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XA-ZF REPAIR MANUAL

XA/ ZF SERIES.
WORKSHOP
MANUAL
FORD MOTOR COMPANY OF AUSTRALIA LIMITED
Registered Office: CAMPBELLFIELO, VICTORIA
Incorporated in Victoria

Copyright - Ford Motor Company of Australia Limited

Reproduction In whole or In part prohibited without written approval

Registered In Australia for transmission by post as a book

Printed by The Dominion Press-Hedges & Bell , Maryborough, Vic.

·~

FOREWORD

This manual provides Nlformation for the proper servicing of the

Ford Falcon-Fairlane. The descriptions and specifications con-

.
tained in this manual were in effect at the time the manual was

approved for printing. The Ford Motor Company of Australia

Limited reserves the right to discontinue models at any time or

change specifications or design, without notice and without in-

curring obligation.

FORD MOTOR COMPANY OF AUSTRALIA LIMITED

(INCORPORATED IN VICTORIAI
MILIOUINI, VICTOIIA
FALCON FAIRLANE w~:~~~~P

·· oROUP
1

PAGE

PART 1·1- · Vehicle Identification XA/ZF Series 1-2

PART 1·2- Accessories 1-4

PART
1-1 VEHICLE IDENTIFICATION

FORD FALCON - FAIRLANE

VEHICLE IDENTIFICATION (XA MODELS) (ZF MODELS)

~PREFIX BODY SER. NO. SIDO NO. MOPEL

I II
ENGINE
II II
TRANS. RR.AX. FT.AX. PAINT TRIM
I
01 II II . II II I
BRK. BSTR., s. v.o.r I
f:ORDf II I 1......_ ......
G. V~.W~.,;:===::;-,-:-L:-BS:-.____. SEA Tl NG CAP ·D
WAS. MANUFACTURED BY
FORD MOTOR COMPANY OF AUSTRALIA LTD.
TO COMPLY WITH AUSTRALIAN DESIGN RULES

NOS. I 4, SA, 7, 20

THIS PLATE IS AFFIXED WITH THE

APPROVAL OF THE
AUSTRALIAN MOTOR VEHICLE CERTIFICATION BOARD
Q- Q
Location: Left hand Upper Firewall Panel.
Engine
Interpretation:
Code Engine Displacement
Prefix: Manufacturers use only. E 200 CID Low Octane
Serial No.: Manufacturers use only. G 200 CID
J 250 CID Low Octane
Sido No.: Dealer Order No.
L 250 CID IV
Model: Digits 1 & 2 Product Line y 302 CID 2V (Disc Brakes Mandatory)
Digit 3 Model Year K 351 CID 2V (Disc Brakes Mandatory)
Digit 4 Body Style T 351 CID 4V (Disc Brakes Mandatory)
Digit 5 Series M 250 CID 2V (Disc Brakes Mandatory)
PART 1-1-VEHICLE IDENTIFICATION 1-3

TRANSMISSION TRIM
•.
Code Type Code Colour

J 3 Speed Column
A Blue
Shift 199333 Series

N 3 Speed Column B Black

Shift 199332& 199331 Series
(All Synchro) G Green
L 4 Speed Floor Shift Manual
RUG AF & RUG BF p Parchment

R 3 Speed Cruisomatic R Red

Column Shift

B T. Bar Cruisomatic
s Saddle

Y. Burgundy
.
u Dark Grey**

PAINT w White
One letter indicates single tone. Two letters .indicate
tu-tone, the first signifying the upper colour, and the
second, the lower colour. **Available on Fleet Orders Only.
Code Colour

A Medium Yellow
B Onyx Black
c Beige
D Yellow
z Wild Violet (Met)
G Turquoise
M Blue
I Jewel Green (Met)
N Burgundy
R Copper (Met)
u Ultra White
y Lime Green (Met)
3 Bright Red
4 Dark Green (Met)
7 Dark Brown (Met)
8 Dark Blue (Met)
J Bright Lime Green (Met)

. .•:
PART
1-2 ACCESSORIES

The following items are Ford Motor Company approved accessories for the XA Falcon and ZF Fairlane range of
vehicles. These accessories are available through all authorised Ford dealers.

Item Part No.

Insect Screen - XA XA 18690A
-ZF ZF 18690 A Item Part No.
Sun Visor - Exterior - Steel - Primed XA 18236 A
-Mesh XA 18236 B BODYSIDE PROTECTION MOULDING
- Black Vinyl XA 18236 C Kit - Bodyside Mouldings - XA Sed. XA 19600A
- Beige Vinyl XA 18236 D
Kit ~ Sun Visor Attaching Hardware XA 18235 A -ZF XA 19000B
Venetian Shades-Sedan-White XA 18246A -XA Ute/Van XA 196000
-Sedan-Black XA 18246 B - XAWag. XA 19600 E
Rear Quarter Window-Wagon XA 18247 A
Weather Shields-Tinted-R.H. (Vented Childs Safety Harness XW 5861204A
door) XA 18492 A Totguard - Child Safety Seat XW5861205A
-Clear-R.H. , XA 18492 B
-Tinted-L.H. '' XA 18493 A
-Tinted-R.H. (Ventless
door) XA 18492 C
-Clear-R.H. " XA 18492 D
-Tinted-L.H. " XA 18493 B
Kit - Windscreen Protector XA 19000A

RADIOS and ANTENNAS FLOOR MATS

Radio Kit - Deluxe Push Button Rubber - Black (High Pile) R6 - 11
(Less Aerial) XA 18805 A - Blue R6 -12
Radio Kit - Delu..x.e Manual (Less Aerial) XA 18805 B - Red . R6 - 13
- Grey R6 - 151
Radio Kit- "Super Fringe" Deluxe XA 18805 C - Sandy Brown R6 -1 52
- Push Button (Less Aerial) Rubber - Black Deluxe R6 - 155A
Radio Kit- "Super Fringe" Deluxe ZA 18805 D -Blue R6 - 155B
-Red R6 -155C
- Manual (Less Aerial) - Grey R6 -155D
Radio/Stereo -Basic Unit (Less Aerial) XA 19A035 A - Sandy Brown R6 -1 55E
- Components Kit
(Less Aerial) XA 18875 AS
Radio Aerial - Motorized XW 18813 B
- Lockdown XW 18813C
-Normal XW 18813A
-Rear Deck XR 18813.A
Radio Extension Speaker XA 18875 A
Kit - Radio Earthing - V/8 Only XW 18A805A
Radio Aerial-Base Gasket Kit-Falcon XA 18813AA
PART 1-2- ACCESSORIES 1-5

Item Part No. Item Part No.

TOW-BARS- Less Goose Neck

Sedan XA XA 19A009 A WHEEL DISCS and COVERS
ZF ZF 19A009A Deluxe- Except wj- Radial Ply Tyres XW 18303A
Station Wagon XA 19A009B w/- Radial Ply Tyres XW 18303B
Utility and Van XA 19A009C Full Wheel Cover - XA ARD2DA 1130BA
Goose Neck - Highlift Full Wheel Cover - ZF ARD20A 1130AA
Sedan XA 19B012A
Lock - Remote Control Deck Release
Station Wagon XA 19B012 B
-XA XA 5443200A
ZF ZF 19B012A
-ZF ZF 5443200 A
Goose Neck Painted Chromed
Foot Tyre Pump N 17052 A
Sedan XA 19B011 A XA 19C011 A
BUMPER GUARD KIT
Station Wagon XA 19B011 B XA 19C011 B Front - XA - Sed. & Wagon XA 18412 A
Utility and Van XA 19B011 C XA 19C011 C Rear - XA - Sed. Only XA 18412 B
ZF ZF 19B001 A
Kit - Rear Spring Helper
ZA 19C011 B
XW5A589A
Rear - ZF - Sed. Only
FENDER ORNAMENT KIT . ZF 18412 A
XA 16Al64A
BONNET ORNAMENT KIT XA 16607 A
MUD FLAP KIT
Vehicle Trailer Electrical Installation Kit XA 16268 A
- Front
XT 14A461 B - Rear XA 16360A
DOOR EDGE GUARD KIT
- Front & Rear XA 5420910 B
Vehicle Trailer Electrical Connection
- Front Only XA 5420910 A
Socket Assembly XR 14B461 A ROCKER PANEL MOULDING KIT
Vehicle Trailer Electrical Connection Plug - XA XA 18243 A
XR 14C461 A ROCKER PANEL& WHEEL ARCH. XA 18243 B
Moulding Kit
Flasher Unit - 3 lamp XR 13350A
ELECTRIC CLOCK XA 15000A
MIRRORS CIGAR LIGHTER KIT XA 15A044A
Door Mounted- L.H. XA.l8402A Kit - Highnote Hom XA 13801 C
XR18402B Kit - Electronic Car Alarm XY 19005 A
Caravan Mirror - Telescopic
liTTER BIN KIT XW 19D504A
Towing- Western Type XW 18402 E
CH 18402A ROOF RACK
Prismatic Day/Night Mirror
-Except Station Wagon XR 18320A
Vanity Mirror and Tissue Dispenser R6-131
-Station Wagon XR 18320B
Vanity Mirror- Glove Box Mounted XW 17A679A
LUGGAGE RACK- Chromed XW 18320C
LIGHTS SKI RACK EH 18320 A
Kit. - Head Lamp DUST REFLECTOR KIT
- Quartz Halogen XA 18207 A -Station Wagon XA 19008 A
ROPE RAIL KIT XA 19010 A
Kit - Head Lamp (Sev. Type) HP 18207 A
LICENCE PLATE FRAMES R6-135
- Quartz Halogen - Hi
Performance BATTERY CABLE lJOOSTER KIT
Headlamp Guards - Hinged, Chromed XR 13005 A -Medium Duty R6-146
-Heavy Duty R6-147
PETROL CAP
STEERING WHEEL - RALLY XA 3600KT
Chromed XA 9030 A
Kit - Hood Lock Pin XA 16700KT
Locking- G.T. XA 9030 C
Kit - Front Spoiler XA 17A779KT
Locking- Except G.T. XA 9030 B
Kit - Rear Spoiler R6-68A
Kit - Sports Road Wheel XY 1007KT
, Kit - Security Lock Nut XY 1A012KT
(Sports Road Wheel)

. .~ .
REFERENCE TO SERVICE INFORMATION AND NOTES

Date Letter No. Page Brief Detail

:
FALCON FAIRLANE w~:~~~~P

GROUP
2

PAGE

PART 2-1 General Broke Service 2-2

PART 2-2 . Brake System 2-9

PART 2-3 Specifications 2-25

2-2 GROUP 2~BRAKES

PART GENERAL BRAKE SERVICE

2-1
~
1 Diagnoiis and Testing .. .... ·•···~ ...... ...... ..... , ......
Preliminaey Tests ... ... .. .... ...... ... ... .. .. .. ...... ......
....
2-2
2-2
Secdoll
3. Cleaning and Inspection
...
.. .... ... ... .. .. ,. ~..... 2-4
Disc Brake Trouble Symptoms and Po11ible 2-6
Road Test ...... ...... ... ... ...... .. .... .... .. .. .. .. .. .... ...... 2-3 Causes .............................................. ..
2 Common Adjustments and Repairs ...... ...... ...... 2-3 Drum Brake Trouble Symptoms and Possible 2-7
Parking Brake Linkage Adjustment 2- 3 Causes ............................................... ..
Hydraulic System Bleeding ...... ...... ...... ... ... 2-3

II DIAGNOSIS AND TESTING

PRELIMINARY TESTS approximate inside diameter of the For cleaning and inspection refer
FLUID LEVEL brake drum. - to Page _2-4.
If all the brake adjusters, brake
Always check the fluid level in the drums and linings are functional and LOCKED BRAKES
brake master cylinder reservoirs be- the brake travel is not within specifi-
fore performing the test procedures. Should one of the brakes be locked
cations, check the pedal linkage for and the car must be moved, open the
If necessary, top up the master missing or worn bushings, or loose
cylinder reservoirs to the level indi- brake cylinder bleeder screw long
attachments. Bleed the brakes. enough to let out a few drops of
cated on the side of the reservoir,
using only the specified brake fluid, HYDRAULIC SYSTEM brake fluid. This bleeding opera-
Motorcraft Brake Fluid. don will release the brakes, but
If the car is equipped with power it will not correct the cause or
AUTOMATIC ADJUSTERS brakes, shut off the engine and ex- · the trouble.
haust all vacuum from the booster
Push the brake pedal down as far system before performing this tesL BRAKE WARNING LIGHT
as it will go while the car is standing. Depress the brake pedal and hold The three tests listed below are
If the car is equipped with power it in the applied position. If the pedal applicable to all models with either
brakes, the engine should be running gradually falls away under this pres- drum or disc brakes.
while making this test. If the brake sure, the hydraulic system is leaking.
pedal travels more than half-way Check all tubing, hoses, and con- 1. Tum the ignition switch to
between the released position and nections for leaks. the ON position. If the light on the
the floor, check the automatic adjus- If the brake pedal movement feels brake warning lamp illuminates, the
ters for being inoperative. To check spongy, bleed the hydraulic system condition may be caused by:
adjuster operation, make several to remove air from the lines and (a) a defective switch.
sharp reverse stops (equivalent to 50 cylinder. See Hydraulic System (b) grounded switch wires.
pounds pedal pressure) with a for- Bleeding, Page 2-3. Also, check for (c) the differential valve switch not
ward stop before each. Move the leaks or insufficient fluid. having been reset after having
vehicle forward for a distance of been activated. ·
approximately ten feet; then reverse - POWER BRAKE FUNCTIONAL TEST The differential valve switch is
for ten feet, apply the brakes sharply With the transmission in neutral, spring loaded. and does not have to be
and hold the brake pedal down until stop the engine and apply the park- reset, however it must be removed
the vehicle is completely stopped. This ing brake. Depress the service brake from the .master cylinder to allow the
will actuate the brake self-adjusters. pedal several times to exhaust all differential valve to centralise. The
If these stops do not bring the brake vacuum in the system. Then, depress valve is self-centering only when the
pedal travel within specification, the pedal and hold it in the applied switch is removed. When either sys-
make several additional forward and position. Start the engine. If the tem is being bled the switch must be
reverse stops as outlined above. vacuum system is operating the pedal removed to prevent damage to the
If the second series of stops do will tend to fall away under foot plunger. Except on G.T. vehicles
not bring the brake pedal travel pressure and less pressure will be when the valve must be centralised
within specifications, remove the required to hold the pedal in the by relieving pressure in the approp-
brake drums and check the brake applied position. If no action is felt, riate system after bleeding.
adjusters to make sure $ey are the vacuum booster system is not
functioning. Check the brake linings functioning. 2. Tum the ignition switch to the
for wear or damage. R,epair or replace START position. If the brake
all worn or damaged parts and non- Refer to Table .1, Page 2-6. warning lamp does not light, check
functioning adjusters. Adjust the For booster removal and instal- the bulb and wiring for defects and
brake lining outside diameter to the lation procedures refer to Page 2-20. repair or replace as necessary.
PART 2-1-GENERAL BRAKE SERVICE 2-3
3. If the brake warning lamp mph to check for the c:xistence of the listed in Table 2, Page 2-7 the trouble
does not light when a pressure trouble symptoms listed in Table 1 , may be caused by vacuum leakage.
differential condition exists in the Page 2-6 with the exception of those Disconnect the vacuum line at the
brake system, -the condition may be resolved in the preliminary tests and booster, remove the vacuum mani-
caused by: brake chatter. For each of the symp- fold and check valve assembly, and
(a) burnt out warning lamp. toms encountered, check and elimin- look for a sticking or faulty check
(b) inoperative warning lamp switch. ate the causes which are also listed in valve. Check all vacuum connections
(c) open circuit in switch to lamp Table 1. To check for brake chatter for leakage or obstruction. Check all
wiring. or surge apply the brakes lightly hoses for a leaking or collapsed con-
from approximately 50 mph. dition. Repair or replace parts as
ROAD TEST necessary.
If the preliminary tests show that If the trouble persists, replace the
The car should be road tested only the booster is inoperative or if a hard vacuum booster. The booster is not a
if the brakes will safely stop the car. pedal condition still exists after serviceable item and if found defec-
Apply the brakes at a speed of 25-30 eliminating the cause of Hard Pedal tive must be replaced.

B COMMON ADJUSTMENTS AND REPAIRS

The brake systems of all car models On all vehicles except the G.T. the
are designed to permit full stroke of warning light switch must be removed
the master cylinder when the brake from the master cylinder prior to
pedal is fully depressed. bleeding the system or after brake
No brake pedal clearance adjust- malfunction; if this is not done the
ment is required or provided for. switch may·be damaged.
With the brake master cylinder outlet
lineS disconnected and the brake MANUAL BLEEDING
pedal fully depress~ at approxi- FIG. 1 - Wrench for Bleeding
mately 50 lbs. force, the brake pedal The primary and secondary (front Brake Hydraulic System
assembly should not touch the dash and rear) hY.draulic brake systems are
panel if the brake system is correctly individual -systems and are bled 5. Repeat this procedure at the
installed. · separately. Bleed the longest line brake wheel cylinder on the opposite
first on the individual system being side. Refill the master cylinder reser-
PARKING BRAKE LINKAGE serviced. During the complete voir after each wheel cylinder is bled
ADJUSTMENT- bleeding - operation, DO NOT and install the master cylinder cover
ALL MODELS allow the reservoir to run dry. and gasket. Be sure the diaphragm
Check the parking brake cables Keep the master cylinder reservoirs type gasket is properly posi-
when the brakes are fully reltased. filled with Motorcraft brake -fluid. tioned in the master cylinder
If the cables are loose, adjust them Do not mix low tempera- cover. When the bleeding opera-
as follows: ture brake fluids with the ~ci­ tion is completed, the fluid level
1. Fully release the parking brake fied fluid during the bleeding should be filled to within i ln. of
handle. operations. Never re-use brake the top of the reservoirs.
2. Raise the car. fluid which has been drained 6. If the primary (front brake)
3. Turn the adjustment nut for- from the hydraulic system. system is to be bled, repeat steps 1-5
ward against the equalizer until a at the left front brake caliper or
moderate drag is felt when turning 1. To bleed the secondary (rear) cylinder and ending at the right front
rear wheels. brake system, position a suitable brake caliper or cylinder.
4. Slacken the adjustment until i in. ring spanner (Fig. 1) on the 7. On disc brake equipped models
the rear wheels are just free to rotate. bleeder fitting on the brake wheel be sure that the front brake pistons
cylinder. Attach a rubber drain tube are returned to their normal positions
HYDRAULIC SYSTEM BLEEDING and that the pad and lining assem-
to the bleeder fitting. The end of the
When any part of the hydraulic tube should fit snugly around the blies are properly seated by depress-
system has been disconnected for bleeder fitting. ing the brake pedal several times until
repair or replacement, air may get 2. Submerge the free end of the normal pedal travel is established.
into the lines and cause spongy pedal tube in a container partially filled 8~ Replace the warning light
action. Bleed the hydraulic system with clean brake fluid, and loosen the switch.
after it has been properly connected bleeder fitting approximately ! of a *G.T. only. Centralize the differential
to be sure that all air is expelled from turn. valve (Page 2-4).
the brake cylindel'$ or disc brake 3. Push the brake pedal down
PRESSURE BLEEDING
calipers and lines. slowly through its full travel. Close
The hydraulic system can be bled the bleeder fitting, then return the Bleed the longest lines first. The
manually or with pressure bleeding pedal to the full release position. bleeder tank should contain enough
equipment. · Repeat this operation until air new Brake Fluid to ·complete the
With disc brakes, more pumping . bubbles cease to appear at the sub- bleeding operation. Use Motorcraft
of the pedal is required and more merged end of the bleeder tube. Brake Fluid.
frequent checking of the master 4. When the fluid is completely Do not mix low temperature brake
cylinder may be necessary while free of air bubbles, close the bleeder fluid with the specified brake fluid
bleeding. fitting and remove the bleeder tube. during the bleeding operations. Never
2-4 GROUP 2-BRAKES
re-use brake fluid that has been with clean brake fluid, and loosen the *CENTRAUZING THE
drained from the hydraulic system. bleeder fitting. PRESSURE DIFFERENTIAL
The tank should be charged with 7. When air bubbles cease to VALVE. G.T. ONLY.
approximately 10 to 30 pounds of air appear in the fluid at the submerged
pressure. Never exceed 50 pounds end of the bleeder tube, close the
pressure. bleeder fitting and remove the tube. After a failure of the primary
1. Remove the warning light (front brake) orsecondary(rearbrake)
8. Repeat steps 3 to 7 at the right
switch from the master cylinder rear wheel cylinder. system has been repaired and bled,
prior to bleeding the system. If this 9. If the vehicle is equipped with the dual-brake warning light will
is not done the switch may be disc brakes, repeat steps 4 to 7, usually continue to be illuminated due
damaged. starting at the left front disc caliper to the pressure differential valve
2. Clean all dirt from the master and ending at the right front disc remaining in the off-center position.
cylinder reservoir cover. caliper. To centralize the pressure differen-
3. Remove the master cylinder tial valve and turn off the warning
reservoir cover and rubber gasket, 10. If the vehicle contains drum- light after a repair operation, a pres-
and fill the master cylinder reservoir type front brakes and the primary sure differential or unbalance condi-
with the specified brake fluid. Install (front) brake system is to be bled, tion must be created in the opposite
the pressure bleeder adapter tool to repeat steps 4 to 7 starting at the left brake system from the one that was
the master cylinder and attach the front wheel cylinder ending at the repaired or bled last.
bleeder tank hose to the fitting on right front wheel cylinder. 1. Turn the ignition switch to the
tHe adaptor. 11. When the bleeding operation ACC or ON position. Loosen the dif-
Master cylinder pressure bleeder is completed, close the bleeder tank ferential valve assembly brake tube
adaptor tools can be obtained from valve and remove the tank hose from nut at the outlet port on the opposite
the various manufacturers of pres- the adaptor fitting. side of the brake system that was
sure bleeding equipment. Follow the 12. On disc brake equipped ve- wheel balanced, repaired and/or bled
instructions of the manufacturer hicles, be sure that the front brake last. Depress the brake pedal slowly
when installing tlte adaptor. pistons are returned to their normal to build line pressure until the pres-
4. If the rear wheel cylinders, the positions and that the shoe and lining sure differential valve is moved to a
secondary brake system, are to be assemblies are properly seated by centralized position and the brake
bled, position a i inch ring spanner depressing the brake pedal several warning light goes out; then, immed-
(Fig. 1) on the bleeder fitting on the times until normal pedal travel is iately tighten the outlet port tube
left rear brake wheel cylinder. established. nut.
Attach a bleeder tube to the 13. Remove the Pressure Bleeder 2. Check the fluid level in the mas-
bleeder fitting. The end of the tube Adaptor Tool. Fill the master cylin- ter cylinder reservoirs and flU them to
should fit snugly around the bleeder der reservoirs to within i inch of the within 1/4 inch of the top with the
fitting. top. Install the master cylinder cover specified brake fluid, if necessary.
5. Open the valve on the bleeder and gasket. Be sure the diaphragm 3. Turn the ignition switch to the
tank to admit pressurized brake fluid type gasket is properly positioned in OFF position.
to the master cylinder reservoir. the master cylinder cover. 4. Before driving the vehicle, check
6. Submerge the free end of the 14. Replace the warning light the operation of the brakes and be
tube in a container partially filled switch in the tntiter cylinder. sure that a firm pedal is obtained.

EJ CLEANING AND INSPECTION

DISC BRAKES eliminate the wheel bearing end play ing dimension from the inboard
by tightening the adjusting nut. bearing cup to the inboard rotor face
1. Remove the wheel and tyre After tightening the nut, check to see
and the shoe and lining assemblies as and the minimum rotor thickness
that the rotor can still be rotated.
outlined on Page 2-22. I'ALCCJM.I'AIRLANE --~
2. On all models make thickness S. · Clamp a dial indicator to the
measurements with a micrometer caliper housing so that the stylus
across the thinnest section of the shoe contacts the rotor at a point approxi-
and lining. If the assembly has worn mately 1 inch from the outer edge.
to a thickness of 0.230 inch Girling Rotate the rotor and take an indicator
.190 P.B.R. (shoe and lining together) reading. If the reading exceeds 0. 003 .0.6 MAX
or 0.030 inch (lining material only) inch total lateral runout on the indi-
at any one of three measuring cator, replace or· resurface the disc
locations or if there is more than brake rotor. The following require-
0.125 taper from end to end or if ment must be met when resurfacing
lining shows evidence of brake fluid disc brake rotors.
contamination, replace all (4) shoe The finished braking surface of the
and lining assemblies on both front rotor must be flat and parallel within
wheels. 0. 007 inch; lateral runout must not
3. Check the caliper to spindle exceed 0. 003 inch total indicator
attaching bolts torque. Torque them reading, braking surfaces are to be
to specification, if required. 80/15 micro inches. FIG. 2 - Disc Brake Rotor
4. To check rotor runout, first On all models the minimum limit- Service Limits
PART 2.-1-GENERAL BRAKE SERVICE 2-5
dimension, must be observed when front end components, to avoid DRUM BRAKES
removing material from the rotor bending or damaging the rotor splash
braking surfaces. A disc and gauge shield on full right or left wheel 1. Remove the wheel from the
bar (R1102-A) is to be used when turns. drum, and remove the drum as out-
checking minimum dimensions (Fig. 8. Riding of the brake pedal lined on Page 2-15. Wash all
2). When the periphery of the disc (common on left foot applications)
the parts except the brake shoes in a
contacts the gauge bar the rotor must should be avoided during vehicle
operations. . cleaning fluid and dry with com-
be replaced.
pressed air.
When the runout check is finished 7. The wheel and tyre must be 2. Brush the dust from the carrier
be sure to adjust the bearings as out- removed separately from the brake plate and interior of the brake drum.
lined in group 3 in order to prevent rotor, unlike drum brakes where the 3. Inspect the brake shoes for
bearing failure. wheel, tyrc and drum are removed as excessive lining wear or shoe damage.
a unit. If the lining is worn to within
8. Check the rotor for scoring.
Minor scores can be removed with a
8. On Girling floating caliper type
disc brakes whenever the caliper is re-
n inch of the rivet heads or shoe for .
fine emery cloth. If the rotor is moved the caliper locating pins and bonded brakes or if the shoes are
~cessively scored, refinish it as out- damaged, they must be replaced.
insulators should be replaced.
lined in step 5 or replace the rotor, Replace the lining in axle sets. Prior
if required. 9. On floating caliper type disc to replacement of the lining, the
7. ViSually check the caliper. If brakes the caliper assembly must be drum diameter should be checked to
the caliper housing is leaking it removed from the spindle prior to determine if oversize linings must be
should be replaced. If a seal is leaking removal of the shoe and lining installed.
the caliper must be disassembled and assemblies. 4. Check the condition of the
new seals installed. If a piston is 10. On floating caliper type disc brake shoes, retracting springs, and
seized in the bore a new caliper brakes the calipers must not be drum for signs of overheating. If the
housing is required. shoes have a slight blue colouring, or
interchanged from one side to the
8. If upon disassembly the caliper other. When the caliper is installed if the springs show a change in free
is found to be distorted or damaged on its proper anchor plate and spindle length, indicating overheating, re-
or if the cylinder bores are scored or the bleeder screw will point to the placement of the retracting and hold
excessively worn replace the caliper rear of the vehicle (Fig. 3). If a down springs is necessary. Over-
assembly. heated springs lose their tension and
Check the brake hoses for signs of BLEEDER SCREW FACING THIS DIRECTION. could cause the new lining to wear
cracking, leaks or abrasion. Replace prematurely if they are not replaced.
· them if necessary. 5. If the car has 30,000 or more
miles of operation on the brake
DISC BRAKE SERVICE linings or signs of overheating are
PRECAUTIONS present when relining brakes, the
wheel cylinders should be dis-
assembled and inspected for wear
1. Grease ·or any other foreign and dirt in the cylinder. The cylinder
material must be kept off the caliper cups and other parts contained in the
assembly, surfaces of the rotor and
overhaul kit should be replaced, thus
external surfaces of the hub during
avoiding future problems.
service operations. Handling of the
8. Inspect all other brake parts
rotor and caliper assemblies should and replace any that are worn or
be done in a way to avoid deforma- damaged.
tion of the brake rotor and nicking or 7. Inspect the brake drums and
scratching of brake linings. if necessary, refmish. Refer to Page
2. If a caliper piston is removed H 1~1-A 2·21 for refinishing.
for any reason, the piston seal must
be replaced. FIG. 3- Floating Caliper
3. During removal and installa- Installed (Girling)
tion of a wheel assembly, exercise BRAKE BOOSTER
care not to interfere with and damage caliper is installed on the wrong side
the caliper splash shield or the bleed- of the vehicle, it is not possible to Check the booster operation as
er screw fitting. bleed the system properly. noted on Page 2,2. Power Brake
4. Front wheel bearing end play 11. Do not attempt to clean or Functional Test. If the brake booster
is critical and must be within speci- restore oil or grease soaked brake is damaged or defective, replace it
fications. linings. When contaminated linings with a new booster. The brake
5. Be sure the vehicle is centred are found, brake linings must be booster is serviced only as an
on the hoist before servicing any replaced in complete axle sets. assembly.
2-6 GROUP 2-BRAKES
TAILE 1
DISC BRAKE TROUBLE SYMPTOMS AND POSSIBLE CAUSES

TROUBLE SYMPTOMS POSSIBLE CAUSES CORRECTION

J

EXCESSIVE PEDAL TRAVEL Pad knock-back from extremely Check for worn or damaged insu-
rough road operation or violent lators or damaged stabilizers and
cornering. replace as necessary.
Incorrectly adjusted rear brakes. Check automatic adjusters.
Air in system, fluid leak, or low Bleed system, correct leak and fill
fluid level. hydraulic system. -
Excessive wheel bearing end play. Adjust wheel bearings to speci-
Damaged and leaking caliper pis- fications.
ton seal. Replace piston seal, fill and bleed
Incorrectly ground rear brake hydraulic system.
lining. Grind or replace rear brake shoe
Brake shoe not to flat surface and lining assemblies.
specification limit. Replace brake shoe and lining
assembly.
Booster linlt not connected to Connect booster link to brake
brake pedal. pedal.
Brake booster not connected to Secure brake booster to firewall.
firewall. Overhaul or replace master cyl-
Detective master cylinder seals. inder.

EXCESSIVE BRAKE PEDAL EFFORT Brake booster malfunction. Replace \>rake booster assembly.
Brake booster check valve leaking. Replace check valve.
Vacuum failure. Check hose and connections.
Brake fluid, oil or grease on brake Replace brake linings. Clean rotor
linings. with alcohol.
Stuck or seized pistons in both Free up pistons and replace piston
calipers. seals.

BRAKE ROUGHNESS OR Brake rotor excessive lateral run- Replace brake rotor.
CHAnER (PULSATING PEDAL) out or thickness variation.
Rear brake drum ovality excessive. Refinish or replace rear brake
drum.

BRAKES PULL, GRAB, OR Unequal front tyre pressures. Equalize tyre pressures.
UNEVEN BRAKING Incorrect front end alignment. Align front end and check toe-in.
Brake fluid, oil or grease on brake Replace brake linings. Clean rotor
linings. with alcohol.
Caliper not properly aligned on Align and tighten anchor plate
rotor. bolts in correct sequence to specified
torque.
Stuck or seized piston one caliper. Free up or replace piston and
piston seal.

BRAKE RAnLE OR CLICK Broken or missing shoe hold-down Replace broken or missing parts.
spring or clip.
Worn or cut insulators or broken Replace broken or damaged parts.
stabilizers.

GRINDING OR GRATING NOISE Worn out lining. Replace lining.

Damaged insulator or stabilizer. Replace damaged part.
Damaged wheel bearings. Replace with new bearings.
PART 2-1-GENERAL BRAKE SERVICE 2-7

TABLE 1-(Continued)
DISC BRAKE TROUBLE SYMPTOMS AND POSSIBLE CAUSES
TROUBLE SYMPTOMS POSSIBLE CAUSES CORRECTION
HEAVY BRAKE DRAG Stuck or seized piston. Free up or replace piston and
piston seal.
Incomplete brake pedal return. · Binding linkage-free up.
Improperly. assembled caliper as- Loosen caliper slide pins and re·
sembly. torque with brake pedal -applied -
Girling only.
Brake booster malfunction. Replace booster.

CALIPER BRAKE FLUID LEAK Loose front brake hose through Replace missing copper gasket or
bolt or copper gasket omitted. tighten through bolt to specification.
Loose bleeder screw. Tighten bleeder screw to specified
torque.
Caliper housing porosity. Replace caliper housing.
Cut or rolled piston seal. Replace piston seal.
Foreign substance in caliper piston Clean piston seal groove and re-
seal groove. place seal.
Piston scored or damaged. Replace piston and seal.
.
TABLE 2
DRUM BRAKE TROUBLE SYMPTOMS AND POSSIBLE CAUSES
TROUBLE SYMPTOMS POSSIBLE CAUSES

ONE BRAKE DRAGS Brake line restricted. Drum out of round.

Faulty retracting spring. Faulty brake cylinder.
Loose carrier plate. Dirty brake fluid.
Air in hydraulic system. Insufficient shoe-to-carrier plate
Distorted or improperly adjusted lubrication.
brake shoe.

ALL BRAKES. DRAG .Mechanical resistance at pedal or Brake line restricted .

shoe. Distorted or improperly adjusted
Dirty brake fluid. brake shoe.
Faulty master cylinder.

HARD PEDAL Mechanical resistance at pedal or Brake line restricted.

~
shoes. Distorted or improperly adjusted
Lining glazed or worn. brake shoe.

SPONGY PEDAL Leaks or insufficient fluid. Air in hydraulic system.

CAR PULLS TO ONE SIDE Brake line restricted. Improper tyre pressure.
Distorted or improperly adjusted Faulty retracting spring.
brake shoe. Drum out of round.
Lining glazed or worn. Oil or grease on lining.
Faulty brake cylinder. Self adjusters not operating.

ONE WHEEL LOCKS Distorted or improperly adjusted Oil or grease on lining.

brake shoe. Faulty brake cylinder.
Loose carrier plate. Tyre tread worn.
Lining glazed or worn.

BRAKES CHATTER Drum out of round. Loose carrier plate.

Oil or grease on lining. Loose lining.
Poor lining to drum contact. Loose front suspension.
Lining glazed or worn.
2-8 GROUP 2-BRAKES

TABLE 2 -(Continued)
DRUM BRAKE TROUBLE SYMPTOMS AND POSSIBLE CAUSES
TROUBLE SYMPTOMS POSSIBLE CAUSES

EXCESSIVE PEDAL TRAVEL Leaks or insufficient fluid. Distorted or improperly adjusted

Lining glazed or worn. brake shoe.
m
Air hydraulic system. Faulty master cylinder.
Cracked drum. Self adjusters not operating.

PEDAL GRADUALLY GOES Leaks or insufficient fluid. Faulty master cylinder.

TO FLOOR

BRAKES UNEVEN Improper tyre pressure. Oil or grease on lining.

Dirty brake fluid.

SHOE CLICK AFTER RELEASE Insufficient shoe-to-carrier plate Threads left by drum turiling tool
lubrication. pulls shoe sideways.

NOISY OR GRABBING BRAKES Distorted or improperly adjusted Lining glazed or worn.

brake shoe. Oil or grease on lining.
Dirt on drum-lining surface. Faulty brake cylinder.
Insufficient shoe-to-carrier plate
lubrication.

BRAKES DO NOT APPLY Leaks or insufficient fluid. Lining glazed or worn.

Dirty brake fluid. Oil or grease on lining. ·
Faulty master cylinder. Air in hydraulic system.

BRAKES FOR THE RESPECTIVE One section dual brake system is

SYSTEM DO NOT APPLY
inoperative.

WARNING LIGHT STAYS LIT . One s.ection dual brake system is Differential pressure valve not
moperattve. centred.
Warning lamp switch is grounded. Wiring to warning lamp switch is
grounded.

PEDAL GRADUALLY MOVES Leaks or insufficient fluid. Faulty master cylinder.

TOWARD FLOOR OR DASH
PANEL

WARNING LAMP DOES NOT Warning lamp is burned out. Warning lamp switch has an open
LIGHT Wiring to warning lamp has open circuit.
circuit.
2·9

PART BRAKE SYSTEM

2·2
Section Page Section Page
1 Description and Operation ...... ...... ...... . .... ...... 2-9 3 Removal and Installation 2-15
2 In-Car Adjustments and Repairs ...... ....... .. . .... 2-14 4 Major Repair Operations .......... . 2-21

a DESCRIPTION AND OPERATION

Disc brakes are available as op-
master cylinder, the dual line &afety
feature will be destroyed. as both
NORIII .".L POSITION systems will be pressurised via a
tional equipment for the front wheels CENTEREO
on Falcon models but are standard on common chamber.
Fairmont, Falcon GT, Fairlane 500 The pressure control
Fairlane Custom and all 8 cylinder (proportioning) valve (Fig. 4) is
and 250 2V 6 cylinder vehicles. The locat~d in the rear system only. It
dual master cylinder equipped hy- provides balanced braking action
draulic brake system employs single between the front (disc) and rear
anchor, internal expanding and self- {drum) brakes. The proportioning
adjusting drum brake assemblies on valve reduces pressure at the rear
the rear wheels of vehicles with disc brakes, since equivalent amounts of
brakes, and on the front and rear hydraulic pressure would cause more
wheels of all others.
A vacuum booster is used with the braking by the self energiSing rear
power disc brake system. brakes than the non energising front
disc brakes.
DUAL ·MASTER CYLINDER BRAKE
DISC BRAKE
SYSTEM
The disc brake .consists of a venti-
The dual master cylinder brake FIG. 4 -Pressure Differentiafand Pressure lated rotor and caliper assembly. The
system has been incorporated in all Control Valve and Brake Warning Light caliper used on all models is a single
models to provide incrersed safety. Switch - G T Only.
piston floating caliper (Fig. 7), and
The system consists of a dual master may be of PBR or Girling design.
cylinder which incorporates a pres-
sure differential valve assembly and FLOATING CALIPER GIRLING
a switch (Fig. 6). The switch on The caliper assembly is secured to
the differential valve activates a dual- the spindle with two safety wired
brake warning light, located on the attaching bolts. The upper attaching
instrument panel. bolt is parallel with the centreline of
On both disc and drum brake the vehicle, and the lower bolt is
systems two front brake tubes are transverse to the car centreline.
fitted to the two primary brake outlet (Fig. 3/8).
ports (rear) on the master cylinder. The upper ends of the flexible steel
The single tube to the rear brakes is FIG.5 stabilizer are attached to the caliper
fitted to the secondary outlet port housing ears with two caliper locating
(front). B.A.I. pins.
GTONLY.
A combination pressure
differential valve warning lamp,
switch and pressure control valve
assembly (proportioning valve) is
fitted on the suspension tower
immediately below the master
cylinder (Fig. 4).
The original differential pressure
valve, which is integral with the
master cylinder is retained to ensure
the integrity of the dual system;
however, the warning lamp switch is
deleted from the master cylinder and
a sealing plug fitted in its place.
Should the original pressure FIG. 6
differential valve be left out of the Differential Valve P.B.R.- Typical.
2-10 GROUP 2-BRAKES
vertical inner surfaces of these FLOATING CALIPER P.B.R.
anchor plate ledges.
A single hydraulic piston is fitted The single piston hydraulic disc
into a bore in the inner portion of the brake caliper is constructed from a
caliper housing. (Fig. 12). A square single casting which contains one large
section seal is fitted into an annular piston bore in the inboard section
groove in the caliper bore (refer Figs. of the casting. (Inboard refers to the
12·13} and a rubber boot is utilized to side of the casting which is nearest the
.... " seal the piston and caliper bore centreline of the car when the caliper
against road splash contamination. A is mounted}.
feed port is provided in the caliper
housing below the piston. A bleed The fluid inlet hole and bleeder
screw is located in the caliper housing valve hole' are machined into the in-
over the piston to bleed air from the board section of the caliper and con-
hydraulic system. It is not necessary nect directly to the piston bore. The
to remove the front wheels to bleed cylinder contains a piston and seal.
the brakes.
The outer brake shoe and lining The seal has a square section, and
assembly is longer than the inner is located in a groove which is
FIG. 7- Disc Brake Assembly- machined in the cylinder bore. It
Floating Caliper- Girling assembly, and the shoe and lining
assemblies are not interchangeable fits around the outside diameter of
Shown. (Fig. 14}. the piston to pr_ovide a hydraulic seal
The lower ends of the stabilizer between the piston and the cylinder
are bolted directly to the lower in- Two lanced abutments on the wall.
board surface of the anchor plate. outer brake shoe fit into the slots on
This permits transverse movement of the outboard legs of the caliper The top of the piston is machined
the caliper assembly (Fig. 8). . housing. The outer brake shoe and to accept a sealing dust boot. The
The caliper housing is a single lining assembly is also held in a fixed outside diameter of the boot is pressed
piece casting positioned between two position by brake shoe hold-down into a recess in the top of the cy·
ears on the top of the anchor plate. pins which extend through the brake Iinder bore. The inside diameter of
The inner brake shoe rests on the top shoe and caliper housing. The pins the boot fits into the groove which
of two anchor plate ledges located at are secured.at the outer surface of the is machined in the piston. The piston
each end of the anchor plate. Two caliper housing with two spring clips. is steel, precision ground and chrome
spring clips are used to maintain the plated giving it a very hard and dura·
shoe in position. Brake shoe endwise A splash shield is bolted to the ble surface. The use of abrasives or
movement is restricted by the ends spindle to protect the brake rotor any attempt to re-machine the piston
of the brake shoe contacting the against road splash contamination. will destroy the plating.

..__ _ I'USH - · TWISn OUTIOAIID tO P11Y1NT

lnBPRINCI WITH IIIAICI H0S1

-
Of ·STHIIING
MUST II CLEAR
STOP ON
-DU AIIM

I VIEW A, .

FIG. 8- Caliper Mounting Bolts

PART 2-2-BRAKE SYSTEM 2-11

P.B.R. FLOATING HEAD CALIPER -FIG. 9

'---.J/0 (l) I
liD

ENSURE THAT SEAL RETAINER IS IN CORRECT POSITION WITH

SERRATED SIDE OF RETAINER FITTED INSIDE OF SEAL.

ROTOR and lining surfaces. The wheel pro-

Shoe wear is automatically com· The cast iron disc is of the venti- vides protection for the outboard
pensated for by the sliding caliper lated rotor-type incorporating forty surface of the rotor.
feature. The caliper floats through fins and is attached to, and rotates DRUM BRAKE
two guide pins located inside the with the wheel hub. A splash shield
anchor bracket sleeves. bolted to the spindle is used pri- The drum brake system employs
marily to prevent road contaminants single anchor, internal expanding and
Each caliper contains two shoe and from contacting the inboard rotor self adjusting brake assemblies.
pad assemblies. They are constructed
of a stamped metal shoe with the
lining integrally moulded to the shoe.
Shoe and pad _assemblies can be re-
moved and replaced only by remov-
ing the caliper assembly from its
mounting on the vehicle. The shoes
are not interchangeable.

c::AUPER OPERATION
When the brake pedal is applied,
brake fluid is displaced into the
cylinder moving the piston outward.
This action forces the inner shoe and
iining assembly against the rotor.
The resultant reaction forces the
caliper housing and outboard shoe
and lining assembly inward against
the rotor. Braking torque is tran!l-
ferred from the outer brake shoe
abutments through the caliper hous-
ing into the anchor plate. Braking
torque from the inner brake shoe is
taken ~y into the anchor plate.·
When the brake pedal is released,
the seal retracts the piston into the
cylinder and the caliper housing P.B.R. CALIPER ASSEMBLED- FIG. 10.
slides outward releasing the brake.
2-12 GROUP 2-BRAKES

CALIPER A~'Y . . , -
28 118 R.H.
28119 L.H. &...._
INSULATOR ,~ SEAL
CLIP 28~29928115
~ · 2207
2BI64 -~:~- ~ BOOT

~.....,-0
ANCHOR PLATE . • , . SHOE
2B293 L.H. ""' 2019
2B292 R.H. .

_..
3105-R.H. 28160
3106·L.H.

ROTOR SPLASH SHIEL

2Koo.I·R.H.
2K005·L.H. ROTOR
1202

1102..1....---'

FIG. 11- Disc Brake- Disassembled- Girling illustrated.

The self adjusting brake mechan-
ism consists of a cable, cable guide,
adjusting lever, adjusting screw as-
sembly and adjuster spring (Fig. 1S).
The cable is hooked over the anchor
pin at the top and is connected to the
lever at the bottom. The cable is
routed along the web of. the secon-
dary brake shoe by means of the
cable guide.
The adjuster spring is hooked to
the primary brake shoe and to the
lever. The automatic adjuster oper-
ates only when the brakes are applied
while the vehicle is moving rearward
and only when the secondary shoe is
free to move toward the drum
beyond a predetermined point.
FIG. 12- Floating Caliper Assembly- With the car moving rearward ~d
the brakes applied, the wrap-around
Sectional View action of i:he shoes following the
PISTON SEAL drum forces the upper end of the
PISTON SEAL RELAXED
DISTORTED PISTON primary shoe against the anchor pin.
The action of the wheel cylinder
moves the upper end of the secon-
dary shoe away from the anchor pin.
The movement of the secondary shoe
causes the cable to pull the adjusting
lever upward and against the end of a
tooth on the adjusting screw star-
wheel. The upward travel of the lever
increases as lining wear increases.
When the lever can move upward far
eno1;gh it passes over the end of the
tooth and engages the tooth. When
CALIPER HOUSING the brakes are released, the adjusting
BRAKES APPLIED BRAKES RELEASED spring pulls the lever downward
causing the star-wheel to turn and
FIG. 13- Function of Piston Seal expand the shoes. The star-wheel is
PART 2-2-BRAKE SYSTEM 2-13

OUTER SHOE turned one tooth at a time as the BRAKE BOOSTER SYSTEM
INNER BRAKE RETAINING CLIPS
SHOE ANO LINING 2066
linings progressively wear. This dual diaphragm-type brake
ASSEMBLY -2019
booster is a self-contained vacuum-
OUTER BRAKE With the car moving forward and
SHOE AND LINING hydraulic braking unit mounted on
ASSEMBLY-2018 the brakes applied, the secondary the engine . side of the dash panel.
shoe is against the anchor pin and the
• primary sltoe is moved toward the
drum. Therefore, the adjuster does
The brake booster is of the
vacuum suspended type which uti·
lizes engine intake manifold vacuum
not operate. and atmospheric pressure for its
power.
The rear brake assembly is basi· The booster unit is to be exchanged
cally the same as the front brake. when it is inspected, checked and
The conventional parking brake found to be defective.
lever, link and spring are used in OPERATION - BOOSTER
the rear brake.
\.1
The Booster Servo Unit is designed
FIG. 14- ShOe and Lining The anchor pin on all brakes are to assist the effort applied by the
Assemblies- Girling Caliper. fixed and are non·adjustable. driver's foot on the brake pedal. It

All Models
Except Taxi

SECONDARY SHOE

PARKING BRAKE CABlE AND

fRONT IRAKE REAR IRAKE

BRAKE YliNOER

Taxi

PRIMA Y BRAKE
SHOE AND LINING
lEAR IRAIII -fRONT Of C A l - fRONT IRAIIE

FIG. 15- Self Adjusting Brake

2-14 GROUP 2-BRAKES

FIG. 16- Brake Booster.

uses the vacuum created in the effort is obtained by admitting manner, but more effort will be
engine inlet manifold to boost force atmospheric pressure to one side of required on the brake pedal.
applied at the master cylinder push both diaphragms which are suspended
rod in an exact and controlled in a vacuum. The difference in pres- PARKING BRAKE
manner. sure moves the diaphragms and this An independent hand operated
The assembly is mounted between movement is used in a controlled parking brake control actuates the
the brake pedal and the master manner to augment the driver's pedal rear wheel brake shoes through a
cylinder, with the push rod from the effort. cable linkage, the operating cable is
rear of the unit connected to the In the case of a vacuum failure, the routed from the parking brake con-
brake pedal, and a push rod from the valve and rod assembly of the servo trol assembly to the equalizer. The
front of the unit abuts the master and the master cylinder push rod act rear brake cables connect the equali-
cylinder piston. as a single push rod.·The brakes will, . zer assembly to the parking brake
The force which assists the pedal therefore, work in the conventional lever at each rear secondary shoe.

EJ IN-CAR ADJUSTMENTS AND REPAIRS

BRAKE SHOE ADJUSTMENTS and expanded, the shoes may drag cover from the backing plate. Work-
- EXCEPT TA:XI when the . drums are cool and con- ing from the backing plate side, turn
tracted. the adjusting screw upward to expand
The car should be in a raised pos- 1. After the shoes have been in- the shoes (Fig. 17). Expand the shoes
ition with the wheels off the floor. stalled or the adjusting screw has until a drag is felt when the drum is
The hydraulic service brakes are been turned, install the drum. Be rotated.
self-adjusting and require a manual sure that all excess grease, oil, and 3. Remove the drum. Mark the-
adjustment only after the brake other foreign material are wiped off tooth on the star-wheel where the
shoes have been relined, replaced, or the backing plate and drum. adjusting lever contacts it. While
when the length of the adjusting Before installing the brake drum holding the adjusting lever out of en-
screw has been changed while perfor- on the front wheel spindle, wipe the gagement with the adjusting screw,
ming some other service operation. spindle completely free of grease. back off the adjusting screw i of a
The brake drums should be at Install the drum carefully so that the turn with the fingers. If finger move-
normal room temperature when ad- grease seal retainers within the hub ment will not tum the screw, free it
justing the brake shoes. If the shoes will not be damaged. up; otherwise, the self-adjusting lever
are adjusted when the drums are hot 2. Remove the adjusting hole will not turn the screw. Lubricate the
PART 2-2-BRAKE SYSTEM 2-15
BRAKE SHOE ADJUSTMENT brake system hose or line re-
-TAXI placement. (See Page 2-3).
The brakes should be adjusted BRAKE TUBE REPLACEMENT
. when the drums are at normal room
temperature. If the shoes are adjusted If a section of the brake tubing be-
when the drums are hot, dragging comes damaged, the entire section
brakes may result when the drums should be replaced with tubing of the
cool. same type, size, shape and length .
1. Raise the car until the wheels Copper tubing should not be used in a
clear the floor. If the car is on a hydraulic system. When bending
frame contact hoist, disconnect the brake tubing to fit underbody or rear
parking brake cables to prevent their axle contours, be careful not to kink
tightening when the rear axle and or crack the tube.
springs sag. All brake tubing should be double
FIG. 17- Expanding 2. Remove the adjusting hole flared properly to provide good leak-
cover from the bottom of the brake proof connections. Clean the brake
Brake Shoes carrier plate, and turn the adjusting tubing by flushing with clean brake
screw with a thin uniform coating of screw ,,..ig. 17} until a' slight drag on fluid before installation .
Moly grease. the wheel is noted. When connecting a tube to a hose,
3. Back off the adjustment just t~be connector, or brake cylinder,
Any other adjustment proce-
dure may cause damage to the enough to allow the wheel to rotate t1ghten the tube fitting nut to specified
adjusting screw with consequent freely. If it fails to rotate freely, the torque with Milbar tool 1112-144 or
self-adjuster problems. wheel and drum should be removed equivalent.
and the dust blown off the brake
4. Apply a small quantity of high- shoes and carrier plate. Apply a light BRAKE HOSE REPLACEMENT
temperature grease to the points coating of Lubricant to the brake
shoe-to-plate contact points. Install A flexible brake hose should be re-
where the shoes contact the backing
the wheel and drum, and adjust the placed if it shows signs of softening,
plate, being careful not to get the
brake again. Install the adjusting cracking, or other damage.
lubricant on the linings. Install the
hole cover. When installing a new front brake
drum.
4. Adjust the remaining brakes. hose, position the hose to avoid con-
On front wheels, install the wheel
5. If necessary, connect and ad- tact with other chassis parts. Place a
outer bearing, washer, and adjusting
just the parking brake cables (see new copper gasket over the hose fit-
nut, then adjust the wheel bearings
as outlined in Group 3. Page 2-3). ting and thread the hose" assembly into
6. When all brake shoes have the front wheel cylinder. Engage the
5. Install the wheel on the drum opposite end of the hose to the brack-
and tighten the mounting nuts to been adjusted, check the operation
of the brakes. et on the frame . Install the horsesho-
specification. · ·e-type retaining clip, and connect the
6. Install the adjusting hole cover tube to the hose with the tube fitting
on the brake backing plate. HYDRAULIC LINE REPAIR nut .
7. When adjusting the rear brake A rear brake hose should be in-
shoes, check the parking brake cables Steel tubing ' is used throughout stalled so that it does not touch the
for proper adjustment. Make sure the brake system with the exception muffler outlet pipe or shock absorber.
that the equalizer lever operates of the flexible hoses at the front Thread the hose into the rear brake
freely. wheels and at the rear axle housing tube connector. Engage the front end
brake tube connection. of the hose to the bracket on the
8. After the brake shoes have Always bleed the applicable frame. Install the horseshoe-type re-
been properly adjusted, check the primary or secondary brake sys- taining clip, and connect the tube to
operation of the brakes. tem after primary or secondary the h9se with the tu~ fitting nut.

EJ REMOVAL AND INSTALLATION

FRONT BRAKE DRUM
4. If the drum will not come off, INSTALLATION
REMOVAL pry the rubber cover from the brake
I. Raise the vehicle until the wheel backing plate. Insert a narrow screw- I. If the drum is being replaced, re-
and tire clear the floor. Remove the driver through the slot and disengage · move the protective coating from the
wheel cover or hub cap, and remove the adjusting lever from the adjusting new drum with carburetor degreaser.
the wheel and tire frotn the drum. screw. While holding the adjusting Then, use sandpaper to insure that no
l. Remove the grease cap from the lever away from the scrt:w, back off residue remains. Wipe the drum with
hub. Remove the cotter pin, nut lock, the adjusting screw wj.th the brake ad- a cloth soaked with denatured alcohol.
adjusting nut, and flat washer from justing tool (Fig. 18}. Be very careful Install new bearings and grease seal.
the spindle. Remove the outer bearing not to burr, chip, or damage the Pack the wheel bearings, install the
cone and roller assembly. notches in the adjusting screw; other- inner bearing cone and roller assembly
3. Pull the drum off the wheel wise the self-adjusting mechanism will in the inner cup, and install the new
spindle. not function properly. grease seal. (see Group 3).
2-16 GROUP 2-BRAKES
2. Adjust the brakes and install the 3. Remove the shoe hold-down
drum assembly as outlined under springs, shoes, adjusting screw, pivot
Brake Shoe Adjustments on Page 2-14. nut, socket and automatic adjustment
parts.
3. Install the outer wheel bearing, 4. On rear brakes, remove the
washer and adjusting nut. parking brake link and spring. Dis-
connect the parking brake. cable from
4. A<!just the wheel be-.uing as out- the parking brake lever.
lined Group 3, then install the 5. After removing the rear brdke
grease cap. Install the wheel and hub secondary shoe, disassemble the park·
cap. ing brake lever from the shoe by re-
moving the retaining clip and spring
w11sher. FIG. 20 - Retracting Spring
Installation- Typical
REAR BRAKE DRUM INSTALLATION
REMOVAL l. Before installing the rear brake ADJUSnNG LEVER
l. Raise the vehicle so that the tire shoes, assemble the parking brake
is clear of the floor . lever to the secondary shoe and secure
l. Remove the hub cap and wheel. with the spring washer and retaining
Remove the drum from the axle · clip.
flange. If the dtum will not come off, l. Apply a light coating of high-
pry the rubber cover from the backing temperature grease at the points
plate. Insert a narrow screwdriver where the brake shoes contact the
through the hole in the backing plate, backing plate.
and disengage the adjusting lever from 3. Position the brake shoes on the
the adjusting screw. While holding the backing plate and secure the assembly
adjusting lever away from the ad- with the hold down springs. On the FIG. 21- Adjusting Screw
justing screw, back off the adjusting rear brake, install the parking brake
link and spring, back off the parking
and Lever Identification
screw with the brake adjusting tool
(Fig. 18). Be very careful not to burr, brake adjustment then connect the
chip, or damage the notches in the parking brake cable to the parking
adjusting screw; otherwise, the self- brake lever .
adjusting mechanism will not 4. Place the cable eye over the an-
function properly. chor pin with the crimped side toward
the backing plate.
INSTALLATION 5. Install the primary · shoe to an-
1. Remove the protective coating chor spring
from a new drum with carburetor de- 6. Install the cable guide on the
greaser; then sand lightly and wipe secondary shoe web with the flanged
with a cloth soaked with denatured al- hole fitted into the hole in the second-
cohol. ary shoe web. Thread the cable
l. Adjust the brakes as outlined around the cable guide groove (Fig.
under Brake Shoe Adjustments on IS). ·
Page 2-14. Place the drum over the It is imperative that the cable be
brake assembly and into position. p'ositioned in this groove and not be-
tween the guide and the shoe web.
3. Install the wheel on the axle 7. Install the secondary shoe to· an-
shaft flange studs against the drum, H1590·A chor spring with the tool shown in
and tighten the attaching nuts to Fig. 20.
specifications. FIG. 18 - .Backing Off Brake
Be certain that the cable eye is not
Adjustment cocked or binding on the anchor pin
BRAKE SHOES AND when installed. All parts should be flat
ADJUSTING SCREW - on the anchor pin. Remove the brake
DRUM BRAKES cylinder clamp.
8. Apply high-temperature grease
REMOVAL to the threads and the socket end of
the adjusting screw .
1. With the wheel and drum re-
Turn the adjusting screw into the ad-
moved install a clamp over the ends of
justing pivot nut to the limit of the
the brake cylinder as shown jn Fig.
threads and then back off 1/2 turn.
19.
l. Remove the secondary shoe to Interchanging the brake shoe ad-
anchor spring with the tool shown in justing screw assemblies from one side
Fig. 19. With the same tool remove of the ,·ehicle to the other would cause
the primary shoe to anchor spring and the brake shoes to retract rather than
unhook the cable eye from the anchor FIG. 19- Retracting Spring expand each time the automatic ad-
oin. Removal- Typical justing mechanism operated. To pre-
PART 2-2-BRAKE SYSTEM 2-17
vent installation on the wrong side of be replaced. metal tube and make installation
the vehicle, the socket end of the ad- b. The cable length should mea- difficult. The tube will separate
justing screw is stamped with an R or sure 9! inches from the end of the from the cylinder when the cylinder
L. (Fig. 21 ). The adjusting pivot nuts cable anchor to the end of the cable is removed from the backing plate.
can be distinguished by the number of hook. · 4. Remove the wheel cylinder
grooves machined around the body of c. Check the cable guide for dam- attaching bolts and lock washers and
the nut. Two grooves on the nut indi- age. The cable groove should be paral- remove the cylinder.
cate a .right thread: one groove indi- lel to the shoe web, and the body of INSTALLATION
. cates a left thread. the guide should' lie flat against the Wipe the end(s) of the hydraulic
9. Place the adjusting socket on web. Replace the guide if it shows line to remove any foreign matter be-
the screw and install this assembly be- damage. fore making connections.
tween the shoe ends with the adjusting d. Check the pivot hook on the 1. To install a front wheel cyl-
screw toothed wheel nearest the sec- lever. The hook surfaces should be inder, position the cylinder to the
·ondary shoe. square with the body of the lever for backing plate. Install the two lock
10. Hook the cable hook into the proper pivoting. Replace the lever if washers and attaching bolts. Torque
hole in the adjusting lever. The adjust- the hook shows damage. them to specifications.
ing levers are stamped with an R or L e. See that the adjusting screw 2. Install a new copper gasket
to indicate their installation on right socket is properly seated in the notch over the hose fitting. Thread the hose
or left brake as!\Cmbly (Fig. 21). in the shoe web. into the cylinder and tighten it to
II. Position the hooked end of the specified torque.
;tdjuster spring completely into the WHEEL CYLINDER 3. Engage the opposite end of the
large hole in the primary shoe web. DRUM BRAKE hose to the bracket on the frame.
The last coil of the spring should be at Install the horseshoe-type retaining
the edge of the hole . Connect the loop REMOVAL clip, and connect the brake tube to
end of the spring to the adjuster lever 1. Remove the wheel and the drum. the hose with the tube fitting nut.
hole. Z. Remove the brake shoe assem- Tighten the nut to specification.
12. Pull the adjuster lever, cable blies, following procedures outlined in 4. To install a rear wheel cylinder,
and automatic adjuster spring down this section. place · the rear wheel cylinder into
and toward the rear to engage the 3. Disconnect the brake line from position. Enter the tubing into the
pivot hook in the large hole in the sec- the brake cylinder . cylinder, and start the tube fitting
ondary shoe web (Fig. 15). On a vehicle with a vacuum brake nut into the threads of the cylinder.
13. After installation, check the ac- booster, be sure the engine is stopped S. Secure the cylinder to the
tion of the adjuster by pulling the sec- and there is no vacuum in the booster backing plate by installing the
tion of the cable between the cable system before disconnecting the hy- attaching bolts and lock washers.
guide and the anchor pin toward the draulic lines. 6. Tighten the tube fitting nut to
secondary shoe web far enough to lift To disconnect the hose at a front specification.
the lever past a tooth on the adjusting cylinder, loosen the tube fitting that 7. Install the shoes and adjuster
screw wheel. The lever should snap connects the opposite end of the hose assemblies, and adjust the shoes as
into position behind the next tooth, to the brake tube at a bracket on the outlined iD. this section.
and release of the cable should cause frame. Remove the horseshoe-type re- 8. Adjust the brake shoes, Page
the adjuster spring to return the lever taining clip from the hose and brack- 2-14 and install the brake drums and
to its original position. This return ac- et, disengage the hose from the brack- wheels. Bleed the brake system as
tion of the lever will turn the adjusting et, then unscrew the entire hose as- outlined on Page 2-3.
screw one tooth. sembly from the front wheel cylinder. WHEEL CYLINDER REPAIR -
If pulling the cable does not pro- At a rear cylinder, unscrew the tube
duce the action described, or if the fitting that connects the tube to the DRUM BRAKE
lever action is sluggish instead of posi- cylinder. Do not pull the metal Wheel cylinders should not be dis-
tive and sharp, check the position of tube away from the cylinder. assembled unless they are leaking or
the lever on the adjusting screw Pulling the tube out of the cyl- unless new cups and boots are to be
toothed wheel. With the brake in a inder connection. will bend the
vertical position (anchor at the top),
the lever should contact the adjusting
wheel 3/16 inch (plus or minus 1/32
BOOT
inch) above the centerline of the

~~
screw. If the contact point is below
this centerline, the lever will not lock
on the teeth in the adjusting screw
wheel, and the screw will not be turned
as the lever is actuated by the cable.
To determine the cause of this con-
PISTON
dition : CYLINDER
a. Check the cable end fittings. The
cable should completely fill or extend
slightly beyond the crimped section of
FIG. 22- Brake Wheel Cylinder- Typical H138S·B

the fittings. If it does not meet this

specification, possible damage is indi-
cated and the cable assembly should
2-18 GROUP 2-BRAKES
installed. It is not necessary to re- If the front backing plate is being INSTALLATION
move the brake cylinder from the replaced, remove the bolts and nuts l. If the rotor is being replaced,
backing plate to disassemble, inspect, · that secure the backing plate to the remove the protective coating from
or hone and overhaul the cylinder. front wheel spindle and remove the the new rotor with carburetor de-
Removal is necessary only when the plate and gasket. greaser. Pack a new set of bearings
cylinder is damaged or scored beyond with specified grease (Refer Group
INSTALLATION
repair. 3) and install the inner bearing
If a rear backing plate is to be re- cone and toller assembly in the inner
DISASSEMBLY placed, position a new rear backing cup. Pack grease lightly between the
1. Remove the links and the plate and gasket on the attaching lips of a new grease seal and install
rubber boots from the ends of the bolts in the axle housing flange. Insert the seal. ·
brake cylinder. Remove the pistons, parking brak.e cable into backing plate
cups, and return spring from the If the original roto~ is being in-
and secure retaining fingers. Install
cylinder bore (Fig. 22). the rear axle shaft stalled, make sure that the hub is
2. Remove the bleeder screw Refer to Group 4 for the proper clean, that the inner bearing and
from the cylinder. installation procedure. grease seal are lubricated and in good
condition, and that the rotor braking
INSPECTION I. If the front brake backing plate surfaces are clean.
l. Wash all parts in clean brake is to be replaced, position a new front
fluid. Dry with compressed air. backing plate and gasket to the wheel Z. Install the hub and rotor assem-
2. Replace scored pistons. Al- spindle and install the attaching bolts bly on the spindle.
ways replace the rubber cups and and nuts. 3. Lubricate and install the outer
dust boots. z. Install the wheel· cylinder and wheel bearing, washer and adjusting
3. Inspect the cylinder bore for connect the brake line as outlined in nut.
score marks or rust. If either condi- this section. 4. Adjust the wheel bearings to
tion is present the cylinder bore inust 3. Install the brake shoe and ad- specification, and then install the nut
be honed. However, the cylinder juster assemblies as outlined in this lock, cotter pin, and grease cap. The
should not be honed more than section. On a rear brake, connect the wheel bearing adjustment is especially
0. 003 inch beyond its original parking bralte cable to the lever. Important with disc brakes.
diameter. 4. Adjust the brakes, Page 2-14. 5. Mount the caliper assembly on
4. Check the bleeder hole to be Install the brake drum and wheel. the spindle following the Disc Brake
sure that it is open. - Bleed the brakes as outlined on Caliper Assembly Installation proce-
Page 2-3. dure in this section.
ASSEMBLY
DISC BRAKE ROTOR
l. Apply a light coating of heavy- FRONT WHEEL HUB AND
SPLASH SHIELD
duty brake fluid to all internal parts. ROTOR ASSEMBLY -
2. Thread the bleeder screw into DISC BRAKES REMOVAL
the cylinder and tighten securely. REMOVAL 1. Remove the caliper and the hub
3. Insert the return spring, cups, l. Remove the wheel and tyre and rotor assembly as outlined under
and pistons into their respective posi- from the hub. Be careful to avoid Removal in the foregoing procedure
tions in the cylinder bore (Fig. 22). damage or interference with the (it is not necessary to disconnect hy-
4. Replace the boots and links. bleeder screw fitting. draulic connections).
Assemble the brake shoes and drums z. Remove the three bolts that at-
Z. Remove the caliper assembly
as previously described. tach the splash shield to the spindle:
5. Bleed the brakes and refit ,the from the spindle and the rotor. If the
caliper does not require servicing, it is and remove the shield .
wheels.
not necessary to disconnect the brake
hose or remove the caliper from the 3. Remove and discard the splash
BRAKE BACKING PLATE - vehicle. Position the caliper out of the shield to spindle gasket.
way, and S\!pport it with a wire to INSTALLATION
DRUM BRAKE
avoid damaging the caliper or stretch- I. Install a new splash shield to
ing the hose. Insert a clean cardboard spindle gasket.
REMOVAL
spacer between the linings to prevent z. If the shield is bent, straighten it
1. Remove the wheel and brake the piston from coming out of the cyl- out before installation. Position the
drum. Disconnect the brake line from inder bore while the caliper is re- shield to the mounting bracket, install
the brake cylinder. moved. the attaching bolts, nuts and torque
Z. Remove the brake shoe and ad- Handle the rotor and caliper assem- them to specification.
juster assemblies and tbe wheel cyhn- blies in such a way as to avoid defor- J. Install the hub and rotor assem-
der as outlined in this section. On the mation of the rotor and nicking, bly and the caliper as outlined under
rear wheels, disconnect the parking scratching or contamination of the Installation in the foregoing proce-
brake lever from the cable. brake linings. dure.
J. Remove the grease cap from the DISC BRAKE CALIPER ASSEMBLY
3. If the rear backing plate is being hub. Remove the cotter pin, nut lock, GIRLING
replaced, remove the axle shaft from adjusting nut, and flat washer from REMOVAL
the applicable rear axle as outlined the spindle. Remove the outer bearing 1. Remove the wheel and tyre
in Group 4, disengage parking brake cone and roller assembly. assemblies from the hub. Use care
cable retainer from ba-cking plate. 4. Remove the hub and rotor as- to avoid damage or interference
Remove the backing plate and gasket. sembly from the spindle. with the bleeder screw fitting
PART 2-2-BRAKE SYSTEM 2-19

duriq removal. ft. and the caliper locating pins to (8) Remove jackstands or lower
2.. Remove about 2/3 of the total 25-35 lb. ft. hoist.
brake fluid capacity from the mas- 12. Install the wheel and tyre (9) Road test the vehicle and
ter cylinder ~eservoir which serves assembly and tighten the wheel nuts make several heavy 40 - 0 m.p.h.
the disc brakes. Do not drain the to 70-115lbs. ft. torque. stops to wear off any foreign material
reservoirs completely. on the brakes and to seat the shoes.
DISC BRAKE CALIPER ASSEMBLY (The vehicle may pull to one side
3. Disconnect the brake hose
REMOVAL P.B.R. on the f~rst application after service.
from the caliper. Cap the hose fitting
to prevent brake system contamina- (1) Remove about 2/3 of the total This is normal until shoes are seated).
tion and loss of brake fluid from the brake fluid capacity from the mas-
master cylinder. Mark the left and ter cylinder reservoir which serves DUAL MASTER CYLINDER -
right caliper assemblies with chalk the disc brakes. Do not drain the DRUM BRAKES
prior to removal from the vehicle. reservoirs completely. REMOVAL
. 4. Remove the caliper locating (2) With vehicle raised evenly on a 1. Remove the hairpin clip from
pms and lower stabilizer attaching hoist or jackstands, remove the front the brake master cylinder push rod
bolts and discard the stabilizer. Refer wheels- pedal pin.
to Fig. 8. · Note 2. Slide the master cylinder push
Lift the caliper from the If more than one brake requires rod and the nylon spacer and bushing
anchor plate Fig. 11. service, work on only one brake at a oft' the brake pedal pin.
time, however, shoe and lining as- 3. Remove the brake tubes from
INSTALLATION semblies must always be replaced in the primary and secondary outlet
S. Position the caliper assembly both brakes. ports of the master cylinder.
over the rotor with the outer brake (3) Locate brake line and wipe 4. Remove the nuts and lock-
shoe against the rotor braking surface area around fitting at · brake with a ~ashers that secure the master cyl-
during installation on the anchor clean cloth to remove dirt and grease. mder to the dash panel and lift the
plate to prevent pinching the piston Remove hose and place dust cap over cylinder forward and upward from
boot between the inner brake shoe end fitting. Insert dust cap into in· the vehicle.
an~ the piston. Verify that the correct let hole of caliper. INSTALLATION
caliper 1S assembled on the correct (4) Remove the two anchor bolts 1. Position the boot on the push
anchor plate as marked during dis- which hold the caliper anchor plate
. assembly. rod and secure the boot to the master
· to the steering spindle, remove the cylinder. Carefully insert the master
8. Position the new stabilizer. two bolts and lift the caliper ··and
Apply methylated spirits on the cylinder push rod af?-d boot through
anchor plate assembly from the the dash panel openmg and position
locating pins and attach the stabilizer spindle. the master cylinder on the panel.
to the caliper. Be sure the locating
INSTALLATION 2. Install the nuts and lock
pins ~ free of on, grease and washers at the dash panel and torque
dirt. T1ghten , the caliper locating (1) Position caliper correctly over
disc and slide straight into position them to specification.
pins finger tight. Coat the nylon bushings with
until anchor bracket bolt holes align
Warning: When ever the caliper SAE lOW oil.
with their respective holes on the
is removed, it is mandatory that 3. Install the inner nylon spacer
steering knuckle.
a new stabilizer, stabilizer locat- (2) Instal the lower bolt fmger the ~aster cylinder push rod, and th;
iq pins and insulator bushes be bushmg on the brake pedal pin.
fitted. tight. Instal the upper bolt and torque
to specification. Torque the lower Secure these parts to the pin with the
7. Install the stabilizer to anchor bolt to specification. Safety wire both hairpin clip.
plate attaching screws. Finger tight. bolts. Be _sure specified wire wraps 4. Connect the brake lines to the
8. Remove the cap from the are made and sharp wire ends point master cylinder leaving the brake line
brake hose fitting. Install a new away from brake hoses. fittings loose.
copper washer on each side of the (3) Loosen the bleeder screw. Re· 5. Fill the master cylinder with
hose fitting and install the brake hose move the plugs from the fluid in· the specified brake fluid to within
on the caliper. Tighten the clutching ~ inch of the top of the dual reser-
sert hole in the caliper and the brake
screw to 27-32 lbs. ft. torque. hose and insert fitting into hole and voirs. Use Motorcraft Brake Fluid
t. Bleed the brake system. tighten. or equivalent for all drum brake
CAUTION: DURING BLEED- (4) Bleed the system. Allow the applications.
ING OPERATIONS THE BRAKE caliper to fill with brake fluid. After 6. Tighten the brakeline fittings.
WARNING LIGHT SWITCH all air bubbles have .escaped, and fluid Bleed the dual master cylinder and
MUST BE REMOVED FROM runs clear from bleeder, close the the primary and secondary brake
THE MASTER CYLINDER TO bleeder screw. Replenish the brake systems. Refer to Hydraulic System
AVOID DAMAGE TO THE fluid in the master cylinder. Bleeding, Page 2-3 for proper
SWITCH. procedure.
Replace the w&ming light switch (S) Pump the brake pedal several 7. Operate the brakes several
on completion of bleeding o~tion. times to actuate the piston seals and times, then check for external hy-
10. Fill the master cylmder as position the hose and pad assemblies. draulic leaks.
required to within one quarter inch (6) Check for fluid leakage at all
connections under maximum pedal DUAL MASTER CYLINDER -
of the top of the reservoir. DISC BRAKES
11. With moderate pressure appli- pressure.
(7) Instal wheel and tighten wheel REMOVAL
ed to the brake pedal torque the
stabilizer attaching screws to 8-lllb. nuts to 70-115 lbs ft Torque. 1. Remove the brake tubes from
2-20 GROUP 2-BRAKES

Fig. 23-Brake Installation

the primary and secondary outlet Bleeding, Page 2-3 for the proper INSTALLATION
ports of the master cylinder. procedure. Replace the wires on the 1. Mount the booster and bracket
Remove the wires from the warning warning light switch. assembly to the dash panel by inser-
light switch. 7. Operate the brakes several ting the push rod or push rod link in
times, then check for external hy- through the hole and boot in the dash
Remqve the secondary piston draulic leaks. panel. Install the bracket to dash
stop bolt from the bottom of the panel attaching nuts (Fig. 23).
primary reservoir. Refer Fig. 25. 2. Connect the manifold vacuum
BRAKE BOOSTER
2. Remove the two nuts and two hose to the booster.
lock washers attaching the master REMOVAL
3. Install the master cylinder and
cylinder to the brake booster assem- torque the attaching nuts to speci-
bly. 1. Working from inside the ve- fications. .
3. Slide the master cylinder for- hicle below the instrument panel, 4. Working from inside the ve-
ward and upward from the vehicle. disconnect the booster push rod from hicle below the instrument panel,
the brake pedal assembly. To do this connect the booster push rod link to
INSTALLATION
proceed as follows: the brake pedal assembly. To do this,
1. Position the master cylinder Remove the hairpin retainer from proceed as follows:
assembly over the booster push rod the brake pedal pin and then remove · Install the inner nylon spacer, the
and onto the two studs on the booster the booster push rod and the nylon booster push rod, and the bushing on
assembly (Fig. 23). spacer and bushing off the brake the brake pedal pin. Secure these
2. Install the attaching nuts and pedal pin (Fig. 23). parts to the pin with the hairpin
lock washers and torque them to 2. Open the hood and remove the retainer.
specifications. master cylinder from the booster. It
3. Install the front and rear brake is necessary to disconnect the brake BRAKE PEDAL ALL MODELS
tubes to the master cylinder outlet lines. Care should be taken that the REMOVAL
fittings. brake lines are not deformed. Perma-
4. Fill the master cylinder with nent deformation of brake lines can 1. Remove the hairpin retainer.
the specified brake fluid to within lead to tube failure. · Slide the master cylinder or booster
: inch of the top of the dual reser- 3. Disconnect the manifold vac- push rod and the nylon spacer and
voirs. Use Motorcraft Brake Fluid. uum hose from the booster unit. bushing off the brake pedal pin
·Do not m1x low temper~ture brake 4. Remove the booster to dash tFig. 23).
fluids with the specified fluids for the panel attaching nuts (Fig. 23). 2. Remove the circlip type re-
disc brake system. Remove the booster assembly from tainer from the brake pedal shaft,
5. Bleed the dual master cylinder the dash panel, sliding the push rod then remove the shaft, the brake
and the primary and secondary brake link out from the engine side of the pedal and the bushings from the
systems. Refer to Hydraulic System dash panel. pedal support bracket.
PART 2-2 -BRAKE SYSTEM 2-21

INSTALLATION the equilizer lever, and remove the on Page 2-16.

cable from the car. 4. Disconnect the rear ends of the
1. Apply a coating of SAE 10
engine oil to the bushings and locate cable from the parking brake levers
bushings in their proper places on INSTALLATION on the brake shoes. Disengage the
the pedal assembly and pedal sup- cable housing retaining grommets
1. Connect the cable lower ball from the carrier plates and withdraw
port bracket (Fig. 23) to the equilizer lever.
2. Position the brake pedal as- the cable ends and housings from the
2. Engage the cable and housing inboard sides of the carrier plates.
sembly to the support bracket, then to the bracket on the cross-member
install the pedal shaft through the S. Slide the cable housings out of
and secure with the hairpin retainer. the main side brac~ets and remove
support bracket and brake pedal 3. Push the upper end of the
assembly. Install the retainer. the cable assembly from the car.
cable up through the hole in the
3. Install the inner nylon spacer, dash panel. INSTALLATION
the master cylinder or booster push 4. Connect the cable upper ball
rod, and the bushing on the brake to the parking brake handle, and 1. Insert both cable ends and
pedal pin. Secure these parts to the install the handle assembly as out- housings · through the holes in the
pin with the hairpin retainer. lined in this section. carrier plates from the inboard side.
S. Install the insulator bracket to NOTE: Ensure that when fitting the
PARKING BRAKE, EQUALIZER the dash panel and secure with the cable ends to the carrier plates that
two attaching screws. they are fitted so that the flat irt the
TO HANDLE, CABLE D-shaped hole in the cable yoke is
PARKING BRAKE EQUALIZER uppermost.
REMOVAL TO REAR WHEEL CABLE 2. Connect the cable ends to the
1. Remove the attaching screws parking brake levers on the brake
and insulator bracket from the dash A single cable passing through the shoes and engage the cable housing
panel. equalizer and cable guides connects retaining grommets to the carrier
2. Remove the parking brake both parking brake assemblies. plate.
handle assembly and disengage the REMOVAL 3. Position the cable housings in
cable from the handle as outlined in 1. Remove the adjusting lock nut the main side brackets and install the
this section. and cable yoke from the equalizer hairpin retainers.
3. Pull the cable down thtough rod, along with the rear cable assem- 4. Position the cable yoke and
the hole in the dash panel. bly. cable on the equalizer rod and install
4. Remove the hairpin retainer, 2. Remove the hairpin retainers the adjusting locknut.
and disengage the cable and housing and disengage the cable rear housings The flat on the threaded section of
from the bracket on the cross- from the brackets on the underbody. the equalizer rod must be uppermost.
member. 3. Remove the wheels and tyres 5. Adjust the parking brake as
S. Disconnect the cable ball from and the rear brake drums as outlined directed on Page 2-3.

II MAJOR REPAIR OPERATIONS

BRAKE DRUM REFINISHING ROTOR REFINISHING with brake fluid, grease or oil must be
Minor scores on a brake drum can replaced. Failure to replace worn
The finished braking surfaces of linings will result in a scored drum.
be removed with sandpaper. A drum the rotor must be flat and parallel
that is excessively scored or shows a Whea it is necessary to replace
within 0 . 0007 inch; lateral runout linings, they must also be re-
total indicator runout of over 0. 007 must not exceed 0 . 003 inch total in-
inch should be turned down. Remove placed on the wheel on the
dicator reading, and the surface finish opposite side of the vehicle.
only enough stock to eliminate the of the braking surfaces are to be
scores and true up the drum. The Inspect brake shoes for distortion,
80/15 micro inches. The minimum cracks, or looseness. If this condition
refinished diameter must not exceed limiting dimensions (Fig. 2) from
0. 060 inch oversize. exists, the shoe must be discarded.
the inboard bearing cup to the out- Do not attempt to repair a de-
Check the inside diameter of the board rotor face and from the in·
brake drum with a brake drum fective brake shoe.
boarq bearing cup to the inboard
micrometer. rotor face must be observed when 1. Wash the brake shoes thor-
If the drum diameter is less than removing material from the rotor oughly in a clean solvent. Remove all
0. 030 inch oversize after refinishing, braking surfaces. On all models, the burrs or rough spots from the shoes.
standard lining may be installed. If limiting dimensions are to be mea- 2. Check the inside diameter of
the drum diameter is 0 .030-0.060 sured with a ball and ·puge bar the brake drum with a brake drum
inch oversize after refinishing, over- (Tool Rll02A). micrometer. If the diameter is less
size lining must be installed. than 0 . 030 inches oversize, standard
After a drum is turned down, wipe lining may be installed. If the dia-
the refinished surface with a cloth BRAKE SHOE RELINING meter is 0 . 030-0. 060 inches over-
soaked in clean denatured alcohol. If Brake linings that are worn to with- size, oversize lining should be in-
one drum is turned down, the oppo- in -:!1., inch of the rivet head or are stalled.
site drum on the same axle should less' than 0 . 030 inch thick (bonded 3. Position the new lining on the
also be cut down to the same size. lining) or have been contaminated shoe. Starting in the centre, insert
2-22 GROUP 2-BRAKES

and secure the rivets, working alter- PISTON RETRACTING TOOL GIRLING
nately towards each end. Replace-
ment linings are ground and no
further grinding is required.
4. Check the clearance between
the shoe and lining. The lining must
seat tightly against the shoe with not Used Outer
more than 0. 008 inch clearance Brake Shoe
between any two rivets.
DISC BRAKE CALIPER GIRLING
OVERHAUL AND BRAKE
SHOE REPLACEMENT i -13 Nut
Weld Nut on tame Weld' securely
DISASSEMBL \' side of Brake Shoe . to Brake Shoe
as Tangs
1. Remove the caliper from the
vehicle as detailed on Pages 2-18.
2. Remove the inner brake shoe
hold down clips from the anchor
plate, remove the locating pin insu-
lators from the anchor plate and re-
move the inboard brake shoe and
lining assembly (Fig. 11).
3. Place a small screw-driver i -13 Nut
Weld securely
under the outer brake shoe retaining to Threaded ·Rod
clip tang and lift away from the pin Drill 33/64 dia.
groove and slide the clip from the in Brake Shoe
brake shoe retaining pin. Repeat the
operation to remove the other shoe
retaining clip
Remove the brake shoe.
4. Apply air pressure to the fluid
port in the caliper with a tubber
tipped nozzle to remove the piston.
Place a cloth over the piston before
applying air pressure to prevent dam-
age to the piston. If the piston is
D D
seized and cannot be forced from the
caliper, tap lightly around the piston IF necessary a similar tool may be made for P.B.R. Caliper from discarded
while applying air pressure. Care brake shoe.
should be taken because the
piston can develop considerable 2. Install a new dust boot by over the rotor.
force due to pressure build up. setting the flange squarely in the 5. Position the new outer brake
5. Remove the dust boot from outer groove of the caliper bore. shoe and lining assembly on the
the caliper assembly. 3. Coat the piston with clean caliper and install the outer brake
6. Remove the rubber piston seal Motorcraft Brake Fluid and insert shoe retaining clips. Hold the retain-
from the cylinder and discard it. into the cylinder bore. ing pins in position with an Allen
CU:ANJN(; ANll INSPF.CTION A piston retracting tool can be wrench or bolt while installing the
Clean all metal parts with de- fabricated from a discarded outer retaining clips.
natured alcohol or a suitable solvent. brake shoe and a threaded rod. See 6. Position the caliper assembly
Use clean, dry, compressed air to diagram for details. over the rotor with the outer brake
clean out and dry the grooves and 4. Install the piston retracting shoe against the rotor braking surface
passage ways. Be sure that the caliper tool in the caliper with the brake shoe during installation in the anchor plate
bore and component parts are com- lances positioned in the slots in the to prevent pinching the piston boot
pletely free of any foreign material. caliper outer legs and retract the between the inner brake shoe and
Check the cylinder bore and piston piston. the piston.
for damage or excessive wear. Re- NOTE: When using the piston re- Verify that the correct caliper is
place the piston if it is pitted, scored, tracting tool, turn the threaded rod assembled in the correct anchor plate
or the chrome plating is worn off. one half turn at a time and pause to as marked during disassembly.
permit the piston to move in the seal. 7. Position the new stabilizer
ASSEMBLY Reduce the time interval as the piston (supplied in the brake kit). Apply de-
1. Apply a film of clean brake nears the bottom of the cylinder bore natured alcohol or methylated spirits
fluid to the new caliper piston seal to ensure bottoming of the piston. If on the locating pins and attach the
and install it in the cylinder bore. Be the piston is not fully bottomed, the stabilizer to the caliper. Be sure the
sure the seal does not become twisted spacing between the linings is in- locating pins are free of oil,
and that it is seated fully in the sufficient to permit the brake shoe grease or dirt. Tighten the caliper
groove. and caliper assembly to be mounted locating pins finger tight.
PART 2-2-BRAKE SYSTEM 2-23

s·. Install the stabilizer to anchor damage it against the outboard (10) Line up sleeve with holes
plate attaching screws and tighten portion of the caliper. A thin block in the caliper assembly and insert
finger tight. of wood or hardboard located in the guide pin using care not to damage
9. Remove the cap from the position of the outboard shoe will boots. Place drift on to head of pin
brake hose fitting. Install a new assure the piston is not damaged. and tap pin into position with hammer.
copper washer on each side of the (11) As the piston slides out, the The pin must be entered from the
hose fitting and install the brake hose I.D. of the rubber boot in the groove outboard hole, i.e. The hole which
on the caliper. Tighten the attaching of the piston should stretch out is not cross drilled to take a cotter
screw to 27-32lbs. ft. torque. around the large portion of the pis- pin.
Bleed the brake system as detailed ton allowing the piston to slide out Note
on Page 2-3 of this manual. and be removed. Assemble guide pin with narrow
10. Fill the master cylinder as re- (12) Peel boot out of cylinder rounded groove at cotter pin end.
quired to within 3/8 inch of the top groove and discard. (11) Place bracket in position with
of the reservoir. (13) Inspect the piston for scor- hook end at the same end as the
11. With moderate pressure appli- ing, pitting, corrosion or areas where bleeder screw. Insert second sleeve
ed to the brake pedal torque the the chrome plating is worn off. If and guide pin as above. Insert two
stabilizer attaching screws to 8-20 lb any damage is evident, replace the split cotter pins to retain guide pin.
ft. and the caliper locating pins to piston. If not wipe clean and set (12) With the aid of expanding
26-50 lb. ft. aside. Black stains, if any, are caused circlip pliers install the single loop
12. Install the wheel and tyre by the seal and will do no harm. anti-rattle spring over the guide pin
assembly and tighten the wheel nuts (14) Use a small pointed "wood sleeve.
to 70-115 lbs. ft. torque. or plastic tool to remove the pis· (13) Place a thin piece of shim
13. Pump the brake pedal prior to ton seal from its groove in the cy- material over sleeve. Locate double
moving the vehicle to position the linder bore and discard, be careful loop anti-rattle spring and press spring
brake pads. to avoid damaging ·the seal seat. over sleeve. Remove shim material.
(15) Clean all parts with brake Note
DISC BRAKE CALIPER OVER- fluid and wipe dry with lint free It is important to ensure that the
HAUL AND BRAKE SHOE RE- cloth, using an air line, blow out guide pin sleeve is not burred or
PLACEMENT P.B.R. the drilled passages and cylinder bore. scored during installation of anti-rattle
springs. Burring of the sleeves could
DISASSEMBLY ASSEMBLY prevent automatic pad adjustment
(1) Remove outboard shoe by (1) Place caliper assembly on a when compensating.for lining wear.
pressing down towards inboard shoe clean bench area with the open end l14) Slide inboard shoe towards
at the same time sliding forward. of cylinder up. caliper piston, at the same time locate
(2) Remove inboard shoe by slid- (2) Dip new piston seal in clean anti-rattle spring inside caliper piston.
ing away from caliper piston. At the disc brake fluid and install in cy- ( 15) Using a screw driver to raise
same time overcoming the resistance linder groove. Position seal at one retaining clip slide one end of out-
of the anti-rattle spring attached to the area in the groove and gently work board shoe onto caliper housing.
shoe. around cylinder bore with a f'lllger Repeat to place remaining end in
(3) Mount the caliper in a vice until properly seated. Check to be p<;>sition. Ensure the two locating
equipped with padded jaws. sure the seal is not twisted or rolled posts locate in the two holes in
(4) Remove two cotter pins in its groove. · Caliper housing.
retaining guide pins. (3) Coat piston boot in P.B.R.
(5) Tap out guide pins using a rubber grease. Place piston boot over DUAL MASTER CYLINDER
suitable pin punch. end of piston.
Note (4) Locate boot into groove in DISASSEMBLY
Drive guide pin out from cylinder caliper bore. 1. Clean the outside of the master
or inboard side of caliper. (5) liberally coat the out- cylinder and remove the filler cover
( 6) Tension on anti-rattle spring side diameter of piston with P.B.R. and diaphragm. Pour out any brake
will then be relieved and spring can rubber grease. fluid that remains in the cylinder.
be removed from anchor bracket hold· (6) Position piston over cylinder Discard the old brake fluid.
ing point. and press the piston straight into the 2. In the case of drum brake
(7) Remove anchor bracket and cylinder until it bottoms. Use ex- vehicles, prise up the two lugs on the
remaining guide and anti-rattle spring. treme care not to scratch the piston retaining plate at the rear of the
Clamp bracket in vice. or tear the dust boot. The boot I.D. master cylinder (Fig. 25). If the
(8) Using screw driver remove should slide up the piston as the secondary piston stop bolt has not
anti-rattle spring from anchor bracket piston moves into the cylinder and been removed from the bottom of
and guide. comes to rest in the piston groove. primary reservoir (Fig. 24) depress
(9) Remove the four guide pin (7) Smear the inside of the guide the primary piston and remove the
boots and discard. Check guide pins pm sleeve with Approved High Melting stop bolt.
for wear and plating damage. Replace Point Grease - refer specifications. 3. Remove the primary piston
guide sleeve pin assy. if damaged. (8) Smear the four guide pin assembly from the master cylinder
(10) Remove piston by applying boots with High Melting Point grease bore. Do not remove the screw
compressed air at the fluid inlet port and assemble into sleeve with the that retains the primary return
of the caliper taking care not to lips facing outwards. spring retainer, return spring
apply air at too high a pressure as to (9) Locate fmt of guide pin and protector on the primary
cause the piston to l)Op out and sleeves in position. piston. This assembly is factory
2-24 GROUP 2-BRAKES

pre-adjusted and should not be

disassembled.
4. Remove the secondary piston
assembly.
5. Remove the brake light warn-
ing switch from the side of the
cylinder. Remove the plug from the
end of the master cylinder and with-
draw the differential valve and
spring.
INSPECTIO"' AND REPAIR
1. Clean all parts in clean de-
natured alcohol, and inspect the parts
for chipping, excessive wear or
damage. When using a master
cylinder repair kit, install all the
parts supplied. .
2. Check all recesses, openings
and internal passages to be sure they
are open and free of foreign matter.
Use an air hose to blow out dirt and
cleaning solvent. Place all parts on a
clean pan or paper.
3. Inspect the master cylinder
bore for signs of etching, pitting,
scoring or rust. Honing of the master
cylinder is not recommended. If it is
necessary to hone the ma~ter cyl-
inder bore to repair damage, do not
FIG. 24- Dual Master Cylinder Disc Brakes exceed allowable hone specifications.
ASSEMBLY
1. Dip all parts except the master
cylinder body in clean motorcraft
Brake Fluid.
2. Carefully insert the complete
secondary piston and return spring
assembly in the master cylinder bore.
3. Install the primary piston as-
sembly in the master cylinder bore.
On drum brake vehicles, fit the
piston retainer plate to the rear of
the master cylinder and lock into
position by bending locking tabs into
the groove.
4. Depress the primary piston
and insert the secondary piston stop
bolt in the bottom of the primary
reservoir.
5. Install the differential valve
and spring assembly and refit the
plug. Do not replace the warning
light switch until the system has
been bled. Failure to observe this
precaution will result in a damaged
switch.
6. Replace the diaphragm gasket
FIG. 25- Master Cylinder- Drum Brakes. and the filler cap.
2-25

PART SPECIFICATIONS
2·3
DISC BRAKES All Dimensions in Inches DRUM BRAKES All Dimensions in Inches
Disc Diameter 11.25 Drum Diameter .. Front 10.0
Disc Thickness (nominal) 0 . 94 Rear 10.0
Maximum Allowable Runout 0.003 Maximum Allowable Runout 0.007
. Lining Maximum Wear Limit .. 0.030 Lining Maximum Wear Limit .. 0 .030
·Lining Dimensions Rear From top of rivets (riveted linings)
Sedan (Except G.T.) Primary 1.75 X 8.35 or top of shoe (bonded linings)
Secondary 1.75 X 10.75 Lining Dimensions Front Rear
G.T. Seadan and Primary 2.25 £8.35 All except 15 cwt Ute & Van
15 cwt Ute and Van Secondary 2.25 X 10.75 Primary 2.25 x 8.35 1. 75 X 8 . 35
Master Cylinder .. P.B.R. Secondary 2. 25 x 10.75 1.75x10.75
Bore Diameter .. 1.00 15 cwt Ute & Van primary 2.25 x 8.35 2.25 X 8.35
Disc Brake Caliper Bore 2 . 375 secondary 2.25 x 10.75 2.25 X 10.75
Rear Wheel Cylinder Bore Master Cylinder P.B.R.
Falcon GT .9375 Bore diameter 1.00
All other Sedans .8125 Rear wheel cylinder bore Sedan .875
Waggon, Ute and Van 8125 Wagon Ute & Van .875
Front wheel cylinder bore
Pedal height with 20" of vacuum All models 1.125
and 120 lb pedal effort 1.90"
Pedal Height- at 1600 p.s.i.
line pressure 3.0"
P.B.R. CALIPER GUIDE PIN LUBRICATING GREASE- CALTEX THERMATEXT E.P.I.
Hydraulic Line Diameter 0 . 188
Pressure Differential Valve-Integral with Master Cylinder.
WARNING: The Warning Light Switch must be removed
prior to bleeding the system and replaced on
completion of the bleeding operation. Failure
to observe this precaution will cause the
switch to be damaged.
On the G.T. vehicles the functional pressure
differential valve is independent of the master
cylinder.

TORQUE LIMITS- GENERAL FT. LBS.

Parking Brake Control Assembly Mounting Rear Brake Backing Plate to Axle Housing
Nuts and Bolts . . 12-25 Removable Carrier .. 50-70
Master Cylinder to Dash Panel Screw . . 13-20 Integral Type . . 20-40
Master Cylinder to Booster 13-20 Front Brake Backing Plate to Spindle 28-35
Booster to Dash Panel . . 13-20 Wheel Cylinder Bleeder Screw . . 32-65 Inch Lb.
Disc Brake Caliper Anchor Plate *Upper 110-140 Disc Brake Calipers Bleeder Screw 6-15 Ft. Lb.
to Spindle Bolts Lower 55- 75 Brake Hose Connection to Front Wheel Cylinder 12-20
Disc Brake Rotor Splash Shield to Spindle 9-14 Brake Line Connection to Rear Axle Housing
Brake Hose to Caliper Connection Bolt 17-25 Removable Carrier 12-19
Caliper Locating Pins . . 26-50 Integral Type .. 12-19
Caliper Stabilizer to Am::hor Plate Bolt 8-20 Hydraulic Tube Connections**
Caliper Brake Shoe Clips 6-10 ~X 24 10-15
Caliper Bleeder Screws . .
Wheel Cylinder to Backing
6-15 * x24
! X 20
10-15
10-17
Plate Screws . . 10-20 -i~ X 18 10-17
Wheel to Hub and Drum or Hub and Rotor Nuts 70-115

*The upper bolt must be tightened first.

• • All hydraulic lines must be tightened to the specified
torque value and be free of fluid leakage.
REFERENCE TO SERVICE INFORMAnON AND NOTES
-
Date Letter No. Pal• Brief Detail

'

'

.
.

---

-
FALCON FAIRLANE w~:~~~~P

GROUP
3

PAGE
PART 3-1 Suspension, Steering, Wheels
and lyres, General Service 3-2
PART 3-2 Suspension 3-11
PART 3-3 Power Steering 3-20
PART ~ Steering Column and Linkage 3-38
PART 3-5 Steering Gear 3-45
PART 3-6 ·_yvheels and lyres 3~48

PART 3-7 Specifications 3-53

3-2

PART SUSPENSION, STEERING, WHEELS

3·1 AND TYRES GENERAL SERVICE

Section Pare Se~tion Pap

1 Diagnosis and Testing ... . .... ...... ...... . 3-2 2 Common Adjustment~~ 4 Repairs ...... .. .... 3-7
Front Wheel Alignment Check• . ... .... .. 3-3
Trouble Symptoms & Causes ...... ...... ... ... .. .... 3-6 3 Cleaning & Inspection ... ... .. .. .. ...... ...... .. .... 3-9

D DIAGNOSIS AND TESTING

MANUAL SRERING
Table I Page 3-6 lists various steer- Check For Pluld Leaks the pump reservoir seal, pump outlet
ing gear and linkage trouble symptoms valve seals, or the support stud seal,
i!Od possible causes. Several of these
1. If the power steering ftuid check the torque of the outlet valve
symptoms are also common to sus- does not already include yellowish nut and the support stud aut. If
pension frame, and wheel and tyre torque is within specifications, replace
troubles. For this reason, be sure that the reservoir seal, outlet valve seals,
the cause of the trouble is in the or the support stud seal, whichever is
steering gear or linkage before adjust- required if leaks are evident other
ing, repairing. or replacing any of the than the lines.
steering parts. Steering gear leaks. Should a leak
be found in the steering gear it will
POWER STEERING be necessary to remove the gear to
FIG. 1 Power Steering Pump
PRELIMINARY TESTS effect repairs. Preloads must be reset
Dipstick after se.a l replacement. (See Page 3-20)'
The following preliminary checks green dye, pre-mix one teaspoonful
should '\!ways be made before per- of oil-soluble aniline dye with 2 Check Turning lffort
forming any trouble-shooting opera- pints of automatic transmission ftuid With the front wheels properly
tions. M2C33-Ft. Then refill the reservoir aligned and tire pressures correct.
with the dye solution. check the effort required to turn the
Check Pulhp lelt l. With the eng10e running at idle ateerina wheel.
If the pump belt is broken, glazed, speed, turn the steering wheel all the 1. With the car on dry concrete,
or worn, replace with a new belt. Use way to the right stop and to the left set the parkin1 . brakes.
only the specified type of belt. stop several times to distribute the 2. With the eaaine warmed up and
dye solution throughout the hydraulic runnin1 at idle speed, tum the steer·
Check The lelt Tension
system. Do not hold the wheel against ina wheel to the left and riaht several
If the belt is too loose or too tight, each wheel stop for more than 3 to times to warm the fluid.
it should be adjusted to the proper S seconds. 3. Attach a torque wrench to the
tension as outlined on Page 3-25. ·
3. Shut off the engine. and check ateerina wheel hub. lFig. 2). Check
A "used belt" Is one that has run
for leaks. the effort required to tum the wheel
10 minutes or longer.
Fitting and Tube Seat Leak. Since at least one complete revolution in
mo~t fluid leaks occur at the fittings both directions. The torque should be
Check Fluid Level and connections in a power steering approximately equal in both direc-
Run the engine until the fluid is at hydraulic system, these parts should tions.
normal operating temperature (165 be checked before any other part is
degrees F to 175 degrees F). Then replaced. Pump-fluid Pressure Test
turn the steering wheel all the way to Dirt, oil, and grease should be removed
the left and right several times, and A ftuid pressure test will show
from all areas where leaks may ex.ist. whether the pump or some other unit
shut off the engine. If the fittings and conn~:ctions do not
Check the fluid level in the power in the power steerina system is caus-
leak, check the other parts of the inJ trouble in the system. Steps out-
steering reservoir. The level must show
on the cross hatching between the ~~m. . lined below should be followed to de·
bottom of the Dipstick and the full Check the hose connection at the termine the cause of the trouble.
mark (Fig. I). If the level is low, add pump for leaks, and tighten the hose I. Measure the pump belt tension.
automatic transmission fluid M2C33F. clamp if necessary. When adjuadaJ the belt tensloa oa
Do not overfill the reservoir. Pump Leaks. If leakage occurs at the power ateerin1 pump, do aot pry
PART 3-1- SUSPENSION, STEERrNG, WHEELS & lYRES GENERAL SERVICE 3-3
...wt the pump to olala the prop- 7. Increase the engine speed to If pressure Is more or ae,. than
er belt load. 1000 rpm; then, slowly close the speclftcadon, rep..ce the pump as-
A h81f-lnch cut boa ba been In· gause shut-off valve. With the valve ~embly.
corporated on the front face of tile fully closed, the pump pressure
If the preceding test results are
pump cover p..te onto which a 'lte should be 1275 ±50 psi. satisfactory, proceed as follows:
Inch open end wrench can be fttte4 to Do not close the •alve for more
,.,. the pump and obtala the proper than a few seconds (maximum 5 ICC• 8. Open the shut off valve fully,
belt teDIIon. onds), as tbls would abnormally In· and run the engine at 1000 rpm.
2. Disconnect the pressure line crease the lubricant (lluld) temper· 9. Turn the steering wheel to full
hose from the pump outlet, and install ature and cause undue pump and/ or lock and read the pressure. If the
a 0-2000 psi pressure gauae and shut steerlna gear wear. En&ine rpm pressure is not to specification,
off valve between the end of the hose should not exceed fast Idle durlq 1275 t 50 psi, the steering gear is at
and the pump outlet (Fig. 3). tbls test• . fault and must be removed for repair.
Do not hold the steering gear
against the stop for more than S
seconds.

FRONT WHEEL ALIGNMENT

CHECKS
Do not attempt to check and ad-
just front wheel alignment without
first making a preliminary inspection
of the front-end parts.
Chec)( all the factors of front wheel
alignment except the turning angle
before making any adjustment~. The
harping angle should be checked only
after caster, camber, and toe-in have
been adjusted to specification.
The front wheel" alignment speci-
fications, given in Part 3-7 are cor-
rect only when the car is at "Curb
Height." Before checking or adjust-
ing the alignment factors, the sus-
pension alignment spacers (Tool
T65P3000-B) must be installed to
,IG. 2 -Checking Turning Effort-Typical obtain the curb heights.

Be ..-e tUt the pre 1 re pap II

between the pmap ud the lbat .,.
..m, all conaeetloal . . apt, ...
. . ~~tat o11 na.e 11 fair opea.
3. Connect a tachometer.
4. Start the engine and operate it
at idle speed for at least two minutes
to warm up the fluid.
5. Cycle the steering wheel ti'om
stop-to-stop several times to expel
any air from the system; stop the
engine. Remove the reservoir filler
cap and check the fluid level in the
reservoir. If necessary, add fluid to
the proper level.

8. With the engine running at ap- ·

proximately 500 rpm and no steer-
ing effort applied, and the fluid at
normal operating temperature, the
pressure gauge should show a pres-
sure of less than 50 psi. If the pres-
sure is higher, inspect the hoses for
kinks and obstructions. FIG. 3 ,..._.. Ttsti.. Tool Installed-Typical
3-4 GROUP 3- SUSPENSION. STEERING. WHEELS . & lYRES

EQUIPMENT INSTALLATION Rear Alignment Spacer tions provided by the equipment

Equipment- used for front wheel Installation manufacturer.
Tool • 3000 B o• C
alignment inspection must be accu- Take the two tubes identified Bl
rate. Alignment height spacers (Figs. and the two remaining supports B3,
4 and · 5 are used to check caster, assemble together with the pins,
camber. The spacers should be located in the holes marked "LIN-
omitted when checking toe-in. COLN" for the Country Ride sus-
Controlled body height for check- pension or in the holes marked FAIR-
ing and setting ~aster and cambe~ is LANE for the Custom Ride
achieved by usmg the suspension suspension.
alignment spacer Tool No. T65P- Raise the rear of the . car
3000-B. When proceeding with an slightly and fit .the spa~ers on ~e
alignment check it is esse~tial that axle housing agamst the mboard side
the alignment spacers are adJusted as of the inner 'U' bolts with the short
described in the following para- end of the curved foot facing the
graphs. rear so as to clear the brake pipe.
Position the spacer vertically so that
Note: Do not use the spacers with the bump rubber plate will rest on
the securing pins inse~ed in the horizontal face of the support.
the hole marked "Falcon" as Lower the car. This provides the 8"
this setting is unsuitable for dimension required between the axle
the Australian built model. FIG. 5 -Typical Rear
housing body side member for the Alignment Spacer
Note: Alignment spacers are not to be Country Ride or 7" for the Custom
used on G.T. and G.T./H.O. Ride suspension. Installation
vehicles or on any vehicle fitted
with the improved handling
suspension option.

Front Alignment Spacer

Installation

Refer specifications.
From the main kit T65-3000-B,
take the two tubes identified B2 and
the two supports B4 ('U'-shaped ALIGNMENT MARKS
plate) and assemble with the pins FIG. 6-Straight Ahead
located in the holes marked FAIRL-
Position Marks-Typical
MUST. For use on the Country Ride , CASTER
suspension or in the holes marked
LINCOLN-MUST. H.D. For use on Check the caster angle at each ·
the Custom Ride suspension. front wheel. ·
Caster is the forward or rearward
Cut two 1" X I!" spacer FIG •. 4 -Typical Front tilt of the top of the wheel spindle
plates from ! " flat mild steel. Raise Alignment Spacer
the front of the body two or three (Fig. 7). If the spindle tilts. to the
inches one side and instal an assem-
Installation rear, caster is positive. If the spin4le
bled spacer over the front outer ball tilts to the front, caster is negative.
1. Drive the car m a straight line The correct caster angle, or tilt, is
joint securing rivet on the flat surface far enough to establish the straight·
of the upper suspension arm and specified in Part 3-7. The maximum
ahead position of the front wheels. difference between both front wheel
position the upper end of the spacer and mark the steering wheel hub and
adjacent to the front face of the re- the steering column collar (Fig. 6). f>OSITIVE
bound rubber as shown in Fig. 4 CAMBER
Do not adjust the steering wheel
_!i-J NEGATIVE-, I I--POSITIVE
Place a 1• X li" X!" spacer plate in
spoke position at this time. If the
front wheels are turned at any time
Ii CASTER
,~l OF TIRE
fY CASTER
the 'U' section of the upper end of .
the support then lower the vehicle during the inspection, align the marks
making sure that the bracket assem- to bring the wheels back to the
bly rests on the spacer plate. straight-ahead position.
l. With the car in position for the
.Repeat this procedure for the front end alil!nment inspection and
opposite side. adjustment, install the alignment
The purpose of the !" thick spacer spacers to establish the curb height. CAMBER FRONT OF
plate is to bring the effective height 3. Install the w h e e I alignment .ANGLE CAR
ofthe spacer to requirements, i.e. 7". equipment on the car. Whichever
For Country Ride or 6.25" for type of equipment is used, follow the FIG. 7 -Caster and Camber
Custom Ride suspension. installation and inspection instruc· Angles
PART 3-1- SUSPENSION, STEERING, WHEELS & TYRES GENERAL SERVICE 3-5

caster angles should not exceed 'h o. justed after the caster and camber and toe-in adjustments and should,
However, a difference of not more has been adjusted to specification. therefore, be measured only after
than lA o is preferred. these adjustments have been made. If
Check the toe-in with the front the turning angle does not measure to
wheels in the straight-ahead posi-
CAMBER specifications, check the spindle or
tion. Run the engine so that the
Check the camber angle at each other suspension parts for a bent con-
power steering will be in the
front wheel. centre (neutral) position (if so dition.
Camber is the amount the front equipped). Measure the dis-
wheels are tilted at the top (Fig. 7). tance between the extreme front and SLEEVE
also between the extreme rear of both
If a wheel tilts outward, camber is front tyres. The difference between
positive. If a wheel tilts inward, cam- these two distances is the toe-in.
ber is negative. The correct camber
anaJe, or outward (positive) tilt, is Correct toe-in, or inward pointing
specified in Part 3· 7. The maximum of both front wheels at the front, is
difference between both front wheel specified in Part 3-7.
camber angles should not exceed 'h o.
FRONT WHEEL TURNING
However, a difference of not more
than lA o is preferred. ANGLE
When the inside wheel is turned
TOE-IN 20°, the turning angle of the outside CLAMP BOLTS
wheel should be as specified in Part
Alignment height spacers are not 3-7. The turning angle cannot be ad-
used to check and adjust toe-in. Toe- justed directly, because it is a result FIG. 9- Spindle Connecting
in should only be checked and ad- of the combination of caster, camber, Rod Sleeve-Typical

CASTER ADJUSTMENT STRUT

FIG. 8- Caster and Camber Adjustments

3-6 GROUP 3- SUSPENSION, STEERING, WHEELS & lYRES

TABLE 1-Troublt Symptoms and Possible Causes

POSSIIU CAUSES OP 'lllOUIU

J
I I
J I
e

I!.,. I .. w

Ij
';
] ! 1
•i
~ J . 1
l I
•
1 i J I i I i J
• ! I I
:1 •
t
• •
J ...tI
I J J f f1 • a :;:1 f 1 :1• .
• a&
a&
I I

f J
0

_.I l ! J a • ! f ! 1 j ... . •
l a.•
~
0
15
• • ~ • •
l. 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 X
4. Power Steering Fluid level low-leak X X X X
5. Saaing or Broken Spring X X X X X X X
6. Glazed, loose or Broken Power Steering Pump Belt X X X X
7. Rear Spring Tie Bolt Off Center X X X
8. Broken Rear Spring Tie Bolts X X X X X X X
9. Rear Spring Front Hanger Mislocated X X X
10. Bent Spindle Arm X X X X
11. Bent Spindle X X X X
12. Lack of Lubrication X X X X X
13. Air in Power Steerin& System X X X X
14. Obstruction in Power Steering Lines X X X
15. Loose or Weak Shock Absorber X X X X X X
16. Loose or Worn Suspension Arm Bushings X X X X
17. Binding Front Suspension Ball Joints or Steering Linkage X X X X X X
18. Loose, Worn, or Damaged Steering Linkage or Connections X X X X X X X
19. Loose Steering Gear Mountings X X X X X
20. Insufficient Steering Pump Pressure X X X
21. Incorrect Steering Gear Adjustment X X X X X X X X X X
22. Incorrect Brake Adjustment X X X X X X
23. Incorrect Front Wheel Bearing Adjustment X X X X X X X
24. Wheel Out of Balance l( X X X
25. Incorrect Front Wheel Alignment X X X X X X X X
26. Out-of-Round Wheel or Brake Drum X X X
27. Frame or Underbody Out of Alignment X X X
28. Bent Rear Axle Housing X X X X
29. Excessive Wear of Steering Pump Internal Parts X X
30. Steering Gear Valve Spool Binding X X X X
31. Obstruction Within Steering Gear X X X X
PART 3-1- SUSPENSION. STEERING. WHEELS & lYRES GENERAL SERVICE 3-7

EJ COMMON ADJUSTMENTS AND REPAIRS

After front wheel alignment factors gauge readings with the wheels downward position before attempting
have been checked, make the neces- positioned 20 o each way from the to turn the eccentric adjuster. Rotate
sary adjustments. Do not attempt to straight ahead position. the bolt and eccentric clockwise from
adjust the front wheel alignment by Caster is controlled by the front the high position to increase camber
bending the suspension or steerln1 suspension strut (Fig. 8). To obtain or counterclockwise to decrease
,....cs. . positive caster, loosen the strut camber.
rear nut and tighten the strut front After the caster and camber has
CASTER AND CAMIIR nut against the bushing. To obtain
ADJUSTMENTS been adjusted to specification, torque
negative caster, loosen the strut the lower arm eccentric bolt nut and
Precaution should be taken when front nut and tighten the strut rear the strut front nut to specification.
checking the front .wheel alignment. nut against the bushing.
TOE-IN AND STEERING WHEEL
When carrying out the check of Note: Always loosen the appropriate ALIGNMENT ADJUSTMENTS
caster angle, it is possible that the nut fir.st before attempting to Check the steering wheel spoke po-
lower strut arm· bushes may not adjust Caster, to avoid sition when the front wheels are in
always be under equal compression collapsing the tube between the the straiaht-ahead position. If the
and therefore, will tend to bias the washers or damaging · the spokes are not in their normal posi-
strut rod in a forward or rearward serrated nut. tion, they can be properly adjusted
position, thus afFecting the steering while toe-in is being adjusted.
caster angle when the wheels are Camber is controlled by the ec-
centric cam located at the lower arm 1. Loosen the two clamp bolts on
turned through their checking posi- each spindle connecting rod sleeve
tions. attachment to the side rail (Fig. 8).
To adjust the camber, loosen the ec- (Fig. 9).
It is essential that whenever the centric bolt nut and spread the re- 2. Adjust toe-in. If the steering
steering caster angle is checked, that taining body bracket sufficiently to. wheel spokes are in their normal
the distance from the strut brac- allow unrestricted lateral movement position, lengthen or shorten both
ket to each of the washers is the of the arm assembly in relation to the rods equally to obtain correct toe-in
same. When checking the caster body bracket. Raise the car by (Fig. 10). If the steering wheel
angle it is mandatory that the strut placingajack under the subframe and spokes are not in their normal posi-
rubbers are centralised before taking allow the suspension to take a full tion, make the necessary rod adjust-

ru•N DOWNWA.D TO TUIN TUIN UPWAID TO

INC.EASE •oo LENGTH TUIN UI'WARD DOWNWARD INCREASE 100 LENGTH
TO DEC.EASE TO DEC.EASE

~~~lj.3 2" «~ RIGHT-HAND SUIYI P1Da7·1

Lin-HAND ILIIVI

FIG. 1 0 -Spindle Connecting Rod Adiustment

WHEN TOE-IN IS CORRECT TURN BOTH CONNECTING ROD
TURN BOTH CONNECliNG ROO SLEEVES DOWNWARD TO
SLEEVES UPWARD TO ADJUST ADJUST SPOKE POSITION
SPOKE POSITION

WHEN TOE-IN
NOT CORRECT
IS~
LENGTHEN LEFT ROD TO LENGIITEN RIGHT ROD
INCREASE TOE -IN
TO INCREASE TOE -IN
SHORTEN RIGHT ROD
TO DECREASE TOE . IN

ADJUST BOTH RODS EQUALLY TO MAINTAIN NORMAL SPOKE POSITION

FIG. 11 -Toe-In and Steering Wheel Spoke Adiustments-

3-8 GROUP 3- SUSPENSION, STEERING, WHEELS & TYRES
ments to obtain correct toe-in and torque the clamp bolts on both con· J. Remove the lower cover-to-
steering · wheel spoke alignment necting rod sleeves to specification. housing attaching bolt.
(Fig. 11). . The sleeve position should be, as 4. With a deaa punch or like in·
J. Recheck toe-in and steering shown in Fig. 12 when the clamp strument, clean out or push inward
wheel spoke alignment. If toe-in is bolts are tightened. the loose ftuid in the filler plug
correct and the steering wheel spokes STEERING GEAR FLUID hole and cover to housina attacbina
are still not in their normal position, CHECKING PROCEDURE MANUAL bolt hole. ·
turn both connecting rod sleeves up- 1. ~nter the steering wheel. 5. Slowly tum the steering wheel
ward or downward the same number l. Remove the steering gear hous· to the right stop, fluid should rise
of turns to move the steering wheel ing filler plug. within the lower cover bolt hole; then
spokes (Fig. 11 ). . · slowly turn the steering wheel to the
4. When toe·m and steering wheel left stop, fluid should rise with-
spoke alignment are both correct. in the filler plug hole. If fluid

FIG. 12 -Typical Manual Steering Linkage

PART 3-1- SUSPENSION. STEERING. WHEELS & TYRES GENERAL SERVICE 3-9
STEERING GEAR FLUID CHECKING PROCEDURE (POWER).
does not rise as specified, further Run the engine until the fluid is at Check the fluid level in the power
lubricant should be added until a normal operating temperature {165 steering reservoir. The level must show
lubricant rise is observed. degrees F to 175 degrees F). Then on the cross hatching between the
8. Install the lower cover-to-hous- turn the steering wheel all the way to bottom of the Dipstick and the full
ing attaching bolt and the filler plug. the left and right several times, and mark (Fig. 1). If the level is low, add
shut off the engine. automatic transmission fluid M2C33F.
Do not overfill the reservoir.

·EJ CLEANING AND INSPECTION

mERINO GEAR CUANING 6. While approximately two quarts TESTING

AND INSPECnON of steering gear fluid are being To check a shock absorber re-
Wash all parts in a cleaning sol- poured into the reservoir, tum the moved from a car proceed as fol·
vent and dry with a lint-free cloth. engine over using the ignition key, lows:
Tile bearlq lhould aot be spun dry at the same time cycle the steering 1. Hold the shock absorber in the
wltb eomprelled *·Inspect the shaft wheel from stop to stop. vertical position w i t h the piston
and worm for scoring, cracks or 7. As soon as all of the fluid has in the same position, push in the pis-
checks, and for straightness .of the been poured in, tum off the ignition ton rod until the shock is extended to
abaft. Check the splines and the key, and attach the coil wire. its full length.
threads on the sector shaft for wear 2. With the shock absorber held
and burn. Inspect the gear teeth for I. Remove the plug from the res-
ervoir return pipe, and attach the re- in the same position, push in the pis·
scoring, pitting and other wear. In- ton rod until the .shock is compressed
spect the ball bearings for free move- turn hose to the reservoir.
9. Check the reservoir fluid level; to its shortest length.
ment, and the cups for wear or irreg-
ular surfaces. Check the housing for if low add fluid to the proper level. 3, Repeat steps 1 and 2 several
cracks and the sector shaft needle Do not overftll. times until all the air is expelled.
bearing ·for free movement or other 10. Lower the car. 4. Clamp the lower end (small di·
wear. 11. Start the engine and cycle the ameter) in a vise in a vertical posi·
Check the power steering pump steering wheel from stop to stop to tion.
pressures. If the pump pressures are expel any trapped air from the sys- S. Extend the shock to its full
not to specification and there are no tem. length and then compress it to its
external fluid leaks, replace the pump. shortest length. There should be a
If the pump has a visible leak, replace constant drag during the complete
the reservoir seal, outlet valve seals, FRONT END GENERAL cycle. Any sudden loss of drag indi·
or support stud seal, whichever is re· INSPECTION cates air in the system, loss of fluid,
quired. or faulty internal valve operation.
Check for damage that would af- Replace defective shock absorbers.
fLUSHING THE POWER fect the runout of the wheels. Wob-
SBERING SYSTEM ble or shimmy caused by a damaged
wheel will cause premature tyre wear UPPER BALL JOINT INSPECTION
Should a power steering pump be·
come inoperative, the shaft and pul- and eventually damage the wheel 1. Raise the car on a frame con-
ley should be checked for freedom of bearings. Inspect the wheel rims for tact hoist or by ftoor jacjcs placed
rotation. If the pump shaft does not dents that could permit air to leak beneath the underbody until the
tum freely (binding), it is 8.!1 indica- from the tyrea wheel falls to the full down posi-
tiel' that there is wear on the pump . tion as shown in Fig. 13. This will
internal components and the need for unload the upper ball joint.
WHEEL BALANCING
flushing the steering system. when in- See the instructions provided with l. Adjust the wheel bearings al>
stalling a new pump. described in
the .Wheel Balancer.
1. Remove the power steering
pump and pulley as outlined in page 3. Attach a dial indicator to the
3-26. SHOCK ABSORBERS upper arm.
Passenger cars and station wagons 4. With the dial indicator at-
2. Install a new pump and connect are equipped with hydraulic shock ab- tached to the upper arm, position
only the pressure hose to the pump sorbers of the direct-acting type and the indicator so that the plunger
(page 3-26). are nonadjustable and nonrefillable, rests against the inner side of the
3. Place the oil return line in a and cannot be repaired. wheel rim adjacent to the upper
suitable container and plug the re- Before replacing a shock absorber, arm ball joint.
servoir return pipe. check the action of the shock ab- 5. Grasp the tyre at the top and
4. Fill the reservoir with fluid sorbers by grasping the bumper and bottom, and slowly move the tyre
M2C33-F. jouncing the car up and down. If the in and out (Fig. 13). Note the read-
shock absorbers are in good condi· ing (radial play) on the dial indica-
S. Disconnect the coil wire to pre- tion the car will immediately settle to tor. If the reading exceeds specifi·
vent the engine from starting and a normal position after the bumper is ~.:ations {l'art 3-1), replace the upper
raise the front wheels off the ground released. ball j~int.
3-10 GROUP 3- SUSPENSION, STEERING, WHEELS & lYRES

LOWER BALL JOINT INSPECTION

1. Raise the car on a frame con-

tact hoist or by floor jacks placed
beneath the underbody until the
wheel falls to the full down posi-
tion.
FIG 13 -Measurln1 Upper Ball
Joint Radial Play
l. Ask an assistant to grasp the
lower edge of the tyre and move
the wheel in and out.
Durln1 the forqolaa cbeck, tbe 4. Any movement between the
upper ball joint wiD be unloaded lower end of the spindle and the
and may move, Disreprd aU sucb lower arm indicates ball joint wear
3. As the wheel is being moved monmeat of the upper ban )oillt. and loss of preload. If any such
in and out, observe the lower end Also, do not mistake loose wbeel movement is observed, replace the
of the spindle and the lower arm. bearin1s for a wom baU joint. lower arm.
3-11

PART SUSPENSION
3·2
Sectioa Page Section Pa1e
Lowel' Arm Strut and/ or Bushing
1 Description &: Operation ...... ...... ...... ...... 3-11
Replacement ...... ...... -.... ...... ...... ...... ...... 3-13
Front Suspension ,_... ...... ...... ...... ...... ...... 3-11
3 Removal & Installation-Front Spring ...... 3-13
Rear Suspension ...... . .... ...... ...... ...... ...... 3-12
Front Suspension Upper Arm ...... ...... ...... ...... 3-14
2 In-Car Adjustments &: Repairs ...... ...... ...... 3-12 Front Wheel Spindle Drum Brakes ...... ...... 3-15
Upper Ball Joint Replacement ...... ...... ...... ...... 3-12 Front Wheel Spindle Disc Brakes ...... ...... ...... 3-16
Upper Arm Shaft and/ or Bushing Front Shock Absorber ...... ...... ...... .. .... .... .. ...... 3-16
Replacement .. .... .. .... .. .. .. .. .. .. .. .... .... .. ...... 3-12 Rear Shock Absorber ...... ...... ...... ...... ...... ...... 3-17
Stabilizer Replacement ...... ...... ...... ...... ...... 3-13 Rear Spring and/ or Bushing ...... ... ... .. .... 3-17

D DESCRIPTION AND OPERATION

fRONT SUSPINSION
Each front wheel rotates on a
spindle. The upper and lower ends of
the spindle are attached to upper and
lower ball joints which are mounted
to an upper and lower arm respective-
ly. The upper arm pivots on a bush·
inJ and shaft assembly which is bolted
to the underbody. The lower arm
pivots on a bolt that il located in an
underbody bracket (Fip. 14 and 22 ).
A coil sprina seats between the up-
per arm and the top of the sprina
housina. A double actina shock ab-
sorber is bolted to the arm and the
top of the sprina housina.
The swivelina action of the ball
joints allow the wheel and spindle as-
semblies to move up and down with
chanaes in road surface. The swivel-
ina ball joints also permit the spindles
and wheels to be tumed to the left or
riaht by the steerinaaear and linkage.
The pivotin~ action of the suspen-
sion arms provides an up ad dowa
movement for the spindles and wheels
as required by bumps or depressions
in the road surface. The coil sprinp,
shock absorbers and stabilizer bar
control the front suspension up and
down movements. The struts, which
are connected between the suspension
RETAINING BOLT
lower arms and the underbody pre-
vent the suspension arms from mov-
ina forward and backward. FIG. 14-lront Suspension-Typical
3-12 GROUP 3- SUSPENSION, STEERING, WHEELS & TYRES
pads integral with the axle housing
rest on a spring plate and rubber
insulator. These are located on two
leaf-type springs. The axle housing
is fastened to the springs by spring
clips (U-bolts), spring clip plates
and nuts. (Figs. 16 and 26.) Each
spring is suspended from the under-
body: side rail by a hanger at the
front and shackle at the rear: The
upper end of each shock absorber
is mounted to a bracket in the
. underbody. The lower end is moun-
ted to the spring clip plate.
The springs and shock absorbers
provide for up and down movement
of the rear axle and wheels as re-
quired by changes in the road sur-
face. They also cushion road shocks.
REAR SUSPENSION Falcon vehicles fitted with the
Each rear wheel hub and brake 351 CID engine and improved hand-
FIG. 15 -Rear Suspension-Typical drum assembly is bolted to the ling suspension and the GT Falcon
rear axle shaft flange. The wheel are fitted with rear axle radius rods
and axle shaft assembly rotates in to give more positive location under
the rear axle housing. Two spring heavy acceleration.

EJ IN-CAR ADJUSTMENTS AND REPAIRS

HOISTING INSTRUCTIONS
UPPER BALL
Damage to suspension and/ or the ball joint to the upper arm and JOINT STUD ARM SUPPORT
steering linkage components may oc- remove the ball joint.
cur if care is not exercised when po- 7. Clean the end of the arm, and
sitioning the hoist adapters of 2 post remove all burrs from the hole edges.
hoists prior to lifting the car. Check for cracks in the metal at the
If a 2 post hoist is used to lift the holes, and replace the arm if it is
car, place the adapters under the cracked.
front suspension lower arms. Do not 8. Attach the new ball joint to the
aDow the adapten to contact the upper arm. Use only the bolts, nuts,
steeringllnkaae. and washers supplied in the kit. Do
not rivet the new ball joint to the
arm. Torque the nut~ to specification
UPPER IALL JOINT
REPLACEMENT
9. Position the ball joint stud in
1. Position .a support between the the spindle bore, and torque the re-
upper arm and frame side rail as taining nut to specification. Install a
shown in Fig16, then, raise the car new cotter pin, tighten the nut if nec-
and position safety stands. essary to line up the cotter pin hole.
l. Remove ·the wheel and tire. FIG. 17 -Loosening Ball Joint
3. Remove the cotter pin and nut Studs in Spindle-Typical
from the upper ball joint stud.
4. Position the ball joint remover 10. Lubricate the ball joint, and
tool as shown in Fig. 17. The tool install the wheel and tire. Torque the
should seat firmly against the ends of lug nuts to specification
both studs, and not against the lower . 11. Remove the safety stands, and
stud nut. It may be necessary to re-
lower the car.
move the lower ball joint cotter pin
if it prevents the tool from seating on 12. Remove the support from be-
the lower stud. tween the upper arm and frame.
5. Turn the tool with a wrench 13. Check and, if necessary, adjust
until both studs are under tension, caster, camber, and toe-ln.
and then, with a hammer, tap the
spindle near the upper stud to loosen
the stud from the spindle. Do not UPPER ARM SHAn AND/OR
loosen the stud with tool pressure BUSHING RELACEMENT
alone. Raise the stud out of the 1. Remove the shock absorber and
WOOD BLOCK upper mounting bracket as an assem-
spindle bore.
6. Drill the three rivets retaining FIG. 16 Upper Arm Support bly.
PART 3-2- SUSPENSION 3-13

2. Raise the car on a hoist, install 11. Position the spacer parallel STABILIZER REPLACEMENT
safety stands, and remove the wheel with the inner shaft, and force the 1. Raise the car high enough to
cover or hub cap. spacer between the flanges of the up- provide working space, and place sup-
· 3. Remove the grease cap from the per arm (Fig.19l ports under both front wheels.
hub; then, remove the cotter pin, nut If the spacer can not be forced be- 2. Disconnect the stabilizer from
lock, adjusting nut and outer bearing tween the arm flanges due to exces- each link. Disconnect both stabilizer
from the hub. sive distortion, replace the upper arm retaining brackets, and remove the
4. Pull the wheel, tire, and the hub assembly. stabilizer.
and drum off the spindle as an assem- 12. With the spacer positioned in 3. Coat the necessary parts of
bly. the arm, torque the bushings to speci- the stabilizer with rubber lubricant,
5. Install the spring compressor, fication. Move the arm on the shaft and slide new insulators onto the
Tool 5310-A and compress the to be sure that no binding exists, then stabilizer.
spring (Fig. 20.21 ). remove the spacer. 4. Connect the stabilizer retaining
13•. Connect the suspension ·u pper brackets, and connect the stabilizer to
6. Remove 2 upper arm to spring arm to the underbody, and release both links. Torque the bracket retain-
tower retaining nuts and swing the the front spring. ing screws and the link bolt nut to
upper arm outboard from the spring specification.
tower. 14. Remove the spring compressor
and position the wheel, tire, and hub S. Remove the supports and lower
7. Rotate the inner shaft so that the car.
the retaining studs can be removed. and drum on the spindle.
8. Unscrew the bushings from the 15. Install the bearing, washer, ad-
shaft and suspension arm; then, re- ju'lting nut and nut lock. Adjust the
move the shaft from the arm. wheel bearing as outlined on page LOWER ARM STRUT AND /OR
9. Position the shaft in the arm, 3-48 BUSHING REPLACEMENT
apply grease to the new bushings and
0-rings, and install the bushings loose
on the shaft and arm. Tum the bush·
lap 10 that the shalt II e:udly cea· Removal
tered lD the arm. The shaft will be 1. Raise the car and install safety
properly centered when dimensions stands.
A and B in FiJ.18 are equal. . 2. Remove the lower arm strut
front retaining nut, washer and bush-
ing at the frame bracket (Fig. 22).
3. Remove 2 bolts and nuts at-
taching the strut to the lower arm
and remove the strut.
4. Remo"e the bushing, washer
and nut from the strut.

Installation
1. Install the rear nut, washer and
bushing on the strut.
2. Position the strut to the front
bushing bracket and to the lower arm.
Install the strut to lower arm attach-
FIG. 19-Torque Upper Ann ing bolts and nuts and torque to spec-
Inner Shaft Bushings-Typical ification.
3. Position the strut front bushing
FIG. 18-Shaft Centered in and install the cotter pin, grease cap and washer on the strut and install
Ann-Typical and hub cap or wheel cover. the adjusting nut.
16. Lower the car and install the 4. Tighten the strut adjusting nuts
10. Fabricate a spacer 8 1/16" shock absorber and upper mounting against the strut frame bracket.
long from a section of ~-inch dia- bracket. S. L.>wer the car and check caster,
meter pipe or metal of comparable 17. Check· caster, camber, and toe- camber and toe-in and adjust as nec-
size and strength. in and adjust as necessary essary.

EJ REMOVAL AND INSTALLATION

hoists prior to lifting the car. FRONT SPRING
HOISTING INSTRUCnONS
If a 2 post hoist is used to lift the
Damage to suspension and I or car, place the adapters under the Removal
steering linkage components. may oc- front suspension lower arms. Do aot 1. Remove the shock absorber and
cur if care is not exercised when po- .Uow the adapten to .:oatact the upper mountina bracket as an as-
sitionina the hoist adapters of 2 post steerlacJiDkaae. sembly.
3-14 GROUP 3- SUSPENSION, STEERING, WHEELS & TYRES

1. Raise the car on a hoist, install

safety stands, and remove the wheel
cover or hub cap .
. 3. Remove the grease cap from
the hub; then, remove the cotter pin,
nut lock, adjusting nut and outer
bearing from the hub.
4. Remove the wheel and tyre
assembly.
5. Install the spring compressor,
Tool 5310-A (Fig.20), and compress
the spring (Fig.21).
6. Remove 2 upper arm to spring
tower retaining nuts and swing the
upper arm outboard from the spring
tower (Fig. 211 .
7. Release the spring compressor
tool and remove the tool from the
spring. Then, remove the spring from
the car
Installation
1. Place the spring upper insulator
on the spring and secure in place with
tape.
2. Position the spring in the spring
tower. Install the spring compressor
Tool 5310-A and compress the SJI().A SJI().A ORB
spring.
3. Swing the upper arm inboard FIG. 20 -Spring Compressor Installed-Upper View -Typical
and insert the bolts through t:te holes
in the side of the spring tower. Then,
install the retaining nuts and torque
. them to specification. 4. Install the spring compressor, remove the spring pivot from the up-
4. Release the spring pressure and using Tool 53 lO-A, and compress the per arm.
spring (Fig.20.21 ). Installation
guide the spring into the upper arm
spring seat. The end of the spring 5. Remove the cotter pin from the 1. Position the spring pivot to the
must seat against the tab on the upper ball joint stud and loosen the upper arm and install the 2 attaching
spring seat. stud nut. bolts and nuts. Torque the nuts to
5. Remove the spring compressor 6. Position the ball joint remover specification.
and position the wheel, tyre and hub tool as shown in Fig. 17. The tool 1. Position the upper arm to the
and drum on the spindle. should seat firmly against the ends of !lpring tower and the ball joint stud
6. Install the bearing, washer, ad- both studs and not against the lower to the spindle. Install but do not
justing nut a:jd nut lock. Adjust the stud nut. It may be necessary to re- tighten the ball joint stud nut.
wheel bearing as outlined on page 3-48 move the lower ball joint cotter pin if 3. Position the upper arm · to
and install the cotter pin, grease cap, it prevents the tool from seating on spring tower and install the washers
and hub cap or wheel cover. the stud. and retait~ing nuts. Torque the nuts
7. Lower the car and install the 7. Turn the tool with a wrench un- to specification.
shock absorber and upper mounting til both studs are under tension; then, 4. Release the spring compressor
bracket. tap the spindle near the upper stud tool while aligning the spring with
8. Check caster, camber, and toe- with a hammer to loosen the stud the upper arm spring pivot. Then, re-
in and adjust as necessary from the spin(JJe. Do not loosen the move the tool.
stud with tool pressure alone. 5. Torque the ball joint stud nut
FRONT SUSPENSION UPPER 8. R :move the ball joint remover to specification Part 3·7. Continue
ARM tool and remove the ball joint stud to tighten the nut until the slots in
nut from the stud. the nut are in line with the hole in
Removal 9. Remove 2 nuts and washers re- the ball joint stud. Then, install a
taining the upper arm to the spring new cotter pin.
· 1. Remove the front shock absorb-
er from the car. tower. Pull the upper arm away from 6. Install the wheel and tyre and
1. Raise the car and install safety the spring tower, lift the ball joint the hub cap or wheel' cover.
stands under the fr,ame side rails. stud from the spindle, and remove 7. Remove the safety stands and
3. Remove the hub cap or wheel the upper arm from the car. lower the car.
cover and the wheel and tyre 10. Remove 2 nuts and bolts and 8. Install the shock absorber.
PART i-2- SUSPENSION 3-15
7. Install the wheel, tyre and hub
and drum on the spindle and adjust
the wheel bearing
8. Install the hub cap or wheel cov-
er, remove the safety stands, and low·
er the car.
9. Check caster, camber, and toe·
in and adjust as necessary.
FRONT WHEEL SPINDLE
DRUM BRAKES
Removal
1. Position a support between
the upper arm and frame as shown
in Fig.16, then, raise the car and
position safety stands.
2. Remove the hub cap or wheel
cover.
3. Remove the grease cap from
the hub; then, remove the adjusting
nut, washer, and outer bearing cone
and roller assembly.
4. Pull the wheel, hub, and drum
assembly off the wheel spindle.
5. Remove the brake carrier plate
from the spindle. Support the plate to
prevent damage to the brake hose.
6. Disconnect the spindle connect-
ing rod end from the spindle arm
FIG. 21 -Compressing Sprin~rlowtr View 7. Remove the cotter pins from
both ball joint stud outs, and loosen
the nuts one or two turns. Do not·re-
FRONT SUSPENSION LOWER 9. Remove the tool and remove JDOYe tiae auCI from the ltuda at tbll
ARM the nut from the lower ball joint stud. dme.
Removal 10. Mark the location of the ec- 8. Position the ball joint remover
centric and eccentric bolt at the low· tool between the upper and lower ball
1. Raise the car and position safe- er arm to underbody attachment.
ty stands under thr. sidt rails. joint studs (Fia. 17 J. The tool
2. Remove the hub cap or wheel
11. Remove the nut, bolt, and ec- lbould seat firmly apbut the eads or
centrics attaching the lower arm to both studs and not apbut the stud
cover. the underbody and remove the low- DUtl. .
3. Remove the wheel, tyre and hub er arm. 9. Tum the tool with a wrench un-
and drum as an assembly.
til the tool plaees the studs under ten·
4. Remove the stabilizer bar link sion, and, with a hammer, tap the
retaining out and remove the wash- Installation
spindle near the studs to loosen them
ers, bushings, spacer, and link bolt 1. Position the lower arm to the in the spindle. Do not loosen the
(Fig. 22). underbody and install the bolt, ec- studs In the spindle with tool ,....
5. Remove the 2 strut to lower centrics, and nut. sure alone.
arm attaching outs and bolts. 2. Position the ball joint stud in the 10. Remove the stud outs and re-
6. Remove the lower bait joint spindle bore and install the r~taioing move the spindle from both studs.
stud nut cotter pin and loosen the out nut.
one or two turns. Do not remove the 3. Adjust the eccentrics to the
nat from lhe stud 8t this dme. previous marked location and torque Installation
7. Position the ball joint remover the nut to specification 1. Position the spindle on the low·
tool between the upper and lower ball 4. Position the strut to the lower er ball joint stud and install the stud
joint studs in the reverse position (up- arm and install the attaching bolts nut (Fig. 22).
side down) from that shown in Fig. and nuts. Torque the nuts to specifi- 2. Raise the lower suspension arm,
17 The tool should seat firmly aplnst cation and guide the upper ball joint stud in·
the ends or both studs and not against 5. Position the stabilizer bar link to the spindle. Install the stud nut.
the stud DUtl. to the lower arm and install the bolt, 3. Torque the upper stud nut and
8. Turn the tool with a wrench un- washers, bushings, spacer, and retain· then the lower stud out to specifica·
til the studs are under tension. Tap ina nut. Torque the nut to specifica- tion. Continue to tighten both nuts
the spindle near the lower stud with a tion until the cotter pin holes and slots
hammer to loosen the stud in the 6. Torque the lower ball joint stud line up. Install new cotter pins.
spindle. Do not l001en lhe stud with nut to specification and 4. Connect the spindle connecting
tool pressure only. install the cotter pin. rod end to the spindle arm.
3-16 GROUP 3- SUSPENSION, STEERING, WHEELS & TYRES

FIG. 22 -Front Suspension Assembly-

5. Install the brake carrier plate 7. Remove the cotter pins from 4. Connect the spindle connecting
on the spindle, and torque the bolts both ball joint stud nuts, and loosen rod end to the spindle arm and install
to specification. the nuts one or two turns. Do not re· the retaining nut. Torque the nut to
6. Install the wheel and drum and move the outs from the studs at this specification and install the cotter
adjust the wheel bearing Page 3-48 time. pin.
7. Remove the safety stands, and 8. Position the ball joint remover 5. Position the splash shield to the
lower the car. tool between the upper and lower ball spindle and install the attaching
I. Remove the support from be· joint studs (FiJ.l7). The tool should bolts and nuts. Torque the nuts and
tween the upper arm and frame. seat firmly against the ends of both bolts to specification.
9. Check and, If necessary, adjust studs and not against the stud outs. 6. Install the hub and disc on the
easter, eamber, and toe·ln. 9. Tum the tool with a wrench un- spindle.
FRONT WHUL SPINDLE til the tool places the studs under ten-
DISC BRAKES sion, and, with a hammer, tap the 7. Position the caliper to the disc
spindle near the studs to loosen them and caliper bracket and install the
Removal in the spindle. Do not loosen the attaching bolts.
1. Remove the hub cap or wheel studs In the spindle with tool pres- 8. Install the wheel and tire on the
cover, and remove the wheel and tire sure alone• • hub and adjust the wheel bearing
from the hub. 10. Position a floor jack under the
2. Remove two bolts attaching lower suspension arm. 9. Install the hub cap or wheel
the caliper to the spindle. 11. Remove the upper and lower cover.
Remove the caliper from the disc ball joint stOd nuts; lower the jack 10. Before driving the car, pump
and wire it to the underbody to pre- and remove the spindle. the brake pedal . several times to
vent damage to the brake hose. obtain normal brake lining to disc
3. Remove the grease cap from Installation clearance and restore normal brake
the hub, then, remove the adjusting 1. Position the spindle on the low- pedal travel.
nu,t, washer, and outer bearing cone er ball joint stud and install the stud
and roller assembly. nut (Fig 22). Torque the nut to
4. Pull the hub and disc assembly specification and install the cotter pin. FRONT SHOCK ABSORBER
off the wheel spindle. 2. Raise the lower suspension arm,
S. Remove four bolts and nuts and and guide the upper ball joint stud in- REMOVAL
remove splash shield from the to the spindle. Install the stud nut. 1. Raise the hood and remove 3
spindle. 3. Torque the nut to specifications shock. absorber upper mounting
6. Disconnect the spindle connect· and install the cotter pin. Then, re- bracket to spring tower retaining
ina rod end from the spindle arm move the floor jack. nuts.
PART 3-2- SUSPENSION 3-17

2. Raise the front of the car and SHOCK ABSORBER ACCESS COVER Installation
place safety stands under the lower 1. Place the inner washer and
arms. bushing on each shock absorber stud.
3. Remove 2 shock absorber lower 2. Expand the shock absorber and
retaining nuts and washers (Fig. 23 ). position it to the spring clip plate and
4. Lift the shock absorber and up- to the mounting in the floor pan.
per bracket from the spring tower 3. Connect the lower stud to the
(Fig. 23 ) and remove the bracket spring clip plate, and install the bush-
from the shock absorber. ing, washer, and nut on the stud (Fig.
261. Be sure tbe spring clip plate Is
free of bum. Tighten the nut to
specification.
4. From the luggage compart-
ment, install the bushing washer and
retaining nut to the upper mounting ·
stud (Fig. 2 5) . Torque to specifica-
tion. On a station wagon, replace the
fioor bed panel
5. Place the spare wheel and tyrE
in the luggage compartment, and se-
LUGGAGE COMPARTMENT cure it in the storage position.
FLOOR PANEL
REAR SPRING AND/OR
FIG. 24 -Rear Shock BUSHING
Absorber Access Cover REMOVAL
. 1. Raise the car on a hoist and
REAR SHOCK ~ ABSORBER- place supports beneath the underbody
Removal and under the axle.
1. Open the luggage compartment 2. Disconnect the lower end of
door, and remove the spare wheel and the shock absorber from the spring
tyre On a station wagon, remove the clip plate, and push the shock out of
floor bed panel. . the way.
2. Fold back the floor mat and 3. Remove the spring clip plate
nuts from the U-bolts; then, remove
remove the shock absorber access
the plate (Fig. 2 6 ).
cover from the floor pan. Rerr..ove the
4. Remove the two retaining nuts,
nut, outer washer, and rubber bush-
the rear shackle bar, and the two
ing that retain the shock absorber to
shackle inner bushings.
the upper mounting in the floor pan
5. Remove the rear shackle assem-
(Fig. 25).
bly and the two outer bushings.
6. Remove the front hanger bolt,
FIG. 23 -Removing or nut, and washer from the eye at the
Installing Front Shock forward end of the spring. Lift out
Absorber-Typical the spring assembly.
7. If the front bushing is being re-
placed, assemble the special tool com-
. '
bination to the bushing in the spring
INSTALLATION front eye as shown in Fig. 27.
'l?~
. <?
1. Install the upper mounting ~ i_J.~. . .
8. While holding the tool nut,
bracket on the shock absorber and tighten the tool bolt against the tool
torque to specification. ;~fi·.'-.
~·. ..•.~·
JL.. _ thrust washer, the adapter, and de-
ACCESS COVER F1155-A
2. Position the shock absorber and tail Al. This operation will force the
upper mounting bracket in the spring FIG. 25 -Rear Shock bushing out of the spring eye into de-
tower, making sure the shock ab- tail A4 of the tool as shown.
sorber lower studs are in the pivot
Absorber Upper Mounting - Typical
plate holes. 3. Raise the car and remove the re-
J. Install the 2 washers a'Dd re- taining nut, outer washer and bush· INSTALLATION
taining nuts on the shock absorber ing from the shock absorber at the 1. Assemble the bushing and the
lower studs and torque to specifica- spring clip plate (Fig. 26). Compress spec1al tool combination to the spring
tion. the shock absorber and remove it front eye as shown in Fig. 28.
4. Install the 3 shock absorber up· from the car. 2. While holding the tool nut, tight·
per mounting bracket to spring towet 4. If the shock absorber is serv- en the tool bolt against the tool thrust
retaining nuts and torque to specifica- iceable and requires new bushings re- washer, adapter, and detail A4 to
tion. Then, remove the safety stands move the inner bushings and washers force the bushing into the spring eye
and lower the car. from the shock absorber studs. as shown.
3-18 GROUP 3- SUSPENSION, STEERING, WHEELS & lYRES

Utility and Van .

FIG. 26 -Rear Spring & Shock Absorber Typical ·

PART 3-2- SUSPENSION 3-19

3. Position the spiina under the

rear axle and insert the shackle as-
sembly into the rear hanaer bracket
and the rear eye of the sprina.
4. Install the shackle inner bush-
inp, the shackle plate, and the lock-
nuts. TiJhten the locknuts finaer
tiaht.
5• Position the ipriog front eye in .5781-84 (n,,., Wash«)
the front hanaer, slip the washer on
the front hanaer bolt, and (from the FIG. 27 -Re• Spring Front Bushing Removal-Typical
inboard aide) insert the bolt throuah
the hanaer and eye. Install the lock
out on me: UIWIJCr oon ana tiahten
ftnaer tisht.
'- Torque the rear shackle lock-
nuts to specification.
7. Lower the rear axle until it resta
on the sprioa. Position the sprina clip
plate on ·the clips (U-bolts). Install
the U-bolt outs and torque to specifi-
. cation.
8. Connect the lower end of the
· shock absorber to the sprina clip
plate.
9. Place safety stands under the
rear axle, lower the car until the
sprina is in the approximate curb
load position, and then torque the
front hanger stud . lockout to specifi-
cation.
10. Remove the safety stands and
· )c)wer the car.
FIG. 28 -Rtar Spring Front Bushing Installation-Typical

REAR SUSPENSION RADIUS ROD Installation specification.

Removal 1. Place the front of the radius Note: The rear suspension must be
1. Raise the car on a hoist or jack. rod in the bracket on the body side at curb weight position before torqu-
2. Remove the wheel. member. Insert the attaching bolt ing the attaching bolts to ensure that
3. Remove the front attaching but do not tighten. the bushes are neutralized.
bolt. 2. Place the rear of the radius rod 4. Replace the wheel, torque the
4. Remove the rear attaching from in the axle bracket and insert the wheel nuts to specification and fit
the axle mounting bracket and remove attaching bolt. the hub cap.
the radius rod. 3. Torque both mounting bolts to 5. Lower the car.
3-20

PART
3·3 POWER STEERING
Section Pare
Section Page Power Steering Pump ·r... ...... .. .. .. ...... ...... ...... 3-26
1 Description & Operation .... u .. . ... •. • • . • •••• .• • ... .. 3-20 6 Cylinder Engine ...... ...... ...... ...... ...... 3-26
Operation .. .. ... . ........... .......... ..... ... ....... . 3-21 8 Cylinder Engine .. ... ...... ...... ...... ...... 3-26
Power Steering Pump ..... ...... .... .. ... ... ........... . 3-24 Power Steering Pump Pulley ...... ...... ...... ...... 3-26
J:o'low Control Valve ... ..... ............ ........ . 3-25 4 Major Repair Operations ...... ...... .. .... ...A. ...... 3-26
Pressure Relief Valve ...... ...... ..... . 3-25 Power Steering Gear - Disassembly ..... ..... ..... 3-30
2 In-Car Adjustments & Repairs ..... . 3-25 Inspection & Overhaul of Component Assemblies 3-30
Pump Belt Tension Adjustment ... ·.. 3-25 Sector Shaft Assembly ..... ..... 3-30
Piston Rack ..... ..... ..... ..... 3-31
Worm Valve & Sleeve Assembly 3-31
Power Steering Pump to Steering Box Hoses Reassembly ..... ..... ..... ..... 3-32
&Tubes ............ .. 3-25 Setting Preloads on Steering Gear..... 3-36
3 Removal & Installation 3-25 Fitment of Steering Geat to Vehicle 3-37

D DESCRIPTION AND OPERATION

DESCRIPTION
The Bendix-Bishop Variable Ratio
Integral Steering Gear is an entirely
new unit, and has unique features
designed to reduce steering wheel
turns, increase road 'feel' and sim-
plify maintenance.

The term 'Integral' is used to

denote that the power cylinder and
valve mechanism are incorporated in
the steering gear itself, as distinct
from having a separate booster cylin-
der and valve as with linkage-boosted
gears. The hydraulic oil supplied
from the power steering pump serves
to lubricate the gear mechanism.
No bleeding of this unit is required.

'Variable Ratio' refers to the fact

that steering in the straight-ahead
position is substantially less direct Fig. 29
than in turns, to such an extent that, Bendix-Bishop Variable
whereas four turns of the steering Ratio Steering Gear
wheel would be required if the 'on
centre' ratio were used constantly
from lock to lock; in fact, only 2*
are needed with this system. This
feature is provided by a variable
pitch hourglass worm.
mal driving very little pressure is
Hydraulic oil flows continually required to maintain the flow, and
from the pump mounted on the hence little power is absorbed. When
engine to the steering gear at a turning or parking however, the free
regulated constant flow of about flow of oil is restricted by the rotary
two gallons per minute, but for nor- valve; pressure builds up almost in·
PART 3-3- POWER STEERING 3-21
stantly in the system iUld is directed ROTARY VALVE
by the valve to whichev~r. side of the
power cylinder is appropriate to assist OUTLET
the driver, thus engine power is
absorbed only when needed.

The manual and power sections

of this steering gear are arranged INPUT
one above the other as shown in SHAFT
Figure 30 and have individual ad-
justments for lash. Thus, should wear
occur in the power section of the
gear and not be adjusted, this will LOCKING SPRING
not affect the fine adjustment of the Fig. 30 WORM FOLLOWER
manual section, which feature is im- Steering Gear- Manual Section ADJUSTER
portant in retaining accurate slack-
free steering. The manual section is ACCESS PLUG FOR WORM
FOLLOWER ADJUSTER SCREW
only subjected to very light loads
under all normal circumstances. TOP COVER

The manual section shown in

Figure 31 comprises an hourglass
worm which engages a single roller
follower mounted on needle bearings WORM ADJUSTING
in the sector shaft shown in section SCREW
in this view. The thread of the hour- LOCKNUT----~a. ~~~~~~~~~~
glass worm has a different pitch or
lead in the middle where it controls
the 'on centre' driving ratio, to that
towards the ends, where it controls
the cornering ratio. There are no Fig. 31
sharp changes of ratio so that the
effects of this variation are not dis- Steering Gear
cernible to the driver except as an
overall reduction in wheel turns.
. Between the worm and the input
shaft is located the rotary valve relative rotation between the parts, input shaft and the inner surface
whose function is to sense the appro- not longitudinal sliding as for most of the sleeve. These grooves slightly
priate conditions calling for the app- . valves. The valve as a whole, com- overlap each other when the valve
lication of power assistance. prising an inner member which forms is central. Drilled holes connect the
part of the input shaft, and the slots in the inside of sleeve to the
The hydraulic pump, belt-driven surrounding sleeve member rotates in circumferential grooves referred to
from the engine crankshaft, draws the steering gear housing as the above. When no power assist is called
fluid from the reservoir and provides steering wheel is turned, but it is only for oil from the pump divides equally
fluid pressure for the system. Within a slight relative rotation between the between the right and left turn sets
the pump itself is a pressure-relief shaft and the sleeve that is used to of slots, and there is no resulting
valve which governs the pressures direct and control the flow of oil. pressure difference across the piston.
within the steering system according Oil is communicated to and from As soon as slight relative rotation
to the varying conditions of opera- the valve to the pump and to the occurs however, oil is restricted in its
tion. After fluid has passed from the left and right hand sides of the power free return to the pump and simul-
pump to the steering box it returns assist piston by circumferential groo- taneously directed to the appropriate
to the reservoir. ves separated by the Teflon seals side of the piston, while at the same
in the outside of the sleeve. The time oil on the inoperative side of
The power steering pump is a sleeve is coupled by a pin drive to the the piston is vented to the return line.
slipper type pump which is integral worm while the input shaft is coup- This action is slight at first so that
with the reservoir. It is constructed led to it by a torsion bar. only a small amount of boost is pro-
~o that the reservoir is attached to
vided, but becomes progressively
the rear side of the pump housing greater as the torsion bar flexes and
front plate and the pump body is Operation of the valve in the the driver requires more assist, so
encased within the reservoir. · left turn is shown in Figure 32 that in parking, more than 90% of
where the sleeve and input shaft are the work is done by the oil. In order
both broken away to show the central to effect this graduated increase of
torsion bar. It will be seen that assist, and to give a realistic 'feel'
OPERATION oil flow is directed by a number and good response, the grooves of the
The term 'Rotary valve' is used of longitudinal grooves alternately shaft are precisely metered in a
because valve operation relies on located in the outer surface of the specific form.
J-22 GROUP J- SUSPENSION, STEERING, WHEE:LS & TYRES

r-
1

RACK ADJUSTING SCREW

RACK ADJUSTING PAD

SECTOR SHAFT

Note, that on extreme load con-"'<.£.:~=..-?·-'

ditions or when for any reason the
boost system is inoperative, the tor-
sion bar deflects suffiCiently to allow
the input shaft to drive the hour-
glass worm directly. This is accom- Fig. 32
plished by having a loose fitting Operation of Rotary Valve on Left Turn
spline between the lower end of tht:
input shaft and the surrounding upper
end of the hourglass worm. Naturally
steering loads are high under these
conditions and a noticeable amount
of slack develops due to the flexing
of the torsion bar, but the steering
gear remains entirely operable. In the
interests of safety, the ·car should be
operated in this manner only for the
minimum distance needed to reach a
point where the system . can be ser-
viced.
Figure 32 shows the power section
• of the gear and it will be seen that
the sector shaft, again in section, PUMP
has three teeth formed in it engag-
ing in the combined rack piston.
This rack piston has a spherical form
to the circumference of the piston STEERING ON CENTRE
head and aligns itself in the housing
bore according to the mesh. of the
teeth. These teeth are specially desig-
ned to provide extra turning power
• PUMP OUTPUT
as needed towards the locks and also VIEW TOWARD WORM
are of varying tightness of mesh so • RETURN TO PUMP
that the centre teeth engagement
may be always kept slack-free. Re- • STATIC
action of teeth engagement is taken STEERING GEAR
by a hardened pad adjustably posi-
tioned in the housing. Wear is mirii-
mal at this point and the infrequent
adjustments should only be made
strictly in accordance with the pro-
cedure laid down on page 3-36. Sen- STEERING GEAR
ous damage can result from improper Fig. 33
adjustment. Oil Flow.- Gear on Centre
PART 3· 3- POWER STEERING 3-23

PUMP

STEERING ON RIGHT TURN

• PUMP OUTPUT

D RETURN TO PUMP

STEERING GEAR
Fig. 34 STEERING GEAR
Oil Flow - Gear on Right Turn

PUMP

STEERING ON LEFT TURN

• PUMP OUTPUT

RETURN TO PUMP

STEERING GEAR
Fig. 35
Oil Flow- Gear on Left Turn
3-24 GROUP 3- SUSPENSION, STEERING, WHEELS & lYRES

POWER STEERING PUMP

The pump rotor has 8 slippers and
springs which rotate inside a cam in-
sert containing two lobes 180° from
each other. The cam insert and the
pump port plates provide a sealed
chamber within which the rotor and
slippers rotate between the two lobes
for pump operation. FIG. 36-Power Steering Pump Cycle
As the rotor turns, the slippers are
forced outward against the inner
surface of the cam insert by a com-
bination of centrifugal force, slipper
spring force and fluid pressure acting
on the under side of the slipper. A
pair of adjacent slippers, along with
the surfaces of the rotor, cam and
pressure plates, form a sealed cham-
ber within the crescent-shaped void.
As this sealed chamber moves
throup the crescent shaped void its
volume cbanaes, resultina in a pump-
ina action.
As the rotor rotates 90° (Fig. 36),
the slipper slides outward in its slot,
ridina on 'the cam and the volume of
the sealed chamber increases. This
creates a vacuum and sets up a suc-
tion area. With the inlet port placed
in this are-a, the chamber will fill with
ftuid. As the rotor rotates from 90°
to 180°, the volume of the sealed
chamber decreases, thus creating a
pressure area. The pressure or outlet
port is located in this area. While this
pumpina action is goina on between ORIFICE PLUG
0° and 180°, the same condition is
Gl479·8
occurring between 180° and 360°.
This combination creates what is
known as a balanced rotor pump.
The two pressure and suction quad- FIG. 37 -Power Steering Pump-Sedional View
PART 3-3- POWER STEERING 3-25
rants are diametrically opposite each through passage A into the flo\1{ con- PRESSURE RELIEF VALVE
other. trol zone. All of flow goes through When the steering wheel is turned
the orifice and out into the line until completely to the stop position in the
the bypass port is cracked open: This right or left turn direction, or in the
FLOW CONTROL VALVE is the regulation point. The oil drops case of a road load of sufficient mag-
in pressure in moving through the nitude, the steering gear will not ac-
Since the pump is a constant dis-
orifice. The lower pressure is then cept any flow from the pump, except
placement pump, the internal flow
will vary directly with the pump sensed through a hole drilled in the for a very limited volume of oil due
speed. However, a power steering cover communicating to the rear of to leakage past valve seals. Because
the spool valve. The difference in of this resistance, excessive hydraulic
gear requires a relatively high con-
pressure thus created on the spool pressure would be developed, if it
stant rate of flow in the parking zol!e . valve increases steadily and propor- were not limited by the pressure re-
and up to approximately 2800 RPM tionally with increasing RPM and lief valve.
and thereafter a lower rate of flow. this moves the valve progressively When relief pressure is reached,
This is accomplished by means of a back into its bore, thus increasing the the pressure relief ball is forced off
variable orifice mechanism shown in openmg of the bypass port. its seat, allowing oil to pass through
f-ig. 37. . The metering pin (Fig. 37) travels the spool valve and dump into the
with the spool valve decreasing the bypass port (Fig. 37). The relief valve
All of the internal pump flow is net area of the orifice at higher will continue to limit oil pressure to
ported from the pumping mechanism speeds. This action reduces flow to the relief setting for the duration of
(rotor, slippers, and cam insert), the steering gear. the overload condition.

EJ IN-CAR ADJUSTMENTS AND REPAIRS

· HOISTING INSTRUCTIONS When adjusting the power steering to release the locking tongue and
Damage to suspension and/ or pump belt tension, do not pry against while compressed lever the two legs
steering linkage components may oc- the pump or reservoir to obtain the of the clamp apart with a screw
cur if care is not exercised when posi- proper belt tension. The reservoir will driver. The clamp and insulator may
tioning the hoist adapters of l post be deformed when pried on or now be removed from the tubes.
hoists prior to lifting the car. pressed against and a leak will result. Installation
If a 2 post hoist is used to lift the 3. Recheck the belt tension. When 8. Install the retaining clamps and
car, place the adapters under the the tension has been correctly ad- insulators on the tubes. When installed ·
front suspension lower arms. Do not justed, torque the bolts and the nut on the insulators it is necessary to
aUow the adapten to contact the to specification. compress the clamp sufficiently to
steering linkage, allow the locking tongue to snap into
place.
Pf.lMP BELT TENSION N.B. The fluid return hose must be
AD)UsTMENT POWER STEERING PUMP TO
STEERING BOX HOSES AND in the uppermost position in the in·
Pump drive belt tension cannot sulators when fitted to the car.
be checked accurately using the TUBES
9. Position the tube and hose as-
thumb pressure or belt deflection Removal semblies on the crossmember, insert
methods. Correct belt adjustment is 1. Remove the fluid from the the attaching bolts and torque to
assured only with the use of a belt pump reservoir with a suction gun. specifications.
tension gauge. 2. Disconnect the fluid return and 10. Lower the car.
1. Check the belt tension with a pressure hoses from the steering box 11. Connect the fluid return hose
. belt tension gauge ( 8620-.H). and allow to drain into a pan. and pressure pipe to the steering box.
With a new belt, or one that has been 3. Disconnect the fluid return and 12. Connect the fluid return and
run for less than 10 minutes, the ten- pressure hoses from the pump. pressure hoses to the pump. Torque
sion should be within 120-150 lbs. 4. Raise the car on a hoist. all unions and clamps to specifica·
With a belt that has been run for 5. Remove the two bolts from the tions.
more than 10 minutes, the tension left hand engine mount and one bolt 13. Fill the pump to the correct
should be within 90-120 lbs. from the right hand engine mount level with M2C33F Automatic trans-
2. To adjust the belt, loosen the that attach the three tube clamps to mission fluid.
mounting bolts incorporated on the the crossmember. 14. Start the engine and turn the
front face of the pump cover plate 6. Lower the tubes, clamps and steering wheel to each end of its
(hub side) and one nut at the rear. insulator assemblies from the car. travel several times to cycle the
Place a Ofto inch open end wrench on 7. To remove the clamp and insu- system. Then, check for fluid leaks.
the projecting lh inch boss on the lator assemblies from the tubes it is 15. Stop the engine and check the
front face of the pump cover plate necessary to compress the clamp and power steering fluid level. Add fluid
and pry upward to adjust belt tension. insulator slightly with a pair of pliers as required.
3-26 GROUP 3- SUSPENSION STEERING, WHEELS & lYRES
EJ REMOVAL AND INSTALLATION

HOISnNG INSTRUCTIONS Installation 4. Loosen the belt adjusting baUs

Damage to suspension and/ or 1. Position the pump to the brack- and nut and remove the drive belt
steering linkage components may oc- et and install the 3 retaining bolts. from the pump pulley.
cur if care is not exercised when po- 2. Position the belt on the pulley 5. Remove 3 bolts and 1 nut re-
sitioning the hoist adapters of 2 post and adjust the belt tension to speci- taining the pump to the bracket and
hoists prior to lifting the car. fication. Torque the retaining bolts remove the pump from the car.
If a 2 post hoist is used to lift the to specification.
car, place the adapters under the 3. Torque the outlet fitting hex
front suspension lower arms. Do not Installation
nut to specification. Then, connect the
dow the adapten to contact the pressure hose to the fitting and torque
steertaa llabp. 1. Position the pump to the brack-
the hose nut to specification. et and loosely install the 2 pivot bolts
4. Connect the return hose to the and 2 adjusting bolts.
STEERING GEAR reservOir and tighten the clamp.
Refer to Page 3-46 for detailed 2. Position the drive belt on the
instructions. 5. Fill the pump reservoir to the pulley and adjust the belt tension
correct level with transmission ftuid to specification . · Tighten
POWER STEERING PUMP M2C33F . Start the engine and the adjusting bolts and pivot bolts to
tum the steering wheel to each end specification.
6-CYLINDER of its travel several times to cycle 3. Torque the outlet fitting hex
Removal the system and -.:heck for leaks.
nut to specification. Then, connect ·
1. Remove the filler cap from the Check the fluid level and fill as · the pressure hose to the fitting and
reservoir and remove the ftuid with required and install the filler cap. torque the hose nut to specifiCation.
a suction gun
2. Discono'ect the ftuid return hose 8..CYLINDER 4. Connect the return hose to the
from the reservoir. reservoir and tighten the clamp.
3. DisconneCt the oil pressure hose Removal 5. Fill the pump reservoir to the
from the pump. 1. Remove the fill cap from the correct level with transmission ftuid
4. Loosen the adjusting bolts and reservoir and remove the ftuid with a M2C 33F. Start the engine and
remove the drive belt from the pul- suction gun. tum the steering wheel to each end
ley. 2. Disconnect the ftuid return hose of its travel several times to cycle
5. Remove 3 bolts retaining the from the reservoir. the system and check for leaks. Check
pump to the bracket and remove the 3. Disconnect the oil pressure hose the ftuid level, fill as required, and
pump from the bracket. from the pump. install the filler cap.

a MAJOR REPAIR OPERATIONS

POWER STEERING PUMP INSTALLATION

PULLEY · 1. Position the pulley to the pump
REMOVAL shaft and install fool 3A733-A as
Other tban puDey removal and res- shown in Fig. 39
ervoir or seal replacement, the pump 2. Hold pump and rotate the tool
should not be disassembled but re· nut clockwise to install the pulley on
placed as a unit. the shaft. The pulley will be ftush
1. Drain as much of the ftuid as with ·the end of the pump shaft. In-
possible from the pump through the stall the pulley without in and out
fill pipe. pressure on the shaft to prevent
2. Install a %-16 capscrew in the damage to internal thrust areas.
end of the pump shaft to prevent 3. Remove the tool.
damage to the shaft end by the tool
screw.
3. Install the pulley remover tool,
T63L-10300-B on the pulley hub,
and place the tool and pump in a
vise as shown in Fig. 38
4. Hold the pump and rotate the
tool nut counterclockwise to remove FIG. 38- Removing Power
the pulley Fig. 38 . Steering Pump Pulley
PART 3·)- POWER STEERING 3-27
reservoir by tapping around the 6. Position the service indentifica-
flange with a wood block Fig. 40 tion tag on the outlet fitting and in·.
4. Remove the reservoir 0-ring stall the outlet fitting hex nut. Torque
seal, the outlet fitting gasket, and the out to specification (Part 3-7).
the support stud copper gasket from Do not exceed specificadon.
the pump. 7. Install the stud out and torque
to specification.
INSTALLATION
1. Install a new gasket on the out-
let fitting, a new copper gasket on OUTLET FITTING
the support stud, and a new reservoir GASKET
0-ring seal on the pump housing
plate Fig. 41. The old gaskets and
leal lbould never be re-used.
2. Apply vaseline to the reservoir
0-ring seal and to tbe inside edge of
the new reservoir flange. Do not
twist the 0-ring seaL
3. Position the reservoir over the
pump and align the reservoir with
the outlet fitting and the stud hole.
4. Install the reser,.oir on the
pump and 0-ring seal with a plastic
or rubber hammer and a block of
wood as shown in Fig. 42 . Tap at
FIG. 39- Installing Power Too/ T57L SOO·A
Steering Pump Pulley
FIG. 41 -Gasket Locations
POWER STEERING PUMP
RESERVOIR REPLACEMENT
Reservoir replacement must be
done on a clean workbench. Clean-
liness of work area and tools is
extremely important when repairing
any hydraulic unit. Thoroughly clean
the exterior of the pump with a
suitable cleaning solvent. Do not 1Jn.
merse tbe shaft oil leal In IOivat.
Plug the inlet and outlet openings
with plugs or masking tape before
cleaning the pump exterior or re-
moving the reservoir.
REMOVAL
FIG. 40' -Removing Pump
1. Position the pump in a bench
mounted holding fixture, Reservoir

2. Rotate the pump so the pulley

aide is facio& down and remove the tbe rear of the reservoir and on the
outlet fittin& hex nut. stud nuts, and outer edges only.
service identification tag. !. Inspect the assembly to be sure
3. Invert the pump so the pulley the reservoir is evenly seated on the FIG. 42 -Installing Reservoir
side is facio& up and remove the pump housing plate. on Pump -Typical
w
~
ASSEMBLY 19 COMPRISES 1.2.3A.5.6.7.89JOJ I AND 18
6

ASSEMBLY 34 COMPRISES 22.23.2<4.35.36. AND 65

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ASSEMBLY

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PART 3-3- POWER STEERING 3-29

1. Collar - Thrust. 35. Housing.

2. Ring- Spacer. 36. Bearing - Sector Shaft.
3. Race- Thrust. 37. Seal - Sector Shaft.
4. Follower - Wonn. 38. Ring- Seal Back-up.
S. Sleeve- Eccentric. 39. Clip- Retainer.
6. Needle Roller. 41. Dust Excluder- Sector Shaft.
7. Adjuster- Eccentric Sleeve. 42. Locknut - Bearing Adjusting Screw.
8. Sector Shaft. 43. Screw- Bearin~ Adjusting.
. 9. Screw -Adjusting. 44. Seal- Be11:• l Adjusting Nut .
10. Clip- Adjusting Screw Locking. 45. Race - ..l!eanng.
11. Screw- Drive. 46. Cage - Bearing.
12. Cover and Bush Assy. 47. Wonn.
13. Cover. 48. Wonn, Valve and Sleeve Assy.
14. Screw and Lockwasher Assy.- Cov~r. 49. Shim.
15. Plug- Cover. SO. Seal - Coupling Sleeve.
16. Seal -Cover. 51. Sleeve - Coupling.
17. Bush - Bearing. 52. Ring- Coupling Sleeve Retaining.
18. Pin. 53. Seal - Sleeve.
19. Sector Shaft and Follower Assy. 54. Pin - Sleeve Drive.
22. Ball - Sealing. 55. Sleeve.
23. Tube- Outlet Connection. 56. Seal- Sleeve.
24. Seat - Inlet Connection. 51. Spacer- Sleeve.
25. Locknut- Rack Adjusting Screw. 58. Bearing- Roller.
26. Seal- Rack Adjusting Screw. 59. Seal- Valve.
27. Screw - Rack Adjusting. 60. Torsion Bar.
28. Pad - Rack Adjusting. 61. Seal- Torsion Bar.
29. Bearing- Sector Shaft. 62. Spring- Coupling and Fail Safe.
30. Cover - Piston. 63. Bush- Bearing.
31. Seal- Piston. 64. Valve.
32. Piston Rack. 65. Dowel.
33. Piston Rack Assy. 66. Seal - Noise Dampening.
34. Housing Assy. - Steering Gear. 68. Spring - Input Shaft.
69. Washer- Input Shaft.
3-30 GROUP 3- SUSPENSION, STEERING, WHEELS & lYRES
THE POWER STEERING GEAR cover turned to the bottom and the 15. Using Tool No. XA- 3526B,
DISASSEMBLY sector shaft sloping at an angle of knock out the sector shaft dust seal,
about 30° to the vertical then gently this will expose the circlip which is
The power steering gear is a preci- tap the end of the sector shaft with a
sion machine. Therefore it is essential removed with a pair of circlip pliers.
copper mallet whilst holding one The seal, backing ring and sector shaft
that cleanliness be maintained at all hand under the top cover. As the top seal can now be removed by hand.
times during disassembly and assembly cover seal slides out from the bore in 16. Using the Tool No. XA-
of the gear, to prevent the ingress of the steering gear housing, position a 3576A, press out the sector shaft
foreign matter which may subse- container to catch the remaining oil bearings. The bearings may be pushed
quently affect the performance of as it drains out. Once the oil has out in either direction.
the gear. It is not good practice to drained the gear should then be posi- 17. The input shaft bearing is
use rag for cleaning parts before tioned with both input and sector pressed into the bearing spacer and
assembly into the gear. Preferably shafts horizontal. these are removed as an assembly
parts should be washed in a petro- 6. Pull the top cover off the end from the housing using Tool No.
leum based solvent, just prior to of the sector shaft (which will also XA- 3'5 26B. The service tool should
assembly and allowed to drain dry. release a small amount of oil from be tapped lightly alternately against
A smear of power steering oil should between the end of the sector shaft opposite sides of the bearing spacer.
be applied to all rubber seals and and the top cover). (The bearing spacer is a zinc die cast-
rubbing surfaces during assembly. 7. The sector shaft assembly can ing, easily damaged if forced exces-
Use of Correct Tools - a list and then be withdrawn manually through sively.) The bearing and its spacer is
description of service tools is provided the top opening of the housing. Take driven inwards into the housing by the
in Group 21 and it is essential that particular . care in this operation not service tool, which is entered through
these tools be used when dismantling to allow any part of the sector to the input shaft seal. Care should be
or assembling the gear to ensure that scratch the top cover bore of the taken not to damage the sealing lip
permanent damage is not done to the housing as this is a sealing surface for of the seal if it is proposed to reuse
components. The following service the top cover seal. the seal. .
work can only be carried out when 8. If a flange is fitted to the input
the gear has been removed from the 18. Once the bearing spacer and
shaft of the gear this must be removed bearing are removed, the bearing can
vehicle. with a puller working against the end be pushed from the bearing spacer
If a Pitman arm is still fitted to the of the torsion bar.
gear, it must first be removed with using a suitable mandrel. .
9. Using the Tool No. XA- I 9. The input shaft seal can now
the aid of a hydraulic press. See page 3745A unscrew the piston cover en-
3-44. No attempt should be be removed using the same tool and
suring that the spanner is held ftrmly tapping the seal inwards into the
made to prise the pitman arm off by against the cover at all times. This
levering against the casting, otherwise housing alternatively on opposite
cover may be very difficult to undo, sides.
damage will result to the. sector shaft due to the rubber seal clinging to the
seal bore causing subsequent leakage. 20. Remove the worm bearing race
cover and housing. Two people may from the housing by lightly tapping
If the gear still contains oil, this must be required to undo this cover; one
first be removed by turning the box with tool entered through the input
holding the spanner firmly against the shaft end of the bore. Shims may be
upside down with the input shaft cover while the other applies a torque
sloping slightly downwards to posi- found in the bearing bore when the
to the handle. An extension tube may race is removed, place these to one
tion the inlet and outlet at the even be needed over the handle of
lowest point of the gear and placing side for use during assembly.
the spanner.
a container under the inlet and 'Outlet
to catch the oil. Most of the oil can INSPECTION AND OVERHAUL OF
10. Push the piston rack out of the COMPONENT ASSEMBLIES
be removed from the gear by turning bore from the inside of the box. Be
the input shaft from lock to lock careful not to damage the teflon seal HOUSING
about 6 to 8 times. Some oil will still on the piston as it passes over the Wash housing in a petroleum based
remain inside the gear but this will be threads at the end of the piston bore. solvent and inspect for cracks. Check
drained when the top cover is re- 11. Lift the rack pad out of the the seal areas and the piston rack bore
moved as described later. rack adjusting screw. for damage or scores.
1. Secure the mbunting bracket 12. Set gear with input shaft and
to the steering box and clamp in a SECTOR SHAFT ASSEMBLY
sector Shaft bore horizontal.
vice. 13. Slacken the worm bearing ad- A selective assembly technique is used
2. Loosen and remove the four justment screw lock nut, Tool No. in the build up of the worm follower
top cover bolts. XA- 3707A, undo and remove the and its bearings into the sector shaft,
3. Slacken the rack adjusting bearing adjustment screw using Tool therefore these items are not serviced
screw lock nut, and loosen the rack No. XA- 3537A. . individually. Little load is concerned,
adjusting screw one turn. (This is not but, in the rare case of wear or
essential but greatly assists the re- 14. Lightly tap the end of the tor- damage to the follower or its bearings,
moval and subsequent re-a-ssembly of sion bar to remove the worm, valve a new sector shaft assembly complete
the sector shaft assembly by intro- and sleeve assembly, catching the seal, must be fitted.
ducing clearance between rack and bearing race and cage as they come Check all bearing, seal and thrust
sector teeth.) out of the adjusting screw bore. With- surfaces for wear or damage. Check
4. Position the input shaft one draw the assembly being careful not the worm follower bearings for rough-
eighth of a turn off-centre towards to damage the teflon seals on the ness or end play. Check the worm
right lock. . sleeve as the assembly is drawn out of follower and sector teeth for scoring.
5. Position the gear with the top the housing. Check the preload screw for binding.
PART 3·3- POWER STEERING 3-31

Caution: Do not over wind tfie pre-

load screw when checking for bind
or the eccentric sleeve adjuster may
become disengaged from the screw.
Check the pitman arm splines and
thread, if reusing the sector shaft
remove any burrs on the splines with
a fine abrasive stone.
PISTON RACK
Inspect the piston, seal and rack
teeth for wear or damage. To replace
a faulty seal proceed as follows.
1. Remove the teflon seal by
squeezing between the thumb and
fmger to raise the seal into a hump at
one point. Use a small flat blunt screw
driver to slip under this hump and
prise seal from its groove. Do not use
a sharp instrument, as this may
damage the groove in the piston and
result in subsequent seal leakage. In
general the seal cannot be reused.
2. Replace with a new seal, by Fig. 44
feeding the seal in from one side and Piston Rack Assembly in Seal Contractor- Tool No. XA-3544·A.
running a thumb around the outside
of the piston, easing the seal carefully
into the groove. Push the rack and
seal assembly into Tool No. XA-
3544A, and leave for S-10 minutes.
(This is important otherwise seal will
not pass through the threaded end of
the piston bore when reassembling
the piston rack assembly to the gear.)
3. Check that the seal is free to
float radially in the piston groove
otherwise effective sealing will not be
achieved.
WORM, VALVE AND SLEEVE
ASSEMBLY
Inspect the valve, sleeve and teflon
. seals, worm track and worm bearings
for wear or damage. Check that no
free play exists between the sleeve
and the worm. Fig. 45
The major components of this Worm, Valve and Sleeve
assembly; namely, worm, valve,
sleeve and torsion bar cannot be
serviced individually as these are in-
herently mated at the drilling and
fitting of the pin in the "trimming" tity of oil will be released from warmed in hot water immediately
operation during manufacture (equa- inside the coupling sleeve). prior to pushing over the fitting tool
lising the steering efforts in dght and 2. Inspect the noise dampening When the teflon seals have been
left turns). seal on the coupling sleeve end of the fitted, push the sleeve in to the
A. Sleeve valve and replace if necessary. This is shrinking tool and leave for 5-10
1. Remove the sleeve complete a rubber seal and may be easily minutes.
with its teflon seals, rubber seal and replaced by stretching over the valve. The rubber seal is easily removed
drive pin from the assembly by hold- The teflon seals are best removed and replaced by stretching over the
ing the assembly vertically by the by cutting diagonally with a sharp end of the sleeve and can be reused
sleeve with the worm uppermost. knife, but care must be taken to avoid provided it shows no sign of deterio-
Strike the torsion bar end of the as- scratching the sides of the grooves ration.
sembly sharply downwards on to a otherwise subsequent leakage will Care must be taken in refitting the
fum block of wood. The sleeve (still result. seal (or a new seal) that it is not
held in the hand) will follow through When fitting new teflon seals Tool twisted on its side or inside out,
down the valve, disengaging from the No. XA-.3589A must be used, and otherwise early failure will result.
coupling sleeve and slot in the worm. the centre seal must be fitted first. The drive pin is not replaceable.
(During this operation a small quan- The seals are more easily fitted if Replace the sleeve assembly by slip-
J-32 GROUP 3- SUSPENSION, STEERING, WHEELS & TYRES
ping it over the valve, drive pin end
flrst, until it is about to enter the
coupling sleeve. Care should be taken
in this operation not to damage
either the bore of the sleeve or the
outside diameter of the valve, as a
very flne working clearance of .0002
- .0006 inch on diameter is held.
Before entering the sleeve into the
coupling sleeve flt the wedge Tool Fig. 46
No. XA- 3771A behind the coup- Sleeve in Contractor -
ling sleeve (Fig. 47) between coupling Tool No. XA-3589-8
sleeve and bearing cage, to ensure
that the coupling sleeve is held furnly
against its retaining ring. Check that
the fail safe and coupling spring is
concentric in the bore of the worm,
with the leg of the spring in the
drive slot and the spring rotated
clockwise (as viewed) to position the
leg against the side of the slot (Fig.
48) . . Line up the drive pin of the
sleeve with the gap between the leg
of the spring and the opposite side of
the slot and "feel" the sleeve into the
coupling sleeve until the pin engages
with the slot. To fully engage the
sleeve, the worm, valve and sleeve
assembly should be held vertically
with worm to the bottom and struck
sharply downwards onto a fum block
of wood, ensuring that the sleeve is
being held at the instant of impact
to drive it fully home against the end
of the worm. Fig. 47
It is important that the pin is fumly Tool No. XA-3771-A
held in the drive slot ofthe worm by in Place on Worm
the spring 2 s this spring ensures that
no slack can develop between the
worm and sleeve, otherwise the steer-
ing gear will not function smoothly.
After assembly, freedom from slack
in this coupling should be confumed
by lightly gripping the worm in a
copper-jawed vice and feeling the
sleeve for rotational slack in either
direction.
Fig. 48 Fail Safe & Coupling Spring Location
B. Valve, Coupling Sleeve and Ball
Cage Assembly
Further dis-assembly of the worm
valve and sleeve assembly necessitates
un-pinning of the valve. Before un-
pinning the valve, fust remove the
sleeve as described above and mark
the relative position of valve and
torsion bar to prevent any possibility
of the valve being refltted 1800 out
of position.
1. Support the end of the valve
over an opening slightly larger than
the pin diameter (5/32") and using a
pin punch drive the pin completely
out of valve and torsion bar.
2. Pull the valve off over the tor-
sion bar. The tapered Delrin split-
bush, flat washer and conical spring
will now be loose on the torsion bar
PART 3-3- POWER STEERING 3-33
and may be removed by hand. Re- The pin can now be refitted by 6. Ensure that the gear can be
move any burr around the hole in the pressing in, between the jaws of a rotated from lock to lock, backing
torsion bar at this time to minimise vice. off any preload on the worm follower
damage during assembly. Fitting a New Worm, Valve and if necessary, then apply preload to
3. The fail safe and coupling Sleeve Assembly. the worm follower until slack is just
spring can be removed if required at If a new worm, valve and sleeve eliminated at one point near the on
this stage. Pay particular attention to assembly is to be fitted, it will be centre position {this may not neces-
the way in which the spring is fitted, necessary to adjust the axial position sarily be exactly on centre at this
a~ if fitted in reverse, the sleeve will of the assembly in the housing to stage).
be wrongly positioned when reas- ensure that the centre point of the 7. Measure the actual slack at 6"
sembled which will cause a malfunc- worm coincides with the on centre radius on the pitman arm with the
tion of the gear. position of the gear. This position of gear positioned alternatively one turn
the worm valve and sleeve assembly (of the input shaft) to the left and
4. To remove the coupling sleeve one turn to the right from the 'on
turn the retaining ring until one end in the housing is adjustable by the
number of shims fitted behind the centre' position.
appears in the slot in the end of the 8. The clearance at the left turn
worm. Hook this end of the ring and bearing race in the housing assembly.
However, as the position of the worm should be greater than that at the
disengage it from its groove in the right turn. Divide the difference be-
worm. Withdraw the coupling sleeve valve and sleeve assembly is varied,
so the distance the bearing spacer is tween these actual readings by 5 to
from the end of the worm, which obtain the correct thickness of shim
then allows removal of the bearing pushed into the housing must be
varied to maintain a clearance of .010 stack to be fitted.
cage. 9. Remove the sector shaft as-
inch between the end of the sleeve
5. The coupling sleeve seal can and bearing spacer. The procedure is sembly and worm and valve assembly
now be removed if required. as follows:- and inner race from the housing. Fit
1. Remove the sleeve from the the number of shims {as determined
6. No further disassembly is pos- above) behind the inner bearing race
sible as the torsion bar is pressed into new worm, valve and sleeve assembly
as described above. and reassemble the worm and valve
the worm and cannot be removed. assembly and sector shaft assembly
2. Remove the bearing race from
7. To replace the coupling sleeve the housing complete with any shims and repeat the procedure above.
seal stretch the old seal out of the which may be fitted and refit the 10. If the difference in slack is less
groove in the end of the worm and bearing race without any shims using than .020 inch then the shim stack is
fit a new seal being careful to avoid the appropriate service tools. acceptable. If the left hand slack is
twisting the seal on its side or inside 3. Enter the worm and valve as- greater than the right slack by more
out. sembly into the housing followed by than this amount, divide the differ-
8. To reassemble the worm and the cage assembly, race and bearing ence by 5 and add this amount of
valve assembly replace the ball cage, adjusting screw. Tighten the bearing additional shims. If the right hand
coupling sleeve and retaining ring in adjusting screw sufficiently to remove slack is greater than the left hand by
that order. The seal on the end of the any slack (preload is not necessary at more than .020 inch divide the dif-
worm should be smeared with a little this stage). ference by 5 and remove this thick-
power steering fluid to assist the 4. Refit the sector shaft assembly ness of shims from the stack.
fitment of the coupling sleeve and and top cover (the seal from the top 11. Confmn again that the differ-
after fitment, the gap in the retaining cover may be removed to assist this ence in slacks are within .020 inch.
ring should be turned to coincide assembly).
with the slot in the end of the worm. 5. Fit the pitman arm and nut to
9. Examine the seal on the end of the end of the sector shaft and
the torsion bar and replace it if it tighten the nut sufficiently to elimi-
shows any signs of deterioration or nate any slack in the splines.
cutting due to disassembly. Examine
the noise dampenin:S seal on the end
of the valve and replace if necessary.
Position the fail safe and coupling
spring on the valve exactly as it was
before removal. Position the conical
spring over the torsion bar with the
large end in the bore of the worm.
Place the split bush over the torsion
bar with the larger diameter toward
the worm. Pass the valve over the
torsion bar and locate the bush in
the end of the valve. Align the marks
made prior to removal on the valve
and torsion bar and push the valve
fully home into the lost-motion
splines of the worm. If the angular
position is correct, the master spline Fig. 49
on the end of the valve will line up
with the slot on the end of the worm. Checking Steering Gear Slack
3-34 GROUP 3- SUSPENSION. STEERING. WHEELS & lYRES
12. Remove the sector shaft as-
sembly and worm and valve assembly.
13. Refit the sleeve to the worm
and valve assembly and position ·the Fig. 50
.010 service shim over the valve Installing Sector Shaft Bearing
against the end face of the sleeve.
14. Enter the worm, valve and
sleeve assembly complete with service
shim into the housing, fit the bearing
cage assembly and race and tighten
the bearing adjusting screw to force
the complete assembly against the
bearing spacer. This will ensure that
the bearing spacer is pushed further
into its bore if the stack up length of
the worm valve and sleeve assembly is
greater than its predecessor.
15. The worm valve and sleeve as-
sembly should then be withdrawn and
the service shim removed from the
valve.
(Note: If the stack up of new worm
valve and sleeve assembly is less than
its predecessor, additional clearance
will exist between the sleeve and the
bearing spacer, this however will not
be detrimental.)
Inlet Port Seat and Outlet Tube
1. The inlet port seat and outlet
tube can both be removed if required
by pulling out of the housing.
2. New components are fitted
using the Tool No. XA- 374309A
for the inlet port seat and Tool No.
XA-3713A for the outlet tube.
Rack Pad Adjusting Screw and Seal
1. The rack pa,d adjusting screw
should only be removed when the
gear is stripped, to prevent any possi-
bility of the rack pad being dislodged
within the assembled gear.
2. The seal however can be re-
placed on an assembled gear, by
removing the locknut and undoing the
screw one to two turns to allow the Fig. 51
seal to be removed from the groove
in the screw. Installing Input Shaft Seal
3. Fit the new seal and replace
the locknut, then reset preloads. is adjacent to the sleeve. Next fit the below the thrust face inside the
bearing onto the mandrel and insert housing when pushed home). Press
RE-ASSEMBLY assembly through the top aperture of the bearing fully home. Withdraw the
1. Replace the worm bearing race the housing. Start the bearing into mandrel from the bearing.. remove
in the housing together with the shims the bore and fit the guide Tool No. the guide from the top aperture and
removed (if any) or the predetermined XA- 3576-A2 for the mandrel to remove the spacer washer.
number of shims if a new worm, the top aperture of the housing. Press Reassembly of the sector shaft
valve and sleeve assembly i~ to be the bearing fully home under a rack seal, backing ring, circlip and dust seat
fitted (see page 3-33). Use the sleeve or hydraulic press. Withdraw the is carried out after refitment of the
Tool No. XA- -3589-B to seat the mandrel · from the bearing, remove sector shaft.
bearing in the housing. the guide from the top aperture· and 3. Fit a new input shaft seal to
2. Replace the sector shaft remove the bearing spacer washer and the Tool No. XA- 3525A. Enter the
bearings. sleeve. mandrel through the bearing adjusting
To fit a new outer (narrow) bear- To fit a new inner (wide) bearing, screw bore and knock the seal in,
ing first fit the spacing washer Tool first fit the spacing washer to the checking first that the seal is fitted
No. XA- 3576A to the assembly mandrel followed by the bearing. with the pressure sealing lip towards
mandrel Tool No. XA- 3576A Ensure that the spigot on the spacing the inside of the housing and the
followed by the spacer sleeve checking washer is adjacent to the bearing (this dust sealing lip to the outside.
that the spigot on the spacing washer will ensure that the bearing is slightly The seal is best fitted with the in·
PART 3-3- POWER STEERING 3-35
put shaft bore of the housing posi· 7. Remove the worm, valve and being careful not to turn the seal
tioned horizontally, then it can be sleeve assembly and discard the ser· inside out. Push the assembly home
easily seen when the seal is fully in vice shims. The bearing spacer will with the thumbs - do not hammer
against the retaining shoulder of the now be correctly positioned to pro· under any circumstances.
bore. It shorlld be noted that this vide a working clearance for the 13. Turn the steering gear so that
shoulder is very small and an excessive sleeve. the input shaft is vertical and the bore
assembly load could push the seal 8. The function of the bearing for the bearing adjusting screw upper·
right through the bore making the seal spacer is to prevent any possibility of most.
unusable. Under no circumstances can the sleeve becoming disengaged from 14. Drop the bearing cage in posi·
a seal be fitted by pushing it straight the worm and as such it constitutes an tion on the worm track. .
into its bore from the input shaft end. important safety feature of the gear. 15. Enter the bearing race into the
4. To replace the input shaft 9. As an additional safety feature, bearing race bore and push carefully
bearing, first press the bearing into the bearing spacer has a flange on its home, keeping the race square as it is
the bearing spacer ensuring that it is outside diameter to limit the maxi· pushed down the bore. Only light
pushed hard up to the shoulder in the mum distance it can be pushed into tapping should be required; if efforts
bearing spacer bore. It is preferable to the housing, in the event of a failure become high remove the bearing race
use a new bearing spacer when fitting of the high pressure seal in the again by tapping out the worm valve
a new bearing as a reused spacer often coupling sleeve. It is important that and sleeve assembly and start again.
fails to provide any interference fit the above procedure is adhered to N.B. It is advisable to break the sharp
between the bearing and/or the and no short cuts taken. If in doubt edge on the bearing with a fine stone
housing. If a loose fit does result, a as to the working clearance between · to avoid damage to the adjusting
new bearing spacer must be used. spacer and sleeve, this can be checked screw bore during fitting.
S. Fit the bearing and spacer as· by placing a small piece of plasticine 16. With the bearing race fully
sembly into the housing using the on the end of the sleeve, pushing the home, place the rubber seal on the
same service mandrel as used for the worm valve and sleeve assembly fully race and fit the bearing adjusting
seal, but only push the assembly to into place and immediately with· screw. Tighten the adjusting screw
within about one tenth of an inch drawing it. The plasticine will be sufficiently to remove end float. (Pre·
from the seal. This can be observed flattened to the thickness of the load is not necessary at this stage.)
by parUy withdrawing the mandrel clearance existing. 17. Set the gear with the input
and looking in through the input 10. Wrap one layer of plastic insu- shaft and sector shaft bores hori-
. shaft seal. lating tape around the valve splines to zontal.
6. The final positioning of the prevent damage to the valve seal when 18. Position the rack pad in the
bearing spacer is carried out by plac· the worm, valve and sleeve assembly rack adjusting screw.
ing the .010 inch service shim at the is being fitted. 19. Carefully enter the piston rack
end of the sleeve on the worm valve 11. Position the steering gear hous- assembly into the bore of the housing,
and sleeve assembly and entering the ing with the input shaft and sector being careful not to allow the rack to
worm valve and sleeve assembly into shaft bores horizontal. touch the bore and support the end
the housing. Fit the ball cage, race 12. Enter the worm valve and of the rack from inside the housing,
and bearing adjusting screw and sleeve assembly in through the bearing whilst easing the teflon seal past the
tighten the bearing adjusting screw to adjusting screw bore and feed the end threads at the end of the bore. The
push the assembly fully home. of the valve through the valve seal piston may be cocked slightly to
assist in passing the teflon seal past
thre~rl~ .
• 0. Position the rack in its mid
p<;snlon ready for assembly of the
sector shaft.
21. Refit the piston cover ensuring
that the rubber seal is not damaged.
If the seal is damaged it must be
replaced with a new seal. Using the
Tool No. XA-374SA tighten the
piston cover to 2040 ft. lbs torque,
ensuring that the spanner is pushed
firmly against the cover at all times.
(Refitting of this cover may be left
until fitting of the sector shaft is
completed if required.) ·
22. Position the steering gear as-
sembly so that the input shaft and
sector shaft bores are horizontal.
23. Check that the rack pad is cor·
rectly positioned in the rack adjusting
fig. 52 screw, and position the piston rack in
its mean position; i.e. with the centre
Bearing Spacer Shim in Place on Valve tooth gap immediately opposite the
sector shaft bearing bush. (i.e., in line
with the rack pad.)
3-36 GROUP 3- SUSPENSION, STEERING, WHEELS & lYRES
SETTING PRELOADS ON THE
STEERING GEAR ASSEMBLY
General
During production of the steering
gear assembly preloads are set slightly
higher than in service to allow for
initial 'bed-in' of mating components.
These higher preload figures are given
below in brackets and should only be
used where new components are
being fitted to the steering gear.
Before setting preloads, the gear
should be substantially drained qf
power steering fluid, otherwise the
readings obtained will be too high
because of the pumping action of the
piston moving oil from one end of
the cylinder to the other. Most con-
sistent results are obtained if the box
is warm.
Fig. 53. Centre Tooth Gap In order to establish the correct
preloads the sequence of preload·
of Rack in Line with Sector Shaft Bush settings following should be strictly
24. If the original sector shaft seal home. A smear of power steering oil adhered to as each reading obtained
is still in position it is in order to on the seal will greatly assist the fit- is a cumulative reading of the preloads
assemble the sector shaft directly ment of the top cover. set before. The gear must be removed
through the seal, provided the splines from the vehicle to set preloads and
are smoothed to remove sharp edges 27. Fit the four screws securing should preferably be mounted in the
or covered with plastic tape. If how- the top cover but do not tighten. special service ftxture in a vice with
ever, a new sector shaft seal is to be 28. Remove the recessed head plug the input and sector shafts horizontal.
fitted, it is advisable to fit the new from the top cover and position the First, undo and remove the plug from
seal after the sector shaft has been gear on centre. Force the top cover the top cover. Position the gear
fitted, using plastic tape to mask the back against the housing aperture by roughly 'on centre'. (The gear is 'on
sector spline and push the seal home. applying a temporary follower pre- centre' when it is positioned midway
25. Enter the sector shaft assembly load of 8-12 inch ounces (to avoid between full left and right lock; in
carefully through the top cover aper- subsequent loss of preload in service this position the blocked splines on
ture into the sector shaft bearing. due to shifting of the cover) and with the sector shaft lie parallel and at
Keep the rack parallel to the bottom the gear still op. centre, tighten the right angles to the plane of the
of the box and roll it slightly to open four top cover bolts to 30 ft. lbs mounting feet and the flat on the
the mesh at entry. It is essential to torque. The recessed head plug will input shaft is in line with the inlet
see that the centre tooth of the sector be replaced after preload adjustment. and outlet ports.) The socket head of
shaft is aligned with the tooth gap in (Refer instructions for setting pre- the adjusting screw for the worm
the rack as the sector shaft is pushed loads.) · follower will now be visible through
in. Use a torch if necessary. At the 29. With the sector shaft splines the top cover plug hole. ·Turn this
same time as the rack and sector covered with one layer of plastic screw 2 to 3 turns anti-clockwise to
teeth are engaging, the input shaft tape fit the sector shaft seal, with the remove any preload from the worm
will need to be turned to align the lips towards the housing, follower, at the same time keeping
groove in the worm with the follower pressure on the Allen key to hold the
on the sector shaft assembly. The Fit the backing ring with its rounded adjusting screw head against the end
sector shaft assembly must never be side towards the seal and its flat side of the sector. Loosen the lock nut on
hammered in during this operation.
If difficulty is encountered, slacken
the rack adjusting screw as described
towards the circlip. (This is important
to ensure that the circlip is loaded
close to the groove in the housing
the bearing adjusting screw *
the bearing adjusting screw and undo

turn to remove any preload from the

to 1
under "Preload Adjustments'? otherwise it will fatigue in service. worm bearings. Loosen the rack adjus-
26. Position the gear slightly off
centre to ensure the sector shaft is
not displaced by any preload between
The rounding of one side of the
backing ring is a legacy of the blank- *
ting screw locknut and undo the rack
adjusting, screw to 1 turn. This will
remove any preload between the rack
ing operation during its . manufac- and the sector teeth. The gear is now
the follower and worm. Then fit the ture). Finally, fit the circlip then the
top cover over the sector shaft journal ready for setting the preloads, which
dust seal using the special service are measured at the input shaft using
and enter it into the steering gear tool.
housing. A new seal should be fitted a torque meter (having a range 0 to
if the old seal shows any sign of 30. Install the flexible coupling to 20 inch pounds in both clockwise and
fretting or if it has lost its sharp the input shaft, making sure to line anti-clockwise direction).
corners. Care should be taken as the up tpe master spline, the lock plate 1. Input Seal Friction
seal is entering the aperture to ensure and nut. Torque to specification. Turn the input shaft of the steering
it is not pinched. Once entered, the 31 . Set all preloads as described gear to either left or right lock. If the
top cover may be lightly tapped on following pages. input shaft is oscillated · 4 or 5° in
PART 3-3- POWER STEERING 3-37

Fig. 54 Fig. 55
Preload Adjusting Points Checking Preloads - Typical

either direction at the locks, a short ced ~y the changing ratio of the increase in preload is observed. When
interval of slack will be observed worm. It may also be observed that a an increase of 3 to 4 inch pounds
where the worm follower and rack slightly higher reading is produced (for new components 6 to 1 inch
and sector teeth are exhibiting back- when turning the gear left. This is pounds) is observed, hold the rack
lash. Note the maximum torque read- due to the 10° inclination of the adjusting screw with an Allen key
ing in this slack interval. This should piston when the gear is set horizontal. and tighten the rack adjusting screw
be approximately ~ to 1 inch pound. The piston is pushed up the inclina- locknut. This adjustment is very sen- "
2. Worm Bearing Preload tion on a left turn and down the sitive and some trial and error will be
Whilst oscillating the input shaft in inclination on a right turn. required to achieve the correct pre-
this same slack interval, the bearing 4. Worm Follower Preload load after the locknut is tightened.
adjusting screw should be tightened Bring the gear to the on centre The locknut should be tightened to
until an increase in torque is noticed. position which will bring the worm 30 foot pounds torque.
The adjusting screw should be locked follower adjusting screw accessible
to achieve an increase over the input through the hole in the top cover. 6. Final Check
seal friction of 1 to 2 inch pounds Turn the adjusting screw a % turn at As a fmal check, turn the box from
(for new parts 2 to 3 inch pounds). a time until an increase in torque lock to lock to ensure that there are
Additionally, note the actual torque reading is noted when oscillating the no 'hang-ups'. Sensible preload should
reading. input shaft 5° either side of centre. occur over a broad angle of approxi-
3. Gar Drag Ensure that the Allen key is with- mately % turn either side of centre,
with the highest preload occurring
~ to *
input shaft over a greater angle (be-
turn off centre. Oscillate the
input shaft over a greater angle be-
drawn from the adjusting screw
during oscillation of the input shaft,
otherwise damage may result to the
through centre.

tween the limits ~ to * turn off threads for the top cover !lug. The Refitment of Gear to Vehicle
The gear must always be refitted
centre) and observe the maximum preload should be adjuste until an
torque reading. It will be noticed increase of 3 to 4 inch pounds is to the vehicle so that the gear is 'on
that this reading is slightly higher achieved over the last actual reading. centre' when the vehicle is tracking
than the previous reading by about (For new components 6 to 7 inch straight ahead. This is important as it
~inch pound (for a new gear 1 to 1~ pounds.) Note the actual reading. ensures that the peak in the ratio
inch pounds). This additional torque Replace the plug in the top cover and curve of the gear occurs when driving
is due to frictional drag between tighten to 7-9 foot pound torque. straight ahead and the ratio change is
worm and follower, rack and sector then symmetrical in right and left
teeth, the piston seal in the housing 5. Rack and Sector Tooth Preload turns.
bore and the sector shaft seal. Be With the gear on centre oscillate Hence first 'centre' the steering
careful not to measure this torque the input shaft 5 degrees either side of wheel then make all tracking correc-
any closer to centre than a ~ turn, centre and sj.owly turn the rack tions by adjustment of the steering
otherwise the results will be influen- adjusting screw clockwise until an side rods only.
3-38

PART STEERING COLUMNS AND

Section
3·4 LINKAGE
Page Section Page
1 Description ... •.. •.. ... ... ... ... ... . .. 3-38 4 Major Repair Operations ... .•. ... •.. ..• ... 3-41
2 In-car Adjustments ..• ..• ... ... ... ... . .. 3-39 S Ignition Lock Replacement... .•• ... ... - ... •.. 3-41
3 Steering Column Removal & Replacement ..• 3-40 6 Steering Linkage Repair... .. : ..• : ... ...... .,. ... 3-43
7 Pitman Arm Replacement Manual
and Power Steering r- ... ... ... ... ... .., 3-44

D DESCRIPTION
The steering column which in·
eludes a combination steering/gear
shift/ignition lock is of the collapsible
type to lessen the possibility of
injury to the driver of the vehicle,
should be become involved in an
accident.
nie lower end of the steering
column tube at the bellows area may
collapse up to approximately eight (8)
inches upon a hard impact.
The shift tube and steering shaft
are provided with spring clips
which will shear and allow them to
collapse upon impact.
The steering column upper moun-
ting brackets are provided with
breakaway retainers which allow the
column to break free under impact.
Once the steering column has been
collapsed, a complete new column
must be installed with new brackets. FIG. 57 -Manual Trans column
The steering/gear shift/ignition
lock is situated to the right of the
steering column. The main body of
the lock is bolted to the steering
column outer tube and is covered by
a shroud which contains the various ·
key positions marked on· the mask
surrounding the barrel.
To engage the steering/gear shift
lock on column shift vehicles the gear

shift must be positioned in park. in the steering shaft locking sleeve.

(Automatic) or Reverse (Manual). (See Fig. 56.)
In the locked position the locking The steering/gear shift/ignition
plunger protrudes through a slot in· lock must be in the locked position
FIG. 56 -Slots in tube the gear shift tube and into a groove before the key can be removed.
PART 3-4- STEERING COLUMN & LINKAGE 3-39
EJ IN-CAR ADJUSTMENTS
STEERING WHEEL REPLACEMENT 2.. Remov~ the steering wheel as move the nut and pipe from the shaft.
outlmed preVIously. 8. Position the turn signal switch
1. Disconnect the negative cable 3. Rem~v~ the turn indicator on the flange, install the three attach-
from the battery. lever and WU'mg cover. ing screws and refit the wiring cover.
2. Working from the underside ~· Remove. the turn in?icator 7. Install the steering wheel as
of the steering wheel spoke, remove s~tch attaching screws. Lift ~e outlined previously.
the crash pad attaching screws. Lift switch over the end of the steermg STEERING COLUMN ALIGNMENT
the crash pad from the wheel. shaft and place it to one si~e.
Remove the hom ring by turning it S. Remove the . snap rmg from A condition of high shift or steer-
counterclockwise. the top of the steermg shaft. ing effort may be experienced caused
3. Remove the steering wheel nut 6. . Loosen the two ~es-to- by improper alignment of the energy
and then remove the wheel using a steet:mg column tube attaching bolts absorbing steering column.
tool made up to the dimensions in to disen~ge them from the tube. . The following procedure outlines
Fig. 59, or using Litchfield tool 7. Ruse the flange upward (if the steps necessary to correctly re~
No E201 necessary, tap the steermg shaft align the column.
· · lightly with a plastic hammer to free It is recommended that before
Do not use a knock off type the bearing and flange from the shaft). attempting realignment, the toe plate
steering wheel puller or strike 8. Remove the bearing and insu- (column retainer) to dash panel
the end of the steering shaft with lator from the flange. fastener holes be inspected for a
a hammer. Striking the puller INSTALLATION binding or misalignment condition.
or shaft will damage the collap- If the condition described above
sible column or bearing. 1. Install flange bolts (square could be attributed to this area, file
head) in flange if they were removed. or ream the toe plate holes for
Tum the nuts onto the bolts one greater clearance.
4. Transfer all serviceable parts complete turn only. 1. Check the clearance between
to the new steering wheel. 2. Position the flange onto the
S. Position the steering wheel on steering column tube.
the shaft so that the alignment mark 3. Engage the two flange bolt
on the hub of the wheel is adjacent to heads with the square holes in the
· the one on the shaft. Install a new column tube. then tighten the two
locknut and torque it to specifications. attaching nuts to specification.
8. Install the hom ring and 4. Position the bearing and insu-
crash pad. lator on the shaft. Work it down onto
the shaft as far as possible, then place
STEERING COLUMN UPPER
R piece of f ID x 21 inch pipe over
BEARING REPLACEMENT the end of the shaft and install the
REMOVAL steering wheel attaching nut (Fig. 61).
1. Disconnect the hom and tum S. Tighten the nut until the bear-
indicator wires at the connector. ing is seated in the flange, then re-

r·
11-e, I
•r
--.;.:.--tf
2j" .......
FIG. 60- Steering Wheel
Removal
NUT
11/32" ~lA.

f" U.N.F.
NUT
WELDED TO PLATE
~--11"--.,.f

USE 2 OFF 5/16"- 24 U.N.F. 4" L.G.

G 1497 · A
I OFF j" U.N.F. BOLT & NUT
FIG. 61 - Installing Upper
FIG. 59 STEERING WHEEL PULLER DIMENSIONS Bearing
3-40 GROUP 1- SUSPENSION. STEERING. WHEELS & JYRES

the steering shaft and the shift tube 3. Loosen the two bolts steering lbs. ft).
at the lower end of the column. The column support bracket to pedal 7. Tighten the steering column
specified minimum clearance is 0. 12 bracket. clamp to support bracket bolts to
inches. 4. Loosen the two bolts steering specification (10 to 20 lbs. ft).
2. Loosen the toe plate (column column clamp to steering column
retainer) to dash panel bolts and in- bracket assembly. 8. Tighten the two steering sup-
spect for binding or misalignment. If 5. Check the steering shaft to port brackets to ped41 bracket nuts
the conditions described above can be shift tube clearance and set to to specification (28-42 lbs. ft).
attributed to this area, file or ream specification. 9. Recheck to ensure the steering
the toe plate holes for greater 6. Tighten the toe plate to dash shaft to shift tube clearance has not
clearance. panel bolts to specification (4-6 altered.

EJ STEERING COLUMN REMOVAL AND INSTALLATION

REMOVAL

1. Disconnect the battery cable 8. Lift the column from the of the column.
from the negative post. vehicle. Transfer parts to the new 5. Tighten the toe plate to dash
2. Disconnect the turn signal column as required, leaving the panel bolts to specification.
switch wires at the connector. column clamp nuts fingertight. 6. Tighten the column clamp to
3. Disconnect the ignition switch INSTALLATION upper support bracket nuts to speci-
wires at the connector. 1. Position the steering column fication.
4. Disconnect the transmission in the vehicle, engaging the flexible 7. Remove the fs-w dia. rod from
control rod(s) from the lever(s) at the coupling bolts in the holes of the the coupling.
lower end of the column. steering shaft flange. 8. Connect the transmission con-
5. Remove the two nuts steering 2. Insert a fa- w dia. rod between trol rod(s) to the lever(s) at the lower
shaft flange to flexible coupling. the fabric ring and the steering shaft end of the column and adjust.
6. Remove the nuts and bolts flange. 9. Connect the turn signal switch
that secure the column retainer and 3. Install but do not tighten the wires.
seal at the toe plate. nuts that secure the column upper 10. Connect the ignition switch
7. Disconnect the nuts that secure and lower brackets to the brake pedal wires.
the column upper and lower brackets support bracket and the dash panel. · 11. Connect the battery cable.
to the brake pedal suooort bracket 4. Check the steering shaft to 12. Check the operation of the
and the dash panel. (Fig. 62). shift tube clearance at the lower end switches.

I
/ · -'

\.·"------ '-~ / -~ -
./ ~·-·- "'

-- 111-11 .. ,.

FIG. 62 -Installation Steering Column

PART 3-4- STEERING COLUMN & LINKAGE 3-41

rJ MAJOR REPAIR OPERATIONS

STEERING SHAn REPLACEMENT 7. On manual transmission ve- IGNITION LOCK REPLACEMENT
REMOVAL hicles remove the three attaching REMOVAL
screws column to lower bearing.
t. Remove the column from the 8. Remove the shift tube from l. Remove the column from the
vehicle. the outer column tube (Fig. 62). On vehicle and remove steering wheel.
2. Remove the steering wheel. automatic column shift and floor- 2. Remove the steering lock
3. Remove the turn indicator shift vehicles the shift tube lower shroud and shift tube.
switch and lever. nylon bushing must be removed with 3. Cut slots in the steering lock
4. Remove the steering shaft the tube, to achieve this, press the attaching bolts with a hacksaw and
upper bearing retaining circlip. three nylon tabs into the holes in the remove bolts with a screw driver or
S. Remove the steering shaft column, ease· the bushing down the hammer and centre punch.
through the lower end of the column tube so that the tabs clear the holes. 4. Rotate the lock around the
(Fig. 62). Withdraw the tube and bush through column tube until one end of the
the bottom of the column tube. base clears the aperture, lift the lock
INSTALLATION from the column.
t. On manual transmission ve-
1. Assemble the steering shaft to hicles, the lower shift tube bearing INSTALLATION
the column. may be removed before or after re- 1. Place the steering/ignition lock
2. Fit the upper bearing retaining moving the shift tube from the assembly into the recessed bush in
circlip. column. the steering column.
3. Assemble the turn indicator NOTE: To remove shift tube upper
switch and lever to the hub. 2. Engage new shear head bolts
bearing, ignition lock must be re- and tighten them evenly until the
4. Assemble the steering wheel moved first. Bearing can then be
and re-install the column into the heads shear off.
removed from lower end of column. 3. Assemble the shroud to the
vehicle.
INSTALLATION column and install shift tube.
4. Assemble the column to the
1. Assemble upper shift tube vehicle.
bearing in the column with the
SHIFT TUIE REPLACEMENT chamfered edge lowermost and install
REMOVAL the ignition lock. LOCK BARREL REPLACEMENT
2. Assemble the lower bearing REMOVAL
1. Remove the steering column and shift levers (manual shift) and
from the vehicle and remove the torque the retaining screws to speci- 1. Remove the lock shroud lower
steering wheel. fication. attaching screw from beneath the
2. Remove the gear selector lever 3. Assemble the shift lever to the shroud.
retaining pin and remove the lever. collar using a new drive pin. 2. Turn the ignition key to the
3. Remove the turn indicator off or on position.
4. Assemble the steering shaft 3. Push a .060" dia pin into the
lever. to the column and fit a new upper lock through the shroud lower moun-
4. Remove the three turn indi- bearing retaining circlip. ting hole to raise the barrel locking
cator switch retaining screws, lift the 5. Assemble the turn indicator pin and remove the barrel.
switch over the shaft and place it to switch and lever to the hub, and
one side. torque the screws to specification. INSTALLATION
S. Remove the steering shaft 1. Refit the steering wheel. 1. Assemble the barrel into the
upper bearing retaining circlip and 7. Re-assemble the column to lock and raise the barrel locking pin
remove the steering shaft. the vehicle. by turning the key to the start
6. On automatic and floor-shift 8. Align the column to the steer- position.
vehicles remove the bolt attaching ing gear and adjust the shift linkage 2. Assemble the shroud lower
the shift collar to the shift tube. as required. attaching screw.
3-42 GROUP 3- SUSPENSION, STEERING, WHEELS & lYRES

FIG . 63 -Steering Linkage- Fairlane, Falcon

PART 3-4- STEERING COLUMN & LINKAGE 3-43

IJ STEERING LINKAGE REPAIR

The steenng linkage (Fig. 63) consists adjustable and is provided with 3. Position the spindle connecting
of the Pitman arm, the Pitman arm- tapered holes to accommodate the rod ends to the centre link and install
to-idler arm (centre link), the idler ball studs (Fig. 63 ). The link should the attaching nuts. Torque the nuts to
arm and bracket assembly and the be replaced when damaged or worn the low end of the specification. Con-
spindle connecting sleeve and end at the ball studs or if excessive tinue to tighten each nut until the
assemblies (tie rods). looseness is noticed in either ball stud slots in the nut align with the hole in
Do not attempt to straighten socket. the stud. Then, install a new cotter
bent linkage; use new parts. THREAD PROTECTOR
pin.
HOISTING INSTRUCTIONS 4. Remove the safety stands,
lower the vehicle, check and adjust
Damage to suspension and/or toe-in to specification (Part 3-7).
steering linkage components may STEERING IDLER ARM
· occur if care is not exercised when
positioning the hoist adapters of 2 AND BRACKET ASSEMBLY
post hoists prior to lifting the vehicle. REPLACEMENT
If a 2 post hoist is used to lift the REMOVAL
vehicle, place the adapters under the lf the idler arm bushings are wom
front suspension lower arms. Do not the complete idler arm assembly must
allow the adapters to contact the be replaced. If the socket at the idler
steering linkage. bracket is excessively loose, replace
SPINDLE CONNECTING ROD the complete assembly.
ASSEMBLY (INNER AND OUTER l. Remove the cotter pin and nut
FIG. 64- Disconnecting attaching the steering centre link at
ENDS} REPLACEMENT
Steering Linkage Ball Stud the idler arm (Fig 63 ).
FAIRLANE, FALCON 2. Disconnect the centre link
The spindle connecting rod ends,
-Typical from the idler arm.
which are ~eaded into the adjusting REMOVAL 3. Remove the two bolts that
sleeves, have non-adjustable, ball l. Raise the vehicle on a hoist attach the idler arm and bracket
studs. These parts cannot be greased and position safety stands. assembly to the frame.
or serviced. A rod end assembly 2. Remove- the cotter pins and INSTALLATION
should be replaced when excessive l. Secure the new idler arm and
looseness at the ball stud is noticed. nuts that attach both inner connec-
ting rod ends to the centre link bracket assembly to the frame with
l. Remove the cotter pin and nut (Fig .•63 ). the two attaching bolts nuts and
from the worn rod end ball stud. washers(as shown in Fig. 63)
2. Disconnect the end from the 3. Disconnect the inner connec-
ting rod ends from the centre link 2. Place the idler arm and the
spindle ann or centre link as shown (Fig.64 ). front wheels in the straight ahead
in Figs. 63 and 65 position to ensure keeping the steer-
3. Loosen the connecting rod 4. Remove the cotter pin and nut
attaching the idler arm to the centre mg wheel aligned and to prevent
sleeve clamp bolts, and count the bushing damage after the attaching
number of turns needed to remove link. Disconnect the idler arm from
the centre link. nut has been torqued. Insert the
the rod end from the sleeve. Discard centre link stud through the hole in
all rod end parts that were removed 5. Remove the cotter pin and nut
attaching the Pitman arm to the cen- the end of the idler arm and install
from the sleeve. All new parts the nut and washer.
. should be used when a spindle tre link. Disconnect the Pitman arm
from the centre link and remove the 3. Torque the idler arm rod nut
connecting rod end is replaced. to specification and install a new
4. Thread a new rod end into the centre link.
cotter pin.
sleeve, but do not tighten the sleeve INSTALLATION
clamp bolts at thi~ time.
5. Insert the stud in the part from l. Replace the rubber seals on the PITMAN ARM
which the old one was removed, and spindle connecting rod ends, if REPLACEMENT-MANUAL ONLY
install the stud nut. Torque the nut to required.
2. Position the centre link to the REMOVAL
specification and install the cotter pin.
6. Check and, if necessary, adjust Pitman arm and idler arm and install 1. Remove the cotter pin from
toe-in (Page 3-5). After toe-in is the attaching nuts loosely. Place the the castellated nut that attaches the
checked and adjusted, loosen the idler arm and the front wheels in the steering centre link to the Pitman
clamps from the sleeve, oil the straight ahead position to insure arm. Remove the castellated nut.
sleeve, clamps and bolts and keeping the steering wheel aligned 2. Disconnect the steering centre
torque the nuts to specification. and to prevent bushing damage after link from the Pitman arm.
The tie rod sleeve clamp-; must be the attaching nuts have been torqued. 3. Remove the Pitman arm at-
installed as shown in Fig. 63 to pre- Ensure that the seal is properly in- taching nut and lock washer.
vent interference with the side rail. stalled on the centre link. Torque the 4. Remove the steering gear from
CENTRE LINK nuts to the low end of the specifica- the vehicle (see page 3-46).
REPLACEMENT tion. Continue to 6ghten each nut 5. Remove the sector shaft cover
until the slots in the nut align with (see page 3-46) and drain oil.
The centre link connecting the the hole in the stud. Then install a 6. Remove Pitman arm by follow-
Pitman arm and the idler arm is non- new cotter pin. ing procedures outlined on page 3-44
3-44 GROUP 3- SUSPENSION, STEERING, WHEELS & lYRES
under Pitman arm removal - power PITMAN ARM REPLACEMENT 5. Takirig care not to damage the
steering. POWER STEERING ONLY. threaded end of the sector shaft,
NOTE - Pitman arm removal is press the sector shaft through the
INSTALLATION- MANUAL casing and remove the pitman arm.
accomplished with steering gear
1. For sector shaft installation pro- assembly removed from the car. For NOTE - Ensure that the sector
cedures and adjustment, refer page removal procedures, see Page 346. shaft does not drop out of the casing
347 and specifications. otherwise damage to the shaft could
2. For steering gear installation REMOVAL occur.
procedure- refer page 346.
3. With the front wheels in the 1. Remove pitman arm securing INSTALLATION POWER
straight ahead position, place the nut from sector shaft. STEERING
Pitman arm on the sector shaft mak· 2. Undo the four bolts securing
the sector shaft cover and remove 1. For sector shaft installation
ing sure it is pointing forward. refer to procedures outlined in pages
4. Install the nut and lock washer. cover - drain oil.
3. Install steering gear assembly 3-34 to 3-36.
Torque the nut to specification. 2. For pre-load setting procedures
5. Connect the steering centre in the press with the sector shaft
splined end upper most. refer pages 3-36 to 3-37.
link to the Pitman arm, fit the nut 3. For pre-load and torque figures
and torque to specification. Fit a new 4. The sector (shaft will fall) down-
wards until the Pitman~ arm is resting refer specifications.
cotter pin and fill steering gear with 4. For steering gear and Pitman
specified oil. against the steering gear casing.
arm installation procedures refer page
346. .
5. Fill steering gear with specified
oil.
3-45
Section Page
1 Description .... .. .. .... ...... . ...... .... .. .. .. .. ...... .. .. .. 3-45
2 In-Car Adjustments & Repairs ...... ...... .. .. .. 3-45

PART STEERING GEAR

Steering Gear Worm & Sector Adjustments
3 Removal & Installation ...... ...... ...... ...... .. .. ..
4 Major Repair Operations ...... ...... ...... ...... ..... .
3-45
3-46
3-46

3·5 Steering Gear Disassembly ... ... ...... .. .. ..

Steering Gear Assembly ... .. . .. .. . .... .. ..... .
3-46
3-47

D DESCRIPTION
The steering gear (Fig. 66)·is of the
worm and recirculating ball type. The
sector shaft is straddle mounted hav-
ing a bushing located in the cover
above the gear and a roller bearing in
the housing below the gear.
The worm bearing preload is con-
trolled by the large adjusting nut
which is threaded into the housing.
The sector shaft mesh load is con-
trolled by an adjusting screw located FIG.66 .
in the housing cover.
The steering linkage consists of the STEERING GEAR
Pitman arm, steering-arm-to-idler
arm rod, idler arm and the spindle
connecting rods (tie rods).

B IN-CAR ADJUSTMENTS AND REPAIRS

STEERING WORM AND
SECTOR
GEAR ADJUSTMENTS

The ball nut assembly and the

sector gear must be adjusted properly
to maintain minimum steering shaft
end play (a factor of preload adjust-
ment) and minimum backlash be-
tween sector gear and ball nut. There
are only two possible adjustments
within the recirculating ball-type .
steering gear, and these should be
made in the following order to
avoid @mage or gear failure.
1. Disconnect the Pitman arm
from the steering Pitman-to-idler
arm rod.
2. Loosen the nut which locks the
sector adjusting screw (Fig. 67), and
turn the adjusting screw counter-
clockwise.
3. Measure the worm bearing FIG. 67- Steering Gear FIG. 68- Checking Steering
preload by attaching an in-lb torque Adiustments - Typical
wrench to the steering wheel nut • Gear Preload - Typical
With the steering wheel offcentre, 7. Turn the sector adjusting
read the pull required to rotate the specified limits. screw clockwise until the specified
input shaft approximately 1! turns 5. Tighten the steering shaft torque (Part 3-7) is necessary to
either side of centre. If the torque or bearing adjuster lock nut, and re- rotate the worm past its centre
preload is not within specification check the preload. (high spot).
(Part 3-7), adjust as explained in the 8. Turn the steering wheel slowly 8. While holding the sector ad-
next step. to either stop. Turn gently against justing screw, tighten the sector ad-
4. Loosen the steering shaft bear- the stop to avoid possible dam- justing screw locknut to specification,
ing adjuster lock nut, and tighten or age to the ball return guides. and recheck the backlash adjustment.
back off the bearing adjuster (Fig. 66) Then rotate the wheel 2f turns to 9. Connect the Pitman arm to the
to bring the preload within the centre the ball nut. steering arm-to-idler arm rod.
GROUP 3- SUSPENSION, STEERING, WHEELS & TYRES

El REMOVAL AND INSTALLATION

REMOVAL
1. On V8 units remove the brake INSTALLATION
master cylinder and booster.
1. Position the steering gear and
2. Remove the two nuts from the flexible coupling in the vehicle; then,
flexible coupling to steering shaft install and torque the steering gear
flange bolts. to side rail bolts to specification.
NOTE: On VS units it may be 2. Position the Pitman arm on
advantageous to remove the flexible the sector shaft and install the
coupling from the steering gear stub attaching nut and lock washer. Tor-
shaft. que the nut to specification. Part 3-7.
3. Remove the nut and lock 3. Install and connect the flexible
washer that secures the Pitman arm coupling attaching nuts and torque
to the sector shaft . them to specification.

{On power steering units remove the {On power steering units replace the
two fluid hoses from the steering two fluid hoses.)
gear.) 4. On V8 units replace the brake
4. Remove the steering gear to master cylinder and booster.
side rail bolts and remove the gear. S. 'Bleed the brakes (See page 2•3.)

EJ MAJOR ·REPAIR OPERATIONS

STEERING GEAR
DISASSEMBLY
1. Rotate the steering shaft to 7. Remove the upper bearing cup bearing and the oil seal from the
centre the nut. from the bearing adjuster and the housing
2. Mter removing the sector ad- lower cup from the housing. It may
justing screw locknut and the housing be necessary to tap the housing or Note: The inner sector shaft bearing
cover bolts (Fig. 70 ), remove the the adjuster on a block of wood to jar is flanged on the inner end and must
sector shaft with the cover. Remove the bearing cups loose. be removed by a suitable drift toward
the cover from the shaft by turning 8. If the preliminary inspection the inside of the housing.
the screw clockwise. Keep the shim shows damage, press the sector shaft The outer or lower bearing and
with the screw.
3. Loosen the worm bearing ad-
juster nut, and remove the adjuster
assembly and the steering shaft upper
bearing (Fig. 71 ).
4. Carefully pull the steering
shaft and ball nut from the housing,
and remove the steering shaft lower
bearing. To avoid possible dam-
age to the ball return guides,
keep the ball nut from running
down to either end of the worm.
Disassemble the ball nut only if
there is indication of binding or FIG. 70- Sedor Shaft and Housing Disassembled
tightness.
5. Remove the ball return guide
clamp and the ball return guides from
the ball nut. Keep the ball nut
damp-side up until ready to
remove the balls.
6. Turn the ball nut over, and
rotate the worm shaft from side to
side until all 54 balls have dropped
out of the nut into a clean pan. With
the balls removed, the ball nut will
slide off the worm. FIG. 71- Steering Shaft and Related Parts Disassembled
PART 3-5- STEERING GEAR 3-47 '

seal may now be removed together ing compound. Do not apply sealer to 19. lubricate the sector shaft jour-
by using a suitable drift through the female threads and especially a¥oid nal and install the sector shaft and
housin)!; toward the outer end of the getting any sealer on the steering shaft cover.
sector shaft aperture. bearings. 20. With the housing cover turned
Assembly 10. Coat the worm bearings, sector out of the way fill the gear with 0.97
shaft bearings, and gear teeth with lbs of gear lubricant. Push the
1. If the sector shaft bearings and housing cover and sector shaft assem-
steering gear lubricant.
oil seal have been removed press a
blies into place, and install the two
new inner (flanged) bearing into the 11. Clamp the housing in a vise, with top housing cover bolts. Do not tight·
housing until the flange abuts the the sector shaft axis horizontal, and
housing. · en the co•er bolts until it is certain
position the steering shaft lower bear-
2. Press the outer or lower bearing ing in its cup.
into the housing until it is just below
the oil seal locating shoulder. 12. Position the steering shaft and
3. Press the oil seal into the ball nut assemblies in the housing.
housing. Do not clean, wash or soak 13. Position the steering shaft
seals in cleaning solvent (Fig. 70). upper bearing on the top of the worm,
Apply the recommended steering gear and install the steering shaft bearing
lubricant to the bearing and seals. adjuster and the adjuster nut and
4. Install a bearing cup in the lower bearing cup. leave the nut loose.
end of the housing and in the adjuster. 14.. Adjust the worm bearing pre-
S,. If the seal in the bearing adjuster load, using an in-Ib torque wrench
was removed, install a new seal. (Fig. 72). See Page 3-56 for the speci·
6. Insert the ball guides into the fled preload.
holes of the ball nut, tapping them 15. Position the sector adjusting
lightly with a wood handle of a screw screw and adjuster shim. and check
driver if necessary to seat them. the end clearance which should not
7. Insert 27 balls into the hole in exceed 0.002 inch between the screw
the top of each ball guide. It may be head and the end of the sector shaft.
necessary to rotate the .shaft slightly If clearance is greater than 0.002 inch, FIG. 72 -Checking Steering
one way, then in the opposite direc- add enough shims to reduce the end
play to within the 0.002 inch toler-
Shaft Bearing Preload - Typical
tion to distribute the balls in the cir-
cuit. ance. that there is some lash between ball
8. After the 54 balls are installed, 16. Start the sector shaft adjusting nut and sector gear teeth. Hold or
install the ball guide clamp. Torque screw into the housing cover. push the. cover away from the ball nut,
the screws to specification. C)lc:ck the 17 . Install a new gasket on the then torque the bolts to specification.
worm shaft to .m ake sure that it ro- housing cover. 21. After loosely installing the sec-
tates freely. 18. Rotate the steering shaft until tor shaft adjusting screw lock nut, ad-
9. Coat the threads of the steering the ball nut teeth are in position to just the sector shaft mesh load. See
shaft bearing adjuster, the housing mesh with the sector gear, tilting the Page 3-56 for the specified mesh load;
cover bolts. and the sector adjusting housing so that the ball will tip then, tighten the adjusting screw lock
· screw with a suitable oil-resistant seal- toward ~he housing cover opening. nut.
Section Page
1. Description & Operation ... ... ... ... .•. ... ... 3-48

PART WHEELS AND TYRES

Front Wheel - Rear Wheel... ... ... ... ...
2. In-Car Adjustments & Repairs... ... ... ... ... ...
Front Wheel Bearing Adjustment ... ............
3-48
3-48
3-48

3-6 3. Removal & Installation ... ... ... ... ... ... ... ...
4. Major Repair Operations .....................
3-49
3~so

D DESCRIPTION AND OPERATION

The road wheels are of pressed

steel double Slifety (JJ) rim construc-
tion and are of five and six inch ADJUSTING
width depending on tyre size. Refer NUT
specification section.

FRONT WHEEL

Each front wheel and tyre assem-

bly is bolted to its respective front
hub and brake drum (or hub and
disc). Two opposed tapered roller
bearings are installed in each hub. WHEEL
A grease retainer is installed at the ASSEMBLY
inner end of the hub to prevent HUI IIOLT
lubricant from leaking into the
drum or on the disc. The entire FIG. 73 -Front Hub, Bearings and Grease Retainer- Drum Brakes-
.assembly is retained to its spindle Typical
by the adjusting nut, nut lock and HUB AND IIOTOit INNER GRWf
cotter pin (Figs. 73 and 74). ASSEMBLY lEAR lNG RETAINEI

~
CUP
ADJUSTING
REAR WHEEL NUT

The rear brake drum wheel and

tire assemblys are mounted on the
rear axle shaft flange studs, and are
retained by the wheel nuts. The rear
wheel bearing is pressed onto the
axle shaft just inside the shaft flange,
and the entire assembly is retained to
the rear axle housing by the bearing
retainer plate which is bolted to the
housing flange.
The inner end of each axle shaft
is splined to the differential in the FIG. 74- Front Hub, Bearings and Grease Retainer- Disc Brakes-
rear axle. Typical

EJ IN-CAR ADJUSTMENTS AND REPAIRS

HOISTING INSTRUCTIONS lteertq Uakap. 1. Raise the car until the wheel
and tire clear the floor.
Damage to suspension and/ or FRONT WHEEL BEARING
steering linkage components may oc- 2. Pry off the hub cap or wheel
ADJUSTMENT cover and remove the grease cap
cur if care is not exercised when
positioning the hoist adapters of 2 The front wheel bearings should from the hub. ·
post hoists prior to lifting the car. be adjusted if the wheel is too loose 3. Wipe the excess grease from
H a 2 post hoist is used to lift the on the spindle or if the wheel does the end of the spindle, and remove
car, place the adapters under the not rotate freely. The followiilg pro- the cotter pin and nut lock.
front suspension lower arms. Do DOt cedure will bring the bearina adjust- 4. If equipped with disc brakes,
dow tbe adapten to eoatact the ment to specification. loosen the bearing adjusting nut
PART 3-6- WHEELS & lYRES 3-49
three .turns. Then, rock the wheel 9. Check the front wheel rotation. 10. Before driving the car (if
and disc assembly in and out several If the wheel rotates properly, install equipped with disc brakes), pump the
times to push the shoe and linings the grease cap and the hub cap or brake pedal several times to obtain
away from the disc. wheel cover. U the wheel still rotates normal brake lining to Diee clear-
5. While rotating the wheel, hub roughly or noisily, clean or replace ance and restore normal brake pedal
and drum or Hub and Disc Assem- the bearings and cups as required. travel.
bly, torque the adjusting nut to
17-25 ft.-lbs. to seat the bearings
(Fig. 75).
a $ t a
6. Back off the adjusting nut 1~
flats i.e. 90° to obtain bearing end
float of the specified .002 - .0065
for disc brakes and .0005 - .0065 for
drum brakes.
7. Selectively position the nut re-
tainer on the adjusting nut so that a WITH WHEEL ROTATING
@
BACK ADJUSTING NUT INSTALL THE LOCK AND
set of.slots lines up ·with the cotter TORQUE ADJUSTING NUT OFF TO OBTAIN THE A NEW COTTER PIN.
pin hole. TO 17-25 FT. LBS. SPECIFIED END FLOAT.

8. Lock the adjusting nut and nut FIG. 75 - Front Wheel Bearing Adjustment
retainer with a new cotter pin.

EJ REMOVAL AND INSTALLATION

HOISTING INSTRUCTIONS If a new wheel is being installed,
Damage to suspension and/ or coat a new valve with lubricant and
steering linkage components may oc- position the valve to the new wheel.
cur if care is not exercised when Use a rubber hammer or a valve re-
positioning the hoist adapters of 2 placing tool to seat the valve firmly
post ·hoists prior to liftina the car. against the inside of the rim.
If a 2 post hoist is used to lift the
car, place the adapten under the 2. Apply rubber lubricant to the
front suspension lower arms. Do aot sealing surface on both tyre beads.
allow the adapten to eoatact the With the outer side of the wheel
ateerlaa Hnkace. · down, pry two beads over the wheel
rim with two tyre irons, or by u5ing
WHEEL AND TYRE REMOVAL FlOSI·A
a rubber mallet.
1. Pry off the wheel hub cap or
cover. Loosen but do not remove 3. Align the balance mark on the
FIG. 76 - Bead Loosening Tool tire with the valve on the wheel.
the wheel lua nuts. with rounded edpe or lroas detlped
1. Raise the car until the wheel for demoundq tubelea tyrea. 4. Hold the beads against the rim
and tyre clear the floor. ftangcs by positioning a tire mount·
3. Remove the wheel lua nuts 4. Leave one tyre iron in position,
and pry the rest of the bead over the ing band over the tire (Fig. 77). If 2
from the bolts, and pull the wheel mounting band is not available, tie
and tyre assembly from the hub and rim with the other iron. Take small
a torniquct of heavy cord around
drum or dise. "bites" with the iron around the tyre
in order to avoid damaging the seal· the circumference of the tire. Tighten
ing surface of the tyre bead. the cord with a tire iron. Center the
REMOVING TYRE FROM WHEEL tire on the wheel with a rubber
5. Stand the wheel and tire up- mallet.
The tire can be demounted on a right with the tyre outer bead in the
mounting machine. Be lUte that tbe drop center wen at the hottom of the 5. Give the tire a few quick bursts
outer lllde of the wheel Ia posidoned wheel. Insert the tyre iron between of air to seat the beads properly,
downward. If tire irons are UJed fol· the bead and the edge of the wheel then inftatc the tire to 40 pounds
low the procedure given here. rim. and pry the wheel out of the pressure. Check to sec that the bead
1. Remove the valve cap and core, tire. positioning rings (outer rings near
and deftate the tyre completely. the side walls) arc evenly visible just
1. With a bead loosening tool, INSTALLING TYRE ON WHEEL above the rim ftanges all the way
break loose the tyr~ side walls from around the .tire. If the rings are not
the wheel (Fig. 69 ). 1. If a used tire is being installed
remove all dirt from the tyre even, deftate the tire completely and
3. Potidon the oater llde of the inftate it again.
wbeel downward, and intert two tyre If a tyre is being mounted to the
irons about 8 inches apart between original wheel, clean the rim with 6. When the rings arc properly
the tyre inner bead and the back side emery cloth or fine steel wool. Check positioned, deflate the tire to the
of the wheel rim. U1e oaly tyre lroal the rim for dents. recommended pressure.
3-50 GROUP 3- SUSPENSION, STEERING, WHEELS & lYRES
WHEEL AND TYRE
INSTALLATION

1. Clean all dirt from the hub.

2. Position the wheel and tyre as-
sembly on the hub. Install the
wheel lug nuts and tighten them
alternately in order to draw the
wheel evenly against the hub.
3. Lower the car to the floor, and
torque the lug nuts to specification FIG. 77 -Tubeless Tyre
Mounting Band

EJ MAJOR REPAIR OPERATIONS

HOISTING INSTRUCTIONS and repacked. If the bearing cups or sembly from the hub with a ·drift.
Damage to suspension and/ or the cone and roller assemblies are 5. aean the lubricant off the
steering linkage components may wom or damaged, they should be inner and outer bearing cups with
occur if care is not exercised when replaced. solvent and inspect the cups for
positioning the hoist adapters of 2 scratches, pits, excessive wear, and
post hoists prior to lifting the car. other damage. If the cups are worn
If a 2 post hoist is used to lift DRUM BRAKES or damaged, remove them with a drift.
the car, place the adapters under 1. Raise the car until the wheel
the front suspension lower arms. Do and tire clear the ftoor. 6. Thoroughly clean the inner and
Dot .Uow the adapten to coatact tbe 2. Remove the wheel cover or outer bearing cones and rollers with
lteertq llabae. hub cap. . Remove the grease cap solvent, and dry them thoroughly.
from the hub. Remove the cotter Do not spin the bearing with
pin, nut lock, adjusting nut, and ftat compressed air.
FRONT WHEEL GREASE SEAL washer from the spindle. Remove
AND BEARING REPLACEMENT the outer bearina cone and roller
AND/OR REPACKING assembly (Fig. 73). 7. Inspect the cone and roller as-
.semblies for wear or damage, and re-
If bearing adjustment will not 3. Pull the wheel, hub, and drum place them if nec:essary. 1'lle CGM
eliminate looseness or roush and assembly off the wheel spindle. ud roller -•blia ad tile ....._
noisy operation, the hub and bear· 4. Remove the arease retainer end IDa cups should be repa.ced • a lllllt
inas shou d be cleaned, inspected, the inner bearing cone and roller u- If .......e to either II CMOUDtend.
PART 3-6- WHEELS & TYRES 3-51

8. Thoroughly clean the r. spindle 4. Remove 2 bolts attaching the

and the inside of the hub with sol- caliper to the caliper bracket. Re-
vent to remove all old lubricant. move the caliper from the disc and
Cover the spindle with a clean wire it· to the underbody to prevent
cloth, and brush all loose dust and damage to the brake hose.
dirt from the brake assembly. To 5. Remove the grease cap from
prevent getting dirt on the spindle, the hub. Remove the cotter pin, nut
carefully remove the cloth from the lock, adjusting nut, and ftat washer
SDindle. from the spindle. Remove the outer
9. If the inner and/ or outer bear- bearing cone and roller assembly INNER CUP OUTER CUP
ing cup(s) were removed, install (Fig. 74). INSTALLATION INSTALLATION
the replacement cup(s) in the hub 6. Pull the hub and disc off the F1057-A
with . the tool shown in Fig. 78. Be wheel spindle. FIG. 78 - Installing Front
. sure to seat the cups properly in 7. Remove the grease retainer and
the hub. the inner bearing cone and roller as-
Wheel Bearing Cup-
sembly from the hub.
Do not pack the cavity between 8. Clean the lubricant off the in- 13. Place the inner bearing cone
the bearings with grease. ner and outer bearing cups with and roller assembly in the inner
solvent and inspect the . cups for cup, and install the new grease re-
10. All old grease should be com-
scratches, pits, excessive wear, and tainer with the reverse end of the
pletely cleaned from the bearings
other damage. If the cups are worn . tool shown in FJg. 78. Be sure that
before repacking them with new the retainer is properly seated.
grease. Pack the bearing cone and or damaged, remove them with a
roller assemblies with wheel bearing drift.
9. Thoroughly clean the inner and
Smear wheel bearing grease
grease. A bearing packer is desira- around seal lip.
ble for this operation. If a packer is outer bearing cones and rollers with
not available, work as much lubri- solvent, and dry them thoroughly. Do 14. Install the hub and disc on
cant as possible between the rollers not spin the bearings with com- the wheel spindle. Keep the bub
and cages. Lubricate the cone sur- pressed air. centered on the spindle to prevent
faces with grease Inspect the cone and roller assem- damage to tht: lff!&Se retainer or the
blies for wear or damage, and re- spindle threads.
11. Place the inner bearing cone place them if necessary. The cone
and roller assembly in the inner cup, and roUer assemblies and the bear· 15. Install the outer bearing cone
and install the new grease retainer ing cups should be replaced as a and roller assembly and the ftat
with the reverse end of the tool unit if damage to either il encoun- washer on the spindle; then, install
shown in Fig. 78. Be Stlre that the tered. the adjusting nut.
retainer is properly seated. 10. Thoroughly clean the spindle · 16. Position the caliper over the
Smear wheel bearing grease and the inside of the hub with solvent rotor and install the 2 attaching bolts.
around seal lip. to remove all old lubricant.
17. Install the wheel and tire on
Cover the spindle with a clean the hub.
12. Install the wheel, hub, and cloth, and brush all loose dust and
dirt from the brake assembly. To 18. Adjust the wheel bearings as
drum assembly on the wheel spin- outlined previously, and install a
dle. Keep the hub centered oa the prevent aettina dirt on the spindle
carefuUy remove· the cloth from the new cotter pin. Bend the ends of the
apindle to prevent diUIUIIe to the cotter pin around the castellations of
puae ret.lner or the apindle threadl. spindle.
the nut lock.
11. If the inner and I or outer
13. Install the outer bearing cone 19. Install the hub cap or wheel
bearing cup(s) were removed, install
and roller assembly and the ftat cover and lower the car.
the replacement cup(s) in the hub
washer on the spindle; then, install
with the tool shown in Fig. 78.
the adjusting out (Fig. 73). FRONT HUB AND DRUM
Be sure to seat the cups propedy In
14. Adjust the wheel bearings as the bub. REPLACEMENT
outlined previously and install a
new cotter pin. Bend the ends of the 12.Do not pack the cavity between
When the hub and drum assembly
cotter pin around the castellatioos of the bearings with grease. is replaced, a new grease retainer
the nut lock. Install the grease cap. All old grease should be com- must be installea in the new assem-
15. Install the hub cap or wheel pletely cleaned from the bearings bly. The new grease retainer sealing
cover. before packing them with new grease. surfaces should be coated with wheel
Pack the bearing cone and roller as- bearing grease.
DISC BRAKES semblies with wheel bearing grease. 1. Raise the car until the wheel
1. Raise the car until the wheel A bearing packer is desirable for and tire clears the ftoor. Pry off the
and tire clear the ftoor. this operation. If a packer is not hub cap or wheel cover, and remove
2. Remove the wheel cover or hub available, work as much lubricant as the wheel and tire assembly from
cap. possible between the rollers and the hub and drum assembly.
3. Remove the wheel and tire from cages. Lubricate the cone surfaces l. Remove the grease cap from
the hub. with grease. the hub. Remove the cotter pin, out
3-52 GROUP 3- SUSPENSION, STEERING, . WHEELS & lYRES

with grease. 4. Remove the protective coating

6. Place the inner bearing cone from the new hub and disc with
and roller assembly in the inner cup, carburettor degreaser. Install new
and install the new grease retainer inner and outer bearing cups in the
with the reverse end of the tool new hub with the tool shown in
shown in F!g. 78. Be sure that the Fig. 78. Be sure to seat the cups
retainer is properly seated. properly in the hub.
Smear wheel bearing grease
around seal lip. S. Do not pack the cavity between
7. Install the new hub and drum the bearings with grease.
assembly on the wheel spindle. Keep
the hub centered on the spindle to All old grease should be com-
prevent damage to the ll'ease ~ pletely cleaned from the bearinp
talner. before repacking them with new
8. Install the outer bearing cone grease. Pack the bearing cone and
and roller assembly and the ftat roller assemblies with wheel bearing
washer on the spindle; then, install grease. A bearing packer is desira-
the adjusting nut (Fig. 73). ble for this operation. If a packer is
9. Position the wheel and tire not available, work as much lubri-
assembly on the new hub and drum cant as possible between the rollen
assembly. Install the wheel lug nuts and cages. Lubricate the cone sur-
and tighten them alternately in order faces with grease. ·
to draw the wheel evenly against 6. Place the inner bearing cone
the hub and drum. Do not exceed and roller assembly in the inner
specifications. cup, and install the new grease re~
FIG. 79- Front Wheel Hub 10. Adjust the wheel bearings as tainer with the reverse end of the
outlined previously, and install a tool shown in Fig. 78. Be sure
Lubrication that the retainer is properly
new cotter pin. Bend the ends of the
cotter pin around the castellations of seated.
lock, adjusting nut, and ftat washer the nut lock. Install the grease cup. Smear wheel bearing grease
from the spindle. Remove the outer 11. Install the hub cap or wheel around seal lip.
bearing cone and roller assembly cover. 7. Install the new hub and disc
(Fig. 73). FRONT HUB AND DISC assembly on the wheel spindle.
3. Pull the wbeel, hub, and drum REPLACEMENT Keep the hub centred on the
assembly off the wheel spindle. spindle to prevent damage to the
When the hub and disc assembly grease retainer.
4. Remove the protective coating is replaced, a new grease retainer
from the new hub and drum with must be installed in the new assem- 8. Install the outer bearing cone
carburetor de greaser. Install new in- bly. The new grease retainer sealing and roller assembly and the ftat
ner and outer bearing cups in the surfaces should be coated with wheel washer on the spindle; then, install
new hub with the tool shown in Fig. bearing grease. the adjusting nut (Fig. 74).
78. Be sure to seat the cups
properly in the hub. 1. Raise the car until the wheel . 9. A4just wheel bearings as out-
and tyre clears the floor. Pry off the lined previously and install a new
hub cap or wheel cover, and remove cotter pin. Bend the ends of the
the wheel and tyre assembly from cotter pin around the castellations of
S. Do not pack the cavity bet the hub and disc. nut lock. ·
ween the bearings with grease. 2. Remove lock wires and 2 bolts 10. Position the caliper over the
attaching the caliper to the spindle. rotor and install the caliper to spindle
All old grease should be com~ Remove the caliper from the rotor bolts. Torque to specification.
pletely cleaned from the bearings and wire it to the underbody to 11. Rewire the caliper mounting
before repacking them with new prevent damage to the brake hose. bolts to specification.
grease. Pack the bearing cone and 3. Remove the grease cap from 12. Position the wheel and tyre
roller assemblies with wheel bearing the hub. Remove the cotter pin, nut assembly on the new hub and disc.
grease. A bearing packer is desirable lock, adjusting nut, and flat washer Install the wheel hub nuts and
for this operation. If a packer is not from tlie spindle. Remove the outer tighten them alternately in order to
available, work as much lubricant as bearing. cone and roller assembly draw the wheel evenly against the
possible between the rollers and (Fig. 77). Pull the hub and disc off hub and disc. Do not exceed
cages. Lubricate the cone surfaces the w.heel spindle. specifications (Part 3-7).
3-53

PART SPECIFICATIONS
3-7

FRONT WHEEL ALIGNMENT

Checki111 Speciftcatiells 0"11111 Re·llttiq SpiCiiiCitieas
Ma1i111m Varlatlo11
FALCON-FAIRLANE-C:.T. * Mill. Mil. letweea WhHis Onlretl Ali1111ellt
Caster -~0 +1" ~· +%0
Camber -~· +1* ~· +W
Toe-in 3/16 in. 5/16 in. - ~in.

Kina Pin Anele 7~·

Turnine Angle of Outside.Wheel With Inside Wheel Turned 20" 17~·

*G.T.-INSTALLATION SPACERS ARE NOT TO BE USED-VEHICLE KERB HEIGHT TO BE EVEN ON BOTH SIDES AT KERB WEIGHT.

FRONT SUSPENSION TORQUE LIMITS REAR SUSPENSION TORQUE LIMITS

Terque ft·LI11 To~• Ft·Us
Ref.
"'· Descrllltlea ....
let.
Dllcrl"lll

1 Shock Absorber Upper Attachment 20-28 1 Sprin~ Shaclde Bars to Body and 15·22
2 Shock Absorber Upper Bracket to 8·13 Spr na
Body 2 Rear Shock Absorber to Upper 15-25
3 Front Suspension Compression 12-17 Mountin& Bracket
Bumper to Body 3 Reer Shock AbsOrber to Rear 15-25
4 Brake Backin& Plate to Spindle 3G-40 Sprin& Clip Plate
5 Upper Arm and Inner Shaft to Body 4 Rear Sprin& to Rear Axle U-bolt Nut 30-45
75-100
6 Spring Seat to Upper Arm 17-25 5 Wheel Nut 85·105
7 Shock Absorber to Sprin& Seat 12-17 6 Rear Sprin& to Rear Sprine Front 45-55
Hanear
8 Wheel Nut 85·105 7 Radius rod (Front) 55·75
9 Wheel Burin& Adjustln& Nut <D17-25 8 Radius rod (Rear) 55-75
10 Ball Joint to Spindle (Upper and ~90
lower)
11 Strut to lower Arm 55-70
12 lower Arm to Underbody 75-100
13 Stabilizer Bar Mountin& Bracket 11·16
to Underbody
14 Strut to Underbody 40-60
15 Stabilizer Bar to Lower Arll 5-10
IALL JOINTS
<D Torque nut to 17-25 ft. lbs. to Radial Plar (Inches)
seat bearings then back off 1~ flats Max. Allowable
i.e.90° . 0.250 at wheel rim
Upper Ball Joint
<J> Torque to specification then Replace if Perceptibly Loose
lower Ball Joint
tighten the nut to the nearest cotter
pin slot and insert the cotter pin.
J-54 GROUP 1- SUSPENSION, STEERING, WHEELS & TYRES

FIG. 80 -Front Suspension Torque Limits

FIG. 81- Rear Suspension Torque Limits

PART 3-7- SPECIFICATIONS 3-55

MUST NOT 8l TWIS TED

FIG. 82-6 Cyl. Power Steering

PULLEY WITH PULL OFF GROOVE
FACING FRONT OF CAR TO BE
PRESSED ON FLUSH WITH END
Torque Limits
OF SHAFT : .010

STEERING LINKAGE TORQUI LIMITS

,.,..n-us
•ef. su-.. Pnlr
No. Descrl~lo• Stllrill Stllrlll
1 Cylinder Mounti'lf Br~eket
to Under body Ide Hole) - 28-35
2 Steerlna Spindle Ann
Connectin1 Rod End to
Spindle Arin ~30-40
3 Idler Ann Mountln1
BriCkel to Underbody 28-35
4 Pitman Ann to Steerln1
Ann·to-ldler Ann ROd or
to Valve and link
Assembly ~35-47
fOR All APPliCATIONS PULLE Y
WITH PUll· OfF GROOVE
5 Steerin1 sclndle Ann
'ACING ,ltONT OF CAR TO Connect n1 Rod to Steer·
,._.,..,_,~"'------ 2!1 ~ Ll Fl
IE PAUSE D ON FlUSH W IT H
END OF SHAFT + .010 inl Ann-to-Idle Ann Rod Gl30-40
6 Cylinder Mountlnlo Bracket
tt to Underbody ( ttom
-
l l. IN.
3A71t MF.
Hole) 40-43
7
8
Power Cylinder to BriCklt
Power t,llinder to Br~eklt
- 18-24

FIG . 82A- 8 Cyl. Power Steering lock ut - 3-5

Torque Limits 9 stnrlq Ge• to Skit Rill 50-&5

10 Pitman Ann to Sector Shaft 150-225
11 Power Cylinder to Control
Rod - 35-47
12 Idler Ann to Steerln1 Ann-
to-Idler Ann Rod. -.so
13 Steeriq S~lndle Ann
Connect1n1 Rod llld
End Clamp to Adjustlna
Sleeve 11-28
G>Torque to low limit of specification; then, tiahten the nut to
the nearest cotter pin slot and insert the cotfer piA.
3-56 GROUP 3- SUSPENSION, STEERING, WHEELS & TYRES

STEERING GEAR POWER

· Gear Ratio
Maxinium (on centre) 17.5:1
Minimum (on lock) 11: 1
Turns of Steerin$ Wheel 2.6
(Stop to Stop)
PRELOADS (AU readings in inch
pounds)
Note: Preloads are cumulative and
must be checked and set in sequence.
1. Seal drag *-1
2. Worm bearing New 2-3 STEERING GEAR MANUAL
Used1-2
3. Gear Drag New 1-1* EXCEPT GT
Used-* GT ONLY
4. Worm follow preload New 6-7 Gear Ratio 20:1 16:1
Used 3-4 Turns of Steering Wheel
5. Rack and Sector New 6-7 (Stop to Stop)
Used3-4 5 4
Total Preload New 15*-19* Worm Bearing Preload in-lbs 3-8 3-8
Used 7*-11~ Total Preload (Worm Bearing
Fluid type M2C33F plus Sector Mesh) in-lbs 10-16 10-16
Fluid capacity'( total syste.r:n) 2.5 pts
Drive belt tension (lbs) Lube Capacity (oz) 11
new belt 120-130 Lube Type ESW-MIC87-A
used belt 90-120

ITIIIINO OIAI TORQUE LIMITS

STIDINO GEAR TOIQUI LIMITS
Sector shaft cover bolts 30ft lbs.
Meshload adjusting screw Sector shaft cover bolts 30 ft lbs.
locknut 30 ft lbs. Meshload adjusting 32.40 ft lbs.
Piston-rack cover 30.40 ft lbs. screw locknut
Pre-load adjuster locknut60.80 ft lbs. Pre-load adjuster locknut60.80 ft lbs.
Flexible Coupling Ball return guide
Attaching nut 48-50 ft lbs. clamp screw 42.60in lbs.
Filler plug 7.9 ft lbs. Flexible coupling
Flexible coupling nuts 12.20 ft lbs. pinch bolts 28,38 ft lbs.

ADJUSTMENTS ALL MODELS: STilliNG COLUMN TORQUE UMITS

Adjusting screw clearance at boHom of sector shaft T-slot-.000"
.002".
Sector Shaft end play-steering link1ge disconnected-none.
DtlcrJ,till T•••
NOTES: ft.US
®Gur-oniJ-IIOt attached to Pttm• Inn.
<!>Total (mesh lold plus worm bea::~~ preiOIID must be 1 minimum
of 2 lb. in. aretter thin worm be«il!l preiOid. . Stearina Wheel Ret1ining Nut 25-30
®Required to rotlle Input shift 1nd Worm wembly pat the Steerina Column to Support Bracket
center high point. !Instrument P1nell 12-16
®Torque required to rotlte input shift 1t :rroxillllttly 1~ Stearina Column Shift Ann to Shift Linklp 20-35
turns either side of center lit• out of Yehle or Pttm• - Sell Ret1iner to DISh P111el
1
16-22
disconnecttell
PART 3-7- SPECIFICATIONS 3-57

COLD TYRE INFLATION PRESSURE P.S.I. (3)

VEHICLE TYRESIZE NORMAL LOAD (1) FULLY LADEN (2)

FRONT REAR FRONT REAR

XA/ZFSEDAN 6.95Ll44PR 24 24 30 32
6 and 8 Cyl. 7.35 L14) 4PR
7.35814) 4PR 24 24 26 28
1858R14 24 22 30 30
E70HR14 22 22 28 28
XAWAGON 7.35L14) 4PR
6and8 Cyl. 7.35814) 4PR 24 24 28 I 32
1858R14 24 24 28 32
E70HR14 24 24 28 32
FALCONG.T. E70HR14 24 24 30 30
UNLADEN LADEN
UTIUTY AND VAN 10 cwt. 7.35L14)4PR 24 24
7.35814) 4PR 28 32
6 and 8 Cyl. 1858R14 24 24 28 32
E70HR14 24 24 28 32
IS cwt. 7.75L14 6PR 24 24 28 36

(1) tyre pressures at normal load apply when the vehicle is loaded with up to three persons.
(2) · fully laden tyre pressures apply when the vehicle is loaded in ex~ss of normal load and up to maximum
rated loads.
NOTE maximum load for passenger vehicles is all seating positions occupied plus 200 lb load in the luggage
compartment when applied to sedan or 300 lb when applicable to station wagon.
Maximum load for commercial vehicles is G.V.W.
(3a) for trailer towing or sustained high speed (1 hour or more) above 75 M.P.H. for bias ply tyres or 85 M.P.H. for radial
ply tyres, cold inflation pressures must be increased by 4 P .8.1.
(3b) do not exceed the following pressures.
Cross ply 4 ply rating 32 p.s.i.
6 ply rating 36 p.s.i.
Radial ply 40 p.s.i.
All tyres are now performance rated by the Australian Rubber Manufacturers Association, and the rating signified by a letter
included in the tyre size nomenclature moulded on the tyre. As applied to the Falcon/Fairlane tyres the letters are as follows:

L 100 mph performance rating (as in 6.95Ll4)

s 110 mph performance rating (as in 7 .35814)
SR 120 mph performance rating (as in 1858R14)
HR(orRH) 130 mph performance rating (as in E70HR14)
w
I
0'1
(X)

TYRE (1) & WHEEL OPTIONS FALCON FAIR LANE

FUT CUS-
0
"c:,.,
STANDARD 500 URA FAIRMONT GT TOM 500 ..
SED WAG UTE VAN SED WAG UTE SED SED WAG SED SED SED
Standard Stamped Whnls: 54A 71A 66A 78A 548 718 668 54C 54D 71D 54H 54E 548 i't'
6.95l14 4 P.R. BSW 5JJ Wheel with 0.5 in. offset STD NA NA NA STD NA NA STD STD NA NA STD STD CJ)
(2) 7.35l14 4 P.R. BSW 5JJ Wheel with 0.5 in. offset RPO STD STD STD RPO STD STD RPO RPO STD NA RPO RPO cCJ)
WSW 5JJ Wheel with 0.5 in. offset RPO RPO RPO RPO RPO RPO RPO RPO RPO RPO NA RPO RPO ""tJ
(6) 7.35S14 4 P.R. BSW 5JJ Wheel with 0.5 in. offset RPO RPO RPO RPO RPO RPO RPO RPO RPO RPO NA RPO RPO m
WSW 5JJ Wheel with 0.5 in. offset RPO RPO RPO RPO RPO RPO RPO RPO RPO RPO NA RPO RPO z
(2) U5L 14 6 P.R. BSW CJ)
&JJ Wheel with 0.5 in. offset NA NA RPO RPO NA NA RPO NA NA NA NA NA NA
(3) 185SR14 Radial 0
ply BSW &JJ Wheel with 0.5 in. offset RPO RPO RPO RPO RPO RPO RPO RPO RPO RPO NA RPO RPO z
ER70H14Wide oval
Rad. ply RSW 6JJ Wheel with 0.5 in. offset RPO RPO RPO RPO RPO RPO RPO RPO RPO RPO NA RPO RPO
~
m
"led Stnl Wheel (4) & Sports Road Whnl (5):
27.35L14 4 P.R. BSW 5JJ Wheel with 0.5 in. offset RPO RPO RPO RPO RPO RPO RPO RPO RPO RPO NA NA NA
m
;o
WSW 5JJ Wheel with 0.5 ill. of.fset RPO RPO RPO RPO RPO RPO RPO RPO RPO RPO NA NA NA
7.35S14 4P.R. BSW 5JJ Wheel with 0.5 in. offset RPO RPO RPO RPO RPO RPO RPO RPO RPO RPO NA NA NA
z
WSW 5JJ Wheel with 0.5 in. offset RPO RPO RPO RPO RPO RPO RPO RPO RPO RPO NA NA NA
G'>
(2) 7.75L14 6 P.R. BSW &JJ Wheel with 0.5 in. offset NA NA RPO RPO NA NA RPO NA NA NA NA NA NA
(3) 185SR14 Radial ~
ply BSW &JJ Wheel with 0.5 in. offset RPO RPO RPO RPO RPO RPO RPO RPO RPO RPO NA NA NA J:
ER70H14Wide oval m
m
,...
Rad. ply RSW 6JJ Wheel with 0.5 in. offset RPO RPO RPO RPO RPO RPO RPO RPO RPO RPO STD NA NA CJ)

~
FOOTNOTES TO TABLE
(1) All lyres are now performance rated by the Australian Rubber Manufacturers Association, and the rating signified by a letter included intyre size nomenclature moulded on the tyre.
As applied to the Falcon/Fairlane tyres the letters are as follows: ~
;o
L - 100 mph performance rating (as in 6.95L 14) m
CJ)
S - 110 mph performance rating (as in 7.35S14)
SR - 120 mph performance rating (as in 185SR14)
HR (or RH)-130 mph performance rating (as in ER70H14)
(2) 7.35l14 Tyras are standard on 10 cwt Utility and Van, however when 15 cwt load option is specified 7.75l14 Six Ply tyres are required and no further tyre option is available.
(3) 185SR14 Radial Ply tyres are minimum requirements with Sports Handling Suspension RPO on 302 CID V-8 and 351 CID 2V V-8 engined vehicles.
(4) The Styled Steel Road Wheels as well as being standard on Falcon GT constitute part of the Rally Pack RPO and 7.35l14 lyres are minimum requirement with the Rally Pack RPO.
(5) 7.35l14 lyres are minimum requirement with the Sports Road Wheel RPO.
(6) 7.35S14 lyres are minimum requirement with 351 2V engine RPO.
FALCON FAIRLANE w~:~~~~P

GROUP
REAR AXLE
4

PAGE

PART 4-1 Rear Axles 4-2

PART 4-2 Rear Axle Overhaul 4-14

PART 4-3 Specifications 4-28

4-2

PART REAR AXLES

4-1
Section Page Section Page
1 Identification, Description and Operation 4-2 3 In-Car Adjustment and Repair ... ... ...... 4-9
2 Diagnosis and Testing . 4-5

0 IDENTIFICATION DESCRIPTION AND OPERATION

IDENTIFICATION ALL INTEGRAL CARRIER All unit bearings are manufac-
REAR AXLE ASSEMBLIES tured with a built-in adjustment of
INTEGRAL CARRIER
HAVE TAPERED ROLLER .007" to .018" "bench" end play
CONVENTIONAL &
UNIT TYPE AXLE SHAFT or axial clearance. This "bench"
LIMITED SLIP AXLES
BEARINGS FITTED end play is reduced when the bear-
A metal tag with the axle assembly Construction design is a single ing is pressed on the axle shaft. The
part number, axle serial number and row, pre-set tapered roller bearing final assembled end play on the
axle ratio is fixed to the right hand capable of accepting thrust loads shaft of .001" to .015" is dependent
upper cover plate bolt. in either direction and radial loads on the dimensions of the inter-
In addition to this tag the integral in any combination. ference fit between the cone and the
carrier limited slip axle has a tag The tapered roller unit type bear- axle shaft. The standard recom-
attached under the oil filler plug. ing consists of five basic parts: mended cone fit is .001" to .0022*
This tag states "SPIN RESIS- the cup or outer race, the cup rib tight. The cups are a loose fit in the
T ANT DIFF. USE APPROVED ring, the cone, or inner race, the housing. Used bearings may have
LUBRICANT ONLY". tapered rollers which roll freely a maximum of .025" end play.
REMOVABLE CARRIER between the cup and cone, and the The bearing is held on the shaft
TRACTION LOK AXLE cage which serves as a retainer to by the interference fit of the bearing
maintain the proper spacing bet- cone and the retaining collar. The
The removable carrier "Traction cup and rib ring are clamped
Lok" rear axle has a tag attached ween the tapered rollers grouped
around the cone. together in the axle housing through
under one of the upper carriers to the seal by the clamping plate. The
housing bolts. This tag identifies When the bearing is manufac-
tured, the cup and rib ring are axle seal wipes on the rotating axle
the 2. 75 : 1 ratio as 2L 75-9 and shaft and at the time functions as a
the 3.00 : 1 ratio as 3L00-9 in the bonded together with an adhesive
to facilitate bearing handling and static seal to prevent lube from
lower left corner. escaping between the housing and
DESCRIPTION installation. Since the cup and rib
ring are clamped together in the seal outside diameter.
INTEGRAL CARRIER It is important to note that the
CONVENTIONAL AXLE axle housing, there is no need for a
permanent bond. When the bear- seal also acts as a "spacer" in the
The rear axle is of the hypoid, clamp up of the bearing in the axle
semi-floating type using shim adjust- ing is serviced the cup will usually
be separated from the rib ring. housing. It is imperative that the
ment of bearing preloads. The specified seal is used.
differential case with ring-gear and TAPERED ROLLER UNIT The UNIT TYPE BEARING
the drive pinion, are mounted in TYPE BEARING requires no periodical maintenance
opposed taper roller bearings in the when in service.
one piece rear-axle carrier. Both two l
LIMITED SLIP AND
and four pinion differential assem-
TRACTION LOK AXLES
blies are used.
The splines on the axle shafts 1. CUP The limited slip and traction lok
engage splines in the differential side 3. axles perform the same functions as
gears and the axle shafts are held in 2. CUP RIB the conventional type rear axle, ·and
the carrier by ball bearings and RING in addition they transfer driving
retainers at the axle housing outer 3. CONE forces to the wheel with traction

1
ends. Axle shaft end play is pre-set should the opposite wheel begin to
and is not adjustable. Gear ratios 4. ROLLERS spin.
are given on the identification tag. 5. CAGE INTEGRAL CARRIER LIMITED
All operations other than removal ------- SLIP
of the axle shafts and the pinion oil The differential housing is identi-
seal, should be carried out with the FIG. 1 -Tapered Roller cal with the conventional axle as is
unit removed from the vehicle. Unit Type Bearing the ring gear and pinion. The differ-
PART 4-1-REAR AXLE 4-3

FIG. 2 - Exploded View Integral Carrier Conventional Axle

Assembly with Tapered Roller Unit Type Axle Shaft Bearings- Typical

DIFFERENTIAL DIFFERENTIAL
COVER BOLTS

~
\
THRUST
WASHER
PINION

~
( DIFFERENTIAL
CAP
DIFFERENTIAL
BOLTS I
/ PINION THRUST
THRUST
WASHER BLOCK
PINION SHAFT
DOWEL

FIG. 3 - Integral Carrier Limited Slip Differential

4-4 GROUP 4-REAR AXLE
entia! case houses two cone type pinion shaft in front of the pinion one composite plate (steel on one
clutches behind the side gears. These gear with a collapsible spacer. A side and friction material on the
cones are splined to the axle shafts, straight roller (pilot) bearing sup- other) stacked on a clutch hub, and
their tapered faces bearing on the ports the pinion shaft at the rear of four ear guides are housed in the
differential case. Springs enclosed the pinion gear. Pinion and ring gear differential cover. Located in the
in two thrust blocks and interposed tooth contact is adjusted by adding differential case between the side
between the two side gears pre-load or removing shims from between the gears is a one-piece pre-load plate
the gears and cones, forcing the pinion retainer and the carrier and block and four calibrated pre-
tapered face of the cones into contact housing. load springs, which apply an initial
with the differential case. The partial The differential assembly is moun- force to the clutch pack. Additional
locking action, due to the spring load ted on two opposed tapered roller clutch capacity is derived from the
on the cones is automatically in- bearings, which are retained in the side gear thrust loads. The four
creased by the inherent separating carrier by removable caps. The friction plates are splined to the
forces between the side gears and entire carrier assembly is bolted to clutch hub which in turn is splined
pinions. This locking action directs the axle housing. to the left axle shaft, and the eared
the major driving force to the wheel Ball bearing assemblies (rear wheel steel plates are dogged to the case;
with the greater traction. bearings) are pressed onto the outer thus, the clutch is always engaged.
ends of the axle shafts and set in the OPERATION
REMOVABLE CARRIER
outer ends of the axle housing. These INTEGRAL CARRIER
TRACTION LOK AXLE
bearing~ support the semi-floating
The rear axle is of the banjo- CONVENTIONAL AXLE
axle shafts at the outer ends. The
housing hypoid gear type using a inner ends of the shafts spline to the The rear axle drive pinion receives
9 inch ring gear, in which the centre- differential side gears. Bearing re- its power from the engine through
line of the pinion is mounted below tainer plates hold the shafts in the the transmission and drive shaft. The
the centreline of the ring gear. housing. The left and right axle pinion gear rotates the differential
The pinion gear and the pinion shafts are not interchangeable, the case through engagement with the
bearings are assembled in a pinion left shaft being shorter than the right. ring gear, which is bolted to the case
retainer which is bolted to the The Traction-Lok (torque se~si­ outer flange. Inside the case, there
carrier. The pinion is straddle tive) locking differential (Fig. 4) are two or four differential pinion
mounted; that is, it is supported by employs a multiple disc clutch to gears mounted on the differential
bearings both in front of and to the control differential action. Shim(s) pinion shaft which is pinned to the
rear of the pinion gear. Two opposed which control side gear mounting case. These pinion gears are engaged
tapered roller bearings support the distance, four steel, four friction and with the side gears, to which the axle

RING GEAR
4209

FRICTION CLUTCH
PLATES-4945

SIDE GEAR
DIFFERENTIAL
THRUST WASHER
CASE COVER
4228
4204

CENTER BLOCK
(SHORT PINION
SHAFT SEATl
4420

PRE"·LOAD SPRING
PLATE-4A326
Plt~IONGEAR
THRUST WASHER
4230 CLUTCH PLATE STEEL CLUTCH
@NION DIFFERENTIAL! EAR GUIDES (4} PLATE S-4947
4A323

FIG. 4 -Removable Carrier Traction Lok Differential

PART 4-1-REAR AXLES 4-5
shafts are splined. Therefore, as the spin will occur if over acceleration is REMOVABLE CARRIER
differential case turns, it rotates the attempted. However, with the limi- TRACTION LOK AXLE
axle shafts and rear wheels. When it ted slip differential, when the ten- The clutch capacity, due to the
is necessary for one wheel and axle dency for wheel spin occurs, the preload springs and side gear thrust
shaft to rotate faster than the other, friction generated between the cones loads, resists differential action.
the faster turning side gear causes and the differential case transfers the Under normal cornering, the clutch
the pinions to roll on the slower turn7 major driving force to the non- slips as the torque generated by
ing side gear to allow differentia'! spinning wheel. In the event of con- differential action easily overcomes
action between the two axle shafts. tinued spinning a whirring sound is the clutch torque capacity allowing
produced due to over-running of the normal differential action to take
INTEGRAL CARRIER cones; such a condition or sound
LIMITED SLIP AXLE place. Under adverse weather condi-
does not indicate failure of the unit. tions where one or both wheels may
When the rear wheels are under be on a low traction surface such as
extreme unbalance tractive condi- snow, ice or mud, the friction
tions, such as one wheel on dry road between the clutch plates will transfer
and the other in mud or ice, with a portion of the usable torque tQ the
the conventional differential wheel wheel with the most traction.

EJ DIAGNOSIS AND TESTING

DIAGNOSIS GUIDE conditions must be considered nor- nostic experts. Axle noises faiJ into
mal. Axle noise tends to peak or be two basic categories: gear noise
Certain rear axle and drive line more pronounced at varying speeds and/ or bearing noise.
trouble symptoms are also common and the noise is in no way a sign
to the engine, transmission, tyces of trouble in the axle.
and other parts of the car. For this
reason, be sure that the cause of Where noise is present in an ob-
GEAR NOISE
the trouble is in the rear axle be- jectionable form, loud and/ or at all
fore adjusting, repairing, or re- speeds, the first effort should be Abnormal gear noise can be rec-
placing any of the axle parts. made to isolate the noise. Rear axle ognised since it produces a cycling
noise is quite often confused with pitch and will be very pronounced
other noises such as tyre noise, in the speed range at which it oc-
REAR AXLE NOISE DIAGNOSIS
transmission noise, driveshaft vib- curs, usuaiJy under drive, float,
Noise characteristics in a rear ration and universal joint noise·. cruise or coast conditions. Gear
axle are more difficult to diagnose Isolation of the noise in any one noise tends to peak in a narrow
and repair than mechanical fail- unit requires skill and experience. speed range or ranges, while bear·
ures. Slight axle noise heard only An attempt to eliminate a slight ing noise will tend to remain con-
at a certain speed or under remote noise may baffle even the best diag- stant in pitch.

REAR AXLE TROUBLE SYMPTOMS AND POSSIBLE CAUSES

Since gears are in mesh, some tyres, drive the car over several
rear axle noise is normal. However, different types of road surfaces.
excessive noise often indicates the Smooth asphalt or black-top roads
beginning of other troubles in the minimize tyre noises. Tyre noises
axle. may be eliminated by cross-switch-
ing the tyres. Snow tyres often
A road test can help determine cause noises not heard with con-
whether the noise is being caused ventional tyres.
by trouble in the rear axle or m
other parts of the car. Before road· Noise caused by a worn or dam-
testing the car, make sure that the aged wheel bearing is often loudest
tyre pressures and the rear axle when the car is coasting at low
EXCESSIVE REAR AXLE NOISE lubricant level are normal. Then speeds, and it usuaiJy stops when
the brakes are gently applied. To
drive the car far enough to warm
find the noisy bearing, jack up each
the axle lubricant to its normal op-
wheel and check each bearing for
erating temperature.
roughness while the wheel is rotat-
With the car stopped and the ing.
transmission in neutral, run the en- If all possible external sources of
gine at various speeds. If the noise noise have been checked and elim-
still exists during this test, it prob- inated, and the noise still exists,
ably comes from the engine or the road test the rear axle under aiJ
exhaust system. four driving conditions~rive,
To determine if the noise is being cruise, float, and coast. Any noise
caused by the rear axle or the produced by the sidegears and pin-
4-6 GROUP 4-REAR AXLE

REAR AXLE TROUBLE SYMPTOMS AND POSSIBLE CAUSES (cont.)

EXCESSIVE REAR AXLE NOISE wns in the differential case will be and ftoat noise differs with speed
most pronounced on turns. A con- and if the noise is very rough and
tinuous whine under a light load irregular; worn, rough or loose
between 20 and 35 miles per hour differential or pinion shaft bearings
indicates rough or brinnelled pinion are indicated. Remove, disassemble,
bearings. If the tone of drive, coast and inspect the axle.

EXCESSIVE REAR AXLE Excessive backlash in the axle lash between the drive pinion and
BACKLASH driving parts may be caused by ring gear, excessive backlash in the
worn axle shaft splines, loose axle differential gears, or bearings which
shaft ftange nuts, loose U-joint are worn or out of adjustment.
ftange mountings, excessive. back-

BEARING NOISE DRIVE SIDE COAST SIDE

DESIRABLE PATTERN'
Defective bearings will produce SHIM CORR~CT
BACKLASH CORRE CT
a whine that is constant in pitch
and varies with vehicle speed. This
fact will help distinguish between TOE T OE
bearing and/ or gear noise.
1. Pinion bearing noise can be
identified as a constant grinding
noise. Pinion bearings are rotating
at a higher speed than differential FIG. 5 -Ideal Tooth Pattern
side bearings or axle shaft bear-
ings. The noise is most noticeable mined by the ratio and the number (a) The drive pattern should be
at a slight pull between 18 to 26 of teeth in the gears. The non-hunt- fairly well centred on the tooth.
miles per hour. ing and partial non-hunting types (b) The coast pattern should be
can be identified by marks on the centred on the tooth but may be
2. Wheel bearing noise may be pinion and ring gear teeth. slightly toward the toe.
confused with rear axle noise. To See Page; 4-2 for complete identification
differentiate between wheel bear- specifications.
ings and rear axle, drive the car
on a smooth road at medium low
speed. With traffic permitting, turn
the car sharply right and left. If
noise is caused by wheel bearings,
the no~se will increase on the de-
fective bearing because of side
loading.
3. Side bearings will produce a
constant grinding noise of a slower
nature than pinion bearing, (side
bearing noise cannot be determined
by the wheel bearing test), but will
be in the same frequency as axle
shaft bearings.

GEAR TOOTH CONTACT FIG. 7 -Unacceptable

PAnERN CHECK
FIG. 6 -Acceptable Non-Hunting Pattern-
Paint the gear teeth and roll a pattern
as described on Page 4 -15 . After diag- Hunting Gear Pattern Centre-Toe-Centre
nosing the tooth pattern as explained
here, make the appropriate adjustments
as outlined in 4-17. THE IDEAL TOOTH PAnERN (c) Some clearance between th~>
pattern and the top of the tooth is
In making a final gear tooth con- Fig. 5 shows the ideal tooth pat-
desirable.
tact pattern check, it is necessary tern. This pattern is not a rigid
to recognise the fact that there are standard but merely a general rule. (d) There should be no hard lines
three different types of gear set, where the pressure is high.
In general, desirable tooth pat-
hunting, non-hunting and partial terns should have the following The individual gear set need not
non-hunting. Each type is deter- characteristics: conform exactly to the ideal pat-
PART 4-1-REAR AXLES 4-7
tern in order to be acceptable. DRIVE SIDE COAST SIDE
Characteristic differences between ; BACKLASH CORRECT
.004 THINNER SHIM
I
the three types of gear sets as well REQUIRED
as differences between individual
gear sets of the same type will re-
sult in patterns that are acceptable
yet dift'erent from those shown in
Fig. 5

HUNTING GEAR SET

BACKLASH CORRECT'
In a hunting-type gear set, any .004 THICKER SHIM
REQUIRED
one pinion gear tooth comes into
contact with all drive gear teeth.
In this type, several revolutions of
the ring gear are required to make
all possible gear combinations.

SHIM CORRECT
DECREASE BACKLASH
.004

SHIM CORRECT
INCREASE BACKLASH
.004

FIG.8 -Unacceptable FIG. 11-Typical Gear Tooth Contact Patterns Indicating

Non-Hunting Pattern- Shim or Backlash Change
Centre-Heel-Centre
ACCEPTABLE PATTERN tooth, the pattern is a result of the
combined tooth contacts. Therefore,
the pattern is uniform from tooth
to tooth.

FIG. 9 -Acceptable Non- FIG. 12-Pinion & Ring

Hunting Gear Set-Coast FIG. 10-Acceptable Non- Gear Tooth Contact
Pattern Hunting Pattern-Uniform Adiustment
4-8 GROUP 4-REAR AXLE

UNACCEPTABLE PATTERN PARTIAL NON-HUNTING limited slip or Traction Lok cone or

An erratic tooth pattern on a GEAR SET clutch plate chatter, the vehicle
hunting gear set indicates gear set
In a partial non-hunting type gear should be driven in fairly tight
runout and is caused by one of the circles, 5 times clockwise and 5 times
following conditions: set, any one pinion tooth comes into anti-clockwise at approximately 5
1. Foreign matter between diff- contact with only part of the ring
gear teeth, but more than one m.p.h. to allow lubricant to work in
erential hemisphere gear locating between the cone friction surfaces or
base and back face of crown wheel. revolution of the ring gear is required clutch plates.
2. Faulty gear set to make all possible gear tooth com- If the chatter persists drain the
NON HUNTING GEAR SET binations.
lubricant, refill the axle with the
In a non hunting type gear set, Tooth to tooth pattern uniformity
will usually be in between the hunt- specified lubricant and repeat the
any <>ne pinion gear tooth comes foregoing procedure.
into contact with only a few ring ing and the non-hunting patterns.
gear teeth . In this type, only one Partial non-hunting gear set patterns Should chatter still be evident dis-
revolution of the ring gear is re- will usually be less uniform than mantling of the differential for
quired to make all possible tooth hunting gear set patterns, but more further inspection and repair will be
contact combinations. uniform than non-hunting gear set necessary.
ACCEPTABLE PATTERNS patterns. A whirring sound due to over-
The drive patterns shown in SHIM AND BACKLASH running of the cones in the integral
Figs. 7 and 8 were rolled on two CHANGES carrier limited slip differential is no
different non-hunting type gear The patterns shown in Fig. 11 are indication of unit failure.
sets. The pattern in Fig. 7 runs typical of gear sets that have either To test the Limited Slip or
from the centre toward the toe and an incorrect backlash or an incorrect Traction Lok differentials for correct
then back to centre. The pattern
shim adjustment. Since each gear set operation proceed as follows:
in Fig. 8 runs from the tooth centre
rolls a characteristic pattern, the 1. Raise one rear wheel and re-
patterns in Fig. 11 should be con- move the wheel cover, attach Tool
toward the heel and then back to sidered as typical only and should be
centre. These patterns are not un- T65K-4204-A at the wheel nuts
used as a guide rather than a rigid (Fig. 13).
usual for non-hunting gear sets and standard. The drive pattern is rolled
are acceptable. The pattern on any 2. Place the transmission in neu-
on the convex side of the tooth, and tral.
one ring gear tooth was formed by the coast. pattern is rolled on the
only one pinion tooth coming into 3. Chock the front wheels.
concave s1de. 4. Attach a torque meter of at
contact with it. Because of this lim- DRIVELINE VIBRATION
ited tooth contact, the non-hunting
least 200 ft. lbs. capacity to the
Vehicle vibration and roughness is torque check tool as in Fig. 13 and
pattern can be more erratic than often the result of driveline vari- rotate the axle.
the hunting pattern and still be ac- ations. Driveline disturbance vibra-
ceptable. Likewise, the coast pat- tions are usually high frequency NOTE: The torque required to
tern on a non-hunting gear set is vibrations and are somewhat worse rotate the shaft should be at least
usually less uniform tooth to tooth on acceleration, or rapid deceleration. 40 ft. lbs. for Traction Lok and
than it would be on a hunting gear The vibration produces a buzzing 50 ft. lbs. for limited slip.
set (Fig. 9 ). feeling, a droning condition or, as The initial breakaway torque may
some customers describe, a "pressure be higher than the continuous turn-
Fig. 10 shows a pattern rolled on noise on the eardrums". It is likely ing torque. This is normal.
another gear set. In this cast:, the that the vibration sensation is more The axle should turn with reason-
pattern is fairly uniform from noticeable in the rear seat and over able evenness. However, the torque
tooth to tooth. the driveline, than in any other area may vary up to 40 ft . lbs. on Traction
UNACCEPTABLE PATTERN of the car. Lok differentials.
A non-hunting gear set should be Driveline vibrations frequently If the torque required to continu-
checked for runout and possible re- originate from excessive runout of ously rotate the wheel is outside
placement if the pattern runs from the driveline components, namely specification check the differential
the tooth centre towards the toe and pinion companion flange, the pinion for
back to centre on some gear teeth itself, driveshaft, slip yoke and
(Fig. 7) while on other teeth of the transmission output shaft. Runout
same gear, the pattern runs from the in these components will produce
tooth centre toward the heel and vibrations due to the fact that the
back to centre (Fig. 8). components will be rotating on a
A hunting gear set showing an centre other than the centre of
erratic tooth pattern could have one balance.
of the following conditions: Unbalance of one or more of the
1. Foreign matter between diff- driveline components will produce
erential hemisphere gear locating vibration.
base and back face of crown wheel. Driveline angles and the amount
2. Faulty gear set. of deflection across the universal
A non-hunting gear set requires a joints will also produce similar
change in shimming or backlash when vibrations. FIG. 13- Limited Slip or
its pattern tends to concentrate LIMITED SLIP AND
toward the heel or toe, top or bottom TRACTION LOK AXLES Traction Lok Differential
of most teeth (Fig. 11). When encountering complaints of -Torque Check on Vehicle
PART 4-1-REAR AXLES 4-9

EJ IN-CAR ADJUSTMENTS AND REPAIR

REAR AXLE SHAFT, WHEEL
BEARING, AND OIL SEAL
REPLACEMENT
REMOVABLE CAR·RIER AXLE
..... --
_ ..ll.

1. Remove the wheel and tyre sw. ...

from the brake drum. y I y
2. Back-off the rear brake shoe
adjustments. Remove the nuts that
secure the brake drum to the axle
flange, and then remove the drum
from the flange.
3. Working through the hole
provided in the axle shaft flange,
A &
~
remove the nuts that secure the
wheel bearing retainer. Then pull
the axle shaft assembly out of the
axle housing (Fig. 14 ) .
The brake carrier plate must not
be dislodged. Install one nut to -
ADJUSTAMI
liD NUS
1MI- :us..&

...... ---.
hold the plate in place after the .......,
axle shaft is removed.
4. If the rear wheel bearing is
to t,e replaced, loosen the inner
retainer (Fig. 15). The retainer
will be : ome loose on the shafts, if

FIG. 14 -Removing Axle

Shaft-Typical FIG. 16- Removing and Installing Rear Wheel Bearing
it is nicked deeply in several places ......_iii;,_ (Removable Carrier Axle only)
with a chisel.
5. Remove the bearing from the
axle shaft with the tool shown in
Fig: 16.
6. Inspect the machined surface
of the axle shaft and the axle hous-
ing for rough spots or other irreg-
ularities which would affect the

REMOVAL
INSTALLATION

FIG. 17- Removing and Installing Axle Shaft Seal -

Typical (Removable Carrier Axle only)
sealing action of the oil seal. Care- tainer seats firmly against the
fully remove any burrs or rough bearing.
spots. 9. If the axle shaft oil seal is
7. With the tool shown in Fig. to be replaced, remove and replace
16 press a new rear wheel the seal with the tools shown in
bearing on the axle shaft. The bear- Fig. 17. Soak the new seal in light
ing should seat firmly against thll weight engine oil for A hour prior
shoulder on the shaft. to fitting.
FIG. 1 5 - Removing Rear
8. With the bearing installation Coat the outside edge of seal
Wheel Bearing Retainer tool, press the bearing inner re- with oil resistant sealer and spar-
Ring -Typical tainer on the shaft until the re- ingly lubricate lip of seal.
4-10 GROUP 4-REAR AXLE

10. Place a new gasket on the the backing shoulder in the

brake carrier plate and then slide housing.
the axle shaft into the housin~. 2. Care should be taken when
Start the axle splines into the installing the axle shaft to avoid
side gear, and push the shaft in seal damage. Start the splined
until the bearing bottoms in the end of the shaft into the
housing. differential and start the cup
11. Install the bearing retainer rib ring and seal into the
and the nuts that secure it. Torque housing.
the nuts to 30-35 foot-pounds. 3. Line up the clamping plate to
12. Install the brake drum and the clamping plate bolts and FIG. 19- Tool for Bearing
the drum retain ing· nuts. Adjust push the axle into the housing Removal
the brakes. as far as possible.
new seals and retaining collars
13. Install the wheel and tyre 4. Start the nuts onto the clamp- must be used.
on the drum. ing plate bolts and tighten to
finger tight only. Then tighten 2. Check the clamping plate for
INTEGRAL CARRIER AXLE damage or distortion with a
all nuts to approximately 15 ft. straight edge. If the plate is
REMOVAL OF AXLE SHAFT pounds torque. The nuts
FROM AXLE HOUSING . should be tightened in such a distorted, replace it.
(Brake drums removed) manner to assure that the seal 3. Clean the axle shaft, ensure
Remove the clamping plate and pull the and cup rib ring are drawn that there are no burrs or nicks
shaft from the housing. The UNIT evenly against the cup in the on the bearing seat, cone back-
TYPE BEARING cup will normally housing. The final tightening ing shoulder and chamfer lead-
stay in place in the axle housing when the of the nuts should be done ing to the seal seat. Sharp
axle shaft is removed. The bearing cup with a torque wrench to 30-35 edges or nicks on the chamfer
can be removed from the axle housing ft. pounds. leading to the seal will damage
by using a standard slide - hammer
REAR AXLE BEARING- the seal lips duririg installation
type puller as in Fig. 14.
REMOVE AND INSTALL of the seal on the shaft. To
To Remove avoid damage to the wheel
UNIT BEARING RIB RING studs, place the axle shaft
MOUNTED TOWARD I. Retaining collar removal. The flange face on a support.
AXLE FLANGE retaining collar can be easily
removed by drilling a !" hole 4. Install the clamping plate on
in the outside diameter of the the axle shaft, ensure that it is
collar to a depth approxi- positioned with the clamping
mately three-quarter the thick- face of the plate toward the
ness of the collar. Do not drill bearing.
all the way through the collar 5. Apply grease to the cavity
as the drill could damage the between the seal lips and care-
axle shaft. After drilling the fully slide seal into position
retaining collar, position a on the seal seat. When installed
chisel across the drilled hole the outer face of the seal must
and strike sharply to break be toward the axle flange. Do
FIG. 1 8 -Seal and Unit the collar. not push the seal onto the
NOTE - Backing collars are rough surfaced portion of the
Type Bearing Installation not reuseable after having once seal seat.
The UNIT TYPE BEARING cone been installed and must be
assembly should not be pulled scrapped after removal even 6. The new UNIT TYPE BEAR-
from the axle shaft unless : if some removal method is ING must be lubricated prior
used which does not cause to installation.
1. The seal is to be replaced. Do not wash a new bearing
obvious damage to the collar.
2. The clamping plate has to be 2. Slide the clamping plate and prior to installation. The new
replaced due to damage or seal toward the axle flange. UNIT TYPE BEARING has a
distortion. 3. Position the guillotine type puller protective grease which pro-
3. The bearing is to be replaced. jaws (tool no. XYTC 1225) vides initial lubrication until
The bearing cone assembly should behind the bearing cone face, the re.a r axle lubricating oil
have all parts completely covered ensure that the jaws do not reaches the bearing.
with rear axle oil prior to re- touch the seal seat. If the new bearing has to be
installation into the axle housing. Install the axle with guillotine washed for any reason, it must
Also apply oil to the seal seat on jaws in position into the guillo- then be completely lubricated
the shaft. tine jaw retainer tool - Remove with rear axle oil prior to
the bearing. installation.
Installation of Axle Shaft in Axle NOTE - Do not heat or cut 7. Place the lubricated UNIT
Housing the bearing assembly as damage TYPE BEARING on the axle
1. Install the bearing cup in the to the axle shaft will result. shaft ensuring the cup rib
axle housing, ensure that the To Inst31l ring is facing toward the axle
cup back face is seated against I. When installing new bearings, flange.
PART 4-1-REAR AXLES 4-11

8. Install new retaining collar on after marking the drive shaft tial carrier assembly from the axle
the axle shaft and allow it to and pinion flange to ensure housing.
rest on the UNIT BEARING correct positioning on re- 1. Raise the vehicle and install
cone assembly (Fig. 20). assembly (Fig. 28.) safety stands. Remove both rear
9. Press the UNIT TYPE BEAR- 3. Hold the flange with the tool shown wheels and brake drums.
ING and the retaining collar in Fig. 21 . Remove the pinion shaft nut 2. Make scribe marks on the
on to the axle shaft simul" and spring washer. drive shaft end yoke and the axle
taneously using an installation 4. Mark the end of the pinion shaft U-joint flange to insure proper
tube. Apply sufficient load to and the pinion flange splines for realign· position of the drive shaft at
assure the proper seating of all ment. assembly. (Fig. 28). Disconnect
parts. Check for proper seat- 5. Clean the pinion bearing retainer the drive shaft from the axle U-joint
ing of the bearing cone assem- around the oil seal. flange. Be careful to avoid drop-
bly against the shaft shoulder 6. Remove the pinion flange with the ping the loose universal joint bear-
and the backing collar against tool shown in Fig. 22 . ing cups. Hold the cups on the
the cone face by using feeler 7. Remove the pinion oil seal. spider with tape. Mark the cups so
gauges. R. Check the spline11 on the pinion that they will be in their original
shaft and pinion flange for burrs and if position in relation to the flange
NOTE - When pressing the nece88ary clean up with fine crocus
bearing and retaining collar on when they are assembled. Remove
cloth. Wipe the flange and shaft clean. the drive shaft from the trans-
the axle shaft, be sure all faces 9. Clean the oil seal seat. The lubri.
of the installation tubes are mission extension housing. Install
cant return passage ~ust be clear. an oil seal replacer tool in the
square, parallel and free from 10. Coat the outer edge of the new
any burrs. Installing the re- transmission extension housing to
seal with oil resistant sealer, and install
taining collar in a skewed prevent transmission fluid leakage.
the seal, using the tool shown in Fig. 23.
manner can reduce its holding II. Align the pinion flang~; spline 3. Install an in-lb torque wrench
ability by as much as 50 per mark with the pinion shaft spline mark, on the pinion nut. Record the torque
cent. and install the flange with a smear of required to maintain rotation of the
10. Install axle shaft assembly into lubricant on the splines. pinion shaft through several revolu-
axle housing as detailed on 12. Align the marks on the drive shaft tions.
page 4 ·10. and the pinion flange and install the
drive shaft. 4. Scribe the pinion shaft and
13. Install a new gasket under the the U-joint flange inner surface for
carrier casting rear cover and install the assembly realignment. (Fig. 28).
cover bolts. While holding the flange (Fig. 21),
14. Torque the rear cover bolts to remove the integral pinion nut and
20-25 foot-pounds. washer.
15. Fill the axle with new lubricant to 5. Clean the pinion bearing re-
1" below filler plug. tainer around the oil seal. Place a

FIG. 20- Axle Shaft

Bearing and Seal
Installation FIG. 21 -Typical Drive
Pinion Shaft Nut Removal
DRIVE PINION OIL SEAL
REPLACEMENT DRIVE PINION OIL SEAL OR
Synthetic seals must not be cleaned, FLANGE REPLACEMENT
soaked or washed in cleaning sol- REMOVABLE CARRIER WITH
vents. COLLAPSIBLE SPACER
1. Loosen, but do not remove Synthetic seals must not be
the carrier casting rear cover cleaned, soaked or washed in
to drain the lubricant. cleaning solvent.
2. Disconnect the drive shaft The drive pinion oil seal can be re- FIG. 22 -Typical Drive
from the drive pinion flange placed without removing the differen- Pinion Flange Removal
4-12 GROUP 4-REAR AXLE

drain pan under the seal, or raise the ly, until an additional preload of 8 to
front of the vehicle higher than the 14 in-lb over the original reading is
rear. reached. The preload should not ex-
ceed 8 to 14 in-lb over the original
6. Remove the U-joint flange. reading, or bearing failure may result.
Under no circumstances should the
1. Remove the drive pinion oil pinion nut be backed off tO> lessen pre-
seal. load. If this is done, a new pinion
8. Clean the oil seal seat. bearing spacer must be installed. In
addition, the U-joint flange must
9. Install the new seal in the re- never be hammered on, or pneumatic
tainer. Fig. 23. tools used.
17. Remove the oil seal replacer
tool from the transmission extension
housing. Install the front end of the
drive shaft on the transmission out-
put shaft.
18. Connect the rear end of the
FIG. 26 -Typical Drive drive shaft to the axle U-joint flange,
Pinion Flange Seal aligning the scribe marks made on
the drive shaft end yoke and the axle
Installation U-joint flange. (Fig. 28).

19. Check the lubricant level.

Make sure the axle is in running
position. Add whatever amount of
specified lubricant is required to
FIG. 23-Typical Drive reach the lower edge of the filler
Pinion Flange Seal plug hole.
Installation CARRIER ASSEMBLY
REMOVAL AND INSTALLATION
REMOVAL
1. Raise the vehicle on a hoist
and remove the two rear wheel and
tyre assemblies.
FIG. 27 -Checking
2. Remove the two brake drums
Pinion Bearing Pre-load (3 Tinnerman nuts at each drum)
from the axle shaft flange studs. If
10. Check splines on the pinion difficulty ·is experienced in removing
shaft to be sure they are free of burrs. the drums, back off the brake shoes.
If burrs are evident, remove them by
using a fine crocus cloth, working in 3. Working through the hole pro-
a rotational motion. Wipe the pinion vided in each axle shaft flange, re-
FIG. 24-U-ioint Flange shaft clean. move the nuts that secure the rear
Holding Tool 11. Apply a small amount of lub- wheel bearing retainer plate. Pull
ricant to U-joint sp~ines. each axle shaft assembly out of the
Align scribe marks on U-joint axle housing (Fig. 14). Care must
flange and pinion shaft. be exercised to prevent damage
12. Install the U-joint flange. to the production-type synthetic
13. Install a new integral nut and oil seal, if so equipped. Any
washer on the pinion shaft. (Apply a roughing or cutting of the seal
small amount of lubricant on the element during removal or in-
washer side of the nut). stallation can result in early seal
14. Whilst holding the flange failure. Install a nut on one of the
tighten the nut. (Fig. 21). brake backing plate retaining bolts
15. Tighten the pinion shaft nut, to hold the plate to the axle housing
rotating the pinion occasionally to after the shaft has been removed.
ensure proper bearing seating, and 4. Make scribe marks on the drive
take frequent preload readings until shaft end yoke and the axle U-joint
the preload is at the original recorded flange to ensure proper position at
reading established in step 3. assembly. Disconnect the drive shaft
FIG. 25-Removing 16. After original preload has been at the rear axle U-joint, remove the
U-joint Flange reached, tighten the pinion nut slow- drive shaft from the transmission ex-
PART 4-1-REAR AXLE OVERHAUL 4-13

tension housing. Install an oil seal housing. Install the copper washers When installing an axle shaft, place
replacer tool in the housing to pre- and the carrier-to-housing retaining a new gasket on each side of the
vent transmission leakage. nuts, and torque to specification. brake backing plate and carefully
slide the axle shaft into the housing
5. Place a drain pan under the 3. Remove the oil seal replacer so that the rough forging of the shaft
carrier and housing, remove the tool from the transmission extension will not damage the oil seal. Start
carrier retaining nuts, and drain the housing. Position the drive shaft so the axle splines into the differential
axle. Remove the carrier assembly that the front U-joint slip yoke splines side gear, and push the shaft in until
from the axle housing. to the transmission output shaft. the bearing bottoms in the housing.
6. Instail the bearing retainers on
INSTALLATION 4. Connect the drive shaft to the the attaching bolts on the axle hous-
axle U-joint flange, aligning the ing flanges. Install the nuts on the
scribe marks made on the drive shaft bolts and torque to specification.
1. Clean the axle housing and end yoke and the axle U-joint flange
shafts using k~rosene and swabs. To during the removal procedure (Fig. 7. Install the two rear brake
avoid contamination of the grease in 28). Install the U-bolts and nuts and drums and the drum retaining (Tin-
the sealed ball bearings, do not allow torque to -specification. nerman) nuts.
any quantity of solvent directly on
the wheel bearings. Clean the mating 8. Install the rear wheel and tyre
surfaces of the axle housing and 5. Install the two axle shaft as- assemblies.
carrier. semblies in the axle housing. Care
must be exercised to prevent 9. If the rear brake shoe were
2. Position the differential carrier damage to the oil seals. The backed off, adjust the brakes.
on the studs in the axle housing using shorter shaft goes into the left side 10. Fill the rear axle with specified
a new gasket between carrier and of the housing. lubricant.
4-14

PART REAR AXLE OVERHAUL

4·2
Section Page Section Page
1 Removal and Installation of Rear Axle Differential Assembly Overhaul-
Housing-All .. 4-14 Integral Carrier Limited Slip Differential 4-20
2 Differential Assembly Overhaul- Differential Assembly Overhaul-Removable
Integral Carrier Conventional 4-15 Carrier Traction Lok Axle 4- 20

0 REMOVAL AND INSTALLATION OF REAR AXLE HOUSINGS-ALL

REMOVAL 10. If the old drive pinion and 2. Place r.he brake carrier plates
differential case assemblies are to be in their normal position on the axle
1. Raise the car and support it installed in a new housing, refer to housing. Use ·new gaskets on each
on the underbody Page 4-15 for removal and installation side of the brake carrier plates.
procedures.
3. Install the axle shafts, brake
2. Loosen the carrier casting drums and . wheels.
rear cover and drain the lubricant.
Discard the old lubricant.
4. Attach the hydraulic brake
line 'T' fitting to the axle housing,
3. Disconnect the drive shaft at and secure the hydraulic brake line
the drive pinion flange (Fig. 28 ). in its retainer on the axle housing.

4. Disconnect the shock absor- 5. Raise the axle housing and

bers at the axle housing. connect the shock absorbers.
FIG. 28 -Drive Shaft to
Drive Pinion Flange
5. Remove both axle shafts using 6. Connect the drive shaft at the
the procedure given on Page 4-9. Connection drive pinion shaft.

INSTALLATION 7. Fm the axle with the proper

8. Remove the hydraulic brake grade and amount of lubricant to
'T' connection from the axle hous- 1. Raise the axle housing into i" beiow filler plug.
ing. Do not open the hydraulic position so that the spring clip
brake system lines. Remove the hy- plates can be installed. 8. Road test the car.
draulic brake line from its retain-
inc clip on the axle housing.

7. Remove both brake carrier

plates from the axle housing and
suspend thern above the housing
with mech•nics' wire. The hydrau-
lic brake lines and the parking
brake cables ar~ still attached to
the brake carrier plates.

8. Support the rear axle hous-

ine on a jack, and then remove the
spring clip nuts. ~move the spring
clip plates.

9. Lower the axle housing and

remove it from under the car. FIG. 29-Rear Axle Installation
PART 4-2-REAR AXLE OVERHAUL 4-15
EJ Dl FFERENTIAL ASSEMBLy OVERHAUL INTEGRAL CARRIER CONVENTIONAL

INSPECTION BEFORE tween the teeth. Wrap a cloth a- Under no circumstances should
REMOVAL round the drive pinion flange to the carrier be spread more than
act as a brake. Rotate the drive .020 inch.
gear back and forth (use a box
The differential case assembly
wrench in the drive gear attaching 3. If the differential bearings
&nd the drive pinion should be in-
bolts for a lever) until a clear arc to be removed use the tools
spected before they are removed
tooth contact pattern is obtained. shown in Fig. 33 to remove the old
from the housing. These inspections
can help to find the cause of the bearings and install the new bear-
Certain types of gear tooth con- ings in a press using replacer tool
trouble and to determine the cor-
tact patterns on the drive gear in- 4221A-B Fig. 34.
rections needed. dicate incorrect adjustment. Noise
caused by incorrect adjustment can
Wipe the lubricant from the in- 4. Remove the bolts that attach
often be corrected by re-adjusting
ternal working parts, and visually t.he drive gear to the differential
the gears. Typical patterns and the
inspect the parts for wear or dam- t::ase. Press the drive gear from the
recessary corrections ar~ explained
age. case or tap it off with a soft-faced
on page 4-6
hammer.
Rotate the gears to see if there
Gear tooth r:unout can !lometimes
is any roughness which would in-
be detected by an erratic pattern
dicate defective bearings or chipped
on the teeth. However, a rlial indi-
gears. Check the gear teeth fc1·
cator should be used to measure
scoring or signs of abnormal wear.
the runout of the back face of the
drive gear, as shown in Fig 31
This runout should not exceed .005
mch.

DIFFERENTIAL HOUSING AND

DRIVE PINION REMOVAL

1. Remove the differential bear-

ing cap bolts and bearing caps.

2. Use a spreader (Tool 4010-A,

Fig 32) to facilitate the removal of
the differential housing and bear-
ing cups (see paragraph of "Instal-
lation: Differential Bearing Pre-
load" for spreader details).

FIG. 32 -Differential
FIG. 30-Ring Gear Housing Spreader
Backlash Check
5. With a drift, drive out the
Check the differential case and differential pinion shaft retainer
the drive pinion for end play. pin.

Set up dial indicator (Fig. 30) and 6. Drive out the differential
check points around drive gear. pinion shaft with a drift.
Backlash should be .005 to .007 inch
at tightest point.
7. Use a soft drift to separate
If no obvious defect is noted, the two piece differential case.
check the gear tooth contact. Paint Drive apart through the axle bore
the gear teeth with suitable gear onto one differential wheel (See
marking compound, such as a paste Fig. 35).
made with dry red lead and a little
11i!. A mixture that is too wet will 8. Remove the differential side
run and ~mear. Too dry a mixture
FIG. 31-Ring Gear Runout gear differential pinions and
cannot be pressed out from be- Check washers.
4-16 GROUP 4-REAR AXLE
9. Hold the drive pinion flange their bores. If a 0.0015 inch feeler Wear on the hub of the difl'erential
and remove the pinion nut (Refer gauge can be inserted between a wheel can cause a "chucking" noise
Fig. 21 ). Remove the spring washer. cup and the bottom of its bore at known as "chuckle" when the car
any point around the cup, the cup is driven at low speeds. Wear of
is not properly seated. splines, thrust surfaces, or thrust
10. Remove the pinion flange (Page washers can contribute to excessive
4-11 Fig. 22.) 14. Remove the pinion rear drive line backlash.
bearing cone (See Fig. 38 ).
11. With a soft-faced hammer,
BEARING CUPS
drive the pinion out of the front
bearing cone and remove it through INSPECTION AFTER REMOVAL
the rear of the carrier casting. AND DISASSEMBLY Check bearing q~ps for rings,
scores, galling, or erratic wear pat-
terns. Pinion bearing cups must be
12. Drive against the pinion Thoroughly clean all parts. Al- solidly seated. Check by attempting
front bearing cone, and drive the ways use new solvent when cleaning to insert a 0.0015 inch feeler be-
bearings. Oil the bearings immed- tween these cups and the bottom
iately to prevent rusting. Inspect of their bores.
the parts for any major defects.
Clean the inside of th~ housing be-
fore rebuilding and installing the CONE AND ROLLER
parts. Inspect individual parts as ASSEMBLIES
outlined below.
When operated in the cups, bear-
ing rollers must turn without
GEARS
roughness. Examine the roller ends
for wear. Step-wear on the roller
The pattern taken during disas-
ends indicates the bearings were
sembly should help in judging if
not preloaded properly or the rol-
gears can be reused. Worn gears
lers were slightly misaligned.
cannot be rebuilt to correct a noisy

DRIVE PINION FLANGE

Be sure that the ears of the

FIG. 33 -Differential flange have not been damaged in
removing the drive shaft or in re-
Bearing Removal moving the flange from the pinion.
The end of the flange that contacts
the bearing cone must be smooth.
Polish this face if necessary.
Roughness aggravates backlash
noises and causes wear of the
flange with a resultant loss in pin-
ion bearing preload.

CARRIER CASTING

Make sure that the difl'erential

EI478·A bearing bores are smooth and the
bearing abutment faces are not
FIG. 34-Differential damaged.
Bearing Installation FIG. 35-Separatlng
Differential Assembly DIFFERENTIAL CASE
pinion flange seal and the bearing
cone out of the carrier casting. Carefully examine the case hubs,
condition. Gear scoring is the result
which may have been damaged
13. If the pinion bearings cups of excessive shock loading or the
when the bearings were removed.
are to be replaced, drive them out use of an incorrect lubricant.
The bearing assemblies will fail if
of the carrier casting with a drift. Scored gears cannot be reused.
they· do not seat firmly on the hubs.
Install the new cups with the tools
4615HF and 4625HR. Make sure Examine the teeth and thrust sur- Check the fit of the difl'erential
the cups are properly seated in faces of the difl'erential gears. wheel hubs in the case.
PART 4-2-REAR AXLE OVERHAUL 4-17

ASSEMBLY AND INSTALLATION drive gear, i.e. a washer this pulled into the front bearing cone
amount thinner must be used. and into the flange.
DRIVE PINION SHIM A negative (e.g. - .002") mark-
SELECTION ing means that a washer this size 8. As soon as there is preload
thicker must be used. A zero mark- on the bearings, turn the pinion
The operating positions of the gears ing indicates that the washer sel- shaft in both directions several
require the use of an adjusting shim ected with the gauge is the correct times to seat the bearing rollers.
between the pinion rear bearing cone and one for this carrier I piniOn com- Tighten nut to 240 lb./ft. torque
the pinion gear (Page 4-7, Fig. 12). bination. Position washers are iminimum).
When the shim thickness is decreased, available: .002" increments from
the pinion gear is moved away from the
.084" to .100".
drive gear. When the shim thickness is
increased, the pinion is moved closer to 4. Remove the tools from the
the drive gear. carrier.

Manufacturing objectives are to DRIVE PINION ASSEMBLY AND

make axles with a gear mounting INSTALLATION
<iistance of 3.720 inches. However,
1. Place the shim and pinion
particular gear sets have optimum
mounting distances differing from rear bearing cone on the pinion
this figure. The variation from this shaft. Press the bearing and shim
standard distance is marked on firmly against the pinion shaft
each drive pinion. shoulder ( Fig. 38 ) .
2. Position drive pinion in car-
The drive pinion and ring gear rier and install the original pre-
markings are shown in Fig. 36. The load washer (chamfered side to-
number 5K-25 is the matching num- ward shoulder).
ber that appears on both the drive 3. Lubricate the pinion rear FIG. 37 -Drive Pinion
pinion and the ring gear. When a bearing with axle lubricant.
new gear set is being installed in 4. Lubricate the pm10n front Washer Selection Tool
an axle, be sure that the same mat- bearing cone and place it in the 9. Measure the preload with the
ching number appears on both the housing. tool shown in Fig. 39 . With the nose
drive pinion and the ring gear. 5. Coat the outside edge of a of the carrier up, and the handle
A positive ( +) number on the new oil seal with gasket cement, of the wrench floating, take read-
drive pinion always means that a and install it in the carrier casting. ings with wrench moving through
thinner shim should be installed to 6. Insert the drive pinion shaft several full turns. The correct pre-
move the pinion gear away from flange into the seal and hold it load is 15 to 30 lb. in. including oil
the drive gear. A negative (-) firmly against the pm10n front seal drag. Correct any binding con-
number means that a thicker shim bearing cone. From the rear of the dition (usually caused by dirt or a
should be used to move the drive carrier casting, insert the pinion faulty bearing). If the preload is
pinion closer to the ring gear. shaft into the flange. not in the specified range, use a
To select the correct shim thick- 7. Place the spring washer on thinner preload washer to increase
ness for the drive pinion to be used, the p1mon shaft (concave side preload, and a thicker washer to
follow these steps: against flange) and start the nut. decrease preload.
1. Fit the pinion bearings to Hold the flange with the tool shown 10. Remove the pinion and spac-
the dummy pinion, and position in Fig. 21 , and tighten the pinion ers from the carrier in readiness for
this with spacer in the carrier. shaft nut. As the pinion shaft nut establishing differential case bear-
Tighten the nut to 15-25 lb. in ia tightened, the pinion shaft is ing preloads.
torque, rotating the dummy pinion
back and forth to ensure correct GEAfl SET IDENTIFICATION
seating of the bearing rollers.
2. Position the depth gauge cy-
linder in the carrier and fit the
bearing caps, tightening lightly.
3. Determine the size of pinion
position washer that will pass be-
tween the depth gauge and the
dummy pinion head, Fig. 37 . Ex-
amine the drive pinion installation
marking (Fig. 36). The size of the
pinion position washer should then
be altered as follows:
A positive (e.g. + .002") mark-
ing means that this pinion has to
be set at this number of thous-
andths of an inch further from the FIG. 36-Drive Pinion and Ring Gear Marking
4-18 GROUP 4-REAR AXLE

DIFFERENTIAL CASE ASSEMBLY 8. Use the lock pin to locate hole, with the dial indicator plung-
the two parts of the differential er in contact with the opposite side
AND INSTALLATION case, and press them together. of the carrier opening.
ASSEMBLY 9. Place the drive gear on the 5. Use the spreader to expand
differential case and install the the case until the differential as-
1. Lubricate all the differential
bolts. Torque the bolts to 40-50 lb. sembly with bearings and selected
parts with the recommended rear
/ft. spacers will fit into the carrier.
axle hypoid lubricant, before they
A spread of .010" to .012" is us-
are installed.
INSTALLATION ually sufficient UNDER NO CIR-
2. Install a side gear with thrust DIFFERENTIAL BEARING CUMSTANCES SHOULD THE
washer in the larger part of the PRELOAD CARRIER BE SPREAD MORE
differential case. THAN .020".
1. Select any two spacer wash-
8. Place thrust washers on both ers and place one against each of 6. The differential assembly,
differential pinions and mesh the the ditferential bearing cups. Place with bearing cups and the selected
pinions with the differential side the cups on the bearing cones and spacers held against the bearing
gear in the larger part of the diff- install the differential assembly in cones, may now be fitted to the
erential housing, having the pin- the carrier. When installed, there carrier, first removing the dial in-
ions 180 deg. apart. should be a small amount of end dicator.
play. 7. Release and remove the
4. Rotate the gears to align the
pinions and washers with the shaft 2. With the differential held spreader tool.
holes in the case. firmly against one side of the car- 8. Fit the bearing caps, tight-
5. Install the pinion shaft with rier, use a feeler gauge on each ening the bolts to 35-45 lb. !'t. tor-
care not to damage the thrust side of the centre line of the case que. Note that the caps are identi-
washers and to have the hole in to measure the end play oetween fied by a brand on the side of the
the shaft aligned with the lock pin the cup and the spacer. (See Fig. cap and on the carrier. The caps
hole in the case. 40 ). Rotate the carrier to seat the MUST be replaced in their original
bearing with the feeler gauges in positions, as they are not inter-
6. Assemblies fitted with four position, and check to see that the changable.
pinion differentials must have the end play has not been increased by
differential block fitted to the p:n- this procedure. Assuming two .258" 9. Rotate the differential as-
ion shaft between the differential spacers were used, and .012" feeler sembly at least six times to seat
pinions. The differential half-shafts gauges were needed to eliminate the bearing rollers.
and the additional two 'pinions are the end play, then two .264" spac-
10. Check the preload by meas-
then fitted. ers would also produce zero end
uring with a spring balance the
play. (i.e . .258" + .012"/2).
7. Install the remaining gear tension in a string wrapped around
with thrust washer, in the small 3. Tentatively select spacers the differential case on the larger
part of the differential case. which will increase the total spacer diameter (6.12") just behind the
thickness. .004" (i.e. increase the drive gear ( Fig. 43 ) . Minimum
spacer on each side .002", e.g. each balance reading must be 3.3 lbs.,
spacer becomes .266"). maximum 6.5 lbs. (equals 10 to
20 lb. in preload torque).
4. Fit the carrier spreader ad-
aptors Fig. 41 and the spreader to 11. Remove the assembly from
the carrier, together with a dial the carrier, using the spreader. I!
indicator Fig. 42, positioned over the preload is correct, tie the sel-
the carrier differential opening, as ected spacers to the bearing cups
close as possible to the centre line to have them available for use in
of the axle shafts. This may be determining gear backlash. If the
done by using a pilot stud screwed preload is incorrect, select larger
into the side bearing lower stud or smaller spacers to increase or
decrease preload, then repeat steps
4 to 11.

DRIVE GEAR AND PINION

BACKLASH
1. Install the pinion in the car-
rier in accordance with the proce-
dure of paragraphs 1-9 of Drive
Pinion Assembly and Installation.
FIG. 38 -Drive Pinion
2. Install the differential assem-
Bearing Removal and FIG. 39 -Drive Pinion bly with the tentatively selected
Installation Preload Check spacers in the carrier, following
PART 4-2-REAR AXLE OVERHAUL 4-19

the procedure in Differential Instal- 2. Increasing backlash moves

lation 4•18. the drive gear away from the pin-
3. Measure the backlash shown ion:
in Fig.26. Measure the backlash on (a) Drive pattern moves slightly
several teeth around the drive gear higher and toward the heel.
to· find the minimum position. Back- (b) Coast pattern moves higher
lash here should be .005 to .007''. and toward the heel.
If the backlash . is not within this
range, dee:rease the thickness of 3. Thicker shim with the back-
one differential bearing spacer and lash constant moves the pinion
increase the other by the same closer to the drive gear:
amount. The amount of change of (a) Drive pattern moves deeper
each spacer is very approximately on the tooth (ftank contact) and
equal to the amount of change re- slightly toward the toe.
quired to correct the backlash read- (b) Coast pattern moves deeper
ing. It is most important that the on the tooth and toward the heel.
total thickness of both spacers be 4. Thinner shim with the back-
the same after backlash adjust- lash constant moves the pinion
ment as before, so that correct pre- further from the drive gear:
load is retained.

GEAR TOOTH CONTACT

PATTERN CHECK
FIG. 42 -Dial Indicator
Paint the gear teeth and take a contact
pattern as described in "Diagnosis and
Position for Checking
Testing", Page 4-7, Fig. 11, shows some Carrier Spread
drive and coast patterns and indicates
changes required to obtain the correct 2. Install the cover and a new
operating position of the gears. The gasket on the carrier casting rear
movement 'of tooth contact patterns with face.
changes in gear locations can be sum-
marised as follows: 3. Torque the cover bolts to 20-
25 foot-pounds.
1. Decreasing backlash moves 4. Fill the axle with the proper
the drive gear closer to the pinion: grade of lubricant. The lubricant
level is 1" below the bottom of the
FIG. 41 -Carrier Spreader filler plug hole with the axle in
Adaptors normal running position.
Replace axle housing assy. in
(a) Drive pattern moves toward vehicle, refer 4-14 .
the top of the tooth (face contact)
and toward the heel.
(b) Coast pattern moves toward
the top of the tooth and slightly
tcward the toe.
If the patterns are not correct,
make the changes as indicated.
When the pattern is correct, re-
move the marking compound from
the gear teeth. Regardless of all
previous measurements and other
FIG. 40 -Bearing Cup to factors, the tooth contact pattern
must be correct for successful rear
Spacer End Play Check ax!e operation.
(a) Drive pattern (convex side
AXLE SHAFT, DRIVE SHAFT AND
of gear) moves slightly lower and
REAR COVER INSTALLATION
toward the toe.
(b) Coast pattern (concave side of FIG. 43 -Ring Gear
gear) moves lower and toward the 1. Install the axle shafts. Refer to
toe. Page 4HO for proper procedure. Bearing Preload Check
4-20 GROUP 4-REAR AXLE

INTEGRAL CARRIER 1. Clamp tool T65K-4204-A or NOTE: If the tool or axle shaft
LIMITED SLIP an axle shaft in a vice with approxi- binds in the spline a light tap with a
mately 3 inches extending above the hammer may be necessary.
The removal and installation pro- vice jaws.
cedure, ring gear and pinion settings, 2. Place the cap side of the dif- Mter the unit has been assembled
tooth markings and overhaul pro- ferential case over the extended tool into the housing, do not attempt to
cedure for the limited slip differen- or axle shaft spline with the interior rotate one axle shaft until the other
tial are the same as for the conven- facing upward. shaft is in position. Rotation of one
tional axle, except for servicing the 3. Install the cone (as identified axle shaft without the other shaft
internal components of the differen- in item 6 of disassembly procedure), installed will result in misalignment
tial assembly. over the splines, seating it in position of cone and side gear splines and pre-
DIFFERENTIAL ASSEMBLY in the cap; followed by a shim (if vent entry of the second axle shaft.
originally fitted) and the side gear. "On car" type wheel balances are
DISASSEMBLY not recommended for use on the rear
4. Place a thrust block on the side
1. Place the assembly in a vice gear with the cut outs in line with wheels of cars fitted with Limited Slip
equipped with copper jaws. the pinion shaft groove in the case. or Traction Lok differentials. One
2. Remove the differential cover 5. Install the pinion shaft, pin- rear wheel will drive if in contact
to cap attaching bolts and lift off the ions and thrust washers. Position the with the ground when the opposite
cover. shaft so that the dowel hole is in line wheel is raised.
3. Remove the cone, side gear, with the hole in the cap, and install The torque required to turn the
thrust block, thrust springs, pinion the dowel. side gears and cones prior to assem-
shaft and gears. 6. Install the thrust springs and bling the differential to the axle
4. Remove the remaining thrust place the second thrust block over housing is 50 lb. ft. minimum. This
block, side gear and cone. the springs. figure can be checked using tool
5. Withdraw the pinion shaft 7. Place the remaining side gear T65K-4204-A as illustrated in Fig.
dowel from the case. 44. If under this test the torque is
on the thrust block.
6. Remove the cones from the 8. Install a shim (if originally below the specified 50 lbs. ft. it may
cap and differential cover, if they fitted) on the side gear and place the be adjusted by altering the shims
have remained with their respective cone on top. between the side gears and cones.
mating parts. 9. Install the differential cover Two shims of 0.005 and 0.010
NOTE: To ensure that the cones over the cone, making sure the inches thick are available for this
are not interchanged during re- matched stampings on both halves purpose.
assembly, mark the cone and the of the case are in line. REMOVABLE CARRIER
corresponding side of the differential 10. Install two attaching bolts in TRACTION LOK AXLE
case with a daub of paint. Also check opposite holes and tighten finger
for any shims which may be fitted tight. OVERHAUL PROCEDURES
between the cones and side gears. 11. Install the remaining part of
tool T65K-4204-A with adaptor Mter removing the carrier from
INSPECTION AFTER REMOVAL the axle housing as described in
spline, or an axle shaft through the
AND DISASSEMBLY differential cover, rotating the tool to Part 4- 2 mount the carrier in a
Thoroughly clean and dry all parts enter the cone splines and then the holding fixture. Then disassemble the
and inspect for the following: side gear splines. Leaving the tool in carrier as outlined in the following
1. The cone seats in the cap and this position install the remaining procedures.
cover should be smooth and free of bolts and tighten evenly to 21-26 REMOVAL AND
any excessive scoring. Slight grooves lbs. ft. DISASSEMBLY OF
or scratches are permissible and 12. Remove the tools or axle shaft DIFFERENTIAL CASE
normal. from the assembly.
1. Mark one differential bearing
2. The land surfaces of the cones cap and the mating bearing support
will duplicate the case surface con- with punch marks to help position
dition. Excessive wear or damaged the parts properly during assembly
cone surfaces will necessitate renewal of the carrier. Also, mark one of the
of the cone and casing. bearing adjusting nuts and the carrier
3. Inspect thrust springs for with scribe marks for proper location
damage and comparitive free-length. during assembly.
Replace where necessary. 2. Remove the adjusting nut
4. Check the thrust blocks for locks, bearing caps, and adjusting
excessive wear. nuts. Then lift the differential
ASSEMBLY assembly out of the carrier.
NOTE: When assembling the unit 3. If the differential bearings are
use tool T65K-4204-A with spline to be removed, use the tool shown in
adaptors or axle shafts·as a mounting Fig. 46.
to ensure correct alignment of the
FIG. 44 -Limited Slip or 4. Mark the differential case,
side gear and cone splines. Attempt- Traction Lok Differential cover, and ring gear for assembly in
ing to force the axle shafts through the original position.
-Torque Check on 5. Remove ten bolts securing the
misaligned splines will result in
damage to the spring thrust blocks. Diff. Assembly Removed ring gear to the differential case
P.ART 4-2-REAR AXLE OVERHAUL 4-21

assembly. The ring gear must be

removed in order to separate the case
halves.
6. Remove the ring gear by tap-
ping the gear with a soft hammer or
press the gear from the case.
7. Place the differential case in a
press to load the case at the bearing
journals so that the pre-load of the
springs is overcome (approx. 1,500
lbs.). (If a press is not available,
two 7/16" bolts and nuts can be
used in the ring gear mounting
holes (one on each side) to com-
press the case halves together
and overcome pre-load spring
tension.) Then, while the case is
still under pressure, loosen the two FIG. 47 -Removing
Allen or Phillips head screws which Differential Pinion
hold the case halves together until
one or two threads of the screws Shaft Lock Pin
remain engaged. Remove the case pin hole ( Fig. 48).
assembly from the press. Tap on the 12. Remove the two short pinion
cover to spring it loose; then, remove shafts using a drift, driving each
both screws. shaft from the centre outward. Lift
8. With the cover facing down, FIG. 46 -Differential out the centre block, then remove the
lift off the case. Remove the pre-load Bearing Removal pinion gears, thrust washers and side
spring plate and four pre-load springs. gear and thrust washer.
9. From the cover remove the the pinion shaft lock pins from the 13. If the differential bearings are
side gear, four clutch plate ear guides, case (Fig. 47 ). removed, the bearing~ can be instal-
clutch hub, friction and steel clutch 11. With a brass drift, drive out led in one of the following ways:
plates and shim(s). the long pinion shaft from the case. a. With the differential case and
10. With a suitable drift, drive out Drive from the end opposite the lock cover completely assembled.

DIFFERENTIAL
COVER
\
SIDE

DIFFERENTIAL
CAP
DIFFERENTIAL
BOLTS I
/ THRUST
THRUST
WASHER BLOCK
PINION SHAFT
DOWEL

FIG. 45 - Integral Carrier Limited Slip Differential

4-22 GROUP 4-REAR AXLE

FIG. 48- Driving Out

Differential Pinion Shaft
DIFFERENTIAL BEARING

b. On the case or cover when dis-

assembled. However, when press-
ing the bearing on the cover, a
block of wood or fibre must be
used as shown in Fig. 49 in order
to avoid damage to the cover.
ASSEMBLY
1. Lubricate all parts with ESW-
M2C-119-A locker lubricant during
assembly.
2. Mount the differential case in
a soft jawed vice and place a side gear FIG. 49-lnstalling Differential Bearing Traction Lok
thrust washer and side gear in the
counterbore of the case.
3. Install the pinion thrust wash-
ers and place the pinion gears on the
side gear aligning the holes in the
washers and gears with the holes in
the case.
4. Install the centre block so that
the shaft holes are aligned with the
holes in the pinion gears and case.
The centre block has two mach-
ined sides and two rough sides.
5. With a brass drift, drive in the
long pinion shaft from the outside of
the case aligning the lock pin holes in
the shaft with the holes in the case.
The centre block should be posi-
tioned so the long shaft is driven
through the rough side and short
shafts driven through the mach-
ined side (Fig. 50). PRELOAD SPRINGS

6. With a suitable drift, install

the shaft lock pins. Make sure the
pinion and side gears move freely.
7. Place the four pre-load springs
in the holes provided in the centre
block.
8. Position a pre-load plate over
the four springs, making sure the
springs are properly seated. The pre-
load plate straddles the centre block
over its narrower or machined width.
9. Mount the differential cover in
a soft jawed vice or holding fixture.
10. Insert shim(s) of 0.050 total
thickness in the cover cavity. FIG. 50 - Center Block and Pre Load Springs
11. When new clutch plates are
used, soak the plates in ESW- Installation
PART 4-2-REAR AXLE OVERHAUL 4-23

M2C-119-A lubricant for approxi-

mately 30 minutes before instal-
lation.
12. Place the clutch hub with the
clutch plates into the clutch ear
cavities in the differential cover.
Make sore that the splines on the last DIFFERENTIAL COVE
friction plate are engaged on the hub.
13. Obtain locally a i" x 2!" or
-&" x 2!" bolt, nut and two lt" out-
side diameter flat washers approx. i •
in thickness. These parts are required
to compress the clutch pack in order
to obtain the proper shim selection
(Fig. 51). Install a flat washer on the
bolt, and place the bolt through the
clutch hub. Hold the bolt in position
and turn the cover over. Place a flat
washer on the bolt and then install
the nut. Be sure the washers are
centred, and torque the nut 10 to
15 lb. ft. (Fig. 52).
14. Place the shim template tool
(T68P-4946-A) in the clutch hub
(Fig. 52). Some clearance should be
observed between the shim tool and
the cover-to-case mating surface.
Using a feeler gauge, determine
the exact amount of clearance.
Refer to the shim pack thickness
chart which will indicate the correct
amount of shim(s) to subtract from
the 0. 050 shim originally installed.
In order to correctly select the
proper shim(s), the shim tem- FIG. 51 -Clutch Pack
plate tool and the chart must be
used.
Installation
15. Mter the proper shim selection
is determined, remove the bolt, nut
and flat washers. If it is necessary to
revise the shim thickness, remove the
clutch hub and clutch plates.
16. Install the selected shim(s) in
the cover cavity, re-install the com-
ponents as outlined in Steps 8 and 9.
17. Install the four steel clutch ear
guides and side gear.
18. Place both assemblies in a press,
and press the two halves together;
then, insert the two Allen head or
Phillips head screws, and tighten
evenly until tight. If a press is not
available, any two stock bolts and
nuts may be used opposite each other
in the ring gear retaining holes to
compress both halves.
19. Install the ring gear and ring
gear bolts and washers. Tighten
evenly and alternately across the dia-
meter of the ring gear. Torque the
bolts to 65-80 ft-lbs.
20. Prior to installation of the
Traction Lok differential into a
vehicle, a bench torque check must
be made. With currently released
locker tools, check the torque re- FIG. 52- Shim Template Tool Application
4-24 GROUP 4-REAR AXLE

SHIM PACK THICKNESS CHART TRACTION-LOK DIFFERENTIAL

Feeler Remove Shim(s) Total Req'd Feeler Remove Shim( s) Total Req'd
Gauae From Shim Pack Gauae From Shim Pack
Readina Nominal Thick ness <D Readina Nominal Thickness <D
0.001
0.002 None 0.050 0.028
0.029
0.030 0.030 0.020
0.003 0.031
0.004 0.032
0.005 0.005 0.045
0.006
0.007
0.033
0.034
0.008 0.035 0.035 0.015
0.009 0.036
0.010 0.010 0.040 0.037
O.Oll
0.012

0.013 0.038
0.014 0.039
0.040 0.040 0.010
0.015 0.015 0.035
0.016 0.041
0.017 0.042

0.018 0.043
0.019 0.044
0.020 0.020 0.030 0.045 0.045 0.005
0.021 0.046
0.022 0.047

0.023
0.024 0.048
0.025 0.025 0.025 0.049 0.050 0.000
0.026 0.050
0.027
<DService Shims are available in 0.010" and 0.005" Thicknesses.

quited to rotate one side gear while gear set is installed during assembly,
the other is held stationary. The a new shim will have to be installed.
initial breakaway torque may exceed The original shim thickness is one of
250 lb. ft. The rotating torque re- the factors necessary in determining
quired to keep the side gear turning the new shim thickness. Extreme
with new clutch plates is 100 to 250 care must be taken not to damage
lb. ft. With re-used clutch plates, the the mounting surfaces of the
minimum torque required is 40 lb. ft. retainer and carrier.
(The torque may fluctuate 10-40
lb. ft.).
REMOVAL AND
DISASSEMBLY OF
DRIVE PINION AND
BEARING RETAINER
1. Turn the carrier case upright,
and remove the pinion shaft nut
(Fig. 24). Then remove the U-joint
flange (Fig. 25).
2. Remove the seal (Fig. 53) and
the slinger.
3. Remove the pinion, bearing,
and retainer assembly from the car- FIG. 54 -Removing
rier housing. Measure the shim
thickness with a micrometer. Record FIG. 53- Removing Pinion Front Bearing
this original shim thickness. If a new Pinion Seal Cone
PART 4-2-REAR AXLE OVERHAUL 4-25

FIG. 55-Removing FIG. 58- Removing Pinion

Pinion Rear Bearing Rear Bearing Cup
Cone
4. Place a protective sleeve (hose)
on the pinion pilot bearing surface.
Press the pinion shaft out of the
pinion front bearing cone (Fig. 54).
5. Press the pinion shaft out of FIG. 56 -Removing
the pinion rear bearing cone (Fig. 55). Pilot Bearing
PARTS REPAIR OR in the retainer by trying to insert a
REPLACEMENT 0.0015-inch feeler gauge between
the cup and the bottom of the bore.
Clean and inspect all the parts. Be- Whenever the cups are replaced
fore assembling the carrier, repair or the cone and roller assemblies should
replace all parts as indicated by the also be replaced.
inspection.
The principal replacement opera- PINION BEARING SPACER
tions are covered in the following INSTALLATION
procedures. All other repair or re- 1. Install the drive pinion rear
placement operations are performed bearing cone and roller on the pinion
during cleaning and inspection, or shaft (Figs. 60 or 61).
during the assembly in this section. Place a new spacer on the pinion FIG. 59 - Installing Pinion
PILOT BEARING shaft (Fig. 62). Front Bearing Cup
2. Place the bearing retainer on
1. Remove the pilot bearing as the pinion shaft, and install the front
shown in Fig. 56. Drive out the pilot
bearing and the bearing retainer to- Tooi-T62F-4625-A
or 4625 -AC-l and 2
gether.
2. Drive the new bearing in until
it bottoms as shown in Fig. 57. l.~~~~-- DRIVE
3. Using the same tool, install a PINION
new pilot bearing retainer with the
concave side up.
PINION BEARING CUPS
Do not remove the p1mon
bearing cups from the retainer
unless the cups are worn or dam-
aged. The flange and pilot of the
retainer are machined during manu-
facture by locating on these cuPS
after they are installed in their bores.
If the cups are worn or damaged,
they should be removed and replaced
as shown in Fig. 58.
Mter the new cups are installed FIG. 57 -Installing Pilot FIG. 60- Installing Pinion Rear
(Fig. 59), make sure they are seated Bearing Bearing Cone
4-26 GROUP 4-REAR AXLE

in the retainer is as specified. If the

torque required to rotate the pinion
is less than specified, tighten the
pinion shaft nut a little at a time until
the proper preload is established. Do
I
C) not overtighten the nut. If exces-
Tooi -4621 -L i sive preload is obtained as a result of
I overtightening, replace the collap-
/ I,,
sible bearing spacer.

FIG. 61- Installing Pinion Rear

FIG. 64- Removing or Installing
Bearing Cone
Pinion and Retainer Assembly
bearing cone and roller. Press the
front bearing cone and roller into
position as shown in Fig. 63. Be care-
ful not to crush the bearing spacer.
3. Lubricate the 0-ring with axle
lubricant and install it in its groove in
the pinion retainer. Be careful not to
twist it. Snap the 0-ring into position. FIG. 63- Installing Pinion
4. Place the proper shim on the Front Bearing
carrier housing and install the pinion
and retainer assembly, being careful Do not back off the pinion shaft
not to pinch the 0-ring (Fig. 64). nut to establish pinion bearing
5. Install the pinion attaching preload. If the torque on the pinion
bolts. Torque the bolts to specifica- shaft nut is less than 175 ft-lbs after
tion. bearing pre-load is established, a new
6. Place the slinger over the collapsible spacer must be used.
pinion shaft and against the front DIFFERENTIAL CASE,
bearing·. BEARINGS AND RING GEAR
7. Install a new seal in the bear-
ing retainer (Fig. 65). If the ring gear runout check (be-
8. Install the U-joint flange. fore disassembly) exceeded specifi- FIG. 65- Installing Oil Seal
9. Start a new iJ?.tegral nut and cations, the condition may be caused entia! side bearings on the case hubs.
washer on the pinion shaft. by a warped gear, a defective case, 2. Place the cups on the bearings
10. Hold the flange and torque or excessively worn differential bear- and set the differential case in the
the pinion shaft nut to 175 ft-lbs. Do ings. carrier.
not exceed 175 ft-lbs at this time. To determine the cause of exces- 3. Install the bearing caps and
11. Check the pinion bearing pre- sive runout proceed as follows: adjusting nuts as outlined in step 11
load as shown in Fig. 66 . Correct 1. Assemble the two halves of the thru 14 under Assembly and Instal-
pre-load will be obtained when the differential case together without the lation of the Differential Case in this
torque required to rotate the pinion ring gear, and press the two differ- section.

0 -RING
PILOT
LOCK FLANGE

mb;
BEARING

N~~, ~'I PILOT

FRONT BEARING PINION BEARING
SEAL RtTAINER SHIM

E 1782-A

FIG. 62- Pinion and Bearing Retainer

PART 4-2-REAR AXLE OVERHAUL 4-27

installed shim is of the correct thick-

ness to adjust for individual vari-
ati(ms in both the carrier housing
dimension and in the original gear
set dimension. Therefore, to select
the correct shim thickness for the
new gear set to be installed, follow
these steps:
1. With a micrometer, measure
the thickness of the original shim re-
moved from the axle and use the
same thickness upon installation of
FIG. 67- Pinion and Ring the replacement carrier assembly or
FIG. 66- Checking Pinion Gear Markings drive pinion. If further shim change
specifications, the ring gear is true is necessary, it will be indicated in
Bearing Preload the tooth pattern check.
and the trouble is due to either a
4. Tighten the right nut two defective case or worn bearings. 2. If the original shim is lost,
notches beyond the position where 7. Remove the differential case substitute a nominal shim for the
it first contacts the bearing cup. from the carrier and remove the side original and use the tooth pattern
Rotate the differential case several bearings from the case. check to determine if further shim
revolutions in each direction while 8. Install new bearings on the changes are required. Nominal shim
the bearings are loaded to seat the case hubs, and again install the differ- thickness is indicated in the Specifi-
bearings in their cups. This step is ential assembly in the carrier with- cations Section.
important. out the ring gear. A new ring gear and pinion should
5. Again loosen the right nut to 9l Check the case runout again always be installed in an axle as a
release the preload. Check to see that with the new bearings. If the runout matched set (never separately). Be
the left nut contacts the bearing cup. is now within limits, the old bear- sure the same identifying (mat-
Using a dial indicator, adjust the ings were excessively worn. Use the ching) number, painted in white,
preload to 0. 012 case spread for new new bearings for assembly. If the appears on the bolt hole face of
bearings or 0. 005 to 0 . 008 for the runout is still excessive, the case is the ring gear and on the head of
original bearings, if re-used. defective and should be replaced. the drive pinion (Fig. 67).
6. Check the runout of the differ- 3. After determining the correct
ential case flange with a dial indicator. DRIVE PINION AND shim thickness as explained in the
If the runout does not now exceed RING GEAR SET foregoing steps, install the new
specifications, install a new drive When replacing a ring gear and pinion and ring gear as outlined
gear. If the runout still exceeds pinion, note that the original factory under Assembly.
4-28

PART SPECIFICATIONS
4-3

ADJUSTMENTS INTEGRAL CARRIER AXLES

Inch
Backlash between Ring Gear and Pinion 0.005"~.007"

Backlash Variation between Teeth Max. 0.003"

Rear Bearing Cone to Drive Pinion-Available Shims
Thickness 0.080"~.1 00" in 0.002" increments
Differential Bearing Adjustment-Available Shims
Thickness 0. 254"~.28·4"' in 0.002" increments
Drive pinion preload adjustment-Available Shims
Thickness 0 .070"~ . 106" in 0.00 I" increments
Runout of beck face of ring gear as assembled Max. 0.005"

INTEGRAL CARRIER LIMITED SLIP AXLE

Minimum rotating torque required to turn axle shaft and side gear with one wheel on ground .. 50 lbs. ft.
Rotating torque required during bench check after assembly original or new cones and housing 50 lbs. ft.

DIIVI PINION ADJUSnNG SHIM THICKNISS CHANGII--INCH

Old P111t1 New Pinion Mullin&

lllrklll -4 -S -2 -1 0 +4
+1 +2 +3
+4 +0.008 +0.007 +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
+1 +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 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
-3 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008
PART 4-3-SPKfiCAnONS 4-29

REMOVABLE CARRIER TRACTION LOK NOTE: All specifications are civen in inches unless otherwise noted.

Backlash between ring qear and pinion 0 . 008-0. 012

Maximum backlash variation between teeth 0 .003
Maximum runout of backface of ring gear 0 .003
Differential side gear thrust washer thickness 0 .030-0.032
Differential pinion gear thrust washer thickness 0 .030-0 . 032
Nominal pinion locating shim 0 .015
Available pinion gear shims in steps of . 001 0 .010-0 .029
Maximum radial runout of U joint flange in assembly 0 .010T.I.R.
•Minimum torque required to tighten pinion flange nut to obtain correct pinion
bearing preload 175 lbs. ft.
Pinion bearing preload original bearings. with oil seal 8-14 lbs. in.
Pinion bearing preload new bearings. with oil seal 22-32 lbs. in.
Minimum rotating torque required to turn axle shaft and side gear with one
wheel on ground 40 lbs. ft.
tRotating torque required during bench check after assembly
original clutch plates 40 lbs. ft. min.
new clutch plates 100-250 lbs. ft.
•If pinion bearing preload exceeds specification before this torque is obtained. install a new spacer.
tRotating torque may fluctuate up to 40 lbs. ft.

TORQUE LIMITS INTEGRAL CARRIER AXLES

Torque Umm Ft. Lbs.

Rear Cover Bolts 20- 25
Differential Bearing Cap Screws 35-45
Drive Pinion Nut (Minimum Torque) 240-280
Ring Gear Attaching Bolts 40- so
Rear Springs to Axle Housing U Bolts 35- so
Universal Joint Bolt Nuts
Axle Identification 199071 199072 199073 12- IS
199069 199070 7- 10
Rear Shock Absorber to Rear Spring IS- 25
Clip Plate Assembly Nuts IS- 25
Axle Shaft Bearing Retainer Nuts 30-35
Pinion Bearing Preload (Including Oil Seal Drag) IS-301b. ins.
Differential Assembly Pre·Load (Pull Measured 3.31b. Min.
From String Wrapped Around the Differential Case
larger Diameter b.Sib. Max.

REMOVABLE CARRIER TRACTION LOK

Differential bearing cap bolt 70-85 lbs. ft.

Differential bearing adjusting nut lock bolts 1 2-25 lbs. ft.
Carrier to housing stud nuts 25-40 lbs. ft.
Pinion retainer to carrier bolts 30-45 lbs. ft.
Ring gear attaching bolts 65-80 lbs. ft.
Oil filler plug 25-50 lbs. ft.
Rear axle shaft bearing retainer bolt nuts 30-35 lbs. ft.
4-30 GROUP 4-REAR AXLE

REAR AXLE LUBRICATION

INTEGRAL CARRIER CONVENTIONAL

GRADE SAE 90
FORD SPECIFICATION ESW-M2C-108A
CAPACITY 2.3 IMP. PINTS

INTEGRAL CARRIER LIMITED SLIP

GRADE SAE 90
FORD SPECIFICATION ESW-M2C-1006A
CAPACITY 2.3 IMP. PINTS

REMOVABLE CARRIER TRACTION LOK

GRADE SAE 90
FORD SPECIFICATION ESW-M2C-119A
CAPACITY 4 IMP. PINTS

REAR AXLE RATIOS, GEAR AND CODE IDENTIFICATION

Identification Ring Gear Ring Gear Pinion Drive Gear

Ratio Type Label Dia.lns. No. of Teeth No. of Teeth

3.23 : 1 2 Diff Pinion 199 265 7.5 42 13

2.92 : 1 2 Diff Pinion 199 267 7.5 38 13
3.5 :1 2 Diff Pinion 199 266 7.75 35 10
3.23 : 1 2 Diff Pinion L.S. 199 268 7.5 42 13 (1)
2.92 : 1 2 Diff Pinion L.S. 199 271 7.5 38 13 (1)
3.5: 1 2 Diff Pinion L.S. 199 269 7.75 35 10 (1)
3.23 : 1 4 Diff Pinion 199 273 7.5 42 13
2.92 : 1 4 Diff Pinion 199 272 7.6 38 13
3.50: 1 4 Diff Pinion 199 270 7.75 35 10
2.75 4 Diff Pinion D2DW-BA 9.00 33 12 (2)
3.00 4 Diff Pinion D2DW-CA 9.00 39 13 (2)

(1) Integral Carrier Limited Slip

(2) Removable Carrier Traction Lock

AXLE APPLICATION BY VEHICLE MODEL

Falcon Falcon Falcon Falcon Fairlane

Engine Transmission Sedan Wagon Ute and Van G.T. Sedan
200-1 v 3 Speed Manual 3.23 3.23 3.5 - -
Auto 3.23 3.23 3.5 - -
250-1 V-2V 3 Speed Manual 3.23 3..23 3.23 - 3.23
4 Speed Manual 3.23 3.23 3.23 - 3.23
Auto 2.92 2.92 3.23 - 2.92
302-2V 3 Speed Manual 2.92 2.92 2.92 - 2.92
4 Speed Manual 2.92 2.92 2.92 - -
Auto 2.92 2.92 2.92 - 2.9 2
351-2V 4 Speed Manual 3.0 - 3.0 Ute only - -
Auto 2.75 - 2.75 Ute only - 2.75
351-4V 4 Speed Manual - - - 3.0 -
Auto - - - 2.75 -

All 351 C.I.D . vehicles are equipped with Traction Lok axles (L.S.D.).
L.S.D. (Integral carrier) is optional on all 2.92. 3.23. and 3.5 axles.
FALCON FAIRLANE w~:~~~~P

DRIVE LINE AND CLUTCH

GROUP
5

PAGE

PART 5-1- Drive Line 5-2

PART 5-2- General Clutch Service 5-8

PART 5-3- Clutch 5-12

PART 5-4- Specifications 5--21

5-2

PART
5·1 DRIVE LINE

~tion Pace Section Pap

1 Description and Opet·ation ...... ...... ...... ...... ...... 5-2 3 Replacement .. .... . ..... ...... ...... ...... ...... ...... 1).2
2 Tl'ouble Diagnosis ... .. .... ...... ...... ...... ...... ...... 5-2 Removal ..... ...... ...... ...... .... .. .. .. .. ...... ...... ... ... 5-2

0 DESCRIPTION AND OPERATION

The drive shaft is the means of joints when necessary. The splines All universal joints have the cap
transferring power from the engine in the yoke and on the transmission retaining clips on the inside of the
to the differential in the rear axle output shaft permit the drive shaft drive-shaft yokes.
and then to the rear wheels. The to move forward and rearward as
drive shaft incorporates two uni- the axle moves up and down. 351 C.l.D. vehicles have U-bolts
versal joints and a slip yoke. The All drive shafts are balanced. If to attach the rear U .J. to the Pinion
universal joints are provided with the car is to be undercoated, cover Flange (Fig. 1). All other vehicles
a threaded plug which can be re- the drive shaft to prevent applica- use clamp plates and bolts as
moved to lubricate the universal tion of the undercoating material. shown in Fig. 2.

B TROUBLE DIAGNOSIS
DRIVE SHAFT TROUBLE DIAGNOSIS AND POSSIBLE CAUSES

Undercoating or other foreign Drive shaft and universal joints

material on shaft. 180 deg. out of phase.
Universal joint U-bolts loose. Broken rear spring centre bolt.
Universal joints worn, or lack of Broken rear spring.
DRIVE LINE VIBRATION lubricant. Rear springs not matched (sagged
Drive shaft mis-aligned (drive to one side).
line angle). Drive shaft damaged (bent) or
Pinion flange runout. out of balance (missing balance
Pinion runout. weights).

Universal joint U-bolts loose. Worn U-joints.

U.JOINT NOISE Lack of lubrication.

EJ REPLACEMENT
REMOVAL 3. Remove the snap rings that opposite bearings so that the smaller
1. To maintain drive line bal- retain the bearings in the yoke and socket becomes a bearing driver and
ance, mark the relation of the slip drive shaft (Fig. 1&2 ). the larger socket becomes a bearing
yoke and the drive flange on the axle 4. Place the U-joint in a vice or receiver when the vice jaws come
with the shaft so that they may be a press. together (Fig. 3).
installed in their original positions. 5. Select a socket wrench with 7. Close the vice jaws until the
2. Disconnect the rear U-joint an outside diameter slightly smaller spider contacts the yoke or drive
from the drive pinion flange. Pull than the U-joint bearings. Select shaft. Remove the driveshaft from
the drive shaft toward the rear of another socket wrench with an the vice. Remove the one bearing
the car until the front U-joint yoke inside diameter slightly larger than with channel lock pliers.
clears the transmission extension the bearing outside diameter. 8. Reverse the sockets and press
housing and the seal. 6. Place the socket wrenches at the opposite bearing outward until .
PART 5-1-DRIVE LINE 5-3

FIG. 1-Drive Shaft Disassembled-3 51 CID only

(Typical}

).
~
0 0
A J!
FIG. 2 -Drive Shaft Assembly Disassembled FIG. 3- Removing Universal
Joint
-other than 351 CID
the spider contacts the yoke or drive manner as in the yoke. mission, lubricate the yoke spline
shaft. Remove the bearing with 4. Use the same procedure to with automatic transmission fluid.
channel lock pliers. remove and replace the rear U-joint Install the yoke on the transmission
9. Remove the spider from the spi~er and bearings. output shaft.
shaft or yoke. Remove the remaining Check the joint for freedom of 7. Install the U-bolts and nuts/
two bearings in the same manner. movement. If a bind has resulted bolts which attach the U-joint to
10. If new U-joint bearings are from misalignment during the fore- the drive pinion flange.
being installed, check the new bear- going procedures, tap the ears of the DRIVE LINE VI BRAliONS
ings for adequate grease. driveshaft sharply to relieve the
bind. Do not install the drive-shaft Vehicle vibration and roughness
INSTALLATION unless the universal joints are free is often the result of driveline vari-
1. Position the spider in the of bind. atiQns. Driveline disturbance vibra-
yo}se. Press a bearing into the bore 5. If the rubber seal installed tions are usually high frequency
and onto the spider. Press another in on the end of the transmission ex- vibrations and are somewhat worse
the opposite bore of the yoke and tension housing is damaged in any on acceleration or rapid deceleration.
onto the spider. manner, install a new seal. The vibration produces a buzzing
2. Install the snap ring on each 6. On a manual-shift transmis- feeling, a droning condition or, as
bearing. sion, lubricate the yoke spline with some customers describe, "pressure
3. Install the spider and bear- conventional transmission lubricant noise on the eardrums". It is likely
ings in ihe drive shaft in the same (Group 19). On an automatic trans- that the vibration sensation is more
5-4 GROUP 5-DRIVE LINE AND CLUTCH
noticeable in the rear seat and over PROPERLY SEA TED CUP SI1AVES LUG
the driveline, than in any other area
of the car.
Driveline vibrations frequently
originate with excessive runout of
the driveline components, namely,
pinion companion flange, the pinion
itself, drive-shaft, slip yoke and
transmission output shaft. Runout in
these components will produce vib-
rations due to the fact that the com-
ponents will be rotating on a centre
other than the centre of balance.
Unbalance of one or more of the
driveline components will produce
vibration.
Driveline angles and the amount
of deflection across the universal
joints will also produce similar
vibrations.
DIAGNOSIS PROCEDURES:

Road test for the presence of con-

ditions described previously.
Driveline and running gear vibra-
tions can be separated from engine
and sometimes transmission vibra-
tions by use of the following methods:
1. Install a tachometer and note FIG. 4 - Universal Cup to Pinion Flange Fit
the engine speeds at which the vibra-
tion occurs. Stop the vehicle and
operate the engine at the speeds
noted above. If the vibration is pre-
sent, the problem is in the engine or
transmission input component areas.
2. Operate the vehicle in high
gear in the speed range which pro-
duces the maximum vibration. If
practicable, shift the transmission
into intermediate gear and note if
there is a change in the vibration. If
the vibration is unchanged, usually
the engine and transmission can be
eliminated as the source of the prob-
lem. Repeat the above procedure but
shift the transmission to neutral and
shut off the engine. Again if the
vibration is unchanged, it can be
assumed that the engine and input
,members of the transmission are not
at fault.
3. Raise the car on a hoist or
place the car on jack stands and
operate the vehicle at the same road FIG. 5 - Checking Flange Bearing Cup Runout
speeds that produce the vibration
noted in the road test. While opera- indicated on the speedometer. Quick- type that supports the axle housing
ting at this speed, carefully adjust ly engaging the driveline should re- and proceed as follows:
engine R.P.M. so that the maximum produce the vibration level of the 1. With the driveshaft removed,
amplitude of the vibration can be driveline which, when being operated check the companion flange for
noted and felt. Holding the acceler- on jack stands, is about twice the damage to the universal joint bearing
ator pedal steady, disengage the level as that actually experienced out location lugs and proper bearing
driveline by either moving the shift on the road. seating. Investigation of driveline
lever to neutral or depressing the vibration complaints has disclosed
clutch and observing whether or not CHECKING COMPANION FLANGE
that some complaints are the result
the vibration diminishes in direct
proportion to speed of the car as
To check a companion flange, of improper assembly of the com-
place the vehicle on a hoist of the panion flange and driveshaft. Accu-
PART 5-1-DRIVE LINE 5-5

mulation of dimensional tolerances in AVERAGE OF READINGS

the companion flange and rear uni-
versal joint assembly can result in Ind icator Flange Bearing Drivesh aft Un iversa l
excessive interference between the Cup Runout Cross Shaft Runout
companion flange locating lugs and 1 3 5
universal joint bearings.
If this condition exists and the 2 5 3
bearings are forced into the com- 3 4 4
panion flange, it is possible to shave Average 4 4
metal off the lugs. The result wi:l be
a severe vibration condition. See
Fig. 4.
It will be necessary to replace the
companion flange whenever inspec-
tion discloses evidence of damage to
either of the universal joint locating
lugs.
Tight or binding universal joint
bearings must be corrected or re-
placed. The universal joint bearings
should be checked for any evidence
of• binding during the companion
flange inspection.
2. Install a universal joint assem-
bly in the companion flange. (Modify
the universal joint assembly by re-
moving the driveshaft bearing cups
and cutting off one of the driveshaft
bearing cup trunnions.) See Fig. 5.
3. Install a dial indicator on the
pinion retainer or pinion nose bumper
bracket in a position that will allow FIG. 6 -Checking Driveshaft Universal Cross Shaft Runout
indicating the ends of the universal
joint bearing cups and the remaining the cross shaft. See Fig. 6. Make Position a straight edge at the amount
end 'of the cross shaft. Install a cup sure that the end surface of the cross of flange bearing cup runout indi-
shaped adaptor on the dial indicator shaft is perpendicular to the indi- cated above on the left hand line of
stem. See Fig. 5. cator cup. This requires that the the chart. Position the other end of
4. Turn the companion flange so cross shaft be moved fore and aft.on the straight edge at the amount of
that the dial indicator cup is bearing the flange bearing cups noting the driveshaft universal cross shaft run-
on the machined end surface of1:he point at which the indicator hand out indicated on the right hand line
bearing cup. Refer to Fig. 5 . The reverses direction. Then rotate or of the chart. The straight edge will
flange should be rotated slightly to rock the flange assembly until the indicate the amount of combined
obtain the reading which indicates cross shaft is perpendicular on the runout on the middle line of the
that the bearing cup surface is per- pinion shaft axis and the indicator chart. For example: with an indicated
pendicular to the indicator cup. This hand reverses direction. . 003" flange bearing cup runout and
will be the point at which the dial 6. Zero the dial indicator and an indicated . 004" driveshaft uni-
indicator cup is closest the centre of recheck the zero point slightly rock- versal cross shaft runout, the com-
companion flange rotation. It is also ing the cross shaft fore and aft and bined companion flange runout,
the point at which the dial indicator then rocking the .companion flange according to the chart will be . 005"
hand will reverse direction as the side to side. as indicated on the centre column of
companion flange is turning. Set the 7. Carefully retract the dial stem the chart.
indicator to zero. and rotate the flange 180°. Rotate the The Falcon companion flange rur.-
5. Carefully retract the dial stem cross shaft 180° on the flange bearing out specification is . 008" maximum.
and rotate the companion flange 180° cups to position the cross shaft under However, in some vehicles it may be
to position the opposite flange uni- the dial indicator cup. Rock the cross necessary to reduce the runout to
versal joint bearing cup machined shaft fore and aft and the companion . 005" in order to obtain maximum
surface under the indicator cup. side to side to establish the point at vibration reduction.
Again slightly rotate or rock the flange which the indicator hand reverses Note that according to the chart,
to position the bearing perpendicular direction. This will determine the runout of . 003" in one dimension
to the dial indicator cup. Again, this is driveshaft universal cross shaft run- and up to . 004" on the other dimen-
the point at which the indicator hand out. Record this reading. sion will result in desirable . 005"
will reverse direction as the flange is 8. Repeat Steps '4' through '7' combined runout. However, if the
rotated. Record the indicator runout at least three times and average the runout exceeds . 005" on either
reading. indicator runout readings obtained. measurement, the combined runout
6. Rotate the companion flange 9. In order to determine the total will be . 005" or more.
90° and position the dial indicator companion flange runout, it will be NOTE: If it is not possible or
cup on the machined end surface of necessary to use the chart in Fig. 7. practical to rework a universal joint
5-6 GROUP 5-DRIVE LINE AND CLUTCH
flAN GE BEAR ING Co.eiNEO RUNOUT OfiiiVE SHAF T UN IVERSAL
CUP RUN().JT CROSS SI1AF T RUN OUT 12. If the runout is still exces-
.009 sive, replace the companion flange
and recheck runout. If necessary,
rotate flange on pinion shaft until
acceptable runout is obtained.
.006 006 13. If excessive runout is still
evident after replacement of the
companion flange, it will be necessary
to replace the ring and pinion gear
.008 and repeat the above checks until
runout is within specifications.
Lateral runout of the pinion drive
flange universal joint bearing cup
seats, can be measured in the fol-
lowing manner.
005
1. Using the modified universal
.007 joint described in the preceding
paragraphs, measure the outside dia-
meter of the two opposite cups and
note any variation; mark the larger
cup. In this case it is preferable to
obtain two cups of the exact same

--
.006 size. Remove the remaining bearing
cup.

---
2. Rework two universal joint

-- - ---
U-boltsfclamp plates as shown is
Fig. 8, i.e. grind half the fiat
;,005 surface away.
,.,.,...,\.,
---
3. Raise the vehicle on a frame
~ contact hoist or jack the rear of the
.003 003 vehicle and fit body stands .
. 00~ 4. Fit the universal joint into
the flange with the relieved portion
of the U-bolts/clamp plate toward
.003 the centre of the flange (refer Fig. 8) .
.001 001
5. Mount a dial gauge from the
.001 differential housing so that the stylus
.00 1 001 contacts the smaller of the universal
.0(11
.000 .000 000 joint bearing cups.
6. Rotate the flange slightly until
FIG. 7 Runout Chart the dial gauge indicates the highest
point of the cap. Zero the dial gauge.
7. Lift the dial gauge stem suffici-
assembly in the manner described, ently to allow clearance as the flange
the above checks can be made with- is rotated through 180° to the
out the rework. This can be accom- opposite cup.
plished by taking readings on both 8. Lower the stylus onto the cup
ends of the cross shaft. However, it and rotate the flange until the highest
wili be necessary to take two com- point of the cup is indicated. Note
plete sets of readings in order to the dial gauge reading and subtract
eliminate any possible dimensional the cup variation as in Item '1'.
errors in the cross shaft from affect- 9. Repeat Steps '6', '7' and '8' at
ing the companion flange runout least three times and average the
readings. The second set of readings
must be read with the universal joint result.
If the average measurement is
assembly rotated 180° on the com-
greater than . 002 inches, a new
panion flange. flange should be fitted and again
10. If the reading obtained in checked to this procedure.
Step '9' exceeds specifications, re- DRIVESHAFT RUNOUT CHECK:
position the:: companion flange on the Check the driveshaft runout 5"
pinion shaft 180° and repeat Steps from each end and in the middle of
'4' through '9'. the shaft. Driveshaft runout should
11. If the repeat readings still not exceed . 020" at any of the three
exceed specifications, reposition the checking points.
FIG.8 - Universal U-bolts flange an additional90 ° on the pinion Many times a vibration condition
reworked shaft and recheck runout. can be reduced to an acceptable level
PART 5-1-DRIVE LINE 5-7

by rotating a driveshaft that has until it just contacts rotating shaft. If excessive, so to reduce this excess,
some degree of runout, 180° on the carefully done, only the heavy side rotate the clamp heads away from
companion flange. (point of maximum runout) will be each other approximately 45 ° (one
DRIVESHAFT BALANCING marked by crayon. This normally each way from the original position).
PROCEDURE: gives a good indication of which side See Fig. 11. Run car and note if
1. Place the car on a twin post of the shaft is heavy for unbalance unbalance has improved.
hoist so that the rest of the car is and indicates a starting point for 5. Continue to rotate the clamps
supported on the rear axle housing initial location of clamps. apart in smaller angular increments
with wheels free to rotate. 3. Install two Jubilee Type hose until the car feel for unbalance is best.
2. A car is normally more sensi- clamps on the propeller shaft, as 6. Road test the car again for
tive to excessive unbalance at the rear shown in Fig.lO.Position each clamp final check of balance.
so that checking should begin at the with heads 180° from crayon mark- NOTE: Slight vibration felt in the
rearward end of propeller shaft. ing. Tighten clan1ps. car on the hoist may not show up i.ti
Therefore, locate the heavy side of 4. Run the car through the speed a road test which is after all the final
the driveshaft by holding crayon or range to 65-70 mph. If no unbalance determining factor.
coloured pencil close to rearward end is felt, nothing further need be done CAUTION: Do not run car on
of shaft while shaft is rotating on the hoist. However, if unbalance hoist for extended periods due to
(speedometer.indicating 40-50 mph). still exists, the combined weight of danger of overheating of transmission
See Fig. 9. Carefully bring crayon up the two hose clamp heads may be or engine.

FIG. 11 - Positioning Jubilee

FIG. 9 - Driveshaft Balancing FIG. 1 0-lnstallation- Type Hose Clamps on the
Procedure WhiHek Type Hose Clamps Propeller Shaft
5-8

PART GENERAL CLUTCH SERVICE

5-2
1 Diagnosis and Testing .... .. ...... ...... .. .... . .... .. .... 6-8 3 Cleaning and Inspection ... .. . ...... .. .... .... .. ...... 6-10
Diagnosis Guide-Clutch ... ... ... ... ... ... . ... . ... .. . 5·8 Release Bearing ...... ...... ...... .. .... ...... ...... .... .. 5·10
2 Flywheel Housing Alignment .... .. .... .. .... .. ... ... 6· 9 Pressure Plate and Cover ...... ...... ...... ...... ...... 5·11
Inspection ... ... ...... .. .. .. .... .. ... ... ...... ... ... ..... . ...... 6·9 Clutch Disc ...... ...... .. .... ...... ...... ...... ...... ...... 6-11
Correction .. .... .... .. .. .. .. . ..... .. .. .. .. ... . ... ... 5· 9 Pilot Bushing ... ... ...... ...... ...... .... .. ...... ...... ...... 5 ·11

II DIAGNOSIS AND TESTING

DIAGNOSIS GUIDE - CLUTCH
TROUBLE SYMPTOMS POSSIBLE CAUSES CORRECTION

1. Worn clutch disc. 1. Replace worn or defective

EXCESSIVE CLUTCH PEDAL 2. Leaking hydraulic system. parts.
FREE PLAY AND/OR 3. Air in hydraulic system. 2. Check system for leaks.
INADEQUATE RESERVE 4. Worn or failed pressure plate. 3. Bleed system.
4. Replace pressure plate.
1. Lack of lubricant on trans- 1. Clean and lubricate retamer
mission input shaft bearing retainer. with a thin coat of MIC75A grease.
Refill grease groove of clutch release
2. Incorrect assembly of release bearing hub with MIC75A grease.
CLUTCH PEDAL HANG-UP OR lever to pivot or release bearing.
2. Check assembly and rectify
EXCESSIVE CLUTCH PEDAL 3. Internal friction in pressure if necessary.
EFFORT plate (302 C.I.D. engine only). 3. Clean and lubricate sparingly
4. Binding of pedal assist spring with lubri-plate.
bushes (302 C.I.D. engine only}. 4. Lubricate bushes with MIC75A.
CLUTCH NOISY WHEN PEDAL 1. Release bearing failure. 1. Replace bearing.
FREE TRAVEL IS TAKEN OUT,
ENGINE RUNNING
1. Binding at pedal support 1. Lubricate with engine oil or
bracket. replace support bracket bushing.
2. Lack of lubricant on slave 2. Lubricate push rod end with
cylinder push rod end at release MIC75A.
CLUTCH NOISY WITH ENGINE lever.
OFF 3. Clean and lubricate retainer
3. Lack of lubricant on trans- with thin coat of moly base grease
mission input shaft bearing retainer. MIC75A. (No polyethylene.)
4. Binding at assist spring pivots 4. Lubricate spring pivots with
(302 C.I.D. engine only). MIC75A.
1. Worn or contaminated clutch 1. and 2. Replace defective part.
lining. (If grease or oil is causing the clutch
2. Grease or oil on clutch facings to slip, replace the disc. Remove
from: the grease or oil from the pressure
CLUTCH SLIPS OR CHATTERS A.release bearing. plate and flywheel and re-use if it is
B. engine. not burned or scored.) Repair
C. release lever. source of leakage.
D. pilot bearing. 3. Replace pressure plate.
E. transmission.
3. Weak or failed pressure plate. 4. Torque bolts to spec.
4. Loose pressure plate to fly-
wheel bolts.
INTERMITTENT SQUAWK 1. Flywheel housing misalign- 1. Realign housing to specifica-
ment. tion.
PART 5-2-GENERAL CLUTCH SERVICE 5-9
DIAGNOSIS GUIDE - CLUTCH (Continued)

TROUBLE SYMPTOMS POSSIBLE CAUSES CORRECTION

CLUTCH NOISY WHEN 1. Pilot bearing worn. 1. and 2. Replace bearing.
DISENGAGED ENGINE
2. Release bearing worn.
RUNNING
1. Failed or worn pressure plate. 1. Replace pressure plate.
2. Grease on linings of clutch 2. Replace clutch disc and de-
disc. grease pressure plate and flywheel.
3. Flywheel housing out of align- 3. Align to specifications.
ment. 4. Replace clutch disc.
4. Damaged clutch disc. 5. Rectify cause of fluid loss,
CLUTCH SPIN OR DRAG 5. Lack of fluid. refill and bleed system.
6. Air in hydraulic system. 6. Bleed system.
7. Clutch disc fitted in reverse. 7. Fit clutch disc correctly, if
8. Uneven centre drive plate re- damaged replace.
lease (twin plate clutch only). 8. a. Dismantle clutch assembly
9. Binding of the disc on the and clean thoroughly with particular
input shaft splines. attention to adaptor drive lugs.
b. Check centralising springs for
even height, reset if necessary.
9. Check splines for burrs, rust-
ing and damage. Clean up splines
or replace input shaft.
Lubricate spline .with Molybond
122L Dry Spray Lubricant.

EJ FLYWHEEL HOUSING ALIGNMENT

Alignment of the flywheel hous- from the mounting face of the the point of maximum runout.
ing bore and rear· face with the en- housin~·. Mark runout on the face of hous-
gine should be checked as a possible ing.
cause of any of the following troub- 3. Install the dial indicator on
les: excessive transmission gear the pilot and adjust the holder so 7. Position the dial indicator to
wear, transmission jumping out of the button will contact a circumfer- check bore alig·nment (.Fig. 1). The
~nce just inside of the transmission bore must be clean and free of
gear, especiall~· top gear, drive
line vibration, excessive pilot bush- mounting· holes (Fig-. 1 ). burrs, nicks and paint.
ing wear, noisy release bearing, or 4. Push the flywheel forward to
excessive clutch spin time. 8. Pull the crankshaft through
l'emove crankshaft end play. Set
one revolution. Note the indicator
INSPECTION the dial indicator face to read zero.
reading and mark the maximum
1. Wrth tht! clutch release bear- point of runout on the face of the
ing removed, install the indicator· 5. Remove the spark plugs to
housing.
pilot tool shown in Fig. 1. alleviate compression.
9. Remove the dial indicator
2. Clean the faces of the fly- (i. While for·cing the flywheel
from the crankshaft and the houa-
wheel housing bolt bosses, and re- for·ward, rotate the crankshaft
ing.
move all burrs, nicks, and paint through one revolution and note
CORRECTION
ENGINE IN CAR
Since any change in face align-
ment will change bore alignment,
it may be possible to correct bore
alignment by changing face align-
ment. Face alignment can be
changed by shimming between the
flywheel housing and ~ngine. Fig.
2 shows the type of shim which can
be fabricated.
Not more than 0.010 inch thick-
- - - ness shims may be used between
MAXIMUM FACE RUN OUT+ 0.009 INCH MAXIMUM NEGATIVE BORE RUN OUT 0.0151NCH Cl017·C
the flywheel housing and engine.
FIG. 1 - Flywheel Housing Alignment Check lf a 0.010-inch shim will not bring
5-10 GROUP 5-DRIVE LINE AND CLUTCH
face and bore alignment within gine out of the car or in the car, moved straight up or .down without
limits, replace the flywheel hous- up to the point of replacing tre fly- disturbing the lateral alignment.
ing. wheel housing. If the bore align- When alignment is within limits,
ment cannot be brought within lim- torque the housing bolts and re·
11----IY•"----tl ita by shimming, follow this pro- check bore alignment.
~w cedure

1. Remove the flywheel housing· 5. If the flywheel housing can-

from the engine and remove the not be moved enough to bring the
dowel pins. Install the flywheel alignment within limits, mark the
housing and tighten the attaching holes restricting movement, and
bolts. then remove the housing and drill
the marked bolt holes 1/32 inch
C1136-A larger.
2. Install the dial indicator (Fig.
FIG. 2 - Fabricated 1 ). Check the face alignment, and
shim as required to bring- face 6. When the flywheel housing-
Flywheel Housing Shim alignment within limits. bore alignment is within limits and
3. Position the indicator to the attaching bolts are at normal
If both the bore and face align- torque, hand ream the dowel pin
ment are out of limits, shim be- c-heck the bore alignment. If the
bore alignment is not within limits, holes 1/32 inch larger. Use a
tween the flwheel housing and en- l!traight reamer and ream from the
gine to bring face alignment with- reduce the tension on the flywheel
housing attaching bolts so that the flywheel housing side. Oversize
in limits. Check the bore alignment. dowel pins can be made from drill
housing can be moved by striking
If the bore alignment is out of it with a lead hammer or a block rod stock.
li;nits and the face alignment is of wood and a steel hammer.
within limits, shim the flywheel 7. Remove the flywheel housing
housing to the limit of face mis- and then i-nstall the oversize dowel
alignment and check the bore align- 4. The lateral alignment should pins in the cylinder block. Complete
ment. If it is not within limits, re- be brought within limits so that an the assembly in the usual way.
place the housing. indicator reading is within limits
Letween the 9 o'clock and 3 o'clock 8. Recheck the flywheel housing
ENGINE OUT OF CAR positions on the bore circle. When with a dial gauge to make sure
The same procedure to correct the lateral alignment is within lim- that the housing is within the spec-
alignment may be used with the en- its, the housing usually can be ified limits.

EJ CLEANING AND INSPECTION

RELEASE BEARING
Wipe all oil and dirt off the re-
lease bearing. The bearing is pre-
lubricated and should not be
deaned with solvent.
Inspect the bearing retainer for damaged
or loose spring clips and rivets.
Inspect the release bearing hub bore
for burrs which may cause the assembly
to drag on the transmission bearing
retainer. Any such burrs should be cleaned
up with fine crocus cloth. If burrs are
found inspect the transmission input
shaft bearing retainer for evidence of
scoring. Any scoring should be polished
out with crocus cloth. Coat bearing
retainer with a thin film of moly-base
grease.
Prior to release bearing installation,
apply a light film of MIC-75 A grease on
both sides of the release lever fork where
it contacts the release bearing hub and
retaining springs. Release lever pivots
and push rod seat. FIG. 3-Release Bearing FIG. 4-Release Bearing
Care must be exercised when applying
lubricants to the release bearing, release and Hub Assembly-351 and Hub Assembly-
bearing hub and the release lever fork to CID Twin Disc Clutch 6 Cyl.
PART 5-2-GENERAL CLUTCH SERVICE 5-11

noisy, replace the bearing and hub The pressure plate should be lub-
assembly. ricated with lubriplate between the
Misalignment between the engine and driving lugs and the edges of the
transmission can cause release bearing pressure plate. Depress the pres-
failure. Other symptoms of misalignment sure plate finge1·s fully, apply the
are: transmission jumping out of gear, lubricant, and then move the fin-
especially top gear, drive line vibration, g-er·s up and down until the lubri-
excessive clutch disc spin time resulting cant is worked in . Do not apply ex-
in gear clash, and excessive transmission ct>ssive lubricant.
gear wear.
CLUTCH DISC
PRESSURE PLATE AND COVER Inspect the clutch disc facings for oil
or grease. Eliminate the source of any
Inspect the surface of the pres-
oil or grease before replacing the disc.
sure plate for burn marks, scores,
An excessive amount of grease in the
OJ' ridges. Generally, pressure plate
release bearing hub will find its way to the
re-surfacing is not recommended. disc facings. Too much lubricant in the
However, minor burn marks, scores, transmission or a plugged transmission
or ridges may be removed. During vent will force the transmission lubricant
the r·esurfacing process, the flat- out the input shaft and onto the disc
ness of the pressut·e plate must be facings.
maintained. If the pressure plate
is badly heat-checked or deeply Inspect the clutch discs for worn or
scored, replace the pressure plate loose facings. Check the discs for dis-
and cover assembly. Clean the tortion and for lose rivets at the hub.
pressure plate and flywheel sur- Check for broken springs. Springs loose
faces with a crocus cloth to be sure the enough to rattle will not cause noise when
surfaces are free from any oil film. Do the car is operating. Replace the discs
not use cleaners with petroleum base, and assemblies if any of these defects are
do not immerse the pressure plate in the present. Be especially c-.areful when instal-
solvent. ling a new disc to avoid dropping it or
contaminating it with oil or grease.
FIG. 5-Release Bearing 302 C.I.D. ONLY
and Hub Assembly- PILOT BEARING
Place the plate on the floor, be-
302V8 ing careful not to score or :scratch Check the fit of the clutch pilot bearing
the surface. Force each individual in the housing of the crankshaft.
avoid excessive grease from contaminating finger down, then release it quickly. The bearing is pressed into the crank-
the clutch di sc. If the finger does not return quick- shaft and should not be loose or cocked
Hold the bearing inner race and rotate ly, a binding condition is indicated, in the bore.
the outer race while applying pressure to and the pressure plate should be If the bearing is worn or damaged,
it. If the bearing rotation is rough or replaced. replace it with a new service bearing.
5-12

PART CLUTCH
5·3
Section Pace Section Page
1 Description and Operation . ...... ...... .. .. .. ...... 6-12 3 Removal and Installation 5-14
2 In car Adjustments and Repairs ...... .... .. ... ... 5-14 4 Hydraulic System Repairs 5-19
Clutch Operating Cylinder Disassembly 5-19
Reservoir Topping-Up .... .. 5-14 Assembly 5-19
Bleeding the Clutch 5-14

0 DESCRIPTION AND OPERATION

DESCRIPTION
There are three types of clutches
used on this model.
A. A 9t or 9! inch single dry plate
diaphragm clutch is used on six
cylinder engines. Fig. 6.
B. A 10 inch single dry plate coil
spring clutch is used with the
302 C.I.D. V-8 engine. Fig. 7.
C. A 9t inch twin disc dry plate
diaphragm clutch is used with
the351 C.I.D. V-8engine.Fig. 8.
All clutches are hydraulically
operated. The discs incorporate a
spring dampened hub, and the
linings are cushion mounted to
ensure a smooth take up of the
drive.
The clutch disc hub is free to slide
along the splines of the main drive
gear shaft, the forward end of which
forms a spigot to fit into the clutch
pilot bearing in the centre of the
crankshaft.

OPERATION

The clutch release mechanism, is

hydraulically actuated by a pendant
pedal, connected by a short push rod
to the clutch master cylinder.
The clutch master cylinder is
mounted on the front face of the
engine rear bulkhead on the driver's
side of the vehicle.
The front spigot end of the piston
accommodates the valve stem and
carries the valve spring retainer. The
return spring, under compression, is
fitted between the spring retainer
and the valve spacer at the forward
end of the cylinder. FIG. 6-Ciutch Disc
A reservoir port, drilled at the and Flywheel6 Cyl.
PART 5-3-CLUTCH 5-13

front of the cylinder, allows fluid

from the reservoir to enter the
cylinder.
A tube connects the master
cylinder port to the slave cylinder.
With the clutch pedal m the fully
released position, fluid is free to flow
from the reservoir into the cylinder.
When the pedal is depressed, the
piston moves forward advancing the
valve spacer and seal. The spacer
contacts the end of the cylinder. The
wave shim between the flange on the
valve stem and the valve spacer
pushes the valve seal into contact
with the end of the cylinder, so
sealing off the reservoir port, pre-
venting the fluid from being pumped
back into the reservoir. The fluid is,
therefore, pumped through the outlet
port to the slave cylinder on the
clutch housing, the increase in
hydraulic pressure assisting the
action of the valve seal.
Pressure in the clutch slave
cylinder operates a non-adjustable
push rod which, in turn, acts on the
release lever end. The release lever
is retained on a fulcrum in the
clutch housing by mear'i of a spring.
When the release lever is actuated,
the release bearing is moved to-
ward the clutch, moving the fingers
of the diaphragm spring.
The release bearing is retained
to the clutch release lever fork by
means of two clips.
This method of clutch operation
ensures smooth clutch engagement
as relative movement between the FIG. 7 -Coil Spring Clutch
engine and the clutch pedal is not
transferred to the operating 302 CID V8 only
mechanism.
The diaphragm spring is pivoted
on a fulcrum ring located on pins
which are riveted to the clutch
housing. As the diaphragm spring
is compressed by the release bear-
ing, the diaphragm's outer edge
deflects thereby causing the clutch
to disengage.
•••
1 11
When the pedal is released, the
master cylinder return spring pushes
back the piston, reducing the pres-
sure in the cylinder. The diaphragm
spring or pressure plate fingers
. .. .. ..
_._._:·
.
acting on the operating cylinder

-Je-·.
piston, via the release arm and push
rod, pushes the fluid back into the
master cylinder. As the piston .
reaches the end of its rearward
travel, the valve spacer and seal will
be pulled away from the reservoir
~~·~
,. .,_ .
. ...
.
' -' - ',, . .
--·-·
port by the valve stem. The valve
uncovers the reservoir port so that
fluid may be replenished in the FIG. 8-351 Twin Disc
cylinder, as necessary. Clutch-Typical
5-14 GROUP 5-DRIVE LINE AND CLUTCH

EJ IN CAR ADJUSTMENTS AND REPAIRS

The maintenance required for the as outlined in Page 5-19 and refill ing it anti-clockwise and slowly
clutch system. is to top-up the master the system with fluid, Rl-39 A. depress and release the clutch pedal
cylinder, and, if necessary, to bleed several times. For each stroke some
the system. Details of these opera- Engine, transmission or other fluid or air should be pumped out of
tions are given in the following mineral oils must not be used in the the tube. If neither fluid nor air is
paragraphs. system or allowed to come into pumped out, the bleed valve is not
contact with seals, pistons, etc., properly opened or there is a block-
being stored. Foreign matter must age in the pipe line.
No manual adjustment is possible be avoided since it may score the
or provided for on any of the clutch pistons or damage the seals and NOTE: Where air in the system is
systems. render the clutch wholly or partially suspected remember that when bleed-
inoperative. ing the system the initial application
RESERVOIR TOPPING-UP
When replacing clutch system of the clutch pedal will cause the air
The fluid level in the reservoir parts, examine the seals and any seal trapped in the bleed tube to be forced
tank, which is integral with the which is imperfect should be re- into the fluid container.
clutch master cylinder body, should placed. Pistons and housings should 4. Continue depressing and re-
be regularly checked. Top up to be checked for scores which may leasing the clutch pedal slowly until
the correct level, marked on the provide a track for fluid leaks under no more air bubbles emerge from the
master cylinder body with approved pressure and any damaged parts rube, ensuring that the fluid level in
fluid. The cap and the area sur- must be renewed. the reservoir is maintained during
rounding it should be wiped with a the bleeding operation.
clean rag before removing the cap, Prior to assembly, immerse hy- Do not replenish the reservoir
to prevent dirt entering when it is draulic components in clean fluid, with the fluid drained from the
removed. Rl-39 A to facilitate fitting and system as it may be aerated or con-
Ensure that the air vent in the provide initial lubrication for work- taminated. If the fluid pumped out
cap is clear before replacing the cap. ing surfaces. of the tube is dirty, drain the system
1. Clean the area surrounding completely and refill with fresh
BLEEDING THE CLUTCH the bleed valve on the cylinder. Rl-39 A.
If it is suspected that an incorrect 2. Fit a suitable tube on the 5. Close the bleed valve tightly
fluid has been used in the hydraulic bleed valve and place the end of the with the pedal fully released, when
system, drain completely and flush tube in a bottle containing fluid, fluid alone comes out of the bleed
out with methylated spirit or com- Rl-39 A. Keep the end of the tube tube with each stroke of the clutch
mercial alcohol. beneath the surface of the fluid pedal.
Renew the piston seals in the throughout the bleeding operation. 6. Refill the reservoir to the
master cylinder and slave cylinder 3. Open the bleed valve by turn- correct level and refit the cap.

EJ REMOVAL AND INSTALLATION

CLUTCH MASTER CYLINDER do not overtighten. blanking plug to prevent dirt enter-
REMOVAL ing the line.
3. Reconnect the clutch master
1. Disconnect the clutch master cylinder push rod to the pedal by
cylinder push rod from the pedal. passing the push rod eye over the 2. Remove the slave cylinder
pedal pin, refitting the shouldered after removing the two retaining
2. Detach the fluid line by un- bolts.
screwing the union nut, using a nylon bush and keeper pin.
blanking plug to prevent dirt enter- 4. Top up the master cylinder
ing the line. reservoir with clean approved fluid, INSTALLATION
3. Withdraw the master cylinder Rl-39 A, and then bleed the system.
Check the action~ of the clutch on 1. Fit the rubber boot to the
after removing the two nuts and operating cylinder and insert the
spring washers securing the master road test.
push rod.
cylinder to the bulkhead.
THE CLUTCH SLAVE 2. Position the slave cylinder
INSTALLATION
CYLINDER REMOVAL on to the flywheel housing and fit
l. Refit the master cylinder to the retaining lock washers and
the engine bulkhead, replace the The clutch slave cylinder is bolts. Torque the bolts to speci-
two securing spring washers and mounted on the clutch housing on fication.
nuts and tighten to the specified the left-hand side, and is retained
torque. by two bolts. 3. Reconnect the fluid tube.
2. Reconnect the fluid pipe, 1. Detach the fluid line by un- Tighten the union nut, but do not
tighten the union nut securely, but screwing the union nut, using a overtighten. Bleed the system.
PART 5-3-CLUTCH 5-15

CLUTCH RELE'ASE LEVER INSTALLATION

REMOVAL
1. Lubricate the knife edge
pivot recess in the release lever with
The clutch release lever is held grease MJC 75 A.
in position on the knife edge pivot 2. Locate the retaining spring
by a spring wire clip Fig. 10. on the release lever (Fig. 10).
1. Remove the flywheel housing 3. Assemble the release lever
as outlined in clutch pressure plate in the flywheel housing with the
and /or disc removal. knife edge pivot in its recess in the
2. Using a large screwdriver lever.
through the transmission input Using a large screwdriver
shaft hole in the flywheel housing, through the transmission input
prise the release lever retaining shaft hole in the flywheel housing,
spring from the tang in the knife lift the release lever retaining spring
edge pivot (Fig. 10). on to the pivot tang. (Fig. 10).
FIG. 9 - Non-Adjustable 3. Remove the release lever 4. Install the flywheel housing
Operating Cylinder toward the centre of the flywheel as outlined in clutch pressure plate
All Vehicles housing. and/or disc installation.

r--- --
.-£'
0 ~~
FIG. 1 0-Ciutch Release ~- -. ~-------~--
I - _:~

Lever and Pivot -

-

FIG. 11-lnstallation Sketch Clutch

Operating Mechanism
5-16 GROUP 5-DRIVE LINE AND CLUTCH

FIG. 12-lnstallation 6 Cyl. Clutch

FIG. 13-lnstallation 302 CID V8 Clutch

FIG. 14-lnstallation 351 Twin Disc Clutch

PART 5-3-CLUTCH 5-17

CLUTCH PRESSURE PLATE cover, then remove the pressure holes in the crossmember, then lower
AND OR DISC plate and clutch disc. the engine and remove the jack.
REMOVAL
Install the two transmission rear
INSTALLATION support-to-crossmember washers and
1. Raise the car on a hoist. 1. Hold the clutch disc, and pres- nuts and torque to specifications.
2. Disconnect the drive shaft sure plate and cover assembly in Tighten the crossmember-to-frame
from the rear U-joint flange. Then position on the flywheel. Start the support nuts.
slide the drive shaft off the trans- cover attaching bolts to hold the 12. Connect the gear shift rods to
mission output shaft. Insert appro- pieces in place but do not tighten the transmission levers. Adjust the
priate Extension Housing Seal In- them. Avoid dropping the parts shift linkage.
stallation tool over the output shaft or contaminating them with oil 13. Remove the tool from the
and into the extension housing oil or grease. transmission output shaft, and install
seal. the drive shaft.
3. Disconnect the speedometer Grade 5 bolts Part No. 382087-S 14. Connect the speedometer cable
cable from the extension housing. must be used. to the extension housing.
4. Disconnect the gear shift rods 2. Align the clutch disc with a
from the transmission levers. clutch arbor or an old transmission 351 C.I.D. TWIN PLATE CLUTCH
5. Support the engine with a input shaft and torque the pressure REMOVAL
transmission jack and remove the plate cover attaching bolts evenly Refer to the preceding paragraphs
two nuts securing the transmission to specification. Then remove the 1-13 of clutch pressure plate and/or
rear support to the crossmember. tool. disc remol'al.
6. Raise the rear of the engine 3. Make certain that the release 1. If the same centre drive plate,
with the transmission jack. Remove bearing and hub is properly installed pressure plate and cover is to be
the two nuts, washers, and bolts on the release lever. Completely fill installed after the clutch is over-
securing the crossmember to the the grease groove in the hub bore hauled, mark them so that they can
frame supports. Remove the cross- and lightly smear the remainder of be installed in the same position, to
member. the bore with a film of moly type maintain a balanced assembly.
7. Remove the bolts that attach grease. Do not lubricate the clutch When removing the twin plate
the transmission to the flywheel disc hub. clutch from the flywheel, it is essen-
housing. 4. Make certain that the fly- tial to firstly relieve the pressure
8. Move the transmission rear- wheel housing and the cylinder block plate clamping load by evenly loosen-
ward until the input shaft clears the mounting surfaces are clean. Position ing the three mounting bolts. Replace
flywheel housing, then remove the the flywheel housing on the cylinder the bolts one at a time with guide
transmission. block and install the attaching bolts. pins, which can be simply made by
9. Remove the clutch slave Torque the bolts to specifications. cutting the head from a 3" x 5/ 16"
cylinder. 5. Lubricate the push rod UNC bolt and cutting a screwdriver
10. Remove the starter cable. release lever end with grease MIC slot in the plain end. The clutch
Remove the starter motor from the 75 A and install slave cylinder as assembly may now be handled with
flywheel housing. shown in Figs. 10-11-12. ease.
11. Remove the bolts that secure 6. Secure the engine rear plate 2. Remove the pressure plate.
the engine rear plate or flywheel or flywheel housing lower cover plate 3. Remove the rear clutch disc.
housing lower cover plate to the to the front of the flywheel housing 4. Remove the centre drive plate.
front lower part of the flywheel with the attaching bolts. NOTE: When placing the centre
housing. 7. Install the starting motor and drive plate on a bench or flat surface
12. Remove the bolts that attach connect the cable. it should be supported to avoid
the flywheel housing to the cylinder 8. The mounting surfaces of the damagmg the centralising springs.
block and remove the housing and transmission and the flywheel hous- 5. Remove the front clutch disc
the release lever as a unit. ing must be free of dirt, paint, and and remove the cylindrical adaptors
13. Loosen the pressure plate burrs. Install two guide pins in the from the flywheel.
cover attaching bolts evenly to release flywheel housing lower mounting The guide pins may be left in
the spring tension. If the same bolt holes. Move the transmission place to assist in re-assembly.
pressure plate and cover is to forward on the guide pins until it
be installed after the clutch is is positioned against the flywheel
overhauled mark the cover and housing.
flywheel so that the pressure 9. Install the two upper mount-
plate can be installed in the same ing bolts. Then, remove the guide
position, to maintain a balanced pins and install the two lower
assembly. When fitting a new pres- mounting bolts. Torque all bolts to
sure plate and/ or flywheel the specifications.
balance marks are to be placed 10. Raise the rear of the engine
opposite each other. The heavy side high enough to provide clearance for
of the pressure plate is marked with installing the crossmember. Install
a daub of paint while the heavy side the two crossmember-to-frame sup-
of the flywheel is marked with a port attaching bolts, washers, and
drill point. nuts. Do not tighten at this time.
14. Remove the attaching bolts 11. Align the bolts in the trans- FIG. 1 5-Fiywheel and
while holding the pressure plate mission rear support with the bolt Cylindrical Adaptors-351
5-18 GROUP 5-DRIVE LINE AND CLUTCH

351 C.I.D. TWIN PLATE ClUTCH

INSTALLATION
Warning: It is mandatory when
replacing a clutch disc on the clutch
installation of the 351 CID engine,
that both clutch discs be replaced at
the one time. If this procedure is
not adhered to, clutch spin may be
experienced.
Special size Grade 8 mounting
bolts Part No. V388021-S2 must
be used.
1. Spray a light coating of FIG. 16- Front Plate Fitted
Molybond 122L over the cylindrical to Flywheel FIG. 20- Clutch Assembly
adaptors prior to their installation Assembled
over the guide pins and assemble
the adaptors over the guide pins
(Fig. 15).
2. Assemble the front clutch
disc. This disc is identified by Part
No. ARC9DA-7550-B and is also
marked flywheel side around the
hub (Fig. 16).
3. Assemble the centre drive
plate. Ensure the drive plate is
fitted as shown in (Fig. 17), i.e. GRADE 8
the centralizing springs, clockwise V388021-52 382087-5
of the cylindrical adaptors. Check MOUNTING BOLTS
that the drive plate slides freely on
the adaptors. FIG. 1 7- Centre Drive Plate
FIG. 21
4. Assemble the rear clutch
disc. This disc is identified by Part
No. ARC9DA-7550-C and is also
marked Pressure Plate side around
the hub (Fig. 18).
5. Assemble the pressure plate
to the cylindrical adaptors. Replace
the guide pins with the grade 8
mounting bolts one at a time.
Tighten the pressure plate to fly-
wheel bolts finger tight (Fig. 19).
Ensure the centre drive plate
centralizing springs are located as
shown in Fig. 20.
6. Insert clutch disc aligning FIG. 18- Rear Plate FiHed
tool No. 7550-A into the discs and to Centre Drive Plate
pilot bearing.
7. Torque the pressure. plate
mounting bolts evenly to 19-21
lbs.-ft.
8. Remove the disc aligning tool
and continue reassembling the FIG. 22-351 Pressure
vehicle as outlined Page 5-17 of Plate Showing Dowel
clutch pressure plate and I or disc
installations.

The 6 cylinder and 351 C.I.D. NOTE: It is essential that the

twin disc clutch pressure plate and correct grade of bolt (pressure
cover assemblies althougl]. very plate to flywheel) be used.
similar must not be interchanged. 6 and 8 cylinder, single plate,
The twin disc pressure plate can be grade 5, three lines on bolt head.
identified by the three dowel holes FIG. 19- Pressure Plate
in the pressure plate friction surface 8 cylinder, twin plate, grade 8,
(Fig. 20). FiHed to Adaptor Drive Plates six lines on bolt head.
PART 5-3-CLUTCH 5-19

IJ HYDRAULIC SYSTEM REPAIRS

MASTER CYLINDER
DISASSEMBLY
1. Empty the contents of the for scores or damage. 8. Fit the master cylinder and
fluid reservoir into a clean container. ASSEMBLY bleed the system as outlined in
2. Remove the rubber boot. Then Pages 5-14.
withdraw the circlip and remove the 1. Replace the piston seal with CLUTCH SLAVE CYLINDER
push rod. the lip away from thr larger diameter DISASSEMBLY
3. Withdraw the piston and valve of the piston.
assembly from the cylinder. 2. Fit the valve seal to the valve 1. Withdraw the push rod and
4. Remove the piston from the stem with the lip outwards and away rubber boot from the operating
valve assembly. The spring retainer from the spring. Slide the shim, the cylinder.
is held in position on the spigot end valve spacer, with the legs over the 2. Remove the piston and seal,
of the piston by a tab which engages valve seal, and the return spring, in lightly tap the cylinder on a block
under a shoulder on the front of the this order, over the valve stem (see of wood. Withdraw the piston and
piston. Prise up the tab (Fig. 24·) Fig. 23 ). Ensure that the convex rubber seal from the cylinder body.
and remove the spring retainer, face of the shim abuts the valve 3. Unscrew the bleed valve on
spring and valve assembly from the stem flange. the side of the cylinder body. Pull
piston. 3. Fit the spring retainer in the the rubber piston seal off the spigot
5. To dismantle the valve as- rear end of the return spring, com- at the front of the piston.
sembly, compress the spring and press the spring and locate the valve 4. Wash all parts in hydraulic
move the valve stem to one side in stem in the key hole slot in the end fluid Rl-39 A, methylated spirit or
the retainer, so releasing the end of of the spring retainer. commercial alcohol and examine
the valve stem from the key slot 4. Insert the front of the piston the rubber piston seal carefully.
hole in the retainer. in the spring retainer, and secure it Renew the seal if there is any sign
Slide the valve spacer and shim . by locating the spring retainer tab of damage to the sealing lip. Never
off the valve stem. under the front shoulder of the use mineral fluids such as engine oil
6. Remove the rubber valve seal piston. or kerosene for washing hydraulic
and the piston seal, if necessary. system parts.
5. Dip the piston and seal in
7. Wash the parts in methylated hydraulic fluid Rl-39 A. Insert the ASSEMBLY
spirit, brake fluid or commercial piston assembly in the cylinder,
alcohol. Do not use mineral fluids valve seal end first. Ensure that 1. Locate the piston seal on the
such as engine oil or paraffin for the piston seal is not damaged as it spigot at the front end of the piston
washing the parts. Carefully inspect enters the master cylinder. with the recess in the seal away from
the piston rubber seal and renew if the piston (see Fig. 25).
there is any sign of damage to the 6. Install the push rod in the 2. To fit the piston dip the piston
sealing lip. It is not advisable to master cylinder. Locate the washer and seal in hydraulic fluid, and care-
turn the seal inside out when examin- and fit the retaining circlip. fully insert, spigot end first, into the
ing as distortion will be caused. 7. Refit the rubber boot to the cylinder.
Examine the piston and cylinder bore clutch master cylinder. 3. Replace the bleed valve but
do not tighten.
4. Fit the operating cylinder and

® bleed the system.

~•o-
VALVE
SPACER

FIG. 24 -Removing the

FIG. 23 -Exploded View Clutch Master Cylinder Piston Valve
5-20 GROUP 5-DRIVE LINE AND CLUTCH

I
FIG. 25- Clutch Operating Cylinder
5-21

PART SPECIFICATIONS
5-4
CLUTCH DISC IDENTIFICATION
Clutch Discs can be identified by Part Numbers stamped on the hub as follows:

Number of
Engine & Transmission Part No. Damping Springs Diameter

6 Cyl 200 CID- -3SPD ARDIDA-7550-B 6 9f'

6 Cyl 250 CID-IV -3SPD ARDIDA-7550-A 6 9f'
6 Cyl 250 CID-IV -4SPD ARDIDA-7550-C 6 9f'
6 Cyl 250 CID-2V -3SPD 72DA-7550-BA 6 9t''
6 Cyl 250 CID-2V -4SPD 72DA-7550-CA 6 9t''
8 Cyl302 CID-3 & 4 -SPD C60Z-7550-G 12 10
8 Cyl 351 CID-2 & 4V-4SPD ARC9DA-7550-B FRONT
ARC9DA-7550-C REAR 6 9t''
PRESSURE PLATE IDENTIFICATION

Engine Part No. Number of Springs Diameter

6 Cyl 200 Cl D- ARC8DA-7563-A Diaphragm 9t''

6 Cyl 250 CID-IV ARD1 DA-7563-A Diaphragm 9t''
6 Cyl 250 CID-2V 72DA-7563-BA Diaphragm 9f'
8 Cyl 302 CID- C20Z-7563-F 9 10"
8 Cyl 351 CID- ARC9DA-7563-C Diaphragm 9t''

NOTE-The 351 Cl D Pressura Plate Assembly can be identified by the three locating dowel holes in the Pressure Plate Friction Surface

TORQUE SPECIFICATIONS
Flywheel housing to cylinder block bolts .. 35-45 lbs. ft.
Clutch pressure plate retaining bolts 12-20 lbs. ft.
7260 Series Universal pinion yoke nuts 7-10 lbs. ft.
1310 Series Universal pinion yoke U-bolt nuts 12-20 lbs. ft.
Clutch master cylinder mounting nuts 13-18 lbs. ft.
Clutch slave cylinder mounting bolts 17-22 lbs. ft.
Twin plate clutch pressure plate to flywheel bolts . . 19-21 lbs. ft.

LUBRICATION

Clutch release bearing hub to bearing retainer MIC 75A

Pressure plate cylindrical adaptors . . Molybond 122L
Pressure plate fingers Lubriplate
Release lever tips . . MIC 75A
Release lever fulcrum both sides MIC 75A
Input Shaft spline . . Molybond 122L
DO NOT USE EXCESS LUBRICANTS ON ABOVE ITEMS
Clutch master cylinder fluid ESW-FM-6C2

DRIVE LINE IDENTIFICATION

Engine- Universal
Vehicle Application Rear Axle Slip Yoke Joint Series
200 C.I.D. Passenger STD 2 pinion 28 Spline 7260
250 C.I.D . Passenger STD 2 pinion 28 Spline 7260
302 C.I.D. Passenger 2 Pinion 28 Spline 7260
200 & 250 C.I.D . Commercial H.D. 4 pi·nion 28 Spline 7260
302 C.I.D. Commercial H.D. 4 pinion 28 Spline 7260
351 C.I.D. Auto. 4V Traction Lok 4 pinion 31 Spline 1310
351 C.I.D. Manual 4V Traction Lok 4 pinion 28 Spline 1310
351 C.I.D . Auto . 2V Traction Lok 4 pinion 28 Spline 1310
351 C.I.D. Manual 2V Traction Lok 4 pinion 28 Spline 1310
REFERENCE TO SERVICE INFORMATION AND NOTES

Date Letter No. Pa1e Brief Detail

FALCON FAIRLANE w~:~~~~P

GROUP
MANUAL TRANSMISSION
6

PAGE
PART 6-1 General Transmission Service 6-2
PART 6-2 3-Speed Partially Synchronised 6-9
Manual Shift Transmission
Series BW 199333.
PART 6-3 3-Speed Fully Synchronised 6-18
Manual Shift Transmission
Series BW 199332 and 199331.
PART 6-4 4-Speed Fully Synchronised 6-24
Manual Shift Transmission
RUG. A.R. and RUG. B. F.
PART 6-5 Specifications 6-36
For shift tube replacement in column shift vehicles refer Group
3 front suspension and steering. This group for linkage adjust-
ment.
6-2

PART GENERAL TRANSMISSION SERVICE

6-1

Section Pare Section Pare

1 Diagnosis and Testing ...... .. .... ...... .. .. .. 6-2 Rear Seal Replacement ...... ...... .. .... 6-7
2 Common Adjustments and Repairs .... .. ...... .. .. .. 6-7 Rear Bushing and Seal Replacement 6-7
Gear Shift Linkage Adjustment .. .. .. .. .. .. .. ... . 6-7 3 Cleaning and Inspection .... .. .. .. .. ...... 6-8

II DIAGNOSIS AND TESTING

The following problems can be outside of the transrruss10n, such possible causes and corrective
experienced with a manual shift as, clutch, clutch linkage, steering measures are listed in the order
transmission: excessive amount of columns and shift linkage. Before they should be checked to eliminate
noise, hard shifting efforts, trans- and during the road test, make sure all possibility of maladjustment or
mission jumps out of gear, gears that the clutch is functioning pro- faulty components outside of the
clash when transmission is shifted perly, the shift linkage is properly transmission prior to any transmis-
from one gear ratio to another, and adjusted, the steering column is sion removal and disassembly. If
lubricant leakage. properly aligned and, that the trans- the transmission was removed, re-
mission is filled to the proper level paired and reinstalled, make certain
The car should be road tested, if with lubricant. the clutch and all gear shift linkage
possible, to determine or confirm is adjusted to specifications. Road
complaint. Under normal operating The following diagnosis proce- test the vehicle to be sure that
conditions, a large percentage of dure is compiled as a guide in cor- the problem has been completely
transmission complaints are due to recting problems related to manual corrected.
maladjusted or faulty components transmissions. Trouble symptoms,

DIAGNOSIS GUIDE- TRANSMISSIONS

To eliminate all possibility of ents in the clutch and/or clutch and Testing, Group 5 (Driveshaft
maladjustments or faulty compon- linkage, refer to Clutch Diagnosis and Clutch), of the shop manual.

TROUBLE SYMPTOMS POSSIBLE CAUSES CORRECTION

GEAR CLASH SHIFT LINKAGE

1. Improper crossover. 1-2. Adjust levers and shift rods
2. Loose nuts at steering column to proper crossover, torque nuts to
levers and shift rods. If the nuts are specification. Replace bell-mouthed
loose, check for bell-mouthing of rods or levers.
slots.
3. Bent transmission shift rods or 3. Replace bent rods.
linkage interference.
4. Lack of lubrication of shift 4. Clean and lubricate with Mol-
linkage, trunnions . ybdenum Disulphide grease.
PART 6-1-MANUAL SHIFT TRANSMISSION 6-3

TROUBLE SYMPTOMS POSSIBLE CAUSES CORRECTION

CLUTCH
GEAR CWH-Continuecl 1. Excessive engine idle speed. 1. Adjust engine idle rpm.
2. Inadequate dutch pedal reserve 2. Check for damaged input.
resulting in excessive spin time. In- shaft pilot bearing or excessive
adequate clutch disengagement. clutch disc runout-replace defective
3. Disc binding on transmission parts.
input shaft. 3. Check for burrs on splines,
4. Excessive disc runout. replace if necessary.
5. Flywheel housing misalign- 4-6-7. Replace clutch disc.
ment. 5. Align to specification.
6. Oil or grease on clutch facings
from:
A. Release bearing
B. Engine
C. Release lever
D. Pilot bearing
E. Transmission.
7. Damaged or contaminated
clutch lining.
TRANSMISSION
1~ Forward Gear Clash 1. A-B-C-D-F. Replace worn or
A. Weak or broken insert springs defective parts.
in the synchronizer assembly.
B. Worn blocking rings and/ or
cone surfaces.
C. Broken blocking rings.
D. Excessive output shaft end
play.
E. Binding input shaft pilot bear-
ing (non-synchronized low gear
transmission only).
F. Worn shifter forks or sleeves.
2. Reverse Gear Clash (allow 2. A. See possible causes under
approximately three-four seconds Clutch for gear clash trouble sym-
after the clutch pedal has been de- ptoms.
pressed before shifting into reverse
gear).
A. If gear clash continues after
allowing proper time for the
clutch plate to stop, check clutch
to make sure that it is within
specification.
B. Excessive engine idle speed. B. Adjust engine idle rpm.
C. Binding input shaft pilot bear- C. Replace defective parts.
ing.
SHIFT LINKAGE
HARD SHIFTIN~ 1. Improper crossover. 1-2. Adjust levers and rods to
2. Loose nuts at steering column proper crossover, torque nuts to
levers and shift rods. If the nuts are specification. Replace bell-mouthed
loose, check for bell-mouthing of levers.
slots.
3. Bent transmission shift rods or 3. Replace bent rods or levers.
linkage interference.
4. Lack of lubrication of shift 4. Clean and lubricate with Mol-
linkage, trunnions. ybdenum Disulphide grease.
STEERING COLUMNS
1. Improper column alignment, 1. Align column properly, replace
looseness, binding and worn sur- defective column parts.
faces.
2. Worn shift key or broken weld 2-3-4. Replace defective parts.
securing shift key to top or bottom
of shift tube.
6-4 GROUP 6-GENERAL TRANSMISSION SERVICE

TROUBLE SYMPTOMS POSSIBLE CAUSES CORRECTION

HARD SHIFTING 3. Loose shift lever pin in die cast
(Continued) selector lever hub.
4. Keyway 10 die cast selector
lever hub pounded out.
5. Loose screws securing die cast- 5. Replace defective parts. Tighten
ing to bottom of tube. Excessive screws securely.
radial movement m the column
linkage. (If the vehicle has high
mileage or is subjected to hard use,
even though the crossover has been
properly set, the column may have
deteriorated to a point where proper
crossover engagement will not occur
due to excessive radial movement in
the column linkage (lost motion).
6. Lack of lubrication in column. 6. Clean and lubricate with Mol-
ybdenum Disulphide grease.

CLUTCH LINKAGE
1. Loss of clutch pedal reserve. 1. Check operating mechanism.

TRANSMISSION
1. Excessive shift effort.
A. Shift levers or forks worn or A-B. Replace worn or defective
bent. parts.
B. Synchronizer worn or broken.
2. Sticking in Gear. 2. A. Fill to bottom of filler plug
A. Low lubricant level. hole.
B. Corroded transmission levers B-D. Free-up and clean parts, re-
(shaft). place if necessary.
C. Defective (right) input shaft C-E. Replace defective parts.
pilot bearing.
D. Stuck interlock sleeve.
E. Burred or battered teeth on
synchronizer sleeve and/ or in-
put shaft.
GEAR JUMPOUT SHIFT LINKAGE
1. Loose nuts at steering column
levers and shift rods. If the nuts are
loose, check for bell-mouthing of
slots. 1. Adjust levers and rods to
2. Bent transmission shift rods or proper crossover. Torque nuts to
linkage interference. specification. Replace bell-mouthed
rods.
2. R..:place bent rods or levers.
3. Lack of lubrication of shift 3. Clean and lubricate with Mol-
linkage, trunnions. ybdenum Disulphide grease.
STEERING COLUMNS
1. Improper column alignment, 1. Align column properly, replace
looseness, binding and worn sur- defective column parts.
faces.
2. Woro shift key or broken weld 2-3. Replace defective parts.
securing shift key to top or bottom
of shift tube.
3. Keyway 10 die cast selector
lever hub pounded out.
4. Loose screws securing die cast- 4. Replace defective parts. Tighten
ing to bottom of tube. Excessive screws securely.
radial movement in the column
linkage. (If the vehicle has high
mileage or is subjected to hard use,
even though the crossover has been
properly set, the column may have
PART 6-1-MANUAL SHIFT TRANSMISSION 6-5

TROUBLE SYMPTOMS POSSIBLE CAUSES CORRECTION

GEAR JUMPOUT deteriorated to a point where proper

(Continued) crossover engagement will not occur
due to excessive radial movement in
the column linkage (lost motion).

TRANSMISSION
1. Transmission misaligned or 1. Align to specification. Torque
loose. transmission - to - flywheel housing
2. Bent or worn shift fork, lever bolts and flywheel housing-to-engine
and/ or camshaft. bolts to specifications.
3. Worn input shaft pilot bearing. 2-3-5-6-7. Replace worn or de-
4. End play in input shaft (bearing fective parts.
retainer loose or broken, loose or 4. Torque retainer bolts to speci-
worn bearings on input and output fication. Replace worn or defective
shafts). parts.
5. Interlock springs broken.
6. Detent notches worn.
7. Worn clutch teeth on the re-
spective gear and/ or worn clutch
teeth on synchronizer sleeve.
8. Failure of the operator to fully 8. Replace worn parts and educate
engage the gears on every shift before the operator.
engaging the clutch and applying
engine power.
LOCKED IN GEAR SHIFT LINKAGE
When a complaint of momentary 1. Loose nuts at transmtsston 1. Adjust levers and rods to proper
blackout is encountered in transmis- levers and shift rods. If the nuts are crossover. Torque nuts to specifica-
sions with non-synchronized low- loose, check for bell-mouthing of tion. Replace bell-mouthed rods and
gear, determine whether or not a slots. levers. Replace bent rods or levers.
normal "blackout" condition does
exist, the customer should be infor-
med that the transmission gears
cannot be pulled into mesh because
of gear tooth to tooth abutment STEERING COLUMN
which can be eliminated by releasing
1. Incorrect adjustment of shift 1-2. Adjust column properly and
and depressing the clutch pedal again
linkage. Make certain that when replace defective parts.
(thus spinning the clutch disc). This
will re-index the drive and driven slowly shifting out of low gear, the
gear teeth and allow the gears to low gear shift lever at the transmis-
mesh. sion is completely out of low gear
detent prior to the column shift lever
dropping through neutral crossover.
If the transmission shift lever is not
completely out of low gear detent the
shift interlock in the transmission
will prevent engagement of second
gear and a lockup condition occurs.
2. Improper column alignment,
looseness, binding and worn surfaces.
3. Worn shift key or broken weld 3-4. Replace defective parts.
securing shift key to top or bottom
of shift tube.
4. Keyway m die cast selector
lever hub pounded out.
5. Loose screws securing die cast- 5. Replace defective parts. Tighten
ing to bottom of tube. Excessive screws securely. Clean and lubricate
radial movement in the column with Molybdenum Disulphide grease.
linkage. (If the Yehicle has high
mileage or is subjected to hard use
even though the crossover has been
properly set, the column may have
deteriorated to a point where proper
GROUP 6-GENERAL TRANSMISSION SERVICE

TROUBLE SYMPTOMS POSSIBLE CAUSES CORRECTION

LOCKED IN GEAR crossover engagement will not occur
(Continued) due to excessive radial movement in
the column linkage (lost motion).
Lack of lubrication in column.

TRANSMISSION
1. Shift components not function- 1-3. Install correctly, replace de-
ing properly. fective parts.
2. Gear seizure. 2. Replace defective parts.
3. Synchronizer inserts out of
position.

NOISY IN FORWARD 1. .Low lubricant level. 1. Fill to bottom of filler plug hole.
SPEEDS 2. Transmission misaligned or 2. Align to specification. Torque
loose. transmission - to - flywheel housing
lOOSe. bolts and flywheel housing-to-engine
bolts to specifications.
3. Input shaft bearings worn or 3-4-5-6-7. Replace worn or de-
damaged. fective parts.
4. Output shaft bearing worn or
damaged.
5. Mainshaft gears worn or dam-
aged. (In any case of scored or
broken gears, the mating gears
should be checked).
6. Countershaft gear or bearings
worn or damaged.
7. Gear roll-over noise, inherent in
manual transmissions, is caused by
the constant mesh gears turning at
engine idle speed, while the clutch
is engaged and the transmission in
neutral; and throwout bearing rub
are sometimes mistaken for main-
shaft bearing noise.
Gear lioll-over noise will disappear
when the clutch is disengaged or
when the transmission is engaged in
gear. Throwout bearing rub will dis-
appear when the clutch is engaged.
In the event that a bearing is de-
fective, the noise is more pronounced
while engaged in gear under load or
coast than in neutral. When com-
plaints of this nature are encountered,
it will be necessary to road test the
vehicle to determine if bearing noise
exists.
Under no circumstances should
any transmission! rework be at-
tempted to eliminate gear roll-
over nC)ise, or throwout bearing
rub.

NOISY IN REVERSE 1. Reverse idler gear, bearing or 1-2. Replace worn or defective
shaft, worn or damaged. parts.
2. Reverse sliding gear worn or
broken.
PART 6-1-MANUAL SHIFT TRANSMISSION 6-7

TROUBLE SYMPTOMS POSSIBLE CAUSES CORRECTION

LUBRICANT LEAKS 1. Excessive lubricant. 1. Drain to bottom of filler plug

hole.
2. Vent plugged. 2. Free up.
3. Input shaft bearing retainer 3. Add sealer and torque retainer
loose or cracked, seal or gasket bolts to specifications. Replace de-
damaged. fective parts.
4. Worn or damaged extension 4-5-8. Replace defective parts.
housing seal or gasket.
5. Wom shifter shaft seals. 5-6-7-9. Add sealer to bolts, and
6. Cover bolts loose. Defective torque to specifications. Replace de-
gasket. Damaged cover. fective parts.
7. Extension housing or bearing
retainer bolts not sealed.
8. Expansion plug at front of case
not seated properly.
9. Access cover loose or gasket
damaged.
10. Vent incorrectly installed. 10. See page 6-17, Fig. 35.

EJ COMMON ADJUSTMENTS AND REPAIRS

GEAR SHIFT LINKAGE 2. Insert the tool shown in Fig. 3 with the bottom of filler hole left
ADJUSTMENT into the extension housing until it side of transmission case.
1. Place the gearshift lever in the grips the front side of the bushing.
neutral position. 3. Turn the screw clockwise until
2. Loosen the two gearshift rod the seal and the bushing are .free of
adjustment nuts. the housing.
3. Insert the gauge pin through 4. Drive a new bushing into the
the holes in the levers and the bearing extension housing with the tool
at the lower end of the column. shown in Fig. 4.
Page 6-10.
4. Place the transmission in neu- 5. Install a new seal in the housing
tral and tighten the two gearshift as shown in Fig. 2.
adjustment nuts. 6. Install the driveshaft.
5. Remove the pin from the levers. LUBRICATION
6. Start the engine and shift the Tool- -7697-A
Lubrication level should be in line OR 7000-AF
selector lever to each position to • 7000 GAE
make sure it operates freely.
REAR SEAL REPLACEMENT
1. Remove the driveshaft.
2. Remove the seal from the ex-
tension housing with the tool shown FIG. 3-Removing
in Fig. 1. Extension Housing
3. Install the new seal in the Bushing
extension housing with the tool
shown in Fig. 2.
4. Install the driveshaft.
REAR BUSHING AND SEAL
REPLACEMENT
1. Remove the driveshaft from the FIG. 2-lnstalling
car. Extension Housing Seal
/

FIG. 4-Replacing
Extension Housing
FIG. 1-Removing Extension Housing Seal Bushing
6-8 GROUP 6-GENERAL TRANSMISSION SERVICE

EJ CLEANING AND INSPECTION

CLEANING distorted. Make sure that the vent is original assembly.
open. 10. Replace all other gears that
1. Wash all parts, except the ball 4. Check the condition of the shift are chipped, broken or worn.
bearings, in a suitable cleaning levers, forks, cams, and shafts. 11. Check the synchronizer sleeves
solvent. Brush or scrape all foreign 5. Examine the ball bearing races for free movement on their hubs.
matter from the parts. Be careful for being cracked, worn or rough. 12. Inspect the synchronizer block-
not to damage any parts with the Inspect the balls for excessive loose- ing rings for widened index slots,
scraper. Dry all parts with com- ness, wear, end play or other damage. rounded clutch teeth and smooth
pressed air. Check the bearings for looseness in internal surfaces (must have mach-
2. Rotate the ball bearings in a the bores. If any of these conditions ined grooves). With the blocker ring
cleaning solvent until all lubricant is exist, replace the bearings. on the cone, the distance between
removed. Hold the bearing assembly 6. Replace roller bearings that are the face of the blocker ring and the
to prevent it from rotating and dry it broken, worn or rough. clutch teeth on the gear must not be
with compressed air. 7. Replace the countershaft (clus- less than 0·010 inches.
3. Lubricate the bearings with ter) gear if the teeth are chipped, 13. Replace the speedometer drive
approved transmission lubricant and broken or worn. Replace the counter- gear if the teeth are stripped or
wrap them in a clean, lint-free cloth shaft if it is bent, scored or worn. damaged. Make certain to install the
or paper until ready for use. 8. Replace the reverse idler gear or correct size replacement gear.
INSPECTION sliding gear if the teeth are chipped, 14. Replace the output shaft if
worn or broken. Replace the idler there is any evidence of wear or if
1. Inspect the transmission case gear shaft if bent, worn or scored. any of the splines are damaged.
for being cracked, worn or damaged 9. Replace the input shaft and 15. Inspect the bushing and the
bearing bores, damaged threads or gear if the splines are damaged or if seal in the extension housing. Re-
any other damage which could the teeth are chipped, worn or place them if they are worn or
affect the operation of the trans- broken. If the roller bearing surface damaged.
mission. in the bore of the gear is worn or 16. Replace the seal in the input
2. Inspect the front face of the rough, or if the cone ·surface is shaft bearing retainer.
case for small nicks or burrs that damaged, replace the gear and the 17. Replace the seals or "0" rings
could cause misalignment of the gear rollers. Make sure that the on the cam shafts.
transmission with the flywheel hous- synchronizer sleeves and their re- 18. Mark the mainshaft splines
ing. Remove all small nicks or burrs spective hubs are marked before dis- and low reverse sliding gear to
with a fine stone. assembly to ensure that on assembly ensure the splines are mated as in
3. Replace a cover that is bent or the splines are mated as in the original assembly.
6-9

PART 3 SPEED PARTIALLY SYNCHRONISED MANUAL

6·2 SHIFT TRANSMISSION SERIES BW 199333

Section Page Section Page

1 Description and Operation ...... ...... ...... 6-9 4 Major Repair Operations ... ... ...... ...... .. .. .. ...... 6-11
2 In-Car Adjustments ...... .. .. .. .. .... ...... ...... ...... 6-10 Disassembly ...... ...... ...... ...... ...... ...... ...... .... .. 6-11
Gear Shift Linkage Adjustment .. .... ...... ...... 6-10 Assembly ...... ...... ...... ...... ...... ...... ...... ...... 6-.13
3 Removal and Installation ...... ...... ...... ...... ...... 6-11

D DESCRIPTION AND OPERATION

DESCRIPTION
The 3·00 C.D. three-speed trans-
mission is used in models fitted with
PART NQ ......___ _ _ _ _ _ _ __
a 6 cylinder engine. The designation
3 · 00 C.D. is the actual distance MODELl I REF. NQ I..____~
between the centreline of the coun-
tershaft and the centreline of the
input shaft. An identification plate
(Fig. 5) is attached to the L/ Hand
-$- SERIAL NQ _ I- - - -

rear of the extension housing. ~~LwARNER BORG- WARNER

A synchronizer is provided for -~r~ 1 (AUSTRAUA ) LIMITED
shifting to second and third speeds.
Shifts to first and reverse speeds are
accomplished with a sliding gear.
Ball bearings support the input shaft FIG. 5 -Identification Plate
and gear and the centre of the output
shaft. Needle bearings in the input gear (Fig. 6). Power flow is now from at output shaft speed.
shaft bore support the front of the the input gear, through the counter-
output shaft. The countershaft gear shaft gear to the first and reverse The synchronizer sleeve with fur-
(cluster gear) runs on 3 rows of sliding gear and out through the ther movement will slide over the
needle bearings. A bronze bushing is output shaft. blocking ring and engage the clutch
used in the reverse idler gear. teeth on the constant mesh inter-
When second gear is selected, the mediate gear. Since the intermediate
A bushing located at the rear of shift lever moves the second and gear is now locked to the output
the extension housing supports the third speed synchronizer sleeve rear- shaft by means of the synchronizer
rear of the output shaft when the ward to force the blocking ring sleeve, power flow is from the input
tailshaft is in position. The synchro- conical surface against the matching shaft through the countershaft gear
nizer and the blocking rings are the cone on the constant mesh inter- to the constant mesh intermediate
conventional tapered ring and straight mediate gear located on the output gear to the output shaft.
clutch gear type. shaft. When the vehicle is moving,
as when shifting from low to a Engagement of third speed is the
OPERATION higher gear ratio, the internal teeth same as second except for ratio. In
of the synchronizer sleeve and those third gear, the clutch teeth on the
When first gear is selected, the on the blocking ring will not index input shaft are locked directly to
shift lever moves the first and reverse until the intermediate gear is brought the output shaft by the second and
sliding gear into mesh with the low up or down to the speed of the third speed synchronizer to provide
gear on the countershaft (cluster) synchronizer sleeve which is rotating a ratio of 1 : 1.
6-10 GROUP 6-GENERAL TRANSMISSION SERVICE

FIG. 6-Powerftow Through Transmission

Reverse gear is accomplished by gear, through the countershaft gear, tion.
moving the first and reverse sliding to and through the reverse idler gear
gear rearward to engage the reverse to the first and reverse sliding gear An interlock pin prevents selection
idler gear. which is splined to the output shaft. of more than one gear at a time.
The gears in this position will rotate Detent balls are provided to hold the
The drive is then from the input the output shaft in a reverse direc- selected gear in the desired position.

EJ IN-CAR ADJUSTMENTS
GEAR SHIFT LINKAGE
ADJUSTMENT

1. Place the gear shift lever in the

neutral position.
2. Loosen the two gearshift rod
adjustment nuts.
3. Insert the gauge pin through
the holes in the levers and the
bearing at the lower end of the
column (Fig. 7).
4. Place the transmission in neu-
tral and tighten the two gearshift
adjustment nuts.
5. Remove the gauge pin.
6. Start the engine and shift the IO·lO La FT
selector lever to each position to 73418
make sure it operates freely.

8 LUBIIUCATa IN.ID8. Ofl INftULATORS. (?MI)

WITM RS•· MIC75·A PI" OR TO At.t.V Of~
f'OD.

FIG. 7 -Gear Shift Linkage Adiustment

PART 6-2-3 SPEED PARTIALLY SYNCHRONISED MANUAL SHIFT 6-11

EJ REMOVAL AND INSTALLATION

REMOVAL

1. Raise the car on a hoist.

2. Remove the driveshaft. Insert
the extension housing seal installa-
tion tool, Fig. 2, page 6-7 into the
opening of the extension housing to
prevent the lubricant from leaking
out.
3. Disconnect the speedometer
cable from the extension housing,
and disconnect the gear shift levers
from ·the transmission. FIG. 8-Typical Transmission
4. Remove the two nuts retaining
the transmission rear support to the INSTALLATION fications.
crossmember. Note. For rear cross- 1. Install two guide pins in the 5. Position the crossmember to
members refer to Group 8. flywheel housing lower mounting the frame supports. Install the
5. Place a transmission jack under holes. Start the input shaft through equalizer lever and brake cable.
the flywheel housing and raise the the release bearing. Align the output
rear of the engine slightly. 6. Secure the transmission rear
shaft splines with the splines in the support to the crossmember. Secure
6. Remove the two cotter pins, clutch disc. Move the transmission
nuts, and bolts that attach the cross- the crossmember to the frame sup-
forward on to the guide pins. If the ports and remove the transmission
member to the frame supports. Note. transmission front bearing retainer
For rear crossmember refer Group 8. jack.
hangs-up on the release bearing hub,
7. Disconnect the brake cable move the clutch release lever to 7. Connect the gear shift rods and
from the equalizer lever. Separate free it. speedometer cable.
the lever from the crossmember.
8. Remove the crossmember from 2. Move the transmission forward 8. Remove the tool (Fig. 2, .page
the frame supports and allow it to until the input shaft is through the 6-7 ) from the rear of the extension
hang by the hand brake cable. clutch hub and enters the pilot housing. Install the driveshaft, and
9. Move the jack under the trans- bearing. torque rear U-bolt nuts to speci-
mission. Remove the four trans- fication.
3. Install the two upper trans-
mission to flywheel housing mount- mission to flywheel housing attaching 9. Fill the transmission with ap-
ing bolts. bolts and lockwashers. proved lubricant. Check the shifting
10. Move the transmission (Fig. action of the transmission.
8), back just far enough to clear the 4. Remove the two guide pins and
input shaft and remove it from install the two lower attaching bolts. 10. Adjust the shift linkage as
under the car. Torque all attaching bolts to speci- required.

EJ MAJOR REPAIR OPERATIONS

DISASSEMBLY

1. Mount the transm1ss1on in a

holding fixture and drain the lub-
ricant.
2. Remove the transmission cover
and gasket.
3. Remove the extension housing
attaching bolts and remove the
extension housing and gasket (See
disassembly Fig. 9).
4. Remove the speedometer drive
gear snap ring, the gear, and drive
ball from the output shaft.
5. Remove the retainer for the
reverse idler shaft and countershaft
(Fig. 10). FIG. 9-Gearcase Dismantled
6-12 GROUP 6-GENERAL TRANSMISSION SERVICE

14. Remove the second and third

speed gearshift fork.

15. Move the first and reverse

spe~~ sliding gear into first speed
posltlon.

16. Move the second and third

gear synchronizer outer sleeve rear-
wards to engage the second speed
gear clutch teeth.

17. Remove the output shaft as-

sembly through the top of the case.

FIG. 12-Removing or 18. Using a soft drift, drive the

reverse idler shaft from the case.
Replacing Input Shaft
19. Remove the reverse idler and
FIG. 10-Countershaft and cluster gear.
Reverse Idler Retainer
20. Remove the synchronizer re-
6. Hold the countershaft gear with taining snap ring and slide off the
a hook and using the tool (dummy second and third speed synchronizer
shaft) shown in Fig. 11, drive the assembly and second speed gear with
countershaft rearward out of the its blocker ring. Take a note of the
countershaft gear and the trans- synchronizer assembly hub end posi-
mission case. Then, carefully lower tion for reference on assembly.
the countershaft gear and dummy
shaft to the bottom of the case. 21. Mark the relative positions of
low-reverse sliding gear and output
7. After removing the input shaft shaft splines for reference on assem-
bearing retainer and gasket, remove bly and remove the sliding gear.
the input shaft assembly and front
synchronizer blocking ring from the REPLACEMENT
transmission case (Fig. 12). FIG. 1 3-Removing Cam CAM AND SHAFTS AND OIL
8. Move the second and third
and Shaft Taper Pins SEALS
speed gearshift cam into third speed 1. Using a plastic hammer, drive
position. 12. Remove the output shaft bear-
ing outer snap ring. Push the output the second and third cam and shaft
9. Remove the gearshift levers. shaft assembly forward so that the toward the inside of the case and
output shaft bearing moves through separate the detent balls and spring
10. From the underside of the into the gear case. Move the output from the plunger. Push out the cam
case, knock out the taper pin from shaft assembly away from the gear- and shaft assemblies, and remove the
each gearshift camshaft (Fig. 13), shift forks. plunger.
11. Push the gearshift cam and
shaft assemblies against the inside 13. Remove the first and reverse 2. If required, the cam shaft oil
of the case. speed gearshift fork. seals or "0" rings may be replaced
~y removing them from their grooves
m the cam shafts or extracting from
case.
INPUT SHAFT BEARING
1. Remove the snap ring and
spacer securing the input shaft bear-
ing, and press the input shaft out of
the bearing, oil slinger and remove
the spacer retaining snap ring and
rollers (14) from the internal bore of
the input shaft.
DUI~MY COUNTER OUTPUT SHAFT BEARING
SHAFT SHAFT
1. Remove the snap ring securing
the output shaft bearing. Remove
the bearing and spacer as shown in
FIG. 11-Removing Countershaft Fig. 15.
PART 6-2-3 SPEED PARTIALLY SYNCHRONISED MANUAL SHIFT 6-13

FRONT BEARING RETAINER SEAL

1. Remove the input shaft seal
from the front bearing retainer as
shown in Fig. 19.
2. Install a new input shaft seal
as shown in Fig. 20.
ASSEMBLY
1. Lubricate the interlock sleeve
bore of the gear case and the outside
of the interlock sleeve. Use grease to
locate one interlock ball in the inter-
lock sleeve and fit the sleeve to the
case.

2. Lubricate a: new "0" ring seal

and fit to the shaft.

3. Lubricate the shaft of the first

and reverse gearshift cam and shaft
assembly and fit it to the case. Align
the shaft retainer groove and the hole
in the case and fit the taper pin.
FIG. 14 -SelectorCamshafts, Levers and Fig. 29 (Use sealer on pin).
Interlock Assembly 4. Lubricate the shaft of the
second and third speed gearshift cam
and shaft assembly. Fit the cam and
shaft assembly and use the centl.'e
detent notch to retain the interlock
spring, interlock pin and second
detent ball, which should now be
fitted. (Interlock sleeves are selective-
ly fitted for axial movement of · 002
to · 010 in all gear selection positions
-refer Fig. 21). Do not fit taper pin
to second and third camshaft at this
stage.

5. Lubricate the bore of the re-

verse idler gear and bush assembly,
and install the gear and bush assem-
bly, fitting the reverse idler shaft to
the case so that the locking groove is
FIG. 15-Removing flush with the outside of the case and
Output Shaft Bearing FIG. 16-Replacing adjacent to the cluster gear shaft bore.
Fig. 22. The reverse idler gear
2. Press the output shaft bearing Output Shaft Bearing should be installed so that the longer
onto the shaft as shown in Fig. 16 boss of the gear is towards the front
and install the spacer and snap ring of the case. Fig. 23.
on the shaft. Select a snap ring to
keep end float to a minimum ( · 000
to ·004).
SYNCHRONIZER
1. Remove the synchronizer sleeve,
blocking rings, inserts, and retainers
from the synchronizer hub (Fig. 17).
COUNTERSHAFT GEAR
IEARINGS
1. Remove the flat washers, dum- FIG. 17-2nd & 3rd Synchronizer
my shaft, spacer, and roller bearings
from the countershaft gear (Fig. 18). Disassembled
6-14 GROUP 6-GENERAl TRANSMISSION SERVICE
~-·· CLUSTER GEAR DISASSEMBLED l inner and outer rear cluster thrust
REAR 81 METAL THRUST washers on rear of the cluster gear.
FRONT THRUST WASHER
WASHER
(Steel washer against cluster, tangs
engaged with slots in cluster. Bimetal

I washer to case, tang to engage with

slot in case).
8. Place the cluster assembly in
the bottom of the gear case, Fig. 24,
ensuring that the tangs of the thrust
washers fit the grooves of the case.
9. Assemble the second and third
gear speed synchronizer as follows:
Lubricate the second and third speed
synchronizer sleeve and fit it to the
FLAT
WASHER second and third speed synchronizer
inner hub with the sleeve selector
groove and the hub inner spline pro-
trusion at opposite ends. Slide the
sleeve across the hub until three
second and third speed shift plates
can be fitted into the slots in the inner
6. Using the dummy countershaft, hub (Fig. 17). Fit the two second
assemble the cluster gear bearing and third speed synchronizer springs,
spacer and needle roller bearings to one in each end of the hub, so that a
the cluster gear, so that there is a tang of each spring fits into the same
single row of 22 needle rollers and a shift plate. The free ends of the
needle roller flat washer at the for- springs should not be in line
ward (large gear) end of the cluster (Fig. 25).
gear, and two rows of 22 needle
roller bearings, separated by a needle 10. Fit the output shaft bearing to
roller flat washer at the rear (small the output shaft behind the splines
gear end) of the cluster gear. Fig. 18. for the first and reverse sliding gear.
Fit a retainer ring and snap ring,
7. Use grease to locate the forward selecting the snap ring to keep end
cluster gear thrust washer (large float to a minimum within the limits
Bimetal washer, tang to engage with · 000 to · 004 inches. (Snap rings are
slot in case) (Refer Fig. 18) and the available in 4 selective sizes). Do not

FIG. 1.9-Removing Input

Shaft Seal

FIG. 20-lnstalling Input FIG. 21-Selector Camshafts, Levers and

Shaft Seal Interlock Assembly
PART 6-2-3 SPEED PARTIALLY SYNCHRONISED MANUAL SHIFT 6-15
fit the bearing outside diameter snap selector groove of the synchronizer
ring. sleeve to the rear of the case (Fig. 26).

11. Lubricate the splines of the 14. Fit the snap ring to the output
output shaft and the first and reverse shaft to retain the second speed gear
sliding gear, and fit the gear to the and synchronizer assembly. Measure
output shaft (Fig. 26). the end float between the snap ring
and the synchronizer assembly to
12. Lubricate the bore of the ensure that this is within the limits
second speed gear and fit it to the ·006 to ·019 inches. It is important
output shaft. Fit a synchronizer that this clearance be maintained to
FIG. 22-Fitting Reverse prevent seizure of the components
blocker ring to the gear cone.
Idler Gear Shaft due to expansion.
13. Lubricate the splines of the
output shaft and the second and third 15. Fit the first and reverse speed
speed inner hub, and fit the second gearshift fork to the first and reverse
and third speed synchronizer assem- speed (rearmost) cam after lubrica-
bly to the output shaft with the ting the shaft of the fork. (Fig. 27).

SYNCH RONISER
- SLEEVE

ST. & REVERSE SLIDING GEAR

FIG. 23-Reverse Idler

Gear

OUTPUT SHAFT

FIG. 26-0utput Shaft Disassembled

FIG. 24-Ciuster Gear in
Case 2ND. t. 3RD. SPEED
LEVER
() ~
I" 0
FIRST ll. REVERS E
/LEVER

"a /
---CAMSHAFT OIL SEALS - - """"
o
• =6 FIRST & REVERS!:
CAMSHAFT
/TAPERED RETAINING PINS '):t .
...:::::==. INTERLOCK SLEEVE - \ - ., ,._~ 9
DETENT ~ DETENT
BALLS --u ==::1 ~ SPRING
~
=
2 NO. & 3 RD. SPEED Fl RST & REVERSE
GEAiiSHIFT FORK GEARSHIFT FORK -

FIG. 25-2nd & 3rd

Speed Syncro Spring FIG. 27-Selector Camshafts, Levers and
Arrangement Interlock Disassembled
6-16 GROUP 6-GENERAL TRANSMISSION SERVICE

16. Move the first and reverse 210. Push the second and third keep the end float to a m1mmum
speed gearshift cam into first gear speed gearshift camshaft inward and within the limits · 000 to · 004 inches.
position. Move the second and third fit the taper pin. (Fig. 29). Fit the
speed synchronizer sleeve to engage bearing retaining outside diameter 22. Use grease to position fourteen
the second speed gear clutch teeth. snap ring. Move second and third needle rollers in the input shaft. Fit
speed synchronizer into neutral. the input shaft assembly to the case.
17. Lower the output shaft assem- (Fig. 12).
bly through the top of the gear case, 21. Fit the oil slinger, (assemble-
fitting the first and reverse gearshift Fig. 31-with projection between 23. Use special tool 77047B to
fork into the selector groove of the input gear teeth), input shaft bearing press the bearing retainer oil seal into
first and reverse sliding gear. with outside diameter snap ring, re- the bearing retainer after coating the
taining ring, snap ring-Fig. 32- oil seal outside diameter with gasket
18. Move the first and reverse and third speed blocker ring to the cement. (See Fig. 20).
speed gearshift cam into neutral input shaft. Select the snap ring to
position, and move the second and 24. Use a light coating of grease to
third speed gearshift cam into third position the bearing retainer gasket,
gear position. Push this cam back and fit the bearing retainer with three
against the inside of the gear case. bolts and lockwashers, tightening the
bolts to 20 to 25 lb. ft. torque. (Fig.
19. Fit the second and third speed 33) (Use sealer on bolt threads).
gearshift fork into the selector groove
of the second and third speed syn- 25. Bring the cluster gear into
chronizer sleeve and roll it into mesh by carefully turning the gear-
position in the second and third box upside down and allowing the
speed cam. The fork must be fitted cluster gear to drop into place. It
so that the pad branded "T" can be may be necessary to rotate the input
seen through the top of the gearbox. shaft to ensure proper meshing of
(Fig. 28). FIG. 30-lnput Shaft the gears.
Rollers
26. Using the countershaft, (Fig.
34), drive out the dummy shaft from
the rear of the case until the locking
plate slot in the countershaft is flush
with the outside rear face of the case.
The slots in the countershaft and the
reverse idler shaft must be parallel
and adjacent.
27. Fit the locking plate to the
countershaft and reverse idler shaft,
tapping to bring the plate against the
case (Fig. 10).

28. Fit the speedometer gear re-

FIG. 28-0uput Shaft taining ball to the mainshaft and
slide on the speedometer gear. Fit
Installation FIG. 31-lnstalling Input the snap ring.
Shaft Bearing

FIG. 29-Fitting Taper

Pins FIG. 32-lnput Shaft Assembly
PART 6-2-3 SPEED PARTIALLY SYNCHRONISED MANUAL SHIFT 6-17

FIG. 34-Replacing
Countershaft
FIG. 35-fitting
FIG. 33-Front Bearing Breather
Retainer in Place 32. Fit both gearshift levers with
lock washers and nuts, tightening to
29, Measure the output shaft 20 to 25lb. ft. torque. (Refer Fig. 21). 36. Fit the drain and filler plugs,
bushing inside diameter. If the size tightening to 20 to 25 lb. ft. torque.
is not in the range 1· 3745 to 1· 3755 33. Install a new welch plug into (Drain plug is brass with integral
inches, fit a new output shaft bushing the front face of the case, ensuring magnet-filler plug is steel).
to the extension housing using special that it does not protrude above the
tool 7657G/ 27 (Fig. 4, page 6-7). case face. (Fig. 21) (Use sealer on 37. Fit the breather in the exten-
plug). sion housing (when removed) with
30. Fit a new extension housing the flat on the breather body on the
oil seal, using tool 7657G (Fig. 2, 34. Pour lubricant over the entire left side and parallel with centre line
page 6-7). gear train while rotating the input or of transmission. (Refer Fig. 35).
output shaft.
31. Position the ew:tension housing 38. Check transmission operation
gasket using a light coating of grease. 35. Use grease to position the through all shift positions.
Install the extension housing with gearbox top cover gasket. Fit the top
six bolts and lockwashers, tightened cover, tightening six bolts and lock- 39. Refill transmission. Ensure oil
to 45 to 55 lb. ft. torque (Use sealer washers to 8 to 12 lb. ft. torque. is level with the bottom of the filler
on bolt threads). (Use sealer on bolt threads). hole on the left side of the gear box.
6-18

PART 3 SPEED FULLY SYNCHRONISED MANUAL

6·3 SHIFT TRANSMISSION SERIES BW 199332
& 199331

Section Page Section Page

1 De~cription r.nd Operation ..... . .. ............ ...... .. .. 6-18 4 Major Repair Operations .. .. ........ .. ...... ........ .. 6-20
Disassembly .... .... .. .. ...... .... ........ .. .......... .... .. 6-20
2 In-Car Adjustments .. .. .. .. ..... .... .... ........ .... .. 6-19
Replacement .. .... .. ..... .. .. ....... .. ........ .. .... .. .. .. .. 6-20
3 Removal and Installation .... .. ..... . .. .... ...... ..... . 6-19 Assembly ...... ... ... .... .. ...... ...... ...... .. .... .. .. .. 6-20

0 DESCRIPTION AND OPERATION

DESCRIPTION

The 3 · 00 Model three-speed trans- 2" ~ 3., SPEED l.r. SP EED

mission is used for 6 cylinder engines SYNCHRONIZER 2 .. SPEED GEAR br S. REV ERSE
and V8 engined vehicles. The desig- GE~. R / 5LI W IG SLEEVE &
GEAR
nation 3 · 00 is the actual distance OUTPUT SHAF1 BEARING
between the centreline of the counter-
shaft and the centreline of the input
shaft.

A transmission service identifica-

tion plate (Fig. 5, page 6-9 ) is INP UT SHAFT
located on the left side of the ex- AND GE~ R
tension housing at the rear. The first
line on the tag will show the trans-
mission model and service identifica-
tion code when required.
This transmission is of the fully
synchronized type, with all gears
except the reverse gear and sleeve \
CLUSTER GEAR
being in constant mesh. All forward-
speed changes are accomplished with
synchronizer sleeves (Fig. 36) in-
stead of sliding gears. The synchro- FIG. 36-Gear Train Layout
nizers enable quicker-shifts, elimin-
ates gear clash and permit easy ings in the input shaft bore support are the conventional tapered ring and
engagement of low gear at low the front of the output shaft. The straight clutch gear type (Fig. 17,
vehicle speeds. countershaft gear (cluster gear) runs page 6-l3and Fig. 39,page6:2l).
on three rows of roller bearings. A
The forward-speed gears are heli- bronze bushing is used in the reverse The shift forks, detent mechanism,
cal-cut and are in constant mesh idler gear on 6 cylinder and roller and related parts are provided in the
(Fig. 36). Gears used in the reverse bearings for 8 cylinder. transmission case (Fig. 37).
gear train are spur-cut and are not OPERATION
synchronized. A bushing located at the rear of
the extension housing supports the When the first-speed gear is selec-
Ball bearings support the input rear of the output shaft. ted, the shift lever moves the reverse
shaft and gear and the centre of the gear and sleeve forward and forces
output shaft (Fig. 36). Roller bear- Synchronizers and blocking rings the synchronizer blocking ring coni-
PART 6-3-3 SPEED FULLY SYNCHRONISED MANUAL SHIFT 6-19

FIG. 37-Shift Mechanism

Disassembled
cal surface against the matching cone
on the constant mesh first gear
located on the output shaft. If the
car is moving, the internal teeth of
the reverse gear and sleeve blocking FIG. 38-Powerflow
ring will not index until the constant
mesh first gear is brought up or down through the reverse gear and sleeve are always locked to the output shaft.
to the speed of the reverse gear and to the output shaft, and out the rear Reverse gear is engaged by sliding
sleeve which is rotating at output of the transmission. the reverse gear and sleeve into mesh
shaft speed. with the reverse idler gear. The drive
Engagement of second and third is then from the input gear, through
The reverse gear and sleeve has gears is the same as first except for the countershaft gear, to and through
internal splines that, with further ratio. the reverse idler gear to the output
movement, will slide over the block- shaft reverse gear and sleeve. The
ing ring and engage external clutch In third gear, the input gear and gears in this position will rotate the
teeth on the constant mesh first gear. shaft is locked directly to the output output shaft in a reverse direction.
Since first gear is now locked to the shaft by the second and third speed
output shaft and is always meshed synchronizer to provide a ratio of 1 : 1. A system of interlocks and detents
with the countershaft (cluster) gear, in the transmission case prevents the
the power flow is from the input Spur teeth are cut on the outside selection of more than one gear at a
gear, through the countershaft gear, of the reverse gear and sleeve. The time and helps to hold any gear in
to the constant mesh first gear, reverse gear and sleeve like the hub the selected position.

EJ IN-CAR ADJUSTMENTS (See page 6-10. )

EJ REMOVAL AND I NSTALLATION (See page 6-11. )

6-20 GROUP 6-GENERAL TRANSMISSION SERVICE

rJ MAJOR REPAIR OPERATIONS

DJSASSEMBL Y case. Move the mainshaft assembly in the cam shafts ("0" rings) or ex-
1. Mount the transm1ss1on in a away from the gearshift forks. tracting them from the case (seals).
holding fixture and drain the lubri- 14. Move the first and reverse INPUT SHAFT BEARING
cant. sleeve and gear forward into first
speed position (do not move first and 1. Remove the snap ring and
2. Remove the six cap screws that reverse gearshift fork out of neutral spacer securing the input shaft bear-
attach the cover to the case. Remove position). ing, and press the input shaft out of
the cover and the gasket from the the bearing and oil slinger.
case. 15. Remove first and reverse gear-
shift fork. 2. Remove the rollers (14) from
3. Remove the six cap screws and the rear end of the input shaft.
lock washers that attach the extension 16. Remove second and third
housing to the case. Remove the speed gearshift fork. l<'RONT BEARING RETAINER
extension and gasket from the case. SEAL
17. Move the second and third 1. Remove the input shaft seal
4. Remove the three cap screws speed synchro outer sleeve rearwards
and lock washers that attach the front from the front bearing retainer as
into second speed position. shown in Fig. 19, page 6·14
bearing retainer to the case. Remove
the retainer and gasket from the case. 18. Remove output shaft assembly 2. Install a new input shaft seal
through top of gear case.
5. Use a soft drift to knock the as shown in Fig. 20, page 6-14
countershaft through from the front 19. Knock out reverse idler gear SYNCHRONIZERS
to allow the lock plate to be removed. and cluster gear assembly.
Remove the lock plate. (Fig. 10, 1. Push the synchronizer hub from
page 6-12 ). each synchronizer sleeve.
20. Remove the synchronizer snap
ring from the front of the output 2. Separate the inserts and insert
6. Push countershaft out through shaft and slide off the second and
rear of case with dummy counter- springs from the hubs. Do not mix
third speed synchronizer assembly the parts from the second and third
shaft tool No. 7111 C. (Fig. 11, page and the second gear with its blocker
6-12). Lower the countershaft and speed synchronizer with the first and
ring. reverse synchronizer (Figs. 39, page
dummy shaft to the case bottom.
6-21 ).
Take note of the synchronizer
7. Remove the snap ring that se- assembly hub end positions for COUNTERSHAFT GEAR
cures the speedometer drive gear on reference in assembly. BEARINGS
the shaft. Slide the speedometer drive
gear off the output shaft. Remove the 1. Remove the dummy shaft, 66
21. Remove the output shaft bear-
speedometer drive gear drive ball roller bearings, and the 3 bearing
ing snap ring and spacer from the
from the shaft. output shaft and remove the bearing. retainer washers from the counter-
(Fig. 15,page 6-13). shaft gear (Fig. 40).
8. Pull out input shaft from front
of case. Remove third speed blocker ASSEMBLY
22. Remove the first speed syn-
ring. (Fig. 12,page6-12). chronizer and reverse gear assembly 1. Use grease to hold 1 ball in rear
snap ring from the output shaft. of interlock sleeve. Fit sleeve into
9. Remove rear (output shaft) Remove the synchronizer and gear case.
bearing outer snap ring. assembly from the output shaft.
2. Lubricate shaft of first and
10. . Move second and third speed REPLACEMENT reverse gearshift cam and shaft
gearshift cam into third gear position. CAM AND SHAFTS AND OIL assembly. Fit cam and shaft assembly
SEALS to case in neutral position (so that the
11. From the underside of the interlock sleeve ball is in extended
case, knock out taper pins from each 1. Using a plastic hammer, drive detent notch of the cam).
gearshift camshaft. (Fig. 13, page the second and third cam and shaft
6-12 ). toward the inside of the case and 3. Lubricate shaft of second and
separate the detent balls and spring third speed gearshift cam and shaft
12. Push gearshift cam and shaft from !he plunger. Push out the cam assembly. Fit the cam and shaft
assemblies against the inside of the and shaft assemblies, and remove the assembly to the case, pushing the cam
case. plunger. against the side of the case so that the
interlock sleeve hole is not blocked.
13. Push the output shaft assem- 2. · If required, the cam shaft oil
bly forward so that the output shaft seals or "0" rings may be replaced 4. Fit interlock pin, spring and
bearing moves through into the gear by removing them from their grooves second ball. Move the cam and shaft
PART 6-3-3 SPEED FULLY SYNCHRONISED MANUAL SHIFT 6-21

FIG. 39-First and Reverse Synchronizer Disassembled

CLUSTER GEAR
FIG. 4 1-Ciuster Gear in
BIMETAL THHUST Case
It/ASHER

"'"" w'7
LARGE BIMETAL

STEEL THRUST synchro spring groove of the inner

WASHER hub at the same ends. Fit three first
speed shifting plates into the hub
slots, with plate pads in the recessed
end of the hub. Fit two synchro
springs under the shift plates, the
white painted spring in the spring
groove of the hub, the other ~n the
hub end recess. Note that the springs
are not identical. The spring tangs
should locate on opposite sides of the
same shift plate, so that the spring
openings do not line up. (See Fig. 39).

10. Assemble second and third

speed synchro as follows:
FIG. 40-Countershaft and Cluster Gear
Fit lubricated synchronizer sleeve
assembly into third gear position, so 22 lubricated needle rollers at the to inner hub with sleeve selector
that extended detent notch of the cam front (largest gear end) of the cluster. groove and hub inner spline pro-
retains the ball and spring. (Interlock Fit two sets of 22 lubricated needle trusion at opposite ends. Slide sleeve
sleeves are selectively fitted for axial rollers at the other end of the cluster, across hub until three second and
movement of ·002 to ·010 in all gear separating the rollers with cluster third speed shift plates can be fitted
selection positions. Three sizel' are gear needle roller retainer was?er. into the slots in the inner hub. Fit
available, refer specifications page Fit cluster gear needle roller rctamer two second and third speed synchro
6-35). washers at each end of the dummy springs under the shift plates behind
countershaft, together with two thrust the pads. Note that the spring tangs
5. 6 Cyl. Install lubricated reverse washers at the rear (small steel should be located in the same shift
idler gear and bush assembly and washer to cluster, engage tangs with plate. The springs should be installed
shaft with bevelled ends of the gear slots in gears) (small bimetal to case, with the free ends opposite. (Fig. 25,
teeth forward. Shaft must be inserted engage tangs with slot in case) of the page 6--15 ).
so that the locking groove is flush cluster gear, and one thrust washer
with the outside face of the gear case, (large bimetal engage tang with slot
in case) at the front end of the gear. 11. Lubricate first speed gear bore
and face towards the cluster gear and fit with blocker ring to output
shaft hole. Refer Fig. 22, page 6-15 These may be retained with grease
(Refer Fig. 40). shaft. The back face of the gear
should be against the rear face of the
6. 8 Cyl. Instali (22) needle rollers mainshaft shoulder. Fit first speed
and (2) thrust washers with a dummy 8. Place cluster assembly in the synchro and reverse gear sleeve
shaft. A dummy shaft can be made bottom of the gear case, ensuring assembly, and snap ring to output
up from an old cluster shaft. Cut off that the tabs of the thrust washers shaft with reverse gear sleeve teeth
nr
at 1 inches. fit the grooves of the case (Fig. 41 ). toward rear of case. Check end float;
this should be within the limits
7. Assemble cluster gear, dummy 9. Assemble first and reverse speed ·006" to ·019''. Fit output shaft
countershaft (7111 C) and bearings synchro assembly as follows: bearing, spacer, ·and snap ring, (Fig.
as follows: 47), selecting snap ring to keep end
Lubricate synchro sleeve and re- float to a minimum (- 004 max.). Do
Insert dummy countershaft and verse gear and fit to the inner hub not fit snap ring to outside diameter
spacer into cluster gear. Fit a set of with the teeth of the gear and the of output shaft bearing (Fig. 42).
6-22 GROUP 6-GENERAL TRANSMISSION SERVICE

FIG. 42-Checking First &

Reverse Synchro
Assembly End Float
FIG. 44-0utput Shaft Assembly

third and neutral positions are still 21. Position the bearing retainer
held by the cams. Tilt the mainshaft gasket with a light coating of grease
assembly away from the camshafts. and fit the bearing retainer and secure
with three bolts and lock washers,
17. Roll the gearshift forks into tightening the bolts to 20-25 lb. ft.
position in the camshaft assembly. torque. (Use sealer on bolt threads).
(Fig. 45). The first and reverse fork
is installed with its selector groove to 22. Bring the cluster gear into
the rear of the shank, and the second mesh by carefully turning the gear-
and third fork with the pad branded box upside down and allowing the
FIG.4S-Checking End "T"upwards. Move the output shaft cluster gear to drop into place. It
assembly so that the second and third may be necessary to rotate the input
Float in Second & Third speed fork lines up with the second shaft to ensure proper meshing.
Speed Synchronizer and third speed synchro sleeve and
continue moving until the groove in 23. Enter the plain end of the
the first reverse fork lines up with the countershaft from the rear of the case
12. Lubricate second speed gear and drive out the dummy shaft until
bore. Fit with blocker ring to output sleeve. Lift the output shaft assembly
to engage the forks in the synchro the locking plate slot in countershaft
shaft so that back face of gear is is flush with the outside rear face of
against front face of output shaft sleeve and reverse sliding gear and
sleeve. (Fig. 45). the case. The slots in the counter-
shoulder. Second speed blocker rings shaft and the reverse idler shaft must
are distinguished from the first speed be parallel and adjacent. Fig. 34,
blocker rings by narrower slots. The 18. Push camshaft assemblies into page 6-17.
second speed blocker ring slots are operating position and fit tapered
· 356 to · 360 inches wide, the first retaining pins into case (use sealer
speed blocker rings ·631 to · 641 on pins). 24. Fit the locking plate to the
wide. slots in the counter shaft and reverse
19. Pull output shaft rearwards idler shaft. Tap the ends of both
entering the rear bearing into the shafts to bring the plate firmly
13. Lubricate the second and third against the case. (Fig. 10, page 6-12 ).
speed synchro assembly. Fit to the case until the bearing outer snap
output shaft with the inner hub inner ring can be fitted. Fit the oil slinger,
spline protrusion to the front of the input-shaft bearing (with outside 25. Measure the extension housing
gear case. Fit the snap ring and check snap ring installed), spacer ring and rear bushing inside diameter. If the
that the end float is within limits snap ring. Select snap ring to keep size is not in the range 1· 3745 to
·003" to · 016". Refer Fig. 43. end float to a minimum within 1· 3755, fit a new bushing to the
limits of · 000 to · 004. Assemble the extension housing.
14. Move the second and third oil slinger with tpe projection be-
speed synchro sleeve to engage second tween gear teeth. · 26. Fit a new extension housing
gear. Move the first and reverse seal using tool 7657G for 6 Cyl. and
synchro sleeve to engage first gear. With grease, position the needle tool T61L-7657-A for 8 Cyl.
rollers (14 for 6 Cyl., 15 for 8 Cyl.)
in the rear bore of the input shaft, 27. Position the extension housing
15. Fit the output shaft assembly and fit. (Do not use an excessive gasket with a light coating of grease.
into the transmission case through quantity of grease.) Install the extension housing with
the top opening, but do not press six bolts and lock washers, tighten
shaft bearing into case. 2q. Fit the input shaft assembly to 45-55 lbs. ft. torque, use sealer on
to the case (Fig. 12, page 6-12 ). bolt threads.
16. Push the gearshift camshafts Ensure correct entry of the output
to the side of the case, ensuring that shaft spigot. 28. Fit both gearshift levers with
PART 6-3-3 SPEED FULLY SYNCHRONISED MANUAL SHIFT 6-23

FIG. 45-Selector Cam Shafts, Levers, Forks &

Interlock Assembly FIG. 47-lnstalling
Output Shaft Bearing

lockwashers and nuts, tightening to 31. Fit the steel filler plug and
20-25 lbs. ft. torque. (Large lever to brass magnetic drain plug. Tighten-
the front camshaft, small to the rear). ing to 20-25 lbs. ft. torque.

29. If removed install a new welsh 32. If it is necessary to fit a new

plug in the front face of the case, en- breather in the extension housing it
suring that it does not project above must be fitted with the flat on the
the case face, Fig. 45 . breather body on the left hand side
and parallel with the centre line of the
30. Position the top cover gasket, transmission. (Fig. 35,Page 6-17).
FIG. 46-0utput Shaft
install the top cover, tighten the six
Assembly Installed in bolts and lock washers to 8-12lbs. ft. 33. Check transmission operation
Gear Case torque. Use sealer on bolt threads. in all gear positions.
6-24

PART 4-SPEED FULLY SYNCHRONIZED

6·4 MANUAL TRANSMISSION
Section Page Section Paae
1 Description and Operation ................. 6-24 Disassembly ............................. 6-29
Description ............................. 6-24 Parts Repair or Replacement .............. 6-29
Operation ............................... 6-24 Gear Shift Lever ....................... 6· 32
2 In-Car Adjustment and Repairs ............. 6-25 Synchronizers ......................... 6-33
Gear Shift Linkage Adjustments ........... 6-25 Input Shaft Bearing .................... 6-31
3 Removal and Installation .................. 6-2S Countershaft Gear Bearings .............. 6-31
Removal ............................... 6-25 Assembly ............................... 6- 32
Installation .............................. 6-26
4 Major Repair Operations ................. 6-27

D DESCRIPTION AND OPERATION

DESCRIPTION (Fig. 50) is provided to seal the chronizer sleeve are spur-type gears.
The Ford designed 4-speed trans- driver's compartment from the ex-
terior. A transmission service identifica-
mission (Fig. 48) is of the fully syn- tion tag is located on the right side of
chronized type with all gears except The shift pattern is shown on the the case at the front. The first line on
the reverse sliding gear being in top of the gear shift lever knob. A the tag will show the transmission
constant mesh. All forward-speed safety measure is incorporated in model and service identification code
changes are accomplished with syn- the shift mechanism which prevents when required. The second line will
chronizer sleeves. The synchronizers accidental engagement of reverse show the transmission serial number.
will enable quicker shifts, greatly re- gear, this consists of a spring which OPERATION
duce gear clash, and permit down- resists movement of the lever from In first-speed (Figure 49), the first-
shifting into any forward-speed gear the neutral position, reverse being and second-speed synchronizer sleeve
while the vehicle is moving. selected by moving the lever against, is moved rearward by the shift fork.
The shift linkage is mounted and over-riding the spring tension. The sleeve engages the first-speed
directly on the extension housing All forward-speed gears in the trans- blocking ring, which acts as a cone
(Fig. 50) and enters the driver's com- mission are helical-type, however, the clutch applied to the free-wheeling
partment through an opening in the reverse sliding gear and the exterior first-speed gear. This action speeds
floor pan. A flexible rubber dust boot of the first- and second-speed syn- up or slows down the first-speed gear

FIG. 41-Four-speed Transmission-Typical

PART 6-4-4-SPEED FULLY SYNCHRONIZED MANUAL TRANSMISSION 6-25
to match the speed of the output SECOND SPEED
shaft. Further movement of the GEAR
sleeve locks the first- and second- FIRST AND SECOND
SPEED SYNCHRONIZER
speed synchronizer hub to ·the first-
speed gear by means of internal
splines. On engagement of the·clutch,
power flows through the input shaft
and gear to the meshed countershaft
gear and thence to the first-speed
gear. This gear transmits the power
through the locked synchronizer hub
to the transmission output shaft. All
the other forward-speed gears are in
idler motion, as they are all driven
by the countershaft (cluster) gear,
but they do not transmit power be-
cause they are not locked to the
output shaft. All the forward-speed REVERSE SLIDING GEAR
shifts are made in the same manner
as the first-speed shift, due to the
constant-mesh features.
Reverse gear is engaged by moving
the reverse sliding gear forward on
the reverse idler gear until it meshes
with the external teeth (spur-type) of
the first- and second-speed synchro-
nizer sleeve. Movement of the sliding
gear is accomplished by the centre
shaft lever. With all forward-speed
synchronizer sleeves in neutral, power
flow in reverse is through the input
NOTE:
shaft to the constant-mesh counter-
shaft (cluster) gear, thence to the All HELICAl GEARS
IN CONSTANT MESH
constant-mesh reverse idler. Splines WITH COUNTERSHAFT
then carry the power through the GEAR
reverse sliding gear to the first- and
second-speed synchronizer sleeve FIG. 49-Power Flow
which is locked to the output shaft.
As the reverse sliding gear is meshed
with the synchronizer sleeve, power
is transmitted to the output shaft,
rotating it in a reverse direction.

EJ IN-CAR ADJUSTMENTS AND REPAIRS

SHIFT LINKAGE ADJUSTMENT An alignment tool can be made 2. Tighten the three linkage ad-
from t" diameter drill rod bent to justment nuts and then remove the
1. Loosen the three shift linkage an "L" shape. The extensions should alignment pin.
and adjustment nuts. Install a t" be 1W' and 3W' from the elbow. Long
diameter alignment tool through the end of alignment pin should be in-
control bracket and levers as shown serted into control bracket and 3. Check the gear shift lever for a
in Fig. 50 linkage holes until it bottoms. smooth cross-over.

EJ REMOVAL AND INSTALLATION

REMOVAL 4. Raise the vehicle on a hoist. cable from the extension housing.
7. Disconnect the parking brake
5. Disconnect the drive shaft from cable from the equalizer lever and
1. Remove gear shift control lever the rear U-joint flange. Slide the separate the lever from the cross-
knob. drive shaft off the transmission out- member.
2. Remove the console and or put shaft and install the extension 8. Remove the hairpin retainer
dust seal and retainer (Fig. 50). housing seal installation tool into the securing the cable to the transmission
extension housing to prevent lubri- rear support crossmember, and then
3. Remove the three gear shift cant leakage.
control lever mounting bolts and pull the cable assembly forward and
remove the lever. 6. Disconnect the speedomett. out of the crossmember.
6-26 GROUP 6-GENERAL TRANSMISSION SERVICE

* With console on'ly.

FIG. 50 Installation Gear Shift Linkage 0 Without console.

9. Support the engine with a trans- .Note: Do not depress the clutch 4. With the transmission extension
mission jack and remove the exten- pedal while the transmission housing resting on the engine rear
sion housing-to-engine rear support is removed. support, install the transmission
attaching bolts. extension housing attaching bolts.
Torque the bolts to specifications.
10. Raise the rear of the engine high INSTALLATION
enough to remove the weight from 5. Secure each shift rod to its re-
the crossmember. Remove the bolts. 1. Make sure that the mounting spective lever with the spring washer,
surface of the transmission and the flat washer, and retaining pin.
retaining the crossmember to the
frame side supports and remove the flywheel housing are free of dirt,
paint, and burrs. Install two guide AN ALIGNMENT TOOL CAN BE MADE
cross member. FROM 1/4" DIAMETER DRILL ROD
pins in the flywheel housing lower BENT TO AN "L" SHAPE. THE
EXTENSIONS SHOULD BE 1 - 1/2"
11. Support the transmission on a mounting bolt holes. Move the trans- AND 3 • 3/4" FROM THE ELBOW.
LONG END OF ALIGNMENT TOOL
jack and remove the bolts that attach mission forward on the guide pins SHOULD BE INSERTED INTO CONTROL
the transmission to the flywheel until the input shaft splines enter the BRACKET AND LINKAGE HOLES
UNTIL IT BOTTOMS.
housing. clutch hub splines and the case is
positioned against the flywheel hous-
12. On 6 cylinder vehicles move the ing.
transmission and jack rearward until
the transmission input shaft clears 2. Install the two upper tr~smis­
the flywheel housing. If necessary, sion to flywheel housing, mounting
lower the engine . enough to obtain bolts snug, and then remove die two
clearance for transmission removal. guide pins. Install the two lower
mounting bolts. Torque all mounting
13. On 8 cylinder vehicles it will bolts to specifications.
be necessary to disconnect the trans-
mission shift rods from the control 3. Raise the rear of the engine and
assembly, remove the control assem- install the crossmember. Install and
bly mounting bolts and the control torque the crossmember attaching
or lower the muffler inlet pipe before bolts to specifications, then lower the
lowering the transmission. engine.
PART 6-4-4-SPEED FULLY SYNCHRONIZED MANUAL TRANSMISSION 6-27

6. Guide the parking brake cable ward end of the drive shaft over the alignment tool in the shift linkage
assembly through the hole in the transmission output shaft. Connect the alignment hole (Fig. 51). Attach the
transmission rear support crossmem- fo
drive shaft the rear U-joint flange. shift rods to the gear shift control
ber. Secure the cable assembly to the levers. Adjust the linkage as necessary
crossmember with the hairpin re- 10. On 6 cylinder vehicles attach and tighten the adjustment nuts to
tainer. the gear shift control lever using specifications. Remove the alignment
7. Insert the parking brake front three mounting bolts. tool.
cable in the equalizer and install the
equalizer in the bracket on the cross- 11. Install the gear lever dust boot, 11. Fill the translDlSSlon to the
member. Secure the parking brake retainer and console where fitted . proper level with the specified lubri-
rear cable to the equalizer. cant.
12. On 8 cylinder vehicles where
8. Connect the speedometer cable the gear shift control has been re·
to the extension housing. moved from the transmission, place 12. Lower the car. Check the shift
both forward gear shift levers and the and crossover motion for full shift
9. Remove the extension housing reverse shift lever in the neutral posi- engagement and smooth crossover
seal installation tool and slide the for- tion and insert a ~ inch diameter operation.

EJ MAJOR REPAIR OPERATIONS

GEAR SHIFT CONTROL port shaft upright in a vice. 11. Lower the vehicle and install
ASSEMBLY the gear shift control lever.
REMOVAL AND DISASSEMBLY 3. Assemble parts to the support 12. Install the dust boot and sur-
shaft in the following order (Fig. 51) round.
1. Remove the gear·lever knob. a. wave washer 13. Install the console (if fitted).
2. For vehicles fitted with centre b. shift lever outer support
console, remove the three screws c. wave washer 14. Install the gear shift control
securing the console and remove the d. 3rd & 4th shift lever lever knob.
console. e. 1st & 2nd shift lever 15. Check the gear shift operation.
3. Remove the gear lever, dust f. shift lever retainer
boot and surround (Fig.50). g. shift lever spacer (long)
h. gear shift lever
4. Remove the three bolts from j. reverse shift lever
the gear shift control lever and re- k. shift lever inner support
move the lever. l. shift lever spacer (short)
S. Raise the vehicle on a hoist. m. shift lever trunion
n. flat washer
6. Disconnect the shift rods by o. support shaft retaining nut.
undoing the nuts at the rear ends of
the rods.
4. Install the two control assembly
7. Remove the reversing light clamping bolts and nuts and torque
switch from the gear shift control to 8-13 ft. lbs.
assembly.
8. Remove the three mounting S. Torque the gear shift lever sup·
bolts and washers,gear shift assembly port shaft nut to 13-18 ft. lbs.
to transmission extension housing 6. Install the gear shift control
and remove the control assembly. assembly on the transmission exten-
sion housing and torque the three
9. Remove the two clamping bolts bolts to 12-15 ft. lbs.
and nuts which retain the outer and
inner supports and the lever retainer. 7. Install the reversing light switch.
10. Remove the retaining nut and 8. Place both forward gear shift
washer from the gear shift lever sup· levers and. the reverse shift lever in the
port shaft and withdraw the shaft. neutral position and insert the ~ inch
diameter alignment tool in the shift
11. Clean and inspect all parts for linkage alignment hole (Fig. 51)
wear or damage particularly the wave
washers. 9. Position the transmission shift
levers in the neutral position and con-
REASSEMBLY AND- nect the shift rods to their respective
INSTALLATION gear shift control levers and torque
the nuts.
1. Lubricate all mating parts with 10. Remove the gear shift lever
ESA-MIC75-B grease during assembly. alignment tool and adjust the reverse
2. Clamp the gear shift lever sup· light switch.
6-28 GROUP 6-GENERAL TRANSMISSION SERVICE

"'
21--.. . .

SHIFT LEVER
ALIGNMENT HOLE
1

22

12
13
~3
11'------14 ucr1011 C
15
~--16

FIG. 51 Gear Shift Control Assembly

DESCRIPTION
1. Spring- Transmission gear shift lever detent
2. Lever- Transmission gear shift
3. Trunion- Transmission gear shift lever
4. Support Assy- Transmission gear shift lever inner
5. Spacer- Transmission gear shift lever (long)
6. Washer- 1/2 wave spring
7. Shaft- Transmission gear shift lever support
8. Detent- Transmission gear shift control lever
9. Support- Transmission gear shift lever outer
10. Retainer- Transmission gear shift lever
11. Lever- Transmission gear shift contro11st & 2nd
12. Lever- Transmission gear shift control 3rd· & 4th
13. Washer- Spring
14. Washer- 3/8 flat
15. Pin- 3/32 x 5/8 cotter
16. Sleeve- Transmission gear shift control rod adjusting
17. Lever- Transmission gear shift control reverse
18. Spacer- Transmission gear shift lever trunion
19. Washer- 3/8 flat
20. Nut- 3/8- 16 unc hex.
21. Retainer- shift lever trunion
22. Bolt &Nut- Support clamping
23. Grommet- Gear shift control mounting.
PART 6-4-4-SPEED FULLY SYNCHRONIZED MANUAL TRANSMISSION 6-29

TRANSMISSION ASSEMBLY the third- and fourth-speed shift rail 14. Remove the output shaft bear-
DISASSEMBLY from the front of the case. Do not lose ing as shown in Fig. 54.
the interlock pin from the shift rail.
15. Remove the input shaft and
1. Mount the transm1ss1on in a bearing and the blocking ring from
holding fixture and drain the lubri- 10. Remove the set screw from the the front of the case.
cant. first- and second-speed shift fork.
Slide the first- and second-speed shift
rail out the rear of the case. 16. Move the output shaft to the
2. Remove the cover attaching right side of the case to provide
screws from the case. Lift the cover clearance for the shift forks. Rotate
and gasket from the case. 11. Remove the interlock pin and the forks as shown in Fig. 55 then
the detent plug from the top of the lift them from the case.
3. Remove the extension housing case (Fig. 53) with a magnet.
attaching screws and lock washers. 17. Support the thrust washer and
Remove the housing and the gasket. 12. Remove the snap ring that first-speed gear to prevent them from
secures the speedometer drive gear to sliding off the shaft, then lift the out-
4. Remove the input shaft bearing the output shaft. Slide the gear off put shaft assembly from the case as
retainer attaching screws. Slide the the shaft, then remove the speedo- shown in Fig. 56.
retainer off the input shaft. meter gear drive ball.
18. Remove the reverse gear shift
5. Support the countershaft gear 13. Remove the snap ring that fork set screw. Rotate the reverse
with a wire hook. Working from the secures the output shaft bearing to shift rail 90° as shown in Fig. 57.
front of the case, push the counter- the shaft. Slide the shift rail out the rear of the
shaft out the rear of the case as
shown in Fig. 52. Lower the counter- ;...-SET SCREW
shaft gear to the bottom of the case
a-SPRING
with the wire hook. Remove the hook.

6. Place the first- and second-speed

gear shift lever and the reverse shift
lever in the neutral position. Place
the third- and fourth-speed gear shift
lever in the third-speed position.

7. Remove the bolt that retains the DETENT PLUG+{j

third- and fourth-speed shift rail de-
tent spring and the plug in the left ' INTERLOCK PIN'i)
side of the case as shown in Fig. 53.
Remove the spring and the plug with
a magnet. SCREW~
THIRD AND FOURTH DETENT PLUG

,:;;,~; ;,,~--
8. Remove the detent mechanism SPEED SHIFT RAIL
set screw from the top of the case.
Remove the detent spring and plug
with a small magnet.
DETENT PLUG-{) REVERSE SHIFT RAIL REVERSE SHIFT FORK

9. Remove the attaching screw SPRING--u

from the third- and fourth-speed shift
fork. Tap on the inner end of the shift
rail to unseal the expansion plug from
the front of the case. Then withdraw

EXPANSION
PLUG

Tooi· -T64P.nii·A
COUNTERSHAFT
I
®-MAGNETIC DRAIN PLUG
FIG. 52-Removing Counter-
shaft from Case FIG. 53-Shift Rails and Forks Disassembled
6-30 GROUP 6-GENERAL TRANSMISSION SERVICE

case. Lift the reverse shift fork from synchronizer, blocking ring and the
the case. first-speed gear off the shaft.

19. Remove the reverse detent 26. Remove the thrust washer,
plug and spring from the case with a first-speed gear and blocking ring
magnet. from the rear of the shaft. The first
and reverse synchronizer hub is a
20. Remove the reverse idler gear press fit on the output shaft. To
shaft from the case as shown in eliminate the possibility of damaging
Fig. 58. the synchronizer assembly, remove
the synchronizer hub using an arbor
21. Lift the reverse idler gear and press as shown in Fig. 69. Do not
the thrust washers from the case. Be attempt to remove or install the
careful not to drop the bearings and hub by hammering or prying.
the dummy shaft from the gear.

22. Lift the countershaft gear and

the thrust washers from the case. Be FIG. 56-Removing Output
careful not to drop the bearings or the Shaft Assembly
dummy shaft from the counter-shaft
gear.

23. Remove the snap ring from the

front of the output shaft. Slide the
third- and fourth-speed synchronizer
(Fig. 59) blocking ring and the third·
speed gear off the shaft.

24. Remove the next snap ring and

the second-speed gear thrust washer
from the shaft. Slide the second-
speed gear and the blocking ring off
the shaft.
FIG. 55-Removing Shift
25. Remove the next snap ring,
then slide the first- and second-speed Fork From Case
Tool- T52T-6500-DJD

FIG. 57 -Rotating Reverse

a,. j +~ Shift Rail

:::;;_, s \' i !ii:o

FIG. 58 -Removing Reverse

FIG. 54-Removing Output Shaft Bearing Idler Gear Shaft
PART 6-4-4-SPEED FULLY SYNCHRONIZED MANUAL TRANSMISSION 6-31

OUTPUT SHAFT

a.-- SPEEDOMETER GEAR

DRIVE BALL

SNAP R:NG

kOC"NG RIN:IRD ~W ~ ~
THRUST WASHER

GEAA
~b
~i
lllOCKING RING

r
BlOCKING RING
FIRST AND SECOND
SPEED SYNCHRONIZER

I
SN.AP RING
SECOND SPEED GEAR

C1529-C

FIG. 59 -Output Shaft Disassembled

CAM AND SHAFT SEALS INPUT SHAFT BEARING speed synchronizer with the third-
and fourth-speed sym:hronizer.
1. Remove the attaching nut, lock 1. Remove the snap ring that 3. Position the hub in the sleeve,
washer and the flat washer from each secures the bearing to the shaft making sure that the alignment
shift lever and remove the three (Fig. 60B). marks are properly indexed.
levers. 2. Press the input shaft gear out 4. Place the three inserts into place
2. Remove the three cam and of the bearing as shown in Fig. 61. on the hub. Install the insert springs
shafts from inside the case. 3. Press a new bearing onto the making sure that the irregular surface
3. Remove the 0-ring from each input shaft with the tool shown in (hump) is seated in one of the inserts.
cam and shaft (Fig. 60A) and discard Fig. 61. Do not stagger the springs.
the 0-rings. 4. Secure the bearing with a snap
COUNTERSHAFTGEAR
4. Dip the new 0-rings in gear ring. BEARINGS
lubricant and install them on the
cam and shafts. SYNCHRONIZERS 1. Remove the dummy shaft, two
5. Slide each cam and shaft into bearing retainer washers, and the 21
its respective bore in the transmission 1. Push the synchronizer hub from roller bearings (Fig. 65) from eac}l
case. each synchronizer sleeve (Fig. 64). end of the countershaft gear.
6. Position a shift lever on each 2. Separate the inserts and insert 2. Coat the bore in each end of the
cam and ~haft and secure with a flat springs from the hubs. Do not mix countershaft gear with grease.
washer, lock washer and nut. the parts of the first- and second- 3. Hold the dummy shaft in the
6-32 GROUP 6-GENERAL TRANSMISSION SERVICE

gear and install the 21 roller bearings gear off the reverse idler gear (Fig. 4. Hold the dummy shaft in the
and a retainer washer in each end of 66). gear and install the 22 roller bearings
the gear. 2. Remove the dummy shaft, two and the retainer washer in each end
bearing retainer washers and the 44 of the gear.
REVERSE IDLER GEAR roller bearings from the reverse idler 5. Install the reverse idler sliding
BEARINGS gear. gear on the reverse idler gear making
3. Coat the bore in each end of the sure that the shift fork groove is
1. Slip the reverse idler sliding reverse idler gear with grease. toward the front (Fig. 66).
FIR ST AND SECOND SPEED CAM AND SHAFT

REVERSE GEAR CAM ~ /

ANDSHAF T ~ ~

Too/-7025 -G
OR 7025-B
5
FIR ST AND SECOND SPEED SHIFT LEVER

~~@@~
SPEED CAM AND SHAFT I

~m}

FIG. 60A -Gear Shift Lever Disassembled-Typical

INPUT SHAFT ROLLER BEARINGS
AND 1

rrv ' ·
INSTALLATION
BEARING I
BLOCKING RING FIG. 61 -Input Shaft Bearing
SNAP RINGS
FIG. 608 -Input Shaft Gear Disassembled (Removal and Installation)

INPUT SHAFT SEAL

1. Remove the seal from the input
shaft bearing retainer as shown in
Fig. 62.
2. Coat the sealing surface with
lubricant.
3. Install the seal as shown in
Fig. 63.
ASSEMBLY
1. Coat the countershaft gear
thrust surfaces in the case with a thin
film of lubricant and position a thrust
washer (Fig. 65) at each end of the
case. FIG. 62 -Removing Input Shaft Seal
PART 6-4-4-SPEED FULLY SYNCHRONIZED MANUAL TRANSMISSION 6-33

2. Position the countershaft gear,

dummy shaft, and roller bearings in INSERT!SPRING
the case.
3. Place the case in a vertical posi-
tion. Align the gear bore and the
thrust washers with the bores in the
case and install the countershaft.
4. Place the case in a horizontal
position and check the countershaft
gear end play with a feeler gauge.
The end play should be 0 · 004-0 · 018
within specification. If not within
these limits, replace the thrust
washers.
5. After establishing the correct
FIRST AND SECOND SPEED SYNCHRONIZER
end play, install the dummy shaft in
the countershaft gear and allow the
gear to remain at the bottom of the ETCH MARKS
case.
INSERT SPRING
6. Coat the reverse idler gear thrust
surfaces in the case with a thin film
INSERT SPRING
~
of lubricant and position the two
thrust washers (Fig. 66) in place ..
7. Position the reverse idler gear,

"""'(
"v
sliding gear, dummy shaft and the
roller bearings in place making sure
that the shift fork groove in the slid-
ing gear is towards the front of the
case.
8. Align the gear bore and thrust GROOVE TO FACE
TOWARD FRONT
washers with the case bores and in- OF TRANSMISSION
stall the reverse idler shaft. THIR'D AND FOURTH SPEED SYNCHRONIZER
9. ~easure the reverse idler gear
end play with a feeler gauge. End FIG. 64 -Synchronizers Disassembled
play should be within specification. If
the end play is not within limits, re- 11. Install the first- and second- shaft making sure that the inserts in
place the thrust washers. If the end speed synchronizer onto the front of the synchronizer engage the notches
play is within limits, leave the reverse the output shaft (Fig. 69) making in the blocking ring.
idler gear installed. sure that the shift fork groove is to- 18. Install the snap ring on the
10. Position the reverse gear shift ward the rear of the shaft. The first front of the output shaft.
rail detent spring and detent plug in and reverse synchronizer hub is a 19. Position the blocking ring on
the case. Hold the reverse shift fork press fit on the output shaft. To the first-speed gear. .
in place on the revers<.: idler sliding eliminate the possibility of damaging 20. Slide the first-gear speed onto
gear and install the shift rail from the the synchronizer assembly, install the the rear of the output shaft making
rear of the case. Secure the fork to synchronizer hub with the teeth end sure that the notches in the blocking
the rail with the Allen head setscrew. of the gear facing toward the rear of ring engage the synchronizer inserts.
the shaft, using an arbor press as 21. Install the heavy thrust washer
shown in Fig. 69. Do not attempt on the rear of the output shaft.
to remove or install the hub by 22. Support the thrust washer and
hammering or prying. first-speed gear to prevent them from
12. Position the blocking ring on ~liding off the shaft and carefully
the second-speed gear. lower the output shaft assembly into
13. Slide the second-speed ·gear the case as shown in Fig. 56.
onto the front of the shaft, making 23. Position the first- and second-
sure that the inserts in the synchro- speed shift fork and the third- and
nizer engage the notches in the fourth-~peed shift fork in place on
blocker ring. their respective gears and rotate them
14. Install the second-speed gear into place.
thrust washer and snap ring. 24. Place a detent plug (Fig. 53)
15. Slide the third-speed gear onto in the detent bore. Place the reverse
the shaft with the synchronizer shift rail into neutral position.
coned surface toward the front. 25. Coat the third- and fourth-
16. Place a blocking ring on the speed shift rail interlock pin with
third-speed gear. grease and position it in the shift rail.
FIG. 63 -Installing Input 17. Slide the third- and fourth- 26. Align the third- and fourth-
Shaft Seal speed gear synchronizer onto the speed shift fork with the shift rail
6-34 GROUP 6-GENERAL TRANSMISSION SERVICE

bores and slide the sl>ift rail into the detent bore. Thread the set screw and tighten them to specifications.
place making sure that the three de- to specification. 31. Install the output shaft bearing
tents are facing toward the outside of 28. Coat the input gear bore with a as shown in Fig. 67. Install the snap
the case. Place the front synchronizer thin film of grease, then install the ring to retain the bearing.
into ,third-speed position and install 15 roller bearings in the bore. A 32. Position the speedometer gear
the set screw in the third- and fourth- thick film of grease could plug drive ball in the output shaft ana
speed shift fork. Move the synchro- the lubricant holes and restrict slide the gear into place. Secure the
nizer to the neutral position. Install lubrication of the bearings. gear with the snap ring.
the third- and fourth-speed shift r~ 29. Position the front blocking ring 33. Place the transmission in a ver-
detent plug, spring and bolt in the tical position as shown in Fig. 68.
in the third- and fourth-speed syn-
left side of the transmission case (Fig. Align the countershaft gear bore and
53). Place the interlock plug (tapered chronizer.
Place the input shaft gear in the thrust washers with the bore in the
ends) in the detent bore. case. Install the countershaft.
transmission case making sure that
the output shaft pilot enters the 34. Use a new gasket and secure
27. Align the first- and second- the extension housing to the case with
speed shift fork with the case bores roller bearings in the input gear.
the attaching screws. Use a sealer on
and slide the shift rail into place. 30. Place a new gasket on the in- the extension housing attaching
Secure the fork with the set screw. put shaft bearing retainer. Dip the screws. Torque the screws to speci-
Install the detent plug and spring in attaching bolts in sealer and install fications.
COUNTERSHAFT

RETAINER WASHER

THRUST
WASHER

\
j~·' ' COUNTERSHAFT GEAR

'
RETAINER
~ROLlfR
......
BEARINGS
WASHER

FIG. 65 -Countershaft Bearing Disassembled

REVERSE IDLER
GEAR SHAFT

REVERSE IDLER GEAR

FIG. 56-Reverse Idler Gear DisaSsembled

PART 6-4-4-SPEED FULLY SYNCHRONIZED MANUAL TRANSMISSION 6-35

35. Install the filler and drain plugs

in the case if they were removed.
Make sure that the magnetic plug is
installed in the bottom of the case.
36. Pour the specified lubricant
over the entire gear train while
rotating the input shaft.
--·- ---
37. Place each shift fork in all posi-
tions to make sure that they operate
properly.

38. Use a new cover gasket and in-

stall the cover. Coat the cover attach-
ing screws with sealer and install and
tighten them to specifications.

39. Coat the third- and fourth-

speed shift rail plug bore with a
sealer and install a new expansidh
plug.

40. If the extension housing bush- j

ing and seal are to be replaced, refer
to page 6-7. FIG. 67 -Installing Output Shaft Bearing

SYNCHRONIZER

IHST ALLA TIOH

FIG. 68 -Installing FIG. 69 -Removing and Installing First and

Countershaft Reverse Synchronizer
6-36

PART
6-5 SPECIFICATIONS
GEAR RATIOS

Transmission Series First Gear Second Gear Third Gear Reverse Gear
199333 6 Cyl. 2.95 : I 1.69 : I 1.00: I 3 . 80 : 1
199332 6 Cyl. 2.95 : I 1.69: I 1.00: I 3 . 67 : 1
199331 8 Cyl. 2.71 : I 1.69 : I 1.00 : I 3 . 367 : 1

Transmission Series First Gear Second Gear Third Gear Fourth Gear Reverse Gear
4 - Speed Manual 2 . 78 : 1 1 . 93 : 1 1 . 36: 1 1 . 00 : 1 2 . 78 : 1

SPECIFIED CLEARANCES (Ins.) 3-speed

First Speed Gear End Float (Series 130033 only) 0.006 - 0.0 19
Second Speed Gear End Float 0.006 - 0,019
Input Shaft Bearing End Float 0.000 - 0.004
Output Shaft Bearing End Float 0.000 - 0.004
Interlock Sleeve (a ll Four Gear Positions) \'v' ith one cam in neutral
and the othe r in gear
there must be 0.002
min. to 0.0 I 0 max. axial
movement of t he inter-
lock slee ve

SPECIFIED CLEARANCES (Ins.) 4-speed

Countershaft Gear End Play 0.004-0 .018

Reverse Idler Gear End Play 0 .004 -0.018

SELECTIVE COMPONENTS (Ins.) 3-speed

Inpu t Sha ft Bea r ing Sna p Ring Th ickne ss , and 0.086 - 0.088
O utp ut Shaf t Bea r ing Snap Ring Thickn ess 0.089 - 0.091
0.092 - 0.094
0.095 - 0.09/
In t erl ock Sleeve A vai lable Leng t hs 1.292 - I .294
I .297 - I .299
1.302 - 1.304

NEEDLE ROLLER BEARINGS 3-speed

Cou nter Shaft Ge ar 3 Sets of 22 Roll ers

Input Sh aft 6 cyl. 14 Rolle rs
Input Shaft 8 cyl. 1 5 Rollers
RP.verse Idler Shaft 8 cyl. 22 Rollers
GROUP 6-GENERAL TRANSMISSION SERVICE 6-37
TORQUES {Lbs-Ft.) 3-speed

Extension Housing to Case Bolts 44-55

Transmission Cover Retain ing Bolts 8 - 12
Input Bearing Retainer Bolts 20 - 25
Operating Lever Retaining Nuts 20-25
Drain Plug (Magnetic) 20 - 25
Filler Plug 20-25

TORQUES (Lbs. Ft.) 4-speed

Input Shaft Bearing Retainer to Transmission Cas.e 19-25

Extension Housing to Transmission Case 42-50

Access Cover to Transmission Case 14-19

Gearshift Lever to Cam and Shaft 18-23

Shift Fork to Shift Rail 10-18

Filler Plug to Case 10-20

Flush to
Detent Set Screw (special) 0.020" below
surface

Third and Fourth Shift

10-18
Rail Detent Bolt
·-
Transmission to Flywheel Housing Bolts 37-42

LUBRICATION 3-speed

Ford Specification ESW- M2C37

Type SAE30
Capacity Imp. Pints
1 30032 Series 3 . 13
1 30033 Series Falcon 2 .7
130033 Ser1es Fairlane 3 .0

LUBRICATION 4-speed

Capacity (Imp. Pts.) Type

3% SAE80 (ESW-M2C-83B)

ASSEMBLY SPECIFICATION 3-speed

Breother AsseMbly Flat on side of Breather Body must be on right hand

side of Extension Housing (Filler Plug side) and
parallel with centre line of Transmission within 5°
REFERENCE TO SERVICE INFORMATION AND NOTES

Date Letter No. Page Brief Detail

·-
---

-
FALCON FAIRLANE w~:~~~~P

AUTOMATIC TRANSMISSION
GROUP
7

PAGE

PART 7-1- Borg-Warner Automatic Transmission 7-2

PART 7-2- C4 Automatic Transmission 7-37
PART 7-3- F.M.X. Automatic Transmission 7-82
PART 7-4- Specifications 7-122
7-2

PART BORG-WARNER AUTOMATIC TRANSMISSION

7-1
Section Page Section Pare
1 Description and operation 7- 2 3 In car adjustments 7-20
Torque converter 7-2 Table of shift speeds 7-21
Transmission 7-3 4 Cleaning and inspection 7-25
Control system 7-4 5 Removal and installation 7-26
Hydraulic circuits and power flow 7-6 6 Major repair operations 7-26
2 Diagnosis and testing 7-11

0 DESCRIPTION AND OPERATION

DESCRIPTION AND OPERATION
The three elements in the torque
converter are an impeller driven by
The automatic transmission con- the engine and a turbine or rotor
sists of a torque converter and a attached to the transmission input
hydraulically controlled epicycle gear- shaft, as in a fluid flywheel, plus a
box which provides three forward stator mounted on a sprag type one-
gears and one reverse. way clutch between the impeller and
The torque converter is an "open" the turbine. The stator can only
type which means that the drive revolve in the same direction as the
through converter is by means of the FIG. 1 - CRUIS-0-MA TIC impeller.
hydraulic fluid circulating therein. When starting from rest only the
This gives good flexibility in top gear 'D' - (Normal Drive Position) -
Car starts in first gear and automatic- impeller revolves and fluid is thrown
which can be engaged at low road outwards by centrifugal force through
speed with ligh~ t~ottle op~ning. ally shifts to second and third gears.
'2' - Second gear - Car starts the impeller vanes and is directed
Economic operation 1s thus achieved. into the turbine thus causing the
The automatic transmission has a and remains in second gear.
'1' - First gear - Car starts and turbine to rotate as well (see Fig. 3).
planetary gear set consisting of 2 sun The fluid passes through the turbine
gears, 2 sets of 3 planet pinior;ts con- remains in first gear.
When a shift to '1' is made from 'D' vanes and is directed backwards into
tained within 1 planetary earner and the stator which remains stationarv as
1 ring gear. or '2' with throttle closed the car will
remain in second gear until approxi- it cannot revolve in the reverse direc-
The various speed ratios are mately 17 mph before shifting to low tion against the one-way clutch. The
obtained by holding or clutching gear. direction of the fluid passing through
various combinations of elements of A part throttle downshift has been the stator vanes is changed and on
the planetary train, and this is per- incorporated in this transmission to
formed by two bands, two multi disc make it sensitive to torque demand.
clutches, and a one way clutch. TOWING
A gear type oil pump driven by Important. Should it be neces-
the engine is employed for supplying sary to tow a vehicle fitted with an
the hydraulic control system. Automatic Transmission, the drive
The engines on vehicles equipped shaft must be disconnected or the
with automatic transmission cannot rear end of the car suspended, other-
be started by pushing or towing the wise subsequent failure of the trans-
vehicle. mission will occur. DEPRESS
. A selector lever may be mounted KNOB
TORQUE CONVERTER TO SHIFT
on the steering column or on the
floor, the range chosen showing in The drive from the engine to the
the quadrant located above the steer- transmission is by means of a three
element hydrokinetic torque conver-
ing wheel centre or on the floor ter which provides an infinitely vari-
console. able torque multiplication between
The transmission has six positions 2: 1, . when starting from rest or
on the selector quadrant and allows during maximum acceleration, and
for fully automatic or manually con- 1:1, when the engine and transmis-
trolled gear changes. sion input shaft speeds are approxi-
mately the same. Under the latter
'P'- (Park) condition the torque converter per-
'R'- (Reverse) forms the same function as a fluid
'N' - (Neutral) flywheel. FIG. 2 - Floor Shift Typical
PART 7-1 AUTOMATIC TRANSMISSION (Borg-Warner) 7-3

\
'II
I
I
I
I

FIG. 3 - Torque Converter Operation

re-entering the impeller assists in the forward sun gear, in reverse operated by hydraulic pistons to
driving it, thus providing a torque power enters through the reverse sun connect the converter to the gear set.
multiplication. gear, power leaving the gear set in For first and second gears the front
As the turbine speed increases, the each case by the ring gear. For for- clutch connects the converter to the
fluid ftow angle from the turbine ward gears the double set of pinions forward sun gear, and for reverse the
vanes changes, until at a speed is used, but in reverse a single set is rear clutch connects the converter to
differential of approximately ninety used so causing the ring gear to the reverse sun gear. Both clutches
per cent of the impeller the stator is rotate in the opposite direction to the are applied locking the epicyclic gear
driven in the same direction as the sun gear. The various mechanical train to give direct drive (1 : 1) for
turbine and the impeller. ratios of the gear set are obtained top gear.
The torque converter then adopts by the engagement of hydraulically The front clutch consists of three
the characteristics of a fluid flywheel operated multi-disc clutches and externally and four internally toothed
and there is no torque multiplication. brake bands. plates. The rear clutch consists of
The torque converter fitted to the MULTIPLATE CLUTCHES five pairs of internally and externally
Falcon has a nominal diameter of The two multiplate clutches are toothed plates.
11 in.
TRANSMISSION
The transmission consists of a
hydraulically controlled epicyclic gear
train with two multi-plate clutches,
two brake bands and a sprag type
one-way clutch. By applying the
clutches and/ or brake bands auto-
matically in various combinations,
three forward gears and one reverse
are obtained. Hydraulic fluid is sup-
plied under pressure to a control
system and thence to the clutch
operating pistons and brake band
servos by an oil pump driven by the
engine. This pump supplies all the
hydraulic needs of the automatic FRONT PUMP
transmission and torque converter. DRIVE TANGS
EPICYCLIC GEAR TRAIN
The gear train consists of two sun
gears, two sets of pinions mounted
on a pinion carrier and a ring gear. In
forward gears power enters through FIG. 4 - Torque Converter Typical
7-4 GROUP 7- AUTOMATIC TRANSMISSION

The internally toothed plates are valves. Regulated pressures are car speed, and provides the correct
faced on each side with friction controlled by the valves oscillat- clutch and servo capacity under
material and are interchangeable ing between a feed and an exhaust operating conditions.
between the front and rear clutches. port to maintain this equilibrium. This control pressure is directed
The externally toothed plates, how- Shuttle valves move in both to the manual valve and throttle
ever, are not interchangeable as the directions a fixed distance. This valve from the primary valve.
rear plates are dished. The dished movement is caused by the forces
plate<> can be readily identified as in one direction exceeding the
some of the teeth are omitted. SECONDARY REGULATOR VALVE
forces in the opposite direction.
These plates must always be fitted This valve controls convertor
These forces are respectively spring
with the dishing in the same direc- and lubrication pressures. Conver-
and hydraulic pressure acting upon
tion. given areas of the valves. These tor pressure acting on one end of
Brake Bands. valves are used to direct or to pro- the valve is opposed by spring
Elements of the gear set are held vide an exhaust for fluid. force on the other end.
stationary, to effect an output shaft The manual valve is controlled by
speed reduction, by two brake the position of the selector lever and
bands, each operated by a hydraulic directs fluid, or provides an exhaust GOVERNOR
servo. The rear band holds the from, the clutch and servo pistons
pinion carrier stationary to provide according to the position selected. The governor, mounted on and
the first gear ratio with engine brak- rotated by the output shaft, is a
ing in Jock-up. The reverse sun gear OIL PUMP
pressure regulating valve which
is held stationary by the front band The oil pump driven by the reduc<:s control pressure to a figure
to provide the second gear ratio. torque converter impeller, oper- that varies with the output shaft,
One-way Clutch. ates whenever the engine is run- speed, and therefore, car speed.
In drive a one-way sprag-type ning. All the hydraulic require-
clutch is used, instead of the rear ments of the torque converter and
automatic transmission are sup- This variable pressure in the
band employed in lock-up, to pre- control system effects up and down
vent anti-clockwise rotation ot the plied by this pump.
changes through the first to second
pinion carrier. and second to third shift valves.
This one- way clutch allows the The oil pump consists of an inner When the governor rotates at low
gear set to freewheel when in first externally toothed gear in mesh with speeds (Fig.6), the governor weight
and assists smooth changes between an internally toothed gear housed and valve move outward by centri-
first and second and vice-versa. eccentrically to the inner gear. The fugal force. This outward force is
drive to the pump inner gear is by opposed by hydraulic pressure pro-
INHIBITOR SWITCH tangs on the drive shaft attached to duced by governor pressure acting
A non-adjustable inhibitor switch the torque converter and the gear upon a small area of the governor
is mounted on the left hand side of revolves about the torque converter valve. Since the governor valve
the transmission. support on the pump adaptor plate. is a regulating valve, and attempts
It is operated by a rod mounted The operation of the oil pump is to remain in equilibrium governor
internally and connected to the shown diagrammatically in Fig. 5. pressure will rise in accordance
parking pawl. As the gears revolve, oil is drawn with the increase in centrifugal
Four terminals are provided-two from the sump through the inlet port force caused by increased speed of
for ignition and two for reversing into the space between the gear teeth rotation.
lamp connections. as they come out of mesh and is
carried round between the gear teeth As output shaft speed increases,
CONTROL SYSTEM to the outlet- port where the teeth the governor weight moves out-
again mesh. wards to a stop in the governor
The control system regulates body. When this happens, a spring
pump pressure and directs fluid The oil is forced out through the located between the weight and
to the converter and lubrication outlet port and flows to the regulator the governor valve becomes ef-
valves which control the delivery fective. The constant force of this
system . Also, it directs fluid to pressure.
the appropriate clutch and servo spring combines with the governor
pistons, but at a pressure which valve centrifugal force to oppose
varies with vehicle speed and en- PRIMARY REGULATOR VALVE governor pressure, so rendering
gine torque. Three types of valves governor pressure less sensitive to
This valve regulates pump pres- output shaft speed variations.
are used, regulating valves, shuttle sure. Control pressure, operating
valves and a manual valve. on a small area of the valve, is
Regulating valves operate in affected by modulated throttle pres-
equilibrium which means that the Manual Centro! Valve.
sure operating on one end of the
total force operating in one direc- valve. These forces are opposed by This valve, actuated by the selector
tion on the valve is opposed by the primary regulator valve spring lever directs control pressure to, or
an equal and opposite force. These and ~hrottle pressure acting on the exhausts fluid from, the appropriate
forces are respectively, spring opposite end of the valve. The con- valves or modulator valve and plun-
forces and hydraulic pressures trol pressure produced varies with ger components, according to the
operating on given areas of the the accelerator pedal position and position selected.
PART 7-1 AUTOMATIC TRANSMISSION (Borg-Warner) 7-5

and second to third valves to con-

trol the change points sensitivity
relative to throttle pressure and ,
INNER
GEAR therefore , accelerator position .
The modulator plunger is a re-
gulating valve that reduces throttle
pressure by a fixed amount. This
modulated pressure operating on
one end of the plunger assisted by
the modulator valve spring, is op-
posed by throttle pressure operating
on the opposite end of the valve .
This modulated throttle pressure is
directed to the primary regulator
valve thus varying the increase
rate of control pressure relative to
throttle pressure .
@ INLET Q) OUTLET The modulator valve is a shuttle
valve . Governor pressure oper-
- @ SUCTION - ® LINE PRESSURE
ating on the large end is opposed
by the modulator spring. As gov-
ernor pressure rises with road speed
FIG. 5 -Oil Pump Operation the valve moves. contacting the
modulator plunger. Further vaJv, :
Downshift Valve and Throttle movement prevents the plunger
gine load and car speed . Th1s pres- from regulating, and modulated
Valve. sure is directed to the primary regu- throttle pressure then becomes
The down shift valve , connected lator valve spring end to vary basic equal to throttle pressure. This
to the throttle linkage by a cable control pressure accordingly , so movement directs throttle pressure
actuated cam, varies control pres- providing correct servo and clutch to a second area of the throttle
sure with accelerator pedal de- capacities and consistent change valve and by this means the high
pression . Movement of the down- quality under operating conditions. throttle and control pressures exist-
shift valve compresses the throttle Full movement of the downshift ing at the converter stall condition
valve spring located between the valve directs throttl e pressure to are reduced when the car is moving
downshift valve and the throttle the shift valves to delay changes for satisfactory gear change quali-
valve . This spring is opposed by up, or effect third to second or ties.
the throttle return S!)ring combined third to first changes at pre-set
with throttle pressure, acting at maximum speeds. Also , throttle Servo Orifice Control Valve.
low car speed , on one area of the pressure is directed to the second
This is a shuttle valve in the
throttle valve , and at high road to third valve plunger. This re-
front servo release circuit with
speed on two areas of the throttle duces the value of throttle pressure
governor pressure acting on the
valve . A pressure is produced by a fixed amount and this pressure
valve opposed by the servo orifice
therefore, proportional to both en- is diFeeted to the first to second control valve spring. At low gov-

WEIGHT
• •
VALVE

GOVERNOR
SPRING

VEHICLE STATIONARY LOW SPEED OPERATION HIGH SPEED OPERATION

FIG. 6 -Governor Operation
7-6 GROUP 7- AUTOMATIC TRANSMISSION
ernor pressures, front servo release value of throttle pressure by a fixed The operation consists of by-
fluid goes direct to the release side amount and is inoperative when passing the orifice restriction in the
of the front servo piston. At throttle pressure is below this fixed rear clutch and front servo release
higher governor pressures the valve amount. Throttle pressure, oper- hydraulic line with a one way ball
moves and fluid is directed through ating on one end of the valve valve. The ball is held in position on
an orifice and then to the release plunger is opposed by this reduced the separator plate with a very light
side of this piston. throttle pressure and the second to spring.
A common line supplies fluid to, third valve spring located between HYDRAULIC CIRCUITS AND
or exhausts fluid from, the rear the plunger and valve. This re- POWER FLOW
clutch and the release area of the duced pressure is directed to the "N" Neutr•l (Refer Fig. 10).
front servo, to effect the second to second to third valve and the first With the engine running the
third and third to second change. to second plunger to vary the primary regufator valve regulates
At low speeds, when the servo change points sensitivity relative to control pressure which is directed
orifice is by-passed, the front servo throttle pressure and accelerator to the manual valve and throttle
releases quickly with the result position. valve and it also permits fluid to
that second to third or third to The second to third valve is a reach the secondary regulator
second changes are smooth . At shuttle valve. In the second gear valve.
higher speeds, the front servo re- position and before the second to The secondary regulator valve
lease fluid passes through the ori- third valve plunger begins regulat- regulates pressure to the conver-
fice which delays the front servo ing, governor pressure, operating ter and lubrication of the front
release and effects a firm second on the large end of this valve is end ot the transmission. The same
to third and third to second change. opposed by the second to third valve pressure is directed to the rear end
The servo orifice control valve spring. ot the transmission.
therefore affects the relationship The valve returns excess ftuid
between the rear clutch and front Mter the plunger begins regulat- to the oil pan through the pump
servo to provide correct change ing, governor pressure, operating on inlet. No power is transmitted
quality under all operating con- the large end of the valve, is opposed since the clutches and bands are
ditiom by reduced throttle pressure opera- released.
ting on the small end of the valve, First Gear with "D" selected.
Shift Valve Operation- and throttle pressure operating on
'D' Selected Hydraulic Circuits
the end of the second to third valve
First to Second Valve and plunger. The latter force is relayed Pressure control of the pump
Plunger. to the second to third valve by the will be as with "N". However,
Both the first to second valve valve spring. Movement of the valve with the downshift valve cam in
and plunger are shuttle valves and to the third gear position directs the full throttle position, throttle
operate together when "D" is se- fluid to the rear clutch and the pressure regulated by the modula-
lected. Governor pressure, operat- release side of the front servo tor valve plunger acts upon the
ing on the large end of the first to through the servo orifice control primary reglf'lator val\1! opposing
second valve, is opposed by reduced valve. This pressure applies the rear throttle pressure, thus modulating
throttle pressure from the second clutch. Since the release area of the control pressure for change quality.
to third plunger and the spring front servo is larger than the apply The manual valve directs con-
operating on the opposite end of area, the front servo and therefore, trol pressure to the front clutch,
the first to second plunger. When front band is released. This move- first to second valve and governor
the governor pressure exceeds the ment also results in an area of the feed. Control pressure reaches the
spring force combined with re- valve being no longer subjected to second to third valve to provide
duced throttle pressure, the valve- control pressure and prevents regu- for the subsequent second to third
lation of the second to third valve change.
moves tn the second 2ear oosition
and control pressure is directed to plunger by forcing the plunger to Power Flow.
the apply side of the front servo the end of the valve bore. Therefore The front clutch is applied con-
piston. Movement of the valve reduced throttle pressure which was necting the converter turbine to
removes control pressure from an acting on the small end of the valve the forward sun gear. The one-
additional area of the valve and is exhausted at the downshift valve. way clutch operates so preventing
exhausts reduced throttle pressure the pinion carrier from rotatina
from the plunger via the downshift This change in forces causes the anti-clockwise. The ring gear,
valve. This allows the change from third to second change to occur at a connected to the output shaft, is
second to first to occur at a lower lower governor pressure, and there- rotated through the planets at an
speed than the change from first to fore road speed, than the second to overall ratio of 2.39 to 1. When
second. When governor force is less third change. the car coasts the one way clutch
than the spring force, the valve overruns and the gearset free-
moves to the first gear position and THIRD TO SECOND DUMP wheels so that engine brakina is
the apply side of the front servo is VALVE not available.
opened to exhaust. Second Gear with "D" selected.
Second to Third Vah·e and The valve allows a quick down-
Plunger. change from top to second gear to Hydraulic Circuits
The second to third plunger is take place when 2 or 1 is manually Change control is provided by
a regulating valve that reduces the selected. the first to second valve movina
PART 7-1 AUTOMATIC TRANSMISSION (Borg-Warner) 7-7

against spring pressure under the Power Flow. spring pressure overcome the gover-
influence of governor pressvre. Once more the front clutch is nor pressure on the end of the 2-3
This allows control pressure to applied, so oonnecting the con- shift valve and the valve moves to
reach the apply side of the front verter turbine to the forward sun second gear position.
servo. The frcnt band thus ap- gear. The rear clutch is applied, The front servo release and the
plied together with the front clutch, connecting the converter turbine rear clutch apply circuits are now
provides second gear. to the reverse sun gear also. Rela- exhausted via line 7 at the manual
With the downshift valve cam in tive movement of the various gears valve.
the forced throttle position, forced in the gear train is impossible and The transmission will now stay in
throttle pressure acts upon the fint therefore the gear set revolves as second gear until road speed drops
to second and second to third a unit, providing a ratio of 1 to 1. below 30 mph, when first gear will
valves so further delaying upward be selected or governor pressure
"R" Reverse overcomes throttle and spring pres-
changes or providing a second to Hydraulic Circuits.
first change at speeds when there sures and moves the valve to third
Pressure control of the pump IS gear position.
is little governor pressure. similar to "P" or "N".
The power !low is the same as in
But, according to the amount second gear 'D'.
Power Flow. that the accelerator pedal is de-
Again the front clutch is applied pressed, throttle pressure is directed
connecting the converter turbine to to the spring end of the primary Kickdown to Low in 'D' (below
the forward sun gear. regulating valve, thus increasing 30 mph approximately).
The front band is contracted control pressure in relation to With the accelerator depressed to
which holds the rev~rse sun gear torque capacity requirements. kickdown position, the 2-3 shift
stationary with the result that the The manual valve directs con- valve is forced to take up 2nd gear
planet pinions "walk" around the trol pressure through the first to position as described in preceding
sun gear, causing the carrier to second valve to the rear servo, and paragraph.
revolve in the same direction as control pressure through the second Simultaneously, throttle pressure
the forward sun gear so that the to third valve to the rear clutch is applied to the small end of the 1-2
ring gear is driven faster than in and front servo release. Due to shift valve via lines 11 and lOA.
first gear. The gearset provides the absence of governor pressure, the Throttle pressure combined with
redflction of 1.45 to 1. shift valves and servo orifice con- spring pressure will overcome gover-
Top Gear with "D" selected trol valve do not operate in this nor pressure (under approximately
Hydraulic Circuits selector position. 30 mph) and the valve will be forced
Pressure control is similar to to take up first gear position. As a
Power Flow. result, the front servo apply circuit
second gear with "D" selected, ex- The rear clutch is applied so that
cept that with minimum throttle will be exhausted at the 1-2 valve.
the converter turbine is connected The vehicle is now in first gear and
no throttle pressure or modulated to the reverse sun gear, whilst the
throttle pressure acts upon the two will not change up until governor
rear band is applied, locking the pressure overcomes the throttle and
ends of the primary regulator valve. planet carrier stationary. The drive
Change control is provided by spring pressures and moves the valve
is then transmitted to the ring gear to second gear position.
the second to third valve moving by the outer planets. The reverse Power flow is the same as in first
against spring pressure inftuence. sun and ring gears rotate in op-
This ·allows line pressure to gear 'D'.
posite directions with a reduction OPERATION OF THE RANGE
reach the rear clutch direct, to- of 2.09 to 1.
gether with front servo release pres· CONTROL VALVE G.T.A. SHIFT
"P" Park PATTERN (Refer Fig. 18).
sure directed through the servo With the engine running, the
orifice control valve. When gov- operation of the hydraulic system '1' - Control pressure, from line
ernor pressure is in evidence, the is identical to "N" except that the 6 at manual valve is directed to the
servo orifice control valve closes, manual valve directs control pres- 1-2 shift valve where it is redirected
forcing front servo release pres- sure to tt.e rear servo, although this to the rear servo apply.
sure through an orifice which thus servo does not perform any func- At the same time control pressure
affects the relationship between tion in "P" is directed from line 1 to line 5 at
rear clutch apply and front servo the manual valve and to the front
release in accordance with road No ,power is transmitted since clutch apply and governor feed lines.
speed. the clutches and bands are re- Governor pressure is fed to the
Since the release side of the leased. However an internal link- range control valve at line 2 where
front servo has a larger area than age from the manual valve detent it feeds line 22. Line 22, governor
the apply side, the front servo dis- lever engages the parking pawl pressure, is directed to the large end
~ngages the band. The rear clute~
with teeth on the output shaft ring of the 1-2 shift valve, where it is
now engaged, in conjunction with gear. opposed by control pressure from
the front clutch, provides third Kickdown to Second Gear 'D' line 6, throttle pressure from 10, and
gear. The absence of throttle pres- Selected (30-50 mph approxi- spring pressure which holds the 1-2
sure, as previously mentioned, ,will mately). shift valve in first gear position.
cause the second to third valve to With the accelerator depressed to '2' -When 2 is selected manually,
move early under the governor kickdown position, throttle pressure control pressure is applied to the
pressure inftuence, so providing a is applied to the 2-3 valve and plun- front clutch and governor from line 5
low speed second to third change. ger at line 11. Throttle pressure and at the manual valve.
7-8 GROUP 7- AUTOMATIC TRANSMISSION

'D' the rear clutch and front servo

release circuits are exhausted at the
manual valve.
The front clutch and the front
servo are now applied giving 2nd gear.
Control pressure is exhausted from
line 3 at the range control valve allow-
ing control pressure at line 12 to move
the valve against spring pressure,
blocking off governor pressure to line
22 and replacing it with control pres-
sure which is directed to the large end
of the 1-2 shift valve holding it in
2nd gear position.
2-1
SHIFT AT SPEED
When the manual valve is shifted
from '2' to '1' control pressure in line
12 at the range control valve is ex-
hausted via the manual valve allowing
spring pressure to move the range
control valve to the left. Control pres-
sure in line 22 is now replaced with
governor pressure which is directed
to the large end ofthe 1-2 shift valve
holding it in the 2nd gear position.
When road speed drops below
approximately 30 mph, depending
FIG. 7 - Typical Selector Linkage on throttle opening, the control
throttle, and spring pressures over-
come the sovernor ~ressure and
Control pressure from line 12 at
the manual valve is directed to the
end of the range control valve mov-
ing it against spring pressure to
block off governor pressure at line 2
and connect line 12 to line 22 and
so replacing governor pressure at
the 1-2 shift valve with control pres-
sure. The 1-2 shift valve is now
moved against spring pressure and
throttle pressure to open a passage
for control pressure from line 5 to
enter the Front servo apply line (19).
At the same time, the rear servo
apply line has been exhausted. The
transmission is now in intermediate
ratio. There is no upshift to 3rd,
because there is no control pressure
being directed to the 2-3 shift valve
from the manual valve.
'D' - third gear - Control pres-
sure in line 3 acts against control
pressure in line 12 at the range con-
trol valve. Because of equal areas and
equal pressures, there is no resultant
force on the valve and the spring is
able to push the valve across cutting
off the control pressure feed to line 22
and replacing it with governor pres-
sure from line 2. The transmission is
now in normal drive range.
3-2
SHIFT AT SPEED
When '2' is manually selected from FIG. 8 - Inhibitor Switch
PART 7-1 AUTOMATIC TRANSMISSION (Borg-Warner) 7-9

The transmission will now remain

in first gear until another drive range
is selected manually.
3-1
SHIFT AT SPEED

Rear clutch apply and front servo

release circuits are exhausted at the
manual valve.
The front clutch and the front
servo are now applied giving 2nd
gear.

The control pressure in lines 12

and 3 at the range control valve is
also exhausted via the manual control
valve. This allows spring pressure to
hold the range control valve station-
ary and retain governor pressure to
line 22.

When road speed drops below

approximately 30 mph, the control
throttle and spring pressures over-
come the governor pressure and
moves the 1-2 shift valve to the first
gear position. The front servo apply
circuit is exhausted and the rear
FIG. 9 -Inhibitor Switch Operating Lever servo apply circuit subjected to con-
trol pressure via the 1-2 shift valves.
moves the 1-2 shift valve to first gear and at the same time control pressure The transmission will now remain in
position. The front servo apply cir- in line 6 from the manual valve is re- 1st gear until another drive range is
cuit is exhausted at the 1-2 shift valve directed to apply the rear servo. manually selected.
7-10 GROUP 7- AUTOMATIC TRANSMISSION

·-
.-~o"'T l" Ml' '5 TION
I
CONVE.l'.T~It.

!I
_l ulJLSECONDARY REG.

r ~~~
11
,..., '\_I- _c
-
Hn I ~ I ri JLr .
Jl
"I~~ o~ ~~~~ ....., _l.ll
....,_

II PRIMA~'lJ
.. a
rx
REG .
•
I
ll.'i.A."l. l'U MP

l:ii.OW"T 'CIUM'P ~
-
I DOWNSHIFT ~~THROTTLE 1'-.l •
~ a l~'J
trl
,....~
Iff"'" ---r
~r- 0.
~
,(J,_
f;: _l _r:::'t ' -~

I ~ -
- MODULATOR
M ~11:~
~
~
"'"'~
I _IXI_J\11 ......__

1- 1
J--
L.=
l
s

w
r---
r---
P R N D 2 L ~
~
+ + + + + • ~ j.! ~' pel { \J

n-n r- l....r\
-
~
~
u-u '-~r::l'"""-. ~
~~~ ~

MANUAL '7 r
.___ -
1-
I 1-
DUMP VALVE r=
r--- r-
[ I I
0-......-1 ~~ ~~ - -- ------ - t- - - - 1"1
~ ~ ~ ~
I

r
~
3
- I I. ~ ...
~. 1~1
----t'i ~
..r
I
I ~

~ ~
a 2 ~ ~
.
::1 r .L
'..::7
t:;' '"" rx
I
I 0
fXI~3 SHIFT 2. SERVO
· '-----
~r-- t-
1-
I ~
\) ORIFICE I ~
.I CONTROL
I ~
._,
X
\)
_I 1 a
...
;:)

..
~
\1 J J L _Ll
% ......
;~ H_ .1! 1·2 SHIFT~
.f). r-L'"'<..
lJ .c. RANGE I
t-=-t r -~
CONTROL t
= m... --
l~ ~ ~H
t-- r----1 1
~ 10 liif'&f .._,
JiQ
• 2. .JJ~ M ~
iJ 6 13
- l' ~ r---:-k
~ .._, '-
........_
~s:,,._,._ ~~,_'10 .lo.VPL.Y l'll.OHT SE.l.'IIO ,._'P'PL.Y
It
ill 'z
t--

FIG. 10- Borg Warner Hydraulic Control System

PART 7-1 AUTOMATIC TRANSMISSION (Borg-Warner) 7-ll

EJ DIAGNOSIS AND TESTING

When diagnosing transmission Aerated fluid will cause low control main bearing or from oil gallery
problems, first refer to the diagnosis pressure, and the aerated fluid may plugs. Be sure to determine the
guide for detailed information on the be forced out the vent. exact cause of the leak.
items that could be causing the Low fluid level can effect the opera-
problem. The following preliminary tion of the transmission and may f'LUID LEAKAGE
checks should be made in the order indicate fluid leaks that could cause CONVERTER AREA
given: transmission damage. In diagnosing and correcting fluid
Incorrect transmission fluid level leaks in the front pump and con-
1. Check the fluid level. Check the can also have the following effects, verter area, use the following pro-
fluid for a burnt clutch plate odor. although they may be attributable to cedures to facilitate locating the
2. Check the engine idle speed. other malfunctions:- exact cause of the leakage. Leakage
3. Check the manual linkage ad- (a) No drive in "D", "1", "2" or at the front of the transmission , as
justment. evidenced by fluid around the con-
"R".
4. Check the accelerator pedal (b) Slip and squawk or judder on verter housing, may have several
height and downshift linkage. full throttle starts in "D", sources. By careful observation, it
5. Check the throttle linkage to "1", "2" or "R". is possible, in many instances, to
assure wide open throttle operation. (c) Overheating due to high fluid pinpoint the source of the leak be-
6. Check the engine for proper level during sustained high fore removing the transmission from
operation. the car. The paths which the fluid
speeds.
takes to reach the bottom of the
TRANSMISSION FLUID converter housing are shown in Fig.
LEVEL CHECK TRANSMISSION FLUID
LEAKAGE CHECKS 1.
1. Make sure that the vehicle is 1. Fluid leaking by the front
Check the speedometer cable con- pump seal lip will tend to move
standing level. Then firmly apply the nection at the transmission. Leakage
parking brake. at the oil pan gasket often can be along the drive hub and onto the
2. Run the engine at normal idle stopped by tightening the attaching back of the impeller housing. Ex-
speed. If the transmission fluid is bolts to the proper torque. If neces- cept in the case of a total seal fail-
cold, run the engine at fast idle speed sary, replace the gasket. Check the ure, fluid leakage by the lip of the
(about 1200 rpm) until the fluid seal will be deposited on the inside
fluid filler tube connection at the
reaches its normal operating tem- transmission. If the filler tube 0-ring of the c0nverter housing only, near
perature. When the fluid is warm, seal is leaking, replace the seal. the outside diameter of the housing.
slow the engine down to normal idle 2. Fluid leakage by the outside
The transmission fluid is water
speed. cooled; check the fluid lines and fit- diameter of the seal and front pump
3. Shift the selector lever through tings between the transmission and body will follow the same path as
all positions, and place the lever at the cooler in the radiator tank for leaks by the front pump seal or may
P. Do not turn off the engine during run down the face of the front pump.
looseness, wear, or damage. If leak-
the fluid level checks. age cannot be stopped by tightening 3. Fluid that leaks by front
4. Clean all dirt from the trans- a fitting, replace the defective parts. pump to case bolts will be deposited
mission fluid dipstick .cap before Check the engine coolant in the on the inside of the converter hous-
removing the dipstick from the filler radiator. If transmission fluid is pre- ing only. Fluid will not be deposited
tube. sent in the coolant, the cooler in the on the back of the converter.
5. Pull the dipstick out of the radiator tank is probably leaking. 4. Leakage by the front pump to
tube, wipe it clean, and push it all case and 0-ring seal may cause
The cooler can be further checked
the way back into the tube. for leaks by disconnecting the lines at fluid to be deposited on the inside
6. Pull the dipstick out of the tube lower part of the converter housing
the cooler fittings and apply 5 psi air
again, and check the fluid level. If as shown in Fig. l.
pressure to the fittings. The radiator
necessary, add enough fluid to the cap must be removed when making Engine oil leaks are sometimes
transmission through the filler tube this check to relieve the pressure on improperly diagnosed as front pump
to raise the fluid level to the F (full) the exterior side of the cooler. If the seal leaks. The following areas of
mark on the dipstick. cooler is leaking and will not hold possible leakage should also be
DO NOT OVERFILL THE this pressure, the radiator must be checked to determine if engine oil
TRANSMISSION. replaced. The cooler cannot be leakage is causing the problem:
Should it be necessary to check the replaced separately. (a) Leakage at the rocker arm
fluid level when the transmission is If leakage is found at the manual cover (valley cover) may allow oil
cold, carry out the above procedure, lever shaft, replace seals that are to flow over the converter housing
when the level should be on "Add" leaking. or seep down between the con-
mark, otherwise it will be too high at The pressure port plug on the left verter housing and cylinder block
normal operating temperature when rear of the case must also be in- causing oil to be present in or at
the fluid has expanded. Re-check the spected. the bottom of the converter housing .
level when the gearbox is at normal (b) Oil gallery plug leaks will al-
running temperature. Fluid leakage from the con- low oil to flow down the rear face
A fluid level that is too high will verter housing may be caused by of the block to the bottom of the
cause the fluid to become aerated. engine oil leaking past the rear converter housing.
7-12 GROUP 7- AUTOMATIC TRANSMISSION

ranges to increase pressures within

the transmission. Observe the front
oi the flywheel. back of the block
(in as far as possible), and inside
the converter housing (Fig. I). Run
the engine until fluid leakage is evi-
dent and the probable source of leak-
age can be determined.
ENGINE IDLE SPEED CHECK
Check and, if necessary, adjust the
engine idle speed, using the proce-
dure given in Group 10.
If the idle speed is too low, the
engine will run roughly. An idle
speed that is too high will cause the
car to creep excessively when the
transmission is shifted into gear and
will cause rough transmission en-
gagement.
MANUAL LINKAGE CHECKS
C'..<mect manual linkage adjust-
ment is necessary to position the
manual valve for proper fluid pres-
sure direction to the different trans-
mission components. Improperly ad-
justed manual linkage may cause
CONVUTEJ cross-linkage and subsequent trans-
mission failure. Refer to Linkage
Adjustments for detailed manual
linkage adjustment procedures.
DOWNSHIFT CABLE CHECKS
Correct downshift cable ad-
CONVUTEJ DltAIN justment is essential for normal
I'I.UG l.fAK
service life of transmission and
proper gear shift feel and con-
trol. Refer to the In Car Adjust-
ments Section 3 Page 7-20 for the
detailed adjustment procedures.
FIG. 11 - Typical Converter Area Leakage Checks INITIAL ENGAGEMENT
CHECKS
(c) Leakage by the crankshaft seal from the top and bottom of the con- Initial engagement checks are made
will work back to the flywheel, and verter housing, front of the trans- to determine if initial band and clutch
then into the converter housing. mission case, and rear face of the engagements are smooth.
Fluid leakage from other areas, engine and engine oil pan. Clean Run the engine until its normal
forward .of the transmission could the converter area by washing with operating temperature is reached.
cause fluid to be present around the suitable non-flammable solvent, and With the engine at the correct idle
converter housing due to blow-back blow dry with compressed air. speed, shift the selector lever from
or road draft. N to D, 2, 1 and R. Observe the
The following procedure should be (c) Wash out the converter hous- initial band and clutch engagements.
used to determ ine the cause of leak- ing, the front of the flywheel. The
Band and clutch engagements should
age before any repairs are made: converter housing may be washed
be smooth in all positions. Rough
(a) Remove the transmission dip- out using cleaning solvent and a
initial engagements in D, 2, 1 or R
stick and note the color of the fluid . squirt-type oil can. Blow all washed
areas dry with compressed air. are caused by high engine idle speed
Original factory fill fluid is dyed red or high control pressures.
to aid in determining if leakage is
from the engine or transmission. (d) Start and run the engine until TRANSMISSION OPERATION
Since road draft may cause leaking the transmission reaches its normal CHECKS
valley cover oil to be present on the operating temperature. Observe the TEST PREPARATION
transmission, this leakage, if present, back of the block and top of the
should be eliminated before per- converter housing for evidence of 1. Attach a tachometer to the
forming work on the transmission. fluid leakage. Raise the car on a engine.
hoist and run the engine at fast idle, 2. Attach a pressure gauge to the
(b) Remove the converter lower then at engine idle, occasionally control pressure outlet at the trans-
housing cover. Clean off any fluid shifting to the drive and reverse mission (Fig. 12).
PART 7-1 AUTOMATIC TRANSMISSION (Borg-Warner} 7-13

3. Firmly apply the parking brake clutch. While making this test, If the stall test speeds are 300 to
and start the engine. do no£ hold the throttle open for 400 rpm below the specified values,
4. With the engine at normal more than five seconds at a time. and the car drags at cruising speeds
operating temperature, adjust the Then move the selector lever to and acceleration is poor, the stator
engine idle speed to the specified Neutral and run engine at 1000 rpm clutch could be installed backwards.
rpm. If the engine idle speed cannot for about 15 seconds to cool the con- Remove the converter and check
be brought within limits by adjust- verter before making the next test. the stator clutch by replacing with
ment at the carburettor idle adjust- a converter known to be operating
ment screw, check the throttle and If the engine speed recorded by the
tachometer exceeds the maximum correctly and retesting.
downshift linkage for a binding con-
dition. If the linkage is satisfactory, limits specified in Table 1, release the Below standard acceleration in top
check for vacuum leaks into the accelerator immediately because gear above 30 mph combined with a
engine. clutch or band slippage is indicated. substantially reduced maximum
speed, indicates that the stator one-
CONTROL PRESSURE TESTS STALL SPEED TOO HIGH way clutch has locke;d in the engaged
The test results of the following A higher stall speed than that condition. This condition will also be
checks should agree with the specifi- specified indicates that the convertor indicated by the transmission over-
cations given in Table 1. When per- is not receiving its required fluid heating, although the stall speed will
forming control pressure tests, make supply or that slip is occurring, de- remain as specified. Renew the con-
certain that the service brake pedal is pending on transmission selector verter.
held in the applied position. lever position. Excessive engine rpm Note - The torque converter is a
It is important that both the only in D, 2 or 1, indicates forward sealed unit without a drain plug. The
engine and transmission are at their clutch slippage. Excessive engine unit must not be dismantled. If a
normal operating temperature. rpm only in R indicates either converter is unsatisfactory in any
reverse-high clutch or low-reverse way then it must be replaced.
TEST No. 1 band slippage. Excessive engine rpm TEST No. 3
only in D indicates gear train one- CONTROL PRESSURE AFTER CUT
CONTROL PRESSURE CHECK way clutch slippage. BACK TEST
AT ENGINE IDLE
STALL SPEED TOO LOW The transmission and engine
Start the engine and allow it and should be at their normal operating
the transmission to reach their nor- When the stall test speeds are low temperature. Accelerate the vehicle
mal operating temperatures. At the and the engine is properly tuned, with full throttle. During accelera-
correct engine idle speed, check the converter stator clutch problems are tion the control pressure should be
transmission control pressure gauge indicated. A road test must be per- suddenly reduced by modulator valve
at all selector lever positions. The formed to determine the exact cause
pressure: <>hould agree with the speci- operation to the specification shown
of the trouble. in Part 7-4.
fications shown in Table 1. If the stall test speeds are 300 to CONTROL PRESSURE AFTER CUT
IDLE PRESSURE TOO LOW 400 rpm below the specifications BACK TOO LOW
Check the downshift cable adjust- shown in Table 1, and the car cruises
ment and revise as necessary. properly but has very poor accelera- Low pressure may be caused by
tion, the converter stator clutch is incorrect downshift cable adjustment
Low pressure may also be due to or faulty regulator valve operation.
excessive leakage in the oil pump, slipping.
case and control valve body, or a
sticking control pressure regulator
valve.
IDLE PRESSURE TOO HIGH
Check the downshift cable adjust-
ment for excessive pullout, sticking
or non-return of the downshift cam
through incorrect assembly of the
cam spring.
High pressure may also be caused
by sticking regulator valves.
TEST No. 2 - STALL TEST
Start the engine to allow it to reach
its normal temperature. Apply both
the parking and service brakes while
making tests.
The stall test is made in D, 2,
1 or R at full throttle to check
engine performance, converter clutch
operation or installation and the
holding ability of the forward clutch,
reverse-high clutch and low-reverse
band and the gear train one-way FIG. 12- Gauge set up for Pressure Test
7-14 GROUP 7- AUTOMATIC TRANSMISSION

TABLE 1 CONTROL PRESSURE CHECKS

IDLE PRESSURE (PSI) STALL PRESSURE (PSI) STALL SPEEDS (RPM)

200CID 58-66 200CID 200-250 200CID 1800-1900
250CID 58-70 250-CID 200-250 250CID 1850-1950

Note - Check pressures with

transmission fluid at normal opera-
ting temperature.
CONTROL PRESSURE AFTER CUT each position selected. 20 mph. Check for slip and
BACK TOO HIGH Test 3. Check converter stall speed clutch squawk, and no upward
High control pressure may be with the transmission in "1" changes.
caused by incorrect downshift cable after connecting a tachometer Test 8. Stop and select "R". Release
adjustments, faulty governor, modu- to the engine and applying the the. brakes and reverse using
lator valve or regulator valve opera- hand-brake. Allow the engine full throttle if possible. Check
tion. and transmission to reach nor- for slip or clutch squawk.
mal operating temperature and Test 9. Stop the car facing downhill
SHIFT POINT CHECKS then momentarily depress to with the brakes and select "P".
Check the light throttle upshifts in the kick-down position, noting Release the brakes and check
D. The transmission should start in the tachometer reading. Do not that the parking pawl holds the
first gear, shift to second, and then stall for more than ten seconds, car. Re-apply the brakes before
shift to third within the shift points otherwise the transmission will disengaging the parking pawl.
specified in the specifications section overheat. Check for slip or Repeat with the car facing up-
(Part 7-4). clutch squawks. (Refer Table 1). hill.
While the transmission is in third Test 4. With the transmission at
gear, depress the accelerator pedal normal operating temperature, AIR PRESSURE CHECKS
through the K.D. detent (to the select "D", release the brakes A NO DRIVE condition can exist,
floor). The transmission should shift and accelerate with minimum even with correct transmission fluid
from third to second or third to first, throttle opening checking for pressure, because of inoperative
depending on the car speed. first to second and second to clutches, bands. The inoperative
third changes. At minimum units can be located through a series
Check the closed throttle down- throttle openings the changes of checks by substituting air pressure
shift from third to first by coasting may be difficult to detect. for the fluid pressure to determine
down from about 30 mph in third Confirmation that the trans- the location of the malfunction.
gear. The shift should occur within mission is in third gear mar, When the selector lever is at D, 2,
the limits specified in the specifica- be obtained by selecting "2 ' or 1, a NO DRIVE condition may
tions section. when a third to second change be caused by an inoperative forward
With the transmission in third should be felt. clutch. A NO DRIVE condition at D
gear and road speed over 30 mph, the Test 5. (a) At 30 m.p.h. in third may be caused by an inoperative
transmission should shift to second gear, depress the accelerator to forward clutch or one-way clutch.
gear when the selector lever is moved the "kick-down" position where When there is no drive in "1", the
from D to 2 or 1. The transmission the transmission should change difficulty could be caused by im-
will downshift from second or third to second. proper functioning of the forward
to first gear when 1 is selected (b) At 15 m.p.h. in third gear, clutch and the one-way clutch. The
below approximately 20 mph. This depress the accelerator to full low-reverse band cannot be checked
check will determine if the gov- throttle position. The trans- in "1". If the low-reverse band or
ernor pressure and shift control mission should change to first clutch fails, the one-way clutch will
valves are functioning properly. gear. hold the gear train and operation will
During the shift check operation, be normal except that there will be
if the transmission does not shift Test 6. (a) Stop the car and re-start no engine braking. Failure to drive
within specifications or certain gear using full throttle acceleration. in reverse range could be caused by a
ranges cannot be obtained, refer to Check the change speeds for malfunction ofthe reverse-high clutch
the Diagnosis Guide to resolve the first to seconel and second to or low-reverse band. If the trans-
problem. third: refer shift speed chart in mission fails to drive in reverse range
the specification section. but operates normally in D, 1 or 2, it
ROAD TEST PROCEDURES (b) At 40 mph in third gear, indicates failure of the low and
Test 1. Check that the starter only release the accelerator and reverse band.
operates with the selector in select "1". Check for third to To make the air pressure checks,
"P" and "N" and that if a second change and engine brak- drain the transmission fluid, and then
reversing light is fitted it only ing. Check that the second to remove the oil pan and the control
operates in "R". first change occurs below 20 valve body assembly. The inoperative
Test 2. Apply the brakes and, with p1ph and for engine braking. units can be located by introducing
the engine idling, select N-D, Test 7. Stop the car with "1" still air pressure into the transmission
N-1, N-2, N-R. Transmission engaged, release the brakes and, case passages leading to the clutches,
engagement should be felt in using full throttle accelerate to servos, and governor.
PART 7-1 AUTOMATIC TRANSMISSION {Borg-Warner) 7-15

FII.ONT CLUTCH II.EAII. CLUTCH FII.ONT lAND II.EAII. lAND

ONE WAY CLUTCH

TUII.IINE

SELECTOR LEVER FRONT REAR FRONT REAR ONE WAY

POSITION CLUTCH CLUTCH BAND BAND CLUTCH

-LOCK UP 1
• • •
D -DRIVE 1
• •
2,1 orO- LOCK UP 2
DRIVE 2 • •
D -DRIVE 3
• •
N - NEUTRAL

R -REVERSE
• •
p -PARK
•
e =APPLIED

FIG. 13 - Power Flow Summary

"'1"1

~
...
~
-~
o-
I lr11'ELLER CLUTCH PISTONS PINION CARRIER PINIONS

..cr
"'
~
~
STATOR FRONT CLUTCH CENTRE SUPPORT GOVERNOR

CD TURBINE FRONT OIL

a.. PUMP
<
ii"

s"
E
~
..
-t
Ill
~
Ill
3
iii.
Ill
..i'
c

a· )>
~
RING GEAR c

FORWARD SUN GEAR

~
()

.....
::0
)>
REVERSE SUN GEAR
z
~
~
FRONT BRAKE
BAND
REAR BRAKE BAND
2
ONE WAY CLUTCH REAR CLUTCH

DRIVE PLATE AND

STARTER RING GEAR FRONT PUMP ADAPTOR ONE WAY CLUTCH
TABLE 2- FAULT INVESTIGATION KEY

.,)>
PRELIMINARY ADJUSTMENT FAULTS ;10
-t
A
B
C
Fluid level incorrect.
Downshift valve cable incorrectly assembled or adjusted.
Manual linkage incorrectly assembled or adjusted.
D
E
F
Incorrect engine idling speed.
Incorrect front band adjustment.
Incorrect rear band adjustment.
-~

)>
c
--i

HYDRAULIC CONTROL FAULTS MECHANICAL FAULTS

~)>
--i
a Oil tubes missing or not installed correctly. N Front clutch slipping due to worn plates or faulty parts. n
--i
b Sealing rings missing or broken. 0 Front clutch seized or plates distorted. ;;o
)>
c Valve body assembly screws missing or not correctly tightened. P Rear clutch slipping due to worn plates or faulty check valve
in piston.
z
d Primary regulator valve sticking.
Q Rear clutch seized or plates distorted. ~
e Secondary regulator valve sticking.
R Front band slipping due to faulty servo, broken or worn band. ~
f Throttle valve sticking. 0
S Rear band slipping due to faulty servo, broken or worn band. z
g
h
Modulator valve sticking.
Governor valve sticking, leaking or incorrectly assembled.
T
U
One-way clutch slipping or incorrectly installed.
One-way clutch seized.
-..,
OJ
0
j Orifice control valve sticking. (Q

k First to second shift valve sticking.

V Input shaft broken.
~
Second to third shift valve sticking.
W Pump drive tangs on converter hub broken. ..,
01
::J
X Pump worn.
-
..,
(I)
m Second to third shift valve plunger sticking.
Z Converter blading and/or one-way clutch failed.
n Converter ..out" check valve missing or sticking.
p Pump check valve missing or sticking.

-':'4
.......,
.....
I

TABLE 2-QUICK REFERENCE DIAGNOSIS GUIDE (Continued) Ia,

ABCDEFabc d e f g h jklmnpNOPQRSTUVWXYZ

Selec:ting "R", "D", "I" or "2" foi'Dl Rest:

Harsh engagement .... .... .... .... .... . 2 I . . s 3 . 4 . . . . . • 6 . 7
Delayed engagement ..... ............... I . 2 3 . 4 7 6 s . . . . 13 8 9 . 10 . .11 . . . . 12
No engagement .. .. .. .. .. .. ... . ... . .. .. I . 2 . 3 4 s 6 . . . . . . . . . . . . . . . .- . • 7 8 9 . 10 lei'
~
Startla1 from Rest: 0
No drive forward .. .. .. .. .. .. .. .. .. .. I . . 3 2 . . . . . . . .s . . . . .
. 4
c
~
No. drive in reverse .. .. .. .. .. .. .. .. .. .. . 1 . 2 7 6 s . . . 3 4 . . . • 9 . . 8 . . . . . . ....I
Box seizes ·in reverse .. .. ... . .. .. .. .. . . I . . . . . . . . . 2 . . . . . . . .
Forward movement in neutral ... . . . 1 . . . 3 . . . . . . 2 . . . . . . c>
Upward Cban1es: 0
No first to second change .. .. .. .. .. ..
No second to third change .... .. .
.
.
1
1
. 2
. .
. 8 9 10
. 8 9 10
.
.
.
.
6 7 3
6 7 2
. 4
. 3 4
. . .
.
.
. s
. s .
. .
. . .
. . .
~
()
Above normal change speeds .. .. . .. . . 1 . . . . 8 9 10 . 2 7 3 . 4 s 6 . . . . . . . . . . . -f
;,o
. . . . s 6 . . . . . . . . . . .
z>
Below normal change speeds .. .. .... 1 . 2 . 3 . 4

Upward Chaa1e Q..lltJ:

~
Slip on first to second change .. .. .. .. 1 2 3 . 4 . 8 9 10 6 . 7 . . . . . . . . s . . . . . ~
Slip on second to third change .... 1 2 3 . 4 . 9 10 11 7 . 8 . . . . . . . . s . 6 . . . . . . 0
Harsh first to second change .. .. .. .. . 1 . 2 . 10 3 . 4 s 6 . . . . . 9 . . . . . 7 8 z
Harsh second to third change .. .. .... 1 . . 2 . . 6 3 . 4 . . . . . . 5 .
Box seizes on first to second change . .
. 1 . s 6 . . . . . . . . . . 2 . 3 4
Box seizes on second to third change . . . . 1 . 2 3 4

Downward Chaa1e:
No second to first change .. .. .. .. .. .. . 1 . . . . . . . . . . 3 . 2 . . . . . . . . 4 . . . . . . .
TABLE 2-QUICK REFERENCE DIAGNOSIS GUIDE (Continued)

A BCDEFabc d e f g h jklmnpNOPQRSTUVWXYZ

. . .
.,
No third to second change I 3 . 2 . 4 s . J>
;g
Involuntary high speed third to -t
. . . . . . . .
second change
Above normal change speeds .
Below normal change speeds
.. . . -· ·· I
l
1
2
s
s
6
6
. 4
. 4
. 2
2
. 3
7 8 3
.
3
. . .
. . . . .
. .
. . . . . .
-
~

)>
c-1
Downward Chance Quality: 0
Slip on second to first change . .. . .. . . . . . . . . . 1 . . . . . ~
)>
Slip on third to second change .. . .. . 1 6 7 8 4 s 3 . • 9 . 2 . . . . . . -1

Harsh second to first change .. . .... 3 . . . 2 . 1 . . . . ()

Harsh third to second change ... ... . 1 s 3 . 4 . 2 . . . . 6 7 8 . . . . .

-1
;;o
)>
z
(/")

I~0
Coatrol Pressure:
Low on idling .. . I 2 3 6 8 s 4 . . .
• 7 . • 9 . .
s . . . . . . . . . . . . lz
High on idling

Low at stall
.. .. ... . ... .

. . .. . . . . . . . . ... .
1

1 2
2

. 6 8 7 3
3 4

s 4 9 . . . . . . . • 10 .
-
OJ
IQ
<0I

High at stall .. . --·· . 4 t 2 3 . . . . . . . . . . . . . . I~..,

Stall Speed:
Below 1300 r.p.m . . ... .......... .. ... . . . . . . . . . . . . . . .1 I!
Over 2000 r.p.m. .... .... .. .. .. .. .... I . 2 . 34S67 . . . 8 • 9 • 10 11 • 12 . . .13
Overheating .... .... .... .... .... .... .... . 1 . 2 3 . . . . . . . . . . . . . . . . . . 4
I~
-
-o
7-20 GROUP 7- AUTOMATIC TRANSMISSION

FORWARD CLUTCH (Front) If the servos do not operate, dis-

Apply air pressure to the trans- assemble, clean and inspect them to
mission case forward clutch passage locate source of the trouble.
(Fig. 15). A dull thud can be heard If the air pressure applied to any
when the clutch piston is applied. If clutch passage fails to operate the
no noise is heard, place the finger tips clutch or operates more than one
on the clutch and again apply air clutch at once, remove, and with
pressure to the forward clutch pas- air pressure, check fluid passages
sage. Movement of the piston can in the case, pump output and
be felt as the clutch is applied. primary shaft to detect cross leakage
Caution: Forward and governor or obstruction. If the passages are
passages are common, therefore if intact and clear, remove the clutch
there is excess air leakage from assemblies and clean and inspect
governor, clutch operation may not the malfunctioning clutch to locate
be audible. the trouble.
GOVERNOR
Apply air pressure, to the control FIG. 15 - Air Pressure
DIAGNOSIS GUIDE (Table 2)
pressure to governor passage and Checks
listen for a sharp clicking or whistling The Transmission Diagnosis
noise. The noise indicates governor Continue to apply air pres!>ure into
the intermediate servo apply pas- Guide lists the most common trou-
valve movement. ble symptoms that may be found in
sage, and introduce air pressure
REVERSE-HIGH CLUTCH (Rear) the transmission, and gives the items
into the intermediate servo release
Apply air pressure to the reverse- passage. The intermediate servo that should be checked to find the
high clutch passage (Fig. 15). A dull should release the band against the cause of the trouble.
thud indicates that the reverse-high appJy pressure.
clutch piston has moved to the ap- The items to check for each
plied position. If no noise is heard, trouble symptom are arranged in a
LOW-REVERSE SERVO (Rear)
place the finger tips on the clutch logical sequence which should be
drum and again apply air pressure to Apply air to the low reverse servo followed for quickest results. The
detect movement of the piston. apply passage (Fig. 15). The low re- letter symbols for each item are ex·
verse band should tighten around the plained in the Key to the Diagnosis
INTERMEDIATE SERVO (Front) drum if the servo is operating pro- Guide.
perly. CAUTION: DO NOT AP- If items A, B, C, D, E, and the
Hold the air nozzle in the inter- PLY AIR PRESSURE TO THE stall test have already been checked
mediate servo apply passage (Fig. SERVO UNLESS IT IS AS AS- during the preliminary checks and
15). Operation of the servo is indi- SEMBLED TO mE TRANS-
cated by a tightening of the inter- MISSION OR mE SERVO MAY adjustments, they need not be re-
mediate band around the drum. BE DAMAGED. peated when following the Diagnosis
Guide.

EJ IN-CAR ADJUSTMENTS AND REPAIR

PROCEDURE FOR CHECKING
(c) Overheating due to high automatic transmission will not oper-
FLUID LEVELS ate satisfactorily and premature fail-
fluid level during sustained
Refer to Part 7-1, Section 2. high speeds. ure may result.
It is unnecessary to drain the con- Incorrect adjustment of the down-
ACCELERATOR LINKAGE AND shift valve control cable can have the
verter and transmission as a normal
DOWN SHIFT VALVE CONTROL following results:-
service item.
The transmission is air and water CABLE
cooled and therefore keep the under- If the accelerator linkage is in- (a) Excessive bump when "D"
side free from mud, etc. otherwise correctly adjusted preventing full or "R" is engaged.
overheating may result. movement of the accelerator pedal, (b) No drive in "D".
the carburettor butterfly will not (c) Delayed or no first to
PRELIMINARY ADJUSTMENTS open fully resulting in poor engine second change.
FLUID LEVEL performance and insufficient control (d) Slip on first to second
Incorrect transmission fluid level pressure in relation to accelerator change.
can have the following effects, al- pedal movement. (e) Delayed or no second to
though they may be attributable to It is therefore essential to ensure third change.
other malfunctions:- that the throttle butterfly fully opens (f) Slip or engine "run-up" on
(a) No drive in "D", "1", "2" as the accelerator linkage is also con- second to third change.
or "R". neated to the automatic transmission (g) Bumpy gear changes.
(b) Slip and squawk or judder down shift valve by a cable, it is (h) Slip and squawk or judder
on full throttle starts in essential for the linkage and cable to on full throttle starts in
"D", "1 ", "2" or "R". be correctly adjusted, otherwise the "D".
PART 7-1 AUTOMATIC TRANSMISSION (Borg-Warner) 7-21

(i) Gearbox changes down too that the choke is fully open.
easily. 2. Note that the position of the
(j) Gearbox will not change downshift valve cam when the
down. throttle butterfly is closed, i.e., the
(k) Slip and squawk or judder accelerator pedal is released. The
on starting in "1 " or "2" . heel of the downshift valve cam
(I) Slip and squawk or judder should lay against the large diameter
on starting in "R". of the downshift valve, see "idling
(m) Slip but no judder on start- position" Fig. 18, with all slack in
ing in " R". the inner cable taken up.
(n) No drive in "R" . 3. With the throttle butterfly fully
The following method of linkage open, i.e., the accelerator pedal
adjustment is used for the setting of pressed down fully in the kick-down
the downshift valve cable. position, the constant radius lobe of
1. Ensure engine and transmission the cam should be in contact with the
are at normal operating temperatures, downshift valve, as seen in "kick-
the carburettor choke is fully open down position", Fig. 18. The posi-
and carburettor correctly adjusted. tion of the cam can be varied by
2. Adjust the rod " F", Fig. 17, altering the adjuster on the down-
to give the correct pedal height. FIG. 16- Transmission shift valve cable.
Correct pedal height is 3. 65" to 4 .16" 4. Fit the sump "nipping" all the
Fluid Dipstick- Typical sump bolts. Then, in one operation,
measured between floor pan (mat in
position) at right angle to pan and a tighten each bolt to 10 ft. lbs.
cable moves away from the end of 5. Road test the vehicle to check
point on the upper surface of the outer cover adjuster.
pedal pad 2.24" from the lower edge. the shift speeds (see table), and
Service downshift cables differ quality of change.
Refer Fig. 17. from original production installation
3. Disconnect the downshift inner 6. Crimp ferrule to inner cable so
in that they are supplied with the that it is .010" off the outer cable end.
cable trunnion "A" (Fig. 17) from ferrule free to move and therefore
the bell crank assembly with the bell the following methods of adjustment TABLE OF SHIFT SPEEDS
crank assembly set at idle. Adjust can be used with either type of cable.
trunnion "A" into hole "B" so that The speeds mentioned below are
the crimped stop on the kickdown Alternate Method to the nearest mph.
inner cable just touches to -h • off the The downshift cable can also be SHIFT POINTS: (D iff. Ratio 3.23: 1)
outer cable without slack. Install the adjusted by determining the position
clip. of the downshift valve cam in relation Shift Shift
NOTE: For safety sake trans- to the accelerator pedal. This method Throttle M.P.H. Throttle M.P.H.
mission selection should can be used when a new downshift 1-2 K.D 31-39 1- 2 Zero 8-10
be in park position. valve cable is being fitted and the
transmission sump is removed. The 2-3 K. D 53-61 2- 3 Ze ro 10-13
4. Check that at full throttle the
cable pull is 1. 75 inches minimum. method of adjustment is as follows: 3-2 K. D 44 -54 3-1 Zero 4-8
This dimension is the measured dis- 1. Remove all the free play from 3-1 K. D 19 -29 2-1 Zero 10-18
tance that the ferrule on the inner the accelerator linkage and ensure
ADJUST ROO • AS.S'v. 19UOI
TO OITAIN fUll THROTTLE
WHEN SHAFT A$SY . !97:151
TOUCHES THE FLOOI COVEtiNG

PEDAl HEIGHT SETTING

HOLE I

lUIIIII(ATE PIVOTS MARKED • •

PU CHART AUTOMATIC TRANSMISSION
CH ...SSIS lUIRICATION SEC l No -457· · K/0 CAllE ADJUSTMENT
WITH THE SHAFT ASSY 9919 SET
AT IOU. ADJUST TPitNION " A "
INTO HOlE I SO THAT THE
CRIMPED STOP ON
KICKOOWN INNU ( ',C:E JUST TOUCHES
THE OUTEI CAllE- WITHOUT SLACK.
THEN INSTAll CliP 9125
FIG. 17- Linkage Adjustment 6 Cylinder Engines
7-22 GROUP 7- AUTOMATIC TRANSMISSION
DOWNSHIFT VALVE the third detent. Ensure that the may be necessary to adjust the
CABLE I selector lever is held against the stop ignition setting.
in the neutral position, and the trans- When a suitable vacuum gauge is
mission lever fully engaged in the not available, the engine should be
neutral detent position. warmed up and the slow-running
adjustment screw turned clockwise
2. With the transmission selector so that the engine is running at a
and the steering column or floor shift fast idling speed. Screw the volume
selector lever still in "Neutral" posi- control screw in or out until the
tion, tighten the selector rod clamp engine runs evenly. Readjust the
nut. slow-running adjustment screw if the
3. With test lamp check that when engine is running too fast, followed
gear selection is made with the steer- by a further readjustment of the
IDLING KICK-DOWN ing column or floor shift selector volume control screw.
P'OSITION P'OSITION lever the lamp will only light in
"Neutral" and "Park" positions. If These operations should be re-
FIG. 18- Downshift Valve the test lamp does not light up in peated until the idling speed is
Cable Adjustment satisfactory and, if necessary, fol-
these positions or lights up in all lowed by a re-adjustment to the
MANUAL LINKAGE selector positions it will be necessary ignition setting.
to readjust linkage or replace switch.
Incorrect manual linkage adjust- FRONT BRAKE BAND
ment can result in the following:- SLOW-RUNNING ADJUSTMENT
(a) No drive in "D". The front brake band is used
To obtain the best slow-running
(b) Slip and squawk or judder in second to hold the reverse sun
adjustment, the engine should be gear stationary and therefore pro-
on full throttle starts in tuned against a vacuum gauge con-
"D". vides the second gear ratio. Incor-
nected to the inlet manifold. This
(c) No manual third to second rect front brake band adjustment
connection can be made by removing
change. the blanking plug in the inlet mani- has the following effects:-
(d) Slip and squawk or judder fold and fitting the appropriate (a) Slip on first to second
on starts in "1" or "2". adaptor and gauge. change.
(e) Slip and squawk or judder (b) No first to second change.
on starts in "R". Before commencing adjustment,
(f) No drive in "R". check the air cleaner to ensure that (c) Delayed or no second to
(g) No parking pawl engage- the element is clean and in a service- third change.
ment. able condition. (d) Slip on third to second
(h) Front clutch burning out. Run the engine, so allowing it to "kick-down" change.
It should be noted that incorrect warm up. To adjust the slow-run- Remove the fifteen bolts and
manual linkage adjustment is not the ning, screw in the slow-running ad- lockwashers securing the transmis-
only cause of the above conditions. justment screw (see Fig. 19) until a sion oil pan and detach the oil pan
fast idling speed is obtained, then and gasket. Slacken the adjusting
MANUAL LINKAGE turn the volume control screw,
ADJUSTMENT screw locknut, move the servo lever
Fig. 19, either clockwise or anti- outwards and place a 0.25 in. gauge
1. Position transmission selector clockwise to obtain the maximum between the servo piston pin and
lever in neutral, to ensure correct vacuum reading. Readjust the idling the adjusting screw (see Fig. 20).
engagement it may be necessary to speed as necessary· and continue the
loosen clamp nut on steering column adjustment until the maximum pos- Tighten the adjusting screw to a
or floor shift lever to selector rod and sible vacuum reading is obtained with torque of 10 in. lbs., tighten the
move shift lever on transmission to a reasonable slow-running speed. It locknut and then remove the gauge
block. Ensure that the mating
faces are clean and refit the oil
pan with a new gasket. Tighten
the fifteen bolts in their lock
washers to a torque of 8 to 10
ft. lbs.
REAR BRAKE BAND
The rear brake band is employed
in "1" and "R" to hold the pinion
carrier stationary. Incorrect rear
brake band adjustment can have the
following results:-
(a) No drive in " R" and no
engine braking in " 1" .
To adjust this band, slacken the
adjusting screw locknut on the right-
hand side of the transmission case
FIG. 19 - Slow Running FIG. 20 - Front Band and then tighten the adjusting screw
Adjustment Screws Adjustment to a torque of 10 ft. lbs. (Fig. 21 ).
PART 7-1 AUTOMATIC TRANSMISSION (Borg-Warner) 7-23

FIG. 21 -Typical Rear Band Adjustment

Slacken the adjusting screw i turn the drain plug and drain the fluid. converter assembly in the car, Do
and tighten the locknut. Remove and thoroughly clean the Not Connect the Cooler Return Une
STARTER INHIBITOR SWITCH oil pan and screen. Discard the oil to the Transmission. Place the trans-
pan gasket. mission selector lever in the P
This particular component is a l. Place a new gasket on the oil (park) position and connect the
safety device to ensure that the pan, and install the screen and pan cooler inlet (converter out) line to
engine will only start in "Park" or oc the transmission. the transmission. Place a pan under
"Neutral" selector positions. If the 3. Add three quarts of fluid to the the end of the cooler return line that
engine will not start in the "P" or transmission through the filler tube. will hold transmission fluid. Do Not
"N" selector positions, or the starter 4. Run the engine at idle speed for Start the Engine.
motor operates in all selector posi- about two minutes. Check the fluid 2. Install 8 quarts of automatic
tions, then the starter inhibitor level, and add fluid if necessary. Run transmission fluid meeting Ford
switch may require replacement. the engine at fast idle speed (about Specification.
1200 rpm) until it reaches its nor- 3. Start the engine and allow it
Check the manual linkage adjust- mal operating temperature. Do not to run at normal idle speed with
ment and wiring connections and race the encine. the selector lever in P, park posi-
loom for faults. 5. Shift the selector lever through tion.
If correction is not obtained the all the positions, place it at P, and 4. Allow approximately two
switch must be replaced. check the fluid level. If necessary, quarts of transmission fluid to drain
TRANSMISSION FLUID DRAIN add enough fluid to the transmission into the pan placed under the end
AND REFILL to raise the level to the F (Full) of the cooler return line.
mark on the dipstick. Do not overfill S. If the fluid does not run clean
Normal maintenance and lubrica- the transmission. after draining two quarts of it
tion requirements do not necessitate through the cooler, shut off the en-
periodic automatic transmission fluid OIL COOLER FLUSHING gine and add two additional quarts
changes. PROCEDURE of transmission fluid.
If a major failure, such as a clutch, 6. Repeat steps 3 through 4 until
band, bearing, etc., has occurred When a clutch or band failure or
other internal trouble has occurred the transmission fluid flowing out
within the transmission, it will have in the transmission, any metal par- of the cooler return line is clean.
to be removed for service. At this ticles or clutch plate or band mate- 7. If there is no fluid flow or the
time the converter must be thor- rial that may have been carried into fluid does not flow freely, shut off
oughly flushed to remove all dirt. the cooler should be removed from the engine and disconnect both
When filling a dry transmissioQ the system by flushing the cooler cooler lines from the transmission
and converter, install 6 quarts of and lines before the transmission is and cooler.
fluid. Start the engine, shift the se- put back into service. In ·no case 8. Use an air hose with not more
lector lever as in Step 5 below, and should an automatic transmission than I 00 psi air pressure to reverse
check and add fluid as necessary. having a clutch or band failure or flush the cooler lines and the cooler.
other internal trouble resulting in After reverse flushing, connect both
Following is the procedure for
fluid contamination, be put back into lines at the cooler and the cooler
partial drain and refill due to minor service without first flushing the inlet line (converter out) to the
repairs. transmis~ion oil cooler. transmission.
1. Place a drain pan under the 1. After installing a new or re- 9. Start the engine and check
transmission. Loosen and remove built automatic transmission and the fluid flow . If the transmission
7-24 GROUP 7- AUTOMATIC TRANSMISSION
fluid flows freely, proceed with steps CONSOLE SHIFT 13. Install the gear lever slide and
3 through 5 If there is no fluid flow, Selector Lever Removal and Re- dial assembly on the console. Attach
check for pinched cooler lines. If placement. the indicator light.
the flow is restricted, replace cooler 1. Raise the vehicle and remove 14. Refit the console ensuring that
lines and/or the radiator. the manual lever control rod (Fig. 23). the dial locating peg is correctly
10. Shut off the engine, and con- located in the bracket on the selector
nect the cooler return line to the
2. Lower the vehicle, remove the
selector lever handle attaching screw lever housing.
transmission. Check the transmission and remove the handle (Fig. 2~).
fluid level as indicated under head- 15. Install the selector lever handle
ing Transmission Fluid Level Check. 3. Remove the two console attach- and tighten the attaching screw.
Refer to Part 7- 1, Page 7-11. ing screws at the front of the console 16. Position the selector lever in
Add or remove transmission fluid as and the four screws in the glovebox the "N" position.
required until the proper fluid level and remove the console and gear lever 17. Raise the vehicle. Install the
is obtained on the dipstick. DO NOT slide assembly. transmission manual lever rod. With
OVERFILL THE TRANSMIS- the transmission in neutral and the
4. Detach the dial indicator light. selector lever against the neutral stop
SION.
11. Do not attempt to correct 5. The gear lever slide assembly, tighten the selector lever to manual
cooler or cooler line leaks by closing which incorporates the dial, may be lever rod nut.
off the lines. detached from the console by remov- 18. Lower the vehicle and check
ing the four attaching screws. the transmission operation in each
OIL COOLER TUBE 6. Remove the selector housing selector lever detent position.
REPLACEMENT and lever assembly attaching bolts
When fluid leakage is found at and remove the selector lever and
the oil cooler, the entire radiator housing.
must be replaced. The oil cooler 7. Remove the selector lever to
cannot be removed from the radla· housing attaching nut. Remove the
tor for replacement. lever from the housing.
When one or more of the fluid 8. Install the selector lever in the
cooler steel tubes must be replaced, housing and install the attaching nut.
each replacement tube must be fabri- Torque the nut to 20 to 25 ft. lbs.
cated from the same size steel tubing 9. Install the selector lever handle.
as the original line. 10. Position the selector as shown
Using the old tube as a guide, in Fig. 22. With a feeler gauge check
bend the new tube as required . Add the clearance between the detent
the necessary fittings, and install the pawl and plate. The clearance should
tube. be 0.005 to 0.010 inches. If neces-
Mter the fittings have been sary adjust the height of the detent
tightened, add fluid as needed and pawl as shown in Fig. 22.
check for fluid leaks. (Replacement 11. Remove the handle from the
tubing must be new and clean). selector lever.
12. Install the selector lever hous-
GEAR SHIFT LINKAGE ing and lever assembly as shown in
COLUMN SHIFT Fig. 23. Torque the attaching screws
See Group 3, Page 3-.37. to 4-6 lbs. it.

FIG. 22- Selector Level Detent Pawl Adjustment

PART 7-1 AUTOMATIC TRANSMISSION (Borg-Warner) 7-25

SEC 8

FIG. 23 -Selector Change Linkage- Floor Shift

EJ CLEANING AND INSPECTION

CLEANING
TRANSMISSION
Clean aH parts with suitable sol-
vent and use moisture-free air to dry
off all parts and clean out the various
fluid passages.
The composidon dutch plates
and bands should not be cleaned in
a vapor degreaser or with any type
of detergent soludon. To clean
these p811s, wipe them oft' with a
lint-free cloth. New clutch plates
and bands should be soaked in trans-
mission fluid for fifteen minutes be-
fore they are assembled.
If there is reason to believe that
the converter has an excessive
amount of foreign material in it, a
service replacement unit should be
installed.

FIG. 24 - Inhibitor Switch

7-26 GROUP 7- AUTOMATIC TRANSMISSION

IJ REMOVAL AND INSTALLATION

REMOVAL 4. Lower the transmission and in-
move the starter attaching bolts and stall the extension housing and cross
1. Raise the car and remove the remove the starter from the con- member attaching bolts. Torque the
two converter cover attaching bolts verter housing. bolts to specification.
at the lower front side of the con- 12. Remove the converter-to-
verter housing. Remove the cover. flywheel attaching bolts. 5. Install the four flywheel-to-con-
2. Remove the drive shaft and 13. Position the transmission jack verter attaching nuts. Torque the
install the extension housing seal re- to support the transmission and nuts to specification.
placer tool in the extension housing. secure the transmission to the jack 6. Remove the transmission jack.
3. Disconnect the downshift cable with a safety chain. 7. Install the transmission fluid
from the bell crank assembly. 14. Remove the crossmember and filler tube. Connect the fluid cooling
4. Remove the two extension mounting pad attaching bolts and lines to the transmission case.
housing to crossmember bolts. lower the crossmember. 8. Connect the neutral start
5. Disconnect the speedometer 15. Remove the converter hous- switch wires to their respective
cable from the extension housing. ing-to-engine attaching bolts. Low- connectors.
6. Remove the parking brake cable er the transmission and converter 9. Connect the linkage rod to the
from the equalizer lever. assembly and remove it from under transmission manual control lever.
7. Remove the drain plug from the car. 10. Connect the speedometer cable
the transmission sump and drain INSTALLATION to the extension housing.
the fluid. This will not drain the . 11. Install and adjust the parking
converter and therefore care should 1. With the converter properly brake cable at the equalizer lever.
be taken when removing the con- installed, place the transmission on
verter from the transmission since the jack. Secure the transmission to 12. Install the converter housing
fluid will spill from the converter. the jack with the safety chain. cover and torque the attaching bolts
Replace the drain plug. 2. Raise the transmission into to specification.
8. Disconnect the fluid cooler position and install the converter 13. Install the starter and torque
lines from the transmission case. Re- housing-to-engine attaching bolts. the bolts to specification. Connect
move the filler tube from the case. Torque the bolts to specification. the starter cable.
9. Remove the manual linkage Remove the safety chain from the 14. Install the drive shaft. Torque
rod from the transmission control transmission. the companion flange U-bolt nuts
lever. 3. Position the crossmember and to specification.
10. Disconnect the neutral ~tart mounting pad into position and in- 15. Lower the car and fill the
switch wires. stall the attaching bolts. Torque the transmission with fluid. Adjust the
11. Remove the starter cable. Re- bolts to specifications. manual and kickdown linkage.

D MAJOR REPAIR OPERATIONS

TO REMOVE THE VALVE situated to the rear of the filter, is secured by four short screws,
BODIES ASSEMBLY. securing the valve bodies assembly spring washers and flat washers.
(Fig. 25). Draw the valve bodies 3. Remove the three screws
1. Jack up the car and fit stands. securing the primary and second-
2. Remove the transmission assembly down evenly to avoid
distorting the three pipes between ary regulator valves retainer plate
drain plug to drain the transmis- and remove the retainer plate. Care
sion fluid, bearing in mi.nd that the valve bodies and the front
pump. should be taken when removing
the fluid will be extremely hot if the three screws since the two
the transmission has just been used. TO DISMANTLE THE VALVE regulator valve springs are retained
3. To remove the sump and gas- BODIES. by the plate. With the plate re-
ket. unscrew the 15 bolts and lock- To facilitate fittin~ valves, etc. moved withdraw the primary regu-
washers around the sump flange. it is advisable to dismantle the lator valve spring, sleeve and
4. Remove the four fluid trans- assembly on a clean steel bench valve. Remove the secondary re-
fer pipes. which are pushed into covered with clean white paper. gulator valve spring and valve
the valve bodies assembly and the Also. lay out the parts as they are (Fig. 26).
body of the servos (Fig. 25) and removed, in order. 4. To separate the upper and
are held in position by the sump. 1. Withdraw the manual control lower valve bodies remove the six
To remove these pipes use a screw- valve. Unscrew two bolts secur- cheese-head screws (one long and
driver with a protected blade, to ing the downshift cam bracket to five short) from the lower valve
ensure that the pipe is not damaged, the valve body and remove the body and the two cheese-head
and prise the pipes out. bracket and downshift cam assem- screws from the upper valve body.
5. Remove the valve bodies as- bly. When the downshift cam 5. The upper valve body (Fig. 27)
sembly. Disconnect the cable from and throttle valve stop have been has two end plates, each secured by
the downshift cam and remove removed the downshift and throttle three cheese-headed screws. Re-
three bolts, two longer bolts pass- valves with their springs may be move . these retainer plates fol-
ing through the rear of valve bodies withdrawn (Fig. 26). lowed by the 2-3 valve, spring,
assembly and the shorter bolt 2. Remove the filter. The filter plunger and 1-2 valve from the
PART 7-1 AUTOMATIC TRANSMISSION (Borg-Warner) 7-27
rear of the body. From the front
of the body withdraw the 1-2 valve
spring and plunger.
6. Remove the oil tube collector
by unscrewing the eight cheese-
head screws. Keeping the separ-
ator plate uppermost, remove two
screws situated in the rear filter
body and remove the governor line
plate. The separator plate can
now be removed, carefully, reveal-
ing the 3-2 dump valve pump, check
valve and downshift valve keep plate
in the lower valve body (Fig. 26).
Remove these items.
7. The servo orifice control valve
is retained by a keep plate and the
modulator valve by a small dowel
pin. Remove the keep plate and
dowel pin then remove both valves
and springs (see Fig. 27).
8. Remove the keep plate from
the range control valve body. Re-
move the retaining plug and range
control valve (Fig. 26).
To avoid confusiOn each com-
ponent of the valve bodies assem-
bly should be washed separately
in clean industrial solvent, carefully FIG. 25 - Transfer Pipes
inspected and replaced in the order
in which they were removed. Be-
fore installing parts they should be LOWER VALVE B \
lubricated with automatic trans-
mission fluid .
REASSEMBLING THE VALVE Q.-.OUMP VALVE ,BALL

BODIES
1. Refit the modulator valve spring,
valve plunger, valve and plug.
Secure the plug with the dowel.
Refit the servo orifice control valve
and spring, locating the spring
inside the counterbore in the end
of the valve and retain with the
keep plate (Fig. 27).
2. Referring to Fig. 27 reposition
the downshift valve keep plate, SERVO ORIF-ICE -
3-2 dump valve spring and ball, and CONTROL VALVE
KEEP PLATE
disc type valve.
3. Carefully reposition the sep-
arator plate on top of the lower
valve body, making sure that the SERVO OR IF\ CE CONTROL VALVE
check valve is not displaced and
particularly that the 3-2 dump valve
ball is centrally located in the
separator plate hole. Reposition the MANUAL CONTROL
governor line plate and secure with. VALVE
two screws from beneath in the
rear of the valve bodies assembly.
Before tightening these screws to
20 to 30 in. lbs., make sure that the
I
~~'"'"""'
dump valve is positioned correctly.
4. Fit the regulator valves (Fig.
26). Fit the primary regulator valve,
sleeve and spring in the lower
valve body. Then, replace second-
ary regulator valve, followed by its FIG. 26- Exploded View of Lower Valve Body and Valves
7-28 GROUP 7-AUTOMATIC TRANSMISSION

1ST-2ND SHIFT VALVE J...

lND-JRD PLUNGER

UPPER VALVE BODY

FIG. 27- Exploded View of Upper Valve

Body and Valves

·. ~
. / ~

FIG. 28- Exploded View of G.T.A. Control

Valve and Body
PART 7-1 AUTOMATIC TRANSMISSION (Borg-Warner) 7-29

spring. Fit the retainer plate and pass through the rear of the valve TO DISMANTI..E
secure with three screws. bodies assembly and the shor!l.:r TRANSMISSION
5. Fit the 1-2, 2-3 valves (Fig. bolt is positioned centrally just to 1. Remove the convertor from
28). Reposition the 1-2 spring, the rear of the filter (Fig. 26). the convertor housing, taking care
plunger and valve in the upper 3. Reconnect the downshift valve to ensure that the pumo driving
valve body. Also, refit the 2-3 cable to the cam and check its lugs are not damaged. Note: The
plunger, 'spring and valve in adjustment, torque convertor is still filled with
the upper valve body. These fluid and therefore precautions
4. Fit the fluid transfer pipes should be taken to avoid spillage.
valves, springs and plungers are (Fig. 30). These pipes are a push
of different diameter and cannot fit and are held in position by the 2. Remove the six bolts and
be confused. Refit and secure sump, when fitted. Each tube is spring washers securing the con-
the retainer plates using three different in length and shape, and vertor housing to the transmission
screws and spring washers for each. is shaped in such a way that it case and remove the convertor
Torque to 20 to 30 in. lbs. Here, cannot be refitted incorrectly. housing.
again, the retainer plates arc dis-
similar and cannot be confused. 5. The front band should be 3. To remove the sump unscrew
adjusted as previously described. the fifteen bolts and spring washers
Fit the range control valve and around the sumo flange and remove
retaining plug to the range control 6. Refit the sump. Ensure that the sump together with its gasket.
body then fit the keep plate (Fig. 26). the lower face of the transmission Remove the fovr fluid transfer pipes
6. Reposition the upper valve body and the sump flange are perfectly (Fig. 25), by prising out with the
and the range control valve body on clean. Fit a new gasket and re- protected blade of a screwdriver.
the separator plate and secure with place the sump. Secure with fif-
eight screws, tightening them to a 4. Withdraw the valve bodies
teen bolts and spring washers, assemblv. Disconnect the down-
torque of 20 to 30 in. lbs. (Fig. 30). tightening them evenly to a torque
7. Replace the manual control shift valve cable from the cam.
of 8 to 10 ft. lbs. Remove the two rear bolts hold-
valve, downshift and throttle valves
(Fig. 26). The downshift and throttle 7. Check the rear band adjust- ing rear end of valve bodies as-
valve spring is interposed between ment. sembly and the bolt just to the rear
the two valves, locating in the of the pump filter (Fig. 25) to remove
counter bore in the end of the down- the valve bodies assembly, taking
shift valve. care to draw this off evenly to
8. Reposition the downshift cam avoid damage to the pump tubes.
and bracket with the cam in contact s; Withdraw the four oil tubes
with the downshift valve and secure from the pump adaotor. It will
with two bolts. Tighten to 20 or be seen that the outside pair are of
30 in. lbs. unequal diameter and therefore
9. Refit the oil tube collector and cannot be fitted incorrectly. The
secure with eight screws. Tighten FIG. 29 - Tightening inner pair are the same diameter,
the screws to a torque of 20 to
30 in. lbs.
Valve Body Screws the short straight one will pull out.
The long bent one may require the
10. Refit the oil strainer ensuring
8. Refill the transmission. Do not adaptor on the outside of the trans-
that it is fiat to -h in. concave and is
add the quantity of oil required to mission case being loosened or re-
free from kinks.
completely fill an empty transmis- moved before this tube can be
TO REFIT THE VALVE sion, since when the drain plug was removed.
BODIES ASSEMBLY removed, the fluid from the conver- 6. Remove the four bolts and
1. If removed, replace the oil ter was not drained. Check the level spring washers securing the exten-
pick-up tubes in the pump housing when the gearbox is at normal sion housing to the transmission
(Fig. 30). The inner pair of tubes operating temperature.
and carefully withdraw the exten-
are smaller in diameter than the sion housing rearward .
other two. One is a short straight
tube, the other is bent into several 7. The speedometer driving gear
planes with one end in the pump is retained in one direction by a
housing and the other in the trans- circlip and driven and retained in
mission case. The outer tubes are the other direction by a ball. Ex-
of different diameters and lengths pand the circlip and remove. Re-
and cannot be confused or incor- move the speedometer driving gear
rectly fitted . and ball.
2. Position the valve bodies as- 8. Before removing the governor
sembly, engaging the oil tubes in it should be noted that the small
the oil tube collector and making rectangular plate secured by two
sure the manual control valve is countersunk screws should face
engaged with the peg on the oper- rearwards . The drive for the gov-
ating lever. Secure the assembly ernor is transmitted through a ball
with three bolts, washers and spring FIG. 30- Location of Oil and, having removed the circlio
washers. The two longer bolts Tubes and drawn the governor rearwards,
GROUP 7- AUTOMATIC TRANSMISSION

care should be taken not to lose the 11. Check gear train end float. side of the case in line with the
ball. Using a screwdriver between the centre support and positioned 1200
transmission case and the front of either side of the rear servo front
the front clutch, lever the front securing screw. Mark the centre
clutch assembly as far rearwards support in relation to the case, and
as possible to take up any end if necessary, tap the end of the out-
float. Set up an indicator dial put shaft with a hide mallet. This
gauge as shown (Fig. 31) and set will drive the centre support for-
gauge to zero. Make sure the ward so that it can be removed.
front clutch is as far rearwards as 16. Withdraw the planet gear as-
possible then lever the front clutch sembly. A steel washer and needle
assembly forward, read the gauge thrust washer is positioned between
to determine the end float and the planet gear assembly and the
record. output shaft.

If this is not between .010-.030

inches the front thrust washer
FIG. 31 -Checking Gear mtJst be replaced with one of a
different thickness on reassembly,
Train End-Float see specifications for thrust washer
9. The rear adaptor is retained dimensions.
by five bolts and spring washers
around the casing. Remove these
and carefully withdraw the adaptor
body and plate. This will reveal
three sealing rings around the out- 12. Withdraw the pump assem-
put shaft. T hese three rings are bly, gasket and thrust washer a~ter
cast iron and should be treated removing the six bolts and spnng
carefully during removal to prevent washers around the pump. FIG. 33 - Removing Rear
damage. Clutch and Sun Gears

17. Disengage the rear band

10. The two servos are each from the stop and remove.
sec ured by two bolts and spring 13. Withdraw the input shaft 18. Extract the one-way clutch
washers an d removal of these bolts and front clutch assembly (Fig. 32).
from the outer race and then re-
will enable the servos to be with- Two thrust washers are positioned move the outer race which is
drawn. When removing the servos between the front and rear clutches, secured by a circlip in the planet
ensu re tha t the two operating struts, the phosphor bronze washer bear-
which transmit movement from the ing against the ground rear face of gear assembly (Fig. 44).
se rvos to the bands, do not fall the front clutch, and the steel 19. Withdraw the output shaft
out, otherwise they may be lost or wasner, which has two flats on the and thrust washer. If necessary,
damaged. internal diameter, locating on the separate the output shaft from
rear clutch projection. the ring gear by removing the cir-
clip which retains them together.
20. Unscrew the inhibitor switch
screws and remove the inhibitor
switch. Unscrew the downshift valve
14. Withdraw the rear clutch and cable retainer and remove the cable.
sun gears (Fig. 33). The needle Drive out the tension pin securing the
thrust race and washer are posi- manual valve operating lever to the
tioned on the rear of the front sun cross-shaft and draw to one side.
gear shaft and sliould be removed. Care should be taken not to lose the
Disengage the front band from the detent ball and spring when remov-
stop in the case, tilt slightly and ing this lever. . .
remove. 21. Drive out the tension pm
securing the cross-shaft locating
collar. The cross-shaft may now be
r withdrawn by tapping the end to
which the manual linkage was pre-
FIG. 32 - Removing Front IS. Remove the centre support. viously attached. This will enable the
Clutch and Input Shaft Unscrew the two centre support spring, inhibitor switch link, parking
Assembly securing screws and lockwashers. pawl linkage, collar and welsh plug
These screws are around the out- to be removed.
PART 7-1 AUTOMATIC TRANSMISSION (Borg-Warner) 7-31

22. Withdraw the parking pawl ing and driven gears in the pump piston and also the seal from the
actuating mechanism (Fig. 34) after body, noting the marks made when piston guide in the clutch cylinder.
removing the spring clip and dismantling, see above, and lightly
washer. Careful note should be lubricate with transmission fluid. To Reassemble (Fig. 37)
made of the manner in which the Fit a new sealing ring around the Thoroughly clean and inspect
spring is fitted before removal since periphery of the pump body. all parts and lubricate with trans-
when removed the assembly will Position the pump body on the mission fluid prior to assembly.
disengage. pump adaptor, lining up the hole
23. From m•tside the case drive in the pump body segment with the Replace the rubber seals around
out the tension pin retaining one corresponding hole in the pump the periphery of the piston and the
parking pawl pivot pin and drive adaptor. Secure the pump body to piston guide. Refit the piston, us-
out the pivot pin from inside the the pump adaptor with five bolts, ing Tool No. B.W. 42 (Fig. 36) en-
case. The second pivot pin is not and lockwashers and one cheese- suring that the steel pressure ring
secured but is retained by a lug on head screw and lockwasher. on the outer face of the piston is
the extension housing. If the case correctly seated. Reposition the
is upended and gently tapped this FRONT CLUTCH AND INPUT spring with the fingers resting on
pin will fall out and the parking SHAFT ASSEMBLY the steel pressure ring of the piston
pawl can be removed. and secure with the large circlip.
To Dismantle: Refit the thick externally splined
With the aid of a screwdriver pressure plate, with the plain face
remove the circlip retaining the in- outwards and alternatively inter-
put shaft to the clutch cylinder. nally and externally splined clutch
Then withdraw the input shaft and plate, ending with the internally
thrust washer. Remove the clutch splined plate. The front clutch
plates, noting their positions. An externally toothed plates are flat,
internally toothed plate should be whereas those for the rear clutch
the first plate viewed when the in- are slightly dished. Replace the
put shaft is removed and the thick central hub and thrust washer.
externally splined pressure plate Reposition the input shaft and se-
the last, the plates alternating. Re- cure with a large circlip.
move the clutch inner hub which
will reveal a further large circlip REAR CLUTCH AND FORWARD
retaining the diaphragm spring and SUN GEAR ASSEMBLY
piston. Remove this circlip and
FIG. 34- Manual Valve spring. To remove the piston, it is To Dismantle:
Lever neces~ary to blank off one end of Carefully remove the three scal-
the clutch cylinder piston guide ing rings, two from the front end
14. Remove the locknut from the and apply air pressure, via a suit-
rear band adjuster and screw the and one from the rear end of the
able adaptor. at the other end of forward sun gear shaft. Withdraw
adjuster screw into the case to re-
the guide. The outer face of the the forward sun gear shaft from
move iL
pistl'n has a steel ring. pressed into the rear clutch assembly. Re-
THE SUB-ASSEMBLIES it. Remove the rubber sealing move the large circlip retaining the
FRONT PUMP ring from the outer periphery of the clutch plates, with the aid of a
TO DISMANTLE: screwdriver. Remove the thick
Remove the five bolts, one externally splined spacer plate and
cheese-head screw and spring the alternative internally and ex-
washer to separate the pump body ternally splined plates. Locate the
from the pump adaptor. Mark clutch spring compressor on the
both inner and outer gears to en- clutch spring retaining plate so that
sure that when reassembled to gear the ends of the circlip are opposite
faces are replaced in the same posi- the latge "window" in the tool
tion as removed . Remove both (Fig. 38). Place the assembly in a
gears. Remove the sealing ring press and press down onto the tool
from around the periphery of the to compress the spring. Using cir-
pump body (Fig. 36). Carefully clip pliers, remove the circlip and
clean and inspect each part for release the press until the spring is
signs of wear, paying particular fully released and then remove
attention to the whitt: metal bear- from the press. Remove the spring
ings in the pump body, adaptor and and spring seat. To remove the
driving gear. If necessary, remove piston, apply air pressure to the
the seal from the pump body.
hole in the groove next to the seal-
TO REASSEMBLE: ing ring closest to the front drum.
If removed, replace the seal in FIG. 35 - RefiHing Front Remove the rubber sealing rings
the pump body. Replace the driv- Clutch Piston from around the periphery of the
7-32 GROUP 7- AUTOMATIC TRANSMISSION

TORQUE CONVERTER
SUPPORT

(?)OUTLET

SEALING RING

FIG. 36- Pump

piston and piston guide . Carefully bly, so sandwiching the thrust race
remove the three sealing rings from between the rear face of the re-
the reverse sun gear shaft. verse sun gear and the front face
of the forward sun gear. Replace
To Reassemble: the three sealing rings in the ap-
Thoroughly clean and inspect all propriate grooves. Replace the
parts, paying particular attention needle thrust race on the rear of
to the needle race which supports the forward sun gear shaft. Fit
the forward sun gear shaft. Re- the steel washer to the shaft, after
place the rubber seals around the the thrust race, with the lip towards
periphery of the piston and piston the rear.
guide. Position the piston, using
Tool No. B.W. 41 (Fig. 39), spring
and spring seat, fit the clutch spring
compressor tool and, using a press,
compress the spring until the cir-
CIRCLIP
s:::: : ~

~ ~~
~ : ;I
~
~· 1
r!: CLUTCH
.
SPRING
COMPRE SS OR
TOOL
clip groove on the piston guide is "-!_../ NO. BW. l7A
uncovered . Refit the circlip, en-
suring that it is seated correctly in
the groove. Release the press and FIG. 37- Refitting Front
remove the clutch spring compres- Clutch Plates
sor. Rerlace the clutch plates, either towards or away from the
externall y splined plate first. and piston, but they must all face the
then alternating internally and ex- same way. Secure the clutch
ternally splined plates, ending with plates with the large circlip. Slide
the thick externally splincd spacer one .needle thrust race onto the
plate (Fig. 40). Note that the outer forward end of the forward sun
splined plates for the rear clutch gear shaft and seat on the front
are dished, whereas the front clutch face of the forward sun gear. Pass
plates are flat. These dished plates the' forward sun gear shaft through FIG. 38 - Dismantling
can be fitted so that the dishing is the centre of the rear clutch assem- Rear Clutch
PART 7-1 AUTOMATIC TRANSMISSION (Borg-Warner) 7-33

FRONT SERVO ton first, into the housing. Retain

with the circlip after depressing the
To Dismantle: piston guide to overcome spring
pressure.
Depress the servo pis~on and
pistoh guide assembly, to over- REAR SERVO
come spring pressure, and remove
the circlip which retains these To Dismantle:
parts (Fig. 41). The piston spring To withdraw the servo piston it
will then push the piston and its is unnecessary to remove the oper-
guide from the servo housing. With- ating lever, the pivot of which is
draw the piston from the guide and secured in the housing. Depress
extract the spring. Remove the the straight arm of the spring and
square section sealin~ ring from ~he disengage from the lug cast in the
guide and the two c1rcular sectiOn side of the servo body. Remove the
sealing rings from the piston. !'.pring, withdraw the piston (see
To remove the operating lever (Fig. 42).
from the housing it is necessary to
withdraw the lever's pivot which To Reassemble:
may be retained by a pin in the If removed, fit the sealing ring
servo housing. This pin can ~e to the piston. Hold the operating
tapped out with the aid of an i m. lever away from the piston bore FIG. 40 - Fitting Rear
diameter drift. and insert the piston spigot into the Clutch Plates
conical seat of the operating lever.
To Reassemble: It is then possible to manoeuvre the TO REASSEMBLE THE
If the operating lever has been piston into the housing (Fig. 38). Fit TRANSMISSION
removed from the servo housing it the spring to pivot pin engaging the
should be refitted so that the ad- bent arm with the servo lever and 1. Refit the rear band adjuster
depress the straight spring arm and by screwing into the case from the
justing screw will pass thro~gh th.e
engage with the lug on the servo inside and fit the locknut to the
hole in the end of the housmg. F1t
body. thread on the outside of the case.
the pivot through the housing and
Reposition the parking pawl
operating lever, ensuring that !he GOVERNOR
retaining pin holes in the housmg mechanism in the box and replace
To Dismantle: the two pivot pins. The stepped
and pivot are in line. Fit the re-
taining pin . To separate the two parts of the pivot should be tapped right home
governor body remove the two and a new tension pin fitted to the
Fit the two circular section seal- cheese-headed screws, together case to prevent this pivot coming
ing rings to the piston and the with their spring washers. The out.
square section scaling ring to the governor valve and spring can be
piston guide . Insert the piston into 2. The parking pawl and inhibitor
removed from the governor' weight switch actuating mechanism should
the guid~ so that the nanges of the in one part of the body by re~ov­
piston and guide ab~t. . Place t~e be repositioned, in the manner re-
ing the governor spnng retamer moved, on the pivot in the case (see
piston retracting sprmg m the P!S- which pa~tially encircles the gov- Fig. 34). To assist, the spring should
ton and insert the assembly, p1s- ernor weight stem (Fig. 43). If neces- not be attached at one end until the
sary, remove the cover plate whiclt complete unit is assembled and se-
is retained by two screws to that cured with the washer and spring clip.
part of the body which accom-
Then, the free end can be posi-
modates the governor weight.
tioned to tension the spring. Before
continuing with the assembly check
the working of the parking pawl
by manual operation.
To Reassemble:
If the cover plate has been re- 3. Replace the seal in the cross-
moved, refit and retain with the two shaft boss in the case. Carefully
screws. Pass the stem of the gov- slide the cross-shaft into the case
ernor weight through the body from the side opposite to the inhi-
from the top, slide the valve, smal- bitor switch and position on the
ler diameter first, over the govern- shaft the collar, parking pawl
or weights stem, followed by the actuating mechanism and bias
spring and sec~re with the . re- spring, in that order (Fig. 34). Pass
tainer, dished s1de to the sprmg. the shaft through into the opposite
After cleaning the mating faces, boss in the case and locate in the
secure the two parts of the g:. ;ernor correct position with the collar and
FIG. 39 - Fitting Rear body together with the two cheese- tension pin. Position the spring
Clutch Piston headed screws and spring washers. and ball and compress with a piece
7-34 GROUP 7-AUTOMATIC TRANSMISSION

PISTON GU IDE PISTON RETRACTING ADJUSTING SCREW

SPRING

APPLY PORT ST RUT LOCATING

GROO VE OPERATING LEVER

FIG. 41 -Exploded View of Front Servo

-
1 '
Rotate the piston about
the cup in the lever to
Secure with the large circlip (Fig.
46). Fit the one way clutch to the
outer race with the lips to the out-
4 remove or replace
side. (See Fig. 46). Turning the
cage whilst presSmg inwards will
assist in fitting the one way clutch.
Then, fit the centre support to the
assembly, so that the centre bou
is inside the one way clutch. Place

ON E WAY
CLUTCH
OUTER RACE

FIG. 42 - FiHing Rear

FIG. 44 - Fitting the One
Servo Piston
Way Clutch
of tube, at the same time sliding the · ~ VALVE ~embly and centre support, engag-
manual valve detent arc over the
ball. When in position line up the ~ GOVERNOR
mg the planet gears with the ring ·
hole in the cross-shaft with the hole ~ - SPRING gear. Ali~n the marks, made when
in the cam boss and secure with a ...,...__(0SPRING di_smantling. on the centre support
tension pin. Connect the parking
GOVERNOR
PRESSURE
RETAINER w1th the marks on the case and
pawl operating link to the actuating
OUTLET
gently tap the centre support into
mechanism and secure with the position. Ensure that the holes in
washer and spring clip. the centre support are in line with
the case holes and fit the two ex-
4. Before fitting the output shaft, ternal securing bolts and lock-
position the rear thrust washer on washers. These lockwashers are
the inside rear face of the case, FIG. 43 - Governor also oil seals, and must, therefore
retaining in position, if necessary, be fitted with the rim facing th~
with petroleum jelly. The three
Exploded
transmission case.
lugs on this thrust washer will con- the steel washer onto the rear of
tact protrusions in the case casting the planet gear assembly with the 8. Reposition the forward band
to prevent the thrust washer from lip rearwards, and then fit a needle in the case, engaging the end of the
turning. thrust race after the steel washer. band with the fixed stop on the
6. Position the rear band in the centre web of the case.
S. Fit the one way clutch outer
race to the planet gear carrier, en- case, engaging the end of the band
with the adjuster. 9. Assemble the rear clutch to
gaging the Jugs on the outer race the front clutch. Centralise the
with the driving lugs on the carrier. 7. Offer up the1 planet gear as- thrust washer in the centre of the
PART 7-1 AUTOMATIC TRANSMISSION (Borg-Warner) 7-35

front clutch. Make sure the seal- the end-float. If this figure is not at one end to locate the centre sup-
ing rings on the sun gear part of between 0.010 in . and 0 .030 in., port (Fig. 47).
the rear clutch are correctly located remove the front pump and r!place 19. Replace the valve bodies
and, if of the hook type, locked. the thrust washer. using ~ne of assembly ~s pr,eviously described.
Fit the steel thrust washer to the a different thickness, see specifica- 20. AdJUSt the servos as previ-
fro~t of the rear clutch engaging tions. ously described.
the mternal flats on the washer with REAR ADAPTOR (Single Range)
the corresponding flats on the rear 13. Reposition the rea: adaptor
clutch . Fit the phosphor bronze plate. 21. Replace the sump. Fit a
thrust washer alongside the steel new gasket to the sump flange and
thrust washer. Align the splines 14. Fit the rear adaptor body
Car~fully refit the adaptor body
replace the sump. Tighten the
of the front clutch plates and care- bolts evenly to 8 to I 0 ft. lbs
fully assemble the rear clutch to makmg sur~ the sealing rincs are
no_t damaged. Align the bolt~holes. t?rque. Replace the drain plug and
the front clutch. ttghten to a torque of l 0 to 14 ft.
usmg the small hole as a register,
10. Fit the front and rear and secure with the five bolts and lbs.
clutches. Check that the needle lockwashers.
thrust race is fttted to the rear of
15. Refit the governor (Fig. 46). 22. Refit the inhibitor switch, en-
the forward sun gear shaft and the
Turn the output shaft until the suring the flats on the shaft mate
sealing rings are correctly seated.
Offer up the front and rear clutch governor driving ball hole is upper- correctly. Secure with two screws
most and position the ball. Then. and lock washers.
assemblies (Fig. 45), passing through
the. ~ront band. When correctly slid_e on the governor assembly en-
posttJOncd rotate the input shaft sunng that the governor cover
plate secured by two screws is fac- 23. Refit convertor housing to
to ensure that the asscmblv will transmission case.
turn freelv . · ing rearwards. Fit the governor
retaining circlip using circlip pliers.
11. Fit the pump. Position the
thrust washer on the rear face of the 16. Replace the speedometer
pump. If incorrect end float was driving gear. Position the drive
noted when dismantling, replace ball in the output shaft and fit the
wtth the appropriate thrust washer speedometer driving gear. Secure
to allow specified end float. with the circlip.
17. Clean the rear face of the
transmission and place a new gas-
ket in position. Refit the extension
housing and secure with the four
bolts and lockwashers.
18. Refit the front and rear
servos. Stick the operating strut
to the servo operating arm by
means of petroleum jelly and offer
the servo assembly into position
engaging the strut with the sho~
band. The two bolts for the front
s~:rvo are of equal length. but the
FIG. 47 - Replacing the Rear
forward bolt for the rear servo is Servo
longer and has a reduced diameter
FIG. 45 - Fitting Front
24. Fit the torque convertor to
and Rear Clutches the transmission.
See specifications. Using a new Note: If the torque converter is
gasket, replace the pump and se- fitted at this stage there is Jess dan-
cure with six bolts and Jockwashers. ger of damaging the pump oil seal.
12. Check the gear train end- Align the pump drive tangs with
float. Using a screwdriver between the slots in the inner gear and
the case and the front of the front carefully replace the torque con-
clutch, push the front clutch as verter taking care not to damage
far rearwards as possible to take up the oil seal
any end-float. Set up a dial indi-
cator gauge as shown in Fig. 31 If the transmission is to be held in
and set the gauge to zero. Make stock fit a transit strap across the
sure the front clutch is as far rear- converter housing to prevent the
wards as possible and then lever the torque converter from being acci-
front clutch assembly forward. FIG. 46 - RefiHing the dentally removed, and to prevent oil
reading the gauge to determine Governor seal or drive damage.
REFERENCE TO SERVICE INFORMATION AND NOTES

Date Letter No. Pace Brief Detail

-
7-37

PART
C4 AUTOMATIC TRANSMISSION
7-2

DIAGNOSIS AND TESTING

When diagnosing transmission 6. Pull the dipstick out of the The cooler can be further checked
problems, first refer to the diagnosis tube again, and check the fluid level. for leaks by disconnecting the lines
guide for detailed information on If necessary, add enough fluid to at the cooler fittings and applying
the items that could be causing the the transmission through the filler 5 psi air pressure to the fittings. The
problem. The following preliminary tube to raise the fluid level to the radiator cap must be removed when
checks should be made in the order F (full) mark on the dipstick. Do making this check to relieve the
given: not overfill the traasmission. pres~re on the exterior side of the
1. Check the fluid level. Check cooler. If the cooler is leaking and
the fluid for a burnt clutch plate FLUID AERATION CHECK will not hold this pressure, the
odor. radiator must be replaced. The
1. Check the engine idle speed A fluid level that is too high will cooler cannot be replaced separately.
and dashpot adjustments. cause the fluid to become aerated. If leakage is found at either the
3. Check the manual linkage Aerated fluid will cause low control throttle lever shaft or the manual
adjustment. pressure, and the aerated fluid may lever shaft, replace either or both
4. Check the accelerator pedal be forced out the vent. seals.
height and downshift linkage. Check the transmission fluid level. Inspect the pipe plug in the case.
S. Check the throttle linkage to Low fluid level can affect the opera- If the plug shows leakage, torque
assure wide open throttle operation. tion of the transmission, and may the plug to specification. If tighten-
6. Check the engine for proper indicate fluid leaks that could cause ing does not stop the leaks, replace
operation. transmission damage. the plug.
When converter drain plugs leak,
TRANSMISSION FLUID TRANSMISSION FLUID remove the two drain plugs with a
LEVEL CHECK LEAKAGE CHECKS six-point wrench. Coat the threads
1. Make sure that the vehicle is Check the speedometer cable con- with a sealing compound, and in-
standing level. Then firmly apply nection at the transmission. Leak- stall the plugs. Torque the drain
the parking brake. age at the oil pan gasket often can plugs to specification. Fluid leakage
2. Run the engine at normal idle be stopped by tightening the attach- from the converter housing may be
speed. If the transmission fluid is ing bolts to the proper torque. If caused by engine oil leaking past
cold, run the engine at fast idle necessary, replace the gasket. Check the rear main bearing or from oil
speed (about 1200 rpm) until the the fluid filler tube connection at gallery plugs. Be sure to determine
ftuid reaches its normal operating the transmission. If the filler tube the exact cause of the leak.
temperature. When the ftuid is 0-ring seal is leaking, replace the
warm, slow the engine down to seal. Oil-soluble aniline or fluorescent
normal idle speed. The transmission fluid is water dyes premixed at the ratio of l
3. Shift the selector lever through cooled; check the fluid lines and fit- teaspoon of dye powder to t pint
all positions, and place the lever at tings between the transmission and of transmission fluid have proved
P. Do not turn off the engine during the cooler in the radiator tank for helpful in locating the source of
the fluid level checks. looseness, wear, or damage. If leak- the fluid leakage. Such dyes may
4. Clean all dirt from the trans- age cannot be stopped by tightening be used to determine whether an
mission fluid dipstick cap before a fitting, replace the defective parts. engine oil or transmission fluid leak
removing the dipstick from the Check the engine coolant in the is present, or if the fluid in the oil
filler tube. radiator. If transmission ftuid is cooler leaks into the engine coolant
S. Pull the dipstick out of the present in the coolant, the cooler system. A black light, however,
tube, wipe it clean, and push it all in the radiator tank is probably must be used with the fluorescent
the way back into the tube. leaking. dye solution.
7-38 GROUP 7-AUTOMATIC TRANSMISSION

FLUID LEAKAGE along the drive hub and onto the case and 0-ring seal may cause
CONVERTER AREA back of the impeller housing. Except fluid to be deposited on the outside
In diagnosing and correcting fluid in the case of a total seal failure, lower part of the converter housing
leaks in the front pump and con- fluid leakage by the lip of the seal as shown in Fig. I.
verter area, use the following pro- will be deposited on the inside of 5. Fluid leakage from the con-
cedures to facilitate locating the the converter housing only, near verter drain plugs will appear at the
exact cause of the leakage. Leakage the outside diameter of the housing. outside diameter of the converter.
at the front of the transmission, as 2. Fluid leakage by the outside Engine oil leaks are sometimes
evidenced by fluid around the con- diameter of the seal and front pump improperly diagnosed as front pump
verter housing, may have several body will follow the same path as seal leaks. The following areas of
sources. By careful observation, it leaks by the front pump seal or may possible leakage should also be
is possible, in many instances, to run down the face of the front checked to determine if engine oil
pinpoint the source of the leak pump. leakage is causing the problem :
before removing the transmission 3. Fluid that leaks by a front (a) Leakage at the rocker arm
from the car. The paths which the pump and converter housing to case cover (valley cover) may allow oil
fluid takes to reach the bottom of bolts will be deposited on the inside to flow over the converter housing
the converter housing are shown in of the converter housing only. Fluid or seep down between the converter
Fig. I. will not be deposited on the back housing and cylinder block causing
1. Fluid leaking by the front of the converter. oil to be present in or at the bottom
pump seal lip will tend to move 4. Leakage by the front pump to of the converter housing.
(b) Oil gallery plug leaks will al-
low oil to flow down the rear face
of the block to the bottom of the
converter housing.
(c) Leakage by the crankshaft
seal will work back to the flywheel,
and then into the converter housing.
Fluid leakage from other areas,
forward of the transmission could
cause fluid to be present around the
converter housing due to blow-back
or road draft.
The following procedure should
be used to determine the cause of
leakage before any repairs are made :
(a) Remove the transmission dip-
stick and note the color of the fluid.
Original factory fill fluid is dyed red
to aid in determining if leakage is
from the engine or transmission.
Unless a considerable amount of
make-up fluid has been added or
the fluid has been changed, the red
color should assist in pinpointing
the leak.
Since road draft may cause leak-
ing valley cover oil to be present on
the transmission, this leakage, if
present, should be eliminated before
performing work on the trans-
CONVERTER
mission.
(b) Remove the converter lower
housing cover. Clean off any fluid
from the top and bottom of the
converter housing, front of the
transmission case, and rear face of
CONVERTER DRAIN the engine and engine oil pan. Clean
PLUG LEAK the converter area by washing with
suitable non-flammable solvent, and
blow dry with compressed air.
(c) Wash out the converter hous-
ing, the front of the flywheel, and
the converter drain plugs. The con-
verter housing may be washed out
D1513-A using cleaning solvent and a squirt-
type oil can. Blow all washed areas
FIG. 1 - Typical Converter Area leakage Checks dry with compressed air.
PART 7-2- C4 AUTOMATIC TRANSMISSION 7-39
%2'STEEl PlATE ~ HEX. HEAD SCREW

DISHED OR
Ya• X 1 ¥a •,
DRill TO SUIT
ff %'-24 X Y2
FlAT WASHER
1 3,4 • O.D., 1~2· I. D. HEX. NUT %"-24

WElD
TOGETHER

CONTROl PRESSURE TAKE-Off HOlE

RUBBER PlUG
1 \12" DIA. X 2"
lONG \12"
SPACER- HOLE THRU
B2Q-9438-A APPROXIMATElY
40 DUROMETER STANDARD BOlT
PLUG \12"-13 X 4\12" VACUUM UNIT D1504-A
lONG SQUARE
CHAIN, 10' lONG
WElD TOGETHER
THREAD END
REMOVE HEAD
FIG. 4- Vacuum Diaphragm
SECURElY -MUST
NOT lEAK
AND WElD TO and Control Pressure Connecting
WASHER
Point - C4 Transmission
STANDARD FIITING-
87971-S
VALVE D1067-A

FIG. 2- Converter Leak Checking Tool

MANUAL LINKAGE CHECKS
Correct manual linkage adjust-
(d) Start and run the engine until ment is necessary to position the
the transmission reaches its normal manual valve for proper fluid pres-
operating temperature. Observe the sure direction to the different trans-
back of the block and top of the mission components. Improperly
converter housing for evidence of adjusted manual linkage may cause
fluid leakage. Raise the car on a cross-leakage and subsequent trans-
hoist and run the engine at fast idle, mission failure. Refer to Linkage
then at engine idle, occasionally Adjustments for detailed manual
shifting to the drive and reverse linkage adjustment procedures.
ranges to increase pressures within
the transmission. Observe the front
of the flywheel, back of the block
(in as far as possible), and inside
the converter housing (Fig. 1). Run ~Tire Pressure Gouge
CONTROL PRESSURE AND
VACUUM DIAPHRAGM
the engine until fluid leakage is UNIT CHECK
evident and the probable source of FIG. 3 - Typical Converter Leak When the vacuum diaphragm unit
leakage can be determined. Checking Tool (Fig. 4) is operating properly and
the downshift linkage is adjusted
CONVERTER LEAKAGE properly, all the transmission shifts
CllECK 4. Place the converter in a tank (automatic and kickdown) should
During the above fluid leakage of water. Observe the weld areas occur within the road speed limits
checks, if there are indications that for bubbles. If no bubbles are specified in the Specification Section.
the welds on the torque converter observed, it may be assumed that If the automatic shifts do not
are leaking, the converter will have the welds are not leaking. occur within limits or the transmis-
to be removed and the following sion slips during shift points, the
check made before the unit is following procedure is suggested to
replaced: separate engine, transmission, link-
ENGINE IDLE SPEED CHECK age, and diaphragm unit or valve
A leak checking tool (Fig. 2),
can be made from standard parts. Check and, if necessary, adjust body problems :
1. Install the plug in the con- the engine idle speed, using the 1. Attach a tachometer to the
verter (Fig. 3) and expand it by procedure given in Group 10. engine and a vacuum gauge to the
tightening the wing nut. Attach the If the idle speed is too low, the transmission vacuum line at the
safety chains. engine will run roughly. An idle vacuum unit (Fig. 6).
2. Install the air valve in one of speed that is too high will cause 2. Attach a pressure gauge to the
the drain plug holes. the car to creep when the trans- control pressure outlet at the trans-
3. Introduce air pressure into the mission is shifted into gear and will mission (Fig. 5).
converter housing. Check the pres- cause rough transmission engage- 3. Firmly apply the parking brake
sure with a tyre gauge and adjust ment. and start the engine.
it to 20 psi.
7-40 GROUP 7-AUTOMATIC TRANSMISSION

If the vacuum reading is lower than

18 inches, an engine problem is
indicated or there is leakage in the
vacuum line. Make necessary re-
pairs to obtain a minimum vacuum
reading of 18 inches.
At engine idle, check the trans-
mission control pressure gauge at
all selector lever positions. Trans-
mission control pressures should
agree with the specifications in
Table I.
At altitudes above sea level, it
may not be possible to obtain 18
inches vacuum at engine idle. At
FIG. 5 - Control Pressure these altitudes with idle vacuum of
Connecting Points. FIG. 7 - Testing Transmission less than 18 inches, refer to the fol-
Vacuum Unit for Leakage lowing specifications to determine
4. Adjust the engine idle speed to idle speed control pressure in for-
the specified rpm. If the engine idle Then connect the vacuum hose to ward driving ranges:
speed· cannot be brought within the transmission vacuum unit. If
limits by adjustment at the car- the gauge still reads \8 inches, the Engine Control
burettor idle adjustment screw, vacuum unit diaphragm is not Vacuum Pressure
check the throttle and downshift leaking. As the hose is removed (At Idle) (psi)
linkage for a binding condition. If from the transmission vacuum unit, 17 Inches 0 0 0 . 0 .... 0. 0 0 0 0 5:2-74
the linkage is satisfactory, check for hold a finger over the end of the 16 Inches 0 0 0 0 0 0 0. 0 0 0 0 0 0 0 52-78
vacuum leaks in the transmission control rod. When the hose is re- 15 Inches 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 52-85
diaphragm unit (Fig. 7), and its moved, the internal spring of the 14 Inches 0 0 0 0 0 0 0 0 0 0 0 0. 0 0 52-90
vacuum unit should push the 13 Inches 52-96
connecting tubes and hoses. Check
0 0 0 0 0 0 0 0. 0-0 0 0.

all other vacuum operated units for control rod outward. 12 Inches 0 •••• 0. 0. 0 ••• 0 052-101
vacuum leaks. II Inches 0 0. 0 0 0 0 0 0 0 0 0. 0 052-101
CONTROL PRESSURE TESTS
2. At engine idle, depress and re-
The test results of the following lease the accelerator pedal quickly
checks should agree with the speci- and observe the vacuum gauge. The
fications given in Table I. When amount of vacuum should decrease
= performing control pressure tests, and increase with the changes in
make certain that the service brake throttle openings. If the vacuum
pedal is held in the applied position. response to changes in throttle
MANIFOLD
VACUUM opening is too slow the vacuum line
LINE HOSE TEST NUMBER I- to the diaphragm unit could be re-
CONTROL PRESSURE CHECK stricted. Make the necessary repairs
AT ENGINE IDLE before completing the test.
TO VACUUM GAUGE
1. With the transmission in neu-
tral, and at the correct engine idle, TEST NUMBER 2-CONTROL
the vacuum gauge should s}low a PRESSURE INCREASE CHECK
minimum of 18 inches at sea level.
The control pressure increase
TABLE 1-C4 Transmission
CONTROL PRESSURE AT ZERO OUTPUT SHAn SPEED

Test En1ine Speed or Throttle ShiH Selector •Control (Line)

No. Manifold Vacuum Position Lewer Position Pressure (psi)

FIG. 6- Typical Vacuum Test P.N.D. 52-85

1 Idle-Above 18 Inches Closed 52-115
Line Connections of Vacuum
1.2
R 52-180
VACUUM UNIT CHECK 2 17.0 Approximate As Line Pressure
To check the vacuum unit for dia-- Inches of Vacuum Required D2 1 Increase
phragm leakage, remove the unit
from the transmission. Use a dis- 3 10 Inches ol Vacuum As Required D2 1 96-110
tributor tester equipped with a
vacuum pump (Fig. 7). Set the 4 Below 1 inch Thru detent D2 1 143-160
regulator knob so that the vacuum of Vacuum at stall R 230-260
gauge reads 18 inches with the end 1
of the vacuum hose blocked off. Transmission oil at normal operating temperature.
PART 7-2- C4 AUTOMATIC TRANSMISSION 7-41

should be checked in all ranges ex- rise with throttle opening, or is primary throttle valve, pressure
cept Park and Neutral. Shift the extremely erratic, use the procedure booster valve, or a stuck control
transmission into D, 2, and R, and given under the following appropri- pressure regulator valve.
check control pressure increase in ate heading to resolve the problem. If control pressure increases be-
each range. With the correct con- fore or after vacuum is decreased
trol ptessure at engine idle, advance CONTROL PRESSURE to approximately 17.0 inches, check
the throttle until the engine vacuum TEST RESULTS for a leaking diaphragm assembly,
reading is approximately 17.0 TEST NUMBER I - bent diaphragm can, or worn or
inches. As the vacuum gauge read- CONTROL PRESSURE IS LOW bent control rod.
ing decreases into these specifica- AT ENGINE IDLE
tions, the control pressure should TESTS NUMBER 3 AND ~
If control pressure at engine idle CONTROL PRESSURE NOT
start to increase. is low in all selector lever positions,
Control pressure increase may be WITHIN LIMITS AT 10 OR 1
trouble other than the diaphragm INCHES OF VACUUM
noted immediately when the throttle unit is indicated.
is opened due to the increased pump When control pressure at engine If idle pressure and pressure point
output, resulting from increased idle is low in all ranges, check for increase are within specifications
engine rpm. When this happens, the excessive leakage in the front oil but pressures at 10 or 1 inch of
pressure increase point can be pump, case, and control valve body, vacuum on the transmission is not
checked by using a distributor or a sticking control pressure within specification in all ranges,
vacuum tester. Install the dis- regulator valve. excessive leakage, low pump capa-
tributor tester vacuum line on the city, or a restricted oil pan screen
diaphragm assembly. Adjust the TEST NUMBER I - is indicated.
tester to provide over 18 inches of CONTROL PRESSURE IS If pressures are not within speci-
vacuum. Increase the engine to 600- HIGH AT ENGINE IDLE fications for specific selector lever
700 rpm. Adjust the tester vacuum positions only, this indicates exces-
reading to approximately 17.0 in- If transmission control pressure sive leakage in the clutch or servo
ches and observe the transmission at engine idle is too high in all circuits used in those ranges.
pressure gauge for the pressure ranges, the trouble may be in the
increase. diaphragm unit or its connecting
vacuum tubes and hoses, throttle
TEST NUMBER 3- valve, or control rod.
CONTROL PRESSURE CHECK With the engine idling, discon-
AT 10 INCHES OF VACUUM nect the hose from the diaphragm
A control pressure check should unit and check the engine manifold
be made at 10 inches of vacuum in vacuum. Hold a thumb over the
D, 2. Advance the throttle until the end of the hose and check for
engine vacuum reading is 10 inches vacuum. If the engine speeds up
and check the control pressure re- when the hose is disconnected and
gulation. Control pressure should slows down as the thumb is held
be as shown in Table 1. against the end of the hose, the FIG. 8- Adiustable Vacuum Unit
vacuum source is satisfactory. When the control pressure is
TEST NUMBER ~ Stop the engine, and remove the within specifications at engine idle,
CONTROL PRESSURE CHECK diaphragm unit and the diaphragm but not within specifications at the
AT 3 INCHES OF VACUUM- unit control rod. Inspect the control pressure rise point of approximately
rod for a bent condition and for 17.0 inches of vacuum, at 10 inches
Check control pressure at one corrosion. Check the diaphragm of vacuum, or at 1 inch of vacuum,
inches of vacuum in D, 2, and 1. unit for leakage with the distributor the vacuum diaphragm unit may
The control pressure should be as tester. need adjustment.
shown in Table l. Then move the
selector lever to R. With the TEST NUMBER 2- The vacuum diaphragm assembly
vacuum at one inch the control CONTROL PRESSURE DOES used on the C4 transmission has an
pressure should be as shown in NOT INCREASE WITH adjusting screw in the vacuum hose
Table I. VACUUM AT connecting tube (Fig. 8). The inner
While making this pressure test, APPROXIMATELY 17.0 INCHES end of the screw bears against a
do not hold the throttle open for plate which in turn bears against
more than five seconds in each When the control pressure is the vacuum diaphragm spring.
detent position. Between each test- within specifications at engine idle, All readings slightly high or all
move the selector lever to neutral but does not increase as the vacuum readings slightly low may indicate
and run the engine at I000 rpm for is decreased to the specified limits, the vacuum unit needs adjustment
fifteen seconds to cool the converter. first check the control rod between to correct a particular shift con-
If the vacuum and pressure gauge the vacuum unit and throttle valve dition.
readings are within specifications, for proper engagement. If the con- For example, if the pressure at
the diaphragm unit and transmission trol rod is not assembled into the lO inches of vacuum was 120 psi and
control pressure regulating system end of the throttle valve or vacuum the pressure at 1 inch of vacuum
are operating properly. unit, the valve cannot regulate was 170 psi and upshifts and down-
If the transmission control pres- throttle pressure to increase con- shifts were harsh, a diaphragm
sure is too low, too high, fails to trol pressure. Next check for a stuck adjustment to reduce the diaphragm
7-42 GROUP 7-AUTOMATIC TRANSMISSION

assembly spring force would be indicates forward clutch slippage. depending on the car speed.
required. Excessive engine rpm only in R Check the closed throttle down-
If pressure readings are low, and indicates either reverse-high clutch shift from third to first by coasting
line pressure does not start to build or low-reverse band slippage. Exces- down from about 30 mph in third
up until vacuum drops to 15 inches, sive engine rpm only in D indicates gear. The shift should occur within
an adjustment to increase diaphragm gear train one-way clutch slippage. the limits specified in the specifica-
spring force is required. tions section.
To increase control pressure, tum When the selector lever is at 2,
the adjusting screw in clockwise. To STALL SPEED TOO LOW the transmission can operate only
reduce control pressure, back the When the stall test speeds are low in second.
adjusting screw out by turning it and the engine is properly tuned, With the transmission in third
counterclockwise. converter stator clutch problems are gear and road speed over 39 mph,
One complete turn of the adjust- indicated. A road test must be the transmission should shift to
ing screw (360.) will change idle line performed to determine the exact second gear when the selector lever
control pressure approximately 2- 3 cause of the trouble. is moved from D to I. The trans-
psi. After adju stment is made, install If the stall test speeds are 300 to mission will downshift from second
the vacuum line and recheck the 400 rpm below the specifications or third to first gear when this same
pressures, part icularly the pressure shown in Table 2 and the car cruises manual shift is made below ap-
at 10 inches of vacuum. properly but has very poor accelera- proximately 38 mph. This check will
The diaphragm should not be tion, the converter stator clutch is determine if the governor pressure
adjusted to provide pressures below slipping. and shift control valves are function-
the ranges previously specified in If the stall test speeds are 300 to ing properly.
order to change shift feel. To do so 400 rpm below the specified values, During the shift check operation,
could result in soft or slipping shifts and the car drags at cruising speeds if the transmission does not shift
and damage to the transmission. and acceleration is poor, the stator within specifications or certain gear
STALL TEST • clutch could be installed backwards. ranges cannot be obtained, refer to
Start the engine to allow it to Remove the converter and check the Diagnosis Guide page 7- 44 to
reach its normal temperature. Apply the stator clutch as described in resolve the problem.
both the parking and service brakes Cleaning and Inspection.
while making tests. When the stall test shows normal AIR PRESSURE CHECKS
The stall test is made in D, 2 and I, speeds, the acceleration is good, but A NO DRIVE condition can
or R, at full throttle to check engine the car drags at cruising speeds, the exist, even with correct transmission
performance, converter clutch oper- difficulty is due to a seized stator fluid pressure, because of inopera-
ation or installation, and the hold- assembly. If the stator is defective, tive clutches, bands. The inopera-
ing ability of the forward clutch, replace the converter. tive units can be located through a
reverse-high clutch and low-reverse series of checks by substituting air
band and the gear train one-way INITIAL ENGAGEMENT pressure for the fluid pressure to
clutch. While making this test, do CHECKS determine the location of the
not hold the throttle open for more malfunction.
than five seconds at a time. Then Initial engagement checks are
made to determine if initial band When the selector lever is at 2,
move the selector lever to Neutral a NO DRIVE condition may be
and run engine at l 000 rpm for and clutch engagements are smooth.
Run the engine until its normal caused by an inoperative forward
about 15 seconds to cool the con- clutch or intermediate band. A NO
verter before making the next test. operating temperature is reached.
With the engine at the correct idle DRIVE condition at D may be
If the engine speed recorded by the caused by an inoperative forward
tachometer exceeds the maximum speed, shift the selector lever from
N to D, 2 and I, and R. Observe clutch or one-way clutch. When
limits specified in Table 2 release there is no drive in I the difficulty
the accelerator immediately because the initial band and clutch engage-
ments. Band and clutch engage- could be caused by improper func-
clutch or band slippage is indicated. tioning of the forward clutch or
ments should be smooth in all
TABLE 2- Stall Speed Limits positions. Rough initial engagements low-rev~rse band and the one-way
in D, 2 and 1, or R are caused by clutch .
Engine Engine Trans- The low-reverse band cannot be
Model Speed mission high engine idle speed or high
control pressures. checked in I. If the low-reverse
CID (rpm) Type band or clutch fails , the one-way
302-2V 1780-2000 C4 SHIFf POINT CHECKS clutch will hold the gear train and
351-2V operation will be normal except
1520-1720 C4 Check the light throttle upshifts that there will be no engine braking.
250-2V 1650-1850 C4 in D. The transmission should start Failure to drive in reverse range
in first gear, shift to second, and could be caused by a malfunction
250-1V 1600-1800 C4 then shift to third within the shift of the reverse-high clutch or low-
points specified in the specifications reverse band. Erratic shifts could be
STALL SPEED TOO HIGH section. caused by a stuck governor valve.
If stall speed exceeds specifica- While the transmission is in third
tions, band or clutch slippage is in- gear, depress the accelerator pedal
dicated, depending on transmission through the detent (to the floor). To make the air pressure checks,
selector lever position . Excessive The transmission should shift from drain the transmission fluid, and
engine rpm only in D, 2 and I, third to second or third to first, then remove the oil pan and the
PART 7-2-· C4 AUTOMATIC TRANSMISSION 7-43

control valve body assembly. The CONV ER TER IN

inoperative units can be located by

introducing air pressure into the
transmission case passages leading
to the clutches, servos, and
governor.

FORWARD CLUTCH
Apply air pressure to the transmis-
sion case forward clutch passage
(Fig. 9). A dull thud can be heard
when the clutch piston is applied. If
no noise is heard, place the finger
tips on the input shell and again
apply air pressure to the forward
clutch passage. Movement of the
piston can be felt as the clutch is
applied.
CONTROL
PRE SSURE
GOVERNOR TO PRIMAR Y
THR OTTLE VALVE
Apply air pressure to the control
PRIMARY THROTTLE
pressure to governor passage and PRE SSURE TO VALVE
listen for a sharp clicking or whist- BODY

ling noise. The noise indicates secon-

dary governor valve movement.

REVERSE-HIGH CLUTCH PRIMAR Y THROTTLE

VALVE EXHAUST
0217 1-A
Apply air pressure to the reverse-
high clutch passage (Fig. 9). A dull FIG. 9- Oil Pressure Passage Holes
thud indicates that the reverse-high
clutch piston has moved to the LOW-REVERSE SERVO DIAGNOSIS GUIDE
applied position. If no noise is Apply air pressure to the low- The Transmission Diagnosis
heard, place the finger tips on the reverse apply passage (Fig. 9). The Guide page 7-44 lists the most com-
clutch drum and again apply air low-reverse band should tighten mon trouble symptoms that may be
pressure to detect movement of the around the drum if the servo is found in the transmission, and gives
piston. operating properly. the items that should be checked to
If the servos do not operate, dis- find the cause of the trouble.
INTERMEDIATE SERVO assemble, clean and inspect them to The items to check for each
locate the source of the trouble. trouble symptom are arranged in a
Hold the air nozzle in the inter- If air pressure applied to any
mediate servo apply passage (Fig. logical sequence which should be
clutch passage fails to operate the followed for quickest results. The
9). Operation of the servo is in-
dicated by a tightening of the inter- clutch or operates more than one letter symbols for each item are ex-
mediate band around the drum. clutch at once, remove and, with plained in the Key to the Diagnosis
Continue to apply air pressure into air pressure, check the fluid pass- Guide.
the intermediate servo apply pass- ages in the case and front pump to If items A, B. C, D, E, and the
age, and introduce air pressure into detect obstructions. stall test have already been checked
the intermediate servo release pass- If the passages are clear, remove during the preliminary checks and
age. The intermediate servo should the clutch assemblies, and clean and adjustments, they need not be re-
release the band against the apply inspect the malfunctioning clutch to peated when following the Diagnosis
pressure. locate the trouble. Guide.

COMMON ADJUSTMENTS AND REPAIRS

TRANSMISSION FLUID DRAIN, vice. At this time the converter partial drain and refill due to minor
AND REFILL . must be thoroughly flushed to repairs.
Normal maintenance and lubri- remove all dirt. 1. Place a drain pan under the
cation requirements do not neces- When filling a dry transmission transmission. Loosen and remove
sitate periodic automatic transmis- and converter, install 5 quarts of all but two of the oil pan bolts,
sion fluid changes. fluid. Start the engine, shift the from the front of the case and drop
If a major failure, such as a selector lever as in Step 5 below, the rear edge of the oil pan to drain
clutch, band, bearing, etc., has and check and add fluid as the fluid. Remove and thoroughly
occurred within the transmission, necessary. clean the oil pan and screen. Dis-
it will have to be removed for ser- Following is the procedure for card the oil pan gasket.
7-44 GROUP 7-AUTOMATIC TRANSMISSION

C4 AUTOMATIC DIAGNOSIS GUIDI

Items to Check
Trouble Symptom Transmission Transmission
in Vehicle Out of Vehicle
Rough Initial Engagement in D or 2 KBWFE
Rough Initial Engagement 2 OnJy OJ
1-2 or 2-3 Shift Points Incorrect ALBCDWE
Rough 2-3 Shift BFE
Engine Overspeeds on 2-3 Shift B G WE F r
No Shift Points BCD E J
No 2-3 Shift CRDE b r
No 3-1 Shift in D BE
No Forced Downshifts LWE
Runaway Engine on Forced Downshift G FE J B c
Rough 3-2 or 3-1 Shift at Closed Throttle KBE
Shifts 1-3 in D G J
No Engine Braking In First Gear-Manuall HI
Creeps Excessively in D or 2 K
Slips or Chatters in First Gear, D ABWFE a c i
Slips or Chatters in Secon" Gear D or 2 ABGWFEJ a c
Slips or Chatters in R AHWFEI b c
No Drive in D onJy CE i
No Drive in 2 only c
No Drive in R onJy CHI E R b c
No Drive in D, 2, or I DWR a
No Drive in Any Selector Lever Position ACWFER c h
Lockup in 2 onl}' H I i
Lockup in R only a I
Parking Lock Binds or Does Not Hold c g
Transmission Overheats AOF n
Maximum Speed Too Low, Poor Acceleration n
Transmission Noisy in N F d
Transmission Noisy in First, Second, and Reverse Gear F h d
Transmission Noisy in P F d
Fluid Leak MNOPQSUX jmp

Kn TO DIAGNOSIS GUIDI
TRANSMISSION IN VEHICLE
TRANSMISSION OUT OF VEHICLE
A Fluid Level
B Vacuum Diaphragm Unit or Tubes a Forward Clutch
c Manual Linkage
D Governor b Reverse-High Clutch
E Valve Body
F Control Pressure Regulator Valve c Leakage in Hydraulic System
G Intermediate Band
H Low-Reverse Band d Front Pump
I Low-Reverse Servo
J Intermediate Servo I Parking Linkage
K Engine Idle Speed
h Planetary Assembly
L Downshift Linkage
M Convertor Drain Plugs i Planetary One-Way Clutch
N Oil Pan Gasket, or Filler Tube
0 Oil Cooler and Connections j Engine Rear Oil Seal
p Manual or Downshift Lever Shaft Seal
Q lh -inch Pipe Plug in Side of Case m Front Pump Oil Seal
R Perform Air-Pressure Check
s Extension Housing to Case Gaskets and n Converter One-Way Clutch
Lock washers
u Extension Housing Rear Oil Seal p Front Pump to Case Gasket or Seal
w Perform Control Pressure Check
X Speedometer Driven Gear Adapter Seal r Reverse-High Clutch Piston Air Bleed Valve
PART 7-2·· C4 AUTOMATIC TRANSMISSION 7-45

2. Place a new gasket on the oil to the Transmission. Place the trans- transmission.
pan, and install the screen and pan mission selector lever in the P (park) 9. Start the engine and check the
on the transmission. position and connect the cooler in- fluid flow. If the transmission fluid
3. Add three quarts of fluid to the let (converter out) line to the trans- flows freely, proceed with steps 3
transmission through the filler tube. mission. Place a pan under the end through 6. If there is no fluid flow,
4. Run the engine at idle speed of the cooler return line that will check for pinched cooler lines. If
for about two minutes. Check the hold transmission fluid. Do Not the flow is restricted, replace cooler
fluid level, and add fluid if neces- Start the Engine. lines and/or the radiator.
sary. Run the engine at fast idle 2. Install 5 quarts of automatic 10. Shut off the engine, and con-
speed (about 1200 rpm) until it transmission fluid meeting Ford nect the cooler return line to the
reaches its normal operating tem- Specification. transmission. Check the transmis-
perature. Do not race the engine. 3. Start the engine and allow it sion fluid level as indicated under
5. Shift the selector lever through to run at normal idle speed for 3 heading Transmission Fluid Level
all the positions, place it at P, and minutes with the selector lever in Check. Add or remove transmission
check the fluid level. If necessary, P (park) position. Stop the engine fluid as required until the proper
and add additional transmission fluid level is obtained on the dip-
add enough fluid to the transmis- fluid required to complete total fill. stick. DO NOT OVERFILL THE
sion to raise the level to the F (Full) Start the engine and allow it to run TRANSMISSION.
mark on the dipstick. Do not overfill at normal idle speed. 11. Do not attempt to correct
the transmission. 4. Allow approximately two cooler or cooler line leaks by closing
quarts of transmission fluid to drain off the lines.
OIL COOLER FLUSHING into the pan placed under the end
PROCEDURE of the cooler return line.
When a clutch or band failure or 5. If the fluid does not run clean OIL COOLER TUBE
other internal trouble has occurred after draining two quarts of it REPLACEMENT
in the transmission, any metal par- through the cooler, shut off the When fluid leakage is found at
ticles or clutch plate or band engine and add two additional the oil cooler, the entire radiator
material that may have been carried quarts of transmission fluid. must be replaced. The oil cooler
into the cooler should be removed 6. Repeat steps 3 through 5 until cannot be removed from the radiator
from the system by flushing the the transmission fluid flowing out for replacement.
cooler and lines before the trans- of the cooler return line is clean. When one or more of the fluid
mission is put back into service. In 7. If there is no fluid flow or the cooler steel tubes must be replaced,
no case should an automatic trans- fluid does not flow freely, shut off each replacement tube must be
mission having a clutch or band the engine and disconnect both fabricated from the same size steel
failure or other internal trouble cooler lines from the transmission tubing as the original line.
resulting in fluid contamination, be and cooler. Using the old tube as a guide,
put back into service without first 8. Use an air hose with not more bend the new tube as required. Add
flushing the transmission oil cooler. than 100 psi air pressure to reverse the necessary fittings, and install the
l. After installing a new or re- flush the cooler lines and the cooler. tube.
built automatic transmission and After reverse flushing, connect both After the fittings have been
converter assembly in the car, Do lines at the cooler and the cooler tightened, add fluid as needed, and
Not Connect the Cooler Return Line inlet line (converter out) to the check for fluid leaks.

CLEANING AND INSPECTION

CLEANING amount of foreign material in it,

I
it is to be replaced.
TRANSMISSION I
Clean all parts with suitable STATOR
solvent and use moisture-free air SUPPORT
to dry off all parts and clean out
the various fluid passages.
The composition clutch plates and
bands should not be cleaned in a
vapor degreaser or with any type of
detergent solution. To clean these
parts, wipe them off with a lint-free
cloth. New clutch plates and bands
should be soaked · in transmission
fluid for fifteen minutes before they
are assembled.
CONVERTER
If there is reason to believe that FIG. 10 - Checking Stator to FIG. 11 - Checking Stator to
the converter has an excessive Impeller Interference Turbine Interference
7-46 GROUP 7-AUTOMATIC TRANSMISSION

STATOR TO IMPELLER 3. Remove the clutch apply rings CONTROL VALVE BODY
INTERFERENCE CHECK and install them in their normal 1. Inspect all valve and plug
1. Position a stator support shaft running position in the clutch drum. bores for scores. Check all fluid
on the bench with the spline end of Then check the ring gaps. This ring passages for obstruction. Inspect
the stator shaft pointing up (Fig. 10). gap clearance should be between the check valves for free movement.
2. Place the front pump rotor 0.002 and 0.009 inch. Inspect all mating surfaces for burrs
over the stator shaft with. the flat 4. Inspect the input shaft bushings or distortion. Inspect all plugs and
side of the rotor down. in the stator support shaft for wear. valves for burrs and scores. Crocus
Check the oil ring grooves in the cloth can be used to polish valves
3. Place the converter over the stator support for nicks, burrs or and plugs if care is taken to avoid
stator &upport shaft so that the front damaged edges. Check the gasket rounding the sharp edges of the valves
pump flats are in normal (running) mating surface of the pump body and plugs.
engagement with the pump rotor. for damaged surface. 2. Inspect all springs for distor-
The converter pump driving hub S. Inspect the converter pump tion. Check all valves and plugs for
will bottom the rotor. drive hub bushing in the front pump free movement in their respective
4. While holding the stator shaft housing. Inspect the pump seal in bores. Valves and plugs, when dry,
stationary, try to rotate the converter the pump housing for defects that must fall from their own weight in
counterclockwise. The converter would cause fluid leakage. their respective bores.
should rotate freely without any
signs of interference or scraping PINION CARRIERS
within the converter assembly. GOVERNOR
S. If there is an indication of 1. Inspect the governor valves 1. The pins and shafts in the
scraping, the trailing edges of the and housing for wear. Crocus cloth planet assemblies should be checked
stator blades may be interfering with may be used to polish the valves if for loose fit and/or complete dis-
the leading edges of the impeller care is taken to avoid rounding the engagement. Replacement, using a
blades. In such cases, replace the sharp edges. new planet assembly, should be
converter. 2. Install the governor valves in made if either condition is found to
the governor housing and check exist.
them for free movement. Each valve 2. Inspect the pinion gears for
STATOR TO TURBINE should fall of its own weight when damaged or excessively worn areas.
INTERFERENCE CHECK dry. 3. Check for free rotation of the
1. Position the converter, front pinion gears.
side down, on the bench. 4. Inspect the front planet thrust
2. Install the front pump as- surface for excessive wear.
CLUTCH ASSEMBLY
sembly (complete) to engage the 1. Inspect the composition clutch
mating splines of the stator support plates for · damage. These plates SERVO-ASSEMBLIES
and stator, and pump drive gear should be flat. If the plates are not
flats. 1. Inspect the servo piston and
flat, they must be replaced. If the seals for defects that would cause
3. Install the input shaft, engag- old plates are to be re-used, they
ing the splines with the turbine hub hydraulic leakage.
must not be cleaned in a vapor de- 2. Inspect the cover seal and
(Fig. 11). greaser or cleaned with any type of
4. While holding the pump sta- gasket cover sealing surface for
detergent solution. Wipe them clean defects.
tionary, attempt to rotate the with lint-free towels.
turbine with the input shaft. The If new composition plates are to
turbine should rotate freely in both CASE
be installed, soak them in automatic
directions without any signs of transmission fluid for at least 15 1. Inspect the case for cracks.
interference or scraping noise. minutes before assembling them in 2. With an air hose, check all
5. If interference exists, the stator the clutch drum. This soaking fluid passages for obstruction or
front thrust washer may be worn, prevents damage to the plates during cross leakage.
allowing the stator to hit the the transmission fluid fill period and 3. Check all case linkage parts for
turbine. In such cases, the converter initial running-in. free travel and proper engagement.
must be replaced. 2. Inspect the steel clutch plates. 4. Check the vent passage for
These clutch plates should also be obstructions with an air hose.
flat. If they are not flat, they should
FRONT PUMP AND STATOR be replaced. ONE-WAY CLUTCH
SUPPORT 3. Inspect the clutch release 1. Inspect the outer and inner
1. Inspect the clutch drum journal springs for being broken or dis- races for scores or damaged surface
for wear and roughness. torted. area where the rollers contact the
2. Check the side clearances 4. Inspect the clutch piston ball races.
between the clutch apply pressure check valve for free movement and 2. Inspect the rollers and springs
seal rings and their grooves in the proper seating. Make sure the for excessive wear or damage.
stator support. These clearances orifice in the clutch piston is open. 3. Inspect the spring and roller
should be between 0.0035 and S. Inspect the clutch drum bush- cage for bent or damaged spring
0.0045 inch. ing for wear. retainers.
PART 7-2- C4 AUTOMATIC TRANSMISSION

DESCRIPTION AND OPERATI ON

DESCRIPTION The converter torque multiplica- When the turbine rotates faster
Figure I shows the location of the tion gradually tapers off as turbine than -fo- impeller speed the con-
converter, front pump, clutches, speed approaches impeller speed, verter no longer multiplies torque.
gear train and most of the ·internal and it becomes I to I when the _The fluid is directed against the
parts used in the C4 transmission. turbine is being driven at -fo- im- back face of the stator blades. As
The identification tag (Fig. 13) at- peller speed. This is known as the the one-way clutch permits the
tached by the lower front inter- coupling point. stator to rotate only in the direction
mediate servo cover bolt. The tag When the turbine is rotating at of impeller rotation, the stator
shows the model prefix and suffix, less than /o impeller speed, the con- begins to turn with the impeller and
engine displacement, and the built verter is multiplying torque. The turbine. The converter operates as
date code. fluid leaving the turbine blades an efficient fluid coupling as long as
strikes the front face of the stator the turbine speed remains greater
OPERATION blades. These blades are held than -fo- impeller speed.
TORQUE CONVERTER stationary by the action of a one- A comtant flow of fluid into and
way clutch (Fig. 14) as long as the out of the converter is maintained.
The hydraulic torque converter fluid is directed against the front The fluid coming out of the con-
(Fig. 14) consists of an impeller face of the blades. verter is forced through a cooler
(pump), a turbine, and a stator. All located in the radiator tank .
these parts are enclosed and operate
in a fluid-filled housing.
When the engine is running, the
fluid in the torque converter flows
from the impeller to the turbine and
back to the impeller through the
stator. This flow produces a maxi-
mum torque increase of about 2 tb
I when the turbine is stalled. When
enough torque is developed by the
impeller, the turbine begins to
rotate, turning the turbine shaft
(input shaft).

ASSEMBLY PART NO. BUILD DATE SHIFT

FIG. 13 - Identification Tag

CASE INTERMEDIATE REVERSE RING GEAR GOVERNOR EXTENSION
DISTRIBUTOf< HOUSING
BAND

l,
SEAL

OJTPUT SHAF~-~
.--~-

REVERSE PLANET CARRIE:-l

LOW· REVERSE SERVO PISTON

FORWARD CL~TCH

CONTROL LEVERS

FIG. 12- C4 Automatic Transmission

7-48 GROUP 7-AUTOMATIC TRANSMISSION

2 (SECOND GEAR HOLD): clutch plates of the forward clutch

When the engine is started and and the composition clutch plates
the shift lever is moved to 2 the cat of the reverse-high clutch. When the
will start off and remain in second reverse-high clutch is applied, the
gear, regardless of throttle opening external area of the clutch hub is
or road speed. This range is splined to and drives the input shell
especially useful for starting t.he car to rotate the sun gear. When the
on icy pavements or other shppery forward clutch is applied, the com-
surfaces. Similarly, when engine position clutch plates drive the
braking is required and the selector forward clutch hub and ring gear.
lever is moved from D to 2, the The ring gear rotates the forward
transmission will engage and remain planet gears.
in second gear. Selector lever When applied, the intermediate
position 2 is not a cruising range in band holds the reverse-high clutch
the usual sense of the term. While drum, input shell and sun gear from
the transmission is capable of rotating.
limited cruising in second gear, The sun gear, which is driven by
maximum fuel economy and best the input shell, is meshed with the
all-around cruising performance are forward and reverse planet gears.
realized in D range. The reverse planet carrier and low
1 (LOW GEAR HOLD): reverse drum are locked together
FIG. 14 - Sectional View of When the engine is started and with external splines. The low-
reverse drum can be held from
Torque Converter- Typical the shift lever is moved to 'I' the
rotating by the low-reverse band.
car will start off and remain in first
OPERATION gear regardless of throttle opening In Dl the low-reverse drum is also
TRANSMISSION or road speed. held from rotating by a roller type
When I is selected from D or 2 one-way clutch.
The new transmission features a The forward planet carrier, re-
drive range that provides for fully the transmission will engage and
retain first gear when road speed is verse ring gear hub, park gear and
automatic upshifts and downshifts, governor oil collector are all splined
and manually selected low and below approx. 39 mph.
When I is selected from D with a to the output shaft.
second gears. Forward Clutch. The input shaft
The six selector-lever positions road speed above 39 mph second
gear will be engaged and retained is splined to and drives the forward
provided are P (Park), R (Reverse), clutch cylinder (Fig. 15). Rotation of
N (Neutral), D (automatic Drive until road speed drops below 39
mph when first gear will be engaged the cylinder drives the steel clutch
Range), 2 (second-gear hold) and plates in the forward clutch and the
I (low-gear hold). and retained.
R-Reverse composition clutch plates of the
Drive (D) is a fully automatic reverse-high clutch.
range providing for a first gear start, Reverse gear is selected.
When the forward clutch piston
with automatic upshifts to second P-Park is applied by hydraulic pressure, the
and high gear occurring at ap- In this position the output shaft movement of the piston against the
propriate intervals. Second gear (2) is locked to the transmission case disc spring locks the steel and com-
is a manually selected second gear preventing the drive shaft from position clutch plates together to
hold. When the selector lever is rotating. The gear set is in drive the forward clutch hub and
moved to (2) the transmission will neutral. ring gear.
engage and remain in second gear, When hydraulic pressure is re-
regardless of throttle opening or N-Neutral leased from the piston, the disc
road speed. Places the gear set in neutral but spring moves the piston to the
does not lock the transmission. released position. As the disc spring
D (DRIVE) TOWING moves, the steel and composition
The normal automatic driving Important. Should it be necessary clutch plates are released. This stops
range is indicated by D. In this to tow a vehicle fitted with a C4 the rotation of the forward clutch
range the car starts off in first gear transmission, the drive shaft must hub and ring gear. The
and gives the best combination of be disconnected or the rear end of forward clutch is applied in all
automatic gear shifts, to provide for the car suspended, otherwise subse- forward drive gear ratios.
economy and fuJi power starts. As quent failure of the transmission Reverse-High Clutch. When
the accelerator is depressed and the will occur. hydraulic pressure is directed to the
car picks up speed, automatic shifts clutch piston, the piston moves
to second and high gears will occur. PLANETARY GEAR TRAIN, against the release spring (Fig. 15).
The transmission will automatically CLUTCHES, BANDS, The piston movement locks the steel
downshift as speed decreases. AND SERVOS and rotating composition clutch
Planetary Gear Train. The gear plates together. The steel clutch
Forced downshifts in D are made train consists of an input shaft that plates drive the reverse-high clutch
by pushing the accelerator to the is splined to the turbine of the drum which is splined to the input
floor (kickdown) and the transmis- converter and the forward clutch shell. Rotation of the input shell
sion will shift to 2nd or Ist depen- cylinder(Fig. l5). The forward clutch drives the sun gear which is splined
ding on road speed. cylinder rotates the steel internal to the input shell.
PART 7-2- C4 AUTOMATIC TRANSMISSION 7-49

To release the reverse-high clutch, into the transmission case and the The power flow is through the input
hydraulic pressure is exhausted band has an external adjustment shaft and into the forward clutch.
from the apply side of the piston. screw (Fig. I 7). To apply the servo, The input shaft is splined· to and
The return spring moves the piston hydraulic pressure is directed from drives the forward clutch cylinder.
to the released position. The steel the control valve body through a Rotation of the forward clutch
and composition clutch plates are hole in the case to a hole in the drives the forward clutch hub and
now released to stop rotation of the piston stem. The pressure then ring gear. The ring gear rotates the
reverse-high clutch drum, input passes through the centre of the forward planet gears clockwise to
shell and sun gear. piston stem to the apply area of the cause the sun gear to rotate counter-
Intermediate Servo and Band. The servo piston. The apply pressure clockwise.
intermediate servo is machined into force moves the piston against the Counter-clockwise rotation ofthe
the transmission case and the band piston return spring to tighten the sun gear turns the reverse planet
has an external adjustment screw low-reverse band around the low- gear clockwise. The reverse planet
(Fig. I 6). To apply the servo, hy- reverse drum. carrier being splined to the low-
draulic pressure is directed from To release the servo piston and reverse drum is held from rotating
the control valve body, through a band, the hydraulic pressure is ex- by the one-way clutch or low-
hole in the case to the hole in the hausted from the apply side of the reverse band.
servo piston stem. The pressure piston. The compressed return With the reverse planet carrier
passes through the centre of the spring expands to release the piston held stationary, the clockwise rota-
piston stem and then to the apply and the low-reverse band. tion of the reverse planet gears
side of the piston. The piston moves POWER FLOW rotates the reverse ring gear and
against the return spring to tighten All Gear Rotations are viewed hub clockwise. The hub of the
the intermediate band a-r ound the from the front of transmission. reverse ring gear is splined to the
reverse-high clutch drum. Table 3 page 7-52 shows the gear output shaft and rotates the output
To release the servo piston, hy- ratios obtained in the different selec- shaft clockwise.
draulic pressure is directed to the tor lever positions. The output shaft rotation is at
release side of the piston. The re- Power Flow Neutral. In neutral a reduced speed, compared to the
lease pressure is assisted by the (Fig. 18) the clutches or bands are input shaft rotation, but at an
compressed return spring to move not applied, therefore, no power is increased torque.
the servo piston and intermediate transmitted to the output shaft. The output shaft rotation at a
band to the OFF position. The Power Flow First Gear. In low reduced speed is caused by the fact
intermediate servo and band are gear (Fig. 18), the forward clutch is that the forward planet carrier ro-
applied only during the intermediate applied, and the planet one-way tates at the same speed of the out-
gear operation . clutch or low-reverse band is hold- put shaft and in the same direction
Low-Reverse Servo and Band. ing the low-reverse drum and re- since the carrier is splined to the
The low-reverse servo is machined verse planet carrier from rotating. output shaft. The forward ring gear
FORWARD CLUTCH and planet assembly are rotating in
\ CYLINDER the same direction, but the planet
\

INTERMEDIATE
BAND

D1479·A

FIG. 15- Gear Train, Clutches and Bands (Typical)

7-50 GROUP 7-AUTOMATIC TRANSMISSION
ring gear driven at the same speed
the forward planet assembly (that
is splined to the output shaft) is
forced to rotate the output shaft at
the same speed and direction to
provide high gear.
Power Flow Reverse. In reverse
(Fig. 18), the reverse-high clutch and
low-reverse band are applied. The
power flow is through the input
shaft, reverse-high clutch, input
shell and to the sun gear. Clockwise
rotation of the sun gear causes
counter-clockwise rotation of the
RELEASE
reverse planet gears.
SIDE OF The low-reverse band, holding
PISTON the low-reverse drum and reverse
PRESSURE planet carrier from turning, causes
~.PPL Y PRESSURE the reverse planet gears to rotate
counter-clockwise.
FIG. 16 - Intermediate Servo and Band This rotates the reverse ring gear
and hub countc:r-clockwise. The hub
splined to the output shaft rotates
the output shaft counter-clockwise
at a reduction in speed and at an
increase in torque for reverse gear.

HYDRAULIC CONTROL
SYSTEM
SCREW FRONT PUMP
A gear type ;:mmp mounted on
the front of the transmission case
supplies the fluid for the operation
of the hydraulic control system.
Pump intake is through a screen
which is part of the main control
assembly and into the case casting
D1485-A
and pump. Discharge is through
the case into the main control as-
FIG. 17 - Low-Reverse Servo and Band sembly. Fluid from the front pump
carrier is rotating at a slower speed Clockwise rotation of the output is directed to the following valves
than the ring gear. Therefore, the shaft causes clockwise rotation of in the main control assembly:
low gear ratio (torque multiplica- the output shaft ring gear, causing Main Oil Pressure Regulator
tion) is a combination of the ratios the reverse planet pinions to also Valve
provided by the forward and reverse rotate (walk) around the sun gear Manual Valve
planet assemblies. in a clockwise direction. The reverse Throttle Booster Valve
Power Flow Intermediate Gear. planet carrier will also rotate clock- 2-3 Shift Valve
In intermediate gear (Fig. 18), the Fluid is also directed to the
wise and the one-wav clutch inner
forward clutch is applied and the race being splined to the reverse primary throttle valve, which is
intermediate band is holding the planet carrier, will overrun. located in the rear of the case. Fluid
reverse high clutch drum, input Power Flow High Gear. In high pressure delivered to these valves is
shell and sun gear from turning. gear (Fig. 18), the forward and re- at a pressure controlled by the main
The power flow is through the verse-high clutches are applied. The oil pressure regulator valve.
input shaft into the forward clutch power flow is through the input
and forward front planet assembly shaft into the for~ard clutch cylin- MAIN OIL PRESSURE
ring gear. The sun gear is held from der. (The forward clutch cylinder REGULATOR VALVE
rotating by the intermediate band. rotates the steel clutch plates of the The main regulator valve assem-
This causes the forward planet forward clutch and the composition bly consists of the main oil pressure
pinions to rotate (walk) around the c1utch plates of the reverse-high regulator valve and spring, main
sun gear, carrying the forward clutch.) The forward clutch directs oil pressure booster valve, spring
planet carrier with them. The for- the power flow through the forward and sleeve, located in one bore in
ward planet carrier, being splined clutch hub and ring gear to the the mi!-in control assembly (Fig. 20).
to the output shaft, causes clock- forward planet carrier. Fluid is delivered to the end and
wise rotation of the output shaft at The reverse-high clutch directs one valley of the main regulator
a reduction in speed compared to the power flow through the input valve from the front pump. Fluid
the speed of the input shaft, and at shell to the sun gear. With the sun pressure on the end land tends to
an increase in torque. gear and the forward clutch hub move the valve against spring force.
PART 7-2- C4 AUTOMATIC TRANSMISSION 7-51

INPUT SHAFT LOW-REVERSE

REVERSE-HIGH FORWARD

INPUT SHAFT OUTPUT SHAFT

NEUTRAL 2 RANGE
OR
D RANGE 2

FORWARD CLUTCH

ONE-WAY CLUTCH HOLDING REVERSE INPUT SHAFT OUTPUT SHAFT

INPUT SHAFT
PLANET CARRIER AGAINST ROTATION
D RANGE LOW
D RANGE HIGH

REVERSE-HIGH CLUTCH LOW-REVERSE BAND

FORWARD CLUTCH

OUTPUT SHAFT INPUT SHAFT

INPUT SHAFT

1 RANGE REVERSE
D1476-A

FIG. 18 - Power Flow

7-52 GROUP 7-AUTOMATIC TRANSMISSION

Spring force is such that at approxi- reverse range only. 20 inches (nominal) of mercury
mately 60 psi front pump pressure, In Neutral and Park the manual vacuum. Primary throttle pressure
the main valve will move so that valve blocks the line pressure pass~ is delivered to the:
the third land uncovers the con- age and exhausts the four passages I. Cutback valve.
verter feed port, allowing additional leading from the manual valve. 2.lntermediate band accumulator
pump volume to be used to charge The D passage supplies fluid to valve (through cutback valve).
the converter. If volume supplied the D2 valve, the forward clutch 3. Second land of coasting boost
by the front pump is greater than and the governor. valve (through cutback valve).
that required to maintain 60 psi The 2 passage supplies fluid to 4. Upper valley of pressure boost-
line pressure, and converter and the adjoining ends of the l-2 shift er valve through top of line coasting
lube requirements, the valve will valve and D2 valve, and through boost valve.
move further allowing the second one ball shuttle valve to the line 5. End of and through the throttle
land to uncover the port which coasting boost valve, 2-3 shift valve booster valve.
allows excess pump volume to be and downshift valve, through the 6. End of pressure booster valve
returned to the pump. Pressures downshift valve to and through the (through ball shuttle valve).
over 60 psi which are required under throttle modulator valve bore to the Figure 19 shows how primary
various operating conditions are l-2 shift valve. throttle pressure varies with engine
obtained by delivering fluid under vacuum.
pressure to the pressure booster The 1-R passage supplies fluid
valve, which it will cause the pres- through a ball shuttle valve to the
sure booster valve to assist the main line coasting boost valve, 2-3 shift
regulator valve spring in increasing valve, downshift valve, and through
regulated line pressure. the downshift valve to and through
Source of these pressures which the throttle modulator valve bore
cause variations in control pressure to the l-2 shift valve. In addition,
are discussed later. fluid is supplied to and through the
02 valve when it is in the closed
(up) position, to and through the
MANUAL VALVE low servo modulator valve to the
One passage delivers line pressure low-reverse servo and the l-2 trans-
to the manual valve. The valve is ition valve. The same fluid is
MANIFOLD VACUUM
positioned by the manual linkage, directed to the spring end of the D2 OlSSB · A
according to the mode of operation valve. FIG. 19 - Primary ThroHie
desired, to direct fluid out of one or
more of the line passages which lead The R passage directs tluid to the Pressure, Boost Throttle Pressure
from the manual valve. The four (4) middle valley of the pressure boost- and Line Pressure Versus
passages leading from the manual er valve, to and through the 2-3 Manifold Vacuum 250 1V and
valve (from left to right) are shown shift valve to the reverse-direct
clutch, applying it , and to the release
351 2V only
in Fig. 20.
side of the intermediate servo
I. 2 (through intermediate servo check PRESSURE BOOSTER VALVE
2. D valve). Fluid is also directed to the (D, 2, l Range)
3. 1-R upper end of the 2-3 backout valve
4. R T.V. pressure is delivered to the
and the spring end of the low servo upper valley of the pressure booster
The 2 passage is charged in the modulator valve. valve and to the end of the pressure
2 range only. booster valve through a ball shuttle
The D passage is charged in all PRIMARY THROTTLE valve. Depending on mode of opera-
forward ranges. VALVE tion, coasting boost pressure instead
The 1-R passage is charged in I The primary throttle valve res- of T.V. pressure may be directed
and reverse ranges. ponds to manifold vacuum changes. from the line coasting boost valve
The R passage is charged in Primary throttle pressure starts at through a ball shuttle valve to the

TABLE 3 -Gtar Ratios

Reverse Low
Transmission Gear Forward Intermediate One-Way
Gear Ratios High Reverse
Selector Position Clutch Band Clutch
Clutch Band
Nor P Neutral -- Off Off Off Off Off
I Low 2.46:1 On Off Off On Holding
D Low 2.46:1 On Off Off Off Holding
D or 2 Intermediate 1.46:1 On Off On Off Over-Running
D . High 1.00:1 On On Off Off Over-Running
R Reverse 2.20:1 Off On Off On Not Affected
PART 7-2- C4 AUTOMATIC TRANSMISSION 7-53

PRIMARY GOVERNOR
X

DRAIN-BACK

CONVERTER
PRESSURE
REUEF VALVE
REAR LUBE

INTERMEDIATE
BAND

X EXHAUST

FIG. 20- Hydraulic Control System- C4 Automatic- 250-VI and 351-2V

- 250-2V and 302-2V are the same but incorporate a ball in the throttle boost
valve spring.
7-54 GROUP 7-AUTOMATIC TRANSMISSION
end of the pressure booster valve. force on the primary governor valve
When force created on the booster THROTTLE BOOSTER
overcomes spring force, and the VALVE
valve by T.V. pressure or T.V. and valve moves outward, opening the
coasting boost pressure exceeds line leakage passage to exhaust. Note: While the throttle booster valve
pressure booster valve spring force, This action reduces the pressure on is fitted to all C4 transmissions it is
the force will be added to the main the end of the secondary governor rendered ineffective on transmissions
regulator valve spring force trans- valve to zero (0), allowing the fitted to 250 C.I.D. 2V and 302
mitted to the regulator valve. This secondary valve to also move out- C.I .D. 2V engines by a ball inserted in
will provide increased line pressures ward, due to spring force and the booster valve spring preventing
required to compensate for in- centrifugal force. When the secon- valve movement.
creased throttle openings and ~r\gine dary valve moves outward, it closes
torque output. Figure 19 shows how Throttle plate openings above
the governor exhaust passage, and 50° provide very little change in
line pressure varies with engine allows line pressure to enter the
vacuum at 0 output shaft rpm. engine vacuum as compared to
governor passage. As pressure builds throttle plate opening below 50°.
in the governor passage it will create The throttle booster valve is pro-
(R Range) a force on the secondary governor vided to boost throttle pressure and
In reverse, additional fluid pres- valve due to the differential in areas provide the necessary shi~t delay for
sure is required to prevent clutch of the inner and outer lands of the engine throttle plate opemngs above
and/or band slippage under stall or valve. This force tends to move the 50°.
partial stall conditions. This addi- valve inward. When the force on Below approximately 60 psi pri-
tional pressure is provided by direct- the valve created by pressure in the mary T.V. pressure, T.V. pressure
ing R oil pressure to the middle governor passage exceeds the centri- flows to and through the throttle
valley of the pressure booster valve. fugal force plus spring force, the boost valve unaffected, working on
The differential in area between the valve will move inward, allowing the end of the boost valve and on
lands creates a force which is added governor pressure to exhaust, and the area differential on the spring
to the forces present due to T.V. close the passage between line pres- side of the boost valve. As a con-
pressure and the line coasting boost sure and governor pressure. When sequence, T.V. pressure passes
valve pressure. The resultant force governor pressure is reduced, the through the throttle boost valve
is added to the force of the main secondary valve will again move unaffected.
regulator valve spring, to boost line outward, closing the governc:: ex- When T.V. pressure increases
pressure to a higher value than is haust port and opening the line above 60 psi, the force created by
available in the forward driving pressure to governor passage. Above · T.V. pressure acting on the end of
ranges. 10 mph, governor pressure is regu- the throttle boost valve, minus the
lated in this manner, and will vary force of T.V. pressure acting on the
GOVERNOR with vehicle speeds. area differential on the spring side,
If vehicle speed drops below I 0 will exceed the force of the spring.
At Rest-O mph mph, the primary valve spring will This causes the valve to move
Control pressure (line) is fed to move the primary governor valve against the spring, closing off pri-
the secondary governor valve in, closing the line leakage exhaust mary T.V. pressure to the area dif-
through the center passage in the port at the primary valve. Pressure ferential on the spring side and
valve body when a forward range in the line leakage passage will be- permitting this area to be fed from
has been selected. Because of the come equal to line pressure, forcing line pressure, causing a boost in the
differential in area of the inner and the secondary governor valve in. pressure used for shift delay only.
outer lands of the valve. the valve This action shuts off line pressure Because the area of the end of the
will be forced inward, shutting off feed to the governor passage and throttle boost valve exceeds the area
line pressure feed to the. governor exhausts the governor circuit. differential on the spring side by
passage and allowing this passage When the secondary governor approximately 2! to I, throttle
to be opened to exhaust, at the inner valve is regulating, governor pres- boost pressure above 60 psi primary
end of the valve. At the same time, sure will be delivered to the cut- T.V. pressure will increase 2.5 psi,
line pressur.e will pass by two flats back valve, end of the 2-3 shift per I psi primary T.V.
on the outer end of the valve, pres- valve and the I -2 shift valve. Figure T.V. pressure from the throttle
surizing the line leakage passage 21 shows the relationship between booster valve is delivered to the
leading to the primary governor governor pressure and output shaft downshift valve, throttle modulator
valve. At rest, the spring on the rpm. valve, cut-back valve, and spring
outer end of the primary governor end of the 2-3 backout valve.
valve holds the primary governor Figure 19 shows the relationship
valve inward, blocking further flow between primary T.V. pressure and
of the fluid in the line leakage pas- boosted throttle pressure.
sage. This causes pressure in the line 100
leakage passage to build to the same :;
..: THROTTLE MODULATOR
60
value as line pressure. As a conse- VALVE
quence, the secondary governor 20 The throttle modulator valve,
valve is held in and there is no pres- 0 located in the end of the 2-3 shift
sure in the governor circuit. 0 10 15 20 25 30
valve bore, reduces throttle pres-
Above 10 mph OUTPUT SHAFT RPM•100 Dl559·A
sure which acts on the ends of the
When vehicle speed reaches ap- FIG. 21 - Govemor Pressure 2-3 shift valve and on the area dif-
proximately 10 mph, centrifugal Versus Output Shaft RPM ferential of the 1-2 shift valve.
PART 7-2- C4 AUTOMATIC TRANSMISSION 7-55

Modulated throttle pressure in these booster valve tends to increase line area between the two lands at the
areas provides shift delay in relation pressure, however coasting boost spring end of the 02 valve, and by
to throttle opening. pressure is decreasing, resulting in a the 1-2 shift valve spring. Governor
CUT BACK VALVE slight reduction in regulated line pressure tends to move the 1-2 shift
pressure from 20" to s· manifold valve train against these forces.
Increased line pressure is required vacuum at Zero or low vehicle When force created by governor
to prevent clutch and band slippage speeds. Below 8" manifold vacuum, pressure exceeds the forces holding
under stall conditions. As vehicle the output pressure of the coasting the 1-2 shift valve train closed, the
speed increases, the requirements boost valve will connect to primary 1-2 shift valve and 02 valve will be
for increased line pressure are con- T.V. pressure from the cutback opened (moved downward), closing
siderably reduced. The cut back valve, which will increase regulated the exhaust port and allowing 0 oil
valve provides for the reduction in line pressure. At high road speeds to pass through the 02 valve to
line pressure. When governor pres- (after cutback) the output of the accomplish the 1-2 shift. When the
sure acting on the end of the cut coasting boost valve will decrease 02 valve is moved downward 0
back valve exceeds the force of T.V. from 20" through o· manifold oil is exhausted from the differential
pressure and throttle boost pressure vacuum which slightly decreases in areas provided by the lower two
opposing governor pressure the regulated line pressure. lands of the 02 valve. This action
cut back valve will move, cutting eliminates the force created by 0
off primary T.V. pressure being fed DOWNSHIFT VALVE oil which tends to hold the 1-2 shift
to the pressure booster valve and (fn 1, R and 2 Ranges) valve train closed.
intermediate band accumulator 1-R or 2 oil pressure is delivered If governor pressure is reduced to
valve. The cut back valve movement to the downshift valve. The dif- the point where spring force and
will therefore vary with engine ference in diameter between the modulated throttle pressure force
throttle opening and vehicle speed. lands provides an area differential exceeds governor pressure force, the
See Figure 22 for line pressure for regulation. This pressure will 1-2 shift valve train will move up
variation with output shaft rpm be referred to later as regulated (close) cutting off the flow of 0 oil
(vehicle speed) at constant vacuum downshift valve oil pressure and is through the valve and opening the
values. used primarily to control the 2-1 exhaust port allowing a downshift
WIDE OPEN THROTTLE- downshift point in 1 range. When to low gear.
I" VACWM NOM. the throttle is opened through de- If the throttle is open to the point
160l-----. tent the downshift valve is forced to where modulated throttle pressure
120 the right against spring pressure. acting on the 1-2 shift valve plus the
Boosted throttle pressure (T.V. pres· 1-2 shift valve spring force creates a
sure on 250 2V and 302) now re· force greater than that provided by
places regulated downshift pressure governor pressure, the 1-2 shift
CLOSED THROTTLE-ABOVE and is directed to the 2-3 and 1-2 valve train will be closed, providing
17'' VACUUM
shift valves. a torque demand downshift to low.
o~-----~-~~-~--
o 5 10 15 20 25 30 If the throttle is open through
OUTPUT SHAFT RPM x 10 (In D Range)
D1569·A Because there is no control (line) detent, the downshift valve moves
to allow boosted throttle pressure
FIG. 22 - Line Pressure Versus pressure feed to the downshift valve
(T.V. pressure on 250 2V & 302)
Output Shaft RPM in this range it is ineffective until the
throttle is opened through detent. to enter the modulated throttle
LINE COASTING At this point boosted throttle pres- pressure passage at the 1-2 shift
BOOST VALVE sure (T.V. pressure on 250 2V and valve to provide a forced 2-1
The line coasting boost valve is 302) enters the valve and is directed downshift.
provided to boost line pressure un- to the 2-3 and 1-2 shift valves to
der light throttle or closed throttle (D Range: 2-3 Upshifts and
give a 3-2 or 2-1 kickdown shift 3-2 Downshifts)
driving conditions in 2, 1 or R depending on road speed.
ranges. The boosted line pressure The 2-3 shift valve is held closed
controls the 2-1 downshift point in 1-2 SHIFT VALVE TRAIN (up) by throttle modulator valve
1 range. AND 2-3 SHIFT VALVE spring force, modulated throttle
Primary T.V. pressure is delivered The 1-2 shift valve train is com- pressure force, and by line pressure
to the end of the line coasting boost posed of the 1-2 shift valve, 02 force acting on the differential in
valve and to the upper valley of the valve, and the 1-2 shift valve spring. area of the lands of the valve to
pressure booster valve. 1-R or 2 oil Operation of the 1-2 shift valve which is it is delivered.
pressure is directed from the manual train, 2-3 shift valve, and the down- Governor pressure tends to open
valve through a ball shuttle valve to shift valve in the various modes is the 2-3 shift valve. When force
the line coasting boost valve. Under as follows : created by governor pressure ex-
throttle off conditions, the force ceeds the forces holding the valve
created by 1-R or 2 oil acting on (D Range: 1-2 Upshifts and closed (up), the valve will move
the area differential will be directed 2-1 Downshifts) downward allowing 0 oil .Pressure
through a ball shuttle valve to the In 0 range the 1-2 shift valve is to apply the direct clutch and
end of the pressure booster valve. held closed (up) by modulated release the intermediate servo to
The output of the coasting boost throttle pressure acting on the dif- accomplish the 2-3 shift.
valve decreases with an increase in ferential area between the two lands With the shift valve open (down)
primary T.V. pressure. Primary T.V. of the 1-2 shift valve, by 0 oil pres- the throttle modulator valve is held
pressure acting on the pressure sure acting on the differential in down cutting off modulated throttle
7-56 GROUP 7-AUTOMA TIC TRANSMISSION

pressure to the 2-3 shift valve and down) the D-2 valve and holds it (R Range)
1-2 shift valve. In addition, the port open and closes (moves up) the 1-2 In reverse 1-R oil pressure is
which delivered line pressure to the shift valve and holds it closed; thus directed to and through the D2
qifferential in area of the shift valve preventing a 2-1 downshift. The valve to the spring end of the D2
lands, is closed. transmission will remain in inter- valve and to the reverse and low
The shift valve will be reopened mediate or second gear until an- servo applying the reverse and low
(moved up) causing a 3-2 downshift other mode of operation is selected. band. The force created by 1-R oil
under one or more of the following (D to 1 Range) pressure on the spring end of the
conditions: D2 valve and the force created by
If the manual valve is moved to I
GOVERNOR PRESSURE range at vehicle speeds greater than regulated downshift valve oil pres-
REDUCED approximately 39 mph, a 3-2 down- sure on the area differential of the
If governor pressure is reduced to shift will be accomplished in the 1-2 shift valve is added to the force
the point where it can no longer same manner as in 2 range, except of the 1-2 shift valve spring,
hold the shift valve down against that 1-R oil pressure instead of 2 preventing any movement of the 1-2
spring force and T .V. pressure force, oil pressure is directed to the 2-3 shift valve train regardless of
the valve wiU move up causing a shift valve. governor pressure.
downshift. Under closed throttle At vehicle speeds of approxi- R oil pressure is directed to and
conditions, the 2-3 shift valve will mately 39 mph or lower, the force through the 2-3 shift valve to the
close at approximately 10 mph created by regulated downshift reverse-direct clutch applying the
(speed at which governor pressure valve pressure acting on the area clutch and to the release side of the
is cut off). Since governor pressure differential of the 1-2 shift valve intermediate servo. The force created
is cut off at this speed the 1-2 shift plus the force of the 1-2 shift valve by regulated downshift valve oil
valve train also closes at the same spring will exceed governor pres- pressure on the spring end of the 2-3
time. This will provide a 3-1 down- sure force holding the 1-2 shift shift valve, and 1-R oil pressure on
shift when coasting in D range. va~ve train open (down). The 1-2 the area differential of the lands
shift valve train will then close adjacent to the top valley of the 2-3
THROTTLE PRESSURE (move up), exhausting intermediate shift valve is added to the force of
INCREASED servo apply and allowing 1-R oil the throttle modulator valve spring,
pressure to pass through the D2 preventing any movement of the 2-3
If throttle pressure is increased
sufficiently, it will move the throttle valve to the spring end of the D2 shift valve regardless of governor
valve, and to the reverse and low pressure.
modulator valve and consequently
the 2-3 shift valve up, causing a 3-2 band via the low servo modulator 2-3 . BACK-OUT VALVE
torque demand downshift. valve. The transmission will remain The. purpose of the 2-3 back-out
in low or first gear until another valve is to provide smooth upshifts,
THROTTLE PRESSURE mode of operation is selected.
INTRODUCED BELOW when the throttle is suddenly closed
2-3 SHIFT VALVE (2 Range) while accelerating in second gear.
In 2 range, 2 oil pressure is intro- Operation is as follows :
If the downshift valve is moved
through detent, boosted throttle duced between the 1-2 shift valve Normal Throttle-On 2-3 Upshifts
pressure (T.V. pressure on 250 2V & and D-2 valve, and regulated down-
shift valve oil pressure is introduced When the 2-3 shift valve moves to
302) is directed to the underside cause a 2-3 upshift, D oil pressure
of the 2-3 shift valve, forcing the between the lands of the 1-2 shift
valve. This action opens the D2 passes through the valve to apply
valve up and causing a forced 3-2 the direct clutch and release the
valve and holds it open and closes
downshift. Maximum 3-2 forced the 1-2 shift valve and holds it intermediate servo. This same pres-
downshift speed is controlled by closed providing a second gear start sure is also directed to the end of
governor pressure. the 2-3 back-out valve. However,
and preventing a 2-1 downshift.
(D to 2 Range) The transmission will remain in with throttle open, T.V. boost
If the manual vafve is moved to intermediate or second gear until pressure (T.V. pressure on 250 2V &
2 range, the force created by 2 oil another mode of operation is 302) on the opposite end of the
pressure acting on the area differen- selected. 2-3 back-out valve, assists spring
tial of the 2-3 shift valve and on force in holding the valve up, so
the spring end of the valve plus the (1 Range) that there will be no valve move-
force of the throttle modulator valve In 1 range, regulated downshift ment until after the 2-3 shift has
spring will exceed the force created valve pressures enter the modulated been completed.
by governor pressure. The 2-3 shift throttle pressure passage to provide
valve will then close (move up) a manual low downshift to first Back-Out 2-3 Upshifts
allowing the direct clutch apply- gear. Once the transmission is in When the throttle is closed during
intermediate servo release oil to low gear 1-R oil pressure, which is a 2-3 upshift, and before the shift is
exhaust, permitting the intermediate directed to the D2 valve, passes completed, there may be enough
band to apply causing a 3-2 down- through the D2 valve and is pressure in the direct clutch cylinder
shift. In addition, D2 oil pressure is delivered to the spring end of the to apply the clutch at the reduced
introduced between the 1-2 shift D2 valve, preventing an upshift. engine torque input, but not enough
valve and D2 valve, and regulated 1-R oil pressure which passes pressure to release the intermediate
downshift valve oil pressure is intro- through the D2 valve also applies servo. This condition could cause a
duced between the lands of the 1-2 the reverse and low servo via the harsh 2-3 shift. However, if the
shift valve. This opens (moves low servo modulator valve. throttle is closed during a 2-3 shift,
PART 7-2- C4 AUTOMATIC TRANSMISSION 7-57

primary throttle pressure will be surized. This pressure acting on the servo before the release of the low/
reduced to Zero (0), and reverse and end of the intermediate servo reverse servo during a manual 1-2
direct clutch apply pressure on the accumulator valve will cause the upshift. In 'I' low / reverse servo
end of the 2-3 back-out valve will accumulator valve to move against apply pressure is directed to the
move the valve down against spring primary T.V. pressure and/or the spring end of the transition valve
force. This action immediately con- accumulator valve spring. The servo forcing the 2-3 backout valve down
nects the clutch apply circuit to the release pressure is exhausted through against throttle pressure and the
intermediate servo apply circuit, the reverse-direct clutch apply circuit backout valve spring pressure and
reducing the pressure on the apply to maintain a certain level of so closing the apply passage to the
side of the servo to the same value pressure on the release side of the intermediate servo.
as in the direct clutch (and also on intermediate servo until it has When '2' is selected from 'I '
the release side of the intermediate completely stroked, applying the apply pressure cannot reach the
servo). When this happens, the band. Force created by this pressure intermediate servo until the low/
intermediate band is released, to on the release side of the servo, plus reverse servo apply pressure has
provide a smooth 2-3 upshift. intermediate servo spring force, is been exhausted at the 02 valve
subtracted from the force of control allowing spring and throttle pres-
INTERMEDIATE BAND
pressure acting on the apply side of sure to move the 2-3 backout valve
ACCUMULATOR VALVE
the servo, thereby controlling the and the transition valve up and
TRAIN
The intermediate band accumula- servo apply force. open the intermediate servo apply
tor valve train is composed of the Should a change to 2 be made ports.
intermediate band accumulator under closed throttle conditions,
governor pressure will hold the cut- THROTTLE PRESSURE LIMIT
valve, and the accumulator valve VALVE
spring. The intermediate band ac- back valve down providing an
exhaust for the intermediate release The throttle pressure limit valve
cumulator valve in conjunction with is a spring-loaded exhaust valve
the intermediate servo check valve circuit via the orifice restriction,
cut-back valve, 2-3 shift valve and used to prevent possible over pres-
controls intermediate servo apply
the manual valve. surization in the throttle circuit.
force on all applications of the
(D Range: 2-3 Upshifts) LOW SERVO MODULATOR
intermediate band, under open
throttle operating conditions in D, During a 2-3 upshift, D oil VALVE
2 or I ranges. pressure from the 2-3 shift valve will
The low servo modulator valve
Operation is as follows: unseat the intermediate servo check
provides improved engagement of
(D Range: 1-2 Upshifts and valve, bypassing the intermediate
the low/ reverse band when manual
3-2 Downshifts) servo accumulator valve, allowing
'I' is selected and during a 3-1
(2 and 1 Range: 3-2 the release side of the intermediate
manual downshift by stabilizing the
servo to be pressurized at the same
Down shifts-Shifting D to 2 or 1) low/ reverse servo apply pressure.
pressure level as the direct clutch,
Fluid pressure from the 02 valve thereby releasing the intermediate In reverse gear control (line) pres-
acting on the apply side of the inter- band. sure is applied to the spring end of
mediate servo piston tending to the valve from the manual valve.
apply the servo, causes the fluid 1-2 TRANSITION VALVE This ensures that full control pres-
which is trapped in the intermediate The 1-2 transition valve prevents sure is applied to the low/ reverse
servo release passage to be pres- application of the intermediate servo when reverse gear is selected.

IN-CAR ADJUSTMENTS AND REPAIRS tor pedal to the floor. Block the
CONTROL LINKAGE must be against the hot idle speed pedal to hold it in the wide open
ADJUSTMENTS adjusting screw at the specified idle position.
The transmission control linkage speed in D. To make sure that the 4. Rotate the downshift lever C
adjustments should be performed in carburetor throttle lever is against counter clockwise to place it against
the order in which they appear in the idle adjusting screw, refer to the internal stop.
this section of the manual. Group 10 for the carburetor adjust- 5. With the lever held in this
THROTTLE ADJUSTMENTS ing procedures. position, and all slack removed
1. Apply the parking brake, and DOWNSHIFT CABLE from the cable, adjust the trunnion
place the selector lever at N. ADJUSTMENT so that it will slide into the ac-
2. Run the engine at normal idle 1. With the engine off, check the celerator shaft lever. Turn it one
speed. If the engine is cold, run the accelerator pedal height measured additional turn clockwise, then
engine at fast idle speed (about 1200 from the top of the pedal at the secure it to the lever with the
rpm) until it reaches normal operat- pivot point (Fig. 26) to the floor pan. retaining clip.
ing temperature. When the engine To obtain the correct pedal height, 6. Remove the block to release
is warm, slow it down to normal idle adjust the accelerator connecting link the accelerator linkage.
speed. at point A. P.EF-C
3. Connect a tachometer to the 2. With the engine OFF, discon- DOWNSHIFT ROD ADJUSTMENT
engine. nect the downshift control cable at 1. Disconnect the throttle and
4. Adjust engine idle speed to the point B from the accelerator shaft downshift return springs.
specified rpm with the transmission lever. 2. Hold the carburettor throttle
selector lever at D position. 3. With the carburetor choke in lever in wide-open position against
5. The carburetor throttle lever the off position, depress the accelera- stop.
7-58 GROUP 7-AUTOMATIC TRANSMISSION

2. Position the transmission

selector lever into the D position
making sure that the selector lever

~~
i-s against the D, stop on the
selector plate.
3. Shift the manual lever at the
transmission into the D detent
·~~ position, third from the rear.
.. --\ 4. Tighten the clamp on the shift
rod at point A.
5. Check the pointer alignment
and transmission operation for all
selector lever detent positions.
CONSOLE SHIFT

Selector Lever Removal and Re-

'"' placement.

Column Shift 1. Raise the vehicle and remove

the manual lever control rod (Fig. 23)
2. Lower the vehicle, remove the
selector lever handle attaching screw
a~d remove the handle. (Fig. 23).
3. Remove the two console attach-
ing screws at the front of the console
and the four screws in the glove box.
Remove the console and gear lever

, slide assembly.
4. Detach the dial indicator light.
~--~
it "f...
(• I
S. The gear lever slide assembly,
which incorporates the dial, may be
)\\
,, . detached from the console by remov-
ti_) ing the four attaching screws.
Floor Shift
6. Remove the selector housing
FIG. 23 - Manual Linkage and lever assembly attaching bolts
and remove the selector lever and
housing.
7. Remove the selector lever to
housing attaching nut. Remove the
lever from the housing.
8. Install the selector lever in the
housing and install the attaching nut.
Torque the nut to 20 to 25 ft. lbs.
9. Install the selector lever handle.

FIG. 24- Selector Lever Detent Pawl Adiustment- Typical

3. Hold the transmission in full tion.
downshift position against internal 6. Install the throttle and down-
stop. shift return springs.
4. Turn adjustment screw on the
carburettor kickdown lever to within MANUAL LINKAGE
0.040 to 0.080 gap of contacting pick- ADJUSTMENT COLUMN SHIFT
up surface of carburettor throttle 1. With the engine stopped,
lever. Fig. 26 loosen the clamp at the shift lever
5. Release the transmission and at point A so that the shift rod is
carburettor to the normal free posi- free to slide in the clamp (Fig. 23). FIG. 25 - Neutral Start Switch
PART 7-2- C4 AUTOMATIC TRANSMISSION 7-59
250 2V
10. Position the selector as shown Tt.t.NS. ONLY
in Fig. 24. With a feeler gauge
check the clearance between the
detent pawl and plate. The clearance
should be 0 .005 to 0 .010 inches. If
necessary adjust the height of the
detent pawl as shown in Fig. 24.
11. Remove the handle from the
selector lever. LEVU "C'

12. Install the selector lever hous-

ing and lever assembly as shown in
Fig. 23. Torque the attaching bolts 250 1V " C"'
BlOCK ~HUATC>a n:Dit.L
IN W .O .T. POSITION .

to 4-6 ft. lbs. .OTATE lEVU " C ' COUNTU

CLOCKWISE TO CONTACT INTEitNAl
STOf'.
13. Install the gear lever slide TlANS DOWNSHIFT LEVU HOlD lEVU " C"' ON STOf' AND
ADJUST CAlLIE TO f iT ACCIELUA TOl
ltOTAUD AND HElD AGA INST
assembly in the console. INTUNAL IUCICDOYIN STOI'
IY P'UUING CAlLE
SHAFT lEVU. TUitN TIU'*"ION
ONE ADDITIONAL TU.N CLOCICWISf
ADJUSTING END. AND SfC\J):E TO LEVU .

14. Refit the dial indicator light. LEVU ··c· ULIEASE ACCHERATOl 'EDAL.

15. Replace the console ensuring 351 2V ~

lOCK

1.
DOWN CONTtOl

W IT H TRANS . ROD 7 A116

ADJUSTMENI

that the dial locating peg is correctly INSTALL ED, HOLD CAI!&UR H TOR

~
THtOTTLE LE VU IN WO.T .
POSITION-AGAI NST STO'
located in the bracket on the selec- 1 HOLD TRA NSM ISSION IN FU LL
tor lever housing. KICK OOWN POSI TION AGAI NST
INTERNA L STO '
3 TURN ADJUSTME NT SCREW ON
16. Install the selector lever handle CA.IIIURHTOR ICICIC · DOWN LEVEll
TO WITHIN 040 TO 010
GAP OF CoF.ifACTING PICIC · UP
and tighten the attaching screw. VI EW W $ SURFACE OF CA Rl THRO TTLE lEVEl

l7. Position the selector lever in <11 RHfASE CARl ANO

FREE POSIT IONS
TR ANS . TO

the ''N" position. ~~~~r:,.,~.. ~~ ~' m -• .5 INSTALL ACCHUATOI ~737 AND

ICICIC · DOWN 711<110 lfUACliNG

18. Ral.se the veh1'cle. Install the ~J.J"'.!;.,·~r.· ;;""''~::..;~~.

SPRINGS.

?~"c;:...:r CAIU JU5f TOI..IOti!S l / D CA••t ADJU$lMENT

transmission manual lever rod to the :. c::;.;~:;,;-~':" ...a<.

selector lever. With the transmission a..:::.:::.:::..::..::._______......~.-_ _,
in neutral and the selector lever 302 2V WITH- THE
ASSEMilED.
liNKAG E COM PLETELY
THIS DISTANCE
TO IE SUCH THAT THE
IS

against the neutral stop· tighten the UANSMISS ION DOWNSH IFT lEVU " C
ltOTATU COUNTU CLOCKWISE COLOU R CODE
AND CONTACTS THE INTERNAL
selector lever to manual lever rod nut. STOf' WITH THE PfOAL
O(flESSfD TO W.O.T. 3.5 1· '1V ILUE

19. Lower the vehicle and check TlANS DOWNSH IFT lEVU
ltOTATfD AND HELD AGA INST
VI EW W 3SI · <~~V O RANGE

the transmission operation in each INTERNAL ICIO::DOWN STO I'

1'1' 1'\Jllii\IG CAllE
,..,TOMATIC TIANSMISSION CONT.Ol
ADJUSTMfNT
ADJUSTING END.
selector lever detent position.
NEUTRAL START SWITCH '' X"
ADJUSTMENT
1. With the manual lever properly
adjusted, loosen the two switch .OTATE lEVEl " C' COUNTU
attaching bolts (Fig. 25). CLOCICWIR TO CONTACT INTERNAL
STOf'.

2. With the transmission manual HOLD LEVU ''C ' ON STOf' Al''t
ADJUST CAlliE TO Flf ACCIELUA TV!t

lever' in neutral, rotate the switch and ~rA~TEI~~~~~ISE VIEW " V"
AND SEC\Jl:E TO LEVU.
insert the gauge pin (No. 43 drill ·lElfASE ACCflEIATOI 'fOAl . LEVU "C"

shank end) into the gauge pin holes

of the switch. The gauge pin has to FIG. 26-Throttle Linkage Installations
be inserted to a full U inch into the result in 10 ft. lbs. torque at the result m 10 ft. lbs. torque at the
three holes of the switch (Fig. 25). screw. (Fig. 27) screw. (Fig. 28)
3. Torque the two switch attach- 3. Back off the adjusting screw 3. Back off the adjusting screw
ing bolts to specification, Remove the
exactly 1i turns. exactly 3 full turns.
gauge pin from the switch. 4. Hold the adjusting screw from 4. Hold the adjusting screw from
4. Check the operation of the turning and torque the lock nut to
turning and torque the locknut to
switch. The engine should start only specification. specification.
with the transmission selector lever NOTE: The lock nut must be NOTE: The lock nut must be
in Neutral and Park. discarded and a new one installed discarded and a. new one installed
BAND ADJUSTMENTS each time the band is adjusted. each time the hand is adjusted.
INTERMEDIATE BAND LOW -REVERSE BAND OIL PAN AND CONTROL VALVE
1. Clean all dirt from the band 1. Clean all dirt from the band
adjusting screw area, loosen the BODY REPLACEMENT
adjusting screw area, loosen the 1. Raise the car so the transmis-
locknut, remove and discard the locknut, remove and discard the
locknut, instal a new locknut, do locknut, instal a new locknut, do sion oil pan is accessible. . .
not tighten. 2. Loosen the oil pan retammg
not tighten. bolts and lower one edge of the oil
2. Torque the adjusting screw to 2. Torque the adjusting screw to pan to drain the transmission oil. If
10 ft. lbs., when using tool no. 10 ft. lbs., when using tool no. the same fluid is to be used again,
121111 or BW-54 7 A-50-2 set the 121111 or BW-54 7 A-50-2 set the filter the fluid through a 100 mesh
torque wrench (W & B model torque wrench (W & B model screen. Re-use the fluid only if it is
3200B) to 60 in. lbs. This will 3200B) to 60 in. lbs. This will in good condition.
7-60 GROUP 7-AUTOMATIC TRANSMISSION

valve while removing the control 13. Lower the car and fill the
assembly could cause the manual to transmission with fluid. Check the
become bent or damaged. transmission oil pan area for fluid
6. Refer to the Major Repair leakage.
Operation for control valve body
repair operation. INTERMEDIATE SERVO
7. Thoroughly clean and remove REPAIR
all the gasket material from the oil 1. Raise the car and remove the
pan and the oil pan mounting face four servo cover to case attaching
of the case. Install the valve body bolts.
to the case, engaging the transmis- 2. Remove the servo cover, gasket,
sion inner control levers with the piston, and piston return spring.
valve body manual and downshift Remove the piston from the cover
valves. (Fig. 61).
8. Shift the manual lever at the 3. Remove the piston seals and
transmission into the P detent posi- cover gasket.
tion. In.stall the valve body to the 4. Install new piston seals on the
case. Position the inner downshift piston. Lubricate the piston seals
lever between the downshift lever with clean transmission fluid. Install
stop and the downshift valve. Make the servo piston in the cover.
sure the two lands on the end of the 5. Install the piston return spring
FIG. 27 - Intermediate Band manual valve engage the actuating in the case. Place a new gasket on
Adjustment pin on the manual detent lever. the cover. Install the piston and
Install seven valve body-to-case cover into the transmission case
bolts. Do not tighten the bolts at making sure that the slotted end of
this stage. the piston is in a horizontal position
9. Position the detent valve spring so that it will engage the strut.
to the lower valve body and install Use two -ilr-18 x ll bolts, 180°
the spring-to-case bolt finger tight apart to position the cover against
(Fig. 29). the case.
10. Hold the detent spring roller 6. Install the two servo cover
in the centre of the manual detent attaching bolts. Remove the two
lever and install the detent spring- ll-inch bolts and install two at-
to-lower valve body bolt. Tighten taching bolts. Torque the bolts to
the bolt to specifications. specification.
11. Tighten all the control valve 7. Adjust the intermediate band.
body-to-case attaching bolts to Lower the car and check the trans-
specifications. mission fluid level.
12. Place a new gasket on the oil 8. If the band cannot be adjusted
pan. Install the oil pan and attach- properly, the struts are not in
ing bolts. Torque the bolts to position. Remove the oii pan and
specification. valve body. Install the struts, valve
On PEF-C models connect body, oil pan, and adjust the band.
the filler tube to the pan and tighten Refill th~ transmission with fluid.
securely.

FIG. 28 - Low-Reverse Band

Adjustment
On PEF-C models disconnect
the fluid filler tube from the trans-
mission oil pan to drain the fluid.
3. Remove the transmission oil
pan attaching bolts, oil pan and
gasket.
4. Shift the transmission manual
lever to the P position and remove
the two bolts that attach the detent
spring to the valve body and case
(Fig. 29).
5. Remove the remaining valve
body-to-case attaching bolts. Hold
the manual valve to keep it from 02058-A
sliding out of the valve body and
remove the valve body from the
case. Failure to hold the manual FIG. 29- Control Valve Body Detent Spring Installed
PART 7-2- C4 AUTOMATIC TRANSMISSION 7-61

FIG. 30 - Removing Extension Housing Seal

EXTENSION HOUSING BUSHING

D1025-1
~~·;.;;,;:==::::::-::::..
EXTENSION HOUSING D1026-B
FIG. 34 - Governor Installed
replacing, carefully remove it with
a tapered chisel or the tools shown
FIG. 31 - Removing Extension FIG. 32 - Installing Extension in Fig. 30. Remove the bushin g as
Housing Bushing Housing Bushing shown in Fig. 31. Use the bushing
remover carefully so that the spline
seal is not damaged.
3. When installing a new bushing
use the special tool shown in Fig.
3l.
4. Before installing a new seal,
inspect the sealing surface of the
universal joint yoke for scores. If
scores are found, replace the yoke.
5. Inspect the counterbore of the
housing for burrs and remove with
crocus cloth.
6. Install the seal into the housing
with the tool shown in Fig. 33. The
seal should be firmly seated in the
FIG. 33 - Installing Extension Housing Seal bore. Coat the inside diameter of
the fiber portion of the seal with
LOW-REVERSE SERVO piston. The seal is bonded to the B8A-19589-A lubricant.
PISTON REPLACEMENT piston. 7. Coat the front universal joint
1. Raise the car on a hoist. 7. Position the spacer on the spline with B8A-19589-A lubricant
2. Loosen the reverse band adjust piston stern. Install a new piston on and install the drive shaft.
ing screw lock nut. Tighten the the stern. Install the attaching nut. EXTENSION HOUSING AND
reverse band adjusting screw to lO Torque the nut to specification. GOVERNOR REPLACEMENT
ft-lbs torque. (Tightening the screw 8. Install the reverse servo piston
assembly in the case. Make sure 1. Raise the car on the hoist.
will insure that the band strut will 2. Remove the drive shaft. Posi-
be held against the case by the band, that the release spring is in position.
9. Install the reverse servo cover tion the transmission jack to support
preventing it from falling down the transmission.
when the reverse servo piston and a new seal, using the same pro-
cedure as with the intermediate 3. Remove the speedometer cable
assembly is removed.) from the extension housing.
3. Remove the four servo covers servo. Torque the bolts to speci-
fication. 4. Remove the extension housing
to case attaching bolts. Remove the to crossmember mount attaching
servo cover and seal from the case. 10. Adjust the reverse band.
11. Lower the car and check the bolts. Raise the transmission and
4. Remove the reverse servo remove the mounting pad between
piston and stem from the case as transmission fluid level.
the extension housing and the cross-
an assembly. EXTENSION HOUSING member.
5. Insert a small screwdriver in BUSHING AND REAR SEAL 5. Loosen the extension housing
the hole of the piston stem (Fig. 59). REPLACEMENT attaching bolts to drain the trans-
Remove the piston attaching nut. mission fluid. Disconnect the ex-
6. Remove the servo piston from 1. Disconnect the drive shaft haust inlet pipes at the manifold
the stem . The piston seal cannot be from the transmission. and lower the inlet pipes.
replaced without replacing the 2. When only the rear seal needs
7-62 GROUP 7-AUTOMATIC TRANSMISSION

6. Remove the six extension 34). Install the attaching bolts and her attaching bolts. Torque the
housing-to-case attaching bolts and torque the bolts to specification. attaching bolts to specification.
remove the extension housing. 10. Install a new extension hous- Remove the transmission jack.
7. Remove the governor housing- ing gasket on the case. Install the 12. Connect the speedometer
to-governor distributor attaching extension housing and six attaching cable to the extension housing.
bolts (Fig. 34). Remove the gover- bolts. Torque the bolts to specifica- Install the drive shaft.
nor housing from the distributor. tion. 13. Install the inlet pipes on the
8. Refer to Major Repair Opera- 11. Install the transmission manifold.
tions for governor repair operations. mounting pad to the crossmember. 14. Lower the car and fill the
9. Install the governor housing Lower the transmission and install transmission with fluid.
on the governor distributor (Fig. the extension housing-to-crossmem- 15. Check the extension housing
area for fluid leakage.

REMOVAL AND INSTALLATION

REMOVAL
1. Raise the car and remove the chain.
two converter cover attaching bolts 2. Raise the transmission into
at the lower front side of the con- position and install the five con-
verter housing. Remove the cover. verter housing-to-engine attaching
l. Remove the two converter bolts. Torque the bolts to specifica-
drain plugs (Fig. 35). Drain the tion. Remove the safety chain from
fluid from the converter. Install the the transmission.
two converter drain plugs. 3. Position the crossmember and
3. Remove the drive shaft and mounting pad into position and
install the extension housing seal install the four attaching bolts.
replacer tool in the extension Torque the bolts to specifications.
housing. 4. Lower the transmission and
4. Disconnect the vacuum hose FIG. 35 - Converter Drain Plug install the extension housing and
from the transmission vacuum unit. Location crossmember attaching bolts.
Disconnect the vacuum line from Torque the bolts to specification.
the retaining clip. 5. Install the four flywheel-to-
5. Remove the two extension converter attaching nuts. Torque
housing to crossmember bolts. the nuts to specification.
6. Disconnect the speedometer 6. Remove the transmission jack.
cable from the extension housing. Connect the vacuum hose to the
7. Disconnect the exhaust pipe transmission vacuum unit. Install
flange from the manifolds. the vacuum line retaining clip.
8. Remove the parking brake 7. Install the transmission fluid
cable from the equalizer lever. filler tube. Connect the fluid cooling
9. Loosen the transmission oil lines to the transmission case.
pan bolts and drain the fluid at one 8. Connect the linkage rods to
corner of the oil pan. Tighten the the transmission downshift and
attaching bolts after the fluid has manual control levers.
drained. 9. Connect the speedometer
10. Disconnect the fluid cooler cable to the extension housing.
lines from the transmission case. FIG. 36 - Transmission Mounted 10. Connect the exhaust inlet
Remove the fluid tube from the on Jack pipes to the manifolds.
case. 11. Install -and adjust the parking
11. Remove the manual and 15. Remove the four crossmem- brake cable at the equalizer lever.
kickdown linkage rods from the ber and mounting pad attaching 12. Install the converter housing
transmission control levers. bolts and lower the crossmember . . cover and torque the attaching bolts
ll. Remove the starter cable. 16. Remove the five converter to specification.
Remove the starter attaching bolts housing-to-engine; attaching bolts. 13. Install the starter and torque
and remove the starter from the Lower the transmission {Fig. 36), the bolts to specification. Connect
converter housing. and remove it from 'Under the car. the starter cable.
13. Remove the four converter- 14. Install the drive shaft. Torque
to-flywheel attaching nuts. INSTALLATION the companion flange U-bolt nuts
14. Position the transmission 1. With the converter properly to specification.
jack to support the transmission installed, place the transmission on 15. Lower the car and fill the
and secure the transmission to the the jack (Fig. 36). Secure the trans- transmission with fluid. Adjust the
jack with a safety chain. mission to the jack with the safety manual and kickdown linkage.
PART 7-2- C4 AUTOMATIC TRANSMISSION 7-63

MAJOR REPAIR OPERATIONS

Before removing any of the sub-
assemblies, thoroughly clean the
outside of the transmission to
prevent dirt from entering the
mechanical parts. During the repair
operations, refer to Part 7-1 for
common adjustments and repairs or
cleaning and inspection procedures.
During the transmission dis-
assembly or assembly operations,
ten thrust washers located between
the sub-assemblies must be removed
and installed. It is important that
each thrust washer be in the correct
position during the assembly opera-
LOW-RE VE RSE BAND LOW RE VERSE
tion. ADJUSTING SC REW BAND STRUTS 0 1384· C
01381-A
To properly locate and identify
the thrust washers, the various FIG. 38 - Removing or Installing FIG. 41 -Band Adiusting Studs
positions of the thrust washers are Primary Throttle Valve and Struts
shown in the illustrations and are 6. Remove control valve body.
numbered 1 through 10. Number I
7. Loosen the intermediate band
is the first thrust washer located at
the front pump. The last thrust adjusting screw (Fig. 41) and
remove the intermediate band struts
washer, No. 10, is located at the from the case. Loosen the low-
parking pawl ring gear. reverse band adjusting screw and
DISASSEMBLY OF remove the low-reverse band struts
(Fig. 41).
TRANSMISSION
1. Remove the converter from TRANSMISSION END
the transmission front pump and PLAY CHECK
converter housing.
2. Remove the transmission 1. To keep the output shaft in
alignm~nt during the . end play
vacuum unit with the tool shown
in Fig. 37. Remove the vacuum unit check, mstall the extenston housing
gasket and control rod. oil seal replacer tool or a front
3. From the vacuum unit hole in universal joint yoke in the extension
the case, remove the primary throttle housing.
valve (Fig. 38). 2. Remove one of the front
4. Remove the two extension pump-to-case attaching bolts and
housing-to-case attaching bolts and mount the dial indicator as shown
mount the transmission in the in Fig. 42.
01382-A
holding fixture as shown in Fig. 39. :\. The input shaft is a loose part
5. Remove the oil pan attaching FIG. 39 - Transmission Mounted and has to be properly engaged with
bolts, and the oil pan and gasket. in Holding Fixture

D 1383·8
D1385-B
FIG. 40- Control Valve
FIG. 37- Removing Vacuum Unit Attaching Bolts FIG. 42 - Checking End Play
7-64 GROUP 7-AUTOMATIC TRANSMISSION

SELECTIVE THRUST WASHERS

(FOR END· PLAY CORRECTION)
THRUST WASHER NO. 1 THRUST WASHER NO. 2
~RONT PUMP
STATOR SUPPORT 0.053· 0.0575 Red No. Stamped Metal
Woaher Thr'(&t Washer
0.070. 0.074 Green
0.087. 0.091 Natural 0.043· 0.041
0.104. 0.108 Block 0.058- O.OS6
0.121-0. 125 Yellow 0.075-0.073
SPACER 0.036· 0.032
(This is o selective spacer
used with washer 2 or 3. When
NYLON SELECTIVE used, install next to stator
THRUST WASHER su ort.
NO.1

0 1865-0
INPUT SHELL
D 1869· B
FIG. 43- Selective Thrust Washer Locations
FIG. 47 - Lifting Input Shell and
the spline of the forward clutch hub Gear Train
during the end play checking pro-
cedure. Move the input shaft and edge of the case. Remove the front
gear train toward the back of the pump and gasket from the case. If
transmission case. the selective thrust washer No. 1
4. With the dial indicator con- did not come out with the front
tacting the end of the input shaft, pump, remove it from the top of the
set the indicator at zero (Fig. 42). reverse-high clutch.
5. Insert a screwdriver behind the 4. Remove the intermediate and
input shell (Fig. 42). Move the input low-reverse band adjusting screws
shell and the front part of the gear from the case. Rotate the inter-
train forward. mediate band to align the band with
6. Record the dial indicator read- the clearance hole in the case (Fig.
ing. The end play should be 0.008 46). Remove the intermediate band
to 0.042 inch. If the end play is not from the case. If the intermediate
within specifications, the selective band is to be re-used, do not clean
thrust washers (Fig. 43) must be it in a vapor degreaser, or with a
replaced as required. D 1867·8 detergent solution. Clean the band
with a lint free cloth.
The selective thrust washers can FIG. 45 - Removing Front Pump 5. Using a screwdriver between
be replaced individually to obtain the input shell and rear planet carrier
the specified end play. (Fig. 47) lift the input shell upward
7. Remove the dial indicator and and remove the forward part of the
remove the input shaft from the gear train as an assembly (Fig. 48).
front pump stator support (Fig. 44). 6. Place the forward part of the
gear train in the holding fixture
REMOVAL OF CASE AND shown in Fig. 49.
' 'P
EXTENSION HOUSING PARTS
1. Rotate the holding fixture to INTERMEDIA BAND
'
,.;
CLEARANCE
HOLE IN CASE D 1389-A
put the transmission in a vertical
position with the converter housing FIG. 46 - Removing or Installing
up. Intermediate Band
2. Remove the five converter
housing to case retaining bolts.
Remove the converter housing from
the transmission case.
Remove the six converter hous-
ing and front pump to case retaining
bolts on the PEE-AC model, or the
five converter housing to case retain-
ing bolts on the PEF-C model.
3. Remove the seven front pump
attaching bolts. Remove the front
pump by inserting a screwdriver D 1870 . B
behind the input shell (Fig. 45). FIG. 48- Removing or Installing
FIG. 44 - Removing or Installing Move the input shell forward until
Input Shaft the front pump seal is above the Forward Part of Gear Train
PART 7-2- C4 AUTOMATIC TRANSMISSION 7-65

FORWARD GEAR TRAIN ASSEMBLY

[)
e

I~
[
19
LOW-R D1396-A

FIG. 53 - Removing or Installing

Low-Reverse Band
If a selective spacer was used. re-
move the spacer. Remove the for-
ward clutch from the forward clutch
hub and ring gear (Fig. 50).
FIG. 52 - Removing or Installing 9. If thrust washer No. 3 (Fig.
Reverse Ring Gear Hub Retaining 50) did not come out with the
Ring forward clutch, remove the thrust
FIG. 49- Forward Part of Gear 7. From the g-ear train in the washer from the forward clutch hub.
holding fixture, remove the reverse- 10. Remove the forward clutch
Train Positioned in Holding high clutch and drum from the hub and ring gear from the front
Fixture forward clutch (Fig. 50). planet carrier (Fig. 50).
8. If thrust washer No. 2 (Fig. 11. Remove thrust washer No. 4
43) did not come out with the front and the front planet carrier from
pump, remove the thrust washer the input shell.
from the forward clutch cylinder. SUN GEAR

FORWARD CLUTCH INPUT SHELL

HUB AND
RING GEAR

REVERSE-HIGH CLUTCH THRUST

NO. 5

FIG. 50- Forward Part of Gear Train Disassembled

I
REVERSE PLANET CARRIER

REVERSE RING GEAR SPRING RETAINER

AND HUB

l ~-
'""" OAC'

THRUST WASHER NO . 7

LOW AND REVERSE DRUM

"iJ
~<!"
ONE-WAY
CLUTCH
SPRINGS (12)
AND ROLLERS ( 1 2)
OUTER RACE

FIG. 51 -Lower Part of Gear Train Disassembled

7-66 GROUP 7-AUTOMATIC TRANSMISSION

12. Remove the input shell, sun GOVERNOR DISTRIBUTOR

gear and thrust washer No. 5 from
the holding fixture (Fig. 50).
13. From inside the transmission
case, remove thrust washer No. 6
(Fig. 51) from the top of the reverse
planet carrier.
14. Remove the reverse planet
carrier and thrust washer No. 7
from the reverse ring gear and hub
(Fig. 51).
15. Move the output shaft for- 01398·8
ward and with the tool shown in FIG. 55 - Removing or Installing
Fig. 52 remove the reverse ring gear
hub to output shaft retaining ring. Governor Distributor Lock Ring
16. Remove the reverse ring gear governor distributor sleeve are re-
and hub from the output shaft. moved.
Remove thrust washer No. 8 from 21. Remove the transmission FIG. 57- Removing One-Way
the low and reverse drum. from the holding fixture. Position Clutch Outer Race Attaching Bolts
17. Remove the low-reverse band the transmission on the bench in a
from the case (Fig. 53). vertical position with the extension 25. Remove the parking pawl
18. Remove the low-reverse drum housing up. Remove the four exten- return spring, pawl and retaining
from the one-way clutch inner race sion housing-to-case attaching bolts. pin from the case (Fig. 56).
(Fig. 51). Remove the extension housing and 26. Remove the parking gear and
19. Remove the one-way clutch gasket from the case. thrust washer No. I0 from the case.
inner race by rotating the race 22. Pull outward on the output 27. Remove the six one-way
clockwise as it is removed. shaft and remove the output shaft clutch outer race to case attaching
20. Remove the 12 one-way and governor distributor assembly bolts with the tool shown in Fig. 57.
clutch rollers, springs and the spring from the governor distributor sleeve As the bolts are removed, hold the
retainer from the outer race (Fig. (Fig. 54). outer race l~cated inside the case in
51). Do not lose or damage any of 23. Remove the governor dis- position. Remove the outer race and
the 12 springs or rollers. The outer tributor lock ring from the output thrust washer No. 9 from the case
race of the one-way clutch cannot shaft (Fig. 55). Remove the governor (Fig. 51).
be removed from the case until the distributor from the output shaft.
extension housing, output shaft and 24. Remove the four distributor PARTS REPAIR OR
OUTPUT SHAFT sleeve-to-case attaching bolts. Re- REPLACEMENT
move the distributor sleeve from the During the repair of the sub-
case. Do not bend or distort the oil assemblies, certain general instruc-
tubes as the tubes are removed from tions which apply to all units of the
the case with the distributor sleeve. transmissions must be followed.

SPRING

PARKING PAWL GEAR

FIG. 54- Removing or Installing

Output Shaft and Governor D1399·A

Distributor FIG. 56- Parking Pawl Mechanism

PART 7-2- C4 AUTOMATIC TRANSMISSION 7-67

COVER SEAL ing nut (Fig. 59). Position the spacer

on the piston stem if it was previ-
ously removed. Install the new servo
SERVO PISTON STEM piston and torque the piston attach-
ing nut to specification.
4. Place the piston return spring
in the servo bore of the case.
Lubricate the piston seal with clean
transmission fluid and install the
servo piston (Fig. 58).
5. Place a new cover seal on the
PISTON RETURN SPRING PISTON AND SEAL COVER
(SEAL BONDED TO PISTON) cover and install the servo cover.
Install the four cover attaching
01401-A bolts. Torque the cover to case re-
taining bolts to specification.
FIG. 58 - Low·Reverse Servo Disassembled Intermediate Servo Repair
These instructions are given here to 1. Remove the four servo cover-
avoid unnecessary repetition. to-case attaching bolts.
Handle all transmission parts 2. Remove the servo cover, gas-
carefully to avoid nicking or burring ket, servo piston, and piston return
the bearing or mating surfaces. spring from the case (Fig. 60).
Lubricate all internal parts of the 3. Remove the intermediate servo
transmission before assembly with piston from the cover (Fig. 61).
clean automatic transmission fluid. 4. Remove the seal rings from
Do not use any other lubricants the servo piston and cover.
except on gaskets and thrust washers 5. Install a new seal on the cover
which mav be coated with vaseline and servo piston. Lubricate the
to facilitate assembly. Always install seals with clean transmission oil.
new gaskets when assembling the Install the piston into the cover. Be
transmission. careful not to damage the piston
Tighten all bolts and screws to seal.
FIG. 59 - Removing or Installing the recommended torque outlined 6. Install the piston return spring
Low-Reverse Servo Piston in the Specification Section. in the servo bore of the case.
7. Place a new gasket on the
servo cover. Position the servo
piston and cover assembly into the
case making sure that the slot is in
a horizontal position to engage the
strut. Use two 1"s-18 bolts, 1~ inch
long, 180° apart, to position the
cover against the case. Install two
cover attaching bolts. Remove the
two I i inch bolts and install the
other two cover attaching bolts.
Torque the attaching bolts to
specification.
FIG. 60 - Intermediate Servo Disassembled Downshift and Manual Linkage
I. Remove the downshift outer
TRANSMISSION CASE AND lever attaching nut. Remove the
down~hift outer and inner levers.
LINKAGE REPAIR
From inside the transmission case.
Low-Reverse Servo remove the upper retaining ring and
1. Remove the four servo cover flat washer from the manual lever
to case attaching bolts. link (Fig. 64). Remove the upper
2. Remove the servo cover, cover end of the lever link from the case
seal, servo piston and piston return retaining pin
spring from the case (Fig. 58). 2. From the back of the trans-
3. The servo piston seal is bonded mission case, remove the upper
to the piston. If the seal has to be retaining ring and flat washer from
replaced, replace the piston as- the parking pawl link (Fig. 62) .
. sembly which includes the seal. Dis- Remove the pawl link from the case
assemble the servo piston from the retaining pin.
piston rod by inserting a small 3. From the back of the trans-
FIG. 61 - Removing Intermediate screwdriver in the hole of the piston miSSIOn case, remove the parking
Servo Piston rod and removing the piston attach- pawl link, toggle rod, and manual
7-68 GROUP 7-AUTOMATIC TRANSMISSION
retaining pin. Install the flat washer
and retaining ring.
13. Operate the manual lever and
check for correct linkage operation.
14. Install the inner and outer
downshift levers. Torque the attach-
ing nut to specifications.
Thread Repair-Case. Thread
service kits may be purchased from
local suppliers. To repair a damaged D1408·A
thread, the following procedures FIG. 65 - Removing Manual
should be carefully followed. Lever Seal
1. Drill out the damaged threads,
using the same drill size as the
thread OD. For example, use a -fg-
FIG. 62- Parking Pawl Link inch drill for a -fk-18 thread.
Installed 2. Select the proper special tap
and tap the drilled hole. The tap is
marked for the size of the thread
being repaired. Thus, the special tap
marked -fs-18 will not cut the same
thread as a standard -fg-18 tap. lt
does cut a thread large enough to
accommodate the insert, and after
the insert is installed the original
thread size ( -fs-18) is restored. D1409-A
3. Select the proper coil inserting
tool. These tools are marked with FIG. 66 - Installing Manual
FIG. 63 - Removing or Installing Lever Seal
Parking Pawl Toggle Rod the thread size being repaired. Place
the insert on the tool and adjust the 5. If the inserts are not properly
lever link as an assembly (Fig. 63). sleeve to the length of the insert installed, they can be removed with
4. Remove the rear parking pawl being used. the extractor tool. Place the extrac-
link lower retaining ring, flat washer Press the insert against the face tor tool in the insert so that the
and link from the toggle rod (Fig. of the tapped hole. Turn the tool blade rests against the top coil i to
64). clockwise and wind the insert into ! turn away from the end of the
5. Remove the manual lever link the hole until the insert is ! turn coil. Tap the tool sharply with a
lower retaining ring, flat washer and below the face. hammer so that the blade cuts into
link from the toggle rod. 4. Working through the insert, the insert. Exert downward pressure
6. Remove the inner manual bend the insert tang straight up and on the tool and turn it counter clock-
lever attaching nut and lever. down until it breaks off at the notch. wise until the insert is removed.
Remove the outer manual lever
from the case.
7. To remove the manual lever
seal, use the tools shown in (Fig. 65).
To install the new seal, use the tool
shown in Fig. 66.
8. Install the outer manual lever
in the case. Install the inner
manual iever and attaching nut
with the chamfer facing toward the
lever (Fig. 64). Torque the nut to
specification.
9. From the back of the trans-
mission case, install the parking
toggle rod and link assembly into
the case (Fig. 63).
10. Install the parking pawl link
on the case retaining pin. Install the
flat washer and link retaining ring
(Fig. 62).
11. Position the inner manual
lever behind the manual lever link,
with the cam of the lever contact-
ing the lower link pin.
12. Install the upper end of the INNER MANUAL LEVER MANUAL LEVER LINK
D1405-B
manual lever link on the case FIG. 64 - Case Linkage
PART 7-2- C4 AUTOMATIC TRANSMISSION 7-69

CONTROL VALVE BODY

Disassembly

When the main control is dis-

assembled and the valve body-
to-screen gasket is removed the
gasket should not be cleaned in
a degreaser, solyent or any type
of detergent solution. To clean
the gasket, wipe it off with a
lint-free cloth.
1. Remove the eight screws that
attach the oil screen to the body and
remove the screen and gasket (Fig.
102). Be careful not to lose the
throttle pressure limit valve and ATTACHING
spring when separating the oil screen SCREWS
02074-A
from the valve body.
2. Remove the nine attaching
screws from the underside of the
lower valve body. Separate the lower
valve body, gasket, separator plate LOWER
VALVE BODY
and hold-down plate (Fig. 67) from
the upper valve body. Be careful not
to lose the upper valve body shuttle
valve and check valve when separat-
ing the upper and lower valve bodies.
3. Slide the manual valve out of
the body.
4. Carefully pry the low servo
modulator valve retainer from the
body and remove the retainer plug,
spring and valve from the body. THROTTLE
While working in the low servo PRESSURE
LIMIT VALVE
modulator valve bore, pry the down-
shift valve retainer from the body
and remove the spring and downshift D207J.A
valve (Fig. 68).
5. Depress the throttle booster FIG. 67- Separating Upper and Lower Valve Bodies
plug and remove the retaining pin. springs, retainer and the main oil 68). Depress the plug and install the
Remove the plug, valve and spring pressure regulator valve. retaining pin.
(and ball on 250 2V and 302 2V). 14. Remove the line coasting boost 4. Place the spring, 2-3 back-out
6. Remove the cut-back valve and valve retainer from the body and valve and the transition valve and
transition valve cover plate from the remove the spring and line coasting spring in the body.
valve body (Fig. 68). boost valve. 5. Place the cut-back valve in the
7. Remove the cut-back valve from body.
the body. Assembly 6. Secure the cut-back and the
8. Remove the transition valve 1. Place the two shuttle valves in transition valve cover plate to the
spring, transition valve, 2-3 back-out the lower body as shown in Fig. 67. body with the two attaching screws.
valve and spring from the body. Position the gasket, separator plate Torque the screws to specification.
9. Remove the 1-2 shift valve and and hold-down plate on the lower 7. · Place the throttle modulator
2-3 shift valve cover plate from the body and install the two attaching valve, spring and 2-3 shift valve in
body. screws. Torque the screws to speci- the body.
10. Remove the 2-3 shift valve, fication. 8. Place the springs, D2 valve and
spring and throttle modulator valve 2. Insert the downshift valve (Fig. the 1-2 shift valve in the body.
from the body. 68) into the body with the small 9. Secure the 1-2 shift valve and
11. Remove the 1-2 shift valve, D2' diameter facing inward. Install the the 2-3 shift valve cover plate to the
valve and spring from the body. downshift valve spring and retainer. body with the three attaching screws.
12. Remove the intermediate servo Insert the low servo modulator valve, Torque the screws to specification.
retaining pin and remove the inter- spring and retainer plug in the body. 10. Place the spring, intermediate
mediate accumulator retainer, valve Depress the plug and install the servo accumulator valve and retainer
and spring from the body. retainer. in the body. Depress the retainer and
13. Press the main oil pressure 3. Place the throttle booster valve install the retaining pin.
booster valve inward and remove the spring (and ball on 250 2V and 302 11. Insert the line coasting boost
retaining pin. Remove the main oil 2V), valve (small diameter end into valve and spring in the body. Depress
pressure booster valve, sleeve, spring) and plug into the body (Fig. the spring and install the retainer.
7-70 GROUP 7-AUTOMATIC TRANSMISSION

2-3 SHIFT _..

VALVE

..---
'-----TRANSITION
,_ VALVE
...

1
2-3 BACK-OUT VALVE

~: tt. /THROTTLE MODULATOR

/ v...
INTERMEDIATE
SERVO ACCUMULATOR
\ALVE
3
.3 ~
i/ u~mM~:m
~
~l
:'io
VALVE

tlt~~s3~LE
REGULATOR
VALVE
i; ----LJ~5s'tD¢1[~EG
I

RETAINER~ -

\,g ~
3 f( i .----RETAINER

~
..,....,
-><-
;.-

.....
it_ _
V'· SLEEVE
PIN

H!
~ ..
~ -------PRESSURE
~ •-
i8J
MAINOIL
BOOSTER
VALVE

D207S.A

FIG. 68- Upper Valve Body Disassembled

PART 7-2- C4 AUTOMATIC TRANSMISSION 7-71

12. Insert the main oil pressure 5. Place the stator support in the
regulator valve and spring retainer pump housing and install the five
in the body (Fig. 68). Install the two attaching bolts. Torque the bolts to
springs, sleeve and the main oil specifications.
pressure booster valve in the body. 6. Install the four seal rings on
13. Hold the main oil pressure the stator support. Two large rings
booster valve in place and install the are assembled first in the ring
retaining pin. grooves toward the front of the
14. Slide the manual valve into the stator support.
valve body. Make sure that the end 7. Check the pump gears for free
with the two lands closest together is rotation by placing the pump on the
inserted first. converter drive hub in its normal
15. Position the rubber ball shuttle running position and turning the
valve and servo check valve in the pump housing.
upper valve body (Fig. 67). 8. If the front pump seal must be
16. Position the lower valve body replaced , mount the pump in the D1418-A
in place on the upper valve body and transmission case and remove the FIG. 70 - Removing Front Pump
secure it with the nine attaching seal with the tool shown in Fig. 70.
screws. Torque the screws to speci- Seal
To install the new seal use the tool
fication. shown in Fig. 71.
17. Position the throttle pressure
limit valve and spring in the lower REVERSE-HIGH CLUTCH
valve body (Fig. 67). Place the gasket 1. Remove the pressure clutch
and oil screen in position on the lower plate retaining snap ring (Fig. 72).
valve body and secure with the eight 2. Remove the pressure plate, and
attaching screws. Torque the screws the drive and driven clutch plates.
to specification. (Fig. 73). If the composition clutch
FRONT PUMP plates are to be reused, do not clean
the plates in a vapor degreaser or
1. Remove the four seal rings with a detergent solution. Wipe the
from the stator support . FIG. 71 - Installing Front Pump
plates clean with lint-free cloth.
2. Remove the five bolts that 3. To remove the piston spring
attach the stator support to the retainer snap ring, place the clutch
front pump housing. Remove the hub in the arbor press. With the
stator support from the pump tools shown in Fig. 74, compress
housing (Fig. 69). the piston return spring and remove
3. Remove the drive and driven the snap ring. When the arbor press
gears from the front pump housing. ram is released , guide the spring
4. Install the drive and driven retainer to clear the snap ring
gears in the pump housing. Each groove of the drum.
gear has an identification mark on 4. Remove the spring retainer
the side of the gear teeth that are and piston return spring.
chamfered. The chamfered side with 5. Remove the piston by inserting
the identification mark has to be air pressure in the piston apply hole
positioned downward against the face of the clutch hub (Fig. 75).
of the pump housing.
FIG. 72 - Removing Reverse-High
Clutch Snap Ring
PUMP ASS EMBLY· 7AI03
I

PUMP HOUSING
FRONT PUMP SEAL · STATOR SUPPORT· 7A108
SEAL RINGS
7A248

f~
-b
()
DRIVE GEAR

) ..
I~' =-
·~., \1
+
DRIVEN GEAR
SELECTIVE
THRUST WASHERS

GASKET· 7A136
D 1894-C

FIG. 69- Front Pump and Stator Support Disassembled

7-72 GROUP 7-AUTOMATIC TRANSMISSION
REVERSE AND HIGH
CLUTCH CYLINDER PI STON SPRIN G RETAI NER

L\
~ J

PIS TON SEALS

PISTON
RETU RN SPR ING SNAP RIN G DRIVEt; PLATES
I
PRESSURE PLATE

01897-B

FIG. 73 - Reverse-High Clutch Disassembled

FIG. 75- Removing Reverse-High

Clutch Piston
Tool T 65 L · 77515· A D 1591.8

FIG. 74- Removing or Installing Clutch Piston Spring

Retainer Snap Ring
6. Remove the piston outer seal by starting first with a steel plate
from the piston and the piston inner then a non-metallic plate (Fig. 73).
seal from the clutch drum. The last plate installed is the
7. Install a new inner seal in the pre!isure plate. For the correct
clutch drum and a new outer seal number of clutch plates required
on the clutch piston (Fig. 73). for each transmission model, refer FIG. 76- Checking Reverse-High
Lubricate the seals with clean trans- to specifications.
mission fluid and install the piston 10. Install the pressure plate Clutch Snap Ring Clearance ·
into the clutch drum. retaining snap ring (Fig. 72). Make
8. Place the clutch piston spring sure the snap ring is fully seated in
into position on the clutch piston. the snap ring groove of the clutch
Place the spring retainer on top hub.
of the spring. To install the snap 11. With a feeler gauge, check
ring, use the tools shown in the clearance between the snap
Fig. 74. As the press ram is moved ring and the pressure plate (Fig. 76).
downward, make sure the spring 12. The pressure plate should be
retainer is centered to clear the held downward as the clearance is
drum. Install the snap ring. Before checked . The clearance should be
the press ram is released make sure 0.050 to 0.071 inch . If the clearance is
the snap ring is positioned inside not within specifications, selective
of the four snap ring guides on the thickness snap rings are available in
spring retainer. these thicknesses, 0.050-0.054, 0.064-
9. When new composition clutch 0.068, 0.078-0.082 and 0.092-0.096
plates are used , soak the plates in inch . Install the correct size snap ring
transmission oi l for fifteen minutes and recheck the clearance .
before the plates are assembled. FIG. 77. - Removing Forward
Install the clutch plates alternately Clutch Pressure Plate Snap Ring
PART 7-2- C4 AUTOMATIC TRANSMISSION 7-73

PISTON SEALS
DRIVE PLATES
SNAP RING

PISTON
DISC SPRING
FORWARD CLUTCH CYLINDER DRIVEN PLATES
01425-A

FIG. 78 - Forward Clutch Disassembled

5. Remove the clutch piston
outer seal and the inner seal from
the clutch hub (Fig. 78).
6. Install new clutch piston seals
on the clutch piston and drum.
Lubricate the seals with clean trans-
mission fluid.
7. Install the clutch piston into
the clutch hub. Install the steel ring
on the piston. Install the disc spring
and retaining snap ring (Fig. 79).
8. Install the lower pressure plate
with the flat side up and radius side
FIG. 81- Checking Forward downward.
FIG. 79 -Removing or Installing Clutch Snap Ring Clearance Install one non-metallic clutch
Disc Spring Snap Ring RING GEAR
plate and alternately install the drive
and driven plates. The last plate
installed will be the top pressure
plate (Fig. 78). Refer to Specifica-
tion Section for the correct number
of clutch plates for the applicable
model transmission.
9. Install the pressure plate re-
taining snap ring (Fig. 77). Make
sure the snap ring is fully seated in
the ring groove of the clutch hub.
01428-A 10. With a feeler gauge, check
the clearance between the snap ring
FIG. 82 - Forward Clutch Hub and the pressure plate (Fig. 81).
and Ring Gear Disassembled Downward pressure on the plate
should be used when making this
EXTERNAL SNAP RING check. The clearance should be
0.025-0.050.
FIG. 80 - Removing Forward 11. If the clearance is not within
Clutch Piston specifications, selective snap rings
are available in these thicknesses,
FORWARD CLUTCH 0.050-0.054, 0.064-0.068, 0.078-
0.082 and 0.092-0.096 inch. Insert
1. Remove the clutch pressure the correct size snap ring and
plate retaining snap ring (Fig. 77). recheck the clearance.
2. Remove the pressure plate,
and the drive and driven clutch FORWARD CLUTCH HUB
plates from the clutch hub (Fig. 78). AND RING GEAR
3. Remove the disc spring re- 1. Remove the forward clutch
taining snap ring (Fig. 79). hub retaining snap ring (Fig. 82).
4. Apply air pressure at the clutch 2. Remove the forward clutch
piston pressure hole (Fig. 80), to hub from the ring gear.
remove the piston from the clutch FIG. 83 - Removing or Installing 3. Install the forward clutch hub
hub. Sun Gear External Snap Ring in the ring gear. Make sure the hub
7-74 GROUP 7-AUTOMATIC TRANSMISSION

EXTERNAL SNAP RING is bottomed in the groove of the

INPUT SHELL
ring gear.
4. Install the front clutch hub
~ retaining snap ring. Make sure the
snap ring is fully seated in the snap
ring groove of the ring gear.

INPUT SHELL AND SUN GEAR

1. Remove the external snap ring
from the sun gear (Fig. 83).
2. Remove thrust washer No. 5
from the input shell and sun gear
(Fig. 84).
3. From inside the input shell,
remove the sun gear. Remove the
SUN GEAR internal snap ring from the sun
THRUST WASHER NO . 5 gear.
4. Install the internal snap ring
on the sun gear. Install the sun gear
FIG. 84- Input Shell and Sun Gear Disassembled in the input shell.
5. Install thrust washer No. 5 on
the sun gear and input shell (Fig.
84).
6. Install the external snap ring
on the sun gear (Fig. 83).

REVERSE RING GEAR

AND HUB
1. ~emove the hub retaining
snap rmg from the reverse ring gear.
2. Remove the hub from the
reverse ring gear (Fig. 85).
3. Install the hub in the reverse
ring gear. Make sure the hub is fully
FIG. 85 - Reverse Ring Gear and seated in the groove of the ring gear.
Hub Disassembled 4. Install the snap ring in the
FIG. 87- Removing or Installing reverse ring gear. Make sure the
snap ring is fully seated in the snap
Retaining Ring ring groove of the ring gear.
GOVERNOR AND OIL
DISTRIBUTOR
1. Remove the rings from the
governor oil distributor (Fig. 86).
2. Remove the governor housing
to distributor attaching bolts.
Remove the governor from the oil
distributor. Remove the governor
oil screen.
3. Remove the primary governor
valve retaining ring (Fig. 87).
Remove the washer, spring, and
primary governor valve from the
housing.
4. Remove the secondary govern-
or valve spring retaining clip,
spring, and governor valve from
the housing.
5. Install the secondary governor
valve in the housing. Install the
spring and retaining clip. Make
ERNOR fi OUS IN(,
sure the clip is installed with the
GOVERNOR ASS EMBLY - 7(063 01907-B
small concaved area facing down-
ward, to hold the spring in the
correct position.
FIG. 86 - Governor and Oil Distributor 6. Install the primary governor
PART 7-2- C4 AUTOMATIC TRANSMISSION 7-75

Transmission Case
1. If the transmission case bush-
ing is to be replaced, press the bus.n-
ing out of the case with the tool
shown in Fig. 88.
2. Install a new transmission case
bushing with the tool shown in
Fig. 88.
Front Pump Stator Support
1. Remove the front and rear
stator support bushings if they are
worn or damaged. Use the cape
chisel (Fig. 89) and cut along the
bushing seam until the chisel breaks
through the bushing wall. Pry the
loose ends of the bushing up with
REMOVAL an awl and remove the bushing.
2. Press new bushings into the
FIG. 88 - Replacing Transmission Case Bushing stator support with the tool shown
in Fig. 90. Use the long end of the
valve in the housing. Install the tool for the front bushing and the
spring, washer and retaining ring. short end for the rear bushing.
Make sure the washer is centered in When installing the rear bushing, be
the housing on top of the spring and sure the hole in the bushing is lined
the retaining ring is fully seated in up with the lube hole in the stator
the ring groove of the housing. support.
7. Install the governor oil screen.
8. Install the governor assembly Front Pump Housing
on the oil distributor and torque 1. Press the bushing from the
the attaching bolts to specification. front pump housing as shown in
9. Install the rings on the dis- Fig. 91.
tributor. Check the rings for free Press a new bushing into the
rotation in the ring grooves of the pump housing with the handle and
oil distributor. tool shown in Fig. 91. Make sure
the bushing is installed with the slot
BUSHfiNG REPLACE~NT and groove positioned to the rear of
A service bushing remover and the pump body and 60 degrees
replacer kit has been released for below the horizontal centre line.
the C4 transmission. The kit con-
tains a handle, cape chisel and Reverse-High Clutch
FIG. 89 - Removing Stator various adapters to remove and 1. Remove the drum bushing if
Support Bushings install the precision bushings in the it is worn or damaged. Use the cape
transmission. If it is necessary to chisel (Fig. 92) and cut a shallow
replace a bushitig, the following groove ! inch in length along the
procedures should be used. bushing seam until the chisel breaks

REMOVAL INSTALLATION D 1 732 · A

FIG. 90 - Installing Stator
Support Bushings FIG. 91 -Replacing Front Pump Housing Bushing
7·76 GROUP 7-AUTOMATIC TRANSMISSION
Hondle

REMOVAL
D 1737 - A

FIG. 95 - Replacing Sun Gear

FIG. 92 - Removing Reverse-High Bushings FIG. 96 - Installing Low and
Clutch Bushing Reverse Brake Drum Bushing
through the bushing walL Pry the
loose ends of the bushing up with
an awl and remove the bushing. To
prevent leakage at the stator sup-
port 0-rings, be careful not to nick
or damage the hub surface with the
chiseL
2. Position the drum in a press,
and press a new bushing into the
drum with the handle and tool
shown in Fig. 93.
Forward Clutch Hub
1. Press the bushing from the
clutch hub as shown in Fig. 94.
2. Install a new bushing into the
clutch hub as shown in Fig. 94.
Sun Gear
Jo 1735 - A I 1. If the sun gear bushings are to
BOITOM
be replaced, use the tool shown in OF CASE 01437- A
Fig. 95 and press both bushings
FIG. 93 - Installing Reverse-High through the gear. FIG. 97 - Number 9 Thrust
Clutch Bushing 2. Press a new bushing into each Washer Location
end of the sun gear with the tool
shown in Fig. 95 .

FIG. 98 - Installing One-Way

FIG. 94 - Replacing Forward Clutch Hub Bushing Clutch Outer Race Attaching Bolt
PART 7-2- C4 AUTOMATIC TRANSMISSION 7-77

Low and Reverse Brake Drum washers, bushings and journal with and the parking pawl retaining pin
1. Replace the low and reverse automatic transmission fluid. If the has to be inserted in the alignment
brake drum bushing if it is worn or end play is not within specifica- hole in the distributor sleeve.
damaged. To remove the bushing, tions, after the transmission is 7. Install the four governor dis-
use the cape chisel and cut along the assembled, either the wrong selec- tributor sleeve-to-case attaching
bushing seam until the chisel breaks tive thrust washers were used, or a bolts and torque the bolts to
through the bushing wall. Pry the thrust washer came out of position specification.
loose ends of the bushing up with during the transmission assembly 8. Install the governor distributor
an awl and remove the bushing. operation. assembly on the output shaft. Install
2. Install a new bushing with the 1. Install thrust washer No. 9 the distributor retaining snap ring.
tool shown in Fig. 96. inside the transmission case (Fig. 97). Fig. 101 shows the correct snap ring
2. Place the one-way clutch outer that is to be used.
ASSEMBLY OF race inside the case. From the back 9. Check the rings in the govern-
TRANSMISSION of the case install the six outer race or distributor, making sure that
to case attaching bolts. Torque the they are fully inserted in the grooves
When assembling the transmission bolts to specification with the tools
sub-assemblies (Fig. 102), make sure and will rotate freely. Install the
shown in Fig. 98. output shaft and governor dis-
sure that the correct thrust washer
3. Place the transmission case in tributor assembly in the distributor
is used between certain subassem-
a vertical position with the back sleeve (Fig. 54).
blies. Vaseline should be used to
hold the thrust washers in their face of the case upward. Install the 10. Place a new extension hous-
proper location. Lubricate thrust parking pawl retaining pin in the ing gasket on the case. Install the
case (Fig. 99). extension housing, vacuum tube
RETURN SPRING PARKING PAWL 4. Install the parking pawl on clip, and the extension housing-to-
the case retaining pin. Install the case attaching bolts. Torque the
parking pawl return spring as shown bolts to specification.
in Fig. 99. 11. Place the transmission in the
5. Install thrust washer No. 10 holding fixture with the front pump
on the parking pawl gear (Fig. 100). mounting face of the case up. Make
Place the gear and thrust washer on sure thrust washer No. 9 is still
the back face of the case (Fig. 99). located at the bottom of the trans-
6. Place the two fluid distributor mission case (Fig. 97).
tubes in the governor distributor 12. Install the one-way clutch
sleeve. Install the distributor sleeve spring retainer into the outer race
on the case. As the distributor sleeve (Fig. 103).
is installed, the tubes have to be 13. Install the inner race inside
inserted in the two holes in the case of the spring retainer.
14. Install the individual springs
between the inner and outer race as
shown in Fig. I 03.
15. Starting at the back of the
transmission case, install the one-
FIG. 99- Parking Pawl and way clutch rollers by slightly com-
pressing each spring and positioning
Gear the roller between the spring and
the spring retainer.
16. After the one-way clutch has
been assembled rotate the inner race
RETAINS REVERSE RING GEAR AND clockwise to center the rollers and
HUB TO OUT?UT SHAFT springs. Install the low and reverse
drum (Fig. 102). The splines of the
drum have to engage with the
splines of the one-way clutch inner
race. Check the one-way clutch
operation by rotating the low and
reverse drum. The drum should
rotate clockwise but should not
rotate counter-clockwise.
17. Install thrust washer No.8 on
top of the low and reverse drum
RETAINS GOVERNOR DISTRIBUTOR
(Fig. I04). Install the low-reverse
TO OUTPU fSHAFT band in the case, with the end of
01549-A
the band for the small strut toward
the low-reverse servo (Fig. 53).
D1441-A 18. Install the reverse ring gear
FIG. 101 -Governor and Reverse and hub on the output shaft.
FIG. 100 - Number 10 Thrust Ring Gear and Hub Snap Ring 19. Move the output shaft for-
Washer Location ldentificatton ward and install the reverse ring
7-78 GROUP 7-AUTOMATIC TRANSMISSION

-----..
'I \

________ ..,.
36 /

1. CONVERTER 12. THRUST WASHER NO. 3 21 • REVERSE RING GEAR 30. THRUST WASHER NO. 9
2. INPUT SHAFT 13. FORWARD CLUTCH HUB AND HUB 31. CASE
3. CONVERTER HOUSING AND RING GEAR 22. tow AND REVERSE BAND 32. THRUST WASHER NO. 10
4. FRONT PUMP 23. BAND STRUTS 33. PARKING GEAR
14. THRUST WASHER NO. 4
5. THRUST WASHER NO. I 24. THRUST WASHER NO. 8 34. GOVERNOR DISTRIBUTOR
6. THRUST WASHER NO. 2 15. FRONT PLANET CARRIER SLEEVE
25. LOW AND REVERSE DRUM
7. FRONT PUMP GASKET 16. INPUT SHELL, SUN GEAR 35. SNAP RING
8. INTERMEDIATE BAND AND THRUST WASHER NO. S 26. ONE·WAY CLUTCH 36. GOVERNOR VAL YES &
INNER RACE
9. BAND STRUTS 17. THRUST WASHER Nd. 6 DISTRIBUTOR
10. REVERSE AND HIGH 27. ROLLER (12) AND SPRING (12) 37. OUTPUT SHAFT
18. REVERSE PLANET CARRIER 28. SPRING AND ROLLER CAGE
CLUTCH DRUM 38. EXTENSION HOUSING AND GASKET
11. FORWARD CLUTCH AND 19. THRU:.r WASHER NO. 7 29. ONE·WAY CLUTCH OUTER 39. CONTROL VALVE BODY
CYLINDER 20. SNAP RING RACE 40. OIL PAN AND GASKET
D 1378-8

FIG. 102 - Transmission Sub-Assemblies

PART 7-2- C4 AUTOMATIC TRANSMISSION 7-79

STEP-1 STEP-2
INSTALL SPRING RETAINER INTO OUTER RACE INSTALL INNER RACE

STE P-3
INSTALL 12 SPRINGS INSTALL 12 ROLLERS 01551-A

FIG. 103 -One-Way Clutch Installation

gear hub to output shaft retaining the splines of the forward clutch fications .
ring (Fig. 52). (Fig. 106). b. Install the reverse-high clutch
20. Place thrust washers Nos. 6 23. Using the end play check and the forward clutch on the stator
and 7 on the reverse planet carrier reading that was obtained during support.
(Fig. 105). the transmission disassembly to c. Invert the complete unit mak-
21. Install the planet carrier in determine which No. 2 steel backed ing sure that the intermediate brake
the reverse ring gear and engage the thrust washer is required, proceed drum bushing is seated on the for-
tabs of the carrier with the slots in as follows: ward clutch mating surface.
the low-reverse drum. a. Position the stator support d. Select the thickest nylon washer
22. On the bench, install the for- vertically on the work bench and (No. 1) that can be inserted between
ward clutch in the reverse-high install the correct No. 2 thrust- the stator support and the inter-
clutch by rotating the units to mesh washer or washer and spacer to mediate brake drum thrust surfaces
the reverse-high clutch plates with bring the end play within speci- and still maintain a slight clearance.
7-80 GROUP 7-AUTOMATIC TRANSMISSION

THRUST WASHER FORWARD CLUTCH HUB FORWARD

8 AND RING GEAR CLUTCH

D1443-A

FIG. 104 - Number 8 Thrust REVERSE-HIGH

CLUTCH
Washer Location D1439-A
FIG. 106 - Installing Clutch Units
Do not select a washer that must D1454-A
THRUST WASHER NO . 3
be forced between the stator sup-
port and intermediate brake drum. FIG. 108 - Installing Forward
e. Remove the intermediate brake Clutch Hub and Ring Gear
drum and forward clutch unit from
the stator support.
f. Install the selected Nos. 1 and
2 thrustwashers on the front pump
stator support (Fig. 43) using
enough vaseline to hold the thrust
washers in position during the front
pump installation.
24. Install thrust washer No. 3
on the forward clutch (Fig. 107).
25. Install the forward clutch hub FIG. 107 - Number 3 Thrust
and ring in the forward clutch by
rotating the units to mesh the for- Washer Location
THRUST WASHER NO . 7

FIG. 109 - Number 4 Thrust

Washer Location
ward clutch plates with the splines
on the forward clutch hub (Fig.
108).
26. Install thrust washer No. 4
on the front planet carrier (Fig.
109). Install the front planet carrier
into the forward clutch hub and
ring gear. Check the forward thrust
bearing race inside the planet carrier
/ for proper location against the thrust
bearing. Make sure the race is cen-
.---· j REVERSE PLANET CARRIER
tered for alignment with the sun
gear on the input shell.
27. Install the input shell and
THRUST WASHER NO. 6 D1444-A sun gear on the gear train (Fig. Ill).
Rotate the input shell to engage the
FIG. 105- Number 6 and 7 Thrust Washer Location drive lugs of the reverse-high clutch.
PART 7-2- C4 AUTOMATIC TRANSMISSION 7-81

FRONT PlANET FORWARD ClUTCH INPUT SHEll

CARRIER HUB AND AND SUN GEAR
GEAR
FORWARD
ClUTCH

FIG. 112 - Installing Vacuum

Unit
low-reverse band. Refer to In-Car
Adjustments and Repair for band
01456-A adjusting procedures.
37. Install a universal joint yoke
01455-A FIG. 111 - Installing Input Shell on the output shaft. Rotate the in-
FIG. 110 - Installing Front support into the reverse-high clutch. put and output shafts in both direc-
tions to check for free rotation of
Planet Carrier Align the pump-to-case attaching
the gear train.
bolt holes. Fit bolts and torque to
If the drive lugs will not engage, specifications. 38. Install the control valve body
the outer race inside the forward 32. Position the converter hous- (Fig. 40) as described in In-Car
planet carrier is not centered to ing on the case. Install all but one Adjustments and Repairs.
engage the end of the sun gear in- front housing to case attaching bolt 39. Place a new oil pan gasket
side the input shell. Center the thrust and torque them to specifications. on the case and install the oil pan
bearing race and install the input 33. Install the input-shaft (Fig. and oil pan-to-case attaching bolts.
shell. 44). Be sure the short splined end is Torque the bolts to specification.
28. Hold the gear tram togetht:r installed toward the rear of the 40. Remove the transmission
and install the forward part of the transmission. from the holding fixture. Install the
gear train assembly in the case Rotate the holding fixture to two extension housing-to-case
(Fig. 48). place the transmission in a hori- attaching bolts. Torque the bolts
The input shell sun gear must zontal position. Check the trans- to specification.
mesh with the reverse pinion gears. mission end play as shown in Fig. 41. Install the primary throttle
The front planet carrier internal 42. If the end play is not within valve in the transmission case (Fig.
splines must mesh with the splines specification, either the wrong selec- 38).
on the output shaft. tive thrust washers (Fig. 43) were 42. Install the vacuum unit, gas-
29. A new band should be soaked used, or one of the I 0 thrust ket, and control rod in the case.
in transmission fluid for fifteen washers (Fig. 102) is not properly Using the tools shown in Fig. 112,
minutes before it is installed. Install positioned. install the vacuum unit .
the intermediate band through the 34. Remove the dial indicator 43. Make sure the iuput shaft is
front of the case (Fig. 46) so that used for checking the en<1 play and properly iustalled iD the front pump
the arrow on the band end forging, install the one converter housing- stator support and gear train. Install
points toward the front of the to-case attaching bolt. Torque the the converter in the front pump and
transmission. bolt to specification. the converter housing. The short
30. Install a new front pump 35. Install the intermediate and spline end of the shaft should be
gasket on the case. Line up the bolt low-reverse band adjusting screws installed to the rear of the trans-
holes in the gasket with the holes in in the case. Install the struts for mission.
the case. each band (Fig. 41).
31. Install the front pump stator 36. Adjust the intermediate and
7-82

PART
7-3 FMX AUTOMATIC TRANSMISSION

Sedloa Pale Seedoa Page

1 Diagnosis and Testing ....•. • . • .•.......•.. 7- 82 S In-Car Adjustment and Repain .•....•....• 7-103
2 Common Adjustments and Repairs •.••.••••• 7- 88 6 Removal and Installation ................. 7-108
3 Cleaning and Inspection ••••.•.••..•.•.•..•..• 7-89 7 Major Repair Operations ................... 7-109
4 Description .•.•.•.•••..••...•••....•••.• 7- 9.5

D DIAGNOSIS AND TESTING

When diagnosing transmission prob- Aerated fluid will cause low control both seals.
lems, first refer to the diagnosis guide pressure, and the aerated fluid may Inspect the pipe plug on the left
for the detailed information on the be forced out the vent. side of the transmission case at the
items that could be causing the prob- Check the transmission fluid level. front. If the plug shows leakage,
lem. Low fluid level can affect the oper- torque the plug to specifications. If
The following preliminary checks ation of the transmission, and may tightening does not stop the leaks. re-
should be m!!tle before proceeding indicate fluid leaks that could cause place the plug.
with other diagnosis checks. transmission damage.
When converter drain plugs leak,
TRANSMISSION FLUID LEVEL CHECK TRANSMISSION FLUID remove drain plugs with a six-point
1. Make sure that the vehicle is LEAKAGE CHECKS wrench . Coat the threads with Fo-
standing level. Then firmly apply the MoCo Perfect Seal Sealing Com-
parking brake. Check the speedometer cable con- pound or its equivalent, and install
2. Run the engine at normal idle nection at the transmission. Replace the plugs. Torque the drain plugs to
speed. If the transmission fluid is the rubber seal if necessary. specification. Fluid leakage from the
Leakage at the oil pan gasket often converter housing may be caused by
cold run the engine at fast idle speed
(about 1200 rpm) until the fluid can be stopped by tightening the at- engine oil leaking past the rear main
reaches its normal operating tem- taching bolts to the proper torque. If bearing or from oil gallery plugs, or
perature. When the fluid is warm, necessary, replace the gasket. power steering oil leakage from steer-
slow the engine down to normal idle Check the fluid filler tube con- ing system. Be sure to determine the
speed. nection at the transmission. If leakage exact cause of the leak before repair
is found here, install a new 0-ring. procedures are started.
3. Shift the selector lever through Oil-soluble aniline or fluorescent
all positions. and place the lever at Check the fluid lines and fittings dyes premixed at the rate of I /2 tea-
P. Do not turn off the engine during between the transmission and the spoon of dye powder to I /2 pint of
the fluid level checks. cooler in the radiator tank for loose- transmission fluid have proved helpful
4. Clean all dirt from the transmis- ness, wear, or damage. If leakage in locating the source of the fluid
sion fluid dipstick cap before remov- cannot be stopped by tightening a leakage. Such dyes may be used to
ing the dipstick from the filler tube. fitting, replace the defective parts. determine whether an engine oil or
S. Pull the dipstick out of the Check the engine coolant in the transmission fluid leak is present or
tube, wipe it clean, and push it all radiator. If transmission fluid is pres- if the fluid in the oil cooler leaks into
ent in the coolant, the cooler in the the engine coolant system . A black
the way back into the tube. Be sure
radiator is probably leaking. light. however. must be used with the
it is properly seated.
The cooler can be further checked fluorescent dye solution.
6. Pull the dipstick out of the for leaks by disconnecting· the lines
tube again, and check the fluid level. from the cooler fittings and applying
If necessary, add enough fluid to 50-75 psi air pressure to the fittings . FLUID LEAKAGE IN
the transmission through the filler Remove the radiator cap to relieve CONVERTER AREA
tube to raise the fluid level to the the pressure build at the exterior of
F (full) mark on the dipstick. Do the oil cooler tank. If the cooler is In diagnosing and correcting fluid
not overfill the transmission. Install leaKing and will not hold this pressure leaks in the front pump and convert-
the dipstick, making sure: it is fully the cooler must be replaced . Cooler er area, use the following procedures
seated in the tube. replacement is described in the Cool- to facilitate locating the exact ca use
ing System Section of Group II. of the leakage . Leakage at the front
FLUID AERATION CHECK If leakage is found at either the of -transmission, as evidenced by
A fluid level that is too high will downshift control lever shaft or the fluid around the converter housing.
l:ause the fluid to become aerated : manual lever shaft, replace either or may have several sources. By ca reful
PART 7-3· F. M.X. AUTOMATIC TRANSMISSION 7-83

observation, it is possible, in many

instances, to pinpoint the source of
the leak before removing the trans-
mission from the vehicle. The paths
which the fluid. takes to reach the bot-
tom of the converter housing are
shown in Fig. I.
I. Fluid leaking by the front pump
seal lip will tend to move along the
drive hub and onto the back of the
impeller housing. Except in the case
Til
of a total seal failure, fluid leakage
by the lip of the seal will be deposited
[ I

CR~~ ~[
on the inside of the converter housing
only, near the outside diameter of the
housing.
2. Fluid leakage by the outside ~I
FRONT PUMP SEAL LEAK
diameter of the seal and front pump
body will follow the same path which
leaks by the front pump seal.
3. Fluid that leaks by a front pump
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.
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 evirlence that
the front pump to case gasket or seal
could be leaking.
S. Fluid leakage from the convert-
er drain plugs will appear at the out-
side diameter of the converter on the
back face of the flywheel, and in the
converter housing only near the fly-
wheel.
Engine oil leaks are sometimes im- CONVERTER DRAIN PLUG LEAK
0 1311·8
properly diagnosed as transmission
front pump seal leaks. The following FIG. 1-Typical Convertor Area Leakage Checks
areas of possible leakage should also
be checked to determine if engine oil or road draft. cover. Clean off any fluid from the
leakage is causing the problem . The following procedures should top and bottom of the converter
1. Leakage at the rocker arm cover be used to determine the cause of the housing, front of the transmission
(valley cover) may allow oil to flow leakage before any repairs are made. case, and rear face of the engine and
over the converter housing or seep 1. Remove the transmission dip- engine oil pan . Clean the converter
down between the converter housing stick and note the color of the fluid. area by washing with carbon tetra-
and cylinder block causing oil to be Original factory fill fluid is dyed red chloride or other suitable non-flam-
present in or at the bottom of the to aid in determining if leakage is mable solvent, and blow dry with
converter housing. from the engine or transmission. Un- compressed air .
2. Oil galley plug leaks will allow less a considerable amount of make- 3. Wash out the converter hous-
oil to flow down the rear face of the up fluid has been added or the fluid ing, the front of the flywheel, and
block to the bottom of the converter has been changed, the red color the converter drain plugs. The con-
housing. should assist in pinpointing the leak. verter housing may be washed out
3. Leakage by the crankshaft seal Fluid used in the power steering sys- using cleaning solvent and a squirt-
will work back to the flywheel, and tem is a red dye. Since type oil can. Blow all washed areas
then into the converter housing. road draft may cause leaking power dry with compressed air.
Fluid leakage from other areas, steering fluid to be pr-·:sent on the 4. Start and run the engine until
such as the power steering system transmission, this leakage, if present, the transmission reaches iis normal
forward of the transmission, could should be eliminated before checking operating temperature . Observe the
cause fluid to be present around the the transmission for fluid leakage. back of the block and top of the con-
converter housing due to blow back 2. Remove the converter housing verter housing for evidence of fluid
7-84 GROUP 7-AUTOMATIC TRANSMISSION

leakage. Raise the vehicle on a hoist

and run the engine at fast idle, then at ~· STEEL PLATE
engine idle, occasionally shifting to o/a• X 1 ¥.•;
DRILL TO SUIT
the drive and reverse ranges to in-
crease pressure within the transmis-
sion. Observe the front of the fly-
wheel, back of the block (in as far
as possible), 3nd inside the converter
housing and front of the transmission
case. Run the engine until fluid leak-
age is evident and the probable source
of leakage can be determined .
CONVERTER LEAKAGE RUBBER PLUG
CHECK 1 Y2• DIA. X 2•
LONG Y2·
SPACER- HOLE THRU
During the above fluid leakage
82Q-9438-A APPROXIMATELY
checks, if there are indications that 40 DUROMETER STANDARD BOLT
the welds on the torque converter are PLUG Y2·-13 X -4 1/2•
leaking, the converter will have to be LONG SQUARE
CHAIN, 10' LONG STANOARD THREAD END
removed and the following check WELD TOGETHER REMOVE HEAD
made before the unit is replaced. SECURELY -MUST AND WELD TO
NOT LEAK WASHER
A leak checking tool (Fig. 2) can
STANDARD l/8" FITTING-87971 ·S FOR
be made from standard parts. The RETAPPED DRAIN PLUG THREADS·USE
tool can be used to check all con- l / 4" OVERSIZE FITTING-87973·S
verters . VALVI D l067· B

I. Install the plug in the converter

(Fig . 3) and expand it by tightening
FIG. 2- Converter Leak Checking Tool
the wing nut. Attach the safety 1. Attach a tachometer to the
chains. engine and a vacuum gauge to the
2. Install the air valve in one of the transmission vacuum line at the
drain plug holes. vacuum unit (Fig. 4).
3. Introduce air pressure into the 2. Attach the pressure gauge to the
converter. Check the pressure with a control pressure outlet at the trans-
tire gauge and adjust it to 20 psi. mission (Fig. 5).
4. Place the converter in a tank
of water. Observe the weld areas for 3. Firmly apply the parking brake
bubbles . If no bubbles are observed, and start the engine .
it may be assumed that the welds are
not leaking. 4. Adjust the engine idle speed to
the specified rpm. If the engine idle
ENGINE IDLE SPEED CHECK speed cannot be brought within lim-

Check and, if necessary, adjust the ~ ............. Tire Preuure Gauge

its by adjustment at the carburetor
idle adjustment screw, check the
engine idle speed, using the proce- throttle and downshift linkage for a
D106--A
dure given in Group 10. binding condition. If the linkage is
If the idle speed is too low, the en- FIG. 3 - Typical Converter Leak satisfactory, check for vacuum leaks
gine will run roughly . An idle speed in the transmission diaphragm unit
that is too high will cause the vehicle
Checking Tool (Fig. 6) and its connecting tubes and
to creep when the transmission is CONTROL PRESSURE AND hoses. Check all other vacuum oper-
shifted into gear and will cause ated units (such as the power brake)
VACUUM DIAPHRAGM UNIT
rough transmission engagement. for vacuum leaks.
CHECK
VACUUM UNIT CHECK
MANUAL LINKAGE CHECKS When the vacuum diaphragm unit
is operating properly and the down- To check the vacuum unit for dia-
Correct manual linkage adjust- shift linkage is adjusted properly, all phragm leakage, remove the unit
ment is necessary to position the the transmission shifts (automatic and from the: transmission . Use a distrib-
manual valve for proper fluid pressure kickdown) should occur within the utor tester equipped with a vacuum
direction to the different transmission road speed limits specified in pump (Fig. 6). Set the regulator
components. Improperly adjusted page 7-126 knob so that the vacuum gauge reads
manual linkage may cause cross- If the shifts do iiot occur within 18 inches with the end of the vacuum
leakage and subsequent transmission limits or the transmission slips during hose blocked off.
failure. Refer to Linkage Adjust- shift point, the following procedure Then connect the ~·acuum hose to
ments in 7-22 for detailed is suggested to determine engine, the transmission vacuum unit. If the
manual linkage adjustment proce- transmission, linkage, vacuum dia- gauge sti II reads 18 inches, the vac-
dures. phragm unit or valve body problems. uum unit diaphragm is not leaking.
PART 7-3- F. M.X. AUTOMATIC TRANSMISSION 7-85

As the hose is removed from the lease the accelerator ped<1l quickly Control Pressure is High at
transmission vacuum unit, hold a fin- and observe the vacuum gauge . The Engine Idle (Test No. 1)
ger over the end of the control rod.
When the hose is removed, the inter- If transmission control pressure at
nal spring of the vacuum unit should engine idle is too high in all ranges,
push the control rod outward . the trouble may be in the diaphragm
unit or its connecting vacuum tubes
CONTROL PRESSURE TESTS- and hoses, throttle valve, or control
The test results of the following rod .
checks should agree with the specifi- With the engine idling, disconnect
cations given in Fig. 7. When per.. lhe hose from the diaphragm unit
forming control pressure tests, make and check the engine manifold vac-
certain that the service brake pedal uum . Hold a thumb over the end of
is held in the applied position. When the hose and check for vacuum. If
the transmission detent position of D the engine speeds up when the hose
FIG. 5 - Vacuum Diaphragm is disconnected and slows down as
is used, position the selector lever
at D on the quadrant.
and Control Pressure Connecting the thumb is held against the end of
Point the hose, the vacuum source is satis-
factory .
: '-"\'NG ~ amount of vacuum should decrease
and increase 'with the changes in Stop the engine, and remove the
!3~~--- - throttle openings . If the vacuum re- diaphragm unit and the diaphragm
I
MANIFOLD
~2"-.j -· sponse to changes in throttle open-
unit control rod . Inspect the control
rod for a bent condition and for cor-
VACUUM ing is too slow the vacuum line to
LINE HOSE the diaphragm unit could be restrict- rosion. Check the diaphragm unit for
ed. Make the necessary repairs be- leakage with the distributor tester
fore completing the test. (Fig. 6).
3. At engine idle, check the trans-
mission control pressure gauge at all TEST NUMBER-2 CONTROL
selector lever positions. Transmission PRESSURE CHECK AT 10
control pressures should agree with INCHES OF VACUUM
the specifications shown in Figs. 7).
A control pressure check should be
made at 10 inches of vacuum in all
forward drive ranges.
Advance the throttle until the en-
gine vacuum reading is 10 inches and
check the control pressure regula-
tion. Control pressure should be as
shown in Figs. 7
FIG. 4 - Typical Vacuum Test
Line Connections Control Pressure Not Within
Limits at 10 inches of
Vacuum (Test No. 2)
TEST NUMBER-I CONTROL
PRESSURE CHECK-AT If idle pressure is within specifica-
ENGINE IDLE tions but pressure. at I 0 inches of
vacuum are not within specification
I. With the transmission in neu- in all ranges, excessive leakage, low
tral, and the engine at the correct pump capacity, or a restricted oil
idle speed, the vacuum gauge should pan screen is indicated .
show a mimimum of 18 inches. If the FIG. 6 - Testing Transmission If pressures are not within specifi-
vacuum reading is lower than 18 Vacuum Unit for Leakage cations for specific selector lever po-
inches, an engine problem is indi- sitions only, this indicates excessive
cated or there is leakage in the vac- leakage in the clutch or servo circuits
uum line . Make necessary repairs to Control Pressure is Low at used in those ranges.
obtain a minimum vacuum reading of When the control pressure is with-
Engine Idle (Test No. 1)
18 inches . in specifications at engine idle, but
At different altitudes above sea lev· not within specifications at I0 inches
el, it ma y not be possible to obtain If control pressure at engine idle
of vacuum, the vacuum diaphragm
18 inches vacuum at engine idle . At is low in all selector lever positions,
unit may need adjustment.
these altitudes, with idle vacuum of trouble other than the diaphragm
less than 18 inches, refer to the speci- unit is indicated. When control pres-
TEST NUMBER-3 CONTROL
fications in Fig. 7 to determine idle sure at engine idle is low in all ranges,
PRESSURE CHECK AT
speed control pressure in forward check for excessive leakage in the
1.0 INCH OF VACUUM
driving ranges. front oil pump, case, and control
valve body, or a sticking control pres-
2. At engine idle, depress and re- sure regulator valve. Check control pressure at 1.0 inch
7-86 GROUP 7-AUTOMA TIC TRANSMISSION

or less of vacuum in all forward drive this indicates excessive leakage in the
ranges. The control pressure should clutch or servo circuits used in those
be as shown in Fig. 7. Then move the ranges.
selector lever to R. With the vacuum
at 1 . 0 inch or less the control pres- CONTROL PRESSURE IS
sure should be as shown in Fig. 7. EXTREMELY ERRATIC
While making this pressure test, do
If transmission control pressure is
not hold the throttle open for more
extremely erratic in D and 2, check
than the seconds in each detent p•
the diaphragm unit tubes, hoses, and
sition. Between each test move the D1491-A
selector lever to neutral and run the diaphragm push rod as given under
engine at 1000 rpm for fifteen sec- Control Pressure Is High. If the vac- FIG. 8 - Adiustable Vacuum Unit
uum source is satisfactory, check the
onds to cool the converter. correct a particular shift condition.
If the Yacuum and pressure gauge diaphragm unit and repeat the tests
for transmission control pressure. If For example, if the pressure at
readings are within specifications, the 10 inches of vacuum was 130 psi and
diaphragm unit and transmission control pressure is still extremely
erratic, the trouble is in the transmis- the pressure at 1.0 inch of vacuum
control pressure regulating system was 190 psi, and upshifts and down-
are operating properly. sion hydraulic regulating circuits.
shifts were harsh, a diaphragm ad-
If transmission control pressure is Clean and inspect the control valve
justment to reduce the diaphragm
too low, too high. fails to increase body.
assembly spring force would be
with throttle opening, or is extremely VACUUM DIAPHRAGM required.
erratic, use the procedure given under ADJUSTMENT If the pressure readings are low,
the following appropriate heading to an adjustment to increase diaphragm
The vacuum diaphragm fitted to
resolve the problem. spring force is required .
the F.M.X. transmission is adjust-
able. This diaphragm should not be To increase control pressure, tur
Control Pressure Not Within the adjusting screw in clockwise .T
Limits at 1.0 inches or Less interchanged with C4 or C6 trans-
missions. reduce control pressure, back the ac.
of Engine Vacuum (Test No.3) justing screw out by turning it coun-
The vacuum diaphragm assembly terclockwise. One complete turn of
If idle pressure and pressures at has an adjusting screw in the vacuum the adjusting screw (360 degrees) will
10 inches of vacuum are within hose connecting tube (Fig. 8 ). change idle line control pressure ap-
specifications but pressure at engine proximately 2-3 psi . After the adjust-
stall are not within specification in The inner end of the screw bears
ment is made, install the vacuum line
all ranges, excessive leakage, low against a plate which in turn bears
and make all the pressure checks as
pump capacity or restricted oil pan against the vacuum diaphragm spring.
outlined in Figs. 7.
screen is indicated. All readings slightly high or all
If stall pressures are not within readings slightly low may indicate The diaphragm should not be
specifications for specific ranges only, the vacuum unit needs adjustment to adjusted to provide pressure

CONTROL PRESSURE AT ZERO GOVERNOR RPM-

Control Une Pressure (PSI)

Tllrottlt Menlfokl llnp
EnJineSpltd Yec.lnL H1o

P, N, D, 2,1 56-82
Idle Closed Above 18<D
R 59-111
, As Required As Required 10 D, 2. 1 82-112
at or D. 2,1 146-175
As Required As Required Below 10
(at stall) R 184-221
fi> At eltitudes ebove see level, it mey not be possible to obtein 18 inches of en&ine v1cuum •t idle. For idle vacuum of less thin 18 inches,
refer to the followln& tlble to determine idle speed pressure speclflc•tion In D drlvin& r.n&e.

EnJint YICUUIII Une Pressure

171nches 57-67
161nches 57-67
151nches 57-72
14 inches 57-79
13 Inches 57-86
12 inches 57-92
11 inches 57-99

FIG. 7
PART 7·3- F. M.X. AUTOMATIC TRANSMISSION 7-87

below the ranges shown in Fig. 7, band slippage. Excessive engine rpm second gear.
in order to change shift feel. To only in D indicates gear train one- With the transmission in third gear
do so could result in soft or sUp- way clutch slippage. and road speed over 38 mph, the
ping shift points and damage to transmission should shift to second
the transmission. STALL SPEED TOO LOW gear when the selector lever is moved
from D to 1. When the same manual
When the stall test speeds are low shift is made below about 38 mph,
and the engine is properly tuned, con- the transmission will shift from third
verter stator clutch problems are indi- to first. This check wil determine
cated. A road test must be performed if the governor pressure and
to determine the exact cause of the shift control valves are function-
trouble. ing properly.
If the stall test speeds are 300 to During the shift point check oper-
400 rpm below the specifications ation, if the transmission does not
shown in Fig. 10, and the vehicle shift within specifications or certain
cruises properly but has very poor gear ratios cannot be obtained, refer
acceleration, the converter stator to the diagnosis guide to resolve the
clutch is slipping. problem.
If the stall test speeds are 300 to
400 rpm below the specified values, AIR PRESSURE CHECKS
and the car drags at cruising speeds
and acceleration is poor, the stator A NO DRIVE condition can exist,
clutch could be installed backwards. even with correct transmission fluid
SERVO 01932-A Remove the converter and check the pressure, because "f inoperative
stator clutch as described in Cleaning clutches or bands. Erratic shifts
FIG. 9 - Case Fluid Hole and Inspection. could be caused by a stuck governor
Identification - When the stall test shows normal valve. The inoperative units can .be
speeds, the acceleration is good, but located through a series of checks by
STALL TEST the vehicle drags at cruising speeds, subsituting air pressure for the fluid
the difficulty is due to a seized stator pressure to determine the location of
assembly. If the stator is defective, the malfunction.
Start the engine to allow it to reach replace the converter. When the selector lever is at 2, a
its normal temperature. Apply both NO DRIVE condition may be caused
the parking and service brakes while SHIFT POINT CHECKS
by an inoperative forward clutch. A
making tests.
Check the mimimum throttle up- NO DRIVE condition at D may be
The stall test is made in D, 2, I or
shifts in D. The transmission should caused by an inoperative forward
R, at full throttle to check engine
start in first gear. shift to second, and clutch or one-way clutch. When there
performance, converter clutch oper-
then shift to third, within the shift is no drive in I, the difficulty could be
ation or installation, and the holding caused by improper functioning of the
ability of the forward clutch, reverse- points specified in the specification
section. forward clutch or low-reverse band
high clutch and low-reverse or inter- and the one-way clutch. Failure to
mediate band and the gear train one- While the transmission is in third
gear, depress the accelerator pedal drive in reverse range could be caused
way clutch. While making this test,
do not hold the throttle open for more through the detent (to the floor). The by a malfunction of the reverse-high
transmission should shift from third clutch or low-reverse band.
than five seconds at a time. Then
move the, selector lever to Neutral to second or third to first, depending To make the air pressure checks,
and run the engine at 1000 rpm for on the vehicle speed. loosen the oil pan bolts and lower one
about 15 seconds to cool the converter Check the closed throttle downshift edge of the oil pan to drain the trans-
before making the next test. If the from third to first by coasting down mission fluid . Remove the fluid pan and
engine speed as recorded by the tach- from about 30 mph in third gear. The the control valve body assembly. The
shift should occur within the limits inoperative units can be located by
ometer exceeds the maximum limits
specified in Fig. 10, release the accel- specified in the specification section. introducing air pressure into the
When the selector lever is at 2. the transmission case passages leading to
erator immediately because clutch or
transmission can operate only in the clutches, servos, and governor
band slippage is indicated.
Selector Lever Clutch Band Engine Speed R.P.M .
ST ALI. SPEED TOO HIGH Position Applied Applied (at stall)
If stall speed exceeds specifica- 2 Front Front
tions, band or clutch slippage is indi- D Front 1650-1850
cated, depending on transmission
selector lever position. Excessive
A and Rear - \

engine rpm only in D, 2, and 1 indi- 1 Front Rear

cates forward clutch slippage as
shown in Fig. 10. Excessive engine R Rear Rear
rpm only in R indicates either
reverse-high clutch or low-reverse FIG. 10
7-88 GROUP 7-AUTOMATIC TRANSMISSION
(Fig. 9). servo apply passage. Operation of the speedometer gear opening.
FRONT CLUTCH servo is indicated by movement of 2. Remove the vacuum diaphragm
the servo piston stem. Continue to unit and the diaphragm unit control
Apply air pressure to the transmis- apply air pressure to the servo apply rod, and reinstall the vacuum unit if
sion case forward clutch or front tube or passage, and introduce air these parts had been previously in-
clutch passage (Fig. 9 ). A dull thud pressure into the front release tube stalled.
can be heard when the clutch piston or the intermediate servo release 3. Install the bench testing tool on
is applied. If no noise is heard, place pressure. The front or intermediate the transmission.
the finger tips on the input shell and servo should release the band against
again apply air pressure to the for- the apply pressure.
ward or front clutch passage. Move- 4. Remove the 1/8-inch pipe plug
ment of the piston can be felt as the at the transmission case. Turn the
clutch is applied. front pump in a clockwise direction
HYDRAULIC SYSTEM BENCH at 75-100 rpm until a regular flow
REAR SERVO TESTS of transmission fluid leaves the hole
in the transmission case. This opera-
Apply air pressure to the rear After the transmission has been as- tion bleeds the air from the pump.
servo apply passage (Fig. 9), move- sembled and is ready for installation 5. Install the pressure gauge
ment of the servo piston stem indi- in the vehicle, check the hydraulic (77820 or T57L-77820-A) as shown in
cates correct operation. system to make sure it is operating Fig. 11.
If the servo does not operate, dis- properly. These hydraulic tests can
assemble, clean, and inspect to locate PRESSURE TESTS
the source of the trouble. be made on the bench so that most
malfunctions of the system can be
If air pressure applied to either of corrected before the transmission is Turn the front pump at 75-100
the clutch passages fails to operate installed in the vehicle. rpm and note the gauge readings.
a clutch or operates both clutches at The pressure readings on the bench
once, remove and, with air pressure, TESTING TOOL test must be within the limits as out-
check the fluid passages in the case INSTALLATION lined in Figure 7, for the engine idle
and front pump to detect obstruc- 1. Install a plug in the filler tube
check.
tions. If pressure gauge readings are
hole in the case or fluid pan, and pour
GOVERNOR within limits in all selector lever po-
about four quarts of clean transmission
sitions, install the vacuum diaphragm
fluid into the transmission through the
Apply air pressure to the control control rod unit.
pressure to governor passage (Fig. 9)
and listen for a sharp clicking or
whistling noise. The noise indicates DIAGNOSIS GUIDE
governor valve movement.
The Diagnosis Guide (Fig. 22)
REAR CLUTCH lists the most common trouble
symptoms that may be found and
Apply air pressure to the reverse- gives the items that should be checked
high clutch or rear clutch passage to find the cause of the trouble.
(Fig. 9). A dull thud indicates that
the reverse-high or rear clutch piston
has moved to the applied position. If The items to check are arranged
no noise is heard, place the finger tips in a logical sequence which should
on the clutch drum and again apply be followed for quickest results. The
air pressure to detect movement of letter symbols for each item are ex-
the piston. plained in the key. If items A, B, C,
Tool-7003 K, and the stall tests have already
FRONT SERVO D 1062·C been checked during preliminary
Hold the air nozzle in the front FIG. 11 -Bench Testing Tool checks and adjustments, they need
servo apply tube or the intermediate Installation- Typical not be repeated.

B COMMON ADJUSTMENTS AND REPAIRS

TRANSMISSION FLUID LEVEL parking brake. speed.
CHECK 2. Run the engine at normal idle 3. Shift the selector lever through
speed. If the transmission fluid is all positions, and place the lever at
The transmission fluid level should cold, run the engine at fast idle P. Do not turn off the engine during
be checked using the following pro- speed (about 1200 rpm) until the the fluid level checks.
cedure. fluid reaches its normal operating
I. Make sure that the vehicle is temperature. When the fluid is warm, 4. Clean all dirt from the trans-
standing level; then firmly apply the slow the engine down to normal idle mission fluid dipstick cap before re-
PART 7-3- F. M. X. AUTOMATIC TRANSMISSION 7-89

moving the dipstick from the filler gasket. run at normal idle speed for 3 min-
tube. 6. Place a new gasket on the pan, utes with the selector lever in p
5. Pull the dipstick out of the tube, and install the pan on the transmis- (park) position . Stop the engine and
wipe it clean, and push it all the way sion. add additional transmission fluid re-
back into the tube. 7. Add three quarts of fluid to the quired to complete total fill. Start the
6. Pull the dipstick out of the tube transmission through the filler tube. engine and allow it to run at normal
again, and check the fluid level. If 8. Run the engine at idle speed idle speed.
necessary, add enough fluid to the for about two minutes, and then run 4. Allow approximately two quarts
transmission through the filler tube it at fast idle speed (about 1200 rpm) of transmission fluid to drain into the
to raise the fluid level to the F (full) until it reaches its normal op~rating pan placed under the end of the cool-
mark on the dipstick. Do not overfill temperature. Do not race the engine. er return line.
the transmission. 9. Shift the selector lever through 5. If the fluid does not run clean
all the positions, place it at P, and after draining two quarts of it
TRANSMISSION FLUID DRAIN check the fluid level. If necessary, through the cooler, shut off the en-
AND REFILL add enough fluid to the transmission gine and add two additional quarts
to raise the level to the F (full) mark of transmission fluid .
Normal maintenance and lubrica- on the dipstick. Do not overfill the 6. Repeat steps 4 through 6 until
tion requirements do not necessitate transmission. the transmission fluid flowing out of
periodic automatic transmission fluid the cooler return line is clean .
changes. OIL COOLER FLUSHING 7. If there is no fluid flow or the
If ·a major failure, such as a clutch PROCEDURE fluid does not flow freely, shut off
band, bearing, etc., has occurred in the engine and disconnect both cool-
the transmission, it will have to be When a clutch or band failure or er lines from the transmission and
removed for service. At this time other internal trouble. has occurred cooler.
the couverter, transmission cooler in the transmission, any metal par- 8. Use an air hose with not more
and cooler lines must be thoroughly ticles or clutch plate or band mater- than I00 psi air pressure to reverse
flushed to remove any dirt. ial that may have been carried into flush the cooler lines and the cooler .
When filling a dry transmission the cooler should be removed from After reverse flushing, connect both
and converter, install five quarts of the system by flushing the cooler and lines at the cooler and the cooler in-
fluid. Start the engine, shift the se- lines before the transmission is put let line (converter out) to the trans-
lector lever as in step 7 below, and back into service. In no case should mission .
check and add fluid as necessary. an automatic transmission having a 9. Start the engine and check the
Following are the procedures for clutch or band failure or other in- fluid flow . If the transmission fluid
partial drain and refill due to in-ve- ternal trouble resulting in fluid con- flows freely, proceed with steps 4
hicle repair operation. tamination, be put back into service through 7. If there is no fluid flow
1. Raise the vehicle on a hoist or without first flushing the transmission check for pinched cooler lines. If
jack stands. oil cooler. the flow is restricted, replace cooler
2. Place a drain pan under the 1. After installing a new or re- lines andjor the radiator.
transmission. built automatic transmission and 10. Shut off engine, remove the
3. Loosen the pan attaching bolts converter assembly in the vehicle, temporary plug from the cooler re-
to drain the fluid from the transmis- do not connect the cooler return line turn line fitting on the transmission
sion. to the transmission. Place the trans- case and connect the cooler return
4. After the fluid has drained to mission selector lever in the P (park) line to the transmission. Check the
the level of the pan flange, remove position and connect the cooler inlet transmission fluid level as indicated
the rest of the pan bolts working (converter out) line to the transmis- under heading Transmission Fluid
from the rear and both sides of the sion. Place a pan under the end of Level Check . Add or remove trans-
pan to allow it to drop and drain the cooler return line that will hold mission fluid as required until the
slowly. transmission fluid . Do not start the proper fluid level is obtained on the
5. When the fluid has stopped engine. dipstick. DO NOT OVERFILL THE
draining from the transmission, re- 2. Install 5 quarts of automatic TRANSMISSION .
transmission fluid meeting Ford 11. Do n•Jt attempt to correct
move and thoroughly clean the pan
Specifications. cooler or cooler line leaks by clos-
and the screen. Discard the pan
3. Start the engine and allow it to ing off the lines.

EJ CLEANING AND INSPECTION

Clean the parts with suitable sol- with any type of detergent solution. CLEANING
vent and use moisture-free air to dry To clean these parts, wipe them off
off all the parts and clean out oil with a lint-free cloth. New clutch CONVERTER CLEANING
passages. plates or bands should be soaked in
The composition clutch plates, transmission oil for fifteen minutes The converter cannot be disassem-
bands and synthetic seals should not before the plates or bands are bled for cleaning. If there is reason
be cleaned in a vapor degreaser or assembled. to believe that the converter has an
7-90 GROUP 7- AUTOMATIC TRANSMISSION
excessive amount of foreign material 10. Remove the converter from the sembly on a bench with the spline
in it, the following cleaning procedure mounting pad and place it on the end of the stator shaft pointing up
should be used: screen and allow all cleaning fluid (Fig.14).
1. Thoroughly clean the outside to drain from it. 2. Mount a converter on the
surfaces of the converter. Remove 11. Repeat steps 5 through 10 to pump so that the splines on the one-
both drain plugs and drain as much complete the cleaning operation. way clutch inner race engage the
fluid as possible. 12. After all cleaning fluid has been mating splines of the stator support,
2. Check the converter as detailed drained, torque the drain plugs to and the converter hub engages the
under Inspection. specification. pump drive gear.
3. Place the converter on the clean- 3. While holding the pump station-
ing machine with the drain holes fac- INSPECTION ary, try to rotate the converter coun-
ing downward. terclockwise. The converter should ro-
4. Flush the inside diameter of the TURBINE AND STATOR END tate freely without any signs of inter-
converter hub for one minute using PLAY CHECK ference or scraping within the convert-
the equipment jog switch to control er assembly.
the pump pressure. 1. Insert the tool (Fig. 12) into 4. If there is an indication of
the converter pump drive hub until scraping, the trailing edges of the
5. Install the filler cap on the con-
it bottoms. stator blades may be interfering with
verter. Place the converter on the 2. Install the guide over the con-
mounting pad with the drain holes the leading edges of the impeller
verter pump drive hub. blades. In such cases, replace the
facing upward. 3. Expand the split fiber bushing
6. Connect the pump pressure line converter.
in the turbine spline by tightening
to the filler cap. Fill the converter to the adjusting nut. Tighten the adjust- STATOR TO TURBINE
the drain hole level, then install the ing nut until the tool is securely INTERFERENCE CHECK
filler plugs finger tight.
locked into the spline.
7. Turn the converter over on the 1. Position the converter on the
mounting pad so that the drain plugs 4. Attach a dial indicator to the
tool (Fig. 13). Position the indicator bench front side down.
are facing downward and are 90 de- 2. Install a front pump assembly
grees to the cross-bar. Secure the con- button on a converter pump drive
hub, and set the dial face at 0 (zero). to engage the mating splines of the
verter with the cross-bar. stator support and stator, and pump
8. Remove both drain plugs from 5. Lift the tool upward as far as
drive gear lugs.
the converter, then start the shaker it will go and note the indicator
3. Install the input shaft, engag-
and flushing pump motors and allow reading. The indicator reading is the
ing the splines with the turbine hub
it to operate for seven mmutes in total end play which the turbine and (Fig. 15).
this manner. stator share. If the total end play ex· 4. While holding the pump sta·
9. Shut off the flushing pump and ceeds the limits specified in Part 7-S, tionary, attempt to rotate the turbine
allow the shaker to operate until the replace the converter unit. with the input shaft. The turbine
converter is nearly dry of cleaning STATOR ONE-WAY CLUTCH should rotate freely in both direc·
fluid, then shut off the shaker motor. CHECK tions without any signs of interfer-
ence or scraping noise.
1. Loosen the adjusting nut to free
Too/- TS8L-7902·A 5. If interference exists, the sta·
the split bushing, and then remove tor front thrust washer may be worn,
the tool from the converter. allowing the stator to hit the turbine.
2. Install the stator outer race In such cases, the converter must be
holding tool in one of the four holes replaced.
provided in the stator (Fig. 13). The converter crankshaft pilot
3. Insert the tool in the converter should be checked for nicks or dam-
pump drive hub. As the tool enters aged surfaces that could cause inter-
the converter, the pins will engage ference when installing the con-
the stator clutch inner race spline. verter into the crankshaft. Check the
4. Place a torque wrench on the converter front pump drive hub for
tool (Fig. 13). The tool (and stator nicks or sharp edges that would
inner race) should turn freely clock- damage the pump seal.
wise from the pump drive hub inside OUTPUT SHAFT AND
the converter). It should lock up and PRIMARY SUN GEAR SHAFT
hold a 10 ft-lb pull when the wrench
is turned counterclockwise. Try the I. Inspect the thrust surfaces and
clutch for lockup and hold in at least journals for scores. Inspect the inter-
five different locations around the nal gear for broken or worn teeth.
converter. 2. Inspect the aluminum sleeve

L 5. If the clutch fails to lock up

and hold a I0 ft-lb torque, replace
the converter unit.
STATOR TO IMPELLER
for scores or leakage. Inspect the
ring grooves for burrs.
3. Inspect the keyway and drive
ball pocket for wear, and inspect the
D 1<499-E splines for burrs, twist or wear.
INTERFERENCE CHECK 4. Inspect the output shaft sleeve
FIG. 12 -Converter Checking Tool I. Position the front pump as- for alignment with the governor
PART 7-3- F. M . X. AUTOMATIC TRANSMISSION 7-91

Split Fib« Bushing

END PLAY CHECK

Torque Wrench

Tooi -T58L -7902-Bor 7946 - A

Tooi- T63P-7902-A

STATOR CLUTCH CHECK

01934- A

FIG. 13- Typical Converter Checking Tool- FMX Transmission

7-92 GROUP 7-AUTOMA TIC TRANSMISSION

drive ball (Fig. 16). GOVERNOR 18) for obstructions and leakage. In-
5. Inspect the external parking DRIVE BAll spect the seal ring grooves for burrs.
gear teeth for damage and the speed- POCKET
9. Inspect the sun gear shaft
ometer drive gear teeth for burrs. splines for burrs and wear.
6. If either the output shaft or 10. Check the fit of the seal rings
ring gear has been replaced, place in the grooves of the shaft. The rings
the assembled unit with the gear face should enter the grooves freely with-
down on the bench, push the shaft out bind.
downward, and check the clearance 11. Check the fit of the seal rings
between the top of the snap ring and in their respective bores. If equipped
its groove (Fig. 17). If this clear- with cast iron seal rings, a clearance of
ance exceeds 0.002 inch, replace the 0.002-0.009 inch should exist between
snap ring with a thicker ring to re- the ends of the rings.
duce the clearance to less than 0.002 12. Install the seal rings on the
inch. Selective snap rings are avail- shaft, and check for free movement
able in several thicknesses for this in the grooves.
purpose .
7. Inspect the rubber seal and PINION CARRIER, ONE-WAY
CLUTCH AND CENTER
stop ring at the front of the output
SUPPORT
shaft spline. If wear or damage is
evident, replace the parts. I. Inspect the clutch outer race,
8. Inspect the primary sun gear inner race, band surface, pinion
for broken or worn teeth. Inspect all gears, bearings, and thrust washer
thrust surfaces and journals for (Fig. 19) for roughness.
scores . Check all fluid passages (Fig. 2. Inspect the center support bush-
ing for roughness.
3. Inspect the one-way clutch
cage rollers and springs for excessive
wear or damage.
01935-A
EXTENSION HOUSING
FIG. 16 - Correct Position of I. Inspect the housing for cracks.
Output Shaft Aluminium Sleeve Inspect the gasket surface for burrs
or warpage.
2. Inspect the bushing for scores
or wear.
3. Inspect the rear seal for hard-
ness, cracks, or wear. If the seal
shows wear or deterioration, replace
FRONT PUMP AND STATOR the seal.
SUPPORT SHAFT 4. Inspect the seal counterbore
D1922·A and remove all burrs and scores with
crocus cloth.
FIG. 14- Stator to Impeller REAR CLUTCH
Interference Check
I. Inspect the drum band sur-
face, the bushing, and thrust sur-
faces for scores. Minor scores may
be removed with crocus cloth. Bad-
ly scored parts must be replaced.
FIG. 17 -Checking Output Inspect the clutch piston bore and
Shaft Snap Ring Clearance the piston inner and outer bearing
surfaces for scores. Check the air

FRONT ClUTCH

D1937·A
FIG. 15- Stator to Turbine
Interference Check FIG. 18 - Primary Sun Gear Shaft- Cross Sectional View
PART 7-3- F. M.X. AUTOMATIC TRANSMISSION 7-93

CENTER SUPPORT "CAM TYPE" CLUTCH RACE

CHAMFER ON PRODUCTION
PART, ONLY-SERVICE PART NOT CHAMFERED PLANET CARRIER

D1931-A

FIG. 19 - Roller Type Planetary Clutch, Carrier and

Center Support
bleed ball valve in the clutch piston that is not flat.
for free movement. Check the ori- 6. Check the clutch hub thrust
fice to make sure it is not plugged. surfaces for scores and the clutch hub
2. Check the fluid passages for splines for wear. Dl'IJP-A
obstructions. All fluid passages must 7. Inspect the turbine shaft bear-
be clean and free of obstructions. ing surfaces for scores. If excessive
3. Inspect the clutch plates for clearance or scores are found, dis- FIG. 20- Clutch Piston Check
wear and scoring and check the card the unit. Valve
plates for fit on the clutch hub ser- Check the splines on the turbine obstructions .
rations. Replace all plates that are shaft for wear and replace the shaft 3 • .Inspect the control pressure
badly scored, worn or do not fit free- if the splines are excessively worn. and converter pressure valves and
ly in the hub serrations. Inspect the bushing in the turbine bores for burrs and scores. Remove
4. Inspect the clutch pressure shaft for scores. all burrs carefully with crocus cloth .
plate for scores on the -clutch plate 4. Check free movement of the
FRONT PUMP AND
bearing surface. Check the clutch re- valves in their bores. The valves
STATOR SUPPORT
lease spring(s) for distortion. should fall freely into the bores
5. Inspect the needle bearing for when both the valve and bore are
I. Inspect the mating surfaces of
dry .
worn rollers. the pump body and cover for burrs.
5. Inspect the valve springs and
FRONT CLUTCH 2. Inspect the drive and driven
spacers for distortion .
gear bearing surface for scores, and
I. Inspect the clutch cylinder
check the gear teeth for burrs. In- VALVE BODY
thrust surfaces, piston bore, and
spect the stator support splines for
clutch plate serrations for scores or
burrs and wear.
burrs. Minor scores or burrs may be
3. Check the fluid passages for
removed with crocus cloth . Replace I. Clean all parts thoroughly in
the clutch cylinder if it is badly obstructions.
4. If any parts other than the sta- clean solvent, and then blow them
scored or damaged. dry with moisture-free compressed
tor support are found defective, rt"-
2. Check the fluid passage in the air.
place the pump as a unit. Minor
clutch cylinder for obstructions. 2. Inspect all valve and plug bores
bourrs and scores may be removed
Clean out all fluid passages. Inspect for scores. Check all fluid passages
with crocus cloth. The stator support
the clutch piston for scores and re- for obstructions . Inspect the check
is serviced separately.
place 1f necessary . Inspect the piston valve for free movement. Inspect all
check ball for freedom of movement REAR SUPPORT mating surfaces for burrs or distor-
and proper seating (Fig. 20). tion. Inspect all plugs and valves for
3. Check the clutch release spring I. Inspect the gasket mating sur- burrs and scores . Crocus cloth can
for distortion and cracks. Replace faces for damage . be used to polish falves and plugs if
the spring if it is distorted or 2. Inspect the support bushing care is taken to afoid rounding the
cracked. for scores . sharp edges of the falves and plugs.
4. Inspect the composition and 3. Inspect the rear support fluid 3. Inspect all springs for distor-
the steel clutch plates and the clutch passages for obstructions. tion. Check all valves and plugs for
pressure plate for worn or scored 4. Check the fit of the fluid free movement in their respective
bearing surfaces. Replace all parts tubes in the support. bores. Valves and plugs, when dry,
that are deeply scored. must fall from their own weight in
PRESSURE REGULATOR
5. Check the clutch plates for fiat- their respective bores .
ness and fit on the clutch hub ser- I. Inspect the regulator body and 4. Roll the manual valve on a flat
rations. Discard any plate that does cover mating surface for burrs. surface to check it for a bent condi-
not slide freely on the serrations or 2. Check all fluid passages for tion .
7-94 GROUP 7- AUTOMATIC TRANSMISSION

Items to Check
Trouble SJmptoms Transmission Transmission
in Car Out of Car
Rough Initial Engagement in D or 2 K BWFEG
1-2 or 2-3 Shift Points Incorrect ABCDWEL
Rough 2-3 Shift BG FEJ
Engine Over speeds on 2-3 Shift BG EF r
No 1-2 or 2-3 Shift DECG J be
No 3-1 Shift KBE
No Forced Downshifts LWE
Runaway Engine Forced Downshift GFEJ B c
Rough 3-2 or 3-1 Shift at Closed Throttle KBE
Creeps Excessively K
Slips or Chatters in First Gear, D ABWFE aci
Slips or Chatters in Second Gear ABGWFEJ ac
Slips or Chatters in R AHWFEIB be
No Drive in D CE i
No Drive in 2 ER C ac
No Drive in 1 CER ac
No Drive in R HI ER C be
No Drive in Any Se~ector Lever Position ACWFER c
Lockup in D Cl J bgc
Lockup in 2 CHI bgc i
Lockup in 1 GJE bgc
Lockup in R GJ age
Parking Lock Binds or Does Not Hold c I
Transmission Overheats OG n
Maximum Speed Too Low, Poor Acceleration n
Transmission Noisy in N F ad
Transmission Noisy in First, Second, Third, or Reverse Gear F habd
Transmission Noisy in P F d
Fluid Leak MNOPQSTUX jmp

Probably Trouble Sources

A. Fluid Level S. Extension Housing to Case Gaskets and Lockwashers

B. Vacuum Diaphragm Unit or Tubes T. Center Support Bolt Lockwashers
C. Manual Linkage u. Extension Housing Rear Oil Seal
D. Governor w. Perform Control Pressure Check
E. Valve Body X. Speedometer Driven Gear Adapter Seal
F. Pressure Regulator a. Front Clutch
G. Front Band b. Rear Clutch
H. Rear Band c. Leakage in Hydraulic System
I. Rear Servo d. Front Pump
J. Front Servo g. Parking Linkage
K. Engine I die Speed h. Planetary Assembly
L Downshift Unkage i. Planetary One-Way Clutch
M. Converter Dr ain PI ugs j. Engine Rear Oil Seal
N. Oil Pan Gasket, Drain Plug or Tube m. Front Pump Oil Seal
0. Oil Cooler and Connect ions n. Converter One-Way Clutch
P. Manual or Throttle Lever Shaft Seal p. Front Pump to Case Gasket
Q. 1/8-inch Pipe Plug in Side of Case r. Rear Clutch Piston Air Bleed Valve
R. Perform Air Pressure Check

FIG. 21 - FMX Automatic Transmission Diagnosis Guide

PART 7·3- F. M.X. AUTOMATIC TRANSMISSION 7-95

GOVERNOR wear. If necessary to replace the accumulator piston and the check
actuating lever or shaft, remove the valve for freedom of movement.
I. Inspect the governor valves and retaining pin and push the shaft out Check the actuating lever socket for
bores for scores. Minor scores may of the bracket. Inspect the adjusting scores.
be removed from the valves with screw threads and the threads in the 7. Replace seals that are damaged.
crocus cloth. Replace the governor lever for damage.
if the valves or body is deeply scored. 3. Check the servo spring and servo CASE:
2. Check for free movement of band strut(s) for distortion.
the valves in the bores. The valves Inspect the case for cracks and
4. Inspect the cover seal and gas- stripped threads. Inspect the gasket
should slide freely of their own ket cover sealing surface for defects.
weight in the bores when dry. In- surfaces and mating surfaces for
spect fluid passages in the valve body REAR SERVO burrs. Check the vent for obstruc-
and counterweight for obstructions. tions, and check all fluid passages
All fluid passages must be clean. I. Inspect the servo body for for obstructions and leakages (Fig. 9).
cracks and the piston bore for Inspect the case bushing for
3. Check the mating surface of the scores. scores. Check all parking linkage
governor. valve and the counter- 2. Check the fluid passages for parts for wear or damage.
weight for burrs or scratches. obstructions.
3. Inspect the band and the struts ONE:-W A Y CLUTCH
FRONT SERVO for distortion . Inspect the band ends I. Inspect the outer and inner
for cracks. races for scores or damaged surface
I. Inspect the servo bore for
4. Inspect the servo spring for area where the rollers contact the
cracks and the piston bore and the distortion.
servo piston stem for scores. Check races.
fluid passages for obstructions. Re- S. Inspect the band lining for ex- 2. Inspect the rollers and springs
place seals that are damaged. cessive wear and bonding to the for excessive wear or damage.
metal band. 3. Inspect the spring and roller
2. Check the actuating lever for case for bent or damaged spring re-
free movement, and inspect it for 6. Check the servo body to case
mating surface for burrs. Check the tainers.

IJ DESCRIPTION
DESCRIPTION (Fig. 25) consists of an impeller clutch permits the stator to rotate
Figure 22 shows the location of (pump), a turbine, and a stator. All only in the direction of impeller ro-
the converter, front pump, clutches, these parts are enclosed and operate tation, the stator begins to turn with
bands, gear train and most of the in a fluid-filled housing. the impeller and turbine. The convert-
internal parts used in the FMX When the engine is running, the er operates as an efficient fluid cou-
Transmission. fluid in the torque converter flows pling as long as the turbine speed
from the impeller to the turbine and remains greater than 9I 10 impeller
The identification tag (Fig. 23) on back to the impeller through the speed.
an F MX transmission is attached stator. This flow produces a max- A constant flow of fluid into and
under the lower right-hand extension imum torque increase of about 2 to out of the converter is maintained.
to case bolt. The tag includes the I when the turbine is stalled. When Some of the fluid coming out of the
model prefix and suffix, assembly enough torque is developed by the converter is forced through a cooler
part number and the build date code. impeller, the turbine begins to rotate, located in the radiator tank.
turning the turbine shaft.
The tag must be kept with the
The converter torque multiplica-
individual transmission it was origin- PLANETARY GEAR TRAIN,
tion gradually tapers off as turbine
ally installed on. If the tag was CLUTCHES, BANDS AND
speed approaches impeller speed, and
removed during disassembly, re- SERVOS
it becomes I to I when the turbine is
install it on the same unit.
being driven at 9110 impeller speed.
This is known as the coupling point. Planetary Gear Train
The FMX transmission is a three
speed unit capable of providing auto- When the turbine is rotating at less
than 9I 10 impeller speed, the convert- The planetary gear train consists
matic upshifts and downshifts through of a primary sun gear, secondary sun
the three forward gear ratios, and also er is multiplying torque. The fluid
leaving the turbine blades strikes the gear, primary and secondary pin-
capable of providing manual selection ions which are held in a common car-
of first and second gears. front face of the stator blades. These
blades are held stationary by the ac- rier, and an internal gear to which
The transmission consists essentially the transmission output shaft is at-
of a torque converter, planetary gear tion of a one-way clutch (Fig. 25) as
long as the fluid is directed against tached (Fig. 26).
train, two multiple disc clutches and a
hydraulic control system (Fig. 24). the front face of the blades. Front Clutch
When the turbine rotates faster
than 9I I 0 impeller speed the convert- The front clutch drive plates (Fig.
OPERATION 27)are connected to the turbine shaft
er no longer multiplies torque. The
TORQUE: CONVERTER fluid is directed against the back face through the front clutch drum. The
The hydraulic torque converter of the stator blades. As the one-way driven plates are connected to the
7-96 GROUP 7-AUTOMATIC TRANSMISSION
TRANSMISSION DISTRIBUTOR EXTENSION HOUSING
TURBINE IMPELLER FRONT OIL SEAL SLEEVE
CASE SEAL
ONE · WAY
CLUTCH

FLYWHEEL D 1133-D

FIG. 22 -Typical FMX Transmission

primary sun gear shaft. clutch drive plates are splined to the driven clockwise at engine speed while
The front clutch is operated by front clutch drum and the driven the steel plates are driven counter-
fluid pressure against the clutch pis- plates are connected to the rear clutch clockwise.
ton. The piston moves against a disc drum and secondary sun gear. When Front Band and Servo
spring which acts as a lever to lock the rear clutch is applied (in the One end of the front band, which
the drive and driven plates together. reverse and third gear ratios) the encircles the rear clutch drum, is an-
When the clutch is applied, the pri- secondary sun gear is driven. The pis- chored to the transmission case, and
mary sun gear is locked to and driv- . ton is returned to the released position the other end is connected to the front
en by the turbine shaft. The piston is by the release spring (Fig. 27). servo (Fig. 28).
returned to the release position by In neutral, the rear clutch composi- Fluid pressure moves the front servo
the disc spring when the fluid pres- tion plates are being driven while the piston against the inner end of the
sure is removed (Fig. 26). A check steel plates are free . In second gear, front servo actuating lever. Force is
ball is installed in the front clutch the composition plates are driven, but transmitted through a strut between
piston to permit fluid exhaust, when the steel plates are held stationary. In the outer end of the lever and the end
the piston is in its released position. first gear, the composition plates are of the band to tighten the band around
In neutral, the front clutch drum
and steel plates are being driven
while the composition plates are
stationary. In reverse, the clutch is not
applied, since the steel and composi-
tion plates must rotate in opposite
directions .

Rear Clutch

The rear clutch (Fig.27) is operated

by fluid pressure against the clutch
piston. Movement of the piston com- ENGINE DISPLACEMENT BUILD DATE SHIFT
presses the release spring and locks
the multiple-disc clutch. The rear FIG. 23 - Identification Tags
PART 7-3- F. M . X. AUTOMATIC TRANSMISSION 7-97

LOW REVERSE
SERVO
FORWARD
CLUTCH

CHECK BALL
USED IN PHD
MODEL
TRANSMISSIONS
ONLY

LOW SERVO
MODULATOR
VALVE

CONVERTER

CONVERTER
PRESSURE
REGULATOR
VALVE

~-~ COOLER RETURN

OIL CHECK
VALVE

X EXHAUST

FIG. 24- Hydraulic Control System

7-98 GROUP 7-AUTOMATIC TRANSMISSION
the rear clutch drum. Under certain gear that uses the one-way clutch. holding the secondary sun gear (Fig.
conditions, the servo is released by 30).The primary pinions drive the sec-
directing fluid pressure to the opposite Power Row-Second Gear ondary pinions, causing them to walk
around the secondary sun gear and to
side of the piston, assisted by release carry the internal gear and output
Second gear ratio is obtained by
spring force . driving the primary sun gear and shaft around with them.
Rear Band and Servo
The rear band fits around the plan-
etary gear drum . One end of the band
contacts the end of the band adjust-
ing screw, and the other end connects
to the rear servo.
POWER FLOWS

Figure 29 lists the ratios obtained

throught the various power flows .
Power Row-Neutral
When the transmission 1S m neu-
tral (Fig . 30), no gears are held or
driven, and no power is transmitted to
the output shaft.
Power Row-First Gear,
Manual Low
In first gear when the selector lever
is at I, the primat.y sun gear is driven
and the pinion carrier is held by the
rear band (Fig.30). Power is trans-
mitted to the primary pinions, the 01006-A
secondary pinions, and the internal
gear, driving the internal gear in the FIG. 26- Planetary Gear Train
same direction as the primary sun
REAR CLUTCH DRUM
gear. The secondary sun gear turns
free in the reverse direction and has
no effect on the gear train .
Power Flow-First Gear, D
In first gear at the D selector lever
position, the pinion carrier is held
against rotation by the one-way
clutch instead of by the rear band
(Fig. 30). First gear in D is the only

D 113S-C

01007
DRIVE PLATES -A FIG. 28- Typical Front Servo
FIG. 27- Front and Rear Clutches
Selector Lever Clutch Band Gear
Gear Position AppUed Applied Rado
Neutral N None None -
First D or 1 Front Rear<D 2.40:1
Second D or2 Front Front 1.47:1
Third D Front and Rear None 1.00:1
Reverse R Rear Rear 2.00:1

CDin first gear D, the planet carrier is held against rotation by the one-way
01004-A
clutch.
FIG. 25- Sectional View of
Typical Torque Converter FIG. 29- Gear Ratios
PART 7-3- F. M. X. AUTOMATIC TRANSMISSION 7-99

Power Row-Third Gear Power Row-Revene Power Row-Park Position

In third gear, the primary and sec- Reverse gear is obtained by driv- When the selector lever is in the
ondary sun gears are locked together ing the secondary sun gear and hold- P (park) position, the parking pawl
and driven as a unit (Fig.30). There- ing the pinion carrier (Fig. 30)- The engages the external teeth on the in-
fore, the pinions cannot rotate and secondary pinions drive the internal ternal gear to lock the internal gear
the entire planetary train revolves as a gear in the reverse direction. The pri- and output shaft to the case. This
unit, which causes the output shaft to mary sun gear and the primary pinions locks the rear wheels to prevent move-
rotate at the same speed as the turbine rotate freely and have no effect on the ment of the vehicle.
shaft. gear train.
FRONT REAR REAR BAND
BAND BAND APPLIED

FRONT BAND
FIRST GEAR I RELEASED
NEUTRAL

PINION CARRIER
REAR BAND FRONT BAND OVERRUNNING
APPLIED ONE-WAY CLUTCH

ONE-WAY
CLUTCH
ENGAGED

- -
REAR CLUTCH
REAR CLUTCH RELEASED
FIRST GEAR D RELEASED SECOND GEAR

REAR BAND
REAR CLUTCH APPLIED
APPLIED

FRONT BAND

-
REAR BAND POWER FLOW . . .
THIRD GEAR REVERSE GEAR RELEASED
RELEASED
ROTATION
0 1136 - B

FIG. 30 -Power Flow

7-l 00 GROUP 7-AUTOMA TIC TRANSMISSION

HYDRAULIC CONTROL SYSTEM The D passage supplies fluid to the valve against spring force plus throt-
FRONT PUMP downshift valve, and through the 1-2 tle pressure force acting at the boost
shift shuttle ball check valve to the valve plug. Below 51 psi, therefore,
The front pump (Fig. 24), driven by 1-2 shift valve . In addition, fluid is throttle pressure will flow through
the converter impeller, delivers fluid directed to the 2-3 shift orifice and the boost valve without interference.
pressure to the hydraulic control sys- through it to the 2-3 shift valve and Throttle pressure above 51 psi will
tem whenever the engine runs. to the bottom of the rear servo lock move the boost valve to the left (Fig.
The pump delivers fluid pressure out valve. 24). This movement will first cut off
to the control pressure regulator and The D-2-1 passage directs apply throttle pressure flow to the shift
control valve body. A regulated con- fluid to the forward clutch, applying valves and the coasting control valve,
trol pressure is available at the con- it, and to the upper end of the transi- and it will then open a passage to per-
trol valve body whenever the engine tion valve, to the governor valve and mit the new boosted throttle pressure
is running. to the compensator cut back valve. to flow to the shift valves and the
The 2-1-R-P passage supplies fluid coasting control valve. Throttle pres-
CONTROL PRESSURE AND
COMPENSATOR PRESSURE to the upper valley of the 1-2 shift sure will continue to work against the
valve, and passes through the 1-2 shift right end of the boost valve. For each
Control pressure is regulated by valve bore to the adjacent ends of the pound of increase in throttle pressure
the spring-loaded control pressure 1-2 shift accumulator and lock-out (above 51 psi), the boosted throttle
regulator valve (Fig. 24). It is adjusted valves. pressure will increase about three
to engine torque, road speed, and se- The 1-R-P passage supplies fluid to pounds.
lector lever position. the valley of the 2-1 scheduling valve, GOVERNOR PRESSURE
To accomplish this, compensator and through the 1-2 shift shuttle ball
pressure under various conditions is check valve to the 1-2 shift valve. Governor pressure is produced from
adjusted by throttle pressure (engine The R passage supplies fluid to the front clutch control pressure by the
torque), governor pressure (road left valley of the throttle valve and valve in the governor body which ro-
speed), or selector lever position . Com- to the upper valley of the 2-3 shift tates at output shaft speed .
pensator pressure, in turn, adjusts con- valve. The governor valve is a balanced
trol pressure. valve. It is balanced between centri-
THROTTLE PRESSURE fugal force acting on the governor
CONVERTER PRESSURE valve plus governor spring force and
Throttle pressure adjusts the trans- governor pressure force (Fig. 24).Gov-
Like control pressure, converter mission operation to engine torque. ernor pressure is, therefore, proportion
pressure is regulated by the conver- Throttle pressure is produced from alto road speed.
tor pressure regulator valve spring control pressure by the throttle valve.
and is adjusted to driving conditions The throttle valve is controlled by a
by compensator pressure and selec- TRANSITION VALVE
spnng-loaded vacuum diaphragm unit
tor lever positions. mounted on the rear of the transmis- The transition valve controls the
MANUAL VALVE sion case (Fig. 24). front servo apply pressure flow.
The vacuum diaphragm is actuated In the D range, the transition valve
Line pressure is delivered to the by the engine intake manifold vacuum blocks front servo apply pressure flow
manual valve through a single pas- working against spring pressure. When until the 1-2 valve is closed by gover-
sage; the valve is positioned in the the vacuum is higher than 16 inches nor pressure.
valve body b,y the manual linkage, the diaphragm moves against spring In the 2 range, the transition valve
according to the mode of operation pressure and moves the push rod away permits front servo apply pressure to
desired. Fluid is distributed from the from the throttle valve to cut off the flow through it all all times. The spring
manual valve through the following throttle pressure regulation. As the en- modifies the action of the valve to im-
passages (Fig. 24). gine throttle is advanced, manifold prove the quality of the manual 1 ~2
vacuum will fall below 16 inches. As upshift.
l. D
the vacuum drops, the spring-loaded
2. D-2-1
d-iaphragm moves the push rod to open 1-2 SHIFT VALVE
3. 2-1-R-P
4. (Lower) 1-R-P the throttle valve and increase the
throttle pressure. The 1-2 shift valve controls the
5. 1-R-P
6. R 1-2 upshift in the D range . On the
7. Exhaust 2-1 downshift, either manual (shift
THROTTLE PRESSURE to I) or kickdown, the 1-2 shift valve
The D passage is charged in D BOOST VALVE controls the shift only within the road
range only . speed range permitted by the inhibitor
The D-2-1 passage is charged in To compensate for the slight mani- valve.
Drive range, manual Second gear (2 fold vacuum changes with throttle The 1-2 valve is held in its rest
range) and manual low gear (I range). movements beyond about 50 degrees (open) position by a spring. It is
The 2-1-R-P passages are charged carburetor valve opening, a throttle closed by governor pressure. Under
in 2, I, Reverse range and Park. pressure boost valve comes into various driving conditions, governor
The 1-R-P passages are charged in operation. At 51 psi throttle pressure, pressure is opposed by spring force
I, Reverse and Park. the spring-loaded boost valve(Fig. 24) plus reduced throttle and reduced
The R passage is charged in R range comes into balance. Throttle pressure boosted throttle pressures, and control
only . below 5 I psi cannot move the boost pressure.
PART 7-3- F. M.X. AUTOMATIC TRANSMISSION 7-101

REAR SERVO 2-3 upshift and the 3-2 downshift. The high gear, direct and reverse clutch
LOCKOUT VALVE valve is held in its rest (closed) posi- apply pressure is routed to the right-
tion by springs. It is opened by gover- hand passage behind the 1-2 shift ac-
The six passages that connect to nor pressure. Under various driving cumulator lockout va lve, a nd through
the rear servo lockout valve are pres- conditions, governor pressure is op- the check valve and 3-2 kickdown
surized as follows: posed by spring force plus throttle control valve to the valley of the 1-2
1. Rear Clutch Apply Pressure or boosted throttle pressures, and con- shift accumulator valve ; the entire
2. Exhaust trol pressure. shift accumulator and lockout valve
3. Rear Servo Apply Pressure INHIBITOR VALVE train moves to the left a nd is held
4. 1-R·P Pressure From Manual there insuring that the release sid e of
Valve the intermediate servo will be pres-
5. Rear Servo Apply Pressure The inhibitor valve prevents a 2-1 surized whenever the transmiss ion is
6. D Pressure From Manual Valve downshift, either manual or kickdown, in high gear. In addition, should the
When the transmission is operating at excessive road speeds . accelerator pedal be depressed to
in D range, line pressure from the The inhibitor valve is held in its force a kickdown into second gea r,
manual valve is directed through the rest (open) position by a spring. It is the shift accumulator va lve will re-
2-lshift orifice ball check valve to the closed by governor pressure . Under main to the left so that clutch a pply/
bottom of the rear servo lockout various driving conditions, governor servo release fluid ca n flow without
valve; this pressure holds the valve in pressure is opposed by spring force obstruction to the 3-2 kickdown con-
the upward position against the force plus control pressure. trol valve, where the exha ust of this
of front clutch apply pressure and fluid is controlled .
spring effort at the top of the valve. 1-2 SHIFT ACCUMULATOR
AND LOCKOUT VALVES When the transmission selector
While the valve is in this position, line lever is moved from D to 2 or I to
pressure from the D passage of the Four passages connect to the bore of provide engine braking, line pressure
manual valve is prevented from pres- the 1-2 shift accumulator and lockout from the 2-1 - R-P passage is directed
surizing the rear servo apply circuit. valves ; from left to right the first pas- through the 1-2 shift valve to the
When the selector lever is in the R sage is connected to direct-reverse third port of the 1-2 shift accumu-
position, R fluid from the manual clutch apply pressure through the 3-2 lator valve at the end adjacent to the
valve is directed through the 2-3 shift kickdown control valve and its orifice; lockout valve. The force produced by
valve to the area differential at the the second is connected to the release this pressure acting on the end of the
lower valley of the rear servo lockout side of the intermediate servo, the valves moves the valve to the left, keep-
valve; the force resulting from this third is connected . to the upper valley ing it in that position. This insures
pressure assists the spring in keeping of the 1-2 shift valve and the fourth is that servo release pressure will be
the valve downward in its bore, so connected directly to direct-reverse quickly exhausted through the direct
that servo apply pressure can pass clutch apply pressure. The 1-2 shift and reverse clutch circuit, permitting
through the bore and pressurize the accumulator and lockout va lves con- an immediate band application.
servo apply circuit. trol the quality of the 1-2 shift by
regulating the servo apply force as DOWNSHIFT VALVE
THROTTLE REDUCING follows :
VALVE To make a complete servo applica- Three passages intersect the bore of
tion, apply pressure must stroke the the downshift valve. The left-hand pas-
Before throttle pressure or boosted servo piston against the force of the sage is vented to exhaust ; the middle
throttle pressure is admitted to the release spring, and at the same time passage is connected to the adjacent
front face of the 2·3 shift valve, plug force out the fluid in the release side ends of the 2-3 throttle reducing valve
and 1-2 shift valve, it must open a of the servo. Fluid from the release and 2-3 shift delay valves and to the
passage past the spring-loaded throt- side of the servo unseats the check inhibitor valve. The third passage of
tle reducing valve. ball to bypass the intermediate servo the downshift valve is connected to the
Approximately 20 psi throttle pres- release orifice and is then routed to D passage of the manual valve.
sure is required to move the valve the valley of the 1-2 shift accumulator When the car is in intermediate or
against its spring far enough to open valve. As pressure builds up in the high gears (G:ive range) and the ac-
the passage. Once past the valve, apply side of the servo causing the celerator pedal is floored, to force
throttle pressure will work on the servo piston to stroke toward the apply the downshift valve in against spring
spring end of the valve and exert a position, a similiar pressure build-up is force, the '!?.lvc seals off the exhaust
force to cut off throttle pressure flow transmitted through the piston to the port and rcat.:s line pressure from the
past the valve. In this case, the valve release circuit and acts on the area manual valve to the inhibitor valve
becomes a balanced valve, wherein the differential of the 1-2 shift accumula- and to the adjacent ends of the 2-3
valve is balanced between throttle tor valve ; this will force the valve to throttle reducing. valve and 2-3 shift
pressure force on the one end and the left against its spring until the delay valve, tending to move the 2-3
spring force plus throttle pressure left-hand passage is uncovered, allow- shift valve upward in its bore. If the
force on the other end. The pressure ing the fluid in the release side of the force due to governor pressure acting
past the valve will, there£ ore, be re- servo to escape to exhaust at the on the area differential at the lower
duced. manual valve. In this way servo a pply valley of the 2-3 shift valve is suffi-
force is reduced to the required level ciently low the valve will move up-
2-3 SHIFT VALVE by regulating a back pressure on the ward and the transmission will engage
release side of the servo. second gear. At the same time, down-
The 2-3 shift valve controls the When the transmission upshifts to shift pressure is directed from the
7-102 GROUP 7-AUTOMA TIC TRANSMISSION

2-3 shift valve to the bottom of the downward force on the valve will be pressure from the 1-2 shift valve shut-
1-2 shift valve, where it tends to force less than the upward effort resulting tle ball check is directed to the inhibi·
a downshift into low gear. from spring force plus 2-1 scheduling tor valve, the inhibitor valve shuttle
pressure on the bottom of the valve ball check seals off the passage to the
3-2 DOWNSHIFT and the inhibitor valve will move up 2-1 scheduling valve, preventing loss
CONTROL VALVE in its bore, opening the necessary of pressure through the 2-1 scheduling
passages to permit a downshift into valve. Similarly when 2-1 scheduling
The 3-2 downshift control valve low gear. pressure is present, the shuttle ball
operates in the front servo release seals off the passage connecting to
pressure passage between the 2-3 the 1-2 shift valve shuttle ball check .
2-3 SHIIT ORIFICE BY-
valve and the front servo . A check PASS BALL CHECK VALVE
valve is installed parallel with the
HYDRAULIC CONTROL
downshift valve in the same passage Line pressure from the D passage of SYSTEM-NEUTRAL
so that release pressure flow to the the manual valve is directed through
servo by-passes it. the 2-3 shift orifice to the 2-3 shift The manual valve at N selector
The downshift valve controls the valve. When the 2-3 shift valve moves 'lever position blocks the fluid flow
rate of front servo release pressure downward in its bore, directing D to both clutches and both bands (Fig.
exhaust (flow from the servo), and fluid from the 2-3 shift orifice into the 24). With no fluid pressure in the
thereby the rate of front band applica- direct and reverse clutch apply circuit, clutches or servos, the clutches and
tion. the 2-3 shift orifice check ball seats on bands are released by spring pressure,
The 3-2 downshift control valve: the bypass hole, causing the clutch preventing power being transmitted
eliminates the possibility of a run-· apply pressure to be orificed. However to the transmission output shaft.
away condition in the transmission when the transmission selector lever Neutral operation of the transmis-
during a 3-2 kickdown at low car is moved to 2 to force a downshift to sion keeps control pressure up to its
speed (about 25 mph). It also elimi- second gear, the check ball unseats proper value, maintains a full torque
nates the possibility of a tie-up during from the bypass hole, allowing direct converter, lubricates the transmission,
the same shift at higher speeds (50 and reverse clutch apply pressure to and maintains a flow of fluid through
mph and more) . exhaust at the manual valve without the cooling system.
2-1 SCHEDULING VALVE further obstruction.
HYDRAULIC CONTROL
Four ports intersect the 2-1 schedul- 1-2 SHIIT VALVE SHUTTLE SYSTEM-D, FIRST GEAR
ing valve bore. From left to right, the BALL CHECK VALVE
first port is vented to exhaust, the sec- When the selector lever is moved
ond is connected to the spring end of Fluid is directed from the D and from N to D, the manual valve opens
the inhibitor valve through the inhibi- 1-R-P passages of the manual valve three passages to control pressure.
tor shuttle ball check valve, the third to the lower valley of the 1-2 shift From left to right, the first passage
is connected to the 1-R-P passage of valve. When the D passage is pressur- admits control pressure to supply the
the manual valve and the right-hand ized the 1-R-P passage is open to ex- 2-3 valve and close the rear servo lock-
port is vented to exhaust. haust at the manual valve, and vice out valve . The second passage admits
When the selector lever is moved versa. Therefore a shuttle ball check control pressure to apply the front
to I to force a downshift from high valve is provided in the line connect- clutch and supply the governor and
or intermediate gear to low, 1-R-P ing to the lower valley of the 1-2 shift transition valve. The third passage ad-
fluid pressure is directed to the third v.elve. When the transmission is opera- mits control pressure to flow through
port of the 2-1 scheduling valve. The aung in D range the shuttle ball seals the 1-2 and inhibitor valves and close
force due to line pressure acting on off the 1-R-P passage, preventing D the transition valve.
the differential area moves the valve pressure from exhausting at the man- With the front clutch applied, .the
to the left, compressing the spring. ual valve. Similarly, when the trans- primary sun gear tries to drive the
As the valve moves to the left it seals mission is in I, 2 or P ranges the pinion carrier in a counterclockwise
off the line pressure port and uncovers shuttle ball seals off the D passage, direction . Counterclockwise rotation
the exhaust passage at the left end of preventing the loss of 1-R-P fluid at at the pinion carrier is prevented by
the valve, allowing some of the fluid the manual valve. the one-way clutch . With the front
in the differential pocket to escape to clutch applied and the pinion carrier
exhaust. The loss of pressure in the INHIBITOR VALVE held, the transmission is in first gear.
differential pocket allows the spring SHUTTLE BALL CHECK
to force the valve back to the right, VALVE HYDRAULIC CONTROL
where it is again charged with line SYSTEM-D, SECOND GEAR
pressure. The pressure resulting from The spring end of the inhibitor
the regulating cycle is routed to the valve is pressurized at various times The 1-2 shift occurs when gover-
spring end of the inhibitor valve, where by the following pressures: nor pressure force on the 1-2 shift
it assists the inhibitor valve spring in I. D fluid and 1-R-P fluid from valve overcomes shift plug pressure
tending to force the valve upward 1-2 shift circuit shuttle ball check . and spring forces . The 1-2 valve moves
against the force due to governor pres- 2. 2-1 scheduling pressure from 2-1 inward, exhausting the fluid which
sure acting on top of the valve. scheduling valve. holds the transition valve closed. The
If vehicle speed and resulting gov- A shuttle ball check valve is pro- transition valve opens and admits con-
ernor pressure on the upper end of the vided in the passage connecting to the trol pressure to apply the front band .
inhibitor valve is low enough the spring end of the inhibitor valve. When The front clutch remains on, and
PART 7-3-F. M . X. AUTOMATIC TRANSMISSION 7-103

the front band applies to put the When the accelerator pedal is de- HYDRAULIC CONTROL
transmission in second gear. pressed through the detent, the down- SYSTEM-REVERSE
shift valve opens a passage that ad-
HYDRAULIC CONTROL mits control pressure behind the 2-3 When the manual valve is shifted
SYSTEM-D, THIRD GEAR shift plug to oppose governor pressure. into reverse, control pressure is direc-
If the transmission is in high and road ted to apply the rear clutch and rear
The 2-3 shift occurs when gover- speed is below 47-69 mph, the 2-3 band. Governor supply pressure is cut
nor pressure force overcomes spring valve will be forced closed against off by the manual valve ; hence, the
and shift plug pressure force at the governor pressure . When the 2-3 valve transmission cannot shift automatic-
2-3 shift valve. When the shift valve closes, control pressure which has ally . Rear clutch pressure is also dir-
opens, control pressure flows through been applying the rear clutch and re- ected to the throttle valve to regulate
it to apply the rear clutch and release leasing the front band is exhausted. throttle pressure to obtain the correct
the front band. With both clutches The apply pressure that was in the line pressure for the reverse circuit.
applied, the transmission is in third front servo in third gear is now free
gear. to apply the front band. As soon as
the front band applies, the transmis- OIL COOLING AND
HYDRAULIC CONTROL sion is in second gear. LUBRICA liNG SYSTEM
SYSTEM-l, SECOND GEAR
HYDRAULIC CONTROL Figure I shows the transmiss ion
When the manual valve is at the 2 SYSTEM-I, FIRST GEAR series cooling circuit. The converter out
selector lever position, control pres-
circuit is directed through the oil cool-
sure to the 1-2 shift valve is cut off.
In I range, first gear, control pres- er, then the cooled oil is used in the
This condition permits control pres-
sure to flow through the transition sure is directed by the manual valve transmission lubricating circuit.
to apply the front clutch and rear A spring-loaded check valve is used
valve to apply the front band.
band . Control pressure is also direct- in the circuit to maintain approxim ate-
With the front clutch and the front
band applied, the transmission oper- ed by the manual valve to lock the 1-2 ly 3-5 psi in the converter out circuit.
and 2-3 shift valves in their closed po- When the converter out circuit exceeds
ates in second gear.
sitions. Since neither shift valve can 3-5 psi, the check ball opens against
HYDRAULIC CONTROL move, the transmission will stay in spring pressure and cooled oil is di-
SYSTEM-D RANGE, first gear regardless of throttle posi- rected to lubricate the various parts
3-l KICKDOWN tion or road speed . of the transmission gear train .

II IN-VEHICLE ADJUSTMENTS AND REPAIRS

CONTROL LINKAGE (Fig. 31). Move the transmission inhibiter switch terminals.
manual lever to the D position, fourth 2. Loosen the locknut and remove
ADJUSTMENTS the switch from its mounting bracket.
detent position from the back of the
The transmission control linkage transmission . TO ASSEMBLE
adjustments should be performed in 3. With the transmission selector Assemble the switch to the moun-
the order in which they appear in this lever a nd manual lever in the D posi- ting bracket and adjust , as outlined
section of the manual. tions, torque the attaching nut 10 to under "INHIBITER SWITCH
20 ft-lbs . ADJUSTMENT".
4. Check the operation of the trans-
THROTTLE AND mission in each selector lever position.
DOWNSHIFT LINKAGE GEAR SHIFT LINKAGE
ADJUSTMENTS INHIBITOR SWITCH ADJUSTMENT See Group 3 Section 3-4 page 3- 38 .
Select 'D? Connect test lamp leads
Adjusting the throttle linkage ·is im- across terminals 1 and 3 and ter- Selector Lever Removal and Re-
portant to be certain the throttle and minals 2 and 4. Slacken the locknut placement.
kickdown systems are properly adjust- and screw the switch inward until the 1. Raise the vehicle and remove
ed. The kickdown system should come lamp goes out. Note the switch the manual lever control rod (Fig. 31 ).
in when the accelerator is pressed position. Continue screwing in the 2. Lower the vehicle, remove the
through detent, and not before detent. switch until the lamp lights, and selector lever handle attaching screw
Refer to Group 10 for detailed again note the switch position. Screw and remove the handle (Fig. 31).
throttle and downshift linkage adjust- out the switch until it is midway 3. Prise the dial from the bezel to
ment procedures. between the two positions, and then gain access to the bezel attaching
tighten the locknut. Check that the screws and remove the bezel.
lamp only lights when the selector 4. Remove the two console attach-
MANUAL LINKAGE lever is at 'P', 'R' and 'N'.
ADJUSTMENT ing screws at the front of the console
NEUTRAL START SWITCH and the screw in the glove box.
I. Position the transmission selec- REPLACEMENT Remove the console.
tor lever in D position . FROM UNDER THE VEHICLE 5. Disconnect the dial indicator
l. Raise the vehicle and loosen the light.
manual lever shift rod retaining nut 1. Remove the wires from the 6. Remove the attaching nuts and
7-104 GROUP 7-AUTOMATlC TRANSMISSION

FIG. 31- Selector Linkage- Floor Shift

screws and remove the console sup- 13. Remove the handle from the selector lever detent position.
port and gear lever slide assembly. selector lever.
7. Remove the selector housing 14. Install the selector lever hous- BAND ADJUSTMENTS
and lever assembly attaching bolts ing and lever assembly as shown in
and remove the selector lever and Fig. 33. Torque the attaching bolts FRONT BAND
housing. to 4--6 lbs. ft. ADJUSTMENT
8. Remove the selector lever to 15. Install the console support and
housing attaching nut. Remove the gear lever slide assembly. I. Drain the fluid from the trans-
lever from the housing. 16. Refit the dial indicator light. mission by loosening the pan attach-
9. Install the selector lever in the 17. Replace the console. ing bolts starting at the rear of the
housing and install the attaching nut. 18. Refit the indicator dial bezel pan and working toward the front.
Torque the nut to 20 to 25 ft. lbs. and refit the dial. When most of the fluid has drained
10. Install the dial indicator light. 19. Install the selector lever handle from the pan, remove the remainder
11. Install the selector lever handle. and tighten the attaching screw. of the attaching bolts. Use a clean
12. Position the selector as shown 20. Position the selector lever in drain can equipped with a 100-mesh
in Fig. 80. With a feeler gauge check the N position. screen if the fluid is to be reused .
the clearance between the detent 21. Raise the vehicle. Install the 2. Remove the pan, then remove
pawl and plate. The clearance should transmission manual lever rod to the the fluid filter and cli_p from the trans-
be 0.005 to 0.010 inches. If neces- selector lever. With the transmission mission. Clean the inside of the pan.
sary adjust the height of the detent in neutral and the selector lever Remove all gasket material from the
pawl as shown in Fig. 74. against the neutral stop, tighten the pan and pan mounting face of the
selector lever to manual lever rod nut.
case.
22. Lower the vehicle and check 3. Loosen the front servo adjusting
the transmission operation in each
screw lock nut.
4. Pull back on the actuating rod,
and insert the I /4 inch spacer between
the adjusting screw and servo piston
stem (Fig . 32). Tighten the adjusting
screw to 10 in-lbs. torque . Remove the
spacer and tighten the adjusting screw
an additional 3/4 turn. Hold the ad-
justing screw stationary and tighten
the lock nut securely.
5. Install the transmission fluid
screen and clip . Install the pan using a
ACTUATING LEVER
new gasket.
·'>.• 6. Refill the transmission to the
0 2048 -A
FULL mark on the dipstick.
FIG. 32 - Adiusting Front Band FIG. 33 - Adiusting Rear Band 7. Start the engine and engage the
Typical transmission in each drive range to fill
Typical
PART 7-3- F. M. X. AUTOMATIC TRANSMISSION 7-105

all fluid passages, then place the selec- output shaft and rear support from 15. Position a new extension hous-
tor lever in the P position . Check the moving rearward to prevent the needle ing gasket on the rear of the transm is-
fluid level and add enough fluid to bearing and race from dropping out of sion case.
bring the level above the ADD mark location. 16. Shde the extension housing into
on the dipstick . 12. Remove the governor to coun- place and secure it to the transmission
terweight attaching screws. Lift the case with the attaching · bolts. Torque
REAR BAND ADJUSTMENT- the bolts to specification. With the ex-
governor from the counterweight (Fig.
Adjustment of the rear band is 34). tension housing installed, rotate the
performed externally. 13. Lubricate the governor valve output shaft. The shaft must rotate
1. Remove all dirt from the adjust- parts with clean transmission fluid. freely by hand. If the shaft is tight or
ing screw threads, then oil the Make certain that the valve moves bound up, it is likely that the needle
threads. freely in the valve body bore. bearing and race have dropped out of
14. Position the governor valve location, in which case, the transmis-
2. Loosen the adjusting screw body on the counterweight with the sion must be partially disassembled
locknut. cover facing toward the front of the and the bearing and race repositioned.
3. Using a torque wrench and vehicle. Install and tighten the two at- 17. Connect the speedometer cable
taching screws to the specified torque . to the extension housing .
adaptor, tighten the adjusting screw
to a torque of 10 ft.-lbs. 18. Raise the transmission high
enough with a jack to position the en-
4. If the screw is found to be gine rear support on the crossmember.
tighter than 10 ft.-lbs. torque, loosen Secure the support to the crossmem-
the screw and then tighten to 10 ber with attaching bolt.
ft.-lbs. torque. 19. Lower the transmission and re-
5. Back off the adjusting screw 1t move the jack. Secure the extension
turns. Hold the adjusting screw housing to the rear support with the
stationary and tighten the adjusting two attaching bolts.
screw lock nut to specification. 20. Connect the p a rking br a ke
Severe damage may result if the cables to the equalizer and adjust the
adjusting screw is not backed cables as required .
off exactly 1% turns. 21. Install the driveshaft.
22. Fill the transmission to the cor-
EXTENSION HOUSING AND
rect level with the specified fluid .
GOVERNOR REPLACEMENT
1. Raise the vehicle so that the OIL PAN AND CONTROL
transmission extension housing is ac- VALVE BODY REPLACEMENT
cessible . D 1815 · A
2. Drain the fluid from the trans-
mission.
FIG. 34- Governor Installed 1. Raise the ve hide so that the

3. Disconnect the drive shaft from COMPEN SATOR MAIN CONTROL VACUUM
the rear a xle and slide the front yoke PRE SSU RE TUBE VALVE TUBE DIAPHR ACM
out of the extension housing.
4. Disconnect the speedometer
cable from the extension housing.
5. Remove the two bolts that secure
the extension housing to the engine
rear support.
6. Remove the nut and bolt that se-
cures the engine rear support to the
crossmember.
7. Raise the transmission high
enough to provide clearance for the
rear mount.
8. Lift the engine rear support from
the crossmember.
9. Lower the jack until the exten-
sion housing just clears the crossmem-
ber to remove all weight from the
housing.
10. Loosen the parking brake cable
RE TAINING CLI P
adj ustment nut enough to disconnect
the cables from the equalizer.
11. Remove the extension housing
a ttaching bolts. Slide the housing off FRONT REAR
the output shaft and remove the gas- SERVO SER VO
D 18 17 · A
ket. When removing the extension
housing and / or governor, hold the
FIG. 35- Typical Hydraulic Control System
7-106 GROUP 7- AUTOMATIC TRANSMISSION

transm1sswn fluid pan is accessible . under the valve .body bolt as shown in the tube in this manner. Failure to do
2. Drain the fluid from the trans- Figure 35. so, could kink or bend the tube caus.
mission by loosening the pan attach- 13. Install the main pressure oil ing excessive transmission internal
ing bolts starting at the rear of the tube. Be sure to Install the end of the leakage.
pan and working toward the front. tube that connects to the pressure re- 3. Remove the pressure regulator
When most of the fluid has drained gulator first. Then, install the other spring retainer, springs, and spacer.
from the pan, remove the remainder end of the tube into the main control Maintain pressure on the retainer to
of the attaching bolts. Remove the valve assembly by tapping it gently prevent the springs from flying out.
pan and gasket. Discard the gasket. If with a soft hammer.
4. Remove the pressure regulator
the same fluid is to be used again in Install the compensator pres- attaching bolts and washers, and re-
the transmission, filter the fluid sure tube to the pressure regulator
move the regulator.
through a 100-mesh screen before in- and the control valve body.
S. Position the replacement regula-
stalling it in the transmission. Re-use 14. Turn the manual valve one full
tor body on the transmission case and
the fluid only if it is in good condi- turn in each manual lever detent posi-
install the two attaching bolts. Torque
tion. tion . If the manual valve binds against
the bolts to specification.
3. Disconnect the hose from the the actuating pin in any detent posi-
6. Check the converter pressure and
vacuum diaphragm unit. Remove the tion, loosen the valve body attaching
control pressure valves to be sure the
diaphragm unit using tool FC0-24. bolts and move the body away from
valves operate freely in the bores.
Do not use any tools on the dia- the center of the case . Move the valve 7. Install the valve springs, spacer,
phragm housing, such as pliers, pipe body only enough to relieve the bind-
and retainer.
wrenches, etc. Do not allow solvents ing. Torque the attaching bolts and 8. Install the main pressure oil
to enter the diaphragm unit. Remove recheck the manual valve for binding. tube. Be sure to install the end of the
the push rod . Remove the fluid screen IS. Position the push rod in the tube that connects to the pressure re-
retaining clip and the screen. bore of the vacuum diaphragm unit. gulator assembly first. Then, install
4. Remove the fluid filter retaining Using the diaphragm unit as a guide, the other end of the tube into the
clip and the filter . insert the push rod into the threaded main control assembly by tapping it
S. Remove the small compensator opening of the case . Torque the dia- gently with ·a soft hammer.
pressure tube . phragm unit to specification . Connect Install the small compensator
Remove the main pressure oil the vacuum hose. pressure tube.
tube by gently prying up the end that 16. Torque the front servo attach- 9. Install the fluid filter and the
connects to the main control valve as- ing bolts to specification . pan, and fill the transmission to the
sembly first. Then, remove the other 17. Adjust the front band. correct level with the specified fluid .
end of the tube from the pressure re- 18. Install the fluid filter and the
gulator. Be sure to remove the tube in filter retaining clip.
this manner. Failure to do so, could 19. Position a new fluid pan gasket FRONT SERVO REPLACEMENT
kink or bend the tube causing exces- on the bottom of the transmission
sive transmission internal leakage. case, and install the pan . Torque the I. Drain the fluid from the trans-
mission, and remove the pan and fluid
6. Loosen the front servo attaching pan screws to specification.
filter.
bolts three turns. ' 20. Adjust the rear band.
7. Remove the three control vaive 2. Remove the vacuum diaphragm
2 I. Fill the transmission with fluid. unit.
body attaching bolts, and lower the If the fluid that was drained from the
valve body while pulling it off the 3. Loosen the three control valve
transmission is to . be used again, filter body attaching bolts.
front servo tubes. Be careful not to the fluid through a 100-mesh screen as
damage the 'alve body or the tubes. 4. Remove the attaching bolts from
it is poured back into the transmis- the front servo (Fig. 35), hold the
8 . Before installing the control sion. Re-use the fluid only if it is in
valve body, check for a bent manual strut with the fingers, and remove the
good condition. servo.
valve by rolling it on a flat surface. 22. If the control valve body was
9. Install the control valve body by 5. To install the front servo, posi-
replaced, adjust the transmission con- tion the front band forward in the
aligning the front servo tubes with the trol linkage.
holes in the valve body. Shift the man- case with the end of the band facing
ual lever to the I detent, and place the downward. Make sure the front servo
PRESSURE REGULA TOR anchor pin is in position in the case
inner downshift lever between the REPLACEMENT
downshift lever stop and the downshift web . Align the large end of the servo
valve . The manual valve must engage strut with the servo actuating lever,
I. Drain the fluid from the trans-
the actuating pin in the manual detent and align the small end with the band
mission, and remove the pan and fluid
end .
lever. filter .
6. Rotate the band, strut, and servo
10. Install but do not tighten, the 2. Remove the small compensator
to align the anchor end of the band
control valve body attaching bolts. pressure tube and the large control
with the anchor in the case.
1). Move the control valve body pressure tube from the control valve
Push the servo body onto the con-
toward the center of the case until the body and the pressure regulator.
trol valve body tubes.
clearance is less than 0.050 inch, be- Remove the main pressure oil
7. Install the attaching bolts and
tween the manual valve and the act- tube by gently prying up the end that
torque to specification .
uating pin on the manual detent lever. connects to the main control valve as-
8. Torque the control valve body
12. Torque the attaching bolts to sembly first. Then remove the other
attaching bolts to specification .
specification. Be sure that the rear end of the tube from the pressure re-
fluid filter retaining clip is installed gulator . Be sure to remove Check the clearance between the
PART 7-3- F. M. X. AUTOMATIC TRANSMISSION 7-107

5. Before installing a new seal, in-

spect the sealing surface of the univer-
sal joint yoke for scores. If scores are
found, replace the yoke.
6. Inspect the counterbore of the
housing for burrs. Polish off all burrs
with crocus cloth.
7. Install the seal into the housing
with tool shown in Fig. 39. The seal
should be firmly seated in the bore.
PARKING PAWL
REPLACEMENT
1. Raise the vehicle and drain .the
FIG. 36 -Removing Extension Housing Seal fluid from the transmission.
manual valve and manual lever actuat- and fill the transmission with fluid . 2. Place the adjustable support
ing pin as given in Oil Pan and Con- stand under the rear of the engine.
trol Valve Body Replacement. IXTINSION HOUSING 3. Remove the driveshaft.
9. Adjust the front band . BUSHING AND lEAR SEAL 4. Disconnect the parking brake
10. Install the vacuum diaphragm IIEPI.ACEMENT cables from the equalizer bracket.
unit and rod . I. Disconnect the drive shaft from 5. Remove the engine rear
II. Install the fluid filter and pan, the transmission. support-to-extension housing bolts.
and fill the transmission with fluid. 2. Carefully remove the seal with 6. Remove the bolt that secures the
12. Adjust the downshift and manu- the tools shown in Fig. 36. engine rear support to the crossmemb-
al linkage . 3. Remove the bushing as shown jn er. Raise the engine with the adjusta-
Fig. 37. Use the bushing remover ble support stand just high enough to
REAR SERVO REPLACEMENT carefully so that the spline seal is not provide clearance for removing the
damaged. support.
I, Drain the fluid from the trans- 4. Wben installing a new bushing 7. Lower the jack until the exten-
mission, and remove the pan and fluid use the special tool shown in Fig. 38. sion housing just clears the crossmem-
filter. ber to remove all weight from the
2. Remove the vacuum diaphragm housing.
unit. 8. Disconnect the speedometer
3. Remove the control valve body cable from the transmission .
and the two front servo tubes. 9. Remove the transmission pan
4. Remove the attaching bolts from and fluid filter .
the rear servo, hold the actuating and 10. Loosen the rear band adjusting
anchor struts with the fingers, and re- screw lock nut and tighten the adjust-
01025-1
move the servo. ing screw to 24 in.-lbs torque. This
5. To install the rear servo, position FIG. 37- Removing Extension will tighten the rear band around
the servo anchor strut on the servo Housing Bushing the planet carrier and will hold
band, and rotate the band to engage the planet carrier and clutch
the strut. assemblies in position during the
6. Hold the servo anchor strut in parking pawl repair operation.
position with the fingers, position the 11. Remove the small compensator
actuating lever strut, and install the pressure tube from the pressure regu-
servo. lator and control valve body.
7. Install but do not tighten the 12. Remove the main pressure oil
servo attaching bolts. The longer EXTENSION HOUSING 01026-1 tube by gently prying up the end that
bolt must be installed in the FIG. 38 -Installing Extension connects to the main control valve as-
inner bolt hole. sembly first. Then, remove the other
IJ. Move the rear servo (with rea- Housing Bushing
sonable force) toward the centerline
of the transmission case, against the
servo attaching bolts. While holding
the servo in this position, torque the
attaching bolts to specification.
9. Install the two front servo tubes
and the control valve body.
Check the clearance between the
manual valve and the manual lever
actuating pin as given above in Oil
Pan and Control Valve Body Replace- EXTENSION HOUSING
ment. REAR SEAl
10. Adjust the rear band.
11. Install the fluid filter and pan, FIG. 39 -Installing Extension Housing Seal
7-108 GROUP 7-AUTOMA TIC TRANSMISSION

end of the tube from the pressure re- slide the toggle lever toward the front and Control Valve Body Removal and
gulator. Be sure to remove the tube in of the case. Cock the lever to one side Installation .
this manner. Failure to do so, could to apply pressure on the pin, then 30. Torque the front servo attach-
kink or bend the tube causing exces.. move the toggle to the rear of the case ing bolts to specification.
sive transmission internal leakage. to move the pin outward. Repeat this 31. Install the main pressure oil
13. Disconnect the vacuum hose procedure until the pin can be re- tube and the small compensator pres-
from the vacuum diaphragm and re- moved from the case. Lift the pawl sure tube to the control valve body
move the vacuum diaphragm and con- and toggle from the case as an assem- and pressure regulator .
trol rod . bly. 32. Adjust the front band.
14. Loosen the front servo attach- 22. Remove the pawl and toggle 33. Adjust the rear band.
ing bolts. lever as an assembly. 34. Position the vacuum control
15. Remove the three control valve 23. Position the new parking pawl rod in the case. Install the vacuum
body attaching bolts and lower the and link assembly, then install the diaphragm unit. Connect the vacuum
valve body while pulling it off the toggle lever pin and the plug. hose.
front servo tubes. Be careful not to 24. Secure the pawl to the case 35. Install the fi Iter, transmissior.
damage the vahe body or the tubes. with the pawl pin. pan and a new gasket.
16. Remove the rear servo attach- 25. Position a new gasket on the 36. Connect the speedometer cable
ing bolts and remove the rear servo front of the support and at the rear. to the extension housing.
and struts. Hold them in place with transmission 37. Raise the transmission high
17. Remove the extension housing fluid or vaseline. enough to position the engine rear
attaching bolts and housing. 26. Make sure that the thrust wash- support on the crossmember. Secure
18. Remove the output shaft and the support with the attaching bolt.
er is in place, then position the sup-
rear support assembly. port and output shaft in place making 38. Lower the transmission and re-
19. Remove the parking pawl pin sure that the pressure tubes are en- move the jack. Install the two exten-
from the case with a magnet. tered in the case. sion housing-to-engine rear support
20. Working from inside of the 27. Secure the extension housing to attaching bolts.
case, drive on the shoulder of the tog- the case with the attaching bolts. 39. Connect the parking brake
gle lever (Fig. 69) pin with a small 28. Install the rear servo and strut cables to the equalizer.
punch to move the retaining plug part as outlined under Rear Servo Remov- 40. Install the driveshaft, then
way out of the case . Remove the plug al and Installation. lower the vehicle.
with a pair of pliers. 29. Install the main control valve 41. Fill the transmission to the cor-
21. To remove the toggle lever pin, assembly as outlined under Oil Pan rect level with the specified fluid.

II REMOVAL AND INSTALLATION

the manifolds and allow them to hang. Remove the six converter housing-
TRANSMISSION AND 6. Disconnect the oil cooler lines to-cylinder block attaching bolts.
CONVERTER REPLACEMENT- from the transmission . Move the jack rearward until the
REMOVAL 7. Disconnect the vacuum hose transmission clears the engine, then
from the vacuum diaphragm unit. tip it forward to provide clearance.
I. Raise the vehicle and remove the 8. Disconnect the speedometer Lower the transmission and remove
cover from the front of the converter cable from the extension housing, and it from under the vehicle.
housing. Drain the fluid from the remove the drive shaft. INSTALLATION
transmission. 9. Disconnect the manual and I. If the converter has been re-
2. Remove one of the converter downshift linkage from the transmis- moved from the converter housing,
drain plugs. Then, rotate the converter sion. carefully position the converter in the
180 degrees and remove the other 10. Disconnect the parking brake housing and install the housing lower
plug. Do not attempt to turn the con- cables from the equalizer bracket. front cover to prevent the converter
verter with a wrench on the converter Remove the two rear support-to- from slipping out of the housing.
stud nuts. crossmember nuts. 2. Rotate the converter until the
3. When the fluid has stopped Position a transmission jack under studs adjacent to the drain plugs are
draining from the transmission and the transmission and secure the in a vertical position. Rotate the fly-
converter, remove the four flywheel- transmission to the jack with a safety wheel as required to align the drain
to-converter nuts. Install the drain chain. plug holes with the drain plugs in the
plugs in the converter and torque to Raise the transmission just enough converter.
specification. Install the converter to remove the weight from the cross- 3. Roll the transmission into posi-
housing front plate to hold th(' con- member. Remove the two cross- tion under the vehicle and raise it to
verter in place when the transmission member-to-frame side support bolts align with the engine. Remove the
is removed . and nuts and remove the cross- housing lower front cover that was
4. Disconnect the starter cables member. previously installed. Move the trans-
from the starter and remove the start- Lower the transmission and re- mission forward until the converter
er. move the bolt that secures the trans- housing contacts the cylinder block.
5. Remove the nuts that attach JruSSlon fluid filler tube to the
cylinder head. Lift the filler tube Install and torque the converter
each muffler inlet pipe to the exhaust housing to cylinder block attaching
manifolds. Separate the pipes from and the dip-stick from the trans-
mission case. bolts.
PART 7-3- F. M.X. AUTOMATIC TRANSMISSION 7-109

4. Remove the jack safety chain torque the rear support-to-crossmem- 14. Connect the speedometer cable
from the transmission. ber nuts. to the extension housing.
5. Install a new 0-ring on the lower 9. Install the converter-to-flywheel 15. Install the linkage rods on the
end of the filler tube. Dip the 0-ring attaching nuts and torque them to transmission downshift and manual
in clean automatic transmission fluid specification. control levers.
and insert the filler tube in the trans- 10. Secure the converter drain plug 16. Connect the parking brake
mission case. access cover to the lower end of the cables to the equalizer bracket.
6. Connect the two oil cooler lines converter housing with the attaching 17. Connect the vacuum hose to
to the transmission case. bolts. the vacuum diaphragm unit.
7. Position the crossmember to the 11. Install the starter and torque 18. Connect the exhaust inlet pipes
frame side supports and install and the attaching bolts to specification. to the manifolds.
tighten the attaching bolts and nuts to Connect the starter cables. 19. Lower the vehicle. Fill the
specification. 12. Install and tighten the filler transmission to the proper level with
8. Remove the transmission jack tube to cylinder head bolt. the specified fluid. Adjust the manual
from under the vehicle. Install and 13. Install the drive shaft. and downshift linkage.

II MAJOR REPAIR OPERATIONS

DISASSEMBLY OF
TRANSMISSION

I. Before removing any of the

transmission ~sub-assemblies, thor-
oughly clean the outside of the trans-
mission case to prevent dirt from get-
ting inside the mechanism.
2. After the transmission has been
removed from the vehicle, place the
assembly in the transmission holder
shown in Fig. 40.
3. Remove the transmission pan,
gasket, and filter retainer clip.
4. Lift the filter from the case.
5. Remove the spring scat from the
pressure regulator. Maintain constant FIG.40 -Transmission Mounted in Holding Fixture
pressure on the seal to prevent distor-
tion of the spring seat and the sudden
release of the springs. Remove the case . support for the shaft.
pressure regulator springs and pilots, 10. Remove the regulator from the 3. Pry the front clutch cylinder to
but do not remove the valves. case. Keep the control pressure valve the rear of the transmission with a
6. Remove the small compensator and the converter pressure regulator large screwdriver. Set the dial indica-
pressure tube from the pressure regu- valve in the pressure regulator to tor at zero while maintaining a slight
lator and the control valve body. avoid damage to the valves. pressure on the screwdriver.
Remove the main pressure oil II. Remove the front servo apply 4. Remove the screwdriver and pry
tube by gently prying up the end that and release tubes by twisting and pull- the units toward the front of the
connects to the main control valve as- ing at the same time. Remove the transmission by inserting the screw-
sembly first. Then, remove the other front servo attaching bolts. Hold the driver between the large internal gear
end of the tube from the pressure re- front servo strut with the fingers, and
gulator. Be sure to remove the tube in and the transmission case.
lift the servo from the case. 5. Record the indicator reading for
this manner. Failure to do so, could
12. Remove the rear servo attach- use during transmission assembly. End
kink or bend the tube causing exces-
ing bolts. Hold the actuating and an- play should be 0.010-0.029 inch (mini-
sive transmission internal leakage.
chor struts with the fingers, and lift mum end play is preferred). If end
7. Loosen the front and rear servo
the servo from the case. play is not within specifications a new
band adjusting screws five turns.
Loosen the front servo attaching bolts TRANSMISSION END selective thrust washer must be used
three turns. PLAY CHECK when the transmission is assembled.
8. Remove the vacuum diaphragm 6. Remove the indicator support,
I. Remove one of the front pump and, then remove the seal replacer
unit and push rod. attaching bolts. Mount the dial indica-
9. Remove the control valve body from the output shaft.
tor support tool 77067 in the front
attaching bolts. Align the levers to pump bolt hole. Mount a dial indica- REMOVAL OF CASE AND
permit removal of the valve body. tor on the support so that the contact EXTENSION HOUSING
Then lift the valve body clear of the rests on the end of the turbine shaft. PARTS
transmission case . Pull the body off 2. Install the extension housing seal I. Remove the rematntng front
the servo tubes and remove it from the replacer on the output shaft to provide pump attaching bolts. Then remove
7-ll 0 GROUP 7- AUTOMATIC TRANSMISSION

FRONT BAND 01957-A

FIG. 43- Removing or Installing

Input Shaft and Clutch
faced hammer, tap the governor as-
OUTPUT SHAFT
D 1819-A sembly off the output shaft. Remove
the governor drive ball (Fig. 42).
6. Remove the rear support and FIG. 44 -Input Shaft and Clutch
FIG. 41 - Rear Support and gasket from the output shaft. Remove in Holding Fixture
Output Shaft Installed the needle bearings and race from the
the bench fixture (fig. 44).
rear support (Fig. 42).
the front pump and gasket. If neces- 14. Remove the thrust washer from
sary, tap the screw bosses with a soft- 7. Remove the selective thrust the front of the input shaft.
washer from the rear of the pinion 15. To remove the front band, posi-
faced hammer to loosen the pump
carrier.
from the case. tion the band ends between the case
8. Remove the pinion carrier. webbing and tilt the bottom of the
2. Remove the lubrication tube
9. Remove the primary sun gear band rearward. Then, squeeze the
from the case. Remove the five trans-
rear thrust bearing and races from the ends of the band together and remove
mission to extension housing bolts. pinion carrier.
These bolts also attach the rear sup- from the rear of the case.
10. Note the rear band position for
port to the case. Remove the exten- 16. Lift the front clutch assembly
reference in assembly. The end of the
sion housing. from the primary sun gear shaft.
band next to the adjusting screw has a
3. Remove the output shaft assem- 17. Remove the bronze and the
depression (dimple) in the center of
bly (Fig. 41). To facilitate output steel thrust washers from the rear
the boss. Squeeze the ends of the rear
shaft removal, insert a screwdriver be- clutch assembly. Wire the thrust
band together, tilt the band to the
tween the output shaft ring gear and washers together to assure correct in-
rear. and remove the rear band from
pinion carrier and pry the output shaft stallation.
the case.
rearward. Be careful not to bend t,he 18. Remove the front clutch seal
II. Remove the two center support
pressure tubes between the rear sup- rings from the primary sun gear shaft.
outer bolts (one each side) from the
port or distributor sleeve and case as 19. Lift the rear clutch assembly
transmission case .
the tubes are removed from the case. from the primary sun gear shaft.
12. Exert enoug'h pressure on the
4. Remove the four seal rings from 20. Remove the rear clutch seal
end of the input shaft to hold the rings from the primary sun gear shaft.
the output shaft with the fingers to clutch units together. Then remove the
prevent breaking the rings. Do not break the seal rings.
center support and the front and rear 21. Remove the primary sun gear
5. Remove the governor snap ring clutch assemblies as a unit (Fig. 43). front thrust washer.
from the output shaft. Using a soft IJ. Install the clutch assemblies in
SNAP
RING
PARTS REPAIR AND
REPLACEMENT

SEAL RINGS
OUTPUT
SHAFT 6 During the repair of the sub-
assemblies, certain general instructions
which apply to all units of the trans-
mission must be followed. These in-
structions are given here to avoid un-
necessary repetition.
Handle all transmission parts care-
fully to avoid nicking or burring the
bearing or mating surfaces.
GOVERNOR Lubricate all internal parts of the
transmission with transmission fluid
GOVERNOR NEEDL ROLLER before assembly. Do not use any other
D~!IVE BALL B6ARING lubricants except on gaskets and
D 1820-A thrust washers which may be coated
with vaseline to facilitate assembly.
FIG. 42- Output Shaft Disassembled Always install new gaskets when as-
PART 7-3- F. M.X. AUTOMATIC TRANSMISSION 7- 111

_'lliifl,_ CLUTCH
PISTON

CLUTCH

02038- A

FIG. 48 -Installing Rear Clutch

Piston
3. Replace the teflon seals with cast
INSTALLATION D 1751. A iron seal rings, and check for free
movement in the groove .
FIG. 45- Replacing Rear Brake Drum Support Bushing
REAR CLUTCH
sembling parts of the transmission. chisel and cut along the bushing seam
Tighten all bolts and screws to the until the chisel breaks through the
I. Remove the clutch pressure plate
recommended torque. For detail bushing wall. Pry the loose ends of
snap ring, and remove the pressure
cleaning and inspection operations the bushing up with an awl and re-
plate from the drum . Remove the
refer to Section 3. move the bushing .
waved cushion spring . Remove the
2. Insert a new bushing into the in-
REAR BRAKE DRUM composition and steel plates.
stallation tool and position the tool
SUPPORT BUSHING 2. Compress the spring with the
and bushing over the output shaft hub .
REPLACEMENT tools shown in Fig . 47 and remove the
Then, press the bushing on the output
snap ring .
shaft hub as shown in Fig. 46.
t. If the rear brake drum support 3. Guide the spring retainer while
PRIMARY SUN GEAR SHAFT releasing the pressure to prevent the
bushing is to be replaced, press the
bushing from the support as shown in retainer from locking in the snap ring
I. Position the primary sun gear grooves.
Fig. 45.
shaft in the clutch bench fixture . 4. Position the primary sun gear
2. Press a new bushing into the
2. Check the fit of the seal rings in shaft in the rear clutch. Place an air
brake drum support with the tool
their respective bores. If equipped hose nozzle in one of the holes in the
shown in Fig. 45.
with cast iron seal rings, a clearance shaft, and place one finger over the
of 0.002-0.009 inch should exist be- other hole . Then force the clutch pis-
OUTPUT SHAFT BUSHING tween the ends of the rings. ton out of the clutch drum with air
REPLACEMENT If equipped with teflon seals that pressure . Hold one hand over the pis-
are worn or damaged, cut the seals ton to prevent damage.
t. Remove the output shaft bushing from the shaft with a sharp knife . He 5. Remove the inner and outer seal
if it is worn or damaged. Use the cape careful not to score the ring grooves. rings from the clutch piston .

Press Rom Tool- T64L.7003.A7

Tool- T 65 l· 77515 ·A

REAR CLUTCH D 1592-A

DRUM
FIG. 46 -Installing Output Shaft
Bushing FIG. 47- Removing Rear Clutch Spring Snap Ring
7-112 GROUP 7- AUTOMATIC TRANSMISSION
against the shoulder in the cylinder;
then push the piston down, out of the
tool, until it bottoms in the cylinder.
Remove the tools.
13. Install the clutch release spring,
and position the retainer on the
spring.
14. Install the tool on the spring re-
tainer as shown in Fig. 47. Compress
the clutch spring, and install the snap
ring. While compressing the spring,
guide the retainer to avoid interference
of the retainer with the snap ring
groove. Make sure the snap ring is
fully seated in the groove. When new
0 1746- A composition clutch plates are used,
soak the plates in automatic transmis-
FIG. 49- Removing Rear Clutch sion fluid for 15 minutes before they D 2049·A
Sun Gear Bushing are assembled.
6. Remove the rear clutch sun gear 15. Install a steel clutch plate and FIG. 51 - Removing or Installing
bushing if it is worn or damaged . Use the waved cushion spring. Then, in- Front Clutch Snap Ring
the cape chisel (Fig. 49) and cut along stall steel and friction plates alternate-
the bushing seam until the chisel ly starting with a steel plate. 3. Remove the composition and the
breaks through the bushing wall. Pry 16. Install the clutch pressure plate steel clutch plates, and then remove
the loose ends of the bushing up with the pressure plate from the clutch
with the bearing surface down. Then
an awl and remove the bushing. drum.
install the clutch pressure plate snap
7. Press a new .bushing into the rear ring. Make sure the snap ring is fully 4. Place the front clutch spring
clutch sun gear with the tool shown in seated in the groove. compressor on the release spring, po-
Fig . 50. sition the clutch drum on the bed of
17. Check the free pack clearance
8. Install new inner and outer seal between the pressure plate and the an arbor press, and compress the re-
rings on the piston . snap ring with a feeler gauge . The lease spring with the arbor press until
9. To install the piston in the clutch clearance should be 0.030-0.055 inch. the release spring snap ring can be re-
drum, lubricate the piston seals and moved (Fig. 51).
If the clearance is not within specifi-
tools (Fig . 48) with clean transmission cations, selective snap rings are avail- 5. Remove the clutch release spring
fluid . able in the following thicknesses : from the clutch drum.
10. Push the small fixture down 0.060-0.064, 0 .074-0.078, 0 .088-0.092 6. Install the special nozzle shown
over the cylinder hub . and 0. 102-0.106 inch . Insert the cor- in Fig . 52 on an air hose. Place the
11. Insert the piston into the large rect size snap ring and recheck the nozzle against the clutch apply hole in
fixture with the seal toward the thin- clearance. the front clutch housing, and force the
walled end. 18. Install the thrust washer on the piston out of the housing.
12. Hold the piston and large primary sun gear shaft. Lubricate all 7. Remove the piston inner seal
fixture and insert as a unit into the parts with automatic transmission from the clutch housing. Remove the
cylinder. Push down over the small fluid or petroleum jelly. Install the piston outer seal from the groove in
fixture until the large tool stops two center seal rings. the piston.
19. Install the rear clutch on the 8. Remove the input shaft bushing
Tool- T64L-7003-A3 OR Tool- T64L-7003-A4 primary sun gear shaft. Be sure all of if it is worn or da maged . Use the cape
the needles are in the hub if the unit is
equipped with loose needle bearings.
Assemble two seal rings in the front
grooves.
20. Install the steel and the bronze
thrust washers on the front of the sec-
ondary sun gear assembly. If the steel
washer is chamfered, place the cham-
fered side down.

FRONT CLUTCH

1. Remove the clutch cover snap

ring with a screwdriver, and remove
the input shaft from the clutch drum .
2. Remove the thrust washer from
the thrust surface of the clutch hub. 01959 -A
Insert one finger in the clutch hub,
FIG. 50 -Installing Rear Clutch and lift the hub straight up to remove FIG. 52 - Removing Front Clutch
Sun Gear Bushing the hub from the clutch drum. Piston
PART 7-3- F. M.X. AUTOMATIC TRANSMISSION 7-113

install the snap ring as shown in Fig.

51. Make sure the snap ring is fully
seated in the groove.
13. Install the front clutch housing
on the primary sun gear shaft by ro-
tating the clutch units to mesh the
rear clutch plates with the serrations
on the clutch hub. Do not break the
seal rings.
14. Install the clutch hub in the
clutch cylinder with the deep counter-
bar down (Fig. 54). Install the thrust
washer on the clutch hub.
15. Install the pressure plate in the
clutch cylinder with the bearing sur-
face up (Fig . 55). Install the composi-
tion and the steel clutch plates alter-
nately, starting with a composition
D 1752. A plate (Fig. 56). Lubricate the plates as
they are installed.
FIG. 53 -Installing Input Shaft FIG. 55 -Installing Pressure Plate
Bushing The final friction plate to be in-
stalled is selective. Install the thickest
chisel and cut along the bushing seam plate that will be a minimum of 0.010
until the chisel breaks through the inch below input shaft shoulder in cyl-
bushing wall. Pry the loose ends of inder. For all other plates, use the
the bushing up with an' awl and re- thinnest available. Refer to the Speci-
move the bushing. fications Section for available plate
9. Slip a new bushing over the end thickness.
of the installation tool and position 16. Install the turbine shaft in the
the tool and bushing to the bushing clutch cylinder, and then install the
hole . Then, press the bushing into the snap ring. Make sure the snap ring is
input shaft as shown in Fig. 53. fully seated in the groo1·e.
10. Lubricate all parts with trans- 17. Install the thrust washer on the
mission fluid . Install a new piston turbine shaft.
inner seal ring in the clutch cylinder. FIG. 56 -Installing Clutch Plates
Install a new piston outer seal in the FRONT PUMP
groove in the piston .
II. I.nstall the piston in the clutch I. Remove the stator support at-
housing. Make sure the steel bearing taching screws and remove the stator
ring is in place on the piston. support. Mark the top surface of the
12. Position the release spring in pump driven gear with Prussian blue
the clutch cylinder with the concave to assure correct assembly. Do not
side up. Place the release spring com- scratch the pump gears.
D 1047-B
pressor on the spring, and compress 2. Remove the drive and driven
the spring with an arbor press. Then FIG. 57- Front Pump Disassembled gears from the pump body.

REMOVAL INSTALLATION 0 1748- A

FIG. 54 -Installing Clutch Hub FIG. 58- Replacing Front Pump Housing Bushing
7-114 GROUP 7-AUTOMA TIC TRANSMISSION

3. Refer to Fig. 57 for a disas- seal from the pump body . 2. Remove the rear support bushing
sembled view of the front pump. In- 9. Clean the pump body counter- if it is worn or damaged. Use a cape
spect the pump body housing, gear bore. Then inspect the bore for rough chisel and cut along the bushing seam
pockets and crescent for scores. spots. Smooth up the counterbore until the chisel breah through the
4. If the pump housing bushing is with crocus cloth. bushing wall. Pry the loose ends of
to be replaced, press the bushing from 10. Remove the pump body from the bushing up with an awl and re-
the front housing with the tools shown the transmission case. move tlie bushing.
in Fig. 58. 11. Coat the outer diameter of a 3. Press a new bushing into the
5. Press a new bushing into the new seal with FoM oCo Sealing Com- support housing with the tool shown
pump housing with the handle and pound, or its equivalent. Then position in Fig . 62.
tool shown in Fig. 58. the seal in the pump body. Drive the 4. Install the pressure tubes.
6. If any parts other than the stator seal into the pump body with the tool PRESSURE REGULATOR
support or bushings are found defec- shown in Fig. 60 until the seal is firm- I. Remove the valves from the re-
tive, replace the pump as a unit. ly seated in the body. Toel 77837 may gulator body .
Minor burrs and scores may be re- be reworked (fig_ 61) to install the 2. Remove the regulator body cover
moved with crocus cloth . The stator latest type seal. - attachin~ screws, and remove the
support is serviced separately. 12. Place the pump driven gear in cover (Fig. 63).
7. Bolt the front pump to the trans- the pump body with the mark on the 3. Remove the separator plate .
mission case with capscrews. gear facing down . Install the drive 4. Wash all parts thoroughly in
8. Install the oii seal remover gear in the pump body with the cham- clean solvent and blow dry with
shown in Fig . 59. Then pull the front fered side of the flats facing down . moisture-free compressed air.
1ooi- 1501-!00-A 13. Install the stator support and 5. Inspect the regulator body and
attaching screws. Check the pump cover mating surfaces for burrs.
gears for free rotation . 6. Check all fluid passages for ob-
REAR SUPPORT BUSHING structions.
REPLACEMENT 7. Inspect the control pressure and
converter pressure valves and bores for
I. Remove the three pressure tubes burrs and scores. Remove all burrs
from the support housing. carefully with crocus cloth.
FIG. 59- Removing Front Pump To ol - T64L-7003-A2 Hondic 8. Check the free movement of the

~
Seal valve in their bores. Each valve should
fall freely into its bore when both the
valve and bore are dry .
9. Inspect the valve springs for dis-
tortion .
10. Position the separator plate on
the regul a tor cover.
11. Position the regulator cover and
separator plate on the regulator body,
and install the attaching screws. Tor-
que the screws to specification.
12. Insert the valves in the pressure
regulator body (Fig. 63).
CONTROL VALVE BODY
During the disassembly of the con-
trol valve assembly, avoid damage to
D2050-A valve parts and keep the valve parts
clean . Place the valve assembly on a
liii~=:iiiiiir'~01963-A FIG. 62 -Installing Rear Support
Housing Bushing
clean shop towel while performing the
disassembly operation. Do not sepa-
FIG. 60 -Installing Front Pump
Seal

01964-A
FIG. 61 - Front Pump Seal
lnstallin9 Tool Modification FIG. 63 -Pressure Regulator Disassembled
PART 7-l· F. M . X. AUTOMATIC TRANSMISSION 7-115

SIDE
PLATE

2·3 SHIFT
DELAY VAL VE

2·3 DELAY AND THROTTLE \

REDUCING VALVE SLEEVE

~ (:?

--
END .
PLATE

/
----- "'
I1 ~~~~~ - -'
'\\
\ THROTTLE
REDUCING
VALVE
~~ /r/CDMPENSATDR ::E......_........_

Qj
AND PLUG

_/DDWNSHIFTVALVE
........
........
'-....... )
\

0 ~ ........ /
0-.~
~ ~ MANUAL
/VALVE
........ - __..
THROTTLE BOOST ~ ~'-

-'".
SHORT VALVE - ~ ' ' '\.
AND SLEEVE ~ '!? 1
' ~> SPRING RETAINER
\ . \ - 2·1 SCHEDULING
-cw VALVE

THROTTLE BOOST
VALVE ~
\..-..., ~·•
~ ~
/

~ -..--UPPER BODY
COMPENSATOR ~~~~
1
VALVE \.·•.,:Jj?'~ COMPENSATOR
- - - C U T-BACK VALVE
~ '
/ ·

,.- - - P L U G

THROTTLE -------<~
VALVE . ~

FIG. 64- Control Valve Disassembled

7-116 GROUP 7- AUTOMATIC TRANSMISSION

rate the upper and lower valve bodies

and co~er until after the ~alves ha~e
been re mo~ed.
Disassembly
1. Remove the manual valve (Fig.
64).
2. Remove the throttle valve body
and the separator plate. Be careful not
to lose the check valve when removing
the separator plate from the valve
body. Remove the throttle valve and
plug.
3. Remove one screw attaching the
separator plate to the lower valve
body. Remove the upper body front
plate . The plate is spring-loaded.
Apply pressure to the plate while re-
moving the attaching screws.
4. Remove the compensator sleeve
and plug, and remove the compensa-
tor valve springs. Remove the com-
P.ensator valve.
' 5. Remove the throttle boost short
valve and sleeve. Remove the throttle
boost valve spring and valve.
6. Remove the downshift valve and
spring. Remove the 2-1 scheduling CHECK VA L VE
valve retainer from the valve body and
D 2051·A
remove the spring and valve.
7. Remove the upper valve body FIG. 65- Check Valve Locations
rear pia te.
8. Remove the compensator cut
back valve. 18. Remove the through bolts and plate.
9. Remove the lower body side screws. Then, separate the bodies. Re- 7. Insert the 1-2 shift accumulator
plate (Fig. 64). The plate is spring- move the separator plates from the lockout valve, 1-J shift accumulator
loaded. Apply pressure to the plate valve bodies and cover. Be careful not valve, and spring in the cover. Install
while removing the attaching screws. to lose the check valves. the valve spring retainer.
10. Remove the 1-2 shift valve and 8. Install the transition valve and
spring. Remove the inhibitor valve and Assembly spring in the lower body.
spring. 9. Install the 2-3 shift valve and
11. Remove the two screws attach- l. Arrange all parts in their correct spring. Install the 2-3 shift delay valve
ing the separator plate to the cover. positions (Fig. 64). Rotate the valves and the spring and throttle reducing
Remove the lower body end plate. The and plugs when inserting them in their valve in the sleeve . Slidt the sleeve
end plate is spring-loaded. Apply pres- bores to avoid shea ring of soft body and valve into position in the lower
sure to the plate while removing the castings . body.
attaching screws. 2. Place the check valve in the 10. Install the low servo lockout
12. Remove the low servo lockout upper body as shown in Fig. 65. Then, valve spring. Install the low servo
valve, low servo modulator valve and position the separator plate on the modulator and low servo lockout
spring. body. valves. Install the lower body end
13. Remove the 2-3 delay and 3. Position the lower body · on the plate.
throttle reducing valve sleeve, the upper body, and start but do not 11. Install the inhibitor valve spring
throttle reducing valve, spring, and the tighten the attaching screws. and valve in the lower body .
2-3 shift delay valve. Remove the 2-3 4. Place the check valve in the 12. Install the 1-2 shift valve spring
shift valve spring and valve. cover (Fig. 65) and position the cover and valve. Install the lower body side
14. Remove the transition valve and separator plate on the lower body. plate.
spring and valve. Start the four through bolts. 13. Install the compensator cutback
15. Remove the plate (Fig. 64) 5. Align the separator with the valve in the upper body. Install the
from the valve body cover. upper and lower valve body attaching upper body rear plate.
16. Remove the check ball spring bolt holes. Install and torque the four 14. Install the 2-1 scheduling valve,
and check ball. Remove the 3-2 kick- valve body bolts to specification. Ex- spring, and spring retainer in the
down control valve spring and valve. cessive tightening of these bolts may body. Install the downshift valve
17. Remove the 1-2 shift accumula- distort the valve bodies, causing ~alves spring and valve.
tor valve spring retainer from the or plugs to stick. 15. Install the throttle boost valve
cover. Remove the spring, 1-2 shift ac- 6. Install the 3-2 kickdown control and spring. Install the throttle boost
cumulator valve and 1-2 shift accumu- valve and spring and the check ball short valve and sleeve.
lator lockout valve . and spring in the cover. Install the 16. Install the compensator valve,
PART 7-~ F. M.X. AUTOMATIC TRANSMISSION 7-117

inner and outer compensator springs, 4. Install the governor valve and 7. Inspect the servo band lining for
and the compensator sleeve and plug. spring assembly in the bore of the excessive wear and bonding to the
17. Position the front plate. Apply valve body. Install the sleeve, and metal. The band should be replaced if
pressure to the plate while installing plug. worn to a point where the grooves are
the two attaching screws. 5. Install the body on the counter- not clearly evident.
1~. Install the throttle valve, plug weight. Make sure the fluid passages 8. Inspect the band ends for cracks
and check valve in the throttle valve in the body and ·the counterweight are and check the band for distortion.
body. Position the separator on the aligned. 9. Lubricate all parts of the front
upper body and install the throttle 6. Position the valve body cover on servo with transmission fluid to facili-
valve body. Install the three attaching the body, and install the screws. tate assembly.
screws. 10. Install the 0-ring on the piston
19. Install four screws attaching the FRONT SERVO retainer. Install new 0-rings on the
cover to the lower body, two screws 1. Remove the servo piston retain- servo piston.
attaching the separator plate to the er snap ring (Fig. 67). The servo
upper body, and one screw attaching 11. Position the servo piston re-
piston is spring-loaded. Apply pres- lease spring in the servo body. Install
the separator plate to lower body. sure to the piston when removing
Torque the cover and body screws to the servo piston and retainer in the
the snap ring. servo body as an assembly. Compress
specitica tion.
20. Install the manual valve. 2. Remove the servo piston retain- the assembly into the body, and
er and servo piston from the servo secure it with the snap ring. Make
GOVERNOR body. It may be necessary to tap the sure the snap ring is fully seated
piston stem lightly with a soft-faced in the groove.
I. Remove the governor valve body hammer to separate the piston 12. Install the adjusting screw and
retainer from the servo body. locknut in the actuating lever if they
3. Remove all the seal rings, and were previously removed.
remove the spring from the servo
body. REAR SERVO

4. Inspect the servo body for I. Remove the servo actuating lever
cracks and the piston bore and the shaft retaining pin with a I /8-inch
servo piston stem for scores (Fig. 67). punch . Remove the shaft and actuat-
Check fluid passages for obstruc- ing lever needle bearings and thrust
VALVE BODY tions. washers.
5. Check the actuating lever for 2. Press down on the servo spring
free movement, and inspect it for retainer, and remove the snap ring.
wear. If it is necessary to replace the Release the pressure on the retainer
actuating lever shaft. remove the re- slowly to prevent the spring from
~VALVE
taining pin and push the shaft out of flying out.
the bracket. If the shaft is not re- 3. Remove the retainer and servo
RETAINING
----'~CLIP tained by a pin, it is retained in the
body by serrations on one end of the
spring (Fig. 68).
4. Force the piston out of the servo

"''"' '"'"' ____.\\~

shaft. These serrations cause a press body with air pressure. Hold one hand
fit at that end . To remove the shaft, over the piston to prevent damage .
press on the end opposite the serra- 5. Remove the accumulator piston
tions. from the servo piston.
PLUG___., Inspect the adjusting screw threads
D1966·A 6. Remove the piston seal ring.
and the threads in the lever. 7. Install a new seal ring on the
6. Check the servo spring and servo servo piston .
FIG. 66 -Governor Disassembled band strut for distortion. 8. Install the accumulator piston in
the servo piston .
9. Install the piston in the servo
body. Lubricate the parts to facilitate
lOCK WASHER BODY
assembly. Install the servo spring with
the small coiled end against the servo
piston.
ADJUSTING SCREW
10. Install the spring retainer.
Compress the spring with a C-clamp.
Then install the snap ring. The snap
ring must be fully seated in the
groove.
II. Install the needle bearings in
PIN _ _ the actuating lever. Install the actuat-

I!ETURN PISTON
SHAFT- 0 D114S·C
ing lever and thrust washers with the
socket in the lever bearing on the pis-
ton stem. Install the actuating lever
shaft, aligning the retaining pin holes,
FIG. 67- Front Servo- Disassembled and install the pin.
7-118 GROUP 7-AUTOMATIC TRANSMISSION
SERVO stall the assembly in the transmission
BODY
SHAFT PIN case by installing the pawl pin and the
toggle lever pin . Install the torsion
lever assembly. Position the spring on
the torsion lever with a screwdriver.
Make certain that the short side of
toggle does not extend beyond the
largest diameter of the ball or the tog-
gle lever pin (Fig. 69). Tap the toggle
lever in or out as necessary to center
CHECK VALVE the toggle lever on the ball.
SPRING
4. Install the manual lever and
ACCUMULATOR SERVO shaft in the transmission case. Posi-
PISTON PISTON tion the detent lever on the shaft, and
SPRING RETAINER secure it with a nut. Tighten the nut
SNAP RING to 20-30 ft-lbs torque . Rotate the
D 1821 - A manual lever to the rear of the case.
FIG. 68- Re•r Servo- Dis•uembled Position the detent spring in the case.
Hold the detent plug on the spring
12. Check the actuating lever for with the pawl link pin, washer, and with a 3f 16-inch socket wrench, then
free movement . pawl return spring. Assemble the tog- depress the spring until the plug is
gle lever to the link with the toggle flush with the case. Carefully rotate
TRANSMISSION CASE link pin. Position the pawl return the manual lever to the front of the
LINKAGE REPAIR spring over the toggle link pin, and se- case to secure the pl11g. A piece of
cure it in place with the washer and thin walled tubing may be used to
Disassembly the small retainer clip (Fig. 69). In- depress the plug if a small socket
I. Remove the inner downshift lever
shaft nut (Fig. 69). Then remove the
inner downshift lever.
2. Remove the outer downshift
lever and shaft. Remove the downshift
MANUAL SHAFT
AND LEVER

DOWNSHIFT
DETENT SPRINGYETENT PLUNGER

,/:t::·
'-'
/
DETEN'r
LEVER II
MANUAL SHAFT NUT
INNER DOWNSHIFT LEVER
DOWNSHIFT
shaft seal from the counterbore in the b, , SHAFT SEAL....,_ i(~ 1.., .. TORSION )I'SHAFT NUT TOGGLE LIFT
manual lever shaft. - "' (, ff:'• LEVE~.-=-,~4C
, , . , , PIN ,
I lf(t'JJC a,/'
LEVER SPRING
3. Remove the cotter pin from the

-
' . V .I r ~
parking pawl toggle operating rod and ·~,. · ~ __ ' ,.TORSION LEVER~@~ PAWL
remove the clip from the parking pawl
operating lever. Remove the parking DO~~~HI~~~AFT s::~u~L ~<~~''" --~~~~~~
1 LIN;A:
pawl operating rod . . "- - ~~LINK PIN PIN
4. Rotate the manual shaft until the Lif~~~~~R ~ ~ ~
detent lever clears the detent plunger. TOGGLE LEVER~ - ~~ ~ ~
Then remove the detent plunger and PAWL RETURN SPRING~~~ (i
spring. Do not allow the detent plung- TOGGLE LEVER PIN~"'''J? \LINK PAWL
er to fly out of the case. PLUG~ RETAINER
5. Remove the manual lever shaft
nut, and remove the detent lever. Re- 01967-A

move the outer manual lever and shaft FIG. 69- Transmission Case Control Linkage
from the transmission case.
6. Tap the toggle lever sharply
toward the rear of the case to remove
the plug and pin.
7. Remove the pawl pin by working
the pawl back and forth . Remove the
pawl and toggle lever assembly, and
then disassemble .
8. Remove the manual shaft seal
and case vent tube . Remove the oil
cooler return check valve from the
back of the case .

Aaembly
I. Coat the outer diameter of a new
manual shaft seal with sealer, then in-
stall the seal in the case witli a driver.
2. Install the vent tube in the trans- REMOVAL INSTALLATION D 1745-8
mission case.
3. Assembly the link to the pawl FIG. 70- Replacing Transmission Case Bushing
PART 7-3- F. M.X. AUTOMATIC TRANSMISSION 7-119

wrench is not available. Installation -Center Support 6. While applying forward pressure
5. Position the ends of the ·parking With Chamfered Edge on the planet carrier, rotate it counte-
pawl operating rod in the detent lever rclockwise, as viewed from the rear
and toggle lift lever, and secure with I. Install the center support and the (Fig. 72). This will cause the clutch
the two small retaining pins. rear band in the case. rollers to roll toward the large open-
6. Install a new seal on the down- 2. Install the primary sun gear rear ing end of the cams in the race, com-
sh ift lever shaft, then install the lever thrust bearing race, needle bearing, pressing the spring slightly, so that the
and shaft in the case . Position the and front thrust bearing race if used rollers will ride up the chamfer on the
inner downshift lever on the inner end in the planet carrier using petroleum planetary support a nd onto the inner
of the shaft with the mark 0 facing jelly to retain them in place. race .
toward the center of the case. Install 3. Lubricate the bearing surface on 7. Push the planet carrier all the
the lock washer and nut, then tighten the center support, the rollers of the way forward .
the nut to 17-20 ft-lbs torque . planetary clutch, and the cam race in 8. Check the operation of the plan-
7. Check the operation of the link- the carrier with petroleum jelly (Fig . etary clutch by rotating the carrier co-
age. The linkage should operate freely 71). unterclockwise. It should rotate count-
without binding. 4. Install the planetary clutch in the erclockwise (viewed from the rear)
carrier (Fig. 72). with a slight drag, and it should lock
5. Carefully position the planet car- up when attempting to rotate it in a
TRANSMISSION CASE
rier on the center support. Move the clockwise dir::ction.
BUSHING REPLACEMENT
carrier forward until the clutch rollers 9. Install the selective thrust washer
are felt to contact the bearing surface on the pinion carrier rear pilot. If the
I. If the transmission case bushing
of the center support. end play was not within specifications
is to be replaced, press the bushing
out of the case with the tools shown in CENTER SUPPORT " CAM TYPE "" CLUTCH RACE
Fig. 70.
2. Install a new transmission case
bushing with the tool shown in Fig.
70.

ASSEMBLY OF TRANSMISSION
Do not use force to assemble mat-
ing parts. If the parts do not assemble
freely, examine them for the cause of
the difficulty. Always use new gaskets
CHAMFER ON PRODUCTION
and seals during the assembly opera- PART, ONLY-SERVICE PART NOT CHAMFERED PLANET CARRIER
tions.
01938-A
CLUTCH ASSEMBLIES
FIG. 71 -Planetary Clutch, Planet Carrier and Center Support
I. Install the front band in the
transmission case so that the anchor
end is aligned with the anchor in the
case .
2. Make sure the thrust washer is
in place on the input shaft. Lift the
clutch assemblies out of the holding
block . Do not allow the clutches to
separate.
3. Install the clutch sub-assemblies
in the transmission case while posi-
tioning the servo band on the drum.
Hold the units together while install-
ing them (Fig. 43).

CENTER SUPPORT,
ONE-WAY CLUTCH,
PINION CARRIER, AND
OUTPUT SHAFT

The production center supports are

chamfered at the edge of the race
(Fig. 71). The service center supports D 1292-C
are not chamfered . The following as- FIG. 72 -Planetary Clutch Installation in Carrier- Chamfered
sembly procedures cover both types of
center supports. Center Support
7-120 GROUP 7-AUTOMATIC TRANSMISSION
when checked prior to disassembly,
replace the washer with one of proper CENTER
thickness. Refer to the Specification
Section of Group 7 for selective thrust
washer thickness.
10. Install the output shaft, careful-
ly meshing the internal gear with the
pinions.
Installation-Center Support
not Chamfered

I. Install the center support and the

rear band in the case.
2. Install the primary sun gear, rear
thrust bearing race, needle bearing
and front thrust bearing race if used
in the planet carrier using petroleum
jelly to retain them in place.
3. Lubricate the bearing surface of
MOVE
the center support, the rollers of the TOWARD CENTER
planetary clutch, and the cam race in
the carrier with vaseline .
4. Install the planetary clutch on
the center support with the saw teeth D 1291·0

of the clutch cage pointing in the

FIG. 73- Planetary Clutch Installation in Carrier- Center Support
clockwise direction as viewed from the
rear (Fig. 73). Make sure that all roll- Not Chamfered
ers are in the cage. attempting to rotate it in a clockwise tain the gasket with transmission
S. Position the planet carrier on the direction . fluid.
support so that the cams in the carrier II. Install the selective thrust wash- 3. Install the rear support. As the
engage the saw teeth on the clutch er on the pinion carrier rear pilot. If support is installed, insert the tubes
cage. the end play was not within specifica- into the case.
6. Push the planet carrier forward tions when checked prior to disassem-
GOVERNOR
until the rollers are felt to contact the bly, replace the washer with one of
surface of the cam race. proper thickness. Refer to the Specifi- I. Position the governor drive ball
7. While applying forward pressure cation Section of Group 7 for selective in the pocket in the output shaft. Re-
on the carrier, rotate it counterclock- thrust washer thick ness. tain the ball with transmission fluid.
wise as viewed from the rear. This will 12. Install the output shaft, cardul- 2. Install the governor assembly, al-
cause the rollers to roll toward the ly meshing the internal gear with the igning the groove with the ball in the
large opening end of the cams in the pinions. output shaft.
race, compressing the springs slightly, 3. Install the governor with the gov-
so that the rollers will enter the cams. REAR SUPPORT ernor body plate toward the front of
8. Some rollers may become the vehicle (Fig. 41). Install the gover-
cocked preventing their entry into the I. Position the needle bearing and nor snap rin~~:.
outer race. These rollers must be posi- retainer on the rear support (Fig. 42). EXTENSION HOUSING
tioned individually with a small screw- 2. Position a new rear support to
driver by. pushing the rear of the roll- case gasket on the rear support. Re- I. Insert the extension housing oil
ers toward the transmission and into
DETENT PAWL
the cam race (Fig. 73). Keep pressure
-fiiii!I~~A.;D
::_J:USTMENT SCREW
applied to the carrier at all times.
9. After all of the rollers have been
started into the cam race, rotate the
carrier counterclockwise while pushing
it forward. Again, straighten any roll-
ers which still may be in a cocked po-
sition and prevent the carrier from
sliding onto the support.
10. Make sure that all springs are
entered in the cam race before at-
tempting to push the carrier on the
support. Push the carrier all the way
forward and check the operation of
the clutch by rotating it in a counte-
rclockwise direction . The carrier 'I
should rotate counterclockwise with a
slight drag and should lock up when FIG. 7 4 -Selector Lever Detent Pawl Adiustment - Typical
PART 7-J- F. M.X. AUTOMATIC TRANSMISSION 7-121

seal replacer and pilot in the housing. band, strut, and servo into position gulator assembly first. Then, install
Position a new gasket to the extension engaging the anchor end of the band the other end of the tube into the
housing and install the extension with the anchor pin in the case. main control assembly by tapping it
housing on the transmission case. gently with a soft hammer.
3. Locate the servo on the case, and
Coat the bolt threads with 85A- install the attaching bolts. Tighten the 5. Install the small control pressure
19554-A sealer and install the exten- attaching bolts only two or three compensator tube in the valve body
sion housing attaching bolts, breather threads. and regulator.
tube clip, vacuum tube clip, and exter- 6. Turn the manual valve one full
4. Install the servo release tube.
nal tooth lock washer. The lock wash- turn in each manual lever detent posi-
ers must be installed with the rolled tion. If the manual valve binds against
REAR SERVO
edge toward the transmission case to the actuating pin in any detent posi-
Insure a tight seal. tion, loosen the valve body attaching
1. Position the servo anchor strut,
1. Torque the extension housing at· bolts and move the body away from
and rotate the rear band to engage the
taching bolts to specification. the center of the case. Move the body
strut.
3. Install the lubrication tube. only enough to relieve the binding.
1. Position the servo actuating
Torque the attaching bolts and check
lever strut with a finger, and then in-
FRONT PUMP the mapual valve for binding.
stall the servo and attaching bolts.
7. TQ'fque the front servo attaching
Move the rear servo (with reasonable
1. Position a new front pump gask- force) toward the centerline of the bolts to specification.
et in the counterbore of the transmis- transmission case, against the servo FRONT AND REAR
sion case . attaching bolts. While holding the BAND ADJUSTMENTS
1. Install the front pump, aligning servo in this position, torque the at-
the pump bolt holes with the holes in taching bolts to specification. · Adjust the front and rear bands as
the · case. Install three of the front 3. Install the front servo apply detailed in Section 5.
pump attaching bolts and torque them tube.
to specification.
PRESSURE REGULATOR VACUUM DIAPHRAGM UNIT
TRANSMISSION END BOD\'
PLA \'CHECK 1. Position the control rod in the
1. Install the pressure regulator bore of the vacuum diaphragm unit
1. Mount the dial indicator support body and attaching bolts, and torqu~ and install the diaphragm unit. Make
in a front pump bolt hole. Mount a the bolts to specifications. sure the control rod enters the throttle
dial indicator on the support so that 1. Install the control and converter valve as the vacuum unit is installed.
the contact rests on the end of the tur- valve guides and springs. Install the 1. Torque the diaphragm unit to
bine shaft. spring retainer. specification.
1. Use a large screwdriver to pry
the front of the clutch drum toward CONTROL VALVE BOD\' FLUID FILTER
the rear of the transmission. Set the AND OIL PAN
dial indicator at zero. 1. Install the control valve assem-
3. Remove the screwdriver and pry bly, carefully aligning the servo tubes l. Position the fluid filter on the
the units toward the front of the with the control valve. Align the inner rear clip ~o that the tang enters the
transmission by inserting a screwdriv- downshift lever between the stop and hole in the filter flange. Then, rotate
er between the large internal gear and the downshift valve. Shift the manual the filter (clockwise) until the grom-
the transmission case. Note the i'ndi- lever to the I position. Align the man- met is over the pump inlet port of the
cator reading. End play should be ual Yahe with the actuating pin in the valve body regulator and press the fil-
0.010-0.029 inch (minimum end play manual detent le•er. Do not tighten ter down firmly. Install the filter re-
is preferred). the attaching bolts. taining clip.
4. Remove the indicator and the 1. Move the control valve body 1. Place a new gasket on the trans-
tool from the extension housing. toward the center of the case until the mission case artd install the pan . In-
5. Install the one remaining front clearance is less than 0.050 inch be- stall the attaching bolts and lock
pump attaching bolt and torque it to tween the manual valve and the act- washers and torque the bolts to speci-
specification. uating pin on the manual detent lever. fication.
3. Torque the attaching bolts to If the converter and converter hous-
FRONT SERVO specification. Be sure that the rear ing were removed from the transmis-
fluid screen retaining clip is installed sion, install these components. Posi-
1. Position the front band forward under the valve body bolt as shown in tion the transmission assembly on the
in the case with the band ends up. Fig. 35. transmission jack, and refer to Trans-
1. Position the servo strut with the 4. Install the main pressure oil mission Installation Procedures for in-
slott~d end aligned with the servo act- tube. Be sure to install the end of the stalling the transmission.
uating lever, and with the small end tube that connects to the pressure re-
aligned with the band end. Rotate the
7-122

PART SPECIFICATIONS
7-4

MODEL · APPLICATION
COLOUR
FALCON TRANSMISSION MODEL TYPE IDENTIFICATION

200 CID 0546·002 G.T.A. Black

250 CID 0546-001 G.T.A. Green

CLUTCH PLATES
CONVERTOR
REAR CLUTCH FRONT CLUTCH
Mean diameter of fluid circuit 11 in. TRANSMISSION
Maximum torque multiplication 2:1 MODEL STEEL COMPOSITION STEEL COMPOSITION
PLATES PLATES PLATES PLATES
Engine RPM
Stall speed in drive 0546-002 5 5 4 3
200 CID 1800-1900
0546-001 5 5 5 4
250 CID 1850-1950

SHIFT POINTS: 3.23:1 Diff. ratio.

Manual Shift Throttle M.P.H. Manual Shift Throttle M.P.H. 8EAIIIIATIOS -All MOORS
D 1-2 K.D. 31-39 D 1-2 Zero 8-10 FIRST 4.78-2.39:1
D 2-3 K.D 53-61 D 2-3 Zero 10-13 SECOND 2.90- 1.45:1
D 3-2 K.D. 44-54 D 3-1 Zero 4-8
THIRD 2.00-1.00:1
D 3-1 K.D. 19-29 1 2-1 Zero 10-18 REVERSE 4.18-2.09:1
a. No shift to 1st or 3rd in 2.
b. No K.D. to 1st gear above 29 mph.

LINE PRESSURE:

Idle Pressure Stall Pressun ltD. Pressure after CutbiCk

D 58-70 D 200-250 D 90-115
2 58-70 2 200-250 2 90-115
1 58-70
1 200-250 1 90-115
Rev. 58-70
Neutral 58-70 Rev. 200-250

Check pressures with transmission at ambient temperature and at 220•f

PART 7-4- SPECIFICATIONS 7-123

LUBRICANT

Cepecity (including converter) Auto-trMsmission Fluid

To Ford Specificotion M2C33 F
14! Imp. pints
Normol operoting temperoture 100 to 115·c

Torque Figures (All Figures expressed 1n Ft. Lbs. excepted where otherwise stoted).
Tronsmission cose to converter housinQ 17-22
l::xtension housinQ to trMsmission cose 8-10
Tronsmission Oil Pon 8-10
Front servo to tronsmission cose 8- 10
Reor servo to tronsmission cose 10-13
Pump odaptor to pump body (set-screwl 24-36
15/16 in bolt} 17-22
Pump odoptor to tronsmission cose 8- 18.5
Kear adaptor to transmission case li in . boltl 4 -5
.._.entre support to transmission cose 10-13
Outer lever to manuol valv& shaft 10- 15
Pressure point (use sealer! 4-5
bearbox droin pluQ IU-14
Oil tube collector to lower body 20-30 in. lb.
Governor line plate to lower body 20-30 in. lb.
_1-_ower body end plote to lower body 20-30 in . lb.
_lJpper body trent or rear end plate to upper body 20-30 in. lb.
Upper body to lower body LU-JU rn. lb.
Valve bodies assembly to tronsmission case 4-5
Front pump strainer to lower body 20-30 in . lb .
Downshitt volve com bracket to volve body LU· JU rn . lb .
Governor body to sleeve 4-!>
Governor cover plote to governor body 20-30 in. lb .
Front servo lever adjustrng screw nut 15-20
Rear servo "djusting screw locknut L!> -JU
_Starter inhibitor switch locknut 4-6
Downshift valve control cable odaptor to case 10- 12
Filler tube t:onnecter odoptor to cose 20-30
Filler tube to connector sleeve nut 17 - 18
Stone Quords to convertor housing 1.4-1.6
Drive plate to torque converter 25 -30
7-124 GROUP 7-AUTOMATIC TRANSMISSION

C4 TRANSMISSION MODELS 250 C.I.D.

250 C.I.D.
1V
2V
PEE-AC
PEE-AC
302 C.I.D. 2V PEE -AC
351 C.I.D. 2V PEF-C
CHICKS AND ADJUSTMINTS
CONTROL PRESSURE AT DRO OUTPUT SHAn'
SPEED-C4 TRANSMISSION O,.,.Utl s,tcllcalltl
Stltct• CHtrtl Tranamission End Plly Check 0.008.0.042 inch
Enlint Thrtttlt Manlftlll LtYir ~~~ Stlectivt Thrust WIShers
Spttd Vac.lna. H8. l'tsiUtll (I'SI) Available
P, N, 0 52-85 Turbine and Stator End Play Check 0.040 inch (maximum)
Idle Closed (!)Above18 lnttrmtdialt Band Adjustment Adjust tcrtw to 10 ft-lbs torque,
I, 2 52-115 tnd back off 1~ turns
R 52-180 low·Rtvtrst Band Adjustment Adjust tcrew to 10 ft·lbs tor9ut,
Pressure and back off thrtt turns
As Req'd. As Req'd. Ap~rox. 0, 2, I ·starts Forward Clutch Pressure Plale 0.025 to 0.050 inch
1.0 olncr... to Snap Rina Clttranc:e Selective Snap Ring Thicknesses
As RfQ'd. As Req'd. 10 0, 2, I 96-110 0.050-0.054
0, 2, I 0.064-0.068
Below 143-160
As Req'd. As Req'd. 0.078-0.082
3 R 230-260 0.092-0.096
(!)Cars checked al hiah altitudes Reverse-Hip Clutch Prtailra 0.048-0.074 inch
Plitt to Snap ttina Clurance Selective Snap Ring Thicknesses
At altitudes above sea level it may not bt l:'lble to obtlin 18" ot enaint 0.050-0.054
vacuum at idle. For idle vacuums of less t n 18" refer to followin& table 0.064-0.068
to determine idle speed pressure specificalion in forward drivin& ranp 0.078-0.082
(0).
0.092-0.096
Enlint Vacuu11 Ctlltrtl l'rassllt (PSI) SILICTIVI THRUST WASHIIS-
17 52-74 CONTROL TRANSMISSION IND PLAY®
16 52-78 (No. 1 and 2)
15 52-85 Tllrust Wash• Itt. 1 Tllrust Wasil• Itt. 2
14 Nvlon Ctl• lilt. Sta•Pttl MICII
52-90
13 52-96
Tllnst
Wulltl
If
Wasw ••
Wa.W
Tllnst
Wasil•
12 52-101 0.108.0.104 Black
11 52-101 0.091-0.087 Natural
0.074.0.070 Green 3 0.075.0.073
LUBRICANT REFILL CAPACITY 0.057-0.053 Red 2 0.058.0.056
302 351 0.121.0.125 Yellow 1 0.043-0.041
Capacity (Imp.) 7'!.. qts. (Imp.) 8'!.. qts. Spacer 0.032-0.0360.
M2C33F a)Selectaon an paars not applicable.
Type M2C33F
®This is a selective spacer. The sp;!cer must be installed next
CONTROL VALVI IODY SPRING IDINTIFICATION to the stator support to obtain correct end play.
Free Spring Wire
Spring Total Length Dia. 0.0. Dia. length at lbs load Spring Color
Coils (Inches) (Inches) (Inches) load length Code
Manual Valve Detent - - leaf Type - 7.25 0.542 None
2-3 Backout Valve 13 1.345 0.345 0.0258 1.45 0.620 Gray
1-2 Transition Valve: 12 1.150 0.330 0.023 0.95 0.480 Dk. Green
Throttle Downshift Valve: 10 0.816 0.280 0.0301 3.00 0.500 None
low Servo Modulator Valve: PEE 12 1.158 0.380 0.0286 1.35 0.553 Yellow
PEF 12 1.335 0.380 0.0286 1.12 0.553 Purple
Throttle Pressure Booster Valve: 15 1.191 0.281 0.033 5.25 0.620 Dk. Green
Throttle Pressure limit Valve: 14 1.192 0.295 0.0379 6.25 0.770 Brown
Throttle Pressure Modulator Valve: 15 1.513 0.292 0.0286 3.575 0.620 Yellow
line Pressure Coast Boost Valve: 10 1.023 0.340 0.0332 4.10 0.494 Dk. Blue
Drive 2 Valve: 11 0.730 0.265 0.0258 0.80 0.580 Violet
Int. Servo Accumulator Valve: Model PEE-AC1 8 0.684 0.300 0.0258 1.50 0.390 Lt. Green
Model PEF 9.5 0.853 0.300 0.0212 2.50 0.390 Orange
Main Oil Pressure Reg., Valve Inner 11 1.40 0.350 0.0286 1.49 0.739 None
Main Oil Pressure Reg., Valve Outer 9 1.667 0.668 0.0507 7.30 0.586 None
PART 7-4- SPECIFICATIONS 7-125

SHIFT SPEEDS- ACTUAL M.P.H . STALL SPEED LIMITS

250 (1 -V) - 2.92 : 1 Rear Axle Engine Model Engine Speed (rpm)
Throttle Range Shift M.P.H. 250-1V 1600-1800
Closed D 1-2 8-11 250-2V 1650-1850
(Above D 2-3 12-22
18' ' D 3-1 6-9 302-2V 1780-2000
Vacuum) 1 2·1 26-36 351 -2V 1520-1720
To D 1·2 26-40
Deten t D 2-3 42-64
(Torque D 3-2 34-36
Demand) D 2-1 or 3-1 24-30
Thru D 1-2 35-45
Det ent D 2-3 50-60 CLUTCH PLAnS
W.O.T . D 3-2 50-60
D 2-1 or 3-1 28-34 AtYirst· Hi&h Clutch Forward Clutch
Transmission
Modtl Sttel Composition Sttel Composition
PlattS Platts Platts Platts
250 (2-V) - 2.92: 1 Rear Axle PEE-AC 4 4 4 5
Throttle Range Shift M.P .H. PEF-C
Closed D 1-2 9-11
(Above D 2-3 12-22 Converter size PEE-AC
18" D 3-1 8-10 PEF-C
Vacuum) 1 2-1 28-38
To D 1-2 28-40
Detent D 2-3 44-64
(Torque D 3-2 28-30
Demand) D 2-1 or 3-1 16-18
1-2 36-46
TORQUE LIMITS
Thru D
Detent D 2-3 52-68
W.O.T . D 3-2 50-64 Description Foot Pounds
D 2-1 or 3-1 28-32
Pressure Gauge Tap . .. . 9-15
Conv. Hse. lower Cover to Trans.. . . 12-16
Downshift lever to Case . . .. . ... . . . .12-16
Oil Pan to Case ..... . ....... . 12-16
302 V-8 - 2.92: 1 Rear Axle Cooler Bracket & Oil Pan to Case .. . .... 12-16
Int. Servo Cover to Case . .. . . . . 16-22
Throttle Shift M.P.H. Rev. Servo Cover to Case ... ...... . . . . . . ... . .... 12-20
Range
Support to Front Pump .......... . . . ... . 12-20
Closed D 1-2 9-10 Distributor Sleeve to Case .... . .... . . . . . .12-20
(Above D 2-3 12-22 Reverse Servo Piston to Rod .. .... .. ....... . .. . . ..
18" D 3-1 9-10 Outer Race to Case . . . . . . ...... 13-20
Vacuum) 1 2-1 30-40 Diaphragm Assy. to Case . . . . . .... ... . . ... . 15-23
Converter Drain Plug . . . .. 20-30
To D 1-2 27-39
Flywheel to Converter . . . . . . .20-30
Detent D 2-3 46-63 . .28-40
28-30
Ext. Hsg. to Case .. .. . .. .. .
(Torque D 3-2 . .28-40
14-16
Conv. Housing & Pump to Case .
Demand D 2-1 or 3-1 .. .28-40
Front Oil Pump to Case ... ... . .
Thru D 1-2 36-48 Converter Housing to Case . . .28-40
Detent D 2-3 56-72 Manual lever to Shaft . . .. .. . . . . .30-40
W.O .T . D 3-2 54-58 Int. Band Adj. Stop to Case . . . ..... .. 35-45
D 2-1 or 3-1 28-30 Rev. Band Adj. Stop to Case . . .35-45
Transmission to Engine:

351 V-8 (2-V) - 2.75:1 Rear Axle Inch Pounds

Throttle Range Shift M.P.H.
End Plate to Control Assy .. .............. . ....... . 20-35
Closed D 1-2 9-11 Lower to Upper Valve Body .. . . 40-50
(Above D 2-3 13-23 Accumulator Plate to Body 80-120
18" D 3-1 9-11 Screen & lwr. to Upper Valve Body ... . .40-55
Vacuum 1 2-1 32-42 Neutral Switch to Case . . . . . ... . . . . .. 55-75
To D 1-2 29-41 Screen & Control Assy. to Case . . .... . . . . . .. 80-120
Detent D 2-3 49-67 Control Assy. to Case ... ... . ... 80-120
(Torque D 3-2 38 Gov. Body to Distributor Body .. .. . .. .. .. . 80;120
Demand) D 2-1 or 3-1 32 Cooler line Fittings . . . " . . " .. . ....... . 80-120
Thru D 1-2 38-51
Detent D 2-3 66-82
W.O.T . D 3-2 63
D 2-1 or 3-1 36-38 *Tighten to 10ft. lbs. and back off 5/a turn
7-126 GROUP 7-AUTOMATIC TRANSMISSION

FMX Transmission MODEL PH B- S -MODEL APPLICATION 351 C.I.D. 4V- 2V

CONTROL PRESSURE AT ZERO GOVERNOR RPM-
FMX TRANSMISSION
Control Line Pressure (PSI)
Manifold
Engine Speed Throttle Range
Vac. Ins. Hg. PHB-S

P. N. D. 2, 1 56-82
Idle Closed Above 18 (i)
R 59-111
As Required As Required 10 D, 2, 1 69-126
D, 2, 1 133-189
As Required As Required Below l
R 184-221
fD At altitudes above sea level, it may not lie possible to obtain 18 inches of engine vacuum at idle. For idle vacuum of less than 18 inches,
refer to the following table to determine idle speed pressure specification in D driving range.

Engine Vacuum Line Pressure

17 inches 57-67
16 inches 57-67
15 inches 57-72
14 inches 57-79
13 inches 57-86
12 inches 57-92
11 inches 57-99

LUBRICANT REFILL CAPACITY STALL SPEED LIMITS

Capacity (Imp) 91/4 QIS. Enaine Model Entine Splld (rpm)
Type M2C33F 351 ClD-4V 1650-1850

FMX TRANSMISSION -WITH 351-4V ENGINE AXLE RATIO 2.75:1

Throttle Range Shift 1

Closed 0 1-2 10-16

(Above D 2-3 12-26
17" D 3-1 5-11
Vacuum) I 2-1 33-43
To Detent 0 1·2 36-54
(Torque 0 23 58-80
Demand) 0 3-2 27-43
Through D I2 49-58
Detent 0 2-3 75-89
(WOT) D 3-2 62-79
0 3-1 or 2-1 33-44

CLUTCH PLATES
FMX TRANSMISSION
FORWARD CLUTCH REAR CLUTCH
Steel Friction Selective Plate Selective Plate Steel Friction Free Pack
Plates Plates Thicknesses Identification Plates Plates Clearance

0.0565-0.0605 No Stripe
4 5Ci; 0.0705-0.0745 One Stripe 4(i) 4 0. 030-0.055
0.0845-0.0885 Two Stripes
0.0985-0.1025 Three Stripes

(o)La sI plale (Fr1ct10n) m FMX forward clutch 1S s~:lect1ve . Install th1ckesl plate 111 pack that w1ll be a mmimum of 0.010 mch below 111put shaft shoulder
111 cylinder. All other fr1ct10n plat es m pack are thmnest available.
0 Plus one waved plate 1nslalled between two steel plates at p1ston end of pack.
PART 7-4- SPECIFICATIONS 7-127

CHECKS AND ADJUSTMENTS

Opention Specific:ltio n
Transmission End Play Check 0.010-0.029 (Selective Thrust Washers Available)
Turbine and Stator End Play Check New or rebuilt 0.023 max., Used 0.040 max. 0
Front Band Adjustment (Use 1/4 inch spacer Adjust screw to 10 in-lbs torque. Remove spacer,
between adjustment screw and servo piston stem) then tighten screw an additional 3/4 turn and lock .
Rear Band Adjustment Adjust screw to 10 in-lbs torque.
then back off exactly 1-1/2 turns and tighten lock nut.
Primary Sun Gear Shaft Ring End Gap Check 0.002-0.009
Rear Clutch Selective Snap Ring Thicknesses 0.060-0 064, 0.074-0.078, 0.088-0.092, 0.102-0.106
0 To check end play, exert force on checking tool to compress turbine to cover thrust washer wear plate. Set indicator at zero.

SELECTIVE THRUST WASHERS

Identification No. Thrust Washer Thickness -Inch Identification No. Thrust Washer Thickness -Inch
By Thickness 0 . 061~ . 063 By Thickness 0.074~ . 076
0 . 067~ . 069 0.081~.083

CONTROL VALVE SPRING ICENT!FICATION

Free Sprin& Wire

Sprin& Total Len&th Dia. O.D. Dia. Le111th at Lbs. Load Spr in& Col or
Coils (Inches) (Inches) (Inches) Load Ltn&lh Code
1-2 Shift Accumulator Valve 8.5 U70 0.470 0.035 2.900 0.445 Yellow
1st-2nd Shift Control Valve: 7 1.880 0.725 0.044 4.600 0.560 White
Throttle Press. Booster Green
15.5 1.660 0.470 0.047 5.250 0.890
Valve:
2-1 Scheduling Valve: 11 0.880 0.265 0.026 2.400 0.415 Pink
Low Inhibitor Valve: 17 1.270 0.230 0.025 1.900 0.890 Yellow
Control Oil Press. Comp.
7 1.09 0.5091.0. 0.034 1.520 0.500 Purple
Valve -Outer :
Control Oil Press . Comp.
10 1.00 0.034 2.720 0.520 None
Val ve -l nner :
Downshift Valve 13.5 1.107 0.250 0.023 1.400 0.640 None
Control Check Valve 12 0.480 0.214 0.014 0.100 0.280 None
3rd-2nd Downshift Control Valve 14.5 0.820 0.200 0.018 0.605 0.520 Purple
Transition Valve : 7 1.320 0.470 I. D. 0.035 2.750 0.460 Orange
2nd-3rd Shift Valve-lnner 21 1.340 0.295 0.028 1.500 0.670 Green
2nd-3rd Shift Valve-Outer 4 1.008 0.692 I. D. 0.041 2.950 0.430 White
Low Servo Modulator Valve 29.5 1.800 0.235 0.028 2.975 1.050 None
7-128 GROUP 7-AUTOMATIC TRANSMISSION

TORQUE liMITS

Item Ft-Lbs Item Ft-Lbs

Converter to Flywheel 23-28 Extension Assy. to Trans. Case 30-40

Converter Hsg. to Trans. Case 40-50 Pressure Gauge Tap 7-15
Front Pump to Trans. Case 17-22 Band Adj. Screw Locknut to Case -
Fron! Servo to Trans. Case 30-35 Yoke to Output Shaft -
Rear Servo to Trans. Case 40-45 Reverse Servo Piston to Rod -
Upper Valv~ Body to lower Valve Body 4-6 Cooler Tube Connector Lock -
Overrunning Clutch Race to Case - Converter Drain Plug 15-28
Oil Pan to Case 10-13 Rear Band Adjusting Screw to Case 35-40
Rear Servo Cover to Case - Front Band Adjusting Screw Locknut 20-25
Stator Support to Pump - Manual Valve Inner Lever to Shaft 8-12
Converter Cover to Converter Hsg. 12-16 Downshift Lever to Shaft 17-20
Guide Plate to Case - Filler Tube to Engine 20-25
Intermedia te Servo Cover to Case - Filler Tube to Pan -
Regulafor to Case 17-22 Transmission to Engine 40-50
Planetary Support to Trans. Case 20-25 Transmission to Engine : Falcon
Mustang-6-Cyl. -
Control Valve Body to Trans. Case 8-10
Diaphragm Assy. to Case 20-30
Lower to Upper Valve Body -
Cooler Return Check Valve 9-12
Reinforcement Plate to Body -
Distributor Sleeve to Case -
Screeo1 and Lower to Upper Valve Body -
Governor to Counterweight 50-60 Neutral Switch to Casec:D -
Neutral Switch to Column 20
Governor Valve Body Cover Screws 20-30
Pressure Regulator Cover Screws 20-30
Accumulator Plate to Body -
Lower Valve Body Cover and Plate to 48-72
Control Valve Body Screws (10-24) 20-30
Valve Body
Front Servo Release Pts ton 20-30 96-120
Control Assy. to Case
End Plates to Body 20-30
Gov. Body to Collector Body -
Stator Support to Pump 23-35
Cooler Line Fttlings -
Inner Downshtft Lever Stop -
FALCON FAIRLANE w~:~~~~P

GROUP
ENGINE
8

PAGE
PART 8-1 -General Engine Service 8-2
PART 8-2-200, 250 C. I. D. Six Cylinder Engines 8-22
PART 8-3-302 C.I.D.-351 C.I.D. Engines 8-44
PART 8-4- Specifications 8-67
8-2

PART GENERAL ENGINE SERVICE

8·1
Section Pace Section Pa1•
1 Diagnosis and Testing 8-2 Cylinder Block 8-15
Diagnosis Guide .... 8-3 Flywheel Ring Gear-Manual Shift
Cam shaft Lobe Lift 8- 8 Transmission 8-15
Compression Test .... 8-8 3 Cleaning and Inspection 8-15
Manifold Vacuum Test 8-9 Intake Manifold ... . 8-15
Hydraulic Valve Lifte,· Tests 8-9 Exhaust Manifold . .. . 8-1 5
Positive Crankcase Ventilation System Test 8-10 Valve Rocker Arm and/or Shaft Assembly 8- 5
Crankshaft End Play B-10 Push Rods .... 8-15
Flywheel Runout-Automatic Transmission 8-11 Cylinder Heads 8·16
Flywheel Ring Gear Runout 8-11 Hydraulic Valve Lift~rs 8- 17
Camshaft End Play 8-11 Timing Chain and Sprockets 8-17
Timing Chain Deflection . .. . 8-11 Camshaft 8-17
2 Common Adjustments and Repairs 8-11 Crankshaft Vib1·ation Damper and Sleeve 8-17
Valve Clearance-Hydraulic Valve Lifters, Crankshaft 8-17
Six cylinder engines 8-11 Flywheel-Manual Shift Transmission 8-.8
Valve Clearance-Hydraulic Valve Lifters Flywheel-Automatic Transmission 8-18
V -8 engines .. 8-12 Connecting Rods ... . 8-18
Valve Rocker Arm· and / or Shaft Assembly 8-12 Pistons, Pins and Rings .... 8-18
Push Rods 8-13 Main and Connecting Rod Bearings 8-1 8
Valves 8-13 Cylinder Block 8-1 9
Camshaft 8-13 Oil Pan 8-19
Crankshaft 8- 14 Oil Pump 8-19
Pistons, Pins and Rings 8- 14 Positive Crankcase Ventilation System 8-20

MODEL YEAR

CHANGE LEVEL
On 351 CID 4V engines only.
This part covers engine diagnosis,
tests and adjustment and repair pro- An identification tag is attached to
cedures. In addition, the cleaning and the engine. The symbol code (Fig. 1)
ir>spection procedure'> are covered. identifies this engine for determining
For engine removal, disassembly, ENGINE
parts usage; i.e., engine cubic inch
assembly, installation and major re- displacement and model year. The
pair procedures, refer to the perti- change level and engine code number
nent part of this group. MONTH OF ENGINE determine if parts are peculiar to a
PRODUCTION specific engine.

FIG. 1.-Engine Identification Tag

351 CID 4V only- Typical

D DIAGNOSIS AND TESTING

the conventional ignition system items
Engine performance complaints that could be at fault are listed in the that affect acceleration are listed.
usually fall under one of the basic order of their probable occurrence. Ch~k all these items before proceed-
headings listed in the Diagnosis Check the items in the order listed. ing to the next probable cause.
Guide. When a particular trouble For example, under Poor Accelera- For diaposls proceclures of ~pi­
can not be traced to a definite cause tion, the ignition system is listed as don system malfancdons, refer to
by a simple check, the possible items a probable cause of the trouble. All Group 9.
PART 8-1- GENERAL ENGINE SERVICE 8-3
DIAGNOSIS GUIDI

The cause of this trouble is usually ~ta~ter. If the engine cranks, it

in the starting system (Group 14). mdicat~s that water is leaking into
ENGINE WILL If the starting system is not at the cylmders. Remove the cylinder
NOT CRANK fault, check for a hydrostatic lock head(s) and inspect the gasket(s)
or a seized engine as follows: and/ or head(s) for cracks. Examine
Remove the spark plugs; then the cylinder block for cracks.
attempt to crank the engine with the

Check the fuel supply. If there is AUTOMATIC CHOKE

ENGINE CRANKS sufficient fuel in the tank and the Check the position of the choke
NORMALLY, IUT WILL proper starting procedure is used, the plate. If the engine is hot, the plate
NOT START cause of the trouble probably lies in should be open. If the plate is not
either the ignition or the fuel system. open, the engine will load up due to
To determine which system is at the excessively rich mixture and will
fault~ perform the following test:
not start. If the engine is cold, the
Dtsconnect a spark plug wire. plate should .be closed. If the plate
Check the spark intensity at the end 1s not operatmg properly, check the
of the wire by installing a terminal following items:
adapter in the end of the wire. Then
~old the adapter approximately
mch from the exhaust manifold and
* The choke plate and linkage for
binding.
The fast idle cam linkage for
crank ~he engine. binding.
. Thermostatic spring housing ad-
IF THERE IS NO SPARK JUStment.
OR A WEAK SPARK
AT THE SPARK PLUGS FUEL SUPPLY AT THE
CARBURETTOR
The cause of the trouble is in the
ignition system. Work the throttle by hand several
Disconnect the brown lead (I times. Each time the throttle is
terminal) and the red and blue actuated, fuel should spurt from the
lead (s terminal) at the starter accelerating pump discharge port
relay. Install an auxiliary starter (6-cylinder) or nozzles (V-8).
switch between the battery and s
terminals of the starter relay. If fuel is discharged by the accel-
To determine if the cause of the erating pump, the engine is probably
trouble is in the primary or the flooded, or there is water in the fuel
secondary circuit, remove the coil system, or an engine mechanical item
h~gh .tension lead from the top of the
is at fault.
dtstnbutor, and hold it approxi- If fuel is not discharged by the
mately 3 / 16 inch from the cylinder accelerating pump, disconnect the
head. With the ignition on, crank carburettor fuel inlet line at the
the engine and check for a spark. carburettor. Use a suitable container
If the spark at the coil high tension to catch the fuel. Crank the engine
lead is good, the cause of the trouble to see. if fuel is reaching the car-
is probably in the distributor cap, burettor.
rotor or spark plug wires. If fuel is not reaching the car-
If there is no spark or a weak burettor, check:
spark at the coil high tension lead, The fuel filter.
~he cause _ of the trouble is probably The fuel pump.
m the pnmary circuit, coil to dis- The carburettor fuel inlet line for
tributor high tension lead, or the coil. obstructions.
The fuel pump flexible inlet line
IF THERE IS for a collapsed condition.
A GOOD SPARK AT The fuel tank line for obstructions.
THE SPARK PLUGS For fuel tank vent restriction.
Check the spark plugs. If the spark If fuel is reaching the carburettor
plugs are not at fault, check the check:
The fuel inlet system including the
following items:
fuel inlet needle and seat assembly
MANUAL CHOKE and the float assembly.
Check the choke linkage for bind-
ing or damage. Make certain the
choke plate closes when the choke ENGINE
knob on the instrument panel is
pulled out and that the plate opens Mechanical failure in camshaft
when the knob is pushed in. drive.
8-4 GROUP 8- ENGINE
DIAGNOSIS GUIDE

ENGINE STARTS, BUT FUEL SYSTEM Check for dirt in the carburettor
FAILS TO KEEP RUNNING Idle fuel mixture needle(s) not not allowing fuel to enter or be dis-
vropE>rly adjusted. charged from the idle system.
Engine idle speed set too low.
The choke not operating properly. IGNITION SYSTEM
Float setting' incorrect. Defective spark plugs.
Fuel inlet system not operating Leakage in the high tension wir-
properly. ing.
Dirt or water in the fuel lines or Open circuit in primary resis-
in the fuel filter. tance wire.
Carburettor icing. Breaker points not properly ad·
Fuel pump defective. jus ted.

ENGINE RUNS, BUT Determine if the miss is steady Ol' High Tension leakage across the
MISSES ·erratic and at what speed the miss coil, rotor or distributor cap.
occurs by operating the engine at Defective ignition switch.
various speeds under load. FUEL SYSTEM
MISSES STEADILY AT Float setting incorrect.
ALL SPEEDS Fuel inlet system not operating
Isolate the miss by operating the properly.
engine with one cylinder not firing. Dirt or water in the fuel lines or
This is done by operating the en- carburettor.
gine with the ignition wire removed Restricted fuel filter.
from one spark plug at a time, until Loose booster venturi (V-8).
.all cylinders have been checked. COOLING SYSTEM
Ground the spark plug wire re- Check the cooling system for in-
moved. ternal leakage and/ or for a condi-
If the engine speed changes when tion that prevents the engine from
.a particular cylinder is shorted out, reaching normal operating temper-
that cylinder was delivering power ature.
before being sho1·ted out. If no ENGINE
~hange in the engine operation is Perform a manifold vacuum or
evident, the miss was caused by compression test to determine
that cylinder not delivering power which mechanical component of the
befo1·e being shorted out. In this engine is at fault.
case, check the:
IGNITION SYSTEM MISSES AT IDLE ONLY
If the miss is isolated in a par- FUEL SYSTEM
ticular cylinder, perform a spark Idle fuel mixture needle(s) not
test on the ignition lead of that cy- properly adjusted.
linder. Restriction in idle fuel system.
If a good spark does not occur, IGNITION SYSTf:M
the trouble is in the seconduy cir- Excessive play in the distributor
cuit of the system. Check the spark shaft.
plug wire and the distributor cap. Worn distributor cam.
If a good spark occurs, check the Defective coil, rotor, condenser,
spark plug. If the spark plug is not Breaker points, ignition wiring or
at fault, a mechanical component of <>park plugs.
the engine is probably at fault. EN~INE
ENGINE Valve clearance set too tight.
Intake manifold gasket leak. Worn tamshaft lobe(s) .
Perform a manifold vacuum or Perform a manifold vacuum or
compression test to determine compression test to determine which
which mechanical component of the mechanical component of the engine
engine is at fault. is at fault.
MISSES ERRATICALLY
AT ALL SPEEDS MISSES AT HIGH SPEED
EXHAUST SYSTEM
ONLY
Exhaust system restricted. FUEL SYSTEM
IGNITION SYSTEM Power valve or passages clogged
Breaker points not properly ad- or damaged.
justed. Low or erratic fu el pump pres-
Defective breaker points, conden- sure.
ser, secondary wiring, coil or spark Fuel inlet system not operating
plugs. properly.
PART 8-1- GENERAL ENGINE SERVICE 8-5
DIAGNOSIS GUIDE (Continued)

ENGINE RUNS, BUT Restricted fuel filter. COOLING SYSTEM

MISSES (Continued) Restricted main fuel system. Engine overheating.
Positive crankcase ventilation ENGINE
system restricted or not operating Perfol'm a man ifold vacuum or
properly. compression test to determine
IGNITION SYSTEM which mechanical component of the
Defective spark plugs. engine is at fault.

ROUGH ENGINE IDLE FUEL SYSTEM IGNITION SYSTEM

Engine idle speed set too low. Improperly adjusted or defective
breaker points.
Idle fuel mixture needle(s) not Fouled or improperly adjusted
properly adjusted. spark plugs.
Float setting incorrect. Incorrect ignition timing.
Air leaks between the carburet- Spark plug misfiring.
tor, spacer and the manifold and/or ENGINE
fittings. Loose engine mounting bolts or
worn engine support insulator.
Intake manifold gasket leak
Cylinder head bolts not properly
(V-8).
torqued.
Fuel leakage at the carburettor Valve clearance set too tight.
fuel bowl. Crankcase ventilation regulator
Power valve leaking fuel (V-8). valve defective or a restricted vent
Idle fuel system air bleeds or tube.
fuel passages restricted. Worn camshaft lobes.
Fuel bleeding from the accelera- Perform a manifold vacuum or
ting pump discharge nozzles. compression test to determine
Leaking fuel pump, lines or fit- which mechanical component is at
tings. fault.

POOR ACCELERATION IGNITION SYSTEM Dirt or corrosion in accelerating

Incorrect ignition timing. system.
Fouled or improperly adjusted
spark plugs.
Improperly adjusted or defective Restricted fuel filter.
breaker points. Defective fuel pump.
Distributor not advancing prop- BRAKES
erly. Improper adjustment-too tight.
TRANSMISSIONS
Clutch slippage (manual shift
FUEL SYSTEM
Accelerating pump malfunction. transmissions.
Jo'loat setting incorre.:t. Improper band adjustment (auto-
Throttle linkage not properly ad- matic transmissions) .
justed. Converter One-Way Clutch (auto-
Accelerating pump stroke not matic transmissions).
properly adjusted. ENGINE
Leaky power valve, gaskets or Perform a manifold vacuum or
accelerating pump diaphragm. compression test to determine
Power valve piston stuck in the which mechanical component of the
up position (6-cylinder and 302 V8). engine is at fault.

ENGINE DOES NOT FUEL SYSTEM IGNITION SYSTEM

DEVELOP FULL POWER, Restricted air cleaner. Ignition timing not properly ad-
OR HAS POOR HIGH Restricted fuel filter. justed.
SPEED PERFORMANCE Clogg·ed or undersize main or sec- Defective coil, condenser or rotor.
ondary jets or low float sett'ing. Distributor not advancing prop-
erly.
Power valve or passages clogged
Excessive play in the distributor
or damaged.
Fvel pump pressure incorrect. shaft.
Distributor cam worn.
Foule.d or improperly adjusted
Power valve piston stuck In the spark plugs, or spark plugs of in-
up position (6-cylinder and 302 V8). correct heat range.
Automatic.' choke malfunctioning Impl'operly adjust ed or defective
or improperly adjusted. breaker points.
8-6 GROUP 8- ENGINE
DI~GNOSIS GUIDE (Continued)

ENGINE DOES NOT DEVELOP EXHAUST SYSTEM ENGINE

FULL POWER, OR HAS POOR Restriction in system. Perform a manifold vacuum or
HIGH SPEED PERFORMANCE engine compression test to deter-
(Continued) COOLING SYSTEM mine which mechanical component
Thermostat inoperative or of in- of the engine is at fault.
correct heat range. One or more camshaft lobes worn
beyond wear limit.
Thermostat installed incorrectly.
Worn valve guides.
Check the cooling system for in- Positive crankcase ventilation sy-
ternal leakage and/ or for a condi- stem not operating properly.
tion that prevents the engine from TRANSMISSION
reaching normal operating temper- Improper band adjustment (auto-
ature. matic transmissions).

EXCESSIVE FUEL Determine the actual fuel con· Automatic choke for proper op-
CONSUMPTION sumption with test equipment in- eration.
stalled in the car. Fast idle speed screw for proper
If the test indicates that the fuel adjustment.
consumption is not excessive, dem- Accelerating pump stroke adjust-
onstrate to the owner how improper ment.
driving habits will affect fuel con-
sumption.
If the test indicates that the fuel Air cleaner for restrictions.
consumption is excessive, make a J:.,loat setting or fuel level.
preliminary check of the following Jets for wear and/or damage.
items before proceeding to the fuel Power valve operation.
and ignition systems. Air bleeds for obstructions.
PRELIMINARY CHECKS Accelerating pump discharge
CHASSIS ITEMS nozzles for siphoning.
Check: Accelerator linkage for binds.
Tyres for proper pressure. Choke adjustment.
Front wheel alignment. IGNITION SYSTEM
Brake adjustment.
Check :
EXHAUST SYSTEM
Ignition timing.
System restricted.
Spark plug condition and adjust-
ODOMETER
ment.
Check calibration.
Distributor spark advance opera-
IGNITION SYSTEM
tion.
Check:
Distributor breaker points.
Ig-nition timing.
EN<:INE ENGINE
Crankt-ase ventilation regulator Pel'form a manifold vacuum or
valvt• defedive or restrided tubes engine compression test to detel'·
(Positive Crankcase Ventilation Sy- mine which met·hanical component
,;tcm). of the engine is at fault.
FINAL CHECKS Check valve clearance .
FUEL SYSTEM COOLIN(; SYSTEM
Che<·k: Check thermostat operation and
Fuel pump prt'ssure. heat range.
E11;.rine idlt• speed. TRANSMISSION
Idle fuel mixture needlt'(s) for Cht'ck han<l adjustment (auto-
prc:>per adjustment. mali<- transmissions) .

ENGINE OVERHEATS TEMPERATURE SENDING Coolin)! system leaks.

UNIT AND GAUGE Orin· helt tension incorrect.
Unit or c:aug·e defective (not in- Radiator fins obstructed.
di<·ating correct temperatures) ot· Thennostat defective.
constant volta).!.'t' regulator defec. Thermostat improperly installed.
tive. Cooling systl'm passages blocked.
ENGINE Water pump inoperative.
Cylinder head bolts not properly IGNITION SYSTEM
tm·qued. lnt·ot..-ect ignition timing.
Incorrect valve clearance. I nco. rect distributor advance.
Low oil level or im·on·ect viscos- EXHAUST SYSTEM
ity oil used . Restl'ictions in system.
COOLING SYSTEM BRAKES
Insufficient coolant. ImpropE-r adjustment-too tig·ht.
PART 8-1- GENERAL ENGINE SERVICE 8-7
DIAGNOSIS GUIDE (Continued)

COOLING SYSTEM Intake manifold to cylinder head

LOSS Of COOLANT Leaking radiator or water pump. gasket defective (V-8).
Loose or damaged hose connec- Cylinder head or intake manifold
tions. bolts (V -8) not properly torqued.
Radiator cap defective. Cylinder block core plugs leak-
Overheating. ing.
Temperature sending unit leaking.
Cracked cylinder head or block,
ENGINE or warped cylinder head or block
Cylinder head gasket defective. gasket ·surface.

TEMPERATURE SENDING COOLING SYSTEM

ENGINE FAILS TO REACH UNIT AND GAUGE
Thermostat inoperative or of in-
NORMAL OPIRAnNG
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 caused by an excessively high or low

NOISY HYDRAULIC be located by operating the engine at oil level, may likewise cause lifter
VALVE LlmR idle speed and placing a finger on malfunction. A damaged oil pick-up
the face of the valve spring retainer. tube may allow air to be drawn into
If the lifter is not functioning prop- the lubricating system.
erly, a shock will be felt when the Check for engine oil aeration as
valve seats. follows:
Another method of identifying a Check the engine oil level to be
noisy lifter is by the use of a piece sure it is within specification and
of hose. With the engine operating correct as required. Be sure the ~or­
at idle speed, place one end of the red engine oU dlpsti~k Is beiDg used.
hose near the end of the valve stem Operate the engine at approxi-
and the other end to the ear and mately 1200 rpm until normal oper-
listen for a metallic noise. Repeat ating temperature is reached. Stop
this procedure on each intake and the engine and remove the oil pres-
exhaust valve until the noisy lifter(s) sure sending unit. Install a fitting in
has been located. this opening with a petcock-type
The most common causes of hy- valve that will permit attachment of
draulic valve lifter troubles are dirt, a 1,4 to ¥s -inch-diameter hose of
gum, varnish, carbon deposits and sufficient length to direct the oil dis-
air bubbles. charge into the oil filler pipe. Close
Dirt in the lifter assembly can the valve.
prevent the disc valve from seating, Start the engine and operate it at
or it may become lodged between approximately 500 rpm for a mini-
the plunger and body surfaces. In mum of S minutes; then, open the
either case, the lifter becomes inop- valve slightly to permit a steady dis-
erative due to failure to "pump-up," charge of oil. Check the oil flow
or because the internal parts are no for air bubbles.
longer free to function properly. Increase the engine speed to ap-
When dirt is found to be respon- proximately 1000 rpm and check for
sible for lifter malfunction, remove air bubbles in the oil. To fa~Uitate
the lifter assembly and thoroughly ~he~ldng for air bubbles, direct tbe
clean it. Recommended engine oil oil flow over white paper or throop
and filter change intervals should be a pie~e of transparent tube. Tbe en-
followed to minimize lifter prob- gine should not be opented at ex-
lems caused by dirt (Group 19). ~esslve speeds or for extended peri-
Deposits of gum and varnish ods with the oU bleed atta~bed.
cause similar conditions to exist If oil aeration is evident, remove
which may result in lifter malfunc- the oil pan for further test and/ or
tion. If these conditions are found
to be presept, the lifter should be inspection of the oil pump intake
disassembled and cleaned in solvent system. Perform corrective action as
to remove all traces of deposits. required to remove air from the lu-
Air bubbles in the lubricating oil, bricating oil.
8-8 GROUP 8-ENGINE
TESnNG 5. Zero the dial indicator. Con- 1,200 r.p.m. or until the engine is
CAMSHAFT LOBE UFT tinue to rotate the crankshaft slowly at normal operating temperature.
Check the lift of each lobe in until the push rod is in the fully Remove the spark plugs.
consecutive order and make a note raised position. 2. Disconnect the brown/red lead
of the readings. 6. Compare the total lift re-
(I terminal) and the red and blue lead
1. Remove the air cleaner and corded on the indicator with speci-
(S terminal) at the starter relay. In-
the valve rocker arm cover(s). fications.
7. To check the accuracy of the stall an auxiliary starter switch be-
2. On a six-cylinder engine, re- tween the battery and S terminals of
move the valve rocker arm shaft original indicator reading, continue
the starter relay. Check valve clear-
assembly. to rotate the crankshaft until the
ances as indicated in Group 8, Sec-
indicator reads zero. H the Uft on
On a V -8 engine, remove the any lobe is below specified wear tion 2, using the auxiliary starter
rocker arm stud, or stud nut, fulcrum switch to turn engine. Crank the
Umits, the camshaft and the valve
seat and rocker arm. Use the adapter engine with the ignition switch
Ufters operating on the worn lobe(s)
for ball-end push rods (Fig. 3). off.
must be replaced.
3. Make sure the push rod is in 3. Set the throttle plates and
the valve lifter socket. Install a dial NOTE
Comparing the size of one cam- choke plate in the wide open position.
indicator in such a manner as to
have the ball socket adapter of the shaft lobe to another, with a micro- 4. Install a compression gauge in
indicator on the end of the push meter or other measuring instrument, No. 1 cylinder.
rod and in the same plane as the is not a satisfactory method of check-
push rod movement (Fig. 2 or 3). ing camshaft lobe lift, owing to 5. Using the auxiliary starter
On a socket-type push rod, posi- tolerances on base circle radii. switch, crank the engine a minimum
tion the actuating point of the indi· 8. On a six-cylinder engine, install of five pumping strokes, and record
cator in the push rod socket and in the rocker arm shaft assemblies. the highest gauge reading.
the same plane as the push rod On a V -8 engine, install the rocker Note the number of compression
movement (Fig. 2). arm, fulcrum seat and stud. strokes required to obtain the high-
4. Disconnect the brown/red lead Adjust the valve clearance (Page est reading.
(I terminal) and the red and blue 8-11 ) 6. Repeat the test on each cylin-
lead (S terminal) at the starter 9. Install the valve rocker arm der, cranking the engine the same
relay. Install an auxiliary starter cover(s) and the air cleaner. number of times for each cylinder
switch between the battery and S as was required to obtain the highest
terminals of the starter relay. Crank COMPRESSION TEST reading on the No. 1 cylinder.
the engine with the Ignition switch Dynamic Compression Test. To
OFF. perform a dynamic compression Test Conclusions. The test pres-
"Bump" the crankshaft over until check, follow the procedures in sures should fall within the band
the tappet or lifter is on the base Part 9-1, Section 1 under Ignition specified and the compression of all
circle of the camshaft lobe. At this System Tests- cylinders should be uniform within
20 psi.
point, the push rod will be In its Compression Gauge Check
lowest position, If one or more cylinders exhibit
1. Be sure the crankcase oil is at the compression figures lower than that
proper level. DISCONNECT AL- specified, re-run the engine at 1200
TERNATOR. Connect a high speed rpm for 5 minutes. Recheck the low
battery charger to battery to ensure reading cylinders to confirm the
cranking speed does not vary bet- original results.
ween cylinders. Operate the engine A reading of more than the allow-
for a minimum of 30 minutes at able tolerance above normal indi-
cates excessive deposits in the cyl-
inder or wrong cylinder head(s) on
the engine.
A reading of more than the allow-
able tolerance below normal indi-
cates leakage at the cylinder head
gasket, piston rings or valves or
wrong cylinder head(s) on the en-
gine.
A low, even compression in two
adjacent cylinders indicates a cylin-
der head gasket leak. This should be
checked before condemning the
rings or valves.
During a compression test, if the
pressure fails to climb steadily and
OF PUSH ROO remains the same during .the first
SOCKET
two successive strokes, but climbs
FIG. 2-Camshaft lobe lift- FIG. 3-Camshaft lobe ltft- higher on the succeeding strokes, or
Six Cylinder Engines V-8 Engines -Typical fails to climb during the entire test,
PART 8-1-GENERAL ENGINE SERVICE 8-9
it indicates a sticking valve.
MANIFOLD VACUUM TEST
TABLE 1-Manifold Vacuum Gauge Readings .
Gauge Reading Engine Condition
A manifold vacuum test aids in
determining the condition of an en- 18 inches or over-All engines. Normal.
gine and in helping to locate the Except where otherwise
cause of poor engine performance. specified.
To check manifold vacuum :
1. Operate the engine for a mini- Low and steady. Loss of power in all cylinders possibly
mum of 30 minutes at 1200 rpm caused by late ignition or valve timing, or
or until the engine is at normal loss of compression due to leakage around
operating temperature. the piston rings.
2. On 6-cylinder engines, install Very low. Intake manifold, carburettor spacer or cyl-
an accurate, sensitive vacuum gauge inder head gasket leak.
in the intake manifold fitting.
On a V -8 engine, remove the plug Needle fluctuates steadily as A partial or complete loss of power in one
or power brake line at the rear of speed increases. or more cylinders caused by a leaking valve,
the intake manifold and install an cylinder head or intake manifold gasket,
accurate, sensitive vacuum gauge. a defect in the ignition system, or a weak
3. Operate the engine at recom- valve spring.
mended idle rpm, with the transmis-
sion selector lever in neutral. Gradual drop in reading at Excessive back pressure in the exhaust
4. Check the vacuum reading on engine idle. system.
the gauge.
Test Conclusions. Manifold vac- Intermittent fluctuation. An occasional loss of power possibly
uum is affected by carburetor adjust- caused by a defect in the ignition system
ment, valve timing, ignition timing, or a sticking valve.
the condition of the valves, cylinder
Slow fluctuation or drifting Improper idle mixture adjustment or car-
compression, the condition of the
of the needle. buretor, spacer or intake manifold gasket
positive crankcase ventilation sys-
leak or restricted crankcase ventilation
tem, and leakage of the intake mani-
system.
fold, carburetor, carburetor spacer
or cylinder head gaskets and a valve lifter reservoir during the time
restricted exhaust system.
the push rod is being lifted to force
Because abnormal gauge readings the valve from its seat.
may indicate that more than one of Air bubbles in the lubricating sys-
the above factors are at fault, exer- tem can be caused by too much oil
cise caution in analyzing an abnor-
in the system or too low an oil level.
mal reading. For example, if the Air may also be drawn into the
vacuum is low, the correction of one
lubricating system through an open-
item may increase the vacuum
ing in a damaged oil pick-up tube.
enough so as to indicate that the
Air in the hydraulic system can
trouble has been corrected. It is im- cause a loss of hydraulic pressure in
portant, therefore, that each cause
the valve lifter.
of an abnormal reading be investi-
gated and further tests conducted, Assembled valve lifters can be
where necessary, in order to arrive tested with tool 6500-E to check the
leak down rate. The leak down rate
at the correct diagnosis of the
specification (Page 8·68) is the time FIG. 4-Piacing SJeel Ball in
trouble. Valve Liftttr Plunger
Table l lists various types of read- in seconds for the plunger to move
ings and their possible causes. the length (Page 8-68) of its travel
Allowance should be made for the while under a 50 lb. load. Test the
effect of altitude on the gauge read- valve lifters as follows:
ing. The engine vacuum will de- 1. Disassemble and clean the lift-
crease with an increase in altitude. er to remove all traces of engine
oil. Lifters cannot be checked with
HYDRAULIC VALVE engine oil in them. Only the test-
LIFTER TESTS ing fluid can be used.
Dirt, deposits of gum and varnish 2. Place the valve lifter in the
and air bubbles in the lubricating oil tester, with the plunger facing up-
can cause hydraulic valve lifter fail- ward. Pour hydraulic tester fluid
ure or malfunction. into the cup to a level that will
Dirt, gum and varnish can keep cover the valve lifter assembly. The
a check valve from seating and ftuid can be purchased from the
cause a loss of hydraulic pressure. manufacturer of the tester. Do not
An open valve disc will cause the use kerosene, for it wiU not provide FIG. 5-Adjusting the Ram
plunger to force oil back into the an accurate test. Length
8-10 GROUP 8- ENGINE
3. Place a 5116-inch steel ball case ventilation system may be in- CRANKSHAFT END PLAY
in the plunger cup (Fig. 4). dicated by loping or rough engine 1. Force the crankshaft toward
4. Adjust the length of the ram idle. Do not attempt to compensate the rear of the engine.
so that the pointer is l/16-inch for this poor idle condition by dis- 2. Install a dial indicator so that
below the starting mark when the connecting the crankcase ventilation the contact point rests against the
ram contacts the valve lifter plung- system and/or making carburettor crankshaft flange and the indicator
er (Fig. 5) to facilitate timing as adjustments. The removal of the axis is parallel to the crankshaft axis
the pointer passes the Start Timing crankcase ventilation system from (Fig. 7).
Mark. the engine will adversely affect the 3. Zero the dial indicator. Push
Use the center mark on the point- fuel economy and engine ventilation the crankshaft forward and note the
er scale as the Stop Timing point with resultant shortening of engine reading on the dial.
instead of the original Stop Timing life. 4. If the end play exceeds the
mark at the top of the scale. To determine whether the loping wear limit, replace the thrust bear-
5. Work the valve lifter plunger or rough idle condition is caused ing. If the end play is less than
up and down until the lifter fills by a malfunctioning crankcase ven- the minimum limit, inspect the
with fluid and all traces of air bub- tilation system, perform either of thrust bearing faces for scratches,
bles have disappeared. the following tests. -- burrs, nicks or dirt. If the thrust
6. Allow the ram and weight to Regulator Valve Test. faces are not defective or dirty, they
force the valve lifter plunger down- Install a known good regulator probably were not aligned properly.
ward. Measure the exact time it valve in the crankcase ventilation sys- Install the thrust bearing and align
takes for the. pointer to travel from tem. the faces following the procedure
the Start Timing to the Stop Tim- Start the engine and compare the recommended under Main Bearing
ing marks of the tester. engine idle condition to the prior idle Replacement in the pertinent en-
7. A valve lifter that is satisfac- condition. gine section. Check the crankshaft
tory must have a leak-down rate If the idle condition is found to be end play.
(time in seconds) within the mini- satisfactory, replace the regulator
mum and maximum limits specified. valve and clean the hoses, fittings. etc. FLYWHEEL FACE RUNOUT-
8. If the valve lifter is not within If the loping or rough idle condi- MANUAL-SHIFT
specifications, replace it with a new tion remains when the good regulator TRANSMISSIONS
lifter. Always test a new lifter be- valve is installed, the crankcase venti- Install a dial indicator so that the
fore installing It in the engine. It is lation regulator valve is not at fault. indicator point bears against the fly-
not necessary to disassemble and Check the crankcase ventilation sys- wheel face (Fig. 8). Turn the fly-
clean new valve lifters before test- tem for restriction at the intake mani-
wheel making sure that it is full for-
ing, because the oil contained in fold or carburetor spacer. If the sys-
ward or rearward so that crankshaft
new lifters is test fluid. tem is not restricted, further engine
end play will not be indicated as tly-
9. Remove the fluid from the cup component diagnosis will have to be
wheel runout.
and bleed the fluid from the lifter conducted to find the malfunction.
If the clutch face runout exceeds
by depressing the plunger up and Air Intake Test. the specifications, remove the fly-
down. This step will aid in de- I. With the engine at normal oper- wheel and check for burrs between
pressing the lifter plungen when ating temperature, remove the oil fill- the flywheel and the face of the
checking the valve clearance. er cap . crankshaft mounting flange. If no
2. Hold the tester C8AZ-6B627-A burn exist, check the runout of the
POSITIVE CRANKCASE over the opening in the valve cover.
VENTILATION SYSTEM TEST Make sure that the surface is flat to
A malfunctioning positive crank- form a seal between the cover and
tester. If the cover is distorted, shape
it as required to make an air tight
seal. An air leak between the cover
and tester will render the tester ino-
perative.
3. Start the engine and allow it to
operate at the recommended idle
speed.
4. Hold the tester over the oi I filler
cap opening making sure that there is
a positive seal between the tester and
cover.
5. If the ball settles in the Good
(green) area, the system is functioning
properly. If the ball settles in the Re-
pair (red) area, clean or replace the
malfunctioning components as re.
quired.
6. Repeat the test after repairs are
made to make sure that the crankcase
FIG. 6- Crankcase Ventilation ventilation system is operating satis-
FIG. 7 -Typical Crankshaft End
System Tester -Typical factorily. Play
PART 8-1-GENERAL ENGINE SERVICE 8-11

FIG. 8-Typical Flywheel Face

Runout
crankshaft mounting flange. Replace FIG. 1 0-Typical Camshaft End
the flywheel or machine the crank- Play
shaft flywheel mounting face if the
mounting flange runout is excessive.
FIG. 9 -Typical Flywheel Ring
If the ring gear runout exceeds Ge• Runout
specifications, replace it or reinstall prevent the indicator point from
it on the flywheel, following the catching between the gear teeth as
procedure under Ring Gear Re- the flywheel is turned. Set the indi-
cator dial on the zero mark and
placement (Page 8-15 ) .
slowly turn the flywheel through one
FLYWHEEL RUNOUT- revolution while observing the total
AUTOMATIC TRANSMISSION indicator reading. The T.I.R. must
Remove the spark plugs. be within specifications, or the ring
Install a dial indicator so that the gear (standard transmission) or fly-
indicator point rests on the face of wheel and ring gear assembly (auto-
the ring gear adjacent to the gear matic transmission) must be re-
teeth. placed.
Push the flywheel and crankshaft CAMSHAFT END PLAY
forward or backward as far as pos- Push the camshaft toward the rear
sible to prevent crankshaft end of the engine. Install a dial indicator
play from being indicated as fly- so that the indicator point is on the
wheel runout. camshaft sprocket retaining screw
Set the indicator dial on the (Fig. 10). Zero the dial indicator.
zero mark. Tum the flywheel one Position a large screw driver between
complete revolution while observing TAKE UP SLACK ON ·LEFT SIDE, ESTABLISH
the camshaft sprocket and the block. REFERENCE POINT. MEASURE DISTANCE A.
the total indicator reading (f.I.R.). Pull the camshaft forward and re- TAKE UP SLACK ON RIGHT SIDE. FORCE
If the T.I.R. exceeds specifications, LEFT SIDE OUT. MEASURE DISTANCE I.
lease it. Compare the dial indicator DEFLECTION IS A MINUS I. A .(
the flywheel and ring gear assembly reading with specifications. If the 1284
must be replaced. end play is excessive, replace the FIG. 11-Typical Timing Chain
thrust plate. Remove the dial indi- Defledion
FLYWHEEL RING GEAR
RUNOUT cator.
opposite direction to take up the
Install the dial indicator so that TIMING CHAIN DEFLECTION slack on the right side of the chain.
the point rests on a tooth of the 1. Rotate the crankshaft in a Force the left side of the chain out
ring gear (Fig. 9), and check the clockwise direction (as viewed from with the fingers and measure the dis-
outside diameter (0.0.) of the the front) to take up the slack on tance between the reference point and
assembled flywheel and ring gear. the left side of the chain. the chain. The deflection is the differ-
For this cheek, carefully adjust the l. Establish a reference point on ence between the two measurements.
Indicator on the gear tooth so that the block and measure from this If the deflection exceeds specifica-
the Indicator point is near the es:- point to the chain (Fig. 11 ). tions, replace the timing chain and
treme Umit of its traveL 1bis wiD 3. Rotate the crankshaft in the sprockets.

EJ COMMON ADJUSTMENTS AND REPAIRS

ADJUSTMENTS adjusting screws to adjust the valve eliminate all push rod clearance,
clearance. This is accomplished by tighten the adjusting screw a further
VALVE CLEARANCE- loosening the rocker arm adjusting ! of one tum.
HYDRAUUC VALVE LIFTERS, screw until there is end clearance in An alternative method may be
Six-Cylinder Engines the push rod, rotate the push rod used for collapsing the lifters.
These engines are equipped with and tighten the adjusting screw to 1. Disconnect the brown/red lead
8-12 GROUP 8- ENGINE

(I terminal) and the red and blue lead 1. Disconnect the brown/red lead
(5 terminal) at the starter relay. (I terminal) and the red and blue lead
Install an auxiliary starter switch (S terminal) at the starter relay. Install
between the battery and S terminals an auxiliary starter switch between
of the starter relay. Crank the engine the battery and S terminals of the
with the ignition switch off until Starter relay. Crank the engine with
the No. 1 piston is on T.D.C. after the ignitions switch 0 FF until the
the compression stroke. No. I piston is on TDC after the
By using procedure in Step 3, compression stroke. ~.

check the following valves: 2. With the crankshaft in the

No. 1 intake. No. 3 exhaust. positions designated in Steps 3, 4 and
No. 1 exhaust. No. 4 intake. 5 position the hydraulic lifter com- FIG. 12 -Yalft ca....c. Check
No. 2 intake. No. 5 exhaust. pressor tool on the rocker arm. Slow- - 6 CYL
2. Now rotate the crankshaft until ly apply pressure to bleed down the
the No. 6 piston is on T.D.C. after hydraulic lifter until the plunger is
the compression stroke (1 revolution completely bottomed (Fig. 14 ). Hold
of the crankshaft). By using the the lifter in this position and check
procedure in step 3, check the the available clearance between the
following valves: rocker arm and the valve stem tip
No. 2 exhaust. No. 5 intake. with a feeler gauge. The feeler gauge
No. 3 intake. No. 6 intake. width must not exceed 3/8-inch.
No. 4 exhaust. No. 6 exhaust. If the clearance is less than specifi-
3. Using tool 6513AG, apply cations, install an undersize push rod .
pressure on the push rod end of the If the clearance is greater than speci-
rocker arm (Fig. 12) to slowly bleed fications, install an oversize push rod.
down the valve lifter until the plunger 3. With the No. I piston on TDC
is completely bottomed. Hold the at the end of the compression stroke,
lifter in this position and check the POSITION A in Fig. 13, check the
available clearance between the rock- following valves:
er arm and the valve stem tip with No. 1 Intake No. 1 Exhaust
a feeler gauge. No.4 Intake No. 3 Exhaust
If clearance is not within specifica- No.8 Intake No.7 Exhaust FIG. 14 Valve Clearance
tions, tum the adjusting screw clock- 4. Rotate the crankshaft to POSI- Check-V-8
wise to decrease or counter-clock- TION 8 in Fig. 13 and check the fol- he valve clearance. However, to ob-
wise to increase, the clearance. lowing valves: tain the specified valve lash. it is im-
Normally, one turn of the adjusting No. 3 Intake No. 2 Exhaust portant that all valve components be
screw will alter the clearancr by No.7 Intake No. 6 Exhaust in a serviceable condition and in-
0.075 inch at the valve stem tip. 5. Rotate the crankshaft to POSI- stalled and torqued properly. ·.
VALVE CLEARANCE- TION C in Fig. 13 and check the fol- With the crankshaft in the
HYDRAUUC VALVE LIFTERS, lowiniZ valves: positions designated in steps 2, 3 and
V-8 Engines No. 21ntake No.4 Exhaust 4 remove the fulcrum seat and rocker ·•
The cylinders are numbered from No. 5 Intake No. 5 Exhaust arm. Inspect them for wear. See Fig.
front to rear-right bank, 1-2-3-4; No.6 Intake No.8 Exhaust 15.
left bank, 5-6-7-8. The rocker arm, bolt, fulcrum seat VALVE ROCKER ARM ::. ...
The valve arrangement on the left and rocker arm eliminates the neces- ASSEMBLY
bank is E-1-E-1-E-1-E-1 and on the If the pad at the valve end of ''·
sity of adjusting.
right bank is 1-E-1-E-1-E-1-E.
POSITION A - No. 1 at TDC ot end of compression str'oke. -:
A 0.060-inch shorter push rod or a POSITION 8 -Rotate the crankshaft 180 degrees (one hoH ,.
0.060-inch longer push rod are avail- revolution) clockwise from POSITION A.
able for service to provide a means of POSITION C - Rotate the cronkshoh 270 degrees (three

compensating for dimensional

changes in the valve mechanism.
quarter revolut ion) clockwise from
POSITION B. .,.

W1th No. 1 at TDC at end of compreu•o~ stroke

Refer to the Master Parts List for the make o chalk mark ot points Band C opproxtmotely
pertinent color code. 90 degrees apart.
Valve stem to valve rocker arm
clearance should be within specifica-
tions with the hydraulic lifter com-
pletely collapsed. Repeated valve re-
conditioning operations (valve and/or
valve seat refacing) will decrease the
clearance to the point that if not
compensated for, the hydraulic valve
lifter will cease to function and the
valve will be held open.
To determine whether a shorter or
a longer push rod is necessary, make FIG. 13 - Position of Crankshaft for Checking and
the following check : Adjusting Valve Clearance
PART 8-1-GENERAL ENGINE SERVICE 8-13

grooves, or to correct the valve seat grooves, etc., may be removed. Dis-

'I-
runout. Mter the seat has been re- card valves that are severely dam-
FULCRUM faced, use a seat width scale to aged, or if the face runout or stem
BOLT
6A529 measure the seat width (Fig. 18). clearance exceeds specifications.
Narrow the seat, if necessary, to Discard any defective part of the
bring it within specifications. valve assembly.
If the valve seat width exceeds Refacing Valves. The valve refac-
FULCRUM
the maximum limit, remove enough ing operation should be closely co-
ROCKER
ARM SEAT stock from the top edge and/ or ordinated with the valve seat refac-
6564 6A528
bottom edge of the seat to reduce ing operation so that the finished
the width to specifications (Fig. 17). angles of the valve face and of the
For exhaust valves use a 30° angle valve seat will provide a compres-
grinding wheel to remove stock from sion-tight fit. Be sure that the re-
the top of the seats (lower the seats) facer grinding wheels are properly
and use a 60° angle wheel to remove dressed.
stock from the bottom of the seats If the valve face runout is ex-
(raise the seats). cessive and/ or to remove pits and
For inlet valves use a 15 ° angle grooves, reface the valves to a true
grinding wheel to remove stock from 44 • angle. Remove only enough
FIG. 15 V8 ENGINE the top of the seats and a 60° angle stock to correct the runout or to
grinding wheel to remove stock from clean up the pits and grooves. If the
the bottom of the seats. edge of the valve head is less than
the rocker arm has a grooved The finished valve seat should con- Ya 2 inch thick after grinding, re-
radius, replace the rocker arm. Do tact the approximate centre of the place the valve as the valve will run
not attempt to true this surface valve face. It is good practice to de- too hot in the engine. The interfer·
by grinding. termine where the valve seat contacts eoce fit of the valve and seat should
the face. To do this, coat the seat not be lapped out.
PUSH RODS with Prussian blue, then set the valve Remove all grooves or score
Following the procedures in Sec- in place. Rotate the valve with light TO REMOVE STOCK TO REMOVE
tion 3 under Push Rod Inspection pressure. If the blue is transferred to FROM TOP OF SEAT, STOCK FROM
USE 30° WHEEL BOTIOM OF SEAT.
check the push rods for straightness. the center of the valve face, the con- USE 60° WHEEL
If the runout exceeds the maxi- tact is satisfactory. If the blue is trans-
mum limit at any point, discard the ferred to the top edge of the valve
rod. Do not attempt to straighten face, lower the valve seat. If the blue
push rods. is transferred to the bottom edge of
the valve face, raise the valve seat.
Reaming Valve Guides. If it be-
comes necessary to ream a valve
guide (Fig. 16) to install a valve
with an oversize stem, a ream-
ing kit is available which contains
the following reamer and pilot com- FIG. 17 -Valve Seat Refacing
binations: a 0.003-inch O.S. reamer marks from the end of the valve
with a standard diameter pilot, a stem, and chamfer it as necessary.
0.015-inch O.S. reamer with a Do not remove more than 0.010
0.003•inch O.S. pilot, and a 0.030- inch from the end of the valve stem.
inch reamer with a 0.0 15-inch O.S. If the valve and/ or valve seat has
pilot. been refaced, it will be necessary to
When going from a standard size check the clearance between the
valve to an oversize valve, always rocker arm pad and the valve stem
use the reamers in sequence. Always. with the valve train assembly in-
reface the valve seat after the valve stalled in the engine.
guide has been reamed. Seled Fitting Valves. If the valve
Refacing Valve Seats. Refacing of stem to valve guide clearance ex-
the valve seats should be closely co- ceeds the wear limit, ream the valve
odinated with refacing of the valve guide for the next oversize valve
face so that the finished seat and stem. Valves with oversize stem di-
valve face will be concentric and ameters of 0.003, 0.015 and 0.030
the specified interference fit will be inch are available for service. Al-
maintained. This is important so that ways reface the valve seat after the
the valve and seat will have a com- valve guide has been reametl.. Refer
pression tight fit. Be sure that the FIG. 16 -Reaming Valve Guides to Reaming Valve Guides.
refacer grinding wheels are properly
VALVES CAMSHAFf
dressed.
Grind the valve seats to a true 45° For inspection procedures refer Remove light scuffs, scores or
or 30° angle (Fig. 17). Remove only to Section 3. nicks from the camshaft machined
enough stock to clean up pits, Valve defects, such as minor pits, surfaces with a smooth oil stone.
8-14 GROUP 8- ENGINE

CRANKSHAFf has been selected, check for a daDl- Fitting Piston Rings
Dress minor imperfections with an aged piston; then, try a new piston. 1. Select the proper ring set for
oil stone. If the journals are severely If the clearance is less than the the size piston to be used.
marred or exceed the wear limit, minimum limit, recheck calculations l. Position the ring in the cylinder
they should be refinished to size for before trying another piston. If none bore in which it is going to be used.
the next undersize bearing. can be fitted, refinish the cylinder for 3; Push the ring down into the
Refinishing Journals. Refinish the the next size pistor;1. bore area where normal ring wear is
journal to give the proper clearance When a piston bas been fitted,
not encountered.
with the next undersize bearing. If mark it for assembly in the cyUn-
der to which it was fitted. 4. Use the head of a piston to
If the taper, out-of-round and position the ring in the bore so that
piston to cylinder bore clearance the ring is square with the cylinder
conditions of the cylinder bore are wall. Use caution to avoid damage
within specified limits, new piston
rings will give satisfactory service.

TABLE 2-0versize Service Piston

PISTON
ENGINE OVERSIZE
(inches)
200 0.003, 0.020,
250 0.030, 0.040,

FIG. 18 -Valve Seat Width 302 0.003, 0.020,

351 0.030 0.040 FIG. 20 -Ring Side Clecwance
the journal will not clean up to
give the proper clearance with the to the ring or cyUnder bore.
maximum undersize bearing avail- 5. Measure the gap between the
able, replace the crankshaft. ends of the ring with a feeler gauge
Always reproduce the same jour- (Fig. 19). if the ring gap is less or
nal shoulder radius that existed greater than the specified limits,
originally. Too small a radius will try another ring set.
result in fatigue failure of the crank- 6. Check the ring side clearance
shaft. Too large a radius will result of the compression rings with a
in bearing failure due to radius ride feeler cauge inserted between the ring
of the bearing. and its lower land (Fig. 20). The
After refinishing the journals, gauge should slide freely around the
chamfer the oil holes, then polish entire ring circumference without
the journal with a No. 320 grit FIG. 19 -Piston Ring Gap binding. Any wear that occurs will
polishing cloth and engine oil. Cro- If the new rings are to be installed form a step at the inner portion of
cus cloth may be used also as a in a used cylinder that has not been the lower land. If the lower lands
polishing agent. refinished, remove the cylinder wall have high steps, the piston should
PISTONS, PINS AND RIMGS glaze. Be sure to clean the cylinder be replaced.
bore thoroughly, following the pro-
Fitting Pistons. Pistons are cedure in Section 3 page 8-19. Fitting Piston Pins.
available for service in standard Install the piston pin, following
sizes and the oversizes shown in To Fit a Piston: the procedure under Piston Assem-
Table 2. 1. Calculate the~size piston to be bly page 8 ·35).
The standard-size pistons are used by taking a cylinder bore. Piston piD bores must not be reamed
color coded red or blue on the dome. check. Follow the procedures out- with hand-driven reamers. Use
Refer to the specifications for the lined in Section 3 page 8..19 . motor-driven reamers, but do not
standard-size piston dimensions. 2. Select the proper size piston exceed the cutting speed (rpm)
Piston pins are provided with new to provide the desired clearance recommended by the reamer manu-
pistons. (refer to the specifications). Measure facturer.
Follow the procedures in Section the piston diameter in line with the If a reamer is used, set the ream-
3 to measure the piston O.D. and centerline of the piston pin and at er to the size of the pin bore; then
cylinder bore I.D. The dimensions 90° to the piston pin axis. expand the reamer slightly and trial
should be within specifications, and 3. Make sure the piston and cyl- ream the pin bore. Take a light cut.
the piston to bore clearance (bore inder block are at room tempera- Use a pilot sleeve of the nearest
I.D. minus piston O.D.) must be ture {70°F). After any refinishing size to maintain alignment of the
within the specified limits. operation, aUow the cyUnder bore bores.
If the clearance is greater than the to cool and make sure the piston Check the hole size, using the
maximum limit, recheck calculations and bore :ae clean and dry before new piston pin. If the bore is small,
to be sure that the proper size piston the piston fit is checked. expand the reamer slightly anrt make
PART 8-1-GENERAl ENGINE SERVICE 8-15

another cut. Repeat the procedure the same weight, both standard and the pistons to correspond to the
until the proper fit is obtained. ovenlze; therefore, various sizes of cylinders in which they are to be
Check the piston pin for fit in the plstous can be used without upset- installed. When the refinishing of
respective rod or rod bushing. ting engine balance. all cylinders that require it has been
CYLINDER BLOCK Refinish the cylinder with the completed and all pistons are fitted,
Refinishing CyUnder WaDs. Hon- most wear first to determine the thoroughly clean the entire block
ing is :recommended for refinishing maximum oversize. If the cylinder and oil the cylinder walls following
cylinder walls only when the walls will not clean up when refinished the procedure under Cylinder Block
have minor imperfections, such as for the maximum oversize piston Cleaning on page 8·f9
light scuffs and scratches or for fit- recommended, replace the cylinder
ting pistons to the specified clear- block.
ance. The grade of hone to be used Refinish the cylinder to within ap- FLYWHEEL RING GEAR-
is determined by the amount of proximately 0.0015 inch of the re- MANUAL-SHIFf
metal to be removed. Follow the in- quired oversize diameter. This will TRANSMISSIONS
structions of the hone manufacturer. allow enough stock for the final step
If coarse stones are used to start of honing so that the correct surface
the honing operation, leave enough finish and pattern are obtained. Use
material so that all hone marks can clean sharp hones of No. 180-220 To replace a defective ring gear,
be removed with the finishing hone grit for this operation. heat the defective ring gear with a
which is used to obtain the proper For the proper . use of the re- blow torch on the engine side of the
piston clearance. finishing equipment, follow the in- gear, and knock it off the flywheel.
Cylinder walls that are severely structions of the manufacturer. Only Do not hit the flywheel when remov-
marred and/ or worn beyond the experienced penonnel should be .._ Ing the ring gear.
specified limits should be refinished. lowed to perform this won. Heat the new ring gear evenly
Before any cylinder is refinished, all After the final operation in either until the gear expands enough to
main bearing caps must be in place of the two refinishing methods de- slip onto the flywheel. Make sure
and tightened to the proper torque scribed and prior to checking the the gear is seated properly against
so that the crankshaft bearing bores- piston fit, thoroughly clean and oil the shoulder. Do not heat any por-
will not become distorted from thtil the cylinder walls, following the tion of the gear to a tempenture
refinishing operation. procedure in Section 3. Check the higher than 500°F. If this Umlt II
Refinish only the cylinder or cyl- piston fit, following the procedure exceeded, the temper will be re-
inders that require it. All plsto4S are in this section and Section 3. Mark 'moved froiD the ring gear teeth.

EJ CLEANING AND INSPECTION

The cleaning and inspection pro- 302 V-8 engines) are completeiy open place the shaft and/ or the rocker
cedures in this section are for a and the cover does not leak. arm. Inspect the ·shaft and the rocker
complete engine overhaul; therefore, Blow out the automatic choke air arm bore for nicks, scratches, scores
for partial engine overhaul or parts heat tube with compressed air. or scuffs.
replacement, follow the pertinent Inspect the pad at the valve end
cleaning or inspection procedure. INSPECTION of the rocker arm for indications of
Inspect the cylinder head joining scuffing or abnormal wear. If the
INTAKE MANIFOLD flanges of the exhaust manifold(s) pad is grooved, replace the .rocker
CLEANING for evidence of exhaust gas leaks. arm. Do not attempt to true this 1111'·
Remove all gasket material from Inspect the manifold(s) for cracks, face by grinding.
the machined surfaces of the mani- damaged gasket surfaces, or other On ball stud rocker arms, check
fold. Clean the manifold in a suit- defects that would make them unfit the rocker arm and fulcrum seat for
able solvent and dry it with corn- for further service. excessive wear, cracks, nicks or
pressed air. burrs. Check the rocker arm stud
VALVE ROCKER ARM .and nut for .stripped or broken
INSPECTION AND/OR SHAn ASSEMBLY threads.
Inspect the manifold for cracks, CLEANING
damaged gasket surfaces, or other Clean all the parts thoroughly. PUSH RODS
defects that would make it unfit for Make sure all oil passages are open. CLEANING
further service. Replace all studs On ball stud rocker arms, make On a V-8 Engine, clean the push
that are stripped or otherwise dam- sure the oil passage in the push rod rods in a suitable solvent. Blow out
aged. Remove all fiilngs and foreign end of the rocker arm is open. • the oil passage in the push rods
matter that may have entered the with compressed air.
manifold as a result of repaln. INSPECTION
On rocker arm shaft assemblies, INSPECTION
EXHAUST MANIFOLDS check the clearance between each Check the ends of the push rods
CLEANING rocker arm and the shaft by check- for nicks, grooves, roughness or ex-
Remove all gasket material from ing the ID of the rocker arm bore cessive wear.
the manifolds. Make sure the auto- and the OD of the shaft. If the clear. The push rods can be visually
matic choke air inlet and outlet ance between any rocker arm and checked for straightness while they
hold (right exhaust manifold on the shaft exceeds the wear limit, re- are installed in the engine by rotat-
8-16 GROUP 8- ENGINE

ing them with the valve closed. They the specifications for the wear lim- upper surface of the valve guide.
also can be checked with a dial indi- its. Inspect the valve face and the Position the dial indicator with
cator (Fig. 21). edge of the valve head for pits, its flat tip against the center portion
grooves, scores or other defects. In- of the tool's spherical section at
CYLINDER HEADS spect the stem for a bent condition approximately 90° to the valve
CLEANING and the end of the stem for grooves stem axis. Move the tool back and
With the valves installed to pro- forth in line with the indicator
tect the valve seats, remove deposits stem. Take a reading on the dial
from the combustion chambers and indicator without removing the tool
valve heads with a scraper and a from the valve guide upper surface.
wire brush. Be careful not to damage Divide the reading by two, the
the cylinder head gasket surface. division factor for the tool.
After the valves are removed, clean Valve Sprlag Pressure. Check the
the valve guide bores with a valve springs for proper pressure (Fig. 27)
guide cleaning tool. Use cleaning at the specified spring lengths. Weak
solvent to remove dirt, grease and valve springs cause poor engine
other deposits. Clean all bolt holes; FIG. 22 -Typical Cylinder Head performance; therefore, if the pres-
be sure the oil transfer passage is
clean. Flatness
or scores. Check the valve head for
signs of burning, erosion, warpage
and cracking. Defects, such as minor
pits, grooves, etc., may be removed.
Discard valves that are severely
damaged. FOR DIMENSIONS,
REFER TO
Inspect the valve springs, valve
SPECIFICATIONS VALVE
FIG. 21 -Push Rod Runout spring retainers, locks and sleeves
FACE
for defects. ANGLE
Remove all deposits from the Valve Face Runout. Check the
valves with a fine wire brush or buf- valve face runout (Fig. 25). It
fing wheel. should not exceed the specified wear
limit. If the runout exceeds the wear
INSPECTION limits, the valve should be refaced
Check the cylinder head for or replaced as outlined under Re-
cracks, and inspect the gasket sur- facing Valves in Section 2. FIG. 24 -Critical Valve Tolerances
face for burrs and nicks. Replace Valve Stem Cleanmce. Check the mre of any spring approaches the
the head if it is cracked. valve stem to valve guide clearance wear limit, replace the spring.
The following inspection pro- of each valve in its resoective valve Valve Sprlag SquareDess. Check
cedures are for a cylinder head that guide with the tool shown in Fig. 26 each spring for squareness using a
is to be completely overhauled. For or its equivalent. steel square and a surface plate
individual repair operations, use Install the tool on the valve stem
only the pertinent inspection pro- (Fig. 28). Stand the spring and
until it is fully seated, and tighten square on end on the surface plate.
cedure. the knurled set screw firmly. Permit Slide the spring up to the square.
Cylinder Head Flatness. When a the valve to drop away from its Revolve the spring slowly and ob-
cylinder head is removed because seat until the tool contacts the serve the space between the top
of gasket leaks, check the flatness
coil of the spring and the square. If
of the cylinder head gasket surface
(Fig. 22) for conformance to speci-
fications.
If necessary to refinish the cylin-
der head gasket surface, do not
plane or grind off more than 0.010
inch.
Vlllve Seat Runout. Check the
valve seat runout with an accurate
gauge (Fig. 23). Follow the instruc-
tions of the gauge manufacturer. If
the runout exceeds the wear limit,
reface the valve and valve seat.
Valve Seat Width. Measure the
valve seat width (Fig. 18). Reface
the valve seats if the width is not
within specifications. FIG. 25 -Valve Race Runout
Valves. The critical inspection
points and tolerances of the valves FIG. 23 -Typical Valve Seat the spring is out of square more than
are illustrated in Fig. 24. Refe~ to Runout *e inch, replace it.
PART 8-1-GENERAL ENGINE SERVICE 8-17

Follow the same procedure to Assemble the lifter assembly and CRANKSHAn VIBRATION
check new valve springs before in- check for freeness of operation by DAMPER AND SLEEVE
stallation. pressing down on the push rod cup. CLEANING
Make certain the proper spriag The lifters can also be checked with
(color coded) is installed. a hydraulic tester to test the leak Clean the oil seal contact sur-
HYDRAULIC VALVE LlmRS down rate. Follow the instructions face on the crankshaft damper with
of the test unit manufacturer or the solvent to remove any corrosion,
The valve lifter assemblies !ihould
procedure in Section 1. sludge or varnish deposits. Excess
be kept in proper sequence so that deposits that are not readily removed
they can be installea in their original TIMING CHAIN AND with solvent may be removed with
position. Inspect and test each lifter SPROCKETS crocus cloth. Use crocus cloth to
separately so as not to intermix the CLEANING remove any sharp edges, burrs or
internal parts. If aoy part of the 6ft. Clean all parts in solvent and dry other imperfections which might
er assembly needs replacing, replace them with compressed air. damage the oil seal durmg instal-
the entire assembly. Lubricate the timing chain with lation or cause premature seal wear.
CLEANING engine oil before installing it on the Do not use crocus cloth to the
Thoroughly clean all the parts in engine. extent that the seal surface be-
comes polished. A finely polished
INSPECTION
surface may produce poor seal-
Inspect the chain for broken, links. ing or cause premature seal
Inspect the sprockets for cracks and wear.
worn or damaged teeth. Replace all
components of the timing chain and INSPECTION
sprocket assembly if any one item
needs replacement. Inspect the crankshaft damper
On a V-8 Engine, inspect the fuel oil seal surface for nicks, sharp
pump drive eccentric for scores, edges or burrs that might damage
nicks or excessive wear. If the the oil seal during installation or
eccentric is scored, replace it. cause premature seal wear.
CAMS HAn CRANKSHAn
CLEANING AND INSPECTION CLEANING
Clean the camshaft in solvent and Handle the crankshaft with care
wipe it dry. Inspect the camshaft to avoid possible fractures or dam-
lobes for scoring and signs of ab- age to the finished surfaces. Clean
FIG. 26 -Typical Valve Stem normal wear. Lobe wear character- the crankshaft with solvent, then
istics may result in pitting in the blow out all oil passages with com-
Clearance general area of the lobe toe. This pressed air.
pitting is not detrimental to the
clean solvent and wipe them with a INSPECTION
clean, lint-free cloth. operation of the camshaft; there-
fore, the camshaft should not be Inspect main and connecting rod
INSPECTION replaced until the lobe lift loss has journals for cracks, scratches,
Inspect the parts . and discard the exceeded 0.005 inch. grooves or scores.
entire lifter assembly if any part Measure the diameter of each
shows pitting, scoring, galling or journal in at least four places to de-
evidence of non-rotation. Replace termine out-of-round. taoer or un-
the entire assembly if the plunger is dersize condition (Fig. 29).
not free in the body. The plunger On engines used with a manual-
should drop to the bottom of the shift transmission, check the fit of
body by its own weight when the clutch pilot bearing in the bore
assembled dry. of the crankshaft. The bearing is
APPLY TORQUE UNTIL CLICK A VS B = VERTICAL TAPER
IS HEARD. READ Torque C VS D = HORIZONTAL TAPER
A VS C AND B VS D = OUT-OF-ROUND
Wrench AND MULTIPLY
READING BY CHECK FOR OUT-OF.ROUND AT
TWO 12). EACH END OF JOURNAL

FIG. 28 -Valve Spring

I
Squareness I
The lift of the camshaft lobes can '
SET KNOB TO
COMPRESSED
LENGTH
OF SPRING
be checked with the camshaft in-
stalled in the engine or on centers.
\
___,
' ','J~~---------~~
Refer to Camshaft Lobe Lift.
Check the distributor drive gear FIG. 29 -Crankshaft Jownal
FIG. 27 -Valve Spring Pressure for broken or chipped teeth. Measurements
8-18 GROUP 8- ENGINE

pressed into the crankshaft and lation to the piston skirt and ring pre-ignition. A shiny surface on the
should not be loose. grooves. thrust surface of the piston, offset
Inspect the pilot bearing for rough- Abnormal connecting rod bearing from the centerline between the pis-
ness, evidence of overheating or loss wear can be caused by either a bent ton pin holes, can be caused by a
of lubricant. Replace it if any of these connecting rod, an improperly ma- bent connecting rod. Replace pis-
conditions are found. chined crilnkpin, or a tapered con- tons that show signs of excessive
FLYWHEEL-MANUAL-SHin necting rod bore. wear, wavy ring lands or fractures
TRANSMISSIONS Twisted connecting rods will not or damage from detonation or pre-
INSPECTION create an easily identifiable wear ignition.
pattern, but badly twisted rods will Check the piston to cylinder bore
Inspect the flywheel for cracks, disturb the action of the entire pis- clearance by measuring the piston
heat checks, or other defects that ton, rings and connecting rod as- and bore diameters. Refer to the
would make it unfit for further sembly and may be the cause of specifications for the proper clear-
service. Machine the entire pres- excessive oil consumption. ance. Refer to Cylinder Block In-
sure plate mounting surface of the
flywheel if it is scored or worn. Inspect the connecting rods for
Ring Groove Cleaner
If it is necessary to remove more signs of fractures and the bearing
than 0.045 inch of stock from the bores for out-of-round and taper.
original thickness, replace the fly- If the bore exceeds the recommend-
wheel. ed limits and/ or if the connecting
Inspect the ring gear for worn, rod is fractured, it should be re-
chipped or cracked teeth. If the placed.
teeth are damaged, replace the ring Check the J.D. of the connecting
gear. rod piston pin bore. Replace the
With the flywheel installed on the connecting rod if the pin bore is
crankshaft, check the flywheel fac·e not within specifications.
runout, following the procedure in Replace defective connecting rod
Section 1. nuts and bolts.
If the connecting rod has been
FLYWHEEL-AUTOMAnC removed from the piston it should
TRANSMISSION be checked for bend or twist before
INSPECI'ION assembling it to the piston. Con- FIG. 30 -Cleaning Ring Grooves
necting rods can be checked for -Typical
Inspect the flywheel for cracks
or other defects that would make bend or twist while assembled to
it unfit for further service. Inspect the piston. Check the connecting spection for the bore measurement
the starter ring gear for worn, rods for bend or twist on a suitable procedure. Measure the o:o. of the
chipped or cracked teeth. If the alignment fixture. Follow the in- piston with micrometers at the cen-
teeth are damaged, replace the structions of the fixture manufact- terline of the piston pin bore and
ring gear and flywheel assembly. urer. If the bend and/ or twist ex- at 90° to the pin bore axis.
With the flywheel installed on the ceeds specifications, the connecting Check the ring side clearance fol-
crankshaft, check the gear face run- rod must be straightened or re- lowing the procedure und<:r Fitting
out and outside diaQleter runout of placed. Piston Rings in Section 2 page 8-14.
the flywheel (refer to Section 1 for PISTONS, PINS AND RINGS Replace piston pins showing signs
the proper procedure). of fra~...ure, etching or wear. Check
CLEANING
the piston pin fit in the piston
Remove deposits from the piston and rod. Refer to Pistons and Con-
CONNECTING RODS
surfaces. Clean gum or varnish from necting Rods Assembly in the per~
CLEANING the piston skirt, piston pins and tinent engine section.
Remove the bearings from the rod rings with solvent. Do not use a Check the O.D. of the piston pin
and cap. Identify the bearings if caustic cleaning solutio& or a wire
they are to be used again. Clean the and the l.D. of the pin bore in the
brush to clean pistons. Clean the piston. Replace any piston pin or
connecting rod in solvent, including r!ng grooves with a ring groove
the rod bore and the back of the piston that is not within specifica-
cleaner (Fig. 30). Make sure the oil tions.
inserts. Do Dot use a caustic cleaaJaa ring slots (or holes) are clean.
solution. Blow out all passages with Replace all rings that are scored,
compressed air. INSPECTION chipped or cracked. Check the end
Carefully inspect the pistons for gap and side clearance. It is good
INSPECTION fractures at the ring lands, skirts practice to always install new rings
The connecting rods and related and pin bosses, and for scuffed, when overhauling an engine. Rings
parts should be carefully inspected rough or scored skirts. If the lower should not be transferred from one
and checked for conformance to inner portion of the ring grooves piston to another regardless of
specifications. Various forms of en- has a high step, replace the piston. mileage.
gine wear caused by these parts can The step will interfere with ring MAIN AND CONNECTING
be readily identified. operation and cause excessive ring ROD BEARINGS
A shiny surface on the pin boss side clearance. CLEANING
side of the piston usually indicates Spongy, eroded areas near the Clean the bearing inserts and caps
that a connecting rod is bent or the edge of the top of the piston are thoroughly in solvent, and dry them
piston pin hole is not in proper re- usually caused by detonation or with compressed air. Do not scrape
PART 8-1-GENERAL ENGINE SERVICE 8-19
aum or vualsh depoalts from the cracks. Minute cracks not visible to ._CENTER LINE OF ENGINE - A
bearing shells. the naked eye may be detected by W AT
INSPECI10N coating the suspected area with a RIGHT
• ANGLE
Inspect each bearing carefully. mixture of 25% kerosene and 75% , TO
Bearings that have a scored, chipped light motor oil. Wipe the part dry CENTER
LINE OF
or worn.surface should be replaced. and immediately apply a coating of ENGINE
Typical examples of bearing failures zinc oxide dissolved in wood alcohol.
and their causes are shown in Fig. If cracks are present, the coating a
PARALLEL
31. The copper lead bearing base will become discolored at the de- TO
may be visible through the bearing fective area. Replace the block if CENTER
LINE OF
overlay. This does not mean that the it is cracked.

.
ENGINE
bearing is worn. It is not necessary Check all machined gasket sur-
to replace the bearing if the bearing faces for burrs, nicks, scratches and .-
clearance is within recommended scores. Remove minor imperfections 1. OUT-OF-ROUND : DIFFERENCE BETWEEN
A AND a
limits. Check the clearance of bear- with an oil stone. Check the ftatness 2. TAPER : DIFFERENCE BETWEEN THE A
ings that appear to be satisfactory of the cylinder block gasket surface MEASUREMENT AT TOP OF
CYLINDER BORE AND THE A
with Plastigage. Fit new bearings following the procedure and specifi- MEASUREMENT AT BOTIOM OF
following the recommended pro- cations recommended for the cylin- CYLINDER BORE
cedure in the pertinent part of der head. The cylinder block can FIG. 32 -Cylinder Bore
Group 8. be machined to bring the cylinder
CYLINDER BLOCK head gasket surface within the fiat- Out-of-Round and Taper
CLEANING ness specifications, but not to exceed Use the finest grade of honing stone
0.010 inch stock removal. for this operation.
After any cylinder bore repair Replace all expansion-type plugs
operation, such as honing or de- OIL PAN
that show evidence of leakage. CLEANING
glazing, clean the bore(s) with soap Inspect the cylinder walls for
or detergent and water. 'Then, Scrape any dirt or metal particles
scoring, roughness or other signs of from the insidr of the pan. Scrape
thoroughly rinse the bore(s) with wear. Check the cylinder bore for
clean water to remove the soap or all old gasket material from the gas-
out-of-round and taper. Measure the ket surface. Wash the pan in a sol-
detergent, and wipe the bore(s) dry bore with an accurate gauge follow-
with a dean, Hnt-free doth. FinaUy, vent and dry it thoroughly. Be sure
ing the instructions of the manufac- all foreign particles are removed
wipe the bore(s) with a dean doth turer. Measure the diameter of each
dipped in engine oil. If these pro- from below the batHe plate.
cylinder bore at the top, middle and INSPECTION
cedures are not foUowed, nudq of bottom with the gauge placed at
the cyHnder bore(s) may occur. Check the pan for cracks, holes,
right angles and parallel to the cen- damaged drain plug threads, a loose
If the engine is disassembled, terline of the engine (Fig. 32). Use
thoroughly clean the block in sol- batHe, and a nicked or warped gas-
only the measurements obtained at ket surface.
vent. Remove old gasket material 90° to the engine centerline when Repair any damage, or replace the
from all machined surfaces. Remove calculadng the piston to cyHnder
all pipe plugs that seal oil passages; pan if repairs can not be made.
bore clearance.
then clean out all the passages.
Blow out all passages, bolt holes, Refinish cylinders that are deep-
etc., with compressed air. ly scored and/or when out-of-round
Make sure the threads in the and/ or taper exceed the wear li~its.
cylinder head bolt holes are clean. If the cylinder walls have m10or
Dirt in the threads may cause bind- surface imperfections, but the out-
ing and result in a false torque of-round and taper are within limits,
reading. Use a tap to true-up it may be possible to remove the
threads and to remove any deposits. imperfections by honing the cyl-
INSPECTION inder walls and installing new serv-
After the block has been thor- ice piston rings providing the piston
oughly cleaned, make a check for clearance is within specified limits.
I FIG. 33 -outer Ract to Housing
Clearance
OIL PUMP
CLEANING
Wash all parts in a solvent and
IMPROPER SEATING dry them thoroughly with com-
pressed air. Use a brush to clean the
inside of the pump housing and the
pressure relief valve chamber. Be
sure all dirt and metal particles are
removed.
INSPECTION
Refer to the specifications for
FIG. 31 -Typical a..ing Failures clearances and wear limits.
8-20 GROUP 8-ENGINE

Check the inside of the pump sion. If the spring tension is not with- Clean the rubber hoses with a
housing and the outer race and rotor in specifications and/ or the spring is low-volatility, petroleum-base sol-
for damage or excessive wear. defective, replace the spring. vent and dry with compressed air.
Check the mating surface of the Check the relief valve piston for
pump cover for wear. If the cover scores and free operation in the bore.
mating surface is worn, scored or POSITIVE CRANKCASE
grooved, replace the cover. VENTILATION SYSTEM
Measure the outer race to housing Refer to Group 19 for the correct
clearance (Fig. 33) which should be mileage interval for maintenance.
to specifications. CLEANING
With the rotor assembly installed Do not attempt to clean the crank-
in the housing so that the identi- case ventilation regulator valve. It
fication mark on the outer race is should be replaced at the specified
toward the bottom of the pump, mileage intervals (Group 19). FIG. 34 -Rotor End Play
place a straight edge over the rotor The oil filler tube breather cap,
assembly and the housing. Measure located on the valve rocker arm
the clearance (rotor end play) be- cover should be cleaned at the
tween the straight edge and the rotor specified interval. Remove the cap
and outer race (Fig. 34). and wash it in a low-volatilty, petro-
1be outer race, abaft and rotor are leum-base solvent. Probe the brea-
replaceable only a an assembly. ther hole(s) to assure r,.moval of
Check the drive shaft to housing any accumulated deposits. Shake the
bearing clearance by measuring the cap dry and install it. Do not dry
OD of the shaft and the ID of the with compressed air as air pressure
housing bearing. may damage the filter element.
Check the rotor tip clearance as Clean the crankcase ventilauon
shown in Fig. 35. system connection on the carbu-
Inspect the relief valve spring for retor spacer by probing the inlet FIG. 35 -Checking Pump Rotor
a collapsed or worn condition. nipple with a flexible wire or bottle
Check the relief valve spring ten- brush. Tip Clearance
REFERENCE TO SERVICE INFORMAnON AND NOTES

Date Letter No. Pa1e Brief Detail

8-22

PART
8-2 200,250C.I.D. SIX CYLINDER ENGINES

Section Page Sectior• Page

1 Description and Operation 8-22 Camshaft Rear Bearing Bore Plug
Manifolds 8 -22 Replacement 8-32
Cylinder Head 8-22 Hydraulic Valve Lifter .... 8-32
Cylinder Block 8-23 Main and Connecting I:od Bearing
Valve Train 8-23 Replacement 8 - 33
Lubrication System 8-23 Pistons and Connecting Rods .. . . 8-34
Crankcase Ventilation .... 8-24 Flywheel 8-36
Cooling System .. .. 8 -25 Clutch Pilot Bushing }{eplarement 8-36
2 In-Car Adjustments and Repairs 8-26 Oil Filter Replacement .... 8-36
Engine Supports 8-26 Oil Pan 8-36
Manitolds Remove and Replace 250 2 V &- 27 Oil Pump . . . . . . . . . .. . .. .. . . . . 8-37
Exhaust Manifold 8-27 3 Engine Removal and Installation 8 -38
Valve Rocker Arm Shaft Assembly 8-27 4 Major Repair Operations 8-39
Cylinder Head 8-28 Ct·ankshaft 8- 39
Valve Spring Retainer and Stem Seal Camshaft Bearing Replacement 8- 40
Replacement 8-29 Cylinder Assembly RE- placemen t 8 -41
Cylinder Front Cover and Timing Chain 8-30 Cylinder Block Replacement 8-41
Camshaft 8-31 Engine Disassembly 8- 41
Engine Assembly 8-42

II DESCRIPTION AND OPERATION

The 200 and 250 six-cylinder

engines (Figs. 1, 2 and 3) are avail-
able with optional high and low
compression ratios (refer specifica-
tions).

MANIFOLDS
Exhaust gases provide the heat
necessary to assist in vaporizing the
incoming fuel mixture.

CYLINDER HEAD
The cylinder bead carries the
valves, valve rocker arm shaft assem-
bly, integrally cast intake manifold,
the coolant outlet and thermostat.
Valve guides are integral with the
bead. The valves are arranged from
front to rear E-1-1-E-1-E-E-1-E-1-1-E. FIG. 1 -Typical Left View
PART 8-2- 200, 250 C.I.D. SIX CYLINDER ENGINES 8-23

CYLINDER BLOCK
The cylinders are numbered from
1 to 6 starting at the front of the en-
gine. The firing order is 1-5-3-6-2-4.
The distributor, located on the left
front of the engine, drives the oil
pump through an intermediate drive
shaft.
The crankshaft is supported by
seven main bearings. Crankshaft and
thrust is controlled by the flanges of
the No. 5 main bearing.

The pistons have two compression

rings and one oil control ring. The
top compression ring is molybdenum
·coated and the lower compression
ring is phosphate-coated. The oil
control ring assembly consists of a
serrated spring and two chrome-
plated steel rails.
VALVE TRAIN
The Six cylinder engines utilize
hydraulic valve lifters to provide
zero lash. The operation and parts
identification of the hydraulic valve 2S0-2v
lifters are shown in (Fig. 4). When FIG. 2-Typical Front View
the valve is closed, the lifter assembly becomes a hydraulic ram which pass valve and mounting gasket.
is on the base circle of the camshaft forces the valve in the cylinder head The by-pass valve permits oil to
lobe and the valve push rod is in to open. During this period, a slight by-pass the filter if it becomes
its lowest position. With the lifter leakage of oil past the plunger occurs clogged, thereby maintaining an
assembly in this position, the plunger (calibrated leak down rate). emergency supply of oil to the
spring expands, forcing the plunger As the high point of the camshaft engine at all times. An anti-drain
upward. This action is transmitted lobe rotates and passes by the foot back diaphragm prevents a reverse
to the valve rocker arm via the of the valve lifter, the valve in the flow of oil when the engine is
valve push rod until there is solid cylinder head seats and the valve stopped.
contact between the valve and the lifter assembly is forced downward.
valve end of the valve rocker arm Reduced force on the lifter plunger From the filter, the oil flows into
(zero valve lash). at . this time relieves the pressure on the main oil gallery. The oil gallery
As the lifter plunger moves up- the lifter plunger and it is free to be supplies oil to all the camshaft and
ward, the volume of the compression moved upward by the plunger spring. main bearings through a drilled
chamber is increased, resulting in This action allows oil to flow once passage in each main bearing web.
reduced oil pressure in the compres- again through the oil holes in the The timing chain and sprockets
sion chamber. Therefore, to equalize lifter body and plunger. are splash-lubricated from the oil
the resulting pressure differential be- The operating cycle is completed pan.
tween the supply chamber and the for each revolution of the camshaft. An oil slinger prevents leaka6e by
compression chamber, the disc valve Zero clearance (lash) in the valve directing oil away from the crank-
moves off its seat and permits oil to train mechanism is maintained at all shaft rear oil seal.
times by the hydraulic force and ex-
flow from the supply chamber to the pansion of the plunger spring be- Cylinder walls, pistons and piston
compression chamber. When the tween the lifter body and plunger. pins are lubricated through a drilled
compression chamber becomes filled hole in each connecting rod which
with oil, the pressures in the two LUBRICATION SYSTEM indexes with a drilled hole in the
chambers are equalized. The oil flow Oil from the oil pan sump is connecting rod journal of the crank-
ceases and the disc valve spring seats forced through the pressure-type lu- shaft.
the disc valve and closes the disc brication system (Fig. 6) by a rotor Oil from the main gallery feeds
valve port. pump. A spring-loaded relief valve pressure oil to the hydraulic valve
As the camshaft rotates, the lifter in the pump limits the maximum lifters and lubricates the lifter bores
assembly is raised by the camshaft pressure of the system. Oil relieved in the cylinder block. A reservoir at
lobe. This increases the push rod by the valve is directed back to the each valve lifter bore boss traps oil
force against the lifter plunger and intake side of the pump. so that oil is available for valve lifter
hydraulic pressure immedately builds All the oil discharged by the lubrication as soon as the engine
up in the compression chamber until pump passes through a full flow- starts.
it acts as a solid member of the valve type filter before it enters the en- Oil under reduced pressure is fed
operating mechanism . The lifter then gine. The filter has an internal by- to the valve rocker arm shaft assem-
8-24 GROUP 8- ENGINE
ing element which filters the incom-
ing air.
From the oil filler cap, the air
flows into the front section of the
valve rocker arm shaft chamber. The
ventilating air moves down past the
push rods and into the crankcase.
Air is diverted from the front sec-
tion of the crankcase through holes
in the front of the cylinder block
wall to ventilate the timing chain
chamber.
The rotating action of the crank-
shaft causes the air to flow towards
the rear of the crankcase and up into
the rear section of the valve rocker
arm cover. The air then enters a
spring-loaded regulator valve that
regulates the amount of air flow to
meet changing operating conditions.
The air is then directed to the intake
manifold through the crankcase vent
hose and the spacer fitting.
During idle, intake manifold
vacuum is high. The high vacuum
overcomes the tension of the spring
pressure and moves the valve to a
low flow position (Fig. 7). With the
valve in this position, all the venti-
lating air passes through the re-
FIG. 3-TYPICAL i Sectional View stricted passage in the valve. With
A2293·A
the valve in this position, there is
bly through a drilled passage in the case ventilation system is shown in minimum ventilation. As engine
cylinder block at the No. 4 camshaft Fig. 5. speed increases and manifold
bearing. The oil is metered by a Ventilating air enters the engine vacuum decreases, the spring forces
groove in the camshaft journal. The through the oil filler cap located on the valve out of the passage and to
passage in the block indexes with &. the front of the valve rocker arm the full open position (Fig. 7 ). This
hole in the cylinder head. The oil cover. The filler cap contains a filter- increases the flow of ventilating air.
passage in the cylinder bead is drilled
from the cylinder head bolt bore to

7"0C'
the No. 6 valve rocker arm shaft
support. The rocker arm shaft sup-
ports have a square cored bolt
mounting hole for more positive
lubrication of the rocker arms, shafts OIL GALLERY
and valves. The oil flows through the
valve rocker arm shaft through
drilled holes in each rocker arm to
lubricate the valve and the push
rod end of the rocker arm. The ·ex-
cess oil spirals down the rotating
push rod and assists in lubricating
the tappet and push rod seat. An
oil outlet in the No. 1 rocker arm
shaft support, exhausts excess oil
from the valve rocker arm shaft.
The oil from each rocker arm drains
into the push rod chamber through
the push rod bore holes in the cylin-
der head.
The oil in the push rod chamber
drains back into the oil pan through
cored openings in the block.
POSITIVI
CRANKCASE VENTILATION A2132-B
SYSTEM
The air flow in the positive crank- FIG. 4-Hydraulic Valve lifter Operation
PART 8·2-. 200, 250 C.I.D. SIX CYLINDER ENGINES 8-25
COOLING SYSTEM
The coolant is drawn from the
bottom of the radiator by the water
pump which delivers the coolant to
.. the cylinder block (Fig. 8) .
"' As the coolant enters the block, it
travels through cored passages to
cool the entire length of each cylin-
der wall. Upon reaching the rear of
·• the cylinder block, the coolant is
A. directed upward into the cylinder
head where it cools the combustion
chambers, valves, and valve seats on
, "' its return to the front of the engine.
At this point, the coolant tl.ows
into the coolant outlet connection,
past the thermostat if it is open, and
irito the top of the radiator. If the
thermostat is closed, a small portion
of tbe coolant is returned to the
water pump for recirculation . The.
entire system is pressurized to 13-15
psi.

FIG. 5-Positive Crankcase Ventilation System -Typical

......

.......
' .

FIG. 6 -Typical lubrication System

8-26 GROUP 8- ENGINE

TO INTAKE MANIFOLD

LOW SPEED OPERATION-HIGH MANIFOLD VACUUM

HIGH SPEED OPERATION-LOW MANIFOLD VACUUM

FROM CRANKCASE
AND / OR ROCKER
ARM COVER

FIG. 7-Positive Crankcase Ventilation Regulator Valve Operation FIG. 9-Engine Front Support

EJ IN-CAR ADJUSTMENTS AND REPAIRS

4. Remove the insulator assembly.
When installing nuts or bolts that Removal
must be torqued (refer to page 8-70 1. Support the transmission with a Installation
for torque specifications), oil the ftoor jack to relieve weight from the 1. Position the engine rear support
threads with light weight engine oil. supporting crossmember. insulator assembly in place beneath
Do not oU threads that require oU· 2. Remove the retaining nuts, the transmission, and install the
resistant or water-resistant sealer. washers, and cotter keys from the retaining screws. Torque them to
ENGINE FRONT SUPPORT supporting crossmember, and remove specifications.
The procedures given apply to the supporting crossmember. 2. Position the supporting cross-
either a right or left installation. 3. Remove the screws and washers member and install the retaining
The engine front supports are lo- which retain the engine rear support washers and nuts. Torque them to
cated on each side of the cylinder insulator assembly beneath the trans- specifications.
block (Fig. 9) mission. 3. Install the cotter keys. If neces-
Removal
1. Remove the insulator to support
bracket retaining nuts.
2. Using a wood block placed
under the oil pan raise the engine
only enough to clear the insulator
bolts at the frame bracket.
3. Remove the retaining bolt and
nut from the insulator to engine
front support insulator bracket, and
remove the insulator.
Installation
1. Position the insulator to the en-
gine front support insulator bracket
and install the retaining bolt and
nut. Torque to specifications.
2. Carefully lower the engine guid-
ing the insulator bolts into the frame
bracket.
3. Install the insulator to frame
bracket retaining nuts and torque to
specifications.
ENGINE REAR SUPPORT
The rear support is located at
the transmission extension housing
(Fig 10) FIG. 8 -Cooling System
PART 8-2- 200, 250 C.I.D. SIX CYLINDER ENGINES 8-27

2. Loosen the alternator belt ad- 2. Remove the effilSSion control

~ justing arm and remove the drive belt,
and swing the alternator outboard as
system vent hose and valve assembly.
3. Remove the carburettor to fuel
I j pump pipe and the carburettor to
far as the mounting brackets will

it
allow. distributor vacuum line.
3. Loosen the muffler inlet pipe 4. Remove the valve rocker arm
to manifold extension pipe clamp and cover and discard the gasket.
free the pipe at the join. 5. Remove the rocker arm shaft
4. Remove the bolts manifold to support bolts by loosening the bolts
I cylinder head and remove the mani-
fold from the vehicle.
two turns at a time in sequence. Re-
move the rocker arm shaft assembly
INSTALLATION (Fig. 11). Remove the valve push
1. Remove all the old gasket mat- rods.
erial from the cylinder head and mani-
fold.
FIG. 10 - Engine Rear Support 2. Using new gaskets assemble the
sary, contmue tightening the two manifold to the cylinder head and
outer nuts as required to align the torque the bolts to specification.
castellations. 3. Connect the muffler inlet pipe
to the manifold extension and torque FIG. 11- Valve Rocker Arm
the clamp to specification.
4. Install the alternator drive belt Shaft Removal
INTAKE MANIFOLD REPLACE·
MENT. 250-2V ENGINE ONLY. and adjust to specification. INSTALLATION
REMOVAL 5. Install the intake manifold as
1. Apply Lubriplate to both ends
1. Remove the aircleaner. described in previous operation.
of the push rods and to the valve
2. Remove the manifold hot water stem tip.
hoses. EXHAUST MANIFOLD 2. Install the valve push rods. Po-
3. Remove the fuel line fuel fil. REMOVAL
sition the valve rocker arm shaft
ter to carburettor. 1. Remove the air cleaner. Dis- assembly on the cylinder head.
4. Remove choke tubes, throttle connect the muffler inlet pipe from 3. Install and tighten all valve
linkage, distributor vacuum and crank· the exhaust manifold. rocker arm support bolts, two turns
case emission tubes. l. Bend the exhaust manifold re- at a time in sequence, until the sup-
5. Remove the bolts manifold to taining bolt lock tabs back and re- ports fully contact the cylinder head.
cylinder head and remove the mani- move the retaining bolts. Remove Torque the bolts to specifications.
fold. the exhaust manifold. 4. If any part which could affect
6. Remove the carburettor from the valve clearance has been
the manifold. CLEANING AND INSPECfiON changed, check the valve clearance
Refer to page 8-15 for the cleaning following the procedure outlined un-
INSTALLATION and inspection procedures. der Valve Clearance-Six cylinder
1. Clean all old gasket material INSTALLATION engines (page 8-11 ).
from the cylinder head and manifold. 1. Clean the mating surfaces of S. Clean the valve rocker arm
2. Apply sufficient grease to the the exhaust manifold and cylinder cover and cylinder head gasket sur-
manifold gaskets to hold them in head. Inspect manifold to muffler faces. Coat one side of a new gasket
position whilst the manifold is being inlet pipe sealing ring. with an oil resistant sealer and lay
fitted. l. Apply graphite .. grease to the the cemented side of the gasket in
3. Position the gaskets on the mating surface of the exhaust mani- place on the cover. Install the cover,
cylinder head or manifold and assem· fold. making sure the gasket seats evenly
ble the manifold to the cylinder head. 3. Position the exhaust manifold around the head. Tighten the cover
4. If previously removed install the on the cylinder head and install retaining bolts in two steps. First,
carburettor on the manifold using a the retaining bolts and tab washers. torque the bolts to specifications;
new flange gasket. Working from the center to the ends, then, retorque to the same specifi-
5. Install choke tubes, throttle torque the bolts to specifications. cations two minutes after initial
linkage, distributor vacuum and crank· Lock the bolts by bending one tab of tightening.
case emission tubes. the washer over a flat on the bolt. 6. Install the emission control
6. Install the fuel line filter to 4. Place sealing ring on the mut- system hose and valve assembly.
carburettor. fter inlet pipe. Position the muffler 7. Install the air cleaner.
7. Install the aircleaner. inlet pipe to the manifold. Install
8. Start engine and check carbur- DISASSEMBLY
and torque the retaining nuts to
ettor adjustment. specifications. 1. Remove the pin and spring
5. Install the air cleaner. Start the washer from each end of the valve
engine and check for exhaust leaks. rocker arm shaft.
EXHAUST MANIFOLD REPLACE- 1. Slide the valve rocker arms,
VALVE ROCKER ARM springs, and supports off the shaft.
MENT. 250 2V ENGINE ONLY.
REMOVAL SHAn ASSEMILY Be sure to identify the parts.
1. Remove the intake manifold as REMOVAL 3. If it is necessary to remove the
previously outlined. 1. Remove the air cleaner plugs from each end of the shaft,
8-28 GROUP 8- ENGINE

drill or pierce the plug on one end. RETAINING SOL T

6A527
Use a steel rod to knock out the (
plug on the opposite end. Working .~370347·5
from the open end, knock out the
• & Ill ·
remaining plug.
lJ ·.J).fl)•i /SUPPORT

,.J!J)'-i
6531 ROCKER ARM
CLEANING AND INSPECTION • / 6564
/SPRING
Refer to page 8'-15 for the cleaning tlil , - 6587
and inspection procedures. ~W ·1J;-~
'REPAIRS
Refer to page 8-39 for the repair
sHAFT
6563
l.l! PulJJo.
PLUG
ft • ,
6572 ., /JI))ni/IJ
procedures. ~o;SPRING ,
, WASHER
ASSEMBLY 1 6598
FRONT OF ENGINE -....:_- - PIN
1. Lubricate all parts with engine ........._372929-S
oil. Apply Lubriplate to the valve
and push rod ends of the rocker FIG. 12- Valve Rocker Arm Shaft Assembly -Typical
arm.
l. If the plugs were removed the cylinder head and blOck as the 6. The cylinder head bolts are
from the ends of the shaft, use a gasket surfaces may become dam- tightened in three progressive steps.
blunt tool or large diameter pin qed. Torque all the bolts in sequence (Fig.
punch and install a plug, cup side Note: On 250-2V engines the inlet 15) to 55 ft-lbs, then to 65 ft-lbs,
out, in each end of the shaft. and exhaust manifolds must be re- and finally to specifications. After
3. Install the spring. washer and moved before the cylinder head can the cylinder head bolts have been
pin on one end of the shaft. be removed. torqued to specifications, the bolts
4. Install the valve rocker arms, should not be disturbed.
supports, and springs in the order INSTALLATION 7. Apply Lubriplate to both ends
shown in (Fig. 12) Be sure the oH Note: On 250-2V engines the cyl- of the push rods. Install the push
holes in the shaft are fadnc dowa- inder head is replaced first followed rods in their original bores, position-
ward. Complete the assembly by ID- by the exhaust manifold then the inlet ing the lower end of the rods into
stalllng the remaining spring washer manifold. See page 8-27 for detail. the tappet sockets. Apply Lubriplate
and pin. to the valve stem tips and to the
CYLINDER HEAD 1. Clean the head and block gas- rocker arm pads.
REMOVAL ket .surfaces. If the cylinder head was 8. Install the valve rocker arm
1. Drain the cooling system. Re- removed for a gasket change, check shaft assembly following steps 1 to
move the air cleaner. the flatness of the cylinder head and 4 under Valve Rocker Arm Shaft
l. Disconnect the muffler inlet block. Install guide studs at each Installation.
pipe at the exhaust manifold. Pull the end of the cylinder block (Fig. 14). Check the valve clearance, fol-
muffler inlet pipe down . lowing the procedure outlined under
3. Disconnect the accelerator rod Valve Clearance (Part 8-1, Section
.. '
2).
retracting spring. Disconnect the
accelerator rod at the carburetor. 15 (i)· 0 0 .e ~ ~ ~ ~ < .;~ "- 9. Install the muffler inlet pipe
4. Disconnect the fuel inlet line at
the fuel filter hose, and the distribu-
~~~~,t~~
., •
..l~~?lt.Tl
/AI" f~
{ ""' 11 ~.
.~r-1 ~~ '
{ ·· -·. - . .. -a.. . . • . • ,
lock washers and retaining nuts.
Torque the nuts to specifications.
tor vacuum line at the carburetor. 10. Connect the radiator upper
5. Remove the radiator upper hose hose at the coolant outlet housing.
at the coolant outlet housing. FIG. 13- Valve Push Rod 11. Replace the valve rocker arm
Removal cover and torque to specifications.
6. Disconnect the distributor vac- 12. Replace the emission control
uum line at the distributor. Discon- 2. Do not apply sealer to six system vent hose and valve assembly.
nect the carburetor fuel inlet line cylinder engine head gaskets.
at the fuel pump. Remove the lines Position the gasket over the guide
studs on the cylinder block. 7 / 16"-14x6" BOLT. CUT OFF HEAD, TAPER
as an assembly. END AND SLOT FOR SCREWDRIVER.
7. Disconnect the spark plug 3. Inspect the muffler inlet pipe
wires at the spark plugs and the sealing ring and replace if necessary.
temperature sending unit wire at the 4. Lift the cylinder head over the
sending unit. guides and slide it down carefully,
8. Remove the emission control guiding the exhaust manifold studs
system vent hose and valve assembly. into the muffler inlet pipe. FIG. 14- Cylinder Head
9. Remove the valve rocker arm 5. Coat the thread of No. 13 bolt Guide Studs
cover. with a small amount of water-resist-
10. Remove the valve rocker arm ant sealer. Install, but do not tighten
shaft assembly. Remove the valve two bolts at opposite ends of the 13. Position the distributor vac-
push rods in sequence (Fig. 13). head to hold the head and gasket in uum line and carburettor fuel inlet
11. Remove the remaining cyl- position. Remove the guides and line on the engine, then connect the
inder head bolts and remov-e . the install the remaining bolts. distributor vacuum line at the carbu-
cylinder head. Do not pry betweea Refer Fig.l5 for No. 13 bolt . rettor.
PART 8-2-. 200, 250 C.I.D. SIX CYLINDER ENGINES 8-29

1 14•• Connect the accelerator rod CLEANING AND INSPECTION and overloading the camshaft lobes
retracting spring. Connect the ac- Refer to page 8-15 for the cleaning which would lead to spring breakage
celerator rod at the carburettor. and inspection procedures. and wom camshaft lobes.
15. Connect the distributor vac-
uum line at the distributor. Connect
the carburettor fuel inlet line at the
fuel pump.
16. Connect the temperature send- ASSEMBLY
ing unit wire at the sending unit.
1. If the cylinder head is being
Conrtect the spark plug wires. Be
replaced, install the manifold assem-
sure the wires are forced aU the way
down into their sockets. bly except on 2V installations. Lub-
17. Fill and bleed the cooling ricate the valve guides and valve stems
system. with engine oil. Apply Lubriplate to
18. Start the engine and check for the tip of the valve stems.
coolant and oil leaks. 2." Install each valve (Fig. 17) in
the valve guide from which it was
DISASSEMBLY removed or to which it was fitted. UNDERSIDE OF SURFACE OF
SPRING RETAINER SPRING PAD
1. Remove deposits from the Install a new stem seal on the valve.
combustion chambers and valve 3. Install the valve spring assem- FIG. 18- Valve Spring
heads with a scraper and a wire bly over the valve. Install the spring Assembled Height
brush before removing the valves. Be retainer. VALVE SPRING, RETAINER
careful not to scratch the cylinder 4. Compress the spring and install AND STEM SEAL
head gasket surfaces. the retainer locks (Fig. 16).
REPLACEMENT
5. Measure the assembled height
Broken valve springs or defective
LOCKS\ valve stem seals and retainer may be
6518
replaced without removing the cyl-
RETAINER~~~
6514 13'
inder head, provided damage to the
valve or valve seat has not occurred.
~) 1. Remove the air cleaner. Re-
;p~~~~-..
6513
move the crankcase ventilation regu-
lator valve from the valve rocker arm
OIL SEAL cover. Remove the fuel and vacuum

~~·~· #M~'
FIG. 15 -Cylinder Head Bolt pipes then remove the valve rocker
arm cover. Remove the applicable
Torque Sequence spark plug.
2. Loosen the valve rocker arm
2. Compress the valve springs
(Fig. 16). Remove the valve retainer
65~ shaft support bolts 2 turns at a time,
in sequence, until the valve spring
locks and release the spring. pressure is relieved. Remove both
3. Remove the spring retainer, INTAKE
valve push rods of the cylinder to
stem seal, and valve. Discard the VALVE be serviced.
6~07
valve stem seals. Identify all valve 3. Install an air line with an
parts. If the cylinder head is to be re- adapter in the spark plug hole.
placed, remove the manifold assem- 4. Tighten the retaining bolts just
bly. enough to seat the rocker arm shaft
supports on the cylinder head. Push
the rocker arm to one side and secure
FIG. 17- Typical Valve it in this position (Fig. 19). To move
Assembly the rocker arm on either end of the
shaft, it will be necessary to remove
of the valve spring from the surface the retaining pin and spring washer
of the cylinder head spring pad to and slide the rocker arm off the shaft.
the underside of the spring retainer 5. Turn on the air supply. Air
with dividers (Fig. 18). pressure may turn the crankshaft un-
6. Check the dividers against a til the piston reaches the bottom of
scale. If the assembled height is its stroke. Using the valve spring
greater than specifications, install the compression tool shown in (Fig. 19)
necessary 0.030-inch thick spacer(s) compress the valve and remove the
between the cylinder head spring pad valve spring retainer locks, the spring
and the valve spring to bring the as- retainer and the valve spring.
sembled height to the recommended If air pressure fails to bold the valve
dimension. Do not install spacers un- in the closed position during this op-
less necessary. Use of spacers in ex- eration, it can be presumed that the
FIG. 16- Compressing Valve cess of recommendations will result valve is not seating or is damaged.
Spring - On Bench -Typical in overstressing the valve springs H this condition occurs, remove the
8-30 GROUP 8- ENGINE

cylinder head for further inspection. Tum off the air and remove the air 2. Coat a new seal with grease
6. Remove the valve stem seal line and adapter. Install the spark and install the seal. Drive the seal in
(Fig. 20). If air pressure has forced plug and spark plug wire. until it is fully seated in the recess.
the piston to the bottom of the cyl· 10. Jnstall the rocker arm shaft
inder, any removal of air pressure by following the instructions under
will allow the valve(s) to faD into the Rocker Arm Shaft Assembly Instal-
cylinder. A rubber band, tape or lation.
string wrapped around the end of the 11. Replace the emission control
valve stem will prevent this condition system vent hose and valve assembly.
and will still allow enough travel to 12. Repjace the fuel pipe and
check the valve for binds. vacuum lines.
13. In.stall the valve rocker arm
cover.
14. Install the air cleaner. TIMING MARKS A 1370-B
CYLINDER FRONT COVER FIG. 21 -Aligning Timing
AND TIMING CHAIN Marks
REMOVAL (Fig. 23). Check the seal after instal-
1. Drain the cooling system and lation to be sure the spring is
the crankcase. Disconnect the radia- properly positioned in the seal.
tor upper hose at the coolant outlet
housing and the radiator lower hose
at the water pump. On a car with
automatic transmission. disconnect
the transmission oil cooler lines from
the radiator.
2. Remove the radiator. Remove
the drive belt, fan and pulley. Using
FIG. 19- Compressing Valve tool6306 AG. Remove the crankshaft
Spring - In Chassis damper.
7. Install a new valve stem seal. 3. Remove the cylinder front cov-
Position the spring over the valve. er and gasket. FIG. 22 - Timing Chain and
Install the spring retainer and sleeve. 4. Rotate the crankshaft in a Sprockets Removal
Compress the valve spring and install clockwise direction (as viewed from
the valve spring retainer locks. the front) to take up the slack on CLEANING AND INSPECTION
8. Apply Lubriplate to both ends the left side of the chain. Refer to page 8-17 for the cleaning
of the push rod, the valve and push 5. Establish a reference point on and inspection procedures. Clean the
rod ends of the rocker arm, and the the block and measure from this crankshaft damper following the ref-
valve stem tip. Remove the rocker point to the chain. Rotate the crank- erenced procedures.
arm shaft and install the push rod(s), shaft in the opposite direction to
making sure the lower end of the take up the slack on the right side INSTALLATION
rod is positioned in the valve lifter 1. Oil the timing chain. Position
of the chain. Force the left side of
push rod cup. the chain out with the fingers and the sprockets and timing chain on
9. Remove the wire securing the measure the distance hetween the the camshaft and crankshaft. Be sure
valve rocker arm and slide the rock- reference point and the chain. The the timing marks on the sprockets
er arm into position. If an end valve deflection is the difference between and chain are positioned as shown in
rocker arm was removed, slide it the two measurements. If the deflec-
into position on the shaft and install tion exceeds t inch, replace the
the spring washer and retaining pin. timing chain and sprockets.
6. Crank the engine until the tim-
in~ marks are aligned as shown in
(Fig. 21). Remove the camshaft
sprocket retaining bolt and washer.
Slide both sprockets and timing
chain forward and remove them as
an assembly (Fig. 22).
7. Remove the oil pan and related
parts.
FRONT OIL SEAL
REP'LACEMENT
It is good practice to replace the
oil seal each time the cylinder front
cover is removed.
1. Drive out the oil seal with a
FIG. 20- Valve Stem Seal pin punch. Clean the recess in the FIG. 23 - Crankshaft Front Oil
Removal cover Seal Replacement
PART 8-2-, 200, 250 C.I.D. SIX CYLINDER ENGINES 8-31

(Fig. 21). Install the camshaft

sprocket retaining bolt and washer.
WASHER
Torque the bolt to specifications. 6278

2. Clean the cylinder front and

the gasket surface of the cylinder (~
block. Apply oil-resistant sealer to t
a new cylinder front cover gasket and 371643-S
CAMSHAFT
position the gasket on the cylinder
front cover. Install the cylinder front
cover using the tool shown in Fig.
24. Torque the retaining bolts to FIG. 25 -Camshaft and Related Parts
specifications.
4. Disconnect the fuel inlet line and release it. Compare the dial
and the distributor vacuum line from indicator reading with specifications.
the carburettor. If the end play is excessive, replace
5. Disconnect the muffler inlet the thrust plate.
pipe frotn the exhaust manifold. 15. Remove the dial indicator.
Pull the muffler inlet pipe iown. Remove the timing chain and
Remove the gasket. sprockets following steps 4 and 5
6. Disconnect the distributor vac- under "Cylinder Front Cover and
uum line from the distributor. Dis- Timing Chain Removal."
connect the carburettor fuel inlet 16. Remove the camshaft thrust
line from the fuel pump. Remove plate. Carefully remove the cam-
the lines as an assembly. shaft by pulling it toward the front of
7. Disconnect the spark plug wires the engine. Use caution to avoid
from the spark plugs and the coil damaging the journals and lobes.
high tension lead at the coil. Remove
the distributor cap and spark plug etm -z
FIG. 24- Cylinder Front Cover wires as an assembly. Disconnect
the primary wire from the coil and
3. Lubricate the hub of the crank- remove it from the retaining clip on
shaft damper with Lubriplate to the cylinder head.
prevent damage to the seal during
installation or initial engine start. 8. Disconnect the engine temper-
Using tool6306 AG, install the crank- ature sending unit wire from the
shaft damper. Torque the retaining sending unit. Disconnect the flexible
bolt to specifications. fuel line from the fuel tank line
and plug the line. Remove the dis-
4. Install the oil pan and related
tributor, the fuel pump, and the oil Magn;l
parts.
filter.
5. Install the fan, pulley and drive 9. Remove the crankcase vent hose, FIG. 26 -Valve Lifter
belt. Adjust the drive belt. regulatQr val~e, valve rocker arm
6. Install the radiator. Connect Removal
cover and cylinder head by following
the radiator upper and lower hoses. steps 8 through 11 under Cylinder
7. Fill and bleed the cooling sys- Head Removal- page 8-28. INSTALLATION
tem. Fill the crankcase with the 10. Using a magnet, remove the
proper quantity and grade of engine valve lifters and keep them in order 1. Clean the oil passage that feeds
oil. so that they can be installed in their the rocker arm shaft by blowing
8. Start the engine and check the original location (Fig. 26). compressed air into the opening in
ignition timing. Operate the engine 11. Lqosen and remove the drive the block. Oil the camsh:tft jour-
belt, fan and pulley. Remove the nals and apply Luhriplate to all the
at fast idle and check all hose con-
nections and gaskets for leaks. crankshaft damper using tool 6306 camshaft lobes. Carefully slide the
AG. camshaft through the bearings.
12. Remove: the oil level dipstick. 2. Install the thrust plate with
CAMSHAn
Remove the oil pan. Remove the oil the oil groove toward the rear of
The camshaft and related parts the engine and torque the retaining
are shown in Fig. 25. pump and inlet tube assembly.
13. Remove the cylinder front bolts to specifications. Replace the
REMOVAL cover and gasket. Remove the crank- crankshaft front oil seal.
1. Drain the cooling system and the shaft front oil slinger. 3. Follow steps l, 2 and 3 under
crankcase. Remove the air cleaner. 14. Push the camshaft toward the Cylinder Front Cover and Timing
2. Disconnect the radiator hoses rear of the engine. Install a dial Chain Installation and install the
from the coolant outlet housing and indicator so that the indicator point sprockets and timing chain, oil sling-
the water pump. Remove the radia- is on the camshaft sprocket cap er, cylinder front cover and crank-
tor. Remove the grille. screw (Fig. 27). Zero the dial indi- shaft damper.
3. Disconnect the accelerator rod cator. Position a large screw driver 4. Clean the oil pump inlet tube
retracting spring. Disconnect the between the camshaft sprocket and screen, and oil the pan and block
accelerator rod from the carburettor. the block. Pull the camshaft forward gasket surfaces. Prime the oil pump
8-32 GROUP 8- ENGINE

and install the oil pump inlet tube and adjust the ignition t1ming. Con-
and oil pump and the oil pan and nect the distributor vacuum line to
related parts. Install thP. oil level the distributor. Check for coolant
jipstick. and oil leaks. Adjust the engine idle
5. Install the fan and fan pulley speed and the idle fuel mixture.
and drive belt. Adjust the belt ten-
CAMSHAn REAR BEARING
sion . . Install the radiator and the
grille. BORE PLUG REPLACEMENT
6. Dip the valve lifter foot in Lu- 1. On a car with a manual-shift
briplate. Coat the remainder of each transmission, slide the transmissi(ln
valve lifter with engine oil. Install to the rear and :.:emove the clutch
the valve lifters in their original pressure plate and disc following the
bores. procedure in Group 5.
7. Install the cylinder head, push On a car with automatic transmis-
rods and the valve rocker arm shaft sion, remove the transmission and FIG. 29 -Camshaft Rear
assembly by following steps 1 to converter housing following the pro-
9 under Cylinder Head Installation. cedure in Group 7. Bearing Bore Plug
8. Using a new gasket, install the 2. Remove the flywheel retaining Installation
fuel pump and connect the flexible bolts and remove the flywheel and
fuel ,Jine. Install the oil filter. engine rear cover plate. HYDRAULIC VALVE LinER
9. Position the No. 1 piston at 3. Drill a t -inch hole in the cam- REPLACEMENT
TDC after the compression stroke. shaft rear bearing bore plug and 1. Remove the cylinder head and
t osition the distributor in the block use a suitable tool to remove the related parts following the procedure
with the rotor at the No. 1 firing plug (Fig. 28). under Cylinder Head Removal.
position and the breaker points open.
2. Using a magnet, remove the
Install the distributor hold down
valve lifters (Fig. 26). Place the lift-
clamp.
ers in a rack so they can be installed
10. Connect the engine tempera- in their original positions.
ture sen.ding unit wire. Connect the If the lifters are stuck in their
coil primary wire. Install the dis- bores by excessive varnish or gum, it
tributor cap. Connect the spark plug may be necessary to use a plier-type
wires and the coil high tension lead. tool to remove the lifters . Rotate the
lifter back and forth to loosen the
gum and varnish which may have
formed on the lifter.
The internal parts of each hy-
draulic valve lifter assembly are
matched sets. Do not intermix the
parts. Keep the assemblies intact
until they are to be cleaned.
3. Install new (or cleaned) hy-
FIG. 28 -Camshaft Rear draulic valve lifters through the push
rod opening£ with a magnet (Fig.
Bearing Bore Plug 26).
Removal 4. Install the cylinder head and
related parts.
4. Clean out the plug bore recess
DISASSEMBLY
thoroughly.
Each valve lifter is a matched as-
FIG. 27 -Camshaft End 5. Coat the flange of a new plug
with oil resistant ·sealer and install sembly; therefore, the parts are not
Play it with the flange facing out and interchangeable. Disassemble and as-
slightly below the chamfer in the semble each lifter carefully, keeping
bore (Fig. 29). the assemblies in proper sequence so
11. Install the carburettor fuel 6. Install the engine rear cover they will be installed in their orig-
inlet line Connect the distributor plate, apply oil-resistant sealer to inal bores.
vacuum line to the carburettor. the flywheel bolts and install the 1. Grasp the lock ring with
12. Install the radiator and con- flywheel. needle nose pliers to release it from
nect the radiator upper and lower On a car with a manual-shift the groove. It may be necessary to
hoses. transmission, install the clutch pres- depress the plunger to fully release
13. Connect the accelerator rod sure plate, disc, and transmission the lock ring.
retracting spring. Connect the accel- following the procedure in Group 5. 2. Remove the push rod cup,
erator rod at the carburettor. On a car with automatic transmis- plunger and spring.
14. Fill and bleed the cooling sys- sion install the transmission and con- 3. Invert the plunger assembly
tem. Fill the crankcase. verter housing following the proce- and remove the check valve retainer
15. Start the engine and check dure in Group 7. by carefully prying up on it with a
PART 8·2-, 200, 250 C.I.D. SIX CYLINDER ENGINES 8-33
screwdriver. Remove the check valve Standard bearings are divided into PLACE Plastigage FULL
CHECK WIDTH OF
two sizes and are identified by a WIDTH OF JOURNAL
and spring. Plastigage
ABOUT Y4 INCH OFF
daub of red or blue paint. Refer to CENTER
CLEANING AND INSPECI'ION the Parts Catalog for the available
sizes. Red marked bearings increase
Refer to page 8-17 for the cleaning --~-
the clearance; blue marked bearings
and inspection procedures.
decrease the clearance. Undersize
bearings, which are not selective fit,
ASSEMBLY are available for use on journals
A typical hydraulic valve lifter that have been refinished.
assembly is shown in Fig. 30. MAIN BEARING
1. Drain the crankcase. Remove

ll'
the oil leyel dipstick. Remove the oil 0.0015"
pan and related parts. CLEARANCE
2. Remove the oil pump inlet
M'ASO.,NG
tube assembly and the oil pump. INSTALLING Plastig age
3. Replace one bearing at a time, Plastigage
leaving the other bearings securely
fastened . Remove the main bearing FIG. 31 -Installing and
cap to which new bearings are to be Measuring Plastigage-
installed.
4. Insert the upper bearing re- Engine Installed
moval tool in the oil hole in the
crankshaft. width of the Plastigage, check at the
LIFTER ASSEMBLY-6500
S. Rotate the crankshaft in the di- widest point in order to get the mini-
mum clearance. Check at the nar-
FIG. 30-Typical Valve rection of engine rotation to force
the bearing out of the block. rowest point in order to get the max-
Lifter Assembly 6. Clean the crankshaft journal. imum clearance. The difference be-
When replacing standard bearings tween the two readings is the taper.
with new bearings, it is good prac- 13. If the clearance is less than
1. Place the plunger upside down the specified limits, try two red bear-
on a clean work bench. tice to first try to obtain the proper
clearance with two blue bearing ing halves or a combination of red
2. Place the check valve in posi- and blue, depending upon the condi-
halves.
tion over the oil hole on the bottom tion .
of the plunger. Set the check valve 7. To install the upper main bear- If the clearance exceeds specified
spring on top of the check valve. ing, place the plain end of the bear- limits, try 0.002 inch undersize
3. Position the check valve retain- ing over the shaft on the locking bearings in combination with blue
er over the check valve and spring tang side of the block and partially or red bearings. The b<'aring clear-
and push the retainer down into install the bearing so that the tool ance must be within specified limits.
place on the plunger. can be inserted in the oil hole in If 0.002 inch undersize main bear-
4. Place the plunger spring and the crankshaft. With the tool posi- ings are used on more than one
then the plunger (open end up) into tioned in the oil hole in the crank- journal, be sure they are all installed
the tappet body. shaft, rotate the crankshaft in the on the same side (cap or cylinder
S. Place the push rod seat in the opposite direction of engine rotation block) of the crankshaft.
plunger. until the bearing seats itself. Remove If the standard and 0.002 inch
6. Depress the plunger and posi- the tool. undersize bearings do not bring the
tion the closed end of the lock ring clearance within the desired limits,
8. Install the cap bearing.
in the lifter body groove. Release the refinish the crankshaft journal; then
plunger; then depress it again to 9. Support the crankshaft so that install undersize bearings.
fully seat the lock ring. its weight will not compress the 14. If the rear main bearing is re-
Plastigage used in Step 10 and pro- placed, replace the lower oil seal in
CLEANING AND INSPECTION vide an erroneous reading. Position the rear main bearing cap as follows:
a jack so that it will bear against the Remove and discard the rear seal.
Refer to page 8~18 for the cleaning
counterweight adjoining the bearing If there is evidence of oil seal leak-
and inspection procedures.
which is being checked. age, the upper half of the oil seal
10. Place a piece of Plastigage on must also be replaced to assure sat-
MAIN AND CONNECTING
the bearing surface the full width of isfactory sealing.
ROD BEARING REPLACEM~NT the bearing cap and about 1/.! inch Clean the mating surfaces of the
The main bearing inserts are off center (Fig. 31). block and rear main bearing cap,
selective fit. Do not file or lap 11. Install the cap and torque the and the rear journal oil seal groove.
bearing caps or use bearing shims bolts to specifications. Do not turn Preform the new seal by hand to
tO obtain the proper bearing clear- the crankshaft while the Plastigage the approximate radius of the cap.
ance. is in place. Insert the seal in the oil seal
Selective fit main bearings are 12. Remove the cap. Using the groove, seating the center of the seal
available for service in standard Plastigage scale, check the width of first with the seal extending equally
sizes and 0.002 inch undersize. the Plastigage. When checking the on both ends. Press the seal down
8-34 GROUP 8- ENGINE

firmly with the thumb at the center 19. Position the oil pan gaskets on fitted with undersize bearings.
of the seal, then press both ends of the oil pan. Position the oil pan front After the bearing has been fit-
the seal into the groove working seal on the cylinder front cover. ted, clean and apply a light coat of
from the ends to the center. Position the oil pan rear seal on the engine oil to the journal and bear-
Position the seal forming tool as rear main bearing cap. Install the oil ings. Install the connecting rod cap.
shown in Fig. 32 and complete the pan and related parts. Install the oil Torque the nuts to specifications.
seal installation. After installation, level dipstick. 11. Repeat the procedure for the
cut the ends of the seal flush. 20. Fill the crankcase. Start the remaining connecting rods that re-
Apply a thin coating of oil resist- engine and check for oil pressure. quire new bearings.
ant sealer to the rear main bearing Operate the engine at fast idle and 12. Follow steps 18 through 20
cap at the rear of the top mating check for oil leak~. under Main Bearing Replacement.
surface (Fig. 32 ). Do not apply
sealer to the area forward of the CONNECTING ROD BEARING
oil slinger groove. 1. Follow steps 1 and 2 under
The upper oil seal in the block Main Bearing Replacement.
cannot be replaced with the crank- 2. Turn the crankshaft until the
shaft installed. connecting rod to which new bear-
15. After the bearing has been ings are to be fitted is down. Remove
fitted, apply a light coat of engine the connecting rod cap. Remove the
oil to the journal and bearings, then bearing inserts from the rod and
install the bearing cap. Torque the cap.
cap bolts to specifications. 3. Be sure the bearing inserts and
16. Repeat the procedure for the the bearing bore in the connecting NOTCH TO FRONT OF ENGINE
remaining bearings that require re- rod and cap are clean. Foreign mate-
placement. rial under the inserts will distort the FIG. 33 .-Piston
17. If the thrust bearing cap bearing and cause a failure. Installation
(No. 5 main beating) has been re- 4. Clean the crankshaft journal.
moved, install it as follows: 5. Install the bearing inserts in CLEANING AND INSPECDON
the connecting rod and cap with the
Install the thrust bea,ring cap with tangs fitting in the slot provided. Refer to page 8 -18 for the cleaning
the bolts finger-tight. Pry the crank- 6. Pull the connecting rod assem- and inspection procedures.
shaft forward against the thrust sur- bly down firmly on the crankshaft
face of the upper half of the bearing
journal. PISTONS AND
7. Place a . piece of Plastigage on CONNECTING RODS
the lower bearing surface, the full
width of the cap and about 1-4 inch REMOVAL
off center. 1. Drain the cooling system and
8. Install the cap and torque the the crankcase.
connecting rod nuts to specification. 2. Refer to Cylinder Head Re-
Do not tum the crankshaft while moval and remove the cylinder
the Plastigage Is in place. head and related parts.
9. Remove the cap; then, using 3. Remove the oil pan and related
the Plastigage scale, check the parts. Remove the oil pump inlet
width of the Plastigage. When tube and the oil pump.
checking the width of the Plastigage, 4. Turn the crankshaft until the
check at the widest point in order piston to be removed is at the bot-
to get the minimum clearance. tom of its travel and place a cloth
Check at the narrowest point in on the piston head to collect the cut-
order to get the maximum clearance. tings. Remove any ridge and/ or de-
The difference between the two posits from the upper end of the
readings is the taper. cylinder bores. Remove the cylinder
FIG. 32 -Seal to Rear 10. If the clearance is less than ridge with a ridge cutter. Follow the
Bearing Cap Installation the specified limits, try two red bear- instructions furnished by the tool
ing halves or a combination of red manufacturer. Never cut into the
and blue depending upon the con- ring travel area in excess of 1/32
dition. inch when removing ridges.
(Fig. 47). Hold the crankshaft for- 5. Make sure all the connecting
ward and pry the thrust bearing cap If the clearance exceeds the spe- rod caps are marked so that they
to the rear (Fig. 47). This will align cified limits, try 0.002 inch under- can be installed in their original po-
the thrust surfaces of both halves of size bearings in combination with sitions. Remove the connecting rod
the bearing. Retain the forward pres- blue "or red bearings. The bearing cap.
sure on the crankshaft. Torque the clearance must be within specified 6. Push the connecting rod and
cap bolts to specification. Umits•. piston assembly out the top of the
18. Clean the oil pump inlet tube If proper clearance cannot · be cylinder with the handle end of a
screen. Prime the oil pump; then achieved with standard or 0.002 hammer. Avoid damage to the crank-
install the oil pump and the inlet undersize bearings, the crankshaft pin or the cylinder wall when re-
tube assembly. will have to be ground undersize and moving the piston and rod.
PART 8-2- 200, 250 C.I.D. SIX CYLINDER ENGINES 8-35

INSTALLATION
1. Clean the oil pump inlet tube
scr~en, and the oil pan and block
gasket surfaces.
2. Oil the piston rings, pistons and

FIG. 34-Typical
Connecting Rod Side
Clearance ~
'
r
INSERT
cylinder walls with light engine oil. ERED PILOT
3. Be sure to install the pistons in PISTON PIN
the same cylinders from which they
were removed, or to which they were
fitted. The connecting rod and bear- Tool- T68P-6 J 35 . A
Cup Detail J
ing caps are numbered from 1 to 6
beginning at the front of the engine.
The numbers on the connecting rod
and bearing cap must be on the same
side when installed in the cylinder
bore. If a connecting rod is ever
transposed from one block or cylin·
der to another, new bearings should
be fitted and the connecting rod FIG. 35 - Removing Piston Pin
should be numbered to correspond 9. Prime the oil pump. Install the
with the new cylinder. oil pump and the oil pump inlet
4. Make sure the ring gaps are tube. Install the oil pan and related FIG. 36 -Typical Piston,
properly spaced around the circum- parts.
ference of the piston. Install a piston
Connecting Rod and
10. Install the cylinder head by
ring compressor on the piston and following steps 1 through 17 under Related Parts
push the piston in with a hammer Cylinder Head Installation. REPAIRS
handle until it is slightly below the 11. Fill the crankcase.
top of the cylinder (Fig. 33). Be 12. Start the engine and check To fit new pistons, pins or rings,
sure to guide the connecting rods to for oil pressure. Operate the engine refer to page 8-14
avoid damaging the crankshaft jour- at fast idle and check for oil and
nals. Install the piston with the notch coolant leaks. ASSEMBLY
in the piston head toward the front 13. Check and adjust the ignition The piston, connecting rod and
of the engine. timing, engine idle speed and the related parts are shown in Fig. 36.
5. Check the clearancP. of each fuel mixture. Check the fit of a new piston In the
bearing following the procedure 14. Install the air cleaner. cyUnder bore before assembUog the
und"r "Connecting Rod Bearing Re- piston and piston pin to the connect-
placement." DISASSEMBLY Ing rod.
6. After the bearings have been 1. Remvve the bearing inserts The piston pin bore of a connect·
fitted, apply a light coat of engine from the connecting rod and cap. ing rod and the diameter of the pis-
oil to the journals and bearings. 2. Mark the pistons and pins to ton pin must be within specifica-
7. Turn the crankshaft throw to assure assembly with the same rod tions. Refer to page 8-69.
the bottom of its stroke, then push and installation in the same cylin- 1. Apply a light coat of engine
the piston all the way down until the ders from which they were removed. oil to all parts. Assemble the piston
connecting rod bearing seats on the 3. Remove the piston pin from to the connecting rod with the on
crankshaft journal. Install the con- the piston and connecting rod usinl squirt hole In the connectblg rod
necting rod cap. Torque the nuts to the tool shown in Fig. 35. Remove and the indentation in the piston
specifications. the piston rings. positioned as shown in F1g. 37.
8. After the piston and connect- 2. Start the piston pin in the piston
ing rod assemblies have been in- CLEANING AND INSPECJ'ION and connecting rod (this may require
stalled, check the connecting rod a very light tap with a mallet). Using
side clearance on each crankshaft Refer to page 8·18 for the cleaning an Arbor Press, press the piston pin
journal (Fig. 34). and inspection procedures. through the piston and connecting
8-36 GROUP 8- ENGINE

rod until the pin is centered in the l. On a manual-shift transmission,

piston. install the clutch pressure plate, disc,
3. Check the end gap of all piston and the transmission following ...the
rings. It must be within specifica- procedures in Group S.
tions. Follow the instructions con- On a car with automatic transmis-
tained on the piston ring package sion, install the converter housing
and install the piston rings. and transmission following the pro-
4. Check the ring side clearance cedure in Group 7. It is not neces-
of the compression rings with a feel- sary to adjust the transmission, when
er gauge. Refer to Fitting Piston it bas been removed only for fly-
Rings on page 8-14. wheel removal.
5. Be sure the bearing inserts and
the bearing bore in the connecting CLUTCH PILOT BEARING
rod and cap Me clean. Foreign mate- REPLACEMENT
rial under the inserts will distort the Inspection procedures are outlined
bearing and cause a failure. Install under Flywheel Cleaning and In-
the bearing inserts in the connecting spection on page 8-17.
rod and cap with the tangs fitting 1. Remove the transmission, clutch FIG. 39 -Typical Clutch
in the slots provided. pressure plate, and disc following the Pilot Service Bearing
procedures in Group S.
FLYWHEEL
2. Using suitable tools, remove the
Installation
REMOVAL pilot bearing (Fig. 38). 3. Operate the engine at fast idle,
and cht!ck for oil leaks. If oil leaks
1. On a manual-shift transmis- 3. Coat the pilot bearing bore in are evident, perform the necessary
sion, remove the tran.>mission, dutch the crankshaft with a small quantity repairs to correct the leakage. Check
pressure plate and disc, following of wheel bearing lubricant. Avoid the oil level and fill the crankcase if
the procedures in Group S. Do not using too milch lubricant as it may necessary.
drain the transmission. be thrown onto the clutch disc when
On a car with automatic transmis- the clutch revolves. OIL PAN
sion, remove the transmission and 4. Using suitable tool install the REMOVAL
converter housing following the pro- pilot service bearing (Fig. 39).
cedure in Group 7. Do not drain the 1. Drain the crankcase.
CLUTCH PILOT BEARING. l. Remove the oil level dipstick
transmission.
l. Remove the flywheel retaining and the flywheel housing inspection
bolts and remove the flywheel. cover.
3. Remove the stabilizer bar.
CLEANING AND INSPECDON 4. Remove the oil pan and gasket.
Refer to page 8-18 for the cleaning 5. Remove the oil pump inlet
and inspection procedures. tube and screen assembly.
REPAIRS
To check flywheel face runout, CLEANING AND INSPECI'ION
refer to page 8-10. Refer to Page 8-19 for the
cieaning and inspection procedures.
INSTALLATION
1. Position the ~ywheel on the INSTALLATION

t
FRONT OF ENGINE
1. Clean and install the oil pump

I FIG. 38 -Typical Clutch

Pilot Bearing Removal
5. Install the clutch pressure plate,
disc, and the transmission following
the procedures in Group 5.
INDENTATION
NOTCH
OIL FILTER REPLACEMENT
1. Place a drip pan under the
FIG. 37-Typical Piston filter. Unscrew the filter from the
adapter fitting. Clean the adapter
and Connecting Rod filter recess.
Assembly l. Coat the gasket on the replace-
crankshaft flange. Apply oil-resistant ment filter with oil. Position the filter
sealer to the retaining bolts. Install on the adapter fitting. Hand tighten
and torque the bolts in sequence the filter unfil the gasket contacts FIG. 40 -Oil Pump Inlet
across from each other to specifi- the adapter face, then advance it lh
cations. turn. Tube· Installed
PART 8·2-, 200, 250 CJ.D. SIX CYLINDER ENGINES 8-37

5. Hold the oil pan in place 3. Position a new gasket on the

against the block and install a bolt, pump housing. Insert the intermed-
finger-tight, on each side of the oil iate drive shaft :nto the oil pump.
pan. Install the remaining bolts. Install the pump and shaft as an as-
Torque the bolts from the center sembly. Do not attempt to force the
outward in each direction to speci- pump into position if it will not seat
fications. readHy. The drive shaft hex may be
6. Install the stabilizer bar. misaligned with the distributor shaft.
To align, rotate the intermediate
drive shaft into a new position.
Torque the oil pump retaining
screws to specifications.
4. Install the oil pan and related
parts as outlined under Oil Pan In-
stallation.

DISASSEMBLY
1. Remove the oil inlet tube from
the oil pump and remove the gasket.
2. Remove the cover retaining
screws, and remove the cover. Re-
move the inner rotor and shaft as-
sembly, and remove the outer race.
INLET TUBE ~......... 3. Insert a self-threading sheet
ASSEMBLY •
34806 5
GASKET metal screw of the proper diameter
6622~ 6626 into the oil pressure relief valve
• • ·t-34806-S
20346
chamber cap and· pull the cap out of
20426·5
the chamber. Remove the spring and
plunger.

-Typical Oil
FIG. 42 CLEANING AND INSPECTION
Refer to Page 8'-19 for
Pump Assembly the cleaning and inspection proce-
7. Install the oil level dipstick. dures.
Fill the crankcase with the proper
grade and quantity of engine oil. ASSEMBLY
FIG. 41-Oil Pan Gaskets Operate the engine and check for The oil pump assembly is shown
oil leaks. in Fig. 42.
and Seals Installed
OIL PUMP 1. Oil all parts thoroughly.
inlet tube and screen assembly (Fig. 2. Install the oil pressure relief
40). REMOVAL
valve plunger, spring, and a new cap.
2. Clean the gasket surfaces of the 1. Remove the oil pan and re- 3. Install the outer race, and the
block and oil pan. The oil pan has a lated parts as outlined under Oil inner rotor and shaft assembly. Be
two-piece gasket. Coat the block sur- Pan Removal. sure the Identification mark on the
face and the oil pan gasket sur- 2. Remove the oil pump retain- rotor and on the outer race both
face with oil-resistant sealer. Position ing bolts and remove the oil pump, face to the bottom of the pump. The
the oil pan gaskets on the cylinder gasket, and intermediate drive shaft. inner rotor and shaft, and the outer
block (Fig. 41). race are serviced as an assembly.
3. Position the oil pan front seal on INSTALLATION
One part should not be replaced
· the cylinder front cover (Fig. 41). 1. Prime the oil pump by filling
without replacing the other. InstaD
Be sure the tabs on the seal are either the inlet or outlet port with
engine oil. Rotate the pump shaft to the cover and torque the cover re-
over the oil pan gasket.
distribute the oil within the pump taining screws to specifications.
4. Position the oil pan rear seal on
the rear main bearing cap (Fig. 41). body. 4. Position a new gasket and the
Be sure the tabs pn the seal are 2. Position the intermediate drive oil inlet tube on the oil pump and
over the oil pan gasket. shaft into the distributor socket. install the retaining bolts.
8-38 GROUP 8- ENGINE

EJ ENGINE REMOVAL AND INSTALLATION

REMOVAL
1. Remove the bonnet. slave cylinder from the clutch hous- 4. Remove the engine lifting
l. Drain the cooling system and ing and suitably support it clear of hooks. Install the flywheel or con·
the transmission. verter housing upper retaining bolts.
the crankcase.
3. Remove the air cleaner. Dis- 11. Raise the car. Remove the fly- 5. On 250-2V engines install the
connect the battery ground cable at wheel or converter housing upper re- starter motor and the exhaust and
the cylinder head, and at the battery. taining bolts through the access inlet manifolds as described on page 8·27
Disconnect the radiator upper hose holes in the underbody. 6. Remove the jack from the
at the water outlet housing and the 12.. Disconnect the muffler inlet transmission. Raise the car.
radiator lower hose at the water pipe at the exhaust manifold. Loosen 7. Remove the guide pin and in-
pump. On a car with automatic the inlet pipe clamp and slide it off stall the flywheel or converter hous-
transmission disconnect the transmis- the support bracket on the engine. ing lower retaining bolts.
sion oil cooler lines from the radi- Disconnect the engine right and left On a car with automatic trans-
ator. mount at the underbody bracket. Re- mission, attach the converter to the
4. Remove the radiator. Remove move the flywheel or converter hous- flywheel and torque the retaining
the drive belt, fan, and pulley. ing cover. nuts to specifications.
5. On a car equipped with air On a car with a manual-shift 8. Install the flywheel orconverter
conditioning remove the compressor, transmission, remove the flywheel housing dust cover.
leaving hoses attached. Place a suit- housing lower retaining bolts. On a car with a manual-shift
ably sized sheet of hardboard or On a car with automatic transmis· transmission, install the clutch equal-
similar material between the air con- sion, disconnect the converter from izer shaft and arm bracket. Connect
ditioning heat exchanger and the the flywheel. Remove the converter the clutch retracting spring.
engine to prevent accidental damage housing lower retaining bolts. 9. Install the engine left and right
occurring to the exchanger. Lower the car. Support the mount to the underbody bracket. In-
6. Disconnect the heater hoses transmission and flywheel or con- stall the sediment bowl on the fuel
from the water pump. Disconnect verter housing with a jack. pump.
the alternator wires from the al- 13. Attach the engine lifting hook 10. Remove the plug from the fuel
ternator, the starter cable from the (Fig. 43). Carefully lift the engine tank line and connect the flexible
starter, the accelerator rod and the out of rne engine compartment. In- fuel line to the fuel tank line. Install
choke control cable from the car- stall the engme on a work stand. the exhaust manifold to muffler inlet
burettt>r. pi~ retaining lock washers and nuts.
Torque the nuts to specifications.
Position the inlet pipe clamp on the
support bracket on the engine and
INSTALLATION tighten the clamp.
11 . Lower the car. Connect the
1. Install guide pins in the fly· oil pressure and the engine temper-
wheel or converter housing bolt holes ature sending unit wires. Connect
in the rear of the engine. Place a the coil primary wire. Connect the
new gasket over the studs of the ex- accelerator rod. Connect and adjust
haust manifold. the choke control cable.
l. Carefully lower the engine into 12. Install the starter motor. Con-
the engine compartment. nect the starter cable. Connect the
3. Make sure the studs on the ex· alternator wires. Connect the battery
A2017-A haust manifold are aligned with the ground cable.
boles in the muffler inlet pipe and 13. Remove the hardboard and
FIG. 43 -Engine Lifting the guide pins in the block engage install the air conditioning com-
Hook the holes in the flywheel housing. pressor. Install the pulley, fan, and
7. Disconnect the flexible fuel On a car with automatic transmis- drive belt. Adjust the drive belt
line at the fuel tank line and plug sion, start the converter pilot into tension. Install the radiator. Con-
the fuel tank line. the crankshaft. nect the radiator upper and lower
8. Disconnect the coil primary On a car with a manual-shift hoses. Fill and bleed the cooling
wire at the coil. Disconnect the oil transmission, start the transmission system. Fill the crankcase with the
pressure and the water temperature main drive gear into the clutch disc. proper grade and quantity of engine
sending unit wires at the sending It may be necessary to adjust the oil.
units. position of the transmission in rela- 14. Install and adjust the bonnet.
9. On 250-2V engines remove the tion to the engine if the input shaft 15. Operate the engine at fast idle
inlet and exhaust manifolds as des· will not enter the clutch disc. U the and check all gaskets and hose con-
cribed on page 8-27. eDgine lump up after tbe shaft nections for leaks.
10. Remove the starter. enten, tum the Cl'llllksWt slowly On a car with automatic trans-
On a car with a manual-shift (tnmsmisslon la lear) undl the sWt mission, check the transmission con-
transmission, disconnect the clutch spUnes mesh with the clutch disc trol linkage (Group 7).
retracting spring. Disconnect the 5pUnes. 16. Install the air cleaner.
PART 8-2- 200, 250 C.I.D. SIX CYLINDER ENGINES 8-39

rJ MAJOR REPAIR OPERATIONS

CLUTCH POLOT BEARINu
7600

MAIN BEARING CAPS

BOLT-6345A A2230-C

FIG. 44-Typical 200 & 250 Six Crankshaft

To perform the operations in this 5. Invert the engine on the work imperfections, etc., refer to Page 8-1 4
section, it will be necessary to re- stand. Remove the flywheel. Remove Section 2.
move the engine from the car and the oil pan and gasket. Remove the INSTALLATION
install it on a work stand. oil pump.
When installing nuts or bolts that 1. Remove the rear journal oil
6. Make sure all bearing caps seal from the block and rear main
must be torqued (refer to Page 8-70 (main and connecting rod) are
for torque specifications), oil the bearing cap.
marked so that they can be installed l. Remove the main bearing in-
threads with light weight engine oil. in their original locations. Turn the
Do not oU threads that require «~H­ serts from the block and bearing
crankshaft until the connecting rod caps.
resistant or water-resistant sealer.
from which the cap is being removed 3. Remove the connecting rod
CRANKSHAFT is down. Remove the connecting rod bearing inserts from the connecting
REMOVAL cap. Push the connecting rod and rods and caps.
The crankshaft and related parts piston assembly up in the cylinder. 4. Clean the rear journal oil seal
are shown in Fig. 44. grooves. Install a new rear journal
Repeat for the remaining caps.
oil seal in the block (Fig. 45) and
1. Loosen the alternator adjust- 7. Remove the main bearing caps. rear main bearing cap (Fig. 32) .After
ing bolts and remove the fan belt. 8. Carefully lift the crankshaft installation, cut the ends of the seals
Remove the oil level dipstick. out of the block so that the thrust ftush.
2. Remove the accessory drive
pulley (if so equipped). Remove bearing surfaces are not damaged. 5. Apply a thin coating of oil re-
the crankshaft damper retaining bolt Handle the cranuhaft with care to sistant sealer to the rear main bear-
and washer. Remove the crankshaft avoid possible fracture or daDulp ing cap at the rear of the top mating
vibration damper using tool 6306 to the fioisbed surfaces. surface (Fig. 32) . Do not apply seal-
AG. CLEANING AND INSPECTION er to the ana forward of the oU
3. Remove the cylinder front Refer to page 8-17 for the cleaning Jlla&er groove.
cover. and inspection procedures. Be sure 6. If the crankshaft main bearing
4. Check the timing chain de- the oil seal surfaces on the crank- journals have been refinished to a
flection, then remove the timing shaft and crankshaft damper are definite undersize, install the correct
chain and sprockets by following properly cleaned. undersize bearings. Be sure the bear-
steps 4 and 5 under Cylinder Front REPAIRS ing inserts and bearing bores are
Cover and Timing Chain Removal. To refinish journals, dress minor clean. Foreign material under the in-
8-40 GROUP 8- ENGINE

PLACE Plostigoge FULL CHECK WIDTH defective or dirty, they probably

WIDTH OF JOURNAL OF Plostigoge
were not aligned properly. Install
ABOUT '/4 INCH
OFF CENTER
the thrust bearing and align the faces
following the recommended proced-
ure (steps 12, 13, 14, and 15).
Check the end play which should
be within specifications.
20. Install new bearing inserts in
PLASTIGAGE the connecting rods and caps. Check
A1023-A the clearance of each bearing fol-
lowing the procedure under Con-
FIG. 46 -Installing
and necting Rod Bearing Replacement.
Measuring Plastigage- 21. If the bearing clearances are
Engine on Work Stand to specifications, apply a light coat
of engine oil to the journals and
17. lnstail a dial indicator so that bearings.
the contact point rests against the 22. Turn the crankshaft throw to
crankshaft flange and the indicator the bottom of its stroke. Push the
axis is parallel to the crankshaft axis piston all the way down until the
rod bearing seats on the crankshaft
~ journal.
A1397-B 18. Zero the dial indicator. Push
the crankshaft forward and note the 23. Install the connecting rod cap.
FIG. 45-Rear Oil Seal to reading on the dial. Torque the nuts to specifications.
Block Installation 19. If the end play exceeds speci- 24. After the piston and connect-
ing· rod assemblies have been in-
serts will distort the bearina and fications, replace the thrust bearing.
stalled, check the connecting rod
cause a failure. If the end play is less than the mini-
side clearance on each connecting
mum limit, inspect the thrust bear-
7. Place the upper main bearing rod crankshaft journal (Fig. 34)
ing faces for scratches, burrs, nicks,
inserts in position in the bores with 25. Turn the engine on the work
or dirt. If the thrust faces are not
the tang fitting in the slot provided. stand so that the front end is up. In-
8. Install the lower main bearing stall the timing chain and sprockets,
inserts in the bearing caps. cylinder front cover and crankshaft
9. Carefully lower the crankshaft pulley or damper, following steps 1
into place. Be careful not to damage thru 3 under Cylinder Front Cover
the bearing surfaces. and Timing Chain Installation.
10. Check the clearance of each 26. Clean the oil pan, oil pump,
main bearing. Place a piece of and oil pump screen.
Plastigage on the crankshaft journal 27. Prime and install the oil
the full width of the journal and pump following steps 1, 2, and 3
about ! inch off centre (Fig. 46). under Oil Pump Installation. Install
Follow steps 11 through 13 under the oil pan following steps 2
Main Bearing Replacement. through 5 under Oil Pan Installa-
11. After the bearings have been tion.
fitted, apply a light coat of engine
28. Position the flywheel on the
oil to the journals and bearings.
crankshaft. Apply oil-resistant sealer
Install all the bearing caps, except
the thrust bearing cap No.5 bearing. to the flywheel retaining bolts. Install
Be sure that the main bearing and torque the retaining bolts to
caps are installed in their orig- specifications.
On a flywheel for a manual-shift
inal locations. Torque the bearing
transmission, use a suitable tool to
cap bolts to specifications. PRY CAP BACKWARD locate the clutch disc. Install the
12. Install the thrust bearing cap
pressure plate. ·
with the bolts finger-tight.
13. Pry the crankshaft forward 29. Turn the engine on the work
against the thrust surface of the stand so that the engine is in the
upper half of the bearing (Fig. 47). normal position . Install the oil level
14. Hold the crankshaft forward dipstick . Install and adjust the drive
and pry the thrust bearing cap to the belt.
rear (Fig. 47). This will align the 3Q. Remove the engine from the
thrust surfaces of both halves of the work stand and install it in the car.
bearing. CAMSHAFT BEARING
IS. Retain the forward pressure REPLACEMENT
on the crankshaft. Torque the cap The camshaft bearings are avail-
bolts to specifications. FIG. 47-TypicalThrust able pre-finished to size and require
16. Force the crankshaft toward no reaming for standard and 0.015-
the rear of the engine. Bearing Alignment inch undersize journal diameters.
PART 8·2-. 200, 250 C.I.D. SIX CYLINDER ENGINES 8-41

THRUST BEARING at the distributor. Remove the fuel

inlet line and distributor vacuum line
as an assembly.
3. Remove the carburettor and
gasket. Remove the exhaust mani-
fold. (Previously removed on 250-2V)
4. Remove the coil. Remove the
distributor cap and spark plug
wires as an assembly. Remove the
distributor, fuel pump, oil pressure
sending unit, oil filter and oil filter
mounting insert. Remove the spark
plugs.
CAMSHAFT BEARING (LOOSE) 5. Remove the valve rocker arm
cover. Remove the valve rocker arm
FIG. 48- Typical Camshaft Bearing Replacement shaft assembly (Fig. 12) by removing
the support bolts evenly and equally
2 turns at a time.
1. Remove the ftywlleel and the CYLINDER ASSEMBLY 6. Remove the valve push rods in
camshaft. Remove the rear bearing REPLACEMENT sequence and. identify them so that
bore'plug (Fig. 28). they can be installed in their original
2. Remove the camshaft bearings DISASSEMBLY positions (Fig. 13).
with the tool shown in Fig. 48. Follow steps 1 to 3, 5 to 13, and 24 7. Remove all cylinder head bolts.
under Engine Disassembly. Remove Lift the cylinder head assembly off
3. Fit the tool shaft and adaptors
the cylinder assembly from the work the engine. Do not pry between the
to the camshaft bearing tunnel bores, stand.
position two adaptors as guides to bead and block as the gasket sur-
CLEANING faces may become damaged.
locate the shaft and one behind Clean the gasket and seal surfaces
the bearing to be removed, fit the Usi'lg a magnet, remove the valve
of all parts and assemblies (refer to lifters and 'keep them in order so
slotted collar to the shaft behind Page 8-19. they can be installed in their original
the adaptor being used to withdraw ASSEMBLY
the bearing. location (Fig. 26).
Install the replacement cylinder
Ensure that it fits snugly on the block assembly on a work stapd. On a flywheel for a manual-shift
shaft. Attach the U plate on the Transfer all parts removed from the transmission, mark the pressure plate
front of the shaft, the pin engaging old cylinder assembly to the new cover so that it can be replaced in
with the keyway in the shaft. Fit cylinder assembly, following the pro- the same position. Remove the
the thrust bearing and wing nut, cedures in steps 28 to 44, 47 to 50, 54 clutch . pressure plate and cover
tighten slowly and remove the bear- assembly.
and 56 to 58 under Engine Assembly.
ing from the block. Check all assembly clearances. Remove the flywheel. Remove the
4. Repeat the procedure for each clutch pilot bearing (Fig. 3Y) and
bearing. CYLINDER BLOCK engine rear cover plate.
5. Replacement. Check bearing REPLACEMENT 8. Remove the dipstick and the
bores for scratches and burrs. Posi- DISASSEMBLY oil pan. Discard the gasket and
tion the new bearing on adaptor and seals.
Follow steps 1 to 3, 5 to 19, 21 and
replace with similar procedure as 24 under Engine Disassembly. Re- 9. Remove the oil pump and inlet
for removal. Align the oil holes in move the cylinder assembly from the tube assembly. Discard the oil pump
the bearings with the oil holes in work stand. gasket.
the cylinder block when the bearings CLEANING 10. Loosen the alternator mount-
are installed. Repeat the pro<:edure Clean the gasket and seal surfaces ing bolts and disconnect the alter-
for each bearing. Be sure the front of all parts and assemblies (refer to nator adjusting arm at the water
bearing is installed 0.115" -0.125" Page 8-19. pump. Remove the drive belt.
below the front face of the cylinder ASSEMBLY 11. Remove the alternator, and
block. Install the replacement cylinder the water pump. Remove the crank-
6. Clean out the f amshaft rear block assembly on a work stand. shaft damper. Remove the damper
bearing bore plug recess, thoroughly. Transfer all parts removed from the by using tool 6306 AG.
Coat the flange of a new plug with old cylinder assembly to the new 12. Remove the cylinder front
oil-resistant sealer and install the cylinder assembly, following the pro- cover. Discard the gasket. Check the
plug with the flange edge of the cedures in steps 1 to 4, 6 to 9, 11 to camshaft end play by following step
plug facing outward. 21, 28 to 50, 54 and 56 to 58 under 15 under Camshaft Removal. Check
7. Install the camshaft, crank- Engine Assembly. Check all assembly timing chain deflection by following
shaft, flywheel and related parts, clearances. step 4 under Cylinder Front Cover
following the appropriate procedures Removal.
on page 8 ·3 i , except do not check ENGINE DISASSEMILY 13. Remove the camshaft sprocket
connecting rod and main bearing 1. Disconnect the distributor vac- re.taining bolt and washer. Slide both
clearances as a part of Camshaft uum line at the carburettor. sprockets and the timing chain for-
Bearing Replacement. Install the eng· 2. Disconnect the carburettor fuel ward and remove them as an assem-
ine in the car. inlet line at the fuel pump. Dis- bly (Fig. 22).
connect the distributor vacuum line 14. Remove any ridges and/ or
8-42 GROUP 8- ENGINE
deposits from the upper end of the After installation, cut the ends of necting rods to avoid damaging the
cylinder bores. Remove the cylinder the seals flush. crankshaft journals. Install the pis-
ridges with a ridge cutter. Follow 5. If the crankshaft main bearing ton with the notch in the piston head
the instructions furnished by the tool journals have been refinished to a toward the front of the engine.
manufacturer. Never cut into the definite undersize, install the correct 17. Check the clearance of each
ring travel area in excess of 1/ 32 undersize bearings. Be sure the bear- bearing following the procedure un-
inch when removing ridges. ing bores are clean. Place the upper der Connecting RC>d Bearing Re-
15. Make sure all bearing caps main bearing inserts m position in placement.
(main and connecting rod) are the bore with the tang fitting in the 18. After the bearings have been
marked so they can be installed slot provided. fitted, apply a light coat of engine
in their original locations. Turn 6. Install the lower main bearing oil to the journals and bearings.
the crankshaft until the connecting inserts in the bearing caps. 19. Turn the crankshaft throw to
rod being removed is down. Remove the bottom of its stroke. Push the
7. Carefully lower the crankshaft piston all the way down until the
the connecting rod cap. into place. Be careful not to dam-
16. Push the connecting rod and connecting rod bearing seats on the
age the bearing surfaces. crankshaft journal.
piston assembly out the top of the 8. Check the clearance of each
cylinder with the handle end of a main bearing following steps 10 20. Install the connecting rod cap.
hammer. Avoid damage to the through 13 under Main Bearing Re- Torque the nuts to specifications.
crankpinorthecylinderwall when placement. In step 10, place the 21. After the piston and connect·
removing the piston and rod. Plastigage on the crankshaft jour- ing rod assemblies have been install-
17. Remove the bearing inserts nal instead of in the bearing cap. ed, check the connecting rod side
from the connecting rods and caps. (Fig. 46). clearance on each crankshaft journal
Remove the main bearing caps. 9. After the bearings have been (Fig. 34)
18. Carefully lift the crankshaft out fitted, apply a light coat of engine 22. Lubricate the timing chain
of the cylinder block so that the thrust oil to the journals and bearings. and sprockets with engine oil. Place
bearing surfaces are not damaged. Install all the bearing caps, except the the keys in position in the slots on
Handle the crankshaft with care thrust bearing cap No. 5 bearing. Be the crankshaft and camshaft.
to avoid possible fracture or sure that the main bearing caps 23. Oil the timing chain. Position
damage to the finished surfaces. are installed in their original the sprockets and timing chain on
locations. Torque the bearing cap the camshaft and crankshaft. Be
19. Remove the rear journal oil sure the timing marks on the
seal from the block and rear main bolts to specifications.
10. Install the thrust bearing cap sprockets and chain are positioned as
bearing cap. Remove the main bear- shown in Fig. 21.
ing inserts from the block and by following steps 12 through 15
bearing caps. under Crankshaft Installation. 24. Install the camshaft sprocket
11. Check the crankshaft end play retaining bolt and washer. Torque
20. Remove the camshaft thrust the bolt to specifications.
plate. Carefully remove the camshaft by following steps 17 through 19
by pulling it toward the front of the under "Crankshaft Installation." 25. Clean the cylinder front cover
engine. Use caution to avoia dam- 12. Turn the engine on the work and the gasket surface of the cylinder
aging the journals and lobes. stand so that the front end is up. block.
21. Remove the camshaft rear 13. Oil the piston rings, pistons, 26. Install a new crankshaft front
bearing bore plug (Fig. 28). and cylinder walls with light engine oil seal.
22. Remove the camshaft bearings oil. 27. Coat the gasket surface of the
(Fig. 48). 14. Be sure to install the pistons block and the cover with oil-resistant
in the same cylinders from which sealer. Position a new gasket on the
23. Remove the dipstick tube and they were removed, or to which they block.
the plug or drain. were fitted. The connecting rod and 28. Using tool 6019-A, install the
bearing cap are numbered from 1 to cylinder front cover on the block.
6 beginning at the front of the Torque the screws to specifications.
ENGINE ASSEMBLY engine. The numbers on the con-
1. Install the camshaft bearings Apply Lubriplate to the seal surface,
necting rod and bearing cap must and to the seal running surface of the
and rear bore plug by following be on the same side when installed
steps 3 and 4 under Camshaft Bear- damper.
In the cylinder bore. If a conqecting 29. Line up the crankshaft damper
ing Replacement. rod is ever transposed from one
2. The camshaft and related parts keyway with the key on the crank-
block or cylinder to another, new shaft.
are shown in Fig. 25. Oil the cam- bearings should be fitted and the
shaft journals and apply Lubriplate 30. Install the crankshaft damper.
connecting rod should be numbered 31. Install the water pump, alter-
to all camshaft lobes. Carefully slide to correspond with the new cyUnder
the camshaft through the bearings. nator, fan pulley, and fan. Install
number. and adjust the drive belt.
3. Install the thrust plate. Torque 15. Make sure the ring gaps are
the retaining screws to specifications. properly spaced around the circum- 32. Prime the oil pump by filling
4. The crankshaft and related ference of the piston. either the inlet or outlet port with
parts are shown in Fig. 44. Be sure 16. Install a piston ring compres- engine oil. Rotate the pump shaft to
that the rear journal oil seal grooves sor on the piston and push the piston distribute the oil within the pump
are clean. Install a new rear journal in with a hammer handle until it is body.
oil seal in the Block (Fig. 45) and slightly below the top of the cylinder 33. Install the oil pump. Clean
rear main bearing cap (Fig. 32). (Fig. 33 ~ Be sure to guide the con- and install the oil inlet tube assembly.
PART 8-2- 200, 250 C.I.D. SIX CYLINDER ENGINES 8-43

Using a new gasket, install the 41. Dip the valve lifter foot in equally 2 turns at a time until the
oil pump. Clean and install the oil Lubriplate. Coat the remainder of specified torque is obtained.
inlet tube assembly. each valve lifter with engine oil. 51. Refer to Page 8-11
34. Make sure the gasket surfaces Install the lifters in their original and check the valve clearance.
of the block and oil pan are clean. bores. 51. Clean the gasket surfaces on
35. Coat the block surface and oil 43. Clean the head and block gas- the valve rocker arm cover and
pan gasket surface with oil-resistant ket surfaces. cylinder head. Coat one side of a
sealer and position the gasket on the 44. Inspect the head for any dam- new gasket with an oil-resistant
block (Fig. 41). age and repair as necessary. sealer and lay the cemented side of
36. Install the oil pan front seal 45. Do not apply sealer to the the gasket on the cover. Install the
on the cylinder front cover and the gasket on six cylinder engines. cover making sure the gasket seats
oil pan rear seal on the rear main Install the cylinder head guide studs evenly around the head. Torque the
bearing cap (Fig. 41). Be sure the (Fig. 14). Position the gasket over the cover bolts to specifications. Torque
tabs on the seals are over the oil guide studs on the cylinder block. the cover bolts to specificc.tions
pan gasket. 46. Lift the cylinder head over again two minutes later.
37. Position the oil pan on the the guides and slide it down care- 53. Install the spark plugs. Install
block. Install the retaining screws. fully. Before installing the cylinder the distributor cap and spark plug
Torque the screws from the center head bolts, coat the thread of the wire assembly. Connect the spark
outward in each direction to speci- end bolt for the right side of the plug wires. Install the coil on the
fications. cylinder head with a small amount block and connect the coil high ten-
38 . .Install the clutch pilot bearing of water resistant sealer. Install, but sion lead.
(Fig. 39). Install the engine rear do not tighten, two bolts at opposite 54. Position the exhaust manifold
cover plate, position the flywheel on ends of the head to hold the head on the cylinder head except on 250-
the crankshaft and install the re- and gasket in position. Remove the 2V. Install the tab washers and bolts.
taining bolts. Torque the bolts to guides, then install the remaining Torque the bolts to specifications.
bolts. Lock the bolts by bending one tab of
specifications. On a manual shift 47. The cylinder head bolts are
transmission use a suitable tool to the washer over a flat on the bolt.
to:-qued in three progressive steps. ·55. Position the carburettor gasket
locate the disc. Install the pressure Follow the sequence shown in Fig.
plate. Torque the retaining bolts to on the manifold. Install the car-
14. Torque the bolts to 55 ft-Ibs; burettor except on 250-2V.
specifications. then torque them to 65 ft-lbs. Final- 56. Install the carburettor fuel
ly, torque the bolts to specifications. inlet line, the manifold vacuum line
39. Using a new gasket, install
After the cyUnder head bolts have and the distributor vacuum line,
the fuel pump.
beea torqued to specifications, the except on 250-2V.
40. Turn the crankshaft until No.
bolts should not be disturbed.
1 cylinder is at TDC after the com- 51. Install the oil pressure sending
pression stroke. Position the distrib- 48. Apply Lubriplate to both ends
unit, dipstick tube and dipstick.
utor and intermediate drive shaft of the push rods. Install the push
rods in their proper sequence, posi- 58. Install the engine in the car.
into the block with the rotor at the
tioning the lower end of the rods in 59. On 250-2V engines install the
No. 1 firing position and the breaker
the lifter sockets. exhaust manifold as described on
points open. Install the hold down
clamp. Make sure the oU pump Ia· 49. Apply Lubriplate to the valve page8-27.
termedlate drive shaft Is properly tips and the rocker arm pads. Posi- 60. On 250-2V engines install the
seated Ia the oU pump. It may be tion the valve rocker arm shaft as- inlet manifold, carburettor etc. as
aec ~asary to reposition the later· sembly on the head. Be sure the oU described on page 8~27 .
mediate shaft Ill order to eng111e It holes In the shaft are fadag dowa- 61. Check the ignition timing and
In the oil pump. ward. adJUSt if necessary. Adjust the
41. Instali the oil filter insert and 50. Install the valve rocker arm engine idle fuel mixture and idle
oil filter assembly. shaft bolts. Tighten them evenly and speed.
8-44

PART 302-351 C.I.D.V8ENGINES

8·3 INDEX Page No.

Description .. . . .. .. .. .. .. .. . . . . .. .. .. . . .. .. .. 8-45
In Vehicle Adjustments and Repairs
Engine Front Supports .. .. .. . . .. .. .. . . .. .. 8-45
Engine Rear Supports ............. . 8-46
Valve Clearance Checking Procedure 8-46
Valve Rocker Arm Cover and Rocker Arm ...... .. 8-46
Intake Manifold .. .. .. . . .. .. .. 8-47
Exhaust Manifold .. .. .. .. .. . . .. .. .. .. 8-48
Crankcase Ventilation System ....... . 8-48
Cylinder Heads .. .. .. ~· .. .. . . .. .. .. .. 8-49
Valve Spring, Retainer and Stem Seal ....... . 8-50
Water Pump ........................ . 8-51
Front Oil Seal .. .. .. .. .. .. .. . . .. .. 8-51
Cylinder Front Cover and Timing Chain 8-52
Camshaft ................... . 8-53
Camshaft Rear Bearing Bore Plug .. .. .. 8-54
Valve Lifter .. . . .. . . .. .. . . .. . . .. .. 8-54
Valve Lifter Disassembly .. . . . . .. . . 8-54
Crankshaft Rear Oil Seal Replacement 8-55
Main Bearings .. .. . . .. .. .. .. . . 8-55
Connecting Rod Bearings 8-56
Pistons and Connecting Rods .. 8-57
Flywheel ........... . 8-58
Clutch Pilot Bushing 8-58
Oil Filter ... . 8-59
Oil Pan .. ....... . 8-59
Oil Pump ...... ................. . 8-59
Engine Removal and Installation
Removal ........ ....... . 8-60
Installation .. .. .. .. . . . . 8-61
Major Repair Operations
Crankshaft .. .. .. .. .. .. 8-61
Camshaft Bearings .. .. .. .. .. .. .. .. .. .. .. 8-63
Cylinder Assembly Replacement .. .. .. .. 8-63
Cylinder Block Replacement .. .. .. .. .. .. 8-64
Engine Disassembly and Assembly .. 8-64
PART 8-4- 302-351 C.I.D. VS ENGINE 8-45
1 DESCRIPTION

FIG. 1 - 351 Engine FIG. 1A - 302 EnginB

V8 302 and 351 CID Engines are basic· Both engines have positive crankcase
ally the same (Fig. 1) the main differences ventilation systems of the semi closed
being length of stroke, air cleaner and type.
carburettor type.

2 IN-VEHICLE ADJUSTMENTS AND REPAIRS

When installing nuts or bolts that IAOU
REdo FOR C4,FWX AUtO TIWIS &~
must be torqued (refer to specifications), ' SPEEO STD TRANS ONLY ~
oil the threads with light weight engine oil.
i i
~(!
Do not oil threads that require oil-resisrant
or water-resistant sealer.

,, ·&

~ II>
e
II>
e
FIG. 3- EnginB Rear Supports

2. Remove the through bolt and

Refer to page 8·15 for cleaning and
inspection procedures. lock nut attaching the insulator to the
insulator support bracket (Figs. 2 and 3).
Refer to page 8 ·2 for test procedures. 3. Raise the engine slightly with a
jack and a wood block placed under the
oil pan.
ENGINE FRONT SUPPORTS 4. Remove the engine insulator
assembly to cylinder block attaching bolts
The front supports are located on and lock washers. Remove the engine
each side of the cylinder block (Figs. 2 insulator assembly and heat shield.
and 3). The procedures given apply to
either a right or left installation. INSTALLATION

REMOVAL 1. Position the engine insulator

assembly and the heat shield to the
1. Remove the fan shroud attaching cy Iinder block and install the attaching
FIG. 2- Engine Front Sup.oorts bolts. bolts and lock washers. Tighten the bolts
8-46 GROUP 8- ENGINE
to specifications. If the clearance is less than
2. Lower the engine into position, specifications, install an undersize push
install the engine insulator assembly to rod. If the clearance is greater than
insulator support bracket through bolt and specifications, install an oversize push rod.
remove the jack and wood block. 3. With the No. I piston on TDC at
3. Install the engine insulator the end of the compression stroke,
assembly to insulator support bracket POSITION A in Fig. 5, check the
nuts. Tighten the nut to specifications. following valves:
4. Install the fan shroud attaching No. 1 Intake No. I Exhaust
bolts. No. 4 Intake No. 3 Exhaust
No. 8 Intake No. 7 Exhaust
ENGINE REAR SUPPORT 4. After these valves have been
checked, rotate the crankshaft to
The rear support is located at the POSITION B in Fig. 5, and check the
transmission extension housing (Fig. 3). following valves:
No. 3 Intake No. 2 Exhaust
REMOVAL No. 7 Intake No. 6 Exhaust
5. After these valves have been
1. Remove the support insulator to FIG. 4 - Checking Valve Clearance checked, rotate the crankshaft to
crossmember attaching nuts. POSITION C in Fig. 7 and check the
2. Remove the support insulator to following valves:
transmission extension housing bolts and Valve stem to valve rocker arm No. 2 Intake No. 4 Exhaust
lock washers. clearance should be within specifications No. 5 Intake No. 5 Exhaust
3. Raise the transmission with a with the hydraulic lifter completely
No. 6 Intake No. 8 Exhaust
floor jack. Remove the support insulator collapsed. Repeated valve reconditioning
and retainer. operations (valve and/or valve seat VALVE ROCKER ARM COVER
refacing) will decrease the clearance to the
AND ROCKER ARM
INSTALLATION. point that if not compensated for , the
hydraulic valve lifter will cease to function
The valve rocker arm is shown in Fig.
I. Position the support insulator and and the valve will be held open.
6.
retainer on the transmission extension To determine whether a shorter or a
housing. longer push rod is necessary , make the
2. Install the support insulator to following check:
transmission extension housing bolts and 1. Disconnect the brown lead (I
lock washers. Tighten the bolts to terminal) and the red and blue lead (S
specifications. Lower the transmission. terminal) at the starter relay. Install an
3. Install the support insulator to auxiliary starter switch between the
crossmember attaching nuts. Tighten the battery and S terminals of the Starter
relay. Crank the engine with the ignition ROCKER FULC RUM
nuts to specifications. ARM SEA T
switch OFF until the No. I piston i~ on 6564 6A528

VALVE CLEARANCE CHECKING TDC after the compression stroke.

PROCEDURE 2. With the crankshaft in the
positions designated in Steps, 3,4, and 5,
The valve arrangement of the left position the hydraulic lifter compressor
bank is E-I-E-I-E-I-E-I and on the right tool on the rocker arm. Slowly apply
bank is I-E-I-E-I-E-I-E. pressure to bleed down the hydraulic lifter
A 0.060-inch shorter push rod or a until the plunger is completely bottomed
0.060-inch longer push rod are available (Fig. 4) . Hold the lifter in this position
for service to provide a means of and check the available clearance between
compensating for dimensional changes in the rocker arm and the valve stem tip with
the valve mechanism. a feeler gauge. FIG. 6- Rocker Arm and Related Parts

POSITION A - No. 1 a t TDC a t end o! com pression stroke.

With No , I ot TDC at end o f compr e ss ion st roke POSITION 8 -R otate the cra nk sha ft 180 deg re es (one ha lf
mak e a chalk mark at poi nt s Band C approx imatel y re vo lution) clock wise fr om POSITION A.
90 degree s aport . POSITION C -R otate the cranksha ft 270 degr e es (three
q uar ter revolution) clockwis e fr om
POSI TI ON B.

A3234.A

FIG. 5- Position of Crankshaft for Checking Valve Clearance and Installing Rocker Arms
PART 8-4-302 351 C.I.D. VB ENGINE 8-47

v'
REMOVAL the crankcase ventilation regulator valve.
Install the air cleaner and intake duct
1. Remove the air cleaner and intake assembly. CHOKE HEATER

M~~~--.._....-
duct assembly. 5. Install the spark plug wires in the
If a right cylinder head rocker arm is bracket on the valve rocker arm cover(s).
to be · removed, remove the crankcase Connect the spark plug wires.
ventilation regulator valve from the valve 6. Start the engine and check for ........,.
rocker arm cover. leaks.

~
2. Disconnect the spark plug wires
from the spark plugs by grasping, twisting
and pulling the moulded cap only. INTAKE MANIFOLD
Remove the wires from the bracket on the
valve rocker arm cover(s) and position the The Intake Manifold Assembly is
wires out of the way. shown in Fig. 7.
3. Remove the valve rocker arm
cover(s). REMOVAL
4. Remove the valve rocker arm INTAKE MANIFOLD
· bolt, fulcrum seat and rocker arm. 1. Remove the air cleaner and intake GASKET-9441

duct.
2. Disconnect the high tension lead
INSTALLATION and wires from the coil. Disconnect the
engine wire loom and position it out of
All rocker arms and fulcrum seats are the way.
to be lubricated with heavy engine oil MS 3. Disconnect the spark plug wires
before installation. from the spark plugs by grasping, twisting SEALS
1. Apply Lubriplate or equivalent to and pulling the moulded cap only. 9A424
the top of the valve stem. Lubricate the Remove the wires from the harness
rocker arm and fulcrum seat with heavy brackets on the valve rocker arm covers.
engine oil MS. Remove the distributor cap and spark plug
2. Position the No. 1 piston on TDC wire assembly. A3238·A
at the end of the compression stroke, 4. Remove the carburetor fuel inlet
POSITION A in Fig. 5 and install the line. FIG. 7- Intake Menifold Assembly
rocker arm, fulcrum seat and bolt on the 5. Remove the heater hoses from the
following valves: retainers and position the hoses out of the
No. 1 Intake No. 1 Exhaust way.
No. 4 Intake No. 3 Exhaust 6. Remove the ignition coil and extensions into the holes in the mating
No. 8 Intake No. 7 Exhaust bracket. surface.
Position the crankshaft in POSITION 7. Disconnect the crankcase Apply non-hardening sealer at the
B in Fig. 5 and install the rocker arm, emission hose at the right rocker arm four junction points of the seals and
fulcrum seat and bolt on the following cover. cylinder heads. Position the intake
valves: 8. Disconnect the vacuum lines from manifold gasket onto the block and
No. 3 Intake No. 2 Exhaust the intake manifold. Remove the bolts cylinder heads with the alignment notches
Jllo. 7 Intake No. 6 Exhaust attaching the vacuum outlet to the left under the dowels on the cylinder heads.
Position the crankshaft in POSITION hand rocker arm covers," if so equipped. Be sure the holes in the gasket are aligned
C in Fig. 5 and install the rocker arm, 9. Disconnect the distributor with the holes in the cylinder head.
fulcrum seat and bolt on the following vacuum hoses from the distributor. 4. Carefully lower the intake
valves: Remove the distributor hold down bolt manifold into position on the cylinder
No. 2 Intake No. 4 Exhaust and remove the distributor. block and cylinder heads.
No. 5 Intake No. 5 Exhaust 10. Disconnect the accelerator linkage 5. Be sure the holes in the manifold
No. 6 Intake No. 8 Exhaust and transmission downshift linkage, if so gaskets and manifold are in alignment.
Be sure that the fulcrum seat base is equipped, and position out of the way. Install the intake manifold attaching bolts.
inserted in its slot on the cylinder head 11. Remove the carburetor. Tighten the intake manifold bolts in three
before tightening the fulcrum bolts. 12. Remove: the manifold attaching steps (Fig. 8);
Tighten the fulcrum bolt to specification. bolts. Remove the manifold. Remove and Tighten all bolts in sequence to 8-10
Check the valve clearance following the discard the intake manifold gasket and ft-lb.
procedures under Valve Clearance seals. Tighten all bolts in sequence to 15-20
Checking Procedure page 8-12 . 13. If the manifold assembly is to be ft-lb.
3. Clean the valve rocker arm disassembled, identify all vacuum hoses Tighten all bolts in sequence to
cover(s) and the cylinder head gasket before disconnecting them. specifications.
surface(s). Apply oil-resistant sealer to one After completing the remammg
side of new cover gasket(s). Lay the INSTALLATION asaembly steps, operate the engine until it
cemented side of the gasket(s) in place in reaches normal operating temperature
the cover(s). 1. If the intake manifold assembly then re-tighten the manifold bolts in
4. Position the cover(s) on the was disassembled, install the engine sequence to specifications.
cylinder head(s). Make sure the gasket identification tag. 6. Instalt the carburetor and gasket.
seats evenly all around the head. Install 2. Clean the mating surfaces of the 7. Rotate the crankshaft damper
the bolts. The cover is tightened in two intake manifold, cylinder heads and until the No. 1 piston is on TDC at the
steps. Tighten the bolts to specifications. cylinder block. Use a suitable solvent to end of the compression stroke. Position
Two minutes later, tighten the bolts to the remove all traces of oil. the distributor in the block with the rotor
same specifications. 3. Position new seals on the cylinder at the No. 1 firing position and the points
If the right cover was removed, install block and press the seal locating just open. lrtStall the hold down clamp.
8-48 GROUP 8- ENGINE

CD 0 ®0 CD 0
FRONT
OF

•
ENGINE

Q) @@@0 0
FIG. 8 -Intake Manifold Torque Saquence

8. Install the accelerator linkage and harness brackets on the valve rocker arm being removed, remove the oil filter.
transmission downshift rod, if so covers and connect the wires to the spark 3. Disconnect the muffler inlet pipe
equipped. plugs. at the exhaust manifold.
9. Install the ignition coil. 16. Start the engine and check for 4. Remove the exhaust manifold
10. Connect the vacuum lines at the leaks. Adjust the ignition timing and attaching bolts and remove the manifold.
manifold. Install the manifold vacuum connect the distributor vacuum line.
outlet attaching bolts at the left hand 17. When engine temperature has INSTALLATION
rocker arm cover, if so equipped. stabilized, adjust idle mixture and speed.
11. Position the engine wire loom Retorque the intake manifold to 1. Clean the mating surfaces of the
under the hold down clips on the left specifications. exhaust manifold and cylinder head. Clean
rocker arm cover and connect the wires at 18. Install the air cleaner assembly the mounting flange of the exhaust
the ignition coil and water temperature and re-check idle speed. manifold and muffler inlet pipe.
sending unit. 2. Apply graphite grease to the
12. Connect the crankcase emission EXHAUST MANIFOLD mating surface of the exhaust manifold.
line at the right hand rocker arm cover. 3. Position the exhaust manifold on
13. Install the heater hoses in the REMOVAL the head and install the attaching bolts.
retainers. Working from the center to the ends,
14. Connect the fuel pump to 1. If a right hand exhaust manifold tighten the bolts to specifications.
carburetor fue1line at the carburetor. is being removed, remove the ait cleaner, 4. Connect the muffler inlet pipes at
15. Install the distributor cap. intake duct and heat stove. the exhaust manifold. Tighten the
Position the spark plug wires in the 2. If a left ,hand exhaust manifold is attaching nuts to specifications.
5. If a left hand exhaust ::1anifold is
being installed, install the oil fllter.
6. If a right hand exhaust manifold
is being replaced, install the air cleaner
heat stove. Install the air cleaner and
intake duct.
7. Start the engine and check for
exhaust leaks.

CRANKCASE VENTILATION
SYSTEM

The crankcase ventilation system

components are shown in Fig. 9.

REMOVAL
1. Remove the ventilation system air
intake hose from the air cleaner and the
oil filler cap.
2. Remove the air cleaner and intake
duct assembly.
3. Disconnect the crankcase vent
hose from the carburetor, regulator valve
and hot idle compensator (if so equipped);
4. Pull the regulator valve out of the
valve rocker arm cover mounting
grommet.
5. Remove the crankcase ventilation
FIG 9. - Typical VB engine crankcase ventilation fllter from the air cleaner body.
system components.
PART 8-4- 302-351 C.I.D. V8 ENGINES 8-49

INSTALLATION

1. Install the crankcase ventilation

IJ
filter in the air cleaner body.
2. insert the regulator valve into the
valve rocker arm cover mounting
grommet.
FIG. 11 -Cylinder Head Bolt Torque
3. Connect the vent hose to the
Sequence
carburetor, regulator valve and hot idle
compensator (if so equipped).
4. Install the air cleaner and intake
duct assembly.
5. Install the ventilation system air FIG. 10- Removing Valve Push Rod
intake hose to the air cleaner and the oil
filler cap.
6. Start the engine and check for INSTALLATION
· leaks.
1. Clean the cylinder head, intake
manifold, valve rocker arm cover and
cylinder head gasket surfaces. If the
cylinder head was removed for a cylinder
CYLINDER HEADS head gasket replacement, check the
flatness of the cylinder head and block
If a cylinder head is to be replaced, gasket surfaces.
FIG. 12- Compressing Valve Spring on
follow the procedures under Cylinder 2. Position the new cylinder head Bench
Head Disassembly and Assembly, and gasket over the cylinder dowels on the
transfer all valves, springs, spark plugs, block. Position the cylinder head on the If the left cylinder head was removed
etc., to the new cylinder head. Clean and block and install the attaching bolts. on a vehicle with an air conditioner, install
inspect all parts, reface the valves (refer to 3. The cylinder head bolts are the compressor.
8-,16 Section 3) and check all assembly tightened in three progressive steps. If the left cylinder head was removed
clearances before assembling the new or Tighten all the bolts in sequence (Fig. 11) on a vehicle with power steering, install
used parts to the new cylinder head. to 50 ft-lbs., then to 60 ft-lbs. and finally the drive belt and power steering pump
to specifications. When cylinder head bolts bracket. Install the bracket attaching
have been tightened following this bolts. Adjust the drive belt to
REMOVAL procedure, it is not necessary to retorque specifications.
the bolts after extended operation. 10. Install the intake manifold and
1. Remove the intake manifold and However, the bolts may be checked and related parts following the procedure
carburetor as an assembly following the retorqued if desired. under Intake Manifold Installation.
procedure under Intake Manifold 4. Clean the push rod in a suitable
Removal. solvent. Blow out the oil passage in the DISASSEMBLY
2. Remove the rocker arm cover(s). push rod with compressed air. Check the
If the left cy Iinder head is to be ends of the push rods for nicks, grooves, 1. Remove the exhaust manifolds
removed on a vehicle with an air roughness or excessive wear. Visually and the spark plugs.
conditioner, isolate and remove the check the push rods for straightness o.r 2. Clean the carbon out of the
compressor. check push rod runout with a dial cylinder head combustion chambers
If the left cylinder head is to be indicator. If runout exceeds the maximum before removing the valves.
removed on a vehicle with power steering, limit at any point, discard the rod. Do not 3. Compress the valve springs (Fig.
disconnect the ·power steering pump attempt to straighten push rods. 12). Remove the spring retainer locks and
bracket from the left cylinder head and 5. Lubricate and install the push release the spring.
remove the drive belt from the pump rods in their original positions. Apply 4. Remove the spring retainer, spring
pulley. Position the power steering pump Lubriplate or equivalent to the valve stem and stem seal. Discard the valve stem seals.
out of the way and in a position that will tips. Remove any burrs from the valve stem
prevent the oil from draining out. 6. Lubricate and install the rocker with Tool TIOP-6506-A as shown in Fig.
3. If the right cylinder head is to be arms following procedures under Valve 13 to prevent damage to the valve guide
removed, remove the alternator mounting Rocker Arm Installation. bore. Remove the valve. Identify all valve
bracket through bolt and air cleaner inlet 7. Connect the exhaust manifold(s) parts.
duct from the right cylinder head at the muffler inlet pipe(s). Tighten the 5. Clean, inspect and repair the
assembly. Remove the ground wire at the nuts to specifications. cy Iinder head as required, or transfer all
rear of the cylinder head. 8. If the right cylinder head was usable parts to a new cylinder head.
4. Disconnect the exhaust removed, install the alternator mounting Note The damper spring is an interference
manifold(s) from the muffler inlet pipe(s). bracket through bolt and air cleaner inlet fit in the valve spring. The spring and
5. Loosen the rocker arm fulcrum duct on the right cylinder head assembly. damper is removed as an assembly.
bolts so that the rocker arms can be Connect the ground wire at the rear of the
rotated to the side. Remove the push rods cylinder head. Adjust the drive belt ASSEMBLY
in sequence (Fig. 10) so that they may be tension to specifications.
installed in their original positions. 9. Apply oil-resistant sealer to one All valves, valve stems and valve guides
6. Remove the cylinder head side of new cover gasket(s). Lay the are to be lubricated with heavy engine oil
attaching bolts and lift the cylinder head cemented side of the gasket(s) in place in MS. The valve tips are to have Lubriplate
off the block. Remove and discard the the cover(s). Install the valve rocker arm or equivalent applied. The lubricant is to
cylinder head gasket. cover(s). be applied before installation.
8-50 GROUP 8- ENGINE

4. Install the valve spring over the 4. Remove the valve rocker arm
valve, and then install the spring retainer. fulcrum, bolts, fulcrum seats, valve rocker
Compress the spring and install the arms and push rods from the applicable
retainer locks (Fig. 12). cylinder.
5. Measure the assembled height of 5. Install an air line with an adapter
the valve spring from the surface of the in the spark plug hole and turn on the air
cy Iinder head spring pad to the underside supply.
of the spring retainer with dividers (Fig. 6. Install the compressor tool as
15). Check the dividers against a scale. If shown in Fig. 16. Compress the valve
the assembled height is greater than spring and remove the retainer locks,
specifications, install the necessary spring retainer and valve spring.
0.030-inch thick spacer(s) between the 7. Remove and discard the valve
FIG. 13- Removing Valve Stem Burrs cylinder head spring pad and the valve stem seal (Fig. 17).
spring to bring the assembled height to the 8. If air pressure has forced the
recommended height. piston to the bottom of the cylinder, any
removal of air pressure will allow the
LOCKS~~~
Do not install the spacers unless
necessary. Use of spacers in excess of valve(s) to fall into the cylinder. A rubber
RETAINER
6518 6514 recommendations will result in band, tape or string wrapped around the
overstressing the valve springs and end of the valve stem will prevent this

SPR~NG
overloading the camshaft lobes which condition and will still allow enough travel
_. D7ER could lead to spring breakage and/or worn to check the valve for binds.
camshaft lobes.

~ SJ.
6. Install the exhaust manifolds and

~
OILSEAL ' I-
the spark plugs.
6571

~651 3 VALVE SPRING, RETAINER AND

STEM SEAL

EXHAUST Broken valve springs or damaged valve

VALVE stem seals and retainers may be replaced
65()1;
without removing the cylinder head,
~ provided damage to the valve or valve seat
has not occurred.
INTAKE
VALVE
1.1\07
REMOVAL
FIG. 17- Removing or Installing Valve
1. Disconnect the automatic choke Stem Seal
heat chamber air inlet hose from the inlet
tube near the right valve rocker arm cover.
A3243-A 2. Remove the air cleaner and intake
duct assembly.
FIG. 14- Valve and Related Parts To remove the right valve rocker arm
cover, remove the crankcase ventilation
regulator valve from the valve rocker arm
cover.
3. Remove the valve rocker arm
cover and the applicable spark plug.

FIG. 18- Removing Crankshaft Vibration

Damper
FIG. 15- Valve Spring Assembled Height
INSTALLATION
1. Clean the spring retainer lock
grooves on the valves to remove any loose 1. Inspect the valve stem for
rna terial left by the valve stem de-burring damage. Rotate the valve and check the
tool. valve stem tip for eccentric movement
2. Lubricate the valve guide and during rotation. Move the valve up and
valve stem with heavy engine oil MS. down through normal travel in the valve
3. Install each valve (Fig. 14) in the guide and check the stem for binds. If the
port from which it was removed or to valve has been damaged, it will be
which it was fitted. Install a new stem FIG. 16- Compressing Valve Spring in necessary to remove the cylinder head for
seal on the valve. Chassis repairs.
PART 8-4-302-351 C.I.D. VB ENGINES 8-51
2. If the condition of the valve 5. Loosen the alternator and remove 3. Loosen the alternator, power
proved satisfactory, hold the valve in the the drive belt. steering and air conditioner drive belts, if
closed position and apply the air pressure 6. If equipped with power steering, so equipped. Remove the drive belts.
within the cylinder. loosen the power steering pump and 4. Remove the crankshaft pulley
3. Lubricate the valve stem with remove the drive belt. from the vibration damper. Remove the
heavy engine oil MS. 7. Remove the water pump pulley. damper attaching screw and washer. Install
4. Install a new valve stem seal (Fig. 8. Remove alternator bracket from the puller on the crankshaft vibration
17). Place the spring in position over the water pump and position it out of the damper (Fig. 18) and remove the vibration
valve and install the valve spring retainer. way. damper.
Compress the valve spring and install the 9. If equipped with power steering, 5. Place the front seal removing tool
valve spring retainer locks.. Remove the remove the power steering pump bracket onto the front cover over the front seal as
compressor tool and stud nut. Turn off from the water pump and position it out shown in Fig. 19. Tighten the two through
the air and remove the air line adapter. of the way. bolts to force the seal puller under the seal
5. Lubricate and install the push 10. Remove the heater hose from the flange.
rod. Apply Lubriplate or equivalent to the water pump. 6. Alternately tighten the four puller
tip of the valve stem. 11. Disconnect the lower radiator bolts a half turn at a time as shown in Fig.
6.. Lubricate the push rod socket, hose at the water pump. 19 to pull the front oil seal from the front
fulcrum seat and the valve pad of the 12. Remove the water pump cover.
rocker arm with heavy engine oil MS. attaching bolts and remove the water
7. Postion the No. 1 piston on TDC pump.
at the end of the compression &troke,
POSITION A in Fig. 5, and install the INSTALLATION
rocker arms, fulcrum seats and fulcrum
bolts on the following valves: Before a water pump is re-installed,
No. 1 Intake No. 1 Exhaust check it for damage. If it is damaged,
No. 4 Intake No. 3 Exhaust replace it.
No. 8 Intake No. 7 Exhaust 1. Remove all gasket material from
Position the crankshaft in POSITION the mounting surfaces of the cylinder
B shown in Fig. 5, and install the rocker front cover and water pump.
arms, fulcrum seats and fulcrum bolts on 2. Position a new gasket, coated on
the following valves: both sides with sealer, on the cylinder
No. 3 Intake No. 2 Exhaust front cover; then install the pump. Coat
No. 7 Intake No. 6 Exhaust the threads of the attaching screws with
Position the crankshaft in POSITION oil-resistant sealer and install the screws.
C shown in Fig. 5, and install the rocker Tighten the attaching screws to
arms, fulcrum seats and fulcrum bolts on specifications.
the following valves: 3. Install the air conditioner
No. 2 Intake No. 4 Exhaust compressor to water pump bracket and
No. 5 Intake No. 5 Exhaust lower idler pulley, if so equipped.
No. 6 Intake No. 8 Exhaust 4. Position the alternator bracket
Be sure that the fulcrum seat base is and power steering pump bracket, if so
Inserted In its slot on the cylinder head equipped, on the water pump and install
before tightening the fulcrum bolt. the bracket bolts.
Tighten the fulcrum bolts to 5. Position the water pump pulley
specifications. on the water pump shaft and install the
8. Oean and install the rocker arm drive belts.
cover. 6. Place the fan shroud over the
If the right cover was removed, install pulley and install the fan and spacer.
the crankcase ventilation regulator valve. 7. Install the fan shroud attaching
9. Install the spark plug and connect bolts. FIG. 19- Removing Front Crenkshaft Seal
the spark plug wires. 8. Adjust the drive belts to
10. Install the air cleaner and intake specifications.
duct assembly. 9. Connect the lower radiator hose
11. Connect the automatic choke at the water pump.
heat chamber air inlet hose. 10. Connect the heater hose at the
water pump.
11. Connect the battery cable. Fill
WATER PUMP and bleed the cooling system. Operate the
engine until normal operating temperature
REMOVAL has been reached and check for leaks.

1. Drain the cooling system and

disconnect the battery. FRONT OIL SEAL
2. Remove the fan shroud attaching
bolts and position the shroud rearward. REMOVAL
3. Remove the fan and spacer. from
the water pump shaft. 1. Remove the bolts attaching the
4. Remove the air conditioner fan shroud to the radiator.
compressor drive belt lower idler pulley 2. Remove the fan and spacer bolts
and compressor mount to water pump from the water pump shaft. Remove the
bracket, if so equipped. fan, spacer and shroud. FIG. 20- Installing Front Crankshaft Saal
8-52 GROUP 8- ENGINE

INSTALLATION

1. Coat a new front oil seal with

Lubriplate or equivalent and place it onto
the front oil seal alignment and
installation sleeve as shown in Fig. 20.
Place the sleeve and seal onto the end of
the crankshaft and push it toward the
engine until the seal starts into the front
cover.
2. Place the installation screw,
washer and nut onto the end of the
crankshaft. Thread the screw into the
crankshaft. Tighten the nut against the
washer and installation sleeve to force the
seal into the front cover. Remove the
installation tool from the crankshaft.
3. Apply Lubriplate or equivalent to
the oil seal rubbing surface of the FIG. 21- Installing Crankshaft Vibration
vibration damper inner hub to prevent Dampar
damage to the seal. Apply a white lead and
oil mixt\lre to the front of the crankshaft 11. Remove the heater hose and
for damper installation. lower radiator hose from the water pump.
4. Line up the crankshaft vibration 12. Remove the crankshaft pulley
damper keyway with the key on the from the crankshaft vibration damper.
crankshaft. Install the vibration damper on Remove the vibration damper attaching
the crankshaft (Fig. 21). Install the cap screw. Install the puller on the crankshaft FIG. 22- Aligning Timing Marks
screw and washer. Torque the screw to vibration damper (Fig. 18) and remove the
sp~cifications. Install the crankshaft vibration damper. bolt and nut and tighten to specification.
pulley. 13. Remove the timing pointer. Connect the fuel pump outlet line.
5. lnst;tll the alternator, power 14. Remove the bolts attaching the 4. Remove the front crankshaft seal
steering pump and air conditioner belts, if front cover and water pump to the from the cylinder front cover with the
so equipped. cylinder block. Remove the front cover tool shown in Fig. 19. Clean the cylinder
6. Position the fan shroud over the and water pump assembly. front cover and the engine block gasket
water pump pulley. Install the fan and 15. Disconnect the fuel pump outlet surfaces.
spacer. Install the fan shroud attaching line from the fuel pump. Remove the fuel 5. Coat the gasket surfaces of the
screws. pump attaching bolt and nut and lay the block and cover with sealer, and position a
7. Adjust the drive belts to pump to one side with the flexible fuel new gasket · on the cylinder block
specification. line still attached. alignment dowels.
16. Discard the cylinder front cover 6. Position the cylinder front cover
gasket and oil pan seal. Remove the and water pump assembly on the cylinder
CYLINDER FRONT COVER AND crankshaft front oil slinger. block alignment dowels.
TIMING CHAIN 17. Check the timing chain deflection 7. Coat the threads of the attaching
does not exceed 0.5 inches. bolts with oil-resistant sealer and install
REMOVAL 18. Crank the engine until the timing the timing pointer and attaching bolts.
marks on the sprockets are positioned as Torque the bolts to specification.
1. Drain the cooling system and shown in Fig. 22. 8. Install thb front crankshaft seal
disconnect the battery. 19. Remove the camshaft sprocket into the cylinder front cover with the tool .
2. Remove the fan shroud attaching cap screw, washer and two piece fuel shown in Fig. 20.
bolts. pump eccentric. Slide both sprockets and 9. Apply Lubriplate or equivalent to
3. Remove the fan and spacer from the timing chain forward, and remove the oil seal rubbing surface of the
the water pump shaft. them as an assembly (Fig. 23). vibration damper inner hub to prevent
4. If equipped with air conditioning, damage to the seal. Apply a white lead and
loosen the lower idler pulley and remove INSTALLATION oil mixture to the front of the crankshaft
the compressor drive belt. 1. Position the sprockets and timing from damper installation.
5. Loosen the alternator and remove chain on the camshaft and crankshaft (Fig. 10. Line up the crankshaft vibration
the drive belt. 24). Be sure the timing marks on the damper keyway with the key on the
6. If equipped with power steering, sprock&ts are positioned as shown in crankshaft. Install the vibration damper on
loosen the power steering pump and Fig.22. the crankshaft (Fig. 21). Install the cap
remove the drive belt. 2. Install the two piece fuel pump screw and washer. Tighten the cap screw
7. Remove the water pump pulley. eccentric, washers and camshaft sprocket to specifications. Install the crankshaft
8. Remove the alternator to water cap screw. Torque the sprocket cap screw pulley.
pump bracket. Position the alternator out to specificati01i's. Be sure the outer 11. Connect me heater hose and the
of the way. eccentric sleeve rotates freely. lower radiator hose at the water pump.
9. If equipped with power steering, Install the crankshaft front oil slinger 12. If equipped with air conditioning,
remove the power steering pump bracket (Fig. 24). install the lower idler pulley and
from the water pump and cylinder head. 3. Coat a new fuel pump gasket with compressor to water pum:? bracket.
Position the pump out of the way. oil-resistant sealer and position the fuel 13. If equipped with power steering,
10. If equipped with air conditioning, pump and gasket on the cylinder block install the power steering pump brackets.
remove the compressor to water pump with pump arm resting on the eccentric 14. Install \he alternator and
bracket and lower idler pulley. outer sleeve. Install the pump attaching brackets.
PART 8-4-302-351 C.I.D. VB ENGINES 8-53
21. Fill the crankcase with the proper
grade and quantity of engine oil Fill and
bleed the cooling system.
22. Connect the battery. Operate the
engine until normal operating temperature
has been reached and check for leaks.

CAMSHAFT

The camshaft and related parts are

shown in Fig. 25.

REMOVAL

1. Drain the cooling system. FIG. 26- Removing Valve Lifter

Disconnect the upper and lower radiator
hoses at the radiator. If equipped with caution to avoid damasffig the camshaft
automatic transmission, disconnect the oil bearings.
cooler lines at the radiator. Remove the
radiator and grille. If equipped with air
conditioning, remove the condenser. INSTALLATION
2. Remove the cylinder front cover,
fuel pump and the timing chain following Camshaft lobes are to be coated with
the procedure under the Cylinder Front Lubriplate or equivalent and the journals
Cover and Timing Chain Removal. lubricated with heavy engine oil MS before
3. Remove the intake manifold installation.
FIG. 23- Removing or Installing Timing following the procedure under Intake 1. Oil the camshaft journals and
Chain Manifold Removal. apply Lubriplate to the lobes. Carefully
4. Remove the valve rocker arm slide the bamshaft through the bearings.
covers. Loosen the valve rocker arm Install the camshaft thrust plate onto the
fulcrum bolts and rotate the rocker arms cylinder block. Check camshaft end play
to the side. as shown on page 8-ll
5. Remove the valve push roads and
identify them so that they can be installed 2. Install the valve lifters in the
in their original positions. bores from which they were removed.
6. Using a magnet, remove the valve 3. Install the timing chain, fuel
lifters and place them in a rack so that pump cylinder front cover and related
they can be installed in their original bores parts following steps 1 thru 13 under
(Fig. 26); Cylinder Front Cover and Timing Chain
If the valve lifters are stuck in their Installation.
bores by excessive varnish, etc., it may be 4. Adjust the drive belts to
necessary to use a plier-type tool specifications.
or a claw type tool to remove the lifters. 5. Install the push rods in their
Rotate the lifter back and forth to loosen original positions.
it from the gum or varnish that may have 6. With No. 1 piston at TDC at the
formed at the lifter. end of the compression stroke, POSITION
A in Fig. 5, apply Lubriplate or equivalent
7. Remove the camshaft thrust to the valve stem tips. Lubricate the
plate. Carefully remove the camshaft by rocker arms and fulcrum seats with heavy
pulling toward the front of the engine. Use engine oil MS. Install the rocker arms and

CRANKSHAFT FRONT OIL SLINGER A3252-A

FIG. 24 - Fuel Pump Eccentric and Front TIMING CHAIN - 6268 AND
Oil Slinger Installed CAMSHAFT SPROCKET- 6256

15. Position the water pump pulley

on the water pump shaft and install the
drive belts. CAMSHAFT
16. Place the fan shroud over the REAR BEARING
BORE PLUG
pulley and install the fan and spacer. 6266
17. Install the fan shroud attaching
CAMSHAFT
bolts. 6250

~~
18. Adjust the drive belts to
specifications.

~ ~1
BOLT

~
19. Raise the vehicle. Remove the oil
pan and install new gaskets and seals
following procedures under Oil Pan ~PUMP TWO PIECE FUEL
ECCENTRIC- 6287
A325J.A
Removal and Installation.
20. Lower the vehicle. FIG. 25- Camshaft and Related Parts
8-54 GROUP 8- ENGINE
perform a valve clearance check on the stabilized adjust the engine idle speed and they can be installed in their original bores
following valves: idle fuel mixture. (Fig. 26) ;
No. 1 Intake No. 1 Exhaust 19. Adust the transmission throttle If the valve lifters cannot be removed
No.4 Intake No. 3 Exhaust. linkage. Install the air cleaner and intake from their bores due to excessive varnish,
No.8 Intake No.7 Exhaust duct assembly. etc., it may be necessary to use a
Position the crankshaft in POSITION plier-type tool or a claw type tool to
B shown in Fig. 5 and install the push remove the lifters. Rotate the lifter back
rods, apply Lubriplate or equivalent to the CAMSHAFT REAR BEARING BORE and forth to loosen it from the gum or
valve stem tips, install the rocker arms and PLUG varnish that may have formed at the
perform a valve stem clearance check on lifter.
the following valves: REMOVAL
No. 3 Intake No. 2 Exhaust
No. 7 Intake No. 6 Exhaust INSTALLATION
1. On a vehicle with a manual-shift
Position the crankshaft in POSITION transmission, remove the transmission,
C shown in Fig. 5 and install the push Tappets or lifters and bores are to be
clutch pressure plate and disc following
rods, apply Lubriplate to the valve stem lubricated with heavy engine oil MS before
the procedures in Group 6.
tips, install the rocker arms and perform a installation.
valve stem clearance check on the 1. aean and install the valve lifters
On a vehicle with an automatic
following valves: in the bores from which they were
transmission, remove the transmission and
No. 2 Intake No. 4 Exhaust removed. If a new lifter(s) is being
converter housing following the procedure
No. 5 Intake No. 5 Exhaust installed, check the new lifter(s) for a ·free
in Group 7.
No. 6 Intake No. 8 Exhaust fit in the bore in which it is to be installed.
2. Remove the flywheel attaching
7. Clean the valve rocker arm covers Lubricate the lifter(s) and bore(s) with
bolts and remove the flywheel. Remove
and the cylinder head gasket surfaces. heavy engine oil MS before inserting it in
the engine rear cover plate.
Apply oil-resistant sealer to one side of the bore.
3. Remove the core plug.
new cover gaskets. Lay the cemented side 2. Install the push rods in their
of the gaskets in place in the covers. original position. Apply Lubriplate or
INSTALLATION
8. Position the covers on the equivalent to the valve stem tips.
cylinder heads. Make sure the gasket seats 3. Position the No. 1 piston on TDC
1. Using tool T70P-6011-A, install
evenly all around the head. Install the at the end of the compression stroke,
the core plug.
bolts. The cover is tightened in two steps. POSITION A in Fig. 5. Lubricate with
2. Coat the flywheel attaching bolts
Torque the bolts to specifications. Two heavy engine oil MS and install the rocker
with oil-resistant sealer. Position the
minutes later, torque the bolts to the same arm, fulcrum seat and bolt on the
engine rear cover plate on the cylinder
specifications. . following valves:
block dowels. Position the flywheel on the
9. Install the intake manifold, dis- No. 1 Intake No. 1 Exhaust
crankshaft flange. Install and torque the
tributor and related parts by following No. 4 Intake No. 3 Exhaust
attaching bolts in sequence across from
procedures under Intake Manifold Instal- No. 8 Intake No. 7 Exhaust
each other to specifications.
lation. Position the crankshaft in POSITION
On a vehicle with a manual-shift
B, Fig. 5. Lubricate and install the rocker
10. Connect the accelerator cable and transmission, install the clutch pressure
arm, fulcrum seat and bolt on the
retracting spring. Install the vacuum lines plate, disc and the transmission following
following valves:
that were disconnected from the intake the procedures in Group 6. No.3 Intake No. 2 Exhaust
manifold during removal.
No. 7 Intake No. 6 Exhaust
11. Clean and install the crankcase On a vehicle with an automatic
ventilation system. Position the crankshaft in POSITION
transmission, install the transmission and
C, Fig. 5. Lubricate and install the rocker
12. Install the distributor cap. converter housing following the procedure
arm, fulcrum seat and bolt on the
Position the spark plug wires in the in Group 7.
folloWing valves:
harness brackets on the valve rocker arm
No. 2 Intake No. 4 Exhaust
covers and connect the wires to the plugs. VALVE LIFTER
No. 5 Intake No. 5 Exhaust
Connect the high tension lead at the coil.
No. 6 Intake No. 8 Exhaust
13. If. equipped with air conditioning, Before replacing a hydraulic valve
Be sure that the fulcrum seat bue ia
install the condensor. lifter for noisy operation, be sure the noise
14. Place the radiator shroud over the inlerted in ita slot on the cylinder head
is not caused by incorrect valve lash or by
before tightenm, the attachm, bolt.
fan. Install the radiator and connect the worn rocker arms or push rods.
Tighten the fulcrum bolts to
hoses. If equipped with automatic
transmission, connect the oil cooler lines specification. Check the valve clearance
REMOVAL
following the procedure under Valve
at the radiator. Install the radiator shroud
attaching bolts. Oearance - Checking Procedure.
1. Remove the intake manifold and
4. Install the valve rocker arm
15. Raise the vehicle. Remove the oil related parts by following procedures
covers. Install the crankcase ventilation
pan and install new gaskets and seals under Intake Manifold Removal.
regulator valve in the valve rocker arm
following procedures under Oil Pan 2. Remove the crankcase ventilation
cover.
Removal and Installation. regulator valve from the valve rocker arm
Lower the vehicle.
S. Install the intake manifold and
cover.
related parts by following procedures
16. Fill and bleed the cooling system. 3. Remove the valve rocker arm
under Intake Manifold Installation.
Fill the crankcase with the proper grade covers. Loosen the valve rocker arm
and quantity of engine oil. fulcrum bolts and rotate the rocker arms
17. Start the engine and check and to the side.
adjust the ignition timing. Connect the 4. Remove the valve push rods and VALVE LIFTER DISASSEMBLY
distributor vacuum lines. identify them so that they can be installed
18. Operate the engine at fast idle and in their original positions. The internal parts of each hydraulic
check all hose connections and gaskets for 5. Using a magnet, remove the valve valve lifter assembly are matched seta. Do
leaks. When the engine temperature has lifters and place them in a rack so that not intermix the parts. Keep the
PART 8-4-302-351 C.I.D. V8 ENGINES 8-55
assemblies intact until they are to be
a:!, /
ul /)"::::. ""
PUSH ROD METERING VALVE PUSH ROD UPPER METERING
cleaned.
CHECK VALVE

,- ~~
- 'j
The disassembly and assembly
procedures for Types I and II valve lifters
are different. Valve lifters should always \ '•.(I )
/CHECK VALVE SPRING

r·~~7'"'
PLUNGER SPRING
be tested after assembly; refer to the test
procedures covered on page 8-9. COC. .NG •,,,~ BODY

TYPE I •cuNG" \ ~ ·~TI':' J. j~~

CHECK VALVE VALVE
Disassembly RETAINER
A2867-A LOCK RING PLUNGER
SPRING
Disassemble and assemble each lifter
separately. Identify the lifter assemblies so BODY
FIG. 27- Type 1 Hydraulic Valve Lifter
they can be installed in their original Assembly
bores. LIFTER ASSEMBLY
6500
1. Grasp the lock ring with needle A 2505-.l
FIG. 28- Type II Hydraulic Valve Lifter
nose pliers to release it from the groove. It
Assembly
may be necessary to depress the plunger to
ful.\y release lock ring. Disassemble and assemble each lifter CRANKSHAFT REAR OIL SEAL
2. Remove the push rod cup, separately. Keep the lifter assemblies in REPLACEMENT
metering valve (disc), plunger and spring. proper sequence so they can be installed in
3. Remove the plunger assembly, the their original bores. Replacement of a crankshaft rear oil
check valve and the check valve retainer 1. Grasp the lock ring with needle seal because of oil leakage requires
and plunger spring. Carefully remove the nose pliers to release it from the groove. It replacement of both the upper and lower
plunger spring, the check valve retainer may be necessary to depress the plunger to seals. Refer to Crankshaft Rear Oil Seal
and, the check valve disc from the plunger. fully release lock ring. Replacement on page 8-55for "replacement
2. Remove the push rod cup, procedure.
Assembly metering valve disc, and the upper
metering valve. Do not bend the metering
Type I hydraulic lifter assembly is valve or the valve tensioning finger.
shown in Fig. 27. 3. Remove the plunger assembly, the
1. Place the plunger upside down on check valve and the check valve retainer MAIN BEARINGS
a clean work bench. and plunger spring. Carefully remove the
2. Place the check valve (disc or ball plunger spring, the check valve retainer The main bearing inserts are selective
check) in position over the oil hole on the and the check valve disc from the plunger. fit. Refer to procedures under Fitting
bottom of the plunger. Set the check valve Main and Connecting Rod Bearings.
spring on top of the check valve (disc or Assembly
ball check).
3. Position the check valve retainer Type II hydraulic lifter assembly is
over the check valve and spring and push shown in Fig. 28.
the retainer down into place on the 1. Place the plunger on a clean work
plunger. surface (table or bench) in an inverted REMOVAL
4. Place the plunger spring, and then position and center the check valve disc on
the plunger (open end up) into the lifter it. Carefully slide the check valve over the 1. Drain the crankcase. Remove the
body. disc and down until it bottoms. A slight oil level dipstick. Remove the oil pan and
5. Position the metering valve (disc) turning motion will help this. Use every related parts.
in the plunger, and then place the push precaution not to distort it in any way, or 2. Remove the oil pump and inlet
rod cup in the plunger. to bend the preformed fingers. With a tube assembly.
6. Depress the plunger, and position slight turning motion slide the plunger 3. Replace one bearing at a time,
the closed end of the lock ring in the spring over the metering valve and d~wn leaving the other bearings securely
groove of the lifter body. With the plunger until it seats. fastened. Remove the main bearing cap to
still depressed, position the open ends of 2. Leaving the assembly in the which new bearings are to be installed.
the lock ring in the groove. Release the inverted position, slide the lifter body 4. Insert the upper bearing removal
plunger, and then depress it again to fully down over the spring until it slightly tool in the oil hole in the crankshaft.
seat the lock ring. compresses the spring.
7. Use the hydraulic valve lifter 3. Position the combined assembly 5. Rotate the crankshaft in the
leakdown tester (pageS-9 ) to fill the lifters right side up on the work surface (table or direction of the engine rotation to force
with test fluid . bench). the bearing out of the block.
4. Position the upper metering valve 6. If the rear main bearing is being
in the plunger taking care not to tilt it to replaced, remove and discard the rear oil
either side, and not to damage or bend the seal from the bearing cap.
TYPE II valve tensioning finger. Place the metering Loosen all main bearing bolts, thereby
valve disc over the metering valve and lowering the crankshaft slightly but not to
Disassembly install the push rod cup. Depress the cup exceed 1/32 inch. Remove the block half
and install the lock ring. of the rear oil seal. Use a seal removal tool
Each valve lifter is a rna tched 5. Use the hydraulic valve lifter or install a small metal screw in one end of
assembly. If parts of one lifter are leakdown tester to fill the lifters with the seal, and pull on the screw to remove
intermixed with those of another, test fluid. the seal. Be careful not to burr the
improper valve operation may result. crankshaft seal rubbing surface.
8-56 GROUP 8- ENGINE
INSTALL SEAL WITH LIP Lubricate the journal with engine oil
TOWARDS FRONT OF ENGINE
and install the thrust bearing cap with the
bolts fmger-tight. Pry the crankshaft
forward against the thrust surface of the
upper half of the bearing (Fig. 44). Hold
the crankshaft cap to the rear. This will
FRONT OF ENGINE align the thrust surfaces of. both halves of
the bearing. Retain the forward pressure
on the crankshaft. Torque the cap bolts to
specifications.
11. Clean the oil pump inlet tube
SEAL HALVES TO PROTRUDE BEYOND PARTING FACES screen. Prime by filling the inlet opening
THIS DI STANCE TO ALLOW FOR CAP TO BLOCK ALIGNMENT with oil and rotate the pump shaft until
oil emerges from the outlet opening.
Install the oil pump and the inlet tube
assembly.
12. Position the oil pan gaskets on the
oil pan. Position the oil pan front seal on
t
3/ 8"
the cylinder front cover. Position the oil
pan rear seal on the rear main bearing cap.
Install the oil pan and related parts. Install
the oil level dipstick.
VIEW LOOKING AT PARTING FACE
13. Fill the crankcase. Start the
REAR FACE OF REAR MAIN
BEARING CAP AND CY LI NDER BLOCK OF SPLIT, LIP· TYPE CRANKSHAFT SEAL engine and check for oil pressure. Operate
A 2639-B the engine at fast idle and check for oil
leaks.
FIG. 29- Installing Crankshaft Rear Oil
Seal
CONNECTING ROD BEARINGS
SEALER
shaft on the locking tang side of the block The connecting rod bearings are
and partially install the bearing so that selective fit. Refer to procedures under
tool 6331 can be inserted in the oil hole in Fitting Main and Connecting Rod Bearings
the crankshaft. With tool 6331 positioned on page 8.·33 .
in the oil hole in the crankshaft, rotate the
crankshaft in the opposite direction of
engine rotation until the bearing seats REMOVAL
itself. Remove the tool.
4. Replace the cap bearing. 1. Drain the crankcase. Remove the
5. Select fit the bearing for proper oil level dipstick. Remove the oil pan and
clearance following procedures under related parts.
Fitting Main and Connecting Rod Bearings 2. Remove the oil pump and inlet
in Part 8-1. tube assembly.
FIG. 30- Seeler Application to Rear Main
Bearing Cap 3. Tum the crankshaft until the
6. If the bearing is being replaced on connecting rod to which new bearings are
journal number 1, 2 or 4, apply a light to be fitted is down. Remove the
INSTALLATION coat of engine oil to the journal and connecting rod cap. Remove the bearing
bearings and install the bearing cap. inserts from the rod and cap.
1. If the rear main bearing is being Tighten the cap bolts to specifications.
replaced, clean the rear oil seal groove in 7. If the rear main bearing is being INSTALLATION
the block with a brush and solvent. replaced, clean the oil seal groove with a
Carefully install the upper seal (split brush and solvent. 1. Be sure the bearing inserts and the
lip type) into its groove with the undercut 8. Install the lower seal in the rear bearing bore in the connecting rod and cap
side of the seal toward the FRONT of the main bearing cap with undercut side of are clean. Foreign material under the
engine (Fig. 29) by rotating it on the seal seal toward the FRONT of the engine inserts will distort the bearing and cause a
journal of the crankshaft until (Fig. 29) allow the seal to protrude failure.
approximately 3/8 inch protrudes below approximately 3/8 inch above the parting 2. Clean the crankshaft journal.
the parting surface. surface to mate with the upper seal when 3. Install the bearing inserts in the
Be sure no rubber has been shaved the cap is installed. connecting rod and cap with the tangs
from the outside diameter of the seal by 9. Apply a thin coating of fitting in the slots provided.
the bottom edge of the groove. oil-resistant sealer to the rear main bearing 4. Pull the connecting rod assembly
Tighten the bolts on main bearings 1, cap at the rear of the top mating surface down frrmly on the crankshaft journal.
2, 3, and 4, thereby raising the crankshaft (Fig. 30). Do not apply sealer to the area 5. Select fit the bearing following
to its original position. Torque the bolts to forward of the oil slinger groove. procedures under Fitting Main and
specifications. Lubricate the journal with engine oil and Connecting Rod Bearings on page 8-33..
2. Clean the crankshaft journals. install the rear main bearing cap with the
Inspect the journals and thrust faces rear surface flush or slightly forward of 6. After the bearing has been fitted,
(thrust bearing) for nicks, burrs or bearing the rear of the cylinder block. Tighten the clean and apply a light coat of engine oil
pick-up that would cause premature cap bolts to specifications. to the journal and bearings. Install the
bearing wear. 10. If the thrust bearing cap (No. 3 connecting rod cap. Torque the nuts to
3. To install the upper main bearing, main bearing) has been removed, install it specifications.
place the plain end of the bearing over the as follows: 7. Clean the oil pump inlet tube
PART 8-4-302-351 C.I.D. VB ENG INES 8-57
screen. Prime by filling the inlet opening OIL RING SPACER
with oil and rotate the pump shaft until
oil emerges from the outlet opening.
Install the oil pump and the inlet tube
assembly.
8. Position the oil pan gaskets on the
oil pan. Position the oil pan front seal on
the cylinder front cover. Position the oil
pan rear seal on the rear main bearing cap.
Install the oil pan and related parts. Install
the oil level dipstick.
9. Fill the crankcase. Start the
engine and check for oil pressure. Operate
the engine at fast idle and check for oil
FIG. 32- Installing Piston
leaks.

PISTONS AND CONNECTING

RODS

REMOVAL
FIG. 31 -Piston Ring Spacing
1. Drain the cooling system and the
crankcase. Remove the intake manifold, engine. The numbers on the connecting
cylinder heads, oil pan and oil pump, rod and bearing cap must be on the same
following the procedures in this section. side when installed in the cylinder bore. If
2. Remove any ridges and/or a connecting rod is ever transposed from
deposits from the upper end of the one block or cylinder to another, new
cylinder bores as follows: bearings should be fitted and the
Tum the crankshaft until the piston connecting rod should be numbered to
to be removed is at the bottom of its correspond with the new cylinder number.
travel and place a cloth on the piston head 3. Make sure the ring gaps are
to collect the cuttings. Remove any ridge properly spaced around the circumference
and/or deposits from the upper end of the of the piston (Fig. 31);
cylinder bores. Remove the cylinger ridge 4. Install a piston ring compressor
with a ridge cutter. . Follow the on the piston and push the piston in with
instructions furnished by the tool a hammer handle until it is slightly below
the top of the cylinder (Fig. 32). Be sure FIG. 33 - Checking Connecting Rod Side
manufacturers. Never cut into the ring
Cl earance
travel area in excess of 1/32 inch when to guide the connecting rods to avoid
removing ridges. damaging the crankshaft journals. Install
3. Make sure all connecting rod caps the piston with the arrow on the piston 13. Install the intake manifold
are marked so that they can be installed in head toward the front of the engine. following procedures under Intake
their original positions. 5. Check the clearance of each Manifold installation.
4. Turn the crankshaft until the bearing following the procedure under 14. Fill and bleed the cooling system.
connecting rod being removed is down. Fitting Main and Connecting Rod Fill the crankcase with the proper grade
S. Remove the connecting rod nuts Bearings on page 8-33. and quantity of engine oil.
and cap. 1S. Start the engine and check and
6. Push the connecting rod and 6. After the bearings have been adj ust the ignition timing. Connect the
piston assembly out the top of the .fitted, apply a light coat of engine oil to distributor vacuum hose at the distributor.
cylinder with the handle end of a hammer. the journals and bearings. 16. Operate the engine at fast idle
Avoid damage to the crankshaft journal or 7. Turn the crankshaft throw to the until it reaches normal operating
the cylinder wall when removing the bottom of its stroke. Push the piston all temperature and check for oil and coolant
piston and rod. the way down until the connecting rod leaks. When the engine temperature has
7. Remove the bearing inserts from bearing seats on the crankshaft journal. stabilized adjust the engine idle speed and
the connecting rod and cap. 8. Install the connecting rod cap. idle fuel mixture.
8. Install the cap on the connecting Torque the nuts to specifications. 17. Install the air cleaner and intake
rod from which it was removed. 9. After the piston and connecting duct assembly.
rod assemblies have been installed, check
INSTALLATION the side clearance between the connecting
rods on each crankshaft journal (Fig. 33).
1. If new piston rings are to be 10. Disassemble, clean, and assemble DISASSEMBLY
installed, remove the cylinder wall glaze. the oil pump. Clean the oil pump inlet
Follow the instructions of the tool tube screen and the oil pan and block 1. Remove the bearing inserts from
manufacturer. gasket surfaces. the connecting rod and cap.
2. Oil the piston rings, pistons and 11. Prime the oil pump by filling 2. Mark the pistons and pins to
cylinder walls with light engine oil. Be sure either the inlet port or outlet port with assure assembly with the same rod and
to install the pistons in the same cylinders engine oil and rotating the pump shaft to installation in the same cylinders from
from which they were removed or to distribute the oil within the hou sing. which they were removed.
which they were fitted. The connecting Install the oil pump and the oil pan. 3. Remove the piston rings. Using an
rod aud bearing caps are numbered from 1 12. Install the cylinder heads Arbor Press aPd the tool shown in Fig. 34,
to 4 in the right bank and from 5 to 8 in following procedures under Cylinder Head press the piston pin from the piston and
the left bank, beginning at the front of the Installation. connecting rod.
8-58 GROUP 8- ENGINE
ASSEMBLY

The piston. connecting rod and

related parts are shown in Fig. 35. Check
L,J-.. . . .. RICHT BANK LEFT BANK

the fit of a new piston in the cylinder bore

before assembling the piston and piston
pin to the connecting rod.
The piston pin bore of a connecting
rod and the diameter of the piston p_in
must be within specifications. Refer
specifications.
1. Apply a light coat of engine oil to NUMBERED SIDE OF ROD A326().A
all parts. Assemble the piston to the
connecting rod with the cylinder number FIG. 36- Correct Piston and Rod Positions
side of the connecting rod and the arrow
on the piston positioned as shown in Fig.
n INSERT
36. On replacement connecting rods, Q TAPERED PILOT
Fri~ ~~I~T~~:ri~AL
1
install the large-chamfered side of the .....,...-

connecting rod bearing bore towards the

crankshaft cheek ; facing towards front of Reversible INSERT THI S END
locator - IN PIS TON HOLE
engine on right bank rods, and facing Detail A-5 ~ - FOR INSTALLATION
towards rear of engine on left bank rods.
2. Start the piston pin in the piston
and connecting rod (this may require a
~Adapter Detail A-3

very light tap with a mallet). Using an

Arbor Press and the tool shown in Fig. 34, T68P-6135-A
Cup Detail A-1
press the piston pin through the piston
and connecting rod until the pin ·is
centered in the piston.
3. Check the end gap of all piston A3258-8
rings (page 8-18 ). It must be within
FIG. 37- Removing Clutch Pilot Bearing
specifications. Follow the instructions
contained on the piston ring package and FIG. 34 - Removing or Installing Piston Pin
install the piston rings.
4. Check the ring side clearance of attaching bolts with oil-resistant sealer.
the compression rings with a feeler gauge Position the flywheel on the crankshaft
inserted between the ring and its lower flange. Install and torque the bolts in
land. The gauge should slide freely around sequence across from each other to
the entire ring circumfere1:1ce without specifications.
binding. Any wear that occurs will forrn a 2. On a vehicle with a manual-shift
step at the inner portion of the lower land. transmission, check the flywheel runout,
If the lower lands have high steps, the following the procedure in Part 8-1 and
piston should be replaced. install the clutch pressure plate, disc and
5. Be sure the bearing inserts and the the transmission following the procedures
bearing bore in the connecting rod and cap in Group 6.
are clean. Foreign material under the On a veh!de with an automatic trans-
inserts will distort the bearing and cause a mission, check the flywheel runout, and
failure. Install the bearing inserts in the install the transmission and converter .
connecting rod and cap with tangs fitting housing following procedure in Group 7.
in the slots provided.

FLYWHEEL

REMOVAL CLUTCH PILOT BEARING

1. On a vehicle with a manual-shift REMOVAL

transmission, remove the transmission,
clutch pressure plate and disc following 1. Remove the transmission, clutch
the procedures in Group 6. pressure plate and disc, following the
On a vehicle with automatic trans- procedures in Group 6.
mission, remove the transmission and 2. Remove the pilot bearing as
converter housing following the pro- shown in Fig. 37.
cedure in Group 7.

A3259.A INSTALLATION
2. Remove the flywheel attaching
belts and remove the flywheel. 1. Coat the pilot bearing bore in the
crankshaft with a small quantity of wheel
INSTALLATION FIG. 35- Piston, Connecting Rod and bearing lubricant. Avoid using too much
Related Parts lubricant as it may be thrown onto the
1. Coat the threads of the flywheel clutch disc when the clutch revolves.
PART .8-4-302-351 C.I.D. V8 ENGINES 8-59
2. Install the pilot service bearing as 4. Position the oil pan front seal on
shown in Fig. 38. the cylinder front cover. Be sure the tabs
3. Install the clutch pressure plate, on the seal are over the oil pan gasket.
disc and the transmission, following the 5. Position the oil pan rear seal on
procedures in Group 6. the rear main bearing cap (Fig. 40). Be
sure the tabs on the seal are over the oil
pan gasket.
6. Position the oil pan against the
block and install a bolt, finger-tight, on
each side of the block. Install the
remaining bolts. Tighten the bolts from
the center outward in each direction to
specifications.
7. Raise the engine and remove the
wood blocks from between the engine
supports and chassis brackets. Lower the
engine and install the engine support
through bolts. Tighten the bolts to
specifications.
8. Install the sway bar to chassis
attaching bolts.
9. Install the starter and connect the
starter cab!e.
10. Lower the vehicle.
Tooi-7600-H 11. Install the fan shroud attaching
Al262-A bolts.
12. Install the oil level dipstick. Fill
FIG. 38- Installing Clutch Pilot Bearing the crankcase with the proper grade and
quantity of engine oil. Start the engine
and operate at idle speed until it reaches
normal operating temperature. Check for
OIL FILTER FIG. 40- Oil Pan Gaskst and Ssals Installed leaks.

CARTRIDGE-TYPE OIL OIL PUMP

FILTER OIL PAN
REMOVAL
The oil filter assembly is shown in Fig. REMOVAL
39. 1. Remove the oil pan and related
1. Remove the oil level dipstick. parts as outlined under Oil Pan Removal.
Removal 2. Remove the fan shroud attaching 2. Remove the oil pump attaching
bolts and position the fan shroud over the bolts and remove the oil pump with pick
Place a drip pan under the filter. fan. up tube and screen, gasket and
Unscrew the filter from the adapter fitting 3. Raise the vehicle. intermediate drive shaft.
and clean the adapter recess. 4. Drain the crankcase.
5. Disconnect the starter cable and INSTALLATION
remove the starter.

.,
FILTER ELEMENT 6. Remove the sway bar attaching 1. Clean and install the oil pump
bolts from the chassis and lower the sway inlet tube and screen assembly (Fig. 41).
bar for clearance. 2. Prime the oil pump by filling
7. Remove the engine front support either the inlet or outlet port with engine
through bolts. oil. Rotate the pump shaft to distribute
8. Raise the engine and place wood the oil within the pump body.
blocks between the engine supports and 3. Position the intermediate drive
ADAPTER FITTING A2875-A chassis brackets. shaft into the distributor socket. With the
9. Remove the oil pan attaching shaft firmly seated in the distributor
bolts. socket, the stop on the shaft should touch
FIG. 39- Cartridge·Typs Oil Filtsr the roof of the crankcase. Remove the
10. If equipped with an automatic
transmission, position the oil cooler lines shaft and position the stop as necessary.
out of the way. 4. Position a new gasket on the
Installation 11. Remove the oil pan. pump housing. With the stop properly
po$itioned, insert the intermediate drive
1. Coat the gasket on a new filter INSTALLATION shaft into the oil pump. Install the pump
with oil. Place the new filter in position on and shaft as an assembly. Do not attempt
the adapter fitting. Hand tighten the filter 1. Clean the gasket surfaces of the to force the pump into position if it wiD
until the gasket contacts the adapter face, block and oil pan. The oil pan has a not seat readily. The drive shaft hex may
and then advance it 1/2 turn. two-piece gasket. be misaligned with the distributor shaft.
2. Operate the engine at fast idle, 2. Clean the oil pump pick-up tube To align, rotate the intermediate drive
and check for oil leaks. If oil leaks are and screen. shaft into a new position. Tighten the oil
evident, perform the necessary repairs to 3. Coat the block surface and the oil pump attaching screw to specifications.
correct leakage. Check the oil level and fill pan gasket with sealer. Position the oil pan Be sure the oil pick up screen is
the crankcase if necessary. gaskets on the cylinder block (Fig. 40). parallel with the oil pan mounting surface.
8-60 GROUP 8- ENGINE

5. Install the oil pan and related 3. Insert a self-threading sheet metal plunger, spring and a new cap.
parts as outlined under Oil Pan screw of the proper diameter into the oil 3. Install the outer race and the
Installation. pressure relief valve chamber cap and pull inner rotor and shaft assembly. Be sure the
the cap out of the chamber. Remove the dimple (identification mark) on the outer
spring and plunger. race is facing outward and on same side as
DISASSEMBLY identification mark on rotor. The race
rotor and shaft and the outer race are
I. Remove the oil inlet tube from ASSEMBLY serviced as an assembly. One part should
the oil pump. not be replaced without replacing the
2. Remove the cover attaching The oil pump assembly is shown in other. Install the cover and tighten the
screws, then remove the cover. Remove Fig. 42. cover attaching screws to specifications.
the inner rotor and shaft assembly, then 1. Oil all parts thoroughly. 4. Install the oil inlet tube and
remove the outer race. 2. Install the oil pressure relief valve screen assembly on the oil pump.

OIL RELIEF VALVE

ASSEMBLY

A326S.A

FIG. 41 - Oil Pump and Inlet Tube Installed FIG. 42- Oil Pump Assembly

3 ENGINE REMOVAL AND INSTALLATION

REMOVAL 11. On vehicles equipped with air 20. Disconnect the starter cable and
conditioning, isolate and remove the remove the starter.
I. Disconnect the battery, drain the compressor. 21. Remove the engine front support
cooling system and remove the hood. 12. Remove the alternator and through bolts and the starter cable clamp
2. Remove the air cleaner and intake bracket. Position the alternator out of the at the right front engine support.
duct assembly. way. Disconnect the alternator ground 22. If equipped with automatic
3. Disconnect the upper radiator wire from the cylinder block. transmission, remove the converter
hose at the engine and the lower hose at 13. Disconnect the heater hoses at the inspection cover and disconnect the
the radiator. On vehicles equipped with block and water pump. flywheel from the converter. Remove the
automatic transmission, disconnect the oil 14. Remove the ground wires from downshift rod.
cooler lines at the radiator. the cylinder block and right cylinder head. Remove the four lower converter
Remove the fan shroud attaching 15. Disconnect the fuel line at the housing-to-engine block bolts and the
bolts and position the shroud over the fan. fuel pump. Plug the fuel tank line. adapter plate-to-converter housing bolt.
Remove the radiator and shroud. Disconnect the vacuum lines at the rear of On vehicles equipped with a manual
5. Remove the fan and spacer. the intake manifold. transmission, remove the clutch slave
6. On vehicles equipped with air 16. Disconnect the accelerator cable cylinder from the cylinder block and
conditioning, loosen the idler pulley and or linkage at the carburetor and in take remove the four lower bell
remove the drive belt. manifold. Disconnect transmission housing-to-engine block bolts.
7. Loosen the alternator and remove downshift linkage, if so equipped. 23. Lower the vehicle.
the drive belt. 17. Disconnect the engine wire loom 24. Remove the two upper converter
8. On vehicles with power steering, at the ignition coil, water temperature or bell housing bolts.
loosen and remove the power steering sending unit and oil pressure sending unit. 25 . Attach engine lifting sling, Tool
pump drive belt. Remove the wire loom from the hold No. T53L-300.A, and hoist to lifting
9. Remove the water pump pulley. down clips. brackets at exhaust manifolds.
10. On vehicles with power steering, 18. Raise the vehicle and secure with 26. Position a jack under the
remove the power steering pump brackets safety stands. transmission.
and position the pump out of the way in 19. Disconnect the muffler inlet pipe 27. Raise the engine slightly and
an upright position to prevent fluid loss. at the exhaust manifolds. carefully pull it from the transmission.
PART 8-4-302-351 C.I.D. VB ENGINES 8-61
Carefully lift the engine out of the engine 5. On automatic transmission 15. Connect the ground wire at the
compartment so that the rear cover plate equipped vehicles, position the downshift right front of cylinder block. Install the
is not bent or components damaged. rod on the transmission and engine. heater hoses at the water pump and
Install the engine on a WOlk stand. 6. Raise the vehicle and secure with cylinder block.
safety stands. 16. Install the alternator and bracket.
INSTALLATION 7. On a vehicle with an automatic Connect the alternator ground wire to the
transmission, position the transmission cylinder block.
1. Attach engine lifting sling, Tool linkage bracket and install the remaining 17. On a vehicle with air
No. T53L-300-A, and hoist to lifting converter housing bolts. Install the adapter conditioning, install the air conditioning
brackets at exhaust manifolds. Remove plate-to-converter housing bolt. Install the compressor and brackets.
engine from work stand. converter-to-flywheel nuts and install the 18.- On a vehicle with power steering,
2. Lower the engine carefully into inspection cover. Connect the downshift install the power steering pump and
the engine compartment. Make sure the rod on the transmission. brackets.
exhaust manifolds are properly aligned On a vehicle with a manual 19. Install the water pump pulley, fan
with the muffler inlet pipes. transmission, install the lower bell housing and spacer. Install the drive belts on their
On a vehicle with an automatic bolts and replace the clutch slave cylinder. respective pulleys and adjust the belt
transmission, start the converter pilot into 8. Install the starter and connect the tension to specifications.
the crankshaft. cable. 20. Position the fan shroud over the
On a vehicle with a manual-shift 9. Connect the muffler inlet pipes at fan. Install the radiator and connect the
transmission, start the transmission main the exhaust manifolds. upper and lower radiator hoses. Insta1l the
drive gear into the clutch disc. It may be 10. Install the engine front support fan shroud attaching bolts.
necessary to adjust the position of the through bolts and install the starter cable 21. Fill and bleed the cooling system.
transmission in relation to the engine if clamp at the right front engine support. Fill the crankcase with the proper grade
the input shaft will not enter the clutch 11. Lower the vehicle. and quantity of oil Adjust the
disc. If the engine hangs up after the shaft 12. Install the ground wire at the transmission downshift linkage, if so
enters, tum the crankshaft slowly right cylinder head. Install the engine wire equipped. Connect the battery.
(transmission in gear) until the shaft loom and connect it to the ignition coil, 22. Operate the engine at fast idle
splines mesh with the clutch disc splines. water temperature sending unit and oil until it reaches normal operating
3. Install the bell housing or pressure sending unit. temperature and check all gaskets and
converter housing upper bolts, making 13. Install the accelerator linkage and hose connections for leaks. Adjust ignition
sure that the dowels in the cylinder block connect the downshift rod, if so equipped. time and idle speed.
engage the flywheel housing. Remove the 14. Connect the vacuum lines at the 23. Install the air cll'.aner and intake
jack from under the transmission. rear of the intake manifold. Connect the duct. Install and adjust the hood.
4. Remove the lifting sling. fuel tank line at the fuel pump.

4 MAJOR REPAIR OPERATIONS

When installing nuts or bolts that alternator and mounting brackets. bearing cap. Push the connecting rod and
must be torqued (to specifications), oil 3. Remove the crankshaft pulley piston assembly up into the cylinder.
the threads with light weight engine oil. from the crankshaft vibration damper. Repeat this procedure until all the
Do not oil threads that require oil-resistant Remove the cap screw and washer from connecting rod bearing caps are removed.
or water-resistant sealer. the end of the crankshaft. Install the 8. Remove the main bearing caps.
puller on the crankshaft vibration damper 9. Carefully lift the crankshaft out
To perform the operations in this (Fig. 18) and remove the damper. of the block so that the thrust bearing
section, it will be necessary to remove the 4. Remove the timing pointer. surfaces are not damaged. Handle the
engine from the vehicle and install it on a Remove the water pump and cylinder crankshaft with care to avoid possible
work stand as previously described. front cover as an assembly. Discard the fracture or damage to the fmished
Refer to page 8-15 for cleaning and gasket and remove the crankshaft front oil surfaces.
inspection procedures. slinger.
5. Check that the timing chain
deflection does not exceed 0.5 inches.
CRANKSHAFT Remove the camshaft sprocket cap screw, INSTALLATION
washer and two piece fuel pump eccentric.
The crankshaft and related parts are Slide both sprockets and the timing chain 1. Remove the rear journal oil seal
shown in Fig. 43. forward and remove them as an assembly from the block and rear main bearing cap.
(Fig. 23). 2. Remove the main bearing inserts
REMOVAL 6. Invert the engine on the work from the block and bearing caps.
stand. Remove the clutch pressure plate 3. Clean the rear journal oil seal
1. Disconnect the spark plug wires at and disc (manual-shift transmission). groove and the mating surfaces of the
the spark plugs and remove the wires from Remove the flywheel and engine rear block and rear main bearing cap.
the ignition harness brackets on the valve cover plate. Remove the oil pan and 4. Remove the connecting rod
rocker arm covers. Disconnect the gasket. Remove the oil pump. bearing inserts from the connecting rods
coil-to-distributor cap and spark plug wire 7. Make sure all bearing caps (main and caps.
assembly. Remove the spark plugs to allow and connecting rod) are marked so that 5. If the crankshaft main bearing
easy rotation of the crankshaft. they can be installed in their original journals have been refmished to a defmite
2. Disconnect the fuel pump outlet locations. Turn the crankshaft until the undersize, install the correct undersize
line at the pump. Remove the fuel pump connecting rod from which the cap is bearings. Be sure the bearing inserts and
from the cylinder block. Remove the being removed is down, and remove the bearing bores are clean. Foreign material
8-62 GROUP 8- ENGINE

MAIN BEARING
INSERTS

AJ266-A

FIG. 43- Crankshaft and Related Parts

PRY CAP
• PRY FORWARD
BACKWARD

THRUST BEARING

FIG. 44 -Aligning Thrust Bearing

under the inserts will distort the bearing Fitting Main and Connecting Rod Bear- original locations. Torque the bearing cap
and cause a failure. ings on page 8-33. bolts to specifications.
6. Place the upper main bearing 14. Install the thrust bearing cap with
inserts in position in the bores with the 11. After the bearings have been the bolts finger-tight.
tang fitting in the slot provided. fitted, apply a thin coating of oil-resistant 15. Pry the crankshaft forward
7. Install the lower main bearing sealer to the rear main bearing cap at the against the thrust surface of the upper half
inserts in the bearing caps. rear of the top mating surface (Fig. 32). of the bearing (Fig. 44).
8. Dip the lip seal halves in clean Do nGt apply sealer to the area forward of 16. Hold the crankshaft forward and
engine oil. Install the lip seals in the the oil slinger groove. pry the thrust bearing cap to the rear. This
bearing cap and block with the undercut 12. Apply heavy engine oil MS to the will align the thrust surfaces of both halves
side of the seal toward the FRONT of the journals and bearings. of the bearing.
engine as shown in Fig. 29. 13 . Install the rear main bearing cap 17. Retain the forward pressure on
9. Carefully lower the crankshaft with the rear surface flush or slightly the crankshaft. Tighten the cap bolts to
into place. Be careful not to damage the ahead of the rear of the cylinder block. specifications.
bearing surface. Install all bearing caps, except the thrust 18. Force the crankshaft toward the
10. Check the clearance of each main bearing cap (No. 3 bearing). Be sure that rear of the engine.
bearing following the procedure under the main bearing caps are installed in their 19. Check the crankshaft end play
PART 8-4- 302-351 C. I. D. VB ENGINES 8-63
(wear limit 0.012 inches). DETAIL-1,-2 or .J
EXPANDING COLLET
20. Install the timing chain and
sprockets, cylinder front cover and fuel
pump, following steps 1 thru 8 under EXPANDING MANDREL
Cylinder Front Cover and Timing Chain
Installation.
21. Install the engine rear cover plate
onto the alignment dowels at the rear of
the cylinder block.
22. Coat the threads of the flywheel
attaching bolts with oil-resistant sealer.
Position the flywheel on the crankshaft
flange. Install and tighten the bolts to
specifications.
On a flywheel for a manual-shift
transmission, use tool 7550 A to locate
the clutch disc. install the pressure pl'ate. DETAIL-5
Tighten the attaching bolts. PULLER SCREW
23. Install new bearing inserts in
the connecting rods and caps. Check the
DETAIL-4
PULLING PLATE ITool-T65L-6250-A I
clearance of each bearing following the
procedures under Fitting Main and
Connecting Rod Bearings on page 8·33 . FIG. 45- Camshaft &lsring Replset~ment A2813-A

24. After the connecting rod bearings

have been fitted, apply a light coat of
engine oil to the journals and bearings.
25. Tum the crankshaft throw to the
bottom of its stroke. Push the piston all 3. Select the proper size expanding
the way down until the rod bearing seats collet and back-up nut and assemble on
on the crankshaft journal. the expanding mandrel. With the
26. Install the connecting rod cap. expanding collet collapsed, install the
Torque the nuts to specifications. collet assembly in the camshaft bearing,
27. After the piston and connecting and tighten the back-up nut on the
rod assemblies have been installed, check expanding mandrel until the collet fits the
the side clearance between the connecting camshaft bearing.
rods on each connecting rod crankshaft 4. Assemble the puller screw and
journal (Fig. 33). extension (If necessary) as shown and
28. Clean the oil pan, oil pump and install on the expanding mandrel. Wrap a
oil pump screen. Prime the oil pump by cloth around the threads of the puller
filling either the inlet or outlet port with screw to protect the front bearing or FIG. 46- C.mlh•ft Front BHrlng
ellline oil and rotating the pump shaft to journal. Tighten the pulling nut against the Meuutwment
distribute oil within the housing. Install thrust bearing and pulling plate to remove
the oil pump and oil pan by following the the camshaft bearing. Be sure to hold a
procedures under Oil Pan and Oil Pump wrench on the end of the puller screw to
Installation. prevent it from turning. CYLINDER ASSEMBLY
29. Install the front oil seal, vibration 5. Repeat the procedure for each REPLACEMENT
damper and crankshaft pulley, following bearing. To remove the front bearing,
steps 10 thru 12 under Cylinder Front install the puller screw from the rear of DISASSEMBLY
Cover and Timing Chain Installation. the cylinder block.
30. Install the spark plugs, distributor Follow steps 1 thru 17, 19, 20 and 24
cap and spark plug wires. Connect the INSTALLATION thru 27 under Engine Disassembly.
spark plug wires and high tension lead. Remove 4 cylinder head dowels from the
31. Install the engine in the vehicle. 1. Position the new bearings at the cylinder block. Remove the cylinder block
bearing bores with the oil holes aligned, drain plugs and remove the cylinder
CAMSHAFT BEARING and press them In place with the tool assembly from the work stand.
shown In Fig. 45. Be sure to center the
Camshaft bearings are available pulling plate and puller screw to avoid
pre-fmlshed to size for standard and damage to the bearing. Failure to use the ASSEMBLY
0.015-inch undersize journal diameters. co""t expanding collet can cauae aewre
The bearings are not interchangeable from bearing damap. Be sure the front bearlnJ Clean the gasket and seal surfaces of
one bore to another. is installed the specified distance below all parts and assemblies.
the front face of the cylinder block (Fia- Install the replacement cylinder
REMOVAL 49). assembly on a work stand. Install the
2. Install the core plug. cylinder block drain plugs and cylinder
1. Remove the camshaft, flywheel 3. Install the camshaft, crankshaft, head dowels. Transfer all parts removed
and crankshaft. Push the pistons to the flywheel and related parts, except do not from the old cylinder assembly, following
top of the cylinders. check connecting rod and main bearing the procedures In steps 19, 20, 24 thru 27
2. Remove the camshaft rear bearing clearances as a part of the Camshaft and 29 thru 64 under Engine Assembly.
bore plug. Remove the camshaft bearings Bearing Replacement. Install the engine in Check all assembly clearances and correct
(Fig. 45). the vehicle. as necessary.
8-64 GROUP 8- ENGINE
CYLINDER BLOCK REPLACEMENT If the valve lifters are stuck in their 27. Remove the oil pump and inlet
bores by excessive varnish, etc., it may tube as an assembly. Remove the
Before replacing a cylinder block, be necessary to use a plier-type tool or a intermediate drive shaft. Discard the oil
determine if it is repairable, and make the claw-type tool to remove the lifters. pump gasket.
necessary repairs. Rotate the lifter back and forth to loosen 28. Make sure all connecting tods and
it from the gum or varnish that may have caps are marked so that they can be
DISASSEMBLY formed at the lifter. installed in their original locations. Tum
the crankshaft until the connecting rod
Follow steps 1 thru 17, 19 and 20 being removed is down. Remove the rod
The internal puts of each hydraulic
thru 32 under Engine Disassembly. cap.
valve lifter assembly are matched sets. Do
Remove the 4 cylinder head dowels and 29. Push the connecting rod and
not intermix the puts. Keep the
the cylinder block drain plugs from the piston assembly out of the top of the
assemblies intact until they are to be
cylinder block. Remove the cylinder block cylinder with the handle end of a hammer.
cleaned.
from the work stand. Avoid damage to the connecting rod
13. Remove the exhaust manifolds journal or the cylinder wall when
ASSEMBLY and the spark plugs. removing the piston and rod.
14. Remove the cylinder head bolts 30. Remove the bearing inserts from
Install the replacement cylinder block and lift the cylinder heads off the block. the connecting rods and caps. Install the
on the work stand. Install the cylinder Discard the cylinder head gaskets. rod caps on the connecting rods from
block drain plugs and cylinder head 15. Remove the crankshaft pulley which they were removed.
dowels. Transfer the parts removed from from the crankshaft vibration damper. 31. Remove the main bearing caps.
the old cylinder block to the new cylinder Remove the cap screw and washer from 32. Carefully lift the crankshaft out
block by following steps 5 thru 64 under the end of the crankshaft. Install .the of the cylinder block so that the thrust
Engine Assembly. Check all assembly puller on the crankshaft vibration damper bearing surfaces are not damaged. Handle
clearances and correct as necessary. (Fig. 18) and remove the vibration the crankshaft with care to avoid possible
damper. fracture or damage to the fmished
16. Remove the timing pointer. surfaces.
17. Remove the cylinder front cover 33. Remove the rear journal oil seal
ENGINE DISASSEMBLY AND attaching screws. Remove the cylinder from the block and rear bearing cap.
ASSEMBLY front cover and water pump as an 34. Remove the main bearing inserts
assembly. Discard the gasket and remove from the block and bearing cap. Install the
DISASSEMBLY the crankshaft front oil slinger. main bearing caps in their original
18. Remove the water pump from the positions.
1. Install the engine on the work front cover. 35. Remove the camshaft rear bearing
stand. 19. Remove the thermostat housing bore plug. Remove the camshaft bearings
2. Remove the distributor cap, coil and thermostat from the block. Remove (Fig. 45).
high tension wire and spark plug wires as the oil pressure and temperature sending
an assembly. units from the block. ASSEMBLY
3. Disconnect the primary wire at 20. Remove the fuel pump.
the coil and remove the coil. 21. Check the timing chain deflection If the cylinder block is to be replaced,
4. Remove the alternator and does not exceed 0.5 inches. transfer the cylinder head dowels, front
brackets from the water pump and Remove the camshaft sprocket cap cover and rear cover plate alignment
cylinder head. screw, washer and two piece fuel pump dowels, dip stick tube, oil filter adapter,
5. Remove the crankcase emission eccentric. Slide both sprockets and the fuel pump retaining stud and drain plugs
valve from the right rocker arm cover. timing chain forward, and remove them as to the new cylinder block and start the
6. Disconnect the carburetor to fuel an assembly (Fig. 23). assembly procedures with step number 5.
pump line and remove the line. Remove 22. Remove the camshaft thrust 1. If the original cylinder block is
the carburetor. plate. Carefully remove the camshaft by used, remove the glaze from the cylinder
7. Disconnect the vacuum lines at pulling it toward the front of the engine. bores by following the instructions in ·
the distributor and control valve. Remove Use caution to avpid damaging the Part 8-1.
the distributor hold down bolt and the journals and lobes. 2. Invert the engine on the work
distributor. 23. Remove any ridge and/or carbon stand.
8. Remove the intake manifold deposits from the upper end of the 3. Position the new camshaft
attaching bolts. Raise the intake manifold cylinder bores. Move the piston to the bearings at the bearing bores with the oil
and carefully remove it from the engine. bottom of its travel and place a cloth on holes aligned, and press them in place with
Discard the gasket and seals. the piston head to collect the cuttings. the tool shown in Fig. 46. Be sure the
9. Remove the rocker arm covers. Remove the cylinder ridge with a ridge camshaft front bearing is installed the
10. Remove the rocker arm fulcrum cutter. Follow the instructions furnished specified distance below the front face of
bolts and remove the fulcrum seats and by the tool manufacturer. Never cut into the cylinder block.
rocker arms. Place the rocker llrms and the ring travel area in excess of 1/32 inch 4. Using tool T70P-6011-A, install
fulcrum seats in order of removal so that when removing ridges. After the ridge has the core plug.
they can be installed in their original been removed, remove the cutter from the 5. Oil the camshaft journals and
location. cylindet bore. apply Lubriplate to all lobes, and then
11. Remove the valve push rods in 24. On a flywheel for a manual-shift carefully slide it through the bearings.
sequence and put them in a rack or holder transmission, remove the clutch pressure Install the camshaft thrust plate and
so that they can be installed in their plate and disc. check camshaft end play as shown in
original position. 2S. Remove. the flywheel and rear Part 8-1.
12. Using a magnet, remove the valve cover plate. Remove the clutch pilot 6. If the crankshaft main bearing
lifters and place them in a rack so that bearing (Fig. 37). journals have been refmished to a defmite
they can be installed in their original bores 26. Invert the engine. Remove the oil undersize, install the correct undersize
(Fig. 26). pan and discard the gaskets and seals. bearings. Be sure the bearing inserts and
PART 8-4-302-351 C.I.D. V8 ENGINES 8-65
bearing bores are clean. Foreign material to specifications. Install the crankshaft over the cylinder head dowels. Do not
under the inserts will distort the bearing front oil slinger (Fig. 24 ). apply sealer to the head gasket surfaces.
and cause a failure. 23. Position a fuel pump gasket on 38. Place the cylinder head on the
Place the upper main bearing inserts in the block and install the fuel pump. engine. Coat the head bolt threads with
position in the bore with the tang fitting Tighten the fuel pump attaching screw and water-resistant sealer, and then install the
in the slot provided. nut to specification. bolts.
7. Install the lower main bearing 24. Remove the front crankshaft seal 39. The cylinder head bolt tightening
inserts in the bearing caps. from the cylinder front cover with the procedure is performed in three
8. Dip the lip seal halves in clean tool shown in Fig 19. Oean the cylinder progressive steps. Tighten the bolts in
engine oil. Install the lip seals in the front cover water pump and the cylinder sequence (Fig. 11) to SO ft-lbs, then to 60
bearing cap and block with the undercut block gasket surfaces. ft-lbs and fmally to specifications. When
side of the seal toward the FRONT of the 2S. Coat the water pump gasket on cylinder head bolts have been tightened
engine as shown in Fig. 29. both sides with sealer. Install the water following this procedure it is not necessary
9. Carefully lower the crankshaft pump and gasket onto the cylinder front to retorque the bolts after extended
into place. Be careful not to damage the cover. operation. However, tlie bolts may be
bearing surfaces. 26. Coat the cylinder front cover checked and retightened if desired.
10. Check the clearance of each main gasket on both sides with oil-resistant 40. Coat the cylinder head mating
bearing following the procedure under sealer. Install the cylinder front cover onto surfaces of the exhaust manifold with a
fitting main and connecting rod bearings the alignment dowels. Install the timing light film of graphite grease.
in Part 8-1. pointer and front cover retaining screws. 41. Position the exhaust manifolds on
· 27. Install the pistons and connecting the cylinder heads and install the attaching
11. After the bearings have been rods by following steps 1 thru 9 under bolts and flat washers. Tighten the
fitted apply a thin coating of oil-resistant Piston and Connecting Rod Installation. attaching bolts to specifications, working
sealer to the rear main bearing cap at the 28. Invert the engine on the work from the center to the ends.
rear of the top mating surface (Fig. 30). stand. Position the intermediate drive 4 2. Install the spark plugs.
Do not apply sealer to the area forward of shaft into the distributor socket. With the 43. Use the hydraulic valve lifter
the oil slinger groove. shaft frrmly seated in the distributor leakdown tester (page8-9) to fill the lifters
12. Apply heavy engine oil MS to the socket, the stop on the shaft should touch with test fluid. Coat the outside of each
journals and bearings. the roof of the crankcase. Remove the valve lifter and lifter bore with heavy
13. Install the rear main bearing cap shaft and position the stop as necessary. engine oil MS to provide initial lubrica-
with the rear surface flush or slightly 29. With the stop properly tion. Place each lifter in the bore from
ahead of the rear of the cylinder block. positioned, insert the intermediate which it was removed.
Install all bearing caps, except the thrust driveshaft into the oil pump.
bearing cap (No. 3 bearing). Be sure that 30. Prime the oil pump by filling 44. Clean the mating surfaces of the
the main bearing caps are installed in their either the inlet or outlet port with engine intake manifold, cylinder heads and
original positions. Tighten the bearing cap oil. Rotate the pump shaft to distribute cylinder block.
bolts to specifications. the oil within the pump body. 4S . Position new seals on the cylinder
14. Install the thrust bearing cap with 31. Position a new gasket on the block and press the seal locating
the bolts finger-tight. pump housing and install the pump and extensions into the holes in the mating
IS. Pry the crankshaft forward and shaft as an assembly. Tighten the oil pump surface.
pry the thrust bearing cap to the rear (Fig. attaching screws to specifications. Apply non-hardening sealer at the
44). This will align the thrust surfaces of 32. Clean the gasket surfaces of the four junction points of the seals and
both halves of the bearing. block and oil pan. Coat the block surface cylinder heads. Position the intake
16, Retain the forward pressure on and the oil pan gasket surface With sealer. manifold gasket onto the block and
the crankshaft. Tighten the cap bolts to Position new gaskets on the block and cylinder heads with the alignment notches
specifications. position a new seal on the cylinder front under the dowels on the cylinder heads.
17. Check the crankshaft end play cover and rear main bearing cap. Make Be sure the holes in the gasket are aligned
(wear limit 0.012 inches). sure the tabs on the seal are over the oil with the holes in the cylinder head.
18. Install the clutch pilot service pan gasket. Install the attaching screws 46. Carefully lower the intake
bearing (Fig. 38). Coat the threads of the and tighten them from the center outward manifold into position on the cylinder
flywheel attaching ~olts with oil-resistant to specifications (one screw secures the heads.
sealer. Position the rear cover plate on the fuel line bracket). 47. Be sure the holes in the manifold
block and the flywheel on the crankshaft 33. Install the front crankshaft oil gaskets and manifold are in alignment.
flange. Install and tighten the bolts to seal into the cylinder front cover with the Install the intake manifold attaching bolts.
specifications. tool shown in Fig. 20. Tighten the intake manifold bolts in three
On a flywheel for a manual-shift 34. Lubricate the crankshaft with a steps (Fig. 8).
transmission, use tool 7SSO-A to white lead and oil mixture and apply Tighten all bolts in sequence to 8-10
locate the clutch disc. Install the pressure Lubriplate to the oil seal rubbing surface ft-lb.
plate. of the vibration damper inner hub to Tighten all bolts in sequence to lS-20
19. Turn the engine on the work prevent damage to the oil seal. ft-lb.
stand so that the front end is up. 3S. Line up the crankshaft vibration Tighten all bolts in sequence to
20. Position the sprockets and timing damper keyway with the key on the specifications.
chain on the camshaft and crankshaft (Fig. crankshaft, and then install the vibration After completing the remammg
23). Be sure the timing marks on the damper on the crankshaft (Fig. 21). Install assembly steps, operate the engine until it
sprockets are positioned as shown in Fig. the damper cap screw and washer, and reaches normal operating temperature,
22. tighten the screw to specifications. Install then retorque the manifold bolts in
21. Lubricate the timing chain and the crankshaft pulley. sequence to specifications.
sprockets with engine oil. 36. Turn the engine on the work 48. Lubricate and install the push
22. Install the two piece fuel pump stand so that the top of the engine is up. rods in their original positions. Apply
eccentric, washer and camshaft sprocket 37. Clean the cylinder head and block Lubriplate or equivalent over the valve
cap screw. Tighten the sprocket cap screw gasket surfaces. Install the head gasket stem tips.
GROUP 8- ENGINE

49. With the No. 1 piston at TDC on

the end of the compression stroke,
POSITION A in Fig. 5 install the rocker
arm, fulcrum seat and bolt and perform a
valve clearance check on the following
valves:
No. 1 Intake No. 1 Exhaust
No. 4 Intake No. 3 Exhaust
No. 8 Intake No. 7 Exhaust
Position the crankshaft in POSITION
B, Fig. 5 and install the rocker arm,
fulcrum seat and bolt and perform a valve
clearance check on the following valves:
No. 3 Intake No. 2 Exhaust
No. 7 Intake No. 6 Exhaust
Position the crankshaft in POSITION
C, Fig. 5 and install the rocker arm,
fulcrum seat and bolt and perform a valve
clearance check on the following valves:
No. 2 Intake No. 4 Exhaust
FIG. 47 - Water Pump By·PIJS$ Orfice Plug FIG. 48- Installing Water Pump By·PIJS$
No. 5 Intake No. 5 Exhaust Orfice Plug
No. 6 Intake No. 8 Exhaust
Be sure the fulcrum seat base is sending unit with electrical conductive Position the spark plug wires in the
inserted in its slot on tht cylinder head sealer. Install the oil pressure and brackets on the valve rocker arm covers.
before tightening the fulcrum bolts. temperature sending units in the block. Connect the spark plug wires and the coil
Tighten the fulcrum bolts to specification. 54. Install the ignition coil Position wire.
Check the valve clearance following the and install the alternator and mounting 61. Clean the oil filter gasket surface.
procedures under Valve Clearance bracket. Coat the gasket on the filter with oil. Place
Checking Procedure. 55. Connect the vacuum lines. the fllter in position on the adapter fitting.
SO. Rotate the crankshaft until the 56 . Clean the valve rocker arm covers Hand tighten the filter until the gasket
No. 1 piston is TDC at the end of the and the cylinder head gasket surfaces. contacts the adapter face, then advance it
compression stroke, then position the Apply oil-resistant sealer to one side of 1/2 turn.
distributor in the block with the rotor at new cover gaskets. Lay the cemented side 62. Install the engine in the vehicle.
the No. 1 fuing position and the points of the gaskets in place in the covers. Fill and bleed the cooling system. Fill the
just open. Install the hold down clamp. 57. Position the covers on the crankcase with the proper grade and
51. Remove the water pump bypass cylinder heads. Make sure the gasket seats quantity of engine oil.
orifice. plug (Fig. 47). Install a new water evenly all around the head. Install the 63. Operate the engine and check for
pump by-pass orifice plug with the tool bolts. The cover is tightened in two steps. oil and coolant leaks. Check and adjust the
shown in Fig. 48. Tighten the bolts to specifications. Two ignition timing. Connect the distributor
52. Coat a new thermostat housing minutes later, tighten the bolts to the vacuum hose to the distributor. Retorque
gasket on both sides with sealer. Install the same specifications. intake manifold bolts to specifications.
thermostat housing, thermostat and 58. Install the carburetor and connect 64. Adjust the engine idle speed, fuel
gasket. Tighten the thermostat housing the fuel pump to carburetor fuel line. mixture and anti-stall dashpot (if
bolts to specification. 59. Install the crankcase ventilation applicable). Adjust the transmission
53. Coat the threads of the oil system. throttle linkage.
pressure sending unit and the temperature 60. Install the distributor cap.
8-61

PART SPECIFICATIONS
8·4
GENERAL ENGINE GENERAL ENGINE (Continued)
ENGINE MODELS AND PISTON DISPLACEMENT 200 (LC) 170@ 2000
Cubic inches 250 (LC) 216@1700
Six 200
250 BORE AND STROKE
Six
200 Six 3.68 X 3.13
V-8 302
250 SIX 3.68 X 3.91
V-8 351
302 V-8 (2-V) 4.00 X 3.00
COMPRESSION RATIO (HC) 351 V-8 (4-V) 4.00 X 3.500
200 Six 8.8 : 1 351 V-8 (2-V) 4.00 X 3.500
250 Six 9.1 : 1
302 V-8 (2-V) 9.8: 1
351 V-8 (4-V) 11.0 : 1 TAXABLE HORSEPOWER
351 V-8 (2-V) 9.5 ·: 1 200 and 250 Six 32.50
302 and 351 V-8 51.20
COMPRESSION RATIO (LC)
200 8.0 : 1 FIRING ORDER
250 8.2 : 1 200 and 250 Six 1-5-3-6-2-4
302 1-3-7-2-6-5-4-8
BRAKE HORSEPOWER @ Specified rpm 351 1-3-7-2-6-5-4-8
200 Six (HC) 130@ 4600
250 Six (HC) 155@ 4000 VALVE ARRANGEMENT-Front to Rear
250-2V 170@ 4600 200 and 250 Six E-1-1-E-1-E-E-1-E-1-1-E
302 V-8 (2-V) 230@ 5000 302 and 351 V-8 Right 1-E-1-E-1-E-1-E
351 V-8 (4-V) 300@ 5400 Left E-1-E-1-E-1-E-1
351 V-8 (2-V) 250@ 4600 ENGINE IDLE RPM
200 (LC) 114 @ 4600 Manual Shift Transmission
250 (LC) 138@ 4000 200 and 250 1V-2V 575-600
302 525-550
TOROUE-Ft-lbs @ Specified rpm 351 V-8 (2-V) 575 600
200 Six (HC) 190@ 2000
351 V-8 (4-V) 650-675
250 Six (HC) 240@ 1600
250-2V 250@ 2800 AUTOMATIC TRANSMISSION-Drive Range
302 V-8 (2 -V) 300@ 2600 200 and 250 1V-2V 500-525
351 V-8 (4-V) 380@ 3400 302 475-500
351 V-8 (2 -V) 355@ 2600 351 550-575
COMPRESSION PRESSURE LIMITS- ALL ENGINES.
Maximum Minimum Maximum Minimum Maximum Minimum
PSI PSI PSI PSI PSI PSI
134 101 174 131 214 160
136 102 176 132 216 162
138 104 178 133 218 163
140 105 180 135 220 165
142 107 182 136 222 166
144 108 184 138 224 168
146 110 186 140 226 169
148 111 188 141 228 171
150 113 190 142 230 172
152 114 192 144 232 174
154 115 194 145 234 175
156 117 196 147 236 177
158 118 198 148 238 178
160 120 200 150 240 180
162 121 202 151 242 181
164 123 204 153 244 183
166 124 206 154 246 184
168 126 208 156 248 186
170 127 210 157 250 187
172 129 212 158

Quick Reference Compression Pressure Limit Chart

8-68 GROUP 8- ENGINE

GENERAL ENGINE (Continued) VALVE MECHANISM (Continued)

ENGINE IDLE MANIFOLD VACUUM-Minimum 351 4-V .150 ± .050
Inches of Mercury @ Specified Engine Neutral Idle
rpm (Sea Level) VALVE STEM DIAMETER
200 and 250-18 17 Standard
302 V-8 18 INTAKE
351V-8 18 200 and 250
IGNITION TIMING 302 and 351 0.3416-0.3423
Manual shift and Automatic transmission EXHAUST
200 6° BTDC 200 and 250
250 6° BTDC 302 and 351 0.3411-0.3418
For altitude operation al')d/or to obtain optimum 0.003 Oversize
engine performance and fuel economy, the initial INTAKE
timing may be advanced 3° over the 'normal' setting 200 and 250
to a maximum initial advance of 9° 302 and 351 0.3446-0.3453
NO FURTHER ADVANCE IS PERMISSIBLE EXHAUST
200 and 250
Manual shift and Automatic transmission 302 and 351 0.3441-0.3448
302 and 351 6° BTDC 0.015 Oversize
For altitude operation and/or to obtain optimum INTAKE
engine performance and fuel economy, the initial 200 and 2.50
timing may be advanced 5o over the 'normal' setting 302 and 351 0.3566-0.3573
to a maximum initial advance of 11°. NO FURTHER EXHAUST
ADVANCE IS PERMISSIBLE. 200 and 250
01 L CAPACITY IMP. PINTS 302 and 351 0.3561-0.3568
200 and 250 Six 7.70* pints 0.030 Oversize
302 and ::l51 (V-8) 8.0* pints INTAKE
*Includes 1.7 pints for filter. 200 and 250
302 and 351 0.3716-0.3723
OIL PRESSURE-Hot @ 2000 rpm EXHAUST
All Engines 40 lbs. min. 200 and 250
302 anc.i 351 0.3711-0.3718
CYLINDER HEAD
VALVE FACE ANGLE
GASKET SURFACE FLATNESS INTAKE
6 Cyl. 29°
200 and 250 0.003 inch in any 6 inches 8 Cyl. 44°
or 0.007 inch overall EXHAUST-All Engines 44°
302 and 351 0.003 inch in any 6 inches
or 0.006 inch overall VALVE STEM TO VALVE GUIDE CLEARANCE
INTAKE
VALVE GUIDE BORE DIAMETER-Standard
200 and 250
Intake and Exhaust
302 and 351 0.001 0-0.0027-Wear
200 and 250
0.3433-D.3443 Limit 0.0045
302 and 351
VALVE SEAT WIDTH EXHAUST
Intake and Exhaust 200 and 250
200 and 250 0.070-0.090 302 and 351 0.0020-0.0032-Wear
302 and 351 0.060-0.080 Limit 0.0045
VALVE SEAT ANGLE VALVE HEAD DIAMETER
200 and 250 Intake 30° INTAKE
Exhaust 45° 200 and 250 1.642-1.657
302 and 351 Intake and Exhaust 45°
302 }
351 2-V 2.032-2.050
VALVE SEAT RUNOUT
Maximum All Engines 0.0015 EXHAUST
COMBUSTION CHAMBER VOLUME-CC 200 and 250 1.381-1.396
200 and 250 56.5-58.5 302 _V } 1.650-1 .660
302 56.38-59.38 351 2
351 4-V EX 1.705-1 .715
351 2-V = 76.76-79.76 351 4-V = 64.6-67.6
351 4-V IN. 2.183-2.198
DECK HEIGHT 0.000-0.025 VALVE FACE RUNOUT
VALVE MECHANISM Intake and Exhaust
200 and 250 0.0015
VALVE CLEARANCE-Lifter Collapsed 302 and 351 0.0020
200 and 250 0.066-0.166 VALVE SPRING FREE LENGTH-Approximate
302 } 200 and 250 1.79
351 2-V .150 ± .050
PART 8-5- SPECIFICATIONS 8-69
CAMSHAFT AND TIMING CHAIN (Continued)
VALVE MECHANISM (Continued)
302
351 2-V
l 2.07
302, 351 2-V Intake
351 4-V
0.235
0.247
302, 351 2-V Exhaust 0.235
351 4-V 2 05
351 4-V 0.262
VALVE SPRING OUT OF SQUARE-Maximum
All Engines .078 CAMSHAFT END PLAY
200 and 250 0.001-0.007-Wear Limit 0.012
VALVE SPRING PRESSURE-Lbs@ Specified Lgth. 302 and 351 0.001 -0.006 -Wear Limit 0.009
200 and 250 51-57@ 1.590
Wear Limit 46 @ 1.590 VALVE TIMING
142-158 @ 1.222 200 and 250
Wear Limit 128 @ 1.222 Intake Opens at 19° BTDC at 0.0022" Lobe Lift
VALVE SPRING-Lbs @Specified Length Intake Closes at 53° ABDC at 0.00475" Lobe Lift
PRESSURE WEAR LIMIT Exhaust Opens at 60° BBDC at 0.0022'" Lobe Lift
302, 351 2-V 76-84 @ 1.820 68 @ 1.820 Exhaust Closes at 16° ATDC at 0.00475'" Lobe Lift
199-221 @ 1.420 179 @ 1.420 302, 351 2-V 4-V
351 4-V 85-95 @ 1.820 79 @ 1.820 Intake Opens at 12 o 18° BTDC at 0.004'" Lobe Lift
271-299 @ 1.320 244 @ 1.320 Intake Closes at66°70° ABDC at0.006" Lobe Lift
VALVE SPRING ASSEMBLED HEIGHT Exhaust Opens at 66 o 81° B B DC at 0.004" Lobe Lift
200 and 250 1 9/16-1 39/64 Exhaust Closes at 20 o 19° ATDC at 0.006'" Lobe Lift
302-} 1 13/16-1 27/32 VALVE ROCKER RATIO
351 200 and 250 1.54 : 1
VALVE PUSH ROD MAXIMUM RUNOUT 302,351 1.73 : 1
All Engines 0.020
VALVE TAPPET DIAMETER-Standard CAMSHAFT BEARINGS
All Engines 0.8740-0.8745 INSIDE DIAMETER
200 and 250 1.8115-1 .8125
VALVE TAPPET TO TAPPET BORE CLEARANCE
No. 1 bearing is installed with the front edge
All Engines 0.0007-0.0027-Wear Limit 0.005
0.11 5 to 0.125 inch toward the rear from the
HYDRAULIC VALVE LIFTER LEAK DOWN RATE front face of the cylinder block.
-Wear Limit
All Engines (measured at 1/16 inch Plunger CAMSHAFT BEARING-Inside Diameter
Travel) 5-50 Seconds 302,351 1 2.1258-2.1268
2 2.0675-2.0685
ROCKER ARM TO ROCKER ARM SHAFT 3 2.0525-2.0535
CLEARANCE 4 2.0375-2.0385
200 and 250 0.002-0.0045-Wear Limit 0.006 5 2.0225-2.0235
ROCKER ARM SHAFT O.D. No. 1 bearing is installed with the front edge
200 and 250 0.780-0.781 0.005 to 0.020 inch toward the rear from the front
face of the cylinder block.
ROCKER ARM BORE DIAMETER
200 and 250 0.783-0.784
CRANKSHAFT
CAMSHAFT AND TIMING CHAIN MAIN BEARING JOURNAL DIAMETER
CAMSHAFT JOURNAL DIAMETER-Standard Standard
200 and 250 2.3990-2.3982
200 and 250 1.8095-1.8105
302, 351 2.7484-2.7492
CAMSHAFT JOURNAL-Diameter
302,351 1 2.1238-2.1248 MAIN BEARING JOURNAL RUNOUT-Maximum
2 2.0655-2.0665 200 and 250 0.0025-Wear Limit 0.0035
3 2.0505-2.0515
4 2.0355-2.0365 302, 351 0.004-Wear Limit 0.004
5 2.0205-2.0215
MAIN BEARING JOURNALS MAXIMUM OUT-
CAMSHAFT JOURNAL TO BEARING CLEAR- OF-ROUND
ANCE
All Engines 0.0004
All Engines 0.001-0.003-Wear Limit 0.006
CONNECTING ROD BEARING JOURNALS
CAMSHAFT JOURNAL MAXIMUM OUT-OF- MAXIMUM TAPER
ROUND 200 and 250 0.0004 per inch
All Engines 0.0005 302 and 351
TIMING CHAIN MAXIMUM DEFLECTION MAIN BEARING JOURNALS MAXIMUM TAPER
All Engines 0.5 All Engines 0.0003 per inch _
CAMSHAFT LOBE LIFT
200 and 250 Intake and Exhaust 0.2455-
Wear Limit 0.240
8-70 GROUP 8-ENGINE
CRANKSHAFT (Continued) CONNECTING ROD (Continued)
THRUST BEARING JOURNAL LENGTH 302 and 351 0.01 0-0.020-
200 and 250 1.275-1 .277 Wear Limit 0.023
302, 351 1.124-1.126 CONNECTING ROD*
Twist Maximum Total Difference
MAIN BEARING JOURNAL THRUST FACE RUN- 200 and 250 0.008
OUT 302 and 351 0.012
All Engines 0.001 Bend Maximum Total Difference
All Engines 0.004
CONNECTING ROD JOURNAL DIAMETER
Standard *Piston pin bore and crankshaft bearing bore must
200 and 250 2.1232-2.1240 be parallel and in the same vertical plane within
the specified total difference at ends of 8-i nch
302, 351 2.3103-2.3111 long bar measured 4-i nches on each side of rod .
CRANKSHAFT FREE END PLAY CONNECTING ROD BEARINGS
All Engines 0.004-0.010-Wear Limit 0.012
BEARING TO CRANKSHAFT CLEARANCE
ASSEMBLED FLYWHEEL CLUTCH FACE Desired Allowable
MAXIMUM RUNOUT 200 and 250 0.0008-0.0015 0.0008-0.0024
200 and 250 0.007 302 and 351 0.001-0.0015 0.0008-0.0026
302 and 351 O.Q1 0
BEARING WALL THICKNESS FOR STANDARD
ASSEMBLED FLYWHEEL O.D. MAXIMUM AND UNDERSIZE JOURNAL
RUNOUT Standard 0.002 U.S.
Standard Transmission 200 and 250 0.0571-0.0574 0.0583- 0.0588
All Engines O.Q18 302}
351 0.0620-0.0625 0.0630-0.0635
Automatic Transmission
All Engines 0.020
PISTON
MAIN BEARINGS
BEARING TO CRANKSHAFT CLEARANCE PISTON DIAMETER-At Right Angle to Pin
Desired Allowable Centreline
200 and 250 0.0005-0.0015 0.0005-0.0022 Colour Coded Red
200 and 250 3.6778-3.6784
302, 351 0.0001-0.0015 0.0008-0.0026 302
351 } 3.9982-3.9988
WALL THICKNESS Colour Coded Blue
Standard 0.002 U.S. 200 and 250 3.6790-3.6796
200 and 250 0.0758-0.0761 0.0768-0.0771 302}
302 and 351 0.0959-0.0962 0.0969-0.0972 351 3.9994-4.0000
PISTON TO CYLINDER BORE CLEARANCE
CONNECTING ROD 200 and 250 0.0010-0.0018
PIN BORE DIAMETER 302 } 0.0014-0.0022
351
Standard PISTON PIN BORE DIAMETER
200 and 250 0.9107-0.9112 All Engines 0.9122-0.9125
302 and 351 0.9104-0.9112
BEARING BORE DIAMETER-Standard
200-250 2.2390-2.2398 RING GROOVE WIDTH
Upper Compression Ring
302-351 2.4361-2.4369
All Engines 0.080- 0.081
BEARING BORE MAXIMUM OUT OF ROUND
Lower Compression Ring
200 and 250 0.0003-0.0004 0.080- 0.081
All Engines
302 and 351 0.0004 Oil Ring
BEARING BORE MAXIMUM TAPER All Engines 0.1880- 0.1890
All Engines 0.0004
PISTON PIN
CONNECTING ROD LENGTH-Centre to Centre PISTON PIN DIAMETER
200 6.274-6.271 250 5.882-5.879 Standard
All Engines 0.9119-0.9124
302,351 5.7785-5.7815
PISTON PIN LENGTH
CONNECTING ROD ASSEMBLY- All Engines 3.010-3.040
Assembled to Crankshaft
Side Clearance PISTON PIN TO PISTON CLEARANCE-Loose
200 and 250 0.0035-0.01 05- 200 and 250 0.0003-0.0005
Wear Limit 0.014
PART 8-5- SPECIFICATIONS 8-71
PISTON PIN (Continued) OIL PUMP-Rotor Type (Continued)
302 and 351 0.0003-0.0005
Wear Limit 0.0008 RELIEF VALVE CLEARANCE
All Engines 0.0015-0.0029
PISTON RINGS DRIVE SHAFT TO HOUSING BEARING
CLEARANCE
RING WIDTH
Compression Ring All Engines 0.0015-0.0029
UPPER ROTOR ASSEMBLY END CLEARANCE-Pump
All Engines 0.0770-0.0781 Assembled
LOWER All Engines 0.0011-0.0041
All Eng ines 0.0770-0.0780
OUTER RACE TO HOUSING-Radial Clearance
SIDE CLEARANCE All Engines 0.006-0.013
Compression Ring Engine Weights (Lbs.)
UPPER 200 Wet 408
All Eng ines 0.0020-0.0040-Wear Dry 390
Limit 0.006 250 Wet 420
LOWER Dry 402
All Engines 0.0020-0.0040-Wear 302. 351 Wet 719
Lim it 0.006 Dry 698
Oil Ring
All Engines Snug
RING GAP WIDTH
Compression Ring-Standard Bore-Upper
TORQUE LIMITs-Ft. Lbs. ALL MODELS
All Engines 0.01 0-0.020
Oil the threads with lightweight engine oil. ex-
Compression Ring-Standard Bore-Lower cept do not oil threads that require oil-resistant
All Engines O.Q1 0-0.020 or water-resistant sealer.
Oil Ring *-Standard Bore MAIN BEARING CAP BOLTS 302 351C 95-105
200 and 250 0.01 5-0.055 Other Engines 60-70
302 and 351 0.015-0.069 CYLINDER HEAD BOLTS
*Steel Rail 6 Cyl.
Step 1 55
Step 2 65
Step 3 70-75

CYLINDER BLOCK
302,351
CYLINDER BORE DIAMETER-Standard Spreads Step 1 55
for 8 Grades Step 2 75
200 and 250 3.6R00-3.6824 Step 3 95-105
302} 4.000-4.0024
351
CYLINDER BORE MAXIMUM OUT-OF - ROUND OIL PAN TO CYLINDER BLOCK
6 Cyl. 7-9
All Engines 0.001-Wear Limit 0.005
CYLINDER BOAE TAPER 8 Cyl 1/4-20 Bolt 7- 9
All Engines 0.001-Wear Lim it 0.01 0 5/16-18 Bolt 11-13

HEAD GASKET SURFACE FLATNESS MANIFOLDS TO CYLINDER HEAD

All Six 0.003 inch in any 6 inches Intake
or 0.007 inch overall
All V-8 0.003 inch in any 6 inches 302, 351. 250 2V 21-25 (5/16)
or 0.006 inch overall 302,351 27-33 (3/8)
MAIN BEARING BORE DIAMETER Exhaust
200 and 250 2.4012-2.4020 13-18
All Engines
302 } 2.9417-2.94?9
351 FLYWHEEL TO CRANKSHAFT
All Engines 75-85
OIL PUMP-Rotor Type
OIL PUMP TO CYLINDER BLOCK
RELIEF VALVE SPRING TENSION- 6 Cyl. 12-15
Lbs. @ Specified Length in inches 8 Cvl. 25-35
200 and 250 9.0-10.1 @ 1.078
302} 23.6-24.6 @ 1.37
351
8-72 GROUP 8- ENGINE
TORQUE LIMITS-Ft. Lbs. ALL MODELS (Cont.) TORQUE LIMITs-Ft. Lbs. ALL MODELS (Cont.)

OIL PUMP COVER PLATE VALVE ROCKER ARM COVER

6 Cyl. Engines 6-9 All Engines 3-5
8 Cyl. Engines 9-12
OIL FILTER ADAPTER TO CYLINDER BLOCK VALVE ROCKER SHAFT SUPPORT TO
8 Cyl. CYLINDER HEAD
351-302 20-50 6 Cyl. 30-35
OIL FILTER TO ADAPTER OF CYLINDER BLOCK ROCKER ARM BOLT TO CYL. HEAD
All Engines With grease on the gasket surface. 18-25
hand tighten until gasket contacts
adapter face. Then tighten 1/2 turn OIL INLET TUBE TO OIL PUMP
more. All Engines 12-15

CYLINDER FRONT COVER FUEL PUMP TO CYLINDER BLOCK OR

6 Cyl. 7-9 CYLINDER FRONT COVER
8 Cyl. 14-20 200 and.250 12-15
302 351 14-20
WATER OUTLET HOUSING
All Engines 12-15 ENGINE FRONT SUPPORT-Nuts or Bolts
OIL PAN DRAIN PLUG Insulator Assembly to Engine
8 Cvl-. 35-60
All Engines 1 5-20 Insulator Assembly to Support Brackets
CAMSHAFT THRUST PLATE TO CYLINDER 6 Cyl. 24-34
BLOCK 302 8 Cyl. }
6 Cyl. 12-15 20-30
351 8 Cyl.
8 Cyl. 9-12
Support Bracket to Body
WATER PUMP TO CYLINDER BLOCK OR 6 Cyl. 18-25
FRONT COVER 8 Cyl. 20-30
All Engines 12-15 Insulator Bracket to Engine
6 Cyl. 18-25
CAMSHAFT SPROCKET TO CAMSHAFT Insulator to Insulator Bracket
6 Cyl. 35-45 6 Cyl. 18-25
8 Cyl. 40-45
ENGINE REAR SUPPORT-Nuts or Bolts
CRANKSHAFT PULLEY TO VIBRATION DAMPER Insulator to Rear Support
UBS BOLTS 25-35 All Engines
PLACE BOLTS 35-45 30-50
Rear Support to Body
CONNECTING ROD NUTS All Engines 50-70
200-250 and 302 19-24 Insulator to Transmission
302,351 40-45 All Engines 30-45
FALCON FAIRLANE w~:~~~~P

,;

GROUP
IGNITION SYSTEM
9

PAGE

PART 9-1- General Ignition System Service 9-2

PART 9-2- Dual Advance Distributor-Bosch 9-14

PART 9-3- Dual Advance Distributor-Motorcraft 9-18

PART 9-4- Specifications 9-24

9-2

PART GENERAL IGNITION SYSTEM SERVICE

9·1
Section Page Section Pare
1 Diagnosis and Testing 9-2 Spark Plugs ...... 9-10
General Information 9-2 Resistance Wire Replacement 9-10
Ignition System Tests-Conventional 3 Cleaning and Inspection 9- 10
Test Equipment . 9-3 Spark Plugs 9- 10
Distributor Checks 9-5 Distributors 9- 10
Di~tributor Tests-Dwell Tester 9-5 Secondary Wiring 9-12
Distributor Tests-Distributor Tester 9-5 Coil 9-12
2 Common Adjustments and Repairs 9-7 Distributor Cap 9-12
Breaker Points and Condenser .. 9-7 Rotor .... ...... . .... .. 9-12
Ignition Timing 9-8
Distributor Vacuum Advance Control Valve 9-12
Spark Plug Wire Replacement 9-9

This part covers ignitioh system ber is stamped on the distributor L.L.C. Yellow.
description and operation, general body. The basic part number for 250 C.I.D. H.C. Red, L.C. White .
ignition system diagnosis, tests, ad- Motorcraft 351 distributors is 12127 250 C.I.D. 2V Green.
justments and repair operations. In and for Bosch 351, 302, 250 & 200 302 C.I.D. Manual & · Auto Red.
addition, the cleaning and inspection distributors is 12100. 351 C.I.D. 2V Auto Yellow.
procedures are covered. A majority of the parts used in the
To procure replacement parts it is
For distributor removal, disassem- necessary to know the complete part Bosch distributor are not inter-
bly, assembly, installation, major number. changeable with earlier models.
repair procedures and specifications, Always refer to the Master Parts
refer to the pertinent part of this In addition, Bosch distributors Catalogue for parts usage and inter-
group. can be identified by their diaphragm changeability before replacing a dis-
colour coding as follows: tribqtor or a component part for a
The distributor identification num- 200 C.I.D. H.C. Blue, L.C. Black, distributor.

D DIAGNOSIS AND TESTING

GENERAL INFORMATION
The ignition system consists of a SPARK PlUG
primary (low voltage) and a second-

••••••••
ary (high voltage) circuit (Fig. 1).
The primary circuit consists of the:
1. Battery. BATTERY

2. Ignition switch.
3. Primary circuit resistance wire.
4. Primary windings of the igni-
tion coil.
5. Breaker points.
6. Condenser.
The secondary citcuit consists of
the:
1. Secondary windings of the
ignition coil.
2. Distributor rotor.
3. Distributor cap.
4. High tension wires.
5. Spark plugs.
When the breaker points are
closed, the primary or low voltage -PRIMARY CIRCUIT
current flows from the battery •••••• ~ECONOARY CIRCUIT
throug~ the ignition switch to the
primary windings in the coil. then to FIG. 1 -Typical Ignition System Circuit
PART 9-1- GENERAL IGNITION SYSTEM SERVICE 9-3
ground through the closed breaker 2. Burned, shorted, sticking or im-
points. When the breaker points properly adjusted breaker points.
open, the magnetic field built up in 3. A defective coil.
the primary windings of the coil 4. A defective condenser.
moves through the secondary wind- To isolate a trouble in the primary
ings of the coil producing high volt- circuit, proceed as follows:
age current. High voltage current is Turn the ignition switch off and
produced each time the breaker remove the auxiliary starter switch
points open. The high voltage flows from the starter relay.
through the coil high tension lead to Install the coil high tension lead in
the distributor cap where the rotor the distributor cap, the red and blue
distributes it to one of the spark plug wire on the starter relay S terminal
terminals in the distributor cap. This and the brown wire on the starter re-
process is repeated for every power lay I terminal.
stroke of the engine. Now perform a primary circuit
test.
IGNITION SYSTEM TESTS- Secondary Circuit
CONVENTIONAL TEST
EQUIPMENT
A breakdown or energy loss in the
secondary circuit can be caused by:
TROUBLE ISOLATION 1. Fouled or improperly adjusted
sparlr plugs.
Ignition system troubles are caused
l. Defective high tension wiring.
by a failure in the primary and/ or
3. High tension leakage across the
the secondary circuit or incorrect ig-
coil, distributor cap or rotor result-
nition timing. If an engine trouble FIG. 3 -Ignition Switch Test ing from an accumulation of dirt.
has been traced to the ignition system cylinder head or any other good To isolate a trouble in the second-
from the "Engine Trouble Diagnosis ground, crank the engine by using an ary circuit, proceed as follows :
Guide," the trouble can be found by auxiliary starter switch between the Turn the ignition switch off and
performing an ignition system test on starter relay battery and S terminals. remove the auxiliary starter switch
a scope or by further isolating the If the spark is good, the trouble from the starter relay.
trouble to the primary or secondary lies in the secondary circuit. Install the coil high tension lead in
circuit as follows: If there is no spark or a weak the distributor cap, the red and blue
1. Disconnect the brown wire spark, the trouble is in the primary wire on the starter relay S terminal
from the starter relay I terminal and circuit, coil to distributor high ten- and the l,rown wire on the starter re-
the red and blue wire from the start- sion lead, or the coil. lay I terminal.
er relay S terminal.
Primary Circuit Now perform a secondary circuit
2. Remove the coil high tension test.
lead from the distributor cap. A breakdown or energy loss in the
3. Turn on the ignition switch. primary circuit can be caused by: PRIMARY CIRCUIT TESTS
4. While holding the high tension 1. Defective primary wiring, or A complete test of the primary cir-
lead approximately 3/t_a inch from the loose or corroded terminals.

FIG. 2 -Battery to Coil and

Starting Ignition Circuit Test FIG. 4 -Resistance Wire Test FIG. 5-Coil to Ground Test
9-4 GROUP 9- IGNITION SYSTEM

cuit consists of checking the circuit tory. and Inspection (Section 3 of this
from the battery to the coil, the cir- 6. If the voltmeter reading is part).
cuit from the coil to ground, and the greater than 0.3 volt, either the ig- Check the coil on a coil tester by
starting ignition circuit. nition switch and/ or the wire are de- following the manufacturers instruc-
Excessive voltage drop in the pri- fective. tions.
mary circuit will reduce the second-
ary output of the ignition coil, result- Resistance Wire Test SECONDARY CIRCUIT TESTS
ing in hard starting and poor per- 1. Connect the voltmeter leads as
shown in Fig. 4. Distributor Cap
formance.
l. Install a jumper wire from the Clean and inspect the distributor
Battery to Coli Test distributor terminal of the coil to a cap by following the procedure under
1. Connect the voltmeter leads as good ground on the distributor hous- Cleaning and Inspection (Section 3 of
shown in Fig. 2. ing. this part).
2. Install a jumper wire from the 3. Turn all of the accessories and
Rotor
distributor terminal of the coil to a lights off.
good ground on the distributor hous- 4. Tum the ignition switch on. Clean and inspect the rotor by fol-
ing. 5. If the voltmeter reading is 6.6 lowing the procedure under Cleaning
3. Turn the lights and accessories volts or less, the resistance wire is and Inspection (Section 3 of this
off. satisfactory. part).
4. Turn the ignition switch on. 6. If the voltmeter reading is Secondary (High Tension)
5. If the voltmeter reading is 6.9 greater than 6.6 volts, replace the re- Wires
volts or less, the primary circuit sistance wire.
The secondary wires include the
from the battery to the coil is satis- wires connecting the distributor cap
Coli to Ground Test
factory. to the spark plugs and the wire con-
6. If the voltmeter reading is 1. Connect the voltmeter leads as
shown in Fig. 5. necting the center terminal of the
greater than 6.9 volts, check the fol- distributor cap to the center terminal
lowing: l. Close the breaker points.
3. Turn all lights and accessories of the ignition coil.
The battery and cables for loose Clean and inspect the secondary
connections or corrosion. off.
4. Turn the ignition switch on. wiring by following the procedure
The primary wiring for worn insu- under Cleaning and Inspection (Sec-
lation, broken strands, and loose or 5. If the voltmeter reading is 0.1
volt or Jess, the primary circuit from tion 3 of this part).
corroded terminals. These wires are the radio resist-
The resistance wire for defects. coil to ground is satisfactory.
6. If the voltmeter reading is ance-type which filter out the high
The starter relay to ignition switch frequency electrical impulses that
for defects. greater than 0.1 volt, test the voltage
drop between each of the following: are the source of ignition noise inter-
Starting Ignition Circuit Test The coil and breaker point termi- ference. The resistance of each wire
1. Connect the voltmeter leads as should not exceed 7000 ohms per
nals of the coil to distributor primary
shown in Fig. 2. foot.
wire.
l. Disconnect and ground the coil When checking the resistance of
The movable breaker point and the the wires or setdng lpltion timing,
to distributor high tension lead at the breaker plate.
distributor. do not puncture the wires with a
The breaker plate and the distri- probe. The probe may cause a sep·
3. With the ignition switch off, butor housing.
crank the engine by installing a jump- aratioa In the conductor.
The distributor housing and engine When removing the wires from the
er wire between the battery and the ground.
"S" terminal of the starter relay while spark plugs, grasp and twist the
observing the voltage drop. moulded cap, then puB the cap off
4. If the voltage drop is 0.1 volt Breaker Points the spark plug. Do not pull on the
or less, the starting ignition circuit is Clean and inspect the breaker wire because the wire connection Ia·
satisfactory. points by following the procedure un- ade the cap may become separated
5. If the voltage drop is greater der Cleaning and Inspection (Section or the Insulator seal may be dam·
than 0.1 volt, clean and tighten the 3 of this part). aged.
terminals in the circuit or replace the The breaker point dwell can be To check the.spark intensity at the
wiring as necessary. checked with a distributor tester or a spark plugs, proceed as follows:
dwell meter by following the proce- 1. Disconnect a spark plug wire.
Ignition Switch Test dure under Distributor Tests in this Check the spark Intensity of one wire
1. Connect the voltmeter leads as section of the manual. at a time.
shown in Fig. 3. 2. Install a terminal adapter in the
l. Install a jumper wire from the The breaker p"int resistance can terminal of the wire to be checked.
distributor terminal of the coil to a be checked with ;_ distributor tester Hold the adapter approximately 3fw
good ground on the distributor body. by following the procedure under inch from the exhaust manifold and
Distributor Tests in this section of crank the · engine, using a remote
3. Turn all of the accessories and
lights off. the manual. starter switch. The spark should jump
4. Turn the ignition switch on. the gap regularly.
Coli
5. If the voltmeter reading is 0.3 3. If the spark intensity of all the
volt or less, the ignition switch and Clean and inspect the coil by fol- wires is satisfactory, the coil, con-
the relay to switch wire are satisfac- lowing the procedure under Cleaning denser, rotor, distributor cap and the
PART 9-1- GENERAL IGNITION SY.STEM SERVICE 9-5
secondary wires are probably satis- 2. Connect the black lead to a 4. Loosen the breaker point as-
factory. good around on the engine. sembly retaining screw near the
If the spark is good at only some breaker point contacts.
wires, check the resistance of the DWELL ANGLE CHECK
faulty leads. 5. With the ignition on, crank the
1. Connect the tester. engine with an auxiliary starter
If the spark is equal at all wires, 2. Turn the test control knob to switch connected between the battery
but weak or intermittent, check the the set position. and S terminals of the starter relay
coil, distributor cap and the coil to 3, Adjust the set control knob un- and adjust the gap to specifications.
distributor high tension wire. til the needle on the dwell meter lines
up with the set line. 6. Release the auxiliary starter
Spark Plugs 4. Start the engine and let it idle. switch and tighten the breaker point
Inspect, clean and gap the plugs 5. Turn the test control knob to assembly retaining screw.
following the instructions in sections the 8 CYL position for eight cylinder 7. Since the adjustment may have
2 and 3. After the proper gap is ob- engines or to the 6 CYL position for changed when the retaining screw
tained, check the plugs on a testing 6 cylinder engines. was tightened, crank the engine again
machine. Compare the sparking ef- 6. Read the dwell angle on the with the auxiliary starter switch and
ficiency of the cleaned and gapped dwell meter and compare the reading check the dwell.
plug with a new plug. Replace the to specifications.
piug if it fails to meet 70% of the 7. Turn off the engine. DISTRIBUTOR TESTS -
new plug performance. 8. If the dwell angle was below the
Test the plugs for compression specified amount, the breaker point DISTRIBUTOR TESTERS
leakage at the insulator seal. Apply a gap is too large. If the dwell angle
coating of oil to the shoulder of the was above the specified amount, the MOUNTING DISTRIBUTOR
plug where the insulator projects breaker point gap is too small.
through the shell, and to the top of Set up the distributor in accor-
If the dwell is to specifications,
the plug, where the center electrode dance with the manufacturer's in-
turn the test selector knob to the
and terminal project from the insula- structions.
OFF position and disconnect the
tor. Place the spark plug under pres- tester leads.
sure with the tester's high tension Bosch distributors fitted to Falcon
wire removed from the spark plug. DWELL ANGLE
ADJUSTMENT engines have only one bearing in the
LeakJge is indicated by air bubbling distributor housing. When phasing
through the oil. If the test indicates If the dwell angle is not within and cam angle testing these dis-
compression leakage, replace the specifications, proceed as follows: tributors a lower bearing must be
plug. If the plug is satisfactory, wipe provided. As a variety of test benches
it clean. 1. Remove the coil high tension
lead from the distributor and ground are available it is impossible to release
it. a common bearing and bracket as an
Ignition Timing
essential tool.
Incorrect ignition timing can be 2. Remove the distributor cap and The sketch and dimensions (Fig.
caused by: place it out of the way. 6) will enable manufacture of a bear-
1. Timing incorrectly adjusted. 3. Disconnect the · brown wire (I ing and support which can be adapted
2. Distributor bushing and/ or terminal) and the red and blue wire to suit individual test benches.
shaft worn, or a bent distributor (S terminal) from the starter relay.
shaft.
3. Defective vacuum advance sys-
tem.
4. Defective centrifugal advance
system.
DISTRIIUTOR CHICKS
Dual Advance Distributor
1. Remove the distributor from
the engine.
2. Place the distributor in the hold-
ing tool and clamp it in a vise with
the gear end up.
3. Push the distributor shaft up-
ward as far as it will go, and check
the end play with a feeler aauae
placed between the collar and the dis-
tributor base. The end play should be
within the specified limits.
DISTRIBUTOR TISTI--
DWELL TESTER
TEST CONNECTIONS
1. Connect the red lead to the dis-
tributor terminal of the coil. FIG. 6 - Iosch Distributor Supports
9-6 GROUP 9- IGNITION SYSTEM

Dimen- mum speed of the engine on which tions, adjust the breaker points.
sion 6 Cylinder 8 Cylinder the distributor is used. Erratic or thin 2. Check the breaker arm spring
A 1.75 1.9 faint flashes of light preceding the tension and adjust it if necessary.
B 1.136 1.16 regular flashes as the speed of rota- The dual advance distributor has
c 1.301-1.300 1.559-1.561 tion is increased can be due to weak two independently operated spark
D 2.520-2.517 4.018-4.021 breaker arm spring tension or bind- advance systems. Each system is ad-
E 3.1 4.5 ing of the breaker arm on the pivot justed separately. Adjust the centrtf·
F 0.516-0.517 0.516-0.517 pin. upl advance before adjusting the
4. Operate the distributor at ap- vacuum advance.
NOTE: proximately 2500 engine rpm.
5. Move the protractor scale with Centrifugal Advance
Missing dimensions according to 1. Operate the distributor in the
individual test bench. the adjustment control so that the
zero degree mark on the scale is op- direction of rotation and adjust the
All dimensions in inches. speed to the initial rpm setting listed
posite one of the neon flashes. The
BREAKER POINT balance of all the flashes should come in the specifications. Move the pro-
RESISTANCE within 1o, plus or minus, evenly tractor scale so that one of the flashes
around the protractor scale. A varia- lines up with the zero degree mark.
1. Turn the test selector to the tion larger than 1 o or erratic or wan- 2. Slowly increase the rpm to the
appropriate position. setting specified for the first advance
dering flashes may be caused by a
2. Revolve the chuck by hand worn cam or distributor shaft or a reading listed in the specifications.
until the distributor breaker points bent distributor shaft. If the correct advance is not indi-
are closed. cated at this rpm, stop the distribu-
DWELL ANGLE tor and bend one spring adjustment
3. The meter pointer on the cam 1. Turn the cylinder selector to bracket to change its tension (Fig.
angle meter should read in the OK the figure corresponding to the num- 7. Bend the adjustment bracket
zone. If the meter pointer does not ber of lobes on the cam of the dis- away from the distributor shaft
fall in the OK zone, there is exces- tributor being tested. to decrease advance (increase
sive resistance caused by a faulty 2. Turn the test selector switch to spring tension) and toward the
contact across the distributor points, the cam angle position and operate shaft to increase advance (de-
a faulty primary lead, or a poorly the distributor at approximately crease spring tension). Mter the
grounded base plate. A faulty contact 250 engine rpm. adjustment is made, identify the
across the distributor points indi- 3. Adjust the distributor breaker bracket.
cates improper spring tension or 3. After an adjustment has been
point gap to the dwell angle shown in
burned or pitted points. made to one spring, check the mini-
the specifications.
INSULATION AND LEAKAGE mum advance point again.
1. Turn the test selector to the
BREAKER PLATE WEAR 4. Operate the distributor at the
A worn breaker plate on the dual specified rpm to give an advance just
cam angle position and revolve the
advance distributors will cause the below the maximum. If this advance
chuck by hand until the distributor
breaker point dwell to change as is not to specifications, stop the dis-
breaker contacts are open.
engine speed and load condition tributor and bend the other spring
2. The cam angle meter should
are varied. bracket to give the correct advance.
show a zero reading. If a zero read-
On the dual advance distributor 5. Check the advance at all rpm
ing is not obtained, a short circuit to adjust the test set to 0 o advance, settings listed in the specifications.
ground exists.
0 inches vacuum, and 250 rpm. Operate the distributor both up and
A short could be caused by poor Adjust the dwell angle to specifica- down the rpm range.
primary lead wire insulation, a tions. Apply vacuum to the distribu-
shorted condenser, or a short be- Vacuum Advance
tor diaphragm and increase it very 1. Connect the test set vacuum
tween the breaker arm and breaker slowly while observing the indicated
plate. line to the fitting on the diaphragm.
dwell angle. The maximum dwell 2. Set the test set to 0 o advance,
MECHANICAL OPERATION angle variation should not exceed 6 o
0 vacuum, and at 250 rpm.
1. Turn the test selector to the when going from zero to maximum 3. Check the advance at the first
SYNCHRO. position and check to vacuum at constant rpm. If the dwell vacuum setting given in the specifi-
make sure the drive chuck is securely angle variation exceeds this limit, cations.
tightened on the distributor shaft. there is excessive wear at the 4. On 8 cylinder single diaphragm
stationary subplate pin or the dia- distributors, if the advance is in-
2. Turn the motor control switch phragm. correct, change the calibration wash-
to the setting for an eight cylinder ers between the vacuum chamber
car or for a six cylinder car. DISTRIBUTOR SPARK spring and out (Fig. 8). After install-
If it Is necessary to reverse the ro- ADVANCE ing or removing the washers, position
tation of the drive motor, tum the The spark advance is checked to the gasket in place and tighten the
motor control switch to the OFF po- determine if the ignition timing ad- nut. The addition of a washer will
sition and allow the chuck to come vances in proper relation to engine decrease advance and the re-
to a complete stop before reversing speed and load. moval of a washer will increase
the switch. advance.
3. Adjust the rpm control to vary Dual Advance Distributor 5. After one vacuum setting has
the distributor speed between 400 1. Check the contact dwell. If the been adjusted, the others should be
and 4000 engine rpm or at the maxi- contact dwell is not within specifica- checked. Do not change the orig-
PART 9-1- GENERAL IGNITION SYSTEM SERVICE 9-7
inal rpm setting when going to a
different vacuum setting. If the
other settings are not within limits,
it ind~cates incorrect spring tension,
leakage in the vacuum diaphragm
and/ or line, or the wrong fibre stop
has been installed in the vacuum
chamber of the diaphragm housing.
To check the diaphragm for leak-
age:
Remove the vacuum line from the SPACING WASHERS
distributor. Adjust the vacuum pres-
sure of a distributor tester to its Vacuum
FIG. 8 -
maximum position. Hold your hand Advance Adjustment
over the end of the tester's vacuum
hose and note the maximum reading ' the diaphragm without changing any
obtained. Do not exceed lS inches of the adjustments. The maximum
HK. gauge reading should not be less than
FIG. 7 - Centrifugal it was above. If it is less, the dia-
If the maximum reading is 25
inches Hg or less, connect the tester's Advance Adjustment phragm is leaking and should be re-
vacuum line to the vacuum fitting on placed.

EJ COMMON ADJUSTMENTS AND REPAIRS

wear, overheating and pitting.
BREAKER POINTS AND 1. Turn the cam so that the break-
CONDENSER er points are closed and check the
REPLACEMENT alignment of the points (Fig. 9 ) .

Dual Advance Distributors

Removal
riil\:a:~
\8) CORRECT-~
1. Remove the distributor cap and
the rotor.
l. Disconnect the primary and the ALIGNMENT
condenser wires from the breaker
point assembly.
3. Remove the breaker point as- CONTACT@
AREA NOT
sembly and condenser retaining CENTERED
screws. Lift the breaker point assem- BEND STATIONARY BRACKET
bly and condenser out of the distribu-
M~::::@NT
FIG. 10- Aligning
tor.
Breaker
Installation AREA NOT
1. Place the breaker point as- CENTERED Points
sembly and the condenser in position ISALIGNMENT
and install the retaining screws. Be 3. After the breaker points have
OF POINT FACES 11019-A
sure to place the ground wire under been properly aligned, adjust the
the breaker point assembly screw FIG. 9 - Breaker Point breaker point gap or dwell.
farthest from the breaker point con- Alignment BREAKER POINT
tacts. GAP ADJUSTMENT
l. Align and adjust the breaker A scope, a dwell meter, or a feeler
point assembly. gauge can be used to check the gap
3. Connect the primary and con- If the distributor is in the engine,
close the points by proceeding as of new breaker points.
denser wires to the breaker point as-
sembly. follows:
4. Install the rotor and the distr-i- Disconnect the brown wire and the A scope or a dwell meter can be
butor cap. red and blue wire from the starter used to check the gap of used breaker
relay and, with the ignition switch points. Due to the roughness of used
BREAKER POINT off, crank the engine by using an aux- points, it is not advisable to use a
ALIGNMENT iliary starter switch between the S feeler gauge to check the gap.
The vented-type breaker points and the battery terminals of the start- To check and adjust the breaker
must be accurately aligned and strike er relay. points with a feeler gauge:
squarely in order to realize the full 1. Check and adjust the breaker
advantages provided by this design l. Align the breaker points to point alignment.
and assure normal breaker point life. make full face contact by bending the l. Rotate the distributor until the
Any misalignment of the breaker stationary breaker point bracket (Fig. rubbing block rests on the peak of a
point surfaces will cause premature 10) . Do not bend the breaker arm. cam lobe.
9-8 GROUP 9- IGNITION SYSTEM

If the distributor is in the engine will flutter at high engine rpm result- MORE TENSION TENSION SPRING
place the rubbing block on the peak ing in an engine miss.
of the cam by proceeding as follows: To check the spring tension on
Disconnect the brown wire and the either the pivot-type or the pivotless
red and blue wire from the starter re- breaker points, place the hooked end
lay and, with the ignition switch off, of the spring tension gauge over the
crank the engine by using an auxiliary movable breaker point. Pull the gauge
starter switch between the S and bat- at a right angle (90°) to the movable
tery terminals of the starter relay. arm until the breaker points just start
Insert the correct blade of a clean to open (Fig. 12 ) . If the tension is
feeler gauge between the breaker not within specifications, adjust the
points (Fig. 11 ). spring tension on the pivot-type
Apply a light film of distributor points or replace the breaker point
cam lubricant (MIC66-A) to the assembly on the pivotless points.
Feeler Gouge LESS TENSION

FIG. 13 -Adjusting
Breaker Point Spring
Tension
rect degree mark should be in line
with the timing pointer when the
timing light flashes .
The other method uses degree
marks on the timing pointer (Fig.
15). These also range from 0° or top
dead center (TDC) to some value be-
fore top dead center (BTDC). When
checking the timing, the correct de-
gree mark should be in line with the
timing mark on the crankshaft pulley
when the timing light flashes .
FIG. 11 -Adjusting New ADJUSTMENT
ng To check and adjust the timing
Breaker Point Gap
cam when new points are installed. Breaker Point Spring with a power timing light, proceed
as follows:
Do not use engine oil to lubricate Tension
the distributor cam.
Set the ignition timing. To adjust the spring tension (Fig.
If a scope or a dwell meter is used 13)
to . adjust new points, be sure the 1. Disconnect the primary or dis-
points are in proper alignment. Also, tributor lead wire and the condenser
set the contact dwell to the low set- lead.
ting. New points must be set to the 2. Loosen the nut holding the
low dwell as the rubbing block will spring in position. Move the spring
wear down slightly while seating to toward the breaker ann pivot to de-
the cam. crease tension and in the opposite di-
To check and adjust the breaker rection to increase tension.
points with a scope, refer to Ignition 3. Tighten the lock nut, and then
System Tests. check spring tension. Repeat the ad-
To check and adjust the breaker justment until the specified spring
points with a dwell meter, refer to tension is obtained.
Distributor Tests. 4. Install the primary or distri~
BREAKER POINT SPRING butor lead wire and the condenser
TENSION ADJUSTMENT lead.
12019-A
AUTOLITE IGNITION TIMING
FIG. 14 -Typical V-8
BREAKER POINT SPRING TIMING MARK LOCATIONS
TENSION ADJUSTMENT There are two methods of showing Engine Timing Marks
Correct breaker point spring ten- the timing position. Both methods
sion is essential to proper engine op- use the cranksl.taft damper and a tim- 1. Remove the plug wire from the
eration and normal breaker point ing pointer. number 1 spark plug.
life. If the spring tension is too great, One method uses degree marks on 2. Install the spark plug adaptor
rapid wear of the breaker arm rub- the crankshaft pulley (Fig. 14) . These on the spark plug.
bing block will result, causing the degree marks range from 0° or top 3. Connect the plug wire to the
breaker point gap to close up and re- dead center (TDC) to some value spark plug adaptor.
tard the spark timing. If the spring before top dead center (BTDC). 4. Clamp the timing light spark
tension is too weak, the breaker arm When checking the timing, the cor- plug lead to the spark plug adaptor.
PART 9-1- GENERAL IGNITION SYSTEM SERVICE 9-9

FIG. 16 -6-Cylinder Engine Ignition Wiring -Typical

Removal the correct sockets in the distributor
1. Disconnect the wires at the cap. Be sure the wires are forced all
spark plugs and at the distributor cap. the way down into their sockets and
l. Remove the coil high tension that they are held firmly in position.
lead. The No. I socket is identified on the
cap. Install the wires in a clockwise
Cleaning and Inspection direction in the firing order (1 -5-3-6-
Refer to section 3 of this part for 2-4) starting at the No. 1 socket.
the cleaning and inspection proce- 3. Install the coil high tension lead.
FIG. 15 -Typical Six dures. Push all weatherseals into position.

Cylinder Engine Timing Installation

Marks 1. Connect the wires to the proper V-8 ENGINES
spark plugs. A typical ignition wiring installa-
5. Connect the timing light battery
leads to the battery terminals. l. Insert the ends of the wires in tion is shown in Fig. 17.
6. Disconnect the distributor vac-
uum line.
7. If necessary, clean and mark
the timing marks.
8. Operate the engine at the spec-
ified idle rpm and point the timing
light at the timing pointer.
9. If the timing is incorrect, loosen
the distributor hold down bolt and
rotate the distributor until the desired
initial advance is obtained.
10. Tighten the distributor hold
down bolt and check the timing again.
11. Turn off the engine.
12. Remove the timing light and
connect the vacuum line.

SPARK PLUG WIRE

REPLACEMENT
When removing the wires from the
spark plugs, grasp, twist and pull the
moulded cap only. Do not pull on the
wire because the wire connection in-
side the cap may become separated
or the weather seal may be damaged.

200 AND 250 C.I.D. SIX

CYLINDER ENGINES
The ignition wire installation is
shown in Fig. 16. FIG. 17 -Typical V-8 Engine Ignition Wiring
9-10 GROUP 9- IGNITION SYSTEM

Removal to the proper spark plugs. Install the 2. Connect the spark plug wires.
t. Disconnect the wires from the coil high tension lead. Be sure the
spark plugs and distributor cap. No.7 spark plug wire is positioned
:Z. Pull the wires from the brackets in the bracket as shown in Fig. 17. RESISTANCE WIRE REPLACEMENT
on the valve rocker arm covers and SPARK PLUGS 1. Disconnect the resistance wire
remove the wires. (pink) from the connection to the
3. Remove the coil high tension REMOVAL . red and green wire adjacent to the
lead. 1. Remove the wire from each brake master cylinder.
spark plug by grasping, twisting and 2. Plug in the new resistance wire
Cleaning and Inspection pulling the moulded cap of the wire and route it with the main wiring
Refer to section 3 of this part for only. Do not puB on the wire be- down to the ignition coil. Tape it
the cleaning and inspection proce- cause the wire coanectlon inside the to the main wiring.
dures. cap may become sepu~~ted or the 3. Connect the new resistance wire
weather seal may be damaged. to the coil battery terminal.
Installation 2. Clean the area around each
1. Insert each wire in the proper spark plug port with compressed air,
socket of the distributor cap. Be sure and then remove the spark plugs.
the wires are forced all the way down
into their sockets. The No. 1 socket CLEANING AND INSPECI'ION
is identified on the cap. Install the Refer to section 3 of this part for
wires in a counterclockwise direction the cleaning and inspection proce-
in the firing order (1-3-7-2-6-5-4-8) dures.
for 302 engines and
for 351 engines starting at the No. 1 ADJUSTMENT
socket. Cylinders are numbered from Set the spark plug gap to specifica-
front to rear; right bank 1-2-3-4, left tions by bending the ground electrode
bank 5-6-7-8. (Fig. 18).
2. Remove the brackets from the
old spark plug wire set and install INSTALLATION
them on the new set in the same rela- 1. Install the spark plugs: Torque
tive position. Install the wires in the 18 mm. to 15-20 ft. lb. and 14 mm.
brackets on the valve rocker arm to 10-15 ft. lb. FIG. 18- Checking Spark
covers. (Fig. 17). Connect the wires Plug Gap

EJ CLEANING AND INSPECTION

SPARK PLUGS DISTRIBUTORS Inspect the breaker plate assembly

Examine the firing ends of the for signs of distortion. In addition, on
spark plugs, noting the type of de- Soak all parts of the distributor as-
sembly (except the condenser, break- the dual advance distributor, inspect
posits and the degree of electrode er point assembly, lubricating wick, the stationary sub-plate for worn ny-
erosion. Refer to Fig. 19 for the var- vacuum diaphragm, distributor base lon contact buttons. Replace the
ious types of spark plug fouling and oil seal and electrical wiring) in a breaker plate assembly if it is defec-
their causes. mild cleaning solvent or mineral tive.
spirits. Do not use a harsh cleaning The breaker point assembly and
Clean the plugs on a sand blast solution. Wipe all parts that can not condenser should be replaced when-
cleaner, following the manufacturer's be immersed in a solvent with a clean ever the distributor is overhauled.
instructions. Do not prolong the use dry cloth. Inspect all electrical wiring for
of the abrasive blast as it will erode fraying, breaks, etc., and replace any
the Insulator and electrodes. After foreign deposits have been that are not in good condition.
Clean the electrode surfaces with loosened by soaking, scrub the parts Check the distributor base for
a small file (Fig. 21). Dress the elec- with a soft bristle brush. Do not use cracks or other damage.
trodes to obtain flat parallel surfaces a wire brush, file, or other abrasive
objec;t. Dry the parts with compressed
on both the center and side elec- air. Check the diaphragm housing,
trodes.
Examine the bushing surface(s) of bracket, and rod for damage. Check
the distributor shaft and the bush- the vacuum line fitting for stripped
After cleaning, examine the plug ing(s) for wear. threads or other damage. Test the
carefully for cracked or broken in- Inspect the distributor cam lobes vacuum fittings, case, and dia-
sulators, badly pitted electrodes, and for scoring and signs of wear. If any phragm for leakage as explained
other signs of failure. Replace as re- lobe is scored or worn, replace the under Distributor Tests. Replace all
quired. cam assembly. defective parts.
PART 9-1- GENERAL IGN ITION SYSTEM SERVICE 9-11

IDENTIFIED BY BLACK . IDENTIFIED BY WET BLACK DEP. IDENTIFIED BY DEPOSIT

DRY FLUFFY CARBON OS ITS ON THE INSULA TOR SHELL BUILD-UP CLOSING GAP
DEPOSITS ON INSULATOR BORE ELECTRODES CAUSED BY BETWEEN ELECTRODES .
TIPS, EXPOSED SHELL EXCESSIVE OIL ENTERING COM BUS. CAUSED BY OIL OR
SURFACES AND ELECTRQDES. TION CHAMBER THROUGH WORN CARBON FOULING. IF
CAUSED BY TOO COLD A RINGS AND PISTONS, EXCESSIVE DEPOSITS ARE NOT EXCESSIVE,
PLUG , WEAK IGNITION , DIRTY CLEARANCE BETWEEN VALVE THE PLUG CAN BE CLEANED.
AIR CLEANER, DEFECTIVE fUEL GUIDES AND STEMS, OR WORN OR
PUMP, TOO RICH A FUEL LOOSE BEARINGS. CAN BE CLEANED
MIXTURE , IMPROPERLY IF ENGINE IS NOT REPAIRED, USE
OPERATING HEAT RISER A HOTTER PLUG.
OR EXCESSIVE IDLING.
CAN BE CLEANED.

IDENTIFIED BY DARK IDENTIFIED BY LIGHT TAN OR IDENTIFIED BY SEVERELY

GRAY , BLACK , YELLOW GRAY DE POSITS ON THE ERODED OR WORN ELECTRODES.
OR TAN DEPOSITS OR A FIRING TIP CAUSED BY NORMAL WEAR .
FUSED GLAZED COATING CAN tlE CLEANED. SHOULD BE REPLACED.
ON THE INSULATOR TIP .
CAUSED BY HIGHLY
LEADED GASOLINE. CAN
BE CLEANED.

PRE-IGNITION

IDtNTifiED [)) MELTEC IDENTIFIED BY A WHITE UR LIGHT IDENliFIED BY MEL TED

OR SPOTTY DEPOSITS GRAY INSULATOR WITH SMALL ELECTRODES AND PDSSIBL Y
RESEMBLING BUBBLES BLACK OR GRAY BROWN SPOTS BL~TEREDIN SULATOR.
OR BLISTERS. AND WITH BLUISH-BURNT, APPEAR. METALLIC DEPOSITS ON
CAUSED BY SUDDEN INSULA TOR INDICATE ENGINE
ACCE LE RAT ION . CAN BE ANCE OF ELECTRODES, CAUSED
BY ENGINE OVERHEATING. WRONG DAMAGE.
CLEANED. CAUSED BY WRONG TYPE
TYPE OF FUEL, LOOSE SPARK
PLUGS, TOO HOT A PLUG, LOW OF FUEL . INCORRECT IGNITION
FUEL PUMP PRESSURE OR INCOR. TIMING OR ADVANCE, TOO HOT
RECT IGNITION TIMING. REPLACE A PLUG. BURNT VALVES OR
THE PLUG. ENGINE OVERHEATING.
REPLACE THE PLUG.

FIG. 19 -Spark Plug Inspection

9-12 GROUP 9- IGNITION SYSTEM

CONDITION CAUSED IY 250 C.I.D. 2V, 302 C.I.D. and 351

C.I.D. engines.
Contacts should be replaced if the contact surfaces
are severely black, extremely dirty or show evidence DESCRIPTION
of excessive oil or grease; such as to cause the The temperature sensitive vacuum
voltage drop across the points to exceed 250 Milli control valve is located in the engine
Volts, when the points are closed 'lllld the ignition coolant outlet. Its function is to
switched on. regulate the ignition spark control
vacuum applied to the distributor at
engine idle.
Incorrect alignment.
Incorrect voltage regulator setting. OPERATION
Radio condenser installed to the distributor side
During extended idle periods,
of the coil.
under high ambient temperature
Ignition condenser of improper capacity.
conditions with the air conditioner
Extended operation of the engine at speeds other
EXCESSIVE METAL operating, the valve regulates the
than normal.
TRANSFER OR PITTING ignition timing according to engine
temperature.
As the engine coolant temperature
FIG. 20- Breaker Point Inspection rises above normal the vacuum
control valve is progressively opened
The breaker point assembly con- so applying vacuum to the dis-
sists of the stationary point bracket tributor spark control unit and
advancing the ignition timing.
assembly, breaker arm and the pri- This has the effect of:
mary wire terminal. 1. Increasing the engine idle speed.
Breaker points should be inspected, 2. Increasing the air flow through
cleaned and adjusted as necessary. the radiator.
Breaker points can be cleaned with 3. Increasing coolant flow through
chloroform and a stiff bristle brush. the engine.
4. Increasing thermal efficiency.
Replace the breaker point assembly
if the contacts are badly burned or
excessive metal transfer between the
points is evident (Fig. 20). Metal
transfer is considered excessive when
it equals or exceeds the gap setting.

SECONDARY WIRING
Wipe the wire with a damp cloth
and check for fraying, breaks or FIG. 21- Cleaning Spark
cracked insulation. Inspect the ter- Plug Electrode
minals and weather seals for loose- B 3104-A
ROTOR
ness or corrosion. Replace any wires
that are not in good condition. Clean the rotor with a soft bristle FIG 22 - Distributor Vaccum
brush and mild cleaning solvent or Control Valve ·
mineral spirits. Dry the rotor with
COIL compressed air. Inspect the rotor for DISTRIBUTOR VACUUM
Wipe the coil with a damp cloth cracks or burning. Replace the rotor CONTROL VALVE TEST
and check for any cracks or other de- if it is defective. (TEMPERATURE SENSING
fects. VALVE)
DISTRIBUTOR VACUUM
CONTROL VALVE 1. Make certain that all vacuum
Check that all vacuum lines are hoses are properly routed and in-
DISTRIBUTOR CAP stalled.
correctly fitted and free from leaks.
2. Attach a tachometer to the en-
Inspect valve for correct operation
gine.
as outlined in Part 2 prior to attempt-
Clean the distributor cap with a 3. Bring the engine up to operating
ing any engine tuning procedures.
soft bristle brush and mild cleaning temperature and be certain that the
solvent or mineral spirits. Dry the DISTRIBUTOR VACUUM choke plate is in the vertical position.
ADVANCE CONTROL VALVE Engine must not be overheated.
cap with compressed air. Inspect the
4. Note the engine idle rpm with
cap for cracks, burned contacts, per- The distributor vacuum advance transmission in neutral and carburettor
manent carbon tracks or dirt or cor- control valve shown in . Fig. 23 is throttle in the curb idle positiorr.
rosion in the sockets. Replace the cap fitted to 250 C.I.D. IV engines equip- 5. Disconnect · the vacuum hose
if it is defective. ped with air conditioning and to all from the intake manifold at the tern-
PART 9-1- GENERAL IGNITION SYSTEM SERVICE 9-13

perature sensing valve and plug or

clamp the hose.
6. Note engine idle rpm with the
hose disconnected. If no change in
idle speed, the valve is acceptable up
to this point. If there is a drop in idle
speed of 100 rpm or more, the valve
should be replaced.
7. Install vacuum line on manifold
fitting; then verify that the all season
cooling mixture is up to specifications,
and that the correct radiator cap is INTAKE
MANIFOLD FITTING
installed.
8. Cover the radiator sufficiently to DISTR !SUTOR
ACCESSORY OUTLETS
induce a high temperature condition. VACUUM CONTROL OR CAPPED
9. Continue to run the engine until VALVE

the red high temperature light comes CARBURETOR

on or the temperature indicated on the
temperature gauge is at the high end
of the band indicating an above nor-
mal temperature.
If the engine idle speed has by this
time increased 100 rpm or more, the
temperature sensing valve is satisfac- DISTRIBUTOR VACUUM UNIT
tory. If not, it should be replaced.
Do not overheat the engine. FIG 23 - Ignition Vacuum Schematic
9-14

PART DUAL ADVANCE DISTRIBUTORS

9-2 BOSCH
6 and 8 Cyl. Models
Section Page Section Pap
1 Description and Operation 9-14 Removal 9-15
Installation __ -- _ 9-15
2 In-Car Adjustments and Repairs 9-14
4 Major Repair Operations • 9-15
Breaker Point and Condenser Replacement 9-14
Bench Disassembly ~-­ 9-15
3 Removal and Installation 9-15 Bench Assembly 9-17

D DESCRIPTION AND OPERATION

LUBRICATING WICK
The dual advance distributor has
ADVANCE
two independently operated spark ADJUSTING BRACKET
advance systems. A centrifugal ad-
vance mechanism is located below
the stationary sub-plate assembly
and a vacuum operated spark control
diaphragm is located on the side ·of
the distributor base.
As speed increases, the centrifugal
weights cause the cam to advance or
move ahead with respect to tlie dis-
tributor drive shaft. The rate of ad-
vance is controlled by calibrated
springs.
The vacuum advance mechanism
has a spring loaded diaphragm which
is connected to the breaker plate. The
spring loaded side of the diaphragm
is airtight and is connected through WEIGHT
a vacuum line to the carburettor
throttle bore. When the throttle plate
opens, the distributor vacuum passage
is exposed to manifold vacuum, which
causes the diaphragm to move against
the tension of the spring. This causes STOP PLATE
the movable breaker plate to rotate on
the stationary sub-plate. The breaker
point rubbing block then moves
against distributor rotation and ad-
vances the spark timing.
FIG. 1-Typical Centrifugal Advance Mechanism

EJ IN CAR ADJUSTMENTS AND REPAIRS

BREAKER POINT AND 4. Remove spacing shims (if any) by depressing the moving contact
CONDENSER REPLACEMENT from contact breaker point pin. spring blade until the terminal block
REMOVAL 5. Remove screw securing contact is clear of the stationary point.
1. Unfasten spring clips holding breaker assembly to breaker plate
distributor cap in place and remove and lift off contact breaker assembly. INSTALLATION
cap. Care must be taken to prevent spac- 1. Instal stationary contact and
2. Carefully lift rotor from the ing shims from under moving contact attaching screw.
cam spindle. from being dislodged and dropped in- ·2. Instal contact height aligning
3. Remove contact breaker lead to the distributor body. The contact shims on pivot post and instal contact
from primary terminal connector. breaker assembly may be separated breaker arm.
PART 9-2-DUAL ADVANCE DISTRIBUTORS 9-15

3. Replace contact breaker arm coil terminal. Breaker Point Gap Adjustment
retaining clip on pivot post. 3. Disconnect breaker point lead A scope, a dwell meter, or a feeler
4. Replace contact breaker lead on from distributor primary terminal, gauge may be used to check the gap
primary terminal. and slide terminal block from dis- of. new breaker points.
tributor body. A scope or dwell meter can be used
5. The breaker points must strike
squarely, to align the breaker points 4. Remove condenser attaching to check the gap of used points. Due
carefully bend the stationary point screw and lift out condenser and wire to the roughness of used points, it is
bracket until full face contact is ob· assembly. not advisable to use a feeler gauge to
tained. REPLACE check the gap.
6. Reset the breaker point gap to Adjustment of the cam angle or
1. Position condenser and tighten
specifications. contact gap is made by loosening the
attaching screw.
7. Replace rotor and distributor contact plate securing screw and in-
2. Slide terminal block into dis-
cap. serting the blade of a screwdriver be-
tributor body and connect primary
CONDENSER: tween the two dowel pins on the base
lead to coil terminal.
plate and the slot in the contact plate.
REMOVAL 3. Connect breaker point lead to
Turn screwdriver clockwise to de-
1. Remove distributor cap. terminal block.
crease cam angle and anti-clockwise
2. Disconnect primary lead from 4. Replace distributor cap. to increase cam angle.

EJ REMOVAL AND INSTALLATION

REMOVAL Do not rotate the cn~~kshaft wblle compression stroke. Position the dis-
1. Disconnect the primary wire at the distributor Is removed, or It wiD tributor in the block with the rotor at
the coil and remove the distributor be necessary to dme the engine. the No. l firing position. Make sure
cap. the oU pump Intermediate drlve shaft
INSTALLATION Is properly seated in the oU pump.
2. Disconnect the vacuum line at Install, but do not tighten, the dis-
the distributor. 1. If the crankshaft has not been tributor retaining bolt. Rotate the
3. Scribe a mark on the distributor rotated while the distributor was re- distributor body clockwise until the
body, indicating the position of the moved, position the distributor in the breaker points are just starting to
rotor, and scribe another mark on the block with the rotor aligned with the open. Tighten the retaining bolt.
body and engine block, indicating the mark previously scribed on the dis- 3. Connect the distributor primary
position of the body in the block. tributor body. wire and install the distributor cap.
These lines will be used as guides Install the distributor retaining 4. Start the engine and adjust the
when installing the distributor in the screw. ignition timing to specifications with
correctly timed engine. 2. If the crankshaft has been ro- a timing light. Connect the distribu-
4. Remove the retaining bolt and tated while the distributor was re- tor vacuum line, and check the ad-
lock washer and lift the distributor moved, rotate the crankshaft until vance with the timing light when the
out of the block. the No. 1 piston is on TDC after the eng;.1e is accelerated.

EJ MAJOR REPAIR OPERATIONS

To perform the operations in this denser and primary terminal block. (8) from shaft (13) place the shaft
section, it will be necessary to remove 6. Remove spring clip (23) and upright in a soft jaw vice so that the
the distributor from the engine and remove the vacuum control unit. vice jaws support the driving plate.
place it in a vice. 7. Remove screws and washers (4) Lever the cam and circlip off the
and lift out the contact breaker plate. drive shaft with two screw-drivers
8. Remove the drive gear securing inserted between the cam and driving
DISASSEMBLY roll pin (20) and remove tlu: drive plate.
1. Whileholdingthedistributorcap gear (21). On 8 cylinder distributors
(15) in place unfasten the spring clips remove the roll pin and drive shaft
(18) then remove the cap. collar. NOTE: Do not remove the lubri-
2. Carefully remove the rotor (17) 9. Extract the distributor shaft cation felt (5) from the cam prior to
from the cam spindle. (13) from the housing (19) by apply- operation 11 as it will prevent the
3. Remove the contact breaker ing light pressure at the drive gear circlip (6) from springing out and
cable from the primary terminal flat end. becoming lost.
pin connector. 10. Mark the advance weights, 12. Remove the centrifugal ad-
4. Remove screw and washers (2) springs and cam posts to ensure cor- vance weights (11) and fibre washers.
and lift out the contact set. rect reassembly. If required remove 13. Remove lubrication felt (5),
5. Remove screw and washer as- the springs (9 and 10). circlip (6) and washer (7) from the
semblies (22) and lift out the con- 11. To remove circlip (6) and cam distributor cam.
9-16 GROUP 9- IGNITION SYSTEM

1 Contact Set 10 Advance Weight Primary Spring

2 Screw & Washer Conta_ct Set to Breaker Plate 11 Centrifugal Advance Weights
3 Contact Breaker Plate 12 Fibre Washer Weights to Driving Plate
4 Screw & Washer Breaker Plate to Dist Housing 13 Distributor Shaft & Driving Plate Assy
5 Lubrication Felt 14 Spacer Shim.
6 Circlip Cam Assy to Dist. Shaft 15 Distributor Cap
7 Washer Cam Assy to Dist. Shaft 16 Carbon Brush and Spring
8 Cam Assy 17 Rotor
9 Advance Weight Secondary Spring. 18 Spring Clip Cap to Housing
19 Distributor Housing
20 Roll Pin Gear to Shaft
21 Helical Drive Gear
22 Cheese Head Screw and Washer Condenser
and Vacuum Control to Dist. Housing
23 Spring Clip Vacuum unit Rod
24 Vacuum Control Unit

3
/ 0-<....-4

·--5 i--16
23-~
c---6
0--7
22

.....-10

25 Condenser with Terminal and Primary Connection

Assy
26 Breaker Plate Earth Lead and Nut.

21
14-Q FIG. 2 - Distributor Assembly
(6 cyl. shown)
PART 9-2-DUAL ADVANCE DISTRIBUTORS 9-17

Checking Dismantled springs must be replaced with the Shaft End Float
Distributor Components correct springs as the springs deter- Shaft end float must be adjusted to
Check bearing surfaces for wear mine the advance curve which is specifications by placing or removing
and replace worn parts. Remember important to optimum engine per- shims from between the drive gear
when checking the shaft bushing that formance. The vacuum control unit and the housing on 6 cylinder dist-
the lower bearing for the shaft is in must be tested for leaks and, in the ributors or between the drive shaft
the engine block. New sintered bush- event of a leak being found, the collar and housing on 8 cylinder
ings should be soaked in oil for an complete unit must be replaced. distributors.
hour before installation. Use the cor-
rect mandrel for pressing out and Reassembly Testing Advance Curve
replacing bushes. Test condenser by To assemble distributor reverse The advance curve must be check-
means of a suitable tester. The brack- disassembly procedure. ed to specifications on an approved
et of the condenser must make good Important: Cleanliness is essential, distributor test bench.
contact with the distributor housing. oil and grease must be kept away
Contact points must be secure and from the electrical contact surfaces Centrifugal Advance
well aligned; adjust height with and insulating parts. Adjustment is made by bending
shims. Displaced contact points The earth lead from the contact the spring bracket at the cam to
should be aligned by means of a set- breaker plate must be connected with increase or decrease spring tension.
ting tool. The rubbing block of the the housing by means of the screw A slot in the base plate gives access
contact breaker lever should not be which secures the vacuum advance to the spring brackets.
worn. Contact spring tension must be unit.
tested with a spring balance. The cam to driveshaft circlip can Vacuum Advance
Failure to comply with any one be installed using a piece of 0.25 The vacuum advance curve can be
of the above requirements makes it steel tube to press the circlip over tested by applying a depression to
necessary to replace the contact set. the shaft. the vacuum unit and reading the
Distorted or stretched advance degrees of advance on the scale.
The vacuum unit is not adjustable
and must be replaced if advance is
not to specification.

FIG. 4- 8 CYL ANTI-CLOCKWISE

ROTATION

FIG. 3 - 6 Cylinder Bosch Distributor -Typical

FIG. 5-6 CYL. CLOCKWISE

ROTATION
9-18

PART DUAL ADVANCE DISTRIBUTORS

9-3 MOTORCRAFT
Section Page Section Pare
l Description and Operation ...... ... ... .. .... 9-18 Replacement ...... .. .... ...... ...... ...... ...... ..... . 9-19
3 Removal and Installation .. .... ...... .... .. ...... ..... . 9-21
2 In-Car Adjustments and Repairs ... ... ...... 9-·19 4 Major Repair Operations ...... ..... .. ...... .. .... ..... . 9-21
Vacuum Diaphragm Replacement ...... ...... ...... 9-·19 Bench Disassembly ...... ...... ..... . .. .. .. ..... . 9·21
Cam and Centrifugal Advance Mechanism Bf.nch Assembly ...... ...... ...... ... .. ...... ..... . ...... 9-22

D DESCRIPTION AND OPERATION

The dual advance distributor has has a spring-loaded diaphragm cam from the pivot pin, then
two independently operated spark which is connected to the breaker moves. against distributor rotation
advance systems. A centrifugal ad- plate. The spring-loaded side of the and advances the spark timing. As
vance mechanism (Fig. 1) is located diaphragm is airtight and is con- the movable breaker plate is rotated
below the stationary sub-plate assem- nected through a vacuum line to the from retard position to full advance
bly, and a vacuum operated spark carburettor throttle bore. When the position, the dwell decreases slightly.
control diaphragm is located on the throttle plates open, the distributor This is because the breaker point
side of the distributor base (Fig. 2). vacuum passage is exposed to mani- rubbing block and the cam rotate on
As speed increases, the centrifugal fold vacuum, which causes the dia- different axes.
weights cause the cam to advance or phragm to move against the tension Note: A dual diaphragm advance/
move ahead with respect to the dis- of the spring. This action causes the retard unit is fitted to some engines,
tributor drive shaft. The rate of ad- movable breaker plate to pivot on however the retard side of the unit
vance is controlled by calibrated the stationary sub-plate. The breaker has been plugged and the vacuum
springs. point rubbing block, which is posi- side operates in the same manner as
The vacuum advance mechanism tioned on the opposite side of the the single diaphragm unit.
LUBRICATING WICK
ADVANCE
ADJUSTING BRACKFT

CAM PLATE CONTROL SLOT

FIG. 1 - Typical Centrifugal Advance Mechanism

PART 9-3-DUAL ADVANCE DISTRIBUTORS 9-19

COIL HIGH TENSION

WIRE TERMII~AL

FIG. 2 - Vacuum Advance Mechanism

EJ IN-CAR ADJUSTMENTS AND REPAIRS

BREAKER POINT AND BREAKER PLATE AND near the primary wire opening in the
CONDENSER REPLACEMENT SUB-PLATE REPLACEMENT distributor).
The replacement procedures are Refer to Figs. 3 and 4 for the 4. Working from the inside of the
covered in page 9-7. proper location of parts. distributor, push the primary wire
through the opening in the dis-
VACUUM DIAPHRAGM REMOVAL tributor.
REPLACEMENT 1. Remove the distributor cap and 5. Install the breaker point assem-
REMOVAL the rotor. bly, the condenser and the vacuum
2. Remove the breaker point as- diaphragm.
1. Remove the distributor cap and 6. Install the rotor and the dis-
the rotor. sembly, the condenser, and the
vacuum diaphragm. tributor cap.
2. Remove the vacuum line from
the diaphragm fitting. 3. Working from the inside of the CAM AND CENTRIFUGAL
3. Remove the spring clip that distributor, pull the primary wire ADVANCE MECHANISM
secures the diaphragm link to the through the opening in the distribu- REPLACEMENT
movable breaker plate. tor.
4. Remove the.spring clip, the flat REMOVAL
4. Remove the diaphragm retain-
ing screws and slide the diaphragm washer, and the spring washer secur- 1. Remove the distributor cap and
out of the distributor. ing the breaker plate to the sub-plate. the rotor.
5. Remove the sub-plate retaining 2. Working from the inside of the
INSTALLATION screws and lift both plates out of the distributor, pull the primary wire
1. Slide the diaphragm into the distributor. through the opening in the distribu-
opening in the distributor and place INSTALLATION tor. •
the link in its position. 1. Place the breaker plate in 3. Remove the sub-plate retaining
2. Install the spring clip that position on the sub-plate. screws and lift the plate assembly
secures the diaphragm link to the 2. Install the spring washer, the out of the distributor.
movable breaker plate and the flat washer, and the spring clip that 4. Mark one of the distrjbutor
diaphragm retaining screws. secures the breaker plate to the weight springs and its brackets.
3. Install the vacuum line on the sub-plate. Also mark one of the weights and
diaphragm fitting. 3. Install the sub-plate hold down its pivot pin.
4. Install the rotor and the dis- screws (the ground wire should be 5. Carefully unhook and remove
tributor cap. under the sub-plate hold down screw the weight springs.
9-20 GROUP 9-IGNITION SYSTEM
6. Lift the lubricating wick from
VACUUM DIAPHRAGM GROUND WIRE the cam assembly. Remove the cam .
assembly retainer and lift the cam
assembly off the distributor shaft.
Remove the thrust washer.
7. Remove the weight retainers
and lift the weights out of the
distributor.
INSTALLATION
1. Fill the grooves in the weight
pivot pins with distributor cam
lubricant (MIC66-A).
2. Position the weights in the dis-
tributor (the marked weight is
placed on the marked pivot pin)
and install the weight retainers.
3. Place the thrust washer on the
shaft.
4. Fill the grooves in the upper
portion of the distributor shaft with
distributor cam lubricant (MIC66-A).
5. Install the cam assembly. Be
sure that the marked spring
bracket on the cam assembly is
LINK SPRING CLIP near the marked spring bracket
on the stop plate.
If a new cam is being installed,
make sure that the cam is installed
with the hypalon covered stop in the
BREAKER POINT ASSEMBLY B227S· B
correct cam plate control slot. This
can be done by measuring the length
FIG. 3 - Breaker Plate Installed- Pivotless Points of the slot used on the old cam and
DISTRIBUTOR HOUSING SU3-PLATE by using the corresponding slot on
the new cam. Some of the cams will
have the size of the slot in degrees
stamped near the slot. H the wrong
slot is used, an incorrect maxi-
mum advance will be obtained.
Place a light film of distributor
cam lubricant on the distributor cam
lobes. Install the retainer and the
wick. Saturate the wick with SAE
lOW engine oil.
6. Install the weight springs. Be
sure that the marked spring is
attached to the marked spring
brackets.
7. Install the sub-plate assembly.
8. Working from the inside of the
distributor, push the primary wire
through the opening in the dis-
tributor.
9. Install the rotor and the dis-
tributor cap.
ADJUSTMENTS
LINK 3PRING CLIP Refer to page 9-7 for the adjust·
ment procedures.

82274-B

FIG. 4 - Breaker Plate Installed- Pivot-Type Points

PART 9-3- DUAL ADVANCE DISTRIBUTORS

EJ REMOVAL AND INSTALLATION

Install, but do not tighten, the re-
REMOVAL INSTALLATION taining clamp and bolt. Rotate the
1. Disconnect the primary wire at 1. If the crankshaft was rotated distributor body counterclockwise
the coil. Disconnect the vacuum while the distributor was removed until the breaker points are just start-
advance line at the distributor. from the engine, it will be necessary ing to open. Tighten the clamp.
Remove the distributor cap. to time the engine. Rotate the crank- 2. If the crankshaft has not been
2. Scribe a mark on the distribu- shaft until No. 1 piston is on TDC rotated, position the distributor in the
tor body and engine block indicating after the compression stroke. Align block with the rotor aligned with the
the position of the body in the block, the TDC mark on the timing pointer mark previously scribed on the dis-
and scribe another mark on the dis- with the timing pin on the crankshaft tributor body, and the marks on the
tributor body indicating the position damper. Position the distributor in distributor body and engine block in
of the rotor. These marks can be used the block with the rotor at the No. 1 alignment. Install the retaining clamp.
as guides when installing the dis- firing position. 3. Install the distributor cap.
tributor in a correctly timed engine. Make sure the oil pump inter- 4. Connect the primary wire to
3. Remove the distributor hold mediate shaft properly engages the coil.
down bolt and clamp. Lift the dis- the distributor shaft. It may be 5. Check the ignition timing with
tributor out of the block. necessary to crank the engine a timing light and adjust to specifi-
Do not rotate the crankshaft with the starter, after the dis- cations if necessary. Connect the
while the diStributor is removed, tributor drive gear is partially vacuum line, and check the advance
or it will be necessary to time the engaged, in order to engage the with the timing light when the
engine. oil pump intermediate shaft. engine is accelerated.

EJ MAJOR REPAIR OPERATIONS

To perform the operations in this moveable breaker plate.
section, it will be necessary to 5. Remove the diaphragm retain-
remove the distributor from the ing screws and slide the diaphragm
engine and place it in a vice. out of the distributor.
BENCH DISASSEMBLY 6. Working from the inside of the
The distributor assembly is shown distributor, pull the primary wire
in Fi~;. 6. through the opening in the distribu-
1. Remove the rotor. tor.
2. Disconnect the primary and the 7. Remove the spring clip, the flat
condenser wires from the breaker washer, and the spring washer secur-
point assembly. ing the breaker plate to the sub-plate.
3. Remove the breaker point as- FIG. 5- Gear Pin Removal or
sembly and condenser retaining Installation PIN-12145 - COLLAR

----e·.
screws. Lift the breaker point assem- DRIVE GEAR-12390

bly and condenser out of the dis- CLAMP- 12144 ~

tnbutor. . . HOUSING-12130

.
4. Remove the spnng chp that SPRING-12191 o• 12192 •
Secures the diaphragm link tll the EG T ~ 1• , ~DIAPHRAGM ASSEMBLy_

WEIGHT RETAINER-379\023
CAM ASSEMBLY-12210~
I
W I H -12188

' '
~ \

UPPER BUSHING , .
<~
1

~
12370

STOP

RETAINER-12177 b... lf.IJ -,.._ 12120 '

CLAMP-
~ GASKET

~ 0,~
STATIONARY SUB-PLATE-12151'-....._

""
' •'

;'
' \ -12175

~SPRING-12191 o• 12192
., 12144 PINR-ET12U1R4N5 SPRING

CALIBRATING WASHERS
r
'"

VACUUM CONNECTION

PRIMARY WIRE-1221~

FIG. 6- Distributor Assembly

9-22 GROUP 9- IGNITION SYSTEM

8. Remove the sub-plate retaining BENCH ASSEMBLY 5. Place the collar in position on
screws and lift both plates out of the ORIGINAL SHAFT AND GEAR the shaft and align the holes in the
distributor. collar and the shaft, then install a
9. Mark one of the distributor 1. Oil the new upper bushing, and new pin. Install the distributor cap
weight springs and its brackets. position it on the bushing replacer clamps.
Also mark one of the weights and 6. Check the shaft end play with
its pivot pin. a feeler gauge placed between the
10. Carefully unhook and remove Preu ltom collar and the base ofthe distributor.
ihe weight springs. If the end play is not within specifi-
11. Lift the lubricating wick from cations, replace the shaft and gear.
the cam assembly. Remove the cam 7. Attach the distributor shaft
assembly retainer and lift the cam supporting tool to the distributor.
assembly off the distributor shaft. Tighten the backing screw in the tool
Remove the thrust washer. enough to remove all shaft end play.
12. Remove the weight retainers 8. Install the assembly in a press.
and lift the weights out of the Press the gear on the shaft (Fig. 14),
distributor. using the marks made on the gear
13. Remove the distributor cap and shaft as guides to align the pin
clamps. holes.
14. If the gear and shaft are to 9. Remove the distributor from
be used again, mark the gear and the press. Install the gear retaining
the shaft so that the pin holes pin (Fig. 5).
can be easily aligned for assem- 10. Position the distributor in a
bly. Remove the gear roll pin (Fig. vice. Fill the grooves in the weight
5), and then remove the gear pivot pins with a distributor cam
FIG. 9 -Shaft Removal lubricant.
(Fig. 7).
tool. Install the bushing (Fig. 12). 11. Position the weights in the dis-
15. Remove the shaft collar roll tributor (the marked weight is placed
pin (Fig. 8). When the tool bottoms against the
distributor base, the bushing will be on the marked pivot pin) and install
16. Invert the distributor and the weight retainers.
place it on a support plate in a installed to the correct depth. 12. Place the thrust washer on
position that will allow the dis- 2. Burnish the bushing to the the shaft.
tributor shaft to clear the support proper size (Fig. 13). 13. Fill the grooves in the upper
plate and press the shaft out of the 3. Invert the distributor and install portion of the distributor shaft with
collar and the distributor housing and burnish the lower bushing in a distributor cam lubricant.
(Fig. 9). similar manner. 14. Install the cam assembly. Be
4. Oil the shaft and slide it into sure that the marked spring
the distributor body. bracket on the cam assembly is
near the marked spring bracket
on the stop plate.
If a new cam is being installed,
make sure that the cam is installed
with the hypalon covered stop in the
correct cam plate control slot. This
can be done by measuring the length
of the slot used on the old cam and
by using the corresponding slot on
the new cam. Some of the cams will
have the size of the slot in degrees
FIG. 7- Gear Removal stamped near the slot. If the wrong
slot is used, an incorrect maxi-
17. Refer to Figs. 10 and 11 and mum advance will be obtained.
remove the distributor shaft upper Place a light film of distributor
and lower bushings. cam lubricant on the distributor cam
lobes. Install the retainer and the
wick. Saturate the wick with SAE
lOW engine oil.
15. Install the weight springs. Be
sure that the marked $pring is
attached to the marked spring
brackets.
16. Place the breaker plate in
position on the sub-plate.
17. Install the spring washer, the
FIG. 8 -Collar Pin Removal or flat washer, and the spring clip that
FIG. 10- Lower Bushing secures the breaker plate to the sub-
Installation Removal plate.
PART 9-3-DUAL ADVANCE DISTRIBUTORS 9-23

and install the retaining screws. Be

sure to place the ground wire under
the breaker point assembly screw far-
thest from the breaker point contacts.
Align and adjust the breaker point
assembly by following the procedure
on page 9·7.
23. Connect the primary and con-
denser leads to the breaker point
assembly.
24. Install the rotor and the dis-
tributor cap.
25. Check and adjust (if neces-
sary) the centrifugal and vacuum
advance (Refer to page 9-6).

FIG. 14- Original Shaft and

FIG. 11 -Upper Bushing Gear Installation
Removal
BUSHING
the shaft to the specified distance
from the bottom face of the gear to
the bottom face of the distributor
mounting flange (Fig. 15). Drill a
!-inch hole through the shaft using
FIG. 13- Burnishing Bushing the hole in the gear as a pilot.
!l. Remove the distributor from

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. 6 for the correct
DRILL~ INCH
location of the parts. HOLE THROUGH
1. Follow steps 1, 2, 3, and 4 SHAFT
under Bench Assembly Original
Shaft and Gear.
2. Attach the distributor shaft sup-
porting tool to the distributor and
FIG. 12- Upper Bushing install the assembly in a vice. Insert
Installation a 0. 024-inch feeler gauge between
the backing screw and the shaft.
18. Install the sub-plate hold down Tighten the backing screw on the
screws (the ground wire should be tool enough to remove all shaft end
under the sub-plate hold down screw play. Remove the feeler gauge and
near the primary wire opening in the allow the shaft to rest on the backing
distributor). screw. Slide the collar on the shaft.
19. Working from the inside of the While holding the collar in place FIG. 15- New Shaft and Gear
distributor, push the primary wire against the distributor base (Fig. 15), Installation
through the opening in distributor. drill a !-inch hole through the shaft
20. Slide the diaphragm into the using the access opening in the collar
opening in the distributor and place as a pilot. the press and remove the support >,

the link in its position. 3. Position the gear on the end of tool. Install the collar retaining pin
21. Install the spring clip that the shaft. Install the assembly in a (Fig. 8) and the gear retaining pin
secures the diaphragm link to the press. (Fig. 5).
moveable breaker plate. 4. With the backing screw on the 6. Complete the assembly by¢fol-
_ 22. Place the breaker point as- support tool tightened enough to re- lowing steps 9 to 25 under Installing
sembly and the condenser in position move all end play, press the gear on Original Shaft ancf'Gkr.
9-24

PART SPECIFICATIONS
9-4
GENERAL 200 & 260 302 351-2V 351-2V MANUAL
AUTO 351-4V MAN & AUTO

Breaker Arm Spring Tension (Ounces) 18-22 17-22 17-22 17-21

Contact Spacing (Inches) 012-.016 .013-.018 .013-.018 .021
Dwell Angle at Idle Speed 36°-40° 26°·30° 26°-30° 24°-29°

CONDENSER
Capacity (Micro Farads) 0.15-0.20 0.15-0.20 0.15-0.20 0.21-0.25
Minimum Leakage (Meg. ohms) 5 5 5 10
Maximum Series Leakage (ohms) 1 1 1 1

COIL
Primary Resistance (ohms) @ 75 °F. 1.40-1.54 1.40 -1.54 1.40-1.54 1.40-1.54
Secondary Resistance (ohms) @ 75°F. 8000-8800 8000-8800 8000-8800 7500-8700
Amperage Draw-Engine Stopped 4.5 4.5 4.5 4.5
-Engine Idling 2.5 2.5 2.5 2.5
Primary Circuit Resistor @ 75 °F. 1.30-1.40 1.30-1 .40 1.30-1.40 1.30-1.40

SPARK PLUGS
Type ( Motorcraft) BF42 AF32 AF32 AF32
Size 18MM 14MM 14MM 14MM
Gap (Inches) 0.032-0.036 0.032-0.036 0.032-0.036 0.032-0.036
Torque (Ft Lbs.) 15-20 10-15 10-15 10-15

IGNITION TIMING INITIAL ADVANCE

Manual and Automatic Transmission °8TDC for 6 6 6 6
altitude operation and/or to obtain optimum
engine performance and fuel economy the initial
ignition timing may be advanced 30 over the
normal setting. No further improvement will be
achieved by advancing beyond this point.

DISTRIBUTOR DIMENSIONS
Shaft end play (inches) Distributor removed 0.022-0.033 0.024-0.035 0.024-0.035 0.024-0.035
Distance from bottom of mounting flange to bottom 2.510-2.515 4.031-4.038 4.031-4.038 4.031 -4.038
of gear (inches)

Note: Some 351 C.I.D. engines are fitted with ARF 42 spark plugs as original equipment. The service replacement is AF32.
PART 9-4 SPECIFICATIONS 9-25
ADVANCE CHARACTERISTICS ARD10E-12100-D 250 C.I.D. 2V H.C. GREEN DOT
CENTRIFUGAL VACUUM
Note: The advance characteristics given apply to the Distributor r.p.m. Advance 0 in. Hg Advance 0

distributor with the indicated nwmber only. The 500 0

distributor number is stamped on the distributor 600 0-2
housing. 800 4-6 5 0
1000 5-7 8 0-2.75
For all distributors set test stand to 0° at 250 1500 7.5-9.5 12 4-6.5
R.P.M. and 0 inches of mercury. 2300 11.5-13.5 17 8.5-11
Maximum advance 13.5 11
ARD1DE·12100-B 200 C.I.D. H.C. BLUE DOT ARD1AE-12100-AB 302 C.I.D. H.C. RED DOT
CENTRIFUGAL VACUUM CENTRIFUGAL VACUUM
Distributor r.p.m. Advance 0 in. Hg Advance 0
Distributor r.p.m. Advance 0 in. Hg Advance 0
500 1-4 5 0-1 350 0
800 6-9 7 1.5-6 500 0-2.25
1000 9-12 8 3.5-8 750 4-6.5 5 0-3.25
1500 12-14 10 7-9 1000 7.5-9.5 10 6.75-11.25
2000 14-16 1500 10.25-12.25 15 11 -13
Maximum advance 16 9 2000 12.75-14.75 20 11-13
2400 15-17 25 11-13
ARD1DE-12100-CA 200 C.I.D. L.C. BLACK DOT Maximum advance 17 13
CENTRIFUGAL VACUUM
Distributor r.p.m. Advance 0 in. Hg Advance 0 ARD1AE-12100-EA 351 C.I.D. 2V AUTO YELLOW DOT
500 0-1 CENTRIFUGAL VACUUM
700 1-.35 5 0-1 Distributor r.p.m. Advance 0 in. Hg Advance 0
1000 5.25-8.75 7 1.5-5.5 350 0
1500 12.25-14.5 10 7.5-11 500 0-1 .75
1700 14-16 12 9-11 750 3.25-5.25 5 0-3
Maximum advance 16 11 1000 7-9 10 6.25-9.75
1500 9.5-11.5 15 8.5-10.5
ARD1DE-12100-DA 200 C.I.D. L.L.C. (EXPORT ONLY) 2000 11.75-13.75 20 8.5-10.5
YELLOW DOT 2150 12.5-14.5
CENTRIFUGAL VACUUM Maximum advance 14.5 10.5
Distributor r.p.m. Advance 0 in. Hg Advance 0
600 0-.5 DOOF-12127-T 351 C.I.D. 2V MANUAL
800 1-4 5 0 CENTRIFUGAL VACUUM
1200 8.5-11.5 7 0-1 Distributor r.p.m. Advance 0 in. Hg Advance 0
1500 14-17 10 1-4 350 0-0.5
1800 16-18 15 5-7.75 500 0-1 .5 5 0-2
2100 17-19 20 8.75-11 .25 750 2-4 10 5-8
Maximum advance 19 11.25 1000 4.5-6.5 15 9-12
1500 7.75-10 20 10-12.5
ARD10E 12100-C 250 C.I.D. H.C. RED DOT 2000 10.0-12.5 25 10-12.5
CENTRIFUGAL VACUUM 2300 11.5-14
Distributor r.p.m. Advance 0 in. Hg Advance 0
Maximum advance 14 12.5
500 0-2
800 3.5-5.5 5 0-1 DOOF-12127-G 351 C.I.D. 4V AUTO
1000 6-8 7 1.5-6 CENTRIFUGAL VACUUM
1500 9.5-11.5 8 3.5-8 Distributor r.p.m. Advance 0 in. Hg Advance 0
2000 13-15 10 7-9 350 0-0.5
2300 15-17 500 0-0.5
Maximum advance 17 9 750 3-5 5 0-1
1000 5.5-7.5 10 1.25-4.5
ARD10E 12100-EA 250 C.I.C. L.C. WHITE DOT 1500 6.75-9 15 5.5-8.5
CENTRIFUGAL VACUUM 2000 7.75-10.25 20 8-10.5
Distributor r.p.m. Advance 0 in. Hg Advance 0
2300 8.5-12.0 25 8-10.5
600 0 Maximum advance 12 10.5
800 0-1.5 6 0
1200 4-6 8 0-3 DOOF-12127-V 351 C.I.D. 4V MANUAL
1900 12-14 10 3-6 CENTRIFUGAL VACUUM
2350 15-17 15 9-11 Distributor r.p.m. Advance 0 in. Hg Advance 0
Maximum advance 17 11 350 0-0.5
500 0-0.5 5 0-1
750 0.75-2.75 10 1-4.5
1000 3.75-5.75 15 5.5-8.5
1500 8.5-10.75 20 8-10.5
2000 10.25-12.75 25 8-10.5
2300 11.5-14.0
Maximum advance 14 10.5
REFERENCE TO SERVICE INFORMATION AND NOTES

Date Letter No. Pace Brief Detail

FALCON FAIRLANE w~:~~~~P

GROUP
FUEL SYSTEM
10

PAGE

PART 10-1- General Fuel System Service 10-2

PART 10-2- Stromberg BV-2 Carburettor 10-11

PART 10-3- Stromberg WW Series Carburettor 10-20

PART 10-4- Ford Motorcraft Model 2100 Carburettor 10-31

PART 10-5- Motorcraft Model 4300 Carburettor 10-45

PART 10-6- Fuel Pump and Fuel Filter 10-61

PART 10-7- Air Cleaner 10-64

PART 10-8- Fuel Tank and Lines 10-67

PART 10-9- Specifications 10-71

10-2

PART GENERAL FUEL SYSTEM SERVICE

10·1

Section Page Section Page

1 D~agnos~s and Testing ...... ...... ...... ...... ...... ......10-2 2 Common Adjustments and Repairs ............ 10-7
Diagnosis ...... ...... ...... ...... ...... ...... ...... ...... ...... ......10-2 Throttle Linkage Adjustments ........................10-7
Fuel Tank and Lines Diagnosis Guide ...... ......10-3 Accelerator Pedal Idle Height Adjustment ...... 10-7
Carburettor Diagnosis Guide ..............................10-3 Throttle Linkage Repair ...... ...... ...... ...... ...... ......1 0- 7
Tests ................., ..................................................... .10-5 3 Cleaning and Inspection .............................. ............ 10-13
Fuel Pump Tests ........................ ............................. .10-5 Carburettors ............................................................10-13
Carburettor Tests ........................ ...... ..................10-6 Fuel Pump .................. ........................ ................. .I0-13
Air Cleaner ...... ...... ...... ...... ...... ...... ...... ...... ...... ......1 0-13

This part covers general fuel sys- carburettors and on a tag attached to
tem diagnosis, tests, adjustment and the upper body on Motorcraft car-
repair procedures. In addition, clean- burettors. To procure replacement
ing and inspection procedures are parts, it is necessary to know the
covered. part number prefix and suffix and,
For fuel system component re- in some instances, the design change
moval, disassembly, assembly, instal-
code
lation, repair procedures, adjust-
Always refer to the Master Parts
ments and specifications, refer to the
pertinent part of this group. Catalogue for parts usage and inter-
The carburettor identification is changeability before replacing a car-
stamped on the carburettor upper burettor or a component part for a
body or float bowl for Stromberg carburettor.

D DIAGNOSIS AND TESTING

DIAGNOSIS If the accumulation of sediment FUEL PUMP
in the filter is excessive, the fuel
FUEL TANK, LINES AND Incorrect fuel pump pressure and
tank should be removed and flushed,
FILTER and the line from the fuel pump to low volume (ftow rate) are the two
Water and dirt that accumulate in the tank should be blown out. most likely fuel pump troubles that
the fuel tank can cause a restricted Leakage in the fuel inlet line can will affect engine performance. Low
fuel line or filter and malfunction of cause low vacuum, and volume con- pressure will cause a lean mixture
fuel pump, or carburettor. Conden- ditions, and loss of fuel. and fuel starvation at high speeds
sation, which is the greatest source A restricted fuel tank vent can and excessive pressure will cause
of water entering the fuel tank, is cause low fuel pump pressure and
formed by moisture in the air when volume and may, in some instances, high fuel consumption and carburett-
it strikes the cold interior walls of result in collapsed inlet hoses or a or flooding. Low volume will cause
the fuel tank. collapsed fuel tank. fuel starvation at high speeds.
PART 10-1- GENERAL FUEL SYSTEM SERVICE 10-3
FUEL PUMP, TANK AND LINES DIAGNOSIS GUIDE
Diaphragm stretched or leaking. Fuel filter clogged (low volume).
Fuel pump diaphragm spring is Fuel line cracked or broken.
weak. Fuel pump valves improperly
LOW FUEL PUMP Rocker arm or eccentric worn or seating.
PRESSURE OR VOLUME undersize. Dirt in fuel tank and/ or lines.
Excessive clearance between rock- Fuel tank vent restricted.
er arm and fuel pump link. Diaphragm ruptured.
Fittings loose or cracked. Main body retaining screws loose.

Diaphragm spring too strong or Pump link has no free play (fro-
HIGH FUEL PUMP improper spring. zen).
PRESSURE OR VOLUME Diaphragm surface too tight Diaphragm vent opening plugged
(over-tensioned). or omitted.

Diaphragm stretched or leaking. Rocker arm or eccentric worn.

LOW FUEL PUMP
Fuel pump springs weak. Excessive clearance between rock-
Fuel pump valves improperly seat- er arm and fuel pump link.
VACUUM
in g. Main body retaining screws loose.
Diaphragm ruptured.

LOW FUEL PUMP Fuel filter clogged. Restriction in fuel supply line to
VOLUME WITH NORMAL Fuel pump to carburettor inlet line fuel pump.
PRESSURE obstructed, crimped or leaks.

Diaphragm defective. Threads on fittings stripped.

FUEL PUMP LEAKS FUEL
Fittings loose. Body cracked.

Fuel pump retaining bolts loose. Diaphragm pull rod oil seal rup-
FUEL PUMP LEAKS OIL Mounting gasket defective. lured or improperly installed.

Rocker arm or eccentric worn. Rocker arm bumper pad defec-

Mounting bolts loose. tive.
FUEL PUMP NOISI Rocker arm springs weak or
broken.

FUEL TANK AND/OR Fuel tank vent restricted.

INLET LIN! HOSIS
COLLAPSED

Dirt accumulation in the fuel and ments and improper fuel level are troubles.
air passages, improper idle adjust- the major sources of carburettor
CARIURmOR DIAGNOSIS GUIDI
Cracked carburettor body. Ruptured accelerating pump dia-
Defective main body and for fuel phragm.
FLOODING OR UAKING bowl gasket. Excessive fuel pump pressure.
CARBURETOR High fuel level or ftoat setting. Defective power valve gasket,
Fuel inlet needle not seating prop- Ruptured power valve diaphragm.
erly or worn needle and/ or seat.

Improper carburettor gasket and /

or spacer combination.
Incorrect setting of choke thermo-
Improper starting procedure caus- static spring housing.
ing a flooded engine. Choke linkage or plate binding.
HARD STARnNG Improper carburettor fuel level. Binding qr broken manual choke
Improper idle adjustments. linkage.
Sticking or incorrectly seating fuel Restrictions or air leaks in the
inlet needle. choke vacuum or hot air passages.
Incorrect fuel pump pressure. Dirty air cleaner element.
1()..4 GROUP 10- FUEL SYSTEM
CARIUREnOR DIAGNOSIS GUIDE-continued
ENGINE HOT OR COLD ment to carburettor.
Incorrect idle fuel mixture. Clogged air bleeds or idle pas-
Engine idle speed too slow (fast sages.
or cold idle adjustments). Defective fuel pump.
Dirt, water or ice in fuel filter.
Positive crankcase ventilation sys- ENGINE HOT ONLY
STAUING tem malfunctioning. Coolant control thermostat defec-
Fuel lines restricted or leaking air. tive.
Fuel tank vent restricted. Excessive looseness of throttle
Leaking intake manifold or car- shaft in bore(s) of throttle body.
burettor gaskets
Carburenor icing (cold, wet or
humid weather).
Incorrect throttle linkage adjust-

ROUGH IDU Incorrect idle mixture adjustment.

Positive crankcase ventilation sys- Idle adjusting needle(s) grooved,
tem malfunctioning or restricted. worn, or otherwise damaged.
Idle air bleeds restricted. Plugged idle fuel channel restric-
Idle air or fuel passages restricted. tor.
Idle discharge holes restricted. Worn or damaged main metering
Idle discharge holes not in proper jet.
relation to throttle plate(s). Accelerating pump discharge ball
Excessive dirt in air cleaner. check and/ or weight not seating
High or low fuel level or float set- properly.
ting. Fuel pump pressure too low, or
Fuel inlet needle not seating prop- excessive.
erly, or worn needle or seat.
Power valve leaking.
Restricted air bleeds.
Restriction in main fuel passage.

Poor acceleration complaints fall spot when accelerated. Poor acceler-

under one of three headings: the en- ation is caused by either an exces-
gine is sluggish on acceleration, the sively lean or rich mixture on ac-
engine stalls when accelerated, or celeration and/ or defects or improp-
the engine hesitates or develops a flat er adjustments in the ignition system.

POOR ACCELERATION A LEAN MIXTURE ON Accelerating pump fuel inlet valve

ACCELERATION CAN IE (Elastomer valve or ball check-
CAUSED IY: Motorcraft 2-V/4·V carburettors) not
Low fuel pump pressure. seating on acceleration.
Sticking fuel inlet needle. Restriction in the accelerating
Low fuel le~l or float setting. pump discharge passage.
Restriction in main fuel passage. Accelerating pump discharge Elas-
Air leak between the carburettor tomer valve (Motorcraft 2-V/4-V car-
and the manifold caused by loose burettors) ball check or weight not
mounting bolts or defective gasket. coming fully off its seat, or failing to
Air leak at the throttle shaft seat properly on the reverse stroke of
caused by a worn throttle shaft. the pump diaphragm.
Accelerating pump diaphragm de- Air leak at the accelerating pump
fective. cover caused by a defective gasket
Incorrect accelerating pump or warped pump cover.
stroke adjUstment.
A RICH MIXTURE ON Incorrect accelerating pump stroke
ACCELERATION CAN IE adjustment.
CAUSED IY: Power valve leakage.
Excessive fuel pump pressure. Restricted air bleeds.
PART 10-1- GENERAL FUEL SYSTEM SERVICE 10-5
CARIURETTOR DIAGNOSIS GUIDI (Continued)
High fuel level or float setting. Worn or damaged main metering
Fuel inlet needle not seating prop- jet.
erly or worn needle and/ or seat. Accelerating pump Elastomer
Malfunctioning automatic choke. valve (Motorcraft 2-V/4-V carburet-
Excessively dirty air cleaner. tors). Ball check and/or weight not
seating properly.

INCONSISTENT ENGINE Fast idle screw contacting low Incorrect throttle linkage adjust-
IDLE SPEED step of cam at curb idle. ment to carburettor.
Binding or sticking throttle link-
age or accelerator pedal.
Sticking carburettor throttle shaft. Idle compensator malfunctioning
Excessive looseness of throttle (if so equipped).
shaft in bores of throttle body. Positive crankcase ventilation sys-
Incorrectly installed throttle tem restricted.
plates. Sticking fuel inlet needle.
Defective power valve or gasket.

Thermostatic choke setting too Defective coolant thermostat.

rich.
AUTOMATIC CHOKE Choke linkage sticking or binding.
SLOW WARM-UP I ON Incorrect choke linkage adjust- Restriction or air leak in the
TOO OnEN ment. choke vacuum or hot air passage.
Choke phite misaligned or binding Choke heat inlet tube restricted.
in air .horn. Choke clean air tube restricted.

SEVERE TRANSMISSION Carburettor fast idle speed setting (highest step) of the fast idle cam.
ENGAGEMENT AnER too high. Binding or sticking throttle link-
COLD ENGINE START Throttle operating on starting step age .

Clogged main jet filter screen.

Improper size main jet Distributor vacuum passage
SURGING (CRUISING Low fuel level or float setting. clogged.
SPEEDS TO TOP SPEEDS) Low fuel pump pressure or vol-
ume.
Clogged fuel filter or carburettor
Float setting too high or too low. Restriction in main fuel passages.
Fuel pump pressure or volume too Excessive dirt in air cleaner.
REDUCED TOP SPEED high or too low. Throttle plate(s) not fully open.
Improper size or obstructed main Faulty choke operation.
jet . Improper throttle linkage adjust-
Power valve spring weak, or ment.
power valve restricted.
Restricted air bleeds.
TESTS
FUEL PUMP TESTS lized at the normal operating tem-
removed. If the pump volume meets p_erature. Make certain the re-
Two tests: fuel pump static pres- specifications with the filter removed, placeable fuel filter is not rest-
replace the filter. If the pump vol- ricted or clogged. When in doubt,
sure and fuel volume are necessary
to determine that the fuel pump is in ume is still below specifications, install a new fuel filter prior to per-
satisfactory condition. repeat the capacity test, using an forming the tests. A clogged or
auxiliary fuel supply. If the pump restricted filter is often the cause of
If both the fuel pump volume and volume still does not meet specifica- fuel system malfunction.
pressure are within specifications tions, replace the pump. If the pump
(pagel0·76) and the pump and lines does meet specifications, there is a Pressure Test
are in satisfactory condition, a vac- restriction in the fuel supply from
the tank or the tank is not venting 1. Remove the carburettor air
- uum test is not required. cleaner assembly (page 10·67 ). Dis-
propedy.
If the pump volume is low, but connect the fuel inlet hose at the fuel
the pressure is within specifications, The tests are performed with the filter. Unscrew the filter from the
a fuel pump capacity test must be fuel pump installed on the engine carburettor. Connect the fuel hose to
made with the in-line filter, if fitted, and the engine temperature stabi- the filter and tighten the retaining
10-6 GROUP 10- FUEL SYSTEM
Fuel Outlet Hose
clamp. Use care to prevent com-
bustion due to fuel spillage.
2. Connect a pressure gauge, re-
strictor and flexible hose (Fig. 1)
between the carburettor inlet port
and the fuel filter connections.
3. Position the flexible hose re-
strictor so that the fuel can be ex-
pelled into a suitable container (Fig.
I) for the capacity (volume) test.
4. Operate the engine at 500 rpm.
Vent the system into the container
by opening the hose restrictor
momentarily before taking a pressure
reading.
5. Operate the engine at 500 rpm.
Mter the fuel pump pressure has
stabilized, it should be to specifica-
tion (page 1()-176).
Capacity (Volume) Test
Perform this test only when the
fuel pump pressure is within specifi-
cations (page 10-'76 ).
1. Operate the engine at 500 rpm.
2. Open the hose restrictor and
expel the fuel into the container
(Fig. 1), while observing the time
required to expel one pint; then close
the restrictor. One pint of fuel
should be expelled within the speci-
fied time limit (page 10-76 ). FIG. 1 -Typical Fuel Pump Pressure and
3. Remove the test equipment,
and connect the fuel inlet line and Capacity Tests
fuel filter assembly to the carburettor. placed unless It is leaking sumclently 3. Connect a line from a vacuum
CARBURETTOR TESTS to cause an unadjustable rough pump to the fitting on top of the
engine Idle condition. Fuel accumu- fixture. Insert one end of the wand
Accelerating Pump Discharge
lation in the power valve cover does Into the tube and attach the other
Test end of the tube to the fitting on the
not necessarily indicate a defective
1. Remove the air cleaner (page l 0-6 7 ). power valve. Fuel vapours will be side of the fixture. Slip a rubber
2. Open the primary throttle drawn into the vacuum side of the gasket over the small OD end or
plates and observe the fuel flow power valve and condense during the wand. Hold th1a end against the
from the accelerating pump dis- periods of deceleration. Leakage in power valve vacuum pick-up port
charge nozzles. If the system is op- the power valve area can· be caused (Fig. 2).
erating correctly, a quick steady by an improperly tightened cover or
stream of fuel will flow from the dis- defective gaskets. Any defect in the
c. Look for bubble formations In
charge nozzles. the water In the bowl. A continuous
gasket sealing qualities must be cor-
stream of bubbles Indicates leakaee
Power By-Pass Jet Test rected before the power valve is re-
through the power valve dlaphrqm
placed.
Stromberg BV-2: or gasket, or the cover or gasket.
Power valve leakage that causes
A faulty power by-pass jet in this an unadjustable rough engine idle If leakage is encountered, the
carburettor will not adversely :1-Hcct condition can be diagnosed, in most power valve, power valve gasket,
the engine idle. If the po·.-:cr by-pass instances, by the fact that the idle
jet is leaking, it will resu't in rich mixture needle<s> must ·be nearly, or
part throttle operation and hi~h fuel completely seated in order to obtain
comumption. If t!-:.e po·.ver by-pass a relatively smooth engine idle con-
jet is not screwed down on 1ts seat dition. If power valve leakage is sus-
or is fitted with a faulty sealing gas- pected, the following test procedure
ket, richness will occur in both part must be performed.
throttle and power application of the
1. Remove the carburettor from the
carburet tor.
Intake manifold. Invert the carbur-
The power by-pass jet or sealing ettor.
gasket must be replaced if found
2. Remove the glass bowl from the 11228-1
defective.
fixture (Fig. 2). Fill the bowl half-
Power Valve Test full of- water. Install the bowl on FIG. 2- Ford Carburettor
A power valve must not be re- the fixture. Power Valve Test -Typic•l
PART 10-1- GENERAL FUEL SYSTEM SERVICE 10-7
cover, and cover gasket should be found, the gasket seats are darnapd um line. The bubbllnr should stop
replaced one at a time with a new and the defective parts should be within appro:.Umately 111 seconds or
part and the test repeated unW the replaced. after the air has been removed from
source of leakage has been found. If A few bubbles may be noticed Im- the system. If no bubbles are seen,
the source of leakage cannot be mediately upon attaching the vacu- the power valve, gaskets and cover
are sealing properly.

EJ COMMON ADJUSTMENTS AND REPAIRS

All XA/ZF Falcon/Fairlane engines are 2. Remove the clip holding the THROTTLE LINKAGE REPAIR
equipped with carburettors that feature trunnion on the adjustable rod in engage-
ACCELERATOR PEDAL
limiter caps fitted to the idle mixture ment with the accelerator shaft.
REPLACEMENT
adjustment screws. The purpose of the
3. Adjust the trunnion on the rod to
limiter caps is to limit the maximum idle Refer to Figs. 3, 4, 5, 6 for views of
give the specified idle height at the accel-
fuel/air mixture richness and so control the accelerator pedal for the applicable
erator pedal.
the quality of gases discharged from the car model.
exhaust system. 4. Replace the clip holding the
Note: Carbon Monoxide emission level at trunnion in engagement with the ac- 1. Remove the retaining screw
idle speed not to exceed 4.5%. celerator shaft. securing the pedal to the shaft. Remove
Two types of limiter cap are used on the accelerator pedal and spring.
5. If the vehicle is fitted with an
current production carburettors. 2. Lubricate the accelerator pedal
automatic transmission adjust the
1. Stromberg lV and 2V carburettors: hinge points with the specified lubri-
kickdown cable. Refer to Group 7 for
a free turning cap is fitted over the head of -cant <Group 19) and position the ac-
the procedure.
the idle mixture adjusting screw/s prevent- celerator pedal and spring assembly
ing any alteration to the factory setting. 6. Lubricate all pivot points with on the accelerator shaft. Apply 2 dots of
· 2. Motorcraft 2V and 4V carburettors: engine oil. locking compound (e.g. Loctite) to the
fixed caps are fitted to the idle mixture screw thread and install the retaining
screws and adjustment is restricted to the screw. Make sure the spring is properly
ACCELERATOR PEDAL IDLE
range provided for by tabs on the limiter seated on the pedal and the accelerator
HEIGHT ADJUSTMENT
caps and stops incorporated in the carbur- shaft. Install the retaining nut.
V-8 Engines
ettor body. ACCELERATOR SHAFT
Under no circumstances should the idle Refer to Figs. 5 and 6 for a view of ASSEMBLY REPLACEMENT
adjusting limiters or the limiter stops be the accelerator linkage and the accelera-
200/250 CID with Borg Warner trans-
mutilated or deformed to render the limi- tor pedal specified idle height. missions.
ters inoperative.
l. Adjust the idle (hot engine) Refer to Figs. 3 & 4 for a view of the
A satisfactory idle should be obtainable
speed to specification. Refer to the accelerator linkage.
within the range of the idle adjusting
applicable carburettor section for pro- 1. Remove the accelerator pedal
limiters providing all other engine systems
are operating within specifications. cedure and to Part l Q. 9 for specifications. assembly. Refer to previous operation.
For idle speed and mixture adjustment 2. With the engine stopped make
z. Disconnect the accelerator re-
procedures refer to the specific carburettor tracting spring.
sure the carburettor choke plate is
section. fully opened.
3. Remove the clip holding the-
THROTTLE LINKAGE 3. Detach the adjustable rod assembly adjustable rod in engagement with the
ADJUSTMENT from the bellcrank. accelerator shaft.
The engine idle speed and fuel
mixture must be adjusted to specification 4. Adjust trunnion connecting the rod t. Undo the four screws holding
prior to performing throttle linkage ad- to the accelerator shaft to give the speci- the two accelerator shaft support.
justments. For these adjustments, refer fied pedal height. brackets to the bulkhead and remove-
to the applicable carburettor section. 5. Adjust the kickdown cable. Refer the accelerator shaft.
Views of the throttle (accelerator) to Group 7 for procedure.
linkage for the various car models are 5. Position the new accelerator
shown in Figs. 3, 4, 5 & ~· 6. Lubricate the pivot points at shaft and replace and tighten the-
both ends of the rods and on four screws holding the two support
the bellcrank using engine oil. brackets. Ensure that the rubber
ACCELERATOR PEDAL IDLE sealing pad is correctlY seated against
HEIGHT ADJUSTMENT the bulkhead.
Six- Cylinder CARBURETTOR SPACER AND/OR
Refer to Figs. 3 & 4 for a view of the GASKETS REPLACEMENT 6. Replace the accelerator pedal
accelerator linkage and the accelerator It is necessary to remove the car- assembly. Refer to Accelerator Pedal
pedal specified idle height. buretor from the car to replace a Replacement in this section for the
l. Warm up the engine and adjust carburettor spacer and/or gaskets proper procedures.
the idle speed to specification. Refer to the Carburettor Removal
Refer to the applicable carburettor sec- and Installation procedure steps in '1. Connect the clip holding the
tion for procedure and to Part 10-9 this group that pertain to the type adjustable rod in engagement with the
for specifications. of carburettor installed on the car. accelerator shaft.
10-8 GROUP 10- FUEL SYSTEM

8. Connect the accelerator retract- accelerator linkage components. 2. Disconnect the rod assemblies
ing spring. 1. Remove the llCCelerator pedal connecting the accelerator shift to
assembly. Refer to Accelerator Pedal the carburettor bellcrank and where neces-
9. Lubricate the pivot points on Replacement, in this section, for thP sary the auto trans kick down cable.
the acceelrator shaft and pedal with proper procedures.
engine oil. 4. Remove the two screws on the
2. Disconnect the accelerator re- bracket supportir.g the carburettor
tracting spring. end of the accelerator shaft. The
10. Warm up the engine and ad-
just the accelerator pedal idle height bracket supporting the pedal end of
3. Remove lever retaining nut and
Refer to Accelerator Pedal Idle the shaft need not be removed.
washer. The accelerator shift to pedal
Height Adjustment, Fig. 3 for the proper lever may now be removed. 5. The accelerator shaft may now
procedures. be removed complete with seal and
ACCELERATOR SHAFT TO t. Install the new lever and re- mounting bracket.
CARBURETTOR BELLCRANK place the retaining nut and washer.
ASSEMBLY ROD REPLACEMENT 6. To replace the shaft, first fit
5. Reconnect the accelerator re- the seal and then insert the shaft
(All engines) tracting spring and replace the pedal through the bulkhead and the pedal
assembly. and mounting bracket.
Refer to Figs. 3, 4, 5, 6 for a view of the
accelerator linkage. 8. Check the accelerator pedal for 7. Bolt the mounting bracket on
the specified idle height and adjust the carburettor end of the shaft to
1. DiscomJect the accelerator re- lf necessary. Refer to Throttle Llnk-
tracting spring. the bulkhead.
ap adjustment In this section for
the proper procedure.
a. Reconnect the rod assemblies
2. Remove the clips at both ends connecting the shaft to the carbu-
of the rod and remove the rod. 7. Lubricate the accelerator pedal rettor bellcrank and refit the transmission
hinge with the specified lubricar.t cable where applicable.
3. Install the new rod and replace
<Group 19>.
the clips. 9. Replace the accelerator shaft to
ACCELERATOR SHAFT
t. Lubricate the pivot points with ASSEMBLY REPLACEMENT pedal lever and check the pedal for
engine oil and adjust the accelerator the specified idle height and adjust
All except 6 cylinder with Borg Warner
pedal idle height. Refer to accelerator transmissions. If necessary. Refer to Throttle Link-
pedal idle height adjUstment in this Refer to Figs. 4, 5 & 6 for views of the age. Adjustment In this section for
section for the proper procedures. the proper procedure.
accelerator linkage components.
ACCELERATOR SHAFT TO
1. R!!move the accelerator shaft 10. Lubricate both mounting brack-
PEDAL LEVER REPLACEMENT
All except 6 cylinder witn Borg Warner to pedal lever. Refer to the appropri- et pivots, the rod assembly pivots
ate part of this section for the proper and the accelerator pedal hinge using
transmissions
Refer to Figs. 4, 5, 6 for views of the procedures. engine oil.
ADJUST ROD ASSY . (97401 IDLE PEDAl HEIGHT
TO OBTAIN FULL THROTTLE WITH CARBURETTOR CHOKE
WHEN SHAFT ASSY . (97251 FUllY OPENED
TOUCHES THE FLOOR COVERING

~ ~·~
VJf:W " W"
35 -65 lB . IN . .,,..
~OTS OF ~

--
-1
lOCKING - COMPOUND PEDAl HEIGHT SETTING I
VIEW " X" CENTRAllY lOCATED
REF.

Cj)
A"'
J -~~
I
G)

~s-
m
z
m
PANEL INSTRUMENT REF .
~
r-
.,
15 -25 LB .

VIEW "Y "

m
c
HOLE
-w · REF. lr-

~VIEW " X"

~
m
LU~•ICATE PiVOTS MARKED e * ~
PER CHART AU i OMATIC TRANSMISSION
(/)
KID CABLE ADJUSTMENT
CHASSIS LUB~ IC ATION SEC. 3 No . 457 -4
WITH THE ~ :~AFT A SSY . 9919 SET
m-
;:tO
AT· IDLE , I .DJUST TPIINION " A "
l oHO HOLE " B'
CRIMPED STOP ON
SO THAT THE <
KICK DOWN INNER (' '.C~ E JUST TOUCHES ()
THE OUTER CABLE WITHOUT SLACK . m
THEN I NSTALL CLIP 9825

Fig.,3
200 & 250 1V & 250 2V Manual
6 cylinder B. Warner Trans.
-
Cj)
~
PANEL -DASH REF
--
9
0
ADJUST ROD TO OBTAIN
FULL THROTTLE WHEN
LEVER ASSY . (9725/99734) 35-65 LB. IN .
~
·~TS
TOUCHES THE FLOOR
COVERING .

,,U r<f:l
OF
LOCKING COMPOUND
CENTRALLY LOCATED

...
VIEW · -y- ·
REF .

~"'~ ·
MANUAL TRANS. ONLY VIEW "Y ' '

PEDAL HEIGHT SETTING

AUTOMATIC TRANSMISSION
ADJUSTMENT
CONTROL

,.,
(i)

0
c.,
LEVER POSITION WITH
PEDAl. AT W.O .T.
POSITION
-
?,
c
m
r-

~
LEVER "C' ~
m
AUTOMATIC

"
TRANSMISSION ONLY ~

~
WITH THE LINKAGE COMPLETELY BLOCK ACCELERATOR PEDAL
ASSEMBLED . THIS DISTANCE IS IN W .O .T. POSITION.
TO BE SUCH THAT THE
TRANSMISSION DOWNSHIFT LEVER " C" ROTATE LEVER "C' COUNTER
ROTATES COUNTER CLOCKWISE CLOCKWISE TO CONTACT INTERNAL
VIEW " W" AND CONTACTS THE INTERNAL STOP.
STOP WITH THE PEDAL
DE.PRESSED TO W .O .T. HOLD LEVER " C" ON STOP AND
ADJUST CABLE TO FIT ACCELERATOR
TRANS DOWNSHIFT LEVER SHAFT LEVER . TURN TRUNNION
ROTATED AND HELD AGAINST ONE ADDITIONAL TURN CLOCKWISE
INTERNAL KICKDOWN STOP AND SECURE TO LEVER .
BY PUllii\IG CABLE
ADJUSTING END. RELEASE ACCELERATOR PEDAL.
LEVER "C .
Fig. 4
250 2V C4 & Man., Typical250 1V-C4
-~ DOTS OF
LOCKING COMPOUND
CENTRALLY LOCATED
ADJUST ROD TO OBTAIN REF.
FUll THROTTLE WHEN
LEVER ASSY . TOUCHES THE
FLOOR COVERING. VIEW " Y"
VIEW "X"
.,
~
:tal
-1
-
PEDAL HEIGHT SETTING PANEL DASH (REF.)
~
VIEW " Z' "
AUTOMATIC TRANSMISSION CONTROL

-
ADJUSTMF"'T
/ 9
I
G)
m
PANEl -DASH REF.

VIEW
z
m
~
)>
~
VIEW ··x· · r-
-n
c

r1:1 VIEW " Z"

Ra----.
l'(lp-11 ~
~~
m
r-

~m
LEVER "C"
OIL PIVOT MARKED ··x··
GREASE PIVOTS MARKE~
VIEW " V" ~
VIEW " V "/ VIEW " W"

I'
(/)
m

~
~
WITH THE LINKAGE COMPLETELY
ASSEMBLED . THIS DISTANCE IS
TO BE SUCH THAT THE
BLOCK ACCELERATOR PEDAL
IN W .O .T. POSITION . <
()
TRANSMISSION DOWNSHIFT LEVER "C ROTATE LEVER "' C'" COUNTER
ROTATES COUNTER CLOCKWISE CLOCKWISE TO CONTACT INTERNAL
m
AND CONTACTS THE INTERNAL STOP.
VIEW " U" STOP WITH THE PEDAL
DEPRESSED TO W .O .T. HOLD LEVER " C' " ON STOP M'r:
ADJUST CABLE TO FIT ACCELERATv~
TRANS DOWNSHIFT LEVER SHAFT LEVER . TURN TRUNNION
ROTATED AND HELD AGAINST ONE ADDITIONAL TURN CLOCKWISE
INTERNAL KICKDOWN STOP AND SECURE TO LEVER .
BY PULLING CABLE

--
ADJUSTING END. RELEASE ACCELERATOR PEDAL

Fig. 5
VS-302 & 351 2V C4 9
-
--
C?
N

·--- ~ 35 -65 LB . IN .

1;- DOTS OF
LOCKING COMPOUND
CENTRALLY LOCATED
VIEW ·· y ·· REF .
ADJUST ROD "19A702 TO OBTAIN
FUll THROTTLE WHEN VIEW
LEVER ASSY TOUCHES THE
FLOOR COVfRING .

PE DAL HEIGHT SETTING

z--
VIEW ·
C:::D PANEL DASH (REF .!

G\
~
0
.,
c:
-.,f
PANEL-DASH REF .

VIEW

~
VIEW

~ c
m

rt:J
r-

~
COLOUR CODE
. z--
351 -2V BLUE
VIEW W

~
351 -4V ORANGE

OIL PIVOT MA~KED X

KICK DOWN CONTROL ADJUSTMENT
SPEASE PIVOTS MARKED
WITH TRANS ROD 7A186
INSTALLED , HOLD CARBURETTOR
THROTTLE LEVER IN W .O .T.
POSITION-AGAINST STOP.

18
cer 3 ~ 2. HOLD TRANSMISSION IN FUll
KICK DOWN POSITION AGAINST
8 AUTOMATIC TRAN ~ MISSION ONLY
C5 3.
INTERNAL STOP

TURN ADJUSTMENT SCREW ON

• CARBURETTOR KICK-DOWN LEVER

~
VIEW ·· u ·· TO WITHIN 04o·· TO 080 ..
GAP OF CONTACT ING PICK -UP
SURFACE OF Cf,RB . THROTTLE LEVER .

4. RELEASE CARS . ANO TRANS . TO

FREE POSITIONS
VIEW ·· w . 8
Fig. 6 5 INSTAll ACCELERATOR 9737 AND
KICK -DOWN 78146 RETRACTING
V8 3514V FMX SPR INGS.
PART 10-1- GENERAL FUEL SYSTEM SERVICE 10-13

EJ CLEANING AND INSPECTION REMOVAL AND

INSTALLATION
CADURmORS it under . water that has been heated Refer to page 10-67, Section 2 for
to just below the boiling point. Bubbles the air cleaner 8886mbly removal and
will appear if there is a leak. If a float installation procedures.
Dirt, gum, water or carbon con- leaks, replace it. Replace the float if the
tamination in the carburettor or the arm needle contact surface is grooved.
exterior moving parts of the carburet- If the float is serviceable, polish the
tor are often responsible for unsatis- FILTER ELEMENT
needle contact surface with crocus cloth
factory performance. For this reason or steel wool. Replace the float shaft
emcient carburetion depends upon The eellulose fibre filter elemen~
if it is worn.
careful cleaning and inspection. must never be cleaned with a solvent
Replace all screws and nuts that or cleanJnr solution. Also, oU must
The cleaning and inspection of have stripped threads. Replace all not be added to the surfac:es of tha
only those parts not included in the distorted or broken springs. filter element or air cleaner body.
carburetor overhaul repair kit are
covered here. All gaskets and parts Inspect all gasket mating surfaces There are two alternate procedures.
included in the repair kit should be for nicks and burrs. Repair or replace that can be used to clean the air
installed when the carburettor is as- any parts that have a damaged gas- filter element. One method is per-
sembled and the old gaskets and ket surface. formed with the use of compressed
parts should be discarded. On 2-V and 4-V oarburettors, inspect air.
the idle tubes in each nozzle bar 8886m·
Wash all the carburettor parts except bly. If they are plugged, bent or broken, The other is perfomed by tapping
the accelerating pump diaphragm, and replace the booster venturi and nozzle the element on a smooth horizontal
the power valve in clean commercial bar 8886mbly. surface.
carburettor cleanmg solvent. If a
commercial solvent is not available,
lacquer thinner or denatured alcohol FUEL PUMP Compressed Air Method
may be used. On all fuel pumps, except Carter
permanently sealed types, clean Direct a stream of compressed air
Rinse the parts in kerosene to re- the fuel pump body, valve housing through the element in the direction
move all traces of the cleaning sol- and cover. Blow out all body, hous- opposite that of the intake air flow,
vent, then dry them with compressed ing and cover passages. Inspect the that is from the inside outward. Ex-
air. Wipe all parts that cannot be pump body, valve housing, cover, treme c:are must be exercised to pre-
immersed in solvent with a clean, rocker arm, spring and pin for vent rupture of the element materiaL
soft, dry cloth. Be sure all dirt, gum, cracks or damage and replace them
carbon and other foreign matter are if necessary. If the fuel valYes are
removed from all parts. not serviceable and replacement is
necessary, replace the valve housing Tappin, Method
Force compressed air tnrough all and valves as an assembly, Inspect
passages of the carburetor. Do not Hold the element in the vertical
the mounting flange for distortion. position and tap it lightly against a
use a wire brush to dean any parts
or a drUI or wire to dean out any smooth, horizontal surface to shake
openin1s or passa1es in the carbu- the dust and dirt out. Do not deform
retor. A drill or wire may enlarge Remove the pump body or lap the the element or clama&'e &be psket
the hole or passage, changing the distorted flange if necessary. sarfaees by tapplnl too hard. Rotate
calibration of the carburettor. the ftlter after each tap until the
On all Carter permanently sealed entire outer surface has been cleaned.
fuel pumps, clean the fuel pump with
Check the choke shaft for grooves,
a cloth. Inspect the fuel pumps for
wear and excessive looseness or
c:racka or damage. Inspect the moun~
binding. Inspect the choke plate for
1ng ftange for cllatortlon. Lap the lnspec:tlon
nicked edges and for ease of opera-
dlatorted flange, if nec:essary. Inspect.
tion and free it if necessary. Make Hold the filter in front of a back-
the rocker arm for wear, cracks or
sure all carbon and foreign material up light and carefully inspect it for
damage. The rocker arm spriD(, pin
has been removed from the auto- any splits or cracks. If the filter is
and &be rocker arm are &be oDiy com-
matic choke housing and the piston. split or cracked, replace it.
poDeD&e on &be perm&Den&ly sealed
Check the operation of the auto-
fael pampa &bat are replaeeable. U
matic choke piston in the choke BODY AND COVER
any other fuel pump components are
housing to make certain it has free
damaged beyond repair, replace the Clean the air cleaner body and
movement.
fuel pump. the cover with a solvent or com-
Check the throttle shaft(s) in the pressed air. Wipe the air cleaner
bore(s) for exceBBive loosenBBB or binding AIR CLEANER dry if a solvent is used. Inspect the
and check the throttle plates for burrs air cleaner body and cover for dis-
which prevent proper closure. MAINTENANCE
tortion or damage at the gasket mat-
Refer to Group 19 for the recom- ing ·surfaces. Replace the cover or
On Stromberg carburettors, check the mended air cleaner assembly main- body if they are damaged beyond
metallic float for leaks by holding tenance mUeage interval. repair.
10-14

PART STROMBERG CARBURETTOR BV2-

200,250 IV 6 CYLINDER ENGINES
10·2
Section Page Section Page
1. DESCRIPTION AND OPERATION ... ... ... ... 10-14 3. REMOVAL, MAJOR REPAIR OPERATIONS AND
Description ... ... ... ... ... ... ... ... ... .. . ... 10-14 INSTALLATION 10-20
Operation ............... ..... . 10-14 Removal ... ... ... ...... 10-20
2. INVEHICLE ADJUSTMENTS AND REP AIRS 10-17 Disassembly .. . .. . ... ... 10-20
Carburettor Adjustments ... . .. 10-17 Cleaning and Inspection 10-21
Initial Idle Speed Adjustment .. . 10-17 Assembly ...... ...... ... 10-21
Idle Limiter Cap Replacement .. . 10-18
Carburettor Repairs ... ... ... ... 10-19

0 DESCRIPTION AND OPERATION

DESCRIPTION The lower throttle body contains the The fuel bowl is vented to atmos-
The Carburettor (Figs. 1 and 2) idle-mixture-adjusting screw and the phere at closed throttle and to car-
throttle valve. burettor air inlet pressure through a
consists of three main assemblies, the
vent tube in the upper air horn at
<uppen Air Horn , the <centre1 Main OPERATION
all other throttle positions. The high
Body and the <lower 1 Throttle Body. The engine speed is controlled by air pressure exerted on the fuel in
The upper air horn assembly con- the proportion of fuel and air deliv- the chamber forces fuel to travel up
tains the power piston assembly, the ered to the cylinders for all engine through the fuel discharge channels
idle vent vah·e and choke valve. operating conditions. and out into the air stream passing
The centre main body contains the through the carburetor. The fuel and
Air is drawn into the carburettor
major metering components of the air are mixed at this point and dis-
air horn by manifold vacuum. As the
carburettor : the main and idle fuel tributed to the engine cylinders for
air passes through the carburettor on
systems the power by-pass system. combustion.
its way to enter the cylinders, a re-
the accelerating pump assembly, the duced pressure is created at the fuel
float chamber and the fuel inlet system. discharge outlets. FUEL INLET SYSTEM

The fuel inlet system (Fig. 3) of

the carburettor maintains a prede-
termined fuel level in the fuel bowl.

The fuel level in the chamber is

extremely important to carburettor
calibration. If the level of the fuel
in the chamber is below the specified
setting, a lean fuel air mixture will
result. A rich fuel air mixture will
occur from a higher than specified
fuel level. The entire calibration of
the carburettor is disturbed if the fuel
level is not set as specified.

Fuel enters the chamber through

the fuel-inlet needle-valve-and-seat
assembly. The amount of fuel enter-
ing is regulated by the distance the
needle valve is moved off the seat
and by fuel pump pressure. Correct
fuel pump pressure is required to
maintain the carburettor fuel level
within the specified limits.

The fuel level is maintained at a

pre-determined level by the float and
lever assembly which controls the
FIG. 1-3/4 Left Rear View movement of the needle valve. The
PART 10-2- STROMBERG BV-2 CARBURETTOR 10-15

venturi causes a pressure drop in the

venturi great enough to bring the
main metering system into operation
as the idle fuel metering system
tapers o.ff.

MAIN FUEL METERING SYSTEM

The main fuel metering system

(Fig. 4 > supplies the fuel required
during the cruise or part-throttle
range. The system begins to func-
tion when the air ftow through the
carburettor venturi creates sufficient
vacuum to start fuel flowing in the
main system. The vacuum at the
tip of the main discha-rge jet will
increase as the air flow increases.
The faster the engine operates, the
more fuel will flow through the
main fuel system.
Fuel entering the main metering
jet, located at the base of the in-
clined main channel, ftows upwards
to the main discharge jet. Air from
the calibrated high-speed bleed ftows
down the high-speed bleed channel
and enters the main channel. The
FIG. 2-Carburettor f Rear View air passes through holes spaced along
needle valve, contacting the tab of the body of the main discharge jet,
valve. The amount of mixture to be
the ftoat and lever assembly, reacts mixing with the fuel passing up the
discharged is determined by the
to any change in height of the ftoat main channel. The fuel and air mix-
position of the idle needle valve in
and the fuel level in the ftoat cham- ture being lighter than solid fuel,
relation to its seat in the throttle
ber. responds faster to changes in ven-
body.
turi pressures. The mixture ftows to
During off-idle operation, when the the tip of the main discharge jet
IDLE FUEL SYSTEM
throttle valve is moved past the idle to be discharged into the filtered air
The idle fuel system functions progression holes, each hole begins moving past and through the small
when the engine is operating at low discharging fuel as it is exposed to venturi.
R.P.M. It supplies the fuel-air mix- the lower air pressure (manifold
ture when the air ftow through the vacuum>. Continued opening of the ACCELERATING PUMP SYSTEM
carburettor venturi is insufficient to throttle valve increases engine R.P.M.
operate the main metering system. and air ftow through the carburettor. Smooth acceleration requires a
The greater air ftow through the momentary increase in the supply of
The range of the idle system will
extend into the operation of the main
metering system. Fuel ftows from the
main channel, up the idle tube chan-
nel and through the calibrated idle
tube assembly. Filtered air from the
carburettor air horn enters the idle-
air-bleed and mixes with the fuel.
The air bleed also serves as a vent to
prevent syphoning of fuel at high
speeds or when the engine is shut off.
The fuel-air mixture then passes
through the idle down channel and
is transferred to the idle channel in
the throttle body. The fuel-air mix-
ture passes down the idle channel,
past the progression holes, to the idle
. needle valve. The progression holes
act as additional air bleeds at normal
idle. The fuel-air mixture ftows past
the idle needle valve and seat and is
discharged through the idle discharge
nozzle located below the throttle FIG. 3-Fuel Inlet System Typical
10-16 GROUP 10- FUEL SYSTEM
HIGH SPEED
BLEED preventing entry of air.
POWER FUEL SYSTEM
MAIN
CHANNEL
When the engine is required to
deliver more power to meet an in-
creased road-load demand or wide-
open-throttle operation, the carburet-
tor must deliver a. richer fuel-ail' mix-
ture than supplied during the opera-
tion of the main fuel system at
cruise or part throttle operation.
When the engine is running under
a. high power demand, intake mani-
fold vacuum is low. The vacuum be-
low the throttle valve approximates
MAIN intake manifold vacuum. The car-
METERING
JET burettor power by-pass jet <Fig. 6 •
will open when the manifold vacuum
drops below a predetermined value.
FUEl ='""
FUEL - AIR~ The fuel-air mixture is thus auto-
AIR- matically enriched to meet the in-
creased power demands.
FIG. 4-Main Fuel Metering System-Typical Manifold vacuum is transmitted
from an opening below the throttle
PUMP valve, through a channel to the upper
SPRING
air hom and to the top of the vacuum
power piston. (An additional open-
PUMP ing into the power piston vacuum
PISTON channel is located in the throttle body
bore above the throttle valve. This
opening bleeds down the vacuum ap-
plied to the power piston under cer-
tain conditions where the throttle is
only partly open. By this means the
power by-pass jet is activated instan-
taneously and provides smoother and
more economical engine operation.)
At idle and normal engine speeds, the
manifold vacuum is great enough to
hold the power piston up.
The power piston is connect~d to
the power piston rod. The foot of
the rod controls the spring-loaded
power by-pass jet. With the piston
FIG. 5-Accelerating Pump System -Typical held up by manifold vacuum, the
fuel. The air ftow through the car- fuel from the accelerating pump cyl- power by-pass jet is closed.
burettor responds almost immediately inder into the discharge channel. (The The power piston spring is located
to any increase in carburettor throttle carburettor as fitted to all models except on the rod. The spring is calibrated
valve opening. The fuel '1\ithin the the 25 0 CID Manual features a small bleed to overcome the vacuum above the
metering passages will lag moment- back hole in the accelerator pump stem. piston when manifold vacuum drops
arily in its response to the pressure The accelerator pump fitted to auto trans- below a pre-determined level. Upon
difference created by this increased mission vehicles has a shorter pump stroke demand for more power, the mani-
air ftow. This lag in fuel response than the one fitted to manual transmission fold vacuum drops below this level.
will cause a temporary leanness in models). The inlet pump check valve closes The spring tension moves the rod
the fuel-air mixture that results In to prevent a reverse flow of fuel. Fuel under down and opens the power by-pass
a. hesitation in engine acceleration. pressure travels through the pump discharge jet by depressing the pin projecting
A mechanically operated accelerating valve and up to the pump restrictor. above the head of the valve. Air
pump system (Fig. 5) supplies added The fuel is sprayed from the pump pressure above the ftoat chamber
fuel to provide a richer fuel-air mix- rcstrictor into the air stream above the forces fuel to flow through the power
ture for this brief period of time. main venturi. by-pass jet, adding to fuel in the
When the throttle valve is closed main system, enriching the fuel-air
The accelerating pump, located in on deceleration, the throttle shaft mixture.
the main body, is controlled by levers levers allow the piston to return to As the demand for power decreases
connected to the throttle shaft. When its upper position drawing fuel and manifold vacuum increases, the
the throttle is opened the pump through the inlet pump check valve vacuum above the piston overcomes
spring actuates the piston and forces while the pump discharge valve closes the spring tension. The piston and
PART 10-2-STROMBERG BV-2 CARBURETTOR 10-17

rod move up and the power Jet closes.

FUEL BOWL VENTING SYSTEM
The fuel bowl requires venting <Fig.
7) to provide proper operation for
the va1'ious systems. Fuel vapours
may form in the ftoat chamber when
a hot engine Is stopped, Idling or
operating at very low speeds. By
venting the ftoat-chamber to atmos-
phere by means of a vent control
valve, engine performance Is Im-
POWER PISTON proved. At higher engine speeds,
ROD
venting to the carburettor air horn
prevents calibration changes due to
POWER PISTON normal air cleaner contamination.
SPRING The vent valve, located over and
operated by the pump stem, is at
the open position during closed or
low part-throttle operation. In this
position, the valve allows venting to
the atmosphere. At higher part-
throttle or wide-open throttle opera-
tion, the valve closes, venting the car-
buretor internally to p1'essures in the
air horn.
FIG. 6-Power Fuel System -Typical (DISTRIBUTOR VACUUM)
CONTROL SYSTEM
The carburettor has a permanent
push-on type vacuum take-off con-
nection located on the throttle body
casting. Tne manifold vacuum is
transmitted to the distributor
vacuum diaphragm take off connec-
tion, through two small holes drilled
in the throttle body above the throttle
plate.

FIG. 7-Fuel Bowl Venting System -Typical

B IN-CAR ADJUSTMENTS AND REPAIRS

INITIAL IDLE SPEED AND The limiter cap fitted to the Stromberg enrlne for twenty minutes before
FUEL MIXTURE ADJUSTM~NT carburettor is free turning on the head of settlnr the enrlne Idle speed. The
the idle mixture adjusting screw, therefore enrlne Idle speed Is adjusted with
THE ONLY IDLE ADJUSTMENT the air conditioner operatlnr.
All Stromberg carburettors fitted to
XA/ZF Falcon/Fairlane engines are equip· ALLOWABLE IN NORMAL SERVICE IS
2. Position the transmission lever
ped with limiter caps on the idle mixture THE ENGINE IDLE SPEED .
In neutral. Allow the throttle to drop
adjusting screws. The limiters control the A satisfactory idle should be obtained,
back to the normal Idle speed posi-
maximum idle richness and help pre- providing all other engine systems are
tion. Attach a tachometer to the en-
vent unauthorised persons from making operating within specifications. gine. Set the parking brake.
overly rich idle adjustments. Carbon 1. Operate the engine until engine
Monoxide emission at idle must not exceed temperatures are stabilized. On a car 3. Turn on the headlamps. It Is
4.5%. with an air eondltloner, operate the necessary to place the alternator un-
10-18 GROUP 10- FUEL SYSTEM

der a la.d condition In this manner 5. Attach an accurate tachometer to 4. Open throttle wide and again
In order to obtain the specified en- the engine. measure from the top of the pump
cine Idle speed durl~ the adjustment 6. Run the engine until normal opera- piston stem to the top face of the
proeedure- ting temperature is reached. carburettor or main body with gasket
7. Adjust the idle air/fuel mixture removed.
4. On a ear with a manual shift screw to give the best quality idle available
transmission, the ~ine Idle speed is 5. The difference between these
at 20 R.P.M. above the specified idle
checked and adjusted with the leal' two measurements will be the length
speed.
shift lever in neutral position. On a of the pump stroke. This length
8. Lean off the idle air/fuel mixture
ear with an automatic tr&Dsmiaion, should be within the specified limits
adjusting screw in a clockwise direction
the e~lne Idle speed is checked &D4 with the mean size of the limits be-
until the engme R.P.M . drops to the speci-
adjusted ftnt with the transmission. ing desirable.
fied idle speed.
~elector lever in the neutral position. 9. Remove the air cleaner. If the measurement is found to be
and adjusted with the transm•uton 10. Carefully install the black service outside the specified limits, the pump
~elector lever in the drive nnre po- limiter cap on the head of the idle mixture stroke can be adjusted by bending
sition. adjusting screw. the arm <top, horizontal position> of
11. Replace the air cleaner and check the pump rod. No more than 1(64"
the idle speed to ensure that the mixture to 1(32" adjustment should be re-
screw was not accidently rotated while quired. Two bends in the arm will
fitting the limiter cap. be necessary to keep the hole in the
12. Remove the tachometer from the arm parellel with the pump stem.
engine. 6. Return the air horn gasket to

FIG. 8 -Idle Speed

Adiustments-BV2-Typical
5. Adjust the engine idle speed to
specifications (Part 10·9) by turning
the engine idle speed screw (Fig. 8)
inward or outward.
If the car is equipped with an auto·
matic transmission, position the selector
lever in drive range to check and adjust
the idle speed to specification (Part 10·9)
FIG. 9-Accelerating
if necessary. Pump Stroke Adiustment FIG. 10-Fioat Adiustment
The ftnal e~lne idle speed may -Stromberg BV2
be varied to suit the conditions un- its position and replace the air hom
ACCELERATING PUMP and air cleaner 6BB6mbly.
der which the ear is to be operated.
ADJUSTMENTS The capacity of the accelerator
(On the Stromberg BV-2 carburettor, Accelerating Pump Stroke-
cold idle speed is automatically obtained pump is correctly calibrated at the
(Fig. 9) specified pump stroke and any varia-
with hot idle adjustment).
Do not remove the carburettor from tion of this stroke outside the limits
the engine to adjust the pump stroke. given must result in reduced per-
IDLE LIMITER CAPS
To check the pump stroke : formance and economy.
Should the idle limiter caps need re-
placement because of deformation or re- FLOAT ADJUSTMENT
1. Start the engine and run at idle
adjustment of idling mixture to meet The dry fioat adjustment is a pre-
to normalise engine temperature. Set
emission level requirements, the following liminary factory adjustment only,
the engine to the correct idle speed.
'thermal conductivity' type of gas analyzer The final adjustment <Fuel Level
This is important as it gives the cor-
found in most service shops is not accurate Float Adjustment-Wet) must be
rect closed throttle position.
enough to give the required carbon monox- made after the carburettor is mount-
ide readings. 2. Stop engine and remove c~.ir ed on the engine.
cleaner assembly (page 10-67, Section 2)
1. Remove the air cleaner.
and carburettor air horn (page 10-20, FUEL LEVEL
2. Cut the plastic limiter cap and care-
Section 3). FLOAT ADJUSTMENT (WET) ·
fully pry the cap apart and remove it from
the idle adjustment screw. 3. Measure from the top of the The fuel pump pressure and volume
3. Replace the air cleaner. pump piston stem to the top face of must be to specification (Part 10-9)
4. Set the ignition timing to specifica- the carburettor main body with gas- prior to performing the following
tion. ket removed. adjustments : -
PART 10-2-STROMBERG BV-2 CARBURETTOR 10-19
1. Operate the engine to normalize drawn from the fuPl bowl.
engine temperatures, and place the
car on a flat surface as near level as 3. If necessary, remove the fuel
possible. Stop the engine. line and unscrew needle valve and
seat from main body.
2. Remove the carburettor air
cleaner assembly (page 10.-67 ,) Section
4. If the float was removed, install
2) if it has not been previously re-
the fulcrum pin in the float hinge
moved.
and position float in float chamber.
3. Disconnect the choke cable from Replace the fulcrum-pin-retaining
the choke lever. clip.
'- Remove the air horn retaining
screws and remove the air horn and 5. If the float needle valve and
reinforcing bar. seat were removed insert the needle
5. Using a suitable piece of material valve into the bore, with the viton
block off the vacuum passage in the carb- tip toward the seat.
urettor body (Fig. 10). Start the engine.
Let the engine idle for sufficient time to 6. Install needle and seat in main
body and tighten with wrench.
stabilize the fuel level then raise the gas- FIG. 11 -Vent Valve
ket to an out-of-the-way position.
Adiustment-Strombe rg 7. Reconnect fuel line and check
6. While the engine Is idling, use
BV2 the float setting. Refer to Float Ad-
justment-Wet in this section for the
a standard depth scale to measure 2. Remove the choke Unk from the proper procedure.
the vertical distance from the top choke lever.
machined surface of the carburettor 8. Install the carburettor air horn
3. Remove t..'lle air horn to main
main body to the level of the fuel and gasket by following steps 6-10
body retaining screws and remove the
In the float chamber <Fig. 10>. The under carburettor Air Horn to Main
measurement must be maae away reinforcing bar.
Body Gasket Replacement in this
from any vertical surface to ensure '- Remove the carburettor air horn. section.
an accurate reading, because the 5. From the top of the pump stem
surface of the fuel 1s concave <higher remove the spring cUp and withdraw MAIN JET REPLACEMENT
at the edges than In the centre) . the pump rod from the main body. 1. Remove the Metering Jet plug,
Remove and discard the gasket. positioned below the fuel bowl. Re-
Float AdJustment moval of this plug allows the fuel
Care must be exercised to measure 6. Install a new gasket on the bowl to drain and care should be
the fuel level at the point of contact carburettor main body. Make sure the taken to prevent accidental ignition
with the fuel. gasket is not damaged and that no of fuel.
Do not apply pressure on the fuel foreign material has adhered to the
inlet needle. The viton tip of the gasket. 2. With a special wrench the main
fuel inlet needle may be damaged metering jet can be unscrewed from
through undue pressure exerted on It, 7_ Insert the pump rod into its its position and withdrawn through
and thus cause Improper fuel level guide hole In the main body and se- the metering jet plug hole.
wjthln the bowl. Refer to the speci- cure on pump stem with spring clip.
3. Place the new main metering
fications <Part 10-9) for the correct jet in position on the wrench and
fuel level <wet> setting. 8. Replace the air horn and re- carefully feed through metering jet
inforcing bar and tighten screws. plug hole. Screw the jet into position
VENT VALVE ADJUSTMENT
without forcing or over-tightening.
9. Replace choke unk and clip.
1. Ensure the engine idle speed is 4. Replace the metering jet plug
correct and engine is at normal oper- 10. Replace air cleaner assembly. making sure that the copper seaUng
ating temperature. This is important gasket is properly positioned. Tighten.
as it gives correct closed throttle 11. Adjust the engine idle speed as out-
ACCELERATOR PUMP PLUNGER
pcsition. lined in this section.
REPLACEMENT
2. Remove the air cleaner assembly
(page 10- 67) Section 2) and with the I. Remove the air cleaner assembly
throttle in the idle position, loosen FLOAT OR NEEDLE VALVE 2. Withdraw cho~e link-retaining
vent valve locknut and adjust from REPLACEMENT- clip and remove choke link.
.05"- .06" to the closed position when I. Remove the carburettor air horn
throttle is opened. and gasket by following steps 1-5 3. Remove the air horn to main
3. Install air cleaner assembly. (page under Air- Horn- to- Main-Body -Gasket body retaining screws and the rein-
10- 67 • Section 2). forcing bar. The air horn can now
Replacement in this section.
be separated from the main body.
CARIURmOR REPAIRS
AIR HORN TO MAIN BODY 2. If necessary, remove the float 4. Place a small lever such as a
GASKET REPLACEMENT- chamber baffle and the fulcrum pin screwdriver under the horizontal area
I. Remove the air cleaner assembly. retaining clip. The float assembly of the pump rod and lever upwards
and fulcrum pin can n0w be with- to remove the split spring retaining
10-20 GROUP 10- FUEL SYSTEM
bush from the top of the pump cyl- tighten air horn retaining screws. and remove from the valve stem. This
inder. Note that the two longer screws are will allow ·the valve stem and valve
5. Remove the pump piston from used to retain the reinforcing bar. spring to be withdrawn from the under-
cylinder, remove spring clip from 9. Replace tne choke link and in- neath side of the air horn.
pump stem and separate pump piston, stall the retaining clip. 5. Locate the vent valve spring on
pump rod, spring, bush and gasket. 10. Perform a vent valve adjust- the spigot provided on the underside
Discard the gasket. ment as outlined in this section. of the air horn and place the vent
valve stem in position. Install vent
6. Insert the new pump piston in 11. Install the air cleaner assembly
valve locknut.
its cylinder taking care not to crease
or fold the leather. A circular twist-
VENT VALVE REPLACEMENT 6. Replace the air horn in position
ing motion applied to the leather
STROMBERG BV -2 on the main body. Holding the re-
assists in this operation as does a
inforcing bar in position, install and
drop of Ught lubricating oil. Place
tighten air horn retaining screws.
the pump spring in position over the I. Remove the air cleaner assembly.
Note that two longer screws are used
pump stem and press in the split
to retain the reinforcing bar.
spring retaining bush tlush with the
surface of the main body. 2. Withdraw choke link-retaining
clip and remove choke link. 7. Replace the choke link and m-
7. Place a new gasket on the main stall the retaining clip.
body then fit the pump rod and 3. Remove the air horn to main
spring clip. body retaining screw's and the rein-
forcing bar. The air horn can now 8. Perform a vent valve adjustment
8. Replace the air horn in posi- be separated from the main body. as outlined in this section.
tion on the main body. Holding the
reinforcing bar in position, install and 4. Loosen the vent valve locknut 9. Install the air cleaner assembly

EJ REMOVAL, MAJOR REPAIR OPERATIONSAND INSTALLATION

REMOVAL spection and assembly. This will allow the valve stem and valve
Flooding, stumble on acceleration spring to be withdrawn from the under-
The following is a step-by-step neath side of the air horn.
and other performance complaints are,
sequence of operations for completely
in many instances, caused by the
overhauling the carburettor, however, 3. Withdraw air cleaner bail pin from
presence of dirt, water or other foreign
certain components of the carburettor its locating holes and remove bail from
matter in the carburettor. To aid in
may be serviced without a complete air horn.
diagnosing the cause of complaint,
disassembly of the entire unit.
the carburettor should be carefully 4. If it is necessary to remove the
removed from the engine without A disassembled view of the car-
choke valve and shaft, lightly scribe
removing the fuel from the bowl. burettor is shown in Fig. 12
the choke valve along the choke shaft
The contents of the bowl may then AIR HORN AND MAIN BODY so that the choke valve can be in-
be examined for contaminatiOn as stalled in the same position during
the carburettor is disassembled. I. Withdraw choke-link-retaining installation.
clip and remove choke link.
Remove the choke valve retaining
1. Remove the air cleaner. (pagel<r67). 2. Remove the air horn to main screws. The retaining screws are staked
body retaining screws and reinforcing in the choke shaft. If the tips of the
2. Loosen the choke outer cable bar. The air horn can now be separated screws are flared excessively, file off the
clamp screw and the inner cable tocking from the main body. flared portion to avoid damage to the
screw. Remove the cable. threads in the choke shaft.
MAIN BODY AND THROTTLE
3. Hold the carburettor fuel line BODY Be careful not to damage the choke
umon and undo and remove the fuel line. shaft or valve while filing the screws.
1. Remove choke outer cable clamp
4. Remove the spring clip and Remove the choke valve from the top
screw and cable clamp. Disconnect
washer from the throttle control l'od. of the air horn. Slide the choke shaft
throttle return spring from lever on
Remove the throttle control rod from and lever from the air horn and separate
throttle shaft.
the carburet tor bracket. shaft, lever and spring.
2. Remove the main body to throttle
5. Remove the distributor vacuum• MAIN BODY
body retaining screws.
line. I. Withdraw screws and remove
3. Separate the main body assembly, choke control bracket assembly.
6. Remove the two flange retaining the gasket and the throttle body.
nuts and lock washers and remove the 2. Place a small lever such as a
Discard the gasket.
carburettor. Remove the gaskets from ~crewdriver under the horizontal arm
the intake manifold 11.nd discard. AIR HORN of the pump rod and levering up-
wards remove the split spring retain-
DISASSEMBLY I. With the special tool unscrew ing bush from the top of the pump
the power piston assembly and re- cylinder.
Use a separate container for the move it from its cylinder.
component parts of the various as- 3. Remove the pump piston from
semblies to facilitate cleaning, in- 2. Remove the vent valve locknut. cylinder, remove spring clip from
PART 10-3-STROMBERG CARBURETTOR . 10-21
to ensure correct Installation.
It Is impol'ta.nt that no probe or
wire be Inserted into the bore of the
main discharge jet. To do so will
cause damage to the screen located
within.

11. Remove pump Inlet check valve.

lZ. Remove strainer screen clip

and strainer screen.

THROTTLE BODY
1. Do not remove the idle mixture
I adjusting screw and spring unless absol-

~
utely necessary.
2. Remove the throttle lever re-
taining nut and lockwasher and re-
move throttle lever assembly.
3. If It Is necessary to remove the
throttle valve and shaft, lightly
scribe the throttle valve along the
throttle shaft so that the throttle
valve can be installed In the same
position during Installation.

Remove the throttle valve retaining

screws and slide the valve out of the
shaft. For assembly purposes note
that the dimple In the throttle valve
Is located above the throttle shaft.
If the tips of the screws are flared
excessively, file off the tlared section
to avoid damage to the threads In
the throttle shaft. Be careful not to
damage the throttle shaft or valve
while filing the screws.

C. Withdraw the throttle shaft

from the throttle body and remove
pump tloatlng lever from shaft.

CLEANING AND INSPECTION

Clean and Inspect the carburettor
component parts. Refer to Part 10-1,
Section 3, for the proper procedure.
FIG. 12 -Carburettor Exploded View Replace all worn or damaged parts.

pump stem and separate pump piston, 7. Remove the main metering jet ASSEMBLY
pump rod, spring, bush and gasket. using special tool <6A12l.
Discard the gasket. Make sure all holes in the new
8. Remove main discharge jet
gaskets have been properly punched
4. Withdrllw float chamber baffle using special tool <6Alll. and that no foreign material has
from guide slots. Remove fulcrum- adhered to the gaskets.
pin- retaining clip and withdraw ful- N.B. The main discharge jet is
crum pin and float assembly. Re- accurately calibrated and assembled During assembly of the carburettor,
move needle valve. Unscrew and re- within close tolerances during manu- certain adjustments are required. The
move needle valve seat and gasket. details of these adjustments are covered
facture. For normal cleaning and
on page 10 17
5. Unscrew and remove idle tube, service operations It Is advisable to
A disassembled view of the car-
power by-pass jet and gasket. leave the main discharge jet undis- burettor is shown in Fig. 12
turbed. If, however, the main dis-
6. Remove the main metering jet charge jet is suspected of being dam- AIR BORN
and pump-inlet-check-valve plugs aged or is to be replaced, care 1. If the choke valve and shaft
and copper gaskets. should be taken to note Its position were removed, reassemble the choke
10-22 GROUP 10-FUEL SYSTEM
shaft, lever and spring and insert the and tighten the main-metering-jet bore. When the valve Is croperly
shaft into the air horn with the lever plug and inlet-check-valve plug. located, hold the valve closed; then
poin~ing downwards. tighten and stake the retaining
6. Install and tighten the idle screws, support the shaft and plate on
Refer to the line previously scribed tube. a block of wood or a metal bar to
on the choke valve and locate the prevent bending of the shaft.
"1. Using a new gasket install and
choke valve in its original position
tighten the power by-pass jet.
with valve !dentation facing upwards. 2. Install the throttle lever, lock-
Install the choke valve retaining 8. Install the fulcrum pin in the washer and nut on the throttle shaft.
screws snug, but not tight. float hinge, place the float In the 3. Install the idle needle valve and
Check for proper valve fit, binding main body so that the ends of the spring in the throttle body if removed.
in the air horn and free rotation of fulcrum pin tit Into the grooves In
the shaft by moving the valve from each side of the float chamber, place MAIN BODY TO THROTTLE.
the closed position to open position. the fulcrum pin clip ends In the BODY ASSEMBLY
If it moves freely, tighten the choke grooves and force the bowed part of
spring down to clip under the pro- 1. Place a new gasket in position
valve retaining screws while holding
jection on the side of the body. Refit on the throttle body and fit the main
the valve in the fully-closed position.
the float chamber baffle. body to throttle body.
Stake the screws.
When staking the screws, support Z. Install retaining screws and
9. Insert the pump piston In its tighten.
the shaft and valve on a block of cylinder taking care not to crease or
wood or a metal bar to prevent bend- fold the leather. A circular twisting 3. Hook one end of throttle re-
Ing of the shaft. motion applied to the leather assists turn spring in hole of throttle lever and
2. Replace the air cleaner . bail in this operation as does a drop of locate other end in hole in choke control
making sure the bail pin engages light lubricating oil. Place the pump bracket assembly.
properly in holes. spring in position over the pump and
press in the split spring-retaining
bush flush with the surface of the
3. Locate the vent valve sprin~ AIR HORN TO MAIN BODY
main body.
On the spigot provided on the under- ASSEMBLY
neath side of the air horn and place 10. Place a new gasket on the malil
the vent valve stem in position. In- body then fit the pump rod and 1. Replace the air horn In pos-
stall vent valve locknut. Perforn, spring clip. ition on the main body. Hold the
the vent valve adjustment operation 11. Locate choke control bracket reinforcing bar in position, Install
after carburettor is assembled and assembly in position, install and and tighten air horn retaining screws.
installed on engine. tighten retaining screws. note that two longer screws are used
to retain the reinforcing bar.
4. Install the vacuum power piston THROTTLE BODY Z. Replace the choke link and in-
assembly and tighten it with special 1. If the throttle shaft and throttle stall the retaining clip.
tool. Check the piston for free move- valve were remoyed, fit the pump
ment in the cylinder. XX CAUTION floating lever to the throttle shaft
-Do not lubricate the piston.
CARIURmOR INSTALLATION
and slide the throttle shaft into the
throttle body, with the pump floating
lever positioned so that it will, when 1. Cle~~:n the gasket surface of the
MAIN BODY ca.rburettor and intake manifold. Place
assembled, make contact with the
1. Install the pump straining a new gasket on the manifold and
pump rod fitted in the main body of
screen and retaining clip. position the carburettor on the mani-
the carburettor.
fold.
Z. Install the pump inlet check
Refer to the line previously scribed
valve.
on the throttie valve and insert the 2. Connect the fuel line and dis-
3. If the main discharge jet was valve through the slot in the throttle tributor vacuum line.
removed, position the jet on the shaft. The valve Indentation must
special tool and install in position. face the top of the body and be on 3. Install the carburettor lockwash-
CAUTION-Make sure that the jet Is the idle mixture adjusting screw side ers and retaining nuts and tighten.
correctly located in the body. The Qf the throttle shaft. Install the 4. Fit the accelerator linkage, re-
mitred face of the jet must be paral- throttle valve screws snug, but not turn spring and choke cable.
lel with the direction of the air flow. tight. Check that the throttle-lever-
locating shoulders on the threaped 5. Adjust the engine idle speed, idle
4. Hold the main body of the car- end of the throttle shaft are proud fuel mixture and choke operation as
burettor in an inverted_ position so of the tHrottle body boss. described under 'Invehicle Adjustments
that there is no possibility of the and Repairs' in this section. Install the
main discharge jet being displaced, Rotate the throttle shaft while air cleaner (page 10-67)
then with the special tool, 6A12, in- lightly tapping the throttle valve
stall the main metering jet and tight- within the throttle bore. Check for
en securely. free rotation of the throttle shaft
Hold tne throttle body up to the light Note: Extreme care must be taken with
Little or no light should show be- the idle air/fuel mixture adjustment (page
5. Place new copper gaskets in the
plug seats of the body, then install tween the throttle valve and throttle 10-18)
10-.23

PART STROMBERG CARBURETTOR- WW SERIES

10-3 250C.I.D. 2 V- 302 C.I.D. ENGINES
Section Section
1 Description and Operation . . . . . . . . . . . . . . 10-23 3 Major Repair Operations .............. 10-31
Description . . . . . . . . . . . . . . . . . . . . . . 10-23 Carburettor Repairs . . . . .............. 10-31
Operation . . . . . . . . . . . . . . . . . . . . . . . . 10-24 Disassembly . . . . . . . . .............. 10-31
2 Invehicle Adjustments and Repairs ........ 10-28 Inspection . . . . . . . . . . .............. 10-31
Carburettor Adjustments ....... . ...... 10-28 Assembly . . . . . . . . . . .... .......... 10-32
Idle Speed and Mixture Adjustment ...... 10-29 Final Assembly . . . . . . .............. 10-33
Idle Limiter Cap Replacement .......... 10-31

D DESCRIPTION AND OPERATION

DESCRIPTION

In common with other WW series carburettors, these units are of the dual-barrel downdraught type
with each barrel having its own Idle System, Main Metering System and Throttle Valve. The two barrels
have a common Float System, Accelerating System and Power System. Each barrel is equipped with a main
and an auxiliary Venturi (Choke Tube).
The carburettors employ an automatic choke control situated in the throttle body, and activated by
hot air delivered to the choke control through a pipe attached to the exhaust manifold.
The float chamber is vented to atmosphere at closed throttle, (i.e. when idling or stopped) and to
carburettor air inlet pressure, through a passage and vent tube in the air horn, at all other throttle positions.
The vacuum connection for the distributor vacuum spark advance is located in the main body. A drilled
passage through the main body meets a channel in the throttle body to transmit the vacuum from the
vacuum spark hole (or holes) located in the throttle body.
A steel connector for the positive crankcase ventilation hose is located in the carburettor throttle body.
10-24 GROUP 10-FUEL SYSTEM
OPERATION FLOAT SYSTEM (Fig. 2)

IOU DISCHARGE HOU5

IDLE SYSTEM (Figs. 2 and 3)

Identical idle systems supply each barrel with
the correctly proportioned fuel/air mixture
required for idling operation.
The throttle valves are held open to the correct
FIG. 1 - 3/4 Left Rear View slow-idle position by the slow idle adjustment
screw. By turning this screw the throttle valve
Fuel enters the carburettor at the fuel inlet, opening is varied . thereby controlling the amount
flowing through the float needle valve and seat into of air entering the engine and regulating the idle
the float chamber. When the fuel reaches a speed . (A single barrel only will be considered in
predetermined level, the float shuts off the fuel the following explanation).
supply by closing the needle valve against its seat.
The needle valve is equipped with a viton
rubber tip to provide increased service life and
greater tolerance of any dirt particles that may
enter with the fuel.
As previously mentioned, the float chamber is
vented internally through a passage and vent tube
whenever the engine is running above idle speed.
(Internal venting ensures that any reduction of air
pressure in the air horn, due to a restricted air
cleaner, is balanced by a similar reduction in the air
pressure acting on the fuel in the float chamber.
The fuel/air mixture ratio will therefore remain tOil DISCHARGE HOlES

unchanged under these conditions). FIG. 3

When the engine is stopped or whilst idling, With the throttle valve closed to idle position,
the float chamber is vented to atmosphere via the engine depression is concentrated on the idle
opening in the air horn, through which the discharge nozzle located below the throttle valve.
accelerating pump piston stem passes. Consequently, fuel flows from the base of the main
This opening is normally closed by a metal discharge jet through the idle tube (Slow-Running Jet)
vent washer which is lifted clear of the vent orifice where it is metered by a calibrated orifice in the base
by a small pin in the pump piston stem as the of the tube.
throttles return to slow-idle position. The purpose The metered fuel mixes with air taken in through
of the external vent is to permit the escape uf fuel the idle air bleed, and the resulting fuel/air emulsion
vapours formed in the float chamber under high passes down the idle channel where it mixes with
temperature operating conditions. Additionally, additional air passing through the secondary idle air
the throttle body has two small vents, one in each bleed and through the two upper idle discharge holes.
barrel to permit the escape of fuel vapours which The mixture finally passes from the idle discharge
may accumulate in this area. (Refer Fig. 2.) nozzle into the air passing the partly open throttle.
PART 10-3-STROMBERG WW CARBURETTOR 10-25
The quantity of mixture discharged through the nozzle
is controlled by an adjustable idle needle valve. Turning
this needle valve "IN" weakens the idle mixture and
turning it "OUT" enriches the mixture.
As the throttle valve is opened slightly, the upper
idle discharge holes com(. under engine depression and
supply the additional fuel required for increased engine
speed.
MAIN METERING SYSTEM (Fig. 4)
The main metering system supplements the idle
system and provides the additional fuel required during
THROTTLI VAt. VI
the intermediate or part throttle range of operation.
FIG. 5
AUXIUAlY VINTUII
TUII During idle and part throttle operation inlet
manifold vacuum is sufficient to hold the vacuum
piston "UP" against its spring. The power by-pass
jet is closed and all mixture is supplied by the main
metering and idle systems.
When the throttle valves are opened beyond a
certain point the manifold vacuum drops to a
lower value than the spring force and the vacuum
piston moves "DOWN" opening the power by-pass
jet and allowing additional fuel to flow into the
two main metering discharge systems.
TI«Oml VAt.VI
FIG. 4 ACCELERATING SYSTEM (Figs. 6 and 7)
Each barrel is equipped with its own main
metering system, the method of operation of the
two systems being identical. (A single barrel only
will be considered in the following explartation).
With the throttle valve in a partially open
position, air flow through the main and auxiliary
venturis (choke tubes) produces a depression at the OUTlfT IIAU CHKK
outlet of the main discharge jet. As a result, fuel 10.001
flows from the float chamber through the main
metering jet and into the main discharge jet where
it mixes with air taken in through the high speed
TI«<TTLI VAI.VI
bleeder. This fuel/air emulsion then discharges into II'.JN' JIISTON FIG. 6
the air stream passing through the auxiliary and
main venturis. To ensure smooth acceleration, additional fuel
must be supplied to the engine during the period of
POWER SYSTEM (Fig. 5) acceleration .
A common power system supplies each main This is achieved by the use of an accelerating
metering discharge system with the additional fuel pump which is operated by the throttle linkage. As
required for the development of maximum engine the throttle valves are opened, the pump lever
power. compresses the pump-piston-duration spring and
This additional fuel is provided by the action the pump piston is forced down, creating a
of a vacuum piston located in the air horn which pressure which closes the inlet ball check valve, and
automatically controls the opening of the power forces a quantity of fuel through the outlet ball
by-pass jet in accordance with throttle opening and check valve and pump discharge nozzle (Fig. 6).
engine load. Inlet manifold vacuum is maintained The pump piston duration spring ensures the pump
above the vacuum piston through a vacuum discharge is spread over a predetermined period of
channel which leads to the mounting flange of the time .
carburettor.
10-26 GROUP 10- FUEL SYSTEM

11\JW OtS(HAIGI
' NOUU

VAlV(

FIG. 7
When the accelerator pedal is released the
pump piston is drawn up and the outlet ball check L_~_J
valve closes (preventing the entry of air into the
pump system) whilst a fresh fuel charge is drawn in
through the now open inlet ball check valve. FIG. 8
The pump discharge nozzle is vented through fast idle stop screw away from the fast idle cam,
the float chamber ve.nt tube to prevent Joss of fuel allowing the cam to turn.
from the pump circuit at high ehgine-·speeds when The choke valve will then assume its closed
a low depression is created at the nozzle outlet by position, which will vary according to the
the high air-flow through the carburettor.
prevailing underbonnet temperature. With the
AUTOMATIC CHOKE (Fig. 8) choke fully closed, the fast idle stop screw is in
The automatic choke control is built integral contact with the highest step of the fast idle cam
with the carburettor throttle body. The control and the throttle valves are opened sufficiently for a
consists of a thermostat spring (I) activated by hot cold start.
air drawn through a pipe from the exhaust
manifold (302) ot cylinder head (250). CHOKE VALVE
The thermostat spring is connected to the
offset choke valve (4) through the thermostat lever
(2), choke rod (3) and choke lever (5). Other
components of the choke system are the choke
kick diaphragm (6) which is dCtuated by inlet
manifold vacuum through a connecting tube and
vacuum passage in the carburettor, and the fast idle
mechanism (Fig. 9) which operates in conjunction
with the automatic choke control to provide the
correct fast idle speeds to prevent stalling during
the engine warm-up period.
An integral part of the choke lever is the choke
modulation spring (7). This spring provides
additional choke valve control as desc'ribed later in
this section.
CHOKE OPERATION
CHOKE CLOSED - FAST IDLE - COLD
ENGINE (Figs. 8 and 9)
As the engine cools the thermostat spring also When the engine fires, inlet manifold vacuum
cools and, gaining tension, tends to rotate the exerts a pull on the choke kick diaphragm which
choke valve towards the closed position. It is, opens the choke valve a small amount against the
however, unable to close the chpke valve until the thermostat spring tension to supply the necessary
throttle valves are opened sufficiently to move the air for a weaker running mixture. Immediately
'
PART 10-3-STROMBERG WW CARBURETTOR 10-27
following a start, the accelerator pedal is depressed CHOKE MODULATION SPRING (Fig. 8)
and released to allow the fast idle cam to rotate
The choke modulation spring (7) is an integral
and assume its normal fast idle position.
part of the choke lever (5) and provides additional
CHOKE PARTIALLY OPEN - ENGINE choke valve control in the following manner.
WARMING UP (Fig. 10)
CHOKE IN WARM IDLE POSITION
As the engine warms, the amount the choke
valve opens in excess of the diaphragm kick
opening is governed by the balance of the forces of
thermostat coil tension and air velocity.
If the throttle opening is increased the
increased air velocity against the offset choke valve
causes the valve to open against the tension of the
thermostat spring.
Heat from the exhaust manifold or cylinder head
gradually decreases the thermostat spring tension,
allowing the choke valve to open progressively until
it assumes its full open position when the engine is
at normal d erating tern erature.

FIG. 11
When the engine is cold, the choke thermostat
spring ( 1) exerts a closing force on the choke valve
FAST IDLE ( 4 ). The colder the temperature the greater is the
CAM
closing force exerted .
Immediately the engine fires , the choke kick
diaphragm unit (6) endeavours to open the choke
valve to prevent overrichness.
Depending upon the engine temperature and
the resulting thermostat spring force acting to close
the choke valve, the modulation spring will deflect
FIG. 10 a varying amount, thereby altering the amount the
choke valve is effectively opened.
During this warm up period, as the choke valve In cold temperatures the choke valve will be
opens, the fast idle rod allows the unbalanced fast opened less than in warmer temperatures.
idle cam to rotate so that the fast idle stop screw
rests on successively lower steps of the cam. The WIDE OPEN KICK DEVICE
engine will therefore idle at progressively slower
fast idle speeds until the next phase of operation is In cases where a cold engine does not start
reached, namely :- readily and becomes flooded, it is necessary to
CHOKE OPEN - ENGINE WARM - SLOW admit air to the engine to clean out the excess fuel
IDLE (Fi2. 11) before starting is possible . This is achieved with the
With the engine at normal operating WW series by opening the throttles wide when a
temperature (choke valve wide open) the fast idle projecting ear on the throttle lever contacts an
cam rotates to its fully released position with ~pace extension on the fast idle cam forcing the cam to
between the cam and the end of the fast idle stop rotate and pulling open the choke valve against the
screw. thermostat spring tension.
The throttle opening is now controlled entirely Further cranking of the engine with the
by the slow idle adjustment screw which is set to throttle held wide open will clean ou t the manifold
provide the normal specified slow idle speed. and allow the engine to start.
10-28 GROUP 10- FUEL SYSTEM

EJ IN-CAR ADJUSTMENTS AND REPAIRS

The adjustments described and illustrated in ~------------------------------------------------,
this part should be performed as required to retain
the desired engine performance characteristics. Refer
to the specifications whenever carburettor adjust-
ments are made.
CARBURETTOR ADJUSTMENTS
The following adjustments should be made in
the sequence listed with the carburettor in situ on
the engine with air cleaner removed (Part 10-7). FAST IDLE C

FAST IDLE SPEED AND CAM POSITION

(Fig. 12) SLOW IDLE
ADJUSTMENT SCREW

FIG. 13

WIDE OPEN KICK (Fig. 14)

BEND EAR OF
THROTTLE
(As required)

FIG. 12

Turn out slow-idle adjustment screw (Fig. 13) (In wide open position)
far enough to clear throttle lever ear when the FIG. 14
throttle valves are fully closed against their bores.
Hold throttles in fully closed position and turn VACUUM KICK (Fig. 15)
fast idle stop screw out until fast idle cam can be
positioned with screw on second step of cam, as
illustrated. From the point of initial contact with
second step of cam, adjust to obtain correct fast idle
R.P.M.
With fast idle stop screw on second step of
cam as illustrated in Fig. 12, apply light closing
pressure to choke valve to take up slack in linkage.
Measure choke opening "G" with a drill shank.

If opening is not 0.165", bend fast idle rod at

Choke Link
point indicated to obtain correct setting. (Bend as required)
Press and Hold Diaphragm
Apply light closing pressure to choke valve, at Its full limit of Travel
then open throttle valves to wide open position. FIG. 15
The choke valve should open just enough to allow
the insertion of drill gauge "C" between the choke lever as required to obtain correct opening of
valve and wall of air hom. Bend ear on the throttle 0.250".
PART 10-3-STROMBERG WW CARBURETTOR 10-29
Depress diaphragm pull rod to the full limit of THERMOSTAT LEVER POSITIONING (Fig. 18)
its travel and apply light upward pressure to choke Hold choke valve closed by applying light
lever to take up slack in linkage and t<.. deflect the upward pressure on thermostat lever pick up ear in
modulation spring so that the choke link is at the direction shown by arrow.
end of its slot in the choke lever.
The dimension "TL" measured from centre of
Hold in this position and check choke valvt> upper right cover screw hole to thermostat lever
opening "D" with a drill gauge. If opening is not pick up ear should be 1.094".
0.140", bend choke link at point indicated to
obtain correct setting. After bending link, ensure
choke valve does not bind in any position.
EXTERNAL VENT AND ACCELERATING
PUMP STROKE (Fig. 16)
With throttle valves fully closed agamst their
bores (i.e. slow idle adjustment screw backed out CHOKE ROO
(Bend as required)
clear of shut throttle lever-), and with pump rod in
throttle lever hole specified, check the external
vent washer, opening "J".
Bend pump rod at point indicated to obtain
specified opening. THERMOSTAT LEVER
PICK-UP EAR
FIG. 18
If dimension is not as specified, adjust by
bending choke rod at point indicated.

IDLE SPEED AND MIXTURE

ADJUSTMENT.
All Stromberg carburettors fitted to XA/ZF
Falcon/Fairlane engines are equipped with limiter
caps on .the idle mixture adjusting screws. The
limiters control the maximum idle richness and
help prevent unauthorised persons from making
overly rich idle adjustments.
FIG. 16 Note: Carbon Monoxide emission at idle speed not
NOTE: Make sure choke valve is held open dunng to exceed 4.5%.
above check so that throttle valves can close fully. The limiter cap fitted to the Stromberg carbur-
CHOKE MODULATION SPRING (Fig. 17) ettor is free turning on the head of the idle mixture
adjusting screw , therefore THE ONLY IDLE
Spring must not rub on ADJUSTMENT ALLOWABLE IN NORMAL SER-
sides of spring guard
after adjustment .
VICE IS THE ENGINE IDLE SPEED.
A satisfactory idle should be obtained, providing
all other engine systems are operating within
specifications.
I. Run the engine until normal operating temp-
erature is reached.
2. Attach a tachometer to the engine.
DRILL GAUGE "M"
Must be perpendicular
\.
Adjust bY bending
spring here.
3. Turn on the headlamps to place the alternator
under load and turn on the air conditioner if so
to lever. equipped.
FIG. 17 4. On a car with manual transmission the engine
Insert drill gauge "M" in slot under choke idle speed is checked and adjusted with the gear-
modulation spring free end. With gauge at 'right shift lever in neutral position. On an automatic
angle to choke lever, spring should contact gauge. transmission car the idle speed is first checked and
Adjust modulation spring tension by bending in adjusted with the transmission selector lever in the
area shown near clamped end of spring to obtain neutral position and again with the lever in the
0.030". drive range position.
10-30 GROUP 10-FUEL SYSTEM

<¥"30

Parts Illustrated are typical In appearance and

may not look exactly like the part required.

FIG. 20
PART 10-3-STROMBERG WW CARBURETTOR 10-31

5. Adjust the engine idle speed to specification 4. Set the ignition timing to specification.
by turning the engine idle speed screw (Fig. 13) 5. Attach an accurate tachometer to the engine.
inward or outward. 6. Run the engine until normal operating temp-
6. Remove the tachometer from the engine and erature is reached.
turn the headlights and airconditioner off. 7. Adjust the idle air/fuel mixture screws to give
the best quality idle at 20 R .P.M. above the
IDLE LIMITER CAPS specified idle speed .
8. Lean off the idle air/fuel mixture screws an
Should the idle limiter caps need replacement equal amount on each screw by turning in a clock-
because of deformation, mutilation or readjustment wise direction until the engine R.P.M. drops to the
of idling mixture to meet emission level require- specified idle speed.
ments, the following pracedure must be adhered to 9. Remove the air cleaner.
as the 'thermal conductivity' type of gas analyzer 10. Carefully install the black service limiter caps
found in most service shops is not accurate enough on the head of each idle mixture adjusting screw.
to give the required carbon monoxide readings. Use a straight thumb push or the end of 3/8" rod.
1. Remove the air cleaner. 11. Replace the air cleaner and check the idle
2. Cut the plastic limiter cap and carefully pry speed to ensure that the mixture screws were not
apart and remove it from the idle adjustment screw. accidently rotated while fitting the limiter caps.
3. Replace the air cleaner. 12. Remove the tachometer from the engine.

EJ MAJOR REPAIR OPERATIONS

CARBURETIOR REPAIRS This item is staked in position.
Clean exterior of carburettor to facilitate NOTE: The pump lever fulcrum screw ( 12) has a
handling and disassembly. Cleanliness of hands, left hand thread.
bench and tools is essential for efficient Choke valve securing screws (7) are staked in
carburettor servicing. their shafts. When removing choke valve (8) file off
Separate the carburettor into its three basic flared end of screws before unscrewing.
sub-assemblies, namely - Air Horn, Main Body and MAIN BODY (Fig. 20)
Throttle Body.
The idle tubes (26) are removed by lifting out
Disassemble each sub-assembly into its of their recesses in main body.
component parts, using the following special tools
in addition to normal workshop tools. When pump pistoa (70) is removed place palm
of hand over pump cylinder and invert main body
Stromberg Tool Part No. 73605 - for bending to remove pump inlet check ball ( 65) from
float lever when adjusting the float level. cylinder.
Stromberg Tool Part No. 73606 - for removal and Place hand over float chamber when removing
replacement of main metering jets (Item 32, Fig. 20). spring clip (63) to prevent possible Injury from
Stromberg Tool Part No. 73608- for removal and flying clip.
replacement of the main discharge jets (Item 31, After pump nozzle (21) is removed, invert
main body and catch outlet check ball (23) as it
Fig. 20). NOTE: Unless damage is evident or
drops from channel.
suspected the main discharge jets should not be
disturbed. THROTTLE BODY (Fig. 20)
DISASSEMBLY NOTE: Because of the very accurate production
fit, the throttle shaft and valves should not be
The throttle valves in the open position extend
removed unless excessive wear is evident.
below the throttle body flange. Care should be
exercised to avoid damaging the valves or changing Throttle valve securing screws ( 41) are staked
their position in the throttle bores. It is in their shaft. If removing valves, file off flared end
recommended that a suitable holding fixture be of screws before unscrewing.
·made up and used when servicing these units. INSPECTION
Having disassembled each sub-assembly,
AIR HORN (Fig. 20) thoroughly clean all castings and metal parts in a
Remove vacuum power piston ( 19) using a suitable cleaning solvent and blow out all passages
block of wood and small open end wrench as a pry. and tubes with compressed air. Inspect castings for
10-32 GROUP 10- FUEL SYSTEM

damage, excessive wear, burrs and warpage. Make

certain the throttle body is free of all hard carbon
deposits.
Clean all jets and main discharge jets (if
removed) by washing in cleaning solvent and
blowing through with air. Do not clean or size
these parts with drills or wires as such treatment
will affect their metering characteristics.
Discard all old gaskets and washers and use a
new Gasket Set when assembling. Genuine Repair
Kits are available and contain all components
required for a normal overhaul.

ASSEMBLY FIG. 21
Re-assembly each sub-assembly replacing all
components exhibiting damage or excessive wear. SETIING FLOAT LEVEL (Fig. 21)
PartiCular attention should be paid to the following
With main body held in an inverted position
points.
and with only weight of float holding float needle
valve shut, the float level "X" is measured from
AIR HORN (Fig. 20) main body (gasket removed) to centre of float
Vacuum piston (19) is staked in place after using Stromberg float gauge No. 73725 or a depth
installation. Check the piston for free movement in gauge.
its cylinder. Do not lubricate piston or cylinder (Refer to the Specification Listing for the
bore. correct float level dimension "X").
Before tightening choke valve securing screws To adjust float level, bend float lever next to
(7) close valve and check for proper valve fit float using Stromberg Tool 73605. Hold lip of
against a light. Stake hollow ends of securing float lever away from needle valve when bending
screws after tightening. The choke shaft (6) should float lever to avoid damaging the rubber needle tip.
be supported during this operation to prevent
bending of the shaft. After float setting is made, turn carburettor to
After air horn is assembled, check free upright position, install idle tubes (26) and place
movement of choke valve and shaft as shaft pump inlet check ball (65) on its seat in bottom of
assembly is moved from its open to closed pump cylinder. Assemble pump bottom spring
position. (66) on pump piston and install pump piston in
its cylinder, making certain that piston leather is
not creased and that it bears evenly on its
MAIN BODY (Fig. 20) complete circumference. (Apply a few drops of
If main discharge jets (31) have been removed , light engine oil to the piston leather before
install each jet with the bevelled side of the jet tip installing).
parallel to the sides of the small auxiliary venturi .
(Use Stromberg Tool 73608 when installing). THROTTLE BODY (Fig. 20)
Replace main metering jets (32) using If the throttle shaft was removed, insert
Stromberg Tool 73606. Screw jets home firmly but throttle shaft in throttle body and assemble
avo.id overti'ghtening as damage to the main throttle valves in same position and barrel that
discharge jets may occur. valves were removed from, leaving securing screws
Pump inlet check ball ( 65) fits in a central seat (41) loose. Close throttle lever and check valves for
located in bottom of pump piston cylinder. Pump J?est closing against a light before tightening screws.
outlet check ball (23) drops into channel under After tightening, the hollow screw ends should be
pump nozzle screw (20). staked. Support throttle shaft and valves during
this operation to prevent bending of shaft.
Assemble float fulcrum pin (62) in float lever
and install float in float chamber. Place ends of Install idle needle valves (45) and springs (44).
fulcrum pin spring (63) against ledges in float Tum each needle valve in lightly against its seat,
chamber and press loop of spring under boss to then back out each valve one and a. half turns.
secure spring. Install thermostat lever & shaft (51). Assemble
PART 10-3-STROMBERG W W CARBURETTOR 10-33

lever (50) on end of shaft and replace lockwasher power by-pass jet (24) and the main body, and to
and nut. Tighten nut. Install slow idle stop s~.:rew ensure the upper ends of the idle tubes (26) engage
(38) and spring (37) also assemble fast idle screw in their passages in the air hom.
(39) if removed. Invert carburettor and place main body gasket
THERMOSTAT COVER ASSEMBLY (35) on main body. Place throttle body (36) on
AND ADJUSTMENT gasket, align holes, and install and tighten the
Do not install thermostat cover (55) until the attaching screws (46 & 47).
Thermostat Lever Positioning Setting "TL'' has
been completed. Install keyed end of fast idle rod (29) to lever
( 11) and insert opposite end of rod in slot of fast
A new gasket (54) should then be placed on idfe cam. Secure with retainer clip (28) assembling
the thermostat cover and the cover assembled on straight side of clip in the rod hole.
its housing with hook of the thermostat spring
"DOWN". Rotate cover counter-clockwise and set Place vent washer (71) over stem of pump
indicator mark on cover as specified in the piston (70) and attach pump stem to pump lever
Specification Listing. Replace and tighten screws (15) with cotter pin (18). Secure pump lever to air
(53) and lug washers (52). hom with fulcrum screw (16) (L.H. Thread).
Assemble upper end of pump rod (17) to pump
FINAL ASSEMBLY (Fig.20) lever (15) and install lower end of pump rod in
Place air hom gasket (10) on main body. hole of throttle lever. Replace cotter pins (18).
Carefully guide air hom over pump piston stem, Assemble keyed end of choke rod (59) in
align holes in air hom (9), gasket (I 0) and main thermostat shaft lever (50) and install opposite end
body, tlren replace and tighten air hom attaching of rod in choke lever using cotter pin ( 60).
screws (5).
Assemble bracket (74) complete with dashpot
NOTE: Hold air hom in exact vertical position (76) under heads of securing screws (75).
when assembling to avoid possibility of the vacuum
piston stem ( 19) becoming wedged between the
10-34

PART MOTORCRAFT MODEL 2100-D 2V CARBURETTOR

10·4
Section
1 Description and Operation ............................................. 10-34
2 Common Adjustments & Repairs ................................... 10-38
Idle Speed Adjustment... ................................................. 10-38
Idle Limiter Cap Replacement......................................... 10-40
3 Major Repairs Operations................................................ 10-43

D DESCRIPTION AND OPERATION

AUTOMATIC
E
DESCRIPTION
The Motorcraft Model 21 00-D 2- V
carburettor (Figs. 1, and 2) has two
main assemblies, the air hom and the
main body.
The air hom assembly, which
serves as the main body cover,
contains the choke plate, choke
diaphragtn assembly and the internal
vents for the fuel bowl.
The throttle plate, the accelerating
pump assembly, the power valve
assembly, and the fuel bowl are in the
main body. The automatic choke
housing is attached to the main body.
Each bore contains a main and
booster venturi, main fuel discharge,
accelerating pump discharge, idle
fuel dis<;:harge and a throttle plate.
The Motorcraft Model 21 00-D 2-V
used on the 351-C engine has a
unique two-piece fast idle lever and
the crankcase emission hose connec-
tion is incorporated in the main body.
OPERATION
FUEL INLET SYSTEM ACCELERATING
PUMP ASSEMBLY
The amount of fuel entering the V120~A

fuel bowl (Fig. 3) is regulated by the FIG. 1 - Motorcraft Modei210Q-D, 2· V

Carburetor- Left Front 3/4 View typical
distance the fuel inlet needle is raised
off its seat and by fuel pump pres- ers the fuel inlet needle to a position the end of the lever of the float as-
sure. Movement of the fuel inlet where it restricts the flow of fuel, ad- sembly. This clip assures reaction of
needle in relation to the seat is con- mitting only enough fuel to replace the fuel inlet needle to any downward
trolled by the float and lever assembly that being used. movement of the float.
which rises and falls with the fuel lev- An integral retaining clip is at-
A wire-type retainer prevents
el. When the fuel in the fuel bowl tached to the fuel inlet needle assem-
reaches a pre-set level, the float low- bly. The clip hooks over the tab on movement of the float shaft within
PART 10-4- MOTORCRAFT MODEL 2100 CARBURETTOR 10-35
INTERNAL CHOKE OIAPHRAGM
BOWL VENTS CHOKE PLATE ASSEMBLY The fuel bowl is internally vented
into the air cleaner. It is also exter-
nally vented to the atmosphere.
AUTOMATIC CHOKE SYSTEM
The choke plate, located in the air
horn above the barrels, when closed,
provides a high vacuum above as
well as below the throttle plates. With
a vacuum above the throttle plates,
fuel will flow from the main fuel sys-
tem as well as from the idle fuel sys-
tem. This provides the extremely rich
fuel mixture necessary for cold en-
gine operation.
The carburettor choke shaft is
linked to a thermostatic choke con-
trol mechanism mounted on the main
body (Fig. 4).
The linkage between the choke le-
ver and the throttle shaft is designed
CHOKE HEAT TUBE so that the choke plate will partially
CONN ECTION open when the accelerator pedal is
fully depressed. This permits unload-
ing of a flooded engine.
The automatic choke is equipped
with a bimetal thermostatic spring
CURB IOL E and a vacuum piston (Fig. 4). The
AOJU STIN G SCREW
V1200-A
bimetal thermostatic spring mecha-
FIG. 2- Motorcraft Modei2100-D, 2- V nism winds up when cold and un-
Carburetor - Left Rear 3/4 View - Typical winds when warm. When the engine
is cold, the thermostatic spring,
through attaching linkage, holds the
choke piston upward and the choke
plate in a closed position prior to
engine start. Manifold vacuum chan-
neled through a passage in the choke
control housing draws the choke
vacuum piston downward, exerting an
opening force on the choke plate.
When the engine is started, mani-
fold vacuum, acting directly on the
piston located in the choke housing,
immediately moves the choke plate
against the tension of the thermostat-
ic spring to a partially open position
to prevent stalling.
As the engine continues to oper-
ate, manifold vacuum draws heated
air from the inlet manifold heat
chamber. The amount of air entering
the choke housing is controlled by
restrictions in the air passages in the
carburet tor.
The warmed air enters the choke
housing and heats the thermostatic
spring, causing it to unwind. The ten-
sion of the thermostatic spring grad-
ually decreases as the temperature of
the air from the heat chamber rises,
. . FUEL
82598-A allowing the choke plate to open. The
FIG. 3-Fuel Inlet System air is exhausted into the intake mani-
fold.
the guides on each side of the fuel die seat. The ends of the retainer are When the engine reaches its nor-
bowl. The retainer fits into a groove hooked over grooves on opposite mal operating temperature, the ther-
ends of the float shaft. mostatic spring exerts tension on the
on the outside of the fuel inlet nee-
10-36 GROUP 10- FUEL SYSTEM

so that the choke plate will partially

open when the accelerator pedal is
fully depressed. This permits unload-
ing of a flooded engine.
THERMOSTATIC
SPRING
IDLE FUEL SYSTEM
CHOKE HOUSING The difference in pressure between
the fuel bowl and the idle discharge
port forces fuel through the idle fuel
system. Fuel flows from the fuel bowl
through the main jet and into the bot-
tom of the main well (Fig. 5).
From the main well, the fuel flows
up through the idle tube and through
a short diagonal passage in the boost-
er venturi assembly into the idle pas-
sage in the main body. A calibrated
restriction, at the upper tip of the idle
tube, meters the flow of fuel.
Air enters the idle system from the
PISTON AND LEVER ASSEMBLY air bleed, located directly above the
idle tube. The air bleed also acts as a
¢:JcLEAN AIR vent to prevent siphoning at off idle
~HEATED AIR or high speeds and when the engine is
stopped. Additional air is bled into
~VACUUM the system through an air bleed lo-
cated at the bottom of the diagonal
passage in the booster venturi wh"re
the fuel enters the idle passage in
B2599·A the main body.
Fuel flows down the idle passage in
FIG. 4-Automatic Choke System the main body past three idle transfer
choke plate forcing it to the full The linkage between the choke le-
ver and the throttle shaft is designed holes. The idle transfer holes act as
open position. In this position, thr additional air bleeds at curb idle. The
choke piston is at its lowest point in
the cylinder. Slots in the piston cham-
ber wall allow sufficient air to bleed
past the piston and into the intake
manifold, causing a continual flow of
warm air to pass through the thermo-
static spring housing. The spring re-
mains heated and the choke plate re-
mains fully open until the engine is
stopped and allowed to cool.
The choke rod actuates the fast
idle cam during choking. Steps on the
edge of the fast idle cam contact the
fast idle adjusting screw. This permits
a faster engine idle speed for smooth-
er running when the engine is cold.
As the choke plate is moved through
its range of travel from the closed to
the open position, the choke rod ro-
tates the fast idle cam. Each step on
the fast idle cam permits a slower idle
rpm as engine temperature rises and
choking is reduced.
During the warm-up period, if the
engine should reach the stall point
due to a lean mixture, manifold vac- IDLE DISCHARGE
uum will drop considerably. The ten-
sion of the thermostatic spring then
Q AIR
• FUEL·AI R
overcomes the lowered vacuum act-
ing on the choke piston and the . . FUEL
B2600.A
choke plate is moved toward the
closed position, providing a richer
mixture to help prevent stalling. FIG. 5-ldle Fuel System
PART 10-4 MOTORCRAFT MODEL 2100 CARBURETTOR 10-37

fuel then flows past the pointed tip of PUMP DISCHARGE NOZZLE PRIMAR Y FUEL BOWL
the adjusting needle which controls
the idle fuel discharge. From the ad-
justing needle chamber, the fuel flows
through a short horizontal passage
and is discharged below the throttle
plates.
During off idle when the throt\le
plate is moved slightly past the idle
transfer holes, each hole begins dis-
charging fuel as it is exposed to man-
ifold vacuum. As the throttle plate is
opened still wider and engine speed
increases, the air flow through the
carburetor is also increased. This
creates a vacuum in the booster ven-
turi strong enough to bring the main
fuel system into operation. Fuel flow
from the idle fuel system tapers off
as the main fuel system begins dis-
charging fuel.
ACCELERATING SYSTEM
Upon acceleration, the air flow
through the carburettor responds al-
most immediately to the increased BALL CHECK PUMP DISCHARGE WEIGHT
throttle opening. There is, however, a PUMP DISCHARGE
brief interval before the flowing fuel,
which is heavier than air, can gain . . FUEL 82601-A
the required flow speed to maintain
the desired balance of fuel and air. FIG. 6-Accelerating Pump System
During the interval, the accelerating
system (Fig. 6) supplies fuel until
¢=l AIR
the other systems can once again
provide the proper mixture. ¢:::::1 FUEL -AIR
When the throttle is closed, the
. . . FUEL
diaphragm return spring forces the
diaphragm toward the cover, drawing 4pm VACUUM
fuel into the chamber through the in-
let. The inlet has an Elastomer
valve which uncovers the inlet hole HIGH SPEED AIR BLEED ANTI-SIPHON AIR BLEED
to admit fuel from the fuel bowl.
The valve covers the inlet hole when
the accelerating pump is operated to
prevent the fuel from returning to
the bowl. A discharge weight and
ball check prevents air from enter-
ing the discharge nozzle when fuel
is drawn into the diaphragm cham-
ber.
When the throttle is opened, the
diaphragm rod is forced inward, forc-
ing fuel from the chamber into the
discharge passage. Fuel under pres-
sure forces the pump discharge
weight and ball off their seat and fuel
passes through the accelerating pump
MAIN WELL TUBE
discharge screw and is sprayed into
each main venturi through discharge
ports .
. An air bleed in the wall of the ac-
celerating pump fuel chamber pre- MAIN WELL 62602 - A
vents vapor entrapment and pressure
build-up in the diaphragm chamber. FIG. 7-Main Fuel System
10-38 GROUP 10- FUEL SYSTEM

MAIN FUEL SYSTEM

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 main discharge port and the fuel
bowl causes fuel to flow through the
maio fuel system (Fig. 7).
At a predetermined venturi vacu-
um, fuel flows from the fuel bowl,
through the maio jets, and into the
bottom of the main well. The fuel
moves up the main well tube past air
bleed holes. Filtered air from the
high speed air bleed enters the fuel
flow in the main well tube through
holes in the side of the tube . The high <;::J AIR
speed air bleed meters an increasing
amount of air to the fuel as venturi <;:::J FUEL- AIR
vacuum increases, maintaining the re·
. . FUEL
quired fuel-air ratio. The mixture of
fuel and air is lighter than raw fuel <II)Im VACUUM
and responds faster to changes in POWER VALVE VACUUM PICK-UP
venturi vacuum. It also atomizes
more readily tha-n raw fuel. The fuel
an. i air continue up the main well 82603-A
tube past another air bleed which
also acts as a vent to prevent siphon- FIG. 8-Power Fuel System
ing when the engine is shut down. load conditions, is great enough to
The fuel is discharged into the boost· tiona) air bleed during the idle fuel
hold the power valve diaphragm
er venturi where it is atomized and system operation. down, overcoming the tension of the
mixed with air flowing through the POWER FUEL SYSTEM spring on the valve stem and holding
carburettor. the valve closed. When high power
During periods of increased road
The throttle plate controls the operation places a greater load on
loads or high speed operation, the
amount of the fuel-air mixture ad- the engine and manifold vacuum
fuel-air ratio must be increased for
mi_tted to the intake manifold, regu- drops below a predetermined value,
added power. The added fuel re-
latmg the speed and power output of the spring opens the power valve.
the engine. quired during this period is supplied
by the power fuel system (Fig. 8). Fuel from the fuel bowl flows
A balance tube is located in each through the power valve and into
The power fuel system is con-
barrel directly below the booster ven- passages leading to the maio fuel
trolled by the intake manifold vac-
turi. When decelerating, the balance well. Here the fuel is added to the
uum.
tube siphons off any excess fuel drop- fuel from the main fuel system, en·
lets remaining around the edge of the Manifold vacuum is transmitted
from an opening in the base of the riching the mixture.
booster venturi and discharges the
main body, through a passage in the As engine power demands are re·
droplets into the equalizing slots in
main body and power valve chamber duced, manifold vacuum increases.
the base of the carburetor where they
to the power valve diaphragm. The The increased vacuum overcomes the
are mixed with the idle fuel. The tension of the valve_stem spring and
manifold vacuum, acting on the pow-
balance tube also acts as an addi-
er valve at idle speed or normal road closes the power valve.

EJ IN CAR ADJUSTMENTS AND REPAIRS

CARBU!tETTOR ADJUSTMENTS
All carburettors are equipped with idle runge of the idle adjusting limiter. Under
The adjustments described and fuel mixture adjusting limiters. The no circumstances are the idle adjusting
illu strated in this part should be limiters control the maximum idle richness limiters or the limiter stops on the
performed JS required to retain the desired Jnd help prevent unauthorized persons carburettor to be mutilated or deformed to
engine performance characteristics. Refer from making overly ri<.:h idle adjustment. render the limiters inoperative On the
to the specifications whenever carburettor The plastic idle limiter cap is installed Motorcraft Model 2100-D 2-V carburettor,
adjustments are made. on the head of the idle fuel mixture the power valve cover must be installed
adjusting screws), (Fig. 9). Any ad- with the limiter stops on the cover in
IDLE SPEED AND FUEL position to provide a positive stop for tabs
justment made on carburettors having
MIXTURE on the idle adjusting limiters (Fig. 9).
this type of limiter must be within the
PART 10-4 MOTORCRAFT MODEL 2100 CARBURETTOR 10-39

A satisfactory idle should be NORMAL IDLE FUEL

obtainable within the range of the idle SETTINGS - ENGINE ON
adjusting limiters, if all other engine
systems are operating within 1. The engine and underhood
specifications. temperatures must be stabilized before
At pre-delivery, follow the Normal idle adjustments are made. Run the engine
Idle Fuel Settings for both Engine Off and a minimum of 20 minutes at 1500rpm.
Engine On and in Step 1 of Additional This can be done by pos1t10mng the fast
Idle Speed and Fuel Mixture Procedures. idle screw or cam follower on the kick-
Other fuel system adjustments should not down step of the fast idle cam (Fig. 12).
be required at pre-delivery service.
Following are the normal procedures 2. Check the initial ignition timing
necessary to properly adjust the engine and the di;tributor advance. Use an OASHPOT LOCKNUT 83134 - A

idle speed and fuel mixture. The specific accurate-reading tachometer and timing FIG.tt- Dashpot - Typical Installation
operations should be followed in the light when checking the initial ignition range of the idle limiter(s}.
sequence given whenever the idle speed or timing and idle fuel mixture and speed.
Check for idle smoothness only with
idle full adjustments are made. 3. On vehicles with a manual-shift
the air cleaner installed.
In isolated cases, a satisfactory idle transmission, the idle setting must be
condition may not be achieved by made only when the transmission is in
ADDITIONAL IDLE SPEED
performing' the normal procedures. If this Neutral.
On vehicles with an automatic AND FUEL MIXTURE
occurs, refer to Additional Idle Speed and PROCEDURES
Fuel Mixture Procedures. transmisSion, the idle setting is made with
the transmission selector lever in the Drive
If satisfactory idle condition is not
NORMAL IDLE FUEL range.
obtained after performing the preceding
SETTINGS - ENGINE OFF normal idle fuel settings, additional checks
of engine systems must be performed.
1. Set the idle fuel mixture screw(s) 1. The following items should be
and limiter cap(s) to the checked and, if required, corrected.
full-counterclockwise position of the a. Vacuum leaks
limiter cap(s). b. Ignition system wiring continuity
2. Back off the curb idle speed c. Spark plugs
adjusting screw (Fig. 10) until the throttle d. Distributor breaker point dwell
plate(s) seat in the throttle bore(s}. angle
3. Be sure the dashpot or solenoid e. Distributor point condition
throttle positioner (if so equipped) is not FIG. 10- Curb Idle Speed Adjusting Screw
f. Initial ignition timing
interfering with the throttle lever (Fig. 11). 4. Be sure the choke plate is in the In certain instances, it may be possible
It may be necessary to loosen the full-open position. that the idle condition is not as good as
dashpot or solenoid to allow the throttle 5. Turn the headlights on high beam normally expected. It is suggested that the
plate(s) to seat in the throttle bore(s). to place the alternator under a load customer with a new vehicle be advised
4. Turn the idle speed adjusting condition in order to properly adjust to that the vehicle be driven 50 to I 00 miles.
screw inward until it just makes contact the specified engine idle speed. Then, when the engine friction has been
with the screw stop on the thottle shaft 6. The final idle speed adjustment is reduced, the idle condition should be
and lever assembly. Then, turn the screw made with the air conditioner (if improved. If, after the break-in period, the
inward I 1/2 turns to establish a equipped) turned ON. idle condition is believed to be
preliminary idle speed adjustment (Fig. I 0). 7. Adjust the engine curb idle rpm unsatisfactory, re-adjust the engine idle
5. Set the parking brake while to specifications. The tachometer reading speed to specification and observe for a
making idle mixture and speed (rpm) must be taken with the air cleaner satisfactory idle.
adjustments. installed. On vehicles with less than 50 2. If the idle condition is not
miles, ~et the idle speed approximately 25 improved after the items in Step 1 have
rpm below specifications to allow for an been checked, perform the following
rpm increase as the engine loosens up in engine mechanical checks:
the first 100 miles of driving. a. Fuel Level
If it is not possible to adjust the idle b. Crankcase ventilation system
speed with the air cleaner installed; c. Valve clearance (using the
remove it, make the adjustment, then collapsed tappet method for hydraulic
replace the air cleaner and check again for valves)
the specified rpm. d. Engine compression
Manual transmission vehicles may be 3. After verification of all engine
fitted with a solenoid throttle positioner. systems has been made. there may be
However this is not connected on these isolated cases where a satisfactory idle
engines and must be adjusted so as not to condition has not been obtained, due
LIMITER STOPS
affect the engine idle speed. Idle speed possibly to a lean idle fuel mixture. If this
83114-A
adjustment is to be made on the normal
condition is encountered, refer to the
FIG. 9- Motorcraft Modei21DO-D 2-V Idle throttle stop screw.
8. Turn the idle mixture adjusting following operation REMOVAL AND
Fuel Mixture Adjusting Limiters INSTALLATION OF IDLE LIMITER
screw(s) inward an equal amount to obtain
Stops-Bottom CAPS.
the smoothest idle possible within the
10-40 GROUP 10-FUEL SYSTEM
REMOVAL AND INSTALLATION Make certain the curb idle speed and
OF IDLE LIMITER CAPS mixture are adjusted to specification
Should the idle limiter caps need before attempting to set the fast idle
replacement because of deformation, muti- speed.
lation or readjustment of idle mixture to 1. With the engine operating
meet emission level requirements the temperature normalized (hot), air cleaner
following procedure must be adhered to removed and the tachometer attached,
as the 'thermal conductivity' type of gas manually rotate the fast idle cam until the
analyzer found in most service shops is not fast idle adjusting screw rests on the
accurate enough to give the required carbon specified step on the cam.
monoxide readings. 2. Turn the fast idle adjusting screw
inward or outward as required to obtain
1. Remove the air cleaner.
the specified fast idle rpm.
2. Cut the plastic limiter cap and
carefully pry apart and remove it from
the idle adjustment screw. ANTI-STALL DASHPOT
3. Replace the air cleaner.
4. Set the ignition timing to specifica- 1. With the engine idle speed and FAST IDLE CAM
mixture properly adjusted, and the engine B2S9S-A
tion.
at normal operating temperature, loosen FIG.12- Fast ldllt Speed Adjustment-
5. Attach an accurate tachometer to Model 2100-D, 2· V
the anti-stall dashpot Jock nut.
the engine.
2. Hold the throttle in the closed
6. Run the engine until the normal position and depress the plunger with a stroke.
operating temperature is reached. screwdriver blade. Measure the clearance The accelerating pump operating rod
7. Adjust the idle air/fuel mixture between the throttle lever and the plunger should be in the specified hole in the
screws to give the best quality idle at 20 tip. Turn the anti-stall dashpot in a overtravellever and the inboard hole (hole
R.P.M. above the specified speed. direction to provide the specified closets to the pump plunger) in the
clearance between the tip of the plunger accelerating pump link (Fig. 13).
B. Lean off the idle air/fuel mixture
screws an equal amount on each screw by and the throttle lever. Tighten the locknut 1. To release the rod from the
turning in a clockwise direction until the to secure the adjustment. retaining clip, press the tab end of the clip
engine R.P.M. drops to the specified idle toward the rod; then, at the same time,
AUTOMATIC CHOKE
speed. press the rod away from the clip until it is
THERMOSTATIC SPRING
9. Remove the air cleaner. disengaged.
HOUSING ADJUSTMENT
2. Position the clip over the
l 0. Install the blue plastic service limi- specified hole in the overtravel lever. Press
ter cap. The automatic choke has an
the ends of the clip together and insert the
Use care not to turn the idle mixture adjustment to control its reaction to operating rod through the clip and the
when installing the cap. Position the cap engine temperature. By loosening the overtravel lever. Release the clip to engage
so that it is in the maximum counter- clamp screws that retain the thermostatic
the rod.
clockwise position with the tab of the spring housing to the choke housing.
limiter against the stop on the carburetor. The spring housing can be turned to
The idle mixture screw will then be at alter the adjustment. Refer to the
the maximum allowable outward or rich specifications for the proper setting. CHOKEPLATEPULLDOWN
setting. To install the service limiter cap, 1. Remove the air cleaner assembly, AND FAST IDLE CAM
use a straight forward push with thumb heater hose and mounting bracket (if so CLEARANCE
pressure or a 3/8" rod. equipped) from the carburettor.
2. Loosen the thermostatic spring Choke Plate Pulldown
11. Replace the air cleaner and recheck
the idle speed to ensure that the mixture housing clamp retaining screws. Set the 1. Remove the air cleaner,Page lo-67.
screws were not accidently rotated while spring housing to the specified index mark
fitting the limiter caps. and tighten the clamp retaining screws. 2. With the engine at normal
12. Remove the tachometer from the 3. If other carburettor adjustments operating temperature, loosen the choke
engine. are not required, install the heater hose thermostatic spring housing retainer
and mounting bracket (if so equipped) and screws and set the housing 90 degrees in
the air cleaner assembly on the carburettor. the rich direction.
FAST IDLE
ADJUSTMENT 3. Disconnect and remove the choke
ACCELERATING PUMP
heat tube from the choke housing
The fast idle adjusting screw (Fig. 12) STROKE ADJUSTMENT
4. Turn the fast idle adjusting screw
contacts one edge of the fast idle cam. outward one full turn.
The cam permits a faster engine idle The stroke should not be changed
from the specified setting. 5. Start the engine, then check for
speed for smoother running when the the specified clearance between the lower
engine is cold during choke operation. As If the pump stroke has been changed
from the specified setting refer to the edge of the choke plate and the air horn
the choke plate is moved through its range wall (Fig. 14).
of travel from the closed to the open following instructions to correct the
stroke to specifications. 6. If the clearance is not within
position, the fast idle cam pick-up lever specifications, turn the diaphragm stop
rotates the fast idle cam. Each position on The primary throttle shaft lever screw (located on the underside of the
the fast idle cam permits a slower idle rpm (overtravel lever) has 4 holes and the choke diaphragm housing) clockwise to
as engine temperature rises and choking is accelerating pump link has 4 holes (Fig. decrease or counterclockwise to increase
reduced. 13) to control the accelerating pump the clearance.
PART 10-4 MOTORCRAFT MODEL 2100 CARBURETTOR 10-41
4. Set the choke thermo static spring
housing to specifications. Adjust the
anti-stall dashpo t, idle speed and fuel
mixture.

OVERTRAVEL
LEVER

FAST
ADJUSTING
TWO- PIECE FAST IDLE LEVER
FOR 351-C ENGINE
V1261-A

FIG. 15- Fast Idle Levers Used on the

Motorcraft 2100-D 2-V Carburetor

FUEL LEVEL FLOAT

ADJUSTMENT - DRY

V1507 - B
The dry float adjustment is a
preliminary fuel level adjustment only.
The final adjustment (Fuel Level Float
FIG. 13 Accelerator Pump Stroke-Model 2100 Carburetor Adjustment - Wet) must be made after
the carburettor is mounted on the engine.

DRILL OR GA UGE OF
SPECIFIED CLEARANCE
7. Connect the choke heat tube and
set the choke thermostatic spring housing
to specifications. Adjust the fast idle speed
to specifications.

Fast Idle Cam Clearance

I. Loosen the choke thermostatic

spring housing retainer screws and set the
housing 90 degrees in the rich direction.
2. Position the fast idle speed screw
at the kickdown step of the fast idle cam
The kickdown step is identified by a V
stamped on the cam (Fig. 15).
On the 351-C engine, a two-piece fast
idle lever is used to provide clearance
between the lever and manifold, and a
tang on the top lever will align with the V
mark on the cam (Fig. 15).
3. Be sure the cam is at the
kickdown position while checking or
adjusting the fast idle cam clearance.
Check for the specified clearance FAS T IDL E
between the lower edge of the choke plate ADJUS T ING SC RE W

and the air horn wall. To adjust the

clearance, turn the fast idle cam clearance
V1202-A
adjusting screw clockwise to increase and
counterclockwise to decrease the FIG. 14- Choke Plate Pul/down Clearance
clearance. - Modei2100-D 2-V Carburetor
10-42 GROUP 10-FUEL SYSTEM

With the air born removed, the float The measurement must be made at least 3. Remove the automatic choke
raised and the fuel inlet needle seated, 1/4 inch away from any vertical surface to plate operating rod to choke lever retainer.
check the distance between the top assure an accurate reading, because the 4. Remove the air horn retaining
surface of the main body (psket removed) surface of the fuel is concave (higher at screws and lock washers, and the car-
and the top surface of the float for the edges than in the centre). Care must be burettor identification tag. Remove the
conformance to specifications. Depress the exercised to measure the fuel level at the air horn gasket.
float tab to seat the fuel inlet needle. Take point of contact with the float with the
the measurement near the center of the fuel. Refer to the specification• for the INSTAlLATION
float at a point 1/8 inch from the free end correct fuel level (wet) setting.
of the float. 5. If any adjustment is required, I. Install a new air horn to main
If the cardboard float g;tu8t is used, stop the engine to minimize the hazard of body gasket. Make sure all holes in the
place the puge in t ..e comer of the the fire due to fuel spray when the float new gasket have been properly punched
enlarged end section of the fuel bowl (Fig. setting is disturbed. To adjust the fuel and that no foreign material has adhered
16). The gauge should touch the float near level, bend the float tab (contacting the to the gasket.
the end, but not on the end radius. fuel inlet valve) upward in relation to the 2. Position the air hom on the main
If necessary, bend the tab on the float original position to raise the fuel level, and body and gasket so that the choke plate
to bring the setting within the specified downward to lower it. Each time an operating rod fits into the opening in the
limits. This should provide the proper adjustment is made to the float tab to choke housing lever. Install the choke
preliminary fuel level setting. alter the fuel level, the engine must be plate rod retainer.
started and permitted to idle for a few 3. Install the air horn retaining
minutes to stabilize the fuel level. Check screws and lock washers and the
the fuel level after each adjustment until identification tag. Install the air cleaner
the specified level is achieved. anchor screw, and tighten to the specified
6. Install a new air horn gasket, the torque.
air horn assembly, carburettor identifica- 4. Connect the automatic choke
tion tag and the retaining screws. Tighten clean air tube to the carburettor.
the retaining screws. Install the air cleaner 5. Adjust the idle fuel mixture and
anchor screw and ·tighten to the specified idle speed and the dashpot as outlined in
torque. this section.
7. Check the idle fuel mixture, idle 6. Install the carburettor air cleaner
speed adjustments and the carburettor o-
assembly. (Page 1 67 )
dashpot adjustment (if so equipped).
Adjust the carburettor as required. FLOAT, NEEDLE VALVE AND
Install the air cleaner assembly. SEAT. INLET SCREEN OR
MAIN JETS

REMOVAL

TOUCH AT TH IS POINT
82590-A
1. Remove the carburettor air horn
to main body gasket by following the
FIG. 16 - Fuel Level Float Adjustment - procedure under Air Horn to Main Body
Dry Gasket Removal.
FUEL LEVEL FLOAT 2. With the use of a screwdriver, pry
ADJUSTMENT- WET the float shaft retainer(s) from the fuel
inlet seat. Remove the float, float shaft
I. ' 'peta te the engine to normalize retainer and fuel inlet needle assembly.
engine te nperatures, and place the vehicle 3. If required, remove the fuel inlet
on a flat surface as near level as possible. needle seat, filter screen and the main jets
Stop the engine. with a jet wrench. Be sure the correct
2. Remove the carburettor air cleaner (specified) jets are installed.
assembly and anchor screw, if they have
not been previously removed. Page 10. INSTALLATION
67
3. Remove the air horn retaining I. If R'quired , install the fuel inlet
FtG. 17 - Fuel Level Float Adjustment-
screws and the carlmrettor identification filter in the inlet valve seat bore. Install
Wet
tag. Temporarily place the air horn and the valve seat and gasket. Install the fuel
gasket in position on the carburertor main inlet needle valve.
CARBURmOR REPAIRS
body and start the engine. Let the engine 2. Slide the float shaft into the float
idle for a few minutes, then rotate the air AIR HORN TO lever. Position the float shaft retainer on
horn out of the way and remove the air MAIN BODY GASKET the float shaft.
horn gasket to provide access to the float 3. Insert the float assembly into the
assembly. REMOVAL fuel bowl and hook the float lever tab
4. While the engine is idling, use a under the fuel inlet needle clip. Insert the
standard depth scale to measure the I. Remove the air cleaner assembly. float shaft into the guides at the sides of
vertical distance from the top machined Remove the air cleaner anchor ~crew . the fuel bowl.
surface of the carburet! or main body to the 2. Disconnect the automatic choke 4. With the use of a screwdriver,
level of the fuel in the fuel bowl (Fig. 17). clean air tube at the carburettor. position the float shaft retainer on the
PART 10-4 MOTORCRAFT MODEL 2100 CARBURETTOR 10-43

groove of the fuel inlet needle seat. and place the cover and diaphragm CHOKE DIAPHRAGM ASSEMBLY
5. Refer to Float Adjustment - Dry, assembly in position on the return spring
and perform a dry float fuel level and ~in body. The large end of the REMOVAL
adjustment on the float. spring must face the Elastomer Yalve. l. Remove the air cleaner.
6. Install the carburettor air horn and
2. Remove the diaphragm cover
gasket and related parts. Refer to Air Horn ~DIAPHRAGM
• attaching screws, then lift the cover,
to Main Body Gasket Replacement. -,. LINK diaphragm assembly and spring from the
7. Refer to Fuel Level Float air hom (Fig. 18). It will not be necessary
Adjustment - Wet, and perform the wet .__PIN to remove the diaphragm stop screw on
fuel level adjustment procedures.
8. Adjust the idle fuel mixture and
engine idle speed.

ACCELERATING PUMP
.,.__COVER the underside of the air hom.
3. Remove the diaphragm rod from
the end of the lever.

INSTALLATION
DIAPHRAGM AND/OR
ELASTOMER VALVE l. Position the diaphragm spring in
.....i...._
~ASSEMBLY
DIAPHRAGM
the air horn. Place the cover on top of the
diaphragm, then attach the diaphragm rod
REMOVAL
to the end of the lever.
l. Remove the carburettor air horn 2. Install the cover attaching screws
to main body gasket following the and tighten to the specified torque.
procedure under Air Horn to Main Body 3. Set the choke plate pulldown and
Gasket Removal. fast idle cam clearance.
2. Remove the ac;:celerating pump 4. Tighten the air cleaner anchor
operating rod retainer. To release the rod screw to the specified torque to help
from the retainer, press the tab ends of the provide a vacuum seal between the air
clip together, then, at the same time, press hom and main body. The choke dia-
the rod away from the clip until it is phragm vacuum passage is in the rear
disengaged. Remove the rod. Remove the portion of the carburettor.
accelerating pump cover, diaphragm 5. Install the air cleaner.
assembly and spring.
3. If inspection proves it necessary POWER VALVE TEST
to remove the Elastomer valve, grasp it
firmly and pull it out. If the Elastomer A power valve must not be replaced
valve tip broke off during removal, be sure unless it is leaking sufficiently to cause an
to remove the tip from the fuel bowl. An unadjustable rough engine idle condition.
FIG. 18- Choke Diaphragm Assembly Fuel accumulation in the power valve
Elastomer valve must be replaced
whenever it is removed from the main cover does not necessarily indicate a
Install the cover screws finger-tight. Push damaged power valve. Fuel vapors will be
body.
the accelerating pump plunger the full drawn into the vacuum side of the power
INSTALLATION
l. If the Elastomer valve was
length of travel and tighten the cover valve and condense during periods of
removed, lubricate the tip of a new valve screws. deceleration. Leakage in the power valve
3. Position the accelerating pump area can be caused by an improperly
and insert the tip into the accelerator
operating rod in the inboard hole (hole tightened cover or damaged gaskets. Any
pump cavity. Using needle nosed pliers,
closest to the pump plunger). gasket sealing deficiencies must be
reach into the fuel bowl and grasp the
4. Adjust the accelerating pump corrected before the power valve is
valve tip. Pull the valve in until it seats,
stroke to specification. replaced.
and cut off the tip forward of the retainer
5. Install the carburettor air horn and If power valve leakage is suspected,
shoulder. Remove the tip from the bowl.
gasket. Refer to the Air Horn to Main carry out test procedure as detailed in
2. Position the new accelerating
Body Gasket Replacement. (Page 10-6)
pump diaphragm assembly to the cover

EJ MAJOR REPAIR OPERATIONS

CARBURETTOR REMOVAL

Flooding, stumble on acceleration and from the choke shield (if so equipped). INSTALLATION
other performance complaints are in many 2. Remove the throttle cable or rod
instances, caused by the presence of dirt, from the throttle lever. Disconnect the 1. Clean the gasket mounting sur-
water or other foreign matter in the distributor vacuum line, in-line fuel filter faces of the spacer and carburettor.
carburettor. To aid in diagnosing the cause and the choke heat tube at the carburettor. Place the spacer between two new gaskets
of complaint, the carburettor should be 3. Disconnect the choke clean air and position the spacer and gaskets on the
carefully removed from the engine tube from the air horn. intake manifold. Position the carburettor
without removing the fuel from the bowls. 4. Remove the carburettor retaining on the spacer and gasket and secure it with
The contents of the bowls may then be nuts; then remove the carburettor. Re- the retaining lockwashers and nuts. To
examined for contamination as the move the carburettor mounting gasket, prevent leakage, distortion or damage to
carburettor is disassembled. spacer (if equipped) and lower gasket, the carburettor body flange, snug the nuts;
l. Remove the air cleaner as detailed from the intake manifold. then, alternately tighten each nut in a
on page 10-67. Remove the heater hose criss-cross pattern to the specified torque.
10-44 GROUP 10- FUEL SYSTEM

2. Connect the in-line fuel filter rod from the air horn. Slide the plastic
throttle cable, choke heat tube, and dust seal out of the air horn.
distributor vacuum line. Position the 5. Remove the choke diaphragm
heater hose behind the choke shield. assembly (Fig. 18).
3. Connect the choke clear air tube 6. If it is necessary to remove the
to the air horn. choke plate, remove the staking marks on
4. Adjust the engine idle speed, the the choke plate retaining screws and
idle fuel mixture, anti-stall dashpot (if so remove the screws. Remove the choke
equipped) and the accelerating pump plate by sliding it out of the shaft from
stroke (if required). Install the air cleaner. the top of the air horn. Slide the choke
shaft out of the air horn .
If the tips of the choke plate screws
DISASSEMBLY are flared excessively, file off the flared
To facilitate working on the car- portion to prevent damage to the threads
burettor and to prevent damage to the FIG. 21 -Float Shaft Retainer Removal
in the shaft.
throttle plates, install carburettor legs on or Installation
the base. If legs are unavailable, install 4
FLOAT HINGE distribution plate, booster venturi and
bolts (about 2 I /4 inches long of the gasket. Invert the main body and let the
correct diameter) and 8 nuts on the a.:celerating pump discharge weight and
carburettor base. ball fall into the hand.
Use a separate container for the 4. Remove the accelerator pump
component parts of the various assemblies operating rod from the over-travel lever
to facilitate cleaning, inspection and and the retainer. To release the operating
assembly. rod from the over-travel lever retainer,
The following is a step-by-step press the ends of the retainer together;
sequence of operations for completely then, at the same time, press the rod away
overhauling the carburettor. However, from the retainer until it is disengaged.
certain components of the carburettor may Remove the rod and retainer.
be serviced without a complete dis- 5. Remove the accelerating pump
assembly of the entire unit. For a com- cover retaining screws. Remove the
plete carburettor overhaul, follow all accelerating pump cover, diaphragm
of the steps. to partially overhaul a assembly and spring (Fig. 22).
carburettor or to install a new gasket kit 6. If it is necessary to remove the
follow only the applicable steps. Elastomer valve, grasp it firmly and pull it
82605-A
out. If the Elastomer valve tip broke off
AIR HORN FIG. 20- Float Assembly during removal, be sure to remove the tip
1. Remove the air cleaner anchor AUTOMATIC CHOKE from the fuel bowl. An Elastomer valve
screw. must be replaced whenever it has been
2. Remove the automatic choke 1. Remove the fast idle cam retainer removed from the carburettor.
control rod retainer. (Fig. 19). 7. Invert the main body and remove
3. Remove the air horn retaining 2. Remove the thermostatic choke the power valve cover and the gasket.
screws, lock washers and the carburettor spring housing retaining screws and Remove the power valve with a box
identification tag. Remove the air horn remove the clamp, housing and gasket. wrench or socket wrench (Fig. 23).
and air horn gasket. 3. Remove the choke housing Remove the power valve gasket. Discard
assembly retaining screws. If the air horn the gasket.
was not previously removed, remove the 8. Remove the idle fuel mixture
choke control rod retainer. Remove the adjusting screws (needles) and the springs.
choke housing assembly, gasket and fast Remove the limiters from the adjusting
idle cam and rod from the fast idle cam screws.
lever. 9. If necessary, remove the nut and
4. Remove the choke lever retaining washer securing the fast idle adjusting
screw and washer. Remove the choke lever lever assembly to the throttle shaft, and
and fast idle cam lever from the choke remove the lever assembly. If necessary,
housing. remove the idle screw and the retainer
from the fast idle adjusting lever.
MAIN BODY 10. Remove the anti-stall dashpot or
solenoid (if so equipped).
1. With the use of a screwdriver, pry 11. If it is necessary to remove the
the float shaft retainer from the fuel inlet throttle plates, lightly scribe the throttle
seal (Figs. 20 and 21). Remove the float plates along the throttle shaft, and mark
float slpft retainer and fuel inlet needle each plate and its corresponding bore with
assembly. Remove the retainer and float a number or letter for proper installation
FAST IDLE CAM
82621-A snaft from the float lever. (Fig. 24).
FIG. 19 -Fast Idle Cam and Fast Idle Lever 2. Remove the fuel inlet needle, 12. Slide the throttle shaft out of the
seat, filter screen, and the main jets with a main body.
4. Remove the choke control rod by jet wrench.
Clean and inspect the carburettor
loosening the screw that secures the choke 3. Remove the booster venturi screw component parts as described in
shaft lever to the choke shaft. Remove the (accelerator pump di>charge) , air Page 10-13.
PART 10-4 MOTORCRAFT MODEL 2100 CARBURETTOR 10-45

ASSEMBLY 14. Slide the float shaft into the float

PUMP COVER AND L EVER
lever (Fig. 20). Position the float shaft
Make sure all holes in the new gaskets RETURN SPRING retainer on the float shaft.
have been properly punched and that no
foreign material has adhered to the j 15 . Insert the float assembly into the
fuel bowl and hook the float lever tab

,~
gaskets. Make sure the accelerating pump under the fuel inlet needle assembly.
diaphragm is not torn or cut. Insert the float shaft into its guides at the
The Motorcraft Model 2100-D 2-V sides of the fuel bowl.
carburettor assembly is shown in Fig. 25. 16. With the use of a screwdriver,
position the float shaft retainer in the
MAIN BODY groove on the fuel inlet needle seat (Fig.
DIAPHRAGM 21 ). Check the float setting.
1. Slide the throttle shaft assembly V1296-A 17 . Drop the accelerating pump
into the main body. FIG. 22- Accelerating Pump Assembly discharge ball in to the passage in the main
2. Refer to the lines scribed on the body. Seat the ball with a brass drift and a
throttle plates and install the throttle light hammer. Make sure the ball is free in
plates in their proper location with the the bore. Drop the accelerating pump
screws snug, but not tight. discharge weight on top of the ball.
3. Close the throttle plates. Invert Position the new booster venturi gasket
the main body, and hold it up to the light. and the booster venturi in the main body.
Little or no light should show between the Install the air distribution plate and the
throttle plates and the throttle bores. Tap accelerator pump discharge screw. Tighten
the plates lightly with a screwdriver handle the screw.
to seat them. Hold the throttle plates
closed and tighten and stake the retaining AUTOMATIC CHOKE
screws. When staking the screws, support
the shaft and plate on a block of wood or 1. Position the fast idle cam lever on
a metal bar to prevent bending of the the thermo ~ tatic choke shaft and lever
shaft. FIG. 23- Power Valve Removal or assembly. The bottom of the fast idle cam
4. If necessary, install the fast idle Installation lever adjusting screw must rest against the
screw pin and the screw on the fast idle tang on the choke lever. Insert the choke
adjusting lever. lever into the rear of the choke housing.
5. Install the anti-stall dashpot, if so Position the choke lever so that the hole in
equipped. the lever is to the left side of the choke
6. If the fast idle lever was removed, housing.
place the fast idle adjusting lever assembly 2. Install the fast idle cam rod on
on the throttle shaft and install the the fast idle cam lever. Place the fast idle
retaining washer and nut. cam on the fast idle cam rod and install
7. If the Elastomer valve was the retainer. Place the choke housing
removed, lubricate the tip of a new vacuum pick-up port to main body gasket
Elastomer valve and insert the tip into the on the choke housing on the main body.
accelerator pump cavity centre hole. Using SCRIBE LINES AND Position the gasket, and install the choke
IDENTIFICATION MARKS
a pair of needle nosed pliers, reach in to 81363-8 housing retaining screws. Install the fast
the fuel bowl and grasp the valve tip. Pull idle cam retainer. Install the thermostatic
FIG. 24 - Throttle Plate Removal
the valve in until it seats in the pump spring housing.
cavity wall and cut off the tip forward of gasket with a wrench (Fig. 23). Tighten
the retaining shoulder. Remove the tip the valve securely. AIR HORN
from the bowl. 11. Install the idle mixture adjusting Refer to Fig. 25 for the correct
8. Install the accelerating pump screws (needles) and springs (Fig. 25). location of the parts.
diaphragm return spring on the boss in the Turn the needles in gently with the fingers 1. If the choke plate shaft was
chamber (Fig. 22). Insert the diaphragm until they just touch the seat, then back removed, position the shaft in the air
assembly in the cover and place the cover them off 1 1/2 turns for a preliminary idle horn, then install the choke plate rod on
and diaphragm assembly into position on fuel mixture adjustment. Do not install the end of the choke shaft.
the main body. Install the cover screws. the idle mixture limiters at this time. 2. If the choke plate was removed,
9. Insert the accelerating pump Install the power valve cover and new insert the choke plate into the choke plate
operating rod into the inboard hole of the gasket. The power valve cover must be shaft. Install the choke plate screws snug,
accelerating pump actuating lever. Position installed with the limiter stops on the but not tight. Check for proper plate fit,
the accelerating pump operating rod cover in position to provide a positive stop binding in the air horn and free rotation of
retainer over the specified hole in the for the tabs on the idle adjusting limiters. the shaft by moving the plate from the
over-travel lever, Press the ends of the 12. Install the main jets and the fuel closed position to the open position. If
retainer together ; then, at the same time, inlet seat, filter screen, and new gasket. Be necessary, remove the choke plate and
insert the operating rod through the sure the correct jets are installed. grind or file the plate edge where it is
retainer and the hole in the over-travel 13. Install the fuel inlet needle binding or scraping on the air horn wall. If
lever. Release the ends of the retainer to assembly in the fuel 'inlet seat. Fuel inlet the choke plate and shaft moves freely,
secure the rod. needles and seats are matched assemblies. tighten the choke plate screws while
10. Invert the main body. Install the Be sure the correct needle and seat are holding the choke in the fully closed
power valve (enrichment valve) and new assembled together. position. Stake the screws. When staking
10-46 GROUP 10-FUEL SYSTEM

the screws, support shaft and plate on a 5. Perform the automatic choke
block of wood or a metal bar to prevent 4. Insert the end of the choke plate plate clearance adjustment after the
bending of the shaft. rod into the automatic choke lever. Install carburettor has been installed on the
3. Position the main body gasket the air horn retaining screws and the
carburetor identification tag. Tighten the vehicle. Refer to Page 10.40.
and the choke 10d plastic seal on the main
body. Position the air horn on the main retaining screws. Install the choke pia te
body and gasket so that the choke plate rod retainer. Install the air cleaner anchor
screw. Tighten the air cleaner anchor 6. After the specified air-fuel is
rod fits through the seal and the opening
screw to the specified torque. obtained, install the idle mix lure limiter
in the main body.
caps.
~ DIAPHRAGM~
~ LINK ~
1\J
u.,
I SOLENOID
Q-i
a-~
SCRE~
COVER___.
c:: o·
"'..,0 -"'s::
BOOSTER VENTURI

DIAPHRAGM~
. 9577

.., 0 AIR DISTRIBUTI<J'l PLATE ( -.

ASSEMBLY -~ - - ~ 9F553 "-..._ LOCKNUT

- 4-_
):,.Cl. CHOKE PLATE - 9545 "tJ
"'"'
"'
"'1\J ACCELERATING PUMP ""' \
:t>
3 - DISCHAR~7E13~~-~L CHECK ~ :::0
o-O -l
-o '- \p_ SOLENOID BRACKET- 9B550
"'6 NOZZLE BAR AND BOOSTER -9B511 ~::--WEIGHT ~

":-> VENTURI ASSEMBLY

9A523 ~
-. '- ~SCREW AND WASHER -43252-S
0
AIR HORN~~ ~
"' g
9 4
~JII 1~~ 1 GASKET - 9A536 ~
'~ ~
MAIN BODY-•9512 ~ ~ .. : DASHPOT-9B549 0
-l
RETURN SPRING-9636 ~.. DASH POT BRACKET -9B550 0
::0
VALVE NUT -33923-S (')
RETAINER
::0

~
375894-S
ACCELERATING PU
OVER-TRAVEL LEV
:t>
"T1
~............ SCREW -l
- ~
0
0
THROTTLE SHAFT AND
LEVER ASSEMBLY
m
9581 r
"'.....
0
0
(')
:t>
CHOKE LEVER -9A 753 ::0

~~
OJ
ADJUSTING SCRE W- 372307-S -
c
SPRING FAST IDLE CAM LEV ER - 9F571 ::0
9578 m
FAST IDL E CAM ROD-90530 -l

~~ ~~-~"" """'"-:~::'..,~.,
-l
f;::::::::: .... 0

~lNG _.-
83
::0
ASKET-95 ,...- . (II
STIDLE 3 GASKET -9871 __j
" -. THERMOSTATIC
CHOKE HCUSING G PIN-9579 b
I
LEVER w~
t t ""-."VJ _ / SPRIN G HOUSING
CLAMP - 9842
NGINE 9538 CHOKE_

(9A l--~
588

~~
F.lt..c;.T lnl FlAM

POWERGASKET
VALVE-9A565
.0
~ -
~ CHOKE ~
~ CHOKE SHIEL

~"" _,., ......... ~ "''"~""·'

LEVER ...--

~/
COVER-9930
Jf:8
SCREW-31061-S
_.i 2 PIECE
IDLE FAST
ADJUSTINNGGINE
LEVER- 351 C E
7. ~ 4
SCRE w- 31061-S
V11J7.B
10-48

PART
10-5 MOTOR CRAFT MODEL 4300 4-V CARBURETTOR

Section Page Section Page

1. DESCRIPTION AND OPERATION 10-48 3. MAJOR REPAIR OPERATIONS 10-59
Description ... ... ... ... ... 10-48 Removal ... 10-59
Operations ... .. . ... ... ... 10-50 Disassembly ... ... 10-59
Fuel Inlet System 10-50 Air Horn ... .. . 10-59
Idle Fuel Supply System 10-50 Main Body 10-60
Primary Main Fuel Metering System 10-51 Throttle Body .. 10-60
Accelerating Pump System ... .. . ... 10-51 Assembly ... ..... . 10-60
Power Fuel Supply System... .. . ... 10-52 Throttle Body 10-60
Seco ndary Main Fuel Metering System 10-52 Air Horn ..... . 10-60
Automatic Choke System ........... . 10-53 Air Horn to Main Body ... 10-62
2. IN-CA R ADJUSTMENTS AND REPAIRS 10-54
Idle Speed Adju stment ........ . 10-55
Idle Limiter Cap Replacement ... ... ... 10-55

0 DESCRIPTION AND OPERATION

DESCRIPTION

HOT IDLE COMPENSATOR

The Motorcraft Model 4300 4-V •THUNDERRIRD. CONTI N ENTAL MARK Ill,
Carburettor (Figs, 1, 2 and 3) is a AND LINCOLN CONTINENTAL ONLYI

three-pie ce , separately cast design

consisting of the air horn, main body and
throttle body.
A cas t-in centre fuel inlet has
provision for a supplementary fuel inlet
system. The fuel bowl is vented by an
internal balance vent.
The hot idle compensator shown in
some illustrations is not fitted when this
carburetor is fitted to the Cleveland
engine.
The main (primary) fuel system has
booster-type venturis cast integral with the
air horn and the main venturis are cast
integral with the main body. The
secondary throttle plates are mechanically
operated from the primary linkage. Air
valve plates are located above the
secondary main ven turis and an integral
-
hydraulic dashpot dampens sudden
movement of the air valve plates to help
prevent flutter and erractic engine
operation. A single fuel bowl supplies both
the primary and secondary fuel systems.
PRIMARY
Pontoon-type floats are used to help THROTTLE FAST IDLE SPEED
cornering and hill climbing capability. The SH.:. FT ADJUSTI NG SC REW

accelerating pump is of the piston -type, VI268. A

located in the fuel bowl.
FIG. 1- Matorcraft Mode/4300 4-V Carburetor
-Right Rear 3/4 View
PART 10-5 MOTORCRAFT MODEL 4300 CARBURETTOR 10-49

THROTTLE SHAFT
AND LEVER

V 1149-A
F /G. 2 - Model 4300 4· V Carburetor - Typical
-Left Front 3/4 View

FUEL INLET
FAST IDLE CAM
CHOKE ADJUSTING SCREW

CHOKE
HCXJSING

LEVER

SECONDARY
AIR VALVE
DASH PDT

¥1'297-A

FIG. 3- Mode/4300 4- V Carburetor

- Top View - Typical.
10-50 GROUP 10- FUEL SYSTEM

SPECIFIED SPECIFIED
FLOAT FLOAT
LEVEL
_j
FLOAT
DROPS
~

0 AIR O AIR
II FUEL • FUEL

Fig. 4-Fuel Inlet System Fig. 5-Auxiliary Fuel Valve Operation

OPERATION float lever to push the inlet valve IDLE FUEL SUPPLY SYSTEM
The Model 4300 4-V Carburet tor is (needle) against its seat. Flow of the When the throttles are closed or
designed to supply a calibrated fuel- fuel into the bowl then is blocked nearly closed, there is not enough air
air mixture to a V -8 engine. In until some fuel is used and the float flow through the venturis to create
normal operation, each of the prim- lowers again. the vacuum needed to operate the
ary venturis supplies all the fuel-air Auxiliary Fuel Inlet Valve primary main metering system.
mixture required by four cylinders. An auxiliary fuel inlet valve is built Therefore, a separate fuel metering
The idle, main metering, power fuel into this system to supplement the system for idle operation is incorpo-
supply, accelerating pump and choke main or primary fuel inlet valve when rated.
systems go into operation automatic- engine fuel requirements are high. The primary idle fuel supply sys-
ally to provide the proper richness The main or primary fuel inlet tem (Fig. 6) uses the pressure dif-
or leanness of the mixture for the valve controls small fuel flows pre- ference between manifold vacuum
operating condition. cisely because of its small area of and atmospheric pl'essure in the
Operation of the fuel metering sys- opening and relatively high valve-to- bowls to cause fuel flow. Idle system
tems is controlled by the accelerator seat sealing pressure. When large fuel flow is from the bowl, through
linkage, throttle position and engine fuel flows are required, as in high the main metering jets and into the
speed. The choke system is controlled engine speeds· and heavy-load con- main wells. From there, the fuel flows
by the throttle position and the tem- ditions, the fuel level and float height up through calibrated restriction in
perature of the engine exhaust mani- drop, thereby opening the auxiliary the idle tubes, then down the idle
fold. valve (Fig. 5) in addition to the main channels to the idle cavities in .the
or primary fuel inlet valve. The total throttle body. It enters the venturis
FUEL INLET SYSTEM combined fuel valve opening is larger below the throttle plates through the
Correct calibration of the carbu- than the previous single valve that idle discharge port and idle transfer
rettor depends on fuel being available has been used in former Ford car- slot. The idle fuel adjustment screw
at a specific level in the fuel bowl. If buretors. r,e gulates the amount of fuel that is
the fuel level is low, the metering In addition to supplying fuel for discharged through the port.
systems deliver Jean mixtures; if the high engine load conditions, the large Air Bleeds
level is high, mixtures are rich. The combined valve opening also purges Filtered air is mixed with the fuel
function of the fuel inlet system is the carburettor-to-fuel rump line, through the idle air bleeds to help
to admit gasoline into the fuel bowl after a hot restart, of fue vapor that the fuel atomize as it is discharged.
and maintain the soecified level. forms during a hot soak condition. The bleed also prevents siphoning
Fig. 4 shows the construction and through the idle system at very high
operation of the fuel inlet system. Venting the Bowl speeds, or when the engine is shut
The fuel inlet is constantly charged Two stand pipes beside the air horn down.
with fuel under pressure from the (Fi~. 4) vent the bowl to the fresh air
fuel pump. This fuel enters the bowl inlet. The stand pipes are open to the Idle Transfer Slot
through the fuel inlet valve, which is carburetor intake air after the air The idle transfer slot in each ven-
permitted to open when the float passes through the air cleaner. Thus, turi serves both as an air bleed and
lowers. the howl pressure and air horn pres- as a secondary discharge port. At
The float moves up-and-down with sure are equal during main metering closed throttle (Fig. 6), the top of
the fuel level. When enough fuel has system operation, and the calihration the slot admits air mto the idle
entered to fill the bowl to the correct o( the carhuretor isn't affected by the cavity, and the bottom of the slot
level, the float is high enough for the air cleaner's condition. delivers fuel to the venturi. When the
PART 10-5 MOTORCRAFT MODEL 4300 CARBURETTOR 10-51
throttle opens slightly ahove an idle the booster venturi causes a pressure Piston-Type Pump
<'ondition. the whole length of the slot drop or partial vacuum at the dis- A piston-type pump (Fig. 9) is
becomes a discharge port to richen charge nozzle. The fuel howl is at air actuated by a link from the accele-
the mixture (Fig. 6). This secon'dary horn pressure, resulting in a preSSJ.Ire rator linkage and by a spring to cause
discharge opening prevents the in- difference that creates flow through the pumping action. The pumping
crease in air flow from making the the system. Fuel is sprayed out the cham her is formed below a cup on the
mixtUie too lean. There would be a discharge nozzle and mixes with the pump piston. A hall-type intake
"flat spot" in the transition from the airstream. check valve and a needle-type dis-
idle to the main metering system The size of the main jet determines charge valve control the flow of fuel
without the transfer slot. how much fuel is delivered for a given into and out of the .pumping chamber
volume of air flow. Increasing or de- and channels. Discharge nozzles
PRIMARY MAIN FUEL creasing throttle opening increases or open into both primary venturis.
METERING SYSTEM decreases the fuel delivery so that Fuel Intake
A primary main fuel metering sys- the mixture proportion or ratio is Fuel intake occurs as the throttles
tem, divided into two parts _ one quite constant. are closed (Fig. 9). The accelerating
for each primary barrel _ provides Bleed Assists Vaporization pump link pulls the piston up, com-
the fuel required by the engine at The high-speed air bleeds (Fig. !!) pressing the piston ring. A partial
cruising speeds. Main metering sys- in the system permits some air to be vacuum is created helow the piston
tems are calibrated to deliver a lean mixed with the fuel in the main well. cup in the pumping chamber.
mixture _about 15 parts air to one The air enters the main well tube Fuel in the bowl, at this time, is
part gasoline _ when the engine is through two holes when fuel is flowing exposed to full atmospheric pressure.
cruising under light load. When more in the system. Adding air at this as the external vent valve lever also
power is required. the main metering point assists vaporization, and com· is actuated by the accelerating pump
system continues to operate, and the pensates for the tendency of the air link to open the valve.
mi¥ture is made richer by other sys- to become less dense at high speeds. The pressure difference pushes the
tems. The bleed also doubles as an anti- intake check valve off its seat and
siphoning vent at low speeds. And it causes fuel to flow from the bowl into
Parts of the Main Metering System discourages percolation when a hot the pumping chamber. The discha'rge
In the Model 4300 carburettor,the engine is shut down by venting the valve is seated. and prevents backflow
primary main metering system (Fig. main well . in the discharge passages.
7' has two main metering jets; main J:'uel Discharge
wells. and main well tubes; calibrated When the throttles open (Fig. 10),
air bleeds; disC'harge nozzles; and the end of the accelerating pump link
booster venturis. At rest, fuel flow!; ACCELERATING PUMP SYSTEM moves down in the piston arm slot,
from the bowl, through the main jets, Air, being very light, responds and the spring pushes the piston into
and into the main wells and tubes. In rapidly to changes in the throttle the oumoine chamber. PressurP.
each well and tube, the fuel assumes opening. Gasoline is heavier, and builds up ~n the chamber to force
the same level as in the bowl until therefore not as responsive. When the the inlet valve closed on its seat.
the engine begins to operate. throttles are opened suddenly, air Fuel is pumped through the dis-
Pressure Difference Causes Flow flow increases rapidly, but fuel flow charge passages __ the discharge
With the engine operating, the lags. So that the engine will respond ·valve is forced open hy the fuel pres-
main metering system delivers fuel instantly to opening the throttle, an sure _ and fuel is spraY,ed out the
in response to the throttle plate accelerating pump system. which discharge nozzle. When the piston
opening. Opening the throttle causes furnishes 1'1 . single spurt of fuel in has reached its limit of travel
air flow through the main venturi each primary venturi when the (depending on how far the accelerator
and booster venturi; the flow through throttles are opened, is incorporatC'd . is depressed), flow stops and the dis-
charge valve seats. The discharge
passages remain primed, or full of
fuel, so that pumping action through
the nozzles is instantaneous on the
next cycle.

OAIR BOOSTER VENTURI

FUEL
1[;1 FUEL AND AIR
VACUUM

OAIR (;11 FUEL AND AIR MAIN

FUEL VACUUM METERING JET

MAIN WELL TUBE

Fig. 6 ·- Idle Transfer Slot is Secondary
Discharge Passage Fig. 7- Primary Main Metering System
10-52 GROUP 10- FUEL SYSTEM

. FUEL

Fig. 8 - High-Speed Air Bleeds

Air Bleed Check Valve
With the engine operating at high
speed, a vacuum exists at the accele-
rating pump discharge nozzles. An
air bleed check valve prevents this
vacuum from siphoning fuel through
the accelerating pump system when
fuel is not being discharged. The
valve is placed at the upper end of CLOSED
the discharge nozzle passage.
POWER FUEL SUPPLY SYSTEM Fig. 10- Accelerating Pump- Discharge
The main metering system provides
a lean mixture for cruising condi- loaded, and tends to push the rod valve spring is overcome and the
tions, when power requirements are down. The stem of the power valve is valve opens (Fig. 12). Opening the
not high. When more power is re- also spring-loaded, tending to hold valve gives another passage from the
quired for high speed operation or the power valve up or closed. bowl to the main wells .. . through
for accelerating it is necessary to Manifold vacuum is sensed on top the valve and power jets. The effect
burn more fuel. The small amount of of the piston through passages in the is the same as if a temporary increase
fuel in a lean mixture does not pro- carburetor bodies. At idle or cruising in the size of the main jets was made.
vide enough heat upon combustion conditions, the vacuum is high enough More fuel is discharged through the
for full engine power. Therefore, a to overcome the p1ston rod sprmg main metering system to make the
way to "step up" or richen the mix- force. The piston and rod are held mixture richer.
ture is provided .. . this "step up" up and away from the power valve When the engine load decreases,
system is termed the power fuel stem. The power valve spring then the process is reversed. The piston is
supply system (Fig. 11). holds the valve closed. pulled up by higher manifold vacuum
Vacuum Piston and Power Valve Another Passage to the Main Well and allows the power valve to close.
The power fuel supply system uses When the engine is under load. the SECONDARY MAIN FUEL
a vacuum-controlled piston in the air vacuum drops. The vacuum piston
horn body and a power valve to admit rod is pushed down by its spring and METERING SYSTEM
more fuel when power is required. the rod pushes on the power valve . All the "action" described in this
The vacuum piston rod is spring- stem. The comparatively light power section so far is within the primary

OAIR
• FUEL

VACUUM PISTON

MANIFOLD
VACUUM
CHANNEL

POWER

. FUEL
PARTIAL
VACUUM . VACUUM
INTAKE CHECK VALVE (UNSEATED) POWER JET

Fig. 9 -Accelerating Pump System-Intake Fig. 11 -Power Fuel Supply System

PART 10-5 MOTORCRAFT MODEL 4300 CARBURETTOR 10-53
SECONDARY CHANNEL
BLEED

MAIN WELL

0 AIR
• FUEL
VACUUM

VALVE OPENS

0 AIR
FUEL
8 FUEL AND AIR
ENRICHMENT
VACUUM DISCHARGE TUBE

Fig. 12- Power Valve Action Fig. 13- Secondary Main Metering System

venturis. The following deals with tubes and out the enrichment dis- act as anti-percolation vents at idle
the "secondaries", the other two ven- charge tubes. or when a hot engine is shut down,
turis that give an extra volume of by relievi-ng pressure in the main
Secondary Main Discharge Tubes well tubes.
fuel-air mixture when maximum A second stage of fuel supply
power is applied. occurs when the air valve plates are AUTOMATIC CHOKE SYSTEM
The secondary throttles are linked pulled open by manifold vacuum To start and operate a cold engine,
mechanically to the primaries, and below them. Increased air flow then
begin to open when the primariPs are it is necessary to supply a richer mix-
causes fuel to be discharged into the ture, because the fuel doPsn't vapor-
three-q uarters open. booster venturis from the secondary ize as readily and because part of the
Air Valve Plates main discharge tubes. vaporized fuel condenses inside the
Each secondary venturi (barrel) The amount that the air valves cold intake manifold. The choke sys-
(Fig. 13) has an offset air valve plate open, and therefore the amount of tem, by regulating the position of the
located below its booster venturi . mixture delivered, is controlled by choke above the primary venturis,
These plates are preloaded by a the difference in air pressure acting provides the means of making the
spiral torsion spring, which holds on the plates balanced against the cold mixture rich. and gradually let-
them closed when the secondary spiral torsion spring. An integral ting it become leaner as the engine
throttles are closed . hydraulic dashpot dampens sudden warms up.
The air valve plates being closed, movemPnts of the plates to prevent Thermostatic Spring Controls
cause a vacuum as soon as the flutter and erratic e ngine operation. Choke Plate
throttles begin to open. The fuel bowl The thermostatic spring in the
is at air horn pressure. The pressure Air Bleeds
Air is introduced into the fuel at choke housing (Fig. 14) exerts a
difference starts fuel flowing from torque that forces the linkage to close
the bowl; through the seconda:y the secondary channel anti-siphon
hleed and at th e high -speed bleeds to the choke plate when the engine is
main jet tube to the secondary roam
wells; · then through the main well help vaporization. The bleeds also cold. The choke plate is closed fully

FAST IDLE ADJUSTMENT SCREW

Fig. 14- Automatic Choke System Fig. 15- Fast Idle Cam
10-54 GROUP 10-FUEL SYSTEM

SECONDARY THROTTLE SHAFT AND LEVER

Fig. 16 - Choke Unloader Operation Fig. 17- Secondary Throttle Lockout

before the engine starts so as to block is thus made richer to prevent a gine warms up. Thus, there are pro-
air flow into the venturis. When the "stumble" or stalling. gressively !ewer fast-idle speeds.
engine is cranked, engine vacuum Exhaust-Heated Air Control
then causes fuel to flow from the Choke Unloader (Dechoker)
main metering and idle systems to As the engine warms up, inlet manifold If the engine becomes flooded while
start the engine. supplied heat warms the thermostatic the driver is trying to start it, the
Choke Plate Pulldown choke spring. The choke closing force is choke unloader (Fig. 16) permits the
gradually relaxed and the choke plate choke, by using the throttle lever, to
When the engine starts, some air is opens as the engine becomes warm.
needed to prevent flooding. The be opened. Pushing the accelerator
choke plate is pulled open slightly by pedal to the floor mechanically moves
the effect of engine vacuum and by Fast Idle Cam a projection on the throttle lever
the operation of tht choke piston. During the engine warm-up period, against the unloader face on the fast
The piston, also located in the choke it is necessary to have a faster idle idle cam. The cam partially opens
housing, is actuated by vacuum as speed to prevent stalling. The fast the choke plate.
soon as the engine starts. Piston idle cam (Fig. 15) increases the idle Secondary Throttle Lockout
travel is limited by vacuum bypass speed by cracking the throttles to The secondary throttle lockout
slots in the choke piston cylinder wall admit more air. (Fig. 17) also is actuated by the choke
and a slot in the piston. When the The cam is rotated into position system to prevent the secondary ven-
slots meet, vacuum starts to bleed off, under the fast idle adjustment screw turis from delivering fuel when the
preventing further piston travel. bv the automatic choke lever. The engine is cold. The throttle lockout
Thus, the choke plate is opened just adjustment screw is mounted on the lever engages with a lever on the
enough to prevent flooding, but not throttle lever and actuates the secondary throttle shaft, and holds
enough to lean out the cold mixture. throttles when the cam contacts it. the throttle plates tightly closed dur-
If the engine is accelerated during The cam has several steps, and moves ing choking. When the choke opens,
warmup, vacuum drops and the choke to succeedingly lower steps under the the lockout lever is disengaged so that
closes for an instant ... the mixture fast idle adjustment screw as the en- the secondaries can operatE>.

EJ IN-CAR ADJUSTMENTS AND REPAIRS

CARBURETTOR ADJUSTMENTS and help prevent unauthorized persons adjusting limiters, if all other engine
The adjustments described and from making overly rich idle adjustment. systems are operating within
illustrated in this part should be The plastic idle limiter cap is installed specifications.
performed as required to retain the desired on the head of the idle fuel mixture At pre-delivery, follow the Normal
engine performance characteristics. Refer adjusting screw(s). (Fig. 18). Any adjust- Idle Fuel Settings for both Engine Off and
to the Specifications when evercarburettor ment made on carburettors having this Engine On and in Step 1 of Additional
adjustments are made. type of limiter must be within the range Idle Speed and Fuel Mixture Procedures.
of the idle adjusting limiter. Under no Other fuel system adjustments should not
IDLE SPEED AND FUEL circumstances are the idle adjusting limiters be required at pre-delivery service.
MIXTURE
or the limiter stops on the carburettor to be Followins are the normal procedures
mutilated or deformed to render the limiters necessary to properly adj\lSt the engine
All carburettors are equipped with idle inoperative. idle speed and fuel mixture. The specific
fuel mixture adjusting limiters. The A satisfactory idle should be operations should be followed in the
limiters control the maximum idle richness obtainable within the range of the idle sequence given whenever the idle speed Qr
PART 10-5 MOTORCRAFT MODEL 4300 CARBURETTOR 10-55
idle full adjustments are made.
In isolated cases, a satisfactory idle
condition may not be achieved by
performing the normal procedures. If this
occurs, refer to Additional Idle Speed and
Fuel Mixture Procedures.
NORMAL IDLE FUEL
SETTINGS - ENGINE OFF

1. Set the idle fuel mixture screw(s)

and limiter cap(s) to the
full-counterclockwise position of the MODEL 4300 4. V
limiter cap(s).
2. Back off the curb idle speed FIG. 19- Curb Idle Speed Adjusting Screws
adjusting screw (Fig. 19) until the throttle Then, when the engine friction has been
plate(s) seat in the throttle bore(s). reduced, the idle condition should be
3. Be sure the dashpot or solenoid improved. If, after the break-in period, the
throttle positioner (if so equipped) is not idle condition is believed to be
interfering with the throttle lever (Fig. 20) . IDLE MIXTURE LIMITER S unsatisfactory, re-adjust the engine idle
It may , be necessary to loosen the speed to specification and observe for a
dashpot or solenoid to allow the throttle FIG. 18- Idle Fuel Mixture Adjusting satisfactory idle.
plate(s) to seat in the throttle bore(s) . Limiter - 4300 4· V 2. If the idle condition is not
4. Turn the idle speed adjusting improved after the items in Step I have
screw inward until it just makes contact installed. On vehicles with less than 50
miles, set the idle speed approximately 25 been checked, perform the following
with the screw stop on the thottle shaft engine mechanical checks:
and lever assembly. Then, turn the screw rpm below specifications to allow for an
rpm increase as the engine loosens up in
inward I 1/2 turns to establish a
the first 100 miles of driving.
preliminary idle speed adjustment (Fig. 19).
If it is not possible to adjust the idle
5. Set the parking brake while speed with the air cleaner installed;
making idle mixture and speed remove it, make the adjustment, then
adjustments. replace the air cleaner and check again for
NORMAL IDLE FUEL the specified rpm.
SETTINGS - ENGINE ON Manual transmission vehicles may be
fitted with a solenoid throttle positioner.
1. The engine and underhood However this is not connected on these
temperatures must be stabilized before engines and must be adjusted so as not to
idle adjustments are made. Run the engine affect the engine idle speed. Idle speed
a minimum of 20 minutes at 1500rpm. adjustment is to be made on the normal DASHPOT LOCKNUT BJ134·A
This can be done by positioning the fast throttle stop screw.
FIG. 20- Dashpot - Typical Installation
idle screw or cam follower on the kick- 8. Turn the idle mixture adjusting
down step of the fast idle cam (Fig. 21). screw(s) inward an equal amount to obtain a. Fuel Level
the smoothest idle possible within the b. Crankcase ventilation system
2. Check the initial ignition timing range of the idle limiter(s). c. Valve clearance (using the
and the distributor advance. Use an Check for idle smoothness only with collapsed tappet method for hydraulic
accurate-reading tachometer and timing the air cleaner installed. valves)
light when checking the initial ignition d. Engine compression
timing and idle fuel mixture and speed. ADDITIONAL IDLE SPEED 3. After verification of all engine
3. On vehicles with a manual-shift AND FUEL MIXTURE systems has been made, there may be
transmission, the idle setting must be PROCEDURES isolated cases where a satisfactory idle
made only when the transmission is in If satisfactory idle condition is not condition has not been obtained. due
Neutral. obtained after performing the preceding possibly to a lean idle fuel mixture. If this
On vehicles with an automatic normal idle fuel settings, additional checks condition is encountered, refer to the
transmisSion, the idle setting is made with of engine systems must be performed. following operation.
the transmission selector lever in the Drive 1. The following items should be
range. REMOVAL AND
checked and, if required, corrected. INSTALLATION OF
4. Be sure the choke plate is in the a. Vacuum leaks IDLE LIMITER CAPS
full-open position. b. Ignition system wiring contmuity
5. Turn the headlights on high beam c. Spark plugs Should the idle limiter caps need
to place the alternator under a load replacement because of deformation, muti-
d. Distributor breaker point ."well lation or readjustment of idle mixture to
condition in order to properly adjust to angle meet emission level requirements the
the specified engine idle speed. e. Distributor point condition fo:'owing procedure must be adhered to
6. The final idle speed adjustment is f. Initial ignition timing as the 'therm'll conductivity' type of gas
made with the air C()nditioner (if analyzer found iri most service shops is
In certain instances, it may be possible not accurate enough to give the required
equipped) turned ON. that the idle condition is not as good as carbon monoxide readings .
7. Adjust the engine curb idle rpm ... "'ltally expected. It is suggested that the 1. Remove the air cleaner.
to specifications. The tachometer reading customer with a new vehicle be advised 2. Cut the plastic limiter cap ana
(rpm) must be taken with the air cleaner that the vehicle be driven 50 to 100 miles. carefully pry apart and remove it from the
10-56 GROUP 10- FUEL SYSTEM
idle adjustment screw. Make certain the curb idle speed and in Fig. 22. Bend the pump control rod to
3. Replace the air cleaner . mixture are adjusted to specification correct the piston stem height to
4. Set the ignition timing to specifi- before attempting to set the fast idle specifications.
cation. speed. If it is necessary to correct the setting,
5. Attach an accurate tachometer to 1. With the engine operating the pump stroke can be altered as follows :
the engine. 1. Remove the pump pivot pin
temperature normalized (hot), air cleaner
6. Run the engine until the normal retainer. Remove pivot pin.
operating temperature is reached. removed and the tachometer attached,
manually rotate the fast idle cam until the 2. Insert the pivot pin into the
7. Adjust the idle air/fuel mixture
screws to give the best quality idle at fast idle adjusting screw rests on the desired hole.
20 R.P .M. above the specified speed. specified step on the cam. 3. Install the pivot pin retainer.
8. Lean off the idle air/fuel mixture 2. Turn the fast idle adjusting screw Position the pump rod end into the pump
screws an equal amount on each screw by inward or outward as required to obtain arm and install the retainer.
turning in a clockwise direction until the the specified fast idle rpm.
engine R.P.M. drops to the specified idle
speed . ANTI-STALL DASHPOT (if fitted) CHOKE PLATE PULLDOWN AND
9. Remove the air cleaner. 1. With the engine idle speed and FAST IDLE CAM CLEARANCE
10. Install the blue plastic service limiter mixture ·properly adjusted, and the engine
cap. at normal operating temperature, loosen CHOKEPLATEPULLDOWN
Use care not to turn the idle mixture
when installing the cap. Position . the cap the anti-stall dashpot lock nut.
so that it is in the maximum counter- 2. Hold the throttle in the closed 1. Remove the air cleaner, then
clockwise position with the tab of the position and depress the plunger with a remove the choke thermostatic spring
limiter against the stop on the carburetor. screwdriver blade. Measure the clearance housing from the carburettor. To remove
The idle mixture screw will then be the thermostatic spring housing from the
at the maximum allowable outward or between the throttle lever and the plunger
rich setting. tip. Turn the anti-stall dashpot in a carburettor installed on the engine, refer to
To install the service limiter cap, use a direction to provide the specified Thermostatic Spring Housing and Gasket
straight forward push with thumb pressure clearance between the tip of the plunger Replacement.
or a 3/ 8" rod. and the throttle lever. Tighten the locknut 2. Bend a wire gauge of 0.036-inch
11. Replace the air cleaner and recheck to secure the adjustment. diameter at a 90 degree angle
the idle speed to ensure that the mixture
screws were not accidently rotated while AUTOMATIC CHOKE approximately 1/8-inch from one end.
fitting the limiter caps. THERMOSTATIC SPRING 3. Block the throttle about
12. Remove the tachometer from the HOUSING ADJUSTMENT half-open so the fast idle cam does not
engine. contact the fast idle adjustment screw,
FAST IDLE The automatic choke has an then insert the bent end of the wire gauge
ADJUSTMENT adjustment to control its reaction to between the lower edge of the piston slot
engine temperature. By loosening the and the upper edge of the right-hand slot
The fast idle adjusting screw (Fig. 21) clamp screws that retain the thermostatic in the choke housing (Fig. 23).
contacts one edge of the fast idle cam. spring housing to the choke housing. 4. Pull the choke piston lever
The cam permits a faster engine idle The spring housing can be turned to counterclockwise until the gauge is snug in
speed for smoothe.r running when the alter the adjustment. Refer to the the piston slot. Hold the wire gauge in
engine is cold during choke operation. As specifications for the proper setting. place by exerting light pressure in a
rearward direction on the choke piston
1. Remove the air cleaner assembly, lever. Check the choke plate clearance
heater hose and mounting bracket (if so (Pull down) between the lower edge of the
equipped) from the carburettor. choke pia te and the wall of the air horn.
2. Loosen the thermostatic spring 5. To adjust the choke plate
housing clamp retaining screws. Set the clearance, loosen the hex head screw (left
spring housing to the specified index mark
hand thread) on the choke plate shaft
and tighten the clamp retaining screws.
(Fig. 23) and pry the link away from the
3. If other carburettor adjustments tapered shaft.
are not required, install the heater hose Use a drill gauge 0.010-inch under the
and mounting bracket (if so equipped) and specified clearance between the lower edge
the air cleaner assembly on thecarburettor. of the choke pia te and the wall of the air
horn. Hold the choke plate against the
ACCELERA TlNG PUMP
gauge and maintain a light pressure in a
STROKE ADJUSTMENT
rearward direction on the choke lever.
The accelerating pump stroke has
With the choke piston snug against the
been set to help keep the exhaust emission
0.036-inch wire gauge and the choke plate
level of the engine within the specified
against the drill gauge, tighten the hex
limits. The additional holes provided for
V1271-A head screw (left hand thread) on the
pump stroke adjustment are for adjusting
FIG. 21- Fast Idle Speed Adjustment -
choke plate shaft.
the stroke for specific engine applications.
The use of a 0.010-inch undersize drill
Motorcraft Model4300 4-V The stroke should not be changed from
gauge is to allow for tolerances in the
the choke plate is moved through its range the specified setting.
linkage. Use a drill gauge equal to the size
of travel from the closed to the open If the pump stroke has been changed
of the specified clearance to make a final
position, the fast idle cam pick-up lever from the specified setting refer to the
rotates the fast idle cam. Each position on check.
following instructions to correct the 6. Install the gasket and
the fast idle cam permits a slower idle rpm stroke to specification. ~efore adjusting thermostatic spring housing on the choke
as engine temperature rises and choking is the accelerating pump stroke, measure the housing. Install the spring housing retainer
reduced. height of the pump piston stem as shown and screws.
PART 10-5 MOTORCRAFT MODEL 4300 CARBURETTOfl 10-57
the choke plate and the air horn wall. fast idle speed lever forward to increase or
IJ END ROD f O
AD JUS I Ht IGHT Turn the fast idle cam adjusting screw backward to decrease the clearance.
inward to increase the clearance or
outward to decrease the clearance. Make FUEL LEVEL FLOAT AND
sure the fast idle speed adjusting screw AUXILIARY (SUPPLEMENTAL)
stays at the kickdown step of the fast idle VALVE SETTING
cam during the adjustment.
On the 351 C engine, a two-piece fast FLOAT SETTING
idle lever is used to provide clearance
To simplify parallel setting of the dual
between the lever and manifold, and a
tang on the top lever will align with the V pontoons, refer to Fig. 24 for the con-
mark on the cam. struction of an adjustable float gauge
3. Set the thermostatic choke and a float tab bending tool.
1. Adjust gauge to the spe.::ified·
housing to the specified index mark and
tighten the retaining screws. height.
4. If the choke plate clearance and 2. Insert gauge into the air horn
outboard holes (Fig. 25).
fast idle cam linkage adjustment was
3. Check the clearance an<i
performed with the carburetor on the
V1298 A alignment of the pontoons to the c;auge.
engine, adjust the engine idle speed and
FIG. 22- Accelerating Pump Piston Stem Both pontoons should just touch the
fuel mixture. Adjust the anti-stall dashpot
Heigh't and Pump Stroke gauge for the proper setting. Align the
(if so equipped).
pontoons if necessary by slightly twisting
FAST IDLE CAM CLEARANCE
the pontoons.
ADJUSTMENT DECHOKECLEARANCE
If it is n~cessary to adju st the float
clearance, bend the primary needle tab
l. Rotate the spring housing l. Open the throttle plate to the
downward to raise the float and upward to
counterclockwise (rich direction) to align wide-open-throttle position .and hold.
lower the float.
the center index mark on the choke 2. Rotate the choke plate towards
To bend the tabs with the float
housing with the index mark on the spring the closed position until the pawl on the
bending tool, the procedure is as follows :
housing. Rotate the spring housing an fast idle speed lever contacts the fast idle
To Raise the Float, insert the open
additional 90 degrees counterclockwise cam.
end of the bending tool to the RIGHT side
and tighten the retaining screws. 3. Check the clearance between the
2. Position the fast idle speed of the float lever tab and between the
lower edge of the choke plate and the air
needle and float hinge. Raise the float
adjusting screw end on the kickdown horn wall.
lever off the needle and bend the tab
(centre) step of the fast idle cam. Check 4. Adjust the clearance to
downward.
the clearance between the lower edge of specifications by bending the pa~l on the
To Lower The Float, insert the open
DRILL GAUGE OF SPECIFIED end of the bending tool to the LEFT side
CLEARANCE SIZE of the float lever tab, between th e needle
and float hinge. Support the float lever
and bend the tab upward .
TAPER ·LOCK CHOKE SHAFT SCREW
AUXILIARY
(LEFT HAND THREAD)
(SUPPLEMENTAL) VALVE
SETTING

Check the auxiliary valve clearance

(Fig. 26). If it is necessary to adjust the
auxiliary valve and float tab to the
specified clearance, use the bending tool
shown in Fig. 25 .

AIR HORN TO
MAIN BODY GASKET

REMOVAL

·INCH WIRE
1. Remove the air cleaner assembly
GAUGE
2. Disconnect the fuel inlet line
from the air horn.
3. Remove the choke clean air
pick-up connecting tube from the air horn .
4. Remove the choke control rod
retainer from the automatic choke lever.
Separate the rod from the lever.
APPLY LIGHT PRESSURE TO CHOKE LEVER
V1235-A 5. Remove the accelerator pump rod
FIG. 23- Choke Plate Pull-Down and Fast retainer or spring from the pump lever.
Idle Cam Adjustment Separate the rod from the lever.
10-58 GROUP 10- FUEL SYSTEM

NO. 12·32 x 2" SCREWS (2 REQ'O.)

NO. 12 NUTS (6 REQ'O.) v 1152-4
FIG. 26- Auxiliary (Supplemental) Valve
Setting

ADJUST BOTH NUTS TO FLOAT

retaining screws in the left rear hole.
HEIGHT SPECIFICATIONS 5. Install the other air horn retaining
screws and the carburettor identification
tag.
6. Insert the accelerator pump
BENDING TOOL- 1/ 16" DIAMETER
SPRING STEEL WIRE OR WELDING control rod into the pump lever. Install
ROD, 8" LONG the pin and the retainer or spring.
7. Insert the choke control rod end
into the automatic choke lever. With long
82859·8 nose pliers, install the retainer.
8. Connect the fuel inlet line.
FIG. 24- Float Gauge and Bending Tool 9. Connect the choke clean air
Details pick-up and heat tubes.
BEND TAB TO RAISE OR LOWER FLOAT 10. Install the air cleaner.
11. Adjust the idle fuel mixture and
engine curb idle speed.

MAIN AND AUXILIARY

~UPPLEMENTAL) FUEL INLET
VALVE

REMOVAL

1. Remove the air horn assembly

from the main bo~y of the carburettor.
2. Pull the float pivot pin and
remove the float and lever assembly.
3. Remove the main fuel inlet needle
valve. then use the proper size screwdriver

....
ACCELERATOR PUMP
DISCHARGE NEEDLE
MAIN JETS

FIG. 25- Float Setting. V 115l·A

6. Remove the air cleaner anchor that no foreign material has adhered to the
screw and the air horn to main body gaskets Gasket surfaces must be clean and
retaining screws, and the carburettor flat and free of nicks or burrs.
identification tag. 2. Install the gasket on the car-
7. Lift the air horn off the fuel burettor main body.
bowl. 3. Carefully position the air horn
8. Remove the gasket. assembly over the main body. Guide the
accelerator pump plunger and the
INSTALLATION secondary throttle dash pot piston in to
v 115S.4
their chambers as the air horn is gently
1. Make sure all holes in the new lowered into position. F /G. 27 - Main Body Valves and Jets
gaskets have been properly punched and 4. Install the longest of the air horn - Model 4300 4- V
PART 10-5 MOTORCRAFT MODEL 4300 CARBURETTOR 10-59
or jet removal tool to remove the main DISCHARGE CHECK VALVE DISC. check ·in the pump inlet hole of the pump
and auxiliary valve. seats and gaskets. chamber. Install the ball check retaining
REMOVAL
ring (Fig. 27).
1. Remove the air hom assembly
INSTALLATION from the main body of the carburettor. 2. Insert the discharge check valve
2. Remove the accelerator rod disc into the valve cavity, and install the
retainer and rod from the accelerating valve retainer flush with the air horn
1. Install new gaskets on the valve pump lever, then remove the lever from surface. The cross slot in the retainer is
seats. Then install the seats in the air horn. the accelerating pump piston and remove towards the valve.
2. Place the main fuel inlet needle the pump assembly from the air horn. 3. Place the accelerating pump
valve in the valve seat. 3. Remove the discharge checK valve discharge needle into the pump discharge
3. Position the float and lever retainer with a small hook. Invert the air cavity.
assembly between the hinge posts and over horn and allow the check valve disc to fall 4. Insert the accelerating pump
the fuel inlet valves, then install the float into palm of hand. piston in the air horn .
pivot pin. The pin must be inserted from 4. Remove the accelerating pump
the pump plunger side for self-retention. inlet ball check retainer with long-nose 5. Compres$ the pump plunger and
4. Install the air horn on the main pliers, then use a magnet to lift the ball insert accelerating pump arm into plunger
body. check from the pump well. stem.
5. Adjust-the idle fuel mixture and 5. Pick the accelerating pump Line up holes in lever and insert pivot
engine idle speed. discharge needle from the discharge cavity . pin through the specified hole in lever and
the air horn casting. Install retainer on pin.
ACCELERATING PUMP, INLET INSTALLATION 6. Install the air horn assembly on
BALL CHECK, NEEDLE.VALVE AND 1. Place the accelerating pump ball the main body.

EJ MAJOR REPAIR OPERATIONS

CARBURmOR REMOVAL 2. Connect the in-line fuel fllter 4. Remove the accelerator pump rod
throttle cable, choke heat tube, and retainer or spring from the pump lever.
Flooding, stumble on acceleration and distributor vacuum line. Position the Separate the rod from the lever.
other performance complaints are in many heater hose behind the choke shield.
instances, caused by the presence of dirt, 5. Remove the air cleaner anchor
3. Connect the choke clear air tube screw and remove the air horn to fuel
water or other foreign matter in the to the air horn.
carburetor. To aid in diagnosing the cause bowl retaining screws.
4. Adjust the engine idle speed, the 6. Lift the air horn off the main
of complaint, the carburetor should be idle fuel mixture, anti-stall dashpot (if so
carefully removed from the engine body.
equipped) and the accelerating pump 7. Pull the float pivot pin and
without removing the fuel from the bowls. stroke (if required). Install the air cleaner
The contents of the bowls may then be remove the float assembly.
(Page 10-67)
examined for contamination as the 8. Using the proper size screwdriver
DISASSEMBLY or jet removal tool, remove the main and
carburetor is disassembled.
1. Remove the air cleaner (Page 10-67) auxiliary (supplemental) fuel inlet valve
To facilitate working on the car-
Remove the heater hose from the choke seats and gaskets.
shield (if so equipped). burettor, and to prevent damage to the
throttle plates, install carburettor legs on 9. Remove the secondary air valve
2. Remove the throttle cable or rod
from the throttle lever. Disconnect the the base. If legs are unavailable, install lever retainer and the rod from the
distributor vacuum line, in-line fuel filter four 5/16 x 2 1/2 inch bolts and 8 nuts; dampener piston assembly and air valve
and the choke heat tube at the carburetor. install nuts on the bolts, above and below plate, then remove the air valve dampener
3. Disconnect the choke clean air the carburetor base. piston rod and spring.
tube from the air horn. Use a separate container for the 10. If it is necessary to remove the
component parts of the various assemblies secondary air valve plate(s) attaching
4. Remove the carburettor retaining
to facilitate cleaning, inspection, and screws. Remove the plates, then slide the
nuts; then remove the carburettor. Re-
assembly. shaft out of the air horn.
move the carburettor mounting gasket,
The following is a step-by-step
spacer (if equipped) and lower gasket, 11. If it is necessary to remove the
sequence of operations for completely
from the intake manifold. choke plate or choke shaft, remove the
overhauling the carburetor. However,
certain components of the carburetot may staking marks on the choke plate retaining
INSTALLATION be serviced without a complete screws. If the tips of the screws are flared
disassembly of the entire unit. excessively, file the flared portion to
1. Clean the gasket mounting prevent damage to the threads in the shaft.
surfaces of the spacer and carburettor. Remove the choke plate, then slide the
Place the spacer between two new gaskets AIR HORN choke shaft and lever out of the air horn.
and position the spacer and gaskets on the The choke lever is attached to the shaft
intake manifold. Position the carburettor 1. Remove the fuel inlet line from with a left hand thread screw.
on the spacer and gasket and secure it with the fuel filter. 12. Do not remove the power valve
the retaining lockwashers and nuts. To 2. Remove the choke clean air pick vacuum piston assembly unless it is to be
prevent leakage, distortion or damage to up connecting tube from the air horn. replaced. It is staked in place in the air
the carburettor body flange, snug the nuts; 3. Remove the choke control rod horn, and care must be used to avoid
then, alternately tighten each nut in a retainer from the automatic choke lever. damage to the air hom casting when
criss-cross pattern to the specified torque. Separate the rod from the lever. relieving the staked areas.
10-60 GROUP 10- FUEL SYSTEM

MAIN BODY 6. Remove the nut from the the bushing through the fast idle cam.
secondary throttle shaft, then remove the Press the bushing in the choke housing and
I. Turn the main body upside down lockout lever and and slide the shaft and into the column. Clean the bushing with a
and catch the accelerating pump discharge return spring out of the throttle body. 1/4-inch reamer.
needle (Fig. 27). 7. Remove the nut from the primary
2. With a 3/8 deep . socket, remove throttle shaft and remove the fast idle 7. Insert the automatic choke shaft
the power valve from the floor of the main lever and adjusting screw (the 351 C and lever in the bushing.
body fuel bowl (Fig. 27).
engine has a two-piece fast idle lever).
Slide the throttle shaft and primary 8. Position the automatic choke
3. Remove the main metering jets piston in the choke cylinder and the lever
throttle shaft and lever assembly out of
(Fig. 27) from the fuel bowl with a jet on the automatic choke shaft. Install the
tool. the throttle plate.
retaining screw.
8. Remove the primary throttle lever
4. Using long nose pliers, remove the 9. Insert the secondary throttle to
assembly retainer, then slide the lever and
accelerating pump inlet check ball primary throttle connecting rod into the
springs off the shaft.
retainer, then turn the main body over and throttle levers and install retainers.
9. If it is nec.essary to remove the
catch the ball from the pump well.
fast idle cam or bushing. carefully press MAIN BODY TO
CHOKE HOUSING the bushing out of the choke housing and THROTTLE BODY
bushing column. The column may bend
out of alignment or break without proper l. Position the main body on a
support to the column during bushing working surface with the fuel bowl down.
removal or installation. 2. Position the main body to
throttle body gasket on the main body.
ASSEMBLY 3. Position the throttle body on the
main body and install the retaining screws.
Make sure all holes in the new gaskets 4. Invert the main body and the
have been properly punched and that no throttle body so the fuel bowl is upward.
foreign material has adhered to the 5. Install the power valve and main
gaskets. Gasket surfaces must be clean and jets in the main body.
flat and free of nicks or burrs. 6. Install the choke to throttle
The carburettor assembly is shown in lockout lever.
Fig. 29 . 7. Place the accelerator pump ball
check in the pump inlet hole of the pump
THROTTLE BODY chamber. Install the ball check retaining
ring.
1. If the throttle plates and shafts 8. Place the accelerator pump
are removed, slide· the primary throttle discharge needle into the pump discharge
return spring (coiled clockwise) on the cavity.
primary throttle shaft (flat milled) and
slide the shaft into the primary shaft holes AIR HORN
SECQoiDARY PRIMARY THROTTLE'
THROTTLE PLATES SHAFT AND LEVER (mixture needle side of body).
ASSEMBLY 2. Position the primary throttle 1. Install the components removed
plates (smaller diameter) in the primary from the air horn in the following order:
FIG. 28- Throttle Body- Bottom View
bores with the ground flat edge of the a. Power valve and gasket.
THROTTLE BODY plates facing up and towards the idle b. Auxiliary fuel inlet valve and
tnix ture needles. Install the plate retaining gasket.
screws snug but not tight. 2. Assemble the accelerator pump
Do not remove the idle mixture
plunger (Fig. 30) and insert into air horn.
limiter caps or the mixture screws from
3. Rotate the throttle shaft to the 3. ·compress the pump plunger and
the throttle body.
closed position and tap the plate lightly insert accelerator pump arm into plunger
1. Remove the throttle body to
with the end of a screw driver handle or stem.
main body screws from the bottom of the similar tool, so that the plates are pro-
throttle body (Fig. 28) and separate the Insert the split pivot pin through the
perly and fully seated in the throttle specified hole in the lever and the air horn
two castings. bores (when viewed with a light behind
2. Remove the choke housing cover casting.
the plates, little or no light should be
screws, cover, gaskets and thermostatic 4. If the choke plate and shaft were
observed). Tighten the throttle plate
spring. removed, slide the choke shaft through the
screws.
3. Remove the choke piston lever holes in the air horn. Install the choke
retaining screw, then remove the piston 4. Install the secondary throttle lock shaft lever on the end of the shaft on the
assembly. out lever. automatic choke side. The lever and shaft
4. Remove the retainers from the are tapered and the attaching screw has a
secondary throttle lever to primary 5. Install the fast idle speed lever left hand thread.
throttle connecting link, then remove the and adjusting screw. Insert the choke plate into the slot in
link. the choke shaft and install the plate
5. If it is necessary to remove the 6. If the fast idle cam and bushing retaining screws snug but not tight.
throttle plates or shafts from the throttle were removed, insert the automatic choke 5. Close the choke plate and gently
body, remove the staking marks on the shaft bushing tlwough the choke housing. tap the plate with the end of a screw
throttle plate attaching screws. Remove Position the fast idle cam between the driver or a similar tool to properly
tlie screws and remove the plates. choke housing and bushing column. Slide position the plate in the air horn.
PART 10-5 MOTORCRAFT MODEL 4300 CARBURETTOR 10-61
ACCELERATOR PUMP LINK-9529

PUMP CONTROL ROD - 9B542

RETAINER- 377918-S ~
AIR VALVE DAMPENER LEVER-9H582~
~.
PIN-9H584 ~ .~

9B544

AUXILIARY (SUPPLEMENTAL) VALVE ASSEMBLY -9564

a--""""'"' ""'' """"

fa 1
-----1
ACCELERATING PUMP PISTON CUP-95n

FLOAT AND LEVER ASSEMBLY-9550

PRIMARY THROTTLE SHAFT

AND LEVER ASSEMBLY-9581
MAIN BODY (SERVICED IN 9510 ASSEMBLY)

SECONDARY
THROTTLE

SECOI'()ARY THROTTLE
SHAFT AND LEVER-9A592

I
SECONDARY THROTTLE
RETURN SPRING-9B504

THROTTLE BODY AND CHOKE HOUSING-9518 ond 34937-S V1154-B

FIG. 29- Model4300 4-V

Carburetor Assembly
10-62 GROUP 10- FUEL SYSTEM

rod through air horn and attach the rod

end to ·the air valve lever.
12. Insert the accelerating pump
bleed disc into the pump bleed cavity.
13. Set the float lever (Refer to In
Vehicle Adjustments and Repairs).

AIR HORN TO
MAIN BODY

1. Position the main body to air

horn gasket on the main body.
2. Carefully position the air horn
FIG. 30- Accelerator Pump in Position assembly over the main body. Guide the
on Air Horn accelerator pump plunger and the
secondary throttle dashpot piston into
Tighten and stake the plate retaining position the plates in the air horn. their chambers as the air horn is gently
screws. Tighten and stake the plate retaining lowered into position.
6. If the air valve plates and shaft screws. Be sure the plates and shaft turn 3. Install the other air hom retaining
were removed, slide the shaft through the freely after assembly. screws.
holes on the secondary side of the air horn 8. Insert fuel inlet needle into the 4. Insert the key end of accelerator
and with the slotted end of the shaft in fuel inlet seat. pump control rod into the keyed hole in
the air valve spring chamber. 9. Position float and lever assembly the primary throttle lever. Insert the other
Position the plain air valve plate in the between hinge post and over fuel inlet end of the rod into the pump lever and
air horn opening on the underside of the valves. install retainer.
air horn and adjacent to the spring Insert the float hmge pin through the 5. Insert the choke control rod end
chamber. post and float lever. The pin must be into the automatic choke lever. With long
Install the plate retaining screws snug inserted from the pump plunger side for nose pliers, install the retaining clip.
but not tight. self-retention. 6. Check the choke gasket cover
Position the other air valve plate in 10. Insert key end of air valve clearance.
the air horn opening with the eye retainer dampener rod into keyed hole in the air 7. Install the choke gasket cover and
for the air valve control rod facing valve lever. retainer. Set the cover to the ninety (90)
upward. Slide other end of rod into eye on the degree rich position.
Install the plate retaining screws snug air valve pl.tte. 8. Check the fast idle cam clearance.
but not tight. Position the air valve dampener lever 9. Reset the choke cover to
7. Close the air valves plates and on the air horn and install pivot pin and spc:cifications.
lightly tap the plates with end of a retainer. 10. Remove the carburettor legs or
screwdriver or similar tool to properly 11. Insert the air valve dashpot piston bolts from the throttle body.
10-63

PART FUEL PUMP AND FUEL FILTER

10·6
Seetion Pqe Seetion Pap
1 Description and Operation 10-63 Fuel Pump Installation _ _ _ 10-64
2 Removal and Installation _ 10-64 3 Major Repair Operations _ _ _ 10-65
Fuel Filter Replacement - 10-64 AC Fuel Pump - 6-Cylinder Engines 10-65
Fuel Pump Removal - _ 10-64 Carter Permanently Sealed Fuel Pumps 10-66

D . DESCRIPTION AND OPERATION

Single action fuel pumps are stand· are mounted on the left-side of the and on the 250-2V engine.
ard equipment for all car models. cylinder front cover. A Carter permanently-sealed fuel
The fuel pumps on the 6-cylinder An AC type fuel pump (Fig. 1) pump ia used on the V -8 engines
engines are mounted on the lower, is used on the 200 and 250 Six en- (Fig. 2).
left-centre of the engine cylinder -- gines. (A Carter Permanently Sealed The fuel pumps are mechanically
block. Fuel pump is used on the 250 C.I.D. actuated by means of the fuel pump
On V -8 engines, the fuel pumps engine fitted with air-conditioning rocker arm and an eccentric on the
camshaft.

FIG. 2 -Typical Carter Sealed

Design Fuel Pump
A separate in-line fuel fllter (Fig.
3) is used on V-8 and 250-2V engines
and 250 engines fitted with air con-
ditioning. The fllter is of one-piece
construction and does not contain a

-
cleanable fllter element.
4 Q FILTER ASSEMBLY-9155

Tt tffT

FIG. 1- Fuel Pump Assembly FIG. 3- Typical In-Line Fuel

AC Type Filter Assembly- 351 C.I.D. Engine
10-64 GROUP 10- FUEL SYSTEM

A flexible fuel pump diaphragm is causes the pump inlet valve to close stationary until pressure against the
operated by a combination of rocker and the ensuing pressr.re build-up carburettor float is relieved by a de-
arm.action and calibrated spring ten- opens the outlet valve. The fuel is mand for fuel at the carburettor.
sion. then forced through the pump outlet
On the fuel intake stroke, the cam- to -.r:.: fuel filter where it is cleansed The A.C. type and the 8 cylinder
before entering the carburettor. Fuel Carter fuel pumps contain pressure·
shaft eccentric causes the rocker arm
to lift the fuel pump diaphragm is delivered to the carburettor relief orifices in the inlet and outlet
against the diaphragm spring pres- only when the fuel inlet valve in valve cages to prevent pressure build·
sure. This action draws fuel through the carburettor is open. The car- up in the line to the carburettor
the intake valve into the pump inlet burettor inlet valve is closed by during hot soak periods.
chamber and closes the outlet valve. fuel pressure on. the float when The Carter sealed fuel pump fitted
At the same time, fuel is drawn from the specified fuel level in the to 250-2V and 250 N (with air
the fuel tank through the fuel intake carburettor float chamber is conditioning) 6 cylinder engines have
line to replace the fuel drawn into reached. an external by-pass pressure relief.
the chamber. When there is no demand for fuel An air vent is located in the fuel
As the camshaft eccentric con- from the carburettor, the diaphragm pump bodies to relieve air pressure
tinues to rotate, the rocker arm re- spring tension is not strong enough build-up on the spring side of the
lieves the pressure on the diaphragm to force the diaphragm against the diaphragm.
spring and allows the spring to move fuel pressure built up in the inlet The fuel pumps contain a dia-
the diaphragm toward the inlet and chamber of the pump. Thus, the up phragm rod seal to prevent the en·
outlet valves, exerting pressure on and down rocker arm action con- trance of engine oil into the fuel
the fuel inlet chamber. This pressure tinues, but the diaphragm remains pump.

EJ REMOVAL AND INSTALLATION

fUEL FILTER REPLACEMENT
The in-line fu~·l filter (Fig. 3) is 4. Place the new filter in position 2. Remove the fuel pump retain-
of one-piece construction and cannot and tighten the flared union filter to ing screws and remove the pump and
be cleaned. Replace the filter if it carburetor. the gasket. Discard the gasket.
becomes clogged or restricted.
5. Tighten the flared union fuel
pipe to filter.
fUEL PUMP INSTALLATION
351 C.I.D. Engine 6. Start the engine and check for
l. Remove the air cleaner. fuel leaks. 1. If the fuel pump on a 200 or
7. Replace the air cleaner. 250 Six engine is to be replaced,
2. Loosen the retaining clamp
securing the fuel inlet hose to the transfer the fuel pump fitting(s) to
250-2V and 250 N (with air con- the new fuel pump.
filter and detach the hose from the ditioner) engines
fllter. Discard the clamp. 1. Loosen the clamp on the by- 2. Remove all the gasket material
3. Unscrew the fuel filter from pass hose at the filter and detach from the mounting pad and pump.
the carburettor. from filter . Apply oil-resistant sealer to both
4 . Screw the new filter into the 2. Hold hex part of filter to pre- sides of a new gasket. Position the
carburettor. vent filter from turning and unscrew new gasket on the pump flange and
5. Place a new clamp on the fuel flared union, fuel pipe to filter. hold the pump in position against
inlet hose and slide the hose onto the the mounting pad. Make sure the
filter. 3. Hold double female adaptor and rocker ann is ridinc on the camshaft
6. Position the hose clamp and unscrew flared union, fuel filter to eccentric.
crimp securely. double female adaptor.
7. Start the engine and check for 4. Remove in-line filter. 3. Press the pump tight against
fuel leaks. 5 • Place a new filter in position and the pad, install the retaining screws,
8. Replace the air cleaner. screw top and bottom flared unions and alternately torque them to speci-
to retain filter by holding hex. on fications.
filter and hex on double female
302 C.I.D. Engine adaptor, respective1y. 4. Connect the fuel inlet line or
l. Remove the air cleaner. hose (use a new clamp on the hose)
2. Hold the hexagonal part of the 7. Replace the by-pass hose. and the outlet line. If a hose is used
fllter and unscrew the flared union at the fuel pump connection, crimp
fuel pipe to filter . 8 • Start the Engine and check for the retaining clamp securely.
3. Hold the hexagonal female fuel leaks.
union on the carburetor and unscrew fUEL PUMP REMOVAL
the flared union fllter to carburetor. 1. Disconnect the inlet line and 5. Operate the engine and check
Discard the filter. the outlet line at the fuel pump. for fuel leaks.
PART 10-6- Fuel Pump and Filter 10-65
EJ MAJOR REPAIR OPERATIONS

AC FUEL PUMP- 11. · Position the valve body and

6-CYLINDER ENGINES pump body so that the previously
scribed marks are aligned.
ll. Install all the screws and the
DISASSEMBLY lockwashers until the screws just en-
The fuel pump assembly is shown gage the fuel pump body. Make sure
in Fig. 1. that all of the screws pass through
1. Scribe a line on the flanges of the holes in the diaphragm without
the pump body and valve housing to tearing the fabric.
identify their original position.
2. Remove the valve housing from
the fuel pump body.
3. Remove the staking marks from
around the valves, remove both FIG. 5-fuel Pump Diaplwagm
valves from t)le valve housing. Care- Remowal
fuDy note the position of the valves
in the valve housing cover so that
new valves can be correctly instaUed. ASSEMBLY
f. Using a blunt punch, drive the 1. Immerse the new oil seal in
rocker arm pin out of the pump body clean engine oil for 2 minutes prior
(Fig. 4) . to installation. Install the diaphragm
actuating rod oil seal and retainer so
5. Press the pump diaphragm into that the seal protrudes towards the
the fuel pump body and pull the diaphragm mounting flange (Fig. 1).
rocker arm outward to unhook the
diaphragm actuating rod from the 2. Seat the oil seal retainer. FIG. 6-Valve Arrange-
rocker arm and link assembly (Fig. 3. Install the valves in the valve
5). body so that the valve positions are ment A. C. Fuel Pump
6. Remove the diaphragm and dia- as shown in Fig. 1.
phragm return spring, rocker arm 4. Seat the valves firmly in the 13. Alternately and evenly tighten
and link assembly, and the rocker valve body. Stake the valves in place. all of the screws.
arm return spring from the pump
5. Lubricate the diaphragm actu- 14. Cover all but one vent hole
body. in the pump lower body, using mask-
ating rod.
7. Remove the diaphragm actua~­ 6. Position the fuel pump dia- ing tape or a similar material.
ing rod oil seal retainer and the oil phragm and spring assembly into the 15. Using a suitable vacuum
seal from the pump body (Fig. 1). pump body. source, apply 15 inches of vacuum
Tool- T56L-9 350-A 7. Hold the diaphragm as!lembly (Hg) to the underside of the pump
Detoil 3 diaphragm at the open vent hole.
in the pump body; position the pump
body so that the mounting flange Use a suitable rubber tipped probe
faces up. Apply slightly more pres- or hose to assure proper sealing at
sure to the lower edge of the dia- the vent bole. Apply vacuum to the
phragm, and insert the rocker arm diaphragm 2 times for a minimum
link assembly with the cam shoe of one minute each time. This will
facing away from the diaphragm. position the oil seal properly on the
Hook the rocker arm link to the diaphragm rod. Remove the sealing
diaphragm actuating rod. tape from the vents.
8. Lift one edge of the diaphragm
and observe the positioning of the
oil seal.
If the oil seal is not properly posi-
tioned, push the diaphragm into the
pump body as far as possible with a
slight twisting motion to the dia-
ROCKER ARM PIN
phragm. This wilf as ;ist the oil seal to
position itself propt rly on the dia-
FIG. 4-Rocker Arm Pin phragm rod. Do not twist the dia-
Remowal phragm too severely or the rod may
be unhooked from the link.
9. Install the rocker arm return
CLEANING AND INSPECI10N spring and hold it in place by cock-
ing the rocker arm slightly.
Refer to Pageto-nfor the cleaning 10. Install the rocker arm pin in FIG. 7 -Rocker Arm Pin Seal
and inspection procedures. the pump body. Plug Removal
10-66 GROUP 10- FUEL SYSTEM

CARTER PERMANENnY
SEALED FUEL PUMPS
DISASSEMBLY CLEANING AND INSPECfJON
The fuel pump assembly is shown Clean and inspect the fuel pump 2. Insert the rocker arm into the
in Fig. 2. component parts. Refer to Cleaning cavity and hook it onto the dia-
1. Scrape away the staking mark and Inspection (Pagelo-13) for the phragm rod, directly below the rod
and remove the rocker arm pin seal proper procedure. Replace all worn ftange. Position the rocker arm
plug as shown in Fig. 7. or damaged parts. spring(s) over the spring locater(s)
on the rocker arm. Align the rocker
2. Release the tension on the arm pin holes and install the rocker
rocker arm spring pressure ~nd al- arm pin. Make certain the rocker
low the rocker arm pin to fall out. If ASSEMBLY
The fuel pump assembly is shown ann spring(s) Is properly posldoned
the pin does not come out freely, tap on the spring locater on the rocker
the fuel pump assembly lightly on in Fig. 2.
1. Insert the rocker arm spring arm.
the bench until the pin sticks out of
the bore; then, remove the pin with into the spring guide bore in the
pliers. Remove the rocker arm and dome of the fuel pump rocker arm 3. Install a new rocker arm pin
spring(s). cavity. plug. Stake the plug into position.
10-67

PART AIR CLEANERS

10·7
Section Pare Section Pap
1 Description and Operation . . . . . . . . . . . . 10-67 Removal . . . . . . . . . . . . . . . . . . . . 10-67
2 Removal and Installation . . . . . . . . 10•67 Cleaning and Inspection . . . . . . . . 10-67
Air Cleaner Maintenance . . . . . . 10-67 Installation . . . . . . . . . . . . . . . . . . 10-67

D GENERAL
All engines are equipped with mounted on a sealing gasket located Note: A heavy duty air cleaner
conventional dry-type air cleaners on the carburetor air horn. The air package which fits over the existing
that have a replaceable filtering cleaner assembly is retained on the filtering element is available for the
element. The air cleaner body is engine 'by a stud on the carburetor 6-cylinder engine.
body and a wing nut above the filter
cover.

EJ AIR CLEANER - 6 CYLINDER AND 302 VS

DESCRIPTION AND OPERATION
OPERATION
DESCRIPTION the air cleaner base for the 302 CID Air from the engine compartment
The air cleaners, as fitted to the engine, whilst being similar to the enters the air cleaner assembly
6-cylinder 200 and 250 IV engines air cleaner as fitted to the 6-cylinder through the opening into a silencing
and the 302-V8 engine, are basically engines, is not interchangeable. chamber and passes through the filter
of the same design. The air cleaner The 250-2V engine has a unique element. Dust particles are trapped
tops and filter assemblies are inter- air cleaner with a peripheral air in the filter element as the air
changeable between engines; however, intake. passes through it. After leaving the
filter element, the air is deflected
down into the carburettor.
REMOVAL AND INSTALLATION
AIR CLEANER MAINTENANCE be removed when the air cleaner 2. Position the air cleaner body
Refer to Group 19 for the air body is mounted on the car- on the carburettor, ensuring that the
cleaner assembly recommended burettor. body is properly seated on the gasket
maintenance mileage interval. 3. Remove the air cleaner cover and located correctly on the car-
and filter element. Discard the air burettor.
REMOVAL cleaner mounting gasket if it is
1. Remove the wing nut retaining excessively worn or damaged. 3. Place the filter element on the
the air cleaner assembly to the car- 4. Inspect the air cleaner filter as air cleaner body. Make sure the
burettor. :lescribed on page 10-13. filter is properly seated. The word
2. Remove the air cleaner ass.!mbly INSTALLATION TOP is indicated on the filter element,
from the carburettor. To prevent 1. Install a new air cleaner mount- make sure the word TOP faces up.
dirt from entering the carburet- ing gasket on the carburettor if Install the cover and tighten the
tor, the filter element must never req\lired. retaining wing nut.
10-68 GROUP 10- FUEL SYSTEM

EJ HOT AND COLD TYPE AIR INTAKE SYSTEM - VACUUM OPERATED

DESCRIPTION AND OPERATION
DESCRIPTION DUCT AND VALVE 3. Raise the air cleaner and duct
The air cleaners as fitted to the ASSEMBLY TEST assembly and disconnect the vacuum
351C-2V and 351C-4V engines are The vacuum-operated duct valve source hose at the bi-metal control
basically the same design, with the is used on all 351 C engines. valve (inlet manifold side only).
filter elements being interchangeable.
The air cleaners feature inlet mani- 1. The duct valve should be open 4. Remove the air cleaner and
fold vacuum operated, bi-metallic when the engine is off. duct assembly from the carburettor:
switch controlled (Fig. 1), hot and 2. Start the engine. The valve To prevent dirt from entering the
cold type duct and valve assembly. should close during engine idle unless carburettor, the filter element must
The duct and valve assembly in- the engine has reached normal operat- never be removed when the air
corporates an access to the under- ing temperature. If the engine is cold cleaner body is mounted on the
hood area (cold), similar to the con- and the valve does not close during carburettor.
ventional type air filter, and has in idle, check for disconnected vacuum
addition an access connected by lines to the vacuum motor and bi- 5. Remove the air cleaner cover
means of a flexible pipe to the front metal switch. Check the bi-metal and filter element. Discard the air
of the exhaust manifold housing switch to see that the bleed valve is cleaner mounting gasket if it is exten-
(hot). seated. sively worn or damaged. On the ram
3. Open and close the throttle air system, inspect the hood-to-air
rapidly. The valve should open dur- cleaner seal for all-around contact.
ing throttle opening. If the valve does Replace the gasket or seal if it is
OPERATION worn or damaged.
From initial cold engine start, high not function properly, check for a
inlet manifold vacuum/air pressure binding condition at the valve. CLEANING AND INSPECTION
difference overcomes the duct butter- Correct as required. Refer to Pagel0-13, for the car-
fly spring tension and closes the duct 4. The bi-metal switch can be buretor air cleaner and filter element
cold access opening and opens the functionally checked by subjecting cleaning and inspection procedure.
hot access (from exhaust manifold) the switch to heated air or removing
opening, as shown in Fig. 2 (A). As and immersing the switch in water INSTALLATION
the engine warms, the resi.Iltani hot heated to 105-110 degrees F. Only 1. Install a new air cleaner to car-
air flowing through the air cleaner slight movement of the bi-metal is burettor mounting gasket, if required.
causes the thermal-operated bi-metal necessary to unseat the bleed valve. On all351 C.I.D. carburettor applica-
switch (Fig. 1) to unseat the bleed tions, torque the air cleaner
valve which 'bleeds' vacuum from mounting stud to specification.
the duct valve. The reduced vacuum/ 2. Position the air cleaner and air
air pressure difference is overcome intake duct and valve assembly on the
by the spring in the duct valve which carburettor and shroud tube.
pens the cold access (under hood) VACUUM OFF 3. Connect the vacuum source
and closes the hot access (Fig. 2 (B)). hose at the bi-metal control valve.
Incoming air is filtered through Secure the clamp attaching the
the filtering element as with the shroud to the air duct.
conventional dry type air cleaner. 4. Install a new filter element in
the air cleaner body, if required. If
the word TOP is indicated on
the filter element, make sure the
VACUUM ON word TOP faces upward. Make
sure the filter element is pro-
FIG. 2- Duct and Valve Assembly perly seated. Install the air cleaner
cover and retaining wing nut
HOT AND COLD TYPE VACUUM HOT AND COLD AIR INTAKE
OPERA TED AIR CLEANER DUCT AND VALVE ASSEMBLY
REMOVAL
Removal and Installation 1. Remove the retaining cap screws
Refer to Group 19 for the air that secure the air intake duet and
cleaner assembly recommended valve assembly to the air cleaner.
maintenance mileage interval. 2. Remove the air intake duct and
REMOVAL valve assembly from the engine.
1. Remove the wing bolt or nut INSTALLATION
retaining the air cleaner and duct to 1. Install the air intake duct and
the carburettor and remove cover. valve assembly on the exhaust mani-
TO VACUUM SOURCE TO DUCT VALVE 2. Disconnect the crankcase venti- fold shroud tube.
MOTOR V1231-A lation system hose and loosen the 2. Connect the air inlet duct and
clamp that secures the exhaust valve assembly to the air cleaner and
FIG. 1.- Bi- Metal Switch shroud hose to the air cleaner duct. tighten the retaining cap screws.
10-69

PART FUEL TANK AND LINES

10-8
Section Paae Section Paae
1 Description and Operation . . . ... . .. . ...... 10-69 Fuel Tank ... . ............ . ... .. ..... . . 10- 70
2 Removal and Installation .. . ...... . ...... 10-69 Fuel Lines .... . ..... . . .. ..... . . . ....... 10- 70
Filler Pipe .... .... .. . .. .. . ... . ........ 10· 69

0 DESCRIPTION AND OPERATION

The fuel tanks used on the sedan moving the fuel tank cover set into the left-hand body side lower.
and station wagon models are located the floor of the carrying compartment. The fuel tank filler pipe on all
in the cehtre of the rear (luggage The fuel outlet line is fastened to models is attached to the tank inlet
compartment) floor and are retained a connecting hose that is attached pipe with a hose and hose clamps.
to the floor by screws. The fuel to a line which enters the fuel tank The fuel line, -{,; in. o.d. tube
tanks used on the utility and van through the sender unit assembly. (except for the 351C engine, which
models are located underneath the A filter is located in the tank on the has i in. o.d. tube) is routed from
floor behind the seat and are retained fuel line pick-up tube. THIS FIL- the fuel tank, passing beneath the
by retaining straps. TER DOES NOT REQUIRE SER- left side of the underbody; then,
The fuel tank sender unit for the VICING. under the left fender and through the
sedan and station wagon models is forward part of the fender apron.
accessible from underneath the car. The fuel tank filler pipe on the
sedan and wagon is located in the The complete fuel line is not norm-
The fuel tank sender unit for the left rear quarter panel. On the utility ally replaced as a unit, only the dam-
van and utility is accessible by re- and van the filler pipe is located on aged segments are usually replaced.

EJ REMOVAL AND INSTALLATION

FILLER PIPE install the siphoned fuel back in the 7. Pull the lower hose from the
fuel tank. fuel tank inlet.
SEDAN Installation
Removal FILLER PIPE - STATION WAGON
1. Drain the fuel tank with a 1. Place the lower hose on the
The station wagon has an upper fuel tank inlet. Position the hose
siphon to a level below the filler pipe filler pipe and hose and a lower filler
opening in the tank. The fuel should clamps.
pipe and hose. See Fig. 2.
be drained into a suitable clean 2. Place the lower filler pipe in
container. Removal position in the body side member and
2. Remove the retaining screws fit the two large grommets. Work the
securing the filler pipe to the body I. Drain the fuel tank to a level pipe into the lower hose.
panel. below the filler pipe opening in the 3. Working through the quartci·
3. Loosen the hose clamp and fuel tank. panel access hole fit the upper hose
loosen the hose from the filler pipe. 2. Remove the inside quarter trim to the lower filler pipe.
4. Rotate the filler pipe and pull panel and loosen the upper hose 4. Place a 3/ 16" bead of sealer on
it outward to remove it from the fuel clamp. body panel opening and insert the
tank. 3. Remove the filler ca-p and the upper filler pipe through the ~ody
Installation filler pipe retaining screws. panel.
1. If necessary install new hose 4·. Pull the upper filler pipe Work the pipe into the upper hose.
clamps on the filler pipe hose. through the body. 6. Replace and tighten the filler
2. Place a bead of sealer on the 5. Lift the floor panel to gain pipe flange screws.
filler pipe flange. access to the spare wheel well and 7. Tighten all hose clamps.
3. Position the filler pipe in the loosen the clamps on the lower filler 8. Lower the spare wheel cover
body panel and slide the hose onto pipe hose.
the filler pipe. panel and replace the quarter trim
6. Prise the two large rubber panel.
4. Install and tighten the filler grommets from the floor member 9. Place the siphoned fuel back in
pipe retaining screws. and extract the lower filler pipe the fuel tank and replace the filler
5. Tighten the hose clamp and through the quarter panel access hole. cap.
10-70 GROUP 10- FUEL SYSTEM

FUEL TANK- STATION WAGON 4. Loosen the hose clamp, slide They must be cut, squared and
Removal the clamp forvard and disconnect formed out of rolls of fuel system
the fuel line at the fuel gauge service tubing and hose material
1. Siphon the fuel from the fuel sending unit. available at dealershipf>.
tank into a suitable container. 5. If the fuel gauge sending unit A damaged section of tubing
2. Remove the cargo compartment is to be removed, turn the unit retain- longer than 12 inches can be cut out
mat, spare wheel cover panel and the ing ring counterclockwise and remove of the existing line and replaced by a
spare wheel. the sending unit retaining ring and comparable service tubing section,
3. Disconnect the fuel gauge send- gasket. spliced into the line by means of con-
ing unit wire at the sending unit. 6. Loosen the clamps on the fuel necting hoses and retaining clamps.
4. Loosen the hose clamp, slide filler pipe rubber hose and remove A damaged section of tubing short-
the clamp forward and disconnect the hose from the filler tank inlet. er than 12 inches can be cut out of
the fuel line at the fuel gauge 7. Loosen the vent pipe hose the line and replaced by a length of
sending unit. clamp at the tank and move pipe service hose and two retaining
5. If the fuel gauge sending unit clear of the tank. clamps. All replacement hoses
is to be removed, turn the unit re- 8. Remove the tank retaining must be cut to a length that will
taining ring counterclockwise and screws and lift out the tank. ensure proper clamp retention
remove the sending unit retaining. beyond the flared ends of the
ring and gasket. connecting tubing.
6. Loosen the inlet pipe to tank Installation
connecting hose clamps and pull the 1. Place the fuel tank in position,
hose clear of the tank inlet pipe. install and tighten the retaining
screws. _
7. Remove the fuel tank to floor 2. Refit the rubber hose to the REMOVAL
pan retaining screws and remove the fuel tank inlet and tighten the clamps. 1. Drain the fuel from the tank.
fuel tank. 3. If the fuel gauge sending unit 2. Disconnect the line at the fuel
Installation was removed, make sure all the old gauge sender unit and the fuel pump.
1. Make sure all the old sealer has gasket material has been removed Remove the lines from the holding
been removed from the fuel tank from the unit mounting surface on clips along the underbody. Remove
mounting flange and mounting sur- the fuel tank. all damaged hose sections and tube
face at the floor pan. Apply caulking Using a new gasket, position the sections.
cord to the fuel tank mounting sending unit to the fuel tank and
secure with the retaining ring. INSTALLATION
surface at the floor pan. 1. Cut a new section of tubing to
2. Position the fuel tank to the 4. Connect the fuel gauge sending
umt wire to the sending unit. approximately the same length as the
floor pan and install the retaining section to be replaced. Allow eztra
screws. 5. Connect the fuel line at the
fuel gauge sending unit and tighten length for flaring the ends of the
3. Position the hose to the fuel tubing. Square the ends of the cut
tank inlet pipe and tighten the hose the clamps securely.
tubing with a file.
clamps. 6. Fill the tank and check all 2. Ream the inside edges of the
4. If the fuel gauge sending unit connections for leaks. cut tubing with the reamer blade on
was removed, make sure all the old 7. Replace the fuel tank cover in the tube cutter. Be sure metal
gasket material has been removed the floor of the carrying compartment. chips are removed from inside
from the unit mounting surface on the tube(s). Flare the ends of the
the fuel tank. Using a new gasket, cut tubing, as required, with a stan-
position the fuel gauge to the fuel dard tube flaring kit and tool (Fig. 5).
tank and secure with the retaining 3. Bend the tube section to con-
ring. form to the contour of the original
5. Connect the fuel gauge sending tube. Cut an ample length of hose
unit wire to the sending unit. to form a coupling between the flared
6. Connect the fuel line at the fuel ends of the fuel lines. Connect the
gauge sending unit and tighten the hose couplings to the tubing and
hose clamps securely. install the retaining clamps.
7. Fill the tank and check all 4. Position the lines in the under-
connections for leaks. body clips and tighten the clips.
8. Replace the spare wheel cover Connect the line to the fuel gauge
panel and the cargo compartment sender unit and the fuel pump. Fill
mat. the tank and check for leaks.
FUEL TANK UTE AND VAN FILLER PIPE
Removal UTILITY AND VAN
1. Siphon the fuel from the fuel 11917-A
tank into a suitable container. FIG. 5-Fuel Line Tube Die The utility and van have an upper
2. Remove the fuel tank cover set filler pipe and hose and a lower filler
into the floor of the carrying com- pipe and hose. In addition they both
FUEL LINES have an external vent pipe between
partment.
3. Disconnect the fuel gauge send- The various fuel lines (Figs. 1, 2, 3 the fuel tank and the upper ftller pipe.
ing unit wire at the sending unit. & 4) are not serviced as a~semblies. See Fig. 3.
PART 10-8-FUEL TANK AND LINES 10-71

Removal 6. Tighten all hose clamps. Installation

1. Drain the fuel tank to a level 7. Replace the floor panel and the 1. Make sure all the old sealer has
below the filler pipe opening iu th e body access panel. been removed from the fuel tank
fuel tank. 8. Replace the siphoned fuel in mounting flange and mounting sur-
2. Remove the floor panel in the the fuel tank and fit the filler cap. face at the luggage compartment
cargo area. floor pan. Apply caulking cord to the
3. Remove the body side access FUEL TANK fuel tank mounting surface at the
panel behind the filler pipe. The fuel tank installations are luggage compartment floor pan.
shown in Figs. 1, 2, 3 and 4. 2. Position the fuel tank to the
4. Remove the vent pipe to filler luggage compartment floor pan and
pipe hose . install the retaining screws. .
5. Loosen the filler pipe hose SEDAN 3. Place a 3/16" bead of sealer
clamps. Removal around the filler neck flange . Position
6. Remove the filler pipe retaining 1. Siphon the fuel from the fuel the hose and filler neck assembly to
screws. tank into a suitable container. the body panel. Position the hose to
7. Remove the upper filler pipe 2. Disconnect the fuel gauge send- the fuel tank neck.
through the body opening. ing unit wire at the sending unit. 4. Install the filler neck to body
8. Remove the lower filler pipe 3. Loosen the hose clamp, slide panel retaining screws and tighten
and hoses through the body access the clamp forward and disconnect the hose clamps.
hole. The vent pipe may also be the fuel line at the fuel gauge 5. If the fuel gauge sending unit
removed through the access hole if sending unit. was removed, make sure all the old
desired . 4. If the fuel gauge sending unit gasket material has been removed
is to be removed, turn the unit re- from the unit mounting surface on
Installation the fuel tank. Using a new gasket,
taining ring cmmterclockwise and
1. Place the lower hose and clamps remove the sending unit retaining position the sending unit to the fuel
on the fuel tank inlet. ring anq gasket. tank and secure with the retaining
2. Insert the lower filler pipe ring.
through the access hole and into the 5. Remove the spare tyre from the 6. Install the spare tyre and posi-
lower hose. luggage compartment. tion the luggage compartment floor
3. Place the upper hose and 6. Remove the fuel tank filler neck mat.
cla~ps on the lower pipe. retaining screws. 7. Connect the fuel gauge sending
4. Place a 3/16" bead of sealer on unit wire to the sending unit.
7. Loosen the filler neck to tank 8. Connect the fuel line at the
the filler pipe flange and insert the
hose clamps. Remove the filler neck, fuel gauge sending unit and tighten
pipe through the body opening. Work
the pipe into the upper hose and and filler neck to tank hose. the hose clamps securely.
install the flange retaining screws. 9. Remove the safety stands and
8 Remove the fuel tank to luggage lower the car.
5. Connect the vent pipe to the compartment floor pan retaining
upper filler pipe. 10. Fill the tank and check all
screws and remove the fuel t~k. connections for leaks.
10-72

PART SPECIFICATIONS
10-9
CARBURETTORS NOTE: All Specifications are given in inches unless otherwise noted.
The basic part number of all the carburettors is 9510. Always refer to the Master Parts Catalogue for parts
The part number prefix and suffix appear on the usage and interchangeability before rep I acing a carb-
identification tag mounted on the carburettor. urettor or a component part of a carburettor.
Carburettor Application and General Information.

200 and 250 IV Six Engines STANDARD AND AUTOMATIC TRANSMISSIONS

200 C.I.D. 250 C.I.D.

Carburettor Model Stromberg 8V2 Stromberg 80V2
Identification (Rubber Stamp on Float Chamber)-Manual (Auto) 200 8 (200 A) 250 8 (250 A)
Venturi diameter 1-5/32 1-9/32
Main discharge jet 28-25 28-25
High speed bleeder No. 70 No. 70
Main metering jet .058 .067
Power bypass jet No. 55 2 X No. 54
Pump discharg·e jet No. 67 No. 67
Idle discharge hole No. 55 No. 55
Idle tube feed hole No. 71 No. 67
Idle air bleed 0.049 0.051
Float-needle valve seat 0.073 0.073
Main metering jet for high altitudes
over 4,000 ft. 0.05 0.064

Fuel level below top face of main body at 500 rpm 5/8" -11 /16" 5/8" -11 /16"

*Accelerating Pump Stroke- Manual Transmission .275-.310 .275-.310

-Auto. Transmission .190-.225 .190-.225
Choke plate pull down clearance .090-.100 .190-. 200
*Vent valve lift .050-.060 .050-.060
Engine Idle Speeds -Manual 575-600rpm 575-600 rpm
-Auto. 500-525 rpm 500-525 rpm
(Air conditioning operating if
equipped and headlights on high beam)

* Measured from _vehicle idle position. not fully closed throttle.

NOTE: Original idle limiter cap colour red- Service replacement cap colour black.
PART 10-9- SPECIFICATIONS 10-73

Bendix Stromberg WW2 250 C.I ,D. 302 C.I.D.

Manual and Auto Manual and Auto
Identification - Rubber Stamp on Float Chamber 250M cv
CARBURETTOR SIZE
Throttle Bore Diameter 1 -7/16 1-7/16
Venturi Diameter 1-3/16 1-3/16
FUEL INLET SYSTEM
Float Level Setting (Wet) 19/32-21/32 19/32-21/32
Float Chamber Vent Lift (at Hot Idle Setting) .050-.080 .050- .080
IDLE SYSTEM
Idle tube No. 59 No. 69
MAIN FUEL SYSTEM
Main Jet .052 .051
High Speed Bleed No. 70 No. 70
Power Jet-1st Stage .028 .032
-2nd Stage .067 .059
Power Jet Operation-1st Stage 12-10 Ins. Vac. 12-10 Ins. Vac.
-2nd Stage 7-3 Ins. Vac. 12-10 Ins. Vac.
PUMP SYSTEM Pump link position Lower hole Lower hole
Accelerator Pump Shot/1 0 Strokes (cc.) 14-18 14-18
AUTOMATIC CHOKE SETTINGS
Thermostat Cover Index Mean Mean
Thermostat Lever 1.094 1.094
Modulator .03 .03
Vacuum Kick .160 .150
Cam Index .160 .160
Wide open Throttle Kick .250 .250
TUNE-UP SPECIFICATIONS Auto 500-525 475-500
Engine Idle Speed RPM Manual 575-600 525-550
(Air Conditioning Operating if Equipped
and Head Lights on High Beam) Manual 1350 1150
Fast Idle RPM- Kick Down Step Auto 1450 1350

NOTE :-Idle tubes must be removed before removing main discharge tubes or jets are ruined.
NOTE: Original idle limiter cap colour red- Service replacement cap colour black.
10-74 GROUP 10- FUEL SYSTEM

MOTORCRAFT Model 2100-0 2-V Carburettor

Carburetor Number (95101 DOO~:_AAuto 1 F- ~AA Manual

B18F-
CARBURETOR SIZE
Throttle Bore Diameter 1.68 1.68
Venturi diameter 1.23 1.21
Air Flow (cfml 351 351

FUEL INLET SYSTEM

Fuel Level (Wetl ± 1/32 13/16 13/16
Float Setting (Dryl ± 1/32 7/16 7/16

FUEL BOWL VENTS

Internal (21 0.400 (}.400

IDLE SYSTEM
Idle Jet 0.031 0.028
Idle Bleed 0 .110 0.110
Idle Channel Restriction 0 .052 0.046
Idle Discharge Port 0 .089 0.089
Idle Transfer Slot 0.030-0.200 O.OJQ-0.200
Support Identification SA CCB
MAIN FUEL SYSTEM
Main Metering Jet 54F 61F
High Speed Bleed 0.038 0.38
Anti-Syphon Bleed 0.031 .100
Power Jet 0 .037 0.045
Power Valve Timing (ln. Hg.l 8 .5 7.5
Power Valve Identification Plain Green
Air Distribution Plate Yes Yes
Spark Port 0.050 0.05X 0.085
PUMP SYSTEM
Rod Position - Overtravel Lever No.4 No.3
Pump Lever B-lnboard Inboard
Capacity/1 0 Strokes 23.28 2Q-25
Pump Jet Diameter 0 .031 0.031
Pump Bleed 0.012 0.012
Pump Weight Steel Alum.
CHOKE SYSTEM
Bi-metal & Cap Identification TB4 TB3
Cap Setting 1 Rich Index
Pull down Setting ± .010 .16-.18 0.240
Idle Cam Clearance . 14-.16 0.210
Dechoke (Minimuml 0.060 0.060
Choke Air Restriction 0.076 0.093
Cam Identification B B

DASH POT
Adjustment - If equipped
± 1/64 1/8 1/8

IDLE SPEED
Idle rpm• 550-575 575 500•
Fast Idle rpm - Kickdown Step 1500 1500
TORQUE REQUIREMENT
Air Cleaner Anchor Screw 11-16 Ft.lbs. 11-16 Ft.lbs.

• Head lamps On - Air Conditioning On (If equipped I

NOTE: Original idle limiter cap colour white- Service replacement cap colour blue.
PART 10-9. SPECIFICATIONS 10-75

MOTORCRAFT Model 4300 4-V Carburettor

888~ =~~ (Manual) '

1
Carburetor Number (9510) DOOF - AC (Auto)
CARBURETOR SIZE
Throttle Bore Diameter - Primary 1.560 1.560
-Secondary 1.690 1.690
Venturi Diameter - Primary 1.250 1.250
Air Flow (cfm) 600 600

FUEL INLET SYSTEM

Float Setting ± 1/32 79-.85 . 79-.85
Supplemental (Aux i liary) Valve
Setting ± 1 /64 1/16 1/16

FUEL BOWL VENTS

Internal (2) 7/32 7/32

IDLE SYSTEM
Idle Jet 0.026 0.026
Idle Bleed - 1st 0.046 0.055
-2nd None None
-3rd None None
Idle Channel Restriction None None
Idle Discharge Port 0.082 0.082
Idle Transfer Slot 0.028 0.028
MAIN FUEL SYSTEM
Main Metering Jet- Primary 61F 62F
-Secondary 0.128 0.128
High Speed Bleed - Primary 0.031 0.035
-Secondary 0.024 0.024
Anti Syphon Bleed - Primary
- Secondary 0.022 0.022
Power Valve Jet 0.059 0.059
Power Valve Timing- ln. Hg. 7.5-8.5 6-7
Air Valve Spring Color Yellow Yellow
Soark Port 0.065 0.065
PUMP SYSTEM
Lever Position (Hole Number) 2 2
Capacity/1 0 Strokes - cc ± 2cc 15 18-8
Pump Jet 0.028 0 .028
Pump Stem Height± 0.020 0.425 0.425
Pump Spring Color Plain Plain

CHOKE SYSTEM
Bi-metal and Cap Identification 4TY 4TX
Cap Setting Index Index
Pulldown Setting .180 .200
Fast Idle Cam Setting .160 .180
Piston and Link Identification No .2 No.2
Dechoke (Minimum) 0.300 0.300
Choke Air Restriction 0.078 0.078
Cam Identification K K

DASH POT
Adjustment (If Equipped) 0.080 0.080

IDLE SPEED 650 675

600
550 575
550
.
Idle rpm*
Fast Idle rprn 1250 1400

• Headlights on High beam- Air Conditioning on (if equipped)

NOTE: Original idle limiter cap colour white- Service replacement cap colour blue.
10-76 GROUP 10- FUEL SYSTEM

CARBURETTOR AIR CLEANERS

Engme Application Color /Description Type

351 C-4V (GT) Blue Dry
351 C-2V Blue Dry
302 C.I.D. VB Blue Dry
200 & 250 C.I.D. IV Blue Dry
250 2V Orange Dry

MECHANICAL FUEL PUMPS

Fuel Pump Static Pressure-Psi @ 500 Engine rpm

8 Cyl. 4-6 6 Cyl. 3.5-5.0
Minimum Fuel Pump Volume-Flow@ 500 Engine
rpm
All 6-Cyl. 1 pint in 36 seconds
8-Cyl. 1 pint in 24 seconds
Minimum Intake Static Vacuum - Inches of
Mercury@ 500 Engine rpm
All . 6.0
Eccentric Total Lift
All 6-Cyl. 0.290-0.310
8-Cyl. 0.690-0.710

Fuel Tank Capacities

Sedan (incl. GT) 17.5 IMP. GALLONS

Station Wagon 16.0 IMP. GALLONS
Utility and Van 16.0 IMP. GALLONS
(RPO-GT only) 30.0 IMP. GALLONS
FALCON FAIRLANE w~:~~~~P

GROUP
COOLING SYSTEM
11

PAGE

PART 11-1- General Cooling System Service 11-2

PART 11-2-Water Pump and Fan Drive Clutch 11-5
PART 11-3-Radiator 11-10
PART 11-4-Specifications 11- 11
11-2

PART
11-1 GENERAL COOLING SYSTEM SERVICE

Section Page Section Page

1 Diagnosis and Testing 11-2 3 Common Adjustments and Repairs 11-4
Trouble Diagnosis Guide 11-2 Drive Belts 11-4
Cooling System Pressure Test 11-3
Fan Replacement 11-4
Thermostat Tests 11-3
2 Maintenance 11-3 Fan Drive Belt Replacement 11-4
Coolant-Cleaning Cooling System 11-3 Radiator Hose Replacement 11-4
Draining and Filling the Cooling System 11-3 Thermostat Replacement 11-4
Fan Drive Belts 11-3

This part covers general cooling component removal, disassembly, as- procedures and specifications, refer
system service. For cooling system sembly, installation, major repair to the pertinent part of this group.

D DIAGNOSIS AND TESTING

DIAGNOSIS plugs. Coolant loss may also be could also be an indication of intern-
Engine overheating and slow en- caused by internal leakage due to a al leakage.
gine warm-up are the two engine defective cylinder head gasket, im- Rust and scale that form in the
troubles most commonly attributed proper tightening of the cylinder engine water passages are carried
to the cooling system. head bolts, or warped cylinder head into the radiator passages by the
Loss of coolant, thermostat stuck or block gasket surfaces. circulation of the coolant. This clogs
in the closed position, restricted air Internal leakage can be detected the radiator passages and causes
flow through the radiator, or ac- by operating the engine at fast idle overheating. Rust can be detected by
cumulation of rust and scale in the and looking for the formation of the appearance of the coolant. If
system are the main causes of over- bubbles in the radiator. Oil in the the coolant has a rusty or muddy
heating. Coolant Joss may, be due to radiator may indicate leakage in the appearance, rust is present.
external leakage at the radiator, engine block or a leak in the auto- A defective thermostat that re-
radiator pressure cap, water pump, matic transmission oil cooler. Water mains open will cause slow engine
hose connections, heater, or core formation on the oil level dipstick warm-up.

TROUBLE DIAGNOSIS GUIDE.

by rust, scale or other foreign mat-

ENGINE OVERHEATS ter.
Belt tension incorrect. Water pump inoperative.
Radiator fins obstructed.
Thermostat stuck closed, or other- Ignition initial timing incorrect.
wise defective. Distributor advance incorrect.
Cooling system passages blocked

ENGINE FAILS TO REACH Thermostat stuck open or of in- Temperature gauge defective (not
NORMAL OPERATING correct heat range. indicating true engine temperature)
TEMPERATURE OR HAS Temperature sending unit defec- or incorrectly installed.
WRONG INDICATED tive (causing gauge to indicate low Incorrect temperature gauge indi-
TEMPERATURE engine temperature). cation.
PART 11-1- GENERAL COOLING SYSTEM SERVICE 11-3

Leaking radiator, radiator supply head bolts.

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

TESTING facturer's instructions be followed If the problem being investigated

COOLING SYSTEM when performing the test. Never ex- is insufficient heat, the thermostat
PRESSURE TEST ceed the rated pressure indicated on should be checked for leakage. This
the pressure cap when performing may be done by holding the ther-
It is recommended that a cooling
the pressure test. mostat up to a lighted background.
system pressure test gauge be used
to properly test the system for: Light leakage around the thermostat
THERMOSTAT TEST- valve (thermostat at room tempera-
1.. Blown or leaking cooling sys- THERMOSTAT REMOVED
tem sealing gaskets. ture) is unacceptable and the ther-
It is good practice to test new mostat should be replaced. It is pos-
2. Internal or external coolant thermostats before installing them in
leakage. sible, on some thermostats, that a
the engine. slight leakage of light at one or two
3. Pressure cap malfunction. Remove the thermostat and im-
Many types of pressure gauges are locations on the perimeter of the
merse it in boiling water. Replace
available for use. Therefore, it is the thermostat if it does not open valve may be detected. This should
recommended that the gauge manu- more than '14 inch. be considered normal.

EJ GENERAL MAINTENANCE
COOLANT
Correct coolant level is essential head bolts are properly tightened to DRAIN PLUG
for maximum circulation and ade- prevent possible water leakage into
quate cooling. In addition, for the the cylinders. Always remove the
cooling system to perform its func- thermostat prior to pressure flushing.
tion, it must receive proper care. This A pulsating or reversed direction
includes periodic flushing of the en- of flushing water flow will loosen
tire system, keeping radiator fins sediment more quickly than a steady
clean, and periodic inspection of the flow in the normal direction of cool-
cooling system for leakage. ant flow.
Use care when removing the radi-
DRAINING AND FILLING
ator cap, to avoid injury from es- THE COOLING SYSTEM
caping steam or hot water. To prevent loss of anti-freeze when
Radiator caps incorporate a red draining the radiator, attach a hose
pressure relief button. on the radiator drain cock and drain
Press this button to relieve internal the anti-freeze from the radiator into
pressure before removing the cap. a clean container.
FIG. 1-Typical Cylinder
To prevent the build up of rust, To drain the radiator, open the Block Drain Plug
sludge and other foreign material in drain cock located at the bottom of level, one inch below bottom of
the cooling system, Ford radiator the radiator. The 6-cylinder engine filler neck.
inhibitor should be added to the block has one drain plug located at After the initial fill the coolant
coolant. If it is found necessary to the right rear of the cylinder block, level may drop approximately one
remove build up of foreign material ahead of the starter (Fig. 1). The quart after the engine has been
from the cylinder block or radiator V -8 engines have a drain plug on operated about 20 minutes at 2000
owing to neglect of adding an each side of the cylinder block. rpm. This is due to the displace-
inhibitor, use Ford radiator cleaner To fill the cooling system, close ment of entrapped air. Refill to the
Rl-64. Removal of such material the drain cock. Install the block proper level.
restores cooling efficiency and avoids drain plug(s). Disconnect the heater
over-heatmg. outlet hose at the water pump to
In severe cases where cleaning bleed or release trapped air in the FAN DRIVE BELTS
solvents will not properly clean the system. When the coolant begins to If the fan drive belt(s) are noisy,
cooling system for efficient operation, escape, connect the heater outlet check the tension of the belts to
it will be necessary to use the hose. make certain they are within speci-
pressure flushing method. Operate the engine until normal fications. Also, check for misaligned
Various types of flushing equip- operating temperature is reached, pulleys. If the drive belts are worn
ment are available. If pressure flush- and add more coolant, if necessary, or frayed, replace them following
ing is used, make sure the cylinder to fill the radiator to the proper the procedures in Page 11-4.
11-4 GROUP 11- COOLING SYSTEM

EJ COMMON ADJUSTMENTS AND REPAIRS

ADJUSTMENTS TO INSTALL
DRIVE BELTS
The fan drive belt(s) should be 1. Position the fan and spacer on THERMOSTAT REPLACEMENT
properly adjusted at all times. A the water pump hub and install
loose drive belt(s) causes improper the lock washers and capscrews. A poppet-type thermostat is
alternator, fan and water pump 2. Torque the capscrews evenly mounted in a recess in the coolant
operation. A belt(s) that is too tight and alternately to specifications. outlet passage at the front of the in-
places a severe strain on the water 3. Refit the fan shroud if take manifold on the V-8 engines.
pump and the alternator bearings. applicable . On 6-cylinder engines, the thermo-
Properly tensioned drive belts 4. Adjust the fan belt to stat is located in the coolant outlet
minimize noise and also prolong specification. passage at the front of the cylinder
service life of the belt. Therefore, it head. When the thermostat is closed,
is recommended that a belt tension coolant flows to the water pump
gauge be used to check and adjust FAN DRIVE BELT through a bypass passage at the
the belt tension. Any belt that has REPLACEMENT front of the engine. When the ther-
operated for a minimum of 10 min- mostat is open, coolant flows through
utes is considered a used belt, and the coolant outlet elbow (thermo-
1. On a car with power steering, stat housing) to the radiator.
when adjusted, it must be adjusted to loosen power steering pump bracket
the reset tension shown in the sped- The thermostat used in production
at water pump. Remove drive belt. is for use with water or permanent-
cations.
Belt Tension 2. Loosen alternator mounting and type anti-freeze. For operating tem-
1. Install the belt tension tool on adjusting arm bolts. Move alternator peratures, refer to specifications.
the drive belt (Fig. 2) and check toward engine. Remove the belt(s) Check the thermostat before in-
the tension following the instructions from alternator and crankcase pulleys, slalling it following the procedure
of the tool manufacturer. and lift them over fan. under "Thermostat Test", Page 11-3.
3. Place the belt(s) over the fan. Do not attempt to repair the
Tooi-T63L·8620·A
Insert the belt(s) in the water pump thermostat. It should be replaced if
pulley, crankshaft pulley and alter- it is not operating properly.
nator pulley grooves. Adjust the belt
Removal
tension to specifications.
4. On a car with power steering, 1. Drain cooling system below level
install the power steering pump drive of the coolant outlet housing.
belt and tighten the pump bracket to 2. Remove coolant outlet housing
the water pump. Adjust the drive retaining bolts and slide housing
belt tension to specifications. (with hose attached) to one side.
3. Remove thermostat and gasket.
RADIATOR HOSE Installation
REPLACEMENT 1. Clean coolant outlet housing and
cylinder head surface. Coat a new
Radiator hoses should be replaced coolant outlet housing gasket with
FIG. 2-Checking Drive Belt sealer. Position gasket on cylinder
whenever they become cracked,
Tension rotted or have a tendency to collapse. head or intake manifold (V -8).
The gasket must be positioned on
2. If adjustment is necessary cylinder head or intake manifold
loosen alternator mounting and ad- 1. Drain radiator; then loosen the
clamps at each end of hose to be before thermostat is installed.
justing arm bolts. Move alternator
away from engine until correct removed . Slide hose off radiator con- 2. Coat edge of thermostat with
tension is obtained. Tighten alter- grease for thermostat adhesion. Pos-
nator adjusting arm and mounting nection and the cylinder head water ition thermostat in recess of coolant
outlet or water pump connection. outlet housing so that copper pellet
bolts.
or heat element will be in the cylinder
2. Position the clamps at least t " head or intake manifold (V-8).
FAN REPLACEMENT from each end of hose. Slide hose
ALL MODELS Install thermostat with the word
on the connections. Make sure the TOP toward the top of the engine
TO REMOVE clam?S are beyond bead and
1. Loosen the fan belt. and valve end of thermostat facing
placed in the centre of clamping outward. If thermostat is impro-
2. If a fan sl·.;o ud is fitted remove surface of connections. Tighten
it from the radiator and lay it back perly positioned, it will cause the
clamps. Fill radiator with coolant.
engine to overheat.
against the engine. Operate engine for several minutes;
3. Remove capscrews and lock then check the hoses and connections 3. Fill radiator. Operate engine and
washers retaining fan and spacer to for leaks. Check for proper coolant check for coolant leaks and proper
the water pump hub . Remove the fan level after the engine has reached coolant level after engine reaches
and spacer. normal operating temperature. normal operating temperature.
11-5

PART WATER PUMP

11-2 Page Section Page
Section
1 Description and Operation 11-5 3 Major Repair Operations 11-6
2 Removal and Installation 11-5 Six Cylinder Engines 11-6
Six C~· linde r Engines 11-5
V8 Engines 11-5 V8 Engines 11-8
Fan Drive Clutch 11-8

D DESCRIPTION AND OPERATION

let ports, one for each cylinder bank,
On 6-cylinder engines, a centri- to provide uniform coolant circula-
fugal-type water pump is mounted engine when the thermostat is closed, tion in both banks of the engine.
on the front of the cylinder block. bypassing the radiator. On the 6- The water pumps have a sealed
On V-8 engines, the centrifugal-type cylinder engines, the water pump bearing integral with the water
water pump is mounted on the bypass passage is aligned with the pump shaft. The bearing requires no
cylinder front cover. The water pump bypass passage in the cylinder block lubrication. A bleed hole in the water
inlet port is connected to the radiator for coolant circulation in the engine pump housing allows water that may
bottom tank to draw coolant from when the thermostat is dosed. leak past the seal to be thrown out
the radiator when the thermostat is A vane-type, impeller supplies by the slinger. This is not a lubri-
open. On the V-8 engines, a bypass coolant through centrifugal action cation hole.
port on the water pump is connected to the water pump outlet port on The cooling fan hub is pressed a
to the coolant outlet housing to 6-cylinder engines. On the V-8 en- specified distance onto the water
permit coolant circulation within the gines, the water pump has two out- pump shaft.

El REMOVAL AND INSTALLATION

SIX CYLINDER ENGINES 4. Connect the radiator lower ing bolts and pos1t1on the shroud
hose and the heater hose to the water rearward if so equipped.
REMOVAL pump. 3. Remove the fan and spacer from
1. Drain the cooling system. 5. Install the water pump pulley, the water pump shaft.
On a car with power steering. fan spacer and fan . Torque the
remove the power steering drive belt. bolts evenly and alternately to 4. Remove the air conditioner
2. Disconnect the radiator lower specifications. compressor drive belt lower idler
hose at the water pump. Remove 6. Install ihe drive belt and ad- pulley and compressor mount to
the drive belt, fan, spacer and just the tension to specifications. water pump bracket, if so equipped.
On a car with power steering, in- 5. Loosen the alternator and re-
water pump pulley.
stall the drive belt and adjust the ten- move the drive belt.
3. Disconnect the heater hose at 6. If equipped with power steer-
the water pump. sion to specifications.
On a car with air conditioner, in- ing, loosen the power steering pump
4. Remove the water pump. and remove the drive belt.
stall the compressor drive belt and
INSTALLATION 7. Remove the water pump pulley.
adjust the tension to specifications.
8. Remove alternator bracket from
1. Clean the gasket surfaces on 7. Fill and bleed the cooling sys-
water pump and position it out of the
the water pump and cylinder block. tem . Operate the engine until normal
way.
operating temperature is reached. 9. If.equipped with power steer-
l. Coat a new gasket on both Check for leaks and check the
sides with water-resistant sealer and ing, remove the power steering pump
coolant level. bracket from the water pump and
position it on the cylinder block.
3. Position the water pump in position it out of the way.
V-8 ENGINES 10. Remove the heater hose from
place and install the lock washers
REMOVAL the water pump.
and retaining bolts (the alternator 11. Disconnect the lower radiator
adjusting arm is retained by one 1. Drain the cooling system and
disconnect the battery. hose at the water pump.
water pump · bolt). Torque the bolts 12. Remove the water pump at-
lO specifications.* 2. Remove the fan shroud attach-

* CAUTION: -When installing pump retaining bolts ensure that the longest bolt is fitted to the hole where the alternator
mounting bracket is located, otherwise damage to the engine block will occur.
11-6 GROUP 11- COOLING SYSTEM
taching bolts and remove the water ing screws to specifications. 7. Install the fan shroud attaching
pump. 3. Install the air conditioner com- bolts, if so equipped.
pressor to water pump bracket and 8. Adjust the drive belts to speci-
INSTALLATION lower idler pulley, if so equipped. fications.
1. Remove all gasket material from 4. Position the alternator bracket 9. Connect the lower radiator hose
the mounting surfaces of the cylinder and power steering pump bracket, if at the water pump.
front cover and water pump. so equipped, on the water pump and 10. Connect the heater hose at the
2. Position a new gasket, coated on install the bracket bolts. water pump.
both sides with sealer, on the cylinder 5. Position the water pump pulley 11. Connect the battery cable. Fill
front cover; then install the pump. on the water pump shaft and install and bleed the cooling system. Operate
Coat the threads of the attaching the drive belts. the engine until normal operating
screws with oil-resistant sealer and 6. Place the fan shroud over the temperature has been reached and
install the screws. Tighten the attach- pulley and install the fan and spacer. check for leaks.

EJ MAJOR REPAIR OPERATIONS (6 Cyl. Engines)

DISASSEMBLY 2. Position the pump on an arbor
press and press the shaft and bearing
out of the housing (Fig. 3), using the 6. Support the assembly on the
The water pump assembly is impeller end of the shaft. Position
shown in Fig. 1. straight end of tool T70PG-8530-A.
3. Remove the impeller from the the water pump hub over the shaft
1. Remove the hub from the im- and press it into place, (Fig. 8),
peller shaft (Fig. 9). shaft (Fig. 4).
holding the specified distance from
the housing mounting face to the
ASSEMBLY hub front face.
1. Clean all gasket material from T70PG-8530-A .

the pump.

2. Coat the bearing outer dia-

meter with grease, and position the
shaft and bearing on the housing.
Using the flanged end of tool T70PG~
8530-A against the bearing, press the
shaft and bearing assembly into the
housing until the outer end of the
bearing is flush with the outer face
of the pump housing to within
±.003 inches.
FIG. 1- Water Pump 6 Cyl.
3. Apply a light film of water-
proof sealer on a new s~l an~ press
the seal into the housmg (F1g. 6),
using tool T70PG-8564-A.
FIG. 3-Shaft and Bearina Removal
4.- Replace the impeller if it is
worn or damaged.

NOTE
If the water pump seal is re-
moved from the pump or shaft
for any reason a new seal must
be fitted on reassembly.
5. Press the shaft into the impeller
(Fig. 7). The impeller rear face to
pump mounting surface ~hould ~e
0.525-0.535 inch after the 1mpeller 1s FIG. 4 -Impeller Removal
FIG. 2- Hub Removal installed as shown in the assembly
drawing (Fig. 1).
PART 11-2- WATER PUMP 11-7

Arbor Preu Rom

AND BEARING

IMPELLER
FIG. 5- Shaft and FIG.7-Impeller Installation
Bearing Installation

FIG. 8 - Hub Installation

Drift
SMALLER
DIAMETER
THAN S~IAFT

FIG. 6- Seal Installation 6 Cyl.

FIG. 9 -Hub Removal

11-8 GROUP 11- COOLING SYSTEM

_ _ _ _ _ 6·/,8:_ _ _.....
6·14~
1 - - - - - - 5·70'' - - - o - i

·050"
• THIS DIMENSION ·030""
MUST BE-MAINTAINED
FROM EXTREME SURFACE
OF IMPELLER
FIG. 10-302-351 VB Water
Pump Assembly Dimensions

FIG. 11 -Water Pump Removal maximum and the minimum air flows
according to conditions, and it limits
fan speed to a maximum rpm, beyond
302-351 WATER PUMP OVERHAUL CAUTION a given engine input speed .
Do not allow oil or grease to The viscous fluid shear principle in
DISASSEMBLY contact the ceramic seal face. general is applied to fan clutch design
1. Position the pump on an arbor 4. Position the impeller on the in the following manner :
press and press the hub off the shaft. shaft and press impeller and ceramic A drive plate totally enclosed with-
2. Press the shaft and impeller and seal on to shaft until a dimension of in the clutch housing is attached di-
the seal assembly out of the housing 6.138/6.146 is obtained from the rectly to the clutch input shaft (as-
using a cylindrical support. pulley end of the shaft to the sembled to the water pump shaft and
NOTE: extremity of the impeller (Fig. 10). pulley). A predetermined clearance
The impeller cannot be separated 5. Position the pulley hub on the between the drive plate and the inner
from the shaft without damage to the shaft and press on until a dimension surfaces of the clutch housing is es-
ceramic seal face and a new ceramic of 5.70" is obtained from the hub tablished -at assembly .
seal must be fitted should the face to the housing mounting face. The clutch housing and the fan
impeller be removed. (Fig. 10). blade assembly are mounted to the
Should a steel impeller be fitted, input shaft by a sealed bearing and
pressure may only be applied to are free to rotate independently of the
sleeve of the impeller. drive plate and input shaft.
The interior chamber of the clutch
housing is filled with a given amount
FAN DRIVE CLUTCH of silicon base oil. Centrifugal force
resulting from the rotation of the
ASSEMBLY clutch. coupled with the constant
1. Apply a light film of water- pumping action designed into the unit
proof sealer on a new seal and press DESCRIPTION forces the silicon base oil evenly
the seal into the housing. about the inner surfaces of the clutch
in the close clearance or drive area .
2. Coat the outer ·diameter of the The fan clutch (Figs. 12, 13 and 14) The drag between the driving and the
bearing lightly with grease, and press permits use of a powerful fan without driven members is thus increased by
the shaft and bearing into the pump paying the penalty of power loss or the presence of the oil, causing the
housing. Press the shaft and bearing noise. The fan clutch is a mechanical clutch action.
into the housing until the bearing is device which provides maximum air A control valve (operated by a te-
flush with the housing hub. flow through the radiator when re- rn perature-sensitive bi-metal coi I or
3. Carefully press the ceramic- quired, and a minimum air flow when strip in the air stream on the front of
faced seal onto the shaft approxi- less than maximum cooling is neces- the clutch) regulates the amount of oil
mately!-"- sary . It can modulate between the pumped in or out of the close clear-
PART 11-2- WATER PUMP 11-9
FAN DRIVE CLUTCH BI·METAL STRIP BI-METAL SPRING

FIG. 12 Typical Fan Drive Clutch CONTROL PIST~ 82631·8 8 1932 - C

Installation FIG. 13 - Fan Drive Clutch With
Flat Bi-Metal Spring FIG. 14 -Fan Drive Clutch With
ance (drive) area. This action deter- Coil Bi-Metal Spring
mines the fan speed in relation to the and moves the control valve to the 3. Remove the retaining capscrews
drive pulley and the radiator core air minimum slip position, retaining a and separate the fan from the drive
flow temperature. maximum amount of oil in the close clutch .
clearance area .
OPERATION
INSTALLATION
MODULATING CYCLE
START-UP
I. Position the fan on the drive
As vehicle operation varies with clutch . Install the capscrews.
At start-up, or after a prolonged heavy to light traffic, terrain, etc., the 2. Position the fan drive clutch and
engine shut-down period, near maxi- fan clutch operates within the high fan assembly to the water pump hub
mum fan noise can be heard as the and low rpm positions, modulating as (Fig. I). Install and torque the retain-
fan clutch fluid is forced into the required as ambient air flow through ing capscrews evenly and alternatel y
close clearance area by centrifugal the radiator core changes . to specifications. Then, check the fan
force, resulting in maximum applica-
drive clutch flange-to-water pump hub
tion of the clutch . As the normal op- HIGH SPEED SUSTAINED for proper mating. Adjust the fan belt
erating temperature is reached, the OPERATION tension to specifications.
amount of fluid allowed to remain in
the close clearance area is regulated 3. Re-install the radiator shroud.
During high speed operation, fan
by the temperature-sensitive control clutch action will limit speed of the
valve. This determines fan speed in
fan to a given maximum rpm . This
relation to the fan drive pulley and
will occur under hot or cold condi-
the radiator core air flow tempera- tions.
ture.

RUNNING-LOW AMBIENT REMOVAL

TEMPERATURE 1. Remove the radiator shroud
attaching bolts and lay the shroud
After the initial start-up · cycle has back toward the engine.
been completed, and as long as the 2. Loosen the fan belt. Remove the
air flowing through the radiator core capscrews retaining the fan drive
does not exceed 150- 180 degrees F clutch to water pump hub (Fig. 1).
temperature, the fan clutch will re- Remove the fan drive clutch and fan
main in or near the maximum slip as an assembly.
position. During this cycle, the con-
trol valve allows a minimum amount
of fluid to remain in the close clear-
ance (drive) area.
TORQUE VALUES (ALL CARS)
RUNNING-HIGH AMBIENT NOTE: All specifiutions are aiven in ft·lbs unless otherwise noted.
TEMPERATURE Fan to Fan Clutch (With A/C)· All Engines 10-15

As ambient temperatures increase,

or air flow temperatures through the Enaine RPM Required Fan Test Speed @ 2000 Water Pump RPM
To Run Water Pump Maximum Slip Minimum Slip
core become increasingly higher, ad-
2000 RPM<D (Cold) <D (Hot) <D
ditional cooling is required. The bi-
metal coil or strip senses this change 1695 1500 1750
11-10

PART RADIATOR
11-3

Section Pare Section Pare

1 Desr.ription and Operation 11-10 2 Removal and Installation 11-10

D DESCRIPTION AND OPERATION

The radiators are of the tube and radiator outlet port is connected to when the thermostat is open.
fin-core type with the tubes arrang- the water pump inlet port. The An oil cooler coil is located in the radiator
outlet header-tank to cool transmission
ed for vertical or horizontal coolant flow . radiator inlet port is connected to fluid for automatic transmission vehicles.
Two header-tanks, one at each end of the coolant outlet housing of the
the core provide uniform distribution engine, thereby permitting coolant
of the coolant to the tubes. The circulation through the radiator

EJ REMOVAL AND INSTALLATION

REMOVAL INSTALLATION
1. If a new radiator is to be in- On a car with automatic trans-
1. Drain the cooling system. Dis· stalled, remove the drain cock from
connect the radiator coolant hoses mission, connect the oil cooler lines
the old radiator and install it in the and re-install the fan shroud if
at the radiator.
new radiator. On a car with auto- previously removed.
2. On a car with automatic trans- matic transmission, remove the oil
mission, disconnect the oil cooler cooler line fittings from the old radia· 4. Close the drain cock. Fill and
lines at the radiator. tor, and install them in the new bleed the cooling system.
3. Remove fan shroud attaching radiator, using oil-resistant sealer. 5. Operate the engine and check
bolts and position the shroud rear- :Z. Position the radiator assembly for leaks at the hose connections and
ward, if so equipped. and install the support bolts. the automatic transmission oil cooler
4. Remove the radiator support 3. Connect the radiator coolant Jines. Check the automatic transmiJ-
bolts and remove the radiator. hoses. sion fluid level.

FIG. 15- Installation Cross Flow Radiator and Shroud. All 302-351-2V 250 with AiC
11- J J

PART
11·4 SPECIFICATIONS
TORQUE VALUES Ft. Lbs.
Water pump to cylinder block (or cylinder front cover) all engines 12-15
Water outlet housing all engines 12-15
Fan and spacer to pulley hub all engines 10-15
Radiator to support all engines 8-13
Radiator to engine hose clamps all engines 1.0-2.5
Transmission oil cooler tube nut to radiator connection ALL 10-15
Fan shrouds are fitted to 250 a/c, all 302 and 351 engines. *

* Fan blade radial clearance to

shroud- 0.75 inches.

SPECIFICATIONS:
200-250 302 351
Cooling system capacity (quarts)* 7.5 12.9
*Includes heater. if deleted, subtract one quart

NOTE : Air conditioned vehicles are fitted with extra heavy duty radiators. Prior to replacement of these units refer to
the parts catalogue for correct part number.

THERMOSTAT 200 & 260 302-351

Opens °F 0 0 0 0 0 0 188-195 188-195
Fully Open °F 0 0 0 0 0 0 210-212 210-212

WATER PUMP ASSEMBLY

DJMENSIONS
Front face of pulley hub to pump
housing face 0 0 0 0 0 0 3.94 5.70
Impeller blade to housing clearance .044-.054 .030-.050
Pump housing face to rear face of
impeller 0 0 0 0 0 0 0 0 0.525-0.535 0.066-0.094

DRIVE BELT TENSION (Lbs.) NEW USED NEW USED

Single belt 0 0 0 0 0 0 110-140 80-110 110-140 80-110
6-Cylinder air conditioned
(dual belts) Front 0 0 0 0 110-140 80-110
Rear 0. 0 0 105-155 75-120
Power steering 0 0 0 0 0 0 120-150 90-120 120-150 90-120
11-12 GROUP 11- COOLING SYSTEM

FINS
RADIATOR CORE FAN No. OF FAN PVS
ENGINE TRANS PER
WIDTH&TYPE BLADES X DIA. RATIO VALUE
INCH
200 CID Manual 20.29" Down Flow 9 4xi7.5" 1.05 No
200 CID Auto 20.29" Down Flow 9 4x I7.5" 1.05 No
250 CID IV Manual 20.29" Down Flow IO 4x I7.5" 1.05 No
250 CID IV Auto 20.29" Down Flow IO 4 X I7.5" 1.05 No
250 CID IV Manual A/C 2I.7" Cross Flow and Shroud 9 6 X I7 .0" 1.18 Yes
Viscous Clutch
250 CID IV AutoA/C 2I .7" Cross Flow and Shroud 9 6 X I7 .0" 1.18 Yes
Viscous Clutch
250 CID 2V Manual 20.29" Down Flow IO 4 X I7.5" 1.05 Yes
250 CID 2V Auto 20.29" Down Flow IO 4 X I7 .5" 1.05 Yes
250 CID 2V Manual A/C 2I.7" Cross Flow and Shroud 9 6 X 17.0" 1.18 Yes
Viscous Clutch
250 CID 2V Auto A/C 21.7" Cross Flow and Shroud 9 6 X I7.0" 1.18 Yes
Viscous Clutch
302 CID Manual 21.7" Cross Flow and Shroud IO 4 X I7.5" 0.96 Yes
302 CID Auto 2I.7" Cross Flow and Shroud I2 4x I7.5" 0.96 Yes
302 CID Manual A/C 21.7" Cross Flow and Shroud I4 5 X I7.5" 1.13 Yes
302 CID Auto A/C 2I.7" Cross Flow and Shroud I4 5 X I7.5" 1.13 Yes
351 CID 2V Manual 2I .7" Cross Flow and Shroud 10 4 X I7 .5" 0 .96 Yes
351 CID 2V Auto 21.7" Cross Flow and Shroud IO x
4 I7.5" 0.96 Yes
35I CID 2V Manual A/C 21.7" Cross Flow and Shroud I3 7 X I7 .5" 1.13 Yes
351 CID 2V Auto A/C 21.7" Cross Flow and Shroud I3 7 X 17.5" 1.13 Yes
35I CID 4V Manual 2I .7" Cross Flow and Shroud I2 4 X I7.5" 0.96 Yes
35I CID 4V Auto 2I.7" Cross Flow and Shroud I4 4 X I7 .5" 0.96 Yes
351 CID 4V Manual A/C 26.0" Cross Flow and Shroud I2 7 X 17.5" 1.13 Yes
35I CID 4V Auto A/C 26.0" Cross Flow and Shroud I2 7 X I7.5" 1.13 Yes
FALCON FAIRLANE w~:~~~~P

GROUP
EXHAUST SYSTEM
12

PAGE

PART 12-1-General Exhaust System Service 12-2

PART 12-2-Exhaust Pipes and Muffler 12-3
PART 12-3-Specifications 12-19
12-2

PART GENERAL EXHAUST SYSTEM SERVICE

12-1
Section Pa1e Section Pa1e
1 Diagnosis and Testinc lZ-2 3 Cleaninc and Inspection .... ... 12-2
2 Common Adjustment. and Repairs .... 12-2

This part covers general exhaust For exhaust system component re- Always refer to the Master Parts
system diagnosis, tests, adjustment moval, disassembly, assembly, instal- Catalog for parts usage and inter-
and repair procedures. In addition, lation, major repair procedures and
the cleaning and inspection proce- specifications, refer to the pertinent changeability before replacing a com-·
dures are covered. part of this group. ponent part of the exhaust system.

D DIAGNOSIS AND TESTING noise is hard to distinguish from other

chassis noises. Look for broken or
DIAGNOSIS usually inaudible and not visible. A loose clamps and brackets and re-
EXHAUST SYSTEM visual inspection of the exhaust sys- place or tighten as necessary. It is
An exhaust system performance tem usually will show the location of important from a noise, vibration or
complaint, such as excessive back a leak. Look for holes, ruptured harshness point of view, that exhaust
pressure is usually noticeable by its joints and eroded areas in the muf- clearances and setting procedures as
effect on engine performance. fter(s), resonator(s), inlet pipe(s) shown in Figures 1 through 14 be ad-
For diagnosis of exhaust system and outlet pipe(s). Examine joints hered to when ever repairs involving
problems that affect engine perform- the exhaust system are carried out.
ances, refer to Part 8-1, Section 1. and connections for greyish white de-
posits that would be caused by ex- As some of the exhaust system to
External leaks in the exhaust sys- haust gas leakage. body clearances are relatively small,
tem are often accompanied by A misaligned exhaust system is ensure they are set to specification
noises or greyish-white smnke emitted usually indicated by vibration, before replacing components in an
from under the car. Small leaks are grounding, rattling, or binding of the endeavour to correct a noise,
components. Often the associated vibration or harshness problem.

EJ COMMON ADJUSTMENTS AND REPAIRS 3. Work from the front of the car
toward the rear and progressively ad-
ADJUSTMENTS just the exhaust system components
EXHAUST SYSTEM
The exhaust system must be free ALIGNMENT and clamps at the various pipe con-
of leaks, binds, grounding and exces- nections to relieve binds and im-
sive vibration. Refer to the pertinent illustration
in Part 12-2 for the clearance speci- proper pipe connections. Be sure the
Exhaust system vibration, ground- Inlet and outlet pipa and muftlen
ing or binds are usually caused by: fications and location of components.
are aligned so that all clearances are
loose, broken or improperly aligned Perform the following procedure to within the limits shown on the Illus-
clamps, or brackets, or improperly adjust the exhaust system compo- trations In Part 12-l. Then torque
connected pipes. Any of the afore- nents: the clamps to specification.
mentioned conditions may cause 1. Loosen the pipe connection 4. Check the exhaust system for
changes to clearances of the exhaust clamps and the pipe support bracket leaks.
system components. If any of these clamp(s). Loosen the inlet pipe to
conditions exist, the exhaust system exhaust manifold retaining nuts. MUFFLERS, INLET PIPES AND
components must be checked, ad- l. Torque the exhaust manifold to OUTLET PIPES
justed or replaced to make certain inlet pipe retaining nuts evenly and Brackets, clamps and insulaton
the specified clearances (refer to the alternately to specification to insure should be replaced if they are defec·
illustrations in Part ll-2) are main- uniform pressure on the seal and in- tive or become badly corroded. Do
tained. let pipe ftange. not attempt repair of these parts.

EJ CLEANING AND INSPECTION

EXHAUST SYSRM damage (holes) that would result in clamp{s) are loosened, and/ or re-
INSPECTION a leaking exhaust system. Inspect moved to replace a pipe or muffler,
Inspect the inlet pipe(s), outlet the clamps, brackets and insulators replace the clamp(s), if there is
pipe(s), and muffler for cracked for cracks and stripped or badly reasonable doubt that its service
joints, broken welds and corrosion corroded bolt threads. When pipe life is limited.
12-3

PART EXHAUST PIPES, MUFFLERS

12·2

Seetioa Pare Section Pare

1 Description 12-3 2 Removal and Installation 12-3

D DESCRIPTION
The single exhaust system on cars brackets eliminate tension on the
The exhaust systems for the with a V-8 engine (Fig. 2) consists supports due to thermal expansion
various car models are shown in of a Y -type muffler inlet pipe, of the system.
Figs. 1 to 14. muffler with integral inlet pipe
extension and outlet pipe.
SINGLE EXHAUST SYSTEMS DUAL EXHAUST SYSTEM
The single exhaust system on cars The location and type of exhaust
with a six cylinder engine (Fig. 1) system gaskets, retaining clamps and The dual exhaust system consists
consists of a muffler inlet pipe, loop-type support brackets are shown of an H-type inlet pipe and an inlet
muffler with integral inlet pipe in the respective exhaust system pipe extension, muffler, and outlet
extension and outlet pipe. illustrations. The loop-type support pipe for each side.

EJ REMOVAL AND INSTALLATION

The replacement procedures given MUFFLER ASS EMILY 2. Loosen the outlet pipe clamp
apply to all car models. Typical REMOVAL at the rear end of the muffler, and
exhaust systems for the various 1. Loosen the inlet pipe clamp at retain the clamp on the muffler loop
car models are shown in Figs. 1 the front end of the muffler inlet mount.
to 14. pipe extension, and slide the clamp 3. Loosen the outlet pipe clamp
forward onto the inlet pipe. at the rear loop mount.
12-4 GROUP 12- EXHAUST PIPES AND MUFFLER
4. Support the inlet and outlet 1. Install a new gasket on the pipe flanges and install the retain-
pipes with soft wire. ing nuts on the studs of the mani-
flared end of the inlet pipe. Slide
fold snug, but not tight.
the clamp onto the inlet pipe which
5. Separate the muffler from the
attaches the inlet pipe to the fly-
inlet and outlet pipes and remove 3. Position the inlet pipe to the
wheel/ converter housing support
the muffler. muffler inlet pipe extension clamp.
bracket.
Remove the temporary support wire.
6. Replace any damaged parts. 2. Install the ihlet pipe to the
muffler inlet pipe extension and 4. Adjust the exhaust system
INSTALLATION components to conform to the clear-
exhaust manifold. Position the in-
1. Slide the muffler onto the in- ances shown in Figs. 8-14. Working from
let pipe flan~. e and install the re-
let pipe, and position the inlet pipe the front of the car toward the rear,
taining nuts on the !ltuds of the
to muffler inlet pipe extension progressively torque the retain ing
manifold snug, but not tight.
clamp. nuts and clamps to specifications.
3. Position the inlet pipe to the
2. Slide the outlet pipe into the
muffler inlet pipe extension clamp.
muffler and position the outlet pipe
Position the inlet pipe to the fly- 5. Start the engine and check the
to muffler clamp.
wheel ; convertor housing support exhaust system for leaks.
3. Adjust the exhaust system
!:racket clamp. Remove the temp-
components to conform to the clear-
orary support wire.
ances shown in Fig. 1 to 14 and torque
4. Adjust the exhaust system
the retaining clamps to specifications. Re- OUTLET PIPE
move temporary support wires. components to conform to the clear-
ances shown in Figs. 1-7. Working from the ALL MODELS
4. Start the engine and check the
exhaust system for leaks. front of the car toward the rear,
progressively torque the retaining REMOVAL
INLET PIPE
nuts and clamps to specifications.
6 CYLINDER ENGINE
REMOVAL 5. Start the engine and check the 1. Loosen the outlet pipe(s) clamp
exhaust system for leaks. at the rear end of the muffler(s) and
1. Loosen the inlet pipe clamp at retain the clamp on the muffler(s) loop
the front end of the muffler inlet mount.
INLET PIPE
pipe extension and slide the clamp
rearward onto the inlet pipe ex- VB ENGINE l. Support the rear end of muffier(s)
tension. with soft wire.
REMOVAL
2. Remove the clamp attaching 3. Remove the outlet pipe(s) clamp
at the rear loop mount.
the inlet pipe to the flywheel/con-
verter housing support bracket. 1. Loosen the inlet pipe(s) clamp(s) at
the front end of the muffler inlet 4. Separate the outlet pipe(s) from
pipe extension, and slide the clanip(s) the JLuffler(s) and remove the outlet
3. Support the front end of the rearward onto the inlet pipe exten- pipe(s).
muffler inlet pipe extension with sion.
·soft wire. l. Support the front end of the
muffler inlet pipe(s) extension with
4. Remove the nuts that secure soft wire.
3. Remove the nuts that secure INSTALLATION
the inlet pipe to the exhaust mani-
the inlet pipe to the exhaust mani-
fold. Separate the· inlet pipe from
folds. Separate the inlet pipe from
the exhaust manifold and muffler
the exhaust manifolds and muffler 1. Slide the outlet pipe(s) into the
inlet pipe extension and remove the
inlet pipe extension and remove the rear end of the muffler(s) and position
inlet pipe.
inlet pipe. the outlet pipe to the muffler clamp.
4. Clean the gasket surface of
5. Clean the gasket surface of the exhaust manifolds. l. Slide the clamp for the rear
the exhaust manifold. 5. Discard the gaskets and re- loop mount onto the outlet pipe(s)
place any damaged parts. and position the clamp on the loop
6. Discard the gasket and replace amount. Remove the temporary sup
any damaged parts. port wire.

INSTALLATION INSTALLATION
3. Adjust the exhaust systems com-
During reassembly of the 250 2V 1. Install l'lew gaskets on the ,JOnents to conform to the clearances
exhaust manifold, it is advisable to re- flared ends of the inlet pipe. shown in Fig. 1-14 and torque the retain-
assemble the manifold to cylinder head ing clamps to specifications.
bolts, starting from the back of the engine.
This is recommended as misalignment of 2. Install the inlet pipe to the
the bolt holes due to distortion can muffler inlet pipe extension and ex- 4. Start the engine and check the
occur with this type of exhaust manifold. haust manifolds. Position the inlet exhaust system for leaks.
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R<LCON Gr ,J!;t-~ (DI.W.. .)

14./SrAL~r'cw· :x•~:"" 9'31'EM

FIG. 14
12-19

PART
12·3 SPECIFICATIONS

TORQUE LIMITS

EXHAUST SYSTEM Ft. LM.

Inlet Pipe(s) to Exhaust Manifold(s) 25-36
Inlet Pipe to Inlet Pipe Extension Clamp 20-28
Outlet Pipe to Muffler Clamp 20-28
Support Brackets and Insulators to Frame Nut! 15-25
Support Insulator Bracket to Muffler 5-7
Support Insulator Clamp to Tailpipe 10-14
250-2V Exhaust Manifold to Cylinder Head 10-14
REFERENCE TO SERVICE INFORMATION AND NOTES

Date Letter No. Page Brief Detail

-
FALCON FAIRLANE w~:~~~~P

GROUP
CHARGING SYSTEM
13

PAGE

PART 13-1-General Charging System Service 13-2

PART 13-2-Bosch Alternator 13-15

PART 13-3-lucas Alternator 13-18

PART 13-4- Bosch Alternator Regulator 13-22

PART 13-5-lucas Alternator Regulator 13-26

PART 13-6-Specifkations 13-30

13-2

PART GENERAL CHARGING SYSTEM SERVICE

13-1
Section Page Section Page
1 Diagnosis 13-2 2 Testing 13-7
Battery Low in Charge, Headlights Dim at Alternator Test 13-7
Idle .. . 13-4 Testing the Altenator System 13-7
Charge Indicator Light Stays On .... 13-4
Battery Tests and Conclusions .... 13-11
Lights and Fuses Fail Prematurely,
Short Battery Life ........ ... . 3 Common Adjustments and Repairs 13-13
13-4
Alternator Noisy ... 13-4 Belt Adjustment 13-13
Warning Light Flickers ... 13-4 4 Cleaning and Inspection 13-13

0 CHARGING SYSTEM DIAGNOSIS

The charging system consists of
an alternator, alternator regulator,
battery, charge indicator light
and the necessary wiring to connect the
components (Figs. 2 & 3).
Four different alternators are used
in the XA/ZF model range.
1. Bosch - 40 amp with remote
regulator.
2. Lucas 40 amp with integral
regulator.
3. Lucas - 55 amp with integral
regulator.
4. Lucas - 55 amp with remote
regulator.
For model application refer to
Specifications.

Battery discharge is not always

due to charging system defects.
Excessive use of lights and access-
ories while the engine is either oft'
or running at low idle; corroded
battery cables and connectors; low
water level in the battery; or pro- FIG. 1-Aiternator Unit -Assembled
longed disuse of the battery, which
would permit self-discharge; are all Alternator regulator failures are by the diodes of the alternator
possible reasons which should be which permit current flow in one
usually not recognised except by the
considered when a battery is run direction (to the battery) only.
down or low in charge. direct effect on the alternator out-
Proper adjustment of the alternator regu-
put, and, of course, eventual battery
Charging system troubles such as lator is very important.
low alternator output, no alternator discharge. As the regulator is the
The wad map t~· pe of procedures
output (indicated by the indicator control valve for the alternator, it which follow will assist in a logical
light being on while the engine is acts to protect the battery by pre·· sequence of pinpointing specific
running), or alternator output vol- venting excessive voltage output. troubles. ALWAYS DETERMINE
tage too high, require testing of THE CAUSE OF FAILURE AS
both the alternator and the alterna- Discharge of the battery to ground WELL AS MAKING THE RE-
tor regulator. through the alternator is prevented PAIR.
PART 13-1-GENERAL CHARGING SYSTEM SERVICE 13-3

-::r
-,-
+
-+-
r
FIG. 2- Lucas Charging Circuit 14 AC Shown. PRECAUTIONS TO TAKE ON
ALTERNATOR EQUIPPED
VEHICLES
1. Polarity and Connections. The
alternator is for use on negative
earth electrical systems only. Polarity
cannot be reversed by 'Flashing' the
field terminals as with the dynamo
and any attempt to do so will damage
the alternator.
2. Refitting Vehicle Battery. Re-
versed battery connections will dam-
age the alternator rectifiers. When
refitting, first fit the positive +
connector to the battery positive +
terminal and then fit the negative -
connector to the negative - battery
terminal.
3. High Rate Battery Charging.
Advisable to first disconnect the
battery negative cable thus isolating
. the alternator from the battery and
external charging equipment.
I
I
4. Battery Connections. The
battery must never be disco!}nected
H while the engine is running or damage
may occur to the rectifier and/or
I I
control box semi-conductor devices.
For this reason the practice of using
a slave battery to start the engine
I I
and subsequently reconnecting the
original battery whilst the engine is
l_ __________ l running must not be attempted. It is
likewise inadvisable to break or make
any other connections in the alterna-
FIG.· 3- Bosch Charging System tor circuit while the engine is running.
13-4 GROUP 13-CHARGING SYSTEM

5. Alternator Main Output Cable. If either type of Lucas regulator is outside Other symptoms covered under this head-
(a)The cable connecting the specification it must be replaced. Adjust ing are: battery uses excessive amount of
alternator and the battery is 'live' the voltage regulator if necessary (Bosch). water; burning of; distributor points,
even when the engine is not running. Refer to applicable alternator part of ignition resistor wire, or coil; high battery
Care must be taken not to earth this group. charging rate.
this live cable if it should ever be NOTE4.
removed, or damage to the cable will An output of 2 to 5 amperes less ALTERNATOR NOISY
occur. than that specified usually indicates an When investigating the complaint
(b )The alternator must never be open diode. An output of approximately of alternator noise, first try to loca-
run with the main output cable dis- 10 amperes less than that specified usually lize the noise area to make sure
connected either at the alternator or indicates a shorted diode. (Also see under
battery end while the field remains that the alternator is at fault
"Alternator Noisy").
energised or the rectifiers may be l'ather than the alternator belt,
NOTES. water pump, or another part of the
damaged.
A condition where normal output
6. Arc Welding. The possibility vehicle. Start the engine and use a
results when testing as in NOTE 2, but
of damage to the semi-conductor stethoscope or similar sound detec-
where low or no output results when the
devices during arc welding operations tor instrument to localize the noise.
system is nbrmally connected, could be
on a vehicle is very slight. However, An alternator bearing, water pump
the result of faulty field circuit wiring.
it is a worthwhile precaution to
Before replacing the regulator, check the bearing or belt noise is usually evi-
isolate the control box and alternator
by disconnecting their wmng field wiring as follows:- denced by a squealing sound.
connectors prior to carrying out any If the regulator operation is satisfactory,
check the wire from the accessory terminal An alternator with a shorted
arc welding work on the vehicle.
7. Testing Semi-Conductor De- of the ignition switch to the voltage diode will normally whine (Magne-
vices. Never use an ohmmeter of the regulator, and the wire from the voltage tic noise) and will be most notice-
type incorporating a hand driven regulator to the alternator. Repair or able at idle speeds. Perform the
generator for checking the rectifier replace as necessary. alternator output tests. If the out-
or transistors. Lucas - Remote regulator put is approx. 10 amperes less than
Remove wiring plug from the regulator. that specified,, a shorted diode is
BATTERY LOW IN CHARGE,
Switch on the ignition and check usually indicated.
HEADLIGHTS DIM AT IDLE
voltage at F and IND terminals in wiring
Refer to Fig. 4 for these symptoms. harness. Battery voltage should be To eliminate the belt(s) as the
indicated. cause of noise, check the belt(s) for
CHARGE INDICATOR LIGHT Lucas - Integral regulator bumps, apply a light amount of belt
STAYS ON Remove wiring plug from IND term- dressing to the belt(s). If the al-
inal of the alternator. Switch on ignition. ternator belt is at fault, adjust the
Refer to Fig. 5 for this symptom.
Check voltage available of IND terminal t.elt to specification, or replace the
Oth~1 · symptoms covered under this
of harness. Battery voltage should be belt if necessary.
heading- a1·e : - batte1·y will not hold
charge; altt>l nator has no output; available. If the belt(s) is satisfactory and
alternator has low output. Bosch - Remote regulator the noise is believed to be in the
Remove wiring plug from the regulator. alternator or water pump, remove
Switch on the ignition and check for the alternator belt. Start the engine
:'\OTE I. and listen for the noise as a double
battery voltage at the D+ terminal in the
If tht> owner has had previous check to be !lUre that the noise is
harness. Switch off the ignition and re-
difficulty with the battery runninJ.~: not caused by another component.
place the wiring plug.
down and past history does not in- Use this test and the sound detec-
If all checks in NOTE 5 are satis-
dicate that thl' problem i:,; due to factory to this point it remains only to tor test to isolate the offending
l'Xl·essive nig·ht driving, l'Xcessive ensure that the regulator is effeotively unit. If the noise is traced to the
use of accessories, short tl"ips Ol' earthed. The Lucas injegral regulator earths alternator, remove it and check
extended periods of .idle, then it is through a mounting screw to the alternator bearings for play or roughness.
suggested that the complete c:harg- frame .
ing system he ehel:kl'd. CHARGE INDICATOR/WARNING
The remote regulators earth through LIGHT FLICKERS
their mounting brackets to the body shed
NOTE2. metal. This condition may be caused by
Test the alternator output as described dirty or oxidised regulator contacts
in the applicable part of this Group. LIGHTS & FUSES FAIL loose o'r damaged connections in the
PREMATURELY, SHORT BATTERY charging system wu·mg harness,
NOTE 3.
LIFE worn brushes, or improper brush
Check the voltage regulator setting.
Only the Bosch regulator is adjustable. Refer to Fig. 6 for these symptoms. tension.
PART 13-1-GENERAL CHARGING SYSTEM SERVICE 13-5

IIATTERY LOW IH CHARGE

HEADLIGHTS DIM AT IDLE

• • CI·UCK I=OA A BROUN, LOOSE: OQ SLIPPING

ALT£RNATOR DRIYit BltLT . IN SPitCT 8.UTI:Cl'f ,
CAILt.S A.NO CMAIIGING SYSHM WIRING FOR
GOOO ltUCTRICAL COtrr.ITACT . CLI:AN nu:
UTHR'f TltRMINALS AND TIGMTitN All
CON'•"CTIONS AS NC:CitSSAAY

BATTERY CAPACITY TEST

USE A SUITABLE HIGH lATE DISCHARGE SAnElY TESTEI

ADJUST RESISTANCE UNTIL AMMETEI lEADS 3 TIMES AMPEI-HOUI IATING OF IAnEIY
HOLD FOil 15 SECONDS AND lEAD VOLTAGE

I
VOLTAGE OVER 9.6
I
VOLTAGE LESS THAN 9.6

CHECK SPECIFIC GRAVITY. CHECK SPECIFIC GRAVITY

CHARGE BATTERY, IF BELOW 1.230. OF EACH CELL
OTHERWISE BATTERY IS OK

LESS THAN SO POINTS MORE THAN SO POINTS

(O.OSO) BETWEEN CELLS (O.OSO) BETWEEN CELLS

ADD WATER IF NECESSARY AND

CHARGE BATTERY PER CHARGING
SCHEDULE AND REPEAT CAPACITY TEST

TOTAL VOLTAGE TOTAL VOLTAGE

LESS THAN 9.6 MORE THAN 9.6

• I~ THE OWNER HAS HAD PREVIOUS DlffiCULITY WITH THE

BATTERY-RUNNING DOWN AND PAST HISTORY
DOES HOT INDICATE THAT THE PROBLEM IS OUE TO EXCESSIVE
NIGHT DRIVING, EXCESSIVE USE Of ACCESSORIES,
SHORT TRIPS -OR EXTENDED PERIODS Of IDLE , THEN
IT IS SUGGESTED THAT THE COMPLETE CHARGING
SYSTEM BE CHECKED.

FIG. 4- Diagnosis Chart, 'Battery Low in Charge, Headlamps Dim at Idle'

13-6 GROUP 13-CHARGING SYSTEM

CHARGE INDICATOR LIGHT STAYS ON

BATTERY WILL HOT HOLD CHARGE

ALTERNATOR HAS HD OUTPUT
ALTERNATOR HAS LOW OUTPUT

CHECK FOR A BROKEN, LOOSE OR SLIPPING DRIVE BELT .

INSPECT BATTERY , CABLES, AND CHARGING SYSTEM WIRING
FOR GOOO ELECTRICAL CONTACT . CLEAN THE BATTERY
TERMINALS AND TIGHTEN ALL CONNECTIONS AS NECESSARY .
CHECK THE BATTERY SPECIFIC GRAVITY, CHARGE THE
BATTERY AND PERFORM THE BATTERY TESTS . SEE NOTE NO. I

BATTERY TESTS UNSATISFACTORY

•
CHECK THE OPERATION OF
•
(II PERFORI.I THE
CHARGING CIRCUIT
(I) CHECK THE BATTERY
TO FIELD WIRING .
THE VOLTAGE REGULATOR RESISTANCE THTS. SEE NOTE NO. 5.
SEE NOTE NO. 3
121 T(ST ALTii:ANATOR C21 Tli:ST ALTii:ANATOR
IHOii:Pii:NO,NT 01= INDii:Pii:NDii:NT OF
VHUCU WIRING . YS:HICU WIRING.
SH FIG . 7. Uli: FIG . 7. ·A

FIG. 5- Diagnosis Chart, 'Charge Indicator Light Stays On'

LIGHTS AND FUSES FAIL PREMATURELY

SHORT BATl fRY LIFE
BATTERY USES EXCESSIVE AMOUNT DF WATER
BURNING OF DISTRIBUTOR POINTS, RESISTOR WIRE, OR COIL
HIGH CHARGING RATE

• CHECK ALL CHARGING SYSTEM WIRING

CONNECTIONS INCLUDING THE REGULA TOR
GROUND WIRE . TIGHTEN OR REPAIR AS
REQUIRED. CHECK THE ALTERNATOR
VOLTAGE LIMITEP. SETTING . IF THE
CONTACTS ARE BURNED, REPLACE THE
REGULATOR.

I VOLTAGE IEGULATOI
WITHIN SPECIFICAnON I VOLTAGE IEGULATOI
5m1NG TOO HIGH

• ADJUST TO THE LOW END • IF THE CONTACTS ARE

OF THE SPECIFIED RANGE. BURNED, REPLACE THE
REGULATOR . IF THE
POINTS ARE SATISFACTORY,
ADJUST TO SPECIFICATION.

FIG. 6- Diagnosis Chart, 'Lights and Fuses Fail Prematurely'

PART 13-1-GENERAL CHARGING SYSTEM SERVICE 13-7

EJ TESTING PROCEDURES
TESTING THE ALTERNATOR ALTERNATOR TESTS capacity is a suitable substitute for a
SYSTEM Make an alternator output test carbon pile .
before testing the Voltage Regula- ALL OUTPUT TESTING IS TO BE
Before any tests are made on the MADE WITH THE ALTERNATOR
alternator or regulator the battery tor.
WARM .
should be checked and the circuit Use care when connecting any RUN ALTERNATOR ON FULL
inspected for faulty wiring or insu- test equipment to the alternator LOAD FOR 5 MINUTES PRIOR TO
lation, loose or corroded connec- system, as the alternator output MAKING TESTS.
tions and poor ground circuits. terminal is connected to the battery
Cheek alternator belt tension to be at all times.
BOSCH
sure the belt is tight enough to Circuits for testing alternators and
prevent slipping under load. Any regulators are shown in Figures 10/11 1. Ensure that the ignition is
unfavourable conditions noted in the and 27/35 . switched off.
inspection should be corrected be- 2. Disconnect the battery earth
fore ·proceeding. ALTERNATOR OUTPUT TEST- cable.
ON ENGINE 3. Remove the connector plugs
from the alternator main (B+) and
NOTE: THE IGNITION SWITCH When the alternator output test field terminals (DF and D+ ).
SHOULD BE OFF AND THE is conducted off the car, a test bench 4. Install the main terminal of the
NEGATIVE BATTERY CABLE must be used. Follow the procedure test connector to the alternator B+
DISCONNECTED FROM THE given by the test bench equipment terminal and one lead to the DF
BATTERY BEFORE MAKING manufacturer. When the alternator terminal of the alternator (Figs. 8
ANY TEST CONNECTIONS. is removed from the car for this and 10).
FAILURE TO OBSERVE THESE purpose always disconnect a battery 5. Connect one lead of the test
STEPS MAY RESULT IN DAM- cable as the alternatol' output con- connector to the + (Red) lead of a
AGE TO THE SYSTEM. nector is connected to the battery moving coil, 0 - 60 amp ammeter ,
at all times. connect the - (Black) ammeter lead
NOTE: To prevent short circuiting during
to the B+ terminal in the wiring
1. BATTERY TEST: testing operations it js essential that a test harness.
connector shown in Fig. 7 be used. 6. Connect the positive lead of a
Test the battery with a hydro- good quality voltmeter to the test
meter. If not fully charged it should A variable load such as a Carbon pile connector aml the negative lead to
be placed on charge or a fully rheostat must be available to place across ground .
t'harged battery temporarily instal- the battery. 7. Replace the battery earth cable.
led for test purposes. A switched lamp bank of 800 Watt 8. Connect the carbon pile rheo-

FIG. 7- Test Connector

13-8 GROUP 13-CHARGING SYSTEM

FIG. 8 - Bosch Alternator Terminals FIG. 9- Lucas Alternator Terminals 14 ACR Shown

stat or the switched lamp bank to the with air-conditioning. Has remote 14AC only: connect a jumper
battery terminals. (Ensure that the regulator. lead from the F terminal to ground.
load control is in the off position). NOTE: When testing the output of 14ACR only: earth the power
9. Connect a tachometer to the the Lucas 14ACR alternator on the transistor case to the slip ring end
engine. vehicle the regulator, the field F head.
10. Start the engine and slowly terminal is not accessible. To isolate 8. Replace the battery earth cable.
increase engine speed to 2400 R.P.M. the regulator, earth the power tran- 9. Connect the carbon pile rheo-
(6000 R.P.M. alternator speed). sistor to the alternator body by using stat or switched lamp bank across the
11. Adjust the carbon pile or lamp a small screwdriver between the battery terminals. (Ensure that the
bank until a constant 14 volts is transistor case and the slip ring end load control is in the off position).
achieved. head. 10. Connect a tachometer to the
12. The ammeter should now 1. Ensure that the ignition is engine.
register a 40 amp output. switched off. 11. Start the engine and slowly
13. Reduce engine speed to idle 2. Disconnect the battery earth increase the engine speed to give
R.P.M. and remove the battery load. cable. approximately 6000 alternator R.P .M.
CAUTION: Never remove the battery 3. Remove the wiring plugs from Refer to specifications for engine
load while the engire is running at speed the alternator (Fig. 9). R.P.M. chart.
14. Switch off the engine and re- 4. Install the main terminal of the 12. Adjust carbon pile or lamp
move the battery earth cable. test connector to the + terminal of bank untill3.4-13.6 volts is achieved.
15. Remove the test meters and the alternator (Fig. 11). Rated output should now be regis-
the test connector and replace the 5. Connect one lead of the test tered on the ammeter. Do not allow
original wiring to the alternator. connector to the IND terminal of voltage to exceed 15V.
16. Replace the battery earth cable. the alternator. 13. Reduce the engine speed to
6. Connect one lead of the test idle R.P.M. and remove the battery
Should the alternator fail to pro- connector to the positive lead of a load.
duce the rated output it must be 0 - 60 amp moving coil ammeter. CAUTION: Never remove the battery
removed from the vehicle for further Connect the .negative (Black) lead of load while the engine is running at
tests and repairs. the ammeter to the + terminal of the speed.
wiring harness. 14. Switch off the engine and re-
LUCAS 7. Connect the positive lead of a move the battery earth cable.
14ACR - all 8 cyl. vehicles. Has good quality voltmeter to the test 15. Remove the test meters and
integral regulator. connector and the negative lead to the test connector and replace the
14AC - All 6 cyl. vehicles fitted ground. original wiring to the alternator.
PART 13-1-GENERAL CHARGING SYSTEM SERVICE 13-9

FIG. 10- Output Test Bosch

9ATR Control

Ammeter

...I..-

FIG. 11 -Output Test Lucas

13-10 GROUP 13-CHARGING SYSTEM

16. Replace the battery earth cable. If the reading is below speci- connecting an ohmmeter between
fications, short circuited windings the winding ends (Fig. 14).
Should the alternator fail to pro- are indicated.
duce the rated output it must be re- The readings must be even on
moved from the vehicle for further each phase .
2. Test the rotor insulation by High reading indicates open circuit.
tests and repairs. using a 12V battery and test lamp Low reading indicates short circuit.
TESTING THE ROTOR (Fig. 13). Place one prod on a slip
1. Test the rotor windings by ring, the other on the rotor shaft.
The test lamp should not light. 2. Test the stator insulation by
connecting an ohmmeter between the using a 12V battery and test lamp
slip rings (Fig. 12). between each winding end and the
TESTING THE STATOR
If the reading is above speci- lamination pack (Fig. 15). The test
fications, an open circuit is indicated. 1. Test the stator windings by lamp should not light.

FIG. 12- Rotor Winding Test FIG. 14- Stator Winding Test

000000 000000
12V

FIG. 13- Rotor Insulation Test FIG. 15- Stator Insulation Test
PART 13-1-GENERAL CHARGING SYSTEM SERVICE 13-11

FIELD DIODES
1. Place one test probe on the
diode terminal strip (Lucas) or
junction (Bosch) and the other probe
on the IND terminal (Lucas) or A
terminal (Bosch) (Figs. 16 & 18).
2. By reversing the probes it can
be established if one or more of the
field diodes has failed due to an
open or short circuit.

HEAT SINKS
The Negative heat sink is grounded
to the alternator frame.
The Positive heat sink is insulated
from the alternator frame and from
the Negative heat sink.
NOTE: The Bosch rectifier is not
repairable and if found faulty in the
foregoing tests it must be replaced.
The Lucas rectifier is .serviced in
three subassemblies.
I. Positive diode and heat sink
assembly.
2. Negative diode and heat sink
assembly.
3. Field diode and insulator
assembly.
BATTERY TESTS AND
CONCLUSIONS
FIG. 16- Rectifier Pack Lucas Tests are made on a battery to
determine the state of charge and
TESTING THE DIODES AND POWER DIODES also the condition. The ultimate re-
(RECTIFIER ASSEMBLY) sult of these tests is to show that
I . Apply one probe to the diode the battery is good, needs recharg-
In the event of a fault in one or terminal strip (Lucas) or junction ing, or must be replaced.
more of the diodes being indicated by (Bosch) and the other probe to the
the. alternator output test, the recti- appropriate heat sink. If a battery has failed, is low in
fier pack must be removed from the 2. Reverse the probes. charge, or requires water frequent-
alternator. The test lamp should light in one ly, good service demands that the
There are two main possibilities direction only. Should the lamp light reason for this condition be found.
which can destroy a diode during in both directions the diode is short It may be necessary to follow
service, either a break-down in resis- circuited. (If both diodes of one trouble shooting procedures to lo-
tance to current flow caused by high phase are short circuited all 6 diodes cate the cause of the trouble. (Sec-
current flow and high temperature, will show a short circuit when tested). tion 1. in this part) .
or an open circuit in both directions If the test lamp does not light
almost always the consequence of in either direction the diode is open Hydrogen and oxygen gases are
excess voltage. circuited. produced during normal battery
CONNECTION
!CATHODE)
CURRENT FLOW

1 HOUSING Take apecial

care ot the ..
aolder connection•
FIG. 17 -Diode Connections
For testing purposes it is not Poeitive
Heat Sink
necessary to disconnect the individual
diodes, however it is essential that the
stator leads be unsoldered from the
rectifier pack.
A 12 volt battery with test probes
and a 2 watt globe in series is used
for diode testing. FIG. 18 -Bosch Rectifier Pack
13-12 GROUP 13-CHARGING SYSTEM

BATTERY CAPACITY TEST

USE A SUITABLE HIGH lATE DISCHARGE IAr:TERY TESTER

ADJUST RESISTANCE UNTIL AMMETER lEADS 3 TIMES AMPER-HOUI IATING OF IATrERY
HOLD FOR 1 5 SECONOS AND READ VOL'T'AGE

I
VOLTAGE OVER 9.6
I
VOLTAGE LESS THAN 9.6

CHECK SPECIFIC GRAVITY . CHECK SPECIFIC GRAVITY

CHARGE BATTERY, IF BELOW 1.230. OF EACH CELL
OTHERWISE BATTERY IS OK

LESS THAN 50 POINTS MORE THAN 50 POINTS

(0.050) BETWEEN CELLS (0.050) BETWEEN CELLS

I
ADD WATER IF NECESSARY AND
CHARGE BATTERY PER CHARGING
SCHEDULE AND REPEAT CAPACITY TEST

I
I
I
TOTAL VOLTAGE
LESS THAN 9.6
TOTAL t OL TAGE
MORE THAN 9.;

FIG. 19- Battery Capacity Test

operation. This gas mixture can tests. THE BATTERY POSTS AND NOT
explode if flames or sparks are A battery can be tested by deter- THE HIGH RATE DISCHARGE
brought near the vent openings of ming its ability to deliver current. TESTER CLIPS. UNLESS THIS
the battery. The sulphuric acid in This may be determined by conduct- IS DONE THE ACTUAL BAT-
the battery electrolyte can cause a ing a Battery Capacity Test. (Fig. TERY TERMINAL VOLTAGE
serious burn if spilled on the skin 19) shows the battery capacity WILL NOT BE INDICATED.
or spattered in the eyes. It should test in outline form. 4. Turn the load control knob in
be flushed away with large quanti- a clockwise direction until the am-
ties of clear water. BATTERY CAPACITY TEST meter reads three times the ampere
A high rate discharge tester hour rating of the battery. (A 45
Before attempting to test a bat-
(Battery-Starter) in conjunction ampere hour battery should be tes-
tery, it is important that it be given
with a voltmeter is used for this ted at 135 amperes load).
a thorough visual examinaton to
test.
determine if it has been damaged. 5. With the ammeter reading
The presence of moisture on the 1. Turn the control knob on the the reuuired load for 15 seconds,
outside of the case and/ or low Rattery-Starter Tester to the OFF note the voltmeter reading. A VOID
electrolyte level in one or more of position. LEAVING THE HIGH DIS-
the cells are indications of possible 2. Turn the voltmeter selector CHARGE LOAD ON THE BAT-
battery damage. switch to the 16 or 20 volt position. TERY FOR PERIODS LONGER
Some batteries incorporate a sin- 3. Connect both positive test THAN 15 SECONDS.
gle one-piece cover which complete- leads to the positive battery post 6. If the voltmeter readin~r is
ly seals the top of the battery and and both negative test leads to the 9.6 volts or more, the battery has
the individual cell connectors. This
cover must not be pierced with test negative battery post. THE VOLT- good output capacity and will readi-
probes to perform individual cell METER CLIPS MUST CONTACT ly accept a charge, if required.
PART 13-1-GENERAL CHARGING SYSTEM SERVICE 13-13

Check the specific gravity. If the is less than 50 points ( 0.050) the
battery should be charged according BATTERY DRAIN TEST
specific gravity reading is 1.230 or
below, add water if necessary and to the charging schedule.
charge the battery until it is fully In some cases the electrolyte This test will determine if there
charged. level may be too low to obtain a is any external load that would
specific gravity reading. In such cause unwanted battery discha rge.
The battery is fully charged when cases water should be added until
Disconnect the battery ground
the cells are all gassing freely and the electrolyte level just covers the
the specific gravity ceases to rise ring in the filler well, then charge cable and connect the positive lead
for three successive readings taken the battery at 35 amperes for the of a voltmeter to the cable. Con-
at hourly intervals. Additional bat- maximum charging time indicated nect the negative lead of the volt-
tery testing will not be necessary in specifications, for capacity of the meter to the battery negative post.
after the battery has been properly battery being tested.
charg-ed . With all circuits off, the meter
10. After the battery has been
r:harged, repeat the capacity test. should read zero. Any battery ex-
7. If the voltag·e reading ob- If the capacity test battery voltage ternal load will cause th e voltmeter
tained during the capacity test is is still less than 9.6 volts, replace to read full battery voltage.
helow !1.6 volts, check the specific the battery. If the voltage is 9.6 or If the car is equipped with an
)!Tavity of each cell. more, the battery is satisfactory electric clock. momentarily connect
for service. the battery ground cable to the bat-
!l. If the difference between any
11 . If the battery is found to be tery negative post to make certain
two cells is more than 50 points that the clock is wound. When the
discharged only, check for a loose
(0.050), the battery is not satisfac- clock runs down at the end of
fan belt, loose electrical connec-
tory for service and should be re- approxima tel y 2 minutes the volt-
tions, charging system perform-
placed. meter will show full battery vol-
ance, and make a battery drain test
9. If the difference between cells (in this secton). tage.

9 COMMON ADJUSTMENTS AND REPAIRS

BELT ADJUSTMENT-
ALTERNATOR
2. Apply pressure on the altern- 3. Check the belt tens ion using
1. Loosen the alternator mount- ator front housing only and tighten tool 8620-B. Adjust the belt for
ing bolt and the adjusting arm the adjusting arm to alternator specified tension.
bolts. bolt. 4. Tighten all mounting bolts.

D CLEANING AND INSPECTION

1. The rotor, stator, and bear- slipring; loose slip ring; damaged Re-solder any poor connections.
ings must not be cleaned with sol- rotor leads; shaft thread damage etc. Replace stator if insulation is
vent. Wipe these parts off with a Replace or repair this assembly burnt and / or flakin g·.
clean cloth. as required. 7. Inspect the brush-card assem-
2. Rotate both the front and 4. Inspect the pulley and fan for bly for distortion and wear. Inspect
rear bearings and assess their con- excessive looseness on the rotor brushes for wear and lead or spring
dition by feelin g for excessive play b,reakage. This is best done by com-
shaft. Inspect the fan for cracks
or roughn ess. Load the bearings parison with a new brush and
and bent blades. Replace the fan if
by hand pressure when checking sprin!(' assembly.
cracks art! apparent.
for roughness and rotate the outer
race at lea5 t six turns in this man- 5. Check both end heads for
nacks, stripped threads (particu- VERY IMPORTANT
ner. Look for excessive lubricant
leakage. lal'ly on the mounting lugs), distor-
Before assembling the Alternator,
tion , enlarged diode holes etc. Re-
Replace bearings if any of these refer to appropriate section for details
place defective end-heads. of Insulating Washers and the posi-
conditions exist.
3. Inspect the t·otor assembly 6. Check the stator windings f01 tion in which they are used.
for damage to the pole surfaces signs of overheating. Make sure the Failure to insulate the compon-
due to contact with stationary com- stator leads are not fractured or ents correctly can damage both the
ponents; scores or bruises on the broken oft' inside the sleeving. Alternator and Regulator.
13-14 GROUP 13-CHARGING SYSTEM

IJ DIAGNOSIS
1. ALTERNATOR DOES NOT D. Open circuit in stator wind- 5. BURNT REGULATOR
CHARGE: ine. CONTACTS~(Bosch)

A. Driving belt loose. A. High regulator setting.

B. Worn brushes or rings. 3. LOW OUTPUT AND LOW
BATTERY B. Shorts in rotor field coil.
c. Sticking brushes.
D. Open field circuit. A. High resistance in charging C. Earthed rotor field coil or
E . Open charging circuit. circuit. slip-rings.
F. Open circuit in stator wind- B. Low regulator setting (Bosch)
6. REGULATOR CONTACT
ing. C. Faulty diode rectifier. POINTS WELDED: (Bosch)
G. Faulty diode rectifiers. D. Grounded stator winding.
H. Faulty regulator. A. High resistance ground cir-
cuit between alternator and regu-
lator.
2. LOW OR VARIABLE .£. OVERCHARGING:
CHARGING RATE: 7. UNSATISFACTORY WARN-
A. Regulator set too high (Bosch) ING LIGHT OPERATION:
A. Driving belt loose.
B. Regulator contacts welded (Bosch)
B. High resistance in charging
circuit (check battery terminals). C. Regulator coil winding open (Bosch) A. Faults in alternator and reg-
ulator operation.
C. High resistance in earth re- D. Regulator not effectively
turn circuit. earthed. B. Low voltage setting (Bosch)

OUTPUT TEST DIAGNOSIS

Temperature Noise Output Probable Fault and

Warning Light Associated Damage
Normal at standstill, goes out at High Normal Higher than normal A positive output diode
cut-in speed but then glows at 6000 rev/min open-circuited (May damage rotor
progressively brighter as speed winding and output stage, overheat
increases. brush boxes and blow warning
light).
Light out under all conditions. High Excessive Very low at A positive output diode short
6000 rev/min circuited (May cause failure of
associated 'field' diode).
Normal at standstill, dims Normal Excessive Poor at low speed. A negative output diode
appreciably at cut-in and gets Slightly below open-circuited
progressively dimmer at normal at
higher spe_eds. 6000 rev/min.
Normal at standstill, dims Normal Excessive Very low at all A negative output diode short-
slightly at cut-in and remains speeds above cut-in. circuited. (The same symptoms
so throughout speed range. would be apparent if one phase
winding was shorted to earth).
Normal at standstill, dims Norm11l Normal Lower than normal A 'field' diode open-circuited.
slightly at cut-in and remains at 6000 rev/min.
so throughout speed range.
Normal at standstill, dims Normal Normal Very low.at A 'field' diode short-circuited.
appreciably at cut-in and 6000 rev/min.
remains so at higher speeds.
13-15

PART BOSCH ALTERNATOR

13·2

Section Page Secdon Page

1 Description and Operation ................ 13-15 3 Major Repair Operations . . .. . .. .. .... . . .. 13-17
2 Removal and Installation ...•.......... . .. 13-17

IJ DESCRIPTION AND OPERATION

The Bosch alternator is a three DC output current to be used for lii'ECTED WITH THE NEGATIVE
phase alternating current (AC) gener- indicator light operation and TERMINAL TO GROUND. FAIL-
ator with six integrally mounted excitation of the field winding URE TO CONNECT A BATTERY
silicon diodes that convert the AC through the regulator. WITH THE CORRECT POLARITY
into direct current (DC) suitable for 4. The two end heads which carry WILL DAMAGE THE ALTERNA-
charging the battery. the ball bearings. TOR AND REGULATOR. DIS-
The drive end head incorporates CONNECT ONE VEHICLE BAT-
A further three smaller diodes are
the mounting lug while the slip ring TERY LEAD WHEN USING A
fitted into the rectifier pack to pro-
vide DC for field excition via the end head contains the brush gear and QUICK CHARGER.
voltage regulator. rectifier pack.
A remote voltage regulator ,
mounted on the fender apron, IS Alternator Terminals - Fig. 8
used to control the alternator voltage D+ Field diode junction for regulator
output. D+ and indicator lamp
The alternator is inherently self DF Field terminal connection for
current limiting and the diodes pre- Portion of this D.C. is directed to the
regulator DF.
vent reverse current flow from the field excitation diodes, one end of each
B+ Battery connection
battery. diode being connected to a phase of the
+ Radio suppressor terminal
The alternator consists of the stator and the other end to the D+
following major parts: - OPERATION terminal. From the D+ terminal the current
is routed through the regulator to the
1. The Stator, a laminated frame With the ignition switch turned DF terminal of the alternator. The current
which carries in slots the three phase on and the engine running (Fig. 3), now passes through the field winding to
star connected output winding. the flow of current through the ro- ground.
2. The Rotor, comprising the slip tor field coil energises the twelve
rings and field (exciter) windings and pole rotating electro magnet. The As the speed of the rotor in-
is constructed of interlaced poles or rotation of the energised rotor unit creases, the induced vol tage in the
fingers which form alternate north
induces an A.C. voltare in the three stator winding increases, causing
and south poles. The field winding is
phase rotor winding which ia con- more current to flow to satisfy the
wound concentric with the shaft
verted into D.C. by the aix diode load equirements. However, the in-
inside the claw poles and has its
rectifiers and conducted to the B+ terminal. ductive reactance of the stator
ends connected to the slip rings.
3. The Rectifier Pack containing The rectifiers, which only conduct winding provides an automatic up-
nine diodes. in one direction, prevent the battery per limit on the cu.rrent output of
The six output diodes are arranged which is directly and permanently the alternator.
in a three phase bridge connection connected to the alternator output The function of the voltage limi-
having three diodes of positive polar- terminal, from diachar&'ing through ter is to control the output voltage
ity and three diodes of negative the alternator. This characteristic of the Alternator to meet the needa
polarity. of the rectifiers eliminates the need of the vehicle electrical system
for a cut-out relay, BUT IT IS which it accomplishes by controll-
The three field diodes are in the ESSENTIAL THAT THE BAT- ing the flow of current in the rotor
D+ circuit and allow portion of the TERY MUST ALWAYS BE CON- field coil.
-
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1. DRIVE END HEAD m

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2. STATOR
3. RECTIFIER PACK
4. SLIP RING END HEAD
5. BRUSH GEAR ASSEMBLY
6. RADIO SUPPRESSOR
7. ROTOR

FIG. 20- Bosch Alternator- Exploded View

PART 13-2-BOSCH ALTERNATOR 13-17

EJ REMOVAL AND INSTALLATION

REMOVAL & INSTALLATION Remove the alternator mounting 2. Install the adjustment arm t o
REMOVAL bolt, disconnect the alternator wir- a lternator bolt.
1. Disconnect the battery ground ing- harness and remove the alter- 3. Adjust th e belt tension using·
cable. nator. tool T63L-8620-A . Apply pressure
2. Loosen the alternator mount- INSTALLATION on the alternator front housing
ing bolts and remove the adjust· <' nly, when ti g htening the belt.
ment arm to alternator bolt. (Bet- 1. Attach the alternator wiring Tig hten t he adjusting arm bolts
ter access to these may be possible harness. Position the alternator to the and the mounting bolt.
with the vehicle raised) . engine, and install the alternator mounting 4. Lower the car and connect the
3. Disengage the alternator belt. bolt finger-tight. batte r y g round cable.

EJ MAJOR REPAIR OPERATION

DISMANTLING THE ALTERNATOR 9. Remove the drive end head with soft jaws and tighten the pulley
bearing by unscrewing the 2 retaining nut to specification.
1. Mark both end housing and the plate screws, re~ove the plate and 7. Press the slip ring end bearing
stator with a scribe mark. withdraw the bearing. onto the shaft shielded side first .
2. Remove the brush holder by 10. Remove the bearing from the 8. Position the rectifier pack in
unscrewing the 2 attaching screws. slip ring and of the rotor shaft with the slip ring end head. Insert the
3. Remove the 4 through bolts. a suitable puller. two long screws in the insulated
4. Separate the drive end head 11. For cleaning and inspection holes and the two short screws in the
and rotor sub-assembly from the slip see Part 1 of this group. other two mounting holes. Tighten all
ring end head and stator sub-assembly. screws.
Do not loose the wave washer from ASSEMBLY 9. Position the stator assembly on
the slip ring end head bearing recess. the slip ring end head and align the
5. Using long nose pliers on the 1. Position the drive end head
·bearing, shielded side first, in the end scribe marks.
diode leads as heat sinks unsolder 10. Using a pair of pliers as a heat
the 3 stator leads from the rectifier head. Secure the retaining plate with
two screws. sink on the diode leads quickly solder
assembly and remove the stator. the stator leads to the terminal strips
2. Place the smaller of the two
6. Remove the 4 attaching screws shouldered washers on the drive end on the rectifier pack.
and withdraw the rectifier assembly of the rotor shaft with the shoulder 11 . Place the wave washer in the
from the slip ring end head. towards the bearing. (Make sure that slip ring end head bearing recess.
7. To remove the rotor from the the jump ring has not been displaced 12. Fit the rotor end head and
drive end head hold the rotor in a vice on the shaft.) rotor sub-assembly to the slip ring
equipped with soft jaws. Remove the 3. Push the rotor shaft through head and ·stator sub-assembly, align
pulley retaining nut , lock washer, the bearing. (This should be a hand the scribe marks and fit the through
spacer and pulley. Remove the second push fit.) bolts.
spacer and the fan. A third spacer 4. Place the larger shouldered 13. Tighten the through bolts
(shouldered) is fitted in the end spacer on the rotor shaft with the evenly.
head, remove this spacer. shoulder toward the bearing. 14. Fit the brush and terminal
8. The end head may now be 5. Position the fan on the shaft assembly and tighten the attaching
supported on a press and the rotor with the blades toward the end head screws.
pressed out. A shouldered spacer and follow it with a spacer, pulley, 15. Ensure that the rotor turns
will be found on the shaft behind lock washer and-nut. freely by hand, install on the vehicle
the bearing. 6. Grip the rotor in a vice equipped and observe operation.

:..: . ,·:·

FIG. 21 - Rectifier Pack Fixing Screws FIG. 22 - Soldering Stator Leads

13-18

PART
LUCAS ALTERNATOR
13-3

Section Page Section Page

1 Description and Operation ................ 13-18 3 Major Repair Operations ................. 13-20
2 Removal and Installation ................. 13-20

LUCAS AlTERNATOR 14 ACR-4D and 6D models with an operation and repair procedures apply
Two types of Lucas alternators integral 13 ATR voltage regulator. to both except as noted.
With the exception of the position-
are used on XA/ZF vehicles. They The 14 ACR-4D and 6D models
ing of the voltage regulator the two
are the 14 AC-6D model with a types of alternator are basically the vary only in their rated output being
remote 9 ATR voltage regulator and same and the following description, 40 and 55 amps respectively.

0 DESCRIPTION AND OPERATION

The stator comprises a 36 slot bracket. Two carbon brushes bear junction with three of the six main
3-phase star connected output wind- against a pair of copper slip rings diodes and at normal operating speeds
ing on a ring shaped lamination pack, which encircle the rotor shaft. this supplies the energy for the alter-
housed between the slip ring end and Rectification of alternator output nator field coil via the slip rings,
drive end brackets. The rotor is of 12 is achieved by six silicon diodes brushes and voltage regulator.
pole construction and carries a slip contained within the slip ring end The diodes and stator windings are
ring fed rotor (field) winding. It is bracket and connected in a three cooled by airflow through the alter-
supported by ball bearings in the phase bridge circuit between stator nator induced by a ventilating fan
drive end slip ring end heads. and output terminals. A second recti- mounted on the rotor shaft at the
The brush gear for the field system fier bridge is formed by using three drive end.
is mounted on the slip ring end auxiliary low current diodes in con- An electronic voltage regulator is

FIG. 24- lucas Charging Circuit 14 ACR Shown

L tlC.&S 14 .&C .&LTBBN.&TOR

011111!11"1119 ~ fi ~
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1. Shaft Nut 12. Slip Rings

2. Shaft Nut Spring Washer 13. Slip Ring End Bearing
3. Bearing Collar 14. Stator
4. Pulley 15. Wavy Washer
5 . Fan 16. Slip Ring End Bracket
6 . Drive End Head 17. Brush Set
7. Fixing Through Bolt 18. Brush Box Moulding
8 . Drive End Bearing 19. Field Diode and Terminal Plate Assembly
9 . Drive End Bearing Retaining Plate 20. Positive Heat Sink and Diode Assembly
10. Retaining Plate Screws 21 . Insulators

-
11 . Rotor 22. Negative Heat Sink and Diode Assembly

w I

FIG. 23- Lucas 14 AC Alternator \()

13-20 GROUP 13-CHARGING SYSTEM
mounted inside the slip ring end OPERATION WILL DAMAGE THE ALTERNA-
head on the ACR type alternator, With the ignition switch turned TOR AND REGULATOR. DIS-
while on the AC type alternator the on and the engine running (Fig. 24), CONN ECT ONE VEHICLE BAT-
remote voltage regulator is mounted the flow of current through the ro- TERY LEAD WHEN USING A
on the fender apron. tor field coil energises the twelve QUICK CHARGER.
In effect its action is similar to pole rotating electro magnet. The Portion of the output current is fed
that of the vibrating contact type rotation of the energised rotor unit through the field diodes to the voltage
of voltage regulator, but switchin~ of induces an A.C. voltage in the three regulator. From the regulator this current
the field circuit is achieved by tran- phase rotor winding which is con- goes to ground via the field windings.
sistors instead of vibrating contacts. verted into D.C. by the aix diode
No cut-out is required since the diodes rectifiers and conducted to the + output As the speed of the rotor in-
incorporated in the alternator prevent terminal creases, the induced voltage in the
reverse currents from flowing. No The rectifiers, which only conduct stator winding increases, causing
current regulator is required as the in one direction, prevent the- battery more current to flow to satisfy the
inherent self regulating properties of which is 'directly and permanently load equirements. However, the in-
the alternator limit the output current connected to the alternator output ductive reactance of the stator
to a safe value. terminal, from discharging through winding provides an automatic up-
Design features include tempera- per limit on the current output of
the alternator. This characteristic
ture compensation without the use of the alternator.
of the rectifiers eliminates the need
a thermistor, radio frequency inter- The function of the voltage limi-
for a cut-out relay, BUT IT IS
ference suppression, requires no ad- ter is to control the output voltage
ESSENTIAL THAT THE BAT-
justment in service. of the Alternator to meet the needa
TERY MUST ALWAYS BE CON-
The voltage regulator and alter- NECTED WITH THE NEGATIVE of the vehicle electrical system
nator are isolated from the battery TERMINAL TO GROUND. FAIL- which it accomplishes by controll-
when the engine is stationary by URE TO CONNECT A BATTERY ing the flow of current in the rotor
means of the ignition switch. WITH THE CORRECT POLARITY field coil.

EJ REMOVAL AND INSTALLATION

REMOVAL & INSTALLATION Remove the alternator mounting 2. Install the adjustment arm to
REMOVAL bolt, disconnect the alterna tor wir- a lternator bolt.
1. Disconnect the battery ground ing harness a nd remove the alter- 3. Adjust the belt tension using
cable. nator. tool T63L-8620-A . Apply pressure
2. Loosen the alternator mount- INSTALLATION on the alternator front housing
ing bolts and remove the adjust- <'nly, when tightening the belt.
ment arm to alternator bolt. (Bet- 1. Attach the alternator wiring Tighten the adjusting arm bolts
ter access to these may be possible harness. Position the alternator to the and the mounting bolt.
with the vehicle raised) . ~ngine, and install the alternator mounting 4. Lower the car and connect the
3. Disengage the alternator belt. bolt finger-tight. battery ground cable.

EJ MAJOR REPAIR OPERATION

DISMANTLING THE ALTERNATOR voltage regulator (ACR models only) and unsolder the three wires from
may now be removed as an assembly. each, this will separate the Positive,
1. Mark both end housings and NOTE: The rectifier pack may now Negative and field diode heat sinks.
the stator with a scribe mark. be tested as detailed on Page 11 of NOTES:
2. Withdraw the three through Part 1 and if further dismantling is (a) Field diode assembly consisting
bolts. necessary proceed .as follows. of three field diodes and insulated
3. Separate the drive end head 6. ACR models only, unsolder moulding is serviced as one unit.
and rotor sub-assembly from the slip the regulator leads at the brush gear. (b)Positive and Negative heat sinks
ring end head and stator sub-assembly. 7. Unsolder field diode connec- are serviced separately as complete
Do not loose the wave washer from tions on brush gear terminal. units, each unit comprising three
the slip ring end head bearing recess. NOTE: It is important this unsolder- diodes and heat sink.
4. Using a pair of long nose pliers ing operation be carried out as quickly ( c) The rectifier insulators and heat
as a heat sink on the stator wire as possible as excessive heat trans- sink separators are serviced as a com-
quickly unsolder the stator leads ference from the soldering iron to the plete kit.
from the terminal strips on the recti- brush box moulding could warp the
fier pack and remove the stator moulding and.result in restricting the For electrical tests on the com-
from the slip ring end head. free movement of the brushes. This ponents refer to pages 10 and 11 of
5. Remove the two rectifier pack also applies when soldering on the part one of this group.
attaching nuts, spring and flat washers. field diode connections during re-
Remove the brush gear attaching assembly of the alternator. ASSEMBLY
screw. Remove the voltage regulator 8. Using a pair of long nose pliers 1. Reassemble the rectifier assem-
attaching screws (ACR models only). as a heat sink grip each of the semi- bly placing the four insulation pieces
The rectifier pack, brush gear and conductor wiring terminations in turn and the Positive male Lucar in original
PART 13-3-L UCAlS ALTERNATOR 13-21

positions. and bend the wire into position with 6 . Place wavy thrust washer in
2. Place the rectifier in position the fingers. This will eliminate the SRE bearing housing.
in the body of the SRE bracket and possibility of the wire becoming de- 7. Compress brushes and insert a
fit fixing bolts, flat and spring tached from the silicon wafer inside 3" x 3/32" diameter steel pin
washers and nuts. the diode assembly. through the guide hole in the
3. Refit the brush gear and fixing 5. ACR models only . Ensure SRE head with approximately
screw. Solder field diode wires onto 6m/mxl 3m/m PVC sleeving pieces 1" of the pin protruding through the
brush gear terminal. on each of the two voltage regulator rear face of the end head. This will
NOTE : It is important that this mounting posts are in position and hold the brushes in a compressed
soldering operation be carried out are not damaged , renew if nec- position whilst the rotor is being
as quickly as possible as excessive essary using PVC sleeving cut to the fitted .
heat transference from the soldering abovementioned lengths (Fig. 25). 8. Fit stator and solder the three
iron to the brush box moulding could Place the voltage regulator in posi- phase leads onto their original term-
warp the moulding and result in tion and fit pan head screws with inals.
restricting the free movement of the the lock washer under the screw on Fit D.E. head and rotor assembly .
brushes. the right hand side of the regulator as Fit and tighten the three through
4. Solder main and field diode viewed from the front (Ref. figure bolts evenly to a torque of 45 lbs/ins.
wires onto their original terminal 33). This washer is important as it ensuring the end brackets are sitting
strips using a pair of long nose pliers ensures a good earth return for the evenly on the stator lamination pack.
to grip the wire and act as a hea t regulator. Withdraw brush gear retaining pin .
dissipater. (Use 'Ersin' 60/40 'M' Refit fan, pulley, spring washer
Regulator Wiring Terminations - and shaft nut, tightening shaft nut
Grade Solder or equivalent).
NOTE : When bending the diode Green wire from regulator to to specification.
wires to link up with the termination rear brush terminal. 9 . Ensuring that the rotor turns
strips, grip each diode wire at its White or Red wire to front or IND freely by hand, install on the vehicle
base with a pair of long nose pliers brush terminal. and observe operation.

White or
Red Lead

Green
Lead

Voltage Regulator Lock Washer under this screw

6mm x 13mm PVC Sleeving

FIG. 25- 14 ACR Alternator S.R.E. Bracket Internal View

13-22

PART ALTERNATOR REGULATOR· BOSCH

13-4
Section Page
I Description and Operation .... . ........ .. .. 13-22
2 In-Car Adjustment and Tests ............ 13-24

DESCRIPTION
The BOSCH alternator regulator
is a single element electro-mechanical
voltage regulator only (Fig. 26).
Because of the inherent current
control of an alternator caused by the
inductive reactance of the stator no
current limiter is required and as
the rectifier diodes prevent reverse
current flow from the battery no
VIBRATING CONTACTS cut-out is required either.
The voltage regulator is a double
contact vibrating unit incorporating
a positive temperature co-efficient
resistor.
An electro-magnet attracting the
armature blade against spring tension
provides the voltage control.
A wire wound choke is used in the
field circuit to smooth out voltage
surge and prolong point life.
OPERATION
There are three phases of opera-
tion of the voltage regulator.
FIG. 26- Bosch Regulator 1. Lower points closed - no
regulation Fig. 29.

~~1 I I I I r-111

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REGULATOR

0 0

FIG. 27- Voltage Reg. Test (Bosch)

PART 13-4-ALTERNATOR REGULATOR 13-23

OF TERMINAL
FIELD WINDING CIRCUIT

OF TERMINAL LAMP
INDICATOR LIGHT CIRCUIT

RESISTOR
DF TERMINAL
FOR RADIO SUPPRESSOR

FIG. 28- Bosch Regulator

When the alternator voltage is
ALTERNATOR
low the lower contacts will be closed
by the armature spring allowing full
system voltage to be applied to the
field windings.
Initial field excitation via the
ignition switch and indicator light
is applied to the field windings
through the lower contacts as resid-
ual magnetism in the alternator is
usually too small to start a voltage
build up.
2. Lower points open - first stage
of regulation Fig. 30.
When the alternator voltage irn·
pressed on the electro-magnet reaches
a predetermined value the armature
is attracted to the core of the electro- IGN. SWITCH BATTERY
magnet, the lower contacts are opened
and a resistor is connected in series
with the field winding. The reduced
field strength causes the alternator FIG. 29- Field Circuit- Lower Points Closed
voltage to fall. As a consequence the
contacts cannot be held open by the
reduced influence of the electro-
magnet and they close. This cycle is
repeated 50-200 times per second ALTERNATOR
and the voltage is maintained at a
predetermined setting.
3. Upper contacts closed - field
circuit grounded - second stage of
regulation Fig. 31.
As the alternator speed and battery
voltage rise the voltage begins to
overcome the resistance and as a result
the alternator voltage will rise. The
influence of the electro-magnet be-
comes so strong that the upper points
will make contact. The stationary
upper point is grounded and so the
field circuit is short circuited. The
drop in voltage impressed on the
electro-magnet allows the armature
spring to open the upper points and IGN. SWITCH BATTERY
the resistor is again in circuit, this
cycle of regulation on the upper
points is also repeated many times
per second. FIG. 30- Field Circuit- Points Open
13-24 GROUP 13-CHARGING SYSTEM
9. Cycle the system by stopping
and re-starting the engine.
ALTERNATOR
10. With the ammeter reading 10
REGULATOR amps the voltmeter reading should
be within 13.5-14.4 volts.
To check the regulating range proceed
as follows :-
11. Increase the engine speed to
2700 - 2800 R.P.M.
The voltage reading with an 8 - 10
amps load should not vary from the
regulating voltage by more .than - 0.2
to +0.4 volts.

Electrical adjustments
1. Switch off the engine.
2. Remove the wiring plug from
IGN. SWITCH
the base of the regulator.
BATTERY 3. Remove the regulator from the
vehicle.
4. Remove the sealing tape and
FIG. 31 -Field Circuit- Upper Contacts Closed remove the regulator cover.
5. Refit the regulator to the
IN CAR TESTS AND ADJUSTMENTS 3. Insert an ammeter between the vehicle.
alternator B+ terminal and the B+ 6. Replace the wiring plug to the
Voltage regulator tests.
terminal of the disconnected wiring base of the regulator.
Before attempting to assess the cable.
performance of the voltage regulator 7. Adjust the bi-metal spring
4. Connect the positive lead of a bracket upwards to increase or down-
always carry out an alternator out- voltmeter to the test connector on
put test - see page 13-7 wards to decrease the voltage setting.
the alternator B+ terminal and the Fig. 26.
Accurate test equipment must be negative lead to ground .
used.
8. Replace the regulator cover,
5. Replace the battery earth cable. start the engine and run it at 700
The voltage regulator tests must
be carried out with a fully charged
6. Install a tachometer on the R.P.M. for 5 minutes to stabilize
battery; with the regulator at normal engine. the temperature.
operating temperature ; and with the 7. Start the engine, switch on 9. Cycle the system by stopping
cover in place. lights and accessories as necessary and restarting the engine.
to obtain a charge rate of 10 amps 10. With the engine running at 700
Regulating voltage test. Fig. 27 and adjust the engine speed to 700 R.P.M. adjust the load (lights etc.)
1. Remove the battery earth cable. R.P.M. to 10 amps. The voltmeter should
2. Remove the wiring plug from 8. Run the engine at this load read 13.5- 14.4 volts .
the B+ terminal of the alternator and and speed for 15 minutes to normal- If the specified voltage cannot be
fit the test connector. ise operating temperature. obtained the regulator must be re-

RE ST POSITION ATTRACTED POSITION

BIMETAL SPRING

~
" L
-~
ARMATURE TIP

~
BIMETAL SPRi riG BRACKET

-- --""

- ~

•t ,.._A .........., .........::~

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B
~ D

II ~p ~~ ~I
LOWER CONTACT BRACKET II"'
lD
~~
UPPER CONTACT BRACKET

. t---l
1\ ....--..,

FIG. 32 - Bosch Regulator Gap Setting

PART 13-4-ALTERNATOR REGULATOR 13-25

moved from the vehicle for further 14. After the adjustments have The gap between the upper or
adjustment or repair. been satisfactorily completed seal high speed contacts should be .008 -
the cover with Polyester tape. A spot .016". Adjust by bending the upper
To reset the regulating range of sealer should be applied at the contact bracket.
11. Increase the engine speed to start of the tape underneath the over- Ensure that the contacts are in
2700- 2800 R.P.M., adjust the load lap to prevent water ingress. alignment with each other.
to 8 - 10 amps, the voltage should 3. Armature air gap - upper
Mechanical adjustments points closed: (C)
be within -0.2 to +0.4 volts.
12. If the re~ulating range exceeds To carry out the mechanical ad- Close the upper points by applying
+0.4 increase/reduce the air gap justments the regulator must be re- light finger pressure to the armature,
between the armature and core. moved from the vehicle. See Fig. 32. gap should be .012- .028".
13. If the regulating range exceeds 1. Armature air gap: (A) 4. Armature to bracket gap: (D)
the permissable decrease of 0.2 volts With the armature in the rest The gap between the armature and
enlarge the air gap. position the gap between the arrna- the bracket should be .008 - .028".
When it has been found necessary ture and the core of the elctro- Adjust by bending the bracket.
to adjust the air gap to achieve the magnet should be .032 - .050". Mter making any mechanical ad-
specified regulating range voltage must This may be adjusted by bending justments to the regulator the electri-
be checked to ensure that it remains the lower contact bracket. cal settings must be checked and
within tolerance. 2. Upper contact gap: (B) adjusted.
13-26

PART LUCAS ALTERNATOR REGULATOR

13·5
Section Page Section Page
I Description and Operation ........ . .. . ..... 13-26 2 In-Car Tests 0 0 0 0 0 0 0 0 0 0 0 .13-29

LUCAS ALTERNATOR board. In effect, the operation is OPERATION

REGULATOR similar to that of the conventional In effect, the operation is similar
Two models of alternator voltage electro-mechanical regulator in that to that of the conventional electro-
regulator are used . the alternator field current is varied mechanical regulator in that the alter-
The 9 ATR model voltage regulator to maintain the output voltage within nator field current is varied ·to main-
is mounted on the fender apron and close limits, but switching is per- tain the stator output voltage within
is matched to the 14 AC model formed by transistors instead of close limits, but switching is effected
alternator, Fig.34. vibrating contacts and a Zener diode with transistors instead of vibrating
The 13 ATR is integral with the provides the voltage reference in contacts, and a Zener diod~provides
14 ACR model alternator and is place of the usual electro-magnet and the voltage reference in place of the
mounted inside the slip ring and tension spring. The unit incorporates usual voltage coil and tension spring.
head. Fig. 33. a radio interference suppression cap- As the alternator is accelerated from
The two regulators have identical acitor. rest, its output voltage is allowed to
circuits and the description and mode Since current can only flow in one build up until it reaches a limiting
of operation described herein apply direction through the alternator out- value set by the Zener diode and a
to both. put diodes, no cut-out relay device is fixed resistance. At this point the
Both regulators are non-adjustable required .. Neither is a current limiting field current is reduced by the action
and if tested and found defective device needed, due to the inherent of a transistor amplifier. Any further
must be replaced . self-regulating characteristic of altern- small increase in voltage beyond the
limiting value serves to switch out
DESCRIPTION ators.
the field completely - again by
The regulator consists of a com- The control unit and alternator transistor action.
pletely static compact assembly of field windings are isolated from the When the ignition is switched on
transistors, diodes, resistors and cap- battery when the engine is stationary the control unit is connected to the
acitors soldered to a printed circuit by means of the ignition switch. battery through the indicator light,

FIG. 33- 13 ATR Regulator FIG. 34-9 ATR Regulator

9ATR REGULATOR
SURGE QUENCH
DIODE

ZENER
DIODE

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FIG. 35- Lucas Charging Circuit AC

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13-28 GROUP 13-CHARGING SYSTEM
this energises the base circuit of the
power transistors T2 through resistor
Rl. Refer in Lucas circuit diagram. 9ATR Control
These transistors then become con-
ducting by virtue of the transistor
action characteristic of the semi-con-
ductor material employed in the
transistor and will permit current to
flow in the collector-emitter section
of the transistor and thus acts as a
closed switch to complete the field
circuit.
As the alternator rotor speed in-
creases the rising voltage generated
across the alternator field-feed diodes
is applied to the potential divider as
illustrated in the diagram and identi-
fied as R3 , R2 and R4. According
to the position of the tapping point
on R2, a proportion of this potential
is applied to the Zener Diode (ZD).
This latter device which opposes
the flow of current through itself
until a certain voltage (known as the
breakdown voltage) is reached,
beyond which the current increases
very steeply for small increases in
voltage. The Zener diode can thus be FIG. 36- Alternator Vo·ltage Test -14 AC.
considered as a voltage conscious
switch which closes when the voltage sipation would occur in the power cumulative and the circuit reverts
reaches its "breakdown" voltage transistor, leading to problems of to the condition where T1 is fully-off
(about 10 volts), and since this is a overheating. For this reason, it is and T2 fully-on. This condition is
known proportion of the alternator desirable to operate the transistor only momentary, since C2 quickly
output voltage as determined by the either in the fully-on or fully~ff charges to the opposite polarity when
position of the tapping point, the condition, and this is the purpose of feed-back current is reduced the
breakdown point, therefore, reflects the positive feed-back circuit com- current again flows in the base of Tl.
the value of the output voltage. When prising RS and C2. As the field The circuit thus oscillates, switching
this point is reached, the Zener diode current in transistor T2 starts to fall, the voltage across the alternator field
conducts and current flows in the base the voltage of F rises and current winding rapidly on and off. This
circuit of the driver transistor T.l. flows through resistor RS and cap- method of operation results in con-
Again by transistor action, current acitor C2, thus adding to the Zener siderably low power dissipation.
will now flow in the collector- diode current in the base circuit of
emitter portion ofTl, so that some of transistor Tl. This has the effect of SURGE QUENCH DIODE
the current which previously passed increasing the current through T1
through Rl and the base circuit of and decreasing the current through Because switching is achieved so
T2 is now diverted through Tl. Thus T2 still further. rapidly, any sudden collapse of the
the base current of T2 is reduced and, This effect is cumulative and the field current would result in a very
as a result, so also is the alternator circuit quickly reaches the condition high induced voltage being applied
field excitation. Consequently, the when T1 is fully-on and T2 fully-off. to transistors T2. They are protected
alternator output voltage will tend As capacitor C2 charges, the feed-back by means of the surge quench diode
to fall: and this in turn will tend to current falls and eventually reaches D connected across the field winding.
reduce the base current in T1 , allow- a value at which the combination This also serves to provide a measure
ing increased field current to flow of Zener diode current and feed-back of field current smoothing, since
in T2. By this means, the field current in the base circuit of Tl is no the current continues to flow in the
current is continuously varied to lbnger great enough to keep T1 fully- diode after the excitation voltage is
keep the output voltage substantially on. Current then begins to flow removed from the field . This current
constant at the value determined by again in the base circuit of T2, so that decays by only a small amount be-
the setting of R2. the field current again begins' to fore the excitation is again applied.
flow through T2. The voltage at
NEGATIVE FEED- terminal F now commences to fall, RADIOINTEREFERENCE
BACK CIRCUIT reducing the feed-back current even- SUPPRESSION
tually to zero. As T2 becomes yet The elimination of radio inter-
Basically, this is the principle of more conductive and the voltage at ference caused by rapid switching
operation of the regulator, but there F falls further, current in the feed- within the regulator is achieved by
are certain desirable additions. If the back circuit reverses in direction, in connecting condenser Cl between
field current were varied continuously effect reducing still further the base the base and collector terminals of
as described , considerable power dis- current in Tl. This effect also is T1 to provide negative feed-back.
PART 13-5-ALTERNATOR REGULATOR 13-29

ZENER DIODE LEAK CIRCUIT be carried out with a fully charged battery terminals (Make sure controls
At high temperatures, a small battery and with the regulator at are in the out or off position).
leakage current may flow through normal operating temperature. 4. Connect a tachometer to the
the Zener diode even though the Before carrying out the tests engine.
latter is in the nominally non-con- ensure that all wiring and connections 5. Start the engine and adjust
ductive state. Resistor R6 provides in the charging circuit (including speed to 1000 R.P.M.
a path for this leakage current which battery terminals) are tight and in 6. Adjust charge rate to 11 amps
otherwise would flow through Tl good condition. and allow the engine to run at this
base circuit and adversely affect the rate for 10 minutes.
regulator action. 7. Increase engine speed to give
Voltage Regulator Test 9 ATR and
6000alternator R.P.M. (see chart) and
13 ATR.
IN CAR TESTS AND
adjust charge rate to 11 amps.
1. Connect a voltmeter across the 8. The voltmeter should now
ADJUSTMENTS battery terminals. register 14.3 ± 0 .4 volts.
Before attempting to assess the 2. Connect a 0.60 amp ammeter Both the 9 ATR and 13 ATR reg-
performance of the voltage regulator in series with the alternator main (+) ulators are non-adjustable units
always carry out an alternator out- lead. therefore if the test figures are not
put test. See page 13-7. 3. Connect a carbon pile rheostat achieved the regulator must be re-
The voltage regulator tests must or switched lamp bank across the placed.
13-30

PART SPECIFICATIONS
13-6

SPECIFICATIONS- 6 Cylinder
BOSCH ALTERNATOR
MODEL UK1 14V40A22

Earth polarity NEGATIVE

Nominal voltage 14 volts
Nominal DC output 40 amps
Stator phases 3
Stator winding connection Star
Number of poles 12
Resistance of rotor windings 4.2 ± .2 ohms
Resistance of stator windings 0.21 ± 1 ohm
Brush length (protrusion)
new .35"
minimum .15"
Minimum diameter of slip rings 1.24"
Tightening torques:
Alternator through bolts 33- 47 in/lbs
Pulley retaining nut 25 - 32 ft/lbs
Rectifier pack fixing screws 20/25 in/lbs
Brush box fixing screws 20- 25 in/lbs

BOSCH REGULATOR
MODEL U- AD1/14V
TYPE Electro-mechanical vibrator

Regulating voltage (warm) 13.5 - 14.4 volts at 1700 RPM (alternator)

and 10 amps output
Voltage range reading at 7000 RPM (alternator) and 10 amps
output must be within - 0.2 to +0.4 volts
of the regulating voltage.
Armature to core air gap
(at rest) .032 - .050"
Armature to core air gap
(upper points closed) .Of2 - .028"
Point opening .008 - .016"
Armature to bracket air gap .008 - .028"
PART 13-6- SPECIFICATIONS 13-31

Engine Alternator Engine

R.P.O. R.P.M. R.P.M.
8 cyl. Standard 6000 2500
8 cyl. Taxi and Police without Power Steering 6000 2500
8 cyl. With power steering 6000 1800
8 cyl With air conditioning 6000 1800
8 cyl. G.T. 6000 1800

6 cyl. With air conditioning 6000 2500

6 cyl. TaW"i and Police 6000 2500

LUCAS ALTERNATOR- V8 only

MODEL 14ACR 4D 6D
Earth polarity Negative
Nominal voltage 12 volts
Nominal output 4D- 38 amps 6D - 55 amps
Stator phases 3
Stator winding connection Star
Number of poles 12
Resistance of rotor winding 3.3 ohms 3.0 ohms
±5%at20C ± 5% at 20° C
Resistance of stator winding 0.23 ohms 0.15 ohms
± 5% ger phase ± 5% ger phase
at 20 C at 20 C
Brush length new .625"
minirnwn .250"

Lucas Regulator
Model 13ATR Solid state transistorized - non adjustable
Volt.age setting 14.3 ± 0.4 volts

LUCAS ALTERNATOR-6 Cylinder Air Conditioning

MODEL 14AC 6D

Earth polarity Negative

Nominal voltage 12 volts
Nominal output 55 amps
Stator phases 3
Stator winding connection Star
Number of poles 12
Resistance of rotor winding 3.0 ohms± 5% at 20° C
Resistance of stator windings 0.15 ohms per phase at 20° C ± 5%
Brush length new .625"
minimum .250"

LUCAS REGULATOR
MODEL 9ATR Solid state transistorized- non adjustable
Voltage setting 14.3 ± 0.4 volts

TIGHTENING TORQUES

Alternator through bolts 35 - 45 lb/in.

End heads must sit evenly on stator.
Pulley retaining nut 25-30 lb/ft
Rectifier pack fixing nuts 20 - 25 lb/ins
Voltage regulator retaining screws 15 lb/ins
Brush box assy. fixing screw 20 lb/ins
Brush box moulding screws 7 lb/ ins
REFERENCE TO SERVICE INFORMATION AND NOTES

Date Letter No. Page Brief Detail

-
FALCON FAIRLANE w~::~~~P

GROUP
STARTING SYSTEM
14

PAGE

PART 14-1- Ford Starting System 14-2

PART 14-2- Ford Starting System Repair 14-7

PART 14-3- Bosch Starting System 14-10

PART 14-4- lucas Starting System 14-13

PART 14-5- Specifications 14-17

14-2

PART
14-1 FORD STARTING SYSTEM

Section Page
1 Description and Operation 14-2
2 Diagnosis and Testing .... .... 14-2

D DESCRIPTION AND OPERATION

Three types of starter motor are tion switch). the neutral-start switch1
used on XA/ZF Falcon/Fairlane the starter relay or solenoid ana
vehicles. heavy circuit wiring. The starter
1. Ford - positive pre-engaged mounting is shown in Fig. I .
pinion operated by a moving pole Turning of the ignition key to the
shoe and remote relay. START position actuates the starter
2. Bosch - positive pre-engaged relay, through the starter control cir-
pinion operated by an integral cuit. The starter relay then connects
solenoid.
the battery to the starter.
3. Lucas - positive pre-engaged
pinion operated by an integral Cars equipped with an automatic
solenoid. transmission have a neutral-start
The function of the starting sys- switch, in the starter control circuit, FIG. 1 -Starter Mounting -Typical
tem is to crank the engine at high which prevents operation of the
enough speed to permit it to start. starter if the selector lever is not in
The system includes the starter motor the N (neutral) or P (park) position.
and drive, the battery, a remote con- The starter utilizes an integral
trol starter switch (part of the igni- positive-engagement drive

D DIAGNOSIS AND TESTING

The following diagnosis and testing charts which may be followed to de- connecdon of the au:dliary cables.
procedures may be applied to all three termine the cause of the difficulty
starter motors. Where applicable and the corrective action. STARTER WILL NOT CRANK
read solenoid for relay. THE ENGINE
A schematic diagram of the start- Refer to Fig. 2 for this symptom.
ing circuit is shown in Fig. 3 ROAD SERVICE
The majority of starting problems On road service calls, connect a
usually fall into one of the following booster battery to the system for NOTE I-NEUTRAL START
situations: the starter will not crank cases of a starter that will not crank SWITCH TEST
the engine; the engine will crank at the engine or a starter that cranks the On vehicles equipped with an au-
normal speed but will not start; and engine very slowly. If the starter tomatic transmission, apply the
the starter cranks the engine very turns the engine over, but the engine brakes and attempt to start the en-
slowly. still will not start, even with the gine while moving the selector lever
If the engine will crank but will booster battery attached, refer to the through all ranges. This may deter-
not start, the trouble is usually in the following charts. Be certain that cor- mine if the problem is caused by a
engine, fuel system or ignition system red battery polarity is observed when maladjusted or defective neutral-
rather than in the starting system. using a booster battery; posidve to start switch. Refer to Group 7 Part 3
Following are road map type posidve, and negadve to negadve for the adjustment of this switch.
PART 14-1- FORD STARTING SYSTEM 14-3

STARTER WILL NOT CRANK ENGINE-ROW lltAP (SEE NOTE NO. 1)

*ICHECK THE BATTERY AND STARTER CABLES FOR GOOD ELECTRICAL CONTACT .
LOOK FOR BROKEN OR CORRODED CONNECTIONS . IN PARTICULAR ASSURE GOOD
GROUND CONNECTIONS . CLEAN AND TIGHTEN THE CABLE CONNECTIONS AS NECESSARY .
CHECK THE BATTERY SPECIFIC GRAVITY .

BATTERY SPECIFIC GRAVITY OK BATTERY SPECIFIC GRAVITY LOW

PERFORM THE BATTERY TESTS. CHARGE OR REPLACE THE

*BATTERY AS NECESSARY . CHECK THE BATTERY AND STARTER
CABLES AND STARTER RELAY FOR EXCE"SSIVE RESISTANCE .

CHECK THE STARTER RELAY·OPERATE THE STARTER (IGNITION) SWITCH .

RELAY DOES NOT CLICK STARTER SPINS,BUT WILL NOT CRANK ENGINE

* BY-PASS THE RELAY WITH A * BY-PASS THE IGNITION SWITCH, * REMOVE THE STARTING MOTOR AND DRIVE . CHECK AND
HEAVY JUMPER CABLE .SEE NEUTRAL STARTS WI TCH AND CLEAN THE STARTER DRIVE AS REQUIRED. CHECK FOR
NOTE NO . 2. WIRING . SEE NOTE NO.3 . DAMAGED FLYWHEEL RING GEAR TEETH . WHEN INSTALLING
THE STARTER, PROPERLY ALIGN IT TO THE FLYWHEEL
HOUSING .

I
ENGINE CRANKS II ENGINE WILL NOT CRANK J ENGINE WILL NOT CRANK

~
* REPLACE RELAY * CHECK THE WIRING TO THE IGNITION * BY·PASS RELAY WITH A
SWITCH, NEUTRAL START SWITCH HEAVY JUMPER CABLE.
AND WIRING TO STARTER RELAY·. SEE SEE NOTE NO. 2.
NOTE NO. 4.

I I
STARTER ENGAGEMENT STARTER ENGAGEMENT ENGINE WILL NOT CRANK
WEAK OR NO FIRM. ENGINE
ENGAGEMENT . LOCKED UP .

I I *REPLACE RELAY

I I
* REMOVE AND TEST THE * REFER TO GROUP 8
STARTER. REPAIR AS
REQUIRED.

STARTER ENGAGEMENT STARTER ENGAGEMENT

WEAK OR NO FIRM, ENGINE
ENGAGEMENT. LOCKED UP

* REFER TO GROUP 8

J 1316-A

FIG. 2-Starter Will Not Crank Engine-Road Map

14-4 GROUP 14- STARTING SYSTEM

1---1~ terminal of the relay to the starter NORMAL SPEED BUT WILL
BATTERY. - ..!. (ignition) switch side of the neutral- NOT START
start switch (Fig. 4, connection No. Refer to Group 8 for this symp-
4). If the engine does not crank, the tom.
_ __.TO GENERATOR REGULATOR
neutral-start switch is out of adjust- STARTER LOAD TEST
STARTER RELAY
ment or defective. If the engine Connect the test equipment as
cranks, check for voltage at the bat- shown in Fig. 6 Be sure that no cur-
tery terminal of the starter (ignition) rent is flowing through the ammeter
switch wiring harness connector wi!h and heavy-duty carbon pile rheo-
a test light or a voltmeter. If voltage stat portion of the circuit (rheostat
is not available, the wiring between at maximum counterclockwise posi-
tion).
the battery terminal of the starter re-
Crank the engine with the ignition
TO lay and the battery terminal of the
IGNITION
OFF, and determine the exact read-
starter (ignition) switch is at fault.
COIL ing on the voltmeter. This test is ac-
STARTER If voltage is available, substitute an
Red·Bive Stripe complished by disconnecting and
---AUTOMATIC
ignition switch from stock. If the en- grounding the high tension lead from
TRANSMISSION ONLY gine cranks, replace the ignition
STARTER NEUTRAL SWITCH the spark coil, and by connecting a
CLOSED WITH SELECTOR IN switch. If the engine still will not jumper from the battery terminal of
N OR P POSITION
Red· Bive Stripe
crank, the trouble is in the wiring or the starter relay to the ignition switch
---STARTER SWITCH connections between the ignition terminal of the relay.
(ON IGNITION SWITCH)
switch and the starter-neutral switch. Stop cranking the engine, and re-
(
duce the resistance of the carbon pile
STARTER CRANKS ENGINE
TO BATTERY TERMINAL OF until the voltmeter indicates the same
GENERATOR REGULA TOR J 1 083 -C SLOWLY
reading as that obtained while the
FIG. 3-Starting Circuit Refer to Fig. 5 for this symptom. starter cranked the engine. The am-
meter will indicate the starter current
1---1~.l
BATTERY. -
draw under load.
NOTE2 STARTER NO-LOAD TEST
Connect a heavy jumper cable The starter no-load test will un-
from the battery terminal of the re- cover such faults as open or shorted
lay to the starter terminal of the relay windings, rubbing armature, and bent
(Fig. 4, connection No. 1). armature shaft. The starter can be
NOTE 3-STARTER RELAY tested, at no-load, on the test bench
TEST only.
Connect a jumper from the bat-
tery terminal of the relay to the
starter (ignition) switch terminal of
the relay (Fig. 4, connection No. 2).
.••• ....,_
I

•
__,
Make the test connections as
shown in Fig. 6. The starter will run
at no-load. Be sure that no current is

If the engine does not crank, the

•
: TO
flowing through the ammeter (rheo-
stat at maximum counterclockwise
starter relay probably is at fault. ~, 3 IGNITION
•
1•
COIL
~--~S~TA~R~T~ER~--~
position). Determine the exact read-
NOTE 4-STARTER CONTROL ing on the voltmeter.
CIRCUIT TEST I --------AUTOMATIC
Disconnect the starter from the
TRANSMISSION
On vehicles equipped with an au- STARTER NEUTRAL SWITCH battery, and reduce the resistance of
Red. Blue Stripe
tomatic transmission, if the engine the rheostat until the voltmeter indi-
cranks, connect a jumper from the ------STARTER SWITCH cates the same reading as that ob-
battery terminal of the relay to the (ON IGNITION SWITCH)
tained while the starter was running.
relay side of the neutral start switch. ( The ammeter will indicate the starter
(Fig. 4, connection No. 3). If the TO BATTERY no-load current draw.
engine does not crank, the wiring be- J 1084. F

tween the neutral-start switch and the

FIG. 4-Starting Control ARMATURE OPEN CIRCUIT
Circuit Tests TEST---oN TEST BENCH
relay is at fault. If the engine cranks,
connect a jumper from the battery ENGINE WILL CRANK AT An open circuit armature may
PART 14-1- FORD STARTING SYSTEM 14-5

STARTER CRANKS ENGI HE SLOWL Y-ROAO MAP

* CHECK THE BATTERY AND HARTER CABLES FOR GOOD
ELECTRICAL CONTACT . LOOK FOR CORRODED OR LOOSE
CONNECTIONS . IN PARTICULAR , ASSURE GOOD GROUND
CONNECTIONS . CLEAN AND TIGHTEN THE CABLES AS
NECESSARY .
CHECK BATTERY SPECIFIC GRAVITY.

BATTERY SPECIFIC GRAVITY OK BATTERY SPECIFIC GRAVITY LOW

* PERFORM BATTERY TESTS . CHARGE OR

REPLACE THE BATTERY AS NECESSARY .
CHECK THE BATTERY AND STARTER
RELAY FOR EXCESSIVE RESISTANCE .
* CHECK THE STARTER CRANKING
VOLTAGE AND CURRENT DRAW.

CURRENT DRAW LOW CURRENT DRAW NORMAL OR HIGH

* REMOVE THE ST AR T ER, INSPECT

TEST AND REPAIR IT AS NECESSARY .
* REMOVE THE STARTER AND CHE CK THE
CURRENT DRAW AT NO LOAD.

CURRENT DRAW ABOVE OR BELOW SPECIFICATIONS CURRENT DRAW IS NORMAL

IN SPECT , TEST AND R E PAl fl

* THE STARTER AS NECE SSAilY . * REFER TO GROUP 8 J 1317-A

FIG. 5

- STARTER SWITCH
(ON IGNITION
SWITCH!
TO IGNITION
COIL

TO BATTERY TERMINAL OF STARTER

GENERATOR REGULA TOR

FIG. 6-Starter Load Test

14-6 GROUP 14- STARTING SYSTEM
This is accomplished by disconnect-
ing and grounding the high tension
lead from the spark coil and by con-
necting a jumper from the battery
terminal of the starter relay to the
ignition switch terminal(s), of the re-
STARTER lay.
TERMINAL
The voltage drop in the circuit will
be indicated by the voltmeter (o to 2
volt range). Maximum allowable
voltage drop should be:
1. With the voltmeter negative
lead connected to the starter terminal
and the positive lead connecte~ to the
battery positive terminal (Fig.lO, con-
nection <D) • • • • • • • • • • • • • 0.5 volt.
VOLTMETER --.....:$. l. With the voltmeter negative
POSITIVE
LEAD J1094 - B lead connected to the battery termi-
nal of the starter relay and the posi-
FIG. 7 -Starter No-Load Test FIG. 9-Field Grounded Circuit tive lead connected to the positive
on Test Bench Test terminal of the battery (Fig. 10, con-
nection ®) .. .. .. .. .. .. 0.1 volt.
3. With the voltmeter negative
lead connected to the starter termi-
nal of the starter relay and the posi-
ARMATURE AND FIELD tive lead connected to the positive
GROUNDED CIRCUIT TEST- terminal of the battery (Fig.lO, con-
ON TEST BENCH nection ®) . •• .......•. . . 0.3 volt.
4. With the voltmeter negative
lead connected to the negative termi-
This test will determine if the nal of the battery and the positive
winding insulation has failed, permit- lead connected to the engine ground
ing a conductor to touch the frame (Fig. 9, connection<!>) . . . . 0.1 volt.
or armature core.
To determine if the armature @.•.......:"""""""'-
windings are grounded, make the •
I -
connections as shown in Fig. 8. If I
I
the voltmeter indicates any voltage,
the windings are grounded.
Grounded field windings can be
\••
detected by making the connections ••••
FIG. 8-Armature Grounded as shown in Fig. 9. If the voltmeter
Circuit Test indicates any voltage, the field wind-
ings are grounded.

sometimes be detected by examining STARTER CRANKING

the commutator for evidence of CIRCUIT TEST
burning. The spot burned on the Excessive resistance in the starter
commutator is caused by an arc circuit can be determined from the
formed every time the commutator results of this test. Make the test con- J1259-1
segment, connected to the open cir- nections as shown in Fig. lO.Crank FIG. 10 -Starter Cranking Circuit
cuit winding, passes under a brush. the engine with the ignition OFF. Test
14-7

PART
14-2 FORD STARTING SYSTEM

Section Page Section Page

1 Removal and Installation 14-7 3 Cleaning and Inspection 14-8
2 Common Adjustments and Repairs 14-7 4 Major Repair Operations 14-8

The Ford Starter Motor is a series engine starts and so prevents over shoe is attached to the starter drive
parallel wound four pole four brush revving of the armature. plunger lever and thus the drive is
machine using a moving pole shoe A remote relay connects the forced into engagement with the fly-
actuated positive pre-engaged pinion. starter to the battery when the starter wheel.
The mam battery supply is not (ignition) switch is operate1. When the movable pole shoe is
connected until the pinion is in When the starter is not in use, one fully seated, it opens the field coil
engagement unless tooth abutment is of the field coils is connected directly grounding contacts and the starter is
encountered. to ground through a set of contacts. then in normal operation. A holding
The starter motor is protected by When the starter is first connected to coil is used to maintain the movable
an overrunning clutch which dis- the battery a large current flows pole shoe in the fully seated position,
engages the drive between the through the grounded field coil, ac- during the time that the starter is
armature and ring gear as soon as the tuating a movable pole shoe. The pole turning the engine.

D REMOVAL AND INSTALLATION

1. Raise the car on a hoist. bolts. Remove the starter assembly: 5. Snug all bolts, then torque them
1.. Disconnect the starter cable at 4. Position the starter assembly to to specification.
the starter terminal. the flywheel housing, and start the 6. Connect the starter cable.
3. Remove the starter mounting mounting bolts.

EJ COMMON ADJUST~ENTS AND REPAIRS

STARTER DRIVE REPLACEMENT the through bolts to specifications possible).
(55-75 inch pounds). 7. Cut (or unsolder) the insulated
CIRCUIT TEST brush leads from the field coils, as
1. Loosen and remove the brush 8. Position the starter drive plung-
er lever cover and the brush cover close to the field connection point as
cover band and the starter drive possible.
plunger lever cover. band, with its gasket, on the starter.
Tighten the brush cover band retain- 8. Clean and inspect the starter
2. Loosen the through bolts motor.
enough to allow removal of the rear ing screw.
9. Replace the front end plate if
end housing and the starter drive BRUSH REPLACEMENT
plunger lever return spring. the insulator between the field brush
Replace the starter brushes when holder and the end plate is cracked or
3. Remove the pivot pin retaining they are worn to 1/.1 inch. Always in- broken.
the starter drive plunger lever and re- stall a complete set of new brushes.
move the lever. 10. Position the new insulated
1. Loosen and remove the brush field brushes lead on the field coil
4. Remove the drive gear stop ring cover band, gasket, and starter drive
retainer and stop ring from the end tenninal. Install the clip provided
plunger lever cover. Remove the with the brushes to hold the brush
of the armature shaft and remove the brushes from their holders.
drive gear assembly. lead to the terminal. Solder the
2. Remove the two through bolts lead, clip and tenninal together,
5. Apply a thin coating of Lubri- from the starter frame.
plate on the armature shaft splines. using resin core solder (Fig. 4).
3. Remove the rear end housing, Use a 300 watt iron.
Install the drive gear assembly on and the plunger lever return spring.
the armature shaft and install a new 11. Install the ground brush leads
4. Remove the starter drive plung- to the frame with the retaining
stop ring. er lever pivot pin and lever, and re-
6. Position the starter gear plung- screws.
move the annature. 12. Clean the commutator with
er lever on the starter frame and in- 5. · Remove the front end plate.
stall the pivot pin. Be sure that the #00 or #000 sandpaper.
plunger lever properly engages the 6. Remove the ground brush re- 13. Position the front end plate
starter drive assembly. taining screws from the frame and to the starter frame, with the end
7. Install a new stop-ring retainer. remove the brushes (cut the ground plate boss in the frame slot.
Position the starter drive plunger lev- brush nearest the starter terminal 14. Position the fiber washer on
er return spring and rear end housing from the brush terminal block, as the commutator end of the armature
to the starter frame, and then tighten close to the brush lead terminal as shaft and install the armature in the
14-8 GROUP 14- STARTING SYSTEM
starter frame. on the commutator end of the arma-
ARMATURE REPLACEMENT ture shaft and install the armature.
15. Install the starter drive gear 1. Loosen the brush cover band 7. Position the drive gear plunger
plunger lever to the frame and starter retaining screw and remove the brush lever to the frame and drive gear as-
drive assembly, and install the pivot cover band, gasket, and the starter sembly and install the pivot pin.
pin. drive plunger lever cover. Remove 8. Position the drive plunger lever
16. Position the return spring on the brushes hom their holders. return spring, the rear end housing,
the plunger lever, and the rear end 2. Remove the through bolts, the and the front end plate to the starter
housing to the starter frame. Install rear end housing, and the drive frame, and then install and tighten
the through bolts and tighten to spec- plunger lever return spring. the through bolts to specification. Be
ified torque (55-75 inch pounds). Be sure that the stop ring retainer is
sure that the stop ring retainer is 3. Remove the pivot pin retaining seated properly in the drive gear
seated properly in the rear end hous- the starter gear plunger lever, and housing. If the starter has needle
ing. remove the lever. bearings apply a small amount of
4. Remove the armature. If the grease to the needles before installing
17. Install the commutator brushes starter drive gear assembly is being the starter ends.
in the brush holders. Center the brush reused, remove the stop ring. retainer 9. Place the brushes in their hold-
springs on the brushes. and the stop ring from the end of the ers, and center the brush springs on
armature shaft, and remove the as- the brushes.
18. Position the plunger lever cov-
sembly. 10. Position the plunger lever cov-
er and the brush cover band, with its er and the brush cover band, with its
gasket, on the starter. Tighten the S. Place the drive gear assembly
on the new armature with a new stop gasket, and then tighten the retaining
band retaining screw. screw.
ring.
19. Connect the starter to a bat- 11. Connect the starter to a bat-
tery to check its operation. 6. Install the fiber thrust washer tery to check its operation.

EJ CLEANING AND INSPECTION

1. Use a brush or air to ciean the amount of grease to the needles. If S. Check the brush holders for
field coils, armature, commutator, the commutator is rough, or more broken springs and the insulated
armature shaft, front end plate, and than 0.005 inch out-of-round, turn it brush holders for shorts to ground.
rear end housing. Wash all other down. Tighten any rivets that may be loose.
parts in solvent and dry the parts. Replace the brushes if worn to 'A
inch in length.
2. Inspect the armature windings
for broken or burned insulation and 6. Check the brush spring tension.
unsoldered connections. Replace the springs if the tension is
not within specified limits (40 ounces
3. Check the armature for open
circuits and grounds. minimum).

4. Check the commutator for run- 7. Inspect the field coils for burned
out (Fig. 1). Inspect the armature or broken insulation and continuity.
shaft and the two bearings for scor- Check the field brush connections
ing and excessive wear. On a starter FIG. 1-Commutator Runout and lead insulation.
with needle bearings apply a small Check

rJ MAJOR REPAIR OPERATIONS

Use the following procedure when move the commutator brushes from taining the starter drive gear to the
it becomes necessary to completely the brush holders. end of the armature shaft, and re-
overhaul the starter. Fig. 2 iilustrates 2. Remove the through bolts, move the starter drive gear assembly.
a partially disassembled starter. starter rear end housing, and the S. Remove the front end plate.
starter drive plunger lever rc;tum 6. Remove the two screws retain-
DISASSEMBLY spring. ing the ground brushes to the frame.
1. Loosen the brush cover band 3. Remove the pivot pin retaining 7. On the field coil that operates
retaining screw and remove the brush the starter gear plunger lever and re- the starter drive gear actuating le-
cover band and the starter drive move the lever and the armature. ver, bend the tab up on the field re-
plunger lever cover. Observe the lead 4. Remove the stop ring retainer. tainer and remove the coil retainer.
positions for assembly and then re- Remove and discard the stop ring re- 8. Remove the three coil retaining
PART 14-4- FORD STARTING SYSTEM REPAIR 14-9

RE AR END
HOUSING
START ER FRAME FIELD COILS 11082 11130
START ER DRI VE
11 350

BRU SH COVER
BAND 11126
ARMATURE 11005 -

""""'~-,)
STARTE R DRIV E...... ~~
n (

~o.
J 0
PLUNGER LEV ER / "'ITt');/ ()
11067 PLUNGER RET URN '
SPRING 111 03 ST OP RING
STOP RIN G RETAINER
COVER 11060 11222 11223

J 1089-D

FIG. 2-Starter Disassembled

Jl 092-C
screws, using tool 10044-A and an turning it down. A brush kit and a
arbor press (Fig. 3). The arbor press contact kit are available. All other
FIG. 4-Field Coil Assembly
prevents the wrench from slipping assemblies are to be replaced rather the starter frame and install the re-
out of the screw. Unsolder the field than repaired. If the starter has nee- taining screws (Fig. 4).
coil leads from the terminal screw, dle bearings, apply a small amount of 9. Position the starter brush end
and remove the pole ~hoes and coils grease to the needles before assembly. plate to the frame, with the end plate
from the frame (use a 300-watt boss in the frame slot.
iron). ASSEMBLY
10. Apply a thin coating of Lubri-
USE Arbor Press TO HOLD 1. Install the starter terminal, in- plate on the armature shaft splines.
Tool IN SCREW SOCKET ~ulator, washers, and retaining nut in Install the starter motor drive gear
the frame (Fig. 4). Be sure to posi- assembly to the armature shaft
tion the slot in the screw perpendicu- and install a new retaining stop
lar to the frame end surface. ring. Install a new stop ring retain-
l. Position the coils and pole er.
pieces, with the coil leads in the ter- 11. Position the fiber thrust wash-
minal screw slot, and then install the er on the commutator end of the
retaining screws (Fig. 3). As the pole armature shaft and position the ar-
shoe screws are tightened, strike the mature in the starter frame.
frame several sharp blows with a soft- ll. Position the starter drive gear
faced hammer to seat and align the plunger lever to the frame and start-
pole shoes, then stake the screws. er drive assembly, and install the piv-
3. Install the solenoid coil and re- ot pin.
tainer and bend the tabs to retain the 13. Position the starter drive
BE SURE TO SEAT DRIVE HEAD coils to the frame. plunger lever return spring and the
IN SCREW SOCKET J1 059- C
4. Solder the field coils and sole- rear end housing to the frame and in-
FIG. 3-Pole Shoe Saew noid wire to the starter terminal us- stall and tighten the through bolts to
Removal ing rosin core solder. Use a 300-watt specification (SS -15 inch pounds).
iron. Do not pinch the brush leads between
5. Check for continuity and the brush plate and the frame. Be
9. Cut (or unsolder) the insulated
grounds in the assembled coils. sure that the stop ring retainer is
brush leads from the field coils, as seated properly in the drive housing.
close to the field connection point as 6. Position the new insulated field
possible. brushes lead on the field coil termi- 14. Install the brushes in the brush
10. Remove the starter terminal nal. Install the clip provided with the holders. Be sure to center the brush
nut, washer, insulator and terminal brushes to hold the brush lead to the springs on the brushes.
from the starter frame. Remove any terminal. Solder the lead, clip, and 15. Position the drive gear plung-
termit>~l together, using rosin core er lever cover on the starter and in-
excess solder from the terminal slot.
solder (Fig. 4). Use a 300-watt iron. stall the brush cover band with a
PARTS REPAIR OR 7. Position the solenoid coil gasket. Tighten the band retaining
REPLACEMENT ground terminal over the nearest screw.
Nicks and scratches may be re- ground screw hole. 16. Check the starter no-load am-
moved from the commutator by 8. Position the ground brushes to perage draw.
14-10

PART
14-3 BOSCH STARTING SYSTEM
250, 302, 351 2V

Section Page
1 Description and Operation 14-10
2 Removal and Installation 14-11
3 Major Repair Operations ...... ,..... ...... 14-11

II DESCRIPTION AND OPERATION

soft iron plunger. The starter then

The Bosch Starter Motor is a series ger is drawn in moving the engaging
rotates and cranks the engine. When
parallel wound, four pole four brush lever which in turn moves the drive
the starter rotates, the pull-in wind-
machine with solenoid actuated pos- assembly towards the ring gear. The ing is de-energised by the isolation of
itive pre-engaged pinion. The main helical splines on the armature shaft its ground connection, providing more
battery supply is not connected until rotate the pinion slowly to assist in power for cranking.
the pinion is in engagement unless engagement.
As the starting speed of the engine
tooth abutment is experienced. The Should a tooth of the advancing exceeds that of the starter, the pinion
drive connection between starter arm- pinion abut a tooth of the ring gear, rotates freely and engine acceleration
ature and ring gear is automatically the engaging lever will compress the
does not affect the starter. The drive
broken by the overrunning clutch helical spring at the pinion until the is pulled back by the tensional helical
coupling, which disengages the drive switch contacts close. The pinion is spring, but, the pinion remains partly
as soon as the engine speed exceeds then turned and engages with the ring engaged as long as the starter switch
that of the starter. gear under the helical spring pressure.
is operated. Once the starter switch is
Closing the mlenoid switching cir- Before the pinion is completely in released, the plunger return spring
cuit energises the pull-in and hold-in mesh the contacts in the solenoid moves the pinion to its rest position
solenoid windings. The soft iron plun- switch are closed by the action of the and the switch contacts open.

FIG 1. BOSCH STARTER MOTOR

PART 10-4 BOSCH STARTING SYSTEM 14-11
EJ REMOVAL AND INSTALLATION
I. Disconnect the starter cable at tube bracket is mounted under the
the starter terminal, remove the 2. Position the starter assembly to starter side mounting bolt. Snug all
flywheel housing to starter retaining the flywheel housing, and start the bolts, then tighten to specifications,
screws. Remove the starter assembly" starter retaining screws. tightening the middle bolt first .
On a car with an automatic trans- 3. Reconnect starter cable from
mission, the transmission dipstick battery and wiring to switch.

EJ MAJOR REPAIR OPERATIONS

DISASSEMBLY
1. Disconnect the solenoid switch
to starter motor lead from the solen-
oid switch terminal (9).
2. Remove the two solenoid switch
attaching screws.
3. Remove solenoid (10) by lifting
and unhooking the plunger yoke from
engaging lever (11).
4. Remove the two bearing cap
screws ( 1), pull off bearing cap (2),
and remove circlip (3) .
5. Remove through bolts (4) .
6. Remove commutator end cover
(5).
7. Remove four brushes (6) and
brush holder (7) plate.
8. Withdraw armature (15) with
drive end housing ( 17) engaging lever
(11).
9. Remove engaging lever ful-
crum bolt (14) to release engaging
lever and armature from drive end
housing. 16 8 15 12 6 7 3
10. Press stop ring (18) on arma-
ture shaft towards drive assembly.
11. Remove spring ring ( 19).
12. Remove drive assembly ( 16). FIG. 2 SECTIONIZED VIEW BOSCH STARTER
TESTING STARTER
COMPONENTS
1. Cleaning and ln:'pection 3. Armature
Clean and inspect all parts. Check Test armature winding for short which time the commutator must be
all bushings, bearing surfaces, pinion, circuits in a growler and test insula- machined. Always replace the com-
engaging mechanism and electrical tion to ground with test lamp as plete brush set. Check brush spring
contacts for wear and replace worn under 2. tension according to the prescribed
parts. Check electrical joints and con- The commutator should not be er- figures with spring balance. Replace
nections and repair where necessary. roded or out-of-round. If it is neces- springs that do not conform to speci-
sary to re-dress the commutator, en- fications.
2. Field Coils sur<! its minimum diameter is not less 5. Bushings
Test field coils for open circuits than specification. Undercut mica Replace worn bushings by pressing
with an incandescent low-voltage test between segments using a ground the old bushing out with a correct fit-
lamp in series. Test lamp must light if down hacksaw blade or undercutting ting mandrel and press the new bush-
circuit through field coils is complete. machine. ing into place in like manner. New
Disconnect all ground connections sintered .bushings should be soaked in
and connect test latnp from field oil for one hour before installation.
winding terminal to ground. Test 4. Carbon Brushes
lamp will not light if field coil insula- Make sure brush~s slide smoothly G. Solenoid Switch
tion is good. in their holders, brush connections Remove switch cover fastening
Defective field coils should be re- are good and brushes are clean and screws. Unsolder external joints
moved with an approved pole shoe not chipped. Brushes worn to less where the winding ends are connect-
screw driver only. than ~" long should be replaced, at ed to the terminals and remove cover.
14-12 GROUP 14- STARTING SYSTEM
Inspect contact bolts and contact
plate for wear and replace worn con- 1-------11•
tacts. The short contact bolt is re-
tained in place, after the terminal
nut is removed, by an external con-
necting strap from the solenoid wind-
ing terminaL This connecting strap
can be removed by prising the strap
away from the switch cover with a
screw driver. A replacement bolt can
be lightly pressed into the connecting
strap and after two or more threads
have entered, the terminal nut can be
used to draw the bolt into place.
The moving contact is secured by
a contracted washer. This washer can terminal (9). ELECTRICAL TESTS OF
be removed with a pair of side-cut- ASSEMBLED STARTER MOTOR
IMPORTANT: Ensure that a
ters. After fitting a new moving con- The electrical test values depend
water tight seal is made at rubber
tact, a circlip and cup washer must be
packing (13). upon the condition of the battery
used to secure the contact; crimp cup (capacity and charge). The testing
washer over circlip.
period also plays an important part
The operation of the detached MECHANICAL ADJUSTMENTS (heating of the starter and battery
switch can be checked by connecting discharge) . Long cables on the test
a battery supply through a variable Armature End Play
bench also influence starter perform-
resistance to both pull-in and hold- The armature end play is the ance. The test period should therefore
in windings and increasing the volt- lengthwise travel (longitudinal) of be as short as possible. The batteries
age gradually until at 6.0 volts or less the armature in its bearings. Too must be in good condition and well
the plunger moves into its operational little or too much end play results in charged or the electrical values of a
position. The plunger should return increased wear of the bearings. faulty starter will differ considerably
to the rest position when the voltage The end play is adjusted by plac- from the specified test data.
is reduced to, from 0.05-0.4 volts. ing or removing shims at the com-
When an ignition coil resistor short mutator end between the end cover
circuiting terminal No. 16 or C is and circlip on the armature. Adjust
incorporated in the switch cover, the to specification. 1. Circuit Diagram
terminal must be energised when the The internal circuitry of the starter
switch is in the closed position. Armature Braking Torque and the electrical connections are
The total armature braking torque given in the diagram above.
A~SEMBLY
is composed of brush, bearing and the
L Replace drive assembly (16). auxiliary armature brake torque. 2. Short-circuit Test
2. Fit the stop ring (18) on the Too high a braking torque results Clamp starter in test bench and
armature shaft to allow the spring in excessive mechanical wear and connect in accordance with the wiring
ring ( 19) to fit in its groove in the armature brake heating. diagram.
armature shaft. Too low a braking torque results in The ring gear of the test bench and
3. Slide the stop ring (18) over extended starter stopping time. Also, the starter pinion must have the same
the spring ring ( 19) to lock the spring the starter overrunning acceleration pitch; adjust backlash and out of
ring in position. will be too high. Armature torque can mesh clearance.
4. Assemble the armature (15) be measured with a torque balance. Operate starter and apply · test
and engaging lever (11) in the drive bench brake until pinion is almost to
end housing (17) and replace the Clutch Overrunning Torque a standstill. At this moment read cur-
engaging lever fulcrum bolt. The overrunning torque of the rent and voltage which must conform
5. Insert the armature and drive clutch assembly is the force necessary to specifications.
end housing assembly in to the car- to turn the pinion in a rotary direc-
cass. tion while the armature shaft is held 3. Load Test
6. 'Replace the brush holder plate s€ationary. Too low an overrunning Clamp starter and connect as in
(7) 'ind the brushes (6). torque may prevent starter power short circuit test. Operate starter and
application. If the overrunning torque apply brake until the specified cur-
7. Assemble the commutator end
is too high, the armature can reach rent draw is recorded, read voltage
cover and through bolts.
too high e speed and may be dam- and RPM.
8. Replace the circlip (3) the aged.
bearing cap (2) and the bearing cap 4. Free Running Test
For measuring overrunning torque,
screen (2).
move the pinion forward at least 0.4", Re-position starter on test bench so
9. Refit the solenoid and attach- with armature stationary measure that pinion and ring gear cannot
ing screws. torque in direction of rotation. Clutch engage. Connect as for previous tests.
10. Reconnect the solenoid switch assemblies not conforming to the Operate starter, read amperage, volt-
to starter motor lead, to the solenoid specifications must be replaced. age and RPM.
14-13

PART
14-4 LUCAS STARTING SYSTEM

Section Page
1 Removal and Installation 14-13

3 Major Repair Operations ...... 14-14

DESCRIPTION
The Lucas starting motor model
M40AK is a pre-engaged, four pole,
four brush, four inch diameter
machine with a series parallel
connected field, an armature with
a face type commutator and a
solenoid operated roller clutch drive.
The face type commutator on the
end face of the armature works in
conjunction with a fully insulated
brush bear assembly comprising two
pairs of brushes and coil type springs
assembled into a brush box moulding
attached to the inside of the end
cover by two Phillips head screws
which also act as earth returns for
the starter earth brushes.
OPERATION
Closing the solenoid switching
circuit energises the pull in and hold
in solenoid windings. The soft iron
plunger is drawn in moving the FIG. 1 -Lucas Starting Motor
engaging lever which in turn moves
the drive assembly towards the ring
gear. The helical splines on the
armature shaft rotate the pinion
slowly to assist in engagement.
Should a tooth of the advancing
pinion abut a tooth of the ring gear,
the engaging lever will compress the
helical spring at the pinion until
the switch contacts close. The pinion
is then turned and engages with the
ring gear under the helical spring
pressure.
REMOVAL & INSTALLAT ION
1. Disconnect the starter cable
at the starter motor terminal, remove
the flywheel housing to starter retain-
ing screws. Remove the starter
assembly.
2. Position the starter assembly
to the flywheel housing and start the FIG. 2- Wiring Diagram M40AK Starting Motor.
14-14 GROUP 14- STARTING SYSTEM
starter retaining screws. On a car with The bush in the drive end housing be renewed as a set. Note the posi-
automatic transmission, the trans- can be pressed out whilst supporting tions of the long and short brush
mission dipstick tube bracket is the housing. leads in relation to the commutator
mounted under the starter side Remove the bush in the end bracket and field winding term-
mounting bolt. Snug all bolts, then commutator end bracket by inserting ination.
tighten to specification, tighten the a 9/16" tap for a few turns into the (a) FIT NEW BRUSHES AS
middle bolt first. bush and withdraw the bush with FOLLOWS:-
3. Reconnect the starter cable the tap. The two earth brushes, flexible leads
from battery and wiring to switch. 4. ROLLER CLUTCH AND and fixing plates are serviced as
MAJOR REPAIR OPERATIONS DRIVE. complete assemblies.
The roller clutch is an over running To replace the field coil brushes,
DISASSEMBLY or free wheeling device, which pre- cut off their flexible lead 1/8 - 1/4"
1. Remove the field coil/solenoid vents the armature from being rotated from the field winding joint. Solder
linking cable from the solenoid at an excessive speed in the event of the new long and short brush leads
terminal. the drive being held in engagement to the ends of the original leads.
2. Remove the starter motor after the engine has started. Ensure that the insulated sleeves
through bolts. A roller clutch drive assembly in on the leads provide maximum
3. Remove the brush gear retain- good condition will provide instan- coverage consistent with satisfactory
ing screws. taneous take up of the drive in one soldering.
4. Withdraw commutator end direction and rotate smoothly and (b) BRUSH SPRINGS.
cover assembly and field yoke assy. easily in the other. The assembly To measure the brush spring pressures,
5. Unscrew the solenoid retaining should move freely round and along position a new brush in each of the
nuts and remove the solenoid. the armature shaft splines without brush boxes in turn and then press
6. Remove the armature assy. any roughness or tendency to bind . on top of the brush with a push type
7. Remove the thrust washer from Should the assembly not meet spring gauge until the top of the
the armature shaft. these requirements, a replacement brush protrudes about 1I16" from the
8. Remove the jump ring. unit should be fitted. brush box moulding. At this point
9. Remove the thrust collar. All moving parts should be liber- the ~pring pressure reading should be
10. Withdraw pinion and drive assy. ally smeared with Molybond GS1 0 approx. 28 oz. F. (see FIG. 3).
11. Remove the pinion engaging grease or a suitable equivalent. 6. COMMUTATOR.
lever pivot lock nut, pivot and re- 5 . BRUSH BOX. A commutator in good condition
move lever. Each of the four brushes should be will be burnished and free from pits
TESTING STARTER COMPONENTS free to move in the brush box mould- and burned spots. Clean the
ing. Sticking brushes can usually be commutator with a petrol moistened
1 . Clean and inspect all parts. freed by cleaning the brushes and cloth. If the commutator is badly
Check all bushings, bearing surfaces, moulding with a petrol moistened worn, mount the armature between
pinion, engaging mechanism and elec- cloth. Brushes which are worn to or centres in a lathe, rotate at high
trical contacts for wear and replace are approaching 3/8" in length must speed and take a light cut with a very
worn parts. Check electrical joints sharp cutting tool. Do not remove
and connections and repair where more metal than is necessary. The
necessary . minimum thickness to which the
2. FlEW COILS. commutator may be skimmed before
The field winding insulation can be replacement is 0 .080". The com-
checked by connecting a 11 0 volt AC mutator surface should be finally
15 watt test lamp between one of polished with very fine glass paper.
the brushes and part of the yoke. If NOTE: The insulators between the
the lamp lights it indicates that the commutator segments must not be
field coils are earthed. Remove and undercut.
rectify or replace the field coils as
required. 7. FOULING OF ARMATURE
Check field coil continuity by AGAINST POLE FACES.
connecting a 12 V battery operated Fouling of the armature against the
test lamp, between each of the field pole faces indicates either worn
coil brushes, and the field terminal. bearings or a distorted shaft. A
The lamp will light if continuity is damaged armature must in all cases
satisfactory. be replaced and no attempt should be
3. BEARING REPLACEMENT. made to machine the armature core
Both end brackets are fitted with or to straighten a distorted shaft.
self lubricating porous bronze bearing 8. ARMATURE WINDING IN-
bushes. New bushes must be immersed SULATION TESTS.
in clean engine oil (SAE 30-40 Grade) (a) To check the insulation of the
for a minimum of 24 hrs. before armature windings, remove all traces
fitting and must not be reamed after of brush dust with a dry air blast
fitting. Using a 11 0 volt AC 15 watt test lamp,
Bushes should be replaced on the connect between a commutator seg-
occasion of a major engine overhaul ment and the armature shaft. If the
or when the starter motor is to be FIG. 3 -Testing the Brush Spring lamp lights replace the armature.
fitted to a replacement engine. tension. (b) Check the armature for short
PART 13-4 LUCAS STARTING SYSTEM 14-15

6. Yoke and Field Coils Assembly. 10. Solenoid 16S.

1. Bracket, Commutator End 11. Lever, Pinion Engaging.
2. Brush Spring and Plate Assembly 7. Drive Assembly.
8. Bracket, Drive End. 12. Pivot Pin and Retaining Nut.
3. Brush Box Moulding 13. Nuts and Washers, Solenoid Fixing.
4. Face Type Commutator. 9. Bush, Bearing.
5. Bolt, Through Fixing.

FIG. 4- Starting Motor (pre-engaged) Model M40AK. DIAGRAM (A)

circuited windings using a "Growler"

equipment. Replace the armature if
a fault is indicated.

TO REASSEMBLE
During assembly operations place
a few drops of engine oil on the
armature shaft bushes. Smear Moly-
bond GSlO grease on the armature
shaft and drive assembly helix. Also
on the pivot points of the pinion
engaging lever.
Always use new jump rings during
assembly.
1. Assemble the pinion and drive
assembly to the armature shaft using
a new jump ring.
2. Assemble the pinion engaging
lever to the drive end bracket (closed
side of the lever toward the drive end
bearing). Do not fit the lock nut to
pivot pin at this stage.
3. Assemble the solenoid to the
drive end bracket and tighten the
nuts.
4. Assemble the brushes to the BRUSH GEAR RETAINING SCREWS
brush box and attach the box to the
commutator end bracket using the
two attaching screws and washers. FIG. 5 -1740 AK starting motor.
14-16 GROUP 14- STARTING SYSTEM

NOTE: Ensure the long field brush

lead "passes through the arch of the DIAGRAM (B)
adjacent earth brush fixing plate.
(FIG. 6). LONGER FIELD BRUSH LEAD THREADED
THROUGH EARTH BRUSH TERMINAL
5. Assemble the armature and
drive assembly to the drive end
bracket.
6. Assemble the yoke and field
coil assembly to the drive end
bracket.
7. Assemble the commutator end
bracket and brush gear assembly to
the yoke and field coil assembly. Fit
the through bolts and torque to
specification.
8. Assemble the field coil/solenoid
linking cable and tighten the nut.

PINION ENGAGING LEVER AD·

JUSTMENT
a. Disconnect the solenoid lead to
the starter motor field .
b. Energise the solenoid with a 6-8
volt supply.
(6-8 volts is used to prevent solenoid
over heating).
c. Using a screw driver in the recess,
turn the pivot pin until the correct
setting of O.Ql5 ± .005 is obtained
between the pinion face and the
thrust collar.
d. Fit the lock nut to the eccentric
pivot pjn and lock pin in position. FIG. 6- Commutator end bracket, inside view.
14-17

PART
14-5 SPECIFICATIONS

FORD STARTER (8 Cylinder

Engine) 3514V

Current Draw Normal Minimum Bruabes

Under Enrine Stall Maximum Brusn
Vendor Normal Crankinr Torque@ Load No·Load Mfr. Wear Sprinr
Load Speed 7 Volts (Amperes) IAmperesl Lenrth Limit Tensio1
!Amperes) lrpml !Foot Pounds! llnchesl llnchesl IDuncesl
Ford Positive Engagement 4 1!2-lnch Diameter 250 250-290 14 600 60 0.5 0.25 40

Maximum commutator runout in inches is 0.005.

Maximum starting circuit voltage drop (battery + terminal to starter terminal @ normal engine temperature) 0.5 volt.
Starter through-bolt torque 55-75 inch pounds.
Starter mounting-bolt torque 3; 8 inch bolt two-hole mounting 15-20 foot pounds, 5/ 16 inch bolt three-hole mounting 12-15 foot pounds.

BOSCH SOLENOID UNIT

Resistance of ma tn closing or 0.40-0.46 ohm·
sertes wtndin g BOSCH STARTER
- R-estslance of hold -on or shunt 1.351 .60 ohms"
wtn dtng
250 1V - 2V - 302 2V - 351 2V
-
Spr tng pr essure to push plunge r 16·20 lb .
fully home Amp Volts R.P.M.
Spring pressure to close sta rte r 10·14 lb.
Short Circuit Test 395-445 6.0 -
Load Test 210-240 9.0 1150-1450
swttch con tact s
No Load Test 50-70 12.0 5900-7100
Tota l spindle trave l 0.170"" -0.210'"
Commutator
Contact " follow-thr ough'' 0.028 "-0.101 "
Out of round 0.002" max.
Mica undercut 0.03125" max.
"Measured betwee11 the small terminal screw and terminal " STA" . W~en
Lucar terminals are ftned. between small terminal on rioht as viewed Brush Gear
from commutator end . Minimum length 0.5"
.. Measured between the small term inal screw and earth. t. e. solenoid Spring Tension 41-46 ozs.
outer case or body.
Armature
End Play 0.002-0.012
Braking Torque 2.2-3.5 in. ozs.
Solenoid
Pull-in Voltage Max.6
Drop-out Voltage 0.05-0.4

The specifications referred to above were in effect at the t ime th is publication

was approved for printing, however Ford Motor Company of Australia Limited
and/ or Ford Sales Company of Australia Limited , reserves the right, su bject to the
laws of any state or territory and the regulations of any competant authority which
may be applicable at the time, at its discretion and without notice , to change the
specifications and prices of the products referred to herein at any time and without
incurring any liability whatsover to any purchaser thereof.
14-18 SPECIFICATIONS

LUCAS M40AK STARTING MOTOR SOLENOID TYPE 16S

USED ON XA FALCON 200 CID ONLY
Pull in voltage 7.5 volts maximum
Lock Torque 15 lb/pt Current draw 2 coils 60 amps maximum
Current 430A Hold in winding 12 amps.
Terminal Voltage 7.0 v ± .1 Resistance Series winding 0 .225 ± .017 ohms
Running Torque 7 lb/ft Resistance shunt winding 0 .95 ± .07 ohms
@ 1000 r.p.m .
Current 280A
TORQUE SPECIFICATIONS
Terminal Voltage 9.4 v ± .1
Solenoid fixing nuts 4-5 lbs/ft.
Terminal nut 20-24 lbs/in.
FALCON FAIRLANE w~:~~~~P

GROUP
LIGHTING
15

PAGE

PART 15-1- General Lighting System, Horns

and Instruments Service 15-2

PART 15-2- Lighting System and Horns 15-7

PART 15-3- Switches, Circuit Breakers and

Fuses 15-12

PART 15-4- Instruments 15-14

PART 15-5- Specifications 15-23

15-2

PART GENERAL LIGHTING SYSTEM, HORNS AND

15-1 INSTRUMENT SERVICE

Section Page Section Page

1 Diag nosis and Testing 15-2 Fuel Guage and Fuel Level Sending Unit Test 15-5
Light Trouble Diagnosis Guide 15-2 Temperature Guage Test 15-5
Instrument Trouble Diagnos is Guide 15-3 Oil Pressure Indicator Light Test 15-5
Horn Trouble Diag nosis Guide 15-3 Charge Indicator Light Test 15-5
Turn Indicator Trouble Diagnosis Guide 15-3 Speedometer Tests 15-4
Windshield Wiper Trouble Diagnosi s Guide 15-3 2 Common Adjustments and Repairs 15-6
Headlight Switch and Beam Selector Switch Horn Adjustment 15-6
Test 15·5 3 Clean ing and Inspection 15-6
Constant Voltage Regulator Test 15-5 Two Speed Wiper Motor 15-6

D DIAGNOSIS AND TESTING

LIGHT TROUBLE DIAGNOSIS GUIDE

1. Loose battery cable. 5. Loose or broken wire to the

l. Loose quick disconnect or bro- bulbs.
ken wire from the battery to the 6. Defective beam selector switch.
ALL HEADLIGHTS DO headlight switch. 7. All headlight bulbs burned out.
NOT LIGHT 3. Defective headlight switch. This may be caused by a defective
4. Disconnected or broken wire or improperly adjusted alternator
from the headlight switch to the voltage regulator (Group 13).
beam selector switch.
1. Burned out bulb. 3. Poor ground.
INDIVIDUAL LIGHTS l. Loose or broken wires to the
DO NOT LIGHT
bulb.
1. Loose or corroded electrical 3. Improperly adjusted or defec-
LIGHTS BURN OUT tive alternator voltage regulator
connections.
REPEATEDLY (Group 13).
l. Excessive vibration.
INSTRUMENT TROUBLE DIAGNOSIS GUIDE

1. Indicator bulb burned out. 3. Defective oil pressure sender

OIL PRESSURE INDICATOR l. Loose or broken wire from the unit (in this part).
LIGHT INOPERATIVE light to the indicator switch.

CHARGE INDICATOR 1. Burned out bulb. l. Loose or broken wires.

LIGHT INOPERATIVE

CHARGE INDICA TOR 1. Faulty alternator and/or reg- 2. Loose fan belt.
LIGHT STAYS ON AT ulator.
IDLE

4. Defective constant voltage reg-

1. Loose terminals on fuel gauge. ulator.
5. Defective fuel tank sending
FUEL GAUGE ERRATIC
l . Defective fuel gauge. unit.
OR INOPERATIVE
3. Loose, broken, or shorted wire 6. Poor ground between fuel tank
from fuel gauge to the fuel tank and body.
sending unit.

CONTINUED ON NEXT PAGE

I""'

pART 15-1- GENERAL LIGHTING SYSTEM, HORNS INSTRUMENTS SERVICE 15-3

INSTRUMENT TROUBLE DIAGNOSIS GUIDE

perature gauge.
1. Loose terminals on temp gauge. 4. Defective temperature sending
TEMPERATURE GAUGE unit.
ERRA TIC OR INOPERATIVE l. Defective temperature gauge. 5. Defective constant voltage reg-
3. Loose or broken wire from the ulator.
temperature sending unit to the tern-

1. Loose or corroded constant 3 Broken or loose conductor from

FUEL, TEMPERATURE, AND voltage regulator ground. or to the constant voltage regulator.
OIL PRESSURE GAUGES l. Defective constant voltage reg- 4. Defective ignition switch.
ERRATIC ulator.

HORN TROUBLE DIAGNOSIS GUIDE

1. Loose connections at horn but- box to horn button.

ton· con tact. 4. Horns defective or out of ad-
HORNS DO NOT SOUND 2. Open wire (blue/red) from justment.
horn to horn button.
3. Open wire (green) from fuse 5. Fuse burned out.

ONE HORN FAILS 1. Broken or loose wire to the l. Horn defective or out of ad-
T0 OPERATE horn (blue/red). justment.

HORNS OPERATE
1. Horn button defective.
cONTINUOUSLY

TURN INDICATOR TROUBLE DIAGNOSIS GUIDE

1. Burned out bulbs, or loose 4. Loose or broken wire from

sockets. flasher to turn indicator switch.
TURN INDICATOR LIGHTS
l. Loose or broken wire from 5. Defective turn indicator switch.
I NOPERATIVE
ignition switch to flasher. 6. Broken, shorted, or loose wires
3. Defective flasher. from switch to lights.

1. Burned out bulb. 3. Defective indicator switch.

TURN INDICATOR LIGHTS l. Loose, broken, or shorted wires 4. Defective flasher.
OPERATE INCORRECTLY from switch to lights.

TURN INDICATOR 1. Cam improperly positioned on l. Coil spring on switch plate as-
cANCELS IMPROPERLY steering wheel hub. sembly loose or weak.

WINDSHIELD WIPER TROUBLE DIAGNOSIS GUIDE

1. Binding linkage. 4. Defective wiring or blown fuse.

I NOPERATIVE OR SLOW 1. Defective switch.
WIPER 3. Defective wiper motor
15-4 GROUP 15· LIGHTING SYSTEM, HORNS AND INSTRUMENTS
•
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FIG. 1 -Installation Speedo Cable.

SPEEDOMETER DIAGNOSTIC I. Loose cable retainer. particularly important where the ca-
PROCEDURES l. Defective drive and/ or driven ble leaves the speedometer head. The
gear. optimum routing would provide that
Speedometer system complaints are
3. Defective speedometer head. the cable and housing take virtually
generally the result of a visible or
4. No lube on cable. no change of direction for at least
audible defect in the system. It is im-
a length of 8 inches from the speed-
perative that the specific defect be ometer head.
determined prior to attempting any SPEEDOMETER REPAIR
3. When installing a new cable
physical repairs to preclude unnec- PROCEDURES and housing it is necessary that the
essarily disassembling system compo- new assembly be guided and routed
nents. The following suggestions are NOTE: To effect any tests or repairs properly to eliminate any kinks.
intended to aid in quick and accurate on the speedometer head the instru-
system problem diagnosis. 4. Proper lubrication of the cable
ment cluster must be detached from core is accomplished by a light
the instrument panel (see page 15·15) application of a lubricant after the
VISIBLE DEFECTS to gain access. cable has been wiped clean. A light
Slight Needle Waver or DEFECfiVE SPEEDOMETER film is all that is required.
Severe Needle Fluctuation HEAD DEFECTIVE DRIVE AND
(No Noise) Before removing a speedometer DRIVEN GEARS
I. Loose cable retainer . head, disconnect the cable at the 1. A score nicked or gouged driv-
l. Defective speedometer head. head and insert a short section of ca- en gear is usually indicative of a de-
3. Bent cable core at attaching ble core in the head. Rotate the sec- fective drive gear on those vehicles
nut. tion of core to check for any drag- that have the drive gear integral
4. Kinked or pinched cable hous- ging or noise. The speedometer shaft with the transmission output shaft.
ing. should turn freely and evenly. The output shaft should be carefully
5. Excessive grease in speedome- inspected for imperfections and re-
ter head. DEFEq'IVE CABLE CORE placed if necessary.
Inoperative
AND HOUSING 2. A driven gear with two or
1. To check for a kinked cable three adjoining teeth badly scored is
1. Broken cable core. core remove and wipe dry. Lay the indicative of improper assembly pro-
l. Defective drive and/ or driven cedure. The gear should be inserted
core out stra\ght on a flat surface
gear. in the transmission while simultane-
and roll it back and forth . Any kinks
3. Defective speedometer head. ously turning the drive shaft. This
or damage will be seen. Then take
AUDIBLE DEFECTS an end in each hand, allowing core will insure initial gear engagement
to hang in approximately a 9-inch and prevent gear damage. Force
Clicking or Ticking (With loop. Rotate both ends to be sure should never be used.
Needle Waver), Grinding core turns evenly. 3. Whenever a drive gear is re-
or Ringing 2. Routing of the cable housing is placed, a new driven gear should al-
PART 15-1- GENERAL LIGHTING SYSTEM, HORNS INSTRUMENTS SERVICE 15-5

so be installed, regardless of its ap- volts. If it does not, the constant out, indicating that the oil pressure
parent condition. voltage regulator is defective, or has built up a safe value.
nSTING there is a short to ground between
the voltage regulator and the gauges. To test the oil pressure switch on
Refer to Group 22 for schemat-
ics and locations of wiring harnes- If a gauge unit is inaccurate or the engine, turn the ignition switch
ses. does not indicate, replace it with a on, engine not running, the indicator
new unit. If the gauge unit still is hgnt snould come on. If the indica-
HORN TEST erratic in its operation, the sending tor light does not come on, shch"t the
The only test necessary on the unit or wiring to the sending unit is terminal of the oil pressure switch
horn is for current draw. faulty. unit to ground. If the tight now
If both the fuel gauge and the comes on, the oil pressure switch is
Current Draw Test
temperature gauge indicate improp- defective or not properly sealed to
Connect a voltmeter and ammeter erly and in the same direcdon, the the engine. Be sure to use electrical-
to the horn and to a voltage supply constant voltage regulator could be ly conductive sealer
as shown in Fig. 2. The normal defectin, as it supplies both gauges.
current draw for the horns at 12 TESTING FUEL AND If the light still does not come on,
volts is 4-5 amperes. the bulb is burned out or the wires
TEMPERATURE GAUGES from the bulb to the ignition switch

N;~~~~
FUEL GAUGE. and oil pressure switch are defective.
A simple check to show whether it
LEAD ~ CHARGE INDICATOR LIGHT
v ~ is the sender unit or gauge unit at
POS.I~ fault is to fit a known good sender TEST
LEAD ~ unit in the circuit.
-4~-...,.--
+ If the gauge unit reads propor- .To test the charge indicator light,
tionate to the float setting, the gauge turn the ignition switch on with the
FIG. 2 -Horn Current Draw Test unit is correct . engine stopped. The light should
Do not test gauge units by shorting come on. If it does not, the bulb is
HEADLIGHT SWITCH AND terminals direct to earth. Minimum burned out, or the wiring to the light
BEAM SELECTOR SWITCH TESTS circuit resistance is to be held to is defective or there is a fault in the
The following tests may be made 10 ohms for high indication. Lower alternator/regulator circuit. Remove
to determine whether a headlight resistances will destroy calibration. the wiring plug from the D+ terminal
switch or a beam selector sw1tch is TEMPERATURE GAUGE TEST of the Bosch alternator regulator
defective: or the IND terminal of the Lucas
Turn on the headlights, and oper- Start the engine and allow it to alternator regulator.
ate the beam selector switch. If none run at 1200 rpm for 30 minutes.
of the headlights turn on when the Place a thermometer in the coolant Connect a jumper lead from the
beam selector switch is operated, yet at the radiator filler cap. The tem- D+ or IND terminal in the cable to
the instrument panel lights operate, perature should read a minimum of earth. The indicator light should
the headlight switch or the red-yel- 180°F., and the gauge in the instru- come on.
low stripe wire from the headlight ment panel should indicate within
switch to the beam control switch is the normal band. If the light comes on the regulator
probably defective. Suhstitute a is at fault. If the light does not come
known good switch for the suspected If the gauge does not indicate, on the fault is in the wiring or globe .
switch to determine whether the short the temperature sender unit
switch or the wiring is at fault. terminal wire to ground (ignition To check the globe and wiring
If the headlights operate only with switch on). Do not leave the sender the instrument cluster surround must
the beam selector switch in one posi- wire grounded longer than necessary be removed to gain access to the
tion, the selector switch or the wir- to make the test, as the gauge may globe .
ing from the switch to the headlight be damaged. If the gauge now indi-
is defective. Substitute a known good cates, the sender unit is defective or SPEEDOMETER TESTS
selector switch for the suspected not properly sealed to the engine. Be
switch to determine whether the sure to use an electrically conductive To test the odometer accuracy,
switch or the wiring is at fault. sealer. If the gauge does not indi- drive the car over a measured mile.
CONSTANT VOLTAGE cate, the gauge, the wires leading to Speedometer accuracy can be
REGULATOR TEST the gauge, or the constant voltage checked by comparing the speedom-
The instrument cluster must be re- regulator are at fault. eter in question against one known
moved to gain access to the voltage to be accurate, while two cars are
regulator and gauge terminals. OIL PRESSURE INDICATOR moving at the same speed, or by
LIGHT TEST timing the car on a measured mile.
Turn the ignition switch on, check
for voltage at the fuel gauge upper
terminal (Falcon) temp gauge term- To test the indicator light, turn on Page 15 24 shows the correct com-
inal adjacent to the regulator screw. the ignition switch. Do not sta~t the bination of gears to use for various
The voltage should oscillate be- engine. The light should come on. rear axle and tyre size combina-
tween zero and about 10 Start the engine. The light should go tions.
15-6 GROUP 15· LIGHTING SYSTEM, HORNS AND INSTRUMENTS

B COMMON ADJUSTMENTS AND REPAIRS

HORN ADJUSTMENT
Horn current can be adjusted by nect the l).orn as shown in Fig. 2. headed screw until the current is
changing the contact tension. Con- Turn the self-locking adjusting pan within the limits for the horn being
adjusted.

FIG. 3 - Falcon Printed Circuit. FIG. 4- Fairlane Printed Circuit.

EJ CLEANING AND INSPECTION

ADJUSTM~NT SCR~W

TWO-SPEED WIPER MOTOR

1. Clean the gear housing of all gears for scored surfaces. Replace
old grease. Do not allow any clean- defective parts and add new grease
Ing ftuld to contact the armature to the housing and gears.
shaft and output shaft bearings.

l. Wipe all other parts with a

clean cloth.

3. Inspect the gear housing for

cracks or distortion. Replace a
cracked or distorted housing.
HIGI-l OR LOW TON~ ID~NTIFICATION

4. Check all shafts, bushings, and FIG. 5- Horn Adjustment.

15-7

PART LIGHTING SYSTEM AND HORNS

15-2
Sec:tion Paae Sec:tion Paae
1 Description and Operation ................ 15-9 Parking Light ........................... 15-10
Headlights .............................. 15-9 Tail, Stop, and Back-Up Light Bulbs .... , ... 15-11
Horns .................................. 15-9 License Plate Light ....................... 15-11
2 In-Car Adjustments and Repairs ........... 15-9 Dome Light ............................. 15-11
Headlight Alignment ..................... 15-9 Instrument Lights ........................ 15-11
Headlight Adjustment ................. . ... 15-9 Horns .................................. 15-11
Back-Up Light Adjustment. ................ 15-9 Horn Switch............................. 15-11
3 Removal and Installation .................. 15-10 Gear Selector Quadrant Light•............ 15-11
Headlights .............................. 15-10

D DESCRIPTION AND OPERATION

Refer to Group 22 for locations The terminals are colour coded. respectively cast into the throat of
of wiring harnesses and schematics. Like colour terminals are connect- the horn (Fig. 3, Part 15-1).
Ed. together.
HEADLIGHTS NOTE: Horns are located forward
The Falcon Models use two HORNS of the left front suspension tower.
No. 2 type sealed-beam headlights. Standard and De-Luxe models are SEAT BElT WARNING LAMP.
Each light has low-beam and high- fitted with one low tone horn. On The standard vehicle has a seat
beam filaments. Fairmont, Futura and G.T. models belt warning lamp fitted which
A conventional beam selector a pair of tuned horns is used, one a illuminates only whilst the ignition
switch is located on the floorboard high pitched tone, the other, which switch is held in the start position.
is similar to the single horn installa- On vehicles fitted with seat belt
at the left of the driver. tion, has a low pitched tone. A horn retractor a relay is used which
Quick disconnect terminals are button closes the circuit to the horn(s).
also provided on the left and right
illuminates the lamp for 12-1 ~
High and low tone horns can be seconds after switching on the
of the radiator support assembly. identified by the letter "H" or "L" ignition.

EJ IN-CAR ADJUSTMENTS AND REPAIRS

HEADLIGHT ALIGNMENT tion of the shop floor. Lay out the properly aimed. This will bring the
floor and wall as shown in Fig. 6. beam into final position with the
All headlight adjustments should unit held under proper tension when
be made with a half-full fuel tank HEADLIGHT ADJUSTMENT operation is completed.
plus or minus one gallon, with a Adjust each upper headlight beam Note: Do not check aim on the
person seated in the driver's seat, as shown in Fig. 6. Some states low beam.
and a person in the passenger seat, may not approve of the D + -
the car unloaded and the trunk 2 inch dimension for the headlights.
empty except for the spare tyre - Check the applicable state law. BACK UP LIGHT ADJUSTMENT
and jacking equipment, and recom- Each headlight can be adjusted
mended pressure in all tyres. Be- by means of two screws located Place the shift lever in the reverse
fore each adjustment, bounce the between the light and radiator grill position. Loosen the switch retain-
car by pushing on the centre of Fig. 5 & 6. ing clamp and position the switch
both the front and rear bumpers, to so that the operating plunger is de-
CAUTION pressed n ~. Ensure that the switch
·level the car. Always adjust aiming screw body is not contacting the shift arm
To align the headlights by means counter clockwise then clockwise and is parallel to the arm. Tighten
of a wall screen, select a level por- until high intensity of light is the clamp.
15-8 GROUP 15- LIGHTING SYSTEM, HORNS AND INSTRUMENTS

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PART 15-2- LIGHTING SYSTEM AND HORNS 15-9

FIG. 7- Headlight and Parklight

Installation - Falcon Typical.

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FIG. 8- Headlight and Parklight
Installation - Fairlane Typical.
15-10 GROUP 15- LIGHTING SYSTEM, HORNS AND INSTRUMENTS

EJ REMOVAL AND INSTALLATION

HEADLIGHTS action to the connector. Remove Whenever a sealed beam umt IS
sealed beam unit from vehicle. replaced or any other alterations are
REMOVAL made to a headlight assembly the
To replace the sealed beam unit, REPLACEMENT headlights should always be checked
remove the radiator grill and remove Align the three-pin connector with for alignment and adjusted as
the three sealed beam retaining rim the contacts in the sealed beam unit described on page 157.
screws. Lift the sealed beam unit and push on. Fit the sealed beam
free of its cradle. unit to cradle ensuring the three
locating lugs engage in cradle locat- PARKING LIGHT
ing slots. Fit the retaining rim and The parking light of Fairlane-
Remove the push-on 3-pin con- fit three screws. Falcon vehicles is shown in Fig. 9
nector by holding the headlight To replace the bulb remove the le~s
assembly and applying a firm pulling Refit grill and aim headlights. retaining screws and the lens.

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FIG. 9- Installation Drg. Park Lamps.

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FIG. 10- Falcon- rear lamp installations.

PART 15-2- LIGHTING SYSTEM AND HORNS 15-11

TAIL, STOP, AND BACK-UP 2. Remove the steering wheel re- wheel and disconnect the horn wires
LIGHT BULBS taining nut and using a suitable puller at the steering wheel hub.
To replace the tail, stop, and/ or withdraw the wheel. 3. Remove the steering wheel
the back-up lights, remove the retain- 3. Remove the globe. pad/horn switch assembly.
ing screws and remove the lens. See Reverse this procedure for
Figs. 10-11-12. GEAR SELECTOR QUADRANT assembly.
LICENCE PLATE LIGHT LIGHT FLOOR SHIFT.
Bulb replacement is straightfor- 1. Remove the console and dial HORN SWITCH G.T. & G.S.
ward as there is no lens covering assy. 1. Remove the steering wheel pad
the licence plate bulb. 2. Remove the globe. by removing the retaining screws
DOME LIGHT from the under side of the steering
Remove the self fixing dome light HORNS wheel spokes.
lens and replace the bulb. 2. Disconnect the rim blow horn
Disconnect the horn wire from the
INSTRUMENT LIGHTS terminal. Remove the horn mounting switch connections at the steering
Instrument cluster illumination bracket to horn retaining screws and wheel hub.
lamp bulb replacement necessitates remove the horn. 3. Strip the horn switch from the
removal of the instrument cluster To install, mount the horn in steering wheel rim.
as described in Part 15-4. position, then connect the horn wire TO REASSEMBLE
Once the cluster has been removed to the horn terminal.
simply remove the bulb holder from 1. Feed the horn switch into the
HORN SWITCH steering wheel rim groove using a
the cluster replace the bulb and
reinsert the assembly in the cluster. 1. Remove the two steering wheel small steel spatula (approx. same
GEAR SELECTOR QUADRANT
centre pad/horn switch retaining size as 6" rule).
screws from the underside of the 2. Connect the horn leads at the
LIGHT COLUMN SHIFT.
steering wheel spokes. steering wheel hub.
1. Remove the horn switch. 2. Lift the pad/horn switch 3. Reinstall the steering wheel pad.
assembly away from the steering

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FIG. 11 - Fairlane- rear lamp installations.

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FIG. 12- Ute·Van- rear lamp installations.

15-12

PART SWITCHES, CIRCUIT BREAKERS, AND

15·3 FUSES
Section Page Section Page
Description and Operation .. . . .. .. . ... . . . . 15-12 Stop Light Switch 15-13
Headlight Switch ........ . ... .. ........ . 15-12 Dome Light Switch
Fuse Panel ..... .. . . . . ........ .. ....... . 15-12 15-13
Mechanical Stop Light Switch ..... . . . ..... . 15-12 Ignition Switch and Lock Cylinder ....... . ... . 15-13
Reversing Light Switch .. . ............... . 15-12 Windshield Wiper Switch ................ . . . 15-13
2 Removal and Installation . .. . ... . ....... . 15-13
Headlight Switch . ......... . ... . ....... . 15-13 Neutral Start Switch ...................... . 15-13
Headlight Beam Selector Switch ....... . ... . 15-13 Back-Up Light Switch . .. . . ..... . ......... . 15-13

D DESCRIPTION AND OPERATION REYIISING LIGHT SWITCH

Refer to Group 22 for locations of The reversing light switch is incor-

wiring harnesses and schematics. porated in the inhibitor switch on
automatic transmission vehicles.
HEADLIGHT SWITCH In column shift manual transmis-
A separate headlight switch and sion vehicles the plunger type switch
circuit breaker is used. The headlight is located on a bracket at the steering
circuit is protected by a 22 ampere column lower bearing where it is
circuit breaker. The tail, parking, actuated by the first and reverse shift
licence plate light and horn circuits lever.
are protected by 8 amp fuses. On floor shift manual transmission
vehicles the plunger type switch is
FUSE PANEL
mounted on a bracket on the front
The fuse panel is mounted on the of the shift mechanism where it is
right of the dash panel under the actuated by the reverse shift lever as
right-hand air vent. Fig.I3 shows the it reaches the reverse position.
fuses, their valves and locations.
MECHANICAL STOP LIGHT
FIG. 13- Fuse Panel Location- Typical.
SWITCH

The mechanical stoplight switch is

located on the brake pedal support
bracket and is operated by a lever
extending from the brake pedal arm.
With the brake pedal in the r~­
leased position and a test lamp con-
nected to the switch terminals adjust
the switch as follows-
1. Release the locknuts retaining
the switch body.
2. Move the switch body forward
until the test lamp goes out.
3. Move the switch body a further
0. 050" forward.
4. Tighten the locknuts.

FIG. 14- Mechanical Stoplight Switch Installation

SWITCHES, CIRCUIT BREAKERS AND FUSES 15-13

EJ REMOVAL AND INSTALLATION

HEADLIGHT SWITCH
1. Disconnect the battery ground
cable.
2. Prise the switch forward from
the instrument cluster.
3. Disconnect wiring and remove
the switch.
4. Connect wiring to the switch
connections.
5. Press the switch assembly into
the aperture.
HEADLIGHT BEAM
SELECTOR SWITCH FIG. 15 - Headlight Beam
Lay the ftoor mat back from the Selector Switch FIG. 16- Typical Ignition Switch
area of the switch, and remove the Removed.
mounting screws (Fig. 15). Discon- 4. Align the barrel tongue and
2. Remove the column from the
nect the wire terminal block from the vehicle. aperture and assemble the barrel
switch. 3. Remove the steering lock to the lock and raise the barrel
To install the switch, connect the shroud and shift tube. Page 3 - 38 locking pin by turning the key to the
terminal block to the switch and in· 4. Cut slots in the steering lock start position.
stall the switch to the floor. Replace attaching bolts with a hacksaw and 5. Assemble the lock shroud lower
the ftoor mat. remove the bolts with a screw driver attaching screw.
or hammer and centre punch.
STOP LIGHT SWITCH 5. Rotate the lock around the WINDSHIELD WIPER SWITCH
column tube until one end of the
1. Disconnect the wires at the 1. Disconnect the battery cable.
base clears the aperture, lift the lock
connector. 2. Prise the switch from the
from the column.
2. Release the locknut (pedal side)
6. Place the steering/ignition lock instrument cluster.
and withdraw the switch. 3. Disconnect wiring and remove
assembly into the steering column
3. Reverse the above procedure to
7. Engage new recessed bush in the the switch.
replace the switch.
shear head bolts and tighten them 4. Connect wiring to the switch
4. Adjust the switch as in section 1.
evenly until the heads shear off. connections.
Install shift tube. 5. Press the switch assembly into
DOME LIGHT SWITCH 8. Assemble the shroud to the the aperture .
The dome light switch is incor- column.
porated in the panel lamp switch. It 9. Assemble the column to the
is actuated by rotating the switch vehicle.
control wheel to the right when once LOCK BARREL REPLACEMENT. NEUTRAL START SWITCH
the panel lamps have reached full See group 7 for replacement of
brilliance . The further rotation of the 1. Remove the steering/ignition the neutral start switch on cars
wheel switches the dome lamp on. lock shroud lower attaching screw equipped with automatic transmis-
The dome lamp also acts as a from beneath the shroud. sions.
courtesy lamp actuated by switches 2. Turn the ignition key to the
off or on position. BACK-UP LIGHT SWITCH
tn the door pillars.
3. Push a 0.062 dia. pin into the 1. Remove the two wires from
IGNinON SWITCH AND lock thiough the shroud lower the switch.
LOCK CYUNDER mounting hole to raise the barrel 2. Loosen the retaining clamp or
1. Disconnect the negative cable locking pin and remove the barrel locknuts.
from the battery. Fig. 16. 3. Remove the switch.
15-14

PART INSTRUMENTS
15-4

Sec:tion Pare Section Pare

1. Description and Operation . .. ........... 15-14 Temperature Sending Unit .............. . 15-17
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-14 Oil Pressure Switch ..................... . 15-17
Constant Voltage Regulator . . . . . . . . . . . . . . 15-14 Turn Indicator Switch ................... . 15-17
Fuel Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-14
Temperature Gauge . . . . . . . . . . . . . . . . . . . . . 15-15 Turn Indicator Flasher ................... . 15-17
Charge Indicator Light . . . . . . . . . . . . . . . . . . . 15-15 Speedometc!r and Tachometer ............ . 15-16
Oil Pressure Indicator Light . . . . . . . . . . . . . . 15-15 Speedometer Cable ..................... . 15-16
Turn Indicator . . . . . . . . . . . . . . . . . . . . . . . 15-15 Windshield Wiper Motor ................. . 15-17
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . 15-15 Wiper Pivot Shaft and Link .............. . 15-17
Brake Warning Lamp . . . . . . . . . . . . . . . . . . . 15-15
2. In-Car Adjustments and Repairs . . . . . . . . . . . . 15-15
Windshield Wiper Blade Adjustment . . . . . . . 15-15 4. Major Repair Operations .................. 15-18
3. Removal and Installation . . . . . . . . . . . . . . . . 15-15 Disassembly-Permanent Magnet Type Two-
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . 15-15 Speed Electric Wiper Motor ............. 15-19
Fuel, Temperature Gauges . . . ........... 15-16 Inspecting and Testing Disassembled Motor .... 15-19
Printed Instrument Circuit . . . ........... 15-16 Testing and Assembled Motor ............. 15-20
Fuel Sending Unit . . . . . . . . . . . . . . . . . . . . . 15-17
NOTE: If the instruments require servicing while the assembly is removed from the instrument panel,
the cluster case must be earthed to the vehicle body. Failure to observe this precaution will cause immediate
damage to the fuel and temperature gauges as soon as any power is applied to the electrical circuits.

D DESCRIPTION AND OPERATION

All of the instruments are electri- heats the bimetallic arm causing it TEMPERATURE GAUGE
UNIT
cally operated except the speedome- to bend and break the contacts, dis-
ter. Brightness of the instrument pan- connecting the voltage supply from
el lights is controlled by a rheostat the heating coil. The bimetallic arm
adjacent to the lighting switch. then cools and brings the contacts
together again. The making and
breaking of the contacts, causes a
GAUGES pulsating voltage, with an effective
average value of S.O volts to be sup-
The instrument cluster includes plied to the gauges. Although these
a fuel gauge, temperature gauge, pulsations are quite rapid, there is
charge indicator light, oil pressure in each gauge a bimetallic arm which
indicator light, speedometer, high changes temperature quite slowly,
beam indicator light, a left- and and this assures steady average read-
right-hand turn signal indicator light, ings.
brake warning light, and stop lamp As the pulsating voltage would
and brake warning light. normally cause radio interference, a
radio interference suppression choke FIG. 17- Gauge Voltage Regulator
CONSTANT VOLTAGE
is connected in series with the con- and Temperature Gauge - Typical.
REGULATOR
The constant voltage regulator stant voltage regulator supply wire.
(Fig. 17) used with the fuel, tempera- FUEL GAUGE
ture, and oil gauges maintains an The fuel gauge consists of a send-
average value of S.O volts at the ing unit, located on the fuel tank, and rheostat that varies its resistance de-
gauge terminals. a remote register unit (fuel gauge) pending on the amount of fuel in the
The regulator operates by means mounted in the instrument cluster. tank. The rheostat is operated by a
of a bimetallic arm and a heating The remote register unit pointer is float control. As the fuel level rises or
coil. When the ignition switch is controlled by a bimetallic arm and falls the float control arm moved by
turned on, the heating coil (Fig. 17). heating coil. The sending unit is a the float, varies the resistance.
PART 15-4- INSTRUMENTS 15-15
COIL TEMPERATURE SENDING UNIT turned on, and it should go out when
the engine comes up to speed. The
light is connected between the oil
pressure switch unit mounted on the
engine at the left rear on the six,
above the oil filter on the V-8 (Fig.
18) and the coil terminal of the
ignition switch. The G.T. has an oil
gauge adjacent to the tachometer.

TURN INDICATOR
The turn indicator uses a single
filament globe in the upper section of
the front park/ indicator combination
lamp and the centre section of the
rear light assembly.
The turn indicator flasher is lo-
cated in the back of the instrument
panel, on the steering column brace.
OIL PRESSURE SWITCH

FIG. 19- Oil Pressure Switch and SPEEDOMETER

Temperature Sending Unit 6 Cyl.
The speedometer is connected to
the output shaft of the transmission
by means of a flexible shaft, and a
FIG. 18 -Temperature Sender and drive gear located inside the trans-
Oil Pressure Switch - V8 Typical. light is used. This light illuminates if
the battery is discharging and the al- mission. The flexible shaft drives the
ternator is not supplymg current. speedometer which registers speed in
When the ignition switch is closed, miles per hour and also drives an
TEMPERATURE GAUGE battery current flows through the odometer which records distance
The temperature gauge consists of charge indicator light and through traveled in miles and tenths of a
a $ending unit mounted in the cylin- the regulator voltage limiter to the mile.
der head at the top front on the field .
V-8 (Fig. 18 or 19), left rear on the When the alternator output voltage
six, and a remote register unit, (tem- BRAKE WARNING LAMP
opposing battery voltage is high
peratl•~e gauge) mounted in the in- enough the charge indicator light
strument cluster. goes out. A red indicator lamp illuminates
Changes of engine temperature when either the front or rear brake
vary the resistance of the sending systems become inoperative. The
OIL PRESSURE INDICATOR warning light switch is located in the
unit which in tum operates the tem- LIGHT
perature gauge. master cylinder body.
An amber indicator light illumin- "Prove out" of the light circuit is
CHARGE INDICATOR ates when the oil pressure is below a conducted by turning the ignition
LIGHT safe value. The light should come on switch to the start position when the
A red alternator charge indicator when the ignition switch is first lamp should illuminate.

EJ IN-CAR ADJUSTMENTS AND REPAIRS

WINDSHIELD WIPER Install the wiper blades so that they
accessory position. Turn the wiper lie flat within 1i-2! ins. from lower
BLADE ADJUSTMENT switch on and off to allow the wiper edge of windsq·een (measured at
Turn the ignition switch to the motor to adopt the park position. centre of blades).

EJ REMOVAL AND INSTALLATION

INSTRUMENT CLUSTER /or Gauges G.T.). ing screws (one in each corner of the
4. Remove the housing from be- cluster body), and partially remove
1. Remove the three screws, (five hind the steering column by moving the cluster.
screws Fairlane) retaining the cluster it toward the centre of the vehicle 6. Disconnect speedo cable and
housing. (select 1st or 1 gears on column printed circuit plug.
2. Remove the housing toward shift vehicles). 7. Complete removal of the cluster
the steering column. by rolling the top back toward the
3. Disconnect warning lamps (and 5. Remove the four cluster retain- column.
15-16 GROUP 15- LIGHTING SYSTEM, HORNS AND INSTRUMENTS

3. Remove the housing from be-

hind the steering column and remove
the gauge retaining screws.
4. Remove the gauges from the
housing.
FUEL & TEMPERATURE GAUGES
FAIR LANE.
l. Remove the instrument cluster
as previously outlined.
2. Remove the four screws attach-
ing the lens and cover to the canister.
3. Remove the terminal speed nuts
from the gauges and remove the
gauges from the canister.
FIG. 20- Speedo Cable to Speedo Connection.
SPEEDOMETER & TACHOMETER.
SPEEDO CABLE DISCONNECT from the temperature gauge mask and
FROM SPEEDO HEAD remove it from beneath the needle. 1. Remove the instrument cluster
4. Remove the terminal speed nuts and separate it as previously outlined
1. Remove the crash pad and retaining the gauges to the rear half
cover (from right hand side). under fuel and temperature gauge
of the canister and remove the removal.
2. Using a long screw driver or
gauges. 2. Remove two retaining screws
solid rod depress the release tab and
pull the cable away from the speedo NOTE: The fuel gauge mask must be from the backs of the speedometer/
head. (Fig. 20). removed before the temp gauge or tachometer.
mask can be removed.
NOTE: On Fairlane remove fuel and
FUEL & TEMPERATURE GAUGES
FUEL & TEMPERATURE GAUGES temperature gauges prior to attempt-
I . Remove the instrument cluster ing to remove the speedometer.
as previously outlined. G.T.&G.S.
3. Remove the speedometer I
2. Remove the two upper screws 1. Remove the instrument cluster tachometer from the cluster.
retaining the lenses and the two housing (3) retaining screws and lay
screws holding the two halves of the the housing toward the steering PRINTED CIRCUIT.
cluster together. column. Replacement of the printed circuit
3. From the front of the gauges, 2. Remove the gauge wiring and can only be achieved once the gauges
remove the two screws retaining the disconnect the warning lamp holders -speedometer/tachometer have been
fuel gauge mask, unclip the mask from the housing. removed. Fig. 3 & 4.

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FIG. 21 - Installation Drg. Cluster Housing.

PART 15-4- INSTRUMENTS 15-17

CLOCK. OIL PRESSURE SWITCH cable and check the operation of the
To replace the unit disconnect the turn signal switch and horns.
1. Remove the instrument cluster
housing. wire from the terminal. Remove the TURN INDICATOR RASHER
2. Remove the instrument panel unit from the engine. Apply con- Disconnect the wires from the
pad, right hand end cover. ductive sealer to the threads and flasher unit terminal, turn flasher
install the wire to the terminal and and remove. Observe the colour code
3. Remove the two clock attaching
check the operation of the unit. and number on the cover of the
screws.
TURN INDICATOR SWITCH flasher. Be certain to replace it
4. Disconnect the clock leads. 'with a new flasher with the same
5. Remove the clock through the REMOVAL colour code and number on the
end opening in the instrument panel. 1. Disconnect the negative cover.
(ground) cable from the battery.
WIPER PIVOT SHAFT AND LINK
WARN lNG LAMPS. l. Remove the steering wheel hub
and steering wheel retaining nut. 1. Remove the windshield wiper
1. Remove the instrument cluster blade and arm assembly.
3. Remove the steering wheel
housing. from the shaft. 2. Remove the-pivot shaft retain-
2. ·Remove bulb holders from the 4. Disconnect the two wire-con- ing nut, bezel and gasket.
housing. nector blocks at the dash panel above 3. Disconnect the wiper link from
NOTE: On Fairlane vehicles remove the steering column. the motor and remove the link and
the heater control panel to gain S. Remove the wires and terminals pivot shaft assembly.
access to the brake warning lamp. from the connector blocks. This can 4. Position the link and pivot shaft
be done by depressing the tab on the assembly on the cowl and wiper
FUEL SENDING UNIT wire terminal with an awl, or by in- motor. Connect the link to the motor.
~rting a ball point pen (refill plas- 5. Install the pivot shaft to the
1. Remove the fuel from the fuel cowl and install the gasket, bezel,
tank. tac type) over the bullet pin and pull
the wire and terminal from the con- and retaining nut.
2. Disconnect the fuel gauge send- 6. Install the wiper blade and arm
ing unit wire from the sending unit. nector block. Record the color code
and location of each wire before re- assembly.
3. Loosen the hose clamp and dis- 7. Check the pivot shaft and link
connect the tank line at the sending moving It from the connector block.
Tape the wires together and attach operation.
unit.
4. Remove any dirt that has ac- a piece of heavy cord to the wires to WINDSHIELD WIPER MOTOR
cumulated around the sending unit help pull the wires through the steer-
ing column during installation. AND WASHER ASSEMBLY
so that it will not enter the tank.
S. Turn the sending unit retaining 6. Remove the turn indicator REMOVAL
ring counterclockwise and remove handle from the side of the steering
column. 1. Disconnect the harness from
the unit, retaining ring, and mount- the Wiper Motor.
ing gasket. 7. Remove 3 bearing retainer at-
taching screws and remove the bear- 2. Remove the three hoses con-
6. Clean the fuel gauge sending nected to the Washer Pump.
unit mounting surface at the fuel ing retainer and tum indicator switch
and wires from the steering column. 3. Remove the three bolts retain-
tank. ing the Wiper Motor and mounting
7. Position the sending unit and Disconnect the heavy cord from the
switch wires. seal assembly to the dash panel.
mounting gasket on the fuel tank and Lower the assembly and disconnect
secure with the retaining ring. the wiper ~inks at the motor. Remove
INSTALLATION
8. Connect the sending unit wire the Motor and Washer Assemblv.
and the fuel tank line. 1. Tape the ends of the switch
9. Fill the tank with the fuel re- wires together and attach the cord INSTALLA liON
moved. to the wires. 1. Position the Motor and Washer
10. Check the fuel gauge opera- l. Pull the wires down through Assembly and assemble the connect-
tion and check for leaks. the steering column with the cord, ing wiper links to the motor.
and position the switch to the steer-
RMPERATURE SENDING UNIT 2. Position the Motor and Washer
ing column hub.
t. Disconnect the temperature 3. Install the bearing retainer and assembly to the dash panel and
sending unit wire from the sending attaching screws. install three retaining bolts.
unit 4. Install the turn indicator switch 3. Connect the harness connector
2. Prepare the new temperature lever. to the Wiper Motor.
sending unit for installation by apply- S. Press the switch wires into the 4. Connect large hose to inlet and
ing a small amount of conductive connector blocks in their correct lo- two small hoses to outlet connec-
water-resistant sealer to the threads. cat.ion recorded during removal. Plug tions on washer pump.
3. Remove the temperature send- the connector blocks together with 5. Connect the battery and check
ing unit from the cylinder head and the mating connector blocks at the the operation of the Wiper Motor
immediately install the new tempera- dash panel. and the 'park position' of the Wiper
ture sending unit. 6. Install the steering wheel on the Blades.
4. Connect the wire to the tem- shaft. WIPER PIVOT SHAFT AND LINK
perature sending unit. 7. Install the steering wheel re- REMOVAL
S. Start the engine and check the taining nut and hub.
sending unit operation. 8. Connect the battery ground 1. Remove the windshield wiper
15-18 GROUP 15- LIGHTING SYSTEM, HORNS AND INSTRUMENTS

blade and arm assembly.

2. Remove the nine cowl panel
attaching screws and remove the
cowl panel.
3. ReQ1ove six bolts retaining '
pivots.
MOUNTING
4. Disconnect the wiper link from CLIP
the Motor and remove the link and
pivot shaft assembly.
INSTALLATION
1. Position the link and pivot shaft
assembly on the cowl and wiper
motor. Connect the link to the motor.
2. Install the pivot shaft to the
SPEEDO>IETER
cowl and install six bolts to retain DRIVEN GEAR
pivots.
3. Install the cowl panel.
4. Install the Wiper Blade and K 1629 · A
Plrm J\ssembly.
5. Check the Pivot Shaft and Link
operation. FIG. 22- Speedo Driven Gear.

IJ MAJOR REPAIR OPERATIONS (Preslite)

FIG. 23- Wiper Motor Assy.

ITEM DESCRIPTION ITEM DESCRIPTION

1 Clamp Nut 2 Motor Crank J\ssembly
3 Seal 4 Grommet Insert
5 Terminal Block J\ssembly 6 Gear Housing J\ssembiy
7 Distance Washer 8 Gear & S ¥ J\ssembly
9 Thrust Cone 10 Washer Pump J\ssembly
11 Terminal 12 Screw
13 Brush 14 Brush Spring
15 Screw 16 Spring Washer
17 Plrmature J\ssembly 18 Ball
19 Thrust Pad J\ssembly 20 Motor Housing J\ssembly
21 Wave Washer 22 Earth Finger
23 Screw
PART 15-4· INSTRUMENTS 15-19

DISASSEMBLY PERMANENT Terminal (11) and Washer Pump to heat. Replace if necessary.
MAGNET TYPE TWO SPEED Assembly (10). 4. Test for grounded armature.
ELECTRIC WIPER MOTOR 7. Disconnect the feed wire (minia- Obtain a test lamp and battery, con-
1. Remove the clamp nut (1), ture terminal) from the wiper motor. nect one probe to the armature shaft
Motor Crank, Assembly (2), Wave 8. Remove the gear and shaft or armature stack, and touch each
Washer (21), Flat Washer (7), Grom- assembly (8) and distance washer (7). commutator segment in turn with the
met Insert (4) and Mounting Seal (3). 9. Insert screwdriver in slot at other probe. The lamp should NOT
2. Clean the gear housing of old base of terminal block assembly (5). light. If the lamp lights the armature
grease. Do not allow cleaning fluid Prise upwards to free terminal block is grounded and must be replaced.
to contact the armature shaft and assembly, unsolder wires and remove 5. Inspect the brush holder plate
output shaft · bearings. Wipe all from housing (6). for cracks or damage. Ensure that
other parts with a clean cloth. 10. Remove self-tapping screw (23) brush boxes are secure and that con-
3. Remove the two screws (15), and earth finger (22). nections are not burned or corroded.
lockwashers (16) and motor housing INSPECTING AND TESTING THE 6. Replace motor brushes that are
assembly (20). Do not pound the DISASSEMBLED MOTOR worn down to f long. Examine brush
Motor housing assembly as the springs for distortion, burning or
ceramic magnets may be damaged. 1. Cover motor housing bearings collapse. Normal brush spring len-
Remove the ball (18) and thrust pad and blow dust from interior with gth is 1!" minimum. Replace if
assembly (19). compressed air. necessary.
4. Note: That the ball may have 2. Visually inspect for damage to 7. Examine the gear housing for
dislodged and become attracted to the ceramic magnets-replace motor cracks and distortion, and the bear-
the magnets during the dismantling housing assembly if necessary. ings for excessive wear. Examine the
operation, and it is essential that this 3. Visually inspect the armature three parking fingers for loss of
item is located. assembly for burned commutator tension, burning or pitting. Replace
5. Retract the brushes (13) and bars, galling or pitting of the arma- gear housing assembly if necessary.
withdraw the armature assembly (17) ture shaft bearing area and worm 8. Examine the gear and shaft
and thrust cone (9). gear for scoring. Check thrust ball for assembly for worn or damaged teeth.
6. Remove the four screws (12), pitting, balling or discolouration due Check cam for wear on face. Replace

6 8

~
3
s

~
4

~\2
t '0

FIG. 24
ITEM DESCRIPTION ITEM DESCRIPTION
1 Housing Assembly 2 Solenoid Assembly
3 Suction Cap 4 Plunger
5 Trim Cup 6 Cover
7 Valve Cover 8 Valve Seat
9 Valve Seal 10 Valve Rubber
11 Screw 12 Plunger & Lever Assembly
13 Bush 14 Spring
15-20 GROUP 15- LIGHTING SYSTEM, HORNS AND INSTRUMENTS

if necessary. INSPECTING AND TESTING 4. (i) Connect motor terminal

DISASSEMBLED WASHER PUMP No. 1 to switch terminal
ASSEMBLY
1. Check operation of non-retur- No.1.
1. Apply grease to the centre- (ii) Connect motor terminal
drilled holes in each end of the arma- ned valves in valve assembly.
2. Check suction cap for damage No. 2 to switch terminal
ture shaft. Assemble the Thrust Cone No.2.
(9) to the worm end of the shaft and or cracks or deterioration.
3. Examine trim cap, solenoid (iii) Connect motor terminal
the -&" diameter ball (18) to the No. 3 to POSITIVE bat-
other end of the shaft. lever and plunger for damage or wear.
4. Check solenoid windings for tery terminal.
2. Assemble brush springs (14) (iv) Connect motor terminal
and brushes (13) to the gear housing continuity or short circuit.
5. Examine housing bush for dam- No. 4 to switch terminal
assembly.
age and excessive wear. No.4.
3. Retract the brushes and assem- (v) Connect washer pump ter-
ble the armature assembly (17) to the 6. Check compression spring for
damage. minal to switch terminal
gear housing assembly. 'W'..
7. Examine washer housmg and
4. Apply stiff grease to the back latch for cracks and distortion, ex- 5. Operate switch assembly and
face of the thrust pad assembly (19) amine timing gear for worn or check for LOW speed and HIGH
and locate in the recess in the bottom damaged teeth. speed operation. Switch to park
of the motor housing assembly (20). Note: Timing gear should rotate position two or three times and check
5. Assemble the motor housing only when latch is retracted. that the motor crank assembly stops
assembly (20) to the gear housing with a positive action in the same
assembly (6). Ensure that the wiring pcsition.
ASSEMBLY OF WASHER PUMP 6. Switch motor to low speed and
to the brushes does-not foul the motor
housing. Assemble the two screws 1. Apply No. 2 cup grease to latch back-off the adjusting screw in the
mechanism (1). gear housing at the end of the arma-
(15) and lockwashers (16).
6. Adjust armature shaft thrust 2. Install spring (14) and guide ture shaft. Adjust end play of the
screw in until resistance is felt and bush (13) to housing. armature by tightening the screw
then back off screw a quarter turn. 3. Install plunger and lever assem- until an ammeter in series shows a
7. To secure earth finger (22) to bly (12) to solenoid assembly (2). slight rise in current. Back-off slightly
gear housing (6), install screw (23). until the current is just normal,
4. Install solenoid to housing tak- apply 'LOCTITE-GRADE CV' to
8. Install terminal plate assembly ing care that lever engages with slot
(5) to gear housing. Ensure that the screw to prevent unlocking.
in latch. Ensure that solenoid is 7. Check the current consumption
flanges on terminal plate assembly located in receiving slot in housing
are located in receiving slot in after running the motor for 30 min-
and solenoid wire is correctly posi- utes. The consumption should be
housing (6). tioned in housing assembly. 2 . 5 amperes maximum at 13. 5 volt
5. Install trim cup (5) and plunger and the output speed 40 rpm LOW
9. Apply No. 2 cup grease to par- (4) to suction cap (3).
king plate and cam track (8). and 65 rpm HIGH.
10. Assemble the distance washer 6. Install solenoid cover (6) to 8. Energising the solenoid of the
(7) on the gear shaft assembly (8) and snap fit over location pin. washer pump, the current consump-
assemble gear and shaft assembly to 7. Install suction cap assembly and tion should not exceed 2 amperes
the gear housing. ensure that plunger is located in over the motor consumption during
11. Install mounting seal (3) to guide bush. the energising period at 13 . 5 volts ±
gear housing and assemble grommet 8. Install valve seat assembly (8, 0 . I. Washer should complete four
insert (4). 10) and valve seal (4). discharge cycles per one revolution of
12. Connect washer lead connector 9. Install valve cover (7) and secure the wiper motor output gear and
to wiper motor terminal, assemble with four screws (11) tighten to a 12-16 discharge cycles for one wash
washer pump assembly (10), terminal torque loading of 10-15lbs. ins. cycle.
(11) and four self-tapping screws (12). LUCAS
Re-locate self-tapping screws care- TESTING THE ASSEMBLED
MOTOR DISASSEMBLY - PERMANENT
fully in existing threads to avoid MAGNET TYPE WIPER/WASHER
stripping and tighten screws to a MOTOR
torque loading of 20-25 lbs. ins. 1. Obtain a switch assembly
ARC9DF.17A553-A, a 12 volt auto- 1. Remove the fixing nut, motor
DISASSEMBLY WASHER PUMP motive battery and an 0 to 10 amperes crank assembly and flat washer.
Ammeter. CAUTION: The moulded gear-
1. Remove the four screws (11) wheel inside the gearbox must be
attaching valve cover, remove valve 2. Connect the Negative terminal prevented from moving while the
cover (7), valve seal (9), valve seat (8), of the battery to the motor earthing crank assembly fixing nut is slackened
suction cap (3), trim cup (5) and terminal (11) and the 'E' terminal of (or tightened on re-assembly). This
plunger (4). the switch ass~mbly. is most easily achieved by securing
2. Remove solenoid assembly (2), 3. The terminal block assembly the crank in a vice while the nut is
with cover from housing assembly ( 1), has four terminal blades and the turned.
dismantle plunger and lever assembly moulding has four identification 2. Remove the three screws attach-
(12) and solenoid cover (6). numbers 1 to 4 respectively. The ing the washer unit to the motor. To
3. Remove bush (13) and spring switch assembly moulding also car- completely detach the washer unit
(14). ries identification numbers. from the motor it will be necessary
PART 15-4- INSTRUMENTS 15-21
to unsolder the washer unit solenoid
lead.
3. Withdraw the shaft and gear
being careful not to lose the dished
washer fitted beneath the gearwheel.
4. Unscrew and remove the two
fixing bolts from the motor yoke and
carefully remove the yoke assembly
and armature.
INSPECTING AND TESTING
THE DISASSEMBLED MOTOR
1. BRUSHES
The original specified length of the
brushes is sufficient to last the life of 1 Negative brush cable 2 Third brush cable
the motor. If due to accidental 3 Positive brush cable
damage to the brushes, or faulty
FIG. 25- Checking brush spring pressure.
commutator action, it becomes neces-
sary to renew the brushes, the com- Mterwards, clear the inter-segment 2.
plete brush gear and body assembly spaces of copper swarf. Armature end-float is 0. 002-
must be replaced. The brush gear 0.008" (0.05-0.2 mm).
assembly must be renewed if the (4) INSPECTION OF MOULDED
main (diametrically opposed) brushes GEAR To obtain a satisfactory end-float
are worn to -k •, or if the narrow Examine the gearwheel, especially adjustment with the motor and gear-
section of the third brush is worn to the teeth, for signs of wear or damage. box completely assembled, position
the full width of the brush. If the gearwheel needs renewing, a the unit with the thrust screw upper-
Check that the brushes move shaft-and-gear service replacement most, tighten the thrust screw until
freely in the boxes. assembly will have to be fitted. abutment takes place and then
(5) BEARINGS slacken it off one quarter turn and
(2) CHECKING BRUSH SPRINGS secure it in this position by tighten-
The design of the brushgear does All bearings are self-lubricating ing the locknut.
not allow for easy removal of the and require no attention for the life
brush springs. This is due to the fact of the motor.
The bearings are not a serviced The yoke fixing bolts should be
that, similar to the brushes, the tightened to a torque of 25 lbs. in. If
springs are expected to last the life of item and if for any reason replace-
ment is required the body and/ or a service replacement armature is
the motor and should not normally being fitted, it is advisable to fint
require renewing. In the unlikely yoke assemblies must be renewed.
slacken the armature end-float thrust
eveDJ: of the spring pressure failing to ASSEMBLY screw before tightening the yoke
meet the specified requirements, the This is generally a reversal of the fixing bolts. Mterwards, reset the
complete brushgear service-assembly dismantling procedure detailed in (b) thrust screw.
must be renewed, in a similar manner but special consideration should be
to that necessary for servicing the given to ..he following:
brushes.
To check the spring pressure press 1.
3 Before fitting the motor crank
on the end face of the brush with a A liberal quantity of Shell Alvania assembly to the gear wheel shaft, plug
push-type spring gauge (see Fig. 6) No. 2 grease is necessary for lubri- in the vehicle wiring and operate the
until the bottom of the brush is level cating the gearwheel teeth, the gear wiper switch to set the motor in the
with the bottom of the slot in the wheel cam and the worm gear on the park position. Fit the crank to the
brush box, when the spring pressure armature shaft. The total quantity of shaft in the position indicated on the
reading should be 5-7 ozf. grease must not be less than 15 cc. wiper body.
Note: In the event of the brush-
gear being renewed, it is important
to re-connect and position the cables
in accordance with Fig. 25
ISW
(3) TESTING AND SERVICING
THE ARMATURE
Use armature testing equipment IIOV........_.
to check the armature windings for
open and short circuits.
Test the soundness of the armature
insulation by using a mains test lamp
(Fig. 7). Lighting of the lamp indi-
cates faulty insulation.
If the commutator is worn, it can
be lightly skimmed while the arma-
ture is mounted in a lathe. FIG. 26- Armature insulation Test.
15-22 GROUP 15· LIGHTING SYSTEM, HORNS AND INSTRUMENTS

WASHER PUMP locking wheel).

8. Prise secondary lever upwards
TO DISMANTLE to disengage from rubber bulb. 4. Replace small tension spring on
1. Remove three screws fixing 9. Lift latch and timing gear in latch; replace spring and retainer clip
pump to wiper motor. one movement. to secure timing wheel.
2. Slip off white plastic cover. 10. Lift locking wheel from pin. 5. Slide secondary lever over the
3. Push cam follower towards bulb 11. Remove four screws from moulded section of rubber bulb and
then slide solenoid assembly out of valve assembly and remove assembly. moulded pin on lever. Replace spring
housing. 12. Remove rubber bulb upwards on lever.
4. Disengage large tension spring from housing. 6. Replace cam follower over pin
from cam follower. ensuring that pawl is engaged in
5. Lift cam follower and pawl TO ASSEMBLE timing wheel. Replace large tension
assembly from locking pin and re- 1. Replace rubber bulb in hous- spring on cam follower.
move pawl from cam follower by ing; insert spring into bulb and screw 7. Push cam follower towards bulb
easing out of the locking hole. on valve assembly. and slide solenoid into housing en-
6. Remove retainer clip and spring 2. Replace locking wheel over pin. suring that black lead is facing
from timing wheel. 3. Stand timing wheel on pin; upwards.
7. Disengage tension springs on stand latch on pin and replace both 8. Replace white plastic cover and
latch and tension spring from secon- in one movement (ensure timing attach pump to wiper motor ensuring
cary lever. wheel meets with top section of that cam follower engages with cam.
15-23

PART SPECIFICATIONS
15-5
CIRCUIT PROTECTION
Function Location Rating Time
Dome Courtesy Fuse Panel 8 8Amp
Tail, Pork.License Fuse Panel 6 8Amp
Stop Light Fuse Panel 7 16Amp
Turn Signals Fuse Panel 4 8Amp
Radio Fuse Panel 2 8Amp
Heater Fuse Panel I 16Amp
Cigar Lighter Fuse Panel 6 8Amp
Windshield Wiper and Fuse Panel 2 8Amp
Back Up Lamps Fuse Panel 4 8Amp
Light-Instrument Panel Fuse Panel 6 8Amp
Light-PRNDL Dial Fuse Panel 6 8Amp
Light-Luggage Compartment Fuse Panel 8 8Amp
Light-Glove Box Fuse Panel 8 8Amp
Light~Headlights Circuit Breaker 9 22Amp
Horns Fuse Panel 3 8Amp

BULB CHART BULB CHART (Continued)

Unit Wattage Unit Wattage
Headlight 50/75
ALL MODELS Warning Light Oil and Alternotor 2.2
Front Turn Signal 21 Brake Warning Light 2.2
Parking 6 Radio Dial 2.0
Rear Turn Signal 21 Turn Signal (Ins. Panel) 2.2
and Stop / Tail 6/ 21 Instruments Jllluminationl 2.2
License Plate 6 Heater Control 2.2
.Sack Up Lights (Sedan) Hi Beam Indicator 2.2
21
Speedometer 2.2
Back Up Lights (Stat. Wagon) 21
Glove Compartment 5.0
Luggage Compartment 10
Courtesy Light Fairmont
Cargo Light (Wagon) 10 15
Front and Rear Door
Dome Light 10 Automatic Transmission Control 2.2
HORN
HEATER MOTOR CURRENT DRAW
I
Horn current draw at 12V 4-5 Amps
At low speed 4.5 Amperes ot 12V
INSTRUMENTS
At high speed 5.6 Amperes at 12V
Fuel and Temperature Gauges SPEEDOMETER CABLE
Average voltoge at terminals 5 Volts

TURN INDICATOR !Mounting Clip Bolt Torque 3~1 Ft. Lbs.l

I
Current draw at 12V 0.4 Amps I
15-24 GROUP 15- LIGHTING SYSTEM, HORNS AND INSTRUMENTS
WINDSHIELD WIPER MOTORS
PRES LITE
CURRENT CONSUMPTION 2.5 Amp maximum at 13.5 V.
(HOT)
OUTPUT SPEED HIGH 65 R.P.M.
(HOT) LOW 40 R.P.M.

LUCAS Two Speed

CURRENT CONSUMPTION 1-1.8 amps at 12 V. (Low)
(after 60 seconds from cold) 2-2.6 amps at 12 V. (High)
Light running (linkage disconnected)
Output Speed (light running) 35-40 R.P.M. (Low)
56-66 R.P.M . (High)
SPEEDO GEAR COMBINATIONS
No. Of Teeth No. Of Teeth
Engine Transmission Axle Ratio Tyre Size Driving Gear Driven Gear Colour
6 Cyl. B.W. 3.23:1 6.95 X 14 (8) (21) (it. Green)
Manual 7.35 X 14 (8) (21) (Lt. Green)
& Auto 7.75 X 14 (8) (20) (Brown)
ER70 x 14 (8) (21) (Lt. Green)
185 X 14 (8) (21) (Lt. Green)
6 Cyl. B.W. 3.50:1 6.95 X 14 (8) (23) (Black)
Manual 7.3 5 X 14 (8) (22) (Grey)
& Auto 7.75x14 (8) (22) (Grey)
ER70 x 14 (8) (23) (Black)
18"5x14 (8) (23) (Black),
8 Cyl. 6 Cyl. B.W. 2.92 :1 6.95 X 14 (8) (19) (Pink)
302 CI.D.[ Manual 7.35 X 14 (8) (19) (Pink)
7.75 X 14 (8) (18) (Purple)
ER70x14 (8) (19) (Pink)
185 X 14 (8) (19) (Pink)

6 Cyl . U.S. 4 Speed 3.23 :1 6.95 X 14 7 18 Green

RUG-D 7.35 X 14 7 18 Green
7.75 X 14 7 18 Green
ER70 X 14 7 18 Green
185 X 14 7 18 Green
8 Cyl. I U.S. 4 Speed 2.92 :1 6.95 X 14 7 17 Purple
302 C.I.D. RUG-D 7.35 X 14 7 1 6, Orange
7.75 X 14 7 16 Orange
ER70 x 14 7 17 Orange
1 85 X 14 7 17 Purple

8 Cyl. US. C4 2.92 :1 . 6.95 X 14 8 i9 Tan

302 CI.D. Auto 7.35 X 14 8 19 Tan
7.75 X 14 8 18 Grey
ER70 x 14 8 19 Tan
185 X 14 8 19 Tan

8 Cyl U S 4 Speed 3.0 1 7.35 X 14 7 17 Purple

351-2V RUG-D 7.75 X 14 7 16 Orange
1 85 X 14 7 17 Purple
ER70 x 14 7 17 Purple

8 Cyl. U.S . 4 Speed 3.50 1 ER70 X 14 6 17 Purple

351 - 4V RUG-AS
8 Cyl. U .S. C4 2.75 :1 6.95 X 14 8 18 Grey
35 1 -2V Auto 7.35 X 14 8 18 Grey
185 X 14 8 18 Grey
ER70 X 14 8 18 Grey
7.75 X 14 8 17 Natural

8 Cyl. U.S. FMX 2.75 :1 6.95 X 14 8 18 Grey

351-4V Auto 7.35 X 14 8 18 Grey
185 X 14 8 18 Grey
ER70 x 14 8 18 Grey
FALCON FAIRLANE w~:~~~~P

VENTILATION, HEATING, GROUP

ACCESSORIES 16

PAGE

PART 16-1- Ventilating and Heating 16-2

PART 16-2- Air Conditioning 16-7

PART 16-3- Radio-Stereo Tape Player 16-26

16-2

PART
16·1 VENTILATING AND HEATING

Section Page Section Pare

1 Description and Operation 16-2 Control Adjustments 16- 5
Ventilating System 16-2 Blower Motor Electrical Circuit 16- 5
Heating System 16-2 Heater Hose Routing 16-5
2 Diagnosis and Testing 16 -3 Heater Hose Replacement 16-5
Ventilating and Heating Trouble Diagnosis Bleeding Air From Heater Core 16-5
Guid~ 16-3 Removal and Installation 16-6
Loose Motor Fan Test 16-5 Heater - Assembly Removal 16-6
Blower Switch Test 16-6 Heater - Asembly Installation 16-6
Plugged Heater Core Test 16-5
3 Common Adjustments and Repairs 16-5
Ventilating System 16-5
Heating System 16-5

0 DESCRIPTION AND OPERATION

VENTILATING SYSTEM vice major components of the heater. The air is then discharged into
Two ventilating air outlet ducts Outside air is drawn into the the distribution chamber. A distri-
are located under and at each end vehicle from the cowl inlet through bution flap valve is located within
of the instrument panel; both ducts the left-hand air duct into the heater the chamber to control the discharge
are open to the cowl air inlet plenum housing and through the heater core of air between the interior and the
chamber. Two manually operated and then discharged through outlets screen and to close off all air in
flap valves are located within the air in the distribution box or windscreen the off position.
ducts. The flap valves are opened, to demister outlets (Fig. 2). The 1apper control lever actuates
allow the entry of fresh air into the a Bowden cable connected to the
passenger compartment, by pulling AIR AND TEMPERATU1tE flap valve in the distribution
the respective left or right hand CONTROL chamber. Air is directed as required
knobs on the instrument panel The control assembly is located on through the interior air outlets or
(Fig. 1). Pull knob half way out for the dash panel in the instrument through the demist outlets below
floor level or full out for face level. cluster assembly. It contains two the windscreen.
horizontal slide levers and a blower The air flow distribution can thus
switch (Fig. 2). be modulated by setting the control
The upper lever is used for con- lever in any position between "in-
trolling mode position. The lower terior" position and the "off" posit-
lever is used for controlling air temp- ion, varying the volume of air
erature. The three-position switch erttering through the interior out-
controls the two-speed motor and lets. All air flow is cut off with the
fan. The air temperature is varied by control lever in the "off" position.
a temperature control door which A single demist nozzle directs the
blends hot and cold air. A tap in the air to two slots in upper dash panel
HEATING SYSTEM engine compartment cuts off water below the windscreen.
The heater is a blown system in the cold position. Two speeds are provided for the
connected to an opening in the As the temperature control lever blower with a 3 position switch
left hand air duct. The entire is moved- from the cold to hot in the control assembly. A resistor
heater assembly is located under the position, a Bowden cable operates located in the motor circuit controls
instrument panel, and it is necessary the temperature control door to mix the "lo" speed. The amount of
to remove the heater assembly to ser- hot and cold air through the heater. heating can be varied by the two
PART 16-1- VENTILATING SYSTEM AND HEATER 16-3

II
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-------- -
FIG. 1 - Fresh Air Ventilation.
blower speeds. be moved to either the "FLOOR" or directing the air flow to the interior
"SCREEN" positions, intermediate or screen as required.
HEATING AND DEMISTING
positions may be selected to give MIXED VENTILATION
For maximum effect : combined effects.
Should it be desirable, with the
1. The left hand air duct must right and left hand air vents full open,
be fully closed. COOL AIR VENTILATION cool air may be admitted to face
2. The temperature control lever level with warm air being directed
moved to the "HOT" position. With the temperature control in to the screen or to the interior or
3. The fan switched to the "HI" the cold position, the unit will both, by normal operation of the
position. The distribution lever may function as a ventilation system, heater.

EJ DIAGNOSIS AND TESTING

VENTILATING AND HEATING TROUBLE DIAGNOSIS GUIDE

1. Burned out fuse or loose wires 6. Improperly connected heater

to the heater blower. hoses.
2. Defective ground, or defective 7. Plugged heater core, or a1r
INSUFFICIENT OR NO blower motor. outlet.
HEAT 3. Fan loose on motor shaft, or 8. Improperly installed or defec-
motor stalled. tive engine thermostat.
4. Defective heater blower switch. 9. Incorrectly installed and ad-
5. A kinked, clogged, or collapsed justed control cables.
water hose. 10. Air leaks in the body.

1. Improperly adjusted demister

control cable.
INSUFFICIENT OR NO 2. Plugged or loose defroster noz-
DEMISTING zle obstructed demister openings at
windshield.

I. Incorrectly adjusted tempera-

TOO MUCH HEAT ture control door.
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FIG. 2- Heater Installation

PART 16-1- VENTILATING SYSTEM AND HEATER 16-5

TESTING listen for the sound of the motor. If remove the outlet hose from the
only a hum is heard, the fan is loose heater core (the hose may be de-
The following tests may be made on the motor shaft. tached from heater in engine com-
on the heater: Burned out fuses, partment). Very little or no flow
loose wire connections, defective of water from the core outlet indi-
wires, collapsed hoses and air leaks BLOWER SWITCH TEST cates that the core is plugged. Make
in the body may be determined by Substitute a known good blower certain the water is being supplied
visual inspection of the parts. switch for the suspected switch. to the core inlet: i.e. the control
PLUGGED HEATER CORE lever is set at HOT.
LOOSE MOTOR FAN TEST TEST
Turn on the heater switch, and Start the engine and temporarily

EJ COMMON ADJUSTMENTS AND REPAIRS

VENTILATING SYSTEM
16 AMP. FUSE IGNITION
Bowden cable operated vents and SWITCH
air inlets are adjusted so that the BROWN +WHITE GREEN+ RED
vents are tightly closed when the ~----------------------------------------~~
control knobs are approx. 1/16" from
being pushed all the way in.
Loosen the Bowden cable retaining
screw at the vent control arm, move
the cable housing back and forth
until the vent is closed when the knob
is -ft to k inch from the in position, HEATER MOTOR HEATER
then tighten the retaining screw. SWITCH~-~
RED
BLOWER MOTOR
ELECTRICAL CIRCUIT YELLOW
For the blower motor circuit
wiring diagram refer to figure 3.

HEATER HOSE ROUTING

Care must be taken when servicing
the hoses to insure a smooth kink FIG. 3-Heater Motor Circuit
free installation for maximum heat-
ing. HEATER SYSTEM 5. Refit the control cable re-
taining clip.
HEATER HOSE CONTROL ADJUSTMENTS 6. Check the leyer travel.
REPLACEMENT TEMPERATURE
To replace a heater hose, drain HEAT AND DEMIST (Fig. 2)
the coolant, remove the hose, cut a
new hose to the same length as the To assure maximum temperature 1. Loosen the distribution control
old hose, install the hose, and replace the following temperature control cable retaining clip (at the heater end
the coolant. Make certain that the adjustments should be made. of the cable).
heater hoses do not come in 2. Move the distribution control
contact with any part of the 1. Loosen the temperature control lever (lower) hard left against the
exhaust system. cable retaining clip (at the heater end internal stop (off position).
After the coolant has been replaced, of the cable).
bleed the air from the heater core. 3. Move the lever to the right -ft •
2. Move the control lever (upper) off the stop.
BLEEDING AIR FROM hard left against the internal stop
HEATER CORE (cold position). 4. Hold the distribution valve
Remove the hose at the outlet con- crank (right hand side of distribution
nection of the heater core (hose that 3. Move the lever to the right -ft" box) in the fully closed position.
leads to the water pump). Allow off the stop.
any trapped air to flow out. When 5. Refit the control cable re-
a continuous flow of coolant is ob- 4. Fully close the temperature taining clip.
tained, connect the hose to the core. control door. 6. Check the lever travel.
16-6 GROUP 16- VENTILATING AND HEATING

EJ REMOVAL AND INSTALLATION

HEATER ASSEMBLY REMOVAL HEATER ASSEMBLY 10. Check the operation of the
INSTALLATION heater.
1. Drain the Cooling System.
2. Remove the glove box. 1. Mount the heater assembly to HEATER CONTROL ASSEMBLY
3. Disconnect the temperature/ the dash panel, Pasten the
mode and left hand air duct control heater in place with the 4 nuts, spring REMOVAL
cables. anq flat washers.
4. Remove the hoses from the 1. Disconnect the wiring plug at
heater pipes in engine compartment. 2. Connect the air vent and temp- the heater.
erature control cables 2. Disconnect the cables from the
5. Disconnect the wiring plug at
the heater assembly. 3. Adjust the control cables and water valve and heater.
6. Remove the left hand air duct install the glove box. 3. Remove the instrument cluster
and the demist nozzle retaining clips. 4. Replace the left hand air duct housing.
7. Disconnect the feed wire at the and cable. 4. Remove the control assembly
top of the heater above the fan . 5. Connect the wiring plug and which is retained by two screws.
8. Remove the 4 heater assembly feed wire.
retaining nuts from the dash panel 6. Refit demist nozzle clips. INSTALLATION
(engine compartment). 7. Connect water hoses. Installation is the reverse of re-
9. Remove the heater assembly 8. Fill the cooling system. moval. For adjustments refer to
from the dash panel. 9. Bleed the system. Section 3.

-WI.TCR IIALVC CAlLI

(All)

CONNECT .S'WI".U
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FIG. 4- Heater Control.

16-7

PART AIR CONDITIONING

16-2
Description and Operation 16- 7 3 Adjustments ... ... ... 16-20
2 Diagnosis and Testing ... . .. 16- 9 Discharging the system 16-20
Controls position and operation 16-11 Evacuation ... 16-20
Sight glass ... ... ... 16-15 Recharging .. . . .. .. . . .. 16-20
Magnetic clutch test 16-15 Major Repairs ... ... ... 16-22
Receiver dryer test 16-15 4 Removal & installation ... 16-22
Compressor seal leak test 16-15 Compressor 16-22
Refrigerant leaks 16-18 Clutch bearing .. .. . . .. 16-24
Compressor oil level check ... 16-18 Specifications ... ... ... 16-25
Safety Precautions ... ... 16-19 Operating instructions ... 16-25

D DESCRIPTION AND OPERATION

This zone ranges in temperature from compression and mechanical heat.
DESCRIPTION 70 to 9Q•F and in relative humidity From the compresf,or, the gas en-
The Air Conditioning System is a from 30% to 70% . Outside conditions ters the condensor where the super-
combined heater-cooler unit located determine the actual recommended heat is first removed and the charge
in the forward part of the automobile. inside conditions. is condensed to the liquid state (still
Functionally, the unit is a normal at high pressure) .
The heater unit is functionally the Leaving the condensor, the high
mechanical refrigeration system,
same as described in Part 16-1. pressure liquid passes to the receiver
combining the primary components
of a compressor, condenser receiver, then to the expansion valve. At this
OPERATION point, the throttling action of the ex-
expansion valve and evaporator. In
addition, a magnetic clutch belt (a) REFRIGERANTCYCLE pansion valve reduces the liquid to
driven from the engine crank, is used The refrigerant cycle is as follows: a low temperature and pressure
for the compressor drive. Low pressure, low temperature gas where it enters the evaporator.
Basically, the capacity of any air from the evaporator enters the com-
conditioning system, be it in a build- pressor at the suction valve. In the
ing or in a car, should be such that compressor the gas is raised to a high In the evaporator, the liquid boils
inside conditions are maintained temperature and pressure. Superheat until the charge is entirely vapour-
within the normal "comfort zone" is added to the gas due to heat of ised , then returns to the compressor.

CAPILLARY TUBE

EXPANSION VALVE

COMPRESSOR

CONDENSER

• HIGH. PRESSURE LIQUID

tal LOW . PRESSURE LIQUID

• HIGH. PRESSURE VAPOR

f/lA LOW. PRESSURE VAPOR

FIG. 1. Refrigerant Cycle

16-8 GROUP 16- VENTILATING AND HEATING

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FIG. 2- Installation.

(b) SYSTEM CAPACITY valve. As a suction is created in the to flow. With reduced temperature
evaporator coil by the action of the the charge contracts, relieving pres-
Design of the components of the
compressor, it allows the refrigerant sure to the valve diaphragm subseq·
system is such as to provide a capacity
entering the coils from the expansion uently causing orifice ir. valve to
potential comparable to any unit pre-
valve to expand and boil. This causes close.
sently marketed. Rated capacity of
an evaporative effect lowering the
the compressor is 3! tons at 4,000 temperature in the evaporator coil. (c) COMPRESSOR Fig. 24
R.P.M. As the warm air is blown across the The compressor is a -reciprocating
Note that one ton of refrigeration is twin-cylinder type driven through a
coils, it is cooled to a comfortable
equivalent to the cooling effect of magnetic clutch, which is belt driven
level.
melting 2,000 lbs of ice in 24 hours. by a special pulley on the engine
(b) EXPANSION VALVE
crankshaft. Belt tension is obtained
(a) EVAPORATORASSEMBLY The expansion valve is a pressure by positioning of an adjustable idler
For the "front end" unit, the evap- reducing control which regulates re- pulley. The fuction of the compressor
orator assembly contains the evapora- frigerant flow to the evaporator. High is to raise the low temperature. low
ting or cooling coil, blower, motor, pressure freon enters the valve in pressure gas entering from the eva·
and controls. This assembly is located be- the liquid state and leaves as a low porator (suction side) to a high tem-
low the instrument panel in the front pressure spray, being approximately perature high pressure gas which is
compartment. Cooled air is discharged into 75% liquid by weight but 25% liquid pumped to the condensor (discharge
the cabin through adjustable louvres. by volume. Its action is analogous side). In this compression process,
The evaporator coil is of fin and to the cor:1mon garden hose nozzles temperature of the discharge gas is
tube construction and is made com- where the hose line is "solid" with raised above that of the condensor air
plete with inlet and outlet mani- water, but a fine spray is emitted from supply (atmospheric temperature) ,
folding. the nozzle. thereby dissipating heat removed
Male fitting s (expansion valve inlet and The expansion valve also senses suction from the car interior.
evaporator outlet) extend through the temperature, thereby actuating the valve. The compressor is equipped with
dash panel for connection to the expansion With rise in suction line temperature two service valves. One is defined as
valve in the engine compartment. the charge in the bulb expands exert- "discharge" and the other "suction".
Refrigerant is sprayed into the ing pressure on the valve, forcing it Both are of the "back seat" type used
evaporator coil from the expansion to open and allow more refrigerant for service checks. With valve stem
PART 16-2- AIR CONDITIONING 16-9
full out (counter clockwise) the The compressor clutch has a ball- condensor must be lower than the
gauge adaptor fitting is closed, allow- bearing which is pressed into the field saturation temperature of the dis-
ing the cap to be removed and line to coil assembly and located with a snap charge gas. Air temperature and
be attached. Turning the stem (clock- ring. The clutch plate assembly is quantity determine the condensing
wise) opens the gauge port. To shut pressed into the bearing and held by a temperature and pressure.
the valve off to or from the compres- snap ring, and the hub is then secured The top fitting of the condensor is
sor, the stems must be full in (clock to the tapered compressor shaft with to be used as the inlet fitting from the
wise) . a locking bolt. This permits the clutch
On compressors equipped with Dill compressor. The lower fitting is for
pulley to free wheel when the field the liquid line returning freon to the
core valve ports, the compressor can coil is not energised.
be shut-off from the system by clamp- receiver.
When the evaporator air and tem- Servicing the condensor coil con-
ing off the suction and discharge perature switches are turned on, cur-
hoses. sists mainly of removing bugs, dirt
rent is allowed to flow to the field and other foreign matter would tend
The compressor mounts horizon- coil energising the electro-magnet; to restrict airflow across the con-
tally to the left (8 cyl.) and 250 2V this causes the clutch plate to be held densor.
to right. 250 1V compressor is in contact with the field coil and
mounted vertically on the right. (f) RECEIVER-DRIER-SIGHT
compressor pulley, thus the compres-
(d) MAGNETIC CLUTCH Fig. 24 GLASS
·sor is being driven through the clutch
The compressor drive clutch allows The receiver is a cylindrical hous-
plate. In the off position of the evap-
the system to be "on" or "off" as ing incorporating inlet and outlet
orator air switch the electro-magnet
desired and also provides positive ports filters, drier and sight-glass.
is not energised and the clutch plate
temperature control when combined It functions as a reservoir for the
does not contact the field coil as-
with a thermostatic switch. The basic liquid refrigerant from the conden-
sembly and therefore does not drive
parts of the clutch are the field drive sor providing sufficient charge for all
the compressor.
assembly. (F ield coil, bearing, slip variations of weather. The drier
(e) CONDENSOR serves as a moisture trap and filters
ring and pulley), clutch plate as-
Like the evaporator, the condensor minute substances which may travel
sembly and brush bracket assembly.
is of fin and tube construction. through the refrigerant circuit. The
The magnetic clutch is employed
Discharge gas from the compressor sight glass aids in determining
also to allow the compressor pulley to
is pumped to the condensor, mounted whether system is fully charged or
free wheel when the air conditioner
ahead of the car radiator. Air passing not. In fully charged systems the
is not being used, therefore, the com-
over the condensor first removes the sight glass will appear clear and
pressor is not operating needlessly.
heat of compression from the gas, when undercharged it will continue
Therefore, during the winter or off
then condenses it to a liquid state. bubbling or frothing when the system
season it is not necessary to remove
Temperature of the air through the is operated.
the belt from the compressor pulley.

EJ DIAGNOSIS AND TESTING

GAUGES INDICATE LOW HEAD by corrosion. hoses.
PRESSURE: 8. Clogged drier indicated by frost 3. Faulty pressure cap on radiator.
1. Defective compressor valves. forming on drier. 4. Radiator plugged or exceedingly
Replace valve plate. 9. Low air supply to evaporator. dirty.
2. Blown or defective gasket. 5. Inoperative thermostat- replace.
Replace gaskets. GAUGES INDICATE HIGH 6. Bugs or dirt clogging fins of con-
GAUGES INDICATE LOW SUCTION PRESSURE: denser or radiator- clean off.
SUCTION PRESSURE: 1. Expansion valve faulty . 7. Excess freon charge- purge over-
1. Insufficient refrigerant. charge.
If bubbles or frothing are appar- 2. Leaking or broken compressor
ent in sight glass, add freon until valves. COMPRESSOR DRIVE BELT
condition is corrected. Repair or replace valves with valve
TROUBLES:
2. Restriction at drier or in lines kit.
usually indicated by frosting at 3. Compressor drive belt slipping. 1. Tension of drive belt - tension
point of restriction or lines being Adjust for proper tension. new belts at 100-140 lbs. and belts
cool on side of restriction away 4. Magnetic clutch slipping. that are worn in at 90-110 lbs.
from compressor. Check electrical circuit for proper 2. Drive belt slipping but correctly
Replace faulty part or remove re- voltage to clutch. tensioned.
striction. 5. Expansion valve not closing. Caused by overcharge of refriger-
3. Expansion valve faulty . Evaporator coil flooding, causing ant, obstruction to cooling by con-
6. Moisture freezing in expansion suction line to frost. denser or air in system resulting
valve. 6. Suction service valve strainer in high head pressures.
Expansion valve and manifolding clogged.
will be frosted while coil tubes will Remove, clean and replace. 3. Belt life affected by incorrect pul-
show little or no frost. Install new ley alignment, broken or buckled
drier, evacuate system and re- OVERHEATING OF ENGINE: pulleys, or excessive oil on belt or
charge. 1. Loose Fan Belt. fracture of cords due to forcing
7. Sticking of expansion valve caused 2. Collapsing or obstructed radiator belt in place.
--
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1972 FALCON· FAIRLANE

.4/C·HEATER CONTROL SETTING

Fl-"4CTIONAL CONTROL LEVER POSITION "

-
A/C HEAT
~C~NI VA(.~
OFF
Sou«~
MAle' FRESH FLOOR • SCREEN

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FIG. 3- Control Setting Chart and Vacuum Source Schematic

PART 16-2- AIR CONDinONING 16-11

MODE ,_ OFF A/C & HEATER

HOT WATER VALVE

FRESH AIR IN
CLOSED
---
A/C CLUTCH SWITCH OPEN
COMPRESSOR NOT OPERATING

A/ C VENTS OUT

HEAT/AC DOOR
VAC MOTOR
AIR IN v
DOOR
MOTOR

DEFROST OUT FLOOR HEAT OUT

RECIRC AIR IN
NV

FLOOR/DEFROST
VAC MOTOR

OFF FLOOR .... DEFROST

COOL WARM

OFF

V = VACUUM
NV = NO VACUUM

FIG. 4 -Off A/C & Heater.

MODE ,_ MAXIMUM AIR CONDITIONING

(RECIRCULATING)

CLUTCH SWITCH CLOSED

HOT WATER VALVE COMPRESSOR OPERATING
CLOSED

FRESH AIR IN A/C VENTS OUT

i HEAT/AC DOOR
VAC MOTOR
AIR IN v
DOOR
MOTOR

FLOOR HEAT OUT

RECIRC AIR IN
NV

FLOOR / DEFROST
VAC MOTOR

!WfJ
MAX A/ C FRESH

COOL WARM
FAN

OFF 3
NOTE : A/C COMPRESSOR
V o VACUUM OPERATES ONLY WITH
BLOWER ON
NV = NO VACUUM

FIG. 5 - Maximum Air-conditioning (recirculating)

16-12 GROUP 16- VENTILATING AND HEATING

MODE : - FRESH AIR - CONDITIONING

CLUTCH SWITCH CLOSED

HOT WATER VALVE COMPRESSOR OPERATING
CLOSED

FRESH AIR IN A/C VENTS OUT

J HEAT/AC DOOR
VAC MOTOR
AIR IN v
DOOR
MOTOR

DEFROST OUT FLOOR HEAT OUT

AECIAC AIR IN
IMPORTANT : FOR MAX COMFORT NV
USE THIS SETTING FOR SHOAT
PERIODS ONLY (5-10 MIN.) IN FLOOR/ DEFROST
HIGH AMBIENT & HIGH HUMIDITY VAC MOTOR
CONDITIONS

FLOOR I DEFROST

COOL WARM

OFF 3

NOTE : A/ C COMPRESSOR
V = VACUUM OPERATES ONLY WITH
NV = NO VACUUM BLOWER ON

FIG. 6- Fresh Air-conditioning

MODE :- FRESH OR RECIRCULATING A/C

.1.
-~-
SHOWING TEMPERATURE CONTROL

___ ,____
CLUTCH SWITCH CLOSED
HOT WATER VALVE COMPRESSOR OPERATING
PART OPEN

FRESH AIR IN A/ C VENTS OUT

HEAT/AC DOOR
VAC MOTOR
AIR IN v
DOOR
MOTOR

FLOOR HEAT OUT

NV

FLOOR / DEFROST
VAC MOTOR
ALT

I~
MAX A/ C FRESH

COOL WARM

OFF

NOTE : AIC COMPRESSOR

V = VACUUM OPERATES ONLY WITH
NV = NO VACUUM BLOWER ON

FIG. 7- Fresh or Recirculating A/C showing Temperature Control

PART 16-2 -AIR CONDITIONING 16-13

MODE : - HEATER - FLOOR/COOL

HOT WATER VALVE

FULLY OPEN

FRESH AIR IN
---
A/C CLUTCH SWITCH OPEN
COMPRESSOR NOT OPERATING

A/C VENTS bUT

HEAT/ AC DOOR
VAC MOTOR
AIR IN
DOOR
MOTOR

DEFROST OUT FLOOR HEAT OUT

RECIRC AIR IN
NV

FLOOR/ DEFROST
VAC MOTOR

r?M I
FLOOR I DEFROST

COOL WARM

OFF

V = VACUUM
NV = NO VACUUM

FIG. 8- Heater- Floor- Cool.

MODE :- HEATER FLOOR - MIDWARM

___........._
A/C CLUTCH SWITCH OPEN
HOT WATER VALVE COMPRESSOR NOT OPERATING
FULLY OPEN

FRESH AIR IN A/C VENTS OUT

HEAT/ AC DOOR
VAC MOTOR
AIR IN
DOOR
MOTOR

DEFROST FLOOR HEAT OUl

RECIRC AIR IN

~ I
FLOOR I DEFROST

COOL WARM

OFF

V = VACUUM
NV = NO VACUUM

FIG. 9- Heater- Floor- Mid-warm.

16-14 GROUP 16- VENTILATING AND HEATING

---
MODE:- HEATER - FLOOR - WARM

-~1,-
ili
HOT WATER VALVE
A/C CLUTCH SWITCH OPEN
COMPRESSOR NOT OPERATING
FULLY OPEN

FRESH AIR IN A/C VENTS OUT

HEAT/AC DOOR
VAC MOTOR
AIR IN
DOOR
MOTOR

FLOOR HEAT OUl

RECIRC AIR IN

FLOOR/DEFROST
VAC MOTOR

FLOOR I DEFROST

COOL WARM

OFF

V = VACUUM
NV = NO VACUUM

FIG.lO- Heater- Floor- Warm.

MODE :- HEATER - MID POSITION FLOOR - DEFROST

-~ 1....-- __..,..._
ili
HOT WATER VALVE
A/ C CLUTCH SWITCH OPEN
COMPRESSOR NOT OPERATING
FULLY OPEN

FRESH AIR IN A/C VENTS OUT

HEAT/AC DOOR
VAC MOTOR
AIR IN
DOOR

;J. .
MOTOR

RECIRC AIR IN ~"00' ~ FLOOR HEAT OUl

VON ID

FLOOR/DEFROST
VAC MOTOR

COOL WARM

OFF

V = VACUUM
NV = NO VACUUM

FIG.ll- Heater- Mid-position- Defrost- Floor.

PART 16-2 -AIR CONDinONING 16-15

MODE : - HEATER - FULL DEFROST

____......._
AIC CLUTCH SWITCH OPEN
HOT WATER VALVE COMPRESSOR NOT OPERATING
FULLY OPEN

FRESH AIR IN A / C VENTS OUT

HEAT/ AC DOOR
VAC MOTOR
AIR IN
DOOR
MOTOR

FLOOR HEAT OUT

RECIAC AIR IN
FULL V

FLOOR/ DEFROST
VAC MOTOR

FLOOR I OEFAOST

COOL WARM

OFF 2 3

V .., VACUUM
NV = NO VACUUM

FIG.12- Heater- Full defrost

NOISY ENGINE COMPONENTS 5. Fan misaligned. RECEIVER- DRYER TEST
AND VIBRATIONS: Operate the air conditioner for
1. Brackets loose due to improper about five minutes; then, slowly move
USE OF SIGHT GLASS
mounting, loose bolts, or broken your hand across the length of the
support legs. Clean the sight glass before check- unit from one end to the other.
2. Missing or improperly applied ing for a proper charge of refrigerant. There should be no noticeable
braces. Then, observe the sight glass for difference in temperature. If cold
3. Clutch retaining bolt loose. bubbles with the engine running at spots are felt, it indicates that the
4. Crankshaft pulley loose or incor-
1500 rpm and the A/C controls set at unit is restricting the refrigerant flow ,
rectly mounted.
maximum cooling. A continuous or and the receiver-dryer must be
large amount of bubbles in the sight replaced.
5. Rough bearings in idler pulley or glass indicate an undercharge of re-
clutch. frigerant . If an under-charge of refrig- MAGNETIC CLUTCH TEST
6.. Compressor oil level below mini- erant is found, check the system for
mum. leaks. Repair any leaks, evacuate the Disconnect the magnetic clutch
7. Engine mounts in poor condition. system with a good vacuum pump, wire at the bullet connector, and con-
8. Drive belt tension below speci- and charge the system with the proper nect it to the negative lead of an
fications. amount of Refrigerant-12 . ammeter. Connect the positive lead
ELECTRICAL PROBLEMS: No bubbles in the sight glass of the ammeter to the battery
CLUTCH INOPERATIVE OR indicate either too much refrigerant positive terminal. The magnetic clutch
NOISY: or a complete loss of refrigerant. should pull in with a distinct click
While observing the sight glass, cycle and the current reading on the
1. Blown fuse. ammeter.
2. Loose connection or broken wire. the magnetic clutch off and on,
3. Shorted slip ring or field coil. with the engine running at 1500
rpm. If refrigerant is in the system, TWO-CYLINDER COMPRESSOR
4. Worn brushes. CRANKSHAFT SEAL LEAK TEST
5. Defective bearing. bubbles will appear while the clutch
6. Defective thermostatic switch. is off and disappear when the clutch Oil leak problems can be identified
BLOWER OR FAN MOTOR WILL is on. If no bubbles appear during by observing the three possible leak-
NOT OPERATE OR OPERATES the on and off cycle of the magnetic age paths shown in Fig.l5
SLOW: clutch, there is no refrigerant in the
Oil Leakage Past
system. If there is no refrigerant in Carbon Ring
1. Blown fuse.
the system, it will be necessary to
2. Wiring connections loose or wire leak test, repair as required, and · Oil weepage through the carbon
broken. charge the system. Under conditions ring forming a streak or drip pattern
3. Defective switch. of extremely high temperatures, as shown in the left illustration of
4. Motor shaft tight or bearings occasional foam or bubbles may Fig.l5 , ia considered normal. How-
worn. appear in the sight glass. ever, if oil is present on the surface
--
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FIG. 13- Installation- A/C Vacuum Control

STA'ITER. el .., To bATUJIY (!lol)

PAS~ Pf\H!L . ...,.

.
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FIG. 14- Installation A/C Electrical Schematic.

--
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16-18 GROUP 16- VENTILATING AND HEATING

NORMAL WEEPAGE LEAKAGE LEAKAGE THROUGH

PAST CARBON RING THROUGH "0-RING" DAMAGED BELLOWS

FIG. 15- Oil Leak paths compressor oil seal.

RUBBER TUBING
4·11 / 1 6 1 N C H - - - - 1

-1-1 12 1NCH-1 I

\
THIS END FOR
HORIZ().ITAL MOUNT
Ca.IPRESSOR

12 NOTCHES 1/8 INCH

APART STARTING AT
EACH END

OIL TO BE CHECKED WITH

KEYWAY IN SHAFT FACING
THE HEAD OF THE COMPRESSOR.
Ll293-A
.
FIG. 16- Compressor oil level dipstick. .
of the compressor beyond the clutch ration of Fig. 15 if the bellows
or has sprayed on the hood and surr- distorts or cracks due to heat. A large FIG. 17- Compressor oil level,
ounding brackets, the leakage is discharge of .oil on the front of the check and oil trap.
excessive. Replace the seal assembly. compressor beyond the clutch indi·
Oil Leakage Through
cates this type of leakage. Replace
the oil seal assembly. COMPRESSOR OIL LEVEL CHECK
0-Ring
Refrigerant-12 Leakage Under normal conditions, when the
Leakage through the 0-ring type
gasket on the cover plate (center Refrigerant-12leakage through any air conditioning system is operating satis-
illustration, Fig.15 ) indicates possible part of the seal can be determined factorily, the compressor oil level need
cracked, pinched, split or loose only by a leak detector. Be sure to not' be checked. There is no place for the
mounting screws. Check the screws wipe all the oil away from the ~eal oil to go except inside the sealed system,
for good condition and proper area before using the leak detector, when the engine is first started, some of
torque (7 to 13 ft-lbs). If there is because the oil may contain refriger- the oil will be pumped into the rest of the
heavy oil discharge with screws of ant which would give erroneous refrigerant system. After several minutes
good condition and correct torque, readings. If refrigerant leakage at the of operation, most of the oil is returned
replace the oil seal assembly. seal exceeds I oz. per year, replace to the compressor crankcase.
the seal as outlined in Section 5. Check the compressor oil level only
Oil Leakage Through If no leak is found at the com- if any portion of the refrigerant system
Damaged Bellows pressor crankshaft seal, thoroughly is being replaced, or if there was a leak in
Oil will leak through the rubber check all system fittings and lines the system and the" refrigerant is being
bellows as shown in the right illust- for leaks as outlined in this Section. replaced.
PART 16-2- AIR CONDITIONING 16-19
The compressor oil capacity is 10 Condenser and receiver assembly add 2 function. Liquid Refrigerant-12, at
fluid ounces. If there is a surplus of oil fluid ounces. normal atmospheric pressures and
in the system, too much oil will circulate Oil should be poured directly into the temperatures, evaporates so quickly
with the refrigerant, cause a reduction in replacement component. that it contacts. For this reason,
cooling capacity of the system. If an evaporator is installed, pour oil extreme care must be taken to pre-
Too little oil will result in poor into inlet pipe with the pipe held vertically vent any liquid refrigerant from
lubrication of the compressor. so oil will drain into the core. coming in contact with the skin and
When it is necessary to replace a If any other components such as especially the eyes.
component of the refrigeration system, valves or hoses are replaced, no additional Refrigerant-12 is readily absorbed
certain procedures must be followed to oil is necessary whilst the air-conditioning by most types of oil. It is therefore
assure that the total oil charge in the system is discharged. The compressor oil recommended that a bottle of sterile
system is correct after the new part has level can be checked using the tools mineral oil and a quantity of weak
been fitted to the car. shown in figures 16-17 as follows:- boric acid solution be kept nearby
When the compressor is operated, 1. Remove the oil filler plug from when servicing the air conditioning
oil gradually leaves the compressor and is the compressor. Insert a flattened 1/8 inch system. Should any liquid refrigerant
circulated through the system with the diameter rod (Fig. 17) in the oil filler ' hole get into the eyes, use a few drops of
refrigerant. Eventually a balanced condition until it bottoms. mineral oil to wash them out, then
is reached in which a certain amount of oil The dipstick must be wiped completely wash the eyes clean with the weak
is retained in the compressor and a certain clean before insertion. If necessary, slightly boric acid solution. Seek a doctor's
amount is continually circulated. rotate the compressor crankshaft by hand aid immediately even though irritation
If a component is removed from so that the dipstick will clear the crank- may have ceased.
the system after operation, some oil will shaft. Always wear safety goggles when
go with it. To maintain the original total On horizontally mounted compressors, servicing any part of the refrigerant
oil charge, it is necessary to compensate for the oil check hole is located on the side of system.
this by replacing oil in the new replace- the crankcase that faces up. On the The Refrigerant -12 in the system is
ment part. opposite or downward side, there is a always under pressure. Because the
The procedure for replacing oil corresponding boss provided on the inner system is tightly sealed, heat applied
is as follows: - wall as an alternate oil check hole for a to any part would cause this pressure
different mounting. When checking the oil to build up excessively.
COMPRESSOR ONLY level on such a compressor, angle the To avoid a dangerous explosion,
1. Idle the engine for 10 minutes at dipstick so that it bottoms against the never weld, use a blow torch, solder,
1000-1500 rpm at maximum cooling and lower side of the crankcase and not steam clean, bake body finishes, or
high blower speed to allow oil to circulate against the boss. use any excessive amount of heat on
in the normal manner. 4. Pull out the dipstick, and check or in the immediate area of any part
2. Discharge the system and remove the oil indication. It should show at least of the air cooling system or refriger-
the. compressor from the vehicle. Remove the minimum amount of oil as indicated ant supply tank, while they are
the drain plug and pour the oil into a in Fig. 16. closed to the atmosphere whether
measuring container. Make a note of the If the oil level is low, add ESA- filled with refrigerant or not.
amount of drained oil, then discard it. M2C31-A (Ford Part No. C9AZ-19577- The liquid refrigerant evaporates so
3_ If a new compressor is being fitted A) oil rapidly that the resulting refrigerant
drain all initial fill oil from the sump. If too much oil is indicated proceed gas will displace the air surrounding
4. If the oil drained from the removed as follows:- the area where the refrigerant is re-
compressor measured less than 4 ounces, (a) Draw out all of the oil using a trap leased. To prevent possible suffo-
replace 6 ounces of new oil in the re- similar to that shown in Fig. 17, or remove cation in enclosed areas, always dis-
placement compressor. the compressor from the vehicle and pour charge the refrigerant from an air
5. If the oil drained from the removed the oil out of the crankcase. cooling system into the garage ex-
compressor measured between 4 and 6 (b) Add oil until at least the minimum haust collector. Always maintain
ounces, the oil is properly distributed amount is indicated on the dipstick . good ventilation surrounding the
throughout the system. Simply replace 5. Remove the dipstick and refit the work area.
an equal amount of new oil in the replace- filler plug.
Although Refrigerant-12 gas,
ment compressor. under normal conditions, is non-
6. If the oil drained from the removed SAFETY PRECAUTIONS poisonous, the discharge of refrigerant
compressor measured 6 ounces or more, The refrigerant used in the air con- gas near an open flame can produce
replace ONLY 6 ounces of new oil in the ditioner system is Refrigerant-12 . Re- a very poisonous gas. This gas will
replacement compressor. frigerant-12 is nonexplosive, nonin- also attack all bright metal surfaces.
REPLACEMENT COMPONENTS flammable, noncorrosive, has practi- This poisonous gas is generated when
cally no odor, and is heavier than air. the flame-type leak detector is used .
Whenever replacing a component of Although it is classified as a safe re- Avoid inhaling the fumes from the
the air conditioning system, add measured frigerant, certain precautions must be leak detector. Make certain that
quantities of oil to the component to observed to protect the parts involved Refrigerant-12 is both stored and
assure that the total oil charge in the and the person who is working on installed in accordance with all state
system is correct before the unit is operated. the unit. and local ordinances.
Oil should be added to replacement Use only Refrigerant-12. Do not When admitting Refrigerant-12 gas
components as follows :- use refrigerant that was canned for into the cooling unit, always keep the
Evaporator Add 3 fluid ounces pressure operated accessories (such tank in an upright position. If the
Condenser Add 1 fluid ounce as boat air horns). It is not pure tank is on its side or upside down ,
Receiver Add 1 fluid ounce Refrigerant-12 and will cause a mal- liquid Refrigerant-12 will enter the
16-20 GROUP 16- VENTILATING AND HEATING

system and damage the compressor. manifold gauge valve at the full frigerant-12 tank with a torch. A
In surrounding air temperatures above counter-clockwise or open position. dangerous explosion may result.
90 degrees F ., prolonged engine idle 4. Set the high pressure (dis- 11. During the charging, the high
will result in excessively high com- charge) manifold gauge valve at the pressure (discharge) side may build
pressor pressures. full clockwi~e or closed position. up to an excessive value. This can
El ADJUSTMENTS
5. Open the Refrigerant-12 tank
valve to allow refrigerant to enter
the system, and observe the gauges.
be caused by an overcharge of refrig-
erant, or an overheated engine, in
combination with high surrounding
DISCHARGING THE SYSTEM When both gauges reach 60 to 80 temperatures. Never allow the high
When replacing any component pounds at approximately 75 degrees pressure to exceed 240 pounds while
in the air conditioning system, the F, shut off the tank valve. charging. If it does, stop the engine,
system must be discharged. To dis- 6. Perform the leak test with the determine the cause, and correct it.
charge the system proceed as follows: leak detector (Fig. 21 ). 12. After the proper charge has
1. Remove the caps from the high 7. Set the A/C controls for max- been made, close the Refrigerant-12
and low pressure service (Schrader) imum cooling (Fig. 5). tank valve, and check the system
valves in the high and low pressure 8. Start the engine and open the pressures for proper operation. (Low
lines at the compressor (Fig. 18). R-12 tank valve again to prevent pressure suction gauge 4-25 psi; high
2. Turn both manifold gauge drawing vacuum on the suction side. pressure discharge gauge 120-170 psi
valves fully clockwise to close the 9. With the engine running at at 70 to 90 degrees F ambient).
gauge set to the center outlet hoses 1500 rpm, complete charging the 13. After satisfactory operation has
(Fig. 19). system until the specified weight of been achieved, disconnect the mani-
3. Connect the high and low refrigerant has entered the system. fold gauge set high and low pressure
pressure gauge hoses with adapters, The sight glass should be clear with hoses from the service valves (Fig. 20).
to the respective high and low no bubbles visible at this time. (Note: 14. Install caps on the service
pressure service valves at the com- Under 70 degrees F ambient a few valves and the manifold gauge set
pressor (Fig. 20). bubbles may appear in the sight glass). lines (Fig. 18).
4. Place the open end of the center 10. If the refrigerant will not enter
hose in a garage exhaust outlet. the systein due to low temperature,
5. Slowly depressurize the refrig- it may be necessary to place the
eration system by opening the low ~efrigerant-12 tank in a container of
pressure gauge valve a slight amount hot water at about 150 degrees F.
and allowing the refrigerant to dis- This will increase the R -12 pressure
charge slowly from the system.Fig. 20 and force the gas from the tank
6. After the system is nearly dis- during charging. Never heat the Re-
charged, open the high pressure
gauge valve very slowly to avoid
loosing an excessive amount of re-
frigerant oil and allow any refrigerant
remaining in the compressor and
high pressure line to discharge.

EVACUATING THE SYSTEM

1. Discharge the system as de-
scribed in the foregoing procedure.
2. Attach a•tank of Refrigerant-12
and a vacuum pump to the manifold
gauge set. Make certain the Refriger-
ant-12 tank valve is tightly closed.
3. Open both manifold gauge set
valves.
4. Run the vacuum pump until
the low pressure gauge reads at least
25 inches and as close to 30 inches
of vacuum as possible . Continue
vacuum pump operation for 20-30 VALVE CLOSED
minutes to remove any moisture out
of the system. Turn off the pump
and close both gauge valves.

CHARGING THE SYSTEM

1. Discharge and evacuate the
system as outlined in the foregoing
procedures. L 1672-B
2. Leave the vacuum pump valve
closed .
3. Set the low pressure (suction) FIG. 18
PART 16-2 -AIR CONDinONING 16-21

TO LOW PRESSU RE

"""'~

L1290-A
FIG. 21- Transistorized
refrigerant
leak gun
FIG. 19- Manifold Gauge Set

CHECKING FOR LEAKS Note - when using transistorized seconds. The flame will normally be
refrigerant leak gun refer to manu- almost colourless. The slightest leak
facturer's instructions. (Fig. 21). will be indicated by a bright green
Attach the manifold gauge set as blue colour to the flame .
shown in Fig. 20. Leave both manifold Be sure to check the manifold
gauge valves at the maximum clock- Flame type gauge set and hoses for leaks as well
wise (closed) position. Both gauges leak detector only. The smaller the as the restof the system.
should show approximately 60 to 80 flame the more sensitive it is to NOTE: If the surrounding air is
pounds pressure at 75°F with the leaks. Therefore, to ensure accurate contaminated with refrigerant gas,
engine not running. If ve~;y little leak indication, keep the flame as the leak detector will indicate this
or no pressure is indicated, leave small as possible. The copper element gas all the time. Good ventilation is
the vacuum pump valve closed, open must be red hot. If it is burned necessary to prevent this situation. A
the Refrigerant-12 tank valve, and set away, replace the element. Hold the fan, even in a well ventilated area, is
the low pressure (suction) manifold open end of the hose just below each very helpful in removing small traces
gauge valve to the counter clockwise suspected leak point for two or three of refrigerant vapour.

LO

MANIFOLD GAUGE Sfl

SIGHT GLASS
CO NDEN SER

V4CUI..L'.1 PUMP

FIG. 20-
16-22 GROUP 16- VENTILATING AND HEATING

EJ REMOVAL AND INSTALLATION

COMPRESSOR 3. Loosen the idler pulley or alter- necessary (Section 3}.
All compressor removal and in- nator and remove the drive belt and
the clutch and then remove the VALVE PLATE AND HEAD
stallation operations, except belt re- GASKET
placement, can be performed only mounting bolts and the compressor.
after the unit has been discharged. Installation The procedure for replacing a
When replacing a compressor, the blown head gasket is identical to the
Before installing the compressor, procedure for replacing the valve
oil level in the old compressor should carefully remove any burrs or dirt
be checked. Then the right amount plate except that the old valve plate
that may be on the compressor is used. If a worn valve plate has
of oil should be removed from - shaft. The shaft must be dry and
added to the new compressor so that caused the cylinder walls to become
brightly polished. scored or has imbedded pieces of
the oil level is the same as that in the
old compressor. This keeps the 1. Mount the clutch on the shaft metal in the pistons, the compressor
amount of oil in the system a con- and install the mounting screw and should be replaced.
stant. Failure to use this procedure washer finger-tight. Place the com- Removal - AU Compressors
is the most common reason for pressor on the mounting bracket and 1. Discharge the system (Section
excessive oil in the crankcase. Refer install the four mounting bolts finger- 3 in this Part), and disconnect both
to Compressor Oil Level Check, Ad- tight. suction and pressure hoses. Place a
justments Section 3. 2. Connect the clutch wire, ener- clean drip pan under the horizontally
Removal gize the clutch and torque the clutch mounted compressor.
mounting bolt to specification.
1. Discharge the system - refer Tighten the compressor mounting 2. Remove the cylinder head bolts.
to Adjustments Section 3, and dis- bolts to specification. 3. Remove the valve plate and
connect the two hoses from the 3. Install the belt and adjust and cylinder head from the compressor
compressor (Fig. 24). Energize the tighten the idler pulley. by tapping upward with a fiber
clutch and loosen and remove the 4. Install new Schrader valves in hammer on the overhanging edge of
clutch mounting bolt. the service valves if the original the valve plate.
2. Install a 5/8-11 bolt in the compressor is to be reinstalled. 4. Remove the valve plate from
clutch drive shaft hole. With the Leak test the compressor, then the cylinder head by holding the
clutch still energized, tighten the evacuate it and connect it back into head and tapping against the valve
bolt to loosen the clutch from the the system. plate.
shaft. Disconnect the clutch wire 5. Check the oil level in the com- 5. Remove the drip pan from
at the bullet connector. pressor, and add or remove oil if under the horizontally mounted com-

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FIG. 22- Installation Drg. 6 Cyl. Compressor

PART 16-2 -AIR CONDmONING 16-23

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P"')W'ER ~n:Ei\ !NO ;,t~;.:>n .\ ,'C

VJEV Sl«lWDiO DISTALl.ATION 0~ CLIJ'i'CH ASSY. 'nEW SII<JtiiiO I!ISTALLATION OP CO'<PIU:S SOIO
~ACK!T ON V!HlC U:S IQtiiPUD VITH f'OIIo'[R
~] i'l!:E'RDfO.

1. Bracket Compressor Mounting 13. Bolt Bracket Attaching Torque to 30-45 lbs. ft.
2. Belt Idler Pulley Assembly 15. Bolt Clutch Attaching Torque to 20-30 lbs. ft.
3. Alternator Assembly 16. Screw Field Attaching Torque to 6-12 lbs. ft .
4. Pulley Assembly Fixed 17. Bolt Bracket Attaching Torque to 20-32 lbs. ft.
5. Clutch Assembly 18. Bolt Compressor Attaching Torque to 20-32 lbs. ft .
6. Compressor Assembly 20. Bolt Idler Pulley Attaching Torque to 30-45 lbs. ft .
7. Nut Pulley Attaching Torque to 25-40 lbs. ft. 21. Stud Bracket Attaching Torque to 30-50 lbs. ft.
9. Oil Gauge Wire. 22. Nut Bracket Attaching Torque to 45-65 lbs. ft .
10. Brace Assembly 25. Stud torque to 30-50 lbs. ft.
11. Field Assy 26. Tag Compressor Identification
12. Washer 27. Clip Tag Attaching
FIG. 23- VB Compressor Installation
pressor. Then, remove all particles of cylinder head gasket. Then, place the Schrader valves for damage. Replace
gasket,_dirt and foreign material from gasket and cylinder head on the if necessary.
the surface of the cylinder head and cylinder with the dowel pins inserted 9. Check compressor oil level.
cylinder face. into the dowel pin holes in the Add or remove oil as required.
gasket and head. 10. Evacuate and recharge the
Be extremely careful not to 5. Insert the two longer cap screws system.
scratch or nick the mating surfaces in the two center holes of the cylinder
head. Then, insert the remaining cap CRANKSHAFT SEAL
or any edges.
screws in the holes around the edge Removal
Installation of the cylinder head. The four 12 1. Discharge the system, loosen
Compressor - Fig. 24 point head screws should be inserted and remove the belt.
1. Apply a thin film of clean into the four holes closest to the 2. Remove the clutch and remove
refrigeration oil to each side of the service ports. the Woodruff key . Carefully remove
valve plate gasket (Fig. 24). 6. Tighten all head cap screws the secondary dust shield so as to
2. Place the new valve plate until they contact the head. Then avoid marring the shaft.
gasket in position on the crankcase so torque the two center screws to 15-23 3. Carefully remove all accumul-
that the crankcase dowel pins go ft-lb . ated dirt and foreign material from
through the dowel pin holes in the 7. Tighten the remaining cap the seal plate and surrounding area
gasket (Fig. 24). screws in a pattern so that the cap of the compressor, and position a
3. Place the valve plate in position screws diagonally opposite each other small drain pan beneath the seal plate.
on the cylinder so that the dowel are evenly tightened to 15-23 ft-lbs. 4. Remove the seal plate cap
pins go through the dowel pin holes After the cylinder head has been screws, and gently remove the plate
(Fig. 24). installed 1/2 hour, retorque the head and gasket. Do not mar or scratch
4. Apply a light film of clean re- bolts to 15-23 ft-lbs. the sealing surfaces, or the polished
frigeration oil on each side of the 8. Inspect hose connections and shaft surface.
16-24 GROUP 16- VENTILATING AND HEATING

5. Remove the carbon seal ring

and seal housing assembly from the
crankshaft. A disassembled view of

SUCTION
SERVICE VALVE
}dL T , '
DISCHARGE SERVICE VALVE
SERVICE VALVE
0-RING
the crankshaft seal assembly is in-
cluded in Fig. 24.
6. Clean all old gasket material
from the seal plate and the com-
pressor. Make certain that the shaft,
MOUNTING BOLTS l ~,.,a-.....t.. CYLINDER HEAD the seal plate and the compressor
gasket surfaces are completely clean.
7. Check the face of the crank-
shaft front bearing journal in the
seal housing to make certain that
there are no nicks or burrs. Check the
VALVE PLATE ASSY. crankshaft surface to be sure it is not
damaged. Check all parts of the seal
assembly to be sure that they are not
VALVE PLAH damaged.
GASKET
8. Inspect the compressor internal
components for damage.
Installation
1. Wash the new seal assembly
components in clean refrigeration oil.
OIL FILLER PLUG
2. Position the seal over the end
GASKET
of the shaft with the carbon ring
retainer facing out. Move the seal in
and out on the shaft a few times to
insure a good seal between the seal
and the shaft.
3. Push the seal all-the-way on
the shaft. Be sure that the seal drive
ring slots engage the drive pins on the
shaft bearing journal face.
4. Place the carbon ring (Fig. 24)
over the shaft and in the seal ring
retainer. The polished surface of the
carbon ring must face out and the
SEAL lugs must engage the ring retainer and
KIT ASSY.
be fully seated.
FIG. 24- Compressor Disassembled. 5. Apply a light film of clean re-
frigeration oil on the matching faces
of the crankcase and seal cover plate.
Then, place the gasket in position
on the crankcase face.
6. Place the seal cover plate in
position (Fig. 24), with the polished
side facing the carbon ring. Then,
install the cap screws. Tighten the
cap screws evenly while turning the
crankshaft. Be sure that the· clearance
between the crankshaft and the hole
in the seal cover plate is even all
BEARING
around the shaft. ·If the clearance is
INTERNAL not equal all around the shaft, gently
RETAINER
tap the seal face into position until
the clearance is equal. Then, tighten
diagonally opposite cover plate cap
screws evenly to 7-13 ft-lbs.
7. Make certain that there are no
~ULLEY ASSEMBLY burrs or dirt on the compressor shaft.
GREASE CATCHER
Install the key and magnetic clutch
on the shaft.
CLUTCH DRIV~ 8. Install the belt and adjust the
PLATE ASSEMBLY
tension to specification.
FIG. 25- Clutch Disassembled. PULLEY ASSEMBLY
9. Check the compressor oil level
(Section 3).
PART 16-2 -AIR CONDITIONING 16-25
10. Evacuate and recharge the COMPRESSOR SPECIFICATIONS
system. TORQUE LIMITS FT-LBS.
CLUTCH Cylinder Head 15-23
Front Seal Plate 7-13
1. Loosen and remove the belt. Mounting Bolt 20-30
2. Energize the clutch and loosen Oil Filler Plug 4-11
and remove the clutch mounting Clutch Mounting 20-30
bolt. · Base Plate 14-22
3. Install a 5/8-11 bolt in the Back Plate 9-17
clutch drive shaft hole. With the
clutch still energized, tighten the Drive Belt Tensicm New 140 lbs.
bolt to loosen the clutch from the (Between Fan pulley and Used 110lbs.
shaft, then remove the magnetic air conditioner compressor) minimum 90 lbs.
clutch. A belt operated for a minimum of
4. Carefully remove any burrs or 10 minutes is considered a used belt.
dirt that may be on the compressor * Refrigerant charge 32 ounces
shaft. The shaft must ·be dry and Clutch current draw 3.75 amps
brightly polished. Install the clutch,
the clutch mounting bolt, and the * When recharging the syst~m, add
washer. 28 ounces and check site glass. If
S. Energize the clutch, and torque bubbles are evident, add Freon 12
the bolt to specification. up to 32 ounces.
6. Install and adjust the belt. COMPRESSOR 01 L CAPACITY
Vertical Horizontal
CLUTCH BEARING 10 fluid ounces 7/8 min. - 1-1/8 max. 13/16 min.- 1-3/16 max.
When installing a new bearing, Do not add oil if dipstick indicates
extreme care must be taken to support proper level of oil between minimum
the bearing and the clutch assembly and maximum. If dipstick is below
so as not to place any pressure on the minimum level, add oil up to mini-
balls of the bearing. mum oil level only.
The following procedure should Compressor oil ESA-M2C31-A
be rigidly adhered to during bearing
replacement. Any exceptions due to grease catcher, but do not remove
clutch design are noted. Refer to the grease catcher from the pulley installing the clutch onto the com-
Fig. 25 . assembly. pressor.
S. Install the clutch on the com-
Removal Installation pressor shaft.
Before installing the bearing, be
1. Remove the clutch assembly
from the compressor shaft as outlined sure that all bearing contact surfaces c=)\
in the foregoing procedure. are clean.
2. With the clutch assembly face 1. Support the pulley assembly ~~ SELECTAIRE
down, remove the external bearing face down, near the bearing bore but
retainer from the drive plate shaft. do not support it by the sides of the ·r Air Conditioning
3. Support the clutch, face down, pulley grooves as this may bend the
OPERATING INSTRUCTIONS
by the outer edge so as to clear the pulley assembly.
I. MOVE TOP CONTROL LEVER TO
drive plate. Insert a 5/8-11 inch bolt 2. Press a new bearing into the - MAX : (CLOSE R.H. AIR VENT)
through the drive plate shaft and bearing bore by the outer race. Do 2. MOVE TEMP CONTROL LEVER TO
not press the bearing in by the inner -cooL:
hand tighten the bolt. 3. SWITCH FAN TO -Hr· SPEED.
4. Smoothly apply enough pres- race. Pressure should be uniform and 4. ADJUST AIR OUTLET LOUVRES TO
sure on the bolt to free the shaft in line with the axis of the bearing DIRECT AIR UPWARDS FOR MAX
bore. Replace the internal bearing EFFICIENCY.
from the bearing inner race and then
remove the drive plate assembly. retainer. WHEN CABIN HAS COOLED TO
A SATISFACTORY LEVEL SET FAN
Before proceeding, check the drive 3. Support the pulley assembly, ON - MED - OR - LO - SPEED.
face plate for any excessive warping face up, by the bearing inner race . INTERIOR TEMPERATURE IS THEN
or breakage. Replace the entire Insert a 5/8-11 inch bolt, into the CONTROLLED BY ADJUSTING THE
TEMPERATURE LEVER .
clutch assembly if any damage is front of the drive face plate and care-
fully press the shaft into the bearing NOTE : FOR MAXIMUM COMFORT IN
evident. HIGH HUMIDITY CONDITIONS USE
S. Remove the internal bearing inner race, exerting pressure on the " FRESH " AIR MODE FOR SHORT
PERIODS ONLY.
retainer from the pulley assembly . bolt. Be certain that the shaft is in
line with the axis of the bearing bore. HEATER:
Support the pulley assembly, face I. SELECT " FLOOR " OR "SCREEN."
up, by the bearing bore making 4. Replace the external bearing 2. ADJUST "TEMP ' LEVER AND FAN
certain that there is no interference retainer onto the drive plate shaft. FOR DESIRED TEMPERATURE.

when the bearing is pressed out. With Rotate the pulley relative to the drive FOR QUICK WARM UP OR DEMIST
MOVE " TEMP" LEVER TO WARM
a suitable plug, force the bearing out plate to make certain that there is AND FAN TO " HI."
of the pulley assembly by the inner free rotation and that there is no
race. The plug should clear the metal looseness of the assembly before FIG.26
16-26

PART RADIO & RADIO TAPE PLAYER

16-3

Section Pare Section Pare

1 Description 16-26 3 Common Adjustments and Repairs 16-27
~ Diaposis and Testing 16-26 4 Removal and Installation 16-27
5 Tape Player ··· ..................... .. 16-28

D DESCRIPTION

Four models of radio receivers are solid state manually tuned 7 transistor The·aerial socker is located on a
available manufacturw by Amalga- radio. short lead at the left hand rear of the
mated Wireless (AUST-RALASIA) . receiver and the aerial trimmer con-
Ltd. Model No. XA-18805-C is a super denser on the top to the left hand
fringe solid state push button 11 and rear of the receiver.
Model No. XA-18805-A is a deluxe transistor radio.
solid state press button 7 transistor The speaker lead and socket is at
radio. Model XA-18805-D is a super the rear of the receiver together with
fringe solid state manually tuned 11 the "A" lead which has its own fuse
Model No. XA-18805-B is a deluxe transistor radio. (See Fig. 1).

B DIAGNOSIS AND TESTING

The procedures given cover only Noisy reception-when car in motion. 2. Check aerial cable.
minor radio receiver troubles. Each 1. Loose or broken aerial cable. 3. Radio nuts tight :
procedure either locates the minor
trouble or determines that the receiver All mounting bolts must be tightened
2. Loose or defective aerial.
should have a major repair. The follo~­ securely in order to provide adequate
ing parts will be required to make the Noisy reception--engiqe running. earthing for the radio.
radio trouble shooting tests:- 1. Defective suppression equipment.
2. Capacitors not properly grounded. 4. Aerial tight :
Spare fuses (8 ampere); Aerial and 3. Receive1· not properly grounded 5. Aerial Connections tight :
lead (XL-18813-A, XL-18814-A); to instrument panel. Aerial lead in cable must be firmly
Speaker (A.W.A. Part No. 50263W) 4. Aerial not properly grounded to inserted into the receptacle in the re-
(Ford Part No. ARC 90C18808A); fender. ceiver.
DISTURBED OR GARBLED 6. Aerial Trimming :
RADIO DIAGNOSIS GUIDE SOUND The radio must be trimmed to match
No reception. Check for the following: Check for the following : the aerial at installation. This pro-
cedure is simple and quick , vitally im-
1. Burned-out fuse. 1. Voice coil rubbing on centre pole
portant for good performance and the
2. Defective aerial or aerial cable. piece of speaker magnet.
most neglected of all the installation
3. Shorted speaker lead or defective 2. Torn speaker cone.
steps.
speaker. (Be sure to turn off the radio 3. Foreign material on cone.
receiver before removing the speaker.) 4. Bent or twisted speaker mounting. 7. General Care:
4. If radio still will not play, remove 5. If still distorted remove for major Many installations suffer due to general-
the receiver for a major repair. repair. ly careless work, causing rattles around
the speaker area, unsightly installa-
NOISY OR ERRATIC RECEPTION tions (cables dangling) and damage to
Check for the following : WEAK RECEPTION the aerial lead-in during installation.
Noisy reception--engine not running. Check for the following : 8. If still weak, remove for major
1. Loose connections. 1. Adjustment of the aerial trimmer. repair.
PART 16-3- RADIO 16-27

D COMMON ADJUSTMENTS AND REPAIRS

ADJUSTMENJ AND OPERATION
OF PRESS BUnONS

Switch the receiver ON by turning

the front right hand knob clockwise.

Allow the receiver to operate for

about fifteen minutes before setting
buttons.
Any of the five buttons may be
set to any station within the tuning
range of the receiver.
AERIAL TRIMMER
1. Pull the desired press-button
out to ita fullest extent (approx-
imately !" movement) to release
the locking mechanism.
2. Carefully tune in the selected
station V~~:th the Manual Tuninr I
RADIO FEED WIRE \
Control. ILLUMINATION LAMP FEED

3. Press the button fully in (total

movement approximately j") to
lock mechanism.
Proceed in the above manner for
FIG. 1-Radio Connections-Typical
the remaining four buttons.
AERIAL RIMMER ADJUSTMENT
Five stations are now instantly slowly in either direction until a peak
volume is reached (Fig. 1).
available and independent of Man-
ual Tuning. Switch the receiver ON and extend
the aerial to its maximum length. WARNING: These receivers are
At any time the choice of pre- Tune to the weakest station near the for 12 Volt negative earth opera-
selected stations may be changed 15 calibration. With the volume tions only. Connection to wrong
by repeating the above simple pro- control set in a suitable position polarity will cause damare to the
cedure. adjust the aerial trimmer control receivers.

rJ REMOVAL AND INSTALLATION

RADIO REMOVAL Check radio operation and adjust cowl side panel, it will be necessary
aerial trimmer. to remove the splash sealing panel
from inside the front wheel arch to
1. Remove instrument cluster AERIAL REPLACEMENT enable access to the aerial hole in
housing . 1. Remove the oblong base outer the cowl side panel.
2. Remove radio knobs and cover and remove the four mounting
surround. SPEAKER REPLACEMENT
screws.
3. Remove heater control mount- 2. List aerial from fender.
ing screws. 1. Unplug the apeaker cable from
3. Disconnect the lead from the
4. Remove the wing nut attach- radio and feed the lead through the the receiver.
ing radio to rear bracket. cowl side panel as the aerial is being 2. Remove the wing nut and two
5. Remove 3 mounting screws at removed. screws retaining the speaker to the instru-
the front of the radio. NOTE: To aid in reassembly, it is ment panel.
6. Withdraw radio and disconnect advisable to attach a piece of cord to 3. Remove the speaker.
the aerial, speaker and power leads. the aerial lead during removal. 4. Fit up the new speaker and replace
Reverse removal operations for If a piece of cord is not used the wing nut and screws.
installation. to draw the aerial lead through the S. Check radio operation.
16-28 GROUP 16-VENTILATING AND HEATING
RADIO TAPE PLAYER UNIT coating residue (oxide) as the tape off switch at the rear of the cartridge
Installation of this unit is as shown passes over the head. slot with the eraser end of a pencil
in Fig. 2. Refer to Fig. 3 for speaker This accumulation may need to and hold the alcohol-moistened swab
installation. be periodically removed, as part of against the rotating capstan.
Removal of the unit from the normal maintenance, if it causes weak
instrument panel is the same as for or wavering sound. The playback Excess alcohol on the swab
single unit radio. head can be cleaned with a cotton may run down the capstan and
The playback head and capstan in swab, slightly moistened with alcohol. damage the bearings. Do not
the tape player may accumulate tape To clean the capstan, trip the on- use carbon tetrachloride.

FIG. 2 - Radio and Stereo.

PART 16-3- RADIO 16-29

~--·-

~"(
- . ·· I;'"
/_; \

( \
--
'-

FIG. 3- Speaker Installation Sedan and Wagon - Typical

16-30 GROUP 16- VENTILATING AND HEATING

i
i I

II
I ,
\

WIR£ W t rHBJ...,M;k. SU!Ell.e' J

7l:' BE CONN~CTED TO
T£.RJ'AIIJI4L Atttt¥HC£D .:;.•

FIG. 4- Stereo speaker in cowl side card.

FALCON FAIRLANE w~:~~~~P

BODY, DOORS AND GROUP

WINDOWS 17
'"

PAGE

PART 17-1- General Body Service 17-2

PART 17-2- Front Sheet Metal Bumpers,

Exterior Mouldings 17-12

PART 17-3- Doors, Windows, Tailgate and

Deck Lid 17-31
17-2

PART GENERAL BODY SERVICE

17-1
Section Page Section Page
1 Diagnosis and Testing ........ ...... .. 17-2 Body Alignment 17-4
Dust and Water Leaks ...... .. 17-2 Paint Refinishing 17-4
2 Common Adjustments and Repairs 17-2 3 Cleaning and Inspection 17-8
Body Sealers and Application ... 17-3 4 HoistiRg 17-10
Door Windlace and Seals .... 17-10

D DIAGNOSIS AND TESTING

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

EJ COMMON ADJUSTMENTS AND REPAIRS

A wide variety of sealers are used MOTORCRAFT MULTI-PURPOSE ADHESIVE
by manufacturers. Since it would be R1-43
difficult to stock all of these sealers,
the all-purpose sealers described
have been selected for service MOTOR CRAFT
use. The method and points of appli- MULTI-PURPOSE
ADHESIVE
cation are given under each sealer
type.

A cement for all weatherstrips.

dry until tacky. Press surfaces to-
gether firmly, i.e., rubber to glass factory to use for cementing
To repair leaks at windshield or rubber to metal of body. weatherstrips to doors, bodies,
and rear windows, apply a ribbon deck lids, windows, weathershields
of this clear cement and allow to This cement is also very satis- etc.
PART 17-1- GENERAL BODY SERVICE 17-3
BODY SEALER SPECIAL MULTI-PURPOSE ADHESIVE
R124 GREY R1·43

R125 BLACK

This Sealer is semi-elastic and is MOTORCRAFT

fast drying. It will not run and can MU L T 1-PU RPOSE
be cleaned up with solvent if neces- ADHESIVE

sary. It is packed inllt2lb. cartons

and is either black or grey coloured.

Multi-purpose cement is a quick drying, strong adhesive cement for general

purposes . It is suitable for cementing rubber to metal, rubber to cardboard or
wood or rubber to rubber.
Surface to be cemented must be cleaned of all grease, dust and mould com-
_pound. To be assured of a clean surface, wash thoroughly with a cloth moistened
with clean petrol or cleaner's Naptha.
Cement is applied to both surfaces, allowed to dry for a few minutes, then
pressed together firmly.
If used according to directions, this white coloured cement gives a clean,
satisfactory result.

These Sqlers are used for semi-

sealing jobs such as are found in the
LUBE STICK
floor pan, wheel houses, dash panel, R1-26 (Dry Lubricant)
rocker panel, door opening, quarter
panels and drip mouldings. It is also
used to seal trim panel and outside
moulding clip holes and for windshield
and back window installation.
The grey coloured sealer is mainly
used for general purpose operations
as described. but the black can be
Prevents squeaks, rust and sticking.
used as an alternative as deemed
necessary . The black sealer is especi- Invaluable as a dry lubricant on car door dovetails, locks, latches, striker
ally suitable for windshield and back plates. Just clean the surface to be lubricated and apply a thin film- only a
window servicing or when paintwork little is required.
etc. is of darker colours. Also has a lot of domestic home uses--cupboard doors, window slides etc.

II BODY ALIGNMENT
Servicing the unitized body should back into alignment with the use restoration of the outer shell and
present no unusual difficulties or of light-weight jacks and hydraulic pillars without excessive strain on
necessitate additional equipment equipment without heating the the parts. Straighten, install, and se-
other than that required for the metal. cure all such parts in place before
conventional frame and body repair. attempting to align the body.
The application of heat and the use Rough out badly damaged areas
of heavy-duty jacks must be care- before taking measurements for In cases of severe or sharp bends,
fully controlled because of the dif- squaring up a body. If necessary, it may be nece'lsary to use heat.
ference in the gauge of the metal remove the glass from the damaged Any attempt to cold-straighten a
in the sub-frame of a unitized body area to prevent damage. In severe severely bent bracket may cause
&nd the stress points developed in a cases reinforcement brackets and ruptures of the welds and may also
single welded unit construction. It other inner construction may have cause cracks in the bent part. Never
is possible to pull damaged areas to be removed or cut to permit heat the area more than a dull red.
17-4 GROUP 17-BODY, DOORS AND WINDOWS
CHECKING BODY FOR both sanding and polishing without the recommended air dry time, sand
MISALIGNMENT the necessity of repainting. Repairs of the primer surfacer with No. 400
To align or square up a body, take this type should apply to an entire grit paper before application of the
two opposite diagonal measurements panel while spot repairs should be repair material. The lacquer or
between pillars. Use a measuring attemped on.Jy in isolated areas. enamel used should be reduced as
tram for these measurements. Take The suggested polish repair pro- recommended by its supplier.
the measurements between reference cedure consists of:
points such as crease lines or weld 1. Remove the defect hy oil sand- PAINT DEFECI'S AND REPAIR
joints which are diagonally opposite ing with 600 grit paper, using water PROCEDURES
each other on the two pillars being or mineral spirits as a lubricant. Listed here are some of the ab-
measured. Since all measurements normal paint conditions that may be
should be made from the bare metal,
2. Apply a white or light colored encountered (Fig. 2). It is very im-
medium grit machine polishing
remove all interior trim from the portant to identify the paint condi-
compound to the painted surface
checking points. tio.:t correctly so that the proper
with a brush.
In some cases, it is difficult to ob- repair procedure may be followed.
tain proper body alignment when 3. Polish the entire panel surface For each of the following paint con-
repairing a body that is damaged using an I 850 rpm wheel and a car- ditions described, the recommended
on both sides. In these cases, hori- pet pad (approximately %-inch nap) repair procedure will be indicated.
zontal and vertical measurements or lambswool pad.
BLISTERING
can he taken from a body of the 4. Buff the surface with a clean
lambswool pad. Blistering is the formation of bub-
same · body.. style. Once these b;~sic bles or pin points on the surface of
dimensions are taken and established Normally. acrylic enamels do not
need polishing to improve their gloss; the finished work. Unless inspected
on the damaged body. alignment can by a magnifying glass, this condition
be made by diagonal measurements however, the foregoing procedure
can he used to restore the original is very hard to identify. In some in-
taken from points on the two pillars. stance;, this complaint may be con-
Do not attempt to correct any luster to the film after weathering,
or to ill}prove the surface smooth- fused with dirt in the paint. To
serious misalignment with one jack- verify blistering, prick the suspected
ing operation. This is particularly ness of the finish on the entire car.
areas, and note whether a hole exists
true if other sections of the body Repair By Repainting. Acrylic
under the bubble. This condition is
also require aligning. Align each enamels can be repaired by repaint-
caused by rust, moisture, or oil be-
section proportionately until the ing with either conventional air dry-
tween the coats, metal not properly
proper dimensions are obtained. ing or low bake enamels, or with
cleaned, or uneven temperatures
Door openings are checked in the acrylic lacquers. When repainting
between the metal and' the paint
same manner as the body. Horizon- metallic colors, it is recommended
being sprayed.
tal, vertical. and diagonal checking that acrylic lacquer be used since a
points are established on all four better color match can be obtained; Acrylic Enamel. Repair by re-
sides of the door opening that is both the original finish and the re- painting (color coat) . Priming pro-
being measured. pair can be polished to provide the cedure must first be followed if
same luster, and the air dry acrylic defect is due to poor metal prepara-
CHECKING UNDERBODY FOR repair lacquer will provide better tion.
MISALIGNMENT CHECKING
durability in service than air dry
enamels. Do not use Nitrocellulose Line checking has the appearance
The dimensions of the underbody
lacquers for exterior repairs. of thin, straight lines criss-crossing
must be restored in the repair of
each other. These lines may be from
major body qamage, to provide cor- When using any one of the three one-half inch to four inches or long-
rect front and rear wheel geometry types of repair materials over acrylic er, increasing in length as the finish
(Fig. 1). All the dimensions are enamel, remove all traces of wax, ages.
detailed to the centre line of exist- polish or grease with a good sili-
Acrylic Enamel. Refinish panel.
ing holes in the underbody assembly. cone remov~r. It is extremely im- (Color coat-primer if damaged.)
Once the frame and suspension portant that a thorough sanding
members are aligned, the balance CHIPPING AND
of the original finish be accom-
of the repair can be performed. plished using No. 400 grit paper. STONE BRUISES
Care should be exercised to ensure Chipping occurs when the surface
PAINT REFINISHING that all surfaces; including edges of the finish coat of paint has been
and areas adjacent to applied broken by a sharp blow, and small
Acr~· lic Enamels. Acrylic enamels p,articles of paint have flaked off.
mouldings, are thoroughly sanded
exhibit better hardness. mar resist- in order to provide adhesion of Frequently, stone bruises result in
ance and gloss retention in metallic the repair top coat. Areas saaded chipping.
colors than the ordinary enamels. to the base metal (cut through) Acrylic Enamel. Refinish panel.
Acrylic enamels also possess the should be treated with an acid Paint may be spotted if in isolated
property of good polishability. cleaner. Follow the directions of areas. (Prime to be bare metal.)
Following are recommended re- the supplier as stated on the con- CRACKING
pair procedures for acrylic enamels: tainer. Cracking is evidenced by the
Repair By Polishing. Repair of After sanding, proceed with the paint curling. Frequently, cracking
minor dirt or fallout. sags, mars. application of a primer surfacer re- starts at the edge of the panel. This
scratches. dry spray. overspray and duced according to the supplier's is caused by poor mixing of paint
orange peel can be accomplished by recommendations to any bare metal or by temperature changes during
machine or hand oolishing or by spots that have been exposed. After the various painting stages.
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DIMENSIONS UNDER too• HAVE A 0 0
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UI'I'EII SUSPENSION IIEAII VARIATION OF t 0·6"EXCEPT AS
HOUNTI.HG HOLE NOTED BY AN ASTERISK. DETAIL OF END OF HEM8E R (/)
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DIMENSIONS OVER 100~ HAVE A SHOWING LOCATING :;o
HOLES
UPPEII SUSPENSION FIIONT
MOUNTING HOLE
VARIATION OF t 0.12~ <
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17-6 GROUP 17- BODY, DOORS AND WINDOWS

RANDOM BLISTERS CROWFOOT lNG PITS AND POP·UPS SCRATCHES

.. .:.....
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PATTERN BLISTERS DIRT IN PAINT CRATERS WATER SPOTTING

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LINE CHECKING MILDEW THIN PAINT INDUSTRIAL FALL·OUT

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CHIPPING OFF COLOR RUNS AND SAGS ORGANIC FALL·OU T

BRUISES "~RANGE PEEL PEELING

CRACKING OVERSPRAY
N -1471 - A

FIG. 2-Paint Defects

PART 17-1- GENERAL BODY SERVICE 17-7
Acrylic Enamel. Refinish panel. depressions in the paint. These may Industrial fallout particles appear
(Prime if both color and primer be caused by not allowing the first to the eye as tiny rust coloured
cracking.) coat ol dry sufficiently before apply- dots on the paint film and the sur-
CROW FOOTING ing the second coat or from failure face feels rough to the touch. Some
Crow footing may be described to remove silicone polishes before of the particles have excellent ad-
as small lines branching off from repainting. hesion and are difficult to remove.
a point in all directions and giving Acrylic Enamel. First use polish However, the following procedure
the appearance of a crow's foot. repair procedure refinish panel if has proven effective in the removal
Crow footing is usually caused by necessary. (Color coat.) of this fallout .
spraying a second coat before the 1. First, wash the car with car
THIN PAINT wash compound to remove loose
first coat is dry, by spraying an ex-
cessively thick coat, or by thinners The primer will show through soil. Rinse well and examine painted
which evaporate too fast. the fini sh coat as a result of an ex- surfaces for iron base fallout par-
cessively thin color coat, or applica- ticles. If there is a significant
Acrylic Enamel. Refinish panel.
(Color coat.) tion of the color coat before the quantity of fallout not removed by
surface is dry. ordinary washing, the acid treat-
Acrylic Enamel. Refinish panel. ment should be used. All cracks,
DIRT IN PAINT
(Color coat.) ledges, grooves, etc., where fallout
Patches where dirt appears are has accumulated should be cleaned
sometimes confused with blistering. RUNS AND SAGS by wiping or by an air blow off.
To vertify the condition, prick the 2. Dilute 1 part hydrochloric acid
suspected areas, and note whether The . uneven collections of paint
on the finish surface are referred to (commercial grade) to 100 parts of
there is foreign material under the warm water and add one or two
surface. as runs and sags. The collections
may appear in the form of tear tablespoonsful of a non-alkaline de-
Acrylic Enamel. Refinish panel. tergent such as car wash compound
procedure will be effective in most drops or sagging lines. Usually these
lines are quite soft and sometimes to every gallon of the diluted acid
cases. (Color coat.) mixture. Other neutral detergents
the y may be wrinkled . This is usually
caused by over-application of paint are permissible, but all alkaline
MILDEW compounds should be avoided. This
or hesitation in the stroke of the
Mildew growth which occurs gun . acid detergent solution must be
along radial lines is most common- prepared and kept in a clean NON-
Acrylic Enamel. Use polish re-
ly found in a very dark gray or METALLIC container.
pai r procedure.
black color.
Acrylic Enamel. Repair by polish- SCRATCHES Apply this solution liberally to
ing.
Scratches are thin marks or tears all affected surfaces of the car
OFF-COLOR that may partiall y or completely with a large sponge. U se a broad
The term off-color is applied to penetrate the surface of the finish wiping stroke and keep the work
adjacent areas on which the colors coat of paint. completely wet for about fifteen
do not match . It may also appear Acrylic Enamel. Use polish re- minutes, or until the operator can
when making spot repairs. pair procedure for shallow penetra- no longer feel any surface rough-
Acrylic Enamel. Refinish panel tion . Refinish panels to correct con- ness or even isolated gritty par-
if polishing does not correct condi- ditions of deep penetration. ticles with bare or gloved finger
tion (Color coat.) tips. If this is not done thoroughly
ORANGE PEEL SPOT DISCOLORATION rust stain may soon re-develop.
Orange peel is a term used to This is evidenced by brown spots Again, it is most important that
describe an uneven, mottled appear- or stains on the surface. Stains or the work be kept wet, since a
ance on the paint surface. This is spots can be caused by road tar, acid dry acid residue is not active in
usually caused by improper thin- or alkali-bearing water from the loosening fallout.
ning of the paint. streets. Be sure that the entire acid
Acrylic Enamel. Refinish panel if Acrylic Enamel. Use polish re- cleaning procedure is performed in
polishing does not correct condition. pair procedure. a sheltered area so that the work
(Color coat.) will be kept as cool as possible,
WATER SPOTTING to prevent rapid evaporation of
OVERSPRAY water and consequent surface dry-
Overspray is evidenced by a Water spotting is evidenced by a ing. DO NOT WORK IN THE
rough, dull finish in the area sur- milky pattern where water drops SUN. Even a strong breeze makes
rounding the paint repair. have fallen . it difficult to keep the job wet over
PEELING Acrylic Enamel. Use polish re- a large area.
Peeling occurs when large areas pair procedure. 3. Rinse the job with clean water.
of the finish or primer coat separate This must be done very thoroughly
from the metal or prime coat. This to prevent possible corrosion.
INDUSTRIAL FALLOUT
is usually caused by wax , grease, IndustJ;ial fallout is the result
rust or oil under the paint. Do not of particles being exhausted into CAUTION : No traces of acid
confuse with orange peel. the air by the various processes should be left on any surface.
PITS AND POf-UPS of heavy industry, in areas where Bright trim parts, particularly ano-
Pits and craters may be ident ified there is a concentration of such dized aluminium and stainless steel
by the appearance of small round industry. may be stained by prolonged con-
17-8 GROUP 17- BODY, DOORS AND WINDOWS
tact with the cleaning solution. The use of Oxalic Acid to remove Acrylic Enamel. Refinish dam-
Even painted areas can be spot- metallic particles derived from In- aged panels. (Color coat and
ted by prolonged exposure. It is dustrial Fallout has been investi- primer.)
also important to keep the acid gated. The use of Oxalic Acid is not
cleaner solution from leaking in- recommended for uncontrolled use INTERIOR PAINT REPAIRS
board because some fabrics might by the public. This acid is extremely
be bleached or discoloured by the poisonous ( 1 gram of solid acid being The proper matching of colors
same. a fatal dose for h\lmans). can be obtained if the following
The Department of Public Health procedures are carefuly adhered to:
NOTE: If the fallout is not com- advise that a 5% solution is safe if
1. Clean the surface to be painted
pletely removed or is deeply im- normal precautions are observed
with wax and silicone remover.
bedded in the paint film, cleaning but it is felt that there are more
with the acid detergent mixture suitable alternatives. Hydrochloric 2. Feather-edge the damaged area
must be repeated. This may be Acid will achieve the same result with 400 grit wet or dry sandpaper.
aided by using a fine scrubbing brush, as Oxalic Acid. This acid is corrosive (Prime all areas of bare metal with
possibly a nylon bristle type. Just but not toxic. M-6J-12S Primer.)
make sure that the light scrubbing 3. Mix the paint per instructions
required does not scratch the paint. on the can and spray several light
It is also helpful sometimes to coats.
brisklv rub the work with a mix- Allow the paint to become tacky
ture ·of equal parts of the acid ORGANIC FALLOUT between coats.
cleaner and a cleaner wax polish, Organic fallout may result from 4. Spray the entire area sparingly
using a piece of heavy towelling. parking cars under trees or from with B7 A-645-S Lacquer Leveler
Again thorough_ water rinsing is the air under certain atmospheric which will blend the repaired area
extremely important. conditions. with existing painted surfaces.

EJ CLEANING AND INSPECTION

FLOOR PAN PLUGS or chipped glass. Rattles and squeaks are sometimes
AND GROMMETS 7. Align the hood, doors, and caused by weatherstripping and anti-
The floor-pan plugs seal the vari- deck lid if necessary. squeak material that has slipped out
ous access holes. If any plugs are of position. Apply additional cement
8. Inspect the windshield wiper or other adhesive, and install the
missing or improperly installed, a
blades and replace them if necessary. material in the proper location to
dust or water leak may result. This
9. Tighten the sill plate and gar- eliminate this difficulty.
also applies to the grommets used
on the dash panel. When dust or nish moulding screws. EXTERIOR CLEANING
water leaks are evident, these plugs 10. Clean the seats, door trim
panels, and head lining. The outside finish should be fre-
and grommets should be checked quently washed. Never wipe the
for proper installation. 11. Touch up or paint chipped
or scratched areas. painted surface with a dry cloth.
12. Drain holes located on the Dusting the finish when it is dry
DRAIN HOLES tends to rub the dust and dirt into
underside of each rocker panel,
Drain holes or valves located on quarter panel, and door, should be the baked enamel, and leaves a
the underside of each rocker panel, sandpaper effect on the surface. To
cleared periodically.
quarter panel. and door should be keep the finish bright and attractive
cleared periodically. and eliminate the necessity of using
polish, wash the car whenever it has
RATTLE ELIMINATION accumulated a moderate amount of
BODY MAINTENANCE Most rattles are caused by a loose dirt and road salt.
Regular body maintenance pre- bolt or screw. Foreign objects such
serves the car's appearance and re- as outs, bolts, or small pieces of
duces the cost of maintenance dur- body d'!adener in the door wells,
ing the life of the car. The follow- pillars and quarter panels are often The bright metal parts of the car
ing steps are suggested as a guide the source of rattles. Door wells can require no special care. Periodic
tor regular body mamtenance: be checked by carefully striking the cleaning will preserve the beauty
1. Vacuum the interior thorough- underside of the door with a rubber and life of these finishes. Wash
ly and wash the car. mallet. The impact made by the with clear water or if the parts
2. Check all openings for water mallet will indicate if loose objects are very dirty use Autolite car
leaks, and seal where necessary. are in the door well. wash. Using a clean soft cloth or
3. Cement all loose weatherstrips In the event that tightening the a sponge and water, rinse and wipe
which are still usable. bolts and sccews, located on such the parts dry. Do not scour alu-
4. Replace all door and deck lid assemblies as the doors, hood, and minium or chrome finished parts
weatherstrips which are unfit for deck lid does not eliminate the rat- with steel wool or polish them with
service. tles, the trouble is probably caused products containing abrasives. A
5. Apply silicone lubricant to the by misalignment. If this is the case, Autolite. Polish will provide excel-
weatherstripping. follow the adjustment and alignment lent protection for all bright metal
6. Replace all cracked, fogged, procedures for these assemblies. parts.
PART 17-1- GENERAL BODY SERVICE 17-9

INTERIOR CLEANING floor covering. Vinyl and woven plas- lacquer thinners, cellulose acetate,
tic trim that is dusty can usually be butyl cellosolve, carbon tetrachlor-
cleaned with a damp cloth. Do not ide, body polish, battery acid, anti-
Use a vacuum cleaner to remove use cleaning materials containing freeze, gasoline, motor oils or other
dust and dirt from the upholstery or kerosene, naptha, toluol, xylol 10°, type lubricants.

REMOVAL OF SURFACE STAINS the surface. Now gently wipe the hot water, then allow it to dry
FROM VINYL TRIM MATERIALS affected area with a cotton cloth thoroughly. Now wipe over with a
Many warranty claims are received moistened with methylated spirits or clean cloth moistened with methy-
at Head Office Service for replace- mineral turps. To complete the clean- lated spirits. In this case, do not use
ing process, wash over with warm, warm, soapy water, as this sets the
mertt of stained body trim.
soapy water. stain.
From examination of displaced
trims returned from the field, it has Battery Acid: Ice Cream:
been found that in many cases the Battery acid is a severe corrosive Try using warm, soapy water at
stains have been further aggravated agent. It may destroy the surface first. If this is not successful, wash
by using incorrect removal agents of your fabric or permanently stain the affected area repeatedly with
and therefore staining the trims to a it. If you have household ammonia very hot soapy water, then rinse with
greater degree than the original stain. handy, apply it at once to the acid. cold water. Now wipe over with a
The following procedures basically This will neutralise it. Now wash clean cloth moistened with methy-
detail the removal agents for stained over with warm, soapy water. Always lated spirits, followed by warm, soapy
vinyl trims and should be used prior dilute the acid quickly. If ammonia water. Ice cream is a very difficult
to replacement being contemplated. is not readily available, use a normal stain to remove if left to harden, so
Ballpoint Pen Inks: household detergent. These usually quick action is important here.
First mix parts of fresh Calcium contain a neutralising agent. Tar:
Chloride* and Fuller's Earth {both Blood: A tar stain is one of the most
available at your local chemist). Now Cold water will remove blood stubborn stains, virtually impossible
add a few drops of methylated stains if used immediately. If marks to remove if left for any length of
spirits and mix with a knife into a persist, use household ammonia, or time. Quick action with a little
fairly thick paste. Add more methy- a starch paste. kerosene or mineral turps on a clean
lated spirits as necessary. Chocolate: cloth is recommended here.
Next, apply the paste with a knife
along the ink stains. Wait for it to Remove the excess chocolate with Paint:
dry, then remove it with a damp a spoon and wipe over with a cloth While the paint is still wet, or
cloth. Finally wash the affected area moistened with methylated spirits, just set, apply mineral turps with a
over with a wet cloth and dry with a then wash with warm soapy water. clean cloth. Now wash over with
clean cloth. Should the stain still Toffee: warm, soapy water. Again, immediate
remain, repeat the cleaning procedure. action is essential, as dry paint cannot
If the removal of the stain leaves Scrape the stained surface with the
edge of a spoon and wash with very be removed without damaging the
the surface dull, wipe it over with surface of the fabric.
cotton wool moistened with glycerine. hot water. Then wipe over with a
Do not use furniture or floor polishes. cloth moistened with methylated
spirits. Then wash with warm soapy IMPORTANT:
* Special Note: water. You should never use abrasive
Use only calcium chloride. Chloride cleaners or cleaners containing sol-
of lime is too drastic as a cleaning Chewing Gum: vents (other than those mentioned
agent and can permanently damage Set the gum with an ice cube, above). Neither should you use steel
the fabric. then scrape with the edge of a spoon . or copper wool. These can perman-
Wipe over with methylated spirits ently damage the surface of your
Lipsticks, Shoe Polishes, Fatty & fabric and spoil its appearance.
Greasy Stains: (as above) and finish with warm,
soapy water. Such cleaners as "dissol", "Plastic
With a dry rag, remove as much of Devil" and "Vyno" are very effective
the stain as possible. Take care not Liquor & Fruit Stains: if used strictly in accordance with
to spread the staining substance over Wash the stained area with very the instructions provided with them.
17-10 GROUP 17- BODY, DOORS AND WINDOWS

E] HOISTING VEHICLE

The unitized body-frame construc- REAR least 12 square inches of underbody

tion requires special precautions and area. Figs. 3 and 4 show recom-
procedures when the car is jacked mended contact points for the hoist
up or hoisted. In some cases, spe- To prevent damage to the shock pads.
cial hoist adapters must be used as absorbers, the rear forks must con-
recommended by specific hoist tact the axle at points as near as
manufacturers. practicable to the differential hous-
Refer to the Owner's Manuals ing. Carefully raise the rear post FLOOR JACK
when using the jack supplied with and check the position of the fork When a stationary floor jack or a
the car. (Fig. 4). roll jack is to be used, there are
several specific recommended points
DRIVE-ON TYPE HOIST of contact. Either side of the car
To prevent possible damages to may be raised at the front by jack
the underbody, do not drive the contact at the lower arm strut con-
car onto the drive-on type hoist nection. Either side of the front
FRONT RAIL TYPE , FORK LIFT
without first checking for possible OR F LOO R J A C K CO NTAC T A REA end of the car may also be raised
interference between the upright by jack pressure on the front cross-
flanges of the hoist rails and the member, or on the crossmember
underbody. Should there be inter- to which the stabilizer is co!'loected.
ference, the hoist flanges should be
modified as necessary and/ or the
approach ramps built up to provide
the needed clearance.

RAIL TYPE-FREE WHEELING

HOIST
FRONT
The front adapters or hoist plates
must be carefully positioned in con-
tact with the lower suspension arms
to assure safe, accurate lifting.

REAR
The hoist adapters must be posi-
tioned carefully under the rear axle
to prevent damage to the shock ab-
sorbers when the car is raised. The
FRONT FRAME CO N TACT AREA
hoist rails should be raised slowly M1111 .A

and the position of the adapters

checked. FIG. 3-Front Hoist
Contact Areas
FORK LIFT - TWIN POST
HOIST
FRONT
To assure safe hoisting, the front FRAME CONTACT HOIST
post adapters must be positioned Frame contact hoist adapters are
carefully to contact the centre of necessary to lift the car. The hoist FIG. 4-Rear Hoist
the lower suspension arms (Fig. 3). adapter pads should each cover at Contact Areas

BODY-DOOR WINDLACE
AND SEAL
The installation of door windlace
and weather seals is shown in Fig. 5.
To remove the combined windlace/
seal remove the screws attaching the
moulded ends to the door frame and
remove the windlace/seal from the
flange .
PART 17-1- FRONT SHEET METAL BUMPERS, EXTERIOR MOULDINGS 17-J 1

FIG. 5- Door Weather Strips and Seals

17-12

PART FRONT SHEET METAL, BUMPERS,

EXTERIOR MOULDINGS
17-2
Section Page Section Page
1 In-Car Adjustments and Repairs 17-12 Hood Hinge 17-12
Hood Adjustments ... .... ... . ... . .... 17-12 Radiator Grille 17-12
Hood Lock Adjustments .. .. .... . .. . 17-12 Front Bumper ... . 17-12
Rear Bumper 17-16
2 Removal and Installation .... .... .... 17-12 Exterior Mouldings }7-16
Instrument Panel 17-19
Sun Roof 17-17

DIN-CAR ADJUSTMENTS AND REPAIRS

HOOD ADJUSTMENTS 3. Tighten the lock retaining
The hood is provided with fore screws. Open and close the hood
and aft, vertical, and side-to-side several times to be sure that it
adjustments (Fig. 1). These directions latches securely.
refer to the position of the hood HOOD LINE ADJUSTMENT
when it is fully lowered. The en-
larged bolt slots in the hinge at 1. Adjust the hood bump stops
the hood provide the side-to-side so that there is no bump stop to
and fore and aft adjustments. The hood contact.
slots in the hinge at the fender
apron provide vertical adjustment. 2. Adjust the hood lock dowel so
that an even bonnet line is ob-
Hood bumpers, located on the top tained.
left and the top right surface of
the radiator support, can be adjust-
ed up and down to provide a level 3. Adjust the bump stops so that
surface alignment of the hood panel they just contact the hood.
with the front fenders FIG. 1-Hood Hinge
Installation 4. Close the hood and check for
HOOD LOCK ADJUSTMENTS correct lock operation.
2. Move the hood lock mechan- Under no circumstances should
1. With the hood open loosen the ism as required to align it with the the bump stops be used to
hood lock retaining screws (Fig. 2). Jock striker. obtain hood line adjustment.

EJ REMOVAL AND INSTALLATION

RADIATOR GRILLE AND 2. Remove the bumper left and
HOOD HINGE SURROUND- FALCON & right inner and outer arm-to-frame
FAIR LANE side rail retaining bolts and remove
1. Prop the front of the hood in the bumper assembly (Fig. 3).
the open position and cover the The grille is a one-piece plastic
moulding and is retained bv eight 3. Remove the bumper inner and
fender and cowl panel. outer arms from the bumper.
screws. To remove the grille frrst
2. Remove the hinge-to-hood re- remove the screws, (~ at each head 4. Remove the licence plate.
taining bolts, the retaining bolts at lamp surround and 2 in the centre)
the fender apron and cowl (Fig. 1), and remove the grille forward. INSTALLATION
and remove the hinge. FRONT BUMPER
1. Install the licence plate on the
3. Position the hood hinge on the REMOVAL new bumper.
body and install the hinge retaining 1. Remove the front bumper arm 2. Install the bumper inner and
bolts. to fender support brackets left and outer arms on the new bumper using
4. Adjust the hood for proper fit. right hand sides. spacers and washers as shown in Fig. 3.
PART 17-2- FRONT SHEET METAL BUMPERS, EXTERIOR MOULDINGS 17-13

I II
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FIG. 2 - Installation Hood Lock

17-14 GROUP 17- BODY, DOORS AND WINDOWS

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PART 17-2-FRONT SHEET METAL BUMPERS, EXTERIOR MOULDINGS 17-15

3. Position the bumper assembly 2. Position the bumper assembly 3. Remove the bumper stone
to the car and loosely install the on the car and install the bumper shield and brackets as an assembly.
bumper arm-to-frame side rail re- arm-to-frame retaining bolts. 4. Transfer brackets, stone shield
taining bolts . 3. Position the license plate lamp and licence plate to new bumper.
4. Align the bumper assembly and assembly to the bumper and install 5 . Position the bumper assembly
tighten the bumper arm-to-frame side the retaining bolts. on the car and install the bumper
rail retaining bolts. 4. Install the license plate. bracket to frame bolts.
5. Replace the front bumper arm 6. Align bumper bar with vehicle .
to fender support brackets. Tighten mounting bolts and install
EXTERIOR MOULDINGS licence plate lamp .
Before removing the exterior
REAR BUMPER mouldings, it should be determined
by the type of retainer used whether REAR BUMPERETTE
REMOVAL WAGON a respective door, quarter or luggage
compartment trim panel must first REMOVAL UTE & VAN
1. Remove the screws retaining
the license plate lamp assembly to be removed to provide access (Figs. 1. Remove bumperette outer
the rear bumper. 9 through 12). support bracket nuts.
2. Remove the rear license plate. 2. Remove main support bracket
bolts to frame ( 4 from beneath
3. Remove the eight bumper arm- vehicle) Fig. 5.
to-frame retaining bolts and remove REAR BUMPER
3. Transfer brackets and pad to
the bumper assembly. REMOVAL SEDAN new bumperette.
1. Remove the licence plate lamp 4. Position bumperette assembly
from the bumper. on the vehicle, install the bumper
INSTALLATION 2. Remove the 6 bolts bumper bracket to frame bolts.
1. Transfer the rear bumper arms support .bracket to body (2 . from 5. Align bumperettes to vehicle.
and rubber bumper to the new beneath vehicle I from inside luggage Assemble bumperette outer support
bumper. compartment each side) Fig. 4 . and tighten mounting bolts and nuts.

1 &JMPERA.S.S ,..- TAll OAT£. TO &JMPfRETTE

e IJA/? I?[AR dUMPrR£.77£ IMPACT
J .ARI\II .45.SY REAR 6UMPli?ETTl INNlR
4 RCIIVrASS'I·REARtwMPER'C.rTE 'SlOE !NNE~
5 REINF' REAR l3VMP£1U7T£ SID£ OUTER
6 A PM REAR 8UMP£RETTE. OUT£R

A 80L T A55Y hf.-14 J( /JfJ <' R(QD

ll SPACE li! 8 REaD
c WA SHEI: ~FLAT d REGV
0 NCJT h<·/4 LOCK 8REQO
E Sl.RE VV .t' WASHER A.55Y k · .4.~~t/A HX HD B REGD
~ NVTOVASHER A.SSY J'4 -CO NX t! IUQD
6 !YtiTtWiJ.sHE..RASSY ht-A!I ZI?EQD

FIG. 4- Installation Rear Bumper Ute/Van

-.-....
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~ FIG. 5 -Installation Rear Bumper Sedan

PART 17-2- FRONT SHEET METAL BUMPERS, EXTERIOR MOULDINGS 17-17

Instructions for Repair and shorter than the original). Reinstall LUBRICATION
Adjustment of Sun Roof. parts and panel, adjust the cable During cable replacement, lubri-
so that the forward edge of the panel cate the cables with petroleum jelly
1. Adjustment of panel align- is parallel with the forward edge of
ment: or vaseline. It is not necessary to
the roof aperture. If necessary lubricate the top surface of the
(a) Front, left and right: Release adjust as indicated in paragraph 3.
lining frame at the front and guide rail covers or the slide tracks.
push back. Loosen the fixing 5. The joints of the cable Periodically, clean off any residue
screws for the slide at the front slides are out of alignment that may accumulate on the guide
end. Adjust the milled nuts and (guide rail, corner and connector rail covers.
re-tighten the fixing screws. rails and cable box) and are DRAIN TUBES
(b) Rear, left and right: Loosen the jamming the cable drive: Loosen
bolt on the closing mechanism. the screws holding the guide rails, During regular maintenance check
The bolt can be moved to the corner and connector rails and cable to ensure the drainage holes at the
desired position in the slot in box a few turns. Retighten the front corners of the roof panel frame
the closing mechanism by turn- screws one by one, continually are open and free of foreign material.
ing the adjusting screw to the activating the drive mechanism. If the drains are plugged , they may
left or right. Re-tighten the nuts Where necessary realign those points be cleaned with an air hose (low
on the bolt. where resistance is felt. pressure) or with a flexible wire.
Checking for alignment of the ramp If the drain tubes can not be
2. Panel rises on one side only: cleaned in this manner, they must be
Examine the ramp in the drainage and lifting elements (see paragraph 2).
replaced.
channel in the frame to see whether If one cable needs replacing, When cleaning with an air hose,
it is properly aligned with the lifting replace both to assure a parallel use low pressure so as not to damage
element at the rear end of the panel. travel of the roof panel. or detach the plastic tubes.
To do this, slide the panel back
completely. The point where the UPPER FRONT GUIDE CONNECT!"" I
LOWER FRONT GUIDE CONNECTIGI
CABLE DRI VE HOJSING COVE R

C~~~ £r~HOJS=ING=====
lifting element makes contact with
the ramp can be clearly seen on the
rearward slope of the ramp. Adjust
the ramp and if necessary, the lifting
element on the panel, so that working UPPER ELBOW
point of the lifting element lies at the GUIDE

middle point of the ramp.

'' F ROHT SLIDE

3. Panel does not run true:

Close the roof. Determine which
.,..f!' . . - - - - ASSEMBLY
DRI VE CAB LE RETAI NING CUP

side of the panel jams. Open the

roof again. Remove alloy cover of
drive mechanism. Lift out the
spring plate over the pinion. To pull
forward the right hand side of the
sliding roof panel, lift the cable at
the front (looking in the direction of
travel) of the pinion, pull it one or
more teeth to the left and replace. REAR SLIDE
AHOCABLE-.............
Note: Do not accidentally move ASSEMBLY

the panel while the cable is off the

pinion. Slide back the spring plate
over the drive pinion. Screw back
the drive mechanism cover.
SLIDE RETAINER REAR STOP GUIDE RAIL _ _ . . .
4. Damaged drive cable includes
remove and replace panel and push
back lining.
Remove the lining frame, unscrew
front slides, remove closing mech- FIG. 6- Sun Roof Sliding Panel- Disassembled View- Typical
anism from the skid at the rear,
lift out the outer roof panel.
Remove the cover of the drive
mechanism box, spring plate over
drive pinion, connector rails and
upper parts of the corner rails. Pull
out the cable with the rear slide from
the guide rail. Install a new cable,
lubricated with grease of molyb-
denum disulphate. (Replacement
cables may be longer but never
17-18 GROUP 17- BODY, DOORS AND WINDOWS

FIG. 7 - Drive Cable and Housing Installation - Typical

FIG. 8 - Removal and Installation of Rear Slide and Cable- Typical

PART 17-2-FRONT SHEET METAL BUMPERS, EXTERIOR MOULDINGS 17-19

INSTRUMENT PANEL 5. Remove the instrument cluster. 12. Release the steering column
REMOVAL AND INSTALLATION 6. Remove heater /air-conditioner upper support to allow access to the
control. bolt instrument panel to pedal
7. Remove radio . support.
REMOVAL 8 Unclip the wiring harness from 13. Remove the instrument panel
1. Remove the crash pad as out- the instrument panel. from the vehicle, Fig. 15.
lined in Group 18-1. 9. Remove two screws, hand
2. Remove the glove box and door. brake handle to instrument panel. INSTALLATION Reverse removal
3. Remove air-conditioner/heater/ 10. Remove brace attachment bolts procedure for installation
ventilation ducts from instrument at the instrument panel.
panel. II. Remove bolts attaching the
4. Remove instrument cluster instrument panel to cowl side
housing brackets.

r----t-=,==fr--.L___-t--..L--L--r'-~~- -@

roR-~-;-;y I
OOYIIVG LM-fPS FOR Gr CW.Y -

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FIG. 9 - Grill and Front Ornamentation ~ - ~-@
($5l!J=L -- - --<tr- (J)

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17-20 GROUP 17- BODY, DOORS AND WINDOWS

@
~.

FIG. 9-A- Grill and Front Ornamentation

@----®-~~
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l )
H

FIG. 10- Exterior Ornamentation (Sedan, Wagon, F/Lane)

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PART 17-2- FRONT SHEET METAL BUMPERS, EXTERIOR MOULDINGS 17-21

@)

FIG. 10·A- Exterior Ornamentation (Sedan, F/Lane)

1 ---
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17-22 GROUP 17- BODY, DOORS AND WINDOWS

I \

I
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,....__ __ I ,

J ~·, \

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FIG. 10-B- Exterior Ornamentation (Sedan, F/Lane)

( -
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PART 17-2- FRONT SHEET METAL BUMPERS, EXTERIOR MOULDINGS 17-23

/0

FIG. 10-C- Exterior Ornamentation (Wagon)

l ARDZOB ·71·517:«.·1 IWCJULCJING ROOf# t:RI<>

ilclI'INISII ,ADf'IT .<0'1 MOtii.S 7/B, 710 1/1 Qfdo

J.
lA. 72DA·li·517M/9 IVOULDING R OO> a<IP 510£
FINISH REAR -I'OA MOlllLS 718. 1JD 1/t A£0'0

2. ARDZDB·/60~ NOUI.DING I'RONT F£ND£R

WH££L~N1NG I'OR NoODEL 110 - 1/1 ACQ "O
NFotC}J CAGH M()()LOINO I-YITH •-
A . 579$60-5/01 '!X-AOV- 7 REO 0

ARDdDB · 71·/01~ - 7 M/)lJL/)1/Vf': rL OOI-l ~ IDC

M£M8£H - FOR. MODEL Jln 1/t 11[~'~ D
AT!ACI-4 EACH /VtOUU' IN6 Will-I
C AIO'C9DB · 54 ·10182. · R~TAINC/i? I<'/OUti)fNC'
A.OOI:l SIDE MCMB£'2 - 7 Ai'CG t)
15 53037- S!J6:SCQ£N • z REGO

4. ARD2DB · 71 ·29144 ·5 MOU.DII\G OUAQTCAi'

WHE:CL OPeNING - R::>Q MODEL 710 ·1/II?COrJ
ATTKH CACH MOULDINC WITH -
A 379560-SO·s=REw-6~0

S. IIR02CB · 54 - 2445G·9 MOULDING CCr<tT/H

BODY QfLLAAi' 0/SIOC ~Ai' I'OR 710
ljl.t:?EQ"Q ATntCH EACH MO~ :LOING 11/irll
A ~79560 ·SIC>/ • SGii!I£/V -6 -'?LOb

6. A/i/DU:IIJ· 11·.29061>·1 AI/OUI.D/1;16 ASSY IUAR

QIJNIT£R Ol/76/DE 1/1 REO.URCD
(At,- 0 AL(. 71 MOCkL:::i)
A T TA ._ H £~ H M Q,_ C N 6 WIT ...
F . AAC9QB·$.. ·e$4tA4e A REWNCR AR 00011
OUTSIDE MOUD/N6 6 RCQ"O.
<> ~-~-z~ IICTNNCR ASSY t:lOCW
OiJT!>JDE. MLD6 I R£0. 0 .
V-'871~-57 /II/IT IREo.:L>

~: rs:;;~:~ lt ~o;~ ASSY IV! DOOR

.4TTACif£A ~H 1. '..,;...;.tlt 'IU. w ~ ~

F' <RC90tJ·S•·Z5+A•6 ~ RETAINER RR{X)()R

OL'T5tD£ "'t('IULDINC ..3 RfG'D
G ARC908 ·5-f • 2 /0 !:HA. R£ TIA.INCif ASSY OOCR
Our5tD£ MLDG 2 .11~Q 'D
V38T7ZS ·Sf NUT 2 R£0"0
8 A.ROCDB -~4 -COTIJ0-1 HnULCING A5SY ~N (')t"Y:;J~
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,ll ':' I .o~ ._· ,.. .4. ' H 4-1 ~-.. ' TI-l

F.A. ~-' . 908 - S4 · c ~ •A~~ ,4 RCTAtN£'k ' P DOOR

OUTS!!)£ HOULt) I !VG ..3 A£Q D
G ARC908 ~54--Z t': 94A R£rAttvF.R A~!Y ~()O,Q
OUTS/~£ .v.. .:>G 2 REG ~
V38llZS ·51 NUT e RCQD
9 AR0208 ·If.. - 8068 / 9 MOULC J\IG A5':t ~R\JN'T
FCIVIJ£k SID£ 1, ··I[ ;r 'L ~ "·. - .,,,-v)( t; '

F .AR; - 9tJ8-5 4 · 2 ~ 4A4~-A. Rc.- TAt!V£R Ff ,,., DCXJR

OUTJt[l£ ,Yr. ;.. .')J fY6 6 PEG., D
G Ah'C 9<J8 ·5 4 - 24094... RETAIIIIFD ..t! SSY f'lOOP
o u · 1r c Hl.LJG_ , ~>t.u.,
V lf47725-57 N •IT t Rra o

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ltiOtiLOtflt• · r"J..':)"'i f!NUCR
,. :'t- r . .~r 2 RCO [) ( . ,., A~- 71 ~s)
-4TTAC ,., EACH MOUL {'' '' . u 7'1 -
H Jl.5890 ~ S100 _ ,_£i~E NUT 1 q£') D

0
17-24 GROUP 17- BODY, DOORS AND WINDOWS

- B
z~ - - ,_
TYP

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IVO'Ir
I ~noo.<s A . BIC >"')ooA'C~ ,t:"f>'?
AU. Mt::IOEL.S .

FIG. 11 -Body Side Stripe

PART 17-2- FRONT SHEET METAL BUMPERS, EXTERIOR MOULDINGS 17-25

(£

Lfl@ IF? ~
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' FIG. 12- Rear End Ornamentation {Van and Wagon)

I I
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17-26 GROUP 17- BODY, DOORS AND WINDOWS

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'

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FIG. 12-A- Rear End Ornamentation (Ute and Fairlane)

nV;'-JL(-J__©S~ ®
13) -®- - - - -9XJ
PART 17-3- DOORS, WINDOWS, TAILGATE AND DECK LID 17-27

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GV;\JL_@ ® l * - ® ®
,ern- - @ -- -®
6£=~-- @ 0
( CSSJ ffl -- - - ® ®

FIG. 12-B- Rear End Ornamentation (Sedan)

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GROUP 17-BODY, DOORS AND WINDOWS

i). _ _

- --- ~

- -()

'
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SYioolo PART NO PART NAiooiE

I -16AI08/9 looiOULDING-FAONT FVIOER AIR !COOP- G.T,
2 -1&01~(6 PANEL FRONT FENDER
l .... 6E106 - 7 DEFLECTOR FAT. FENDER Alii SCOOP

" f3 7388&--.1 iol!'> NUT- r SELF THREADING

FIG_ 13- Fender Air Scoop G.T.

SEC A
PART 17-3- DOORS, WINDOWS, TAILGATE AND DECK LID 17-29

, [ 02_:':~ AT PEkiPHERY

I. ~ f ~,------ .\r~-
~. _ -1 DIMO: HEA~[J
I -16612- BA HOOD MJY
_ ~~ -16C612-AA MOULDING A.SSY.·-

LJ J.IOOD AIR SCOOP OPENING

~
{37.3888-540) NUT (12 REQD)
·16A70.J-A LATCH NOOD D(TERNAl
5£CTION CC -16A704-A8 SPRING- 1-1000
f x TC/rNAL LAT('l--1
@/17?1 536 PIN-GROOVED

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( fl

V!£W- B

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NOTE:- PIN(S) MUST BE ASSEM8LED
5YM A&:vT STEM o,:- LATCH TNRI.J
SeLECTED HOI..€ W!I!Cfl TO-
<ieTHt:R. WITH SPACER WAS#ERS
UNDER RErA!NER ASSY

),: ( l:r.JN A -A

FIG. 14- Hood Air Scoop G.T.

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2 10A892'1JCZ£l AS SY. INST Cli/STCR MA IN
A j587~S· 5 8 SCREW • 8 ·15 ~ 38 CRS . R£C l-ID. WASHeR ~ RCQ

Q lJ. V .J88U ~9- 5l Nf/T A SSY. CA GC 1"~ ·18 UNC .

C . 42758 5 36 SCI: CW(~ SHCR A SSY ¥6·/8 '
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SS!:ti~7 S ~
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KNOCKOUT AS REQD

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17-31

PART DOORS, WINDOWS, TAILGATE AND DECK LID

17-3
Section Page Section Page
I In-Car Adjustments and Repairs .. .. .. .. .. I 7-31 Front Duor Window Regulator I 7-38
Dour Alignment ...... .. I 7-31 Rear Door Glass .. .. .. .. .. .. 17-38
Lock Striker Adjustment .. .. I 7-31 Rear Door Window Regulator I 7-39
Vent Window Adjustment .. .. 17-31 Rear Quarter Window and / or Weatherstrip
Front Door Glass Adjustment 17-3 I Station Wagon .. .. .. .. .. .. .. 17-39
Rear Door Window Adjustment 17-31 Windshield .. .. .. .. .. .. .. .. .. 1740
Single Action Tailgate Hinge Adjustment 17-33 Back Window and / or Weatherstrip .. 17-41
Deck Lock Adjustment .. .. .. .. .. 17-53 Tailgate Glass . . . . . . . . . . . . .. I 7-43
Deck Lid Alignment .. .. .. .. .. .. .. .. 17-37 Tailgate Window Handle and Lock Cylinder
2 Removal and lnstalla tiun .. .. .. .. I 7-37 - Manual .. .. .. .. .. .. .. .. .. .. 17-43
Doors .. .. .. .. .. .. . . . . . . . . 17-37 Tailgate Switch and Lock Cylinder - Power .. 17-47
F runt Door Lock .. .. .. .. 17-37 Deck Lid Lock .. l 7-53
Re:n Door Lock .. .. 17-37 Power Window s .. .. .. .. 17-54
Door Lock Cylinder .. .. .. .. .. .. 17-37 R/Vision Mirror .. 17-41
Door Handle .. .. .. .. .. I 7-37 Dual Actinn Tailgates 17-48
Door Lock Remote Control Handle i 7-37 Description and Operation .. .. .. .. 17-48
Door Vent Window Frame . . . . . . . . . . .. l7-3X
Adjustments .. .. .. .. 17-48
Front Door Glass . . . . . . . . . . .. 17-38
Remova l and Installation 17-48

D IN-CAR ADJUSTMENTS AND REPAIRS

DOOR ALIGNMENT
R.P.O. VENT WINDOW ADJUST- FRONT DOOR GLASS AD-
The door hinge> provide >uflicient MENTS - JUSTMENTS-
adjthlnl.:nt to correct mo>t mi,align- The vent glass and / or the vent The door trim panel must be re-
mcnt condition\. Loosen the door window frame may be adjusted in moved to make any of the following
hmgc attaching holts and adjust the various ways. With the vent glass in- adjustments.
door '>0 that it is centered in the door stalled, the lower pivot spring ten- Fore-and-aft adjustment for snug
opening \\hen clo~ed. Then. tighten sion may he adjusted with a socket. glass tit within the runs may be made
the hinge attaching holt~. extension, and ratchet used through hy using suitable shim stock between
After adju,tment at the hmgc the access hole in the door inner the front run and the vent window
att.tchmg point~. check the align- panel. Adjust so that the glass will division bar. The front and/ or the
ment het\\t'en the door lock anJ stay open at highway speeds. The rear run may also be shimmed at the
,tnl-.:r pl.tte for prope r Joor closing. door frame mounting holes are lower attaching point(s).
no not conr up poor door adjust- elongated to provide a tight tit for
ment "ith ~trikcr plate adjustment. the vent window frame in the door Vertical adjustment is possible
LOCK STRIKER ADJUSTMENT frame. The upper pivot mounting by moving the regulator in its
holes are slotted to help provide attaching holes.
The ~.triker pin can he adju>ted
a weather-proof tit of the glass frame Lateral adjustment for smooth
laterally and vertically as well as

J
within the vent window frame. movement of the glass within the
fore and aft. The lock striker shC'•Jid lOCK STRIKER
not be adjusted to correct door s.ag. runs can he maJe by moving the

: ·~~': ~ -
The lock strika !>hould he shimmed lower attaching points of the run
I<' l!Ct the clearance 'hown in Fig. I (Fig. 2, 3 & 4).
hetween the lock striker and the . ' ': " REAR DOOR WINDOW
lock . To check this clearance. clean
the Jock jaws and the striker area. ', >'\ . 1!--
'- I
MINIMUM ADJUSTMENT-
anJ then apply a thin layer of dark '\:, ' MAXIMUM I. Remove the door trim panel
and watershield .

~·~. '
grease to the Jock striker. As the
2. To obtain proper alignment of
Joor is closed and opened. a measur-
ahlc pattern will result. Move the retainer and division har assembly-
stnkcr a~>emhly laterally to provide to-door window frame, shim the
FIG. 1-Door Lock attachment points until desired align-
a tlu-,h tit at the door and the pillar
or 4Uarter panel. Striker Adjustment ment is obtained.
17-32 GROUP 17- BODY DOORS AND WINDOWS

GLASS RETAINER REMOVAL

PUSH BUTTON IN UNTIL
PUSH RETAINER IN FIRMLY FLUSH WITH RETAINER

GLASS RETAINER INSTALLATION N2179-B

FIG. 2-Front Door Ventless Window Mechanism - Typical

PART 17-3- DOORS, WINDOWS, TAILGATE AND DECK LID 17-33
3. Install the watershield and door screwdriver. Be sure to protect the To adjust the tailgate from side to
trim panel. trim panel from scratches. side in the tailgate opening, loosen
Power windows are not available 3. Remove the panel by attaching the hinge to tailgate bolts and shift
where vent windows are fitted. two wire hooks in the upper holes the tailgate as required.
and slide the inner panel up and off
TAILGATE EMERGENCY the tailgate.
OPENING PROCEDURE 4. Remove the water shield. DECK LOCK ADJUSTMENT
If the window regulator or the 5. Disconnect the regulator arms The striker plate can be adjusted
manual regulator handle is in- from the glass lower channel. Care- laterally and \'ertically and the lock
operative, the tailgate can be opened fully lower the glass to the down can be adjusted laterally. Before ad-
using the following procedure. position and open the tailgate. justing the deck lid lock, make sure
I . Remove the tailgate interior TAILGATE HINGE ADJUSTMENT that the deck lid is properly aligned.
cover panel retaining screws. The tailgate can be adjusted fore To adjust the lock, loosen the
2. To remove the tailgate cover or aft and up or down at the hinge attaching screws, move the lock as
panel, carefully pry loose with a large to body mounting bolts. required to make good contact and

~:.- . ... ...r;. ·• ~ ~ · I . oM - .. ..... <1. (

Ill"'!' .'. IITJJ~QJo~ •Af. ICJ.r ll US'rA ~SO l'l.t.Tl'IO.
vr. • 1 • :.0:00 4 , r.tl tP • n~ •w• rc. Tl'll JXD '1U.M!

r----
-:"". r..CH.ITA~ l lllltAWTlOII I.ISr (t a-111'191'1'9·• } ~
..
~;~lfn:~:J ~O:c~ I ~~ ~ vurm~~~~

1. Glass - Front Door Window A Retainer Assy - Door Window Glass Channel
2. Weather Strip Assy - Front Door Glass at Belt Bracket
Outside with Clips B Screw & Washer Assy Torque 6-11 lbs. ft .
3. Bracket Assy- Front Door Window Glass Mounting c Screw & Washer Assy Tor que 6-11 lbs. ft .
4. Weatherstrip Assy - Front Door Glass at Belt D Screw & Washer Assy Torque 6-11 lbs. ft .
Inside with Clips E Screw Hex head Tapping
5. Run Assy- Front Door Glass F U Nut
6. Retainer Assy - Front Door Glass Run Lockside G Screw Torque 18-43 lbs·in
7. Run·Door Vent Window Division Bar Glass H Screw & Washer Assy Torque 6-11 lbs. ft.
8. Retainer Assy - Door Vent Window Division Bar J Screw & Washer Assy Torque 6-11 1bs. ft .
Glass Run R & L K Screw & Washer Assy Torque 6·11 lbs. ft.
9. Regulator Assy - Front Door Glass (Manual) L Spacer - Rear Door Window Regulator Motor
10. Window Assy - Front Door Vent Bracket
11. Bracket Assy- Front Door Window Equalizer Arm M Bracket - Rear Door Window Regulator Motor
12. Regulator Assy - Front Door Window (Power) N Nut & Washer Assy Torque 18-43 lbs·in
p Black Sealer - .25 dia applied along entire Inside
Corner and on Top of Channel & Window Assy
(item 10) before Installation of Vent Window Assy
Q Adhesive Bead .18- .25 Applied to Areas Between
FIG. 3-Front Door Vented Window Points V and Won Both Corners.
17-34 GROUP 17- BODY DOORS AND WINDOWS

1. Glass - Rear Door Drop A Retainer Assy - Door Window Glass Channel Bracket
2. Glass - Rear Door Drop B Screw
3. Glass - Rear Door Stationary C Screw & Washer Assy
4. Weatherstrip - Rear Door Stationary Window D Screw & Washer Ass y
5. Glass - Rear Door Stationary Window E Screw & Washer Assy
6. Weatherstrip - Rear Door Stationary Window F Screw & Washer Assy
7. Weatherstrip Assy- Rear Door Glass at Belt Outside G Screw & Washer Assy
with Clips H Screw & Washer Assy
8. Bracket Assy- Rear Door Window Glass Channel J Screw & Washer Assy
9. Run Assy - Rear Door Glass K Spacer - Rear Door Window Regu lator
10. Run Assy- Rear Door Glass L Bracket- Rear Door Window Regulator Motor
11. Weatherstrip Assy- Rear Door Glass at Belt Inside M Nut & Washer Assy
with Clips N Adhesive Bead - Apply both Corner s Shown X and Y
12. Run - Rear Door Glass Rear P Black Sealer - .19 Dia . around Perimeter of Stationary
13. Run - Rear Door Glass Rear Glass as Shown View B
14. Retainer & Division Bar Assy - Rear Door Glass Run
15. Retainer & Division Bar Assy- Rear Door Glass Run
16. Regulator Assy- Rear Door Window (Manual)
17. Retainer Assy - Rear Door Glass Run Front
18. Regulator Assy - Rear Door Window (Power)
FIG . 4-Rear Door Window Mechanism
z -- AREA Z -- 08 DESIGN CLEARANCE
NOTE ·
APPLrfr:.- 8 -MIC9J ·Aj LUBRICANT

I~ ,o;:::.~
AI-(A 09 '
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TO LOO< R[LEA5£ LEVER OF HANOLL
DESIGN
CL EARANCE

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1. Handle Assy - Rear Door Lock Inside

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~

II vtew£
2. Latch Assy - Door - Rear
3. Link Assy- Door Latch Remote Control
4. Link Assy - Door Lock Control Rod
-
-:-a
w
5. Rod - Rear Door Lock Push Button I

9 10 6. Knob - Door Lock Control Rod

8 G
7. Bell Crank Assy- Rear Door Lock Control
§
~
8. Handle Assy Rear Door Outside
9. Rod & Washer Assy- Rear Door Handle Actuating
10. Plate- Front Door Handle Outside Mounting
11 . Handle Assy- Rear Door Outside
"'
~

12. Pad - Door Outside Handle ~

13. Plate- Front Door Handle Outside Mounting
14. Striker Assy Door Lock
z

MODELS XA-54 ( 71 (tl) -~

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FIG. 5 Door handles and locks installation
17-36 GROUP 17- BODY, DOORS AND WINDOWS

.06
.03 ...... 2
AREA Z 7
13

H J
·H 14
II 09MIN
10 10
IS MAX.

VIEwC
9
VIEW 8 ALL MODELS VI[W D
NOTE
APPt.Y{ESB-MIC93·A} LUBRICANT
TO LOCK RELEASE LEVER OF 1-/ANOL£
ASS'Y. TT£MI2t4 AT AREAZ"IN
VIEWS A; BBEFORE IN:5TALLATION
OF HANDLE A.SS'Y
B

VIEW G
VIEW£

VIEWF

ALL MOtJt:LS

J
1. Handle Assy - Door Inside A Screw & Washer Assy
2. Latch Assy - Door Front B Clip Assy
3. Link Assy - Door Latch Remote Control C Screw
4. Handle Assy - Front Door Outside D Clip- Door Lock Rod Retaining
5. Plate & Lever Assy- Front Door Outside Handle Mounting
6. Knob- Door Lock Control F Nut & Washer Assy
7. Rod- Door Lock Push Button G Grommet Door Lock Knob
8. Ref - Door Lock Pillar H Clip Door Lock Rod Ret
9. Striker Assy - Door Lock J Shim - Rear Door Lock Striker Plate
10. Rod - Door Lock Control to Cylinder K Screw & Washer Assy Torque 10-20 lbs. ft.
11 . Lock Assy - Door L Retainer- Door Lock Cylinder
12. Rod Assy - Door Lock Actuating M Clip Door Lock Rod Retaining
13. Handle Assy Front Door Outside
14. Pad - Door Outside Handle
15. Plate - Front Door Outside Handle

FIG. 5A Door locks and handles installation

PART 17-3- DOORS, WINDOWS, TAILGATE AND DECK LID 17-37
tighten the attaching screws. Move DECK LID ALIGNMENT Slotted hinge bolt holes in the mount-
the striker plate up or down as The deck lid can be shifted fore ing bracket provide up and down
necessary to increase or decrease and aft, up and down, and from movement. Enlarged hinge mounting
the clearance between the deck lid side to side. Slotted holes in the lid bolt holes in the lid inner panel pro-
and the lower back panel. provide fore and aft movement. vide limited lateral movement.

EJ REMOVAL AND INSTALLATION

DOORS
REMOVAL
1. Remove the door hinge-to-door 2. Position the lock in the door, 1. Remove the trim panel and
attaching bolts, and remove the door. and install the retaining screws. Con- position the water shield away from
2. If a hinge is damaged, remove nect the lock control to cylinder the access holes.
the pillar attaching bolts and remove rod, the lock actuating rod, and the 2. Disconnect the lock control to
the hinge. remote control link at the lock. In- door lock cylinder rod at the lock
3. If the door is damaged, a re- stall the push button. cylinder.
placement door is furnished as a 3. Position the glass rear run in 3. Pull the door lock cylinder re-
sheet metal shell in prime paint. the door. Install the retaining bolt, tainer rearward to release the cylin-
It has no hinges, trim, glass, runs, or adjust the rear run, and tighten the der, and remove the lock cylinder
hardware. When a door is replaced, retaining bolt. from the door.
make any needed minor repairs to 4. Check the operation of the 4. Transfer the lock cylinder arm
the new shell, drill holes necessary lock. If necessary, adjust the lock to the new lock cylinder.
for mouldings, paint the door, and striker. 5. Position the lock cylinder in
transfer all usable parts. Cement the 5. Carefully position the water the door, and install the lock cylin-
weatherstrip properly. shield to the inner panel; and install der retainer (Fig. 5).
If only a door outer panel is seri- the trim panel. 6. Connect the lock control to
ously damaged, the whole door need door lock cylinder rod at the lock
not be replaced. A replacement outer REAR DOOR LOCK cylinder.
panel is available. REMOVAL 7. Carefully position the water
1. Remove the trim panel and shield to the inner panel and install
INSTALLATION position the water shield away from the trim panel.
1. If the hinge was removed, in- the access holes.
stall it to the pillar. 2. Disconnect the door lock re- DOOR HANDLE
2. Position the door to the hinges. mote control rod and door lock
Partially tighten the bolts, align the control rod at the door lock assem- 1. Remove the door trim panel,
door, and tighten the bolts securely. bly. and position the water shield away
3. Align the door glass, glass runs, 3. Remove the three screws re- from the access holes.
stops, regulator, and remote control. taining the lock assembly to the
2. Disconnect the lock actuating
4. Install the door water shield door and remove the lock assembly
rod.
and the door trim. from the door (Fig. 5). 3. Remove the handle retaining
INSTALLATION nuts and remove the handle (Fig. 5).
FRONT DOOR LOCK 4. Connect the lock actuating link
1. Position the lock assembly in
to the door handle and install the
the door, and install the retaining
REMOVAL screws. handle.
2. Connect the door lock remote 5. Carefully position the water
1. Remove the trim panel and shield to the inner panel, and install
position the water shield away from control rod and the door iock con-
trol rod at the door lock assembly. the trim panel.
the access holes.
2. Disconnect the door lock re- 3. Check the operation of the DOOR LOCK REMOTE CONTROL
mote control link, the lock actuat- lock. If necessary, adjust the lock HANDLE
ing rod and the lock control to striker.
cylinder at the lock (Fig. 5). Re- 4. Carefully position the water
move the knob from the push but- 1. Remove the remote control
shield to the inner panel, and install housing bezel by sliding the bezel
ton rod. the trim panel.
3. Remove the glass rear run towards the front of the car, then
lower retaining bolt and position DOOR LOCK CYLINDER
lifting clear of the trim pad.
the run away from the door lock. 2. Remove the window regulator
The key code is stamped on the handle (manual windows) and remove
4. Remove the lock assembly lock cylinder to assist in replacing
from the door. Remove the push the door trim panel.
lost keys.
button rod from the lock. 3. Slide the remote control hous·
When a lock cylinder is replaced, ing forward clear of its location in
both door lock cylinders and the the door inner panel, unhook the
ignition lock cylinder should be re- remote control rod and remove the
INSTALLATION placed in a set. This will avoid housing.
carrying an extra key which will fit
1. Connect the push button rod to only one lock. Reverse the preceding operations
the lock. for re-assembly.
17-38 GROUP 17- BODY, DOORS AND WINDOWS
R.P.O.
DOOR VENT WINDOW FRAME 9. Adjust the front run and 4. Remove the regulator retaining
1. Remove the door trim panel and tighten the retaining nut. bolts (Fig. 3). and remove the regu-
the watershield. 10. Lower the window so that lator through the door access hole.
2. Remove the i:mer and outer the top of th~ glass is le·1el with the
door belt line weatherstrips by prying window opening belt line. INSTALLATION
them loose from the door. 11. Install the belt line weather-
3. Remove the window lower strips.
12. Install the door watershield 1. Position the regulator inside
stop (power windows) and completely
and trim panel. the door and install the retaining
lower the door window.
bolts snugly.
4. Remove the front glass run 2. Lower the glass and connect
adjusting bolt, lock nut and washer. FRONT DOOR GLASS- the regulator.
5. Remove the front glass run 3. Check the operation of the
from the division bar retainer at REMOVAL glass, adjust it if necessary, and
the vent frame by sliding the run 1. Remove the trim panel and tighten the retaining bolts.
down and removing it from the position the water shield away from 4. Carefully position the water
door through the inner panel access the access holes. shield to the inner panel and install
hole . 2. After removing the stop, the trim panel.
6. Remove the three screws re- lower the glass until the regu-
taining the vent frame to the door lator arm roller is out of the glass
frame . Remove the vent window channel. REAR DOOR GLASS
assembly and place it on a bench . 3. Unsnap and remove the belt
7. Remove the screws retaining weatherstrips, loosen the front run REMOVAL
the upper vent pivot to the vent attaching bolt at the mounting
frame assembly. Remove the nut bracket, and remove the bracket
retaining the lower pivot bolt and attaching bolt from the inner panel.
remove the spring nylon bushings, 4. Remove the front run from
washer and stop washer. the division bar by pulling rearward l. Remove the door trim panel
8. Remove two screws from the on the edges of the run. and watershield.
top of the assembly and remove the 5. Remove the glass. 2. Remove the two screws retain-
four rivets retaining the vent frame ing the regulator roller channel
and division bar weatherstrip. Sepa- bracket to the lower window channel
rate the frame and division bar. (Fig. 4) .
9 . Using suitable tool, remove the INSTALLATION 3. Remove the lower stop as-
glass. Remove the weatherseal. sembly.
4. Remove the screw and nut re-
l. Disconnect the glass retainer taining the rear run retainer and
and remove the channel from the stationary glass. Move the run re-
glass. tainer and glass back and down in
INSTALLATION 2. Install the channel, using new the door.
retainers. 5. Remove the door belt, outside
3. Simultaneously, position the w~atherstrip .
1. Position new weatherseal to glass and run in the door, and install 6. Tilt the door window down
the vent glass. the belt weatherstrips. and then lift it out of the door.
2. Lubricate the weatherseal with 4. Position the regulator arm rol- 7. Disconnect the glass retainers
rubber lubricant and seat the glass ler in the channel. and finally posi- and remove the glass from the lower
assembly in its channel. tion the run in the division bar. channel.
3. Position the division bar to 5. Connect the run and bracket,
the vent frame . Position the vent making necessary lateral adjustment.
frame and division bar weatherstrip 6. Install the stop, making neces-
and install the four rivets and two sary adjustment. INSTALLATION
screws at the top of the frame. 7. Carefully position the water
4. Assemble the vent tension shield. the inner panel, and install
spring to the lower pivot and adjust the trim panel. I. Install the lower channel on the
the pivot spring tension so that the glass using new retainers.
window will stay open at highway 2. Position the glass and channel
speeds. FRONT DOOR WINDOW assembly in the door.
5. Position the frame assembly on REGULATOR 3. Position the rear run retainer
the door and install the three retain- and stationary glass assembly and
ing screws. REMOVAL install the retainer screw and nut.
6. Position the glass front run in 1. Remove the trim panel and p~ 4. Install the regulator roller chan-
the door and slide it into the vent sition the water shield away from the nel bracket on the window channel.
frame retainer. access holes. 5. Install the lower window stop.
7. Loosely install the front run 2. Disconnect the regulator from 6. Install the door trim water-
adjusting bolt and nut. the glass channel roller. shield and the door trim panel.
8. Raise the window halfway and 3. Raise the glass by hand and 7. Install the window outside belt
loosely in stall the lower glass stop. secure it in the raised position. weatherstrip.
PART 17-3- DOORS, WINDOWS, TAILGATE AND DECK LID 17-39

REAR DOOR WINDOW REAR QUARTER WINDOW INSTALLATION

REGULATOR AND/OR WEATHERSTRIP
REMOVAL 1. Apply a bead of sealer around
STATION WAGON the window opening flange.
1. Remove the trim panel and REMOVAL 2. Position the weatherstrip on
position the water shield away from the glass and install the outer mould-
the access holes. 1. Remove the quarter window
ing in the weatherstrip.
2. Disconnect the regulator from inside rear garnish moulding.
3. Install a draw cord in the
the glass channel roller.
2. Remove the quarter window weatherstrip, and apply rubber lubri-
3. Raise the glass by hand and cant to the weatherstrip surfaces
secure it in a raised position. outside front moulding (Fig. 6).
that will contact the window opening
4. Remove the regulator retaining flange.
screws and remove the regulator 3. Working from inside the car,
through the door access hole. loosen the weatherstrip from the 4. Position the window assembly
window opening flange, and push to the window O;Jening and use the
INSTALLATION the window, weatherstrip and draw cord to pull the weatherstrip
1. Position the regulator inside moulding assembly out of the open- over the window opening flange.
the door and install the retaining ing. S. Using a caulking gun, apply
screws snugly. sealer between the outside of the
2. Lower the glass and connect glass and the weatherstrip.
the regulator. 4. Remove the moulding and 6. Install the outside front mould-
3. Check. the operation of the weatherstrip from the glass. ing retaining screws (Fig. 6).
glass, adjust it if necessary, and
7. Install the inside quarter window
tighten the retaining bolts. 5. Using solvent, remove all old gear garnish mouldings.
4. Carefully position the water sealer from the window opening
shield to the inner panel and install flange, the window and the weather- 8. Check for water leaks, then clean
the trim panel. strip. the glass and mouldings.

c
/
/

VlEW-A VIEW-B VlEW -C I VtE W-0

FIG. 6-Stationary Rear Quarter Window - Wagon

17-40 GROUP 17- BODY, DOORS AND WINDOWS
WINDSHIELD REPLACEMENT remove the outside top moulding. tape seal away from the body pinch
PROCEDUKE weld ftange by grasping the seal near
Before removal of the windshield 4. Remove the outside side mould- the flange and pulling directly away.
glass, carefully examine the mould- ing retaining screws and remove the If the glass is not broken it can be
ings, interior and exterior, to locate outside side moulding. removed by using a piece of small
any areas of moulding interference 5. Remove the outside lower diameter piano wire to cut the butyl.
with the glass which will require re- moulding retainer retaining screws. The piano wire is threaded through
work prior to re-installation to pre- Remove the outside lower moulding the butyl tape leaving about ten
vent recurrent windshield breakage. and retainers. inches of wire on either side of the
Prior to removing the windshield 6. Remove the sun visor and glass. Each end of the wire is
proceed as follows: bracket assemblies. wrapped around small wood dowels
7. Remove the interior garnish to permit the operator to firmly grasp
1. Remove the wiper arm and mouldings.
blade assemblies. the wire and with a sawing motion
2. Remove the cowl top ventilator cut the butyl.
grille panel retaining screws and re- 2. Remove the window from the
move the cowl top ventilator grille Removal (Fig. 7): body opening.
panel. CAUTION: Care must be .used
3. Unsnap the upper moulding 1. If the glass has been broken, to prevent cutting the rubber tip on
retainers using the special tool and remove loose glass fragments. Be- existing retainers or lower glass
ginning at the comer, peel the butyl supports.
RETA I~R ·Iii IUQ 'D £tTHLR Sl« ()." WINDSHIILD OP£N1Ne . O'Otl'iti . - - DIN£NSIONS !'DR IJI/T>'L "It> GLASS
CONYACT Alfl' SIIOWN IN VICWJ '.
At1H£R ~ ~PPt.ICD TO BODY 4 '¥1- ON IJNDERSID£ or GI.A5.S
IIOTC ' GLA3S NIJST /J£ C£N17:/KD IN IW""'-D
.SliRI74C£ AROUNO £ NTtlt£ PUUNCT£Jt O' ASSY. 1'011 APPI.CATION NVST IJ£ IJNirof(lf WITH
WIND$H~tD OI'Eit~ . OAr- ~UCN 1'11AT TN£ 01rrrc..a - l A
NO SI(IPS ~CR/IfiSSI6LE.
SIDE ItA~ 1$ 11t1T GRCA"IW"~ "!"NAN ·"'0
ALLOW 20 SECONDS NINIJWH DltYINO Tll't£ At~ ALOM> £1mRC "A' PILJ.Aif .
3 ) SEAL A$5Y • Wl/rrOSHIClO GlASS ,
APPI.IED 10 - ENS/016 SilO- IN VI£WS"8 : o 4 G
TO INSTAlLATION 0' GLASS A$SY·

£-
~ !II'MC£R ASSY. · WINDSHieLD
AROUND ENTIRE PERI!tf£T£R OF WIN(JS/1/CLD !f. GI.ASS ASSY·IOIIOD~ IOLASS LOWCR · I "1"00 · ATTACH CACH -4SsY Wmt
Ol'rNtNG AI"TCR INSTAl lATION 0" R£Ti'. IN£/i. l"r£/11 I GLASS ASSY·-c>SH~C) A. SCIIUI flllt · 51 Z Rl.f:IIJIIIO>
SEAL ASSY. HIJST ~£ C 1./T ON ANGCC A !5 .SNOWir IN VIEW ..)t.Cf.AIW: BY PfM5S/IIG IN PI.ACC 10MSUW A COHI'I.C'f'E
'1-1' AND £~ Ht.IST 6UTT , A Pf'ROX. AT CINTfR 0' SIAL AlfO<.NIJ PrRIIWTE"f OF" WJNDSJ«r.D 7 :ZAL£1?(8LACif) ·ALL YEHICUS · ltllll
MAD Al'lf.l£0 M7Wr£N ~ A.JSY, 11'CN J ,AND IIOD'I
' ALL AIIOVND AFT£/f IISTALLAT10N 01' &ASS ASSY.
ITCN S .S£C VICW t-:

15 ~ -~LDCIASI« 701"
' ":JI.Jt.DIIiriG ASSY -
WINDSHIELD ourstD£ SID£ .
10. WHCN A 'MHOSHIELD ..,.AtS 1l) l'f£E T "DfE
0\li!ltLAP -£/'1£~ .
I. Pfii/IIE EDGE CY ,GLA$$ A/liD NINIItfUN 040 ,
0111'51/IE SIIIFN:E AT AR£"' OF PDM OVIlRL.AP .
Z. ALLO/tlf 10 ·S«<NDS NININIM DlfY TIN£
.5 AI¥'LY RCIWR /MJIYL ST101P AS S - N IN
VICW .!J:
II.· 1101./LDIHG WINOSHI£LD
OUTSIO~ TOP COI#NIIf 1Jt lf~'D .
SECURE £ACH NOI.IlDING • ._ CLI-NG Ollif
SID£ ANO T'OP ltiOULDINGS .
IZ ltiOULDI"i(J WINDSHICLD
OUTS« BCLT ' I' "flO 'D .
SECUIIC LACN I«JUU.DIN(; W!Tit THC 'Ott.OW.tiiG ITEIII$
Z ,lf£TA1HIIf. WIND$Nin0 .EL T
NOIJL~ • 7 RCQ"D .
Y ~CREW - 7 R£Q 'Q .
13 SAACER WINDSNICLD
OUTSIJ¥_ ULT HOULDtNG - ~ ltlQ 'D

PRErERR£0
CVT. .......,~,..,.._

DPT'ION.IU.
CUT.

FIG. 7- -15 WI()TH riSI/Jl£ ~

'
CONTACT ( TYPICAL ) . / " ,
NOTC: · tltR£GUI.AIItriCS
Windshield 0' l l.NIN. WfD'r/1 AlfL
ACCEPTA6L£ NIOYIDING
T~L'r DO NOT EW:ECD
Installation THE I'CIUOWIMI . -
i 'NAX lENG"nt lAC/If
ONC(I} PCR IS" SCG/fENT
TrN (I O)'rOTAL Eln'!IIC
P£/fi JiwCJ!f.Y.
PART 17-3- DOORS, WINDOWS, TAILGATE AND DECK LID 17-41

3. Remove and retain the lower 7. Cement spacers to pinch flange least ss•F to insure satisfactory
rubber glass supports from the with rubber cement as shown in curing of the sealer.
windshield. Fig. 8.
8. Temporarily position replace-
4. Clean body flanges thoroughly Subsequent replacements of glass
ment glass in opening and adjust
by removing all butyl tape and if can be made in the following man-
to the best glass to body pinch
vinyl top model, removt! any excess ner:
weld overlap position. Mark this
vinyl top cement in the sealing
location with crayon. Remove the
area. If the glass has previously When a windshield glass is re·
glass and clean the glass thorough-
teen replaced using a different moved which had previously been
ly.
sealer, the old adhesive must be installed with the same type of
completely removed from the pinch 9. Apply the primer, furnished in sealer, it is not necessary to remove
weld flange. the kit, to the entire pinch flange' all of the sealer from the body
and around the entire perimeter of glass opening. The remaining film
5. Examine the glass opening
the underside and edge of the g·lass of sealer on the body flange can
pinch weld flange and rework if
that will contact the sealer. (Refer be used as a base for the new ap-
ree>uired to eliminate high-low
to Fig. 8). plication of sealer.
areas on flange. Paint repair as
required .
10. Place cartridge in caulking
IMPORTANT: If any doubt ex-
gun and pump out a 5/16" diameter
ists as to whether the old sealer
INSTALLATION bead along the sealing surface of
is of the same type as the new
the glass opening.
sealer, then remove all of the old
If a new windscreen is being fitted,
attach the bracket rear view mirror to the sealer and prime the pinchweld
windscreen in the position shown in Fig. 11. Place glass in position using flange.
22 . Using Arildite or similar adhesive, the crayon mark on the glass to
apply masking tape over the bracket to locate the glass in the body open·
ensure the bracket does not move during
in g.
windscreen installation and adhesive curing
time.
~OTE: The side windows should

1. Based on the initial moulding be opened and left open for at

and glass examinations, rework ex- least one half hour after repair so BACK WINDOW
terior and j or interior mouldings to the new glass is not forced out of
position if the doors are slammed AND/OR WEATHERSTRIP
eliminate any points of moulding
interference with the glass. shut.

REMOVAL
2. Procure a windscreen replace- 12. Clean excess sealer from the
ment kit. glass with a razor blade and wipe
off with a clean cloth dampened l. From in3ide the car, hosen the
with a glass cleaner. weatherstrip edges and then push
3. Check all moulding retainers
out the back window and weather-
and replace or repair them to in·
strip as an assembly .
sure adequate moulding retention 13. Visually inspect appearance
and glass positioning. of sealer through the glass. Dull
spots indicate areas where sealer 2. Place the window assembly on a
bench and remove the mouldings and
is not contacting the glass sur-
4. On vinyl top Model: Apply weatherstrip from the glass.
face. Repair these areas by apply-
masking tape or other protective
material over vinyl roof cover in ing additional sealer.
INSTALLATION - (Fig . 9).
area of the glass opening to aid
in clean-up operations after the 14. Allow the sealer to cure be- 1. Clean the glass, weathentrip
glass installation. fore reinstalling any mouldings to and the body opening flange.
avoid cementing the mouldings to
5. Reinstall the lower supports the sealer, then reinstall the mould-
2. Using a sealer gum, apply
(removed in Step 4 of removal pro- ings.
sealer in the weatherstrip glass
cedure). opening.
NOTE: Cure time is seven hours
6. Fabricate four rubber spacers in temperatures over 70•F. The 3. Position the weatherstrip on
c" x f' x I" from mechanical temperature of the area where this the glass, and then install the
rubber. work is performed should be at mouldings in the weatherstr:p.
17-42 GROUP 17- BODY, DOORS AND WINDOWS

RU68ER SPACER
(FOUR RECUIRED)

REFER VIEW '8' FOR

PRIMER APPLICATION

VIEW 'A'

APPLY PRIMER TO UNDERSIDE

AND E OGE OF GLASS AND TO
METAL SURFACE - - - -

FIG. &-Windshield Replacement

PART 17-3- DOORS, WINDOWS, TAILGATE AND DECK LID 17-43

S EC A

SEC 8

CIR CLe(.

FIG. 9- Back Window Installation---- Utility

4. Insert the draw cord in the 3. Remove the regulator arms 1. Remove the taiigate trim
weatherstrip, and apply rubber lub- from the window regulator channel J:anel and watershield and align
ricant to the weatherstrip surfaces and remove the window assembly. a ccess holes in regulator asemblsy
that will contact the back window with those in tailgate inner panel.
opening flange. INSTALLATION
2. Unscrew the two nut and
5. Using a sealer gun, apply a 1. With a glass remover tool, r e-
washer assemblies fastening the
bead of sealer completely around move the glass lower retainer and
window handle assembly to the tail-
the back window openin!; . channel assembly and then clean
gate and remove the handle assem-
the glass groove.
6. Position the window assembly bly, the regulator stem socket, the
in the body opening . With a helper 2. Position the weatherstrip into spring and the rubber pad.
applying hand pressure from the the glass lower channel. Install the
outside, use the draw cord to pull weatherstrip and channel to the 3. To remove the lock cylinder,
the lips of the weatherstrip over g-lass. turn the key in the cylinder to align
the window opening flanges . the cylinder locking pin with the
3. Position the window assembly access hole in the handle assembly.
7. Clean the window and mouldings. in the gate and install the regula- Depress the locking pin and remove
tor arms to the regulator channel. the lock cylinder.
TAILGATE GLASS Lower the window into the tailgate.
REMOVAL 4. Install the tailgate watershield
INSTALLATION
1. Open the tailgate and remove and trim panel.
the trim panel and watershield.
I. To replace the Jock cylinder,
TAILGATE WINDOW HANDLE
2. On power operated models, transfer the 0 ring, and then with
turn the right hand side lock pivot AND LOCK CYLINDER-MANUAL the key in the cylinder, install the
to the closed position and raise lock cylinder in the handle assem-
REMOVAL bly.
the window partially out of the
gate. On manually operated models 2. Relocate the parts removed
wind the window partially out using Refer to Fig. 12 for views of th e and replace the two nut and washer
the handle. assembly. assemblies and tighten securely.
17-44 GROUP 17- BODY, DOORS AND WINDOWS

S ECTf()N- AA

MODElS 44 6, C . 0, £, G, H

SECTION- 66

SCCTION· CC

~--_:::::::; -

~-~
FIG. 9A Back window installation - Sedan
-MOlllL ~1 A

84CJI' WINDOW AND EXTERIOR MOl/WINGS rOR AlL 54 MODELS

(!) !!>lACK SEALER APPUef) AKOUNO lNTtJ.t

->£TAll /IF ._ ffl r l £ f'
h .. !-': METER OF !JACK WINDOW :JPENING.

@ WEATHER STRIP AS5Y. BACK WINDOW

nmJJ ON ALL .54 MODELS EXCEPT "<fA

GlASS !JACI( WINDOW

@) MO:Jl O ING bACJt' WINI>OW OiJfj/lJE U~PlR

R£QU/4t.O FVRAll :~4 MCJ{)EL~ EXCtPT 5-/ -1 ATTACH TO W/STRIP A~" SHOWN

(3:) MOUlDING BACK WINDOW OUTS![)£ lOWEk

lfEQIJ/{(1[) fOR AlL .54 MObllS EXCEI'T 44A ATrACH TO W(STRIP AS 5HOWN

@ WfATNERSTIIIP ASSY lw:l< WIN{)()IV IIE~D fOil 44A ONLY

(Z) MOULD/NV BACK W!Nl>OW OUTSIDE LOWE!? I(EQ'D

S"'f ;II MODE£. ONlY

NOTE: ArTEA APPliCATION o,- lJIArK .'i/A/li?-I.XOSS !>lt4llR

lrll/ST M W!Pl. "[) ("[ EAN FROM £- LASS A.~·.r.y, Kl A Till~ StRIP ASSY
M0l/LDING5 A/IV All /JODY S'./RFA(L:::,
PART 17-3- DOORS, WINDOWS, TAILGATE AND DECK LID 17-45

II 1/

~ ~li
' '~
TYPICAL 2 P LACES
EACH SlDE
VIEW-F
L~
I VIEW-H

FIG. 10 Tailgate weatherstrip installation

1. Moulding Assy- Back Window Outside Side A . Screw

2. Weatherstrip & Assy - T /gate B. Screw
3. Moulding - Back Window Outside Upper C. Nut & Washer Assy
4. Run Assy- Back Window Glass Top D . Screw
5. Retainer Assy - Back Window Glass Ru n
6. Retainer - Back Window Moulding O utside - Upper
7. Sealer - Gray or Black . 19 Dia . 10 Pl aces Vi ew " 8 "
8. Alternate Sealer - Pressu re Sensitive o n o ne Wide Side On ly.
Applied Entire Length of Retainer - Item 5
See View A. C, D & H .
10. Adhesive Sealer - . 19 D ia. Bead as Shown Each Side V iew " C & H "
1 1. Black Tape 1.00 x 6.00 Long - Each Side of Car o n We ld F lan ge
12. Sealer- Black .25 Dia . to fill Space Betwe en Fl ange and Mo uld ing -
Back WindoliV Cu tside Upper- View "A"
13. Adhesive- Applied Between Items 4 and 2 afte r Posit io ning
17-46 GROUP 17- BODY, DOORS AND WINDOWS

FIG. 11 Single action tailgate l')inges and locks

1. Striker- T/gate Upper RH A. Screw- Torque 17-27 lbs ft.

2. Stop - T /gate Check Cable Spring B. Shim
3. Bushing- T /gate Counter Balance Torsion Bar C. Sealer- Gray or Black, .19 Dia. 15 places
4. Bracket - T /gate Counter Balance Torsion Bar on Body D. Nut & Washer Assy- Torque 25-38 lbs ft.
5. Retainer- T/gate C/balance Torsion Bar on Body E. Bolt Truss Head
6. Cable Assy- Tailgate Check F. Washer FIat
7. Spring- T /gate Check Cable R H G. Screw & Washer Assy- Torque 25-38 lbs ft.
8. Hinge Assy - T /gate R H H. Shim
9. Striker Assy- T /gate Upper Latch LH J. Nut & Washer Assy- Torque 25-38 lbs ft.
10. Hinge Assy T/gate LH K.Shim
11. Spring T /gate Check Cable LH L. Screw- Torque 17-27 lbs ft.
12. Cable Assy - T /gate Check M. Screw & Washer- Torque 25-38 lbs ft.
S. Washer FIat
PART 17-3- DOORS, WINDOWS, TAILGATE AND DECK LID 17--47

on the lock cylinder and install the

spring clip.
3. The window may now be wounc;l
to the open (in) position.
4. Return the catch pawl on the
right-hand side lock assembly to
the open position.
5. Install the tailgate cover panel
and replace the retaining screws.
/l SOCKET RETAINING
SP~IHG

PIEGULATOR HANDL!
AS5£M&LY
/

PAD

FIG. 12-Tailgate Handle and Lock Cylinder

3. Replace the watershield and
trim panel.

TAILGATE SWITCH AND LOCK

CYLINDER - POWER

REMOVAL
Refer to Fig. 13 for views of the
assembly.
1. Wind down the window and
open the tailgate.
2. Remove the tailgate cover panel
retaining screws and remove the
panel.
3. Rotate the catch pawl on the
right-hand side lock assembly to
the closed position. The tailgate
window may now be wound to the
closed (out) position. The glass
must be supported while in this
position. CYLI~DE R
4. Detach the spring clip and re- RETAI~ER

move the switch assembly from the

lock cylinder.
5. The clip retaining the lock
cylinder may now be removed en-
abling the lock cylinder to be with-
drawn.
INSTALLATION

1. Insert the lock cylinder in the

tailgate outer panel and install the
retaining clip. FIG. 13-Tailgate Lock
2. Replace the switch assembly Cylinder (Power)
17-48 GROUP 17- BODY DOORS AND WINDOWS

FIG. 14-Deck Lid Torsion Bar

DUAL ACTION TAILGATES
DESCRIPTION AND OPERATION vided for the dual action tailgate, no the pillar backed by floating tapping
Dual action tailgates are available unique methods are employed. The plates. Lateral adjustment is accom-
with manual or power rear window following information will assist in plished by adding or removing shims
operation. The Dual action tailgate locating and performing tailgate ad- (Fig. 5).
can be opened in the normal manner justments to obtain the clearances
(same as single action) or it can be shown in Fig. 17. REMOVAL AND
swung from left to right. The fore and aft and up and down
The ·right side hinges are designed adjustment of the tailgate is accom- INSTALLATION
to accommodate both vertical and plished at the hinge side by means of
horizontal opening. square holes in the body pillar, backed
by floating tapping plates, at the TAILGATE ASSEMBLY
To open the gate vertically , wind
the window down, lift the lock-bar upper and lower hinge attachments REMOVAL
and lower the tailgate. (Figs. 16 - 17). l. Lower the tailgate vertically.
To open the tailgate horizontally, Lateral adjustment of the tailgate 2. Remove the right hand cover
lower the window, turn the outside is accomplished at the upper hinge by hinge outer bolts to body.
handle and swing the tailgate to the adding or removing spacer shims be- 3. Close the tailgate and swing it
right. tween the hinge on the body and the open horizon tally.
If the tailgate has been opened pillar. Lateral adjustment at the lower 4. Disconnect the power window
horizontally, and vertical opening is hinge is accomplished by means of wiring (if fitted).
desired, the tailgate must be closed oversize holes in the tailgate at the 5. Support the tailgate and remove
before vertical release is possible and hinge on the gate attachment (Figs. the remaining right hand hinge to
vice-versa. 16- 17). body bolts and vertical opening
Fore and aft and up and down ad- support cable.
ADJUSTMENTS justment of the strikers is accom- 6. Remove the tailgate from the
While full adjustments are pro- plished by means of square holes in vehicle.
PART 17-3- DOORS, WINDOWS, TAILGATE AND DECK LID 17-49

FIG. 15- Dual Tailgate Lock & Handle Installation

JIOTE: APPLY (ESB-MlC93· A) UIBRICHfl' '1'0 Eln'IR! ~ACE <7

IT!)( lO, '1'0 A~&IR E PIIOPER I liST; ~TION OP' !lA !rOLE
ASSY. Il'EII 13. THE IJR.I..IN5 I~ ''L'' , IllS'!' 8!: Ill
'1'1!:: 000'11 POSITION 1-Im MEDALLIOII ON IIA!rDLE MUST !IIi
UPRIGII'I WIIEJI wlNDOo I 5 Ill CLO:i£0 ?OSITIOII. ~KE'I',
IT!:M 10, MUST BE IIISTALLED JI'l'll ii!l:t1', ITEM '' H" Ill
IJF P031TION A3 !IIOW!f Ill • PA'JI. I'l'!)l "M" Ill IIA!rDLE
,:;;;," '!., I'l'EM 13.

1. Regulator Assy - Back Window 15. Lock Set (Power)

2. Glass & Channel Assy- Back Window 16. Retainer- Door Lock Cylinder
3. Run & Retainer Assy- Back Window Glass Lower Side LH 17. Switch Assy- Window Regulator Control
4. Bracket Assy - Back Window Regulator 18. Retainer- Window Regulator Switch
5. Bumper - Back Window Stop 19. Sealer .25 Dia. Bead
6. Run & Retainer Assy- Back Window Glass Lower Side RH
7. Handle & Housing Assy- T /gate A Screw & Washer Assy - Torque 8-13 lbs. ft.
8. Pad T /gate Outside Handle B Screw
9. Bracket - T /gate Outside Handle C Screw & Washer Assy - Tor que 8-13 lbs. ft.
10. Socket- Back Window Regulator Stem D Nut & Washer Assy - Torque 8-13 lbs. ft.
11 . Pad - Back Window Regulator Socket Retaining E Screw & Washer Assy - Torque 8-13 lbs. ft.
12. Pad - Back Window Regulator Handle F Nut & Washer Assy - Torque 6-11 lbs. ft.
13. Handle Assy- Back Window Regulator G Nut & Washer Assy -Torque 13-32 lbs. ft.
14. Lock Set K Seal- "0" Ring
17-50 GROUP 17- BODY, DOORS AND WINDOWS

FIG. 16- Dual Tailgate Hinges

1. Hinge Assy- Tailgate Upper on Body C Sealer Grey or Black .19 Dia. or Bulk 14 Places
2. Bushing -Tailgate Counter Balance Torsion Bar on Body D Nut & Washer Assy- Torque 25-38 lbs. ft.
3. Bracket T/gate C/balance Torsion Bar on Body E. Bolt-washer Head Shoulder -Torque 17-27 lbs. ft.
4. Retainer T/gate C/balance Torsion Bar on Body F Washer - Flat
5. Cable Assy - T /gate Check G Bolt Truss Head -Torque 17-27 lbs. ft .
6. Hinge Assy - T /gate Lower R H H Spring - T /gate Check Cable R H
7. Striker Assy- T/gate Upper Latch LH J Screw & Washer Assy- Torque 25-38 lbs. ft.
8. Striker Assy - T /gate Lower Lock K Nut & Washer Assy -Torque 25-38 lbs. ft .
9. Shim L Shim
M Screw - Tor que 17-27 lbs. ft.
A Screw & Washer Assy- Torque 25-38 lbs. ft. N Screw- Torque 17-27 lbs. ft.
B Spacer T/gate Upper Hinge on Body P Shim
PART 17-3- DOORS, WINDOWS, TAILGATE AND DECK LID 17-51

AnrtJ9J'MEJI1' ~ IATCI COift'AOL AKD JWIDL£ SY$ ':)t

~ AAJUm., U:.: A.aGLJ, WITH CO!ri'ROL AS311eLI, I'l'DI 9 1 LOOSE, ftE
U'l'CR Assr.LY, nDI 11. KJS!' BE IW 'fBI lA'JICII!l) HAIDLl ASSDCBLT, IT!Jf 3, A.IID UlfK AsaDG:lUIS,
POSJTlOI AID W! t'All.OA~ U'l"C'R OPDU.TIIm IZYD , I'l'EMS 2 .&IC> .. , M! 183T.nLED. LA'rCH. TKE LA'ICH
PAift ~ LA.'l'Cll ~L!, lTDI S, '«191 U I..GAIIIS!' 1-s.:natLT, I~"'! S· str B.UDU: A.iSE)(BJ.Y, JTDI
ftl SI'OP ta 'ftiB lMAC'ftiATED POsmOS, R2 11'111 3, · r:;.'IIf3T ft'J38Dt SI'OPj, I'l'Dt .. Z". SE:I VI~
•M" II r10Uitl 1, LlJ8C ASSDGLY, IT'Dl 16, JIIAJ "C" . .:i!'I GS U?r~ U'll£ LEVER A6 SHOW. VIEW
Kill • lWIJl'.aWD M.\liTA.llfl~ TilE A.1JOVS CC*DI· "D", ROl'AT! COIRROL ASSDOLT TO REMOVE ~CK
TICIIS. '10 Carlt ADJ\Jrmal' ~:CT!~ CCJWmOL ASSICBLY A'M'ACHJNC PAin'S,

K7ft 1. UPPDt LA'rCII lTDC S Nl131' !101' LA'l'CII

WD'R I.CIWllt LA'l'CII 1'1'111 17 IS II OPEl
POtm'lOif.
lOrE ~. ELICTRIC \llJXN Jti:CJJLA~ 11119'1' .aT
OPERATE WREI U'PP'ER Lo\'ICB I'l'Dt ~ I8
II 01'!1 PO$JTIC'

~~
'e
lOft: ALL .:rrl.,PAM'S, PIYO'I' POlin'S, OUIIZS
AID LA'lal ASSDGILIES 'nlAT RAVE 1101'
BED W.ICAT!D AT .!IXR:E ,_,91' IE
waiCAftD ~E ASSDIBLT WITI (ESB-
IUC93·A) <II AJPTDIWIJIDS 1111'1 ( ESII-
IUClo6) WliiiCAifl'.

/8 APPLT (•S8-MlC9)·A) WliiiCAIT A'l!

AltUS "W"', •x" • " Y".

FIG. 17-Dual Tailgate Lock Mechanism

1. Hinge Assy -Tailgate Upper on Body 10. Torsion Bar Assy
2. Rod - Door Lock Control LH 11. Valve- T/gate Drain
3. Rod - Door Lock to Handle 12. Hinge Assy- Lower RH on Body
4. Rod- Door Lock Control RH 13. Hinge Assy- Lower RH on T/gate
5. Lock - Assy Upper LH 14. Bracket - T /gate Torsion Bar Link
6. Bushing- Torsion Bar 15. Rod- T/gate Safety Release
7. Cover-T/gate Access Hole 16. Rod- Lower Left Lock
8. Retainer- Torsion Bar 17. Lock Assy- Lower LH
9. Control Assy - Door Lock 18. Grommet- T/gate Handle Rod
17-52 GROUP 17- BODY, DOORS AND WINDOWS

DUAL-ACTION TAILGATE POWER shield and access panel. DUAL-ACTION TAILGATE

WINDOW SWITCH AND MANUAL 2. Engage the upper latch pawl to VERTICAL LATCH RELEASE
CONTROL HANDLE the closed position and raise the CONTROL
Removal and installation pro- window partially out of the gate.
Removal
cedures for manual and power window Remove the regulator arms from
the window regulator channel and 1. Remove the interior trim panel
control handle and switch are the
remove the window assembly. from the tailgate.
same as for single action tailgates.
3. Disconnect the linkage at the 2. Raise the glass part way out of
See Page 17-43
upper latch. Remove the wire connec- the tailgate.
tor from the upper latch safety switch. 3. Disconnect the three links
DUAL-ACTION TAILGATE
4. Remove the right guide upper (rods) from the latch release control
HINGES-
retainer bolt. Remove the three (Fig. 17).
Upper Right Hinge screws, retaining the latch and remove 4. Remove three latch release con-
1. Open the tailgate (horizontally, the latch assembly. trol attaching screws, and remove the
as a dropgate) and scribe a location 5. Transfer the linkage retainer control from the tailgate.
mark around that part of hinge to be clips and the safety switch to the new
Installation
replaced. latch assembly.
2. Remove the hinge retainer 6. Position the latch in the gate 1. Position the latch release con-
screws. and install the latch retainer screws. trol to the tailgate and install the
3. Position the hinge to the scribe Install the window guide upper re- three attaching screws snug.
marks and install the retainer screws. tainer bolt. 2. Connect the three links (rods)
7. Connect the wire connector to to the latch release control.
lower Right Hinge 3. Lower the glass and adjust the
the switch and connect the linkage
1. Open the tailgate (horizontally, to the Ia tch. latch release control.
as a dropgate) and position a support 8. Position the window assembly 4. Install the trim panel on the
under the hinge side of the gate. in the gate and install the regulator tailgate.
2. Remove the torsion bar link. arms to the regulator channel. Close
3. Scribe the hinge location on latch pawl to engage the switch and DUAL-ACTION TAILGATE .
the body and the tailgate. Remove lower the window into the tailgate. HORIZONTAL LA TCK RELEASE
the hinge retainer screws and remove 9. Install the tailgate access panel, (OUTSIDE) HANDLE -
the hinge. watershield, and trim panel. Open the Removal
4. Position the hinge to the body upper latch and close the tailgate.
and tailgate scribe marks and install Check the latch alignment to the 1. Remove the interior trim panel
the hinge retainer screws. striker. Adjust the latch striker if and access cover from the tailgate.
5. Close the tailgate and check necessary. 2. Remove the glass and channel
for proper lower hinge alignment. assembly from the tailgate.
TORSION BAR 3. Remove two nuts retaining the
Adjust the hinge if necessary.
6. Reconnect the torsion bar link . 1. Lower the tailgate vertically handle to the tailgate. Remove the
and remove the torsion bar link and handle bracket and handle from the
DUAL-ACTION TAILGATE the torsion bar to tailgate brackets tailgate
LATCHES- and bolts along the tailgate lower edge. 4. Remove the lock cylinder from
NOTE : The torsion bar will be under the handle.
left lower latch light tension at this stage.
1. Open the tailgate (side opening). 2. Remove the torsion bar from Installation
Remove the tailgate trim panel, water- the vehicle. 1. Install the lock cylinder in the
shield and access panel. DUAL-ACTION TAILGATE outside handle.
2. Disconnect the linkage from VERTICAL LATCH RELEASE 2. Position the outside handle and
the latch. Remove the three retaining HANDLE- handle bracket to the tailgate and in-
screws and remove the latch. stall the two retaining nuts (Fig. IS.).
3. Transfer the linkage retainer 1. Remove the rod retainer from
3. Install the glass and channel
clips to the new latch. Position the the rod at the latch release handle.
assembly.
latch in the gate and install the re- 2. Remove two screws attaching
4. Install the access cover and the
tainer screws. the latch release handle to the tailgate.
trim panel on the tailgate.
4. Install the linkage to the latch. Disengage the handle from the rod
Install the access cover, watershield and remove the handle.
3. Position the latch release handle TAILGATE WINDOW REGULATOR
and trim panel.
to the tailgate and rod, and install the The procedure for removal of the
left Upper latch two attaching screws. Dual action tailgate glass and regulator
1. Open the tailgate (side opening). 4. Install the rod retainer at the assembly is the same as for single
Remove the tailgate trim panel, water- release handle. action tailgates. See Page 17-43
PART 17-3- DOORS, WINDOWS, TAILGATE AND DECK LID 17-53

DECK LID HINGE OR and from inside the luggage compart- farther rearward the anchor end is
TORSION BAR ment remove the bar. twisted, the greater the tension.
4. Position a cover under the hinge 3. Remove the prop and check
REMOVAL edge of the deck lid to prevent the lid position. After any necessary
paint damage. Remove the hinge adjustment, tighten the hinge attach-
attaching bolt from the deck lid and ing bolts.
1. Prop the deck lid open. from the mounting bracket, and DECK LID LOCK
2. Mark the hinge position on the remove the hinge.
lid and on the mounting bracket for INSTALLATION 1. Unlock and open the deck lid.
reference when a new hinge is in- 1. Position the hinge, and partially 2. Remove the bolts retaining the
stalled. tighten the mounting bolts. lock assembly and remove the lock.
3. Pry the anchor end of the 2. Remove the protective cover 3. Position the lock assembly t<'
torsion bar out of its adjustment and install the torsion bar, reversing the deck lid and loosely install the
notch (Fig. 14). Lower the deck lid the procedure in step 3 above. The retaining bolts.
4. Adjust the lock assembly and
tighten the bolts.
DECK LID LOCK CYLINDER
REMOVAL
1. Open the deck lid and remove
the lock assembly and the door lock
extension.
2. Remove the sleeve assembly re-
taining nut, lock washer, spacer, and
sleeve and cylinder (Fig. 18)
3. To remove the lock cylinder
from the sleeve assembly, turn the
key in the cylinder Vs turn clockwise
from the locked position, depress the
cylinder retaining pin, and remove
the key and cylinder.
INSTALLATION
1. To install the lock cylinder
and insert the cylinder into the
sleeve assembly.
1. Position the sleeve assembly
turn the key in the cylinder Vs turn
clockwise from the locked position
spacer, and washer to the deck lid
door and install the retaining nut:
3. Position the door lock exten-
sion, install the lock assembly and
adjust it.

FIG. 18-Deck Lid Lock Installation

1.Weatherstrip - Luggage Compt. Door

2.Latch Assy - Luggage Compt. Door
3.Retainer - Luggage Compartment Door Lock Cylinder
4.Pad- Luggage Compartment Door Lock Cylinder
5.Extension- Luggage Compartment Door Lock Cylinder
6.Lock Set
1.Striker- Luggage Compartment Door Lock
A Adhesive -Apply a .25 Max. Bead to Bottom of Weatherstrip Trough
B Adhesive -Apply a .093 approx. Bead Under Outboard Lip of Luggage
Compartment Weatherstrip After Installation of Weatherstrip in Trough.
Application of Adhesive Must Extend Downward on Vertical Surface
as Shown in View "A"
C Screw & Washer Assy
D Screw & Washer Assy
17-54 GROUP 17- BODY, DOORS AND WINDOWS
POWER WINDOWS individual door switches.
trolled from the master switch panel Wiring schematics for power win·
DESCRIPTION in the driver's door. dows are in Group 22, Fig. 2 of
Each door window is controlled Included in the master switch this manual.
by a separate switch set into the door panel is a "lock out" switch which
trim panel. The rear and front prevents operation of the rear and Wiring and switch installation is
passenger windows can also be con- front passenger windows by the as shown in Fig. 20 • 21 of this part.

D DIAGNOSIS AND TESTING

DOOR AND QUARTER
POWER WINDOWS

Before making any of the following ing all windows not to operate should switch disconnects and the motor.
trouble checks, mare sure that the have been found and corrected. The If the wiring leads are open, replace
battery is fully charged, and turn chances of having all of the control the wiring.
the ignition switch to the accessory switches, ground circuit breakers, 3. If the window operates nor-
position. switch to motor wires, or motor mally in one direction, the motor is
defective at the same time are very not defective.
ALL WINDOWS DO NOT remote.
OPERATE WINDOW OPERATES
1. Connect a voltmeter or test ONE WINDOW DOES NOT SLUGGISHLY
light from a ground to the power OPERATE 1. Check the regulator and win-
window relay red/blue wire which is 1. Activate the switch and listen dow runs for binding. Adjust the
connected to the 20-ampere circuit for the motor running free. If tb,e runs, repair and lubricate the regu-
breaker attached to the battery ter- motor runs and the window does not lator. Lubricate the runs with silicone
minal of the starting motor relay. move, the rubber coupling or gear lubricant.
If no voltage is available, repair or teeth have failed. 2. Check for frayed insulation
replace the 20-ampere circuit breaker 2. If the motor does not run, dis- where the window wires may partially
or the connecting black wire. connect the wires at the motor in ground. Check for loose connections
2. Connect a voltmeter from a order to check for voltage at each which will cause high resistance, and
ground to the red wire terminal of feed wire while actuating the window make sure that paint is not insulating
the power window relay. If no voltage switch at the door or from the master the ground wires.
is available, repair or replace the switch. If there is no voltage at the 3. Check motor current draw dur-
ignition switch or the red wire from motor feed terminals, check for volt- ing operation (place an ammeter in
the ignition switch to the relay. age at the switch feed wire. If there series with the ground lead of the
3. Connect a voltmeter from a is voltage at the switch, replace the battery). Motor current draw should
ground to the remaining terminal switch. not exceed 12 amperes during normal
blue wire of the power win- WINDOW OPERATES IN operation and should exceed 20
dow relay. If no voltage is available, ONE DIRECTION ONLY amperes at stall. If the current draw
replace the power window relay. 1. Check the operation with the is above 12 amperes during operation
4. Check the blue ·wire at the individual and master switches. Re- of the window, readjust the glass
master control switch for voltage. If place a defective switch if the window mechanism. If the stall current is
no voltage is available, repair or operates normally from one and not below 20 amperes at stall, look for
replace the blue wire from from the other. poor electrical connections.
the master control switch to the 2. If the window will not function 4. Motor current draw when dis-
power window relay. correctly from either switch, check connected from the regulator plate
5. At this point the trouble caus- for defective wiring between the should not exceed 5 amperes.
PART 17-3- DOORS, WINDOWS, TAILGATE AND DECK LID 17-SS

EJ REMOVAL AND INSTALLATION

POWER WINDOW RELAY 8. If equipped with electric win- and the door inner panel and install
REMOVAL dows, mount the regulator assembly the two attaching screws.
1. Disconnect the ground cable in a vise. Drill a -& inch hole through 8. Position the motor bracket to
from the battery. the regulator sector gear and the door inner panel and install attaching
2. Remove two screws attaching regulator plate (Fig. 19). Install a screw. Connect the motor wires and
the relay to the right side of the dash l inch bolt and nut in the hole to fit trim panel.
panel in the engine compartment. prevent the sector gear from moving REAR DOOR WINDOW
3. Disconnect the wires from the ~hen the motor and drive assembly
REGULATOR- AND/OR MOTOR
relay and remove the relay. 1s removed. Remove the motor REMOVAL
assembly from the regulator. 1. Remove the trim panel and
INSTALLATION watershield from the door.
INSTALLATION 2. Disconnect the motor wires at
1. Connect the wires to the relay. 1. Lubricate the glass mechanism:
2. Position the motor and trans- the connector.
2. Position the relay to the dash 3. Remove the equalizer arm
panel and install the two attaching mission to the regulator and install
the three attaching screws. bracket from die door inner panel.
screws. 4. Support the glass and channel
3. Connect the battery ground 3. Position the regulator assembly
in the door. assembly and remove the three glass
cable, and check the operation of the channel bracket attaching screws.
power window(s). 4. Insert the front run and retainer
into the vent window division bar. Separate the glass channel bracket
5. Position the glass and channel from the regulator arm rollers.
POWER WINDOW SWITCH assembly in the front and rear runs. 5. Remove the screw attaching the
1. Remove the trim panel. Raise ¢.e glass and support in the motor bracket to the door inner
2. Disconnect the wire connector up position. Install the washer and panel.
from the window switch. nut on the vent window division bar 6. Remove four window regulator
3. Remove the switch attaching lower adjusting screw. attaching screws and remove the
screws and remove the switch from 6. Insert the regulator arm roller regulator from the door.
the trim panel. in the glass channel bracket. Then 7. Remove the motor from the
4. Position the switch and retainer position the regulator assembly to regulator. If equipped with electric
to the trim panel and install the the door inner panel and install the windows, mount the regulator assem-
attaching screws. four attaching screws. bly in a vise. Drill a -& inch hole
5. Connect the wire connector to 7. Position the regulator arm roller through the regulator sector gear and
the window switch and install the bracket to the regulator arm roller the regulator plate (Fig. 19). Install
trim panel. a ! inch bolt and nut in the hole to
prevent the sector gear from moving

FRONT DOOR WINDOW

REGULATOR ARM ASSEMBLY
REGULATOR-AND / OR MOTOR

REMOVAL
1. Reinove the trim panel and
watershield from the door.
2. Remove two screws attaching
the regulator arm roller bracket to
the door inner panel and remove the
bracket.
3. Disconnect the motor wires at
the connector.
4. Remove the motor bracket-to-
door inner panel attaching screw.
5. Remove four screws attaching
the window regulator to the door
inner panel. Support the glass and
channel assembly and disengage the
regulator arm roller from the glass
channel. Then, lay the window regu-
lator in the bottom of the door panel.
6. Remove the lower stop from ORILL 5/ 16" OIAMETER HOLE THROUGH WINDOW
REGULA TOR SECTOR GEAR AND PLATE .
the door inner panel.
7. Remove the window regulator
assembly from the door. FIG. 19:- Motor and Drive Assembly Removal Precaution
17-56 GROUP 17- BODY DOORS AND WINDOWS.

when the motor and drive assembly bracket. 6. Position the glass channel brac-
is removed. Remove the motor 3. Position the window regulator ket to the glass channel and install
assembly from the regulator. to the door inner panel and install the three attaching screws.
the four attaching screws. 7. Connect the motor wires at the
INSTALLATION 4. Install the motor bracket to connector.
1. Install the motor on the window door inner panel attaching screw. 8. Remove the window support
regulator. 5. Insert the regulator arm roller and check the operation of the
2. Position the window regulator in the equalizer arm bracket. Position window mechanism.
in the door and engage the regulator the bracket to the inner panel and 9. Install the watershield and trim
arm rollers in the glass channel install the two attaching screws. panel on the door.

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FIG. 20- Relay and Wiring Installation
VIEW 8
PART 17-3- DOORS, WINDOWS, TAILGATE AND DECK LID 17-57

(j) : .-ICif AND ltOU.JIIfG A.U,Y

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POWER WINDOW
Detail of circle "A " Detail of circle "B" MOTOR & SWITCH WIRING

FIG. 21- Door Switch and Wiring Installation

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FIG. 22-
.RKK£T lfi.IST IU IJNISNED
ON CONTACTIN6 3UIVACI REAR VISION MIRROR.
~~~ ASSIMtl~

../ ~
~
'(:/ FOR XA 5[0AN,
POWER TAILGATE DIAGNOSIS AND TESTING
-
.....
VJ
00

NOTES: THE BATTERY GROUND CABLE SHOULD BE

DISCONNECTED WHEN REPAIRS ARE MADE
OR WHEN CONTINUITY CHECKS ARE CALLED STATION WAGON POWER BACK LITE
FOR WHICH INVOLVE SELF POWERED DOES NOT OPERATE WITH EITHER NOTE : BAlTERY SHOULD BE
TESTING DEVICES . SWITCH (INSTRUMENT PANEL OR FULLY CHARGED (ABOVE
TAILGATE KEY I 1.225 SPECIFIC GRAVITY)
DURING DIAGNOSIS ALL CONNECTIONS MUST
BE CHECKED TO ASSURE POSITIVE CONNECTION G')

s
.,
c:
PERFORM POWER WINDOW RELAY AND
CONTROL CIRCUIT DIAGNOSIS AS
OUTLINED ON CHART 1 IALl POWER
WINDOWS DO NOT OPERATE)
NOTE : VEHIClES WITH OTHER
FUNCTIONAL POWER WINDOWS
-':-1
~
OR POWER SEATS WILl NOT
REQUIRE THIS CHECK

AT THE POWER WINDOW RElAY BATTERY

'~
TERMINAl ASSURE CONNECTION OF THE
DIRECT BATTERY FE. EO BETWEEN THE
POWER WINDOW RElAY AND THE TAilGATE
KE'f SWITCH
§
:;10
(/)
CHECK THE PRIMARY GROUND CIRCUIT
THROUGH THE INSTRUMENT PANEl SWITCH

~
AND TO THE GROUND ATTACHMENT

~
REPAIR THE PRIMARY GROUND CIRCUIT WITH IGNITION SWITCH AT ""ON " OR ACCESSORY
z

~
AND/OR REPlACE THE INSTRUMENT PANEl CHECK FOR FEED TO THE INSTRUMENT PANEL
SWITCH TO ASSURE GROUND FOR THE SWITCH FROM POWER WINDOW RElAY
TOTAl SYSTEM
POWER TAILGATE DIAGNOSIS AND TESTING (Cont.)
.,,...
::a
-t
-
......
w
I

80
;Q
,C/'1
RECONNECT THE CONNECTOR TO THE
INSTRUMENT PANEL SWITCH CHECK
THE FEED CIRCUITS WITH AN AMMETER
WHilE ACTUATING THE SWITCH If
BACKLIT£ MOTOR IS LABORING AND ~
DRAWI N G CURRENT . PROCEED AS '0 K •.
!IG NIT IO N SWITCH ON ! z
0

OK

• DISCONNECT MOTOR IN TAILGATE AND

'~
~
CHECK THE TAILGATE LIMIT SWITCH
CONNECT EXTERNAl POWER SOURCE TO
CONTINUITY
THE MOTOR CONNECTOR (S) lUP OR DOWN
CONNECTOR ATTACHMENT FEED I AND CHECK WITH AMMETER IF
ADJUSTMENT MOT O R IS LABORING AND DRAWING CURRENT ,
OPERATI ON OF PLUNGER PROCEED AS ··o K "
r-

~
--f
m
CHECK THE CONTINUITY OF THE
REMOVE THE REGULATOR ASSY WITH MOTOR
TWO CONTROL CIRCUITS BETWEEN
AND DRIVE ASSY !SEE SHOP MANUAL I AND )>
THE BACKLIT£ KEY SWITCH AND
THE MOTOR CONNECTOR CHECK OPERATION WITH EXTERNAL POWER
SOURCE ISEE ''MOTOR TEST "l z
0
0
DISCONNECT THE MOTOR CONNECTOR AND
m
CHECK FOR FEED AT BOTH TERMINAlS
()
WHILE ACTUATING THE BACK liTE KEY ~
SWITCH USING A 12 VOLT TESTER
HGNITION SW . OFF & LIMIT SW CLOSEOl r-
0
REMOVE DRIVE ASSEMBlY WORM GEAR AND
REPLACE WITH APPliCABLE SERVICE GEAR KIT

-
......
I
VI
\()
POWER TAILGATE AND DIAGNOSIS (Cont.)
-.....
0\
I

0
NOTES THE BATTERY GROUND CABLE SHOULD BE
DISCONNECTED WHEN REPAIRS ARE MADE
OR WHEN CONTINUITY CHECKS ARE CAllED
FOR WHICH INVOLVE SELF POWERED
TESTING DEVICES
DURING DIAGNOSIS All CONNECTIONS MUST
BE CHECKED TO ASSURE POSITIVE CONNECTION
CHECK AND REPAIR THE OPEN AT THE BACKLIT£ KEY SWITCH
BATTERY FEED CIRCUIT BETWEEN CHECK FOR FEED IN BOTH CONTROL
THE POWER WINDOW RELAY 6 THE CIRCUITS WHILE OPERATING THE
BACK UTE KEY SWITCH INSTRUMENT PANEl SWITCH
UGNITION SWITCH ONI

,.,
G')

0
.,
NOTE BATTERY SHOULD BE
STATION WAGON POWER BACK UTE
DOES NOT OPERATE WITH THE
FULLY CHARGED (ABOVE
1.225 SPECIFIC GRAVITY) c
-.....
TAILGATE KEY SWITCH BUT DOES
WITH THE INSTRUMENT PANEL
CHECK CONTINUITY OF THE TWO SWITCH
FEED - GROUND CIRCUITS BETWEEN
THE BACK LITE KEY SWITCH AND
INSTRUMENT PANEl SWITCH
I

o:J
0
0
AT THE POWER WINDOW RELAY BATTERY
TERMINAL CHECK CONNECTION OF THE
,-<
DIRECT BATTERY FEED BETWEEN THE
POWER WINDOW RELAY AND THE TAILGATE

§
KEY SWITCH

;;o
(/')
UNDERINSTRUMENTPANELCHECKFOR
PROPER CONNECTION AND/OR FEED AT )>
THE CONNECTOR lSI FOR THE TAILGATE
WINDOW AND POWER SEATS, IIF SO
EOUIPPEDJ USING A 12 VOLT TESTER
z
0

~
z
0

~
REPAIR OPEN FEED CIRCUIT BETWEEN
THE POWER WINDOW RELAY BATTERY
FEED TERMINAL lOR STARTER MOTOR
RELAY I AND THE CONNECTOR lSI UNDER
THE INSTRUMENT PANEL

CHECK AND REPAIR THE

OPEN BATTERY FEED CIRCUIT
BETWEEN THE KEY SWITCH ANO
INSTRUMENT PANEL CONNECTOR

REPAIR OR REPLACE
THE TAILGATE KEY
SWITCH & WIRING
ASSY AS REOUIREO
POWER TAILGATE AND DIAGNOSIS (Cont.)
,).
,.,-4
-
......
w
I
I

NOTES THE BATTERY GROUND CABLE SHOULD BE NOTE : BATTERY SHOULD BE

DISCONNECTED WHEN REPAIRS ARE MADE FULLY CHARGED (ABOVE
OR WHEN CONTINUITY CHECKS ARE CALLED
FOR WHICH INVOLVE SELF POWERED
STATION WAGON POWER BACK LITE
DOES NOT OPERATE WITH TltE
1 .225 SPECIFIC GRAVITY I
0
TESTING DEVICES INSTRUMENT PANEl SWITCH BUT
DOES WITH 1 AILGATE KEY SWITCH
0
DURING DIAGNOSIS All CONNECTIONS MUST
BE CHECKED TO ASSURE POSITIVE CONNECTION 0
;;o
Ul

VEHICLES WITH POWER BACK LITE ONlY

~
PROCEED WITH THE SAME DIAGNOSIS ON
CHART 1 !All POWER WINDOWS DO NOT
z
OPERATE) FOR POWER WINDOW RELAY & 0
CONTROl CIRCUITS THEN. IF NECESSARY ,
FOLLOW DIAGNOSIS BELOW· 0

VEHICLE WITH OTHER POW£ A WINDOWS AND

'~
POWER SEATS THAT OPERATE tPOWE R WOW.
RELAY FE:. ED OK I --i
)>
r-
G)
)>
--i
m
)>
z
0
0
m
()
NOTE FEED CIRCUITS BETWEEN THE
INSTRUMENT PANEl SWITCH AND
THE TAILGATE SWITCH AND MOTOR
""'
r-
ARE 0 K. IN THIS CONDITION
SINCE THEY ARE USED FOR GROUND
0
CIRCUITS FOR THE TWO MOTOR
DIRECTIONS OPERATING BY THE
TAILGATE KEY SWITCH

-
......
I
0\
POWER WINDOW SYSTEM DIAGNOSIS
-
.....
~
I

All POWER WINDOWS DO NOT OPERATE

NOTES: THE BATTERY GROUND CABLE SHOULD BE NOTE ; BATTERY SHOULD BE
DISCONNECTED WHEN REPAIRS ARE MADE FULLY CHARGED (ABOVE
OR WHEN CONTINUITY CHECKS ARE CALLED 1.225 SPECIFIC GRAVITY)
FOR WHICH INVOLVE SELF POWERED
TESTING DEVICES
DURING DIAGNOSIS All CONNECTIONS MUST
BE CHECKED TO ASSURE POSITIVE CONNECTION C)
TURN IGNITION SWITCH TO THE "ON '' OR ACCESSOftY POSITION ~
CHECK FOR FEED THROUGH THE POWER WINDOW RELAY FROM
0
c.,
BATTERY USING A 12 VOLT TESTER

OK

ON VEHICLES SO EQUIPPED
CHECK THE CIRCUIT BREAKER IN
THE FEED CIRCUIT FROM THE POWER
WINDOW RELAY
-
.....
I

OJ
0
0
~

0
0
0
;10
(/)

)>
z
0

~
z
0

~
AS REQUIRED
POWER WINDOW SYSTEM DIAGNOSIS (Cont.)
.,,....
~
-f
NOTES: THE BATTERY GROUND CABLE SHOULD BE
DISCONNECTED WHEN REPAIRS ARE MADE
OR WHEN CONTINUITY CHECKS ARE CALLED
FOR WHICH INVOLVE SELF POWERED
TESTING DEVICES
ONE POWER WINDOW DOES NOT OPERATE
WITH MASTER AND /OR INDIVIDUAL SWITCH
NOTE . BATTERY SHOULD BE
FULLY CHARGED lABOVE
1.225 SPECIFIC GRAVITY)
-
.....
•
w
DURING DIAGNOSIS All CONNECTIONS MUST
BE CHECKED TO ASSURE POSITIVE CONNECTION •
0
0
0
:;o
!.ll
~
ACTl.JA TE THE INDIVIDUAL WINDOW SWITCH
AND CHECK FOR FEED AT EACtl HRMINAL
OF THE MOTOR CONNECTOR USING A 12
VOLT TESTER
z
0
OK

CONNECT EXTERNAL POWER SOURCE TO THE

~
y')
MOTOR CONNECTOR(S) (UP OR DOWN FEED)
AND CHECK WITH AMMETER . IF MOTOR IS
LABORING AND DRAWING CURRENT, PROCEED -i
AS " O.K ." )>
r-
OK G)
)>
REMOVE THE REGULATOR ASSY WITH MOTOR
AND DRIVE ASSY . lSEE SHOP MANUAL! AND
-i
CHECK OPERATION WITH EXTERNAL POWER m
SOURCE !SEE "MOTOR TEST " I

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z
0
0
m
()
~

r-
REMOVE DRIVE ASSEMBLY WORM GEAR AND
REPLACE WITH APPLICABLE SERVICE GEAR
0
KIT FOR All CAR LINES AND MODELS
EXCEPT THUNOERBIROS PRIOR TO 1970
WHICH Will REQUIRE COMPLETE MOTOR
AND DRIVE ASSEMBLY REPLACEMENT

-
.....
l
(]\
UJ
-
...... I

POWER WINDOW SYSTEM DIAGNOSIS (Cont.)

"'
~

~
:a
0
.,
NOTE : BATTERY SHOULD BE
NOTES: THE BATTERY GROUND CABLE SHOULD BE
DISCONNECTED WHEN REPAIRS ARE MADE
FULLY CHARGED lABOVE
1.225 SPECIFIC GRAVITY! c

-
OR WHEN CONTINUITY CHECKS ARE CALLED
FOR WHICH INVOLVE SELF POWERED
TESTING DEVICES
DURING DIAGNOSIS All CONNECTIONS MUST
BE CHECKED TO ASSURE POSITIVE CONNECTION ......
I

ONE POWER WINDOW OPERATES

THROUGH INDIVIDUAl SWITCH OJ
BUT NOT WITH MASTER CONTROL
SWITCH 0
0
-<
CHECK FEED CIRCUIT TO THE
AFFECTED CONTROL SWITCH IN
THE MASTER CONTROL SWITCH
ASSEMBLY . USING 12 VOLT TESTER

8
::10
(j')

)>
CHECK THE FEED CIRCUITS FROM
MASTER SWITCH FOR THE AFFECTED
z
0
WINDOW CIRCUITS AT THE MASTER
CONTROL SWITCH WIRING , USING
A. 12 VOLT TESTER

:E
z
LOCATE CMI'EN FEED CIRCUIT 0
IN HARNESS BETWEEN THE
"LOCK OUT" SWITCH AND THE 0
~
AFFECTED INDIVIDUAL SWITCH
AND REPAIR AS REQUIRED
NOTE FEED CIRCUITS BETWEEN THE
MASTER CONTROL SWITCH A.ND THE
INDIVIDUAL SWITCH ARE GOOD IN
THIS CONDITION SINCE THEY ARE
USED FOR GROUND CIRCUITS FOR THE
TWO MOTOR DIRECTIONS OPERATING
BY THE INDIVIDUAL SWITCH
THE INDIVIDUAL SWITCH IS ALSO
GOOD SINCE IT OPERATES THE
WINDOW IN EITHER DIRECTION
FALCON FAIRLANE w~:~~~~P

GROUP
TRIM &SEATS
18

PAGE

PART 18-1- Interior Trim and Vinyl Top Cover 18-2

PART 18-2- Seats 18-6

18-2

PART INTERIOR TRIM AND VINYL TOP COVER

18-1
Section Page Section Page
1 Door and Quarter Trim Panels .. ........ .. .... 18--2 3 Instrument Panel Safety Cover . . .......... ..... 18- -4
2 Headlining ............................. . .... 18--2 4 Roof Outside Cover ...... .. ...... ... ......... 18- -4

D DOOR TRIM PANELS

REMOVAL INSTALLATION

1. Place a ring of sealer around in place along the top edge of the
1. Remove the window regulator trim panel and install the trim panel
the window regulator and door
handle and the door inside handle. by pushing the retaining clips into
handle shaft holes.
2. Remove the arm rest retaining the holes in the door inner panel.
screws.
3. With a putty knife or similar 2. Fasten the water shield to the
tool, pry the trim panel retaining inner panel (Fig. 1).
clips out of the inner panel and 5: Install the arm rest retaining
remove the trim. 3. Make sure that all sleeves are screws.
On models fitted with 'roll top' installed in the inner panel and that
door trim panels the lock control all the retaining clips are installed in 6. Place the friction plates against
knob must be removed before at- the trim panel. the trim panel and install the window
tempting to remove the trim. regulator handle. Install the door
4. Remove the water shield. 4. Ensure that the finish strip 1s inside handle.

B HEADLINING
REMOVAL an) or rear quarter windows (station respective retaining holes in the roof
wagon) and unstick the headlining side rails. Make sure that the head-
1. Remove the sun visors, rear from the flange( s). Refer to Section lining rear support hooks are in
view mirror and centre pillar head- 17-3 for rear window removal pro- position, and that the material is taut
lining cover. cedure. With the station wagon, between supports.
remove the rear quarter panel trim
2. Remove the finish strip from mouldings and the tail-gate window
the windshield header flange . glass top channel. 4. Apply a strip of trim adhesive
to the face of the windshield header
3. Pull the door opening finish 9. Peel the headlining from the flange.
strips down far enough to provide windshield header flange and the
access to the headlining perimeter. door openings. Apply trim adhesive to the inside
10. Unhook the headlining sup- of the windshield header flange, the
port rods and remove the headlining top and sides of the back window
4. Remove the rear seat cushion assembly from the car. flange and the door flanges. Adhesive
and seat back (sedan). should also be applied to the peri-
meter of the headlining.
INSTALLATION
5. Remove the rear package tray
1. Unpack and lay out the new
trim panel (sedan). headlining.
5. Stretch the headlining forward
6. Remove the coat hooks and the and adhere it to the centre of the
interior light lens assembly. 2. Transfer the support rods from windshield header flange across a
the old headlining to the new one, width of about 20".
ensuring that they are located in the
7. Unhook the headlining from
correct position. 6. Working outwards, stretch and
the rear quarter retaining strips
(sedan). adhere the headlining across to one
3. With the headlining in the car, windshield pillar and then to the
8. Rem6ve the rear window (sed- insert the support rod ends into their other.
PART 18-1-INTERIOR TRIM AND VINYL TOP COVER 18-3

A·A

FIG. 1 - Door Trim Panel and Water Shield- Typical

18-4 GROUP 18- TRIM AND SEATS
7. Stretch the headlining out and 10. Stretch the lining down at the 14. Replace the coathooks and the
adhere it to the door flanges on each lower front edge of the quarter panel interior light lens assembly.
side, working from front to rear. and hook it over the retainer tabs.
Where necessary, cut nicks in the
lining to prevent puckering.
15. Replace the rear package tray
trim panel, the rear seat back and the
11. Position the retaining strip rear seat cushion (sedan).
8. Stretch the rear edge of the over the rear edge of the quarter
headlining to the centre section of panel lining and pull down over the 16. Replace the rear quarter panel
the rear window flange and adhere lanced tabs. Secure the tabs (sedan). tr~m mouldings and the tail-gate
a section approximately 20" wide. wmdow glass top channel (station
Stretch the lining out and adhere it wagon).
to the rest of the top and sides of the
flange, working out from the centre.
Cut three nicks in the lining at each 12. Trim excess lining material 17. Reposition the door opening
corner of the rear window to prevent from the roof side rail and back finish strips and replace the centre
puckering. window or rear quarter window pillar headlining cover and the finish
flanges. strip on the windshield header flange.

18. Replace the sun visors and

9. Stretch the front edge of the 13. Replace the rear window (sed- rear view mirror.
material at the quarter panel to the an) or rear quarter windows (station
rear edge of the door flange and wagon). Refer to Section 17-3 for 19. Clean the interior and head-
adhere. the correct procedure. lining.

EJ INSTRUMENT PANEL SAFETY COVER

REMOVAL INSTALLATION

1. Open the glove box door. Re- 1. Position the new safety cover to 4. Position the glove box liner in
move the glove box liner retaining the instrument panel (Fig. 2). place and install the glove box liner
screws and remove the glove box 2. Install the safety cover retaining retaining screws.
liner. screws.
2. Remove the instrument cluster Replace the trim cover at the right
housing Refer part 15-4 hand end of the instrument panel.
3. Remove the trim cover from the 3. Position the instrument cluster
right hand end of the instrument housing into the panel and fit screws.
panel.
4. Remove the screws retaining the
safety cover to the instrument panel.
5. Pry up and remove the safety
cover.

EJ ROOF OUTSIDE COVER

new cover be retained with drive
REMOVAL 7. Cut the cover away from the nails installed adjacent to the old
drive nails at the windshield and rear nails. Therefore each location should
1. Remove the rear seat cushion window openings, remove the screws be identified with a wax crayon.
and back. at the seams of the cover, and remove 1. Carefully measure and mark the
2. Remove the package tray panel the cover from the roof. centre of the vehicle roof.
and loosen the headlining in the 8. Remove the old adhesive from
quarter area sufficiently to permit the roof area with a scraper or use 2. Carefully position the outside
access to the side belt moulding an appropriate cleaning solvent. It is cover on the roof panel. (Fore and
retainer nuts. extremely important that the Aft centre punch marks have been
3. Remove the side and rear belt entire roof and drip rails are provided in the cover for centering
mouldings. thoroughly cleaned. purposes.)
4. Remove the side, top and bottom 3. With the cover properly posi-
wmdshield outside mouldings. INSTALLATION tioned and temporarily secured, fold
5. Remove the drip rail mouldings. back approximately half the cover
6. Remove the outside cover re- It is recommended that the existing and apply an even coating of adhesive
tainer strips from the drip rails. drive nails be left in position and the to the roof panel and a like amount
PART 18-1- INTERIOR TRIM AND VINYL TOP COVER 18-5

FIG. 2-lnstrument Panel Safety Cover Installation

to the corresponding area of the at windshield and rear window open- 8. Install the rear and side belt
roof outside cover assembly. For ings and install drive nails. Existing mouldings.
best results, secure limited sections holes may be used for the screws at 9. Reposition and secure the head-
at a time. Make certain that the each seam. lining.
adhesive is not lumpy as it will be 5. Trim the excess cover material 10. Install the package tray panel,
objectionable from an appear- from around the entire perimeter. rear seat squab and cushion.
ance standpoint. 6. Using a fibre or wood block 11. Install the windshield exterior
Stretch out all wrinkles progres- snap the outside cover retainers into mouldings.
sively. place in the drip rail trough.
4. Drill or punch drive nail holes 7. Install the drip rail mouldings.

FIG. 3-0utside Cover Installation-Typical

18-6

PART SEATS
18-2
Section Pare Section Pare
1 ~nch Seats - Removal and Installation 18·6 Rear Seat Back Cover .... .... .. .. .. .. .... .. .. 18··8
Seat and Seat Track .... 18·6
Front Seat Cushion and Back 18-6 2 Bucket Seats - Removal and Installation 18·11
Rear Seat Cushion and Back 18-6 Front Seat and Seat Track .. .. .. .. 18-11
Front Seat Cushion Cover 18-6 Front Seat Cushion Cover 18·11
Rear Seat Cushion Cover 18·8 Front Seat Back Cover .. .. .. .. 18-12
Front Seat Back Cover 18-8 Rear Seat Cushion Cover 18-14
Seat Belts- General Information .18-14

D BENCH SEATS
REMOVAL AND INSTALLATION FRONT SEAT CUSHION
SEAT AND SEAT TRACK AND/OR BACK
2. Remove 2 rear seat back attach-
Work, other than that of minor ing screws located at the bottom of
nature, is more easily performed 1. Remove the front seat and seat
track from the car if the cushion is to the seat back.
when the front seat assembly is 3. Lift up on the seat back to dis-
removed from the car. be replaced.
2. To replace the seat cushion, engage the seat from the upper
1. Remove the nuts retaining the hooks and remove the seat back from
seat tracks to the floor pan. Lift remove the seat assembly from 'the
seat track. the car.
the seat assembly from the car 4. Position the seat back in the car
(Fig. I) and disconnect and remove 3. Remove the bolts and washers
attaching the seat back to the seat and engage the seat with the upper
the release cable. hooks.
2. Remove the seat tracks from cushion frame. Before being able
to remove the attaching bolts, it is 5. Install the seat back lower
the seat frame. retaining screws. Then install the
3. Transfer the seat adjusting necessary to remove the seat backs
and seat cushion trim from the rear seat cushion.
lever knob and the retracting springs,
if necessary, to the new track bolts.
assembly. 4. Position the seat back assem-
bly on the seat. Install the bolts FRONT SEAT CUSHION
4. Position the seat tracks on the COVER
seat frame and install the retaining and washers attaching the seat
bolts and release cable. back to the seat and fasten the
5. Position the seat assembly in seat back and seat cushion cover
the car and install the retaining bolts trim with hog rings. Fig. 2 shows a front seat cushion
and nuts. 5. Position the seat cushion on the build-up. Seat cushions for all models
seat track and install the retaining are built-up in basically the same
bolts if removed. manner. Therefore, when installing
6. Install the front seat and seat new seat cushion covers or pads,
Release Cable Adjustment. Re- track in the car. refer to Fig. 2 for the location of
lease cable maladjustment will af- listing wires, hog rings, anti-squeak
fect only the side of the seat. In pads, and seat pad stack-up.
case the latch retaining the track 1. Remove the seat and seat track
fails to release, turn the release assembly.
cable turnbuckle or eye bolt enough 2. Remove the bolts and washers
turns to shorten the release cable REAR SEAT CUSHION attaching the seat back to the seat
travel sufficiently to release the AND/OR BACK cushion frame.
track latch. If the latch fails to 3. Remove the seat back assem-
secure the seat travel, turn the bly.
release cable turnbuckle or eye bolt 4. Remove the hog rings retaining
to lengthen the release cable enough 1. Lift the front edge of the rear the seat cushion cover and remove
to allow the latch to snap in the seat cushion and pull it forward to the cover (Fig. 2). Inspect the pad
locking position. remove it from the car. and replace it if necessary.
PART 18-2- SEATS 18-7

0 61~ - ·A TAA,;II •JJY rUONT SCAT Ar1

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0 61UU &A TRAC.I'I. ,I,J,l"Jo'·FRat/1 Jl./1.1

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0 ~PR!NC TRONT SEA r TRACK A.,.StST

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-- ---- ------
-

.-t., ' - .t X

FIG. 1-Front Seat Tracks

18-8 GROUP 18 TRIM AND SEATS

FIG. 2-Front Seat Cushion

5. Transfer the listing wires to the REAR SEAT CUSHION COVER
new cover. 3. Remove the hog rings retain-
1. Remove the rear seat cushion
ing the seat back cover to the frame.
6. With the seat cushion assembly from the car by lifting on the front of
Unhook the listing wires from the
right side up, make sure that the pads the seat and pulling it forward .
seat spring assembly tabs, and re-
are stacked properly and centered; 2. Remove the cushion cover hog move the cover (Fig. 3)
then place the cover over the pads to rings and remove the cushion cover
4. Transfer the listing wire to the
hold them in position. from the seat frame.
new seat back cover.
3. Inspect the pad and replace it
if necessary . S. Inspect the seat pad and spring
7. Carefully turn the seat assem- assemblies, and repair or replace as
4. Transfer the listing wire to the necessary
bly over so that the pads do not shift new cushion cover.
out of position. 6. Careiully place the cover over
5. Position the new cushion cover the seat frame and pad assembly.
8. After centering the cover and
on the seat frame and springs and at- Pull the cover taut over the pads,
straightening the seams along the tach it in place with hog rings 1 Fig. 4)
front edge of the cushion, fasten the hook the listing wires on the seat
6. Install the seat cushion in the spring assembly tabs and install the
cover to the front of the seat frame car.
with hog rings . Make sure that the hog rings (Fig. 3)
hog rings encircle the listing wire . In-
NOTE 7. Cut a hole in the cover for the
Two types of rear seat and se~t ash receptacle retainer, if equipped,
stall I hog ring in e.ach hole provided back springing are employed and, 1f
in the seat cushion frame . and install the receptacle assembly.
replacement of a frame and spring 8. Install the seat back to the seat
assembly is required, it must be of cushion .
9. At the rear of the seat assem-
the same type as that removed.
bly. pull the cover taut over the REAR SEAT BACK COVER
pads. and install hog rings at the FRONT SEAT BACK COVER
I. Remove the rear seat back
seat frame . Repairs to seat backs are per- from the car.
formed out of the car and are
10. Fasten the side of the cover 2. Remove the hog rings retaining
usually limited to replacement of
to the seat frame side with hog rings the seat back cover to the frame and
torn or burned seat covers. In a few
throu~h the holes provided (Fig. 2).
remove the rear seat back cover.
instances, the pads may be damaged
11. In sta ll the seat back and require replacement. 3. Transfer the listing wires' to the
new cover.
Fig. 3 shows a front seat back 4. Position the new cover on the
build-up. pad and seat frame and secure it in
12. Install the seat tracks to the 1. Remove the seat back. place with hog rings (Fig. 5)
cushion anu the seat assembly in the 2. Remove the ash receptacle and 5. Install the rear seat back in
car . ash receptacle retainer, if equipped . the car.
PART 18-2- SEATS 18-9

L
su.A

FIG. 3-Front Seat Back

FIG. 4-Rear Seat Cushion Installation Typical

18-10 GROUP 18- TRIM AND SEATS

FIG. 5-Rear Seat Back Typical

PART 18-2- SEATS 18-11

EJ BUCKET SEATS
REMOVAL AND INSTALLATION on the seat cushion and install the 3. Undo the two retaining screws
retaining nuts and remove the side valance.
FRONT SEAT AND SEAT TRACK
5. Place the seat assembly in the 4. Remove the four hog rings re-
car and install the washers and taining seat back lower valance
The seat track assembly is easily
nuts on the retaining studs. panel to the seat cushion.
replaced if the seat assembly is
removed from the car.
5. Remove the two hog rings re-
FRONT SEAT CUSHION COVER taining the tags of the sleeve
1. From under the car, remove
the seat track reta ining stud nuts assl!mbly on the reclining mechan-
and washers. Remove the seat as- ism cross bar.
Repairs to seat cushions or seat
sembly f r om the car and place it tracks are performed out of the car
on a clean work area. 6. Loosen the screws holding the
and are usually limited to replace-
reclining hinge assembly to the seat
ment of torn or burned seat cov-
back and remove the bolts holding
2. Remove the nuts which retain ers. In a few instances, the pads
the hinge assembly to the seat cush -
the seat track assembly to the may be damaged and require re-
ion. The cushion may now be de-
cushion and remove the seat track placement.
tached.
assembly.
1. Remove the seat and track as- 7. Remove the two sea t cu shi on
3. Disconnect the release cable sembly from the car and place it buttons and remove the hog rings
from the track being replaced and on a clean work area. holding the cushion cover.
conn.e ct it to a new seat track .
2. Remove the seat track assem- 8. Turn back the cover and re-
4. Place the seat track assembly bly from the seat cushion. move the surround pad . Remove the

FIG. 6-Bucket Seat Front Typical

18-12 GROUP 18- TRIM AND SEATS

hog rings holding the cushion in- 16. Replace the side valance and 7. Turn back the lower corners
sert and remove the cushion cover the seat track assembly. of the cover and remove the lower
and insert pad. four hog rings, retaining the in-
17. The seat may now be instal- sert
9. Inspect the pad, flexilator and led in the car.
spring assemblies and repair or re-
8. The top corners of the cover
place as necessary.
may now be turned back and the
FRONT SEAT lACK COVER
suround pad removed.
10. Transfer the listing wires to
the new cover. 1. Remove the l!e&t and track as-
sembly from the car and place it 9. Remove the remaining hog
11. Place the cushion insert pad on a clean work area. rings around the insert II'Tld remove
on the flexilator and position the the cover and in~ert pad.
cushion cover. Hog ring the insert 2. Undo the two retaining screws
pad to the retainer and spring and remove the side valance. 10. Inspect the pad, flexilator and
frame . spring assemblies and repair or re-
3. Remove the four hog rings re- place as necessary.
12. Replace the surround pad, taining the seat back lower valance
t.urn the cushion cover over the panel to the seat cushion.
pad and secUJ·e with hog rings. 11. Transfer the listing wires to
Replace the two seat cushion but- the new cover.
4. Loosen the bolts holding the
tons.
hinge assembly to the seat cushion
and remove the screws holding the 12. Position the insert pad and
13. Replace the bolts holding the the cover on the flexilator and
hinge assembly to the seat cushion seat back to the hinge assembly
Remove the seat back. replace all except the lower four
and tig·hten the screws holding the hog rings retaining the in~ert .
hinge assembly to the seat back.
5. Remove the rear cover panel
J.t. Hog ring the cross bar sleeve by pulling downwards to disengage 13. Replace the surround pad and
assembly tags to the underside of the clip. pull the top corners of the cover
the seat cushion. over the frame .
6. Remove the two seat back but-
1;;. Hog ring the seat back lower tons and the hog rings retaining 14. Replac e the lower four hog
valance panel to the seat cushion. the cover. rings retaining the insert.

covu
ASSlMII.Y WA5HU

lUTTON
A!>S[MtlY

LOW[R
WI~[

FIG. 7-Rear Seat Back Typical

-
m

-
I 0 601508 I'HNC:L A.::.SY-RR .SCAT BACK
ao @613A.!!B
FLOOR I R£0D
CABLE ( LAT'CH A.S.SY SCAT &tCK
2. R£QD
@60!iAI!5 SPRNG - .sEAT BAt;~( LATCH ~
2.R£0'0
~ "1 42.7'4 - .S
(!)613!'51
SPRING RETAINER
L£YER Akl\1 - .sEAT BK:J<
2 REQ'D
LArGH
I RE.OD
"
IBY.$8l'IS.59-5 .SCQEW - .5HOUL££R
I
Pf/OT
RE.Ob ~

~
~-'920-S NUT-HE.f ..tAM I REO'D
~56.38.' - .S WASHER- SPQING I R£Q'D
61~ 79 KNOB - LEVER APfl.f S£AT BACH
LATCH I R£0'0
@otM40 E..fTENSION ASSY- R'R -'CAT 8ACJC
REAR I RE.a'D
0 6~AI6 BI--+'WP£R R'R SEAT BACH E.rT:
2. R£00
@616AM MOULDING - WIJIR .STRIP FLOOR
E.rT 2 RE:QD

i
3!5/17.Jtj-.$ .SCRtiJV 4 REQ'D
016A5.!! TAPPING PLAT£ 2. REOV
.349a9- .S i1HSI-IE P - L OCX 4 R£0'0
37'4067 - .S Sc.Rl:W 4- R'i<a'D
6/.316/7 .SUPPORT A.s.SY- R'R SEAT tJA:J<
I RH ILH REQ'D
B .!!74-49-.S .SCR£W 4 REO'D
(il 34"40 - .S MH.SHE:R 4- R£Q'D
+ RE.Q'D

1
56.320 - .S .SC.ROV

~
£.58- 11114G~2--A .SEALER 4 PLACE:.S
6003.2 ~ A.S5Y - R 'R SEAT I RED'D
<{ 11'-~877'08-.:5 .scRE:W 4 R£0'D
w eOOBO CUSHON ASSY I RCO'D
(/) .371527>'i - .S ' scRE:W 2. RED.'D
or,...._-46/7 .STRI;(£R - li£4R. SCAT iS4CK ''"10<
I RH ILH REr:ID

~
@3 11387~-J SAC.ER - R.s.B. LATCH S TRIKER
6 H£'0'0

-
:u940-.5 ~HER 6 REQ'D l OCATCN Gi/1/X OIMiff 1'1 .

!
I
00 !57'4!50 v .SCRE:W 6 RE:Q'D RW CENTRE nOOK TO '
6l6>+n PIID- ANn - RATTLE 2 REo'D
lOCAT£ ITTM' 15 (+ PlACES)
FOLD A4D OVER WIRE ( STAPLE lllltn
E.SB - MIA-<V-A OR ESB-IIIIA-112 - A .STAPu
t- TH£N .sECURE YV'.J<' ADH£.51V£ -
E.SS-MC!f514 -A TO \!) l'lt7 · WA Y IJCTOI££11
~ HANOLE AND LATCH£.$.
~ @) 1/SfX> ~L - REAR f:LCX)I:( 7/::I.W IREQD
A.
llZJ Yllld:'44 5100 .SCREW 13 REQD
@ G/3A57 ~ - ST101<ER /:lEAR SEAT &li£K.
2 RBilD

~-- ~ ~-- j
~ -~l_j ~~
)
•
\ ~ ( ~- ~ - ~ ) "EW
WITH SCAT
Z
BJ'.CK REit«:JYE.D

'I

FIG . 8- Wagon Rear Seat Latch Installation

18-14 GROUP 18- TRIM AND SEATS

15. Pull the bottom corners of 3. Remove rear seat cushion pad the upper filler flap and remove the
the cover frame and hog r ing the assembly, upper and lower. bolts holding the armrest assembly
cover to the frame. in position. Remove the armrest by
4. Inspect the pad assembly and drawing it back through the seat.
16. Replace the two rear seat spring assemblies and repair or re-
back buttons and the rear cover place as necessary. 5. Remove the seat back buttons
panel. and all hog rings retaining the seat
5. Transfer the listing wires to back cover.
17. Install the seat back on the the new cover.
hinges and tighten the hinge as- 6. Remove pad assembly.
sembly to seat cushion retaining 6. Replace pad assemblies, upper
bolts. and lower. 7. Inspect the pad and spring as-
semblies and repair or replace 83
7. Replace the seat cushion but-
18. Hog ring the seat back lower necessary.
ton:s and hog ring the corner in
valance panel to the seat cushion.
position. Replace the cushion in the 8. Transfer the listing wires to
19. Replace the side valance and car. the new cover.
install the seat in the car.
REAR SEAT BACK COVER 9. Replace pad assembly.
1. Remove the rear seat cushion 10. Hog ring the seat back cover
FAIRMONT REAR SEAT and undo the two screws holding in position.
thP. lower end of the rear seat back
REAR SEAT CUSHION COVER in the car. 11. Replace the armrest and hog
ring the upper filler flap in position.
1. Remove the rear seat cushion 2. Lift the seat back to disen-
gage it from the uppP.r hooks and 12. Hog ring the lower filler flap
from the car by lifting on the
remove the seat back from the car. in place.
front of the seat and pulling it
forward. 3. Undo the hog rings retaining 13. Engage the seat back on the
the lower filler flap and remove it upper hooks and replace the two
2. Remove the cushion cover hog
from the seat back. seat back attaching screws.
ring3 and turn back the corner.
Remove the seat cushion buttons. 4. Undo the hog rings retaining 14. Replace the rear seat cushion.

SEAT BELTS Sealer should be placed around all 15 degrees .

seat belt anchor bolt holes in the If a component portion (buckle por-
GENERAL INFORMATION floor pan. tion, retractor portion. etc) of a seat
Belt assemblies must be installed in belt or sash belt assembly is non
The seat and sash belts are factory matched sets as received and must functional or damaged the entire
installed in their proper locations. If not be interchanged between models . assembly (buckle, tongue and
the seat belts or sash belts are re- The position of inboard front seat shoulder harness portions) must be
moved for any reason, they should be belts at the tunnel shall be pointing replaced.
installed as shown in Fig. 9 & 10. in a forward direction , plus or minus

I I'

V6W~

S'TD J!lt. 7J 0Nl V Jr&J ~#lrJ o.._,

'Ottt./IIQCW'"UIIIII"N~ ...... ~' $ l/r1'A1If OtlfPIT
.-Loot ,..,n, .-tCIOf' ,...,.n

BOLT J MCMJLD:;:Jt
BOLT - - / 16" 1 I 1 '8"
BOLT J MOI..rUD
..; Pit , MG V~ ; KEI '(' 16
PL.f. "' " • " ' " '
WAV'. ,'. l:. t1f..R
"' i'l!"t:R
BELT &3::i!, COMI, RT. SU.f
BELT .lS..OT. PaT. lJ!! .t.T t.A.P
aol.T s.auu.a
..; PACD

FIG. 9- Seat Belt Installation

PART 18-2- SEATS 18-15

\I
FIG. 10- Seat Belt Installation
CLEANING Do not use carbon tetrachloride , be caused to the webbing.
naptha, etc. Bleaching or redyeing of Inspect for loose, cuts or damaged
Wash the webbing with any com- the seat belts is not recommended webbing.
mercial soap or detergent. because of deterioration which may
REFERENCE TO SERVICE INFORMAnON AND NOTES

Date Letter No. Paae Brief Detail

FALCON FAIRLANE w~:~~~~P

MAINTENANCE SCHEDULE GROUP

AND LUBRICATION CHARTS 19

PAGE

PART 19-1- Lubrication and Maintenance Schedule 19-2

19-2

PART LUBRICATION AND

19·1 MAINTENANCE SCHEDULE

Reliable opera t ion of all Ford 3. The operation of the vehicle filter should be changed more fre-
vehicles depends t o a great extent includes long periods of idling such quently:-
on t he use of lubrican ts and ser- a3 encountered in taxi and police
vice component s which meet Ford units, where mileage is not an ac- The following charts list the lub-
Specifications. It is possible that curate indication of the engine ricant specifications and specified
the use of lubricants or service hours run. change periods for normal vehicle
products which do not meet these operation.
specifications may cause damage to
4. The temperature for periods
important operating mechanisms.
of two months at a time regularly
range below 45•F. IMPORTANT
Conditions under which vehicles are
driven vary greatly co nsidering the ex-
The lubricants listed are specified
tremes of temperature, urban and rural 5. Dust conditions encountered
traffic, paved and unpaved roads and dry :for the maximum service periods
are more severe than those in a
approved by Ford Motor Company
areas where dust is prevalent. typical suburban area where the
of Australia Limited.
majority of the streets are paved.
Operating conditions are considered
" norm al" unless:- Manufacturers of these products
6. The vehicle is used for con- may advocate service periods in ex-
sistent high speed or competition cess of those currently recommend-
1. More than 50% of the opera- driving. ed. We do not propose to comment
tion is stop and go as in city on the validity of these claims but
traffic. Where the conditions are more point <>ut that it is mandatory that
severe than normal, i.e., one or the3e products be used in Ford ve-
2. The average trip is less than more of the above conditions ap- hicles only for the perio<ls current-
10 miles. ply, then the engine oil and the ly !~commended.

ENGINE CRANKCASE OILS

Use of SAE 20W-4 0 oil wi ll defined by ASTM committee 02 for Sequence III - High Tempera-
prov ide the proper viscosity for all Section G-IV of technical committee ture Deposit Formation - (Va r-
no rmal ra nges of outside tempera- nish).
tures. B and are published in the SAE
Handbook. These tests cover oil
~quence IV - Conosion and
characteristics as follows :-
Rust Prevention.
OIL QUALITY
Sequence I - Low Temperature Sequence V - Sludge F ormat ion .
Use only oils which have been Wear.
tested and certified by the maker OIL FILTER
as satisfying automobile manufact-
Prevention - (Cold Starts) .
urers specifications for Engine Op- Use of the ri ght oil filter is also
erating sequence Tests for Service essential to good engine life and
MS . The Ford Motor Company Sequence II - High Speed - cperation. For 6,000 mile filter
specification covering these tests is High Temperature Wear. Preven- change interval s it is essential that
ESE M2C I OI-C These tests are tion. only a genuine Ford filter be used .
PART 19-1- LUBRICATION AND MAINTENANCE SCHEDULE 19-3

ITEM NAME FORD SPEC . CAPACITY

BODY HINGES SAE 20 W / 40 ESE M 2C 10 1- C as required
HOOD LATC H SAFETY CATCH Petroleum Jelly as required
LOCK CYLINDERS Lock lu br 1ca nt ESB-M2C 20-A
FRONT SUSPENS ION BALL JO INT S Ball jo1nt grease MIC75-A 10 gram s at
serv1cmq 1nterval
FRONT END UPPER INNER Ball jo int qrease MIC 75-A 3 grams at
PIVOT PINS serv 1c1ng 1nterval
FRONT WHEEL BEARINGS Wheel beanng grease ESW FM 1 C2 1 oz. per hub
BRAKE MASTE R CYLINDER 500 ° bollmg po1n t ESW FM 6C2 .48 pints
CLUTCH MASTER CYLINDER } Brake flu1d .0 7 pints
STEER IN G GEAR HOUSING L1fet1me steermg ESW M 1 C 87 --A 0 7 lb. ::J- 07 lb .
gear grease
STEER IN G POWER PUMP RESERVOIR Automati C trans - M2C 33 F 2.5 pints
miSSIOn fluid
POWER STEER ING ACTUATOR BALL STUD Rubber grea se
REAR AXLE CONVENT IONAL Hypoid gear lube ES W -M2C 108A 2 3 p1nts
LIMITED SL I P L S. o il ESW- M2C 1 006A 2 3 p1nts
TRACT ION LOK L.S. oil ESW - M2C 119A 4 p1nts
TRANS\~ISSION MANUAL- 4 SP EED SAE 80 ESW- M2C 83A 3 25 pints
3 SPeED FUL L SYNC HRO SAE 30 ESW- M2C 37 2 7 p ints
3 SPEED PART SYNC HRO SAE 30 ESW -- M2C 37 3 . 1 3 pints
TRANSM ISSION- AUTOMATIC Automatic trans - M2C 33f B.W 14 . 5 pt.
miSSIOn fluid C4 1 6 . 5 pt.
FMX 18 5 pt.
UNIVERSAL JOINTS ES W-M1C 87A T ota l ca pacity of
U.J.s 5 grams
ENGINE M.S. Sequen ce ES E- M2C 101 - C 200-250 8 pt.
tested 302-35 1 8 pt.
( In cludes Oil Filter
capacity)
I::NGINE OIL I-ILLER BREATHER CAP SAE 20W , 40 ESE - M2 C 101 - C
6.000 - mile type 1 . 7 pints
E GINE O I L FILTER
D1st cJm greJse M1 C 66A Smear
DISTRIBUTOR CAM
19-4 GROUP 19- LUBRICATION AND MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE
Maintenance Operations
Carry out the operations listed
below at the mileages shown Months 3 6 9 12 15 18 21 24 27 30 33 36
or at the equtvalent
monthly tntervals . Miles OOO's 3 6 9 12 15 18 21 24 27 30 33 36
Under Hood:
Change engine oil and install new Motorcra ft/Ford Filter X X X X X X
Clean crankcase breather cap X X X X X X
Clean fuel pump filter screen and sedtment bowl X X X

Replace closed em1sston regulator control valve X X X

Check torque manifold bolts and tnlet ptpe to
mantfold nuts X X X
Check and adjust steering gear pre·load (ma nual only) X X
Compress1on test eng1ne X X
Cl ean carburett or air cleaner and filter (r epl ace cleaner
element as requ ired) X X X X X X

Replace fuel filter where fitt ed j XI X X

Check idle R .P.M . X X x lx x X X X X X X X
Ch eck, adjust and lubricate accelerator lin kage X X X X X X
Check, adjust and lubricate transmissio n linkages
(manual, auto.) X XX X X X
Check and adjust inhibitor switch X X X X X X X X X
X X IX
Adjust fan belt tenston ' X X X X X X
Che ck al l flutd levels (master cylt nders . stee r1ng
box. automatt c transmtsston) X X X X XIX X X X X X X

Check battery electrolyte, termmals for secu r1ty

(clean where necessary) , top up ele ctrolyt e X X X X X X X X X X X X
Inspect engtne compartment for flu1d leaks X X X X X X X X X X X X
Drain, flush , refill and add inhibitor to ra diator and
check c ondition of hoses X X X
Clean and adju st po1nts. plugs and reset 1gn 1t1on
t1m1ng (replace as requ1red) X X X X X X
Under Body:
Vtsually 1n spe ct d1s c brake pads for wear . re p lace
where necessary and adjust whee l bear1ng s X X X X
Remo ve and clean brake drum assembl1es . C heck
l1 n1ngs for wear and adjust hand brake mec han 1sm X X X X X X
Repa ck and adjust front wheel bear1ngs X X
Inspect tyres X X X X X X
Ch eck and adjust toe-in X X X X X X
Se rv1ce automati C transm iSSion and ad just b ands . X X
Inspe ct shock absorber rn ountmgs X X X X X X

Che ck flu1d levels (transrn1SS1on-rnanual . re ar axle) X X X X X X

Check under body for exhaustjflu 1d leaks X X X X X X X X X X X X
Inspect all steer1ng l1 nkages and steer1ng bo x for
wear and secunty X X X X X X X X X X X X
Inspect brake hose s X X X X X X X X X X X X
Torque rear sprtng Ujbo lts X X X
Lubricat e handbrake linkages and check a djustment X X X X X X
Lub r1cate fro nt end upper 1nn er p1vot p1n s. X X X X X X
Lubricat e front suspension ball joints X
General:
Che ck w 1n dsh1eld w1per;washer operat 1o n a nd
bl ade cond1 t 1on X X X X X X
Lu bncat e and ch ec k operat 1on of door loc ks .hood
and d eckl1d catches X X X X X X
Ens u re correct operat1on of alll1ght1ng X X X X X X X X X X X
Road test veh >cl e X X X X X X X X X X X
ADDENDUM 19-5

POLICE AND TAXI UNITS MAINTENANCE SCHEDULE

MILEAGE INTERVAL

As Each each each each each each

Required Daily 5000 10000 15000 20000 25000 30000

E N G I N E

Change engine oil and filter X

Check engine oil level X
Check radiator coolant level X
Check battery electrolite level X
Clean crankcase breather cap X
Replace engine coolant and add r?diator inhibitor Rl-36 (or
every two years) X

Check engine accessory drive belts X

Ignition timing check and adjust if necessary X

Clean carburettor air cleaner and filter (replace as required) X

T R A N S M I S S I 0 N.

Adjust automatic transmission band and service !'{)000 ,and 35000

Accelerator linkage and down shift valve control cable.
Check and adjust if necessary (automatic) X

Gear change linkage. Check and adjust if necessary. X

Check ftiud level, rear axle, manual tran s mission, automatic X

transmission

c H A s s I s
Check brake linings and / or pads for excessive wear and
check brake lines for damage and. leaks X

In spect all steering lin~age s amJ sll:ering bus for wear a ml

security anJ adjust front wheel alignment if necessary X

Steering gear preload check (manual on ly) · X

\
Lubncate' front end upper 1nner p1vot pins.
i X

Repa ck and ad1ust front wheel bear1ngs X

N.B.- The above information only applies to Police and Taxi units and must be used in conjunction with
the chart on the previous page.
REFERENCE TO SERVICE INFORMATION AND NOTES

Date Letter No. Page Brief Detail

FALCON FAIRLANE w~:~~~~P

GROUP
MAINTENANCE OPERATIONS
20

PAGE

PART 20-1- Maintenance Operations 20-2

20-2

PART MAINTENANCE OPERATIONS

20-1
Section Page Section Page

1 Engine and under hood 20-2 3 Under body, Steering and Alignment .. ' 20-16
2 Transmission, Clutch and Rear Axle 20-14 4 Body .. 20-22

D ENGINE AND UNDER HOOD

INSPECT COOLING SYSTEM and observe all the connections for
HOSES AND LINES fuel seepage. Tighten or replace fuel
lines as necessary.
Inspect the cooling system hoses
for evidence of cracking or extreme REPLACE FUEL FILTER
weathering. Replace cracked hoses. Refer to Part 19, Maintenance
Check for leaking or porous hoses Schedules, for recommended
and tighten or replace. frequency of filter replacement.
Make sure all supporting brackets The in-line fuel filter used on V-8
for hoses are in place and that the engines 250 CID 2V six cylinder, and
hoses are properly installed in the the 250 CID 1V six cylinder engine
brackets. equipped with air-conditioning is of
Inspect the radiator core and tanks one-piece construction and cannot be
for seepage or leaks. cleaned. Replace the filter (and gasket
Check all fittings to see that they if so equipped) if it becomes clogged
are tight and in good condition. FIG. 1 -Typical Cylinder Block or restricted. Otherwise, replace it at
Examine the hoses at the fittings for Drain Plug-Six the interval specified in the mainten-
cuts or weakness. Repl.ace any hose ance schedule.
in questionable condition.
IN-LINE FILTER REPLACEMENT
REPLACE RADIATOR COOLANT -VB
Refer to Part 19, Maintenance 1. Remove the air cleaner.
Schedule, for recommended fre- 2. Loosen the retaining clamp se-
quency of service. DRAIN PLUG
curing the fuel inlet hose to the fuel
11196-A
To drain the radiator, open the filter.
drain cock located at the bottom of FIG. 2 - Typical Cylinder Block 3. Unscrew the fuel filter from the
the radiator and remove the cylinder Drain Plug V-8 carburettor and discard the gasket, if
block drain plug(s). The 6-cylinder so equipped. Disconnect the · fuel
engine block has one drain plug locat- coolant level will drop approxi- filter from the hose and discard the
ed at the right rear of the cylinder mately one quart after the engine retaining clamp.
block ahead of the. starter (Fig. 1). has been operated about 20 min- 4. Install a new clamp on the inlet
The V-8 engines have a drain plug on utes at 2,000 rpm. This is due to hose and connect the hose to the
each side of the cylinder block (Fig. the displacement of entrapped filter. Place a new gasket (if used) on
2). air. Add more coolant to fill the the new fuel filter and screw the filter
To fill the cooling system; close the radiator supply tank. into the carburettor inlet port.
drain cock. Install the block drain CHECK ENGINE COOLANT LEVEL Tighten the filter.
plug(s). Disconnect the heater 5. Position the fuel line hose clamp
outlet hose at the water pump to The coolant level should be kept and crimp the clamp securely.
bleed or release trapped air in one inch below the filler neck 6. Start the engine and check for
the system. When the coolant begins opening. fuel leaks.
to escape, connect the heater outlet INSPECT FUEL LINES AND FILTER IN-LINE FILTER REPLACEMENT
hose. FOR LEAKS 250 CID 2V SIX CYLINDER, 250
Add radiator inhibitor of approved CID 1V SIX CYLINDER ENGINE
specifications. With the engine off, examine the EQUIPPED WITH AIR-CONDITION-
Operate the engine until normal fuel ·line connections for wetness or ING
operating temperature has been washed or stained areas that might
reached. After the. initial fill, the indicate a fuel leak. Start the engine 1. Hold hex. part of filter to pre-
PART 20-1- MAINTENANCE OPERATIONS 20-3
vent filter from turning and unscrew
flared union, fuel pipe to filter.
2. Hold double female adaptor and
unscrew flared union, fuel filter to
double female adaptor.
3. Remove in-line filter.
4. Place a new filter in position and
screw top and bottom flared unions
to retain filter, by holding hex. on
filter and hex. on adaptor, respec-
tively.
5. Start the engine and check for
fuel leaks.
CLEANING THE FUEL PUMP FILTER
SCREEN & SEDIMENT BOWL
AC type only
l; Unscrew the sediment bowl re-
taining nut.
2. Remove the sediment bowl.
3. Remove and clean gauze filter.
4. Replace gauze filter.
5. Refit the bowl after cleaning,
using a new gasket.
6. Tighten the sediment bowl re- ">; VENT HOSE
taining nut. ( ~/-, \
7. Start the engine and check for
leaks.
CLEAN CRANKCASE
\( \ A\3141-A

VENTILATION SYSTEM FIG. 3- Crankcase Ventilation System

COMPONENTS
Components Typical
XA/ZF vehicles are equipped with
crankcase ventilation systems which
have the components located at
different . points on each type of
engine. Fig. 3 shows typical ventila-
tion system for the V-8 engines.
The following is a general pro-
cedure.

REMOVAL

Remove the following components

from the crankcase ventilation sys-
tem!
1. Remove the oil filler cap

2. Remove the air cleaner (and

duct and valve assembly, if so
equipped).
3. Remove the hose or hose ass-
embly from the ventilator valve in the
rocker arm cover. Remove the other
end of this hose (or hose assembly)
from the intake manifold connection,
or carburettor spacer connection, if
so connected.
4. Pull the ventilator valve from
the grommet in the rocker arm cover.
CLEANING
1. Wash the crankcase filler cap in
a low-volatility, petroleum-base sol-
vent. Shake the cap dry. Do not dry
20-4 GROUP 20-MAINTENANCE OPERATIONS
with compressed air, since air Tool- -8620-B and adjusting arm bolts. Move the
pressure may damage the filter alternator toward the engine. Re-
element. move the belt(s) from the alternator
3: Clean the rubber hoses with a and crankshaft pulleys, and lift them
low-volatility petroleum-base solvent over the fan.
and dry them with compressed air. 3. Place the belt(s) over the fan.
Remove all deposits from inside walls Insert the belt(s) in the water pump
of the hoses. Heavy deposits can flake pulley, crankshaft pulley and alter-
off in service. Replace any hose that nator or generator pulley grooves.
cannot be cleaned satisfactorily. Adjust the belt tension to specifica-
4. Clean the intake manifold or tions. ·
carburettor spacer connection by 4. On a car with power steering,
probing the inlet nipple or threaded install the power steering pump drive
opening with a flexible wire brush. belt and tighten the pump bracket
5. Do not attempt to clean the to the water pump. Adjust the drive
crankcase ventilator valve. It belt tension to specifications.
should be replaced at the specified FIG. 4 - Checking Drive Belt
mileage intervals or when test indi- Tension CHANGE ENGINE OIL AND FILTER
cates it is not working properly.
CHECK ENGINE ACCESSORY 1. Raise the car.
INSTALLATION DRIVE BELTS 2. Remove the oil pan drain plug
1. Install the ventilator valve into and allow the engine oil to drain into
BELT TENSION a container.
the grommet in the rocker arm cover. Properly tensioned drive belts
If the grommet is loose or damaged, 3. Place a drip pan under the filter.
minimize noise and also prolong Unscrew the filter from the adaptor
use a new grommet. service life of the belt. Therefore, it is
2. Assemble the components of the fitting.
recommended that a belt tension
hose assembly (if an assembly was gauge be used to check and adjust the
removed). 4. Coat the gasket on the new
belt tension. Any belt that has Motorcraft/Ford filter with oil. Place
3. Connect one end of the hose (or operated for a minimum of 10
hose assembly) to the ventilator valve. the filter in position ori the adaptor
minutes is considered a used belt, fitting. Hand tighten the filter until
4. Connect the other end of the and when adjusted, it must be
hose (or hose assembly) to the fitting the gasket contacts the adaptor face,
adjusted to the reset tension then advance it t turn.
on the intake manifold, or carburettor shown in the specifications.
spacer (if so connected). 1. Install the belt tension tool
5. Install the carburettor air cleaner 5. Replace the oil pan drain plug
(Part No. 8620B) on the drive belt and tighten it securely.
(and ducts, if so equipped). (Fig. 4) and check the tension
6. Install the oil filler cap on the following the instructions of the tool
oil filler pipe. 6. Refill the crankcase with the
manufacturer. proper amount and grade of oil.
CHECK ENGINE ACCESSORY 2. If adjustment is necessary,
PULLEYS AND DRIVE BELTS loosen the alternator mounting and 7. Lower the car.
PULLEY CONDITION adjusting arm bolts. Move the alter-
nator toward or away from the 8. Operate the engine at fast idle,
Inspect pulley belt surface for de- engine until the correct tension is and check for oil leaks. If oil leaks
posits of rust. If rust is present but obtained. Tighten the alternator are evident, perform the necessary
can be removed easily with a cloth adjusting arm and the mounting repairs to correct the leakage.
moistened with kerosene, rust is bolts. Check the belt tension.
harmless and can be ignored. If rust
cannot be so removed, remove belt(s) DRIVE BELT REPLACEMENT CHECK ENGINE OIL LEVEL
and polish pulley belt surfaces with 1. On a car with power steering,
fine sandpaper. Wipe or blow clean loosen the power steering pump Check the oil level dipstick to be
with compressed air. Install belt(s) bracket at the water pump and re- sure it indicates the correct quantity
and adjust the tension to specifica- move the drive belt. of oil in the crankcase. Be sure the
tions. 2. Loosen the alternator mounting oil is clean.
PART 20-1- MAINTENANCE OPERATIONS 20-5

TORQUE INTAKE MANIFOLD

BOLTS
8 CYLINDER ONLY

Refer to Fig. 5 for the correct

tightening sequence. Using a torque
wrench, and following the sequence
given, tighten the manifold bolts to
specifications.
Intake Manifold Bolt Torque
Engine (Ft-Lb) IDENTIFIED BY WET BLACK DEP.
IDENTIFIED BY BLACK, IDENTIFIED BY DEPOSIT
302 DRY FLUFFY 'CARBON OS ITS ON THE INSULA TOR SHELL BUILD ·UP CLOSING GAP
BORE ELECTRODES CAUSED BY
351 ............ 5/ 16 bolt 23-25 DE POSITS ON INSULA TOR
TIPS, EXPOSED SHELL EXCESSIVE OIL ENTERING CO'ABUS.
BETWEEN ELECTRODES.
CAUSED BY OIL OR
3/ 8 bolt 28-32 SURFACES AND ELECTRODES. TION CHAMBER THROUGH WORN CARBON FOULING. IF
CAUSED BY TOO COLD A RINGS AND PISTONS, EXCESSIVE DEPOSITS ARE NOT EXCESSIVE,
PLUG , WEAK IGNITION, DIRTY CLEARANCE BETWEEN VALVE THE PLUG CAN BE CLEANED.

CD CD ®0CD 0 AIR CLEANER,DEFECTIVE FUEL

PUMP, TOO RICH A FUEL
MIX TUR!, IMPROPERLY
OPERATING HEAT RISER
GUIDES AND STEMS, OR WORN OR
LOOSE BEARINGS . CAN BE CLEANED
IF ENGINE IS NOT REPAIRED, USE
A HOTTER PLUG.
OR EXCESSIVE IDLING.
CAN BE CLEANED.

0 0®®00
FIG. 5- Intake Manifold Torque
Sequence- 302 and 351 Engines
BATTERY CABLES
Check battery cable connections
IDENTIFIED BY DARK IDENTIFIED BY LIGHT TAN OR IDENTIF lED BY SEVERELY
for tightness. Check cables for GRAY , BLACK, YELLOW GRAY DEPOSITS ON THE ERODED OR WORN ELECTRODES.
frayed insulation or excessive corro- OR TAN DE POSITS OR A FIRING TIP. CAUSED BY NORMAL WEAR.
FUSED GLAZED COATING CAN i3E CLEANED. SHOULD BE REPLACED.
sion. Replace as required. ON THE INSULATOR TIP.
CAUSED BY HIGHLY
LEADED GASOLINE. CAN
INSPECT SECONDARY IGNITION BE CLEANED.
WIRING
Inspect the secondary (high-ten-
sion) wiring for cracked insulation
or indications of heat damage. Be PRE-IGNITION
sure that the spark plug wires are
fully seated on the spark plugs and
that the connections to the coil and
distributor are bottomed in the
receptacles provided.

INSPECT, CLEAN, ADJUST AND

TEST SPARK PLUGS- REPLACE
AS REQUIRED

REMOVAL IDENTIFIED BY MELTEu IDENTIFIED BY A WHITE OR LIGHT IDENTIFIED BY MEL TED

OR SPOTTY DEPOSITS GRAY INSULATOR WITH SMALL ELECTRODES AND POSSIBLY
RESEMBLING BUBBLES BLACK OR GRAY BROWN SPOTS BLISTERED INSULATOR.
1. Remove the wire from each OR BLISTERS.
AND WITH BLUISH-BURNT APPEAR. METALLIC DE POSITS ON
CAUSED BY SUDDEN
spark plug by grasping, twisting and ACCE LE RAT ION. CAN BE ANCE OF ELECTRODES, CAUSED INSULATOR INDICATE ENGINE
BY ENGINE OVERHEATING. WRONG DAMAGE.
then pulling the moulded cap of the CLEANED.
TYPE OF FUEL, LOOSE SPARK CAUSED BY WRONG TYPE
wire only. Do not pull on the wire PLUGS, TOO HOT A PLUG, LOW OF FUEL, INCORRECT IGNITION
TIMING OR ADVANCE, TOO HOT
FUEL PUMP PRESSURE OR INCOR.
because the wire connection in- RECT IGNITION TIMING. REPLACE A PLUG, BURNT VALVES OR
ENGINE OVERHEATING.
side the cap may become sepa- THE PLUG.
REPLACE THE PLUG.
rated or the weather seal may
be damaged.
2. Clean the area around each
spark plug port with compressed air,
then remove the spark plugs. FIG. 6- Spark Plug Inspection Guide
20-6 GROUP 20- MAINTENANCE OPERATIONS

CLEANING AND INSPECTION the cap out of the way (if necessary,
remove the air cleaner and/ or the
1. Examine the firing ends of the high tension wire to gain access to
spark plugs, noting the type of de- the distributor).
posits· and the degree of electrode Lift the rotor off the cam.
erosion. Refer to Fig. 6 for the Refer to applicable section of the
various types of spark plug con- Shop Manual for distributor point
ditions and causes. specifications.
2. Clean the plugs on a sand blast
cleaner, following the manufacturer's INSPECTION
instructions. Do not prolong the Replace the distributor point as-
use of the abrasive blast as it sembly if the contacts are badly
will erode the insulator. Remove burned or excessive metal transfer
carbon and other deposits from the between the points is evident. Metal
threads with a stiff wire brush. Any transfer is considered excessive when
deposits will retard the heat flow from it equals or exceeds the gap setting.
the plug to the cylinder head causing REMOVAL-BOSCH DISTRIBUTORS
spark plug overheating and pre- 6 CYL. AND 302 VS
ignition.
3. Clean the electrode surfaces 1. Remove contact breaker lead
with a small file (Fig. 7). Dress FIG. 7- Cleaning Spark Plug from primary terminal connector.
the electrodes to secure flat Electrode 2. Remove screw securing contact
parallel surfaces on both the breaker assembly in breaker plate
centre and side electrode. and lift off contact breaker as an
4. Mter cleaning, examine the plug assembly.
carefully for cracked or broken insu- 3. The contact breaker assembly
lators, badly pitted electrodes, and may be separated by depressing the
other signs of failure. Replace as moving contact spring blade until the
required. terminal block is clear of the station-
ary point.
ADJUSTMENT
INSTALLATION
Set the spark plug gap by bending
the ground electrode (Fig. 8). 1. Assemble the contact breaker
Never bend the centre electrode. assembly by depressing the contact
spring blade and pushing the mov-
TESTING able breaker on to the stationary
breaker.
After the proper gap is obtained, FIG. 8 -Checking Spark Plug 2. Position the contact breaker
check the plugs on a testing machine. Gap assembly on to the breaker plate and
Compare the sparking efficiency of secure with screw.
the cleaned and gapped plug with a CHECK AND ADJUST 3. Replace contact breaker lead on
new plug. Replace the plug if it fails DISTRIBUTOR POINTS - REPLACE primary terminal.
to pass the test as outlined in the AS REQUIRED 4. The breaker points must strike
tester instruction manual. squarely, to align the breaker points
Test the plugs for compression Unsnap the distributor cap retain-
ing clips, lift the distributor cap off carefully bend the stationary point
leakage at the insulator seal. Apply a bracket until full face contact is
coating of oil to the shoulder of the the distributor housing, and position
obtained.
plug where the insulator projects
through the shell, and to the top of CONDITION CAUSED BY
the plug, where the centre electrode
and terminal project from the insula-
tor. Place the spark plug under pres- Incorrect voltage regulator setting.
sure with the tester's high tension Radio condenser installed to the distributor
wire removed from the spark plug. side of the coil.
Leakage is indicated by air bubbling
through the oil. If the test indicates
compression leakage, replace the
plug. If the plug is satisfactory, wipe Incorrect alignment.
it clean. Incorrect voltage regulator setting.
INSTALLATION Radio condenser installed to the distributor
side of the coil.
1. Install the spark plugs and
torque each plug to 15-20 ft-lbs. Ignition condenser of improper capacity.
2. Connect the spark plug wires. EXCESSIVE METAL
Extended operation of the engine at speeds
Check wire position in support TRANSFER OR PITTING other than normal.
81443 -C
brackets. Press wires firmly into
proper bracket slots. Push all weather
seals into position. FIG. 9 -Breaker Point Inspection
PART 20-1- MAINTENANCE OPERATIONS 20-7

ing and snap the retaining clips in

rfi=D:=::~
place.
CHECK IGNITION TIMING

~CORRECT.~ ALIGNMENT
To check and adjust the ttmmg
with a power timing light, proceed
as follows:
1. Remove the plug wire from the
C ONOT
AREA NTACT@ number 1 spark plug.
CENTERED 2. Install the spark plug adaptor
on the spark plug.
MISALIGNMENT 3. Connect the plug wire to the
spark plug adaptor.
4. Clamp the timing light spark
o:o:::TR@
AREA NOT
plug lead to the spark plug adaptor.
CENTERED 5. Connect the timing light battery
B 3318-A leads to the battery terminals.
ISALIGNMENT 6. Disconnect the distributor vac-
OF POINT FACES 11019-A FIG. 12- Aligning Breaker uum line.
FIG. 10- Breaker Point Points 7. If necessary, clean and mark the
timing marks.
Alignment Guide 3. After the breaker points have 8. Operate the engine at the speci-
been properly aligned, adjust the fied idle rpm and point the timing
breaker point gap or dwell. light at the timing pointer.
DWELL ANGLE ADJUSTMENT 9. If the timing is incorrect, loosen
the distributor hold down bolt and
Use a dwell meter to check the rotate the distributor until the de-
contact dwell. It is not advisable to sired initial advance is obtained.
use a feeler gauge to check the gap of 10. Tighten the distributor hold
used breaker points because the down bolt and check the timing
roughness of the points makes an again.
accurate gap reading or setting im- 11. Turn off the engine.
possible. 12. Remove the timing light and
If the used points are serviceable, connect the vacuum line.
set the gap using a dwell meter as
follows: CARBURETTOR AIR CLEANER
1. Connect the dwell meter follow- CLEAN OR REPLACE FILTER
ing the manufacturer's instructions. REMOVAL:
BEND STATIONARY BRACKET 2. Operate the engine at specified
idle speed and note the reading on
FIG. 11 -Aligning Breaker the dwell meter. 1. Remove the wing nut retaining
Points - Typical 3. Stop the engine and adjust the the air cleaner (and duct if so equip-
gap (decreasing the gap increases the ped) assembly to the carburettor.
5. Reset the breaker point gap to dwell). Now check the dwell again. 2. Remove the air cleaner (and
speci.fications. 4. Repeat this .procedure until duct if so equipped) assembly from
6. Replace rotor and distributor specified dwell is obtained. the carburettor. To prevent dirt
cap. If new points are installed, set the from entering the carburettor,
BREAKER POINT gap to specifications using a feeler the filter element must never be
ALIGNMENT 351C gauge. Check setting with dwell removed when the air cleaner
meter. body is mounted on the carburet-
The vented-type breaker points If the distributor is equipped with tor.
used in Ford distributors must be ac- dual breaker points, adjust the dwell 3. Remove the air cleaner cover
curately aligned in order to realize the of each set separately in order to get and filter element. Discard the air
full advantages provided by this de- the specified combined dwell. The cleaner mounting gasket if it is ex-
sign, and to assure normal breaker most precise method is to disconnect cessively worn or damaged.
point life. Any misalignment of the one set of points while adjusting the
breaker point surfaces will cause pre- other, since spring tension on the cam
mature wear, overheating and pitting. is then equal. Alternately, a piece of
1. Turn the distributor cam so that plastic can be inserted between the
the breaker points are closed and contacts of one set to take it out of
check the alignment of the points the circuit. As an example: where a
(Fig. 10). 33 degree combined dwell is specified,
2. Align the breaker points to make the points are set separately at 25-25
full face contact by bending the 1/ 2 degree to secure the specified 33
stationary breaker point bracket degree dwell.
(Figs. 11 and 12). Do not bend the 5. Install the rotor. Install the dis-
breaker arm. tributor cap on the distributor hous-
20-8 GROUP 20- MAINTENANCE OPERATIONS

CLEANING FILTERING ELEMENT sUN the word TOP faces up. IDLE SPEED AND FUEL MIXTURE
4. Install the cover and tighten the
The cellulose fibre filter ele- All XA/ZF Falcon/Fairlane
wing bolt.
ment must never be cleaned carburettors are equipped with idle
with a solvent or cleaning solu- CHECK BRAKE MASTER CYLINDER fuel mixture adjusting limiters. The
tion. Also, oil must not be added FLUID LEVEL limiters control the maximum idle
to the surfaces of the filter ele- richness and help prevent unauthor-
ment or air cleaner body. 1. Remove the filler cap from the ized persons from making overly rich
There are two procedures that can master cylinder. The diaphragm idle adjustments.
be used to clean the air filter element. which seals the master cylinder The plastic idle limiter cap is in-
One method is performed with the should come off with the cap. stalled on the head of the idle fuel
use of compressed air. The other is 2. Fill the reservoir to i inch from mixture adjusting screw(s) (Figs. 13
performed by tapping the element on the top with approved fluid. and 14). Any adjustment made on car-
a smooth horizontal surface. 3. Install the filler cap, making burettors having this type of limiter
Compressed Air Method. Direct sure that the diaphragm is properly must be within the range- of the idle
a stream of compressed air through seated in the cap. adjusting limiter. Under no cir-
the element in the directioh opposite CHECK CLUTCH MASTER cumstances are the idle adjusting
that of the intake air flow, that is CYLINDER FLUID LEVEL limiters or the limiter stops on
from the inside outward. Extreme the carburettor to be mutilated
care must be exercised to pre- 1. Remove the filler cap from the or deformed to render the limi-
vent rupture of the element master cylinder. ters inoperative. On the Motorcraft
material. 2. Top up the reservoir to t inch 21 00-D 2-V carburettor, the power
Tapping Method. Hold the ele- below the top face, with approved valve cover must be installed with the
ment in a vertical position and tap fluid. limiter stops on the cover in
it lightly against a smooth, horizontal 3. Install the filler cap.
surface to shake the dust and dirt out. CHECK POWER STEERING
Do not deform the element or RESERVOIR FLUID LEVEL
damage the gasket surfaces by
tapping too hard. Rotate the filter Start the engine, turn the steering
after each tap until the entire outer wheel all the way to the left and right
surface has been cleaned. several times, and shut off the engine.
Inspection. Hold the filter in Check the fluid level in the reser-
front of a back-up light and carefully voir. If the level is low, add enough
inspect it for any splits or cracks. If fluid to raise the level to the bottom
the filter is split or cracked, replace it. of the filler neck. Do not overfill
the reservoir.
CLEANING BODY AND COVER CHECK BATTERY FLUID LEVEL
Clean the air cleaner body and the The battery is mounted under the
cover with a solvent or compressed hood at the right front side of the
air. If the air cleaner contains an engine compartment.
opening for the crankcase ventilation Keep the fluid in each battery cell
system air flow, probe the opening to up to the level of the ring in the
assure removal of deposits. Wipe the bottom of the filler well. Generally,
air cleaner dry if a solvent is used. tap water may be added unless it FIG. 13 -Idle Fuel Limiters-
Inspect the air cleaner body and has a high mineral content or has Motorcraft 4300 4-V
cover for distortion or damage at the been stored in a metal container.
gasket mating surfaces. Replace the IDLE ADJUSTING LIMITERS
cover or body if they are damaged
beyond repair. CLEAN CHOKE EXTERNAL
LINKAGE
INSTALLATION
1. Install a new air cleaner mount- Examine the choke external linkage
ing gasket on the carburettor, if for free operation. If the linkage ap-
necessary. pears to be sticking, or is dirty, clean
2. Install the air cleaner body on the linkage using a brush and com-
the carburettor or position the air mon mineral-spirits type cleaning
cleaner and air intake duct and valve fluid. Operate the choke plate manu-
assembly on the carburettor. ally to make sure that it moves freely.
3. Place the air cleaner filter ele- Lubricate the choke plate shaft at LIM IT ER STOPS 83114-A
ment in the air cleaner body. each end and the choke operating link
Make sure the filter is properly with engine oil if necessary. Refer to
FIG. 14- Motorcraft Modei2100-D
seated. If the word TOP is indi- the applicable section for choke 2-V Idle Adjusting Limiters and
cated on the filter element, make adjustment specifications. Limiter Stops - Bottom View
PART 20-1- MAINTENANCE OPERATIONS 20-9

throttle plate(s) to seat in the throttle 4. Be sure the choke plate is in the
bore(s). full-open position.
4. Turn the idle speed adjusting 5. Turn the headlights on high
screw inward (outward for Stromberg beam to place the alternator under a
BV2) until it just makes contact with load condition in order to properly
the screw stop on the throttle shaft adjust to the specified engine idle
and lever assembly. Then, turn the speed.
screw inward (outward for BV2) 1t 6. The final idle speed adjust-
turns to establish a preliminary idle ment is made with the air condi-
speed adjustment (Fig. 17). tioner (if equipped) turned ON.
5. Set the parking brake while 7. Adjust the engine curb idle rpm
making idle mixture and speed to specifications. The tachometer
adjustments. reading (rpm) must be taken with the
NORMAL IDLE FUEL SETTINGS- air cleaner installed.
ENGINE ON If it is not possible to adjust the
idle speed with the air cleaner in-
1. The engine and underhood tem- stalled, remove it, make the adjust-
peratures must be stabilized before ment, then replace the air cleaner and
FIG. 15 -Idle Fuel Mixture idle adjustments are made. Run the check again for the specified rpm.
Adiustment (BV2) engine a minimum of 20 minutes at Manual transmission vehicles may
position to provide a positive stop for 1,500 rpm. This can be done by be fitted with a solenoid throttle
tabs on the idle adjusting limiters positioning the fast idle screw or cam positioner. However, this is not con-
(Fig. 14). follower on the kickdown step of the nected on these engines and must be
A satisfactory idle should be fast idle cam (Fig. 18). (Not applic- adjusted so as not to affect the engine
obtainable within the range of able to Stromberg BV2). idle speed. Idle speed adjustment is
the idle adjusting limiters, if all 2. Check the initial ignition timing to be made on the normal throttle
other engine systems are opera- and the distributor advance. Use an stop screw.
ting within specifications. accurate-reading tachometer and tim- 8. Turn the idle mixture adjusting
ing light when checking the initial screw(s) inward to obtain the smooth-
Note: The limiter caps fitted to ignition timing and idle fuel mixture est idle possible within the range of
Stromberg carburettors is free turn- and speed. the idle limiter( s), Motorcraft car-
ing on the head of the idle mixture 3. On vehicles with a manual-shift burettors only. Turn the idle mixture
adjusting screw. THE ONLY IDLE transmission, the idle setting must be adjusting screws inward an equal
ADJUSTMENT ALLOWABLE IN made only when the transmission is amount.
NORMAL SERVICE IS THE in Neutral.
ENGINE IDLE SPEED. On vehicles with an automatic On 2- and 4-venturi carburettors,
Following are the normal proce- transmission, the idle setting is made turn the idle mixture adjusting
dures necessary to properly adjust the with the transmission selector lever screws inward an equal amount.
engine idle speed and fuel mixture. in the Drive range. Check for idle smoothness only
The specific operations should be with the air cleaner installed.
followed in the sequence given when-
ever the idle speed or idle fuel
adjustments are made.
In isolated cases, a satisfactory idle
condition may not be achieved by
performing the normal procedures.
If this occurs, refer to Additional Idle
Speed and Fuel Mixture Procedures.
NORMAL IDLE FUEL SETTINGS -
ENGINE OFF
1. Set the idle fuel mixture screw(s)
Motorcraft craburettors only; to the
full-counterclockwise position of the
limiter cap(s) (Figs. 13 to 14).

2. Back off the curb idle speed ad-

justing screw (Fig. 17) until the
throttle plate(s) seat in the throttle
bore(s).
3. Be sure the dashpot or solenoid
throttle positioner (if so equipped) is
not interfering with the throttle lever IDLE MIXTURE ADJUSTING SCREWS
(Fig. 19).
It may be necessary to loosen the FIG. 16 -Idle Fuel Mixture -
dashpot or solenoid to allow the ww
20-10 GROUP 20- MAINTENANCE OPERATIONS

FAST I OLE
( Bend u ••ou•••.. ll+',····

FAST IDLE

MOTORCRAFT MODEL 4300-4V

STROMBERG (WW SERIES)

STROMBERG (BV2)

MOTORCRAFT MODEL 2100-D, 2V

FIG. 17 - Curb Idle Speed Adjusting Screws
ADDITIONAL IDLE SPEED AND FAST IDLE ADJUSTMENT
FUEL MIXTURE PROCEDURES
If satisfactory idle condition is not 2. If the idle condition is not im- The fast idle adjusting screw (Fig.
obtained after performing the pre- proved after the items in Step 1 have 18) contacts one edge of the fast idle
ceding normal idle fuel settings, been checked, perform the following cam. The cam permits a faster engine
additional checks of engine systems engine mechanical checks: idle speed for smoother running when
must be performed. a. Fuel Level. the engine is cold during choke oper-
1. The following items should be b. Crankcase ventilation system. ation. As the choke plate is moved
checked and, if required, corrected: c. Valve clearance (using the col- through its range of travel from the
a. Vacuum leaks. lapsed tappet method for hy- closed to the open position, the fast
b. Ignition system wiring contin- draulic valves). idle cam pick-up lever rotates the
uity. d. Engine compression. fast idle cam. Each position on the
c. Spark plugs. 3. Mter verification of all engine fast idle cam permits a slower idle
d. Distributor breaker point dwell systems has been made, t!lere may be rpm as engine temperature rises and
angle. isolated cases where a satisfactory choking is reduced.
e. Distributor point condition. idl~ condition has not been obtained, Make certain the curb idle
f. Initial ignition timing. due possibly to a lean idle fuel mix- speed and mixture are adjusted
In certain instances, it may be pos- ture, If this condition is encountered,
sible that the idle condition is not as refer to the specific carburettor sec-
good as normally expected. tion of Group 10 of this manual for
correction procedure.
FAST IDLE ADJUSTING SCREW

FAST
(Bend .u ••ou,, .. ,....,..,.

FAST IDLE CAM

STROMBERG (WW SERIES)
MOTORCRAFT MODEL 2100-D, 2V MOTORCRAFT MODEL 4300-4V
FIG. 18- Fast Idle Speed Adjustment
PART 20-1- MAINTENANCE OPERATIONS 20-11

to specification before attempt- retaining screws. the choke lever.

ing to set the fast idle speed. 3. If other carburettor adjustments Hold in this position and check
1. With the engine operating tem- are not required, install the heater choke valve opening "D" with a drill .
perature normalized (hot), air cleaner hose and mounting bracket (if so gauge. If opening is not 0.140", bend
removed and the tachometer attach- equipped) and the air cleaner assem- choke link at point indicated to
ed, manually rotate the fast idle cam bly on the carburettor. obtain correct setting. After bending
until the fast idle adjusting screw THERMOSTATIC SPRING HOUSING INDEX MARK
link, ensure choke valve does not
rests on the specified step on the bind in any position.
cam. (Refer to the applicable car-
burettor section for specifications.)
2. Turn the fast idle adjusting
screw inward or outward as required
to obtain the specified fast idle rpm.
ANTI-STALL DASHPOT where fitted
1. With the engine idle speed and
mixture properly adjusted, and the
engine at normal operating tempera- Preu and Hold Olaphratm
ture, loosen the anti-stall dashpot at Its full llmU of Trav..

lock nut.
2. Hold the throttle in the closed
position and depress the plunger with FIG. 22- Vacuum Kick-
a screwdriver blade. Measure the Stromberg WW Series
clearance between the throttle lever CHOKE HOUSING INDEX MARK 82394-A
and the plunger tip. Turn the anti- MOTORCRAFT MODEL 2100D-2V
stall dashpot in a direction to provide FIG. 20- Automatic Choke CHOKE PLATE PULL DOWN
the specified clearance between the Thermostatic Spring Housing CLEARANCE
tip of the plunger and the throttle Adjustment - Typical
lever. Tighten the locknut to secure 1. Remove the air cleaner.
the adjustment. 2. With the engine at normal oper-
CHOKE PLATE PULL DOWN ating temperature, loosen the choke
CLEARANCE thermostatic spring housing retainer
STROMBERG WW SERIES screws and set the housing 90 degrees
(Figs. 21 and 22) in the rich direction.
3. Disconnect and remove the
Apply light closing pressure to choke heat tube from the choke
choke valve, then open throttle valves housing.
to wide open position. The choke 4. Turn the fast idle adjusting
valve should open just enough to screw outward one full turn.
allow the insertion of drill gauge 5. Start the engine, then check for
"C" between the choke valve and the specified clearance between the
wall of air horn. Bend ear on the lower edge of the choke plate and the
throttle lever as required to obtain air horn wall (Fig. 23) .
DASHPOT LOCKNUT 83134-A correct opening of 0.250". 6. If the clearance is not within
specifications, turn the diaphragm
FIG. 19- Dashpot- Typical stop screw (located on the underside
Installation of the choke diaphragm housing)
clockwise to decrease or counter-
AUTOMATIC CHOKE clockwise to increase the clearance.
THERMOSTATIC SPRING 7. Connect the choke heat tube and
HOUSING ADJUSTMENT set the choke thermostatic spring
The automatic choke, where ap- BEND EAR OF
housing to specifications. Adjust the
plicable, has an adjustment to control
THROTTLE
(AI reQuired)
fast idle speed to specifications.
its reaction to engine temperature by FAST IDLE CAM CLEARANCE
loosening the clamp screws that re-
tain the thermostatic spring housing 1. Loosen the choke thermostatic
to the choke housing. spring housing retainer screws and
The spring housing can be turned set the housing 90 degrees in the rich
to alter the adjustment. Refer to the FIG. 21- Choke Plate Pull Down direction.
specifications for the proper setting. 2. Position the fast idle speed screw
Clearance - Stromberg WW Series at the kickdown step of the fast idle
1. Remove the air cleaner assem-
bly, heater hose and mounting bracket Depress diaphragm pull rod to the cam. The kickdown step is identi-
(if so equipped) from the carburettor. full limit of its travel and apply light fied by a V stamped on the cam
2. Loosen the thermostatic spring upward pressure to choke lever to (Fig. 24).
housing clamp retaining screws. Set take up slack in linkage and to deflect On the 351-C engine, a two-piece
the spring housing to the specified the modulation spring so that the fast idle lever is used to provide
index mark and tighten the clamp choke link is at the end of its slot in clearance between the lever and man-
20-12 GROUP 20-MAINTENANCE OPERATIONS
DRILL OR GAUGE OF
SPECIFIED CLEARANCE

FOR 351-C ENGINE

Vl261-A

FIG. 24- Fast Idle Levers Used

on the Motorcraft Model2100-D 2-V
Carburettor
3. Block the throttle about half-
open so the fast idle cam does not
contact the fast idle adjustment
screw, then insert the bent end of the
FAST IDLE
ADJUSTING SCREW
wire gauge between the \ower edge of
the piston slot and the upper edge of
the right hand slot in the choke
V1202-A housing (Fig. 25).

FIG. 23- Choke Plate Pulldown Clearance- Motorcraft Model

21 00-D 2-V Carburettor
ifold, and a tang on the top lever will
align with the V mark on the cam
DRILL GAUGE OF SPECIFIED
(Fig. 24).
CLEARANCE SIZE
3. Be sure the cam is at the
kickdown position while checking
or adjusting the fast idle cam
clearance.
Check for the specified clearance
between the lower edge of the choke
plate and the air horn wall. To adjust
the clearance, turn the fast idle cam
clearance adjusting screw clockwise
to increase and counterclockwise
to decrease the clearance.
4. Set the choke thermostatic
spring housing to specifications.
Adjust the anti-stall dashpot, idle
speed and fuel mixture.

MOTORCRAFT MODEL 4300-4V

CHOKE PLATE PULL DOWN
CLEARANCE

1. Remove the air cleaner, then re-

move the choke thermostatic spring
housing from the carburettor. Tore-
move the thermostatic spring housing
from the carburettor installed on the
engine, refer to Thermostatic Spring
Housing and Gasket Replacement. APPLY LIGHT PRESSURE TO CHOKE LEVER
V1235-A
2. Bend a wire gauge of 0.036-inch
diameter at a 90 degree angle approxi-
mately %-inch from one end. FIG. 25 -Choke Plate Pull-Down and Fast Idle Cam Adjustment
PART 20-1- MAINTENANCE OPERATIONS 20-13

4. Pull the choke piston lever 4. If the choke plate clearance and the arm parallel with the pump stem.
counterclockwise until the gauge is fast idle cam linkage adjustment was 6. Return the air horn gasket to
snug in the piston slot. Hold the wire performed with the carburettor on its position and replace the air horn
gauge in place by exerting light pres- the engine, adjust the engine idle and air cleaner assembly. The capa-
sure in a rearward direction on the speed and fuel mixture. Adjust the city of the accelerator· pump is
choke piston lever. Check the choke anti-stall dashpot (if so equipped). correctly calibrated at the specified
plate clearance (Pull down) between pump stroke and any variation of
the lower edge of the choke plate and ACCELERATING PUMP STROKE this stroke outside the limits given
the wall of the air horn. ADJUSTMENT: must result in reduced performance
5. To adjust the choke plate clear- STROMBERG (BV 2) and economy.
ance, loosen the hex. head screw (left Do not remove the carburettor
hand thread) on the choke plate shaft Stromberg WW Series
from the engine to adjust the pump
(Fig. 25) and pry the link away irom stroke. With throttle valves fully closed
the tapered shaft. To check the pump stroke:- against their bores (i.e. slow idle
Use a drill gauge 0.010-inch 1. Start the engine and run at idle adjustment screw backed out clear of
under the specified clearance to normalise engine temperature. shut throttle lever), and with pump
between the lower edge of the choke Set the engine to the correct idle rod in throttle lever hole specified,
plate and the wall of the air horn. speed. This is important as it gives check the external vent washer open-
Hold the choke plate against the ing "J" as shown in Fig. 27.
the correct closed throttle position.
gauge and maintain a light pressure 2. Stop engine and remove air Bend pump rod at point indicated
in a rearward direction on the choke cleaner assembly and carburettor air to obtain specified opening.
lever. horn.
With the choke piston snug against 3. Measure from the top of the
the 0.036-inch wire gauge and the pump piston stem to the top face
choke plate against the drill gauge, of the carburettor main body with
tighten the hex. head screw (left hand gasket removed (Fig. 26).
thread) on the choke plate shaft.
The use of a 0.010-inch undersize
drill gauge is to allow for tolerances
in the linkage. Use a drill gauge
equal to the size of the specified
clearance to make a final check.
6. Install the gasket and thermo-
static spring housing on the choke FIG. 27- Accelerator Pump
housing. Install the spring housing
retainer and screws. Clearance -Stromberg WW Series
FAST IDLE CAM CLEARANCE NOTE: Make sure choke valve is
held open during above check so that
1. Rotate the spring housing coun- throttle valves can close fully.
terclockwise (rich direction) to align
the centre indeJC mark on the choke MOTORCRAFT MODEL 2100-D 2V
housing with the index mark on the
spring housing. Rotate the spring The stroke should not be
housing an additional 90 degrees changed from the specified set-
counterclockwise and tighten the re- ting.
taining screws. FIG. 26- Accelerator (6 cyl.) If the pump stroke has been
2. Position the fast idle speed ad- Pump Adjustment changed from the specified setting
justing screw end on the kickdown refer to the following instructions to
(centre) step of the fast idle cam. 4. Open throttle wide and again correct the stroke to specifications.
Check the clearance between the measure from the top of the pump The primary throttle shaft lever
lower edge of the choke plate and the piston stem to the top face of the (overtravel lever) has 4 holes and the
air horn wall. Turn the fast idle cam carburettor main body with gasket accelerating pump link has 4 holes
adjusting screw inward to increase removed. (Fig. 28) to control the accelerating
the clearance or outward to de- 5. The difference between these pump stroke.
crease · the clearance. Make sure two measurements will be the The accelerating pump operating
the fast idle speed adjusting length of the pump stroke. This rod should be in the specified hole in
screw stays at the kickdown step length should be within the specified the overtravel lever and the inboard
of the fast idle cam during the limits with the mean size of the hole (hole closest to the pump
adjustment. limits being desirable. plunger) in the accelerating pump
On the 351-C engine, a two-piece If the measurement is found to link (Fig. 28).
fast idle lever is used to provide be outside the specified limits, the 1. To release the rod from the re-
clearance between the lever and mani- pump stroke can be adjusted by taining clip, press the tab end of the
fold, and a tang on the top lever will bending the arm (top, horizontal clip toward the rod; then, at the same
align with the V mark on the cam. position) of the pump rod. No more time, press the rod away from the
3. Set the thermostatic choke hous- than ·h " to ~~" adjustment should clip until it is disengaged.
ing to the specified index mark and be required. Two bends in the arm 2. Position the clip over the speci-
tighten the retaining screws. will be necessary to keep the hole in fied hole in the overtravel lever.
20-14 GROUP 20- MAINTENANCE OPERATIONS
!lEND ROD TO
AD JUS f HUGHT

FIG. 29- Accelerating Pump

Piston Stem Height and Pump
Stroke

/
I

V1507- B

FIG. 28 "ACCELERATOR PUMP STROKE

MODEL 2100 CARBURETTOR"

Press the ends of the clip together pump stroke, measure the height of
and insert the operating rod through the pump piston stem as shown in
the clip and the overtravellever. Re- Fig. 29. Bend the pump control rod
lease the clip to engage the rod. to correct the piston stem height to FIG. 30- Vent Valve Adjustment
MOTORCRAFT MODEL 4300-4V specifications.
If it is necessary to correct the (6 cyl.)
The accelerating pump stroke has setting, the pump stroke can be ting pump stroke adjustment has
been set to help keep the exhaust altered as follows: been completed.
emission level of the engine within 1. Remove the pump pivot pin 1. Ensure the engine idle speed
the specified limits. The additional retainer. Remove pivot pin. is correct and engine is at normal
holes provided for pump stroke ad- 2. Insert the pivot pin into the operating temperature. l'his is im-
justment are for adjusting the stroke desired hole. portant as it gives correct closed
for specific engine applications. The 3. Install the pivot pin retainer. throttle position.
stroke should not be changed Position the pump rod end into the 2. Remove the air cleaner assembly
from the specified setting. pump arm and install the retainer. and with the throttle in the idle posi-
If the pump stroke has been tion, loosen the vent valve locknut
changed from the specified setting VENT VALVE ADJUSTMENT: and adjust from .05"-.06" to the
refer to the following instructions to STROMBERG (BV 2) closed £OSition when throttle is
correct the stroke to specification. The vent valve adjustment is opened (Fig. 30).
Before adjusting the accelerating always performed after the accelera- 3. Install air cleaner assembly.

EJ TRANSMISSION, CLUTCH AND REAR AXLE

CHECK TRANSMISSION FLUID the filler hole, fill the case with the reaches its normal operating temper-
LEVEL specified lubricant until it is level ature. When the fluid is warm, slow
with the lower edge of the filler hole. the engine down to normal idle speed.
3. Install the filler plug. 3. Shift the selector lever through
Refer to Part 19, Maintenance AUTOMATIC TRANSMISSION($) all positions, place the lever at P and
Schedule, for recommended fre- 1. Make sure the car is standing check the fluid level.
quency of service. level. Then firmly apply the parking 4. Clean all dirt from the trans-
brake. mission fluid dipstick cap before re-
MANUAL TRANSMISSION($) 2. Run the engine at normal idle moving the dipstick from the filler
1. Remove the filler plug from the speed. If the transmission fluid is tube.
side of the case. cold, run the engine at fast idle speed 5. Pull the dipstick out of the tube,
2. If lubricant does not flow from (about 1200 rpm) until the fluid wipe it clean, and push it all the way
PART 20-1- MAINTENANCE OPERATIONS 20-15
back into the tube. Be sure it is pro- quency of service. washers securing the transmtsston
perly seated. oil pan and detach the oil pan and
6. Pull the dipstick out of the tube C4 gasket. Slacken the adjusting screw
again, and check the fluid level. If INTERMEDIATE BAND locknut, move the servo lever out-
necessary, add enough fluid to the 1. Clean all dirt from the band ad- wards and place a 0.25 in. gauge
transmission through the filler tube justing screw area, remove and dis- between the servo piston pin and the
to raise the fluid level to the F (full) ca.cd the lock nut, install a new lock
mark on the dipstick. Do not over- adjusting screw (see Fig. 33).
nut, do not tighten.
fill the transmission. 2. Torque the adjusting screw to Tighten the adjusting screw to a
ADJUST AUTOMATIC 10ft. lbs., when using tool J-21111 or torque of 10 in. lbs., tighten the lock-
TRANSMISSION BAND(S) BW-547A-50-2 set the torque wrench nut and then remove the gauge block.
Refer to Part 19, Maintenance (W & B model 3200B) to 60 in. lbs. Ensure that the mating faces are
Schedule, for recommended fre- This will result in 10 ft. lbs. torque clean and refit the oil pan with a new
at the screw(see Fig. 31). gasket. Tighten the fifteen bolts in
3. BACK OFF THE ADJUST- their lock-washers to a torque of 8 to
ING SCREW EXACTLY 1t 10ft. lbs.
TURNS. REAR-REVERSE BAND
4. Hold the adjusting screw from 1. Clean all the dirt from the band
turning and torque the lock nut. to adjusting screw area. Loosen the
specification. lock nut several turns.
LOW- REVERSE BAND 2. With the tools shown in Fig. 34,
tighten the adjusting screw to a tor-
Proceed as for intermediate band que of 10ft. lbs.
adjustment except for Step (3), where 3. Back off the adjusting screw
the adjusting screw is backed off exactly i of a turn.
exactly three (3) full turns (see Fig. 4. Hold the adjusting screw from
32). turning and torque the lock nut to
BORG WARNER specification.
FRONT BAND ADJUSTMENT Where neces~ary, to gain access
FIG. 31-lntermediate Band Remove the fifteen bolts and lock- to the adjusting screw, support the
Adiustment - C4 transmission with a floor jack and
remove the two nuts securing the
rear support assembly to the sub-
frame. Lower the transmission to
allow sufficient clearance between
the transmission and floor pan.
FMX TRANSMISSION
FRONT BAND ADJUSTMENT
1. Loosen the pan attaching bolts
starting at the rear of the pan and
working towards the front. When
most of the fluid has drained from the
pan, remove the remainder of the
attaching bolts. If the same fluid is
to be used again in the transmis-
sion after the band adjustment,
filter the fluid through a tOO-
FIG. 32 - Low-Reverse Band FIG. 33- Front Band Adiustment mesh screen as it drains from the
Adiustment - C4 transmission. Make sure that the

FIG. 34- Rear Band Adiustment- Borg Warner

20-16 GROUP 20- MAINTENANCE OPERATIONS
and clip from the transmission. Clean threads.
the inside of the pan. Do not 2. Loosen the reverse band adjust-
attempt to clean the filter. If ing screw lock nut. Use the tool
dirty install a new one. Discard shown in Figure 36 to loosen the nut.
the pan gasket. Remove all gasket Using the torque wrench shown in
material from pan and pan mounting Fig. 38 tighten the adjusting screw
face of case. until the tool handle clicks. The tool
3. Loosen the front servo adjusting is a preset torque wrench which
screw locknut two full turns. clicks and breaks when the torque on
4. Pull back on the actuating lever, the adjusting screw reached 10 ft.lbs.
then insert the Gauge Block Tool 3. If the screw is found to be tight-
7225-CI3-B, of front band adjusting er than wrench capacity (10 ft. lbs
Tool 7225-C (Fig. 35) between the torque), loosen the screw and tighten
servo piston stem and adjusting until the wrench clicks and breaks.
screw. 4. Back off the adjusting screw It
01015-C Tighten the adjusting screw until turns. Hold the adjusting screw
FIG. 35- Typical Front Band the wr~nch overruns (this should be stationary and tighten the adjusting
Adjustment- FMX exactly 10 in. lbs). Remove the gauge screw lock nut to 35-40 ft.lbs torque.
block. Tighten the adjusting screw an Severe damage may result if the
additional ! turn. Hold the adjusting adjusting screw is not backed off
screw stationary and tighten the exactly 1l turns.
locknut to specifications.
CHECK REAR AXLE FLUID LEVEL
5. Install the transmission fluid
screen and clip. Install the pan, using The lubricant level should be
a new gasket. maintained at ·the lower.edge of the
6. Refill the transmission. filler plug hole with the specified
7. Start the engine and engage the lubricant.
transmission in each drive range to fill
all fluid passages, then place the CLUTCH LINKAGE (MANUAL
selector in the "P" position. Check TRANSMISSION)
the fluid level and add enough fluid
to bring the level above the ADD There is no adjustment required or
FIG. 36- Adjusting Rear Band mark on the dipstick with engine provided for on any of the clutch
-FMX running at idle speed. systems. The only maintenance re-
container is clean. Reuse the fluid REAR BAND ADJUSTMENT quired is to top up the master
only if it is in good condition. cylinder to the correct level, approxi-
2: Remove and thoroughly clean 1. Remove all dirt from the adjust- mately t in. below the top face, with
the pan, then remove the fluid screen ing screw threads, then oil the approved fluid.

EJ UNDER BODY, STEERING AND ALIGNMENT

LUBRICATE AUTOMATIC By utilising the access holes in the ments within the recirculating ball-
TRANSMISSION KICKDOWN suspension towers, wipe off any type steering gear, and these should
LINKAGE accumUlated dirt from around the be made in the following order to
lubrication fittings and lubricate the avoid damage or gear failure.
Lubricate all pivot points in the inner bushes using a maximum of
kickdown linkage with the specified 3.2 grams per bushing.
engine oil. 1. Loosen the nut which locks the
sector adjusting screw (Fig. 38), and
LUBRICATE FRONT SUSPENSION CHECK STEERING GEAR PRE- turn the adjusting screw counter-
BALL JOINTS clockwise.
Wipe any accumula~ed dirt from LOAD POWER STEERING ONLY
around the lubrication plugs.
Remove the plugs and install lub- To check and adjust the power 2. Measure the worm bearing pre-
rication fittings. Lubricate the ball steering gear pre-load it is necessary load by attaching an in. lb. torque
joints using a maximum of 10 grams to remove the steering box from the wrench to the steering wheel nut
(one level teaspoon) of the specified vehicle and carry out the operation (Fig. 37). With the steering wheel off
lubricant and remove the lubrication on the bench. See page 3-36 centre, read the pull required to
fittings. Install the plugs. rotate the input shaft approximately
1t turns either side of centre. If the
LUBRICATE UPPER ARM INNER CHECK STEERING GEAR PRELOAD torque or preload is not within speci-
BUSHES cation (Part 3-6), adjust as explained
MANUAL STEERING ONLY in the next step.
Refer to Part 19, Maintenance
Schedule, for recommended fre-
quency of lubrication. There are only two possible adjust- 3. Loosen the steering shaft bear-
PART 20-1- MAINTENANCE OPERATIONS 20-17
CHECK BRAKE LINES AND LINING
1. Raise the car until the wheel and
DRUM BRAKES tyre clear the floor.
Raise all four wheels. Remove one 2. Remove the wheel cover or hub
of the front brake drums, and inspect cap. Remove the grease cap from the
the drum and the linings (the wheel hub. Remove the cotter pin, nut lock,
bearings should be inspected at this adjusting nut, and flat washer from
time and repacked if necessary). Do the spindle. Remove the outer bear-
not let oil or grease touch the ing cone and roller assembly.
drum or the linings. If the linings 3, Pull the wheel, hub, and drum
are worn to within "3~ inch of the assembly off the wheel spindle.
rivet heads on rivetted linings or shoe 4. Remove the grease retainer and
on bonded linings, replace or reline the inner bearing cone and roller
both sets (primary and secondary) on assembly from the hub with a drift.
the front or rear wheels. Under no cir- 5. Clean the lubricant off the inner
cumstances replace one lining and outer bearing cups with solvent
only, or one wheel set. Both front and inspect the cups for scratches,
FIG. 37- Checking Preload wheel sets or both rear wheel pits, excessive wear, and other
ing adjuster lock nut, and tighten or sets should be replaced whenever damage. If the cups are worn or
back off the bearing adjuster (Fig. 38) a respective lining or shoe is damaged, remove them with a drift.
to bring the preload within the speci- worn or damaged. If the drum 6. Thoroughly clean the inner and
fied limits. braking surface is excessively scored, outer bearing cones and rollers with
4. Tighten the steering shaft bear- refinish it. The condition of the re- solvent, and dry them thoroughly.
ing adjuster lock nut, and recheck the maining front linings is usually about Do not spin the bearings dry
preload. the same as that of the one inspected. with compressed air.
5. Turn the steering wheel slowly The rear brake linings may also need 7. Inspect the cone and roller
to either stop. Turn gently against replacing at the same time. assemblies for wear or damage, and
the stop to avoid possible dam- replace them if necessary. The cone
age to the ball return guides. FRONT WHEEL DISC BRAKES and roller assemblies and the
Then rotate the wheel 2! turns to bearings cups should be replaced
Raise all four wheels. Remove one as a unit if damage to either is
centre the ball nut. of the front wheel and tyre assem-
6. Turn the sector adjusting screw encountered.
blies, and inspect the disc caliper, 8. Thoroughly clean the spindle
clockwise until the specified pull and linings (the wheel bearings
(Part 3-6) is necessary to rotate the and the inside of the hub with
should be inspected at this time and solvent to remove all old lubricant.
worm past its centre high spot (Fig. repacked if necessary). Do not let
37). No perceptible backlash is per- Cover the spindle with a clean
oil or grease touch the disc or cloth, and brush all loose dust and
missible at 300 on either side of the linings. If the linings are V'{Orn
centre. dirt from the brake assembly. To
to within 0.030 inch of the surface of prevent getting dirt on the
7. While holding the sector adjust- the shoe, replace both sets of shoe
ing screw, tighten the lock nut to spindle, carefully remove the
and lining assemblies (inboard and cloth from the spindle.
specification and recheck the back- outboard) on the front wheels.
lash adjustment. 9. If the inner and/ or outer bear-
Under no circumstances replace ing cup(s) were removed, install the
8. Connect the Pitman arm to the one shoe and lining assembly
sector shaft and torque to specifica- replacement cup(s) in the hub. Be
only, or one wheel set. Both front sure to seat the cups properly
tion. wheel sets should be replaced
I'IWI PWG ADJUSTB LOCK NUT
in the hub.
whenever a respective shoe and . 10. No grease should be packed
lining is worn or damaged. mto the hubs between the bearing
If the disc braking surface is cups.
excessively scored, distorted, warped, 11. All old grease should be com-
worn or shows excessive runout, it pletely cleaned from the bearings
should be replaced. If the caliper is before repacking them with new
cracked or otherwise damaged, it grease. Pack the bearing cone and
must be replaced as a unit. roller assemblies with wheel bearing
With the parking brakes in the grease. A bearing packer is desirable
fully released position, check the for this operation. If a packer is not
brake cables. The cable adjustment available, work as much lubricant as
should be just tight enough to remove possible between the rollers and•
the slack. Excessive tightening cages. Lubricate the cone surfaces
may pull the brake shoes off with grease.
their anchors. 12. Place the inner bearing cone
Check all brake lines for leakage or and ~oller assembly in the inner cup,
physical damage and replace or repair and mstall the new grease retainer.
as .required. Be sure that the retainer is pro-
SECTOI SHAFT
ADJUSTING SCREW CLEAN AND PACK FRONT WHEEL perly seated. Smear wheel bear-
BEARINGS ing grease around seal lip.
FIG. 38- Typical Steering Gear 13. Install the wheel, hub, and
Adjustments DRUM BRAKES drum assembly on the wheel spindle.
20-18 GROUP 20- MAINTENANCE OPERATIONS
prevent getting dirt on the spin-
dle, carefully remove the cloth
from the spindle.
11. If the inner and/ or outer bear-
ing cup(s) were removed, install the
replacement cup(s). Be sure to seat
the cups properly in the hub.
. 12. No grease should be packed
mto the hubs between the bearing
Wi th drum/ d i s c and wheel Back off adjusting nut Selectivly position .tne cups.
r ot ati ng, to rq ue ad jus ting nut loc~ retainer on the
nut t o 17-25 ft lbs . until an end float of adjysting nut and locr 13. All old grease should be com-
.002-.008" in post tion with a new pletely cleaned from the bearings
cotter pin .
before repacking them, with new
grease. Pack the bearing cone and
FIG. 39- Front Wheel Bearing Adjustment roller assemblies with wheel bearing
grease. A bearing packer is desirable
HUB AND ROTOR INNER GREASE for this operation. If a packer is not
ASSEMBLY BEARING RETAINER
available, work as much lubricant as

~~~
possible between the rollers and
ADJUSTING cages. Lubricate the cone surfaces
NUT with grease.
14. Place the inner bearing cone
and roller assembly in the inner cup,
GREASE and install the new grease retainer.
CAP Be sure that the retainer is pro-
INNER BEARING perly seated. Smear wheel bear-
CONE AND ing grease around the seal lip.
ROLLER
15. Install the hub and rotor on the
wheel spindle. Keep the hub cen-
WHEEL
tred on the spindle to prevent
ASSEMBLY damage to the grease retainer or
the spindle threads.
F 1259 - A 16. Install the outer bearing cone
and roller assembly and the fiat
FIG. 40- Hub and Bearing- Disc Brakes washer on the spindle, then install
bearing cone and roller assembly the adjusting nut.
Keep the hub centred on the 17. Position the caliper over the
spindle to prevent damage to the (Fig. 40).
6. Pull the hub and disc off the disc and install the attaching bolts.
grease retainer or the spindle 18. Install the wheel and tyre on
threads. wheel spindle.
7. Remove the grease retainer and the hub.
14. Install the outer bearing cone 19. Adjust the wheel bearings, and
and roller assembly and the fiat the inner bearing cone and roller
assembly from the hub. install a new cotter pin. Bend the
washer on the spindle; then install ends of the cotter pin around the
the adjusting nut (Fig. 40). 8. Clean the lubricant off the inner
and outer bearing cups with solvent castellations of the nut lock. Install
15. Adjust the wheel bearings the grease cap.
(Fig. 39) and install a new cotter and inspect the cups for scratches,
pits, excessive wear, and other dam- 20. Install the hub cap or wheel
pin. Bend the ends of the cotter pin cover and lower the car.
around the castellations of the nut age. If the cups are worn or damaged,
remove them from the hub with a CHECK AND ADJUST PARKING
lock. Install the grease cap.
16. Install the hub cap or wheel drift. BRAKE LINKAGE
cover. 9. Thoroughly clean the inner and
outer bearing cones and rollers with Check the parking brake cables
DISC BRAKES solvent, and dry them thoroughly. when the brakes are fully released.
1. Raise the car until the wheel and Do not spin the bearings with If the cables are loose, adjust them
tyre clear the floor. compressed air. as follows:
2. Remove the wheel cover or hub Inspect the cone and roller assem- 1. Fully release the parking brake
cap. blies for wear or damage, and replace by turning the handle counter clock-
3. Remove the wheel and tyre them if necessary. The cone and wise and pushing it inward.
from the hub. roller assemblies and the bearing 2. Pull the parking brake handle
4. Remove the bolts attaching the cups should be replaced as a outward to the first notch from its
caliper to the spindle. Remove the unit if damage to either is en- normal released position.
caliper from the disc and wire it to countered. 3. Raise the car and loosen the
the underbody to prevent damage to 10. Thoroughly clean the spindle adjustment lock nut.
the brake hose. and the inside of the hub with solvent 4. Turn the locking adjustment nut
5. Remove the grease cap from the to remove all old lubricant. forward against the equalizer until a
hub. Remove the cotter pin, nut Cover the spindle with a clean moderate drag is felt when turning
lock, adjusting nut, and fiat washer cloth, and brush all loose dust and the rear wheels in the direction of
from the spindle. Remove the outer dirt from the brake assembly. To forward rotation (Fig. 41).
PART 20-1- MAINTENANCE OPERATIONS 20-19

VIEW .. C.CLE W
TYPICAL 3 ~ACES

VIEW IN CIRCLE Y

YIEW .. CIRCLE T

TORO.I.£ 'TO
?-10 LI. H

VIEW IN OACL[ U

FIG. 41 -Parking Brake Linkage

5. Release the parking brake, and ing the upper and lower surfaces of 6. Check the action of the shock
make sure that the brake shoes return the tyre. Check the front suspension absorbers. If the shock absorbers are
to the fully released position and no ball joints and mountings for loose- not in good condition, the car may
drag is felt when turning the rear ness, wear, and damage. Check the not settle in a normal, level position,
wheels. brake backing plate mountings. Tor- and front wheel alignment may be
que all loose nuts and bolts to affected.
CHECK TIRE PRESSURES Wheel Inspection. Wheel hub
specifications.
Check all tyres for specified pres- 3. Check the steering gear mount- nuts should be inspected and tight-
sures (cold). ings and all steering linkage connec- ened to specification at pre-delivery.
tions for looseness. Torque all Loose wheel hub nuts may cause
INSPECT AND CROSS-SWITCH mountings to specifications. If any of shimmy and vibration. Elongated
WHEELS AND TIRES the linkage is worn or bent, replace stud holes in the wheels may also
Switi::h tyres according to Fig. 42. the parts. result from loose hub nuts.
Tighten the wheel nuts to specified 4. Check the front wheel bearings. Keep the wheels and hubs clean.
If any in-and-out free play is noticed, Stones wedged between the wheel
torque. adjust the bearings to specification. and drum and lumps of mud or
CHECK FRONT WHEEL Replace worn or damaged bearings. grease can unbalance a wheel and
ALIGNMENT AND LINKAGE 5. Check and balance each wheel tyre.
as required. Check for damage that would
FRONT WHEEL ALIGNMENT affect the runout of the wheels. Wob-
CHECKS ble or shimmy caused by a damaged
Do not check and adjust front wheel will eventually damage the
wheel alignment without first wheel bearings. Inspect the wheel
making the following inspection rims for dents that could permit air
for front end maladjustment, to leak from the tyres.
damage, or wear. Check all the factors of front wheel
1. Check for specified air pressures F1019-A alignment except the turning angle
in all four tyres. before making any adjustments. The
2. Raise the front of the car off the FIG. 42- Tyre Cross-Switching turning angle should be checked only
floor. Shake each front wheel grasp- Diagram after caster, camber, and toe-in have
20-20 GROUP 20-MAINTENANCE OPERATIONS
been adjusted to specifications.
Equipment Installation. Equip-
ment used for front wheel alignment
inspection must be accurate. If port-
able equipment is being used, per-
form all inspection operations on a
level floor.
Alignment height spacers (Figs. 44
and 45) are used to check caster and
camber except on GT. The spacers
should be omitted when checking
ALIGNMENT MARKS
toe-in.
1. Drive the car in a straight line FIG. 43- Straight Ahead
far enough to establish the straight-
ahead position of the front wheels,
Position Marks - +3 Typical
Tool - 3000- A or B
and then mark the steering wheel hub
and the steering column collar (Fig.
43). Do not adjust the steering FIG. 45- Alignment Spacers-
wheel spoke position at this time. Rear
If the front wheels are turned at any wheels are tilted at the top. If a
time during the inspection, align the wheel tilts outward, camber is posi-
marks to bring the wheels back to the tive. If a wheel tilts inward, camber
straight-ahead position. is negative. Correct camber specifi-
2. With the car in position for the cations are given in Part 3-7. The
front end alignment inspection and maximum difference between both
adjustment, install the alignment front wheel camber angles should not
spacers as follows to establish th.:: exceed to. However, a difference of
curb height. not more than ! o is preferred.
Toe-In. Before attempting to
Insert the pin in the spacer hole check toe-in, remove all the align-
marked for the model being checked. ment spacers. Toe-in should only be
checked and adjusted after the caster
Raise the front of the car and and camber have been adjusted to
position the alignment spacers be- FIG. 44- Alignment Spacers - specifications. Check the toe-in with
tween the suspension upper arm and Front
the spring tower as shown in Fig. 44. CASTER ADJUSTMENT STRUT
The lower end of the spacer should
be placed over the head of the ball
joint front outside attaching rivet.
Position the alignment spacers for
the rear of the car between the rear
axle and the side rail as shown in
(Fig. 45).
3. Install the wheel alignment
equipment on the car. Whichever
type of equipment is used, follow
the installation and inspection in-
structions provided by the equipment
manufacturer.
Caster. Check the caster angle at
each front wheel.
The caster is the forward or rear-
ward tilt of the top of the wheel
spindle. If the spindle tilts to the
rear, caster is positive. The spindle
tilts to the front, caster is negative.
See Part 3-7 for the correct caster
specifications. The maximum differ-
ence between both front wheel caster
angles should not exceed f How-
0
•

ever, a difference of not more than

! o is preferred.
Camber. Check the camber angle
at each front wheel.
Camber is the amount the front FIG. 46- Caster and Ca.mber Adiustments
PART 20-1- MAINTENANCE OPERATIONS 20-21

the front wheels in the straight-ahead SLEEVE 2. Adjust toe-in. If the steering
position. Run the engine so that wheel spokes are in their normal
the power steering control valve position, lengthen or shorten both
will be in the centre (neutral) rods equally to obtain correct toe-in
position if so equipped. Measure (Fig. 49). If the steering wheel
the distance between the extreme spokes are not in their nortmll posi-
front and also between the extreme tion, make the necessary rod adjust-
rear of both front wheels. The differ- ments to obtain correct toe-in and
renee between these two distances is steering wheel spoke alignment.
the toe-in. Specifications are in 3. Recheck toe-in and the steering
Part 3-7. · wheel spoke position. If toe-in is
Front Wheel Turning Angle. correct and the steering wheel spokes
When the inside wheel is turned 20°, CLAMP BOLTS noaa-• are still not in their normal position,
the turning angle of the outside FIG. 47- Spindle Connecting Rod turn both connecting rod sleeves
wheel should be as specified in Part upward or downward the same
3-7. The turning angle cannot be Sleeve number of turns to move the steering
adjusted directly because it is a result wheel spokes (Fig. 50).
of the combination of caster, camber, 4. When toe-in and the steering
and toe-in adjustments and should wheel spoke position are both correct,
therefore, be measured only after torque the clamp bolts on both con-
these adjustments have been made. necting rod sleeves to specification.
If the turning angle does not measure The sleeve position should be
to specifications, check the spindle or as shown in Fig. 48 when the
other suspension parts for a bent clamp bolts are tightened.
condition.
Mter front wheel alignment factors
have been checked, make the neces-
sary adjustments. Do not attempt
to adjust front wheel alignment FIG. 48-Spindle Connecting Rod
by bending the suspension or Sleeve Clamp Position
steering parts.
TURN DOWNWARD TO TUIN TUIN Uf'WAID TO
CASTER AND CAMBER INCREAsE ROD l.fNGTH TUIN UPWARD DOWNWARD INCREASE ROD lfNGTH
ADJUSTMENTS TO DECREASE TO DECREASE

~'6;~-; C«fl
Caster is controlled by the front
suspension strut (Fig. 46). To obtain
negative caster, loosen the strut front
nut and tighten the strut rear nut
against the bushing. To obtain posi- Lin-HAND SLIIVI liGHT-HAND SL11V1 P1037-1
tive caster, loosen the strut rear nut
and tighten the strut front nut FIG. 49- Spindle Connecting Rod Adjustments
against the bushing.
Camber. Camber is controlled by
the eccentric cam located at the lower WHEN TOE . IH IS CORRECT TURN BOTH CONNECTING ROD
TURN IIOTH CONNECTING ROD
arm attachment to the side rail (Fig. SLEEVES UPWARD TO ADJUST
SLEEVES DOWNWARD TO
46). To adjust the camber, loosen the SPOKE POSITION
eccentric bolt nut and rotate the bolt
and eccentric clockwise from the high
position to increase camber or coun-
terclockwise to decrease camber.
Mter the caster and camber have
been adjusted to specification, torque
the lower arm eccentric bolt nut and
the s_trut front nut to specification.
TOE-IN AND STEERING WHEEL
SPOKE POSITION ADJUSTMENTS
WHEN TOE·IN
NOT CORRECT
IS~
Check the steering wheel spoke LENGTHEN LEFT ROO TO
position when the front wheels are INCREASE TOE ·IN LENGHTEN RIGHT ROO
in the straight-ahead position. If the TO INCREASE TOE -IN
SHORTEN RIGHT ROO
spokes are not in their normal posi- TO DECREASE TOE .IN
tion, they can be properly adjusted
while toe-in is being adjusted. ADJUST BOTH RODS EQUALLY TO MAINTAIN NVRMAL SPOKE POSITION
1. Loosen the two clamp bolts on
each spindle connecting rod sleeve
(Fig. 47). FIG. 50- Toe-in and Steering Wheel Spoke Adjustments
20-22 GROUP 20- MAINTENANCE OPERATIONS

~~ BODY
LUBRICATE BONNET LATCH foreign substance which cannot be make doors easier to close.
easily rubbed off.
Apply Petroleum Jelly to all pivot Generally, if the wiper pattern LUBRICATE LUGGAGE
points and to the striker plate as across the glass is still uneven and COMPARTMENT LOCK CYLINDER
required to eliminate any binding streaked after these tests, replace the
condition. Operate the latch mechan- blades. Apply Ford lock lubricant spar-
ism several times to be sure that the ingly through the key slot. Insert
LUBRICATE DOOR LOCK
lubricant has effectively worked in. the key and operate the lock s_everal
CYLINDERS times to be sure that the lubricant
LUBRICATE BONNET SAFETY Apply Ford locK lubricant sparing- has effectively worked in.
CATCH ly through the key slot. Insert the key
and operate the lock several times to LUBRICATE LUGGAGE
Apply Petroleum Je11y to ail pivot be sure that the lubricant has COMPARTMENT HINGE PIVOTS
points as required to eliminate any effectively worked in.
binding conditions. Operate the catch Apply approved Engine Oil to the
several times to be sure that the LUBRICATE DOOR HINGE AND hinge pivot points as required. Open
lubricant has effectively worked in. HINGE CHECK and close the luggage compartment
LUBRICATE BONNET HINGE several times to be sure that the
Apply approved Engine Oil on the hinge pivots do not bind.
PIVOTS hinge pivot points as required to
Apply approved Engine Oil to the eliminate any binding condition. LUBRICATE TAILGATE LOCK
hinge pivot points as required. Open Open and close the door several times CYLINDER
and close the bonnet several times to be sure that the lubricant has
to be sure that the hinge pivots do effectively worked in. Apply Ford lock lubricant spar-
not bind. ingly through the key slot. Insert the
LUBRICATE SEAT TRACK key and operate the lock.
REPLACE WINDSHIELD WIPER
BLADES Use Petroleum Jelly on the seat CLEAN BODY DRAIN HOLES OR
track slides, as required, for ease of EXAMINE DUST VALVES FOR
Wiper blade replacement inter-vals operation. PROPER OPERATION
will vary with the amount of use,
type of weather, chemical reaction LUBRICATE WEATHERSTRIP AND Make sure the drain holes in the
from road tars or salts and the age RUBBER SEALS doors, rocker panels and quarter
of the blades. Be sure that the wind- panels are free from obstruction.
Use Silicone Lubricant AM400 to Visually check the dust valves for
shield glass surface is not contami- lubricate door weatherstrips to
nated with oil, tree sap or other proper sealing and draining opera-
eliminate weatherstrip squeaks and tion.
FALCON FAIRLANE w~:~~~~P

GROUP
SPECIAL TOOLS
21

PAGE

PART 21-1- Special Tools 21-2

21-2

PART
21-1 SPECI AL TOOLS

The service tools illustrated in this are essential to prevent damage to in the service operations for which
part have been developed especially parts, to assure correct assembly and they are specified.
for Ford vehicles by the Sales Service quality workmanship, or where sub-
Engineering Department. stantiated time saving can be achieved RECOMMENDED: These are
by the use of the tool. tools which, while not considered
mandatory, will contribute substan-
Engineering prototypes, test ve- This part lists Special Service tially to the performance of high
hicles, assemblies and components Tools in two categories. quality service work in the minimum
are used to thoroughly evaluate the possible time.
need for Special Service Tools . Dur- MANDATORY: These are tools
ing this evaluation, general purpose which are considered essential to per- Tools indicated * on the following
hand tools are used wherever possible formance of quality service work. It pages are distributed by George
for assembly, disassembly and adjust- is required that these tools be avail- Sample and Son Pty. Ltd. Those
ment. Special Service Tools are able in every dealership service area marked t by Repco . Those marked
developed and specified where they and that they be consistently used ** by Litchfield.
PART 21-1- SPECIAL TOOLS 21-3

• 1177-C
ReF· l11cer-Re"r Wheel Be11ring
Oi Se11l (All Models)

FIG. 1- Replacer-ear Wheel Bearing Oil Seal

REAR AXLE
• AGF-1225-A
Re11r Axle Sh.,ft Be11ring Remover
& Repl11cer

FIG. 2-Axle Shaft Bearing Remover & Replacer

AGF 1225-A-1

t Rear Axle Shaft Bearing Remover

& Replacer Adaptor
Use with Tool AGF-1225-A

FIG. 3-Rear Axle Shaft Bearing Remover FIG. 4- Tapered Axle Bearing Remover
& Replacer Adaptor - XYTC-1225-A
21-4 GROUP 21- SPECIAL TOOLS

2 4

t Breke Tools (Drum Brekes) All

Models
t M818 Breke Cylinder Clemp
2 M402 Sternut Breke Tool
3 M804 Reteining Spring Tool
4 M802 Return Spring Tool

FIG. 5- Brake Tools (Drum Brakes)

·--
--- --·---~,-~

t Disc Brake Rotor Gauge

- R1102A.

t FIG. 6- Disc Brake Rotor Gauge- R-1102-A

t • T65P-3A733-A
Power Steering Pump Pulley
Replocer

FIG. 7- Power Steering Pump Pulley Replacer

21-5

• \b3L-10300 B
Power Steering PumP Pulley
Remover
·t)

FIG. 8- power Steering PumP PulleV Remover

1bSL-33bi0-0 Pressure
Power Steering PumP
Gauge \All Models)

FIG- 9- power Steering pumP Pressure Gauge

~ •• XA-3526·A

~::::::::::::=~~="""""""""""=R=em~!ov:e:lnPut) Snaft Seal

- andSP'<"

** )(A-3521-B
ExtractorWorm Race

** XA-374309-A
Fitting Tool lube Seat

f\G. 12- fitting Tool Tube Seat

21-6 GROUP 21- SPECIAL TOOLS

** XA -3771 -A
Wed ge Sl eeve Coupl ing

FIG. 13- Wedge Sleeve Coupling

** XA -3544-A ** XA -3589 -B
Contra ctor Sleeve Rings
Contractor Pisto n Ring

1-'
'

FIG. 14- Contractor Piston Ring FIG . 15 - Cont ra ctor Sleeve Rings

XA -370 7-A
R 1ng Spanner

FIG. 16 - Ring Spanner

.,. . XA -3525 -A, 1

Replacer Input Shaft Beari ng
and Sector Shaft Sea l

" XA -35 25 A
Replacer Input Shaft Bearing
and Sea l

FIG. 17 - Replacer Input Shaft Bearing FIG . 18 - Replacer Inp ut Shaft Bearing and Seal
and Sector Shaft Seal
PART 21-1- SPECIAl TOOLS
21-7
** XA -3576-A
** XA-3576-A3
Sector S haft Bearing Too l
Was her Sector Shaft Bearing
Tool
** XA -3576-A 1
Sector Shaft Bearing Tool
Spacer

0
.
\
~~
~ \
FIG. 21 -Sector Shaft Bearing Tool

FIG . 20 - Washer Sector

II ** XA -3576-A2
Se<tor Sh•ft Be.riog Tool
Guide

FIG. 19- Sector Shaft Shaft Bearing Tool FIG. 22- Sector Shaft Bearing
Bearing Tool Spacer Tool Guide

** XA- 10064-A
Mou nt ing Bracket

FIG . 23 - Mounting Bracket

** XA -3589 -A ** XA -3775 -A
Expander Sleeve Seals Gauge for Bearing Spacer

** XA -371 3- A

.© F itt ing To ol Outlet Tube

FIG. 25 - Gauge for Bearing

Spacer

FIG. 24 - Expander Sleeve Seals

FIG. 26- Fitting Tool Outlet Tube
21-8 GROUP 21-SPECIAL TOOLS

t • T65P-3000B
Suspension Alignment Spocers

FIG. 27- Suspension Alignment Spacers

SUSPENSION-STEERING
-WHEELS AND TYRES

• ACX 3006
Remover Press-Spindle
Ball Joint (All Models)
t • ACX 3006 D
Adaptor. Spindle Ball Joint
Press

FIG. 28- Ball Joint Tool

4010 A
Reor Axle Spreoder ond Adopter
Plotes
(§Jo 0~
Adaptor Plates 40 I0-A- 1

FIG. 29- Rear Axle Spreader

PART 21-1- SPECIAl TOOLS 21-9

t Limited Slip Rear Axle

Torque Check Tooi-
T65K-4204-A.

FIG. 30- Limited Slip Rear Axle Torque Check Tool- T65K-4204-A

4209 B
t

•
Pinion Setting Gauge
(All Models)

FIG. 31 -Pinion Setting Gauge

21-10 GROUP 21- SPECIAL TOOLS

t 4221 A-8
I Replacer-Differpntial Bearing
Cone (All Models)
t 4621-B
2 Replacer-Pinion Bearing Cone
(All Models)
2

FIG. 32- 1. Replacer Differential Bearing Cone

2. Pinion Bearing Cone

-4221 AR
t Remover Pilot Differential Bear-
ing Cone

FIG. 33- Remover Pilot Differential Bearing Cone

• 4615 HF
Replacer-Pinion Bearing Front
Cup

FIG. 34- Replacer- Pinion Bearing Front Cup

PART 21-1- SPECIAL TOOLS 21-11

• 4625-H R
Replacer-Pinion Bea ring Rear
Cup

FIG. 35- Replacer- Pinion Bearing Rear Cup

• 4676 G
Replacer-Pinion Oil Seal (All
Models)

FIG. 36- Replacer- Pinion Oil Seal

t Gauge Tool
Traction Lock Differentiai-
T68P-4946-A.

t FIG. 37- Gauge Tool Traction Lock Differential- T68P-4946-A

MANDATORY TOOLS

Front Suspension & Steering

t Port No. 53100

Front Spring Remover & Replacer

off T63 P-53 I0-A 1-Screw

oo T63P-5310-A2-Nut
oo T63P-5310-A3-P1ote
00 T63P-5310-A -Piote
00 Thurst Beoring to Suit

FIG. 38- Front Spring Remover & Replacer

21-12 GROUP 21-SPECIAL TOOLS

f 5781-A
Remover Md Replt~cer, Front
Bushinq Rellr Spring (All Models)
I off T64N-5781-A4-Tube
TMN-5781-A 1-Remover
& Replt~cer
&!) lllllllllllllllllllllllllllllllllllllllllllllllllllllllllllll llllli ll ) TMK-5781-82-Spt~cer _
TMK-5781-B 1-Bolt
T64K-5 78.1-83-Nut
TMK-5781-84-Wt~shers

FIG. 39- Remover & Replacer, Front Bushing Rear Spring

f M470
Oil Ct~rtridge Remover

FIG. 40- Oil Cartridge Remover

ENGINE
* 6000 AE
Brt~cket Engine Lifting (6 Cyi.J
111\\\1\\11111

FIG. 41 -Bracket Engine Lifting

*t T70P-6011-A
Camshaft Bearing Bore Plug
Installer 8 cyl.

*t FIG. 42- T70P-6011-A

*t Camshaft Bearing Bore Plug Installer - 8-cyl.
PART 21-1-SPECIAL TOOLS 21-13

6019
f Pilot Cylinder Block
Front Cover

FIG. 43- Pilot Cylinder Block Front Cover

*t T70P-6049-A
Valve Spring Compressor 8 cyl.

*t FIG. 44- T70P-6049-A

Valve Spring Compressor - 8-cyl.

, ~ I
\ : '1 * t T70P-68070-A
'
I
l J
Front Cover Seal Installer 8 cyl.

•
*t FIG. 45- T70P-6B070-A
Front Cover Seal Installer- 8-cyl.

* t T70P-6B070-B
Front Cover Seal Remover.

*t FIG. 46- T70P-6B070-B

Front Cover Seal Remover - 8-cyl.

Reamer - Valve Guide.

Reomer Kit Oversize Valve Guides
(0.003"-0.015"-0.030")
Cl eo•
t 6085 B All engines.
FIG. 47- Reamer- Valve Guide
21-14 GROUP 21- SPECIAL TOOLS

.... . . '"· __ .,. . _...,,.

..
,.

:,.i
~~.,..,..

•...,,--.,;.!"cr.<' •>'::""""
~

.., '

*t T68P-6135-A.
Remover Replacer Piston Pin.
All engines.

FIG. 48 - T68P-6135-A
Remover-Replacer Piston Pin All Engines

• 6261 c
Remover & Replocer Comshoft
Beorings

FIG. 49- Remover & Replacer Camshaft Bearings

•
• 6261 AD
Remover & Replacer-Adoptors
Camshaft Bearing (8 Cyl.)

FIG. 50- Remover & Replacer Adaptor Camshaft Bearing

t Replacer Camshaft
Rear Bearing Plug -
T62F-6266-A.

t FIG. 51 - Replacer Camshaft Rear Bearing Plug- T62F-6266-A

PART 21-1- SPECIAL TOOLS 21-15

*t 6306-AG.
Remover- Crankshaft Pulley.
All engines.

*t FIG. 52- 6306-AG

Remover- Crankshaft Pulley- All Engines

* 6500 E
Hydraulic Tappet Tester.
Use oil 6500 Det 2.

FIG. 53- Hydraulic Tappet Tester

* t T?OP-6505-A.
Valve Stem Deburring Button.

*t FIG. 54- T70P-6505-A

Valve Stem Deburring Button

* 6513 AG
Hydroulic Volve Lifter Bleed
Down Tool (b Cyl.)

FIG. 55- Hydraulic Valve Lifter Bleed Down Tool

* 6513 H
Volve Spring Compressor
(6 Cyl.)

FIG. 56- Valve Spring Compressor

21-16 GROUP 21- SPECIAL TOOLS

* t T70P-6K517-A.
Water Pump Bypass Plate
Installer.

*t FIG. 57- T70P-6K517-A Water Pump

Bypass Plate Installer

*t T70P-6564-A
Tappet Bleed Down Wrench 8 cyl.

*t FIG. 58- T70P-6564-A

Tappet Bleed Down Wrench- 8-cyl .

• 6700 c
Remover and Replacer Crank-
shaft Front Oil Seal (6 Cyl.)

FIG. 59- Remover & Replacer Crankshaft Front Oil Seal

Replacer Crankshaft
Rear Oil Seal.
T?OPG-6701-B 6 Cyl.
670 1-E 8 Cyl.

FIG. 60- Replacer Crankshaft Rear Oil Seal

PART 21-1- SPECIAL TOOLS 21-17

MANUAL TRANSMISSION
t * 7000 AF 6 CYL.
I -~- •
I
t T57P-7697-A 8 CYL.
Remover Extension Housing
Bush. Use with Slide Ham-
mer 982019
•
FIG. 61 -Remover- Extension Housing Bush

( I 7111 c
Ret11iner-Ciuster Ge11r
Be11rings (All Models)
Roller

FIG. 62- Retainer Cluster Gear Roller Bearings

t FIG. 63- Gear Shift Linkage Grommet Pliers- 7341-C

-·- _ _ ,_ .... . I .
Twin Disc Clutch
Aligning Pilot- 7550-A.
'

t FIG. 64- Twin Disc Clutch Aligning Pilot- 7550-A

t * 7657-G 6 CYL'.
t T61L-7657-A 8 CYL.
Replacer Extension Housing
Bush & Seal

FIG. 65- Replacer- Extension Housing Bush & Seal

21-18 GROUP 21- SPECIAL TOOLS

t * 7657-G-27 6 CYL.
t T61L-7657-Al 8 CYL.
Adaptor-Replacer Extension
Housing Bush

FIG. 66- Adaptor- Replacer Extension Housing Bush

t 77047-Bl
Input Shaft Oil Seal
Replacer VB 3SPD

77~7-B

f Replacer-Input Shaft Oil Seal

FIG. 67- Replacer-Input Shaft Oil Seal

PART 21-1-SPECIAL TOOLS 21-19

.
..-

I
I

I '

FIG. 68- Remover & Replacer Adaptors C4 Auto Trans Bushings- T66L-7003-B
"T1
G') -
N
I

~
~

C)

.,"'
0
c:

-
N
I
(/)
"U
m
n
7 I)>
r-
~
0
0r-
(/)

5 Replacer- Front Pump Oil Seal - T63L-77837-A

6 Replacer- Transmission Extension Housing Oil Seal Assembly

- T61L-7657-A
7 Automatic Transmission Clutch Spring Compressor- T65L-77515-A

8 Replacer- Transmission Extension Housing Bushing - AT-7697-B

PART 21-1- SPECIAL TOOLS 21-21

1- 5/16" Socket 3/8" Drive Socket- Clutch Race to Case Bolb

2 - AF2-440S-TV Crowfoot Wrench, Vacuum Control Unit

3 3- W & B Tension Wrench, Model 32008

FIG. 70

Rear Band Adjuster.

* J2 11 11.

FIG. 71 -Rear Band Adjuster

* BW 35
Bench Cradle Adaptor
(All Models)

FIG. 72- Bench Cradle Adaptor

21-22 GROUP 21-SPECIAL TOOLS

• BW 37 A
Clutch Spring Compressor
(All Models)

FIG. 73- Clutch Spring Compressor

t • BW 38
Hydraul ic Pressure Test Gauge
Kit (All Models)

FIG. 74- Hydraulic Pressure Test Gauge Kit

• BW 38 Z
FIG. 75- Banjo Adaptor Detail1 Banjo Adaptor (All Models)

* Banjo Ada ptor Detail 2.

FIG. 76- Banjo Adaptor Detail 2

GROUP 21-SPECIAL TOOLS 21-23

* BW 41
Rear Clutch Piston Replacer

FIG. 77- Rear Clutch Piston Replacer

* BW 42
Front Clutch Piston Replacer

FIG. 78- Front Clutch Piston Replacer

* BW 548-1
Torque Screw Driver Adaptor

FIG. 79- Torque Screw Driver Adaptor

AUTOMATIC TRANSMISSION

* BW -548 -2
Front Servo Adaptor

FIG. 80- Front Servo Adaptor Typical

21-24 GROUP 21- SPECIAL TOOLS

. ~ -~~~~
- '.C!!_ __ - -
--~ ~

* t T?O PG-8530-A .
Remove r, Rep la ce r - Water Pump
Shaft & Bea ring . 6 Cy l.

*t FIG. 81 - T70PG -8530-A

Remover-Replacer"Water
Pump Shaft & Bearing, 6 Cyl.

T?OPG-8564-A.
Installer Water Pump Seal.
6 Cyl.

* t FIG. 82- T70PG -8564-A

Installer - Water Pump Seal, 6 Cyl.

8620 B

Drive Belt Tens ion Gauge

FIG. 83- Drive Belt Tension Gauge

PART 21- J- SPECIAL TOOLS 21-25

Carburettor Tools. {6 Cyl.)

I 9533.A Jet Wrench
2 9550-A Float Arm Setting Tool
3 9A516-A Discharge Jet Re-
mover

FIG. 84- Carburettor Tools

• AGI6
Vacuum Gloss lifte,

FIG. 85- Vacuum Glass lifter

• TM-F-<42006
Windshield Upper Moulding Re-
mover

FIG. 86- Windshield Upper Moulding Remover

21-26 GROUP 21- SPECIAL TOOLS

BODY
• SP 1832-12
Windshield Coulking Gun
(All Models)

FIG. 87- Windshield Caulking Gun

GROUP 21- SPECIAl TOOlS 21 - 2 7
SPECIAL SERVICE TOOL INDEX
Ill us- Ill us -
tration t ration
Description Tool No. Fig . No. Description Tool No. Fig . No.

WHEELS Replacer-Pinion Bearing Cone 4621-B 32

Remover-Pilot Differential
Replacer Rear Wheel Bearing
Bearing Cone 4221 -AR 33
Oil Seal 1177C
Replacer-Pinion Bearing
Axle Shaft Bearing Remover &
Front Cup 4615-HF 34
Replacer AGF - 1225-A 2
Replacer-Pinion Bearing
Rear Axle Shaft Bearing Remover
Rear Cup 4625-HR' 35
& Replacer Adaptor AGF-1225-A-1 3
Replacer Pinion Oil Seal 4676-G 36
Tapered Axle Bearing Remover XYTC-1225-A 4 Gauge Tool Traction Lock
BRAKE SYSTEM Differential T68P-4946-A 37
Brake Cyl1nder Clamp M818 5
Star Nut Brake Tool M402 5 SPRING SYST EM
Return Spring Tool M802 5 Front Spring Remover & Replacer 5310-D 38
Disc Brake Rotor Gauge R1102-A 6 Remover & Replacer
Front Bushing Rear Spring 5781-A 39
POWER STEERING SY ST EM
Power Steering Pump Pulley ENG tNE SYSTEM
Repla cer T65P-3A733-A 7 Oil Cartridge Remover M470 40
Power Steering Pump Pulley
Bracket Engine Lifting 6-cyl. 6000AE 41
Remover T65L - 10300-B 8 Camshaft Bearing Bore Plug
Power Steering Pump
Insta ller 8-cyl. T70P-6011-A 42
Pressure Gauge T65L-33610-D 9
Pilot Cylinder Block Front Cover 6019 43
Remover Input Shaft Sea l Valve Spring Compressor
and Spacer XA-3526-A 10 8-cyl. T70P-6049-A 44
Extractor Worm Race XA-3521-B 11
Fitting Too l Tube Seat XA-374309-A 12
Wedge Sleeve Coupling XA-3771-A 13 Front Cover Aligner & Seal
Contractor Piston Ring XA-3544-A 14 Insta ller 8-cy I. T70P-6B070-A 45
Contractor Sleeve Rings XA-3589-B 15 Front Cover Seal Remover
Ring Spanne r XA-3707-A 16 8-cyl. T70P-6B070-B 46
Replacer Input Shaft Bearing
and Sector Shaft Seal XA-3525-A/1 17
Replacer Input Shaft Bearing Reamer Valve Guide All Engines 6085-B 47
and Seal XA-3525-A 18 Piston Pin Remover & Replacer
Sector Shaft Bearing ToQJ All Engines T68P-6135-A 48
Spacer XA-3576-A l 19 Remover & Replacer Camshaft
Washer Sector Shaft Bearing Bearing _ 6261-C 49
Tool XA-3576-A3 20 Remover & Replacer Adaptor
Sector ·Shaft Bearing Tool XA-3576-A 21 Camshaft Bearing 6261-AD 50
Sector Shaft Bearing Tool Replacer Camshaft Rear
Guide XA-3576-A2 22 Bearing Plug T62F-6266-A 51
Mounting Bracket XA-10064-A 23 Crankshaft Pulley Remover
Expander Sleeve Seals XA-3589-A 24 All Engines 6306-AG 52
Gauge for Bearing Spacer XA-3775-A 25 Hydraulic Tappet Tester 6500-E 53
Fitting Too l Outlet Tube XA -3713-A 26 Valve Stem Deburring Button T70P-6505-A 54

SUSPENSION SYSTEM
Suspension Alignment Spacers T65P3000-B 27 Hydraulic Valve Lifter Bleed
Ball Joint Tool Remover Press ACX3006 28 Down Tool 6-cyl. 6513-AG 55
Adaptor Ba ll Jo1nt Press ACX3006-D 28 Valve Spring Compressor 6-cyl. 6513-H 56
Water Pump By-pass Plate
Installer T70P-6K517-A 57
REAR AXLE SYSTEM
Tappet Bleed Down Wrench
Rear Axle Spreader 4010-A 29 8-cyl. 58
Adaptor Plates 401 0-A - 1 & 2 29
Remover & Replacer
L1mited Slip Rear Axle Torque Crankshaft Front Oil Seal 6700-C 59
Check Tool T65K - 4204 -A 30
Pin1on Setting Gauge 4209 -B 31
Replacer-Differentia l Replacer Crankshaft Rear Oil
Bearing Cones 4221-A&B 32 Seal 6-cyl. T70PG-6701-B 60
21-28 GROUP 21- SPECIAL TOOLS
SPECIAL SERVICE TOOL INDEX
Ill us- Ill us-
tration tration
Description Tool No. Fig. No. Description Tool No. Fig. No.

TRANSMISSION SYSTEM Socket Clutch Race to Case Bolts fe-AF 70

Crowfoot Wrench. Vacuum
Remover Extension Housing Control Unit AF2 -4405-TV 70
Bush 6-cyl. 7000AF 61 W & B Tension Wrench 3200-B 70
Remover Extension Housing Rear Band Adjuster Wrench J21111 . 71
Bush 8-cyl. T57P-7697-A 61 Bench Cradle Adaptor BW35 72
Retainer Cluster Gear Clutch Spring Compressor BW37A 73
Roller Bearings 7111-C 62 Hydraulic Pressure Test Gauge Kit BW38 74
Gear Shift Linkage Grommet 75
Pliers
Twin Disc Clutch Aligning Pilot
7341-C 63
Banjo Adaptor. Detail 1
Banjo Adaptor. Detail 2
} BW38-Z { 76
77
Replacer-Rear Clutch Piston BW-41
351 C.I.D . 7550-A 64 Replacer-Front Clutch Piston BW-42 78
Replacer Extension Housing Torque Screw Driver Adaptor BWA-548-1 79
Bush & Seal 6-cyl. 7657-G 65 Front Servo Adaptor Typical BW-548-2-A 80
Replacer Extension Housing
Bush & Seal 8-cyl. T61 L- 7657-A 65
COOLING SYSTEM
Adaptor-Replacer Extension
Housing Bush 6-cyl. 7657-G-27 66
Adaptor-Replacer Extension
Housing Bush 8-cyl. T61 L-7657-A1 66 Water Pump Shaft & Bearing
Replacer-Trans. Input Shaft Remover-Replacer 6-cyl. T70PG-8530-A 81
Oil Seal 3SPD 6-cyl. 77047 - B 67 Installer-Water Pump Seal
Replacer-Trans. Input Shaft 6-cyl. T70PG-8564-A 82
Oil Seal 3SPD 8-cyl. 77047-B1 67 Drive Belt Tension Gauge 8620-B 83
Remover & Replacer Adaptors
C4 Auto. Trans. Bushing T66L-7003-B 68 FUEL SYSTEM
Replacer-Front Pump Oil Seal
C4 Auto. Trans. T63L-77837 -A 69 Jet Wrench 9533-A 84
Replacer-Extension Housing Float Arm Setting Tool 9550-A 84
Oil Seal C4 Auto. Trans. T61 L-7657-A 69 Discharge Jet Remover 9A516-A 84
Clutch Spring Compressor Vacuum Glass Lifter AG.16 85
C4 Auto. Trans. T65L-77515-A 69 Windshield Upper Moulding
Replacer-Transmission Extension Remover T64F-42006 86
Housing Bush C4 Auto. Trans. AT-7697-B 69 Windshield Caulking Gun SP1832-12 87
REFERENCE TO SERVICE INFORMATION AND NOTIES

Date Letter No. Pa1e Brief Detail

REFERENCE TO SERVICE INFORMATION AND NOTES

Date Letter No. Page Brief Detail

FALCON FAIRLANE w~:~~~~P

SCHEMATICS
GROUP
22

PAGE

PART 22-1- Schematics 22-2

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22-4 GROUP 22- SCHEMATICS

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PART 22-1- SCHEMATICS 22-5

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FIG. 4- Printed Circuit Fairlane Only

22-6 GROUP 22-SCHEMATICS

WIRING COLOUR CODE 39 RED- WHITE

2 WHITE- BLUE 44 GREEN- BLACK
3 LT. GREEN- WHITE 53 BLACK- BLUE
5 GREEN- BLUE 54 RED- BLUE
8 GREEN 55 YELLOW- BLUE
9 GREEN - YELLOW 56 BLUE- YELLOW
10 GREEN- RED HASH 57 BLACK
11 YELLOW- GREEN STRIPE 58 WHITE
12 GREEN- BLACK 63 RED
13 RED - BLACK 140 BLACK- RED
14 BROWN 234 BLUE
15 RED- YELLOW

16 RED-LT. GREEN 262 BROWN- RED

17 WHITE 450 YELLOW- BLACK
18 YELLOW- RED 482 BLUE- RED
19 643 BLACK- YELLOW
BLUE- BLACK
21 BLUE - BLACK 648 WHITE- GREEN
25 BLACK- RED 763A BROWN- WHITE
26 904 GREEN- RED
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29 YELLOW- WHITE 977 PURPLE- WHITE
32 RED - BLUE 7638 BROWN- WHITE
763C ORANGE- WHITE
35 BROWN- YELLOW
BLACK - YELLOW 763 ORANGE- WHITE
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