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Pontiac 1969 Firebird, Service Manual

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Pontiac 1969 Firebird Service Manual Download Page 681

Summary of Contents for 1969 Firebird

Page 1: ...Released by www 78ta com Serial Number 69SER 002 1012 ...

Page 2: ......

Page 3: ...de may be found stamped on the Body Identification Plate Fig 0 2 This plate is SERIAL N U M B E R S S T A R T I N G W l T H 1 0 0 0 0 1 T O BE USED F O R A L L V 8 E N G I N E S PONTIACS TEMPESTS FIREBIRDS A N D G R A N D PRIX SERIAL NUMBERS S T A R T I N G W l T H 6 0 0 0 0 1 T O BE USED F O R A L L 6 CYL E N G I N E S TEMPEST FIREBIRD O N L Y IN E A C H C A S E NUMBERS ARE T O BE U S E D IN C O ...

Page 4: ...vertible 23767 LE MANS SAFARI 2 Seat Station Wagon 23935 23935 G T O Hardtop Coupe 24237 24200 Convertible 24267 FIREBIRD Hardtop Coupe 22337 22300 Convertible 22367 i Fig 0 4Car Model Identification ENGINE IDENTIFICATION 6XYL The 8 1 engine code is located beneath the produc tion engine number on a machined pad on the right hand bank of the engine block Fig 0 5 and should be used whenever refemng...

Page 5: ...e model year For more details and location of V I number derivative see section 7G of this manual TWO SPEED AUTOMATIC The transmission identification number located on the TRANSMISSION IDENTIFICATION Fig 0 7 Turbo Hydra Matic M 40 Serial Number Location lower semo cover Fig 0 9 right side of the transmission contains model and assembly date code For more complete information and location of V I nu...

Page 6: ...he steering wheel must be centered and held in position by a steering wheel holding clamp or by tying it to the window division channel Tire to ground clearance should not exceed 6 inches while towing the car and speeds should not exceed 35 mph for distances up to 50 miles CAUTION Power steering equipped cars towed with all four wheelson the ground require extreme caution since there is nopower as...

Page 7: ...e key with the outline as accurately as possible 2 Starting at the base of the key blade determine the lowest level visible in position No 1 3 Determine the lowest visible level for the remaining five positions As each tumbler level is determined WAVE WASHER E K E Y FOR IGNITION AND DOOR LOCKS USE CODE SERIES OJOO TO 9J99 AND OK00 TO 9KOO ti K E Y FOR REAR COMPARTMENT AND GLOVE COMPARTMENT LOCKS U...

Page 8: ...Basic Dimensions Tread Fmnt 1 n dRW 0verh q Frmt Owrhaq R r r ROCKER PANEL SECTION A A ROCKER PANEL HEIGHT FRONT REAR 9 50 9 20 EXCEPTSTATIONWAGON 8 H D SPRINGS 9 80 9 80 WITH STATION WAGON 9 80 10 25 ALL H D SPRINGS Fig 0 16 Rocker Panel Heights Pontiac E F G U 6 0 M 40 7 42 3 81 O c en 40 1 C a 8 48 4 48 4 40 4 48 4 48 4 40 4 W 8 48 4 48 4 48 4 48 4 48 4 40 6 64 9 40 6 ...

Page 9: ...RB LOAD CONDITION 1 Y A L 3 3 0 0 4 PANEL nElGnT CURB ROCKER PANEL HElOHT NOMINAL MODELS FOR REFtRENCt ONLY CURB LOAD CONDITION A A CURB ROCKER ruLL rut1 TANK srrqlrlto Tire rntssunr P A N L nEIcnT STANDARD EQUIPMENT SPRINOS f TO GROUND Fig 0 17 Rocker Panel Heights Tempest and Grand Prix Fig 0 18Rocker Panel Heights Firebird ...

Page 10: ...nge every other oil change thereafter MANIFOLD HEAT CONTROL VALVE Observe for freedom of movement Lubricate with heat valve lubricant STATION WAGON TAILGATE HINGE AND LINKAGE Engine oil every six months more often if required CHASSIS LUBRICATION Lubricate all normally greased suspension parts includ ing balljoints POWER STEERING SYSTEM AND PUMP RESERVOIR Maintain lubricant level with GM power stee...

Page 11: ... 65625 43 64 671875 11 16 6875 45 64 703125 23 32 71875 47 64 734375 3 4 75 Drill Diameter Inches 0 2280 0 2210 0 2130 0 2090 0 2055 0 2040 0 2010 0 1990 0 1960 0 1935 0 1910 0 1890 0 1850 0 1820 0 1800 0 1770 0 1730 0 1695 0 1660 0 1610 0 1590 0 1570 0 1540 0 1520 0 1495 0 1470 0 1440 49 64 765625 25 32 78125 51 64 796875 13 16 8125 53 64 A28125 27 32 84375 55 64 859375 7 8 875 57 64 890625 29 32...

Page 12: ...LIQUID CAPACITY I quart 0 94633 liters 1 liter 1 05671 quarts 1 gallon 3 78533 Liters 1 liter 0 z6418 gallons DRY CAPACITY 1 quart 1 1012 liters 1 liter 0 9081 quarts 1 peck 3 071 liters 1 liter 32562 pecks HOOD LATCH INTERVALS WHICHEVER OCCURS FIRST Engine oil on pivots and spring anchor points and light grease on release pawl every six months or as FRONT WHEEL BEARINGS required Use high melting ...

Page 13: ...4 5 6 0 5 0 U S Pt 3 5 2 8 3 5 2 5 5 0 15 0 7 5 19 0 6 0 20 0 U S Pt 3 0 meeting SAE AND IMPERIAL TEMPEST Imp Gal 18 0 16 5 Imp Qt 10 0 10 25 15 25 16 5 16 75 17 75 Imp Qt 4 25 3 75 5 0 4 25 Imp Pt 3 0 2 5 3 0 2 0 4 25 12 5 6 25 15 75 5 O 16 75 Imp Pt 2 5 70R3 U S Gah 18 5 U S Qt 12 0 12 25 18 5 18 75 19 5 20 25 U S Qt 5 0 4 5 6 0 5 0 U S Pt 3 5 2 8 3 5 2 5 5 0 15 0 7 5 19 0 6 0 20 0 U S Pt 3 0 sp...

Page 14: ...rease BRAKEASSEMBLIES CAUTION Grease must be kept off brake linings remove by sanding MANUAL STEERING GEAR Add lubricant as necessary Change lubricant only when necessary to disassemble Use water resistant EP grease to level of center side cover bolt hole BODY DOOR LOCKS AND STRIKERS Stick type lubricant use sparingly as required DOOR HINGE HOLD PINS Light grease on friction surface Use sparingly ...

Page 15: ... is mounted on a ball bearing and a roller bearing Both bearings have a grease supply which eliminates the need for periodic lubrication The alternator brushes are extra long and under normal operating conditions will provide ex tended service CONVERTiBLE HYDROELECTRIC PUMP MOTOR The hydroelectric pump motor does not require periodic service CLUTCH RELEASEBEARING The clutch release bearing require...

Page 16: ...lace air control lever in OFF position 2 Hold air door crank on heater case in a closed position Crank rotated full clockwise when viewed from above 3 While holding air control door in closed position 1 Insure that cable is secured at control and at heater adjust turnbuckle to move lever against bottom of slot and routed smoothly and free of sharp kinks or bends in control panel then turn turnbuck...

Page 17: ...AIR CONTROL LEVER IN OFF POSITION A N D FREE FROM BENDS A N D KINKS 2 H O L D AIR D O O R C R A N K O N HEATER CASE IN CLOSED POSITION CRANK ROTATED FULL CLOCKWISE W H E N VIEWED FROM ABOVE AIR INLET CABLE 3 WHILE H O L D I N G AIR CONTROL D O O R IN CLOSED POSITION ADJUST TURN W C K L E T O M O V E L N ER A G A I N S T E N D O F SLOT IN CONTROL PANEL THEN TURN TURNBUCKLE IN OPPOSITE DIRECTION T O...

Page 18: ... NOT COME TO REST AT END OF TRACK REPEAT STEPS 3 8 4 UNTIL CABLE IS PROPERLY ADJUSTED SEE VlEW A VIEW B BLOWER SWITCH Fig 1 2Grand Prix HeaterCable and Vacuum Hose Routing ALL REMOVE AND REPLACE BLOWER SPEED SWITCH 1 Remove radio PONTIAC AND GRAND PRIX REMOVE AND 2 Remove screws retaining control to instrument REPLACE panel 1 Remove radio 3 Disconnect lamp and wire connectors and vacuum hoses on G...

Page 19: ...move switch attaching screws and switch 5 Check for operation 5 To install reverse removal procedure Blower speed is controlled by the blower motor HEATER WIRING HARNESS resistor esistancevalues for t s unit are shown on the heater wiring schematic ALL REMOVE AND REPLACE BLOWER MOTOR RESISTOR 1 Remove wire connector at blower motor dash ALL REMOVE AND REPLACE grommet and feed through dash opening ...

Page 20: ...EXCEED 118 DE ICE DEFROST CABLE Tnls A NON ADJUSTABLE ITEM Fig 1 4Firebird HeaterCable Routing 2 Disconnect blower switch connector AIR CONTROL OR DEFROSTER CABLE 3 Disconnect connector at accessory feed PONTIAC REMOVEAND REPLACE 4 Disconnect resistor connector 1 emove control from instrument panel 5 Pull harness from wire clips and remove harness 2 Remove nut and screw retaining cable to control ...

Page 21: ...rtment 2 Remove heater outlet Fig 1 6 2 Pull through grommet in dash to inside of car 3 Remove diaphragm retaining nuts from below 3 Disconnect hose from control panel and untape from harness 4 Remove nut retaining actuating lever to pin 4 To replace reverse removal procedure being certain 5 To replace reverse removal procedure to re tape to harness AIR DIAPHRAGM AND HOSE BLOWER MOTOR IMPELLER ANW...

Page 22: ...3 Remove motor or duct 4 Remove blower motor or duct retaining screws as desired 4 To replace reverse removal procedure using care to reseal duct NOTE Impeller is accessible with either 5 Remove motor or duct as desired duct or motor removed 6 To install reverse removal procedure using care to HEATER CORE ANDOR CASE reseal duct if removed GRAND PRIX REMOVE AND REPLACE ALL REMOVE AND REPLACE 1 Disc...

Page 23: ...ly from the firewall 5 Remove the bowden cables and all electrical connectors from the heater assembly and remove assembly On Grand Prix models disconnect vacuum hoses 6 Remove the core tube seal and core assembly retaining strips and remove core 7 Install the replacement core NOTE Be sure the core to case sealer is intact before installing core Use new sealer i f necessary 8 Install core retainin...

Page 24: ...ll radiator ALL REMOVE AND REPLACE Fig 1 8 is typical of defroster and heater duct HEATER HOSE INLET AND OUTLET installation and should be referred to when replacing these components ALL REMOVE AND REPLACE HEATER WIRING SCHEMATIC 1 Partially drain radiator ALL 2 Remove hose clamps and slide hose from fittings 3 Replace hose and secure clamps The heater wiring schematic is shown on Fig 1 9 Note tha...

Page 25: ...o the upper regions of the vehicle and is standare on all models When the valve is opened by the 4 Pull assembly from body area actuating lever air enters the vehicle from the plenum chamber One way valves in the door pillar post allow 5 To repla reverse removal prmdure using care to air in the passenger compartment to pass under the reseal duct rear seat into the trunk forward over the wheelhouse...

Page 26: ...TRUMENT PANEL OUTLA r PLENUM CHAMBER REAR WALL Fig 1 10Pontiac UpperVentilation System INSTRVMENT PANEL LH ONLY GRAND PRlX LH S H O W N RH OPPOSl Fig 1 11Tempest and Grand Prix UpperVentilation System I VlEW 0 L H SlDE A PLENUM PANEL L H SlDE Fig 1 12Firebird Upper Ventilation System ...

Page 27: ...t A three O f f Low High position switch on the instrument panel controls operation of the motors Fig 1 14 The two motor speeds are achieved by use of a 3 35 ohm resistance wire to each motor Approximately 106 inches of resistance wire provides low speed while high speed uses no resistance The motor harness is routed on the upper inner side of the dash to each motor VENT MOTOR ALL REMOVE AND REPLA...

Page 28: ...at enters the system PRECAUTIONARY SERVICE MEASURES Before any service is attemped which requires opening of refrigeration pipes or units the person doing the work should be thoroughly familiar with the material in the Diagnosis Manual Basic Air Conditioning Information Also he should follow very carefully the instructions given on the following pages for the unit being serviced 3 If for any reaso...

Page 29: ...hart DEPRESSURIZINGTHE SYSTEM ALL 1 Remove caps from suction gauge fitting on P O A valve and discharge valve gauge fitting on compressor 2 With both valves on manifold gauge set J 5725 01 closed clockwise attach manifold to P O A valve and compressor using J 5420 Schrader valve adapter at suction gauge fitting and J 6163 Schrader valve adapter at discharge gauge fitting 3 Crack open high pressure...

Page 30: ... of refrigeration system and the pump Pressure is now being reduced on both sides of refrigeration system 3 Attach a flexible gauge hose to center fitting of the NOTE oil is blownfrom vacuum pump it be gauge set and attach the other end of this hose to the relflled to the proper level with Frigidaire 150 viscosity vacuum pump J 5428 or J 5428 01 Fig 1A 2 oil or equivalent 4 The system can now be e...

Page 31: ...ting J 5462 9 to attachflexible line to refrigerant drum 2 Place refrigerant drum in a pail of water which has been heated to a maximum of 125OF CAUTIQN Do not allow temperature of water to exceed I2PF High temperature will cause excessive pressure and possible softening of fusible safety plugs in the refrigerant drum It may not be necessary to use hot water i f a large drum is used over approxima...

Page 32: ...TION TEST on one can 9 When satisfied that air conditioning system is operating properly stop engine remove gauge set and replace protective caps on P O A valve and compres sor fittings NOTE A considerable amount of refrigerant will colkct in the high pressure line since some of this rejhgerant will have condensed into liquid repigerant Wrap the highpressure gaugefiring at the compressor with a sh...

Page 33: ... operate system and test for proper operation as outlined under OPERATIONALTEST 8 When satisfied that air conditioning system is operating properly stop engine remove gauge set and replace protective caps on suction and discharge fittings NOTE A considerable amount of refrigerant will collect in the high pressure line since some of this refrigerant will have condensed into liquid refrigerant Wrap ...

Page 34: ... refrigerant that may have been lost by leaks or while opening system for servicing the compressor Before adding refrigerant to replace that lost by leaks check for evidence of oil loss if excessive add oil if necessary See ADDING OIL NOTE This procedure will only apply i f the air inlet temperature is above 7BF at the condenser 1 Remove caps from P O A valve and compressor gauge fittings Attach g...

Page 35: ...hance return of oil to the compressor under partially depleted refrigerant charge conditions on the custom air conditioning system an oil bleed line from the bottom of the evaporator to the suction line at the P O A valve has been provided The core in the bleed line fitting at the P O A valve has a special low force spring in it which allows the core to open a 5 to 12 psi pressure difference It is...

Page 36: ... following will apply DO NOT add any more oil than is necessary or maximum cooling will be reduced 1 Remove compressor from car drain and measure the oil 2 If amount drained in 1 above is more than 1 1 2 fluid ozs SUBTRACT this amount drained from the original oil charge of 11 ozs to obtain oil loss Take new compressor assembly and drain from it the amount of oil loss above provided the refrigerat...

Page 37: ...essor in this manner will prevent any oil from being thrown onto the clutch surfaces which would causeslippage and eventual clutchfailure 1 Stamp refrigerant charge of refrigerant system on new compressor in space on plate provided for this information NOTE Follow procedure for replacing oil in new compressor explained under REMOVING AND INSTALLING COMPRESSOR 2 Install new compressor on car leavin...

Page 38: ...ately 03lV 057 1 32 1 16 space between the frictional faceson pulley and drive plate Fig 1A 8 8 Remove J 9480 assembly 9 Install hub spacerwasher 10 Install hub and drive plate assembly retainer ring with flat side of ring facing spacer using J 5403 No 21 Truarc pliers J 9399 can be used to snap retainer ring in place 11 Install a new armature plate and hub lock nut using J 9399 special thin wall ...

Page 39: ...OR PULLEY ANWOR BEARING ASSEMBLY REMOVE AND REPLACEPONTIAC TEMPEST FIREBIRD OR GRAND PRlX REMOVE 1 Remove hub and drive plate assembly 2 Remove pulley assembly retainer ring using J 6435 No 26 Truarc pliers Fig 1A 9 3 Place J 9395 puller pilot over compressor shaft and remove pulley assembly using J 8433 pulley puller 4 Remove puller and J 9395 puller pilot 5 Remove pulley bearing wire retainer ri...

Page 40: ... CLUTCH COIL AND HOUSING ASSEMBLY ALL REMOVE AND REPLACE REMOVE 1 Remove hub and drive plate assembly 2 Remove pulley and bearing assembly 3 Remove electrical connection plug from terminals on coil 4 Note position of electrical terminals and scribe location of coil housing terminals on compressor body 5 Use J 6435 No 26 Truarc pliers and remove coil housing retainer ring Fig 1A 13 6 Remove coil ho...

Page 41: ...or brbken shaj seal See CHECKING COMPRESSOR OIL LEVEL AND ADDING OIL REMOVE COMPRESSOR ASSEMBLY TO NOTE Compressor shaft seals other than those SERVICE ENGINE PONTIAC AND TEMPEST replaced during a compressor overhaul are to be rblaced only on the basis of actual rejhgerant leakage 1 Disconnect compressor clutch coil ground wire at as determined by test with a propane torch rype leak compressor and...

Page 42: ... on the shaft using J 9392 3 Coat the seal face of the new seal seat with clean refrigeration oil and install the new seal seat using J 9393 1 and 2 Be sure the seal seat O ring is not dislodged and seal seat is making a good seal with 0 ring 4 Install new seal seat retainer ring using J 5403 No 21 Truarc pliers with flat face against seal seat The sleeve from J 9393 may be used to press on retain...

Page 43: ...embly 8 Service cylinder assembly front rear halves with main bearing in place and halves dowel pinned together 9 Major interior mechanism assembly 10 Suction reed valve front rear 11 Discharge valve assembly front rear 12 Gasket kit service containing all gaskets seals O rings etc This is to be used each time a compressor is rebuilt after a teardown 13 Shaft seal kit 4 14 Nuts head to shell and s...

Page 44: ...il from the compressor at this time 2 Attach J 9396 holding f t u r eto compressor and mount in vise 3 Remove compressor pressure relief valve 4 Remove four lock nuts from threaded studs welded to compressor shell and remove rear head NOTE Some oil may drain when the head is removed 5 Examine surface on the rear head casting web If any damage is observed the head should be replaced Fig 1A 18 6 Rem...

Page 45: ...l drain om compressor when mechanism assembly is removed 7 Remove compressor front head casting assembly from compressor shell Examine sealing surface for damage and or deep scratches Replace if necessary 8 Remove compressor front head casting to shell 0 ring seal and inspect for damage cuts nicks or imperfections A damaged seal may be the cause of a refrigerant leak In any event this O ring must ...

Page 46: ...sfactory for reuse put aside in assembly tray in compartment associated with proper end of piston 9 Remove rear combination of thrust races and thrust bearing Discard all three pieces Fig 1A 26 10 Push on shaft to remove shaft from front half cylinder 11 Remove front combination of thrust races and thrust bearing Discard all three pieces Fig 1A 24 Compressor Parts in Tray 12 Examine swash plate su...

Page 47: ...bearing pack tightly against swash plate hub while lifting shaft Fig 1A 30 11 Repeat this operation for No 2 and No 3 pistons Balls and shoes must adhere to piston during this assembly 12 Align rear cylinder casting with bores suction passage discharge crossover holes dowel pins etc Tap into place using a hard wood or plastic block and mallet Fig 1A 31 13 Place cylinder assembly in J 9397 compress...

Page 48: ...iston Drive 16 RING Pulley Bearing Ret 47 DISC Shoe 17 PULLEY ASSY Compressor 48 TUBE PKG Crossover Discharge No 33 Included 18 SNAP RING Bearing to Head Retainer 49 BEARING Needle Thrust 19 PLATE ASSY Clutch 50 KEY Clutch Hub 20 SPACER Clutch Hub 51 RACE Thrust Bearing 21 SNAP RING Clutch Hub 52 COVER Suction Passage 22 NUT Pulley Clutch to Shaft 53 SEAL Suction PassageCover See Note Group 9 170 ...

Page 49: ...shoe package f Place shoes in J 9402 assembly tray in compartment corresponding to piston number and rear bail pocket position REAR THRUST Fig 1A 30Installing Piston with Balls g Repeat in detail same gauging procedure explained above for each of the other two pistons 15 The next gauging operation is to determine space between REAR thrust bearing and upper or outer rear thrust race Check compresso...

Page 50: ...r stock Select a race accordingly Fig 1A 34 Measurements and Table of Available Service Shoes and Thrust Races d Select from stock a numbered thrust race that corresponds to dial indicator reading Fig 1A 37 NOTE Thrust races are made of steel and ground to a B e d thickness A total of fourteen thrust races are available for field service They will have increments of 000 5 thicknesstoprovide the re...

Page 51: ...bly tray 20 Remove REAR outer ZERO thrust race from shaft and replace it with numbered thrust race determined in step No 15 Apply a LIGHT smear of petrolatum to thrust races to aid in holding them in place during assembly NOTE This ZERO thrust race may be put aside for reuse in additional gauging andor rebuild operations 21 Apply a light smear of petrolatum to numbered shoes and place them over co...

Page 52: ...viscosity oil or equivalent Check for free rotation of mechanism 7 Check operation and smoothness of piston travel before proceeding with remainder of assembly If any improper operation is observed during this check the mechanism may have to be regauged Complete assemblywhen correct operation is obtained 8 Install crossover cover in cylinder 9 Place internal mechanism in J 9397 compressing fixture...

Page 53: ...faces of shell with clean 525 viscosity Frigidaire oil or equivalent Line up oil sump with oil intake tube hole and slide mechanism into shell Maintain this alignment when lowering mechanism into place Fig 1A 41 10 Place an O ring on the oil pick up tube apply oil to cavity and O ring Insert tube and O ring Fig 1A 42 rotating compressor mechanism as necessary and align tube with hole in the shell ...

Page 54: ... press on the retainer ring so that it snaps into place Remove tool J 21303 from end of shaft 11 Leak test compressor as described under LEAK TESTING THE COMPRESSOR using a propane torch type of leak detector in good condition Correct any leaks found 12 Wipe out any excess oil inside compressor neck and on shaft resulting from installing new seal parts 13 Install new absorbent sleeve by rolling th...

Page 55: ... 8 CLUTCH ASM REF VIEW A NOTE INSTALL RECEIVER ASSY WlTH FITTING LABELED COND AT POSITION SHOWN HIGH PRESSURE ALIGN END OF HOSE WlTH BEAD O N PIPE COAT END OF TUBE WITH COMPRESSOR 0 RING GASKET OIL BEFORE ASSY Fig 1A 46Refrigeration System Typical Tempest and Grand Prix Pontiac ...

Page 56: ... A valve Compressor belt tension specificationsare as follows 4 Remove intlet and outlet fittiqgs of valve New Belt 140 145 lbs Old belt 100 105 lbs EXPANSION VALVE AND SEALS ALL REMOVE AND REPLACE NOTE On some Firebirds it may be necessary to loosen and tip the compressor to gain access to thesefiltings 5 If valve is not immediately replaced cap openings to prevent entry of dirt and moisture 6 Re...

Page 57: ...els remove left case half 12 Remove core 13 To replace reverse removal procedure 14 Use care to reseal case halves and case to dash EVAPORATOR CASE LEFT HALF PONTIAC REMOVE AND REPLACE Follow procedure for core removal Case half can then be removed TEMPEST AND GRAND PRlX MODELS REMOVE AND REPLACE 1 Remove screws attaching left case and separate from dash and right case half Remove expansion valve ...

Page 58: ...screw 5 Remove front strap 6 Remove receiver 7 To replace reverse removal procedure FIREBIRD REMOVE AND REPLACE 1 Depressurizesystem 2 Remove baffle covering receiver dehydrator assem bly Fig 1A 47 3 Remove the receiver inlet and outlet connections and attaching screw from bracket 4 Remove from vehicle and plug openings 5 To replace reverse removal procedure and add one fluid oz of refrigerant oil...

Page 59: ...remove located in the kick pad and the other in the right hand battery and tray and then remove fender and skirt as plenum area Refer to Fig 1A 50 for service informa an assembly tion 5 Remove blower motor or inlet duct retaining screws BLOWER MOTOR IMPELLER ANDOR If remoVing inlet duct remove P O A valve heater BLOWER MOTOR CASE hoses and screws retaining duct to right case half ALL REMOVE AND RE...

Page 60: ...se to cowl attaching nuts Fig 1A 51 One some models it may be necessary to drill a 10 Adequately mark heater cam and bracket assembly On inch hole in fender skirt to gain access to lower nut in three places to insure proper reinstallation 3 Remove two water hoses attached to heater core 11 Remove heater cam and bracket assembly 4 Remove lower duct and outlet assembly 5 Remove glove box 6 Remove de...

Page 61: ...er design The select lever provides the mode of opera tion The temperature lever moves the temperature door to control incoming air temperature The blower lever controls blower speed The vent lever controls compressor operation and will turn on the compressor whenever the select lever is moved The lever may then m be moved to vent to turn off the compressor Serviceable items include the rotary vac...

Page 62: ...CUSTOM AIR CONDITIONING 1A 35 ...

Page 63: ...1A 36 1969 PONTIAC SERVICE MANUAL ...

Page 64: ...ins the in car A C harness through a rubber grommet just to the left of the 5 R diaphragms evaporator assembly The jumper lead used on V 8 models provides power to the compressor and blower DEFROSTER DIAPHRAGM via a 30 amp line fuse from the generator When servicing use care to route the harness as shown PONTIAC TEMPEST AND GRANDPRlX REMOVE in Fig 1A 60 AND REPLACE DIVERTER DOOR DIAPHRAGMS ALL REM...

Page 65: ...VACUUM CONNECTIONS 3 UNTIL CABLE IS PROPERLY Fig 1A 55Grand Prix Air ContitioningControl Cable and Vacuum Hoses 3 Remove vacuum hose then diaphragm 6 To replace reverse removal procedure 4 To replace reverse removal procedure AIR INLET DIAPHRAGMS PLENUMAIR VALVE DIAPHRAGM ALL REMOVEAND REPLACE FIREBIRD REMOVEAND REPLACE 1 Remove kick panel 2 Remove vacuum hoses 3 Remove two attachingscrews 4 Remov...

Page 66: ...center and side outlets All of the five 5 outlets have adjustable nozzles Right and left hand nozzles on Pontiac models may be mately 3 4 inch between instrument pad and upper edge of nozzle to disengage two retaining tabs There is a tab on each comer On Tempest models insert screwdriver in same position as Pontiac however the blade need only be inserted a short distance since tabs are directly be...

Page 67: ...s air control panel switches to the A C engine harness The system doors These hoses are contained in a harness which is receives control power from the power feed connector routed as shown in Figs 1A 52 53 54 and 55 Vacuum brown lead in instrument panel harness To senice schematics for these systems are shown in Figs 1A 69 the harness refer to Fig 1A 65 which shows typical 70 71 harness connection...

Page 68: ...CUSTOM AIR CONDITIONING 1A 41 CONNECTS TO IN CAR A C HARNESS CONNECTOR VIEW A 0 ENGINE Fig 1A 60Typical NC Engine Harness Installation ...

Page 69: ...o all 1969 standard air conditioned cars Note that each ALL REMOVEAND REPLACEOR ADJUST BELT model has a specific resistor block and that the resistance values are shown in the lower left hand Follow detailed instructions on illustration for corn corner Values for A can be obtained by connecting a pressor belt adjustment Fig 1A 66 for V8 engines previously calibrated ohm meter across terminal 1 and...

Page 70: ...CUSTOM AIR CONDITIONING 1A 43 O U T L E T NOZZLE Fig rn 62Tempest Air DistributionSystem VIEW A FLEX HOSE Fig 1A 63Firebird Air DistributionSystem ...

Page 71: ...1A 44 1969 PONTIAC SERVICE MANUAL RIGHT HAND DUCT I N S E R T THIN BLADE SCREW D R I V E R T H R U COLD AIR DUCT LEFT HAND WCT Fig 1A 64Grand Prix Air Distribution System ...

Page 72: ...CUSTOM AIR CONDITIONING IA 45 EXISTING RADIO S P E A K E MOUNTING BRACKET 6 H E A T E R POWER F E E D Fig 1A 65Typical N C In Car HarnessRoutingAnd Connections ...

Page 73: ...E L T TOAON BORROUGHS GAGE BT 3395 ACB STEP 3 TIGHTEN BOLT 1 TO 20 35 L B FT STEP 4 TIGHTEN BOLTS 2 3 4 5 6 6 TO 20 35 10 FT W F FIREBIRD AIR CONDITIONING WIRE WASHER COMPRESSOR B E L T THICKNESS PONTIAC TEMPEST COMPRESSOR Fig 1A 66Typical Compressor InstallationV 8 Models ...

Page 74: ... 6 6 7 SEE VlEW A COMPRESSOR 135 150 LBS TENSION INITIAL ADJ ON NEW BELT 100 105 LBS TENSION ANY ADJ THEREAFTER INSTALL BELTS OVER THIS PULLEY U S T ASSEMBLED VIEW A COMPRESSOR SPACE VlEW A MOUNTING U T E Fig IA 67 TypicalCompressor Installation6 Cyl Models ...

Page 75: ...Fig 1A 68 Air Conditioning Wiring Shcematic All ...

Page 76: ... C SLLECI I UPPER DCOR I 1r I f ORANTf INSEX iw ZOhTWL HEAD eBLKK O R VENDORCOOED ALLuM M E TAN STRIPE UPPER OOOR A C W C T Fig 1A 69Typical Pontiac and Grand Prix Vacu irn Schematic ENGME WCUUM oe ctDOOR V A W M VALVE Fig 1A 70 Tempest Vacuum Schematic ...

Page 77: ...1A 50 1969 PONTIAC SERVICE MANUAL 1 ENGINE VACUUM S O U I C I v Y a T R VALVE VENDOR CODED 4 L Fig 1A 71FirebirdVacuum Schematic ...

Page 78: ...ystem A T C is IN CAR SENSOR an option offered with air conditioning on all Pontiac and Grand Prix models The A T C system controls ALL REMOVEAND REPUCE incar temperature automatically by utilizing two thermistors temperature sensing devices and a varia ble resistor id the control panel controled by opera 1 Remove glove box on Pontiac and cold air duct on tor Grand Prix models The refrigeration po...

Page 79: ... ohms at 75 F The switch should be open at or below 32 F 6 To replace reverse removal procedure GRAND PRlX REMOVEAND REPLACE When checking with an ohmmeter the resistance value of the iiisar sensor should be approximately 1 Remove two wire connectors Fig 1 3 1000ohms at 75 2 Remove retaining screws AMBIENT SENSOR AND SWITCH 3 Remove sensor and switch assembly PONTIACREMOVEAND REPLACE VACUUM HOSE H...

Page 80: ...tic Temperature Control systems can be removed by using TO LOWER THE IN CAR TEMPERATURE to procedures for landard ystems These proccdum are suit owner preference insert tool J 23187 in slot in section 1A adjacent to lever as shown in Fig 1B 8 CONTROL PANEL COMPONENTS 2 Engage teeth on variable resistor and pull towards you to lower outlet temperature Several items on the Automatic Temperature Cont...

Page 81: ...1B 4 1 9 PONTIAC SERVICE MANUAL WAlER CONTROL PROGRAMMER BLUE CONTROL PANEL Fig 18 4Grand Prix Vacuum Hose Installation Fig 10 5Pontiac Vacuum Hose Installation ...

Page 82: ...RMINAL H TERMINAL K MASTER SWITCH VENT MEANS LINE VENTED TO ATMOSPHERIC PRESSURE VAC MEANS VACUUM APPLIED TO L l W TEMP CONTROL C O N S MEANS P O W CONNECTED TO ANOTHER PORT SEAL MEANS LINE SEALED AT END Fig 18 6 Pontiac Contrd Panel ...

Page 83: ... cold allowing removal of tool 3 Loosen screw retaining link to programmer arm and 11 Connect programmer connector separate the units Fig 1B 9 12 Replace glove compartment and cold air duct 4 Disconnect programmer connector shown in Fig 1B 10 IN CAR NC WIRE HARNESS 5 With ignition on and lever ofc ground The in car sensor programer bi level boost switch terminals2 3 and 4 Fig 1B 10identifies termi...

Page 84: ...ot to break heat sensor Pontiac and Grand Prix programmers are of the same To replace reverse removal procedure construction and the following procedure apply to both models Programmer links are differentm length ALL DISASSEMBLE Grand Prix links are colored black 1 Remove cover from programmer by removing five ALL REMOVE AND REPLACE 1 Remove positive battery terminal 2 Remove cold air duct and glo...

Page 85: ...nting screws making certain that ground lug is under the mounting screw nearest wheel Note that circuit board comes with a new finger blodr and lead cable attached 5 Solder previously disconnected leads Use resin core solder for all soldering operations ALL REMOVE 1 Scribe a thin line using a screwdriver knife or other sharp instrument on the potentiometer clip in line with edge of wheel rib so th...

Page 86: ...wire in same manner Be sure to use resin core solder 4 Install new motor making certain that worm gear is properly seated in its bearing block and properly meshed with helical spur gear 5 Reassemble unit by reversing disassembly proce dure When reinstalling programmer wheel follow specialinstructionsprovided below PROGRAMMER WHEEL REPLACE MOTOR REMOVE AND REPLACE 1 Follow procedure for programmer ...

Page 87: ...block with two screws 1 Remove cover plate on lower side of programmer 2 Unsolder green and orange lead 3 Install new resistor board and solder leads 4 Replace cover plate BI LEVEL BOOST SWITCH PONTIAC REMOVE AND REPLACE 1 Remove cover plate on bottom of heater core and case 2 Remove wire connector 3 Remove retaining screws then switch 4 Replace by reversing removal procedures GRAND PRlX REMOVE AN...

Page 88: ...hematic Fig 1B 16 shows the vacuum hose attachment and function Some of the hoses are color coded those The in car and engine A C harnesses are represented which are not in connectors Hoses at connectors can schematically in Fig 1B 17 Wire color function and be identified by using numbers on rotary vacuum connector identification can be obtained from figure ...

Page 89: ...1B 12 1969 PONTIAC SERVICE MANUAL ...

Page 90: ...two for the 124 wheelbase vehicles The Pontiac convertible and station wagon frames are essentially the same as other corresponding wheelbase frames but have the center side rail fully boxed for additional stiffness Five different frames of two wheelbases are used on Tempest models all 4 door styles and station wagons are 116 and all 2 door styles 112 The basic frame for the sedans and station wag...

Page 91: ...6 3567 3767 4267 A 41 30 41 30 41 30 41 34 B 20 65 20 65 20 65 20 67 C 52 36 52 36 52 36 52 36 D 21 59 21 59 21 59 21 59 E 43 18 43 18 43 18 43 18 P 10 63 10 63 9 43 10 63 F 66 19 62 19 66 19 62 19 G 68 18 68 18 74 38 68 18 H 7 03 9 03 7 03 7 05 4 59 4 59 4 59 4 59 J 11 05 11 05 11 05 11 05 K 4 30 4 30 4 30 4 30 12 24 12 24 12 24 12 24 L M N 7 91 7 91 7 91 7 91 ...

Page 92: ...nd flush to adjacent surface metal unless otherwise specified The master gage holes adjacent to the No 1 body mount Fig 2 7 and in the side rails near the rear spring front attachment are key locations and should be used whenever possible as a basis for checking other referencepoints 4 LIFTING FlREBlRD Lifting can be accomplished without adapters when using a drive on hoist or with a twin post typ...

Page 93: ...c Body Bolts and FrameGage Line Dimensions r MODELS 5269 D F35 5236 5246 5636 5646 6246 5639 5669 5237 5637 6237 6239 5239 6269 D F35 I 6267 5267 5269 W F35 6240 6290 5639 5669 5237 6237 6239 5239 5637 6269 W F35 lBOLT INNER B A C D B D C 2BOLT OUTER B A C D B D C 3 BOLT B A B D A D A 4 BOLT B A F D A D F 5 BOLT 7 BOLT F G F R H F F L H F E G E E F E G F E G 8 BOLT B A B D B B 9 BOLT B K B D B B ...

Page 94: ...3029 CUSHION COMBINATION J COMBINATION E 9793708 RESTRICTOR 3920609 CUSHION ASM 9787703 CUSHION 3920609 CUSHION ASM 9787703 CUSHION 3760886 WASHER 9798420 CUSHION 3760886 WASHER 1366144 BOLT COMBINATION H 1366144 BOLT COMBlNATlON D COMBINATION G 9791997 CUSHION ASM 9 7 9 1 9 9 6 CUSHION 9791997 CUSHION ASM 9787703 CUSHION 3760886 WASHER 9787703 CUSHION 1366144 BOLT 3760886 3902231 WASHER BOLT COMB...

Page 95: ...UAL 4 LIFT POINTS I NO 1 NO 2 BODY MOUNT NO 3 SUPPORT AND BAFFLE BODY BODY DRIFT HOL 1 BODY MOUNT NO 2 BODY MOUNT AS SHOWN b L H SIDE SHOWN R H SIDE THE SAME Fig 2 7 FirebirdChecking Dimensions Lift Points and BodyBolt Locations ...

Page 96: ...l on same side of body G 331h Center of master gage hole in side rail H 5 5 w Center of master gage hole in side rail and a point at inboard edgeof sameside rail at centerline of shackle bolt hole Fig 2 8 1 661H6 Center of master gage hole in side rail and a point at inboard edge of opposite side rail at centerline of shackle bolt hole Fig 2 8 J 42 Inboard edge of side rail at centerline of shackl...

Page 97: ...2 8 FRAME AND BODY MOUNTINGS Fig 2 8Side Rail at Spring Rear Shackle Hole Fig 2 10Firebird Convertible Floor Pan Reinforcement VIEW 0 Fig 2 9Firebird Body Damper Locations ...

Page 98: ...regular lubrication as outlined in the GENERAL LUBRICATION section Lubrication fittings are provided at the front suspen sion ball joints Shock absorbers do not require lubrication and in case of leaks or malfunction they should be replaced Periodically it may be necessary to make certain adjustments and checks of the suspension system to maintain desirable handling and steering characteris tics a...

Page 99: ...SPENSIONALIGNMENT Front suspension components are adjusted to a specific alignment while the vehicle is motionless so that suspension components can properly function together when vehicle is moving to minimize tire wear and maintain desirable steering and handling characteris tics NOTE This will maintain load on the balljoints INSPECTION BEFORECHECKING FRONT WHEEL 2 Remove hub cap or wheel disc f...

Page 100: ...o frame bolts Tool J 22618 can be used to loosen upper control arm shaft to frame bolts on the Pontiac Fig 3 6 1 To increase negative caster add shims to front bolt or remove shims from rear bolt Fig 3 3 Wheel BearingAdjustment 2 Check front wheel bearing adjustment and correct if necessary 3 Check wheel and tire run out 4 Check wheel and tire for excessive unbalance which would affect steering 5 ...

Page 101: ...n when marked at front wheels toe in by this amount see SPECIFICATIONS Fig 3 5Caster CamberShims TempestShown UPPER CONTROL ARM EACH BOLT Fig 3 6RemovingPontiacUpper ControlArm Nuts With J 22618 b WHEEL FELLOES When using this type of equipment wheel run out will have a very direct bearing on the readings Since the allowable run out is 1 8 the readings could possibly be off as far as 1 8 on each w...

Page 102: ...ables With front wheels resting on turn tables turn wheels to left until left wheel has been turned 20 from straight ahead The right wheel should have turned 18 to 19 2 Turn wheels to right until right wheel has been turned 20 from straight ahead Left wheel should have turned 18 to 19 3 Incorrect toe out on turns may be caused by incorrect front end adjustments but generally indicates bent steerin...

Page 103: ...ing with a non flammable non toxic solvent such as denatured alcohol 3 a Standard Brakes Carefully install hub and drum assembly with wheel on spindle b Disc Brakes Carefully install hub and disc assembly on spindle 4 I n s t a l louter wheel bearing 6 Install washer and adjusting nut 7 Adjust wheel bearings as outlined under ADJUST MENT PROCEDURES 8 a Standard Brakes Check brake adjustment if nee...

Page 104: ...frame bracket NOTE Shock absorber piston rod must not turn while loosening nut If necessary use pliers or wrench to hold top of rod while removing nut 2 Raise car and support front end with stands at frame side rails 3 Remove two shock absorber lower attaching screws and remove shock through lower wntrol arm 4 Remove stabilizer link nut link spacer grommets and retainers 5 Using a hydraulic transm...

Page 105: ...ck off models except Firebird Torque nut to 8 lb ft on brake adjustment to remove hub and wheel assembly Firebird b Disc Brakes Remove brake caliper assembly before STEERING KNUCKLE removing cotter pin wheel adjustment nut and washer from spindle Then remove hub and disc assembly REMOVE from spindle 1 Raise car and support at front lower control arm 5 a Standard Brakes Remove backing plate and bra...

Page 106: ...d mounting bracket upper bolt to 125 Ib ft torque and two lower bolts to 75 Ib ft torque while holding nuts Tighten two caliper assembly mounting bolts to 35 Ib ft torque 4 Adjust wheel bearings as outlined in this section under ADJUSTMENT PROCEDURES 5 Disc Brakes Tighten wheel nuts to 70 Ib ft WITH SPRING SEATED IN FRAME 6 LOWER C O N T R O L A R M SEAT THE E N D O F BOTTOM C O I L M U S T BE VIS...

Page 107: ... nut NOTE Turn nut in tightening direction only to align slot with hole to insert cotter pin Do not back off nut 3 Tighten the control arm shaft nuts or bolts on Firebird if control arm bushings have been replaced Torque nuts on all models except Firebird to 50 lb ft and on Firebird torque bolts to 35 lb ft with control arm in normal curb height position 4 Install wheel and tighten nuts to 70 lb f...

Page 108: ...er lock washer and bolt in both ends of shaft NOTE Do not tighten bolts until control arm is installed on car and is in normal curb heightposition UPPER CONTROL ARM SHAFT ANWOR BUSHINGS CONTROL ARM REMOVED FROM CAR EXCEPT FIREBIRD REMOVE 1 Remove nut and retainer from both ends of control arm shaft 2 Place control arm in ao arbor press and position tools J 9502 3 and J 22899 as shown in Fig 3 16 N...

Page 109: ...rection only to align slot with hole to insert cotter pin Do not back off nut 2 Install spring see SPRING INSTALL LOWER CONTROLARM BUSHING NOTE If the control arm is not removedpom car The bushings can be replaced without removing control arm porn car by disconnecting control armfrom pame at the two pivot bolts When performing the repair in this manner care must be taken to raise car off ground an...

Page 110: ...8 RemovingPontiac Lower Control Arm Front Bushingor Tempest and Grand Prix Rear Bushing REAR BUSHING PONTIAC REMOVE 1 Remove lower control arm see LOWER CON TROL ARM REMOVE SOCKET Fig 3 17 Installing Upper Control Arm Bushing Except Firebird Fig 3 19 Installing Pontiac Lower Control Arm Front Bushingor Tempest and Grand Prix Rear Bushing 2 Remove bushing from control arm by arranging tools as show...

Page 111: ...3 2 Remove bushing from control arm by arranging 4 Remove ball joint assembly from upper control arm tools as shown in Fig 3 22 by chiseling or drilling rivet heads which retain ball joint assembly to control arm and drive out rivets INSTALL INSTALL 1 Install bushing in control arm by arranging tools as shown in Fig 3 22 I Install new ball joint assembly using the special bolts washers and nuts su...

Page 112: ...stall new ball joint using the special bolts washers and nuts supplied with ball joint package CAUTION Use only the special alloy bolts supplied withh balljoint package 2 Tighten ball joint assembly attaching nuts to 9 Ib ft torque 3 Insert lower ball joint stud into steerin and tighten nut to 50 lb ft torque Insert CAUTION Care should be taken to insde that steering knuckle hole ball stud and nut...

Page 113: ...w until the ball joint assembly is seated properly in the control arm 3 Insert ball joint stud ilito steering knuckle hole and tighten nut to 85 lb ft torque Insert cotter pin CAUTION Care should be taken to insure that steering knuckle hole ball stud and nut are jiee of dirt and grease before tightening nut NOTE Turn nut in tightening direction only to align slot with hole to insert cotterpin Do ...

Page 114: ...ner Bearing Cup Installer Use with J 8092 Front Upper Control Ann Bushing Remover L Installer C Washer Upper Control Arm Bushing Boll Joint Remover L Installer Tool No Name Ball h i n t Remover L Installer Control Arm Bushing Remover L Installer Control Ann Bushing Service Set Front Upper Control Arm Spacer Lower Control Arm Oblong Bushing Installer Upper Control Ann Torque Wrench Adapter Front Co...

Page 115: ...ntiac using J 22618 and 12 Torque Wrench 65 Tempest Grand Prix and Firebird 50 Nut Lower Control Arm to Frame Pivot 80 Bolt Lower Control Arm to Frame Pivot 110 Nut Shock Absorber Upper Stud 8 Screw Shock Absorber to Lower Control Arm 20 Nut Stabilizer Link to Shaft Pontiac Tempest and Grand Prix 15 Firebird 8 Screw Stabilizer Shaft Bracket to Frame Pontiac 30 Tempest Grand Prix and Firebird 12 Nu...

Page 116: ... procedure is listed below 1 Fill compressor through service valve with air at available line pressure 2 Raise the car on twin post or drive on hoist Disassembly of First Stage Housing and Valve Mechanism Disassembly of Second Stage Housing s s e m b l y of Second Stage Housing Assembly of First Stage Housing and Valve Mechanism Assembly of Piston Diaphragm Assembly Assembly of Major Components Co...

Page 117: ...ve shock absorber 1 Raise car at axle housing NOTE Clean and inspect rubber inserts If rubber inserts have shi led from their originalposition in either 2 Remove nut and lock washer from shock absorber eye replace shock absorber lower end stud INSTALL NOTE Compressshock to move out oJway 1 Install shock absorber by reversing the above steps 2 Tighten upper screws to 20 Ib ft torque Tighten lower n...

Page 118: ...ontrol arm upperjlange and the rear lower control arm a l e housing bracket when lowering the axle housing 7 Remove spring 8 Remove rubber insulator from upper spring seat inspect and replace if in poor condition INSTALL 1 Install spring making sure that the end of the bottom coil is towards the rear of car 2 Either raise axle housing or lower car until shock absorber can be connected to axle hous...

Page 119: ...le and withdraw spring from vehicle 10 Remove spring shackle upper bolt and withdraw shackle bushings from frame side rail INSTALL NOTE Do not tighten spring front mounting bracket screws and eye bolt nuts until car is at curb height 1 Position spring front mounting bracket to spring front eye and loosely install spring eye bolt and nut 2 Position spring shackle upper bushing in frame side rail po...

Page 120: ...ngth of the spring effected INSTALL 1 Reverse the above steps for reassembly NOTE If any leaf clips or clip liners are damaged or worn they must be replaced 2 Tighten spring center locating bolt nut to 23 lb ft torque 3 Install spring see LEAF SPRING AND SPRING EYE BUSHING FIREBIRD INSTALL LEAFSPRING TIP INSERTS FlREBlRD CAUTION If both control arms are to be replaced remove and replace one contro...

Page 121: ...urb height when tightening pivot bolts 4 Removejack stand and lower car REMOVE IN CONTROL ARM 1 Remove upper control arm see UPPER CONTROL ARM EXCEPT FIREBIRD REMOVE 2 Arrange tools as shown in Fig 4 7 and press bushing from control arm INSTALL 1 Install bushing in control arm by arranging tools as shown in Fig 4 8 and press into place Fig 4 6 Installing Upper Control Arm Rear Bushing Except Fireb...

Page 122: ...TIC LEVEL CONTROL SYSTEM PRECA UTIONS The precautions outlined below should be heeded to insure satisfactoryfunction of the system MINIMUM PRESSURE For best ride characteristics with an emply car a minimum pressure of 10psi should be maintained MAXIMUM PRESSURE Thepressure may be varied to a maximum of 90psi to level the car with loads LINES AND FITTINGS The air lines cannot withstand exhaust syst...

Page 123: ... discard cover gasket 7 Remove three compressor retaining short bolts that hold fmt and second stage housings together 8 Separate first and second stage housings by sliding second stage housing straight off piston 9 Remove two pressure regulator valve assembly retaining screws Remove valve assembly from second stage housing and discard O ring seal 10 Disconnect distributor arm tension spring from ...

Page 124: ...Y boss dee Figs 4 19 and 4 20 1 Inspect piston for scoring Replace if necessary 5 Remove intake check valve retaining spring intake 2 Inspect check valve seat Seat should be smooth and check valve and washer using a pocket knife clean 6 If necessary rocker and arms 3 Inspect diaphragm for holes looseness or other pin with pliers and remove pin Fig 4 17 defects Replace if necessary DISASSEMBLY OF S...

Page 125: ...or wear and replace ASSEMBLY OF SECOND STAGE HOUSING if necessary 5 Inspect distributor valve seat on housing for wear 1 Install new check valve and spring Replace housing if necessary 2 Insert new expansion plug retainer and tap in until it bottoms Fig 4 18 SECOND STAGE HOUSING ASSEMBLY OF FIRST STAGE HOUSING AND VALVE MECHANISM 1 Inspect piston bore replace housing if scored 1 If removed positio...

Page 126: ...not stretch seal more than is necessary to install Seals must be installed so they are not twisted ASSEMBLY OF MAJOR COMPONENTS 1 Slide piston assembly straight into first stage large diameter housing 2 Install actuating arm and secure to first stage housing with arm pivot screw Tighten to 12 lb in torque 3 Connect arm tension spring to swivel arm 4 Rotate piston in first stage housing to align el...

Page 127: ...LE WITH TO COMPRESSOR STATION WAGON INSTAU BOLT IN THIS HOLE WITH A U MODELS UCEPT VlEW 0 STATION WAGON RADIATOR SUPPORT AND INSTALL CUPS TO THIS DIMENSION UNE PARAUEL TO SERVICE VALVE OF REAR AXLE TO SHOCK ABSORBER VlEW H FlTnNG UNTIL IT 6 REAR F CAR VIEW D VlEW E INSTAUATION OF CLIP D CEm AT FRAME VlEW F UNBOXED CENTER SIDE BAR TO COMPRESSOR Fig 4 12 Pontiac Automatic LevelControl System ...

Page 128: ... U M TUBE VlEW G INSTAUATION OF CUP VlEW E INSTAUATION OF CLlP EXCEPT FRAME CROSSMEMBER LINE PARALLEL TO q O F REAR AXLE VlEW J REAR OF CAR VlEW D INSTALLATION OF CLlP BOTH SIDES UPPER INSERT TUBE INTO ONTRoL ARM F m m o u N n L n BOTTOMS BEFORE TIGHTENIN0 NUT VlEW C DISASSEMBLED VlEW OF FlllINGS REF Fig 4 13Grand PrixAutomatic LevelControl System ...

Page 129: ...in RockerArm Ret 28 lntake Valve 29 Washer 30 Spring Intake Valve Ret 31 Pin Bushing Retaining 32 Piston Assy 33 Plate Diaphragm 34 Diaphragm 35 Washer 760 765 I D 36 Retainer Diaphragm 37 Check Valve 38 Spring 39 Expansion Plug Retainer 40 0 Ring 357 367 I D 41 Seal 5 6 9 5 7 1 42 0 Ring 732 742 I D 43 Seal 943 945 44 Piston 45 Distributor Valve 46 Bushing Distributor Valve 47 Washer 160 I63 I D ...

Page 130: ... service valve to maximum NOTE Fill compressor through service valve with air at available pressure Fig 4 24 available linepressure 2 Add weight equivalent to two passenger load 300 NOTE Ifavailable pressure is less than 140 psi start to rear bumper or tailgate car begin to engine to build up reservoir to thispressure level in 4 18 seconds Final position should be within 1 of original measurement ...

Page 131: ... Fig 4 22 Installing DiaphragmRetainer COMPRESSOR OUTPUT TEST ON CAR 1 With all engine operated accessories turned off and ignition turned off deflate system through service valve Remove high pressure line at regulator and connect test gage Fig 4 25 2 Inflate reservoir to 70 psi through service valve 3 Observe test gage for evidence of compressor air leak 4 If leaking proceed to leak test the comp...

Page 132: ... CHECK TIME DELAY CHECK 1 Disconnect overtravellever from link 2 Disconnect lines at Superlift and intake port 3 Connect test gage to intake valve port and open air pressure 95 psi Move overtravel lever approximately one inch down from neutral position as measured from end of lever 4 Quickly move overtravel lever upward two inches at the same time begin timing number of seconds before air starts t...

Page 133: ...o enter through vacuum port If bubbles are evident the probable cause is a defective second stage housing check valve 6 Correct any leaks by either tightening screws or replacing parts 7 If the cover gasket area is inadvertenly submerged remove cover and tjlt unit so that water may drain through openings by distributor valve mechanism Move distributor valve from side to side until all water is pur...

Page 134: ...om water Actuate over 3 Leak check all connections with a soap and water travel lever to expel any water from unit solution 10 Shut off air pressure and remove line from SUPERLIFT LEAK TEST Superlift port 1 See SHOCK ABSORBER EXCEPT FIREBIRD Fig 4 27Special Tools Tool No Name Universal Pressure Checking Gage Rear Upper Lower Control Arm Spacer Screw Assembly Nut Receiver Upper Lower Control Arm Bu...

Page 135: ...o Floor Pan Firebird 8 Nut Upper Shock Absorber Mount to Bracket Firebird 8 Nut Spring and Shock Absorber Anchor Plate Attaching Firebird 40 Nut Spring Front Eye Bolt Firebird 75 Screw Spring Front Bracket to Frame Firebird 25 Nut Spring Rear Shackle Firebird 50 Nut Air Line Fitting Superlift and Auto Level Control 70 Lb In Nut Height Control Valve Auto Level Control 60 Lb In Screw Compressor Brac...

Page 136: ...Replace Pinion Bearing Outer Races 4A 19 Setting Pinion Depth 20 Replace Pinion Assembly and Adjust Pinion Preload 4A 22 Replace Differential Caee and Adjust Side Bearing Preload 4A 23 Adjusting Differential Backlash 4A 25 Oil Leaks 4A 26 Specifications 4A 26 Special Tools 4A 27 Three different cases which differ in ring gear mounting dimensions arc used one for 2 29 2 41 and 2 56 ratios one for t...

Page 137: ...differential should be checked for leaks at each chassis lubrication If there is evidence of leakage the leak should be corrected and lubricant added if needed Lubricant level should he even with hottom of filler plug hole Rear axle capacity is 4 1 2 pints for Pontiac 3 pints for Tempest Firebird and Grand Prix Use multi purpose hypoid gear lubricant in the standard differential Because of the imp...

Page 138: ... Shaft 6 Rin Gear to Differential Case Bolt 21 Differential Side Gear 36 Front Pinion Bearing Outer Race 7 ifferentialCase 22 Side Gear Thrust 37 Front Pinion Bearing 8 Rear Pinion Bearing Outer Race Washer 38 Pinion Oil Seal 9 Bearing Spacer 23 Cover Gasket 39 Companion Flange 10 Drive Pinion Bearing 24 Cover 40 Washer 11 Bearing Shim 25 Cover Bolt 41 Pinion Nut 12 Drive Pinion Gear 26 Inner Reta...

Page 139: ...4A 4 1969 PONTIAC SERVICE MANUAL NOTE t Special Radiator Required Fig 4A 4A Pontiac Rear Axle Usage and Identification ...

Page 140: ...WI z I 3 2 g zEi z 0 m m z C L 2 GUa I g5 2 z z a 5 ...

Page 141: ... 13 42 13 0 2 56 2 78 2 93 3 08 3 23 Lock Diff 5 X X x X X c 0 t CI I N ZB ZC ZD ZE ZF Code c 0 c CI e I 00 2 O S 2S 2 u u u I I f u l a a e e X X X X X X X X X X X c a X X _ X X 0 z 2 X X X X X 3 3 c a t i v v v X X X 0 g m Y U 5 r g r g X X X X 0 C fu nc Q VI I 8 8 8 8 0 0 _ Release fu X X X X X X X X X C C Z Z i Z y g X X X g s E L L X X i m s m m i c d W m t o o o X X X X 1 m A h 1 X X m X X X...

Page 142: ... Transmission 0 z U C Type Axle Regular Duty Medium Duty Medium Duty Heavy Duty Axle Shafts Cold Extruded Cold Extruded Cold Extruded Hot Forged Engine c 0 Diff Asm 2 Pinion Non lock 4 Pinion Non lock 4 Pinion Lock 4 Pinion Lock TY e Diff Standard Standard Safe T Track Safe T Track Diff Carrier Gray lron Gray Iron Gray Iron Nodular Iron Trailer Prw Air Cond C o d e Std Diff ...

Page 143: ...heavy rubber band or tape to hold bearings onto journal to prevent loss of bearing rollers when joint is disconnected if tie wire has been Fig 4A 7 Removing Drive Pinion Nut removed Fig 4A 5 3 Attach a 1 2 drive adapter and socket to a lb in torque wrench Place socket over drive pinion nut and turn pinion two or three revolutions to ensure free movement Then take a torque reading while rotating pi...

Page 144: ...on flange using puller J 8614 2 snd 3 Fig 4A 8 8 Remove oil seal by prying it out of carrier with a pointed tool using care to keep tool away from the exposed front bearing Discard seal CAUTION Use care to keep dirt and other foreign matter out of exposedfront pinion bearing REPLACE 1 Lubricate lip of new seal with clean gear lube Coat outer diameter of seal case with suitable sealer Install seal ...

Page 145: ...l NOTE DO NOTpress bearing and inner retainer on in one operation AXLE SHAFT SEAL CAUTION The outer retainer late which retains REMOVE bearing in housing must be on axli shaft before bearing is installed A new outer retainer gasket can be installed 1 Insert tongs J 943 Fig 4A 13 behind seal and pull ajer bearing Use care not to wedze outer retainer swaight Out remove between bearing and shoulder o...

Page 146: ...epairs However if the housing is damaged the rear axle assembly may be removed and installed using the following procedure REMOVE 1 Raise rear of car high enough to permit working underneath Place a floor jack under center of axle housing so it just starts to raise rear axle assembly Place car stands solidly under frame members on both sides 2 Disconnect rear universal joint from companion flange ...

Page 147: ... brakes as outlined in Section 5 PRE REPAIR INVESTIGATION A close examination of the differential prior to disassembly will often reveal valuable information as to the extent and type of repairs or adjustments necessary The information thus gained coupled with the report of malfunctioning will provide a basis for determining the degree of disassembly required Since the frequent causes of axle nois...

Page 148: ...hat thering gear and pinion are not good or should be destroyed It only means they will not operate quietly in the carrier in which they are presently installed These same parts may operate quietly in another carrier when tooth pattern is checked Removing backlash moves ring gear into pinion gear driving the pinion deeper into the ring gear Whenever pressure lines are noted as explained above inst...

Page 149: ... end and down toward center of the tooth on both drive and coast sides Insufficient backlash provided the pinion is properly positioned will give a low toe pattern on both drive and coast sides Fig 4A 18 Increasing backlash will cause the pattern to move toward the heel end and up toward top of the tooth on both drive and coast sides 1EFFECTSOF PINION POSITION ON TOOTH I PATTERN When the drive pin...

Page 150: ...E Bearing caps are not marked for identification Use daub of paint to identiB as the caps are not interchangeable 8 Pontiac Remove two ring gear to case assembly bolts Install ring gear and case remover 521322 left hand bolt and sleeve set J 22042 and slide hammer J 2619 Fig 4A 23 NOTE Ring gear to case bolts have lefi hand threads Tempest Firebird and Grand Prix Remove two ring gear to case bolts...

Page 151: ...gears Place them in sets so they may be reinstalled in their original position J 8107 4 PONTIAC JB 107 2 TEMPEST FIREBIRD AND GRAND PRlX Fig 4A 24 RemovingDifferential Side Bearing 11 If ring gear is to be removed clamp case in vise so jaws are 90 to pinion shaft holes Remove twelve ring gear retaining bolts for Pontiac ten retainer bolts for Tempest Firebird or Grand Prix NOTE Ring gear to case b...

Page 152: ...o force ring gear on case Fig 4A 27Installing pinion shaft Lucking Bolt 4 Place side gear thrust washers over side gear hubs and install side gears in case ktplace any reused parts in original sides 5 Position one pinion without washer between side iears and rotate gears until pinion is directly opposite from loading opening in case Place other pinion between side gears so that pinion sHaft holes ...

Page 153: ...To install puller back out puller screw insert puller through holder and rotate 1 8 turn Fig 4A 34 4 Remove pinion assembly If necessary tap pinion out with soft hammer being careful to guide pinion with hand to avoid damage to bearing outer races DISASSEMBLEPINION ASSEMBLY NOTE Both fiont bearing and outer race and rear bearing and outer race are matched parts If either bearing is to be replaced ...

Page 154: ...e assem bly is being replaced thoroughly clean and inspect new housing paying particular attention to machined surfaces in bearing caps and carrier Be sure all metal filings and foreign material are removed fiom the bearing cap bolt holes in the carrier Be sure bearing caps seat squarely on carrier Use mill file lightly to remove nicks and burrs REPLACEPINION BEARING OUTER RACES 1 If replacing rea...

Page 155: ... roduced for service are nominal or zero pinions and are unmarked Pinion depth is set with pinion depth setting gauge J 21777 which consists of the following one J 21777 1 cross shaft assembly two J 21777 3 discs Pontiac one J 21777 2 A B gauge plate one 58619 12 pilot one J 21777 8washer Pontiac only and one J 8619 13 bolt and nut A J 8001 dial indicator must also be used with the cross shaft The...

Page 156: ...l indicator and mount loosely on cross shaft Position stem of indicator on head of gauge pin so that stem is slightly depressed causing a low indicator reading Tighten thumb screw on indicator and set at zero 5 Make certain bearing support bores are free of burrs and dirt Place discs J 21777 3 P J 8619 10 T F or G P cross shaft assembly Position assembly in the carrier with the discs resting on th...

Page 157: ...ully forward and drive bearing over pinion until seated using installer J 21285 01 a If reusing production pinion and pinion is marked plus correct shim will have a thickness equal to gauge reading found in step 7 plus the amount specified on pinion b If production pinion is marked minus correct shim will have a thickness equal to gauge reading found in step 7 less the amount specified on pinion c...

Page 158: ...ch Fig 4A 43 CAUTION After preload has been checked final tightening should be done very cautiously Tighten the pinion nut further only a little at a time and check preload after each slight amount of tightening Exceeding preload specifications will compress the collapsible spacer too far and require its replacement Backing off nut to correct excessivepreload will unload the fiont bearing and pini...

Page 159: ...fferential case with bearing outer races in position in carrier 3 Slip one 170 service spacer between each bearing race and camer housing with flat edge against housing Fig 4A 45 NOTE As a safety precaution install the left bearing cap loosely so that the case may be moved while checking adjustments one 716 14 x 4 1 2 bolt can be added as an extra safety precaution in the lower right bearing cap h...

Page 160: ...emove shim pack installed in step 7 Select two shims each 004 thicker than those removed and install one on each side This additional thickness will prbvide proper bearing preload It will be nemsary to tap the final shim into place with a soft hammer Fig 4A 48 ADJUSTING DIFFERENTIAL BACKLASH 1 Rotate differential case several times to seat bearings then mount dial indicator Fig 4A 49 Use a small b...

Page 161: ...4A 4B for Tempest See Fig 4A 4C for Firebird See Fig 4A 4D for Grand Prix Pinion Bearing Preload with Ring Gear New Bearings New Seal 25 lb in Old Bearings New Seal 17 lb in Side Bearing Preload Slip Fit Plus 008 Torque Lb R Differential Cover to Carrier Bolts 25 Differential Bearing Caps to Carrier Bolts 70 Differential Ring Gear to Case Bolts Pontiac 90 Differential Ring Gear to Case Bolts Tempe...

Page 162: ...staller Front Pinion Bearing Outer Race Installer Drive Handle Side Bearing Puller Not Shown Split Plate Differential Side Beuring Installer Reur Pinion Baring Outer Race l n s l l e r Rear Pinion Bearing Remover AxIe Shaft Bearing Installer Differential Side Bearing Installer Axle Shaft Oil Seul Installer Pinion Oil Seal Installer Case Remover Rear Pinion Baaring Remover Axle Shaft Remover Pinion...

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Page 174: ...haft yoke for optimum balance DISASSEMBLEUNIVERSALJOINTS MINOR SERVICES AND REPAIRS ALIGNMENT OF ENGINE AND PROPELLER SHAFT All necessary differential pinion angle requirements are designed and built into rear upper and lower control arm geometry Slots in the engine support rear crossmember provide for fore and aft movement of engine transmission assembly to provide for variation in positioning NO...

Page 175: ...ontal Be sure weight is evenly distributed on each side of splined yoke 2 Using piece of pipe or similar tool with diameter sufficiently large slightly larger an 1 1 8 to encircle the bearing shell apply orce on propeller shaft fmed yoke until downward movement of propel ler shaft fmed yoke and stationary position of journal forces the bearing assembly almost completely out top of yoke Force appli...

Page 176: ...e bearing ensuring that roller bear ings do not jam on journal Check for free movement of journal in bearings 4 Install snap ring retainer in each journal with gaps toward rear fuced yoke Fig 4C 7 5 Install two remaining trunnion bearings onto journal arms using suitable rubber band or tape to hold bearings tojournal INSTALLPROPELLER SHAFT ASSEMBLY 1 Inspect outer diameter of splined yoke to ensur...

Page 177: ...0 3 4 Speed Manual 2 Speed Automatic Turbo Hydra Matic M38 3 Speed H D Manual Turbo Hydra Matic M40 3 Speed H D Manual 4 Speed Manual Turbo Hydra Matic M40 3 Speed H D Manual Turbo Hydra Matic M40 3 Speed H D Manual Turbo Hydra Matic M40 Color Band Code 1 Blue 1White 1 Green 1 Red 1 Pink 1 Black 1 Purple 1 Brown 1 Green 1 Red 2 White 1 Red 1White 1 Red 1 Yellow 1 Pink 1 Brown 1 Green 1 Black 1 Pur...

Page 178: ...uld be made as outlined in this section The braking system should be visually checked periodically for example each time the car is Hydraulic System 5 10 Master Cylinder 5 10 Wheel Cylinder 5 13 Bleeding Brakes 5 13 Flushing Hydraulic System 5 14 Parking Brake 5 14 Pontiac Specifications 5 16 Tempest Firebird and Grand Prix Specifications 5 17 Special Tools 5 17 lubricated When the car is raised o...

Page 179: ...a return spring on thepedal hub REPLACE 1 Lubricate and install nylon bushings and spacer in pedal hub All manual brakes with cruise control control install return spring on pedal hub CAUTION If pedal bracket prevents full return of brake pedal and master cylinder push rod the master cylinderpistons may beprevented fiom returning to their stops This can block off the compensatingports which preven...

Page 180: ...hs or 24 000 miles any time major brake work is done or any time a customer complains of excessive pedal travel STOP LIGHT SWITCH REMOVE 1 Disconnect wires from switch 2 Remove switch by pulling out of retainer REPLACE A l l four brake assemblies incorporate a self adjusting mechanism to automatically adjust the brake shoes when the car is operated in reverse NOTE Normally the self adjustingfeatur...

Page 181: ...is is the case Section 3 of this manual a rod Or screwdriver the NOT Ar completion of adjustment d m n must mtate screw lot in the baclring plate and without any drag Replace any parts that prevent rce adjuster lever away from adjusting screw star wheel rotation and rotate adjusting screw downward Fia 5 5 and w 5 6 Proper clearance can also be obtained by lengthening the star wheel adjuster screw ...

Page 182: ...rease or brake fluid from getting on linings Even oily fingerprints on linings may affect the operation of brakes 6 Remove the primary to secondary shoe spring and the adjusting screw 7 On rear brakes remove the parking brake lever from the secondary shoe SCREWDRIVER Fig 5 5 Preparingto Back Off Adjusting Screw badly burned or worn nearly flush with rive ts or if linings show evidence of oil greas...

Page 183: ...L Fig 5 7Gauging Shoe to Drum Clearance 4 SECONDARY SHOE RETURN ACTUATING GUIDE RETURN PRIMARY SHOE AND LINING SPRING ADJUSTER LEVER SPRING WASHER SCREW Fig 5 8Typical Self Adjusting Brake Assembly ExplodedView Right Hand Side Rear ...

Page 184: ...s will allow the proper drum surface necessary to burnish new linings CAUTION Removing material from brake drum reduces the strength of the drum and also its ability to transfer heat Never remove more than is absolutely necessary and in no case remove more than 0 030 increasingdiameter by 0 060 After a drum is turned be sure it isfree of all metal particles Whenevera drum is turned the drum on the...

Page 185: ...ont and right rear adjusting screws backing plate and all other contacting surfaces with a have leji hand threadr and can be identijied asfollows small amount of brake lubricant or wheel bearing lubricant Do not lubricate teeth of star wheel PONTIAC 2 Pull parking brake cable forward and rearward ght front 3 wide grooves through conduit and lubricate freely with light grease or chassis lubricant R...

Page 186: ... between lever and primary shoe 7 Position the upper end of actuating link over anchor pin 8 Engage the adjuster lever with the ovemde pivot then position the adjuster lever and ovemde spring assembly on the secondary shoe Fasten with the hold down spring assembly Fig 5 8 NOTE THE FRONT BRAKE SPRING RETAINING PINS ARE IDENTIFIED WITH THE NUMERAL 6 PONTIAC OR 4 TEMPEST GRAND PRIX AND FIREBIRD STAMP...

Page 187: ...ng the same two letter identification see Master Cylinder Usage Chart Fig 5 14 2 The lengths of component pistons in a master cylinder are critical factors in displacement capabilities of a master cylinder Pistons are coded using rings or grooves in shank of piston When pistons are replaced replacement piston must contain same identification marks and same contour at push rod end as piston which w...

Page 188: ...e alcohol or clean brake fluid to clean all metal brake parts thoroughly Immerse parts in cleaning fluid using a bristle brush to remove foreign matter Blow out all passages orifices and valve holes Air dry and place cleaned parts on clean paper or lint free cloth NOTE Dirt is the major cause of trouble and wear in service Be sure to keep parts clean until reassembly Rewash at reassembly if there ...

Page 189: ...t and secure master cylinder to dash tighten fasteners to 25 lb ft torque The flange on the push rod retainer and flange on boot will be held between the dash and master cylinder 2 Connect push rod to brake pedal and attach brake lines to appropriate bosses on master cylinder Outlet boss thread sizes and brake line fittings for front and rear are different to assure that correct connectionsare mad...

Page 190: ...the cylinder bore and counterbore with brake fluid and insert spring expander assembly 2 Install new cups making sure cups are lint and diit free Do not lubricate cups prior to assembly 3 Install new pistons in the as received condition to insure proper corrosion inhibiting properties Do not lubricate pistonswith brake fluid 4 Press new boots into cylinder counterbores by hand Do not lubricate boo...

Page 191: ...and valves so they become inoperative NOTE If it becomes necessary to replace brake fluid lines use only steel lines with double flaredends To flush hydraulic system proceed as follows 1 Attach bleeder tube and open bleeder valve at left front wheel 2 Flush out system thoroughly with cleah denatured alcohol pumping the fluid from master cylinder reservoir and out of wheel cylinder bleeder valve 3 ...

Page 192: ...ry cable FRONTCABLE REMOVAL NOTE Remove positive cablefiom battery to eliminate thepossibility of creating short circuits under dash 1 Place parking brake pedal in released position 2 Remove equalizer check nut and separate cable stud from equalizer 3 Remove clip from cable at inner side of frame rail 4 Remove end of cable from pedal clevis 5 Pontiac Tempest and Grand Prix Position left fender and...

Page 193: ...E Standard system 1 Disc Brake system 1 125 0008 SURFACE FINISH 60 120 micro inch with a non PEDAL HEIGHT 4 directional lay Underside of standard pedal pad to floor pan 749 FLUID WHEEL CYLINDER BORE Fluid which complies with heavy duty standards of Front 1 SAE 70 R 3 specifications Rear 6 is PONTIAC TORQUE SPECIFICATIONS Torque in Ib ft unless otherwise specified APPLICATION TORQUE Bolt Wheel Cyli...

Page 194: ... 21 5 Rear 2 WHEEL CYLINDER BORE Thickness Front and Rear Primary 0 196 Front llh Secondary 0 265 Rear TEMPEST GRAND PRlX AND FIREBIRD TORQUE SPECIFICATIONS Torque in Ib ft unless otherwise specified APPLICATION TORQUE APPLICATION TORQUE Front brake to steering knuckle lower bolt and nut 75 Parking brake lever to dash nut 8 Front brake to steering knuckle upper bolt I00 Parking brake front cable t...

Page 195: ...A 6 Front Housing Replace 5A 7 Gaging Procedure 5A 7 Torque Specifications 5A 10 Special Tools 5A 10 CHECKSAND ADJUSTMENTS ON CAR 3 Check fluid level in hydraulic cylinder reservdirs Fluid level should be as shown in Section 5 1 Check for free operation of brake pedal If binding exists check pivot points for binding and lubricate as 4 Check vacuum hose check valve grommet and required carburetor v...

Page 196: ... MORAINE POWER 4 Install tool J 22805 01 at front housing Insert a 22 BRAKE long x 1 1 4 square channel tube in end of tool MASTER CYLINDER ONLY REMOVE 5 Using a 14 cremnt wrench or equivalent twist the square channel tube counterclockwise enough to Certain revair overations such as redacement of parate front housing from rear housing Fig 5 2 master dnder hema pam pennit the master 6 Remove front ...

Page 197: ...ate and of power piston group Diaphragm should be guarded position assembly on tool J 21524 so that three lugs on against greaseJ oil and foreign matter and must be tool fit into three notches in power piston Fig 5A 10 protected fiom nicks or cuts that might be caused by rough surf u esJdamaged tools or dropping thepiston 7 Press down on supportplate and rotate counterclock wise until support plat...

Page 198: ... from the air valve in second groove from air valve operating rod end 14 Remove power piston bearing from rear housing MASTER CYLlNDER DISASSEMBLE Fig 5A 13 Refer to Section 5 Standard Brakes for disassembly procedures INSPECTION AND CLEANING Thoroughly wash all parts in alcohol and air dry Blow Refer to e on 5 Standard Brakes for assembly procedures POWER PISTON ASSEMBLE 1 Place a new O ring seal...

Page 199: ... element over end of push rod and into power piston hub 10 Install felt silencer and retaining clip in end of power piston hub 11 Assemble power piston diaphragm to support plate from side of plate opposite locking tangs and press raised flange of diaphragm through hole in center of plate NOTE Be sure that edge of center holejts into groove inflange of diaphragm 12 Pulldiaphragm away from O D of s...

Page 200: ...ug of power piston until end of ring is seated under lug with raised divider CAUTION Make sure that both en of lock ring are securely under large lug 22 Remove power piston assembly from vise Install large foam air filter ring over neck of power piston hub 20 Place small end of hydraulic push rod in hole in POWER PISTON INSTALL center of reaction plate and line up ears on reaction retainer with no...

Page 201: ...nsert square channel tube in end of tool J 22805 01 and ushi a crescent wrench turn front housing 1 Place new front housing seal in center of front clockwise until fully bcked housing so that flat surface of cup lies against bottom of depression in housing 6 Remove all tools 2 Install new vacuum check valve grommet GAGING PROCEDURE Fig 5A 15 3 Attach tool J 22805 01 to front housing Lubricate NOTE...

Page 202: ...heprimary cup to overlap the compensating port of the master cylinder which will trap fluid in the hydraulic system causing brake drag 2 Replace master cylinder on front housing studs Install attaching nuts on studs Torque to 25 lb ft 3 Install vacuum check valve 4 Tempest Grand Prix and Firebird install clevis lock nut to push rod finger tight Attach clevis and tighten clevis against lock nut to ...

Page 203: ...R l r n w Piston Spring 8 wndw Plston Stop 9 Piston Extendon Sasrr 10 sronday Srl 11 S sonday Srl 12 S sonder Plston Front 13 R l m r y Snl P r o m o r 14 Prlnuy el 16 Spring R m l m r 16 S sonduv Plmn Spring 17 MNW Cvllnder Cnmg 18 slop Bolt 19 Rnnvoir DImphnprn 1 0 Rmrvoir C o w 21 R olr Rmlnlng Ball 22 T u b SM l n r r t l 23 Check V a h 24 Check V a h S p r l w 16 8 1 4 V a h n 2 Fig 5A 13 Exp...

Page 204: ...talling Front Housing Fig 5A 15Push Rod Adjustment TORQUE SPEC1FlCAPlONS LB FT Power Cylinder Housing to Master Cylinder Nuts 25 Rear Housing to Pedal Bracket Nuts 24 Push Rod Clevis Tempest Grand Prix and Firebird 90 in Ib Fig 5A 16 Special Tools ...

Page 205: ...Power Unit Assemble 5B 5 Push Rod Adjustment 5B 6 Power Brake Assembly Install 5B 6 Torque Specifications 5B 6 Special Tools 5B 7 CHECKS AND ADJUSTMENTS ON CAR 1 Check for free operation of brake pedal If binding exists check all pivot points for binding and lubricate as required 2 Check stop light switch for proper setting and operation 3 Check fluid level in hydraulic cylinder reservoirs Fluid l...

Page 206: ...3 Remove nuts from vacuum cylinder studs under dash and remove vacuum power section 4 Clean exterior of power brake POWER UNIT DISASSEMBLE Fig 58 2 1 Using tool J 2280541 mount power brake assembly in vise clamping on tool so that valve operating rod is UP 2 Scribe a line across the front and rear housings to facilitatereassembly 3 Using tool J 9504 press down firmly and rotate tool and housing cl...

Page 207: ...op screw under master cylinder bore Use 3 8 wrench to remove stop screw and O ring seal Maintain pressure on rear piston and use Tru Arc pliers to remove snap ring from groove in master cylinder bore 3 Remove rear piston and spring assembly and discard Do not attempt to disassemble it since complete new assembly is provided in repair kit 4 Remove front piston assembly front return s e g and retain...

Page 208: ... wheel cylinders The sealing surfaces should be clean and smooth Check for cracks and damaged threads Be sure that the by pass and compensating ports to the master cylinder reservoirsare not restricted Check for distortion of all springs and deterioration of all rubber parts Any evidence of soft or swollen rubber parts indicates contaminated brake fluid requir ing flushing of the entire brake syst...

Page 209: ...ragm plate 7 Install large foam air filter and boot Press boot onto housing until it bottoms 8 Coat all surfaces of reaction disc with power brake lubricant and install disc button side first in hub cavity of diaphragm plate 9 Apply power brake lubricant to piston end and shaft of hydraulic push rod and install firmly against reaction disc in diaphragm plate DO NOT LUBRI CATE ADJUSTING NUT END OF ...

Page 210: ...HRAGM PLATE AND FALL INTO FRONT VACUUM CHAMBER Use a 5 16 wrench to turn adjusting nut in to shorten or out to lengthen push rod After assembly of the master cylinder to the power unit the primary cups of the master cylinder must clear the compensating hole when the unit is in the released position This can be checked by partially filling the reservoirs and then stroking the power unit If fluid sp...

Page 211: ...BENDIX POWER BRAKE 5B 7 Fig 58 8Special Tools ...

Page 212: ...for binding and lubricate as required 3 Remove clevis pin retainer from brake pedal inside the car 2 Check stop light switch for proper setting and operation 4 Remove nuts from power cylinder studs and remove power cylinder 3 Check fluid level in hydraulic cylinder reservoirs Fluid level should be as shown in Section 5 5 Clean exterior of power brake assembly and drain reservoirs of hydraulic flui...

Page 213: ...e ball end of the valve rod POWER SECTION DISASSEMBLY Fig 5C 5 1 Assemble special tool combination as shown in Fig 5C 3 2 Place assembly in arbor press Fig 5C 3A with rear shell and spanner wrenches up Secure tool J 8433 to press to prevent tilting of front shell NOTE On some modeb it will be necessary topry open the four tangs located at the seam to bllow shell separation CAUTION f i n separating...

Page 214: ... or screwdriver DIAPHRAGMS PLATES RETAINER AND PLUNGER DISASSEMBLE Fig 5C 5 1 Wet rear diaphragm spring retainer with alcohol and remove using fingers only Remove rear dia phragm from rear plate assembly on hex stock with hex opening in center of front plate on bar Twist rear plate counterclockwise using hand leverage only either on atmosphericpressure channel or on outside circumference of rear p...

Page 215: ...nd use Tru Arc pliers to remove snap ring from groove in master cylinder bore 3 Remove rear piston and spring assembly and discard Do NOT attempt to disassemble it since a completenew assembly is provided in the repair kit 4 Remove front piston assembly front return spring and ret r Slide primary cup and protector off nose of front piston Use dull scribe to lift both secondary seals from the groov...

Page 216: ...e piston Maintain pressure on piston and use Tru Arc pliers to install snap ring in groove inside bore Make sure snap ring is seated securely in groove 6 Maintain pressure on rear piston while installing piston stop screw and new O ring seal in port underneath bore Torque screw with 3 8 wrench to 40 lb in 7 Remove master cylinder from vise Install reservoir diaphragm and cover and plug ports tempo...

Page 217: ...e valve plunger return spring on valve plunger as shown and set spring and plunger in recess of front plate hub grommet side up 5 Set rear plate threaded bore down over valve plunger and using hands only screw rear plate onto front plate hub To tighten plates place 1 1 16 hex bar stock or tool J 22839 in vise and set plate assembly front plate down on hex bhr Using air channel slot or rear plate e...

Page 218: ...disc and to piston end of hydraulic push rod 2 Place reaction disc on piston end of push rod CAUTION Under NO condition should lubricant be allowed toget on adjustment screw or threads 3 Insert push rod with reaction disc on piston end into cavity in front plate hub Twist push rod to make certain reaction disc is seated in front plate hub and to eliminate air bubbles between hub disc and push rod ...

Page 219: ...serrated end of push rod with pliers and turn adjusting screw IN to shorten or OUT to lengthen push rod Measure push rod height with push rod installed in unit using either a height gage or tool J 7723 01 See Figure 5C 10 for details for making height gage POWER BRAKEASSEMBLY INSTALL 1 Place power brake assembly into position and install four rear housing to dash attaching nuts from inside of car ...

Page 220: ... Piston Assemble 5D 5 Power Cylinder Assemble 5D 9 Gaging Procedure 5D 9 Power Cylinder Only Install 5D 10 Master Cylinder Only Install 5D 10 Torque Specifications 5D 10 Special Tools 5D 11 3 Check fluid level in hydraulic cylinder reservoits Fluid level should be as shown in Section5 1 Check for free operation of brake pedal If binding exists check all pivot points for binding and lubricate 4 Che...

Page 221: ...s be carefitl not to bend or kink lines 3 Remove clevis pin retainer at brake pedal 4 Remove four power unit to dash attachingnuts 5 Remove power cylinder OVER ALL BRAKE UNIT DISASSEMBLE POWER CYLINDER DISASSEMBLE Fig 5D 1 4 1 Clean exterior of power cylinder 2 Scribe a line across front and rear housings to facilitatereassembly 3 Remove front housing seal 4 Attach tool J 2280541 to master cylinde...

Page 222: ...m theprimary piston before theprimary piston unscrews fiom the secondary piston If this happens continue to turn primary support plate counterclockwise Tabs stops onprimary support plate will temporarily lock primary support plate to primary power piston and pennit continued counterclockwise rotation to unscrew primwy power pistonfiom secondarypower piston 5 Remove housing divider from secondary p...

Page 223: ... support plate Grip edge of support plate with hands and rotate in a counttrclockwise direction to unlock support plate from power piston PRIMARY SUPPORT PLATE Fig 5D 6Preparingto Remove Primary Support Plate 13 Remove primary diaphragm from primary support plate 4 14 Remove air filter and pushrod limiter washer from tubular section of primary piston 15 Remove rubber reaction bumper from end of ai...

Page 224: ...EMBLE BRAKE UNIT Small imperfections can be smoothed out with fine emery cloth Replace if badly nicked scored or MASTER CYLINDER ASSEMBLE otherwise damaged MASTER CYLINDER Inspect bore from the open end The bore should be free from scores deep scratches and corrosion It it appears that corrosive brake fluid has damaged the bore replace damaged parts and flush out entire brake system including whee...

Page 225: ...D 11Gaging Reaction Piston 7 Stretch the foam filter element over pushrod eye and press into primary power piston tube 8 Using Truarc No 2 pliers place the retaining ring into groove on air valve Fig 5D 10 9 Position the rubber reaction bumper on end of air valve NOTE Tolerances of the component parts affecting output of the tandem power brake are very critical In order to maintain correct power b...

Page 226: ...ace of flange that fits into groove in ptimary power piston with light coat of silicone lubricant 14 Mount Tool J 23101 small diameter end up in a vise Position primary power piston so that the two radial slotsin piston fit over ears of tool 15 Fold primary diaphragm away from O D of primary support plate 16 Holding edges of support plate with locking tangs down place primary support plate and dia...

Page 227: ... 13 Securing Front Housingto Arbor Press 33 Fold primary diaphragm away from O D of primary support plate power piston contact stops on support plate Fold 34 Position primary power piston on tubular portion secondary diaphragm back into position On of secondary power piston making sure that air valve support plate Leave the secondary Power piston return spring seats down over raised center section...

Page 228: ...t end first into piston rod retainer 3 Press down on master Qlinder piston rod to assure that it is properly seated 7 Hold rear housing assembly with mounting studs up over front housing so that scribe marks will be aligned when housings are locked together NOTE Whilejoining the housings care must be taken to assure that the piston rod retainer plate is centered on thepiston rod retainer 8 Slowly ...

Page 229: ... clip 3 Position master cylinder over attaching studs and install two nuts Torque nuts to 25 lb ft 4 Installvacuum hose and vacuum check valve 5 Check stop lightswitch adjustment see Section 5 MASTER CYLINDER ONLY INSTALL hation beyond these two limits must be 1 Position master cylinder on power cylinder studs compensated for by obtaining the service adjustable Secure master cylinder with two nuts...

Page 230: ...HEAVY DUTY POWER BRAKES 5D 11 Fig 5D 17Special Tools ...

Page 231: ...t the weight of the caliper 6 Transfer the inboard shoe anti rattle spring to the new shoe and lining assembly NOTE Wheelmust be removed to inspect lining 7 Using hand pressure push the sleeves from the SHOE AND LINING REPLACEMENT inboard ears of the caliper Next remove the rubber bushings from the grooves in each of the four caliper CALIPER REMOVE 1 Remove two thirds of the total fluid capacity f...

Page 232: ... the caliper with the ears at the top of the shoe over the caliper ears and the tab at the bottom of the shoe engaged in the caliper cut out Fig 5E lo 5 With both shoes installed position the caliper so it w i l l enter the mounting bracket without binding Do not force caliper if it becomes cocked Allow the bottom edge of the outboard lining to rest on the outer edge of the rotor and make sure tha...

Page 233: ...firm brakipedal i s obtained NOTE Whenever the front wheel disc brakes are relined the rear drum brakes should be checked ako CALIPER OVERHAUL CALIPER REMOVE Removal of the caliper for overhaul is the same as for shoe and lining replacement except that it will be necessary to disconnect the brake hose at the caliper Discard the copper gasket on each side of the brass hose fitting CALIPER DISASSEMB...

Page 234: ... Use a piece of wood or plastic a plastic toothpick the caliper bore DO NOT USE A METAL TOOL OF is ideal to remove the piston seal from its groove in ANY TYPE FOR INIS OPERATION BOOT 0 8888 LUBRICATE AREAS INDICATED Fig 5E 6Boot Installation Fig 5E 7Lubrication Points ...

Page 235: ...o not use abrasives in an attempt to clean the bolts replace them Fig 5E 9 Installing InboardShoe s Fig 5E 10InstallingOutboard Shoe 2 Carefully examine outside of piston for scoring nicks corrosion and worn or damaged chrome plating If any surface defects are detected replace the piston CAUTION The piston OD is the primary sealing surface in the caliper assembly It is manufactured and plated to c...

Page 236: ...ont wheels 2 Remove caliper assembly and rest on front suspen 1 Lubricate the seal groove in the caliper and the new sion as described in Caliper Remove piston seal with clean brake fluid Position the seal in the caliper bore groove Lubricate the piston with 3 Remove spindle nut and hub and rotor assembly clean brake fluid and assemble a new boot into the groove in the piston so that the fold face...

Page 237: ...cts the rotor face approximately one inch from the rotor edge Set the dial at zero Move the rotor one complete rotation checking the indicator as the rotor moves For lateral runout specifications see SPECIFICA TIONS PARALLELISMCHECK rotor Measurements must be made at the same distance from the edge of the rotor and an indicator which reads 0001 must be used A rotor that varies beyond the recommend...

Page 238: ...crew and remove switch from vehicle 3 To install reverse above procedure and bleed brakes as outlined below Disc Brake Type Fixed Rotor Sliding Caliper Location Front Wheels Only Rotor Type Ventilated Cast Iron Rotor Diameter Pontiac 11 75 Tempest Grand Prix Firebird 1 1 Rotor Runout Maximum OM Total Rotor Surface Finish 20 60 Micro Inch w Non Directional Lay Rotor Thickness New Pontiac 1 240 Temp...

Page 239: ...DISC BRAKES 5E 9 I I Fig 5E 16Special Tools ...

Page 240: ...ck in front of the right bank of cylinders The 10 5 1 with the same bore and stroke engine code for 6 cylinder engines is stamped on the cylinder head contact surface of the block behind the Six optional V 8 engines are available on special order oil filler pipe Fig 6 4 By referring to the identifica two having 350 cubic inch displacement with 3 7 8 tion code and the engine chart each engine may b...

Page 241: ... valve Engines use 45 intake valve seat NOTE All large valve engines use 30 intake valve seat b Uws hardened drive sear for use with 60 D s oil DumD and hiah tension distributor oints c Two speed M31 i f equipped with A C urbo drbmaiic 3 8 J optional without A C d Uses distributor 1 1 11965 e Uses distributor 1111966 Fig 6 3FirebirdEngineChart ...

Page 242: ...g 6 5Engine Number and Code Location V 8 Seven different Grand Prix engine transmission combi nations are available as shown on the engine chart Fig 6 1 The standard engine is of 400 cubic inch displacement with large valve heads 10 5 l C R and a 4 Bbl carburetor Engine identification is facilitated by a letter code stamped below the production engine number By referring to Fig 6 1 and using the i...

Page 243: ...ead or Gasket Remove and Cylinder Bores Inspect 6 27 Replace 6 15 Honing or Boring 6 28 Cylinder Head and Valves Recondition 6 16 Piston Fit and Replace 6 29 Fitting Valve Stems to Guides 6 17 Assemble Rod and Piston 6 30 Valves and Seats Recondition 6 17 Piston Rings Replace 6 30 Harmonic Balancer Remove and Replace 6 18 Piston Rings Install 6 31 Lower Front Timing Belt Cover Remove Install Rod a...

Page 244: ...SIX CYLINDER ENGINE 6 5 TOP DEAD CENTER Fig 6 7 ValveTiming Marks ...

Page 245: ...ertor retaining bolts and slide convertor to rear 18 If equipped with manual transmission disconnect clutch linkage and remove clutch cross shaft 19 Remove four lower bell housing bolts two each side 20 Disconnect transmission filler tube support and starterwire harness shield from cylinder head 21 Remove two front motor mount to frame bracket bolts 22 Lower vehicle 23 Using jack and block of wood...

Page 246: ...ng one attaching bolt and two nuts at center of assembly Reassemble manifolds using new gasket Tighten finger tight and torque nuts to 25 lb ft and bolt to 22 Ib ft after assembly to cylinder head 4 Position new gasket over manifold studs on cylinder head and carefully install the manifold in position making sure the gasket is in place 5 Coat face of manifolds liberally with a solution of graphite...

Page 247: ...e whenever timing bell tension is checked 1 Remove timing belt top front cover 2 Using J 22232 2 calibration bar as shown in Fin 6 12 set poiGer of tension firture J 22232 1 to line u with mark on minus side NOTE This calibration must beperformed prior to each use of the J 22232 fixture to insure an accurate timing belt adjustment 3 Remove the camshaft sprocket to camshaft bolt and washer and inst...

Page 248: ...KET OR SEAL CAUTION Do not use tools of any type other than hands to pry on the timing belt during belt removal or replacement or during other service operations REMOVE 1 Remove timing belt top front cover 2 Remove sprocket to camshaft retaining bolt Fig 6 7 NOTE For ease of reassembly index three timing mark as shown in Fig 6 7 3 Loosen six accessory drive to engine block mounting bolts Fig 6 11 ...

Page 249: ...langes REPLACE 1 Install new rocker arm cover gasket on cylinder head 2 Check all rocker arms for correct position on hydraulic valve lash adjusters and valves 3 Install rocker arm cover assembly on four mounting studs 4 Install rocker arm cover assembly retaining bolts and nuts Tighten to 15 lb ft 5 Reverse steps one through five of Removal to complete installation procedure NOTE Install camshaft...

Page 250: ...Fig 6 16 3 Install retaining washer and bolt Tighten to 40 lb ft 4 Using J 8894 install new oversize camshaft bore plug until fully seated Fig 6 17 IMPORTANT A camhaft bore plug not fully seated could result in excessive camhaft end play Corkect end play is 003 W1when read at the sprocket end with a dial indicator Fig 6 18 NOTE Lubricate camhaft lobes and iocker arm paris with Engine Oil Supplemen...

Page 251: ...h adjusters play in the operation of an engine and the close tolerances to which they are manufactured proper handling and above all cleanliness cannot be overstressed when servicing theseparts New adjusters are serviced as individual units pack aged with a plastic coating Leave the coating on until ready to check leak down rate It is necessary to remove the oil from new adjusters prior to checkin...

Page 252: ...ted and assembled after cleaning but beforeproceeding to the next adjuster 7 Inspect adjuster body Both inner and outer surfaces of adjuster body should be inspected for scoring Adjuster assembly should be replaced if body is roughly scored grooved or galled 8 Inspect adjuster plunger Using a magnifying glass inspect check ball seat tor defects Inspect outer surface of plunger for scratches or sco...

Page 253: ... assembly 2 Rwmove rocker arm of valve to be serviced 3 Remove spark plug from cylinder of valves to be serviced and install J 22278 Fig 6 2 3 C A UTZON Ifpiston is not in itsfull downposition fan willturn 4 Connect air hose with a constant source of compressed air to J 22278 5 Install hook end of tool J 22263 2 into oil feed hole in lash adjuster bore Fig 6 23 1 I LASH ADJUSTER TEST LEAK DOWN RAT...

Page 254: ... seal into place using a seal installing tool VSIT 1 Fig 6 25 3 Replace spark plug 4 Install rocker arm CYLINDER HEAD OR GASKET REMOVE 1 Drain cooling system and remove air cleaner 2 Disconnect accelerator pedal cable at bell crank on manifold and fuel and vacuum lines at carburetor 3 Disconnect exhaust pipe at manifold flange then remove manifold bolts and clamps and remove manifolds and carburet...

Page 255: ...valves from bottom of cylinder head and place them in a rack in their proper sequence so they can be assembled in their original positions CLEAN AND INSPECT 1 Clean all carbon from combustion chambers and valve ports 2 Thoroughly clean the valve guides using tool J 8101 Fig 6 28 3 Clean all carbon and sludge from rocker arms 4 Clean valve stems and heads on a buffing wheel 5 Clean carbon deposits ...

Page 256: ... the 003 oversize reamer first and then ream the 005 oversize Always reface the valve seat after reaming valve guide NOTE Valves are marked 001 003 or 005 with colored ink VALVES AND SEATS RECONDITION 1 Reface valves and seats as follows Valves should be ground on a special bench grinder designed specifically for this purpose and built by a reputable manufacturer Valve seats should bebground with ...

Page 257: ...oncentric with one another NOTE Both tests in steps 2 and 3 are necessary to insureproper valve seating IMPORTANT If it is necessary to grind any pit from rocker arm end of valve stem feed end squarely against grinding wheel Only the extreme end of the valve stem is hardened to resist wear Do not grind end excessively ASSEMBLE 1 Starting with No 1 cylinder place exhaust valve in the port and place...

Page 258: ...flange and sprocket Fig 6132 9 Pry seal from crankcase cover Fig 6 33 using care not to distort the cover REPLACE 1 Install new seal with lip of seal inward u ingseal installer J 22260 Fig 6 34 2 Replace crankshaft timing belt sprocket and flange 3 Align timing marks Fig 6 7 and replace timing belt 4 Replace timing belt loGer front cover and harmonic balancer 5 Adjust timing belt tension 6 Replace...

Page 259: ...EREGULATOR VALVE OILPUMP REMOVE AND REPLACE 1 Remove cap washer and spring from housing assembly 2 Using magnet remove valve from housing assem bly 3 Install valve on spring and install as an assembly 4 Install cap and washer OIL PUMP REMOVE AND REPLACE 1 Remove oil pump cover and gasket 2 Remove drive gear and driven gear Fig 6 37 3 Inspect gears for wear and pump cover for excessive scoring 4 In...

Page 260: ...rive Housing ExplodedView to cylinder block using six retaining bolts 2 Align timing marks Fig 6 7 and install timing belt 3 Connect fuel lines to fuel pump 4 Replace distributorcap vacuum lines and wires 5 Adjust timing belt tension See Fig 6 12 6 Replace timing belt top front cover OIL FILTER BY PASSVALVE REMOVE AND REPLACE 1 Remove housing assembly 2 Remove by pass valve retaining screw Fig 6 3...

Page 261: ... compressor from mounting brackets and position to one side 4 Inspect all water hoses and wiring harness for proper routing to prevent excessive binding when engine is raised NOTE Before raising vehicleprop hood open at least 6 to insure adequate clearance between timing belt cover and inner hoodpanel 5 Raise vehicle and drain crankcase 6 Remove starter assembly and flywheel cover 7 Reroute or dis...

Page 262: ...y rearward force to engine transmissionassem bly sufficient to allow oil pan to clear flywheel housing Tempest Fig 6 42 InstallingBearing 3 Install oil pan and tighten retaining bolts to 12Ib ft 4 Lower engine remove engine support bracket and install engine insulator bracket to frame thru bolts 5 Tighten transmission insulator to crossmember bolts to 30 Ib ft 6 Replace flywheelcover and starter a...

Page 263: ...ap using J 22325 Fig 6 44 and torque bearing cap bolts 100 lb ft MAIN BEARINGS REMOVE AND REPLACE The main bearings are of precision insert type and do not utilize shims for adjustment If the clearances are found to be excessive a new standard or undersize bearing insert both upper and lower halves will be required NOTE To replace the upper half of the rear main bearing it will be necessary to loo...

Page 264: ...02 undersize 5 Install a new rear main bearing oil seal in cylinder block and main bearing cap if rear main bearing was checked and or replaced 6 Check crankshaft end play with feeler gauge at No 7 main bearing Fig 6 52 If end play is over 006 replace bearing CONNECTING ROD BEARINGS REMOVEAND REPLACE Connecting rod bearing inserts are available in standard size and undersizes of 001 and 002 These ...

Page 265: ...M BLY REMOVE AND REPLACE REMOVE 1 Remove rocker a r mcover 2 Disconnect fuel line and vacuum lines at carburetor 3 Remove cylinder head intake and exhaust mani folds as an assembly 4 Remove ring ridge using a suitable ring ridge 5 Remove oil pan 6 Check connecting rod and piston for cylinder number identificationand if necessary mark them 7 Remove bearing cap and install connecting rod bolt guide ...

Page 266: ...rt J 9510 1 2 Press piston pin rest of way out of piston CONNECTING ROD AND PISTON CLEAN AND INSPECT 1 Clean carbon varnish and gum from piston surfaces including underside of piston head Clean ring grooves and oil holes in oil ring groove using suitable cleaning tools and solvent Fig 6 51Cylinder Ring Ridge 2 Clean piston pin rod cap bolts and nuts in suitable solvent Reinstall cap on connecting ...

Page 267: ...CheckingPiston Pin Fit the top of the cylinder Subtract the smallest measure ment found from the largest If this figure exceeds 0006 a piston cannot be fitted properly and the cylinder must be honed New rings and a new oversized piston must be fitted Fine vertical scratches made by ring ends will not cause excessive oil consumption therefore honing to remove is unnecessary HONING OR BORING If a pi...

Page 268: ...ve are not removed rapid wear of new rings and piston will result Intermixing different size pistons has no effect on engine balance as all Pontiac pistons from standard size up to 030 oversize weigh exactly the same Pontiac does not recommend boring beyond 010 during warranty period so that if necessary engine can be serviced at high mileage without cylinder block replacement PISTON FITAND REPLAC...

Page 269: ... lubricant Fig 6 61Piston Pin Replacement 2 Position connecting rod in its respective piston so that oil squirt hole faces toward distributor side of engine Fig 6 60 3 Install piston pin on installer and pilot spring and pilot J 9510 4 in support Fig 6 61 Use piston pin removing and installingtool J 9510 4 Install piston and rod on support indexing pilot through piston and rod 5 Place support on a...

Page 270: ...ing traveled part of cylinder bore in which it will be used Square ring in bore by pushing it into position with head of piston 3 Measure gap between ends of ring with feeler gauge Fig 6 62 Gaps should be as follows Fig 6 62CheckingRingGap Fig 6 63CheckingRingSide Clearance Compression Rings 0058 0258 Oil Ring 0058 0558 Incorrect ring gap indicates that wrong size rings are being used If rings are...

Page 271: ...pper bearings installed and pistons into place 4 Install rod bearing caps with bearings but do not tighten nuts 5 With rubber mallet hit both ends of crankshaft to center thrust bearing 6 Tighten main bearing caps 100lb ft 7 Tighten connecting rod bearing caps 33 lb ft 8 Install key from old crankshaft keyway in new crankshaft 9 Install crankcase front cover using new seal and gaskets 10 Install o...

Page 272: ... new block on stand 14 Align timing marks and adjust timing belt tension 19 Remove new piston and pin assemblies from new NOTE It will be necessary to remove distributor cap to block and identify each according to cylinder from make certain that the rotor arm points toward number which it was removed one cyIindersparkplug contact See Fig 6 7 This completes disassembly for block assembly replace 15...

Page 273: ...loy Cast Iron Installation Angle 4 19 Cylinder Head Material Alloy Cast Iron Combustion Chamber Wedge Type Fully Machined Pistons Material Tin plated Aluminum Alloy Type Cam and Contour Ground Slipper Skirt Measurement Taken At Top of Skirt Clearance in Cylinder 0022 0028 Piston Rings Compression Rings Two Cast Iron Reverse Twist Barrel Face Moly Channel Material Upper Channel Moiy Filler Lower Lu...

Page 274: ...l Hardened Cast Iron No of Teeth 38 Timing Chain Neoprene Belt with Fiber Glass Cord Reinforcement No of Teeth 98 Harmonic Balancer Cast Iron Weight with Rubber Floated Cast Pulley Camshaft Material Hardened Alloy Cast Iron Bearings Number 7 Type Integral with Aluminum Cover Diameter All 2 22 Valve System Valve Lifter None Lash Taken Up By Stationary Hydraulic Lash Adjuster Leak Down Rate 34 Sec M...

Page 275: ...6 0033 Exhaust 0021X 0038 Valve Seat Angle Intake 46O Exhaust 46O Valve Face Angle Intake 45 Exhaust 45 Lubrication System Type of Lubrication Main Bearings Pressure Connecting Rods Pressure Piston Pins Splash Camshaft Bearings Pressure Lash Adjusters and Cam Followers Pressure Timing Gears and Belt None Cylinder Walls Metered Jet Oil Pump Type Spur Gear Externally Mounted Oil Pickup Stationary Sc...

Page 276: ...er J 8894 Adapter Bore Plug lnstaller J 9510 Piston Pin Remover and lnstaller Set J 22230 Valve Seal lnstaller and Tester J 22232 Timing Belt Adjustment Fixture J 22260 Crankshaft Front Cover Seal lnstaller J 22261 Camshaft Oil Seal Remover J 22262 Camshaft Oil Seal lnstaller J 22263 Valve Spring Compressor J 22264 Bearing and Seal Remover Housing J 22267 Bearing and Seal Installer Housing J 22278...

Page 277: ...ompression ratios 9 2 1and 10 5 1 A 400 cubic inch V 8 engine is standard on the G T O Grand Prix and all Pontiacs except Bonneville This engine has 4 120 bore and 3 3 4 stroke and is available in three compression ratios 8 6 1 10 5 1 and 10 75 1 Both the 350 and 400 cubic inch V 8 engines are optional on the Firebird model A large valve 428 cubic inch V 8 engine is standard on all Bonneville mode...

Page 278: ...AND CONNECTING RODS The pistons used in all compression ratio engines are Fig 6 68Cylinder Block 400 RamAir and 428 Except Standard 428 Bonneville flat on top as shown in Fig 6 71 The top of the piston has a relief machined into it for valve clearance VALVE TRAIN All V 8 engines utilize the simple ball pivot type valve train consisting of the valve rocker arm push rod and valve lifter All valve li...

Page 279: ...mechanical portions of the engine Periodic services connected with the engine consist of tune up lubrica Raise hood and using 22603 engine fifting tool tion replacing oil Pter etc Procedures and rewmmen i 6 75 take weightof engine onfront insulators dations for these services will be found in appropriate sectionsof this manual and the Owner s Manual CAUTZON Disconnect battery ground strap before r...

Page 280: ...ension and cross member support 6 Install upper retainer to transmission extension bolts Tighten to 30 lb ft torque 7 Lower transmission until lower retainer stud en gages lower cross member support Install flat washer lockwasher and nut and tighten to 30 lb ft torque 1 Raise hood and using J 22603 engine lifting tool Fig 6 75 take weight of engine off front insulators NOTE Disconnect battery grou...

Page 281: ...ator bolts and washers and tighten to 30 lb ft torque REAR INSULATOR REMOVE AND REPLACE 1 Remove two cross member to insulator bolts 2 With suitable lifting equipment raise transmission at rear to provide clearance for removing insulator to transmission housing bolts 3 Remove two insulator to transmission bolts and remove insulator 4 Install new insulator with two insulator to transrnis sion housi...

Page 282: ...accessory drive belts may be adjusted REMOVE by use of the Borroughs Belt Tension gauge or equivalent Section 6A gives the correct specifications 1 Disconnect battery cables at battery ENGINE BLOCK TRANSMISSION EXTENSION TRANSMISSION REAR CROSSMEMBER 8 CYL ENGINE VIEW SHOWING TRANSMISSION SUPPORT MOUNT Fig 6 77 Firebird Engine Insulators ...

Page 283: ...sconnect transmission filler tube support and starter wire harness shield from cylinder heads 22 Remove two front motor mount bolts at frame 23 Lower vehicle 24 Using jack and block of wood support transmis sion automatic transmission 25 Remove two remaining bell housing bolts auto matic transmission 26 Raise transmission slightly 27 Using suitable lifting equipment remove engine INSTALL 1 Install...

Page 284: ...er head 4 Install remaining bolts and new bolt locks 5 Tighten all bolts evenly and securely to 30 Ib ft torque Bend tabs of bolt lock against bolt heads 6 Install carburetor air pre heater shroud 7 Attach exhaust pipe to manifold and tighten to 30 lb ft torque INTAKE MANIFOLD OR GASKET REMOVE 1 Drain water from radiator and from each side of cylinder block NOTE Most water can be drained from the ...

Page 285: ...o intake manifold fitting 12 Connect heater hose to fitting 13 Install water outlet fitting 14 C o e c t wire to thermogauge unit terminal 15 Install vacuum hoses connecting distributor vac uum advance unit to carburetor 16 Install spark plug wire bracket 17 Replace air cleaner attaching closed ventilation pipe vacuum source and hot air duct 18 Close drain plug and fill radiator to proper level 19...

Page 286: ...29 2 Install valve stem seal Fig 6 80 and retainer cup locks Remove spring compressor and valve holder then test valve stem seal using suction cup end of tool J 22330 Fig 6 81 2 Install rocker arm tighten rocker arm ball retaining nut to 20 lb ft torque 3 Remove air fittingJ 22278 4 Replace rocker arm cover spark plug distributor cap and connectspark plug wire PUSH ROD OR VALVE LIFTER REMOVE 1 Rem...

Page 287: ... and as free of oil as possible VALVE LIFTER DISASSEMBLE 1 Remove push rod seat retainer ring by holding seat down with push rod while dislodging spring from lifter body with a pointed tool Fig 6 83 2 Invert lifter and allow push rod seat and plunger to slide out of body If plunger sticks in body place lifter in large end of hydraulic valve lifter plunger remover J 4160 A with push rod end of lift...

Page 288: ... roughness and make sure that hole in centeris open 10 Inspect valve lifter ball Carefully examine ball for nicks imbedded material or other defects which would prevent proper seating Such defects may cause intermittently noisy lifter operation Also inspect plunger face of ball retainer for excessivewear VALVE LIFTER ASSEMBLE NOTE All parts must be absolutely clean when assembling a hydraulic 11Ye...

Page 289: ...pressor attaching bolts if equipped with A C and move compressor to one side when removing head BALL CHECK VALVE RETAINER BODY VALVE SPRING VALVE ROCKER FEED METERING VALVE REiggER 6 Remove battery ground strap and engine ground strap on left head or engine ground strap and automatic transmission oil level indicator tube bracket on right head 7 Remove cylinder head bolts dowel pins will hold head ...

Page 290: ...d using new gaskets 10 Install exhaust pipe to manifold attaching nuts 11 On Firebird models replace right side insulator to bracket bolt on A C equipped V 8 s ROCKER ARM STUDS PRESSED IN STUDS REMOVE AND REPLACE NOTE Only 005 oversize studr are available This stud is to be used i f stud has become loose broken or because offaulv threaa3 The procedures shown are for replacement without removal of ...

Page 291: ...h new seals any time they are removed 2 Place valves in valve and valve train holding stand CYLINDER HEAD AND VALVES CLEAN AND INSPECT Efficient engine performance depends to a great degree upon the condition of engine valves Close inspection of intake valves is especially important as excessive clearance of valve stems in guides will permit oil to be pulled into the combustion chamber causing fou...

Page 292: ...s done Intake valve seat angle is 30 on all large valve heads 45 on all small valve heads and exhaust valve seat angle is 4 5 O on all cylinder heads Intake valve face angle is 29 on large valves 440 on small valves and exhaust valve face angle is 4 4 on all valves This will provide hairline contact between valve and seat to provide positive sealing and reduce build up of deposits on seating surfa...

Page 293: ...guide NOTE Valves are marked 001 003 or 005 with colored ink CYLINDER HEAD AND VALVES ASSEMBLE 1 Install valves valve springs valve stem shields valve spring retainer cups valve stem seals and retainer cup locks using suitable spring compressor The valve stem seals must be installed in the second groove from end of stem Valve stem seal installer and tester J 22330 can be used to install this seal ...

Page 294: ...lip of seal inward using seal installer J 21147 6 Replace harmonic balancer 7 Install drive belts and adjust to proper tension TIMING CHAIN COVER GASKET OR FUEL PUMP ECCENTRIC REMOVE AND REPLACE 1 Drain radiator and cylinder block 2 Loosen generator adjusting bolts 3 Remove fan belt and accessory drive belt 4 Remove fan and pulley from hub of water pump 5 Disconnect lower radiator hose 6 Remove fu...

Page 295: ...r tension 26 Install fuel pump 27 Refill cooling system and check for leaks TIMING CHAIN AND SPROCKETS REMOVE AND REPLACE 1 Remove timing chain cover making certain O ring seal and hollow dowels are retained for installation at assembly 2 Remove fuel pump eccentric bushing and timing chain cover oil seal 3 Align timing marks to simplify proper positioning of sprocketsduring reassembly Fig 6 97 4 S...

Page 296: ...remover bears against rear edge of bearing NOTE If rear bearing is to be removed it will be necessary to remove camshaft rearplug 15 Remove four oil pan to timing chain coverscrews 3 Place indexing collar J 6173 6 on threaded end of shaft with open side toward unthreaded end and start 16 Remove timing chain cover and gasket thrust washer and nut on shaft Fig 6 98 17 Remove fuel pump eccentric and ...

Page 297: ... shoulder at end of counter bore for camshaft rear plug visible behind bearing 8 Remove remover and replacer set J 6173 9 Visually observe that holes in bearing line up with drillings in block 10 Carefully remove rags used to catch particles of metal and use magnet or vacuum cleaner to make sure that all metal particles are removed from block surfacesand oil drillings CAMSHAFT REPLACE 1 Coat inner...

Page 298: ...etor linkage fuel lines and ther mogauge unit 20 Connect all water hoses vacuum hose and spark plug wires 21 Install carburetor air filter 22 Refdl cooling system and check for leaks OIL PAN ANVOR OIL PAN GASKET PONTIAC AND FIREBIRD MODELS REMOVE 1 Disconnect battery cable 2 On Firebird models remove distributor cap 3 Remove fan shield 4 On air conditioned cars remove fan and pulley assembly 5 Dis...

Page 299: ...imately 1 1 It 16 Remove oil pan by first rotating clockwise facing forward to clear oil pump NOTE If work other than oil pan gasket replacement is to be performed remove jack and support engine with suitable blocks of wood REPLACE 1 Install new gasket on oil pan Fig 6 101 6 102 6 103 2 Replace oil pan Tighten retaining bolts to 12lb ft Fig 6 104 Oil Pump and Oil Pump Drive Shaft 3 Install left mo...

Page 300: ... and cover for evidence of wear 5 Inspect pump gears and end of drive gear shaft for wear Fig 6 105 6 Inspect oil pump drive shaft distributor to pump shaft for evidence of wear and cracks ASSEMBLE OIL PUMP 1 Install drive and driven gears REMOVE 1 Remove engine oil pan See Oil Pan Remove and Replace Remove splash baffle 2 Remove oil pump attaching bolts while holding oil pump in place Carefully l...

Page 301: ...ock and drive the seal gently into the groove until the tool bottoms b Remove the tool and repeat at the other end of the seal in the cylinder block 5 Clean the block and bearing cap parting line thoroughly 6 Form a new seal in the cap Fig 6 107 7 Remove the newly formed seal from the cap and cut four 4 pieces approximately 318 long from this seal 8 Work two 3 8 pieces into each of the gaps which ...

Page 302: ...tion This will cause bearing to be moved from between shaft and bearing seat 6 Oil bearing surface of shell and install by inserting plain end of bearing shell at indented side of bearing seat and gently rotating shell into place by turning shaft Fig 6 111Measuring Plastigage 8 Install bearing cap and check fit of bearing using Plastigage as outlined below CAUTION Under no circumstances should bea...

Page 303: ...e next size undersize bearing and recheck clearance Bearings are available in standard size 001 and 002 undersize 4 Install a new rear main bearing oil seal in the cylinder block and main bearing cap if the rear main bearing was checked and or replaced 5 Replace oil pump cylinder block to oil baffle tube and oil baMe if they were previously removed 6 Replace oil pan using new gaskets CONNECTlNG RO...

Page 304: ...aft so crank pin carrying assembly to be replaced projects straight downward Fig 6 112 4 Remove ring ridge Fig 6 113 using suitable ring ridge remover 5 Remove bearing cap and install connecting rod bolt guide set J 5239 6 Carefully remove connecting rod and piston assem bly by pushing out with knurled handle of long guide Fig 6 114 REPLACE 1 Install connecting rod bolt guide set on connecting rod...

Page 305: ...h or scored bearing surfaces cracks in skirt or head cracked Fig 6 118 Measuring Cylinder Bore broken or worn ring lands scored galled or worn piston bosses Damaged or faulty pistons should be replaced NOTE If piston pin bosses are rough or worn out ofround and the piston is otherwise serviceable the pin bosses may be honed for oversize pins Before fitting oversize pins however it is advisable to ...

Page 306: ...e covered or taped to protect them during boring or honing operation When 7 SIZING POINT taking final cut with a boring bar leave 001 on the diameter for finish honing to give required piston to cylinder clearance specifications NOTE Honing or boring operation mut be done under close supervision so that specifed clearance between pistons rings and cylinder bores is maintained By measuring the pist...

Page 307: ...me mixed FITTING PIN IN PISTON The piston pin fit in the piston is 0005 to 0007 loose with pin and bosses clean and dry NOTE Piston and pin must be at room temperature when checking fit and pin must be able to fall fiom piston by its own weight FIl TING OVERSIZE PINS IN PISTONS AND CONNECTING ROD PIN BORES In case the standard size piston pin does not fit properly in the piston an oversize piston ...

Page 308: ... oil control ring all above the piston pin are used on pistons for both standard and premium fuel engines The compres sion rings are taper faced and also have either a step or chamfer on the inside diameter of the bottom side The top compression ring is molybdenum filled which results in the center section of ring sealing edge appearing porous or grainy The lower compression ring varies depending ...

Page 309: ...EMOVE AND INSTALL 2 Remove clutch SM and install engine on suitable stand 3 Remove spark plugs 4 Remove engine oil pan 5 Remove oil pump assembly and oil pump drive shaft Fig 6 104 6 Remove oil baMe and oil baMe tube 7 Remove harmonic balancer 8 Remove fuel pump 9 Remove timing chain cover gasket and O ring seal 10 Remove fuel pump eccentric and bushing Fig 6 96 11 Remove sprockets and timing chai...

Page 310: ...sembly 14 Install engine oil pan 15 Install spark plugs 16 Remove engine from stand and install clutch SM 17 Install complete assembly in vehicle ENGINE BLOCK CORE HOLE PLUGS AND OIL PASSAGE PLUGS INSPECT AND REPLACE Engine moving part failures may be caused by lack of proper lubrication In such case it may be necessary to trace oil supply in the block to determine area of obstruction Oil pressure...

Page 311: ... e wire to check two drain holes in lifter gallery FITTEDBLOCKASSEMBLY Fig 6 127 Fitted block contains pistons rings pins and camshaft INSTALLNEW PLUGS bearings The following plugs can be installed by driving into DISASSEMBLE place using a flat piece of metal or hard wood bearing against the outer surface Camshaft plug water Jacket 1 Remove flywheelhousing and clutch assembly plugs rear oil galler...

Page 312: ...vel indicator 17 Remove rocker arm covers 18 Loosen rocker arm nuts rotate rocker arms and remove push rods Store push rods so that they may be reinstalled in the same position as removed 19 Remove cylinder heads and exhaust manifolds 20 Remove cylinder head gaskets 21 Remove oil filter assembly 22 Remove valve lifters use J 3049 if necessary Place valve lifters in a storage box so lifters can be ...

Page 313: ...al 26 Remove bame and oil indicator tube extension position 27 Remove crankshaft 28 Remove all connectingrod and piston assemblies This completes disassembly for fitted block replace ment Proceed with assembly ouerations Use new 29 Remove connecting rods from pistons and identify gaskets throughout and pay specid attention to torque for installation in original location requirements MAIN BEARING O...

Page 314: ... a straight line passing through shaft centers Fig 6 97 Alignment can be simplified by first installing sprock ets without chain to align tirning marks If timing chain is excessively loose new chain or new chain and sprocketsshould be used NOTE Number one cylinder is now at T D C in its firing position When installing distributor position so that rotor is inposition tofire number one cylinder 13 I...

Page 315: ... will also be necessary to turn the oil pump drive shaft so it will index with distributor shaft 22 Install distributor hold down clamp and special bolt and tighten enough to hold distributor in place 23 Install coil 24 Cement new gasket to push rod cover and install push rod cover 25 Cement new gaskets to rocker arm covers and install covers 26 Install intake manifold gasket with plastic locating...

Page 316: ...0 cu in 44 3 400 cu in 54 3 428 cu in 54 3 HORSEPOWER AND TORQUE COMPRESSION ENGINE CARBURETOR RATIO HORSEPOWER 350 2 Bbl 9 2 265 4600 350 Firebird Q Jet 10 5 325 5100 350 Tempest Q Jet 10 5 330 5100 400 GTO 2 Bbl 8 6 265 4600 400 GTO Q Jet 10 75 350 5000 400 Ram Air GTO Q Jet 10 75 366 5100 400 Ram Air IV GTO Q Jet 10 75 370 5500 400 Firebird Q Jet 10 75 330 4800 400 HO Firebird Q Jet 10 75 335 5...

Page 317: ...in plated Aluminum Alloy Ram Air Forged Aluminum Type Cam and Contour Ground Slipper Skirt Measurement Taken At Top of Skirt Clearancein Cylinder 350 and 400 0025 0031 428 0030 0036 400 Ram Air IV 0055 0061 Piston Rings Compression Rings Two Cast Iron Reverse Twist Taper Face Material Upper Lower 350 Channel Moly Filled Tin plated 400 GTO Firebird 400 and R A Channel Moly Filled Channel Moly Fille...

Page 318: ... PSI PSI Outer 135 145 1 134 135 145 1 134 180 190 1 299 135 145 1 134 59 65 1 586 59 65 1 586 93 99 1 712 59 65 1 586 Inner 99 105 1 114 118 128 1 114 118 128 1 114 28 34 1 566 48 53 1 566 48 53 1 566 Valves Material Intake GM 8440 Steel with aluminized Face and Flash Chrome Stem Exhaust Standard 21 2N Steel with Aluminized Face and Flash Chrome Plated Stem Exhaust H O and R A 21 2N Steel with Al...

Page 319: ...wer Moraine 100 A GTO and Firebird 400 Lower Exc 5 Moraine 400 A Pontiac 400 Exc 4 Lower Moraine 100 A Pontiac 400 4 Lower Moraine 400 A 428 Moraine 400 A Thrust Taken On No 4 Crankshaft Endplay 003 009 Journal Diameter 350 and 400 3 00 428 3 25 Main Bearing Length Nos 1 2 3 94 NO 4 350 400 1 13 NO 4 428 1 19 No 5 1 59 Clearance 0002 0020 Crankpin Diameter 2 25 Flywheel and Sprockets Flywheel Mate...

Page 320: ... A Screwed in to Head Lubrication System Type of Lubrication Main Bearings Pressure Connecting Rods Pressure Piston Pins Splash Camshaft Bearings Pressure Lifters Rocker Arms Pressure Timing Gears Chain Metered Jet Cylinder Walls Metered Jet Oil Pump Type Spur Gear Oil Pickup Stationary Screen Pressure Standard 30 40 2600 RPM GTO 428 45 50 2600 RPM Oil Capacity 5 Qts with Filter 6 Qts Fuel System ...

Page 321: ...amshaft Bearing Remover and Replacer J 6384 Valve Spring Compressor Set J 6621 Valve Guide Reamer OO5 O S J 6647 Piston Ring Compressor 350 J 6901 Piston Pin Remove and Replace Set J 7117 Piston Ring Remove and Replace Tool 400 428 J 7588 Rear Main Bearing Oil Seal lnstaller J 8021 Piston Ring Remove Replace Tool 350 J 8062 Valve Spring Compressor J 8087 Cylinder Bore Gauge J 8101 Valve Guide Clea...

Page 322: ...demands A drain rock 1s located at inside Icrwer lei1 corner of radiator RADIATOR CAP A pressure vent cap is used on the radiator to allow a build up of 15 psi of prefsure i n the cnuling system This pressure raises the boding poinr i l T cnolanr to approxitllately 258 F at sea level C A UTION As long as rh u e is pressurtmi n he ooling system the temperature can be considerab higher than rke boil...

Page 323: ...except for maintaining an adequate coolant level If GM gly col type inhibited engine coolant is used it is not necessary to drain the coolant for summer driving because this coolant has been especially formulated to last 24 months in the cooling system After service for 24 months drain the system flush it with water and refill with an inhibited year round coolant meeting the GM 1899M specification...

Page 324: ...t either thermometer or thermostat on bottom of container as this will cause them to be at higher temperature than the water b Agitate water to insure uniform temperature of water thermostat and thermometer A new thermostat 190 valve should start to open 002 at a temperature of 187OF to 1930F and should be fully open 3 8 or more at a temperature not in excess of 222 F A used thermostat can be abou...

Page 325: ...g new radiator transfer fittings from old radiator to new radiator 8 Replace radiator assembly by reversing the above steps checking to assure radiator lower cradles are located properly in radiator recess 9 Refill radiator Run engine for a short period of time and check for leaks If Automatic transmission radiator recheck transmissionoil level RADIATOR FIREBIRD REMOVEAND REPLACE Fig 6A 3 REMOVE 1...

Page 326: ...then REPLACE every other oil change thereafter 1 Replace radiator by reversing the above procedure 2 Torque all mounting screwsto 12 lb ft 3 Refdl radiator with enough coolant to ensure all weather corrosion protection 20 F protection ENGINEOIL SeeGENERAL LUBRICATION SECTION OIL PUMP SeaSECTION 6 ENGINE MECHANICAL 1 Turn the filter counterclockwise to unscrew filter from base Fig 6A 4 and 5 NOTE T...

Page 327: ...il to bring to FULL mark on dipstick 22775 7 Run engine and check for leaks at filter to base 4 m d tighrn filter until gasket contacts filter base gaskets Recheck crankcase oil level If necessary add then tiawn a further 2 3 of a t using J 22775 for oil to bring level to FULL mark on pstick conveniena Do not over tighten OIL FILTER 5 Lower vehicle REMOVEAND REPLACE FIREBIRD400 H O AND 6 Remove ol...

Page 328: ...BINATIONS BELT NAME BORROUGHS 6AU6E NEW USED Water Pump and Generator Belt All 6 Cyl and 8 Cyl I20 Lbs 75 Lbs Power Steering Pump Belt 6 Cyl w o A C 145 Lbs 105 Lbs Power Steering Pump Belt All 8 Cyl and 6 Cyl with A C 145 Lbs 105 Lbs 46 Generator to Power Steering Belt 6 Cyl 60 Lbs 50 Lbs 1 5 g A C Compressor Belt All 6 Cyl and 8 Cyl 145 Lbs 105 Lbs L5i2 Power Steering Belt V 8 145 Lbs 105 Lbs ...

Page 329: ...ll 480 Sq in Core Area 6 Cyl Std 353 Sq in Core Area 6 Cy1 Firebird 353 Sq in Core Area 6 Cyl A C Tempest only AS0Sq in Core Area V 8 Tempest only 353 Sq in Core Area V 8 Firebird 390 Sq in Core Area 400 480 Sq in Thermostat 190 F Cooling System Cap 400 Pont All 18 qts Cooling System Cap G P 400 18 6 qts Cooling System Cap 428 17 2 qts Cooling System Cap 400 17 8 qts Cooling System Cap 500 A C 19 ...

Page 330: ... 428 H O 7 Blade Power Flex 18 Diameter Firebird 6 cylinder with A C or KB2 7 Blade Power Flex 19 z Diameter Firebird V 8 M T with A C Firebird 400 Exc Ram Air with KB2 G T O Exc Ram Air and 2 Bbl option with KB2 Grand Prix with KB2 All 350 engines with A C with KB2 Firebird 400 A T Exc Ram Air with A C with KB2 Grand Prix and G T O with A C with KB2 Bonneville Heavy Duty Chassis Bonneville with A...

Page 331: ...969 PONTIAC SERVICE MANUAL FlREBlRD NOTE USE PB RADIATOR WHEN TRAILER PROVISION IS ORDERED NOTE PONTIAC FlREBlRD 8 G P CARS REQUIRE HEAVY DUTY RADIATOR WITH AXLE RATIOS ABOVE 3 55 Fig 6A 6 Radiator Usage Chart ...

Page 332: ...ions Six GTO s cylinder 4 Bbl engines are not affected by this change and continue to use the heat riser valve An optional heavy duty dual stage air cleaner is available on all models except the 428 H O engine GTO and Tempest Sprint This air cleaner consists of a replaceable oil wetted paper inner filter surrounded by a glycol wetted polyurethane foam outer filter The polyurethane element and cran...

Page 333: ...SE SAME AS 2 LBL CARB HOSE PART OF AIR CLEANER ASM 2 BBL CARB Fig 68 2Air Cleaner Installation 8 Cyl AIR CLEANER ELEMENT a SHROUD REHEATER RAM AIR ONLY VIEW B CRANKCASE BREATHER DUC RED N S T I I Fig 68 3 Air Cleaner and Seal Installation GTO Ram Air ...

Page 334: ...N SLOT IN BRACKET T Q SEAL BAFFLE WARDS CENTER OF BAFFLE ASSEMBLY UNTIL VALVE ASSEMBLY IS IN CLOSED 4 PULL KNOB ON CABLE IN SIDE OF CAR 1 4 FROM MOUNTING BRACKET 5 T I G H T E N S C E W S Fig 68 4 Baffleand HoodScoop InstallationGTO Ram Air PREHEATER DUCT PREHEATER DUCT Fig 68 5Air Cleaner Seal Installation Firebird Ram Air ...

Page 335: ...EMBLE CABLE ENDS TO 3 POSITION HEAD OF BOLT IN BRACKET SLOT TOWARDS R H SIDE OF BAFFLE ASSEMBLY UN TIL VALVE ASSEMBLY VIEW A l IS IN CLOSED POSITION 4 PULL CONTROL CABLE KNOB INSIDE OF CARL 1 4 FROM MOUNTING BRACKET Fig 68 6Baffle Hood Scoop Installation Firebird Ram Air RBLlRElOR INTAKE AVAILABLE AIR UNDER H Fig 68 7 Ram Air Intake Schematic ...

Page 336: ...allowing the carburetor idle mew to contact the idle cam In this position the engine speed should drop to the specified lower solenoid inactive speed Fig 68 9Idle Stop Solenoid 6 Cyl Shown Fig 68 10Accelerator Linkage Tempest and Grand Prix AFTER INSTALLING SWITCH ASM DEPRESS PLUNGER FULLY IN DIRECTION O F ARROW E AS SHOWN T O INSURE PROPER SETTING SPREAD ENDS AFTER INSTALLATION L 4 C A R B EXTENS...

Page 337: ...ailable on 4Bbl 6 cylinder engines therefore no vapor divertersare used with 6 cylinder engines ROCHESTER MV MONOJET CARBURETOR CARBURETOR MODEL NUMBER USAGE 7029165 250 Manual Trans 7029166 250 Auto Trans 7029167 250 Manual Trans A C 7029168 250 Auto Trans A C All Rochester M V adjustments can be performed on the car With the exception of idle speed and mixture adjustments outlined in Section 6D ...

Page 338: ...AIR HORN REMOVAL Fig 6B 13 diaphragm plunger rod through hole in air horn 1 Remove upper choke lever retaining screw at end of choke shaft Then remove choke lever from shaft 2 Remove choke rod from fast idle cam by rotating rod Remove upper lever from other end of choke rod Note position of rod in relation to levers for ease in reassembly 3 Remove six air horn to float bowl attaching screws three ...

Page 339: ...move actuating lever on throttle shaft by removing attaching screw in end of shaft 8 Hold the power piston down in float bowl then remove power piston drive link by sliding out of hole VACUUM BREAK LEVER IDLE VENT VALVE vmw BREAK Fig 6B 14Air Horn Disassembly FUYTNEEDLEB SEAT ASSEMBLY Fig 6B 15Float Bowl Disassembly in power piston plunger rod The power piston metering rod can now be removed from ...

Page 340: ... damage 6 Inspect holes in levers for excessive wear or out of round condition If levers or rods are worn they should be replaced 7 Examine fast idle cam for excessive wear or damage 8 Check throttle and choke levers and valves for binds and other damage 9 Check all spring for distortion or loss in tension replace if necessary CARBURETOR ASSEMBLY AND ADJUSTMENT PROCEDURES THROlTLE BODY ASSEMBLY AN...

Page 341: ...y in float bowl 12 Install pump discharge ball spring and spring retainer Make sure spring retainer is in flush with top of bowl casting 13 Install fuel filter relief spring fuel inlet filter filter nut and gasket Tighten to 25 lb ft NOTE Open end of filter should face hole in fuel inlet nut 14 Install float needle seat and gasket and tighten securelyusing care not to damage needle seat 15 Install...

Page 342: ... the choke shaft lever End of rod points away from air horn casting when installed properly 7 Install lower end of choke rod into fast idle cam Steps on fast idle cam should face fast idle tang on throttle lever 8 Install upper choke lever to choke shaft End of lever faces towards vacuum break diaphragm See Fig 6B 13 Install choke lever screw Tighten securely IDLEVENT ADJUSTMENT Fig 68 21 Set engi...

Page 343: ...d between choke shaft lever and stationary part of carburetor 3 Grasp vacuum breaker plunger rod with needle nose pliers and push straight inward until diaphragm seats 4 With specified plug gauge measure clearance between lower edge of choke valve and inside air horn wall at center of valve as shown 5 Bend end of vacuum break lever at point shown to adjust UNLOADERADJUSTMENT Fig 68 25 1 Hold choke...

Page 344: ...IODICSERVICE There are no periodic services required on the Rochester 2GV carburetor however choke linkage choke valve and levers and pump linkage should be kept free of dirt and gum so that they will operate freely DO NOT OIL CHOKE VALVE SHAFT OR ANY PART OF THE LINKAGE OVERHAUL AND ADJUSTMENT Flooding stumble on acceleration and other perform ance complaints are in many instances caused by prese...

Page 345: ...ping lightly on air horn with a nonmetal 6 Remove vacuum break unit and hose lic object U s e car not to bend piston stem 7 Place cover on flat surface Remove float hinge pin and lift float from cover Fig 6B 30 Float needle may now be removed from seat 8 Remove float needle seat screen Fig 6B 30 and gasketwith wide blade screwdriver CHOKE STOVE FRESH CHOKE VALVE POWER PISTON INNER PUMP ARM 0 L PUM...

Page 346: ... by loosening set screw on inner arm and removing outer lever and shaft 3 Check all Darts for wear If wear is noted defective 10 The cover gasket may now be removed parts must b replaced Not especially the following a Check float needle and seat for wear If wear is 11 Remove two choke valve attaching screws then noted the assembly must be replaced remove choke valve 12 Remove choke valve shaft fro...

Page 347: ...djusting needle for burrs or ridges cam it should be replaced as it may upset engine idle Such a condition requires replacement speed during the warm up period f Inspect pump plunger cup Replace plunger if cup is damaged g Inspect power piston and spring for burrs or distortion Replace if necessary 4 Check all filter screens for dirt or lint Clean and if they are distorted or plugged replace with ...

Page 348: ...efully into position ASSEMBLY OF BOWLCOVER 1 Install choke ha0 in air horn then install choke valve on choke shaft using two attaching screws Letters RP on choke valve should face towards top of air horn Center choke valve before tightening screws by installing the fast idle lever and choke trip lever Maintain approximately 020 clearance between the fast idle lever and air horn casting Then tighte...

Page 349: ...nt PUMPRODADJUSTMENT Fig 68 41 Place tool on top of cleaner mounting ring as shown Then with throttle valves fully c l o d the top surface of pump rod should just touch the end of gauge Measurement should be 1 11 32 Bend pump rod to adjust 1 Install fast idle link and fast idle cam as an assembly and install fast idle lever on other end of fast idle link Place fast idle lever on choke shah with th...

Page 350: ... at the end of PLACE GAUGE BETWEEN UPPER EDGE O F CHOKE VALVE AND AIR SH DIAPHRAGM UNGER INUNTIL Fig 68 44Vacuum Break Adjustment GAUGE BETWEEN UPPER EDGE OF CHOKE VALVE AND AIR HORN CASTING I column x 3 w Fig 68 45 Unloader Adjustment the slot in the choke shaft lever gauge between the upper edge of the choke valve and inside wall of the air horn casting To adjust bend the vacuum break rod UNLOAD...

Page 351: ...five turns out from the lightly seated position may be used as a preliminary setting of the mixture screws on six cylinder engine and six turns out on V 8 engines The mixture is to be leaned out from this initial setting to achieve the best lean idle PERIODIC SERVICE ROCHESTER 4MV CARBURETOR There are no periodic services required on the Rochester 4MV carburetor however choke linkage choke valve a...

Page 352: ...ENGINE FUEL 6B 21 PUMP LEVER RETAINING PIN VALVES ACTUATING Fig 68 47Rochester4MV Carburetor COMPENSATOR Fig 68 48Rmhester 4MV Carburetor ...

Page 353: ...NG SCREWS 3 REMOVE SECONDARY METERING RODS ALL SCREWS SHOULD BE TIGHTENED INSERT A EVENLY AND SECURELY IN SEQUENCE A S NUMBERED 4 REMOVE NlNE AIR HORN ATTACHING SCREWS NUMBERED 3 INSTALL SECONDARY METERING RODS AND HANGER INSERT A 5 REMOVE INTERMEDIATE CHOKE ROD CLIP AND REMOVE ROD 4 REPLACE INTERMEDIATE CHOKE ROBAND CLIP 6 REMOVE IDLE VENT AND COVER ASSY 5 REPLACE VACUUM BREAK ROD AND 7 REMOVE AI...

Page 354: ...LE VENT THERMOSTATIC SPRING AND VALVE IDLE VENT VALVE LEVER VACUUMBREAK AND DASHPOT ACTUATING ROD CHOKEVALVE CHOKE VALVE CHOKEVALVE ATTACHING PIN LEVER DISASSEMBLE ASSEMBLE 1 REMOVE CHOKE VALVE SCREWS 1 INSTALL PUMP LEVER AND DRIVE IN ROLL PIN 2 L I F T CHOKE VALVE FROM AIR HORN AND REMOVE SHAFT 2 INSTALL CHOKE VALVE SHAFT AND TWO NEW RETAINING SCREWS 3 DRIVE OUT PUMP LEVER ROLL LIGHTLY STAKE SCRE...

Page 355: ...3 SLIDE GASKET FORWARD TO CLEAR POWER PISTON AND LlFT OFF NOTE GASKET IS CUT AWAY IN AREA OF POWER PISTON FOR EASE OFREMOVALANDREPLACEMENT ASSEMBLE 1 INSTALL AIR HORN GASKET AROUND PRIMARY METERING RODS AND POWER PISTON 2 REPLACE ACCELERATOR Fig 68 51 Air Horn Gasket Remove Replace ...

Page 356: ... E SPRING TIC FlLl EEDLE ITlL FUL I Fig 68 52 Plastic Filler Pump Spring R R ...

Page 357: ...SKYBLE REPLACE RODS IN HANGER X l D E POWER PISTON INTO BORE AND LINE UP METERING RODS WITH JETS WITH RODS IN PRIMARY JETS PUSH WIM ON POWER PISTON TO INSURE PLASTIC RETAINER IS LOCATED PROPERLY IN BORE TENSION SPRING ROTATE METERING RODS IN DIRECTION OF ARROWS TO DISCONNECT FROM HANGER AND TENSION SPRING TO REPLACE REVERSE ABOVE PROCEDURE NOTE RODS SHOULD NOT BE BENT OR DAMAGED 68 53 Power Piston...

Page 358: ...L 2 DISCONNECT NEEDLE PULL CLlP AND REMOVE NEEDLE ASSEYBLE 1 INSERT NEW NEEDLE AND PULL CLlP IN FLOAT PIN 2 INSTALL FLOAT BY HOLDING FLOAT AT TOE AND INSTALL RETAINING PIN FROM PUMP WELL SIDE 3 ADJUST FLOAT LEVEL FIG 60 59 Fig 68 54 Float Float Needle Remove Replace ...

Page 359: ...D BALL 6 REMOVE SECONDARY BAFFLE 7 SPREAD RETAINING EARS WlTH PLIERS TO REMOVE VACUUM BREAK ASSEMBLY ASSEMBLE 1 REPLACE VACUUM BREAK UNIT CLOSE EARS TO RETAIN 2 REPLACE SECONDARY BAFFLE WlTH NOTCHES TOWARD TOP 3 REPLACE ACCELERATOR PUMP CHECK BALL AND RETAINER 4 REPLACE PRIMARY JETS 5 REPLACE FLOAT NEEDLE SEAT 6 REPLACE POWER PISTON SPRING RETAINING 7 REPLACE PUMP RETURN SPRING EARS ACCELERATORPUM...

Page 360: ...D LEVER ASSY ASSEMBLE 1 POSITION INTERMEDIATE CHOKE ROD AND LEVER IN FLOAT WELL 2 INSTALL CHOKE ASSY LINING UP FLATS ON INTERMEDIATE CHOKE SHAFT WITH CUT OUTS IN CHOKE ROD LEVER 3 INSTALL RETAINING SCREW AND TIGHTEN SECURELY 4 REMOVE INTERMEDIATE CHOKE ROD FOR INSTALLATION LATER Fig 68 56 Throttle Body Float Bowl Disassembly Assembly ...

Page 361: ... IDLE MIXTURE BODY SCREWS AND SPRINGS ATTACHING BACK OUT SCREWS FIVE TURNS SCREWS FROM LIGHTLY SEATED POSITION AS A PRELIMINARY ADJUSTMENT 2 INSTALL NEW THROTTLE BODY TO BOWL GASKET 3 INSTALL THROTTLE BODY GASKET OVER DOWELS ON FLOAT BOWL INSERT THREE ATTACHING SCREWS TIGHTEN EVENLY AND SECURELY ACCELERATOR 4 PLACE CARBURETOR ON PUMP HOLDING FIXTURE FUEL 5 INSTALL FUEL INLET SPRING NEW INLET s FUE...

Page 362: ...im should be replaced mersed in carburetor cleaner However the delrin cam on the air valve shaft will with 7 Examine fast idle cam for wear or damage stand normal cleaning in carburetor cleaner 8 Check air valve for binding conditions If 2 Blow out all passages in castings with com air valve is damaged air horn assembly must be pressed air Do not pass drills through jets or replaced passages 9 Che...

Page 363: ...ROD I N INNE Fig 60 60 Pump Adjustment AT THlS POINT NOTE THlS ADJUSTMENT TO BE PERFORMED AFTER PUMP ADJUSTMENT OPEN PRIMARY THROTTLE TO A POINT WHERE IDLE VENT VALVE ARM JUST CONTACTS 81 METAL STRIP AT VALVE 60 61 Idle Vent Adjustment ...

Page 364: ...ENGINE FUEL 08 33 AIR VALVE CLEARANCE BETWEEN ROD AND END OF SLOT 030 Fig 68 62Air Valve Dashpot Adjustment AIR VALVE CLOSED TURN ADJUSTING TIGHTEN LOCK SCRE Fig 68 63Air Valve SpringAdjustment ...

Page 365: ...S C O N T A C T A D J U S T ON CAR TO OBTAIN O N LEVER TURN SCREW I N 3 TURNS SPECIFIED RPM SEE CHART TO ADJUST BENCH SETTING IN SECT 6D 4 4 Fig 66 64Fast IdleAdjustment NOTE TO BE MADE AFTER FAST IDLE ADJUSTMENT GE BETWEEN WALL LOWER EDGE OF KE VALVE loo BEND CHOKE ROD TO ADJUST C A M FOLLO O N SECOND STEP OF CAM Fig 66 65Choke RodAdjustment ...

Page 366: ... C 400 AT 350AT 400 MT 350MT 250 AT 7029261 7029262 7029283 7029288 7029270 7018273 7028270 7028273 FLOAT SETTING 9 32 9 16 3 16 100 FLOAT DROP PUMP ROO 1 3 4 1 11 32 085 250MT 428 BonnevilleAT 350 400 428MT 350 400 428 AT 400 Ram Air IV AT 400 Ram Air IV MT 400 Ram Air AT 400 R a m Air MT 3 8 CHOKE ROD 200 2W I 8 0 180 i 3 16 9 32 114 114 246 180 IDLE VENT W 1 9 32 015 VACUUM BREAK 275 275 260 26...

Page 367: ... AGAINST STOP Fig 68 66 Choke Coil Rod Adjustment CO GAUGE BETWEEN AIR HORN WALL A N D LOWER EDGE O F CHOKE VALVE SPECS FIG 68 73 APHRAGM SEATED USING TERNAL VACUUM SOURCE TO ADJUST PUSH UP LIGHTLY ON VACUUM BREAK LEVER UNTIL T A N G CONTACTS ROD Fig 68 67 Vacuum Break Adjustment ...

Page 368: ...68 36 1969 PONTIAC SERVICE MANUAL Fig 68 68 Unloader Adjustment 1 OPEN PRIMARY THROTTLE UNTIL LINK CONTACTS TANG I I CENTER OF SLOT Fig 68 69Secondary OpeningAdjustment ...

Page 369: ... of 106 is 85 While all cylinders are well above 85 they are all excessively low This indicates all Remove any foreign matter from around spark plugs valves or if accompanied by oil consumption worn by blowing out with compressed air then disconnect rings or low crank speed wires and remove plugs COMPRESSION TEST Test compression with engine warm all spark plugs removed and throttle and choke wide...

Page 370: ...llation of the plugs using excessive torque which changes gap settings Installation of plugs on dirty gasket seal Installation of plugs to corroded spark plug hole threads Failure to install plugs properly will cause them to operate at excessively high temperatures and result in reduced operating life under mild operation or a m plete destruction under severe operation where the intense heat canno...

Page 371: ...wn bolts properly tightened Particular care should be taken to see that the top of the battery is kept clean of acid film and dirt because of the high voltage between the battery terminals For best results when cleaning batteries wash fust with a dilute ammonia or soda solution to neutralize any acid present and then flush off with clean water Care must be taken to keep vent plugs tight so that th...

Page 372: ...e speed should drop to the specified lower solenoid inactive idle speed See Section 6D for proper idle setting and procedures CONNECT TUNE UP EQUIPMENT Follow manufacturer s recommendations for the use of testing equipment Fig 6C I shows a basic schematic for instrumentation which will apply to many types of test equipment and may be used as a rough guide if equipment manufacturer s instructions a...

Page 373: ...Reinstall Crankcase Ventilation System using a new P C V valve 6 Adjust carburetor idle to specifications Section 6D ROADTEST TEST PERFORMANCEOF CAR Observe performance of engine at low speed during acceleration and at constant speed Check for missing stalling surging poor acceleration or flat spots on acceleration If any irregularity is found a complete diagnosis should be conducted to find and c...

Page 374: ...DCOMBUSTION SYSTEM In order to provide eff cientengine operation of cars equipped with the Controlled Combustion System all normal tune up items should receive careful and thorough attention every 12 months or 12 000 miles Adherence to these items will assure that exhaust emissionsare kept to the desired level Essential servicesincluded in the tune up items are 1 Check engine idle speed 2 Check ig...

Page 375: ...NE IDLE SPEEDS CURB IDLE RPM AUTOMATIC ENGINE MANUAL I I Cond turned off I Exc Ram Air I 4004 BBL I looO I Sol Inactive I Sol Energized 650 I Sol Inactive I CURB IDLE SETTING PROCEDURE RAM AIR 1 With idle stop solenoid energized adjust mixture screws to best lean carburetor setting using solenoid stop screw for idle speed adjustment 2 With idle stop solenoid disconnected adjust idle speed screw on...

Page 376: ... idle cam 1 Bend fast idle tang on throttle lever for adjustment Fig 6D 2 IdleStop Solenoid 6Cyl and Ram Air 1 Bbl carburetor only 2 Adjust fast idle screw on four barrel carburetor NOTE Curb idle on automatic transmission cars to be set in drive withA C turned off wheref2ted NOTE It i s important that the idle and timing specifcations are strictly adhered to in order to ensure proper control of e...

Page 377: ...ing Switch 6E 20 Spark Plugs 63 22 terminal of the solenoid Excessive resistance in the solenoid control circuit is indicated and should be corrected if the voltage drop exceeds 3 5 volts If the voltage drop does not exceed 3 5 volts and the solenoid does not pull in measure the voltage available at the switch terminal of the solenoid If the solenoid does not feel warm it should pu1l in whenever t...

Page 378: ...move solenoidreturn spring and switch terminal 4 Remove shift lever pivot pin 5 Remove shift lever 6 Replace by reversing above procedures 2 Remove two screws securing cover and carefully remove cover 0 CAUTION Terminal studs have welded lead connec tions therefore be extrekly careful not to twist during removal of nuts If solenoid contacts are slightly burned or ditty contacts should be cleaned W...

Page 379: ...ll 1969 model cars is of the molded type and should not be undercut since undercutting will reduce the bonding of the molding material When turning the modled commutator only a very light clean up cut should be made The minimum diameter of the commutator after turninn should not be less than 1 650 inches As a final step tbis procedure the commutator should be sanded lightly with No 00 sandpaper to...

Page 380: ...e FIELD COIL connector strap and the other on the field frame Fig Field coils can be removed from the field frame easily by use of a pole shoe screwdriver A pole shoe spreader should also be used since this prevents distortion of the field frame Careful installation of field coils is necessary to prevent shorting or grounding of field coils as the pole shoes are tightened into place Formed insulat...

Page 381: ...eld frame over armature apply sealing compound between frame and solenoid case Position frame carefully against drive housing to prevent damage to brushes 4 Place a small amount of high melting point grease in bushing in commutatoPend frame Place leather thrust washer on armature shaft and slide commutator end frame onto shaft 5 Install through bolts and tighten securely 6 Reco ect field coil lead...

Page 382: ...y cable and connect cable to battery 5 Measure the distance between pinion and pinion post stop Fig 6E 10 CHARGING CIRCUIT EELER G A U G E I E S S ON C L U T C H I O o vZNT A _ I _ Fig 6E 10Measuring Pinion Clearance GENERATOR PERIODIC SERVICE The generator does not require periodic lubrication The rotor shaft is mounted on ball bearings at drive end and roller bearing at slip ring end and each ha...

Page 383: ...2 Remove two leads at generator 3 Loosen adjusting bolts 4 Remove generator drive belt 5 Remove bolts which retain generator 6 Remove generator from car DISASSEMBLE GENERATOR 1 If rotor drive end frame bearings or pulley and fan need replacement remove and replace shaft nut using Allen wrench 3 Remove four through bolts 4 Separate drive end frame and rotor assembly from stator assembly by prying a...

Page 384: ...cator reading Remove only enough material to make rings smooth and round Finish with 400 grain or finer polishing cloth and blow away all dust DRNE END FRAME BEARING 1 Remove three screws from retainer plate and remove retainer plate inner collar and gasket 2 Press out bearing and oil slinger 3 The bearings in generator are permanently lubri cated and require no lubrication during life of bearing ...

Page 385: ...ls to supply rated output shorted stator windings are indicated d Stator which fails above test should be replaced 4 If necessary stator may be cleaned by brushing with oleum spirits CAUTION Do not clean in solvent 5 The stator can be installed by reversing steps 1 and 2 DIODE TRIO C S I GENERATOR The diode trio is identified in Fig 6E 13 Before removing the diode trio connect an ohmeter using low...

Page 386: ...ctifier bridge of the C S I generator contains all of the diodes found in the heat sink and slip ring end frame of the standard generator If one diode is defective the entire rectifier bridge must be replaced To check the rectifier bridge connect an ohmeter to the ground heat sink and base of m e of the three terminals Fig 6E 18 Then reverse the connections to the grounded heat sink and base of th...

Page 387: ...d any oftke brush ko r msed parts req lr eplacement it will be e a qto pephe the mtfre bmh kal r BRPcmb I d w g a l pmt8 me 110 serviced for th particulm ms in the G SZ Generator th neratox q l a c e voltage regulator 9 At bmh holder hro end frme cnoting cmf gy srwk ap of p m as shorn ia Fig 6E 19 and f lE 20 M m wood sr toohpick to proaude thou hole in a d am adirastall stator or diode trio lead ...

Page 388: ...hich will be prepacked with proper amount and type of lubricant 1 With stator disconnected check a diode in heat sink by connecting one of ohmmeter leads to heat sink and 3 Place flat plate over bearing and Press in from other ohmmeter lead to diode lead and note reading Fig 6E 22 2 Reverse ohmmeter leads and note reading 3 If both readings are very low or very high read the same the diode is defe...

Page 389: ...r fails t o light in both 2 Tighten vise to remove diode checks the diode is defective When checking a good diode the lamp will light in only one of two checks CQUTION Never attempt to remove diode by striking Diodes which fail the electrical tests hould be it shmk m y damage other replaced To replace diodes in the C S I generator see DIODE TRIO or RECTIFIER BRIDGE replacement 3 To install a diode...

Page 390: ...enerator to mounting bracket with bolts washers and nuts Do not tighten 2 Install generator drive belt 3 Tighten belt to 120 lb ft for new belt or 75 lb ft for used belt See Section 6A for proper belt tensioning procedures 4 Tighten bolts to 30 lb ft except bolt at sliding slot on bracket used for other than air conditioned cars which is 20 lb ft 5 Install field and battery leads to generator 6 C ...

Page 391: ...vance on these types of distributors The procedure for replacing contact set and adjusting point opening is covered under CHECKS AND ADJUSTMENITS OF DISTRIBUTORON VEHICLE DISASSEMBLY AND ASSEMBLY DISASSEMBLE Fig 6E 27 1 Remove rotor 2 Disconnect primary and condenser leads from between plastic retainer and breaker set spring Remove breaker points adjusting hold down screw and remove breaker points...

Page 392: ... timing This should be done at each tune up and at least every spring and fall ADJUSTMENT 1 With engine operating raise window provided in cap 2 Insert Hex type wrench into head of adjusting screw as shown in Fig 6E 28 3 Turn screw to adjust point opening by one of the following methods Preferred Method Turn adjusting screw until 30 dwell is obtained as measured by dwell meter When using dwell met...

Page 393: ...eaker cam DISASSEMBLY AND ASSEMBLY DISASSEMBLE Fig 6E 30 1 Remove rotor by removing two attaching screws lockwashers and flatwashers Fig 6E 30 NOTE It will be observed that rotor is doweled to weight base so that it can be installed in only one position 2 Remove both weight springs and both advance weights 3 Remove retaining pin from gear by driving it out of gear with a drift and hammer CAUTION D...

Page 394: ...as noted when distributor was removed This will simplify indexing distributor shaft and gear with oil pump drive 1 Check to see that engine is at f n g position for No and drive gear on i t r i b and 1 cylinder No 1 piston at top of mmpression stroke rotor wll be positioned as shown in Fig 6E 31 when and timing mark on harmonic balancer is indexed propsrly installed with N I pistonin f i g with th...

Page 395: ...sition IGNITIONTIMING Correct timing marks are on the front engine covers and harmonic balancer Figs 6E 33 6E 34 Due to vacuum advance at idle it is imperative to disconnect distributor vacuum advance line before setting ignition timing Fig 6E 32 Rotor in No 1Firing Position 6 cylinder At time spark is adjusted the general appearance of breaker points should be observed If smudge line appears on p...

Page 396: ...activated stop lights directional signals parking brake warning light radio power antenna power windows and seats back up lights and electric windsheild wipers In the RUN position the ignition primary circuit is activated through the resistance and the air conditioning and heater and defroster circuits are activated There are seven terminals on the back of the switch Fig 6E 35 The Bat terminals Bl...

Page 397: ... IGN 1 ACC BAT IGN 1 RUN I IGN SW 6 LOCK ROD IGN 2 IGN 1 ACC BAT 1 i IGN SW L LOCK ROD IGN 2 IGN 1 ACC BAT OFF LOCKED I IGN SW L LOCK ROD IGN 2 IGN 1 ACC BAT ACCESSORY I IGN SW L LOCK ROD NOTE ALL ABOVE IGNITION SWITCH AND KEY 6 LOCK CYLINDER POSITIONS ARE S H O W N VIEWING THE COMPONENTS FROM THE BACK SIDE ...

Page 398: ...er from around spark plugs by blowing out with compressed air 3 Using a 13 16 spark plug socket remove the spark plugs INSPECT Spark plug life is governed to a large extent by operating conditions and plug life varies accordingly To insure peak performance spark plugs should be checked cleaned and regapped every 12 months or 12 000miles Worn or dmy plugs may give satisfactory operation at idling s...

Page 399: ...r gauge to adjust the spark plug gaps to 035 Fig 6E 36 INSTALL I Inspect s k plug hole threads and clean before installing pugs P Corrosion deposits can be removed with a 14 mm x 1 2 5 SAE spark plug tap available through local jobbers or by using a small soft wire brush in an electric drill If a tap is used coat it with plenty of grease to catch any chips CAUTION Use extreme care when using tap t...

Page 400: ... I A n 0 p PT OPT R59 2900 61 A R 1 J R59 2900 61 55 32 660 50 1660 2 2 2 6 r u L L Y 59 2350 53 R 59 ZPOO 61 11074 0 11 14358 14 S16 5 41 47 1119515 11 16368 13 S16V GRAND PRIX w s m I LCD R 1 R I m b E y EA7 R59 2900 61 42 l e e 7 3 0 1 0 1825 2 2 2 6 1 1 074W 0 37 25 730 35 I825 2 2 2 6 1107293 0 11 19515 t 11 16368 13 5 16V 1107355 2 1114356 14 S16 5 41 47 37 25 730 35 1825 2 2 2 6 55 32 660 5...

Page 401: ...MCONTROLMODEL In HG to start advance In HG for full advance Max adv dirt deg 1111940 c c 30 18 23 DEG RPM 5 2 5 500 7 5 9 5 950 15 17 2275 1115365 8 10 15 17 1 0 1 11 0474 c 32 O 18 23 DEG RPM 0 2 550 6 8 875 11 5 13 5 2375 197341 9 5 7 10 5 1 1 5 7 5 1111960 c c 30 18 23 DEG R PM 1 3 3 3 700 6 8 1000 10 12 2300 11 15365 10 12 17 18 8 1 O0 1111946 c c 300 18 23 DEG RPM 0 2 500 5 7 1000 9 11 2300 1...

Page 402: ...ering column lock requires that manual transmission be in Reverse gear before removing the ignition key the clutch safety switch prevents engine cranking in gear when the steering column is unlocked while starting PERIODICSERVICE LUBRICATION Every 6 000 miles lubricate all pivot points with 2 With clutch pedal against stop loosen jam nut sufiiciently to allow the clutch fork push rod to be turned ...

Page 403: ...ten ball stud nut to 21 lb ft torque 1 Disconnect battery to starter lead at battery 2 Remove propeller shaft and transmission See TRANSMISSION SECTION Exercise care to avoid damaging transmission front bearing retainer release bearing support when transmission is pulled back to free main drive clutch gear from flywheel housing 3 Remove clutch release bearing through rear opening in clutch housing...

Page 404: ...sion if relieved 12 Remove all but top bolt and move clutch assembly away from flywheel at bottom so as to permit removal of clutch driven plate 13 Remove remaining bolt to remove clutch cover plate assembly INSPECTION 1 Inspect clutch driven plate for broken or distorted torsion springs worn or loose facings oil on facings or damaged spline which could cause binding If any of the above defects ar...

Page 405: ...ot bearing in crankshaft for roughness REPLACE 1 Position clutch driven plate so that long end of hub is in flywheel and install clutch driven plate and cover assembly on flywheel but do not tighten bolts install lock washer under each cover to flywheel bolt NOTE Align marks placed on jlywheel and on cover during disassembly 2 Use a spare transmission main drive gear inserted in spline of clutch d...

Page 406: ... pins in upper holes in clutch housing 9 C o e c t clutch linkage to release fork 10 Adjust pedal lash See lash adjustment under PeriodicSenice NOTE If interference is encountered with the clutch fitlly engaging the transmission shifr linkage should be adjusted as outlined in sections 7A thru 70 because the shij linkage interlock mechanism is controlled by clutch action FLYWHEEL OR CLUTCH PILOT BE...

Page 407: ... V 8 4 Bbl 6 Cyl 4 Bbl Bent finger disc spring STARTER RING GEAR REMOVE 1 With flywheel removed from vehicle place the flywheel crankshaft side down on a solid flat surface or block which is slightly smaller in diameter than the flywheel 2 Drive the ring gear off the flywheel using a suitable drift and hammer NOTE Keep working around the circumference of the ring gear to avoid binding the ring gea...

Page 408: ...nd 3rd in Ndbtral position and rear transmission shifter lever Reverse and 1st in Reverse position 4 Tighten swivel clamp mew C to 20 lb ft unlock steering column and shift into Neutral 5 Align gearshift lower control levers E and F in Neutral position and insert a 186 185 diameter gage pin through hole in lower control levers view A 6 Tighten swivel clamp screw D to 20 lb ft remove No periodic se...

Page 409: ... 8 Slide transmission straight back on guide pins until the main drive gear splines are free of splines in clutch frictionpiate 9 Remove transmission INPUT SHAFT SEAL REMOVE AND REPLACE 0 1 Remove transmission from car EXTENSIONHOUSING BUSHING AND OIL SEAL 2 Remove input shaft bearing retainer REMOVE AND REPLACE 1 Remove propeller shaft 2 Insert Tool J 4830 02 over output shaft and tighten set scr...

Page 410: ...SYMBOL IS ADJACENT TO CALLOUT FOR MEMBER TO BE TORQUED VIEW B 2nd 3rd Fig 7A 1Pontiac Column Shift Controls LUBRICATE WlTH CHASSIS LUBRICANT A 30 LB FT SHIFT LEVER WlTH A iO LB FT GAGE PIN IN PLACE TORQUE SYMBOL IS NEUTRAL POSITION ADJACENT TO CALLOUT FOR MEMBER TO BE TORQUED Fig 7A 2 Tempest and Grand Prix Floor Shift Controls ...

Page 411: ...TO CALLOUT FOR MEMBER TO BE TORQUED SHIFTER ASSY SHIFTER ASSY GAGE PIN 2501 249 DIA 1 VIEW B 0 Fig 7A 3 Firebird Floor Shift Controls LUBRICATE WITH TORQUE SYMBOL IS ADJACENT TO CALLOUT FOR MEMBER TO BE TORQUED CONTROL ROD SPEEW CABLE CLIP Fig 7A 4A Tempest and Grand Prix Back Drive Linkage ...

Page 412: ...ve countershaft out rear of case Fig 7A 9 After removing countershaft lower countergear to bottom of case 12 Remove speedometer drive gear snap ring drive gear and retaining ball 13 Remove rear bearing retaining snap ring 14 Remove large snap ring from rear bearing 17 a Install Tool J 21774 5 over output shaft and position against speedometer drive gear snap ring b Slide Tool J 21774 2 onto output...

Page 413: ...r Rear Spring 33 1st Rev Synchronizer Assy 35 Drive Gear Rear Bearing Retaining Snap Ring 36 Drive Gear Rear Bearinpr to Shaft Snap Ring 37 Drive Gear Rear Bearing 38 Speedometer Drive Gear 39 Front Bearing to Shaft Snap Ring 40 Front Bearing Retaining Snap Ring 41 Front Bearing 42 lnput Shaft 43 lnput Shaft Roller Bearings 44 2nd 3rd Synchronizer Blocking Ring 45 2nd 3rd Synchronizer Spring 46 2n...

Page 414: ...lat washer 2 Remove shift lever 3 Slide shift lever shaft out of case and discard O ring seal 4 Lubricate new seal and slide on shaft Fig 7A 8Rotating Second and Third Shift Rail 5 Install shaft in case 6 Install shift lever and secure with nut lockwasher and flat washer INPUT SHAFT BEARING REPLACEMENT 1 Re install input shaft in case 2 Install large snap ring on bearing 3 Remove bearing to shaft ...

Page 415: ...aining snap ring thrust washer 1st gear and blocking ring Fig 7A 11 RemovingReverse Idler Gear Shaft 7 Remove reverse gear retaining snap ring 8 Mark hub and gear so they can be matched on reassembly and using an arbor press as shown in Fig 7A 16 remove reverse gear synchronizer hub and slidinggear 9 Clean and inspect all parts except countergear 10 Disassemble clean and inspect tountergear and be...

Page 416: ...ot stagger the springs 10 Place a synchronizer blocking ring on each end of the synchronizer sleeve 11 Lubricate main shaft splines and machined surfaces with transmission lubricant 12 Using an arbor press install the first and reverse synchronizer hub and sliding gear onto the mainshaft with the teeth end of the gear facing toward the rear of the shaft Fig 7A 19 When pressed into place install th...

Page 417: ...nd install the 15 bearings in the bore NOTE A thick film of grease will plug the lubricant holes and prevent lubrication of the bearings 4 4 Install the input shaft and bearing through the top of the case into the bore in the front of the case Install the large snap ring on the bearing and slide input shaft fully forward 5 Position the mainshaft assembly in the case 6 Install the second and third ...

Page 418: ...eat the main of the synchronizer shaft pilot in the roller bearings of the input shaft 14 Align the shift fork and install the fist and reverse 19 Tap the input shaft bearing into place in the case shift rail Move the rail in until the center notch is aligned with the detent bore 15 Install the remaining detent plug and spring Secure the spring with the slotted head set screw Turn screw in until t...

Page 419: ...gear snap ring on output shaft b Back Tool J 21774 2 out of J 21774 1 using Handle J 8614 1 until bearing is positioned correctly on output shaft NEEDLE BEARINGS 25 EACH END COUNTERSHAFT BEARING RETAINER RETAINER R O L L PIN Fig 7A 21Exploded View of Countergear Fig 7A 22 Input Shaft Roller Bearing Installation c Remove speedometer drive gear snap ring and tools and install rear bearing retaining ...

Page 420: ...talled in buttom of case 33 Place the transmission in gear and put lubricant over the entire gear train while rotating the input shaft 34 Coat a new access cover gasket with sealer and install it on the case 35 Install access cover and torque screws to 17 Ib ft TRANSMISSION REPLACE 1 Install guide pin in upper right transmission to flywheel housing bolt hole for alignment and place transmission on...

Page 421: ...ons This code consists of two letters 2 inches high on the R H side of the case CLEARANCES The letters DA identify the standard Pontiac or Grand Countershaft Gear End Play 0 004 0 018 Prix three speed manual Dearborn transmission and Reverse Idler Gear End Play 0 004 0 018 DB identifies a heavy duty Tempest or Firebird three speed manual Dearborn transmission A number derived from the vehicle iden...

Page 422: ...pt checking for leaks and proper lubrication level every 6000 miles If there is evidence of leakage leak should be corrected and lubrication added as needed Refill capacityis 3 1 2 pinu Transmission Side Cover 7B 4 Major Repairs 7B 4 Transmission Remove 7B 4 Transmission Disassemble 7B 5 Transmission Cleaning and Inspection 7B 6 Transmission Assemble 7B 9 Transmission Install 7B 1 3 Firebird Drive...

Page 423: ...h console loosen two attaching bolts shifter assembly to shifter support align shifter assembly to specification shown in view C and tighten attaching bolts to specified torque view B b Except console loosen two attaching bolts shifter assembly to shifter support align shifter assembly centrally in its floor boot and tighten attaching bolts to specified torque view B 4 Position both transmission s...

Page 424: ...se seal to leak or damage bushing 5 Coat new seal with sealing compound and start new seal in opening 6 Place Collar J 6403 2 onto Tool J 6403 1 Fig 7B 6 NOTE Flat side of J 6403 1 must be toward rear of J 6403 1 8 Tap end of tool with soft hammer to seat seal 9 Reinstall propeller shaft EXTENSION HOUSING SEAL AND BUSHING REMOVE AND REPLACE 1 Remove propeller shaft 2 Insert Tool J 483042 over outp...

Page 425: ... cam retainer and detent cams 5 Inspect and replace necessary parts 6 Inspect shifter shaft O rings and replace if neces sary REPLACE 1 Install shifter shaft O rings if removed 4 C o e c t control rods to levers 5 Refill transmission NOTE Detent cams shifier shafts and forks are interchangeable MAJOR REPAIRS TRANSMISSION REMOVE 1 Disconnect speedometer cable 2 Disconnect transmission shifter lever...

Page 426: ... and gasket 3 Remove front bearing to main drive gear snap ring 4 Pull main drive gear out of case as far as possible and remove front bearing Fig 7B 10 NOTE Although fiont bearing is a slip fit on main dn ve gear it may be necessary to aid removal with screwdriver 5 Remove extension housing to case attaching bolts 6 Remove reverse idler shaft to gear snap ring Fig 7B 11 Slidereverse idler gear fo...

Page 427: ...peed gear on press plate using idler shaft and woodruff key through rear of case Fig 2 pieces of stock 6 1 718 114tr i 7B 19 7B 15 Remove second third speed synchronizer assembly and second speed gear 14 Remove reverse idler gear and tanged steel thrust washer 15 Remove second third synchronizer sleeve Fig INSPECTION 7B 16 1 Check synchronizer hubs sliding keys and springs 16 Remove rear bearing s...

Page 428: ...on each side of hub so all three keys are identifes the end that must be oppositefork slot in sleeve engaged by both springs Fig 7B 20 when assembled This groove indicates the end of the hub with a greater recess d The tanged end of each synchronizer spring should be installed in different key cavities on either side of 2 Wash front and rear bearings thoroughly in hub Slide sleeve onto hub alignin...

Page 429: ... N TCAMS DETENT C A M S P R I N G Fig 78 10Removing Front Bearing 3 Check for cracks in blocking rings 4 Wash transmission case thoroughly inside and outside with suitable cleaning solvent then inspect case for cracks a Check front and rear case faces for burrs and if present remove with a fine mill file b Check and clean magnet in bottom of transmission case 5 All main drive gear and countergear ...

Page 430: ...e needs replace ment pry out oil seal with screwdriver Replace with new seal using flat plate and tap until seal is seated in its bore Fig 7B 22 NOTE L i p of seal mustface rear of bearing retainer ASSEMBLE 1 Turn the front of the mainshaft upward and install second speed gear and synchronizer on mainshaft Using hydraulic or arbor press and Press Plate J 21858 press second third speed synchronizer...

Page 431: ...ar 24 Counte ear Bearing ROIlersT27 25 Thrust Washer Rear 26 Countenhaft 27 Woodrvff Key 28 Reverse ldler Gear 29 Reverse ldler Gear Snap Ring 30 Reverse ldler Shaft 31 Woodruff Key 32 Reverse ldler Gear Thrvst Washer Fig 78 16Mainshaft Countergear and Reverse ldler Gear Details CAUTION Make certain notches in blocking press rear bearing into position Fig 7B 25 Install ring align with keys infirst...

Page 432: ...ergear to case bronze thrust washers 10 Install countergear assembly into case Install countergear shaft from rear of case Make certain woodruff key is in position 11 Install reverse idler gear tanged steel thrust washer Install reverse idler gear shaft and woodruff key ASSEMBLY 2 PLATES 6 x l 7 8 x 1 1 4 mla Fig 76 19 RemovingSecond Third Synchronizer and Gear Fig 76 20Synchronizer Assembly ANTI ...

Page 433: ... grease to hold bearings in into case Install extension housing to case bolts plaa Fig 7B 26 Torque to 45 Ib ft 14 Assemble third speed blocking ring on main drive CAUTION Make certain that notches in blocking ring gear align with keys in second third synchronizer 15 Pilot main drive gear and third speed blocking ring 18 Install front bearing onto main drive gear Outer over front of mainshaft snap...

Page 434: ...wheel housing bolt hole for alignment and place transmission on guide pin Rotate transmission as necessary to start main drive gear splines into clutch friction plate Slide transmission forward NOTE Make certain splines of clutch friction plate are concentric with pilot bearing in crankshaft and release bearing isproperly installed 2 install two 2 lower transmission mounting bolts Remove guide pin...

Page 435: ...unting which in turn is attached to the underside of the transmission A driveline damper is used to reduce power train extension through an adapter Fig 7B 27 SPECIALTOOLS J 1126 Aligning Studs J 8904 Press Plate Not Shown J 2619 Slide Hammer J 21858 Adapter Axle Shaft Bearing Remover J 4830 02Extension Housing Bushingand Oil Seal Remover J 22246 CountershaftAlignment Tool J 6403 01Extension Housin...

Page 436: ... cyl floor shift FB 8 cyl 350 cu in FB GEAR RATIOS First Speed Second Speed Third Speed Reverse FIREBIRD CODE 6 cyl column shift FK LUBRICATION 6 cyl floor shift FY 8 cyl 350 cu in RJ Capacity 3 4 pints TORQUE SPECIFICATIONS APPLICATION LB CT Front Bearing Retainer to Case Bolts 10 Side Cover to Case Bolts 1 0 Extension Housing to Case Bolts 45 Shift Lever to Shifter Shaft Bolts I5 Lubrication Fil...

Page 437: ...shifter assembly lever view A of Fig 7C 1 Transmission Remove 7C 4 Transmission Disassemble 7C 4 Transmission Cleaning and Inspection 7C 5 Transmission Assemble 7C 5 Transmission Install 7C 9 Driveline Damper 7C 9 Specifications 7C 9 Special Tools 7C 9 4 Insert a 250 249 diameter gage pin inio shift assembly view B of Fig 7C 1 NOTE Gagepin in place will maintain shifterassembly in Neutralposition ...

Page 438: ...emove shift forks from shifter shaft assemblies Remove all three shifter shaft assemblies Remove reverse shifter shaft detent ball and spring Fig 7C 3 6 Remove detent cam spring and pivot retainer C ring Mark to identify both detent cams and remove 7 Inspect O ring seals on shifter shafts Replace any damaged parts REPLACE 1 Install shifter shaft O rings if removed A LUBRICATE WITH CHASSIS LUBRICAN...

Page 439: ...detent cam pivot pin with the detent cam spring tang up over the kt and 2nd shifter shaft opening 4 Install kt 2nd and 3rd 4th shifter shaft assembliesin cover being careful not to damage seals Install shift forks to shifter shafts lifting up on detent cams to allow forks to seat fully NOTE Shifrlorks are not interchangeable 5 Install reverse detent ball and spring to cover then install reverse sh...

Page 440: ...ft Fig 7C 7 and remove extension housing 1 Main Drive Gear 2 Front Bearing Retainer 3 Bearing Roller 4 Case 5 4th Speed Blocking Ring 6 3rd 4th Svnchronizer Snap i n g 7 3rd 4th Synchronizer Hub 8 Blocking Ring 9 Third Speed Gear 10 Second Speed Gear 1 1 Blocking Ring 12 1st 2nd Synchronizer Hub 13 1st 2nd Synchronizer Snap Ring 14 1st Speed Blocking Ring 15 First Speed Gear 16 Reverse Gear Thrust...

Page 441: ...e taken out in which case speed blocker riag and se nd speed gear off end of 27 roller bearings and a spacer must be removed ram mainsha i 7 12 each end of the shaft 10 Use a long drift or punch through the front bearing CLEANING AND INSPECTION case bore and drive the reverse idler shaft and Refer to Section7B woodruff key through rear of the case Fig 7C 9 ASSEMBLE 11 Remove 3rd and 4th synchroniz...

Page 442: ...in everse Idler Gear Shaft Fig 7C 10 Removing3rd and 4th Synchronizer and Gear Fig 7C 11Removing Rear Bearingand First Speed Gear Fig 7C 12 Removing1st and 2nd Synchronizer and Second Gear Fig 7C 13Installing3rd and 4th Synchronizer and Third Gear ...

Page 443: ...haft upward and install second sped gear with clutching teeth upward front of gear will butt against flange on mainshaft 6 Install blacker ring with clutching teeth downward over synchronizingsurfaceof second gear 7 With fork slot downward press 1st a d 2nd synchronizer assembly onto splines of mainshaft Fig 7C 14 CAUTION Be sue notches of blockei ring align with keys ofsynchronizerassembly 8 Inst...

Page 444: ...nap ring groove must be toward front of gear 28 Install retaining snap ring Fig 7C 17 Drive Line Damper 29 Install front bearing retainer gasket and four attaching bolts torquing bolts to 10lb ft 10 Install first gear with clutching teeth downward 11 Install first gear thrust washer steel and spring washer 12 With snap ring slot downward press rear bearing onto mainshaft Fig 7C 15 13 Install rear ...

Page 445: ...7 Refer to Section 7B SPECIFICATIONS TRANSMISSION IDENTIFICATION LUBRICATION An identifying code is marked in yellow paint on all four speed manual transmissions This code consists of two letters one inch high on the RH side of the h e The letters FH identify the Firebird Saginaw four speed transmission The vehicle identification number is also stamped on the transmission case as shown in Fig 7C 1...

Page 446: ... r b i r d bosen trunnion jam nuts t v and ztton pedal is far transmission control rods 1st and 2nd and Reverse disengage the clutch and disconnect trunnion Y from its shifter assembly PERIODIC SERVICE lever view A of Fig 7D 2 TRANSMISSION 4 Insert a 250 249 diameter gage pin into shifter assembly view B of Figs 7D 1 or 7D 2 No periodic service of the transmission is required 5 If shift control le...

Page 447: ...ge pin and check complete shift pattern for freenessof operation 4 Pry O ring from groove in fitting and discard 8 Position floor shift control lever in Reverse position 5 check gear and fitting for wear and replace if set steering column lower lever in Lock position and lock imition Y NOTE Check for correct usage by referring to Push On gearshift rod Fig 7D 3A Or 3B speedometer drive and driven g...

Page 448: ...Wash counterbore with cleaning solvent and inspect gear and sleeve assembly for damage TRANSMISSION EXTENSION OIL SEAL REMOVE AND REPLACE 5 Inspect propeller shaft yoke for nicks burrs or scratches which would cut new seal or cause seal to leak or damage bushing 6 Coat new seal with sealing compound and press Remove lock plates or lochashe Straight inlo bore of case extension with J 5154 A Fig and...

Page 449: ...OUE SYMBOL IS ADJACENT TO CALL0 FOR MEMBER TO BE TORQUED ADJUSTING SWIVEL CLAMP Fig 7D 3A Tempest and Grand Prix Back Drive Linkage LUBRICATE WlTH TORQUE SYMBOL IS ADJACENT TO CALLOUT FOR MEMBER TO BE TORQUED SHIFTER LEVER 3rd 4th SHlFTER LEVER 1st 2nd Fig 7D 3B Firebird Back Drive Linkage ...

Page 450: ... and replace necessary parts Fig 7D 6Removingand Installing Side Covir REPLACE 1 Install 1 2 detent cam to cover pivpt pin first then install 3 4 detent cam so the detent spring notches are offset or opposite each other Detent cam notches must be facing downward 2 Install detent cam retaining C ring to pivot shaft and hook spring into detent cam notches 3 Install both shifter shaft assemblies in c...

Page 451: ...ring Retainer to Case 55 Spacers 33 Case Extension 56 Bearing Rollers 34 Extension Bushing 57 Countergear 35 Rear Oil Seal 58 Countergear Roller Spacer 36 Reverse Idler Front Thrust 59 Bearing Rollers Washer Tanged 60 Spacers 37 Reverse Idler Gear Front 61 Bearing Rollers 38 Reverse Idler Gear Rear 62 Spacer 39 Reverse Idler Rear Thrust 63 Tanged Washer Washer Flat 64 Countershaft 40 Reverse Idler...

Page 452: ...ble from speedometer Fig 7D 10RemovingReverse Shifter Shaft Lock Pin Fig 7D 113rd and 4th Speed Synchronizer Sleeve in 4th Gear Position driven gear fitting and disconnect back up light leads from back up light switch 2 Disconnect transmission shifter levers 1st 2nd and 3rd 4th and Reverse from transmission shifter shafts Figs 70 1 and 7D 2 Remove two 2 shifter assembly to extension support bolts ...

Page 453: ...2 studs from cross member support and withdraw transmission from clutch housing 8 Remove the transmission DISASSEMBLE 1 Remove transmission side cover assembly from transmission case and drain lubricant NOTE If cover assembly is to be disassembled for inspection or replacement of worn parts follow procedures 5 through 8 under TRANSMISSION SIDE COVER REMOVE 2 Remove insulator assembly from transmis...

Page 454: ... by tapping bearing retainer with a soft hammer 11 Unload 17 bearing rollers and cage from main drive gear and remove fourth speed synchronizing ring 12 Lift the front reverse idler gear and thrust washer from case Fig 70 17 Installing Reverse Shifter Shaft and Detent Ball 14 From inside case tap out front bearing and snap ring 15 From the front of the case tap out the counter shaft using Loader J...

Page 455: ...haft lock pin intoplace until the extension has been installed on the transmission case EXTENSION CASE BUSHING AND OIL SEAL REMOVE AND REPLACE 1 Remove oil seal with punch or other suitable tool and discard seal Fig 7D 4 2 Using Tool J 6399 drive bushing forward into case extension Fig 7D 18 3 Drive new bushing in from rear of case extension with same tool J 6399 until end of bushing is slightly b...

Page 456: ... of accuracy to which these parts are machined the bushings are not serviced separately Check bushings for excessive wear by using a narrow feeler gauge between the shaft and bushing or use a micrometer The proper clearance is from 003 to 005 ASSEMBLE 1 From the rear of m inshaft assemble the second speed gear with hub of gear toward rear of shaft 2 Install 1 2 synchronizer clutch assembly to main...

Page 457: ...ntergear 14 Using heavy grease to retain the rollers install a 050 spacer and 28 rollers in either end of the countergear a 05OU spacer 28 more rollers and another 050 spacer Fig 7D 22 15 Follow the same procedure for the opposite end of the countergear 16 Rest the transmission case on its side with the side cover opening toward the assembler Put countergear tanged thrust washers in place retainin...

Page 458: ...rear bearing retainer 31 Install the remaining flat thrust washer on reverse idler shaft If new idler shaft is being used drive out the roll pin and press it into new shaft 32 Install reverse idler shaft roll pin and thrust washer into gears and front boss of case Make sure to pick up front tanged thrust washer NOTE Rollpin should be in a verticalposition 33 Position reverse gear at rear of spline...

Page 459: ...ers and tighten to 55 lb ft torque 5 Install rear extension to cross member support insulator and tighten bolts to 30 lb ft torque 6 Install propeller shaft drive line assembly by reversing steps 3a through 3c under TRANSMIS SION REMOVE 7 Install shifter assembly and secure it to transmission rear extension support with two shifter to extension support bolts Tighten upper bolt to 50 lb ft torque T...

Page 460: ...earing Extension Bushing Remover and Installer J 22379 Countershaft Bearing Loader Fig 70 28 SpecialTools Lever and Bracket Assembly to Transmission Control Rod to Support Bolt Lower 30 Transmission Lever Nuts 30 Support Insulator to Extension Housing Speedometer Gear Retainer Bolts 4 and to Cross Member Bolts 30 Speedometer Cable to Driven Gear Nut 4 Transmission to Clutch Housing Bolts 55 ...

Page 461: ... of Control Valve 73 26 Oil Pump 7E 28 Disassembly of Oil Pump 73 28 Inspection of Pump Body and Cover 73 28 Assembly of Oil Pump 7E 30 SUBJECT PAGE Forward Clutch 7E 3 1 Disassembly of Forward Clutch 7E 31 Inspection of Forward Clutch 7E 3 1 Assembly of Forward Clutch Y E 2 Direct Clutch and Intermediate Sprag 73 34 Disassembly of Direct Clutch and Intermediate Sprag 73 34 Inspection of Direct Cl...

Page 462: ...me engine oil level is checked or every 6000 miles when engine oil is changed CAUTION Since the Turbo Hydra Matic M 40 transmission is very sensitive to oil level special precautions should be taken when checking the oil level to ensure against an over 11 see Checking Procedure page 7E 4 Transmission fluid should be changed every 24 000 miles or 24 months When the car is in heavy duty service poli...

Page 463: ...INTERMEDIATE ROLLER OUTPUTCARRIER CLUTCH CLUTCH AND INTERNAL GEAR SPEEDOMETER DRIVEN GEAR SHAFT VALVE ASSY Fig 7E 1 Side Cross Section of Turbo Hydra Matic M 40 Transmission ...

Page 464: ... engine To bring the fluid level from the ADD mark to the FULL mark requires one pint Fluid level should be to the FULL mark with transmission at normal operating temperature 180 190 F With warm fluid room temperature the level should be approximately 7 10 below the ADD mark NOTE In checking the oil insert the dipstick in the jilter tube with the markings up toward center of car NEUTRALIZER SWITCH...

Page 465: ...ENGINE Move manual control lever through each range 2 Immediately check fluid level with selector lever in Park engine running and vehicle on LEVEL surface At this point when a reading is made fluid level on the dipstick should be 7 10 below the ADD mark 3 If additional fluid is required add fluid to bring level to 7 10 below the ADD mark on the dipstick CAUTION Do Not Overjll as foaming and loss ...

Page 466: ...oximately 7 112 pints of fluid are required to refill 5 Thoroughly clean bottom pan transmission after oil pan has been drained When unit 6 f f new gasket to bottom pan with petrolatum has been disassembled and rebuilt approximately 19 pints will be required to refill Use only DEXRON 7 Install bottom pan with attaching screws and torque or equivalent automatic transmission fluid to 12 lb ft DRAINI...

Page 467: ...ssembly NOTE Do nor remove solenoid attachingscrews 2 Compress regulator boost valve bushing against pressure regulator spring and remove snap ring using 4 Remove control valve body assembly and governor snap ring pliers and tool as shown in Fig 7E 8 pipes If care is taken in removing control valve body the six 6 check balls will stay in place above the 3 Remove regulator boost valve bushing and v...

Page 468: ... WlTH CURVED SlDE UP UNDERBODY LOWER RlNG TO BE INSTALLED WlTH CURVED SlDE DOWN LOWER RlNG LUBRICATE WlTH CHASSIS UNDERBODY LUBRICANT SHIFT CABLE TRANS COVER TORQUE SYMBOL IS ADJACENT TO CALLOUT FOR MEMBER TO BE TORQUED Fig 7E 7Console Shift Controls Firebird Fig 7E 8RemovingPressure Regulator Valve ...

Page 469: ...ator assembly Adjust oil level 2 Disconnect speedometer cable electrical lead to case connector vacuum line at modulator and oil cooler pipes 3 Disconnect shiftcontrol linkage PARKING LINKAGE 4 Support transmission with jack REMOVAL 5 Disconnect rear mount from transmission and frame crossmember 1 Remove bottom pan and strainer Discard gasket 2 Unthread jam nut holding detent lever to manual shaft...

Page 470: ...tool Base J 3289 20 with bottom pan facing up 4 Remove modulator attaching screw and retainer Fig 7E 10 5 Remove modulator assembly and O ring seal from case Fig 7E 1I 6 Remove modulator valve from transmission case REMOVAL OF GOVERNOR SPEEDOMETER DRIVEN GEAR PAN STRAINER AND INTAKE PIPE 1 Remove attaching screws governor cover and Fig 7E 10 Removing Modulator Retainer gasket Discard gasket Fig 7E...

Page 471: ...g 7E 17 Fig 7E 14Removing Transmission Oil Pan Attaching Screws NOTE Do not remove solenoid attaching screws 2 Disconnect solenoid lead from connector terminal 3 Remove control valve body assembly and governor pipes Fig 7E 18 CAUTION Do not drop mmual valve 4 Remove governor pipes from control valve assem bly 5 Remove control valve assembly to spacer gasket REMOVAL OF REAR SERVO VALVE BODY SPACER ...

Page 472: ...e with attaching screws b Apply 25 ft Ib torque and select proper pin to be used during assembly of transmission There are three selective pins identified as follows a If both steps of J 21370 5 are below the gage surface the long pin identified by 3 rings should be used DETENT ROLLER A N D Fig 7E 17 RemovingDetent Roller and Spring Assembly Fig 7E 18 RemovingControl Valve Assembly and Governor Pi...

Page 473: ...ocation of ballsfor aid in reassembly 9 Remove front servo piston washer pin retainer and spring from transmission case Fig 7E 25 REMOVAL OF REAR OIL SEAL AND EXTENSION HOUSING 1 If necessary to replace pry rear oil seal from extension housing Fig 7E 26 5 Remove solenoid attaching screws solenoid assem 2 Remove extension housing to case attaching bolts bly and gasket Fig 7E 22 3 Remove extension h...

Page 474: ... Should be 003 024 9 Selective washer controlling this end play is the washer located between pump cover and forward clutch housing If more or less washer thickness is Fig 7E 26 Removing Rear Oil Seal from Case Extension Fig 7E 27 Location of Case Extension Gasket required to bring end play within specifications select proper washer from the following chart THICKNESS 4 IN INCHES COLOR 060 064 Yell...

Page 475: ...ion Fig 7E 31 6 Remove forward clutch hub to direct clutch housing Fig 7E 31RemovingForwardClutch Assembly and Turbine Shaft thrust washer if it did not come out with foryard clutch housing 7 Remove direct clutch assembly Fig 7E 32 NOTE I f necessary remove manual linkage asfollows a Unthread jam nut hol ng detent lever to manual shaft b Remove manual shaft retaining pin from case Fig 7E 33 CAUTZO...

Page 476: ... parking pawl Fig 7E 39 Fig 7E 35Removing Parking Bracket 8 Remove front band Fig 7E 40 9 Remove sun gear shaft Fig 7E 41 REAR END PLAY CHECKING PROCEDURE 6 10 Check end play as follows a Install J 21904 into an extension housing attaching bolt hole b Mount Dial Indicator J 8001 on rod and index with end of output shaft Fig 7E 42 c Move output shaft in and out to read end play End play should be f...

Page 477: ... 098 I02 lTabO D 4 106 I10 2TabsO D 5 114 118 3 Tabs0 D 6 Fig 7E 39Removing Parking Pawl and Shaft with 0 Rfb 11 Remove case center support to case bolt using a 3 8 12 point thin wall deep socket Fig 7E 43 12 Remove intermediate clutch backing plate to case snap ring 13 Remove intermediate clutch backing plate three 3 composition and three 3 steel clutch plates Fig 7E 44 14 Remove center support t...

Page 478: ... Place gear unit assembly with output shaft facing down in hole in work bench or Holding Fixtures J 6116 and J 21364 18 Remove rear unit selective washer from transmis sion case Fig 7E 47 19 Remove rear band assembly Fig 7E 48 DIAL INDICATOR 1 I Fig 7E 44Removing Intermediate Clutch Backing Plate and Clutch Plates Fig 7E 42Checking Rear Unit End Play Fig 7E 45Removing Center Support to Case Snap R...

Page 479: ... roller clutch assembly Fig 7E 51 5 Remove front internal gear ring from output carrier assembly 6 Remove sun gear Fig 7E 52 7 Remove reaction carrier to output carrier thrust washer 8 Turn carrier assembly over Fig 7E 46Removing Center Support and Gear Unit from Case 9 Remove output shaft to output carrier snap ring Fig 7E 47Removing Selective Washer Fi 10 11 g 7E 53 4 Remove output shaft If remo...

Page 480: ...cated in step b below TRANSMISSIONS WITH STEEL SPEEDOMETER DRIVE GEAR ROLLER CLUTCH ASSEMBLY I REACTIC CARRIER SUN GEAR PLASTIC GEAR A RING JTPUT iRRlER Fig 7E 52RemovingSun Gear a Installing Speedo Gear Removing Tools J 21427 and J 8433 and Bolts J 21904 on the output shaft remove the speedometer drive gear Fig 7E 56 b Install a new STEEL speedometer drive gear and drive to location 11 29 64 from...

Page 481: ...llingSpeedometer DriveGear NOTE Do not drop bearings 14 Remove rear internal gear to sun gear thfust bearing and two 2 races 15 Remove rear internal gear to mainshaft snap ring to remove mainshaft Fig 7E 59 GOVERNOR ASSEMBLY All componentso f governor assembly with exception of driven gear are a select fit and each assembly is REAR Fig 7E 58RemovingRear InternalGear and Mainshaft ...

Page 482: ... pin and remove pins governor thrust cap governor weights and springs Governor weights are interchangeable from side to side and need not be identified Fig 7E 60 2 Remove governor valve from governor sleeve Be careful not to damage valve or sleeve 3 Perform the following inspections and replace governor driven gear if necessary I INSPECTION OFGOVERNOR Fig 7E 59Removing Rear Internal Gear to Mainsh...

Page 483: ...ge holding governor as shown with governor weights extended completely outward Fig 7E 61A b Check valve opening at exhaust with feeler gage holding governor as shown with governor weights c mpletely inward Fig 7E 61B Fig 7E 61BChecking Exhaust Port opening GOVERNOR DRIVEN GEAR REPLACEMENT To facilitate governor repdr in the field a governor driven gear and replacement pins are available for servic...

Page 484: ... sleeve 2 Install governor weights and springs and thrust cap on governor sleeve 3 Align pin holes in thrust cap governor weight assemblies and governor sleeve and install new pins Crimp both ends of pins to prevent them from falling out 4 Check governor weight assemblies for free operation on pins and governor valve for free movement in governor sleeve Fig 7E 63ExplodedView of Front Servo FRONT S...

Page 485: ...CONTROL VALVE ASSEMBLY 1 Position control valve assembly with cored face up and accumulatorpocket toward operator 2 Remove manual valve from upper bore 3 Install Special Tool J 21885 on accumulator piston valve and remove retaining ring Fig 7E 67 4 Remove front accumulator piston and spring Fig 7C 68 5 From the top right hand bore remove the 1 2 valve train as follows Fig 7E 69 a All models except...

Page 486: ...own the bore plug 1 2 secondary accumulator spring 1 2 accumulator valve 1 2 accumulator bush ing 1 2 primary accumulator valve and the 1 2 pnmary accumulator spring 10 Remove the governor oil screen from the governor oil feed hole Fig 7E 70 Fig 7E 68 Removing Front Accumulator Piston and Spring the 1 2 accumulator bushing and install the bushing into the bore 6 Install 1 2 secondary accumulator s...

Page 487: ...Exploded View of Control Valve 2 3 Shift Valve 3 2 Intermediate Spring 2 3 Modulator Valve 2 3 Shift ValQeSpring 2 3 Modulator Bushing Retaining Pin 3 2 Valve Bpacer 3 2 Valve Spring Bore Plug Retaining Pin 17 Install the 1 2regulator valve train as follows spring and 1 2 modulator valve into the 1 2 modulator bushing Install parts into valve body bore a All models except PA PC and PR Install the ...

Page 488: ...ody 8 Remove retaining pin and bore plug from pressure regulator bore Fig 7E 75 9 Remove hook type oil rings from pump cover 10 Remove pump to forward clutch housing selective washer 11 Mark drive and driven gears for reassembly and remove gears Fig 7E 76 REGULATOR BOOST VALVE SNAP RING BUSHING AND VALVE J 5403 1 REGULATOR SPRING PUMP ASSEMBLY Fig 7E 73Removing Pump Regulator Valve Snap Ring INSPE...

Page 489: ...pect pump cover face for overall flatness Fig 7E 77Checking Pump Body Face to Gear Face Clearance 10 Check for scores or chips in pressure re gulator bore 11 Check that all passages are open and inter con nected in pump cover Fig 7E 79 12 Check for scoring and damage at pump gear face 4 13 Inspect stator shaft for damaged splines or scored bushings If replacement of bushings is necessary proceed a...

Page 490: ...ssure regulator bore Fig 7E 74 4 Install pressure regulator valve from opposite end of bore stem end first 5 Install boost valve into bushing stem end out and install both parts into pump cover by compressing bushing against spring 6 Install retaining snap ring 7 Install pressure regulator valve bore plug and retaining pin into opposite end of bore 8 Install previously selected front unit selectiv...

Page 491: ...plates 5 Place forward clutch and turbine shaft in arbor press and remove turbine shaft Fig 78 83 6 Using Clutch Spring Compressor J 4670 with Adapters J 6129 and J 8765 compress spring retainer and remove shop ring Fig 7E 84 7 Remove snap ring spring retainer and sixteen 16 clutch release springs 8 Remove forward clutch piston 9 Remove inner and outer clutch piston seals Fig 7E 85 10 Remove cente...

Page 492: ...spect splines for damage c Inspect ground bushing journals for damage d Inspect shaft for cracks or distortion CLUTCH CENTER SEAL Fig 7E 86 Removingand Installing ForwardClutch Center Seal ASSEMBLY OF FORWARD CLUTCH NOTE Apply automatic transmiss on oil to all seals and clutchplates before re assembly FORWARD CLUTCH ASSEMBLY FLAT STEEL FORWARD THRUST WASHERS Fig 7E 87ExplodedView of Forward Clutch...

Page 493: ...d install piston rotating piston on drum until seated Fig 7E 88 4 Install sixteen 16 clutch release springs into pockets in piston 5 Place springretainer and snap ring on springs 6 Compress springs using Clutch Compressor Tools J 4670 J 6129 and J 8765 and install snap ring Fig 7E 84 7 Install turbine shaft in forward clutch housing using arborpress 8 histall forward clutch hub washers on forward ...

Page 494: ...lutch outer race bushings and sprag assembly 3 Turn unit over and remove backing plate to direct clutch housing snap ring Fig 7E 94 4 Remove direct clutch backing plate five 5 composition and five 5 steel clutch plates 5 Usine Clutch Comvressor Tools J 4670 J 6129 and J 8765 mpress sprink retainer and remove snap ring Fig 7E 95 1 Remove intermediate clutch retainer snap ring and 6 Remove retainer ...

Page 495: ...c oil to all seals 2 Install a new outer clutch piston seal with lip facing away from springpockets Fig 7E 100 NOTE Care should be exercised when installing the piston to make certain thepoperpiston is used The direct clutch piston can be identified by the ball check installed in the casting Fig 7E 102 4 Place seal protectors Tools J 21362 Inner and J 21409 Outer over hub and clutch housing and in...

Page 496: ...ER RACE INTERMEDIATECLUTCH SPRAG ASSEMBLY DIRECT CLUTCH PISTON RELEASE SPRINGS DIRECT CLUTCH SPRING RETAINER SNAP RING Fig 7E 97 ExplodedView of Direct Clutchand Intermediate Sprag NO WAVED STEEL SNAP RlNG Fig 7E 98 Exploded View of Direct Clutch Fig 7E 99 InstallingDirect Clutch Piston Inner Seal ...

Page 497: ... FORWARDCLUTCH Fig 7E 102Identifications of Clutch Pistons Fig 7E 103lnstalling Direct Clutch Piston Fig 7E 104lnstalling Direct Clutch Spring Retainer and Snap Ring DIRECT CLUTCH BACKING PLATE FLAT STEEL PLATES 4 COMPOSITION PLATES 5 WAVED STEEL PLATE 1 STEEL PLATES NO WAVED STEEL PLATE IN PQ 8 PS Fig 7E 105lnstalling Direct Clutch Backing Plate Composition and Steel Plates ...

Page 498: ...ct clutch assembly over center support and air check operation of direct clutch Fig 7E 111 INNER CYiE R Fig 7E 108 Correct Sprag Clutch Rotation NOTE If air is applied through reverse passage right oil feed hole it will escape from direct clutch passage left oil feed hole This is considered normal Applying air through direct clutch passage 1 4 oil feed hole will activatepiston and move direct clut...

Page 499: ... or e approx 020 dia is open Fig 7E 50 2 Inspect bushing for scoring wear or galling If replacement is necessary proceed as follows a Using Tool J 21465 6 with Driver Handle J 8092 remove bushing b From front side of center support align thre elongated slot in bushing with the drilled hole in the oil delivery sleeve closest to piston c Using tool J 21465 6 and Driver Handle J 8092 drive bushing sq...

Page 500: ... springs 5 Compress springs and install snap ring 6 Install four 4 hook type oil rings Fig 7E 115Installing lntermediate Clutch Piston 7 Air check operation of intermediate clutch piston Fig 7E 116 INSPECTION OF REACTION CARRIER ROLLER CLUTCH AND OUTPUT CARRIER ASSEMBLY 1 Inspect band surface on reaction carrier for signs of burning or scoring 2 Inspect roller clutch outer race for scoring or wear...

Page 501: ...uture failure would beprobable 3 Using a tapered punch drive or press pinion pins out of camer Fig 7E 119 4 Remove pinions thrust washers and roller needle bearings 5 Inspect pinion pocket thrust faces for burrs and remove if present s Fig 7E 117Checking Reaction Carrier Pinion End Play Fig 7E 118 Checking Output Carrier Pinion End Play 6 Install eighteen 18 needle bearings into each pinion using ...

Page 502: ...nstall bushing into place until tool bottoms 2 Inspect bearing and thrust washer surfaces for damage 3 Inspect governor drive gear for rough or damaged teeth 4 Inspect splines for damage Fig 7E 121InstallingPlanet Pinion Pin 2 Inspect splines for damage 3 Inspect bushings for scoring or galling If necessary to replace proceed as follows A SUN GEAR SHAFT BUSHING FRONT With sun gear shaft properly s...

Page 503: ...ly for any signs of bending or distortion Fig 7E 122 rMODULATOR CAN I MODULATOR SLEEVE ROLL MODULATOR O N FLAT SURFACE TO DETERMINE IF THE SLEEVE IS CONCENTRiC TO THE MODULATOR CAN IF THE SLEEVE IS BENT RUNOUT WILL BE VISIBLE Fig 7E 122Checking Concentricity o f Sleeve VACUUM C Fig 7E 123Vacuum Modulator Seams and Seal a Roll main body of modulator on a flat surface and observe the sleeve for conc...

Page 504: ...er modulator sleeve just touches the line in the center of the gauge Fig 7E 126 MOBULATOC XRT NUMBER COMPARISON RS IN A HORIZONTALPOS UTER GAUGE LINE MODULATOR BELLOWS GOOD Fig 7E 127Modulator Bellows Good d The gap between the opposite modulator sleeve ends and gauge line should be 1 16 or less Fig 7E 127 If gap is greater than 1 16 the modulator in question should be replaced Fig 7E 128 6 Inspec...

Page 505: ...ad damage 4 Inspect intermediate clutch driven plate lugs for damage or brinneling 5 Inspect snap ring grooverfor damage 6 Inspect governor assembly bore for scratches or scoring 7 Inspect modulator valve bore for scoring or damage 8 Inspect cup plug inside case for good staking and sealing 9 Inspect case bushing If necessary ro replace proceed as follows a Remove With case properly supported usin...

Page 506: ...sen hex nut while holding brass nut stationary Fig 7E 134InstallingTool J 21371 3 allowing converter internal assembly to lower until dial indicator shows that internal assembly has bottomed Fig 7E 135 f The reading obtained on dial indicator represents converter end clearance If clearance is under 050M the converter is acceptable If clearance is 050 or over replace the converter ASSEMBLY OF REAR ...

Page 507: ...earing or down 4 Install output carrier over mainshaft so that pinions mesh with rear internal gear 5 Place above portion of build up through hole in bench so that mainshaft hangs downward 6 Install rear internal gear to output shaft thrust races FLANGED RACE Fig 7E 137 Installing Rear Internal Gear to Main Fig 7E 138Installing Rear Internal Gear to Sun Gear Shaft Snap Ring Bearing and Races ...

Page 508: ...ond race on bearing with outer flange cupped over bearing 7 Install output shaft into output carrier Fig 7E 140 8 Install output shaft to output carrier snap ring CAUTION The 1969 output shaft to output carrier snap ring is flat and thinner then pre 1969 snap rings The change in design of the 1969 snap ring required a change in the groove of the output carrier The 1969flat snap ring and the pre 19...

Page 509: ...D FLANGED 15 Install center support to sun gear thrust races and 18 Install center support to reaction carrier thrust hearings retaining with petrolatum as follows washer into recess in center support Retain with petrolatum Fig 7E 146 19 Install center support into reaction carrier and roller clutch assembly Fig 7E 147 NOTE with reaction carrier held center support should only turn counterclockwis...

Page 510: ...T WASHER Fig 7E 148lnstalling Case to Output Shaft Thrust Washer 3 Install new cup plug using a 318 dia rod and drive into transmission case until parking pawl shaft bottoms on case rib Fig 7E 151 4 Install parking pawl return spring square end hooked on pawl and other end on case Fig 7E 152 5 Install parking brake bracket guides over parking pawl using two attaching bolts Torque to 18 lb ft Fig 7...

Page 511: ...ing Tool J 23093 into case direct clutch passage with handle of tool pointing to Fig 7E 152 lnstalling Parking Pawl Return priilg right as viewed from front of transmission and parallel to the bell housing mounting face Fig 7E 156 Apply pressure downward on tool handle which will tend to rotate the center support counterclockwise as viewed from front of transmission While holding center support fi...

Page 512: ...asher and rear face of transmission case If a different washer thickness is reauired to brine end C E N T E R SUPPORT LOCATING TOOL Fig 7E 156 Installing Center Support Bolt play within specifications it can be selected fro m the followingchart AND OR STAMPED THICKNESS NOTCHES NO 074 078 None 1 082 086 1 Tab Side 2 090 094 2 Tab Side 3 098 lo2 lTabO D 4 106 I10 2TabsO D 5 114 118 3 Tabs O D 6 15 I...

Page 513: ...al position and remove J 21795 17 Install direct clutch and intermediate spran assem Fig 7E 159 Installing Front Band Fig 7E 160 InstallingManual Shaft to Case bly It will be necessary to mist housing to allow sprag outer race to index with composition clutch plates Housing hub will bottom on sun gear shaft Fig 7E 162 NOTE Removal of direct clutch composition and steel plates may be helpful 18 Ins...

Page 514: ...follows Fig 7E 165 a Install a 5 16 18 threaded slide hammer or J 6125 into bolt hole in pump Fig 7E 163 InstallingForwardClutch and Turbine b Mount a dial indicator on rod and index indicator to Shaft registerwith end of turbine shaft c Push turbine shaft rearward d Push output shaft forward e Set dial indicator to zero f Pull turbine shaft forward Read resulting travel or end play should be 003 ...

Page 515: ... f Check Balls 2 Install flat washer on front servo pin on end opposite taper 3 Install pin and washer into case so that taper end is contacting band 4 Install oil seal ring on fr t servo piston if removed and install on apply pin so that identification numbers on shoulders are exposed Fig 7E 167 5 Check freenessof piston by stroking piston in bore 6 Install six 6 check balls into transmission on ...

Page 516: ...screws to 15P lbs and recheck pin to make certain it doh not bind b Apply 25 lb ft torque and select pfbper servo pin to be used from scale on tool c Remove tool and make note of proper pin to be used during assembly of transmission There are three selective pins identified as follows a If both steps are below the gage surface the long pin identified by 3 rings should be used b If the gage surface...

Page 517: ...ts Torque valve body bolts to 8 lb ft and solenoid bolts to 8 Ib ft Fig 7E 175 Installing Rear Servo Cover and Gasket INSTALLATION OF STRAINER AND INTAKE PIPE 1 Install case to intake pipe O ring seal on intake pipe and assemble new strainer to intake pipe Fig 7E 16 2 Install strainer and intake pipe assembly attaching strainer to control valve assembly with the retainer bolt Fig 7E 15 NOTE Ajier ...

Page 518: ...LLATION OF SPEEDOMETER DRIVENGEAR 1 Install speedometer driven gear Fig 7E 181 2 1DETENT ROLLER A N D I VACUUM MODULATOR Fig 7E 179lnstalling Vacuum Modulator and Valve Install speedometer driven gear retainer and attaching bolt INSTALLATIONOF CONVERTER ASSEMBLY With the transmission in cradle or portable jack install the converter assembly into the pump assembly making certain that the converter ...

Page 519: ...opening As the vehicle decreases in speed to 0 mph h 2 1 shift should occur Lo Range Position the selector lever in Lo Range No upshift should occur in this range regardless of throttle opening 2nd Gear Overrun Braking Position the selector lever in the drive Range and with the car speed at approximately 35 mph move the selector lever to Super Range The transmission should downshift to 2nd An incr...

Page 520: ...e Rev Zero to full throttle 95 260 Fig 7E 182Oil Pressure Check Road or Normal OperatingConditions Approximate Altitude Ft above sea level D N P S or L R 0 150 150 244 2 000 150 150 233 4 000 145 150 222 6 000 138 150 212 8 000 132 150 203 10 000 126 150 194 12 000 121 150 186 14 000 116 150 178 Fig 7E 183Oil Pressure Check Car Stationary Vacuum Tube Disconnected Drive Neutral Park Super or Lo Rev...

Page 521: ...d Speedogear O ring damaged e Manual shaft seal damaged improperlyinstalled f Line pressure tap plug stripped shy sealer com pound g Parking pawl shaft cup plug damaged improperly installed h Vent pipe refer to item 5 i Porouscase 4 FRONT END LEAK a Front seal damaged check converter neck for nicks etc also for pump bushing moved forward garter spring missing from pump to converter hub seal b Pump...

Page 522: ... sure the area to be repaired is completely covered 6 If 1360016 Z epoxy is used allow THREE 3 hours to cure before starting enqine 7 Road test car to bring transmission fluid to operating temperature of 180 and re check transmis sion for leaks TORQUE SPECIFICATIONS LB FT Pump Cover Bolts 18 Parking Pawl Bracket Bolts 18 Case Center Support Bolt 22 Pump to Case Attaching Bolts 18 Extension Housing...

Page 523: ...ure Adapter J 21366 Converter Holding Clamp 5 21370 5 Rear Band Apply Pin J 21370 6 Rear Band Apply Fixture J 21465 01 Bushing Tool Set J 21477 Oil Cooler Pipe Wrench Pontiac Only J 21795 Gear Unit Assembly HoldingTool J 22731 Oil Cooler Pipe Wrench Tempest and Firebird J 21465 13 0 a 8 J Q 21465 17 J 21465 9 J 21465 16 21465 15 J 21465 6 0 e It B 81 J 21465 8 J 21465 1 J 21465 2 J 21465 3 J 21465...

Page 524: ...edo Gear Remover J 8763 Holding Fixture J 8763 20 Holding FixtureAdapter J 8765 Clutch Spring CompressorAdapter Ring J 21368 Pump Body and Cover Alignment Strap J 21369 Converter Pressure Check Fixture J 21409 Forward Clutch Outer Seal Protector J 21427 Speedo Gear Remover J 21465 10 Staking Tool J 21885 Accumulator Piston Installer J 21904 Speedo Gear Remover Bolts Fig 7E 186 Special Tools ...

Page 525: ...31 Installation of Low Servo Assembly Low Band and Forward Clutch 7F 3 1 Determination of Selective Thrust Washer Thickness 7F 32 Installation of Oil Pump 7F 34 Low Band Adjustment 7F 34 Installation of Speedometer Drive Gear 7F 34 Installation of Rear Beaflng Retainer Governor Vacuum Modulator Speedometer Drive Gear and Valve Body 7F 35 Installation o f Converter IF 35 Installation of Transmissio...

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Page 560: ...Released by www 78ta com Serial Number 69SER 002 1012 ...

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Page 562: ...be repaired with a cleaning solvent and a brush then air dry NOTE A clean dry soldering acid brush can be used to clean the area arid also to apply the epoxy cement 4 Using instructions of the manufacturer mix a sufficient amount of epoxy cement Group No 4 103 0 423 Part No 1360016 Zl or 3M Scotch Weld 2216 to make the repair NOTE Observe cautions of manufacturer in handling 5 While transmission c...

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Page 564: ... Oil Pump Assembly 76 22 Direct Clutch Assembly 76 28 Forward Clutch Assembly 7G 30 Sun Gear and Sun Gear Drive Shell Assembly 76 34 Low Reverse Roller Clutch Support Assembly 76 35 Input Ring Gear 7G 36 Output Carrier Assembly 76 36 Reaction Carrier Assembly 76 36 Output Ring Gear and Output Shaft Assembly 76 57 Transmission Case 76 37 Extension Housing 76 38 Intermediate Overrun Brake Band 7 3 9...

Page 565: ...AND N D REVERSE CLUTCH PISTON SPEEDOMETER DRIVE GEAR SPEEDOMETER DRIVEN GEAR STATOR ASSEMB LOW AND REVERSE INPUT SHAFT OVERRUN ROLLER COOLER BY PASS PARKING PAWL PRIMING VALVE ROLLER CLUTCH UTPUT CARRIER INPUT RING GEAR STATOR SHAFT Fw 761 Side Cross Section of Turk Hydra Matic M 38 Transmission ...

Page 566: ...K position by rotating transmission rangeselector lever clockwise viewA 3 Set upper gearshift lever in PARK position and lock ignition 4 Push up on gearshift control rod to take up clearance in steering column lock mechanism and tighten screw on adjusting swivel clamp to 20 lb ft Tempest tighten nut on adjusting swivel clamp to 30 lb ft Firebird CONSOLE SHIFT CONTROLS NOTE For Tempest models see F...

Page 567: ...PONTIAC SERVICE MANUAL COAT ENTIRE PERIPHERY OF SHAFT WITH WHERE SHAFT PR JECTS OUT OF TRANS CASE BQS TO INSURE POSITIVE SEAL UMN TRANSMISSION TRANWlSlON RANGE LEVER VIEW A Fig 76 4Column Shift Controls Firebird ...

Page 568: ...VER TORQUE SYMBOL IS ADJACENT TO CALLWT FOR MEMBER TO BE TORQUED Fig 76 5ConsoleShift Controls Tempest TOWARDS FRONT OF TOP OF LETTERS AR UPPER RlNG TO BE INSTALLED WlTH CURVED SlDE UP LOWER RlNG TO BE INSTALLED WlTH CURVED SlDE WWN LUBRICATE WlTH CHASSIS LUBRICANT TRANS COVER TORWE SYMBOL IS ADJACENT TO CALLWT FOR MEMBER TO BE TORWED Fig 766Console Shift Controls Firebird ...

Page 569: ... 7G 8 fully rearward against the washer and insert on the detent cable 4 The detent cable is adjusted under the hood at the carburetor in the following manner 2 To adjust the cable push the carburetor lever DETENT CABLE A 8 0 LB IN TORQUE SYMBOL IS ADJACENT TO CALLOUT FOR MEMBER 1 BBL TO BE TORQUED CARB 4 BBL CARB DETENT CABLE V A C U PlPE CABLE CLlP C CARBURETOR LEVEL EXTENSION RETAINER WASHER DE...

Page 570: ...d level the transmission fluid level must be at room temperature 7 0 F With the fluid at room temperature 70 F follow steps 1 2 and 3 below 1 With manual control lever in PARK position start engine DO NOT RACE ENGINE Mcve manual control lever through each range 2 Immediately check fluid level with selector lever in PARK engine idling and vehicle on LEVEL surface At this point when a reading is mad...

Page 571: ...ual control lever in PARK position start engine and place on cold idle cam DO NOT RACE ENGINE Move manual control lever through each range 3 Immediately check fluid level with selector lever in PARK engine running and vehicle on LEVEL surface 4 Add additional fluid to bring level to 7 10 below the ffADD mark on the dipstick VALVE BODY ASSEMBLY REMOVAL 1 Remove oil pan and strainer Discard gaskets ...

Page 572: ...e spring and intermediate clutch accumulator piston INSTALLATION Installation of the intermediate clutch accumulator piston assembly is the reverse of REMOVAL Install new O ring seal and adjust the fluid level VACUUM MODULATOR AND MODULATOR VALVE ASSEMBLY REMOVAL 1 Disconnect vacuum hose from vacuum modulator stem and remove vacuum modulator attaching screw and retainer 2 Remove modulator assembly...

Page 573: ...member NOTE On Firebird 6 cylinder remove driveline a damper 6 Remove converter dust pan mark flywheel and converter for reassembly in same position and remove flywheel to converter bolts NOTE After bolts are removed makg certain converter hub isfiee of crankshaft 7 Disconnect transmission filler pipe at engine and remove pipe from transmission 8 Lower transmission and engine assembly to gain acce...

Page 574: ...screw and retainer clip modulator O ring seal and modulator valve from case Discard O ring seal Fig 7G 9 REMOVAL OF EXTENSION HOUSING SPEED0 DRIVEGEAR AND GOVERNOR 1 Remove bolt retainer and speedometer driven gear from side of extension housing 2 Remove four 4 extension housing to case attaching bolts extension housing and its square cut oil seal from case or housing Fig 7G 10 3 If necessary to r...

Page 575: ... Balls 15 Disconnect parking pawl actuating rod from range selector inner lever and remove both from case Fig 7G 20 16 If necessary to replace remove manual shaft to case lip oil seal using a screwdriver Fig 7G 21 17 Remove two 2 bolts and parking lock bracket 18 Disconnect and remove parking pawl disengaging spring 19 If necessary to replace parking pawl shaft or parking pawl clean up shaft bore ...

Page 576: ...olts with washer type seals Fig 76 24 SE RETAINER SC REWDRIVER UPARKlNG PAWL Fig 7G 20Removing Inner Lever and Actuating Rod 2 Install two 2 Slide Hammers J 6125 1 and Adapters J 6125 2 into threaded bolt holes in pump body at approximately 4 and 11 o clock and remove pump assembly from case 3 Remove pump to case gasket and tools from pump Discard gasket 4 On V 8 models remove intermediate clutch ...

Page 577: ...asher hasfour 4 internal tangs 10 Using a finely pointed awl and a small screwdriver Fig 7G 24Removing Oil Pump Attaching Bolts remove output carrier to output shaft snap ring Dis card ring 11 Remove output carrier assembly AFig 76 28 12 Remove sun gear drive shell assembly Fig 76 29 13 Remove sun gear drive shell to low and reverse roller clutch inner race thrust washer from drive shell or inner ...

Page 578: ...tes from reaction carrier assembly or case on 6 cylinder models remove four 4 faced plates and four 4 separator plates Fig 76 28Removing Output Carrier Assembly 18 Remove reaction carrier assembly from output ring gear and shaft assembly Fig 76 33 19 Remove reaction carrier to output ring gear thrust washer from ring gear or reaction carrier NOTE Washerhas three 3 narrow external tangs 20 Remove o...

Page 579: ...of Clutch Support Retainer Spring Fig 76 32 RemovingClutch Support Retainer Spring 25 Remove outer center and inner flat seals from low and reverse clutch piston 6 26 Move transmission to horizontal position and using two 2 oil pan bolts install Compressor J 23069 on oil pan face compress intermediate clutch accumu lator piston cover and remove its retaining ring Remove tool Fig 76 38 27 Remove in...

Page 580: ...y in order to replace the driven gear disassembly may also be necessary due to foreign material causing OUTPUT RlNG GEAR Fig 76 35 Output Ring Gear and Output Shaft Assembly Fig 76 36 Compressing Low and ReverseClutch Piston Assembly improper operation To disassemble governor assem bly proceed as follows 4 DISASSEMBLY 1 Cut off one end of each governor weight pin and remove pins governor thrust ca...

Page 581: ...iven gear for looseness of governor sleeve for nicks burrs or damage If replacement is necessary follow replacement below GOVERNOR DRIVEN GEAR REPLACEMENT To facilitate governor repair in the field a governor driven gear and weight pin are available for service use The service package consists of a driven gear governor weight retaining plns 2 and a governor gear retaining split pin Replacement of ...

Page 582: ...minimum Fig 76 42 7 Check governor valve opening at exhaust port while holding weights completely inward Opening must be 020 minimum NOTE If less than 020 minimumfeed port or exhaust port isfound governor assembly must be replaced VALVE BODY ASSEMBLY DISASSEMBLY Fig 76 43 1 Position valve body assembly with cored face up and accumulator piston assembly at upper left corner 2 Remove manual valve an...

Page 583: ...o 27 Detent Valve 39 Retainer EM Ring 7G 43 Exploded View of Valve Body Assembly 10 From top bore remove retaining pin detent NOTE Free length of spring is 1 78 by 5 716 regulator valve spring valve spring seat and detent diameter regulator valve 3 In next bore down install manual low control valve with stem end out manual low control valve svrine INSPECTION and plug compress plug and install reta...

Page 584: ...ct clutch accumulator piston into its core in valve body face 5 In next bore down install 2 3 shift valve with Stem NOTE Free length of spring is 1 34 by 1 1 20 end out and 2 3 shift valve spring with narrow end in diameter Install control valve spring into 2 3 shift control valve and install both into 2 3 shift control valve sleeve 9 Using Accumulator Compressor J 21885 compress Install sleeve as...

Page 585: ...h Return springs and Piston Fig 76 48Removing Oil Seal Rings and Selective Thrust Washer 3 Place pump assembly stator shaft down through hole in bench and remove five 5 pump cover to body attaching bolts Fig 76 46 4 Remove intermediate clutch spring seat retainer thirty 30 clutch return springs and intermediate clutch piston assembly Fig 76 47 5 Remove intermediate clutch piston inner and outer se...

Page 586: ... all oil passages and air dry 2 Inspect pump drive and driven gears gear pocket and crescent for nicks galling or damage 3 Inspect pump body and pump cover faces for nicks or scoring 4 Inspect pump cover hub outer diameter for nicks or burrs which might damage direct clutch drum bushing 5 Check three 3 pump cover and hub lubrication IMING VALVE Fig 7G 51RemovingCooler By PassValve Seat holes to ma...

Page 587: ...eration of priming valve in pump body and replace if necessary 12 Check oil passages in pump body Fig 76 54 and in pump cover Figs 76 55 and 76 56 10 Check condition of cooler by pass valve and replace if valve leaks excessively 13 Inspect three 3 pump cover stator shaft bushings for galling or scoring If any of these bushings is 11 Check all springs for distortionor collapsed coils damaged replac...

Page 588: ...GS a Remove front bushing as described above Then SLIDE HAMMER PUMP COVER AND STATOR SHAFT ASSEMB Fig 76 58Installing Stator Shaft Front Bushing thread Bushing Tool J 21424 7 in Extension J 21465 13 and Drive Handle J 8092 Place tool assembly through front of stator shaft and drive out center and rear bushings b Install new center bushing into hub end of pump cover by using Bushing Tool J 23062 2 ...

Page 589: ...o it is flush to 010 below face of pump body Fig 7G 61 3 Install oil pump priming valve spring and priming valve Fig 7G 50 IN1 PIS ERA INTERMEDIATE CLUTCH PISTON Fig 76 62Installing Seals in lntermediate Clutch Piston 4 Install drive and driven gears into pump body with alignment marks up Fig 76 49 NOTE Tangface of drive gear is upotoprevent damage by converter 5 Install pump cover to pump body al...

Page 590: ...ing Direct Clutch To Forward Clutch Thrust Bearing ETAlNlNG RING PRESSURE PLATE LUTCH DRUM Fig 7G 66RemovingRetainingRing and Pressure Plate piston assembly into pump cover Fig 76 62 NOTE Lips of seals should be facing into pump cover when piston is installed For aiding installation of piston intopump cover use a piecbof 020 music wire crimped into short section of copper tubing 9 Install thirty 3...

Page 591: ...42 1 and Pilot J 9542 4 or J 23327 1 in arbor press compress direct clutch piston return spring seat and remove piston retaining ring CENTER SEAL Fig 7G 69 Removing Direct Clutch Piston Center Seal 9 Remove tools spring seat seventeen 17 piston return springs and direct clutch piston assembly NOTE Direct clutch piston contains s ball check Fig 76 67 10 Remove outer and inner seals from direct clut...

Page 592: ...th of springs is 1 I 16 by 1 2 diameter 4 Using Clutch Spring Compressor J 9542 1 and Pilot J 9542 4 or J 23327 1 in arbor press compress spring seat and install piston retaining ring 5 e m o v e tools and lubricate plates with transmission fluid 6 On V 8 models install cushion spring four 4 faced plates and four 4 steel separator plates starting with cushion spring and alternating steel and faced...

Page 593: ...tch piston assembly retainer and front retaining ring Fig 76 63 Fig 76 77 NOTE When overrun roller clutch assembly is properly installed outer race will free wheel counterclockwise only FORWARD CLUTCH ASSEMBLY DISASSEMBLY 1 Place forward clutch assembly in hole in bench with input shaft down and remove forward clutch drum to pressure plate retaining ring and forward clutch pressure plate Fig 76 75...

Page 594: ...or signs of burning scoring or wear 3 Inspect all springs for collapsed coils or signs of distortion I PRESSURE PLATE I Fig 76 75Removing Forward Clutch Retaining R ing and Pressure Plate 4 Inspect piston for cracks 5 Inspect clutch drum for wear scoring cracks proper opening of oil passages and free operation of ball check Fig 7G 80 6 Inspect input shaft for a Open lubrication passages at each en...

Page 595: ... serviced install using a ram press or arbor press separately 4 ASSEMBLY 2 Install forward clutch piston outer and inner seals 1 If inpit shaft was removed from clutch drum re Lips down in clutch piston Fig 70 78 FORWARD CLUTCH PISTON ASSEMBLY R lNIN STEEL SEPARATOR PLATE CUSHION SPRlN PISTON RETURN SEAT RETAINING RING FORWARD CLUTCH PRESSURE PLATE I Fig 7G 79 Exploded View of Forward Clutch Assem...

Page 596: ...seat and install piston retaining ring Fig 7G 81Installing Forward Clutch Piston Assembly Fig 7G 82Checking Free Back Height 6 Remove tool and lubricate plates with transmission fluid 7 On V 8 models install c shion spring five 5 faced plates and five 5 steel separator plates starting with cushion spring and alternating steel and faced plates on 6 cylinder models install cushion spring four 4 face...

Page 597: ...tangs SUN GEAR AND SUN GEAR DRIVE SHELL ASSEMBLY DISASSEMBLY 1 Remove sun gear to sun gear drive shell rear retaining ring Discard ring Fig 76 84 Fig 76 86 Removing Sun Gear From Sun Gear Drive Shell 2 Remove sun gear to drive shell rear flat thrust washer Fig 70 85 3 Remove sun gear from drive shehand remove front retaining ring from sun gear Discard ring Fig 76 86 INSPECTION 1 Wash all parts in ...

Page 598: ... ASSEMBLY Fig 76 88 DISASSEMBLY 1 Remove low and reverse overrun clutch inner race from support assembly NOTE Before removal check for correct assembly Inner race shouldfree wheel clockwise only 2 Remove low and reverse roller clutch front retaining ring and low and reverse roller clutch assembly from support INSPECTION 1 Wash parts in cleaning solvent and air dry 2 Inspect roller clutch inner and...

Page 599: ...g Fig 76 89 a Using Bushing Tool J 23062 5 and Drive Handle J 8092 and with input ring gear properly supported drive out bushing Fig 76 89Removingor Installing Input Ring Gear Bushing b Using Bushing Tool J 23062 5 and Drive Handle J 8092 install new bushing to 050 060 below rear face inside gear end OUTPUT CARRIER ASSEMBLY INSPECTION 1 Wash in cleaning solvent and air dry 2 Inspect output carrier...

Page 600: ...dry 2 Check output ring gear for tooth damage 3 Inspect output ring gear and output shaft splines for nicks or damage 4 Check output shaft bearing surface for nicks or scoring 5 Check output shaft bushing for nicks scoring or wear If bushing is damaged replace as follows Output Shaft Bushing a Thread Bushing Tool J 9534 into output shaft Fig 7G 92InstallingOutput Shaft Bushing bushing thread Adapt...

Page 601: ...ar seal drain back port is not passages using air gun or smoke Figs 76 76 and obstructed 76 77 5 Inspect extension housing bushing for nicks scoring 3 Inspect threaded holes for thread damage or wear If bushing is damaged replace as follows 4 Inspect ring grooves for damage Extension Housing Bushing Fig 76 96 5 Inspect governor bore for scoring or damage a Remove lip oil seal from extension housin...

Page 602: ...ic and modulator valve is free within sleeve modulator is acceptable 2 Atmospheric leak check a Apply liberal coating of soap bubble solution available at 5c 10c store to vaculim connector pipe seam crimped upper to lower housing seam and to threaded screw seal Fig 76 98 b Using a short piece of rubber tubing apply air pressure to vacuum pipe by blowing into tubing and observe for leak bubbles c I...

Page 603: ...wl actuating rod for cracks or broken retainer lugs 5 Inspect actuator for free fit on parking actuator rod 6 Inspect parking pawl disengagipg spring for de formed coils or ends 7 Inspect parking lock bracket for cracks or wear 8 If removed inspect parking pawl and parking pawl shaft for cracks wear or other damage MANUAL AND PARKING LINKAGE CONVERTER ASSEMBLY INSPECTION 1 Inspect manual shaft for...

Page 604: ...owing converter internal assembly to lower until dial indicator shows that internal assembly has bottomed Fig 7G 107 Fig 76 106 Installing Tool J 21371 3 f Reading obtained on dial indicator will represent converter end clearance If clearance is under 05OV converter is acceptable if clearance is 050 or over replace converter g Remove tools TRANSMISSION REASSEMBLY GENERAL Before starting to assembl...

Page 605: ...with two 2 oil pan bolts compress intermediate accumulator cover and install its retaining ring Remove bolts and tool Fig 7G 38 NOTE A production day and shift built number transmission model and model year are stam edon the intermediate clutch accumulate piston c ver If cover is replaced this information must be stamped on new cover Fig 7G 2 5 Install outer center and inner flat seals to low and ...

Page 606: ...action carrier starting with a steel separator plate NOTE Notch in steel separator plates should be placed in bottom notch 5 30dclock position of case Fig 7G 112Installing Low and Reverse Clutch gck V 8 Model 13 Install low and reverse clutch support retainer spring Fig 76 32 14 Install low and reverse roller clutch and support assembly into case puslfing firmly until support assembly is seated pa...

Page 607: ... 6 115 lubricate with transmission fluid and a On V 8 models install three 3 intermediate clutch faced plates and three 3 steel separator plates starting with a faced plate and alternating steel separator plates Fig 76 25 b On 6 cylinder models install two 2 faced and two 2 separator plates starting with a faced plate NOTE Notch in steel separator plates should be placed in case notch adjacent to ...

Page 608: ...or thinner selective thrust washer as required to obtain specified clearance re install pump and repeat the above checking proce dure NOTE There are three 3 selective washers available 065 067 082 084and 099 I01 32 When end play is within specifications remove tools install remaining pump attaching bolt with its new washer type seal and torque bolt to 20 Ib ft IMPORTANT Make sure input shaft can b...

Page 609: ...disengaging spring square end hooked on pawl other end hooked over lug in case Fig 7G 120 3 Install parking lock bracket and its two 2 bolts torquing to 29 lb ft 4 If removed install a new manual shaft to case lip oil seal using a 7 8 diameter rod to seat oil seal flush with case bore 5 Connect range selector inner lever to parking pawl actuating rod and install actuating rod under parking lock br...

Page 610: ... 123 4 CAUTION When handling valve body assembly do not touch sleeves as retainerpins willfall into transmission 16 Connect detent control valve link to detent valve actuating lever insert free end of link into its case opening connect actuating lever assembly to valve body actuating lever bracket and retain the lever assembly to the lever bracket with its retaining pin 17 Install detent roller an...

Page 611: ... Install converter assembly into transmission making certain that converter hub drive slots are fully engaged with oil pump drive gear tangs and converter is installed fully towards rear of transmission Fig 7G 125 4 Retain converter assembly to transmission with Converter Holding Clamp J 21366 remove transmis sion assembly from bench place in portable jack and remove TransmissionHolding Fixture an...

Page 612: ...tion selector lever in DRIVE ranee accelerating When road testing vehicle a reliable pressure gage vehicle from 0 mph A 1 2 and 2 3 shlft should occur should be attached to the line pressure port on the at all throttle openings shift points varying with the right side of the transmission case behind and throttle opening As vehicle speed decreases to 0 mph adjacent to the intermediate clutch accumu...

Page 613: ...engine rpm and an engine braking effect should be noted Line pressure should change from 55 psi to approximately 80 psi in second gear First Gear Engine Braking With selector lever in SUPER range and with vehicle speed at approximately 30 m h at constant throttle move selector lever to LO4 range Transmission should downshift to first Fear An increase in engine rpm and an engine bralung effect shou...

Page 614: ...ct an oil leak the actual b Improperly installed or damaged pan gasket source of the leak must be determined In many cases c Oil pan gasket mounting face not flat the source of the leak can be deceiving due to wind flow around the engine and transmission 2 Extension Housing Leak The suspected area should be wiped clean of all oil a Attachingbolts not correctly torqued before inspecting for the sou...

Page 615: ...brush can be used to clean the area and also to apply the epoxy cement d Converter leak in weld area 4 Using instructions of the manufacturers mix a e Porouscasting pump suffficient amount of epoxy Group 0 423 Part No 1360016 or equivalent to make the repair 5 Oil Comes Out Vent Pipe NOTE Make certain the area to be repaired is fully a Transmission over filled covered b Water in oil 5 Allow cement...

Page 616: ...ing Bushing Remover and lnstaller Fig 76 132 J 21465 13Drive Handle Extension J 21465 15Stator Shaft Front Bushing Remover J 21904 1 Slide Hammer Belt J 23062 1 Case Bushing Kastaller J 23062 2 Stator Shaft Center and Rear Bushing Installer J 23062 3 Sun Gear Bushing Remover and lnstaller Reaction Carrier Bushing Remover and Installe J 23062 4 Direct Clutch Bushing Installer J 23062 5 Input Ring G...

Page 617: ...ing Compressor Pilot J 21359 Pump Oil Seal lnstaller J 21366 Converter Holding Strap J 21369 Converter Leak Test Fixture J 21371 2 8 Converter End Play Fixture J 21420 2 Clutch Spring Compressor Pilot J 21885 Direct Clutch Accumulator Compressor J 23069 Intermediate Accumulator Cover Compressor J 23071 Band A ply Pin Gauge J 23327 1 2 Clutch gpring Compressor Forward Low Reverse Clutches Fig 76 13...

Page 618: ... Exhaust System 8 15 Tempest and Grand Prix Exhaust System Clearance Requirements 8 16 Pontiac Single Exhaust System 8 17 Pontiac Dual Exhaust System except 428 H O Engine 8 18 Pontiac Duel Exhaust System 428 H O Engine 8 10 Pontiac Exhaust System Clearance Requirements 8 20 General Specifications 8 21 5 Disconnect rear vent tube hose from filler neck on all models and front vent hose on Tempest a...

Page 619: ...est Tighten front support strap nut on Pontiac to 9 Ib ft torque and bolt on Tempest to 8 lb ft torque Tighten bame to wheel well screws to 17 lb in torque on Pontiac and 25 lb in torque on Tempest 1 Remove tank see FUEL TANK EXCEPT STATION WAGON REMOVE 2 Clean away any dirt that has collected around gage unit and terminal so it will not enter tank when gage unit is removed Fig 8 11 3 Remove tank ...

Page 620: ...D CLIP UPWARDS AGAINST BODY AFTER PIPE IS INSTALLED NTAING RESTRICTOR IN POSITION S H O W N ND PRlX REAR VENT TEMPEST GRAND PRlX FRONT VENT FIREBIRD VENT TEMPEST REAR VENT PONTIAC VENT NOTE PIPES MUST ENTER HOSES 13 16 MIN Fig 8 3 Vent Hose Routing ...

Page 621: ...ed Fig 8 11 3 Remove tank gage unit by using tool J 23346 Fig 8 4 INSTALL NOTE Before the new unit is installed in the tank the float arm should be checkedfor fieedom of movement by raising it to variouspositions and seeing if it will always fall to the empty position 1 Install by reversing the abovesteps making sure a new tank gage unit gasket is installed 2 Install tank see FUEL TANK STATION WAG...

Page 622: ...AK POINT HOSES TO B E ASSEMBLED TO TANK BEFORE LATION OF TANK VAPOR RETURN PIPE 4 VIEW 0 SUPPORFPART FUEL PIPE OF INNER WHEEL VlEW C VAPOR RETURN HOSE VlEW F VIEW E VIEW D NOTE PIPES MUST ENTER HOSES 13 16 MIN Fig 8 5 Installationof FuelTank Pontiac Station Wagon ...

Page 623: ...8 6 1969 PONTIAC SERVICE MANUAL i OUTER PANEL INNER PANEL NOTE PIPES MUST E N T E R HOSES 13 16 MIN Fig 8 6Installation of Fuel Tank Tempest Station Wagon ...

Page 624: ... A C 4 0 0 SPORTS OPTION WlTH A C HOLE AND PROTRUDE THRU LOWER HOLE AS SHOWN 6 CYL ENO EXC A C D 350 H 0 ENG EXC A C 400 SPORTS OPTION EXC A C Fig 8 7 Installation of Fuel Tank Firebird YwuL E ISTlNG CLIPS O N INNER EXISTING REAR WHEEL HOUSE PANE 1 WIRE HARNESS Fig 8 8Pontiac Fuel Gage Wiring Station Wagon ...

Page 625: ...8 8 1969 PONTIAC SERVICE MANUAL Big 8 9Tempest Fuel Gage Wiring Station Wagon TEMPEST AND GRAND PRlX EXECUTIVE AND BONNEVILLE Fig 8 10FuelGage Wiring except Station Wagon ...

Page 626: ...PUEL TANK AND EXHAUST SYSTEM 8 9 ...

Page 627: ...EW A REAR EXHAU ST W l BBL CAR0 ENG VlEW A FRAME W 4 BBL CAR0 ENG TAlL PlPE FRAME VlEW D VlEW B TYPICAL TAIL PIPE TAlL PlPE VlEW C NOTE COAT ALL SLIP JOINTS WITH SEALER BEFORE INSTALLING VIEW E ACOAT I D WlTH SEALER IF REQUIRED TO INSURE LEAK TIGHT JOINT ONE BOLT IS TO BE TIGHTENED FINGER TIGHT WlTH PARTS SEATED BEFORE OTHER BOLT IS TIGHTENED TO PRESCRIBED TORQUE Fig 12 Tempest 6 CylinderEngine Ex...

Page 628: ...AL AT ALL RAIL PIPE CONNECTORS 1 MIN 1 1 2 MIN VlEW F ALL SYSTEMS VIEW A L H SIDE DUAL 8 CYL SINGLE EXHAUST EXHAUST NUTS 17 LB n VIEW D L H SIDE DUAL EXHAUST EXHAUST PIPE VIEW K R H SIDE DUAL EXHAUST L H SIDE SINOLE DUAL EXHAUST R H LH RESONATORS DUAL EXHAUST ONLY UFFLER ASSY VlEW A WEW 1 VIEW M 1 H SIDE SINOLE EXH R H SIDE SINOLE EXC 8 CYL ENO DUAL EXHAUST R H LH SIDE DUAL EXHAUST NUTS 17 LB FT V...

Page 629: ...CARB ENGINE OTHERWISE SAME AS ROTATING DIAMETER SINGLE BBL CARB ENO OF PROP SHAFT YOKE 4 BBL CARB ENGINE SHOWN 27 32 MIN VIEW C 4 CARB CARB ENO REINFORCEMENT CONVERTIBLE ONLY BOLTS 25 LB FT VIEW E 4 BBL CARB ENO A COAT I D WITH SEALER IF REQUIRED TO INSURE LEAK TIGHT JOINT VIEW B BOLTS 25 LB FJ SINGLE BBL CARB ENGINE Fig 8 15Firebird6 CylinderEngineExhaustSystem ...

Page 630: ...ON WAGONS VlEW A COAT I D WlTH S E A L E R IF REQUIRED TO VlEW F BOLTS2s LB n ONE BOLT TO EACH MANIFOLD IS TO B E TIGHTENED FlNOER TlOHT WlTH PARTS SEATED BEFORE OTHER BOLT IS TIOHTENED TO PRESCRIBED VIEW C TORQUE NOTE COAT A L L SLIP JOINTS WlTH S E A L E R BEFORE INSTALLIN0 HORIZONTAL LINE VlEW G ...

Page 631: ...WISE SAME AS SINGLE BBL CARB ENG ROTATING DIAMETER OF PROP SHAFT YOKE 4 001 CARB ENGINE SHOWN 27 32 MIN VlEW C 4 HORIZONTAL CARB CARB ENG REINFORCEMENT CONVERTIBLE ONLY BOLTS 25 LB FT NUT 25 LB FT VlEW E VlEW A 4 BBL CARB ENO A COAT 1 0 WITH SEALER IF REQUIRED TO INSURE LEAK TIGHT JOINT VIEW B BOLTS 25 18 Ff SINGLE BBL CARB ENGINE Fig 8 15Firebird 6 Cylinder Engine Exhaust System ...

Page 632: ... ENGINE UNDERBODY REINFORCEMENT CONVERTIBLE ONLY 400 H O ENGINE VIEW B STANDARD ENGINE STANDARD ENGINE 4 ONE SIDE IS TO B E TIGHTENED FINGER TIGHT WITH PARTS SEATED BEFORE OfH E R BOLT IS TIGHTENED TO PRESCRIBED TORQUE Fig 8 16Firebird V 8 Engine Single or Dual Exhaust System ...

Page 633: ... H LH REAR AXLE CONTROL IPE ARM CROSS FRAME y e y FRAME 0 VlEW F TYP R H L H A COAT 1 0 WlTH SEALER IF REQUIRED TO INSURE LEAK TIGHT JOINT ONE SIDE IS TO BE TIGHTENED FINGER TIGHT WITH PARTS SEATED VIEW D VIEW E BEFORE OTHER NUT IS TIGHTENED TO PRESCRIBED TORQUE NOTE COAT ALL SLIP JOINTS WlTH SEALER BEFORE INSTALUNO Fig 8 17Tempest and Grand Prix Dual Exhaust System ...

Page 634: ...ION HANGER ASSY TYP R H L H TYP R H L H REAR SPRING TYP R H L H ALL BRACKET W M A N TRANS G P G T O VlEW R TYP R H LH 1 11 16 PIPE T O PANEL 7 1 6 MIN CLEARANCE VALENCE PANEL VlEW E REAR BUMPER TYPICAL R H LH G P ONLY O U N T I N G BRACKET ENGINE REAR CROSSMEMBER CONSTANT L E A R A N C E 6 C Y L SYSTEMS G C Y L SINGLE 5 8 MIN CLEARANCE EXHAUST SYSTEM VlEW E TIP R H LH TEMPEST O N L Y RESONATO VlEW...

Page 635: ...17 LB FT EXTENSION ASSY VlEW G STA WON ONLY LOCATION OPT INSERT TAIL PlPE INTO RESONATOR UNTIL POSITIONED VIEW E AOAINST STOP O N E BOLT I S TO B E TIOHTENED FINOER A COAT I D WITH SEALER I F VIEW F TIOHT WITH PARTS SEATED BEFORE REQUIRED TO INSURE LEAK EXC STA WON OTHER BOLT I S TIOHTENED TO TlOHT JOINT PRESCRIBED TORQUE NOTE COAT ALL SLIP JOINTS WlTH SEALER BEFORE INSTALLINO Fig 8 19Pontiac Sing...

Page 636: ...OPPOSITE E UPPER CONTROL SSMEMBER LOCATION OPTIONAL VIEW D VIEW E R H SHOWN L H OPPOSITE R H SHOWN L H OPPOSITE NOTE COAT ALL SLIP JOINTS WlTH SEALER BEFORE INSTALLINO A COAT 1 0 WITH SEALER IF ONE SIDE IS TO BE FINOER TIGHT WITH PARTS REOUIRED TO INSURE LEAK TlOHT JOINT SEATED BEFORE OTHER BOLT IS TIGHTENED TO PRESCRIBED TOROUE Fig 8 20Pontiac Dual ExhaustSystemexcept428 H O Engine ...

Page 637: ... E VIEW C NOTE COAT A L L SLIP JOINTS WITH S E A L E R BEFORE INSTALLINO A COAT I D WITH S E A L E R IF REQUIRED TO INSURE L E A K TlOHT JOINT ONE BOLT IS TO BE TIOHTENED FINGER TlOHT WITH PARTS SEATED BEFORE OTHER BOLT IS TIOHTENED TO PRESCRIBED TORQUE Fi 8 21Pantiac Dual ExhaustSystem428 H O Engine ...

Page 638: ...EXHAUST DUAL EXHAUST VlEW L VlEW G ALL MODELS EXC STA WGN MUST BE POSITIONED JUST FORWARD OF OIL FILTER MUFFLER NIPPLE TO MIN OBTAIN PROPER 4 j INSERTION OF PIPE FRAME 5 8 MlN TAlL PlPE EXHAUST PIPE VIEW H STATION WAGON ONLY 3 8 VlEW A SINGLE EXHAUST SYSTEM VIEWS E K M TAlL PlPE 6 VlEW F VlEW B PLAIN VIEW Fig 8 22 Pontiac Exhaust System Clearance Requirements ...

Page 639: ...D EXHAUST SYSTEM 8 21 GENERAL SPECIFICATIONS FUEL TANK CAPACITY U S GALS Pontiac except Station Wagon 26 Pontiac Station Wagon 24 Tempest except Station Wagon 2141 Tempest Station Wagon 20 Grand Prix 21 Firebird 18 ...

Page 640: ...his type of towing If neither of the above methods can be used disconnect the shift linkage and shift the transmission into neutral tow the car with the front end raised Major Service Remove Disassemble Cleaning and Inspection Assemble Install P w e r Steering Gear Minor Service Adjustments Pitman Shaft Seals Major Service Remove Disassemble Cleaning and Inspection Assemble Inatall Adjust Pump Bel...

Page 641: ...EL WITH INDEX MARK ON STEERING SHAFT WITHIN O N E FEMALE SERRATION STEERING C CANCELING CAM TOWER MUST DELUXE STEERING WHEEL BE CENTERED IN SLOT O F LOCK PLATE COVER BEFORE ASSEMBUNG WHEEL a CUSTOM SPORT STEERING WHEEL F i e9 1ExplodedView of SteeringWheel and Horn Button ...

Page 642: ... REMOVE 1 Remove steering wheel see STEERING WHEEL REMOVE Fig 9 3 Depressing Lock Plate 2 Remove the three cover screws and lift cover off the shaft NOTE Screw retainers will be lost if screws are removed completelyfrom covpr 3 Depress lock plate downward as far as possible using J 23131 Pry the round wire snap ring out of the shaft groove Fig 9 3 Remove the snap ring and lock plate Fig 9 4 Discar...

Page 643: ...ee cover screws to 35 Ib in torque 3 Install steering wheel see STEERING WHEEL INSTALL LOCK CYLINDER INSTALL REMOVE 1 Install turn signal switch by reversing above steps NOTE Be sure the hazard warning knob ispushed in to allow clearance for the cover and to avoid damage to switch CAUTION On tilt column play or slack should be left 1 Remove steering wheel see STEERING WHEEL REMOVE 2 Pull turn sign...

Page 644: ......

Page 645: ...wheel use standard wheel puller J 3044 1 Do not hammer on end of shafr as hammering could loosen plastic injections which maintain column rigidity Fig 9 11Installing Buzzer Switch 1 Remove both attaching nuts securing flexible coupling to steering shaft 2 Disconnect transmission linkage from column shift levers 3 Disconnect all electrical connectors from steering column 4 Remove screws securing to...

Page 646: ... itself torque 5 a Pontiac Hold left outboard cover plate tightly 7 a Pontiac Retighten two right inboard cover against dash panel and secure to right inboard cover plate screws Add remaining cover plate screws to plate with two clamp screws tightening to 40 lb in cover plates tightening them to 40 Ib in torque torque b Tempest and Grand Prix Attach right inboard CAUTION Do not permit the rolled s...

Page 647: ...9 8 1 9 PONTIAC SERVICE MANUAL Fig 9 13ExplodedView of Typical Regular Column Automatic and Manual Transmission ...

Page 648: ...ift 53 Shaft Assy Steering 54 Ring Upper SteeringShaft Retaining 55 Shaft Assy Steering 56 Spring lntermediate Steering Shaft Coupling 57 Bearing lntermediate Steering Shaft Coupling 58 Ring Intermediate Shaft Seal Retainer 59 Clamp Plug and Coupling Interme diate Shaft 60 Bolt Coupling to Upper Shaft 61 Nut Coupling to Upper Shaft 62 Shaft Assy Steering Intermediate 63 Yoke lntermediate Shaft par...

Page 649: ...9 10 1969 PONTIAC SERVICE MANUAL Fig 9 14Exploded View of Typical Tilt Column ...

Page 650: ...Plate Steering Column Lock 53 Gate Steering Shaft Housing Support 54 Screw Steering Shaft Housing Suooort Gate or Detent Plate 55 Pin ieering Column Housing Dowel 56 Support Steering Column Housing 57 Shaft Assy Steering Lower 58 Sphere Steering Shaft Centering 59 Spring Steering Shaft Joint Preload 60 Shaft Assy Steering Upper 61 Screw Upper Bearing Housing Support 62 Ring Steering Column Shift T...

Page 651: ...bly Fig 9 17 11 Remove thrust cup if still attached to housing Fig 9 18 Fig 9 19Removingor InstallingRack and Lock Bolt 12 Remove the rack and lock bolt Fig 9 19 13 Remove the rack load spring Fig 9 20 14 Remove the shift gate Fig 9 21 15 Remove the sector through the lock cylinder hole by pushing firmly on the block tooth of the sector with a blunt punch Fig 9 22 4 16 Remove shift bowl and shroud...

Page 652: ... screws from shift tube support at lower end Fig 9 27 7 Remove both 005 maximum shims Fig 9 23 Removing Back UpLight or Neutral Start Switch 8 Remove wave washer and lower shift bowl bearing from top of jacket Fig 9 28 ASSEMBLE LOWER END Apply a thin coat of lithiur soap grease to all friction surfaces 1 Press the lower bearing assembly into the adapter assembly if removed 2 Insert the shift tube ...

Page 653: ...ity of cocking the lever is eliminated 6 T u r n shift tube support down until levers are bottomed out 9 Assemble the spring and adapter assembly into the bottom of the jacket Holding the adapter in place insert the retaining clip in the jacket slots 10 Install the back up light or neutral start switch loosely to the jacket assembly This will be tightened to the jacket after installing column in c...

Page 654: ...housing Fig 9 18 7 Install lower bowl bearing in jacket and place wave washer in bowl bearing Fig 9 28 8 Install bowl and rotatt it to be sure it is seated in bearing 9 Position shift indicator assembly if removed to upper bearing housing and install retaining spring on all models except Pontiac 10 With the bowl in place install the upper bearin8 housing assembly on the jacket The bowl should be i...

Page 655: ...sembly if it needs to be serviced by removingretaining springand liftingassembly off upper bearing housing on all models except Pontiac 6 Remove steering wheel if still attached see STEERING WHEEL REMOVE 7 Remove turn signal switch see TURN SIGNAL SWITCH REMOVE steps 2 through 10 8 Remove lock cylinder see LOCK CYLINDER REMOVE step 3 9 Remove buzzer switch if it needs to be serviced see BUZZER SWI...

Page 656: ...not tojam Iower shifi lever into 7 slot on Iower end of mast jacket while forcing out shift tube CAUTION Do not hammer or pull on lower or upper shift tube becauseplastic joint may be sheared 23 Remove shitt tube from bowl using tool J 23072 Fig 9 34 Pilot sleeve in upper end of shift tube and force tube out of bowl 24 Remove shift tube assembly from mast jacket lower end Fig 9 34 Installation of ...

Page 657: ...lly hammer race out of housing until bearing puller can be used Repeat for other race ASSEMBLE BEARING HOUSING Apply thin coat of lithium grease to allfriction paAs 1 Install bearings in bearing housin if removed 2 Install lock shoe springs lock shoes and shoe pin in bearing housing Use J 22635 or 180 diameter rod approx to line up shoes for pin installation NOTE With tilt lever opening on the lej...

Page 658: ...an 114 or damage to the shift tube will occur 9 Install centering spheres and anti lash spring in upper steering shaft Install lower steering shaft from same side of spheres that spring ends protrude 10 Install steering shaft assembly in shift tube from upper end Carefully guide shaft through shift tube and bearing 11 Install ignition switch actuator rod through bowl from bottom and insert in slot...

Page 659: ...r unsupported when either the toe plate instrument panel mounting orgear mounting i s connected 29 Adjust back up light or neutral start switch see Section 12for adjustment procedure POT JOINT LOWER STEERING SHAFT TEMPEST NOTE Thepot joint need only be disassembled if there is looseness or binding in the assembly Fig 9 13 DISASSEMBLE 1 Remove steering column from car see STEERING COLUMN REMOVE 2 S...

Page 660: ...riginal location place tie rod end with dust cover in steering arm tighten castellated nut securely and install new cotter pin Tighten nut to 35 lb ft torque on a l l models except Pontiac and tighten nut to 50 lb ft torque on Pontiac 5 When new tie rods or tie rod ends are installed it is necessary to check toe in Check clamp bolts on tie rod adjuster sleeve assembly for tightness 17 lb ft torque...

Page 661: ...P A R A L L E L TO FACE OF INTERMEDIATE ROD BOSS WITHIN 4 AFTER TlE ROD CLAMPS ARE TIGHTENED A S S E M B L E D I N S T A L L A T I O N O F C O T T E R P I N CORRECT ASSEMBLY ARM BOSS WITHIN 4 AFTER N U T 20 LB FT METHODS OPTIONAL A S SHOWN NOTE SLOT I N TIE ROD ADJUSTER T I E ROO CLAMPS ARE E A C H C L A M P SLEEVE MAY BE I N ANY TIGHTENED V I E W B y ASSEMBLE TIE ROD CLAMPS OeTO 15 POSITION EXCEP...

Page 662: ...O TO IS P O S I T I O N O F T I E R O D A D J U S T E R FORWARD i FROM A VERTICAL DOWN METHODS O P T I O N A L S L E E V E a C L A M P POSITION A S S H O W N V l E W B TYPICAL B O T H SIDES WITH FRONT WHEELS I N STRAIGHT AHEAD POSITION aI N C O R R E C T A S S E M B L Y INTERMEDIATE R O D 1 a aC O R R E C T A S S E M B L Y 3 4 NOTE SLOT I N T I E ROD ADJUSTER SLEEVE MAY B E I N ANY POSITION EXCEPT...

Page 663: ...LOT WlTH HOLE NOT TO EXCEED 50 LB FT TORQUE REF TYPICAL B O T H SIDES TYPICAL B O T H SIDES EACH C L A M P POSITIONED WITHIN 15 EITHER SIDE OF TIE ROD SLEEVE SLO POSITION RELATIVE TO GROUND UNIMPORTANT ASSEMBLED I N S T A L L A T I O N CAUTION ASSEMBLE TIE ROD SLEEVE O F COTTER P I N ADJUSTING CLAMP BETWEEN DIMPLES HOUSING MUST BE AT ENDS OF SLEEVE BOTH ENDS P A R A L L E L T O M E T H O D S O P T...

Page 664: ...s mounted on holdingfixture J 5205 or J 6448 1 CAUTION DO NOT clamp housing in vise Cleanli ness is of utmost importance therefore bench tools and parts must be kept clean at all times ADJUSTING SCREW Before disassembling gear thoroughly clean exterior with suitable solvent and dr n as muchfluid aspossible 1 Mount steering gear on holding future J 5205 2 Rotate wormshaft with flexible coupling unt...

Page 665: ...juster 24 GASKET Housing Side Cover 25 COVER Housing Side 26 LOCKWASHER Cover to Housing 5 27 BOLT Cover to Housing 16 x h9 28 NUT Sector Adjusting Screw Ch6 2O Check 29 SHIM PKG Lash Adjuster 30 BOLT Shaft Flange to Shaft Clamping Fig 9 48 Exploded view of ManualSteering Gear 11 Remove ball nut from worm would necessitatereplacement NOTE Unless all balls are removed nut cannot be 4 Inspect housin...

Page 666: ...h remove upper cup from gear housing PITMAN SHAFT CLEARANCE Fig 9 51Removing Pitman Shaft Bushing INSTALL UPPER CUP 1 Install bearing cup in housing using tool J 57 55 replace worm shaft seal REMOVE LOWER CUP 1 Remove lower bearing retainer from bearing adjuster Bearing cup is P slip fit and will come out with lower bearing and Belleville washer INSTALL LOWER CUP 1 Install Belleville washer bearin...

Page 667: ... socket and torque wrench 6 Install pitman shaft adjusting screw and selective shim in pitman shaft Fig 9 50 NOTE Screw must be free to turn but have no more than 002 end play If end play of screw in slot is too tight or too loose select new shim to give proper clearance Shims are furnished in four thicknesses 063 MY 067 and 069 7 Position pitman shaft seal on pitman shaft and seat seal using suit...

Page 668: ... to the power steering gear to correct conditions such as shimmy hard or l se steering road shock wander or weave a check should be made of front end alignment shock absorbers wheel balance or for tight front wheel bearings loose steering rod ends or loose pitman arm ADJUSTMENTS CAUTION Prior to checking gear make certain that the steering shafr is not binding or tight in the steering column On ca...

Page 669: ...not remove seals turn off engine remove steering gear from car and disassemble gear refer toprocedures outlinedfarther in this section 6 Clean seal bore of housing pitman shaft and inspect housing bore for any burrs which might damage seals during installation 7 Wrap a piece of thin tape around splines of pitman shaft this will prevent damage of seals during installation Use only one layer of tape...

Page 670: ...rom socket set To aid in loosening end plug tap end plug with brass drift PITMAN SHAFT GEAR AND SIDE COVER REMOVE 1 Remove side cover retaining screws and washers 2 Rotate cover as necessary to see when pitman shaft is centered in gear housing opening while rotating gear coupling Fig 9 58 3 Remove pitman shaft and cover assembly 4 Remove side cover O ring seal and discard RACK PISTON NUT REMOVE 1 ...

Page 671: ...remain in housing 9 Remove adjuster plug O ring seal and discard ADJUSTER PLUG ASSEMBLY TO WORM 0RING LOWER THRUST STEERWG WORM BEARING RACES Fig 9 61Adjuster Plugand O Ring Removal LASH ADJUSTER SPRING LASH ADJUSTER THRUST WASHER LASH ADJUSTER RETAINER Fig 9 62 Partsin End of PitmanShaft Gear DO NOT DISASSEMBLE PlTMAN SHAFT GEAR AND SIDE COVER DISASSEMBLE 1 Hold lash adjuster with 7 32 Allen wren...

Page 672: ...h stub shaft and valve cap assembly V A L V E S P O O L SPRING V A L V E S P O O L D A M P E N E R 0 RING R O T A R Y V A L V E TORSION B A R V A L V E S P O O L R O T A R Y V A L V E TEFLON RINGS TORSION B A R AND S T U B S H A F T A S S E M B Fig 9 65Exploded View of RotaryValve by tapping end of torsion bar lightly with a plastic hammer This will dislodge the cap from valve body cap in Fig 9 65...

Page 673: ... bearing bore Remove thrust bearing spacer thrust bearing and thrust bearing races 2 Remove adjuster plug O ring and discard 3 Remove retaining snap ring and dust seal 4 Using a screwdriver pryout stub shaft seal be careful not to score bore or adjuster plug 5 Using tool J 6221 drive needle bearing out of adjuster plug 6 If needle bearing was removed install bearing using tool J 6221 position bear...

Page 674: ...leaking or raised above the housing surface drive in flush to 1 16 below surface The ball plug can be tightened by staking housing Housing should be replaced only if leaks in this area cannot be properly sealed NOTE Clean area of leak with solvent andor a wire b m h Dry thoroughly and apply a liquid sealairt which will flow into the area between the ball plug and the housing and then harden Devcon...

Page 675: ...1969 PONTIAC SERVICE MANUAL ...

Page 676: ...Adjuster 44 SCREW LOCKWASHER ASSY Clamp to Rack an 28 x 5 16 45 C A M P t r hear Ball Return Guide 46 GUIDE S Gear Ball e t u r n 47 BALL PKG Recirculating Bright Finish Selective 48 BALL PKG Recirculatinn Black Finish Selective 49 RACK piston 50 RING Strg Gear Power Cylinder Piston 51 SEAL Piston Ring Back Up 0 Ring 52 COVER Steering Gear Lower End 53 RING Lower End Plug Retainer 54 SEAL Steering...

Page 677: ...seal is cut and spool can be removed c Replace O ring seal and proceed with assembly as before HOUSING ASSEMBLE 1 With stamped end of pitman shaft needle bearing INNER BACK UP WASHER E LIP OIL SEAL against shoulder of adapter J 6278 3 use remover and repla cer J 6278 1 to drive bearing into bore from outside of housing until flush to 1 32 below shoulder Make sure needle bearings rotate freely CAUT...

Page 678: ...nut Fig 9 74 5 Insert guides into guide holes of rack piston nut Guides should fit loosely BALL RETURN GUIDE Fig 9 74Ball Return Guide 6 Place return guide clamp over guides and install two screw and lock washer assemblies and tighten to 10 Ib ft torque CHECK WORM PRELOAD The worm groove is ground with a high point in the center When the rack piston nut passes over this high point a preload of 0 5...

Page 679: ...8117 5695512 A rack piston nut with a ball size of 7 does not have a number stamped on flat surface For ball sizes other than No 7 ball size is stamped on flat surface of rack piston nut In order to obtain proper worm bearing preload install proper new balls 7 Remove rotary valve assembly from worm head 8 Position arbor tool J 7539 against worm end Turn worm out of rack piston assembly following w...

Page 680: ...er groove of rack piston is aligned with center of pitman shaft needle bearing 2 Install new sidecover O ring seal 3 Install pitman shaft gear so that center tooth of gear meshes with center groove of rack piston Make sure that side cover O ring seal is in place before pushing cover against housing 4 Install side cover screws and tighten to 30 lb ft torque R O T A R Y V A L V E A S S E M B L Y TOR...

Page 681: ...all steering housing to frame bolts finger tight Shift gear assembly to obtain best alignment with flange on steering shaft Tighten housing to frame bolts to 70 Ib ft torque 3 Install pitman arm and secure with lock washer and nut Tighten nut to 140 Ib ft torque 4 Connect pressure and return hose assemblies to gear assembly and tighten to 25 Ib ft torque 5 Install two flange flexible coupling atta...

Page 682: ...RVOIR TO FULL MARK WlTH 9985010 FLUID AIR SHOULD BE BLED FROM SYSTEMwHlLe MAINTAINING FLUID LEVEL IN RESERVOIR TO AVOID AERATING FLUID OVERFILL OR UNDERFILL SHOULD BE AVOIDED INSPECT SYSTEM FOR LEAKS ESPECIALLY AT HOSE CONNECTIONS AND FITTINGS C R I M P I N G T O O L M U S T F O R M C L A M P F L A T A S S H O W N AFTER A S S E M B L Y V l E W O F C L A M P AFTER ASSEMBLY W I T H O U T C O O L E R...

Page 683: ...HEY DO NOT CONTACT AFTER INSTALLATION IS COMPLETE AND WlTH FRONT WHEELS IN STRAIGHT AHEAD POSITION FILL PUMP RESERVOIR TO FULL MARK WlTH 9985010 FLUID AIR SHOULD BE BLED FROM SYSTEM WHILE MAINTAINING FLUID LEVEL IN RESERVOIR 6 CYL 8 CYL E N G TO AVOID AERATING FLUID OVERFILL OR PRESSURE H O S E UNDERFILL SHOULD BE AVOIDED INSPECT SYSTEM FOR LEAKS ESPECIALLY AT HOSE CONNECTIONS AND FITTINGS Fig 9 8...

Page 684: ...L A M P F L A T A S AIR SH6ULD BE BLED FROM SYSTEM WHILE S H O W N ATTERASSWBLY MAINTAINING FLUID LEVEL IN RESERVOIR TO AVOID AERATING FLUID OVERFILL OR UNDERFILL SHOULD BE AVOIDED INSPECT SYSTEM FOR LEAKS ESPECIALLY AT HOSE CONNECTIONS AND FITTLNGS V I E W OF C L A M P AFTER ASSEMB fi W I T H O U T C O O L E R PlPE W I T H A I C A X L E R A T I O S B E L O W 2 93 EXCEPT A I C PRESSURE U L A T O R...

Page 685: ...ON IS COMPLETE AND WITH FRONT WHEELS IN STRAIGHT AHEAD POSITION FILL PUMP RESERVOIR TO FULL MARK WlTH 9985010 FLUID AIR SHOULD BE BLED FROM SYSTEM WHILE MAlNTAlNlNG fLUlD LEVELIN RESERVOIR TO AVOID AERATING FLUID OVERFILL OR UNDERFILL SHOULD BE AVOIDED INSPECT SYSTEM FOR LEAKS ESPECIALLY AT HOSE CONNECTIONSAND FITTWGS 3 36 1 A X L E R A T I O A B O V E W I T H O U T A C I CRIMPING T O O L MUST FOR...

Page 686: ...s without air condition NOTE Do not hold hand valve on gage closedfor over 5 seconds during this test toprevent damage topump 8 If pressure does not reach specifications in step 7 pump is malfunctioning 9 If pressure is within specifications in step 7 problem is due to internal leakage in steering gear 10 Shut off engine remove testing gage spare hose reconnect pressure check fluid level or make n...

Page 687: ...e O ring 8 With pump housing turned over remove flow control valve and spring Fig 8 6 and tap housing on wood block until pressure plate falls free Fig 9 87 9 Remove pressure plate pump ring and vanes being careful not to drop parts Fig 9 88 10 Remount housing in vise Using a suitable tool remove shaft retainer ring on end of drive shaft Discard ring 11 Remove rotor and thrust plate 12 Remove shaf...

Page 688: ...rotor with flat side toward rear of 6 Install vanes in rotor slots with radius edge towards pump Fig 9 93 outside Figs 9 95 and 9 96 1 Union 2 Seal 3 Mounting 00th 4 Reservoir 5 Dip Stick and Cover 6 End Plate Retaining Ring 7 End Plate 8 Spring 9 Pressure Plate 10 Pump Ring 11 Vanes 12 C Washer 13 Rotor 14 Thrust Plate 15 Dowel Pins 16 End Plate 0 Ring 17 Pressure Plate 0 Ring 18 Mounting Bolt 0 ...

Page 689: ...e diameter and chamber of pressure plate with petroleum jelly to insure against damaging O ring and install on dowel pins with ported face toward pump ring Applying pressure to outer edge only seat pressure plate Never press or hammer on the center of the pressure plate as this will cause Fig 9 93 InstallingRotor Fig 9 95 Installing Pump Vanes ...

Page 690: ...ion O rings 14 Drop reservoir into place and press dbwn until reservoir seats on housing 15 Install studs and outlet union and torque to 35 lb ft Install drive shaft key Support shaft on opposite side of key when installing key INSTALL 1 Position pump assembly on mounting bracket with holes lined up and install bolts loosely Figs 9 88 and 9 89 2 Slide pulley on shaft 3 Install pulley nut finger ti...

Page 691: ...lant 3 Cut each clamp attaching each return hose to cooler pipe Fig 9 80 and 9 82 Discard clamps 4 Check and correct transmission fluid level 4 Disco ect upper and lower radiator hoses 5 Check and correct power steering fluid level 5 Remove fan blade 6 Check for fluid leaks at a1 hose and pipe 6 Remove screws attaching shroud to radiator support co ections that were disconnected GENERAL SPECIFICAT...

Page 692: ...5 l Ratio 3 5 approx Variable Ratio 3 0 approx Power SteeringPump Pressures Tempest Models all 1100to 1200psi Pontiac and Grand Prix Models except Pontiac Catalina without A C 1200to 1300psi without A C 1230to 1350psi Fluid Capacity 2 5 pints Oil Cooler Pipe Variable Ratio Steering Only soine models Worm Bearing Preload Pontiac and Grand Prix except Pontiac Catalina without A C 1 5 to 4 5 lb in Te...

Page 693: ...Cup Instalfar Valve Connector Seat Installer Stwring Gear Pitman Shaft Oil Seal Installer Adjuster Plug baring Remover 6 Installer Pitman Shaft Bearing Remover 6 Installer Piston Rack Arbor Teflon Seal Installer baring Pre Load Spanner Wench Teflon Seal Installer Pivot Pin Remover Power Steering Checking Gage Adapter Lock Shoe 6 Release bvgr Pin Remover 6 Replacer Tilt Column Shift Tuba Remover Ti...

Page 694: ...pport to Frame 35 Nut Steering Wheel to Steering Shaft 30 Nut Steering Column Mounting Bracket to Instrument Panel 20 APPLICATION TORQUE Bolt Mounting Bracket to Steering Column 15 Bolt or Nut Flexible Coupling Clamping to Steering Shaft 30 Bolt Steering Gear to Frame 70 Screw Toe Cover Plate to Dash Panel 401b in Nut Adjuster Plug Lock Nut 85 Nut Pitman Shaft Adjusting Screw Lock Nut Manual Gear ...

Page 695: ... 4 pounds per square forward as possible inch over the recommended pressures up to a maxi mum of 32 pounds per square inch cold for 4 ply 5 Vehicles with luggage racks do not have a vehicle rating tires or 40 pounds per square inch for 8 ply load limit greater than s w e d rating tires Sustained speeds above 75 mph are not recommended when the 4 pounds per square inch 6 When towing trailers the al...

Page 696: ...emoved and press out the stud CAUTION If hub and drum are not supported undeneath pressure fiom thepress may distort the drum orpush the hub assembly awayfiom the drum 2 Clean out the existing hole by drilling through the hub and drum assembly Use a 41 64 6406j drill on Pontiac and a 9 16 5625 drill on Tempest and Firebird 3 Ress in replacement stud REMOVE TIRE FROM WHEEL 1 Remove valve capand val...

Page 697: ...that the beads are resting uniformly on the bead ledge quickly apply a large volume of air This forces the bead on the bead sear and against the flanges where the air seal for the tire is obtained Inflate tire until beads art completely forced against rim flanges CAUTION Do not stand over tire when inflating Bead wire may break when bead snaps over safety hump Do not exceed 40 lb air pressure when...

Page 698: ...out is 035 maximum wheel lateral runout is 045 BALANCEPROCEDURE The preferred method of balancing wheels and tires is with on the car type equipment But whether on or off car type equipment is used always follow the manufac turer s instructions for the equipment being used In addition pay particular attention to the following points 1 Be sure tires are free of stones or other foreign objects that ...

Page 699: ... J78 x 15 L 8 85 x 15 8 85 x 15 4 ply rating4 ply J78 x 15 h MODELS Catalina Executive Bonneville Bonne Brougham Station Wagons Police Option EQUIPMENT A l l except station wagons Bomeviue Brougham Police Car 2 or 3 seat STANDARD 8 55 x I5 8 85 x 15 9 15 x 15 8 55 x 15 4 ply rating 4 P Y G70x 14 Fibreglas G78 x 14 8 25 x 14 6cyl only G78 x 14 Fibreglas 7 75 x 14 Space Saver G70x 14 Fibreglas G78 x...

Page 700: ...s not to interfere with adjustment or service repair conditions The hood Fig 11 I of rigid sheet metal construction A ADJUSTMENT is composed of a single sheet metal outer panel and a rugged inner panel reinforcement Further rigidity is obtained by the insertion of reinforcement braces and Slotted holse are provided at all hood hinge attaching 4 I l 6 0 APPROX INNER PANEL VIEW C APPLY LUBRICANT TO ...

Page 701: ...me assembly locks securely with the latch plate mounted in the hood After proper positioning of the hood bumpers hood height is automatically controlled by the vertically self adjusting hood latch Proper hood alignment is essential for ease of latch operation To open the hood pull the release handle under the center portion of the front bumper grille downward A pop up spring on the support and baf...

Page 702: ...CHASSIS SHEET METAL 11 3 Fig 11 2Pontiac Hood Latch SKIRT VIEW A ...

Page 703: ...11 4 1 9 PONTIAC SERVICE MANUAL VlEW B GRAND PRlX ONLY FENDER VlEW A GRAND PRlX ONLY Fig 11 3 Tempest and Grand Prix Hood Latch ...

Page 704: ...CHASSIS SHEET METAL 11 5 Fig 11 4 FirebirdHoodLatch ...

Page 705: ...der to support and baffle assembly attaching screws 4 Remove hood hinge to fender attaching screws 5 Remove fender to inner skirt attaching screws at wheelhouse 6 Disconnect fender from cowl at door opening and from rocker panel area 7 Remove fender REPLACE 1 To install reverse above procedure 2 Align fender with other sheet metal and body parts 3 Torque all fender to cowl and rocker panel attachi...

Page 706: ...brace 1 To replace reverse above procedure checking fender alignment with other sheet metal and body parts 4 Disconnect any components attache d to skirt such as cruise control hoses electrical harnesses etc 2 Torque all fender inner skirt to fender attachin mews 12 lb ft and lower fender attaching screws 5 Remove skirt lb ft f ...

Page 707: ...11 8 1 9 PONTLAC SERVICE MANUAL ...

Page 708: ...VIEW C F i i 116 band Rbc Front Fenders ...

Page 709: ......

Page 710: ...CHASSIS SHEET m A L 11 11 ...

Page 711: ...11 12 1 w PONTIAC SERVICB MANUAL ...

Page 712: ...CHASSIS SHEET METAL 11 13 ...

Page 713: ......

Page 714: ...USE WITH METAL PANEL USE WRH PLASTIC PANEL FENDER SUPPORT LOWER REINFORCEMENT I fig 11 12 Firebird Valance Pand ...

Page 715: ...8 m Ir as a loop of wire approximate 5 in kngth protrudingfi om engine wiring harness along j i 1 Remove positive and negative battery cables using rocker arm cover where harness breaks out for pliers alternator On Firebird or Tempest 6 cylinder mOdth lwp will be located at breakout for voltage regulator 2 Remove battery clamp fiom engine wiring harness 3 Strip away all melted harnessinsulation 3 ...

Page 716: ...RII m r n R u S 2 4 6 8 A I U NDL V l R R LC Fig 12 1Pontiac EngineCompartmerrtWiring ...

Page 717: ...CHASSIS ELECTRICAL SERVICE 12 3 Fig 12 2 PontiacPassengerCompartmentWiring ...

Page 718: ...Fig 123 Pontiac PassengerCempartmemtWiring Continued ...

Page 719: ...CHASSIS ELECTRICAL SERVICE 12 5 310 L mn u WY YLnI La L 52L 56 xne3 c C STATDU IU GOW WUAQIW KI uL W L L C Y X L A W UO wLYI Fig 124 Pontiac Rear EndWiring ...

Page 720: ...12 6 1969 PONTIAC SERVICE MANUAL IW r Gr LOW I W W I E U BLK SGL TAU ELK SCL L r CRN Fig 12 5Tempest EngineCompartment Wiring ...

Page 721: ...CHASSIS ELECTRICAL SERVICE 12 7 I F F Fig 126 Tempest PassengerCompartment Wiring ...

Page 722: ...12 8 1969 PONTIAC SERVICE MANUAL Fig 12 7Tempest Passenger Compartment Wiring Continued ...

Page 723: ...CHASSIS ELECTRICAL SERVICE 12 9 STOP 8 DIR LP Y U l m CO CCTrn DOYC LA TANK W I T STW a DIR LP 0 0 E W C R W STATION WAGON ALL CYIPT U T I O AU I L ILAUP Fig 12 8 Tempest Rear End Wiring ...

Page 724: ...12 10 1969 PONTIAC SERVICE MANUAL BLK SGL TAN TERNATOR M R SGL LT GRN MORN RELAI Fig 12 9Firebird EngineCompartment Wiring ...

Page 725: ...CHASSIS ELECTRICAL SERVICE 12 11 DI GRN C W LTR L W Fig 12 10FirebirdPassengerCompartment Wirinn ...

Page 726: ...12 12 1969 PONTIAC SERVICE MANUAL b Tau rtca uwn cod CCLLOYRnL I LAMP SWITCH Fig 12 11Firebird Passenger Compartment Continued ...

Page 727: ...CAL SERVICE 12 13 R H k W M R LAW R H T ST r a SIG L A P R H OoOR SWITCH R H TAL STOP SIDE MARKER LAMP GROUND Mu4 BODY M C T O R LH TAL STOP LEFT HSTRVY T L n TAIL STOP 4DR S t LAMP Fig 12 12 Firebird Rear End Wiring ...

Page 728: ...Fig 12 13Grand Prix EngineCompartmentWiring ...

Page 729: ...CHASSIS ELECTRICAL SERVICE 12 15 OK GRN A I Fig 12 14Grand Prix PassengerCompartment Wiring ...

Page 730: ...12 16 1 9 PONTIAC SERVICE MANUAL Fig 12 15Grand Prix PassengerCompartment Wiring Continued ...

Page 731: ...CHASSIS ELECTRICAL SERVICE 12 17 BUK UP L uP LICENSE LAMP FUEL GAVGE TANK UNIT STOP 6 01R L R BACK UP LAMP STOP6 DIR L R Fig 12 16Grand Prix Rear End Wiring ...

Page 732: ...TOR CS 1 BATTERY 8 CHARGE CIRCUITS I BUw O COmLCm AU EXCEPT PONTIAC wlTn RALLY GAGE IGNITION W T C n C S 1BATTERY 8 CHARGE CIRCUITS PONTIAC WITH RALLY GAGE BATTERY 8 CHPRGE CIRCUITS PONTIAC WITH RALLY GAGE Fig 12 17Typical Rally Gage Wiring ...

Page 733: ...CHASSIS ELECTRICAL SERVICE 12 19 Fig 12 18Pontiac BatteryCable Routing ...

Page 734: ...A circuit passing through a given NOT Chassis wiring schematics will aid in ident1Bing terminal may be identified by using the embossed wires letters on the bulkhead connector For example Fig 12 23 bulkhead connector cavity DSU is the circuit to 4 TOreplace revem removal procedure the horn relay operating coil circuit ENGINE WIRE HARNESS ALL REMOVEAND REPLACE 1 Remove bolt holding fro111e11d and e...

Page 735: ... BEFORE POS Fig 12 20Firebird Battery Cable Routing WIPER MOTOR TERMINAL MUST ROUTE BEL HORIZONTAL AS SHOWN ENGINE WIRE HARNESS VlEW D WATER TEMP SWITCH TO DOWNSHIFT SWITCH VlEW C SLACK IN BAT SOL LEAD RED MUST BE LOOPED INBOARD BATTERY POS CAB1 SOLENOID LEAD PURPLE INSTALL TO 3 TERMINAL WITH LUG VIEW A IN VERTICAL POSITION VlEW 0 Fig 12 21Typical V8 ENgine Harness Installation ...

Page 736: ...ay be determined from Fig 12 24 SEAL BEAM ALL REMOVEAND REPLACE INCLUDES ADJUSTMENT 1 Remove bezel 2 Remove seal beam rim retaining screws 4 To replace reverseremoval procedure 5 Adjust headlights as shown in Fig 12 25 If commercial aiming devices are used follow manufac turer s instructionsas well as local variations FRONT PARK AND SIGNAL LAMPS PONTIACAND TEMPEST REMOVEAND REPLACE 1 To remove bul...

Page 737: ...T TO AMMETER SHUNT PONTIAC ONLY B OIL PRES GA C TEMP GA DS TO HORN RELAY WERATINQ COIL CIRCUIT D l TO L H FRONT DIRECTIONAL SIGNAL Lb NOTE Y C BLOWER MOTOR FUSE D U TO R H FRONT DIRECTIONAL SIGNAL LT 30 AMP LOCATED IN DV NOT USED LINE AT ALTERNATOR OW MIIERY FEED TO FUSE PANEL DX TO WINDSHIELD WIPER EXC PONTIAC AND TUNS ACCESSORY POWER CONNECTOR ABOVE FUSE BLOCK DOWNSHIFT SWITCH O N FIREBIRD TO AM...

Page 738: ...f TO AIMING SCREEN car Use for both right and left sets of headlights LEFT EDGE OF HlGH INTENSITY LIGHT PATCH 2 IN FROM VERTICLE HORIZONTAL OF OUTBOARD HEADLAMP t 6 IN LIMIT TRANSFERRED TO AIMING XREEN C UPPER EDGE OF HlGH INTENSITY LIGHT PATCH AT HORIZONTAL 22 IN INBOARD LAMP ADJUST HlGH BEAM ONLY I LATERAL AIM HIGH INTENSITY ZONE CENTERED O N VERTlCLE 6 IN 4 HORIZONTAL OF INBOARD HEADLAMPr TRANS...

Page 739: ...with the park lamp All other models are equipped with a plastic lamp retained to the front fender by a steel retainer Bulb and socket then twist into lamp The marker lamp is of single filament type and has a single wire leading to it from the front end harness The rear marker lamp located in the quarter panel is also fed by a single wire contained in the rear harness INSTRUMENT PANEL CLUSTER Remov...

Page 740: ...ews then left hand toe plate to dash GRAND PRlX REMOVE AND REPLACE 1 Disconnect battery 2 Remove glove compartment 3 Disconnect speedo cable and wire connectors at headlamp switch windshield wiper turn signal igni tion switch printed circuit heater and or air condi tioner control panel 4 Remove lower column trim and disconnect air control cable at heater case 5 Remove three 3 screws at instrument ...

Page 741: ...h steel portion of dash 9 Drop steering column by loosening toe plate screws and removing lower column support nuts 10 Placc shop towels on top of column and then pull panel rearward to rest on column 1I Disconnect printed circuit accessory windshield wiper cigar lighter 12 Remove ground straps then cluster retaining screws 13 Remove clustercarefullyso as not to scratch face INSTRUMEN1 REMOVE THES...

Page 742: ...for sharp bends and breaks If breaks are noted replace casing 5 To insure quiet operation assemble cable in following manner a Wipe cable clean using lint free cloth Flush bore of casing with oleum spirits or suitable solvent solution and blow dry with air under pressure b Place an approved speedometer cable lubricant in palm of hand c Feed cable through lubricant in hand and into casing until lub...

Page 743: ...TO R H DOOR JAM SWITCH TO HEATER OR A C CONTR 01 RTIBLES ONLY TO BODY HARNESS CODNECTOR P Fig 12 31 Pontiac Instrument Panel Harness ...

Page 744: ...lbs on right side of printed circuit and gently fold it back 6 Remove screws retaininggage to cluster 7 Remove gage 8 To replace reverse removal procedure TEMPEST FlREBlRDOR GRAND PRlX REMOVEAND REPLACE 1 Disco ect battery 2 Remove nuts screws and bulbs retaining left side of printed circuit to instrument cluster 3 Carefully fold back printed circuit so as not to crease rcmove screw retaining gage...

Page 745: ...tton on switch and remove knob and shaft 2 Remove retaining nut 3 Remove wire connector from switch and remove switch 4 On vacuum operated headlight models re move vacuum connector 5 To replace reverse removal procedure CIGAR LIGHTER ALL REMOVEAND REPLACE 3 Remove switch retaining screws and reposition 1 Remove lighter ground straps 2 Remove bezel and case by pushing retainer clips 4 Remove switch...

Page 746: ...PLACEAUTOMATIC TRANSMISSION 1 Remove wire connector 2 Remove retaining screws 3 Remove switch 4 To replace position shift tube in drive position 5 Insert switch drive tang in shifter tube slot and assemble switch to steering column jacket with retain ing screws and adjust ADJUST AUTOMATIC TRANSMISSION 1 Position and hold the shift lever in low range while inserting the blade of the reset gage J 23...

Page 747: ...move switch 4 To replace reverse removal procedure No adjust ment is necessary INSTRUMENT PANEL HARNESS Instrument panel harness installation is shown in Fig 12 35for Pontiac and 12 36for typical Tempest Firebird and Grand Prix ALL REMOVE AND REPLACE 1 Disconnect battery 2 Disconnect bulkhead and fuse block pulling from dash 3 Disconnect all harness connectors 4 On Pontiac models pull harness from...

Page 748: ...ps retaining actuator to pivot rod POWER SERVO REMOVE AND REPLACE Fig 12 40 1 Remove parking lamps and valence panel 5 To replace reverse removal procedure 2 Remove vacuum hoses to servo and servocover 6 Use Fig 12 41for connection of vacuum hoses PRINTED CIRCUIT CONNECTOR OCK POWER LEAD RADIO FEED LA CIGAR LIOHTER TURN SIGNAL BACK UP LAMP SWITCH MANUAL TRANS H START SWITCH Fig 12 36Typical Firebi...

Page 749: ...1 0 TOWER SEA1 ACC RED W I t L A BLOWER I n MOWER MOTOR M O l o R Fig 12 37 Pontiac Accessory Schematic ...

Page 750: ...I I Fig 12 38 e est and Grand Prix Accessory Schematic I ...

Page 751: ...OWER FRT BODY BLOO HARNESS POWER TOP 6 POWER SIDE WINDOWS TO POWER MOCK POWER TOP POWER SEAT 6 POWER SIDE POWER SEAT TO POWER 7 100 h B 1 2 0 V B C I BKR ON F U S d 2BLOCK POWER TOP 6 POWER SEAT POWER TOP SWITCH TO POWER SEAT HARN O N FUSE HARNESS BLOCK POWER FLOW VENTILATION MOWFR SYITCH TO POWER MOCK TO POWER SEAT HARN MOCK llOWN B R N PINK R J W Cut 20 WH OR 6 YUOW ta w n m S T PUR CRTR Y W UNE...

Page 752: ...12 38 1969 PONTIAC SERVICE MANUAL PIVOT ROD WELD NUT REF HEADLAMP BODY ASS Y HANGER BAR REF VACUUM OPERATED HEADLAMP DOORS Fig 12 40 Vacuum Operated Headlamp Doors GTO ...

Page 753: ...SIS ELECTRlCAL SERVICE 12 39 LOSE RH HEADLIGHT ELK ACTUATOR ASM I L t l KaDLlGHT DOOR ACTUATOR ASM VACWM T A M NOTE VACUUM HOSES ROUTED WITH FRONT END HARNESS Fig 12 41Vacuum Operated Headlamp Door Schematic ...

Page 754: ...and some Tempest models All motors have two speeds and piston type washer pumps WIPER BLADE ARM BLADEASSEMBLY ALL REMOVEAND REPLACE Pontiac Tempest and Grand Prix with Depressed Park Removeand Replace 1 Unload wiper arm by installing pin on Pontiac models 2 Remove arm from transmission driver then remove clip from drag link retainer 3 To replace turn wiper switch to off position so that motor is i...

Page 755: ...CE R H BLADE O N AND MUST REG1 SPRING IN BLADE D O W N TO ALLOW STOP IN MLDG BLADE TO SLIP OFF OF THE PIN VlEW OF NORMAL OPERATING 8 PARK POSITION WHEN ARM IS SEATED D O W N TIGHT LIFT ARM HE REMOVE LOOSE UNLOAD ARM SP WHEN DRAG LINK IS PROPERLY POSITION O N PIVOT PIN SLIDE PINK TRPCER BLADE END O N HEAD BLADE END JUST BELOW APPLY GREASE WHEN INSTALLING VIEW 0 VIEW C INSTALLING POSITION INSTALLING...

Page 756: ...WINDSHIELD WIPERS 12A 3 ...

Page 757: ...12A 4 1969 PONTIAC SERVICE MANUAL ...

Page 758: ...assembly against stop follow proper adjustment procedure listed below on moulding ARM AND BLADE PONTIAC ADJUST 1 With motor in park position and wiper switch off place drag link of left arm and blade assembly on pin With arm end in position as shown in view C push head of arm on transmission shaft Fig 12A 1 2 Place drag link of right arm and blade assembly on pin Lock retainer on pin with blade pi...

Page 759: ... the motor circuit If quickly released the system will make one cycle and park With the exception of this feature the switchesoperate the same 1 Washer button complete wash cycle and lo speed wiper 2 Wiper button first position lo speed wiper 3 Wiper button second position hi speed wiper See SecZion 12 WIPER SWITCH REMOVE AND REPLACE DEPRESSEDPARK WIPER MOTOR OVERHAUL BRUSH PLATEAND CIRCUIT BREAKE...

Page 760: ...ches from relay carefully lift brush holder off mounting legs far enough to clear armature commutator c Unsolder two leads from relay switch terminals 9 Allow brush held in step 8 to move out of its 4 If only terminal board requires replacement holder Remove brush spring and lift brush holder off proceed as follows armature shaft 10 Lift the brush plate circuit breaker assembly from the field coil...

Page 761: ...al board into wiper housing being careful to position terminal board resistor lead as shown in Fig 12A 7 NOTE With relay switch replaced in housing and washerpump reinstalled the relay switchplastic housing applies pressure against resistor lead to form a positive ground connection to wiper housing Without this resistor ground the wiper probably would have excessive speed in high while having a no...

Page 762: ...y careful to maintain lock and drive pawl guide pins in their respectivepockets during step 9 9 Assemble inner spacer washe r over gear shaft and assembly gear mechanism in housing so that the pawls are approximately 180 away from the latch assembly Fig 12A 8 10 Reassemble outer spacer washer shield shim washers are required to obtain 005 max end play snap ring and rubber seal cap in order indicat...

Page 763: ...ers Fig 12A 14 2 Drill out gear box cover staking ping a 1 4 drill and remove cover from gear box CAUTZON Mark ground strap location for reassembly purposes NOTE Screws nuts and lockwashers for reassembling cover to wiper are contained in a service repairpackage 3 Remove washer pump 4 lobe cam output gear and shaft assembly then slide intermediate gear and pinion and pinion spring washer off shaft...

Page 764: ...Arm in Park Position 1 Follow steps 1 through 4 a under GEAR BOX DISASSEMBLY Fig 12A 16 2 Remove tie bolts then work gear box off armature shaft 3 Release brush spring pressure against brushes as shown in Fig 12A 16 4 Move brushes away from armature and slide armature out of frame and field assembly Pull end plate assembly off armature CAUTION Use care to insure that small thrust plug at e n d of ...

Page 765: ...g off mounting plate RELAY TERMINAL BOARD 1 Remove 4 lobe cam 2 Remove ratchet pawl and pawl spring 3 Remove relay armature and spring 4 Chisel off the four bent over tabs that secure the coil mounting bracket to the base Remove and discard relay coil and terminal board assembly To mount a replacement relay hold it securely against the base mounting surface and bend locking tabs over CAUTION Be ca...

Page 766: ...he cam follower pin Fig 12A 18 PISTON 1 Remove valve Fig 12 17 Brush Spring Rectangular Motor VALVE 1 Note position of valve relative to the pump housing for reassembly then remove four screws that secure valve to housing 2 Remove housing to valve body gasket and save for reassembly 2 Remove front of piston containing sea from housing 3 Remove rear of piston and spring by turning 90 to separate fr...

Page 767: ...chet pawl retaining ring and slide ratchet pawl off cam follower shaft RATCHET WHEEL 1 Follow step 1 under SOLENOID RATCHET DOG DISASSEMBLY 2 Move ratchet wheel spring out of shaft groove and slide ratchet wheel off shaft PUMP AND ACTUATOR PLATE ASSEMBLY 1 Remove solenoid assembly ratchet dog ratchet pawl and ratchet wheel as outlined in their respective procedures 2 To separate the pump and pump ...

Page 768: ...Firebird 50 Wiper to firewall attaching bolts 25 WlPER SPECIFICATIONS Operating Voltage Pontiac or Optional Tempest System 12 14 VDC Operating Volts Tempest or Firebird 12 VDC Crank Arm Rotation looking at Crank Arm Counterclockwise Crank Arm Speed rpms No Load LO 40 Min HI 70 Min Current Draw Recess Park Tempest and Grand Prix Bench Check LO Speed 6 0 Amps Max HI Speed 4 5 Amps Max Installed in C...

Page 769: ...D TEMPEST REMOVE 1 Disconnect positive battery cable 2 Open drain cock at bottom of radiator and drain radiator and cylinder block Remove filler cap so coolant will flow freely NOTE To save coolant remove radiator overflow hose and connect to drain cock 3 Loosen hose clamps and disconnect upper and lower radiator hoses at radiator inlet and outlet pipes 4 On cars equipped with power steering remov...

Page 770: ...VlEW B WITH AIR CONDITIONING1 VlEW A AIR CONDITIONING ONLY Fig 13 1 PontiacSupport and BaffleAssembly ...

Page 771: ...TEMPEST 6 CYLINDER L H SHOWN SYMMETRICALLY RAM AIR ENGINES ...

Page 772: ...t and Insulator Tempest 6 Cylinder Only FAN GUARD 6 CYL RECEIVER DEHYDRATOR ALL V 8 6 CYL WITH AIR CONDlTlONlNQ R H ONLY SHROUD ALL V 8 C i ALL V 8 6 CYL WlTH AIR CONDITIONIN0 ALL V 8 6 CYL WlTH AIR CONDITIONIN0 LH ONLY Fig 13 4FirebirdSupport and BaffleAssembly ...

Page 773: ...the REMOVE TEMPESTBUMPER Fig 14 3md4 frame and bumper to frame attachment bars provide fore and aft lat al as well as vertical adjustment 1 Disconnect parking lights headlights and vacuum REMOVE PONTIAC BUMPER Fig 14 1 hoses GTOonly 1 Disconnect parking lights and headlights 2 Remove valance panel See Section 11 3 Remove upper fder panel 4 Loosen front bumper s t a b h r s Fig 14 1 2 Remove valanc...

Page 774: ...Fig 14 1 Pontiac Front Bumper PRESS FIRMLY I N T O F R O N T E X T E N S I O N ...

Page 775: ...Fi 14 2 Grand Prim Frmt unper ...

Page 776: ...14 4 1969 PONTIAC SERVICE MANUAL Fig 14 3Tempest Front Bumper Fig 14 4GTO Front Bumper ...

Page 777: ...FRONT A N D REAR BUMPERS 14 5 ...

Page 778: ...ter opening for access to the gasoline filler Grand Prix taillight assemblies are mounted in the bumper Bonneville has a resilient urethane applique All station wagon bumpers have a step built in for easier access optional on Tempest Custom Shims may be required at the center hanger bar bracket where the face bar is mounted to prevent possible rattles REMOVE PONTIAC REAR BUMPER Fig 14 6 1 Remove v...

Page 779: ...the bumper does not recover its shape or the surface is gouged a repair system has been developed to restore the original shape and appear ance of the foam base material The polyurethane material is used for GTO front bumpers Pontiac front bumper center extension and Bonneville rear bumper applique The repair sequence amounts to a filling operation with a flexible epoxy resin After curing the patc...

Page 780: ......

Page 781: ...FRONT AND REAR BUMPERS 14 9 ...

Page 782: ...14 10 1969 PONTIAC SERVICE MANUAL ...

Page 783: ...Fi 14 9 Grand Prix Rear Bumper ...

Page 784: ...0 V E a fC F 1 REAR COMPARTMENT PAN REAR COMPARTMENT PANEL HANGER BAR TO BODY REAR BUMPER OUTER SNUBBER TO BODY VIEW A REAR CROSS MEMBER OUTER SNUBBER TO IMPACT BAR Fig 14 10 Tempest Rear Bumper Except Station Wagon ...

Page 785: ...FRONT AND REAR BUMPERS 14 13 ...

Page 786: ...14 14 1969 PONTIAC SERVICE MANUAL ...

Page 787: ...llowing flash timebetween coats 3 N o w 15 to 30 minutes drying time at room temperature When dry water sand the glazed area with 400 sandpaper Block sand for maximum leveling NOTE Dry sanding clogs the sandpaper due to the elastomer typevehicle used in the compound 4 Re clean the repair area with a final solventwash 5 Thoroughly stir the color and apply in sufficient quantity to achieve hiding on...

Page 788: ...14 16 1969 PONTIAC SERVICE MANUAL GRILLE ASSEMBLY BEZEL PART OF GRILLE ASSEMBLV Fig 14 13Pontiac BonnevilleGrille I I I Fig 14 14PontiacCatalina and ExecutiveGrille ...

Page 789: ...FRONT A N D REAR BUMPERS 14 17 Fig 14 15Grand Prix Grille ...

Page 790: ...14 18 1969 PONTIAC SERVICE MANUAL Fig 14 16Tempest Grille Fig 14 17FirebirdGrille ...

Page 791: ...FRONT AND REAR BUMPERS 14 19 ...

Page 792: ...tallation of clip Cut off exass chain BRAKERELEASESWITCH ADJUSTMENT Fig 153 Apply brake pedal and push both switches forward as far as possible Pull pedal forcibly rearward to adjust switches CENTERING SPRING ADJUSTMENT Fig 151 1 If Cruise Control holds speed three or more mph Accessory Switch Cutouts 15 16 Rear Window Defogger 15 17 Heated Rear Window 15 18 Cornering Lamps 15 20 Underhood Lamp 15...

Page 793: ...REGULATOR M O U N T I N G TEMPEST 6 G P VENT HOSE TEE REGULATOR M O U N T I N G PONTIAC CLIP MUST BEAD CHAIN REGULATOR M O U N T I N G FIREBIRD 2BBL CARD ENGINE 4BBL CARD ENGINE 6 TEMPEST L C A R B ENGINE 1 CARD ENGINE FIREMRD Fig 15 2ACruiseControl Installation ...

Page 794: ...SS CHAIN SERVO MOUNTINO ALL TO ENGINE VACUUM HOSE ROUTINO PONTIAC HOUSE ROUTINO TEMPEST OP HOSE ROUTINO AREBIRD TAPE CRUISE CONTROL WIR ASM TO FRONT END WIRE HARNES HOSE ROUTINO FIREBIRD Fig 15 28CruiseControl Installation ...

Page 795: ...E ASM WASTER ROUTING VIEW PONTIAC BRAKE 6 CLUTCH PEDAL VACUUM HOSE 0 REGULATOR MA1N WlRE HARNESS AS ROUTE AS SHOWN THROUGH J CLlP ACESS WlRE GROMMET CONNECTOR HOT ONNECT CRUISE LEVER 6 SWITCH ASM PART OF MAIN HA WIRE TO CRUISE CONTROL WIRE ASM MASTER ROUTING VIEW TEMPEST 6GRAND PRlX WlRE GROM CONNECTOR HOT LEA PART OF MAlN HARNE VACUUM HOSE TO TEE CONNECT CRUISE LEVER 6 SWITCH ASM WIRE TO CRUISE C...

Page 796: ...SWITCH ASM THEY STOP AGAINST BRACKET OR ARM PULL PEDAL REARWARD WlTH I S TO 20 LBS FORCE TO ROPERLY ADJUST SWITCHES VACUUM RELEASE SWITCH CRUISE RELEASE a TANDARD COLUMN BRAKE LIGHT SWITCH BRAKE PEDAL ASM WIRE AND ALONG PROTRUDING RIB ON SWITCH ADJUSTMENT ALL VIEW OF BOTTOM OF BOWL WlTH CRUISE WlRE INSTALLED STANARD COLUMN TILT COLUMN OF STEERING COLUMN ASM SWITCH ASM CONNECTORS PART OF CRUISE BRA...

Page 797: ...dometergear 4 If input cable is turning and speedometer was inoperative cable to speedometer or regulator transfer gear is broken MAJOR SERVICE REGULATOR REMOVEAND REPLACE Fig 15 2 1 Disconnectvacuum hoses and electrical connector 2 Disconnect both speedometercables 3 Remove screws holding regulator to fender skirt and remove regulator 4 To replace reverse above steps Note proper hookup of vacuum ...

Page 798: ...ch Fig 15 5Cover and Intake Filter Assembly REGULATOR DISASSEMBLE Fig 15 4 b Thescrew in the bearing support assembly NOTE Do not tamper with the following screws Fig Thescrew on top ojthe rotenoid coil 15 6 a Vacuumrestriction screw in regulatorhousing Thesescrews arepre adjusted at thefactory ACTUATOR PIN GOVERNOR SPRING BEARING SLIPPORT Fig 15 7BearingSupport Removal ...

Page 799: ... regulator housing and install four screws NOTE Make sure the rubber gasket on the boitom of the valve body and magnet assembly liesflat against the regulator housing Under no circumstances should this gasket be glued to the valve body and lhagnet assembly 3 With weights in an up and down position insert the long end of the governor shaft through the bearing support mounting hole keeping the actua...

Page 800: ...WIRING DETAILS SPEEd0 CLUSTER Fig 15 10Clock Installation Pontiac HARNESS CO Fig 15 11Clock Installation Tempest and Grand Prix Fig 15 12Clock Installation Firebird SAFEGUARD SPEEDOMETER 1 BRAKE 6 CLUTCH BRACKET BROWN POWER 1 I Fig 15 13Safeguard Speedometer Pontiac ...

Page 801: ...4Safeguard Speedometer Except Pontiac RALLY GAGES IGNITION FUEt GAGE TANK U PRINTED CIRCUIT Fig 15 15Rally Gages Firebird TEMP SENDING UNIT IGNITION POWER PRIMED CIRCUIT FUEL GAGE TANK UNIT 4 Fig 15 16Rally Gages Pontiac ...

Page 802: ...ACCESSORIES 15 1 1 TACH LEAD TO ROUTE THRU EXISTING CONDUIT FUEL GAGE TANK UNIT IGNITION POWER Fig 15 17RallyGages Tempest and Grand Prix ...

Page 803: ...T I N S T A M T I O N CONNECTORPART OF TACH ASM OF TACH ASM BLACK 6 PINK NEG TERMINAL O N COIL VOLTAGE REGUL BUCK 6 PINK 4 Fig 15 18Hood Mounted Tachometer Tempest If TACHOMETER IS MORE THAN 200 RPM Off AT 3500 RPM AS SHOW OY HOOKING UP A PRECISION TACHOMETER IN CONJUNCllON WITH THIS SEE FIG 15 1 TACHOMETER REMOVE FOR SERVICE 1 AMP FUSE 6 CYLINDER Fig 15 19HoodMountedTachometer Firebird ...

Page 804: ...K hFRONT OF TO DECK LID MECHANISM SEE FISHER BODY MANUAL FOR DECK LID MECHANISM GRAND PRlX INSTALLATION Fig 15 20Deck Lid Release Tempest and Grand Prix E FISHER BODY MANUAL FOR INSTALLATION OF Fig 15 21Deck Lid Release Pontiac FUSE PANEL ASM Fig 15 22Deck Lid Release Firebird ...

Page 805: ...CK AND UNLOCK DOORS TWICE AFTER ENGINE IS TURNED OFF 4 Fig 15 23Vacuum Door Locks Pontiac TO REMOTE CONTROL VALVE TO REMOTE CONTROL VALVE SPARK PLUG WIRES TO ENGINE VACUUM SOURCE TO ENGINE VACUUM SOURCE 0 H C 6 ENGINES SYSTEM TEST V 8 ENGINES SYSTEM SHOULD LOCK AND UNLOCK DOORS TWICE AFTER ENGINE I S TURNED OFF R E F E R TO FISHER BODY MANUAL FOR INSTALLATION OF REMAINDER OF SYSTEM Fig 1524 Vacuum...

Page 806: ...ACCESSORIES 15 15 VACUUM TIRE PUMP I 1 BBL CARB ENGINE I V 8 6 CYL 4 EEL CARE ENGINE 4 BBL CARB ENGINE OTHERWISE SAME AS 2 BBL CARB ENG OTHERWISE SAME AS 1 BBL CARB ENG Fig 15 25Vacuum Tire Pump All ...

Page 807: ... PIERCING CUTOUTS 1 OCATE 6 PUNCH CENTER OF U T O U T 2 DRILL 9 16 HOLE THRU DASH 6 APPLIQUE 3 ASSEMBLE SQUARE STUD OF TOOL J 23118 THRU Ff L PORTION OF TOOL 6 STUD THRU DRILLED HOLE FROM BEHIND DASH 4 INSTALL MALE CUTTER 6 NUT O N STUD 5 CAR U l o N P N H WITH TEMPEST ornll Cb 3 I N EA H 6 WHILE HOLDING TOOL FROM ROTATING TIOHTEN NUT TO PIERCE CUTOUT I Fig 1527AccessorySwitch Cutouts All ...

Page 808: ...ACCESSORIES 15 17 REAR WINDOW DEFOGGER C E N T E R OPENING Fig 15 28Rear Window Defogger Pontiac E N T E R OPENING Fig 15 29Rear Window Defogger Tempest ...

Page 809: ... SWITCH BULB RED CONNECTORS UNDER I P CURRENT DRAW OF REAR WINDOW GRIDS IS 5 AMPS ON LO AND 20 AMPS ON HI ACCESSORY I F E E D WIRE HEATED WINDOW RELAY SMOUL PULL CONNECTION IN WITH 9 0 VOLTS APPLIED AT RELAY r GREEN PULL IN TERMINAL AT REAR SEAT BRACE rk TCONNECTION ACCESSORY CONNECTOR RED CONNECTOR SWITCH INSTAILATION ALL L J IN TRUNK I I GROUND AT RH ROOF SAH AREA GRIDS ...

Page 810: ...RH GRIDS ROOF SAIL AREA HEATED REAR WINDOW WlTH AUTOMATIC TEMPERATURE CONTROL A C NOTE WlTH THlS COMBINATION OF OPTIONS HEATED WINDOW AND ATC UC THREE RELAYS ARE INSTALLED ON THE COWL JUST BEHIND THE ENGINE THE U C HI BLOWER RELAY NOT PICTURED HERE HAS THREE TERMINALS THE U C MUTER RELAY NOT PICTURED HERE M D THE BLOWER OVER RIDE RELAY HAVE FOUR TERMINALS EACH AND ARE INTERCHANGEABLE THEY CAN BE R...

Page 811: ...15 20 1969 PONTIAC SERVICE MANUAL CORNERINGLAMPS VIEW STEERING COLUMN RIGHT SIDE Fig 15 33CorneringLamps Pontiac R H SIDE Fig 15 34CorneringLamps Tempest ...

Page 812: ...ACCESSORIES 15 21 Fig 15 35Cornering Lamps Grand Prix UNDERHOODLAMP IP UPPER CAVITY ROUTE LEAD BETWEEN TAPE INNER PANEL AND HOOD INSUUTOR PAD Fig 15 36Underhood Lamp Firebird ...

Page 813: ...15 22 1969 PONTIAC SERVICE MANUAL INSULATOR PA REMOVE RETAINERS LIFT PAD FOR LAMP WIRE INSTAL Fig 15 37 Underhood Lamp Tempest and Grand Prix Fig 15 38UnderhoodLamp Pontiac ...

Page 814: ...ULD TURN OFF WHEN LID IS 9 INCHES FROM CLOSED I Fig 15 39Luggage Lamp Firebird NOTE FOR PROPER OPERATION LAMP SHOULD TURN OFF WHEN DkCI LID I S 9 INCHES DOME LAMP FROM CLOSED P C0NVERT IBLES ONLY BRACKET NOTE FOR PROPER OPERATION LAMP SHOULD TURN OFF WHEN DECK LID IS 9 INCHES FROM CLOSED POSITION Fig 15 40Luggage Lamp Tempest and Grand Prix Fig 15 41Luggage Lamp Pontiac ...

Page 815: ... ESCUTCHEON APPLIQUE INDICATOR SEE FIG 15 46 BRACKET INSTALLATION OF FLOOR FLOOR ATTACHING PARTS SHIFTER AND ADJUSTMENT OF CABLE Fig 15 43Console Firebird Automatic Transmission AUTOMATIC TRANSMISSION DOOR BOX ASSY Fig 15 44Console Grand Prix ...

Page 816: ...5 DIAL HOUSING FREE POSITION INSTALLED POSITION GROUND WIRE BLACK CLIP TO SHIFTER ASS Y SEE SECTION 7 OF THIS MANUAL FOR INSTALLATION AND ADJUSTMENT OF SHIFTE AND CABLE Fig 15 42 Console Tempest Automatic Transmission ...

Page 817: ...C SERVICE MANUAL CENTER BRACKET 8 INSERT CONN ROUTE WIRE OVER CLUTCH L BRAKE B R A C K E T FOR INSTALLATION OF FLOORSHIFT MECHANISM SEE SECTION 7 i ORANGE I L I 1 I I i a I i Fig 15 45Console Tempest Manual Transmission ...

Page 818: ...ACCESSORIES 15 27 REAR APPLIQUE Fig 15 46Console Firebird Manual Transmission ...

Page 819: ...AKER BRKT ASSY DARK GREEN WIRE TO SPEAKER WIRE HARNESS Fig 15 47Radio Receiver and Front Speaker Pontiac TRlM RADIO TO MAXIMUM VOLUME WlTH ANTENNA AT 31 INCHES AND DIAL AT 1400 KC O N AM BAND DO NOT TRlM O N FM BAND AM FM RADIO Fig 15 48 Radio Receiver and FrontSpeaker Firebird ...

Page 820: ...TENNA AT 31 INCHES AND DIAL AT 1400 KC O N AM BAND DO NOT TRlM ON FM BAND I GRAND PRlX I YELLOW POWER DARK GREEN WI ES TO INSTRUMENT PANEL WIRES TO INSTRUMENT PANEL YELLOW POWER WIRE HARNESS Fig 15 49Radio Receiver and Front Speaker Tempest and Grand Prix ...

Page 821: ...PMENT Fig 15 50RadioSuppression Equipment Pontiac STRAP MUST B E INSTALLED WlTH LOOP UP AS SHOWN BOllOM VIEW OF R H FENDER HOLE IN UPPER CONTROL ARM FRONT OF CAR J F CAPACITOR INSTALLATION HEATER WIRE GROUND WIR AM FM STEREO RADIO EXC WITH A C WITH A C ONLY ...

Page 822: ...1RadioSuppression Equipment Tempest and Grand Prix EVAPORATOR ASH HEATER BLOWER MOTOR CLIP AM FM RADIO WITH GROUND STRAP AIR CONDITIONING 6 CYLINDER AM FM RADIO EXCEPT AIR CONDITIONING REGULATOR R H ROCKER COVER CAPACITOR GROUND STRAP ALL 6 AND g s 8 CYLINDERS A I ALL 6 AND 8 CYLINDER 8 CYLINDERS Fig 15 52RadioSuppression Equipment Firebird ...

Page 823: ...SERVICL3 MANUAL MANUALANTENNA RETAINER WITH ALTERNATE TWO PIECE LEAD IN SOME A C CARS Fig 15 53Manual Antenna Pan lac MAST SHOULD BE TILT FROM 1 TO 4 I N 0 0 REARWARD WHEN I Fig 15 54 ManualAntenna Tempest and Grand Prix ...

Page 824: ...ACCESSORIES 15 33 MAST SHOULD B E TILTED 1 TO 4 INBOARD AND REARWARD WHEN INSTALLED Fig 15 55Manual Antenna Firebird POWER ANTENNA ANtENNA ASSY Fig 15 56Power Antenna Tempest p p ...

Page 825: ...15 34 1 PONTIAC SERVICE MANUAL LEFT OPENING IN PANEL SEE F I S H E R BODY MANUAL F O R WIRING 8 LEAD IN INSTALLATION STATION WAGON SEDAN Fig 15 57 Power Antenna Pontiac ...

Page 826: ...ACCESSORIES 15 3 5 SEE FISHER BODY MANUAL FOR INSTALLATION OF UPPER OPENING IN DASH Fig 15 58Power Antenna Firebird ...

Page 827: ... until entire length of nylon cord has been expelled from drive To prevent kink or bend in nylon cord keep it taut by pulling on mast NOTE If drive assembly is inoperative it will be necessary to manually remove nylon cord from drive To remove nylon cordj om disabled drive place assembly in vise so normal plane of nylon cord is parallel withfloor Then using both hand pull on 3OO diameter mast tube...

Page 828: ...ACCESSORIES 15 37 REAR SEAT SPEAKER CONTROL C L I P CONN TO RADIO A M RADIO Fig 15 59Rear Seat Speaker Pontiac REAR SPEAKER TO REAR SPEA Fig 15 60Rear Seat Speaker Firebird ...

Page 829: ...OPERATION 2 WITH RADlO OPERATING TURN FADER CONTROL FULL CLOCKWISE TO CHECK FRONT SPEAKER OPERATION 1 P CONN TO RADlO TO FRT SPEAKER CLIP CONN TO RADlO AM FM RADlO INSTALLATION SHOWN IS FOR ALL MODELS EXCEPT STATION WAGONS CONVERTIBLES S E E FISHER BODY MANUAL FOR SPEAKER INSTALLATION Fig 15 61Rear Seat Speaker Tempest and Grand Prix Released by www 78ta com Serial Number 69SER 002 1012 ...

Page 830: ...ACCESSORIES 15 39 VERBRA PHONIC SYSTEM INSTRUMENT PANEL 1 PLATE AM FM RADIO REVERB SWITCH RIGHT HAND OPENING Fig 15 62Verbra PhonicSystem Pontiac ...

Page 831: ...FOR INSTALLATION OF REVERB AMPLIFIER SAME AS MULTIPLEX UNIT AND TO FIG 15 61 REAR SEAT SPEAKER FOR INSTALLATION OF FADER SWITCH BLACK WHITE BLACK SPEAKER TERMINAL TO FACE TO FRONT S P E AM FM RADIO REAR SEAT SPEAKER Fig 15 63Verbra PhonicSystem Tempest HARNESS ASM AM FM RECEIVER LOWER REINFO REVERB AMPLIFIER Fig 15 64Verbra Phonic System Grand Prix ...

Page 832: ...IGURES FOR TO FRT SPEAKER STALLATION AND RADIO 8 F R O M SPEAKER FOR FRONT SPEAKER INSTALLATION FM STEREO RADIO TAPE PLAYER NOTE D O NOT CUT WIRES TO TAPE PLAYER TO REMOVE FOR SERVICE REMOVE HOUSING AND BRACKETS PRIOR TO SHIP MENT TO REPAIR STATION 1 BASE Fig 15 65Stereo Tape Player Pontiac ...

Page 833: ...O ONN T O RA REFER T O FIGURE 15 75 FOR STEREO SPEAKER INSTALLATION FRT SPEAKER WlTH CONSOL HARNESS NOTE D O N O T CUT WIRES T O TAPE PLAYER TO REMOVE FOR SERVICE REMOVE HOUSING A N D BRACKETS PRIOR T O SHIPMENT t T O REPAIR STATION 1 EXC WITH CONSOLE TUNNEL Fig 15 66StereoTape Player Tempest ...

Page 834: ...IEW OF Q PLAYER L SIDE RETAINER SIDE RETAINER STEREO HARN MANUAL TRANSMISSION CONNECT CLIP TO STEREO RADIO ONLY CONSOLE HARNESS FRONT STEREO SPEAKER HARN HARNESS USING PROTECTIVE PLAYER ASM ROUTE HARNESS ASM MOUNTING CUTOUT SPLIT IN CARPET Fig 15 77 Stereo Tape Player Grand Prix ...

Page 835: ... NOTE D O N O T CUT WIRES T O TAPE PLAYER T O REMOVE FOR SERVICE REMOVE HOUSING A N D B RACKETS PRIOR T O SHIPMENT T O REPAIR STATION TAPE PLAYER CONSOLE FLOOR BRACKET REAR VIEW FRONT OF CAR BRACKET L a 2 Fig 1567 Stereo Tape Player Firebird ...

Page 836: ...PEAKERS FOR FURTHER DETAILS Fig 15 68Stereo Tape Player Wiring Firebird FM STEREO RADIO REAR OF ASHTRAY REt RADIO FRONT SPEAKER STEREO REAR SPEAKERS AND STEREO TAPE PLAYER NOTE D O NOT SEPARATE RECEIVER FROM AMPLIFIER THESE UNITS ARE A MATCHED SET AND MUST BE SERVICED Fig 15 69FM Stereo Radio Pontiac ...

Page 837: ...POWER GRAY RHEO NOTE DO NOT SEPARATE RECEIVER FROM AMPLIFIER THESE UNITS ARE A MATCHED SET AND MUST BE SERVICED TOGETHER CAUTION NEVER TURN RADIO O N UNLESS BOTH FRONT AND REAR SPEAKERS ARE CONNECTED Fig 15 70FMStereo Radio Tempest CAUTIONI NEVER TURN RADIO ON UNLESS BOTH PROM AND REAR SPEAKERS ARE CONNECTED Fig 15 71FMStereo Radio Grand Prix ...

Page 838: ...ore o matched set and must be serviced together NEVER TURN RADIO S ALL FRONT AND TO REAR SPEAKER KERS ARE CONNECTED MAIN WIRE HARNESS RADIO AND FRONT SPEAKERS YELLOW POWER STEREO SPEAKERS AND GRAY RHK STEREO TAPE PLAYER FOR FURTHER DETAILS I Fig 1572 FM Stereo Radio Firebird ...

Page 839: ... the passenger s seat 2 With BALANCE rotatod to oxtromo countor Both the left front and loft rear speakors should operate Volume should k appraximately equal as heard from the driver s seat DARK BLUE WlRE FRONT SPEAKER EXT WlRE CO NNECTOR SPEAKER CONNECTOR WITH CLIP FROM STEREO DAPTER OR TAPE PLAYER WlRE ASM L H FRONT SP WlRE ASM BLACK Fig 15 73Stereo Front Speakers Firebird ...

Page 840: ...VERTIBLE SPEAKERS Fig 15 74Stereo Rear Speakers Pontiac SEE FISHER BODY MANUAL FOR INSTALLATION OF STATION W A G O N OR CONVERTIBLE SPEAKER FROM AMPLIFIER SPEAKER TERMlNAl 5 L H SPEAKER FOR TO FACE CENTER OF CAR GRAND PRlX ONLY NOTE RIGHT AND LEFT SPEAKERS ARE IDENTICAL AND INTERCHANGEABLE Fig 15 75Stereo Rear Speakers Tempest and Grand Prix ...

Page 841: ...15 50 1 9 PONTIAC SERVICE MANUAL AUXILIARY SPEAKER REAR SPEAKER EXT WIRE L H AUXILIARY Fig 15 76Stereo Rear Speakers Firebird ...

Page 842: ...nt Codes 0 1 Auto Therm Air Cleaner 6D 1 Axle Rear See Differential Back up Lamps Section 12 Ball Joints Section 3 Remove and Replace Upper 3 14 Remove and Replace Lower 3 14 Battery 6C 2 1 2 1 Bearings See Unit Concerned Belt Tension Chart 6A 7 Body Vibration Dampeners Section 2 Body Mountings Section 2 Brakes Disc Section 5E Bleeding Disc Brakes 5E 6 Disc Brake Caliper 5E 1 Lining Inspection 5E ...

Page 843: ...7 6 Column Standard Steering 9 3 9 6 Tilt Wheel 9 16 Companion Flange 4A 8 Compression Test 6C 1 Compressor Air Conditioning 1A 9 Condenser Air Conditioning 1A 31 Connecting Rods 6 Cyl Engine 6 26 V 8 Engine 6 65 Console 15 24 Control Arms and Bushings Front Lower 3 11 Upper 3 12 Rear Lower 4 7 Upper 4 5 Dampeners Body Vibration 2 3 Damper Driveline 7B 14 7C 9 Decimal Equivalents 0 9 Differential ...

Page 844: ...ting Rod 6 64 Crankshaft 6 70 Fitted Block 6 72 Oil Pump 6 61 Piston Rings 6 69 Rear Main Oil Seal 6 61 Rod and Piston Assembly 6 65 Service Periodic 6 40 Specifications 6 77 Engine Tune up Section 6C Air Cleaner Service 6C 3 Engine Tune Up Continued Battery 6C 2 Choke 6C 4 Compression 6C 1 Connections Tune up 6C 4 Coolant Level and Hoses 6C 3 Crankcase Oil Level 6C 3 Ventilation 6C 5 Fan Belt 6C ...

Page 845: ...Heights 0 6 Series Identification 0 2 Towing 0 3 Transmission Serial Numbers 0 2 Units of Measure 0 10 Vehicle Identification Plate 0 1 Instruments 12 25 Insulators 6 Cyl Engine 6 4 V 8 Engine 6 40 Key Blanks 0 5 Coding 0 5 Lifting and Towing 0 3 Linkage Carburetion 6B 5 Steering 9 21 Transmission 7A 1 7B 1 7C 1 7D 1 7E 2 7F 3 7G 3 Lock Coding 0 5 Lubrication 0 8 Oil Filter 0 8 6A 5 Oil Pan Pontia...

Page 846: ...Ignition 6C 4 6E 19 Belt 6 Cyl Engine 6 8 Chain and Cover V 8 Engine 6 54 Tire Balance 10 4 Tires 10 1 Toe In Adjustment 3 4 Transistor Regulator 6E 14 Transmission Four Speed Muncie Manual Section 7D Adjustments 7D 1 Description 7D 1 Major Repairs 7D 5 Minor Repairs 7D 2 Periodic Service 7D 1 Specifications 7D 14 Four Speed Saginaw Manual Section 7C Adjustments 7C 1 Description 7C 1 Driveline Dam...

Page 847: ...Units of Measure 0 10 Universal Joints 4C 1 Vacuum Advance Valve 6D 1 Valance Panel See Chassis Sheet Metal Valve Train 6 Cyl Engine 6 12 V 8 Engine 6 46 Verbra Phonic Speaker 15 39 Vehicle Identification Plate 0 1 W Water Control Valve Section 1A Water Pump 6A 1 Weights and Measures 0 10 Wheel Bearings 3 1 3 5 Wheel Cylinders Brake 5 13 Wheel Steering 9 3 Wheels and Tires Section 10 Balancing 10 ...

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