Pontiac firebird 1968 Page 36 Service Manual Download

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Summary of Contents for firebird 1968

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Page 2: ...RAL MOTORS CORPORATION PONTIAC MICHIGAN 48053 S 6804 September 1967 Litho in U S A General Motors Corporation 1 967 TABLE OF CONTENTS TITLE SECTION GENERAL INFORMATION 0 HEATING AND VENTILATION SERVIC...

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Page 4: ...ation as to body style trim number body number and paint code may be found stamped on the Body Identification Plate Fig 0 2 This plate is attached to the left side of the cowl assembly just below the...

Page 5: ...ertible 24267 Firebird Coupe 22337 Convertible 22367 Fig 0 4 Car Model Identification hand bank of the engine block Fig 0 5 and should be used whenever referring to a specific enginee For a complete l...

Page 6: ...lower than the side rails Lift adapters must provide adequate clearance height for these parts TOWING PRECAUTIONS Always place a rubber mat or other suitable ma terial between the bumper and the tow...

Page 7: ...e level for the re maining five positions As each tumbler level is determined write that number in the blank space above the position numbers After the key code has been determined the cor rect tumble...

Page 8: ...6 206 6 206 6 206 6 206 6 203 4 206 6 206 6 WIDTH B 74 4 HEIGHT Unloaded C 54 4 1 54 4 54 4 54 41 54 4 54 4 54 4 54 4 54 9 54 9 54 9 54 9 55 4 54 2 54 2 WHEELBASE D 115 TREAD FRONT E 58 TREAD REAR F...

Page 9: ...37 4 2 6 7 E X C H D S P R I N G S 9 60 9 20 3369 3569 10 25 10 00 3535 3 9 3 5 INC H D S P R I N G S 10 50 10 50 A L L H D S P R I N G S E X C 3 5 3 5 3935 T A N K S P E C I F I E D T I R E P R E S S...

Page 10: ...0 H 0 266 19 0 1660 46 0 0810 73 0 0240 G 0 261 20 0 1610 47 0 0785 74 0 0225 F 0 257 21 0 1590 48 0 0760 75 0 0210 E 0 250 22 0 1570 49 0 0730 76 0 0200 D 0 246 23 0 1540 50 0 0700 77 0 0180 C 0 242...

Page 11: ...083 feet 1 yard 0 914402 meters 1 meter 1 093611 yards 1 mile 1 609347 kilometers 1 kilometer 0 621370 miles LIQUID CAPACITY 1 quart 0 94633 liters 1 liter 1 05671 quarts 1 gallon 3 78533 liters 1 lit...

Page 12: ...nly Change lubricant only when necessary to dis assemble Manual Transmission 0 Check for leaks Maintain lubricant level with SAE 80 where available or SAE 90 Multi Purpose gear lubricant meeting requi...

Page 13: ...all 6 cylinder 1 BM and 4 Bbl engines Replace NOTE Clean and re oil after each occasion of driving under severe dust conditions Allow excess oil to drain out of filter prior to installation ITEMS REQ...

Page 14: ...Engine oil as required Stick type lubricant use sparingly as required Use Pontiac solvent part 1050418 or equivalent and follow instructions on label to ensure proper opera tion of washer and to preve...

Page 15: ...bearing lubricated and sealed for life SPEEDOMETER CABLE Periodic lubrication is not required When install ing a new drive cable apply a light coat of speedom eter cable grease wiping off all excess t...

Page 16: ...gainst end of cam slot 5 If any of first red bars are exposed repeat steps 3 and 4 until cable is properly adjusted TEMPEST 1 Make sure cable is secure at both ends SUBJECT PAGE Tempest 1 6 Firebird i...

Page 17: ...Move panel rearward 4 Remove fan switch connector light and cables 5 Remove panel 6 To install reverse removal procedure SELECT AND VACUUM VALVE SWITCH REPLACEMENT Fig 1 4 TEMPEST 1 Remove screws ret...

Page 18: ...tor to the new switch 6 Rotate the control knob until four red bars are seen 7 Rotate the switch in the slots until the blower just passes into the MED 2 operating speed there are four speeds LO MED 1...

Page 19: ...ctor 3 Remove connector at accessory feed 4 Remove resistor connector 5 To replace reverse removal procedure 6 Check for operation TEMPERATURE CONTROL CABLE REMOVE AND REPLACE PONTIAC 1 Disconnect tem...

Page 20: ...ng above 6 Check for operation AIR CONTROL CABLE REPLACEMENT TEMPEST 1 Remove glove compartment 2 Remove air control bowden cable from heater core and case assembly Fig 1 2 3 Remove air control bowden...

Page 21: ...e removal procedure AIR DIAPHRAGM AND HOSE REMOVE AND REPLACE PONTIAC 1 Remove green supply hose Fig 1 6 2 Remove diaphragm retaining screws and spring 3 Remove diaphragm 4 To replace reverse removal...

Page 22: ...lignment marks and remove hood 4 Remove right front fender and skirt as an assembly 5 Disconnect the blower motor wire at the motor flange 6 Either remove the motor to case mounting screws and remove...

Page 23: ...ble 10 Install fender and skirt assembly 11 Clip the heater hoses to fender skirt replace battery and tray and connect cables 12 Install hood HEATER CORE AND OR CASE REMOVE AND REPLACE PONTIAC Fig 1 7...

Page 24: ...g I I O J 1 Drain radiator 2 Remove heater hoses at their connections be side the air inlet assembly NOTE The hose from the water pump must go to the top heater core pipe the other hose runs from the...

Page 25: ...ler is in tact before installing core Use new sealer if necessary 8 Install core retaining springs and core tube seal 9 Within the vehicle insert the five studs on heater through the holes in cowl and...

Page 26: ...ove IP pad 4 Remove glove compartment box 5 Remove screws retaining duct to dash and heater case 6 Remove duct 7 Check for air flow leaks 8 Replace by reversing removal procedure TEMPEST 1 Disconnect...

Page 27: ...For removal and installation of defroster duct refer to Fig 1 4 1 Remove glove compartment ash tray bracket and radio 2 Remove two duct retaining screws 3 Pull heater case from firewall as described...

Page 28: ...nsion valve and freeze valve stem The presence of moisture can also cause the for mation of hydrochloric or hydrofluoric acids in the system REFRIGERATION SUB ASSEMBLIES l a All sub assemblies are shi...

Page 29: ...rque specification P O A valve and discharge valve gauge fitting on compressor 2 With both valves on manifold gauge set J 5725 01 closed clockwise attach manifold to P O A valve and compressor using J...

Page 30: ...oil or equivalent If necessary to bring to proper level Make sure dust cap on dis charge side of vacuum pump has been removed 4 Start the vacuum pump and slowly open low and high pressure sides of ma...

Page 31: ...ed to a maximum of 125 F CAUTION Do not allow temperature of water to exceed 125 F High temperature will cause exces sive pressure and possible softening of fusible safety plugs in the refrigerant dru...

Page 32: ...the gauge fit ting to prevent injury to personnel 10 Using leak detector J 6085 check complete system for leaks as e x p l a i n e d under LEAK DETECTORS Fig 1A 3 Schematic Charging Refrigeration Sys...

Page 33: ...gh the proper amount of re frigerant is in the system Air inlet temperature must be 70 F or above to make an accurate check 7 When refrigerant has been installed continue to operate system and test fo...

Page 34: ...uge below 50 psi by regulating refrigerant control valve Closing valve will lower pressure This is to prevent liquid refrigerant from reaching the compressor while the compressor is operating When req...

Page 35: ...eaks and make operational check of system as outlined under OPERATIONAL TEST CHECKING COMPRESSOR OIL LEVEL AND ADDING OIL The refrigeration system with the six cylinder axial compressor requires 11 fl...

Page 36: ...oil More oil is retained in a drained compressor than one that has been rebuilt REPLACING AN INOPERATIVE COMPRESOR In the case when it is not possible to idle the com pressor to be replaced to effect...

Page 37: ...NG COMPRESSOR OIL L E V E L AND ADDING OIL COMPRESSOR REPLACEMENT NOTE Before installing a new compressor ro tate compressor shaft four or five times This permits proper lubrication of compressor seal...

Page 38: ...or pound on hub of drive J 9401 1 J 9401 2 J U flflHHH Fig 1A 6 Removing Hub Retainer and Spacer plate assembly or on end of shaft If proper tools to remove and replace clutch parts are not used it i...

Page 39: ...1 Truarc pliers J 9399 can be used to snap retainer ring in place 11 Install a new armature plate and hub lock nut using J 9399 special thin wall 9 16 socket Tighten to 15 1 lb ft torque The air gap b...

Page 40: ...ow evidence of warpage due to overheating they should be replaced 1 When replacing a new ball bearing assembly into pulley use J 9481 pulley bearing installer Fig 1A 11 2 Replace the pulley assembly w...

Page 41: ...und wire at compressor and wire connector at coil 2 Remove compressor drive belt 3 Remove compressor rear brace to cylinder head brace bolt at compressor mounting bracket 4 Remove compressor front pla...

Page 42: ...shaft Fig 1A 16 8 Remove O ring from interior of compressor neck using J 9553 A wire with a hook formed on end may be useda This hook may be made in a man ner shown in Figure 1A 17 9 Re check the shaf...

Page 43: ...sleeve into place until the outer edge of the retainer is recessed approximately 1 32 from the face of the compressor neck 9 Re install the hub and drive plate assembly 10 Evacuate and charge refriger...

Page 44: ...f oil from the compressor at this time 2 Attach J 9396 holding fixture to compressor and mount in vise 3 Remove compressor pressure relief valve 4 Remove four lock nuts from threaded studs welded to c...

Page 45: ...using a wire with a hook formed in one end Fig 1A 21 6 Push on front end of compressor head to re move mechanism from rear of shell DO NOT ham mer on end of compressor shaft or use undue force to rem...

Page 46: ...discharge crossover tube out of rear head assembly toward front of compressor or use a wooden block as shown in Fig 1A 23 DO NOT drive toward rear of com pressor as discharge crossover tube may damag...

Page 47: ...of parts to FRONT end of com pressor main shaft 3 Place FRONT half of cylinder on J 9397 com pressing fixture Insert threaded end of shaft with front bearing assembly through front main bearing and al...

Page 48: ...ey Assembly 25 Rear Discharge 43 Discharge Crossover Tube I K Pulley Bearing Plate Assembly 44 Armature Plate and Hub 12 Pul ley Bearing Retainer Ring 26 Rear Suction Reed to Mainshaft Key Front Thrus...

Page 49: ...as follows a Use J 9661 gauge set selecting a suitable feeler gauge leaf until the result is a 4 to 8 oz REAR THRUST RACES AND BEARING PISTON SWASH PLATE FRONT THRUST RACES AND BEARING I Fig 1A 30 In...

Page 50: ...5 9 6 5 5 6 2 2 0 2 2 6 5 5 6 1 0 0 1 0 6 5 5 6 1 0 5 1 0 6 5 5 6 1 1 0 1 1 6 5 5 6 1 1 5 1 1 6 5 5 6 1 2 0 12 Fig 1A 33 Measuring for Proper Shoe Fig 1A 34 Measurements and Table of Available Service...

Page 51: ...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 quite likely that the...

Page 52: ...the discharge crossover tube with hole in rear half cylinder making sure flattened portion of this tube faces inside of compressor for swash plate clearance c When satisfied that all parts are in pro...

Page 53: ...6 Examine location of dowel pins and contour of webs mark dowel location Rotate so as to posi tion it properly over discharge reed retainers Use care to avoid damaging sealing surfaces When in proper...

Page 54: ...gear NOTE Before attempting the final assembly of the rear head casting position outer gear as follows a Observe position of oil sump in shell b Locate approximate centerline of this sump c While fac...

Page 55: ...g with tool J 5403 with flat face against seal seat The sleeve from tool J 9393 may be used to press on the re tainer ring so that it snaps into place Remove tool J 21303 from end of shaft 11 Leak tes...

Page 56: ...fitting 4 Loosen inlet and outlet fittings 5 Remove valve from bracket NOTE If valve is not immediately replaced cap openings to prevent entry of dirt and moisture 6 Replace by reversing above procedu...

Page 57: ...olding and loosen lower fender attaching bolts 5 Disconnect expansion valve Inlet and P O A valve outlet 6 Remove water control valve 7 Disconnect blower motor lead and resistor block lead 8 Gently pu...

Page 58: ...bracket retaining screws 7 Remove condenser and receiver assembly 8 Cap openings 9 Separate condenser from brackets 10 To replace reverse removal procedure add one ounce of refrigerant oil and purge...

Page 59: ...7 To replace reverse above procedure A C BLOWER MOTOR IMPELLER AND OR INLET DUCT PONTIAC OR TEMPEST 1 Unclip hoses from fender skirt 2 Remove rocker molding 3 Loosen lower rear fender retaining screw...

Page 60: ...Fig 1A 49 Air Inlet Assembly Pontiac...

Page 61: ...retaining core attaching bands and remove core 15 Replace by reversing the above procedure TEMPEST Fig 1A 53 1 Remove glove box 2 Remove lower instrument panel air conditioning duct and outlet assemb...

Page 62: ...rance of core inlet and outlet pipe 13 Remove core from front case 14 To install reverse removal procedure 15 Adjust temperature control cable 16 Replace glove box 17 Use a 1 diameter plastic plug to...

Page 63: ...reverse removal procedure CAM ASSEMBLY TEMPERATURE DOOR ALL 1 Remove glove compartment 2 Scribe alignment marks on case for cam placement 3 Remove control cable 4 Remove cam hold down screws 5 Remove...

Page 64: ...pin into left indexing hole in heater cam 4 Adjust turnbuckle by threading left or right until pin falls into matching indexing hole in cam bracket 5 Remove gauge pin and turn temperature control knob...

Page 65: ...bracket index holes 4 With gauge pin In place adjust turnbuckle to move lever against lower end of slot in control panel then turn turnbuckle in opposite direction to move control lever 1 8 to 3 16 aw...

Page 66: ...nnectors to switches and vacuum connectors for correct reassembly and remove 4 Remove blower switch and temperature control knobs and escutcheon nuts 5 Lower control panel assembly 6 Remove temperatur...

Page 67: ...n Pontiac models remove switch attaching screws 4 Remove wire connector 5 On Pontiac models loosen set screws and re move pulley 6 To replace reverse removal procedure COMPRESSOR CLUTCH SWITCH OR MAST...

Page 68: ...est Control Panel Fig 1A 59 Firebird Control Panel 2 Remove resistor retaining screws A Q 3 Remove resistor assembly Fig 1A 61 4a To replace reverse removal procedure 1 Remove cold air duct I I I A S...

Page 69: ...Remove harness 5 To replace reverse removal procedure MASTER RELAY PONTIAC ONLY 1 Remove wire connector Front relay on bracket 2 Remove relay retaining screws 3 Remove relay 4 To replace reverse remov...

Page 70: ...LL Air conditioning refrigerant hose routing is shown on Figs 1A 47 1A 48 and 1A 49 These connections should be tight and contaminent free Use the torque chart in Fig 1A 1 as a guide for securing hose...

Page 71: ...is riveted to in strument panel face pad Should it become neces sary to replace the bezel use pop rivets and not screws FIREBIRD 1 Remove two exterior retaining screws 2 Pull assembly from dash 3 Rem...

Page 72: ...tors 3 Remove switch 4 Reverse removal procedure to replace VACUUM HOSE HARNESS PONTIAC OR TEMPEST Figs 1A 56 and 1A 57 1 Remove cold air duct and instrument panel face pad 1 2 Remove hoses at air inl...

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Page 74: ...Remove glove box 2 Remove wire connector 3 Remove aspirator hose 4 Remove retaining screws 5 Remove sensor When checking with an ohmmeter the resistance valve of this sensor should be approximately 1...

Page 75: ...ove distribution duct 2 Remove glove compartment 3 Loosen screw retaining link to programmer arm and separate the units 4 Disconnect programmer connector shown in Fig 1B 5 5 With ignition on and O F F...

Page 76: ...IFIER REPLACEMENT 2 Unsolder seven leads two orange one light green one dark green one brown one gray and one red lead The nine leads two orange two red two green one light green one dark green one br...

Page 77: ...area 2 Remove finger block assembly and move out of way 3 Remove retaining screw in hub of wheel and remove potentiometer clip Program wheel may now be slipped off GEAR INSPECTION 1 Remove program wh...

Page 78: ...new motor to same point Replace green motor wire in same manner Be sure to use resin core solder 4 Install new motor making certain that worm gear is properly seated in its bearing block and properly...

Page 79: ...iously on program wheel and clip line up Tighten retaining screw on pro gram wheel hub 4 Slip the round circuit board off of wheel and check to be certain that four ball bearings are still in their pr...

Page 80: ...are for the 121n wheelbase vehicles and three for the 124 wheelbase vehicles The convertible hardtop 124 wheelbase sedan station wagon and Grand Prix frames are essentially the same as other correspon...

Page 81: ...4 50 68 68 10 85 64 6 64 11 51 4 78 16 06 7 83 3 53 11 11 6267 38 40 19 20 60 20 25 34 50 68 68 10 85 64 6 64 11 51 4 78 16 06 7 83 3 53 11 11 6657 38 40 19 20 60 20 25 34 50 68 68 10 78 64 6 64 11 51...

Page 82: ...nderbody be thoroughly checked and if necessary realigned in order to accurately establish suspension locations To assist in checking alignment of the underbody components repairing minor underbody da...

Page 83: ...D D D D 6657 A A A A A A A 5639 5669 5287 6287 6239 5239 5687 W F35 B B F F F H B B B 5267 D D D D D D D 9 7 7 8 2 7 0 I N S U L A T O R A S S Y S H A P E C O L O R 4k B L A C K B L A C K o 9 7 7 9 9...

Page 84: ...B A C E E A D 3 3 6 9 3 5 3 9 3 5 6 9 3 7 3 9 B A C A B A D OF C H A S S I S 2 0 1 4 J C O M B I N A T I O N I C O M B I N A T I O N B 9 7 9 1 9 9 7 C U S H I O N A S M 9 7 8 7 7 0 3 C U S H I O N 3...

Page 85: ...No 1 body mount and center of master gauge hole in side rail on opposite side of body G H K Dimension Location 65 1 4 Center of master gauge hole adjacent to No 1 body mount and center of master gaug...

Page 86: ...on trol arms and rear wheels Since there is a bolted on stub frame in front and welded side rails at the rear the car may also be lifted at the points illus trated in Fig 2 7 Proper adapters must be u...

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Page 88: ...Firebird Lower Control A r m Ball Joint Replace 3 14 Alignment Specifications 3 15 Torque Specifications 3 16 Special Tools 3 16 PERIODIC SERVICE Periodic service of the suspension system consists of...

Page 89: ...spindle Move ment greater than 005 indicates a loose bearing If necessary to inspect bearings see Minor Re pairs Wheel Bearing Remove and Replace To Adjust TORQUE WRENCH METHODS Preferred Fig 3 3 1 Ra...

Page 90: ...characteristics INSPECTION BEFORE CHECKING FRONT WHEEL ALIGNMENT Before any checking or corrective work is started on wheel alignment elements including toe in caster camber steering axis inclination...

Page 91: ...difference from trammel marks made when chalk was in front of wheel if trammel marks are now greater than when marked at front wheels toe in by this amount see SPECIFICATIONS EQUIPMENT MEASURING FROM...

Page 92: ...rt CHECK TOE OUT ON TURNS Check toe out after any necessary corrections to camber caster and toe in have been made 1 Check with any reputable front end aligning equipment using full floating turn tabl...

Page 93: ...se car sufficiently to allow removal of shock 2 Remove nut retainer and grommet which attach upper end of shock absorber to frame bracket NOTE Shock absorber piston rod must not turn while loosening n...

Page 94: ...e bolt to upper plate d Place J 7592 6 ball up thrust bearing and J 7592 3 nut threads down on the bolt and screw up snug 6 While holding upper end of rod turn nut at lower end to compress spring 7 Su...

Page 95: ...ONT SPRING TEMPEST REMOVAL 1 Raise front end of car supporting so that lower control arm hangs free 2 Remove wheel and drum assembly 3 Remove shock absorber 4 Disconnect stabilizer link from lower con...

Page 96: ...39 to the jack and position under the two inner control arm bushings Fig 3 11 6 Remove two inner control arm to front cross member bolts 7 With care lower control arm by lowering jack CAUTION Allow sp...

Page 97: ...and install two bolts wash ers shims and self locking nuts Tighten nuts 75 lb ft torque on Pontiac and 50 lb ft on Tempest and Firebird while holding bolts 2 Connect upper ball stud to steering knuck...

Page 98: ...is snug between inner faces of arm J21482 J 2 1 4 7 4 2 Fig 3 13 Installing Upper Control Arm Bushing Firebird b Position cross shaft in control arm c Insert bushings on ends of shaft d Press bushing...

Page 99: ...and tighten nut to 80 lb ft torque NOTE On Pontiac lower control arm to frame bolts must be assembled with head of bolt towards rear of car and on Tempest bolt head must be toward front of car Tighte...

Page 100: ...arm on car as outlined above FRONT BUSHING TEMPEST FIREBIRD REAR BUSHING PONTIAC J 2 1 4 7 4 6 J 2 1 4 7 4 1 2 J 21474 5 J 21474 4 J 21474 8 FIREBIRD 4 malm y Fig 3 18 Removing Lower Control Arm Fron...

Page 101: ...eel 3 Remove ball stud from steering knuckle with J 6627 Fig 3 6 4 Remove ball stud from upper control arm by chiseling or drilling rivet heads which retain ball stud to control arm and drive out rive...

Page 102: ...ng knuckle on ball stud and tighten nut to 85 lb ft Fig 3 22 Ball Joint Installation CAUTION Care should be taken to ensure that steering knuckle hole and ball stud are clean and dry Tighten nut to pr...

Page 103: ...gon 2 1 2 Firebird 1 2 1 2 Camber All Models 1 4 1 2 Toe In All Models Except Firebird 0 to 1 8 Toe In Firebird Only l 8 n to 1 4 Steering Axis Inclination Pontiac 8 1 2 1 2 with 1 camber Tempest 9 1...

Page 104: ...spension system to maintain desirable handling and steering char acteristics and minimize tire wear These checks and adjustments are explained in section 3 REPAIRS REAR SUSPENSION REAR SHOCK ABSORBER...

Page 105: ...RING PONTIAC AND TEMPEST REMOVAL 1 Raise car at frame 2 Place safety stands under frame at both sides to support car 3 Remove brake connector and line from axle housing Do not disconnect b r a k e lin...

Page 106: ...nut J 21058 8 against thrust bearing f Check to make sure that all puller parts are properly aligned Then proceed to tighten nut until bushing is pulled free of spring eye Disassemble puller tool g Po...

Page 107: ...laced on a work bench re move the center locating nut and bolt 3 With a screwdriver pry the tabs of the spring leaf clips up and remove insulator and clip from spring 4 Separate the smaller leafs of t...

Page 108: ...G REPLACEMENT 1 Remove pivot bolt from upper control arm at axle housing 2 Arrange tools as shown in Fig 4 5 and press bushing from axle housing 3 Install new bushing in axle housing by arrang ing too...

Page 109: ...EAR BUSHING REPLACEMENT 1 Remove control arm from car as outlined above 2 Support arm and remove bushing using com ponents of tool J 21474 as shown in Fig 4 7 3 Replace using components of tool J 2147...

Page 110: ...torque The air lines cannot withstand exhaust system temperatures At least 1 50 clearance should be maintained between the air lines and any portion of the exhaust system LINES AND FITTINGS Fig 4 11 a...

Page 111: ...Fig 4 16 The compressor is a precision built mechanism that should be carefully handled and assembled Care must be taken to prevent entrance of dirt or other foreign matter This unit must not be lubr...

Page 112: ...gs together 8 Separate first and second stage housings by sliding second stage housing straight off piston 9 Remove two pressure regulator valve assembly retaining screws Remove valve assembly from se...

Page 113: ...move valve tension spring from boss Do not distort spring take check valve and washer using a pocket knife 6 If necessary remove rocker and swivel arms Grip pin with pliers and remove pin Fig 4 19 DIS...

Page 114: ...E EXISTING TUBING WITH PREVIOUSLY INSTALLED SUPER LIFT SHOCK ABSORBERS ON RIGHT HAND A N D LEFT HAND SIDES OR TUBING IN V SUPERLIFT SHOCK ABSORBER PACKAGE DISASSEMBLED VIEW OF FITTING HORIZONTAL LINE...

Page 115: ...screw to 12 lb in 6 Install two distributor valve stop bushings and two arm assembly stop bushings NOTE Do not install actuating arm arm tension spring or arm pivot screw at this time as rocker arm mu...

Page 116: ...ting 54 Spring Arm Tension 55 Screw Arm Pivot 56 Cover 57 Gasket 58 Screw Cover Retaining 59 Gasket Cover 60 Mount Flexible 61 Adapter 62 Tube Fitting 63 Filter Fig 4 16 Exploded View of Compressor 2...

Page 117: ...4 19 Removing Rocker Arm Pin TROUBLE DIAGNOSIS TESTS QUICK CHECK OF AUTOMATIC LEVEL CONTROL SYSTEM 1 Record rear trim height of empty car measure from center of rear bumpter to ground 2 Add weight equ...

Page 118: ...hich has three 1 8 female taper pipe threads 3 One adapter which has a 1 4 female taper pipe thread on one end and a 1 8 male taper pipe thread on the other end Fig 4 22 Positioning Distributor Valve...

Page 119: ...tor assembly 6 If regulated pressure exceeds 130 psi replace regulator assembly HEIGHT CONTROL VALVE TEST ON CAR EXHAUST SUPERLIFTS INFLATED 1 Disconnect overtravel lever from link 2 Hold lever down i...

Page 120: ...5 Remove test gage and plug intake port with Fill Valve 6 Connect test gage to Superlift port and open air pressure 95 psi Move overtravel lever approxi mately one inch up from neutral position as me...

Page 121: ...7 With overtravel lever in neutral position no air should escape If bubbles escape from exhaust port replace control valve 8 If air escapes around edge of cover plate the gasket must be replaced 9 Re...

Page 122: ...Mount to Frame Firebird 10 Nut Front Spring Bushing to Bracket Firebird 100 Bolt Front Spring Bracket to Frame Firebird 25 Nut Rear Spring Bushing to Shackle Firebird 50 Nut Compressor Fitting Auto L...

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Page 124: ...ent axle ratios are available for the various car models They can be identified by the code stamped on the rear of the L H axle tube adjacent to the carrier Fig 4A 1 Three differential cases which dif...

Page 125: ...irebird Use multi purpose hypoid gear lubricant in the standard differential Because of the importance of using factory recommended lubricant a container of this lubricant is furnished with each servi...

Page 126: ...Gear 26 Inner Retainer Gasket 41 Pinion Nut Fig 4A 3 Exploded View of Typical Differential Assembly bearing rollers when joint is disconnected if tie wire has been removed Fig 4A 5 3 Attach a 1 2 dri...

Page 127: ...2 PASS COACH X X STANDARD X X X X X X HIGHWAY PATROL o 1 m FREEWAY ENFORCER o 1 m X X X X X X x X X X X X X x X x X X X X X X X 3 SPEED MANUAL I TO 3 ZL G O X X X X X X X X X X 4 SPEED MANUAL I TO 3 Z...

Page 128: ...X X X X X X X XX X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X x x x X X X X X X X X X X X X X X X X X X WF YF 37 11 3 36...

Page 129: ...P I N I O N 4 P I N I O N X X X X X 41 16 2 56 X X X X X X XB ZB X X X X 39 14 2 78 X X X X X X X X X X X X X XC ZC X X X X X 41 14 2 93 X X X X X X XD ZD X X X X X X 40 13 3 08 X X X X X X X X X X X...

Page 130: ...ock nut Remove lock nut with a heavy duty socket while holding companion flange with J 8614 1 Fig 4A 7 2 Remove U bolts which hold rear universal joint to companion flange Use a heavy rubber band or t...

Page 131: ...excessive Inserting a shim inboard of the bearing to compensate for the end play J 21285 01 is not recommended This ignores end play of the bearing itself and may result in improper seating of the ga...

Page 132: ...ONLY J 21022 TEMPEST AND FIREBIRD J 6407 1 2 until tool bottoms on bearing shoulder in housing Fig 4A 14 INSTALL AXLE SHAFT ASSEMBLIES 1 Apply a coat of wheel bearing grease in bear ing recess of hous...

Page 133: ...spring from its shackles and brackets and remove rear axle assem bly from under car 9 Pontiac and Tempest Disconnect upper cen trol arms at axle housing 10 Pontiac and Tempest Disconnect lower con tr...

Page 134: ...n matter such as grinder dust soot or sand away from differential to prevent possibility of subsequent failure GEAR TOOTH NOMENCLATURE The side of the ring gear tooth which curves out ward or is conve...

Page 135: ...FFECTS OF INCREASING LOAD ON TOOTH CONTACT PATTERN When load on ring and pinion gear is increased such as when car is accelerated from standstill or from normal drive the tooth contact will tend to sp...

Page 136: ...the heel end and up toward top of the tooth on both drive and coast sides TOE 4 HEEL HEEL DRIVE SIDE C O A S T SIDE CONVEX CONCAVE Fig 4A 20 Effect on Pattern As Shim Thickness is Increased side Fig...

Page 137: ...erential side bearings for visible damage of rollers and outer races 2 Place one outer race onto its matching inner race and roller assembly and turn slowly applying hand load 3 If bearing outer race...

Page 138: ...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 parts as necessary and coat with clean gear lube befor...

Page 139: ...pinion assembly by shaking Looseness indicates need for bearing replacement If assembly is run with loose bearings for any extended period ring gear and pinion will also need to be replaced REMOVE PIN...

Page 140: ...y and are serviced only in sets Never attempt to replace either a ring gear or pinion without its matching member 2 Thoroughly clean and inspect carrier for cracks or other damage 3 Be sure oil passag...

Page 141: ...nsert assembled gauge plate and bolt through front and rear bearings with underside of plate against J 21777 8 washer Fig 4A 34 Slip J 8619 12 pilot over bolt end with underside against front bearing...

Page 142: ...inion reassembly on the following basis NOTE Pontiac Fifteen 15 shims are avail able in increments of 002 two thousandths from 020 to 050 Fig 4A 37 Tempest or Firebird Ten 10 shims are available in in...

Page 143: ...il seal and seal surface of companion flange with gear lube Install companion flange on pinion by tapping with a soft hammer until a few pinion threads project through flange 5 Install pinion washer a...

Page 144: ...ght and left shims equally thus leaving the original backlash undisturbed 1 Before installation of case assembly make sure side bearing surfaces are clean and free of burrs Lubricate side bearings wit...

Page 145: ...n step 6 Install one of these shims between each side bearing race and service spacer CA UTION If insertion of second shim causes excessive pinion to ring gear contact noticeable by difficulty in rota...

Page 146: ...ecessary to exceed 009 backlash to obtain the desired tooth contact It is important however not to exceed 009 backlash on new gear sets If readjusting the backlash doesn t give the cor rect tooth cont...

Page 147: ...80 Rear Axle Bumper Spacer to Axle Housing Bracket Bolt and Nut Station Wagon Tempest 50 Rear Axle Upper Control Arm Assy to Frame Bolt Pontiac or Tempest 110 Rear Axle Upper Control Arm Assy to Frame...

Page 148: ...staller J 6197 Rear Pinion Bearing Outer Race Installer J 6407 1 2 Press Plate Holder Insert J 6547 Rear Pinion Bearing Installer J 6783 Axle Shaft Bearing Installer J 7817 Front Pinion Bearing Outer...

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Page 150: ...t may be necessary to drive the car several miles to allow the lubri cant to work through the clutches and eliminate the chatter If chatter persists drain and refill again to eliminate contamination I...

Page 151: ...ac Safe T Track DIFFERENTIAL CASE FLANGE HALF FLANGED CAP SCREW BRAKE CONE PRELOAD SPRINGS SIDE GEAR SPRING BLOCK PINION GEAR THRUST WASHER PINION GEAR THRUST WASHER PRELOAD SPRINGS PINION SHAFT L I V...

Page 152: ...ASSEMBLE PONTIAC NOTE Keep side bearing outer races with side bearings so these matched parts can be correctly replaced during build up 1 Before disassembling differential case inspect differential si...

Page 153: ...from case Note location in case to aid in reassem bly Remove side gear clutch pack and shims from opposite side NOTE If a side gear or clutch pack cannot be readily removed from case drive out with b...

Page 154: ...embly CLEANING AND INSPECTION OF CASE PONTIAC 1 Thoroughly clean differential case and inspect paying particular attention to ring gear mounting flange ring gear pilot and side bearing hubs 2 Remove n...

Page 155: ...bolts evenly and alternately across diameter to 90 lb ft torque CAUTION Do not use hammer to force ring gear on case 4 If side bearings were removed lubricate the bearings and install on case hubs as...

Page 156: ...it will be impossible to install shafts at final as sembly Attempting to force shafts into position may result in damage to spring thrust blocks TWO LARGE FLAT WASHERS 2 C CLAMP s i P T H R U S f BLO...

Page 157: ...ar will mesh with pinion gears 7 Place shim if provided and remaining cone over side gear 8 Install flange half of differential case over cone in proper position to match alignment marks insert two ca...

Page 158: ...4B for Tempest See Fig 4A 4C for Firebird Pinion Bearing Preload with Ring Gear New Bearings New Seal 25 lb in Old Bearings New Seal 17 lb in Side Bearing Preload Slip Fit Plus 008 TORQUE Lb Ft Diffe...

Page 159: ...s Plate Holder Insert J 21028 Differential Side Bearing Instal ler J 6547 Rear Pinion Bearing Installer J 21129 Axle Shaft Oil Seal Installer J 6783 Axle Shaft Bearing Installer J 21285 01 Pinion Oil...

Page 160: ...g rollers while rear universal joint is being disconnected Fig 4C 1 4 Remove complete propeller shaft assembly by sliding it rearward and downward to disengage splined yoke from splines on transmissio...

Page 161: ...will allow propeller shaft fixed yoke to be moved downward Fig 4 C 5 Support rear of propeller shaft on a stand so that propeller shaft is horizontal Be sure weight is evenly distributed on each side...

Page 162: ...f bearings i i i I i 3 Install one bearing one quarter way in one side of splined yoke using soft faced hammer Check for proper alignment 4 Insert journal into splined yoke with dust shields installed...

Page 163: ...2 Apply engine oil to inside spline and outside diameter of yoke and slide propeller shaft splined yoke onto transmission output shaft 3 Position rear universal joint to rear axle com panion flange m...

Page 164: ...r est els 3 and 4 Speed Manual 3 Speed H D Manual 2 Speed Automatic Turbo Hydra Matic 1 Brown 1 Gold Band 1 Red 1 Yellow Band 1 Purple 1 Yellow Band 1 White Band 116 60 00 60 00 60 00 59 34 3 25 0 L 1...

Page 165: ......

Page 166: ...necessary should be performed as outlined in this section Each time the car is serviced for any reason there is an opportunity and obligation to check the opera tion of the brake system If the brake p...

Page 167: ...dal assembly in support brace and install clevis pin 3 Pontiac and Tempest Slide pedal pivot shaft bolt through support brace and pedal bore Firebird Slide pedal pivot shaft through sup port brace and...

Page 168: ...e should be used 18 Remove clevis pin retainer 2 Remove clevis pin 3 Loosen lock nut 4 Adjust clevis to obtain proper pedal height 5 Retighten lock nut against clevis to 90 lb in torque 6 Reinstall cl...

Page 169: ...released position BRAKE WARNING LIGHT CHECKING PROCEDURE 1 Determine if bulb is functioning by depressing parking brake S C R E W D R I V E R Fig 5 4 Preparing to Back Off Adjusting Screw BACKING INS...

Page 170: ...ake certain parking brake mecha nism and linkage are properly adjusted 4 With wheels removed remove adjusting hole cover from backing plate and lengthen adjusting screw using J 4735 Pontiac or J 8915...

Page 171: ...ront wheels front hub and drum as semblies rear wheels and rear drums NOTE It may be necessary to back off the brake shoe adjustment before the brake drums can be removed To back off shoe adjustment i...

Page 172: ...s may be installed If drum diameter is 11 030 11 060 oversize linings must be installed NOTE If new linings are installed on one wheel they must also be installed on the opposite side of the car 2 Ins...

Page 173: ...djusted lin ings 12 Inspect hoses and hydraulic lines for wear kinks or damage and replace as necessary 13 Check to make sure all bolts and nuts securing backing plate to suspension are tightened to 1...

Page 174: ...must be installed with the star wheel end of the screw toward the rear of the car 6 Position shoe assembly on the backing plate Be sure wheel cylinder links are properly positioned in the shoe notche...

Page 175: ...over shoes Check to see that adjuster lever can turn adjusting screw star wheel with minimum of effort 14 Install drums observing instructions for front wheel bearing adjustment as outlined in sectio...

Page 176: ...assembly and bleed other master cylinder bleeder valve NOTE If a power brake unit has been installed on a Tempest or Firebird and the original manual master cylinder without bleeder valves is used the...

Page 177: ...front brakes will not contain a check valve and spring MASTER CYLINDER REMOVE 1 Disconnect brake lines from two outlets on master cylinder and tape end of lines to prevent entrance of dirt 2 Disconnec...

Page 178: ...ary seals from front piston Cleaning Use a reputable cleaner or clean brake fluid to clean all metal brake parts thoroughly Immerse parts in cleaning fluid using a bristle brush to re move foreign mat...

Page 179: ...ng torn cut or heat cracked boots should be completely overhauled Inspection for leakage may be accomplished at the boot center hole after removal of the link pin Fluid coatings on the piston within t...

Page 180: ...adjuster lever so that it continues to adjust to compensate for wear caused by the drag The result is a cycle of wear and ad justment that can wear out linings very rapidly 1 Jack up both rear wheels...

Page 181: ...sition then place check nut on stud 5 Adjust parking brake as outlined under Parking Brake Adjustment 6 Connect positive battery cable CENTER CABLE REMOVAL AND INSTALLATION 1 Place parking brake pedal...

Page 182: ...ad to floor pan 0 7 3 8 WHEEL CYLINDER BORE Front 1 1 8 R e a r 15 16 TORQUE SPECIFICATIONS Torque in lb ft unless otherwise specified APPLICATION TORQUE APPLICATION TORQUE Bolt Wheel Cylinder to Back...

Page 183: ...nt 1 1 8 Effective braking surface area 149 4 sq in R e a r 7 8 TORQUE SPECIFICATIONS Torque in lb ft unless otherwise specified APPLICATION TORQUE APPLICATION TORQUE Front brake to steering knuckle W...

Page 184: ...t in the mounting sleeve which permits positive adjustment by pulling the brake pedal up firmly against the stop The pedal arm forces the switch body to slip in the mounting sleeve bushing to properly...

Page 185: ...KE UNIT DISASSEMBLE housing and remove power cylinder assembly 1 Using an old master cylinder or tool J22805 01 5 Clean exterior of power brake assembly and put power brake unit in a vise push rod up...

Page 186: ...inder assembly from front housing 5 Using tool J 9504 rotate rear half housing counterclockwise to unlock rear half from front housing Disassembly of Tempest and Firebird units may be facilitated by u...

Page 187: ...ded with shop towels with tube end down CAUTION Do not clamp on tube as outside sur face of tube acts as bearing surface i Fig 5A 5 Removing Rear Housing 10 Remove snap ring on air valve using Truarc...

Page 188: ...cked scored or otherwise damaged MASTER CYLINDER Inspect bore from the open end The bore should be free from scores deep scratches and corrosion If it appears that corrosive brake fluid has damaged th...

Page 189: ...control valve is a component part of this assembly and cannot be disassembled 5 Wipe thin film of power brake lube on large O D of floating control valve and on O ring of air valve 6 Press air valve p...

Page 190: ...ress down and rotate support plate clockwise until lugs on power piston come against stops on support plate 14 Invert assembly and place in padded vise with power piston tube end down and insert snap...

Page 191: ...d of ring is seated under lug with raised divider CAUTION Make sure that both ends of lock ring are securely under large lug 21 Place new front housing seal in center of front housing so that flat sur...

Page 192: ...ving Support Plate Fig 5A 13 Removing Air Valve 24 Coat inside of power piston bearing with power brake lube 25 Place air silencer over holes on tube of power piston and wipe tube with power brake lub...

Page 193: ...d to hold silencer against power piston tube 32 Tempest and Firebird Seat plastic boot against rear housing Raised humps on side of boot will locate in large holes In center of brackets Install jam nu...

Page 194: ...DELCO MORAINE POWER BRAKE 5A 11 Fig 5A 16 Special Tools J 9504 Power Cylinder Spanner Wrench J 21524 Power Piston Remover and Installer J 21601 Power Brake A i r Valve Installer J 22647 Height Gauge...

Page 195: ......

Page 196: ...GE Inspect Power Brake Assembly 5B 3 Inspect Hydraulic Master Cylinder Assembly 5B 3 Inspect Air Filters 5B 4 Power Unit and Master Cylinder Assemble 5B 4 Master Cylinder Assemble 5B 4 Power Piston As...

Page 197: ...ing 4 Carefully remove rubber diaphragm from dia phragm plate 5 Tilt diaphragm plate and depress valve operat ing rod slightly to remove valve assembly retainer valve plunger stop key See Fig 5B 3 6 P...

Page 198: ...outlet ports Place thin washer on self tapping screw and install screw in tube seat with washer bottomed against tube nut Fig 5B 5 Hold screw with screwdriver and use wrench to remove tube nut screw w...

Page 199: ...ster cylinder Fig 5B 5 Master Cylinder Exploded View 1 Snap Ring 2 Splash Shield Retainer 3 Splash Seal 4 Secondary Seal 5 Rear Piston and Spring Assembly 6 Primary Cup 7 Secondary Seals 8 Front Float...

Page 200: ...faces of the valve plunger and outer edge of valve poppet with power brake lubricant 3 Insert control valve assembly into diaphragm plate hub Push on valve enough to insert the valve plunger stop key...

Page 201: ...in der should be rechecked either with a micrometer depth gauge to a dimension of 1 225 to 1 210 or with height gauge J 22644 Place gauge over the push rod on the front housing Cutout portion of the g...

Page 202: ...BENDIX POWER BRAKE 5B 7 SPECIAL TOOLS J 9504 SPANNER WRENCH J 22644 j 22677 HEIGHT GAUGE SEAL INSTALLER Fig 5B 8 Special Tools...

Page 203: ......

Page 204: ...cate as required 2 Check stop light switch for proper setting and operation 3 Check fluid level in hydraulic cylinder reser voir Fluid level should be as shown in Section 5 4 Check vacuum line and con...

Page 205: ...od VALVE ROD RETAINERS FILTERS AND POPPET PARTS REMOVE Fig 5C 2 Remove air filters from valve hub with ice pick USE CARE TO AVOID DAMAGING PLASTIC HOUS ING With valve rod in vertical position squirt a...

Page 206: ...is under pressure Use care in separating shells to avoid the spring flying out REMOVAL OF REAR SHELL VACUUM SEAL Fig 5C JJ Place rear shell on bench with studs up and drive out seal with punch or scre...

Page 207: ...Loosen front diaphragm from center plate and slide center plate carefully off front plate hub CAUTION DO NOT DAMAGE OR REMOVE SEAL FROM CENTER BORE OF CENTER PLATE Remove diaphragm from front plate R...

Page 208: ...ction 5 under Master Cylinder Disassembly 5 Install spare tube nut in outlet ports Place thin washer on self tapping screw and install screw in tube seat with washer bottomed against tube nut Hold scr...

Page 209: ...earing surfaces of valve plunger being careful NOT to get any lubricant on rubber grommet inside plunger Assemble valve plunger return spring on valve plunger as shown and set spring and plunger in re...

Page 210: ...emble poppet in valve housing small diameter end of poppet first wet poppet retainer in alcohol and assemble in housing with flange out Press in against retainer to make certain shoulder on retainer i...

Page 211: ...etainer NOTE Pedal height is not adjustable 3 Adjust stop light switch if necessary to provide 3 16 plunger extension from body Attach wire 4 Attach vacuum hose to vacuum check valve 5 Attach hydrauli...

Page 212: ...o drain After pistons are bottomed tighten bleed screw before relieving pressure on shoes and linings NOTE This step is necessary when replacing worn disc brake shoes since insertion of full thickness...

Page 213: ...m mounting bracket by removing two hex head bolts and take to clean work area CALIPER DISASSEMBLE 1 Remove and discard cotter pin from inboard end of shoe retaining pin slide out retaining pin and rem...

Page 214: ...is flush with end of bore If not re check piston and location of piston spring and seal 6 Assemble boot in groove of piston closest to concave end of piston Fold in boot must face toward end of piston...

Page 215: ...ts Torque mounting bolts to 75 lb ft 2 Connect brake line tube nut to caliper 3 Calipers are now ready to be bled with Delco Supreme No 11 brake fluid or equivalent BRAKE DISC In manufacturing brake d...

Page 216: ...eld open This is done by depressing and holding in the plunger in the end of the valve either by hand or by tapping Tool J 22793 may also be used to aid bleeding SPECIFICATIONS Disc Brake Type Fixed C...

Page 217: ...NUAL SPECIAL TOOLS J 22262 J 22674 J 22591 Disc Brake Piston Installer J 22262 Disc Brake Boot Installer Overhead Camshaft Oil Sea Fig 5D 8 Special Tools J 22674 Disc Brake Piston Retainers J 22793 Me...

Page 218: ...ode for 6 cylinder engines is stamped on the cylinder head contact surface of the block behind the oil filler pipe Fig 6 4 By referring to the identi fication code and the engine chart each engine may...

Page 219: ...X X X X With 60 PSI Oil Pump Spring All Cars Use CCS Fig 6 1 Pontiac Engine Chart HORSEPOWER 1 E N G I N E COCE DISP TRANS CARB COMP RATIO CAMSHAFT STANDARD DISTRIBUTOR VALVE SPRINGS HORSEPOWER 1 E N...

Page 220: ...N Os i s Os o CO o 1111281 CN CO CN rs 1111270 Os XT SINGLE o H d H t H D TWO SPEC RAM AIR 175 Z K X X X X X X X 175 Z N X X X X X X X 215 Z D X X V A X X X X 215 ZE X X X X X X X 265 w c X X X X X X...

Page 221: ...Fig 6 5 Engine Number and Code Location V 8 8 CYLINDER 6 CYLINDER STAMP VEHICLE IDENTIFICATION NUMBER CONSISTING OF THE FIGURE 2 FOLLOWED BY THE LAST 8 DIGITS OF THE CAR SERIAL NUMBER Fig 6 6 Vehicle...

Page 222: ...ove and Replace 6 24 Main Bearings Remove and Replace 6 25 Connecting Rod Bearings Remove and Replace 6 26 Connecting Rod and Piston Assembly Remove Rod and Piston 6 27 Disassembly Rod and Piston 6 27...

Page 223: ...6 6 1968 PONTIAC SERVICE MANUAL ijjlssss 4 CAMSHAFT TIMING ALIGNMENT CAMSHAFT SPROCKE DISTRIBUTOR TIMING ALIGNMENT CRANKSHAFT TIMING ALIGNMENT Fig 6 7 Valve Timing Marks...

Page 224: ...ts may be ad justed by use of the Burroughs Belt Tension Gauge Belt Tension Specifications are given in Section 6A ENGINE REMOVE AND INSTALL REMOVE 1 Disconnect battery cables at batterya Fig 6 8 6 C...

Page 225: ...g bolts two each side 0 20 Disconnect transmission filler tube support and starter wire harness shield from cylinder head 21 Remove two front motor mount to frame bracket bolts 22 Lower vehicle 230 Us...

Page 226: ...over 2 Lift up cover to disengage side clips 3 Remove retaining clips from cover REPLACE 1 Place cover in position and install three attach ing screws Tighten to 12 lb ft 2 Install two side clips TIMI...

Page 227: ...cessary to replace camshaft seal reinstall camshaft sprocket retaining bolt 7 Thread tool J 22261 2 into camshaft seal Fig 6 13 8 Tighten center bolt on tool J 22261 1 until seal is extracted REPLACE...

Page 228: ...mounting studs 9 Remove rocker arm cover to cylinder head gasket and clean gasket flanges REPLACE 1 Install new rocker arm cover gasket on cylinder head 2 Check all rocker arms for correct position o...

Page 229: ...shaft from the rear in rocker arm cover using caution not to damage bearing surfaces in rocker arm cover 2 Install thrust washer in rocker arm cover as shown Fig 6 16 3 Install retaining washer and bo...

Page 230: ...rocker arms and cover assembly HYDRAULIC LASH ADJUSTER RECONDITION NOTE Because of the important part hydraulic lash adjusters play in the operation of an engine and the close tolerances to which they...

Page 231: ...g but before proceeding to the next adjuster 7 Inspect adjuster body Both inner and outer surfaces of adjuster body should be inspected for scoring Adjuster assembly should be replaced if body is roug...

Page 232: ...from top with SAE 10 engine oil 2 Swing weight arm up out of the way raise ram and position adjuster into boss in center of tester cup 3 Adjust ram with weight arm clear of ram so that the pointer is...

Page 233: ...T HOLES is Jul PLASTIC INSTALLATION CAP SEAL INSTALLING TOOL INTAKE VALVE GUIDE SEAL r Fig 6 24 Valve Spring Removal Fig 6 25 Intake Valve Guide Seal Installation 2 Disconnect accelerator pedal cable...

Page 234: ...press the valve springs and remove valve keys Remove spring caps spring seats oil seals and springs 3 Remove valves from bottom of cylinder head and place them in a rack in their proper sequence so th...

Page 235: ...aming valve guide NOTE Valves are marked 001 003 or 005 with colored ink VALVES AND SEATS RECONDITION 1 Reface valves and seats as follows Valves should be ground on a special bench grinder designed s...

Page 236: ...ls and valve locks in cylinder head Check seals by placing vacuum cup of J 22330 over valve stem and cap squeeze vacuum cup to make sure no oil leaks past oil seal 3 Install cylinder head as previousl...

Page 237: ...belt upper front cover FRONT CRANKCASE COVER AND GASKET REMOVE AND REPLACE 1 Remove crankshaft timing belt sprocket as shown above 2 Remove four front oil pan to crankcase cover retaining bolts 3 Loo...

Page 238: ...6 Accessory Drive Housing Exploded View 7 Using new gasket installed over dowels Fig 6 35 and if necessary new seal reverse removal procedures tightening oil pan and crankcase cover bolts to 12 lb ft...

Page 239: ...on See Fig 6 12 6 Replace timing belt top front cover H0USING M0UNTING Fig 6 38 Housing Mounting Bolts OIL F I L T E R BY PASS V A L V E Fig 6 39 Oil Filter Bypass Valve OIL FILTER BY PASS VALVE REMOV...

Page 240: ...ing Bearing proper routing to prevent excessive binding when en gine is raised NOTE Before raising vehicle prop hood open at least 6 to insure adequate clearance between tim ing belt cover and inner h...

Page 241: ...s 5 Tighten transmission insulator to crossmember bolts to 30 lb ft 6 Replace flywheel cover and starter assembly 7 Lower vehicle Fig 6 44 Removing Rear Main Bearing Cap REAR MAIN BEARING CAP SIDE OIL...

Page 242: ...viewed from front of engine This will roll upper bearing shell out of engine R E P L A C E 1 Oil new upper bearing shell and insert plain unnotched end of shell between crankshaft and in dented or no...

Page 243: ...damage out of round and taper Fig 6 48 Plastigage in Place Fig 6 49 Measuring Plastigage REPLACE 1 Reassemble cap and rod with new bearings and check clearance with Plastigage as outlined below 2 Inst...

Page 244: ...as sembly by pushing out with knurled handle of long guide CONNECTING ROD AND PISTON DISASSEMBLE NOTE Use care at all times when handling and servicing connecting rods and pistons To prevent possible...

Page 245: ...loose with pin and bosses clean and dry NOTE Piston and pin must be at room tempera ture when checking fit and pin must be able to fall from piston by its own weight Fig 6 55 Piston pins are available...

Page 246: ...HONING OR BORING If a piston in excess of honed to effect a true bore 005 oversize is to be bored rather than To eliminate the possibility of honing taper into the cylinder full strokes of the hone s...

Page 247: ...and measurements recorded If there is excessive clearance between a cylinder bore and piston which was installed in that bore a new piston should be used New pistons are serviced in standard size and...

Page 248: ...ression rings are taper faced and also have either a step or a chamfer on the inside diameter of the bottom side The top compression ring is molyb denum filled which results in the center section of t...

Page 249: ...ke and exhaust mani fold as an assembly 7 Connect f u e l l i n e and vacuum l i n e s to carburetor 8 Install rocker arm cover CRANKSHAFT REMOVE AND REPLACE REMOVE 1 Remove engine from vehicle 2 Remo...

Page 250: ...om stand and mount new block on stand 19 Remove new piston and pin assemblies from new block and identify each according to cylinder from which it was removed This completes disassembly for block asse...

Page 251: ...xable Horsepower 36 0 H O R S E P O W E R A M U T O R Q U E Compression Engine Carburetor Ratio Horsepower Torque 250 1 Bbl 9 0 175 4800 240 2600 250 Q Jet 10 5 215 5200 255 3800 Compression Pressure...

Page 252: ...n Bearing Length 1 6 80 Rear 1 01 Clearance 0003 0020 Crankpin Diameter 2 00 Flywheel and Sprockets Flywheel Material Manual Cast Iron Automatic Stamped Steel No of Teeth 155 Starter Motor Drive No of...

Page 253: ...80 Q Jet 4 89 Diameter of Stem 34 Stem to Guide Clearance Intake 0016 0033 Exhaust 0021 0038 Valve Seat Angle Intake 30 Exhaust 45 Valve Face Angle Intake 29 Exhaust 44 Lubrication System Type of Lubr...

Page 254: ...ve Spring Compressor J 8087 Cylinder Bore Gauge J 8092 Camshaft Rear Bore Plug Installer J 8101 Valve Guide Cleaner J 8894 Adapter Bore Plug Installer J 9510 Piston Pin Remover and Installer Set 22230...

Page 255: ...Recondition 6 64 Piston Rings Replace 6 67 Crankshaft Remove and Replace 6 69 Fitted Block Assembly Replace 6 71 Specifications 6 76 Wrench Torque Specifications 6 76 Special Tools 6 80 G E N E R A L...

Page 256: ...r valve clearance VALVE MAIN All V 8 engines utilize the simple ball pivot type valve train consisting of the valve rocker arm push rod and valve lifter Rocker studs are pressed Into the cylinder head...

Page 257: ...ngine and in stall attaching screws and washers Tighten to 70 lb ft torque 7 Lower engine 8 Install frame to insulator bolt with lockwasher and plain washer and tighten to 50 lb ft weight from rear in...

Page 258: ...d terminals may contact the steering gear which could energize the starting motor if ground cable is not disconnected 2 Loosen rear insulator by removing crossmem ber to insulator bolts and raise rear...

Page 259: ...Install two crossmember to Insulator bolts and washers and tighten to 30 lb0 ft torque REAR INSULATOR 1 Remove two crossmember to insulator bolts 2 With suitable lifting equipment raise trans mission...

Page 260: ...er motor 14 Raise vehicle and drain crankcase 15 Disconnect gas tank lines at fuel pump 16 Disconnect exhaust pipes from manifolds 17 Disconnect starter wires 18 If equipped with automatic transmissio...

Page 261: ...ar by using long handled screwdriver NOTE Locks are used on front and rear pairs of bolts only 5 Remove manifold attaching bolts and remove manifold REPLACE 1 Thoroughly clean gasket surfaces of cylin...

Page 262: ...wire to thermogauge unit terminal 15 Install vacuum hoses connecting distributor vacuum advance unit to carburetor Care should be taken not to interchange advance and retard hoses 16 Install spark pl...

Page 263: ...ake manifold retaining O ring seal 2 Remove push rod cover 3 Remove rocker arm cover 4 Loosen rocker arm ball nut and move rocker arm off push rod 5 Remove push rod 6 Remove lifter Hydraulic valve lif...

Page 264: ...valve lifters This tank should be used only for valve lifters and should be kept covered when not In use All servicing should be done In an area removed from grinders or other sources of dust and fore...

Page 265: ...n galled or otherwise damaged 8 Inspect lifter plunger Using magnifying glass inspect check ball seat for defects Inspect outer surface of plunger for scratches or scores Small score marks with rough...

Page 266: ...ite resistance is 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...

Page 267: ...t all bolts NOTE Bolts are three different lengths When inserted in proper holes all bolts will project an equal distance from the head Do not use sealer of any kind on the threads 3 Tighten bolts eve...

Page 268: ...ONNECTOR WILL HAVE TO BE REMOVED BEFORE STRAIGHT EDGE CAN BE POSITIONED CORRECTLY 15 With valve seated slowly drive rocker arm stud into cylinder head until gauge projects about midway between end of...

Page 269: ...ean rocker arms and rocker arm balls and visually inspect for evidence of wear 9 Clean spark plugs as outlined in ELECTRICAL SECTION 10 Clean and inspect valve lifters VALVES AND SEATS RECONDITION 1 R...

Page 270: ...fit valve stem according to above limits Carefully ream valve guide using valve guide reamer J 5830 1 for 003 oversize stems and valve guide reamer J 6621 for 005 oversize stems Fig 6 92 For best resu...

Page 271: ...in cover seal by prying out of bore with a pry bar Fig 6 94 5 Install new seal with lip of seal inward using seal installer J 21147 6 Replace harmonic balancer 7 Install drive belts and adjust to prop...

Page 272: ...wels install bolts and nuts and tighten securely 19 Install four oil pan to timing chain cover screws and tighten to 12 lb ft torque 20 Install harmonic balancer retainer bolt with retainer and tighte...

Page 273: ...O ring seal between intake manifold and timing chain cover is retained and installed during assembly 10 Remove push rod cover 11 Loosen rocker arm ball retaining nuts so that rocker arms can be diseng...

Page 274: ...t over replacer adapter J 6173 3 Indexing notch in edge of bearing with pin on replacer adapter NOTE The notch in edge of bearing is used to properly position the bearing with respect to oil holes whe...

Page 275: ...ush rod cover 12 Install intake manifold and gasket Tighten bolts 40 lb ft torque NOTE O ring seal must be installed between in take manifold and timing chain cover before mani fold is securely positi...

Page 276: ...hten retaining bolts to 12 lb ft 3 Install left motor mount to cylinder Mock and tighten right motor mount to block bolts ALUMINUM COATED GASKET CEMENT G R O O V E 1 to 1W BOTH SIDES J Fig 6 102 Rear...

Page 277: ...gasket between pump and block Index drive shaft with pump drive gear shaft Install two attaching screws with lockwashers and tighten securely NOTE Removal and installation of pump does not affect igni...

Page 278: ...spring will be 60 psi pressure Engines with unplated gear will have 50 psi spring The 60 psi spring must not be used without cad mium plated gear J 7588 Fig 6 106 Forming New Seal in Cap CAUTION Do no...

Page 279: ...ng caps remove oil baffle To gain access to rear main remove oil pump in addition to oil baffle 3 Remove bearing cap of main bearing to be replaced 4 Make a tool for removing upper half of bear ing sh...

Page 280: ...T I N G ROD CAP ROD CAP V Fig 6 111 Crankshaft Positioned For Removal of No 1 and No 2 Connecting Rod Caps pin carrying bearing to be replaced straight down Fig 6 111 4 Remove bearing cap of bearing t...

Page 281: ...move connecting rod and piston assembly by pushing out with knurled handle of long guide Fig 6 113 REPLACE 1 Install connecting rod bolt guide set on con necting rod bolts with long handle guide on sa...

Page 282: ...d nuts in suitable solvent Reinstall cap on connecting rod to assure against subsequent mixing of caps and con necting rods 3 Carefully examine piston for rough or scored bearing surfaces cracks in sk...

Page 283: ...r for finish honing to give required pistonrto cylinder clearance specifications NOTE Honing or boring operation must be done under close supervision so that specified clear ance between pistons rings...

Page 284: ...y its own weight FITTING OVERSIZE PINS IN PISTONS AND CONNECTING ROD PIN BORES In case the standard size piston pin does not fit properly in the piston an oversize piston pin must be fitted Piston pin...

Page 285: ...ston Pin lower compression ring varies depending upon the engine See specifications Pg 6 Regardless of engine type always install com pression rings with the stamped markings toward the top of piston...

Page 286: ...nkshaft End Play toward front of engine Measure clearance between rear of connecting rod and crankpin Proper clear ance is 006 to 011 If clearance is outside these limits a new rod or rods is required...

Page 287: ...seal 10 Install fuel pump 11 Install harmonic balancer 12 Install oil baffle and oil baffle tube 13 Install oil pump drive shaft and oil pump assembly 14 Install engine oil pan 15 Install spark plugs...

Page 288: ...lifter gallery Fig 6 126 INSTALL NEW PLUGS The following plugs can be installed by driving into place using a flat piece of metal or hard wood bearing against the outer surface Camshaft plug water jac...

Page 289: ...rockets off end of cam shaft and crankshaft 10 Remove camshaft thrust plate 11 Remove distributor and high tension wires 12 Remove coil 13 Remove starter assembly 14 Remove intake manifold 15 Remove p...

Page 290: ...over 25 Remove oil pump assembly and drive shaft 26 Remove baffle and oil indicator tube extension 27 Remove crankshaft 28 Remove all connecting rod and piston assem blies 29 Remove connecting rods fr...

Page 291: ...y way cut out in camshaft sprocket 9 Position timing cover gasket over mounting studs and dowels on block 10 Install timing cover water pump fan and pulley Do not install stud nuts at this time 11 Sli...

Page 292: ...butor hold down clamp and spe cial bolt and tighten enough to hold distributor in place 23 Install coil 24 Cement new gasket to push rod cover and in stall push rod cover 25 Cement new gaskets to rock...

Page 293: ...2400 400 Tempest Q Jet 10 75 350 c 5000 445 3000 400 HO Tempest Q Jet 10 75 360 c 5100 445 3600 400 Ram Air Tempest Q Jet 10 75 360 c 5400 445 3800 400 Firebird 9 Jet 10 75 330 c 4800 430 3300 400 HO...

Page 294: ...to Groove 0015 005 Piston Pin Material Extruded SAE 1016 Steel Diameter 9802 Wall Thickness 38 Length 3 25 Fit in Piston 0005 0007 Fit in Rod Press Connecting Rod Material Arma Steel Weight oz 31 7 L...

Page 295: ...5 0 8 4 0 0 Reg Fuel 4 9 8 4 0 0 Prem Fuel and R A 5 0 7 GP 4 2 8 and H O 5 0 8 Diameter of Stem o 3 4 Stem to Guide Clearance Intake 0 0 1 6 0 0 3 3 Exhaust 0 0 2 1 0 0 3 8 Valve Seat Angle Intake 3...

Page 296: ...r Arm Material Stamped Steel Ratio 1 5 to 1 Rocker Arm Stud Standard Pressed in to Head G T O Firebird 400 GP 428 400 R A Screwed in to Head Lubrication System Type of Lubrication Main Bearings Pressu...

Page 297: ...S J 6173 Camshaft Bearing Remover and Replacer J 6384 Valve Spring Compressor Set J 6621 Valve Guide Reamer 005 O S J 6647 Piston Ring Compressor 350 J 6901 Piston Pin Remove and Replace Set J 7117 P...

Page 298: ...capacity for greater cooling demands A drain cock is located at inside lower left corner of radiator RADIATOR CAP A pressure vent cap is used on the radiator to allow a build up of 15 psi of pressure...

Page 299: ...the pump inlet from the radiator is the inlet from the heater core Located beneath the coolant outlet at the side of the rocker arm cover is the recirculation hose which connects to the inlet side of...

Page 300: ...point over a range of temperatures THERMOSTAT REMOVE AND REPLACE 1 Drain radiator level to below thermostat and remove water outlet assembly from rocker arm cover 6 cyl intake manifold 8 cyl 2 Remove...

Page 301: ...r hoses 4 On vehicles equipped with automatic transmis sion disconnect and plug transmission cooler lines 5 Remove fan shroud where applicable 6 Remove radiator assembly by lifting straight up NOTE Th...

Page 302: ...screws and lift radi ator and shroud out of vehicle REPLACE 1 R e p l a c e radiator by reversing the above procedure 2 Torque all mounting screws to 12 lb ft 3 Refill radiator with enough coolant to...

Page 303: ...ws are tight 4 Apply light grease or oil on gasket 5 Hand tighten filter on hollow oil filter connec tor until gasket contacts filter base then complete tightening with additional 2 3 turn of filter D...

Page 304: ...further 2 3 of a turn using J 22775 for convenience Do not over tighten 5 Lower vehicle 6 Remove old cartridge from engine compartment DRIVE BELTS F O R P O N T I A C TEMPEST FIREBIRD E N G I N E AND...

Page 305: ...3 Sq in Core Area 6 Cyl A C 480 Sq in Core Area 350 Std 480 Sq in Core Area 400 480 Sq in Thermostat 190 F Fan Diameter V 8 Std 19 in Fan Diameter 6 Cyl Std 17 5 8 in Fan Diameter Power Flex 19 in Fan...

Page 306: ...Enforcer Highway Patrol N K N L N L X A X A X A X A 252 256 26239 45 67 87 N A N M N M N M N N N N N L XB XB XB Turbo 266 N A N M N M N M N N N L XB XB XB Hydra 26240 50 90 N N XB XB Matic Police N M...

Page 307: ...6A 10 1968 PONTIAC SERVICE MANUAL Fig 6A 8 Radiator Usage Chart Firebird...

Page 308: ...ILENCER A combined air cleaner silencer and air pre heater 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 th...

Page 309: ...tle linkage adjustments A reference dimension of 1 9 16 between the bottom of the accelerator pedal roller and floor pan Fig 6B 4 should be used only as a check for bent bracket assemblies PONTIAC Wit...

Page 310: ...YL I BBL CARB ENGINE 6 CYL 4 BBL CARB ENGINE Fig 6B 4 Accelerator Linkage Tempest opening with accelerator fully depressed Adjust as necessary by removing cotter pin and turning trunnion to obtain the...

Page 311: ...k diaphragm assembly 3 Remove fast Idle cam attaching screw Then fast Idle cam and choke rod can be removed from upper choke lever by carefully rotating assembly upward and sliding end of rod out of u...

Page 312: ...d 2 Remove four air horn attaching screws Lift air horn straight up from bowl so as not to damage float Fig 6B 7 Place air horn inverted on flat surface 3 Remove float hinge pin and lift float from ai...

Page 313: ...MAIN METERING JET Fig 6B 10 Removing Main Metering Jet 3 Remove pump plunger from float bowl by pull ing straight upward Fig 6B 13 4 Remove pump return spring from bottom of pump well Fig 6B 14 NOTE D...

Page 314: ...mer cial carburetor cleaner Clean in clean solvasol or equivalent Plastic vacuum break diaphragm unit should not be immersed in any cleaner 2 After cleaning blow all passages and castings with compres...

Page 315: ...wnward with index finger 3 Install pump plunger assembly in bowl making sure not to curl rubber during installation 4 Attach pump link to pump plunger rod and throttle lever using two hair pin clips N...

Page 316: ...gasket inside fuel inlet nut filter relief spring filter element retaining in place with fuel inlet nut and gasket and tighten nut to 25 lb ft CHOKE LEVER TRIP LEVER i VACUUM BREAK CHOKE ROD IDLE SPE...

Page 317: ...as shown then carefully insert upper end of choke rod into upper choke lever Fig 6 B 2 1 The dog leg of rod must face towards idle mixture adjusting needle 9 Attach fast idle cam to throttle body asse...

Page 318: ...t of its travel The lower edge of rod should be even with top edge of hole in choke shaft lever for maximum rod length while the rod should just line up with hole for minimum rod length To adjust bend...

Page 319: ...OAT BOWL DISASSEMBLY Fig 6B 28 1 Remove air horn to float bowl gasket Gasket is slit next to metering rod lever so that it can be slid over lever for ease in removal CHOKE V A L V E __ VACUUM BREAK LE...

Page 320: ...ot be immersed in carburetor cleaner However the air horn which has the plastic vent valve guide and cranking enrichment valve will withstand normal cleaning in carburetor cleaner Make sure the cleane...

Page 321: ...nd faces outward away from throttle bore 9 Install end of power piston actuating rod into groove on side of power piston Then install power piston spring power piston metering rod assembly and actuati...

Page 322: ...crews and stake securely 3 Install vacuum break diaphragm and plunger into cavity at side of air horn With choke valve in the open position slide eyelit of plunger rod over end of vacuum break lever o...

Page 323: ...of the fast idle cam and hold firmly against the rise to the high step 2 Rotate choke valve towards direction of closed choke by applying force to choke coil lever 3 Bend choke rod at point shown to g...

Page 324: ...adjust 5 Connect coil rod to choke lever and install re taining clip FAST IDLE ADJUSTMENT ON CAR 1 Warm up engine 2 Place fast idle cam follower on top step of fast idle cam 3 With cam follower held a...

Page 325: ...contamination as carburetor is disassembled The following is a step by step sequence by which the Rochester 2GV carburetor may be completely disassembled and reassembled Adjustments may be made and v...

Page 326: ...and shaft 10 The cover gasket may now be removed 11 Remove two choke valve attaching screws then remove choke valve 12 Remove choke valve shaft from bowl cover DISASSEMBLY OF BOWL 1 Remove pump inlet...

Page 327: ...6B 45 through 6B 49 dry with compressed air and blow off all parts until they are dry CAUTION Do not pass drills or wires through calibrated jets or passages as they may en large orifices and seriousl...

Page 328: ...sembly must be replaced 6 Use new gaskets in reassembly ASSEMBLY OF THROTTLE BODY 1 Install idle screw in throttle lever if removed 2 Screw idle mixture adjusting needles and springs into throttle bod...

Page 329: ...n seat carefully position float and insert hinge pin 8 Check float level and drop adjustments FLOAT LEVEL ADJUSTMENT Fig 6B 50 With air horn inverted gasket in place and needle seated there should be...

Page 330: ...ouch the end of gauge Measurement should be 1 11 32 1 32 Bend pump rod to adjust 1 Install fast idle link and fast idle cam as an assembly and install fast idle lever on other end of fast idle link Pl...

Page 331: ...7028263 400 428 M T A B 7028264 400 400 H O A T F 7028265 400 M T F 7028266 350 A T A F 7028267 400 H O 428 H O M T A B 7028268 400 400 H O A T A 428 428 H O A T B 7028269 350 M T A F 7028271 400 H O...

Page 332: ...ri Four long screws three short screws two counter sunk screws 7 Remove air horn by lifting straight up Air horn gasket should remain on bowl for removal later CAUTION Care must be taken not to bend t...

Page 333: ...mbly from float bowl NOTE If further disassembly of choke is neces sary spread the retaining ears on bracket next to vacuum break assembly then remove vacuum break assembly from bracket 14 Remove fast...

Page 334: ...operly located over dowels on float bowl then install throttle body to bowl screws and tighten evenly and securely Place carburetor on proper holding fixture 3 Install fuel inlet filter spring filter...

Page 335: ...justment 17 Install pump plunger in pump well AIR HORN ASSEMBLY Fig 6B 59 1 Install the following if removed a Install pump lever and retain with roll pin b Install choke shaft choke valve and two at...

Page 336: ...per lever with spring clip 7 Install vacuum break rod and clip PRIMARY THROTTLE AFTER SCREW MAKES VALVE CLOSED CONTACT ON L E V E R TURN SCREW IN 3 TURNS TO ADJUST Fig 6B 70 Choke Rod Adjustment PUMP...

Page 337: ...K SHOULD BE IN CENTER OF SLOT Fig 6B 74 Secondary Opening Adjustment FAST IDLE ADJUSTMENT Fig 6B 69 With primary throttle valves completely closed and cam follower over high step of fast idle cam turn...

Page 338: ...hould be in the center of the slot in the secondary lever Bend tang on secondary lever if necessary to adjust ROD IN TOP OF SLOT CHOKE VALVE WIDE OPEN SPECIFIED CLEARANCE BETWEEN FRONT EDGE OF VALVE A...

Page 339: ...0 To 7028062 350 AT 9 16 1 3 4 1 11 32 085 150 180 Choke 7028066 400 MT 9 16 1 3 4 1 11 32 085 170 180 Adjust 7028071 350 MT 160 ment Rochester 4 MV 7028260 250 AT 5 16 085 245 7028261 250 MT 5 16 085...

Page 340: ...ottle and choke wide open Crank engine through at least five compression strokes to obtain highest possible reading No cyl inder should be less than 80 of the highest cylinder see examples Excessive v...

Page 341: ...es Installation of plugs with insufficient torque to fully seat the gasket Installation of the plugs using excessive torque which changes gap settings Installation of plugs on dirty gasket seal Instal...

Page 342: ...ing area loose or broken carriers cracked or bulged cases dirt and acid electrolyte leakage and low electrolyte level Fill cells to proper level with distilled water or water passed through a deminera...

Page 343: ...UNLOADER OPERATION AND ADJUSTMENT The specified choke setting provides ideal choke operation in all climates No seasonal changes are necessary For setting see ENGINE FUEL sec tion 6B Choke linkage and...

Page 344: ...ress or plug hot idle compensator valve while adjusting all engines so equipped 6 cyl 1 bbl with A C and 6 cyl 4 bbl only Follow procedures outlined in EXHAUST EMIS SIONS SECTION and adjust idle speed...

Page 345: ...indicate need for adjustment STEERING GEAR See that steering operates nor mally and that steering wheel does not have ex cessive play Also observe for alignment of steering wheel pull wander or other...

Page 346: ...p items should receive careful and thorough attention every 12 months or 12 000 miles Adherence to these items will assure that exhaust emissions are kept to the desired level Essential services inclu...

Page 347: ...justment Fig 6D 2 3 With idle stop solenoid disconnected adjust idle speed screw on carburetor to attain the lower sole noid inactive idle speed Do not re adjust carburetor mixture screws Fig 6D 2 Idl...

Page 348: ...tang on throttle lever of one barrel manual transmission carburetor 2 Adjust f a s t Idle s c r e w on f o u r barrel carburetor NOTE Curb idle on auto matic transmission cars to be set in drive with...

Page 349: ......

Page 350: ...ead to the distributor at the coil If the voltage drop for any one of the above three checks exceeds 0 2 volt excessive resistance is indicated in that portion of the cranking circuit being checked Lo...

Page 351: ...fully remove cover CA UTION Terminal studs have welded lead con nections therefore be extremely careful not to twist during removal of nuts If solenoid contacts are slightly burned or dirty contacts s...

Page 352: ...ed with a clean cloth If the commutator is dirty it may be cleaned with No 00 sandpaper Never use emery cloth to clean commutator 1 Open The most likely place for an open to occur is at the commutator...

Page 353: ...d of shunt coils Fig 6 E 6 Disconnect shunt coil grounds before check is made If lamp does not light the shunt coil is open and must be replaced FIELD FRAME GROUND v fflflR N CONNECTOR f STRAPS i SHUN...

Page 354: ...on shaft with shoul der next to snap ring Fig 6 E 8 f Place armature flat on work bench and po sition retainer and thrust collar next to snap ring Then using two pairs of pliers at same time one pair...

Page 355: ...ion Clearance 3 Flash a jumper lead momentarily from the solenoid motor terminal to the solenoid frame This will shift the pinion into cranking position and it will remain so until the battery is disc...

Page 356: ...rator 5 When connecting booster battery make certain to connect negative battery terminals together and positive battery terminals together 6 When connecting charger to battery connect charger positiv...

Page 357: ...out spinning rotor may result in flat spots on slip rings causing brush noise Slip rings which are rough or out of round should be trued in lathe to 002 maximum indicator read ing Remove only enough m...

Page 358: ...st equipment due to low resistance of windings However if all other electrical checks are normal and alternator fails to supply rated output shorted stator windings are indicated BRUSH HOLDER ASSEMBLY...

Page 359: ...othpick to protrude through hole in end frame and install stator lead to strap attaching nut and washer SLIP RING END FRAME BEARING AND SEAL 1 With stator removed press out bearing and seal with tube...

Page 360: ...he diode is defective When checking a good diode the lamp will light in only one of two checks Diodes which fail the electrical tests should be replaced If diodes must be replaced 1 With stator remove...

Page 361: ...ink assembly noting stack up of parts shown in Fig 6E 20 5 Attach condenser lead to heat sink with washer and screws Be sure insulating washer is between heat sink and end frame 6 Install stator and c...

Page 362: ...breaker lever spring and point alignment preadjusted at factory Only point opening requires adjusting after replacement ADJUSTING POINT OPENING Loosen distributor clamp bolt and turn distributor unti...

Page 363: ...nce position since the dwell angle may vary with vacuum advance on these types of distributors The procedure for replacing contact set and ad justing point opening is covered under Checks and Adjustme...

Page 364: ...stributor cap 7 Adjust timing and then tighten distributor clamp nut 8 Attach vacuum line s to distributor DISTRIBUTOR 8 CYLINDER ENGINE PERIODIC SERVICE A permanent lubricant reservoir is built into...

Page 365: ...an be set in same position when distribu tor is being installed NOTE Always set distributor in upright position so oil from distributor shaft will not run out onto breaker plate and points INSPECT Wit...

Page 366: ...ear and washer off shaft 5 Pull shaft and cam weight base assembly from the housing 6 Remove contact set assembly 7 Remove condenser hold down screw condenser and bracket from the breaker plate 8 Remo...

Page 367: ...ump drive shaft and drive gear on camshaft Dis tributor and rotor will be positioned as shown in Fig 6E 27 when properly installed with No 1 piston in firing position Kill DISTRIBUTOR HOUSING Fig 6E 2...

Page 368: ...screw and rotate distributor until power timing light shows that the proper mark on the cover lines up with the mark on the harmonic balancer Tighten distributor clamp screw The timing specifications...

Page 369: ...START I G N 1 O N OR RUN ACCESSORY Fig 6E 32 Tempest Ignition Switch SOLENOID SOLENOID SOLENOID ACCESSORY ACCESSORY ACCESSORY J 1 W B A T T E R Y G R O U N D I 4pU BATTERY GROUND j GROUNDI W BATTERY W...

Page 370: ...e bulb check circuit which is connected to the ignition terminal never attempt to jumper the cranking motor sole noid with the ignition switch in the OFF position as this will result in burning of the...

Page 371: ...me make and number or heat range Use a round feeler gauge to adjust the spark plug gaps to 035 Fig 6E 35 Test spark plugs following instructions fur nished with Spark Plug Cleaner and Indicator Fig 6E...

Page 372: ...ENGINE ELECTRICAL 6E 23 J 9782 J 7607 J 6788 01 J 22087 Fig 6E 37 Special Tools...

Page 373: ...5 1825 2 2 2 6 55 32 660 50 1660 2 2 2 6 REGULATOR MODEL Trans istor Normal Range 1119511 13 5 16V 1116379 14 3 15V 1119511 13 5 16V 1116370 13 9 14 7 1116379 14 3 15V 1119515 13 5 16V 1119515 13 5 16...

Page 374: ...6 4 6 4 6 4 6 TEMPEST AND FIREBIRD MODEL 1 1 1 0 4 3 0 1110431 1111281 1111282 1111447 1111272 1111270 1111449 ROTATION VIEWED FROM TOP C C C C C C C C C C C C C C DWELL SET TO 32 32 30 30 30 30 30 30...

Page 375: ......

Page 376: ...and requires no lubrication CLUTCH PEDAL ADJUSTMENT Figs 7 3 7 4 and 7 5 Wear on the clutch parts necessitates occasional lash adjustment No other adjustment is made Lash adjustment should be made as...

Page 377: ...sion See TRANSMISSION SECTION Exercise care to avoid damaging transmission front bearing retainer re lease bearing support when transmission is pulled back to free main drive clutch gear from flywheel...

Page 378: ...plate with new assembly 2 Inspect pressure plate and cover assembly to see that it is free of oil and grease Check pressure plate for scores or cracked surface NOTE Servicing of clutch driven plate o...

Page 379: ...pressure plate to flywheel bolts one at a time until snug then tighten to 25 lb fte torque Remove spare main drive gear used to align clutch disc 3 Lubricate surface of release fork fingers which con...

Page 380: ...tment under Periodic Service NOTE If interference is encountered with the clutch fully engaging the transmission shift link age should be adjusted as outlined in sections 7A thru 7D because the shift...

Page 381: ...lywheel 3 Remove all b u r r s and rough s p o t s from flywheel INSTALLING RING GEAR ON FLYWHEEL 1 Support flywheel in level position with cylinder block side facing up 2 Support ring gear on metal s...

Page 382: ...evidence of leakage leak should be corrected and lubrication added as needed Refill capacity is 2 3 4 pints Use SAE 90 Multi purpose Gear Lubricant No special additive to this lubrication is required...

Page 383: ...o 2 upper transmission to flywheel housing bolts and insert guide pins 7 Remove two 2 lower transmission to flywheel housing attaching bolts 8 Slide transmission straight back on guide pins until the...

Page 384: ...THREE SPEED DEARBORN MANUAL TRANSMISSION 7 A 3 T R U N N I O N Fig 7 A 2 Pontiac Floor Shift Controls Fig 7 A 3 Tempest Floor Shift Controls...

Page 385: ...nchronizer Assembly 34 Drain Plug 35 Drive Gear Rear Bearing Retaining Snap Ring 36 Drive Gear Rear Bearing to Shaft Snap Ring 37 Drive Gear Rear Bearing 38 Speedometer Drive Gear 39 Front Bearing to...

Page 386: ...THREE SPEED DEARBORN MANUAL TRANSMISSION 7 A 5 Fig 7 A 5 Exploded View of Transmission...

Page 387: ...ring retainer and gasket 3 Remove access cover and gasket 4 Remove extension housing and gasket 10 Using brass drift drive 2nd and 3rd shift rail and welch plug out front of case 11 Using countershaft...

Page 388: ...tput shaft and thread it into J 21774 1 until bearing becomes free of output shaft 18 Remove bearing and tool 19 Slide input shaft forward until input gear rests against the case 20 Remove shift forks...

Page 389: ...t blocking ring Fig 7A 14 2 Remove synchronizer insert retaining spring T T ff 11 Fig 7A 12 Pressing input Shaft Out of Bearing I Fig 7A 13 Installing Input Shaft Bearing 3 Remove 2nd and 3rd gear syn...

Page 390: ...g ends cover the same slots as does the other spring NOTE Do not stagger the springs 10 Place a synchronizer blocking ring on each end of the synchronizer sleeve 11 Lubricate main shaft splines and ma...

Page 391: ...t shaft and bearing through the top of the case into the bore in the front of the case Install the large snap ring on the bearing 5 Position the mainshaft assembly in the case 6 Install the second and...

Page 392: ...ER Fig 7A 18 Synchronizer Insert Spring Installation Fig 7A 21 Exploded View of Countergear Fig 7A 19 Installing Reverse Synchronizer Hub R E V E R S E I D L E R G E A R T H R U S T W A S H E R R O L...

Page 393: ...he input shaft 19 Tap the input shaft bearing into place in the case while holding the main shaft to prevent the roller bearings from dropping out 20 Install the front bearing retainer and new gasket...

Page 394: ...est or Firebird three speed manual Dearborn transmission A number derived from the vehicle identification number is also stamped on the transmission case as shown in Fig 7A 25 GEAR RATIOS First Speed...

Page 395: ...Jam Nuts 30 Clamp Screws 20 S P E C I A L T O O L S J 6403 01 J 4830 02 J 3049 Fig 7A 26 Special Tools J 3049 Shift Rail Rotating Pliers J 8614 1 Companion Flange Holding Tool J 4830 02 Extension Hous...

Page 396: ...er engine gear ratios are 2 54 1 in first 1 50 1 in second 1 00 1 in high and 2 63 1in reverse PERIODIC SERVICE TRANSMISSION No periodic service of the transmission is re quired except checking for le...

Page 397: ...with cleaning solvent and in spect for damage 4 Inspect propeller shaft yoke for nicks burrs or scratches which would cut new seal or cause seal to leak or damage bushing 5 Coat new seal with sealing...

Page 398: ...inspection or replacement of parts in transmission side cover assembly but cover itself must be removed from transmission case Fig 7B 8 1 Loosen side cover bolts to allow transmission fluid to drain...

Page 399: ...connect speedometer cable 2 D i s c o n n e c t shift c o n t r o l rods f r o m transmission 3 Scribe a mark on companion flange and shaft yoke to assure proper reassembly and remove propeller shaft...

Page 400: ...TRANSMISSION 7 B 5 GAGE PIN 250 249 DIA VIEW B Fig 7B 4 Firebird Floor Shift Controls J 6 4 0 3 2 J 6403 1 Mi BUSHING J 4 8 3 0 0 2 J 2619 Fig 7B 5 Installing Extension Housing Seal Fig 7B 6 Removing...

Page 401: ...rd speed block ing ring from inside of case and remove 14 bearing rollers from mainshaft drive gear 10 Using snap ring pliers expand snap ring at front of extension housing which retains extension hou...

Page 402: ...hronizer assembly and second speed gear _ _ i Fig 7B 11 Removing Mainshaft CLEANING AND INSPECTION 1 Check synchronizer hubs sliding keys and springs and if necessary replace NOTE The synchronizer hub...

Page 403: ...rear case faces for burrs and if present remove with a fine mill file 3 Check and clean magnet in bottom of trans mission case BEARING ROLLERS All main drive gear and countergear bearing Fig 7B 14 Rem...

Page 404: ...s 27 23 Countergear 24 Countergear Bearing Rollers 27 25 Thrust Washer Rear 26 Countershaft 27 Woodruff Key 28 Reverse Idler Gear 29 Reverse Idler Gear Snap Ring 30 Reverse Idler Shaft 31 Woodruff Key...

Page 405: ...ear 6 Install second third synchronizer sleeve Fig 7B 15 COUNTERGEAR ASSEMBLE 1 Install countershaft alignment tool J 22246 2 From each end of countergear install 27 bear ing rollers and spacer Fig 7B...

Page 406: ...over front of mainshaft 8 Using heavy grease install extension housing to case gasket Fig 7B 21 Installing Front Bearing Retainer Oil Seal MAKE CERTAIN NOTCHES IN BLOCKING RING ALIGN WITH KEY IN SYNC...

Page 407: ...per TRANSMISSION INSTALL IN VEHICLE 1 Install guide pin in upper right transmission to flywheel housing bolt hole for alignment and place transmission on guide pin Rotate transmission as necessary to...

Page 408: ...gh an adapter Fig 7B 26 SPECIFICATIONS TRANSMISSION IDENTIFICATION An identifying code is marked in yellow paint on all three speed manual transmissions This code con sists of two letters 2 inches hig...

Page 409: ...J6403 01 1 J4830 02 3 J22246 J 1126 Aligning Studs J 6403 01 Extension Housing Bushing and Oil Seal Installer J 2619 Slide Hammer J 21858 Adapter Axle Shaft Bearing Remover J 4830 02 Extension Housing...

Page 410: ...the Three Speed Saginaw Manual Transmission Section Section 7B PERIODIC SERVICE REFER TO SECTION 7B ON CAR ADJUSTMENTS SHIFT LINKAGE ADJUSTMENT Fig 7C 1 7C 2 1 Position selector lever in neutral posit...

Page 411: ...st and 2nd shifter shaft opening NOTE Detent cams are not interchangeable 3 Install pivot retainer C ring to pivot shaft and hook spring into notches in detent cam spring tangs 4 Install lst 2nd and 3...

Page 412: ...hift Linkage 10 Remove filler plug and add 3 1 2 pints of SAE 80 or 90 multi purpose gear lubricant MAJOR REPAIRS TRANSMISSION REMOVE REFER TO SECTION 7B TRANSMISSION DISASSEMBLE 1 Drain lubricant 2 R...

Page 413: ...35 36 37 38 39 40 41 Fig 7 C 4 Saginaw Four Speed Transmission 1 Main Drive Gear 2 Front Bearing Retainer 3 Bearing Roller 4 Case 5 Fourth Speed Blocking Ring 6 Third and Fourth Synchronizer Snap Rin...

Page 414: ...Use a long drift or punch through the front bearing case bore and drive the reverse idler shaft and woodruff key through rear of the case Fig 7C 9 12 Remove 3rd and 4th synchronizer snap ring Fig 7C...

Page 415: ...d of mainshaft Fig 7 C 1 2 CLEANING AND INSPECTION REFER TO SECTION 7B TRANSMISSION ASSEMBLE MAINSHAFT ASSEMBLE Turn the front of the mainshaft upward and Install the following components REARWARD END...

Page 416: ...rear bearing onto mainshaft Fig 7C 15 4 Install 3rd and 4th synchronizer snap ring Both synchronizer snap rings are the same 5 Turn the rear of the mainshaft upward and in stall second speed gear with...

Page 417: ...in place Fig 7C 16 6 Assemble fourth speed blocking ring on main drive gear 7 Pilot main drive gear and fourth speed blocking ring over front of mainshaft CAUTION Make certain notches in blocking rin...

Page 418: ...LOWED BY T H E LAST 8 DIGITS OF CAR S E R I A L NUMBER Fig 7C 18 Vehicle Identification Number Location An identifying code is marked in yellow paint on all four speed manual transmissions This code c...

Page 419: ......

Page 420: ...he Saginaw 4 speed in that the reverse lever on the Muncie is mounted in the extension housing where on the Sagi naw it is mounted in the side cover PERIODIC SERVICE TRANSMISSION No periodic service o...

Page 421: ...l e to speedometer driven gear and sleeve assembly TRANSMISSION EXTENSION OIL SEAL REMOVE AND INSTALL To inspect or replace the rear extension oil seal it is necessary to remove the propeller shaft as...

Page 422: ...ft Controls straight into bore of case extension with J 5154 A Fig 7D 5 CAUTION Do not excessively force the seal against the seat in the extension 7 Install propeller shaft assembly by reversing step...

Page 423: ...w transmission to drain 4 Remove transmission side cover assembly from transmission case Fig 7D 6 5 Remove outer shifter lever nuts lockwashers and flat washers Pull levers from shafts 6 Remove both s...

Page 424: ...n detent cam to allow forks to fully seat into position 4 Install outer shift levers flat washers lock washers and nuts torquing to 30 lb ft 5 Shift 1 2 shifter lever into second speed for ward positi...

Page 425: ...dler Front Thrust Washer Tanged 37 Reverse Idler Gear Front 38 Reverse Idler Gear Rear 39 Flat Thrust Washer 40o Reverse Idler Shaft 41 Reverse Idler Shaft Roll Pin 42 Reverse Shifter Shaft Lock Pin 4...

Page 426: ...1126 in these holes NOTE The use of two aligning studs during this operation will support the transmission and pre vent damage to the clutch disc through springing 7 Remove the two lower transmission...

Page 427: ...ge from main drive gear and remove fourth speed synchronizing ring 12 Lift the front reverse idler gear and thrust washer from case 13 With soft hammer tap main drive gear down from front bearing as s...

Page 428: ...xtension removed from transmis sion the reverse shifter shaft lock pin will already be r e m o v e d see step 5 under Transmission Disassemble Fig 7D 16 Pressing Mainshaft from First and Second Speed...

Page 429: ...ng is slightly below counterbore for oil seal 4 Coat I D of bushing with transmission oil new seal with sealing compound and start straight into bore of case extension Using installer J 5154 A tap sea...

Page 430: ...RING G R O O V E 1 Fig 7D 20 Installing Rear Bearing 5 Choose the correct selective fit snap ring 087 090 093 or 096 and install it in the groove in mainshaft behind rear bearing With prop er ring max...

Page 431: ...thrust washers in place retaining them with heavy grease and making sure the tangs are resting in the notches of the case 2 Set countergear in place in bottom of trans mission case making sure that t...

Page 432: ...of case tap rear bearing retainer into position with a soft hammer Vv v CLUTCH KEY NOTCH IN SYNCHRONIZING RING Fig 7D 25 Installing Mainshaft Assy 14 From rear of the case insert the rear re verse idl...

Page 433: ...in a raised position 2 Move transmission forward until extension bracket studs engage holes in cross member sup port and main drive gear shaft enters clutch housing Care should be taken to make certai...

Page 434: ...rth 1 00 1 00 Reverse 2 59 2 27 Lubrication Capacity 2 1 2 pints STAMP V E H I C L E IDENTIFICATION NUMBER CONSISTING O F T H E FIGURE 2 F O L L O W E D BY T H E LAST 8 DIGITS OF CAR S E R I A L NUMBE...

Page 435: ...ft Lever to Shifter Shaft Nuts 30 Transmission Filler Plug 30 Lever and Bracket Support to Extension Bolts 30 Lever and Bracket Assembly to Support Bolt Upper 50 Lever and Bracket Assembly to Support...

Page 436: ...mp Body and Cover 7E 30 Assembly of Oil Pump 7E 32 Forward Clutch Disassembly of Forward Clutch 7E 32 Inspection of Forward Clutch 7E 33 SUBJECT PAGE Assembly of Forward Clutch 7E 34 Direct Clutch and...

Page 437: ...hecking the oil level to ensure against an overfill see Checking Procedure page 7E 4 Transmission fluid should be changed every 24 000 miles or 24 months When the car is in heavy duty service police t...

Page 438: ...ASSY TURBINE STATOR mM Sm mm m ROLLER f W iW t CLUTCH wK miMi l m it OUTPUT SHAFT SPEEDOMETER DRIVE GEAR V v SPEEDOMETER DRIVEN GEAR R E A R INTERNAL GEAR STATOR SHAFT TURBINE SHAFT 1 SUN GEAR SUN GE...

Page 439: ...d level should be to the FULL mark with transmission at normal operating temperature 180 190 F With warm fluid room temp the level should be approximately 1 4 below the ADD mark NOTE In checking the o...

Page 440: ...OR TO PARK POSITION REMOVE ADJUSTING GAGE STEERING COLUMN ADJUSTING GAGE NEUTRALIZER SWITCH TRANSMISSION SELECTOR LEVER STEERING COLUMN VIEW SHOWING SWITCH INSTALLATION VERTICAL OF STEERING COLUMN ADJ...

Page 441: ...E ENGINE Move manual control lever through each range 2 Immediately check fluid level with selector lever in Park engine running and vehicle on L E V E L surface At this point when a reading is made f...

Page 442: ...Gearshift Controls Column Firebird In all 1967 and earlier model automatic trans missions use either DEXRON automatic transmis sion fluid or Type A automatic transmission fluid identified by the mark...

Page 443: ...ix new gasket to bottom pan with petrolatum 7 Install bottom pan with attaching screws and torque to 12 lb ft 8 Pour approximately 7 1 2 pints of fluid into the transmission If the valve body has also...

Page 444: ...T O PARK POSITION R E M O V E A D J U S T I N G G A G E TRANSMISSION S E L E C T O R LEVER NUT C A B L E ASSEMBLY A D J U S T V I E W A ASSEMBLED Fig 7 E 7 Gearshift Controls Console G T O 2 Compress...

Page 445: ...LED ROTATE TRANSMISSION LEVER CLOCKWISE TO PARK POSITION ADJUST PIN TO THIS DIMENSION PRIOR TO INSTALLATION OF CABLE Fig 7E 8 Gearshift Controls Console Firebird 3 Remove control valve body attaching...

Page 446: ...tor valve from case INSTALLATION Installation of the modulator assembly and modula tor valve is the reverse of the removal Use a new O ring seal on the modulator assembly Adjust oil level PARKING LINK...

Page 447: ...mounting bolts 11 Raise transmission to its normal position slide rearward from engine and lower it away from car CAUTION When lowering transmission keep rear of transmission lower than front so as no...

Page 448: ...from case 5 Remove bottom pan attaching screws bottom pan and bottom pan gasket Discard gasket Fig 7E 15 SB mmmm M O D U L A T O R O RING SEAL VACUUM MODULATOR mi l M M mm mm Fig 7E 13 Removing Gover...

Page 449: ...ly and gover nor pipes Fig 7E 19 CAUTION Do not drop manual valve 1 DETENT ROLLER AND SPRING ASSEMBLY Fig 7E 18 Removing Detent Roller and Spring Assembly 4 Remove governor pipes from control valve as...

Page 450: ...etween the steps the medium pin identified by 2 rings should be used TORQUE WRENCH J 21370 6 P H I J 21370 5 illijF Fig 7E 22 Checking Rear Band Pin c If both steps are above the gauge surface the sho...

Page 451: ...ssary to replace pry rear oil seal from extension housing Fig 7E 27 2 Remove extension housing to case attaching bolts 3 Remove extension housing and extension housing to case gasket Fig 7E 28 4 Make...

Page 452: ...097 Brown 104 108 Green 115 119 Black 126 130 Purple DIAL INDICATOR J 8 0 0 1 Fig 7E 30 Removing Front Seal NOTE An oil soaked washer may tend to dis color so it will be necessary to measure washer fo...

Page 453: ...a Unthread jam nut holding detent lever to manual shaft b Remove manual shaft retaining pin from case Fig 7E 34 Fig 7E 34 Removing Manual Shaft Retaining Pin from Case CA UTION Do not lose jam nut as...

Page 454: ...front band Fig 7E 41 9 Remove sun gear shaft Fig 7E 42 Fig 7E 37 Removing Parking Pawl Return Spring Check Rear End Play As Follows a Install J 21904 into an extension housing at taching bolt hole Fig...

Page 455: ...Side 3 098 102 1 Tab O D 4 106 110 2 Tabs O D 5 114 118 3 Tabs O D 6 10 Remove case center support to case bolt Fig 7E 44 11 Remove intermediate clutch backing plate to case snap ring 12 Remove inter...

Page 456: ...wn in hole in work bench or holding fix tures J 6116 and J 21364 17 Remove rear unit selective washer from transmission case Fig 7E 48 18 Remove rear band assembly Fig 7E 49 B A C K I N G PLATE C O M...

Page 457: ...emove output shaft H 5 H H ROLLER C L U T C H 4 Fig 7E 50 Removing Case Center Support Assembly NOTE If replacement of drive speedo gear is necessary remove in following manner a Install speedo gear r...

Page 458: ...gear and mainshaft Fig 7E 57 NOTE Do not drop bearings 13 Remove rear internal gear to sun gear thrust bearing and two 2 races 14 If necessary remove rear internal gear to mainshaft snap ring to remov...

Page 459: ...oving Rear Internal Gear to Mainshaft Snap Ring and springs Governor weights are interchangeable from side to side and need not be identified Fig 7E 59 2 Remove governor valve from governor sleeve Be...

Page 460: ...r in the field a gov ernor driven gear and replacement pins are available for service use The service package contains a nylon driven gear two governor weight retaining pins and one governor gear reta...

Page 461: ...ssemblies for free operation on pins and governor valve for free move ment in governor sleeve INSPECTION OF FRONT SERVO 1 Inspect servo pin for damage ACCUMULATOR PISTON 2 Inspect servo piston for dam...

Page 462: ...retaining ring Fig 7E 64 4 Remove front accumulator piston and spring Fig 7C 65 5 From the top right hand bore remove the 1 2 valve train as follows a All models except PA and PC Remove retaining pin...

Page 463: ...g 7E 67 1 Inspect all valves for scoring cracks and free movement of their respective bore 1 Manual Valve 2 Retaining Pin 3 Bore Plug 4 Detent Valve 5 Detent Regulator Valve 6 Spacer 7 Detent Regulato...

Page 464: ...t PB and PT models 12 Install 3 2 spring spacer bore plug hole out and retaining pin Except PB and PT models 13 In next bore up install 2 3 valve stem end out and 3 2 intermediate spring 14 Install 2...

Page 465: ...r other damage 8 Remove retaining pin and bore plug from pres sure regulator bore Fig 7E 72 9 Remove hook type oil rings from pump cover 2 Place pump gears in pump and check pump body face to gear fac...

Page 466: ...O COOLER LINE MODULATOR OR INTERMEDIATE DRIVE Fig 7E 75 Pump Body O i l Passages 10 Check for scores or chips in pressure regu lator bore 11 Check that all passages are open and not inter connected F...

Page 467: ...taining snap ring 7 Install pressure regulator valve bore plug and retaining pin into opposite end of bore 8 Install previously selected front unit selective 1 m thrust washer fiber over pump cover de...

Page 468: ...retainer and sixteen 16 clutch release springs 8 Remove forward clutch piston Fig 7E 80 Removing Turbine Shaft from Forward Clutch Housing J 4670 RING J 8765 p i p lir i SPRING RETAINER Fig 7E 81 Rem...

Page 469: ...t ground bushing journals for damage d Inspect shaft for cracks or distortion NOTE Turbine shaft and clutch housing are serviced separately Shaft may be removed from housing by using a suitable size b...

Page 470: ...kets in piston 5 Place spring retainer and snap ring on springs 6 Compress springs using clutch compressor tools J 4670 J 6129 and J 8765 and install snap ring 7 If removed install turbine shaft in fo...

Page 471: ...ry sleeve and air check clutch operation Fig 7E 88 DIRECT CLUTCH AND INTERMEDIATE SPRAG DISASSEMBLY OF DIRECT CLUTCH AND INTERMEDIATE SPRAG 1 Remove intermediate sprag retainer snap ring and retainer...

Page 472: ...rag 2 Inspect sprag bushings for wear or distortion 3 Inspect inner and outer races for scratches or wear 4 Inspect clutch housing for cracks wear proper opening of oil passages or wear on clutch plat...

Page 473: ...7E 96 Installing Direct Clutch Piston Outer Seal The direct clutch piston can be identified by the ball check installed in the casting Fig 7E 99 4 Place seal protectors tools J 21362 Inner and J 2140...

Page 474: ...acking plate retaining snap ring Fig 7E 102 11 Turn unit over and install one spring bushing cup side up over inner race 12 Install sprag assembly into outer race 13 With ridge or shoulder on inner ca...

Page 475: ...ainst the inner race on the center support CLOCKWISE rotation allows the reaction carrier to over run the rollers and rotate freely Fig 7E 104 Correct Sprag Clutch Rotation Fig 7E 105 Installing Inter...

Page 476: ...STON SNAP RING OIL SEAL RINGS SPRING RETAINER Fig 7E 109 Exploded View of Center Support 2 Inspect bushing for scoring wear or galling If replacement is necessary proceed as follows a Using tool J 214...

Page 477: ...ing over springs 5 Using clutch spring compressor J 4670 and J 6129 compress springs and install snap ring Fig 7E 113 6 Install four 4 hook type oil rings 7 Air check operation of intermediate clutch...

Page 478: ...116 12 Inspect parking pawl lugs for cracks or damage 13 Inspect output locating splines for damage 14 Inspect front Internal gear ring for flaking PINION REPLACEMENT PROCEDURE Reaction Carrier Shown...

Page 479: ...ace ment is necessary proceed as follows a Thread tool J 21465 16 into bushing and using slide hammer J 2619 remove bushing b Using tool J 21465 1 install bushing to 070 below the thrust washer face 2...

Page 480: ...acks or distortion 3 Inspect end for damage at anchor lugs or apply lugs G CASE EXTENSION 1 Inspect bushing for excessive wear or damage If replacement is necessary proceed as follows b Using tool J 2...

Page 481: ...USHING Remove With c a s e properly supported u s i n g tool J 21465 8 with handle J 8092 remove bushing 9o Inspect parking bracket for cracks or wear 10 Inspect detent roller and spring assembly J CA...

Page 482: ...snap ring Fig 7E 126 3 Install sun gear to internal gear thrust races and bearings against inner face of rear internal gear as follows and retain with petrolatum a Place large race against internal ge...

Page 483: ...Sun Gear Bearing and Races O D F L A N G E D RACE THRUST BEARING Fig 7E 128 Installing Rear Internal Gear to Output Shaft Bearing and Races c Place second race on bearing with outer flange cupped over...

Page 484: ...2 Fig 7E 130 Installing Front Internal Gear Ring to Output Carrier Fig 7E 131 Installing Reaction Carrier 16 Install rollers that may have come out of the roller cage by compressing the energizing spr...

Page 485: ...tput shaft to case thrust washer tabs in pockets and retain with petrolatum Fig 7E 137 ROLLER CLUTCH ASSEMBLY REACTION CARRIER Fig 7E 135 Installing Roller Clutch ASSEMBLY OF UNITS INTO TRANSMISSION C...

Page 486: ...Check to make sure band is seated on lugs Fig 7E 142 7 Install proper rear selective washer proper washer determined by previous end play check into slots provided inside rear of transmission case mKm...

Page 487: ...Ring and torque to 5 lb ft Lubricate and install case to center support bolt and torque to 22 lb ft Remove locating screw and keep for use on future rebuild jobs to properly locate the case center su...

Page 488: ...ace of transmission case If a different washer thickness is required to bring end play within specifications it can be selected from the following chart DIAL INDICATOR 1 J 2 1 9 0 4 If t FRONT BAND 4...

Page 489: ...Removal of direct clutch drive and driven plates may be helpful 18 Install forward clutch hub to direct clutch housing thrust washer on forward clutch hub Retain with petrolatum 19 Install forward clu...

Page 490: ...ss washer thickness is required to bring end play within specifications select proper washer from the chart below Thickness in inches Color 060 064 Yellow 071 075 Blue 082 086 Red 093 097 Brown 104 10...

Page 491: ...ifica tion numbers on shoulders are exposed Fig 7E 156 5 Check freeness of piston by stroking piston in bore I f Fig 7E 158 Installing Control Valve Spacer Plate and Gasket 6 Install six 6 check balls...

Page 492: ...and J 21370 5 to transmission case lever pivot pin to rear with rear servo cover at taching screws NOTE Attach tool attaching screws finger tight and check freeness of selective pin Torque at taching...

Page 493: ...ER AND INTAKE PIPE 1 Install case to intake pipe O ring seal on Intake pipe and assemble new strainer to Intake pipe Fig 7E 17 REAR SERVO COVER REAR SERVO G A S K E T Fig 7E 165 Installing Control Val...

Page 494: ...ear retainer and attaching bolts MODULATOR VALVE O RING SEAL VACUUM MODULATOR Fig 7E 1 69 Installing Governor INSTALLATION OF CONVERTER ASSEMBLY With the transmission in cradle or portable jack instal...

Page 495: ...ld occur in this range regardless of throttle opening 2nd Gear Overrun Braking Position the selector lever in the Drive Range and with the car speed at approximately 35 mph move the selector lever to...

Page 496: ...ission oil at the assembly plant and will indicate if the oil leak is from the transmission The use of a black light to identify the oil at the source of leak is also helpful Comparing the oil from th...

Page 497: ...tor If this is found with out the presence of oil the modulator should not be changed 2 Atmospheric Leak Check Apply a liberal coating of soap bubble solution obtainable at a 5f 10 store to the vacuum...

Page 498: ...re used TOiQUE SPECIFICATIONS Lb Ft Pump Cover Bolts 18 Parking Pawl Bracket Bolts 18 Case Center Support Bolt 22 Pump to Case Attaching Bolts 18 Extension Housing to Case Attaching Bolts 22 Rear Ser...

Page 499: ...arrier Bushing Installer J 8001 Dial Indicator Set J 8092 Driver Handle J 2 1 0 2 8 Speedo Gear Installer Spacer J 21359 Pump Oil Seal Installer J 21362 Seal Protector Forward and Direct Clutch J 2136...

Page 500: ...25 2 Adapter J 6129 Clutch Spring Compressor J 8433 Speedo Gear Remover J 8763 Holding Fixture J 8763 20 Holding Fixture Adapter J 8765 Clutch Spring Compressor Adapter Ring J 21368 Pump Body and Cove...

Page 501: ......

Page 502: ...rque Specifications Special Tools TRANSMISSION IDENTIFICATION The identification data is located on the right side of the transmission Fig 7F 2 The transmission model model year and the assembly date...

Page 503: ...CLUTCH X I N P U T SUN G E A R G O V E R N O R DRIVE G E A R r OUTPUT SHAFT mm MANUAL SHAFT LOW BAND ADJUSTING S C R E W LOW SUN G E A R CAR SERIAL NUMBER LOCATION 3fc V SPEEDOMETER Y DRIVE GEAR j lp...

Page 504: ...n in View A 3 Torque selector pin nut to 30 lb ft set the gearshift lever in PARK position and connect shift cable to pin SERVICE OPERATIONS TRANSMISSION IN CAR The 2 speed automatic transmission serv...

Page 505: ...ATION OF C A B L E VIEW C Fig 7F 3 Tempest Floor Shift Linkage 2 Remove speedometer cable and speedometer driven gear assembly 3 Remove rear bearing retainer 4 If necessary replace speedometer drive g...

Page 506: ...as driven gear disengages from drive gear teeth machined into output shaft Fig0 7F 11 INSPECTION Check for sticking governor valve broken or missing governor weight springs damaged driven gear or wor...

Page 507: ...ion of roll pin and gear This can be best accomplished by above method 5 Support end of governor sleeve not gear on a wood block Install new roll pin then using small chisel stake pin in place at both...

Page 508: ...nkage INSPECTION AND REPAIRS Check modulator valves for burrs If such minor imperfections cannot be removed with a slip stone replace valve The modulator diaphragm can be checked with vac uum source f...

Page 509: ...I N E R Fig 7F 10 Installing Rear Bearing Retainer Bushing Fig 7F 8 Installing Rear Bearing Retainer Oil Seal N O T C H IN REAR BEARING RETAINER REAR B E A R I N G RETAINER BUSHING J 8400 1 G O V E R...

Page 510: ...Fig 7F 17 Speedometer Driven Gear and Sleeve Fig 7F 14 Right Side of Transmission INSPECTION AND REPAIRS Fig 7F 17 Was On V A C U U M M O D U L A T O R mwmJm __ C A S E T O V A C U U M M O D U L A T...

Page 511: ...all new gasket on solenoid so that gasket notch will face bottom of valve body 5 Install solenoid on valve body and secure con nector to case connector INNER P A R K L O C K AND R A N G E S E L E C T...

Page 512: ...d cause valve hang up ASSEMBLY 1 Install high speed downshift timing valve wash er and springs Fig 7F 23 Depress spring with needle nose pliers and install retaining pin MODULATOR LIMIT VALVE RETAININ...

Page 513: ...o the rear and install converter holding strap J 21366 to hold con verter in position until transmission is to be dis assembled To install transmission reverse the above proce dure TRANSMISSION DISASS...

Page 514: ...d remove pump and gasket Fig 7F 28 2 Remove input shaft from forward clutch drum Fig 7F 29 3 Remove forward clutch assembly by pulling straight out of case Fig 7F 30 4 Remove low band and struts from...

Page 515: ...se piston return seat snap ring gap is acces sible 5 With return spring fully compressed remove snap ring 60 Release pressure on the return springs being careful that piston return seat does not catch...

Page 516: ...and range se lector lever Fig 7F 40 NOTE Before sliding range selector lever shaft out of case remove any burrs on inner end of shaft that could score case bore or make removal dif ficult INSPECTION...

Page 517: ...lows N U T O U T E R R A N G E S E L E C T O R L E V E R INNER P A R K L O C K A N D R A N G E S E L E C T O R ASSY I M P A R K I N G L O C K S P R I N G i i i i i i l i i i i i f i l M P A R K I N G...

Page 518: ...ton grooves FORWARD CLUTCH RANGE SELECTOR SHAFT OIL SEAL REPLACEMENT 1 Pry out old seal 2 Tap new seal gently until it bottoms in case bore Use a piece of flat metal or wood to avoid damaging seal PAR...

Page 519: ...piston apply area centri fugal force acting on fluid could partially apply the piston and burn clutch pack unless the relief orifice is openQ During normal piston application F O R W A R D CLUTCH HUB...

Page 520: ...BUSHING REPLACEMENT 1 Remove old bushing using bushing chisel J 8400 1 or tool J 21424 4 Fig 7F 51 Avoid dam aging bushing bore 2 Install new bushing using tool J 21424 4 Fig 7F 52 Press in bushing u...

Page 521: ...trolatum aligning tangs in clutch SPRING RETAINER f 111 CLUTCH SPRING 2 0 i CLUTCH HUB FRONT THRUST WASHER ALIGN TANGS IN CLUTCH HUB WITH GROOVES IN THRUST WASHER CLUTCH HUB Fig 7F 55 Installing Clutc...

Page 522: ...nicks or scoring 6 Inspect output shaft splines for nicks or damage To disassemble the planet carrier to replace worn or damaged parts proceed as follows DISASSEMBLY 1 Remove planet pinion shaft lock...

Page 523: ...hafts J9534 1 J6125 J6125 2 Fig 7F 63 Removing Output Shaft Bushing 4 Check output shaft bushing for nicks severe scoring or wear If replacement is required pro ceed as follows OUTPUT SHAFT BUSHING RE...

Page 524: ...NOTE Repeat steps 1 through 4 above to install remaining two long pinions OIL G R O O V E S F R O N T P L A N E T P I N I O N THRUST W A S H E R 8 Install short pinion thrust washer with oil grooves f...

Page 525: ...ECTION AND REPAIR Visually examine parts for damage or wear Dis card worn or damaged parts Remove and discard piston oil seal ring ASSEMBLY 1 Install washer into secondary piston assembly Fig 7F 71 2...

Page 526: ...egulator valve Fig 7F 75 9 Remove oil pump seal with a small pry bar and discard seal Fig 7F 76 INSPECTION 1 Check oil pump bushing for nicks severe scor ing or wear 2 Check stator shaft bushing for n...

Page 527: ...en so bush ing is not driven past shoulder ASSEMBLY 1 Using tool J 21359 install new oil seal Fig 7F 80 i iffffr J 21424 7 BRASS DRIFT Fig 7F 78 Removing Stator Shaft Bushing 2 Install new oil pump to...

Page 528: ...s been tightened firmly install dial indicator and adjust for zero reading while plunger rests on end of screw Fig 7F 82 5 Loosen hex nut allowing converter internal assembly to lower until dial indic...

Page 529: ...ck pawl and spring in position and retain with parking lock pawl shaft Fig 7F 83 2 Install range selector shaft into case with a twisting motion 3 Install inner park lock and range selector as sembly...

Page 530: ...verse clutch reaction plates and drive plates as shown In Fig 7F 89 Notched lug in each steel reaction plate is installed so that it is at top of groove at 5 o clock position In case Fig 7F 90 NOTE Nu...

Page 531: ...ERVO ASSEMBLY LOW BAND AND FORWARD CLUTCH LOW SERVO ASSEMBLY 1 Install low servo assembly into case Position notch to receive low band apply strut pi j H i I J Fig 7F 94 Installing Low Servo Cover Sna...

Page 532: ...he input sun gear rear thrust washer in the planet carrier are centered before installing the forward clutch as sembly DETERMINATION OF SELECTIVE THRUST WASHER THICKNESS The thickness of the oil pump...

Page 533: ...and proceed in accordance with instructions in INSTALLATION OF OIL PUMP below Correct Thrust Washer If End Play is Thickness is 008 to 038 061 039 to 060 079 061 to 085 097 Fig 7F 101 Selective Thrust...

Page 534: ...car a Install oil pressure gauge b Road test using all selective ranges noting when discrepancies in operation or oil pressure occur c Attempt to isolate the unit or circuit involved in the malfuncti...

Page 535: ...With engine off check for oil leaks due to the raised oil level caused by drain back Fig 7F 107 Pump to Case Passages Fig 7F 108 Case to Pump Passages B POSSIBLE POINTS OF OIL LEAKS 1 Transmission Oil...

Page 536: ...Check strainer and suction pipe assembly for leaks 2 Check suction pipe O ring 3 Low oil level 4 Check for defective modulator EXCESSIVE SLIP OR ENGINE FLARE ON COASTING TO A STOP WHEN CORNERING 1 Ch...

Page 537: ...ch is self adjusting 2 Check for stuck detent valve and shift valves 3 Check orifice in detent valve 4 Check solenoid on valve body FORWARD CLUTCH EXHAUST FORWARD CLUTCH PRESSURE DRIVE PRESSURE MODULA...

Page 538: ...ed Line pressure should decrease as car speed increases at a constant engine manifold vac uum for example about 13 psi between 40 60 mph Reverse pressure should be about 85 psi at idle to over 200 psi...

Page 539: ...embly to Case Bolts Rear Bearing Retainer to Case Bolts Oil Pan to Case Bolts Speedometer Sleeve Clamp Bolt Governor Cover Bolts Park Lock Bracket Bolts o e o e e e e e e e e o o 0 o o o o o o e e e e...

Page 540: ...125 Slide Hammer 13 J 6125 2 Slide Hammer Adapter 14 J 9542 4 Forward Clutch Spring Compressor Pilot 15 J 22269 Low Servo Remover and Installer 16 J 8092 Handle 17 J 21510 1 Reverse Clutch Spring Comp...

Page 541: ......

Page 542: ...lower tank 7 Disconnect tan wire from fuel gauge tank unit on Pontiac 8 Complete tank removal Installation E X H A U S T S Y S T E M THIS S E C T I O N SUBJECT PAGE Fuel Lines 8 4 Exhaust Systems Tem...

Page 543: ...ower tank 6 Disconnect tan wire from fuel gauge tank unit 7 Complete tank removal Installation 1 Replace tank by reversing above steps 2 Tighten ground screw to 2 lb ft torque Tighten fuel tank retain...

Page 544: ...fuel tank as necessary to insure fuel level is below point where unit is installed in tank 2 Remove left rear wheel from automobile 3 Remove fuel tank front splash shield 4 Disconnect ground connectio...

Page 545: ...side of the frame The gasoline line has two hose connections one connecting the fuel pump inlet line to the front gasoline line and one connecting the rear gasoline line to the tank gauge unit The fue...

Page 546: ...FUEL T A N K A N D EXHAUST SYSTEM 8 5 Fig 8 5 Installation of Fuel Tank Tempest Station Wagon...

Page 547: ...ONTIAC SERVICE MANUAL Fig 8 6 Firebird Fuel Tank Installation FULL POSITION EMPTY POSITION Fig 8 7 Pontiac Fuel Gauge Tank Unit All Except Station Wagon Fig 8 8 Fuel Gauge Tank Unit Tempest Except Sta...

Page 548: ...rt clamps 2 Slide tailpipe off rear of muffler on Tempest models only 3 Loosen U bolt clamp at front of muffler 4 Slide muffler off exhaust pipe 5 Replace muffler by reversing above procedure Tighten...

Page 549: ...connecting exhaust pipe to manifold Y pipe and remove exhaust pipe 5 Remove four bolts holding Y pipe to exhaust manifold and remove Y pipe 6 To install reverse above procedure Tighten Y pipe to manif...

Page 550: ...STEMS O F REAR SPRING 88 R H L H SIDE ALL SYSTEMS SINGLE EXHAUST SYSTEMS PLATE L H SIDE O N L Y TAIL PIPE VIEW H L H SIDE DUAL EXHAUST R H L H RESONATORS DUAL EXHAUST ONLY MUFFLER ASSY EXHAUST PIPE Hi...

Page 551: ...ve tailpipe and if necessary disconnect resonator from tailpipe 4 To install reverse above procedure Tighten tailpipe front bracket clamp behind muffler 18 lb ft torque Tighten tailpipe to resonator U...

Page 552: ...sover to exhaust pipe flange and inside diameter of tailpipe to muffler flange with sealer before installing Tailpipe Remove and Replace 1 Loosen front behind muffler and rear tailpipe support clamps...

Page 553: ...Coat inside diameter of front muffler opening and tailpipe flange with sealer before in stalling muffler Tailpipe Remove and Replace 1 Remove front behind muffler and rear tailpipe support U bolt cla...

Page 554: ...connect crossover pipe at right and left manifold 2 Loosen crossover pipe to exhaust pipe U bolt clamp 3 Loosen tail pipe front bracket clamp behind muffler 4 Loosen tail pipe or resonator assembly re...

Page 555: ...Disconnect crossover pipe from exhaust pipe and remove crossover pipe assembly 7 Install crossover pipe by reversing above pro cedure Tighten one 1 bolt finger tight with parts seated before tightenin...

Page 556: ...FUEL T A N K AND EXHAUST SYSTEM 8 15 Fig 8 17 Pontiac Dual Exhaust System 428 376 Engine...

Page 557: ...p behind muffler 14 lb ft torque 5 Replace tail pipe by reversing above procedure NOTE Coat outside diameter of rear muffler opening with sealer before installing tail pipe Tighten tail pipe front bra...

Page 558: ...L REMOVE AND REPLACE Fig 9 1 lo Lift to remove ornament 2 Remove nut and washer from shaft 3 Remove horn bar deluxe wheel or extension and switch standard wheel 0 SUBJECT PAGE Power Steering 9 27 Peri...

Page 559: ...H HORIZONTAL BARS STEERING COLUMN STANDARD STEERING WHEEL PONTIAC SHOWN PULL WIRES LIGHTLY TO TAKE UP SLACK BENEATH BARS ALIGN INDEX MARK O N STEERING WHEEL WITH INDEX MARK O N STEERING SHAFT WITHIN O...

Page 560: ...moving the four short bolts attaching bracket to steering column also remove two nuts and wedge bolt that attaches bracket to the instrument panel Remove wedge shaped shim placed between bracket and i...

Page 561: ...driving pivot pin back into shift bowl if shift bowl was replaced 2 Assemble spring and thrust ring and on SM only the bowl bearing washer into shell and press shell into place on housing Assemble ov...

Page 562: ...r bearing pre load spring onto steering shaft NOTE Prior to installing cancelling cam be sure that turn signal switch is in neutral position and hazard flasher is in the off position This will prevent...

Page 563: ...e 7 Install signal switch and tighten three attaching screws to 35 in lb Be sure that the shortest at taching screw is located in the topmost position above the lock shoes 8 Install turn signal switch...

Page 564: ...space and tighten front instrument panel mounting bolt to 20 lb ft torque Do not force wedge shim into gap 5a Tempest Position the left outboard toe plate against floor pan and start a screw in lower...

Page 565: ...Fig 9 12 Exploded View of Typical Regular Column Automatic Transmission...

Page 566: ...Steering Column Removed From Car The following procedures cover the complete dis assembly and assembly of steering columns after their removal from car and should only be used to the extent necessary...

Page 567: ...9 10 1968 PONTIAC SERVICE MANUAL Fig 9 13 Exploded View of Typical Regular Column Standard Transmission...

Page 568: ...Steering Shaft Lever Bearing Adapter and Sleeve 44 Lower Bearing Reinforcement Ring 45 Lower Bearing Adapter and Sleeve Bolt 46 Upper Steering Shaft Retaining Ring 47 Steering Shaft Assembly w Flange...

Page 569: ...D S P R I N G C L A M P X L O W E R S T E E R I N G S H A F T U P P E R S T E E R I N G S H A F T P O T JOINT ASS Y Fig 9 17 Removing Pot Joint and Lower Shaft from Upper Steering Shaft Tempest Only F...

Page 570: ...springs onto screws and start screws into lock plate three turns for ease of as sembly into column jacket 6 Run switch wire through shift bowl and place upper end assembly on top of bowl 7 Place the...

Page 571: ...9 14 1968 PONTIAC SERVICE MANUAL Fig 9 21 Exploded View lypical Ti It Column...

Page 572: ...Bracket Nut 60 Column to Support Bracket Bolt 61 Support Bracket to Mounting Bracket Washer 62 Support Bracket to Mounting Bracket Bolt 63 Steering Shaft Lower Bearing Adapter 64 Steering Shaft Beari...

Page 573: ...until ears align 12 SIDED N U T J22599 s INNER R A C E SEAT INNER RACE Fig 9 24 Removing Pivot Pin with grooves in housing and remove retainer and spring WARNING Care should be taken when releasing t...

Page 574: ...ALF OF FLEXIBLE COUPLING PLASTIC INJECTED TOLERANCE RING SLEEVE SPRING I m f a PLUNGER RETAINING RING LOWER STEERING SHAFT 4 SHIFT BOWL J 22551 KEY WAY IN SHIFT TUBE Fig 9 28 Installing Tool J 22551 1...

Page 575: ...29 CA UTION Do not push on top or end of shift tube assembly 6 Pull the shift bowl up to compress the wave washer and install thrust washer and retaining ring 7 Install support assembly aligning V in...

Page 576: ...ing cam and cancelling cam spring on upper steering shaft prior to steering wheel installation NOTE Prior to installing cancelling cam be sure that turn signal switch is in neutral position and hazard...

Page 577: ...necting rod is removed the pit man arm may be removed from pitman shaft by removing nut and lock washer and by using puller J 5504 01 To install pitman arm on pitman shaft replace arm lock washer and...

Page 578: ...pressure are correctly ad justed and or operating satisfactorily There are two adjustments on the recirculating ball type steering gear I N T E R M E D I A T E R O D STEERING GEAR STEERING GEAR FACE O...

Page 579: ...1 Raise vehicle and disconnect steering connect ing rod from pitman arm Fig 9 35 and Fig 9 36 using tool J 5504 01 2 Loosen pitman shaft adjusting screw lock nut and back off adjusting screw a few tu...

Page 580: ...all times Before disassembling gear thoroughly clean ex terior with suitable solvent and drain as much fluid as possible 1 Mount steering gear on holding fixture J 5205 2 Rotate wormshaft with flexibl...

Page 581: ...39 Exploded View of Standard Steering Gear 3 Inspect all bearings bearing cups worm groove bushings seals teeth for scoring wear pitting which would necessitate replacement 4 Inspect housing and cover...

Page 582: ...ll cause im proper operation of ball nut 3 Place upper bearing on worm shaft Center ball nut on worm then slide worm shaft bearing and nut into housing 4 Install adjuster in housing NOTE Adjuster shou...

Page 583: ...g 9 45 Position of Pitman Shaft and Ball Nut 7 Position pitman shaft seal on pitman shaft and seat seal using suitable socket as a driver 8 Install pitman shaft and adjusting screw with sector and bal...

Page 584: ...eering column On cars with tilt column be sure steering is in straight position and not tilted NOTE All checks and adjustments must be made in the order listed in step 3 1 Raise vehicle and disconnect...

Page 585: ...04 01 3 Remove pitman shaft outer dust seal retaining ring using Truarc pliers 4 Remove outer dust seal using screwdriver or similar tool and place a cloth around housing and pitman shaft to absorb oi...

Page 586: ...GEAR AND SIDE COVER 1 Remove side cover retaining screws and washers 2 Rotate cover as necessary to see when pitman shaft is centered in gear housing opening while rotating gear flange Fig 9 49 3 Remo...

Page 587: ...n housing 9 Remove adjuster plug O ring seal and discard DISASSEMBLE PITMAN SHAFT GEAR AND SIDE COVER 1 Hold lash adjuster with 7 32 alien wrench and remove lash adjuster nut and discard 2 Screw lash...

Page 588: ...ing Valve Spool from Rotary Valve Fig 9 56 Exploded View of Rotary Valve 4 Remove stub shaft torsion bar small diameter bar extending through stub shaft and valve cap as sembly by tapping end of torsi...

Page 589: ...eing careful not to score needle bearing bore Remove thrust bearing spacer thrust bearing and thrust bearing races 2 Remove adjuster plug O ring and discard 3 Remove retaining snap ring and dust seaL...

Page 590: ...Lash Adjuster Thrust Washer 21 Lash Adjuster 22 Spring Thrust Washer 23 Lash Adjuster Spring 24 Pitman Shaft 25 Steering Gear Housing 26 Pitman Shaft Needle Bearing 27 Single Lip Oil Seal 28 Inner Bac...

Page 591: ...Inspect gear housing for any defects in the piston bore or the rotary valve bore Inspect all re taining ring grooves and seal surfaces for scratches or nicks If any major defects are found the housin...

Page 592: ...oval of spool a Remove valve spool spring and disassemble rotary valve assembly b Press on spool until O ring seal is cut and spool can be removed c Replace O ring seal and proceed with as sembly as b...

Page 593: ...m into rack piston nut to bearing shoulder Fig 9 64 3 Align ball return guide holes with worm groove Load 15 balls into the guide hole nearest Teflon piston ring While slowly rotating worm to left fee...

Page 594: ...1 0 3 0 in lb torque on all other Pontiac models NOTE Do not use torque wrench having maxi mum torque reading of more than 100 lb in When taking following torque readings take reading pulling torque w...

Page 595: ...nd plug retainer ring so end of ring ex tends over 1 2 beyond ring removal assist hole Fig 9 69 ADJUST PITMAN SHAFT PRELOAD THROUGH CENTER HIGH POINT NOTE DO NOT use a torque wrench having max imum to...

Page 596: ...HEY DO NOT CONTACT AFTER INSTALLATION IS COMPLETE AND WITH FRONT WHEELS IN STRAIGHT AHEAD POSITION FILL PUMP RESERVOIR TO FULL MARK WITH 9985010 FLUID BLEED SYSTEM WITH ENGINE OPERATING BY TURNING FRO...

Page 597: ...OF HOSE ROUTING XC COOLER PIPE r PANEL PRESSURE RETURN HOSES SHOULD BE POSITIONED S O THEY DO NOT CONTACT PRESSURE HOSE 7 16 RADIATOR ASM NOTE COOLER PIPE IS USED WITH VARIABLE RATIO STEERING AND AXL...

Page 598: ...two full turns 2 Tighten belt with power steering pump to give 72 lbs as indicated on Burroughs gauge for used belt and 110 lbs for new belt 3 Holding adjustment tighten pump plate to bracket bolts PU...

Page 599: ...ey from shaft Do not hammer on rim of pulley as this will damage pulley or pump 7 Remove bracket to pump bolts 80 Drain pump of oil 9 Clean exterior of pump DISASSEMBLY AND ASSEMBLY OF PUMP DISASSEMBL...

Page 600: ...be replaced and should not be immersed in cleaning solvent Lubricate all O ring seals and the drive shaft seal with vaseline and install in proper location Be sure not to immerse drive shaft seal in c...

Page 601: ...sure plate with vaseline to insure against dam aging O ring and install on dowel pins with ported face toward pump ring Applying pressure to outer edge only seat pressure plate Never press or hammer o...

Page 602: ...stall studs torque to 35 ft lb and outlet union and torque to 35 ft lb Install drive shaft key Support shaft on opposite side of key when installing key INSTALLATION OF STEERING PUMP Figs 9 88 and 9 8...

Page 603: ...End Plate on the Burroughs gauge for initial tension of a new belt tighten used belt to 72 lbs Tighten mounting bolts 30 ft0 lb0 torque0 7 Tighten pulley nut to 60 ft lb0 torque 8 Fill reservoir with...

Page 604: ...ATIONS STANDARD STEERING Type Saginaw Recirculating Ball Nut Steering Gear Ratio Pontiac Tempest Firebird 24 1 Firebird with V8 and Air Conditioning 28 1 Lubricant Capacity 11 Fluid Ounces Worm Bearin...

Page 605: ...talina Firebird and Tempest 17 5 1 Pontiac Except Catalina 16 1 to 12 2 1 Variable Ratio Number of Turns of Steering Wheel Stop to Stop Pitman Arm Disconnected 1705 Ratio 4 0 approx Variable Ratio 3 1...

Page 606: ...Steering Shaft Nut Steering Column to Instrument Panel Bolt Steering Column to Instrument Panel 0 Bolt Steering Column to Mounting Bracket Nut Flexible Coupling to Steering Shaft 0 Bolt Steering Gear...

Page 607: ......

Page 608: ...nch for 8 ply rating tires Sustained speed above 75 mph are not recommended when the 4 pounds per square inch adjustment would require pressures greater than maximum stated above 3 Cold tire inflation...

Page 609: ...htening a wheel CAUTION Under no circumstances should wheels be brazed welded or peened In the event the wheel is severely damaged it should be replaced PREPARATION OF TIRE Remove excess strings of ru...

Page 610: ...owly rotate wheel and check for total lateral run out of wheel and tire See Fig 10 3 Maximum allowable total lateral run out is 1 8 If total lateral run out exceeds 1 8 then attach a dial indicator to...

Page 611: ...heel radial run out is 035 maximum wheel lateral run out is 045 BALANCE PROCEDURE The preferred method of balancing wheels and tires is with on the car type equipment But whether on or off car type eq...

Page 612: ...seat station wagon All except Police Option Disc Brakes Trailer Provision 8 55 x 14 8 55 x 14 4 ply rating 4 ply 8 85 x 14 8 85 x 14 8 ply rating 4 ply 8 45 x 15 8 45 x 15 4 ply rating 4 ply 8 45 x 1...

Page 613: ......

Page 614: ...itions A ADJUSTMENT Slotted holes are provided at all hood hinge attach ing points for proper adjustment both vertically and fore and aft To lower the rear corners for proper alignment to the cowl and...

Page 615: ...g of the hood bumpers hood height is auto matically controlled by the vertically self adjusting hood latch No lateral adjustment of the latch is possible However proper hood alignment is es sential fo...

Page 616: ...d install attaching screws and tighten snug 3 Replace spring NOTE When replacing spring hook rear end of spring on pin first then stretch and hook at front 4 Carefully close hood and check for proper...

Page 617: ...of alignment shims used 1 Remove valance panel and front bumper assembly 2 Remove fender to support and baffle assembly attaching screws 3 Remove hood hinge to fender attaching screws 4 Remove fender...

Page 618: ...er away from frame CAUTION Exercise care in pulling fender away from frame to avoid bending fender 8 Disengage inner fender skirt lip from outer fender panel by pulling out and down on inner edge of s...

Page 619: ...pest and Firebird All are integral with the front bumpers the split grille shells being re tained and entirely surrounded by the front face bar The Grand Prix and GTO have their own distinct grille de...

Page 620: ...CHASSIS SHEET METAL 11 7 Fig 11 7 Pontiac Support and Baffle SECTION A A ASSEMBLED Fig 11 8 Pontiac Rear Fender Skirt...

Page 621: ...11 8 1968 PONTIAC SERVICE MANUAL VALANCE PANEL REF Fig 11 9 Tempest Support and Baffle T Y P I C A L BOTH ENDS Fig 11 10 Firebird Support and Baffle...

Page 622: ...in an upright position 4 If desired remove battery tray 5 To replace reverse removal procedures NOTE On Tempest models it is important to route cable as shown in Fig 12 10 BATTERY CABLE Battery Cable...

Page 623: ...3 5 7 L H SPARK PLUGS A L T E R N A T O R s 0 VOLTAGE REGULATOR BLAClk 5 G L RED IGNITION C O I L O I L P R E S S S W DOWN SHIFT _ SOLENOID 0 BLACK S G L WHT t4J IDLE STOP S O L E N O I D B L A C S G...

Page 624: ...ributor to replace brake warning light switch Instructions for removal of the switch can be found in Section 5 CORNERING LAMPS For installation of cornering lamps see Fig 12 22 SIDE MARKER LAMPS Front...

Page 625: ...H BLK DSL L T BtT HEATER CONTROL LAMP HAZARD FLASHER BLACK SOL WHT BLK 5GI_ ORN PURPLE B U L K H E A D CONNECTOR BLK SGL PWK WHITE B L A C K D K BL DBL WHT DK GRN BROWN RADIO PWR 0 NEUT SAFTY SW WHT D...

Page 626: ...CHASSIS ELECTRICAL SERVICE 12 5 Fig 12 2A Pontiac Passenger Compartment Wiring...

Page 627: ...CENSE LAMP I V Y L T O crc ofL BODY GRD WIRE i l i i SIDE MARKER LP TAIL LAMP STOP L DIR LP TAIL LAMP STOP DIR LP BACK UP LAMP LICENSE LAMP 2 BACK UP LAMP TAIL LAMP STOP DIR LP J i SIDE MARKER LP 2 BA...

Page 628: ...CHASSIS ELECTRICAL SERVICE 12 7 Fig 12 4 Tempest Engine Compartment Wiring...

Page 629: ...12 8 1968 PONTIAC SERVICE MANUAL Fig 1 2 5 Tempest Passenger Compartment Wiring...

Page 630: ...CHASSIS ELECTRICAL SERVICE 12 9 GREEN BLACK L H DOOR JAMB SW ORANGE LT GREEN PINK Fig 12 5A Tempest Passenger Compartment Wiring...

Page 631: ...MANUAL W s SIDE MARKER LP BACK UP LAMP EB 3 2 SIDE MARKER L P GROUND BACK UP L P I LICENSE LAMP BROWN us 9 BACK UP LAMP s BACK UP L P 5IDE MARKER LP ALL EXCEPT STATION WAGON STATION WAGON W G Fig 12...

Page 632: ...DIR SIGNAL LAMP L T S T R i crj s fc L H MARKER L A M P NEGATIVE POST P O S I T I V E POST B R N DK VOLTAGE REGULATOR C8 1 T E M P E R A T U R E SWITCH O R N T H E R M O H W PLK SGL W H T S T R RED c...

Page 633: ...L K P R I N T LOW B R A K E FLUID WARNING SWITCH B L K S G L ORN STR HEATER M O T O R DOWN SHIFT SOLENOID DOWN S H I F T SWITCH 8LK 5GL YELSTR wis WIPER MOTOR 91 W S WASHER BLK S G L Y E L S T R QLK S...

Page 634: ...n from both ends of casing 3 Take short piece of speedometer cable with a tip to fit speedometer and insert it in speedometer socket Spin short cable between fingers in direction that higher speed is...

Page 635: ...12 14 1968 PONTIAC SERVICE MANUAL Fig 12 8 Firebird Passenger Compartment Wiring...

Page 636: ...CHASSIS ELECTRICAL SERVICE 12 15 Fig 12 8A Firebird Passenger Compartment Wiring...

Page 637: ...AIL STOP U 4 DIR SIG LAMP OUTBOARD R H BACK UP LAMP R H TAIL STOP DIR SIG LAMP INBOARD FUEL GAUGE TANK UNIT LICENSE LAMP L H TAIL STOP 1 J r D I R SIG LAMP INBOARD L H BACK UP LAMP 7 I L H MARKER W LA...

Page 638: ...ircuit Fig 12 10 Tempest Battery Cable Routing FUEL GAUGE TEMPEST OR FIREBIRD 1 Remove instrument cluster FUEL GAUGE PONTIAC 1 Remove two screws that retain gauge to cluster 2 Remove screws that retai...

Page 639: ...12 18 1968 PONTIAC SERVICE MANUAL Fig 12 11 Pontiac Battery Cable Routing...

Page 640: ...bove procedure HEADLIGHT SWITCH 6 To install reverse removal procedure WINDSHIELD WIPER SWITCH 1 Remove knob 2 Remove retaining nut securing shaft and bezel 3 Remove switch and disconnect terminals 1...

Page 641: ...emove bezel retainer NOTE Use care not to destroy fibre optic light 3 Remove wire connector 4 To replace reverse removal procedure IGNITION SWITCH L Remove Ignition lock 2 Remove bezel retaining switc...

Page 642: ...CHASSIS ELECTRICAL SERVICE 12 21 H E A D L I G H T S W I T C H Fig 12 14 Instrument Panel Wiring Fig 12 15 Rear Lamp Harness Grand Prix...

Page 643: ...LADE ASSEMBLY REPLACEMENT With wiper switch off and motor in parked posi tion place drag link of arm and blade assembly on pi Slide retainer onto pin before placing head of a r m on transmission shaft...

Page 644: ...viced Check master parts catalog for correct service packages Service packages will include installation instructions 8 To install reverse above procedure Make sure wiper blades are in park position a...

Page 645: ...12 24 1968 PONTIAC SERVICE MANUAL Fig 1 2 1 8 Instrument Panel Switches Tempest...

Page 646: ...adjustable retainer at motor crank arm 4 Position left blade and arm assembly against stop on moulding 5 Tighten adjustable retainer 6 Install right arm and blade assembly against stop on moulding 2...

Page 647: ...per assembly to fire wall 5 Tempest and Firebird models Carefully pull wiper assembly away from firewall until retainer securing wiper crank to wiper transmission arm can be removed 6 Tempest models R...

Page 648: ...CEDURES The disassembly assembly procedures for the wiper are broken down into two major areas The motor section and gear box section Each section may be serviced independently of the other WIPER MOTO...

Page 649: ...commutator 9 Allow brush held in step 8 to move out of its holder Remove brush spring and lift brush holder off armature shaft 10 Lift the brush plate circuit breaker assembly from the field coil ret...

Page 650: ...roceed as follows a Remove relay switch attaching screw Fig 12 34 and carefully lift relay switch out of gear box b Unsolder two motor leads at relay c Slide terminal board out of gear box housing d U...

Page 651: ...HING R H EDGE OF SLOT AND ASSEMBLE SWITCH REMOVE GAUGE PIN MANUAL TRANSMISSION COLUMN SHIFT WITH LEVER IN REVERSE POSITION ADJUST SWITCH SO THAT THE PLUNGER IS FULLY DEPRESSED AGAINST LEVER V I F W A...

Page 652: ...AC AND TEMPEST OPTIONAL SYSTEM DRIVE GEAR RE ASSEMBLY 2 Assemble lock pawl over drive pawl as shown In Fig 12 39 3 Slide gear and tube over the drive shaft Fig 12 40 Make drive and lock pawls as requi...

Page 653: ...12 32 1968 PONTIAC SERVICE MANUAL Fig 12 29 Wiper Transmission Replace Pontiac...

Page 654: ......

Page 655: ...ig 12 33 Retainer Holding Brush in Place Pontiac tighten or loosen adjusting screw as required until end of screw barely touches end of armature PONTIAC WIPER ADJUSTMENTS a Armature end play 1 Loosen...

Page 656: ...ainer ring and end play washers 2 Drill out gear box cover retaining rivets 8 and remove cover from gear box CAUTION Mark ground strap location for reas sembly purposes m A INNER SPACER WASHER LOCK PA...

Page 657: ...witch are included with replacement assembly ASSEMBLY Reverse steps 1 through 4 above except as noted 1 Reassembly of gear cover be sure cover is located properly over locating dowel pins and be sure...

Page 658: ...V E S C R A N K ARM G R O O V E S 4 Move brushes away from armature and slide armature out of frame and field assembly Pull end plate assembly off armature CAUTION Use care to insure that small thrus...

Page 659: ...Gear Clutch Mechanism Relay attaching screw internal Gear Shaft Pontiac and Tempest Optional System 30 Seal Cap inside Crank arm nut 60 Armature Worm Wiper to firewall attaching bolts 25 WINDSHIELD W...

Page 660: ...ATE C A M RATCHET P A W L ft Fig 12 46 Exploded View Pump Assembl y Pontiac and Optional Tempest R E L A Y RATCHET P A W L R A T C H E T D O G V A L V E A S S E M B L Y R A T C H E T I 1 A S P R I N G...

Page 661: ...ove ratchet wheel ratchet wheel dog ratchet pawl and spring 2 To release the plastic pump housing from the sheet metal base pull it in the direction toward the valve end until the housing grooves clea...

Page 662: ...that secure valve to housing BELLOWS AND BELLOWS SPRING 1 Remove valve 2 Manually rotate ratchet wheel as required to release pump from lock out position 3 Hold end of plunger arm from moving At this...

Page 663: ...E S I D E R O O F R A I L R E A D I N G L A M P O P T I O N A L O R D E R O N L Y C I R C U I T B R E A K E R B Y P A S S B A R ON C O N N E C F U S E B L O C K C I R C U I T B R E A K E R U S E D W...

Page 664: ...FT REAR QUARTER LEFT FRONT r if DOWN ALL SWITCHES RED WHITE STR DK BLUE BROWN 1 DK B mm fyyl DK GREEN WHT STR RED WHT STR PPL WHT STR RED WHT STR PURPLE POWER WINDOW COURTESY LP GLOVE BOX LP DRANGE K...

Page 665: ......

Page 666: ...unted in two bottom slots and secured at the top by one center bolt Fig 13 1 Lower Cradle Bracket and Insulator RADIATOR REMOVAL AND REPLACEMENT PONTIAC AND TEMPEST REMOVAL 1 Disconnect positive batte...

Page 667: ...tioned cars be sure rubber seals around radiator are carefully replaced to prevent possible flapping or loss of coolant due to over heating Purpose of seals is to ensure that all in coming air goes th...

Page 668: ...d plug the trans mission cooler lines 5 Remove upper fan shield six cylinder or upper shroud bracket V 8 6 Remove radiator attaching screws and lift radi ator and shroud out of vehicle REPLACE 1 Repla...

Page 669: ......

Page 670: ...and 4 8 Remove face bar reinforcement REMOVE TEMPEST BUMPER Fig 1 4 5 1 Disconnect parking lights headlights and vac uum hoses GTO only SUBJECT PAGE Rear Bumpers 14 2 Pontiac or Tempest 14 2 Firebird...

Page 671: ...to prevent possible rattles REMOVE PONTIAC OR TEMPEST BUMPER Figs 1 4 7 7 thru 74 75 1 Disconnect all lights contained in or attached to the bumper 2 Support bumper on Pontiac loosen two forward fram...

Page 672: ...move bumper from vehicle 4 Remove license plate bracket from face bar using J 22413 REPLACE BUMPERS ALL 1 To install reverse the above procedures mak ing sure rear bumper assembly is properly aligned...

Page 673: ...htly dimples and dents in steel bumpers The new bumper material will withstand minor impacts and the resultant damage such as occur in parking lots by recovering its original shape The paint film resp...

Page 674: ...s cut or gouged use the DA sander and a clean disc to enlarge the cut or gouged area s This must be done to ensure removal of grease oil or dirt from the area to be contacted by the repair material Th...

Page 675: ...glaze coat color coats and clear top coats that are to be used are specially formulated with an elastomer vehicle so that the cured film may bend under impact without cracking or splitting Material G...

Page 676: ...ndard blending techniques after each color coat 7 Allow the color to dry 5 to 10 minutes at room temperature 8 Thoroughly mix and apply the top coat clear using two coats as done previously with the c...

Page 677: ...used only if a reduction of gloss Is desired NOTE In using this material the following cau tions should be noted All the bumper refinishing materials are packaged at spraying viscosity Only if veilin...

Page 678: ...dency The clear coat tends to soften the color over to yellow if subjected to prolonged elevated tern which it is applied For this reason premature peratures 300 F featuring within 24 hours of air dri...

Page 679: ...14 10 1968 PONTIAC SERVICE MANUAL Fig 14 10 Firebird Grille...

Page 680: ...FRONT AND REAR BUMPERS 14 11 Fig 14 11 Pontiac Rear Bumper Exc Sta Wag...

Page 681: ...14 12 1968 PONTIAC SERVICE MANUAL Fig 14 12 Pontiac Sta Wag Rear Bumper...

Page 682: ...FRONT AND REAR BUMPERS 14 13 Fig 14 13 G P Rear Bumper...

Page 683: ...14 14 1968 PONTIAC SERVICE MANUAL Fig 14 15 Tempest Sta Wag Rear Bumper...

Page 684: ...FRONT AND REAR BUMPERS 14 15 Fig 14 16 Firebird Rear Bumper...

Page 685: ......

Page 686: ...nsion Fig 15 1 3 Adjust bead chain at extension to provide min imum chain slack and assemble clip to extension by straddling extension 4 A minimum of two beads must extend outside of clip after adjust...

Page 687: ...A T O R MOUNTING PONTIAC F E N D E R SKIRT 4 LEAsKwiTCH REGULATOR MOUNTING TEMPEST TO TRANSMISSION TO SERVO BEAD CHAIN C L I P MUST S T R A D D L E EXTENSION ONLY ONE BEAD TO E X T E N D BEYOND C L I...

Page 688: ...RIES 15 3 EXCESS CHAIN E VACUUM SERVO MOUNTING A L L TO SERVO HOSE ROUTING P O N T I A C TO SERVO TO ENGINE VACUUM HOSE ROUTING F I R E B I R D HOUSE ROUTING TE MP E ST Fig 15 1B Cruise Control Instal...

Page 689: ...C FIREBIRD WITH POWER BRAKES OTHERWISE SAME AS M A N U A L BRAKES WITH P E D A L F U L L Y R E L E A S E D ADJUST SWITCHES SO T H A T PLUNGERS ARE F U L L Y DEPRESSED AGAINST ARM ASSEMBLY BRAKE RELEA...

Page 690: ...TOR R O U T E H O S E O V E R B R A K E B P E D A L M O U N T I N G B R A C K E T B R A C E A C C E S S O I C O N N E C T O R F U S E B L O C K C R U I S E C O N T R O L W I R E T O L A Y F L A T B E...

Page 691: ...Inoperative cable to speedometer or regulator transfer gear is broken 1 Disconnect v a c u u m h o s e s and electrical connector 2 Disconnect both speedometer cables 3 Remove screws holding regulato...

Page 692: ...Fig 15 6 Adjusting Low Speed Switch Fig 15 5 Cover and Intake Filter Assembly DISASSEMBLY Fig 15 5 NOTE Do not tamper with the following screws Fig 15 6 1 Vacuum restriction screw in the regulator hou...

Page 693: ...sembly from the regulator housing Fig 15 9 VALVE BODY AND MAGNET ASSY RETAINING PIN f DRIVEN GEAR ATTACHING SCREWS Fig 15 9 Valve Body and Magnet Assy Removal 7 Remove driven gear from regulator by pr...

Page 694: ...r duct if equipped with A C 3 Disconnect clock lead wire 4 Remove two 3 8 nuts at bottom and one 5 16 screw at top of clock and remove clock 5 To replace reverse the above Fig 15 10 Clock Installation...

Page 695: ...al components The speedo head should be sent to the repair station complete Do not remove safeguard mechanism alone RADIO BRACE BUZZER RED POWER LEAD BLACK TRIGGER LEAD BROWN BLACK BROWN BROWN ACCESSO...

Page 696: ...O 1L GAUGE GAS GAUGE N S T R U M E N T P A N E L W I R I N G H A R N E S S G R A Y AMMETER WHITE TO G E N E R A T O R S L A C K TO B A T T E R Y PINK TO I G N N O 1 Fig 1 5 i6 A u x i l i a r y G a u...

Page 697: ...at rivets are used to re install unit to hood If screws are substituted here the anti theft feature of this tachometer will be destroyed INSTRUMENT PANEL TACHOMETER Refer to Fig 15 22 for installation...

Page 698: ...L E A D NOT USED T A C H O M E T E R G R A Y GRAY RHEO L E A D 6 When proper needle setting has been obtained as indicated on precision instrument turn engine off remove precision tachometer and repla...

Page 699: ...T A N K ALL EXCEPT G R A N D PRIX V A C U U M T A N K W I T H G R A N D PRIX REFER T O FISHER BODY SERVICE M A N U A L FOR A D D I T I O N A L I N F O R M A T I O N SYSTEM TEST SYSTEM S H O U L D L O...

Page 700: ...r to Fig 15 24 for installation of underhood Refer to Figs 15 25 26 and 27 for service of vacuum tank and hoses See Fisher Body Manual individual components for Installation of remote control valve an...

Page 701: ...Remove compartment lamp remove bulb and terminal from switch and bulb socket 3 Remove gearshift knob Automatic Transmission Fig 15 29 1 Remove console back panel held with two screws 2 Remove ash tra...

Page 702: ...nual Transmission 9 Remove two screws at rear holding console to 11 Remove two screws attaching two halves of floor pan Remove console console cover 10 To disassemble remove six screws holding 12 To r...

Page 703: ...15 18 1968 PONTIAC SERVICE MANUAL Fig 15 29 Console Pontiac Automatic Transmission...

Page 704: ...B R A K E S S I X J i x SLIT INSULATOR t x J J A A S S H O W N F O R I N S T A L L A T I O N O F F L O O R S H I F T L Y M E C H A N I S M S E E S E C T I O N 7 C O N S O L E H A R N E S S I B L A C...

Page 705: ...move gearshift knob 4 Snap out gearshift escutcheon 5 Remove screw holding center bracket to floor cover 6 Remove one screw at front and three screws at rear under compartment box holding console to f...

Page 706: ...cheon 7 To replace reverse above Automatic Transmission Fig 15 33 1 Remove gearshift handle 2 Remove gearshift escutcheon by prying straight up 3 Remove shift indicator housing 4 Remove three screws h...

Page 707: ...15 22 1968 PONTIAC SERVICE MANUAL INSTRUMENT F i g 15 33 Console Firebird Automatic Transmission...

Page 708: ...FRONT SPEAKER Fig 15 34 1 Remove radio as outlined above 2 Remove four 3 8 nuts from speaker to speaker brace and remove speaker 3 To replace reverse the above LOCATOR PINS MUST ALIGN WITH HOLES IN R...

Page 709: ...quipped 4 Disconnect antenna and speaker leads 5 Remove two 5 16 screws from bottom radio brace and remove brace 6 Remove dial light socket and lower radio to floor 7 To replace reverse above procedur...

Page 710: ...ACCESSORIES 15 25 Fig 15 36 Radio Receiver and Front Speaker Firebird...

Page 711: ...NSTALLED WITH LOOP UP AS SHOWN RIGHT HAND SIDE OF FRAME NOTE ATTACH CAPACITOR WITH BLOWER IMPELLER MOTOR ASSEMBLY ATTACHING SCREWS HEATER WIRE VIEW SHOWING CAPACITOR WIRE ASSEMBLY INSTALLATION AM FM O...

Page 712: ...trols and lower receiver out left side of LP 10 Reverse above procedure to Install 11 If radio receiver was removed for service readjust trimmer Whenever the AM FM Radio that is fitted with a multiple...

Page 713: ...15 28 1968 PONTIAC SERVICE MANUAL Fig 15 39 Radio Suppression Equipment Firebird...

Page 714: ...ure antenna is properly mounted onto wheel house flange Adjust nut which retains lower bracket to antenna by tightening finger tight plus four full turns Fig 15 40 Manual Antenna Pontiac Fig 15 41 Man...

Page 715: ...I C A L L Y W H E N V I E W E D F R O M SIDE OF C A R R O D A N D M A S T A S S E M B L Y A N T E N N A S H O U L D L E A N I N B O A R D A P P R O X 4 WHEN V I E W E D F R O M F R O N T OF C A R A N...

Page 716: ...orth rotary motion at same time until support tube is removed from antenna To replace support tube 7 If only replacing a damaged support tube as sembly apply the reverse of steps 1 through 6 making su...

Page 717: ...to tubular fitting before nylon cord completely disappears into drive as sembly Remove power if necessary to seat these parts EXISTING WIRE A S S Y Fig 15 45 Electric Antenna Ternpest 13 Push 400 tube...

Page 718: ...WITCH AND WIRE ASS Y AS SHOWN RADIO LEAD PART OF RECEIVER ASS Y ATTACH CONNECTOR TO RADIO BY INSERTING CLIP ON CONNECTOR INTO HOLE ON RADIO CASE BLUE POWER TO SWITCH CONNECTOR ON LIGHT BLUE WIRE NOT U...

Page 719: ...K AUDIO TO REAR SPEAKER RED POWER TO AMPLIFIER INSTALLATION OF REVERB AMPLIFIER SAME AS MULTIPLEX ADAPTER SEE F I G I S V f BLUE POWER TO SWITCH SUPER DELUXE RADIO G R E E N AUDIO TO SWITCH NOT USED W...

Page 720: ...T IS PROBABLY BECAUSE THE SHAFT HAS NOT YET ENGAGED THE KNOB FLAT WHEN THIS OCCURS TURN KNOB SLIGHTLY UNTIL IT DROPS INTO FULL ON POSITION DO NOT ROTATE KNOB THROUGH FULL TRAVEL IN EITHER DIRECTION UN...

Page 721: ...onnect adapter connector from back of radio receiver 5 Disconnect six wire speaker connector from stereo speaker connector or from connector to multiplex tape player switch connector C in figure 15 54...

Page 722: ...STEREO RECIEVER TAPE PLAYER BLACK WHITE STRIPE TAPE PLAYER G R E E N YELLOW GREEN BLACK STRIPE YELLOW BLACK STRIPE YELLOW GREEN BLACK STRIPE CLIP HERE INSTRUMENT PANEL WIRE HARNESS GREEN AM RECIEVER T...

Page 723: ...R E E N TO FT S P E A K E R C L I P T O T A P E P L A Y E R A S S H O W N G R E E N W B L A C K S T R I P E V I E W I N CIRCLE A P A R T O F T A P E P L A Y E R P A R T O F T A P E TAPE PLAYER P L A...

Page 724: ...ER EXTENSION WIRE CONNECTOR CENTER BRACE ON INSTRUMENT PANEL SPEAKER CONNECTOR WITH CLIP TAPE PLAYER INSTRUMENT PANEL HARNESS ASM POWER FEED YELLOW POWER FEED GREEN PLAYER BRACKET ADAPTER ASM TAPE PLA...

Page 725: ...15 40 1968 PONTIAC SERVICE MANUAL Fig 15 53 Stereo Tape Player Firebird...

Page 726: ...Unplug tape player wiring harness and remove player 6 To replace reverse the above REMOVE AND REPLACE TEMPEST Fig 15 52 1 Remove stereo tape player side trim panel by removing two phillips head screw...

Page 727: ...ide of radio 4 Disconnect fader lead green wire from con nector at back of radio 5 Disconnect tape player speaker connector six wire connector from stereo speaker connector If also equipped with multi...

Page 728: ...ANCE rotated to extreme counter clockwise position and front rear knob in FRONT position left hand front speaker should operate When FRONT REAR knob is rotated to REAR the right hand rear speaker shou...

Page 729: ...15 44 1968 PONTIAC SERVICE MANUAL TO REAR SPEAKER Fig 15 58 Rear Seat Speaker Pontiac...

Page 730: ...ACCESSORIES 15 45 SPEAKER T E R M I N A L T O F A C E LEFT H A N D SIDE O F C A R Fig 15 59 Rear Seat Speaker Tempest...

Page 731: ...peaker Firebird R E M O V E AND REPLACE MULTIPLEX TAPE PLAYER SWITCH Fig 15 54 1 Disconnect power feed from switch green wire from power feed from I P harness yellow wire 2 Disconnect power feed black...

Page 732: ...1968 P O N T I A C S E R V I C E M A N U A L 15 47 RECEIVER ASSEMBLY Fig 15 61 Rear Speaker Controls Firebird...

Page 733: ......

Page 734: ...1A 42 Antenna Electric 15 29 Antenna Manual 15 29 Automatic Level Control 4 7 Clocks 15 9 Defogger Rear Window 15 15 Radios 15 23 15 35 Accessories Continued Speaker Rear Seat 15 46 Speaker Verba Phon...

Page 735: ...n 7 1 Service and Repairs 7 2 Clutch 7 2 Control Linkage 7 2 Flywheel 7 5 Pilot Bearing 7 5 Starter Ring Gear 7 6 Specifications 7 6 Column Standard Steering 9 1 9 9 Tilt Wheel 9 5 9 15 Companion Flan...

Page 736: ...ic 6 5 Specifications 6 34 V 8 Engine Belt Adjustments 6 43 Engine Camshaft 6 56 Cylinder Heads 6 49 Manifolds 6 43 6 44 Valve Trains 6 45 Harmonic Balancer 6 53 Insulators 6 40 Engine Mechanical Cont...

Page 737: ...V 8 Engine 8 10 i Ignition Circuit 6E 13 Switch 6E 19 Timing 6C 5 6E 19 Information General Section 0 Basic Dimensions 0 5 Body Identification Plate 0 1 Car Model Identification 0 1 Decimal Equivalent...

Page 738: ...Front Section 3 Adjustment and Checks 3 1 Alignment 3 3 Ball Joints 3 14 Minor Repairs 3 5 Periodic Service 3 1 Shock Absorbers 3 6 Specifications 3 15 3 16 Rear Section 4 Automatic Level Control Ser...

Page 739: ...ble 7E 50 Disassemble 7E 12 Inspection 7E 44 Install 7E 59 Remove 7E 12 Minor Repairs 7E 4 Periodic Service 7E 2 Pressure Checks 7E 60 Road Test 7E 60 Transmission Continued Turbo Hydra Matic Continue...

Page 740: ......

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Pontiac firebird 1968, Service Manual

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