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Hudson Hornet 1955 Technical & Service Manual

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  • Page 5: Engine Section

    ENGINE SECTION (6 Cylinder) ENGINE IDENTIFICATION Series, and the studs on "Rambler" Series, as The engine number is located on the upper left they connect to water passages in the cylinder hand forward portion of the cylinder block on head. the "Hornet"...
  • Page 6 E N G I N E C Y L I N D E R engine supports and loosening the rear sup- ports. The engine may then be moved slightly upward and to the left. To assist in the installation of valve locks, Tool J-1953 can be used on the "Hornet"...
  • Page 7 T E C H N I C A L S E R V I C E M A N U A L 1. Correct Valve Refacing 2. Incorrect Valve Refacing 1. Valve Guide Removing Tool J-2814 FIGURE 7—Correct Valve Refacing The "Wasp"...

  • Page 8: Valve Timing

    E N G I N E C Y L I N D E R Series valve guides. Drive the guides flush mark on the inner timing mark radius (5.06" with the opening of the guide bore in the flywheel radius). block.
  • Page 9 T E C H N I C A L S E R V I C E M A N U A L 1. Marked Tooth on the Camshaft Sprocket 2. Marked Tooth on the Crankshaft Sprocket 3. 91/2 Links or 19 Pins FIGURE 12—Valve Timing Diagram "Wasp"...
  • Page 10 E N G I N E C Y L I N D E R lip of leather is in good condition and pressure. Tool J-2776 is used to remove and install not curled over. the timing chain cover oil seal (Figs. 16 and 17): FIGURE 17—Installing Timing Chain Cover Oil Seal—"Hornet"...
  • Page 11 T E C H N I C A L S E R V I C E M A N U A L The slinger is held in place by the crankshaft sprocket and vibration damper. CAMSHAFT AND BEARINGS The camshaft is supported by four steel shelled, babbitt lined bearings which have been pressed into the block and line reamed.
  • Page 12 E N G I N E C Y L I N D E R End Play: .003"-.005" "Hornet" and "Wasp" Series .004"-.006" "Rambler" Series The camshaft end play can be checked with a feeler gauge between the rear of the camshaft sprocket front surface...

  • Page 13: Piston Rings

    T E C H N I C A L S E R V I C E M A N U A L to bore clearance is .0006" to .0012". Rings must be installed on pistons with a ring installation tool to prevent distortion PISTON RINGS and ring breakage.
  • Page 14 E N G I N E C Y L I N D E R CAUTION: Because of the backlash clear- ance requirement, it is suggested that no ring be filed to fit a bore size smaller than the ring size. "Rambler"...

  • Page 15: Piston Pins

    T E C H N I C A L S E R V I C E M A N U A L FIGURE 30—Step 4—Make Sure Compressor FIGURE 27—Step 1—Place "U" Flex Ring in Rests Squarely on Top of Block, and Bottom of Oil Ring Groove.
  • Page 16 E N G I N E C Y L I N D E R Tighten piston pin clamp screw to 18-22 foot pounds torque. CONNECTING RODS "Hornet" and "Wasp" Series The connecting rods have oil squirt holes to provide cylinder wall lubrication, at low and idle speed, thrust...
  • Page 17 T E C H N I C A L S E R V I C E M A N U A L FIGURE 34—Checking Connecting Rod Alignment for Twist FIGURE 35—Checking Connecting Rod Connecting Rod Bearings Alignment for Bend The connecting rod bearings are the steel backed babbitt lined precision type.
  • Page 18 E N G I N E C Y L I N D E R caps should never be filed. When either half of a bearing requires replacement, a complete set should be in- stalled. To replace the upper half of a bearing, remove bearing...
  • Page 19 Crankshaft Main Bearing Clearance Then release the plunger so that it is up against the journal and lock the adjusting screw in position. Remove the gauge carefully The standard clearance of .0005" to .0015" and double the micrometer reading across the on the "Hornet"...

  • Page 20: Vibration Damper

    E N G I N E C Y L I N D E R After the rear main bearing cap is replaced, cotton waste must be driven into the vertical packing holes to seal the side of the cap. A punch smaller in diameter than the vertical holes and at least 4"...
  • Page 21 T E C H N I C A L S E R V I C E M A N U A L 1. Outer Member 5. Spacer 2. Rubber Discs 6. Oil Seal 3. Inner Member 7. Retainer Plate 4. Damper Cap Screw 1.

  • Page 22: Lubrication System

    E N G I N E C Y L I N D E R STARTER RING GEAR Oil under pressure passes the plunger of the oil relief valve assembly and fills the With the exception of the flywheel, as used main horizontal oil gallery from which it is with the automatic transmission, which is a directed through drilled passages to lubri-...
  • Page 23 T E C H N I C A L S E R V I C E M A N U A L In the event the engine crankshaft was not moved, replacement of the oil pump presents no problem. However, if the crankshaft was moved, the following procedure can be used to insure basic distributor timing location inasmuch as the distributor is driven by the...

  • Page 24: Engine Specifications

    E N G I N E C Y L I N D E R ENGINE SPECIFICATIONS Series "Hornet" "Wasp" "Rambler" Type L-Head L-Head L-Head No. Cylinders Bore 3-13/16" 3" Stroke 41/2" 43/4" 41/4" Compression Ratio (Standard) 7.5:1 7.5:1 7.32:1 (Optional) 8.0:1 Piston Displacement 308 Cu.

  • Page 25: Oil Systems

    T E C H N I C A L S E R V I C E M A N U A L OIL SYSTEMS Series "Hornet" "Wasp" "Rambler" Oil Pump Type Rotor Rotor Gear Normal Oil Pressure 40 P.S.I. @ 40 P.S.I.
  • Page 26 E N G I N E C Y L I N D E R TUNE-UP DATA Plug Tappet Clr. Cold Distributor Dwel Series Igniton Timing Int. Exh. Point Gap Angle "Hornet" .032" .10" "Go" .14" "Go" .020" 38º T.D.C. .11" "No-go" .15"...
  • Page 27 T E C H N I C A L S E R V I C E M A N U A L TECHNICAL SERVICE LETTER REFERENCE Date Letter No. Subject Changes of informatin on Page. No.
  • Page 29 ENGINE SECTION FIGURE 1—V-8 Engine Assembly CYLINDER HEAD AND GASKET ENGINE IDENTIFICATION The engine number is located at the right After thoroughly cleaning the top surface of rear upper corner of the cylinder block below the block and the bottom surface of the the rear exhaust manifold port (Fig.
  • Page 30 E N G I N E V - 8 Then retighten to 55 to 60 foot pounds with torque wrench following the sequence outlined in Figure 4. FIGURE 4—Torque Tightening Sequence 1. Exhaust Valves 55-60 Ft. Lbs. 2. Intake Valves ROCKER ARM AND SHAFT ASSEMBLY FIGURE 6—Valve Arrangement Intake or Exhaust Valve Spring:...
  • Page 31 T E C H N I C A L S E R V I C E M A N U A L FIGURE 9—Checking Valve Seat Runout under pressure flows into the body through the check valve assembly maintaining the tappet fully charged.
  • Page 32 E N G I N E V - 8 When removing the tappets, they must be kept in an order that will insure replacement in their respective operating bores in the engine because they are select fitted to that bore. Keep each tappet component group by itself as all detail components are select fitted to one another in manufacturing.

  • Page 33: Timing Chain Cover

    T E C H N I C A L S E R V I C E M A N U A L To prevent damage to this seal, it is important that the cover be properly aligned when installing the vibration damper. This is accomplished by leaving the cover to block screws loose until the vibration damper has been partially installed.
  • Page 34 E N G I N E V - 8 The ring belt area provides for three piston rings, two compression and one oil control ring above the piston pin. The pistons are removed from the top of cylinder bore after removing ring ridge. The piston pin boss is "offset"...
  • Page 35 E N G I N E V - 8 FIGURE 20—Measuring Clearance at Bottom FIGURE 21—Burnishing Piston Pin Bushing of Piston Skirt When other than standard ring sizes are used, rings should be individually fitted to their PISTON RINGS respective bores for a gap clearance of .010" to .018".

  • Page 36: Connecting Rods

    E N G I N E V - 8 FIGURE 22 PISTON RING GAP LOCATION arranged so that the gap for the oil ring The cylinders are numbered 1, 3, 5, 7 in expander is to the outside of the block and the left bank of engine from front to rear, oil ring gap is toward the inside of the and even numbers 2, 4, 6, 8 in the right...
  • Page 37 T E C H N I C A L S E R V I C E M A N U A L CRANKSHAFT The crankshaft is a precision steel cast shaft having five main journals, four crankpins, and provided with an oil stinger at rear journal inboard of the rear oil seal.

  • Page 39: Cooling System

    COOLING SYSTEM WATER PUMP "Hornet" and "Wasp" Series The water pump is a centrifugal type utiliz- ing a nonadjustable packless type seal. The shaft and sealed double row ball bearings are an integral assembly. The water pump discharges into a brass water distributing tube to provide uniform coolant circulation around the valves.
  • Page 40 C O O L I N G S Y S T E M 1. Shaft and Seal Assembly 2. Seal Housing Rubber Retaining Ring 3. Impeller FIGURE 5— Water Pump and Manifold Assembly "Hornet" V-8 Series 4. Pump Body 5. Impeller Rivet "Rambler"...

  • Page 41: Fan Assembly

    T E C H N I C A L S E R V I C E M A N U A L idling during the refilling operation to "Hornet" V-8 Series prevent trapped air interferring with the circulation or Weather Eye operation. The thermostat is located in the coolant A drain cock is provided on the lower tank distribution manifold outlet.

  • Page 43: Electrical Section

    ELECTRICAL SECTION BATTERIES (Auto-Lite) on the "Hornet" 6 and "Wasp" Series are six volt, two brush, shunt units with a ball The battery is a three cell, six volt unit bearing supporting the armature at the drive with adequate storage capacity for the normal end and a bronze bushing at the commutator requirements of the car.
  • Page 44 E L E C T R I C A L FIGURE 1—Generator Auto-Lite Model GCW-4801-F Wiring Armature Be sure all connections are clean and tight The armature should be visually inspected for and that there are no broken wires. The mechanical defects.
  • Page 45 T E C H N I C A L S E R V I C E M A N U A L field circuit ground connect To test for open coils, connect the probes voltmeter from the armature terminal to the to the two leads of each coil.
  • Page 46 E L E C T R I C A L a resistor when the contacts are opened. When Circuit Breaker the voltage rises to a predetermined value, The circuit breaker consists of an electro- there is sufficient magnetism created by the magnet and a set of contacts.
  • Page 47 T E C H N I C A L S E R V I C E M A N U A L VIBRATING CURRENT-VOLTAGE REGULATOR SPECIFICATIONS (AUTO-LITE VBE-6010-A) Volts Ground Polarity Positive Carbon Resistors Two used—R1 marked 38, Resistance 34.5 to 42 Ohms. R2 marked 7, Resistance 6.5 to 8 Ohms.
  • Page 48 E L E C T R I C A L -meter from the regulator "A" terminal to the regulator base and place a reliable thermometer near the regulator (about 2" from the regulator cover but not touching the regulator). Disconnect the field lead from the regulator "F"...
  • Page 49 T E C H N I C A L S E R V I C E M A N U A L to pick up the sound of the opening and closing of the contacts. The clicks should be regular and clear without irregularities or missing.

  • Page 50: Operation

    E L E C T R I C A L units as described in the preceding para- graphs. Be sure cover is on regulator when taking readings. Quick Checks CHARGING RATE WITH FULLY CHARGED BATTERY: A fully charged battery and a low charging rate indicates...
  • Page 51 T E C H N I C A L S E R V I C E M A N U A L OPERATION EFFECT CAUSE AND REMEDY Connect a headphone from the A steady beat should be heard. Voltage regulator operating. regulator field terminal to the An unsteady beat is heard.
  • Page 52 E L E C T R I C A L OPERATION EFFECT CAUSE AND REMEDY Remove the regulator cover and Voltage should build up. Current regulator contacts hold the current regulator Voltage does not build up. burned or dirty or incorrect contacts closed.
  • Page 53 T E C H N I C A L S E R V I C E M A N U A L Inspect commutator for roughness, grease and dirt, dirt in slots, high mica, out of round, or burned bars. With any of these conditions, the commutator must be turned down in a lathe and mica undercut.
  • Page 54 E L E C T R I C A L CURRENT AND VOLTAGE Voltage Regulator Air Gap .075" REGULATORS (Delco-Remy) *Voltage Setting Range 6.9-7.4 Volts Adjust to 7.2 Volts The Delco-Remy Models 1118828 and 1118841 (six volt) current and voltage regulators (Fig. 9) NOTE: Adjustment need not be made if check are designed for operation with a positive shows value within range given.
  • Page 55 T E C H N I C A L S E R V I C E M A N U A L Cut-Out Relay the armature spring tension, pulls the armature down, and the contact points separate. This The cut-out relay has two windings, a series inserts resistance into the generator field winding of a few turns of heavy wire and a shunt circuit.
  • Page 56 E L E C T R I C A L magnetic field changes. These surges This indicates that the voltage regulator is partially dissipated by the two resistors, thus not reducing the generator output as it should. preventing excessive arcing at the contact A high charging rate to a fully charged battery points.
  • Page 57 T E C H N I C A L S E R V I C E M A N U A L always check car wiring before installing a new Air Gap—Push down on armature until contact regulator. Otherwise the new regulator may also points are just touching.
  • Page 58 E L E C T R I C A L head. Final setting of the unit should NOTE: IT IS NOT NECESSARY TO MEASURE THE always be made by increasing spring AMOUNT OF CURRENT FLOWING DURING TESTING AND tension, never reducing ADJUSTING.
  • Page 59 T E C H N I C A L S E R V I C E M A N U A L FIGURE 16—Cut-out Relay Air Gap Check and Adjustment. Battery Must be Disconnected When this Check is Made FIGURE 18—Voltmeter Connections to Check Point Spacing—Check point spacing and adjust Cut-out Relay Closing Voltage.
  • Page 60 E L E C T R I C A L Adjust as described for the voltage regulator are available. Regardless of the method used, (Fig. 14). connect an ammeter into the charging circuit at the regulator "Bat" terminal. The first Adapting Voltage Regulator Setting For Unusual method listed...
  • Page 61 T E C H N I C A L S E R V I C E M A N U A L connecting regulator, momentarily connect a "Hornet" 6 Standard and Overdrive MCH-6109 jumper lead between the "Gen" and "Bat" Hydra-Matic MCH-6306 terminals BEFORE STARTING THE ENGINE.
  • Page 62 E L E C T R I C A L on the wires is not worn or damaged. The loss. starting circuit should be given a voltage loss test to make sure there is no loss of If the commutator is dirty or discolored, it starting motor efficiency due to high resis- can be cleaned with No.
  • Page 63 T E C H N I C A L S E R V I C E M A N U A L grounded. Overhaul Procedure To test for shorted armature coils, a growler At periodic intervals, the starting motor is necessary. The armature is placed against circuit should he thoroughly checked and the the core and a steel strip held on the armature.
  • Page 64 E L E C T R I C A L the spring scale reading and the length of (mounted on the starting motor) specifica- the arm in feet. If the torque is not up to tions are: specifications, check the seating of the Pull in coil 31.5 to 36.0 amperes at 3.0 brushes on the commutator and the internal volts.
  • Page 65 T E C H N I C A L S E R V I C E M A N U A L FIGURE 24—"Rambler" Series Starting Motor (Regular or Overdrive Transmission) replaced. If brushes wear rapidly, check for band of the starting motor and inspect the excessive brush tension and roughness or high brushes and commutator.
  • Page 66 E L E C T R I C A L Starting Motor Automatic Drive Unit R.P.M. in addition to the current draw. "Hornet" 6, "Wasp," and "Rambler" Series TORQUE TEST: It is advisable to use a high current carrying variable resistance in the The Bendix Folo-Thru type drive is designed to circuit so that the specified voltage at the overcome premature demeshing of the drive...

  • Page 67: Ignition Systems

    T E C H N I C A L S E R V I C E M A N U A L The screwshaft on the FOLO-THRU Drive is flows into condenser. Therefore, divided into sections with dentil condenser brings the current flow to a quick connection between them.
  • Page 68 E L E C T R I C A L FIGURE 27—Top View, V-8 Distributor Dual Contact Mounting Tune-Up Procedure Both the primary and secondary circuits of the ignition circuit should be checked individu- ally. Each circuit should be carefully checked for loose connections, damaged insulation or corroded terminals.
  • Page 69 T E C H N I C A L S E R V I C E M A N U A L Intermediate 22° at 1200 R.P.M. 16° at 1700 R.P.M. Intermediate 38° at 2270 R.P.M. 30° at 3300 R.P.M. Full Advance 40°...
  • Page 70 E L E C T R I C A L of the breaker contacts. When checking the distributor, the con- denser should always be checked for both leakage and capacity with an approved con- denser tester. Four factors affect condenser performance and each factor must be considered in making any condenser tests.
  • Page 71 T E C H N I C A L S E R V I C E M A N U A L performance while, if the tension is too Distributor Assembly strong, excessive wear of the cam and breaker arm rubbing block will result. NOTE: After the distributor has been reassembled, all of the points men- Governor Adjustment...
  • Page 72 E L E C T R I C A L FIGURE 30 - “Rambler” Series Distributor Distributor Specifications (Delco-Remy) “Rambler” Series Make Delco-Remy Model 1112382 Clockwise at Drive End Rotation 31 to 37 Degrees Cam Angle 17 to 21 Ounces Contact Point Pressure .022"...
  • Page 73 T E C H N I C A L S E R V I C E M A N U A L tween the diaphragm and the distributor stem Centrifugal Control is drawn into the vacuum units, causing the distributor to rotate in its mounting to With speed variations, it is desirable to secure vacuum advance.

  • Page 74: Ignition Timing

    E L E C T R I C A L To refill the reservoir, remove the oil plug and angle is the angle in degrees of cam rotation add Grade 20W oil. When replacing plug, seal with through which the points remain closed. a compound that will hold against oil.

  • Page 75: Ignition Coils

    T E C H N I C A L S E R V I C E M A N U A L "Hornet" 6, "Wasp", and "Rambler" Series All distributors on these models have off-set drives so they can only be installed in one position, provided the oil pumps have not been removed and replaced.

  • Page 76: Instrument Cluster

    E L E C T R I C A L INSTRUMENT CLUSTER "Hornet" and "Wasp" Series The instrument cluster housing is mounted in the left side of the dash panel. In addition to the speedometer, it contains the panel lights, high beam indicator light, no-charge indicator light, low oil pressure light, electric gauge...

  • Page 77: High Beam Indicator Light

    T E C H N I C A L S E R V I C E M A N U A L 1. Windshield Wiper Control 4. Light Switch 2. Instrument Cluster 5. Weather Eye Control Valve 3. Ignition Switch 6.
  • Page 78 E L E C T R I C A L does not produce a steady D.C. voltage output, but rather a pulsating voltage at an effective constant average value of 5.0 volts. The input voltage source can, therefore, be D.C. intermittent or interrupted D.C. or A.C.
  • Page 79 T E C H N I C A L S E R V I C E M A N U A L If both gauges read too low, either the input voltage to the voltage regulator is too low (below 5.0) or the voltage regulator is not functioning properly and should be replaced To check instrument cluster complete: Connect...
  • Page 80 E L E C T R I C A L Obtain a known-to-be-good tank unit from parts stock. The "Hornet" and "Wasp" Series requires a King-Seeley variable resistor type. The "Rambler" Series requires King-Seeley bi-metal type. Do not attempt checking one system with the tank unit from the other.

  • Page 81: Ignition Switch Removal

    T E C H N I C A L S E R V I C E M A N U A L unit, or reversed wiring on the dash unit. If Briggs and Stratton type lock cylinders are the dash unit needle reads low scale at all used on the "Hornet"...

  • Page 82: Light Switch

    E L E C T R I C A L below. For access to the adjustment screws on each sealed beam, it is only necessary to remove the head lamp door. To obtain maximum results in road illumi- nation and the safety that has been built into the headlighting equipment, the head- lamp beams must be properly aimed.
  • Page 83 T E C H N I C A L S E R V I C E M A N U A L the other for directional signal light. Bulb #1154 (Trade Number) Directional Light Element 21 cp 6-8 volts Parking Light Element 3 cp 6-8 volts Tail, stop, and directional signal lights are all contained in the rear fender light...
  • Page 84 E L E C T R I C A L stops the horn operation, inspect the button licensemounting bracket. lead for grounds especially where it enters Bulb #T-63 (Trade Number) 3 cp 6-8 volts the steering column. If the horns do not stop HORNS AND RELAYS when "S"...

  • Page 85: Battery Specifications

    T E C H N I C A L S E R V I C E M A N U A L To insure the use of speedometer cable removed and taken to an authorized service cores which will give quiet and satisfac- station.

  • Page 86: Starting Motor Specifications

    E L E C T R I C A L ELECTRICAL VOLTAGE AND CURRENT REGULATOR SPECIFICATIONS "Hornet" "Rambler" and "Wasp" Make Auto-Lite Delco-Remy Delco-Remy Model VBE-6101-A 1118841 1118828 (Without A.C.) (With A.C.) Cut-Out Relay 6.3-6.8 5.9-6.7 5.9-6.7 Voltage at Closing Adjust to 6.4 Adjust to 6.4 Air Gap...
  • Page 87 T E C H N I C A L S E R V I C E M A N U A L...

  • Page 88: Electrical Wiring Diagrams

    ELECTRICAL WIRING DIAGRAMS...
  • Page 91 ELECTRICAL WIRING DIAGRAMS...

  • Page 104: Fuel Tanks

    FUEL- CARBURETION EXHAUST SYSTEM decalcomania is present, it should be serviced FUEL SYSTEM at every engine crankcase oil change. CARBURETOR AIR CLEANER More frequent service will be required where dusty conditions exist. The air cleaners are required to protect the Disassemble the air cleaner and clean all fuel system as well as the working parts of parts in kerosene or solvent;...
  • Page 105 FUEL - CARBURETION - EXHAUST SYSTEM FIGURE 2—Assembly Sequence Single Action Fuel Pump (Carter) Both type pumps have an air dome on the Single acting type pumps are used only on discharge side to dampen pulsations in the cars equipped with standard transmission. fuel flow.
  • Page 106 FUEL - CARBURETION - EXHAUST SYSTEM FIGURE 5—Sectional View Double Action Fuel Pump (Carter) on the single action fuel pumps, all Series. Fuel Pump Tests Test is made with a pressure gauge connected to a "T" fitting at the carburetor. The Carter Type Fuel Pumps pressure gauge connecting hose must not exceed six inches in length.
  • Page 107 FUEL - CARBURETION - EXHAUST SYSTEM FIGURE 6—Assembly Sequence Double Action Fuel Pump (Carter) Vacuum Pump Test (Double Action Fuel Pump) float bowl height in one minute maximum. Assembly on the Engine With engine idling, turn on the vacuum windshield wiper to make certain the wiper Carter and A.C.
  • Page 108 FUEL - CARBURETION - EXHAUST SYSTEM FIGURE 7—Measuring Float Level (WGD-2231-S) FIGURE 9—Adjusting Accelerator Pump (WGD Type) FIGURE 8—Measuring Float Level (WA1-2013-S) Accelerator Pump Adjustment Models WGD-2231-S and WGD-2252-S Open the choke valve and back out throttle lever set screw until the throttle valves are seated in the bores of the carburetor.
  • Page 109 FUEL - CARBURETION - EXHAUST SYSTEM Models WA1-2013-S, WA1-2009-SA, Place the base of the gauge on the ridged and WA1-2113-S portion of the bowl cover so that the indicator rests on the top of the connector Remove the metering rod and insert gauge (Tool link at the pump shaft.
  • Page 110 FUEL - CARBURETION - EXHAUST SYSTEM port). Adjust by bending connector link at the lower angle. Use Bending Tool T-109-213 (Fig. 15). FIGURE 13—Adjusting Metering Rod (YF-2014-S) FIGURE 15—Adjusting Fast Idle (WGD-2231-S) Anti-Percolator Adjustment Models WA1-2013-S, WA1-2009-SA, Models WA1-2013-S, WA1-2009-SA, and WA1- and WA1-2113-S 2113-S With the fast idle cam held in a normal idle...
  • Page 111 FUEL - CARBURETION - EXHAUST SYSTEM 1. Bend Cam FIGURE 16—Fast Idle Adjustment (WA1 Carburetor Shown) FIGURE 18—Unloader Adjustment (WA1 Type) SYNCHRONIZATION ADJUSTMENT "Hornet" 6 and "Wasp" Series Remove the clevis pins from the throttle shaft to carburetor rod devises. Connect a vacuum gauge and tachometer.

  • Page 112: Exhaust Manifolds

    FUEL - CARBURETION - EXHAUST SYSTEM operation. "Rambler" Series Adjust the front carburetor idle speed to a point where an increase of 10 to 15 R.P.M. is The intake manifold, is cast as an integral noted. Adjust the idle mixtures. part of the engine.
  • Page 113 FUEL - CARBURETION - EXHAUST SYSTEM MUFFLERS resonators The "Rambler" Series use a reverse flow oval The "Hornet" V-8, 6, and "Wasp" Series are equipped type muffler with straight-through type mufflers and tail pipe 1955 CARBURETOR TOOLS Kent-Moore Number Carter Number Description J-818-3 T-109-28...
  • Page 114 FUEL - CARBURETION - EXHAUST SYSTEM TECHNICAL SERVICE LETTER REFERENCE Date Letter No. Subject Changes of informatin on Page. No.

  • Page 115: Carburetor Specifications

    FUEL - CARBURETION - EXHAUST SYSTEM CARBURETOR SPECIFICATIONS Model Numbers WGD-2252-S WGD-2231-S WA1-2113-S "Hornet" 6 Car Models "Hornet" "Hornet" V-8 Twin-H-Power Championship 6 Dimensions Flange Size 1-1/4" (Dual 4 Bolt) 1-1/4" (Dual 4 Bolt) 1-1/2" S.A.E. Primary Venturi 1-1/32" I.D. 11/32"...
  • Page 116 13-a FUEL - CARBURETION - EXHAUST SYSTEM CARBURETOR SPECIFICATIONS (Cont’d) Model Numbers WA1-2009-SA WA1-2013-S YF-2014-S "Wasp" "Wasp" Car Models Hi-Torque 6 Twin-H-Power "Rambler" Dimensions Flange Size Primary Venturi 1-1/4" S.A.E. 1-1/4" S.A.E. 1-1/4" S.A.E. Secondary Venturi 11/32" I.D. 1-1/32" I.D. 1-1/32"...
  • Page 117 FUEL - CARBURETION - EXHAUST SYSTEM CARBURETOR SPECIFICATIONS (Cont’d) Model Numbers WGD-2252-S WGD-2231-S WA1-2113-S Main Nozzle Installed Installed Slip Nozzle Flush Permanently— Permanently— Do Not Type Discharge Jet Do Not Remove Remove Size .110" Inner Nozzle (Seats in Slip Nozzle) I.D. No.
  • Page 118 14-a FUEL - CARBURETION - EXHAUST SYSTEM CARBURETOR SPECIFICATIONS (Cont’d) Model Numbers WA1-2009-SA WA1-2013-S YF-2014-S Main Nozzle Slip Nozzle Flush Type Slip Nozzle Flush Type Installed Discharge Jet Size Discharge Jet Size Permanently— .110" Inner Nozzle .110" Inner Nozzle Do Not Remove (Seats in Slip Nozzle) (Seats in Slip Nozzle) I.D.

  • Page 120: Clutch Disassembly

    CLUTCH SECTION The is a single plate, dry disc type. A steel covet bolted to the flywheel contains the drive plate, the pressure plate, levers, and springs (Fig. 1). 1. Engaged Position 2. Released Position FIGURE 2—Clutch Lever they will be in their same relative positions (Fig.
  • Page 121 CLUTCH FIGURE 3—Compress Springs to Remove Nuts Clutch Pressure Springs A thorough inspection of the clutch springs should always be made. They should be tested spring tension when spring compressed to a given length. (See Clutch Pressure Spring Specifications correct spring heights.) 1.

  • Page 122: Clutch Lever Adjustment

    TECHNICAL SERVICE MANUAL TRANSMISSION CLUTCH SHAFT and "Rambler" Series clutch, the center spring boss in each group is not used.) Check the anti-rattle springs in the clutch Slide the driven plate onto the transmis- cover and place the cover on top of the sion shaft to make sure that it is free on the splines.

  • Page 123: Clutch Installation

    CLUTCH 1. 1/32" Above Hub FIGURE 10—"Hornet" and "Rambler" Series Clutch Lever Height FIGURE 8—Each Lever Should be Depressed Several Times to Settle all Parts in Their Proper Positions Place the gauge on the hub as shown in Figure 9. To check the lever, turn the lever adjusting nut until the lever is flush with the underside of the gauge.
  • Page 124 TECHNICAL SERVICE MANUAL 1. Rivets FIGURE 12—Drill Out Rivets depressed until the transmission has been installed as the plate will drop out of alignment position. 1. Transmission Front Bearing Cap CLUTCH THROW-OUT RELEASE BEARING 2. Release Bearing Sleeve Assembly 3. Throw-out Lever Return Spring 4.
  • Page 125 CLUTCH 1. This point of Clutch Beam Lever to Project From the Clutch Beam 5/16" for "Hornet" Series, and 1/2" for the "Rambler" Series FIGURE 14—Assembled View of Clutch Linkage "Rambler" Series Shown Clutch Slipping—A slipping clutch may be caused by: Incorrect adjustment of clutch pedal Lack of lubrication in clutch linkage Broken clutch pressure springs...
  • Page 126 FUEL - CARBURETION - EXHAUST SYSTEM TECHNICAL SERVICE LETTER REFERENCE Date Letter No. Subject Changes of informatin on Page. No.

  • Page 128: Transmission Section

    TRANSMISSION SECTION (STANDARD TRANSMISSION) 1955 "Hornet" Standard Transmission and Rear Bearing Cap Extension "HORNET" SERIES marked "FRONT" on both the cover and the gasket. Removing the Clutch Shaft Assembly The transmissions are supplied with or without the overdrive unit (as optional equipment). After removing the front bearing cap, remove The "Hornet"...
  • Page 129 TRANSMISSION (“Hornet”) 1. Bearing Puller (J-1298N) 2. Thrust Yoke (J-3042) 1. Roller Bearings FIGURE 2—Use Bearing Puller and Thrust FIGURE 4—Bearing Rollers Inside the Clutch Yoke to Pull the Front Bearing and Prevent Shaft Hold Themselves in Place by a Damage to the Synchro-Clutch "Keystone"...
  • Page 130 TECHNICAL SERVICE MANUAL FIGURE 6—Removing the Main Shaft FIGURE 8—Transmission Synchronizer Unit Snap Ring Etching Marks The Synchro-Clutch Assembly Remove the synchro-clutch assembly. The bronze friction rings may be removed with the clutch shaft and second speed gear (Fig. 7). FIGURE 9—Removing the Second Speed Gear FIGURE 7—Removing the Synchro-Clutch Assembly...
  • Page 131 TRANSMISSION (“Hornet”) Removing the Countershaft Gear Assembly tap the rear of the main shaft using a plastic or lead hammer. The rear bearing and speedometer gear will remain on the shaft. Remove the reverse idler and countershaft lock plate I Fig. 13). FIGURE 11—Remove the Snap Ring From the Front of the Rear Bearing Cap Remove the main shaft snap ring and the speedom-...
  • Page 132 TECHNICAL SERVICE MANUAL To maintain the position of the needle bearings in the countershaft gear, drive the countershaft out of the rear of the case using a dummy shaft machined to .750" x 71/16" (Fig. 14). 1. Dummy Shaft .750" x 7-1/16" FIGURE 14—Use a Dummy Shaft Machined to .750"...

  • Page 133: Cleaning And Inspecting Parts

    TRANSMISSION (“Hornet”) Remove the shifter shafts from the inside of the To wash a bearing, submerge it in a cleaning solution that is absolutely free of dirt, and case slowly to catch the two interlock ball rotate it to flush away all oil and dirt. Dry bearings as the shafts are being removed.
  • Page 134 TECHNICAL SERVICE MANUAL REASSEMBLY When reassembling the transmission, always use new gaskets and oil seals. Shifter Shafts and Levers Install shifter shaft seals. Then reinstall the low and reverse shifter shaft. the interlock sleeve. ball bearing, and spring. With the second and high shifter shaft installed against the case, place the second ball bearing in position.
  • Page 135 TRANSMISSION (“Hornet”) 1. Dummy Shaft 2. Rear Thrust Washer FIGURE 22—Install the Countershaft Gear Assembly in the Transmission Case Reinstalling the Reverse Idler Gear Install the reverse idler gear with the chamfered side of the teeth (or the hub section) to the front of the case.
  • Page 136 TECHNICAL SERVICE MANUAL 1. Rear Ball Bearing Lock Ring 6. Rear Bearing Cap 2. Rear Ball Bearing 7. Oilite Bushing Felt 3. Woodruff Key 8. Oilite Bushing 4. Speedometer Drive Gear 9. Rear Bearing Cap Oil Seal 5. (Main Shaft) Snap Ring 10.
  • Page 137 TRANSMISSION (“Hornet”) Install the main shaft assembly through the rear Friction Ring Clearance of the case. As this is done, move it to the right Measure the clearance of the friction rings side of the case so as to engage the shifter forks. using friction ring clearance gauge (J-1410).
  • Page 138 TECHNICAL SERVICE MANUAL "WASP" AND "RAMBLER" SERIES "WASP" SERIES TRANSMISSION REMOVAL To remove the transmission, disconnect the brake tube bracket that is fastened to the underside of the body; then disconnect the torque tube at the rear of the transmission. Disconnect the hand brake cable at the bell crank and the brake cable housing at the bell crank bracket.
  • Page 139 TRANSMISSION (“Wasp” and “Ranbler”) Clutch Shaft Roller Bearings Inside the rear end of the clutch shaft are thirteen roller bearings. These form the front bearing assembly for the main shaft. Worn or loose rollers will result in a noisy transmis- sion.
  • Page 140 TECHNICAL SERVICE MANUAL FIGURE 38—Remove the Second Speed Gear From the Main Shaft FIGURE 41—Remove the Lock Plate maintain position needle bearings in the countershaft gear, drive the countershaft out of the rear of the case using a dummy shaft machined to .677" x 578" (Fig. 42).
  • Page 141 TRANSMISSION (“Wasp” and “Ranbler”) interlock sleeve and spring can then be removed. Now remove the shifter shaft oil seals from the case. This completes the disassembly of the transmission. CLEANING AND INSPECTING PARTS With the transmission completely disassembled, all parts should be carefully cleaned so that they can be thoroughly examined.
  • Page 142 TECHNICAL SERVICE MANUAL FIGURE 45-”Rambler” Series Transmisson case, place the second ball bearing in position. (Figs. 47 and 481. While compressing the interlock spring with After installing the bearings in the coun- finger pressure, locate the ball in the detent of tershaft gear, and holding it in such a manner the quadrant (Fig.
  • Page 143 TRANSMISSION (“Wasp” and “Ranbler”) 1. Interlock Sleeve 2. Interlock Balls 3. Interlock Spring 1. Needle Bearings 4. Low and Reverse Shift Shaft and Fork 2. Dummy Shaft 5. High and Second Shift Shaft and Fork FIGURE 48—Loading the Countershaft Gear 6.
  • Page 144 TECHNICAL SERVICE MANUAL Now install the second speed gear and the synchroclutch assembly on the main shaft. Then install the snap ring. When the synchro-clutch hub is pressed tight against the snap ring, there should be a .003" to .010" clearance between the second speed gear and the shoulder of the main shaft.
  • Page 145 TRANSMISSION (“Wasp” and “Ranbler”) Install the speedometer drive gear. A Woodruff key holds the speedometer gear from rotating on the main shaft. Then install a main shaft snap ring to hold the speedometer gear in position. To install the main shaft Oilite bushing on the "Wasp"...
  • Page 146 TECHNICAL SERVICE MANUAL Remove the main shaft ball bearing and oil Where the ball bearing in the adapter requires replacement, it then becomes necessary to disas- baffle from the adapter. Then remove the main shaft snap ring and press the bearing from the semble the overdrive (See Overdrive Section).
  • Page 147 OVERDRIVE SECTION Overdrive—"Hornet", "Wasp" and "Rambler" Series Overdrive—"Hornet", "Wasp" and "Rambler" Series OPERATION THE OVERDRIVE CONTROL UNITS In order to service this control system, it is The overdrive unit, when in operation above the very important to understand just how it works. governor cut-in speed, automatically reduces the The follow.
  • Page 148 TECHNICAL SERVICE MANUAL FIGURE 1-The Governor Circuit (Light Line), The Solenoid Circuit (Heavy Line), and The Kickdown Circuit (Dotted Line) All Operate to Energize or De-energize the Solenoid side load on the pawl. The car will now free the voltage regulator to No. 1 terminal on the wheel and when throttle is applied will pull in overdrive relay, through a 30 ampere fuse.
  • Page 149 OVERDRIVE FIGURE 3—Above 30 Miles Per Hour the Governor Points Automatically Close, Thus Closing the Governor Circuit and the Relay, Which Energizes the Solenoid...
  • Page 150 TECHNICAL SERVICE MANUAL Kickdown Switch direct conventional third speed operation is obtained. To place the overdrive in overtake position "Rambler" Series when car is in cruising gear at speeds above 30 M.P.H., depress the foot accelerator all Governor Circuit the way to the floor. In doing so, voltage governor circuit starts...
  • Page 151 OVERDRIVE...
  • Page 152 TECHNICAL SERVICE MANUAL As soon as the solenoid plunger has been of the overdrive relay where it passes through a permitted enter lock plate, 30 ampere fuse to open contact points. contacts "C" in the solenoid actuating circuit The circuit is resumed at the solenoid terminal are opened, permitting a decreased flow of "SOL"...

  • Page 153: Diagnosing Overdrive Troubles

    OVERDRIVE opening the points "E" and "K" in the kickdown At Speeds Below 30 Miles Per Hour switch and closes points "J" and "L". This at the same time breaks the governor circuit and With the cruising gear control forward at speeds completes the kickdown circuit.
  • Page 154 TECHNICAL SERVICE MANUAL FIGURE 9—With the Kickdown Switch Open, De-energized. Also, the Distributor is broken and the Solenoid De-energized. Also, the Distributor is Shorted Out to Release Engine Torque button pushed forward, use a test wire or a Incorrect terminal locations of connecting wires. 6-volt test light as follows: Circuits grounded by water, dirt, or deformation.
  • Page 155 OVERDRIVE Governor Operation Inspection: Suspend the axle and operate the engine at low speed in high gem*. Apply a test lamp across the governor contact from the live terminal "H" to the ground strap. The test lamp should light. Now increase engine speed.
  • Page 156 TECHNICAL SERVICE MANUAL 1. Rear Oil Seal Removing Tool FIGURE 12—Use Tool J-2497 to Remove the Rear Oil Seal Adapter 1. Lock Pin FIGURE 15—Drive Out Tapered Lock Pin Removing the Overdrive Case Remove the cap screws that hold the overdrive case to the transmission.
  • Page 157 OVERDRIVE To remove the ring gear from the main shaft, hammer. This will keep the shaft from coming out, remove the large ring gear snap ring. The gear and will prevent the free wheeling rollers from will then separate from the main shaft (Fig. 191. dropping into the case.
  • Page 158 TECHNICAL SERVICE MANUAL Removing the Solenoid Remove the two cap screws that hold the solenoid to the bearing adapter. Turn the unit one- quarter turn clockwise to release the solenoid plunger from the overdrive locking pawl. The solenoid can then be removed (Fig. 23). 1.

  • Page 159: Inspecting Parts

    OVERDRIVE Removing the Lockout Spring and Shift Shaft Remove the cover plate and trough assembly and the sun gear hub assembly. Then the overdrive The shifter shaft can easily be removed from locking pawl can be lifted out (Fig. 25). the in•...
  • Page 160 TECHNICAL SERVICE MANUAL Pinion Cage and Gears Examine the pinion gears in the planetary pinion cage for worn, cracked, or chipped teeth. Rotate each gear to see that it does not bind on the pinion shaft. Then examine the oil slinger which is a part of the pinion cage.
  • Page 161 OVERDRIVE Reinstalling the Sun Gear and Shifter Rod Assembly Install the fork of the shifter rod in the sun gear shift collar. Then hold them together as you slide the sun gear onto the main I spline 1 shaft and the shifter rod into the opening in the hearing adapter I Fig.
  • Page 162 TECHNICAL SERVICE MANUAL 1. Rubber Band FIGURE 33—With the Free Wheeling Cam and FIGURE 35—A Rubber Band Serves to Hold Pinion Cage on the Main (Spline) Shaft, the Free Wheeling Rollers in Position Lock Them in Place With the Pinion until the Ring Gear and Main Shaft can be Installed Cage Retaining Clip and the Free...
  • Page 163 OVERDRIVE this ring. Then install the bearing outer snap ring (Fig. 37). 1. Snap Ring 1. Snap Ring FIGURE 38—Use Snap Ring Pliers to Install the Snap Ring FIGURE 37—Install a Snap Ring on Each Side of the Overdrive Rear Bearing Then install the oil seal adapter and oil seal (the "Wasp"...
  • Page 164 TECHNICAL SERVICE MANUAL Where difficulty in shifting is experienced For atmospheric temperatures above 32° Fahren- in subzero temperatures, dilute the transmission heit, use Mineral Oil Gear Lubricant SAE No. 90 and overdrive oil as required, using light engine in the transmission and overdrive. oil.
  • Page 166 SHIFTING SYSTEM SECTION ADJUSTING THE SHIFTING MECHANISM Standard and Overdrive Transmission Place the gear shift lever in the neutral posi- tion. Disconnect the gear shift rods at the transmission shift levers, and place the levers in a neutral position. Install an aligning tool by inserting in the small holes in the gear shift operating levers and the grooves of the bearing housing.

  • Page 167: Shifting System

    SHIFTING SYSTEM Place the jacket tube assembly on a cloth covered bench to protect the paint surface. Then remove the dirt seal spacer retainer (Fig. FIGURE 3—Lift Bearing Retainer from the Steering Jacket Tube and fold the floor mat over toward the center of the floor.
  • Page 168 TECHNICAL SERVICE MANUAL Remove the gear shift operating levers, spacer, outer spring, and bronze fulcrum from the bearing housing (Fig. 9). 1. Selector Pin FIGURE 7—Removing the Selector Pin 1. Gear Shift Operating Levers 2. Spacer and Outer Spring NOTE: The selector pin can only be removed through the machined notch on FIGURE 9—Removing Operating Levers and the second and high operating lever;...
  • Page 169 SHIFTING SYSTEM 1. Selector Pin FIGURE 11—Installing the Selector Pin 1. Lever Ball 11. Dirt Seal 2. Gear Shift Lever 12. Dirt Seal Spacer 3. Pressure Spring Pin 13. Selector Pin 4. Pressure Spring 14. Dirt Seal Spacer 5. Pressure Spring Retainer Washer 15.
  • Page 170 TECHNICAL SERVICE MANUAL the steering jacket tube. The entire bearing housing assembly can now be lowered into the engine compartment to facilitate further disas- sembly. Remove the dirt seal spacer retainer from between the operating levers, and remove the two halves of the spacer (Fig. 15). FIGURE 13—Installing the Bearing Retainer DISASSEMBLING THE SHIFTING MECHANISM...
  • Page 171 SHIFTING SYSTEM and high operating levers, the bronze fulcrum, and the inner spring to be removed (Fig. 17) . FIGURE 17—Remove the Large Outer Spring and Spacer The gear shift lever and operating shaft can be removed from the passenger compartment to complete the disassembly.
  • Page 172 TECHNICAL SERVICE MANUAL the shift lever and instrument panel, when the lever is in the second gear position. To complete the assembly, replace the shift rods, adjust shifting mechanism, lubricate with pressure lubricant. ADJUSTING THE AUTOMATIC TRANS- MISSION SHIFTING MECHANISM Hydra-Matic Transmission Place the selector lever in the D-3 position.
  • Page 173 SHIFTING SYSTEM DISASSEMBLING THE AUTOMATIC TRANSMISSION SHIFTING MECHANISM "Hornet" and "Wasp" Series Remove the horn blowing parts and remove the steering wheel. Then remove the gear shift lever knob and lever. Remove screw retaining selector pointer light shroud to the jacket tube, and raise the shroud from the tube (Fig.
  • Page 174 TECHNICAL SERVICE MANUAL at the opening in the floor. Loosen the clamp bolt at the lower end of the jacket tube and turn the jacket tube clockwise. Remove the two cap screws and two metal screws from the gear shift housing and remove the gear shift operat- ing lever housing bracket (Fig.
  • Page 175 SHIFTING SYSTEM 1. Lever Knob 11. Operating Lever Bracket 2. Gear Shift Lever 12. Operating Lever Grommet 3. Pressure Spring Pin 13. Operating Shaft Fulcrum 4. Pressure Spring 14. Operating Shaft Upper Spring 5. Gear Selector Pointer Shroud 15. Operating Shaft Lever 6.
  • Page 176 TECHNICAL SERVICE MANUAL ASSEMBLING THE AUTOMATIC TRANSMISSION SHIFTING With the lower spring in position in the bearing housing, compress the spring enough to install MECHANISM the operating lever and upper spring (Fig. 32). "Hornet" and "Wasp" Series Place the gear shift operating shaft housing in a vise.
  • Page 177 SHIFTING SYSTEM SECTION Install the gear shift pressure pin and gear shift operating lever. Lift spring assembly on the operating shaft housing assembly off of the "U" clamp and apply lubriplate to the pin. Then bracket and separate the housing from the install the gear shift lever vibration gear shift operating shaft.
  • Page 178 TECHNICAL SERVICE MANUAL TECHNICAL SERVICE LETTER REFERENCE Date Letter No. Subject Changes Information on Page No.
  • Page 180 BRAKES AND WHEELS HUBS AND DRUMS SECTION Inspection and Assembly of The Lockheed Hydraulic System is used in conjunction with the Bendix Servo type brake Master Cylinder on the "Hornet" and "Wasp" Series and the floating shoe type on the "Rambler" Series. When reconditioning a master cylinder, clean all component parts in alcohol.
  • Page 181 BRAKES, AND WHEELS-HUBS AND DRUMS BLEEDING HYDRAULIC LINES to return slowly to "off" position. Repeat the pumping action until enough fluid has passed through to expel all the air from Bleeding the entire brake system is necessary the line. Do this at each of the four wheels. whenever a hydraulic line is disconnected from Watch the flow of fluid from the hose, the master cylinder, or whenever the brake pedal...

  • Page 182: Brake Adjustments

    TECHNICAL SERVICE MANUAL 1. Wheel Cylinder 8. Brake Shoe 2. Compression Spring 9. Brake Lining 3. Rubber Cup 10. Flat Pressure Spring 4. Piston 11. Brake Shoe Support Plate 5. Rubber Boot 12. Anchor Spring 6. Bleeder Connection 13. Flexible Hose 7.

  • Page 183: Parking Brake

    BRAKES, AND WHEELS-HUBS AND DRUMS of the brake shoes (Fig. 7). This is accom- plished by bending the anchor lip slightly toward the brake support plate so that 15 pounds pressure is exerted by the coil spring to retain the shoes on the ledges of the support plate. This can be measured with a spring scale hooked to the end of the shoe.
  • Page 184 TECHNICAL SERVICE MANUAL 1. Hand Brake Lever Assembly 5. Adjusting Rod 2. Hand Brake Cable 6. Hand Brake Cable Equalizer 3. Bell Crank Bracket 7. Rear Brake Cable 4. Bell Crank FIGURE 8—Hand Brake Lever Assembly "Hornet" and "Wasp" Series 1.
  • Page 185 BRAKES AND WHEELS-HUBS AND DRUMS FIGURE 10—Hand Brake Lever Adjustment FIGURE 11—Hand Brake Bell Crank "Hornet" and "Wasp" Series Shown "Hornet" and "Wasp" Series Shown FIGURE 12—Cross Section View Treadle-Vac FIGURE 12—Cross Section View Treadle-Vac OPERATION Released Position check valve to the Treadle-Vac vacuum unit tube and vacuum reservoir tank.
  • Page 186 TECHNICAL SERVICE MANUAL FIGURE 13—Released Position Atmosphere after passing through the air poppet spring to close the atmosphere poppet. After the atmosphere poppet closes, the pivot cleaner enters the power cylinder. It then arm, which pivots freely on the push rod passes through the open atmospheric poppet to plunger, opens the vacuum poppet (Fig.
  • Page 187 BRAKES, AND WHEELS-HUBS AND DRUMS FIGURE 14—Applied Position the push rod and plunger during initial applica- power piston balances the physical pedal pressure and allows the power piston and tion of the power unit by use of the inner rod plunger to reach a holding position. "first stage"...
  • Page 188 TECHNICAL SERVICE MANUAL Residual Check Valve During application, fluid passing throaugh the master cylinder outlet causes the rubber lip of the residual check valve to expand allowing the fluid to pass to the lines and wheel cylinders. Upon release, the hydraulic pressure existing in the lines forces the residual check valve spring to compress moving the check valve slightly off...
  • Page 189 BRAKES, AND WHEELS-HUBS AND DRUMS 1. Outlet Fitting 1. Valve 2. Rubber Seal 2. Outlet Fitting Gasket 3. Retainer 3. Residual Check Valve 4. Spring 5. Fitting 4. Spring FIGURE 19—Compensating Valve FIGURE 18—Residual Check Valve Pull the rubber stop washer off the steel stop poppet retaining clips (if necessary break washer.
  • Page 190 TECHNICAL SERVICE MANUAL CLEANING AND INSPECTION OF POWER BRAKE UNIT Thoroughly w ash all parts in alcohol. Use air pressure to remove fluid from all internal passages. Inspect the vacuum cylinder shell bore for scoring. nicks, or dents. If slight, they may be removed with fine emery cloth.
  • Page 191 BRAKES, AND WHEELS-HUBS AND DRUMS fluid on the master cylinder piston rod and place retainer and cup onto the rod. Install the piston rod washer and piston rod stop washer against the cup (Fig. 17). Clamp the master cylinder body in a vise and insert the piston rod assembly into the bore exercising care to prevent cutting the cup.
  • Page 192 TECHNICAL SERVICE MANUAL in piston plate. Vacuum Cylinder Assembly Cut a new cotton wick to correct length. Dip it in vacuum cylinder oil and place it inside Place new hydraulic rubber seal in recess of the leather packing. master cylinder. Install expanding packing ring so that Position new paper gasket on master cylinder projections will point up and into wick.
  • Page 193 BRAKES, AND WHEELS-HUBS AND DRUMS adjust thelength of the push rod so that the With the engine stopped and the transmission power unit will be in the completely released in neutral, make several pedal applications to position when the brake pedal rod cushion is up eliminate all vacuum from the system.

  • Page 194: Brake Specifications

    TECHNICAL SERVICE MANUAL POSSIBLE DIFFICULTIES AND CORRECTIONS CONDITIONS AND PROBABLE CAUSE CORRECTION Brakes Do Not Release Properly Improper Brake Adjustment Adjust Pedal Linkage Binding Free Up Friction in the Master Cylinder Piston Rod Stroke Leather Seal Bind Residual Check Valve Replace—Bleed Interference in Vacuum Piston Stroke Rubber Vacuum Line should Maintain Om during...

  • Page 195: Wheels And Tires

    BRAKES, AND WHEELS-HUBS AND DRUMS WHEELS AND TIRES Series "Hornet" "Wasp" "Rambler" Wheel Size 15" 15" 15" Tire Size Standard 7.10 x 15" 6.70 x 15” 6.40 x 15" Tire Pressure Cold Front and Rear Wheels 24 Lbs. 14 Lbs. 24 Lbs.
  • Page 196 TECHNICAL SERVICE MANUAL FIGURE 28—Static Unbalance—When Wheel Weight is not Evenly Distributed around the Hub as a Center, the Heavy FIGURE 26—Check Wheel for Run Out Point Goes to the Bottom Dynamic unbalance is an unequal distribution To check whether the run-out is in the wheel or of weight around the vertical center line of the hub, mark the high spot on both the wheel the wheel (Fig.

  • Page 197: Rear Wheel Bearings

    BRAKES, AND WHEELS-HUBS AND DRUMS REAR WHEEL BEARINGS (AXLE SHAFT) Rear Axle Shaft Bearing Removal Attach Rear Hub Puller 1-736-B to the rear wheel hub I Fig. 32) and remove the hub. FIGURE 30—Tire Rotation FRONT WHEEL BEARINGS The front wheel bearings are of the taper roller bearing type.
  • Page 198 BRAKES, AND WHEELS-HUBS AND DRUMS Axle Shaft Bearing Installation The axle shaft bearings have no provision for lubrication after assembly. These hearings should be packed with a good quality wheel bearing lubricant before the reassembly operation. Press axle shaft bearings onto the axle shafts with the small diameter of the cone toward the outer tapered end of the shaft using Bearing Replacing Tool J-2995.
  • Page 200 TECHNICAL SERVICE MANUAL...

  • Page 201: Rear Axle Disassembly

    REAR AXLE AND PROPELLER SHAFT SECTION Place the rear axle on suitable stands to REAR AXLE DISASSEMBLY facilitate overhaul. Axle Assembly Removal "Rambler" Series Remove the plug at the bottom of the axle Raise and support the rear of the body. housing and allow the lubricant to drain from Remove the rear wheels and rear wheel the axle.
  • Page 202 TECHNICAL SERVICE MANUAL The coupling nut dust shield will serve puller partially remove propeller shaft from the rear axle pinion. Disconnect the rear shock absorbers, the rear brake line at the bracket on the body floor pan, and the rear springs from the body.
  • Page 203 REAR AXLE - PROPELLER SHAFT Inspecting Axle Shafts Inspecting the Axle Housing Install a differential side gear on the A bent axle or housing may put an excessive strain spline of the rear axle shaft and place the on axle parts and make the axle noisy. It is, shaft between lathe or similar type centers.
  • Page 204 TECHNICAL SERVICE MANUAL Tie the side bearing shims to their respective bearing caps and cups to prevent misplacement whenever the differential is removed. This is done if the bearings are in good condition and are to be re-used. Differential Side Bearing Removal A puller (J-2497) is used to remove the side bearing cones from the differential case (Fig.
  • Page 205 REAR AXLE - PROPELLER SHAFT Differential Side Gears Inspect side gear for worn, cracked, or chipped teeth. The gear should be a snug fit on the axle shaft spline. Also inspect the fit on the side gear in the differential case bore.

  • Page 206: Rear Axle Assembly

    TECHNICAL SERVICE MANUAL Pinion Bearing Cups A recess is located behind each pinion bearing cup to provide a means of driving the cup from the housing. The cups should be driven out of the housing using a brass punch. CAUTION: Keep the cups square in the bore to prevent damaging the cup bores.
  • Page 207 REAR AXLE - PROPELLER SHAFT FIGURE 19—Rear Axle, "Wasp" Series The pinion gear shaft is installed with the lock pin hole in line with the lock pin hole in the differential case. Prior to pressing the differential pinion shaft in place, install the thrust block through a side gear, aligning the hole in the block with the differential pinion shaft.
  • Page 208 TECHNICAL SERVICE MANUAL "Hornet" Series shims are available in thick- Differential Side Bearing Replacement nesses from .070" to .100" in .002" variations. "Wasp" and "Rambler" Series are available in The differential side bearings are pressed onto thicknesses from .075" to .098" in .002" the case using side bearing replacer J-2646 on variations.
  • Page 209 REAR AXLE - PROPELLER SHAFT The gear is marked "Plus" or "Minus" the number of thousandths that the gear varies above or below standard. Thus "Plus" ( ) means the pinion gear is closer to the center line of the axle than standard and the "Minus" (–) means farther from the center line.
  • Page 210 TECHNICAL SERVICE MANUAL Remove the gauge block. Use a two to three inch micrometer and measure the distance from end of anvil to top of plunger head as shown in Figure This measurement represents a portion of the distance from the rear face of the pinion to the center line of the rear axle.
  • Page 211 REAR AXLE - PROPELLER SHAFT In the example shown, it requires 21/2 pounds "Wasp" and "Rambler" Series at 6 inches, or 15 inch-pounds to turn the shaft (within the limits for the "Hornet" Series). The bearing is held in position by the pinion nut, If the preload is too high, increase the thrust washer, and lockwasher;...
  • Page 212 TECHNICAL SERVICE MANUAL Adjust the backlash as follows: To increase backlash, install a thinner shim on the ring gear side and a thicker shim on the opposite side; to decrease backlash, reverse the proce- dure. However, do not change the total thick- ness of the shims.
  • Page 213 REAR AXLE - PROPELLER SHAFT drive and coast side of ring gear teeth. "Wasp" and "Rambler" Series). Preloading the side This is the tooth contact pattern, the bearings may change the backlash setting, there- pattern that is the final proof of the fore, recheck the backlash and correct if neces- adjustments.
  • Page 214 TECHNICAL SERVICE MANUAL using bearing replacing tool J-2995. Checking and Adjusting Axle Shaft End Play Axle Shaft Installation Strike the end of each axle shaft with a lead hammer to seat the bearing cups against the The inner axle oil seal is extremely important. support plate.

  • Page 215: Rear Axle Installation

    REAR AXLE - PROPELLER SHAFT Install the propeller shaft on the rear axle pinion, and install the rear springs on the axle tubes. The axle assembly is then installed on the car. Install brake lines, shock absorbers, springs, brake cables, and the wheel hubs. With the body supported at the body side sills, permit the rear axle assembly to hang freely with the shock absorbers fully extended.
  • Page 216 TECHNICAL SERVICE MANUAL load and will produce no noise other than bearing noise. If. however, there are any noises which appeared in the first test but did not appear in the second test, they may be in the rear axle. To find out. make Test No.

  • Page 217: Propeller Shafts

    REAR AXLE - PROPELLER SHAFT 1. Propeller Shaft Coupling Oil Seal 2. Propeller Shaft Coupling Oil Seal Retainer 3. Torque Tube Rear Oil Seal FIGURE 43—Rear Axle Companion Flange 4. Torque Tube Rear Oil Seal Retainer "Wasp" Hydra-Matic Equipped 5. Spacer 6.
  • Page 218 TECHNICAL SERVICE MANUAL The center bearing can be removed from the "Rambler" Series-108" Wheelbase, center hearing retainer with a brass drift. Standard Transmission and Overdrive NOTE: The yokes of the universal joints must be in alignment when the propeller shaft is Remove the propeller shaft coupling nut from the reassembled.
  • Page 219 REAR AXLE - PROPELLER SHAFT thread on which the trunnion bracket operates. as illustrated in Item "B," Figure 48. This bracket is slotted on the underside and The bearings are retained on the propeller is provided with an adjustable clamp screw. shaft with snap rings and/or a machined shoulder This clamp screw should be drawn up tight enough to the rear of the bearing.

  • Page 220: Universal Joints

    TECHNICAL SERVICE MANUAL Always check the connection at the rear axle and body bracket. Looseness at these points can produce noise and body sway. FIGURE 50—Rear Axle Track Bar UNIVERSAL JOINTS Universal Joint Disassembly The four end bearings or roller retainers are held in yoke ends by snap rings.

  • Page 221: Torque Chart

    REAR AXLE - PROPELLER SHAFT so that the snap rings are seated against the Unless dismantled for other service reasons, it inside surface of the yoke. is not necessary to lubricate them. Spicer type used 108" wheelbase Lubrication "Rambler" Series with a two piece propeller shaft is equipped with Universal joints not provided with lubrication lubrication fittings.

  • Page 222: Specifications

    TECHNICAL SERVICE MANUAL SPECIFICATIONS “Hornet” “Wasp” “Rambler” Type Semi-Floating Semi-Floating Semi-Floating Drive Gear Type Hypoid Hypoid Hypoid Ring Gear and Pinion Backlash .002"—.006" .002"—.006" .002"—.006" Axle Shaft End Play .002"—.004" .002"—.004" .002"—.004" Pinion Shaft Bearing Tension 15" lbs.-18" lbs. 12" lbs.-14" lbs. 12"...

  • Page 224: Front Suspension

    FRONT SUSPENSION- STEERING GEAR SECTION STABILIZER BAR FRONT SUSPENSION "Hornet" Series The front suspension is an independent linked The greater weight of this series requires the use parallelogram type. The left or right assemblies of a front stabilizer bar to provide complete may be removed as well as the complete assembly control of body roll.
  • Page 225 FRONT SUSPENSION - STEERING GEAR SECTION Spring Installation five coils as illustrated in Figure 4. "Hornet" and "Wasp" Series Raise the front of the car and remove the front wheel, hub, and drum as an assembly. The spring may be compressed with two spring Tighten compressors evenly...
  • Page 226 TECHNICAL SERVICE MANUAL pin. CAUTION: The lip of the lower spring seat MUST engage seat knuckle pin to prevent the spring from shifting during operation. UPPER AND LOWER CONTROL ARMS Upper Control Arm "Hornet" and "Wasp" Series The upper control arms contain rubber insu- lated bush- ings installed in the inner end of the arms.
  • Page 227 FRONT SUSPENSION - STEERING GEAR SECTION FIGURE 9—Upper Control Arm Assembly Sequence—"Rambler" Series FIGURE 9 - Upper Control Arm Assembly Sequence - “Rambler” Series thrust bearing installed on the knuckle pin Lower Control Arms between the lower side of the upper trunnion "Hornet"...
  • Page 228 TECHNICAL SERVICE MANUAL STEERING SPINDLE AND SUPPORT End thrust on the spindle pivot pin is absorbed by ball bearings (7) between the "Hornet" and "Wasp" Series upper end of the pivot pin and the upper support bushing cap. The steering spindle support is attached to the control arms by pivot pins and conven- The pivot pin oil seals are located in tional internal external threaded bushings.

  • Page 229: Front Wheel Alignment

    FRONT SUSPENSION - STEERING GEAR SECTION Pivot Pin Removal and Installation "Hornet" and "Wasp" Series Remove the wheel, hub, and drum as an assembly. Then remove the brake support plate. The steering arm is removed with remover J-1373. Removing the grease fitting at the top of the spindle support to provide access to and drive the pivot pin out of the spindle and support.
  • Page 230 TECHNICAL SERVICE MANUAL will permit turning the bolt and the eccen- trics to provide adjustment of 0° to 1/2° positive caster (1/2° to 1° on Power Steering equipped cars) and 1/4° positive to 1/4° negative camber. FIGURE 16—Caster and Camber Adjusting Eccentric—"Hornet"...

  • Page 231: Steering Gear

    FRONT SUSPENSION - STEERING GEAR SECTION Toe-in Adjustment Adjust ball socket joints tightening the adjusting plug until solid Toe-in is the difference in measurement between contact is attained. Then loosen to the first the front and rear of the front wheels at cotter pin hole, not to exceed 1/4 turn or approximately eight inches from the road surface.

  • Page 232: Power Steering

    TECHNICAL SERVICE MANUAL Steering Gear Removal ball and socket joints, wheel bearings, and "Hornet" and "Wasp" Series steering knuckle pin for looseness. Correct if required prior to making adjustments on the The steering gear complete with jacket tube steering gear. is removed up through the' access opening in the toe-board.
  • Page 233 FRONT SUSPENSION - STEERING GEAR SECTION pressure on the reaction piston as well as the same manner as the left turn with the spring pressure. When the valve spool is in exception that the valve spool is moved to the the centered position, it directs oil pressure left (Fig.
  • Page 234 TECHNICAL SERVICE MANUAL FIGURE 21—Schematic Oil Circuit—Left Turn FIGURE 22 —Schematic Oil Circuit—Right Turn "Wasp" Series valve parts will be supplied prevent cutting the "0" rings. The end plug should be reinstalled and tightened to the only with the cylinder and valve assembly as original marked position.
  • Page 235 FRONT SUSPENSION - STEERING GEAR SECTION FIGURE 22—Control Valve Assembly—“Hornet” Series FIGURE 23—Control Valve Assembly—”Wasp” Series...
  • Page 236 TECHNICAL SERVICE MANUAL cylinder. and still permit free movement of the stud. The piston rod guide will be removed with Over-tightening the stud will cause poor the piston and rod assembly. recovery from turns and binding when steering. A punch may be used to remove the felt dirt When the stud has been correctly adjusted, seal located in the plug.
  • Page 237 FRONT SUSPENSION - STEERING GEAR SECTION Oil Pump The pump shaft oil seal is located in the pump body and is removed using combination pump "Hornet" V-8 Series shaft seal and power cylinder seal puller J-5503. Lubricate the lip of the new seal with The pulley is keyed to a straight shaft and Lubriplate and press the seal into the pump body retained by a bolt and washer.
  • Page 238 TECHNICAL SERVICE MANUAL 1. Pump Cover 6. Orifice Plate 2. Flow Control Valve 7. Flow Valve Spring 3. Relief Valve Spring 8. "0" Ring 4. Relief Valve 9. Valve Cap Adapter 5. Snap Ring 10. Pump Outlet Fitting FIGURE 27—Oil Flow Control and Relief Valve Assembly Sequence—"Hornet" V-8 Series Shown Place the rotor key in the recess of the Place the orifice plate in the recess of the shaft and install the rotors, noting their...
  • Page 239 FRONT SUSPENSION - STEERING GEAR SECTION retaining nut and tap lightly on the pump The shaft bearing is retained in the pump shaft while pulling on the pulley. body with a "Tru-arc" snap ring. Remove the Remove the reservoir cover and drain the pump pulley shaft...
  • Page 240 TECHNICAL SERVICE MANUAL The large outer bearing is installed on CAUTION: Do not turn steering wheels the threaded end of the shaft with the during this initial ten minute period. stamped face of inner race to the front. Check refill reservoir.
  • Page 241 FRONT SUSPENSION - STEERING GEAR SECTION CONDITION CAUSE CORRECTION Hard Steering or Lack of Internal Leak in Cylinder Disassemble Cylinder, Inspect, Sufficient Power Assistance and Correct or Poor Recovery from Turns (Continued) Front Wheel Alignment Align Front Wheels Incorrect Steering Spindle Pivot Pins Inspect for Worn or Binding Tight Trunnions...
  • Page 242 TECHNICAL SERVICE MANUAL FRONT WHEEL ALIGNMENT SPECIFICATIONS “Hornet” “Wasp” “Rambler” Turning Angle Inside Wheel 26° 24° 25° Outside Wheel 20° 20° 21-1/2° Kingpin Angle 3° 36" 3° 36" 8-1/2º Caster Angle without 0° to 1/2° 0° to 1/2° 3/4° to 1-1/4° 1° Power Steering 1/2°...

  • Page 244: Winter Driving

    WEATHER EYE SYSTEM "Hornet" and "Wasp" Series. Pull the knob out on WEATHER EYE the "Rambler" Series to close the cowl ventilator damper. The Weather Eye is designed to provide clean, fresh During summer operation, with the water control filtered air for summer driving and fresh filtered valve in the fully closed position and the cowl and heated air within the car for winter driving.

  • Page 245: Water Control Valve

    WEATHER EYE SYSTEM warmer air is required, it is necessary to open the Water Valve Control and Switch Assembly water control valve wide open to allow more heated Removal air to be directed to the windshield. "Hornet" and "Wasp" Series The "Hornet"...
  • Page 246 TECHNICAL SERVICE MANUAL 1. Control Switch Shaft and Knob Sweated Together 5. Switch Control Stop Collar 2. French Mounting Nut 6. Heater Motor Wire Terminal 3. Ignition Switch to Heater Switch Terminal 7. Control Cable Conduit Clamp 4. Control Cable Threaded End FIGURE 5—Water Valve Control and Switch Assembly—"Rambler"...

  • Page 247: Air Filter

    WEATHER EYE SYSTEM The thermostat incorporated in the valve has The equalizer spring on the "Hornet" and a flexible capillary control tube leading from "Wasp" Series water control valve serves as a a small gas filled chamber and bellows to a counterbalance for the bellows spring to prevent position directly behind the heater core in the movement of the valve without control operation.
  • Page 248 TECHNICAL SERVICE MANUAL The heater core is held in place by the heater "Rambler" Series hoses when they are attached to the heater core Disconnect cowl ventilator damper and the heater hopper box cover. After the removal of the cover and the hoses, the heater cable from the damper arm.
  • Page 249 WEATHER EYE SYSTEM Remove inlet ring located "Rambler" Series inside of the heater hopper box. Remove from heater Remove heat deflector (Fig. 14). defroster motor shaft remove from Disconnect motor wire and ground wire. heater hopper box through heater hopper Remove the water control valve, capil- box cover opening.
  • Page 250 TECHNICAL SERVICE MANUAL TECHNICAL SERVICE LETTER REFERENCE Date Letter No. Subject Changes Information on Page No.
  • Page 252 ALL SEASON AIR CONDITIONING SYSTEM 1. Air Discharge Outlets 8. Receiver 2. Fresh Air Intake 9. Check Valve 3. Heat Distribution Duct 10. Solenoid By-pass Valve 4. Compressor 11. Filter and Liquid Indicator 5. Magnetic Clutch and Pulley 12. Heater Core (Heating Unit) 6.
  • Page 253 ALL SEASON AIR CONDITIONING SYSTEM which denotes the quantity of heat present in the and the relative humidity range of 30 per cent to substance. 70 per cent. Combinations of temperatures and Cold is the absence of heat or the lack of heat. relative humidities outside of this range produce Then heat being energy cannot be destroyed and cold various types of discomfort.

  • Page 254: Description And Operation

    TECHNICAL SERVICE MANUAL liquid, it loses the previously absorbed heat. By For example, latent heat of evaporation for causing evaporation to take place where tempera- Freon-12 is 71.95 B. T. U. at atmsopheric pressure ture is to be lowered, then causing condensation as compared to that of water which is 970 B.T.U.
  • Page 255 ALL SEASON AIR CONDITIONING SYSTEM Figure 2 - Freon-12 Temperature Pressure Relation Curve...

  • Page 256: Manual Controls

    TECHNICAL SERVICE MANUAL enable the temperature to be pulled-down more The cooling system is placed in operation by rapidly. having the water valve control knob in the Start the engine before operating the Air extreme "Low" position, and by rotating the knob Conditioning System to reduce the battery load counterclockwise to the first position for low and provide easier starting.
  • Page 257 ALL SEASON AIR CONDITIONING SYSTEM located under the left side of the instrument The sun visors may also be used to control the panel controls the air recirculation damper. distribution of the air. With the sun visors "up", air can be circulated more readily toward AIR FLOW the rear.
  • Page 258 TECHNICAL SERVICE MANUAL effect, the rear window or ventilator may be covered by the blower to dash duct. The air opened slightly. passes over a baffle or rain shedder to prevent The air discharge outlet door is closed at water from entering the car. this time;...
  • Page 259 ALL SEASON AIR CONDITIONING SYSTEM FIGURE 9—Defroster Air Flow FIGURE 11—"Forced-Heat" Air Flow DAMPER ADJUSTMENTS "Hornet" and "Wasp" Series The damper control cables and housings are routed behind the glove box mounting panel. The cowl ventilator cable and housing is routed through a hole and grommet in the dash FIGURE 10—Defroster Door Position panel.
  • Page 260 TECHNICAL SERVICE MANUAL arm. Place the Boden wire loop on the consists of the compressor, (line dis- evaporator shroud damper. dampers charge muffler "Rambler" Series) should be open when the control knob is condenser, receiver, sight glass, fil- pushed in. ter, (heat exchanger in "Rambler"...
  • Page 261 ALL SEASON AIR CONDITIONING SYSTEM FIGURE 13—Continuous Air Conditioning Cycle "Rambler" Series Compressor is the cooling effect resulting from the melting of 2,000 pounds of ice in 24 The compressor is designed to be capable hours or one ton equivalent to a cooling of having sufficient capacity at variable rate of 12,000 B.T.U.
  • Page 262 TECHNICAL SERVICE MANUAL Discharge and Suction Service Valves The discharge and suction service valves are three position valves and are mounted on each side of the compressor. The discharge service valve is located on the left hand side of the compressor. The suction service valve is located on the right hand side of the compressor.
  • Page 263 ALL SEASON AIR CONDITIONING SYSTEM The receiver is equipped with a fusible plug, Discharge Line Muffler set to discharge at extremely high temperatures "Rambler" Series and pressures. In the event of a fire or The discharge line muffler is used in the "Rambler" development of excess refrigerant pressure, the Series to dampen high pressure pulsations.
  • Page 264 TECHNICAL SERVICE MANUAL 1. Thermo Bulb 6. Expansion Valve Outlet (Low Pressure Line to 2. Evaporator Evaporator) 3. Expansion Valve Inlet (High Pressure Line) 7. Temperature Thermostat Control Capillary Tube 4. Equalizer Connection and Line 8. Temperature Thermostat Control 5. Expansion Valve FIGURE 18—Expansion Valve Location "Hornet"...
  • Page 265 ALL SEASON AIR CONDITIONING SYSTEM 1. Equalizer Screw 8. Pusher Pin 2. Equalizer Connection 9. Diaphragm 3. Valve Spring 10. Pusher Plate 4. Ball Carrier 11. Pin Guide 5. Valve Ball 12. Strainer 6. Outlet Connection to Evaporator 13. Inlet Connection 7.
  • Page 266 TECHNICAL SERVICE MANUAL The low pressure liquid admitted to the evaporator and the by-pass line will open. With the by-pass by the expansion valve vaporizes due to the heat line open, the pressure on the inlet side of the which it absorbs from the air passing over the check valve is less than the pressure on the outlet evaporator surface.
  • Page 267 ALL SEASON AIR CONDITIONING SYSTEM FIGURE 20—Freon By-Pass Cycle—"Hornet" and "Wasp" Series Shown line portion of the heat exchanger in the -ioning fulfilled, refrigeration "Rambler" Series. It then goes back to the modified until such time that the mean compressor suction line.

  • Page 268: Wiring Circuit

    TECHNICAL SERVICE MANUAL with iron filings. When the air conditioning switch is turned on, current is directed to the contact brush, the electromagnet is energized, and the clutch plate is held in contact with the compressor pulley. Thus, the compressor is being driven by the clutch plate.
  • Page 269 ALL SEASON AIR CONDITIONING SYSTEM CORRECT HANDLING OF FREON cause restrictions to the flow of refrigerant. The lines should be carefully stored to avoid crushing or bending. Use safety glasses to protect eyes as —21.7°F., The proper size wrenches should be used in the boiling point of Freon-12, is a temperature tightening fittings.

  • Page 270: Discharging The System

    TECHNICAL SERVICE MANUAL This connection is common to the other two connections. If the gauge set is used to diagnose pressures while the system is in operation, it should be capped. The hand shut-off valves do not close off pressure to the gauges. They close each opening to the center connection and to each other.

  • Page 271: Evacuating The System

    ALL SEASON AIR CONDITIONING SYSTEM The compressor lubricant is soluble in Freon- 12. To prevent pulling too much oil out of the system, release the charge slowly so that the remains Freon vaporizes into atmosphere. If there is no oil foaming out with the Freon, the valve may be opened wider to allow the gas to escape more rapidly.

  • Page 272: Charging The System

    TECHNICAL SERVICE MANUAL by tightening or replacing the leaking part and repeat the procedure. Heat a Freon drum in a container of hot water (125°) or with rags soaked in hot water. Then attach the drum to the center connection gauge line. Loosen the gauge line fitting to the center connection slightly.
  • Page 273 ALL SEASON AIR CONDITIONING SYSTEM check the system for a normal charge. Bubbles of vapor passing through the sight glass would indicate a low or short charge of refrigerant. Allow the system to run for a period of 5 to 10 minutes to normalize before checking the sight glass for vapor bubbles.
  • Page 274 TECHNICAL SERVICE MANUAL system for proper performance. After unit operates satisfactorily, stop engine, close the service valves to the service valve port fittings by backing the stems out all the way, disconnect lines, cap the fittings, and leave the service valves in this position for normal operation.

  • Page 275: Checking And Adding Oil

    ALL SEASON AIR CONDITIONING SYSTEM If the system operates normally, move the CAUTION: The oil in the container origi- service valves to the operating position. nally is packed moisture free and every Remove the gauge lines and cap the gauge port effort should be made to maintain its fittings.

  • Page 276: Purging Air From The System

    TECHNICAL SERVICE MANUAL ice forms. Such intermittent refrigeration is and using the gauge set the head or high indication excessive water pressure builds up, air is certain to be in the system. system. Clogging due to particles of dirt reduces stops refrigeration completely...

  • Page 277: Leak Test Procedure

    ALL SEASON AIR CONDITIONING SYSTEM process must be repeated. When bleeding off the excessive amount of refrigerant, a cloth placed over the gauge line opening will prevent the refrigerant or any oil from contacting on the car or persons. LEAK TEST PROCEDURE Outward leaks of Freon-12 are detected and located with the help of a device called a Halide Torch, Tool J-6048.
  • Page 278 TECHNICAL SERVICE MANUAL paste to male threads. This paste sets hard in a short time. Leaky solder connections may be soldered. A good grade of silver solder with silver solder flux is recommended. CAUTION: Never solder a joint with gas in the system.
  • Page 279 ALL SEASON AIR CONDITIONING SYSTEM The seal bellows can be removed by forcing a crankcase pressure and a defective snap ring screw driver behind the brass stamped flange will allow the seal to be blown out of the at various points and prying it out of the compressor.
  • Page 280 TECHNICAL SERVICE MANUAL Inability of the compressor to build up to or hold normal pressures, while the system is operating, would also indicate inefficiency. This is, of course, if the charge is known to be correct and no air, moisture, or dirt is in the system.
  • Page 281 ALL SEASON AIR CONDITIONING SYSTEM NOTE: If during evacuation, the compres- oil level may be determined by referring to sor is discharging after two minutes, it "Checking and Adding Oil" section. indicates considerable refrigerant ab- sorbed in the oil or there is a leak. Magnetic Clutch and Flywheel Removal Test for leaks and again evacuate.
  • Page 282 TECHNICAL SERVICE MANUAL The clutch plate is adjusted to prevent Receiver Removal and Replacement contact with the magnetic pulley while the compressor running. Shims .010" The receiver is mounted on the right hand thickness are available to make this adjust- side of the front engine crossmember.
  • Page 283 ALL SEASON AIR CONDITIONING SYSTEM Install connector to wire on valve. Check After installing heat exchanger, the valve by connecting jumper wire to install gauge manifold set. Evacuate the battery and listen to see if valve clicks system and leak test. Install charge. Start "On"...

  • Page 284: Service Diagnosis

    TECHNICAL SERVICE MANUAL Remove the screws on top outside of housing right hand air duct. The thermostat is now that hold the evaporator core in place in the accessible for removal. retainer housing. Removal of Blower Fan and Motor Remove the evaporator core from its housing. "Hornet"...
  • Page 285 ALL SEASON AIR CONDITIONING SYSTEM “Hornet” Ambient Average Discharge Head Suction Speed Temperatures Air Temperatures Pressure Pressure 30 M.P.H. 80° 47° 30 M.P.H. 85° 48° 30 M.P.H. 90° 50° “Wasp” 30 M.P.H. 80° 52° 30 M.P.H. 85° 53° 30 M.P.H. 90°...
  • Page 286 TECHNICAL SERVICE MANUAL SERVICE DIAGNOSIS (Continued) DEFECT CAUSE CORRECTION Low Suction Pressure Blower Fan Inoperative Check Motors and Wiring (Continued) Temperature Control Thermo- Replace Thermostat stat Does Not Cut-out Moisture or Freeze-up Open, Evacuate, and Recharge Expansion Valve Replace High Suction Pressure Leaky or Broken Replace Valves Compressor Valves...
  • Page 290 TECHNICAL SERVICE MANUAL TECHNICAL SERVICE LETTER REFERENCE Date Letter No. Subject Changes Information on Page No.

This manual is also suitable for:

1955 wasp1955 rambler

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