GMC X-7425 1973 Maintenance Manual Download

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X-7425

1973 GMC Motorhome

Maintenance Manual

Table of Contents

Section Description

Information, Periodic Maintenance and Lubrication

Body, Heating and Air Conditioning

2 Frame

3A Front

Suspension

3B Drive

Axles

3C Final

Drive

4 Rear

Suspension

5 Brakes

6A Engine
6K Engine

Cooling

Engine Fuel System

Emission Control Systems

6Y Engine

Electrical

7 Transmission
8

Fuel Tank and Exhaust

9 Steering

System

10 Wheels

and

Tires

12 Chassis

Electrical

Radiator and Coolant Recovery System

14 Bumpers
24 Miscellaneous

Living Area Facilities

24A

Periodic Maintenance and Lubrication

24B

Living Area Electrical System

24C Motor

Generator

24D Refrigerator

24E

Roof Mounted Air Conditioner (Information not available at time of publication)

24F

LP Gas System

24G Furnace
24H Range/Oven

24J

Living Area Water System

24K Toilet

24L

Holding Tank and Drainage System

24M Thermasan

System

24N

Cabinets and Furniture

24P Exhaust

Vents

24Q

Other Equipment (Vacuum Cleaner)

Wiring

Diagrams

Summary of Contents for X-7425 1973

Page 1: ...haust 9 Steering System 10 Wheels and Tires 12 Chassis Electrical 13 Radiator and Coolant Recovery System 14 Bumpers 24 Miscellaneous Living Area Facilities 24A Periodic Maintenance and Lubrication 24B Living Area Electrical System 24C Motor Generator 24D Refrigerator 24E Roof Mounted Air Conditioner Information not available at time of publication 24F LP Gas System 24G Furnace 24H Range Oven 24J ...

Page 2: ...se which in turn drives the driven sprocket in a clockwise direction This in effect is a reverse in the direction of engine torque due to the side mount ing of the gear unit SECTION 7 TRANSMISSION Contents of this section are listed below are First 2 48 1 gear ratio Second 1 48 1 gear ratio Third 1 0 1 gear ratio Reverse 2 08 1 gear ratio OCTOBER 1973 SUBJECT PAGE N0 General Information 7 1 Troubl...

Page 3: ... be multiplied by as much as 2 2 1 depending upon the slip speed of the converter pump and turbine A vacuum modulator is used to sense engine torque input to the transmission automatically The vacuum modulator transmits this signal to the pres sure regulator which controls line pressure so that all torque requirements of the transmission are met Figure 1 Turbo Hydra matic Transmission and proper s...

Page 4: ... above second speed to retain acceleration when extra performance is desired L Lo range permits operation at a lower gear ratio and should be used where maximum engine braking is desired such as in descending a steep grade When selector lever is moved from Drive to Lo range at normal highway speeds the transmission will shift to second gear and remain in second gear until vehicle speed is reduced ...

Page 5: ...e vehicle operator through the manual selector lever Governor Assembly Generates a speed sensitive oil pressure that in creases with output shaft or vehicle speed Governor pressure is used to control the shift points and modulator pressure regulation Vacuum Modulator Valve Provides modulator pressure that senses engine torque and vehicle speed The vacuum modulator is used to vary the shift points ...

Page 6: ...ift Front Servo TRANSMISSION 7 5 The front servo piston applies the front band to provide engine braking in 2nd gear in Super and Lo ranges The front accumulator piston cushions the apply of the direct clutch and in conjunction with a series of check balls controlling orifices is a part of the timing for the release of the direct clutch To prevent the apply of the front band in Neu tral Drive and ...

Page 7: ...s are ap plied therefore no power is transmitted Cooling and Lubrication Oil flows from the pump to the pressure regulator valve which regulates pump pressure When the pump output exceeds the demand of line pressure oil from the pressure regulator is directed to the con verter feed passage to fill the converter Oil from the converter is directed to the transmission cooler Oil from the cooler is di...

Page 8: ...MAINLINE PRESSURE INTAKE CONVERTER PRESSURE GOVERNOR PRESSURE MODULATOR PRESSURE DETINT PRESSURE 1 7 ACCUMULATOR PRESSURE ...

Page 9: ...sition the manual valve is repositioned to allow line pressure to enter the drive circuit Drive oil then flows to the 1 Forward Clutch 2 1 2 Shift Valve 3 Governor Assembly 4 1 2 Accumulator Valve 5 Detent Regulator Valve Basic Control Drive oil is directed to the forward clutch where it acts on two areas of the clutch piston to apply the forward clutch The first or inner area is fed DRIVE AND SUP...

Page 10: ...MAINLINE PRESSURE INTAKE PRESSURE CONVERTER PRESSURE GOVERNOR PRESSURE MODULATOR PRESSURE DETENT PRESSURE 1 2 ACCUMULATOR PRESSURE ...

Page 11: ...overcome the force of regulated modulated oil pressure and the 1 2 valve spring This allows the 1 2 shift valve to open permitting drive oil to enter the intermediate clutch passage Intermediate clutch oil from the 1 2 shift valve is directed to the 1 Intermediate Clutch 2 Rear Servo Accumulator 3 Front Servo Accumulator 4 2 3 Shift Valve DRIVE SECOND SPEED POWER FLOW FIGURE 7 OIL FLOW FIGURE 8 Ba...

Page 12: ...MAINLINE PRESSURE INTAKE PRESSURE CONVERTER PRESSURE GOVERNOR PRESSURE MODULATOR PRESSURE DETENT PRESSURE 1 2 ACCUMULATOR PRESSURE D J omm ...

Page 13: ...il to the direct clutch passage Direct clutch oil from the 2 3 shift valve is di rected to the 1 Direct Clutch 2 Front Accumulator Piston 3 3 2 Valve Basic Control Direct clutch oil from the 2 3 shift valve flows past a one way check valve to the inner area of the DRIVE THIRD SPEED POWER FLOW FIGURE 9 OIL FLOW FIGURE 10 Figure 9 Drive Third Gear Power direct clutch piston to apply the direct clutc...

Page 14: ...MAINLINE PRESSURE Em INTAKE PRESSURE Elll CONVERTER PRESSURE E GOVERNOR PRESSURE MODULATOR PRESSURE E DETENT PRESSURE 1 1 2 ACCUMULATOR PRESSURE LiLiff 6 Imiu flp11N j IEB ...

Page 15: ...e intermediate clutch is applied to allow the intermediate sprag to hold the sun gear against clockwise rotation Turbine torque through the drive sprocket link assembly and driven sprocket to the forward clutch is now applied through the mainshaft to the rear internal gear in a counterclockwise direction Counterclockwise rotation of the rear internal gear turns the rear pinions counterclockwise ag...

Page 16: ...MAINLINE PRESSURE INTAKE PRESSURE CONVERTER PRESSURE GOVERNOR PRESSURE MODULATOR PRESSURE I I DETENT PRESSURE 1 2 ACCUMULATOR PRESSURE ...

Page 17: ...in 3rd Front Band Released Rear Band Released Intermediate Clutch Applied Intermediate Sprag Effective in 2nd Intermediate Sprag Ineffective in 3rd DETENT DOWNSHIFT OIL FLOW FIGURE 12 2 Detent Passages DETENT 2 1 DOWNSHIFT DETENT 3 2 DOWNSHIFT POWER FLOW b 2 3 Modulator Valve a 1 2 Modulator Valve b 2 3 Modulator Valve c 1 2 Primary Accumulator Valve d Modulator Valve Detent oil in the modulator p...

Page 18: ...MAINLINE PRESSURE INTAKE CONVERTER PRESSURE GOVERNOR PRESSURE MODULATOR PRESSURE DETENT PRESSURE 1 2 ACCUMULATOR PRESSURE ...

Page 19: ...Super engine braking is prov ided by the front band as it holds the sun gear fixed Without the band applied the sun gear would over run the intermediate sprag When the selector lever is in Super intermediate oil from the manual valve is directed to the 1 Pressure Boost Valve 2 2 3 Shift Valve Intermediate oil at the boost valve will increase line pressure to 150 psi This increased intermediate oil...

Page 20: ...MAINLINE PRESSURE INTAKE Ply CONVERTER PRESSURE GOVERNOR PRESSURE MODULATOR PRESSURE J DETENT PRESSURE 1 2 ACCUMULATOR PRESSURE ...

Page 21: ...s below approximately 45 mph with the selec tor lever in Lo position as this directs Lo oil from the manual valve to the 1 Rear Servo 2 1 2 Accumulator Valve 3 Detent Regulator Valve 4 1 2 Shift Valve Basic Control Lo oil flows past a ball check to the apply side of the rear servo piston and to the 1 2 accumulator valve to raise the 1 2 accumulator oil to line pressure for a smooth band apply Lo o...

Page 22: ...MAINU14E PRESSURE INTAKE E llJ CONVERTER PRESSURE C GOVERNOR PRESSURE MODULATOR PRESSURE DETENT PRESSURE 1 1 2 ACCUMULATOR PRESSURE ...

Page 23: ...IIMe NMI ...

Page 24: ... and gear ratios is approximately 4 57 1 When the selector lever is moved to the Reverse position the manual valve is positioned to allow line pressure to enter the reverse circuit Reverse oil then flows to the 1 Direct Clutch 2 2 3 Shift Valve 3 Rear Servo Piston 4 Pressure Boost Valve Basic Control Reverse oil from the manual valve flows to the REVERSE POWER FLOW FIGURE 17 OIL FLOW FIGURE 18 TRA...

Page 25: ...AL LUBRICATION 6 PUMP COVER PLATE PASSAGE TO CASE PASSAGE NOTE THE NUMBERS IN THE CROSS SECTION 7 CASE PASSAGE TO PRESSURE REGULATOR VALVE INDICATE THAT THERE ARE ADDITIONAL 8 PRESSURE REGULATOR VALVE TO CASE PASSAGE LUBRICATION HOLES IN THIS AREA THAT 9 CASE PASSAGE TO PUMP COVER PLATE PASSAGE ARE NOT SHOWN IN THE CROSS SECTION 10 PUMP COVER PLATE PASSAGE TO CONVERTER 17 FRONT SEAL DRAIN BACK HOL...

Page 26: ...THRU EXHAUST SERVO OIL LINE A MODULATOR PRESS REG BORE MODULATOR BOR GOVERNOR INTAKE MODULATOR INTERMEDIATE Figure 20 Case Oil Passages Front Bottom TRANSMISSION 7 25 ...

Page 27: ...7 26 TRANSMISSION RND TO F SERVO LINE TO DETENT Figure 21 Spacer for Control Valve Assembly Figure 2 2 Pump Cover Oil Passages ...

Page 28: ...ND CLUTCH SPRAG CLUTCH BAND PARK NEUT 60 150 OFF OFF OFF OFF OFF OFF OFF DRIVE 1 60 150 ON OFF OFF OFF OFF ON OFF LEFT 2 60 150 ON OFF OFF ON ON OFF OFF 3 C0 150 ON ON OFF ON OFF OFF OFF DRIVE 1 150 ON OFF OFF OFF OFF ON OFF RIGHT 2 150 ON OFF ON ON ON OFF OFF LO 1 150 ON OFF OFF OFF OFF ON ON 2 150 ON OFF ON ON ON OFF OFF REV 95 230 OFF ON OFF OFF OFF OFF ON ...

Page 29: ...If oil leak is found to be in transmission check for leak in following areas REAR END It will be necessary to remove converter cover to determine location of leaks at rear end To correct leaks at rear end it will be necessary to remove trans mission from vehicle 1 Pump oil seal leak Check pump oil seal to make certain it is correctly installed and not da maged When installing a new pump oil seal m...

Page 30: ...E 1 O ring damaged or improperly installed on pipe 2 Filler Pipe not fully seated in case INTERNAL LEAKS It will be necessary to remove bottom pan to determine location of internal leaks 1 Governor pipes damaged 2 Control valve assembly to spacer or case gas kets damaged 3 Control valve assembly attaching screws loose Tighten to 8 foot pounds 4 Solenoid gaskets damaged TRANSMISSION 7 29 5 Solenoid...

Page 31: ...OTTLE FOOT ENGINE 2000 1200 RPM OFF ACCELERATOR AND TAKE PRESSURE READING NOTE WITH CLOSED THROTTLE AND DRIVING WHEELS OFF THE GROUND ENGINE RPM WILL DROP RAPIDLY PRESSURE READING MUST BE TAKEN WITHIN RPM S INDICATED AND WITH CLOSED THROTTLE Preliminary Checking Procedure CHECK OIL PRESSURES IN FOLLOWING MANNER RANGE OIL PRESSURE NORMAL P S I DRIVE BRAKES APPLIED ENGINE AT 1000 RPM 60 TO 90 SUPER ...

Page 32: ...1000 TO 3000 OIL OIL OIL OIL OIL OIL WHEELS FREE PRESSURE PRESSURE PRESSURE PRESSURE PRESSURE PRESSURE TO MOVE NORMAL NORMAL NORMAL NORMAL NORMAL NORMAL DROP MALFUNCTION IN CONTROL VALVE ASSY MALFUNCTION IN GOVERNOR OR NORMAL NORMAL NORMAL NORMAL NORMAL NORMAL NO DROP GOVERNOR FEED NO 1 2 UPSHIFT AND OR DELAYED SYSTEM UPSHtFT MALFUNCTION IN HIGH NORMAL NORMAL NORMAL HIGH _ DETENT SYSTEM MALFUNCTIO...

Page 33: ... 90 PSI 55 70 PSI DETENT SYS CHECK SOLENOID FOR FUNCTION OR DAMAGE CHECK LINE TO DETENT ORIFICE IN SPACER PLATE CHECK DETENT VALVE TRAIN NO 1 2 UPSHIFT AND OR DELAYED UPSHIFT OR 1 2 2 3 UPSHIFT FULL THROTTLE ONLY CHECK TRANS OIL LEVEL WITH BRAKES APPLIED CHECK LINE PRESSURE IN NEUT AT 1000 RPM CHECK MOD FOR LEAKING DIAPHRAGM OR BENT NECK 70 160 PSI CHECK CASE FOR DAMAGE OR POROSITY AT MOD VALVE CH...

Page 34: ...nt SOFT SHIFT SLIPS OR LONG DRAWN OUT SHIFT WITH END BUMP CHECK VACUUM SYSTEM FOR RESPONSE AT MODULATOR VAC SHOULD VARY AND RESPOND RAPIDLY TO QUICK CHANGES IN THROTTLE OPENINGS CHECK CENTER SUPPORT BOLT TORQUE AND SUPPORT LOOSENESS AIR CHECK INT CLUTCH FOR LEAKAGE AT SEALS WITH BRAKES APPLIED CHECK LINE PRESSURE IN DRIVE AT 1000 RPM REMOVE CONTROL VALVE ASSEMBLY AND DETENT SOLENOID TRANSMISSION 7...

Page 35: ...BLOCKED DIR CLUTCH FEED ORIFICE OR MISPO SITIONED GASKET RESTRICTED EXHAUST SYSTEM VEHICLE ON LIFT IGNITION ON ENGINE NOT OPERATING DISCONNECT ELECT PLUG FROM TRANS CONNECT TEST LIGHT TO DETENT TERMINAL OF DISCONNECTED WIRE HARNESS SEE ILLUSTRATION BELOW DEPRESS ACCELERATOR FULLY DETENT 2 3 Shift 1st 2nd Speeds No Detent SOFT SHIFT SLIPS OR EXTENDED TIME DURING SHIFT WITH END BUMP WITH BRAKES APPL...

Page 36: ... In Overrun Braking Lo Range Refer To Shop Manual For Pin Selection 3 Defective Rear Servo Piston or Bore NO DRIVE IN DRIVE RANGE CHECK TRANS OIL LEVEL CHECK OUTSIDE MANUAL LINKAGE CORRECT WITH BRAKES APPLIED CHECK LINE PRESSURE IN DRIVE AT 1000 R P M NO REVERSE OR SLIPS IN REVERSE CHECK TRANS OIL LEVEL CHECK OUTSIDE MANUAL LINKAGE d CORRECT WITH BRAKES APPLIED CHECK LINE PRESSURE IN REVERSE AT 10...

Page 37: ... PISTON COCKED OR STUCK INCORRECT COMBINATION OF FRONT SERVO AND ACCUMULATOR PARTS FRONT BAND BROKEN BURNED CHECK FOR CAUSE NOT ENGAGED ON ANCHOR PIN AND OR SERVO PIN WON T HOLD IN PARK OR WON T RELEASE FROM PARK CHECK OUTSIDE MANUAL LINKAGE CORRECT INTERNAL LINKAGE I Parking Brake Rod Assy Check Actuator For Chamfer 2 Parking Pawl Broken Chamfer Omitted 3 Parking Brake Bracket Loose Burr Or Rough...

Page 38: ...G GEAR ASSEMBLED BACKWARDS CRESCENT INTERFERENCE BUZZING NOISE ORIFICE CUP PLUG IN PRESSURE REGULATOR DAMAGED OR MISSING SEAL RINGS DAMAGED OR WORN CONVERTER LOOSE BOLTS CONVERTER TO FLYWHEEL CONVERTER DAMAGE CRACKED OR BROKEN FLEX PLATE TRANSMISSION NOISY FIRST SECOND AND OR REVERSE PLANETARY GEAR SET GEARS OR THRUST BEARINGS DAMAGED FRONT INTERNAL GEAR RING DAMAGED There is no approved way of ch...

Page 39: ...n Oil Level 2 Modulator Assembly 3 Filter a Blocked or restricted b O Ring on intake pipe and or grommet omitted or damaged c Split or leaking intake pipe age d Wrong filter assembly 4 Pump a Pressure regulator or boost valve stuck b Gear clearance damaged worn Pump will become damaged if drive gear is installed back wards or if converter pilot does not enter crankshaft freely c Pressure regulator...

Page 40: ...efective 5 Control Valve Assembly a Spacer plate to case gasket off location b Wrong spacer plate to case gasket CAUSES OF IMPROPER VACUUM AT MODULATOR c Vacuum operated accessory leak hoses vacuum advance etc ting 1 Engine a Requires tune up b Loose vacuum fittings TRANSMISSION 7 39 2 Vacuum Line to Modulator a Leak b Loose fitting c Restricted orifice or incorrect orifice size d Carbon build up ...

Page 41: ... channels h Manual valve bent and center land not ground properly 3 Direct Clutch a Restricted orifice in vacuum line to modulator poor vacuum response b Check ball in direct clutch piston damaged stuck or missing maged c Defective Modulator bellows d Center support bolt loose Bolt may be tight in support but not holding support tight to case e Center support oil rings or grooves da maged or missi...

Page 42: ...hrottle linkage to wide open position One click should be heard from transmission 3 Allow throttle to return to closed position One click should be heard from transmission 4 If system performed as described above down shift circuit is operating properly If system does not perform as described above proceed to step 5 5 Use test light to check orange wire at connec tor on side of transmission case T...

Page 43: ...l foreign material possible Then flush through the inlet line and finish by flushing through the return line Clean remaining solvent from cooler with compressed air applied to the return line and flush with transmission fluid LINKAGE ADJUSTMENT FIGURE 26 CAUTION Block vehicle wheels and apply ON VEHICLE SERVICING b If test light lights it will be necessary to locate the short in the wiring Test th...

Page 44: ...Figure 26 Transmission Manual Linkage TRANSMISSION 7 43 ...

Page 45: ...ting temperature 180 F 190 F Careful attention to transmission oil temperature is necessary as proper fluid level at low operating temperatures will be below the ADD mark on the dipstick Figure 27 and proper fluid level at higher operating temperatures will rise above the FULL mark Fluid level must always be checked with the vehicle on level surface and with engine running to make certain converte...

Page 46: ...hicle on hoist or place on jack stands and provide container to collect draining oil ket 3 Remove bottom pan and gasket Discard gas 4 Drain fluid from bottom pan Clean pan with solvent and dry thoroughly with clean compressed air Figure 27 Transmission Oil Level TRANSMISSION 7 45 5 Remove intake pipe and filter assembly Remove and discard intake pipe O ring 6 Install new intake pipe O ring into pi...

Page 47: ...attery cables 2 Remove engine access cover 3 Position engine holding fixture as shown in Figure 28 and adjust mechanism to remove slack from cable 4 Raise vehicle 5 Disconnect starting motor wires 6 Remove starting motor transmission without removing transmission from vehicle While the detailed procedure for removing each of the units is not outlined separately the procedures covered under the tra...

Page 48: ...Figure 26 Engine Holding Fixture TRANSMISSION 7 47 ...

Page 49: ...ion to neutral to align weld nuts to the flywheel Rotate the crankshaft to install three 3 attaching bolts and torque to 30 ft tbs Note Weld nuts must be flush to flywheel 9 Remove safety chain and jack from transmis sion 9 Install three 3 rear support bracket to trans mission bolts Torque to 55 ft lbs 10 Install two 2 rear motor mount to support bracket bolts Torque to 55 ft lbs 11 Install final ...

Page 50: ...eedometer driven gear attaching screw and retainer clip figure 31 3 Remove speedometer driven gear assembly from case bore Remove and discard O ring seal 4 Remove the governor attaching bail wire 5 Remove governor assembly and O ring seal from case bore figure 32 6 Remove stud from output end of case and place a piece of plywood under output end of case place transmission on work bench with bottom...

Page 51: ... and filter must be replaced 1 Remove thirteen bottom pan attaching screws Figure 32 Governor Removal Figure 33 Arrangement of Transmission on Bench 2 Remove bottom pan and discard gasket 3 Remove oil filter assembly 4 Remove and discard the intake pipe to case O ring seal from the oil filter assembly or from the case counterbore REMOVE PRESSURE REGULATOR VALVE NOTE Unit may be removed with transm...

Page 52: ...ve governor feed pipe from transmission case and valve body by lifting straight out 4 Remove nineteen remaining control valve as sembly attaching screws Do not remove detent so lenoid attaching screws at this time ket NOTE If the transmission is in the vehicle the front servo piston assembly may drop down as the control valve assembly and governor pipe are removed 5 Remove control valve assembly w...

Page 53: ...gage facing toward converter housing and smaller diameter end of Gage Pin J 21370 7 in servo pin bore 3 Secure Adapter Plate to transmission case with two 5 16 18 x 1 inch screws tightening screws to 18 foot pounds and secure Selector Gage to Adapter Plate tighten attaching screws to 18 foot pounds Make certain that stepped gage pin is free to move up and down in both tool and servo pin bore Stepp...

Page 54: ...ING C O RING SEAL A 2156 Figure 39 Manual and Parking Linkage TRANSMISSION 7 53 8 Remove parking pawl shaft parking pawl and return spring REMOVE SPROCKET COVER LINK ASSEMBLY DRIVE AND DRIVEN SPROCKETS 1 Remove eighteen cover attaching screws 2 Remove cover and gasket and discard gasket 3 Install Snap Ring Pliers J 4646 into sprocket bearing retaining snap rings located under the drive and driven ...

Page 55: ...p ring using Snap Ring Pliers J 8059 Figure 43 Figure 42 Removing Tight Sprockets Figure 43 Removing Sprocket Bearing Snap Ring b Mount sprocket with turbine or input shaft placed down between two 2 x 4 x 10 wood blocks NOTE Wood blocks are positioned on sides or ends depending on which bearing is to be re placed c With a hammer and brass rod drive the inner race alternately through each of the ac...

Page 56: ... 19 for location of holes 5 Inspect spline for damage 6 Inspect ground bushing journal for damage INSTALL SPROCKET BEARINGS 1 Turn sprocket so that turbine or input shaft is pointing upward TRANSMISSION 7 55 2 Install new sprocket bearing as follows a Install support snap ring letter side down onto shaft b Assemble bearing assembly on turbine or input shaft c Using a piece of pipe drive the bearin...

Page 57: ...rmine its actual thickness 6 Remove end play tool from transmission and remove dial indicator and slide hammer bolt from transmission REMOVE OIL PUMP 1 Remove two opposite pump attaching bolts from the drive support housing 2 Install two 5 16 18 x 4 guide pins in holes from previously removed bolts 3 Remove the remaining pump attaching bolts from the drive support housing 4 With one hand hold the ...

Page 58: ...ng bolts for gasket guides j Install driven sprocket support housing into Figure 47 Converter Out Check Valve TRANSMISSION 7 57 pump cover plate by using a plastic mallet to seat the housing k Install all but one driven support housing to pump cover plate attaching bolts Torque to 20 ft lbs 6 Install proper front unit end play selective thrust washer on the hub of the driven sprocket sup port hous...

Page 59: ...d play End play should read 007 to 019 The selective washer controlling this end play is the steel washer having three lugs that is located between the output flange thrust washer and the rear face of the transmission case If a different washer thickness is required to bring the end play within specifications it can be selected from the following chart 3 Remove intermediate clutch backing plate an...

Page 60: ...e Tool J 21795 9 Remove support to case spacer Figure 52 Intermediate Clutch Snap Ring TRANSMISSION 7 59 Figure 53 Center Support Snap Ring 10 Remove rear band assembly To facilitate re moval rotate band lugs away from pins and pull band assembly out of transmission case 11 Remove rear unit selective washer from transmission case INSPECTION OF TRANSMISSION CASE 1 Inspect case assembly for cracks p...

Page 61: ...n carrier and roller clutch as sembly from output carrier Figure 56 and remove roller clutch assembly from reaction carrier 4 Remove center support to sun gear races and thrust bearing from sun gear NOTE One of the races may have stuck to back of center support 5 Remove front internal gear ring from output carrier assembly Figure 57 bly 6 Remove sun gear from output carrier assem 7 Remove reaction...

Page 62: ...RRIER 1 Inspect front internal gear for damaged teeth 2 Inspect pinion gears for damage rough bear ings or excessive tilt 3 Check pinion end play Pinion end play should be 009 inch 024 inch Figure 58 4 Inspect parking gear lugs for age cracks or dam 5 Inspect output flange locating splines for dam age 6 Inspect front internal gear ring for flaking or cracks INSPECT REACTION CARRIER 1 Inspect band ...

Page 63: ...asher on each side of pinion gear with steel washers against gear Figure 59 Hold washers in place with petrolatum HEADED END PMICN PIN BRONZE WASHER I SIEEL WAS BRONZE WASHER A 2176 Figure 59 Planet Pinion Components 8 Place pinion gear assembly in position in car rier and install a pilot shaft through rear face of assembly to hold parts in place 9 Drive a new pinion pin into place from the front ...

Page 64: ...E SNAP RING 00r REACTION CARRIER ASSEMBLY REAR INTERNAL GEAR BEARING MAIN SHAFT BEARING SUN GEAR TQ Ik1 ROLLER J ASSEMBLY SUN GEAR SHAFT I D FLANGE RACE A 2178 a Install large diameter race first with flange facing up Figure 62 b Install thrust bearing in race c Install small diameter race on bearing with inner flange facing down 3 Lubricate pinion gears in output carrier with transmission fluid a...

Page 65: ... transmission fluid and install reaction carrier on output carrier so that pinion gears mesh with front internal gear NOTE When a new output carrier and or reac tion carrier is being installed and if the front internal gear ring prevents assembly of the carri ers replace the front internal gear ring with the service ring The front internal gear ring is a selective fit at the factory but not in ser...

Page 66: ...e lubrication hole is open 2 Inspect bushing for scoring wear or galling TRANSMISSION 7 65 3 Check oil ring grooves for damage 4 Air check oil passages to be sure they are open and not interconnected 5 Inspect piston sealing surfaces for scratches 6 Inspect piston seal grooves for nicks or other damage 7 Inspect piston for cracks 8 Inspect springs for collapsed coils or signs of distortion 9 Inspe...

Page 67: ... on tool to secure tool on shaft and pre vent movement of the roller clutch during installa tion of the gear unit assembly Figure 54 Figure 67 Center Support to Reaction Carrier Thrust Washer INSTALL REAR BAND AND COMPLETE GEAR UNIT ASSEMBLY 1 Inspect rear band for cracks or distortion and band ends for damage to anchor lugs and apply lug Also inspect lining for cracks flaking burning and loosenes...

Page 68: ...outlined below Place center support locating tool into the case direct clutch passage with the handle of the tool pointing to the left as viewed from the front oftrans mission and parallel to the bell housing mounting Figure 71 Lift upward on the tool which will tend to rotate the center support counterclockwise as viewed from the front of transmission While holding the center TRANSMISSION 7 67 Fi...

Page 69: ... Turn unit over and remove direct clutch back ing plate to clutch housing snap ring 4 Remove direct clutch backing plate and six composition and six steel clutch plates 5 Using Clutch Spring Compressor J 4670 Rear Clutch Spring Compressor J 6129 or an arbor press and Adapter J 21664 compress spring re tainer and remove snap ring with Snap Ring Pliers J 8059 or J 5586 6 Remove tools spring retainer...

Page 70: ...g up 3 Place Forward and Direct Clutch Inner Seal Protector J 21362 over direct clutch hub Install clutch piston inside Forward and Direct Clutch Pis ton Installer J 21409 insert assembly in direct TRANSMISSION 7 69 Figure 74 Installing Direct Clutch Piston clutch housing Figure 74 and install clutch piston by rotating it slightly in a clockwise direction 4 Install 16 clutch release springs into s...

Page 71: ...te clutch hous ing to allow sprag outer race to index with inter mediate composition clutch plates Removal of direct clutch composition faced and steel plates may be helpful and applying air pressure through the center support screw to apply the intermediate clutch plates may facilitate assem bly 4 Check operation of direct clutch by applying air pressure through direct clutch passage next to cent...

Page 72: ...te seal groove in forward clutch housing with petrolatum and install seal into clutch housing with lip facing up 3 Inspect clutch hubs for worn splines proper 3 Place Forward and Direct Clutch Inner Seal lubrication holes and thrust faces Protector J 21362 over forward clutch hub Install clutch piston inside Forward and Direct Clutch Pis 4 Inspect piston or cracks ton Installer J 21409 insert asse...

Page 73: ...Lubricate the dished and five flat steel and five composition clutch plates with tansmission fluid and install clutch plates in forward clutch housing Start with dished steel plate O D up and place a flat steel plate on top of the dished steel plate Then alternate composition and flat steel clutch plates 10 Install direct clutch hub in forward clutch housing over clutch plates and install snap rin...

Page 74: ...maining bolt E in driven support housing tightening to 20 foot pounds A 9 BOLTS 5 16 18x 750 B 9 BOLTS 5 16 18X 875 C 1 BOLT 5 16 18X1 00 D 4 BOLTS 5 16 18 X 1 125 E 5 BOLTS 5 16 18X 875 F 6 BOLTS 5 i6 18X1 50 A 2197 Figure 80 Pump Cover Plate Screws OIL PUMP DISASSEMBLY 1 Mark drive and driven gears for reassembly in same position and remove the pump body NOTE Installing the gears in the same pos...

Page 75: ...e gear into pump body with drive tangs up Figure 83 Figure 82 Installing Pump Front Seal Figure 83 Installing Pump Drive Gear NOTE Drive gear should always be installed with counterbore down INSTALLATION 1 Rotate transmission in holding fixture base so that cored oil passages are up 2 Install pump assembly over stator shaft and position to drive support housing rotating pump as necessary to align ...

Page 76: ...for damaged threads 6 Inspect inside detent lever for cracks or a loose pin 7 Inspect parking pawl return spring for de formed coils or ends 8 Inspect parking bracket for cracks or wear 9 Inspect detent spring and roller assembly INSTALL DETENT LEVER MANUAL SHAFT AND PARKING LINKAGE 1 Install parking pawl tooth toward inside of case pawl return spring and parking pawl shaft into case Figure 84 TRA...

Page 77: ...ear accumulator piston unless the oil seal rings require replacement Figure 86 Rear Servo and Accumulator If the teflon inner oil seal ring small diameter re quires replacement for service use the aluminum oil seal ring The rear accumulator piston large diameter ring groove depth is machined shallower to take the large teflon oil seal ring if this requires replacement use only the teflon oil seal ...

Page 78: ...PISTON CAN ENTER BORE Figure 87 Spacer Plate Holding Bracket TRANSMISSION 7 7 7 TEFLON OIL SEAL RING Figure 88 Front Servo Components oil seal ring from the front accumulator piston unless the oil seal ring requires replacement For service the oil seal ring will be cast iron 1 Inspect servo pin for damage 2 Inspect piston oil ring for damage 3 Inspect piston for cracks or porosity 4 Check fit of s...

Page 79: ...ompress piston and remove E ring retainer Figure 92 6 Remove Installer J 21885 and remove ac cumulator piston and spring 7 Using pin punch remove retaining pin from lower left bore pressing on pin from outer side of valve body Remove 2 3 modulator bushing 2 3 shift valve spring 2 3 modulator valve 3 2 intermediate spring and 2 3 shift valve from left bore NOTE 2 3 modulator valve will be inside of...

Page 80: ...VALVE 3E 1 2 SECONDARY ACCUMULATOR SPRING 37 1 2 ACCUMULATOR VALVE PLUG 38 RETAINING PIN A 2208 WARNING HOLD HAND OVER BORE WHEN REMOVING RETAINER PIN AS 3 2 VALVE SPRING MAY FORCE BORE PLUG OUT 12 Remove bore plug 3 2 valve spring and spacer from bottom left bore 13 Remove retaining pin from top bore by pry ing out with long nose pliers from outer side of valve body WARNING HOLD HAND OVER BORE WH...

Page 81: ...e port on the end of the bushing with hole for retaining pin 5 Install the 1 2 secondary accumulator spring and the 1 2 bore plug into bushing 6 Compress 1 2 accumulator valve train install grooved retaining pin grooved end entering hole last from outer side of valve body pressing pin flush with valve body Remove the temporary retaining pin 7 Insert spacer inside of 3 2 valve spring and install sp...

Page 82: ...ring does not catch on lip of bore when installing piston Figure 93 Control Valve Screws TRANSMISSION 7 81 21 Secure piston and spring with E ring retainer and remove Installer J 21885 22 Install manual valve into top bore 23 Placing control valve assembly on cored sur face position downshift solenoid gasket and detent solenoid on valve body 24 Install downshift solenoid attaching screws 25 Instal...

Page 83: ...essure regulator valve on spring stem end first 3 Install boost valve into bushing stem end out and stack parts so that pressure regulator spring is against valve bushing 4 Install complete assembly pressure regulator valve first into pressure regulator valve bore being careful not to drop parts during installation 5 Using a screwdriver or steel rod compress regulator boost valve bushing against p...

Page 84: ...ometer drive gear for looseness on governor sleeve 9 Inspect governor springs for distortion or dam age 10 Check governor weights for free operation in their retainers TRANSMISSION 7 8 3 11 Check valve opening at entry and exhaust 020 minimum GOVERNOR DRIVEN GEAR REPLACEMENT To facilitate governor repair in the field govcr nor driven gear and replacment pins are available for service use The servi...

Page 85: ...gear for damaged teeth or shaft 2 Inspect sleeve for scores damaged threads or cracks INSTALL SPEEDOMETER DRIVEN GEAR 1 Install new O ring seal on speedometer driven gear assembly 2 Lubricate housing lip with a thin coat of Dex ron transmission fluid 3 Install speedometer housing and seal assembly and white nylon driven gear into transmission case Figure 97 4 Position retaining clip to transmissio...

Page 86: ...til the shafts are piloted and the converter lugs are indexed in the pump gear 4 Ifdifficulty is experienced in alignment tap on outer diameter of converter with plastic headed hammer while turning converter TRANSMISSION 7 85 5 Install Converter Holding Clamp J 21366 on transmission case 6 Remove two 2 8 bolts from case to engine mounting face INSTALLING FINAL DRIVE FIGURE 29 1 Install new gasket ...

Page 87: ...edometer Driven Gear Retainer 5 16 18 18 J 4646 Snap Ring Pliers J 4670 01 Forward Clutch Spring Compressor Use with J 6129 J 21664 J 5907 Pressure Gauge Set 0 300 psi 9 hose J 6116 01 Clutch Unit Holding Fixture J 6129 Direct Clutch Spring Compressor J 6133 01 Rear Oil Pump Bearing Speedo Gear Installer J 21359 Front Pump Oil Seal Installer J 21362 Forward Direct Clutch Inner Seal Protector J 213...

Page 88: ...apor arrest is accomplished through the use of a charcoal canister s which ab sorbs the fuel vapors and stores them until they can be removed to be burned in the engine Removal of vapors from the canister s to the engine is accom plished by a calibrated purge orifice in the carbu retor In addition to the carburetor modifications and the canister s the fuel tank requires a special Contents of this ...

Page 89: ...r loss of Leak in fuel line s Replace line or hose fuel rough idle or hose s Purge hose improperly Route hose correctly routed Disconnected purge hose Connect hose to proper fitting Plugged canister filter Replace filter High volatility fuel Change brand of fuel Collapsed tank or pres Plugged or pinched vent Remove obstruction or replace line sure in tank line s Defective canister Replace canister...

Page 90: ...nister Refer to Canister Remo val earlier in this section 2 Filter is located in the bottom of the canister If vehicle is equipped with two canisters the filter is in the lower canister 3 Remove filter SERVICING E C S FUEL TANK AND EXHAUST 8 3 INSTALLATION Figure 2 Replacing Canister Filter 1 Install filter See Figure 2 2 Install canister Refer to Canister Installa tion earlier in this section HOS...

Page 91: ...NG SIGNS AND A C02 FIRE EXTINGUISHER NEAR WORK AREA WEAR SAFETY GLASSES AND SIPHON OR PUMP FUEL FROM TANK INTO AN EXPLOSIVE PROOF CONTAINER The fuel tanks incorporate a drain plug in the left front corner of the tanks See figure 4 some identification to assure proper matching of hoses and outlets 3 Disconnect hoses and remove separator INSTALLATION 1 Connect hoses to proper ports 2 Install separat...

Page 92: ...FUEL TANK AND EXHAUST 8 5 FUEL FILLER NECK FUEL TANK STRAP BOLT FUEL TANK VENT LINE FUEL FILL TUBE A 2333 Figure 3 Fuel Tanks and Lines ...

Page 93: ...L TANK 3 Remove fuel tank See FUEL TANKS RE PLACEMENT 4 Remove fuel inlet filter at carburetor and in spect for contamination If filter is plugged replace Leave fuel line disconnected 5 Locate tank away from heat flame or other source of ignition Remove fuel gauge tank unit and inspect condition of filter If filter is contaminated a new filter should be installed upon reassembly 6 Complete drainin...

Page 94: ... a longer length tail EXHAUST SYSTEM manufacturer s specifications Use an available emulsifying agent such as Product Sol No 913 or equivalent 5 Fill tank with water to capacity and agitate again 6 Empty contents FUEL TANK AND EXHAUST 8 7 7 When empty refill to overflowing with water to completely flush out remaining mixture and then empty tank 8 If any vapor is present repeat Steps 4 thru 8 Repea...

Page 95: ... During installation of a new exhaust pipe muf fler or tail pipe care should be taken to properly position components in relation to each other On all joints except exhaust manifold apply sealer GM 9985020 or equivalent to prevent possi ble leaks Incorrectly assembled parts of exhaust system are frequently the cause of annoying noises and rat tles due to improper clearances Exhaust compo nents mus...

Page 96: ...Figure 8 Exhaust Pipe Clamp Installation FUEL TANK AND EXHAUST 8 9 ...

Page 97: ...he performance of vital components and systems and or couldresult in major repair expense They must be replaced with one ofthe same part number or with an equivalent part ifreplacement becomes necessary Do not use a replacement part oflesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention ofthese parts STEERING LINKAGE Figure 1 Stee...

Page 98: ... in tie rod or inter age resulting in loss of necessary mediate rod pivots or lubricant corrosion and excessive vertical lash excessive wear n idler support Hard Steering 1 Low or uneven tire 1 Inflate to specified pressures Excessive Effort Re pressure uired at Steering Wheel 2 Steering linkage or 2 Lube with specified lubricant ball joints need lubrication 3 Tight or frozen inter 3 Lube or repla...

Page 99: ...pressure plate is fitted against the ring and located with the same two dowel pins This plate has six through ports The four central through ports connect from cavity 1 figure 4 to supply undervane 4 Remove bolt and nut securing idler arm to frame 1 Secure idler arm to frame using bolt and lock nut Torque nut to 85 to 110 foot pounds 2 Connect idler arm ball stud to intermediate rod Install ball s...

Page 100: ... the pump This is accomplished by the pressure drop which occurs across the flow con trol orifice 2 The pressure is reduced at the bottom of the flow control valve 9 because the orifice 11 is connected by 8 to the bottom of valve 9 The pressure unbalance of the valve is sufficient to overcome the force of the spring 10 allowing the valve to open the bypass hole 5 and diverting oil into the intake ...

Page 101: ...still will transmit valve hiss into passenger compartment through the steering column Rattle or chuckle noise 1 Gear loose on frame 1 Check gear to frame mounting n steering gear screws Tighten screws to 70 foot pounds 2 Steering linkage loose 2 Check linkage pivot points for ness wear Replace if necessary 3 Pressure hose touching 3 Adjust hose position Do not other parts of car bend tubing by han...

Page 102: ...s not installed 1 Install properly pump properly 2 Vanes sticking in rotor 2 Free up by removing burrs slots varnish or dirt Swish noise in steering 1 Defective flow control 1 Replace part pump valve Whine noise in steering 1 Pump shaft bearing 1 Replace housing and shaft Flush pump scored system Poor return of steering 1 Lack of lubrication in 1 Lube linkage and ball joints wheel to center linkag...

Page 103: ...mind road con dition and wind Test vehicle on flat road go ing in both directions 2 Unbalanced steering 2 Replace valve gear valve NOTE If this is cause steering effort will be very light in direction of lead and heavy in op posite direction Momentary increase in 1 Low oil level in pump 1 Add power steering fluid as effort when turning required heel fast to right or left 2 Pump belt slipping 2 Tig...

Page 104: ...er center 7 Adjust to specification with lash gear out of vehicle Hard steering or lack 1 Loose pump belt 1 Adjust belt tension to of assist specification 2 Low oil level in res 2 Fill to proper level If exces ervoir sively low check all lines and joints for evidence of external leakage Tighten loose connectors to 30 ft lbs NOTE Low oil level will also result in excessive pump noise 3 Steering gea...

Page 105: ...es recorded are within 1250 1350 psi and the range of readings are within 50 psi the pump is functioning within specs b If the pressures recorded are high but do not repeat within 50 psi the flow controlling valve is sticking Remove the valve clean it and remove any burrs using crocus cloth or fine hone If the system contains some dirt flush it If it is exceptionally dirty both the pump and the ge...

Page 106: ...w tion should the oil level be low If oil level is correct and pump still foams remove pump from vehi cle and separate reservoir from housing Check welsh plug and hous ing for cracks If plug is loose or housing is cracked replace housing Low pressure due to 1 Flow control valve 1 Remove burrs or dirt or replace steering pump stuck or inoperative 2 Pressure plate not 2 Correct flat against cam ring...

Page 107: ...als from counterbored spaces between reservoir and housing Discard these seals also figure 9 5 Remove the end plate retaining ring by insert ing a small punch in the 1 8 inch diameter hole in thehousing side opposite the flow control valve hole Compress the retaining ring with the punch and remove by inserting a screwdriver underthe ring and twisting the screwdriver figure 10 Figure 8 Studs Union ...

Page 108: ...refully clean all pump parts in non toxic clean ing solvent Replace any damaged or worn parts Figure 12 Removal of Relief Valve STEERING 9 15 Figure 13 Tapping Shaft to Unseat Pressure Plate 1 Inspect flow control valve assembly for score marks wear burrs or other damage 2 Inspect castings for cracks or other visual evi dences of damage Check machined surfaces espe cially mating surfaces on O ring...

Page 109: ...ed or exces sively worn 6 If any internal parts are found to be worn or damaged flush steering gear or disassemble gear and clean internal parts ASSEMBLY OF PUMP 1 Install new pump shaft seal using seal protec tor J 22616 and seal installer J 7728 or a 1 inch socket with an arbor press or hammer figure 16 3o not use any more force than necessary to seat the seal 2 Lubricate new pressure plate O ri...

Page 110: ... Power Steering Fluid and install in second groove from rear of housing 11 Install end plate spring in groove provided in pressure plate figure 11 12 Lubricate end plate with Power Steering Fluid so as not to damage O ring and press into housing with an arbor press figure 21 Depress only far enough to enable retaining ring to seat properly in groove 13 Install end plate retaining ring and release ...

Page 111: ...EL un der ADJUSTMENTS ADJUSTMENTS FLUID LEVEL 1 Run engine until Power Steering Fluid reaches normal operating temperature approximately 170 F then shut engine off Remove reservoir filler cap and check oil level on dipstick 2 If oil level is low add Power Steering Fluid to proper level on dipstick and replace filler cap NOTE When adding or making a complete fluid change always use special power st...

Page 112: ...from the housing pressure port passes through the slots in the STEERING GEAR a Loosen the pump attaching bolts and ad just the belt to correct tension by moving the pump outward away from the engine b Snug all pump mounting bolts and remove pry bar c Tighten all pump mounting bolts to speci fied torque d Check belt tension and remove the belt tension gage 2 When the power steering pump pulley is d...

Page 113: ...ROUBLE DIAGNOSIS under POWER STEERING PUMP earlier in this section STEERING GEAR REMOVAL 1 Disconnect the power steering hoses from the steering gear and cap the hose fittings 2 Remove the pitman arm shaft nut Mark the relation of the pitman arm to the pitman shaft Dis connect the pitman arm from the pitman shaft using tool number J 24319 or similar puller 3 Loosen steering shaft yoke cinch bolt 4...

Page 114: ... Ball Retainer Tool J 21552 from gear housing 6 Remove the adjuster plug as follows a Loosen the adjuster plug locknut and remove Figure 22 Power Steering Gear b Remove adjuster plug assembly with Span ner Wrench J 7624 figure 27 Remove and discard the adjuster plug O ring 7 Grasp the stub shaft and pull the valve assem bly from the housing bore Separate worm and valve and remove the lower shaft c...

Page 115: ...er Plug 22 Thrust Bearing 37 Plug 7 O Ring 23 Thrust Washer 38 O Ring 8 Thrust Washer Large 24 Housing 39 Housing End Cover 9 Thrust Bearing 25 Locknut 40 Retainer Ring 10 Thrust Washer Small 26 Attaching Bolts and 41 Needle Bearing 11 Spacer Washers 42 Oil Seal 12 Retainer 27 Side Cover 43 Back Up Washer 13 O Ring 28 O Ring 44 Oil Seal 14 Spool Valve 29 Pitman Shaft 45 Back Up Washer 15 Teflon Oi...

Page 116: ... needle bearing dust seal and oil seal from adjuster plug using Bearing Remover J 8524 2 and Driver J 7079 2 as shown in Figure 30 Discard the seals Figure 25 Removing Rack Piston End Plug STEERING 9 23 Figure 26 Removing Rack Piston 4 Wash all parts in clean solvent and dry parts with compressed air 5 Inspect thrust bearing spacer for wear or cracks Replace if damaged 6 Inspect thrust bearing rol...

Page 117: ...ust Washer Small 10 Spacer 11 Retainer 6 A 1510 Figure 28 Adjuster CAUTION Place a block of wood under the adjusterplug to protect it during driving of the bearing 2 Place dust seal and a new oil seal on Tool J 8524 1 lip of seal away from tool Lubricate seal Figure 29 Removing Retainer Plug Exploded View Figure 30 Removing Bearing and Seal ...

Page 118: ...e of the retainer figure 33 NOTE The projections must not extend beyond the spacer when the retainer is seated The spacer must be free to rotate VALVE AND STUB SHAFT ASSEMBLY Disassembly Figure 33 Install Retainer STEERING 9 25 1 Remove and discard O ring in the shaft cap end of the valve assembly 2 To remove the stud shaft assembly from the valve body proceed as follows a While holding the assemb...

Page 119: ... evidence of leakage between the torsion bar and the stub shaft or scores nicks or burrs on the ground surface of the stub shaft that cannot be cleaned up with crocus cloth the entire valve assembly must be replaced 4 Check the outside diameter of the spool valve and the inside diameter of the valve body for nicks burrs or bad wear spots If the irregularities cannot be cleaned up by the use of cro...

Page 120: ...E COVER Disassembly Remove the locknut and unscrew the side cover from the adjusting screw Do not attempt to disas semble pitman shaft Discard locknut Cleaning and Inspection 1 Wash all parts in clean solvent and dry with compressed air 2 Check pitman shaft bearing surface in the side cover for scoring If badly worn or scored replace the side cover assembly 3 Check the sealing and bearing surfaces...

Page 121: ...ating the worm counter clockwise IMPORTANT The black balls are 0005 smaller than the silver balls The black and silver balls must be installed alternately into the rack piston and return guide 5 Alternately install 5 balls into the return guide and retain with grease at each end of guide Install the return guide clamp and tighten the 2 clamp screws to 6 foot pounds STEERING GEAR HOSE CONNECTOR AND...

Page 122: ...r J 6217 figure 41 11 Check operation of valve by pushing lightly against valve with a small punch or small rod Valve should reseat itself against connector seat when pres sure is removed from spring 12 Connect pressure and return line hoses on steering gear Tighten hose fittings to 30 foot pounds 13 Check fluid level in pump reservoir and add if necessary PITMAN SHAFT NEEDLE BEARING AND SEALS Rem...

Page 123: ...eal double lip backup washer and inner seal with the lips ofthe seals facing away from the adapter Seal identification toward adapter b Drive the seals into the housing until the top of Adapter J 6278 2 is flush with the housing figure 45 c Remove the tool and adapter then install the back up washer and seal retaining ring The re taining ring will not seat in the groove at this time d Reinsert Too...

Page 124: ...asher in only far Figure 46 Installing Pitman Shaft Seals enough to provide clearance for the retaining ring Install retaining ring 8 Fill pump reservoir to proper level with Power Steering Fluid Start engine and allow engine to idle for at least three minutes without turning steering wheel Turn wheel to left and check for leaks Add Power Steering Fluid as required 9 Remove tape and reconnect pitm...

Page 125: ...over stub shaft then install the adjuster plug assembly in the housing until it seats against the valve body figure 51 Remove Seal Protector Figure 49 Installing Valve Body Figure 50 Valve Body in Housing 4 Adjust thrust bearing preload as follows a Using spanner wrench J 7624 3 4 12 point socket and in lb torque wrench tighten adjuster plug up snug clockwise Back adjuster plug off 1 4 turn and me...

Page 126: ...center groove of the rack piston STEERING 9 33 Figure 53 Torquing Over Center Locknut c Install the side cover bolts and tighten to 35 foot pounds 7 Install the rack piston plug in the rack piston and torque to 75 foot pounds 8 Install a new housing end cover O ring and lubricate it with Power Steering Fluid Install the end cover and retaining ring 9 Adjust the over center preload as follows a Mak...

Page 127: ...e first time Since a handling stability complaint can be caused by improperly adjusted worm thrust bearings as well as an improper gear over center adjustment it is necessary that the steering gear assembly be removed from the vehicle and both thrust bearing and over center preload be checked and corrected as necessary An in vehicle check of the steering gear will not pin point a thrust bearing ad...

Page 128: ...ee Figure 55 Limits for new and old gears are different as follows a New gear over center torque to be 4 8 inch pounds additional torque but total over center torque must not exceed 18 inch pounds b Used gear 400 or more miles Over center torque to be 4 5 inch pounds additional torque but total over center must not exceed 14 inch pounds 2 Record total over center torque This consists of over cente...

Page 129: ...pecifica tion in order that the bracket will break away under impact When the column is removed special care must be taken in handling this assembly Only the speci fied wheel puller should be used When the column is removed from the vehicle such actions as a sharp blow on the end of the steering shaft or shift lever leaning on the column assembly or dropping of the assembly could shear or loosen t...

Page 130: ... start A Actuator rod deformed A Straighten or replace B Any high effort B Check items under high effort condition section Key can not be removed A Ignition switch is not A Readjust in off lock set correctly B Defective lock cy B Replace lock cylinder linder Lock cylinder can be A Lock cylinder with A Replace lock cylinder removed without de defective retainer pressing retainer B Lock cylinder wit...

Page 131: ...G Loose sight shields G Bend to eliminate rattle H Lower shaft bearing H Replace bearing Check shaft and worn or broken replace if scored 1 Upper shaft bearing I Replace bearing assembly worn or broken J Shaft lock plate J Tighten three screws to 15 cover loose in lbs or if missing replace Caution Use specified screws K Shaft lock snap ring K Replace snap ring Check for not seated proper seating i...

Page 132: ...applied to the steering wheel Lash in mounted column A IP to column bracket A Tighten to 20 foot pounds assembly mounting bolts loose B Broken weld nuts on B Replace jacket assembly jacket C IP bracket capsule C Replace bracket assembly sheared D Loose shoes in housing D Replace shoes E Loose tilt head pivot E Replace pivot pins pins F Loose shoe lock pin in F Replace pin support G Loose support s...

Page 133: ...Replace pivot pins to return to top tilt position B Wheel tilt spring is B Replace tilt spring defective C Turn signal switch C Readjust wires too tight Noise when tilting A Upper tilt bumpers A Replace tilt bumper column Worn B Tilt spring rubbing in B Lubricate housing Condition Possible Cause Correction Turn signal will not A Loose switch mounting A Tighten to specified torque cancel screWs 25 ...

Page 134: ...de B Replace spring tent or cancelling springs C None of the above C Replace switch Hazard switch cannot be A Foreign material be A Remove foreign material turned off tween hazard support can 1 No foreign material impeding celling leg and yoke function of hazard switch replace turn signal switch Hazard switch will not A Loose switch mounting A Tighten mounting screws stay on or difficult to screws...

Page 135: ...opens grounds etc Front or rear turn sig A Burned out or damaged A Replace bulb nal lights not flashing turn signal bulb B High resistance con B Remove or repair defective nection to ground at bulb connection socket C Loose chassis to column C Connect securely connector D Disconnect column to D Replace turn signal switch chassis connector Connect new switch into system and operate switch by hand I...

Page 136: ...sockets at light sockets D Loose chassis to col D Connect securely umn connection E Disconnect column to E Replace signal switch chassis connector Connect new switch into system without removing old Operate switch by hand If flashing occurs at normal rate the signal switch is defective F If the flashing rate F Locate and repair as required still extremely slow Use manual as guide check chassis wir...

Page 137: ... black and F black w pink stripe female contacts on the chassis side figure 56 Bent paper clip will work if buzzer sounds continue diagnosis If not locate and repair chassis wiring use manual as guide NOTE 1 If the buzzer fault has not yet been detected connect a continuity meter light to the male E and F connector contacts figure 57 Insert the key the full depth into the lock cylinder If contact ...

Page 138: ...gure 58 Check buzzer switch pads with continuity meter If contact is made function is normal If not replace signal switch NOTE 3 If the fault has not yet been isolated and repaired connect a continuity meter to the buzzer switch probes figure 59 Fully insert and remove the key from the lock cylinder If contact is made with the key in and is broken with it out the function is normal Retrace diagnos...

Page 139: ...not made replace buzzer switch L Buzzer switch contact L Reset contact gap gap too large NOTE 4 Setting the contact gap Press a 030 wire type spark plug gap wire with flat piece of stock on the actuator pad figure 63 If contact is not made adjust switch as shown in Figure 64 until positive contact is made Use continuity meter With positive contact at 030 use a 025 plug gap wire beneath the flat st...

Page 140: ...lace lock cylinder operate with key out start position if buz but stops when door zer stops in run posi is closed tion or when turned past run towards start the problem is a sticky lock cylinder actuator B Chips foreign material B Remove reassemble and recheck in lock cylinder bore function C Sticky lock cylinder C Replace lock cylinder actuator tip D Damaged or broken buz D Replace buzzer switch ...

Page 141: ...e hammered upon as hammering could loosen plastic injections which maintain column rigidity 1 Disconnect column from lower steering shaft at cinch clamp 2 Disconnect the shift linkage from the shift lever 3 Remove screws securing toe pan cover to fire wall and loosen cover 4 Remove bolts securing bracket to instrument panel and disconnect PARK RNDSL pointer on the automatic shift column 5 Disconne...

Page 142: ...Figure 6 7 Standard Column ...

Page 143: ...ling cam off upper steering shaft Figure 69 Removing Lock Plate Figure 70 Removing Protector 5 Slide thrust washer off upper steering shaft 6 Remove turn signal lever screw and lever 7 Push hazard warning switch in and unscrew knob 8 Remove three switch mounting screws Remove the four mounting bracket screws and the bracket from thejacket Pull theconnector out of the bracket on thejacket Remove th...

Page 144: ... can be performed in the vehicle Figure 73 Removing Buzzer Switch 16 Remove thrust cup figure 75 STEERING 9 5 1 Figure 74 Removing Upper Housing Assembly 13 To remove any further parts from the upper end the ignition switch should be removed The switch should be positioned in off unlocked posi tion before removing If the lock cylinder has already been removed the connecting rods to the switch shou...

Page 145: ...rom the jacket 22 Remove lower bowl bearing from top of jacket figure 80 Figure 77 Removing Rack Preload Spring Figure 78 Removing Shift Gate DISASSEMBLY OF LOWER END Steering wheel cover lock plate retaining ring spring cancelling cam and flat washer must be removed prior to disassembly of the lower end Fol low instructions above 1 Pull steering shaft assembly from bottom of column 2 Remove the t...

Page 146: ...es Figure 81 Removing Neutral Start Switch STEERING 9 53 Figure 82 Removing Bearing Adapter Clip 1 Install the sector in the lock cylinder hole over the sector shaft with the tang end to the outside of the hole Press the sector over the pin with a blunt tool figure 84 2 Install the shift gate to the housing 45 in lbs 3 Insert the rack preload spring in the housing from the bottom side figure 77 4 ...

Page 147: ...upper bear ing housing assembly on the jacket Figure 85 Bolt and Rack Assembly Figure 86 Installing Rack and Lock Bolt The bowl should be in the park position and the rack pulled downward Be sure the housing is seated on the jacket and drive the screws 60 in lbs figure 87 10 Assemble buzzer switch to spring clip with formed end of clip around the lower end of switch and spring bowed away from swit...

Page 148: ...he slider hole and as semble to the column with two screws Caution should be exercised to prevent moving the switch out of detent Use only the correct screws Tighten to 35 in lbs 14 Assemble washer spring and cancelling cam on shaft making certain that the turn signal switch is in neutral and the hazard warning plunger is REASSEMBLY OF LOWER END STEERING 9 55 Accessory Off Lock Off Unlock 2 Positi...

Page 149: ... Remove upper shift lever from bowl Remove indicator wire if automatic transmisssion column Remove neutral start switch 8 Depress lock plate with finger and pry retain ing out of groove with screw driver figure 92 Figure 90 Removing Wire Protector Figure 91 Connector and Wires Taped Tool J 23653 canbe used figure 93 but the full load of the upper bearing spring should not be relieved as then the r...

Page 150: ...Lock STEERING 9 5 7 in full tilt up position Remove tilt spring retainer using screw driver blade that just fits into slot open ing Insert screw driver in slot press in approxi mately 3 16 in turn approximately 1 8 turn counter clockwise until ears align with grooves in housing and remove spring and guide figure 98 16 With the ignition switch in acc position remove two ignition switch mounting scr...

Page 151: ...aining ring with screw driver Remove thrust washer If service is required on upper end only steps 1 thru 22 may be performed in the vehicle It is neces sary to remove the mounting bracket and loosen toe plate to prevent bending of jacket and toe plate to service the signal switch 23 Remove clip bearing adapter retainer and bearing adapter assembly from lower end ofjacket 24 Remove shift tube from ...

Page 152: ...re 101 Figure 101 Removing Tilt Lever Shield Figure 103 Removing Drive Shaft STEERING 9 59 Figure 102 Removing Lock Bolt Spring 29 Remove lock bolt spring by removing spring retaining screw and moving spring clockwise to remove from bolt figure 102 30 If there is a snap ring remove it from sector drive shaft With small punch lightly tap drive shaft from sector figure 103 Remove drive shaft Remove ...

Page 153: ...n bearing housing Again relieve load on release lever as in step 31 of Disassembly of Steering Column 4 Install drive shaft in housing Lightly tap sec tor onto the shaft far enough to expose snap ring groove Replace snap ring if it was removed 5 Install lock bolt and engage with sector cam surface figure 102 6 Install rack and spring Replace shim if one was removed Block tooth on rack to engage bl...

Page 154: ...crew driver in retainer slot Turn re tainer clockwise to engage figure 98 19 Install tilt lever opening shield in housing figure 101 Figure 106 Engaging Rack STEERING 9 6 1 20 Remove tilt release lever install housing cover and seat screw at 12 o clock position first Tighten to 100 inch pounds 3 screws 21 Assemble buzzer switch to spring clip with formed end of clip under end of switch and spring ...

Page 155: ...up light switch Do not tighten screws Neutral start switch will be adjusted in the car and should be tightened to 20 inch pounds DO NOT SUBSTITUTE SCREWS 31 Install lower wire protector over wires and on jacket figure 90 32 Install mounting bracket DO NOT SUBSTI TUTE BOLTS Mounting bracket torque 15 foot pounds 33 Install steering wheel Torque steering wheel nut to 30 foot pounds 34 Install horn p...

Page 156: ...NKAGE Torque Part Location Ft Lbs Nut Steering Arm to Tie Rod End 40 50 Nut Tie Rod Clamp Nuts 19 24 Nut Tie Rod To Intermediate Rod 40 50 Nut Idler Arm To Intermediate Rod 40 50 Nut Idler Arm To Frame 85 110 Nut Relay Lever To Intermediate Rod 40 60 Bolt Relay Lever To Frame 250 300 Nut Drag Link To Relay Lever 40 60 Nut Drag Link To Pitman Arm 40 60 Nut Pitman Arm To Steering Gear 160 210 POWER ...

Page 157: ...092 Handle J 8524 1 Adjuster Plug Bearing Installer J 8524 2 Adjuster Plug Bearing Remover J 21552 Ball Retainer J 21854 01 Pivot Pin Remover J 22407 Pitman Shaft Bearing Installer J 22616 Pump Shaft Seal Protector J 23063 Spring Remover J 23072 Shift Tube Remover J 23073 01 Shift Tube Installer J 23653 Lock Plate Compressor J 24319 Ball Stud Puller Tilt Column In Lb Spring Retaining Screw 35 Supp...

Page 158: ... in driving cornering and braking traction occurs when water snow ice gravel or other material is on the road surface Driving prac tices and vehicle speed should be adjusted to the road conditions When driving on wet or slushy roads it is possi ble for a wedge of water to build up between the tire and road surface This phenomenon known as hy droplaning may cause partial or complete loss of tractio...

Page 159: ...oint where removal of cap nuts is dif ficult If this is a persistent problem the threads of the stud and the threads of the inner cap nut should be cleaned with a wire brush WHEEL MAINTENANCE Thoroughly remove rust dirt and other foreign materials from all surfaces Hand or electric wire brushes sand blasting or chemical baths may be used Bead seat areas of rim should be free of rust and rubber dep...

Page 160: ... pressed as All tires should always carry the same air pressure A 5 pound under inflation in one front tire not only can destroy ease of steering but creates steering hazards which generally point to a potential accident An under inflated rear tire can destroy the value of the most efficient brakes Balance tires for ease of steering comfort in riding safety in driving as well as for minimum fuel c...

Page 161: ...nted with the balance mark on the tire if any lined up with the valve Bent wheels that have run out over 3 32 should be replaced Inspect tire and wheel assembly to determine if an eccentric or out of round condition exists Note that this condition if servere cannot be balanced out An assembly which has an out of round condi tion exceeding 5 16 is not suitable for use on the front of the vehicle It...

Page 162: ...th clip on chuck so air pressure build up can be closely watched and so that you can stand well back from the assembly dur ing the bead seating process to avoid possibility of personal injury MOUNTING 1 Inspect rim to insure bead seats are clean and smooth Then place rim on floor with wide side down and lubricate first bead of tire and upper bead seat of rim figure 5 2 Push first bead into well of...

Page 163: ...10 6 WHEELS AND TIRES Figure 8 Inserting Tire Iron to Lift Bead Figure 10 Inserting Tire Iron in Second Bead Figure 9 Lifting Bead Over Rim Figure 1 1 Prying Second Bead from Rim ...

Page 164: ... more noticeable A certain amount of heel and toe wear is normal Excessive wear is usually due to high speed driving and excessive use of brakes The best remedy in addition to cautioning the owner on his driving hab its is to rotate tires regularly Side Wear This may be caused by incorrect wheel camber underinflation high cambered roads or by taking corners at too high a rate of speed The first tw...

Page 165: ...life of the tire Temperature Considerably less mileage can be expected from a tire used in all warm weather driving as compared to all cool weather driving or from a tire first put into service in warm weather WHEEL INSPECTION Do not use wheels with bent rims The continued use of such wheels will result in excessive tire wear and if wheel is mounted on front of vehicle dif ficulty in steering will...

Page 166: ...heel may also be checked for radial and lateral run out if desired by temporarily mounting it to a hub on vehicle Follow the previous Steps 2 3 4 and 5 WORN WHEEL STUD HOLES FIGURE 14 This condition will usually be accompanied by appearance of a shiny worn surface on wheel face indicating that loose wheels were moving against CRACKED DISC WHEELS FIGURE 14 Cracks running from hand hole to stud hole...

Page 167: ...s and Cracked Disc Wheels SPECIFICATIONS Inflation Pressure Cold 60 PSI For Sustained Speeds Over 65 MPH 70 PSI Tires Size 8 75 16 5 Load Range D Construction Bias Ply polyester Cord Bias Ply Steel Belted Wheels Diameter 16 5 Width 6 0 Off Set 4 67 ...

Page 168: ...2 20 Headlight Switch 12 23 Directional Signals 12 23 Dimmer Switch 12 23 Horn 12 23 Horn Diagnosis 12 24 Component Replacement 12 24 Radio and Tape Player 12 26 Radio and Tape Diagnosis 12 29 Servicing 12 29 Mobile Radio Transmitters 12 31 Cruise Control 12 31 General Description 12 31 Component Operation 12 31 Diagnosis 12 37 Servicing 12 37 Brake Release Switches 12 37 Engagement Switch 12 37 S...

Page 169: ...Remove the headlight switch knob as de scribed under HEADLIGHT SWITCH RE PLACEMENT later in this section Then remove wiper control knob 3 Disengage the fiber optic ribbon from the source bulb assembly located on the lower left side of the instrument panel assembly This can be ser viced from below the dash panel 4 Remove the 4 upper bezel edge retaining screws and remove bezel from instrument panel...

Page 170: ...er head from the instru ment panel 9 When installing new or repaired speedometer head the gear indicator cable should be routed around the metal post on the back side of the instru ment panel See figure 4 10 Reverse steps 1 8 to install speedometer head and test operation SPEEDOMETER HEAD REPLACEMENT 1 Disconnect battery ground cables 2 Remove instrument panel bezel 3 Remove instrument panel rear ...

Page 171: ...nel electrical connector 4 Remove the 2 panel retaining screws and remove the panel See figure 6 5 To install reverse steps 1 4 BATTERY SELECTOR SWITCH REPLACEMENT CIGAR LIGHTER REPLACEMENT 1 Disconnect battery ground cables and remove instrument panel bezel 1 Remove the element portion of the lighter from the instrument panel 2 Remove the 2 switch retaining screws shown in Figure 5 3 Pull switch ...

Page 172: ...is sion end of conduit The fuse panel Figure 7 is mounted on the bulk head panel behind the glove box assembly To gain access to the fuse panel open the glove box and depress the hooking tang which allows the glove box to be swung out of the way The following fuses are located in this panel aux battery switch heater A C tail and dome lights windshield washer cigar lighter directional and stop ligh...

Page 173: ... light to 41 of the printed circuit and the other probe to 920 with the cruise bulb in place If the test light lights the bulb and the circuit are good If the test light does not light proceed to step 4 4 If the test light does not light remove the 920 bulb cruise and check bulb if bulb is good problem is in the cruise tell tale printed circuit board b Door ajar 1 Follow the same procedure outline...

Page 174: ... apply 12 volt current directly to the fuel tank float unit body feed wire as this will destroy the units resistive element 3 Body harness connector 10 way connector at instrument panel 4 Body harness connector to printed circuit at gauge The fuel gauge shows the approximate fuel level in the main tank when fuel selector switch is in the FUEL MAIN position and the fuel level in the auxiliary tank ...

Page 175: ...e are OK in spect tank unit ground and wire to tank unit Repair as necessary to insure good electrical con nections and no shorts through out 5 If fuel gauge system is still not functioning properly after com pleting Step 4 replace tank unit 6 If any one of 1 2 or 3 are not OK inspect wiring from ignition switch to the rear wiring con nector including grounds Re pair as necessary to insure good el...

Page 176: ...rcuit grounded between battery and x Insulate grounded circuit dash gauge 8 Open circuit between ignition switch x Clean and tighten appropriate and dash gauge terminals or repair broken wire 9 Open circuit between ground terminal x Clean and tighten mounting bracket on gauge and ground where contact is made between dash gauge and ground 10 Open circuit between sending unit x Clean and tighten app...

Page 177: ...he instrument panel rear cover 2 Remove the fuel gauge wire from the 7 wire connector on the gauge head GRAY DBL BLACK STR 3 Gauge should now read FULL If the gauge continues to read EMPTY replace the dash unit 5 If engine unit tests satisfactory under previous conditions check the following items according to nature of difficulty a If gauge does not register with ignition on this may be caused by...

Page 178: ...still does not light replace low fuel switch If low fuel indicator light remains on at all times when tank level is above the 1 16 to 1 8 level re place the low fuel switch 3 Connect the wire and check wiring for open circuit between unit and connector at the back of gauge head MISCELLANEOUS DOME LIGHT SWITCH 4 Check for continuity in printed circuit trace 5 If no defective wiring or connections e...

Page 179: ...l scale pressure DO NOT START ENGINE 4 If 1 2 and 3 above are OK clean sender terminal to insure good electrical contact with wire and make sure sender unit is ground ing to engine 5 If pressure gauge system is still not functioning properly after com pleting Step 4 replace sender unit 6 If any one of 1 2 and 3 are not OK check wiring and all connections including grounds 7 If any one of 1 2 and 3...

Page 180: ...ecessary to splice a wire or repair one that is broken always use rosin flux solder to join the wires and insulating tape to cover the spice on bare wires Circuit tests for continuity can be made by referring to ENGINE AND CHASSIS WIRING DIAGRAM When replacing wire it is important that the correct gauge be used NOTE Never replace a wire with one of a smaller size Fusible links in the wiring are fo...

Page 181: ...the instrument panel wiring harness Figure 16 shows the female portion of the front lighting harness and the appropriate wire posi tion in the connector body Front wiring for front clearance indentification dome lamps and front speakers is shown in Figure 17 Door jamb switch wiring is found on the right hand side of the vehicle and is shown in Figure 18 INSTRUMENT PANEL WIRING Wiring to the instru...

Page 182: ...olumn Refer to vehicle wiring diagram for applicable wire size and color REAR BODY WIRING Wiring for rear identification and clearance lamps along with rear speakers is fed around therear of the body through a plastic loom This harness is connected to the side body through a 6 way multiple connector located in the L H rear corner of thevehi cle See figure 22 Refer to ENGINE AND CHAS SIS WIRING DIA...

Page 183: ... CONNECTOR BACK UP LAMP CONNECTOR STEERING COLUMN POWER LEVEL WARNING CONNECTOR A 1799 BODY SIDE HARNESS REAR BUMPER A 2337 Figure 21 Steering Column Wiring Figure 22 Rear Body Wiring BODY SIDE HARNESS TRAILER WIRING HARNESS REAR END WIRING REAR SPEAKER CONNECTION A 1801 Figure 23 Trailer Wiring ...

Page 184: ...p socket assembly Regardless of the method used for checking head lamp aim the vehicle must be at normal ride height that is with gas water and passenger weight most frequently traveled with HEADLAMP REPLACEMENT FIGURE 25 1 Remove 4 headlamp bezel retaining screws 2 Disengage spring from retaining ring 3 Turn headlamp unit to disengage assembly from headlamp adjusting screws NOTE Some states have ...

Page 185: ...k Unit Re taining Components Replace Sealed Replace Sealed Beam Beam A 1804 N FAILURE CONDITIONS J OD n E7 2 F D Broken Cracked Too Bright and or fly lor Does Not Light Intermittent I Not Aim or Discolored Inside Burns Out Filament Glows Dim Will Properly U m r M 0 5 Check for Impact Rock Damage or Check for 6 Volt Check Wiring Improperly In Unit Installed in Connections to Check for Open Check fo...

Page 186: ...lace bulb and check operation See Specifi cations at the end of this section for bulb No PARKING AND DIRECTIONAL SIGNAL BULB FRONT REPLACEMENT FIGURE 25 3 Install lens and retaining screws NOTE Check for proper positioning of lamp as sembly felt drain plug See figure 27 1 Remove 2 lens retaining screws and remove lens from housing 2 Replace bulb and check operation See Specifi cations at the end o...

Page 187: ...r as possible in housing locking tabs will hold the lens in place ENGINE COMPARTMENT LAMP BULB REPLACEMENT 1 Remove the 2 lens retaining screws and then remove lens 2 Replace bulb and check operation Lighting for windshield wiper control main light switch and washer switch is transmitted through a fiber optic ribbon from a main source bulb located on the L H side of the lower instrument panel cove...

Page 188: ...12 volt test light prods from switch s dimmer switch terminal to ground Head lights off Touch 12 volt test light prods between dimmer switch feed terminal and ground Insert good light switch into connector body Check for headlight flickering after one minute operation Test light Lights Light switch OK Repair open in circuit between dimmer switch and headlights No flickering Head lights on Test lig...

Page 189: ...oltage at Light Switch Red Wire Terminal With 12 Volt Test Light Switch to Battery Bulb If Bulb Fails to Light Repair Open Red Wire Circuit to Battery Possible Open Fusible Link Circuit Shorted to Ground If After a Few Minutes Operation Headlights Flicker On and Off and or a Thumping Noise Can be Heard From the Light Switch Cir cuit Breaker Opening and Closing Repair Short to Ground in Circuit Bet...

Page 190: ...nd directional signal systems refer to STEERING SECTION 9 of this manual Two air tone S type vibrating electric horns figure 34 are mounted behind the left front access door The electric air tone S type horn is carefully adjusted and inspected during manufacture and should operate indefinitely without attention The horn assembly should not be adjusted or repaired HORN The foot operated dimmer swit...

Page 191: ...and remove the dark green wires and connectors from the horn assembly Figure 35 Horn Relay Buzzer installation 2 Remove the horn mounting bolts and remove horns See figure 34 3 Reverse steps to install horns and check oper ation HORN RELAY BUZZER 1 Disconnect battery ground cables 35 2 Remove horn relay buzzer connector figure 3 Remove mounting bolt which attaches relay buzzer to panel 4 Install b...

Page 192: ...P OFF Repair Grounded Wire From Directional Signal Switch Connector To Horn Relay r Role On nnri i RELAY DOES NOT HVrtivo iivr rtr i v r CLICK 1 Ground One Lead of a 12 Volt Test Light and Touch Other Lead To Black Wire No 2 Terminal On Horn Relay LAMP ON Touch Test Light Lead To Two Black Wires In One Terminal In Directional Signal Switch Connector LAMP ON Remove Horn Button And Touch Test Light ...

Page 193: ...er To change tape programs momentarily depress the volume control knob To eject the tape cartridge from the engaged position depress the EJECT pushbutton A car tridge should not be left inserted in the tape player due to possible tape damage SPEAKER CONTROL RADIO AND TAPE PLAYER The right radio knob is used to tune stations manually The ring around the knob is the speaker control When the ring is ...

Page 194: ... MISSING 3 CHECK GROUND STRAPS FOR CLEAN AND TIGHT CONNECTIONS 4 CHECK ANTENNA LEAD IN CONNECTOR AT RADIO 5 HAVE HELPER SIT IN VEHICLE TO EVALUATE NOISE USE A LARGE RAT TAIL FILE AND BRIDGE ACROSS FROM FRAME TO VARIOUS SECTIONS OF EXHAUST SYSTEM DO THE SAME WITH FUEL TANK ENGINE FRONT FENDERS ETC WHEN HELPER REPORTS NOISE IS REDUCED CONNECT BRAIDED GROUND STRAP TO FRAME AND TO UNIT FILE WAS TOUCHI...

Page 195: ...ND OR DEFECTIVE CONNECTORS OK Check for loose Correct Check as speaker Tape player o Check speaker mounting tape required connections by substitution player or speakers LOOSE MTG MOUNTING LOOSE OR DEFECTIVE CONNECTIONS S PEAKER TAPE PLAYER OK CONNECTIONS O K OK OR SPEAKERS Remove tape player Remove Tape Player Replace or for repair Correct as required Remove tape for repair correct as player for r...

Page 196: ...ust antenna trimmer located behind right control knob ring for maximum volume Access to antenna trimmer is gained by removing right control knob and ring and inserting screwdriver to adjust screw figure 39 NOTE If during adjustment the station becomes strong so that a change in volume can not be heard with further screw rotating tune to a weaker station and continue the adjustment ANTENNA MAST REP...

Page 197: ... car tridge played in the player will be degraded STEREO TAPE PLAYER CONVECTOR FIGURE 41 On units equipped with a stereo tape player power transistors are located on a remote heat con vector due to space limitations The convector as sembly is located behind the glove box door Connection is made to the convector by means of a 6 wire harness and plug connector running parallel to the fuse block wiri...

Page 198: ...bulb from the holder and replace 7 To assemble reverse steps 1 6 above Stereo Indicator Lamp Replacement In cases ofa failed stereo indicator lamp on stereo radio models remove radio and have service per formed by an authorized Delco radio repair facility MOBILE RADIO TRANSMITTERS Mobile radio transmitting equipment is subject to Federal Communications Commission regulations and must be installed ...

Page 199: ... regulator re leases control of the throttle which returns to idle and the vehicle slows When the button is released the solenoid is pulled in and held in respectively and the regulator resumes speed control at the speed of the vehicle during the moment of button release at vehicle speeds over 35 mph BRAKE RELEASE SWITCHES Two brake release switches are employed in the Cruise Control System When t...

Page 200: ...s electrically engaged and disen gaged through operation of the engagement switch and the electric brake release switch It has two subassemblies which make up the unit one being the Figure 44 Servo Unit Installation CHASSIS ELECTRICAL 12 33 magnetic speed sensing assembly and the other being the solenoid actuated vacuum switch air bleed and filter and low limit speed switch assembly Magnetic Speed...

Page 201: ...s possi ble Figure 45 Regulator Cross Section Surrounding the rubber drum is a U shaped spring clip which is held spread away from the drum by the nose or cam of the solenoid when the solenoid is in the relaxed position The rubber drum and this clip comprise the speed clutch of the regulator When the solenoid is energized the solenoid nose moves toward the drum and releases the ends of the clip Th...

Page 202: ... which uncovers the air bleed ports With more air bleeding into the Tee fitting a lower vacuum level is achieved at the servo dia phragm decreasing the throttle angle to correct for the overspeed condition 7 Driver accelerates by pressing accelerator pedal vehicle speed increases and the system re sponds by moving the diaphragm to decrease throttle opening Since an adjustable link is used the link...

Page 203: ...needed and or Casing Assemblies Defective Regulator Replace Regulator System does not disengage with Brake and or Vacuum Switch mis adjusted Adjust or replace as required Refer to Servo brake pedal or defective and Vacuum System Check Out and Electrical Check Out wires which should be connected to the oedal Reroute wires to stoplight switch switch es connected to the fuse block System steadily acc...

Page 204: ...ed 1 4 inch measured at the switch figure 47 VACUUM Service An inoperative sticking plugged or leaking switch must be replaced Switch replace ment is similar to brake switch replacement Be cer tain that the hose to the switch is connected firmly and is not cracked or deteriorated Adjustment The brake switch plunger must clear the pedal arm w7en the arm is moved 5 16 inch measured at the switch fig...

Page 205: ...to Figure 48 1 Check fuse and connector 2 Check electric brake switch as follows Unplug connector at switch Connect ohmmeter at points A and B on brake switch The ohmmeter must indicate infinity when the pedal is depressed and continuity when pedal is released The cruise release brake switch electric is adjusted as is the standard stop light brake switch Replace electric brake switch if needed 3 C...

Page 206: ...e plastic connector with a small blade screw driver When measuring the solenoid coil circuit resist ance between Point E Hold Terminal to ground the ENGAGEMENT SWITCH TEST Figure 48 Cruise Control Electrical Diagram CHASSIS ELECTRICAL 12 39 ideal ohmic resistance should be between 5 and 6 ohms A reading of less than 4 ohms indicates short ing in the coil circuit A reading ofmore than 7 ohms indica...

Page 207: ...line and check for leakage The cruise release brake switch vacuum and connecting hoses can likewise be checked using a vacuum pump Bulb Application Quantity Bulb No Part No Low Air Tell Tale 1 74 Brake System Tell Tale 1 161 Generator Tell Tale 1 161 Park Brake Tell Tale 1 74 Cruise Control Tell Tale 1 74 Door Ajar Tell Tale 1 74 Low Fuel Tell Tale 1 74 Power Level Tell Tale 2 74 High Beam Indicat...

Page 208: ...f servicing or replacement of such components before failure occurs 1 Frequently check coolant level If low add recommended coolant as required Contents of this section are listed below Refer to GENERAL INFORMATION AND LUBRICATION SECTION O for information relative to coolant recommendations and coolant system capacities OCTOBER 1973 2 Check hose connections and tighten clamps if seeping is eviden...

Page 209: ...tors requires the use of special tools and equipment as well as provisions for making proper tests If radiator core requires painting spray with special radiator paint do not use paint mixed with oil as oil mixed paint will form an insulation and prevent efficient dissipa tion of heat clips attaching seal and venturi ring 4 Raise vehicle 5 Disconnect lower radiator hose transmission cooler and eng...

Page 210: ...orm an air tight seal Seal of filler cap and operation of pressure relief valve can be checked using a conventional cooling system testing kit CAUTION When the engine is at normal op erating temperature or above the internal pressure built up in the cooling system will blow out scalding fluid and vapors if the radiator cap is suddenly removed To pre vent loss ofcoolant and to avoid the danger ofbe...

Page 211: ...ys tem for leakage and then test coolant with hydrometer to determine if adequate anti freeze pro tection is provided TORQUE SPECIFICATIONS COOLANT PRECAUTIONS 1 Overheating is not always caused by a defec tive cooling system incorrect ignition timing drag ging brakes under inflated tires can cause overheating 2 Keep water pump and fan drive belts at proper tension Refer to ENGINE COOLING SYSTEM S...

Page 212: ...g Bumper SECTION 14 BUMPERS ENERGY ABSORBERS LEAKAGE DIAGNOSIS OCTOBER 1973 A trace of oil on the piston tube is normal due to grease packed in the seal area during manufacturing If oil is dripping from the unit it should be replaced DAMAGE Inspect the bumper bracket frame bracket piston tube and cylinder tube for evidence of visible distor tion Scuff marks on the piston tube are normal If there i...

Page 213: ...STOP RING HYDRAULIC FLUID CYLINDER TUBE ASSEMBLY ORIFICE A 1910 Figure 2 Energy Absorber Collapsed Position GAS FILLED PISTON TUBE ASSEMBLY HYDQAULIC FLUID FILLED FLOATING PISTON ORIFICE CYLINDER TUBE 1 f ASSEMBLY Figure 3 Energy Absorber Extended Position ...

Page 214: ...bumper did not return to its original position the energy absor ber s will require replacing Figure 4 Relieving Pressure from Energy Absorber WARNING BE SAFE PROTECT YOUR EYES WEAR APPROVED SAFETY GLASSES 1 Stand clear of the bumper 2 Provide positive restraint such as a chain or cable 3 Relieve the pressure by drilling a 1 8 inch hole in the piston tube near the bumper bracket See fig ure 4 4 Rem...

Page 215: ...rly mounted so replacement procedures bar s and install on new face bar s are the same for front and rear Also due to the fact that both front and rear bumper face bars 3 Once it has been determined that the energy are two piece assemblies in some cases it may absorbers are operative install the face bar assembly only be necessary to replace half of the face bar on energy absorbers and secure with...

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GMC X-7425 1973, Maintenance Manual

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