Cadillac 54-6219 1954, Shop Manual

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Page 2: ...c S4 62 60 75 Passenger Cars and 86 Commercial Cars Service Depanncnt CADILLAC MOTOR CAR DIVISION General Motors Corporrion Betrot Michigan Copyright 195 1 Cadillac Motor Cr Division Price S20O Pri ntcd kn U S A Cexiera Motors Cotporation 19 M 4 54 ...

Page 3: ...cneral Information Lubrication Body Chassis Sheer Metal Frame Chassis Suspension Steering Rear Axle Brakes Engine Mechanical Engine Electrical Engine Fuel and Exhaust Fngine Cooling Hydra Macic Transmission Chassis Electrkal Accessories ...

Page 4: ...hich is Ia the best interest of Ihe ownen to perform that work for which r am responsible in accordance with Cad illac standards to the best of my ability and in oIl my dealings wIh Cadillac owners Ia be courteous honest and ethical and to do everything within my power to further he owners satisfaction and promote his good wilJ to Cadillac and to my dealer ...

Page 5: ...s spac is pro vsded for raons nnrcs and references I lere articles frosts the C DILLAC SERViCEMAN cnau Id Pu oct00 along si Lhi ithe aLlIes led bolIeLinathieh pertLil 0 Fi material in Usut 8cc to L Identification ESL h Cadillac car or elms sis ishe shipped eLtrieS LII enia tt serial nLnther and an engine unit nt n er Thc e tgin aerial oimh r is Osco in lcc a isrosrj isai rustce application_s u sd ...

Page 6: ...mbes tonndon 7 T l oUDI Rear axle gear cilia applicstinns in the va ioos C acillac s mu the identifying nssmhet on she rear axle caste are listed below 7 1 K 00001 Serica Ratio Ident No 50 02 5 07 150 b2 nptlona It 6 ad 62 Wi Conditsoner 6 75 2 77 7 Power Steerang and Air Conditioning 5 TK ddiCl The dv style number Ixsfv number and paint and tr ins O hers are eta pcd on a plate alt aclse En tI e r...

Page 7: ... serial number plate for the evaporator is located on the toll rigis hand end of the evaporator housing Fig i S The radio send oamher p ale 5 located oIl the aLtolii of the radio unit and to the left pig 2 9 i he Aisrronlc Eve aerial number plate is lace rod on the Lortoms of the Pisoto tube unit mounted on the err side of the instrtlltienl panel near the top of the Photo tube nousstiog bracket Fi...

Page 8: ...l base Over all Length Starting EngineNo 54 6219 V S 3 13 16 x 3 5 8 331 cu in 129 216 13 32 546200001 54 6237 67 v s 3 13 16 x 3 5 8 331 cu in 129 223 13 32 546200001 54 605 v S 313 16 x 3 5 8 331 cu in 133 227 13 32 546000001 54 75 V 8 3 13 16 x 3 5 8 331 cu in 149 3 4 237 5 32 547500001 54 86 V 8 3 13 16 x OTHER 3 5 8 NOTES 331 cu in AND REFERENCES 158 246 548600001 ...

Page 9: ...ri cation Chart and by helping to impress owners with the necessity of lubricating their cars aecerding to the schedule recommended by Cadillac TIlE LUBRICATION NOTICE Fig 1 1 isapiate on the left front door body pillar The mileage and date at which a lubrication La performed should be posted here Omi coiLpe styles this plate is located on the door Lock pillar rho enginc scriai number is also prin...

Page 10: ...e Eery10 iIe Ery 1O iPes I eo rh r l eek Su pen ion Ami and Steering Knurkie Ay Chsi Lbk p iFi 2000 Po er Stee in9 Tank q ippd Cbeth id kv d All Fk th AQ A IF WhI E y 3 tOO the p e A I Steering and Suspension 1k od D g L k Ses As Lft 5d CIsi b i g ith ec e g Every CW mIes 2lX Eng n 0 f IFe E ey WOO ked heed 10cJ C d C _i deoll picte Key Nu ers on C Ens si Ill st ion nfe to bded Fig 2 2 U seot o Ch...

Page 11: ...sdy b e 6II6 Ci 1 t F Cf DC r 2o 6 16 A661r Lb iFIC ppIy Ii h _CC6 p6d6 d pyi k6y yIdCn Jydra Switch Appip Lsbiplote where iedftoted by o ro eeeO Every 2000 6 ks A CC Y b ek _66 2ea iI66 06 A I6l6 _ CF 2062 r iL 6f16 7 Ai CInnn 620 s4 7 i 26 D 6ie clo ood rrAll Thi on pinp ol o l u SAE 40 bo 32 F nnd SAt 2 3 be Ioo 37CF Every 1000 ik SIn ing Sear LJd Oteeriog g nf Ubri b log ICf 6l p to rile pUg I...

Page 12: ...ained in Section 6 Brake System Clean and flush once a year 4 Body a Body Hardware Lubrication of the body hardware is an important part of each 2000 mile lubrication operation The following should be performed Apply a slight amount of petrolatum to the door wedge plates and door check mechanism Apply a drop or two of lOW oil at the lift bolt roller and allow it to drain inside the roller Lubricat...

Page 13: ...e and exhaust manifold screws and nuts 25 30 Ft Lbs 9 Tighten rear spring clips and U bolts 45 to 52 Ft Lbs 10 On Air Conditioner equipped cars clean and wash filters At 4000 Miles 1 Check with the owner concerning his experience with the car and clarify any questions he may have on controls or function of any part of the car 2 Correct any conditions reported to you by the owner when your inspecti...

Page 14: ... Factory Parts Department under Part No 146 1598 Each tube contains sufficient lubricant for one complete refill of the power steering gear Manual gears require only two thirds of a tuhe The fluid level in the pump reservoir on cars equipped with power steering should be checked every 2 000 miles and filled withAutomatic Trans mission Fluid type A to the mark on the outside of the reservoir as sho...

Page 15: ...ds and differential hibricants should be avoided The use of these lnatriats is entirely 000cceawarv aj the proper operation of a C adi lie car Iuring the firs L Sot miles of operation the oil in the c rs kcsse a he ll the car is shipped should be used When it is necessary to add nil during this period use nothing heavier then S A E lOW oil In winier fir 20 in summer Change the oil at Liar end of 5...

Page 16: ...omitenhinate the engine oil nm re quickly t mrlng extremely cold weatbmer trequecit starts low operating speeds and short r u las may con taoi male the oil with water cu1tdemmse ion insidc time cramthcase Hard dciv og Ic ild 5 tn thicken oils and timi 5 may imlterfere w hh easy starting in cold weather Drain the crankccseonly after the engine has been heoteil r m normal operating mcampcrature The ...

Page 17: ...filling The fluid level should be checked every 2 000 miles and fluid added to bring the level to the Full mark on the dipstick Run engine with selector lever in N neutral position at 800 R P M for approximately 1 1 2 minutes The oil level is always checked after the engine has been run ning to be sure the fluid coupling is full in order to obtain an accurate reading Reduce the engine speed to slo...

Page 18: ...h Heater 22 quarts 24 1 2 quarts 22 quarts Without Heater 19 3 4 quarts 19 3 4 quarts 19 3 4 quarts Gasoline Tank 20 gallons 20 gallons 20 gallons Tire Pressure Front 24 lbs 28 lbs 24 lbs Rear 24 lbs 28 lbs 30 lbs Air Conditioner Freon 12 7 lbs 7 lbs 7 lbs Frigidaire 525 Oil Dry 22 ozs 22 ozs 22 ozs Refill 16 ozs 16 ozs 16 ozs Hydra Matic Transmission Dry 11 quarts 11 quarts 11 quarts Refill 10 qu...

Page 19: ...l and 2 3 5 Installation 2a 3 5 Door Lock Cylinder Disassembly and 2b 3 5 Assembly Disassembly 3 3 5 Assembly 3a 3 5 Keys and Locks 3b 3 6 Cutting Keys 4 3 6 Assembling Cylinder Locks 4a 3 6 Door Outside Handle Push Button 4h 3 6 Shaft Replacement Door Outside Handle Assembly 5 3 6 Installation Door Lock Remote Control Assembly 6 3 6 Adjustment Removal and Installation 7 3 7 Adjustment Removal and...

Page 20: ...val and 38a 3 26 Installation 38b 3 26 6237 6267 6219 60S 39 3 27 Front Seat Assembly Removal and 39a 3 27 Installation 39b 3 27 Seat and Manual Adjusters 40 3 27 Seat Including Adjusters and 40a 3 27 Electric Regulators 4Db 3 28 Seat Less Adjusters and Electric Regulators 41 3 28 Seat Adjuster Removal and 41a 3 28 Installation 41b 3 28 Manual 41c 3 29 Electric Horizontal Electric Regulator 42 3 2...

Page 21: ...and front seats is standard equipment on all styles except the 6219 and 6237 electrical controls for these styles are optional Vertical adjustment of the front seat may be obtained as an accessory on all cars having electrical controls except the 75 series Controls for operation of the windows and the front seat are connected through the ignition switch which must be ON or at the ACCESSORY positio...

Page 22: ...sed between the deck lid opening and the deck lid This weatherstrip is primarily secured around the entire decklidusing the gutter as a mechanical retainer A bead of weatherstrip cement is applied to the base of the gutter before installing the weatherstrip to effect a satisfactory seal All deck lid hinges employ adjustable torque rods as a counterbalance and hold open for the lid These torque rod...

Page 23: ...aged install new Strips 3 Wadding pad must be smooth and eveil Add additional padding if iteeceesry 4 Isition cover on petit1 nob app1 y trim cement to rear edge and rear corners or panel a so to the correspeodilic surfaces of cover Allow Ce iCnl to become tacky 5 Press cemented surfaces together Iirmly sod evenly making are rita cover see is straight across the entire rear ril I of panel Allow to...

Page 24: ... ig h t cables cause slow oporat ing wiper action nose cahlea catist bale slap or overtravel a end of a tn ik If eidicr of these c andi t oi s exist readjrat cable tensIon as foilows Remnve windshield wiper l lace and arm as semh ies 2 Hold serrated tra iai ossion slmft and loosen acrev in end of ehnft as eliown In Fig 3 4 3 Tap screw lighlly siti at t or screwdriver Spring oodcd Ira Is Laaioii pu...

Page 25: ...eal is0 WLodsh kid Wi pet Tronsmis I os Skaft apply sealer it transmission housing After installation scsi area indicated at 3 FIg 3 7 Apply a bead of sealer around the shaft housing at the hole in gasket 2 Foiilinn transmission assembly up thrnogh opening in cowl op duct panel and install trans mission escutcheon and spanner not IMPOTMIT Tighten spanner nut socorely before proceeding further 3 C ...

Page 26: ...t to prolong wiper motor operation and counter clockwise to sitorren wiper motor tsperasioii period aitor tIme washer hutton has been Jrt sed b Removai ond Installation Dfsco onset sac t 01 hose from cnnrdinator 2 Remove screws A and B Fig 3 9 from wiper motor 3 Si ide coordinator out of slot in wiper motor hotisiog 4 ft reinstall coordinator rcvcrae above pro cedr re and check operation of wiper ...

Page 27: ...noel 6 Insert a strong cord Into pinchweld cavity of robber channel e ompletely eraund windshield with loose ends taped to insiUs of cLass at bottom center Fig 3 Il 7 Apply a ribbon of niedioio bodied soaler a round hase of robber channel 6 With ihe aid of a helper place windshield assembly its to windshield opening While pressing firmly from outside have helper no insIde slowly ptili ctm d frosn ...

Page 28: ...ihation of parts 14 Front Door Heater Duct and Connecting Hose Removal and Installation Operate door window glass to tsp position a td remove door tritn pad 2 Remove artachtog screws i toi ated in I7ig 3 13 and rc r evc beater duct and attached grille 3 Remmiove larger loading istie ctiver and screws ace ring smital her he a di tmg hole cover 4 Working tltroitgh larger leadIng bela dhscon mlcct ho...

Page 29: ...d regulator teat attaching holes Apply rar e over arm rest attaching holes Apply tape over trim pod oait slots at deer lock ootlet sealer gaskel II it ceopes proceed a e follows Apply eaohking compound to window regulator hester duel wiring clip and stationary cam attach ing screws Ap1 y water proof tape over attn rest attaching holes lower gage hole at 0th pillar end trim pad naul shots 16 Remova...

Page 30: ...wiring harness to door inner panel and disconnect motor lead wires ftem tlte wiring harness Then carefully polL wirhmtg harness from betweeti door panels through cutout in doc r hijige pillar 7 With door properly sopported remove door attaehittg bolts securing upper and tower hinge to front body hinge pillar or bolts securing door to hinge straps Pig 3 17 depending on what tnctliod or removal he b...

Page 31: ...oe ttt in Cr panel as specified i Note 15 asinstall Lr or heater dlttct oor tt fro pad and roitiaitltog door hardware 7 Rear Door Asiembly Removal and Installation o Removal 1 The door cad hinges may cc removed as an ass J iy fremn the center Hope pillar or the door Be tettoaved frnttt the hinge etcaps 2 If doer i t being retnavec front hinge straps lenseti weatherotrip a o g donr r tnge pillar On...

Page 32: ...tit Fig 3 19 4 Before hInge cover plates are Installed deer hinges most be weatltersealed with ntedhuet bodlcd sealer or caulliing compatind as outlined below At top and bottom of hinge ose sofficient sealer to ehisiti f o s c conditien with top of hmge and aur face of pillar completely fit ling opening in the area T0 underside of hsnge cover plates body side across both top cad bottom and extendi...

Page 33: ...pillar te deer attaching bolts Fig 3 21 and eltlf door vertically as re quired 5 Tighten attachi og silts and cneck tolerances shoiaq itt Fig 3 19 6 Install hinge co er sa ttd deer eck striket b Adlusimeni at Center Pillat ht and net and fore and aft adjustment may he made at tite cer ier ph La r 2 Follow Steps 2 and 3 of Note IS above 3 Remove hittge covcr piaies end scrihe lecatsno of lunge stra...

Page 34: ...Cylinder Locks New lnck cylinders for duplicating any 1954 Codblec locks are seaLable ftc m the Eac nry Iarts Department with the eck cylinder and lock ittg bar staked in place lea a t iutthlo ma Ta a Mets ate also available atut tnoat be oseembled Lie c 2 i do r Sc cord iutg to iiuo 5 sic ial eod c When it it necessary to asse n b Ic a new lock uivliutder to agrco with a key code number install t...

Page 35: ...and install access hole cover 6 Install weatherstrIp In original position tising weatherstrip centeltt bcett tat ailed on the doer its ttdlle lock e yl ittder tIre shaft toust be nut to proper length as das ctib oe in N te2S 27 Door Lock Remote Control Assembly Adjustment Removal and Installation a Adjustment 1 Remove door window garnish molding 1 I noeen three remote central ease a lily at trchin...

Page 36: ... I tli rear door iutsrtle safety locking rod knob st the cp position 2 Insert adjusting tool through the lack boit slot with the bolt at the hottotn of the slot and engage trip levem NOTE The tool required ta Feriorm the ad jutstrnent con be made fto rr a piece ofwire seven ittcitoa in length appmnxitr amelv I indianneter wimlt 0 ig t angle book 3 8 long at one end 3 L a edj Os lock in free wheeli...

Page 37: ...shan in Fig attd rorn t g tine screw in nr out and isitiottltig ci ore or aft as required Tighten s tlud leek tot d Ventilator Assembly Adju tm nt 6237 1 Exceaaivo lJicr fi ter of ture vcttrilatot at uitc pivot sIua eltou the c tiiatot is open may be eliminutao 1w righme iit g mi a screw u hicn nnoonis iha etutilaror t ac sitaft n the ragulatnr Fig 3 32 l ighten carefully to avnid str pping thread...

Page 38: ...pau ai sealing tnrocedore Nate 15 snd rein Cts II praviot slv me moved parts Fnm a 01 1 n tal adjoattttent refer to the dour ventilator mcgtuarar wriuc Nc te itti 31 Door Ventilator Regulator Removal and Installation a 6237 Renvuve ct n nm mr i pad doat heater cItusm both inaPt ng hn Ia c ova ta 2 Roittove the regelamr nt nchiutg sc I ewe Fig 3 35 b 6319 605 Fcurrove dnor gamtni sh cur belt iini s...

Page 39: ... heater duct Sea Nate 14 2 Break seal at ho t joint Of uppat and lower Luitugu pillar waathet a trios Lxs en renla ntle r of lower itlnge pillar weatherstrip frt m casting 3 Rentave two bai s B and adjusting atad not C altett tt in Fg 3 31 4 Retinove annal let loading Itale covet and lower adjusting stud nut l 5 Wittu doom g asa itt doe Nuaitkan it piUtit and wing aseemhl LIP from deutveen door pa...

Page 40: ...l 3 23 follows OTE To Iter forto ulti a a ttd ul uc foliate iulg adicstttuetuc pta doer crib pa1 viii hove to be rennoved Uao sen glass t u t utanne I attaching Screws at t tC doot Iock pillar Rig 3 33 Loosen adja s ittp s a J nut rLum u adlt atutug stud a nd paaition glass ran hsnne I at Ottac lack pal thr as requ IL ccl t he tigh ren srrews and nut 3 ro c r recr a condition whets the door glass ...

Page 41: ...ration afrer tite regtttntut is te moved freon the door Operalfott o uitd motor with the road removed nisy damage titC LinIt uttd iniake it inoperatIve 7 To Inetall rave t se tetnioval procedure and scat door ittttut panel 35 Front Door Window Regulator Removal and Installation Manual and Electric a 6219 605 1 lie tn nve front ukttt r Itea tcr d tc I boil loaditig Pale covatat and tape that covems...

Page 42: ...moval procedure Seal deer ioeer pane as spec iiicd un Note 15 36 Window Regulator Electric Motor Assembly Removal and In sta II tion 1 Remove el c tric windv regulatar assembly front deer sad clamnp secutrely in vise NOTE The pesitien of the regulator clamped in the visa will vary with One type of regulator and position of the lift arm c AL r ON Ilk 5t 103 TO PERFORM STEPS 2 and 3 REPOR Ut IEMrINC...

Page 43: ...oor lock pillar Pig 3 38 3 Rennovs the glass ran ciasat el fram the door throaglt the loading hole 4 To install reverse the rennoval proccdture 38 Rear Door Window Glass Adjustment Removal and Insta Ilatioti a Adiusimeat I Ta cartccr a condition where tite deer glass is cocked in the glass ran channels beeaen stationary cant screw Fig 32 and adjust rear end of statienary cam Lup or dawn as require...

Page 44: ...nside the body I Clean old sealer from around vctttilator epening and lip of rubber weatherstrip 1 Apply a bead of weatherstrip celn ett tct outer lips of rubber woathers ri n and place assembly into body ttpentng freon inside of the body i install three upper and three lower retaioing ecrews ttig 341 e nd place headlining back into pesbiott 4 Install uppcr re er quarter tn itt p nd and rctlr quar...

Page 45: ...ow can be adjusted by loosening the dawn sto1n attach itig scrcw 0 on the front guide channel l his CLOT rite be set n any location along the front guide cl e ut cl 41 Removal and Installation of 0 6267 Rear Quarter Window 1 Lower the ftikiing top slid remove near seat cLieition and rear seat back I Sntt atc the window so that it is iii the i eif dtn in ca a niott flten diaconnect positive battery...

Page 46: ... 9 TO install the rear quarLer window reverse the removal procedure 42 Rear Quarter Window Guide Removal and Installation 6237 0 Reor Guide Remove rear seat c uehion and back 2 Rctutave quarter hardware and trim assem bliss 3 icemove acc c ws hole co era 4 With the rear quarter window iii the LP positian rcmtive the rear quarter rear gaide attaching screan s A Fig 3 45 NOTE l he rear quarter windo...

Page 47: ... side roof rail mechanical sealing outer weatherstrip rear 4 eanavc the scaling strip a tra c mi1t Sc row a 5 With a se Itable tool inscrted he een front end of sealing strip and roof rail carefully pry seating strip dow tward b To unstall reverse the removal procedure 7 To adjust guide See Nate 40a 43 Rear Quarter Window Regulator Removal and Installation a 6237 1 Retnnve rear quarter window as d...

Page 48: ...anical sealing strip are slotted laterally far ignment vdth the tap of the door wittdow and door ventilator 2 Loosen sealing strip attacldng screws 3 Adjust strip in or out as required then tighten screws 0 Adjustment the side rnof rail wea titers trips together a i t c seaiing strips may be adjusted in ar out ro act dsL rctnovc at caching screws looeett e ttaclting nuts a d adjust as re qtt irsd ...

Page 49: ...l sealing strip to side roof rail Rring sctews to snug fit and rear other weatherstrips as indicated at and C Fig 3 50 and install weatherstr 7 Align sealing strip with top uf door window and ventilator and tighten screws Wine off cx cessive sealer NOTE Sealing strip a taehing screws must be drawn to uniform rightness 48 Door Weotherstrjp Removal and Installation a Removol 1 Bend back tat s of wea...

Page 50: ...icated IL ittsCtt Figure 3 51 lnstaU acrews and clean nff excessive sealer j50 Deck Lid Weatherstrip Removal and Installation Separate the butte etide a tne wcetltcrstl at the lxntrotn of cotttpartunnetit opening and care tutly disengage wea tlnerstrip from gutter fniunds turn using a flat tnol 2 ht ck tine gutter ruond tita rear cotnpartnte at opening 0 moke sore that the saace is clean for cemen...

Page 51: ... Seat Side Panel Removal and Installation a 6237 6267 Ott manual control sears remove seat atL juster control handle 2 Remove two screws and washers at front of panel twn screws and washers at rear u f panel and one screw and washer at rear inside edge of panel 3 Disengage panel from front of seat a6sembly and from center support by raising panel and pulling outward Move patiel taward rear then an...

Page 52: ...juster to floor pan screws and carefully tennave seat assembly with regulators from car 7 I o reineta Ii assembly reyerse removal pro cedore being sure that regulator groo td wire and cigar lighter grnond wire nn sedan models are secured under support and adluater screws c Seat Less Adjosters and Regulators Operate se at to raised position and remove seat side panels 2 Uetaelt switch wire ltarnoss...

Page 53: ... o Manual Retnove front seat assembly RC escribod in Note 5 3n 2 Detach locking rod A shown in tig 3 62 from sest fratnne 3 Retuinve seat adluistar to_sesu cra nne screws Muive adloster track forwsrd and retuiove screw indicated at C 4 Dieengage seaL aditsrer frL n lock ing rod und ra niove sdjoster b Electrical I Rennove ti c seat assembly ss described in N nte SIc 2 Lemavc huoriznntal equalizing...

Page 54: ...lation I Operate coat to a raised end for sord position 2 Disconnect hnrl natal regulator leaC wirea at ctnnnector a Under left side of seat on sedan models detach tensioner spring fracn equalizing rod S Torn hack carpet remove cegu tator floor pan soppoct cover A Fig 3 64 and remove suppect sccews F 4 On sedan mrslels detach horiznntal regulasr seat frame support at front of seat retoined by bolt...

Page 55: ...e and remove panel from seat 2 Remove cotter pin and cu u waaher front aeat back outer hinge pin indic atad at A in hig 3 48 3 Pull setp beck toward oizaiae ofcar sofficient ly to disengage outside support arm from hinge pin itidicated at 4 Swiag seat back forward and lift opward to disengage hooked end of cettter hinge pin from hole in hinge pin support and rcmnve seat back 5 Rennove fiber washer...

Page 56: ...nter arm rest in the half down 2 Remove two assist handle screws position and disengage the upper ends of the center arm rest filler panel from behind the rear seat 3 Pull assist handle away from finish panel and back detach robe cord from spring 3 Remove the two center arm rest hanger plate 4 Repeat steps 2 and 3 to removeopposite assist to seat back support attachingbolts working through handle ...

Page 57: ...ing from tine retaining clips attae hed to he pinchwem flange 9 ilsiunu a soitainle tool pry back winudow Lupper reveal molding from the retatuuiti clips attached to ma pinc wcidi flange Iii With a putty haife loosen seal tweeuI line rubber chaoocl aind pinc luweld flange around he periunneuer of the back wittdnw upning U from inside the car carelufly push top of tine glass ooLward with the palm o...

Page 58: ...ross the top end down the sides of t tc back win dow opening as i io ca c d by lime V Frig 1 71 Ota coupe sLylcw extend this load of sealer COt k piP LC ft aroLund juC back window opening rabbet as itudieaLcdbv lines A and B in cases where the upper revealnanoid leg retaining clips are replaced Lostul a 3 id inead of mediunl bodied sealer in mc corner of the clip sttd eotulcc L tide bead of ace is...

Page 59: ...et over which a rubber is Placed prior to inserting into a slot in ha left aide roof rail View U 2 Fig 344 B Bend down tine metal tabs of the center r l bow to disengage the support wire at the eerier roof bow location Roll headlining with support wires on outside to keep material clean 9 Remove the entIre headlining w1th support wires attached to it from the bojy BODY Fig 3 74 Rennocol nf Hacdiin...

Page 60: ...reft I lyd isengaget inec eitteotede dgeo ft heh eadlining 4 i 00sent hee dgeeo ft hep arc ela he ft rimt og aina ccesst ot heh eadliningi nt her earq uartera rea 3 R otnovet ackso rs taplesf rotnlt heh eadlininga roundt her eorq uarter induw boths idesa nda crosst heb ackw indowo pening l inenc arefully disengage he cemented ends of the headlining View rn s and LI 3 Fig 3 77 6 Carefully disengage...

Page 61: ...nshade assemblies Rear seat back and cushion b 6237 DX 1 Install support wires in listing pockets and roof bows to headlining Use extreme care when in serting cardboard foundation strips into grooves of roof bows to prevent damage to headlining material 2 Lift entire headlining assembly into body Loosely attach ends of each roof bow to the side roof rails Install ends of each support wire into the...

Page 62: ...opetliog tliroul i the use of elolngawd bolt holes in the hinge straps amid movable bolt attaching plates iti lie lid To adjust iooaen hinge sLrap retaining bolts A Fig I 7G shift id to required position ond cigh en bolts 2 Shimmitng lnerieen the hinge strap and rear compartment lid Itmer panel amy aisu he used to raiec or lower the hinge area of die lid a To raise lid at hittge a tea place a thin...

Page 63: ...artment lid inner panel aud remove twa bolts k securLap the lid to the hinge srrap ilig i SI 3 At cunter of sheff panel disengage the roYqL C reds from the torque rod support 4 UsIng a suitable length of pipe disengage time torque rod for the hinge to be removed from the retaining notches located at tine inboard face of tine appaaite hinge box Fig 3 81 NOTE Suitably mark the notch from which tue t...

Page 64: ...essary a ad ttse a SjnaC r rhich is availabjv hir extreme adjuattnneat require Talents Tiglntett cii attaching screws b Lack Cylinder and Lock Remov I Througin the opeaing hi rear cumpartmelnt lid loner paoe pig 3 84 Insert a suitable honked tool to ptdi the lack a vi mdc I Ic taitjje r a a y iru the lock cylinder 2 Restiua e the lock cylinder and gasket rota the outer panel of the rear cntnlnartn...

Page 65: ...rse above removal rrocsduru S Center move screw log Reverse P lar Lnwer Reveal Molding Re rrom aide of pillar and renvavc tinoid procedure to iustall 10 Ponder Shield Molding xtonsiumm Proat II a a e rear nnoicI 11w cx tci IC Ic in and sour front molding cxtenalon a trashing screws Reverse re nvav al procadure to in staiL II Reur Quarter Window Reveal Moidiug eonove rear quarter window garnish nno...

Page 66: ...e escutcheon from under belt molding Reverse I above procedure tu Inatail I 2 Convertible Rear Quarter and Rear End Pinchwoid Finishing Molding Ta romrmuae apply tape on panel below innoid dig a n proac c t finish on inside of body detach front edge of folding top catmtpar ttmunm bag from rear sea r back panel and detach trim stick to gain access to screw at each cod of each rear quarter molciog P...

Page 67: ...circuit As the window rtt l seat cnntrul circuits are connected thtough the igoition switch these units will not operate until the igoamun a witch is tot ned U N When mimc igmlition witch h t rmmc d on current flows to a sulenoid iii the relay located near the left ftont body pillar uoder the inatrucnelit paneL flus solenoid cluses the contacts between the power source and rho feed wire to door wi...

Page 68: ...t tester Checking a Doom Window Mutu 1 Cheek the ground of the Innotom gt nundwd on er or inner panel through frame a tachitng screws 2 Oa tmtoct coo emid uf a I2 juniper wire to hattcry positive pole and the other end to the lowering cycle motor lead tetminal Fig 3 R4 if motor fails to npsmate mmitnr unit is defective or a mechanical bind exists in the windew usaembl V 3 Repeat above ehccg witlt ...

Page 69: ... cylinders Fig 396 2 I pump to Fig 3 74 checking u nd Adjothag Hydraulic RJrnp PIe nurR 4 W itln the top in the full up lxaitlon push control knob in and hold far a few seconds the pressure should read between 24U and 230 psi If p resau Ce is he low him is Cs imgo the pit nm is not delivering the proper pre ssure or iimcrc is fluid leakage past IDe pi cton un one or both cylinders 5 ConiIcct press...

Page 70: ...s but tine top does not operate or operates slowly tito fluid nlay bc leaking past the piston in one or both of the lift cylinders Kydro Lectric Electric Circuit BODY Fig 3 78 Checking Switch 0 Mnthr Lead Wires rnl Switch 1 Connect a light tester to the feed wire term mel of the control switch Pig 3 9 2 Ground the light tester ground lead to the body me ta 2 If light tcster does tto light there is...

Page 71: ... locking action catisod by misalignment of the sunahade supports Is 0 1 countered cr the ro ir roof rail nr af a closer fit or rin c t mot rt ui rail to the windshield header is desired proceed us follows 1 Unlatch top anti raise it above windshield header 2 Lnoson screws Fig 3 IUU and adjust sun shade support up or dowit or from side to aide Ad ustm nl of Top at M e Hinge 7 ateh tito se itch cont...

Page 72: ... of the ron hoot e Adjustment of Tap at Mal Hinge Support NW S if the side roof rqil is too high or too low at dcc roar quarter wlow area proueed us 3 55 I Inosen nnatce hinge support attaching toits C Pip 3 101 N OTE In additiami to the ho its the support is secured firmly in place by serrations on tite co t acti sg surfaces of support add brace 2 Adjust support up or dow as required then tighrot...

Page 73: ...easored fr nm the cimrome heIr moldimlg to the iowcet edge on the rear roof bow 75 Convertible Top Trim Installation a Complete Top Trim Ae a hotsch operation tack the rear quarter stay pads to lime large trim stick Sec Fig 3 105 N te that inner edges of pad are 26 1 4 inches from the center of the trim stick The lower edges at the naOs are sot flush with the lawer edge of the trim stick for posit...

Page 74: ...nter bow as indiostcd by dimension in Fig 3_lop this dimension is approximately 19 i S inches from time rear how end 5 measured from the center of each bow at the inner ed of the pad 7 Remove spacer sticks when tide pads have been installed in Fig 3 110 Make sure all fiallness has bcetl drawm from curtain before trimming off excess Cr resr hnw NOTE It may he necessary ta install addi taonei mric a...

Page 75: ...ass the front roof rail wh ic it must he iock cd to the wint a hiehi header When most at the foiimsees has been removed mark the under side of r Te op material npposite the front edge of tIle rail 15 Unlock the rouf rail and epply a good tnim b cement to the rower aide oldie rami nr n En the top material almicti sill cumtcacl tM s portion of the rail I Alimrn and cement the tnp material to true fr...

Page 76: ...tall wire nn binding 22 InsIde the body dm aw quarter eectiomm of top to desired position with short tri n stick held in place by hand While holding material to trim stick roll stick to expose tacking surface and tack top material to t im sticd Then ineta I trim sticks with metal screws The finished installation is illustrated in Pt 3 117 23 When ctmmpleted the folding top should be free of wrinkl...

Page 77: ...Wire Orange tamp Ground Wire Black A Right Stop Signal tight Feed Purple B Left Stop Signal tight Feed Pink C telt Fro r t Door Jamb Switch Feed Black D Bock u p tight Feed Light Green Tail License Light Feed Dark Green F Dome Rear Compt tight feed Orange GBlonk Map courtesy Lamp Ground Right Black Left Pillar A F F C Switch Black Gas Gouge Wire Brown Light Switch Wire Brown Dome tamp Reor Door Ja...

Page 78: ...g 3 119 Body Wiring Closed Coupes Left Back up Light Wire Light Green L Left Tail Light Wire Dark Green A B C Note Denotes Body Wiring Denotes Power Wiring D Bock up Light Feed Lig hr Green Tail License Light Feed Dark Green F Rear Compt tight Feed Orange C Blank Right Stop Signal Light Feed Furple p Gas Gauge Feed Wire IBrown Left Stop Signal Light Feed Pink ç Feed Wire Light Switch Ye low Blank ...

Page 79: ...1stt iii BODY Fig 121 Special Tools OTHER NOTES AND REFERENCES 3 62 Body Cement Gun 32 96 Headlining installer J 2772 C C W W Trans Escutcheon Nut Spanner Wrench J 5659 I Hag Ring Pliers J 3286 ...

Page 80: ......

Page 81: ... The fronL bumper assembly conslsrs of four holted mogerher sections the noter impact bars a center impact bar and a hamper goard tie bar The rear hunçer assenthly consists nf three halred to gether sections Wi di thle design rep sceictenL nf any one sectIon mey lx made on either rho front or rear bumper bt case of damage The radiator grille asentbly consisting ofclose lv spaced ha r izonta I and ...

Page 82: ...also enter hole in cowl This will hold hinge oi psitiolt at this point Fig 4 3 2 Rotate hinge assembly upward and rearward around pin ac far as possible and tightan screws 3 Laasen three hinge to hood panel attaching screws at each side Elongated holes provide fore aft and sida to side adjustment of die hood 4 Lsyaeen the hInge reinforcement to hood eater moulding attaching nat 5 t hve hood trward...

Page 83: ...e door and fender at the top sod bottom should also he checked and adjusted at the same tithe to prevent interference 3 Tighten render mounting screws 4 Check the wedge shaped rubber bumpers attached to the fenders to see tlmt they are sup porting the hood when it is in a closed position to prevent metal to metal contact 5 Removal and Installation of Hood Spring 1 Open hood and prup as high as pos...

Page 84: ...or support to hood lock screws six each side and remove grille extensions catch plate screws and center baffle to air deflector screws 3 Remove parking lamp or fog lamp attaching bolts and remove lamps from grille 8 Remove four air deflector screws and re move air deflector with horns hood lock catch 4 Remove vertical fin retainer by removing plate and center baffle On Air Conditioned cars ninetee...

Page 85: ...ender bracket to radiator fore and aft as follows support a Bumper mounting bars are slotted horizontally 13 On Air Conditioned equipped cars proceed for horizontal adjustment as follows b Assembly may be adjusted vertically by means a Install and connect the condenser tocompres of vertical slots in the frame sor line c Fore and aft adjustment is obtainedbyplacing b Install and connect the condens...

Page 86: ...wire to blower motor 15 Working from under side of fender remove 14 Connect wires to Autronic Eye power relay grille extension to fender hanger screw 15 Install junction block on fender bracket 16 Remove two bolts at rocker panel extension 16 Install wire harness behind clip on fender 17 Remove rocker sill molding and insert loose end of harness through radiator support opening 18 Remove three dus...

Page 87: ...t holding strut to bumper move bumper assembly from car bar end 4 To install reverse above procedure being 6 Remove three tail pipe hanger to bumper certain that bumper assembly is aligned with bar end screws and remove hanger fenders 19 Rear Bumper Disassembly 7 Remove bumper guards from center impact bar and Assembly 8 Remove license plate bracket 1 Remove two bumper mounting bar to bumper impac...

Page 88: ...4 8 CHASSIS SHEET METAL OTHER NOTES AND REFERENCES ...

Page 89: ...s essential when using either method of checking frame dimensions to have the car on a flat level floor to obtain any degree of accuracy in the measurements 2 Checking Frame for Twist 1 Place car on section of level floor inflate tires to proper pressure 1 5 1 2 5 1 3 5 i 3a 5 1 3b 5 4 2 Measure distance from bottom of extreme front end of left side bar to floor Repeat measure ment for right side ...

Page 90: ... BOLT NUMBERS BodyStyle 1234 4A 4B 4C 567 234 4A 4B 4C 5 6219 6019 6237 6237D 6267 6267S 7523 7533 x x x x x x x x x x x x x x x xxx xx xxx 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 TORQUE TIGHTNESS All body bolts on all series except the Convertihle 20 to 35 ft lbs All body bolts on the Convertible 40 to 55 ft lbs ...

Page 91: ...1 32 5 21 32 5 21 32 Fig 5 2 Frame Checking Dimensions A Maximum spread of frame at front cross mem ber B Outside of front end of leftfrontbumperbracket to outside front end ofrightfrontbumperbrack et C Left front body bolt to right front body bolt D Over all rear cross member E Outside face of front bumper bracket to center line of front wheels F Front wheels to front body bolts C Front body bolt...

Page 92: ... Spring Liners Removal and installation of Rear 16 6 11 Spring 16a 6 li Diagnosis Chart i6b 6 11 Torque Tightness 17 6 11 Specifications Special Tools 18 6 12 GENERAL DESCRIPTION All 1954 series Cadillac cars utilize the indepen dently sprung front wheel suspension system This design permits either front wheel to follow the irregularties of the road without appreciably af fecting the other front w...

Page 93: ...e rear intermediate frame memher This ses_heg type of mounting of e rear shock absorbers gives them tho double function of rnhth LLng trauFeocrec roll sod oh eorhing road shocks The rear springs are of rite seuniU1pticah leaf type with waxed lull length lioersbetween the leaves to provide the correct Interleaf friction and prevent squeaking throughout the life of the springs The springs are cushio...

Page 94: ...nimum pressures when the tires are cold for normal driving For sustained speeds above 75miles per hour tire pressure should be increased four pounds over specifications when checked cold When checking tires the valve stem caps should be reinstalled These caps provide an essential fun ction in keeping dirt out of the valves and in re ducing the possibility of slow leaks 3 Wheel Bearing Adjustment I...

Page 95: ...so tOs I Ijc seo nul ha a iw tetuien cv to r Irate b itself diane i lbalance catises the poundi ig aooiua on the front wheels tljat is caitcu hramp b Correction of Static Unbolonce Special Equipment Not Avaltoble I fte nave wl ccl and hub from spindle as stlnit 2 Clean sll grease from vJ esi bearings aid races 3 Clomp a clean spindle in a hench SOSC at if spindle on car must hr used clean it csrea...

Page 96: ...lowly pe rntirting the eat tu assume 1 5 normal position NOTE New springs settle considerably dLtr 1mg the firat 2 Oho miles and therefore tile springs shuuid non ac replaced due to excessive hefght hefora this tUlle a Front Spring Measure the distance from tilt l uuf the lower LonLruI arm to the center of the rubber banicer bracket front Inwe r rivet on the fret ito Fog 6 4 Die spring height ahau...

Page 97: ...ont end and check the runout on the outer surface of the tire Mark the spot where maximum runout occurs 6 Place the maximum runout either to the front or rear as shown in Fig 6 6 This neutralizes the effect of runout on caster or camber Lower the wheels 7 Normalize the position of front spring by working the bumper up and down to get normal height of front spring 8 Caster and camber may now be che...

Page 98: ... pin should be tscked This s Ioid be 95u itt correct angle thdicutes damaged suapeneion arms or bent steering knuckle support Any damaged parts should bc replaced 8 After ad iustment P a s heett made tighten clump screw antt recheck NOTF its adviseabie after making a c amr adju a ment to cbs nge tlte tires pu Lung the ftoi cocos on currespondiag rear wheele and rear tires on npposite front wheels ...

Page 99: ...ctured Mode r tt C mm Sit ce ri tt imttprov emmme mtt S result itt greater car nandling ease high engitle tttrc tta and more efficicttt brakes permit uwmtera to accelerate faster drive around ctmrves at higher spoeds and stop quicker tItan they eeutd with older cars Owners driving ltah Its ntay cause cnvnerieg wear rear tire inane wear and frunt tre heel and toe wear even huugh att wheel atignment...

Page 100: ...mtmtrnt ehutild aleu be checked d Yoe n nd Toe nut Adlusinient Excessi a tue in or toe out has time effect of dragging tht tirue sideways down the road cc rap ing the trend and feathering rihhed sectiuns Fig 6 i3 Improper toe in is indies ted by feather edges on the tnaide of tire riha Fig 6 14 Toe out is imidi cated hy feather edge s on the uutstde of tire ribs Fig 6 IS Tue in should he 5 tb to 1...

Page 101: ...ssure If the noise for which the test is being made is caused by tires it will noticeably decrease when the tire pressure is increased whereas rear axle noise should show no change in volume Thump is a noise that cannot be corrected by balancing 01 realignment of wheels and tires It is a beat started by the tire on the road trans mitted and amplified by certain components of the car body not to be...

Page 102: ...ing as ortli ed in NoteS 17 Cleaning White Sidewall Tires 16 Removal and Installation of a Removal Front Wheel Hub and Bearings 1 Remove wheel di sc 2 Jack up cnr 5 temnve duet cup and take out radio stanc collector Fig 6 17 4 Remove cotmer pit wheat nut washer uuLer bearing cutue and hearing retainer with baU 5 Retmiove wheeL from spindle 6 Remove inner hearing packing rove and bearing retaine rw...

Page 103: ... helt tuek washer and not b Instollation 1 Install brecket rubber hushing c snacer bolt tecTe ssst c r and nut on shock ahsorbe I 2 TI alt retainer and r u bhc r gl ottttmte L 0mm ttpPo chock alteurher s cm 3 Install shock absorher iisothtv up into can epring and jide atc tt tlmrovglt tower in cross niem her Lhen place lower support aver nrL niiag studs in tower spring seat 4 InstalL tack wasiters...

Page 104: ...g knuckle Fig 6 1 3 Install knuckle pin through bushings steer ing knuckle and thrust bearing 4 Drive lock pin in from front of support 5 Install new dust caps and lubricate both fit tings thoroughly 6 Complete assembly by reversingdisassembly procedure 21 Removal and Installation of Steering Knuckle Support a Removal 1 Raise car drive lock pin out of steering knuckle support remove dust caps from...

Page 105: ...td support is equal on hoot sdc 8 C ItTTcIT casTer camher and me in 221 Removal and Installation of Upper Suspension Arm a Removal 1 Jack up car at front frame TTrOSC member sod also place a Ieck under tins lower auspemision arm mm side on Which upper arm is to he remtved to support spring 2 Remove upper steering knuckle suptott pivot pin and nut 3 RellIove upper suspension arm immner shaft nnaunt...

Page 106: ...ross melnnher ltot ate spring so that iOwCr angel end wifl fit in fcirr ned der ras ato n Fig 6 23 ti ttteola tor when lower sospen sion arm is ra Ls nd OnTo position luwer atissr sloi arnn and raise armtt itmto iTcatin t Guide sprIng into nnsi tion cnn instmlator witlt tanged et d in furnned de pression Pig 6 24 6 Install rohher seals hrT sasn Ttppera amtd SrTTi 5 and install pivot pin anti iuot ...

Page 107: ...the top et mhat it may beheld my a wrench to prevent the stem frt m turning wltomt 2 Remove ntit frum shock absorber moimnting stud mm ipritig U hoit plate attd remaaove bushing retelaer TtnC auter robber hushing 3 Rennove shack absorber frounn stud sr d guide stem out of upper mTi tnTirg bracket 4 i tn install reverse the above procedure being etmre the cupped shaped rataii era are in stalled wit...

Page 108: ...tiaa or the hack of the saw blade to 1 4 width wtlt permut sewing litner without spreading spring leaves too tar apart 6 it tat all tcw litter ftp w itIm U i t iota e tad toward axle and work otut wedge keeping ifner lip 10 O TiOti 7 Repeat above operatian at each end 0i the twa upper liners in each rear spring Itista Ii new hush inge tIn SIT eye at front and rear 2 Imtstnfl spring an rear in e r ...

Page 109: ...n steering system EFFECT CAUSE REMEDY Low or Steering adjusted uneven tire pressure gear or connections too tight Inflate tires to proper pressure Test steering system for bind ing with front wheels off floor Adjust as necessary and lubri cate Insufficient or incorrect lubri cant used Excessive caster or toe in Suspension arms bent or twisted Front springs sagged King pin bushings scored Steering ...

Page 110: ...ate tires to proper pressure Check forwheel and tire wobble See that wheels and tires are properly mounted Adjust toe in to specifications Check wheel alignment Replace with new knuckle Cupped Tires Normal cupping of tires Tires improperly inflated Wheels tires or brake drums out of balance Incorrect drag link height Worn steering knuckle bear ings or wheel bearings incor rectly adjusted or worn E...

Page 111: ...rative Front springs weak or sagged Wrong type or size of tires used Deflate tires to proper pressure Adjust steering gear and con nections Check shocks and replace if necessary Check spring height and replace if necessary Install new tires of correct type and size TORQUE TIGHTNESS Ft Lbs Ft Lbs Application Size Mm Max Knuckle to brake plate and steering arm 7 16 20 60 70 Knuckle support arm fixed...

Page 112: ...ate Per In 54 6019 Without Air Conditioner 1460194 Light Blue 2240 350 54 6219 6237 and 6237D Without A C 1460193 Green 2180 350 54 6267 and 6267S Without A C 1460195 Pink 2320 375 54 6019 6219 6237 and 6237D With A C 1460195 Pink 2320 375 54 7523 and 7533 Without A C 1460191 Purple 2430 400 54 7523 and 7533 With A C 1460192 Orange 2550 400 54 86 1460189 None 2500 540 Inside diameter of springs is...

Page 113: ...ir Conditioner 1460925 Pink 1260 120 5 54 6019 and 6237D With Air Conditioner 54 60 and 62 Heavy Duty 54 7523 and 7533 Except Exports 54 7523 and 7533 Export 54 86 54 86 Heavy Duty 1460925 1460930 1460927 1460929 1460928 1460931 Pink Dark Red Purple Yellow None white 1260 1330 1440 1430 1700 1900 120 140 140 170 235 235 5 6 6 7 9 9 All springs are 2 50 inches in width Color daub to appear on rear ...

Page 114: ...ly operated power steering gear Fig 7 1 which combines the recirculating ball type gear with a hydraulic booster mechanism is used on all 1954 series 62 60S and 75 cars and is available as optional equipment on the 86 series when the chassis is ordered at the factory The hydraulic booster is linked to the pitman shaft through a separate power rack and is controlled by a valve assembly on the steer...

Page 115: ...STEERING 7 I O DIiI ...

Page 116: ...spool is localed 000scen hc steering shaft and the spool This a Iceve is n einteicl a position centric with the s cer gshsft hyn ruhher located in a gnlove n the shaft Pig 7 3 The sleeve is held in position an the shaft by upper ar d lower thrust hearings a springtvpe cone tasner and a stake type nut The sleeve and valve spool are centered laterally in the valve body by f ve sets of plungers which...

Page 117: ...n line and oil on this side of the piston is per mitted to return to the pump The hydraulic pump is of the constant displace ment type with a flow control valve and builds up only enough pressure to overcome the resistance to the rotation of the pitman shaft The oil pres sure which operates the piston is also diverted to the plungers on the spring side to assist in building up a preload which must...

Page 118: ...rs to filL gap at this point if shims are required in the gear hoosing alignment adjustnicnt ntt sd ahave the straight ahead pasition of the front wheels itt relation to the steering gear high spot sitinn and toe in should he rechecked d Tighten three mounting Screws tO 40 45 ft lhs torque 3 Turn steering wheel to either crop then check pull required to flirt steering wheel hack to 90 from the str...

Page 119: ... arm 4 Checking and Bleeding Hydraulic System a Checking Fluid Level 1 With engine shut off retitove tank cover held down screw ajid remove cover and gasket 2 Levei of fluid shotttd ha 1 2w belttw top edge at oil level mark as itttlicaned on ootsitie oi tank Fir 7 9 3 Fill to level with Hydra Matic transmission Said 2 Tighten adjusting screw leek not and recheck puil through center Lower Rock Guid...

Page 120: ...idle 5 Turn wheels on ground against stops Pres sure should not be less than 900 psi 6 If pressure is less than 900 psi slowly close gauge valve observinggauge for pressure increase Pressure will increase as valve is closed if pump is operating properly If pressure increases 950 psi when valve is closed the trouble is in the gear CAUTION Do not leave valve closed for more than fifteen seconds 7 If...

Page 121: ...is cd i th this adjustment It indlt ote a bent Ldlc r arm which should be replaced Ir Tito pEivtej ari cndofdraglinkis hot within limIts Tile p rm all urn tustho roroavcdalldhent as rcpuire c AU lUON r c bending one a ir n nn the pit man arm niusr Iii done very carefully to avoid internal streases and must be performed cud w th a tool placed midway between the ball stud anti the splined hole in th...

Page 122: ...om left end ofa ccri tg coLt necting I nk to remove pitman arm from connecting link Fig 7 id 2 Ram t naidc bail seat spring stop plug spaccr end tie rod o ror hail seat to remove left tie rod 3 Remove cotter pin plug and ootcr hall seat from right end of steering connecting link to remove idler arm trom ronnectrng link 4 Re nove inner ball ata spring stop p log long spacer cover ontl ball seat a r...

Page 123: ...completed ho cure that opon side or clamps are over open side of tie rod adjustor before tightening clamp nots Fig 7 17 12 Removal of Tank arid Pump fliscnnnect hoses at unions on pomp When hoses are disconnected secure ends of hoses n a raised sitil n to p e vent drainage of of 2 install two caps at pump onions to prCVenl drainage of oil from pump I Remove drive policy attaching no 4 Loosen brack...

Page 124: ...ion 11 Remove rotor with vanes from pump shaft 12 Remove and discard 0 rimtg from groove in pump body 14 Remove shaft bearing retainer snap ring from front face of pummlp body 15 Rentovc drive shaft with large seole bearing from p Im body IS Remove do seal frnm pomp body with a iong p ommehm inserted through large holes in macId no face of poctmp body and discard seal Fig 7 ic 17 II l ece s sary t...

Page 125: ...ing points imt direction of pomp rotation 10 install prescore plate on dowel pins which extend through cam ring with small arrow on pressure plate at the top 11 install cactrol valve and spring in front face of cover i2 install new ring which fits hi front face of pump cover 13 Position puntp cover assemblyoverpro asore plate and sgsinst Ca rmt ring i4 Install four cover to body attaching screws w...

Page 126: ... and nut assembly out of Steering Gear steering housing 1 Raise front end of car until front wheels are 9 Remove pitman shaft seal from gear housing approximately 6 inches above floor 18 Assembly of Manual 2 Remove steering wheel as described in Note Steering Gear 8 1 Install new pitman shaft seal in gear housing 3 Remove horn wire from terminal at lower 2 Install steering shaft and nutassemblying...

Page 127: ...1 1 E F e Hent g rn e Cyli td Sr ea I Ri t0 I Coe tn t Cosla F N N Eoke Ntt b S tVaIeeBad N N N Cn th VaI e k 0 ag N N Fats i SpnI PI Sen I Ileiatt Ben i Skne Cstta6 Ring FInt g fi btthitg _ 1 F0 cLing N tod W k LiSa P stva Kate Patnt kitg Ri Ad a pte Wothe Hon Wire U 1 m m 0 z C Fig 7 27 SIe ng Ceor Di a tsmb led ...

Page 128: ...ontct brackeL and loosen lower jacket clamp bolt 4 Disconnert h drauli steering pump to valve body hoses at pump end valve body install caps on pomp to prevent lose of oil 5 Remove fitting from valve bodyon side cioaeat to frame 7 DIsconnect left exhaust pipe from exhaost manifold altd disconnect intermediate hanger PuLl exhaust pipe doUn from machold and move in toward engine S Remove three hol h...

Page 129: ...w down through cover n removu aide cover from housing Re tiove cover and gnskot 5 Mark pitman gear tuoLh ha I not and powor rack as shown in Rig 7 26 to insure proper posi tioning of parts when reassembling gear 6 Remove pit isn ahaft front gear housing 7 Remove cylinder to gear housing screws and remove power cyLinder guiding power tack through opening in housing 8 Remove Large and small a ring s...

Page 130: ...ia he fec ive it will he necessary to replace he gear huusing and roller hearing as sn asseirthly Re ittoval of the heuringirom the hoosingis oat recoin ti tetide d 22 Assembly of Power Steering Gear a Assembly of Gear Housin9 Iosta i pitman shaft hush n to its bore in gear hoLl ing 2 instaLl pittr ao sitaft seal io ilo tsiog 3 install oil seal in upper housing fiange osing T ol No j 5i89 Fig 7 29...

Page 131: ...centering 0 riog on steering shalt Lubricate with Hydra Ma tic ii otdi stceri tg rtthe il holes in htome n cc of valve beoc mu st line up with uiL hales itt twtetng flsnpo log 7 31 4 Install large thnits tea sher hearing with retainer antI attial I iirttsr tra sher above valve hody LnstaU a new sprittg washer cu cide down nnd new etakittg oct NOTE Be eLite r ew tt turtts freely on shaft threads 6 ...

Page 132: ... ada pLc a uten Thimble ante Dieteo nuLl F g 7 34 4 Joerali pisroti rings oh pisrtat 3 Liemnyc t3linlhlc and ns a i piston tvt h rhtrus wishers ot Itoh sides e pistan rod and install pistet t reo net Cupped suer piston tttUst be towsrd udspter 6 tns a i pisutnint yii thar osit lingCetllpres SOr Tl No J 3i86 tn compress ptstett r tis Fig 7 35 7 S i ir adapter into cyltnden and in stsll 5 ie Ot rims...

Page 133: ...arm shaft Seal itratec or Ton No J 3L39 en upper end of steering shaft 2 C c reMLy inssrt uppn end arsitart ttru siturter tube and slide assemhiy up lore positianontilhalea it srecri tg gem housing line upwitlnitc ics utt frame side her 3 ltts tail screws th rnugn fra mc tt e steaming gear ieese s 4 Align steering gear by use of shims as de scrthed in Ntrte 2 3 Rentuve seal protector from steering...

Page 134: ...ough center adjustment Loose thrust bearing adjustment Loose piston to power rack pin Adjust Adjust Adjust Replace as required 6 Pump noise Low oil Belt squeal Hose grounded Pump mechanical trouble Clogged intake line Pump shaft seal leaking air Sticky pump vanes Fill as required Adjust belt tension Reroute hose Overhaul or replace pump Clean out or replace Replace seal Check vanes 7 External oil ...

Page 135: ... P0 L r Rack Adj us Ut ts Wren en Presattre Testing Gattge Steering Wheel ul Ic Ri tolan at Pulie n 4 Scale IS Scale Seal itiateiler Beuruog nrtd Ssal Inetolier Hc ar ng listener Besring Puller Bee ring Adj Lte tiog W met ei Ottahing ProKetor Ps Lttn Rod los erte m is ten Ring Compressor Src cring Rstio Menus I In sad V rt n ReKr I y_Irtt Ltl c putllp ptc a atu L tviti_ e eet i tg tcc I t elJ spai...

Page 136: ...S PropoUer SheLls 1954 75 86 Disassembly d S Assembly Specifications 6 8 6 rorqoe Tightness Ca 8 6 Special Tools h 2 h GENERAL DESCRIPTION The design of all rear axle gear assemblies us on 1954 care as shoai In PIg 8 I I fdentical although the gear rotios for different series vary to provide aptimom performance aml economy on all models The 3 07 tO 1 ratio rear axle gear assembly is used as standa...

Page 137: ...enger car and the 1954 86 commercial chassis use a special yoke with a threaded plug in combination with a snap ring on the transmission shaft to lock the yoke to the transmission output shaft On these series cars the sliding yoke is located at the rear of the rear propeller shaft assembly seals as this may cause leakage after installa tion Even a slight scratch across the sealing lip may provide ...

Page 138: ...slowly for at lea L 2 torm Fig R 4 Repeat tni tI rque Chock itt least eight times which ed II insure an accurate check over The entire circum iv rcsncc or the ri n C a r R cc cr0 all tor qL C read Inge O lR Eefore each check ot the orql e rtlrare the pinion aT a it 1 4 urn in e ad recd on to free it up thus eliminL ring an unusoalls high starting torque that ynk e can he ins nled in seine joaiLio ...

Page 139: ...htcn and nov er back off ttn the It to redtir a preload torqne The naxi LLIm alloccahle torque on oIl ar sc Ii L i wIth over lihILi miles a is lncItEIoaaJsIJSe cc d an 10 inch pounds with a new seal The ircrqLle lIlt 0 cats nsacIILhlv Is 50 inch pounce 7 Stake piniojL shaft into not 9 Refill rear axle to correct level 4 Measurement of Rear Axle Backlash 1 Place car nLI oiL 2 Pua eo one end of a oh...

Page 140: ...nencl bearing and over dowela C UTIiN Step 3 I o r he perfortticd to de crease ri e dange r of rite hesrinp exploding while under erhee ireea load 4 Prese axle shaft through bearing ksfnhholion of Beariog on Ax Shaft I irssclllb Is retainer and new be a r itcg o It axle ft 2 Place a eselIlilly Lii rough ring of In eta 11cr tool on arbor l r eiSa Fig 8 9 3 ees bearing on shaft up to laIr nLIt qoiLe...

Page 141: ...ssembly except seal or yoke replacement See Note 3 should be handled by replacement of the complete assembly No disassembly or adjust ment of this unit should be attempted in the field because special equipment is used at the factory for mating parts and setting side bearingpreload a Removal 1 Disconnect rear universal joint as explained in Note 8 2 Remove lubricant from differential with a suctio...

Page 142: ...ld the center bearing support assembly to the in sulators at the frame a Removal and Disassembly of Universal Joint I Remove bearing retainer lock rings from oulversal joint as illustrated in Fig S_lu 2 SopE ort the yoke or bearing tronnion on vise jaws 3 Ploce Bearing Remover Toni No 1 4174 over 7 Inspect rerajllers nod e ork seals sod replace ii dalllaged or if cork is brittle b Assembly oad Ins...

Page 143: ... ernss until it enters beth bearings 7 Tighten vise mdl both hearings are in far enough to allow lock rings to be installed NCiIt Ii bearinge do not go Into position ith normal pressure on the vise a needle bearing may have fa lieu out of place and the bearing must be re1neved and needle repositioned 8 Install lock rings 9 Commercial Chassis Universal Joint Yokes Wear ill the drive hoe afrer high ...

Page 144: ...ento4O 50 foot pounds Back off 1 2 turn and then install cotter pin 4 Slide yoke off propeller shaft 6 Install universal joints In propeller shafts as 5 Slide large flat washer off shaft explained in Note 9 6 Press center bearing assembly off shaft over 7 Install propeller shafts as explained In Note 8 SPECIFICATIONS Subject and Remarks 54 62 ÔOS 54 75 54 86 Axle shaft length Left 30 1 4 30 1 4 32...

Page 145: ...Rear Axle Shaft Puller Adapter Shown with slide hammer 1 2619 A F C 1 I 1 J J 2623 1 1357 J 4174 J 3069A J 1355A Pinion Oil Seal Remover Shown with slide hammer J 2619 A and J 838 PInion Oil Seal Replacer Universal Bearing Remover Rear Axle Shaft Oil Seal Re placer Rear Axle Shaft Oil Seal Re placer 54 86 with adapter OTHER NOTES AND REFERENCES REAR AXLE 14B__ I __ ___ L VP Hg 8 15 Rear Axle Speci...

Page 146: ...at all times regardless of expansion or contraction due to temperature changes and to transfer mechanical pressure at the brake pedal to hydraulic pressure on the wheel cylinders When the brake pedal is depressed the master cylinder piston cup closes the by pass port and builds up pressure in the brake lines and wheel cylinders When the pedal is released however the return of the piston and primar...

Page 147: ... driver when the bend brakc is on while the ignition esi ch is O The broke s8op lighL switch ie operated mechani rally hy the brake pedal lever arm cc iLSiLCOLiXIn beneath the toe hoard When the brake pedal s depressed Lhe switch arm under sprang pose surc I lows the brake 1ev er dci wnccorc on t the witch is One When the brakes are released Lhe swiLcil arm is returned to iLa nurmai Off poe rica I...

Page 148: ...is sufficient to jiiakc at icuat tine brake stop with power lassist even when nionild vacuum u5 er law or non existent a teil ch k and the power piston Fig 9 2 are exposed manifold vacuum As ide brakc pcdad is depressed the hydraucic pressure developed an the master ylinder ia transmitted to the power b rake Ijydra 0 Inc cylinder aod to the hydraulic piston in the vacuum corirot valve As the hydra...

Page 149: ...ers le the somof the push rod pressure act 1 tiae press tire developed in the rta ster cylinder rio 9 4 mc degree of poser brake asata Is rcy ula cd in the v ncc um contr Ivalve assc r hlv hy cnnarolling the pressure c fferen iai between arca and D Here hydraulic in sauve asainat tea piston is ap posed by air preasure at d spring pressorc at the area R side of rile d aphranm whcn rlbediaphragni ia...

Page 150: ... off less than 14 notches to obtain a high pedal can cause serious brake troubles 6 Repeat this operation on all four wheels 7 Lower car and check for brake pedal free play Adjust as explained in Note 1 3 Major Brake Adjustment 1 Jack up car and remove all four wheels Re move adjusting hole cover from each brake back ing plate 2 Check fluid level in master cylinder filler tube and add fluid if nec...

Page 151: ...ified or down if clearance is less than 010 Reset lower clearance with star wheel and recheck upper clearance The clearance be tween drum and linings at any point should not be less than 010 4 Hand Brake Adjustment NOTE Service brakes should be properly adjusted before adjusting the hand brake 1 Lubricate complete hand brake linkage and check for free movement of cables in conduit and in equalizer...

Page 152: ... Paris Department 6 Relining Brakes I jack up car and dismount all but wheels 2 Remove irccJ hub and braku drum assem blies See Section 6 Notes l and 26 CAUTION not depress brake dal when uric or more brake drums are removed 3 Loosen hand brake cable iuck ma Sr equalizer 4 Remove brake shoe hold dn1 cups and springs Fig 9 S 5 Install Wheel Cylinder Clamp Tool No KMO 143 to held wheel cylinder pist...

Page 153: ...rums refinished on cars in service To break in the linings and drums it is only necessary to apply the brakes lightly at low speeds a nunther of times and to use discretion about applying them at full force at high speeds 9 Bleeding Brakes Bleeding the brakes may be made considerably easier through the use of one of the pressure brake bleeder tools now available This equipment com prises a tank pa...

Page 154: ... from end of cylinder barrel 10 Lightly tap cylinder on a block of wood to remove return spring primary cup with retainer and check valve assembly from cylinder barrel 11 Remove master cylinder head and valve seat from front end of cylinder 12 Remove master cylinder cover After all parts have been removed from master cylinder they should be washed in clean alcohol Special care should be taken to m...

Page 155: ...Do not handle hydraulic cups and seals with greasy 8 Wash all parts in clean alcohol after washing hands hands thoroughly with soap and water 1 Loosen hydraulic cylinder nut and unscrew 9 Install a plug in brake line fitting hole to pre hydraulic cylinder assembly from the end plate vent entry of dirt into cylinder Fig 9 9 13 Assembly and Installation of 2 Hold the end cap in a vise and remove the...

Page 156: ...ook Bolt Packin9 N Piston Piston Packing Plate Gasket Valve Valve fffting Dicphrarn Cup i Seal Washer t Snap Ring Tube Stud N Sc reen Bleeder Screw P End Plate Plug Plate Ring amer Spring 0 m cn Washer Cylinder Bleeder Fig 9 9 Power Dk Dl5 bled ...

Page 157: ... spriitg a idlxili 1 Remmiove retainer plate packing andexpant er ring 3 Remove somail diameter piston plate with rubber seal ring 4 Remove leather pack ng larger diameter pis ton pLate and washer from pLLsh i or d Disassembly of Check Valve 12 RenIove the hydreulic cylinder end seal IS Remove the retaining ring and time hydraulic cylinder stop washer 1 Reaasve In end plate check vs ve assettib Iv...

Page 158: ...lve body place push rod in hole with threaded end up with smallendover raised areaof poppet valve seat 2 Install flat washer and larger diameterpiston 10 Install screen with depression in larger plate chamfered side of hole up over threaded end of poppet valve spring and install snap ring end of push rod 11 install filter upper screen and retainer 3 Install rdbber seal ring over shaft into chamfer...

Page 159: ...ain off in addition coat inside or cylinder shell lightly with Delco Shock Ahsorher Fluid is Insert piston into shell by tipping piston as shosq in Pig 9 12 19 Align scribe marks on shell and end plate attach hook bits end tightct each bolt evenly until all jolts are uniformly tight d A mbly of Check Vdve 1 macU end or spring over check bali 2 Install spring retainer plate with dcpreasiuo in plate...

Page 160: ...1 Remove bolt holding retaining plates over brake cable pin and brake lever at left side of cowl 2 Disconnect hand brake cable from lever at left side of cowl by removing bolt holding retaining plates to lever and over pin 3 Remove two bolts holding hand brake handle assembly to instrument panel 4 Lower assembly from instrument panel and disconnect wire from hand brake warning light switch 5 Loose...

Page 161: ...se of overheating Disassemble all hydraulic parts and wash with alcohol Dry with compressed air before assem bly to keep alcohol out of system Replace all rubber parts in system including hoses Replace brake shoe assemblies or linings if glazed by brake fluid leakage Refill and bleed with Delco Super No 11 Brake Fluid No pedal after hard usage Excessive heat cuases fluid to vaporize Drain fluid fl...

Page 162: ...e or defective wheel bear Adjustor replace bearings with ings new ones as necessary Badly misaligned wheels Correct wheel alignment Steering gear out of adjustment Adjust steering gear and link age Be certain location and pull through high spot is correct Backing plate loose on steering Tighten backing plate Read knuckle or axle just anchor and shoes on both sides Anchor adjustment uneven be Perfo...

Page 163: ...essary to stop car Brake shoes improperly ad justed Brake pedal or linkage binds Lining making only partial con tact with drum Incorrect linings used Lining glazed Check anchor adjustments Re adjust brakes with properclear ances at all wheels Check pedal rod for binding in floorboard grommet Reposition grommet as required Lubricate pedal shaft Check for bind in master cyl inder and overhaul assemb...

Page 164: ... Rivets loose Instatl a new spring or clean drum and spring Adjust anchor and shoes Roughen lining or replace Check anchor and shoe adjust ments Replace shoe assemblies if dis torted If lining is new follow break in procedure Replace lining Replace shoes or lining DIAGNOSIS CHART Power Brake EFFECT CAUSE REMEDY Momentary hissing noise as brakes are applied Air passing through filter and atmosjteri...

Page 165: ... draulic power piston cup or ball check Correct leak at point of origin Check and correct Shock Ab sorber Fluid level in vacuum cylinder If necessary overhaul unit and check for rusty dirty or distorted vacuum cylinder wall dry or worn vacuum pis ton leather packing swollen rubber cups due toheat or wrong brake fluid worn or damaged rubber cups or dirt rust sludge or foreign matter in power piston...

Page 166: ...se completely weak vacuum power piston re turn spring or atmospheric poppet return spring Check for dirty or sticky con trol valve Internal friction Check vacuum cylinder lubri cant level Overhaul unit and check for binding in power piston assem bly No power assist on first appli External vacuum leak Check and correct leaks at valve cation after engine shut off body external pipe vacuum cylinder a...

Page 167: ...1 4 11 45x2 1 2xl 4 Rear 11 45x2 1 2x1 4 11 45x2 l 2xl 4 11 45x2 1 2x1 4 Lining Secondary Length width thickness Front 12 92x2 1 2x1 4 12 92x2 l 2x1 4 12 92x2 1 2x1 4 Rear 12 92x2 1 2x1 4 12 92x2 1 2x1 4 12 92x2 1 2x1 4 Type Moulded Moulded Moulded Attached to shoes by Rivets Rivets Rivets Wheel cylinder bore Front 1 1 8 1 1 8 1 1 8 Rear 1 1 1 1 2 wide circumferential groove 1 8 deep full length T...

Page 168: ...moval and Installation of Crankshaft Pilot Bearing Removal Installation Engine Support Mountings Removal of Engine with Transmission from Car Installation of Engine and Trans mission in Car Specifications Torque Lightness GENERAL DESCRIPTION The enne used in all 1954 series Cadillacs is of the 90 overhead valve V 8 type It has a bore of 3 13 1 6 inches and a stroke of 3 5 8 inches giving a piston ...

Page 169: ...ed tn Lhe underside of the oil pump and is driven by a hexagonal drive shaft between the two pumps I lydraulic valve lifters are used in maintain zkru clearance IhrnuinuL Lhe valve traiti Thu arrangement assures quiet oprratiun and ci innii atcs the necessity for valve tapt adjustments The lliters operate in guide hales drilled I 1 C cylinder bluck The valve lifter plunger and lifter hody are n ma...

Page 170: ...ment acts as a metering device to prevent excess oil heing supplied to the upper end of the rocker arm This angular passage in the rocker arm intersects a vertical passage which lubricates the push rod seat and provides an exit for oil to the top surface of the rocker arm where it flows slowly to the valve end of the arm and luhricates the valve tip at this point Oil from the cylinder heads drains...

Page 171: ...a c 0 a a ...

Page 172: ...ENGINE MECHANICAL S Fig 0 3 bThe Trnser S i ...

Page 173: ...Rcke 5Jift C N Wi e T 0 Pi I1d Ph 9 R gFn Lo g d h d II d c h ft Sp kt ig N tdbg Di C ni 7 C 1 m ni n z n LR L J i di V Oil ld kth ii 4 Oil Fig 10 4 E gi Lubioi ...

Page 174: ...perature gauge wire If right cylinder head is to be removed remove windshield wiper pipe clamp 11 Remove vacuum advance line from front of carburetor to vacuum advance on distributor 12 Disconnect hose from intake manifold vacuum 13 Disconnect ignition coil high tension wire and primary wire at distributor 14 Disconnect black resistor wire from porce lain resistor at coil 15 On cars equipped with ...

Page 175: ... it ft is tvucaaama LO remove valve gaddes because of OVccwivL c l m rance between valve areni and valve guide s rues cu red iFI N F 5 drive u n valve guides from xnTFDFn side of cyl inder head using VaLve ire ni Guide Rettiover Toot No J lO2 as shinra in Fig Id S 5 Reconditioning Valves and Seats Valve recnnditio Ig uurtttahv is required snccit less requemty n engines having itydraLl hey alve ien...

Page 176: ...e Stem Goide as ahler Tout Nn 3066 through plate and slide Valve Guide Adapter Tl No J 3066 4 on installer pi iot Fig tO 9 2 Slide valve guide on Installer mlot and lubri cate ooter surface nf uido CAIITION Be acre etld or valve guide witlt longest chamfer enters bore firs pehoting to ward rocker arm aide of head 3 Drive guide into head unti shoulder on in staller contacts plate on cylinder heed i...

Page 177: ... nncyl inder head with rntci e an cad coil nr rocker arm shaft poi ntiits downward a tad toward cc itc rare agitte Pig IC Hi and macor arm hnoi ie s wiali laarc nr machined surface next to l cad lb Tighten all cviittder head cap screwa tn 65 711 f n vmnds tnrqoe sta iing franc center row and working ooesard end toward each end Do not instalL oil titer bracket cap screw 11 Install exhaust pipe to m...

Page 178: ...lt If too ldw air may In either case noisy valve pressure If valve action is is hot it may be due to low Low pressure usually results from a leak in the oiling system a stuck or improperly operating oil pressure relief valve scored parts worn bearings worn oil pump gears or poor operation of oil pump 3 Weak valve lifters springs These can cause noisy valve operation by causing sluggish plunger mov...

Page 179: ...Lk g F k Rd C 1 P RI EEII Ad A F EEu Ad Mi Nlt B V L V I 0 B Il C6I V Op C 01 0 Op Ek OF V L Slithi Lc Body 10 12 ENGINE MEChiANICAL 0 VI Ad VI LilE E dd M II C Pk Rd P s F 10 Il VoI Life echim ...

Page 180: ...h Air Conditioning re move rtar bracket and lonsen generator 4 Remove Mack resistor wire front porcelaio resistor at coil 5 Remove distrihutor cap coil and rocker cmi covers as an assembly Set timing mark C Jo Imrnioitic balancer to pointer and observe position of distributor rotor Check each lifter as Outlined in he following table 3 Intake 4 lr raket Rotor ot Ne 6 firing position l ointing iuwar...

Page 181: ...ler Ineda over pluliger aaaoOiAly Valve Lifters a Disassembly 1 E ress do co 0 center of valve lifter push r d ctlp 2 t eltng a pointed tool remove hock irc from groove aluIo _ ddiitg clip ci 5n 3 invert liftcu nod slide on qsa rod cup p10 1 er hal i reta 1 cc and spring NOTh lfpl1jnger is atock in lil or hndy pdcc llfler push rod cad thom in Valve Li let Plu tgcr Remover Ton I No j 1 50 F g 10 19...

Page 182: ...t coil 12 Repiaco l Ieo cr Iloed s i I rackete cm Cove clips 13 Ii car is equipped niti I lydro V ac power brakes cool ec t c tIc liii I nc at iit take manifold 13 Vacuum Pump Test I Make sure wtdahicid wiper s C et a to vs tip faetatiiy cdli all lilies connected N0 ph Wiper action ahould be chec cec on wet windshield 2 Die connect eact ani ptIirlp 11050 lead ng from crankcase at cech calve ncowl ...

Page 183: ...nes and spring from rotor 16 Inspection Assembly and Installation of Vacuum Pump a Inspection 2 Inspect cover plate as explained in Note 18 Step 6 b Assembly CAUTION Parts must be free from foreign matter before installation Foreign particles caught between the rotor and pump body may cause the shaft to break 1 Install spring and vanes in rotor 2 Compress vanes and install rotor in pump body 3 Pos...

Page 184: ...nstall oil pu top drive ges C iac l pomp hod 2 dress cull a on end of sl afi and iI stsLh loeL P in 3 Slide idiet gc ar into pump body mashing gear wiLh drive gear 4 Place vacuum pump assembly cdli hexagonaL dnve shaft onder nit pump and isaiah six screw c 5 Sliac oil press re regulsior valve into pump body 6 Cumpcese assembly md install cOtLor pin Slide oil lliap SI ra i c r into OPOOint in pump ...

Page 185: ...inter c a1nesahle Crar kaha C nd l u ust he isLr by Ole rc ar lIiail 003 r ny Bearings wor i more than 005 i Icil eI oald be replaced Paring wears hest he me cured by icc of time CII gi s O as e l a icsd in No tc 20 Wile n mimI nI am he ring is he agcr ockc 1 l e l cr four cape ehuuId he might unless rite e igilie is upside d rn Tu replace the main bearing 1 Rentove cap and mke out eoi l silt h NG...

Page 186: ... looaalv on puller screw amId pacr assembly ian arborpress aeshu mid Fig dO To 5 Press is sl pin mut fp s nc ud rodaseemnl ly i ensove ass ens UI from 1 1cc 5 5 a tI ro u5ove guller nt s l POri and piStOli piui from pu ler screw 7 Rem ve ulier screw fto T gisun ad re usS v pilot icom p15 0 n t ons ec I ir g rod Fig Io_l Rmoviag Pi uur Ph b Installation I i chr co e pision Ph lie c s to f iT i Itat...

Page 187: ...nIT p ui er screw a cI ril reI tn rIp i wr eI e I to STsul p mol r Th ir un so hteu g u od Pig tO 24 if i en be sI t i la ccli neeiing rod viih less t aI IS ft 0 a naininluni ritqt r he pl e s i fit between pisrs pi I and rod is imtauffieiet It and e It her the piston asse s hia cm c l lec i g r d must he replaced 9 l eiali eotlac over pisLun p Fig tC 24 iG l reas pL lcr screw due r anti top of pi...

Page 188: ...3 3136 The rl sm t i ldicl e a tel c li jcr IIzc s I 5T1 he rahi c of i I Pt c rc tr t e tv size ever e a_Ic let r is t nhicr or if lie letter is su uiil e d no utic left the cri ndcr it If letter is stauiiped to the right of cvii der ii is _ I lm r k es it rlc iu ou c 0 iI i i Ii a 22 i mnerly it iIe_I Foe servici one punt n s ure ft mnIe o _ it the L or fT code I7 os only if a double letter AA a...

Page 189: ...t fee I flue ir a de ic ro meter 11 b4 a one ci of tIe bar sn ta e the exact center of the cyliuidet as ia a Ins cac ha led t ermic plane reninve t t Infcrur clCr l ld lllc as ore its length witf the oultstde iicrolluc ter ft is sho i d be done ho i e e eli _l a ru al vil of Ole lu ei at emete r n ud urt alit p the s stcw the same feel ha obna cd a s eu felt hi m c l oar_mug the piston Ry nih S dl...

Page 190: ...in cylinder as follows Using a ribbon which gives between 2 and 6 pounds pull insert the ribbon with the piston open end down into the cylinder about one inch taking the resulting pull at this point and in in tervals of each two inches downward until the open end of the piston is 1 8 below the bottom of the cylinder By keeping a record of results the clearance difference can be read from the chart...

Page 191: ...temperature is much above or below 70 F The correction fotlowing is for the difference between the expansion of aluminum and iron or steet there fore no consideration should be given to cylinder temperature or the tools used for measuring other than that they he at approximately the same tem perature as the pistons when measured The tem peature correction for piston size at other than 70 F is as f...

Page 192: ...f engthe arid Lost the rods ore on the proper crank pins 4 15 all new so If locking lLi Le and ig Len Ln 411 45 ft the torque 5 Repeat this operstino r 0 0 uiher seven connecting rods 28 Replacement of Rear Main Bearing Oil Seal lEiaaliatinn of a rice rear nisin hearing oil cr10 rC qu ire ase of Main Fear i 0 I Seal Coil i preesor Tool No 5 3448 After critthsitaa has been removed from unigona and ...

Page 193: ...er collet of Camshaft Bearing Re moving and Installing Tool No J 3063 in No 5 bearing Fig 10 30 NOTE Install a rubber band over both collet fingers next to thumb screw to hold fingers while installing collet 2 Tighten thumb screw and check to see that fingers are securely behind No 5 bearing 4 Remove timing chain and sprockets as ex plained in Note 29 3 Install arbors B C and Nos 1 2 and 3 respect...

Page 194: ...igfron rod rend of shaft 3 I ooe en poller no and si Lde shaft rearward ujiril C washer csn be removed frnm behind pilot L4 InaLaL C washers behind arbors B and E respectively hearinge 2 and Is T gh en poller not dr ri hrarit gs Nn I 2aio 3 are removed lb Remove poller nut fr or end oi shaft 17 Rensove all pieces of the Camshaft Sciritig Removing and nstolli g iaol a id all bearings from cylinder ...

Page 195: ...pped with Air Conditioning 10 Make sure that pilot D is in No 3 bearing 5 Install hood lock plate support bore and that large diameter of arbor C is in 6 Install generator and compressor drive belts No 2 bearing bore These pilot the shaft in the as explained in Section 11 Note 21 if car is cylinder block equipped with Air Conditioning 11 Using a hammer drive the cap nut in until 7 Install power st...

Page 196: ... hear i caps lb Lo t at crat kvhaf ftoo eng oe 37 Installation of Crankshaft Engine in Cad 1 Raise ctankahaft into position and auprort in place whie installing main hearing caps rSee Note 21 Step 5 ositip a itc w rcarmsin beardir cdl seal ass xn lamed in Note 28 2 Lubricayc crank pins and pull COtifleCti tg ted and irsTor a eset h icsitown roward crank shaft Instal nnnnecong md cops yn ctankshaiL...

Page 197: ...g and remove hearing by tapping slicic itammner agamnes heodof tool Fsg 10 33 b Installation 1 in siall sew pilot hearing on Crankshaft dilul Bearing Too No I _2 SS 2 oaiiot bcar tg t litte ei 3i tt y drive tlt cttr g flatvn of not toorhes the IP 34 attl its bore ity craok into r e shaft otynl the crankshaft face Ftg 3 Install tratistllissitfl as mlecc r hed in N yteSd ram engines on all 1954 seri...

Page 198: ... pre 27 Take up slack on rope or chain vent oil leakage 28 Disconnect and remove rear engine support 8 Disconnect refrigerant lines as explained in bracket from frame and extension housing Section 16a Note lOa on cars equipped with Air Conditioning 29 Lift engine with transmission out of car 9 Disconnect all heater hoses at water pump 30 Remove transmission from engine if so Remove right heater ho...

Page 199: ...nditioning 16 Connect power steering pump to valve body hoses and fill tank to proper level with Hydra Matic Transmission fluid 17 Connect wires to generator 18 Install hood top panel and align to cowl and fenders 19 Connect battery cables 20 Raise front of car and install stands 21 Connect speedotncter cable and shift linkage at transmission 22 Install transmission linkage slush deflector 23 Inst...

Page 200: ...over Rear Main Bearing Oil Seal Installer Valve Lifter Lock Ring In D J 3066 A Valve Stem Guide Installer Set L 3 3049 stallcr Valve Lifter Remover E F J 3224 J 4383 Connecting Rod Bolt Guide Set Crankshaft pilot Bearing Puller usedwith Slide Ham mer 3 2619 A M N 0 KMO 740 3 3074 3 2985 Piston Ring Compressor Valve Lifter Leak Down Tester Crankshaft Pilot Bearing In staller G J 4160 Hydraulic Valv...

Page 201: ...length Pressure in pounds when compressed to 1 844 Long spring end Free length Pressure in pounds when compressed to 2 219 VALVE TIMING Without ramp Intake opens Intake closes Exhaust opens Exhaust closes CONNECTING RODS New limits Worn limits not over Diameter lower end without bearing Length center to center Endplay of rods on crank pin PISTON RINGS Clearance between rings and sides of grooves i...

Page 202: ...vity CRANKSHAFT AND MAIN BEARINGS Piston Sizes 3 8110 3 8112 3 8112 3 8114 3 8114 3 8116 3 8116 3 8118 3 8118 3 8120 3 8120 3 8122 3 8122 2 8124 3 8124 3 8126 3 8126 3 8128 3 8128 3 8130 Aluminum Alloy 3 8110 3 8140 3 8210 3 8230 3 8310 2 8330 Clearance between valve 3 8410 3 8430 plunger and housing 0015 New limits 000 Worn limits not over Normal pressure to 30 M P H mm Idle average Spring Free l...

Page 203: ...ront motor support stud nut 1 2 20 80 90 Front support cushion to engine nut 3 8 24 25 30 Harmonic balancer to crankshaft 1 2 20 60 65 Intake manifold to cylinder head 3 8 16 25 30 Intake manifold to cylinder head nut 3 8 24 25 30 Main bearing caps to crankcase 1 2 13 90 100 Oil filler support to crankcase 5 16 18 15 18 Oil pan baffle to crankcase 5 16 18 15 18 Oil pan to crankcase screw 5 16 18 1...

Page 204: ...n Reading Meter Calibration Coil Heat Coil Secondary Continuity Test Coil Capacity Test Condenser Test Starter Pinion Adjustment Starting Motor Circuit Normal Cranking Motor Maintenance Checking Inoperative Cranking Motor Starter Motor Tests Interpretation of No Load and Torque Tests Removal and Disassembly of Starter Motor Assembly and Installation of Starter Motor Engine Tests Specifications GEN...

Page 205: ...rks arc loeu cdon the narmot lc halan cc r at the fran L of the c r aak shaft hr aC nit lettered A and C are located tin the hal tncer so that the piston in numher cUte cylknder is at top deed CenLer when the C mark is in tine witn tIle pointer on the engine front covet fl A mne wi l then he five crankshafr degrees ahead of the C tine 1954 generator located on the front of the right exhausL manifo...

Page 206: ... specific gravity register5d by the hydrometer should be 1 260 1 280 at 80 F when the battery is fully charged A gravity read ing of 1 150 or below indicates that the battery is entirely discharged Temperature affects the re sistance of the electrolyte for this reason a cold battery requires a much higher charging voltage than a warm battery Whenever a reading under 1 250 at 80 F is due to a tempo...

Page 207: ...ll connect ammeter across battery causing a direct short 6 With test ammeter at 180 or2lO amps for 15 seconds the voltmeter should read 9 6 volts or more which will indicate satisfactory discharge capacity 7 Turn ampere control knob to OFF position before disconnecting clips b Test Charging Battery If voltage in above test was below 9 6 volts the battery should be testcharged to determine whether ...

Page 208: ...be measured as an indication of this resistance Pro ceed as follows 1 Using the Battery Starter Tester turn the voltmeter selector switch to 15 volt scale 2 Remove high tension wire from coil center terminal so the engine will not start 3 Connect solenoid starter clicker switchand test leads as shown in Fig 11 4 4 Connect positive voltmeter lead to the center of the positive battery post on which ...

Page 209: ... from the distributor and inspect the contact points for pitting oxidation misalignment or an oily surface Pitted or oxidized points should be replaced and misaligned points should be properly aligned and set Contact points with an oily surface should be inspected for pitted or oxidized condition and the source of oil located and corrected If the points are worn evenly and show a uniform gray surf...

Page 210: ...spring until required tension is obtained Adjust contact points as outlined in Note lOb The gap measurement should be 016 12 Removal and Disassembly of Distributor a Removal 1 Remove distributor cap from distributor 5 Remove distributor hold down nut and clamp 6 Lift the distributor out of the engine NOTE The distributor rotor will turn slightly as the drive gear becomes disengaged from the teeth ...

Page 211: ... Assembly To assemble the diszti numr r000rs e hc die essc iai ptocedLite as ntit ir ed shove heinz sure to inst eli Lie W gave mar weight held sin rn to ock washers Bead isags of these washers up arc ijad Jic s b Installation I inatau rubber O ting scsi helaw diattihutot Lousing matlating flang 2 install dietributur cutting with tutor eiaL ing toward rear end slightly to might of engine NOTE if t...

Page 212: ... ino Ca lrnt v or c bsienccr to eii i ate PINC 6 Insert an a sptc r pi alongside Na virs cad ante the chafe inc with re Ia lien to the pointer when light flashes if lie chaik line si nw s up he fnre or af sr he pclinier set the distrihuor at di NUlL lfthis varisone 5 excessive the trihuter and iLs alignment sliuuid be rccIIeckcd 7 Tighten cian p nut to 15 Lu iS ft the and recheck timing to oke sur...

Page 213: ... outlet 4 Using test points check for groundfrommain brush lead on A terminal to generator frame 5 If a ground is indicated in above tests raise and insulate both brushes and check in turn the insulated brush holder armature commutator and fields to locate the ground d Checking for Open Circuit or Shorts 2 Connect ammeter leads of Volt Ampere Tes ter as shown in Fig 11 11 3 Be sure knob on Volt Am...

Page 214: ...If voltmeter reading exceeds 8 volt it indicates excessive resistance in the circuit With charging rate at exactly 20 amperes place voltmeter leads across each part of the circuit in turn The readings should not exceed the following values a From armature terminal of generator to armature terminal of regulator b From armature terminal of regulator to battery terminal of regulator c Average voltage...

Page 215: ...gned 5 Inspect Durex bearing in commutator end frame for wear If bearing is worn excessively replace commutator end frame 6 Remove generator pulley attaching nut and lock washer 7 Remove generator pulley using vise as hold ing fixture for armature 8 Remove key from shaft and slide outside spacer washer off the shaft 9 Remove drive end frame with bearing and bearing retainer plate from armature sha...

Page 216: ...om the car body to the engine when the lights and accessories are turned on This condition will re sult in light flare up or could cause reverse genera tor polarity NOTE This test must be made with engine off 1 Turn the voltmeter selector switch to the 4 volt position car body and the other lead to ground on the engine 3 Turn on all lights and accessories then note the voltmeter reading This shoul...

Page 217: ...igh temperature determine the cause of trouble by disconnecting the lead from the regulator F terminal with the generator operating at medium speed If the out put remains high the generator field is grounded either in the generator or in the wiring harness If the output drops off the regulator is at fault and it should be checked for a high voltage setting or grounds c Low Battery and High Chargin...

Page 218: ...ever use emery cloth or sandpaper to clean the contact points 26 Voltage Regulator Adlustments The voltage control unit of the regulator limits charging system voltage to the value for which the unit is adjusted This test should be made at normal operating temperature 1 Make certain jumper wire is removed from field terminal of generator 2 Switch voltmeter to 16 volt scale and rezero the pointer t...

Page 219: ...dle flickers and the ammeter starts to register 5 The cut out relay points should close between 11 8 and 13 6 volts at operating temperature with cover on If closing voltage is outside these limits the cover should be removed and the air gap between the cut out armature and center of core should be checked and adjusted to 020 The air gap may be adjusted by loosening the two screws on the back of r...

Page 220: ...dicates a cracked distributor cap or insulation breakdown between spark plug wires d Low reading at all plugs indicates excessive resistance in either the primary or secondarycir cuit or a weak coil e If the reading is unusually low at one or two plugs remove the wire from the plug and again note the reading If the reading improves with the wires removed the plug is shorted out 30 Cleaning and Set...

Page 221: ...the primary wire from the coil to the distributor as shown by dotted leads in Fig 11 21 Voltmeter should read less than 1 volt NOTE If voltmeter reading exceeds the spe cified maximum isolate the point of high resis tance by placing the test leads across each con nection and wire in turn The reading across a connection should be zero The reading across any one wire should be proportionate to its l...

Page 222: ...should be brought to operating temperature If the coil is on a vehicle which has been operated for a sufficient period of time to bring the coil to normal operating temperature the coil does not need additional heating before testing If however the coil is not up to temperature the coil must be heated with the Coil Heater 1 Disconnect primary ignition lead at the dis tributor and remove the high t...

Page 223: ...et Regulator until meter reads at set point 8 3 Maximum insulation breakdown resistance 7 Turn switch to Coil Test position The coil meter should be steady in the GOOD hand These factors are tested on the Condenser Tester with one hook up by turning the Selector Switch NOTE If coil tests BAD reconnect positive to the proper position First however the meter tester lead as shown by dotted lines in F...

Page 224: ... Turn switch to M oli i position 2 i o inL Ler should read in the blue megohm bar at left of scale 3 lIthe meter reads to the rightofthe blue bar condenser Insulation is leaking NOTE When teslngeundenser off the vehicle connect one cotidetiser tcs load to thc Insulated cnndenser Eermin3 I and the other tear lead to ground on condenser dv Aways dscharge con dcnsL r atLer testing loin Is Blocked Ope...

Page 225: ...running direction The solenoid switch contacts should be checked for burned condition and the contact disc and terminal studs replaced if necessary If the above are all in order inspect the brushes and commutator The brushes should form a good contact with the commutator and have the correct spring tension If there are burned bars in the com mutator it may indicate open circuited armature coils wh...

Page 226: ...peed with ow dc veped turque and lugli curren draw indicates shorted fields 40 Removal and Disassembly of Starting Motor AL regular intervals tIle cranking rratur should be disassembled for coaoing and ins pocrion of all parts The nver llning cuLC armature andfields should not a cleejic i n an ynegreaa u tank or with greaae dissolving solvents since those would die solve the lubr i e an L in lmo C...

Page 227: ... so feat cemiter of spring c ears tIte reiaiiiemlg slaT Slide tiff the hm u so spring ann two brush holdem s as a grnaP c Repeat procedure for remaining set of brtlsh holders 41 Assembly and Installation of Starter Motor Thu assembly and installation of thu stsrtcr motor is b to reverse of the prouedurc doscrihed she cc w irli LI te cacepI ion of tl e foLio wi up p roce du r e foe rep lacing CItI ...

Page 228: ...r for topsr jeeforimmoen as explained in Notes 24 2h 7 Teat spark timing Note 14 S To provide an ilIdleadon of Oio over all per rmance of the ejlti re ignition avatemli make the secondary efficiency test Note 29 The eel system 51 01i Id he inspected thorough ly Clean all feel lines straiI ere andflexthle lines The fuel fills rsIroiIwr must be reolaccri ifplugged 10 Clean end service carburetor air...

Page 229: ...14 15 14 5 1107622 IGNITION Coil amperes draw engine running Coil Delco Remy type number Distributor Delco Remy Type No Distributor advance engine degrees Centrifugal advance Vacuum advance Dwell angle range New and used point gap Tension of contact arm spring Timing mark ahead of center Spark plugs A C type number Gap Thread Ignition switch Delco Remy type number Firing order Cond Capacity in Mic...

Page 230: ...rator to adjusting link 5 16 24 15 18 Generator mounting 5 16 24 12 15 Generator terminal nut No 12 24 12 15 In Lbs Ignition coil mounting screw 5 16 18 15 18 Regulator mounting screws 1 4 20 2 3 Spark plugs 14 mm 20 25 Starter mounting 7 16 14 45 50 Starter solenoid terminal nut 8 32 15 18 In Lbs Spring Scale Tool No J 2945 Fig 1 35 Speciol Tools OTHER NOTES AND REFERENCES ...

Page 231: ...11 28 ENGINE ELECTRICAL OTHER NOTES AND REFERENCES ...

Page 232: ...peed Up Control Assembly Bowl Cover Installation Fuel Pump Tests Fuel Pump Removal Fuel Pump Disassembly Fuel Pump Assembly Fuel Pump Installation 5 12 22 Removal of Exhaust System Assembly Removal of Exhaust Pipe Removal of Muffler Removal of Intermediate Pipe Removal of Resonator Removal of Tail Pipe Removal and Installation of Heat Control Valve Removal Installation 11 1226 Installation of Exha...

Page 233: ...ater Model 4CC or Cutter Model VQC FE carburetor are used inter changeably on 1954 engines While both carhurc o ra differ in design operatingprincipies and character istics are similar he basic carburetion systems of each carburetor are briefly described in the following paragraphs Rochester Carburetor Circyits The aochester Mode I 4GC Carburetor consists basically of two dual carburetors The two ...

Page 234: ...ry float bowl It then passes through the calibrated restriction in the end of esch idle tube The fuel is then drawii up through the idle tube es bled at the idle air bleeds passe s through other calibrated restrictions and is again bled by additional calibrated air bleeds flds iliixture is drawn rhiroughi thin channel In the fiosr bowl around the secondary throttle body bores is further bled by th...

Page 235: ...ld vacconl Cs well as by air flea a the thr ictiit calves are opened the fuel mialure to rl e An sddi tio na I so an c a of ftie I to mainta a a cnnsts a nlixru r e ratio at wide prams r y throttle pe nir g is furnished by tLic lower idle air bleecs which prlliect into to l 1 sides of o achprim arvthirottlebors i hese nozzles a upp ie mcilt the fuel discharged by the eta II svstt m to fill the gap...

Page 236: ...rapid acceleration When the piston drops down it unseats the spring loaded power valve permitting additionai fuel to low from rho float howl through thie cstihrstedpower restrictions cod into the main weLl This additional fuel supple nicole that already flowing through the nislo meter fog jets loto the main well on the primary side raIsing the fuel level in the maui well and hca making the mixture...

Page 237: ...ightest change in throttle opening Upon acceleration or down stroke of the pump plunger the force of fuel in the pump well seats the inlet ball The fuel is then forced through the discharge channel unseats the pump outlet ball and dis charges through the pump jets into the main air stream No targeting of these pump jets in required The accelerator pump system is vented to acquire peak operating ef...

Page 238: ...hereby closing the choke valve it is desirable to provide increased carbure tor air flow by opening the choke valve mechanically To accomplish this a tang on the fast idle cam is contacted by the primary throttle lever at wide open position so as to sufficiently open the choke valve This is called the choke unloader and also serves to dechoke an over richcondition during cold opera tion This choke...

Page 239: ... the main wells from the primary bowl through the metering rod jets on the primary side of the carburetor and is drawn up through calibrated low speed jets at the bottoms of the idle tubes These low speed jets measure the amount of fuel to be used The fuel is then drawn up and air is bled through the by pass restriction This mixture is drawn up and through the cross over passage in the bowl cover ...

Page 240: ...e into action as the throttle valves open sufficiently to allow mani fold vacuum to reachthe large andsmall venturi in each of the four barrels Manifold vacuum is multiplied at the venturi causing fuel to be drawn up through the main dischargc pauoages to the nozzles Fuel enters the main wells through the metering rod jets on the primary side and through smaller jets without metering rods on the s...

Page 241: ...l in the float chambers since the upper end of this cylinder is open to the air horn and is sealed from the float chambers by the bowl cover gasket Since the secondary side of the carburetor has no metering rods fuel enrichment for power opera tion is performed entirely by the primary side Accelerator Pump System When the throttle is opened suddenly at speeds be low approximately 30 miles per hour...

Page 242: ...ot air stove located on the exhaust manifold through the climatic control housing The flow of warm air in turn heats the thermostatic spring and causes it to lose some of its tension The thermostatic spring loses its tension gradually until the choke valve reaches full open position If the engine is accelerated during the warm up period the corresponding drop in manifold vacuum allows the thermost...

Page 243: ...xhaust manifold nod exhaust pipe controls ti e flow or exhaust gases from the left eylitmder head During the engine warm up period cite vnlve is closed forcing the hot exhaust gases though the ribbed heat passage tinder the inae manifold to heat the intake ga set to provide Optimum performance and economy when the engine is cu d A ui a pci of this paseuge conducts exhaust gases up to the carbureLo...

Page 244: ... and e f j when one adjos nient of a graiJe is mails the rest in the group ettuat be performed a Flool Level Adlustm nt Roth flouts Lv be ad its ted as described i t lu Re move howl cover with gasket fee m ca rhuce tot bowl as oimoiiled iii Nnte IlIc 2 With bowl cover invertod oct e flat surface bend float arms vcrtics fly an ii Lu a tea prtna r icye I Ii relation to Ca C h other NO rE hueiic srer...

Page 245: ... bend the atmosplric ent conct arm oeing Tl Nc 7 t en eec 5 time atmoepheric cMm valve hi the bow cover rig i2 _l9 e Choke Modifier Aaiusiment 2 Loos0o thetm ioeter Jet er reroinfng stcrew Rotate metal pointer eei prt rt sk from free pasftlon ore ii then n nero spring e to close Choke valve Cnntintio cotumnr i cnn I nie ni kcer ilnee with the index posiLresm o i thernto_ stat cover 3 Tighten retai...

Page 246: ...I I drill between the top edge of the choka valve and ole dividing wall in the air hrmrn Fig 12 23 Use Bemtding Twl No j 3I97 as shown in lig 12 14 Secondary Throttle Openin9 Adjustment 1 With carhttretcir invdrteai move choke tofufly opaited positioti 2 Rotate prin ary throttle to fully openpocitlon 3 Check opening of secondary throttle valves They shotild reach wide opem pusabon at the same tote...

Page 247: ...e tlte rest in thtc group must be performed a Float Level Adjustmenl NOTE The Carter carburetor float level adjustment is made with the bowl cnver ga sct remo zad Primary end secondary floats are act at dii erent heigltte osiag two separate gattgcs I Remove bowl cover eesemttbly frottt carburetor how I ae outlined in Note lc 2 Remove float Itinge pbts primttarv and secon dafl floats witl needles a...

Page 248: ... ti e lease it drop or awac fron seat to increase drop 4 iit e r hswl cover assembly and rei nve floats 3 Inspect bowl cover gic spetcarefully If dumage is noted discard IL a iIC use a new casket Place gasket on boa rover 6 metaL flttata with nondlas and clips beittp Ce re fol to di sti tip a is tent eer prin r y a i r sec on dary floats 7 it stail vncuometer piston at d assen bie bowl cover ta ca...

Page 249: ...Re s u re the arceleratnr pttnlp end metering rods are properly adjusted as l e idle vent adjustment depetids ml the putttp adjustment 1 t he c k velts va ive opening by Ittea so ring tlte difference in height ar the rivet i ead IW velve whli the prin ary throttle valve in the acer positiatt and then In tlte closed Itot Idle pasltion Re sure choke is off This should be 1 32 Inc rIg 12 37 2 If the ...

Page 250: ... until mhern ostatic spring itirts to close choke valve Contit ne counterclock wise uniil Detr I painter lines ttpwith plastic painter on coil hooting 4 IlaIw ng metal painter in this position loosen clamp screw end rotate tmiodilier lever until lever paints forward toward fuel inlet and scribed line is vertical Ftetighten Cian p screw 1100k upper end of choke tticdifier rtxi into mttadifier lever...

Page 251: ...es i ey snn t id be rally ape 1 at mite settee tiltee 4 if edjostment is required ren ove the secon ds ry tlirott IC Sc toe tlttg litik i Clteck wide open stops an prittrnrv and cacao dory t hrto ia shafts and bend tang a with heavy pliers as reqaired to obtain wide open position H I itata II aec ondsry throttle actua ing link Note that Ute llttk gcs in the hole nearest the center of the set u mdc...

Page 252: ...1 5 Adjust tang as required to obtain a minitl uIn clearance of Jl5 between secondary throttle shaft tatig sad lackctut cam asing Bending Tool No 3 5197 as ahavn in inset or rig 12 41 6 Check to see titat taag Dl caltt trip lever retmtrns secottdarv lockout ccItt to locked position whete choke valve is fully closed Adjust cam trip lever tang for n inimom clearance if necessary k Fost Idle Adjustme...

Page 253: ...ow engine and transmissiou to reach operating temperature Tachameter ahould still be connected from previous adjustments iran issinn sitnulb be in neutral 2 Make ccl thin choke La fully dpcn 3 Hold throttle Loser closed so tltat fast id e djL sa log screw re s on Itigitest step of fast idle catn C hoke stOve vul Lot be stisto axi ilt nginu is warm 4 Adjust fast idle screw to gIve a speed of ran RI...

Page 254: ...en fuel line to carburetor Tighten fuel line at fuel filter Note Be sure 1 Remove air cleaner and air cleaner mounting strainer nut on RPD carburetor is tight stud and gasket 2 Disconnect fuel line from carburetor and 8 Insert throttle relay rod in lower throttle loosen fuel line at fuel filter Note Carter requires lever hole Secure with hook end of throttle re a 5 16 straight tube fitting in carb...

Page 255: ...fled r cr015 float henge pins and floats Rc ove ieedles from their seats NOU B Keep parts front prii lary side se mr etc from those the secooda rv sick log plate to bowl cover 4 Lift idle speed up eonLrol and mounting plate from bowl cover b Idle Speed Up Coitirol Disassembly I Remove 2 screws and washers from bokelite cner 2 Remove spring from coil 3 RCLII0VC val o front inside idle support contr...

Page 256: ...ends of the 2 brass screws 3 Holding choke valve closed remove 2 choke valve screws Discard used screws and elide choke va lye out of slot in shaft 4 Remove thermostat cover with 3 screws anti remainers F0 not remove metal pointer or ther mostat coil from shaft in cover 5 Remove thermostat cover gasket and choke baffle plate 6 Carefully rotate choke shaft counter clock wise ontil choke pistnn clea...

Page 257: ...plunger assembly thermostat coil and cover assembly or pump boot in cleaning solvent Wash these parts in clean gasoline only h Throttle Body Disassembly 2 Clean and blow out all passages with com 1 Remove 2 Idle adjusting mixture screws with pressed air Remove any gum deposits which may springs have accumulated within carburetor pans Clean 2 Remove nipple for distributor vacuum line carbon out of ...

Page 258: ...ached in hole in secondary throttle lever Retain it with a horseshoe clip to secondary throttle lever 5 Start secondary throttle setuating lever onto primary thrutde shaft with curved siot portion out ward nod rearward With inner side of lever nfl shaft place override spring nfl shaft long ersi In ward and slide lever fully onto shaft with wusher end of throttle link inserted rhrntgh curved slot R...

Page 259: ...iver 5 Tighten 3 oilIer screws uniformly using a i iiilllpe screwdriver fig 2 47 Bowl Aebl f Ojianembled 6 If howl cover was not removed install 3 fl age rods as outlined in Note 121 If any linkage parts were replaced pcflorn adjustments 2c through ij Bowl Assenibly 1 lnstau fuel sight plugs 2 With bowl upright drop ball and copper spring into Fore under primary venturi cluster location Refer to F...

Page 260: ... choke housing with 2 self lockIng at tacLung screws 3 Install choke pistols on link attached to choke shaft with piston pio 4 Slide choke shaft into housing and howl cover Rotate shrift so that piston enters vacuum cylinder s Slide choke volve with letters EP down through slot in choke shaft Retaiti valve with 2 new brass screws Press firmly on choke housing cod of shaft and hold valve tightly cl...

Page 261: ...ing pump plunger into its bore CAUTION Be careful not to hold bowl cover in such a way as to press against floats 2 Install the 3 inner and 10 outer bowl cover screws with lockwashers tightening inner group first NOTE If car is equipped with air condition ing install the idle speed up control to the bowl cover on the right side of the fuel inlet 3 Install end of choke rod in choke lever from side ...

Page 262: ...rews nnd washers from circu lar housing 5 Open a ssemh lv exercizing care not to lose capered coil spring and little btass red iii shaft hole on opposite side oi diuplireglm C Bowl Cover Removal stud if carburetor is o be left on tile cimgi Ie 2 Remove meditier red by removing spring clip on lower end sith screwdriver pres sing againsi the open end of the clip and rotating rod to disengage upper e...

Page 263: ... s 0 I s ha ft before loosening to insure proper a seembiv ater pn It Remove idle vent arm screw and ikvasher 12 Slide pump shaft out of bowl cover 13 Rc move clamps anc metering red carric r with sprimig e Choke Disassembly With howl cover r igr r sins cit on the he nd loosen time clamp screw on choke ever and remnve lever 2 Rethuve 2 choke valve screws using a sown screwdriver 3 Remove 3 thermus...

Page 264: ...haft The spring will come off when the secondary throttle lever is removed from the shaft NOTE Do not attempt further disassembly of throttle body The low speed ports in each throttle valve bore are bored at the factory after the valves are installed and adjusted gaged from the closed throttle valve If original adjustment of throttle valves is changed the low speed meter ing calibrations will be c...

Page 265: ...o center hnle uf secondary throttle nctuating lever and retain with spring clip See Figs 12 53 and 12 54 4 Referring to Fig 12 53 aesenthle fast idle N i r t 1 cam nd spring cam trip lever and lookout cnm with pawl to throttle y wit bearing screw NOTE Long tang on trip lever faces oonvard and slips between fact idle cam and long end of spring Short cod of spring hooks over unloader tang un fast id...

Page 266: ...Tool No J 211U and a small hammer Be sure that retainer falls in position with raised portion upward 4 Drop pun check valve into its bore pointed me _ 1 _ 4 I v rp I 04 1 4 12 56An wIA sn hIyDi sassen bI 4en ddo wn an dme teII ga sket po mpje t sn dsc rew Re ferto Fi g 12 56 5 Gr ipre liefva lvew ithga sketan dpl acein se at Ti ghtenwi thsc rewdriver 6 Lo werpr imaryje tsin tose atus ingaL e ntpa ...

Page 267: ... z7Jhanoawe choke ShoE P 0w ENGINE FUEl AND EXHAUST Sow I o F Lkwooh Pomp L l k i Pod Li IJA I PLO wh0 p i iwy S F 001 m s choke BwI F Pai p Sho FE 9c is N cii Flt Fig 12 57 Bowl Cose Aomernbly Oiiossembled ...

Page 268: ...ary side Install brass plug and gasket on secondary side 5 Invert bowl cover and install primary and secondary needle valve seats with gaskets using a screwdriver 7 Install primary and secondary float assem blies with hinge pins 8 Perform float adjustment as outlined in Notes 3a and 3b 9 Remove float assemblies and install a new bowl cover gasket 10 Reinstall primary and secondary float as semblie...

Page 269: ... NOTE It is therefore possthle to removethe bowl cover assembly for float adjustment or other routine service without removing the car buretor from the engine If levers on choke or pump shafts are loosened however the full ad justment procedure on the bench and on the en gine must be performed 10 Install dust cover and gasket with 2 screws and lockwashers 11 Install air cleaner gasket mounting stu...

Page 270: ...ned castings must he reniaced Check strainer screen for damage or obstruction Replace scrcei if deposrs cannot he renved by swishing in ao vcn 19 Fuel Pump Assembly I Soak new diaphragm in clean kerosene UhilC r forming following steps 1 Make an aaeemhly of link and rocker arms wIth hu slng Fig 12 5S 3 l lace rocker arm sod link in body with link honk x n lng away om aphrugmf ange Fusition spring ...

Page 271: ...or 3 Crank engine until pump push rod in oil filler housing is at its lowest poInt 1 Raise rear of car 2 Remove resonator to intermediate pipe coup 4 Lubricate end of push rod with a drop of ling screws engine oil 3 Remove hanger at rear of resonator from 5 Position pump assembly on engine fittingpump frame to oil filler housing with bearing surface of rocker 4 Drive resonator off intermediate pip...

Page 272: ...ct to such extreme variations in temperature that the metal expands d Installation of Muffler and contracts to a considerable degree For this reason care should be exercised not to tighten 1 Install muffler on intermediate pipe the manifolds bolts too tight The manifold bolts should be tightened to 25 30 foot pounds and re 2 Install exhaust pipe as explained in Note 22e tightened after the engine ...

Page 273: ...Secondary Main Metering Jets Primary Secondary Power Valve Restriction Metering Rods Economy Step Power Step Float Setting Primary Secondary Choke Setting Accelerator Pump Capacity 10 strokes Idle Screw Setting Turns Open Idle Speed 1 5 16 1 5 16 1 1 1 16 1 4 1 4 046 026 026 048 064 038 Gasket to Bottom of floats 1 19 32 1 19 32 index 15 cc minimum 1 to 1 1 4 400 RPM in drive 1 5 16 1 5 16 1 1 16 ...

Page 274: ...24 15 20 Exhaust pipe to manifold left 3 8 24 30 35 _ A F I K I M NT Fig 12 59 Special Tools Key Tool No Name Key Tool No Name A B C D E F J 5457 J 5458 J 5195 KMO 658 J 1136 KMO 657 Primary Float Gage 1 8 Carter Secondary Float Gage 3 16 Carter ldleVentGage 063 Roches ter Fast Idle Gage 026 Roches ter Choke Rod Cage 040 Ro chester Wire Gage 015 and 018 Carter C H I J K L M N 0 KMO 658 J 5683 J 81...

Page 275: ...12 44 ENGINE FUEL AND EXHAUST OTHER NOTES AND REFERENCES ...

Page 276: ... controlled by a pressure operated vent type radiator cap which prevents the coolant from reachfng the overflow pipe As a pressureof 12 to 15 pounds is required to open this valve the boiling point of the solution is raised and there is less likelihood of loss of coolant particularly volatile anti freezes The water pump is centrally mounted at the front of the cylinder block to assure even distri ...

Page 277: ...reeze or water mixed with engine oil may form sludge which will interfere with lubrication and in some cases may form varnish like deposits whidh will cause gumming and sticking of moving parts A cooling system sealer such as DuPont Sealer should be added if permanent type anti freeze is to be used The water pump seal must be leak tight not only to avoid loss of liquid but to prevent air from bein...

Page 278: ... temperature of the solution wen testing may cause an error as large as 30 F Some testing devices are made to test only one kind of anti freeze solution Others have several scales and may be used for the corresponding kinds of anti freeze The freezing point of a solution containing both alcohol and ethylene glycol cannot be determined accurately by means of a hydrometer Also the freezing point of ...

Page 279: ...ature between 163 F and 1680F When the water reaches a temperature of 188 F the valve should be fully open High temgerature shermostats should start to open aj 177 F to 182 F and should be fully open at 202 F 10 Installation of Thermostat 1 Install thermostat in opening at top of water pump with valve up NOTE Be sure that the thermostatic spring strap is parallel to the centerline of the car fore ...

Page 280: ... been drilled oat 3 Attach a length nf to lie radiator uerfluw other en co hose in a water 3 i inch rubber tubing pipe and submer the ar par iaily fiLed with 4 jack up car and r ull ua mc with Lrane uo Sian in drive range or high gear Lvidence of leak age from lower radiator hose water Putill Or c y I indor head gaskets will be bubbling cif air through rubber l asc ir to Jar Cylii oer heao gasket ...

Page 281: ...assembly a Check radiator core for leaks 1 Loosen side straps where they are soldered b Check radiator air passages for pluggingwith to the upper and lower radiator tanks bugs leaves etc c Check thermostat to see that it opens and 2 Remove the overflow tube from side of radia closes properly tor by loosening clips d Check condition and tension of generator drive belt 3 Melt solder at tank to heade...

Page 282: ...move tItO plastic impeller frum pcnip shaft with Water Pump Impeller Poller Too No J 3211 Fig 13 5 6 ieinove seal daotpe te r a 11 seal wssher aasenibly from pump body b Inspection Inspect he iuipelle r blades for iad car ion of improper clearance or for escessive wear 1 Inspect sea lwasher and spring loaded seal for wear or cracks and repLace if necessary S Check shaft bearing in pump for roughne...

Page 283: ...ering install hydraulic steethig p Imp in peeltion wtth front moon ring h racker over cit p0 p ao tlet flange and insull two mnii b i bg seress Fig 13 7 Frmi m g tao ig ad Shaft Into Pump Na Fag On Air ConcUr loner equipped cars p rccee as allnv s a Figllte I lie One caiirJrosdor support to cyl 4 Press Iew hub on shaft ii ng I bib Spocer inder head screw Toni No j 3249 umii tool hotmi s or shalt b...

Page 284: ...1 A Water Pump Shaft Installer and Hub Spacer Too No J 3249 Fig 13 7 tng1a CooKog lprial la t Tool No Name Model Adaptation 1543 A Cylinder Block Air Con 1938 54 All Models J_ 3249 water Punip Shaft Insta let and Hub Sparer 1949 254 All Moils 3 3211 A Water Pump Impeller PUllor 1947 54 Al I ModeLs 5 2999 A Water rump Seal Seat Refinisher TORQUE TIGHTNESS 1949 54 All Nledeia Location Size Ft Lbs FA...

Page 285: ...ke Radiator core center constant standard Radiator core center constant Air Conditioner cars Tube spacing Hose thermostat housing to radiator top Diameter inside Length Standard 3255 Mean Air Conditioner equipped cars Type 95 to 1 0 Hose radiator to water pump 1 1 to 1 0 Diameter inside Length Standard 4 Air Conditioner equipped cars 4 Type 5 WATER PUMP Clearance between impeller and 359 93 pump b...

Page 286: ...tion and Assembly 5 14 10 of Front Pump and Front Drive Gear Installation of Front Pump and Front Drive Gear Disassembly Inspection and Assembly of Governor and Rear Pump Assembly 20 14 33 Installation of Governor and Rear Pump Assembly Disassembly Inspection and Assembly of Front Servo 10 14 12 Disassembly Inspection and Assembly 11 14 13 of Rear Servo Installation of Front and Rear Servo ha 14 1...

Page 287: ...GOVERNOR r 0 1 n 0 nl FRONT PUMP we puRr CHECK V4Vf REM PUMP 3 4 OVER CONTROL VALVE Fig 14 1 HydraMotk Transmission Oil Circuit ...

Page 288: ...throttle shaft 0 ring seal is improved The diameter is smaller and will improve the seal between the throttle shaft and detent lever To allow for proper location and seating of the 0 ring the throttle shaft has an additional groove SERVICE INFORMATION 1 Hydra Matic Diagnosis a Shop and Road Tests for Slippage Check fluid level with transmission at operating temperature and connect a tachometer to ...

Page 289: ...ary remove he rear eJtgi a C Stlppot he frame anti the tnx c l 5 ion housing so that the extension housing rests in i l c rra tiLe era as Connect Blow Gun Tool No J 4353 I in a urce or air pressure approximatelY 30 pounds and carcr tily check each passage in sequence Pig 4 2 Refer to tile nil passage chart Fig i 4 3 liatilig tie operetta uf unit actauted and presence of any tintistiei leakage NCyr...

Page 290: ...area where servo body rests on case There should be no appreciable amount of air escape at this point Check other passages on side of case for interconnection While a very small amount of air may be emitted from passage No 7 there should be no blow by from any other passage 6 Rear Clutch Apply Air pressure applied into this passage should actuate rear clutch As pressure is intermittently applied m...

Page 291: ...r a to cod not he chocked ill tlmi s di agnusia procedure 13 Reverse Cane Clutch i istorl Apply Air pressure applied inaL this passage should actuate tlt o reverse cone clutch piston s pressore is intermotoLitly applied Enuvement of the clutch piston should he audible and in most cases can he felt by hoidiog t he revcree internal ar with free hanc If an onu saai amount of aIr is heard escaping aro...

Page 292: ... rsiareoir o1 the fast idle steo approximately 375 41 3 F Xi eo the hood and remove tritlsnlisston dipstmck located at tite right rear side of engin ci wipe it clean and check fluid level 3 With engine atil rai IIing add fluid to bring level to oF full mark un dipstick I to F marking LIe dipstick is unu qLiart CAUTION nut rh ahovu F iiisrk 00 dipstick as this will cause foaming w hen trans miiiesi...

Page 293: ...r ih shait tliroitgll gaging hole iii disht relay lever and nta dash relay bracket See Pig 14 ñ shove e t carburetor th rtm tthe imi I oi idle position 375 II I M with transmission in drive range 0 Adlust carburetor to dash relay rod rrmlnnion to allow free entry into dash rclsy lever 7 hr tu1h spring chip in truniiiou 8 flack off both jani nats on the throttle valve rad at carburetor to allow fre...

Page 294: ...2 67 72 67 72 Shifts 2 4at 38 4 3 13 16 25 28 64 69 64 70 66 72 66 72 Shifts 4 2 at 37 3 2 7 11 6 9 19 22 Same as Drive 4 Range 2 1 3 6 5 8 7 10 Same as Drive 4 Range Same as Drive 4 Range 3 77 AXLE 75 SERIES 1 2 4 7 12 15 16 19 Same as Drive 4 Range Same as Drive 4 Range 2 3 8 13 27 31 30 34 Same as Drive 4 Range 3 4 17 21 55 61 60 64 60 64 60 64 60 64 Shifts 2 4 at 34 MPH 4 3 12 14 22 25 57 61 5...

Page 295: ...c m by lnatnd titer steinn jI S V tn mc tei piston 6 Aeinnove floor onst over hsin l srlju sti it s hmila cover and remove cover 7 Loasen band ad umatitne screw lock nmit adjusting aerew mn EL Lime bard odtasLtog gage tighten hi mrd saeLirehy ta 4o 50 ft Tighten ran I bard knurled wisher an tap of is joet free to t i pIe ld naod ai jmme irp dj a at ing Sc new Inc k nLi Iha t n tore Lse t i4aec tmd...

Page 296: ...rottle pressure road test Full throttle pressure in fourth gear at 30 M P H full throttle without going through detent should be at least 40 P S I higher than zero throttle pressure test reading Car on jacks 3 To check the operation of the rear pump alone drive the car at 40 to 45 MJ H in fourth speed Then shift to neutral and turn off the igni tion Pressure should be at least 75 P S Low rear pump...

Page 297: ...r flywheel housing wash the flywheel and torus cover thoroughly with cleaning solvent and allow to dry completely Then spread a clean piece of paper under the flywheel and cover and run the engine at a speed equivalent to 50 60 miles per hour When spray appears on the paper shut off the engine and check the flywheel and torus cover for the pre sence of fluid NOTE To perform the above operation it ...

Page 298: ... f y wheel hnusinz cieers fl xr pan 16 Remove thur screws holding fl heel hous ing to engine crankcase IV Iteonove transmission ond flywheel housing as a uhi by moving back Lowurd reer ulcer and at the same rime Lowering assembly to the floor Fig 14 32 Ii Disassembly of Transmission a R niavol of Torus Members lortis Cover and Flywheel Housing from Transmission Flo 14 12 NOTE Fioid coupling Cannot...

Page 299: ... pan and gasket 14 Remove side roveracrews 7 16 i and cover with gasket FIg 14 14 NO 1L When ret ovcd ci car roar engine moo mc elm old he removed to si owl i a euse of removal 15 To avoid damnge to oIl pan screen reen and front PU O intake pipe Os an a s scowl a fm n Lhe froit t pomp and rear pa np intake p PC Fig 14 15 b Removal of Valve Body Assembly mission in car Side cover must he rer nvee O...

Page 300: ...n to caee a tm a from reverse i mite rilaI gee r Paw ca ii ant be removed at this Dm0 3 Loosen lock plate and remove two bolts Irlding bracket aesembiv to cose 4 Pal I governor sleeve off he ing care f I lot tO tilt it because oil rings souldcwistendbe damaged Do ot lose rolet for tie parking bracket crank Fig 14 IS 5 Remove park ag pawl from case d Removal af Frani and Rear Servos NOTif Scnrvos m...

Page 301: ...ts may removed with Trans mission in car Rcuiccs removal of oil pan parking braccet Note II valve kidy Nc tc I Ito and rear servo No e I1d Fig 4 I Removing Oaveronr Oil Del ve y Pip is loosened enough hand applt spring attachimig screws Fig 14 21 Removing Reo Oil Purre nod Gov erna a nib ly 3 Remove front tad rear servo oltaching screws 9 4 Separate rear servo from front servo at compensator trans...

Page 302: ... the oil tleitvery Cioove 4 5sive ni einshaft hack and forth Endclears ice should be 004 to OIS He sure ttt get last free mainaliaft end play Fore rig ni vi mishaft w ill give Regolotot tapladed inaccurate reading OTE Record amount of end clearance so rita the proper Selective vrasher ceo beina aded when the tranamieaioli is reassembled S Remnve screwdriver from between front clutch drum and cente...

Page 303: ...Oil pan side cover porking bracket I in valvc body Ilhl rcsr servo I Id and rear oil pump lie must be removed Re mova extension housing nil sea I using slide hanliner Tool No J 26l9 A atid coliet No J 2623 Nig 14 16 NOTL Removal of seal will not be neces sary unless complete overhaul is required however this aeal cd n do removed and itratal led with transmfssinn in car If It iv leaking 2 Remove si...

Page 304: ...mg st rews NOTE lance by em I mayor miecessary to equalize die moving front and rear clutch drums nt k wrench to cet arc rc w head ina cli suitable epri mg em wire o hold front bait on fi oni unit drum 4 l irt hoth fratv and rear clutch and rti 1 a see mh Iie s v Lli bands 1mm trans miss ion case Fig 14 29 5 Remove bands from front and rear unit k Removal of Front and Rear Unit from Planet Carrier...

Page 305: ...hers from recess in front unit 12 Disassembly of Individual Units a Disassembly of Front Unit I Place front unim aesemhly in press and re move clutch cnver retaining ring Fag i4 l Z Separate drur b tapping front 1ace oI cearer gear en front clutch drum with plastic er similar hammer 3 Remove front clutch clutch drum by bm titpiag gear on soft wood black Fig 14 31 4 Remove six inner and six outer f...

Page 306: ...r s s replacement is necessary Disassembly of Reverse Assembly I Remnve speedometer driven gear frnm rear hearing retailter I wmc mcl l 2 Remove oil seal from extension housing usiag Oil Seal Remover Caller Fool Ne 3 2623 If seol has previously been required NOTE Col let and Slide I larruner may also he used to remove nil seal In cares ebmown in Fig 14 2C 3 Remove cover and gasket frammm rear bear...

Page 307: ...9 Seap Ring 9 w th I oel No 5 9670 A ctmmpress clutch re lease cnil cprlnga smtd remove large snap rfng Fig i4 37 IU Remove special tool 1 Rernave coil spring retai tc 12 Xemavc the aix coil release springs 13 Remove rho reverse cone pisten by palling straight ouc not try w turn piston s it is located by fnur cawc pi r s Saap Pttg Cane c i tc C Pielan Foam Bwanmmj S aa R m 3 Fig t 4 35 Rema ing Re...

Page 308: ...ing screw band anchor stopj Blow out miii oil passages through case theck far restricted leaky or interconnected passages 3 Make certain pencil type breather is not driven tee far imtto case Outer edge of hrcathcr plug ntmsr be Qesh with surface of case Fig 14 39 Otherwise it is possible to restrict time case vent passage and catmac teaming nf the oil 5 lmtapcct oil dolivei y sleeve far scored or ...

Page 309: ...7 Inspecr front cltitch drum for scores mn pistea hors oil delivery sleeve bore and all seal grooves Inspect gear teeth and thnmst faces for damage S lnsper r front planet carrier gears fur da maged teeth amid excessive roller bearIng wear 9 Inspect bearimig aurfoces of planet carrier shaft ID Iaapect steel and bronze thrust washers II Clean all parts thoroughly Inpectian af Rear Unit inspect mwar...

Page 310: ...rsverse planet carrier II gear is worn or damaged replace as follows a ltenvavc snap ring holding gear to carrier Saw beveen two teeth to within 1 64 Inch of tile inside diameter c Insert chisel in sawsd slot and break gear off cattier CAUTION Make sure nat to lose sleek Inca ting hail under gear d Place new gear on nettal supported by two bricks and heat with torch from mlnderaeath antil gear jus...

Page 311: ... Imp 2 InstaLl four drive and four driven plates into front drum alrcr matcly starting with a compesi tion plate NOTE ln stall driven plaLes wIth square notches over dram pitta Also apply Hydra Matic fluid Lu face of each plate surface es assembled 3 Install six outer cloIc1 release and mc eix ittnc r elI tcli release springs t I rougl plates ir LU sprittg holes uf drum 4 Irsta II new im m e r bra...

Page 312: ... into ring groove of clutch drum with expanding lips down 5 While holding the brass expander in position work the rubber seal into ring groove with lip down over brass expander 6 Place a new rubber seal over rear annular piston beyond seal groove 7 Install a new brass expander in piston groove with the lips facing up While holding expander in position work rubber seal with lip up well into the gro...

Page 313: ...trnuhle corrected C A embly of Reven Unit Hold reverse center gear it left hand with drive finnge up fnstuil the steel thrust washer and titen ihe bronze thrust washer ii the recess of the drive flange 2 Still holdIng the reverse center gear in the left hand pick up the output shaft with the right hand insert nutput shaft atmd through drive flange and center goer until carrier bottoms on the tet t...

Page 314: ...ating haIl bcaring 22 Install reverse internal ge an and stationary cone into rear bearing retainer by tur apressing stationary cone by hand slrion keyway of aratinnary cone so it will line up with kc vway in case when itlstahc Fig 14 46 23 mace small spacc r ovor output shaft 24 Instail outpnt shaft in rear bearing huusing FiG 14 46 Imtallin Stotionry Cone and mesh carrier gear with the reverse i...

Page 315: ...ring end clearance within limits of 004 018 Selective thrust washers are furnished in the following eight sizes Mark 1 2 3 4 5 6 7 11 Install mainshaft in output shaft meshing center gear with planet pinions 12 Install gasket on extension housing using petrolatum to hold it in place 13 Install mainshaft and reverse assembly into rear end of transmission case aligning stationary cone lock key into ...

Page 316: ...plug with air to make certain liies are free 5 Check pressure plug coal and gasket for damage or wear C Assembly 1 lostall pressure regulator valve In presstLre rugulatur spring Small end of spring must fit ill groove nit valve 3 Install reverse booster plug and spring in pressure regulator assembly with chamfered end II regulator plug 4 InstaI presscrc regL laLsr spriog in pressure regulator plug...

Page 317: ...SI 0 Remove lrnnt cover oil seal trout pump cover using a siiIail screwdriver Discard oil seal VI 0 Sails Rirr Inspect sot i nc ltttitur lirt sc o rc s u rb trrs 411 edges sLi ulcI Ld siturp aithoct chsniers on radii Fig 14 12 2 U spect slide to be sure the two hI eed holes are open and tree of dirt 1 Inspect slideforfres movement i i puIhIpcovei It abou Id not bind under cii y circumstances 4 Che...

Page 318: ...es 9 Lubricate internal parts of pump cover with flydra Matic fluid 10 Place pump body over dowel pins in pump cover Pump body should fit freely on dowel pins 11 Assemble pump body to pump cover with four attaching screws using new washers Tighten to 12 15 ft lbs torque 12 With pump completely assembled move rotor by hand to be sure rotor vanes and slide are free Be sure priming springs will retur...

Page 319: ...nor plungers still stick re place complete assembly 6 Inspect governor blocked passages c Assembly 1 Install rear oil pump driven gear in pump body 2 Position cover on pump body and install four mounting screws 3 Install governor oil seal rings Place oil seal rings in bore of parking bracket assembly and check ring gap Gap should be 001 to 007 Groove clearance should be 001 to 003 4 Install 01 and...

Page 320: ...mage as it is made of dio cast material 2 Remove 4 3 downshift valve from front servo K 4 3 wnahift Valve Overrun Control Retainer Pin M Overrun Control Valve Plug N Overrun Control Valve Spring Overrun Control Valve P Valve Body Q Line Exhous Line xbaoat S Line Exhaust 3 Remove line exhaust valve spring retainer clip hoe exhaust vave sprilig and valve from front servo valve idy 4 Remove Overrun c...

Page 321: ...in is Si tgv in place Assembly Instal overroi cuntrn F vtlire spr ng plug and retainer pin ir aecv T valve back Fig 14 57 Remoereg Frtor Servo ttae Piston 2 ltistalã line exlmost valve spring a lire Liner clip in front servo vn ve bode 3 Install 41 snwnshmft vs ve in servo booy Install check ball spri ig sad ball in 8L rao bode ace arofoiiy assemble front servo valvo nerve bode and install tl tc c...

Page 322: ... pod S Remove booster piston and spring from sorao body 9 Kemovs entter pin from each end of pivot pin hoiddug band actuating ever at hraeker on servo body P051 pivot pin out of servo body bracke to nd bans ac to sLug bear CAUTION Take care not to lose needle bee rings out of hand at n sri it lever whets re t av mug river pin Fig Is SO Check Boll end Sgring Lorotion b Inspection 1 Wash aLl parts i...

Page 323: ...rc w driver The was it ion of ii to b lead hale itt tite check valve in relation to rho drilled hole in the accumulator dy is no nipar tan r as long o s the bleed hole is nor abstruicred it is impassible for abe civck vaive to sm Sr thor touch 4 Inspect actuating ever for crac ca bends or brinelling Inspect nesdls hearings and repaceany hat have flat spots or are excessively worn 5 Inspect arromul...

Page 324: ... servo body bracket 2 Lubricate booster piston with clean fluid and insert in servo body using extreme care not to damage oil ring on booster piston Place booster spring in booster piston and install in accumulator body using extreme care not to damage oil ring on boost r p ton Place booster spring in booster piston 4 Install small booster piston springon accumu Lator piston rod with small tapered...

Page 325: ... assembly Fig 10 Tiglate ntvofioncpuihiiaatti cI iiIg acrcwa with steei washers In Ill IS ft lhs torque 25 Internal Band Adlustments Per orb iic i itc rital band adjust nae nan as oea crihed ii NoteS 26 Disassembly Inspection and Assembly of Valve Body a Disassembly Oulec Valve Body Fig I 4 66 CAUTION Never use a vise to hold any parL of the valve body during repair as body is a de coaling al con ...

Page 326: ... La 5cc thaI II s plug which fa very a tIer aloes ttot drop and become lodged in the 000y as alto casting av y ild probably he dalaaaged in acreltipas to dIslodge it b Disassembly Timing Valve Body Fig 4 68 I iletnove Iwo screws and reltIove 3 2 Liming vaLve body asaetith y from iI Iaer valve body 2 Remove timing valve plug retainer pin iIIg spring and voice Disos5embIy Rear Valve Body ig I 4 68 1...

Page 327: ...preferred is ma avail able a flat glass oaay he itseci with No 4011 grit emery paper and kerosene I Wash off and inspect carefully Nigh sonic wilL show up as dIlL gray patches abbe ally low s1xats a n iiueicared by arrows Fig 14 will ha shiny If visoal iospec ion indicates aorfaces are not perfectly flaL ootitm c lapping utitil all shiny spets se disappeared and the eiatire car fare isa doll gray ...

Page 328: ...lve dy V 1 2 Regulator Flog Z 4 I Si clutle Valve 3 4 Rcgc ator AB 1 2 Regltlanor FLog Spring AC 3 4 Shirt Valve Spriblg ltD 3 4 Shift Valve AlL Coverlbon I Iit 3 P 1 1 feteiut iag AC 2 3 Govennnr Sleeve AH 2 3 venrr Flog Al Rear Valve Body Spacer Plato AK Roan Valye cIy AL Valve hody Spacer FLoe AM Dole n Valve Ilody F 1 ont Nate AN Compensator Valve AD Conapensater Valve Spniiug Al Detent Plug V...

Page 329: ...T manual valve detent spring and plan ge r Align manual valve with the Ins ida date 11 lever pin and rotate lever ciockaiae to index Ide plunger on the detent control lever assemhl y 9 IneLail 3 1 by pass valve spring steel into on Len valve Lsidy 6 Install manual shaft ruhher seal outer and h Assembly Timing Volve Body Fig 4 68 littie r seal a aaher e i tad piti Inse r L 3 1 lion ing valve mu Lin...

Page 330: ...a I P a a a a H a n a 5 a a a a 0 S o ar r a a a P o S ta ha a C C O a a a C H a r 3 c T 0 0 S L S 0 0 P a n a 7 1 a a a a a I a a a C a It 5 a It I a I 5 C a 04 a i I C pa It a E a C 5 a C C5 a a an rIt a a Cr a a ia a S S a or a b a or or U to c tO b i be P F p i o y 0 i B in C a a 5la _c a a 0 U S c V 5 a or a a a to a a a 55 55 a a US I US t a a a a S a a Pt a 5 B a 0 a r Pt a a a r tO a ibbli...

Page 331: ...governor rage in i llacr valre IxIdy insert 1 1 detent plug il PIe inner valve body N Ci l Vt IUC Ii Cocking alt sleeve vav oiaiily ace en iar a salve ia free ill hone 3 Install rear td e lands aoi apacer plate ro inner valve U A1 The 2 I boron pltlg can he 01 1 in ln alrDI ar ui the piaLe able startilag nbc rilrea attaching eCre va Assembly Outer to Inner Yoke Body Lki HiLhi l apac c 1t are a Ic ...

Page 332: ...blocker piston wh h slottedend el r iil stalt reverse bhllcker piste i spni lg in reverse blacken oiatt n e ud i i d iii whla a scrawilriven while instaii ng bisiccer pistol ia ola Clila l een hnthend aof pita an ack in piece 6 Inspect parking pawi on cracks or eigns of unusual a San 7 Cheek oil delivery sleet e br aL c r C t a arka Cr cseoesivc wear Check governor feed passage by itu serting tag ...

Page 333: ... Alignment Thai NIl J 4731 in place beta can gavertiar and sleeve Fig 14 79 tighten the rear pump bolts and parka ig brake bracket screws Tad should rotate freely and gavernor shauld rotate t neclv as Innuch s gear haekiaabt allows Rotate nutpot altars to urn gayer ann 1 4 Lola mid check governor and tool again for freeness If gavernar on tool hind at lay pnint loosen hracket sad or near pomp and ...

Page 334: ...bs torqllo 4 Install outer shift lever Tighten m tfi i 3 ft iha torque clatiup hal 32 Installation of Transmission Oil Screen and Pan 1 lh ts II oh Is reen and front i i tap in Lake pipe a s Sul aasenubiy 2 01 a new o l p ol gasket an traa a mi sai r I case Pasiui0n ad l 1 tlver gaakct 4 Start attaching bolts wino sock weshicra to lhae lJl pan TLc i igl tcia screws to 11 I d ft lhs torque 5 litats...

Page 335: ...nata LI torus covers on splijues of front drive gear Push on cover evenly winhota nockiiig to prevent datnage to oil seal and rings 4 hnetaii drfve torus nucitibar on splanes of inter media to ahuaft and install stiap ring using Snap Ring Pliers Tool Na KMO 410 Pig 14 12 NOTE To rca hubs are a hand po si fit ott the traaxnnhssian shafts not use force Ca asscluu ble if they stick reunova anti exatn...

Page 336: ...not designed to lift weight of entire engine Remove Engine Support Stand Tool No J 3068 10 Install bracket that carries engine rear support lower engine and connect support 11 Install slush deflector to flywheel housing 12 Install transmission fluid filler tube in oil pan 14 Connect rear universal joint using new lock plates 15 Connect speedometer cable 16 Install starter and spark plugs 17 Instal...

Page 337: ...tainer to jacket bolts and tighten 7 9 ft lbs torque 9 Install shift indicator and lamp 10 Install anti rattle spring selector lever and pivot pin after it has been lubriplated 11 Install directional signal switch and wires through steering jacket and install 4 cross head screws 12 Install steering gear See Section 7 13 Connect manual control rod to lower shift lever 14 Install neutral switch on s...

Page 338: ...2184 A J 2184 1 J 2184 2 KMO 30 J 1465 J 4731 J 4752 J 5157 KMO 410 1 2182 J 1942 A Front Pump Cover Oil Seal Installer Transmission Mainshaft End Play Gauge Front Pump Holder and Socket Holder Socket Dial Indicator Set Mainshaft End Play Dial In dicator Extension Rod Governor to Sleeve Aligning Tool Piston to Drum Installing Tool Regulator End Casting Assembly Clamp Snap Ring Pliers Transmission ...

Page 339: ...1 8 pipe 10 24 1 1 16 16 5 16 18 1 4 20 3 8 16 drum 5 16 18 5 16 18 1 4 20 1 4 28 3 8 24 1 8 pipe Subject and Remarks All Series Subject atxl Remarks All Series FLYWHEEL COVER AND TORUS ASSEMBLIES REAR OIL PUMP Flywheel Cover maximum runout End play of gears 0 001 to 0 004 of hub 0 005 Backlash of gears 0 006 to 0 010 Backlash between splines of cover Mainshaft end play 0 004 to 0 018 and front un...

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Page 356: ...in pan and directed to outlets which extend through the lug gage compartment floor pan Note Name Note Name Precautions in Handling Freon l2 i iô A 4 or Shaft Seal Operation iOa i6 A i4 Precautions in Handling Lines 2 16 A 6 To Replace Damaged Compressor iOb i6 A i5 Maintenance and Inspection 3 i6 A 6 Precautions Disassembly Assembly Preliminary Check 3a 16 A 6 and Adjustment of Compressor Seasonal...

Page 357: ...lo Blower Motors Fresh Air Inlet Scoop Evaporator Roof Duct 0 n 0 z a g 0 z rn Dehydrator Filter Sight Gloss Fig 16A 1 Location of Air Conditioner Units ...

Page 358: ... to to talc without turn jug the shaft Another re tsiuler ring is snapped into a gronve in the shaft to retain the heoring and pidley assembly on the shaft Clutch plates two clutch pierce are used One cluLch plate is counterweighted and the orher is known as the clutch plate actuator The cowitor weight pi ate ha e a splined center which matches the aplines on Lhe compressor shaft A flat ring of I ...

Page 359: ...e ventilation without refrigeration Clutch solenoid is de ener gized disengaging the clutch at the pulley Knobs on each side of the panel permit control of blower speed ON Blowers are turned on clutch solenoid is energized engaging the clutch and compressor to the pulley The system is now in operation for maximum cooling The blower speed may be de creased if the car becomes too cool OFF Compressor...

Page 360: ...mon radiator stove or use torches for heating during charging d Do not fill drum completely when filling one drum from another always allow space above liquid for expansion e Do not discharge Freon 12 into a room having an exposed flame concentrations of this gas in contact with an open flame will pro duce a toxic gas f Do not expose the eyes to liquid protect them with glasses or goggles If Freon...

Page 361: ... clutch en gages and disengages when the On and Off e Gage set and lines should be kept clean switch is operated Make certain clutch is not and free from moisture slipping f Do not leave Frigidaire oil container open any Place toggle switch in On position and operate longer then necessary as the special oil is mois engine for fifteen minutes at 1300 RPM ture free and will absorb moisture from the ...

Page 362: ...eann and Welding Excessive hea applied at any section of tIre rcfrigoranr lines will c eate excessively high preesLiree For this reason steant cleaning or welding slruld not be performed on any perLinn of the car ndj scent to the refrige canon OniLs or lines c UndercoaIin To facilitato service operations under coating should not he appl led to any connecliuns on the rcfrigerniun syetem Whi e it i ...

Page 363: ...J 5462 4 High Pressure Gage J 5416 From Cooling Coil Manifold i 5415 Gage Lines5 5418 Connector J 5462 7 Ring Seat J 5462 8 Pressure j 5417 Drum J 5462 3 1 Connector 3 8 Connector 5462 6 Vacuum Pump 5428 Fig I6A 7 Gage Connections for Evacuating ar Adding Refrigerant ...

Page 364: ...62 l to the connector aL the vacoont pornip l sra II a gage line from one side of tee con nector to the valve at time eaclmcmmmm pomp Valve should he closed NO l E Make sore dust cap on discharge side of vacommni pomp has been remavod Chock fluid level flits should he between the high and low screws in time sIde of the pump Fig IdA 8 dd Frigidaire 7 5 viscosity od Lu bring to proper cvol Chmange n...

Page 365: ...n determine when a complete charge of seven 7 pounds of refrigerant has been added to the system a Charging Precautions In all refrigerant charging procedures where the compressor is in operation the following cautions should be observed 1 Always wear goggles whenever handling Freon 12 This is also necessary when breaking line connections 2 The high pressure should not exceed 275 pounds 3 The low ...

Page 366: ...sore lmarmd shuL ntf ValVe oil gage cci to Operata engimre uL L51i0 i I M with the rnnl pressnr C lotclr sngaged LI Observe gages sight glass arldentire system for proper parfurrnanre 12 Armc r five moLes of operatiomi iroulcl bob bies reappear eight glass add 1 mnjrc pound of rc frigeranL 1 3 Re move tIme gage cm mnmroe Lim rn Sm mn the compra 5 so r and disconnc ct Freon drLmm 14 Cap the gage cn...

Page 367: ...evel and therefore oil ciii have to ho added b Adding Oil Minor Loss If the oil level is be 525 visoosit Frigidoire oil should he addeml as outlined beiow I Shut off 111gb amid low pressure hand shut off valves at the compres sor mmsiog I 4 key Tool No J 4fl Figs l6A I 2 and 16A l3 2 Depress Schrnder valve core on high pros sore test connection em porge l reon mrntil a ioa audible hiss is heard Al...

Page 368: ...ressure until amy a slighL audibLe hiss can be heard Repeat if necessary to he sure prceeore is at a mnhlrillmurii 3 Remove valve flange n moonting screw and re move hand shut offvaivea froir Lxmre of compressnr Fig l6 A f6 4 hbcrarave cumpressni as descrIbed in Note lila and h 5 Reorve high pressure reiLefvove and gasket 6 l mvcrr compressor and draIn oIl Into a clean container NOTE Examine the c...

Page 369: ... of the car grille may be neces sary to direct a flow of air over the condenser This will eliminate excessive engine tempera tures and provide more accurate pressure read ings 5 Disconnect the gage set replace the flare nuts and tighten all fittings 10 Compressor Removal Since there are several reasons for removing a compressor from the car each of which requires a somewhat different service proce...

Page 370: ...e frictions lining msterial on cluLch plates ax this vii result hI improper operation b Disassembly I Ii necessary remove compressor from car as described in ete lOa and h may be disassembled no car 2 Diactlnect cud remove ul uLcn actuating arm at cnmpressor and solenoid a Precaution 2 Remove polley clotch assembly from damaged compressor and install on replacement compressor as described in Note ...

Page 371: ...ighc position install Lhe coomer weigltt clotch plate on splined silsft iricLitins lining towards cnmprcs ar To do hie it li he necessary to position the on6 hlind ep iii 0 0 the shaiL svtLh the opect spline of the inner Li plate hub Jhis is necnasary sance the inner clutch place will oni fit en the shaft In ttne pasiliolt Pig IdA 2 1 6 Place the three steel halls in the tC ar drop depressions of ...

Page 372: ...longer and torn the adjosting not to secure proper ciectence Tighten lock not e Ch kiag Cletch Operation With the engine idling toni tee air cttndtionmg switch On and Off s number oftimes ta burnish the clutch plates until the clutch properly engages NOTI Pror engagement can he observed hy watching rhe accosting pin cc be sore it torni in relation ship Lo the policy when dtc elutc Is is engaged in...

Page 373: ...y Ri g Cco p e stat Sb aft NOTE i i 5 can be done nY rev ersingthe tool so that the emstil tubular end is prcsscd firmly be bond ngain st 7115 ittsscr rtogiifsqitl etiu rubber 11 ts will assure a better contact bctwcon the radios of the cea aid the shaft shoUlder 12 App v nica i FrIgidaire o t t j he nitraltoy ring seat hratio seal ti at coiltacts the nitralloy ritig and tha first tltrec torns of ...

Page 374: ... Cot ip rev sor Asscttth caiid iiistsll dote on Compressor shaft us described in Note lie 2 install coxttr rc ssor as dese ril c d in Note l la 3 Purge the air from tlte compressor by de presaing the valve stern in the high pressore gage connection for a few eeconde 4 Star the engine and alinw it to aperato for several to inotes then repeat purging eperatiot as explained in Step 3 ave This will re...

Page 375: ...s previously described in Nate 5 2 Rettiove spare tiro and disconnect all of the atr ets fto on the ev apor star 3 Disconnect blower motor leads 4 itea ove oceess pond and aisc toec the re frigerailt htie connactions at the evaporator unit biottsing 5 Remove the evaporator ttnit mounting nuts and bolts and remove jttit from the logsage com portment 6 ReUtiov 0 the panels from the Ut nit hot 5 Pig ...

Page 376: ...l repisce_ tr C t t of the sight glass is required proceed as follows Purge l e systetn as oo iinsd itt Notc 5 Nave replacement sight glass within reach for iillmediate mstaliation 2 Diaconoect the flare Iit ittgs a the sight glass and U ct tovc sight glass 3 iaa a Il the clew stghtt glass 4 llcfor evacuating tU e syStCUtt aipiysoff cieot drt prossure to the systom to obtain a good lCak test 4 bUd...

Page 377: ...motor defective Blower motor rotates in wrong direction Check for short Replace fuse Instruct owner Replace switch Replace rheostats Inspect connections and wires Repair or replace motor Replace motor Restricted air flow Filters in evaporator clogged with dirt and or other foreign material Outside air scoops restricted Roof ducts restricted Air flow under rear seat re stricted Condenser clogged or...

Page 378: ...lectrical Toggle Switch not on Loose connections or broken wires between electrical units 20 Amp fuse blown Instruct owner Inspect and repair Inspect for short and replace fuse B TOO COLD Clutch does not disengage Defective solenoid Toggle switch inoperative Clutch lever arm bent broken or binding Replace solenoid Replace switch Free up replace if necessary Blower speed can not be re duced Defecti...

Page 379: ...ide to expansion valve for re strictions Check cooling system Open valve all the way Check for restricted air pas sage Adjust valve See Note 14 Insufficient pressure on high pressure side Shortage of refrigerant Incorrect expansion valve ad justment Divider blocks in compressor not seating Check for leaks repair and add refrigerant Adjust expansion valve See Note 14 Replace compressor Excessive pr...

Page 380: ...ector With AnIiydruu Alcohol Gauge Aater Set or 2 Por ot SlTermometer iitfl23JO 16 Tube Wrench 4 Tube Wrench Tru Arc Pliers 488J J 5 25 5426 J 5427 J 5428 J J 5455 1 5462 Tru Arc Pliers 2 Sea I Centeriog Tool Sf16 Valve Key 1 1 Liquii Vs lye Key Vac en Pump ISv 50 60 Cycle 7 HP iLa Special Oil ggIee i llig Sc Gatjge I ookup Set OTHER NOTES ND REFERENCES lô A 25 J 54a7 HOOK UP SEF J 542S J 455 PLUG...

Page 381: ...l6 A 26 AIR CONDITIONER OTHER NOTES AND REFERENCES ...

Page 382: ...for the heater and for summer ventilation is scooped up through an air intake located horizontally along the outside cowl top panel between the rear of the hood and the lower wind shield reveal molding Air entering the intake is directed first against a series of two baffles which force any rain in the air to drop into a drain gutter provided for this purpose The water thus collected is routed to ...

Page 383: ...on and defrosting of the windshield For upper level summer venti Eatiomt the blower motors turn ON when he Deir kvcr is moved from the tFF position As the lever Is depressed t mc ventilator valve in the heate toni begins in open allowing fresh air to by pass the heater cores enter the defroster duels and over the windeljioid area The upper vent valve roaches its nlsxitmtm opel pea tioim as the Def...

Page 384: ...lever in OFF position and depress Deft lever all the way down to the Ice position c Summer V ntilation 1 Heat and Defr levers in OFF position 2 Pull out both ventilator knobs at right and left of steering column below instrument cluster These knobs operate the right and left fresh air intake valves on the lower inner cowl panel Fig 164 5 Control Lever Position Winter Ventilation d Winter Ventilati...

Page 385: ...all cowl kick pads and heater grilles c Fresh Air Ventilator Knobs 2 Push both fresh air vent knobs in as far as possible 3 Fully close both fresh air intake valves NOTE It is essential that a perfect air tight seal be maintained at the fresh air intake valves as cold air leaks at this point will strike the thermostatic valve capillary tubes and affect heater operation during cold weather 4 Connec...

Page 386: ...lide the clamp over the pipe and then install hose over pipe past enlarged portion of pipe Using special ICtC ehde camn over hose so that it ia poeitioned between the enlarged tortion of pipe and end of hose as shown in Fig 168 7 NEVER PLACL TIlE CLAMP Oh THh hOSE FIRST AND HORCE iT OVER THE ENLARGED IORTION OF THE PIPE AS TillS WOULD EX PAND THI SI IUNC CLAMPHXCaSSIVELV C1V ING IT A SIiJ WIIICII ...

Page 387: ...ower unit and heater core housing 13 Connect air intake duct to heater air intake case 8 Remove twelve metal screws joining the two heater housing sections and remove core 14 Connect water hoses to heater core nipples using special snap on pliers to install spring type 9 lb install reverse above procedure hose clamps NOTE Make sure that seal around core is 15 Lower front end of car properly instal...

Page 388: ...ores Solder obstructing flow in core g Defect in wiring circuit h Summer air vent not fully closed i Defective temperature con trol j Obstructed front or rear compartment air ducts k Obstruction In cowl air blis ter 1 Control cables not properly secured to thermostatic valve m Air leaks between heater valve case and heater core a Obstructions In windshield outlets Blower motor not connected Defect...

Page 389: ...r a Air leaks b Hoses routed incorrectly Repair leaks or close summer ventilator Also see Trouble 1 Connect as in Fig lôa 1 Blower fan will not run a Blown fuse b Defective Motor c Open circuit d Defective Switch Replace fuse Replace motor Repair circuit between ignition switch blower switch and blower motor Replace Switch 7 Underseat heater fan will not run 75 series only a Open circuit b Defecti...

Page 390: ... owners option When the pre selector radio is being operated with the push buttons it is necessary to first depress the selector bar manually before operating the radio with the foot control A 6 x 9 elliptical permanent magnet speaker is mounted separa ely from the radio The speaker is located to the right of the radio with the grille opening on the front of the instrument panel and extending bene...

Page 391: ...e clockwise position 3 Tune in a weak station near 1400 KCand adjust the antenna trimmer located on the left side of radio case near the antenna lead socket to maxi mum volume Fig 16C l NOTE If during adjustment the station be comes strong tune to a weaker station and con tinue adjustment b Push Button Station Selection 1 Open the door directly below the dial to gain access to the five red plastic...

Page 392: ...nt as compared with a known good vibrator replace withanew one Defective vibrators may cause a noisy weak dead intermittent or poor toned radio c Antenna Use a test antenna and lead in plugged into the set with the test antenna held outside the car If the radio works satisfactorily with this test as sembly the antenna should be checked for a short or ground and the lead in should be checked for co...

Page 393: ... to the accessory terminal of the ignition switch 10 Connect rear speaker wire at left side of radio 11 Connect front speaker wire at right side of radio 12 lnsert antenna lead in wire at left side of radio 6 Replacement of Front Speaker 1 Remove radio as outlined in Note 4 to pro vide access to front speaker attaching screws 2 Remove attaching screws at top and bottom of speaker on left side 3 Re...

Page 394: ...llowing order Engine Ground Straps Two ground straps one from each cylinder head to cowl should be checked for breaks and proper ground contact Hood Ground Clips There are two hood ground clips located on the left fender near the vacuum antenna Check for proper ground contact or replace if missing Coil Condenser Mounted on outside of coil Replace if necessary Distributor Rotor Suppressor Built int...

Page 395: ... Replace vibrator See Note Sf Identify type of noise Replace Check distributor rotor See Note Sf Check generator condenser See Note 4f Check installation Intermittent Loose antenna connection Intermittent tube Intermittent vibrator Check connections Check tubes See Note 3d Replace vibrator See Note 3h Poor Tone Defective tube Worn vibrator Low battery Check tubes See Note 3d Replace vibrator See N...

Page 396: ... the lower plug This prevents the piston from revolving while the rod is being unscrewed SERVICE INFORMATION 1 Removal and Installation of Vacuum Antenna 1 Separate lead in cable at plug in connector at rear of left front fender dust shield 2 Raise antenna rod slightly by hand and lower it back into position slowly while rotating it until the dogs in the bottom of the piston can be felt to lock in...

Page 397: ...aler and press plug in bottom of vacuum cylinder until screw holes line up S Place large thin copper washer aild small steel washer in position on bottom or drain plug and theit x sltion shield cup over bottom of cylinder and in stall the no retaining errews 6 Install Inwer vaclJum elbow 4 Maintenance and Repair Procedures Many antenna troubtes can be prevented by cleaning the antenna rod on all c...

Page 398: ...E Cover bottom drain holes with mask ing tape before undercoating car b Antenna Will Not Raise or Lower Inability of the antenna rod to raise or lower is usually due to a defective antenna rodpiston vacuum hose leak or a bent antenna rod No attempt should be made to correct this condition by addingoil to the cylinder If a check of the three possthle causes listed above fails to correct the conditi...

Page 399: ... The headlamps are controlled automatically in only one position of the standard foot dimmer switch The other position of the standard foot dimmer switch provides the lower beam only The auxiliary foot switch functions only in the automatic position of the standard foot dimmer switch When pressed down and held it provides the upper beam regardless of light on the photo tube unit This arrangement p...

Page 400: ...uxiliary switch The lights should now change to the upper beam and back to the lower beam when the aaxiliary switch is released I lights do not operate as described in steps I and 2 refer to Notes 4 and S 3 Cover the photorube unit lens with palm of the hand The heediamps should switch to the upper heam and back to the lower beam wthen the hand is removed if the standard root swatch is in thu auto...

Page 401: ...ment CAUTION The Auttonic Eye develops 1U volts headlamps must be turned off before removing cover from phototube unit 1 Remove two ova i head screws from bottom of the phototube unit 2 tAft off cover remove lens and replace lens with test amp Fig 16E 3 3 Replace cover and screws NOTE Re sure to use corruct DIM posi tion for clear or tinted winmhshieids g insert the eonnectot Into the cigar lighte...

Page 402: ...TY ADJUSTMENT BAR Checking F1OLO Sensititiv Adjustment I With DIM sensitivity cnrractly adjusted turn selector switch to DIM jsitioJl anti turn intensity rheostat clockwise to end of adjustment 2 Tnro the selectat switch to hOLD position NOTE Be sure to use correct HOLD posi tion for clear or tiiited wintishleld 3 Turn intensity rheostat coonterclockaise carefully and slowly just to the point wher...

Page 403: ... plug in connections of phototube unit under the instrument panel 2 Turn on the headlamps and feel the amplifier for vthrator buzz If vibrator does not buzz a Be sure vibrator is firmly seated in socket b Replace vibrator with new 12 volt vibrator DO NOT USE RADIO 6 OR 12 VOLT TYPE VIB RATOR 3 Inspect tube filaments for glowing except the amplifier large tube and phototube Check or replace one tub...

Page 404: ...lifier cover d Phototube Unit 1 If the amplifier unit is functioning properly connect the phototube unit to the amplifier unit With light entering the phototube unit the headlamps should be on lower beam in both positions of the standard foot dimmer switch With no light enter ing the phototube unit the headlamps should be on Upper Beam in one position of the standard foot dimmer switch automatic p...

Page 405: ...AUTRONIC EYE 16 E5O a Fi Ia F c SpdoI TI ...

Page 406: ... Aiming Procedure Lamp housing and adjust lamp until top of beam js four inches below horizontal centerline of Fog 1 Place car on a level floor 25 feet from a Lamp and centered on its vertical centerline wall or screen Draw on this surface a horizontal line at the same height at the centerline of the Fog Lamps 5 Tighten aiming screw 2 Sight through the rear window over radiator NOTE The above aimi...

Page 407: ... A 7 is 16 A il 16 A 16 17 16 A i 4 16 A 4 24 16 A is 16 A 18 26 16 A 16 18 l6 A 13 19 16 A 14 16 B i 16 B i 4 16 5 2 2 16 B i 3 16 B 2 16 B i 1 16 B I 5 16 B 2 16 C I 4 16 C 2 3 16 C 2 16 C i Note Page No No 2 16 C i 1 16 C i 16 C I 3 1 3 10 5 3 3 3 1 2 3 1 6 3 4 7 3 4 13 3 9 3 3 2 10 3 5 9 3 5 8 3 5 3 1 3 10 ii 3 6 4 3 4 12 3 7 1 3 i 9 1 2 9 3 1 9 1 4 9 4 2a 9 3 4c 9 4 5 9 5 9 1 3 9 4 4a 9 4 2c ...

Page 408: ...ng Leaks Torque Tightness E ENGINE COOLING General Description Pump Water Removal and Installation Radiator Assembly Removal and Installation Service Information 15 1 Specifications Torque Tightness 15 5 2 15 1 15 2 ENGINE ELECTRICAL Distributor Advance Curves 7 15 4 General Description Service Information 6 15 3 Specifications 5 15 3 Torque Tightness 15 5 15 1 ENGINE MECHANICAL 15 1 General Descr...

Page 409: ... Mile Related Items Lube Chart Lubrication Agreement Operations Miscellaneous Points Requiring None Rear Axle Schedule Series 75 Service Information Steering Gear REAR AXLE General Description S 7 14 7 STEERING Bearing Upper Steering Shaft Lower Removal and Installation Bearing Upper Steering Shaft Removal and Installation Gear Adjustments Gear Disassembly and Assembly Gear Installation General De...