the 20-ampere cir-
cuit breaker (Fig. 1).
6. Connect the ground lead to the
battery.
P D ASSEMBLY 7. Check the operation of the seat
to make certain that it moves in all
directions.
FRONT SEAT BACK
1. Open the door and install a
cover.
VIEW AA
2. Position the front seat to the
top rear of its travel, and remove the
seat track to seat cushion retaining
screws.
3. Disconnect the seat wiring re-
taining clips and the wiring.
4. Remove the front seat assembly
and place on a clean bench or work-
ing surface.
VIEW BB
5. Remove the front seat back
ASSEMBLED ( cover panel and retaining clips.
/
}
/
6. Remove the front seat cushion
or:=== ---~
side shield assembly and the shield
support bracket.
7. Remove the seat back to center
arm rest frame retaining screws (Fig.
3).
8. Remove six hog rings retaining
R1255-A the seat cushion cover to the seat
cushion frame.
FIG. 5-Rear Seat Back Assembly 9. Remove the seat back to seat
cushion outer retaining screw and
screws that secure both relays to the '>fOn.Separate the six cables and remove the seat back assembly.
mounting bracket and remove the housings from the transmission. 10. Remove the seat back cover or
relays. pad and transfer the listing wires to
3. Remove the two cap screws and the new cover.
3. Secure both relays to the mount- lock washers that secure the trans-
11. To install the cover or pad
ing bracket with two sheet metal mission to the mounting bracket. reverse the removal procedure.
screws. Make sure that the motor Separate the transmission from the
control relay (four-prong connector) mounting bracket. FRONT SEAT CUSHION
is toward the driver's side of the seat. 1. Open the door and install a
4. Secure the transmission to the
4. Connect each connector to its mounting bracket with two lock cover.
respective relay. washers and cap screws. 2. Position the front seat to the
top rear of its travel, and remove the
5. Slip the six cables and hous-
TRANSMISSION seat track to seat cushion retaining
mgs into their respective ports. Install
screws.
1. Disconnect the three leads from the two cable housing retainers.
3. Disconnect the seat wiring re-
the three solenoids on the transmis- 6. Connect the first lead to the taining clips and the wiring.
sion (Fig. 1) . front solenoid, the second lead to the 4. Remove the front seat assembly
2. Remove the cable housing re- center solenoid and the third lead to and place on a clean bench or work-
tainer from each end of the transmis- the rear solenoid. ing surface.

5. Remove the left and right front the seat cushion cover to the right back panel to seat cushion frame
seat back cover panels and retaining and left seat cushion frame. retaining screws.
clips. 9. Remove the right and left seat 12. Remove the center arm rest to
6. Remove the left and right front back to seat cushion outer retaining seat cushion frame retaining screws
seat cushion side shield assemblies screws and remove the seat back as- and remove the arm rest assembly.
and the shield support brackets. semblies. 13. Remove the seat cushion cover
7. Remove the right and left seat 10. Remove hog rings retaining or pad from the cushion frame (Fig.
backs to center arm rest frame retain- the carpet portion of the seat cushion 4).
ing screws (Fig. 3). cover to the center arm rest frame. 14. To install the cover or pad,
8. Remove 10 hog rings retaining 11. Remove the center arm rest reverse the removal procedure.
EJ REAR SEAT
REMOVAL AND INSTALLATION 2. If working on the seat back, back cover and/or pad, and trans-
REAR SEAT CUSHION COVER remove the center arm rest assembly. fer the listing wires to the new cover
OR SEAT BACK COVER 3. If working on the seat cushion, (Figs. 5 and 6).
I. Remove the seat cushion or remove the heelboard cover. 5. To install the cover or pad,
back and place on a clean bench. 4. Remove the seat cushion or reverse the removal procedure.
HOG RINGS
A-(4 REQUIRED)
8-(13 REQUIRED)
C-(11 REQUIRED)
D-(21 REQUIRED ALONG BOLSTER WIRE)
E-(23 REQUIRED ALONG REAR EDGE)
F-(40 REQUIRED ALONG FRONT AND SIDE EDGES)
G-(35 REQUIRED ALONG FRONT AND SIDE)
FILLER
SPRING
REAR PAD
R1256-A
FIG. &-Rear Seat Cushion Assembly

(371) 18-11
PART CONVERTIBLE TOP

Section Page
1 Description and Operation ................-18-11
18-3 2 Diagnosis and Testing .................... 18-20

The convertible features automatic fasten the rear window at the zipper sure lines, close and prevent further
lowering of the top assembly into the and roll it up. Use the straps with movement of the top assembly until
luggage compartment. The deck lid the snap buttons provided to hold the circuit is reactivated by moving
completely conceals the top when it it in position. Push the top control the top control switch. Do not at-
is in the retracted position. The op- switch down and hold it until the tempt to manually force the top
eration of the top is accomplished deck lid has fully opened. Then, or the deck lid either up or down.
by electrically powered mechanical make sure that nothing is stored
and hydraulic linkage. in the luggage compartment that ELECTRICAL SYSTEM
The top operation is divided into could interfere with the top as it is
two cycles; the retract cyc1e in lowered. Hold the top control switch The electrical system includes four
which the top unlocks and lowers down again until the top retract reversible motors; the top lock mo-
into the luggage compartment, and cycle is completed. tor, that drives two hook locking
the erect cycle in which the top is To erect (raise the top), push the rods that lock and unlock the top to
raised from the stacked position and top control switch up to open the the windshield header; the upper
locks to the windshield header. deck lid and raise the top assembly back panel motor that drives the
The car should be stopped and all into position. After the deck lid upper back panel by a small trans-
side windows lowered before the top closes and locks, release the top con- mission; the deck lock motor that
is operated. The ignition switch must trol switch. locks and unlocks the deck lid
me in the ACC or ON position, The top can be stopped at any through flexible drive cables; and the
preferably with the engine running. time in either cycle (retract or erect) top-deck motor that drives a hy-
The transmission selector lever must -;imply by releasing the top control draulic pump which supplies hydraul-
be in either the N or P position, switch. When the top control switch ic fluid pressure to open and close
then, actuate the top control switch. is released, the solenoid valves, which the deck lid and the top assembly.
To retract (lower the top), un- are connected to the hydraulic pres- There are 11 relays; the top con-
TO BATTERY UPPER BACK

TERMINAL PANEL ERECT
RELAY
FOR LUGGAGE
COMPARTMENT LAMP
Blue
TO 10 AMP
JUNCTION
CIRCUIT BREAKER V' I 1 o-
BLOCK Biaclc ~
-Yellow Stripe Red Orange
o-
Blue-Red Stripe
Blue
Black TOP CONTROL
NEUTRAL RELAY
TO ACCESSORY Brown DECK TOP
ij'J
TERMINAL OF LOCK UP
IGNITION SWITCH
DECK DECK
NEUTRAL UNLOCK OPEN L...-R•E;....LA_Y_ _.
SWITCH RELAY RELAY
CJ c:J c::J
Blue
Red -Blue Stn'pe
N1234-B
FIG. 1-Control and Power Feed Circuits

MOTOR, PUMP AND

RESERVOIR ASSEMBLY
N1347-A
FIG. 2-Hydraulic System
UPPER BACK
PANEL ERECT
RELAY
TOP
TOP LOCK DOWN
LIMIT SWITCH RELAY
DECK CONTROL
SOLENOID VALVE
TOP AND
DECK MOTOR
TOP CONTROL
TOP DOWN SOLENOID VALVES
LIMIT SWITCH
UPPER BACK
PANEL MOTOR
N123S-B
FIG: 3-Parts Location

(373) PART 18-3-CONVERTIBLE TOP 18-13
trol neutral relay is used as a safety cycle and top erect cycle. Current circuit breaker in the power circuit,
device in the control circuit. This flows from the ignition switch, a 10-ampere circuit breaker in the
relay is located on the horn relay through the top control neutral relay, top control· circuit, and three in-
mounting plate located behind the the transmission neutral switch, and dividual 15-ampere circuit breakers.
right cowl panel. The control cir- the starter motor relay to ground. one for each motor feed circuit. The
cuit cannot be energized until the The top control neutral relay is en- 50-ampere circuit breaker is l~cated
top control neutral relay contacts ergized, closing the relay contacts, on the wiring and circuit breaker
are closed. The circuit is complete and current flows from the 10-amp- assembly and the 1O~ampere circuit
only when the neutral switch is ere circuit breaker through the top breaker is located in the fuse box.
closed. The circuit is closed when control switch.
the transmission selector lever is in The remaining 10 relays are used HYDRAULIC SYSTEM
P or N and the ignition switch is in to energize the motors and the three The deck lid and convertible top
the ACC or ON position. The control solenoids (Fig. 1). assembly are each operated by two
circuit to the top control switch The electrical system is protected hydraulic cylinders, receiving pres-
is identical for both the top retract by five circuit breakers; a 50-ampere sure from one electrically powered
DECK UNLOCK RELAY
UPPER BACK PANEL

LIMIT SWITCH
TOP CONTROL SWITCH

PUSHED DOWN DECK LOCK MOTOR
TO BATTERY
Red-Blue St" e
TERMINAL
50-AMP DECK OPEN LIMIT SWITCH L.H.
CIRCUIT BREAKER
FOR LUGGAGE COMPARTMENT LAMP
TOrr:)_
Black- Yellow Stripe
JUNCTION j Bl ue
1
1 0 -AMP
CIRC~IT BREAKER Violet
_j o-i
~j P
<>-
BLOCK • ~ ~ '->--+----.,
Bla''\~" Stt~' Black
Red Black
TOP CONTROL
NEUTRAL RELAY UPPER BACK PANEL
TO ACCESSORY
liMIT SWITCH
TERMINAl OF
Brown
IGNITION SWITCH DECK LOCK MOTOR
Red-Blue Stripe DECK

UNLOCK
RELAY
Black
DECK OPEN
MOTOR LIMIT SWITCH L.H.
Orange
0 0
N1221-B
FIG. 4-Deck Lid Unlock-Top Retract Cycle

reversible motor and pump. The hy- function of these components is ex- switch, the left hand deck open limit
draulic fluid pressure is controlled plained in detail with the circuits of switch (usually called deck open
by three electrically activated sole- each phase of the retract and erect limit switch L.H.), and the deck un-
noid valves, two for the top assem- cycle in Figs. 4 through 15. lock relay coil to ground. The deck
bly, and one for the deck lid (Fig. unlock relay coil is energized, clos-
TOP RETRACT CYCLE ing the relay contacts which com-
2).
DECK LID UNLOCK plete the power circuit from the 50-
ELECTRICAL COMPONENTS With the top control switch in ampere circuit breaker, through the
The location and proper nomen- the top down position (Fig. 4), cur- 15-ampere circuit breaker to the deck
clature for each electrical compo- rent flows from the top control switch, lock motor. The motor is energized
nent is illustrated in Fig. 3. The through the upper back panel limit and the deck lid is unlocked.
DECK
SOLENOID
TOP CONTROL SWITCH

PUSHED DOWN TOP AND DECK MOTOR
DECK LOCK MOTOR
DECK
OPEN
RELAY
DECK OPEN LIMIT SWITCH L.H.
Orange-Brown Stripe
Blue
Yellow- Violet Stripe
50-AMP
DECK CLOSED
CIRCUIT BREAKER Blue
LIMIT SWITCH
Red
Yellow- Violet Stripe
Blue
DECK
OPEN
UP RELAY
TOP CONTROL SWITCH o--
Blue
Red Black
UPPER BACK PANEL

LIMIT SWITCH
Red-Blue Stripe
0 0
Yellow-Red Stripe DECK
SOLENOID
15-AMP
CIRCUIT BREAKER DECK
UNLOCK
RELAY
Black
DECK OPEN liMIT

SWITCH l.H.
Orange
0 0
N1222-B
FIG. 5-Deck Lid Open-Top Retrad Cycle

(375) PART 18-3-CONVERTIBLE TOP 18·15
DECK LID OPEN are opened to the deck control cyl- through the 15-ampere circuit break-
As soon as the deck lid is un- inders. At the same time the top- er to the upper back panel motor.
locked, the deck lock limit switch deck motor is energized and the The motor is energized and the upper
contacts are repositioned (Fig. 5) . deck lid is opened. The deck locks back panel is erected.
The current now flows from the top continue to operate until the deck
control switch through the back is completely open. TOP UNLOCK
panel retract limit switch, through As soon as the upper back panel is
UPPER BACK PANEL ERECT
the deck open limit switch L.H., in the erect position, the upper back
through the deck lock limit switch When the deck lid is completely panel limit switch is actuated and
and the deck open relay coil to open, the plunger of the deck open the switch contacts are repositioned
ground. This closes the deck open re- limit switch L.H. is depressed and (Fig. 7). The current now flows from
lay multiple contacts which complete the switch contacts are repositioned the top control switch, through the
the power circuits from the 50-amp- (Fig. 6). The current now flows top unlock limit switch, the upper
ere circuit breaker to the top-deck from the top control switch, through back panel limit switch and the top
motor and the deck solenoid valve. the deck open limit switch L.H., the unlock relay coil to ground. The
The deck solenoid valve is ener- upper back panel relay contacts close relay contacts close and complete
gized and the proper hydraulic lines and the power circuit is completed the power circuit through the 15-
UPPER BACK PANEL

LIMIT SWITCH
UPPER BACK
PANEL MOTOR
TOP CONTROL SWITCH

PUSHED DOWN
DECK OPEN LIMIT

SWITCH L.H.
UPPER BACK
PANEL ERECT
50-AMP CIRCUIT Blue RELAY
CIRCUIT BREAKER
•
Blue Blue-Green Stripe Blue-Orange Stripe
TO BATIERY
TERMINAL Blaclc-Biue Stripe
UP
0
TO JUNCTION BLOCK~---· Red

DOWN
UPPER BACK PANEL

LIMIT SWITCH
Grey
0 0
DECK OPEN
LIMIT SWITCH l.H.
0 0
Red
N1223-8
FIG. 6-Upper Bock Panel Erect- Top Retract Cycle

ampere circuit breaker to the top lines are opened to the control cyl- circuit is complete to the top-deck
lock motor. The motor is energized inders. At the same time the top- motor and the deck control solenoid
and the top is unlocked. deck motor is energized and the top valve.
is lowered into the luggage com- The deck control solenoid is en-
TOP RETRACT partment. ergized and hydraulic lines are open-
When the top is unlocked, the top ed to the deck control cylinders. The
unlock limit switch is actuated and DECK LID CLOSE AND LOCK top-deck motor is also energized
the switch contacts are repositioned When the top is stowed in the and the deck lid is closed. This ac-
(Fig. 8). The current now flows luggage compartment, the top down tion is interrupted when the deck
from the top unlock limit switch, limit switch is actuated and the lid depresses the plunger on the deck
through the top down limit switch, switch contacts are repositioned closed limit switch.
and the top down relay coil to (Fig. 9). The current now flows At the same time the deck lid is
ground. This closes the relay mul- from the top control switch, through closing, the deck lock motor is en-
tiple contacts and completes the the top down limit switch, the deck ergized. This is accomplished by the
power circuits to the top-deck motor. closed limit switch, and the deck current flowing from the top down
The two top solenoid valves are close relay coil to ground. The relay limit switch through the deck lock
energized and the proper hydraulic contacts are closed and the power relay to ground. This closes the re-
TOP LOCK MOTOR
TOP UNLOCK
LIMIT SWITCH
UPPER BACK PANEL
LIMIT SWITCH
TOP CONTROL SWITCH

PUSHED DOWN
Block- Yellow Stripe
Blue Blue-Green Stripe Blue- Yellow Stripe
50-AMP Red
CIRCUIT BREAKER
UP
TOP LOCK
TOP CONTROL SWITCH 0
MOTOR
Red
DOWN UPPER BACK PANEL

LIMIT SWITCH
0 0
Brown-Green Stripe
TOP UNLOCK
liMIT SWITCH Brown-Green Stripe
0 0
FIG .. 7-Top Unlock-Top Retrad Cyde

lay contacts and completes the power circuit is completed to the deck lock completed. The deck solenoid valve
circuit to the deck lock motor. The motor. The motor is energized and is energized and the hydraulic lines
deck lock motor is energized until the luggage compartment is unlocked. are opened to the deck hydraulic
the top control switch is released. control cylinders. The top-deck motor
DECK LID OPEN
TOP ERECT CYCLE is energized and the deck lid is
As soon as the deck lid is un- opened. The deck lock motors con-
DECK LID UNLOCK locked, the deck closed limit switch tinue to run until the deck is com-
With the top control switch in the contacts are repositioned (Fig. 11). pletely open.
top up position, current flows from Now the current flows from the deck
the top control switch, through the open limit switch R.H., through TOP ERECT
top down limit switch, the right hand the deck closed limit switch, and
deck open limit switch and the deck the deck open relay to ground. The When the deck lid is completely
unlock relay coil to ground (Fig. relay multiple contacts close and the opened, the deck open limit switch
10). The relay is energized, the power circuits to the deck solenoid R.H. plunger is depressed and the
contacts are closed, and the power valve and the top-deck motor are switch contacts are repositioned (Fig.
TOP UNLOCK LIMIT SWITCH
TOP DOWN
RELAY
I
TOP CONTROL SWITCH
PUSHED DOWN
TOP DOWN
White
TO BATTERY
TERM~--~8~/u~e~---------------------~~--~8~/u~e---------+~~r-1
50-AMP
CIRCUIT BREAKER Yellow-White Stripe TOP
DOWN
RELAY
TOP SOLENOID (2)
TOP DOWN
LIMIT SWITCH
Violet- White Stripe
N1225-B
FIG. 8- Top Retrad- Top Retrad Cycle

18-18 GROUP 18- TRIM, SEATS, AND CONVERTIBLE TOP (378)
12) . The current now flows from TOP LOCK ground. The relay contacts close
the top control switch, through the As the top approaches the full up and the power circuit is completed
top up limit switch, the deck open position, and the package tray seats to the top lock motor. The motor is
limit switch R.H., and the top up in position, the top up limit switch energized and the top is locked into
relay to ground. The relay multiple rear is depressed, opening the circuit position. The lock motor remains
contacts are closed and the power to the top up relay (Fig. 13). This energized until the upper back panel
stops the top motor and pump as- is retracted.
circuits are completed to the top-
deck motor and the two top con- sembly. At the same time the top UPPER BACK PANEL
trol solenoid valves. The two top comes in contact with the windshield RETRACT
control solenoid valves when ener- header, the contacts of the top up During the top locking action, the
limit switch front are closed. The top lock limit switch is actuated and
gized open the hydraulic lines to current now flows from the top con- the switch contacts are closed (Fig.
the top hydraulic control cylinders; trol switch, through the top up limit 14). This permits the current to flow
at the same time the top-deck motor switch front upper back panel limit from the top control switch, through
is energized and the top is erected. switch, and the top lock relay to the top lock limit switch, the upper
DECK CONTROL
SOLENOID VALVE
TOP CONTROL SWITCH

PUSHED DOWN
TOP DOWN
LIMIT SWITCH
DECK LOCK MOTOR
Blue Blue
50-AMP .
CIRCUIT BREAKER Black-Green Stripe
DECK
CLOSE
RELAY~---'
Blue
UP Blue-Green Stripe
Yellow-Red Stripe
Yellow
DECK CLOSED
LIMIT SWITCH
Blue-Red Stripe
Violet- White Stripe TOP AND

MOTOR
DECK CONTROL
SOLENOID VALVE_(
~
N1226-8
FIG. 9-De(k Lid Close and Lo(k-Top Retrad Cyde

(37_9} PART 18-3-CONVERTIBLE TOP 18-19
back panel limit switch, and the up- is retracted, the upper back panel close and the power circuits are com-
per back panel retract relay to limit switch is actuated and the plete to the deck control solenoid
ground. The relay contacts close, switch contacts are repositioned valve and the top-deck motor. The
completing the power circuit to the (Fig. 15). This stops the top lock deck control solenoid valve and the
upper back panel motor, and the motor and the upper back panel mo- top-deck motor are energized, clos-
upper back panel is retracted. The
tor. The current now flows from ing the deck lid. Current also flows
top lock motor remains energized
until the upper back panel is fully the top control switch, through the through the upper back panel limit
retracted. upper back panel limit switch, the switch, through the deck lock relay
deck closed limit switch, and the to ground. The relay is energized,
DECK LID CLOSE AND LOCK deck close relay to ground. The closing the circuit to the deck lock
As soon as the upper back panel deck close relay multiple contacts motor. As the deck lid reaches the
DECK CLOSED LIMIT SWITCH
TOP CONTROL SWITCH I

PUSHED UP
DECK OPEN LIMIT

SWITCH R.H.
TO BATTERY AI .. ~ ~ Ill .. ~
TERMINAL ~ ~-~.-----~
50-AMP
CIRCUIT BREAKER DE~K OPEN LIMIT
Brown SWITCH R.H.
TOP DOWN
FOR LIMIT SWITCH 0 0
Red- Yellow Stripe
DECK
UNLOCK
RELAY
TO ACCESSORY TOP CONTROL

TERMINAL OF NEUTRAL RELAY
IGNITION SWITCH
Brown
Orange-Brown Stripe Orange-Black Stripe
Red-Blue Slnpe
N1227-B
FIG. 10-Deck Lid Unlock-Top Ered Cycle

closed position, the deck closed limit close circuit is broken. The deck lock and the locks will ratchet until the
switch is depressed and the deck circuit will continue to be energized, top control switch is released.
EJ DIAGNOSIS AND TESTING

To properly accomplish diagnosis derstood. There should also be an failures will be due to maladjusted
and testing, the convertible top op- adequate power supply from the switches in the control circuit. The
erating principles and sequence of battery. power circuits can be individually
operations should be thoroughly un- The most common operational operated by energizing the correct
DECK OPEN RELAY
DECK CONTROL
SOLENOID VALVE
TOP DOWN
LIMIT SWITCH
Yellow-
Violet Stripe
Blue
Red
DECK CLOSED
LIMIT SWITCH
DECK
Blue Blue OPEN
RELAY DECK CONTROL
50-AMP SOLENOID VALVE
CIRCUIT BREAKER
Yellow
Red- Yellow Stripe
DECK
UNLOCK
Orange
RELAY
-Black Stripe
DECK OPEN LIMIT

TOP DOWN
~
T
SWITCH R.H.
~~~----------------------------~B~ro~w~n______________________L_IM_IT__
S_W_IT_C_H-o
0 0
N1228-B
FIG. 11-Deck Lid Open-Top Erect Cyde

power relay by means of a jumper check should be made on the com- there is a probability of a stuck re-
wire. The following cautions must ponents of that particular control lay. Disconnect the battery to stop
be observed: circuit. However, before this is at- the motor, then replace the applic-
1. Do not use an external power tempted, the motor relay feed able relay.
source. Extensive damage to elec- (power circuit) circuit breaker (50- Before proceeding, the main power
trical components could occur if ampere) must be checked and it source circuit breaker, the top con- ·
an external power source is used. must be ascertained that the motor trol neutral relay, and the t~p con-
2. When an individual compo- is not jammed or stalled. trol switch should be tested, as they
nent is cycled by means of a jump- If bypassing the control circuit is control the complete top circuit. tt
er wire, that component must be not effective and no mechanical fail- no voltage is available at the top
returned to its original position ure is evident, a failed relay, a failed control neutral relay, the control cir-
in the t 0 p cycle before proceeding. motor, or an open circuit in the cuit 10-ampere circuit breaker or the
If this is not done, damage to the motor feed circuit is indicated. The neutral switch is at fault. Don't over~
top, deck, and/ or back panels relay can be bypassed to test the look the hydraulic system. This
could occur. motor. system must be operating prop-
This method is applicable since If at any point during the opera- erly in order to obtain proper
it permits bypassing various limit tion of the top, a motor continues operation of the top.
switches and operating the motors to run after a cycle has been com- Sluggish operation of the top or
directly. If bypassing a control cir-· pleted, and releasing the top control deck lid assemblies is often accom-
cuit operates the motor, a continuity swirch does not stop the motor, panied by a loud and irregular pump
DECK MOTOR
DECK OPEN LIMIT

SWITCH R.H.
White-Red Stripe
TO BATTERY
TERM~--~8~/u~e----------------+-------·--~8~/u~e-----------~tL_J~_J
50-AMP
CIRCUIT BREAKER Grey
UP
ig~,~g~r·~A~:::~~~;"'
TOP CONTROL~-]
TO JUNCTION BLOCK -i::l 0

Yellow DOWN
DECK
DECK OPEN LIMIT
~T~O~P~u-0P~L-IM_I_l---------------------------~---------SW-ITCH
_SWITCH REAR Brown- White Stripe •:· I oJ
N1229-B
FIG. 12- Top Erect- Top Erect Cyde

18-22 GROUP 18-TRIM, SEATS, AND CONVERTIBLE TOP {382)
noise. Very frequently this is caused access cover and manually turning 2. Fabricate a jumper wire (12
by a low hydraulic fluid level. When the motor coupling to unlock the gauge), that has a sufficient capac-
this condition exists, cycle the top top. ity to conduct 50 amperes of current
and then check the pump reservoir (Fig. 16).
MANUALLY OPENING DECK
for proper fluid level. The fluid level LID 3. Remove the multiple plug from
should be within V.. inch of the filler the deck unlock relay. This is the
plug hole with the deck lid and top There are two methods of opening
the deck lid. With a jumper wire the relay that is closest to the centerline
in the raised position. of the car.
deck unlock relay plug and deck
open relay plug can be activated. If 4. Energize the deck unlock motor
EMERGENCY PROCEDURES directly through the multiple plug
this procedure does not work, the
deck lid can be unlocked and opened with the jumper wire. If the motor
MANUALLY UNLOCKING does not operate, it will be necessary
mechanically.
TOP to mechanically unlock the deck lid.
Opening Deck Lid With Jumper
If the top unlocking mechanism Wire. (See "Mechanically Opening and
becomes inoperative, and the top will 1. Remove the rear seat cushion Raising the Deck Lid" in this sec-
not unlock at the header, it may be and seat back. This will allow access tion).
necessary to manually unlock the to the deck unlock relay and deck 5. After the deck lid is unlocked,
top by removing the No. 1 bow open relay. actuate the top control switch to
TOP UP LIMIT SWITCH FRONT
UPPER BACK PANEL

LIMIT SWITCH
TOP
LOCK
Red -Black Stripe RELAY
TO BATTERY
TERMINAL Blue-Green Stripe
Blue Blue- Yellow Stripe
50-AMP
CIRCUIT BREAKER
UP
TOP CONTROL~
Orange
TO JUNCTION BLOCK -c::::J O Yellow
DOWN
Red-Green Stripe
TOP UP LIMIT
SWITCH FRONT 0
UPPER BACK PANEL
LIMIT SWITCH 0
N1230-B
FIG. 13-Top Loc:k-Top Erec:t Cyde

determine if the deck lid will open relay to prevent damage to the lock housings, the nut and housing
in the normal manner. nut assembly. portion of the locks will re-
6. If the deck lid will not open 4. Lift the forward edge of the main attached to the deck lid
by operating the top control switch, deck lid approximately one inch, lock screws.
remove the multiple plug from the then actuate the top control switch ADJUSTMENTS
deck open relay. to complete the opening of the deck LIMIT SWITCHES
7. Energize the top-deck motor lid. If the deck lid hydraulic cylin- Accurate adjustment of all the
and pump directly through the mul- ders fail to operate, the deck lid can limit switches is very important to
tiple plug with the jumper wire. If be manually opened an follows: assure smooth operation and to main-
the top-deck motor does not operate, a. Unlock the deck lid with the tain continuity of the deck lid cycles.
it will be necessary to mechanically top control switch or with When checking a switch, it should
open the deck lid. the above procedure. first be checked for proper function
Mechanically Opening and b. From underneath the rear and then adjusted as outlined in the
Raising the Deck Lid cross member, remove the following procedures. A pair of in-
1. Raise the car. deck lid hydraulic cylinder sulated test leads, a jumper wire,
2. From the underside of each attaching screws (both sides). and a self-powered DC test light
rear wheel house, remove each deck c. Manually lift the deck lid are essential tools for testing and
lid lock nut retaining screw. from the body opening. If the adjusting switches. A self-powered
3. From behind the rear seat cush- deck lock nuts have been retest light should be used to check
ion, disconnect the deck lid unlock leased here from the wheel the electrical components. Do not
TOP LOCK liMIT SWITCH
UPPER BACK PANEL

LIMIT SWITCH
UPPER BACK
PANEL MOTOR
TOP CONTROl
PUSHED UP
15-AMP
CIRCUIT BREAKER
Blue-Green Stripe Blue-Green Stripe Blue-Orange Stripe White-Red Stripe UPPER BACK PANEL
50-AMP
CIRCUIT BREAKER i .
Blue Yellow Stnpe
15-AMP CIRCUIT
BREAKER
RETRACT RELAY
L~ Red-Black Stripe·---y-~---'
TOP UP LIMIT
UP SWITCH FRONT
Yellow
TOP CONTROl~-
White-Blue Stripe
TO JUNCTION BLOCK -cJ <r- Red-Gree.n Stripe Black
DOWN -Red Stripe
Yellow
UPPER BACK PANEL 0

liMIT SWITCH
TOP LOCK
LIMIT SWITCH UPPER BACK PANEL MOTOR
Green- White Stripe Orange
N1231-8
FIG. 14-Upper Back Panel Retract- Top Erect Cycle

use the car battery for the power POWER SUPPLY CHECK dent, check the circuit and make
source, because the jumping of a PROCEDURE repairs.
switch will cause the · cycle to 3. With the starter circuit function-
continue and possibly the cycle 1. Check from the blue wire tering properly, turn the ignition switch
will go out of phase. minal of the 50-ampere circuit to the ON or ACC position and check
breaker to ground, using a simple for an adequate voltage supply at
Figs. 17 through 24 illustrate the
test ]amp, a voltmeter or other ap- the violet wire terminal of the top
correct adjustment of the limit
propriate test equipment, to deter- control switch. Use the same equip-
switches.
mine that an adequate voltage sup- ment as in step 1.
TROUBLE DIAGNOSIS ply is available at this point. 4. If difficulties are encountered
Before a systematic trouble shoot- 2. Check for full functioning of in the deck unlock and/or deck lid
ing procedure is attempted a trouble the neutral switch and top-control open phases of the top retract (top
free source of current should be es- neutral relay by placing the trans- erect) cycle, when the deck lid is
tablished at the top control switch mission selector lever in neutral and subsequently open for access, check
and the service side of the 50-ampere starting the engine. If any malfunc- the voltage supply at the bus bar on
circuit breaker (Fig. 3). tion in this (starting) circuit is evi- the relay panel located on the inside
DECK CLOSE
RELAY
DECK LOCK
RELAY
TOP CONTROL SWITCH

PUSHED UP
DECK lOCK MOTOR
Yellow
TO BATIERY Blue
TERMINAL
Blue Blue Blue
50-AMP
CIRCUIT BREAKER
Blue Block-Green Stripe
UP
Violet-Red Stripe
DECK LOCK RELAY
Yellow-Red Stripe
TO JUNCTION BLOCK --CJ 0
DOWN
Violet
Yellow
Blue-Green Stripe
O UPPER BACK PANEL DECK

LIMIT SWITCH TOP AND
DECK MOTOR LOCK MOTOR
Violet
0 0
DECK CONTROL
SOLENOID VAlVE
N1232-B
FIG. 15-Deck Lid Close and Lock-Top Ered Cyde

(385) PART 18-3-CONVERTIBLE TOP l8-25 '·
DECK CONTROL
SOLENOID VALVE TOP CONTROL SWITCH
JUMPER
HARNESS DECK UNLOCK RELAY PLUG
12 GA. WIRE
ALTERNATE METHOD OF UNLOCKING

AND OPENING DECK LID USING A
FABRICATED JUMPER HARNESS
JUMPER
HARNESS
12 GA. WIRE
DECK OPEN RELAY PLUG
N1233-B
FIG. 16-0pening Deck Lid With Jumper Wire

WITH DECK LID FULLY OPEN, ATTACH TEST LIGHT TO NORMAUY CLOSED
SWITCH CONTACTS (YEUOW WIRES ON SWITCH). ADJUST SWITCH TO
ACTUATOR UNTIL TEST LIGHT GOES OUT. REPEAT ADJUSTMENT PROCE-
DURE FOR LEFT-HAND SWITCH.
YELLOW
DECK OPEN LIMIT SWITCH RIGHT VIEW IN DIRECTION

y HAND SHOWN. L.H. SYMMETRICALLY OF ARROW Y
OPPOSITE.
FIG. 17 -Deck Open Limit Switches Adiustment
IF DECK LID SOLENOID VALVE AND TOP AND

DECK MOTOR AND PUMP DO NOT BECOME
ENERGIZED WHEN DECK LID IS UNLOCKED, AD-
JUST SWITCH DOWNWARD SLIGHTLY.
IF DECK LID SOLENOID VALVE AND TOP AND

DECK MOTOR AND PUMP BECOME ENERGIZED
BEFORE DECK LID IS COMPLETELY UNLOCKED, AD-
JUST SWITCH UPWARD SLIGHTLY.
1
BEGIN BY SETTING SWITCH AT MIDPOINT OF
ADJUSTMENT SLOT. ADJUST SWITCH SLIGHTLY
UPWARD OR DOWNWARD UNTIL COMPLETE UN-
LOCKING AND START OF DECK LID OPENING
MOVEMENT ARE SIMULTANEOUS.
N1348-A
FIG. 18-Deck Close Limit Switch Adiustment

of the right rear quarter panel. Use bar, and through the 15-ampere cir- nosis Guide are to be performed
the same equipment as in step 1. cuit breakers. with the top control switch pressed
Also check the voltage supply at the 6. When using a self-powered test down (retract position). In the
service side of the three 15-ampere light for checking the limit switches, event of a stop in the cycle, re-
circuit breakers located in the same disconnect the switch from the cir- lease the control switch ta avoid
area. cuit. burning out a motor. If jamming is
5. The trouble shooting chart fol- suspected, do not reactivate con-
lowing assumes an adequate voltage TOP RETRACT CYCLE trol switch for over five seconds
supply, for system operation pur- All checks and tests detailed in at one time until the condition
poses, at the top control switch, bus the top retract cycle Trouble Diag- is cleared.
TROUBLE DIAGNOSIS GUIDE - TOP RETRACT CYCLE - DECK LID UNLOCK (FIG. 4)
Malfunction Probable Cause Corrective Action

(a) Deck unlock relay defective. (a) Move top control switch to up
(erect) position; listen for
ratcheting of deck lid locks.
Move top control switch to down
position intermittently and listen
for click of deck unlock relay
1 NO UNLOCKING ACTION- (behind rear seat back cushion).
DECK UNLOCK RELAY NOT If no click, remove cushion and
FUNCTIONING (NO check for voltage at orange-
AUDIBLE CLICK). brown wire terminal. If terminal
is hot, relay is defective. Replace
deck unlock relay.
(b) No voltage at relay orange- (b) Bypass relay by means of a
brown terminal. jumper from relay terminals as
shown in Fig. 16 to activate
deck lock motor.
wtTH TOP UP AND THE PACKAGE TRAY ALIGNED WITH REAR SEAT BACK,
ADJUST SWITCH AGAINST PIVOT ARM UNTIL TEST LIGHT GOES OUT.
APPLY SELF-POWERED
TEST LIGHT TO SWITCH
TERMINALS
MOUNTING AND
ADJUSTING SCREWS
N1349-A
FIG. 19- Top Up Rear Limit Switth Adiustment

TROUBLE DIAGNOSIS GUIDES- TOP RETRACT CYCLE- DECK LID UNLOCK (FIG. 4) (Continued)
(a) Maladjusted deck closed limit (a) A maladjusted deck closed limit
switch. switch will allow the top-deck
motor and pump to operate and
apply pressure to the deck lift
cylinders and cause lock screws
to bind. Release top control
switch and unlock deck lid as
2 NO UNLOCKING ACTION- outlined in 1 (b) . If this fails,
DECK UNLOCK RELAY deck lid will have to be un-
FUNCTIONING locked mechanically. See 3 (a)
(AUDIBLE CLICK). in "Deck Lid Open." See Fig. 18
for deck closed limit switch ad-
justment.
(b) Defective deck lock motor cir- (b) If jumper is not effective in
cuit or motor. Circuit and mo· activating deck lock motor, the
tor are inaccessible until deck deck lid will have to be unlocked
is open.
LOOSEN SWITCH RETAINING NUTS (A) AND SWITCH ADJUSTMENT RETRACT UPPER BACK PANEL UNTIL RUBBER STOPS HAVE BEEN
SCREWS IB & C). OPERATE THE UPPER BACK PANEL TO THE DESIRED COMPRESSED 30 TO 60% OF NORMAL ROTATE THE OUTER
ERECT POSITION. ROTATE THE INNER ADJUSTING RING (D) UNTIL ADJUSTMENT RING {E) UNTIL TEST LIGHT APPLIED AT GREEN-
THE NORMALLY CLOSED SWITCH CONTACTS OPEN (CHECK WITH WHITE TO RED-WHITE WIRE TERMINALS GOES OUT. CHECK
SELF-POWERED TEST LIGHT, GREY TO BLACK-BLUE WIRE TERMINALS) ORANGE TO RED-GREEN WIRE TERMINALS FOR OPEN CONTACTS.
LIGHT GOES OUT. TIGHTEN ADJUSTING SCREW (B). TIGHTEN ADJUSTING SCREW {C).
NOTE: RED TO BROWN-GREEN WIRE CONTACTS ARE CLOSED NOTE: BLACK TO RED WIRE AND VIOLET TO YELLOW WIRE
AT THIS POINT. CONTACTS ARE CLOSED AT THIS POINT.
AFTER BOTH ADJUSTMENTS HAVE BEEN ACCOMPLISHED, TIGHTEN

UPPER BACK PANEL SWITCH RETAINING NUTS (A).
LIMIT SWITCH
X OUTER ADJUSTMENT
RINGE
INNER ADJUSTMENT
RING D
GREY
VIEW IN DIRECTION
OF ARROW X
N1351-A
FIG. 20-Upper Ba'k Panel Limit Swit'h Adiustment

~--------------------------------------------~~
TOP DOWN
LIMIT SWITCH
TEST VIOLET-WHITE TO YELLOW-WHITE PAIR OF WIRE TERMINALS. ADJUST SWITCH

AGAINST PIVOT ARM UNTIL TEST LIGHT GOES OUT. TEST REMAINING TWO PAIRS
OF WIRE TERMINALS (RED TO VIOLET- WHITE AND YEllOW TO BROWN). IF THE
TEST LIGHT DOES NOT COME ON, THE SWITCH IS DEFECTIVE.
FIG. 21- Top Down Limit Switch Adiustment N1353-A
RAISE THE TOP UNTIL THE NO. 1 BOW RESTS FIRMLY ON THE WINDSHIELD HEADER
AND THE LOCK HOOKS ARE ALIGNED WITH THE HOOK POCKETS. -ADJUST THE
SWITCH FORWARD UNTIL TEST LIGHT COMES ON.
ATTACH SELF-POWERED TEST LIGHT TO

WIRE TERMINAlS.
N1354·A
FIG. 22- Top Up Front Limit Switch Adiustment

OPERATE THE TOP LOCK MOTOR UNTIL THE LOCKS ARE FULLY
LOCKED. ADJUST THE SWITCH AGAINST THE ACTUATOR UNTIL
THE SWITCH PLUNGER IS FULLY DEPRESSED. TEST LIGHT IS ON.
AITACH SELF-POWERED TEST

LIGHT TO WIRE TERMINAL'S.
N1355-A
FIG. 23- Top lock limit Switch Adiustment
OPERATE THE TOP LOCK MOTOR UNTIL THE LOCKS ARE FULLY
UNLOCKED AND THE LOCK ARM IS FIRMLY SEATED TO THE RUBBER
STOP.
RUBBER STOP PLACE A .06 SHIM BETWEEN THE SWITCH PLUNGER AND THE
ACTUATOR. ADJUST SWITCH AGAINST ACTUATOR UNTIL SWITCH
PLUNGER IS FULLY DEPRESSED. TEST LIGHT OUT.
N1356-A
FIG. 24- Top Unlock Limit Switch Adiustment

TROUBLE DIAGNOSIS GUIDE- TOP RETRACT CYCLE- DECK LID UNLOCK (FIG. 4) (Continued)
2 NO UNLOCKING ACTION- mechanically to gain access to

DECK UNLOCK RELAY deck lock motor and complete
FUNCTIONING {AUDIBLE circuit.
CLICK). (Continued)
3 NO UNLOCKING ACTION- (a) Broken flexible shaft or loose (a) Unlock deck lid mechanically.
DECK LOCK MOTOR lock nuts, one or both sides.
RUNNING
(a) Maladjusted deck closed limit (a) When deck lidhas been opened,
switch allows top-deck motor adjust deck closed limit switch.
4 UNLOCKING ACTION- and pump to operate early in (Fig. 18.)
DECK LID JUMPS OFF LOCKS phase and apply pressure to deck
lid hydraulic cylinders before
locks are clear.
TROUBLE DIAGNOSIS GUIDE - TOP RETRACT CYCLE- DECK LID OPEN (FIG. 5)
(a) Defective deck open relay ( cy- (a) Check for voltage at yellow-
cling stops as soon as deck lid violet wire terminal of deck open
locks clear) . relay. If terminal is hot, relay is
defective. Replace deck open
relay. See Fig. 16.
(.b) Defective circuit. Top control (b) If yellow-violet wire terminal of
switch through upper back panel deck open relay is dead, use a
limit switch, deck open limit jumper to bypass the deck open
switch L.H. and deck closed relay and activate the top and
limit switch to yellow-violet wire deck motor and pump the deck
terminal on deck open relay. control solenoid to raise the
deck lid. See Fig. 16. See also
malfunction 3 (b), (c) and (d).
c: c) Defective upper back panel limit (c) With deck open for access, RE-
switch. LEASE TOP CONTROL
SWITCH, using a self-powered
test light check for open circuit
between red wire terminal and
1 NO DECK OPENING ACTION- black wire terminal of the eight-
DECK OPEN RELAY terminal group. If light does not
NOT FUNCTIONING come on, the switch should be
adjusted before deciding it is de-
fective. Replace defective upper
back panel limit switch. At this
time check violet to yellow wire
terminals of the eight-terminal
group and grey to black-blue
wire terminal of four-terminal
group.
(d) Defective deck open limit switch (d) TOP CONTROL SWITCH RE-
L.H. Deck lid must not be fully LEASED. Using a self-powered
open to avoid repositioning of test light, check for open circuit
switch terminals. between yellow wire terminals of
switch. If test light fails to come
on, switch is defective. Also
check yellow wire terminals of
deck open limit switch R.H. Re-
place deck open limit switch ( es)
found defective.

TROUBLE DIAGNOSIS GUIDE- TOP RETRACT CYCLE- DECK LID OPEN (FIG. 5) (Continued)
Malfunc.tion Probable Cause Corrective Action
(e) Defective deck closed limit (e) TOP CONTROL SWITCH RE-
switch. Deck lid open for ac- LEASED. Using a self-powered
cess. test light, check for open circuit
1 NO DECK OPENING ACTION- between yellow wires, red wires,
DECK OPEN RELAY NOT and white wires of switch. If test
FUNCTIONING (Continued). light fails to come on for any
check, switch is defective. Re-
place deck closed limit switch.
(a) Maladjusted deck closed limit (a) Raise the deck lid manually until
2 NO DECK OPENING ACTION- switch. deck motor and pump become
DECK OPEN, RELAY NOT energized. After deck lid is open,
FUNCTIONING. DECK BUMPS adjust deck closed limit switch.
UP AND DOWN ON LOCKS See Fig. 18.
(a) Defective power circuit to top- (a) A defective power circuit or

deck motor and pump or deck defective motor or solenoid will
control solenoid. prevent deck opening regardless
of relay function and will be
evident when relay jumper is
applied. See 1 (b). Deck lid
must be opened mechanically to
gain access for repairs.
(b) Defective deck lock motor cir- (b) TOP CONTROL SWITCH RE-
cuit or motor. LEASED. If deck lock motor is
not functioning, check power
circuit for voltage at motor red-
yellow wire terminal. Deck lid
should be open, sufficient for
access, only to avoid reposition-
ing of deck open limit switch
L.H. If no voltage, repair the
circuit. If terminal is hot, motor
is defective. Replace deck lock
motor.
3 NO DECK OPENING ACTION- (c) Broken deck lock flexible
FUNCTIONING DECK (c) TOP CONTROL SWITCH RE-
shaft(s). LEASED. Unlock deck lid me-
OPEN RELAY
chanically. With deck lid open
check deck lid lock shafts and
lock nuts. If shaft ( s) are bro- ·
ken, replace shafts. Otherwise,
tighten lock nuts.
(d) Faulty deck control solenoid (d) Open deck lid mechanically.
valve or top-deck motor and Check solenoid and motor cir-
pump assembly power circuits. cuits. Repair faulty circuit (Fig.
5).
(e) Faulty deck control solenoid (e) TOP CONTROL SWITCH RE-
valve. LEASED. Open deck lid me-
chanically, sufficient for access.
If circuit checks out hot at blue-
red terminal on valve and the
top-deck motor and pump oper-
ates when top control switch
is momentarily depressed, but
there is no action at deck open-
ing cylinders, the solenoid valve
is defective. Replace valve.
L

TROUBLE DIAGNOSIS GUIDE-TOP RETRACT CYCLE-DECK LID OPEN (FIG. 5) (Continued)
(f) Faulty top-deck motor and pump (f) TOP CONTROL SWITCH RE-
assembly. LEASED. Open deck lid me-
chanically, sufficient for access.
If circuit checks hot at red wire
3 NO DECK OPENING ACTION- terminal of motor and pump as-
FUNCTIONING DECK OPEN sembly, and motor does not op-
RELAY (Continued). erate when top control switch is
momentarily depressed, motor is
defective. Replace top-deck mo-
tor and pump assembly.
TROUBLE DIAGNOSIS GUIDE -TOP RETRACT CYCLE- UPPER BACK PANEL ERECT (FIG. 6)
(a) Defective upper back panel erect (a) Depress top control switch in-
relay. termittently while listening for
click. If no click, check for volt-
age at black-blue wire terminal
on relay. If terminal is hot, relay
is defective. Replace upper back
panel relay.
(b) Defective deck open limit switch (b) Check out circuit from black-
L.H. to upper back panel erect blue terminal on upper back
relay circuit. panel erect relay connector,
through upper back panel limit
switch, to violet wire terminal
on deck open limit switch L.H.
repair circuit. See 1 (d) .
(c) Defective deck open limit switch (c) Loosen switch actuator, press
L.H. switch plunger all the way in and
check between violet wire ter-
1 DECK OPEN-NO UPPER minals on switch with self-pow-
BACK PANEL ACTION- ered test light. If light does not
UPPER BACK PANEL ERECT come on, switch is defective.
Also check violet wire termin-
1 RELAY NOT FUNCTIONING
(NO AUDIBLE CLICK) al ( s) of deck open limit switch
L.H. Replace defective deck
open limit switch ( es).
(d) Defective upper back panel (d) If circuit check performed in

I imitswitch. If defective circuits 1 (b) showed open circuit at
are found at this switch after black-blue to grey terminals of
switch terminals have been reposi- upper back panel limit switch,
tioned by erection of upper back adjust the four-terminal section
panel, check red-green to orange of switch. If adjustment does
and red-white to green-white wire not close circuit, switch is de-
terminals of 8-terminal group and fective. Replace upper back
red to brown-green wire terminals panel limit switch.
of 4-terminal group.
(e) Defective power circuit to upper (e) Check between ground and blue-
back panel erect relay. white wire terminal on upper
back panel motor. If terminal is
dead, circuit is open. Repair cir-
cuit.

18-34 GROUP 18-TRIM, SEATS, AND CONVERTIBLE TOP (394}
TROUBLE DIAGNOSIS GUIDE-TOP RETRACT CYCLE-TOP UNLOCK (FIG. 7)

(a) Faulty top unlock relay. (a) Depress top control switch in-
termittently and listen for relay
click. If no click, bypass relay
with jumper. If top lock motor is
activated, check for voltage at
red wire terminal on relay. If
terminal is hot, relay is defec-
tive. Replace top unlock relay.
If red wire terminal is dead, pro-
ceed as in 1 (b), (c), and (e).
If top lock motor is not acti-
vated by jumping the relay con-
nector, proceed as in 1 (d) in
"Top Retract."
(b) Defective top unlock limit switch (b) Check out circuit from red wire
to top unlock relay circuit. terminal on top unlock relay,
through upper back panel limit
switch, to brown-green wire ter-
minal on top unlock limit switch.
Repair circuit. See 1 (d) in "Top
Retract."
1 UPPER BACK PANEL ERECT- (c) Defective top unlock limit switch. (c) Check between yellow wire ter-
NO TOP UNLOCK ACTION. minal and brown wire terminal
TOP UNLOCK RELAY NOT on top unlock limit switch with
FUNCTIONING (NO self-powered test light. Manually
AUDIBLE CLICK) reposition switch and check yel-
low to white wire terminals. If
light fails to come on either way,
switch is defective. Replace top
unlock limit switch.
(d) Defective power circuit to top (d) Check between ground and
unlock motor. black-yellow wire terminal on
motor. If terminal is dead, cir-
cuit is open. Repair circuit.
(e) Defective upper back panel limit (e) If circuit cheek performed in
switch. 1 (b) showed open circuit at
If defective circuits are found at red to brown-green terminals of
this switch after switch terminals upper back panel Jimit switch,
have been repositioned by erec- adjust the four-terminal section
tion of upper back panel, check of the switch. If adjustment does
switch adjustments before switch not dose the circuit, the switch
is considered defective. is defective. Replace upper back
panel limit switch.
(f) Defective top lock motor. (f) lf yellow-black terminal wire is
hot at motor case, motor is de-
fective. Replace top lock motor.
TROUBLE DIAGNOSIS GUIDE -TOP RETRACT CYCLE- TOP RETRACT (FIG. 8}
(a) Defective top down relay. (a) Depress top control switch in-
termittently and listen for relay
click. If no click, bypass relay
1 TOP RETRACT-NO TOP with jumper to activate top-deck
ACTION-TOP DOWN RELAY motor and pump. Check for cur-
NOT FUNCTIONING. '(NO rent at yellow-white wire ter-
AUDIBLE CLICK) minal on relay. If terminal is
hot, relay is defective. Replace

. (395) PART 18-3-CONVERTIBLE TOP 18-35
TROUBLE DIAGNOSIS GUIDE- TOP RETRACT CYCLE- TOP RETRACT (FIG. 8) (Continued)
Probable Cause Corrective Action

Malfunction
(a) Continued top down relay. If yellow-white

wire terminal is dead, proceed
as in 2 (b) , (c) , and (d) . •
(b) Defective top unlock limit switch (b) Check circuit from yellow-white
to top down relay circuit. wire terminal on top down relay,
through top down limit switch
to white wire terminal on top
unlock limit switch. Repair cir-
cuit. See 2 (c) and (d).
(c) Defective top unlock limit (c) Check switch adjustment with
switch. See top unlock phase. the top unlock switch fully de-
1 TOP RETRACT-NO TOP
pressed. Check between white
ACTION-TOP DOWN RELAY
wire terminal and yellow wire
NOT FUNCTIONING. (NO
AUDIBLE CLICK) (Continued)
terminal on top unlock switch
with self-powered light. If light
fails to come on, switch is de-
fective. Replace top unlock limit
switch.
(d) Defective top down limit switch. (d) Check between yellow- white
wire terminal and violet-white
wire terminal on top down limit
switch with self-powered test
lamp. If lamp fails to come on,
switch is defective. Replace top
down limit switch.
2 NO TOP RETRACT ACTION- (a) Defective top control solenoid (a) Check for voltage at the white-
TOP DOWN RELAY valves. blue wire at the top control sole-
FUNCTIONING (AUDIBLE noid valves. If wire is hot, sole-
CLICK). TOP-DECK MOTOR noid valve is defective. If wire
AND PUMP ASSEMBLY is dead, check power circuit and
OPERATING repair.
3 NO TOP RETRACT ACION- (a) Defective top-deck motor and (a) Check voltage at the yellow
TOP DOWN RELAY pump assembly or power circuit. wire at top motor and pump as-
FUNCTIONING (AUDIBLE sembly. If wire js hot, motor is
CLICK). TOP-DECK MOTOR defective. If wire is dead, check
AND fUMP ASSEMBLY power circuit and repair.
NOT OPERATING
TROUBLE DIAGNOSIS GUIDE -TOP RETRACT CYCLE- DECK LID CLOSE AND LOCK (FIG. 9)
l (a) Defective deck close relay. (a) Check for voltage at black-
green wire terminal on relay. If
terminal is hot, relay is defective.
I Replace deck close relay. If
black-green wire terminal is
I dead, proceed as in malfunction
l (b) below.
1 NO DECK CLOSE ACTION-
DECK CLOSE RELAY NOT (b) Defective deck close relay to (b) Check out circuit from black-
FUNCTIONING top down limit switch circuit. green wire terminal on deck
close relay through deck closed
limit switch to violet-white wire
terminal on top down limit
switch. Repair circuit. See mal-
function 2 (c) on following page.

18-36 GROUP 18- TRIM, SEATS, AND CONVERTIBLE TOP (396)
TROUBLE DIAGNOSIS GUIDE -TOP RETRACT CYCLE- DECK LID CLOSE AND LOCK (FIG. 9) (Continued)
(c) Defective top down limit switch. (c) Check between violet-white wire
See top retracting phase. terminal and red wire terminal
on top down limit switch with
self-powered test light. If light
fails to come on, switch is ·de-
1 NO DECK CLOSE fective. Replace top down limit
ACTION-DECK CLOSE switch.
RELAY NOT FUNCTIONING
(Continued) (d) Defective deck closed limit (d) Check between red wire termi-
switch. nals on deck closed limit switch
with self-powered test light. If
light fails to come on, switch is
defective. Replace deck closed
limit switch.
2 NO DECK CLOSE ACTION- (a) Defective deck control solenoid (a) Check for voltage at deck con-
DECK CLOSE RELAY valve. trol solenoid valve lead. If wire
FUNCTIONING-TOP AND is hot, solenoid valve is defec-
DECK MOTOR AND PUMP tive. If wire is dead check power
ASSEMBLY IS OPERATING circuit and repair.
3 NO DECK CLOSE ACTION- (a) Defective top-deck motor and (a) Check voltage at the yellow wire
DECK CLOSE RELAY pump assembly or power circuit. at top-deck motor and pump as-
FUNCTIONING. TOP-DECK sembly. If wire is hot, motor is
MOTOR AND PUMP NOT defective. If wire is dead, check
OPERATING power circuit and repair.
(a) Defective deck lock relay. Deck (a) Check for voltage at the violet-
lock relay is activated simul- red wire terminal of relay. If
4 NO DECK LOCK ACTION taneously with deck close re- wire is hot, deck lock relay is
DECK LOCK MECHANISM NOT lay. defective. If wire terminal is
FUNCTIONING WHEN DECK dead, check for break in violet-
LID STARTS TO CLOSE red wire to violet-white wire cir-
cuit to the deck closed limit
switch. Repair circuit.
(a) Open power circuit to deck lock (a) When deck lid starts to close,
motor or defective deck lock observe deck lock mechanism.
motor. If deck lock mechanism is not
functioning disconnect the motor
leads at the motor. Use a jumper
between motor yellow-red lead
5 NO DECK LOCK ACTION and yellow-blue wire receptacle
DECK LOCK RELAY of deck lock relay connector. If
FUNCTIONING motor operates, power circuit
(yellow wire) is open. Repair
circuit. If motor does not oper-
ate, motor is defective. Replace
deck lock motor. Release top
control switch.
TOP ERECT CYCLE phases. The circuits, switches, and/or In the event of a stop in the cycle,
The top erect cycle utilizes the switch positions differ in the various release the control switch to avoid
same motors as the top retract cycle. phases. All checks and tests de· burning out a motor. If jamming
These motors, however, operate in tailed in the Top Erect Cycle Diag- is suspected, do not reactivate the
the reverse direction of that for the nosis Guide are to be performed control switch for over five sec-
retract cycle in the upper hack panel with the top control switch pushed onds at one time until the condi-
retract, top erect, and top lock up (erect position). tion is cleared.

(397) PART 18-3- CONVERTIBLE TOP 18-37
TROUBLE DIAGNOSIS GUIDE- TOP ERECT CYCLE- DECK LID UNLOCK (FIG. 10)

(a) Deck unlock relay defective. (a) Move top control switch to
down (retract) position. Listen
for ratcheting of deck lid locks.
Move top control switch to up
(erect) position intermittently
and listen for click of deck un-
1 NO UNLOCKING ACTION- lock relay (behind rear seat back
DECK UNLOCK RELAY NOT cushion). lf no dick, remove
FUNCTIONING (NO AUDtBLE cushion and check for voltage at
CLICK) orange-brown wire terminal. If
terminal is hot, relay is defec-
tive. Replace deck unload relay.
(b) No voltage at relay orange- (b) Bypass deck unlock relay by
brown terminal. Also see 1 (b) means of a jumper at connector
''Deck Lid Open." terminals, as shown in Fig. 10,
to activate deck lock motor.
(a) Maladjusted deck dosed limit (a) A maladjusted deck dosed limit
switch. switch will allow the top-deck
motor and pump to operate and
apply pressure to the deck lift
cylinders and cause lock screws
to bind. Release top control
switch and unlock deck lid as
outlined in 1 (b). If this fails,
2 NO UNLOCKING ACTION- deck lid wiH have to be un-
DECK UNLOCK RELAY locked mechanically. See 3 (a),
FUNCTIONING "Deck Lid Open." See Fig. 18
(AUDIBLE CLICK) for deck closed limit switch ad-
justment.
(b) Defective deck lock motor cir- (b) If jumper is not effective in ac-
cuit or motor. Circuit and tivating deck lock motor, the
motor are inaccessible until deck lid will have to· be un-
deck is open. locked mechanically to gain ac-
cess to deck lock motor and
complete circuit. See 2 (a),
"Deck Lid Open."
3 ~0 UNLOCKING ACTION- (a) Broken flexible shaft or loose (a) Unlock deck lid mechanically.
DECK LOCK MOTOR lock nuts, one or both sides.
RUNNING
(a) Maladjusted deck closed limit (a) When deck lid has been opened,
switch allows top-deck motor adjust deck closed limit switch.
4 UNLOCKING ACTION-DECK and pump to operate early in See Fig. 18.
LID JUMPS OFF LOCKS phase and apply pressure to deck
lid hydraulic cylinders before
locks are clear.
TROUBLE DIAGNOSIS GUIDE - TOP ERECT CYCLE- DECK LID OPEN (FIG. 11)
(a) Defective deck open relay (cy- (a) Check for voltage at yellow-
cling stops as soon as deck lid violet wire terminal of deck open
1 NO DECK OPENING ACTION- relay. If terminal is hot, relay is
locks clear) .
DECK OPEN RELAY
defective. Replace deck open re-
NOT FUNCTIONING
lay. See Fig. 16.

TROUBLE DIAGNOSIS GUIDE -TOP ERECT CYCLE- DECK LID OPEN (FIG. 11) (Continued)
(b) Defective circuit. Top control (b) If yellow-violet wire terminal of

switch through the top down deck open relay is dead, use a
limit switch, the deck open limit jumper to bypass the deck open
switch R.H., and the deck closed relay and activate the top-deck
limit switch to the yellow-violet motor and pump and deck con-
wire terminal on the deck open trol solenoid to raise the deck
relay (Fig. 11). lid (Fig. 16). See in "Deck Lid
Unlock." 4 (b), (c) and (d).
(c) Defect in top down limit switch. (c) With deck lid open for access
only, use a self-powered test
lamp to check brown to yellow
wire terminals of top down limit
switch. Light should come on.
Also check red to violet-white
pair of wire terminals. Light
should come on. If light does
not come on in either case,
1 NO DECK OPENING switch is defective. Replace top
ACTION-DECK OPEN down limit switch.
RELAY NOT FUNCTIONING
(Continued) (d) Defective deck open limit switch (d) TOP CONTROL SWITCH RE-
R.H. Deck lid must not be LEASED. Using a self-powered
fully open to avoid reposition- test light, check for open circuit
ing of switch terminals. between yellow wire terminals
of switch. If test light fails to
come on, switch is defective.
Also check yellow wire terminals
of deck open limit switch R.H.
(Replace deck open limit switch
( es) found defective.
(e) Defective deck closed limit (e) TOP CONTROL SWITCH RE-
switch. Deck lid open for ac- LEASED. Using a self-powered
cess. test light, check for open circuit
between yellow wires, red wires,
and white wires of switch. If test
fails to come on for any check,
switch is defective. Replace deck
closed limit switch.
2 NO DECK OPENING ACTION- (a) Maladjusted deck closed limit (a) Raise deck lid manua1Jy until
DECK OPEN RELAY NOT switch. deck motor and pump become
FUNCTIONING. DECK BUMPS energized. After deck lid is open,
UP AND DOWN ON LOCKS adjust deck closed limit switch
(Fig. 18).
(a) Defective power circuii. to top- (a) A defective power circuit or

deck motor and pump or deck defective motor or solenoid will
control solenoid. prevent deck opening regardless
of relay function and will be
evident when relay jurr..:>er is
applied. See 1 (b), "Deck Lid
3 NO DECK OPENING ACTION- Open-Top Retract Cycle." Deck
DECK OPEN RELAY lid must be opened mechanically
FUNCTIONING to gain access for repairs.
(b) Defective deck lock motor cir- (b) TOP CONTROL SWITCH RE-
cuit or motor. LEASED. If deck lock motor is
not functioning, check power
circuit for voltage at motor red-
yellow wire terminal. Deck lid
should be open sufficient for

TROUBLE DIAGNOSIS GUIDE -TOP ERECT CYCLE- DECK LID OPEN (FIG. 11} (Continued)
Malfunction I Probable Cause Corrective Action
'I (h) Continued access only to avoid reposition-

ing of deck open limit swjtch
L.H. If no voltage, repair the
circuit. See 1 (b). If terminal
Il is hot, motor is defective. Re-
place deck lock motor.
(<') Broken deck lock flexible (c) TOP CONTROL SWITCH RE-
II shaft(s). LEASED. With deck lid open
check deck lid lock shafts and
lock nuts. If shaft ( s) are broken,
I replace shafts. Otherwise tighten
I lock nuts.
(d) Faulty deck control solenoid (d) Open deck lid mechanically.
I valve or top-deck motor and Check solenoid and motor cir-
pump assembly power circuits. cuits. Repair faulty circuit (Fig.
5).
3 NO DECK OPENING I ( t~) Faulty deck control solenoid (e) TOP CONTROL SWITCH RE-
ACTION-DECK OPEN I valve. LEASED. Open deck lid me-
RELAY FUNCTIONING
(Continued) I chanically, sufficient for access.
If circuit checks out hot at blue-
i
I red terminal on valve and the
top-deck motor and pump op-
! erate when top control switch is
I momentarily pushed up, but
there is no action at deck open-
ing cylinders, the solenoid valve
is defective. Replace valve.
(f) Faulty top deck motor and pump (f) TOP CONTROL SWITCH RE-
assembly. LEASED. Open deck lid me-
\.'hanically. sufflcient for access.
If circuit ch,'ck-; htlt at red wire
terminal of mot.:-•r and pump as-
sembly and motor docs not op-
erate when top control switch is
momentarily pushed up, motor
is defective. Replace top-deck
motor and pump assembly.
(a) Defective top up relay. (a) Push top control switch up in-
termittently while listening for
click of relay. If no click, check
for voltage at green wire ter-
minal on relay. If terminal is
top up relay. If green wire termi-
4 NO TOP ERECTING ACTION- nal is dead proceed as in 4 (b).
TOP UP RELAY
NOT FUNCTIONING (b) Detective circuit from top con- (b) I OP CONTROL SWITCH RE-
(NO AUDIBLE CLICK) trol switch, through top up limit LEASED. Check out circuit and
switch rear, deck open limit switches using a self-powered test
switch R.H. to top up relay. light (Fig. 12). See 4 (c) and
(d).
(c) Defective top up limit switch. (c) TOP CONTROL SWITCH RE-
LEASED. Check hctween ter-
minals of switch. If light fails to
come on. switch is defective. Re-
place top up limit switch.
CONTINUED ON NEXT PAG£

TROUBLE DIAGNOSIS GUIDE - TOP ERECT CYCLE- DECK LID OPEN (FIG. 11) (Continued)
Malfunctio·n Probable Cause Corrective Action
4 NO TOP ERECTING (d) Defective deck open limit switch (d) TOP CONTROL SWITCH RE-
ACTION-TOP UP R.H. LEASED. Check between violet
RELAY NOT wire terminals of switch. If light
FUNCTIONING fails to come on, switch is de-
(NO AUDIBLE CLICK) fective. Replace deck open limit
(Continued) switch. See 1 (c), "Upper Back
Panel Erect-Top Retract Cycle."
(a) Defective top and deck motor (a) Disconnect the 2-wire connector
and pump assembly. on motor leads. Jumper from
each motor lead in turn to bus
bar on relay panel. If motor is
not activated, it is defective. Re-
place top-deck motor and pump
assembly.
(b) Defective top-deck motor power (b) If motor will operate, connect
circuit. leads disconnected in 5 (a)
above and push top control
switch up. If motor still does not
S NO TOP ERECT ACTION- operate, the motor power circuit
TOP UP RELAY is defective. Repair defective cir-
FUNCTIONING cuit (red wire) or ( yeiiow wire) .
(c) Defective top control solenoid (c) Disconnect solenoid valve leads,
valves power circuits. and with ordinary test lamp,
check for voltage from lead ter-
minal to ground. If· either or
both leads are defective, check
and repair wire circuit (Fig. 13).
(d) Defective top control solenoid (d) If solenoid power lead(s) is hot,
valves. solenoid valve ( s) is defective.
Replace top control solenoid
valve.
TROUBLE DIAGNOSIS GUIDE - TOP ERECT CYCLE- TOP LOCK (FIG. 13)
(a) Defective top lock relay. (a) Push top control switch up in-
termittently, while listening for
click. If no click, check for
voltage at orange wire terminal
of relay connector. If wire is
top lock relay. If orange wire
terminal is dead proceed as in
5 (b), "Deck Lid Open -Top
Erect Cycle." The top Jock relay
1 NO TOP LOCK ACTION- may be bypassed and the top
TOP LOCK RELAY NOT lock motor may be energized by
FUNCTIONING {NO a jumper wire from center recep-
AUDIBLE CLICK) tacle to the black-red wire re-
ceptacle of top lock relay con-
nector. See 1 (e).
(b) Defective circuit from top con- (b) TOP CONTROL SWITCH RE-
trol switch, through top up limit LEASED. Check out circuit wir-
switch front, and upper back ing and switches using self-
panel limit switch to top lock powered test Iight (Fig. 13) .
relay. Remove top front bow See 1 (c) and (d).
cover to reach top lock motor
and switches.
..

TROUBLE DIAGNOSIS GUIDE - TOP ERECT CYCLE- TOP LOCK (FIG. 13) (Continued)
(e) Defective top up limit switch (c) Open top No. I bow cover.
front. Check between wire terminals of
switch. If light does not come
on, switch is defective. Replace
top up limit switch front.
(d) Defective upper back panel limit (d) Check between red-green and
switch. orange wire terminals. If test
1 NO TOP LOCK ACTION- light does not come on, switch
TOP LOCK RELAY NOT is defective.
FUNCTIONING (NO
AUDIBLE CLICK) (e) Defective top lock motors or (e) If top Jock motor or circuit is
(Continued) circuit. See 5 (a), "Deck Lid found to be defective when relay
Open-Top Erect Cycle." is bypassed by jumper, check
the motor circuit for voltage at
the live side of the motor con-
nector. If circuit is dead, repair
circuit (black-red wire). If cir-
cuit is hot, motor is defective.
Replace top lock motor.
TROUBLE DIAGNOSIS GUIDE- TOP ERECT CYCLE- UPPER BACK PANEL RETRACT (FIG. 14)
(a) Defective upper back panel re- (a) Push top control switch up in-
tract relay. termittently while listening for
relay click. If no click, check
for voltage at the red-white wire
receptacle of the relay connector.
If circuit is hot, relay is defective.
Replace upper back panel re-
tract relay. If circuit is dead,
proceed as in 1 (b).
trol switch, through the top lock LEASED. Check out circuit wir-
limit switch, and the upper back ing and switches using self-
panel retract relay. powered test light (Fig. 14),
see 1 (c) and (d) .
(c) Defective top lock limit switch. (c) Open No. 1 top bow cover and
apply test light between the ter-
{ minals of switch. (The switch
1 NO UPPER BACK PANEL plunger should be fully de-
RETRACT ACTION-RELAY pressed when top is locked). If
NOT FUNCTIONING (NO light does not come on, switch is
AUDIBLE CLICK) defective. Replace top lock limit
switch.
(d) Defective upper back panel limit (d) Using self-powered test light,
switch. check between the green-white
and the red-white wire terminals
of the switch. If light does not
come on, make sure the switch
is properly adjusted before de-
ciding it is defective (Fig. 20).
(e) Defective upper back panel mo- (e) Disconnect motor leads at mo-
tor or power circuit (Fig. 14). tor. Use a jumper between each
motor lead and bus bar on relay
panel. If motor does not operate,
the motor is defective. Replace
upper back panel motor. If mo-
tor operates, check the power
circuits back to the relay and the
15-ampere circuit breaker.

TROUBLE DIAGNOSIS GUIDE- TOP ERECT CYCLE- DECK LID CLOSE AND LOCK (FIG. 15)
(a) Defective deck close relay. (a) Check for voltage at black-green
wire terminal on relay. If ter-
minal is hot, relay is defective.
Replace deck close relay. If
black-green wire terminal is
dead, proceed as in 1 (b) .
trol switch, through the upper LEASED. Check out circuit wir-
back panel limit switch, and the ing and switches using self-
deck closed limit switch to relay. powered test light (Fig. 15).
1 NO DECK CLOSE ACTION- See 1 (c) and (d).
DECK CLOSE RELAY
NOT FUNCTIONING (c) Defective upper back panel limit (c) Check between violet and yellow
switch. wires of switch. If the light does
not come on, switch is defective.
Check switch adjustment before
replacing switch.
(d) Defective deck closed limit (d) Check between red wire termi-
switch. nals on deck closed limit switch
with self-powered test light. If
light fails to come on, switch is
defective. Replace deck closed
limit switch.
2 NO DECK CLOSE ACTION- (a) Defective deck control solenoid (a) Check for voltage at deck con-
DECK CLOSE RELAY valve. trol solenoid valve lead. If wire
FUNCTIONING. TOP-DECK is hot, solenoid valve is defec-
MOTOR AND PUMP tive. If wire is dead, check
ASSEMBLY IS OPERATING power circuit and repair.
3 NO DECK CLOSE ACTION- (a) Defective top-deck motor and (a) Check voltage at the yellow wire
DECK CLOSE RELAY pump assembly or power circuit. at top motor and pump as-
FUNCTIONING. TOP-DECK sembly. If wire is hot, motor is
MOTOR AND PUMP NOT defective. If wire is dead, check
OPERATING power circuit and repair.
4 NO DECK LOCK ACTION- (a) Defective deck lock relay. Deck (a) If relay is not activated in the
DECK LOCK MECHANISM lock relay is activated simulta- cycle, relay is defective.
NOT FUNCTIONING WHEN neously with deck close relay.
DECK LID STARTS
TO CLOSE
(a) Open power circuit to deck lock (a) When deck lid starts to close,
motor or defective deck lock observe deck lock mechanism.
motor. If deck lock mechanism is not
functioning, disconnect the motor
leads at the motor. Use a jumper
5 NO DECK LOCK ACTION- between motor yellow-red lead
DECK LOCK and yellow-blue wire receptacle
RELAY FUNCTIONING of deck lock relay connector. If
motor operates, power circuit
(yellow wire) is open. Repair
circuit. If motor does not op-
erate, motor is defective. Replace
deck lock motor.

(403) 19-1
GROUP
19
THOUSANDS OF MILES OR NUMBER OF MONTHS
WHICHEVER OCCURS FIRST (Except Where No!f·,!). 36
ENGINE
Change oil and f1lter X X X X X X
Adjust carburetor~ Idle speed. 1dle m1xture. and
fast (cold) idle speed
Clean carburetor air cleaner and filter
Replace carburetor air cleaner filter
-------
-----=rI X
X X X X X
X
Replace crankcase oit filler treather cap
--
--
x--f-- X X
Check engine accessory dme belts and adJust or
replace as required X X I X
Clean positive crankcase venti!aticn system X
~~
X
I Clean positive crankcase ventilatiOn system valve
Check ignition trming and adjust as required
-
X X
X
X X
X
X--
X
Check and adjust or replace distributor pornts X
Check and adjust or replace spark plugs X
---
Replace fuel filter
Adjust accelerator pump lever
Replace engine coolant
r-----~---------
~
----
---+ X
X-
I
X
I
X
X*
Check engine coolant level X
TRANSMISSION
Adjust Turbodnve transm1ssion bands as require!~ jRear Xt
!Front Xt
--
Check transmisSion oil level X X X X X X
CHASSIS
-~- ~
Inspect and cross-switch wheels and tires X X X X X
~--~---
Checl\ power steenng ~eservorr fluid level
--~-------~---
Check master cylinder flu1d !eve!

Check axle flUid level
--~-=+= I X
X I
X
X
X
-- -<
-- -------y-
-f--
X
X
X
X
X
X
X
X
X
Lubncate front suspension ball JOints X
Lubricate steering linkage :~---+- X
Change power steering filter ---. =~ X
Check and adjust steenng gear pre-load as reqUIIf:cJ _____ ~
I X X
I
X X X
I
Clean and pack front wheel bearings as requ1red Xt
··-----~ --~--~ t---·--·- ---
iubrrcate unrversal joints X
-----------
Check braKe lines and lming X
----------
Check air conditioning system ANNUALLY AT BEGINNING 0 F A/C SEASON
-- -
Check front wheel alignment ~::_d adjUSt as re91!_11_<'li X X X
>---
-~~~-
-
Check tire pressure X
----··
Chetk battery fluid level X
BODY
Lubricate hood latch X
Lubricate hoed auxiliary catch
------ +--f-----x- -----+--
X
II
Lubricate door lock cylinders
Lubncate luggage compartment lock cylinder
------
---
X ----+---
----1---~- r---- -----
Lubricate fuel filler door hmges
----
X
+
Check convertible top operatiOn
Clean body dram holes
Check convertible top fluid level
---·-··--
------ ---
X
X
X
·+--------- ~----- ---
~--~-· --~
Replace windshield w1per blades X

~----~----~.----~----:---------
-----· ----- -~--- ~- --
Lubricate door h1nge and hinge cneck X
-- -~---
Lubricate hood hinge p1vots X

-,--~-------- -- --------~ -~---·--- ---~
--+---- -~
Lubricate luggage compartment h1nge p1vots X

•Or every two years_ TAt mileage 1nterv11 only_

(405) 20-1
GROUP
20
PART MAINTENANCE OPERATIONS
20-1
1 Engine ...................... . . ....... 20-1 3 Chassis . . . . . . . . . . . . . . . . . . . .............. 20-7
2 Transmission ................. . . ....... 20-6 4 Body ................................. 20-11
II ENGINE
CHANGE OIL AND FILTER quired level with the proper type (Fig. 2). Turn the screws inward
and grade of lubricant. to lean the mixture, and outward
REMOVAL 5. Start the engine. Operate the to enrich the mixture supplied to
1. Raise the car. engine at fast idle and check for oil the intake manifold.
2. Remove the oil pan drain plug, leakage. The idle speed (air) adjustment
and allow the engine oil to drain 6. Add additional lubricant if re- screw (Fig. 2) is used to adjust idle
into a container. quired. speed. Turn the screw outward to
3. Place a drip pan under the increase speed. Conversely, turn the
ADJUST CARBURETOR-IDLE screw inward to decrease speed.
filter assembly (Fig. 1).
SPEED, IDLE MIXTURE, AND Turning the screw outward leans
4. Turn the filter counterclock-
FAST (COLD) IDLE SPEED the mixture, thus requiring an ad-
wise and remove it from the adapter.
IDLE FUEL MIXTURE AND justment at the idle mixture screws.
INSTALLATION If one of the idle adjustments is
IDLE SPEED ADJUSTMENTS
changed, the other idle adjustments
1. Clean the gasket surfaces at The idle fuel mixture is controlled may also be affected. It is necessary
the adapter. by the idle mixture adjusting screws that the adjustments be made in the
2. Coat the gasket on the filter
with a light film of oil. Screw the
filter onto the adapter until it is ACCElERATING PUMP STROKE .'..DJUSTMENT
snug; then, advance it lf4 turn. Do
not overtighten the filter.
3. Remove the drip pan and lower
tHe car.
4. Fill the crankcase to its re-
ADAPTER ASSEMBlY
I
FAST IDlE SPEED
81968-A
FIG. 1-Rotunda Oil FIG. 2-ldle Fuel Mixture, Idle Spe.ed and Accelerator
Filter & Adapter Pump Stroke Adiustments

20-2 GROUP 20-MAINTENANCE OPERATIONS (406)
order listed, and all of the idle ad- 2. Remove the tachometer. Turn surfaces. Replace the cover or body
justments that follow the one being off the engine. Connect the vacuum if they are damaged beyond repair.
made must be checked: line to the .vacuum power unit of
I. Idle Mixture Adjustment. the vacuum release parking brake INSTALLATION
2. Hot Idle Rpm Adjustment. assembly. 1. Install a new air cleaner mount-
3. Fast Idle Rpm Adjustment. 3. Install the air cleaner assembly. ing gasket, if necessary. Install the
When setting the engine idle speed air cleaner body on the carburetor
on cars equipped with an air CLEAN CARBURETOR AIR so that the word "FRONT" faces
conditioner, the air conditioner CLEANER AND FILTER the front of the car.
should be turned off and the air 2. Place the element in the air
cleaner removed. If the air condi- REMOVAL cleaner body. Make sure the ele-
tioner is turned on (with the air 1. Remove the wing nuts retain- ment gasket is properly seated.
cleaner removed), a slight rough- ing the air cleaner assembly to the Install the cover and connect the air
ness of the engine idle may be carburetor and the air duct. duct to the air cleaner. Tighten the
noted. This may be disregarded, 2. Remove the air cleaner assembly retaining wing nuts.
since the air cleaner traps vapors from the carburetor. To prevent
and allows them to enrich the dirt from entering the carburetor, REPLACE CARBURETOR AIR
mixture to again regain a smooth the filter element must never be CLEANER FILTER
idle. removed when the air cleaner
body is mounted on the carbu- REMOVAL
Hot Idle RPM Adjustment
retor. 1. Remove the wing nuts retain-
1. Run the engine until it reaches 3. Remove the cover and filter ing the air cleaner assembly to the
normal operating temperature. If element. Discard the air cleaner carburetor and the air duct.
the engine is cold, it should be run mounting gasket on the carburetor 2. Remove the air cleaner assem-
for approximately one-half hour at if it is excessively worn or damaged. bly from the carburetor. To pre~
1200 rpm to stabilize the tempera- vent dirt from entering the carbu-
ture. FILTER ELEMENT
retor, the filter element must never
2. Allow the throttle to drop back The filter element must never be removed when the air cleaner
to the normal idle speed position. be cleaned with a solvent or clean- body is mounted on the carbur-
Attach a tachometer to the engine. ing solution. Also, oil must not be etor.
Remove the vacuum line from the added to the surfaces of the filter 3. Remove the cover and filter ele-
vacuum power unit of the automa- element or air cleaner body. ment. Discard the filter element.
tic vacuum release parking brake There are two procedures that can Discard the air cleaner mounting
assembly, and plug the vacuum line. be used to clean the air filter element. gasket if it is excessively worn or
Set the parking brake. It is neces- One method is performed with the damaged.
sary to inactivate the vacuum use of compressed air. The other is
power unit to keep the parking performed by tapping the element INSTALLATION
brake engaged during the adjust- on a smooth horizontal surface. 1. Install a new air cleaner mount-
ment procedures. Compressed Air Method. Direct ing gasket, if necessary. Install the
3. Place a small weight on the a stream of compressed air through air cleaner body on the carburetor
idle compensator spring to hold the the element in the direction opposite so that the word "FRONT" faces the
compensator closed. If the compen- that of the intake air flow, that is front of the car.
sator is open, because of high from the inside outward. Extreme 2. Place the new element in the
underhood temperatures, the idle care must be exercised to prevent air cleaner body. Make sure the
speed adjustment would be incor- rupture of the element material. element is properly seated. Install
rect when the compensator closes. Tapping Method. Hold the ele- the cover and connect the air duct
4. Adjust the idle speed and mix- ment in a vertical position and tap to the air cleaner. Tighten the re-
ture screws (Fig. 2) to obtain the it lightly against a smooth, horizontal taining wing nuts.
specified engine idle speed with the surface to shake the dust and dirt
transmission selector in DRIVE po- out. Do not deform the element or
sition. The final mixture setting damage the gasket surfaces by tap-
REPLACE CRANKCASE OIL
should be slightly on the rich side. FILLER BREATHER CAP
ping too hard. Rotate the filter after
5. Remove the weight from the each tap until the entire outer surface
compensator spring. has been cleaned.
CHECK ENGINE ACCESSORY
Fast Idle RPM Adjustment. This Inspection. Hold the filter in front
DRIVE BELTS AND ADJUST OR
adjustment is made only after the REPLACE AS REQUIRED
of a back-up light and carefully in-
engine has been run for 30 minutes spect it for any splits or cracks. If Adjust the tension of the drive
at 1200 rpm. the filter is split or cracked, replace it. belts as follows:
1. With the engine at a stabilized, 1. Remove the alternator spl~sh
BODY AND COVER
normal operating temperature and shield. Loosen the alternator mount-
the fast idle screw resting on the Clean the air cleaner body and ing bolts.
lowest (slowest) step of, the cam, cover with a solvent or compressed 2. Loosen the alternator adjusting
adjust the fast idle screw (Fig. 2) air. Wipe the air cleaner dry if a bracket bolt.
to obtain the specified fast idle rpm solvent is used. Inspect the air 3. Install the belt tension gauge
with the transmission in DRIVE cleaner body and cover for distor- on the fan drive belts (Fig. 3). Move
range. tion or damage at the gasket mating the alternator toward or away from

(407) PART 20-1-MAINTENANCE OPERATIONS 20-3
hose to the ventilation tube and car- CLEAN POSITIVE CRANKCASE

huretor spacer. Remove the hose and VENTILATION SYSTEM
clamps. REGULATOR VALVE
4. Loosen the ventilation tube
hracket retaining nuts and washers, REMOVAL
then slide the ventilation tube out.
5. Remove the retammg bolts 1. Remove the air cleaner.
"ecuring the outlet adapter to the 2. Loosen the clamp securing the
valve push rod chamber cover. Re- hose to the regulator valve. Remove
move the outlet adapter gasket and the hose and clamp. Remove the
l~il separator element. regulator valve from the ventilation
tube fitting.
CLEANING 3. Clean the valve in clean car-
buretor solvent and dry it with com-
Clean the valve, element, tube and pressed air.
FIG. 3-Fon Drive Belt ,)utlet adapter in clean carburetor sol- 4. Install the regulator valve in
Tension Adiustment . ent and dry them with compressed the ventilation tube fitting.
nr. Clean the rubber hose connec-
5. Install the hose and clamp on
; wns with a low-volatility, petro- the regulator valve. Position and
the engine until the specified belt
~:um-hasc solvent and dry them with
tension is obtained. Remove the tighten the damp.
.omprcssed air. 6. lnstall the air cleaner.
gauge. Tighten the alternator ad-
justing bracket bolt; then tighten the
INSTALLATION
alternator mounting bolts. Imtall the CHECK AND ADJUST
tension gauge and check the belt 1. Install the oil separator element IGNITION TIMING
tension. m the valve push rod chamber cover.
4. On cars equipped with air \1 ake certain the screen is positioned TIMING MARK LOCATIONS
conditioning, remove the bolts se" ,nugly around the edges of the The crankshaft damper (Fig. 5)
curing the compressor to the support .>pening. has 15 timing marks ranging from
bracket that is attached to the cyl- 2. Coat a new outlet adapter gas- top dead center (TDC) to 30° be-
inder head. Ket with oil-resistant sealer and posi- fore top dead center (BTDC). Refer
Loosen the bolts sccurmg the com- l ion it on the push rod chamber
to specifications for the correct igni-
pressor to the compressor mounting ,_ over. Position the outlet adapter on tion timing.
bracket. 1 he cover and install the retaining
Install the tension gauge on the holts.
compressor clutch drive belt. Move 3. Slide the ventilation tube brack-
the compressor toward or away from ets under the retaining washers and
the engine until the specified belt nuts. Tighten the nuts. Install the
tension is obtained. Remove the -egulator valve in the ventilation
gauge. Tighten the compressor to rube fitting.
support bracket holts. l nstall the 4. Install the hose and clamp on
tension gauge and check the belt the outlet adapter and regulator
tension. . alve. Position and tighten the clamp.
5. New he1t(s): Run the engine 5. Install the hose and clamps on
for 10 minutes, then check the ten- ihe carburetor spacer and ventilation
sion of the belts to make certain 'ube.
that they are \Vithin the reset speci- 6. 1nstall the air cleaner.
fications. Adjust the belts, if re-
quired.
6. Install the alternator splash
shield.
CLEAN POSITIVE CRANKCASE

VENTILATION SYSTEM
FIG. 5- Timing Marks
The positive crankcase ventilation
components are shown in Fig. 4. TUBE
TIMING
REMOVAL 1. Disconnect the vacuum line. If

necessary, clean and mark the de-
1. Remove the atr cleaner. sired timing mark (Fig. 5).
2. Loosen the clamp securing the CLAMP 2. Attach a timing light to the
hose to the regu Ia tor \:dve. Remove number one spark plug.
OIL SEPARATOR ELEMENT
the hose and clamp. Remove the A1833-A 3. Connect a tachometer to the
regulator valve from ;Jw ventilation engine.
tube fitting. FIG. 4-Positive NOTE: When connecting a tach-
3. Loosen the damps securing the Cronk(ose Ventilation System ometer to a car equipped with

a transistorized ignition, connect the tachometer block rather than

the leads to the tachometer block the coil.
(positive lead to red terminal, Operate the engine at idle speed
negative to black). and note the reading on the dwell
4. Start the engine and adjust the meter.
speed to the specified rpm for initial Stop the engine and adjust the gap
timing adjustment. Allow the engine (decreasing the gap increases the
to warm up. dwell). Now check the dwell again.
5. Observe the timing with the Repeat this procedure until speci-
light. fied dwell is obtained.
6. If the timing is not correct, If new points are installed, set
loosen the hold down bolt and ro- the gap to specifications using a
tate the distributor clockwise to ad- feeler gauge.
vance the timing or counterclockwise 3. Install the dust cover ( transis-
to retard it. torized ignition).
7. Tighten the hold down bolt and 4. Install the rotor. Install the dis-
check the timing. tributor cap on the distributor hous-
ing and snap the retaining clips in
CHECK AND ADJUST place.
OR REPLACE 5. Install the air cleaner and/or the
DISTRIBUTOR POINTS high tension lead if either was re-
moved.
Unsnap the distributor cap retain- The distributor point assembly con- FIG. &-Cleaning Plug Electrode
ing clips, lift the distributor cap off sists of the stationary point bracket
the distributor housing, and position assembly, breaker arm and the pri- cap of the wire only. Do not pull on
the cap out of the way (if necessary, mary wire terminal. Distributor points the wire because the wire con-
remove the air cleaner and/or the can be cleaned with chloroform and nection inside the cap may become
high tension wire to gain access to a stiff bristle brush. Replace the separated or the weather seal may
the distributor) . distributor point assembly if the con- be damaged.
Lift the rotor off the cam. Remove tacts are badly burned or excessive 2. Clean the area around each
the dust cover (transistorized igni- metal transfer between the points spark plug port with compressed
tion). is evident. Metal transfer is con- air, then remove the spark plugs.
INSPECTION sidered excessive when it equals or ADJUSTMENT
exceeds the gap setting.
Replace the distributor point as- To remove the distributor points: Set the spark plug gap to specifi-
sembly if the contacts are badly 1. Unsnap the distributor cap re- cations by bending the ground elec-
burned or excessive metal transfer taining clips, lift the distributor cap trode (Fig. 7).
between the points is evident. Metal off the distributor housing, and posi- Examine the firing ends of the
transfer is considered excessive when tion the cap out of the way (remove spark plugs, noting the type of
it equals or exceeds the gap setting. the air cleaner and the distributor- deposits and the degree of electrode
to-coil high tension wire to gain erosion.
REMOVAL access to the distributor) . Clean the plugs on a sand blast
2. Lift the rotor off the cam. Re- cleaner, following the manufactur-
1. Remove the primary distributor-
move the dust cover (transistorized er's instructions. Do not prolong
transfer is considered excessive when
ignition). the use of the abrasive blast as it
(if equipped) from the breaker plate.
3. Working from the inside of the will erode the insulator. Remove
2. Remove the screw nearest the
distributor, remove the primary dis- carbon and other deposits from the
distributor points, then remove the
tributor-transistor lead and con- threads with a stiff wire brush. Any
distributor point assembly.
denser wire (if equipped) from the deposits will retard the heat flow
INSTALLATION breaker plate. from the plug to the cylinder head
1. When installing new distributor 4. Remove the screw nearest the
points, reverse the procedure for distributor points, then remove the
removal and make sure that the distributor point assembly.
ground wire is attached to the dis- 5. When installing new distributor
tributor point assembly attaching points, reverse the above procedure
screw which is furthest from the and make sure that the ground wire
distributor points. is attached to the distributor point
2. If the used points are service- assembly attaching screw which is
able, set the gap using a dwell meter. furthest from the breaker points.
To set the gap width with a dwell
meter: CHECK AND ADJUST OR
Connect the dwell meter following REPLACE SPARK PLUGS
the manufacturer's instructions. REMOVAL
NOTE: On a car equipped with
transistor ignition, make sure that 1. Remove the wire from each
the dwell meter is connected to spark plug by grasping the moulded FIG. 7-Gapping Spark Plug

{409) PART 20-1- MAINTENANCE OPERATIONS 20-5
causing spark plug overheating and

pre-ignition.
Clean the electrode surfaces with
a small file (Fig. 6) . Dress the elec-
trodes to secure fiat parallel sur-
faces on both the center and side
electrode.
After cleaning, examine the plug
carefully for cracked or broken in-
sulators, badly pitted electrodes, and
other signs of failure. Replace as re-
quired.
INSTALLATION
1. Install the spark plugs and
torque each plug to 15-20 ft-lbs.
When a new spark plug is installed
in a new replacement cylinder head,
torque the plug to 20-30 ft-lbs.
2. Connect the spark plug wires.
Push all weather seals into position.
REPLACE FUEL FILTER

A replaceable fuel filter is located
between the fuel pump and the car-
buretor fuel inlet line (Fig. 8) .
TO ADJUST, BEND HERE AS NECESSARY 11941-A
FIG. 9-Arceleration Pump Adiustment

the throttle plates closed, measure the install the cylinder block drain plugs.
distance from the top surface of the Move the heater control dial indi-
air horn to the top of the plunger cator clockwise to the "MAX" heat
shaft (Fig. 9) . The distance should zone.
be within specification. ' 2. Fill the system with coolant to a
2. To adjust the distance, bend the point one inch below tlie bottom of
accelerating pump operating rod at the supply tank filler neck.
the existing lower bend, as neces- Install the pressure cap and turn
sary (Fig. 9). it clockwise until the first stop is
FIG. 8-Fuel Filter
PUMP STROKE
reached. This will allow the cooling
system to vent entrapped air into
REPLACEMENT The accelerating pump stroke ad- the atmosphere. Do not tighten the
JUStment compensates for the fuel cap fully.
1. Disconnect the fuel line from needs of the engine during extremes 3. Operate the engine until normal
the filter. Unscrew the filter from of hot or cold temperature. Insert operating temperatures are reached.
the fuel pump. the accelerating pump operating rod After the initial fill, the coolant
2. Screw the new filter into the into the appropriate hole in the level drops due to the displace-
fuel pump. Do not over-tighten it. pump arm for the climate in which ment of entrapped air. Add more
Connect the fuel line to the fuel the car is to be driven (Fig. 9). coolant to fill the supply tank to the
filter. Use a wrench on the filter required level. Tighten the pressure
connection to prevent it from turn- cap.
ing when connecting the line. REPLACE ENGINE COOLANT 4. Check the cooling system for
3. Operate the engine and check 1. Remove the radiator cap slowly. leakage. Move the heater control dial
the fuel line and filter connections Sudden release of the pressure will indicator to the "MIN" heat zone.
for leaks. cause "false boiling" and ejection Turn the ignition key to the "OFF"
of coolant. Open the radiator drain position.
ADJUST ACCELERATING cock and remove the cylinder block
PUMP LEVER drain plugs to drain the cooling sys-
tem. CHECK ENGINE
OPERATING ROD COOLANT LEVEL
2. Clean or flush the cooling sys-
1. With the accelerating pump op- tem, if required. The coolant level should be kept
erating rod in the top hole (long To fill the cooling system: 1 inch below the bottom of the filler
pump stroke) of the pump arm and 1. Close the radiator petcock and neck.

EJ TRANSMISSION
ADJUST TRANSMISSION ing screw is tighter than wrench from the adjusting screw threads,
BANDS capacity (10 ft-lbs), loosen the ad- then oil the threads (Fig. 12).
justing screw and readjust the 3. Loosen the rear band adjusting
FRONT BAND ADJUSTMENT screw. screw Jock nut with tool 7195-C, as
The front band is adjusted ex- 4. Back the adjusting screw off shown in Fig. 12. Using the T-
ternally. The adjusting screw is exactly three turns. Severe damage handle on the tool, tighten the ad-
threaded through the left front side may result if the adjusting screw justing screw until the wrench over-
of the transmission case (Fig. 10). is not backed off exactly three runs. If the screw is found to be
Tools 7345 and 7345-L are required complete turns. tighter than wrench capacity (10
to adjust the front band (Fig. 11). 5. Hold the adjusting screw sta- ft-lbs), loosen the screw and re-
1. Raise the car. Remove the trans- tionary and tighten the lock nut to tighten until the wrench overruns.
mission linkage splash shield. 35-40 ft-lbs. 4. Back off the adjusting screw
2. Remove all dirt from the adjust- 1lh turns. Hold the adjusting screw
ing screw threads, then oil the REAR BAND ADJUSTMENT stationary, and tighten the adjusting
threads. Loosen the adjusting screw screw lock nut to approximately 35-
lock nut. 1. Fold back the floor mat to ex- 40 ft-lbs.
3. Tighten the adjusting screw with pose the right side of the floor pan. Severe damage may result if the
tool 7345 until the tool handle 2. Remove the access hole cover adjusting screw is not backed off
"breaks" over center. If the adjust- from the floor pan. Remove all dirt exactly 1lfz turns.
EXTERNAL
FRONT BAND
ADJUSTMENT
CONVERTER RETURN
PRESSURE TO OIL
0
COOLER
EXTERNAL
REAR.BAND
ADJUSTMENT
COOLED OIL RETURN

FROM OIL COOLER
....:::.t.:.;;,;.;,;.o.p....- TO PRESSURE
REGULATOR
D1328-A
FIG. 10-External Transmission Components

( 411) PART 20-1- MAINTENANCE OPERATIONS 20-7
Too/-7195-C
FIG. 12-Rear Band

Adiustment
fluid reaches its normal operating

temperature. When the fluid is warm,
slow the engine down to normal idle
speed.
3. Shift the selector lever through
all positions, and place the lever at
P. Do not turn off the engine during
the tluid level checks.
4. Clean all dirt from the trans-
mission fluid dipstick cap before re-
moving the dipstick from the filler
tube.
5. Pull the dipstick out of the
FIG. 11-Front Band Adiustment tube, wipe it clean, and push it all
the way back into the tube.
6. Pull the dipstick out of the
CHECK TRANSMISSION 1ng level. Then firmly apply the tube again. and check the fluid level.
FLUID LEVEL parking brake. If necessary. add enough fluid to the
The transmission fluid level should 2. Run the engine at normal idle transmission through the filler tube
be checked using the following pro- speed. If the transmission fluid is to raise the tl uid level to the F (full)
cedure: cold. run the engine at fast idle mark on the dipstick. Do not over-
1. Make sure that the car i'-> stand- "pccJ (about 1200 rpm) until the fill the transmission.
EJ CHASSIS
INSPECT· AND CROSS- CHECK MASTER CYLINDER CHECK AXLE FLUID LEVEL
SWITCH WHEELS AND TIRES FLUID LEVEL The lubricant level should be
Switch the tires according to Fig. maintained at the bottom edge of
Remove the filler cap from the
13. Tighten the wheel lugs to the the filler plug hole with the specified
ma~tcr cy1 inder.
specified torque. lubricant.
Fill the reservoir to ·%-inch from
the top.
LUBRICATE
In"ta11 the filler cap.
CHECK POWER STEERING FRONT SUSPENSION
RESERVOIR FLUID LEVEL BALL JOINTS
Cican the area around the plugs,
Start the engine, turn the steering
remove the plugs and install lubri-
wheel all the way to the ldt and
cation fittings. Lubricate the ball
right several times. and shut off the
joints and remove the lubrication
engine.
fittings. Install the plugs.
Check the Huid level in the rescr·
voir. If the level is low. add enough
fluid to raise the level to the F ma~k LUBRICATE
on the dipstick. On a car equipped F1019-A
STEERING LINKAGE
with air conditioning. fill the reser- Clean the area around the plugs,
voir to within 1;4 -inch or the top. FIG. 13-- Tire then rcm,Jvc them.
Do not overfill the reservoir. Cross-Switching Diagram Install lubrication fittings.

Apply the recommended lubricant 8. Locate the mechanical center 3. Remove the wheel cover or hub
to each steering linkage fitting with of the steering gear by rotating the cap. Remove the grease cap from
a pressure gun, remove the lubrica- steering wheel right or left to the the hub. Remove the cotter pin, nut
tion fittings and replace the plugs. stop, then back it off 134 turns. lock, adjusting nut, and 6.at washer
9. Rotate the steering gear to the from the spindle. Remove the outer
CHANGE POWER STEERING left stop. Using an inch-pound torque bearing cone and ro1ler assembly.
FILTER wrench, back it off at a constant 4. Pu11 the wheel, hub, and drum
pull, reading the torque at the exact assembly off the wheei spindle.
Remove the power steering pump mechanical center. 5. Remove the grease retainer
reservoir cover, spring, and washer. Rotate the gear to the right stop (Fig. 16) and the inner bearing cone
Remove all fluid from the reservoir and take the reading in the opposite and roller assembly from the hub.
with a suction gun. Lift the filter direction.
from the reservoir. Wipe the reser- If two slightly different readings
voir clean with a lint-free cloth. are obtained, the larger should be
Place a new filter on the seat. Posi- recorded as total on-center mesh-
tion the washer and spring on the load.
cover stud. Install a new gasket in 10. If total over-center meshload
the cover. Install the cover on the is not within 15-17 in-lbs, loosen the
reservoir and add fluid. sector adjuster lock nut (Fig. 15)
and turn the adjuster screw to ob-
CHECK STEERING GEAR tain proper adjustment.
PRELOAD
1. Remove the fluid from the
power steering reservoir with a suc-
tion gun.
2. Disconnect the fluid return line
from the reservoir. Place the end of
the return line in a container and
turn the steering wheel in both direc-
tions as required to discharge the
fluid from the gear.
3. Working from under the car,
disconnect the Pitman arm from the
steering gear.
4. Remove the hub cap from the
steering wheel.
G1203-A
5. Attach an inch-pound torque
wrench to the steering wheel attach-
ing nut (Fig. 14).
FIG. 15-Preload and
Meshload Adiustment
NOTE: 1/16 turn of the adjuster
will increase the meshload ap-
proximately 2 in-lbs.
Tighten the adjuster lock nut mak-
ing sure the adjusting screw does not
FIG. 16-Removing
turn. Check the meshload.
Grease Retainer
6. Clean the lubricant off the inner
CLEAN AND PACK FRONT
and outer bearing cups with solvent.
WHEEL BEARINGS
7. Soak a new grease retainer in
1. Raise the car until the wheel light engine oil at least 30 minutes
G1202·A
and tire clear the floor. before installation. Thoroughly clean
2. Insert a narrow screwdriver the inner and outer bearing cones
FIG. 14-Checking through the brake adjusting hole at and rollers with solvent, and dry
Steering Gear Preload the inner side of the brake backing them thoroughly. Do not spin the
plate, and disengage the adjusting bearings dry with compressed air.
6. Measure the force required to lever from the adjusting screw. Inspect the bearing cups, cones
move the worm shaft approximately While holding the adjusting lever and rollers for wear or damage, and
200 away from the stop. away from the screw, back off the replace them if necessary. The cone
7. If the reading is not within 6-8 adjusting screw with the brake ad- and roller assemblies and the bear-
in-lbs, loosen the adjuster lock nut justing tool. Be very careful not to ing cups should be replaced as a unit
and turn the bearing adjuster to ob- burr, chip, or damage the notches if damage to either is encountered.
tain the proper reading. Tighten the in the adjusting screw, otherwise 8. Thoroughly clean the spindle
lock nut, making sure the adjuster the self-adjusting mechanism will and the inside of the hub with sol-
docs not turn. Recheck the preload. not function properly. vent to remove all old lubricant.

(413) PART 20-1-MAINTENANCE OPERATIONS 20-9
Cover the spindle with a clean

cloth, and brush all loose dust and
dirt from the brake assembly. To
prevent getting dirt on the spindle,
carefully remove the cloth from
the spindle.
9. Pack the inside of the hub with
specified wheel bearing grease. Add
lubricant to the hub only until the
grease is flush with the inside diam- WITH DRUM AND WHEEl BACK OFF NUT AND NUT
ROTATING, TORQUE THE INSTALL LOCK ON NUT SO THAT
LOCK ONE CASTELLATJON
eter of both bearing cups. ADJUSTING CASTELLA TIONS ARE ALIGNED
INSTALL COTTER PIN.
10. Pack the bearing cone and NUT TO 15-20ft. lbs. WITH COTTER PIN HOLE.
F1138-A
roller assemblies with wheel bearing
grease. A bearing packer is desirable FIG. 18-Front Wheel Bearing Adiustment
for this operation. If a packer is not
available, work as much lubricant spindle. Under no circumstances replace
as possible between the rollers and 17. Install a new cotter pin. Bend one lining only, or one wheel set.
cages. Lubricate the cone surfaces the ends of the cotter pin around Both front wheel sets or both rear
with grease. the castellations of the nut lock to wheel sets should be replaced
11. Place the inner bearing cone prevent interference with the radio whenever a respective lining or
and roller assembly in the inner cup, static collector in the grease cup. In- shoe is worn or damaged. If the
and install the new grease retainer stall the grease cap. drum braking surface is excessively
with the tool shown in Fig. 17. Be 18. Adjust the brake shoes. Install scored, refinish it. The condition of
sure that the retainer is properly the wheel cover. the remaining front linings is usually
seated. about the same as that of the one
LUBRICATE UNIVERSAL inspected. The rear brake linings
JOINTS may also need replacing at the same
time.
Clean the area around the plugs, 2. Check the fluid level in the
then remove them. Install special master cylinder reservoir. If neces-
lubrication fittings and lubricate with sary, add enough heavy-duty brake
special tool (Fig. 19). Remove the fluid to bring the level to within
lubrication fitings and install the :Ys -inch of the top of the reservoir.
plugs. 3. With the parking brakes in the
fully released position, check the
brake cables. The cable adjustment
should be just tight enough to remove
the slack. Excessive tightening may
pull the brake shoes off their
anchors.
FIG. 17-Grease
Retainer Installation CHECK AIR CONDITIONING
I
SYSTEM
.12. Install the wheel, hub, and
AIR CONDITIONING
drum assembly on the wheel spindle.
Keep the hub centered on the A quick test of the refrigerant
spindle to prevent damage to the supply can be made by observing
grease retainer or the spindle the flow of refrigerant through the
threads. sight glass (Fig. 20).
13. Install the outer bearing cone FIG. 19-Lubrication Tool
and roller assembly and the flat
washer on the spindle, then install
CHECK BRAKE LINES AND
the adjusting nut.
LINING
14. While rotating the wheel, hub,
and drum assembly, torque the ad- 1. Raise all four wheels. Remove
justing nut to 15-20 ft-lbs to seat the one of the front brake drums, and
hearings (Fig. 18). inspect the drum and the linings
15. Locate the nut lock on the ad- (the wheel bearings should be in-
justing nut so that the castellations spected at this time and repacked if
on lhe lock are aligned with the necessary). Do not let oil or grease
cotter pin hole in the spindle. touch the drum or the linings. If
16. Back off both the adjusting nut the linings are worn to within V:t.!
and the nut lock together until the inch of the rivet heads, replace or
next castellation on the nut lock rei ine both sets (primary and sec- FIG. 20-Expansion
aligns with the cotter pin hole in the ondary) on the front or rear wheels.· Valve and Liquid Sight Glass

To check the refrigerant supply, 3. Check the shock absorbers for caster angle. Correct caster is oo to
place a large fan in front of the radi- leaks. Replace the shock absorbers negative 1 Y2 o. The maximum differ-
ator to aid in cooling the engine. Set if necessary. ence between wheels should not ex-
the servo control for maximum cool- 4, Check for looseness at the tie- ceed V2 o with '4 o preferred.
ing and the blower on high. Operate rod ends. Looseness can affect the 2. To adjust caster, raise the hood.
the engine at 1300 rpm and observe toe-in readings and adjustment. To Loosen the bolts that secure the
the sight glass while the compressor inspect the front suspension for upper suspension arm shaft to the
is operating. There should be no looseness or wear, it will be neces- frame member and, with the aid of a
bubbles in the sight glass after the sary to raise the car. pry bar, move the shaft in or out,
start of the compressor. Bubbles will Do not raise the car by means as required. A movement of approxi-
appear when the compressor starts of the lower suspension arms. This mately :;;{:! of an inch at either the
but should clear after a few moments. will release the tension on the front or rear bolt location will change
lower ball joints. the caster 1/2 o. Inboard movement of
IDLE SPEED-UP CONTROL
5. Be sure the wheels are balanced. the front bolt, or outboard move-
1. Remove the air cleaner. Operate 6. Check the runout of each front ment of the rear bolt, will change
the engine and the air conditioner. wheel and tire using a dial indicator caster in the negative direction. Out-
2. Place a finger on the air passage against the rim outer band. If the board movement of the front bolt,
inlet tube projecting through the runout exceeds Vs inch, correction or inboard movement of the rear
air horn. If the idle speed-up con- may be made by rotating the wheel bolt, will change caster in the posi-
trol unit is operating correctly, on the drum. When the minimum tive direction.
the pull of vacuum will be suffi- runout has been obtained, mark the 3. When the caster is correct,
cient to be felt by finger applica- point of greatest runout so the wheels torque the shaft retaining bolts to
tion and the engine rpm will can be positioned as shown in Fig. 100-125 ft-lbs and check the caster
decrease. 21 when checking the front end and camber to insure the readings
alignment. Hold a piece of chalk have not changed.
CHECK FRONT WHEEL CAMBER
ALIGNMENT 1. With the car on runway-type
CHALK MARK IN THIS POSITION
If abnormal tire wear or ride and WHEN CHECKING TOE-IN AND TOE-OUT wheel alignment equipment, or on a
ON TURNS level floor, position a suitable gauge
handling' characteristics such as car
lead or wander are experienced on the wheels and check the camber
with properly inflated tires, the front angle. Correct camber is oo to posi-
end alignment should be checked. tive % o. The maximum difference be-
tween wheels should not exceed 1h o
PRELIMINARY with 1,4 o preferred.
2. To adjust camber, raise the
Whenever possible, front wheel hood. Loosen the bolts that secure
alignment checks should be per- the upper suspension arm shaft to
formed on stationary wheel aligning the frame member and, with the aid
equipment. In the absence of such of a pry bar, move the shaft in or
equipment, portable equipment may out, as required. A movement of
be used and the work may be per- approximately %-t inch of the entire
formed on a level floor. The floor shaft will change the camber 1,4 o.
area should be level within ~ inch Inboard movement will change the
from front to rear of the car and camber in the negative direction.
within lfs inch from side to side. It CHALK MARK IN THIS POSITION
Outboard movement will change the
WHEN CHECKING CASTER AND CAMBER
might be well, if portable equipment camber in the positive direction.
is used frequently, to mark off a LOCATION OF POINT OF GREATEST 3. When the camber is correct,
known level area on the shop floor. lATERAl RUN-OUT ON FRONT
WHEELS WHEN CHECKING torque the shaft retaining bolts to
Prior to checking or setting the ALIGNMENT FACTORS I 00-125 ft-lbs and check the cam-
front wheel alignment, be sure all ber and caster to insure the readings
front suspension and steering system F1215·A have not changed.
nuts and bolts are properly torqued.
It is especia1Iy important to have the FIG. 21-Front Wheel TOE-IN
drag strut nut and the upper arm Position For Checking Alignment Toe-in is adjusted by means of the
torque specification, as a loose nut sleeve at the outer end of each
or bolt can directly affect the caster spindle connecting rod. The toe-in
against the wheel rim or the tire side- specification is %; of an inch to
or camber reading. The items which
follow also should be checked and, wall while spinning the wheel. The :1),; of an inch.
if necessary, corrected before align- chalk win mark the rim or tire at 1. Set the front wheels in the
the point of greatest runout. straight-ahead position. To be sure
ing the wheels.
1. Be sure the tires are inflated to CASTER the wheels are straight-ahead, push
the proper pressure at all four the car backward about six feet;
wheels. 1. Position the car on a level floor then, pull it forward about three feet.
2. Be sure the front wheel bear- or on runway-type wheel alignment The last movement of the car must
ings are adjusted properly and that equipment. Position a suitable gauge be forward to position the wheels
the wheels turn freely. on the front wheels and check the properly.

(415) PART 20-1- MAINTENANCE OPERATIONS 20-11
2. Remove the cap from the steer- rod sleeve. Lengthen or shorten both sures (cold) .
ing wheel hub by pressing downward spindle connecting rods an equal
and turning the cap to the left. Make amount to obtain the correct toe-in. CHE·CK BATTERY FLUID LEVEL
sure the alignment mark on the hub l engthening both rods increases The battery is mounted under the
of the steering wheel is lined up toe-in. hood at the right front side of the
with the mark on the end of the 4. Torque the adjusting sleeve engine compartment.
steering shaft. The mark on the end clamp bolts to 22-28 ft-lbs. To pre- Keep the fluid in each batter¥ cell
of the shaft indicates the high-point vent interference, both bolts should up to the level of the ring in the
of the steering gear. With the front be in a vertical position on the bottom of the filler well. Generally,
wheels straight-ahead, the alignment rear side of the sleeve and the tap water may be added unless it
marks should be vertical and the clamps should not project beyond has a high mineral content or has
steering wheel spokes shou1d be in the ends of the sleeve. been stored in a metal container.
their normal position. If the tap water is unsuitable for
3. To adjust toe-in, loosen the two CHECK TIRE PRESSURE the reasons stated above, then dis-
clamps on each spindle connecting Check all tires for specified pres- tilled water should be used.
IJ BODY
LUBRICATE HOOD LATCH CHECK CONVERTIBLE TOP use, type of weather, chemical re-
OPERATION action from road tars or salts and
Apply lubricant M99C40-A or -B the age of the blades. Be sure that
to all pivot points and to the striker If convertible top operation be- the windshield glass surface is not
plate as required to eliminate any comes sluggish or slow, check the contaminated with oil, tree sap or
binding condition. Operate the latch hydraulic reservoir fluid level. Fluid other foreign substance which can-
mechanism several times to be sure level should be approximately 1;4 not be easily rubbed off.
that the lubricant has effectiveiy inch from the filler opening. The Generally, if the wiper pattern
worked in. proper fluid is automatic transmis- across the glass is still uneven and
"ion fluid "Type A, Suffix A." streaked after these tests, replace the
LUBRICATE HOOD blades.
AUXILIARY LATCH CLEAN BODY DRAIN HOLES
Apply lubricant M99C40-A or -B Body drain holes located in the LUBRICATE DOOR HINGE
to all pivot points as required to hottom of the door panels and lower AND HINGE CHECK
eliminate any binding conditions. hody side panels (rocker panels)
Operate the catch several times to Apply lubricant M99C40-A or -B
not protected by rubber valves
be sure that the lubricant has effec- to the hinge pivot points as required
"hould be checked occasionally. Use
tively worked in. to eliminate any binding condition.
;1 small screwdriver or awl to clean
Open and close the door several
, hese holes of obstructions.
LUBRICATE DOOR LOCK times to be sure that the lubricant
CYLINDERS has effectively worked in.
CHECK CONVERTIBLE TOP Apply lubricant M99C40-A or -B
Apply lock lubricant M2C20 FLUIO LEVEL to the door check as required to
sparingly through the key slot. In- eliminate any binding condition.
1. Open the deck lid and raise the
sert the key and operate the lock Open and close the door several
top.
several times to be sure that the times to be sure that the lubricant
2. Remove the right side luggage
lubricant has effectively worked in. has effectively worked in.
compartment liner.
3. Place absorbent cloths below
LUBRICATE LUGGAGE the filler plug. LUBRICATE HOOD HINGE
COMPARTMENT LOCK 4. Remove the filler plug, and PIVOTS
CYLINDER check the fluid level. It should be
Apply lock lubricant M2C20 spar- level with the bottom edge of the Apply M99C40-A or -B lubricant
ingly through the key slot. Insert hole. to the hinge pivot points as required.
the key and operate the lock several 5. If the level is low, check the Open and close the hood several
times to be sure that the lubricant -..;ystem for leaks, adding automatic times to be sure that the hinge pivots
has effectively worked in. transmission fluid "Type A, Suffix do not bind.
,\" as necessary.
LUBRICATE FUEL FILLER 6. Replace the filler plug. LUBRICATE LUGGAGE
DOOR HINGES 7. Replace the luggage compart- COMPARTMENT HINGE
ment liner. PIVOTS
Apply lubricant M99C40-A or -B
to the hinge pivot points as required REPLACE MfiNDSHIELD Apply M99C40-A or -B lubricant
to eliminate any binding condition. WIPER BLADES to the hinge pivot points as required.
Open and close the door several Open and close the luggage com-
times to be sure that the lubricant Wiper blade replacement inter- partment several times to be sure
has effectively worked in. vals will vary with the amount of that the hinge pivots do not bind.

(416)
NOTES
·--··--· -~~-----------------

(417) 21'-1
GROUP
21
LUBRICANT SPECIFICATIONS
Part Ford
Item Number Part Name Specification Alternate Lubricant
Body Hinges R-113-A or-B Rotunda Silicone Lubricant M-99C40-A or -B
Brake Master Cylinder Rl03-A-B, C Rotunda Heavy Duty Brake Fluid M-3833-D Alternate fluid must meet SAE J70B
specifications for 70R3 type extra
heavy-duty brake fluid.
Distributor Cam Distributor Cam Grease M-lC-66-A Use a good high temperature No. 2
grade sodium soap grease.
--
Distributor Wick and Bushing Engine Oii-SAE lOW
Front Suspension Ball Joints and C1AZ-19590-B FoMoCo Ball Joint Grease ESA-M-1C47-A
Steering Linkage
Front Wheel Bearings C2ZA-19585-A FoMoCo Wheel Bearing Grease ESA-M1C60-A
Hood Latch and Safety Catch Rll3-A or-B Rotunda Silicone Lubricant M-99C40-A or -B
Lock Cylinders R117-A Rotunda Lock Lubricant ESB-M-2C20-A
Rear Axle COLY-19A508-B FoMoCo Hypoid Gear Lubricant M2C16-B
Convertible Top Reservoir R-106-A Rotunda Automatic Transmission M2C33-C or D Automatic Transmission Fluid
Fluid marked "TYPE A, SUFFIX A".
Steering-Power (Pump Reservoir)
Transmission (Automatic) R106-A Rotunda Automatic Transmission M2C33-C or 0 Only one quart of Automatic
Fluid transmission fluid marked
"TYPE A, SUFFIX A" may be
used to "add to" factory fill.
Universal Joints ClAZ-19586-B FoMoCo Universal Joint M-IC57 Substitute lubricant must conform
Lubricant to Ford Specification.
ENGINE CRANKCASE OILS tests are defined by ASTM committee If engine oils are used which do
02 for Section G-IV of technical not meet these requirements, it will
Use of SAE lOW-30 oil will pro- committee B and are published in be necessary to change oil more fre-
vide the proper viscosity for all the SAE Handbook. quently than every 6,000 miles.
normal ranges of outside tempera- If it is necessary to use an "MS"
tures. For operation at sustained out- These tests cover oil characteristics
as follows: oil which is not certified by the
side temperatures below -10°F. a marketer as having passed the Engine
5W-20 oil should be used. Sequence I- L9w Temperature Operating Sequence Tests, the addi-
Wear Prevention-(Cold Starts) tion of Rotunda Oil Conditioner to
Oil Quality the oil will satisfy the requirements.
Sequence II - High Speed - High
Use only oils which have been Temperature Wear Prevention
tested and certified by the maker as Oil Filter
Sequence III- High Temperature
satisfying automobile manufacturers Deposit Formation- (Varnish) Use of the right oil filter is also
specifications for Engine Operating essential to good engine life and op-
Sequence Tests for Service M.S. The Sequence IV --Corrosion and Rust eration. For 6,000-mile filter change
Ford Motor Company specification Prevention intervals, filters must meet Ford
covering these tests is M2C27. These Sequence V- Sludge Formation Specification ES-COAE-6714-A.

21-2 GROUP 21-LUBRICATION CHART (418)
FUEL FILTER
BATTERY
OIL FILTER
(UNDER CAR)
OIL Fill CAP
COOLING SYSTEM FILL
AIR CLEANER ELEMENT

DISTRIBUTOR (OIL CUP-WICK
UNDER ROTOR)
BRAKE MASTER
CYLINDER (CAP)
POSITIVE CRANKCASE VENTILATION

SYSTEM FILTEI<
UNIVERSAL JOINTS FRONT WHEEL BEARINGS
FRONT SUSPENSION BALL JOINTS (4 PLUGS)

STEERING LINKAGE (5 PLUGS)
Y-1006-A
FIG. 1-Lubrication Chart

22-1
GROUP
22
The usage of special service tools proper tool applications. dor tool numbers. These tooli may
is illustrated and described in the The numbers shown in the first he obtained from Ford by ordering
text of this manual. Refer to the L~olumns are Ford tool numbers. The by the complete tool number as
specific service procedure for the ,econd column indicates former ven- shown in the first column.
BRAKES REAR AXLE

T
Ford Tool No. Former No. Descnption Ford Tool No. Former No. J Description
- LM-119 Brake Cylinder Retaining Clamp T50T-100-A T50T -100-C Slide Hammer
- 2018-A Brake Adjusting Tool T50T-100-A &
- 2162 Adapter Cap TOOL-1175-AB 1175-A£ Seal Remover
- 2035-N Brake Shoe R & R Spring TOOL-1225-DA 1225-DA Axle Shaft Remover
2086-L TOOL-4000-C 4000-C Differential Housing Spreader
TOOL-33621 33621 Internal Snap R1ng Pliers TOOL-4005 4005 Engine Repair Stand Axle Adapter
-Keyed Shaft
TOOL -4020-8 4020-8 Pinion Depth Gauge-Complete With
Depth Mtcrometer and Gauge
Block
SUSPENSION, STEERING, WHEELS AND TIRES
TOOL-4201 4201 Pinion Shaft Dnve Nut
I TOOL-4201-C 4201-C Differential Backlash & Runout
Ford Tool No. \ Former No. Descnption Gauge With Univ. Bracket, Dial
TSOT-100-A & I TOOL-4205-8

I
4205-B
Indicator and Bracket
Differential ,A.ssembly Bench Holder I
TOOL-1175-AB 1175-AE Seal Remover I
TOOL-1175-AH
TOOL-1217-J
1175 AH
1217-J
Seal Replacer
Front Hub Outer Srg. Cup Replacer
TOOL-4205-C
TOOL4209-C
4205 c
4209-C
Axle Housing Dummy Bearings
(l pr.)
Pinion Tension Scale With 4209-Cl2
I
TOOL-1217-K
TOOL-1217-L
1217-K
1217-L
Front Hub Inner Brg. Cup Replacer
Front Hub Outer Brg. Cup Remover I TOOL-4221-C 4221-C
Socket
Differential Side Bearing Remover I
TOOL-1217-M 1217-M Front Hub Inner Brg. Cup Remover
TOOL-4222-H 4222-H Differential Bearing Cone Replacer
TOOL-3044-LA 3044-LA Front Suspens1on Upper Arm
Bush1ng Remover TOOL -4235-C 4235 c Axle Shaft & Bearing Remover
T54P-3044-A 3069-H Front Suspension Upper and I TOOL-4245 B 4245- B Wheel Bearing Sea! Replacer
3069-L Lower Arm Overhaul Kit TOOL-4616 4616 Drive Pinion Bearing Cup Replacer
T63P-3044-A
TOOL-3068
3044-.AB 3
3068
Front Suspenswn Lower Arm
Bushing Remover and Replacer
Front Suspens1on Upper Arm
TOOL-4621-A 4621-A
(Front)
Drive Pinion Bearing Replacer I
TOOL-4621- BA 4621-BA Rear Pinion Bearing Remover
Bushing Addpter
TOOL-3069-f.A 3069-AA Front SuspenSI'l'l Lower Arm TOOL-4628 4628 Pinion Rear Bearing Cup Replacer
3069-AA-2 Bushing Ren•over TOOL-4628-B 4628-B Pinion Bearing front Cup Remover
TOOL-3069-M 3069-M Lower Arm Bush111gs-Remover TOOL-4628-D 4628-0 Plflion Rear Bearing Cup Remover
I TOOL -3290-C 3069-M -5
3290-C
and Replacer Kit
Tie Rod Bali Er;Js &
I
TOOL-4676 4676 Pinion Shaft Oil Seal Replacer

I
I -
T61B-3576-A
3500-E
-
Centro! Valve Bal! Stud Remover
Pressure Test1ng Gauge Assembly
Sector Shaft Bushtng and Seal
T57L -4851-A
TOOL-4858-8
4851-K
4858-B
Universal Joint Flange Haider
CompaniOn Flange & Pinion Bearing
Replacer
I
I
Remover and Replacer - 4858-D Compa"'on flarge Remover-Mod.,
T62B-3576-A - Power Steerin;s Gear Oil Seals TOOL -4858-G 4858-G Pinion Flange Nut Adjusting Wrench
TOOL -3583- J 3583 J

Replacer Ajapter
Control Valvp P"1flnR ilnd Se;;i
I
i TOOL-4859 48S9
(Use With Tooi-4858-B)
CompaniOn Flange Dust Shield .
Remover & Replacer Replacer
TOOL-3590-L 3590 L Steering Arm Remover TOOL-7657-J 7657 .J Extension Housing Bushing &
TOOL-3600 AA 3600-AA Bolt-On Type Steenng Wheel Seal Replacer
3826 Remover
T63B-3B673-A -- Power Steering Sleeve & Spool
Assembly Bea:tng Remover DRIVE LINE
& Replacer
•
TOOL-5310-A 5310-A Front Coil Spnng Compressor
TOOL-6306-AG 6306-AG Crankshaft Da1i1per Remover & Ford Tool No. Former No. I Description
Power Steer:ng Pump Sprocket
Replacer TOOL-7657-i 7657 J Extension Housing Bushing and
TOOl-33623-D 33623- D Pump Oil Sea; P;lot Seal Replacer

22-2 GROUP 22 -SPECIAL SERVICE TOOLS (420)
AUTOMATIC TRANSMISSION ENGINE (Cont'd)
Ford Tool No. Former No. Description Ford Tool No. Former No. Description
TOOL-1175-AB 1175-AB Seal Remover (head only) TOOL-6500-F 6500-F Hydraulic Tappet Plunger Remover
T50T-100-A & & Replacer
TOOL-1175-AB 1175-AE Seal Remover TOOL-6505-F 6505-f Valve Stem Clearance Checking Tool
TOOL-4201-C 4201-C Differential Backlash & Runout TOOL-6513-ABA 6513-AB Valve Holdup Air Adapter and Hose
Gauge, With Uni. Bracket, Dial TOOL-6513-DD 6513-DD Valve and Clutch Springs Tester
Indicator & Bracket
TOOL-7000-AG 7000-AG Extension Housing Bushing
- 6513-EE Valve Spring Compressor-Head Off
Remover- Automatic TOOL-6513-J 6513-J Valve Spring and Rocker Arm
Transmission Compressor
TOOL-7000-CJ 7000-CJ Transmission Overhaul Holding TOOL-6513-K 6513-K Push Rod Check Compressor
Fixture TOOL-6565 6565 Cam lift Dial Indicator
- 7000-EHJ Transmission Jack TOOL-6565-AB 6565-AB Cup-Shaped Adapter for Tool-6565
- 7000-EG Jack Adapter Kit T58T-6701-B 6701-B Crankshaft Rear Bearing Seal
Replacer
- 7000-LC Jack Bracket Kit
T58L-101-A &
TOOL-7000-DE 7000-DE Air Nozzle, With Tooi-7000-DD
Rubber Tip T59L-100-B 7600-E Clutch Pilot Bearing Remover
TOOL-7195-C 7195-C Rear Band Adjustment Wrench
TOOL-7345-l 7345-l Front Band Adjustment Wrench
TOOL-7657-J 7657-J Extension Housing Bushing and
IGNITION SYSTEM
Seal Replacer
T58l-7902-A 7937-A Welded Converter Sprag Driver and Ford Tool No. Former No. Description
7946-A Gauge Post
T63P-7902-A - Converter Stator Check Adapter T57L-1212Q-A 12132-B Distributor Base Upper Bushing
TOOL-77067 77067 Dial Indicator Support Fixture Replacer
T59P-77370-B 7345 -Front Band Torque Wrench T52L-12131-CAD 12131-C Distributor Shaft Gear and Collar
Retaining Pin Remover and
T59L-77515-B 77515-A Rear Clutch Spring Compressor
Replacer Fixture
TOOL-77530-A 77530-A Clutch Assembly Fixture
TOOL-12132 12132 Distributor Shaft Bushing Burnisher
TOOL-77565 77565 Front Clutch Spring Compressor
T58L-12132-B - Distributor Body Holding Clamp
T63L-77837-A 77837 Front Pump Seal Replacer
- 12132-B1
12132-H Distributor Shaft Bushing Remover
- 12150-D
12150-E Distributor Adjustment Wrench
ENGINE TOOL-12151 12151 Distributor Point Tension Scale
T52L-12390-CAD 12390-C Distributor Shaft Drive Gear
Ford Tool No. Former No. Description Remover Kit
T57l-12390-A 12175-B Tech. Gear and Drive Gear locating
T53L-300-A 6000-BA Engine Lifting Sling & Installing Fixture
- 3600-E Piston Pull Scale
- 4201-0 Indicator Bracket Assembly-Less
Indicator FUEL SYSTEM
TOOL-6000-K 6000-K Engine lifting Eyes-One Pair
TOOL-6011-E 6011-E Cylinder Ridge Reamer Ford Tool No. Former No. Description
TOOL-6011-F 6011-f Swivel Arm Only-To Convert
TOOL-6085-l 6085-L
6011-A to 6011-E
Cylinder Head Overhaul Fixture,
T62P-9A274-A -
9545
Fuel Line Tube Die
Choke Unloader Gauge
.
TOOL-9545
4 Pes, 430 Engine 9550-AJ Float Gauge
TOOL-9550-AJ
T58P-6085-B 6085-H Valve Guide Reamer Kit 9564-A Float Bending Tool
TOOL-9564-A
- 6110-E Ring Groove Cleaner
TOOL-9581 9581 Throttle Shaft Bending Tool
TOOL-6135-F 6135-F Piston Pin Remover & Replacer, 9597 Wire Gauge
TOOL-9597
430 Engine
TOOL-9597-B 9597-B Wire Gauge
- 6149-E Ring Compressor
99798 Throttle Connecting Link Bending
TOOL-99798
- 6149-14 Ring Installer Tool
TOOL -6261-AC 6261-AC Camshaft Bearing Adapters,
430 Engines
T54T -6250- B &
T52L-6261-CEE 6261-F Camshaft Bearing Remover & COOLING SYSTEM
Replacer
TOOL-6306-AG 6306-AG Crankshaft Damper Remover & Pow. Ford Tool No. Former No. Description
St. Pump Sprocket Replacer
TOOL-6306-AJ 6306-AJ Crankshaft Damper Remover & TOOL-3600-AA 3600-AA Bolt-On Type Steering Wheel
Replacer Remover
T58T -6306-A 6306-AH Crankshaft Gear Remover T57l-7657-A 7657-F Oil Seal Assembly Replacer
TOOL-6331-E 6331-E Upper Main Bearing Insert Remover T52L-8501-DAD 8501-DD Water Pump Overhaul Kit
& Replacer 8501-00-18
TOOL-6500-C 6500-C Hydraulic Tappet Clip Replacer T63l-8620-A 8620 Belt Ten sian Gauge
TOOL -6500-E 6500-E Hydraulic Tappet Leakdown Tester BT-33-73-F

(421) GROUP 22 -SPECIAL SERVICE TOOLS 22-3
CHARGING SYSTEM ELECTRICAL AND ACCESSORIES
Ford Tool No. Former No. I Description Ford Tool No. Former No. Description
T58P-7563-A - Disc Clutch Pilot ACM-57-2- Tool ACL-57-2 Leak Detector-Complete

T63l-8620-A 8620 Belt Tension Gauge ACM -57-3-Tool ACL-53-3 Pressure Test Manifold-Complete
BT-33-73-F With Hoses
TOOl-10044-A 10044-A ACl-53-18-Tool ACL-53-18 Adapter-Freon Cylinder Valve
Generator Pole Screw Wrench
TOOl-J-8465 J-8465 Complete Test Light Unit
T63l-10300-A - Alternator Pulley Remover TOOL-J-8674 J-8674 Tester Adapter Kit
BODY
STARTING SYSTEM
Ford Tool No. Former No. Description
Ford Tool No. Former No. Description
T64N-16A605-A - Hood Torsion Bar Remover &
Installer
TOOl-10044-A 10044-A Generator Pole Screw Wrench T57P-53510-A 53510-A locknut Wrench (Convertible Top)

(422)
IJG=OO&) rP&®§
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1964 LINCOLN-CONTINENTAL SHOP MANUAL
------------------------------
INDEX

2 (424)
Page Page
A
Alignment ........................... . 17-3
AIR CLEANER AND AIR DUCT Bumpers and Hood ; .................. . 17-12
Cleaning and Inspection . . . . . . . . . . . . . . . . 10-10 Convertible Top ...................... . 18-11
Description and Operation . . . . . . . . . . . . . . 10-25 Deck Lid, Doors and Locks ............ . 17-17
Disassembly and Assembly - Air Duct . . . . 10-26 Grilles ............................... . 17-14
Removal and Installation . . . . . . . . . . . . . . . . 10-26 Hoisting Procedures ................... . 17-10
Maintenance · ......................... . 17-1
AIR CONDITIONING ••••. •. . . . . •. . •••. . . •••. 16-13 Paint ................................ . 17-6
Cleaning and Inspection . . . . . . . . . . . . . . . . 16-9 Seats ................................ . 18-5
Description and Operation . . . . . . . . . . . . . . 16-13 Trim ................................ . 18-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1 Windows ............................ . 17-18
In-Car Adjustments and Repairs ......... 16-14 Windshield ........................... . 17-27
Removal and Installation . . . . . . . . . . . . . . . 16-16
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 16-30 BRAKES ••••••••••••••.•••••••••••••••..•. 2-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-5 Cleaning and Inspection ............... . 2-4
Common Adjustments and Repairs ...... . 2-2
ALTERNATOR • • • • • • • • • • • . • • • • . • • • . • • • • . • • . • 13-8 Parking Brake Linkage ................ . 2-2
Cleaning and Inspection . . . . . . . . . . . . . . . . 13-7 Master Cylinder Push Rod ............. . 2-2
Description and Operation . . . . . . . . . . . . . . 13-8 Brake Bleeding ...................... . 2-4
Diagnosis and Testing . . . . . . . . . . . . . . . . . . 13-1 Description and Operation ............. . 2-6
In-Car Adjustments and Repairs . . . . . . . . . 13-8 Diagnosis and Testing ................. . 2-1
Major Repair Operations . . . . . . . . . . . . . . . . 13-8 In-Car Adjustments and Repairs ........ . 2-8
Removal and Installation . . . . . . . . . . . . . . . . 13-8 Brake Shoes ........................ . 2-8
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13 Brake Drums ....................... . 2-9
Brake Lines and Connections .......... . 2-12
ALTERNATOR REGULATOR . . • . . • . . • • • . . • . . . . • . 13-11 Wheel Cylinders ..................... . 2-11
Description and Operation . . . . . . . . . . . . . . 13-11 Major Repair Operations ............... . 2-16
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 Brake Booster ....................... . 2-18
In-Car Adjustments and Repairs ......... 13-11 Brake Drum Refinishing .............. . 2-16
Removal and Installation . . . . . . . . . . . . . . . 13-12 Master Cylinder ..................... . 2-17
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13 Removal and Installation .............. . 2-13
Testing ............................... 13-5 Specifications ......................... . 2-20
AUTOMATIC HEADLIGHT DIMMER • • • • • . . • • • • • • • 16-27 BREAKER POINTS
Description and Operation . . . . . . . . . . . . . . 16-27 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17

In-Car Adjustments and Repairs . . . . . . . . . 16-28 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Removal and Installation . . . . . . . . . . . . . . . 16-29 Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-9
BUMPERS •••••••.•••••.•.••••.••••••.•••••• 17-10
AXLES • • . • • • • • . • • . • • • • • • • • • . • • . • • • • • . • • • • 4-1
c
Cleaning and Inspection ............... . 4-4 CAMSHAFT
Common Adjustments and Repairs ...... . 4-2 Bearing Replacement .................. . 8-48
Description and Operation ............. . 4-6 Cleaning and Inspection ............... . 8-14
Diagnosis and Testing ................. . 4-1 Lobe Lift ............................ . 8-7
In-Car Adjustments and Repairs ........ . 4-8 Rear Bearing Bore Plug Replacement .... . 8-36
Major Repair Operations ............... . 4-11 Removal and Installation .............. . 8-35
Differential Case .................... . 4-11 Repair ............................... . 8-11
Drive Pinion and Ring Gear ........... . 4-13 Specifications . . . . . . . . . . . .............. . 8-53
Removal and Installation ............... . 4-9
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 CARBURETOR
Bench Adjustments .................... 10-5

B Cleaning and Inspection . . . . . . . . . . . . . . . . 10-9
BATTERY 13-6 Description and Operation . . . . . . . . . . . . . . 10-11
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6 Diagnosis and Testing . . . . . . . . . . . . . . . . . . 10-3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-l Disassembly and Assembly . . . . . . . . . . . . . . 10-19
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 3 In-Car Adjustments and Repairs ......... 10-18
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6 Major Repair Operations . . . . . . . . . . . . . . . 10-19
BODY . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . • . 17-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34

(425) 3
Page Page
c
Description and Operation ............. . 9-22
CLOCK 15-16 Disassembly and Assembly -Bench ..... . 9-24
COIL .................................. . 9-12 Disassembly and Assembly - In-Car ..... . 9-22
In-Car Adjustments and Repairs ........ . 9-22
COMPRESSION TEST - ENGINE . . . . . . . . . . . . . . . • • 8-8 Major Repair Operations .............. . 9-24
CONDENSER . . • . . . . . . . . . . . . . . . . . . . ....... . 9-13 Removal and Installation .............. . 9-23
Specifications . . . . . . . . . . . . . . . . . . . . . . . . .. 9-27
CONNECTING RODS Tests ........................... ·. · · · · 9-14
Cleaning and Inspection ............... . 8-15
DRIVE BELT- FAN
Disassembly and Assembly ............. . 8-40
Removal and Installation .............. . 8-38 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
CONNECTING ROD BEARINGS Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
8-38 DOORS ••..............•.•••••.•..•••.••• 17-17
Replacement ......................... .
Specifications . . . . . . . . . . . . . . . . . . . . . . . .. . 8*54 DRIVE LINE 5-1
CONVERTIBLE TOP 18-11
E
Description and Operation ............... 18-11
Diagnosis and Testing . . . . . . . . . . . . . . . . . . 18-20 ENGINE
Cleaning and Inspection . . . . . . . . . . . . . . . . 8-1.3
COOLING SYSTEM Description and Operation . . . . . . . . . . . . . . 8-18
Cleaning and Inspection ............... . ] 1-4 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Common Adjustments and Repairs ...... . 11-3 Disassembly and Assembly . . . . . . . . . . . . . . 8-49
Diagnosis ............................ . 11-1 In-Car Adjustments and Repairs . . . .. . . . . . 8*23
Maintenance ......................... . L1-2 Lateral Restrictor . . . . . . . . . . . . . . . . . . . . . . 8-24
Specifications ........................ . 11-10 Major Repair Operations . . . . . . . . . . . . . . . 8-46
Testing .............................. . 11-2 Removal and Installation . . . . . . . . . . . . . . . . 8-43
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53
CRANKSHAFT
Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Bearing Replacement .................. . 8-36 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Cleaning and Inspection ................ . 8-15
Damper Removal and Installation ....... . 8-32 EXHAUST SYSTEM
Removal and Installation ............... . 8-46 Description ....................... :. . . . 12-1
Repair ............................... . 8-11 In-Car Adjustments and Repairs . . . . . . . . . 12-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54 Removal and Installation ................ 12-3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
CYLINDER BLOCK
!Cleaning and Inspection ............... . 8-16 F

Plugs and Fittings .................... . 8-50
FAN DRIVE CLUTCH
Repair ............................... . 8-12
Specifications ......................... . 8-55 Description and Operation . . . . . . . . . . . . . . 11-9
CYLINDER FRONT COVER . . . . . . . . . . . . . . . • . . . . . 8-33 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Removal and Installation . . . . . . . . . . . . . . . . 8-33 FAN REPLACEMENT . . . . • . . . . . • . . . • . • . . • • . • . . 11*3
CYLINDER HEAD FLYWHEEL REPLACEMENT . . • . . • • . . . • • . . . . . . . . • 8-41
Cleaning and Inspection ................ . 8-13
Disassembly and Assembly ............. .
FUEL FILTER REPLACEMENT . . . . • . • . . . • . . . . . • . . . 10-8
8-30
Removal and Installation .............. . 8-29 FUEL LINE REPLACEMENT 10-33
Repair ............................... . 8-10
Specifications ......................... . 8-53 FUEL PUMP
Cleaning and Inspection ................. 10-10
D Description and Operation . . . . . . . . . . . . . . 10-27
DECK LID ................................ 17-17 Diagnosis and Testing . . . . . . . . . . . . . . . . . . 10-1
Disassembly and Assembly . . . . . . . . . . . . . . 10-29
DISTRIBUTOR Major Repair Operations . . . . . . . . . . . . . . . 10-29
Cleaning and Inspection . . . . . . . . . . . . . . . 9-21 Removal and Installation ............... 10-28
Common Adjustments and Repairs . . . . . . . 9-17 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 10-34

4 (426)
Page Page
F L
FUEl SYSTEM LIGHTS
Common Adjustments and Repairs 10-5 Description and Operation . . . . . . . . . . . . . . 15-5
Diagnosis and Testing . . . . . . . . . . . . . . . . . . 10-l Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . I 0-34 In-Car Adjustments and Repairs . . . . . . . . . 15-5
FUEL TANK REPLACEMENT . . • . . . . . . . . • . . . . . . . . 10-31 Removal and Installation . . . . . . . . . . . . . . . . 15-5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 15-18
FUEL TANK FILLER PIPE REPLACEMENT . . . . . . . . . . . 10-31
LOCKS
FUSES AND CIRCUIT BREAKERS . . . . . . . . . . . . . . . . . 15-10
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1 7
G In-Car Adjustments and Repairs . . . . . . . . . 17-24
GRILLE REPLACEMENT 17-14 Removal and Installation . . . . . . . . . . . . . . . . 17-27
H M
MAIN BEARINGS
HEATER . . . . • • . . • . . • . . . . . . . . . . . . . . • . . . . . . . 16-1 l
Cleaning and Inspection . . . . . . . . . . . . . . . . 16-9 Cleaning and Inspection . . . . . . . . . . . . . . . . 8-16
Description and Operation . . . . . . . . . . . . . . 16-11 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
Diagnosis and Testing . . . . . . . . . . . . . . . . . . 16-1 Specifications ........................ ·. . 8-54
In-Car Adjustments and Repairs . . . . . . . . . 16-ll MAINTENANCE AND LUBRICATION •..•.•••.••.• 20-l
MANIFOLDS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 16-30
Cleaning and Inspection . . . . . . . . . . . . . . . . 8-13
HOISTING PROCEDURES . . • . . • . . • . . • . . . . . . . . . . 17-10 Exhaust Manifold Replacement . . . . . . . . . . 8-25
HOOD . . . . • . . . . • . • . • • . . • . . . . . • . . . . . . . . . . . 17-12 Intake Manifold Replacement . . . . . . . . . . . . 8-24
Intake Vacuum Test . . . . . . . . . . . . . . . . . . . . 8-7 ~
HORNS . • • • • . . • . . . . • . . . • . . . . • . . . . . . • . • . • • 15-5
Description and Operation . . . . . . . . . . . . . . 15-5 MIRROR - INSIDE 17-29
Diagnosis and Testing . . . . . . . . . . . . . . . . . . 15-2
In-Car Adjustments . . . . . . . . . . . . . . . . . . . . 15-4 0
Removal and Installation . . . . . . . . . . . . . . . . 15-9 OIL FILTER AND ADAPTER REPLACEMENT 8-41
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 15-18
OIL PAN
HYDRAULIC VAL VI LIFTER
Cleaning and Inspection 8-16
Cleaning and Inspection ............... . 8-14 Removal and Installation 8-41
Disassembly and Assembly ............ . 8-28
Removal and Installation ............... . 8-27 OIL PUMP
Tests 8-8 Cleaning and Inspection ............... . 8-16

Disassembly and Assembly ............. . 8-42
IGNITION SYSTEM Specifications ......................... . 8-45
Diagnosis and Testing ................. . 9-1 p
Specifications ......................... . 9-27 PAINT 17-16
Timing ........................ · · · · · · · 9-19
PISTON
INSTRUMENTS . . . . . . . . . . . • . . • • . • • . • . . • . . • . . 15-4 Cleaning and Inspection ............... . 8-15
Description and Operation . . . . . . . . . . . . . . . 15-4 Repairs .............................. . 8-11
Diagnosis and Testing . . . . . . . . . . . . . . . . . . 15-1 Specifications ......................... . 8-55
In-Car Adjustments and Repairs ........ ~ 15-4
PISTON AND CONNECTING ROD ASSEMBLY
Removal and Installation . . . . . . . . . . . . . . . . 15-14
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 15-18 Disassembly and Assembly ............. . 8-40
INTERIOR TRIM . . . . • . . . . . . . . • . . . . . . . . . . . . . . 18-1
Door Trim Replacement . . . . . . . . . . . . . . . . 18-1 PISTON PIN
Headlining Replacement . . . . . . . . . . . . . . . . 18-3 Cleaning and Inspection ............... . 8-15
Instrument Panel Safety Cover Repairs .............................. . 8-12
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 18-3 Specifications ......................... . 8-54
Power Seat ............................ 18-5
PISTON RINGS
Description ........J. • • • • . • • • • . . . • • • • • 18-5
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-8 Cleaning and Inspection ............... . 8-15
Removal and Installation . . . . . . . . . . . . . . . 18-8 Repairs .............................. . 8-11
Rear Seat Removal and Installation . . . . . . 18-10 Specifications ......................... . 8-55

(427) 5
Page Page
p STEERING 3-15
.......•..........••.••••.•..•.•
POSITIVE CRANKCASE VENTILATION SYSTEM Description and Operation ............. . 3-15
Cleaning and Inspection . . . . . . . . . . . . . . . . 8-17 Diagnosis and Testing ................. . 3-1
Removal and Installation . . . . . . . . . . . . . . . . 8-28 In-Car Adjustments and Repairs ........ . 3-17
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Major Repair Operations ............... . .3-21
Steering Gear ....................... . 3-21
POWER BRAKES . . . . . . . . . . . . . . . . . . . . 2-1 Pump .............................. . 3-26
POWER SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-5 Removal and Installation ............... . 3-20
Specifications ......................... . 3-5
POWER STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
POWER WINDOWS 17-18 SUSPENSION . . • . . . . . . . . . . . • . • . . . . • . . • • . • . • 3-7
Cleaning and Inspection . . . . . . . . . . . . . . . . 3-4
PUSH RODS
Riding Height Measurements . . . . . . . . . . . 3-6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Common Adjustments and Repairs . . . . . . . 3-3
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 0 Steering Wheel Spoke Position . . . . . . . . . . 3-4
Valve Spool Centering Check . . . . . . . . . . . 3-3
R Wheel Alignment . . . . . . . . . . . . . . . . . . . . . 3-3
RADIATOR Diagnosis and Testing . . . . . . . . . . . . . . . . . . 3-1
Cleaning and Inspection . . . . . . . . . . . . . . . . 1 l-4 In-Car Adjustments and Repairs . . . . . . . . . 3-7
Description and Operation . . . . . . . . . . . . . . 11-7 Major Repair Operations . . . . . . . . . . . . . . . 3-13
lfose Replacement ...................... 11-3 Removal and Installation . . . . . . . . . . . . . . . . 3-9
Maintenance .......................... 11-2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Removal and Installation . . . . . . . . . . . . . . . . 11-8
RADIATOR SUPPLY TANK T

Description and Operation . . . . . . . . . . . . . . . 11-7 THERMOSTAT
Removal and Installation . . . . . . . . . . . . . . . 11-8 Description and Operation . . . . . . . . . . . . . . . 11-7
RADIO .................................. 16-21 Removal and Installation . . . . . . . . . . . . . . . 11-8
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-10
Description and Operation . . . . . . . . . . . . . . 16-21 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2
In-Car Adjustments . . . . . . . . . . . . . . . . . . . . 16-21 TIMING CHAIN AND SPROCKETS
Removal and Installation . . . . . . . . . . . . . . . 16-21 Cleaning and Inspection . . . . . . . . . . . . . . . . 8-14
Specifications . . . . . . . . . . . . . . . . . . . 16-30 Removal and Installation . . . . . . . . . . . . . . . 8-34
s TIRE SPECIFICATIONS . . . . . . . . • . . • . . . • . • • . • . . • 3-5
SPARK PLUGS
TOOLS - SPECIAL . . . . . . . . • • . . . . . . . . • • . . . • . • • 22-1
Replacement ......................... . 9-19 TRANSMISSION . . • . . . . . • • . . • . . . . • • • . . . . • . . . 7-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . .. 9-27 Cleaning and Inspection ............... . 7-8
Test ........................... · · .... · 9-6 Common Adjustments and Repairs ...... . 7-8
Description and Operation ............. . 7-13
· SPARK PLUG WIRE REPLACEMENT . . . . . . . . . . . . . . . 9-19 Diagnosis and Testing ................. . 7-1
SPEED CONTROL . . . . . . . . . . . . . . . . . . . . ..... . 16-25 Fluid Leakage Checks ................ . 7-1
16-25 Control Pressure Checks .............. . 7-3
Description and Operation ............. .
Diagnosis and Testing ................. . 16-2
Air Pressure Checks .................. . 7-5
In-Car Adjustments and Repairs ........ . 16-25 Shift Point Checks ................... . 7-5
16-26
Diagnosis Guide ..................... . 7-7
Removal and InstaUation ................ .
16-30 Disassembly and Assembly ............. . 7-28
Specifications . . . . . . . . . . . . . . . . . . . . . . . ..
In-Car Adjustments and Repairs ........ . 7-21
SPEEDOMETER . . . . . . , . . . . . . . . . . . . . . . . . . ... . 15-16 Band Adjustments ................... . 7-24
Extension Housing Oil Seal or Bushing
STARTER . . . . . . . . • . . . . . . . . . • . . . . . . . . . . . . . . 14-6 Replacement ...................... . 7-27
Description and Operation . . . . . . . . . . . . . . 14-6 Linkage Adjustments ................. . 7-21
Diagnosis and Testing . . . . . . . . . . . . . . . . . . 14-1 Oil Pan and Valve Body Replacement ... . 7-25
Major Repair Operations . . . . . . . . . . . . . . . . 14-6 Parking Pawl Replacement ............ . 7-26
Removal and Installation . . . . . . . . . . . . . . . 14-6 Pressure Regulator Replacement ........ . 7-26
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8 Starter Neutral Switch Adjustment ...... . 7-23
Starter Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4 Major Repair Operations ............... . 7-28

6 (428)
Page Page
T VENTILATION •••.••••...•.••...•..•..• ~ ,. ·! .16-ll
Parts Repair or Replacement ........... . 7-32 Description and Operation ............. . 16-11
Control Valve Body .................. . 7-33 In-Car Adjustments and Repairs ........ . 16dl
Front Pump ........................ . 7-32 Removal and Installation ............... . 16-1 i-
Governor ........................... . 7-36 Specifications ......................... . 16-30
Manual and Parking Linkage ........... . 7-36 Testing .............................. . 16-4
Pressure Regulator ................... . 7-33
Rear Pump ......................... . 7-33 w
Removal and Installation ............... . 7-27 WATER PUMP
Specifications ......................... . 7-39 Cleaning and Inspection . ,: .. : .......... ~ 11-4
TURN INDICATOR 15-16 · · Description 'and Operation ............. ·.. 11-5
· D~assembly and Assembly ............. . 11-5
Removal and Instltllation .............. . 11-5
v Specifications .. "; ...................... . 11-10
VALVE
Cleaning and Inspection ............... . 8-13 WHEELS AND TIRES •••..••.•••.•••••.••.• , •• 3-38
Clearance ............................ . 8-9 Des~ription and Operation ............. . 3-28
Repair ............................... . 8-11 In-Car Adjustments and Repairs ........ . 3-28
Specifications ......................... . 8-53 Major Repair Operations .............. . 3-29
Removal and Installation .............. . 3-29
VALVE PUSH ROD CHAMBER COVER •••.••..••.. 8-26 3-5
Specifications ......................... .
VALVE ROCKER ARM COVER . . • • . • • . • . . . . . . • . . 8-26
WINDOWS
VALVE ROCKER ARMS, SHAFTS AND PUSH RODS Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-18
Cleaning and Inspection ............... . 8-13 In-Car Adjustments and Repairs . . . . . . . . . 17-25
Disassembly and Assembly ............. . 8-27 Removal and Installation . . . . . . . . . . . . . . . 17-27
WINDSHIELD WIPER
Repair ............................... . 8-10
Specifications ......................... . 8-53 Blade Adjustment ...................... 15-14
Control Replacement ................... 15-17
VALVE SPRING, RETAINER AND STEM SEAL Motor Replacement ..................... 15-17
REPLACEMENT ......•••••••••.•.•.•••.••.•• 8-31 Pivot Shaft and Link Replacement . . . . . . . . 15-17

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This shop manual provides the Service Technician with com-

plete information for the proper servicing of the 1964

The information is grouped according to the type of work

being performed, such as diagnosis and testing, frequently

performed adjustments and repairs, in-vehicle adjustments,

overhaul, etc. Specifications and recommended special tools

Refer to the opposite page for important vehicle identifica-

The descriptions and specifications' in this manual were in

Ford Motor Company reserves the right to discontinue models

at any time, or cha/zge specifications or design, without notice

and without incurring obligation.

FORD MOTOR COMPANY

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LIGHT SILVER BLUE METALLIC CRINKLE LEATHER

DAY OF MONTH CONVENTIONAL 2 891 RATIO AXlE

1964 MODEL YEAR - - - " CONSKUTiVE UNIT NUMBER

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PART GENERAL BRAKE SERVICE

II DIAGNOSIS AND TESTING

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BRAKE BOOSTER TROUBLE DIAGNOSIS GUIDE

This condition may result from a Refer to "Disassembly of Booster

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TABLE 1 -Brake Trouble Symptoms and Possible Causes

Leaks or Insufficient Fluid I

Improper Tirr Pressure

1mproperly Adjusted or Worn Whee' ikaring: ! X X

Distorted or Improperly Adjusted Br.,

Faulty Retracting Spring

Drum Out of Round X X X

Lining Glazed or Worn X X X X X X X

Oil or Grease on lining I X X X X X X

Loose Carrier Plate

Dirt on Drum-Lining Surface

Faulty Brake Cylinder X X X X

Dirty Brake Fluid X X X X

Air in Hydraulic System

Self Adjusters Not Operating

Insufficient Shoe-to-Carncr Plate Lur~ricatwn X X X

Tire Tread Worn X

Poor Lining to Drum Contact X

Loose Front Suspcnsi,,n X

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EJ COMMON ADJUSTMENTS AND REPAIRS ..

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EJ CLEANING AND INSPECTION

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PART BRAKE SYSTEM

D DESCRIPTION AND OPERATION

FIG •. 1-Lincoln Self-Adiusting Bralc:e Assemblies

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D HYDRAULIC FLUID PRESSURE