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Pontiac BONNEVILLE 1972, Service Manual

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Summary of Contents for BONNEVILLE 1972

Page 1: ...Released by www 78ta com Serial Number 72SER 001 1033...

Page 2: ...the right Black tabs on the first page of each section register with this table to assist in readily locating information desired A detailed table of contents appears at the beginning of each section...

Page 3: ...tification Plate Towing 0 4 Ignition Lock 0 5 Nut and Bolt Markings 0 7 Basic Dimensions 0 9 Lubrication 0 13 I DIVISION S E R I E S 1 rBODY S T Y L E UNIT NUMBER7 I G J N E s CER IF1 3 T I THE DEALER...

Page 4: ...2 Door Hardtop 25257 2L57 25200 B 4 Door Hardtop 25239 2L39 B 4 Door Sedan 25269 2L69 B 2 Door Convertible 25267 2L67 B 2 Seat Station Wagon 25235 2L35 B 3 Seat Station Wagon 25245 2L45 CATALINA BROU...

Page 5: ...Single V V8 455 2 BBL Dual U V8 455 4 BBL Single W V8 455 4 BBL Dual Y V8 455 H O 4 BBL Dual X Fig 0 5 Vehicle Identification Plate Engine Code Chart Fig 0 6 8 Cylinder Engine Serial Number Location...

Page 6: ...ode 72 following the two letter code represents the model year For more details and location of V I number derivative see Section 7G of this manual TWO SPEED AUTOMATIC The transmission identification...

Page 7: ...d clear ance should not exceed 6 inches while towing the car IGNITION AND TRUNK LOCKS REMOVE 1 Remove lock assembly from steering column See Section 9 2 Production Lock is not serviceable and should b...

Page 8: ...ough five 9 stamped on its side Before the lock cylinder may be coded the correct code must be determined If the numbered blank in the key head has not been removed determine the code by consulting th...

Page 9: ...ly into steering column See Section 9 2 Insert spring in each round cavity of each tumbler lock between slots Figs 0 16 and 0 17 S A E NUT AND BOLT MARKINGS CAUTION Do not pull springs apart unscrew t...

Page 10: ...0 8 1972 PONTIAC SERVICE MANUAL MARKINGS STRENGTH I N P S I Fig 0 20 S A E Nut and Bolt Markings STANDARD STRENGTH HIGH STRENGTH...

Page 11: ...1 3 9 1 6 9 1 5 7 1 3 9 1 6 9 1 3 5 45 1 4 7 1 4 9 67 OVERALL LENGTH I A 1228 0 1 22 4 1228 0 1 222 4 1 222 4 222 4 222 4 1 222 4 1 222 4 1 226 2 1 226 2 1 226 2 1 228 0 1 228 0 1 226 2 1 226 2 1 226...

Page 12: ...1 ALL EXC STA WAG H D SPRINGS I 1 9 80 1 9 80 1 H D SPRlNGS EXC STA WAG 1 10 05 10 50 ALL STATION WAGONS ROCKER PANEL TO GROUND 1 SECTION A A TYPICAL BETWEEN WHEEL HOUSE OPENINGS 1 FOR REFERENCE ONLY...

Page 13: ...NGS EXC 276 10 50 10 50 3536 3546 10 65 3536 3546 WITH 10 65 10 65 H D SPRINGS ROCKER PANEL ROCKER PANEL UNDERBODY 10 40 HEIGHT 3536 3546 EXC H D SPRINGS SECTION A A t NOTE TO CORRECT FOR ROCKER PANEL...

Page 14: ...ARTER PANEL INNER PANEL UNDERBODY ROCKER PANEL CURBROCKER ROCKER PANEL SECTION AA PANEL HEIGHT HEIGHT NOMINAL FOR REFERENCE ONLY CURB LOAD CONDITION FULL FUEL TANK AND SPECIFIED TIRE PRESSURE Fig 0 24...

Page 15: ...es are equipped with specially engi neered piston rings These rings allow oil to flow freely on Oil change interval should be lowered to two 2 months the cylinder walls during the break in period Ther...

Page 16: ...cross shaft COLUMN SHIFT LINKAGE MANUAL TRANSMISSION Engine oil at alljoints below steering column shift levers Chassis grease at cross shaft bearing points FLOOR SHIFT LINKAGE MANUAL TRANSMISSION Ch...

Page 17: ...vity Wipe any grease off exposed surface Replace bronze filter or paper element clean filter cavity of hub and seal ITEMS REQUIRING LUBRICATION OR SERVICE EVERY 24 MONTHS OR 24 000 MILES WHICHEVER OCC...

Page 18: ...d spring anchor points as re quired REAR COMPARTMENT LID HINGES Engine oil as required CONVERTIBLE FRONT DOOR TO LOCK WEDGE PLATE Stick type lubricant use sparingly as required WINDSHIELD WASHER SOLVE...

Page 19: ...ength of the cable tion It is a ball bearing lubricated and sealed for life SPEEDOMETER CABLE CAUTION Excessive amounts oflubricant can cause speedometerhead failure Lubricate new Periodic lubrication...

Page 20: ...8 16 8 17 8 US Qt 12 5 15 5t 16 5t 19 5 20 5 US Qt 5 0 4 0 5 0t 4 0t US Pt 3 5 3 0 18 25 20 0 5 0 21 0 Imp Qt 10 5 13 0t 13 8t 16 2 17 1 Imp Qt 4 25 3 25 4 25t 3 25t Imp Pt 3 0 2 5 15 2 16 75 4 2 175...

Page 21: ...1 peck pk 4 pecks 1 bushel bu 105 quarts 1 barrel CUBIC MEASURE 1 728 cubic inches 1 cubic foot 27 cubic feet 1 cubic yard COMMON WEIGHT 1 6 o u n c e s lpound 100 pounds 1 hundred weight cwt 2000 po...

Page 22: ...omponents Blower Motor and Impeller Heater Hoses Heater Core Heater Case Lower Ventilators Upper Ventilation DIAGNOSIS HEATER SYSTEM WIRING SCHEMATICS F Series These schematics should be referred to f...

Page 23: ...tion of controls Advise operator of proper operation of heater controls Explain operation of cowl vents and controls Low coolant level Check control cable and blower operation Check for seal between e...

Page 24: ...open Temperature door does not open Obstructions in defroster outlets at windshield Dinged defroster outlets Blower motor not connected Inoperative blower motor NOTE B Series blower motor operates whe...

Page 25: ...ary Check for bind or obstruction at air door Check for loose vacuum hose connection at diaphragm Check for loose vacuum hose connection at diaphragm MISCELLANEOUS CORRECTION Locate and correct short...

Page 26: ...the air inlet duct to the heater case There depending on the control panel setting air is directed either through or around the heater core to the outlets Here again depend ing on control panel settin...

Page 27: ...wer speed range is LO MED HI with the blower motor oper ating wheneverthe ignition switch is in the RUN position even if the heater control selector lever is in the OFF position On all other models th...

Page 28: ...ure lever in WARM or HOT all output air from the heater system is air which has passed through the heater core Moving the temperature lever will introduce more air which has by passed the heater core...

Page 29: ...ove system selector lever to DEFROST A Hot air comes chiefly from defroster nozzles with some air from heater outlet 4 Move temperature lever to OFF COLD A Air from defroster is about the same tempera...

Page 30: ...hat wire loop at heater 3 Adjust turnbuckle on temperature control cable Fig case end of cable is disconnected from heater case crank 1 10 until cable wire loop lines up with pin on tem perature door...

Page 31: ...control cable turnbuckle Fig 1A 10 until wire loop on cable lines up with pin on heater air door crank 3 Place wire loop over crank pin and secure attachment with push nut Move control panel selector...

Page 32: ...Fig 1 12 A Series Heater Control Panel and Cables...

Page 33: ...1 12 1972 PONTIAC SERVICE MANUAL I...

Page 34: ...A SERIES All cable adjustments are to be made after cables have been securelyconnected at both ends and routed smoothly and free of sharp kinks or bends TEMPERATURE CABLE 1 Hold lever on top of heater...

Page 35: ...detent when lever is moved full travel DEFROST CABLE The defrost cable is not adjustable F SERIES Cable adjustments are to be made with cables routed smoothly free of sharp kinks or bends and securely...

Page 36: ...rew retaining cable to control panel and remove cable 4 To replace cable reverse removal procedure Route cable smoothly check operation and adjust if neces sary see Fig 1 12 1 Connect cable at heater...

Page 37: ...t electrical and vacuum connections at control panel Fig 1 11 HEATER CONTROL PANEL REMOVE AND REPLACE B SERIES 4 Remove rear attaching screw 5 Loosen 2 screws securing control panel to instru ment pan...

Page 38: ...l panel 9 Disconnect all electrical connections at control and remove control panel 5 Disconnect electrical connectors and remove control panel Fig 1 15 10 To replace reverse removal procedure Adjust...

Page 39: ...re REMOVE AND REPLACE F SERIES 1 Perform steps 1 through 4 of procedure for heater control replacement 2 Remove switch knob Fig 1 13 3 Disconnect electrical connector 4 Remove 2 switch retaining screw...

Page 40: ...wer motor and con nector at blower resistor on B Series remove dash grommet and feed wire harness through dash open ing into passenger compartment For installation drawing seeFig 1 16 B Series Fig 1 1...

Page 41: ...I P trim plate 5 screws and remove radio Remove plastic filler panel on top of I P at base of windshield Remove windshield garnish mouldings at both ends of instrument panel Remove 4 bolts retaining...

Page 42: ...to rest on steering column 6 Remove defroster nozzle screw at heater case Straighten nozzle retaining tabs Fig 1 20 and remove nozzle 7 To replace reverse removal procedure Check tem perature cable op...

Page 43: ...ttery 2 Remove lower instrument panel trim and upper trim plate at cluster 3 Remove lower left hand A C duct 4 Remove steering column support bracket 5 Remove 4 steering column nuts and lower column 6...

Page 44: ...hrough 8 of heater core replacement proce dure 2 Remove 2 upper defroster nozzle attaching screws 3 Remove lower attaching screw and washer and remove defroster nozzle Fig 1 24 4 Replace defroster noz...

Page 45: ...se removal procedure VACUUM HARNESS REMOVE AND REPLACE G SERIES AIR DIAPHRAGM REMOVE AND REPLACE G SERIES 1 Disconnect vacuum hose from diaphragm Fig 1 21 2 Remove diaphragm retaining screws and sprin...

Page 46: ...t back to its original position and retain cut out with sheet metal screws Seal cut out area with undercoating or body joint and seam sealer The cut out panel can be retained using a 2 by 3 piece of s...

Page 47: ...3 Remove all fender skirt attaching bolts except those attaching skirt to radiator support 4 Pull out then down on skirt and place wooden block between skirt and fender to allow clearance for blower...

Page 48: ...cept B Series 2 Remove 2 air inlet case attaching screws through 2 Loosen hose clamps and remove hose opening between fender and skirt 3 When replacing hose refer to Figs 1 27 B Series 3 Remove 5 air...

Page 49: ...in ing strips and remove core 8 Install the replacement core Be sure the core to case sealer is intact before installing core Use new sealer if necessary 9 Install core retaining strips and core tube...

Page 50: ...HEATING AND VENTILATION 1 29 A SERIES V 8 WITHOUT A C I I A SERIES WITH 6 C Y L A N D A C VlEW A COMPRESSOR VlEW B Fig 1 28 Heater Hose Routing A and G Series...

Page 51: ...1 30 1972 PONTIAC SERVICE MANUAL...

Page 52: ...HEATING AND VENTILATION 1 31 WITHOUT A C Fig 1 30 Heater Hose Routing X Series 307 Engine...

Page 53: ...1 32 1972 PONTIAC SERVICE MANUAL TIGHTEN ALL HEATER HOSE CLAMPS TO 12 18 LB IN Fig 1 30A Heater Hose Routing X Series 350 Engine...

Page 54: ...nnect heater cables and blower resistor connec tor from heater caseand remove core and case assem bly from car Remove the core tube seal and core assembly retain ing strips and remove core Install rep...

Page 55: ...1 Remove screw securing park brake bracket to lower instrument panel reinforcement and position bracket toward right side of car for access to left hand kick pad 2 Perform steps 1 through 5 of right...

Page 56: ...erse removal procedure 4 Loosen door sill plate to gain access to rear edge of kick pad REMOVE AND REPLACE G AND A SERIES 5 On models with upper ventilation disconnect upper vent cable 1 On left side...

Page 57: ...f upper ventilation instrument panel at taching parts see Figs 1 33 B Series 1 34 A and G Series and 1 35 F Series REMOVE AND REPLACE F AND X SERIES UPPER VENT DOOR VALVE 1 Perform steps 1 through 4 o...

Page 58: ...3 Remove right hand upper vent nozzle adapter and duct Fig 1 35 4 Remove 5 vent door mount screws and remove door assembly 5 To replace reverse removal procedure LEFT SIDE 1 Perform steps 1through 4 o...

Page 59: ...CE B SERIES 1 Remove center ash tray and remove lower I P trim plate 4 screws 2 Remove radio knobs and bezels Remove upper I P trim plate 5 screws 3 Remove headlamp and wiper switch bezel from I P ope...

Page 60: ...vel and Adding Oil 1A 55 Replacing Refrigeration Components 1A 55 Refrigerant Hose Asms 1A 56 Service Procedures Compressor Assembly 1A 62 Superheat Shut Off Switch 1A 85 P O A Valve 1A 87 Expansion V...

Page 61: ...or purple When the suction hose is moved awav from the leak the flame will CORRECTION FOR YELLOW FLAME If the flame is yellow insufficient air is being aspirated or the reaction plate is dirty Insuff...

Page 62: ...k operat ion remove cap from reference leak remove sensor probe from brackets and hold electrode cage near the reference leak The reference leak 1 2 oz per year will cause a tone to be generated from...

Page 63: ...1A 4 1972 PONTIAC SERVICE MANUAL...

Page 64: ...CUSTOM AIR CONDITIONING 1A 5...

Page 65: ...GA BLKIWHT 16 GA BLKIRED 16 GA 7 18 GA F A N SWITCH BLKIRED 1 6 GA 1 BLKIORN 12 GA THERMAL LIMITER I AMBIENT SWITCH MASTER SWITCH TO SUPERHEAT SHUT OFF SWITCH LT GREEN 18 GA i BLACK 18 GA BROWN 16 GA...

Page 66: ...CUSTOM AIR CONDITIONING 1A 7...

Page 67: ...LET DOOR VAC RECIRC AIR PURPLE 30 60SECONDS DOOR OPEN DOOR VAC FULL DOWN D ROsT I ORANGE VENT OUTSIDE AIR VENT OPEN TEMP LEVER VALVE DEFROST DOOR TEMP LEVER VALVE SWITCH PORT PORT TEMP LEVER POSITION...

Page 68: ...CUSTOM AIR CONDITIONING 1A 9 L T K W W S k S 3...

Page 69: ...DOOR BLACK OR VENDOR CODED L ORANGE INSIDE AIR Fig 1A 10 A C Vacuum Schematic A Series OPERATIONAL TEST The purpose of performing an operational test Fig 1A 14 is to prove that the air conditioning el...

Page 70: ...CUSTOM AIR CONDITIONING 1A 11...

Page 71: ...1A 12 1972 PONTIAC SERVICE MANUAL INSIDE POSITION ENGINE BI LEVEL POSITION ENGINE HEAT POSITION D E F R O S T POSITION Fig 1A 12 A Series Vacuum Valve Positions...

Page 72: ...CUSTOM 4IR CONDITIONING 1A 13...

Page 73: ...ntly of the effect of atmospheric pressure However any gauge used to check the P O A valve pressure will not be free rom the effect of atmospheric pressure This altitude effect on the gauge must be ta...

Page 74: ...TION AND CAUSE Engine overheated Overcharge of refrigerant or air in system Note Always disconnect thermal limiter before depressurizing system CORRECTION See Engine Section Systems with excess discha...

Page 75: ...I I Check T X V I equallzer h e I cmdltlon I I I I I I Check englne c m h g system v m s fan clutch and for restricted alr flcu thw condenrer 2 Check T X valve bulb mntact and msulalmn Correct if n s...

Page 76: ...rpm A C mode Hi blower and maximum cooling Add refrigerant until sight glass clears add an additional 1 2 pound It is not unusual for bubbling to occur on minimum cooling and LO blower in mild weathe...

Page 77: ...charge Pressure Too Low See P O A Valve Inlet Pressure Too High See P O A Valve Inlet Pressure Too High NOZZLE OUTLET TEMPERATURE TOO COLD CONDITION AND CAUSE CORRECTION P O A valve faulty See P O A V...

Page 78: ...to procedure recharge system and replace thermal limiter SWITCH CONTACTS I SUPERHEAT SHUT OFF SWITCH CHECK On Car 1 Disconnect electrical connector at superheat switch in rear head of compressor 2 Che...

Page 79: ...rature of 212 F additional heat will not change the temperature of the water but will change its state from liquid to vapor This same reasoning applies when heat is dissipated As water vapor cools and...

Page 80: ...uid refrig erant flow into the evaporator Since the pressure in the evaporator is relatively low the refrigerant immediately begins to boil As the refrigerant passes through the evaporator it continue...

Page 81: ...6 Do not discharge vapor into area where flame is ex posed 7 Do not expose eyes to liquid All refrigerant drums are shipped with a heavy metal screw cap The purpose of the cap is to protect the valve...

Page 82: ...ealed again the system must be properly evacuated GENERAL DESCRIPTION Pontiac s air conditioners operate by combining with the heater to provide a year round air conditioning system This permits the a...

Page 83: ...1A 24 1972 PONTIAC SERVICE MANUAL OPERATNG PIN VALVE BODY COVER ASM CONNECTOR Fig 1A 19 Cross Section Expansion Valve...

Page 84: ...me of refrigerant entering the evaporator as signaled by the temperature and pressure in the evaporator outlet pipe FUNCTION OPERATION The purpose of the expansion valve is to regulate the flow of liq...

Page 85: ...r passing over the evaporator to a tem perature at or just above the freezing point of water The evaporator core with this design permits a very effi cient distribution of refrigerant at the moment re...

Page 86: ...OR ADJUSTING SCREW SEAT SPRING NEEDLE SEAT ASM BELLOWS COVER BELLOWS ASM HOLDDOWN CPRING PISTON SPRING PISTON RING PISTON LIQUID BLEED CONN SCREEN ASSEMBLY CORE ASM INLET BAFFLE EVAP GAGE CO INLET CON...

Page 87: ...pressure therefore outlet side compressor side has lower pressure than inlet side Vacuum Bellows is contracted because outlet pressure is still over 28 5 psi 3 Piston IS open because pressure on botto...

Page 88: ...ING CONDITIONS BELLOWS OPENS The pressure surroundina bellows and on to i f Diston is now sufficientlv over 28 5 a a c u u m Bellows has contracted due to I Needle Valve opens again allowing com Incre...

Page 89: ...s used to control a small needle valve which in turn controls a large piston The bellows is con structed so that it has a tendency to expand when the pressure surrounding it goes below 28 5 psi or con...

Page 90: ...uperheat switch port opening allows the superheat switch to be affectedby suction gas pressure and tempera ture for operation of the low refrigerant protection system which prevents compressor damage...

Page 91: ...ng Front Head lutch Coil and Housing Assembly Outer Oil Pump Gear Rear Discharge Valve Plate Assembl Crossover Cover Spacer Front Discharge Valve Plate Assembly Fig 1A 26 Exploded View Compressor Asse...

Page 92: ...epara tors Each bearing is sandwiched between two steel thrust races and this combination of three pieces is placed be tween the shoulders of the swash plate and the shoulders of the cylinder hubs on...

Page 93: ...linder are on their compression stroke the high pressure vapor is caused to flow into the discharge cavity in the front head through the discharge tube and into the rear head dis charge cavity This va...

Page 94: ...S W r I ku3 THERMAL LIMITER SUPERHEAT SWlTCH 4 I CLUTCH REPRESENTS A C CONTROL SET FOR COMPRESSOR OPERATION Fig 1A 27 Low Refrigerant Charge Protection System SWITCH SENSING TUBE SWITCH TERMINAL RETAI...

Page 95: ...diaphragm and sensing tube assembly is charged with R 114 refrigerant and the sensing tube protrudes into the suction cavity of the rear compressor head to sense suction gas tempera tures The internal...

Page 96: ...the superheat shut off switch This stops com pressor operation and prevents damage to the compressor assembly When the cause of refrigerant loss is detected and cor rected and the system is recharged...

Page 97: ...1A 38 1972 PONTIAC SERVICE MANUAL Fig 1A 32 Cross Section Clutch Assembly...

Page 98: ...Because of the constant pressures in side the compressor the seal surfaces must be protected against any damage such as scratches and nicks even finger markings may cause surface damage to prevent oil...

Page 99: ...id to diagnosis The appearance of bubbles or foam beneath the sight glass liquid indicator above 70 F ambient indicates air or a partial discharge of refrigerant in the system A solid liq uid column a...

Page 100: ...between the core fins is warmed by the coolant tubes carrying hot coolant This warm air is then directed 1nto the passenger compartment by the blower and ducts DIAPHRAGM I Fig 1A 38 B Series Air lnle...

Page 101: ...L or the defroster nozzles with slight air flow from the heater outlet DEFROST TEMPERATURE LEVER The temperature lever determines the temperature of out let air flow from the A C system by positioning...

Page 102: ...conditions DEFROST The DEFROST position directs maximum air flow to the windshield This quickly clears the wind shield of fog or frost WARNING Operate the A or G Seriessystem in heater or air conditi...

Page 103: ...oor outlets with the tem perature of the air from the floor outlets slightly warmer than the air from the upper air outlets When the lever is set to HEATER all air is distributed from the floor out le...

Page 104: ...on complete car with engine running coolant warm and environment above 45 F 1 Move selector lever to OFF set fan switch at HI full up and move temperature lever to full HOT all the way to the right A...

Page 105: ...1A 46 1972 PONTIAC SERVICE MANUAL Fig 1A 44 Typical A C Mode Air Flow Fig 1A 45 Typical Bi Level Mode Air Flow...

Page 106: ...with some air from defroster nozzles b Compressor is running 4 Move selector lever to BILEVEL and temperature lever to mid travel a Air flows from both heater and air conditioning outlets b Air condit...

Page 107: ...g joints use another wrench to hold stationary part of the connection so that a solid feel can be attained This will indicate proper assembly CAUTI0NI Tighten all tubing connections as shown in Fig IA...

Page 108: ...re gauge and connect this adapter fit ted hose to discharge gauge fitting 3 Attach a flexible gauge hose to center fitting of the gauge set and attach the other end of this hose to vacuum pump J 5428...

Page 109: ...the vacuum applied to the discharge side of the system will suck oil into system from container Therefore close observation of oil level in the container is necessary e Note level of oil in container...

Page 110: ...ng of fusi ble safety plugs in the refrigerant drum It may not be necessaryto use hot water if a large drum is used over approximately 100 Ibs 3 Place refrigerant drum in pail of water on scales bathr...

Page 111: ...r from thermal limiter connector ter minals check superheat switch terminal to ground for open switch no continuity and connect limiter DISPOSABLE CAN METHOD After having depressurized repaired if nec...

Page 112: ...auge line for three seconds then connect low pres sure gauge line to low pressure gauge fitting on P O A valve Place J 9459 adapter on hose then attach adapter to gauge fitting CHARGING THE SYSTEM 1 W...

Page 113: ...amounts of 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 and...

Page 114: ...requires 11fluid ozs of 525 viscosity oil After the system has been operated oil circulates throughout the system with the refrigerant Hence while the system is running oil is leaving the compressor...

Page 115: ...part Add one ounce of refrigerant oil to new receiver and install in system FLUSHING SYSTEM Flushing can be accomplished by connecting a refrigerant drum to the unit to be flushed and then turning the...

Page 116: ...LIGN END OF HOSE WlTH BEAD ON TUBE COAT END OF TUBE WITH REFRIGERANT OIL VIEW A TYPICAL OF HOSE O RING SEAL COAT WlTH SEAL INSTALLATION CONDENSER DEHYDRATO CLAMPING ENDS 750 CLEARANCE VIEW B E V A T O...

Page 117: ...ANT O I L TYPICAL O RING SEAL INSTALLATION ALIGN E N D OF HOSE WlTH BEAD ON TUBE COAT E N D OF TUBE WlTH REFRIGERANT 0 1 L LAMP ALIGN CLAMP TAB WlTH E N D OF HOSE TYPICAL C L VIEW P Fig 1 A 5 0 A a n...

Page 118: ...CUSTOM AIR CONDITIONING 1A 59...

Page 119: ...Fig 1A 52 Refrigeration System F Series...

Page 120: ...TEN REFRIGERANT HOSE CLAMPS T O 35 45 LB IN DEHYDRATOR Fig 1A 53 Refrigeration System X Series 3 5 0 Engine RIVET 4 FT FT FT FT FT 1 O RING GASKET COAT WITH O c L m N REFRlGERAm OIL Fig 1A 53A Refrige...

Page 121: ...ulation of oil from compressor to other components of system will require adjustment of the oil charge in the new compressor as explained under RE PLACING COMPONENTS OTHER THAN COM PRESSOR After drain...

Page 122: ...1 Connect the high and low pressure gauge lines from the gauge set to the respective connections on the P O A valve and compressor Disconnect thermal limiter connector and jumper terminals B and C Be...

Page 123: ...ieved remove screw fittings assembly and O ring seals 6 Immediately cover all openings in compressor and rest of system A simple way to cover compressor openings is with a plate similar to the one on...

Page 124: ...CUSTOM AIR CONDITIONING 1A 65...

Page 125: ...1A 66 1972 PONTIAC SERVICE MANUAL...

Page 126: ...sary cleanfiont of 9 Drain all oil from compressor just removed into a clean dry container and replace compressor drain plug screw Measure amount of oil drained See CHECKING COMPRESSOR OIL LEVEL AND A...

Page 127: ...y Outer Oil Pump Gear Rear Discharge Valve Plate Assembly Rear Suction Reed Piston Did Piston Ring 7Shoi I Discharge Crossaver Tube Thrust Rac Front Cylinder Half I 1 I I I 1 I I I I I I I r o h Sucti...

Page 128: ...limiter connector and connect thermal limiter COMPRESSOR HUB AND DRIVE PLATE ASSEMBLY REMOVE AND REPLACE REMOVE 1 Hold the clutch hub with J 9403 wrench and using J 9399 special thin wall 9 16 socket...

Page 129: ...drive plate assembly onto shaft approximately 1 4 Remove tool and look into armature plate hub to make certain key remains in place Install J 9480 01 and press until there is approxi mately 002 057 1...

Page 130: ...xisting pulley and drive plate and hub assembly are to be reused clean the drive faces on each part with al cohol or similar solvent If these parts show evidence of warpage due to overheating they sho...

Page 131: ...r Ring 6 Remove coil housing assembly REPLACE 1 Position clutch coil on compressor front head casting so electrical terminals are in their proper location as previously scribed on compressor body Make...

Page 132: ...AND ADD ING OIL Compressor shaft seals unless replaced during a compres sor overhaul are to be replaced only on the basis of actual refrigerant leakage as determined by test with a propane torch or el...

Page 133: ...Install new seal seat retainer ring using J 5403 No 21 pliers with flat face against seal seat The sleeve from J 9393 may be used to press on retainer ring so that it snaps into place Remove seal pro...

Page 134: ...ould be used whenever it is necessary to overhaul or rebuild the entire compressor internal mechanism or when replacing some individual internal part OVERHAUL PREPARATIONS Anytime a major overhaul or...

Page 135: ...Remove seal assembly by pulling straight out from shaft Remove O ring from interior of front head casting bore Remove oil pick up tube and O ring using a wire with a hook formed in one end or J 5139...

Page 136: ...own in Fig 1A 80 Use care so that discharge crossover tube is not damaged by swash plate Separate front and rear cylinder assemblies being careful not to damage any parts during separation Remove rear...

Page 137: ...bearings 2 Stack a ZERO thrust race a new thrust bearing and a second ZERO thrust race Assemble this sand wich of parts to FRONT end of compressor main shaft 3 Place FRONT half of cylinder on J 9397 c...

Page 138: ...this assembly Fig 1A 87 Installing Rear Cylinder Half on Front Cylinder Half 12 Align rear cylinder casting with bores suction pas sage discharge crossover holes dowel pins etc Tap into place using a...

Page 139: ...l correspond to the last three numbers of the part number of the part to be used RUNNING CLEARANCE 0003 0013 MEASURED WlTH DlAL INDICATOR CHECKING FOR REAR THRUST AND RACE THICKNESS I J 93 COA FlXT I...

Page 140: ...tion of thrust races or shoes is made and the tolerance is GREATER than the maximum clearance noisy operation of the com pressor will result If the tolerance is LESS than the minimum clearance it is l...

Page 141: ...s inside of compressor for swash plate clearance Fig 1A 94 Installing Service Discharge Crossover Tube I O SERVICE DISCHARGE CROSS OVER TUBE KIT Fig 1A 95 Installing Service Discharge Crossover Parts...

Page 142: ...ace compressor shell with J 9396 holding fixture in vise so shell is up Examine FRONT FRONT HEAD Fig 1A 97 Installing Front Head Casting Fig 1A 98 Installing Compressor Shell corners of oil baffle to...

Page 143: ...Fig 1A 100 with head and install head REPLACING REAR HEAD ASSEMBLY 1 Generously oil valve plate around outer edge where large O ring will be placed Oil valve reeds pump gears and area where teflon ga...

Page 144: ...may be used to install the retainer press and tap with a mallet set ting the retainer and sleeve into place until the outer edge of the retainer is recessed approximately 1 32 from the face of the co...

Page 145: ...witch housing with clean refrig erant oil and carefully insert switch into switch cavity until switch bottoms in cavity 5 9393 seat seat remover and installer may be used to install the switch NOTE Sw...

Page 146: ...ean compressor oil 7 Evacuate and charge system For P O A Valve installation refer to Figs 1A 103 B Series 1A 104 G Series 1A 105 A Series 1A 106 F Series and 1A 107 and 1A 107A X Series EXPANSION VAL...

Page 147: ...r bame 5 screws 4 Remove hood latch and support brace Remove LH headlamp filler panel support 2 screws 5 Disconnect receiver outlet Disconnect refrigerant hose at lower condenser tube and cap openings...

Page 148: ...IR CONDITIONING 1A 89 P O A VALVE Fig 1A 106 F Series Evaporator and Blower Assembly O RING SEAL COAT WITH REFRIGERANT EVAPORATOR CORE A N D CASE Fig 1A 107 X Series P O A Valve Installation with 3 5...

Page 149: ...1A 90 1972 PONTIAC SERVICE MANUAL Fig 1A 107A X Series Evaporator and Blower Assembly with 3 0 7 Engine Fig 1A 108 Condenser Mounting B Series...

Page 150: ...d latch support 7 Remove 4 condenser mounting nuts Fig 1A 110 8 Loosen top of radiator to allow clearance of con denser pipes raise front of car and remove condenser from below car 9 Cap all openings...

Page 151: ...rigerant oil 8 Evacuate and charge system Connect thermal li miter CONDENSER ASM O RING SEAL COAT WITH REFRIGERANT 0 1L 11 13 LB FT DEHYDRATOR 7 30 40 LB IN Fig 1A 113 Receiver Dehydrator Mounting A a...

Page 152: ...n valve thermo bulb and remove clamps 5 Remove screw retaining expansion valve to bracket 6 Remove screws retaining P O A valve to bracket 7 Remove screws and nuts retaining left half of case inboard...

Page 153: ...1A 94 1972 PONTIAC SERVICE MANUAL Fig 1A 1 16 A and G Series Evaporator Core and Case Installation Fig 1A 1 17 F Series Evaporator Core and Case Installation...

Page 154: ...low removal of case 3 Remove case and carefully reseal when replacing REMOVE AND REPLACE F SERIES For removal and replacement of the left evaporator case half follow procedure for evaporator core repl...

Page 155: ...ve blower motor Pry motor flange gently if sealer acts 3 Remove 3 nuts and one screw retaining core and case as an adhesive assembly to dash 8 Remove impeller retaining nut and separate impeller 4 Rem...

Page 156: ...ses attached to heater core 3 Remove lower duct and outlet assembly 4 Remove glove box 5 Remove defroster duct attaching screw 6 Remove screws retaining case to dash 7 Move core and case assemblyrearw...

Page 157: ...1A 98 1972 PONTIAC SERVICE MANUAL...

Page 158: ...e if equipped If equipped with con sole and tape player remove consolewith tape player intact If equipped with tape player and no console remove tape player 15 Disconnect temperature cable at heater c...

Page 159: ...5 Loosen hose clamp and disconnect lower heater hose from core pipe Remove lower right hand heater core and case assembly attaching nut 6 Install plugs in heater core pipes to prevent spilling coolant...

Page 160: ...CUSTOM AIR CONDITIONING 1A 101...

Page 161: ...and connections 2 Remove cowl vent grille 3 Remove plenum diaphragm assembly to plenum chamber attaching screws Fig 1A 129 PLENUM AIR INLET DOOR DIAPHRAGM REMOVE AND REPLACE F SERIES 4 Disconnect vac...

Page 162: ...Remove two retaining screws and actuator link re taining screw 4 Remove vacuum hose then diaphragm 5 To replace reverse removal procedure AIR INLET DIAPHRAGM REMOVE AND REPLACE EXCEPT X SERIES 1 Remo...

Page 163: ...A P H R A G M r CHECK 4 APoRAToR CORE AND CASE TEMPERATURE CAB LET VlEW D SEE 1Vl EW C VlEW B h RETAINER 7 U VlEW C HARNESS YELLOW SEE VlEW C VlEW A Fig 1A 126 F Series Control Cable and Vacuum Harne...

Page 164: ...hold down screws 5 Remove cam 6 To replace reverse removal procedure 7 Adjust cable 2 Remove glove compartment and disconnect cable at heater case 3 Disconnect cable at control panel On B Series remo...

Page 165: ...d rotating in the other direction shortens the sleeve Adjustment is to be made after cables are securely con nected at both ends and routed smoothly and free of bends and or kinks B SERIES 1 Place tem...

Page 166: ...tly short of end of slot 4 If cam is not at end of slot or if lever is more than 1 8 inch from end of travel repeat steps 2 and 3 until cable is properly adjusted F SERIES 1 Place control panel temper...

Page 167: ...ing screws nuts on A Series 6 Lower control panel assembly 7 Disconnect temperature control cable and remove control 8 TOreplace reverse removal procedure See installa tion of control panels on Figs 1...

Page 168: ...SWITCH VIEW A C O N T R O L P A N E L LOW BLOWER SWITCH A I C WIRE HARNESS TEMPERATURE C A B L E C A B L E DEFROSTER C A B L E VIEW C A I R O U T L E T VIEW B Fig 1 A 1 3 2 A C Control Panel Installa...

Page 169: ...L SUIIPIPORT BIRIAlCKET SWITCH F O L D BACK Gl3W Y T O WATER SHUITADFF V A L V E BLAlCK N O T USIED R H C Y L I N D E R T H E R M A L SWITCH EVAPORATOR A N D BLOWER ASM COVE R Fig llA 133 Engire bmpa...

Page 170: ...Fig 1 A 1 3 4 B Series A C Wire Harness Routing...

Page 171: ...panel and remove control panel 5 To replace reverse removal procedure MASTER SWITCH REMOVE AND REPLACE F SERIES 1 Perform steps 1 through 4 of procedure for A C control panel 2 Remove switch knob fro...

Page 172: ...OVE AND REPLACE B SERIES 1 Disconnect battery 2 Remove cold air duct 3 Remove glove compartment and door 5 Remove harness from clips retaining harness to in strument panel 6 Underhood disconnect elect...

Page 173: ...A 137 8 To replace reverse removal procedure REMOVE AND REPLACE X SERIES X Series in car A C wiring can be easily removed by referring to Fig 1A 138for harness connections and rout ing For remainder o...

Page 174: ...1A 142A X Series with 307 engine for harness routing and electrical connections A C AMBIENT SWITCH WlRE HARNESS REMOVE AND REPLACE B SERIES 1 Remove RH headlamp filler panel support bracket screws to...

Page 175: ...IAC SERVICE MANUAL1 MASTER RELAY G SERIES WITH ATC ONLY A C BLOWER MOTOR BLOWER RESISTOR Fig 1A 139 A C Underhood Main Wire Harness A and G Series V 8 Fig 1A 140 A C Underhood Main Wire Harness A Seri...

Page 176: ...duct on A Series Fig 1A 147 On G Series Fig 1A 146 a fourth screw attaching the cold air duct and left extension duct must also be removed LEFT HAND LOWER A C DUCT REMOVE AND REPLACE F SERIES 1 Remov...

Page 177: ...Fig 1A 142 A C Compressor Engine Wire Harness Routing V 8 Engine Except 307...

Page 178: ...CUSTOM AIR CONDITIONING 1A 119...

Page 179: ...1A 120 1972 PONTIAC SERVICE MANUAL...

Page 180: ...CUSTOM AIR CONDITIONING 1A 121...

Page 181: ...1A 122 1972 PONTIAC SERVICE MANUAL...

Page 182: ...Fig 1A 147 A Series A C Air Distribution Ducts...

Page 183: ...Disconnect battery 2 Remove lower instrument panel trim and upper trim plate 3 Remove lower left hand A C duct 4 Remove steering column support bracket 4 bolts 11 Remove 3 upper I P screws at cluster...

Page 184: ...TIONING 1A 125 INST PANEL OPENING MPARTMENT A C ADAPTER R H A C OUTLET COLD AIR DIST DUCT UPPER A C ADAPTER I OUTLET L H AIC OUTLET EXTENSION SPACER VIEW A VIEW B VIEW C Fig 1A 149 A C Air Distributio...

Page 185: ...pening Fig 1A 148 7 To replace reverse removal procedure 1 Remove cold air duct 2 On A Series remove radio 3 Remove control panel 4 Remove screws attaching duct to outlet adapter 2 screws on G Series...

Page 186: ...GLOVE BOX ADHESIVE APPLIED 3 PLACES AS INDICA VIEW B TYPICAL BOTH BEZELS Fig 1A 15 1 F Series Air Distribution Outlets...

Page 187: ...nozzle may then be removed by inserting a screwdriver into the nozzle and disengaging these retainers pulling the nozzles out toward rear of car and removing screw which holds duct to nozzle OUTLET N...

Page 188: ...Series Programmer 1B 56 Programmer Amplifier 1B 57 Gear Inspection 1B 57 Programmer Wheel 1B 57 Power Resistor 1B 58 Bi Level Boost Switch 1B 58 B SERIES ATC DIAGNOSIS ATC TESTER J 23678 Automatic Tem...

Page 189: ...not the temperature dial clutch should be held and the dial slipped to read the correct temperature see Temperature Dial Calibration Proce dure The Temperature Dial Calibration switch should always be...

Page 190: ...AUTOMATIC TEMPERATURE CONTROL 1B 3...

Page 191: ...rounded and or terminal 2 has no battery voltage ap plied to it Trace appropriate wire to find mal function in car ATC electrical system See Fig 1B 2 10 Plug the tester dummy vacuum plug on the progra...

Page 192: ...ELLOW HTRANSDUCER PROGRAMMER BLACK RESTRICTOR 1 2 MIN OA TO RECIRC 4 8 MIN RECIRC TO OA 4 GRAY HOT WATER CONTROL VALVE I I VAC CLOSED i i J VENT oPEN r i 1 VACUUM I I RESERVE I I T A N K L J Fig 1 B 3...

Page 193: ...1B 6 1972 PONTIAC SERVICE MANUAL 320 o a z...

Page 194: ...WATER SHUT OFF PROGRAMMER AND CASE ASM ATC 11 11 I 11 WHITE LT GREEN DARK GREEN BLACK J Fig 18 5 B Series ATC Vacuum Hose Diagram...

Page 195: ...the transducer and the rotary vacuum valve Refer to Fig 1B 6 for identification of all programmer compo nents Equipment required D C power supply rated at 5 amperes at 12 volts J 23678 Automatic Tempe...

Page 196: ...2V VACUUM I HOT VALVE 4 RECIRC D o o n 7 LOWER MODE SIGNAL VALVE a VAC SUPPLY INPUT I MODE I N P U T 8 UPPER M O D E DOOR 11 LEVEL PORTS 3 N C I M INPUT 6 UPPER M O D E DOOR N O Dl LEVEL 9 CHECKED V A...

Page 197: ...supply hose If proper vacuum is pre sent restore hose connection If 20 inches Hg or more vacuum is not present check the vacuum sup ply vacuum level and then go to Steps 14through 17 to check for vacu...

Page 198: ...IC I I I I AIR INLET DOOR PORT 4 OlA CLOSED I I HEATER WATER VALVE PORT 1 OPEN AlC I I MODE PORT 8 A C OR BI LEVEL 1 MODE PORT I 7 HEAT INPUT RESISTANCE AT TERMINAL 3 TO GROUND IN OHMS Fig 16 8 Typic...

Page 199: ...position Rotate the Manual Control knob to the MAX HEAT position The voltmeter reading should be 12 volts D C supply voltage As the Manual Control knob is slowly rotated toward MAX COLD at about 175...

Page 200: ...nalconnectors 3 terminals are not used of the tester to the corresponding con nectors of the J 22684 51 adapter TEMPERATURE LEVER CALIBRATION Before proceeding with the various readings the tempera Fi...

Page 201: ...l l dA b l IWITC LOC IION I l L I l l l l CHICI I Y I S I I I I I IWITC I VOL C I I IC D I ICE lF 1 A W W VOLIAG II I I II NO V a l A O l I S U B TROUBLE SHOOTING CARD LACK IlNClt SO I01 LIAD U1TZ1 V...

Page 202: ......

Page 203: ...use from alternator Programmer Master Relay C Control Panel Vacuum Valve Air Inlet Door Dual Diaphragm D Fuses Master Relay Resistor Block Blower Range Switch Blower Motor Programmer Water Control Val...

Page 204: ...OACHES THE MAXIMUM COLD POSITION ENGINE VACUUM SOURCE NORMAL POSITION OPERATING I N BI LEVEL ENGINE VACUUM SOURCE U THESE LINES WlLL CHANGE TO VENT PUllING THE AIR DOOR AT 50 INSIDE AIR WHEN THE PROGR...

Page 205: ...ATING I N BI LEVEL THIS LlNE WlLL CHANGE TO VENT AND SHUT T H E WATER VALVE OFF WHEN PROGRAMMER APPROACHES T H E MAXIMUM COLD POSITION ENGINE VACUUM 1SOURCE INSIDE POSITION OPERATING I N A C DEFROST P...

Page 206: ...H I I I V SYSTEM IV DEFROST 1 I AIR INLET DOOR DOES NOT G O TO FULL OUTSIDE AIR POSITION 1 I V SYSTEM I N N O R W L SET TEMPERATME CONTROLTO 75 ALLOW SYSTEMTO STABLIZE I VI A RETURN BLOWER RANGE SWITC...

Page 207: ...1 NO VACUUM REPLACE CONTROL PANEL VACUUM VALVE I I VOLTAGE BELOW 6V S E E PROGPAMMER DIAGNOSIS m I INSERT OTHER PROBE INTO BLACK WlTH DOUBLE ORANGE STRIPE WlRE O N MASTER RELAY 1 I 1 T E S T LlGHT LI...

Page 208: ...ROBE INTO BLACK WlTH SINGLE WHITE STRIPE WlRE AT HI BLOWER RELAY I I D HI BLOWER RELAY SHOULD PICK UP I I r l REPLACE HI BLOWER RELAY E USING A I 2 VOLT TEST LAMP OR A VOLTMETER WITH ONE PROBE TO GROU...

Page 209: ...ACUUM I VACUUM REPAIR OR REPLACE BLUE HOSE TO DEFROSTER AS NECESSARY I I TEST I VACUUM TO DEFROSTER DOOR REPLACE DEFROSTER DOOR DIAPHRAGM CHECK FOR BINDING DOOR I N O VACUUM REPLACE CONTROL PANEL VACU...

Page 210: ...modulate cool ing to whatever degree is required to maintain constant comfort In mild weather the interior of the vehicle re mains comfortable without having to reset controls In cold weather the syst...

Page 211: ...LL BEARINGS I N PROPER POSITIONS 1 1 REPLACE GEARS I IF WORM GEAR DEFECTIVE MOTOR MUST B E REPLACED I CHECK TO INSURE PIN OF VACUUMVALVE IS LOCATED I N GROOVE OF WHEEL IT WILL B E NECESSARY TO REMOVE...

Page 212: ...sting the signal to the programmer amplifier to compensate for in car tempera ture changes TO COWL AREA FROM HEATER CASE FROM IN CAR SENSOR J FROM HEATER CASE Fig 16 23 Aspirator B SERIES DESCRIPTION...

Page 213: ...in the RUN position The blower runs at lo blower speed and outside air is distributed into the passenger compartment of the car through the A C out lets See Fig 1B 25 LO Position With the control hea...

Page 214: ...head selector lever in the DEFROST position the system comes on immediately when the igni tion switch is turned on The fan is locked on hi blower speed and all of the air is distributed from the defr...

Page 215: ...and to the rotary vacuum valve on FROM TRANSDUCER TO VACUUM MOTOR ENGINE VACUUM INPUT CHECKED VACUUM OUTPUT Fig 16 29 Checking Relay Open I FROM TRANSDUCER r TO VACUUM MOTOR ENGINE VACUUM INPUT CHECKE...

Page 216: ...AUTOMATIC TEMPERATURE CONTROL 1B 29...

Page 217: ...ntering the amplifier ELECTRICAL SYSTEM OPERATION OFF Position When the control head selector lever is in the OFF posi tion 1B 32 the system is locked in LO blower operation when the ignition switch i...

Page 218: ...AUTOMATIC TEMPERATURE CONTROL 1B 31...

Page 219: ...1B 32 1972 PONTIAC SERVICE MANUAL...

Page 220: ...AUTOMATIC TEMPERATURE CONTROL 1B 33...

Page 221: ...1B 34 1972 PONTIAC SERVICE MANUAL...

Page 222: ...at Lo blower speed The programmer is in the maximum A C LO Position When maximum cooling is required cold air is distributed from the A C outlets The blower is locked on Lo blower speed Recirculation...

Page 223: ...1972 PONTIAC SERVICE MANUAL...

Page 224: ...AUTOMATIC TEMPERATURE CONTROL 1B 37...

Page 225: ...1B 38 1972 PONTIAC SERVICE MANUAL...

Page 226: ...nozzles at the same time DEFROST MODE Air flow is from defroster nozzles with slight air flow from heater outlet and no air flow from A C outlets LO BLOWER Lowest available blower speed This speed is...

Page 227: ...mpressor 7 Move selector lever to HI A Blower operates at high speed Air flow and tem perature remain same as step 6 B Step assures Hi blower mode control tempera ture control and operational compress...

Page 228: ...ate system operation The air control lever system selector lever selects the mode of operation desired by the opera tor In all but extreme conditions the Normal mode will be exclusivelyselectedfor max...

Page 229: ...hich requires a greater quantity of air movement The remainder of the electrical components such as the hi blower relay compressor clutch coil line and fuse block fuses and ambient switch all function...

Page 230: ...initial settings are made it is not necessary to turn the windshield SERVICE PROCEDURES The refrigeration portion of the ATC system is the same 5 Remove sensor as the Custom Air Conditioning system an...

Page 231: ...p Fig 18 43 G Series ATC In Car Wiring...

Page 232: ...Fig 18 44 B Series ATC Wire Harness Routing...

Page 233: ...VIEW A Fig 18 45 B Series ATC Vacuum Harness and Control Panel Installation...

Page 234: ...R ASM VlEW A ASPIRATOR H0sE76_0R I P PAD A N D VIEW C RETAINER ATC VACUUM HARNESS ASPI RATOR b VlEW B AIR INLET AND VALVE ASM CONTROL PANEL J L Fig 18 46 G Series ATC Vacuum Harness and Programmer Ins...

Page 235: ...ual with the addition of disconnecting and connecting the vacuum connec tor at the programmer rotary vacuum valve Vacuum hose harness routing is illustrated in Figs 1B 45and 1B 46 for B and G Series r...

Page 236: ...TCH 1 6 DE ICE SWITCH 2 8 MASTER RELAY VlEW A r TEMPERATURE TEMPERATURE DOOR MUST BE HELD FIRMLY AGAINST STOP DURING SETTING TO INSURE PROPER DOOR ANGLE SET TOOL J 22667 01 L K VlEW B ASM PROGRAMMER B...

Page 237: ...ervicing in dividual components VARIABLE RESISTOR POTENTIOMETER G SERIES Two methods of adjusting the temperature control varia ble resistor are available Use the first method to adjust the unit in th...

Page 238: ...IAL LIGHT SOCKET MTG L SELECT SWITCH FUNCTION AUTO F 1 A B A B F 1 D G 0 VIEW A B L i A B F I DEFST 1 A B C F I D G PACKARD CONN WIRE CONNECTION CONNECTION COLOR Fig 18 50 B Series Control Panel Outli...

Page 239: ...N 5 5 1 OUTSIDE AIR OPEN CONN 4 CONN 4 1 CONN 6 CONN 4 CONN 4 6 i PROGRAMMER 3 1 SEAL 1 SEAL I CONN 5 SEAL 1 S E A L 7 I PROGRAMMER f 1 1 VENT VAC I I I I I I b INPUT V AC I I I I t I t 9 I PROGRAMMER...

Page 240: ...PARE button pressed in rotate the temperature dial on the control panel until the voltm eter reading is the same as it was in step 5 button not pressed in The control panel temperature dial should be...

Page 241: ...t valve drive arm off of vacuum motor mechanism boss when removing valve To replace reverse removal procedure Make certain vacuum valve spring is in place Refer to Figs 1B 54 and 1B 55 t Fig 18 54 Int...

Page 242: ...from port on motor 4 Remove 2 motor retaining screws and remove mo tor lifting upward WWEW SPRING Fig 78 58 Vacuum Motor and Power Spring 5 To replace reverse removal procedure See Figs 1B 57 and 1B...

Page 243: ...uit board 3 Remove 3 electrical terminals from programmer electrical connector body 4 To replace reverse removal procedure See Figs 1B 60 and 1B 61 G SERIES PROGRAMMER REMOVE AND REPLACE 1 Disconnect...

Page 244: ...ng screw in hub of wheel and remove potentiometer clip Programmer wheel may now be slipped off 4 To replace reverse removal procedure GEAR INSPECTION 1 Remove programmer wheel as previously described...

Page 245: ...ve is visible through alignment hole in wheel Fig 1B 65 It may be necessary to move the vacuum valve slightly to accomplish this Install potentiometer clip and rotate so that scribe marks made previou...

Page 246: ...ost type hoists with hoists or lifts mak ing contact with front suspension lower control arms or rear axle Since the frame is perimeter type some hoists designed to contact side rails require adapters...

Page 247: ...bber mounts see Figure 2 5 F X SERIES The frame is isolated from the unitized body by means of soft butyl rubber mounts refer to Fig 2 3 FRAME IDENTIFICATION The manufacturer s identification is stamp...

Page 248: ...NT BODY MOUNT NO 1 NO 2 BODY MOUNT NO 3 SUPPORT AND SPEC WASHER INSTALL AS SHOWN JYPICAL SECTION THRU BODY MOUNT BAFFLE BOD BODY BODY DRIFT HOL NO 2 BODY FRAME w 8 L H SIDE SHOWN R H SIDE THE SAME Fig...

Page 249: ...4 1972 PONTIAC SERVICE MANUAL LOWER FLANGE B SERIES SWB B SERIES LWB STATION WAGON H J K L A SERIES 4 DOOR MODELS 41 30 A SERIES 2 DOOR MODELS A SERIES STATION WAGON 41 30 Fig 2 4 Frame Alignment Char...

Page 250: ...MOUN B Series Exc Station Wagon Heavy Duty Chassis I B Series Station Wagon A Series 4 Dr Exc Station Wagon B Series Heavy Duty Chassis A Series 2 Dr LeMans G Series G N H M M F J MOUNT UPPER LOWER 1...

Page 251: ...2 6 1972 PONTIAC SERVICE MANUAL MANUFACTURER CODE PARRISH P A 0 SMITH BUDD B MANUFACTURER IDENTIFICATION LOCATION ON LEFT REAR SIDE RAIL F i g 2 6 F r a m e Identification...

Page 252: ...or Brake Application 3 4 Car Pulls to Right or Left 3 4 Car Wanders 3 5 Shock Absorbers 3 5 General Description 3 11 Shock Absorbers Description 3 12 Operation 3 12 Suspension Alignment 3 13 Caster 3...

Page 253: ...ngs incorrectly adjusted or worn c Adjust or replace parts as necessary d Uneven camber d Check camber and adjust as necessary e Toe in incorrect e Adjust toe in as required f Tires out of balance f B...

Page 254: ...Bleed tires to recommended pressure but not when warm b Install new tires of correct type and size c Adjust or replace bearings as necessary d Adjust steering gear and connections Refer to Section 9...

Page 255: ...roximately the same at both wheels Compare dimensions with those on car having about same mileage and equipment and believed to be standard Replace front springs if sagged f Check and adjust caster as...

Page 256: ...S Follow the Procedures Outlined Below in the Order In dicated I Preliminary lnspection and Ride Test a Tire Pressure Check tire pressure to vehicle specifications and ad just as required Poor vehicle...

Page 257: ...sed by internal noise in the shock weak leaking etc 1 lnspecting Shocks for Possible Loss of Hydraulic Fluid a Disconnect each shock lower mounting as re quired and pull down on the shock until it is...

Page 258: ...rocedures are discussed for two general types of shocks Refer to Figures 3 3 and 3 4 I Spiral Groove Reservoir 11 Superlift I Spiral Groove Reservoir The spiral groove reservoir type shock is installe...

Page 259: ...3 8 1972 PONTIAC SERVICE MANUAL TROUBLE DIAGNOSIS Continued p Fig 3 3 Spiral Groove Reservoir Shock Absorber Fig 3 4 Superlift Shock Absorber...

Page 260: ...sition top end down If when stroked a lag is notices it means the gas filled cell has been ruptured and the shock should be re placed If no lag is noticed the remainder of the bench check is the same...

Page 261: ...ncorrect shock d Secondary or rough roads 7 Low or Uneven Trim Height CORRECTION None Normal condition 11 C 1 None Normal condition gives appearance of leak 11 C 1 Locate source and correct 11 C 1 Rep...

Page 262: ...ct bottom end and stroke shock Replace if binding Bounce test 11 A replace one 1 shock is noticeably weaker than mate GENERAL DESCRIPTION Independent front suspension is used on all models Fig An inte...

Page 263: ...e located between each frame side rail and lower control arm Sealed direct acting double action shock absorbers are located inside each front coil spring Maximum full compression or rebound travel of...

Page 264: ...at curb weight and height see Curb Height chart in Section 0 so that suspension components can properly function together when vehicle is moving to minimize tire wear and maintain desirable steering...

Page 265: ...ns the amount of angle movement TOE IN Toe in is a measurement of the difference between the front and rear edges of the front tires as viewed from the top side of the front suspension system Fig 3 11...

Page 266: ...eel and tire assembly off ground by supporting the lower control arm with a floor jack Raise wheel and tire high enough so rubber rebound bumper is not touching the upper control arm or frame Examine...

Page 267: ...of ball stud NOTE Instead of using a pry bar the PRE FERRED METHOD using toolJ23742 1 can be used Fig 3 23 Mount a dial indicator using a C clamp and exten sion on lower control arm Position plunger...

Page 268: ...ove cotter pin from spindle and spindle nut 5 Adjust bearing as shown in Fig 3 16 6 Insert cotter pin and bend ends against nut cut off extra length to ensure ends will not interfere with dust cap Fro...

Page 269: ...ell within the range of safe vehicle operation In the event the actual settings are beyond the specifica tions set forth in column 1 or 2 whichever is applicable or whenever for other reasons the alig...

Page 270: ...plac ing shims between the upper control arm shaft and the frame support Fig 3 17 Both adjustments can be made at the same time In order to remove or install shims loosen the control arm shaft to fra...

Page 271: ...oor at front of wheels I UPPER CONTROL ARM RACKET CikI EACH Fig 3 17 Caster Camber Shims A G Series Shown 3 Push car forward never backward until chalk mark with trammel marks is 9 above floor at rear...

Page 272: ...ount until toe in is set at proper specification CAUTION Discard the nut and bolt ofan ad juster sleeve clamp ifrusted and afterbreaka way nut starts to turn the removal torque of thenut exceeds 716 f...

Page 273: ...between race and spindle Fig 3 13 11 If necessary to replace an outer race drive out old race from the hub with a brass drift inserted behind race in notches in hub Install new race by driving it int...

Page 274: ...ing 9 Use a bearing lubricator if available and thoroughly lubricate bearing assemblies with new high melting point wheel bearing lubricant Remove any excess lubricant NOTE Be sure bearing parts have...

Page 275: ...PPER ARh4 BRACKET kNuT PART OF FRAME RETAINER COIL SPRING SHOCK AbSORbER LOWER A M ASS V i LSCREW ASS Y Fig 3 19 Shock Absorber Installation be tightened until it bottoms at end of steel threads 2 Tig...

Page 276: ...lower control arm bushings Fig 3 21 NOTE When positioning spring tool under lower controlarm bushings on some models it is necessary to tilt the tool at a slight angle to provide clearance to let con...

Page 277: ...t studs from steer ing knuckle by prying on control arm using a suitable pry bar and tapping sharply on knuckle in area of ball stud NOTE Instead of using a pry bar the PRE FERRED METHOD using toolJ 2...

Page 278: ...t may be necessary to back offbrake adjustment to remove hub and wheel assembly Disc Brakes Remove brake caliper assembly before removing cotter pin spindle nut and washer from CAUTION Whenhuband disc...

Page 279: ...ng on control arm using a suitable pry bar and tapping sharply on knuckle in area of ball stud NOTE Instead of using a pry bar the PRE FERRED METHOD using tool J 23742 1 can be used Fig 3 23 4 Remove...

Page 280: ...both ends of shaft CAUTION Do not tighten nuts until control arm is installed on car and is in normal curb height position SOCKEl Fig 3 25Installing Upper Control Arm Bushing LOWER CONTROL ARM REMOVE...

Page 281: ...nstall bushing removal tools Afier bushings are replaced reposition control a m to frame and installpi vot bolts tighten bolts to proper torque with control arm at curbheightposition Use toolJ 23028 t...

Page 282: ...ball joint assembly to control arm and drive out rivets I WARNING THIS KEEPS SPRING COM PRESSED INSTALL 2 Remove wheel and tire assembly 3 Remove ball joint stud from steering knuckle by pry ing on co...

Page 283: ...Remove lower ball joint stud from steering knuckle by prying on control arm using a suitable pry bar and tapping sharply on knuckle in area of ball stud NOTE Instead of using a pry bar the PRE FERRED...

Page 284: ...e except B F Series 80 holenot to exceed 11016 ft on B Series or 100 1b ft on A G F X Series 4 B F Series Install brake caliper assembly see STEERING KNUCKLE AND OR STEERING KNUCKLE ARM INSTALL steps...

Page 285: ...1 112 9116 Toe In t o Cross Caster Cross Camber 1 1 2 112 0 112 118 1 16 3116 Toe Out l 0 t o I 0 1 4 to 1 314 1116 t o 5116 X Series See explanatory copy in Front Suspension Section 112 112 1 lo Cast...

Page 286: ...Control Arm Bushing 21894 2 installer Remover Installer J 9502 3 C Washer Upper Control Arm Bushing J 22618 Upper Control Arm Torque Wrench J 95 19 7 I Adapter J 9519 10 J 23028 Front Coil Spring Rem...

Page 287: ...es Car Too High When Car is Unloaded 4 3 Automatic Level Control Raises Car When Loaded But Leaks Down Only When Car is Driven 4 3 Quick Check of Automatic Level Control System 4 4 Automatic Level Con...

Page 288: ...water If air bubbles appear repair leak d Remove Superlifts from car and immerse in water with air pressure applied to Superlift If air bubbles appear Superlift is leaking and should be replaced SUPE...

Page 289: ...down list until problem is corrected CAUSE a Excessive load over axle b Control valve setting incorrect c Low pressure in system CORRECTION a Distribute load shift forward if practical and caution own...

Page 290: ...aptor package J 22695 or equivalent A test gage can be made up by collecting and assembling the following parts 1 Fill valve 2 A tee which has three 1 8 female taper pipe threads 3 One adapter which h...

Page 291: ...te perform Intake Check If Superlifts do not deflate remove exhaust adapter from control valve and hold lever down as in Step 2 Replace adapter 0 ring and filter if this deflates Superlifts Replace co...

Page 292: ...egulator to compress 0 ring d Regulator boot defective internal 0 ring e Diaphragm between first and second stage housings tightening through bolts may correct the leak f Service valve g Test gage con...

Page 293: ...e for optimum handling characteristics Fig 4 4 Two coil springs support the weight of the car in the rear suspension They are retained between seats in the frame and brackets welded to each axle housi...

Page 294: ...d 10 rearward of the spring front eye bushing and its purpose is to dampen out excessiveor unwanted spring oscillations A steil stabilizer shaft is used to improve side roll stability on Formula and T...

Page 295: ...X SERIES ING BRACKET REF Oo 250 UPPER END OF SUPPORT ASM IN VERTICAL POSITION TO 25 REAR OF VERTICAL AS SHOWN POSITION SLIT IN INSULATOR TOWARDS FRONT OF CAR BRACKET 40 LB FT 20 LB FT VIEW A 0 8 Fig 4...

Page 296: ...ad changes The system consists of an air compressor reservoir tank and pressure regulator assembly height control valve link two Super lift rear shocks and flexible air lines See Compressor As sembly...

Page 297: ...it stops operating After reservoir pressure drops due to system air usage the compressor again begins to cycle and replenish the reservoir Fig 4 12 First Stage compression Stroke Pressure balance will...

Page 298: ...l Lever SUPERLIFT SHOCK ABSORBER The Superlift shock absorber is essentially a conventional hydraulic unit with a pliable nylon reinforced neoprene boot acting as an air chamber Fig 4 8 The unit will...

Page 299: ...he link to the height control valve lever and tighten the lever adjustment nut 1 Fill compressor through service valve with air at available line pressure NOTE Do not move control valve lever and 2 Ra...

Page 300: ...ar and test shock absorber action COIL SPRING REMOVE 1 Raise rear of car 2 Remove clip attaching brake hose to frame cross member NOTE Do not disconnect brakeline from con nector 3 a Place jack stand...

Page 301: ...ING SHOCK ABSORBER VIEW A ANCHOR PLATE TIGHTEN WlTH VEHICLE WEIGHT ON SPRINGS TIGHTEN WlTH VEHICLE WEIGHT ON SPRINGS SPRING REF VlEW E FRONT OF SPRING REF VlEW F Fig 4 19 Installation of Rear Suspensi...

Page 302: ...PONTIAC SERVICE MANUAL 5 LB VlEW A R E A R OF SPRING REF VlEW E L H SHOWN R H OPPOSITE 50 LB FT TIGHTEN WITH VEHICLE WEIGHT ON SPRINGS Fig 4 20 Installation of Rear Suspension on F Series Leaf Spring...

Page 303: ...OlL TOWARDS REAR OF CAR WITHIN LIMITS SHOWN 0 FRONT d I 1 11 16 A G SERIES CENTER LINE OF SPRING SEAT FRAME SlDE RAIL REF POSITION SPRING WlTH END OF TOP COlL R H SlDE OF VEHICLE BOTTOM VlEW TOWARDS R...

Page 304: ...ring and position mounting bracket to floor pan CAUTION Be sure tab on spring mounting bracket is indexed in slot provided in the floor pan Positionparking brakecableon topside of spring 4 F X Series...

Page 305: ...ting slot over tab Remove any excess bends in retainer strap before finally bending tab back to lock retainer in position 8 Test dampener retention assuring that no movement exists between strap and d...

Page 306: ...aust sys tem kick under p1peon B Seriesstation wag ons when using an axle engaging hoist Remove nut retainer and grommet or nut and lock washer which attach lower end of shock absorber to spring and s...

Page 307: ...Series Remove the screws securing the spring front mounting bracket to the floor pan 6 F X Series Lower axle assembly enough to permit access to spring front mounting bracket and remove bracket from s...

Page 308: ...or to 55 lb ft on X Series CAUTION Make sureallgrommets and retain ersare correctlyinstalled F XSeries Shock absorber stud must not rotate while tightening nut If necessary usepliers or wrench to hold...

Page 309: ...50 Ib ft torque STABILIZER SHAFT FORMULA TRANS A M X SERIES REMOVE 1 Raise rear of car 2 Disconnect lower end of each support assembly from stabilizer shaft by removing clamping bolts Fig 4 7 View A 3...

Page 310: ...torque on X Series CAUTION Tighten upper end of support as semb y in vertical position to 25 rearward of vertical Fig 4 7 ViewA 3 Tighten support assembly lower end clamping nuts to 20 lb ft torque U...

Page 311: ...ION height when 4ING 1 Raise rear of car 2 Support nose of axle housing with jack stand 3 Remove pivot bolt at axle housing and lift upper control arm to clear boss on axle housing 4 Arrange tools as...

Page 312: ...RING SUSPENSION REMOVE CAUTION If both control arms are to be re placed remove and replace one control arm at a time toprevent the axle from rolling or s11p ping sideways as might occur with both lowe...

Page 313: ...OF FITTING ASM FRAME SIDE FRAME REF T B I N G INSTALLATION OF CLIPS CENTER CONNECTOR ONCENTEROF CROSSMEMBER RAIL REF PPER END OF SHOCK ABSORBER ASM REF VlEW B INSERT TUBING INTO FITTING UNTIL I T BOTT...

Page 314: ...4 28 1972 PONTIAC SERVICE MANUAL J VlEW A VlEW I 3 ITYPICAL FRONT Y I E W D VlEW C TYPICAL Fig 4 35 Installation of Superlift Shock Absorber on B Series Station Wagons...

Page 315: ...OVE 2 Remove bushing using components of tool J 21474 as shown in Fig 4 32 INSTALL 1 Install bushing using components of tool J 21474 as shown in Fig 4 33 2 Install lower control arm see LOWER CONTROL...

Page 316: ...1972 PONTIAC SERVICE MANUAL VIEW H TO COMPRESSOR ASM BOTH SIDES INSERT TUBING INTO FITTING UNTIL IT BOTTOMS BEFORE TIGHTENING NUT Fig 4 37 Installation of Automatic Level Control System on B Series...

Page 317: ...L VALVE ASM SIDE SHOCK VIEW E BRACKET ABSORBER ASM INSTALLATION OF CLIP VlEW B ING FROM COMPRESSOR ASM ACUUM HOSE 0COMPRESSOR LlNE PARALLEL TO CENTER VIEW C LINE OF SPRING VIEW H VIEW G INSERT TUBING...

Page 318: ...5 Inflate system through service valve to maximum available pressure Fig 4 2 DISASSEMBLE The compressor Fig 4 39 is a precision built mechanism that should be carefully handled and assembled Care mus...

Page 319: ...Ring 357 367 I D 41 Seal 569 571 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 48 Arm Assy Distributor 49 Screw 50 Spring Valv...

Page 320: ...boss Do not distort spring NOTE Tension spring has one short foot and one long foot The short foot fits under the distributor valve and the long foot fits into a hole drilled at an angle in the boss s...

Page 321: ...in rocker and swivel arms and install retaining pin small end first CAUTION If distributor mechanism failed to operate properly or one or more parts were found defective use new parts in Distributor V...

Page 322: ...ted in order to affectan air tight seal against the co prene seal 3 Install new 0 rings by rolling into groove Relieve any resulting twist 4 Install new seals using a piece of 02OVshim stock Fig 4 48...

Page 323: ...28 Ib in torque 11 Compressor should be output tested before installa tion on car see COMPRESSOR OUTPUT TEST ON CAR 12 If compressor passes output test install Compressor Reservoir and Regulator Valve...

Page 324: ...4 Nut J 21474 5 Receiver J 21474 8 Upper Lower Control Arm Bushing Remover J 21474 13 Upper Lower Control Arm Bushing Installer J 21474 16 Rear Control Arm Bushing Receiver J 21978 1 Rear Spring Bush...

Page 325: ...noises reported as coming from the rear axle actu ally originate from other sources such as tires road sur faces wheel bearings engine transmission mumer or body drumming A thorough and careful check...

Page 326: ...t rear axle noise when correctly in stalled Check to see that no metallic contact exists between the springs and spring opening in frame or between upper and lower control arm bushings and frame or ax...

Page 327: ...ial is run with wheels off the ground Noise in this area can easilv be confused with rear wheel bearing noise Inspect and replace as required 3 Rear Wheel Bearings A rough rear wheel bearing produces...

Page 328: ...aft is causing vibration drive car through speed range and note speed at which vibration is most pronounced Shift transmission into lower gear range and drive car at same engine speed as when vibratio...

Page 329: ...to crank as shown Leave bolt loose enough to per mit knob to turn 4 Closely inspect tooth pattern on ring gear to deter mine whether pressure lines are apparent If observa tion reveals pressure lines...

Page 330: ...HEEL HEEL DRIVE SIDE COAST SIDE TOOTH PATTERN PINION TOO CLOSE TO RlNG GEAR PINION SHlM THICKNESS EXCESSIVE TOE HEEL DRlVE SlDE HEEL COAST SlDE TOOTH PATTERN PINION TOO FAR AWAY FROM RlNG GEAR PINION...

Page 331: ...will cause the high heel contact on drive side to lower and move toward the toe the high toe contact on coast side will lower and move toward the heel Fig 4A 2F When the pinion is too close to the rin...

Page 332: ...ring is pressed against a shoul der recessed in the carrier Tightening the pinion nut com presses a collapsible spacer which bears against the inner race of the front bearing and a shoulder on the pin...

Page 333: ...axles in A and G Series vehicles are all of the non type C type whereas all other P coded axles are of the C type After determining the axle code from the right hand axle tube reference should be made...

Page 334: ...ntial Pinion Shaft 35 Axle Shaft 6 Ring Gear t o i f f e r e n t i a l Case Bolt 7 Differential Case 8 Rear Pinion Bearing Outer Race 9 Bearing Spacer 10 Drive Pinion Bearing 11 Bearing Shim 12 Drive...

Page 335: ...ilick under7 pipe on B Series station wag backing plates with a soft hammer to ensure that om when using an axle engaging hoist brakes are free Most rear axle service repairs can be made with the rea...

Page 336: ...toin Step 2 below Replace companion flange and washer and nut Hold companion flange with tool J 8614 10and tighten nut only a little at a time stopping frequently to check preload step 3 above Tighten...

Page 337: ...ith the wheel and brake drum removed by measuring the difference between the end of the housing and the axle shaft flange while moving the axle shaft in and out by hand End play over 032 is excessive...

Page 338: ...4 B Series B or 0 coded axle with grease Tighten tool retaining bolts only finger tight Press off axle shaft bearing and inner retainer using plate J 6407 and remover J 23469 or J 23674 Figs 4A 12 and...

Page 339: ...printed with the manufacturer s name on one face This bearing must be installed with this printed face P R E S S BEARING ON B E F O R E PRESSING Fig 4A 16 Installing Retainer B Series pointing toward...

Page 340: ...Step 7be10w Install wheels and tighten wheel nuts to 75 lb B Series 70 lb ft A and G Series MAJOR REPAIRS REAR AXLE ASSEMBLY 2 Disconnect rear universal joint from companion flange by removing retain...

Page 341: ...top of housing and bend tabs over brake lines on housing Fill rear axle with specified gear lubricant Bleed rear brakes as outlined in Sections 5 and 5E DIFFERENTIAL CASE REMOVE sure the checks under...

Page 342: ...ing outer race must also be replaced 5 Inspect fit of inner races on case hubs by prying against shoulders at puller recesses Bearing inner races must be tight on case hubs NOTE If either bearing is l...

Page 343: ...02 tight to 001 loose If ring gear easily falls into position it must be replaced NOTE If ring gear is replaced pinion gear must also be replaced as they are only serviced in matched sets 6 Replace pa...

Page 344: ...installed Figs 4A 23 and 4A 24 Reverse differential case support previously installed side bearing with J 8901 B Series J 8980 A and G Series and press on other side bearing using J 22761 B Series J 2...

Page 345: ...ion bearing If replacing this bearing drive its outer race from carrier using a drift CLEANING AND INSPECTION 1 Check drive pinion stem and gear for excessive wear NOTE Ring gears and pinions are matc...

Page 346: ...o move the pinion away from the ring gear and position the pinion at the nominal setting Pinion depth is set with pinion depth setting gauge J 21777 which consists of the following one J 21777 1 cross...

Page 347: ...he gauge plate The discs must be dial indicator to zero Fig 4A 35 Repeat rocking fully seated in the side bearing bores action of gauge shaft to verify the zero setting Fig 4A 34 Pinion Gauge Tools In...

Page 348: ...e of com panion flange with gear lube Install companion flange on pinion by tapping with a soft hammer until a few pinion threads project through flange Install pinion washer and nut Hold companion fl...

Page 349: ...ocedure in all cases CAUTION To adjust differential side bearing preload change the thickness of the right and left shims equally thus leaving the original backlash undisturbed 1 Before installation o...

Page 350: ...side This additional thickness will provide proper bearing preload It will be necessary to tap the final shim into place with a soft hammer or with BT 6623 A and G Series Fig 4A 42 ADJUST DIFFERENTIAL...

Page 351: ...AIL TYPE ABILITY TRANS STANDARD CODE UD LlD NK NK NK NK N A N A NA N A SAFE T TRACK CODE VD V D N T N T N T NT 400 2 Bbl 400 4 Bbl 455 2 Bbl 455 4 Bbl 400 2 Bbl 400 4 Bbl 455 2 Bbl 455 4 Bbl A L L A L...

Page 352: ...5 5 WF XF P X 3 23 WH XH 4 pinion P X 3 5 5 WH XH P X 3 55 WT XT K X 3 07 WV XV K X 3 55 WU XU K X 3 31 WT XT K X 3 07 WV XV K X 3 55 WU XU K X 3 31 WV XV K X 3 5 5 AB BE 4 pinion P X 3 0 8 AF BF 4 pi...

Page 353: ...lts pass through gasket holes Torque to 25 lb ft NOTE It may be necessary to readjust the backlash to obtain the correct tooth contact pattern Onhigh mileagegearsets whereadefi nite wearpattern has be...

Page 354: ...nd around the O D of the new seal B Buick G Chevrolet K G M of Canada M G M of Canada 0 Oldsmobile P Pontiac W Chevrolet Warren AXLE MANUFACTURER S IDENTIFICATION LETTERS Fig Axle Manufacturer s Ident...

Page 355: ...Control Arm Assy to Axle Housing Bolt 110 Rear Axle Upper Control Arm Assy to Axle Housing Nut 80 Rear Axle Lower Control Arm Assy to Axle Housing Bolt 110 Rear Axle Lower Control Arm Assy to Axle Ho...

Page 356: ...e lnstaller J 6407 1 2 Press Plate Holder Insert J 7817 Front Pinion Bearing Outer Race lnstaller J 8092 Drive Handle Not Shown J 8107 Side Bearing Puller Not Shown J 8916 1 Split Plate Differential S...

Page 357: ...e railroad tracks etc ad versely affect rear wheel action With a conventional dif ferential when one wheel bounces free of the road it picks up speed When this rapidly spinning wheel contacts the road...

Page 358: ...FFERENTIAL THRUST WASHER 2 Fig 48 1 Exploded View of Safe T Track B Series 0 Axle DIFFERENTIAL CASE FLANGE HALF BRAKE CONE PRELOAD SPRINGS t FLANGED CAP SCREW DIFFERENTIAL CASE CAP HALF Fig 48 2 Explo...

Page 359: ...mbly is held together with eight bolts In addition to the above parts it also houses the differential pinion shaft pinion gears thrust washers and the two piece spring thurst block two pinion differen...

Page 360: ...vice procedures are the same for the Safe T Track as for the conventional differential provided they 2 Do not use on the car type wheel balancers on the have the same last letter in the three letter a...

Page 361: ...e side gears until pinions are in open area of case Remove pinions and thrust washers 14 Remove a side gear clutch pack and shims from case Note location in case to aid in reassembly Remove side gear...

Page 362: ...on opposite sides of ring gear 10 Remove ring gear from case by alternately tapping on bolts CAUTION Do not pry between case and ring gear 11 Scribe mark or paint differential case halves Fig 4B 7 to...

Page 363: ...ones will duplicate case surface coridition Re place any parts which are excessively scored pitted or worn Both halves of case must be replaced if one half is damaged or worn DIFFERENTIAL CASE ASSEMBL...

Page 364: ...is in line with hole in the preload spring retainer The spring retainer can be moved slightly to correct misalign ment A AND G SERIES P CODED AXLES The following procedure is to be used in assembling...

Page 365: ...pinion shaft from sliding out and causing damage to carrier Fig 4B 12 PINION CROSS SHAFT I PlNlON GEARS DIFFERENTIAL CASE CAP HALF Fig 48 13 lnstalling Parts in Cap Half Four Pinion Fig 48 14 lnstalli...

Page 366: ...clean and free of burrs position ring gear on case so holes are in line 13 Lubricate attaching bolts with clean engine oil and install CAUTION Do not use hammer to force ring gear on case Ring gear to...

Page 367: ...ower Control Arm Assy to Axle Housing Bolt Rear Axle Lower Control Arm Assy to x l e Housing Nut Rear Axle Bumper Spacer to Axle Housing Bracket Bolt and Nut Station Wagon A Series Rear Axle Upper Con...

Page 368: ...ce lnstaller J 6407 1 2 Press Plate Holder Insert J 7817 Front Pinion Bearing Outer Race lnstaller J 8092 Drive Handle J 8107 Side Bearing Puller Not Shown J 8916 1 Split Plate J 8980 Differential Sid...

Page 369: ...earings consist of an outer race 15 rollers and two snap rings which retain the cage and rollers in the outer race The outer race and roller assembly is press fit in the outer end of the rear axle tub...

Page 370: ...de of the case to the other The case houses two side gears in mesh with two pinion gears Both the side gears and the pinion gears are backed by thrust washers The pinion gear shaft is an chored in the...

Page 371: ...Series G GEAR RATIO CODES AND IDENTIFICATION OF C DIFFERENTIAL The three letter identifying code for the type C differen tial is located in the same place as in the standard differen tial the front fa...

Page 372: ...and wheel s Torque wheel nuts to 65 1b ft X Series 75 lb ft B Series 70 lb ft A G F Series 8 Raise the car to remove supports jack stands and lower the car CAUTION Use care not to crush exhaust sys t...

Page 373: ...using Installer J 5292 all A and G Series J 22761 all F X and B Series with G or K coded axles or J 8901 B Series P or M coded axles See Fig 4C 8 4 Install side gears and respective thrust washers 5...

Page 374: ...Removing Pinion Flange Fig 4C 1 1 Removing Rear Pinion Bearing B Series P and M coded axles or 5 21493 X Series and note the shim used See Fig 4C 1I 6 The front and rear pinion bearing outer races can...

Page 375: ...s G or K codes axles or 5 8619 10 all F X and B Series G or K coded axles discs on gauge shaft OUAOL PLATE 1 11717211A AND O IFRlESi 1 2 1111 8 SllllLS P COOED AXLLSI 211111bl8 AND F SLRlCb G OR K COD...

Page 376: ...m required is 035 plus 003 Shim re quired is 038 NOTE All service pinions have a number 45 code 10 Install proper shim on shaft of pinion gear NOTE Shims are availablein a01 increments ranging from 02...

Page 377: ...ide bear ing preload shims used in production are cast Shims used during service repairs of the differential are of a stamped steel design and are used along with a production type 160 or 001 thick ca...

Page 378: ...lash is 002 too much decrease thickness of right shim 004 and increase thickness of left shim 004 If backlash is 002 too little increase thickness of right shim 004 and decrease thickness of left shim...

Page 379: ...k Lash 005 008 TORQUE SPECIFICATIONS TORQUE LB FT Differential Cover to Carrier Bolts 25 Differential Bearing Caps to Carrier Bolts 70 Differential Ring Gear to Case Bolts 90 Differential Pinion Shaft...

Page 380: ...4C 12 1972 PONTIAC SERVICE MANUAL Fig 4C 23 Special Tools...

Page 381: ...ring Pilot Stud Assembly J 9746 Rear Pinion Bearing Remover J 21777 1 Pinion Depth Gauge Cross Shaft J 21777 2 Pinion Setting Gauge Plate J 21777 3 Pinion Depth Gauge Discs J 21777 26 Pinion Setting G...

Page 382: ...differen tial is the same as outlined in Section 4 A and 4 B except as listed below If there is a doubt that a car is equipped with a C type Safe T Track differential or to determine if this option is...

Page 383: ...se of differentials used in B Seriesmodels with G coded axles and a letter W immediately adjacent to the carrier and all F Series models is similar to the conven tional case assembly with the addition...

Page 384: ...G 7 CLUTCH PACK G U I D E 10 SIDE GEAR 14 PINION SHAFT 4 PINION LOCK SCREW A N D WASHER 8 CLUTCH DISC 11 SPRING RETAINER 15 PRELOAD SPRING Fig 4D 2 Type C Safe T Track Differential With Clutch Packs E...

Page 385: ...IAC SERVICE MANUAL DIFFERENTIAL CASE NGE HALF DIFFERENTIAL CASE a m t FLANGED PINION GEAR CAP SCREW THRUST WASHER P I N I O SHAFT BRAKE CONE Fig 4D 3 Type C Safe T Track Differential With Brake Cones...

Page 386: ...ve the same last letter in the three letter axlecode except for the clutch or cone and spring portion of the case assembly Also the ring gear must be removed in order to perform repairs inside the cas...

Page 387: ...f case and keep them with flange half of case assembly CLEANING AND INSPECTION 1 Make certain that all differential parts are absolutely clean and dry Contamination may result in differen tial chatter...

Page 388: ...e between the pinion shaft and the side gear Fig 4D 9 d Install dial indicator with the contact button against a pinion gear tooth Fig 4D 9 e Rotate pinion gear back and forth and observe clearance Pi...

Page 389: ...nd cone spline alignment Do not ignore this procedure or it will be impossible to install shafts at final assembly Attempting to force shafts into position may result in damage to spnhg thrust blocks...

Page 390: ...Fig 4D 15 Torquing Case Half Bolts 12 After making sure that matching surfaces are clean and free of burrs position ring gear on case so holes are in line 13 Lubricate attaching bolts with clean engi...

Page 391: ...eload Slip Fit Plus 008 TORQUE SPECIFICATIONS TORQUE LB FT Differential Cover to Carrier Bolts 25 Differential Bearing Caps to Carrier Bolts 70 Differential Ring Gear to Case Bolts 90 Differential Pin...

Page 392: ...7817 Front Pinion Bearing Outer Race lnstaller J 8092 Drive Handle J 8107 Side Bearing Puller Not Shown J 8916 1 Split Plate J 8980 Differential Side Bearing Installer Rear Pinion Bearing Remover Axl...

Page 393: ...ASSURE PROPER RETENTION OF THIS PAR T CONTENTS OF THIS SECTION Trouble Diagnosis and Testing 4E 1 Major Service 4E 5 General Description 4E 3 Dissassemble Universal Joints 4E 7 Inspection 4E 5 Assembl...

Page 394: ...universal joints f Worn universal joints g U joint retainer bent against bearing cup h Burrs or gouges on companion flange i Propeller shaft or companion flange unbalance CORRECTION a Tighten b Remov...

Page 395: ...h mates with another groove in the I D of the propeller shaft yoke Fig 4E 1 Once the grooves are properly aligned on A G F and B Seriesvehicles a nylon composition material is injection molded between...

Page 396: ...CONSTANT VELOCITY UNIVERSAL JOINT Fig 4E 2 Cross Section of Double Cardon Constant Velocity U Joint FRONT YOKE PROPELLER SHAFT REAR U JOINT L _ TRANSMISSION FRONT U JOINT FRAME DIFFERENTIAL Fig 4E 3...

Page 397: ...in the engine support rear crossmember provide for fore and aft movement of engine transmission assembly to provide for minor variation in positioning MAJOR REPAIRS REMOVE PROPELLER SHAFT CAUTION Use...

Page 398: ...tallation F Series differential companion flange to insure their correct 2 Remove U bolt nuts or four bolts lockplates or alignment on re assembly lockwashers and U bolts or straps from rear axle driv...

Page 399: ...essed out This shears nylon retainersinhalf renderingbearingsandjournal unsuitable for re use Therefore upon re assembly new bearing and journal assemblies Fig 4E 9Supporting Splined Yoke employing co...

Page 400: ...er Fig 4E 11 5 Remove journals from propeller shaft fixed yoke 6 Remove bearings and journal from splined yoke in a similar manner DOUBLE CARDON CONSTANT VELOCITY REAR U JOINT NOTE For ease ofdisassem...

Page 401: ...bearings next Proceed and remove remaining bearings by repeating steps 2 thru 7 DISASSEMBLY OF BALL STUD SEAT 1 Position flangeyoke in a vise so that the ball stud seat is accessible for removal 2 Wi...

Page 402: ...eed as follows NOTE Inspect ball seat cavity If the ball seat bore is scored or worn replacement ofthepro peller shaftassembly will be required 2 Pack spring cavity with grease supplied in repair pack...

Page 403: ...n A G Series 2 Door Convertible B Series Sedan 3 Blue 1 Black 1 Purple 1 Red 1 Brown 1 Green 1 Pink V 40014 Bbl V 455 with M 40 V 40012 Bbl with M 40 B Series I 1 Red 1 Yellow I All Station Wagon Fig...

Page 404: ...1 Inspecting System 5 11 Brake Pedal 5 11 Brake Mechanisms and Drums 5 15 Hydraulic System 5 22 Master Cylinder 5 23 Brake Hoses and Pipes 5 25 Brake Fluid Precautions 5 29 Parking Brake 5 29 TROUBLE...

Page 405: ...and refill with brake fluid complying with specifications REMEDY Adjust parking brake cables and lubricate Replace defective brake shoe springs and lubricate brake shoe ledges and shoe contact at anch...

Page 406: ...sition 1 See that pedal returns freely and is not stopped by contact with stop light switch body or pedal bracket 2 See that compensating ports are not plugged by dirt To check compensating port remov...

Page 407: ...in surfaces of linings See COMPLETE BRAKE RECONDITIONING regarding road dirt grooving brake drums Seriously charred linings should be replaced Check boot for holes Check for burrs on wheel cylinder p...

Page 408: ...cases replace shoes Warn owner regarding abuse of brakes Remove all particles that have become imbedded in surfaces of linings Slightly scored drums do not require replacing or turning Install factory...

Page 409: ...tall factory specified shoes REMEDY Check adjustment Sand lining high spots Angle on shoe web at adjusting screw notch File straight Bent backing plate Top of shoe webs should be Straighten or replace...

Page 410: ...this system only on rear brakes The standard front brake system on the B and G Series is power disc while the F Series uses manual disc brakes on the front The standard system consists of a brake peda...

Page 411: ...eplace Excessive Brake Lining Dust Remove with Air Heat Spotted or Scored Brake Drums or Rotors Out of Round or Vibrating Brake Drums Out of Parallel Brake Rotors Excessive Rotor Run Out X XX 1 lncorr...

Page 412: ...h in the junction block which is located on the frame in drum brake vehicles and in the combination valve in disc brake vehicles is normally held in the off position by equal pressures from the front...

Page 413: ...When the brake pedal is released quickly the master cyl inder pistons return to the released position faster than fluid returns from the lines Holes in the piston heads allow fluid to pass from the re...

Page 414: ...IA for removal of air conditioning components ifnecessary 1 A X F and G Series Remove brake pedal clevis pin retainer and pin Figs 5 5 5 6 5 7 5 8 5 9 B Series Power Brake Clevis pin is part of pedal...

Page 415: ...g and then releasing parking brake 5 Depress brake pedal Do not release pedal The light should come on due to a pressure differencebetween 3 Check to make sure both master cylinder reservoirs front an...

Page 416: ...master cylinder Fig 5 11 reservoir if needed The recommended checking interval should be 24 months 7 Repeat by opening one front brake bleed screw or 2 4 miles any tirnema or brake work is done or any...

Page 417: ...JUSTMENT Fig 5 8 F Series Power Brake System STOP LIGHT SWITCH REPLACE REMOVE 1 Disconnect wires from switch 1 Position stop light switch in retainer and push in to maximum distance 2 Remove switch by...

Page 418: ...AND DRUMS just with the drums removed using toof number 22364 not only togive a more accu ADJUST rate clearance but also to allow a thorough inspectionofthebrakemechanismfor possible All four brake a...

Page 419: ...he web of the backing plate using a chisel or similar tool in order to gain access to the adjusting screw on rear wheel brake assemblies CAUTION Be sure to remove the metal knock outplug fiom the back...

Page 420: ...DISASSEMBLY CAUTION Extreme care must be taken topre vent oil grease or brake fluid from getting on linings Even oily fingerprints on linings may affectthe operation of brakes 1 Raise all four wheels...

Page 421: ...he operat ing lever 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 8 Remove the actuating links from the...

Page 422: ...shoecontacting points Sand shoe pads if necessary to remove grooves 5 Disassemble the adjusting screw assembly and in spect as follows a Inspect teeth on star wheel for wear b Remove all foreign mate...

Page 423: ...ter with a I sanding disc 40 grit The drums should showa unifonnfinish aftercross sanding This method of refinishing drums will allow the proper drum surfacenecessary to burnish new linings WARNING RE...

Page 424: ...0 Inspect front wheel bearings and oil seals and replace as necessary When installing new seal saturate with S A E 30 engine oil and wipe off excess Saturating seal with S A E 30 oil prevents absorpti...

Page 425: ...ion the adjuster lever and override spring assembly on the secondary shoe Fasten with the hold down spring assembly Fig 5 15 NOTE THE FRONT BRAKE SPRING RE TAININGPINS ARE IDENTIFIED WITH THE NUMERAL...

Page 426: ...e bolt against the washer until the insert is removed 6 Remove master cylinder from vise and inspect bore for corrosion pits and foreign matter Make sure outlet ports are clean and free of brass cutti...

Page 427: ...master cylinder Assemble new boot over push rod and press it down over push rod retainer REPLACE CAUTION See Caution on page I of this Sec tion regarding the fasteners referred to in step I below 1 Mo...

Page 428: ...as outlined under Service Operations in this section Necessary replacements should be made as follows CAUTION Use care not to damage steel brake pipes by twisting Soak all connections with ample amoun...

Page 429: ...ove procedure being sure that the rear hose fitting mounts at the proper angle and that the hose is free of kinks and that the metal pipes are well seated in their clips on the axle housing Kinked met...

Page 430: ...CH AS PART NUMBER 3830196 14 3830195 st OR EQUIVALENT NEVER USE COPPER TUBING ALL FITTINGS MUST BE DOUBLE FLARED BEND AS REQUIRED CUTTER CUT TUBING TO DESIRED LENGTH INSTALL FITTINGS TIGHTEN CLOSEST W...

Page 431: ...cylinder with out bleeder valves is used these units may be bled by unscrewing the master cylinder brake line three quartersof a turn depressing brake pedal tightening brake line then releasing brake...

Page 432: ...Supreme 11or equivalent Never use hydraulic fluid as it has a petroleum or syn thetic base and is not intended for brake systems Never re use brake fluid or use fluid which is cloudy dirty or has air...

Page 433: ...ingshort cir cuits 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...

Page 434: ...ve cable anchor screws at REMOVE AND INSTALL backing plate and withdraw cable 9 To install reverse above procedure and adjust as ou 1 Place parking brake pedal in released position tlined under Parkin...

Page 435: ...5 Screw Wheel Cylinder Bleeder 75 lb in Bolt and Nut Brake and Clutch Pedal Shaft 30 Nut Brake and Clutch Pedal Mtg Bracket to Dash 24 Bolt Parking Brake Lever to Instrument Panel 8 Nut Parking Brake...

Page 436: ...s Front Brake to Steering Knuckle Upper Bolt 140 Parking Brake Cable to Equalizer 90 in lbs Rear Brake to Axle Housing Bolt 35 Screw Brake Line to Frame 100 in lbs Master Cylinder to Dash 24 Combinati...

Page 437: ...UBLE DIAGNOSIS AND TESTING SYSTEM TESTS Road test the brakes by making a brake application at about 40 mph to determine if the vehicle stops evenly and quickly If the pedal has a spongy feel when appl...

Page 438: ...ST TO THE FLOOR Fluid reservoir needs replenishing Power brake hydraulic system leakage a Defective primary or secondary cups b Cracked master cylinder casting c Leaks at wheel cylinder pipes hoses or...

Page 439: ...s valve is controlled by the valve operating rod that projects through the end of the power cylinder housing The reaction mechanism consists of a hydraulic piston reaction plate and a series of levers...

Page 440: ...push rod it forces the rod against the master cylinder pistons which build up the hydraulic line pressure The pedal pressure required for a manual application such as described is considerably greater...

Page 441: ...5 for service All models use the same switch for both standard and power brakes MASTER CYLINDER ONLY REMOVE Certain repair operations such as replacement of master cylinder internal parts permits the...

Page 442: ...lugs 2 Remove reaction retainer vacuum cylinder push rod reaction plate three reaction levers and air valve spring Fig 5A 7 3 Remove hydraulic cylinder push rod from center of reaction retainer and O...

Page 443: ...tal parts for scoring pitting dents or nicks Small imperfections can be smoothed out with fine emery cloth Replace if badly nicked scored or otherwise damaged Do not attempt to repair any plastic part...

Page 444: ...ston 1 I Fig 5A 8 Positioning Power Piston on Support Plate Remover POWER PISTON ASSEMBLE 1 Place a new O ring seal in groove on hydraulic cylin der push rod Wipe thin coat of power brake lubri cant o...

Page 445: ...ower piston Holding support plate on bare metal with locking tangs down place support plate and diaphragm as sembly down over hub of power piston Flange of diaphragm will fit into groove on power pist...

Page 446: ...sure the housings will be completely mated afterassembl and to eliminate anypossibility of cutting the diaphragm 4 Hold power piston return spring in position between front housing and power piston th...

Page 447: ...aster cylinder on front housing studs In stall attaching nuts on studs Torque to 25 lb ft 3 Install vacuum check valve 4 Install clevis lock nut to push rod finger tight At tach clevis and tighten cle...

Page 448: ...7 Principles of Operation 5B 5 Disassemble Master Cylinder 5B 8 Released Position 5B 5 Inspection and Cleaning 5B 9 Applying Position 5B 5 Assemble Master Cylinder 5B 10 Holding Position 5B 6 Assembl...

Page 449: ...wer brake unit trouble a Jammed poppet valve b Vacuum leaks in unit caused by faulty poppet valve seal or support plate seal damaged floating control valve faulty seal of master cylinder or power cyli...

Page 450: ...ting his heel from the floor The power brake unit utilizes engine intake manifold vacuum and atmospheric pressure in its operation These units are self contained requiring no additional external rods...

Page 451: ...ween these two units seals the front power cylinder chamber against atmospheric pressure leaks A secondary seal around the rear master cylinder piston prevents hy draulic fluid in the master cylinder...

Page 452: ...he brake svstems to the fluid reservoirs or to enter either brake system from its reservoir in order to compensate for the expansion or loss of fluid in either system APPLYING POSITION Fig 5B 3 As the...

Page 453: ...amber to the right and with constant vacuum to the left of the power piston and diaphragm assembly Any increase in hydrau lic pressure to the wheel brakes beyond this point must be supplied by physica...

Page 454: ...tem 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 stoplight switch for proper setting a...

Page 455: ...ragm plate power piston from rear housing 4 Carefully remove rubber diaphragm from diaphragm plate 5 Tilt diaphragm plate and depress valve operating rod slightly to remove valve assembly retainer val...

Page 456: ...nd cleaning fluid out of all internal passages If inside of front housing is slightly scored or scratched clean with crocus cloth or fine emery cloth If scratches cannot be removed replace housing All...

Page 457: ...nose of front piston and dip assembly in brake fluid Press and twist piston to ease cups past snap ring groove into bore Slide assembly to bottom of bore Dip new rear piston and spring assembly in br...

Page 458: ...sings Place rear housing assembly over diaphragm return spring and using tool J 9504 press down firmly on rear housing guiding push rod into front housing seal while making certain scribe marks will a...

Page 459: ...compensating port is open Failure to clear the compensating port in the released position traps fluid in the hydraulic lines and wheel cylinders and causes brake drag when the fluid warms up If compe...

Page 460: ...ecial Tools BT 7004 Power Brake Housing Disassembly Tools J 9 5 0 4 Power Brake Housing Disassembly Tools J 22644 Pushrod Gauge J 22677 Rear Vacuum Seal Installer J 22805 01 Power Brake Unit Mounting...

Page 461: ...mp Switch 5C 8 Master Cylinder and Power Unit Remove 5C 9 Master Cylinder Remove 5C 9 Valve Assembly Remove 5C 9 Power Section Disassemble 5C 10 Master Cylinder Disassemble 5C 12 Master Cylinder Assem...

Page 462: ...t housing c Mechanical 1 Badly dented vacuum cylinder 2 Bound up pedal linkage 3 Improperly adjusted stop light switch 4 Galled valve plunger 5 Broken or missing springs GRABBY BRAKES APPARENT OFF AND...

Page 463: ...king system The dual system hydraulic section of the power brake is similar to the manually operated dual system master cylinder except that the hydraulic push rod is a part of the power section The s...

Page 464: ...with the foot pressure applied to the valve operating rod through the brake pedal linkage The control valve consists of a single poppet with an at mospheric port and a vacuum port The vacuum port seat...

Page 465: ...ont end the unit incorporates another special seal to close the opening between the front shell and the hy draulic push rod The hydraulic push rod is the link be tween the vacuum power diaphragm assem...

Page 466: ...t on both sides of both diaphragms The vacuum power diaphragm return spring is then free to return the diaphragm and plate assembly with the hy draulic push rod to the fully released position With the...

Page 467: ...UT THE HYDRA ULIC PUSH ROD SHOULD AL WAYS REMAIN IN CONTACT WITH THE REAR PISTON Both fluid reservoirs cast integrally with the master cylin der supply fluid to the space around its piston between the...

Page 468: ...correct as buretor vacuum fitting for possible air leaks required MINOR REPAIRS BLEEDING BRAKES STOP LAMP SWITCH Brakes should be bled in the same manner as standard See Section 5 for service brakes...

Page 469: ...REMOVE 1 Remove the two master cylinder attaching nuts and lockwashers and remove master cylinder Remove 2 Carefully remove push rod boot and air filter from valve rod VALVE ROD RETAININERS FILTER AN...

Page 470: ...NOTE Special tool BT 7 1 K 1 4 or J 23456 Fig 5C 8 may be used for housing disassembly as an option to the following method 1 Assemble special tool combination as shown in Fig 5C 9 2 Place assembly i...

Page 471: ...in line with lances in rear shell 6 Slowly release pressure on assembly DIAPHRAGMS PLATES RETAINER AND 7 Using fingers remove diaphragm assembly from rear PLUNGER shell Fig 5C 11 DISASSEMBLE Fig 5C 7...

Page 472: ...plate and slide center plate carefully off front plate hub CAUTION DO NOT DAMAGE OR REMOVE SEAL FROM CENTER BORE OF CENTER PLA TE MASTER CYLINDER DISASSEMBLE Fig 5C 12 Always use the correct master c...

Page 473: ...nst rear piston with blunt tool to com press return springs Do NOT use screwdriver or other sharp edged tool since this will damage the push rod seat inside the piston Maintain pressure on piston and...

Page 474: ...outer rim of front dia phragm into rear shell so that outer rim of front diaphragm is under each of retaining lances on rear shell NOTE Tool BT 7 W or J 23456 Fig 5C 8 may be used for housing assembl...

Page 475: ...care to avoid tearing Press boot against rear shell CAUTION See cautionon Page I ofthissection regarding fastener referredto in step 2 below 2 Before mounting master cylinder check distance A Fig 5C 1...

Page 476: ...5C 16 1972 PONTIAC SERVICE MANUAL TORQUE SPECIFICATIONS Power Cylinder Housing to Master Rear Housing to Dash Nuts 24 lb ft Cylinder Nuts 24 lb ft...

Page 477: ...TANDEM DIAPHRAGM POWER BRAKE BENDIX 5C 17 J 8433 1 Fig 5C 16 Spec al Tools...

Page 478: ...acuates the housing chambers Wait no less than 90 seconds then try brake action If not vacuum assisted for two or more applications vacuum check valve is faulty or there is a leak in the vacuum system...

Page 479: ...OM ITS NORMAL POSITION 1 Broken or damaged front or rear hydraulic brake line 2 Fluid reservoir needs replenishing 3 Power brake hydraulic leakage a Defective primary or secondary seals b Cracked mast...

Page 480: ...primary power piston The primary diaphragm is held in position on the O D of the housing divider by stretching the bead on the O D of the diaphragm and positioning it over the turned up edge of the di...

Page 481: ...nt at all times in the spaces to the left of each power piston is now also present on the right side of each power piston With the power head in the released position the primary seals on the primary...

Page 482: ...against the reaction piston This results in a movement of the reaction piston toward the air valve The air valve and the reaction piston contact each other to transmit this reactionforce through the...

Page 483: ...uickly as the pis tons a low pressure area is created in front of both pri mary cups This low pressure area is compensated for by the flow of fluid from the reservoir through the compen sating holes t...

Page 484: ...epair operations such as replacement of master cylinder internal parts permit the master cylinder to be removed by itself leaving the power cylinder pedal and brackets in the car 1 Remove hydraulic co...

Page 485: ...ngs rotate slowly as unit is under spring tension 6 Applying downward pressure rotate rear housing counterclockwiseto unlock housings It is normal for this operation to require heavy pressure to unloc...

Page 486: ...Fold back primary diaphragm from O D of primary support plate Grip edge of support plate with hands and rotate counterclockwise to unscrew primary power piston from secondary power piston Fig 5D 11 N...

Page 487: ...ondary power piston should still be positioned on tool J 23101 Fold back secondary diaphragm fro n O D of secondary support plate Grip edges of support plate with hands and rotate clockwise to un lock...

Page 488: ...from tubular section of primary piston Remove rubber reaction bumper from end of air valve Using snap ring pliers remove retaining ring from air valve Remove air valve pushrod assembly from tube end...

Page 489: ...parts indicates contaminated brake fluid requiring flushing of the entire brake system and replacement of wheel cylinder cups as well as all rubber parts in master cylinder ASSEMBLE Refer to Section...

Page 490: ...ISTON TOO SHORT TOO LONG Fig 5D 17 Gaging Reaction Piston valve spring The air valve pushrod assembly should be secured to the primary power piston as described in step 8 b Insert the reaction piston...

Page 491: ...secondary diaphragm and raised surface of flange that fits into groove in sec ondary power piston 22 Mount Tool J 23101 with large diameter end up in vise Position secondary power piston so that radi...

Page 492: ...condary piston cone lubricant 35 Grip edge of primary support plate with hands press 41 If check valve grommet was removed during servic down and start threads on secondary power piston ing replace wi...

Page 493: ...er piston rod to assure that it is properly seated 4 Place gage J 22647 over piston rod in a position Fig 50 21 Joining Front and Rear Housings which will allow gage to be slipped to the right or left...

Page 494: ...n master cylinder on power cylinder studs Secure master cylinder with two nuts torque to 25 lb ft 2 Attach hydraulic fluid lines 3 Fill master cylinder reservoirs and bleed brakes as described in Sect...

Page 495: ...5D 18 1972 PONTIAC SERVICE MANUAL Fig 50 23Special Tools...

Page 496: ...scription 5E 3 Rotor Measurements 5E 16 Operation 5E 4 Rotor Service 5E 13 Combination Valve 5E 5 Specifications 5E 16 Lining Inspection 5E 6 TROUBLE DIAGNOSIS AND TESTING Since the car is equipped wi...

Page 497: ...if necessary 7 Disassemble caliper and remove corrosion or roughness or replace caliper 8 Free up and lubricate 9 Replace combination valve GRABBING OR PULLING Severe Reaction To Pedal Pressure and O...

Page 498: ...1 Repair or replace defective parts 2 Drain hydraulic system flush system with brake fluid and replace all cups and seals in complete brake system 3 Remove check valve 4 Disassemble caliper and free u...

Page 499: ...ars The shoe and lining assemblies are constructed of a stamped metal shoe with riveted lining INBOAR0 SHOE OUTBOlRO SHOE The rotor is a cast iron ventilated type with two machined braking surfaces se...

Page 500: ...tor allows the disc to throw off water 4 Disc brakes are less subject to pull because they do not have the inherent self energizing feature of drum brakes Disc Brake Pad Wear Disc brake linings normal...

Page 501: ...ulic pressure brake systems and when activated completes a circuit to the brake warning lamp in the instrument panel The switch is designed to compare front and rear brake pres sure and is activated a...

Page 502: ...assemblies on both sides should be replaced NOTE Wheelinust be removed to inspect lin ing SHOE AND LINING REPLACEMENT NOTE Whenreplacing shoe and lining assem blies on disc brake vehicles after milea...

Page 503: ...aliper Next remove the rubber bushings from the grooves in each of the four caliper ears Fig 5E 8 Discard these parts new ones are provided with new linings Thoroughly clean the holes and the bushing...

Page 504: ...SLEEVES 4 b w LUBRICATE AREAS INDICATED Fig 5E 1 1 Shoe Support Spring 3 Install shoe support spring by placing the single tang end over the notch on the top edge of the inboard shoe Press the double...

Page 505: ...with the holes in the mounting bracket NOTE Make sure that the brake hose is not twisted orkinkedand that theskirt ofthemetal fitting which attaches to the caliperis installed BETWEEN the ears on the...

Page 506: ...overhauled Discard do not bother to clean and inspect these parts Clean all other parts in alcohol or brake fluid Use dry filtered compressed air to dry parts and blow out all pas sages in the caliper...

Page 507: ...the calipers must be bled Use either the manual or pressure tank method See Bleeding Disc Brakes BLEEDING DISC BRAKES If the caliper was removed for overhaul or if the brake hose or steel line was di...

Page 508: ...one complete rotation checking the indicator as the rotor moves ROTOR INSPECTION CHECK ROTORS ONLY WHEN A SPECIFIC COM PLAINT POINTS TOWARD A PROBLEM IN THIS AREA LATERAL RUNOUT CHECK Lateral runout...

Page 509: ...RVICE MANUAL Fig 5E 18 Installation of Steering Knuckle Hub and Disc Assembly B and F Series places around the rotor to measure the rotor thickness at a minimum of twelve Disc brake roughness is most...

Page 510: ...use a brake pull If the rotor is too thin the linings may become dislodged Because of the accuracy required refinishing of the rub bing surface is not recommended unless precision equip b DO NOT USE F...

Page 511: ...the master cylinder F and X Series and remove valve 4 To install reverse the above procedure 5 Bleed entire brake system following the procedure described under BLEEDING DISC BRAKES SPECIFICATIONS Di...

Page 512: ...DISC BRAKES 5E 17 Fig 5E 24 Special Tools...

Page 513: ...g choke c Excessive moisture on plugs caps or ignition system j Faulty fuel pump d Damaged distributor rotor cracked distributor cap and or corroded d stributorcontact points k Faulty solenoid or star...

Page 514: ...d 1 Excessively worn fuel pump diaphragm e Excessive play in distributor shaft f Insufficient spring tension on points g Distributor cam lobe worn h Weak coil or condenser m Weak valve spring n Worn c...

Page 515: ...overheating v Transmission regulator valve sticking Hydra Matic w Sub standard fuel EXTERNAL ENGINE OIL LEAKAGE CAUSE a Improperly seated or broken fuel pump gasket h Worn or improperly seated rear ma...

Page 516: ...b Oil pump not functioning properly Regulator ball e Leakage at internal oil passages stuck in position by foreign material c Excessive clearance at main and connecting rod bear ings NO OIL PRESSURE...

Page 517: ...ing clearance e Low oil pressure c Eccentric or out of round crankshaft journals f Connecting rod bolts not tightened correctly NOISY MAIN BEARINGS CAUSE a Low oil pressure and or insufficient oil sup...

Page 518: ...6 6 1972 PONTIAC SERVICE MANUAL...

Page 519: ...dels with the G T O option are equipped with a 400 4 Bbl engine as standard The 455 4 Bbl and 455 H O engines are also available with the G T O option Sixteen different A Series engine transmission co...

Page 520: ...8 4 l 455 where the vehicle identification number can also be found H O Fig 6 4 The same information for V 8 engines is located on the machined face of the cylinder block below the R H Engine identifi...

Page 521: ...r Bores Inspect 6 38 Honing or Boring 6 39 Piston Fit and Replace 6 40 Piston Rings Install 6 41 Crankshaft Remove and Replace 6 43 Fitted Block Assembly Replace 6 44 Special Tools 6 46 Specifications...

Page 522: ...6 10 1972 PONTIAC SERVICE MANUAL...

Page 523: ...SIX CYLINDER ENGINE 6 11 Fig 6 6 250 L 6Cross Section...

Page 524: ...bearings are lubricated through oil holes which intersect the main gallery The main gallery runs parallel to the cylinder bores along the right side of the block PISTONS AND CONNECTING RODS The piston...

Page 525: ...ush rod The ball check valve will then move off its seat and the lifter reservoir will remain full I PUSH I ROD 1 ROCKER FEED METERING VALVE LIFTER q BODY RETAINER RlNG BALL CHECK VALVE BALL CHECK VAL...

Page 526: ...seat angles to further provide easy breathing for high combustion efficiency Exhaust valve seat angle is also 46 GENERAL INFORMATION ON ENGINE SERVICE The following informationonengineserviceshould b...

Page 527: ...and cause extensive damage when the engine is started In the mechanical procedures described in this section generally no references will be made to the removal of optional equipment such as power st...

Page 528: ...und hood hinges and remove hood from hinges Disconnect coil starter and generator wires engine to body ground strap oil pressure and engine tem perature sender wires and all external vacuum hoses Remo...

Page 529: ...CROSS MEMBER FRONT ENGINE REAR MOUNT Fig 6 17 Engine Insulators 6 Cyl F Series 17 Remove four lower bell housing bolts two each side 19 Remove two front motor mount to frame bracket bolts 18 Disconne...

Page 530: ...is guiding engine to align with bell housing With engine supported by lifting equipment install two upper bell housing bolts CAUTION Do not lower engine completely whilejack is supporting transmission...

Page 531: ...ghten center clamp bolts to 30 lb ft and end bolts to 20 lb ft Fig 6 20 7 Connect exhaust pipe to manifold using a new pack ing seal 8 Reverse Steps 1 4 of Removal to complete installa tion procedure...

Page 532: ...nal lifter boss Replace push rod exactly as removed Position rocker arm on push rod With lifter on base circle of camshaft tighten rocker arm nut until valve train play is removed Turn nut down one ad...

Page 533: ...Fig 6 25 CAUTION Valve lifier body and plunger are selectively fitted and must not be interchanged withparts ofother liften Keeping all parts of lifters together will also aid in trouble diagno sis C...

Page 534: ...s it is sharp or burred A blackened appearance is not a defective condition Sometimesthe discoloration serves to highlight slight grinder chatter marks and give the outer surface of the plunger a ridg...

Page 535: ...stributor primary wire lead at coil and remove coil 8 Remove rocker arm cover Back off rocker arm nuts pivot rocker arms to clear push rods and remove push rods 9 Remove the cylinder head bolts cylind...

Page 536: ...eaks 15 With lifter on base circle of camshaft tighten rocker arm nut until valve train play is removed Tighten nuts one more turn 16 Install spark plugs and tighten to 15 lb ft 17 Install rocker arm...

Page 537: ...WN Fig 6 31 Rethreading Stripped Rocker Arm Stud 2 Install new stud using tool J 6880 Tool should bot tom on head Fig 6 34 3 Install push rod and rocker arm 4 Remove spark plug frorr cylinderof valve...

Page 538: ...rm nuts ball seats and rocker arms 3 Using tool 5 22891 compress the valve springs and remove valve locks Remove spring caps spring seats oil seals springs and spring dampers Fig 6 35 4 Remove valves...

Page 539: ...5830 Fig 6 37 10 Check valve spring tension with suitable tester Fig 6 38 Fig 6 38 Checking Valve Spring Tension Fig 6 37 Reaming Valve Guide Bore 11 Springs should be checked by compressing to a heig...

Page 540: ...4 Check concentricity of valve stem and valve face After cleaning prussian blue from valve and seat lightly coat valve seat with prussian blue again and rotate valve in guide If blue appears all the...

Page 541: ...rankshaft and drive into posi tion until it bottoms against crankshaft gear Fig 6 42 Installing Harmonic Balancer 4 Install water pump pulley fan and fan belt and adjust belt tension see Section 6A 5...

Page 542: ...ver gasket in position on block with light grease 4 Install cover over centering tool Fig 6 45 and in stall cover screws Torque screws to 7 lb ft Remove centering tool It is important that centering g...

Page 543: ...camshaft gear thrust plate and gear spacer ring to camshaft proceed as follows Fig 6 46 Removing Camshaft Thrust Plate Screws Fig 6 47 Removing Camshaft Timing Gear 1 Firmly support shaft at back of f...

Page 544: ...ll side cover with a new gasket Attach coil and wires Then install distributor as follows Turn crankshaft to firing position of number one cylinder number one exhaust and intake valve lifters both on...

Page 545: ...iling holes and install new expansion plug 4 Disconnect exhaust pipe at manifold 5 Remove starter and set to one side 6 Remove flywheel housing inspection cover 7 Install engine lift support tool 5 23...

Page 546: ...drive gear and shaft in pump body 2 Install idler gear so that smooth side of gear will be toward the cover 3 Install a new gasket to assure correct end clearance of the gears 4 Install cover and atta...

Page 547: ...ndersize bearing insert both upper and lower halves will be required REMOVE 1 Remove oil pan 2 Remove cap on main bearing requiring replacement and remove bearing from shell If a tool is not available...

Page 548: ...tisfactory If the clearance is more than 0025 replace the bearing with the next undersize bearing and recheck clearance Bearings are available in standard size 001 and 002 under size Install a new rea...

Page 549: ...d and piston assem bly by pushing out with knurled handle of long guide CONNECTING ROD AND PISTON ASSEMBLY REMOVE Remove rocker arm cover Loosen rocker arm nuts rotate rocker arms and remove push rods...

Page 550: ...s assemblies The piston pin fit in the piston is 0003 to 0005 loose with pin and bosses clean and dry Piston andpin must be at room temperature when check ing fit and pin must be able to fall from pis...

Page 551: ...tions Hon ing or boring operation must be done carefully so that specified clearance between pistons rings and cylinder bores is maintained Fig 6 62 Normal Cylinder Wear Pattern By measuring the pisto...

Page 552: ...are servicedin standard sizeand 005 010 020 and 030 oversize Sincethese are nominal or basic sizes it is important that new pistons be measured to ensure proper fit All new pistons are serviced with s...

Page 553: ...d for the standard size pistons and for 005 010 020 and 030 oversize pistons When selecting rings be sure they match the size of the piston on which they are to be installed i e standard rings forstan...

Page 554: ...m beneath engine pull connecting rod with bear ing into place against crankpin 4 Remove guide set 5 5239 and install bearing cap with oil groove facing camshaft Tighten cap nuts to 35 lb ft 5 Install...

Page 555: ...ve spark plugs 4 Remove fan and fan pulley 5 Remove harmonic balancer using tool 5 6978 6 Remove oil pan and oil pump assembly 7 Remove timing gear cover 8 Remove crankshaft timing gear with tool 5 69...

Page 556: ...manifolds as an assembly Fitted block assembly contains pistons rings pins cam shaft bearings and oil filter by pass valve 24 Remove two camshaft thrust plate screws through holes in the camshaft gea...

Page 557: ...intake valve lifters both on base circle of camshaft and timing mark of harmonic balancer indexed with top dead center mark on timing pad Position new distributor to block gasket on block Install dis...

Page 558: ...BALANCER P U L L E R J 8021 PISTON RlNG REMOVER AND INSTALLER J 8934 ROCKER ARM STUD REMOVER J 9510 PISTON PIN ASSEMBLY TOOL J 9534 DISTRIBUTORBUSHING REMOVER J 9535 DISTRIBUTORBUSHING INSTALLER J 210...

Page 559: ...ect 6 88 Honing or Boring 6 89 Fit and Replace Piston 6 90 Fitting Pin in Piston 6 90 Piston Rings Remove and Replace 6 92 Crankshaft Remove and Replace 6 92 Engine Block Core Hole Plugs and Oil Passa...

Page 560: ...6 48 1972 PONTIAC SERVICE MANUAL Fig 6 75 V 8 Cross Section...

Page 561: ...The rear main bearing shells have two oil grooves Fig 6 81 When replacing main bearings it is very important that bearings are installed with the recommended material M100 A or M400 A located in the p...

Page 562: ...ISTONS AND CONNECTING RODS Pistons are of a light weight cast all aluminum slipper skirt type Their light weight results in reduced inertia forces These pistons maintain thermal control through contou...

Page 563: ...two sizes large and small The small intake valve size is used in all V 8 engines except 400 4 Bbl 455 4 Bbl and 455 H O The 307 engine uses positive valve rotators on exhaust valves only Fig 6 117 The...

Page 564: ...boss Oil then enters the lifter from this groove and passes into the plunger cavity From the plunger cavity oil under pres sure is also fed up the push rod to lubricate the friction area between the u...

Page 565: ...cker arm asbefore the enginewas disassem bled Push rods will be polished somewhat in the area where the rod passes through the head GENERAL INFORMATION ON ENGINE SERVICE PERIODIC SERVICE When hydrauli...

Page 566: ...7 engine lifting tools take weight of engine off front insulators Figs 6 95 6 96 6 97 6 98 and 6 99 Proper Engine Lifting procedure will be found under OIL PAN AND OR GASKET REMOVE On A Series it will...

Page 567: ...n to 50 lb ft REAR INSULATOR REMOVE AND REPLACE 1 Support transmission at rear to remove engine weight from rear insulator using suitable lifting equipment 2 Remove attaching nuts or bolts at insulato...

Page 568: ...th power steering or air conditioning remove pump and compressor from mounting brack ets and set aside Do not disconnect hoses 8 Remove engine fan and pulley 9 Disconnect accelerator control linkage a...

Page 569: ...ENGINE 6 57 7 I TRANSMISSION EXTENSION REAR ENGINE MOUNT LOCATION WITH M40 TRANSMISSION ENGINE REAR CROSS MEMBER T FRON 81 ENGINE REAR MOUNT Y ENGINE FRONT MOUNTS Fig 6 93 Engine Insulators V 8 F Seri...

Page 570: ...wer vehicle 21 Using jack and block of wood support transmission automatic transmission 22 Remove two remaining bell housing bolts 23 Raise transmission slightly 24 Using suitable lifting equipment re...

Page 571: ...pre heater stove Disconnect exhaust pipe from manifold Straighten tabs on manifold front and rear individual bolt locks and remove manifold attaching bolts manifold and gaskets Locks are used on fron...

Page 572: ...d all except 307 engine 6 307 Engine Connect battery ground cable 8 Attach exhaust pipe to manifold and tighten to 30 lb 7 307 Engine Install air cleaner pre heater stove ft 9 307 Engine Install spark...

Page 573: ...r Disconnect distributor solenoid to carburetor vacuum hose Disconnect fuel line connecting carburetor and fuel Pump Disconnect crankcase vent hose from intake mani fold Disconnect throttle cable from...

Page 574: ...er 307 Engine Install upper radiator hose and water outlet fitting using new gasket 307 Engine Install coil 307 Engine Install distributor with the rotor point ing at the chalk mark then install distr...

Page 575: ...or parts compress springs with valve spring compressor J 6384 1 and nut J 8929 2 Install valve stem seal Fig 6 103 and retainer cup locks Remove spring compressor and valve holder then test valve ste...

Page 576: ...ne until mark on harmonic balancer lines up with center or 0 mark on the timing tab Exhaust 2 5 6 7 and the engine is in the number 1firing position This may be determined by placing fingers on the In...

Page 577: ...pointed tool Fig 6 107 Invert lifter and allow push rod seat and plunger to slideout of body If plunger sticksin body place lifter in large end of hydraulic valve lifter plunger remover J 4160 A with...

Page 578: ...ss in spect check ball seat for defects Inspect outer surface of plunger for scratches or scores Small score marks with rough satiny finish will cause plunger to seize when hot but operate normally wh...

Page 579: ...detected 5 Raise weight arm to allow plunger spring to expand fully lower arm onto ram and commence turning crank slowly 1 revolution every 2 seconds Time indicator travel from lower line first line a...

Page 580: ...ill project an equal distance from the head Do not use sealer of any kind on the threads except 307 engine Tighten bolts evenlyto 95 lb ft on all but 307 engines and to 65 lb ft on the 307 Install pus...

Page 581: ...reamer did not clean up completely it will be necessary to replace cylinder head ORIGINAL ROCKER ARM STUD IS318 24 N F IF STUD IS STRIPPED USE 318 16 N C D I E T 0 RETHREAD STUD THEN PULL THE STUD ASS...

Page 582: ...ght 8 Clean rocker arms and rocker arm balls and visually inspect for evidence of wear 9 Clean spark plugs as outlined in ENGINE ELEC TRICAL SECTION 10 Clean and inspect valve lifters 2 Place valves i...

Page 583: ...ngle is 45 on all cylinder heads Intake valve face angle is 29 on all except 307 engine 45 on 307 valves and exhaust valve face angle is 44 on all valves except 307 which is 45 This will provide hairl...

Page 584: ...e same valve stem to guide clearance applies for over size stems Fig 6 12 1 Reaming Valve Guide CYLINDER HEAD AND VALVES ASSEMBLE 1 Install valves valve springs valve stem shields valve spring retaine...

Page 585: ...ng balancer bolt L J Fig 6 123 Removing Harmonic Balancer 9 307 Engine CAUTI0N It is necessary to use installer tool toprevent theinertia weightsectionfrom walk ing offthe hub during installation of b...

Page 586: ...old bolt I Pull timing chain cover forward to clear studs and remove On all but 307 engine remove O ring seal from recess in intake manifold water recirculation passage Remove timing chain cover gaske...

Page 587: ...r oil seal 3 Align timing marks to simplify proper positioning of sprockets during reassembly Fig 6 127 4 On 307 engine remove three camshaft sprocket re taining bolts Fig 6 128 and remove sprocket an...

Page 588: ...sion and clutch housing must first be removed To replace the camshaft and or the rear center center front center or front camshaft bearing without removing and completely disassembling the engine proc...

Page 589: ...t removal is very limited and in cases where engine mounts are worn exces sivel it may be necessary to raise the front of the engine to permit removal 22 Stuff clean rags through openings in engine bl...

Page 590: ...6 and V 8 NOTE Iffrnt bearingis being replaced insert removeradapterin centerbearing toactassup port for the shaft b Insert pilot J 6173 7 into hole in which bearing is to be installed c Coat outside...

Page 591: ...128 4 Install fuel pump eccentric and bushing all except 307engine Tighten camshaft sprocket retaining bolt to 40 lb ft all except 307 engine or 20 lb ft 307 engine 5 Install timing chain cover dowels...

Page 592: ...and position en gine lifting crossbar 523515 1 to adapter J 23515 2 or J 23515 19 and attach nut to jackscrew to hold it to the adapter NOTE Be sure thrust bearing is in place A B Series Slip chain a...

Page 593: ...ighten fuel pump bolts 12 Lower vehicle 13 Replace fan 14 Connect battery cable 15 Refill engine crankcase OIL PUMP REMOVE 1 Remove engine oil pan see OIL PAN REMOVE AND REPLACE Remove splash bafile 2...

Page 594: ...all parts thoroughly Screen must be thoroughly cleaned by using a fluid such as used for carburetor cleaning 2 Inspect pressure regulator spring Figs 6 139 and 6 140 for distortion cracks and wear on...

Page 595: ...nder block d Clean the block and bearing cap parting line thoroughly e Form a new seal in the cap Fig 6 142 f Remove the newly formed seal from the cap and cut four 4 pieces approximately 3 8 long fro...

Page 596: ...Position seal between crankshaft and tip of small screwdriver so that seal bead contacts tip of tool Make sure that oil seal lip is positioned toward front of engine h Roll seal around crankshaft usi...

Page 597: ...IN BEARING CLEARANCE When checking main bearing clearance with engine in the car place a 002 brass shim between the crankshaft iour Fig 6 147 Tool Installed for Removing Upper Half of Main Bearing nal...

Page 598: ...ARINGS REMOVE Remove oil pan see OIL PAN REMOVE AND REPLACE To gain access to numbers 5 6 7 or 8 connecting rod caps it will be necessary to remove oil pump and oil baffle Pump must be removed as an a...

Page 599: ...ize bearing and recheck clearance Bear ings are available in 001 and 002 undersize Rotate the crankshaft after bearing adjustment to be sure bearings are not tight CONNECTING ROD AND PISTON ASSEMBLY R...

Page 600: ...e pilot plunger and spring from base 5 Complete removal of pin using pin driver J 6901 3 all except 307 engine or J 9510 2 307 engine and base alone 1 PISTON J 9510 3 i 8 1 REMOVAL TOOL Fig 6 154 Remo...

Page 601: ...hone should be made in addition to checking measurement at top middle and bottom of bore repeatedly Always be sure the crankshaft is out of way of boring cutter when boring each cylinder Crankshaft b...

Page 602: ...endicular to the piston pin Fig 6 159 Measuring Piston Fig 6 160 Cylinder Bore and Piston Identification boss piston pin removed and at sizing point indicated in Fig 6 158 Make sure the micrometer is...

Page 603: ...NECTING ROD TO PISTON There is a notch cast in the top of all piston heads to facilitate proper installation The piston assembliesshould always be installed with notch toward front of engine Fig 6 161...

Page 604: ...rviced for the standard size pistons and for 01OV and 030 oversizepistons When selectingrings be sure they match the size of the piston on which they are to be installed i e standard rings for standar...

Page 605: ...s pistons rods manifolds and other upper engine components installed but the flywheel clutch and transmission assemblies must be removed Remove engine and clutch SM as an assembly See ENGINE REMOVE AN...

Page 606: ...using pen light to see that wire is visible in passage to rear main bearing Fig 6 168 3 Visually check passage from each main bearing to corresponding camshaft bearing Fig 6 169 4 Check passage from...

Page 607: ...pins and camshaft bearings Front oil gallery plugs in the block must be driven into place using a tool which bears against the bottom of the plug A 1 2 x 3 bolt will make a satisfactory tool for this...

Page 608: ...r all except 307 engine timing cover mounting studs 16 Remove oil level indicator 8 Remove fuel pump eccentric and bushing all except 307 engine 17 Remove rocker arm covers 9 Slide timing chain and sp...

Page 609: ...ly and drive shaft 22 Remove valve lifters use J 3049 if necessary 26 Remove bame and oil indicator tube extension Place valve lifters in a storage box so lifters can be 27 Remove crankshaft reinstall...

Page 610: ...hammer handle between block and crankshaft counterweight to keep crankshaft from turning and tighten harmonic balancer to crankshaft bolt to 160 lb ft all except 307 engine or 60 lb ft 307 engine 12 I...

Page 611: ...utor Intake Manifold Vacuum Hole Nut Distributor to Carburetor Vacuum Control Bolt Exhaust Manifold to Intake Manifold 25 Bolt Engine Motor Mount Bracket to Cylinder Block 33 Bolt Engine Motor Mount t...

Page 612: ...2 2993 Bearing Length Overall 1 2 3 4 5 6 752 7 76OV Thrust Taken On 7 Crankpin Journal Diameter 1 999 2 000 Pin Maximum Out of Round New 002 Pin Maximum Taper New 0003 End Play Limits When New 002 00...

Page 613: ...CATION TORQUE APPLICATION TORQUE Bolt Main Bearing Cap to Block 100 Bolt Rear Main Bearing Cap to Block 120 Bolt Cylinder Head 95 Bolt Flywheel to Crankshaft 95 Nut Connecting Rod Bearing Cap 43 Bolt...

Page 614: ...l Moly Filled Lower 350 400 and 455 2 Bbl Tin plated 400 and 455 4 Bbl Channel Moly Filled Ring Gap Upper 350 and 400 019 455 021 Lower 015 Side Clearance 0015 005 Oil Ring Three Piece Material Rails...

Page 615: ...Lash 374 404 403 408 Exhaust Opens BBC 72 77 78 90 Closes ATC 25 23 31 32 Duration 277 282 289 302 Lift Zero Lash 407 408 406 406 Valve Overlap 51 55 54 63 CRANKSHAFT Material Nodular Iron No of Beari...

Page 616: ...ifters and Rocker Arms Pressure Timing Gears and Chain Metered Jet Cylinder Walls Metered Jet OIL PUMP Type Spur Gear Oil Pickup Stationary Screen Pressure All exc 4 Bbl Engines 30 40 PSI 2600 RPM 4 B...

Page 617: ...1 495 1 505 Overall Length Intake A 4 902 4 922 Exhaust 4 913 4 933 Diameter of Stem 3410 3 117 Stem to Guide Clearance Intake 0010 0027 Exhaust 0012 0029 Valve Seat Angle Intake 4C Exhaust 4C Valve F...

Page 618: ...ocker Arm Stud Pressed in Head Lifters and Rocker Arms Pressure Timing Gears and Chain Metered Jet Cylinder Walls Metered Jet OIL PUMP Type Spur Gears Oil Pickup Stationary Screen Pressure 40 to 45 PS...

Page 619: ...Ring Compressor 350 Piston Pin Remove and Replace Set Piston Ring Remove and Replace Tool 400 Rear Main Bearing Oil Seal Installer Piston Ring Remove Replace Tool 350 Valve Spring Compressor Cylmder B...

Page 620: ...SSOR J 6978 HARMONIC BALANCER PULLER J 8021 PISTON RING REMOVER AND INSTALLER J 8929 VALVE SPRING COMPRESSOR J 5823 ALTERNATE TOOL J 9510 PISTON PIN REMOVER AND INSTALLER J 21054 HANDLE FOR CAM BEARIN...

Page 621: ...may occur in the area around the bearing assembly However if the degree of leak age appears excessive proceed to item 4 4 ENGINE OVERHEATING a Start with a cool engine to insure complete fan clutch d...

Page 622: ...ED BY HOT LlGHT OR TEMP GAGE FURTHER DIAGNOSTIC CHECKS SHOULD NOT BE REQUIRED 4 IS OVERHEATING OCCURRING AFTER PROLONGED DRIVING IN SLOW CITY TRAFFIC TRAFFIC JAMS PARAPES ETC IF ANSWER IS YES INSTRUCT...

Page 623: ...nary or of a major nature Listed o n Sheet 3 are t w o groups of problem areas that should be checked i n the order listed Fig 6 A 2 C o o l i n g S y s t e m D i a g n o s i s C h a r t LEAKS Check H...

Page 624: ...PROBLEMS REQUIRING DISASSEMBLY OF COOLING SYSTEM INCORRECT OR DAMAGED F A N CHECK PART NO AGAINST PARTS LlST FAULTY EMISSION SYSTEM COMPONENTS COULD CAUSE OVERHEATING A T IDLE VALVE SEE CHASSIS SERVI...

Page 625: ...1500 r p m g After several minutes the fan clutch should disen gage as indicated by a reduction in fan speed and roar GENERAL DESCRIPTION The cooling system consists of the radiator cap radiator hoses...

Page 626: ...6A 6 1972 PONTIAC SERVICE MANUAL...

Page 627: ...to provide recirculation of water when the thermostat is closed The timing chain cover also has a heater water return connec tion The cooling systems water pump is of the centrifugal vane impeller typ...

Page 628: ...ail and fly apart during subsequent use creating an extremely dangerous condition The majority of non A C cars use a fan which has four blades which are unevenly spaced and have curled tips to provide...

Page 629: ...ped holes in the rear face provide for attachment of the engine fan The front surface of the housing has six deep circular grooves which index with six matching bosses on the rear face of a floating c...

Page 630: ...the valve remains closed while the coolant is cold preventing circulation of coolant through the radia tor but allowing the coolant to circulate throughout the engine to warm it quickly and evenly As...

Page 631: ...e properly prepared for the system After service for 24 months drain the system addition of coolant every two years flush it with water and refill with an inhibited year round coolant meeting the GM 1...

Page 632: ...pera ture at which hydrometer is calibrated for if the solution is warmer or colder large errors may result in some cases as much as 30 F Most good hydrometers are equipped with a thermometer and temp...

Page 633: ...6A 15 NOTE Never open plastic cover when taking readings Evaporation of water from the fluid sample being tested can afXect the reading READING Point the instrument toward any light source and look i...

Page 634: ...best contrast between the light and dark portions of the intake manifold 8 cyl field of view Tilt the instrument toward the light source until best results are obtained NOTE On some models it will be...

Page 635: ...at a temperature of 192 F to 198 F and should be fully open 3 8 or more at a temperature not in excess of 222 F A used thermostat can be about 7 F above or below this setting 188 202 without adverse...

Page 636: ...all models belt from fan pulley WATER PUMP 4 Remove fan and pulley 5 Remove front generator bracket 8 CYLINDER Except 307 6 Remove heater hose and radiator hose at pump REMOVE 7 Remove water pump reta...

Page 637: ...generator bracket 4 Remove fan belt 5 Remove radiator hose at pump 6 Remove power steering belt 7 Remove water pump bolts water pump and fan as sembly REPLACE 1 Transfer fan blade pulley and heater ho...

Page 638: ...istributor drive gear Maximum oil pressure is regulated by a spring loaded ball type pressure regulator valve No adjustment of the pressure regulator valve is provided Oil is taken into the pump throu...

Page 639: ...all Overflow lubricates the top of the valve stem and other valve train surfaces Lubrication of the camshaft thrust plate timing chain and sprockets fuel pump eccentric and fuel pump rocker arm is pro...

Page 640: ...6A 20 1972 PONTIAC SERVICE MANUAL DISTRIBUTOR SHAFT J TIMING CHAIN FUEL PUMP PUSH ROD OILING OIL FILTER A N D BY PASS VALVE Fig 6A 23 Engine Lubrication 307 V 8...

Page 641: ...ENGINE COOLING AND LUBRICATION 6A 21 OIL PRESSURE SENDING UNIT DISTRIBUTOR SHAFT OILING I TIMING GEAR OIL NOZZLE FULL FILTER BY PASS SYSTEM Fig 6A 24 Engine Lubrication 6 Cyl...

Page 642: ...the connecting rods and crankshaft as they rotate OIL FILTER V 8 AND 6 CYL A full flow oil filter is standard equipment on the engine The filter is mounted on a machined boss on the right front side...

Page 643: ...sket Do not use wrench to tighten filter 6 Add oil to bring to FULL mark on dipstick 7 Run engine and check for leaks at filter to base gas kets 8 Re check crankcase oil level If necessary add oil to...

Page 644: ...6A 24 1972 PONTIAC SERVICE MANUAL...

Page 645: ...N 135 145 LBS NEW 85 95 LBS USED 11 k EXC AIR CONDITIONING BELT TENSION 120 130 LBS NEW WITH AIR CONDITIONING 70 80 LBS USED BELT TENSION 120 130 LBS NEW 70 80 LBS USED WlTH AIC I Fig 6A 3 1 Accessory...

Page 646: ...6A 26 1972 PONTIAC SERVICE MANUAL VIEW A 70 80 LBS USED Fig 6A 32 Accessory Drive Air Conditioning L 6...

Page 647: ...ENGINE COOLING AND LUBRICATION Fig 6A 33 Accessory Drive Belt Routing...

Page 648: ...6A 28 1972 PONTIAC SERVICE MANUAL VIEW A Wl455 H O Fig 6A 34 Accessory Drive Belt Routing...

Page 649: ...ENGINE COOLING AND LUBRICATION 6A 29 BELT TENSION 110 125 LBS NEW Fig 6A 35 Accessory Drive Power Steering Mounting V 8...

Page 650: ...6A 30 1972 PONTIAC SERVICE MANUAL Fig 6A 36 Accessory Drive Generator Mounting...

Page 651: ...LUTCH 18 x TAPER 4 Blade CROSS FAN 19 x 2 5 16 5 Blade FLEX FAN 18 718 x 2 114 7 Blade FLEX 19 1 14 x 2 114 6 7 1 9 1 7 Blade THERMO CLUTCH 1 18 x 2 114 WIO AIC A C W O A C 7 Blade THERMO CLUTCH 19 11...

Page 652: ...U NT NU NT N A NT NJ NK N A NK NM NM NJ NK NJ NK N A NK NM NM HEAVY D M T MODELS ENGINE 252 Exa Police L30 L65 L78 L66 EXC SMI L66 SMI L75 252 Police 252 Police Highway N A P P N A P P N A PO N A P P...

Page 653: ...r 15 Bolt Water Outlet Fitting 30 30 20 Check for alignment bottoming height and or leaks lb in Type Pressure with vent Operating Pressure 14 17 PSI Pump Type Centrifugal Pump and Fan Drive V Belt Pum...

Page 654: ...if filter element is changed Oil Pressure When Refilling 307 V 8 4 qts V 8 exc 4 Bbl engines 30 40 PSI 2600 rpm 5 qts if filter element is changed V 8 4 Bbl engines 55 60 PSI 2600 rpm When Refilling 6...

Page 655: ...dic Service 6B 68 Overhaul and Adjustment 6B 68 Carburetor Service Specifications 6B 82 Unloader and Fast Idle Tang 6B 31 GENERAL TROUBLE DIAGNOSIS AND TESTING All Pontiac engines have been designed t...

Page 656: ...6B 2 1972 PONTIAC SERVICE MANUAL 2 BBL CARB ENGINE OTHERWISE SAME AS 4 BBL CARB ENGINE Fig 6 6 2 Air Cleaner Installation V 8 Std...

Page 657: ...preheater with an oil wetted paper element is standard on all models An optional heavy duty dual stage air cleaner is available on all models except the Ram Air A and F Seriesengines This air cleaner...

Page 658: ...uel mixture As the engine warms up the thermostatic heat control valve opens allowing all gases to be exhausted via the normal route The assembly is kept from rattling by an anti rattle spring mounted...

Page 659: ...ing proce dure HOT IDLE COMPENSATOR The hot idle compensator is used on all 6cyl automatic ACCELERATOR CONTROLS V 8 400 and 455 4 Bbl with automatic transmission ex cept Ram Air and A C equipped F Ser...

Page 660: ...or diverter is integral with the pump on all V 8 engines with A C and on all 4 Bbl engines except B Series The fuel pump diaphragm is retained with a crimped edge This provides a greater effective dia...

Page 661: ...ible to the fuel pump and when a malfunction is detected it will be necessary to replace the pump assembly TROUBLE DIAGNOSIS AND TESTING There are three tests that can be performed to evaluate the fue...

Page 662: ...e Retainer into hole on Accelerator Pedal Rod to assure the cable is not KINKED or DAMAGED in any way TORQUE 90 IN LBs AT qrRE SLEEVE ROD CABLE ASSEMBLY CAUTION Care must be taken during installation...

Page 663: ...reading pressure gauge Hold the gauge up so that it is approximately 16 above the fuel pump 2 Start engine and run at slow idle using gasoline in carburetor bowl and note reading on pressure gauge 3...

Page 664: ...6B 10 1972 PONTIAC SERVICE MANUAL M V MONOJET CARBURETOR SPARK VACUUM TUBE Fig 68 12 MV Monojet Carburetor...

Page 665: ...ORRECT STARTING PROCEDURE USED STILL NO START STICKING I N SEAT OR PROCEDURE USED I I ADJUST IDLE SPEED I STILL NO START I I CORRECTLY STALLIN I IF UNABLE TO ADJUST CHECK IDLE SYSTEM FOR DIRT AIR I CH...

Page 666: ...R ING JETS I FOR BEING PLUGGED LOOSE METER ING ROD BENT OR INCORRECT PART ALTERED OR INCORRECT I O A D T I CARBURETOR FLOODING 1 OPENING AT CARBURETOR L DIRTY OR F L UGG D 1 THROllLE VALVE ST1 CK I NG...

Page 667: ...which vents vapors externally during hot engine operation The carburetor part number is stamped on a vertical sec tion of the float bowl next to the fuel inlet nut Fig 6B 13 When replacing the float b...

Page 668: ...he float bowl The fuel inlet filter has a pressure relief spring located at the rear of the filter It seats between the rear of the filter and the inlet casting Should the filter become clogged from i...

Page 669: ...combine to produce a smooth fuel flow at all engine speeds The lower idle air bleed is used strictly as an air bleed during idle operation It supplies additional air to the idle circuit for improved...

Page 670: ...where it is metered and flows on into the main fuel well In the main well the fuel is mixed with air from the air bleed at the top of the well and another air bleed which leads into the main well fro...

Page 671: ...nsists of a spring loaded pump plunger and pump return spring oper ating in a fuel well The pump plunger is connected by linkage directly to a lever on the throttle shaft T DISCHARGE SPRING RETAINER P...

Page 672: ...sts in closing the choke valve along with tension from the thermostatic coil for improved cold starting The choke closing assist spring only exerts pres sure on the vacuum break link to assist in clos...

Page 673: ...ove air horn by lifting straight up invert and place on clean bench Air horn to float bowl gasket can remain on bowl for removal later The idle vent valve on the air horn assembly has been replaced by...

Page 674: ...nk from pump plunger shaft by rotat ing link until lip on link aligns with notch in plunger shaft Remove pump plunger from float bowl 15 Remove main metering jet from bottom of float bowl 16 Remove tw...

Page 675: ...out four turns as a prelimi nary idle adjustment NOTE The plastic limiter cap should not be installed on the idle mixture needle until the idle mixture has been adjusted as specifiedin Section 6D 2 I...

Page 676: ...ock Part No 7041970 2 Install air horn to float bowl by lowering gently onto float bowl until seated Install three long and three short air horn to float bowl attaching screws Tiehten After adjustment...

Page 677: ...curely 3 Install the choke vacuum break diaphragm hose to the diaphragm on air horn and tube on air horn 4 Assemble choke rod into the slot in the upper choke lever End of rod points away from air hor...

Page 678: ...t NOTE Refer to the idle speed chart in Section Slow and fast idle RPM specificationsare also 6D for the remaining adjustments Adjust shown on the chart ments must be performed in sequence shown CHOKE...

Page 679: ...g 6B 28 EN LOWER VE AND PLACE GAUGE BETWE USE OUTSIDE VACUUM SOURCE TO SEAT DIAPHRAM DIAPHRAGM PLUNGER IN UNTIL IT SEATS i END Fig 66 28 Vacuum Break Adjustment CHOKE COIL ROD ADJUSTMENT Fig 6B 30 CHO...

Page 680: ...6B 26 1972 PONTIAC SERVICE MANUAL UNLOADER ADJUSTMENT Fig 6B 29 Fig 68 29 Unloader Adjustment...

Page 681: ...one single barrel carburetor OPERATION OF WGD FLOAT SYSTEM Fuel enters the carburetor at the gasoline connection and flows through the needle seat into the float chamber When the fuel reaches the pres...

Page 682: ...nd a variable purge system are used During normal engine idle the constant bleed purge is in operation It is a small bleed hole located in the canister In order to provide additional purge to the vapo...

Page 683: ...re additional fuel is required for satisfactory operat ion manifold vacuum decreases sufficiently so that the piston spring moves the piston link and metering rods upward to the proper metering rod st...

Page 684: ...that leaner mixtures are maintained during warmer tempera tures and richer mixtures for colder temperature operat ion This is accomplished in the following manner During extreme cold operation the the...

Page 685: ...to obtain proper clearance Fig 6B 39 NOTE With choke fully closed tang on fast idle cam must clear stop on throttle body flange Hold choke closed lightly Fully open throttle forc ing choke valve open...

Page 686: ...ing Remover T 109 56or a stiff wire having a short hook on the end Remove both metering rod jets Remove pump jet screws jet housing and gasket Invert car buretor and catch pump inlet check ball and ou...

Page 687: ...ton spring is distorted it should be replaced Accelerating Pump Parts Inspect countershaft as sembly for wear of shaft and make sure that lever is tight on countershaft Inspect throttle connector rod...

Page 688: ...point downward in pump outlet well then install a new gasket the dis charge jet housing and screw Install both metering rod jets no gaskets used 5 Install vacuum piston spring Install lower pump spri...

Page 689: ...rew 12 Using a wire hook wind countershaft return spring 1 2 turn and hook on boss on casting Install pump rod and two spring clips with offset end of rod up 13 To adjust pump plunger back out throttl...

Page 690: ...escribed previously 19 Adjust fast idle cam choke unloader and fast idle screw as described previously 22 Make final fast idle speed adjustment as described previous1y 20 Pack two countershaft lubrica...

Page 691: ...M I N c o R R r c n v i ICHOKE COIL ADJUSTE I SPEED 1 LEAKS AND PUGGED PASSAGES CHECK CHOKE VALVE AND STILL STALLS ADJUST LINKAGE FOR BINDING OR VACUUM BREAK INTER MEDIATE CHOKE ROD AND CHOKE ROD BOWL...

Page 692: ...ttle metering deviceis pre set 1 1 2 carburetors used on the larger engines at the factory and plugged No adjustment should be attempted in the field The following differences should be noted so that...

Page 693: ...etor uses a calibrated clusterdesign in which is placed the main well tubes idle tubes mixture passages air bleeds and pump jets The cluster can easily be removed for cleaning and inspection purposes...

Page 694: ...text OPERATING SYSTEMS FLOAT SYSTEM The float system Fig 6B 52 controls the level of fuel in the carburetor bowl The float pontoon is solid and is made of a closed cell plastic material for added buo...

Page 695: ...eed hole which leads into the carburetor bore area and is used to pull vapors from the vapor canis ter during engine idle In order to provide additional purge to the vapor canister two extra purge por...

Page 696: ...uel supplied at higher air flows to meet engine demands POWER ENRICHMENT SYSTEM To achieve the proper mixtures required when more power is desired or for extreme high speed driving a vacuum operated p...

Page 697: ...e closed for cold engine starting To close the choke valve it is necessary that the accelera tor pedal be depressed so that the fast idle screw attached to the throttle lever will clear the steps on t...

Page 698: ...fuel filter in the carburetor air horn should be cleaned and replaced periodically Normal recommen dations are that it be cleaned or replaced during the nor mal engine tune up or between approximately...

Page 699: ...10 Remove power piston by depressing piston stem and allowing it to snap free Use care not to bend the power piston stem 11 A tang on the inner pump lever retains the pump plunger assembly in the inne...

Page 700: ...e the throttle body assembly or if the idle mixture needles are da maged New idle mixture limiter caps are provided in the repair kit Before the new limiter caps are in stalled it will be necessary to...

Page 701: ...ct power piston and spring for burrs or dis tortion Replace if necessary 4 Check all filter screens for dirt or lint Clean and if they are distorted or plugged replace with new parts 5 Inspect cluster...

Page 702: ...uld move freely in air horn bore 6 7 FLOAT LEVEL ADJUSTMENT Fig 6B 65 Install pump lever and shaft assembly into air horn casting Then install inner pump lever and tighten retaining screw securely NOT...

Page 703: ...crews evenly and se curely Fig 6B 67 3 Install inlet filter pressure relief spring and tighten nut to 25 lb ft 4 Install pump rod into upper pump lever by rotating off set end into hole in lever and i...

Page 704: ...6B 50 1972 PONTIAC SERVICE MANUAL PUMP ROD ADJUSTMENT Fig 68 68 Fig 68 66Pump Rod Adjustment...

Page 705: ...ENGINE FUEL 6B 51 CHOKE ROD ADJUSTMENT Fig 6B 69 GAGE BETWEEN UPPER EDGE OF CHOKE VALVE AND AIR HORN CASTING BENDTANG n TO ADJUST N D STEP OF CAM NST HIGH STEP Fig 68 69 Choke Rod Adjustment...

Page 706: ...NTIAC SERVICE MANUAL VACUUM BREAK ADJUSTMENT Fig 6B 70 PLACE GAUGE BETWEEN UPPER EDGE OF CHOKE VALVE AND AIR ROD AGAINST TO ADJUST UPLUNGERMUST BE SEATED USE OUTSIDE VACUUM SOURCE Fig 68 70 Vacuum Bre...

Page 707: ...ENGINE FUEL 6B 53 UNLOADER ADJUSTMENT Fig 6B 71 GAUGE BETWEEN UPPER 2 EDGE OF CHOKE VALVE O AND AIR HORN CASTING fl THROTTLE VALVES WIDE OPEN BEND TANG TO ADJUST r Fig 68 7 1 Unloader Adjustment...

Page 708: ...6B 54 1972 PONTIAC SERVICE MANUAL CHOKE COIL ROD ADJUSTMENT Fig 6B 72 Fig 68 72 Choke Coil Rod Adjustment...

Page 709: ...5 4MV QUADRAJET CARBURETOR SECONDARY VALVES ACTUATING ROD IDLE MIXTURE LIMITER I PUMP LEVER RETAINING PIN Fig 68 73 4MV Quadrajet Carburetor SECONDARY AIR VALVE HOT IDLE COMPENSAT 1 Fig 68 74 4MV Quad...

Page 710: ...ALLING HIGH I N O K ADJUSTED CONTINUES FLOAT BOWL NOT CLOSING I N CARBURETOR CHOKE VALVE CHOKE COlL OR STUCK CHOKE W O THROTTLE CHECK FLOAT ADJUSTMENT FLOAT ALIGNMENT NO FUEL I N TANK i DEFECTIVE FUEL...

Page 711: ...NDARY METER ING RODS MISALIGNED STICKING DIRTY OR BENT SECONDARY M A l N METERING R O U G H I D L E S T A L L S I FUEL FILTERS OR SCREENS I N CARBURETOR DIRTY OR PLUGGED FLOAT STICKING OR NOT PRORRLY...

Page 712: ...nlet filter is mounted in the fuel inlet gives a more stable and finer fuel control in the idle and casting which is an integral part of the float bowl and is economy ranges of operation Fuel metering...

Page 713: ...cy and allows the use of a smaller float to maintain constant fuel levels A pleated paper fuel inlet filter is used with a pressure relief spring The relief spring allows fuel pump pressure to force t...

Page 714: ...e discharge holes below the throttle valves are exposed directly to engine manifold vacuum With the idle discharge holes in a very low pres sure area and the fuel in the float bowl vented to atmos phe...

Page 715: ...ister are provided in the carburetor throttle body They consist of a variable purge plus the constant bleed purge The constant bleed purge is a small orifice and is used during idle operation to provi...

Page 716: ...ive fuel vapors entering the engine manifold cause richer than normally required mixtures resulting in rough engine idling and stalling At a predetermined tem perature when extra air is needed to offs...

Page 717: ...nel to the vacuum operated power piston connected to the primary main metering rods Fuel flow from the float bowl is metered between the metering rods and main metering jet orifice As the primary thro...

Page 718: ...gins to open the upper edge of the air valve passes the accelerating well port As the valve passes the port it exposes the port to manifold vacuum The port will immediately start to feed fuel from the...

Page 719: ...ing a momentary leanness The accelerator pump Fig 6B 81 is used to provide the extra fuel neces sary for smooth operation during this time The accelerating pump system is located in the primary side o...

Page 720: ...pull over from the pump discharge passage CHOKE SYSTEM The Quadrajet choke valve Fig 6B 82 is located on the primary side of the carburetor It provides the correct air fuel mixture enrichment to the e...

Page 721: ...in the vacuum break unit is a spring loaded plunger The purpose of the spring is to off set choke thermostatic coil tension and balance the greater opening of the choke valve with tension of the chok...

Page 722: ...exception of the idle speed and mixture adjustment Carburetor Model Number Calif or Non Calif Both Both Both Both Both A C or Non A C Both Both Both Both Both Engine Trans Usage 455 Auto Exc H 0 i 400...

Page 723: ...IGHT UP 2 REMOVE SECONDARY METERING RODS UNTIL THE BLEED TUBES A N D PUMP PLUNGER INSERT A STEM CLEAR THE FLOAT BOWL T H E N ROTATE VERTICALLY TO REMOVE THE VACUUM BREAK 3 REMOVE NINE AIR HORN ATTACHI...

Page 724: ...SEE INSET Y VACUUM BREAK AND OASHPOT ACTUATING ROD CHOKEVALVE CHOKEVALVE ATTACHING i DISASSEMBLE 1 REMOVE CHOKE VALVE SCREWS 2 L I F T CHOKE VALVE FROM AIR HORN AND REMOVE SHAFT NOTE AIR VALVES SHOULD...

Page 725: ...C L E A R POWER PISTON AND L I F T O F F NOTE GASKET IS C U T AWAY I N AREA O F POWER PISTON FOR EASE O F REMOVAL AND R E P L A C E M E N T ASSEMBLE 1 I N S T A L L AIR HORN GASKET AROUND PRIMARY METE...

Page 726: ...IBLE MP SPRING IN ASTIC FILLER NEEDLE UNTIL FULLY Fig 68 86 Plastic Filler Pump Spring R R...

Page 727: ...P METERING RODS WlTH JETS WlTH RODS I N PRIMARY JETS PUSH DOWN ON POWER PISTON T O LOCATE PLASTIC RETAINER PROPERLY I N BORE THEN PRESS PLASTIC RETAINER INTO MACHINED RECESS IN BORE USING BLADE OF SCR...

Page 728: ...BOWL 2 DISCONNECT NEEDLE PULL CLlP AND REMOVE NEEDLE ASSEMBLE 1 INSERT NEW NEEDLE AND PULL CLlP IN FLOAT PIN 2 INSTALL FLOAT BY HOLDING FLOAT AT TOE AND INSTALL RETAINING PIN FROM CHOKE SIDE 3 ADJUST...

Page 729: ...REMOVABLE 5 REMOVE ACCELERATOR PUMP CHECK BALL RETAINER AND BALL 6 REMOVE SECONDARY BAFFLE 7 SPREAD RETAINING EARS WITH PLIERS TOREMOVEVACUUMBREAK ASSEMBLY ASSEMBLE 1 REPLACE VACUUM BREAK UNIT CLOSE E...

Page 730: ...OKE ASSY LINING UP FLATS ON INTERMEDIATE CHOKE SHAFT WITH CUT OUTS I N CHOKE ROD LEVER 3 INSTALL RETAINING SCREW AND TIGHTEN SECURELY 4 REMOVE INTERMEDIATE CHOKE ROD FOR INSTALLATION LATER INTERMEDIAT...

Page 731: ...TTLE BODY IS REQUIRED ASSEMBLE INSTALL IDLE MIXTURE SCREWS AND SPRINGS BACK OUT SCREWS FIVE TURNS FROM LIGHTLY SEATED POSITION AS A PRELIMINARY ADJUSTMENT INSTALL NEW THROTTLE BODY TO BOWL GASKET INST...

Page 732: ...er 2 Blow out all passages in castings with com pressed air Do not pass drills through jets or passages 3 Inspect idle mixture needles for damage 4 Examine float needle and seat for wear Replace if ne...

Page 733: ...SH FLOAT D CASTING TO TOP OF FLOAT AT TOE BEND FLOAT ADJUST 5 VISUALLY CHECK FLOAT ALIGNMENT AFTER ADJUSTING Fig 66 93 Float Level Adjustment 1 A I R V A L V E 0COMPLETELY CLOSED AND END O F SLOT Fig...

Page 734: ...TEP OF FAST IDLE CAM PRIMARY THROTTLE VALVES CLOSED AFTER SCREW MAKES CONTACT ON LEVER TURN SCREW I N 3 TURNS TO ADJUST BENCH SETTING ADJUST ON CAR TO OBTAIN SPECIFIED RPM Fig 68 95 Fast Idle Adjustme...

Page 735: ...ENGINE FUEL 6B 81 Fig 68 98 Vacuum Break Adjustment SPECIFIED CLEARANCE BETWEEN FRONT EDGE OF VALVE AND TANG 015 Fig 68 99 Air Valve Lockout Adjustment...

Page 736: ...f 250 A T Calif 250 M T Calif 400 A T 400 A T 350 A T 455 A T 307 A T 307 M T 455 A T All exc Ram Air 400 M T All exc Ram Air 455 H O A T IRamAir 7 16 350 M T 1 5 16 1 1 I 1AIR I A I R ILlI l Erfi CHO...

Page 737: ...removed and throttle and choke wide open Crank engine through at least five compression strokes to obtain highest possible reading No cylinder should be less than 80 of the highest cylinder see exampl...

Page 738: ...gs must be of the same make and number or heat range See section 6E for correct spark plug usage 4 Adjust spark plug gaps to 035 using a round feeler gauge CAUTION Never bend the center electrode to a...

Page 739: ...or as far as possi ble then releasing the rotor to see if the springs return it to its original position If the rotor does not return readily the distributor must be disassembled and the cause of the...

Page 740: ...hould be clean and the battery hold down 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 bet...

Page 741: ...OPERATION AND ADJUSTMENT The specifiedchoke setting provides ideal choke operation in all climates No seasonal changes are necessary For setting see ENGINE FUEL Section 6B CAUTION Choke linkage and fa...

Page 742: ...anual Trans CB T D C 307 V 8 Auto Trans 8 B T D C 5 Disconnect timing light 6 Reconnect distributor spark advance hose then per form idle speed and mixture adjustment See Section 6D IDLE SPEED AND MIX...

Page 743: ...and that steering wheel does not have excessive play Also observe for alignment of steering wheel pull wander or other irregularity that might indicate need for front end alignment WINDSHIELD WIPER W...

Page 744: ...INTRODUCTION There are two types of emissions to be controlled crank case emissions and exhaust emissions Crankcase emis sions are controlled by use of the closed Positive Crankcase Ventilation P C V...

Page 745: ...where it mixes with the normal fuel air charge and is later burned At high road speeds or heavy acceleration engine blow by is increased and at the same time intake manifold vacuum decreases When thi...

Page 746: ...n required This control of carburetor air temperatures allows leaner carburetor calibrations with accompanying reduced emis sions than would normally be possible for acceptable cold weather operation...

Page 747: ...st check to determine if the motor linkage is prop erly connected to the door or if a bind is present If the linkage is found satisfactory then motor replacement is indicated a With the engine shut of...

Page 748: ...from air cleaner after noting the installed position of the sensor In order to provide efficient engine operation on cars equipped with the Controlled Combustion S C S C E C T C S Systems Fig 6D 8 all...

Page 749: ...1972 PONTlAC SERVICE MANUAL VIEW A Fig 6D 10 Vacuum Solenoid Location 6 cyl...

Page 750: ...n of the T C S or S C S systems trolled Spark System which is used on all engines on both allow vacuum controlled spark advance to the distributor manual and automatic transmissions Fig 6D 11and 6D in...

Page 751: ...n 95 Fand 230 F S C S only shift trans mission into Drive rear wheels raised and accelerate car observe timing mark on harmonic balancer Timing should advance when the car shifts into high gear T C S...

Page 752: ...D ENERGIZED PROVIDING NO V A C U U M A D V A N C E BELOW 38 MPk DURING N O R M A L OPERATING TEMPERATURE 1 T C S SOLENOID ENERGIZED PROVIDING N O VACUUM ADVANCE I N ALL TRANSMISSION RANGES BUT HlGH GE...

Page 753: ...l models reconnect throttle solenoid wire Manually extend solenoid screw and adjust to specified RPM Fig 6D 16 With auto trans in Park man trans in Neutral check fast idle speed with fast idle speed s...

Page 754: ...l vapors which normally escape from the fuel tank Vapor arrest is accomplished through the use of a char coal canister which adsorbs the fuel vapors and stores them until they can be removed to be bur...

Page 755: ...USED ON 350 400 455 V 8 w STANDPIPE I CANISTER RESTRICTION LIQUID RETURN TO TANK IIII EXPANSION VOLUME 7 USED ON 350 400 455 V 8 WITH 2GV OR 4MV CARBURETORS WITH WGD CARBURETOR USED ON 250 L 6 307 V 8...

Page 756: ...or into the engine where they are burned The purge valve three tube 6 cyl and 307 V 8 canis ter operates basically the same as the two tube type However a purge valve is added which is an integral par...

Page 757: ...d check valve and hoses necessary to connect the various components Carburetors and distributors for engines with the A I R Systemare designed particularly for these engines there fore they should not...

Page 758: ...atio such as the crankcase ventilation system the carburetor and the carburetor air cleaner Because of the similarity of many parts typical illustra tions and procedures are used except where specific...

Page 759: ...loose outer disc of filter fan 3 Pull remaining portion of filter off with pliers Fig 6D 26 NOTE Care should be taken to prevent frag ments from entering the air intake hole INSTALL 1 Install the new...

Page 760: ...eak exists Fig 6D 28 REMOVE To replace any hose and or tube note routing then remove hose s and or tube s as required INSTALL 1 Install new hose s and or tube s routing them as when removed 2 Tighten...

Page 761: ...gnal lines and check sys tem for leaks AIR INJECTION PUMP INSPECTION Accelerate engine to approximately 1500 RPM and ob serve air flow from hose s If air flow increases as engine is accelerated pump i...

Page 762: ...ting bolts loose 2 Install pump pulley as outlined 3 Install and adjust belt as outlined 4 Connect the hoses at the pump PRESSURE RELIEF VALVE REPLACEMENT NOTE Thepressure relief valveisincorporated i...

Page 763: ...ctrical system can be divided into three basic sections 1 The Cranking Circuit 2 The Charging Circuit 3 The Ignition Circuit Wiring 6E 30 Timing 6E 31 Distributor 6E 31 6 cyl 6E 32 8 cyl 6E 33 Coil 6E...

Page 764: ...tive Battery Tighten Cables or Change Should Be Over 9 5 Vol s Wires at Starter Connections O K I a 1 IRiT Z IEL 1I Less Than 9 5 Volts Over 9 5 Volts ICheck Condilion of Ballcry Verify lhat Low Temp...

Page 765: ...es or Low httery I Check Accessory Operation I Correct As Necessary Ezl Accessories Do Not Operate Accessories Operate O K r l Llght Only Liphts Lipht Lights At I Li Eilher II at One Wire II Bolh Wlre...

Page 766: ...COlL POSITIVE TERMINAL n RESISTANCE WIRE P U L L IN COlL PLUNGER SHIFT LEVER FLYWHEEL I BAT BULKHEAD CONNECTOR I A K I C K WI I L H PINION COMPRESSION SPRING CRANKING MOTOR Fig 6E 3 Cranking Circuit A...

Page 767: ...or terminal to the in sulated brushes Fig 6E 5 The brush rigging has brush arm supports attached di rectly to the extruded section of the field frame One ground brush and one insulated brush are both...

Page 768: ...ugh the starting motor cannot be checked against OVERHAUL PROCEDURES specificationson the car a check can be made for exces sive resistance in the cranking circuit by measuring REMOVE FROM CAR 6 CYL E...

Page 769: ...e a standard half inch pipe coupling or other metal cylinder of suitable size an old pinion of suitable size can be used if available onto shaft so end of coupling or cylinder butts against edge of re...

Page 770: ...ded com mutator only a very light clean up cut should be made The minimum diameter of the commutator after turning should not be less than 1 650inches As a final step in this procedure the commutator...

Page 771: ...e field winding can be checked for an open or a ground by using a test lamp as follows 1 Using a 110 volt test lamp place one lead on each end of the field coils connected in series Fig 6E 8 If lamp d...

Page 772: ...ar next to snap ring Then using two pairs of pliers at same time one pair on either sideof shaft grip retainer and thrust collar and squeeze until retainer is forced over snap ring Fig 6E 12 2 Place a...

Page 773: ...nector from the solenoid motor terminal and insulate it carefully INSTALL IN CAR V 8 ENGINE 1 Position starter motor on engine 2 Connect battery cable and solenoid wires to solenoid and fasten securel...

Page 774: ...n 2 Insert scrwdriwer into test hole to ground rotor I If battery is fully charged use the starter to partially discharge i t before recording maximum current output 5 Turn on all accessories lights o...

Page 775: ...left side of engine next to rocker cover a r o x i m a t e l v 6 from front of enqine FIG A 3 Ignition switch on engine and accessories F G h e s ethree voltage readings off check the voltage reading...

Page 776: ...mbly and checking as described in Fig 6E 20 FIG J FIG K 8 a Disconnect energizer ground strap b Disconnect red wire from BAT termi nal on Delcotron c Connect ammeter black lead to red wire and red lea...

Page 777: ...ush hold er to end frame Fig 0 OR WORN INSULATION FIG 0 INSULATING SCREWS FIG P Also observe insulating washer under recti fier bridge Check for cracked or broken insulators Fig P Visually inspect bru...

Page 778: ...Check rotor Fig U 15 Use a wooden plastic toothpick to retain brushes and reinstall regulator and brush assembly in end frame fitting toothpick through slot in end frame Reassemble generator carefull...

Page 779: ...gulator cannot be set within range replace NOTE To adjust transistor voltage regulator 1 Remove pipe plug 2 lnsert small screwdriver into slot 3 Turn clockwise to raise setting 0 3 volt for each notch...

Page 780: ...ide the generator slip ring end frame A11 regulator components are enclosed into a solid mold and this unit along with the brush holder assembly is attached to the slip ring end frame The regulator vo...

Page 781: ...the stator supplies d c field current through the diode trio the field TRl and then through the grounded diodes in the rectifier bridge back to the stator Also the six diodes in the rectifier bridge c...

Page 782: ...re current to flow through the field windings to insure voltage build up in stator wind ings As the generator begins to operate voltage from the R or relay terminal is impressed through the regulator...

Page 783: ...t always observe the following precautions Do not polarize theCgenerator Do not short across or ground any of the terminals in the charging circuit except as specifically in structed herein NEVER oper...

Page 784: ...er reading is low the field winding is grounded Fig 6E 30 2 To check for opens connect test lamp or ohmmeter to each slip ring If lamp fails to light or if the ohmm eter reading is high infinite windi...

Page 785: ...ate inside of generator Re place dry worn or rough bearings with new bearings which are prepacked with proper amount and type of lubricant 4 To install press in bearing and grease slinger with tube or...

Page 786: ...lows a To check for grounded windings connect lamp or ohmmeter from any stator lead to frame If lamp lights or ohmmeter reading is low the stator is grounded see Fig 6E 26 b To test for opens successi...

Page 787: ...n the screw is assembled over the top of the diode trio connector To check the diode trio after removing it from the end frame assembly connect an ohmmeter having a 1 1 2 volt cell to the singlebrush...

Page 788: ...dry cloth and must be completely free of oil 7 If there is any doubt about condition of brush springs they should be replaced 8 Install springs and brushes into brush holder they should slide in and o...

Page 789: ...belt to the specified belt tension See Section 6A for proper belt tensioning procedures 4 Tighten bolts to 30 lb ft except bolt at sliding slots on brackets which is 20 lb ft 5 Install generator termi...

Page 790: ...resistor from ignition switch to coil positive I terminal and repair or replace harness as required I ENGINE WILL NOT CRANK BATTERY AND CABLES IN I switch connections 1 Connect 12 volt test light to e...

Page 791: ...esult from use of too cold a plug Correct engine condition In most cases plugs in this condition will be servicable after proper cleaning and regapping If troubles are not eliminated use hotter type p...

Page 792: ...park plugs and primary and secondary wir ing These components are connected electrically as in Fig 6E 38 PERIODIC SERVICE The distributor and spark plugs are the only components of the ignition circui...

Page 793: ...ed for chips or cracks and carbonized paths which would allow high tension leakage to ground The rotor spring should be checked to insure it has good positive contact against cap button CONTACT SET OR...

Page 794: ...the movable plate The centrifugal advance mechanism is located under the breaker plate assembly and is a part of CIRCUIT BREAKER PLATE ASSEMBLY LUBRICATION RESERVOIR PRIMARY CONTACT SET DWELL ANGL PLA...

Page 795: ...ed as one complete assembly Due to the location of the radio antenna the radio is more sensitive to interference originating in the distributor For this reason all distributors contain a new Radio Fre...

Page 796: ...resistance is by passed automatically through the ignition and starting switch when switch is in the START position SECONDARY IGNITION CABLES All ignition cablesin the secondary or high tension system...

Page 797: ...rk plugs which are too cold will also result in carbon deposits Red brown etc oxide deposits a conse quence of the use of leaded fuel usually result in spark plug failure under severeoperating conditi...

Page 798: ...nic balancer is indexed with O mark on the timing chain cover Fig 6E 49 Remove vacuum hose from distributor Remove distributor clamping nut and hold down clamp from stud Remove distributor It will be...

Page 799: ...n stroke and timing mark on harmonic balancer is indexed with the 0 mark on the timing chain cover Fig 6E 49 2 Position new distributor to block gasket on block 3 Before installing distributor index r...

Page 800: ...meter before testing dwell angle Alternate Method Turn adjusting screw clockwise until engine begins to misfire Then turn screw one half turn in opposite direction counterclockwise This will give pro...

Page 801: ...tal loss of ignition Fig 6E 54 Timing Marks on V 8 Engine contact set assembly in place Fig 6E 55 Sighting Timing Marks on F Cars With A C INSPECT With distributor removed from vehicle it is advisable...

Page 802: ...and tworegis ter identations are resting on top of theplate DO NOT CROSS THREAD SCREW b Look to make sure lead clips arepushed all the way down into the hap lock point set The clips must not touch th...

Page 803: ...ENGINE ELECTRICAL 6E 41 CONTACT k SET BREAKER CONDENSER PLATE FELT WASHER GASKET NOT INC IN ASSY VACUUM ADVANCE GEAR WASHER PIN b SHAFT Fig 6E 57 Exploded View of V 8 Distributor...

Page 804: ...ces left side of engine and rotor points toward contact in cap for No 1 cylinder Before in stalling distributor index rotor with housing as noted when distributor was removed This will simplify in dex...

Page 805: ...rk 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 regapped or replaced every 12 month...

Page 806: ...e bolts may cause poor performance and radio interference I 1 1 I 1 Connect ohmmeter Fig 4 2 Parts A and B each should be practically zero If infinite on either reading replace coil 3 Part C should be...

Page 807: ...SWITCH The switch is located in the steering column on the right hand side just below the steering wheel The electrical switching portion of the assembly is separate from the key and lock cylinder How...

Page 808: ...d the air conditioning heater and defroster circuits are activated There are six terminals on the back of the switch Fig 5E 66 The BAT terminals Bl B2 and B3 which are connected to form one common ter...

Page 809: ...11 and I3 will be found on the back of the switch The 11 and 13 terminals are energized when the ignition switch is in the normal operating position RUN position The 11 directs current to the ignition...

Page 810: ...GN 1 ACC 1 BAT 1 IGN SW LOCK ROD IGN KEY AND LOCK BAT 1 IGN SW LOCK ROD AND LOCK I IGN 1 ACC 1 BAT B A T 3 1 0 GRD IGN SW LOCK ROD On Unit Distributor Ignition Systems the IGN 1 terminal is used to A...

Page 811: ...0 V 13 15 5 A SERIES 1 1 2 5 0 L 6 3 5 0 V 8 4 0 0 V 8 4 5 5 V 8 STD AIC OR H D S T 0 AIC H D STD OR AIC H D S T 0 OR AIC H D 1 MAINT FREE Battery Y54 R58 Y58 R58 R58S R58 R58S R58S R88X C89 watts OOF...

Page 812: ...A L A D V A N C E I Start Intermediate Maximum V A C U U M Dist Deg Dist Deg Dist Deg C O N T R O L DEG RPM DEG RPM DEG RPM M O D E L I I I In Hg to In Hg for Max advancr Dist Deg Fig 6E 68 Distribut...

Page 813: ...g retainer 3 Insufficient tension between clutch fork spring and ball stud 4 Fork improperly installed 5 Weak linkage return spring NOISY 1 Worn throw out bearing 2 Fork came off ball stud heavy click...

Page 814: ...vent sticking of the plate to the flywheel and the pres clutch is used on all cars with manual transmissions The sure plate due to vacuum between the members on disen clutch assembly consists of the c...

Page 815: ...pivots on its ball socket The inner end of the fork then pushes the release bearing forward so that it presses against the Fig 7 1 Pedal effort is transmitted by the pedal through the countershaft and...

Page 816: ...shift can be made smoothly the clutch is fully releasing b If shift is NOT smooth clutch is not fully releasing and adjustment is necessary 2 Check clutch pedal bushing for sticking or excessive wear...

Page 817: ...stud nut and slide stud out of bracket slot REMOVE 4 Move countershaft outboard and lift out to remove from vehicle 1 Remove return spring and anti lash spring 2 Disconnect clutch pedal push rod and c...

Page 818: ...ball studs and seats with graph REMOVE ite grease before reassembly 1 Disconnect battery to starter lead at battery REPLACE 2 e k o v e propeller shaft and transmission See appli 1 Reverse the removal...

Page 819: ...flywheel housing shield 7 Remove flywheel housing bolts and pull housing off of dowels 8 Remove flywheel housing 9 Disconnect clutch release fork from ball stud by forc ing it toward the center of the...

Page 820: ...re transmission main drive gear inserted in spline of clutch driven disc to move disc into correct alignment so pilot on end of drive gear will enter clutch pilot bearing Tighten clutch cover and pres...

Page 821: ...ace Position flywheel on crankshaft flange with scribe marks in alignment and install flywheel to crankshaft bolts and tighten evenly to 95 lb ft torque NOTE Flywheel bolts do not require lock washers...

Page 822: ...ansmission to Flywheel Housing Bolts 55 Flywheel to Crankshaft Bolts 95 Countershaft Stud to Engine Boss F and X Series 28 Countershaft Stud to Frame Bracket Lock Nut 20 Lever Hub to Engine Boss Bolt...

Page 823: ...bricant level 1 Loose bolts at transmission outer shifter levers 2 Transmission misaligned or loose 2 Bent gearshift control rods loose swivel clamps or linkage interference 3 Main drive gear bearing...

Page 824: ...y releasing REVERSE GEAR CLASHES Allow approximately three seconds after depressing clutch pedal before shifting into reverse gear If gear clash is still present a Check clutch adjustments b Check for...

Page 825: ...key may be removed Also the clutch safety switch will not Fig 7A 6 Transmission Controlled Spark Switch permit engine cranking unless the clutch pedal is de pressed far enough to completely disengage...

Page 826: ...MN SHIFT LINKAGE Figs 7A 7 and 3 Position front transmission shifter lever 2nd 3rd 7A 8 in Neutral position and rear transmission shifter lever 1st Rev in Reverse position 1 Set gearshift lever in Rev...

Page 827: ...ROMMETS BUSHINGS STEERING COLUMN ASM TRANSMISSION ASM GEARSHIFT CONTROL LE ROD 2ND 3RD 1ST REV Fig 7A 8 Column Shift Controls F and X Series CHASSIS LUBRICANT 25 LB FT A 45 LB FT A20 LB FT NEUTRAL FRO...

Page 828: ...shift pattern FLOOR SHIFT AND BACK DRIVE LINKAGE Figs 7A 9 and 7A 10 1 With steering column unlocked position the floor shift control lever into its Neutral position 2 Loosen the swivel clamp nut reta...

Page 829: ...h soft hammer to seat oil seal 9 Reinstall propeller shaft REAR EXTENSION OIL SEAL AND BUSHING REMOVE AND REPLACE Before raising car disconnect the battery and release the parking brake Fig 7A 12 Remo...

Page 830: ...tall shifter shaft seals if removed 2 Install detent cams detent cam retainer ring shifter shafts shift forks and detent cam spring 3 Attach case cover to transmission case 4 Connect control rods to l...

Page 831: ...t all parts for wear cracks or other defects 6 Install control lever spring and spring retainer into the control lever bracket 7 Install control lever control lever pin pin washer and pin retainer int...

Page 832: ...Support rear of engine and remove transmission mount 5 Remove four 4 crossmember bolts and slide mem ber rearward Fig 7A 18 Removing Reverse Idler Gear Retainer Ring Fig 7A 19 Removing Mainshaft Asse...

Page 833: ...ossible and 6 Remove reverse idler gear retainer ring Fig 7A 18 remove bearing Fig 7A 17 Slide reverse idler gear forward on shaft Fig 7A 23 Exploded View of Mainshaft Assembly 1 Main Drive Gear 8 2nd...

Page 834: ...16 Depress speedometer retaining clip and slide gear from mainshaft 17 Remove rear bearing snap ring 18 Using hydraulic or arbor press press off rear bearing spring washer thrust washer and reverse ge...

Page 835: ...bearings are clean then lubricate with light engine oil and check them for roughness by slowly turn ing race by hand Check for cracks in blocker rings Wash transmission case thoroughly inside and out...

Page 836: ...cker ring and synchronizer assembly on mainshaft Fig 7A 30 Using hydraulic or arbor press and Press Plate J 21858 press 1st speed gear and synchronizer assem bly onto mainshaft Install retaining snap...

Page 837: ...nchronizer clutch hub 18 Install bearing onto main drive gear Outer snap ring groove must be toward front of gear 19 Install bearing to main drive gear snap ring 20 Install main drive gear bearing ret...

Page 838: ...the 307 cu in V 8 engine and the Saginaw transmis sion used on A and F Series equipped with the 350 cu in V 8 engine GEAR RATIOS First Speed Second Speed Third Speed Reverse LUBRICANT Capacity 56 flu...

Page 839: ...ssion Aligning Studs J 2 6 1 9 Slide Hammer J 4830 02 Extension Bushing and Oil Seal Remover J 6403 01 Extension Bushing and Oil Seal Installer J 8904 Press Plate Not Shown J 21858 Press Plates J 2 2...

Page 840: ...ually caused by the transmission 12 Wheels out of balance 13 Tire treads humming or vibrating at certain speeds NOISES FROM OUTSIDE TRANSMISSION In some instances drivers have insisted that noise was...

Page 841: ...to a thumping or bumping noise 7 Excessive back lash or unmatched constant mesh gears 8 Sprung worn or excessive end play in countershaft 9 Excessive end play in reverse idler gear NOISE IN FORWARD S...

Page 842: ...r broken The following may cause this condition a Often small chips may lodge temporarily in a synchronizer which would prevent proper syn chronization and cause a raking shift Continued operation may...

Page 843: ...en on the thrust bosses of the case Gear shifting is manual through a floor mounted shifter assembly from a control rod to the outer rear shifter lever of the side cover assembly for first and reverse...

Page 844: ...s a neutral position and the 2nd 3rd synchro nizer sleeve is moved rearward on its hub to engage the rotating 2nd speed gear Since the 2nd 3rd synchronizer sleeve is keyed to its hub and the hub is sp...

Page 845: ...e is evidence of leakage leak should be corrected and lubricant added as needed It is recommended that any additions required to bring up lubricant level should be made using the same type lubri cant...

Page 846: ...EARSHIFT CONTROL ROD SPEEDO CABLE CLIP 7 A FLOOR SHIFT AND BACK DRIVE LINKAGE Figs 78 2 and 78 3 Fig 78 3 Back Drive Linkage A Series ON CAR ADJUSTMENTS 1 Position floor shift control lever in Neutral...

Page 847: ...d assemblysothat slot in fitting is toward retainer boss on extension housing and insert assembly into extension housing Push fitting in until retainer can be inserted into its groove install bolt tor...

Page 848: ...Extension Housing Bushing 3 Attach Slide Hammer J 2619 Using hammer pull bushing and seal from extension housing Fig 7B 5 TRANSMISSION SIDE COVER ASSEMBLY REMOVE 1 Raise vehicle on hoist and disconne...

Page 849: ...LEVER REMOVE 1 Release control lever by inserting a thin rule or a piece of 015 to 020 thick shim stock into the socket alongside the base of the floor gearshift lever on the driver s side 2 Insert ru...

Page 850: ...ing 34 Synchronizer Key Springs 2 35 Synchronizer Keys 3 36 1st Rev Synchronizer Hub 37 Hub To Mainshaft Snap Ring 38 1st Rev Synchronizer Sleeve 39 Main Drive Gear 40 Mainshaft Pilot Bearings 16 41 3...

Page 851: ...ers remove 2nd 3rd synchronizer hub snap ring from mainshaft Support 2nd speed gear with press plates and press on front of mainshaft to remove 2nd 3rd synchronizer assembly 2nd speed blocker ring and...

Page 852: ...gs with soft bristled brush until all dirt has been removed Remove loose particles of dirt by striking bearing flat against a block of wood d Rinse in clean solvent then blow bearings dry with air pre...

Page 853: ...eth for wear or other damage b Plate and two damper springs are retained to countergear by three rivets disassembly is not recommended 7 Inspect all parts for discoloration or warpage due to heat Chec...

Page 854: ...Install rear bearing snap ring into its mainshaft groove 8 Install speedometer drive gear and retaining clip on mainshaft 9 With front of mainshaft upward install 2nd speed gear with its clutching te...

Page 855: ...return hole should be at 6 o clock Shift both synchronizer sleeves to neutral position and install side cover assembly and its gasket to case While installing cover be sure that shifter forks align w...

Page 856: ...model year produced 1972 D represents month built 03 represents day produced B represents first gear ratio LUBRICANT Capacity 44 fluid ounces 2 3 4 pints TORQUE MONTH CODE APPLICATION LB FT A January...

Page 857: ...ds 2 J 2619 Slide Hammer J 4830 02 Bushing and Seal Remover J 6399 Bushing Remover J 6403 1 Bushing Installer Fig 78 15 Special Tools J 6403 2 Oil Seal Installer 1 dia x 9 5 8 Countergear Shaft Aligne...

Page 858: ...located between the ends of the gear and the thrust bosses in the case An anti rattle plate assembly at the front of the countergear provides a constant spring tension between the counter and clutch...

Page 859: ...Ring 27 Front Thrust Washer Tanged 28 Rear Thrust Washer Tanged 29 Bearing to Extension Snap Ring 30 Rear Bearing 3 1 Countergear Bearing Rollers 32 Anti Rattle Plate 33 Magnet 34 3rd 4th Synchronizer...

Page 860: ...on rod and to remove any slack in the column mechanism and tighten clevis jam nut 8 Check transmission shift operation Readjust shift controls if necessary Lower and remove vehicle from hoist MINOR RE...

Page 861: ...NUAL CHASSIS LUBRICANT TRUNNION 81PIN ASSY E PIN 249 250 D1 A _ T FIT FREELY THROUGH ERS WHEN IN NEUTRAL Fig 7C 3 Floor Shift Linkage A Series Shown SLEEVE BUSHING J g m 150 LB IN A 20 LB FT Fig 7C 4...

Page 862: ...vers and TCS switch 2 Remove both shift forks from shifter shaft assem blies Remove all three shifter shaft assemblies from cover The lip seal in the cover and 0 ring seal on the 1 2 and reverse shaft...

Page 863: ...ubricant specified in install reverse shifter shaft assembly to cover Section 0 to level of filler plug hole Lower and 5 Install TCS switch in cover remove vehicle from hoist MAJOR REPAIRS TRANSMISSIO...

Page 864: ...speed blocker ring and 3rd speed gear from front of mainshaft Fig 7C 13 13 Depress speedometer retaining clip and slide gear from mainshaft J Fig 7C 10 Removing Countershaft I Fig 7C 11 Removing Reve...

Page 865: ...GS 1 Wash transmission case thoroughly inside and out side with cleaning solvent then inspect for cracks 2 Check front and rear faces of case for burrs and if present remove them with a fine mill file...

Page 866: ...place if necessary Replace all worn washers GEARS 1 Inspect all gears for excessive wear chips or cracks and replace any that are worn or damaged 2 Check both synchronizer clutch sleeves to see that t...

Page 867: ...With fork slot downward press 1st and 2nd synchro nizer assembly onto splines of mainshaft Fig 7C 21 Fig 7C 20 Installing 3rd and 4th Synchronizer and 3rd Speed Gear Fig 7C 21 Installing 1st and 2nd...

Page 868: ...lace Fig 7C 23 Assemble 4th speed blocker ring on main drive gear Pilot main drive gear and 4th speed blocker ring over front of mainshaft CAUTION Make certain notches in blocker ring align with keys...

Page 869: ...dentify the floor shift Saginaw four TORQUE speed manual transmission used on A and F Series equipped with the 350 cu in V 8 engine APPLICATION LB FT GEAR RATIOS First Speed Secoud Speed Third Speed F...

Page 870: ...ial Tools NOlSY IN ALL GEARS TROUBLE DIAGNOSIS 2 Countershaft roller bearings and or countershaft worn or damaged 1 Incorrect lubricant or low lubricant level 2 Clutch gear bearing or mainshaft rear b...

Page 871: ...orrect lubricant or low lubricant level 3 Defective tight mainshaft front bearing rollers 4 4th speed synchronizer blocker ring frozen on main drive gear cone 5 Burred or battered clutching teeth on s...

Page 872: ...ilable for 400 and 455 cu in engine models These are gear ratios of 2 20 first 1 64 second 1 28 third 1 00 fourth and 2 27 reverse The transmission may be used as an aid in decelerating by downshiftin...

Page 873: ...located at the rear end of the transmission case The countershaft gear is carried on a double row of bear ing rollers positioned at both ends of the gear while thrust is taken on thrust washers locat...

Page 874: ...mainshaft torque I Fig 7D 4 Power Flow First Speed is imparted to the mainshaft from the 1st speed gear through the 1st 2nd speed synchronizer assembly SECOND Fig 7D 5 In second speed the 1st 2nd spe...

Page 875: ...ery 60 1 days If there is evidence of leakage the leak should be corrected and lubricant added if needed 2 Refill capacity is 39 fluid ounces approx 2 1 2 pints Remove filler plug at side of case and...

Page 876: ...sition transmission shifter levers 1st 2nd 3rd 4th and Reverse in Neutral position and tighten jam nuts to 20 lb ft 7 Remove gage pin and check complete shift pattern for freeness of operation 8 Posit...

Page 877: ...AC SERVICE MANUAL SLEEVE 150 LB IN A 20 LB FT SPEEDO CABLE CLIP FRAME Fig 7 0 1 0 Back Drive Linkage A Series LUBRICATE WITH CHASSIS LUBRICANT A I50 LB IN A 20 LB F T REVERSE Fig 7 0 1 1 Back Drive Li...

Page 878: ...ly Fig 7D 12 Removing Rear Extension Oil Seal TRANSMISSION REAR EXTENSION OIL SEAL REMOVE AND REPLACE 1 Remove propeller shaft as outlined in Section 4E 2 Use punch or other suitable tool to loosen oi...

Page 879: ...orward position and position cover gasket on case I Fig 7D 14 Removing or Installing Case Cover DETENT CAM SPRING 1 2 DETENT CAM 1 1 4 DtTEN1 CAM 1 2 SHIFTER SHAFT SHIFT RK 1 2 SHIFT FORK 3 i 5 h i T...

Page 880: ...ansmission to clutch hous ing bolts 7 Tilt rear of extension upward to disengage bracket studs from cross member support and withdraw transmission from clutch housing 8 Remove the transmission DISASSE...

Page 881: ...position forward before trying to remove mainshaft assembly from case Fig 7D 19 11 Carefully remove the rear bearing retainer and main shaft assembly from the case by tapping bearing re tainer with a...

Page 882: ...ension 34 Extension Bushing 35 Extension Oil Seal 36 Reverse ldler Front Thrust Washer Tanged 37 Reverse ldler Gear Front 38 Reverse ldler Gear Rear 39 Reverse ldler Rear Thrust Washer Flat 40 Reverse...

Page 883: ...nchronizer blocker ring and 2nd speed gear from the mainshaft Fig 7D 25 REVERSE SHIFTER SHAFT AND SEAL REMOVE AND REPLACE 1 With rear extension removed from transmission the reverse shifter shaft lock...

Page 884: ...12 NOTE Thesynchronizerhubs and theirsleeves are a selected assembly and should be kept together as originally assembled but the three shiftingplates and two springs may be replaced if worn or broken...

Page 885: ...ynchronizer blocker ring on either side so their keyways line up with the shifting plates Fig 7D 28 3 Press 1st speed gear sleeve onto mainshaft using a 1 3 4 I D pipe cut to convenient length 4 Insta...

Page 886: ...ite end of the countershaft gear 15 Rest the transmission case on its side with the case cover opening toward the assembler Put counter shaft gear tanged thrust washers in place retaining them with he...

Page 887: ...on the 4th speed synchronizer blocker ring correspond to shifting plates in the 3rd 4th synchronizer assembly Fig 7D 34 26 With the guide pin in rear bearing retainer aligned with hole in rear of case...

Page 888: ...forward until extension bracket studs engage holes in cross member support and main drive gear shaft enters clutch housing Care should be taken to make certain clutch release bearing remains seated 3...

Page 889: ...luid ounces approx 2 1 2 pints TORQUE APPLICATION LB FT Clutch Gear Bearing Retainer Nut 40 Main Drive Clutch Gear Bearing Retainer Bolts 20 Case Cover Bolts 20 Extension to Case Bolts Upper 20 Extens...

Page 890: ...9 3 3 Clutch Gear Retainer Nut Wrench J 112 6 Aligning Studs J 5 154 A Extension Oil Seal Installer Fig 7D 37 Special Tools J 58 14 A Speedometer Drive Gear Remover Not Shown J 6 3 9 9 Extension Bushi...

Page 891: ...ket and Front Servo 7E 43 Removal of Rear Oil Seal and Case Extension 7E 45 Front End Play Checking Procedure 7E 45 M 40 TRANSMISSION THIS SECTION Removal of Oil Pump 7E 46 Disassembly of Gear Unit 7E...

Page 892: ...consider the job done A road test after repair could indicate that secondary effects or problems could have resulted as a side effect of the original problem ROAD TEST ATTACH PRESSURE GAUGE TO TRANSMI...

Page 893: ...RPM With the transmission oil pressure gauge attached and the vacuum modulator tube disconnected the transmission pressures should check approximately as shown in Fig 7E 2 VEHICLE STATIONARY AND ENGI...

Page 894: ...advance etc 2 Manual linkage maladjusted correct alignment in manual lever shift quadrant is essential manual 2 Modulator valve disconnected from manual lever pin a Stuck modulator valve 3 Low oil pre...

Page 895: ...heck forward clutch seals b Direct clutch leak pressure low in Reverse pres sure normal in all other ranges 1 Check center support oil seal rings 2 Check direct clutch outer seal 3 Check rear servo an...

Page 896: ...ing into forward clutch apply passage 4 Forward Clutch a Burned plates check cause b Clutch doesn t release will also cause no drive in Reverse NO DRIVE IN REVERSE OR SLIPS IN REVERSE INSTALL PRESSURE...

Page 897: ...tuck a 1 2 accumulator valve train sticking b Porosity in valve body or case c Broken or missing spring d Bore damaged c Valve body attaching bolts not properly torqued 5 Intermediate clutch clutch pl...

Page 898: ...o Reverse NO PART THROTTLE DOWNSHIFT INSTALL PRESSURE GAUGE 1 Oil Dressure refer to HIGH OR LOW OIL PRES 2 Control valve 3 2 valve stuck spring missing or broken NO DETENT DOWNSHIFTS 1 Detent switch a...

Page 899: ...d d Intake pipe split porosity in case intake pipe bore e Water in oil f Porosity or voids at transmission case pump face intake port g Pump to case gasket off location 2 Pump Assembly a Gears damaged...

Page 900: ...llows 1 Attaching bolts not correctly torqued d Center support bolt loose bolt may be tight in support but not holding support tight to the case 2 Improperly installed or damaged pan gasket 3 Oil pan...

Page 901: ...hoist or jack stand engine running with rear wheels free to turn and locate source of oil leak Check for leaks with transmission in LOW and SUPER ranges NOTE Use of a mirror is helpful in locating le...

Page 902: ...7E 12 1972 PONTIAC SERVICE MANUAL Fig 7E 4Cross Section of Transmission...

Page 903: ...eed increases the direction of the oil leaving the turbine changes and flows against the rear side of the stator vanes in a clockwise direction Since the stator is now impeding the smooth flow of oil...

Page 904: ...and the entire gear train will rotate as a unit I A planetary gear train is compact and sturdy because the load is distributed over several gears instead of only two as in the sliding gear type of gea...

Page 905: ...ESCRIPTION PRESSURE CONTROL The transmission is automatically controlled by a hydrau lic system Hydraulic pressure is supplied by the transmis sion gear type oil pump which is engine driven Main line...

Page 906: ...ressure Regulator Valve Fig 7E 9 Manual Valve nor pressure is used to vary the shift points and modulator pressure regulation Fig 7E 10 4 Modulator valve regulates line pressure to a modula tor pressu...

Page 907: ...hausted at the end of the valve when the detent solenoid is ener ENGINE 1 VACUUM DETENT GOVERNOR Fig 7E 1 1 Modulator and Valve gized This directs detent pressure to the 1 2 and 2 3 modulator valves a...

Page 908: ...e front band in Neutral Drive and Reverse ranges oil is directed from the manual valve to the release side of the servo piston In Drive range the servo release oil from the manual valve is used to cha...

Page 909: ...nsfer of the drive load to the intermediate sprag Fig 7E 17 The controlled release pressure lets the en gine increase its rpm for the lower gear ratio of second gear during detent downshifts resulting...

Page 910: ...oth 1 2 shift REAR SERVO RFV OR In TO INT CL REAR SERVO RCV OR LO Fig 7E 20 Lo Range First Gear LO RANGE FIRST GEAR Overrun engine braking in Lo range first gear is provided by the rear servo applying...

Page 911: ...to the 1 2 accumulator primary valve to raise 1 2 accumulator pres sure during detent 1 2shifts Lo range oil is directed to the 1 2accumulator valve during Lo range operation to raise 1 2 accumulator...

Page 912: ...and will prevent the transmission from upshifting out of first gear regardless of vehicle speed NEUTRAL RANGE ENGINE IDLING POWER FLOW Forward Clutch Released Roller Clutch Ineffective Direct Clutch...

Page 913: ......

Page 914: ...7E 24 1972 PONTIAC SERVICE MANUAL...

Page 915: ...areas of the clutch piston to apply the forward clutch The inner area is fed through an unrestricted passage The outer area is fed through an orifice to insure a smooth shift from Park Neutral and Rev...

Page 916: ...1972 FONTIAC SERVICE MANUAL...

Page 917: ...ve to move feeding intermediate clutch oil to the direct clutch passage Direct clutch oil from the 2 3 shift valve is directed to the 1 Direct Clutch 2 Front Accumulator Piston 3 3 2 Valve BASIC CONTR...

Page 918: ......

Page 919: ......

Page 920: ...ft is possible by depressing tent conditions detent oil is directed to the 1 2accumula the accelerator fully This engages an electrically operated tor primary valve to increase 1 2accumulator oil pres...

Page 921: ......

Page 922: ...e clutch oil acting on the servo piston to move the piston and apply the front band Once the transmission is in second gear Super it cannot upshift to third gear regard less of vehicle speed SUMMARY T...

Page 923: ...IT...

Page 924: ...nt Solenoid De energized In reverse gear the direct clutch is applied to transmit turbine torque from the forward clutch drum to the sun gear shaft and sun gear The rear band is also applied preventin...

Page 925: ......

Page 926: ...LS Figs 7E 34 thru 7E 36 ADJUST 1 Loosen screw on adjusting swivel clamp 2 Set transmission range selector lever in PARK de tent NOTE Obtain PARK position by rotating transmission range selector lever...

Page 927: ...he Fig 6B 7 thru 6B 9 in Section 6B right rear of the engine To bring the fluid level from the ADD mark to the FULL mark requires ONE PINT 2 Then fully depress the accelerator pedal to properly set th...

Page 928: ...ay miles or its equiva lent and it becomes necessary to check fluid level the transmission fluid must be at room temperature 70 F With fluid at room temperature 70 F follow steps 1 2 and 3 below 1 Wit...

Page 929: ...oximately 7 1 2 pints of fluid are required to refill transmission after oil pan has been drained When unit has been disassembled and rebuilt approximately 19pints will be required to refill Use only...

Page 930: ...g snap ring pliers and tool as shown in Fig 7E 38 A I I THREAD 4 1 i T I 3 Remove regulator boost valve bushing and valve 4 Remove pressure regulator spring 5 Remove regulator valve spring retainer an...

Page 931: ...ift control linkage 4 Support transmission with jack 5 Disconnect rear mount from transmission and frame crossmember 6 Remove two bolts at each end of frame crossmember and remove crossmember 7 Remove...

Page 932: ...TAKE PIPE REMOVE 1 Remove attaching screws governor cover and gasket Discard gasket Fig 7E 41 2 Withdraw governor assembly from case 3 Remove speedometer driven gear speed control switch attaching scr...

Page 933: ...vernor screen assembly from the gov ernor feed pipe hole in the case or from the end of the governor feed pipe I ig 7E 48 Fig 7E 47 Removing Control Valve Assembly and Governor Pipes 4 Disconnect sole...

Page 934: ...7E 55 REAR OIL SEAL AND CASE EXTENSION REMOVE 1 If necessary to replace pry rear oil seal from case extension Fig 7E 56 SERVO PISTON Fig 7E 55 Removing Front Servo Assembly 2 Remove case extension to...

Page 935: ...pump Fig 7E 59 2 Remove pump attaching bolts 3 Install 3 8 16 threaded Slide Hammer Adapters J 6125 2 into bolt holes in pump body attach Slide Hammers J 6125 1and remove pump assembly from case See...

Page 936: ...anual linkage as follows a Unthread jam nut holding detent lever to manual shaft b Remove manual shaft retaining pin from case Fig 7E 63 c Remove manual shaft andjam nut from case Fig 7E 64 CAUTION Do...

Page 937: ...UAL I C Fig 7E 64 Remov ng Jam Nut and Manual Shaft Fig 7E 65 Removing Parking Bracket Fig 7E 66 Removing Parking Pawl Return Spring Fig 7E 67 Removing Retaining Spring from Parking Pawl Shaft Fig 7E...

Page 938: ...uired to bring end play within specification it can be selected from the followine chart THICKNESS NOTCHES AND OR IN INCHES NUMERAL 074 078 None 1 082 086 1 Tab Side 2 090 094 2 Tab Side 3 098 102 1 T...

Page 939: ...e washer from transmission case Fig 78 77 20 Remove support to case spacer from inside of case Fig 7E 78 21 Remove rear band assembly Fig 7E 79 GEAR UNIT Fig 7E 74 Removing Intermediate Clutch Pack DI...

Page 940: ...sembly Fig 7E 82 5 Remove front internal plastic gear ring from output carrier assembly 6 Remove sun gear Fig 7E 83 Fig 7E 79 Removing Rear Band Fig 7E 80 Removing Center Support Assembly 7 Remove rea...

Page 941: ...and slide gear off the out put shaft Fig 7E 85 b To install place retaining clip square end toward flange of shaft into hole in output shaft Fig 7E 86 Align slot in speedometer drive gear with retaini...

Page 942: ...rive gear Fig 7E 87 d Install a new steel speedometer drive gear and drive to location approximately 11 15 32 from end of output shaft to rear face of gear for models PA PB PC PG and PH to location 11...

Page 943: ...sembly in order to replace driven gear Disassembly may also be necessary due to foreign material causing improper operation In such cases proceed as follows DISASSEMBLE and springs Governor weights ar...

Page 944: ...d in exhaust slots of sleeve position new gear in sleeve and with suitable socket press gear into sleeve until nearly seated Carefully remove any chips that may have shaved off gear hub and press gear...

Page 945: ...vo pis ton Fig 7E 96 2 Remove E ring retaining rear servo piston to band apply pin Fig 7E 97 Fig 7E 95 Exploded View of Front Servo Fig 7E 96 Removing Accumulator Piston From Rear Servo Piston 3 Remov...

Page 946: ...4 242 Part No 8627153 ASSEMBLE 1 Install spring retainer spring and washer on band apply pin 2 Install band apply servo pin retainer spring and washer into bore of servo piston and secure with E ring...

Page 947: ...ment For service the replacement oilseal ring will be cast iron 5 From the top right hand bore remove roll pin 1 2 modulator bushing 1 2 regulator valve 1 2regulator CAUTION The front accumulator pis...

Page 948: ...bore up install detent spring and spacer Compress spring and secure with small screwdriver Fig 7E 102 TOR DETENT VALVE 8 Install detent regulator valve wide land first 9 Install detent valve narrow l...

Page 949: ...pump cover Fig 7E 106 9 Remove pump to forward clutch housing selective washer 10 Mark drive and driven gears for reassembly in same position and remove gears from pump body Fig 7E 107 INSPECT 6 Remo...

Page 950: ...r nicks If replacement is necessary proceed as follows a Using Tool J 21465 17 with Driver Handle J 8092 remove bushing c Fig 7E 109 Checking Body Face To Gear Face Clearance I V E N T C O O L E R RET...

Page 951: ...ring grooves for damage or wear 15 Inspect selective washer thrust face for wear or dam age BRE 17 Inspect pump cover for open 1 8 diameter breather Fig 7E 1 1 2 Aligning Pump Cover to Pump Body hole...

Page 952: ...time 11 Place Pump Aligning Strap J 21368 over pump body and cover and tighten tool Fig 7E 112 12 Tighten pump cover bolts 18 lb ft torque 13 Install and align pump to case gasket 14 Install pump to...

Page 953: ...ch piston Fig 7E 118 10 Remove center piston seal from forward clutch hous ing Fig 7E 119 INSPECT 1 Inspect composition and steel clutch plates for signs of burning scoring or wear 2 Inspect sixteen 1...

Page 954: ...ng lip faces up Fig 7E 119 3 Place Seal Protector Tool J 21362 over clutch hub and install outer clutch piston Seal Protector J 21409 into clutch drum and install piston rotating piston on drum until...

Page 955: ...mooth sur face configuration SNAP RING CLUTCH DIRECT CLUTCH BACKING PLATE I DIRECT CLUTCH HOUSING Fig 7E 125 Removing or Installing Backing Plate Snap Ring CAUTION Do not confuse the flat steel plate...

Page 956: ...l from direct clutch hous ing 4 Inspect composition and steel clutch plates for sign of wear or burning INSPECT 1 Inspect roller assembly for popped or loose rollers 2 Inspect inner and outer races fo...

Page 957: ...Clutch Piston and Intermediate Roller Assembly 3 Install a new clutch center seal on hub of direct clutch housing with lip of seal facing up Fig 7E 132 NOTE When installing the piston make cer tain t...

Page 958: ...d and install four 4 composition three 3 flat steel and one 1 waved steel clutch plates starting with the waved steel plate and alternating composition and flat steel clutch plates Fig 7E 126 Models P...

Page 959: ...I SASSEMBLE Fig 7E 138 Remove three 3 hook type cast iron oil seal rings from the center support Do not remove the teflon oil seal ring unless replacement is required All service center support oil se...

Page 960: ...lon gated 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 squarely into the bore until bushing is flush...

Page 961: ...Installing Clutch Piston Snap Ring C A S T IRON OIL SEAL RINGS AL RING SUPPORT Fig 7E 143 Oil Seal Rings on Center Support of seal facing away from spring pocket Fig 7E 139 and 7E 140 2 Install Inner...

Page 962: ...7 Inspect roller clutch for damaged members 8 Inspect roller clutch cage for damage 9 Inspect front internal gear output carrier for da maged teeth 10 Inspect output carrier pinions for damage rough 1...

Page 963: ...N PIN BRONZE WASHER 7 7 HEADED END L NEEDLE BEAR1 STEEL WASHER BRONZE WASHER Fig 7E 148 Exploded View of Planet Pinion C c P L A N E T PINION PIN HEAD END U P Fig 7E 149 Driving Pinion Pin Into Carrie...

Page 964: ...Remove With sun gear shaft properly supported thread Tool J 21465 14 into bushing and using Slide Hammer J 2619 and Adaptor J 2619 4 remove bushing Replace Using Tool J 21465 5 with Drive Handle J 80...

Page 965: ...r leak bubbles c If bubbles appear replace the modulator RIREADED S C R E W S E A L VACUUM CONNECTOR SEAM UPPER TO LOWER HOUSING SEA Fig 7E 151 Vacuum Modulator Seams and Seals BELLOWS DIAPHRAGM Fig 7...

Page 966: ...7E 156 6 Inspect modulator valve for nicks or damage 7 Check freeness of valve operation in case bore Once the modulator assembly passes all of the above tests it is an acceptable part and should be r...

Page 967: ...nspect governor assembly bore for scratches or scor ing 7 Inspect modulator valve bore for scoring or damage 8 Inspect for missing or loose intermediate clutch cup plug See Fig 7E 158 for location If...

Page 968: ...alling Tool J 2137 1 3 a Fully release collet end of Tool J 21371 2by turn ing its brass nut clockwise b Install collet end of Tool J 21371 2into converter hub until it bottoms then tighten its brass...

Page 969: ...checked by placing a finger into the converter neck and with side pressure against splines of the stator race turning the stator race The race should turn fairly freely in a clockwise direction and n...

Page 970: ...d View of Rear Unit 8 Install output shaft to output carrier snap ring 1 Fig 7E 166 Installing Mainshaft Snap Ring 9 Turn assembly over and support so that output shaft hangs downward 10 Install react...

Page 971: ...ing Gear Ring to Output Carrier 3 Install sun gear shaft with long splined end down 4 Install reaction carrier Fig 7E 171 NOTE When a new output carrier and or reaction carrier is being installed and...

Page 972: ...roller clutch into reaction carrier outer race Fig 7E 174 Fig 7E 174 lnstalling Roller Clutch Assembly 18 Install center support to reaction carrier thrust washer into recess in center support Retain...

Page 973: ...ARKING PAWL SHAFT I Fig 7E 178 lnstalling Parking Pawl and Shaft 6 Install rear band so that two lugs index with two anchor pins Check to make sure band is seated on lugs Fig 7E 182 7 Install the sup...

Page 974: ...led flat side of ring is against the center support Fig 7E 18 1 Installing Parking Pawl Return Spring NOTE Dip washer in transmission oil before installation 9 Install complete gear unit assembly into...

Page 975: ...nd three 3 composition intermediate clutch plates Start with the waved steel and alternate com position and steel clutch plates Fig 7E 187 14 Install intermediate clutch backing plate ridge up 15 Inst...

Page 976: ...apply lug facing serbo hole Fig 7E 189 L I Fig 7E 190 Positioning Actuator Rod Plunger a I Fig 7E 191 Installing Jam Nut onto Manual Shaft 18 Install manual linkage as follows a If necessary install a...

Page 977: ...nstall all but one pump attaching bolt and seal Torque to 18 lb ft NOTE If turbine shaft can not be rotated as pump is being pulled into place forward or direct clutchhousinghas not been properly in s...

Page 978: ...on out side of seal body and using Oil Seal Installer J 21359 drive seat into place Fig 7E 196 b PD model only If necessary to install a new rear seal use non hardening sealer on outside of seal body...

Page 979: ......

Page 980: ...ont servo spring and spring retainer into transmission case 7 Install retainer ring in front servo pin groove and install pin into the case so that tapered end contacts the front band Make certain tha...

Page 981: ...etent wire and lead wire to electrical con nector Fig 7E 204 REAR SERVO ASSEMBLY INSTALL 1 Before installing rear servo check band apply Servo pin using Tools J 21370 5 and 6 as follows Fig 7E 205 a A...

Page 982: ...5 Install attaching screws Torque bolts to 18 lb ft Fig 7E 207 lnstalling Rear Servo Piston Fig 7E 209 lnstalling Governor Screen Assembly Fig 7E 208 lnstalling Rear Servo Cover CONTROL VALVE ASSEMBLY...

Page 983: ...ve assembly attaching bolts and make certain that lead wire assembly clip is installed DETENT ROLLER AND Fig 7E 212 lnstalling Filter and Intake Pipe Assembly NOTE If transmission is in car remove shi...

Page 984: ...iven gear speed control switch assembly into case extension 2 Install speedometer driven gear speed control switch retainer and attaching bolt CONVERTER ASSEMBLY INSTALL With the transmission in cradl...

Page 985: ...n 4 bbl engine A and G Series PT 400 cu in 2 bbl engine A and F Series PX 400 cu in 4 bbl engine G Series It is very important that any communications concerning the Turbo Hydra Matic M 40 transmissio...

Page 986: ...Spacer J 21359 Oil Seal lnstaller Except Model PD J 21362 Seal Protector Inner Forward and Direct Clutch J 21363 Seal Protector Inner Intermediate Clutch J 21366 Converter Holding Clamp J 21370 5 Rear...

Page 987: ...Adapter Ring Fig 7E 217 Special Tools J 21368 Pump Body and Cover Alignment Strap J 2 1369 Converter Leak Test Fixture J 2 137 1 2 3 End Play Checking Fixture Not Shown J 2 1409 Seal Protector Outer F...

Page 988: ...ear Assembly 7F 35 Extension Housing Assembly 7F 35 Governor Assembly 7F 35 Governor Support Assembly 7F 36 Valve Body Assembly 7F 36 Oil Pump Oil Seal 7F 38 Oil Pump Assembly 7F 39 Clutch Drum Assemb...

Page 989: ...g brake applied shift selector lever in Drive range and engine idling low servo apply Mainline pressure should be as shown on the pressure check chart Fig 7F 1 If pressures are not within these ranges...

Page 990: ...ator valve 4 Defective oil pump 5 Broken input shaft 6 Sticking oil pump priming valve 1126 3406 4083 ENGINE FLARES ON STANDSTILL STARTS BUT ACCELERATION LAGS UPSHlFT 1 Low oil level 2 Clogged oil suc...

Page 991: ...ragm ruptured c Sticking vacuum modulator valve pressure regulator valve or booster valve NO DRIVE IN REVERSE 1 Improper manual valve lever adjustment 2 Stuck reverse clutch piston 3 Worn out reverse...

Page 992: ...removing the oil pan assembly The valve body consists of an upper and lower body located on either side of a trans fer plate The vacuum modulator is located on the left rear face of the transmission c...

Page 993: ...lnner Weight Retainer Ring 33 Governor Outer Weight 34 Governor Spring 35 Governor lnner Weight 36 Speedometer Drive Gear Retaining Clip 37 Extension Housing Rear Oil Seal 38 Extension Housing Rear Bu...

Page 994: ...b section of the oil pump extends rearward to serveboth as the high clutch support and as an oil distribution mem ber for the clutch assembly Fig 7F 6 Oil sealing is accomplished between the hub and c...

Page 995: ...low band or the reverse clutch determines whether the planet INPUT SUN GEAR 1 I Fig 7F 8 Typical Planet Carrier Gear Set carrier output shaft rotates clockwise or counterclock wise REVERSE CLUTCH The...

Page 996: ...clip at each end A hole is drilled through the output shaft to facilitate use of this type gov ernor shaft The weight assembly consists of the large diameter outer weight a coil spring and an inner w...

Page 997: ...of the planet carrier rather than in a space between the teeth the linkage remains in the park position with the spring holding pressure against the pawl Slight rotation of the carrier will then immed...

Page 998: ...aulic systems have been separated into three groups to aid their understanding These groups are Fig 7F 15 Operation in Reverse Range Reverse Gear General Information Pressure Development and Control H...

Page 999: ...alve Valve 1 1 Drive Valve Inner Spring 24 Upper Valve Body 12 Drive Valve Outer Spring 25 Manual Control Valve 13 Low and Drive Regulator Valve 26 Vacuum Modulator Valve Spring and Plunger 27 Throttl...

Page 1000: ...ince the converter is bolted to the engine flywheel the oil pump operates and provides pressure any time the engine is running As the engine is started and the oil pump begins operating fluid is drawn...

Page 1001: ...ressure until the number 3 spool of the valve uncovers a port which leads to exhaust through an oil pump suction passage Fig 7F 22 Any drop in mainline pressure such as this exhaust per mits spring fo...

Page 1002: ...ne pressure enters the open port and becomes I GOVERNOR I Fig 7F 24Governor Circuitry EXHAUST I n Fig 7F 25 Throttle Valve Circuitry governor pressure This pressure while acting on the vari ous contro...

Page 1003: ...To provide an automatic upshift governor pres sure is delivered to the low drive shift valve opposing spring pressure Fig 7F 29 As governor pressure overcomes the spring force vehicle speed increases...

Page 1004: ...d NOTE COOLER BY PASS I PICK UP SCREEN OIL PUMP W I I OIL PUMP PRIMING VAL GOVERNOR THROTTLE DETENT VALVES MAINLINE PRESSURE SUCTION PRESSURE 1 CONVERTER PRESSURE GOVERNOR PRESSURE r MODULATOR PRESSUR...

Page 1005: ...LOW DRIVE VALVE I I MANUAL CONTROL VALVE Fig 7F 27 Drive Range Low Gear CLUTCH MAINLINE PRESSURE SUCTION PRESSURE r CONVERTER PRESSURE I GOVERNOR PRESSURE 0 MODULATOR PRESSURE...

Page 1006: ...GH SPI EEC DOWN SHIV TIMING VALVE THROTTLE DETENT VALVES 7 L RfV MAINLINE PRESSURE SUCTION PRESSURE U CONVERTER PRESSURE GOVERNOR PRESSURE r MODULATOR PRESSURE L O W SERVO LOW S t l V O Awl LOW SERVO...

Page 1007: ...ure allows the low drive shift valve to snap to the right allowing shift valve main line pressure to enter the high clutch apply passage This snap action of the low drive shift valve is aided by main...

Page 1008: ...dy for instant re sponse and acceleration To Detent Forced Downshift At low to moderate road speeds increased pressure on the accelerator will result in regulating TV pressure high enough to move the...

Page 1009: ...ainline pressure through its normal passage and through the modulator exhaust passage from the manual control valve Fig 7F 38 Mainline pressure at the modulator valve prevents the vacuum modulator val...

Page 1010: ...SERVO PRESSURE REGULATOR VALVE LOW DRIVE VALVE THROTTLE DETENT VALVES L REV REVERSE CLUTCH hi j MAINLINE PRESSURE SUCTION PRESSURE I CONVERTER PRESSURE GOVERNOR PRESSURE L MODULATOR PRESSURE m MVmIOI...

Page 1011: ...e FULL mark on the indicator DOnot overfill for when fluid level is at the full mark it is just slightly below the planetary gear unit If additional fluid were added to bring the level above the full...

Page 1012: ...3 NOTE COOLER BY PASS VALVE NOT USED ON L 6 Uj PRESSURE REGULATOR VALVE GOVERNOR VACUUM MODULATOR VALVE...

Page 1013: ...gearshift control rod to take up clearance in steering column lock mechanism and tighten screw on adjusting swivel clamp to 20 lb ft torque 2 Remove protective cap from transmission adjusting 5 Unloc...

Page 1014: ...elector lever fully clockwise 5 Push up on the gearshift control rod to take up clear ance in steering column lock mechanism and tighten screw on adjusting swivel to 20 lb ft torque 6 Unlock ignition...

Page 1015: ...SERVICE MANUAL LUBRICATE WlTH CHASSIS LUBRICANT A 150 LB IN 20 LB FT Fig 7F 44 Column Shift Controls F Series LUBRICATE WlTH CHASSIS LUBRICANT 20 LB FT 15 LB FT LEVER SHIFT CABLE Fig 7F 45 Shift Cabl...

Page 1016: ...ON SO TOP OF LETTERS ARE TOWARDS FRONT OF CAR CLIP RING 40 LB IN 120 LB IN CLIP SECTION THRU SHIFT KNOB ERBODY SEAL PART OF CABLE ASM Fig 7F 46 Console Shifter Mounting F Series 0LUBRICATE WITH CHASSI...

Page 1017: ...for throttle valve linkage freeness 2 Disconnect accelerator linkage at carburetor 3 Disconnect accelerator return spring and T V rod return spring 4 With right hand pull T V upper rod forward until...

Page 1018: ...ame Slide crossmember rearward or remove Remove flywheel housing bottom cover scribe fly wheel and converter relationship to maintain bal ance re assembly and remove flywheel to converter bolts Suppor...

Page 1019: ...Fig 7F 51 8 Remove four 4 governor support to case bolts drain back baffle governor support and its gasket from transmission case and output shaft 9 If necessary unscrew pressure switch from side of s...

Page 1020: ...essor J 23327 1 and 2 through inside rear base of case and with Pilot J 9542 4 on outside rear face of case turn down wing nut to compress reverse piston return springs and retainer Fig 7F 54 10 With...

Page 1021: ...uator levers parking pawl and its bracket from case Fig 7F 58 as follows a Loosen allen head screw on inner TV lever and remove outer TV lever and shaft from its inner TV lever Remove 0 ring seal and...

Page 1022: ...ear and shaft for wear or damage Replace if necessary Fig 7F 60 Removing or Installing Extension Housing Bushing EXTENSION HOUSING ASSEMBLY INSPECT 1 Wash extension housing thoroughly with cleaning so...

Page 1023: ...olts and retorque 6 Loosen hub drive screw remove governor shaft and valve from body and remove governor assembly from output shaft GOVERNOR SUPPORT ASSEMBLY INSPECT 1 Wash support thoroughly in clean...

Page 1024: ...ve Valve 11 Low Drive Valve Inner Spring 12 Low Drive Valve Outer Spring 13 Low Drive Regulator Valve 14 Low Drive Regulator Valve Sleeve 22 Downshift Timing Valve Spring 23 High Speed Downshift Timin...

Page 1025: ...and retain with snap ring b Low and drive shift valve train on other end of lower valve body install low and drive shift valve stem end out into its bore and install inner and outer springs Install lo...

Page 1026: ...drop or nick gears These gears are not heat treated Fig 7F 65 Checking Pump Gear End Clearance 4 Remove rubber oil seal ring mark gear faces for reassembly and remove pump gears from pump body INSPEC...

Page 1027: ...l in pump body assembling gears with marked faces up recessed side of drive gear lugs downward facing the converter Install downshift timing valve conical end out into place in pump cover to a height...

Page 1028: ...Remove clutch piston with a twisting motion from drum and separate inner seal from clutch drum and outer seal from piston Discard seals INSPECT 1 Wash all parts in cleaning solvent and air dry DO NOT...

Page 1029: ...ace and lay snap ring on top of retainer Using Spring Compressor J 23327 1 and 2 Adapter Ring J 23466 and Pilot J 9542 4 compress piston return springs and retainer to expose groove in clutch hub Inst...

Page 1030: ...amage the planet carrier assembly must be replaced TRANSMISSION CASE INSPECT 1 Wash case thoroughly in cleaning solvent air dry and Fig 7F 72 Installing Case Rear Bushing blow out all oil passages DO...

Page 1031: ...ket Lubricate shaft and seal and insert selector outer lever and shaft into case being careful of shaft oil seal and pick up selector inner lever with park lock actuator attached and tighten its 3 16...

Page 1032: ...everse ring gear with these plates Engagement can be made by feel while jiggling and turning reverse ring gear until all clutch plates are engaged and ring gear has bottomed in the transmission case P...

Page 1033: ...n to Case Seal Ring 36 Speedometer Shaft Fitting 37 Fitting Oil Seal 38 Retainer Plate Bolt 39 Retainer Plate 40 Speedometer Driven Gear and Shaft 4 1 Transmission Extension 42 Extension Bushing 43 Ex...

Page 1034: ...or Strut 29 Band Anchor Adjusting Screw 30 Adjusting Screw Lock Nut 31 Low Brake Band 32 Clutch Drum 33 Clutch Drum Bushing 34 Piston Outer and Inner Seals 35 Clutch Piston 36 Piston Return Springs 37...

Page 1035: ...o case attaching bolts and torque to 25 lb ft 7 Install speedometer driven gear assembly retainer and bolt to extension housing Torque to 4 lb ft 8 If removed install pressure switch into servo boss o...

Page 1036: ...out into case bore and valve body insert modulator plunger into modulator body and screw vacuum modulator body and gasket into case bore Torque to 15 lb ft using Wrench J 9543 or thin 1 tappet type wr...

Page 1037: ...n through filler tube following recommendations prov Install transmission case to engine lower attaching ided for earlier under DRAINING AND REFILL bolts and torque to 35 lb ft ING Remove support from...

Page 1038: ...2 Drive Handle Holding Fixture Holding Fixture Adapter Spring Compressor Pilot Modulator Wrench Oil Seal Installer Fig 7F 82 Special Tools Converter Holding Strap Leak Test Fixture Bushing Tool Bushin...

Page 1039: ...sion Removal 76 39 Transmission Disassembly 7G 39 Removal of Converter and Modulator 7G 40 Removal of Extension Housing Speedo Drive Gear and Governor 7G 40 Removal of Valve Body Assembly 7G 41 Remova...

Page 1040: ...jacent to the intermediate clutch accumulator cover Observe and re cord results of pressure checks comparing results with transmission pressures shown under OIL PRESSURE CHECKS Check all the shifts in...

Page 1041: ...ED the transmission line pressures should check approximately as shown in Fig 7G 3 VEHICLE STATIONARY AND ENGINE AT 1200 RPM While vehicle is stationary service brake on engine speed set to 1200rpm wi...

Page 1042: ...lutch does not apply piston cracked seals missing or damaged clutch plates burned see BURNED CLUTCH PLATES below b Pump feed circuit to forward clutch oil seal rings missing or broken on pump cover le...

Page 1043: ...ve body gaskets leaking damaged or incor rectly installed b Detent valve train stuck c 1 2 valve stuck closed in downshifted position 4 Case Assembly porosity 1 Detent downshift cable binding 2 Govern...

Page 1044: ...OTION IN REVERSE OR SLIPS IN REVERSE 2 Low Oil Pressure refer to LOW LINE PRESSURE above Install pressure gauge 3 2 3 Accumulator oil ring damaged or missing 1 Low Oil Level add oil 4 1 2 Accumulator...

Page 1045: ...ticed 3 Intermediate Clutch check for burned and number type of plates 4 Case 2 Detent Valve and Linkage sticks disconnected or broken a Check for correct number and location of check balls 3 2 3 shif...

Page 1046: ...t one time PARK NEUTRAL AND ALL DRIVING RANGES 1 Pump Cavitation a Low oil level b Plugged or restricted strainer c Strainer to valve body gasket damaged d Porosity in valve body intake area e Water i...

Page 1047: ...icate if the oil leak is from the transmission The use of a Black Light to locate the point at which the oil is leaking is helpful Comparing the oil from the leak to that on the engine or transmission...

Page 1048: ...ear of the converter pump blades and sets Four multiple disc clutches two roller clutches and impede its pumping action So at low turbine speeds oil an intermediate overrun band provide the friction e...

Page 1049: ...POWER FLOW In neutral or park all clutches and the intermediate over run band are released Also in park range the parking pawl is engaged preventing movement of the vehicle Therefore no power is tran...

Page 1050: ...tch OFF nterrnediate Overrun Roller Clutch LOCKED Low and Reverse Roller Clutch LOCKED ntermediate Overrun Band O F F Fig 7G 7 Operation in Drive Range First Gear In Drive D range second gear the inte...

Page 1051: ...ELING REAR GEAR SET Intermediate Clutch ON Direct Clutch ON Forward Clutch ON Low and Reverse Clutch OFF Intermediate Overrun Roller Clutch FREE WHEELING Low and Reverse Roller Clutch FREE WHEELING In...

Page 1052: ...f the input ring gear causes the output planet pinions to rotate in a clockwise direction driving the sun gear counterclockwise In turn the sun gear turn ing counterclockwise will cause the output rin...

Page 1053: ...run Roller Clutch Locked Low and Reverse Roller Clutch LOCKED Intermediate Overrun Band O F F Fig 7G 1 1 Operation in Low Range First Gear F R O N T G E A R S E T 3 t R E A R G E A R SET Intermediate...

Page 1054: ...modulator pressure high engine vacuum low modulator pressure To reduce the effect of engine power loss at high altitudes on shift points the effective area of the diaphragm is made some what larger t...

Page 1055: ...l push the 1 2 accumulator piston back towards the line oil to allow a gradual build up of the 1 2 clutch pressure Fig 7G 18 1 The vacuum modulator bellows that increases modulator pressure 2 Engine v...

Page 1056: ...the regulated modula tor pressure tending to hold the 1 2 shift and 2 3 shift valves in the downshift position and provides areas for modulator and detent regulated pressures for detent 2 1 3 1 and 3...

Page 1057: ...ning at idle speed with the range selector lever in Neutral N oil from the sump is picked up by the pump and is directed to 1 Pressure Regulator Valve 2 Converter with Pressure Regulator Valve regulat...

Page 1058: ...7G 20 1972 PONTIAC SERVICE MANUAL...

Page 1059: ...TURBO HYDRA MATIC M 38 TRANSMISSION 7G 21...

Page 1060: ...essure becomes shift valves to the manual control valve and to the drive oil and is fed to modulator valve SUMMARY The forward clutch is applied and the transmission is in first gear DRIVE RANGE SECON...

Page 1061: ...w n i u n t Patrsuat m SUCTION PRESSURE rn CONVERIIR PRESSURE 0 GOVERNOR PRESSURE m MODULATOR PRESSBE 0 DnENl REGULAlOR Fig 7 G 2 8 Drive Range Second Gear...

Page 1062: ...70 24 1972 PONTIAC SERVICE MANUAL...

Page 1063: ...ermediate Overrun Roller Clutch Locked Low and Reverse Roller Clutch Locked Intermediate Overrun Band Off OIL FLOW With the range selector lever in Low L line oil leavesthe manual valve as low oil and...

Page 1064: ...76 26 1972 PONTIAC SERVICE MANUAL...

Page 1065: ...TURBO HYDRA MATIC M 38 TRANSMISSION 76 27...

Page 1066: ...simply moving the range selector lever from Drive D to Super S range When the car slows down to approximately 9 m p h a 2 1 shift will occur when the 1 2 shift control spring overcomes the decreased...

Page 1067: ...TURBO HYDRA MATIC M 38 TRANSMISSION 76 29...

Page 1068: ...out of the 1 2 shift control valve as low or reverse oil and is directed to the inner area of the low and reverse piston Reverse oil at the 2 3 shift valve is regulated to 2 3 clutch oil and applies t...

Page 1069: ...TURBO HYDRA MATIC M 38 TRANSMISSION 7G 31...

Page 1070: ...150 LB IN A 20 LB FT Fig 76 34Column Shift Controls A series Shown ALIGN BUTTON SO TOP OF LETTERS ARE TOWARDS FRONT OF CAR THIS RING TO BE INSTALLED WITH CURVED SIDE UP UNDERBODY W O N THRV SHIFT KNO...

Page 1071: ...and C on lower control rod E Set transmission lever F in DRIVE position NOTE Obtain DRIVE position by moving transmission lever counterclockwise to LOW then clockwise twodetentpositions to DRIVE Set...

Page 1072: ...ark to the FULL mark requires one pint of fluid Fluid level should be to the FULL mark with the trans mission fluid at normal operating temperature 180 190 F With warm fluid room temperature 70 F the...

Page 1073: ...1 4 below the ADD mark on If vehicle is not driven 15 miles of highway type driving or its equivalent and it becomes necessary to check the fluid level the transmission fluid may be at room tempera t...

Page 1074: ...and install oil pan Tighten its thirteen 13 attaching bolt and washer assemblies to 12 lb ft torque Lower car and add approximately 3 pints of trans mission fluid through filler tube With selector le...

Page 1075: ...rom case 2 Withdraw governor assembly from case INSTALLATION Installation of the governor assembly is the reverse of REMOVAL Install a new O ring seal and retaining clip on governor cover and adjust t...

Page 1076: ...lator piston cover and remove its retaining ring and piston cover from case 3 Remove spring and intermediate clutch accumulator piston INSTALLATION Installation of the intermediate clutch accumulator...

Page 1077: ...e wire harness vacuum hose at modulator detent downshift cable and shift control linkage from transmission CAUTI0N Whenremoving detent downshifi cable fiom detent link do not bend cable 5 Support tran...

Page 1078: ...ard O ring seal EXTENSION HOUSING SPE EDO DRIVE GEAR AND GOVERNOR REMOVE 1 Remove bolt retainer and speedometer driven gear speed control switch from side of extension housing 2 Remove four 4 extensio...

Page 1079: ...ve sixteen 16 of remaining seventeen 17 valve body to case attaching bolts complete draining fluid from transmission move transmission to hori zontal position and remove last body to case bolt 5 While...

Page 1080: ...manual shaft to case retainer with a screw driver 76 55 L i OIL P U M P PRESSURE S C R E E N Fig 7G 54 Removing Governor Screens Loosen jam nut that holds range selector inner lever to manual shaft Re...

Page 1081: ...cteristic and does not indicate leakage during operation To remove carefully cut teflon ring and remove both the ring and the restrictors from the piston groove Fig 76 58 Removing Pump Attaching Bolts...

Page 1082: ...and or chips metal particles imbedded in lining Fig 76 62 Removing Output Carrier If a faced plate exhibits any of the above condi tions replacement is required Wipe the steel separator plates dry and...

Page 1083: ...oller clutch inner race thrust washer from drive shell or Fig 7G 66Removing Retainer Spring inner race This washer has four 4 wide internal tangs 14 Remove low and reverse roller clutch support to cas...

Page 1084: ...ly or case Fig 76 68 1 OUTPUT R I N G G E A R 7 I Fig 7E 69 Output Ring Gear and Output Shaft Fig 7G 70 Compressing Low and Reverse Clutch Piston 21 If it is necessary to separate ring gear from outpu...

Page 1085: ...hts are interchangesble from side to side and need not be identified 2 Remove governor valve from governor sleeve Use care in not damaging valve INTERMEDIATE CLUTCH ACCUMULATOR PISTON Fig 7G 73Removin...

Page 1086: ...le through sleeve and gear using a stand ard 1 8 drill 6 Install new retaining split pin 7 Wash governor assembly thoroughly to remove any chips that may have collected GOVERNOR ASSEMBLE 1 Install gov...

Page 1087: ...press piston evenly and remove retainer E ring Remove tool direct clutch accumulator piston metal oil seal ring and direct clutch accumulator spring From lower right hand bore compress boost valve sle...

Page 1088: ...install 1 2 shift valve with stem end out install control valve spring into its bore in 1 2 shift control valve and both into 1 2 shift control valve sleeve Install control valve sleeve assembly into...

Page 1089: ...BLE 1 Remove pump body to case O ring seal square cut from pump body Discard seal 2 Continue scribe mark made earlier before removal of pump from case down side of body and cover for aid in re assembl...

Page 1090: ...oil seal with screwdriver or a small pry bar Discard seal Fig 76 83 INSPECT Fig 7G 84 Wash all parts in cleaning solvent blow out all oil passages and air dry Inspect pump drive and driven gears gear...

Page 1091: ...er Figs 76 86 and 76 87 2 Inspect three 3 pump cover stator shaft bushings for galling or scoring If any of these bushings is da maged replace bushing s as follows STATOR SHAFT FRONT BUSHING REPLACE 1...

Page 1092: ...tor shaft and drive out center and rear bushings J 2619 4 ADAPTER PUMP COVER AND STATOR SHAFT ASSEMBLY J 8092 DRIVE HANDLE J 21424 7 PUMP COVER AND STATOR SHAFT ASSEMBL Fig 76 89Installing Shaft Front...

Page 1093: ...ing marks made earlier 6 Install pump cover to direct clutch drum selective thrust washer over pump cover oil delivery sleeve hub This washer has one 1 external tang 7 Install and engage three 3 direc...

Page 1094: ...fore removal check for correct as sembly Outer race should free wheel counter clockwise only k INTERM EDIATE OVERRUN I Fig 7G 95 Removing Roller Clutch Fig 7G 96 Removing Roller Bearing 3 Remove inter...

Page 1095: ...ed air and inspect for pitting and flaking wear glaz ing cracking charring and or chips metal par ticles imbedded in lining If faced plate exhibits any of these conditions replacement is required b Wi...

Page 1096: ...CLUTCH OVERRUN INNER C A M INTERMEDIATE CLUTCH OVERRUN OUTER RACE LOCKS O N CLOCKWISE ROTATION P O S l T l O N WITH 2 HOLES TO W A RD REA R OF TRANSMISSION Fig 7G 101 Exploded View of Intermediate Ove...

Page 1097: ...I 1 16 by 1 2 diameter and springs are violet in color 4 Using Clutch Spring Compressor J 23327 1 in an arbor press compress spring seat and install piston retaining ring 5 Remove tools and lubricate...

Page 1098: ...eel separator plates and the forward clutch housing cushion spring Fig 7G 107 C U S H I O N SPRING I SEPARAT PLATES Fig 7G 107Removing or Installing Forward Clutch Plates Fig 7G 108Removing Retaining...

Page 1099: ...served plates should be re used If surface is scuffed or shows severe heat discoloration the plates must be replaced 3 Inspect all springs for collapsed coils or signs of dis tortion 4 Inspect piston...

Page 1100: ...lates into the forward clutch drum Fig 7G 107 8 Install forward clutch pressure plate and its retaining ring Fig 7G 108 9 Using a feeler gage check the free back height be tween the forward clutch pre...

Page 1101: ...ect sun gear and sun gear drive shell for wear or damage 3 Inspect sun gear bushings for galling or scoring If bushing s is damaged replace as follows a Using Bushing Tool J 23062 3 Extension J 21465...

Page 1102: ...ir dry 2 Inspect roller clutch inner and outer races for scrat ches wear or indentations 3 Inspect roller clutch assembly rollers for wear and roller springs for distortion NOTE If rollers are removed...

Page 1103: ...nput ring gear properly sup ported drive out bushing Fig 7G 120 b Using Bushing Tool J 23062 5 and Drive Handle J 8092 install new bushing to 050 060 below rear face inside gear end Fig 7G 120 INPUT R...

Page 1104: ...tput shaft splines for nicks or damage 4 Check output shaft bearing surface for nicks or scor ing 5 Check output shaft bushing for nicks scoring or wear If bushing is damaged replace as follows a Thre...

Page 1105: ...scoring or wear If bushing is damaged see REPLACEMENT OF CASE BUSHING INSTALLATION OF GOVERNOR BUSHING IN CASE 1 Position transmission case in Fixture J 8763 01 into a vise with the case governor face...

Page 1106: ...tinue reaming until the reamer bottoms out on the dowel pin in the case shown in Fig 76 129 e Remove the reamer by rotating clockwise and using 5 to 10 pounds of upward force CAUTlON Pulling reamer wi...

Page 1107: ...ng 2 Using Bushing Tool J 23062 1 Extension J 21465 13 and Drive Handle J 8092 drive new bushing in from front of case to 195 below front surface of bore Fig Fig 7G 133 Installing Case Bushing NOTE Ma...

Page 1108: ...ends of band for damage at anchor lug or apply 1 b Using a short piece of rubber tubing apply air pressure to vacuum pipe by blowing into tubing and observe for leak bubbles VACUUM MODULATOR c If bub...

Page 1109: ...re 8 If modulator assembly passes all of above checks it is an acceptable part and should be re used r I MODULATOR PART NUMBER IS LOCATED ON BACK SIDE HOLD MODULATORS IN A HORIZONTAL POSITION AS SHOWN...

Page 1110: ...preventingbrass nut from turning tighten hex nut to 3 lb ft torque Fig 70 144 d Install Dial Indicator J 8001 and set it for zero while its plunger rests on brass nut e While holding brass nut station...

Page 1111: ...Install piston assembly into its bore in case Fig 7G 146 3 Install piston spring into case and install O ring seal to piston cover Fig 7G 146 Exploded View of Intermediate Clutch Accumulator NOTE Fre...

Page 1112: ...output shaft assembly into case OUTPUT RING GEAR TANGED THRUST WASHER Fig 7G 149 Installing Output Ring Gear Thrust Washer Fig 7G 150 Installing Carrier onto Output Shaft NOTE Lip on inner race of ne...

Page 1113: ...nstall forward clutch housing to input ring gear thrust washer into input ring gear face This washer has three 3 wide external tangs Install direct clutch drum to forward clutch drum needle roller bea...

Page 1114: ...nd index plunger of indicator on end of input shaft Zero the indicator Fig 76 154 Push up on output shaft and record the amount of end play registered by the dial indicator Indicator should read from...

Page 1115: ...7 Exploded View of Intermediate Servo Piston and Pin PARKING LINKAGE VALVE BODY AND OIL PAN INSTALL 1 If removed install the park pawl into case with its tooth toward center of case Install park pawl...

Page 1116: ...Check Balls Fig 7G 16 1 lnstalling Spacer Plate Gasket 14 Connect detent control valve link to detent valve ac tuating lever and while connecting manual control valve link to range selector inner leve...

Page 1117: ...nsion housing to case bolts tor quing to 35 lb ft 5 If extension housing lip oil seal was removed install new extension housing lip oil seal by using Seal In staller J 21426 NOTE Outerdiameter ofseal...

Page 1118: ...al shaft The application of each transmission model is as follows JE 250 cu in 1Bbl engine A and F Series SB 307 cu in 2 Bbl engine X Series MA 350 cu in 2Bbl engine A F and X Series Whenever the 1 2a...

Page 1119: ...062 1 Case Bushing lnstaller Adapter J 3289 14 Holding Fixture Base J 9534 Output Shaft Bushing J 23062 2 Stator Shaft Center Not Shown Remover and Rear Bushing J 22976 1 Drill Bushing Fixture J 21424...

Page 1120: ...p Oil Seal Installer J 21366 Converter Holding Strap J 2 1369 Converter Leak Test Fixture Fixture Accumulator Cover J 21420 2 Clutch Spring Compressor Pilot Low Reverse Clutches J 21426 Rear Oil Seal...

Page 1121: ...valve in the gas cap and by reverse flow through the canister at lower rates Sedan and coupe tanks haw a fuel limiter inside This provides room for fuel expar on and prevents liquid fuel from being fo...

Page 1122: ...T NEVER READS FULL 1 7 A ERRATIC FUEL GAUGE READINGS I 1 FUEL TANK MUST B E FILLED TO CAPACITY 2 NOTE DASH UNlT NEEDLE POSITION WlTH ENGINE RUNNING 3 DISCONNECT FEED WlRE TO TANK UNIT 4 WlTH OHMMETER...

Page 1123: ...hat has collected in the standpipe common chamber to drain back into the fuel tank through its rear top center vent when the car is level or pointing uphill This vent is normally below the standpipe a...

Page 1124: ...the resistance for electrical current to flow through the tank unit and the amount of current flowing through the dash unit see Sedtion 12 for operation of the dash unit When the fuel tank is empty th...

Page 1125: ...TERIAL D FRAME REF VlEW B I VIEW E INSTALL HOSE AGAINST FLANGE ON PIPE HOSE WHEEL HOUSE OUTER PANEL c p ECLAMP REF FLANGED PIPE PlPE I CANISTER PlPE REF ENDS OF FRONT STRAP VlEW D UNFLANGED PIPE HOSE...

Page 1126: ...1 518 T STRAP VlEW B FUEL CANISTER HOSE j O S E REF RETURN HOSE REF 8 CYL ENGINE INSTALL HOSE AGAINST FLANGE ON PlPE 7PlPE HOS HOSE INSTALLATION FLANGED PIPE H o s E x E M I N CLAMP HOSE INSTALLATION...

Page 1127: ...rt lengths of rubber hose IMPORTANT IMPORTANT Use only hose marked EVAP or GM 6107M ifneces sary to replace an evaporation control system DIAPHRAGM SPRING I Fig 8 8 Fuel Tank Filler Cap ECS hose Gasol...

Page 1128: ...O FLANGE CANISTER HOSE CONTAINS RESTRlCTlON WHEN REPLACING HOSE BE SURE TO INSERT RESTRICTION P P E CLAMP HOSE INSTALLATION UNFLANGED PIPE HOSE INSTALLATION FLANGED PIPE Fig 8 9 Installation of Liquid...

Page 1129: ...FUEL TANK AND EXHAUST SYSTEM 8 9 Fig 8 10 Installation of Fuel and Vapor Return Hoses to Fuel Pump B F Series...

Page 1130: ...ER ASM REF EXHAUST PlPE REF VlEW C FRAME REF T A I L PIPE RESONATOR REF EXHA PlPE VIEWS G M ASM REF VIEW F VIEW H TIGHTEN ONE N U T FINGER TIGHT WlTH PARTS SEATED BEFORE TIGHTENING OTHER N U T COAT A...

Page 1131: ...FINGER TIGHT WITH PARTS SEATED FRAME OTHER NUT FRAME VIEWS A B RESONATOR VlEW F R H SHOWN RESONATOR ASM VlEW D R H SHOWN MUFFLER ASM REF VlEW E VlEW C R H SHOWN I COAT A L L SLIP JOINTS WlTH SEALER B...

Page 1132: ...EXHAUST T A I L PlPE REF VlEW M STA WAG COMM CHASSIS VlEW C MUFFLER REF 1 VlEW B FRONT CROSS OVER PIPE REF 2L EXHAUST 318 PlPE REF VlEW A T A l L PlPE REF STA WAG COMM CHASSIS QUARTER VANEL REF 112 I...

Page 1133: ...cation of a problem in one of these areas Any defects should be corrected immediately To help insure continued integrity the exhaust system pipe s and resonator rearward of the muffler must be replace...

Page 1134: ...T TIGHTEN ONE NUT FINGER TIGHT WlTH PARTS SEATED BEFORE TIGHTENING OTHER NUT VlEW A STATION WAGON FRAME AIL PIP REF 8 VlEW C EXC STA WAG NUTS 17 LB FT KEY ON TAlL PlPE END OF SLOT F TAlL PlPE REF COAT...

Page 1135: ...grity the exhaust system pipe rearward of the muffler must be replaced whenever a new muffler is installed Resonators are not used F X SERIES Exhaust extensions installed on the GTO and GT options hav...

Page 1136: ...RAME CROSSMEMBER REF TAIL PlPE REF VlEW E FT TAIL PlPE REF VlEW F T HORIZONTAL CROSS OVER T PIPE REF F VlEW C VlEW B TIGHTEN ONE NUT FINGER TIGHT WlTH PARTS SEATED BEFORE TIGHTENING OTHER NUT A COAT A...

Page 1137: ...A X L E CONTROL ARM CROSSMEMBER A ENGINE VlEW D M U F F L E R BOLTS 25 LB FT 0 VlEW B NUTS 17 LB FT TAIL PIPE FRAME STANDARD ENGINE TYP R H L H EXHAUST VlEW C TYP R H L H TIGHTEN ONE SIDE FINGER TIGHT...

Page 1138: ...UFF1 REF FRAME REF VlEW D VlEW C TYPICAL RH LH TYPICAL RH LH DUAL EXHAUST ENGINE REAR CROSS HANGER ASM REF G SERIES DUALS CROSSMEMBER REF VlEW K 7 16 MIN A TYPICAL RH L H DUALS RH ONLY SINGLE HORIZONT...

Page 1139: ...FUEL TANK AND EXHAUST SYSTEM 8 19 HORIZONTAL LINE Fig 8 20 Installation of GTO GT Exhaust Extension...

Page 1140: ...PE AGAINST END OF SLOT EXHAUST PlPE REF T 17 LB FT VIEW D LD I EXHAUS MANIFO REF 15 LB FT VlEW A UNDERBODY UNDERBODY REF TAIL PlPE REF VIEW B MUFFLER REF UNDERBODY VIEW C VIEW E REF I A COAT SLIP JOIN...

Page 1141: ...RAIL REF EXHAUST PIPE VIEW B VlEW A REF ALIGN CLAMP WITH SLOT I N MUFFLER M MUFFLER REF PIPE EXHAUST REF A d 1 1 314 MIN 1 13 64 MIN N Wl REAR AXLE FUEL TANK REF STRAP REF MUFFLER REF VlEW C VlEW D BO...

Page 1142: ...help insure continued integrity the exhaust system pipe rearward of the mumer must be replaced whenever a new muffler is installed V 8 ENGINE Two exhaust systems are used with V 8 engines single and...

Page 1143: ...VIEW A VIEW B UNDERBODY REF VlEW H A COAT ALL SLIP JOINTS WlTH SEALER BEFORE INSTALLING VlEW G VERTICAL CENTER LINE 17 LB FT f PlPE DIATE H VlEW C EXHAUST PIPE REAR VlEW D MUFFLER REF REF EXHAUS PlPE...

Page 1144: ...0 ENG H 0 ENG UNDERBODY REF PlPE FT VlEW F A COAT ALL SLIP JOINTS WITH SEALER BEFORE INSTALLING EXHAUST TENSION nCHn FRONT EXHAUS EXHAUST PlPE REF PIPE RE REF VlEW A VlEW B MUFFLER REF 17 LB K REAR EX...

Page 1145: ...NGLE EXH BOTH SIDES DUAL EXH VlEW G L H SlDE SINGLE EXH BOTH SlDES DUAL EXH EX ENSION REF VIEW F UNDERBODY REF EXHAUST PlPE REF VlEW A SINGLE EXH VlEW J R H SlDE SINGLE EXH L H SIDE SINGLE EXH BOTH SI...

Page 1146: ...to the pas senger compartment carpets Check complete exhaust system and nearby body areas and trunk lid for broken damaged missing or misposi tioned parts open seams holes loose connections or other...

Page 1147: ...iller neck Otherwise the cap will be retained loosely to the filler neck by the second set of tangs encountered during removal and since this set of 3 With chuck of air hose inserted into hose slit a...

Page 1148: ...Series 9 Complete tank removal INSTALL 1 Install tank by reversing the above steps 2 Torque fuel tank support strap nuts and bolts as listed below APPLICATION TORQUE B Series Except Wagon 25 lbs ft B...

Page 1149: ...to let axle assembly hang on brake hose Replace brake hose if weight of suspension is allowed to hang on hose The suspension coil spring may be loose enough to be removed 5 B Series Remove left rear...

Page 1150: ...TATION WAGON A a EXCEPT TEMPESl F U L L HUl Tnt FLOAT AIM A6YNST CHECKIIG FLOAT R I V E 1 B SERIES S T A T I O N W A G O N ERIES ATlON W A G O N 1 1 32 R E F HMD FLOAT A I M AT F SERIES A SERIES S T A...

Page 1151: ...aking sure a new tank gage unit gasket is installed NOTE Before the new unit is installed in the tank the float arm should be checked for free dom o fmovement by raising it to variousposi tions and se...

Page 1152: ...crews to 40 Ib in torque NOTE V 8 CANISTER SHOWN BCYL CANISTER HAS THREE HOSE CONNECTIONS FRONT t U STANDPIPE I c Fig 8 37 Installation of Canister X Series CANISTER REMOVE 1 Disconnect hoses from can...

Page 1153: ...rew for strap holding ter is mounted on and use hole behind head canister to 75 lb in torque lamp in headlamp filler panel for access GENERAL SPECIFICATIONS FUEL TANK CAPACITY U S GALS APPROX B Series...

Page 1154: ...System Has a Groan or Growling Noise 9 5 Power Steering Pump Has Whine Noise 9 5 Power Steering Pump Leaking Oil 9 5 Power Steering Gear Leaking Oil Externally 9 5 Energy Absorbing Steering Column Des...

Page 1155: ...of travel or when slowly turning at standstill Follow steps below If first step is O K proceed down list until problem is corrected CAUSE CORRECTION a Misaligned steering column causing metal to meta...

Page 1156: ...ering gear inspect steering gear for worn or damaged internal parts d Align steering column if steering shaft is still binding disassemble steering column and inspect for bent or damaged parts e If ab...

Page 1157: ...a Fill fluid level to proper level and be sure air is not present in system I Loose pump belt P S equipped cars only Steering linkage hitting engine oil an at full turn I Sticky flow control valve P S...

Page 1158: ...earing scored or rough CORRECTION a Replace shaft bearing and damaged parts as needed POWER STEERING PUMP LEAKING OIL NOTE Wipeparts thoroughly and make sure source ofleakage is deter mined Fig 9 1 Fo...

Page 1159: ...TROUBLE DIAGNOSIS Continued REPLACE RESERVOIR 0 RING REPLACE RIVE SHAFT SEAL E SHAFT FOR SLIGHT OR SEVERE PITTING TIGHTEN FITTING I F LEAKAGE PERSISTS REPLACE BOTH 0 RlNG C l Fig 9 1 Diagnosis of Pow...

Page 1160: ...SS CONNECTOR REPAIR FITTING NUT OR REPLACE HOSE AS REQUIRED IF HOUSING THREADS ARE BADLY STRIP PED REPLACE HOUSING dl REPLACE END PLUG REPLACE BOTH PITMAN SHAFT SEALS CHECK PITMAN SHAFT FOR SLIGHT COR...

Page 1161: ...ey cannot be removed from the lock The locking feature is incorporated in the two column applications available regular energy absorbing and tilt energy absorbing The regular column is standard on all...

Page 1162: ...that of the neutral safety switch used on vehiclesequipped with auto matic transmission The energy absorbing steering column is used on all series cars This column is designed to compress under impact...

Page 1163: ...and secured to the support by two pivot pins Two lock shoes are pinned to the actuator and engage pins in the support assembly When the release lever is pulled up and the lock shoes disengage the sup...

Page 1164: ...of the pitman shaft gear Fig As the steering wheel is turned to the right the nut moves upward When the wheel is turned to the left the nut moves downward The teeth on the sector which are forged as p...

Page 1165: ...between the steer ing wormshaft and rack piston The rack piston nut is geared to the sector of the pitman shaft Lash between the pitman shaft and rack piston nut is maintained by an adjusting screw wh...

Page 1166: ...f special tools required to service the unit Being a self bleeding unit the steering gear requires no external bleeding The rotary valve is shown schematically in Figs 9 11 9 12 and 9 13 and is an ope...

Page 1167: ...the valve body Fig 9 11 Grooves are slightly wider than the stub shaft and the valve spool together and a pin in the their mating land and clearance on both sides of the land valve body retains the to...

Page 1168: ...nd plug and the rack piston nut to force the rack upward permit ting the steering worm to screw into the rack piston nut This forces the pitman shaft to turn and reduces driver turning effort in execu...

Page 1169: ...oil The reservoir has a filler neck fitted with a vented cap The reservoir is sealed against the pump housing leaving only the housing face and shaft hub ex posed A shaft bushing bronze on steel and s...

Page 1170: ...e steering system pressures and thereby oil flow to the gear drive shaft and secured with a retaining ring It is located as required under various operating conditions centrally within the ring and be...

Page 1171: ...surface of the thrust plate and two suction openings in the pressure plate Oil fills the lower opening in the thrust plate to feed the rising portion of the rotor ring Air is pumped out of the pump th...

Page 1172: ...oil 12 is used for drive shaft bushing lubrication and then bled to the reservoir SLOW C O R N E R I N G During slow cornering maneuvers Fig 9 17 the oil pres sure required will usually not exceed 400...

Page 1173: ...m the discharge fitting but due to the force of the flow MODERATE TO HIGH SPEED OPERATION control spring 10 the valve remains closed to the bypass hole 5 The oil pressure does not build up high enough...

Page 1174: ...essure drop is transmitted to the bottom of the flow control valve 9 via orifice 11 and passage 8 The pressure unbalance on the valve is sufficient to overcome the force of the spring lo allowing the...

Page 1175: ...rame crossmember in accordance with the steering gear location ahead of the front wheels The X Series steering gear and linkage is located behind the front wheels The steering knuckle arm is part of t...

Page 1176: ...EFORE ASSEMBLING WHEEL Do NOT hammer an end of Stba ng Shah LIFT OFF NOT NECESSARY TO DISASSEMBLE WHEN REMOVING WHEEL USE J 3044 1 STEEWNG WHEEL PULLER noh ndex of wheel to shah A PUSH INSULATOR INTO...

Page 1177: ...ing preload spring and turn signal cancelling cam off upper steering shaft 5 Slide thrust washer off upper steering shaft I I Fig 9 22 Depressing Lock Plate and Removing Snap Ring Remove turn signal l...

Page 1178: ...emove lock cylinder in RUN position by insert ing a thin tool small screwdriver 6 steel rule or knife blade into the slot next to the switch mounting screw boss right hand slot and depress spring latc...

Page 1179: ...ock should re main in the RUN position 8 Install turn signal switch see TURN SIGNAL SWITCH INSTALL 9 Install steering wheel see STEERING WHEEL INSTALL BUZZER SWITCH REMOVE 1 Remove steering wheel see...

Page 1180: ...lamping screw Remove instrument panel trim cover screws and remove cover NOTE Remove lower air conditioning duct if so equipped Remove shift indicator pointer cable attaching screw from shift bowl on...

Page 1181: ...E MANUAL A G F SERIES A G F SERIES NON TI LT TILT WITH TRANSMISSION IN NEUTRAL ADJUST CABLE IN SLOT TO CENTER POINTER ON N INSTRUMENT CLUSTER REF INSTRUMENT B X SERIES 6SERIES SHOWN Fig 9 3 1 Installa...

Page 1182: ...COLUMN IGNITION SWITCH REF A t 4 LB FT 13 Ltl t I 20 LB FT CAUTION DO NOT EXCEED MAXIMUM OF 25 LB FT OF TORQUE TO PREVENT CRUSHING OF CAPSULES STEERING GEAR FLEXIBLE COUPLING SEAL 7 COVER PLATE UPPER...

Page 1183: ...mmering could loosen plastic injections which maintain column rigdity 1 Remove both attaching nuts securing flexible cou pling to steering shaft 2 On column shift transmission and floor shift cars dis...

Page 1184: ...OT JOINT n 15 LB FT DASH REF 15 LB FT 20 LB FT CAUTION DO NOT EXCEED MAXIMUR OF 25 LB FT OF TORQUE TO PREVEN CRUSHING OF CAPSULES 2 112 UPPER LOWER REACTION TABS CLAMP SCREW COVER PLATE RIGHT INBOARD...

Page 1185: ...shift levers 3 Disconnect all electrical connectors from steering column 4 Remove the floor pan trim and insulator cover 5 Remove screws securing toe plate to dash panel 6 Loosen instrument panel trim...

Page 1186: ...JOINT UPPER END OF STEERING COLUMN REF 15 LB FT b20 LB FT CAUTION DO NOT EXCEED MAXIMUM OF 25 LB FT OF TORQUE TO PREVENT CRUSHING OF CAPSULES LOWER END OF STEERING COVER 8 SEAL WELDED TO STEERING COLU...

Page 1187: ...ng bracket to in strument panel and carefully withdraw column INSTALL NOTE Make sure thisprocedure is Mowed in exactly this order that cover assembly is snug on column but still will move with respect...

Page 1188: ...STEERING 9 35 Fig 9 36 Exoloded View of Tvoical Reaular Column Automatic and Manual Transmission...

Page 1189: ...ER Steering Column Shift Tube Return Spring Thrust 49 TUBE ASM Gearshift 50 SHAFT ASM Steering 5 1 RING Upper Steering Shaft Retaining 52 SHAFT ASM Steering 53 SPRING lntermediate Steering Shaft Coupl...

Page 1190: ...STEERING 9 37 Fig 9 37 Exploded View of Typical Tilt Column...

Page 1191: ...lease 47 ACTUATOR ASM Steering Column Housing Switch 48 BOWL Part of Cover 49 SPRING Gearshift Lever Bowl 50 WASHER Steering Column Bowl Wave 5 1 PLATE Steering Column Lock 52 GATE Steering Shaft Hous...

Page 1192: ...ibility of damage to the small plastic buzzer switch actuator protruding from the Iock cylnder The s p n g action of the buzzer switch holds this actuator up into the cylnder so that it willnot catch...

Page 1193: ...RST REVERSE lever Fig 9 48 NOTE Bearing may be removed from adapter bya lightpress out operation on theouterrace Fig 9 43 Removing or Installing Rack Load Spring 6 Remove three screws from shift tube...

Page 1194: ...ighten the three bolts to 10 lb ft torque Fig 9 47 Removing Bearing Adapter and Shift Tube Spring 8 Remove both 005 maximum shims Perform step 9 on all models except cars equipped with column shift ma...

Page 1195: ...wide tooth on sector Fig 9 42 5 Install the thrust cup on the bottom hub of the hous ing Fig 9 41 005 SHIM BETWEEN TH LEVER AND SPACER O N EACH SIDE OF SHAFT Fig 9 5 1 Adjusting Lower Shift Lever Cle...

Page 1196: ...4 Remove two screws attaching back up light or neu tral start switch and remove switch Fig 9 45 5 Remove shift indicator assembly if it needs to be serviced by removing retaining spring s and lifting...

Page 1197: ...apter assembly at lower end of the mast jacket Remove steering shaft assembly from upper end Disassemble steering shaft assembly by removing center spheres and anti lash spring Fig 9 36 Remove four sc...

Page 1198: ...9 58 Removing or Installing Tilt Lever Opening Shielc Fig 9 59 Removing or Installing Lock Bolt Spring punch lightly tap drive shaft from sector Remove drive shaft washer sector and bolt Fig 9 60 4 Re...

Page 1199: ...and spring Wide tooth on rack to engage wide tooth on sector Fig 9 62 7 Install lock bolt spring and spring retaining screw Tighten to 35 lb in torque Fig 9 59 ASSEMBLE COLUMN 1 Install upper shift l...

Page 1200: ...CH INSTALL steps 1 through 3 CAUTION Buzzer switch should be installed BEFORE thelock cylinder Thereason for re placing in this orderis toreduce thepossibility of damage to the small plastic buzzer sw...

Page 1201: ...r shaft With slight pressure pull on steering shaft this will separate shaft from housing Remove bearing cups and clip from steering shaft NOTE If the rubber boot or cross shaft in lowersteeringshafti...

Page 1202: ...nsert cotter pin 30 lb ft SERIES X SERIES B FSERIES 0 45 Next notch 45 Ib ft min 45 Ib ft A G SERIES 0 15 3B F SERIES 85 Ib ft max to insert cotter pin 50 Ib ft A G SERIES 55 Ib ft max to insert cotte...

Page 1203: ...ken to insure that steering a m hole stud and nut are free ofdirt and grease before tightening nut Turn nut in tighteningdirection onlytoalignslot withhole in tie rod stud to insert cotter pin DO NOT...

Page 1204: ...om a vertical down position on B A G and F Series Open end of clamps should be a 30 forward or rearward from a vertical up position on X Series INTERMEDIATE ROD REMOVE 1 Raise front of car 2 Remove le...

Page 1205: ...or to 140lb ft torque on X Series Tighten intermediate rod stud nut to 40 lb ft on B and F Series or to 30 lb ft on A and G Series or to 45 lb ft on X Series Insert cotter pin CAUTION Careshould be t...

Page 1206: ...regarding the fasteners referred to in steps 2 and 3 1 Install by reversing the above steps 2 Tighten steering knuckle to steering arm bolts to 80 lb ft torque 3 Tighten tie rod stud nut to 30 lb ft t...

Page 1207: ...URE HOSE PlPE AGAINST VlEW OF CLAMP AFTER ASSEMBLY NUTS 25 LB FT F SERIES ECYL ENG CENTER LINE OF NUT 35 LB FT CLAMP 8 G A SERIES 8 CYL ENG TYPICAL HOSE INSTALLATION POSITION PlPE VlEW A F SERIES BCYL...

Page 1208: ...ft torque 3 Install pitman arm and secure with lock washer and nut Tighten nut to 185 lb ft torque 4 Connect pressure and return hose assemblies to gear assembly and tighten to 25 lb ft torque Figs 9...

Page 1209: ...excess of worm bearing preload NOTE Total worn bearingpreload adjostment andpitman shaftadjostmentshouldnot exceed 16 lb in 4 If necessary readjust lash adjuster screw to obtain proper torque Tighten...

Page 1210: ...ng 13 RACE Strg Gear Worm Thrust Bearing 14 ADJUSTER Worm Thrust Bearing 15 NUT Worm Bearing Adjusting 17 BEARING Strg Gear Thrust 18 BALL Steering Gear Worm 19 SHAFT Steering Gear w Balls Nut 20 BEAR...

Page 1211: ...Retainer from Adjuster Plug With a magnifying glass inspect the bearings and bearing races for signs of indentation Also check for any signs of chipping or breakdown of the surface Any parts that sho...

Page 1212: ...ousing using tool J 1614 inserted from the lower end of the housing Fig 9 73 Remove the wormshaft bearing race with a slide hammer puller as shown in Figure 9 74 INSTALL Press the new bearing race int...

Page 1213: ...Load the balls into one of the guide holes while turn ing the wormshaft gradually away from that hole Fig 9 76 Filling Ball Circuits When all 25 of the balls have been installed the circuit is complet...

Page 1214: ...8 Rotate the wormshaft until the ball nut isabout in the center of travel NOTE This is to make sure that the pitman shaftsector and ball nut will engageproperly with the center tooth ofthe sector ente...

Page 1215: ...nstallation 7 Clean the end of housing thoroughly so that dirt will not enter housing with the installation of the new seals INSTALL 1 Lubricate the seals thoroughly with power steering fluid to insta...

Page 1216: ...rust bearing adjuster plug 1 2 turn and retighten lock nut 5 Turn gear stub shaft to right stop and then back 1 2 turn 6 Using a 25 pound inch torque wrench on gear stub shaft measure drag torque 7 Ti...

Page 1217: ...9 64 1972 PONTIAC SERVICE MANUAL...

Page 1218: ...Oil 58 WASHER Pitman Shaft Seal Back Up 59 SEAL Strg Gear Pitman Shaft Oil Double Lip 60 WASHER Pitman Shaft Seal Back Up 61 RING Pitman Shaft Seal Retaining 62 LOCKWASHER Pitman Arm 7 8 63 NUT Steer...

Page 1219: ...9 84 Removing Rack Piston c Turn the flexible coupling flange until the pitman shaft teeth are centered in the housing opening d Tap the pitman shaft with a soft hammer and remove the pitman shaft and...

Page 1220: ...move the spacer thrust bearing washer thrust bearing and washer c Discard the retainer 3 If the needle bearing is to be replaced proceed as follows a Remove the retaining ring using internal pliers J...

Page 1221: ...e the large thrust bearing washer on the adjuster plug hub then install the upper thrust bearing small bearing washer and spacer grooves of spacer away from bearing washer 6 Install a new bearing reta...

Page 1222: ...3 If there is evidence of leakagebetween the torsion bar and the stub shaft or scores nicks or burrs on the ground surfaceof the sub shaft that cannot be cleaned up with crocus cloth the entire valve...

Page 1223: ...e spool valve 6 Align the notch in the shaft cap with the pin in the valve body and press the spool valve and shaft assem bly into the valve body Fig 9 95 CAUTION Make sure that the shaftcap notch is...

Page 1224: ...or excessive wear Inspect the external ground surfaces for wear scoring or burrs ASSEMBLY 1 If the plastic oil seal and 0 ring were removed lubricate a new 0 ring and sealwith power steering fluid an...

Page 1225: ...move any metal chips or dirt 7 Remove poppet check valve and spring from pressure port and discard Fig 9 98 Removing Hose Connector Seat INSTALL 1 Install new check valve spring in pressure port with...

Page 1226: ...J 22407 since damage to the bearing would result NOTE Bearing can be installed using adapterJ 6278 3withremoverand replacer J 6278 1 Be carefulflanged bearing is not driven into hous ing and bottomed...

Page 1227: ...hen in stalling If pressure is applied to the lower shaft during installation the shaft may be forced out of the va1 re body Fig 9 106 STUB VALVE SHAFT BODY WORM SHAFT LOWER THRUST BEARIN LOWER THRUST...

Page 1228: ...ch fits into the 0 ring groove in the side cover When the gasket seal is correctly seated in the side cover 0 ring groove the gasket cannot be rotated If the wrong gasket face is against the side cove...

Page 1229: ...0 psi on all cylinder models If pressure does not reach specifi cation there is either internal leakagein steeringgear or pump is malfunctioning CAUTION Vehicle sfront wheels must be on ground and sup...

Page 1230: ...nge rocking back and forth 4 Remove mounting bolt and union 0ring 5 Remove end plate retaining ring Push end plate re taining ring out of groove using a punch through 1 8 diameter hole in pump housing...

Page 1231: ...front of housing Fig 9 116 I Fig 9 1 15 Remov ngDowel Pin vent Lubricate all 0 ringsand thednieshaftseal with power steeringfluid and installinproper location Be sure not toimmene dn ve shaftsealin c...

Page 1232: ...Fig 9 118 2 Install thrust plate on dowel pins with ported face to rear of pump housing Fig 9 119 3 Install rotor must be free on splines on pump shaft at splined end CAUTION Assemble rotor with flat...

Page 1233: ...ressure plate as this will cause permanent distortion with resulting pump fail ure Pressure plate will travel about 1 16 to seat 8 Install end plate 0 ring ROTATION ARROW Fig 9 122 Installing Pump Van...

Page 1234: ...lide pulley on shaft 3 Install pulley nut fingertight 4 Connect and tighten hose fitting Tighten outlet fit ting to 35 lb ft torque Fig 9 66 5 Fill reservoir with GM power steering fluid or equivalent...

Page 1235: ...ORQUE TO TURN WORM SHAFT 100 1 30 Lbs POWER MANUAL GEAR 5 to 8 Ib in 4 to10 lb in 16 Ib in X SERIES POWER GEAR 3 to 4 Ib in 4 to 8 Ib in 4 to 5 Ib in 18 Ib in 14 Ib in Used 100 105 Lbs B SERIES B SERI...

Page 1236: ...in 30 X Series Then tighten to next slot for cotter pin insertion 45 Nut Tie Rod Adjuster Sleeve Clamp Except X Series 20 APPLICATION TORQUE X Series 12 Nut Idler Arm Support to Frame 40 Nut Steering...

Page 1237: ...Connector Seat lnstaller Steering Gear Pitman Shaft Oil Seal lnstaller Adjuster Plug Bearing Remover lnstaller Tool No Name Pitman Shaft Bearing Remover lnstaller Piston Rack Arbor Plastic Ring Seal...

Page 1238: ...Tire rotation at recommended intervals will assist in minimiz ing this type of wear Fig 10 2 Careful inspection of tires may show that improper wheel alignment poorly adjusted brakes poor driving hab...

Page 1239: ...RVICE MANUAL I 4 TREADCONTACT WITH ROAD IUNDERINFLATION SHOULDERS OF TREAD WORN IRREGULAR DEPRESSIONS IMULTI PROBLEMJ ONE SIDE OF TREAD WORN OVERINFLATIONI CENTER OF TREAD WORN FEATHERED EDGE Fig 10 1...

Page 1240: ...wheel alignment cornering and inflation pressure as mentioned previously There are sev eral factors which must be considered in analyzing tread wear A careful driver may obtain many times the mileage...

Page 1241: ...as high as it is wide The lower the number the wider the tire TIRE BODY CORDS TREAD RUBBER FIBERGLASS LAYERS Fig 10 3 Bias Belted Tire Construction I 1 7 35 7 75 8 25 etc 1 83 Section Ratio Convention...

Page 1242: ...bruising or carcass damage directly under the tread 3 Poor traction at rear wheels resulting in uneven wear 4 Rapid tread wear at center of tire Lower inflation pressures than recommended can cause 1...

Page 1243: ...damage to the tire Dynamic balance is the equal distribution of weight about the plane of rotation Fig 10 7 such that when the tire spins there is no tendency for the assembly to move from side to sid...

Page 1244: ...with Bucket Seats 950 LBS All F Series 800 LBS STANDARD INFLATION FOR ALL LOADS INCLUDING FULL RATED POUNDS PER SQUARE INCH COOL Front Rear 26 30 24 28 24 32 24 32 26 26 24 28 26 28 24 28 26 26 NOTES...

Page 1245: ...r and surrounding the stud to be removed and press out the stud CAUTION If hub and drum or rotor are not supported underneath pressure from thepress may distort the drum or rotor orpush the hub assemb...

Page 1246: ...volume of air This forces the bead on the bead seat and against the flanges where the air seal for the tire is obtained Inflate tire until beads are completely forced against rim flanges WARNING DO NO...

Page 1247: ...E Always split weight evenly between in side and outside of wheel to avoid changing dynamic balance Wheels and tires must be balanced statically before being balanced dynamically Recheck static balanc...

Page 1248: ...O BALANCE A TIRE ON A DRlVE WHEEL WITH THE OTHER DRlVE WHEEL ON THE GROUND SINCE THE CAR MAY DRlVE THROUGH THlS WHEEL If car is equipped with Safe T Track rear axle the balanc ing of the rear wheels s...

Page 1249: ...ll 14x6 KT RALLY I1 OPTIONAL 15x7 KR I HONEY COMB 14x7 JX HONEY COMB 15x7 KP I STANDARD RALLY 11 HONEY COMB SPACE SAVER SPARE G SERIES 14x7 14x7 14x7 14x6 CL or JZ KS JX NONE F SERIES STANDARD with E7...

Page 1250: ...yl Except LeMans Sport Convertible 6 Cylinder LeMans Sport Convertible LeMans Luxury Except 4 Door Hardtop 8 Cyl LeMans except 455 without Endura Front Bumper and AIC LeMans Luxury 4 Door Hardtop LeMa...

Page 1251: ...10 14 1972 PONTIAC SERVICE MANUAL MOVING UDS Fig 10 15 Special Tool...

Page 1252: ...ADJUST Slotted holes are provided at all hood hinge attaching points Fig 11 1 for proper adjustment both vertically and fore and aft NO 1 NOTE Adjost one side at a time To lower the REAR corners of th...

Page 1253: ...mounted on the underside of 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 essentia...

Page 1254: ...CHASSIS SHEET METAL 11 3 LUXURY LE MANS Fig 11 3 A Series Hood Latch and Release Lever Except GT and GTO Fig 11 4 GT and GTO Hood Latch and Release Lever...

Page 1255: ...11 4 1972 PONTIAC SERVICE MANUAL Fig 11 5 F Series Hood Latch and Release Lever Fig 11 6 X Series Hood Latch and Release Lever...

Page 1256: ...CHASSIS SHEET METAL 11 5 Fig 11 7 B Series Hood Striker and Release Cable Fig 11 8 B Series Hood Latch...

Page 1257: ...attaching bolts Remove hood release cable clip on latch assembly Remove cable from radiator support REPLACE To replace reverse the above procedure taking precau tions to prevent binding of the cable C...

Page 1258: ...CHASSIS SHEET METAL 11 7 SKIRT REF BRACKET STATION WAGON ONLY Fig 1 1 10 B Series Front Fenders...

Page 1259: ...11 8 1972 PONTIAC SERVICE MANUAL pVIEW A Fig 1 1 1 1 A Series Front Fenders Fig 1 1 1 2 F Series Front Fenders...

Page 1260: ...assembly at taching screws 4 Remove headlamp filler and fender extension to fender attaching screws 5 Remove hood hinge to fender attaching screws and block up hood 6 Remove fender to inner skirt atta...

Page 1261: ...n on inner edge of skirt 10 Remove inner fender skirt by rotating rearward REPLACE 1 To replace reverse above procedure checking fender alignment with other sheet metal and body parts 2 Torque all fen...

Page 1262: ...CHASSIS SHEET METAL 11 1 1 Fig 1 1 1 5 G Series Grille Assembly Fig 1 1 16B Series Headlamp Filler Panel and Front Fender Extensions...

Page 1263: ...s 3 Disconnect headlamp wires and remove complete panel assembly 4 Separate sections and remove grille assembly 5 Remove headlamp assembly bumper close out pan els and remaining parts REMOVE A SERIES...

Page 1264: ...CHASSIS SHEET METAL 11 13 Fig 11 18 A Series Headlamp Filler Panel LUXURY LE MANS Fig 11 19 A Series Grille Assembly...

Page 1265: ...n the fiberglass panels A Glass Woven 7 Cloth should be installed on the underside of a crack in With a lacquer removing solvent remove paint from damaged area down to the fiberglass Scuff sand area s...

Page 1266: ...CHASSIS SHEET METAL 11 15 VIEW B VIEW A Fig 1 1 21 G Series Moldings and Ornaments 4 VIEW A PROTECTIVE PAPER Fig 11 22 G Series Paint Stripe Decals...

Page 1267: ...11 16 1972 PONTIAC SERVICE MANUAL Fig 11 23 B Series Molding and Ornaments Fig 11 24 I3 Series Wood Side Moldings...

Page 1268: ...CHASSIS SHEET METAL 11 17 VlEW C VlEW D VlEW A Fig 11 25 A Series Moldings VlEW A 8 VlEW B Fig 11 26 A Series Wood Side Moldings...

Page 1269: ...NTIAC SERVICE MANUAL PROTECTIVE PAPER BACKING PAPER WRAP EXCESS STRIPE STRIPES INTO WHEEL OPENING 1 12 ON CREASE SECTION AA I VIEW C Fig 11 27 A Series Paint Stripe Decals Fig 11 28 F Series Moldings...

Page 1270: ...PER BACKING 50 REF ROTECTIVE QUARTER PANEL TO BE PAPER COLOR AROUND CENTER DECAL ON BEZEL 12 IN REAR MARKER LAMP VIEW B DECAL TO TERMINATE FLUSH WITH REAR END PANEL 50 CONSTANT I 25 FROM WHEEL VlEW A...

Page 1271: ...h 12 62 Side Marker Lamps 12 62 Instrument Panel Cluster 12 63 Printed Circuit 12 67 Speedometer Cable 12 69 Instrument Panel Pad 12 70 Fuel Gage r 12 84 Windshield Wiper Switch 12 89 Headlamp Switch...

Page 1272: ...OD I I CLEAN A N D RETURN ENERGIZERIBATTERY CHARGE ENERGIZERIBATTERY IF NECESSARY U N T I L A L L I CELLS A R E I T LEAST zoospEclFlc GRAVITY I IF UNABLE TO O B T h I N SPECIFY GRAVITY OF 1 2 0 0 8 0...

Page 1273: ...s being operated continu ously This develops sufficient heat to melt wires in winding causing an open circuit Overheating is ac companied by a characteristic odor which indicates that horn should be r...

Page 1274: ...to insure that the buzzer wire is connected If the results of these three checks are normal proceed to the harmonica a multiple wire connector which con nects the column to the chassis Separate it and...

Page 1275: ...wire from relay to turn Remove horn button pad or cup and touch test light lead to horn contact assembly 1 wire from relay GROUND 0 K POOR GROUND LAMP OFF 0 LAMP ON Q Replace horns Repair ground Chec...

Page 1276: ...Contact Gap To set the switch to the low contact limit insert a typical feeler gauge firmly onto the actuator pads If contact is not made adjust the switch by bending the moveable internal member with...

Page 1277: ...inuity checks both the switch and pad checks are positive the indication is that poor or no contact is being made between the buzzer terminals and the switch pads The switch may either be replaced or...

Page 1278: ...up under the instrument panel adjacent to the column 2 Check for secure connection at the chassis switch connector This is the harmonica connector on the column Figure 12 10 Secure if loose Check all...

Page 1279: ...ker to C and check for continuity 4 Move turn signal switch to Left turn 5 Touch other end of checker to B and check for continuity Alternate Method Electrical Check of the Turn Signal Switch Another...

Page 1280: ...le Figure 12 14 check for missing springs Replace any spring that is miss ing inspecting the molded pins which secure them If these pins are broken the switch must be replaced 2 Check the position of...

Page 1281: ...N SIGNAL CONNECTOR USE A 12 VOLT TEST LAMP TO TEST FOR VOLTAGE IN WIRE AND CONNECTOR DO NOT DISCONNECT BETWEEN FRONT LAMP AND WIRE BETWEEN PRINTED 1 TEST LAMP DOES TEST LAMP NOT LIGHT A T LIGHTS EITHE...

Page 1282: ...AND REPAIR OPEN CIRCUIT BETWEEN I N CONNECTOR CONNECTOR TO THE SWITCH FLASHER AND STEERING OR REPLACE TURN SIGNAL COLUMN CONNECTOR HAZARD WARNING LAMPS I IINOPERATIVE I I CHECK FUSE STOP HAZARD FUSE...

Page 1283: ...h Check voltage at light switch red and blue wire terminals with test bulb If bulb lights at red wire terminal but not at light blue replace light switch UPPER OR LOWER BEAM WILL NOT LIGHT OR INTERMIT...

Page 1284: ...l lamps do not light replace tail fuse if blown If new fuse blows repair short to ground between fuse and lamps Secure connectors at light switch and steering column column If tail lamps light check v...

Page 1285: ...urn signal switch Improper bulb or defective turn signal switch Turn on hazard warning system If all front and rear lamps operate check for improper bulb 1034 Instead of 1157 If bulbs are OK replace S...

Page 1286: ...se is OK switch on turn signals If lamps operate replace defective hazard flasher on fuse panel Open wiring or defective turn signal switch With 12 volt test bulb check voltage at brown wire in turn s...

Page 1287: ...f park and tail lamps operate repair open Multiple bulbs out ground connections Replace burned out bulbs ALL LAMPS INOPERATIVE Fuse blown Loose connection Open wiring Defective light switch See side m...

Page 1288: ...e circuit between fuse panel through light switch to lamps Secure connector at light switch If test bulb does not light on either side of fuse repair open circuit between fuse panel and battery Possib...

Page 1289: ...round in circuit from fuse through neutral safety switch to back up lamps Secure all connectors If OK check continuity by voltage checking circuit from fuse to lamps with test bulb If test bulb does n...

Page 1290: ...fuse blown CORRECTION Replace bulb Loose connection open wiring or defective bulbs Defective directional signal switch or cancelling cam ONE SIDE INOPERATIVE Turn on direction signal If lamp does not...

Page 1291: ...ase Readjust properly If switch still malfunctions replace SPEEDOMETER CORRECTION Loosen over tightened casing nuts and snap on at speedometer head Replace housing and core Replace broken cable Check...

Page 1292: ...break in printed circuit TEMPERATURE WARNlNG LAMP CAUSE CORRECTION Temperature warning lamp stays on if Check sender for abnormal ground electrical failure Check for short between bulkhead and sender...

Page 1293: ...AL Fig 12 25 Non Sealed Battery The battery date code is located between the first and second vent cap from the negative post This date code should always be included on product information reports or...

Page 1294: ...ould be replaced SPECIFIC GRAVITY CELL COMPARISON TEST The hydrometer test will indicate the state of charge of a battery unless water has recently been added to the battery or the battery has been re...

Page 1295: ...nufactured and sold by a number of companies The 421 designation is shown on the meter face indicating that the above de scribed programmed test is followed For particulars in the use of the test foll...

Page 1296: ...ages are less than Fig 12 30 replace battery If measured voltages are the same as or greater than Fig 12 29 fully charge clean and return battery to service BATTERY MODEL AMP LOAD Fig 12 29 Battery Lo...

Page 1297: ...ed on the basis of fail ure to crank the engine after an emergency boost charge Although an emergency boost charge may put enough energy into the energizer to crank the engine once further charging us...

Page 1298: ...serviced separately An efficient tool for fuse clip removal can be made from a cotter pin approximately 2 1 2 long Cut off long leg even with short leg File bevel on outside of both legs Spread pin w...

Page 1299: ......

Page 1300: ...B U TO L H PARK MARKER L I G H T S BX TO PLUS I TERMINAL ON C O I L BY TO O I L PRESSUkE S ITCH B A T 1 POWER TD H E A D L I G H l SWITCH EXCEPT STU CAR 1 INDEX I E N L I N E HARNESS1 INDEX FRONT E N...

Page 1301: ...g ring in body against tension of springs There is no adjustment for focus since sealed beam unit is set for proper focus when it is manufactured Headlamp aiming equipment is commercially available Fo...

Page 1302: ...ng circuit and the contacts then re close This cycle then repeats many times per second to give the buzzing sound Closing the door or removing the key will stop the buzzer action When the horn switch...

Page 1303: ...about 60 120 flashes per minute If either a front or rear signal bulb burns out the reduced current in the circuit will cause the remaining signal on that side of car to burn steadily The flasher whic...

Page 1304: ...a test circuit is closed to indicate whether the red lamp is functioning properly The engine thermostat is calibrated to control the coolant temperature within certain limits of atmospheric pressure W...

Page 1305: ...gnet speed A pointer is attached to the speed cup spindle to indicate speed on the speedometer dial A finely calibrated hair spring also part of the speed cup assembly opposes mag netic pull on the sp...

Page 1306: ...DICATOR 14 LEFT TURN SIGNAL INDICATOR 15 RIGHT TURN SIGNAL INDICATOR 25 GENERATOR TELLTALE 30 FUEL GA SENDER P 31 OIL TELLTALE 33 BRAKE WARNING INDICATOR 35 TEMP 39 IGNITION BAT WlDE CONNECTOR LOCKING...

Page 1307: ...LE 33 BRK WARNING INDICATOR 35 TEMP TELLTALE 39 IGNITION 140 CLOCK 150 GROUND Fig 12 42 F Series Printed Circuit Without Rally Gage LEGEND OF CONNECTOR PADS 8 ILLUMINATION 1I HIGH BEAM INDICATOR 14 LE...

Page 1308: ...1972 PONTIAC SERVICE MANUAL...

Page 1309: ...CHASSIS ELECTRICAL 12 39...

Page 1310: ...ill aid in placing identifying wires FUSIBLE LINK 4 To replace reverse removal procedure REMOVE AND REPLACE ENGINE WIRE HARNESS 1 Disconnect battery REMOVE AND REPLACE 2 Locate burned out link Engine...

Page 1311: ...VIEW B 0 1 Fig 12 46 B Series Battery Cable Routing...

Page 1312: ...V 8 ENGINE POSITIVE CABLE ROUTING FOR 455 HO ONLY L 6 ENGINE WlTH HEAVY DUTY BATTERY L 6 ENGINE WlTH STANDARD BATTERY TYPICAL V 8 NEG CABLE INSTALLATION Fig 12 47 A Series Battery Cable Routing...

Page 1313: ...BELOW TOP SURFACE OF BATTERY TERMINAL POST POSITIVE CABLE A 60 90 LB IN A 20 35 LB FT PARALLEL TO CL OF CAR FRT OF CAR POSITION OF BATTERY CABLE TERMINALS TO BE PARALLEL WITH Q OF CAR TO 30 OUTBOARD...

Page 1314: ...V 8 ENGINE NEGATIVE CABLE L 6 ENGINE WIHD PATTERY NEGATIVE CABLE TO BATTERY POSITIVE TERMINA VlEW A TYPICAL V 8 ENGINE NEG CABLE ATTACHMENT NEGATIVE CABLE L 6 ENGINE WISTD BATTERY I TERMINAL VlEW C V...

Page 1315: ...K TARTER MOTOR JUNCTION BLOCK CABLE 2 BATTERY TRAY L 6 ENGINE BATTERY TRAY 1 20 30 LBS FT V 8 ENGINE 2 70 90 LBS IN 3 20 30 LBS IN 1 4 100 150 LBS IN 5 85 115 LBS IN VIEW A VIEW B Fig 12 50 X Series B...

Page 1316: ...MANUAL ENGINE GROUND STRAP ENGINE WIRE HARNESS VlEW A 0 1L IDLE STOP PRESSURE SWITCH SOLENOID CONN VlEW B TEMPERATURE TRANSDUCER WIRALLY GAGE WITH UNITIZED Fig 12 5 1 B Series Engine and Transmission...

Page 1317: ...CHASSIS ELECTRICAL VIEW C w UNITIZED DISTRIBUTOR Fig 12 52 A G Series V 8 Engine Wire Harness Installation...

Page 1318: ...ith a screwdriver turn adjusting slot of floor level compensator in each aimer until adjoining dial reads same as dial on transit Fig 12 73 g Aimers are now adjusted for use on this specific floor are...

Page 1319: ...CHASSIS ELECTRICAL 4 SPEED MANUAL TCS SWITCH 3 SPEED AUTO M 38 SCS ASM WIV a EN GIN 3 SPEED AUTO M 40 Fig 12 54 A and G Series Transmission Wire Harness Installation...

Page 1320: ...RAP WlTH 455 H O PRESSURE SWITCH VlEW A WINON DEPRESSED WIPERS TRANSDUCER w1RALLY GAGE VIEW B EXC 455 HO POSITIVE BATTERY CABLE VlEW B w 0 PURPLE NOTE YELLOW LEAD DELETED WITH UNITIZED IGNITION Fig 12...

Page 1321: ...CHASSIS ELECTRICAL TO POSITIVE BATTERY TERMINAL Fig 12 56 F Series L 6 Engine Wire Harness lnstallation...

Page 1322: ...1972 PONTIAC SERVICE MANUAL CS SWITCH ASM ENGINE 3 SPEED MANUAL w L 6 ENGINE Fig 12 57 F Series Transmission Wire Harness Installation...

Page 1323: ...CHASSIS ELECTRICAL 12 53...

Page 1324: ...12 54 1972 PONTIAC SERVICE MANUAL...

Page 1325: ...L 6 ENGINE Fig 12 60 X Series Engine Starter W i r e Harness Installation...

Page 1326: ...12 56 1972 PONTIAC SERVICE MANUAL VlEW A Fig 12 61 B Series Front End Wire Harness Installation LOW BRAKE VlEW D VlEW A Fig 12 62 A Series Front End Wire Harness Installation...

Page 1327: ...scales are facing straight up and the horizontal aiming target can be seen from the viewing port in top of the opposite aimer Fig 12 75 Aimers are now installed for checking the no 2 units low beam o...

Page 1328: ...12 58 1972 PONTIAC SERVICE MANUAL...

Page 1329: ...readjustment of factory cali bration unless they are dropped or damaged in some man ner 1 Using a carpenter or stone mason spirit level of known accuracy locate a vertical plate giass window or smooth...

Page 1330: ...tates have special requirements for head light aim adjustment and these requirements should be observed Low Beam Place vehicle on a known level floor 25 feet from aiming screen or light colored wall F...

Page 1331: ...Remove lens 2 Remove lamp retaining screws 3 Pull lamp assembly and disconnect wires 4 To replace reverse removal procedure FRONT PARK AND SIGNAL LAMP LENS REMOVE AND REPLACE G SERIES 1 Remove 2 retai...

Page 1332: ...arning lamp switch Instructions for removal of the switch can be found in Section 5 SlDE MARKER LAMP HOUSING REMOVE AND REPLACE FRONT 1 B and G Series a reflecting surface is integral with park and tu...

Page 1333: ...ion Wagon models remove lens assembly at rea quarter and twist bulb and socket from behind INSTRUMENT PANEL SPEEDO CLUSTER Removal of these units can be accomplished by using the following installatio...

Page 1334: ...1 Disconnect battery and remove lower A C duct if 8 Position crash pad outward on steering column equipped 9 Disconnect printed circuit 2 Remove lower instrument panel trim and glove box 3 Lower stee...

Page 1335: ...umn Fig 12 72 Checking Slope of Floor Fig 12 73 Adjusting Aimer to Compensate for Floor Slope 6 Remove upper air outlet vents and instrument panel attaching screws at steering column console ends and...

Page 1336: ...printed circuit connector 5 To replace reverse removal procedure X SERIES 1 Disconnect battery and remove steering column cover trim Remove three 3 screws retaining heater or A C control panel to IP c...

Page 1337: ...replace reverse removal procedure A SERIES Figs 12 83 NOTE Refer to Section 9 SteeringColumn Reinstall for proper alignment of column PRINTED CIRCUIT NOTE Tool J 22746 Carburetor Adjusting Tool is ha...

Page 1338: ...r air outlet vents and instrument panel attaching screws at steering column console ends and upper center 10 Remove bulbs ground screws gage terminal nuts retaining printed circuit to cluster 11 Remov...

Page 1339: ...able with a tip to fit speedometer and insert it in speedometer socket Spin short cable between fingers in direction that higher speed is indicated on speedometer dial and note if there is any tendenc...

Page 1340: ...wer IP trimplates 2 Remove wiper headlamp switch bezel and discon nect connectors 3 Remove heater or A C control and bezel 4 Remove cluster bezel and speedometer cluster in cludes removing automatic s...

Page 1341: ...c CLUSTER ASM Fig 12 82 B Series Speedometer Cluster and Printed Circuit Installation...

Page 1342: ...12 72 1972 PONTIAC SERVICE MANUAL...

Page 1343: ...CHASSIS ELECTRICAL 12 73...

Page 1344: ...12 74 1972 PONTIAC SERVICE MANUAL...

Page 1345: ...es Speedometer Cluster and IP Carrier Installation A SERIES 3 Remove glove box and radio 1 Disconnect battery and remove lower air condition 4 Separate fuse block ing ducts if equimed A 2 Remove lower...

Page 1346: ...le 3 Separate bulkhead connector and disconnect neces sary wires at horn relay 9 Remove upper screws at gages nuts at upper right end and lower attaching screws 4 Remove plastic toe plate at steering...

Page 1347: ...l wire harness radio and speaker heater or air conditioning control panel switches cluster clock and miscellaneous trim and retention parts 21 To replace instrument panel pad reverse removal procedure...

Page 1348: ...EMPEST 3 SPEED MANUAL HEAVY DUTY TEMPEST 4 SPEED MANUAL FlREBlRD 3 SPEED MANUAL HEAVY DUTY 4 SPEED MANUAL CABLE b 2 SPEED AUTOMATIC 1 SPEEDO DRIVEN GEAR SEAL AND SLEEVE ASM SPEEDO DRIVEN GEAR DO DRIVE...

Page 1349: ...CHASSIS ELECTRICAL 12 79...

Page 1350: ...1972 PONTIAC SERVICE MANUAL...

Page 1351: ...near left pillar post 5 Remove steering column cover disconnect shift quadrant indicator cable at shift bowl if automatic transmission 6 Remove two 2 steering column nuts at IP remove four 4 lower ca...

Page 1352: ...12 82 1972 PONTIAC SERVICE MANUAL...

Page 1353: ...CHASSIS ELECTRICAL 12 83...

Page 1354: ...oving nuts and screws from back of cluster REMOVE AND REPLACE B SERIES 1 Remove speedo cluster and printed circuit as previ ously described under B Series 2 Remove fuel gage nuts and gage 1 Disconnect...

Page 1355: ...ering column 6 Remove upper air outlet vents and instrument panel attaching screws at steering column console ends and upper center 7 Remove lower defroster duct screw 8 Position crash pad rearward on...

Page 1356: ...1972 PONTIAC SERVICE MANUAL Fig 12 97 G Series Glove Box and Ash Tray with Bench Seat...

Page 1357: ...CHASSIS ELECTRICAL 12 87...

Page 1358: ...Fig 12 99 F Series Instrument Panel Pad Attaching Parts...

Page 1359: ...rom gage REMOVE A N D REPLACE Remove gage attachment screws and remove gage from rear of cluster 1 Disconnect battery To replace reverse removal procedure 2 Pull control knob to full ON position WINDS...

Page 1360: ...sition Fig 12 101 and 102 8 Install switch with rod in hole 9 Reverse remaining procedure referring to section 9 for column alignment instructions ADJUST STANDARD STEERING COLUMN When replacing the ig...

Page 1361: ...ignition lock in full counterclockwise acces sory position and tighten ignition switch mounting screws 5 Check lock for proper operation a Ability to operate into accessory b Key removal in lock dete...

Page 1362: ...move pin REMOVE AND REPLACE AUTOMATIC TRANSMISSION CONSOLE SHIFT ONLY 1 Remove wire connector 2 Remove retaining screws 3 Remove switch 5 Insert switch drive tang in shifter tube slot and as semble sw...

Page 1363: ...Neutralposition and locate lever tang against transmission selector plate 4 Align slot in contact support with hole in switch and inset a 092 diameter pin to hold support in place Switch is now in dri...

Page 1364: ...ary to disconnect instru ment panel pad and position on steering column see instrument cluster removal in order to remove har ness from protective conduit 4 To replace reverse removal procedure X Seri...

Page 1365: ...WAGONS CC SWITCH P W I R E HARNESS T U R N S I G N A L FLASHER Fig 12 104 B Series Instrument Panel W i r e Harness Installation...

Page 1366: ...R JAMB SWITCH A C C O N T R O L IGAR P R I N T E D C I R C U I T V I E W A IP WIRE HARNESS C L U T C H STOP S A F E T Y L A M P SWITCH SWITCH Fig 12 105 A Series Instrument Panel W i r e Harness Inst...

Page 1367: ...CHASSIS ELECTRICAL...

Page 1368: ...EATER OR A C CONTROL T O DOOR JAMB INDICATOR LAMP CONNECTOR VIEW A CLOCK CLUSTER I HEADLAMP DY CONNEC lP WIRE HARNESS FLASHER LAMP TOR Fig 12 107 G Series Instrument Panel W i r e Harness Installation...

Page 1369: ...ANTENNA LEAD IN WITHOUT RADIO Fig 12 108 G Series Instrument Panel Wire Harness Connections...

Page 1370: ...12 100 1972 PONTIAC SERVICE MANUAL...

Page 1371: ...RCUIT CONNECTOR ER CONTROL LAMP T O T U R N SIG SW HARN GROUND T O NEUTRAL SAFETY SW INSTR PNL WIRING WIRE HARNESS GROUND HEADLAMP SWITCH GROUND TO BACK UP WIRE PART OF STRAP T O STOP LP SW Fig 12 1 1...

Page 1372: ...12 102 1972 PONTIAC SERVICE MANUAL I Fig 12 1 1 1 G Series Rear Lamps Installation...

Page 1373: ...CHASSIS ELECTRICAL 12 103...

Page 1374: ...S 3250 62 250 L 6 307 V 8 STD 1H D STD ORA CI H D Side Terminal Battery Side Terminal Sealed Case Fig 12 113 Battery Usage Chart 350 V 8 STD ORA CI H D Battery Watts 0 F Amo Hrs STD OR AIC R88S 3250 6...

Page 1375: ...m l l R H PARK D I R LAMP q 18 BLACKILT EEN n 11 R H HORN 18 8LACK L H HORN 18 BLACKILT GREEN L H HI BEAM Bt L H HI LOW HEADLAMP FREON PRESSURE SWITCH 20 DK GREEN 18 BLACKITAN 1B BLACKILT OREEN 18 BRO...

Page 1376: ...EXCEPT RADIO WITH HTD RR GLS ONLY PARKING BRAKE SWITCH I 1 I I II 18 BROWN I...

Page 1377: ...WlDE CONNECTOR LOCKINGTAB WIDE LOCKINGTAB CONNECTOR Fig 12 114 B Series Chassis Electrical Wiring Diagram...

Page 1378: ...GETME INTRA CONN D COMMON BUS BAR X CONN D TO CASE4 SWITCH AS GROUL R H FRT DR R H FRT DR JAMB SWITCH JAMB SWITCH FRONT REAR 18 WHITEIBLACK DOME DOME L H FRT DR JAMB SWITCH JAMB SWITCH 25235 25245 262...

Page 1379: ...FEED 7 WHITE R H FRT DR JAMBSWITCH r 8 18 WHITE 1 FUELTANK GAUGE UNIT T A l L LAMP FEED FRONT REAR DOME DOME LAMP LAMP FOR POWER ACCESSORY DIAGRAMS SEE INTERIOR CIRCUT DIAGRAM L H RR DR JAMB SWITCH 18...

Page 1380: ...BROWN R H PARKING SIG LAMP L H HORN d BLACK YELL01 WINDSHIELD WASHER 0t SOLENOIO DIST 0 3 YELLOW 3 POSITIVE POST STARTER LOW BRAKE 18TAN WITH HTD RR GLSONLY 1 II 1 II 4 16BROWNIWHIT6 WITH HTD RR P HAZ...

Page 1381: ...20 ORANGE BLACK CLOCK POWER m 18 ORANGEIBLAC ORANGEIBLACK EXC HTD RR GLS I 20 WHITE 18 ORANGE 18WHITE COURTESY LAMPS ICONVERTIBLES ONLYl 12 ORANGE 12 ORANGEBLACK I 12 ORANGE WITH HTD RR GLS ONLY 14 B...

Page 1382: ...INDICATOR 1 5 mGHT TURN SIGNAL INDICATOR zs O NERATORTELLTALE 3 FUEL GA SENDER 31 OIL TELLTALE 38 RAKE WARNING INDICATOR 3 0 IGNITION BAT I P PRINTED CIRCUIT EXC RALLY GA WIDE CONNECTOR LOCKING TAB OF...

Page 1383: ...I R H DOOR JAMB SWITCH IGNITION SWITCH NHITE t CONN D TOGETHER INTRA CONN D COMMON BUS BAR X CONN D TO CASE OF SWITCH AS GROUND CIRC 18 BROWN A Miring Diagram 4 PIN CONN IGN 31 BAT31 GRD l l G R D 2 I...

Page 1384: ...D BACK UP LAMP FEED BACK UP LAMP GROUND TAlL LAMP FEED STOP DIR LAMP FEED TAlL LAMP GROUND DOME LAMP RR HD LAMP FRO CON SlDE MARKER LAMP FEED SlDE MARKER LAMP GROUND ALL EXCEPT STATION WAGON 9 TAIL LA...

Page 1385: ...SIG LAMP R H HIGHILOW 18 BLACK 2 G R D 0 R H HORN I 16 BLACK L H HORN L GRD 18 BLACK I IGP 1 3 5 7 L H SPARK PLUGS NO 2 SENSING ALTERNATOR NO 1 FIELD STARTER LOW BRAKE 1 FLUID SWITCH 1 8TAN L H PARK...

Page 1386: ...MOTOR RESISTOR 18 ORANGEIBLACK DISTRIBUTOR OIL PRESSURE ELECTRIC PIENSING WINDSHIELD WINDSHIELD 18 BLACKIYELLO 14 RED 12 BLACKIRED I DK BLUEMlHl TEMPSWITCK RALLY GA ONLY EXC L L Y GAUGE 718 TAN CLOCK...

Page 1387: ...qa WITE WIS WIPER Ffl 18 BLACK C EXC RALtY GAUGE I 8 ORANGEIBLACK CLOCK POWER I8 DK GREEN I 4 PINK 14 R E BACK UP LAMP 1B BROWN LPS ONLY s dl Fig 12 116 G Series Chassis Electrical Wiring Diagram...

Page 1388: ...ATION 11 HIGH BEAM INDICATOR 14 LEFT TURN SIGNAL INDICATOR 15 RIGHT TURN SIGNAL INDICATOR CONN D TOGETHER 25 GENERATOR TELLTALE INTRACONN D 30 FUEL GA SENDER COMMON BUS BAR 31 OIL TELLTALE X CONN D TO...

Page 1389: ...AR COMPARTMENT LAMP CONNECTOR WHITE 18 BLACKIORANGE 18 T A M 18 LT GREEN 18 DK G R E E N 18 YELLOW l a w SlDE MARKER LAMP GROUND SlDE MARKER LAMP FEED TAlL LAMP GROUND STOP DIR LAMP FEED TAlL LAMP FEE...

Page 1390: ...R H PARKING SIG LAMP OPTIONAL HORN 18 BLACK HEADLAMP L H aoi L H PARKING SIG LAMP L H MARKER L 18 BLACKILT BLUE 1 TRANSMISSION IDLE SOLENOID ED STARTER LOW BRAKE 16 BLACK 18 BROWN 18DK BLUE 18 BLACWLT...

Page 1391: ...ORN RELAY I 4 i E R l B T A LOW BRAKE FLUID SWITCH 18 BLACKIPINK 1 18 BROWN I u I 20 OK GREEN D 16 BLACKILT GREEN I P COMP LAMP t a uzt L DECK LID REL m m CONSOLE CONNECTOR BLOWER RESISTOR HEATER SWIT...

Page 1392: ...4 b5 1 a 1 20 GRAY 1 18 PINK Fig 12 117 F Series Chassis Electrical Wiring Diagram I P RALLY GA I 4 VOLTMETER WJ FUEL GAUGE...

Page 1393: ...OR LEGEND OF CONNECTOR LAMP RR WINDOW t RALLY GAUGE 8 ILLUMINATION I tf 11 HIGH BEAM INDICATOR 14 LEFTTURN SIGNAL INDICATOR L W L 15 RIGHTTURN SIGNAL INDICATOR 31 OIL GA SENDER 1 33 BRK WARNING INDICA...

Page 1394: ...AMP IAlN BODY ONNECTOR LEGEND ilE STANDARD CAR LINE EXCEPT STD CAR 18 BLACK SIDE MARKER LAMP GROUND r18 BROWN 0 SIDE MARKER LAMP FEED 18 BLACK TAIL LAMP GROUND BACKLIP LAMP FEED LICENSE LAMP TAlL LAMP...

Page 1395: ...SD MARKER LAMP v 18 BLACK IHW 18 PURPLE IHW PARK DIR SIGNAL LAMP R H GRD 20 BLACK 7 HIGH AND LOW BEAM 14 DK GREEN INY JKT I 10 RED 1 I ORANGE J...

Page 1396: ...14 ORANGE I 14 LT BLUE I I Fig 12 118 X Series Chassis l e c t r i c...

Page 1397: ...1 8 ORANGE INYJKT W C 1BBLACK l4 OWN 12 PURPLE I SWITCH 20PlNK 1 8BLACK SEAT BELT LIGHT q SEAT BELT BUZZER TEMP Fig 12 1 18 X Series Chassis Electrical Wiring Diagram...

Page 1398: ...JAMB SWITCH 1BORANGE INY JKT PVCF aLIGHTER I TO SEAT SENSOR GROUND DOME JND TO LEFT SEAT BELT RETRACTOR 18 YELLOWIBLACK L FRONT DOOR JAMB SWITCH e l 8 ORANGE 8 LT GREEN 18 LT GREEN 180K GREEN 16 DK OR...

Page 1399: ...LAMP FEED R H BACK UP LAMP FEED 18LT GREEN A 16 DK GREEN R H TAIL LAMP FEED R H STOP SIGNAL LAMP FEED 18 BROWN l B BLACK LICENSE 18BROWN 18TAN 18 LT GREEN TANK UNIT 16YELLO L H TAIL LAMP FEED L H STO...

Page 1400: ...cradles are attached to the bottomside of the upper panel mounting assembly which in turn is fastened to the front end support and baffle assembly for radiator removal and replace refer to Section 6A...

Page 1401: ...ries 14 7 Polyurethane Bumper Repair 14 14 FRONT BUMPERS GENERAL DESCRIPTION REMOVE G SERIES Fig 14 1 1 Support bumper remove bumper hanger bar to frame attaching bolts ADJUST 2 Remove bumper from veh...

Page 1402: ...1972 PONTIAC SERVICE MANUAL Fig 14 2 B Series Front Bumper Assembly Fig 14 3 B Series Lower Grille Assemblies...

Page 1403: ...s 3 Remove bumper assembly 4 Remove bumper reinforcement REMOVE GT and G T O Fig 14 8 1 Remove parking lamp assembly 2 Remove valance panel 3 Remove upper support bolts 4 Support bumper remove bumper...

Page 1404: ...14 4 1972 PONTIAC SERVICE MANUAL Fig 14 5 B Series Front Bumper Hanger Assembly FRONT BUMPER REF FRONT BUMPER REF 1 VlEW B FRONT FENDER REF VlEW A Fig 14 6 A Series Valance Panel...

Page 1405: ...FRONT AND REAR BUMPERS 14 5 Fig 14 7 A Series Front Bumper Assembly Fig 14 8 GT and G T O Front Bumper and Valance Panel...

Page 1406: ...14 6 1972 PONTIAC SERVICE MANUAL Fig 14 9 GT and G T O Grille Assembly Fig 14 70 F Series Valance Panel...

Page 1407: ...ts 3 Remove bumper assembly 4 Transfer parts if replacing bumper 5 Remove hanger bars from bumper 6 Remove parking lamps REPLACE 1 To install reverse above procedures making sure the front bumper is p...

Page 1408: ...14 8 1972 PONTIAC SERVICE MANUAL Fig 14 12 F Series Grille Assembly Fig 14 13 X Series Front Bumper Assembly...

Page 1409: ...FRONT AND REAR BUMPERS 14 9 Fig 14 14 B Series Front Bumper Close Out Panels Fig 14 15 X Series Front Bumper Close Out Panel...

Page 1410: ...ent possible rattles REMOVE G SERIES Fig 14 16 1 Remove license lamp assembly 2 Disconnect tail lamps 3 From below bumper remove bumper hanger to body attaching bolts 4 Support bumper remove bumper br...

Page 1411: ...FRONT AND REAR BUMPERS 14 11 Fig 14 17 B Series Rear Bumper Assembly Fig 14 18 B Ser es Stat on Wagon Rear Bumper Assembly...

Page 1412: ...or attached to the bumper 2 Remove step and tread assembly 3 Support bumper remove hanger bracket to frame at taching bolts 4 Remove brackets from bumper 5 To remove the latch cover assembly from the...

Page 1413: ...FRONT AND REAR BUMPERS 14 13 MIOR ASM REF s VlEW 8 COVER VlEW A Fig 14 20 A Series Station Wagon Rear Bumper Assembly REAR END FINISHING PANEL VlEW A Fig 14 2 1 F Series Rear Bumper Assembly...

Page 1414: ...license lamp from bumper face bar REPLACE 1 To install reverse the above procedures making sure rear bumper assembly is properly aligned LB FT Face bar to attachment bar bolts 20 30 Attachment bar to...

Page 1415: ...Coats and Clear Top Coats that are to be used are specially formulated with an elas tomer vehicle so that the cured film may bend under impact without cracking or splitting Material Sealer Primer Sur...

Page 1416: ...t Speaker Radio Dial Lamp Sliding Sun Roof Radio Suppression Rear Speaker Cassette Stereo Tape Player Eight Track Stereo Tape Player Rear Stereo Speakers Console Air Deflector Electric Door Lock Switc...

Page 1417: ...ENGAGE M E N T SWITCH C O N N E C T T E S T L A M P F R O M B L U E WlRE A T 3 WIRE CONNECTOR ON STEERING COLUMN TO GROUND I CIRCUIT I N B L U E L A M P F R O M BROWN WIRE BETWEEN WIRE A T STEERING C...

Page 1418: ...accelerator linkage adjustment Weak or disconnected throttle return spring CORRECTION Replace cable Adjust accelerator linkage Connect or replace spring PULSATING ACCELERATOR PEDAL CAUSE Speedometer c...

Page 1419: ...r tape EIGHT TRACK STEREO TAPE PLAYER Fig 15 3 The tape player trouble diagnosis guide is intended as an aid in locating minor faults which can be corrected with out a specialized knowledge of electro...

Page 1420: ...CHY OR RASPY SOUND1 F I I 1 7 1 7 1 A I CIRCUIT CHECK CONNECTOR TO LEAD I N SOCKET A T BASE OF WINDSHIELD FOR LOOSE CONNECTION OR CORROSION IF NO TROUBLE FOUND INSTALL W H I P ANTENNA OR NEW WINOSHIEL...

Page 1421: ...connectlons heel o f hand CONNECTORS LOOSE OR DEFECTIVE OR DEFEZTIVE THUMP HEARD r NO THUMP HEARD 7 Remove tape player for CONNECTIONS LOOSE CONNECTORS h e c k for short power connect ons If D agnos s...

Page 1422: ...TION INSERT TEST TAPE SPEED INCORRECT T O MID POSITION INSERT TEST TAPE FAST OR CONSTANTLY Remove tape player Tape Player ok ONE CHANNEL CHANNELS I L p a i r I J CABLE AND OR CABLE AND Correct as CONN...

Page 1423: ...15 8 1972 PONTIAC SERVICE MANUAL...

Page 1424: ...ed Note 3 I t may be necessary t o remove the cold air duct t o provide access t o antenna socket Note 4 Check tester on a k n o w n good car t o make sure it is operating properly and that the batter...

Page 1425: ...l is depressed When the engagement button in the turn signal lever Fig 15 8 is depressed to the engage position a circuit is made between contacts A B and the power source contact C Current will now b...

Page 1426: ...nding to hold the valve up although not enough to pull it up once it is released The driver s speed is now automatically regulated The electrical circuit can be broken by the driver in three different...

Page 1427: ...when cruise is resumed When the switch is engaged the solenoid valve coil is also energized pulling the valve off its seat and opening port M to port S As car speed increases or decreases causing the...

Page 1428: ...e tachometer is available as a dash mounted unit on A and F Series This dash unit is mounted in the IP clock location On F Series a combination tachometer clock unit is the only tachometer available E...

Page 1429: ...esirable to trim the radio while using the front speaker 4 Adjust antenna trimmei screw until maximum volume is achieved 5 Reinstall both right knobs The antenna trimmer adjustment should be made afte...

Page 1430: ...earance of car Noticeably improves FM reception All FM signals are transmitted and received in a horizontal plane The top segment of each antenna conductive element is mounted horizontally and measure...

Page 1431: ...y especially at extreme tem peratures Do not bring any magnetized tools near the tape head If the head becomes magnetized every cartridge played in the player will be degraded CASSETTE STEREO TAPE PLA...

Page 1432: ...7 Distributor point shield V 8 engines only SLIDING SUNROOF X SERIES The sun roof consists of two 2 layers of fabric an outside water repellent material bonded to a grained vinyl coating and an inner...

Page 1433: ...L ADJUST REGULATOR Fig 15 13 SERVICE PROCEDURES 1 If Cruise Control holds speed three or more mph higher than selected speed turn centering spring ad justing screw C clockwise 1 8 turn or less 2 If Cr...

Page 1434: ...D WlTH 15 TO 20 LBS FORCE TO PROPERLY ADJUST SWITCHES GROMMET MAIN WIRE HARNESS 7 r SPEEDO SHAFT LEVER SWITCH ASM STOP LIGHT SWITCH CONNECTOR CONNECTOR HOT END HARNESS VlEW A BRAKE PEDAL MOUNTING BRAC...

Page 1435: ...v OR ARM P U L L PEDAL REAR I WARD W l T H 15 T O 20 LBS FORCE TO PROPERLY ADJYST SWITCH r BRAKE PEDAL PFONT OF VEHICLE SWITCH ADJUSTMENT WIRE PROTECTOR PART OF INSTALLATION OF PLUGPEEDO W L E HOLE S...

Page 1436: ...0 180 LB IN BRACKET 3 40 55 LB IN 4 40 50 LB IN 5 15 25 LB IN 4 7 VIEW C TO ENGINE FENDER SKIRT VlEW D 2 BBL CARB ENGINE CABLE ROUTIN FENDER SKIRT VlEW D 4 BBL CARB ENGINE MAIN HOSES AND CABLE ROUTING...

Page 1437: ...SPOT TAPE CRUISE CONTROL WIRE ASSEMBLY TO FRONT END WIRE HARNESS EXTENSION 4 BBL GARB ENGINE CABLE ASSEMBLY Fig 15 1 7 A and G Series Cruise Control Installation...

Page 1438: ...ted at the factory 1 Remove screws and cover To replace air filter in cover push filter out from under filter plate Fig 15 20 2 Remove two screws securing bearing support rotate support 180 and slide...

Page 1439: ...rnor assembly to be removed from the regulator For further disassembly of governor see Fig 15 18 6 Remove four screws 2 internal 2 external holding the valve body and magnet assembly Remove valve Fig...

Page 1440: ...until the pin engages the actuator coupling hole Install governor spring over governor shaft with closed end of spring toward the actuator cup Install bearing support in regulator Rotate 180 and secu...

Page 1441: ...15 26 1972 PONTIAC SERVICE MANUAL Fig 15 24 A and G Series Clock Installation VIEW A Fig 15 25 F Series Clock Installation...

Page 1442: ...ELEASE SWITCH REMOVE A N D REPLACE All except G Series with Console 1 Remove ash tray and bracket on models with air conditioning to gain access to switch 1 Disconnect battery and remove radio include...

Page 1443: ...28 1972 PONTIAC SERVICE MANUAL Fig 15 27 B Series Deck Lid Release Switch r CLOCK POWER LEAD RELEASE SWlTC SEE BODY MANUAL FOR INSTALLATION OF TRUNK MECHANISM Fig 15 28 A Series Deck Lid Release Swit...

Page 1444: ...Series Deck Lid Release Switch Bench Seat G Series with Console 1 Remove console compartment box 2 Disconnect wires from switch 3 Remove switch Fig 15 30 4 To replace reverse removal procedure Fig 15...

Page 1445: ...15 30 1972 PONTIAC SERVICE MANUAL PRINTEDCIRCUIT VIEW A Fig 15 31 B Series Rally Gage and Clock Installation...

Page 1446: ...NTO RECEPTACLE ON BACK OF DISTRIBUTOR PRINTED CIRCUIT VIEW A WITH U N I T Z E D S T R I B U T O R I FROM OIL SENDING UNlT A TO IP TACHOMETER NSTALL ON TERMINAL WITH STANDARD IGNITION Fig 15 32 A Serie...

Page 1447: ...ASM FROM FUEL GAGE CLOCK ASM FROM TEMPERATURE SENDING UNlT SENDING UNlT PRINTED CIRCUIT INSTRUMENT PANEL HARNESS CONDUIT Fig 15 33 G Series Rally Gage Installation V I E W Y PLATE PRINTED CIRCUIT i I...

Page 1448: ...ACCESSORIES 15 33 VIEW OF STEERING COLUMN WIRING LAMP ASM 1 30 60 LB IN I Fig 15 35 G Series Cornering Lamp Installation...

Page 1449: ...BLOWER DEFOGGER BLOWER R E A R WINDOW DEFOGGER ELECTRIC R E A R WINDOW DEFOGGER Fig 15 36 B Series Electric and Blower Rear Window Defogger...

Page 1450: ...ACCESSORIES 15 35 VIEW A Fig 15 37 A Series Electric Rear Window Defogger...

Page 1451: ...15 36 1972 PONTIAC SERVICE MANUAL Fig 15 38 G Series Electric Rear Window Defogger REAR SEAT Fig 15 39 A Series Blower Rear Window Defogger...

Page 1452: ...ACCESSORIES 15 37 A TO FUSE BLOCK VlEW B VlEW A Q A TO FUSE BLOCK Fig 15 40 F Series Electric and Blower Rear Window Defogger...

Page 1453: ...switch harness connections 5 Remove retainer clip A and G Series only and 2 On B Series remove lower I P trim at steering col remove switch umn When installing an accessory package or replacing the 3...

Page 1454: ...DIMENSIONS 1 L O C A 8 PUNCH CENTER OF CUTOUT 2 DRILL 9 16 HOLE THRU DASH 8 APPLIQUE 3 ASSEMBLE SQUARE STUD OF TOOL J 23118 THRU FEMALE PORTION OF TOOL 8 INSTALL STUD THRU DRILLED HOLE FROM BEHIND DAS...

Page 1455: ...1972 PONTIAC SERVICE MANUAL SPRING V1EW A ASM LAMP ASM VlEW B Fig 15 44 A Series Underhood Lamp VlEW A Fig 15 45 G Series Underhood Lamp...

Page 1456: ...RIMMER SCREW UNT NG BRACKET INSTRUMENT PANEL LOWER REINFORCEMENT WITH CONSOLE 4 2 A AMIFM STEREO RAD MOUNTING BRACKET m WITHOUT CONSOLE TO SPEAKER SPEAKER CONNECTOR f SPEAKER CONNECTOR TO INSTRUMENT P...

Page 1457: ...D VIEW A UNDERHOOD Fig 15 47 X Series Underhood Lamp Installation NOTE VIEW A DEPRESS SWITCH LEVER TO FULL ON POSITION TO PERMIT SWITCH LEVER TO REST ABOVE HINGE LEVER IN THE INSTALLED POSITION ASM Fi...

Page 1458: ...O 20 0 FROM REAR DECK WITH CAR ON LEVEL SURFACE Fig 15 49 F Series Luggage Compartment Lamp LAMP ASM NOTE For proper operation Lampshould turn off when lid is 22 inches 6 inches from the closed positi...

Page 1459: ...ALLEN WRENCH SLOl SPRlPlG CLI KNOB A and G Series Figs 15 53 and 15 54 1 Disconnect battery and remove lower A C duct if equipped 2 Remove radio control knobs and hex nuts 3 Remove radio support brac...

Page 1460: ...R LEADS VlEW A AMlFM STEREO RADIO POWER I FRONT SPEAKER EXC AMIFM STEREO e h FRONT SPEAKER LEADS FRONT SPEAKER LEADS E FRONT OF CAR VlEW A AM FM RADIO FRONT OF CAR VlEW A AM RADIO Fig 15 52 B Series R...

Page 1461: ...SPEAKER AND BRACKET ASM AM FM STEREO RADlQ AM FM TO INSTRUMENT PANEL AM RADIO ONLY WIRE HARNESS Fig 15 53 A Series Radio and Front Speaker Installation...

Page 1462: ...ER STUDS ON SPEAKER RETAINER WITH CONSOLE 3 A TO SPEAKER SRAKUI CONNECTOR SPEAKER CONNECTOR I TO INSTRUMENT PANEL Wl R E HARNESS VIEW A WITHOUT CONSOLE M F M RADIO INSTRUMENT PANEL Wl R E HARNESS AM R...

Page 1463: ...ECTOR VIEW B SPEAKERCONNECTOR HEATER CONTROL SUPPORT HEATERCONTROL SUPPORT Y VlEW A AM FM RADIO SPEAKER CONN VlEW A AM RADIO ONLY HEATERCONTROL SUPPORT L SPEAKER CONN VlEW A AM FM STEREO RADIO Fig 15...

Page 1464: ...tape and or cover from top of radio for access to dial light 3 Remove light from socket 4 To replace reverse removal procedure B Series 1 Tune radio dial pointer to high end of band 2 Press the dial...

Page 1465: ...ng compound from the rear retainer memory sealer tape to smear on the headliner material The sealer cannot be removed without damaging head liner the rear retainer screws through the ac cess holes Do...

Page 1466: ...OR ASSY 2 Remove the six 6 countersunk screws and trim nuts from the side trim moulding and slide rails Remove the trim moulding INSTALLATION 1 Remove any sealer residue from the inner surface of the...

Page 1467: ...nel INSTALLATION 1 Remove any sealer residue from the retainer and the roof top panel Apply a bead of fresh sealer Dow Corning Silastic or equivalent on the inner surface along the full length of the...

Page 1468: ...andle block and install the pin 2 Using the three 3 handle retaining screws install the handle assembly to the latch mechanism with both the cut out in the handle block and the latch hook forward 3 As...

Page 1469: ...ON Channels are bonded to the roof with sealer adhesive Toprevent damage use a fiber stick tool to pry the channels and outer retainerfrom the roofpanel 4 The headliner is attached to the edge of the...

Page 1470: ...CEIVER ASM FRONT PEAKER LEADS REAR SEAT SPEAKER LEADS TENNA LEAD IN ECEIVER ASM TAPE CARTRIDGE REAR SEAT SPEAKER LEADS VIEW A Fig 15 58 B Series Stereo Radio Tape Player IP COVER Fig 15 59 B Series Fr...

Page 1471: ...AY WlTH A C HOOD CLIP PLUG INTO BAT TE RMINAL Fig 15 60 B Series Radio Suppression Equipment ClTOR VlEW SHOWING CAPACITOR INSTALLATION TO HEATER A C BLOWER MOTOR WlTH AM FM ONLY ASSEMBLY INSTALL ON SI...

Page 1472: ...COlL ALL V 8 ENGINES HOOD WINDSHIELD ANTENNA GROUND AM FM RADIO WITH AIC Fig 15 62 G Series Radio Suppression Equipment d INSTALL ON SIDE EVAPORATOR HEATER VlEW OF CAPACITOR INSTALLATION ON COlL ALL 8...

Page 1473: ...COIL V 8 ENGINE REGULATOR Fig 15 64 X Series Radio Suppression Equipment LEAD IN POWER LEAD PART OF INSTR PANEL WIRE HARNESS ANTENNA LEAD IN 11 111 FRONT OF CAR FISHER LEAD FROM REAR S KR VIEW A AM FM...

Page 1474: ...TO CHECK FRONT EAKER OPERATION TH RADIO OPERATING TURN FADER CONTROL rAl ION WAGON UK FULL CLOCKWISE TO CHECK REAR SPEAKER CONVERTIBLE SPEAKER OPERATION Fig 15 66 A Series Rear Seat Speaker Installat...

Page 1475: ...VlEW A AM F M RADIO ONLY CONNECTOR VlEW A AM RADIO ONLY I Fig 15 68 F Series Rear Seat Speaker Installation FRONT SPEAKER CONNECTOR AMiFM RECEIVER SHOWN AM R ECEIVER CONNECTION SPKR Fig 15 69 X Serie...

Page 1476: ...ACCESSORIES 15 61...

Page 1477: ...CARTRIDGE G SERIES WICONSOLE A SERIES WICONSOLE WITH BENCH SEAT Fig 15 7 1 A and G Series Cassette Tape Player Installation...

Page 1478: ...POWER FROM IP HARNESS POWER FROM IP HARNESS 1 WIRE ROUTING AM FM AND STEREO WICASSETTE TAPE PLAYER Fig 15 72 A Series Cassette Tape Player Wiring...

Page 1479: ...M COVER 1 1 FLOOR MOUNTED CARTRIDGE CASSETTE PLAYER ASM 1 CONSOLE CONSOLE MOUNTED Fig 15 73 F Series Cassette Tape Player Installation TI 1 WIRE HARNESS CASSETTE TAPE PLAYER ASM WIMANUAL TRANS Fig 15...

Page 1480: ...ACCESSORIES 15 65...

Page 1481: ...15 66 1972 PONTIAC SERVICE MANUAL...

Page 1482: ...TO FRONT SPEAKER RECEIVER I ROUTE WlRE ASM THRU CUT OUT IN CARPET AND PLAYER HARNESS 1 LAYER I WlRE ASM ROUTING ALL MODELS TAPE PLAY AM RECEIVER TAPE PLAYER Fig 15 77 A Series Eight T r a c k T a p e...

Page 1483: ...15 68 1972 PONTIAC SERVICE MANUAL...

Page 1484: ...ACCESSORIES 15 69...

Page 1485: ...15 70 1972 PONTIAC SERVICE MANUAL Fig 15 80 F Series Eight Track Tape Player Installation...

Page 1486: ...LS TO EXISTING FISHER REAR SEAT SPEAKER CONNECTOR TO FRT SPEAKER AM FM WITH STEREO RECEIVER TAPE PLAYER VIEW A AM FM WITHOUT STEREO RECEIVER T A P E PLAYER AM RECEIVER STEREO TAPE PLAYER Fig 15 8 1 F...

Page 1487: ...AKERS REAR SEAT SPEAKER LEAD Fig 15 82 B Series Rear Seat Stereo Speakers LF PANEL I RETAINER CLIP SPEAKER TERM1NALS I r TO FACE CENTER OF CAR GRAND PRlX VIEW IN CIRCLE B I GRAND PRlX ONLY SEE BODY MA...

Page 1488: ...ACCESSORIES 15 73...

Page 1489: ...15 74 1972 PONTIAC SERVICE MANUAL VIEW A Fig 15 85 A Series Console Wiring...

Page 1490: ...ACCESSORIES 15 75 VlEW B VlEW A DOOR BOX ASM CONSOLE ASM Fig 15 86 G Series Console Installation...

Page 1491: ...15 76 1972 PONTIAC SERVICE MANUAL...

Page 1492: ...ACCESSORIES 15 77...

Page 1493: ...15 78 1972 PONTIAC SERVICE MANUAL e ASH TRAY ESCUTCHEON CONSOLE ASM Fig 15 89 F Series Rear Console Installation...

Page 1494: ...FLECTOR ASM VlEW B ROOF PANEL REINFORCEMENT VlEW IN CIRCLE A Fig 15 90 A Series Station Wagon Air Deflector...

Page 1495: ...O FUSE BLOCK Fig 15 9 1 F Series Electric Door Lock Switch Installation FUSE BLOCK CIRCUIT BREAKER INSERT INTO IGN POSITION ON FUSE BLOCK EXISTING LEADS FROM FISHER HARNESS SWITCH ASM CONSOLE Fig 15 9...

Page 1496: ...ACCESSORIES 15 81...

Page 1497: ...15 82 1972 PONTIAC SERVICE MANUAL...

Page 1498: ...ACCESSORIES 15 83...

Page 1499: ...LOCK 5 0 UO D ELEC TRIC DOOR LOCX WITH ELECTRIC SEAT 8ACK LOCK ZDOOR AUS RN REAR D O O R LOCK SOLEnO D L N DOOR L M F U S L L 4 L FIT DO sw DRlWfR S E A T LOCC S O L EL EC TRIC DOOR LOCKS W TH P O W E...

Page 1500: ...ACCESSORIES 15 85...

Page 1501: ...15 86 1972 PONTIAC SERVICE MANUAL...

Page 1502: ...E m m BLU LI RR SPKR 1 4 Z O B L U DK RR SPKR Y r n B i u DK i n RR L I I R FEED m m BLU DK l l l B L I 8 D I A L LP FfED t8 8 GRA C P O W R lEED IP3 18 Y L b FR1 SPKR L 31 20 C R N 11 W RR SPKR I06 P...

Page 1503: ...nm BLU a P TAPE PlYR G R D I I I B EL Q IUMPIR WIM r 9 n m 1 1 u m R RADIODIAL I P M m G R A 5 I U W L R WIR1 I W x r m G R N D K 1 I U W i I PI n m Z o a L o w w u TRI SPrR I W X G R Y 1 1 v IIIMPCP...

Page 1504: ...1 Camber 3 14 Camshaft 6 9 30 50 76 Canister Evaporation Control System 6D 11 Capacities 0 18 Carburetor 6B 1 10 29 36 55 82 Carburetor Air Cleaner and Silencer 6B 3 Carburetor Service Specifications...

Page 1505: ...aust System 6 14 53 8 1 Expansion Valve A C lA 23 87 Extension Housing 7A 7 7B 8 7C 3 7D 9 15 7E 45 75 89 7 F 3 1 35 48 76 40 69 79 Fan 6A 7 31 Fan Belt 6C 4 Fan Switch Heater Control 1 17 F Cont Fend...

Page 1506: ...amps Front Park and Signal 12 14 61 Leaf Springs 4 17 L Cont Leak Detectors A C Refrigerant 1A 1 Lift Points Frame 2 2 Lifting and Towing 0 4 Limiter A C Thermal 1A 18 36 Liquid Vapor Separator 8 3 32...

Page 1507: ...nerator 6E 26 Reverse Shifter Shaft 7D 14 Rings Piston 6 41 92 R Cont Road Test Tune up 6C 6 Rocker Arm Studs 6 24 68 Rocker Panel Heights 0 10 Rotor 5D 13 Safe T Track Differential 4 B 1 1 4D Saginaw...

Page 1508: ...Transmission M 38 7G 1 Turbo Hydra Matic Transmission M 40 7E 1 Turn Signal Switch 9 23 Two Speed Automatic Transmission M 35 7F 1 Underhood Lamp 15 39 Unit Distributor 6E 44 U Cont Universal Joints...

Page 1509: ......

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