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Hudson 1948 - 1952, Service Manual

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7. Remove 1/4" rod from levers. It should come out easily.

8. Check manual shift crossover by moving control lever up 

and down. If crossover is not smooth, shorten or 

lengthen shift rod attached to low and reverse lever by mov-

ing adjusting

 nuts at trunnion, 1/4 turn at a time, until smooth action 

is obtained.

9. Check gear shifting by moving control lever through the 

various positions. If interference or sticking is encountered 

when going into low or reverse, check for proper adjust-

ment of the spring retainer (B).

REFERENCE

Source of

Information

Date

Subject

Summary of Contents for 1948 - 1952

Page 1: ...HUDSON SHOP SERVICE MANUAL 1 9 4 8 1 9 5 2...

Page 2: ...This manual courtesy of Hudson Essex Terraplane Club member Drew Meyer...

Page 3: ...able service at reasonable cost Special tools that have been developed are shown in their respective positions New Tools are developed only when it is found to be essential to good workmanship and the...

Page 4: ...7 5 7 3 7 7 7 3 7 5 7 9 7 1 7 10 7 8 7 6 7 8 7 8 7 3 7 7 7 1 7 7 7 7 7 10 5 1 5 3 5 COOLING SYSTEM Continued Cooling System Diagnosis Description and Operation Diagnosis Draining System Fan Belt Adju...

Page 5: ...6 5 6 6 6 5 6 7 6 6 6 6 6 7 6 7 6 8 6 8 6 7 6 7 6 8 6 23 6 12 3 35 3 37 3 35 3 24 3 25 3 25 3 26 3 27 3 27 3 12 3 12 3 12 6 ENGINE Continued Cylinder Honing Engine Removal 8 Cylinder Engine Removal 6...

Page 6: ...21 2 10 2 16 2 5 2 8 2 8 2 11 2 9 2 10 2 8 2 9 2 9 2 14 2 11 2 14 2 20 2 17 2 15 2 14 2 14 2 21 2 ENGINE TUNE UP Continued Ignition Timing Manifold Heat Control Metering Rod Setting Milliampere Test P...

Page 7: ...5 4 7 4 7 4 6 4 5 4 7 4 7 4 16 4 20 4 18 4 17 4 16 4 17 4 26 4 16 4 16 4 17 4 15 4 17 4 30 4 27 4 40 4 42 4 42 4 38 4 38 4 39 4 39 4 FUEL SYSTEM Continued Fuel Level Gauge Continued Gauge Trouble Dia...

Page 8: ...9 10 9 10 9 10 9 11 9 11 9 11 9 13 9 12 9 8 9 9 9 15 9 15 9 19 9 17 9 12 9 22 9 15 9 16 9 22 9 17 9 12 9 22 9 16 9 12 9 13 9 124 9 27 9 23 9 24 9 24 9 24 9 24 9 23 9 23 9 7 10 4 10 PROPELLER SHAFT Co...

Page 9: ...ection and Repair Installing Transmission Lubrication Reassembly Assembly of Synchronizer Countershaft Countershaft Gear Cluster Main Drive Gear Main Shaft Assembly Reverse Idler Gear and Gear Cluster...

Page 10: ...VIII...

Page 11: ...cation Schedules and the following paragraphs NOTE The lubricants used at the time of assembly are of the best quality and need not be changed until the recom mended change period shown in the Lubrica...

Page 12: ...1 2 LUBRICATION FIGURE 1...

Page 13: ...LUBRICATION 1 3...

Page 14: ...1 4 LUBRICATION...

Page 15: ...nti Freeze strength Hudson Hydraulic Brake Fluid Check Brake Master Cylinder fluid level Hydra Matic Transmission Check Level 2 000 Miles Perform operations included in 1 000 mile lubrication in addit...

Page 16: ...ant Front Wheel Bearings Remove Clean and Repack Rear Wheel Bearings Remove Clean and Repack 15 000 Miles Hydra Ma t i c transmission fluid should be changed every 15 000 miles instructions for draini...

Page 17: ...caps are packed to prevent oil leakage and a large oil retainer collects oil from the outside of the rear main bearing and returns it to the oil pan The oil return tube leading from the rear main bear...

Page 18: ...quarts for six cylinder and 8 quarts for eight cylinder engines When the oil is drained in the conventional manner the refilling quan tity is 7 quarts for both six and eight cylinder engines When the...

Page 19: ...epend able brands and of the proper viscosity to suit the seasonal and customer driving requirements Theoilrefinersormarketerssupplyingengineoilsareresponsiblefor the quality of their products and the...

Page 20: ...mber cover CRANKCASE VENTILATOR Inlet The crankcase ventilator inlet is part of the crankcase oil filler cap assembly on the 6 cylinder engines This filler cap contains copper gauze which filters the...

Page 21: ...5 at 12 Hq 10 at 1200 RPM 5B 6B 7B 020 38 17 20 oz 4 at 8 Hq 9 at 2000 RPM 8B 017 27 17 20 oz 40 at 16 Hq 17 5 at 1700 RPM Generator Output RPM Cold 870 Hot 950 RPM Cold 1800 Hot 2000 Voltage Regulato...

Page 22: ...below 1 225 at 70 F indicates a low battery that should be recharged FIGURE 1 If gravity varies more than 25 points between cells battery should be recharged and tested under load CAUTION Electric st...

Page 23: ...stance in the connections to the starter Check battery cables and con nections and repeat the Load Test INDIVIDUAL CELL TEST To use a Starter Battery Tester 1 Connect the positive ammeter lead to the...

Page 24: ...heck for loose connections or frayed cables STARTER SOLENOID 1 Connect negative voltmeter lead to Bat terminal of starter solenoid switch and positive lead to motor terminal of the solenoid switch Fig...

Page 25: ...t in the radiator filler neck radiator filled with coolant to the over flow pipe indicates a leaking cylinder head gasket cylinder head or internal cracks in the water jackets An extreme blow by at th...

Page 26: ...he plugs and replace plugs in cylinder head 5 Tighten plugs finger tight then tighten with a torque wrench to 25 to 30 foot pounds If torque wrench is not available tighten 3 4 of a turn 6 Examine spa...

Page 27: ...10 TAPPET ADJUSTMENT To adjust tappets on six or eight cylinder engines proceed as follows 1 Raise front end of car and place stand jacks under frame crossmember 2 Remove the right front wheel 3 Remov...

Page 28: ...to hone pitted contact points as refaced contacts do not have the finish for satisfactory performance NOTE If points are badly pitted check the condenser for over or under capacity See Electrical Sect...

Page 29: ...obtained on the Dwell Meter The highest reading will occur when the points are entirely closed The meter should read inside the b lock bar at the right end of the scale Point Resistance A reading out...

Page 30: ...ether Turn the condenser con trol knob to the Microhm position and allow the tester to warm up for one minute Then turn the control knob to read on the set line 4 After calibrating the condenser teste...

Page 31: ...inter vals for the Hudson Eight If the f lashes do not appear to within one degree of the respective angles it indicates an inaccurate cam 14 Turn vacuum switch to the ON position 15 Set degree ring...

Page 32: ...ected from the distributor primary terminal and the ground lead to the battery starter terminal Figure 16 3 With ignition switch on turn Master Control Switch to Coil Set and adjust Coil Set Regulator...

Page 33: ...the Milliam pere position and read Coil Meter Milliampere Scale 3 The reading should be the same at each spark plug A low reading established on a comparative basis may indicate a weak coil excessive...

Page 34: ...st until a spark jumps from the wire to the cylinder head then tighten quadrant screw Correct ignition timing is indicated by a slight ping at about 15 MPH when accelerating at full throttle from 10 M...

Page 35: ...ths or less 5 If the resistance is more than 8 make the following checks with the ammeter connected as in paragraph 1 a Remove the positive voltmeter lead from the battery and Install to the A termina...

Page 36: ...he voltmeter positive lead to the regulator base and the negative lead to the regulator B terminal Figure 25 FIGURE 25 3 Run engine at approximately 2000 R P M 4 Turn resistor knob in until ammeter re...

Page 37: ...ant pressure under the varying conditions of fuel consumption and engine speed 1 Remove and clean the fuel pump sediment bowl and screen 2 Replace the screen if damaged NOTE If the combination fuel an...

Page 38: ...t cover FIGURE 28 FIGURE 29 3 Remove screws attaching carburetor air horn 4 Disconnect throttle connector rod and remove bowl cover 5 Float setting should be measured as in Figure 23 for Models WA1 74...

Page 39: ...en the metering rod arm set screw J METERING ROD SETTING WA1 1 Remove air cleaner and dust cover 2 Remove hairpin clip and disconnect spring from metering rod 3 Remove metering rod and disk 4 Insert m...

Page 40: ...35 and hold choke valve closed by holding arm down on choke lever L 2 Then close throttle There should now be 026 clearance use gauge KMO 658 T 109 189 between the throttle valve and bore of carbureto...

Page 41: ...JUSTMENT WA1 1 Open throttle wide open and check clearance be t we en lower edge of choke valve and air horn Clearance should be 7 16 A Figure 38 2 Adjust by bending cam B on throttle lever IDLE ADJUS...

Page 42: ...correct reading for combustion efficiency and perfor mance at an idle speed of 540 560 R P M 490 510 on cars equipped with Hydra Matic should be 70 plus or minus 3 with a peak manifold vacuum Adjust...

Page 43: ...ING ALL MODELS 3 points in rubber with standard transmission 4 points in rubber with Hydra Matic transmission Material Drive Bearings Type Number Diameter Length No 1 No 2 No 3 No 4 No 5 Radial Cleara...

Page 44: ...None Bronze 750 x 29 32 0 to 0003 at 70 F PISTON 232 Cu In Type Cam Ground Material Aluminum Alloy Weight and Length 18 1 8 Oz x 3 3 4 Pin Center to Top 2 310 to 2 314 Piston Clearance 0015 to 0025 Ri...

Page 45: ...77 lbs at 2 3 16 160 lbs at 1 27 32 Mushroom Integral with block 6245 to 6250 62325 to 62375 00075 to 0015 2 310 26 7 BTC 91 9 ABC 67 BBC 40 3 ATC On Flywheel Pressure 40 lbs at 30 MPH Rotor Worm on C...

Page 46: ...3 4 ENGINE FIGURE 1...

Page 47: ...aft bearings main bearings connecting rod bearings pistons piston pins and bushings timing chain and sprockets and all other movable parts requiring lubrication Figure 8 NOTE Normal oil pressure is 40...

Page 48: ...something is wrong with the oiling system OIL CHECK VALVE 6 CYLINDER Oil pressure is regulated by a built in non adjustable oil check valve consisting of a plunger spring plug retainer and plug gaske...

Page 49: ...uced and possibly stopped 3 Install shaft and bushing align hole of bushing with hole in pump body and ball of shaft in hole in plunger Installation To Install reverse procedure of removal OIL PUMP 6...

Page 50: ...or 4 pressed to one side of pump body with feeler gauge measure clearance between the outer rotor and body at opposite side This clearance should measure 008 If clearance is more than this replace pum...

Page 51: ...rs 4 Remove one bolt and loosen the second bolt in each shock absorber anchor plate which will allow the shock absorbers to slide out of the anchor plates 5 Remove the outer bolt each side of 2 crossm...

Page 52: ...3 10 ENGINE FIGURE 8...

Page 53: ...tube 2 Before Installing oil pan place two quarts of recom mended oil in the oil pan troughs and Install oil pan to engine Installing two screws each side to hold oil pan until all screws have been en...

Page 54: ...emoval 8 Cylinder and in addition the following operation Remove vacuum advance tube at octane selector Installation 1 Make sure cylinder head is free from carbon and dirt Check cylinder head with a s...

Page 55: ...e pin will engage the upper half of the bearing and turn it out with the rotating action of the crankshaft Figure 14 NOTE Check main bearing oil seal for leaks and if it is necessary to replace the se...

Page 56: ...Replacer Tool entered in oil hole of crank shaft and with hinged head of Replacer against bearing end rotate crankshaft pulling the bearing into position Figure 14 NOTE The bearing shells are held in...

Page 57: ...ing Installed to make a solid seal flush with front face and bottom face of the bearing caps MAIN BEARINGS 8 Cylinder NOTE To determine shell thickness proceed as follows 1 Add the diametral clearance...

Page 58: ...nt SIZE CODE When replacing crankshafts the undersize dimension is located on the front face of No 1 counterweight When replacing main bearings the 010 undersize di mension is noted by a spot of green...

Page 59: ...irst then into the horizontal holes of the front bearing bearing cap Insertion of packing is greatly facilitated by using tool J 392 Figure 19 SIX AND EIGHT CYLINDER ENGINE REMOVAL NOTE The engine and...

Page 60: ...nder tie panel and radiator support channel 4 Remove the four hex bolts attaching radiator to channel NOTE Remove the nuts located inside the radiator channel 5 The radiator may now be lifted up and f...

Page 61: ...rottle rod and selector 10 Install speedometer driven gear and speedometer cable 11 Install universal joint to transmission companion flange Lock plates securely 12 Install propeller shaft center supp...

Page 62: ...be noted by reference to Figure 21 that the end gap is equal to the back lash of the ring notch on pin Therefore the ends of a ring are filled to obtain the desired 005 to 009 gap on 8 cylinder and 0...

Page 63: ...ation KEY TO CODE MARKINGS 8 Cylinder 254 Cu In PISTON CYLINDER RING SIZES Ring Oversizes Apply Only to Production Type Rings NOTE Piston size shown above is the major diameter at top of skirt at A Fi...

Page 64: ...he top of the piston is 2 310 to 2 314 for the 232 Cu In engine Figure 24 and 2 060 to 2 064 for the 262 Cu In engine Figure 25 Also note dimensions of the 308 Cu In engine Figure 26 FIGURE 24 3 22 EN...

Page 65: ...change the pull on the feeler only a few pounds and the use of this scale will eliminate guessing FIGURE 27 CAUTION When pistons are fit to reconditioned bores the cylinder block should be allowed to...

Page 66: ...linder engine REPLACEMENT 1 Press out old bushings by supporting the bushing end of the connecting rod on Bushing Burnisher Block J 2950 for 6 cylinder and J 2951 for 8 cylinder Remove the bushing 2 I...

Page 67: ...reby spraying the exposed cylin der wall with an additional supply of oil Connecting rods have steel backed babbitt lined bearings interchangeable on all rods upper and lower and are held in position...

Page 68: ...he index pin located at the bottom of the fixture so that it touches the connecting rod bearing end 2 Remove the rod from the arbor and turn the rod around and reassemble the rod to the arbor placing...

Page 69: ...of engine Figure Figure 32 On the 8 cylinder engine the connecting rod dipper opening must be toward valve side of engine Figure 33 NOTE The notches in the lower and upper caps should be on the same...

Page 70: ...3 28 ENGINE FIGURE 32...

Page 71: ...ENGINE 3 29 FIGURE 33...

Page 72: ...to make sure that lower half oil retainer fits squarely and tightly against the upper half retainer Also make sure that gaskets are in good condition Screw holes in cap mounted oil retainer are elon...

Page 73: ...ibration dampener TIMING GEARS 6 8 Cylinder TIMING GEAR COVER REMOVAL 1 Drain cooling system 2 Disconnect hoses and remove radiator 2 bolts each side of radiator cradle 3 Remove fan blade pulley and f...

Page 74: ...nt 2 Use a new timing gear cover gasket and Install the gear cover Install all screws centralize cover seal on spacer sleeve and tighten screws finger tight then tighten all screws to 15 20 ft lbs NOT...

Page 75: ...l both at the same time engaging the chain with the crankshaft gear NOTE If crankshaft has not been rotated during the removal it will not be necessary to check the timing If timing has been disturbed...

Page 76: ...3 34 ENGINE FIGURE 40...

Page 77: ...h the service parts department in both finish reamed and unfinished The finish reamed bearings are sufficiently oversize so that when pressed into place they will be the proper dimensions thus elimina...

Page 78: ...3 36 ENGINE FIGURE 41...

Page 79: ...reversing procedure of removal 18 Replace coolant and start engine 19 Adjust tappets engine hot Intake 008 Exhaust 010 20 Replace tappet covers and breather pipe NOTE Tighten breather pipe attaching...

Page 80: ...hin 0015 Figure 42 One method of obtaining alignment is to tighten clamp nuts just less than snugly then bump outer face of clamps sharply inward using a wide piece of fiber or brass inter posed betwe...

Page 81: ...ENGINE 3 39 FIGURE 44...

Page 82: ...ve timing Valve seats in the cylinder block should be cut with a suitable valve seat cutter The seats should be cut only enough to remove pits and surface glaze If seats are made too too wide in the c...

Page 83: ...er Pilots Figure 47 page 3 41 to Install the valve guides The Installer pilots are fitted with collars to control the height of the valve guides when Installing the exhaust guide should be 1 3 32 and...

Page 84: ...le shown as A Figure 49 When checking eight cylinder valve timing dimension A should be 9 16 4 Reset No 1 intake valve to recommended clearance of 010 hot or 012 cold and reInstall tappet cover VALVE...

Page 85: ...ill Outside Only No 10 drill Square vertical nee dle Size No 46 081 drill hole in needle seat 5 16 weatherhead nipple Length 190 width 040 136 to 140 above valve with valve closed No 46 drill Slip noz...

Page 86: ...r Idle bleed size No 52 0635 drill Outside only No 10 drill Square vertical push pull needle size No 46 081 drill hole in needle seat Length 190 Width 040 178 t o 182 above valve with valve tightly cl...

Page 87: ...e No 53 0595 drill Outside only No 10 drill Square vertical push pull needle size No 46 081 drill hole in needle seat Length 165 width 030 120 t o 124 above valve with valve tightly closed No 46 drill...

Page 88: ...choke linkage to hold the choke open on all wide open throttle operations A cam on the choke valve shaft is brought against an adjusting screw when the choke is closed The screw is adjusted to hold t...

Page 89: ...mitted to the carburetor throat through the high speed circuit is controlled by a stepped and tapered metering rod Figure 3 2 Opening the throttle raises the metering rod allowing more fuel to pass th...

Page 90: ...der of gauge should be less than 005 with throttle valve seated Gauge must not drag on pin 6 Adjust by bending lip on piston link at A 7 Remove gauge and Install metering rod and disk 8 Reconnect mete...

Page 91: ...et screw B Figure 8 4 Clearance between lower edge of choke valve and air horn should be 5 8 A Figure 7 5 Adjust by bending fast idle link at offset portion FIGURE 8 IDLE ADJUSTMENT 1 Start engine and...

Page 92: ...ly Figure 9 FIGURE 9 2 Remove air horn and climatic control assembly Figure 10 and lift off air horn gasket FIGURE 10 3 Disconnect throttle connector rod then remove bowl cover with all parts attached...

Page 93: ...t Figure 14 FIGURE 15 8 Remove the pump discharge ball retainer and gasket and check ball Figure 15 FIGURE 16 9 Remove nozzle passage plug nozzle retainer plug and nozzle Figure 16 Be sure to remove s...

Page 94: ...ve screws choke valve shaft and piston assembly from air horn Do not remove the piston housing attached to the air horn with rivets 16 Remove all parts from the bowl cover ASSEMBLY 1 Clean casting and...

Page 95: ...y before tightening screws Peen ends of screw threads to keep screws from loosening FIGURE 25 NOTE Back out throttle lever adjusting screw be fore Installing shaft assembly FIGURE 26 7 Install idle po...

Page 96: ...ather of plunger for damage If leather is not in good condition replace entire plunger assembly 15 Install metering rod jet and gasket assembly Figure 34 Examine for wear FIGURE 34 If jet is worn repl...

Page 97: ...by bending throttle connector rod at lower angle 21 Adjust metering rod after pump adjustment is made See Figure 4 Insert metering rod gauge 1 1265 in place of metering rod seating tapered end in jet...

Page 98: ...n bore by tapping lightly Hold in place with finger while tightening screws Peen ends of screw threads to keep screws from loosen ing 27 Install the piston housing and thermostatic coil assembly Figur...

Page 99: ...e of valve with valve closed tight Size 0615 t o 0655 diame ter Nozzle Metering Rod Jet Metering Rod Accelerating Pump Pump Adjustment Choke In primary venturi round end type Inside diameter No 30 dri...

Page 100: ...res F of carburetor and leave screw backed out until carburetor is Installed on engine 2 With the pump connector link in the outer hole D in pump arm long stroke the pump plunger should travel 5 16 fr...

Page 101: ...de after making the fast idle adjustment 1 Hold the throttle valve wide open and close the choke valve as far as possible without forcing 2 Check clearance between upper edge of choke valve and inner...

Page 102: ...remove the carburetor assembly DISASSEMBLY 1 Remove the dust cover screws cover and gasket Figure 53 FIGURE 53 2 Remove the retainer clips and remove the throttle connector rod and choke connector rod...

Page 103: ...VER ASSEMBLY FOR MORE THAN ONE HALF HOUR NOTE Carefully note slots in choke piston cylinder If they are carbonized remove the welsh plug by piercing center with a small pointed instrument and pry outw...

Page 104: ...ll the throttle valves Small c at A Figure 66 in circle should be toward idle port at B when viewing casting from manifold side Center throt tle valves by tapping lightly and holding in place with fin...

Page 105: ...FIGURE 69 6 Assemble body casting to flange Figure 70 Use new gasket FIGURE 70 7 Install the intake ball check G Figure 71 Then Install the retainer ring H and the strainer I FIGURE 71 8 Install disc...

Page 106: ...loat lip at N FIGURE 76 Figure 76 then lower needle into seat until float and lever line up with holes and Install float lever pin Set float to specifications Page 4 15 and Install new bowl cover gask...

Page 107: ...rm and Install hair pin clip Insert the lower end of pump connector link in hole in plunger shaft Hold arm R in place and press shaft through arm Hold metering rod arm U with lip extending through slo...

Page 108: ...oosen metering rod arm set screw c Press down on the vacumeter link until metering rods bottom in body casting d With torque on arm touching lip top of slot of link tighten metering rod arm set screw...

Page 109: ...nk choke connector rod and retainer clip Figure 89 FIGURE 89 26 Install choke trip lever assembly Figure 90 FIGURE 90 27 With the choke valve tightly closed adjust the fast idle by bending choke conne...

Page 110: ...our gaskets on each side of heat deflec tor Figure 95 Replace all broken or damaged gaskets and straighten deflector if damaged FIGURE 95 1 Install carburetor and Install nuts and lock washers on the...

Page 111: ...twin carburetor manifold to the exhaust manifold 10 Remove studs from the exhaust manifold 11 Layout and center punch the location of the second hole for choke heater tube 1 9 16 from the center of th...

Page 112: ...bes front and rear in exhaust manifold heater tubes and connect upper ends to carburetors 24 Install the intake manifold compensator tube assembly 6 using the gaskets cap screws and lock washers provi...

Page 113: ...or adjust ment purposes This pin serves to locate the bellcrank while rod adjustments are made 34 On cars not equipped with Overdrive transmission the accelerator pedal stop must be shortened by cutti...

Page 114: ...s of both throttle shaft t o carburetor rods While holding the front carburetor fast idle cam in the off position turn the throttle stop screw until it just touches the cam Repeat with rear carburetor...

Page 115: ...A E oil for temperatures above 32 F and 20 S A E for lower temperatures COPYRIGHT 1949 BY CARTER CARBURETOR CORPORATION ALL RIGHTS RESERVED FIGURE 103 FUEL PUMP Carter mechanical fuel pump M 729SZ Fi...

Page 116: ...um gauge to inlet port of pump and operate engine Gauge should show 6 of mercury or higher for satisfactory operation 8 If fuel pump pressure is low but vacuum reading satisfactory difficulty is in th...

Page 117: ...FUEL SYSTEM EXHAUST 4 33 FIGURE 105 COPYRIGHT 1949 BY CARTER CARBURETOR CORPORATION ALL RIGHTS RESERVED...

Page 118: ...nt needed These are AC tools No Pt 8 and two 10 32 x 1 1 211 screws If you do not have these tools or equivalent do not attempt to overhaul the pump 1 Mark edges of fuel cover 25 Figure 106 and body d...

Page 119: ...FUEL SYSTEM EXHAUST 4 35 FIGURE 106...

Page 120: ...er Replace bullet type pin with head type pin and washer 6 Link Replace because amount of wear cannot be determined visually 7 Rocker Arm Spring Replace Spring may be weak from distor tion or corrosio...

Page 121: ...eal on vacuum diaphragm pull rod in the following sequence oil seal spring 31 upper retainer 34 oil seal washer 32 and lower retainer Turn lower retainer 90 degrees to lock in position 12 Lift the pum...

Page 122: ...f 5 0 volts The input source can therefore be DC intermittent or interrupted DC or AC just so long as the average input voltage does not drop below 5 0 volts Input voltage lower than 5 0 volts will re...

Page 123: ...er terminal of panel gauge and eliminate the lead wire from the panel indicator to the unit from the regular circuit Repeat empty and full check If tank check If now operating O K correct or replace b...

Page 124: ...ve coil bracket and manifold 6 Remove all traces of old gasket material Installation Use new manifold gaskets and reverse procedure of removal EXHAUST MANIFOLD 8 Cylinder REMOVAL 1 Remove air cleaner...

Page 125: ...emove air cleaner by loosening the attaching screw at the carburetor air horn 2 Remove the throttle connection from carburetor 3 Remove the fuel line and vacuum line from carburetor 4 Remove heat rise...

Page 126: ...ime 3 Install exhaust pipe bracket at clutch bell housing 4 Now tighten bolts at connection to exhaust manifold and in clamp connecting front and rear pipes 5 Install the oil pump heat shield and inse...

Page 127: ...tem Capacity 6 or 8 Cylinder 6 Vane Impeller Pump Fan VBelt 30 G P M at 50 M P H Two Sealed Ball Bearings Pre Lubricated Generator Mounting Pump Shaft 4 Blade 18 7 8 18 1 2 Quarts With Heater 19 1 2 Q...

Page 128: ...evel to approximately 2300 F with a 7 lb pressure cap CAUTION When removing pressure cap while the engine is hot always turn cap slowly counter clockwise until the stop is reached Keep the cap in this...

Page 129: ...lcohol methanol synthetic wood alcohol and ethylene glycol It is recommended that the cooling system system be cool before adding an antifreeze solution To facilitate accurate testing of freezing poin...

Page 130: ...P REMOVAL 1 Drain the cooling system by opening drain cock at lower right side of radiator and remove the pipe plug from left rear side of cylinder block NOTE It is not necessary to remove the radiato...

Page 131: ...lug 6 Bearing retainer 7 Body to block bolt 8 Shaft slinger 9 Pulley assembly 10 Fan blade assembly 11 Body cover to block gasket 12 Impeller 13 Shaft seal 14 Shaft seal washer 15 Body to cylinder blo...

Page 132: ...hat they can be turned with the fingers the bearing should be replaced 3 Worn shafts and shafts with a worn spring retainer groove should be replaced REASSEMBLY 6 Cylinder 1 Assemble the shaft and bea...

Page 133: ...ket 4 Body pipe plug 5 Body 6 Bearing retainer 7 Shaft slinger 8 Pulley assembly 9 Fan blade assembly 10 Body cover gasket 11 Impeller 12 Shaft seal 13 Shaft seal washer 14 Body to cylinder block bolt...

Page 134: ...definite amount of slack to prevent an overload being placed on the water pump and generator bearings Adjustment of the belt is obtained by swinging the gener ator on its mountings as follows 1 Loose...

Page 135: ...tance in the unit causes the instrument panel gauge to read at the cold end of the dial with ignition switch turned on FIGURE 8 FIGURE 9 When the coolant is hot the low resistance in the unit causes t...

Page 136: ...or Installation Reverse procedure of removal NOTE Proper clearance between the fan blades and the radiator core is 7 8 Should the fan be too close there is danger of damaging the radiator core on an e...

Page 137: ...brushes Bronze Ball 003 to 010 Positive 1 3 to 1 5 at 5 0 Volts Measure from armature to field Terminals 3 9 to 4 4 amperes at 5 0 Volts Have field terminal grounded to the frame and measure from arma...

Page 138: ...h Spring Tension Armature End Play Cranking Voltage Cranking Amperage Approx Free Running Test Volts Amperes RPM Stall Test Volts Amperes Min Ft Lbs Auto Lite MZ 4167 6 4 4 42 53 oz 005 to 062 5 Volts...

Page 139: ...2 Bronze 005 max 003 010 Flywheel Centrifugal Governor Advance Distributor degrees and distributor RPM IAT 4009 232eng IAT 4009A 262 8 308 eng IAT 4009B 232 262 308 eng IGT 4204B 254 eng 0 at 300 RPM...

Page 140: ...rolyte level in the battery should be at the bottom of the square in filler cap opening Only pure distilled water should be added to the battery Electrolyte level should be checked at chassis lubricat...

Page 141: ...the starter Voltage should not exceed 2 volts 3 Connect positive voltmeter lead to car frame and nega tive lead to starter motor frame Crank the motor with the starter Voltage should not exceed 2 volt...

Page 142: ...tch and turn battery tester control knob clockwise until volt meter reads exactly the same as when cranking the engine with starter 5 Read Test Ammeter for starting motor amperage draw 6 After complet...

Page 143: ...with a set of test probes in series with a lamp and a source of electricity 2 Touch one probe to the armature core and touch the other to the end or shoulder of each commutator segment in turn FIGURE...

Page 144: ...ra Matic Drive equipped cars Install Bendix Drive Housing and through bolts Installation Reverse procedure of removal BENDIX DRIVE The inboard Bendix drive is exposed and may be serviced without remov...

Page 145: ...B terminal of the voltage regulator and connect a reliable ammeter between the terminal and the lead 2 Run the engine and turn on lights or accessories until a 10 ampere charge shows on the ammeter 3...

Page 146: ...is made with a resistor type tester the resistance knob must be turned to the out position 5 If generator fails to build up remove generator for overhaul DISASSEMBLY 1 Remove cover band N Brush Sprin...

Page 147: ...T 1 Touch one test probe to armature terminal stud and one to field terminal stud 2 If lamp does not light an open circuit is present 3 To determine which coil is open hold one test probe on the conne...

Page 148: ...6 12 ELECTRICAL SYSTEM FIGURE 10...

Page 149: ...ELECTRICAL SYSTEM 6 13...

Page 150: ...trip of steel or hack saw blade on the armature core 2 Rotate armature slowly 3 Steel strip will vibrate if armature is shorted 4 If short is present replace armature ARMATURE COMMUTATOR REPAIR 1 Plac...

Page 151: ...sembly 3 Install felt washer retainers and bearing in drive head end 4 Install bearing retainer gasket felt washer and bearing retainer 5 Install snap ring on armature and assemble on drive head end 6...

Page 152: ...6 16 ELECTRICAL SYSTEM FIGURE 12...

Page 153: ...tall to the A terminal at the voltage regulator Ammeter should show less than 1 tenth B Connect the voltmeter negative lead to the regulator A terminal and the voltmeter positive lead to the regu lato...

Page 154: ...to 7 volts the circuit breaker points should close and the ammeter will now show that the generator is charging 5 Next slowly reduce the engine speed and watch the am meter NOTE When the ammeter reads...

Page 155: ...ry and set load to 50 amperes or use the equivalent in seal beam lamps 3 Run engine to approximately 2000 RPM amperage reading should be 40 amperes If it is not within a toler ance of one to two amper...

Page 156: ...ht load and engine vacuum is high the breaker plate is rotated to the maximum advanced position However under heavy load conditions as when the throttle is opened for additional acceleration or accele...

Page 157: ...mbly and Install screws C and nuts H 11 Check alignment of contact points Bend the station ary contact arm if necessary to secure proper align ment and contact DO NOT bend breaker arm 12 Tighten screw...

Page 158: ...nstall cam hairpin retainer and oil wick Apply a drop of engine oil to centrifugal weight pivots and cam slots 6 Pack breaker plate bearing 1 2 full of high melting point grease and Install breaker pl...

Page 159: ...tributor counter clockwise Clockwise rotation of the distributor retards the spark Ignition timing may be accurately set by using a neon timing light Connect the timing light as recommended by manufac...

Page 160: ...ire feeler gauge and adjust by bending the ground side electrode Figure 22 FIGURE 22 When replacing spark plugs always use new gaskets to assure correct seal Seat the plug with the fingers and use a t...

Page 161: ...capacity If the pit is on the stationary contact positive the condenser is over capacity 21 to 25 micro farad for 6 cylinder 20 to 25 microfarad for 8 cylin der CONDENSER TEST 1 Block distributor poin...

Page 162: ...l Set and adjust Coil Set Regulator knob until meter reads on proper Set Line 4 Turn switch to Coil Test position The meter re ad i n g must be within the Good C oil band and hold steady to denote a g...

Page 163: ...he lamp housing D and is held to the housing by four coil springs E plus the vertical adjustment screw F and the horizontal adjustment screw G The three locating lugs H are located so that the reflect...

Page 164: ...een to the right and left of the center line at a distance equal to one half of the center to center distance 28 1 2 between the two lamps Place dimmer switch in position which produces highway upper...

Page 165: ...se at back of clock Weather Control Fourteen ampere fuse in a fuse case on left side of weather control housing Radio Fourteen ampere fuse incorporated in the radio A lead wire Drivemaster Ten ampere...

Page 166: ...Tighten lock nut E securely before checking gap The armature B should be approximately parellel with the field A After the air gap has been properly adjusted it is necessary to readjust nut H to obta...

Page 167: ...Pin should strike left pawl and disengage switch 8 Repeat with switch lever down and turn wheel right Pin should strike right pawl and disengage switch 9 If pin fails to strike pawl pin may be too sho...

Page 168: ...d X Figure 35 3 Connect two 21 C P test lamps in parallel to terminal marked L Lamps and to the battery Lamps should flash on and off 4 With above lamps connected connect a 2 C P test lamp to terminal...

Page 169: ...te and flywheel against the pressure of the engaging springs 7 This action disconnects the driv ing plate 1 and drive gear 15 from the flywheel CLUTCH PEDAL ADJUSTMENT To assure full disengagement of...

Page 170: ...h throwout finger retainer 6 Clutch throwout finger retainer nut 7 Clutch engaging spring 8 Clutch engaging spring inner 9 Clutch cover 10 Clutch cover gasket 11 Clutch cover bolts 12 Clutch collar as...

Page 171: ...st pan and turn fly wheel until drain plug is at its lowest position Remove plug and drain out the old clutch compound 2 Turn flywheel until clutch filler hole is opposite timing opening in rear engin...

Page 172: ...ch housing 15 Re m e the two engine rear mounting bolts and nuts at third crossmember 16 Jack up rear end of engine about 1 2 off the frame CAUTION Place a block of wood under head of jack to prevent...

Page 173: ...hook in the corresponding hole in the opposite frame side rail 15 Remove two screws attaching the flywheel dust pan to bottom of clutch housing and remove dust pan 16 Remove the two engine rear mount...

Page 174: ...lowest finger to top of cover hub A as shown in Figure 6 On a clutch in good condition the distance should be 1 1 4 to 1 1 2 when the interposed driving plate is 200 to 213 and the gaskets are 028 to...

Page 175: ...e 3 holes should not exceed 008 Covers that are not within these limits should be replaced unless equipment and skill is available for doing an accurate job of straightening Cover hub bore C against w...

Page 176: ...for flatness 3 Assemble the previously tested engaging springs into seats on pressure plate spacing inner spring arrange ment equally to insure proper balance 4 Check position of corrolation marks on...

Page 177: ...il over bore wall Care must be exercised to prevent damaging the lip of the oil seal or curling it over in the bore 6 Center the throwout bearing grease retainer leather washer 17 Figure 1 not the oil...

Page 178: ...frame 10 Remove the two bolts from the pedal lever housing and bushing assembly to frame and remove the master cylin der and bracket assembly the brake pedal lever and the pedal lever housing and bus...

Page 179: ...1530 301532 16 16 4 1 10 4 5 9 7 10 or 7 60 x 15 7 10 or 7 60 448212 448214 All with Overdrive All with Overdrive SECTION 8 TRANSMISSION Manual Type Single Shift Lever SPECIFICATIONS Bearings and Bush...

Page 180: ...8 2 TRANSMISSION FIGURE 1...

Page 181: ...Cluster Bushing Front 40 Countershaft Gear Cluster 41 Main Drive Gear Clutch gear 42 Countershaft 43 Drain Plug 44 Cluster Bushing Rear 45 Speedometer Cable 46 Speedometer Pinion 47 Speedometer Cable...

Page 182: ...his will disconnect the linkage connecting the Gear Shift to the transmission 9 Remove 2 screws and remove flywheel guard from bottom of clutch housing and remove the two engine rear mounting bolts an...

Page 183: ...ve the speedometer drive gear 8 Remove 2nd and high shift rail stop screw FIGURE 4 9 Remove lock screw from low speed shifter fork an d lock screw from the low speed shifter Figure 4 NOTE To remove th...

Page 184: ...m needle roller pilot bearing in rear end of main drive gear Move synchronizer shift sleeve into 2nd speed position and low reverse sliding gear as far rearward as it will go then lift mainshaft assem...

Page 185: ...st FIGURE 13 washer and two bronze thrust washers through cover opening Figure 12 20 Working through mainshaft bearing hole in front face of case drive out reverse idler gear shaft with Driver J 1574...

Page 186: ...d out of housing Figure 17 FIGURE 17 27 With retainer removed from case insert the two seal engaging jaws of Oil Seal Remover J 1576 one at a time between metal portion of seal and retainer Place the...

Page 187: ...w engine oil rotating the bearings by hand in order to spread the lubricant over all surface Transmission mainshaft bearings are built originally with end play and because they may feel quite loose it...

Page 188: ...out e r selector lever in position pointing toward left of case Install plain washer shakeproof washer and nut and tighten securely 4 Apply a few drops of oil to shift shaft then insert shaft in case...

Page 189: ...Remove lock ring and ring center die case 3 Insert the new stop ring and ring centers and turn ring center in the stop ring 1 4 turn to line up recesses in the ring FIGURE 24 center with the 8 locking...

Page 190: ...nion flange being careful to prevent injury to the oil seal Install plain washer and self lock ing nut Tighten to 90 100 foot pounds using a torque wrench THIS NUT MUST BE KEPT TIGHT COUNTERSHAFT Inse...

Page 191: ...il lock ball and lock spring 8 Install transmission cover using a new gasket FIGURE 28 Install clutch bell housing use new gasket Tighten each of the 6 cap screws to 45 foot pounds Install drain plug...

Page 192: ...otherwise reduce the diameter of the dowel bolt to facilitate Installation 5 Remove the two headless screws or guide studs J 2969 6 Install remaining clutch bell housing bolts and screws and tighten w...

Page 193: ...ar loose on main shaft splines Sliding gear teeth worn or tapered Worn misaligned mainshaft splines Worn countershaft first speed gear Excessive end play of reverse idler Insufficient gear mesh Too mu...

Page 194: ...sing and Bracket 18 Control Wire Anchor Bracket Upper 19 Control Wire Anchor Bracket Lower 20 Control Wire Dust Boot Steering End 21 Control Wire Dust Boot Trans End 22 Control Wire Anchor 23 Control...

Page 195: ...bell crank to shift shaft outer lever rod 27 and outer shift shaft lever back and forth The outer shift shaft lever is attached to the transmission shift shaft an inner lever mounted on the shift sha...

Page 196: ...eering wheel 2 Remove upper bracket 5 and ring 6 3 Remove gear shift lever fulcrum screw 4 lever 1 and anti rattle spring washer 3 4 Remove hairpin clip anchor 22 at lower end of control tube and disc...

Page 197: ...nd second and high gears through forks and an interlock arrangement common to both shafts Separate rubber mounted rods connect the outer shift shaft levers to the two levers on the transmission contro...

Page 198: ...8 20 TRANSMISSION FIGURE 10...

Page 199: ...ive Gear Snap Ring 29 Main Drive Gear Bearing Snap Ring 30 Main Drive Gear Bearing 31 Main Drive Gear Oil Retaining Washer 32 Main Drive Gear 33 Main Drive Gear Bearing Retainer Gasket 34 Transmission...

Page 200: ...ring and removing the transmission 7 With a universal socket on a 10 extension remove the two top bolts attaching transmission to clutch housing Insert in their places guide studs J 2969 to guide tran...

Page 201: ...in their proper positions Figure 34 FIGURE 34 11 To remove main drive gear place a brass bar or drift against the rear face of the drive gear teeth at the top not synchronizer gear teeth and carefully...

Page 202: ...rear face projects 1 4 beyond the retainer The shift shaft oil seals are renewed by driving out the old seals from the inside of the case with a punch and tapping the new ones in place from the outsi...

Page 203: ...e interlock sleeve contacting a shift shaft cam measure the clearance with a feeler gauge be tween the opposite end of the sleeve and the cam of the other shift shaft Figure 42 This clearance should b...

Page 204: ...offset to front and engage fork in groove of low sliding gear 3 Installsecondspeedgear 4 Assemble synchronizer hub shift plates shift sleeve springs and synchronizerringstogetherasaunitandslideonmain...

Page 205: ...smis sion case with a feeler gauge Take off retainer 5 Select a gasket 003 to 005 thicker than clearance shown by feeler and Install between retainer and case 6 Install and tighten 4 cap screws holdin...

Page 206: ...ush Rod Tube 12 Key Lower End 13 Retaining Ring Lever 14 End Push Rod Lower 15 Pin Lever Operating 16 Lever Assembly 2nd High 17 Lever Assembly Low and Reverse 18 Bracket Lower Control Tube 19 Spring...

Page 207: ...ts in new control tube and fulcrum bracket assembly reversing procedures covered in the foregoing operations When Installing spring retainer 2 2 adjust retainer bolt 23 so there will be a space of 27...

Page 208: ...en shift rod attached to low and reverse lever by mov ing adjusting nuts at trunnion 1 4 turn at a time until smooth action is obtained 9 Check gear shifting by moving control lever through the variou...

Page 209: ...OVERDRIVE 9 1...

Page 210: ...lever 25 Shift rail sleeve spring 26 Shift rail sleeve Single Lever Type 27 Shift fork 28 Sun gear shift collar 29 Sun gear pawl 30 Sun gear pawl oil seal 31 Solenoid assembly 32 Overdrive mainshaft r...

Page 211: ...driver while operating in overdrive may require additional acceleration beyond that available by opening the throttle wide His natural impulse is to press the accelerator further and his act releases...

Page 212: ...l the overdrive gears and their directly associated control parts revolve together as a unit On the other hand if the throttle is closed removing the driving force the rollers release their wedging co...

Page 213: ...ither consciously or un consciously and according to his own choice may mo mentarily close the throttle whereupon the roller clutch releases and the engine slows down At the same time the sun gear slo...

Page 214: ...shift rail and shift fork back wards shifting the sun gear so that the lockup teeth will engage the corresponding teeth of the pinion cage This causes the entire group of working parts to revolve as...

Page 215: ...OVERDRIVE 9 7 FIGURE 10...

Page 216: ...ar through the overdrive gear train the pawl is pinched by the torque reaction and cannot release until the driving torque is removed This is accomplished as follows The solenoid stem is provided with...

Page 217: ...al with sharp punch Coat outside of new seal with white lead and drive seal into place with a tubular driver having an inside diameter of 5 8 and outside diameter of 15 16 SERVICING UNITS REQUIRING RE...

Page 218: ...ing rollers NOTE Removal of the overdrive housing will expose the overdrive mainshaft and ring gear free wheeling cam pinion and cage assembly shift rail and fork stationary gear stationary gear cover...

Page 219: ...arate these units Figure 15 FIGURE 16 6 Remove the sun gear and shift rail assembly Figure 16 FIGURE 17 FIGURE 18 8 Remove the large snap ring at the adapter plate Figure 18 FIGURE 19 9 The retainer p...

Page 220: ...le to mix with the lubricant in the bearings Bearings should be washed in clean gasoline or kerosene DO NOT SPIN the bearings and particularly do not spin bearings with an bearings with an air hose Sp...

Page 221: ...overdrive housing coat the shift shaft oil seal counter bore with white lead and tap in a new oil seal 23 Dip the threaded end of the shift shaft in liquid soap and using care push the shaft through...

Page 222: ...ion OF ADAPTOR PLATE SOLENOID PAWL SUN GEAR CONTROL PLATE AND BLOCKER SOLENOID SUN GEAR SHIFT RAIL AND FORK Double Lever Type 1 Install the adaptor plate and use one of the overdrive housing attaching...

Page 223: ...shaft inward and engage the slot in the shift rail with the shifter shaft lug Lug must be up and outside control lever down Insert J 4149 O D Aligning Pilot in lower right hand hole of adaptor and hou...

Page 224: ...s holding clutch housing to engine end plate and Install two J 2969 headless screws or studs to support the transmission until the balance of the screws are removed 25 Remove breather pipe bracket fro...

Page 225: ...hen remove shift fork and shifter also the shift rail interlock 5 Remove the set screw from the second and high shift fork and the shift rail stop screw then slide the shift rail out of front of case...

Page 226: ...proper assembly of these parts in reassembly 12 Remove the synchronizer shift sleeve and hub assembly intermediate gear and low and reverse gear from mainshaft 13 Remove the large snap ring from the a...

Page 227: ...n the mainshaft with the tapered end of the shift sleeve toward the front of the mainshaft 8 Install synchronizer shift sleeve hub lock ring on end of mainshaft using lock ring pliers 9 Apply a coatin...

Page 228: ...a shift shaft cam measure the clearance with a feeler gauge between the opposite end of the sleeve and the c am of the other shift shaft Figure 28 This clearance should be from 001 to 007 If not with...

Page 229: ...ong hub of the sleeve pointing forward Be sure that marks painted on parts during disassembly are in proper alignment also that the hooked ends of the two synchronizer springs engage in the same shift...

Page 230: ...s precaution is not taken difficulty will be encountered when Installing the transmission and the front end of the drive gear shaft and pilot bearing in the flywheel will be damaged 2 Rotate clutch co...

Page 231: ...he solenoid pawl rod to move out If solenoid chatters in Check A Hold In Coil is defective B ENGAGING SPRING With jumper wire still con nected as in paragraph A solenoid energized plunger extended pla...

Page 232: ...down switch mounted in the floor under the accelerator ped al The accelerator pedal rod on these cars should be adjusted so that the carburetor throttle is wide open just before the accelerator pedal...

Page 233: ...the dash control knob is pushed in the lockup switch may be held open thus disabling electrical control operation Likewise it may hold the shift rail in such a position as to interlock the pawl agains...

Page 234: ...awn from its normal loca tion This may cause the blocker ring to rotate so that its two lugs are not located with respect to the pawl In other words the solid portion of the blocker ring may be in ali...

Page 235: ...elay fuse replace it if necessary If fuse is good connect the test lamp between ground and each of the fuse clips in turn If lamp does not light at either fuse clip inspect wire between relay terminal...

Page 236: ...wire at control switch If click occurs inspect wire for ground also inspect switch terminal for grounding contact with some other part of the car If no click occurs replace connection and F With gove...

Page 237: ...le stiff the shift into reverse will be easier if done as follows A Shift lever into reverse position as far as it will go easily then allow clutch to engage slightly while continuing to push on lever...

Page 238: ...9 30 OVERDRIVE REFERENCE Source of Information Date Subject...

Page 239: ...sed on cars equipped with Hydra Matic Transmissions as shown in Figure 1 all other models with standard transmission use the same conventional type mounting as previously used 8 Universal joint 9 Prop...

Page 240: ...lock plates U bolts and disconnect universal joint at transmission companion flange NOTE Use adhesive tape or rubber band to keep journal bearings assembledtoUniversaljournalwhenremovingthepropellersh...

Page 241: ...as just removed and remove the remaining bearing cup and rollers 6 Wash all parts in gasoline and replace all worn parts FIGURE 3 1 Companion Flange 2 Propeller shaft U bolt 3 Propeller shaft U bolt n...

Page 242: ...moulded or painted red Standard Production 40 Durometer Hardness Both cushions on all models with Black moulded 60 Durometer Hardness used on left side of mounting for models equipped with Hydra Mati...

Page 243: ...he pinion and the rear bearing Oil leakage is prevented by a hydraulic type inner spring oil seal of chrome leather The ring gear is mounted on the differential case flange by eight special alloy stee...

Page 244: ...lock washer 14 Differential carrier to housing bolt nut 15 Differential carrier to housing bolt 16 Differential carrier to cap assembly 17 Differential case left half 18 Drive pinion 19 Rear pinion b...

Page 245: ...izer bracket 44 Rear axle housing vent assembly 45 Differential pinion thrust washer 46 Drive shaft thrust button 47 Differential gear 48 Differential gear thrust washer 49 Drive gear bolt 50 Drive ge...

Page 246: ...stands under the body frame so that the rear axle will be suspended to permit removal and servicing of the rear axle unit 2 Remove rear fender shields by lifting up lever 1 front and rear over and out...

Page 247: ...ntal movement of the body and car It also prevents lateral shake of the axle under the car on rough roads IMPORTANT The ends of the steel bar are cushioned in rubber and no lubrication should be appli...

Page 248: ...o be removed from both sides of the axle that each set should be kept sepa rate and reassembled in their original location in order that proper bearing adjustment is maintained If an axle shaft bearin...

Page 249: ...the axle shaft removing the thrust button shank 4 Clean out the thrust button hole 5 Drive anew thrust button in the hole making certain it is firmly seated in the shaft DIFFERENTIAL CARRIER DISASSEMB...

Page 250: ...d case See Figure 15 4 All internal differential parts will then be loose and can be removed by hand DRIVE PINION OIL SEAL REMOVAL NOTE The pinion oil seal can be removed without re moving the pinion...

Page 251: ...pinion oil seal and pinion front bearing cone replacer J 2639 to Install new oil seal Fig ure 18 and reverse procedure of removal DRIVE PINION 1 With companion flange holding tool J 2637 and J 2971 de...

Page 252: ...ved from bearings 3 After cleaning lubricate bearing with clean engine oil and inspect for wear scoring and rough spots When the rear axle has been completely disassembled gears carrier and housing sh...

Page 253: ...liable soak thoroughly in SAE 20 engine oil prior to Installation 4 Install rear bearing shims 002 and 003 thick on the drive pinion shaft See Note 5 Sliderearbearingoverpinionshaftwithtaperfacingtowa...

Page 254: ...produc tion and 095 washers are available for service 3 Assemble differential pinions spacer and thrust washers on the differential pinion shaft and place in the left hand half of the differential ca...

Page 255: ...t while this operation is being accomplished the ring gear be rotated to allow the tapered bearings to seat properly FIGURE 31 12 Rest plunger of dial indicator on the outer edge of the ring gear toot...

Page 256: ...axle shafts Use J 2995 1 speedometer gear In staller tool and with a light hammer tap bearing into position with a single light blow approximately 2 pounds CAUTION Excessive hammering or Installing b...

Page 257: ...rear spring to rear shackle but do not Install shackle bushings at this time 3 Install spring mounting clips plates insulators washers and nuts and tighten to 65 foot pounds Install lock nuts 4 Instal...

Page 258: ...es that A The axle shaft drive pinion or differential bearings are improperly adjusted B Differential ring gear and pinion tooth contact is improp erly set 4 Coast noise will be more pronounced by all...

Page 259: ...cup and the housing to control the fore and aft position of the pinion and its mesh with the drive gear Another shim pack placed between the rear face of the front bearing cone and the shoulderofthepi...

Page 260: ...11 18 REAR AXLE FIGURE 25...

Page 261: ...ear Bearing Shims 25 Drive Pinion Rear Bearing Cup 26 Drive Pinion Rear Bearing Cone 27 Differential Side Bearing Shim 28 Differential Side Bearing Cup 29 Differential Side Bearing Cone 30 Housing Cov...

Page 262: ...ts and clamps from rear universal joint and disconnect propeller shaft Place tape around bearing cups 14 Remove nuts from rear axle U bolts and take off U bolts mounting plates cushions and retainers...

Page 263: ...screwdrivers placed under the differen tial case an d resting against the housing as shown P r y out assembly as straight upward as possible to prevent damage Figure 41 7 Remove cups from differentia...

Page 264: ...2 5 Figure 45 Carefully remove shim pack from behind bearing cup Measure and record thickness and tie shims together for reInstallation FIGURE 45 19 Remove drive pinion oil seal assembly wick oil slin...

Page 265: ...sing opening facing upward clean bearing bores in housing and Install differential as sembly 7 Install bearing caps in correct positions with letters on caps matching those on housing and tighten bolt...

Page 266: ...r face of pinion with clamp bar and screw Figure 49 15 Mount discs of pinion setting gauge J 5223 on gauge arbor and Install gauge in differential bearing bores of axle housing Figure 49 Place differe...

Page 267: ...bore at front of housing Place new oil seal in housing and Install with rear face seated against gasket 25 ReInstall companion flange washer an d nut torquing nut to 180 220 foot pounds 26 Inspect dif...

Page 268: ...lock washers and nuts Install new oil seals in caps and tighten flange bolt nuts to 12 17 foot pounds 4 Check axle shaft end play which should range between 001 and 004 Change thickness of shim pack o...

Page 269: ...cket is attached to the frame side member by three bolts The outer end is attached to the steering spindle support by the eccentric bushing pivot bolt STEERING SPINDLE The steering spindle and the ste...

Page 270: ...rs 6 Figure 1 Turn shock absorber 1 4 turn and remove through opening 6 Shock absorber anchor plate and attaching nuts 7 Front stabilizer bar 8 Stabilizer connectors 9 Brake backing plates 10 Steering...

Page 271: ...ds 14 Right and left steering arms 15 Drag link assembly 16 Pitman steering arm 11 Remove front wheel suspension assembly INSTALLATION 1 Replace assembly and install upper support arm pivot 28 and bus...

Page 272: ...left side of car 6 Install stabilizer connector 8 7 Install tie rod end at steering arm 13 8 Install brake backing plate 9 9 Install wheel assembly and lower car When the car does not seem to be leve...

Page 273: ...f support arm and the exact distance of 1 1 2 between the inner face of support arm and the center line of the nuts holding the pivot to the cross member These distances must be maintained A 010 overs...

Page 274: ...er spread of the pressed steel support arm to insure proper tension on the threads of the pivot after the bush ings have been installed 1 Install the gauge tool J 1360 Figure 9 on the outer stud of th...

Page 275: ...Remove bushing 23 from the steering spindle support and upper support arm 6 Remove eccentric bushing from steering spindle support using upper support arm eccentric bushing adjusting wrench KMO 366 F...

Page 276: ...n key seal is lead and is used with the key that holds the steering arm to the steering spindle This key also holds the pivot pin and the lead seal prevents lubricant being forced down the outside of...

Page 277: ...er removing the grease fitting insert tool J 479 through the hole at top of steering spindle and begin to drive pivot pin 32 Figure 13 out of spindle This action will force out expansion plug and reli...

Page 278: ...he steering arm nut with a torsion wrench to 110 to 120 foot pounds CENTER STEERING ARM REMOVAL 1 Remove draglink 15 Figure 2 at front by backing off adjusting plug and ball seat 2 Remove tie rod ends...

Page 279: ...ie rod clamp 45 Tie rod end bearing 46 Tie rod end stud 47 Tie end rubber seal TIE ROD REMOVAL 1 Remove cotter pin and nut from both ends of the tie rod 2 Using Tool 1 2781 remove outer end 3 Using To...

Page 280: ...isted Check wheel alignment by testing camber steering pivot pin inclination and caster If support arms have been removed from the car check specifications as shown in Figure 21 Replace arms do not at...

Page 281: ...operating 4 Wheel bearings adjusted too tight 5 Incorrect toe in unequal caster or camber 6 Coil springs sag 7 Rear axle shifted 8 Front frame bent or broken 9 Front stabilizer not centralized REMEDY...

Page 282: ...of adjustment 5 Steering spindle spindle support or tie rods bent CAR WANDER CAUSE 1 Low or unequal tire pressure 2 Steering gear or connections loose or worn 3 Steering gear or connections not proper...

Page 283: ...her of the front wheels at the front STEERING GEOMETRY Steering Geometry or toe out on turns is controlled by the movement and angularity of the tie rods GENERAL INSPECTION Before checking the alignme...

Page 284: ...er angle and pivot pin inclination angle have been checked NOTE When checking the caster the wheels should be turned on their bearings to bring the high spot or that portion of the tire with the great...

Page 285: ...en the front and rear wheels The center steering arm will now be centered an d steering gear will be on the high point for a straight ahead position TOE OUT Steering geometry or toe out on turns is co...

Page 286: ...12 18 FRONT SUSPENSION REFERENCE Source of Information Date Subject...

Page 287: ...stiffly operating unit and one having lost motion since adjustments can be set at the will of the adjuster at the most desirable point Worm and 3 tooth roller 20 4 to 1 18 2 to 1 Needle Tapered roller...

Page 288: ...0 Figure 1 over steering column jacket tube 9 3 Place steering wheel and cover assembly in position on column with two spokes horizontal and third spoke straight down 4 Insert horn wire contact cup 5...

Page 289: ...12 Direction Indicator canceling pin spacer 13 Main column tube 14 Worm shaft upper bearing cup 15 Worm shaft upper bearing 16 Oil filler plug 17 Worm shaft lower bearing 18 Worm shaft cover 19 Worm...

Page 290: ...screw lock nut 12 Worm cover shims 13 Oil filler plug 14 Main column tube 15 Worm shaft cover 16 Grease retainer tube 17 Worm shaft lower bearing 18 Worm shaft lower bearing cup 19 Worm shaft upper b...

Page 291: ...ng column tube and remove bearing FIGURE 4 INSTALLATION 1 Start bearing into jacket tube by hand 2 Using Replacer tool J 2952 Figure 4 drive bearing to a depth of 31 32 on cars without direction indic...

Page 292: ...pitman arm is clear 8 Remove steering gear through wheel opening in left front fender FIGURE 6 DISASSEMBLY 1 Drain lubricant and mount assembly in a vise 2 Using puller No J 1374 Figure 6 remove pitm...

Page 293: ...and tighten nut 11 Replace felt washer on column tube at steering gear housing INSTALLATION 1 Install steering gear assembly on frame and insert but DO NOT TIGHTEN three bolts attaching steering gear...

Page 294: ...e gear shaft cover and adjustment screw assembly 5 If oil seal is not to be replaced cover serrations on gear shaft with waxed paper to protect seal 6 Remove gear shaft needle bearings and bearing spa...

Page 295: ...hori zontal position of spokes is attained and attach drag link 9 Remove gauge and replace nut on center steering arm pivot Before re using elastic stop nut strike the face of the nut a sharp blow wi...

Page 296: ...without resulting in excess worm bearing end play Align steering gear as follows 1 Disconnect drag link at pitman arm 2 Loosen three bolts attaching steering gear h o u s in g to frame and allow hous...

Page 297: ...eering arm bracket 43 Tie rod clamp 3 Remove the 3 bolts attaching the center steering arm bracket 42 to the No 2 cross member Figure 9 4 Remove the center pivot nut 41 and remove the center steering...

Page 298: ...DER OR WEAVE Insufficient caster Incorrect toe in adjustment Worn king pins bushings Worn front wheel bearings Tight steering assembly Loose spring shackles Sagging broken springs Bent broken frame Lo...

Page 299: ...dth Number of Leaves Including Rebound Leaf Heavy Scale Load Weight Rate Length Width Number of Leaves Including Rebound Leaf Lubrication Shackles Spring Eye Dimension Part Number Markings Head of Cen...

Page 300: ...or both coil springs The light and heavy coil springs may be identified by the part number stamped on the top coil of spring FRONT COIL SPRINGS REMOVAL 1 Raise the car and place stand jacks under inne...

Page 301: ...of some cars equipped with metal covers This type spring should be lubricated every 10 000 miles Lubricate through hole in cover using viscous chassis lubri cant use special tool for that purpose REMO...

Page 302: ...55 75 lbs torque 6 Finish tightening the rear shackle nut It is important that the shackle be located properly so as to insure the bushing being threaded far enough on the shackle but not far enough t...

Page 303: ...or rear position Resistance calibration is different in front and rear shock absorbers and is properly set at the factory The principles of operation are the same in the present shock absorbers as pre...

Page 304: ...se procedure of removal Shock absorber inspection procedure is as follows 1 Remove units from car 2 Check condition of grommets and replace if worn 3 Mount shock absorber in a vise being careful that...

Page 305: ...at axle and well up on the bar and the cushions and washers in place at both ends 2 Push the bar through axle bracket and then put frame end in place with cushion and washer and locating guide rod in...

Page 306: ...14 8 SPRINGS SHOCK ABSORBERS STABILIZERS REFERENCE Source of Information Date Subject...

Page 307: ...to the hydraulic system past the rubber cups behind the pistons as the shoes are manually expanded BRAKE MASTER CYLINDER The brake master cylinder is a combined supply tank and master cylinder It main...

Page 308: ...le lever guide plate 25 Rear brake cable clevis 26 Rear axle tee to left rear wheel tube 27 Rear axle brake tee 28 Rear axle tee to right rear wheel tube 29 Brake shoe to anchor pin spring rear 30 Bra...

Page 309: ...supply tank filler cap 1 can be reached by raising the front floor mat and removing three self tapping screws and lifting off the round floor cover FIGURE 3 NOTE Master cylinder should be kept at lea...

Page 310: ...its groove 6 Assemble push rod guard boot 8 and push rod 6 in place and install strap 7 INSTALLATION 1 Install master cylinder bracket and insert the two 3 1 2 long bolts 13 Figure 1 through bracket a...

Page 311: ...s use KMO 526 Replacer Position small end of tool over anchor pin place spring hook over shaft of tool and pry spring into position Figure 6 FIGURE 6 WHEEL CYLINDERS REAR NOTE Use same procedure as sh...

Page 312: ...urn hold down spring cups 6 and remove cups springs and pins on both shoes 4 Remove shoes 5 Remove adjusting screw 8 6 Disconnect adjusting screw spring 9 7 Thoroughly clean away all traces of rust an...

Page 313: ...ingbrake lines Remove dirt around filler cap before removal for inspection of fluid level NOTE If there is any doubt as to the grade of brake fluid present in the system flush out entire system with a...

Page 314: ...system and glucose forms a sticky mass when exposed to air and has no lubricating qualities Mineral oil in even the smallest quantity should never be used The slightest trace of mineral oil will destr...

Page 315: ...push rod 8 Remove bolt holding bracket at rear of master cylinder 9 Remove clutch operating lever held by woodruff key and lock bolt 10 Remove master cylinder push rod 11 Remove lock ring at brake cr...

Page 316: ...drums 8 Disconnect end of brake cable from cable lever at brake shoes To Install Reverse Procedure and Lubricate Cables FIGURE 11 LINKAGE LUBRICATION A thin film of chassis lubricant should be applied...

Page 317: ...under Major Brake Adjustment 7 Reinstall the adjusting hole covers in the backing plates 8 With the hand brake fully released the brake cables should permit the anchor ends of the rear brake shoes to...

Page 318: ...gure 10 8 Push cable into conduit and after the shoes have been reinstalled connect the cable to the shoe cable lever 5 Figure 1 leaving the adjustable yoke ends 25 of cables disconnected from toggle...

Page 319: ...After moving the anchor pin it will be necessary to pry the primary shoe against the drum by inserting a pry between the lining of the secondary shoe and drum through the drum feeler gauge hole and mo...

Page 320: ...raulic system will cause a springy or rubbery action of the pedal Should a sufficient quantity of air be allowed to get into the system the pedal will go to the toe board under normal pressure In this...

Page 321: ...the other 3 Loose backing plate will allow the brake assemblies to shift on their locating bolts which determine the exact centers and any shift causes an unequal brake efficiency Tighten backing pla...

Page 322: ...15 16 BRAKES REFERENCE Source of Information Date Subject...

Page 323: ...subsequent tire wear causes them to go out of balance T o maintain proper balance and assist in prolonging tire life it is the tire manufacturers recom mendation that the wheel and tire assemblies be...

Page 324: ...ined as in Figure 1 The putty can then be weighed and balanced weight or weights attached permanently to the rim to correspond to the weight of the putty The sum of the weights of section 1 and 2 is e...

Page 325: ...and also pre cludes the possibility of dust and dirt getting into the valve Replace missing valve caps promptly Keep tires inflated to the following pressures Size Front Rear 7 10 x 15 Standard 26 lb...

Page 326: ...emove cotter pin and turn nut to the right sufficiently to insure that parts are properly seated and then back off the nut until a slight drag is felt when turning the wheel by hand 4 Loosen the nut s...

Page 327: ...outer bead and rim at a point opposite the valve stem and work bead over the rim Leave tool in place and work other tool around bead and force remainder of the bead over the rim BE CAREFUL NOT TO DAM...

Page 328: ...Upper Bolt Nut Spark Plugs Speedometer Housing Screw Strg Arm outer Nut Strg Arm center Nut Steering Arm Center Pivot Support Bracket Bolt Steering Gear Shaft Nut Strg Gear to Frame Bolt Strg Spindle...

Page 329: ...5 203125 21875 234375 25 265625 28125 296875 3125 328125 34375 359375 375 390625 40625 421875 4375 453125 46875 484375 5 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 5...

Page 330: ...REFERENCE Source of Information Date Subject...

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