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Buick Electra 225 1965, Service Manual

The Buick Electra 225 1965 Service Manual is an indispensable resource for car enthusiasts and mechanics alike. With detailed instructions, diagrams, and troubleshooting tips, this manual ensures that you can effectively maintain and repair your classic vehicle. Download it for free at manualshive.com, your go-to source for user manuals.

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Summary of Contents for Electra 225 1965

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Page 3: ... 1964 Buick Motor Division General Motors Corporation Flint Michigan ...

Page 4: ...oup whether or not the group is divided into sections Paragraph titles and page numbers are listed on the first page of each Section if used or on first page of the Group if sections are not used 4 SUB PARAGRAPHS Where necessary for clarity or distinction between models Paragraphs are divided into appropriately titled Sub paragraphs These are usually lettered in alphabetical order within the parag...

Page 5: ...or Pillarless Sport Coupe 46637 Custom 4 Door Pillarless Sedan 46639 2 Door Convertible 46667 Electra 2 Door Pillarless Sport Coupe 48237 225 4 Door Pillarless Sedan 48239 4 Door Thin Pillar Sedan 48269 Electra 2 Door Pillarless Sport Coupe 48437 225 4 Door Pillarless Sedan 48439 Custom 2 Door Convertible 48467 4 Door Thin Pillar Sedan 48469 Riviera 2 Door Pillarless Sport Coupe 49447 VEHICLE AND ...

Page 6: ...Body Number Plate Information such as style and body numbers trim numbers and paint color code is found on this plate Refer to the 1965 Body Service Manual for detailed information regarding this plate Engine Numbers All 1965 engines are stamped with two different identification codes One is the production code number See Figure 0 2 This identifies the type of engine and its production date The ot...

Page 7: ...When viewed from the front of the car it will appear right side up Automatic Transmission Identification Numbers On Super Turbine 300 transmissions identifi cation information is stamped on the low servo cover as shown in Figure 0 3 On Super Turbine 400 transmissions this information can be found on a plate attached to the right side of the case Synchromesh Transmission Serial Numbers All synchrom...

Page 8: ... 2 3 SP AUTO ALL 45 SYNC 45 2 3 SP AUTO ALL FIELD IDENTIFICATION FOR FIELD IDENTIFICATION ALL AXLE ASSEMBLIES TO BE STAMPED ON BOTTOM OF AXLE TUBE AS INDICATED FROM CHART SAMPLE MARKING FOR 3 08 RATIO DATE JULY 22 WOULD BE STANDARD AXLES A 203 POSITIVE TRACTION AXLES e A 20 3 SAMPLE MARKING FOR S C O RATIO DATE JULY 22 WOULD BE STANDARD AXLES 2 56 203 POSITIVE TRACTION AXLES 0 2 56 203 50 DIA APPR...

Page 9: ...TO TRANS 46 SYNC ALL SERIES SPECIAL ORDER AXLE RATIOS 50 DIA APPROX ALL POSITIVE TRACTION DIFFERENTI TO HAVE STAMPED ON BOTTOM SIDE OF CARRIER FLANGE FOR FIELD IDENTIFICATION ALL AXLES TO HAVE RATIO CODE a DATE STAMPED ON BOTTOM OF HOUSING FOR FIELD IDENTIFICATION SAMPLE MARKING FOR 3 07 RATIO DATE JULY 22 WOULD BE STANDARD AXLES PA 203 POSITIVE FRACTION P N 203 SAMPLE MARKING S C O SPECIAL CAR OR...

Page 10: ...matic Automatic Ratio 3 55 3 08 3 42 3 42 3 07 3 07 3 07 used for either standard or rear axles PAINT COLOR CODES 1965 BUICK EXTERIOR COLORS CODE A C D E H J K L N Y R S T V z COLOR NAME DESCRIPTION REGAL BLACK ARCTIC WHITE ASTRO BLUE MIDNIGHT BLUE SEA FOAM GREEN VERDE GREEN TURQUOISE MIST MIDNIGHT AQUA BURGUNDY MIST BAMBOO CREAM FLAME RED SAHARA MIST CHAMPAGNE MIST SHELL BEIGE SILVER CLOUD NOTE C...

Page 11: ...Sabre Series 4500 Rear Tread 63 0 8 45 15 Wildcat Series 46000 Rear Tread 63 0 8 85 15 Length 217 Optional Length 220 Optional Electra 225 Series 48000 Front Tread 63 4 8 85 15 Front Tread 63 4 8 45 15 Standard Rear Tread 63 0 Riviera 49000 Rear Tread 59 0 8 85 15 Length 223 Length 208 Optional Width 80 Oversize Width 80 Oversize Width 80 Width 76 6 Oversize Height 55 2 Height 55 2 Height 56 0 Hei...

Page 12: ...cted for the lowest anticipated temperature at which cold engine starting will be required as rec ommended in the temperature viscosity chart above Oil level should be checked more frequently during the break in period since somewhat higher oil c Engine Oil Change and Viscosity Recommendations Anticipated Lowest Temperatures Above Freezing 32 F Below Freezing 32 F to 0 F Below 0 F Use S A E Viscos...

Page 13: ...Power Steering Fluid Equivalent Acceptable If It Meets Specifications CAPACITIES GASOLINE TANK Gallons All Exc 49000 25 49000 20 REAR AXLE Pts All Exc 45000 Ah 45000 2 y i CRANKCASE Qts 4 0 Cu In 4 5 Dry Filter 401 x 425 Cu In 4 5 Dry Filter STEERING LINKAGE 4 CL 6 000 or 6 Mos BATTERY Colorl is Odorless Drinking Water Do Not Overfill LOWER STEERING KNUCKLE BALL JOINTS C L 6 0 0 0 or 6 Mos AIR CON...

Page 14: ...TEERING KNUCKLE BALL JOINTS 2 C l 6 000 or 6 mo STEERING LINKAGE 4 C t 6 0 0 0 or 6 Mos AIR CONDITIONER Check Operation ONCE A YEAR OIL FILTER ELEMENT RECOMMENDATION Replace with Engine Oil Change Nearest 6 000 or 6 mos Whichever Occurs 1st FUEL FILTER Replacement of Element Recommended 24 000 POSITIVE CRANKCASE VENTILATOR Replace with Correctly Calibrated Valve 12 000 UPPER STEERING KNUCKLE BALL ...

Page 15: ...stilled water to bring level to split ring at bottom of filler wells NOTE Do not overfill Clean top of battery if wet with acid neutralize with soda and wash clean See Figure 1 3 b Tires For maximum tire life with cor responding softness of ride maintain the tire pressures rec ommended in the Owners Guide Tire pressures should be checked and corrected only when the car has been standing at least 3...

Page 16: ...been lubricated with a long effec tiveness lubricant at the factory and should be re lubricated with a long effectiveness lubricant equivalent to Buick Specification No 742 every 6 000 miles or six months whichever occurs first NOTE If lubricants not intended for long effectiveness application are used the lubrication interval should be shortened and should not exceed 2 000 miles Wipe dirt from th...

Page 17: ... 000 miles must not be completely refilled with any lubricant other than Factory Hypoid Lubricant 6 Positive Traction Rear Axle On Wildcats Electra 225 s and Rivieras this axle can be identi fied by a tag attached to the filler plug reading Use Limited Slip Diff Lube Only On LeSabres this same tag can be found at tached to a bolt on the rear cover On all Positive Traction axles check lubrication l...

Page 18: ...s carburetor set engine timing and adjust idle speed b Engine Air Cleaner Exc Super Wildcat Engine Recommendation is to normally service every 12 000 miles If VSLIP SPLINE PLUG V C0NSTAN1 VELOCITY U JOINT FRAME TUNNEL ACCESS HOLE ADAPTER ALEMITE 1 327045 OR EQUIV GREASE GUN NOZZLE COUPLER ALEMITE 3326375 OR EQUIVALENT Figure 1 11 Propeller Shaft Slip Spline and Constant Velocity Universal Joint Lu...

Page 19: ...ubricated when ever brake drums are removed Always follow with the correct bearing adjustment as outlined in paragraph 7 10 1 6 MAINTENANCE EVERY 24 000 MILES Suggested in addition to the 6 000 and 12 000 mile recommendations a Fuel Filter Replacement of the disposable fil ter is recommended More fre quent replacement may be necessary if contaminants have entered the fuel system Replace with filte...

Page 20: ...rotection solution should be used during the Winter months The proper type corrosion pro tector and anti freeze solution may be recognized by the infor mation printed on the container which states Meets General Motors Standard GM 1899 M Your Buick dealer is qualified to advise you in the selection of the proper anti freeze Summer Clear water and Heavy Duty Cooling System Protector and Water Pump L...

Page 21: ...1 9 REAR AXLE LUBRICANT RECOMMENDATIONS a Standard Differential Axle Buick standard rear axles are filled at the factory with a special hypoid gear lubricant It is not necessary to remove the original lubricant at any time except when it has become contaminated or when it is required for inspection of parts or for repairs Therefore there is no drain hole in the rear axle housing Draining and flush...

Page 22: ...of the rear axle on Wildcats Electra 225 s and Rivieras On LeSabres this same tag is attached to the lower right bolt on the rear axle rear cover See Figure 1 10 1 10 VEHICLE OPERATION UNDER DUSTY CONDITIONS When cars are operated in ad verse dusty climates or condi tions the following precautions should be taken to prevent dirt and other foreign materials from entering the engine a Change Engine ...

Page 23: ...d without straining or dis torting the parts The specifica tions are for clean and lightly a Torque Specifications for 401 and 425 Cubic Inch Engines Part Location lubricated threads only Dry or dirty threads produce increased friction which prevents accurate measurement of torque Torque ft lbs Main Bearing Caps to Cylinder Block 95 120 Cylinder Head to Cylinder Block Bolts 65 80 Harmonic Balancer...

Page 24: ... Synchro 50 65 Oil Pan to Cylinder Block 9 13 Oil Pan Drain Plug 25 35 Oil Pump Cover to Timing Chain Cover 8 12 Oil Pump Pressure Regulator Retainer 25 30 Oil Screen Housing to Cylinder Block 6 9 Oil Pan Baffle to Cylinder Block 9 13 Oil Gallery Plugs 20 30 Filter Assembly to Pump Cover 10 15 Timing Chain Cover to Block 17 23 Water Pump Cover to Timing Chain Cover 6 8 Fan Driven Pulley 17 23 Ther...

Page 25: ... 51 340 4400 465 2800 99 Research 90 Motor 1 2 7 8 4 5 6 3 5 Steel Backed 1 4 M 400 5 Durex 100A 3 Steel Backed M 400 Cast Aluminum Alloy Lubrited Cast Iron Hump Type Expander Steel Above Pin Cast Alloy Iron Chain 5 Hydraulic Inner Outer Helical Lubrication System Oil Supplied to Bearing Surfaces Pressure Oil Supplied to Crankshaft Camshaft Pressure Oil Supplied to Connecting Rods Pressure Oil Sup...

Page 26: ...Head Material Cast Iron Engine Idle Speed Synchromesh 550 RPM Automatic 550 RPM In Drive A C Cars 600 RPM Automatic In Drive Ring Specifications Compression Ring Material Surface Treatment 1 Cast Iron Chrome Plated 2 Cast Iron Lubrited Oil Ring Type Dual Steel Rail With Spacer Oil Ring Expander Steel Humped Ring Location of Rings Above Piston Pin Crankshaft Specifications Material Pearlitic Mallea...

Page 27: ...ater 12 7 qts With Air Conditioning 15 0 qts Fan Diameter and Number of Blades Less AC 18 x 4 With AC 18 x 7 Fan Drive Less AC Water Pump Shaft With AC Torque and Temperature Sensitive Clutch Piston and Piston Pin Specifications Piston Material Cast Aluminum Alloy Piston Treatment Tin Plated Piston Pin Material SAE 1018 or 1118 Steel Piston Pin Type Pressed In Rod Connecting Rod Specifications Mat...

Page 28: ...5 45 Valve Stem Diamter Exhaust 372T 3715B 372T 3715B Valve Stem Clearance in Guide Inlet 001 003 Top 002 004 Bottom Same as 401 Exhaust 0015 0035 Top 0025 0045 Bottom Same as 401 Valve Spring Outer Valve Closed Lbs Length 46 1 600 46 1 60CT1 Valve Open Lbs Length 101 1 160 101 1 160 Valve Spring Inner Valve Closed Lbs Length 25 5 1 690 25 5 1 690 Valve Open Lbs Length 76 1 250 76 1 250 Note All M...

Page 29: ...86 2 1 755 1 756 3 1 725 1 726 4 1 695 1 696 5 1 665 1 666 Journal Clearance in Bearings 0005 0025 1 0005 0035 2 3 4 5 Valve System Specifications Rocker Arm Ratio 1 6 to 1 Rocker Arm Clearance On Shaft 0017 0032 Valve Lifter Diameter 8422 8427 Valve Lifter Clearance In Crankcase 0015 003 Valve Lifter Leakdown Rate 12 to 60 Sec in Test Fixture Intake Valve Head Diameter 1 625 Seat Angle 45 Stem Di...

Page 30: ...2 8 SPECIFICATIONS ENGINE f i CN ...

Page 31: ...ENGINE SPECIFICATIONS 2 9 ...

Page 32: ...2 1 0 SPECIFICATIONS ENGINE Figure 2 3 300 Cu In Engine Front View ...

Page 33: ... the crankcase and the cross member at front end of car frame The front mountings are designed to support the weight of the engine and control its tor sional characteristics The rear transmission mounting is located between the transmis sion rear bearing retainer and the transmission support 2 5 ENGINE CONSTRUCTION ALL ENGINES a Cylinder Crankcase The cylinder crankcase has two banks of four cylin...

Page 34: ...ng bosses on each side so that metal can be removed as required to secure correct weight and balance during manufacture The lower end of each rod is fitted with a steel backed full precision type bearing The upper end of the connecting rod has a hole into which the wrist pin is pressed The outer ends of the pin float in the bosses in the piston The tin plated aluminum alloy pistons have full skirt...

Page 35: ...ge As noncombustible ex haust products are removed frorn the area around the spark plug the tendency toward misfiring at part throttle is reduced The central location of the spark plug causes burning of the fuel charge to proceed uniformly out ward in all directions toward edges of the combustion space The short flame travel speeds up the combustion process causing the fuel mixture to burn in a sh...

Page 36: ...pring then presses the lifter body down against the camshaft and presses the plunger and seat up against the push rod with an eight pound load which is enough to take up all lash clearances between parts in the valve linkage without affecting positive seating of the valve Oil is fed to all lifters through galleries in the crankcase as described in paragraph 2 6 Oil enters each lifter through groov...

Page 37: ... and circulated by the spur geared oil pump assem bly which is mounted on the lower side of the cylinder crankcase at the rear end where it extends down into the oil sump The pump shaft is coupled to the ignition distributor shaft which is driven from the camshaft through spiral gears The pump inlet is equipped with a stationary screen of ample area If the screen should become clogged for any reas...

Page 38: ...distributes oil at full pressure to all crankshaft and camshaft bearings from which oil is then distributed to all other working parts of the engine See Figure 2 12 See 2 13 for 300 cu in engine Crankshaft Rods and Pistons Holes drilled in the crankshaft carry oil from the crankshaft bearings to the connecting rod bearings Pistons and cylinder walls are lubricated by oil forced through a small not...

Page 39: ...ight cylinder head On 401 and 425 cu in engines the switch closes one set of contacts to light a green signal on the instrument panel when engine water tempera ture is below 110 F If engine water temperature is between 110 and 245 approximately neither contact is closed Engine water temperature above 245 causes the second set of contacts to close and light a red signal on the instrument panel A Ha...

Page 40: ...EAL IMPELLER Figure 2 16 Water Pump Cover Assembly Figure 2 15 Pressure Type Radiator Cap Installation face of the impeller which is mounted on the bearing shaft with the vanes facing rearward Cool ant flows through the inlet pas sage to the low pressure area at the center where it then flows rearward through three holes in the impeller Vanes on the ro tating impeller cause the coolant to flow rad...

Page 41: ...ion through the radiator ture control permits the engine to reach its normal operating ant returns to the water pump for This thermostatically operated temperature quickly The ther recirculation whenever the ther by pass type of water tempera mostat valve opens at 180 degrees F TO HEATER Figure 2 17 Coolant Flow 300 Cu In Engine ...

Page 42: ...TORQUE TO 30 40 LB FT TORQUE TO 30 40 LB FT Figure 2 18 Engine and Transmission Mounting 45000 Series ...

Page 43: ...ENGINE SPECIFICATIONS 2 2 1 ...

Page 44: ...TORQUE TO 30 40 LB FT TORQUE TO 30 40 LB FT TORQUE TO 45 60 LB FT TORQUE TO 30 40 LB FT TORQUE TO 30 40 LB FT USED ONLY WHEN REQUIRED VIEW A Figure 2 20 Engine and Transmission Mounting 49000 Series ...

Page 45: ...all items affecting compression and igni tion have been satisfactorily corrected Most of the procedures for per forming a complete engine tune up are covered separately in other sections of this manual therefore this paragraph pro vided an outline only with refer ence to other sections where detailed information is given a If compression improves con siderably rings are worn b If compression does ...

Page 46: ...e lowest reading obtained was 145 psi the car is within limits and the compression is considered satisfactory Maximum Pressure pounds sq inch 134 136 138 140 142 144 146 148 150 152 154 156 158 160 162 164 166 168 170 172 174 176 178 180 182 184 Minimum Pressure pounds sq inch 101 102 104 105 107 108 110 111 113 114 115 117 118 120 121 123 124 126 127 129 131 132 133 135 136 138 Maximum Pressure p...

Page 47: ...d or when rocker arm cov ers are removed At approxi mately 500 RPM to 1200 RPM particularly when engine is cold the valve mechanism has a normal operating noise which is audible with the hood raised and still more audible when rocker arm covers are removed When engine is at operating tem perature close the hood and listen for valve noise while sitting in the driver s seat Run engine at idle speed ...

Page 48: ...ign particles varnish or defective surface of check ball or seat Recondition noisy lifters par 2 15 checking carefully for presence of grit or metal particles which would re quire a thorough cleaning to re move source of such material 3 Noise on Idle and Low Speed If one or more valve lifters are noisy on idle and up to approxi mately 25 MPH but quiet at higher speeds it indicates excessive leak d...

Page 49: ...on freely extreme roughness will be produced which may eventually cause breakage of the crankshaft if it is not cor rected A balancer which shows external evidence of damage or which is suspected of being in operative should be replaced and the result checked since it is not possible to test the balancer in any other way e Unbalanced Connecting Rods or Pistons Vibration will result if connecting r...

Page 50: ...water bottle A continuous flow of bub bles indicates that air is being sucked into the cooling system or exhaust gas is leaking into the cooling system past the cylinder head gasket b Overheating of Cooling System It must be remembered that the Buick pressure system operates at higher temperatures than sys tems operating at atmospheric pressure Depending on the pres sure in cooling system the temp...

Page 51: ...n the engine compartment it is necessary to leave some of the bolts and push rods in the head during removal The push rods should be pulled up and taped in position while cylinder head is being removed These same parts must be in the head during installation 11 Slightly loosen all cylinder head bolts then remove bolts and lift off the cylinder head Remove gasket 12 With cylinder head on bench remo...

Page 52: ...rmal height of the valve stem above the valve rocker arm cover gasket surface of the cyl inder head is 1 540 7 Lightly lap valves into seats with fine grinding compound The refacing and reseating operations should leave the refinished sur faces smooth and true so that a minimum of lapping is required Excessive lapping will groove the valve face and a grooved valve will not seat tightly when hot 8 ...

Page 53: ...After installation of cylinder head tighten all bolts a little at a time about three times around in sequence shown in Figure 2 26 then finally tighten in same se quence to 65 75 ft lbs torque Figure 2 25 Rocker Arm Shaft Installation Figure 2 26 Cylinder Head Bolt Tightening Sequence Always use an accurate torque wrench when tightening cylinder head bolts to insure uniform and proper torque on al...

Page 54: ...ng dirt into the hydraulic valve lifters 5 Remove rocker arm cover rocker arm and shaft assembly and push rods from bank where valve lifters are to be removed 6 Remove valve lifter cover and remove the valve lifters that re quire service Place lifters in a wooden block having numbered holes or used other suitable method of identifying them ac cording to original position in engine If less than a f...

Page 55: ... waste can and then remove the ball retainer and spring A strainer placed over waste can will prevent dropping these parts into can 3 Place all parts of each lifter in a separate compartment of a tray from Cleaning Tank J 5093 The body and plunger are selec tively fitted to each other and must not be interchanged with parts of other lifters Keeping all parts of the lifter together until cleaned an...

Page 56: ... condition will not cause improper operation there fore it may be disregarded 3 Push Rod and Seat Replace the push rod seat if the area where the push rod contacts is rough or otherwise damaged Re place any push rod having a rough or damaged ball end 4 Check Ball Using a magni fying glass carefully examine the check ball for nicks imbedded material or other defects which would prevent p r o p e r ...

Page 57: ...llow the lifter plunger to come up to its retainer then lower the arm to rest on the ram roller As the pointer s t a r t s moving upward start rotating the fluid cup by turning the handle one revolution every two seconds See Fig ure 2 34 7 Use a stop watch to check the time required for the pointer to move from the lower to the upper mark on scale where marked BUICK V 8 The cup must be rotated dur...

Page 58: ...hain and Sprockets Properly Installed b Replacement of Crankshaft Oil Seal in Timing Chain Cover 1 With timing chain cover on bench remove the braided fabric packing with a screwdriver and then tap the pressed steel shedder out of the cover 2 Work new packing into the shedder then drive shedder into recess in timing chain cover using Installer J 5250 1 See Fig ure 2 36 View A 3 Push Packing Expand...

Page 59: ... is disturbed If the pump is not packed it may not begin to pump oil as soon as the engine is started 2 The gasket surface of the block and timing chain cover must be smooth and clean Use a new gasket and be certain it is positioned correctly 3 Position timing chain cover against block and be certain dowel pins engage dowel pin holes be fore starting bolts 4 Lube the bolt threads before installati...

Page 60: ...Gear Installation 4 Replace camshaft by reversing removal procedure taking par ticular care to avoid damage to the camshaft bearings g Camshaft Bearings The steel backed babbitt lined camshaft bearings are pressed into the crankcase Going from front to rear each bearing is bored 030 smaller than the pre ceding bearing and each cam shaft journal is correspondingly reduced in diameter The camshaft b...

Page 61: ...cal condition check for proper clearance on crankpins as described in subparagraph b below If crankpin journals are scored or ridged the crankshaft must be replaced or reground for under size bearings to insure satis factory life of connecting rod bearings Slight roughness may be polished out with fine grit polishing cloth thoroughly wetted with engine oil Burrs may be honed off with a fine oil st...

Page 62: ...ing shell is dis turbed or replaced it is necessary to line up the thrust surfaces of the bearing shell before the cap bolts are tightened To do this move the crankshaft fore and aft the limit of its travel several times with the bearing cap bolts finger tight Crankshaft bearings are the pre cision type which do not require reaming to size or other fitting Shims are not provided for ad justment si...

Page 63: ...oil and place shell against crankshaft journal so that tang on shell will engage notch in crankcase when shell is rotated into place 6 Rotate bearing shell into place as far as possible by hand then insert Installer J 8080 in crankshaft oil hole and rotate crankshaft to push shell into place CAUTION Bearing shell should move into place with very little pressure If heavy pressure is required shell ...

Page 64: ...ridge exists at this point remove ridges with a ridge reamer to avoid damaging rings or cracking ring lands in pistons during re moval Chamfering at 15 degree angle will prevent ring damage when pistons are reinstalled 3 Use a silver pencil or quick drying paint to mark the cylinder number on all pistons connecting rods and caps Starting at front end of crankcase the cylinders in right hand bank a...

Page 65: ...ith the pressed pin and rod as semblies Piston pins must fit pistons with an easy finger push fit at 70 F 00005 0001 Examine all piston rings for scores chips or cracks and for tension as compared with new rings Place all compression rings in cylinder bores at lower end of ring travel and check gaps which are normally 010 to 020 If gaps are excessive it indicates that rings have worn considerably ...

Page 66: ...ollows 1 Expand a telescope gauge to fit the cylinder bore at right angles to the piston pin and be tween 1 1 2 and 2 from the top of the bore See Figure 2 45 2 Measure the telescope gauge See Figure 2 46 3 Measure the piston to be in stalled See Figure 2 44 The piston must be measured at right angles to the piston pin below the oil ring groove 4 The tolerance of piston clear ance is 001 to 0016 B...

Page 67: ...arated they may be installed as individual pieces 7 Install compression rings in first and second lands of each piston Top rings are assembled with inner bevel toward top of piston and second ring inner bevel toward bottom of piston See Fig ure 2 48 All compression rings are marked either with a dimple or a letter O to identify the side of the ring which must be as sembled UP NOTE On 425 cu in eng...

Page 68: ...rks will be toward the other connecting rod on the same crankpin 15 Check end clearance between connecting rods on each crankpin using feeler gauges Clearance should be 005 012 16 Install cylinder heads par 2 15 d oil pump par 2 25 and oil pan IMPORTANT After installation of new pistons and rings care should be used in starting the engine and in running it for the first hour Avoid high speeds unti...

Page 69: ...ine long enough to open the thermostat for complete circulation through the system then completely drain the cooling system before sediment has a chance to settle c Conditioning the Cooling System Rust Inhibitor and Stop Leak listed under Group 8 800 is rec ommended for use in the cooling system particularly when pre paring for installation of anti freeze solution This material stops small seepage...

Page 70: ...the rec ommended coolant installed every two 2 years It is advisable to test the anti freeze solution at intervals during the winter to make certain that the solution has not been weak ened by evaporation or leakage Use only hydrometers which are calibrated to read both the spe cific gravity and the temperature and have a table or other means of converting the freezing point at various temperature...

Page 71: ...lack in the belt On a car equipped with power steering it is also necessary to remove the oil pump drive belt after loosening the pump mounting bolts The Delcotron generator must be moved sidewise to adjust the fan belt After the Delcotron genera tor brace and mounting bolts are securely tightened the fan belt tension should be checked as shown in Figure 2 49 and 2 50 for 401 and 425 engines Figur...

Page 72: ... container as this will cause them to be at higher temperature than the water Agitate the water to insure uniform temperature of water thermostat and thermometer The standard thermostat 180 valve should start to open at a temperature of 177 F to 182 F and should be fully open at a temperature not in e x c e s s of 202 F If thermostat does not operate at specified temperatures it should be replaced...

Page 73: ...mp shaft bearings for end play or roughness in oper ation If bearings are not in serv iceable condition the assembly must be replaced b Installation 1 Make sure the gasket surfaces on pump and timing chain covers are clean Install pump assembly with new gasket Bolts with lock washers must be tightened uniformly 2 Connect radiator hose to pump inlet and heater hose to nipple then fill cooling syste...

Page 74: ...Clearance should be not more than 005 or less than 0005 8 Pack cavity and space between gears and body with petroleum jelly Do not use chassis lube 9 Install pump cover side with groove toward gears 10 Tighten bolts to 6 8 ft lbs torque 11 Use new gasket and install pipe and screen to body Tighten bolts to 6 8 ft lbs torque 12 Before installation of pump be sure surface of crankcase is free of dir...

Page 75: ...nd Installation 1 Lubricate and install pressure relief valve and spring in bore of oil pump cover See Figure 2 55 Install cap and gasket Torque cap to 30 35 pounds with a reliable torque wrench Do not over tighten NOTE Pressure relief valve cap has no hole tapped for instal lation of oil pressure switch 2 Install filter by pass valve flat in its seat in cover Install spring cap and gasket Torque ...

Page 76: ...tant that the position of the support not be changed by the removal of shims to move it side ways Whenever it is necessary to re move the support the number and location of the shims at each end of the support should be noted so they may be reinstalled in the same location The following procedure should be used when tightening mounts to obtain proper adjustment 1 Loosen exhaust pipe or pipes at ex...

Page 77: ... AND EXHAUST SYSTEMS a General Specifications Gasoline Grade Required with LeSabre 2 Barrel Carburetor Engine Regular Gasoline Grade Required Other Engines Premium Gasoline Tank Capacity Gal 25 Gasoline Gauge Make and Type AC Electric Fuel Pump Make and Type AC Mechanical Drive Eccentric at Camshaft Sprocket Fuel Pump Pressure At Carburetor Level Pounds 300 Engine 4 to 5 1 4 401 425 Engines 4 3 4 ...

Page 78: ...351 Unloader Opening at Choke Valve Edge 7 32 Initial Idle Speed 1 2 Turn In Initial Idle Mixture 3 4 Turn Out Fast Idle Speed in Drive Hot on Low Step 600 RPM 425 Eng Auto Trans AFB 4 3923S 1 9 16 1 3 16 1 11 16 1 9 16 7 32 3 4 38 68 185 x 030 52 120 256 120 159 120 165 16 167 16 256 401 425 Eng Syn Trans AFB 4 3922S 1 9 16 1 3 16 1 11 16 1 9 16 7 32 3 4 38 68 185 x 030 f52 120 256 120 165 120 16...

Page 79: ...Bleed Hole Pump Setting at Closed Throttle Pump Discharge Jet Vacuum Spark Control Hole Choke Coil Housing Number Choke Thermostat Setting Choke Suction Hole Choke Piston Setting With 026 Wire Closing Shoe Clearance F I Cam Setting Choke Closed F I Cam Number Unloader Opening at Choke Valve Edge Initial Idle Speed Initial Idle Mixture Fast Idle Speed in Drive Hot on Low Step d Rochester Carburetor...

Page 80: ...16 Pump Rod Adjustment 1 1 64 Center Hole Choke Rod Adjustment 53 060 Fast Idle Cam Number 7029553 Choke Unloader Adjustment 31 120 Initial Idle Speed 2 Turns In Initial Idle Mixture 11 2 Turns Out Choke Piston Setting Choke Closed Must Project 1 32 Secondary Contour Adjustment 030 Secondary Lock Out Adjustment 015 Fast Idle Speed in Drive Hot on Low Step 600 RPM 300 Eng Syn Trans 69 56 2 55 2 68 ...

Page 81: ... VENT HOSE AS SHOWN CLIP PART OF BODY PRIOR TO ASSEMBLY COAT OUTER SURFACE OF FILLER PIPE WITH M 4728 M M 5OO THIS DISTANCE CLIP ABOVE TRANS SUPPORT RET PIPE SEDANS RET PIPE CONVERTIBLES PIPE SEDAN o m X c to 1 HEAVY DOTTED LINES REPRESENT CONVERTIBLE FUEL a FUEL RETURN PIPES VARIATION OTHERWISE SAME AS SEDANS o in Figure 3 1 Fuel System Air Cond LeSabre ...

Page 82: ...3 6 DESCRIPTION ENGINE FUEL AND EXHAUST SYSTEMS I ...

Page 83: ...OSITION SHOWN r VAPOR RETURN HOSE I END TO BE 75 INCH 1 BEYOND BEAD i BOTH ENDS OF PIPE BRACKET SCREW fUEL FILTER ASM VIEW C FUEL FEED HOSE END V IFW F TO BE TIGHT AGAINST BEAD vi aw n BOTH ENDS OF PIPE o z m X in o 70 O Nl Figure 3 3 Fuel System Air Cond Riviera ...

Page 84: ...TANK UNIT ASM UNIT ASM FUEL FILLER OPENING BAFFLE CLIP 2 TANK HOSE VIEW A 2 00 VIEW D STRAP 7 VIEW C CAP 00 o m 73 o Z o z 5 Figure 3 4 Fuel Tank Information Riviera ...

Page 85: ... The pump is inverted thereby placing it in a lower cooler location It has a built in air dome with a diaphragm to dampen out p u l s a t i o n s in fuel pressure The construction and operation of the pump are de scribed in Section 3 D c Air Cleaner and Intake Silencer All engines except dual 4 barrel engines are equipped with oil wetted polyurethane foam element air cleaners combined with intake ...

Page 86: ...e stator blades to switch the pitch to high angle This reduces the transmission load on the engine at idle thereby reducing the tendency of the car to creep See Figure 3 17 3 3 DESCRIPTION OF INTAKE AND EXHAUST SYSTEMS a Intake Manifold Distribution A low restriction dual 2 section intake manifold is bolted to the inner edges of both cylinder heads where it connects with all inlet ports The end br...

Page 87: ...f the tail pipe to the muffler is made with a U bolt and clamp The muffler is of the oval shaped dynamic flow type having very low back p r e s s u r e It is double wrapped of heavy gauge galva nized steel with a layer of asbes tos placed between wrappings to aid in reduction of noise transfer and to prevent any oil canning effect The exhaust system is supported by free hanging rubber fabric mount...

Page 88: ...PIPE ASM EXHAUST FRONT ADAPTER ASM SPRING SEAT 1 125 CLEARANCE CLAMP SCREW 84_ _ O8lLB IN RESONATOR ASM VIEWG VIEW F 2 3 O o Q m X I Figure 3 8 Single Exhaust System LeSabre ...

Page 89: ...ADAPTER ASM FLANGE BOLT 1 00 CLEARANCE PIPE ASM CENTER yiEW D IEW F RESONATOR ASM i lEW G Figure 3 9 Single Exhaust System Wildcat and Electra ...

Page 90: ...SPRING SEAT TRANS SUPPORT END OF TAIL PIPE MUST FACE OUTBOARD SIDE OF CAR BOTH SIDES VIEWH HANGER ASM 2 VIEW F RESONATOR ASM VIEW G Figure 3 10 Dual Exhaust System Wildcat and Electro ...

Page 91: ...HANGER ASM RT HANGER ASM LT HANGER ASM RT HANGER ASM LT SCREW 2 J CLAMP 2 VIEW C VIEW F VIEW B Figure 3 11 Dual Exhaust System Riviera tn ...

Page 92: ...ning and stalling will result If the choke unloader goes into action too soon it may cause hard starting when engine is cold If choke unloader goes into action too late or not at all it may cause hard starting when engine is flooded See paragraph 3 17 Rochester 2 Bbl 3 21 Carter or 3 25 Rochester 4 Bbl d No Fuel at Carburetor No fuel may be delivered to car buretor due to empty gasoline tank or st...

Page 93: ...ition par 10 33 or improper settings in the high speed circuit of carburetor Surging at high speed may be caused by low fuel pump pressure par 3 12 With Rochester carburetors surging at 75 to 80 MPH constant speed indicates that the power jet is stopped up or the vacuum piston is sticking If there is lack of power at top speed check throttle linkage to insure full throttle valve opening par 3 9 d ...

Page 94: ...ileage test indicates that the fuel con sumption is above normal check the following items Fuel Leaks Check all gaso line hose connections fuel pump gasoline filter and carburetor bowl gasket 2 Tires Check for low tire pressures par 1 1 3 Brakes Check for dragging brakes 4 Ignition Timing Spark Plugs Late ignition timing causes loss of power and increases fuel con sumption par 10 35 Dirty or worn ...

Page 95: ...ge of water under ordinary conditions The filter should be replaced every 24000 miles for maximum filter ing efficiency See paragraph 1 1 After assembling the fuel filter always start the engine and ob serve the filter carefully to make sure that the clamps are not leaking A woven plastic filter is located on the lower end of the fuel pickup pipe in the gas tank This filter prevents dirt from ente...

Page 96: ...t should be replaced Fully open and fully closed posi tions of the exhaust manifold valve may be checked by the posi tion of the heavy section of the manifold valve weight If the heavy section is to the rear and approximately 45 degrees up the valve is fully closed if the heavy section is forward and approxi mately 45 degrees up the valve is fully open See Figure 3 15 f Positive Crankcase Ventilat...

Page 97: ... air is drawn in from the air cleaner down through a rubber tube through a mesh filled breather assembly and into the left rocker arm cover The oil filler cap is sealed air tight in the closed PCV sys tem See the illustrations With the standard PCV system any blow by in excess of the sys tem capacity from a badly worn engine sustained heavy load etc is exhausted to the atmosphere through the oil f...

Page 98: ...3 2 2 ADJUSTMENTS ENGINE FUEL AND EXHAUST SYSTEMS I to c o ...

Page 99: ...ENGINE FUEL AND EXHAUST ADJUSTMENTS 3 2 3 i ...

Page 100: ...3 2 4 ADJUSTMENTS ENGINE FUEL AND EXHAUST to c o ...

Page 101: ...loading or rolling of engine on warm up with the standard thermostat set ting A Rich setting should be used only when excessive spitting occurs on engine warm up with the standard thermostat setting When making either a Lean or Rich setting change one point at a time and test results with en gine cold until the desired per formance is obtained If the engine operates on fast idle too long after sta...

Page 102: ...sh pot does not delay closing action just before throttle is closed adjust dash pot for more interference If return to idle drags out excessively more than 2 seconds adjust dash pot for less interference 2 As a final check hold car with brakes and put transmission in drive then jab accelerator pedal If car stalls adjust dash pot for slightly more interference and recheck as necessary 3 Tighten loc...

Page 103: ...UEL GAGE ASSEMBLY SCREW ASSEMBLY 5 FUEL FILLER OPENING BAFFLE CLIP 2 FUEL GAGE ASSEMBLY HOSE FILTER NUT 2 O 5 LBS FT VIEW A 6 S VIEW D 5TRAP VIEW C CAP z o Q m X CO I CO SI Figure 3 21 Fuel Tank Riviera ...

Page 104: ... Fuel Pump The fuel pump draws gasoline from the tank and supplies it to the carburetor in sufficient quan tity to meet engine requirements under all operating conditions The principle parts of the fuel section are shown in Figure 3 22 The rocker arm spring holds the rocker arm in constant contact with the eccentric on the engine camshaft sprocket so that the rocker arm swings up and down as the c...

Page 105: ...pump diaphragm flange To correct tighten cover screws alternately and securely 5 Disconnect feed pipe at car buretor Ground distributor ter minal of coil with jumper wire so that engine can be cranked without firing Place suitable con tainer at end of pipe and crank engine a few revolutions If no gasoline or only a little flows from pipe the feed line is clogged or fuel pump is inoperative Be fore...

Page 106: ... pump always use all new parts in kit as amount of wear of these parts cannot be determined visually 1 If rocker arm and link were removed subpar b above place new rocker arm spring and link in position in pump body with rocker arm and use a slightly undersize rod through pin hole to line them up See Figure 3 24 Drive new rocker arm pin through body forcing lineup rod ahead of it Install new steel...

Page 107: ...ts on a flat portion of the carburetor bowl in front of the main venturi with a gasket underneath See Figure 3 26 The idle and main well tubes are permanently in stalled in the cluster body by means of a precision pressed fit and therefore cannot be serv iced separately The main noz zles and idle tubes are suspended in the fuel in the main wells of the float bowl The main metering jets are of the ...

Page 108: ...at and replenishing the fuel in the bowl thereby keeping the fuel level constant See Figure 3 27 A float tang located at the rear of the float arm between the float hangers prevents the float assem bly from moving too far down ward but allows the float assembly to move down far enough for maximum fuel flow into the carburetor bowl A float needle pull clip connecting the float arm to the needle val...

Page 109: ...lly diminishes With the increased throttle open ing there is increased velocity in the venturi system This causes a drop in pressure in the large venturi which is increased many times in the small venturi Since the low pressure high vac uum is now in the small venturi fuel will flow in the following manner Fuel from the float bowl passes through the main metering jets into the main well and rises ...

Page 110: ... pump plunger seats the inlet ball check and forces the fuel through the discharge passage where it un seats the pump discharge ball and then passes on through to the pump jets where it sprays into the venturi The ball check located in the pump plunger head serves as a vapor vent for the pump well Without this vent vapor pressure in the pump well might force fuel from the pump system into the engi...

Page 111: ...on encountered during cold starting To prevent stalling during the warm up period it is necessary to run the engine at a slightly higher idle speed than for a warm engine This is accomplished by steps on the fast idle cam The fast idle cam is in turn linked to the choke valve shaft by the choke rod choke trip lever and choke lever and collar assembly This holds the throttle valves open suf ficient...

Page 112: ...n Dirt gum water or carbon con tamination in or on the exterior moving parts of a carburetor are often responsible for unsatisfac tory performance For this rea son efficient carburetion depends upon careful cleaning and inspec tion while servicing 1 Thoroughly clean carburetor castings and metal parts in car buretor cleaning solvent CAUTION Pump plunger or any fiber or rubber parts shouldnever be ...

Page 113: ...at and gasket in air horn Tighten needle seat se curely using a wide bladed screwdriver 8 Install power piston into vac uum cavity Lightly stake piston retainer washer in place Piston should travel freely in cavity 9 Install air horn gasket on air horn fitting gasket over guide pin 10 Attach float needle to float Carefully position float and in sert float hinge pin Drop tang on rear of float arm s...

Page 114: ...52 See Figure 3 37 b Choke Rod Adjustment Turn idle stop screw into the normal idle position normal idle position would be with the idle stop screw turned in approxi mately 3 turns against the fast idle cam with the choke valve held wide open Place idle stop screw on the second step of the fast idle cam against shoulder of the high step Wire gauge marked 055 should just go between the upper edge o...

Page 115: ... pedal and the connecting throttle link age The s e c o n d a r y throttle valves are operated by the pri mary throttle valve shaft through delayed action linkage which per mits a predetermined opening of the primary valves before the secondary valves start to open Action of the linkage then causes both sets of throttle valves to reach the wide open position at the same time b Operation of Float S...

Page 116: ... the carburetor when the vehicle is parked down hill on a very steep grade c Operation of Idle Low Speed Systems Each barrel of the carburetor has a separate idle system but the general operation is identical in all barrels The idle system in each barrel supplies fuel to the engine whenever the position of the throttle valve is such that suction is created at the idle discharge holes in the thrott...

Page 117: ...r so that a mixture of fuel and air is discharged from the main discharge nozzle into the air stream passing through the small venturi in the barrel of the carburetor See Figure 3 44 The main metering systems in the primary section control the flow of fuel during the interme diate or part throttle range of operation and up to approximately 85 MPH if the car is accelerated gradually The secondary t...

Page 118: ... The power piston cylinder in the air horn of the carburetor is connected by a channel to the face of the mounting flange so it is subject to intake manifold vacuum At part throttle position the vacuum is sufficient to hold the power piston in its up po sition against the tension of the piston spring When the throttle valves are opened to a pointwhere manifold vacuum drops to approx imately 9 to 5...

Page 119: ...tat contains a bi metal spring and a vacuum actuated piston A choke rod connects the choke valve to a fast idle cam on the throttle body A heat pipe con nects the choke housing to a heat stove in the right exhaust mani fold See Figure 3 46 The heat stove in the exhaust manifold heats the air which is drawn through it and the heat pipe into the choke housing A restriction in the choke housing cover...

Page 120: ...rom choke shaft and disengage lower end of choke rod from fast idle cam Then remove choke lever and collar and choke rod as an assembly See Figure 3 47 4 Remove two choke valve at taching screws Remove choke valve from slot in shaft Remove burrs from choke shaft then re move shaft from air horn 5 Remove all air horn screws then carefully lift air horn straight up from main body to avoid damaging f...

Page 121: ...The throttle body assembly consisting of the body primary and secondary throttle valves shafts levers and springs is serviced only by replacing the as sembly Therefore the throttle body should not be disassembled further for normal cleaning and inspection 3 2 0 ASSEMBLY AND INTERNAL ADJUST MENT OF ROCHESTER 4 BARREL CARBURETOR When assembling the carburetor use all new gaskets and any addi tional ...

Page 122: ...ary and secondary float assembly and torsion springs on the air horn retaining in place with hinge pins Make sure tor sion springs are installed cor rectly See Figure 3 49 17 Adjust Float Level Primary and Secondary With the air horn inverted and air horn gasket in place measure the distance from ADJUST TO 1 13 32 GAGE FROM GASKET SURFACE TO TOP OF FLOAT BEND FLOAT ARM TO ADJUST CENTER FLOAT PONTO...

Page 123: ...erator pump rod in pump lever Install clip on upper end of pump rod 3 21 EXTERNAL ADJUST MENT OF ROCHESTER 4 BARREL CARBURETOR 1 Fast Idle Cam Adjustment Close throttle so that fast idle screw contacts second highest step of fast idle cam with side of screw against rise to high step of cam then check clearance be tween choke valve and air horn dividing wall using 060 gauge See Figure 3 52 2 If cho...

Page 124: ...btain this clear ance using Tool J 6058A See Figure 3 59 9 If adjustment was necessary to correct lock out tang to con tour c l e a r a n c e the tang to lock out slot clearance should be rechecked Steps 5 6 to be sure it was not disturbed 10 Pump P l u n g e r Adjustment Push fast idle cam to full down position and back out throttle stop screw until primary throttle valves can be fully closed Wit...

Page 125: ...olutely free in any position mechanism is free if choke will fall open from its own weight Install choke baffle plate Install choke cover and gasket Rotate c o u n t e r c l o c k w i s e until index marks align and choke valve is just closed then tighten screws and retainers See paragraph 3 8 14 Fast Idle Speed Adjustment Make fast idle speed adjustment on car with engine at normal operating temp...

Page 126: ... carburetor which cuts in to assist the primary sec tion when a predetermined car speed or engine load is reached This section contains its own high speed system It has a separate set of throttle valves and a set of auxiliary valves which are located in the barrels above the throttle valves The primary throttle valves are operated by the accelerator pedal and the connecting throttle link age The s...

Page 127: ... the gasoline and a i r mixture to enter the carburetor bores The secondary throttle valves remain seated at idle The low speed jets air bleed economizer and by pass bushings are pressed in place in the ven turi assemblies Do not remove in servicing If replacement is necessary use a new venturi as sembly To insure proper align ment of the low speed mixture passage each primary venturi assembly is ...

Page 128: ... the nozzle passage and the main vent tube serves to break the flow of fuel from the high speed circuit quickly as the throttle is closed upon deceleration A clogged air bleed or main vent tube may cause excessively rich mixtures The high speed bleed and main vent tubes are perma nently installed If replacement is necessary use a new venturi assembly The high speed bleeds also act as anti percolat...

Page 129: ...ECK Figure 3 70 Pump Circuit insure smooth acceleration When the throttle valves are opened a predetermined amount the pump plunger bottoms in the cylinder eliminating further pump discharge Be sure the pump plunger cup is in good condition and the intake and discharge checks and pump jet are free of lint gum or other foreign matter The pump intake check is a one piece assembly located in an angul...

Page 130: ...thereby preventing the shaft and valves from turning The choke fast idle linkage per mits the choke valve to float in that it can close a few degrees if necessary should the engine falter while running on fast idle during the warm up period When the engine starts manifold vacuum applied to the choke pis ton pulls the choke valve partially open Should the engine falter the choke piston will sense t...

Page 131: ...n on bench or mounting fixture Install primary and secondary metering jets and tighten securely NOTE The primary jets are the two having the larger orifices and are in stalled in the holes nearest the center of the main body below step up rod holes in air horn 2 Install pump discharge check needle point down Install pump jet housing and gasket Install pump intake ball check assembly 3 Install ther...

Page 132: ...two step up piston springs Install each assembled retainer spring Carefully push down on each step up piston and rod until rod enters metering jet Use care to avoid bending step up rods Then install cover plates holding plates down while tightening screws 16 Install upper end of pump rod in pump arm Install spring and retainer on rod making sure that bronze washer is on opposite side of pump arm f...

Page 133: ...to obtain this clearance using pliers See Fig ure 3 80 7 Adjust Throttle Opening At wide open throttle primary throttle valves should be vertical Secondary throttle valves should be a few degrees from vertical Upper edge of secondary valves should just contact auxiliary valves when both are wide open If necessary bend wide open stop lug Primary and secondary throttle valves should reach wide open ...

Page 134: ...ered by a single brass air adjustment screw in a by pass channel Operation of the dual carburetor system from idle to wide open is as follows As the accelerator pedal is gradually depressed the primary of the rear carburetor starts to open When it is ap proximately half open the pri mary of the front carburetor starts to open Next the secon dary of the rear carburetor starts to open and last the s...

Page 135: ...WITH PRIMARY CARBURETOR AT WIDE OPEN THROTTLE ADJUST BOLT UNTIL SECONDARY CARBURETOR IS AT WIDE OPEN THROTTLE CAUTION DO NOT ADJUST THE BOLT SO THE SECONDARY CARBURETOR PREVENTS THE PRIMARY CARBURETOR FROM REACHING WIDE OPEN THROTTLE LEVER PART OF REAR CARBURETOR ASM ROD ASM REAR 49 ROD ASM REAR 46 48 ROD ASM FRONT LEVER PART OF FRONT CARBURETOR ASM BOLT TRUNNION VIEW A 00 70 n 70 m 70 Figure 3 83...

Page 136: ...re as follows 1 Remove air cleaner Connect a tachometer from distributor terminal of coil to ground 2 Start engine and run it at fast idle until upper radiator tank is hot and choke valve is wide open 3 On automatic transmission cars place a block in front of a front wheel and apply parking brake firmly then shift trans mission into drive 4 Make sure that all throttle valves close fully then set i...

Page 137: ...4 5 Removal Lubrication Inspection and Installation of Clutch 4 3 Clutch Trouble Diagnosis 4 6 4 1 CLUTCH SPECIFICATIONS a Tightening Specifications Part Bolt Special Stud Bolt Bolt Location Thread Size Clutch Cover to Flywheel 3 8 16 x 1 Clutch Release Fork Ball 3 16 16 Transmission to Flywheel Housing 1 2 13 x 1 1 2 Flywheel Housing to Cylinder Block 3 8 16 x 1 1 4 Torque Ft Lbs 30 40 35 45 45 6...

Page 138: ... a ball stud acts upon the throw outbear ing The bearing in turn forces the tangs of the diaphragm spring in the direction shown in Figure 4 2 The diaphragm spring be ing retained in the clutch cover by 9 rivets and 2 wire rings is mounted in such a way that the spring can pivot or dish on these rings again reversing the direc THROWOUT BEARING PRESSURE PLATE PIVOT POINT CLUTCH FORK DRIVEN PLATE FL...

Page 139: ...rmal wear of clutch facings As the driven plate wears thinner pedal lash decreases It is very important to maintain pedal lash at all times Insuf ficient pedal lash will cause the throw out bearing to ride against the diaphragm spring tangs con stantly resulting in abnormal wear of these parts It may also cause clutch slippage and abnor mal wear of the driven plate fly wheel and pressure plate if ...

Page 140: ...PEDAL ROD CLUTCH FORK OPERATING ROD CLUTCH RELEASE ROD CLUTCH EQUALIZER J n to I I O in Figure 4 3 Clutch Linkage ...

Page 141: ...scored or grooved the part should be replaced 2 Clutch Driven Plate Inspect driven plate for condition of facings loose rivets broken or very loose torsional springs and flattened cushion springs If facings are worn down near rivets or are oily the plate as sembly should be replaced A very slight amount of oil on clutch facings will cause clutch grab and chatter A large amount of oil on facings wi...

Page 142: ...g as sembly and hook up all clutch linkage NOTE Make certain clutch fork is seated in throw out bearing See Figures 4 1 and 4 2 8 Install transmission as out lined in paragraph 4 15 4 5 45000 CLUTCH TROUBLE DIAGNOSIS SYMPTOM AND PROBABLE CAUSE PROBABLE REMEDY FAILS TO RELEASE PEDAL PRESSED TO FLOOR SHIFT LEVER DOES NOT MOVE FREELY IN AND OUT OF REVERSE GEAR a Improper linkage adjustment b Improper...

Page 143: ...k improperly installed e Weak linkage return spring NOISY a Worn throw out bearing b Fork off ball stud Heavy clicking PEDAL STAYS ON FLOOR WHEN DISENGAGED a Bind in linkage b Springs weak in pressure plate c Weak pedal return spring HIGH PEDAL EFFORT a Bind in linkage b Driven plate worn a b c d e a b a b c a b PROBABLE REMEDY Install new disc Replace transmission clutch gear Tighten or replace m...

Page 144: ... to Transmission Stud Clutch Equalizer to Bracket to Frame Bolt Transmission to Flywheel Housing Thread Size 5 16 18 3 8 16 7 16 20 7 16 14 1 2 13 7 16 14 Torque Ft Lbs 25 35 45 60 60 85 50 60 20 30 40 45 b Clutch Specifications Clutch Type Single Plate Dry Disc Clutch Pedal Pressure 28 32 Lbs Clutch Pedal Lash 7 8 1 1 8 Driven Plate Diameter 11 x 6 1 2 Driven Plate Facings Type and Number Woven M...

Page 145: ...over cover to pressure Figure 4 6 Clutch Wear Plates plate and from pressure plate and flywheel to driven plate When the clutch is disengaged the clutch release bearing presses forward on the inner ends of the release levers which pivot and force the pressure plate rearward against the pressure of clutch springs The pressure plate is moved rearward far enough to free the driven plate See Fig ure 4...

Page 146: ... lease fork and clutch equalizer see Figure 4 10 The clutch release yoke is posi tioned to push forward on the throw out bearing when the clutch pedal is depressed A U shaped spring riveted to the throw out bearing holds the throw out bear ing in contact with the clutch re lease yoke The clutch release rod length must be adjusted to provide clearance between the throw out bearing and the clutch re...

Page 147: ...CLUTCH S M TRANSMISSION 46000 CLUTCH 4 1 1 I ...

Page 148: ...DRIVEN PLATE PRESSURE PLATE THROW OUT BEARING CONE POINT CAP SCREW SOCKET HEAD CAP SCREW CLUTCH RELEASE YOKE WELCH PLUG CLUTCH RELEASE SHAFT n n Figure 4 10 Clutch Information Assembly ...

Page 149: ...ch is removed from the car NOTE Before clutch release shaft is installed apply a small amount of wheel bearing lubricant where right side of clutch release shaft pilots in flywheel housing 1 Very sparingly apply wheel bearing lubricant in pilot bushing in crankshaft If too much lubri cant is used it will run out on face of flywheel when hot and ruin driven plate facings Make sure that surface of f...

Page 150: ...utch levers and inner edge of clutch cover A string or wire fastened to each spacer will keep it from dropping inside the clutch 5 Turn clutch assembly over so that pressure plate side is up and adjusting screw buttons are con tacting a solid surface 6 Stake each adjusting screw to release lever by peening release lever material into adjusting screw slot at both sides A blunt screwdriver which nea...

Page 151: ...urface is deeply scored or grooved the part should be replaced 2 Clutch Cover Inspect clutch cover for cracks or distortion Check clearance between pres sure plate driving lugs and edges of slots in cover using feeler gauges The clearance should be 005 to 008 excessive clear ance may cause rattle when en gine is intermittently accelerated with clutch disengaged 3 Clutch Driven Plate Inspect driven...

Page 152: ...gnment should be checked be fore the flywheel clutch and transmission are installed When checking alignment the engine DIAL INDICATOR HOLE ATTACHMENT SLEEVE SUPPORT J 4710 1 Figure 4 13 Checking Alignment of Housing at Pilot Hole must be in an upright position dowel pins must be installed and all housing bolts must be tight a Checking Alignment of Flywheel Upper Housing 1 Remove transmission par 4...

Page 153: ...ent paper shims of proper thickness to crankcase in position required to give an indicator reading of 003 or less when all bolts are securely tightened IAL INDICATOR UPPORT 4710 1 SLEEVE KMO 30 K 10 Install transmission clutch and Figure 4 14 Checking Run Out of Rear Face of Housing 4 1 2 46000 SERIES CLUTCH TROUBLE DIAGNOSIS SYMPTOM AND PROBABLE CAUSE PROBABLE REMEDY FAILS TO RELEASE PEDAL PRESSE...

Page 154: ... spring NOISY a Worn throw out bearing b Fork off ball stud Heavy clicking PROBABLE REMEDY b Install new disc and correct oil leak at its source c Replace disc d Replace same e Replace cover assembly f Make 20 50 normal starts g Allow to cool Check lash a Install new disc b Replace transmission clutch gear c Tighten or replace mountings d Replace pressure plate or flywheel e Sand off if superficia...

Page 155: ...h Gears 2nd Gear Sliding Gears 1st and Reverse Gears Gear Ratios 1st 2 58 1 2nd 1 48 1 3rd 1 00 1 Reverse 2 58 1 Gear Shifting Remote on Steering Column c Speedometer Gears Speedometer Driving Gear on Mainshaft Press Fit 4 14 S M TRANSMISSION DESCRIPTION The synchromesh transmission is solidly bolted to the rear face of the upper flywheel housing form ing a unit assembly with the en gine The clutc...

Page 156: ...r respective gears causing the rings to rotate when the gear rotates This arrange ment allows the ring to slide on the gear An energizing spring positioned in a groove on the gear provides resistance to this movement As the clutch sleeve is slid forward or rearward the beveled outer diameter of the ring contacts the beveled inner diam eter of the clutch sleeve The ring which is rotating at the sam...

Page 157: ...ed Clutch 8 First and Reverse Sliding Gear 10 Second Speed Gear 11 Thrust Washer 12 Case Extension 13 Main Rear Bearing 15 Mainshaft 18 Front Pilot Bearing Rollers 19 Thrust Washer 20 Thrust Washer 21 Rear Pilot Bearing Rollers 22 Synchronizer Ring 36 Snap Ring 37 Countershaft 38 Thrust Washer 39 Roller Bearing 40 Countergear 41 Transmission Case 42 Roller Thrust Washer n O m en 4 ...

Page 158: ...ft Pin 10 Second Speed Gear 11 Thrust Washer 12 Case Extension 13 Mainshaft Rear Bearing 14 Speedometer Drive Gear 15 Mainshaft 16 Bushing 17 Oil Seal 18 Front Pilot Bearing Rollers 19 Thrust Washer 20 Thrust Washer 21 Rear Pilot Bearing Rollers 22 Synchronizer Ring 23 Second and Third Shifter Fork 24 Second and Third Shifter Shaft 25 Detent Cam 26 Detent Cam Spring 27 O Ring Oil Seal 28 Second an...

Page 159: ...e Gear Power Flow Torque imparted to the main drive gear is applied to the countergear The middle gear on the counter being in mesh with the idler gear transmits the torque to the idler gear The idler gear in turn is in mesh with the ring gear and transmits torque to it and the clutch sleeve to which the ring gear is splined The clutch sleeve then turns the mainshaft 4 15 REMOVAL AND INSTALLATION ...

Page 160: ...car Weld a piece of 1 4M rod 8 long in the main shaft pilot bore Assemble a good bearing on the shaft and secure it with a clutch gear bearing nut 1 Remove the transmission from the car and completely disassemble 2 Install the case extension on the case and tighten the extension to case bolts securely 3 Install the special tool with the dial indicator in the transmission case with the face of the ...

Page 161: ...n 26 First and Reverse Shifter Lever O Ring 27 Second and Third Shifter Lever O Ring 28 Thrust Washer 28a Thrust Bearing 28b Thrust Bearing Washer 29 Reverse Idler Gear 30 Reverse Idler Shaft Pin 31 Reverse Idler Shaft 32 Countershaft 33 Countergear and Roller Thrust Washers 34 Bearing Roller 35 Countergear 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 Shifter Interlock Retainer Stud Nut S...

Page 162: ...assembly from the clutch gear and then remove through the side cover opening 5 Remove the pilot bearing rollers from clutch gear 6 Remove the four clutch gear bearing retainer screws and washers Remove retainer and gasket 7 Using Tool J 5777 remove the countershaft Leaving the tool in place lower the countergear to the bottom of the case See Fig ure 4 21 NOTE It is necessary to lower the counterge...

Page 163: ... shaft 3 Remove second speed gear thrust washer and second speed gear 4 Inspect and replace worn or damaged parts 5 Lubricate bore of second speed gear and install on mainshaft 6 Install bearing Make sure the groove in O D of bearing is toward second speed gear 7 Install correct size snap ring Determine size by using ring that gives no more than 004M of end play between bearing and shaft Figure 4 ...

Page 164: ...Tool J 0932 in the open ing in the clutch sleeve Expand Figure 4 29 Removing Synchronizing Rings ENERGIZING SPRING LOCATE OFFSET END OF SPRING BETWEEN 3RD AND 4TH TEETH OF EITHER BANK OF TEETH Figure 4 31 Energizing Ring Location the retainer with the fingers just enough to catch the tips of the tool jaws Then open the jaws of the tool enough to expand the retainer back into the counter bore and a...

Page 165: ...LY 1 Coat reverse idler thrust washers and the thrust bearing with grease and install as shown in Figure 4 33 Coat bushings with transmission lubricant 2 Place gear assembly in posi tion in case with thrust bearing toward rear 3 Install the idler shaft making sure the lock pin hole in the shaft lines up with the hole in the case at the same angle See Figure 4 26 4 Coat a new idler shaft lock pin w...

Page 166: ...retainer using the special shakeproof washers Tighten to 12 15 ft lbs torque 13 Lubricate and insert counter shaft in rear of case Align countergear with shaft and tap shaft thru pushing Tool J 5777 out front of case Be sure the flat on the end of countershaft is horizontal and to the bottom of the case See Figure 4 37 14 After shaft is aligned as de scribed above and as shown in Figure 4 37 drive...

Page 167: ...1 8 45000 SERIES 3 SPEED SYNCHROMESH TRANSMISSION TROUBLE DIAGNOSIS SYMPTOM AND PROBABLE CAUSE PROBABLE REMEDY SLIPS OUT OF HIGH GEAR a Transmission loose in clutch housing b Control rods interfere with clutch throw out lever c Control linkage does not work freely binds d Does not fully engage e Damaged mainshaft pilot bearing f Clutch gear bearing retainer broken or loose g Dirt between transmiss...

Page 168: ...sufficient lubricant b Worn or damaged clutch gear or countergear NOISY IN SECOND ONLY a Damaged or worn second speed constant mesh gears b Worn or damaged countergear rear bearings PROBABLE REMEDY a Determine cause for example worn shift fork and control lever or rod interference Replace worn or bent parts b Replace 2nd or 3rd speed clutch sleeve and or first and reverse sliding gear Possible cor...

Page 169: ...transmission b Loose or broken clutch gear bearing retainer c Clutch gear bearing retainer gasket damaged d Cover loose or gasket damaged e Operating shaft seal leaks f Idler shaft expansion plugs loose g Countershaft loose in case h Lack of sealant on bolts i Worn extension oil seal PROBABLE REMEDY a Replace worn gear b Replace countergear assembly a Replace reverse idler gear b Replace reverse i...

Page 170: ...4 3 4 45000 SYNCHROMESH CLUTCH S M TRANSMISSIONS J 0933 01 J 8092 J 0932 J 5586 J 21424 9 J 5777 Figure 4 40 3 Speed Synchromesh Tools ...

Page 171: ...Reverse 3 154 to 1 4 20 S M TRANSMISSION DESCRIPTION The synchromesh transmission is solidly bolted to the rear face of the flywheel upper housing to form a unit assembly with the engine The transmission drive gear shaft extends the clutch driven plate into a bronze bushing seated in the rear end of the engine crankshaft The front bearing retainer projects into a bore in the flywheel housing servi...

Page 172: ...ONT BEARING RETAINER REAR BEARING RETAINER CASE EXTENSION SPEEDOMETER DRIVE GEAR FIRST AND REVERSE GEAR CASE EXTENSION OIL SEAL n I m COUNTERSHAFT BEARING ROLLERS COUNTERSHAFT THRUST WASHER COUNTERSHAFT BEARING SPACER COUNTERGEAR COUNTERGEAR THRUST WASHERS 6 Figure 4 77 Cross Section of 46000 3 Speed Synchromesh Transmission ...

Page 173: ...after which the springs allow the shift plates to slide out of the detent notches in the sleeve to permit the sleeve to engage the gear quietly and easily c Speedometer Gears The speedometer driving worm gear is held against a shoulder on the transmission mainshaft by forward pressure of the front companion flange When changing rear axle ratios it is necessary to change the driven gear and on some...

Page 174: ... moved forward the notched cam is rotated in the other direction and the first reverse gear is moved rearward to engage the reverse idler gear When either shift lever is moved from the center or neutral po sition an interlock mechanism located between the second third shift cam and the first reverse shift cam prevents the other shift lever from being moved from its neutral position This prevents t...

Page 175: ...or a distance of about 1 inch Do not apply an excess that will push off at driven plate hub and get on clutch facings Fill groove in inner surface of throw out bearing with wheel bearing grease 2 Make certain that front face of transmission case and rear face of flywheel housing are absolutely clean Install J 1126 guide pin in upper left flywheel housing hole install guide pin in lower right hole ...

Page 176: ...rks and levers in place lower side cover intoplace Install attaching bolts using sealer in lower right bolt and tighten evenly 4 2 2 DISASSEMBLY AND ASSEMBLY OF 3 SPEED SYNCHROMESH a Disassembly of 3 Speed Synchromesh Transmission 1 Remove transmission side cover assembly from transmis sion case NOTE If cover as sembly is to be disassembled for inspection or replacement of worn parts follow proced...

Page 177: ...clutch hub retaining snap ring from front end of main shaft using snap ring pliers as shown in Figure 4 88 25 Remove 2nd and 3rd speed clutch sleeve and hub from main shaft See Figure 4 88 26 Remove rear synchronizing ring and second speed gear from mainshaft See Figure 4 88 27 Remove lst reverse sliding gear from mainshaft See Figure 4 88 28 Spread rear bearing retainer snap ring and with a soft ...

Page 178: ...y in the hub Place the keys in position and holding them in place slide the hub into the sleeve as shown in Figure 4 91 d Transmission Assembly Mainshaft Assembly 1 Using J 8853 press on the rear bearing with the snap ring Figure 4 86 Removing Main Drive Gear groove toward the front of the transmission See Figure 4 92 Firmly seat bearing against the shoulder on the mainshaft Figure 4 87 Removing M...

Page 179: ... Install 1st reverse sliding gear on mainshaft See Figure 4 94 5 Install second speed gear hub forward over front end of main shaft See Figure 4 95 6 Install 2nd 3rd speed clutch sleeve on clutch hub as shown in Figure 4 96 7 Place synchronizing ring on rear of sleeve and hub assembly CLUTCH KEY CLUTCH KEY SPRING CLUTCH HUB 4 CLUTCH KEY CLUTCH KEY Figure 4 91 Clutch Hub Assembly Figure 4 90 Removi...

Page 180: ...l in the other end of coun tergear 20 more rollers and an other 050 spacer See Figure 4 99 15 Place large bronze thrust washer at front end of counter gear tang facing out so that it will seat in groove at front of case Retain with heavy grease 16 Place smaller bronze thrust washer against rear of counter gear tangs facing gear and seated in grooves Retain with grease 17 Through rear of case inser...

Page 181: ... outlet hole in case 26 Coat bore at rear end of main drive gear with heavy lubricant and insert the 14 needle roller bearings in bore 27 Install bearing spacing wash er See Figure 4 104 28 Position reverse idler gear in rear of case chamfer on teeth toward front and from rear start idler gear shaft through case and gear Figure 4 104 Installing Bearing Spacer 29 Place lock key in notch at rear of ...

Page 182: ...ash ers before it enters countergear NOTE Rotating main drive gear back and forth will help in align ing countergear thrust washer with shaft opening in case 36 Slide countershaft through countergear forcing Tool J 9573 out opening at front of case See Figure 4 106 37 Before countershaft is driven fully into place install lock key retain key is countershaft with heavy grease in notch at rear of sh...

Page 183: ...etween transmission case and clutch housing causing misalignment h Damaged or worn crankshaft pilot bushing SLIPS OUT OF LOW AND OR REVERSE a First and or Reverse gears damaged from operating during partial engagement b Improper mated or worn splines on inside of first and reverse gear and mainshaft c Improperly adjusted linkage PROBABLE REMEDY a Tighten mounting bolts b Replace or bend levers and...

Page 184: ...sh gears b Worn or damaged countergear rear bearings NOISY IN LOW AND REVERSE ONLY a Worn or damaged first and reverse sliding gear b Damaged or worn countergear NOISY IN REVERSE ONLY a Worn or damaged reverse idler gear b Worn reverse idler gear bushings c Damaged or worn reverse countergear PROBABLE REMEDY a Fill to correct level b Replace countergear bearings and shaft c Replace worn or damaged...

Page 185: ...retainer c Clutch gear bearing retainer gasket damaged d Cover loose or gasket damaged e Operating shaft seal leaks f Idler shaft expansion plugs loose g Countershaft loose in case h Lack of sealant on bolts i Worn extension oil seal PROBABLE REMEDY a Replace thrust washer b Replace bearing lock or case as necessary c Replace countergear bearings and shaft a Replace countergear bearings and shaft ...

Page 186: ...el upper housing to form a unit assembly with the engine The transmission main drive gear shaft extends through the clutch driven plate into a bronze bushing seated in the rear end of the engine crank shaft The front bearing retainer projects into a bore in the fly wheel housing serving as a pilot to center the transmission with the engine crankshaft a Transmission Gears and Shafts The transmissio...

Page 187: ...ING RING FIRST SECOND SPEED CLUTCH ASSEMBLY FIRST SPEED SYNCHRONIZING RING REVERSE GEAR FRONT BEARING RETAINER MAINSHAFT COUNTERSHAFT BEARING ROLLER COUNTERSHAFT BEARING ROLLER SPACER REVERSE IDLER GEAR REAR COUNTERSHAFT GEAR REVERSE IDLER GEAR FRONT TOP VIEW OF REVERSE IDLER GEARS REVERSE IDLER SHIFT LOCK PIN o to O in 3 m a z 2 i in Figure 4 112 Four Speed Transmission ...

Page 188: ... cable casing d Front Companion Flange The front companion flange is splined to the rear end of the transmission mainshaft and is re tained by a heavy steel washer and bolt An oil seal is located in the rear end of the case extension e Shift Linkage Gearshifting is manual through a floor type gear shift lever which activates shift control rods con nected to the transmission cover shifter levers fo...

Page 189: ...ar the direction of rotation will be opposite that of the engine See Figure 4 118 4 26 TRANSMISSION SIDE COVER REMOVAL AND INSTALLATION NOTE It is not necessary to remove transmission from vehicle for inspection or replacement of parts in transmission side cover assembly but the side cover as sembly itself must be removed from the transmission case a Removal 1 Remove drain plug at the bot tom of t...

Page 190: ...on CAUTION If weight of transmis sion is allowed to rest on main drive gear while drive gear splines are in clutch driven plate driven plate may be damaged b Installation of Transmission 1 Lightly coat splines on end of main drive gear with Lubriplate for a distance of approximately 1 inch Fill groove in inner sur face of throw out bearing with wheel bearing grease 2 Make certain that front face o...

Page 191: ...en the reverse idler shaft is out as far as it will go move extension to left so reverse fork clears reverse gear and re move extension and gasket 6 Remove rear bearing snap ring on mainshaft 7 Remove case extension oil seal See Figure 4 123 8 Remove the speedometer gear with J 8760 as shown in Figure 4 124 9 Remove the reverse gear re Figure 4 126 Removing Main Drive Gear verse idler gear and tan...

Page 192: ... and Rear Bearings 1 Wash the front and rear thor oughly in a cleaning solvent 2 Blow out bearing with com pressed air NOTE Do not allow the bearings to spin but turn them slowly by hand Spinning bearings will dam age the race and balls 3 Make sure the bearings are clean then lubricate them with light engine oil and check them for roughness Roughness may be determined by slowly turning the outer r...

Page 193: ... Bearing Retainer to Case Extension Gasket 37 Case Extension 38 Rear Oil Seal 39 Reverse Idler Shaft 40 Reverse Shifter Shaft Lock Pin 41 Reverse Shift Fork 42 Reverse Shifter Shaft and Detent Plate 43 Reverse Shifter Shaft Ball Detent Spring 44 Reverse Shifter Shaft Detent Ball 45 Reverse Shifter Shaft O Ring Seal 46 Reverse Shifter Lever 47 Speedometer Driven Gear and Fitting 48 Retainer and Bol...

Page 194: ...ssembly and should be kept to gether as originally assembled but the three keys and two springs may be replaced if worn or broken Figure 4 135 Installing Synchronizing Ring 1 Push the hub from the sliding sleeve The keys will fall free and the springs may be easily removed 2 Place the two springs in po sition one on each side of hub so a tanged end of each spring falls into the same keyway in the ...

Page 195: ... 9 Install the third speed and fourth speed gear clutch assembly hub and sliding sleeve with taper toward the front making sure that the keys in the hub corres pond to the notches in the third speed gear synchronizing ring Figure 4 137 Installing Rear Bearing Retainer 10 Install snap ring in the groove in mainshaft in front of the third and fourth speed clutch assembly NOTE If there is no end play...

Page 196: ...e 4 143 Checking Countergear End Play 2 Set countergear in place in bottom of transmission case making sure that tanged thrust washers are correctly positioned Figure 4 145 Bearing Retainer to Transmission Bolt 3 Press bearing onto main drive gear snap ring groove to front using J 5746 Figure 4 141 Be sure bearing fully seats against shoulder on gear 4 Install spacer washer and se lective fit snap...

Page 197: ... rear reverse idler gear engaging the splines with the portion of the gear within the case 15 Using heavy grease place gasket into position on rear face of rear bearing retainer 16 Using heavy grease install the remaining thrust washer into place on the reverse idler shaft making sure tang on the thrust washer is in the notch in the idler thrust face of the extension 17 Place the two clutches in n...

Page 198: ... n g retainer c Clutch gear b e a r i n g r e t a i n e r gasket damaged PROBABLE REMEDY a Adjust or repair clutch b Free up and adjust as required a Shifting into low gear above 45 MPH and second above 65 MPH causes extra work for synchronizers and will require extra time or more force on lever to complete There is also danger of over speeding the engine if low or second is used at high car speed...

Page 199: ...ainshaft ball bearings e Damaged speedometer gears NOISY IN HIGH GEAR a Damaged clutch gear bearing b Damaged mainshaft bearing c Damaged speedometer gears NOISY IN NEUTRAL WITH ENGINE RUNNING a Damaged clutch gear bearing b Damaged mainshaft pilot bearing roller PROBABLE REMEDY d Tighten cover or replace gasket e Replace operating shaft seal f Replace expansion plugs g Replace case h Coat bolts w...

Page 200: ...R 3 SPEED J 8965 COMPANION FLANGE HOLDER AND REMOVER J 8614 SNAP RING PLIERS J 5586 COUNTER GEAR BEARING LOADER 4 SPEED J 9573 SEAL INSTALLER J 8864 SPEEDOMETER WORM GEAR REMOVER J 8760 GUIDE PINS J 1126 J 9574 CLUTCH PILOT BEARING PULLER J 4383 Figure 4 150 Four Speed Synchromesh Tools ...

Page 201: ...4A 5 4A C Super Turbine 300 Transmission Linkage Adjustment 45 Series 4A 7 Section Subject 4A D Super Turbine 400 Transmission Linkage Adjustment 45 46 48 Series 4A E Super Turbine 400 Transmission Console Linkage Adjustment 46 Series 4A F Super Turbine 400 Transmission Linkage Adjustment 49 Series Page 4A 9 4A 11 4A 13 SECTION 4A A 3 SPEED SYNCHROMESH TRANSMISSION LINKAGE ADJUSTMENT 45 46 SERIES ...

Page 202: ...through clamps 1ST REVERSE ADJUSTING CLAMP BOLT 2ND 3RD ADJUSTING CLAMP BOLT Figure 4A 2 Install 1 4 round stock such as shown in view A into the bearing tab and lst reverse lever 2ND 3RD LEVER SELECTOR PLATE 1ST REVERSE LEVER BEARING TAB USE 1 4 ROUND STOCK ONLY SUCH AS A 1 4 BOLT 1 4 DIA STOCK Figure 4A 3 ...

Page 203: ...ges tang on both shift levers 2ND 3RD LEVER 1ST REVERSE LEVER B 3 SELECTOR PLATE MAKE CERTAIN THESE DISTANCES ARE EQUAL WHEN SCREWDRIVER IS INSERTED Figure 4A 4 5 1 Tighten shift rod adjusting clamps Torque 17 to 23 ft lbs CAUTION Do not over torque 1ST REVERSE ADJUSTING CLAMP BOLT 2ND 3RD ADJUSTING CLAMP BOLT Figure 4A 5 ...

Page 204: ...ver down to the 2nd 3rd position and find the neutral detent position Check to see if the two detents line up as shown by the mark made on the mast jacket c If the two detents line up the cross over is correctly adjusted If they do not line up then shorten the lst reverse rod by pulling it through the swivel by no more than 3 16 REV 2ND 1ST 3RD Figure 4A 6 ...

Page 205: ...SHIFT LINKAGE ADJUSTMENTS 4A 5 SECTION 4A B 4 SPEED SYNCHROMESH TRANSMISSION LINKAGE ADJUSTMENT 46 SERIES 1 With Transmission in Neutral Install a V Dia Rod as Shown Figure 4A 7 ...

Page 206: ...ts 4 1 Remove V Dia Rod Figure 4A 8 4th Gear Stop Bolt After Shift Controls are Adjusted to Neutral Position Hold Shift Lever in 4th Gear by Merely Resting Hand On Shift Lever to Remove all Lash in H Linkage Then Turn Stop Bolt Until it Contacts Shift Lever Torque Jam Nut to 20 30 Ft Lbs Repeat same Operation for Third Gear Note Stop Bolt forThird Gear is Located on Front Side of Linkage Figure 4A...

Page 207: ...SHIFT LINKAGE ADJUSTMENTS 4A 7 SECTION 4A C SUPER TURBINE 300 TRANSMISSION LINKAGE ADJUSTMENT 45 SERIES Set Manual Control Lever in Park Position 2 Loosen Shift Rod Adjusting Clamp Bolt Figure 4A 10 ...

Page 208: ...4A 8 SHIFT LINKAGE ADJUSTMENTS 3 j Set Transmission Shift Lever in Park range Transmission Shift Lever Jm Figure 4A 11 TIGHTEN SWIVEL 41CLAMP BOLT TORQUE 17 23 FT L B Figure 4A 12 ...

Page 209: ...SHIFT LINKAGE ADJUSTMENTS 4A 9 SECTION 4A D SUPER TURBINE 400 TRANSMISSION LINKAGE ADJUSTMENT 45 46 48 SERIES PLACE SELECTOR LEVERJNJPARK 9 1 LOOSEN SWIVEL LAMP B Figure 4A 13 ...

Page 210: ...4A 10 SHIFT LINKAGE ADJUSTMENTS TRANSMISSION IN PARK Figure 4A 14 TIGHTEN SWIVEL 41CLAMP BOLT TORQUE 17 23 FT LB Figure 4A 15 ...

Page 211: ...AGE ADJUSTMENTS 4A 11 SECTION 4A E SUPER TURBINE 400 TRANSMISSION CONSOLE LINKAGE ADJUSTMENT 46 SERIES 21 LOOSEN ADJUSTING CLAMP BOLT Figure 4A 16 Hiiiiii 31 PLACE TRANSMISSION IN PARK p R N D L2 L1 Figure 4A 17 ...

Page 212: ...IFT LINKAGE ADJUSTMENTS 4 INSTALL 1 4 DIA ROD AS SHOWN TIGHTEN ADJUSTING CtAMP BOLTS TORQUE 17 23 FT LB OVER TORQUING WILL CAUSE HARD SHIFTING ADJUSTING CLAMP BOLT 1 4 DIA ROD ADJUSTING CLAMP BOLT Figure 4A 18 ...

Page 213: ...SHIFT LINKAGE ADJUSTMENTS 4A 13 SECTION 4A F SUPER TURBINE 400 TRANSMISSION LINKAGE ADJUSTMENT 49 SERIES Figure 4A 19 TRANSMISSION PARK Figure 4A 20 ...

Page 214: ...4A 14 SHIFT LINKAGE ADJUSTMENTS TIGHTEN ADJUSTING ADJUSTIN CLAMP BOLT Figure 4A 21 ...

Page 215: ... No Notch No Notch Notch in Valve Body Plate Reverse Clutch Pressure Plate S e e F l g u r e 5 295 Reverse Clutch Piston 1366133 1366133 1366132 Reverse Clutch Driven Plate Reqa 5 5 4 Drive Plate Reqil 5 5 4 Forward Clutch Driven Plate Reqa 6 6 5 Drive Plate Reqa 5 5 4 Forward Clutch Piston 1357081 1357081 1357082 Modulator Can Assembly 8623364 8623365 8623947 8623364 8623365 8623947 1367031 13670...

Page 216: ...Band Adjusting Screw Bolt Pump Body to Pump Cover Bolt Stator Control Valve Body to Transmission Case Bolt Valve Body Assembly to Transmission Case Bolt Solenoid Valve to Valve Body Bolt Vacuum Modulator to Transmission Case Bolt Pump Assembly to Transmission Case Bolt Rear Bearing Retainer to Transmission Case Bolt Special Oil Pan to Transmission Case Bolt Speedo Sleeve Retainer to Bearing Retain...

Page 217: ...SUPER TURBINE 300 DESCRIPTION OPERATION 5 3 ...

Page 218: ... STATOR OVERRUNNING CLUTCH STATOR SHAFT O O m TO O TO 03 z Figure 5 3 Stator and Stator Shaft ...

Page 219: ...TURBINE H x i s CO n 3 o O Figure 5 4 Converter Turbine Ul Ul ...

Page 220: ...d transmit that torque to the input shaft See Figure 5 4 2 Oil Pump A positive displacement internal external gear type oil pump is used to supply oil to fill the con verter for engagement of forward and reverse clutches for applica tion and release of the low band and to circulate oil for lubri cation and heat transfer See Figure 5 5 3 Planetry Gear Set and Controls The planetary gear set consist...

Page 221: ...SUPER TURBINE 3 0 0 DESCRIPTION OPERATION 5 7 ...

Page 222: ...5 8 DESCRIPTION OPERATION SUPER TURBINE 300 J2 I ...

Page 223: ...V LOW BAND FORWARD CLUTCH DRUM PISTON CLUTCH PACK SPRING LOW SUN GEAR AND FLANGE ASSEM H 70 W 8 n o o 3 TO o i o Figure 5 7 Forward Clutch and Low Band ...

Page 224: ...5 1 0 DESCRIPTION OPERATION SUPER TURBINE 300 1 i o ...

Page 225: ...SUPER TURBINE 3 0 0 DESCRIPTION OPERATION 5 1 1 o I in ...

Page 226: ... at input shaft speed See Figure 5 10 2 Operation of Components in Manual or Automatic Low Range In Low range the forward clutch is released and the low band is applied to the outside diameter of the forward clutch drum With the low band applied the low sun gear and flange assembly is held stationary Drive then is from the converter through the input shaft to the input sun gear in the plane tary g...

Page 227: ...LOW BAND RELEASED ORWARD CLUTCH APPLIED REVERSE CLUTCH DISENGAGED 73 73 00 8 DRIVE RANGE to n TO o o 3 O Ui Figure 5 10 Operation of Components in Drive Range ...

Page 228: ...RWARD CLUTCH DISENGAGED REVERSE CLUTCH DISENGAGED LOW SUN GEAR HELD STATIONARY 4 a m 70 1 o 3 70 5 O en 70 W DRIVE RANGE BEFORE UPSHIFT AUTOMATIC LOW CO 8 Figure 5 11 Operation of Components in Manual Low or Automatic Low ...

Page 229: ...SUPER TURBINE 300 DESCRIPTION OPERATION 5 1 5 I o u c JO 2 8 O ...

Page 230: ...OW BAND RELEASED FORWARD CLUTCH DISENGAGED REVERSE CLUTCH DISENGAGED to O 79 o o m 70 6 OPERATION OF COMPONENTS IN NEUTRAL PARK en C i z CO 8 Figure 5 13 Operation of Components in Neutral and Park Range ...

Page 231: ...the pressure regulator valve in first stage regulator position 2 Second Stage Regulation As higher engine speeds are at tained the volume of oil leaving the pump increases until the valve moves to the position shown in Figure 5 15 which opens a port to allow main line oil to escape REV MOD 7 If U I I EX MAIN PRESSURE REGULATOR VALVE J Figure 5 14 Pressure Regulator Valve First Stage Regulation Fig...

Page 232: ...s directed to the front of the stator blade piston and converter charging pressure then moves the piston connected to the stator blade cranks to shift the blades to high angle See Figure 5 17 c Shift Valve and Shift Control Valve The shift valve and shift control valve are housed together in the main valve body They interpret STATOR CONTROL VALVE Figure 5 17 Stator Blades in High Angle Figure 5 16...

Page 233: ...igure 5 21 Up Shifted The modulator valve spring is housed in a sealed container in such a way that engine manifold vacuum may act upon it to reduce the force of the spring against the valve and thus affect modulator oil pressure Conditions of load or grade that lower manifold vac uum increase modulator oil pres sure while high manifold vacuum decreases modulator pressure See Figure 5 23 2 Altitud...

Page 234: ... modulator limit valve is a pressure regulator valve that regulates the point at which a wide open throttle up shift will occur The valve regulates limited feed oil main line pressure to pro vide diminishing oil p r e s s u r e bearing against the shift control valve as car speed is increased This decrease in oil pressure is accomplished by governor valve pressure bearing on the third land of the ...

Page 235: ...en this occurs oil is exhausted from the band release chamber of the low servo through the coast down shift timing valve A rush of oil through the valve moves the ball retainer and ball against light spring pressure off its seat oil may then escape around the ball retainer and spring This action cushions the initial engagement of the low band See Figure 5 31 j Operation of Hydraulic Controls in Dr...

Page 236: ...ETENT REVERSE CODE LIMITED FEED LIMITED MODULATOR GOVERNOR MODULATOR MODULATOR BOOST DRIVE EXHAUST DETENT HIGH CLUTCH 2ONVERTER REVERSE DRIVE RANGE UPSH1FTED PART THROTTLE I I L FEED L MOD GOV MOD MOD BST DR EX DET HI CL CONV REV Ul I u r r n O z TO o r C o c MODULATOR LIMIT VALVE Figure 5 32 Drive Range Upshiffed Part Throttle o o ...

Page 237: ...lve to the space between the first land of the valve and the valve body Oil pressure in this area plus governor pressure on the second land of the second modulator valve will tend to move the valve against the force of its spring to regulate modulator oil pressure leaving the valve At the same time line oil pressure enters the area between the first and second lands of the modula tor valve and int...

Page 238: ... CODE LIMITED FEED LIMITED MODULATOR GOVERNOR MODULATOR MODULATOR BOOST DRIVE EXHAUST VDETENT HIGH CLUTCH NVERTER REVERSE DRIVE RANGE UPSHIFTED FULL THROTTLE TO DETENT SWITCH PITCH ONLY L FEED L MOD GOV MOD MOD BST DR EX DET Hl CL CONV REV a 70 v z MODULATOR LIMIT VALVE r ra Z Figure 5 33 Drive Range Full Throttle to Detent Switch Pitch Only CO ...

Page 239: ...ODE LIMITED FEED LIMITED MODULATOR GOVERNOR MODULATOR MODULATOR BOOST DRIVE EXHAUST DETENT J HIGH CLUTCH I CONVERTER i REVERSE DRIVE RANGE DOWNSHIFTED FULL THROTTLE DETENT SWITCH PITCH I FEED L MOD GOV MOD MOD BST DR EX DET HI CL CONV REV m c E z faS o o 10 8 MODULATOR LIMIT VALVE Figure 5 34 DrIve Range Full Throttle to Detent and Switch Pitch m ...

Page 240: ...LATED LIMITED MODULATOR DETENT REVERSE CODE LIMITED FEED LIMITED MODULATOR GOVERNOR MODULATOR MODULATOR BOOST DRIVE EXHAUST DETENT HIGH CLUTCH CONVERTER REVERSE LOW RANGE CLOSED THROTTLE COAST L FEED L MOD GOV MOD MOD BST DR ex DET HI CL CONV REV o c L _ r n 6 z MODULATOR LIMIT VALVE G c e o Figure 5 35 Low Range Closed Throttle Coast ...

Page 241: ...EGULATED LIMITED MODULATOR DETENT REVERSE CODE LIMITED FEED LIMITED MODULATOR GOVERNOR MODULATOR MODULATOR BOOST DRIVE EXHAUST DETENT JHIGH CLUTCH r _I DNVERTER TREVERSE ENGINE MANIFOLD VACUUM L FEED L MOD GOV MOD MOD BST DR X DET HI CL CONV REV REVERSE RANGE LIGHT THROTTLE MODULATOR LIMIT VALVE C 6 c E z c n n 6 5 A Figure 5 36 Reverse Range Light Throttle ...

Page 242: ...REGULAJED LIMITED MODULATOR DETENT REVERSE CODE LIMITED FEED LIMITED MODULATOR GOVERNOR MODULATOR MODULATOR BOOST DRIVE EXHAUST DETENT 1IGH CLUTCH 3NVERTER EVERSE NEUTRAL RANGE THROTTLE CLOSED L FEED L MOD GOV MOD MOD BST DR EX DET HI CL COMV REV P so c f O g z i Q MODULATOR LIMIT VALVE m c CD z Figure 5 37 Neutral Range Throfrle Closed ...

Page 243: ...utch release for a smooth down shift m Operation of Hydraulic Controls in Low Range Closed Throttle Coast During operation in Low range the manual shift control valve is positioned as shown in Figure 5 35 During a closed throttle coast in low range main line oil is directed to the modulator valve and manual shift control valve Main line oil entering the manual shift control valve is routed into dr...

Page 244: ...to case tapping screws Remove flywheel cover pan 14 Mark flywheel and converter pump for reassembly in same position and remove three con verter pump to flywheel bolts 15 Remove transmission case to engine block bolts CAUTION Install Tool J 21366 to retain converter 16 Move transmission rearward to provide clearance between con verter pump and crankshaft Lower transmission and move to bench b Inst...

Page 245: ...TOR LEVER PIN THEN SCREW LINK INTO PLUNGER 1 1 2 TURNS INSTALL WASHER AND RETAINER ATTACHING SCREWS S SCREW A 00 m H 0 z ft c 70 H 73 00 CO ADJUST IDLE STATOR SWITCH AS FOLLOWS ADJUST SWITCH WITH THROTTLE AT CLOSED POSITION ND RETURN SPRING ATTACHED WITH ATTACHING SCREWS LOOSE ROTATE SWITCH IN DIRECTION SHOWN ABOUT SCREW A UNTIL SWITCH STOP SCREW BOTTOMS AGAINST CASE HOLD SWITCH IN THIS POSITION A...

Page 246: ...ner Bushing Oil Seal Bearing Retainer and Speedo Drive Gear Driven 5 62 Installation of Valve Body 5 63 Installation of Governor and Vacuum Modulator 5 64 Checking Converter 5 65 Trouble Diagnosis Guide 5 66 Oil Pressure Checks 5 75 5 9 DISASSEMBLY OF TRANSMISSION TO REMOVE MAJOR PARTS AND UNITS 1 Preliminary Instructions a Before starting disassembly of the transmission it should be thoroughly cl...

Page 247: ...Figure 5 101 ure 5 106 Figure 5 101 3 Remove fourteen 14 oil pan attaching bolts using a 1 2 socket See Figure 5 102 b Removal of Oil Strainer and Pipe 1 Remove the PF 162 filter on V 8 models See Figure 5 104 c Removal of Valve Body FILTER USED O N V 8 MODELS ONLY SOLENOID CONNECTOR SOLENOID SWITCH Figure 5 104 2 Remove the oil strainer from model V 6 transmissions See Figure 5 105 Figure 5 107 1...

Page 248: ... with a 1 2 socket Re move s p r i n g detent assembly from valve body See Fig ure 5 113 Figure 5 116 9 Remove manual control valve link by rotating valve body in a counterclockwise direction to re move link from Park lock and range selector inner valve See Figure 5 116 Figure 5 111 4 With a grease pencil mark sta tor control solenoid with an S This S will identify stator con trol solenoid for rea...

Page 249: ... and Piston Assembly Figure 5 122 Figure 5 124 3 Remove tool J 21495 1 from case Remove low servo cover NOTE If necessary aid removal with s c r e w d r i v e r See Fig ure 5 124 NOTE If low servo cover has to be replaced make certain all model information is stamped on new cover 4 Inspect low servo cover seal LOW SERV COVER Figure 5 125 Figure 5 126 If nicked torn or worn discard See Figure 5 125...

Page 250: ...low band and struts from inside the case See Fig ure 5 131 2 Remove low band adjusting screw See Figure 5 132 5 12 REMOVE SPEED OMETER DRIVEN GEAR REAR BEARING RETAINER RETAINER OIL SEAL RETAINER BUSHING AND GOVERNOR a Removal of Speedometer Driven Gear NOTE Transmission need not be removed from the car to per form the following operations paragraphs 5 12 and 5 13 Figure 5 132 1 With transmission ...

Page 251: ...iver with hammer to collapse bushing See Fig ure 5 138 e Removal of Governor Figure 5 137 Figure 5 140 1 Remove three 3 attaching bolts retaining governor cover to case using a 1 2 socket Re move cover and gasket See Fig ure 5 140 2 With a twisting motion slide governor assembly out of its bore in case See Figure 5 141 Figure 5 141 5 13 SPEEDOMETER DRIVE GEAR AND VACUUM MODULATOR a Removal of Spee...

Page 252: ...erse ring gear from case See Figure 5 146 Figure 5 148 2 Lift reverse clutch pressure plate from transmission case See Figure 5 150 Figure 5 146 3 Remove needle bearing and two 2 bearing races from rear of planet carrier See Figure 5 147 Figure 5 150 3 Remove reverse clutch pack from transmission case See Fig ure 5 151 Figure 5 147 b Removal of Reverse Clutch 1 Place transmission in vertical posit...

Page 253: ...surface of the piston it will pop out far enough so it can be removed Insert air nozzle to rear of case as shown in figure See Figure 5 155 REVERSE CLUTCH PISTON OUTER SEAL Figure 5 156 8 Examine reverse clutch piston outer seal If nicked torn or worn remove seal See Figure 5 156 9 Examine reverse clutch piston inner seal If nicked torn or worn remove seal See Figure 5 157 c Removal of Range Selec...

Page 254: ...If damaged replace as follows Place screwdriver in notch in case then tap screwdriver with hammer to collapse bushing See Figure 5 166 5 15 VALVE BODY DISASSEMBLY INSPECTION AND REASSEMBLY a Disassembly NOTE Transmission need not be removed from the car to per form the following operations Paragraphs 5 15 5 16 and 5 17 GASKET S O L E N O I D VALVE BOLTS Figure 5 167 1 Remove two 2 bolts attaching ...

Page 255: ...st 2 Test each valve in its bore All valves must move freely of their own weight Figure 5 173 2 Install modulator limit valve and spring into bore of valve body With aid of Tool J 21547 compress spring and install re taining pin See Figure 5 173 3 Install shift valve washer spring shift control valve and shift control valve sleeve De press shift control valve sleeve SHIFT VALVE SPRING SHIFT CONTRO...

Page 256: ...n springs spring retainer washer and piston apply rod See Figure 5 179 b Reassembly INNER RETURN S SPRING 4jbfk M T WASHER ROD RETAINING PIN PISTON LOW SERVO P R I N G T tfff M J P APPLY SPRING OUTER RETURN SPRING 1 Assemble the inner anc outer return springs into the piston Install spring retainer See Fig ure 5 180 Install this assembly into the ram press as shown in Figure 5 180 Figure 5 180 Fig...

Page 257: ...re 5 186 5 Mark but do not scar gear faces so gears can be reassem bled in same manner See Figure 5 186 Figure 5 190 8 Remove seat valve and spring from cooler by pass valve Use Tool J 21361 to remove seat from bore in pump cover See Figure 5 190 Figure 5 187 6 Remove oil pump drive gear See Figure 5 187 Figure 5 191 9 Remove coast down shift tim ing valve from the pump cover and inspect for damag...

Page 258: ...ows Support oil pump body on wood blocks Remove oil seal Figure 5 194 with a screwdriver and discard See Figure 5 194 13 Check oil pump bushing for nicks severe scoring or wear If bushing replacement is neces sary proceed as follows Support pump on wood blocks using Tool J 21465 17 and Drive Handle Figure 5 195 J 8092 P r e s s bushing out of pump body See Figure 5 195 14 Check stator shaft bushin...

Page 259: ...NOTE Extreme care must be taken so bushing is not driven past counterbore 3 Using Installer J 21359 tap in new oil seal See Figure 5 201 4 Install new oil pump to case seal See Figure 5 202 5 Assemble pressure regulator valve washer spring reverse Figure 5 202 and modulator boost valve and s l e e v e See Figure 5 203 When installing spring and shim make certain the same springs and the proper num...

Page 260: ...re 5 206 bolts but do not tighten Place Tool J 21368 around pump to ob tain proper alignment Tighten bolts to 16 24 ft lbs torque See Figure 5 207 NOTE The bolt location at the pressure regulator takes a longer bolE 5 19 DISASSEMBLY INSPECTION AND REASSEMBLY OF FORWARD CLUTCH a Disassembly COAST DOWNSHIFT TIMING VALVE Figure 5 204 Figure 5 205 Figure 5 207 ...

Page 261: ...CH HUB FRONT THRUST WASHER Figure 5 215 7 Using Tools J 2590 3 J 2590 5 and J 2590 12 com press spring retainer Remove snap ring Then remove Tool J 2590 and component parts being careful that spring retainer does not catch in snap ring groove See Figure 5 215 NOTE Place a piece of hard board between Tool J 2590 3 and surface of forward clutch hub Figure 5 213 5 Remove clutch hub front thrust washe...

Page 262: ...ure 5 222 13 Check low sun gear and flange assembly bushing for nicks severe scoring or wear If bush ing replacement is necessary proceed as follows Support low sun gear assembly on press plate using Tool J 21424 4 and Drive Handle J 8092 press out bushing See Fig 5 222 b Inspection 1 Wash all parts in a suitable cleaning solvent Use compressed air to dry 2 Cneck steel ball in the forward clutch d...

Page 263: ...ith Tools J 2590 3 J 2590 4 and J 2590 5 far enough so the spring retainer snap ring can be in stalled Make sure retainer doesn t catch in snap ring groove when compressing springs See Figure 5 230 NOTE Place a piece of hard board between Tool J 2590 3 and forward clutch drum ALIGN TANGS IN CLUTCH HUB WITH GROOVES IN THRUST WASHER Figure 5 231 8 Install clutch hub front thrust washer to clutch hub...

Page 264: ...following operations Paragraphs 5 20 and 5 21 REAR OF SPEEDO DRIVEN GEAR SLEEVE SPEEDO DRIVEN GEAR SLEEVE SPEEDO DRIVEN GEAR OIL SEAL SPEEDO DRIVEN GEAR SHAFT OIL SEAL OIL SEAL RETAINING RING Figure 5 236 a Disassembly 1 Remove speedo See Figure 5 236 driven gear gear sleeve Install oil seal re taining ring 2 Install speedo driven gear oil seal See Figure 5 236 3 Install speedo driven gear 5 21 RE...

Page 265: ...re placement gear kit between the second and third lands of gover nor sleeve See Figure 5 241 c Make certain new gear is po sitioned squarely on sleeve and press gear onto sleeve Gear must be seated against sleeve See Figure 5 241 If either secondary tab wear or less than 019 feed port opening is found the complete governor assembly must be replaced a Removal 1 Support governor sleeve on wood bloc...

Page 266: ...lve is free in its bore Any burrs that are left on governor sleeve will damage the case 5 22 PLANET CARRIER DISASSEMBLY INSPECTION AND ASSEMBLY NOTE It is important that the hole for roll pin be drilled Disassembly straight as possible to insure proper retention and installation of roll pin and gear This can be best accomplished by above method 3 Support end of governor sleeve not gear on a wooden...

Page 267: ...net pinion 7 Remove input sun gear See thrust washer and long planet Figure 5 251 pinion gear See Figure 5 254 THRUST WASHERS PINION SHAFT SPACER NEEDLE BEARINGS Figure 5 252 8 Remove input sun gear thrust washer See Figure 5 252 Figure 5 255 11 Remove needle b e a r i n g s spacer and two 2 thrust washers from the long planet pinion gear See Figure 5 255 Figure 5 250 6 Remove low sun gear needle ...

Page 268: ... 5 258 2 Install the long planet pinion gears first Install the r e a r planet pinion thrust washer Oil groove must be toward pinion gear See Figure 5 260 Figure 5 260 3 Install front planet pinion thrust washer Retain t h r u s t washer to case with grease Oil grooves on the thrust washer must be toward the pinion gears See Figure 5 261 THRUST W A S H E R S PINION SHAFT SPACER r r i NEEDLE BEARIN...

Page 269: ...LE BEARINGS Figure 5 270 certain that it picks up the thrust washers Turn the pinion shaft so the groove faces center of planet carrier See Figure 5 272 Figure 5 265 7 Install input sun gear into planet carrier See Figure 5 266 Figure 5 266 8 Install low sun gear needle thrust bearing See Figure 5 267 Figure 5 268 10 Install twenty 20 needle bearings and one thrust washer in the pinion gear See Fi...

Page 270: ...before installation Thrust washers may be held in place with petroleum jelly sparingly applied 3 Do not take a chance on used gaskets and seals use new ones to avoid oil leaks 4 Use care to avoid making nicks or burrs on parts particularly at bearing surfaces and surfaces where gaskets are used 5 It is extremely important to tighten all parts evenly and in proper sequence to avoid distor tion of p...

Page 271: ...re 5 282 Figure 5 283 9 Install range selector shaft re tainer See Figure 5 283 NNER PARK K AND RA ELECTOR Figure 5 281 NOTE Make certain longest end on range selector lever is to the bottom of transmission Figure 5 284 10 Install parking bracket to transmission case Torque bolts to 8 12 ft lbs torque See Figure 5 284 11 If outer range selector lever was removed install nut torque to 20 30 ft lbs ...

Page 272: ...ing See Figure 5 293 Figure 5 294 NOTE Cars equipped with V 6 engines have 4 driven and 4 drive clutch plates Cars equipped with V 8 engine have 5 driven and 5 drive clutch platesT 9 Install reverse clutch pres sure plate with the identification mark being installed in the 5 o clock groove in case See Fig ure 5 295 REVERSE CLUTCH CUSHION SPRINGS Figure 5 291 Figure 5 293 8 Align notches on the ste...

Page 273: ...all thrust bearing race with a lip needle bearing and a sec ond plain thrust bearing race to the rear face of the planetary gear set Retain with grease See Figure 5 298 Figure 5 300 2 Install reverse ring gear into case Rock and turn ring gear to pick up clutch plate splines See Figure 5 300 LOW SERV COVER Figure 5 303 2 Install low servo cover oil seal See Figure 5 303 Figure 5 301 3 Install plan...

Page 274: ...tall low band into case See Figure 5 3O7f 3 This picture is for illustration purposes only It shows the proper positioning of the low band apply strut and band adjusting screw anchor strut See Figure 5 310 Figure 5 312 Figure 5 314 NOTE BAND APPLY STRUT POINT UPWARD Figure 5 310 1 Install forward clutch assem 2 Grease and install selective bly turning slightly to engage low fit washer to pump cove...

Page 275: ...igure 5 318 O rings under head See Fig ure 5 321 6 Torque the eight 8 pump re taining bolts to 16 24 ft lbs See Figure 5 322 5 26 LOW BAND ADJUSTMENT INCH LBS TORQUE WRENCH 4 Coat input shaft oil rings with oil and install into oil pump Then install pump into case Apply a thin coat of oil around edge of pump See Figure 5 320 Figure 5 323 1 Adjust low band by first tight ening adjusting screw to 40...

Page 276: ...RETAINER AND SPEEDO DRIVEN GEAR a Installation of Rear Bearing Retainer Bushing 1 Using Drive Handle J 8092 and Installer J 21424 1 install rear REAR BEARIN RETAINER OIL SEAL Figure 5 327 bearing retainer bushing See Figure 5 327 b Installation of Output Shaft to Rear Bearing Retainer Oil Seal Figure 5 330 Torque bolts to 25 35 ft lbs torque See Figure 5 331 REAR BEARING RETAINER OUTPUT SHAFT TO R...

Page 277: ...E V 6 valve body plate have identification notch See Fig ure 5 120 bly See Figure 5 336 the stator control valve body Torque bolts to 8 12 ft lbs See Figure 5 340 STATOR CONTROL VALVE BODY Figure 5 337 4 Install manual control valve link into park lock and range selector inner lever See Fig ure 5 337 Figure 5 341 7 Install stator control solenoid and gasket to stator control valve body Torque bolt...

Page 278: ... 10 Install detent solenoid wire to connector See Figure 5 344 IL STRAINER USED ON V 6 MODELS ONLY Figure 5 350 16 Install fourteen 14 oil pan attaching bolts Torque bolts to 10 12 ft lbs See Figure 5 350 5 30 INSTALLATION OF GOVERNOR AND VACUUM MODULATOR a Installation of Governor 1 Slide governor into its bore in case Turn governor assembly so teeth on governor gear engage teeth on output shaft ...

Page 279: ...b Fill converter with air 80 psi c Submerge in water and check for leaks 2 Check converter end clearance as follows a Install Tool J 21371 2 and tighten brass nut See Figure 5 357 Figure 5 355 NOTE V 6 vacuum modulators have a brown daub of paint for identification V 8 has no paint identification 3 Install vacuum modulator re tainer Install retainer so tang points toward vacuum modulator Torque bo...

Page 280: ...ctive front pump c Erratic Operation and Slippage Light to Medium Acceleration 1 Check filter or screen and suction pipe assembly for leaks 2 Check suction pipe O ring 3 Low oil level 4 Check for defective modulator See Figure 5 362 d Excessive Slip or Engine Flare on Coasting to A Stop or When Cornering 1 Check engine idle See para graph 3 8 2 Check for suction leak as de scribed in items 1 and 3...

Page 281: ...rottle Downshift 1 Check detent control switch adjustment and continuity in wiring Wiring fused with wind shield wiper 2 Check for stuck detent valve and shift valves See Figure 5 32 3 Check orfice hole in detent valve 4 Check solenoid on valve body 0 Engine Flares On Wide Open Throttle Downshift 1 Check low band adjustment See paragraph 5 26 2 Check item 20 3 Check for r e s t r i c t i o n in va...

Page 282: ...vel PLACE PLUG AS SHOWN AND FILL HIGH CLUTCH PRESSURE LINE WITH TRANSMISSION OIL Figure 5 362 Cheeking Modulator Can Assembly Figure 5 363 Checking Cross Leakage Between Pump Cover and stator shaft MODULATOR PRESSURE EXHAUST CONVERTER FEED PRESSURE STATOR LOW APPLY MODULATOR PRESSURE LINE PRESSURE MODULATOR PRESSURE EXHAUST GOVERNOR DETENT PRESSURE MODULATOR BOOST HIGH CLUTCH EXHAUST HIGH CLUTCH P...

Page 283: ... PROCEDURES 5 6 9 TRANSMISSION VENT LUBE PRESSURE CONVERTER FEED PRESSURE FRONT PUMP SUCTION REVERSE PRESSURE LINE PRESSURE MODULATOR PRESSURE FRONT PUMP SEAL DRAIN HIGH CLUTCH PRESSURE Figures 5 366 Oil Passages in Pump Cover ...

Page 284: ...E PRESSURE LUBE PRESSURE TRANSMISSION VENT TRANSMISSION PRESSURE FRONT PUMP SUCTION TRANSMISSION VENT CONVERTER FEED PRESSURE Figure 5 367 Oil Passages in Pump Body SUCTION REVERSE CLUTCH PRESSURE CASE VENT OIL COOLER LINE PRESSURE BAND RELEASE STATOR FEED COVERTER FEED PRESSURE MODULATOR PRESSURE FORWARD CLUTCH PRESSURE Figure 5 368 Oil Passages in Rear Face of Pump Cover ...

Page 285: ...E 300 SERVICE PROCEDURES 5 7 1 Figure 5 370 Oil Passages in Front Transmission Case 1 E X H A U S T CONVERTER FEED PRESSURE STATOR FEED Q H H C O N V E R T E R EXHAUST Figure 5 371 Oil Passages in Staror Valve Body ...

Page 286: ...D MODULATOR PRESSURE LIMIT FEED LIMITED MODULATOR PRESSURE EXHAUST REVERSE PRESSURE MODULATOR BOOST DRIVE PRESSURE LINE PRESSURE REVERSE PRESSURE EXHAUST GOVERNOR PRESSURE LOW APPLY PRESSURE EXHAUST Figure 5 372 Oil Passages in Main Valve Body DETENT SOLENOID WIRE SHORT WIRE STATOR SOLENOID WIRE LONG WIRE Figure 5 373 Checking for Plug in Front Pump Cover Figure 5 374 Location of Solenoid Wires Fi...

Page 287: ...cuum Modulator Part No 8623364 or 8623365 D and L R 4 PSI 6 PSI 149 230 142 219 131 203 117 183 MINIMUM LINE PRESSURE CHECKS line connected Engine and or car are to be made while speed as shown in note MINIMUM LINE PRESSURE CHECKS USED Pressures not affected by Park Neutral and Drive Low Reverse 60 90 93 FOR ALL Altitude or 2 4 4 PSI PSI PSI road testing car below MODELS REGARDLESS OF Barometric P...

Page 288: ...5 7 4 SERVICE PROCEDURES SUPER TURBINE 300 CO 3 ...

Page 289: ...LLER SLIDE HAMMER SLIDE HAMMER SNAP RING PLIERS SPEEDO GEAR REMOVER CONVERTER END PLAY CHECKING FIXTURE CHECK VALVE SEAT REMOVER CHECK VALVE SEAT INSTALLER MODULATOR LIMIT VALVE SPRING COMPRESSOR PLANET CARRIER BUSHING REMOVER SPEEDO GEAR INSTALLER DIAL INDICATOR SET CONVERTER HOLDING STRAP SNAP RING PLIERS FORWARD CLUTCH SPRING COMPRESSOR OUTER SHIFT LEVER SEAL INSTALLER OIL PUMP SEAL INSTALLER C...

Page 290: ...5 76 SUPER TURBINE 300 ...

Page 291: ...er A production identification number is stamped on a metal tag located in the lower left side of the trans mission case The production code number is located along the bottom of the tag Since the production identification num ber furnishes the key to construction and interchangeability of parts in each transmission the number should be used when selecting replacement parts as listed in the master...

Page 292: ...ultiply engine torque High stator blade angle means greater redirection of the oil and increased engine speed and torque multiplication for maximum per formance At engine idle it re duces the efficiency of the converter which reduces creep Low angle results in a more effi cient converter for coupling operation As turbine speed increases the direction of the oil leaving the turbine changes and flow...

Page 293: ...1 at stall Clockwise motion of the rear in ternal gear causes the rear pinions to turn clockwise to drive the sun gear counterclockwise In turn the sun gear drives the front pinions clockwise thus turning the front internal gear output carrier and output shaft clockwise in a reduction ratio of approximately 2 5 1 The reaction of the front pinions against the front internal gear is taken by the rea...

Page 294: ...5 8 0 DESCRIPTION OPERATION SUPER TURBINE 400 LL U_ o a 7 CO LU C2 U_ U_ O BAN FRONT L n Y A ir W llf ogo T CX LUTCI ORNA LUJC C i 1 I H O P B i HP wLmL j 3 1 f IK 5 LU RST SPE k L U 1 0 RIVE f i r I ...

Page 295: ...SUPER TURBINE 4 0 0 DESCRIPTION OPERATION 5 8 1 S 8 CO ...

Page 296: ...5 8 2 DESCRIPTION OPERATION SUPER TURBINE 400 8 to E ...

Page 297: ...5S DIRECT CLUTCH OFF FORWARD CLUTCH ON FRONT BAND ON IN L2 RANGE ONLY REAR BAND OFF CD Z L2 RANGE SECOND SPEED a m O 70 3 o m 73 o 00 0 Figure 5 204 Low L2 Range Second Speed ...

Page 298: ...5 8 4 DESCRIPTION OPERATION SUPER TURBINE 400 ...

Page 299: ...SUPER TURBINE 400 DESCRIPTION OPERATION 5 8 5 ...

Page 300: ...in response to a pressure signal from a modulator valve in such a way that the torque requirements of the trans mission are met and smooth shifts are obtained at all throttle openings See Figure 5 207 To control line pressure proper ly a modulator pressure is used which varies in the same manner as torque input to the transmis sion Since the converter torque output is the product of engine torque ...

Page 301: ... ondary weights Governor pressure acts on the modulator valve to cause modula tor pressure to decrease as vehi cle speed increases 5 4 FUNCTIONS OF VALVE AND HYDRAULIC CONTROL UNITS 1 Pressure Regulator a Regulates line pressure ac cording to a fix d spring force and forces controlled by modula tor and reverse pressure See Figure 5 211 b Controls the flow of oil that charges the torque converter f...

Page 302: ...ent pres sure for detent 2 1 shifts See Figure 5 217 8 2 3 Shift Valve Controls the oil pressure that causes the transmission to shift from 2 3 or 3 2 Its operation is controlled by modulator inter mediate governor and detent pressure as well as a spring force See Figure 5 218 9 2 3 Modulator Valve Senses modulator pressure to ap ply a variable force proportional Figure 5 220 to modulator pressure...

Page 303: ...al valve to the release side of the servo piston In Drive Range the servo release oil from the manual valve is used to charge the servo in preparation for the apply of the direct clutch Direct clutch oil is directed to the front servo accumulator piston where spring force plus 3rd clutch pressure stroke the piston up against the force of servo re lease oil This lowers the clutch C O N V E R T E R ...

Page 304: ...release of the direct clutch is softened by the front servo three orifices and three check balls to allow a smooth transfer of the drive load to the inter mediate sprag The controlled release pressure lets the engine increase its RPM during detent downshifts to prepare for the low er gear ratio of 2nd gear which results in a smooth shift and better acceleration Servo oil seats a check ball in term...

Page 305: ...e for a smooth 1 2 shift See Figure 5 233 d Rear Servo Operation L1 Range 1st Speed Overrun engine braking in Lo Range 1st gear is provided for by the rear servo applying the band to hold the reaction carrier from clockwise rotation 1 2 Accumulator oil is directed to the accumulator piston which attempts to prevent the servo from applying Lo Range oil di 1 k T O I N T C L j INT CL H n t i wr M 2A ...

Page 306: ...r pres sure is that at light throttle shifts 1 2 accumulator pressure is on a lower pressure slope for smooth shifts and on heavy throt tle shifts 1 2 accumulator pres sure is on the second slope of higher pressures for smooth durable shifts Detent oil is directed to the 1 2 primary valve to raise 1 2 ac cumulator pressure during detent 1 2 shifts for clutch durability Lo Range oil is directed to ...

Page 307: ...r to the lubrication cir cuit if the cooler becomes restricted Line Pressure acts on the 1 Manual Valve 2 Detent Valve 3 Detent Solenoid 4 Modulator Valve 5 Stator Valve 6 Stator Solenoid Line pressure at the modulator valve is regulated to a pressure called modulator oil which acts on the pressure boost valve 1 2 accumulator and primary valves and passes through the detent valve and 3 2 valve to ...

Page 308: ...5 9 4 DESCRIPTION OPERATION SUPER TURBINE 4 0 0 0 z ...

Page 309: ...MAINLINE PRESSURE INTAKE PRESSURE CONVERTER PRESSURE GOVERNOR PRESSURE MODULATOR PRESSURE DETENT PRESSURE 1 2 ACCUMULATOR PRESSURE EZ3 on C rn TO Q m 70 9 Figure 5 243 Drive Range First Speed Ui ...

Page 310: ...5 9 6 DESCRIPTION OPERATION SUPER TURBINE 4 0 0 ...

Page 311: ...mulator pistons Intermediate clutch oil is also directed to a land of the 2 3 shift valve SUMMARY The f o r w a r d and intermediate clutches are applied The trans mission is in second gear d Drive Range Third Speed As vehicle speed and governor pressure increase the force of governor oil acting on the 2 3 shift valve overcomes the force of the 2 3 shift valve spring and modulator oil This allows ...

Page 312: ...5 9 8 DESCRIPTION OPERATION SUPER TURBINE 4 0 0 ...

Page 313: ...MAINLINE PRESSURE INTAKE PRESSURE CONVERTER PRESSURE GOVERNOR PRESSURE MODULATOR PRESSURE DETENT PRESSURE 1 2 ACCUMULATOR PRESSURE C TO n TO Figure 5 246 Detent Downshift Valves in Second Speed Position ...

Page 314: ...5 1 0 0 DESCRIPTION OPERATION SUPER TURBINE 400 a ...

Page 315: ...MAINLINE PRESSURE INTAKE PRESSURE CONVERTER PRESSURE GOVERNOR PRESSURE MODULATOR PRESSURE DETENT PRESSURE 1 2 ACCUMULATOR PRESSURE QEZ c c m 73 z n TO G Z Q a m 5 z Figure 5 248 L1 Range First Speed ...

Page 316: ...ver is in the L2 position L2 oil from the man ual valve is directed to the See Figure 5 247 1 Pressure Boost Valve 2 2 3 Shift Valve L2 oil at the boost valve will in crease line pressure to 150 psi This increased intermediate oil pressure at the 2 3 shift valve will close the 2 3 shift valve regardless of car speed For engine braking the front band is applied by exhausting servo oil at the manual...

Page 317: ...MAINLINE PRESSURE I 1 INTAKE PRESSURE IT I CONVERTER PRESSURE GOVERNOR PRESSURE MODULATOR PRESSURE DETENT PRESSURE 1 2 ACCUMULATOR PRESSURE CZH m J I C w Z 6 o m n O z o o z Figure 5 250 Reverse ...

Page 318: ... Basic Control Reverse oil from the manual valve flows to the large area of the direct clutch piston and to the 2 3 shift valve From the 2 3 shift valve it enters the di rect clutch passage and is di rected to the small area of the direct clutch piston to apply direct clutch Reverse oil flows to the rear servo and acts on the servo pis ton to apply the rear band Reverse oil also acts on the pressu...

Page 319: ...IRECTION SHOWN ABOUT SCREW A UNTIL SWITCH STOP SCREW BOTTOMS AGAINST CASE HOLD SWITCH IN THIS POSITION AND TIGHTEN ATTACHING SCREWS WASHER RETAINER STATOR AND DETENT SWITCH ADJUST STATOR AND DETENT SWITCH AS FOLLOWS WITH CARBURETOR IN WIDE OPEN POSITION AND SWITCH PLUNGER BOTTOMED ADJUST LINK UNTIL IT WILL SLIP OVER CARBURETOR LEVER PIN THEN SCREW LINK INTO PLUNGER 1 1 2 TURNS INSTALL WASHER AND R...

Page 320: ...e transmission fly wheel cover pan to case tapping screws Remove flywheel cover pan 14 Mark flywheel and converter pump for reassembly in same position and remove three con verter pump to flywheel bolts 15 Remove transmission case to engine block bolts 16 Move transmission rearward to provide clearance between con verter pump and crankshaft In stall Tool J 21366 to retain converter Lower transmiss...

Page 321: ...nspection and Reassembly 5 131 Inspection of Reaction Carrier Rear Sprag and Output Carrier Assemblies 5 134 Pinion Replacement Procedure Reaction and Output Carrier Assemblies 5 134 Inspection of Output Shaft 5 134 Assembly of Rear Unit 5 137 Assembly of Units Into Trans mission Case 5 139 Rear Extension Housing Assembly 5 142 Install Manual Linkage 5 143 Installation of Check Balls Front Servo G...

Page 322: ... car 1 Remove attaching screws gov ernor cover and gasket See Fig ure 5 503 Figure 5 504 2 Withdraw governor assembly from case Figure 5 505 Figure 5 507 Figure 5 508 5 Remove oil pan attaching screws See Figure 5 507 3 Remove the speedometer 4 Withdraw speedometer driven driven gear attaching screw and gear assembly from case See 6 Remove oil pan and gasket See retainer See Figure 5 505 Figure 5 ...

Page 323: ...anual valve to fall out of control valve assembly 3 Remove the governor pipes from control valve assembly See Figure 5 513 4 Remove the control valve as sembly to spacer gasket See Figure 5 515 5 Disconnect s tat or connector from case sleeve connector See Figure 5 514 6 Disconnect detent electric wire short from stator connector Figure 5 515 NOTE Do not remove electric wire long from stator conne...

Page 324: ...ins identified as follows Pin Identification Pin Size 3 Rings 2 Rings 1 Ring Long Medium Short Figure 5 519 Figure 5 522 The identification ring is located Figure 5 520 on the band lug end of the pin Selecting the proper pin is the equivalent of adjusting the band 6 Compress fingers on connector and withdraw connector and O ring seal See Figure 5 521 Figure 5 523 7 Remove the solenoid attaching sc...

Page 325: ...e the detent lever from the manual shaft b Remove manual shaft retain ing pin from case See Figure d Remove the manual shaft and 5 527 jam nut from case PARKING BRAKE ACTUATOR ASSEMBLY Figure 5 530 NOTE If necessary to replace pry the manual shaft seal out of case e Remove parking actuator rod and detent lever assembly f If necessary remove the de tent lever retaining E ring and detent lever See F...

Page 326: ...her located between the pump cover and the forward clutch housing If more or less washer thickness is required to bring end play within specifications select the proper washer from the chart below Thickness 060 064 071 075 082 086 093 097 104 108 115 119 126 130 Color Yellow Blue Red Brown Green Black Purple NOTE An oil soaked washer may tend to discolor so that it will be necessary to measure the...

Page 327: ...ng assembly Figure 5 543 7 Remove the direct clutch as sembly See Figure 5 542 8 Remove the front band assembly 9 Remove the sun gear shaft See Figure 5 543 10 Check follows rear end play as a Install J 7004 with 3 16 adapter into an extension housing attaching bolt hole b Mount the dial indicator J 8001 on the rod and index with the end of the output shaft See Figure 5 544 c Move the output shaft...

Page 328: ...te to case snap ring See Figure 5 545 13 Remove the intermediate clutch backing plate 3 composi tion and 3 steel clutch plates See Figure 5 546 Figure 5 551 14 Remove the center support to case retaining snap ring See Figure 5 547 15 Remove the entire gear unit assembly by lifting with Gear As sembly Installing and Removing Tool J 21795 with J 7004 Slide Hammer See Figure 5 548 16 Remove the outpu...

Page 329: ...removed with the cen ter support 4 Remove the reaction carrier and sprag assembly See Figure 5 557 5 Remove front internal gear ring from output carrier assem bly See Figure 5 558 Figure 5 555 Figure 5 556 6 Remove sun gear See Figure 5 560 7 Remove reaction carrier to output carrier thrust washer See Figure 5 561 Figure 5 558 Figure 5 560 8 Turn assembly over and place mainshaft in hole in work b...

Page 330: ...6 NOTE Do not drop bearings Figure 5 564 O D FLANGED RACE THRUST BEARING Figure 5 565 13 Remove the rear internal gear to sun gear thrust bearing and two 2 races See Figure 5 567 Figure 5 567 14 If necessary remove the rear internal gear to mainshaft snap ring to remove mainshaft See Figure 5 568 5 15 GOVERNOR ASSEMBLY All components of the governor assembly with the exception of the driven gear a...

Page 331: ...s a nylon driven gear two governor weight re taining pins ana one governor gear retainer split pin Replace ment of gear must be performed with care in the following manner 1 Drive out governor gear re taining split pin using small punch See Figure 5 570 2 Support governor on 3 16 inch plates installed in exhaust slots of governor sleeve place in arbor press and with a long punch press gear out of ...

Page 332: ...73 E RING SERVO PISTON Figure 5 573 4 Remove washer spring and retainer b Inspection 1 Inspect freedom of accumulator ring in piston 2 Inspect fit of band apply pin in servo piston 3 Inspect band apply pin for scores and cracks Figure 5 575 c Reassembly 1 Install spring retainer spring and washer on band apply pin See Figure 5 574 2 Install band apply pin retainer spring and washer into bore of se...

Page 333: ...d of the as sembly top bore remove the re taining pin and bore plug See Figure 5 582 11 Remove the detent valve de tent regulator valve spring and spacer See Figure 5 582 12 In the next bore check the operation of the 1 2 accumulator valve train by compressing the valve against the springs See Figure 5 582 NOTE The 1 2 accumulator valve is factory adjusted 1 2 ADJUSTING PIN RETAINING PIN Figure 5 ...

Page 334: ...he detent valve nar row land first See Figure 5 582 12 Remove the screwdriver as the bore plug hole out and re taining pin are installed See Fig ure 5 582 13 In the lower right hand bore install the 3 2 valve See Figure 5 582 14 Install the spacer bore plug hole out and retaining pin See Figure 5 582 15 In the next bore up install the 2 3 valve stem end out and 3 2 intermediate spring See Fig ure ...

Page 335: ...ATOR VALVE BUSHING 1 2 ACCUMULATOR SECONDARY VALVE SPRING L RETAINING PIN MANUAL CONTROL VALVE 2 DENTENT rMANUAL l_UN I I 1 2 was 1 2 VALVE SPRING p 2 3 MODULATOR 2 3 VALVE VALVE r 1 2 REGULATOR VALVE ING I 1 2 M 0 D U L A T 0 R BUSHING I RETAINING 7 BUSHING SPRING RETAINING PIN g to SPACER to i Figure 5 582 ...

Page 336: ...Figure 5 586 8 Remove pump cover from body See Figure 5 587 9 Remove the retaining pin and bore plug from the pressure regulator bore See Figure 5 588 10 Remove the stator valve re taining pin See Figure 5 590 11 Remove s t a t o r valve and spring See Figure 5 591 12 Remove the hook type oil RETAINING PIN Figure 5 590 SPRING STATOR VALVE Figure 5 591 13 Remove the pump to forwaru clutch housing s...

Page 337: ...be 0008 0015 See Figure 5 597 3 Check face of pump body for scores or nicks 4 Check oil passages 5 Check for damaged cover bolt attaching threads 6 Check for overall flatness of pump body face 7 Check bushing for scores or nicks If damaged replace as follows a Support oil pump on wood blocks Using Tool J 21465 17 and Drive Handle J 8092 press bushing out of oil pump body Figure 5 597 b Using Tool ...

Page 338: ... spacer s if used retainer and spring into the pressure regulator bore See Figure 5 602 3 Install the pressure regulator valve from opposite end of bore stem end first 4 Install the boost valve into the bushing stem end out and install both parts into the pump cover by compressing the bushing against the spring 5 Install the retaining snap ring Figure 5 604 6 Install the pressure regulator valve b...

Page 339: ...Place forward clutch and tur bine shaft in hole in bench and re FORWARD CLUTCH HUB FORWARD CLUTCH HOUSING Figure 5 612 move the forward clutch housing to direct clutch hub snap ring See Figure 5 610 2 Remove the direct clutch hub See Figure 5 611 3 Remove the forward clutch hub and thrust washers See Figure 5 612 4 Remove five 5 composition and five 5 steel clutch plates See Figure 5 613 NOTE The ...

Page 340: ...t sixteen springs for collapsed coils or signs of distortion 3 Inspect the clutch hubs for worn splines proper lubrication holes thrust faces Figure 5 619 4 Inspect the piston for cracks 5 Inspect the clutch housing for wear scoring open oil passages and free operation of the ball check c Reassembly 1 Place new inner and outer oil seals on clutch piston lips face away from spring pockets See Figur...

Page 341: ...re blue into pockets in piston See 5 626 Figure 5 625 igure 7 If removed install oil seal ring washers Retain with petrolatum 5 Place spring retainer and snap on turbine shaft and install in See Figure 5 630 ring on springs forward clutch drum See Fig _ _ _ _ 5 6 27 9 Place forward clutch hub into 6 Compress springs using clutch forward clutch housing and clutch compressor tool or J 2590 and 8 Ins...

Page 342: ...mposition and 4 steel 3 flat and 1 waved 11 Install the direct clutch hub and retaining snap ring See Fig ure 5 632 12 Place forward clutch housing on pump delivery sleeve and air check clutch operation See Fig ure 5 633 5 21 DIRECT CLUTCH AND INTERMEDIATE SPRAG DISASSEMBLY INSPECTION AND REASSEMBLY a Disassembly 1 Remove sprag retainer snap ring and retainer See Figure 5 634 2 Remove sprag outer ...

Page 343: ...s spring retainer and remove snap ring See Figure 5 638 6 Remove retainer and sixteen 16 piston release springs See Figure 5 640 7 Remove the direct clutch pis ton See Figure 5 641 8 Remove the outer seal from the piston See Figure 5 642 Figure 5 638 Figure 5 642 Figure 5 640 9 Remove the inner seal from the piston See Figure 5 643 10 Remove the center piston seal from the direct clutch housing Se...

Page 344: ...ure 5 647 away from spring pockets See Figure 5 645 1 Install a new inner clutch pis 2 Install a new outer clutch ton seal on piston with lips facing piston seal See Figure 5 646 Figure 5 650 3 Install a new center seal on clutch housing with lip of seal facing up See Figure 5 647 4 Place Seal Protectors Tools J 21362 Inner J 21409 Outer over hub and clutch housing and install clutch piston See Fi...

Page 345: ...5 654 NOTE Outer race should not turn counterclockwise Figure 5 654 Figure 5 655 14 Install s p r a g retainer over sprag cup side down See Fig ure 5 655 15 Install sprag retainer and snap ring See Figure 5 656 Figure 5 657 16 Place direct clutch assembly over center support and air check operation of direct clutch See Figure 5 657 NOTE If air is applied through reverse passage it will escape from...

Page 346: ...nner race to the center support 6 Remove the outer piston seal See Figure 5 665 b Inspection 1 Inspect the sprag inner race for scratches or indentations Be sure the lubrication hole is open See Figure 5 666 Figure 5 665 2 Inspect the bushing for scor ing wear or galling If replace ment is necessary proceed as follows a Using bushing Tool J 21465 6 remove b From sprag side of support in stall bush...

Page 347: ...ee 3 Install inner seal protector Tool J 21363 on the center sup port hub install the piston See Figure 5 671 4 Install twelve 12 release springs into the piston See Fig ure 5 672 5 Place the spring retainer and snap ring over the springs 6 Using the Clutch Spring Com pressor J 2590 compress the springs and install the snap ring See Figure 5 673 Figure 5 673 Figure 5 674 7 Install four 4 hook type...

Page 348: ... Using a tapered punch drive or press the pinions out of the carrier See Figure 5 680 3 Remove the pinions thrust washers and roller needle bearings 4 Inspect the pinion pocket thrust faces for burrs and remove if present 5 Install nineteen 19 needle bearings into each pinion using petrolatum to hold the bearings in place Use a pinion pin as a guide See Figure 5 681 6 Place a bronze and steel thru...

Page 349: ...ear teeth for damage or wear 2 Inspect splines for damage 3 Inspect the gear for cracks d Inspection of Sun Gear Shaft 1 Inspect shaft for cracks or splits 2 Inspect splines for damage 3 Inspect bushings for scoring or galling 4 Inspect the ground bushing journals for damage 5 Be sure the oil lubrication hole is open e Inspection of Turbine Shaft 1 Inspect for open lubrication passages at each end...

Page 350: ...modulator bellows modulator plunger is under pres sure 16 lb If bellows is dam aged the plunger will have very little pressure j Inspection of Manual and Parking Linkage 1 Inspect the parking actuator rod for cracks damaged snap ring groove or broken spring re tainer lugs See Figure 5 685A 2 Inspect the actuator spring for damage 3 Inspect actuator for a free fit on the actuator rod 4 Inspect the ...

Page 351: ...er and the oil has the appearance of having been mixed with aluminum paint replace the converter See Fig ure 5 690 5 26 ASSEMBLY OF REAR UNIT 1 Install rear internal gear on end of mainshaft having snap ring groove INTERNAL GEAR SNAP R I N G I f I MAINSHAFT 7 i Figure 5 691 2 Install internal gear retaining snap ring See Figure 5 691 3 Install the sun gear to internal gear thrust races and bearing...

Page 352: ...ut carrier assembly See Figure 5 693 Figure 5 694 Figure 5 695 8 Install the output shaft to out put carrier snap ring See Figure 5 694 9 Turn assembly over and sup port so that the output shaft hangs Figure 5 697 downward See Figure 5 695 10 Install the reaction carrier to output carrier thrust washer with the tabs facing down in pockets See Figure 5 696 11 Install the sun gear splines with chamf...

Page 353: ...p port and sprag assembly as follows a Place a rubber band on the sprag assembly O D to hold the Figure 5 702 in Figure 5 705 and finish installation by pressing on case support See Figure 5 705 NOTE With reaction carrier held case support should only turn counterclockwise 19 Install output shaft to case thrust washer tags in pockets 5 27 ASSEMBLY OF UNITS INTO TRANSMISSION CASE Figure 5 703 1 Ins...

Page 354: ... washer into slots provided inside rear of transmission case See Figure 5 712 8 Install the complete gear unit assembly into the case See Fig ure 5 713 9 Oil and install center support to case retaining snap ring with bevel side up and locating gap adjacent to band anchor pin Make Figure 5 713 certain ring is properly seated in case 10 Install center support screw tool for locating Torque to 2 4 f...

Page 355: ...g the end play within specification it can be se lected from the following chart Notches Thickness 078 086 094 102 110 118 082 090 098 106 114 122 Figure 5 718 None 1 Tab Side 2 Tabs Side 1 Tab O D 2 Tabs O D 3 Tabs O D 16 Install front band with band anchor hole placed over the band anchor pin and apply lug facing servo hole See Figure 5 721 17 Install the direct clutch and intermediate sprag ass...

Page 356: ...olt hole See illustration for location c Mount the dial indicator on the rod and index indicator to regis ter with end of turbine shaft d Push turbine shaft rearward e Push output shaft forward f Set dial indicator to zero g Pull turbine shaft forward Read the resulting travel or end play which should be 003 024 The selective washer controlling this end play is the phenolic resin washer located be...

Page 357: ...e 5 731 5 30 INSTALLATION OF CHECK BALLS FRONT SERVO GASKETS SPACER AND SOLENOID 1 Install the front servo spring and retainer into the transmis sion case Figure 5 730 Figure 5 732 Figure 5 733 2 Install flat washer on front servo pin on end opposite taper 3 Install pin and washer into case so that tapered end is contacting band 4 Install oil seal ring on front servo piston if removed and in stall...

Page 358: ... screws NOTE Attach tool at taching screws finger tight and check freeness of pin Torque attaching screw and recheck to make certain pin does not bind b Apply 25 ft lb torque and se lect proper servo pin to be used from scale on tool See Figure 5 737 c Remove the tool and make note of the proper pin to be used during assembly of the transmission There are three selective pins identified as follows...

Page 359: ...ttaching bolts washer electric wire clips and manual detent and roller assembly Cen ter roller on detent See Fig ure 5 745 NOTE One bolt has copper washer See Figure 5 508 7 Attach stator solenoid electric wire to clips 8 Tighten the solenoid and con trol valve attaching bolts Torque bolts to 6 10 ft lbs 5 33 INSTALLATION OF STRAINER AND INTAKE PIPE Figure 5 745 intake pipe assembly See Figure 5 7...

Page 360: ...Y 1 Install the governor assembly into the case See Figure 5 750 2 Attach the governor cover and gasket with four 4 attaching bolts Torque bolts to 15 20 ft lbs See Figure 5 751 5 36 INSTALLATION OF SPEEDOMETER DRIVEN GEAR ASSEMBLY 1 Install the speedometer driven gear assembly See Figure 5 752 2 Install the speedometer driven gear retainer and attaching bolt See Figure 5 753 Figure 5 751 SPEEDOME...

Page 361: ...he items listed in this sequence are covered further in the text 5 38 SEQUENCE FOR DIAGNOSIS IN THE SUPER TURBINE 4 0 0 1 Check and correct oil level 2 Check and correct detent and stator switches 3 Check and correct vacuum line and fittings 4 Check and correct manual linkage 5 Road Test Install line pressure gauge and road test correcting Items 1 2 3 and 4 on previous page may have eliminated the...

Page 362: ... Drive Range and with the car speed at approximately 35 MPH move the selector lever to Inter mediate Range The transmission should downshift to 2nd An in crease in engine RPM and an engine braking effect should be noticed Line pressure should change from 70 psi to approxi mately 150 psi in 2nd 1st Gear Downhill or Overrun Braking With the selector lever in Inter mediate at approximately 30 MPH at ...

Page 363: ...ous casting 3 Case Leak a Filler pipe O ring seal damaged or missing misposition of filler pipe bracket to engine loading one side of O ring b Modulator assembly O ring seal damaged or improperly installed c Governor cover gasket and bolts damaged loose case face leak d Speedo gear O ring damaged e Manual shaft seal damaged improperly installed f Line pressure tap plug stripped shy sealer compound...

Page 364: ...talled D Direct clutch 1 Case center support oil rings missing broken defective 2 Clutch piston seals missing improperly assembled cut piston ball check stuck or missing V Drive In Neutral A Manual linkage 1 Maladjusted B Forward clutch 1 Clutch does not release this condition will also cause No Reverse VI No Drive in Reverse or Slips in Reverse Install Pressure Gauge A Low oil level B Manual link...

Page 365: ...mbly 1 1 2 accumulator valve train 2 Valve body to case bolts loose 3 Wrong gaskets or off location damaged C Case 1 Intermediate clutch ball miss ing or not sealing 2 Porosity between channels D Rear servo accumulator assembly 1 Oil rings damaged 2 Piston stuck 3 Broken or missing spring 4 Bore damaged X Slips 2 3 Shift Install pres sure gauge A Oil level B Oil pressure low refer to oil p r e s s...

Page 366: ...s positioned spacer plate orifice holes missing or blocked E Case porosity intermediate plug leaking missing XVIL Won t Hold in Park A Manual linkage maladjusted B Internal linkage 1 Parking brake lever and actua tor assembly defective Check for chamfer on actuator rod sleeve 2 P a r k i n g pawl broken or inoperative XVIII No Converter Stator Angle Change A Stator switch inoperative or maladjuste...

Page 367: ...clean and lightly lubricated threads only dry or dirty threads produce increased friction which prevents accurate measurement of tightness Part Location Nut Rear Universal Joint to Pinion Flange Bolt Differential Pinion Shaft Locking Bolt Bolt Rear Axle Housing Cover to Carrier Bolt Nut Upper End of Shock Absorber to Rear Suspension Cross Member Nut Brake Assembly to Rear Axle Housing Bolt Ring Ge...

Page 368: ... gear is bolted to the case The case houses two side gears in mesh with two pinions mounted on a pinion axle which is anchored in the case by a bolt The pinions and side gears are backed by thrust washers The axle shaft inner splines en gage the differential side gears with a floating fit The outer ends are supported in the axle housing by thrust type ball bearings which are factory packed for the...

Page 369: ...3 POSITIVE TRACTION AXLES 2 56 203 50 DIA APPROX TO BE ON BOTTOM OF AXLE TUBE WITH FIELD IDENTIFICATION CODE NOTE S C O INDICATES SPECIAL ORDER AXLE Fig 6 1 Rear Axle Markings surfaced concrete cause noise which may be mistaken for tire or rear axle noise Driving on a different type of road such as smooth asphalt or dirt will quick ly show whether the road surface is the cause of noise Road noise ...

Page 370: ...mains about the same 4 Front Wheel Bearing Noise Loose or rough front wheel bear Fig 6 2 Rear Axle Assembly ings will cause noise which may be confused with rear axle noises however front wheel bearing noise does not change when com paring pull and coast Light application of brake while holding car speed steady will often cause wheel bearing noise to diminish as this takes some weight off the bear...

Page 371: ...n Objectional body boom noise or vibration at 55 65 MPH can be caused by an unbalanced propeller shaft Excessive looseness at the spline can contribute to this unbalance Other items that may also con tribute to the noise problem are as follows 1 Undercoating or mud on the shaft causing unbalance 2 Shaft balance weights missing 3 Shaft damage such as bending dents or nicks 4 Tire type roughness Swi...

Page 372: ...ng upward un til shock absorbers will reach 5 Connect shock absorbers and tighten nuts to 30 60 ft lbs Con nect lower control arms and tighten pivot bolts to 20 30 ft lbs Connect upper control arm bolts and tighten to 65 90 ft lbs 6 Connect parking brake cables Adjust parking brake according to procedure in paragraph 9 9 7 Connect rear universal joint to pinion flange Tighten nuts evenly to 15 18 ...

Page 373: ...h Holder J 6407 See Figure 6 8 CAUTION Retainer plate which retains bearing in housing must be on axle shaft before bearing is installed retainer gasket can be installed after bearing 4 Press new r e t a i n e r ring against bearing using Installer J 8853 c Remove and Install Rear Wheel Bolt 1 To remove and install a rear wheel bolt axle shaft assembly must be out of car Remove rear wheel bolt by ...

Page 374: ...in their original positions f Disassemble Differential Case Assembly 1 If differential side bearings are to be replaced insert Re mover Adapter J 2241 8 in center hole and pull bearing using Puller J 2241 or Hydraulic Puller J 9005 See Figure 6 12 2 Remove bolt that retains dif ferential pinion axle See Figure 6 13 Remove differential pinions side gears and thrust washers from case 3 If ring gear ...

Page 375: ...aring Outer Races in Carrier 1 If rear pinion bearing is to be replaced install new outer race using Installer J 6197 with Driver Handle J 8092 See Figure 6 17 2 If front pinion bearing is to be replaced install new outer race using Installer J 7817 with Driver Handle J 8092 See Figure 6 18 b Set Pinion Depth Ring and pinion gear sets are matched in a special test machine which permits adjustment ...

Page 376: ...f the indicator gauge also check the centering hole and disk pads on the master gauge Setting Gauge 2 Install the J 8619 10 Disks on the indicator gauge Install the small ball tipped contact button on the stem of the dial indicator and mount the dial indicator on the indicator gauge See Figure 6 19 NOTE When gauging for pinion depth the ball tipped con tact button must be used on dial indicator in...

Page 377: ... se lected as further qualified in Step 12 following NOTE An average dial indicator reading will range from 65 to 75 thousandths with a corresponding shim thickness range of 35 25 thousandths 11 Examine the ring gear for nicks burrs or scoring Any of these conditions will require re placement of the gear set 12 Select the correct pinion shim to be used during pinion reassem bly on the following ba...

Page 378: ...eload to specification d Assemble Differential Case Assembly Holder J 8614 will no longer pivot freely as pinion is rotated pre load specifications are being neared Further tightening should be done only after preload has been checked Fig 6 27 Installing Pinion Nut ential examine the wearing sur faces of all parts for scoring or unusual wear Also make certain that all parts are absolutely clean Lu...

Page 379: ... precaution in stall bearing caps using four 7 16 14 x 4 1 4 cylinder head bolts 4 Rotate differential case sev eral complete turns to seat bear ings Check bearing preload using an inch pound torque wrench con nected at ring gear attaching bolt With wrench projecting approxi mately straight out bearing pre load should read 30 to 40 in lbs with new bearings or 15 to 25 in lbs with reused bearings S...

Page 380: ...all wheels wheel nuts drums over and tighten h Install Pinion Oil Seal with Differential Installed in Car In case of pinion oil seal failure remove old oil seal and install new one with differential remain ing in car as follows 1 Mark propeller shaft and com panion flange to permit proper alignment at reinstallation Dis connect propeller shaft from companion flange and support shaft out of way If ...

Page 381: ...ereby minimizing adverse effects b Operation The design of the Positive Trac tion Differential is basic and simple The unit is completely interchangeable with a conven tional differential However this unit has in addition coarse spiral threaded cone brakes in stalled behind the side gears These brakes are statically spring preloaded to provide an internal resistance to the differ ential action wit...

Page 382: ...stamped on the bottom edge of the carrier housing flange See Figure 6 37 However if the wrong lubricant is accidentally added it will be necessary to completely remove all lubricant flush with light engine oil and then fill with the special lubri cant Capacity of the rear axle housing is 2 1 2 pints 6 9 POSITIVE TRACTION DIFFERENTIAL SERVICE PROCEDURES All rear axle service procedures are the same...

Page 383: ...s 1 Clamp one axle shaft in a vise allowing three inches to extend above vise jaws Then place the cap side of differential case over extended axle shaft with interior of case facing up See Figure 6 39 2 Install proper cone over axle shaft splines seating it into po sition in cap half of case NOTE Be certain that each cone is in stalled in proper case half since tapers and surfaces become matched a...

Page 384: ...ential assembly over cone in proper position to match align ment marks insert two bolts fin ger tight 180 apart See Figure 6 42 9 Install other axle shaft through flange half of differential case rotating axle to enter cone splines Fig 6 43 Torquing Differential Bolts and then side gear splines Leaving the axle shaft in this po sition insert remaining bolts and tighten to 15 18 ft lbs See Fig ure ...

Page 385: ...lange 49000 Nut Differential Carrier to Housing Nut Spring Upper End to Frame 49000 Bolt Nut Upper Control Arm Inner to Outer Arm 49000 Bolt Nut Upper Lower Control Arm Pivot All 49000 Bolt Nut Upper Lower Control Arm Pivot All 46 48000 Bolt Nut Upper Control Arm Bracket to Frame 46 48000 Nut Rear Shock Upper Lower Ends 49000 Bolt Nut Rear Shock Upper End 46 48000 Nut Rear Shock Lower End 46 48000...

Page 386: ...packed for the life of the bearings and sealed on both The drive pinion is mounted in sides The axle shaft oil seals i i DESCRIPTION OF t w 0 a Pere r Her bearings which are located inboard of the bear REAR AXLE a r e p r e l o a d e d b v t w 0 selected ings The bearings are secured REAR AXLE spacers at assembly See Figure against a shoulder on the shaft by The rear axle assembly is of the 6 4 T1...

Page 387: ...OSITIVE TRACTION DIFFERE TO HAVE 0 STAMPED ON BOTTOM SIDE OF CARRIER FLANGE FOR FIELD IDENTIFICATION ALL AXLES TO HAVE RATIO CODE a DATE STAMPED ON BOTTOM OF HOUSING FOR FIELD IDENTIFICATION SAMPLE MARKING FOR 3 07 RATIO DATE JULY 22 WOULD BE STANDARD AXLES PA 203 POSITIVE FRACTION PN 203 SAMPLE MARKING S CO SPECIAL CAR ORDER RATIO DATE JULY 22 WOULD BE STANDARD AXLE 2 56 203 POSITIVE TRACTION AXL...

Page 388: ... parts in the rear axle assembly 1 Road Noise Some road sur faces such as brick or rough surfaced concrete cause noise which may be mistaken for tire or rear axle noise Driving on a different type of road such as smooth asphalt or dirt will quickly show whether the road surface is the cause of noise Road noise usually is the same on drive or coast 2 Tire Noise Tire noise may easily be mistaken for...

Page 389: ...ne speeds cor responding to car speed at which the noise was most pronounced If a similar noise is produced with car standing it is caused by the engine or transmission and not the rear axle b Rear Axle Noises If a careful test of the car shows that the noise is not caused by external items as described in subparagraph a it is then reason able to assume that the noise is caused by the rear axle as...

Page 390: ...from the bot tom edge of the brake backing plate is caused by either a leak ing wheel bearing seal or a leak ing brake cylinder The feel and smell of the leaking oil will help determine the type leak to expect 2 Oil coming from between the rear pinion flange slinger and the carrier is caused by a leaking pinion seal Oil coming out around the pinion nut is caused by a de fective O ring seal between...

Page 391: ...s required See paragraph 6 28 6 14 REMOVAL AND INSTALLATION OF AXLE SHAFT WHEEL BEARING OR OIL SEAL a Remove Axle Shaft Assembly 1 Place car stands solidly under rear axle housing so that wheels are clear of floor 2 Remove rear wheel and brake drum Both left and right side wheel bolts have right hand threads 3 Remove nuts holding wheel bearing retainer plate to brake backing plate leaving bolts in...

Page 392: ...e flange Check new bolt for looseness if bolt can be moved at all with RAM YOKE ASSY J 6180 PUMP HOSE ASSY J 6207 Fig 6 50 Removing Rear Wheel Bearing fingers axle shaft must be replaced e Install Axle Shaft Assembly Rear axle shafts are not inter changeable between sides the right shaft is longer than the left 1 Apply a coat of wheel bearing grease in wheel bearing recess of housing Install new o...

Page 393: ...of the way 3 Remove rear wheels and brake drums Remove axle shaft as semblies as described in para graph 6 14 4 Remove carrier to axle hous ing nuts except two opposite nuts back these two nuts out until they engage only a few threads 5 Locate a drain pan under car rier flange then move carrier forward to drain gear lubricant 6 Remove carrier assembly using a transmission jack if available b Insta...

Page 394: ...ng Support Puller panding screw in puller body J 9744 5 in a counterclockwise direction to retract pins then in sert puller body into differential bearing support until reference line on tool is flush with end of support and punch mark is in general direction of hole in sup port See Figure 6 54 b Expand pins a slight amount by turning expanding screw with screwdriver in a clockwise di rection unti...

Page 395: ...ive bearings requiring replacement If run long with very loose bear ings ring and pinion gears will be damaged and also need replacing 2 Install Holder J 8614 01 on pinion flange using two 5 16 18 x 2 bolts with flat washers On 49000 install Holder J 8614 01 on pinion flange using Adapters J 21619 Remove pinion nut us ing a 5 16 3 4 drive socket on Handle J 6246 Remove washer See Figures 6 58 and ...

Page 396: ...ified rear axle lubricant just before assembly NOTE If the Buick is equipped with a Positive Traction Differ ential only Positive Traction Lube should be used CAUTION If the ring gear and pinion are changed only factory hypoid lubricant should be used for filling because of its special anti scoring properties For this reason the proper lubricant is in cluded in the carton with the re placement gea...

Page 397: ... J 8619 13 PILOT v W J 5647 37 Fig 6 65 Pinion Setting Gauge J 5647 and Adapters Figure 6 65 It is not necessary to reassemble and install the pin ion depth shim since the pinion depth setting gauge arrangement provides in effect a nominal or zero pinion as a gauging reference b Checking Pinion Depth NOTE Before setting pinion depth the pinion bearing races must be in position and the pinion oil s...

Page 398: ...ped estal bore farthest from pinion and over gauge pin Then slide short adapter in place on other side c Position the spring loaded pin of the indicator gauge in the cen tering hole of Gauge Plate J 5647 36 and position the contact button of dial indicator to bear against machined surface of Gauge Plate See Figure 6 67 9 Press gauge yoke down firmly Record number of thousandths dial indicator move...

Page 399: ... Replacer J 8611 with driver handle See Figure 6 68 2 Drive rear pinion bearing outer race against shoulder in carrier using Replacer J 9745 with driver handle See Figure 6 69 3 Plate correct shim as deter mined in subpar b against head of pinion and install rear pinion bearing using Replacer J 6377 and Holder J 6407 with Ring J 6407 2 in a press or as shown in Figure 6 70 4 For a starting pinion ...

Page 400: ...erential Case Gears and Bearings 1 Drive differential bearing outer races into case using Re placer J 9742 See Figure 6 75 2 Install side gears pinions and washers in case If same parts are used replace in original sides Install pinion axle Drive Fig 6 76 Installing Ring Gear on Differential Case spring pin through hole in pinion axle until flush with case 3 Check matching numbers on ring gear and...

Page 401: ... torted case flange and make necessary corrections CAUTION Any gear lash check must be made with pinion locked to carrier to be sure it cannot turn c Adjust gear lash at the point of minimum lash to 008 for all new gears If original gear set is being reinstalled the original lash should be maintained 4 Measure with a shim between each bearing and its pedestal Do not remove support tools for measur...

Page 402: ...e The Positive Traction Differential consists of a different type of dif ferential case assembly which is used in place of the conventional case assembly All rear axle parts are identical b Operation The Positive Traction Differential has pinion gears and side gears which operate in a manner simi lar to those in a conventional differential However this unit has in addition clutch packs in stalled ...

Page 403: ...ve Traction Differential P o s i t i v e Traction Differentials filler plug or by an X in a c i r c l e ure 6 83 However if the wrong can be easily identified either by stamped on the bottom edge of the lubricant is accidentally added it a stainless steel plate around the carrier housing flange See Fig will be necessary to completely ...

Page 404: ... 6 82 Positive Traction Differential Exploded View remove all lubricant flush with light engine oil and then fill with the special lubricant Capacity of the rear axle housing is 4 1 2 pints 6 2 0 POSITIVE TRACTION DIFFERENTIAL SERVICE PROCEDURES All rear axle service procedures are the same in the Positive Traction rear axle as in a con ventional rear axle except for servicing the internal parts o...

Page 405: ...emove the pinions and thrust washers 7 Remove a side gear clutch pack and shims from the case noting location in the case to aid in reassembly Remove the side gear clutch pack and shims from the opposite side 8 Remove the clutch plate guides and separate the shims and clutch plates from the side gears NOTE Keep the clutch plates in their original location in the clutch pack b Cleaning and Inspecti...

Page 406: ...press the clutch stack by inserting a screwdriver or wedge between the side gear and the pinion shaft d Install dial indicator with the contact button against the pinion gear See Figure 6 85 e Rotate pinion gear Clearance should be 001 to 006 f If clearance is more than 006 add shims between clutch pack and case If clearance is less than 001 remove shims A 002 shim will change clear ance approxima...

Page 407: ... The spring retainer can be moved slightly to correct misalignment d Simple Procedure for Testing a Positive Traction Differential If there is a doubt that a Buick is equipped with a Positive Traction Differential or to determine if this option is performing satis factorily a simple test can be performed 1 Place transmission in neutral 2 Raise one wheel off floor and place a block of wood in front...

Page 408: ...d on a cross member between the right and left sides of the perimeter frame A splined front yoke on the front end of the rear propeller shaft extends into a splined coupling in the rear end of the front propeller shaft This slip spline permits the slight lengthening and short ening of the propeller shaft re quired by the up and down movement of the rear axle as sembly See Figure 6 88 The constant ...

Page 409: ...t The rubber cushion in turn is held in a round open cup by a flat washer and a wire snap ring The locknut which retains the center bearing in place also prevents the slip joint from separating The seal which retains the lubricant in the slip spline is located inside the lock nut See Figures 6 88 and 89 The propeller shaft assembly re quires very little periodic serv ice The center support bearing...

Page 410: ...NG RETAINER ASSEMBLY FRONT PROPELLER SHAFT FR PROP SHAFT SLIP YOKE SLINGER SPACER REAR PROPELLER SHAFT REAR AXLE PINION FLANGE BEARING INDEX SPRING SPLINED YOKE SHAFT WASHER 1 SPIDER SNAP RING LINK YOKE y m Figure 6 89 Exploded View Propeller Shaft 45 46 48000 Series ...

Page 411: ...PROPELLER SHAFT 45 46 48 49000 SERIES 6 45 ...

Page 412: ...DESCRIPTION OF PROPELLER SHAFT 49000 The propeller shaft used on 49000 Series utilizes a front universal joint and two constant velocity joints one at the center of the shaft and the other at the rear All components other than the center bearing support and the rear constant velocity joint are similar in appearance and func tion to the 45 46 and 48000 pro peller shaft See Figure 6 90 The center an...

Page 413: ...place On 49000 check to s e e if sufficient clearance exists between rear frame tun nel and propeller shaft if car is raised on a frame hoist Grind out frame for sufficient clearance if necessary Align or check for proper in stallation of mountings Impact yokes with hammer to free up Replace joint if unable to free up or if joint feels rough when rotated by hand Replace Replace Clean up shaft Chec...

Page 414: ...ecrease front angle by shimming t r a n s m i s s i o n support Place car on hoist with rear wheels free to rotate and diag nose for source of noise Re place center support bearing if found to be noisy 1 Lube 2 Replace with ball socket kit if lube does not correct Shim up or replace center bearing mount Replace with splined yoke or ball seat replacement kit Tighten bolts Replace center bearing sup...

Page 415: ...r 2 Place the smaller O D end of adapter J 2241 8 Differential PULLER CENTER J 2241 2 BEARING SUPPORT Figure 6 91 Removing Center Support and Bearing 49000 Series side carrier bearing puller adap ter 1955 and previous into the splines of the propeller shaft Position Differential Side Bearing Puller J 2241 2 as shown in Fig ures 6 91 and 6 91b Pull the center support and bearing as sembly from the ...

Page 416: ...853 as possible 4 Release the pump and remove the propeller shaft Install Spacer J 9522 5 over the spider journal at the space provided with the bearing forced partially through the link yoke See Figure 6 96 Reposition propeller shaft in fix ture as before and force with the added assistance of the Spacer 5 Release the pump and the propeller shaft Install Guide J 9522 8 through the bearing hole in...

Page 417: ...e Figure 6 100 Reposition the propeller shaft in the fixture as before and force the bearing com pletely out of the yoke with the added assistance of the Spacer 5 Release pump and propeller shaft Install Guide J 9522 8 through the bearing hole in the yoke and over the journal end of the spider See Figure 6 101 This guide assures alignment of the spider while removing the opposite bearing Figure 6 ...

Page 418: ...he spider journals engage the bear ings squarely to avoid damage and binding If binding exists remove the bearings and spider and examine for dislodged rollers or damaged journals 3 Observing the previous pre cautions install the balance of the bearings necessary to com plete the assembly and install snap rings 4 Strike the yoke with a hammer to fully seat the snap rings against the yoke Turn the ...

Page 419: ...to the yoke continuing to hold the spider up in this bear ing Failure to do this could cause the bearing needles to be come dislodged if engaged incorrectly When the bearing is correctly po sitioned in the yoke turn the assembly over Again place the bearing over the hole in the yoke Carefully slide the spider parti ally out of the previously seated bearing and start it carefully into the bearing b...

Page 420: ... SHAFT The propeller shaft must be sup ported carefully during handling to avoid jamming or bending any o the parts 1 Protect the oil seal diameter on the front slip yoke by taping or wiring a cloth over the complete front universal joint 2 Slide complete propeller shaft assembly forward through frame tunnel 49000 only 3 Remove protecting cover from front universal joint Fill space between lips of...

Page 421: ... as the name implies transmits at a constant velocity regardless of the angle through which it is operating Therefore no means is provided or needed for adjusting the con stant velocity joint However the rear universal joint angle can vary and must be ad justed It is adjusted by rotating the rear axle housing this is ac complished by lengthening or shortening the upper control arms by means of shi...

Page 422: ...3 SPACER 2 1 USE f WXII tfaOLTB 1 O N L Y s m Figure 6 114 Checking Rear Universal Joint Angle 45 46 48000 Series ...

Page 423: ... above was not correct the pin ion nose must be moved up or down as required This is done by shimming the upper control arms Adjust rear universal joint angle using the following procedure 1 Place a jack under pinion nose Because of the geometry of the rear suspension the pinion nose will tend to move downward when released and must be held upward 2 Loosen nuts and bolts retain ing upper control a...

Page 424: ... is rotating speed ometer indicating 40 50 MPH and carefully bringing the crayon upwards until it just contacts this rotating shaft If carefully done the heavy side point of maximum runout only will be marked by the crayon This normally gives a good indication of which side of the shaft is heavy for unbalance and serves as a starting point for initial location of the hose clamps MOUNTING BOLTS PRO...

Page 425: ...worse if worse return the clamps to the original position Apparently the combined weight of the two hose clamp heads was excessive so to reduce this excess rotate the clamp heads away from each other 45 one each way from the original position See Figure ROTATING CLAMP HEADS AWAY FROM EACH OTHER REAR PROPELLER SHAFT Figure 6 118 Rotating Hose Clamp Heads from Each Other 6 118 Run car and note if un...

Page 426: ...6 60 PROPELLER SHAFT 45 46 48 49000 SERIES J 21009 J 9732 J 9522 1 J 9522 8 J 21007 J 9522 2 J 7013 24 J 7273 22 J 7013 1 J 8853 Figure 6 119 Propeller Shaft Tools ...

Page 427: ...PROPELLER SHAFT 45 46 48 49000 SERIES 6 61 J 8614 3 J 9744 5 J 9745 J 8592 J 21005 J 6552 15 J 8614 1 J 6552 20 J 6552 19 Figure 6 120 Rear Axle Tools ...

Page 428: ...Shock to Upper Bracket 45 46 48000 Rear Shock to Lower Bracket 49000 Rear Shock to Lower Bracket 45 46 48000 Front Shock to Lower Control Arm 49000 Front Shock to Lower Control Arm 45 46 48000 Front Shock to Frame Stabilizer Bushing to Frame Idler Arm Support to Frame Upper Control Arm Shaft to Frame 49000 Upper Control Arm Shaft to Frame 45 46 48000 Upper Control Arm Upper Ball Joint Knuckle Lowe...

Page 429: ...ese specifications apply to new parts only Where limits are given T means tight and L means loose Item All Series Caster Camber Toe in Effective K P I and Steering Geometry See Figure 7 34 Steering Knuckle Spindle Large End Diameter 1 3743 1 7348 Small End Diameter 8430 8435 Wheel Bearing Cone on Spindle Outer 0004 L 0014 L Inner 0005 L 0015 L Wheel Bearing Cup in Hub Outer 0005 T 0025 T Inner 000...

Page 430: ... of chassis spring A similar rubber bumper is mounted on each upper control arm to limit travel of arm during rebound of chassis spring Side roll of the front end of chas sis is controlled by a spring steel stabilizer shaft The shaft is mounted in rubber bushings sup ported in brackets attached to lower flange of each frame side rail The ends of stabilizer shaft are connected to the front sides CO...

Page 431: ... is mounted to the frame so that the front end of the shaft is higher than the rear end at an angle rel ative to that of the lower control arm shaft Thus when the brak ing force is applied the tendency of the car s front end to dive rotates the backing plate and spindle assembly in a rearward direction while the braking torque tends to rotate the backing plate and spindle assembly in a forward dir...

Page 432: ...y Alignment is frame through a link type sus and the frame maintain fore and maintained by the rigid rear axle pension system Two rubber aft relationship of the axle hous housing See Figure 7 4 bushed lower control arms ing to the chassis Two rubber LOWER CONTROL ARM CENTER BEARING ASSEMBLY PROPELLER SHAFT REAR UNIVERSAL JOINT FRONT UNIVERSAL JOINT UPPER CONTROL ARM ATTACHMENT SHIMMED FOR PINION A...

Page 433: ...ssible for ride and handling calibrations to be worked out for each one Standard production tire sizes are given in paragraph 7 1 Tires other than those used as standard equipment may cause a wander Larger tires will reduce clear ance at fenders and be difficult to mount in spare carriers Tires with more plys may cause hard riding Some types of tire and tube combinations are difficult to balance a...

Page 434: ...o the pressure tube it occupies space previously filled with fluid and this displaced fluid is forced out of the lower chamber into the reservoir through the restricting orifice in the compression valve On fast or extreme movements when the fluid flow exceeds the capacity of the orifice the spring loaded relief valve in the com pression valve assembly is forced open to permit more rapid escape of ...

Page 435: ...ire made High speed on straight highways or expressways normally causes more rapid wear on the rear than on the front tires although cup ping of front tires can result if the tires are not periodically switched from wheel to wheel Driving turns and curves at too high a rate of speed causes the front tires to wear much faster than the rear tires An inspection of the tires to gether with information...

Page 436: ...exces sive toe in while the same con dition in the outer sides of ribs indicate excessive toe out Usu ally excessive toe in causes ex cessive tire wear on the outer edge of the right front tire and toe out causes tire wear on the inner edge of the left front tire See paragraph 7 18 for toe in correction Cornering wear caused by high speed driving on curves subpar f following sometimes has the appe...

Page 437: ...n clude underinflation incorrect toe in setting or camber setting and steady highway speeds on smooth paved surfaces as op posed to gravel or rough asphalt See Figure 7 6 The following recommendations suggest action that may be taken to help prevent cupping 1 Rotate tires as recommended in paragraph 7 8 2 Frequently inspect front tires for irregular wear due to under inflation improper toe in sett...

Page 438: ...it may be assumed that the shock absorber action is nor mal if it operates satisfactorily in the test given above c Loose Ball Joints The upper ball stud is spring equipped and thus preloaded in its socket at all times This min imizes looseness at this point and compensates for normal wear If the upper stud has any perceptible lateral shake during testing or if it can be twisted in its socket with...

Page 439: ... develop in either front or rear wheels and occurs at speeds above 35 MPH 1 Wheel tire or brake drum out of balance par 7 8 2 Excessive tire and wheel run out par 7 7 3 Shock absorber inoperative par 7 5 4 Items 1 2 or 3 in combination with one or more items listed under Front Wheel Shimmy sub par e above 7 7 CAR ROUGHNESS OR VIBRATION a Various Causes Car roughness or vibration may be caused by r...

Page 440: ...mblies at points shown on Figure 7 5 Tire runout should be checked immediately after the car has been driven as tires take a set after standing for a short period NOTE It should be stressed that the runout found is a mere indication and not proof of the source of trouble Procedure 1 Make certain that the wheel lug nuts are tightened adequately and evenly 2 If checking front wheels and tires make c...

Page 441: ...running mates can be sus pected of having a leaking valve or a puncture All tires should be inspected reg ularly to avoid abnormal deterio ration from preventable causes If tires show abnormal or uneven wear the cause should be deter mined and correction should be made See that no metal or other foreign material is imbedded in the tread Any such material should be re moved to prevent damage to tre...

Page 442: ... must be smooth and clean to avoid damaging rim seal ridges Take small bites if tire irons are used DO NOT USE HAMMERS WARNING Due to the extremely heavy pressure under which the outer tire bead seats to the rim it is recommended that an exten sion gauge with a clip on check be used for mounting inflation This will allow the operator to remain at a safe distance Remove valve core to increase flow ...

Page 443: ...of the stabilizer links for grease resistance This offers protection from chassis lube overflow from the lower ball joints The upper stabilizer grommets are rubber as they are out in the open where grease resistance is not required To disassemble remove nut from lower end of the link rod then re move rod spacer retainers and grommets When new the link grommets are 7 8 free length When assembling i...

Page 444: ...ble shake or if it can be twisted in its socket with the fingers the upper control arm ball joint assembly should be re placed See Figure 7 11 Removal 1 Raise car with jack under frame Remove wheel and tire 2 Remove cotter pin from cas tellated nut on upper ball joint tapered stud BACKING PLATE O RING STEERING KNUCKLE GREASE SEAL Figure 7 10 Front Wheel and Hub Bearings 3 Loosen but do not remove ...

Page 445: ... to bracket nuts to 100 ft lbs The nuts may be torqued from within the engine compartment through the use of a standard 11 16 1 2 drive socket and J 1313 Torque Wrench or its equivalent 8 Assemble tapered stud to knuckle with cotter pin holes fore and aft Install castellated nut Torque to 35 ft lbs and install cotter pin 9 Install wheel Check and ad just front end alignment if necessary When worki...

Page 446: ...T 4 1001 LBFTl z COTTER P N 2 NUT 2 KNUCKLE RT LT NUT 2 160 751 LB TT1 COTTER PIN 2 CASTER AND CAMBER ADJUSTMENT FOR INCREASED OR POSITIVE CASTER DECREASE SHIMS AT BOLT A AND WCREASE SHIMS AT BOLT B AN EQUAL AMOUNT FOR OEOCASED OR NEGATIVE CASTER INCREASE SHIMS AT 9DLT A AND DECREASE SHIMS AT BOLT B AN EOUAL AMOUNT TOR tNCREASEO CAMBER DECREASE SHIMS AT BOTH A AND B BOLTS SHIMMING GREATER THAN 5 0...

Page 447: ...MBER ADJUSTMENT FOR INCREASED OR POSITIVE CASTER DECREASE SHIMS AT BOLT A AND INCREASE SHIMS AT BOLT B AN EQUAL AMOUNT FOR DECREASED OR NEGATIVE CASTER INCREASE SHIMS AT BOLT A AND DECREASE SHIMS AT BOLT B AN EQUAL AMOUNT FOR INCREASED CAMBER DECREASE SHIMS AT BOTH A AND B BOLTS SHIMMING GREATER THAN 500 NOT PERMISSIBLE NO MORE THAN 5 SHIMS TO BE USED AT EACH LOCATION BOLT 2 STOP 2 FOR PART NUMBER...

Page 448: ...Move the steering knuckle out of the way 6 On 49000 Series install Lower Ball Joint Remover and Installer J 9519 as shown in Figure 7 16 Note that the larger O D portion of Detail J 9519 2 is positioned in J 9519 10 7 On 45 46 48000 install lower ball joint remover and installer as shown in Figure 7 17 8 Tighten Detail J 9519 8 with a socket and handle as shown in Figure 7 18 Removing Lower Ball J...

Page 449: ...kle 6 To replace knuckle wipe stud of upper ball joint clean assem ble to knuckle with cotter pin hole fore and aft seat with sharp blow of hammer torque nut to 35 ft lbs and install cotter pin 7 Wipe lower ball joint stud clean and assemble to knuckle as outlined in installation Steps 1 thru 6 subparagraph b preceding 7 12 REMOVAL AND INSTALLATION OF UPPER CONTROL ARM OR SHAFT The removal and ins...

Page 450: ...1965 MODEL FRONT T CURB WEIGHT WEIGHT 4 26 f _4Jj LJ4 Al 4 14 3 J at 4 14 4 85 AR CURB 6 20 flL 6 42 n z 45 46 48 REAR COIL SPRING BUMPER THESE DIMENSIONS DO NOT APPLY TO OPTIONAL SPRINGS CURB WEIGHT TRIM ON AIR CONDITIONED CARS SUBTRACT 10 FROM FRONT TRIM DIMENSIONS 49 REAR COIL SPRING m 0 n m 2 o n m O 70 Figure 7 22 1965 Chassis Trim Dimensions 10 ...

Page 451: ...23 Wiring Brake Backing Plate out of Way bumper from the lower control arm but leave attached to the front frame cross member 7 As a safety precaution place a floor jack under the lower con trol arm as far outboard on the arm as possible to gain maxi mum leverage advantage It would be advantageous to remove the lube fitting at the lower ball joint so that it will not be damaged by the jack Do not ...

Page 452: ...t Spring with Tool J 9552 Figure 7 28 Pushing Spring onto Lower Control Arm Seat NOTE Never use standard bolts nuts or washers at this location If replacement parts are needed package Group 6 171 Part 1389760 contains the two special nuts and four special washers necessary for this installation 10 Reinstall stabilizer link and grommets Assemble in same relative position as maintained after removal...

Page 453: ... the lower con trol arm to facilitate attachment of the spring to the lower control arm 3 Raise control arm to contact spring and slip spring between spring and control arm 4 Insert a long tapered punch through the control arm bolt hole from the bottom to maintain alignment of the control arm and spring seat hole 5 Slip spring clamp over punch and position straight side of clamp along straight end...

Page 454: ...trimental car hand ling characteristics 4 On 45 46 48000 install two attaching nuts and bolts to lower control arm Torque to 55 ft lbs Reposition stabilizer link install lower grommet retainer and nut and torque to 7 ft lbs 5 Torque nut at frame end of brake reaction rod to 50 ft lbs NOTE CASTER AND CAMBER MUST BE CHECKED AFTER RE PLACEMENT OF BRAKE RE ACTION ROD NOTE If there is any question conc...

Page 455: ...ART NUT 2 2O 3OXBTT 10 00 i n m I ARM a BUSHING ASM BUMPER 2 BUMPER 2 RETAINER 2 SCREW 4 VIEW C BAR ASM VIEW D f LENGTH OF LOWER PIGTAIL OVERHANG ON EITHER SIDE OF LOWER CONTROL ARM VIEW A VIEW F ARM a BUSHING ASM INNER ARM a BUSHING A S M OUTER WASHER 2 SPECIAL BUSHING SLEEVE ARM BUSHING SLEEVE ARM UPPER ARIV bOLTS 2 VIEW B I i I Figure 7 30 Rear Suspension Detail 49000 ...

Page 456: ...VIEW B MODELS 46 8 48 INSULATOR BRACKET C VIEW E NUT 4 SCREW 4 103329 L WASHER 2 942IO85 NUT 2 VIEW D n in m VIEW C Figure 7 31 Rear Suspension Detail 45 46 48000 ...

Page 457: ...rque to 25 ft lbs 8 Raise rear axle assembly to reconnect shock absorber at lower bracket Remove short piece of 2 x 4 behind spring 9 Tighten shock absorber bolt to a minimum of 35 ft lbs and tighten control arm bushing bolts to 75 ft lbs NOTE Car should be in normal load position when tightening shock absorbers and lower con trol arms Thus where possible car should be supported by wheel noist by ...

Page 458: ... lower con trol arm 3 Make certain the shock ab sorber being installed is correct for car model as indicated by part number stamped on outer tube See Master Parts List Group 7 345 4 Assemble lower grommet re tainer and grommet on shock stem Extend shock and install through lower control arm 5 On 49000 install two shock bracket to lower control arm bolts and lock washers Tighten to 20 ft lbs On 45 ...

Page 459: ... the majority of cases services consisting of inflating tires to specified pressure and inter changing tires at recommended intervals par 7 8 adjusting steering gear par 8 4 manual and par 8 13 power and setting toe in correctly subpar e fol lowing will provide more im provement in car handling and tire wear than will front end alignment adjustments as usually made on front end of alignment equipm...

Page 460: ...mber and caster vary in proportion to the height of the front springs all caster and camber measurements are to be taken at curb height Nominal curb trim heights are shown on chassis trim dimension chart Fig 7 22 When equipment is used which bears against the tire or wheel rim to obtain readings it is very essential that the tires or wheels be checked for runout Readings must be taken at points wh...

Page 461: ...then with tires on the floor and front end at running height meas ure between scribed lines with a suitable trammel 4 Roll the car forward until measuring points on tires are ap proximately 10 from the floor at the rear and measure the dis tance between points used in Step 3 above The measurement at the front dimension A should be 7 32 to 5 16 less than the measurement at the rear dimen sion B See...

Page 462: ...HEEL SPOKE MUST BE HELD IN HORIZONTAL PLANE DURING TOE IN SETTING AFTER TOE IN SET THE STEERING WHEEL SPOKE MUST BE CENTERED WITHIN 1 00 LEFT AND 5 8 RIGHT r I O 4 3 AT 0 53 CAMBER POSITIVE CASTER BOTH SIDES SHOULD BE WITHIN 0 3 0 OF EACH OTHER CAMBER CURB 1 4 POS 3 4 l 4 BOTH SIDES SHOULD BE WITHIN 0 3 0 OF EACH OTHER NOTE ALL CASTER AND CAMBER MEASUREMENTS ARE TO BE TAKEN AT CURB HEIGHT NOMINAL ...

Page 463: ... SPOKE MUST BE HELD IN HORIZONTAL PLANE DURING TOE IN SETTING AFTER TOE IN SET THE STEERING WHEEL SPOKE MUST BE CENTERED WITHIN 1 00 LEFT AND 5 8 RIGHT FRAME DATUM LINE 2 41 FISHER 5 LINE BOTH SIDES SHOULD BE WITHIN 0 30 OF EACH OTHER CAMBER CURB l 2 P0S t 2 BOTH SIDES SHOULD BE WITHIN 0 30 OF EACH OTHER NOTE ALL CASTER AND CAMBER MEASUREMENTS ARE TO BE TAKEN AT CURB HEIGHT NOMINAL CURB TRIM HEIGH...

Page 464: ...s of adjustment and theo retical king pin inclination is cor rect or nearly so a bent steering knuckle is indicated If camber and theoretical king pin inclination are both incorrect by approximately the same amounts a bent upper or lower control arm is indicated There is no adjustment for theo retical king pin inclination as this factor depends upon the accuracy of the front suspension parts Disto...

Page 465: ...g Specifications Use a reliable torque wrench to tighten the parts listed to insure proper tightness without straining or distorting parts These specifications are for clean and lightly lubricated threads only dry or dirty threads produce increased friction which prevents accurate measurement of tightness Thread Torque Part Location Size Ft Lbs Bolt Nut Lower Coupling Clamp 5 16 18 25 35 Bolt Gear...

Page 466: ...ring shaft turn to the left the ball nut is moved downward by the balls which roll between the worm and nut As the balls reach the outer surface of nut they enter the re turn guides which direct them across and down into the ball nut where they enter the circuit again When a right turn is made the ball nut moves upward and the balls circulate in the reverse di rection See Figure 8 1 Teeth on the b...

Page 467: ...oo tight or idler arm binding on support par 8 21 4 Front wheel alignment incor rect Group 7 c Rattle or Chuckle in Steering Gear 1 Insufficient or improper lub ricant in steering gear Group 1 2 Excessive backlash between ball nut and pitman shaft sector in straight ahead position or worm thrust bearings adjusted too loose par 8 4 NOTE On turns a slight rattle may occur due to the increased lash b...

Page 468: ...ries greatly and feels rough gear assembly should be removed for inspection of internal parts 12 When installing pitman arm on pitman shaft torque nut to 135 ft lbs b Adjustment of Steering Gear on Bench 1 Attach Torque Wrench J 5853 to worm shaft and turn shaft to extreme right or left position See Figure 8 5 2 Turn worm bearing adjuster to obtain a reading of 5 to 9 inch pounds with worm shaft t...

Page 469: ...h wheel properly located on shaft install nut and tighten to 30 ft lbs in place 4 Install horn parts on steering wheel 5 Plug horn wires together at mast jacket 8 6 REMOVAL AND INSTALLATION OF MANUAL STEERING GEAR a Removal of Steering Gear Assembly 1 Remove two nuts securing gear coupling to flange on lower end of steering shaft See Figure 8 9 2 Remove cotter pin and nut se curing pitman arm to i...

Page 470: ... locknut Remove three side cover bolts 4 Remove side cover by turning lash adjuster clockwise through cover Slip lash adjuster with shim from slot end of pitman shaft Remove and discard side cover gasket 5 Remove pitman shaft from housing by lightly tapping on spline end with a soft mallet Pry pitman shaft seal out of housing with a screwdriver Discard seal 6 Loosen worm bearing adjuster locknut w...

Page 471: ...f nec essary The lower worm bearing cup is not replaced separately but is serviced with the worm bearing adjuster If upper worm bearing cup is defective drive cup out of housing with a punch and install new cup using Instal ler J 8811 with Driver Handle J 8092 3 Check fit of the pitman shaft in the bushing in side cover If bushing is worn side cover must be replaced as bushing is not serviced sepa...

Page 472: ...ls are installed correctly and rotate freely 2 Place upper bearing on worm shaft and slide worm shaft as sembly into housing 3 Place lower bearing in worm bearing adjuster and install bear ing retainer with Installer J 8564 Install adjuster assembly with locknut in housing Tighten ad juster only enough to hold worm bearings in place Final adjust ment will be made later 4 Turn worm shaft until cent...

Page 473: ... of tightness NOTE See Figures 8 29 and 8 30 for pump mounting bolts and nuts Thread Torque Part Location Size Ft Lbs Bolt Lower Coupling Flange Pinch 3 8 24 20 35 Bolt Gear Side Cover to Housing 3 8 16 25 35 Stud Pump Reservoir to Housing 3 8 16 25 35 Bolt Gear Housing to Frame 7 16 14 60 75 Union Pump Pressure Outlet 5 8 18 20 30 Nut Steering Wheel to Steering Shaft 1 2 20 20 35 Nut Pitman Arm t...

Page 474: ...age A twist off cap is used on the reservoir to simplify checking the oil level With the engine running steering is manual under conditions which require an effort of less than one pound at the steering wheel rim When a greater effort is required the power mechanism operates to assist in turning the front wheels The effort then required of the steering wheel rim is limited to a maximum of approxim...

Page 475: ...Gear end is supported by a bearing and its lower end by an adapter and ball bearing assembly The steering shaft is connected to the power steering gear through a flexible coupling which is riveted to the steering shaft flange This flexible coupling helps absorb minor shocks and vibrations and dampens out hydraulic noises from the gear assembly and the steering column jacket assembly The power stee...

Page 476: ...r as low as only PRESSURE SLOT 4 RIGHT TURN HOLE 4 j 3fc V A L V E B O D Y I mm EFT TURN HOLE 4 _ RETURN j S C SLOT 4 1 7 VALVE SPOOL Figure 8 16 Upper End View of Rotary Valve Left Turn 0004 in smaller than the inside diameter of the valve body This close fit allows very little if any oil flow between the two surfaces The valve spool has four holes drilled near the upper end of it which are in li...

Page 477: ...ng pump from the engine Inside the flow control valve is the pressure relief valve Also in the end of the flow control VALVE BODY TO VALVE BODY CAP PIN STUB SHAFT TO VALVE SPOOL PIN VALVE BODY PIN TORSION BAR TO STUB SHAFT PIN Figure 8 17 Attaching Pins for Valve Parts valve is a filter screen which filters the oil that enters this valve The pressure union which is the pump outlet contains the pum...

Page 478: ... union The flow control valve regulates the opening of a by pass passage through which oil may be returned back to the suction and reservoir section of the pump When the pump is running without demand for steering pressure pressure in the discharge cavity is great enough to push the flow control valve open against a spring load of approximately ten pounds See Figure 8 21 The pressure in the spring...

Page 479: ...flow control valve then resumes normal operation The flow control valve starts to open at 300 400 RPM of pump and is functioning when the pump is running 465 RPM 400 RPM of en gine The minimum flow a new pump 46000 48000 and 49000 Se ries must produce is 1 75 gal per minute or 1 25 for 45000 Series at 465 pump RPM against a pressure of 700 psi The flow plunger permits a maximum flow of 2 3 gal per...

Page 480: ...mum of restriction to oil flow in the straight ahead position b Right Turn Figure 8 23 illustrates the opera tion of the gear when the steering wheel is turned to the right Due to the resistance to turning be tween the front wheels and the roadbed the torsion bar is de flected changing the relationship between the slots in the valve spool and the slots in the valve body The right turn slots on the...

Page 481: ...mber is forced through the valve back to the reservoir When the driver stops applying steering effort the valve spool returns to its straight ahead position d Check Valve Poppet The check valve is located in the pressure port of the housing un der the connector The valve con sists of a poppet and a spring and its purpose is to reduce the pos sibility of steering wheel kick back If when making a tu...

Page 482: ...ficient pressure build up in gear power cylinder due to leak or faulty valve Incorrect installation or operation of the gear check valve poppet 1 2 3 4 POOR RETURN OF STEERING GEAR TO CENTER Lower coupling flange rubbing against ad juster plug Tighten pitman sector to rack piston nut adjustment Rack piston nut to worm preload too tight Thrust bearing adjustment incorrect Sticky valve spool PUMP IN...

Page 483: ...THE RIGHT OR TO THE LEFT Air in system Low oil level in pump High internal leakage EXTERNAL OIL LEAKS 1 2 3 Bleed gear Check oil level in pump reservoir Replace rack piston ring and back up O ring rack piston nut end plug seal and or replace valve NOTE Wipe gear and pump thoroughly and make sure source of leakage is determined 1 2 Gear leaks a Loose hose connections b Damaged hose c Side cover O r...

Page 484: ...eased lash when off the high point This is normal and the lash must not be reduced below the specified limits to eliminate this slight rattle b Gear loose on frame Gear Noise hissing sound A hissing noise is natural when steering wheel is at end of travel or when slowly turning at stand still Gear Noise squawk when turning or when recovering from a turn Cut or worn dampener O ring on valve spool C...

Page 485: ... steering wheel pressure should not exceed 125 psi See Figure 8 25 Check operation of check valve poppet paragraph 8 16 subparagraph c Step 6 f Lap away light scoring Replace heavily scored part g Install properly h Free up by removing burrs or dirt i Replace part j Lap away light scoring Replace heavily scored part k Lap away light scoring Replace heavily scored part 1 Replace EXCESSIVE WHEEL KIC...

Page 486: ...ve open note the oil pressure on the gauge while turning steering wheel from one extreme position to the other Especially note the maximum pressure which can be built up with the wheel held in either right or left extreme position CAUTION Do not hold wheel in extreme position for an extended period of time because it will drastically increase the oil temperature and will cause undue wear on the oi...

Page 487: ...ts will indicate source of trouble as follows Step b pressure low and Step d pressure nor mal indicates faulty external oil lines or steering gear Step b and Step d pressures equally low indicates faulty oil pump a Remove kink b Remove hoses and remove restricting object or replace hose a Replace defective seals b Remove gear from car for disassembly and inspection of rings and housing bore c Remo...

Page 488: ...SE 45000 SERIES ONLY PINS TO BE 1 16 TO 1 8 THRU FLANGE AT ASM WITH GEAR NOTE PUMP TO GEAR HOSES MUST CLEAR EACH OTHER TO PREVENT CHAFING AND NOISE TRANSMISSIOfs 1 32 TO 1 16 DISTANCE BETWEEN GEAR LOWER FLANGE MUST BE MAINTAINED I o o 3 o n O c CO Figure 8 26 Power Steering Installation 45000 46000 48000 Series ...

Page 489: ...NSTALLATION NOTE PUMP TO GEAR HOSES MUST CLEAR EACH OTHER TO PREVENT CHAFING AND NOISE TRANSMISSION PINS TO BE 1 16 TO 1 8 THRU FLANGE AT ASSEMBLY WITH GEAR 1 32 TO 1 16 DISTANCE BETWEEN GEAR AND LOWER FLANGE MUST BE MAINTAINED STEERING GEAR ASSEMBLY 3 2 I o m 3 I 7s o 3 m to z o 00 Figure 8 27 Power Steering Installation 49000 Series ...

Page 490: ...ner seal does not bot tom on the counter bore Install the outer double lip seal and the second back up washer in only far enough to provide clearance for the retaining ring Install re taining ring 8 Fill pump reservoir to proper level Start engine and allow en gine to idle for at least three minutes without turning steering wheel Turn wheel to left and check for leaks 9 Remove tape and reinstall p...

Page 491: ...STEERING GEAR STEERING COLUMNS AND LINKAGE POWER STEERING 8 2 7 ...

Page 492: ...8 2 8 POWER STEERING STEERING GEAR STEERING COLUMNS AND LINKAGE FT 1 IlN 1 BOL LJ C O _ l z CN 1 3 Z F i z 25 M I o CCi CO 1 I BOL LL C O CN I to o CO CO I ...

Page 493: ... shaft overcenter preload The overcenter ad justment is made without remov ing gear from car thus on handling complaints this adjust ment should be checked and cor rected and car road tested before removing gear to change thrust bearing preload or ball preload 1 Remove pitman arm from pit man shaft See Figure 8 28 NOTE Never attempt to adjust steering gear with pitman arm connected to pitman shaft...

Page 494: ...ut 5 If readings are within specifi cations check and adjust if necessary pitman shaft over center adjustment Reading on torque wrench should be 4 to 8 inch pounds higher than was ob tained in Step 5 See Figure 8 33 This reading is taken when ro tating stub shaft through high point range with lash adjuster nut tight Torque required should not exceed 18 inch pounds 8 14 DISASSEMBLY INSPECTION AND R...

Page 495: ...STEERING GEAR STEERING COLUMNS AND LINKAGE POWER STEERING 8 3 1 o 0 O O c Q X LLJ ...

Page 496: ...d of adjuster plug by pressing against identification end of bearing using Tool J 6221 End of bearing must be flush with bottom surface of stub shaft seal bore Figure 8 41 Withdrawing Valve From Valve Body 2 Lubricate new stub shaft seal with automatic transmission oil and install seal with spring in seal toward adjuster plug using Tool J 5188 See Figure 8 38 Install seal only far enough in plug t...

Page 497: ... the spool with a steady rotating pull to pre vent jamming See Figure 8 41 If slight sticking occurs make a gentle attempt to reverse the withdrawal p r o c e d u r e If this does not free spool it has become cocked in the valve body bore Do not attempt to force the spool in or out if it becomes cocked but continue with the following step CAUTION The valve spool must be removed with extreme care T...

Page 498: ...d If damaged the valve assembly should be replaced f Reassembly of Rotary Valve Assembly CAUTION All parts must be free and clear of dirt chips etc before assembly and must be pro tected after assembly 1 If removed from valve body lubricate three new ring back up O ring seals in automatic transmission oil and assemble in the three ring grooves on the valve body Assembly three new valve body rings ...

Page 499: ...e gear housing should be fully visible when valve is assembled properly See Figure 8 47 CAUTION Do not push against the stub shaft during assembly as this may cause the stub shaft and cap to pull out of the valve body allowing the spool dampener O ring seal to slip into valve body oil grooves Be sure valve is properly seated before install ing adjuster plug assembly 2 Place Seal Protector J 6222 o...

Page 500: ...cover for exces sive wear or scoring If worn or scored replace side cover 2 Check the pitman shaft sector teeth and the bearing and seal surfaces If worn pitted or scored replace pitman shaft 3 Check the torque on the lash adjuster See Figure 8 49 If torque exceeds 15 inch pounds pitman shaft assembly should be replaced d Reassembly of Pitman Shaft Assembly 1 If pitman shaft needle bearing was rem...

Page 501: ...K PISTON NUT AND WORM ASSEMBLY a Removal of Rack Piston Nut and Worm Assembly 1 Thoroughly clean exterior of gear assembly with a suitable solvent Drain the unit by placing the valve ports down and turning the worm through its entire range two or three times 2 Remove pitman shaft assem bly as outlined in paragraph 8 15 a 3 Rotate housing end plug re tainer ring so that one end of ring is over hole...

Page 502: ...s To install new con nector use Replacer J 6217 to drive connector in place 6 Check the operation of check J 5853 JT TORQUE WRENCH l l l j RACK PISTON 2 M P NUT SHB Pi 3 4 i SOCKET VALVE ASSEMBLY WORM I Figure 8 57 Checking Rack Piston Nut Ball Preload valve poppet located under con nector in pressure port of hous ing Poppet should reseat itself against connector after being lightly pushed down If...

Page 503: ...assembly to a horizontal position in the vise and insert ball retaining Tool J 7539 in end of worm and turn worm out of the rack piston nut Do not allow the tool to separate from the worm until worm is fully removed from rack piston nut e Installation of Rack Piston Nut and Worm Assembly 1 Assemble lower thrust bearing and races on worm Install new cap to worm O ring seal As sembly rotary valve as...

Page 504: ...nd on bench and press down on housing until shaft is free Turn housing over and remove shaft and rotor assembly being careful not to drop parts If the two dowel pins did not come out with assembly remove dowel pins from housing 12 Remove and discard pres sure plate O ring seal 13 Remove shaft seal if defec tive by prying out with small screwdriver b Inspection of Oil Pump Parts Clean all parts tho...

Page 505: ...ss down with thumb on splined end to properly seat shaft Be careful not to damage shaft seal in housing 5 Install the two dowel pins in housing and install thrust plate on the pins with ported face of plate to rear of housing 6 Install pump ring with small holes in ring on dowel pins and with arrow on outer edge to rear of housing 7 Install rotor on pump shaft with alignment sleeve toward front of...

Page 506: ...ing in housing Press end plate down by tightening studs until ring groove in housing is evenly exposed Install retaining ring Be sure ring is completely seated in housing groove and end plate is aligned properly Remove studs CAUTION Press end plate into housing only far enough to install retaining ring in groove 14 Install new reservoir O ring seal on housing Place a new small reservoir to housing...

Page 507: ...him stock approximately 2 1 2 long around shaft and push it past seal until it bottoms in pump housing See Figure 8 65 7 Remove seal by cutting metal body of seal with a sharp tool and prying out See Figure 8 65 Ex treme care must be used to pre vent damage to shaft and pump housing b Installation 1 Place seal Protector J 7586 over shaft Lubricate new seal with automatic transmission oil and drive...

Page 508: ...3 3 ft Series 49000 43 6 ft Toe in Caster Camber etc See Group 7 8 20 DESCRIPTION OF STEERING LINKAGE The parallelogram type steering linkage is used to connect both front wheels to the steering gear pitman arm The right and left tie rods are attached to a forged intermediate rod by ball studs The left end of the intermediate rod is supported by the pitman arm and the right end by an idler arm whi...

Page 509: ... NOTE TIE ROD END NUTS MUST BE PULLED UP TO TORQUE AND TIGHTENED TO NEAREST SLOT FOR INSERTION OF COTTER PIN THE NUT MUST NEVER BE BACKED OFF TO INSERT COTTER PIN FACE OF INNER TIE ROD BALL STUD MUST BE PARALLEL WITHIN 4 DEG TO FACE I OF INTER MEDIATE ROD BOSS WHICH IS 90 TO C _ OF STUD NOTE THE NUMBER OF THREADS VISIBLE ON TIE ROD AND TIE ROD BALL STUD SHOULD BE EQUAL BEFORE TIGHTENING CLAMP NUTS...

Page 510: ...e idler arm bushing until the dis tance from the center of the sup port lower bolt hole to the nearest face of the idler arm is 2 15 16 to 3 1 16 as shown in Figure 8 67 and 8 69 When the idler arm is installed on support it must be free to rotate a minimum of 90 degrees in a counterclock wise direction IMPORTANT If the Saginaw idler arm support is dismounted from the frame for other work wire the...

Page 511: ...AN SHAFT NUT TO ASSEMBLE PITMAN ARM TO PITMAN SHAFT USE PULLER FOR REMOVAL NOTE TIE ROD END NUTS MUST BE PULLED UP TO TORQUE AND TIGHTENED TO NEAREST SLOT FOR INSERTION OF COTTER PIN THE NUT MUST NEVER BE BACKED OFF TO INSERT COTTER PIN BOTTOM OF HOUSING ON TIE ROD END MUST BE APPROX PARALLEL WITH STEERING ARM BOSS AFTER TIE ROD CLAMPS ARE TIGHTENED 2 O O m I to 3 s o VIEW C 00 Figure 8 68 Power S...

Page 512: ...ER SHIFT TUBE ASSY LOWER HOUSING SCREW 2 CORNERING LIGHTS ONLY NOTE ADJUST UPPER BEARING UNTIL LEVERS MOVE FREELY WITH 005 MAX TOTAL CLEARANCE BETWEEN LEVERS AND SPACER RETAINER SPRING SEAL UPPER BEARING SPACER FIRST REVERSE NOTE LOWER BEARING MUST BE TIGHT AGAINST JACKET ASM BEFORE ADJUSTING BEARING M AM REINFORCEMENT BEARING ASM STEERING SHAFT MANUAL STEERING STEERING WHEEL VIEW A r LEVER ASM SE...

Page 513: ...LY CLIP NOTE WHEN INSTALLING RING AND SEAL IN PROPER POSITION ON SHAFT GENEROUSLY LUBRICATE BETWEEN SEAL AND SHAFT USING GREASE GUN WHILE ROTATING SEAL ON SHAFT PINS TO BE 1 16 TO 1 8 THRU FLANGE STEERING SHAFT FLANGE MANUAL STEERING STEERING SHAFT POWER STEERING 3 70 S 70 8 i 2 o O 00 Figure 8 70 Automatic Transmission and Four Speed Transmission Console Shift Steering Column Manual and Power Ste...

Page 514: ...CREW WASHER WASHER WASHER SPRING WASHER M A S T JACKET SPRING HOUSING LOWER HOUSING SCREW CORNERING LIGHTS ONLY L RETAINER BEARING ASM STEERING SHAFT MANUAL STEERING STEERING SHAFT POWER STEERING STEERING WHEEL 1 3 4 BOTTOM EDGE OF WHEEL TO HOUSING FOR PART NO SEE DASH UNITS FRONT FLOOR INSTALLATION ASM SEAL BUSHING PINS TO BE 1 16 1 8 THRU FLANGE o O n O O 3 o n O Figure 8 71 Automatic Transmissi...

Page 515: ...tman Shaft Oil Seal Installer J 6221 End Cover Bearing Remover and Installer AdjusterPlug Needle Bearing J 6222 End Cover Seal Protector Stub Shaft Protector J 6657 Pitman Shaft Needle Bearing Remover and Installer J 7539 Power Steering Gear Ball Retaining Tool J 7624 Power Steering Gear Adjustable Spanner Wrench J 7663 Power Steering Pump End Plate Installer J 8564 Worm Shaft Oil Seal Installer M...

Page 516: ...e support and actuator and pro vide for the spring return of the steering wheel to the upward position The upper shaft is secured in the actuator assembly by an upper and lower bearing The bearings are preloaded by means of a 12 sided nut on the steering shaft When the lever is released the lock shoes will engage the pins in the support and hold assembly at angle desired When the tilt wheel releas...

Page 517: ... in the sequence that they are removed 1 Remove steering wheel ref par 8 5 2 Remove direction signal switch from mast jacket Disconnect control cable from switch 3 Remove direction signal lever and tilt wheel release lever 4 Straighten locking tabs of lock plate see Figure 8 74 and re move 12 sided nut lockplate and inner race seat from upper por tion of mast jacket HORN CONTACT RIN 1 UPPER BEARIN...

Page 518: ...t and support from mast jack et Refer to subparagraph a 3 Remove the shift tube retainer ring and washer from the top of shift tube See Figure 8 80 4 Remove steering shaft bearing and adapter from the lower end of the mast jacket 5 Remove the shift tube down ward through column using two Slide Hammers J 7004 and Re mover J 21180 see Figure 8 81 6 Remove lock plate wave washer and shift bowl from u...

Page 519: ...ver compress joint preload spring enough to remove from upper shaft then remove spring from centering spheres See Figure 8 84 3 Turn upper shaft 90 from centerline of lower shaft and re move shaft over flats of centering sphere 4 Remove the sphere from the upper shaft by rotating so sphere flats align with shaft socket LOCK SHOE SHOE RELEASE ACTUATOR SIGNAL SWITCH CABLE RUBBERJ STOP TOP VIEW BOTTO...

Page 520: ...tuator 8 Raise tilt release lever and position actuator at extreme up position 9 Connect the upper ends of the two tilt springs using Installer J 21181 See Figure 8 86 to lobes on actuator 10 Install the turn signal actuator yoke and detent spring Be sure yoke engages turn signal cable operating lever in actuator 11 Install upper bearing inner race plastic bearing cap and horn contact ring in orig...

Page 521: ... ONLY PIN COLUMN SHIFT ONLY UPPER HOUSING LEVER DIRECTION SIGNAL DIRECTION SIGNAL SWITCH TRANSMISSION SHIFT POINTER ASSEMBLY LEVER WHEEL POSITIONING NEUTRAL SAFETY NOTE WITH SHIFT TUBE INFARK POSITION LIGN HOLE IN SWITCH ASM WITH SLOT IN LEVER BEFORE TIGHTENING MOUNTING SCREWS INSTALLATION FOR 49000 SERIES ONLY SCREW LOWER HOUSING LEVER TRANS SHIFT POINTER ASSEMBLY LEVER VIEW B AUTOMATIC TRANSMISS...

Page 522: ...8 5 8 TILT STEERING COLUMN STEERING GEAR STEERING COLUMNS AND LINKAGE o 0 0 0 ...

Page 523: ... which prevents accurate measurement of tightness Name Nut Brake Pedal Pivot Shaft to Mounting Bracket Screw Wheel Cylinder to Brake Backing Plate Nut Brake Cylinder and Pedal Mounting Bracket to Dash Standard and Power Bolt Nut Brake Assembly and Steering Arm to Knuckle Front 49000 Bolt Nut Brake Assembly and Steering Arm to Knuckle Rear 49000 Bolt Nut Brake Assembly and Steering Arm to Knuckle F...

Page 524: ...ribs and fins for better heat dissipation while the cast iron liner provides the best braking surface The lighter 45000 Series has finned all cast iron drums The brake assembly at each wheel uses a primary front and sec ondary rear brake shoe of welded steel construction with one piece lining attached by tu bular rivets The primary shoe lining is shorter and thinner than the secondary shoe lining ...

Page 525: ...of the idler lever and a ball on the forward end of each rear cable engages a slot in this equalizer See Figure 9 3 and 9 4 On the 45 46 and 48000 Series the parking brake control system uses a foot operated lever con duit enclosed front cable non en closed connecting cables and brake shoe levers and struts By means of an equalizer the front parking brake cable is connected to the forward portion ...

Page 526: ...ice Brake Control System Standard Brakes NOTE See Sections 9 D and 9 E for power brakes The regular foot powered service brake control system is a pedal operated hydraulic system which applies the brakes at all four wheels with equalizer pressure The hydraulic system consists of one master cylinder connected by pipes and flexible hoses to a wheel cylinder mounted between the brake shoes at each wh...

Page 527: ...1 LB IN BRACKET VIEW B VIEW C MANUAL JPIPE ASM SHOWN CLIP 2 FRONT SPRING SUPPORT CROSS MEMBER CONV ONLY VIEW D PIPE ASM r NUT 2 80 110 LB IN l PIPE ASM NUT 2JI 80 1101 LB IN CLIPS SEE FUEL SYSTEM INFORMATION ASM HOSE ASM 80 100 LB IN PIPE ASM PIPE ASM NUT 2 80 TiOTLB IN l CLIP 137396 NUT 2 80 110 LB IN 9742802 HOSE ASM 2 1370334 HOSE ASM 2 25 30 LB FT AT WHEEL CYL 231343 WASHER 2 CLIPS 4 PART OF R...

Page 528: ... PIPE VIEW E CLIP PIPE ASSEMBLY NUT CLIPS 2 PART OF REAR AXLE HOUSING ASSEMBLY BEND CLIPS TO HOLD BRAKE PIPES SECURELY PIPE ASSEMBLY NUT L BRAKE P P E ASSEM MUST B E S K S S J SECURED FIRST AT FRONT BRAKE JUNCTION BLOCK NEXT AT REAR BRAKE HOSE AND FINALLY ON MCDLE OF FRAME FITTING ASSEMBLY BRAKE PIPE DIST SCREW MINIMI IM PIPE ASSEMBLY NUT VIEW B Figure 9 6 Service Brake Control System 49000 Series...

Page 529: ... operating conditions A vented cover and flexible rubber dia phragm at the top of the master cylinder reservoir seal the hy draulic system from possible en trance of contamination while at the same time permitting expan sion or contraction of fluid within the reservoir without direct vent ing In the pressure chamber a coil spring holds a rubber pri mary cup against the inner end of the piston This...

Page 530: ...l wheel cylinders Fluid forced into the wheel cylinders between the pistons and cups causes the pistons and connecting links to move outward and force the brake shoes into contact with the drums See Figure 9 9 View B Movement of all brake shoes into contact with drums is accomp lished with very light pedal pres sure Since pressure is equal in all parts of the hydraulic system effective braking pre...

Page 531: ...RY CUP SPRING CHECK VALVE A BRAKES RELEASED FLOW THROUGH CHECK VALVE PUSH ROD PISTON PRIMARY CUP PRESSURE CHAMBER B BRAKES BEING APPLIED FLOW THROUGH BLEEDER HOLES CHECK VALVE SEATED PISTON PRIMARY CUP C START OF FAST RELEASE FLOW AROUND CHECK VALVE COMPENSATING PORT SPRINGI PRESSURE CHAMBER D FINISH OF BRAKE RELEASE Figure 9 9 Operation of Brake Hydraulic System ...

Page 532: ...true test cannot be made if road way is crowned so as to throw weight of car toward wheels on one side or is so rough that wheels tend to bounce Test brakes at different car speeds with both light and heavy pedal pressure however avoid locking the wheels and sliding the tires on roadway Locked wheels and sliding tires do not indicate brake efficiency since heavily braked but turning wheels will st...

Page 533: ...ose Brake Backing Plate Tighten all backing plate bolts 3 Brake Shoes Not Properly Adjusted 4 Excessive Dust in Brake As semblies When excessive dust is present brakes are usually more severe Thoroughly clean brake shoe linings to remove embedded dirt par 9 10 5 Faulty Brake Shoe Linings or Drums Charred linings or scored drums cause grabbing action A small amount of grease or brake fluid on linin...

Page 534: ...roove in primary cup 3 Wheel Cylinder Piston Cups Distorted If the rubber parts in master cylinder are found to be swollen and distorted Step 2 above it indicates the presence in hydraulic system of a mineral base oil such as kerosene gaso line or engine oil Such sub stances will cause all rubber parts to swell and distort there fore it is necessary to thoroughly flush the hydraulic system par 9 6...

Page 535: ...ned with a noticeable lead shoes tend to follow lead and produce a regular slapping noise against backing plate during brake application Polishing drums with light emery cloth will reduce noise I Brakes Fade Fail to Hold The condition known as fade is caused by loss of friction be tween brake lining and drums as a result of abnormally high lining temperatures E x c e s s i v e heat cooks out the m...

Page 536: ...ng action Air will be introduced into the hydraulic system if the brake pedal is operated when the fluid is too low in master cylinder reservoir Air will also enter the system whenever any part of hy draulic system is disconnected It will be necessary to bleed the hydraulic system at all four wheel cylinders if air has been intro duced through low fluid level or by disconnecting brake pipe at mast...

Page 537: ...Unscrew bleeder valve 3 4 of a turn See Figure 9 10 4 Open pressure tank hose valve to apply fluid to master cylinder under pressure that does not ex ceed 35 pounds It is not neces sary to pump the brake pedal when using pressure tank 5 When fluid flows from bleeder tube into glass jar in a solid stream that is free of air bubbles that particular cylinder and line are bled tighten bleeder valve se...

Page 538: ...ake adjust ment as described in paragraph 9 8 5 Remove jacks and road test car for service and parking brake performance par 9 4 9 8 PARKING BRAKE ADJUSTMENT CABLE LUBRICATION a Adjustment Adjustment of the parking brake is necessary whenever the rear brake cables have been discon nected or when the cables have stretched due to extended use or if thicker linings have been installed On 49000 Series...

Page 539: ...replacing brake lining is to install new shoe and lining assemblies This insures brake shoes that are not distorted through use and linings properly riveted to shoes and ground to correct radius by accurate factory machinery Each brake shoe and lining set listed under Group 5 017 is packed in a carton containing two prima ry and two secondary shoe and lining assemblies enough for two wheels Sets a...

Page 540: ...e brake shoe adjust ment before the brake drums can be removed To back off shoe adjustment rotate shoe adjusting screw upward See Figure 9 11 2 Unhook the primary and sec ondary shoe return springs using large pliers 3 Remove shoe hold down springs 4 Lift up on actuator unhook actuating link from anchor pin then remove 5 Spread shoes to clear wheel cylinder connecting links remove parking brake st...

Page 541: ...0 Turn adjusting screws to provide an equal two hand drag and back off 30 notches for proper shoe clearance par 9 8 11 If any hydraulic connections were disturbed bleed hydraulic system par 9 7 If new parts were installed in brake system flushing of hydraulic system is recommended par 9 7 12 Adjust parking brake as de scribed in paragraph 9 8 13 Inspect all brake pipe hose and connections for evid...

Page 542: ...an be obtained If brake linings are to be re placed a grooved drum should be rebored for use with oversize linings subpar c following A grooved drum if used with new lining will not only wear the lin ing but will make it difficult if not impossible to obtain efficient brake performance b Out of round or Tapered Drum An out of round drum makes ac curate brake shoe adjustment im possible and is like...

Page 543: ... the edges NOTE Front wheel cylinder pis tons and cups are 1 1 8 dia meter and rear wheel cylinder parts are 1 diameter 7 Install wheel cylinder on brake backing plate and connect brake pipe or hose 8 Install brake shoes drum and wheel then flush and bleed hy draulic system par 9 6 9 Adjust brakes par 9 7 then road test car for brake perform ance par 9 4 9 13 BRAKE MASTER CYLINDER OVERHAUL a Remov...

Page 544: ...ed cylinder may not give satisfactory length of service e Installation of Brake Master Cylinder d Assembly of Brake Master Cylinder 1 Dip all internal parts in clean brake fluid just before installa tion Also wet master cylinder bore with brake fluid 2 Install valve seat washer check valve spring primary cup and piston with secondary cup Then install push rod and stop plate assembly Hold push rod ...

Page 545: ...hen the vacuum stored in the unit has been lost or in case of vacuum failure at the unit or its vacuum connec tions the brakes can be applied in the conventional manner Since the vacuum assist is not avail able the pedal force will be greater b Construction of Power Brake Unit The Unit is composed of two main sections The vacuum power cyl inder and the hydraulic master cylinder The vacuum power cy...

Page 546: ...28JLBS FT E ENDS OF CLAMP MUST BE A S S E M B L E D N wumibm POSITION AS SHOWN TRIM TABS MUST BE QRIMPED DOWN TO HOLD PEDAL TRIM PLATE SECURELY TO PAD PEDAL TRIM PLATE MUST BE HELD IN A SUITABLE L U 8 R 1 C A T E AREAS INDICATED FIXTURE TO PREVENT DISTORTION Q OF PLATE WHILE CRIMPING TABS CLAMP 2 N 300 CU IN ONLY 401 a 425 CU IN H Q S E VIEWB VIEW C VIEW D 09 70 Figure 9 15 Power Brake Installatio...

Page 547: ...EMENT BRKT ASM NUT 4 12O 28ILB FTI ASM ARM CYLINDER ASM 401 425 SINGLE 4 BBL CARB 8 4 2 5 2 4 BBL FRONT CARB VIEW C L0wlm T R I M T A B S M U S T B E C R M p E D PEDAL TRIM PLATE SECURELY TO PAD PEDAL TRIM PLATE MUST BE HELD IN A SUITABLE FIXTURE TC PREVENT DISTORTION OF PLATE WHILE CRIMPING TABS SCREW 2 09 70 m 3 m 70 00 TO m i Figure 9 15a Power Brake Installation 49000 Series ...

Page 548: ...so that its retaining ring rests against the power piston The floating control valve as sembly is held against the air valve seat by the floating control valve spring In this position the by pass hole in the hydraulic master cylinder is open to the reservoir and fluid can flow freely in either direction between the hydraulic cylinder and the fluid reservoir A residual pressure is maintained in the...

Page 549: ...o the brake pedal This gives the operator a feel which is proportional to the de gree of brake application In case of vacuum source inter ruption as the pedal is pushed down the end of the air valve contacts the reaction levers and forces them in turn against the hydraulic reaction plate Since the hydraulic reaction plate is fastened to the piston rod it f o r c e s the piston rod against the mast...

Page 550: ...eturned Figure 9 18 Power Brake Unit Holding the hydraulic master cylinder piston moves back and the fluid from the wheel cylinders flows back into the master cylinder through the check valve If the brake pedal is released quickly the master cylinder pis ton immediately returns to the released position If the fluid in the lines cannot return as quickly as the piston compensation is provided for by...

Page 551: ... t e d air f i l t e r elements e Worn or badly distorted re action plate or levers f Cracked or broken power pis ton or reaction retainer b Grabby Brakes Apparent Off and On Condition 1 Power brake unit valve trouble a Sticking air valve b Restricted diaphragm passage 2 Reaction system a Dislodged reaction levers b Broken air valve spring c Worn or distorted levers or plates c Pedal goes either t...

Page 552: ...ngs in line with master cylinder reservoir cover to facilitate re assembly 2 With the master cylinder res ervoir unit firmly clasped in a vise rotate the housings counter clockwise into the unlocked posi tion Use pry b a r s to assist removal as shown in Figure 9 20 NOTE Loosen housing carefully as it is heavily spring loaded 3 Lift the power piston assembly and rear housing from the unit 4 Remove...

Page 553: ...reaction bumper and the air valve spring retainer from the air valve See Figure 9 23 REACTION PLATE1 POWER PISTON Figure 9 23 Removing Reaction Retainer 3 Place Power Piston Wrench J 21524 in vise with square shank in vise Hold support plate and power piston with the tube of the power piston up See Figure 9 24 4 Pull the diaphragm edges away from the support plate so that the hands can grip on the...

Page 554: ...aned parts on clean paper or lintfree clean cloth 2 If slight rust is found inside either the front or rear half hous ing assemblies polish clean with crocus cloth or fine emery paper washing clean afterwards NOTICE Dirt is the major cause of trouble and wear in service Be sure to keep parts clean until reassembly Re wash at reas sembly if there is any occasion to doubt cleanliness such as parts d...

Page 555: ...tion or corrosion of I Dt or O D All seats to be smooth and free of nicks and dents Push rod must move freely in air valve but must not pull out CORRECTIVE ACTION Cleanup or replace Replace Clean Replace Replace Do not repair replace If worn replace air valve push rod assembly c Over All Unit PART Front Rear Half Housing Air Filters Silencer INSPECT FOR Scratches scores pits dents or other damage ...

Page 556: ...or equivalent on the O rings 2 The master cylinder piston rod is now inserted through the re action retainer so that the round end of the piston rod protrudes from the end of the tube on the reaction retainer 3 Place the Power Piston Wrench J 21542 in a vise Po sition the power piston on the wrench with the three lugs fitting into the notches in the power pis ton See Figure 9 29 SUPPORT PLATE REMO...

Page 557: ...iner with the notches in the power piston and push the reac tion retainer down until the ears seat in these notches 21 Maintain pressure on the re action retainer and position the large lock ring down over the master cylinder push rod 22 There is a lug on the power piston which has a raised divider in the center One end of the lock ring goes under the lug and on one side of the divider See Figure ...

Page 558: ...wer brake assem bly in a vise so that the master cylinder is up Remove the mas ter cylinder from the front housing The master cylinder push rod is now exposed 2 Place Gauge J 7723 01 over the piston rod so that it fits be tween the two studs on the front housing It should be parallel to the studs and resting on the sur face of the housing The cutout portion of the gauge should never be lower than ...

Page 559: ...to deplete all vacuum reserve in the system Depress brake pedal hold light foot pressure on the pedal and start the engine If the vacuum system is operating the pedal will tend to fall away under foot pressure and less pressure will be required to hold pedal in applied position If no action is felt the vacuum system is not functioning 3 Stop engine Again deplete all vacuum reserve in the system De...

Page 560: ...et and an atmospheric port and a vacuum port The vacuum port seat is a part of the valve body attached to the power piston as sembly The atmospheric port seat is a part of the valve plunger which moves within the valve housing and power piston assembly 3 A single piston hydraulic mas ter cylinder of the Lealed type is used with the power brake and contains all of the elements of Figure 9 34 Extern...

Page 561: ...he valve return spring to CLOSE the atmospheric port and OPEN the vacuum port With the valve in this position the chamber to the rear of the power piston is also open to vacuum through the porting in the valve housing Since vacuum is present on both sides of the diaphragm the power piston return spring is free to re turn the power piston assembly and the hydraulic push rod to the fully released po...

Page 562: ...ir respective contact areas The pressures acting against the air valve plunger and valve oper ating rod tend to move the air valve plunger slightly to the right in relation to the power piston and valve housing assembly to close off the atmospheric port Since this counter force or reac tion force is in direct proportion to the hydraulic pressure de veloped within the brake system the driver is abl...

Page 563: ...ston full power application is attained which is referred to as the run out point of the power unit Any increase in hydraulic pressure Figure 9 37 Power Brake Applied Position beyond this point must be supplied by physical effort of the driver 9 24 REMOVAL INSTALLATION ADJUSTING TESTING OF POWER BRAKE UNIT j Removal of Power Brake Unit 1 Disconnect brake pipe from hydraulic m a s t e r cylinder an...

Page 564: ...ake pipe to hydrau lic cylinder 4 Connect vacuum hose to check valve on front housing 5 Bleed hydraulic system ac cording to procedure in paragraph 9 6 Bleed left front wheel cyl inder first and check for proper pedal feel If system still has air in it bleed other three wheel cylinders 6 After bleeding bring fluid level to 1 8 below lip of reser voir opening and install reservoir lid NOTE When pre...

Page 565: ...pedal with engine running Hold this pres sure at least 15 seconds and ob serve brake pedal If pedal goes down gradually check first for a leak in system outside of power brake unit When possibility of an external leak is eliminated leak is in hydraulic cylinder of power brake unit 3 Vacuum Leak Allow engine to idle a minute to build up vacuum reserve Shut off engine and wait several minutes at lea...

Page 566: ...er and remove air silencer with air filter from valve housing being careful not to chip plastic housing Remove dia phragm from power piston then remove valve retainer lock key valve and rod assembly Press out reaction disc from diaphragm plate See Figure 9 43 8 From the master cylinder re move snap ring piston assembly Figure 9 42 Removal of Seal Push Rod and Check Valve primary cup spring and ret...

Page 567: ... side in dome of cover and assemble cover hand tight See Figure 9 44 2 If rear bearing seal is to be replaced use Installer J 9540 to press bearing seal in rear shell with plastic side up See Figure 9 45 3 Apply power brake lubricant to O D of valve housing section of power piston and to bearing surfaces of air valve plunger and to outer edge of floating control valve Insert air valve plunger and ...

Page 568: ...bly by master cylinder in a vise 6 Install power piston return spring and then install rear hous ing assembly by using pry bars to rotate rear cover clockwise until scribe lines align NOTE When using pry bars make certain that nuts are in stalled on rear housing studs in 7 Remove master cylinder from housing 8 Apply power brake lubricant sparingly to hydraulic push rod keeping lubricant away from ...

Page 569: ...LVE RETURN SPRING DIAPHRAGM SILENCER RETAINER Figure 9 46 Assembly of Valve and Rod Lock Key Diaphragm Filter and Retainer FELT WASHER SEAL CHECK VALVE Figure 9 47 Assembly of Reaction Disc Push Rod and Seal Check Valve Retainer Plate Washer and Boot ...

Page 570: ...nd of rod with pliers and turn adjusting screw IN to shorten OUT to lengthen push rod Whenever adjustment is necessary use a height gauge to check dimension as follows 1 With master cylinder removea mount power brake in a vise with master cylinder push rod up 2 Place Gauge J 7723 01 over the piston rod so that it fits be tween the two studs on the front housing It should be parallel to the studs a...

Page 571: ...t Amps Hrs 20 Hr Rate Number of Cells Plates Cell Specific Gravity Full Charge 80 F Bench Charging Rate Start Bench Charging Rate Finish Separators Case Dimensions 10 1 4 45 Delco 1980558 R F Fender Skirt Negative 12 61 6 11 1 260 to 1 280 5 Amps 2 Amps Porous Rubber Hard Rubber x 6 13 16 x 8 27 32 High 46 48 49 Delco 1980570 L F Fender Skirt Negative 12 70 6 11 1 260 to 1 280 5 Amps 2 Amps Porous...

Page 572: ...Air Gap None No Moving Parts Voltage Setting After 15 Minutes Warm Up 14 3 Volts 10 3 CRANKING STARTER SYSTEM SPECIFICATIONS a Cranking Motor Make Number Location Side of Engine Type of Shift Shift Actuation Shift Operation Type of Drive Rotation Viewing Drive End Gear Ratio Motor to Engine No Teeth on Ring Gear and Drive Pinion Cranking Speed Engine RPM at Operating Temperature No Load Test Amper...

Page 573: ...gines 425 Engine 300 Engine Except Dual 4 Bbl Dual 4 Bbl with with Auto Trans Auto Trans Distributor Number less Cap 1111083 1111055 1111058 Timing Crankshaft Degrees before U D C with Vacuum Hose Disconnected and Engine Idling 2 1 2 2 1 2 12 Centrifugal Advance Crankshaft Degrees and RPM Start Advance RPM 550 to 750 600 to 800 550 to 950 Medium Advance Degrees RPM 12 to 16 1400 13 to 17 1400 1 2 ...

Page 574: ...use Block Fuse Block Fuse Block Fuse Block Fuse Block Fuse Block Fuse Block Fuse Block Fuse Block Fuse Block Fuse Block Fuse Block Fuse Block Fuse Block In Back of Lighter In Light Switch Under Left Kick Pad c Lamp Bulbs Location Bulb No Candlepower Ash Tray 1445 5 Ash Tray Riviera 53 1 Auto Trans Control Dial Console 1816 3 Back Up 1156 32 Clock Dial Riviera 1816 3 Cornering Except Riviera 1195 5...

Page 575: ...gnal and Stop Light Fuse See Par 10 5 b Horn Make and Type Delco Remy Solenoid Horn Number High Note 9000470 Low Note _ 9000469 Horn Amperage Draw at 12 Volts Either Horn 4 5 to 5 5 Horn Relay and Junction Block Number 9779867 Horn Relay Adjustment Closing Voltage 3 0 to 9 0 Speed Warning Buzzer Number 1361529 Amperage Draw 14 5 Volts 14 Max ...

Page 576: ...ay re sult from inactivity and self discharge All automotive wet batteries will slowly discharge on standing idle whether in stored vehicles or in stock and will self discharge much faster when warm than when cold Batteries in stock should be rotated and the older ones used first Figure 10 1 Battery To minimize the extent of self discharge always store batteries fully charged and in cool place whe...

Page 577: ...ntainer for antidotes to use if electrolyte comes into contact with the body It is strongly recommended that a person filling batteries with electrolyte wear glasses prefer ably safety glasses to prevent possible damage to the eyes should any spattering of the elec trolyte occur 1 Remove dry charged battery from its original carton 2 Remove the vent plugs 3 Using a glass or acid proof plastic funn...

Page 578: ...ight at battery posts engine mounting bracket and junction block If a connection is found loose it should be cleaned before being tightened as arcing and corrosion may have taken place in the loose connection Check condition of cables and re place if badly corroded or frayed See paragraph 10 11 for instruc tions on cleaning and tightening cable terminals and replacement of cables 10 9 LIGHT LOAD T...

Page 579: ...se early failure Such high readings are caused by improper addition of electrolyte Adjusting the specific gravity will not correct the damage that has been done by high specific gravity b Use of Hydometer The hydrometer measures the percentage of sulphuric acid in the battery electrolyte in terms of specific gravity As a battery drops from a charged to a dis charged condition the acid leaves the s...

Page 580: ...onnected in s e r i e s with the ammeter 1 Adjust rheostat to provide maximum resistance OFF position 2 Connect ammeter positive lead to battery terminal stud on junction block Connect ammeter negative lead to one side of rheostat and connect other side of rheostat to ground on engine preferably at point where battery ground strap is attached In the instrument shown in Figure 10 5 the ammeter and ...

Page 581: ...ls are gassing freely Due to the low rate during slow charging plenty of time must be allowed Charge periods of 24 hours or more are often required b Quick Charging Since time is often of most im portance to the battery owner quick charging must sometimes be used to partially charge the battery so that the engine will start and the owner can be on his way Charge at 50 amperes for 20 minutes 50 x 2...

Page 582: ...ure of a battery consideration must be given to the conditions under which the car is operated In very low temperatures the ca pacity of a storage battery is con siderably reduced and the energy required for cranking the engine is considerably increased Frequent starting particularly in cold weather accompanied by short runs may take more energy from the battery for cranking than the generator can...

Page 583: ...he charging cir cuit Failure to observe these precautions will result in serious damage to the e l e c t r i c a l equipment 1 When installing a battery always make absolutely sure the negative post is toward ground 2 When connecting a booster battery make certain to connect the negative battery terminals to gether and the positive battery terminals together 3 When connecting a charger to the batt...

Page 584: ...ould be between 2 2 and 2 6 amperes An ammeter reading above the specified value indi cates shorted windings If the rotor is not defective but the generator failed to supply rated output the trouble is in the stator or rectifying diodes c Stator Checks To check the stator windings re move all three stator lead attach ing nuts and then separate the stator assembly from the end frame The fit between...

Page 585: ...that the slip rings will be cleaned evenly Cleaning the slip rings by hand without spinning the rotor may result in flat spots on the slip rings causing brush noise Slip rings which are rough or out of round should be trued in a lathe to 002 inch maximum indicator reading Remove only enough ma terial to make the rings smooth and round Finish polish with crocus cloth and blow away all dust g Bearin...

Page 586: ...placement The heat sink may be replaced by removing the BAT and GRD terminals from the end frame and the screw attaching the con denser lead to the heat sink Dur ing reassembly note carefully the proper stack up of parts as shown in Figure 10 15 j Reassembly Reassembly is the reverse of disassembly See Figure 10 16 for connection of internal leads Remember when assembling the pulley to secure the ...

Page 587: ...h the generator indicator light in the instrument cluster causing it to light to the 4 terminal of the regulator See Figure 10 22 The indicator light circuit allows only about 1 4 ampere to flow which is not sufficient to initially energize the field Therefore a parallel circuit is necessary this circuit allows about 3 4 ampere to flow from the ACC terminal through the large cowl connector through...

Page 588: ...ield current When the contacts are open the entire field current must flow through the resistor which limits current to about 3 4 ampere While the lower contacts are vibrating then field current will be somewhere between 2 amperes and 3 4 ampere depending on the rate of vibration c Both Contacts Open When the balance of the accessory load and the engine speed is such that approximately 3 4 ampere ...

Page 589: ...4 Check generator output Hook up test instruments and check current output of generator as described in Delcotron Generator Tests paragraph If output is low remove generator for disassem bly test and repair If generator output tests okay leave test in struments hooked up and proceed with Step 5 5 Check voltage regulator set ting as described in Delcotron Generator Tests paragraph If voltage fluctu...

Page 590: ...e indicates it is necessary A sooty or dis colored condition of the contacts is normal after a relatively short period of operation and is not an indication that cleaning is neces sary However if the voltage fluctuates as evidenced by an un steady voltmeter reading when checking the voltage setting the contacts may have excessive re sistance or be sticking and they therefore should be cleaned CAUT...

Page 591: ...test light connec tions and again observe light The test light should light in only one of the two directions 5 If the test light lights in both directions in either Step 3 or Step 4 there is at least one de fective diode Remove generator and disassemble on bench Test diodes individually and replace as necessary c Test and Adjust Voltage Regulator Setting 1 Test current output as de scribed above ...

Page 592: ... determine the proper voltage setting The proper setting is attained when the battery remains fully charged with a minimum use of water If not circuit defects are found yet the battery is continually undercharged raise the setting by 3 volt and then check for an im proved battery condition over a service period of reasonable length If the battery is contin ually overcharged lower the setting by 3 ...

Page 593: ...16 YELLOW 16 PINK r B R O W N OK BLUE OK GREEN LT GREEN l RED i A DELCOTRON IND OK GREEN PINK START 20 W0 RCT BAT GRD IGNITION SWITCH RES WIRE 1 8 OHMS 24 B W S RES WIRE 10 OHMS lU_r i I FUSE BLOCK THIS CIRCUIT USEO ON 4 7 0 0 CARS ONLY THIS CIRCUIT USEO ON 4 6 0 0 8 4800 CARS P s t t i 1 p 10 Figure 10 23 Delcotron Generator Wiring Diagram ...

Page 594: ...TEM When the ignition switch is turned fully clockwise to the START position a connection is made from the battery terminal of the ignition switch to the solenoid terminal of the switch From here a large wire carries the current to a terminal on the sole noid switch of the cranking motor A neutral safety switch is located in series in this wire The trans mission control lever must be in neutral N ...

Page 595: ... SIDE OF TEMPERATURE INDICATING SWITCH MAKES ON START POSITION ONLY SOLENOID PULL IN COIL HOLD IN COIL PLUNGER SHIFT LEVER CLUTCH PINION COMPRESSION SPRING CHARGE INDICATOR LAMP ACCESSORY SIDE OF FUSE BLOCK BATTERY NEUTRAL SAFETY SWITCH AUTO TRANS ONLY VOLTAGE REGULATOR 10 OHMS RESISTANCE IN HARNESS BAT DELCOTRON n i n IGNITION COIL o to 3 m p en Figure 10 24 Starter and Generator Circuit Diagram ...

Page 596: ...D FOR SYNCROMESH TRANSMISSION CARS OPPOSITION L TO HOT SIDE OF TEMPERATURE INDICATING SWITCH MAKES ON START POSITION ONLY SOLENOID PULL IN COIL HOLD IN COIL PLUNGER SHIFT LEVER 1 8 OHMS RESISTANCE IN HARNESS T THIS CIRCUIT USED IN W O O CARS ONLY THIS CIRCUIT USED IN 4 6 0 0 a 4 8 0 0 CARS BAT o DELCOTRON PINION COMPRESSION SPRING IGNITION COIL in Figure 10 25 Starter and Generator Circuit Diagram...

Page 597: ...to engagement with fly wheel ring gear by action of the solenoid upon the shift lever which engages the shift collar of drive assembly The shift collar moves the drive assembly by pushing on the clutch spring which serves as a cushion in case the pinion and gear teeth butt instead of meshing The helical splines assist in obtaining proper pinion engagement The drive pin ion is pulled out of engagem...

Page 598: ...CT FINGER SWITCH TERMINAL GROMMET BRUSH INSULATED BRUSH HOLDER BUSHING BRUSH SPRING GROUNDED BRUSH HOLDER SOLENOID PLUNGER RETURN SPRING ARMATURE FIELD COIL PINION STOP RRUNNING CLUTCH 00 n I Figure 10 26 Cranking Motor ...

Page 599: ... is due to an internal condition of engine This may be due to use of engine oil which is too heavy for prevailing temperatures 10 27 PERIODIC INSPECTION OF CRANKING MOTOR No periodic lubrication of the cranking motor or solenoid is required The cranking motor and brushes cannot be inspected with out disassembling the unit so no service is required on the crank ing motor and solenoid between inspec...

Page 600: ... amperes small starter See Figures 10 24 and 25 for dia grams of solenoid circuits S TERMINAL SOLENOID GROUND _ Figure 10 29 Solenoid Switch Contact Test Connections Figure 10 30 Amperage Test of Solenoid 5 Remove jumper wire from solenoid motor terminal and re adjust resistance until voltmeter reads 10 volts then note ammeter reading This shows current draw of hold in winding alone and should be ...

Page 601: ...between the in sulated terminal and the frame If lamp lights raise other brushes from commutator and check fields separately to determine whether it is the fields or armature that is grounded 2 Failure to operate with high current draw may result from a a direct ground in the termi nal or fields b Frozen shaft bearings which prevent the armature from turning 3 Failure to operate with no cur rent d...

Page 602: ...r lubricate solenoid plunger or plunger cylinder 2 Assemble solenoid by revers ing the disassembly procedure Install return spring Apply seal ing compound on both sides of solenoid flange where it extends between drive housing and field frame Then install solenoid 3 Lubricate armature shaft with silicone grease Install drive as sembly with pinion outward 4 Slide pinion stop retainer down over shaf...

Page 603: ...d into the instru ment cluster energizes the fuel gauge and indicator lights d In START all ignition switch supplied accessories are temporarily disconnected A con nection is made to the starter solenoid lead The water temper ature light circuit is temporarily grounded to provide a means of checking the TEMP light bulb When the ignition switch is re leased a spring returns it to ON 2 Ignition Coil...

Page 604: ...urces of elec trical energy the primary circuit contains the ignition switch igni tion coil resistance unit primary winding of the ignition coil dis tributor contact points conden ser and all connecting low tension wiring 2 The Secondary Circuit car ries the high voltage surges pro duced by the ignition coil which result in high voltage spark be tween the electrodes of the spark plugs in engine cy...

Page 605: ...trifugal Advance is gov erned by engine speed The cen trifugal advance mechanism is located above the circuit breaker cam inside the rotor and consists of an advance cam which is in tegral with the distributor shaft a pair of advance weights two springs and a weight base plate which is assembled to the dis tributor cam At idle speeds the springs hold the advance weights as shown in Figure 10 35A s...

Page 606: ...p or rotor 4 Inspect ignition cables for pos sible short circuits and corroded terminals Remove and inspect spark plugs par 10 36 5 If cause of trouble has not been found check approximate ig nition timing par 10 35 6 If engine still fails to run the trouble is probably due to causes other than ignition such as lack of fuel carburetion or compres sion loss 7 If spark did not occur at coil high ten...

Page 607: ...MITS 4500 5000 0 C2B P D V3P S Figure 10 37 Distributor Spark Advance Chart 300 Engine FLYWHEEL DEGREES TIMING TOTAL ADVANCE AUTOMATIC 1 ADVANCE 32 5 30 i C U S DISTRIBUTOR SPARK ADVANCE 401 425 CHIN ENGINE 40ia425 l 4BBL CARB ALL TRANSMISSIONS 425 2 4BBL CARB SYNCHROMESH TRANS j r k A PART THROTTLE VACUUM ADVANCE PLUS CENTRIFUGAL PRODUCTION LIMITS _ J _ I L 1 0 10 2 C f 00 3 s a I r 1500 0 s i 20...

Page 608: ...t point set over boss on breaker plate and under the two screw heads Tighten two screws and lock washers 3 Install condenser and primary leads NOTE Leads must be properly positioned so they will not come in contact with bottom of weight base or rotor 4 If engine does not start readi ly position contact arm rubbing block on peak of cam lobe insert a 1 8 Allen wrench in adjusting screw and turn scre...

Page 609: ...the starter will cause damage to this ground contact in the ignition switch To time the ignition on any engine which will run use subparagraph b only However if the timing of an engine is completely off the following procedure must first be used to get the engine to run 1 With rocker arm cover for No 1 cylinder removed rotate crankshaft in a forward direction using a suitable wrench on the harmoni...

Page 610: ... 8 Recheck timing mark 9 Reconnect vacuum hose and recheck idle 10 36 SPARK PLUG AND WIRE SERVICE a Rempve and Inspect Spark Plugs and Wires 1 To disconnect wires pull only on boot because pulling on wire might cause separation of the core of the wire Remove spark plugs and gaskets using a 13 16 deep socket wrench Use care in this operation to avoid cracking spark plug insulators 2 Carefully inspe...

Page 611: ...tle accelera tion with 45S spark plugs may re sult in damaged pistons When installing spark plugs make sure that gaskets are in good con dition to insure a tight seal and that all surfaces on plugs and in cylinder heads are clean Install spark plugs then tighten them to 30 ft lbs torque using a 13 16 socket an extension and a torque wrench If a torque wrench is not available do not tighten plugs e...

Page 612: ...ure because internal defects often fail to show up on a cold test 10 38 DISTRIBUTOR CONDENSER TESTS When a condenser is suspected of being faulty it should be tested with a reliable condenser tester to determine whether it is actu ally the cause of ignition trouble The condenser should be tested for a high series resistance b insufficient or excessive capacity c low insulation resistance A special...

Page 613: ... note the direction the vacuum unit points in relation to the engine so that the distrib utor can be replaced in the exact same position after it is serv iced See Figure 10 44 or 10 45 CAUTION If engine is turned over while distributor is out complete ignition timing proce dure must be followed par 10 33 3 Remove distributor clamp and lift distributor out of crankcase 4 Remove rotor from end of di...

Page 614: ...osition Repeat several times Springs should return weights to stop without sticking and there should be no excess free movement in the retard position b Cam and Weight Base Plate Inspect cam lobes for scoring or excessive wear Check weight base plate for bind or excessive looseness on distributor shaft c Breaker Plate Attempt to ro tate plate to check for excess free motion between plate and vacuu...

Page 615: ...in engine block so that rotor is pointing to mark made on distributor base with vacuum advance unit pointing in exact original direction Con nect vacuum pipe to advance unit 14 Install distributor clamp and bolt with lock washer leaving bolt just loose enough to permit move ment of the distributor with heavy hand pressure 15 Connect primary wire to dis tributor side of coil Install dis tributor ca...

Page 616: ...ng satisfactorily the lock cylinder can be removed as follows Figure 10 51 Ignition Switch 1 Draw a centerline on cylinder at 90 to left side of key slot insert key and make a prick punch mark on centerline 3 8 from side of key Carefully drill a 0465 hole No 56 drill through cylinder flange at this point 2 File the end of a stiff wire paper clip to a taper Insert this end of wire in drilled hole t...

Page 617: ... fully counterclockwise turns the dome light on The dome light can be turned on regardless of the in or out position of the switch b Description of Thermo Circuit Breaker A thermo circuit breaker is in corporated in the lighting switch assembly to protect wiring from damage due to short circuits in the headlight and front parking light circuits only The thermo circuit breaker con sists of a bi met...

Page 618: ...the negative post of battery 3 Adjust rheostat to give 26 am peres The circuit breaker should open within 60 seconds 4 Adjust rheostat to give 15 am peres on ammeter The circuit breaker should remain closed in definitely at 15 amperes 5 If circuit breaker does not operate as specified the lighting switch assembly must be replaced since internal repairs cannot be made f Dual Headlamp Assembly A dua...

Page 619: ...ovided by two adjusting screws which move the mounting ring in the body against the tension of the coil spring There is no adjust ment for focus since the sealed beam unit is set for proper focus during manufacturing assembly 10 43 PARKING TAIL STOP LICENSE BACK UP AND TRUNK LIGHTS NOTE See paragraph 10 5 for lamp bulb and fuse specifications Front Parking and Signal Lights Each front parking and ...

Page 620: ...R CODE WIRE HARNESS ASSEMBLY ENGINE COMPARTMENT RIGHT WATERPROOF CONNECTORS USE ASSEMBLY AID TO FACILITATE INSTALLATION CONNECTORS MUST SNAP V TOGETHER SECURELY SPEEDOMETER CABLE m o CLIP 3 CABLE ASSEMBLY BACK UP LIGHT SWITCH EXTENSION a 2 n Figure 10 53 Back Up Light Switch Wiring 4 Speed Transmission 3 m CO ...

Page 621: ...wise until gauge is parallel Then retighten screws 5 To recheck adjustment turn on ignition switch place shift control lever in reverse and make sure back up lights are lit Set parking brake place shift lever in Neutral and make sure engine will start Then place shift lever in Park and try starting engine again Engine must not start in Drive or Reverse 10 44 INTERIOR LIGHTS AND CIGAR LIGHTERS NOTE...

Page 622: ... is equipped with an ash guard to prevent ashes and loose tobacco from falling on the user s clothing and to permit the lighter to be passed around with out danger of burning the fingers The Casco lighter has a replace able thermal fuse screwed into the lighter base to protect the lighter element against over heating f Courtesy Lights The courtesy light has a 6 CP bulb located above the glove box ...

Page 623: ... on the steel hub of the steering wheel to ground the horn relay winding close the relay contacts and blow the horn When the actuator bar is released two springs move the actuator bar and contact plate assembly clear of the ground plate Current is supplied to the contact plate by a spring loaded brush which rides on the contact ring located at the upper end of the steering column A wire attached t...

Page 624: ...ARTRIDGE ASSEM SEE LUBE NOTE 1 032 1 022 WHEN MEASURED 1 00 FROM BOTTOM OF HUB o o z a I STEERING WHEEL ASSEM NOTE LUBRICATE HORN CONTACT RING IN STEERING COLUMN JACKET a HORN CONTACT IN STEERING WHEEL ASSEM APPLY SPARINGLY TO LOBES ON TURN SIGNAL CANCELLING CAM AND TO CONTACTING AREAS ON TURN SIGNAL ACTUATOR ARMS IN STEERING COLUMN WITH WHITE LUBRIPLATE BEFORE ASSEMBLY VIEW A OPTIONAL EQUIPMENT O...

Page 625: ...to short circuit in horn 3 Voltage between 7 and 11 in dicates that wiring is okay Look for sticking or improper adjust ment of horn 4 Voltage above 11 indicates im proper adjustment or open circuit in horn due to broken coil lead e Adjustment of Horns 1 Remove horn from car 2 Connect an ammeter in series with horn and a fully charged 12 volt battery to measure cur rent draw while horn is blowing ...

Page 626: ... front rear or indicator light first check fuse on fuse block marked DIR SIG Since this fuse also protects the stop light system functioning stop lights indicate that fuse is OK If fuse checks OK next eliminate flasher unit by substituting a known good flasher If new flasher does not cure trouble check signal system wiring connections at fuse block and at signal switch 2 Signals One Direction Only...

Page 627: ...ELECTRICAL SYSTEMS DIRECTION SIGNAL 1 0 5 7 p JC _c J 1 CO c D in 3 O ...

Page 628: ...M 2 SWITCH ASM NEUTRAL SAFETY LEVER WHEEL POSITIONING WITH SHIFTER TUBE IN PARK POSITION LIGN HOLE IN SWITCH ASM WITH SLOT IN LEVER BEFORE TIGHTENING MOUNTING SCREWS INSTALLATION FOR 4 9 SERIES ONLY SCREW 2 SCREW 49 45 46 48 TRANS SHIFT POINTER ASM 00 2 73 m 3 O in s 3 LEVER VIEW B OMIT ON ALL CONSOLE SHIFT JOBS Figure 10 58 Shift Pointer Neutral Safety and Turn Signal Switch Installation Tilt Whe...

Page 629: ...ELECTRICAL SYSTEMS DIRECTION SIGNAL 1 0 5 9 ICQ Q J Lu r r 1 I I i KOI Q f4 I v 3 _J S So i s Q DC or r r 2 OTCLO I LL 5 d ...

Page 630: ...own in Figure 10 60 or 62 con tains the speedometer fuel gauge indicator lights and clock For the instrument cluster location in the instrument panel see Figure 10 61 or 63 A printed circuit is used to com plete the circuits for all the lights AIR COND OUTLET BUZZER SETTING POINTER HOT GAS TEMP GAUGE LIGHT COLD TEMP i AMPERE LIGHT I LIGHT TRIP MILEAGE BUZZER SETTING KNOB OIL CLOCK PRESSURE RESET I...

Page 631: ...ew locations NOTE When removing the speedometer assembly from the instrument cluster housing it is not necessary to disconnect the speedo cable You only have to disconnect the speedo cable when the entire cluster housing is being removed When it becomes necessary to remove the instrument cluster housing to replace a defective printed circuit for instance pro ceed as follows 1 Disconnect battery 2 ...

Page 632: ...luster to the 4 terminal of the regulator through the lower contacts of the voltage regulator held closed by the spring out the F termi nal of the generator through the brush and slip ring through the field through another brush and slip ring to ground Before the engine is started the generator light should glow at about 1 2 brightness This is because the voltage in the circuit before the light is...

Page 633: ...Indicator Warning Light Circuits 45 Series This light should come on when the ignition is turned on and the engine is not running If not lit either the bulb is burned out the wiring has an open or the oil switch is defective below a safe level during opera tion the c i r c u i t is completed through the pressure switch to ground and the Oil indicator light in the cluster will be turned on If the e...

Page 634: ...E W O P C T WHITE WITH ORANGE ft PURPLE CROSS TRACER Figure 10 66 Indicator Warning Light Circuits 4 6 4 8 4 9 Series pressure switch if light stays on trouble is in wiring 2 Switch defective Replace switch e Temperature Indicator right cylinder head controls the operation of a Cold tempera ture indicator with a green lens and a Hot temperature indi cator with a red lens NOTE LeSabres do not have ...

Page 635: ...10 21 Negative diode shorted Loose or broken generator belt Resistance or open in field circuit Defective field light relay Bulb burned out Replace Open in light circuit Locate and correct Oil pressure switch defective Replace Wiring between light and switch grounded Locate and correct Oil pressure switch defective Replace Oil pressure below 2 lbs Locate cause and correct Bulb burned out Replace O...

Page 636: ...ed See Figure 10 67 or 68 There is no regulator knob be cause regulation is accomplished automatically by the action of re setting the time If a clock is running fast the action of turning the hands back to correct the tinie will automatically cause the clock to run slightly slower if a clock is running slow the action of turning the hands forward to correct the time will automati cally cause the ...

Page 637: ...is at fault The units and wiring may be tested by using a known good tank unit with a 12 foot piece of red insu lated 16 wire attached to bind ing post of unit and a similar 5 foot piece of black wire attached to flange of unit Attach a spring clip to end of black wire and a terminal to end of red wire 1 Test of Wiring Between Dash Unit and Tank Unit a Disconnect the tank unit tan wire at frame si...

Page 638: ...le There is a permanent magnet in the speed ometer head which rotates at the same speed as the cable This magnet exerts a pull on a speed cup causing it to move through an arc in direct ratio to the revolving magnet speed A pointer is at tached to the speed cup spindle to indicate speed on the speed ometer dial A calibrated hair spring part of speed cup opposes the magnetic pull on the speed cup s...

Page 639: ...T CABLE MUST BE LEFT FREE TO SLIDE IN HOLE THROUGH DASH PANEL UNTIL CLUSTER IS SECURED IN INSTRUMENT PANEL RETAINER SCREW ASSEMBLY VIEW B SYNCRO TRANS TORQUE I2O 8OILB INI SEE VIEWS A a B 70 n RUBBER GROMMET TURN INNER CABLE WITH THUMB FINGERS AT LOWER END TO MAKE CERTAIN THERE IS NO BIND IN SYSTEM BEFORE CONNECTING CABLE TO TRANSMISSION BINDING CABLES MUST BE REPLACED CHASSIS FRAME ON DASH TO FRA...

Page 640: ...BEFORE CONNECTING CABLE TO TRANS BINDING CABLES MUST BE REPLACED INSTRUMENT CLUSTER ASSEMBLY MOUNTED IN INSTRUMENT PANEL TORQUE 5 I O I L B I N TURN INNER CABLE WITH THUMB 8 FINGERS AT LOWER END TO MAKE CERTAIN THERE IS NO BIND IN SYSTEM BEFORE CONNECTING CABLE TO TRANSMISSION BINDING CABLES MUST BE REPLACED CHASSIS FRAME T O R Q U E H 2 0 8 0 J L B I N 1 SEE VIEW C FLEXIBLE SHAFT ASSEMBLY SPEEDOM...

Page 641: ...th the hot insulated pin on the safety buzzer pointer This grounds the circuit causing the buzzer to buzz If the car speed is increased beyond the safety buzzer setting the insu lated pin on the safety buzzer p o i n t e r picks up the hair spring as the speedometer pointer passes under the safety buzzer pointer and the light grounding hair spring winds up slightly 1 Buzzer Will Not Operate Or Ope...

Page 642: ...TRUMENT PANEL FOR HEATER a DEFROSTER CONTROL INSTALLATION FOR CLOCK INSTALLATION UPPER TIE BAR FOR INSTRUMENTS 8 SWITCHES IN INSTRUMENT PANEL LEFT COVER a INSTRUMENT ASSEMBLY COVE MOULDING TRIM PLATE INSTRUMENT PANEL CENTER ASH RECEIVER ASSEMBLY o 1 0 2 g n SECTION A A Figure 10 73 instrument Panel Installation Index ...

Page 643: ...ELECTRICAL SYSTEMS INSTRUMENT PANEL 1 0 7 3 Ld CO CO Q ...

Page 644: ...1 0 7 4 INSTRUMENT PANEL ELECTRICAL SYSTEMS ...

Page 645: ...ELECTRICAL SYSTEMS INSTRUMENT PANEL 1 0 7 5 I ...

Page 646: ...1 0 7 6 INSTRUMENT PANEL ELECTRICAL SYSTEMS o I I ...

Page 647: ...ELECTRICAL SYSTEMS INSTRUMENT PANEL 1 0 7 7 c o ...

Page 648: ...AME CREW 8 BRACKET INST PANEL LOWER TIE BAR TO PILLAR RT 8 LT CENTER DUCT PANEL BRACKET INST PNL COVER LEFT 2 BRACE FRONT BODY HINGE PILLAR TO DUCT PLATE INST PANEL MOUNTING SUPPORT TO DUCT PANEL MOUNTING BRACKET RT a LT SCREW 4 TO m FILLER PANEL INST PNL END Figure 10 79 Instrument Panel Mounting Bracket Installation ...

Page 649: ...ELECTRICAL SYSTEMS INSTRUMENT PANEL 1 0 7 9 ...

Page 650: ...R ASSEM RETAINER 4 CLAMP 4 VIEW IN CIRCLE A TYPICAL J NUT INSTALLATION VIEW IN DIRECTION OF ARROW B POSITION CLAMP BETWEEN COLUMN WIRES AS SHOWN VIEW IN DIRECTION OF ARROW C o 00 o 53 TO m Figure 10 81 Instrument Panel Cover Installation ...

Page 651: ...OR INSTALLATION OF CLOCK CLOCK ASSEM STD C SERIES OPT ON ALL B SERIES 73 O to SCREW 3 VIEW IN DIRECTION OF ARROW GASKET TELL TALE CLUSTER DEALER S NOTE LOOSEN SCREW DEALER S NOTE REUSE EXISTING SCREW WHEN REPLACING CLUSTER 70 132 40 1 OZ IN PLUG MOVE AND DISCARD o 00 Figure 10 82 Clock Installation ...

Page 652: ...RING HARNESS SCREW 2 KNOB ASSEMBLY VIEW IN DIRECTION OF ARROW A TACH LEAD BROWN TACHOMETER ASSEMBLY MEDALLION ASSEMBLY NOT SHOWN USED WHEN TACH IS NOT SPECIFIED p 00 s TO I CONSOLE ASSEMBLY VIEW IN DIRECTION OF ARROW B 1 Figure 10 83 Console Installation Wildcat with Auto Trans ...

Page 653: ...EGATIVE MARKED TERMINAL ON IGNITION COIL AS SHOWN TAPE WIRES AS SHOWN WHEN TACH IS NOT SPECIFIE WIRING HARNESS ASSEM CONSOLE CLIP 5 THIS CONNECTION IS MADE THROUGH TRASH RECEPTICAL OPENING AND THEN CLIPPED TO LOWER PORTION OF CONSOLE WITH SNAP IN CLIP ON CONNECTOR SCREW 2 BULB SELECTOR LEVER INDICATOR LAMP VIEW IN DIRECTION OF ARROW D SCREW 5 FORCE WIRES BETWEEN CONSOLE 8 BRACE TO PROVIDED CLEARAN...

Page 654: ... END PANEL TO CLOSE UP GAP INSTRUMENT CLUSTER TRIM PANELS ACCESS DOORS THESE SURFACES TO BE FLUSH 8 GAP 12 MAX TO BE EQUALLY DIVIDED BOTH SIDES 8 PARALLEL CONSOLE 8 ATTACHING PARTS IGNITION SWITCH MUST BE ASSEMBLED WITH PANEL TIGHT TO END PANEL TO CLOSE UP GAP m GLOVE BOX PANEL TRIM RIGHT LOWER INST PANEL COMPARTMENT BOX LAMP 8 SWITCHES RIGHT CENTER INSTRUMENT PANEL ASSEM TO n m Figure 10 85 Instr...

Page 655: ...ELECTRICAL SYSTEMS INSTRUMENT PANEL 1 0 8 5 ...

Page 656: ...o 00 CLUSTER ASSEM ELECTRIC CLOCK LIGHT SWITCH KNOB ASSEM MOULDING LOWER LT SNAP 2 RET NUT I48 60ILB INl CYLINDER ASSEMBLY TO s MOULDING LOWER HT Figure 10 87 Instrument Cluster Assembly Riviera ...

Page 657: ...L JOBS END PANEL SUPPORT NUT HEX FLANGE CLUSTER ASSEMBLY VERTICAL SUPPORT SCREW 5 LOWER REINE FLANGE SNAP 4 v MOULDING UPPER LT 7 x SCREW 5 SCREW 4 ACCESS DOOR LT 5 1 1 i o 00 N Figure 10 88 Instrument Cluster Installation Riviera ...

Page 658: ...SCUTCHEON STAKE SECURELY GLOVE BOX DOOR ASSEMBLY PANEL ASM CENTER RT MOULDING LOWER RT LOCK CYLINDER ASSEMBLY LATCH ASSEMBLY INSTRUMENT PANEL COMPARTMENT DOOR TO WIRING HARNESS LAMP ASSEMBLY COURTESY SCREW 2 O 00 00 I 3 n Figure 10 89 Right Center Instrument Panel Assembly Riviera ...

Page 659: ...ELECTRICAL SYSTEMS INSTRUMENT PANEL 1 0 8 9 ...

Page 660: ...E VIEW IN CIRCLE E TO WIRING HARNESS SWITCH PLATE SET SCREW VIEW IN DIRECTION OF ARROW Z PLATE ASSEM VIEW IN CIRCLE D NUT 4 SCREW 6 PANEL ASSEM INST PANEL LOWER RT TO I 2 n IS Figure 10 91 Center and Right Lower Instrument Panel Installation Riviera ...

Page 661: ...T BOX NON A C JOBS COMPARTMENT BOX A C JCBS CLIP FOR OWNERS GUIDE A C JOBS VIEW IN DIRECTION OF ARROW H REINFORCEMENT GLOVE BOX LIGHT ASSEA i SCREW 2 I n m m VIEW IN DIRECTION OF ARROW J Figure 10 92 Glove Box Installation Riviera ...

Page 662: ...IO SPEAKER GRILLE COVER ASSEMBLY BUMPER RUBBER 2 LATCH ASSEMBLY 2 SCREW 4 PAD UPPER INSTRUMENT PANEL COVER CEMENT TO COVER ASSEM I m UPPER TIE BAR m m 3 Figure 10 93 Instrument Panel Cover Assembly Riviera ...

Page 663: ...EMBLY CENTER TRIM SCREW 4 SCREW 2 BULB WIRE 8 SOCKET ASSEM SCREW 2 MOULDING KNOB 8 ELEMENT ASSEMBLY BASE 8 FUSE ASSEMBLY ASH RECEIVER ASSEMBLY PLATE ASSEM REAR TRIM LAMP ASSEM REAR COURTESY 9 n C l m o to Figure 10 94 Console Assembly Riviera ...

Page 664: ...1 0 9 4 INSTRUMENT PANEL ELECTRICAL SYSTEMS ...

Page 665: ... wiper gear box Figure 10 99 controls stopping the wiper The operation of the park switch is explained in the following para graph Refer to the wiring dia gram in Figure 10 101 When the car owner shuts the wiper off at the dash switch the motor circuit to ground is opened at the dash However the parking switch contacts which are normally closed maintain the motor circuit to ground at the wiper Thi...

Page 666: ... ness from wiper and check for 12 volts at harness terminal that connects to wiper terminal No 2 Figure 10 102 No voltage indi cates defective car wiring CAUTION DO NOT connect hot line to No 1 terminal c Connect 12 volt supply to No 2 wiper terminal and connect a jumper wire from terminal No 1 to ground Figure 10 102 If wiper operates the dash switch or wiring between dash switch and wiper is def...

Page 667: ...o o L o D MECHANICAL P PARKING SWITCH BLACK 16 YELLOW OFF ON 1 1 INSTRUMENT PANEL SWITC IN FUSE BLOCK UNLESS OTHERWISE SPECIFIED ALL WIRES ARE 18 GAUGE I n 3 to 70 O 09 O 2 o o Figure 10 100 Windshield Wiper Schematic Diagram Single Speed ...

Page 668: ... C SERIES OPTIONAL ON B SERIES TRANSMISSION NON OVER LAP REGULAR EQUIP B SERIES VIEW J VIEW H GROMMET W S WIPER NUT 2 ACCESSORY HOLE LEFT SIDE ONLY SHROUD LUBRICATE AS REQUIRED WIPER MOTOR VIEW K o 00 TO o to o 2 o 3 m Figure 10 101 Wiper Linkage Installation ...

Page 669: ...ELECTRICAL SYSTEMS TROUBLE SHOOTING 1 0 9 9 8 o ...

Page 670: ...for the following items 1 Open armature 2 Brushes sticking 3 Brush springs improperly po sitioned See Figure 10 104 4 Brush pigtail connections at splice joints Figure 10 103 c Current Draw 10 12 amps 1 Check for open shunt field circuit 2 Check for broken gear 2 Wiper Will Not Shut Off Wiper crank arm fails to stop in park position when jumper wire is removed from wiper terminal No 1 Figure 10 10...

Page 671: ...ssembly of Gear Box Cover Be sure cover is located properly over locating dowel pins and be sure to reinstall ground strap 2 Reassembly of Crank Arm Operate wiper to park position Figure 10 102 and install crank arm on output shaft in the position shown in Figure 10 100 Clamp crank in vise before securing the retaining nut c Motor Disassembly and Assembly 1 Follow Steps 1 thru 7 a under gear box d...

Page 672: ... Current Draw Amps No load 3 Max Dry windshield 3 5 Max Stall 11 0 Max 10 57 DESCRIPTION AND OPERATION TWO SPEED a General Description Single speed wipers are standard on 44 and 46 Series with the two speed overlapping system Figure 10 107 Motor Assembly available as an option The two speed overlapping system is standard on 48 and 49 Series Windshield washers are standard on all overlapping system...

Page 673: ...hes to the drive crank arm on the motor shaft on one end The right and left housing and link assemblies attach to the bell crank The linkage used with the overlap sys tem is different from that used on the single speed wipers and cannot be interchanged CAUTION It is important that when the wiper arms of the over lap system are in the park posi tion the right arm must be positioned below the left a...

Page 674: ...gear drive pawl lock pawl drive plate and shaft assembly and crank arm rotate as a unit See Figure 10 111 3 Wiper On High Speed Turning the wiper dash switch to the high speed position opens the shunt field circuit to ground at the dash switch However the shunt field circuit is then completed to ground through the resistor lo cated on the wiper terminal board See Figure 10 112 With the shunt field...

Page 675: ... e l y mounted d Fuse e With ignition switch turned on there is a 12 volt supply at cen ter terminal of wiper terminal board 2 Checking Wiper Operation Operate wiper independently of the car wiring or dash switch as shown in Figure 10 114 Check low and high speeds and if wiper shuts off correctly a If wiper operates correctly see TROUBLE CHART WIPER IN CAR b If wiper still fails to operate correct...

Page 676: ...ck the Following Items Open lead wire from wiper terminal 1 to dash switch Dash switch not securely mounted Dash switch defective Ground condition in lead from wiper termi nal 1 to dash switch Check for corroded wiper terminals Clean terminals and spread a thin coat of water proof grease over board Defective dash switch Open in lead wire from wiper terminal 3 to dash switch Dash switch mounting lo...

Page 677: ... plane accompanied by a loud Hunk 2 Drive pawl s p r i n g dis connected 3 Wiper has one speed fast caused by open shunt field 4 Wiper has one speed Fast 1 Shunt field open This usually results in typi _ _ cal trouble 3 2 D f active soldering a termi nal No 3 on wiper terminal board 5 Wiper has one speed Slow 1 Shunt field internally grounded 2 Shunt field lead to terminal board black grounded 3 S...

Page 678: ...der con nections at c i r c u i t breakers defective d To determine if relay coil is open connect test lamp to wiper Terminal No 1 Figure 10 116 If lamp doen t light coil is open or solder connection to No 1 Terminal is defective e Test relay switch as follows If gear mechanism is in full park position use a small screwdriver in the switch slot and push latch arm down toward relay coil See Figure ...

Page 679: ...d 5 Procedure C Wiper will not shut off Recycles NOTE Crank arm oscillates in a somewhat horizontal plane and is accompanied by a loud knock with each revolution of the gear a Check that drive pawl and relay latch arm springs are properly connected as shown in Figure 10 117 b Check wiper for low speed operation If wiper has high speed only check the following items 1 Solder joint at No 3 wiper ter...

Page 680: ...igure 10 115 Connect ammeter Range 0 3 0 amps in feed wire circuit to wiper and observe current draw Allow motor to run until it be comes hot 1 If current draw is normal 3 5 5 amps max and wiper cycles on and off a weak circuit breaker is indicated Replace case and brush assembly 2 If current draw exceeds 5 amps proceed to Steps c d and e c Adjust armature end play as required and recheck current ...

Page 681: ...ed in the housing under light pres sure and should be carefully checked prior to removal If necessary remove the field as follows a Cut the plain black and black with pink stripe leads that extend through the case assembly rub ber grommet in a location con venient for splicing b Cut the internal field leads enclosed in black plastic tubing approximately two inches from the brush holder to which th...

Page 682: ...be necessary at this point to rotate armature slightly before the worm will en gage with worm gear 6 Rotate the case as required to align the holes in the case with those in the housing 7 Being very careful not to pinch any of the motor leads between the case and edge of the field push the case onto the field until it butts against the housing 8 Secure the case to the housing with the two tie bolt...

Page 683: ...drive plate as shown in Figure 10 127 2 Assemble lock pawl over pawl as shown in Figure 10 128 3 Slide gear and tube over the drive shaft See Figure 10 129 Move drive and lock pawls as required to allow their respec tive pins to fit in the gear guide channel 4 Holding the gear manually ro tate the drive plate until the drive and lock pawl guide pins snap into their respective pockets in the gear 5...

Page 684: ...tch Mechanism Gear Shaft Seal Cap inside Armature Worm 2 Performance Operating Test Voltage Delco Remy Cranking Motor and Distributor Lubricant 12 Bench Check No Load Installed in Car 3 1 4 5 Amps 3 5 5 0 Amps Crank Arm Rotation CCW Crank Arm Speed RPM S Lo 40 50 Hi 70 85 Figure 10 121 Removing Field Coils THE TWO GROOVES INDICATED BY THE ARROWS SHOULD LINE UP WITH THE HOUSING TIE BOLT HOLES Figur...

Page 685: ...three wiper motor bolts 2 Replacement Reverse Steps f through a b Wiper Transmission 1 Removal a Remove wiper blade and arm DRIVE SHAFT PLATE ASSEMBLY DRIVE PAWL Figure 10 127 Assembly Drive Pawl on Drive Plate assemblies escutcheon retaining nuts and escutcheons b Remove air intake grille re taining screws Slide grille out from under reveal molding c Remove grommet from hole over wiper motor leve...

Page 686: ...ve the short shaft The other end of the pump slide lever is fitted with a rubber cup type pump diaphragm and a coil spring The ratchet pawl is slotted on the end opposite the pivot shaft The slotted end contacts a nylon ratchet wheel which has 21 teeth During pump operation the slot in the ratchet pawl slips over one tooth on the ratchet wheel and rotates the wheel one tooth at a time until the ra...

Page 687: ...the first stroke The pump completes one pumping stroke for each ratchet whell tooth move ment After the wheel has rotated approximately 1 2 turn the ramp engages the armature hair spring and moves it out from under t e armature The armature drops and the tang contacts the ratchet wheel but does not affect the ratchet pawl action After another 1 8 to 1 4 turn of the ratchet wheel the pump slide lev...

Page 688: ...1 0 1 1 8 WINDSHIELD WIPER ELECTRICAL SYSTEMS 8 E lo 1 I 8 ...

Page 689: ...ELECTRICAL SYSTEMS WINDSHIELD WIPER 1 0 1 1 9 8 ...

Page 690: ...GASKET SCREW 8 LOCK WASHER ASSEM 3 FOR NON OVERLAP WIPERS W S WIPER MOTOR FOR OVERLAP WIPERS VIEW B SELF DRILLING FILTER ASSEM SELF DRILLING SCREW 2 BRACKET ASSEM W S WASHER JAR SKIRT ASSEM BRACKET ASSEM VIEW D BOTTLE S CONCENTRATE VIEW C O m 5 in Figure 10 133 Wiper Motor and Washer Jar Installation ...

Page 691: ...ELECTRICAL SYSTEMS WINDSHIELD WIPER 1 0 1 2 1 ...

Page 692: ...O PUMP REMOVE TOP VENT GRILLE FOR TRANSMISSION d MOTOR ASSEMBLY TO DASH 312 DIA 2 H0LES DRILL THRU LOCATING DIMPLES AT ASM TUBING RUBBER 157 I D X51 00 LONG W S WASHER NOZZLE TO PUMP S TO TUBING RUBBER 218 I D X 13 00 LONG WASHER JAR TO PUMP FILTER WATER HOSE ASSEM ES BELOW LEFT HOOD HINGE TUBING RUBBER 218 D X 7 0 0 LONG CJVER TO FILTER COVER W S WAShER JAR W S WASHER JAR BOTTLE CONCENTRATE SCREW...

Page 693: ...ELECTRICAL SYSTEMS WINDSHIELD WIPER 1 0 1 2 3 P 8 g no 0 ...

Page 694: ...ENT GRILLE Z o OUSING NOZZLE ASSEM W S WASHER 2 TOWARD FRONT OF CAR in vl0 T S VIEW E VENT SCREEN V W B VENT GRILLE VIEW D CO en Figure 10 137 Windshield Wiper Linkage and Washer Nozzle Mounting Riviera ...

Page 695: ...straight hard push to seat it in the socket A hard steady pull on the terminal is required to detach if from the socket A central fuse block is mounted under the left side of the instru ment panel This fuse block serves as a convenient junction point for a number of circuits provides a mounting for the di rection signal flasher and con tains most of the fuses The fuse block is held in its bracket ...

Page 696: ...TER WIRING 3 0 0 CU IN ENGINE BATTERY STARTER AND ENGINE COMPARTMENT WIRING RIGHT HAND SIDE INSTRUMENT CLUSTER FUSE BLOCK AND PARKING BRAKE WIRING LIGHT INFORMATION 3 0 0 CU IN ENGINE WIRING LEFTj HAND SIDE 401 AND 425 CU IN ENGINE WIRING WINDSHIELD WIPER AND WASHER WIRING STEERING COLUMN AND STOP LIGHT SWITCH WIRING 2 o TO if m n INDEX ELECTRICAL INFORMATION Figure 10 138 Electrical Information I...

Page 697: ...H HEATER CONTROL B L A C K IGNITION SWITCH LAMP 7 IGNITION SWITCH PRINTED CIRCUIT ONNECTOR HEADLAMP SWITCH GLOVE BOX LIGHT SWITCH BLACK WHITE DBL BLK STR TO REAR COMPARTMENT WIRING MATES WITH FISHER WIRING IN RIGHT FRONT HINGE PILLAR REAR WINDOW DEFROSTER REAR SPEAKER POWER ANTENNA HEATER RED BLOWER GRAY SWITCH APE PINK TO AIR CONDITIONING TO CIGAR LIGHTER N S A f K BROWN STEERING COLUMN WIRING YE...

Page 698: ... BLUE PURPLE BLACK BROWN LT GREEN YELLOW DK GREEN TAN ORANGE WHITE RED OIL INDfCAT LAMF DIMMER SWITCH OMIT WHEN GUIDE MATIC IS SPECIFIED LTGREEN DK 6LUE DBL WHITE STRIPE GRAY DBL BLACK STRIPE GRAY PARKING BRAKE WARNING LAMP WHEN SPECIFIED INSTRUMENT WIRING HARNESS BLACK S DK GREEN DBL WHITE STRIPE RED DBL WHITE STRI PE WHITE BLACK GUIDE MATIC CONNECTOR TO DIMMER SWITCH COMPOSIT HARNESS ONLY FISHER...

Page 699: ...ER SECURELY TO BACK UP LIGHT T O NEUTRAL SAFETY SWITCH A AUTOMATIC TRANSMISSION WITH BACK UP LIGHTS 0 T O CORNERING LIGHT SWITCH CONNECTOR NEUTRAL SAFETY SWITCH CONNECTOR n m SWITCH f g 1 3 SPEED SYNCHROMESH TRANSMISSION WITH BACK UP LIGHTS TURN SIGNAL SWITCH TILT WHEEL TURN SIGNAL SWITCH WIRING o g o TO STEERING COLUMN AND STOP LIGHT SWITCH WIRING Figure 1 0 1 4 1 Steering Column and Stop Light S...

Page 700: ...BLACK LT GREEN BLACK 2 SEALED BEAM SEE HEADLAMP INSTALLATION DRAWING DK BLUE LTBLUE DBL BLK YELLOW BLACK DBL ORN STR HEADLAMP CONNECTORS CORNERING LAMP CONNECTOR SEE CORNERING LAMP INSTALLATION DRAWING THIS CONNECTION MUST BE MADE AFTER BUMPER IS INSTALLED AND PARKING LAMP PORTION OF CONNECTOR IS PLUGGED INTO WHEEL HOUSE WATERPROOF CONNECTON 2 HORN ASM SEE HORN HORN ASM INSTALLATION DRAWING ORANGE...

Page 701: ...ACKET WIRING HARNESS BOOT MUST BE SNAPPED ON TO DELCOTRON AFTER NUT IS TIGHTENED ASM ENGINE COMPARTMENT RIGHT HAND TO TRANS DOWN SHIFT SWITCH FEED WIRE DK GREEN POINT ADJUSTMENT FOR CONTINUATION SEE SHEET 7 300 CU IN ENGINE WIRING LEFT HAND SIDE CAPACITOR SCREW WHEN RADIO IS SPECIFIED CABLE ASM NO 3 5 CABLE s 73 n ASM NO I O g O 70 to Figure 10 143 300 Engine Wiring Left Side ...

Page 702: ... ASM NO 8 CLOSE CLIP AFTER HARNESS IS INSTALLE CABLE ASM NO 4 6 BATTERY EXISTING BOLTS DELCOTRON BRACKET CABLE ASM NO 2 CABLE ASM POS TO STARTER CABLE ASM NEG TO DELCOTRON MOUNTING BRACKET BOLT OIL PRESSURE SWITCH CLIP DRILL 25 HOLE AT ASM BATTERY GABLE AT ASM YELLOW PURPLE VIEW B STARTER WIRING 300 CU IN ENGINE BATTERY STARTER 8 ENGINE WIRING RIGHT HAND SIDE EXISTING BOLT t O a O TO CO n Figure 1...

Page 703: ...RIGHT HAND SIDE OF ENGINE EXISTING BOLTS BOOT MUST BE SNAPPED ON TODELCOTRON AFTER NUT IS TIGHTENED v XT GREEN DBL STR VIEW B AUTO TRANS WATFR TFMP SWITCH POINT ADJUSTMENT ENGINE GROUND WHFN RADIO IS SPECIFIED TRANS DOWN SHIFT SWITCH 3 3 S WIRING HARNESS ASM ENGINE COMPT RIGHT LESS CRUISE CONTROL A C 8 TACHOMETER WIRING HARNESS ASM ENGINE COMPT RIGHT CRUISE CONTROL A C a TACHOMETER O 401 425 CU IN...

Page 704: ...ALLATION WITHOUT POWER STEERING 46 ONLY CABLE ASSEMBLY JUNCTION BLOCK TO STARTER CABLE ASSEMBLY EXISTING BOLT BATTERY POWER STEERING PUMP BOLT STARTER SOLENOID CABLE ASM BATTERY NEGATIVE L WASHER EXISTING NUT VIEW B 401 a 425 CU IN ENGINE COMPARTMENT BATTERY STARTER WIRING VIEW C NEGATIVE BATTERY CABLE INSTALLATION WITH POWER STEERING Figure 10 146 401 and 425 Engrne Compartment Wiring ...

Page 705: ...BLUE TAPE BACK WITH 1366621 LEFT HAND ENGINE COMPARTMENT WIRING BLACK DBL ORANGE STR YELLOW DK BLUE YELLOW 3 WINDSHIELD WIPER SINGLE SPEED WINDSHIELD WIPER AND WASHER TWO SPEED 2 O g WINDSHIELD WIPER AND WASHER WIRING Figure 10 147 Windshield Wiper and Washer Wiring ...

Page 706: ...2 TAIL STOP 8 DIRECTIONAL LAMPS RNESS ASSEMBLY 4 5 4 6 SERIES REAR VIEW BULB I LICENCE LAMP BULB 2 BACK UP LAMPS 48 SERIES REAR VIEW FUEL GAGE GROUND WIRE FEED WIRE WIRING HARNESS ASSEMBLY BULB 6 TAIL STOP 8 DIRECTIONAL LAMP WATERPROOF C0NNECT0R 4 RING HARNESS ASSEMBLY VIEW A REAR LAMPS AND FUEL GAGE WIRING 2 3 n Figure 10 148 Rear Lamps and Fuel Gauge Wiring ...

Page 707: ...NG BULKHEAD CONNECTORS INSTRUMENT CLUSTER AND FUSE BLOCK IDENTIFICATION 425 CU IN V 8 ENGINE WIRING REAR LAMPS AND FUFL GAGE WIRING HEATER WINDSHIELD WIPER AND WASHER WIRING ENGINE COMPARTMENT WIRING BATTERY STARTER HORN RELAY 8 JUNCTION BLOCK AND VOLTAGE REGULATOR WIRING Ill 3 I o g O I to Figure 10 149 Electrical Information Index Riviera ...

Page 708: ... SWITCH ASM CLIP 2 GROUND PINK vi DK B L U E BLACK E WITH i DBL WHITE STRIPE ROUTE WIRES DOWN THRU PILLAR POST TO DOOR JAMB SW BOTH SIDES HEATER CONTROL ILLUMINATION ACK WITH DBL WHITE STRIPE E INNER TAB MTG SCREW I N VENT CONTROL ILLUMINATION TO CONSOLE WIRING HARNESS RED BLACK PURPLE WITH DBL WHITE STRIPE BLACK WITH DBL WHITE STRIPE TO DIR SIGNAL SWITCH TO HORN SWITCH BODY FLAT WIRE DK GREEN LT ...

Page 709: ...ELECTRICAL SYSTEMS WIRING DIAGRAMS 1 0 1 3 9 ...

Page 710: ...IGHT LAMP ASM 2 RED PURPLE WITH WHITE STRIPE RED CIGAR LIGHTER FEED BLACK GROUND INSTRUMENT PANEL WIRING HARNESS ASM SCREW BLACK HORN CONTROL WIRING HARNESS ASM CONSOLE INSTRUMENT PANEL WIRING HARNLSS SEE SHLCT 2 DIR SIGNAL SWITCH BLACK W1TH DBL WHITE STRIPE BULB RIGHT SIDE OF REAK SEAT HEATER DUCT l362545 CUP 2r COURTESY LAMP 3 SWITCH ASM CLIP SHIFT QUADRANT NEUTRAL SAFETY a BACK UP LAMP SWITCH c...

Page 711: ...E CROSS TRACER BULB IGNITION SW LIGHT LIGHT SWITCH FLASHER WIRES USED WITH CRUISE CONTROL BULKHEAD CONNECTOR BULKHEAD CONNECTOR VIEW C BROWN WITH WHITE STRIPE BROWN WHITE ORANGE a PURPLE CROSS TRACER CONNECTOR BODY TO IGNITION SWITCH VIEWE DK BLUE WITH DBL WHITE STRIPE DK BLUE LT GREEN INSTRUMFNT CLUSTER WIRING HARNESS STANDARD INSTRUMENT CLUSTER WIRING HARNESS COMPOSITE FUSE BLOCK RETAINER SHOWN ...

Page 712: ...SHED AND INSTALLED BY FISHER BULB 2 BACK UP WATER PROOF CONNECTOR 3 USE ASSEMBLY AID TO FACILITATE MAKING CONNECTION CONNECTORS MUST SNAP TOGETHER SECURELY CLIP OMIT WHEN LUGGAGE COMPARTMENT LAMP IS SPECIFIED 2987881 WIRING HARNESS ASSEMBLY REAR BUMPER CLIP FURNISHED IN BODY FUEL GAGE TANK UNIT LT GREEN GROMMET LUGGAGE COMPARTMENT LAMP ASSEMBLY CLIP ATTACH TO REAR FRAME CROSS MEMBER BROWN f YELLOW...

Page 713: ...M SCREW 2 FRONT SCREW ALSO HOLDS GROUND WIRE HORN ASM LONOTE HORN ASM HI NOTE DK GREE PURPLE DK BLUE TO FRONT FENDER SKIRT THIS CONNECTION MUST BE MADE AFTER VISOR MOTOR IS INSTALLED AND MOTOR PORTION OF CONNECTOR IS PLUGGED INTO FRONT FEN DER LOWER TIE PANEL ASM SEE NOTE ACK BROWN CLIP 2 TO FRONT FRAME CROSS MEMBER BULKHEAD CONNECTOR LH ENGINE COMPT HARNESS VIEW B 2 BLACK TAN 2 LT GREE VISOR MOTO...

Page 714: ...RADIO IS SPECIFIE BROWN RED WHITE CL BATTERY CABLE ASM NEG BLACK BATTERY CABLE ASM JUNCTION BLOCK TO STARTER EXISTING NU L WAS HER BATTERY CABLE ASM POS TO JUNCTION BLOCK STARTER SOLENOID SCREW 8 L WASHER ASM CABLE ASM JUNCTION BLOCK TO STARTER VIEW A BATTERY STARTER HORN RELAY a JUNCTION BLOCK AND VOLTAGE REGULATOR WIRING Figure 10 156 Starter Battery Voltage Regulator Horn Relay and Junction Blo...

Page 715: ...ELECTRICAL SYSTEMS WIRING DIAGRAMS 1 0 1 4 5 ...

Page 716: ...KING CONNECTION CONNECTORS MUST SNAP TOGETER SECURELY ORANGE BLOWER FEED BLACK LT BLUE YELLOW LT BLUE YELLOW ORANGE APPLY SEALER AROUND GROMMET HARNESS 8 CABLES AFTER INSTALLATION W S WIPER SWITCH L H ENGINE COMPT WIRING HARNESS R H ENGINE COMPT WIRING HARNESS W S WIPER a WASHER WIRING RESISTOR BLOWER FEED VIEW A Figure 10 158 Heater Windshield Wiper and Washer Wiring Riviera ...

Page 717: ...INSTALLED TAPE 6 PLACES AS SHOWN WIRING HARNESS ASM AIR CONDITIONER 8 HEATER WIRE COLOR CODE ORANGE RED DK BLUE ORN BLK STR ORN DK BLUE N BLK STR CIRCUIT BREAKER EXISTING NUT WASHER HEATER HOSE BOLT WASHER DK GREEN BLACK WATERPROOF CONNECTOR USE ASSEMBLY AID TO FACILITATE MAKING CONNECTIONS CONNECTORS MUST SNAP TOGETHER SECURELY TAPE COMPRESSOR 2 CO g CO DK GREEN Figure 10 159 Air Conditioner Wiri...

Page 718: ...E 12 ORANGE WITH A BLACK STRIPE I2RE0 COMPRESSOR CLUTCH COIL r 2 BROWN 14 ORANGE 16 LT BLUE 18 YELLOW WITH BLACK STRIPE 16 DK GREEN CLUTCH TERMINAL l6DK GREEN 6 DK GREEN FEED TERMINAL BATTERY M 8 DK GREEN WITH AWHITE STRIPE LOW LOW TERMINAL FEED TERMINAL HEATER a A C BLOWER SWITCH B M A C I SWITCH CLOSED A C POSITION SWITCH HELD OPEN 1 HEATER POSITION INTERNAL GROUND TO BRACKET S 4 Figure 10 160 A...

Page 719: ... HOSES 8 BOWDEN CABLE GROMMET TO CONTROL UNIT R H ENGINE COMPT WIRING HARNESS EXISTING BOLT CLIP 2 TO CONNECTOR ON INST PANEL WIRING HARNESS WIRING HARNESS ASM AIR CONDITIONING WITH HEATER CONTINUE HARNESS THRU GROMMET INTO ENGINE COMPT II A C POWER RELAY AIR COND SWITCH 5 70 to en 70 O D o to O Figure 10 161 Air Conditioner Wiring Riviera ...

Page 720: ...SITION VENT POSITION CIRCUIT CONTROL SWITCH Mil YELLOW 14 BROWN 16 OK GREEN VENT RECIR NORM POSITION TO BLOWER SW TO RESISTOR TO BATTERY TO COMPRESSOR COU 14 ORANGE BLOWER mUKANbt 7 VER RELAY 18 GRAY 14 ORANGE 1 HEATER CONTROL SWITCH 14 ORANGE HEATER BLOWER SWITCH TO IGNITION SW S CO Figure 10 162 Air Conditioner Schematic Diagrams Riviera ...

Page 721: ...ELECTRICAL SYSTEMS WIRING DIAGRAMS 1 0 1 5 1 ...

Page 722: ...NESS RIGHT HAND SIDE MOUNTED ON DASH HEATER HOSE SERIES 49 WIRE WIRE TO TRANSMISSION TO TRANS DOWN SHIFT SWITCH WIRE TOP OF DASH PANEL DK BLUE TO HEATER HARNESS LOCATION 49 SERIES HARNESS L0CATI0N 46 8 48 SERIES Figure 10 164 Dual 4 Barrel Engine Wiring ...

Page 723: ...HOLE IN FRONT OF DASH FOR CABLE ASSEMBLY SEE VIEW A 2 ASSEMBLE CABLE ASSEMBLY BRACKET TO INSTRUMENT P A N E L S E E V I E W S 3 ATTACH CABLE TO THROTTLE BRACKET FASTEN CABLE ARMOR TO FRONT OF DASH AS SHOWN IN VIEW A SEAL THIS AREA WITH SEALING COMPOUND POSITION HOLE INBOARD OF DIMPLE AS SHOWN SEAL THIS AREA WITH SEALING COMPOUND 2 to STOP PART OF CABLE ASM Figure 10 165 Hand Fast Idle Control Inst...

Page 724: ...IEW A PRODUCTION WASHER BOLT l6 25 L6 BRACE JO a 2 73 rSPG WASHER P NUT I5O 6OILB F 1 PART OF DELCOTRON VIEW B TO ADJUST VOLTAGE REMOVE COVER PLUG AND ROTATE LEVER HAVING SCREW DRIVER SLOT PRODUCTION CONNECTOR REGULATOR VIEW D REGULATOR MOUNTING INSTRUCTIONS REMOVE PRODUCTION VOLTAGE REGULATOR 8 DISCARD INSTALL NEW VOLTAGE REGULATOR USING PRODUCTION SCREWS Figure 10 166 Police Generator Installati...

Page 725: ...CONTROL VENT CONTROL HEATER aOR A C CONTROL TACHOMETER INTERIOR ILLUMINATION DOME ROOF CENTER DOME ROOF SIDE RAIL DOME REAR ARM REST CONVERTIBLE COURTESY LIGHT SAIL PANEL CENTER CONSOLE REAR COURTESY LIGHT FRONT CONSOLE COURTESY LIGHT REAR CONSOLE asisisi FLASHER in P T FLASH ER l U M t LAMP NO 4001 4002 L 4002 L II57A 4404 1195 1157 1 157 1 157 1156 97 89 194 161 194 194 194 194 194 194 194 1893 ...

Page 726: ...WIPER TRANS SHIFT SW FEED GLOVE BOX COURTESY LAMPS CLOCK POWER ANTENNA MOTOR REAR WINDOW DEFROSTER GUIDE MATIC AMPLIFIER PARKING BRAKE WARNING LAMP CLUSTER AND SPEED SAFETY BUZZER OR ELECTRO CRUISE CONTROL AMPERES 7 5 10 10 10 30 20 3 25 7 5 10 7 5 7 5 7 5 TYPE AGC AGC AGC AGC AGC SFE AGC AGC AGC AGC AGC AGC AGC LENGTH 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 F...

Page 727: ...R aTRANS SHIFT SW FEED GLOVE BOX COURTESY LAMPS 8 CLOCK POWER ANTENNA MOTOR REAR WINDOW DEFROSTER GUIDE MATIC AMPLIFIER PARKING BRAKE WARNING LAMP CLUSTER AND SPEED SAFETY BUZZER OR ELECTRO CRUISE CONTROL AMPERES 7 5 10 9 10 30 20 3 25 5 9 6 5 6 TYPE AGC AGC SFE AGC AGC SFE AGC AGC AGC SFE AGW AGC AGW LENGTH 1 1 4 1 1 4 7 8 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 7 8 7 8 1 1 4 7 8 Figure 10 169 Fuse C...

Page 728: ...ES WIRE 1 8 OHMS DG W S DARK GREEN WITH WHITE STRIPE G B S D BW S DA YBS YELLOW WITH BLACK STRIPE BWS BLACK WITH WHITE STRIPE R W S RED WITH WHITE STRIPE LBBS LIGHT BLUE WITH B L A C K STRIPE LUE WITH WHITE STRIPE B O S BLACK WITH ORANGE STRIPE BR W S BROWN WITH WHITE STRIPE NDGS NATURAL WITH DK GREEN STRIPE PBS PINK WITH BLACK STRIPE OBS ORANGE WITH BLACK STRIPE DKGREEN PURPLE DK BLUE TAN BROWN D...

Page 729: ...ELECTRICAL SYSTEMS WIRING DIAGRAMS 1 0 1 5 9 CLUSTER Figure 10 171 Wiring Diagram Rear Half 45 Series ...

Page 730: ... STRIPES LETTER IN LAMP DENOTES C0L0P WOPC WIRE COLOR CODE WHITE WITH ORANGE PURPLE CROSS TRACERIRES WIRE 1 8 OHI NATURAL WITH BLACK STRIPE GRAY WITH BLACK STRIPE TAN WITH BLACK STRIPE BRW S BROWN WITH WHITE STRIPE NOGS NATURAL WITH DK GREEN STRIPE PBS PINK WITH BLACK STRIPE Figure 10 172 Wiring Diagram Front Half 46 48 Series ...

Page 731: ...ELECTRICAL SYSTEMS WIRING DIAGRAMS 1 0 1 6 1 IN LIGHT SWITCH CLUSTER I r CONSOLE i 1 I I COURTESY Figure 10 173 Wiring Diagram Rear Half 46 48 Series ...

Page 732: ... STRIPE W QRGT WHITE WITH ORANGE AND PURPLE CROSS TRACER H T HIGH TENSION D B D W S DARK BLUE WITH DOUBLE WHITE STRIPE B D WS BROWN WITH DOUBLE WHITE STRIPE B W S BLACK WITH WHITE STRIPE LG B S LIGHT GREEN WITH BLACK STRIPE D G1V S DARK GREEN WITH WHITE STRIPE L GDBS LIGHT GREEN WITH DOUBLE BLACK STRIPE I ORANGE WHITE A E N LTBLUE BLACK DK BLUE RED Figure 10 174 Wiring Diagram Front Half 49 Series...

Page 733: ...ELECTRICAL SYSTEMS WIRING DIAGRAMS 1 0 1 6 3 R E D fl GUIDE MATIC BLACK H AMPLIFIER LT BLUE d Figu e 10 175 Wiring Diagram Rear Half 49 Series ...

Page 734: ... AND OPERATING INSTRUCTIONS a Description The Sonomatic and the Wonderbar Radios see Figures 1 1 and 11 2 are available as optional equipment The Buick Sonomatic and Wonder bar radio installation consists of a receiver with separate speaker mounted at the center of the in strument panel on 45000 46000 48000 and 49000 Series All speakers have an impedance of 10 ohms When replacing a speaker the rep...

Page 735: ...y hand This will cause permanent damage to the oper ating mechanism Radio noise interference is re duced by use of noise suppressor capacitors see Figure 11 3 and also the inherent resistance of the wiring The built in resist ance of each spark plug wire ap proximates 4 000 ohms per foot The ignition coil noise suppressor capacitor 0 3 MF is mounted on the coil bracket and the lead is connected to...

Page 736: ...Wonderbar tuner is oper ated in certain shielded localities or around buildings where an ade quate signal is not available the tuner may automatically search the band from one end to the other without stopping The sensitivity control should be moved to the full right position and the antenna fully extended when this condition is encountered or manual tuning should be used e Manual Tuning Operation...

Page 737: ...11 4 RADIO AND ANTENNA ACCESSORIES D to ...

Page 738: ...oblems are generally corrected by United Motors Service repair shops there is a tendency for many dealer servicemen to re move a set when a problem is reported The irritation to an owner of having his radio sent out can frequently be avoided if the following quick checks are used to eliminate any problems which are external to the receiver or involve antenna trimming RADIO TROUBLE DIAGNOSIS CONDIT...

Page 739: ...tenna from full up to full down position and note that full travel time does not exceed 12 seconds If time exceeds 12 seconds see op posite causes POSSIBLE CAUSE AND CORRECTION Incorrect Radio Trim Adjust ment Trim radio Refer to subparagraph 11 4 a Corroded Antenna Connections or Defective Antenna Repair or replace as required Loose Antenna Connections and Mounting Tighten Defective Antenna Lead ...

Page 740: ... to paragraph 11 3 d RADIO RECEIVER RADIO ANTENNA TRIMMER SCREW ADJUSTMENT ADJUSTMENT MUST BE MADE WITH ANTENNA MAST EXTENDED 31 INCHES ABOVE FENDER TUNE RADIO TO A STATION AT OR NEAR 1400 KC THAT CAN BARELY BE HEARD WITH VOLUME FULL ON A PROPERLY ADJUSTED SIGNAL GENERATOR MAY BE SUBSTITUTED INSERT SCREWDRIVER THROUGH OPENING IN RECEIVER 8 CAREFULLY TURN TRIMMING SCREW BACK 8 FORTH UNTIL A POSITIO...

Page 741: ... INSERT SCREWDRIVER THROUGH OPENING IN RECEIVER CAREFULLY TURN TRIMMING SCREW BACK FORTH UNTIL A POSITION IS FOUND THAT GIVES MAXIMUM VOLUME NUT CONTROL KNOB ASSY g O SCREW 17 MlN lFT LBS 1 GRAY GREEN WIRES TO WIRING HARNESS RADIO TRIM PLATE FELT WASHER INNER RADIO CONTROL KNOB SHIELDED CABLE TO FOOT SWITCH WIRING HARNESS SONOMATIC REAR VIEW OF RADIO CONNECTIONS _CONNECTOR FROM WIRING WONDER BAR H...

Page 742: ...nual and Electric Antenna 49000 Series REMOVAL 1 Turn front wheels full right and remove antenna access hole cover from right fender outer skirt see Figure 11 9 2 Loosen pinch clamp around lower portion of adapter assembly 3 Disconnect lead in wire from antenna On electric antenna also disconnect motor wire connector 4 Remove antenna assembly through access hole in skirt INSTALLATION 5 Position an...

Page 743: ...1 1 1 0 RADIO AND ANTENNA ACCESSORIES FRONT TRIM PLATE ASSEMBLY SCREW 2 AIR CONDITIONER CONTROL ASSEMBLY Figure 11 6 Center Console Front Trim Plate and Air Conditioner Control Assembly 49000 Series ...

Page 744: ...ACCESSORIES RADIO AND ANTENNA 1 1 1 1 Figure 11 7 Electric Antenna Installation 45000 46000 and 48000 Series ...

Page 745: ...assembly shaft re move the 3 8 hex nut see Fig ure 11 14 12 Remove the 7 16 hex nut and washer 13 Lift antenna pressure adjuster spring off shaft see Figure 11 11 NOTE When removing any of the following parts observe their lo cations and positions to facilitate reassembly 14 Remove drive pin retainer 15 Remove the drive pressure beam 16 Slide the drive pin from hole in the shaft and take off drive...

Page 746: ...W WASHER ASSEMBLY TAPPING ANTENNA ACCESS HOLE COVER ELECTRIC ANTENNA ADAPTER ASSEMBLY FENDER CLEAN THIS SURFACE TO INSURE PROPER ELECTRICAL CONTACT BY GROUND ARM ADAPTER ASSEMBLY MUST BE POSITIONED IN SLOTS AS SHOWN PINCH CLAMP ELECTRIC ANTENNA ASSEMBLY n o m 8 WASHER 2 SUPPORT ASSEMBLY I5 7 51FT LBSi o O m Figure 11 9 Manual and Electric Antenna Installation 49000 Series ...

Page 747: ...N CABLE LOWER TIE BAR FUSE BLOCK CABLE ASSEMBLY TOP VIEW ANTENNA LEAD IN CABLE LOFCAR SWITCH INST PANEL WIRING HARNESS ASSEMBLY FUSE BLOCK ELECTRICAL ANTENNA TO SWITCH ANTENNA ASSEMBLY a O m Figure 11 10 Antenna Lead in Wire and Motor Control Wire 49000 Series 2 m en ...

Page 748: ...e hook up wire extends below the lower edge of the body and upper insulator assembly tubular fitting of antenna drive 25 Solder the free end of the before the nylon reed completely disappears in drive assembly HOOK UP WIRE BODY UPPER INSULATOR ASSY Figure 11 12 Hook Up Wire to Mast Connection Figure 11 13 Removing and Installing Mast and Insulator Bushing hook up wire to the 0 40 inch diameter sec...

Page 749: ...ting Test a PPly power to the green up terminal Run the mast all the way out and allow the motor to continue running until the clutch has made a minimum of 15 en gagements or clicks 8 Do the same in the down position 9 Run antenna up and down for a 3 minute period then reassemble spring scale to mast and recheck for maximum pull Adjust as necessary 10 Snap front cover onto antenna drive and make s...

Page 750: ...ACCESSORIES RADIO AND ANTENNA 1 1 1 7 RADIO SPEAKER GRILLE TO RADIO RECEIVER TO WIRING HARNESS UPPER TIE BAR Figure 11 18 Front Radio Speaker Installation 49000 Series ...

Page 751: ... 8 BOLT a CLIP ASSEM 4 REQURED REAR METAL SHELF FIBERBOARD SHELF COVER TRIM CLOTH CLIP INSTALL AS SHOWN ON RIGHT SIDE OF CAR IGHT GREEN REAR SPEAKER WIRE COIL EXCESS WIRE AT THIS POINT AND ATTACH TO CLIP GROUND CLIP 8 32 HEX WITH EXT TOOTH L WASHER NUT TYPE7T 4 REQUIRED CARS WITH FIBERBOARD SHELF COVER ONLY CLIP SPEAKER ASSEM GROUND CLIP NUT CARS WITH TRIM CLOTH OVER SHELF COVER ONLY n n m o 70 Fi...

Page 752: ...speaker grille by grasp ing lower edges and firmly pull ing rearward Cover plate is wedged between rear seat cushions 2 Remove two s c r e w s from lower end of rear speaker grille and partially remove grille by pulling lower end of grille out ward and sliding grille down and out 3 Disconnect speaker connector and complete removal of speaker and grille 4 Further disassembly of speak er and grille ...

Page 753: ...HOUT JUMPER OR FADER FADER CONTROL FRONT SPEAKER WIRE TO REAR FADER CONTROL WASHER RADIO MOUNTING BASE INSTRUMENT PANEL JUMPER WIRE REQUIRED FOR TRIMMING RECEIVER ON REAR SPEAKER EQUIPPED CARS ONLY FRONT SPEAKER o 2 o D I INSTRUMENT PANEL WIRING HARNESS 8 m o ...

Page 754: ...to top and center holes behind inner knob see Figure 8 21 4 Install right inner and outer knobs b Setting Push Buttons to Desired Stations 1 Turn on the radio 2 Pull push buttons outward It is desirable to set up the push buttons in logical sequence For example lowest frequency of desired station on first button next higher frequency station on second button etc 3 Carefully tune in the desired sta...

Page 755: ...T 1 2 2 RADIO AND ANTENNA ACCESSORIES Figure 11 23 Rear Speaker Wiring 45000 46000 and 48000 Series ...

Page 756: ... INSIDE OF RIGHT HINGE PILLER Figure 11 24 Rear Speaker Wire Routing 45000 46000 and 48000 Series REAR SEAT SPEAKER GRILLE GROUND SCREW GROUND BLACK WIRE SPEAKER FEED BLACK WIRE WITH WHITE STRIPE NUT FASTENERS SPEAKER LEAD ASSEMBLY Figure 11 25 Rear Speaker Installation 49000 Series ...

Page 757: ...SCRIPTION AND 46000 and 48000 Series cars is a air mix type system in which the temperature of the air is varied by diluting heated air with un heated air The outside air after it enters the system is divided into two air streams Part of the The heater system for the 45000 air flow is diverted to the heater DESCRIPTION AND OPERATION OF HEATER SYSTEM 45000 46000 and 48000 SERIES core and the balanc...

Page 758: ...s forced to circulate around the core When the door is fully open the air stream through the by pass around the core is blocked and all air is forced through the heater core Intermediate positioning of the door mixes heated and unheated air in proportionate amounts After the air passes through or around or both through and around the heater core it flows past the outside air door and is directed t...

Page 759: ...ositioned at the mid position the outside air door is fully opened permitting outside air to flow thru the system to the in terior heater outlets Movement of the lever fully to the right will fully open the defroster door and direct all the air flow to the de froster outlets Intermediate positioning of the lever from mid position to full right position will apportion the air to both defroster and ...

Page 760: ...TER SYSTEM 1 1 2 7 HEATER ASSEMBLY COWL CLIP T AIR INLET ASSEMBLY CLIP VACUUM DIAPHRAGM BLOWER RESISTOR ASSEMBLY BLOWER ASSEMBLY OUTSIDE AIR DOOR AND CASE ASSEMBLY Figure 11 34 Heater System Installation 49000 Series ...

Page 761: ...LEFT FRONT AIR OUTLET AIR HOSE ADAPTER ASSEMBLY DUCT ASSEMBLY DEFROSTER OUTLET CONNECTOR ASSEMBLY a RIGHT FRONT AIR OUTLET CENTER CONSOLE DUCT ASSEMBLY GASKET REAR OUTLET n m 8 ...

Page 762: ...ACCESSORIES HEATER SYSTEM 11 2 9 o u on UJ o a Figure 11 36 Heater and Defroster and Vent Control Assemblies Installation 49000 Series ...

Page 763: ...UND WIRE PLAIN VACUUM HOSE SOURCE GREEN VACUUM HOSE OUTSIDE AIR DOOR FENDER SKIR Figure 11 37 Vacuum Hose and Water Hose Routing 49000 Series b Description and Operation of Heater System Controls The heater system for the 49000 Series cars has three control l e v e r s HEATER lever DE FROSTER lever and BLOWER lever see Figure 11 39 They function as follows 1 HEATER Control Lever This lever regulat...

Page 764: ...ACCESSORIES HEATER SYSTEM 1 1 3 1 I H I i Figure 11 38 Heater System Air Flow 49000 Series ...

Page 765: ... clamp on heater securely b Temperature and Outside Air Cables Installation and Adjustment 1 Attach control cables to in strument panel control 2 Secure respective assembly control cables to lever on heater 3 Rotate adjuster nut on tem perature and outside air cables to obtain 1 8 to 3 16 inch spring back when TEMPERATURE and HEATER levers on instrument panel are fully to the left position SUPPORT...

Page 766: ...osition defroster duct hoses are cemented in position it is recom mended that the hoses be cut for removal purposes Retape hoses together for installation 2 Place vent knobs on instrument panel in full OFF position and rotate adjuster nut so that it has approximately 1 8 inch spring back from OFF position d Removal of Heater System Components Removal of the blower and air inlet assembly see Figure...

Page 767: ...tely 1 16 inch spring back exists Work lever back and forth several times and recheck for proper adjustment b Removal of Heater System Components To remove heater core it is nec essary to take out heater assem bly Removal of components of heater system will be obvious upon inspection see Figures 11 34 11 35 and 11 36 11 9 HEATER SYSTEM TROUBLE DIAGNOSIS NOTE It is suggested that prior to inspectin...

Page 768: ...ant Check operation of outside air door ref subpar 11 7 a or b temperature door or defroster door Also refer to above corrections 2b and 2c Check fuse Check for defective heater blower switches 2 located on heater defroster control assembly Check blower motor ground wire see Figure 11 37 Check for defective blower resistor assembly see Fig ure 11 34 Check for loose connections or broken wires Chec...

Page 769: ...Charging of Air Conditioner 11 103 11 19 Air Conditioner Functional Test 11 105 11 20 Air Conditioner Trouble Diagnosis 11 105 11 10 SPECIFICATIONS a Tightening Specifications Part Location Ft Lbs Nut Drive Plate Nut to Compressor Shaft 14 16 Nut Compressor Rear Head to Shell 19 23 Cap Schrader Service Valve 4 5 For compressor mounting bracket bolts see Figures 11 92 and 11 93 Metal Tube Outside D...

Page 770: ...her in formation pertaining to the heater system refer to Section 11 B c Both Systems 45000 46000 48000 and 49000 Series Both the 45000 46000 and 48000 Series system and the 49000 Se ries system are similar in that the components of the refriger ating circuit are basically identi cal except for variations in mounting of the components in the engine compartment adjust ment valves and capacities Bot...

Page 771: ...LVE VACUUM HOSE YELLOW HOSE ASSEMBLY HOSE ASSEMBLY P INSULATOR HOT FUEL VAPOR WATER HOSE BYPASS FILTER SUCTION HOSE ASSEMBLY WATER VALVE VACUUM HOSE YELLOW VACUUM SOURCE HOSE VACUUM SOURCE FITTING SUCTION THROTTLE VALVE VACUUM HOSE B LACK VACUUM HOSE RED DISCHARGE HOSE ASSEMBLY 46000 and 48000 SERIES Figure 11 48 Air Conditioner Installation 45000 46000 and 48000 Series ...

Page 772: ...RAGM VACUUM STORAGE TANK MUFFLER RECEIVER DEHYDRATOR SUCTION THROTTLE VALVE WHITE DASH CLAMP VACUUM HOSE ROUTING ELECTRICAL HARNESS MAIN WIRING HARNESS HEATER INLET HOSE BLUE HEATER OUTLET HOSE FUEL VAPOR BY PASS FILTER WATER VALVE VACUUM HOSE RED 49000 SERIES Figure 11 49 Air Conditioner Installation 49000 Series ...

Page 773: ...SERT CAPILLARY TUBE OPERATING PIN OPERATING DIAPHRAGM EQUALIZER LINE ADJUSTING NUT JUSTING SPRING WASHER TOSTV OUTLET Figure 11 50 Expansion Valve assembly functions to absorb any moisture that might be present in system after assembly Also it traps foreign material which may have entered system during assembly NOTE IN and OUT are stamped on receiver IN attaches to con denser and OUT to liquid lin...

Page 774: ... pressure area While pressures in the expansion valve are almost equal the addition of the valve adjusting spring pres sure behind the needle will hold the needle valve over to close the needle valve orifice When the air conditioning system first begins to operate the com pressor will immediately begin to draw refrigerant from the evaporator and in the area under the operating diaphragm As the pre...

Page 775: ...ne fit as the compressor runs on an adequate oil supply With partial ly depleted refrigerant charge oil and refrigerant mixture will flow from the bottom tank of the evaporator through the oil bleed line to the compressor This oil flow helps to prevent oil deficien cies in the compressor that could arise under these conditions During times of zero change no refrigerant will be available to carry o...

Page 776: ... Figure 11 52 The flow of the low pressure vapor from the evaporator to the compressor is determined and controlled by the position of the piston in the valve body of the STV The position of the piston in the body is determined by the balance of the forces that are applied to the piston diaphragm These forces consist of the re frigerant vapor pressure return ing from the evaporator on one side and...

Page 777: ... unusual for the compressor inlet pressure to be from 10 to 15 psi while the evaporator is controlled at 30 psi Frost accumulates on the compressor inlet line after prolonged operation at these con ditions At minimum or further reduced load conditions when the throttling demands on the STV are again increased the com pressor inlet pressure may drop to zero psi or even 6M 8M of vacuum Compressor in...

Page 778: ...separate from the heater outlets and are located as shown in Figures 11 54 and 11 55 Air is introduced into the car through three outlets two at each end of the instrument panel and one at the upper center of the instrument panel The outer outlets have a rotating ball to control air flow direction See Figure 11 56 e Air Conditioner Controls 49000 Series NOTE See paragraph 11 13 for 45000 46000 and...

Page 779: ...he lever is moved to HIGH position the vacuum modu lator is permitted to be com pletely shut off and all vacuum is removed from the vacuum dia phragm of the suction throttling valve provided the air condi tioner temperature lever is in COOLER position When the FAN lever is in HIGH position the air lever in RECIRC and the air con ditioner temperature lever in COOLER position maximum cooling will re...

Page 780: ... assem bly and the head at each end of the compressor The heads are connected with each other by gas tight passage ways which direct refrigerant gas to a common output a Suction Reed Valves and Discharge Valve Plates A three reed suction valve disc is assembled to both the front and rear cylinder heads See Fig ure 11 62 These reeds open when the pistons are on the in take portion of their stroke t...

Page 781: ... EVAPORATOR CORE FREEZE UP RECEIVER ACTS AS A RESERVOIR TO x FURNISH A SOLID COLUMN OF LIQUID TO EXPANSION VALVE DEHYDRATOR FILTER ABSORBS MOISTURE AND TRAPS FOREIGN MATERIAL PRESENT IN SYSTEM ilGHT GL USED AS SYSTEM DIAGNOSIS AID TO DETERMINE REFRIGERANT SHORTAGE AUTOMATICALLY CONTROLS REFRIGERANT FLOW INTO EVAPORATOR THE VALVE S PRESSURIZED BULB CONTROLS THE OPENING OF THE VALVE TO MAINTAIN HIGH...

Page 782: ...ID TO EXPANSION VALVE DEHYDRATOR FILTER ABSORBS MOISTURE AND TRAPS FOREIGN MATERIAL PRESENT IN SYSTEM p r rr r l h i t 1 I ft Ttfl T t f I i f lU N A44 JX U J EXPANSION VALVE SIGHT GLASS USED AS SYSTEM DIAGN09SAID TO DETERMINE REFRIGERANT SHORTAGE AUTOMATICALLY CONTROLS REFRIGERANT FLOW INTO EVAPORATOR THE VALVE S PRESSURIZED BULB CONTROLS THE OPENING OF THE VALVE TO MAINTAIN HIGHER REFRIGERANT TE...

Page 783: ...NG SEAL OIL INLET TUBE REAR NEEDLE THRUST BEARING RACES FRONT NEEDLE THRUST BEARING RACES SHAFT NEEDLE BEARING FRONT DISCHARGE VALVE PLATE SUCTION REED VALVE SEAL SEAT O RING SEAL SHAFT SEAL STEEL SLEEVE DRIVE KEY SPACER NUT SHAFT RETAINER RING PULLEY RETAINER RING BEARING RETAINER WIRE SEAL SEAT RETAINER RING o o n O O m TO to n m to to o TO Figure 11 60 Sectional View of Compressor 46000 48000 a...

Page 784: ...ACCESSORIES OPTIONAL HEATER AIR CONDITIONER SYSTEM 1 1 5 1 ...

Page 785: ...on each side provides the proper head clear ance below the top of cylinder and the underside of the suction and discharge valve plates See Figure 11 65 The rear end combination con sisting of a needle bearing with a selected thrust race on each side obtains a 005 to 0015 running clearance between the hub sur faces of the swash plate and the front and rear hubs of the cylinder f Cylinder Block and ...

Page 786: ...ACCESSORIES OPTIONAL HEATER AIR CONDITIONER SYSTEM 1 1 5 3 ...

Page 787: ...ons and cyl inders at the front of the compressor j Production Type Discharge Tube The double acting pistons pro duce a high pressure vapor at both ends of the compressor The outlet discharge port for the high pressure vapor is located in the rear head of the compressor See Figure 11 66 A discharge vapor tube is used to connect the front head dis charge cavity to the rear head discharge cavity Thi...

Page 788: ...compressor clutch is not engaged the compressor shaft does not turn although the pulley is still being turned by the com pressor belts The clutch armature plate which is the movable member of the clutch drive plate assembly is attached to the assembly by means of flat springs The hub of this assembly is pressed over the compressor shaft and is aligned with a square drive key located in the keyway ...

Page 789: ...hat if the air conditioning system was in use when the engine was turned off the armature plate may remain in contact with the pulley assem bly due to residual magnetism This will cause no trouble as the armature plate and pulley will separate as soon as the engine is started p Compressor Shaft Seal A replaceable shaft seal is used at the front of the compressor to seal the air conditioning system...

Page 790: ... the compressor clutch control switch is closed completing half the circuit of the compressor clutch the FAN switch must also be closed before the compressor clutch will be energized Vacu um is supplied to 2 port of outside recirculated air door vacuum diaphragm This causes the door to partially open thereby permitting the system to draw out and recirculate air inside the passenger compartment see...

Page 791: ... culated thru the heater core Further movement of the lever to the right opens the temperature door via a control cable attached to the lever Regardless of the position of the Climate Control lever REC NORM VENT or HTR the air flow will be warmed proportionate with the travel of the lever to the right 4 DEFROST Lever This lever is connected to the defroster door 2 3 3 D RESISTANCE 3 St 5 R ASi HEA...

Page 792: ...CH CONTROL SWITCH OPEN VACUUM TO 1 AND 2 PORT OF OUTSIDE RECIRCULATED DIAPHRAGM n n m rr rri r fi V fc rffn HI WARMER REC NORM o A C o VENT HIR i L __ J J L DEFROST VACUUM TO SUCTION THROTTLE VALVE DIAPHRAGM AND VENTING WATER VALVE DIAPHRAGM CLUTCH CONTROL SWITCH OPEN AND VACUUM TO 1 AND 2 PORTS OF OUTSIDE RECIRCULATED DIAPHRAGM AND ALSO HEATER AIR CONDITIONER DIAPHRAGM o o n O o AIR IS DIRECTED T...

Page 793: ...acuum Disc Switch Operated BLUE by Climate Control Lever YELLOW Htr A C Diaphragm I i VACUUM SOURCE J J L r VACUUM STORAGE I TANK CHECK Lrnl i VALVE 1 PORT Fan Lever OFF and WARMER Lever fully left System Inoperative MAIN VACUUM SWITCH OPEN n S T V VALVE WATER VALVE7 YELLOW RED OUTSIDE RECIRCULATED DIAPHRAGM Water Valve and STV Vacuum Disc Switch Operated by WARMER Lever o m 5 m TO 8 g O m 70 n rn...

Page 794: ...ED 1 PORT DIAPHRAGM SUCTION THROTTLE VALVE Outside Recirculated Diaphragm 1 YELLOW BLUE MAIN VACUUM SWITCH OPEN WATER VALVE J YELLOW VACUUM DIAPHRAGM Outside Rec Htr A C Vacuum Disc Switch Operated BLUE by Climate Control Lever YELLOW Htr A C Diaphragm VACUUM SOURCE VACUUM STORAGE TANK CHECK DVALVE S T V VALVE XT BLACK RED Water Valve and STV Vacuum Disc Switch Operated by WARMER Lever O O m o 79 ...

Page 795: ...ROTTLE VALVE Outside Recirculated Diaphragm ttl YELLOW BLUE MAIN VACUUM SWITCH OPEN Outside Rec Htr A C Vacuum Disc Switch Operated by Climate Control Lever BLUE y Htr A C Diaphragm Y E L L O W V A C U U M SOURCE VACUUM STORAGE TANK CHECK VALVE 2 PORT OUTSIDE RECIRCULATED DIAPHRAGM 1 PORT o 3 73 n O WATER VALVE7 YELLOW RED S T V VALVE Water Valve and STV Vacuum Disc Switch Operated by WARMER Lever...

Page 796: ...EC WARMER Lever full left FAN Lever on Outside Recirculated Diaphragm 2 1 YELLOW BLUE MAIN VACUUM SWITCH OPEN Outside Rec Htr A C Vacuum Disc Switch Operated by Climate Control Lever Htr A C Diaphragm VACUUM SOURCE VACUUM STORAGE TANK CHECK VALVE OUTSIDE RECIRCULATED DIAPHRAGM WATER V A L V E YELLOW RED S T V VALVE Water Valve and STV Vacuum Disc Switch Operated by WARMER Lever Figure 11 77 Air Co...

Page 797: ...EVER RECIRCULATED Q j DIAPHRAGM 3g4 A C DIAPHRAGM VACUUM SOURCE VACUUM STORAGE TANK 8 CHECK SOURCE VACUUM HOSE IN SOURCE VACUUM HOSE OUT MAIN VACUUM SWITCH OPEN RECIRCULATED AIR DEFROSTER CONTROL CABLE BLUE WATER VALVE AND STV VACUUM DISC SWITCH OPERATED BY WARMER LEVER HEATER AIR CONDITIONER DIAPHRAGM VACUUM HOSE YELLOW GRIP WASHER VACUUM STORAGE TANK WATER VALVE VACUUM HOSE CONNECTOR PLUG V TEMP...

Page 798: ...UM DISC SWITCH CLUTCH CONTROL SWITCH BLOWER SWITCH M A I N VACUUM SWITCH WATER VALVE STV VACUUM DISC SWITCH PLUG FOR OUTSIDE REC HTR A C VACUUM DISC SWITCH PORT WATER VALVE S PLUG FOR WATER VALVE STV VACUUM DISC SWITCH Figure 11 79 Vacuum Hose Installation at Rear of Control Assembly ...

Page 799: ...wer speed and air will flow from air conditioner outlets Kinked plugged nected hose o r discon Outside defective R e c Diaphragm Outside Rec Air Door sticking Main vacuum switch defective or misadjusted Defective vacuum storage tank Vacuum hoses on wrong ports on vacuum diaphragm Vacuum hoses incorrectly as sembled to connector plug on cowl Kinked vacuum hoses Defective water valve and STV vacuum ...

Page 800: ...pplied to Htr A C diaphragm and door will reposition directing air out of heater outlets Defective or misadjusted clutch control switch Loose or broken wire Defective compressor clutch coil Compressor clutch ground wire broken Connector loose at compressor coil NOTE If neither the blower motor nor the compressor can be actuated check the fuse and the blower switch Defective blower resistor as semb...

Page 801: ... to only one stage of the vacuum diaphragm of the outside and recirculated air door the door will partially open to the re circulated position If vacuum is applied to only one stage of the vacuum diaphragm of the heater and evaporator air door the door will partially open to the heat and A C position see Figure 11 86 to permit air flow to both the evaporator and heater assem blies Application of v...

Page 802: ... applied when air conditioner air lever NORMAL VENT or RECIR and heater DEFROSTER and or HEATER TEMP lever s Outside Recirculated Diaphragm Vacuum is applied to both stages of diaphragm when heater DEFROSTER and or HEATER TEMP levers on or when air conditioner air lever NORMAL or VENT Vacuum applied when air conditioner air lever in RECIR Air Conditioner Vacuum Disc Switch o 5 5 m TO TO n O g 6 to...

Page 803: ...ER COOLER Defroster Door fully open Temperature Door fully open Applies vacuum to both stages of Outside Recirculated Diaphragm heater controls off Applies vacuum to both stages of Heater and Air Conditioning Diaphragm Closes one half of double contact Circuit Control switch blower circuit o Same as for VENT except double contact Circuit Control Switch completely closed compressor actuated Same as...

Page 804: ...LOWER AIR DOOR ASSEMBLY OUTISDE RECIRCULATED AIR DOOR CLOSED OUTSIDE RECIRCULATED DIAPHRAGM DEFROSTER DOOR COWL HEATER AIR CONDITIONER DIAPHRAGM HEATER AIR CONDITIONER AIR DOOR CLOSED SELECTOR DOOR CASE ASSY m n O a o m TO Figure 11 82 Air Conditioner and Heater Off 49000 Series ...

Page 805: ...1 1 7 2 OPTIONAL HEATER AIR CONDITIONER SYSTEM ACCESSORIES 6 g o ...

Page 806: ...STER DOOR COWL PLENUM BLOWER AND AIR DOOR ASSEMBLY OUTSIDE AIR HEATER EVAPORATOR AIR DOOR FULL OPEN OUTSIDE RECIRCULATED DIAPHRAGM HEATER AIR CONDITIONER DIAPHRAGM n m cr to O m o 3 6 ili a m 7Q O O D o I Figure 11 84 Air Conditioner Ventilation or Normal Heater Off 49000 Series ...

Page 807: ...ION 5 EFROSTER DOOR COWL n O o m 70 PLENUM BLOWER AND AIR DOOR ASSEMBLY OUTSIDE AIR RECIRCULATED AIR OUTSIDE AND RECIRCULATED DIAPHRAGM HEATER AND AIR CONDITIONER DIAPHRAGM HEATER AND AIR CONDITIONER AIR DOOR FULL OPEN O n m Figure 11 85 Air Conditioner Recirculate Heater Off 49000 Series ...

Page 808: ...R PLENUM BLOWER AND AIR DOOR ASSEMBLY i OUTSIDE AIR HEATER AND AIR CONDITIONER AIR DOOR HEAT AND A C POSITION HEATER AIR CONDITIONER DIAPHRAGM OUTSIDE RECIRCULATED DIAPHRAGM n o m m o o 70 n O I O to I Ui Figure 11 86 Air Conditioner Ventilation or Normal Heater On 49000 Series ...

Page 809: ...lated air All air through heater outlets All air through A C outlets POSSIBLE CAUSE Check heater and evaporator air door dual stage vacuum diaphragm No vacuum should be present Check outside and recirculated air door dual stage vacuum diaphragm No vacuum should be present Check outside and recirculated air door vacuum diaphragm Vacuum should be applied to one or both stages depending on position o...

Page 810: ...ent twist ing and to prevent hose kinking as kinked hoses are apt to trans mit noise and vibration CAUTION Tighten all connec tions in accordance with recom mended torques See pipe and hose connection chart See Fig ure 11 47 Insufficient torque when tightening can result in loose joints Over tightening can result in distorted joint parts and either condition can result in refrig erant leakage 6 Do...

Page 811: ...cuum diaphragm 7 To adjust valve rotate dia phragm assembly clockwise to in crease evaporator pressure and counterclockwise to decrease pressure 8 After adjusting the valve ob serve operation of the system for a few minutes to check readings 9 Tighten lock nut on sleeve and reinstall the vacuum hose on the 49000 vacuum diaphragm 10 Check operation of suction throttle valve a On 45000 46000 and 480...

Page 812: ...ACCESSORIES OPTIONAL HEATER AIR CONDITIONER SYSTEM 1 1 7 9 Figure 11 88 Distribution Duct Installation 45000 46000 and 48000 Series ...

Page 813: ...NSTALLATION ONLY 8 WILL DROP OFF RESIDUAL TORQUE MUST NOT BE LESS THAN 20 LB IN AT ANY TIME IF TORQUE FALLS TO LESS THAN 20LBS IN AFTER INITIAL IN STALLATION CLAMP SCREW SHOULD BE TIGHTENED TO 20 25 LB IN C L A M P MUFFLER HOSE CLAMP INSTALLATION MUFFLER TO COMPRESSOR HOSE SCREW DEHYDRATOR ASSEMBLY INSULATOR CLAMP BRACKET o 3 LIQUID LINE CLAMP 2 m 70 70 8 g O m TO I BRACKET 8 m o 70 Figure 11 89 M...

Page 814: ...OL CABLE DEFROSTER CONTROL CABLE HEATER TEMPERATURE CONTROL CABLE WASHER INSTRUMENT PANEL SCREW VACUUM MODULATOR AIR CONDITIONING CONTROL ASSEMBLY n o m O 70 m o o m 70 n O a O Figure 11 90 Vacuum Hose Installation at Rear of Control Assembly 49000 Series ...

Page 815: ...ion throttle valve The 45000 46000 and 48000 suction throttle valve is basically the same except a dif ferent diaphragm is used and an O ring is not used on the vac uum diaphragm 2 Remove spring from cover 3 Remove the five screws that retain cover to body of valve and remove cover 4 Remove diaphragm and piston assembly 5 Remove retainer cup from diaphragm The diaphragm should be handled with care...

Page 816: ... tains some refrigerant IMPORTANT Whenever a com pressor replacement is being made the oil in the original com pressor should be drained and measured The new compressor should contain the same amount of new 525 viscosity oil as was drained from the original com pressor This step is necessary as some of the oil from the orig inal compressor remains in the system The addition of a com plete change o...

Page 817: ...11 8 4 OPTIONAL HEATER AIR CONDITIONER SYSTEM ACCESSORIES Figure 11 92 Compressor Installation 45000 46000 and 48000 Series ...

Page 818: ...to determine amount to install in a replacement com pressor or in a compressor that has been disassembled for repair To drain compressor remove drain plug and place compressor in a horizontal position with drain plug opening downward Allow all oil to drain into a container measure total amount then dis card oil To determine the amount of oil that should be installed in the compressor if there has ...

Page 819: ...ROM COMPRESSOR a More than 4 oz b Less than 4 oz a More than 1 1 2 oz See Note b Less than 1 1 2 oz a More than 4 oz b Less than 4 oz a More than 1 1 2 oz See Note b Less than 1 1 2 oz a More than 4 oz b Less than 4 oz AMOUNT OF 525 OIL TO INSTALL IN COMPRESSOR a Amount drained from com pressor plus amount for component being replaced as follows Evaporator Add 3 oz Condenser Add 1 oz Receiver Dehy...

Page 820: ...ure to properly install drain hoses and use new O rings on refrigerant lines See Figure 11 97 To remove distribution duct to service heater core on 49000 lower evaporator assembly from instrument panel Then discon nect distribution duct and re move from right side of instrument panel 11 16 COMPRESSOR CLUTCH COIL AND SHAFT SEAL REMOVAL AND INSTALLATION It is not necessary to remove compressor from ...

Page 821: ...1 1 8 8 OPTIONAL HEATER AIR CONDITIONER SYSTEM ACCESSORIES a i ...

Page 822: ...ACCESSORIES OPTIONAL HEATER AIR CONDITIONER SYSTEM 1 1 8 9 ...

Page 823: ...1 1 9 0 OPTIONAL HEATER AIR CONDITIONER SYSTEM ACCESSORIES k 8 5 i I ...

Page 824: ...GE 60 84 LB IN CEMENT SECURELY TO OUTSIDE OF EVAPORATOR INLET EQUALIZER LINF L IQUID LINE UCTION LINE LIQUID HOSE HOLE EVAPORATOR DRAIN HOSE BRACKET SCREW SCREW EVAPORATOR DRAIN HOSE EQUALIZER HOSE HOLE SUCTION HOSE HOLE SEAL AROUND REFRIGERANT LINES o n m co O 2 m to o o i 73 n O g O VIEW IN DIRECTION Of ARROW _E_ INSTRUMENT PANEI UNITS Figure 11 97 Evaporator and Distributor Duct Installation 49...

Page 825: ... move in swash plate resulting in damage to the cylin der mechanism Figure 11 101 Positioning Clutch Drive Plate on Shaft NOTE Do not remove pulley bearing unless it is going to be replaced 4 Remove bearing to pulley re tainer wire with a small screw driver See Figure 11 106 5 Remove bearing using punch or a suitable socket Figure 11 104 Removing or Installing Bearing to Head Retainer Ring d Pulle...

Page 826: ...tch drive plate Subparagraph a 2 Remove pulley assembly and bearing Subparagraph c 3 Note position of electrical ter minals and scribe location of coil and housing assembly terminals on compressor body to insure correct location of terminals when coil is reinstalled 4 Use J 6435 No 26 Truarc Pliers and remove coil and hous ing retainer ring then remove coil and housing assembly See Figure 11 109 f...

Page 827: ...er and insert shaft seal in side front head Be sure seal is Figure 11 112 Removing or Installing Shaft Seal Figure 11 114 Installing Seal Seat O Ring Figure 11 115 Charging Compressor to Check for Leaks properly seated on shaft The shaft has two flats provided for the shaft seal 2 Install a new seal seat O ring in its groove inside front head using Installer J 21508 Be sure it is not in seal seat ...

Page 828: ...raph g 9 Attach J 9396 Holding Fixture to compressor and firmly mount assembly in vise See Figure 11 116 10 Remove pressure relief valve and washer if head is going to be replaced 11 Remove four lock nuts from threaded studs welded to com pressor shell and remove rear Figure 11 116 Removing or Installing Pressure Relief Valve SUCTION SCREEN J REAR HEAD JjZk 1 k TEFLON M AT SURFACES yaffil T HEAD h...

Page 829: ...If cylinder assembly has sustained major damage due pos sibly to loss of refrigerant and or oil it may be necessary to replace unit with a service cyl inder and shaft assembly rather than replace individual parts 5 Remove compressor front head using rubber mallet or wood block to unseat head from shell See Figure 11 122 Care must be used to protect teflon surface on head from being damaged 6 Remov...

Page 830: ... by holding on to it with pliers and tapping on pliers 13 Examine swash plate surfaces for excessive scoring or damage If satisfactory reuse If neces sary replace mainshaft and swash plate assembly 14 Wash compressor internal parts in a tank of clean trichloro ethylene alcohol or similar sol vent Blow dry all parts using a source of clean dry air If drive balls show any signs of damage replace 15 ...

Page 831: ...front of compressor and at same time place front ball and shoe and rear ball only over swash plate IMPORTANT It is necessary to lift shaft assembly when installing pistons Hold front thrust bearing pack tightly against swash plate hub while lifting shaft 10 Repeat this operation for No 2 and No 3 pistons Balls and shoes must adhere to piston dur ing this assembly 11 Align rear cylinder half cast i...

Page 832: ...120 and repeat check with feeler gauge between these same parts e From this total of three checks between the same ball and swash plate at 120 increments on swash plate use the minimum feeler gauge reading to select a numbered shoe to correspond to this reading See Example below Example Posi Posi Posi tion tion tion 1 2 3 Piston 1 019 020 019 Select and use a No 19 Shoe Piston 2 020 020 020 Select...

Page 833: ...and or rebuild operations e Assembly of Compressor Cylinder Assembly Be sure to install all new seals and O rings and to lubricate all the parts generously with 525 compressor oil during assembly 1 Assemble a piston ring scrap er groove toward the outside of piston to each end of the three pistons 2 Apply a light coat of petroleum jelly to selected numbered shoes and place them over correct ball i...

Page 834: ...Start one side of seal and cover into dove tail slot in the cylinder c Use J 9433 suction pass cover seal installer as a shoe horn by placing it between the seal on opposite side and the dove tail slot See Figure 11 143 d Center cover and seal with ends of cylinder faces e Press down on cover to snap it into place f Remove J 9433 installer as shown in Figure 11 144 g Examine cover and seal to be s...

Page 835: ... used to prevent large O ring seal from being damaged Maintain this alignment when lowering mech anism into place See Figure 11 150 10 Place O ring on the oil inlet tube apply oil to cavity and O ring Insert tube and O ring rotating compressor mech anism as necessary and align tube with hole in the shell baffle Be sure O ring and inlet tube are properly seated 11 Install discharge O ring and bushi...

Page 836: ...e compressor and correct any leaks as necessary 15 Remove charging line adapter plate from compressor and install end plate 16 Refer to paragraph 11 15 subparagraph j for amount of 525 compressor oil to install in compressor The oil is installed through oil drain screw opening 17 Install coil and housing as sembly Paragraph 11 16 sub paragraph i 18 Install pulley assembly and bearing Paragraph 11 ...

Page 837: ...inder in a bucket of hot water which does not exceed 125 F CAUTION Never heat refrig erant cylinder above 125 F as tremendous hydrostatic pressures will develop capable of rupturing cylinder When there is a pos sibility of overheating cylinder the cylinder must be opened to a suitable pressure relief mecha nism at all times 2 Place cylinder and bucket on a suitable scale and record the total weigh...

Page 838: ...e attach gauge set Figure 11 153 and functional test air conditioner b Diagnosis of Components Listed below are the air condi tioner components and the pos sible conditions that could be encountered with each unit if defective 1 Compressor Compressor malfunction will appear in one of four ways noise seizure leak age or low discharge pressures Even resonant compressor noises are not cause for alarm...

Page 839: ...edure in par 11 15 sub par f NOTE The lower outlet temperature can be achieved on dry days and the higher on humid days Ambient Temperature F 70 80 90 100 110 TEST NO 2 Evaporator Pressure at Suction Throttling Valve PSIG 28 30 28 30 28 30 28 30 28 31 Compressor Head Pressure PSIG 160 195 180 235 200 280 230 310 270 335 Left Outlet Temperature F 38 41 40 43 40 45 42 47 44 52 Right Outlet Temperatu...

Page 840: ...tioning unit NOTE If evaporator pressure is not correct for indicated ambient temperature ad just suction throttle valve following procedure in par 11 1 sub par f NOTE The lower outlet temperature can be achieved on dry days and the higher on humid days Compressor Ambient Evaporator Pressure Head Pressure Rt Outlet Temperature F PSIG PSIG Temperature F 70 80 90 100 110 20 22 20 22 20 22 20 22 22 2...

Page 841: ...ure in paragraph 11 15 subparagraph g and h c Use of Receiver Sight Glass for Diagnosis At temperatures higher than 70 F the sight glass may indi cate whether the refrigerant charge is sufficient A shortage of liquid refrigerant is indicated after about five minutes of com pressor operation by appearance of slow moving bubbles vapor or a broken column of refrigerant under the glass Continuous bub ...

Page 842: ...triction exists in the high pressure side of the sys tem 2 If discharge pressure drops slowly it indicates excessive refrigerant If pres sures drop to specifications and sight glass remains clear stop depressurizing and re check operational pressures If pressures are satisfactory depressurize until bubbles appear in the sight glass stop depressuriz ing then add one half pound refrigerant Recheck o...

Page 843: ...ction in system tubes or hoses c Suction throttle valve adjusted improp erly or defective NOTE It compressor suction line from STV is tor this indicates that STV outlet pressure defective CORRECTION b See EVAPORATOR PRESSURE TOO LOW c Repair compressor a Check for tightness b Replace valve c Check operation of STV paragraph 11 15 subparagraph V Repair valve if necessary d There should be no vacuum...

Page 844: ...tor Check for proper seal Evaporator Pressure Low Ice may be forming on evaporator Re adjust suction throttle valve to proper control pressure If cooling remains low after pressure is normal follow diagnosis under Evaporator Pressure Normal If stv does not respond to adjustment hoses to and from valve may be restricted valve or compressor may be defective Evaporator Pressure High Re adjust suction...

Page 845: ...IRING SCHEMATIC 16 LT BLUE OFF POSITON VENT POSITION I 16 LT BLUE RESISTOR 3 VENT RECIR NORM POSITION TO BLOWER SW TO RESISTOR TO BATTERY TO COMPRESSOR COIL o TO n O a 3 o CO TO IGNITION SW HEATER CONTROL SWITCH HEATER BLOWER SWITCH 8 m to o 70 m CO Figure 11 157 Heater Air Conditioner Schematic 49000 Series ...

Page 846: ...ACCESSORIES OPTIONAL HEATER AIR CONDITIONER SYSTEM 1 1 1 1 3 ...

Page 847: ...1 1 1 1 4 OPTIONAL HEATER AIR CONDITIONER SYSTEM ACCESSORIES U ...

Page 848: ...9527 J 9392 J 9432 j 9393 J 9433 6 J 9481 J 9401 J 9480 J 9553 J 6586 BURNER DETECTOR UNIT J 5184 J 7316 J 21508 J 5403 NOTE ALL SPECIAL TOOLS PICTURED HEREIN MAY BE ORDERED FROM KENT MOORE ORGANIZATION 28635 MOUND ROAD WARREN MICHIGAN Figure 11 160 Air Conditioner Compressor Tools ...

Page 849: ... CONDITIONER SYSTEM ACCESSORIES J 8433 a o J 5462 J 5421 J 5428 01 J 5725 01 j 5453 J 5420 J 5418 FRONT REAR FRONT REAR FRONT REAR J m mti FRONT REAR FROtHT REAR v f FRONT REAR 1 PRONT1 W REAR I Figure 11 161 Air Conditioner Tools ...

Page 850: ...nsists of a photo tube unit amplifier unit power relay and a combination dimmer override type foot switch The phototube unit mounted on top of the instrument panel is the light sensing device which converts light into an electrical signal for use by the amplifier unit A control knob is located on the rear of the unit and allows the driver to limit the amount of sensitivity of the unit Manual opera...

Page 851: ...ly 30 seconds warm up period the Guide Matic will provide complete automatic switching of the headlamp beams Street lights and other extraneous lights encountered in the city are sufficient to maintain its vehi cle headlamps on low beam Occasionally when trailing an older model car with poor light ing on the rear or due to some other unfavorable condition it may be desirable to change the foot swi...

Page 852: ...lifier unit is faulty and should be removed for servicing 2 If upper beam is not ob tained trouble is in power relay foot switch or car harness 4 Headlamps Stay On Upper Beam a Ground the white wire of the phototube harness It may be necessary to lower amplifier If so use external ground for case of amplifier 1 If headlamps remain on upper beam go to Step b 2 If headlamps go to lower beam trouble ...

Page 853: ...SS GUIDE MATIC POWER RELAY 45000 46000 AND 48000 SERIES SCREW NUT WIRING HARNESS TO AMPLIFIER BRAKE PEDAL BRACKET ASSEM SCREW INSTRUMENT PANEL WIRING HARNESS POWER RELAY SCREW TO PHOTOTUBE AMPLIFIER SERIAL NUMBER SUPPORT 49000 SERIES I i n i n O o n 49000 SERIES Figure 11 166 Amplifier and Power Relay Installation ...

Page 854: ...ies from main harness See Figure 11 164 b Disconnect phototube harness from amplifier See Figure 11 166 Figure 11 167 Tester J 8465 c Remove the amplifier attach ing screws d To install reverse the pro cedure After installing the amplifier unit check the dim and hold sensitivity adjustments See subparagraph d d Adjustments and Tests Tester J 8465 made by Kent Moore is required for checking or adju...

Page 855: ... the point where headlamps switch to upper beam The meter pointer should now read in the green HOLD ADJ range on the meter scale See Figure 11 167 If not proceed to the hold and dim sensitivity adjustments 3 Hold and Dim Sensitivity Adjustments CAUTION Hold sensitivity must be properly adjusted before ad justing dim sensitivity Phototube unit must be covered with a black cloth during adjustments a...

Page 856: ...or dis engaged however car speed will only be controlled by the Electro Cruise when the system is en gaged If the speed setting is changed while the system is en gaged car speed will increase or decrease automatically to coin cide with the desired setting 2 ENGAGEMENT The engage ment switch lever and CRUISE lamp assembly is located to the right of the speedometer on 49000 Series cars and fully con...

Page 857: ...n sion closing the air port to at mosphere and opening the vacuum port to the diaphragm chamber The vacuum admitted then tends to increase tension on the bead chain to open the throttle valve Similarly when the control valve coil is not energized spring ten sion positions the teeter totter armature of the control valve to close the vacuum port and open the air port to the diaphragm chamber The air...

Page 858: ...e or below the set speed 3 AMPLIFIER AND RELAY The electronic control unit con sists of a relay assembly and a transistor amplifier assembly mounted on a common junction block which is an integral part of the system s wiring harness Both assemblies are designed to in dividually plug into the junction block therefore each can be service separately A two am pere fuse is incorporated into the junctio...

Page 859: ...SE LINE FITTING VACUUM ORIFICE DIAPHRAGM RETURN SPEED CONTROL COMPENSATING SPRING POWER DIAPHRAGM DIAPHRAGM RETURN SPEED CONTROL COMPENSATING SPRING DIAPHRAGM CHAMBER AIR ORIFICE CONTROL VALVE COIL AIR FILTER CONTROL VALVE COIL AIR VACUUM DIAPHRAGM CHAMBER Figure U 173 Power Unit 49000 Series ...

Page 860: ...M FOLLOWER RING FLEXIBLE SHAFT INPUT CRUISE SPEED SETTING SHAFT OSCILLATING CONTACT PIN CLOSED CAM FOLLOWER MOUNTING RING MAIN HAIRSPRING CRUISE SPEED SETTING SHAFT CONTACT HAIRSPRING OSCILLATING CONTACT PIN UP ARM SPEED SETTING POINTER SPEED POINTER Figure 11 174 Speedometer and Speed Transducer 49000 Series ...

Page 861: ... amplifier circuit is opened by opening of the speed trans ducer contact points and the in hibiting coil circuit will be opened allowing the holding coil to move the contact points to the down position The CRUISE lamp cir cuit will then be completed indi cating the system is locked in cruise operation and the inhibit ing coil circuit will be opened to prevent energizing of the coil when the amplif...

Page 862: ...ded stud two full turns b Brake Release Switch Adjustment 1 Disconnect wiring harness connector from brake release switch and connect an ohm meter or test lamp J 21005 across switch terminals NOTE If desired the cruise lamp of the engagement switch may be used as a test lamp by unplugging speed transducer connector at speedometer and leaving brake release switch wiring connector on switch Then tur...

Page 863: ...RIES TAN POWER UNIT COIL 1 MOM ON ENGAGE N 0 R W S RED ON S 49000 SERIES DK GREEN ON 49000 SERIES WHITE GRAY ON 49000 SERIES AR1 CR1 C E w TEXAS INST GP 290 B R2 TAN DK BLUE ON 49000 SERIES HOLDING COIL CONTINUOUS DUTY A INHIBITING COILJ T INTERMITTENT 1 DUTY Kl DIFFERENTIAL RELAY CRUISE TELLTALE _ GRAY W S GRAY ON 49000 SERIES DS1 53 BLACK TRANSISTOR AMPLIFIER R W S RED ON 49000 SERIES s 9 n 70 m...

Page 864: ... 46000 48000 MOUNTING POSITION FOR MANUAL BRAKES PULLEY AND BRACKET ASM SCREW MOUNTING POSITION FOR POWER BRAKES BRAKE PEDAL MOUNTING BRACKET ASSEMBLY RELEASE SWITCH TUBING ASM CLAMP POWER UNIT ASM o n m O 2 THROTTLE FITTING ASM CUT AND ADJUST CHAIN TO BE TAUT WHEN CARBURETOR IS AT CURB IDLE POSITION THEN BACK OFF ADJUST ING SCREW TWO TURNS TQ PERMIT CHAIN TO HAVE SLIGHT SLACK SECURE ADJUSTING SCR...

Page 865: ...TH 2 4 BBL CARBURETOR ENGINE USE THIS INSTALLATION IN REAR CARBURETOR REDUCER FITTING CLAM BRAKE PEDAL MOUNTING BRACKET ASSEMBLY SCREW ADJUST SWITCH TO OPEN CIRCUIT WITHIN 1 4 PEDAL TRAVEL CUT AND ADJUST CHAIN TO BE TAUT WHEN CARBURETOR IS AT CURB IDLE POSITION THEN BACK OFF ADJUSTING SCREW TWO TURNS TO PERMIT CHAIN TO HAVE SLIGHT SLACK SECURE ADJUSTING SCREW WITH JAM NUT ARM ASM VIEW OF VACUUM CO...

Page 866: ...air of the power CONTROL VALVE VALVE SPRING FILTER ELEMENT CONTROL HALF ASSEMBLY RETURN SPRING DIAPHRAGM ASSEMBLY COVER f L SC SCREW 8 FITTING BEAD CHAIN ASSEMBLY Figure 11 179 Exploded View of Power Unit unit will be required Paragraph 11 23 subparagraph c 5 With engine still running and bead chain still disconnected push cruise engagement lever forward and hold If power unit diaphragm rod moves ...

Page 867: ...ther of the above connections the lamp should light Failure of the lamp to light indi cates a defective relay and must be replaced c Amplifier Test The amplifier can be checked using one of two methods similar to checking the relay 1 The first method is to sub stitute a known good amplifier and perform the procedure out lined in the Trouble Diagnosis Test Procedure chart Fig ure 11 183 or road tes...

Page 868: ...T AND GROUND WHEN ENGAGE BUTTON IS DEPRESSED IF NO VOLTAGE _ CHECK WIRING IS PRESENT HARNESS CONTINUITY IF VOLTAGE IS PRESENT HCHECK CONTINUITY OF POWER UNIT COIL IF CAR ENGINE ACCELERATES CHECK TRANSISTOR AMPLIFIER DISCONNECT SPEEDOMETER WIRING HARNESS DEPRESS ENGAGE LEVER AND RELEASE NORMAL RESULT ENGINE WILL REMAIN AT IDLE CRUISE LAMB WILL COME ON CRUISE LAMP COMES ON AND L ENGINE DOES NOT RACE...

Page 869: ...eps accelerating up past set speed Automatically locks in CRUISE when car goes over bumps POSSIBLE CAUSE 1 Disconnected e l e c t r i c a l connections or open in wiring 2 Blown fuses 3 Brake release switch adjustment 4 Vacuum leakage 5 Power unit coil open 6 Defective transistor amplifier 1 Harness to speedometer unplugged or loose 2 Defective speed transducer 3 Defective transistor amplifier 4 D...

Page 870: ... d POSSIBLE CAUSE 1 Defective relay 2 Loose electrical connections 3 Brake release switch adjustment 1 Loose electrical connections 2 Defective speedometer 3 Defective power unit 4 Vacuum leakage 1 Vacuum leakage 1 Defective speedometer 2 Bead chain adjustment 3 Stiff accelerator linkage 4 Vacuum leakage 5 Dragging brakes 1 Shorted wire harness 2 Shorted engage switch 3 Defective relay 1 Burned ou...

Page 871: ...graph Subject Page 11 25 Servicing Accessories 11 138 11 2 5 SERVICING ACCESSORIES The following accessories pictured herein are provided as optional equipment on the 1965 Buick 45000 46000 48000 and 49000 Series cars The servicing such as removal and installation of the accessory components will be obvious when viewing the installation illustrations contained on the following pages ...

Page 872: ...UND VIEW IN DIRECTION OF INSTALL SUPPORT AND CLAMP RELATIVE TO EACH HORN AS SHOWN HOOD ASSEMBLY DARK GREEN HORNS TO RELAY ROUTE WIRE THRU EXISTING CLIP ON INNER SKIRT CONNECTOR RESET TANG BEFORE INSERTING INTO CONNECTOR TERMINAL DK GREEN Figure 11 184 Four Note Horn Installation 45000 46000 and 48000 Series ...

Page 873: ...ND PLACE GROUND 8 RELAY WIRES IN DASH CLIPS AS SHOWN ROLL CLIPS UPWARD TO RETAIN WIRES WIRING HARNESS ASSEM ROUTE WIRE THRU CLIP CONNECTOR RESET TANG BEFORE INSERTING IN TERMINAL BLACK Figure 11 185 Four Note Horn Installation 49000 Series ...

Page 874: ...M STORAGE TANK HOSE VACUUM SOURCE TO TANK VACUUM OUTLET VACUUM TRUNK LOCK WITH AIR CONDITIONING TO DOOR LOCK VACUUM TANK 4 6 4 8 0 0 0 LOCATION ONLY VACUUM TANK ASSEM SCREW VACUUM TRUNK LOCK WITH VACUUM DOOR LOCKS Figure 11 186 Vacuum Trunk Release Installation 45000 46000 and 48000 Series ...

Page 875: ...1 1 1 4 2 MISCELLANEOUS OPTIONS ACCESSORIES ...

Page 876: ...ACCESSORIES MISCELLANEOUS OPTIONS 1 1 1 4 3 ...

Page 877: ...1 1 1 4 4 MISCELLANEOUS OPTIONS ACCESSORIES ...

Page 878: ...ACCESSORIES MISCELLANEOUS OPTIONS 1 1 1 4 5 ...

Page 879: ... GRILLE CABLE ASM SWITCH PLATE ASSEMBLY SCREW INSTRUMENT PANEL WIRING HARNESS Figure 11 191 Rear Window Defroster Installation 49000 Series ...

Page 880: ...ACCESSORIES MISCELLANEOUS OPTIONS 1 1 1 4 7 E D O O 1 ...

Page 881: ...VACUUM TANK TO SOURCE NON A C JOBS HOSE VACUUM TANK TO DASH COLOR CODED WHITE CONNECTOR VALVE VACUUM HOSE ASSEM CLIP VIEW B VACUUM OUTLET SOURCE 48239 69 48439 69 Figure 11 193 Vacuum Door Lock 48000 Series ...

Page 882: ...2 4 The front of the hood is held down by a ratchet type hood latch lo cated on the upper tie bar c Radiator Mounting and Adjustment The radiator is mounted in rub ber using a three point mounting system of rubber faced U shaped brackets Two of the brackets are included in the lower support bracket as sembly which attaches at each end of the frame The third is located at the top center in the guar...

Page 883: ...the body openings If fenders and door panel surfaces are not reason ably flush correction may be made by adding or removing shims between the fender and the cowl Where spacing between the rear edge of front fender and door is objectionably uneven from top to bottom it may be necessary to adjust the shims between fender inner skirt and frame to adjust shims between fender and rocker panel or to loo...

Page 884: ... shift rear of hood up or down with re spect to hinge 2 Rear Tension Too little ten sion is indicated if the rear hood area flutters To increase ten sion add special washers be tween the hood and the hinges at the front bolts Too much tension is indicated if the rear area of the hood bends as it is closed To decrease ten sion add special washers between the hood and the hinges at the rear bolts 3 ...

Page 885: ...12 4 FRONT END SHEET METAL BUMPERS o 5 ...

Page 886: ...FRONT END SHEET METAL BUMPERS 12 5 ...

Page 887: ...NSULATOR INSTALL SECTIONS IN THEIR CORRECT PLACE HARD SIDE EXPOSED CEMENT SECURELY TO HOOD INSTALL UNDER FLANGE AS SHOWN AROUND PERIPHERY OF ALL PADS LUBRICATE ALL PIVOT POINTS 115 MIN 1 LB FT1 73 o m 5 HOOD HINGE ASSEM Figure 12 3 Hood Installation 45 46 48 Series to ...

Page 888: ...AD HOOD INSULATOR INSTALL IN THEIR CORRECT PLACES HARD SIDE EXPOSED CEMENT SECURELY TO HOOD CEMENT WATER DISPERSED CEMENT TO BE APPLIED IN AREA OF A 4 00 DIA IN THE CENTER OF THE THREE LOCATIONS ALSO AT THE INNER EDGE OF THE COMPRESSOR CLEARANCE HOLE II5 MIN ILB FT HOOD HINGE ASM WHERE MINIMUM TORQUE ONLY IS SPECIFIED FAILURE TORQUE IS AT LEAST IA HIGHER 70 o D 1 03 to Figure 12 4 Hood Hood Hinge ...

Page 889: ...12 8 FRONT END SHEET METAL BUMPERS Figure 12 5 Removing and Installing Hood Hinge Spring ...

Page 890: ...o SCREW FENDER ASSEM FRONT BUMPER LOWER FACE PLATE SUPPORT ASSEM ANCHOR NUT o to I m m TO to FRONT BUMPER LOWER FACE PLATE Figure 12 6 Front Bumper Installation 49 Series S O ...

Page 891: ...WITH IDENT RIB IN HORIZONTAL POSITION AS SHOWN SCRFW 15 MIN LB FT SUPPORT FRONT BUMPER GUARD LOWER NUT FRONT FENDER LOCK WASHER SPECIAL NUT 65 MIN LB FT 1 INSULATOR OUTER 2 BRACKET ASSEMBLY FRONT BUMPER BACK BAR ANCHOR NUT 65 MIN LB FT LOCK WASHER SPECIAL GUARD ASSEMBLY 70 o o to I 3 Figure 12 7 Front Bumper Assembly 49 Series ...

Page 892: ...MPER OUTER RT LT FRONT END SHEET METAL SHIM SPEC AS REQ D MOUNT SUPPORT ASSEM INSULATOR WASHFR BOLT FILLER FRONT PLATE ASSEMBLY CAR FRONT BUMPER FACE LICENSE PLATE m 09 s to WHERE MIN TOR CUE ONLY IS SPECIFIED FAILURE TORQUE IS AT LEAST 1 3 HIGHER B C SERIES TURN SIGNAL PARKING LAMP ASSEM LT 8 RT BOLT Figure 12 8 Front Bumper Installation 45 46 48 Series ...

Page 893: ...NUT SCREW RADIATOR GRILLE BAR CENTER K 70 o ILLER RADIATOR GRILLE TO BUMPER SCREW 8 HEADLAMP DOOR OUTER RT 8 LT HEADLAMP ASSEM OUTER LT 8 RT HEADLAMP ASSEM INNER LT 8 RT HEADLAMP DOOR INNER RT a LT 45000 48000 I m 0 2 S Figure 12 9 Radiator Grille Headlamp Hood Latch Installation 45 48 Series ...

Page 894: ...1 1 2 0 MINI LB IN I BAR RADIATOR GRILLE U P P E R SCREW DOOR HEADLAMP ASSEM LT 8 RT SCREW SELF DRILLING BAR RADIATOR GRILLE LOWER ASSEM RT 8 LT SCREW FRAME ASSEM RT 8 LT O a en I I 5 TO CO Figure 12 10 Radiator Grille Headlamps and Hood Latch Installation 46 Series ...

Page 895: ...12 14 FRONT END SHEET METAL BUMPERS o ...

Page 896: ...HEADLAMP 8 VISOR ASSEMBLY WASHER ACTUATOR LINK ASSEM RING VIEW S1 SCRE FILLE LINK ACTUATOR BUMPER 2 VIEW Q m I i to VIEW R Figure 12 12 Headlights 49 Series Ui ...

Page 897: ...12 16 FRONT END SHEET METAL BUMPERS X CO T CM ...

Page 898: ...IE BAR WHERE MIN TORQUE ONLY IS SPECIFIED FAILURE TORQUE IS AT LEAST 1 3 HIGHER LOWER TIE PANEL ASSEM 70 o 00 m 70 VIEW B RT SIDE SHOWN LT SIDE TYPICAL 15 MIN ILBS FTJ Figure 12 14 Radiator Grille Front End Installation 49 Series ...

Page 899: ...CATIONS ONLY AS SHOWN FENDER LOWER PEAK 1358455 CLIP MOULDING FRONT FENDER WHEEL OPENING SCREW TAPPING 10 VIEW F TVPICAL 10 PLACES HOLES SIGNALED ARE FOR ASSEMBLY ALIGNMENT ATTACHING PARTS AT THESE HOLES MUST BE SECURED FIRST WHERE MIN TORQUE ONLY IS SPECIFIED FAILURE TORQUE IS AT LEAST 1 3 HIGHER 1 0 I 00 m o I 180 MINl LB IN I I 3 to Figure 12 15 Radiator Gril e Front End Installation 49 Series ...

Page 900: ...PER CEMENT SECURELY AS SHOWN SHIM SPECIAL BAFFLE RT a LT LB INl HOLES SIGNALED NETJ ARE FOR ASSEMBLY ALIGNMENT ATTACHING PARTS AT THESE HOLES MUST BE SECURED FIRST WHERE MIN TORQUE ONLY IS SPECIFIED FAILURE TORQUE IS AT LEAST 1 3 HIGHER o m D to m m 00 m TO VIEW B1 VIEW C i Figure 12 16 Radiator Grille and Front End Installation 49 Series ...

Page 901: ... WHEELHOUSE PANEL NUT ANCHOR MOULDING FRONT FENDER RT 8 LT STAPLES TO BE LOCATED BELOW NOTCH DEFLECTOR FRAME 10 O FENDER ASSEM SCREW IO CLIP o a 2 VIEW H 09 i Figure 12 17 Radiator Grille and Front End Installation 45 46 48 Series ...

Page 902: ...RCEMENT ASSEM RT 8 LT ANCHOR NUT 2 FRONT FENDER ASSEM ASSEM RT 8 LT SCREW FRONT WHEELHOUSE PANEL RADIATOR SUPPORT ASSEM SCREW SCREW 180 MIN LB INl SEE VIEW D 70 o a m OB I s to WHEELHOUSE PANEL REINFORCEMENT I8O MIN L B IN BATTERY BASE I8O MIN LB iNJ VIEW C Figure 12 18 Radiator Grille and Front End Installation 45 46 48 Series K ...

Page 903: ...D SCREW ASSEM 2 CAR BODY UPPER SHROUD SHIM SPECIAL AS REQ D SHIM SPECIAL AS REQ D J SHIM SPECIAL AS REQ D FRONT FENDER ASSEM CAR BODY 120 30 I LB FT SCREW ASSEM 2 CAR BODY FRONT FENDER ASSEM SCREW ASSEM 17 25 1 LB FT o 1 09 3 70 CO Figure 12 19 Radiator Grille and Front End Installation 45 46 48 Series ...

Page 904: ...EM WITH INDENT RIB IN HORIZONAL POSITION AS SHOWN ANCHOR BRACKET RT LT 73 o NUT NUT m to 50 BACK UP LAMP SCREW PLATE ASSEM REAR BUMPER FACE I 65 MIN 1 LB FT IO CO Figure 12 20 Rear Bumper Installation 48 Series ...

Page 905: ...RT 8 LT RT LT BACK UP LAMP ASSEM SPECIAL EQUIPMENT 1 4 DIA 5CREW 2 FURNISHED bY DEALER SCREW RT LT ORNAMENTAL BACK UP ASSEM WHERE MIN TORQUE ONLY IS SPECIFIED FAILURE TORQUE IS AT LEAST 1 3 HIGHER WASHER SPECIAL BOLT SPECIAL m i i 70 Figure 12 21 Rear Bumper Installation 45 46 Series ...

Page 906: ... WITH IDENT RIB IN HORIZ ONTAL POSITION AS SHOWN BRACKET GAS TANK FILLER DOOR ASSEM BUMPER WHERE MIN TORQUE ONLY IS SPECIFIED FAILURE TORQUE IS AT LEAST 1 3 HIGHER m S D m 70 in BOLT VIEW IN DIRECTION OF ARROW A Figure 12 22 Rear Bumper Installation 49 Series ...

Page 907: ...12 26 FRONT END SHEET METAL BUMPERS ...

Page 908: ...TAINER ORNAMENT BRACKET FRONT FENDER ASSEM MOULDING WHEEL OPENING RT 8 LT MOULDING SIDE SECTION AA 588546 ORNAMENT MOULDING SIDE RT 8 LT 70 o o to 00 o m 70 Figure 12 24 Front Fender Trim 45 46 48 Series ...

Page 909: ...nd Test Page Page Bearing Adjustment Front Wheels 7 17 Bearing Lubrication Front Wheels 1 8 Bearing Replacement Connecting Rod 2 39 Crankshaft 2 40 Differential 45000 Series 6 9 Differential 46 48 49000 Series 6 29 Rear Wheel Axle Shaft 45000 Series 6 7 Rear Wheel Axle Shaft 46 48 49000 Series 6 24 Bell Housing Alignment 5 50 Breaker Points See Contact Points Brakes 9 1 Adjustment 9 15 Bleeding 9 ...

Page 910: ...tor 10 24 Bench Test 10 31 Periodic Inspection 10 29 Repairs on Bench 10 31 Specifications 10 2 Voltage Test 10 29 Trouble Diagnosis 10 27 Crankshaft and Bearings 2 11 Bearing Replacement 2 40 Dimensions 2 5 Oil Seal Replacement 2 37 Cruise Control 11 123 Cylinder Crankcase 2 11 Page Dash Pot and Throttle Linkage Adjustment 3 25 Defroster Windshield 11 24 Diagnosis Trouble Air Conditioner 11 66 11...

Page 911: ...er 10 49 H Hard Starting 3 16 Headlamps 10 47 Aiming Adjustment 10 49 Page Heater and Defroster 11 24 Air Conditioner 11 36 Non Air Conditioner 11 24 Horns Relay and Button 10 53 Adjustments 10 53 Trouble Diagnosis 10 53 Hydraulic Control System Automatic Transmission 5 16 Hydraulic Valve Mechanism 2 14 Hydraulic Valve Lifter Service 2 32 Hydrometer Test of Battery 10 9 I Identification No Vehicle...

Page 912: ...0 Page Pinion Setting Gauges 45000 Series 6 9 Pinion Setting Gauges 46 48 49000 Series 6 29 Pistons Pins Rings 2 39 Dimensions 2 6 Replacement 2 42 Ring Fitting 2 44 Positive Traction Differential 45000 Series 6 14 Positive Traction Differential 46 48 49000 Series 6 37 Propeller Shaft Assembly 6 50 Installation 6 53 Removal 6 24 Pump Fuel 3 29 Pump Oil Engine 2 15 Repairs 2 24 Pump Hydraulic Steer...

Page 913: ...ng Gear Manual 8 1 Steering Gear Lubrication 1 9 Steering Linkage 8 44 Transmission Automatic 5 1 Speedometer 10 68 Trouble Diagnosis 10 71 Springs Chassis 7 22 Spring Hood Hinge 12 2 Stabilizer Link 7 16 Starter 10 24 Page Steering Gear Power 8 9 Steering Gear Manual 8 1 Steering Gear Lubrication 1 9 Steering Geometry Turning Angles Checking 7 34 Steering Knuckle Replace 7 17 Steering Linkage 8 4...

Page 914: ... Specifications 2 4 Ventilation Crankcase 3 21 Page Ventilator Outside Air 11 33 Voltage Regulator 10 16 Voltage Test Cranking Motor 10 29 w Warning Signal Parking Brake 10 51 Water Pump 2 18 Repairs 2 50 Wheel Alignment 7 Wheel Bearing Front Adjust 7 15 Wheel Bearing Lubrication Front 1 7 Wheel Bearing Replacement Front 7 16 Wheel Bearing Replacement Rear 45000 Series 6 7 Wheel Bearing Replacemen...

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