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Pontiac Firebird 1977 Manuals
Manuals and User Guides for Pontiac Firebird 1977. We have
1
Pontiac Firebird 1977 manual available for free PDF download: Service Manual
Pontiac Firebird 1977 Service Manual (1444 pages)
Brand:
Pontiac
| Category:
Automobile
| Size: 79.28 MB
Table of Contents
Table of Contents
3
General Information
4
Body Identification Plate
4
Vehicle Identification Plate
4
Ignition, Door and Trunk Locks
4
Key Blanks
6
Depressing Lock Cylinder Retaining Pin
6
Coding Side Bar Lock
6
Key Coding Diagram
6
Installing Tumblers
7
Staking Tumbler Spring Retainer
7
Installation
7
Metric Fasteners
7
Cross Recess Screw
8
Fastener Strength Identification
8
Thread Notation
8
Bolt Strength Markings
9
Decimal and Metric Equivalents
10
Conversion Chart-Customary and Metric
10
U.S. and Imperial Capacities (Approximate)
11
Maintenance & Lubrication
12
Vehicle Maintenance Schedule
13
Lubrication and Genenal Maintenance
13
Emission Control Maintenance
13
Engine Families
15
Explanation of Complete Vehicle Maintenance Schedule
15
Lube & General Maintenance
15
Body Lubrication
15
Safety Maintenance
16
Emissions
18
Maintenance Service Specifications
19
Fluids and Lubricants
20
Engine Oil and Filter
20
Recommendations
20
Checking Oil Level
21
Recommended Viscosity
21
Supplemental Engine Oil Additives
21
Types of Oil
21
Recommended SAE Viscosity Grades
22
Lift Points A, B and G Series
23
Lift Points-F and X Series
24
Lift Points-H Series
24
Lubrication Chart
25
Heating and Ventilation
26
Table of Contents
26
Heater Control Functional Test
27
1977 A & G Series Heater Control
27
General Description
27
1977 B Series Heater Control
28
1977 F Series Heater Control
28
1977 X Series Heater Control
29
1977 Astre and Sunbird Heater Control
29
1977 Ventilation Controls
30
1977 Typical Interior Body Air Flow & Exit
30
1977 Typical Heater Air Flow Except B & H Series
31
1977 B Series Heater Air Flow
32
1977 Astre and Sunbird Heater Air Flow
33
Heater Wiring Diagram
34
Heater Trouble Diagnosis "Insufficient Heating"
34
"Inadequate Removal of Fog or Ice"
35
Too Warm in Car
35
Blower Inoperative
35
Miscellaneous
36
On-Car Service Procedures
36
Available Heater Control Cable Adjustments
36
1977 A and G Series Heater Service Procedures
37
1977 F Series Heater Service Procedures
40
1977 X Series Heater Service Procedures
42
1977 Astre and Sunbird Heater Service Procedures
45
1977 B Series Heater Module
47
1977 B Series Heater Interior Service Procedures
49
1977 B Series Heater Exterior Service Procedures
51
Custom Air Conditioning
52
1977 Custom A/C Control
53
C.C.O.T. Refrigerant Oil Distribution
54
Cautions in Handling Refrigerant-12
54
1977 A & G Series C60 & C65 A/C Wiring
55
1977 F Series C60 A/C Wiring
57
1977 X Series C60 A/C Wiring
58
1977 Astre Series C60 A/C Wiring
59
1977 Sunbird C60 A/C Wiring
60
1977 Typical A/C Air Flows
61
1977 A & G Series C60 A/C Vacuum Diagram
61
1977 B Series C60 A/C Vacuum Diagram
62
1977 F Series C60 A/C Vacuum Diagram
63
1977 X Series C60 A/C Vacuum Diagram
64
1977 Astre C60 A/C Vacuum Diagram
64
1977 Sunbird C60 A/C Vacuum Diagram
65
1977 C.C.O.T. Major System Components & Refrigerant Flow
65
1977 Pressure-Temperature Relationship of R-12
66
1977 R-12 Charging Capacities
66
Precautions in Handling Refrigerant Lines and Fittings
66
Maintaining Chemical Stability in the Refrigeration System
67
Refrigerant Charging Precautions
67
With 14 Oz. Disposable Can Charging
67
With J 23500-01 Charging Station
67
Leak Testing the System
68
Liquid Leak Detectors
68
Electronic Leak Detector J-23400
68
Preliminary Checks
68
C60 Custom & C65 Auto. Temp. A/C Functional Test-A, F, G Series
69
C60 A/C Functional Test-All H & X Series
69
C60 Custom A/C Functional Test-B Series
69
1977 C.C.O.T. System Diagnostic Procedure
70
C.C.O.T. A/C System Diagnostic Procedure "Insufficient Cooling"
70
Trouble Diagnosis
73
Insufficient Heating
73
A/C Refrigerant System Diagnosis
73
Insufficient Cooling "Quick-Check" Procedure
73
Thermostatic Switch Diagnosis
74
B Series A/C Diagnostic Connector
74
B Series C60 & C65 Air Conditioning Electrical Diagnosis
74
1977 B Series Diagnostic Connector Wiring Diagram
77
Precautionary Service Measures
77
1977 Pipe & Hose Connection Torque Chart
77
Discharging, Adding Oil, Evacuating and Charging Procedures for C.C.O.T. A/C Systems
78
Discharging the C.C.O.T. A/C System
78
Evacuating, Adding Refrigerant Oil and Charging the C.C.O.T. A/C System
78
Discharging the 1977 C.C.O.T. A/C System with J 23500-01 Station
79
Discharging the 1977 C.C.O.T. A, C System Without 23500-01 Station
80
Disposable Can or Refrigerant Drum Method
80
To Begin Charging of the C.C.O.T. A/C System
80
Additional Charging Instructions
80
Charging the 1977 C.C.O.T. A/C System with Disposable Can or Refrigerant Drum
81
Accumulator Assembly
81
Compressor Overhaul
82
Minor Repair Procedures for the A-6 Compressor
82
A-6 Compressor Clutch Plate and Hub Assembly
82
Exploded View of A-6 Compressor
83
Compressor Cross Section
84
Removing 1977 A-6 Shaft Lock Nut
84
Removing 1977 A-6 Clutch Plate and Hub Asm.
85
Removing or Installing Retainer Ring in 1977 A-6 Clutch Drive Plate
85
Replace
85
Aligning 1977 A-6 Drive Plate Key
85
Installing 1977 A-6 Drive Plate
86
A-6 Compressor Pulley and Bearing Assembly
86
Remove
86
Inspection
86
Installing 1977 A-6 Pulley and Bearing Asm.
87
A-6 Compressor Pulley Bearing
87
Removing 1977 A-6 Pulley and Bearing Retainer Ring
87
Removing Bearing from 1977 A-6 Pulley Asm.
87
Installing Bearing on 1977 A-6 Pulley
88
A-6 Compressor Clutch Coil and Housing Assembly
88
Removing 1977 A-6 Coil Housing Retainer Ring
88
Installing 1977 A-6 Coil Housing
88
Major A-6 Compressor Repair Procedures
89
A-6 Compressor Shaft Seal
89
Seal Leak Detection
89
Specification 1977 A-6 and R-4 Compressor Shaft Seal Kit
90
Removing or Installing 1977 A-6 Shaft Seal Seat Retaining Ring
90
Removing 1977 A-6 Shaft Seal Seat and 0
90
Replacing 1977 A-6 Seal and 0-Ring
90
1977 A-6 Compressor Shaft and Seal
91
Leak Testing 1977 A-6 Compressor
91
A-6 Compressor Pressure Relief Valve
91
1977 A-6 High Pressure Relief Valve
92
A-6 Compressor Internal Mechanism
92
1977 A-6 Compressor Installed in Holding
92
1977 A-6 Rear Head Removal
92
Removing 1977 A-6 Rear Discharge Valve Plate
93
Removing 1977 A-6 Rear Suction Reed
93
Removing 1977 A-6 Oil Pick-Up Tube
93
Removing 1977 A-6 Suction Cross-Over Cover
93
Disassembly
94
Numbering 1977 A-6 Piston and Cylinder Bores
94
Separating 1977 A-6 Cylinder Halves
94
Notch Identifying Front End of 1977 A-6 Piston
94
1977 A-6 Parts Tray
95
Installing 1977 A-6 Needle Bearing
95
A-6 Comressor Internal Mechanism
95
Gaging Operation
95
Installing 1977 A-6 Rear Thrust Races and Bearings
96
Installing 1977 A-6 Front Shoe Disc
96
Installing 1977 A-6 Piston During Gaging Operation
96
Gaging Procedure
96
Assembling 1977 A-6 Cylinder Halves
97
Gaging 1977 A-6 Rear Piston Ball
97
Available 1977 A-6 Service Shoes and Thrust Races
98
Selection of Proper 1977 A-6 Shoe Disc
98
Gaging 1977 A-6 Rear Thrust Race
98
Checking 1977 A-6 Piston and Shaft End Play
98
A-6 Teflon Piston Ring Replacement
99
Teflon 1977 A-6 Teflon Piston Ring Installing, Sizing and Gaging Tools
99
1977 A-6 Teflon Piston Ring Positions Ring Installer Guide
100
Installing 1977 A-6 Teflon Piston Ring
100
1977 A-6 Teflon Piston Ring Installed in Piston Groove
100
Gaging 1977 A-6 Piston Ring Size
101
Installing 1 St 1977 A-6 Piston Assembly into Front Cylinder Half
101
Installing 2Nd 1977 A-6 Piston
101
Installing 1977 A-6 Discharge Cross-Over Tube
101
1977 A-6 Pistons Positioned in Stair-Step Arrangement
102
Installing 1977 A-6 Suction Cross-Over Cover
102
Installing 0-Ring on 1977 A-6 Discharge Cross-Over Tube
102
Installing 1977 A-6 Front Suction Reed
103
Installing 1977 A-6 Front Discharge Valve Plate
103
Front and Rear 1977 A-6 Discharge Valve Plates
103
Installing 1977 A-6 Front Head Casting
103
1977 A-6 Front Head 0-Ring Installed
104
Installing 1977 A-6 Compressor Shell
104
Installing 1977 A-6 Oil Pick-Up Tube
104
Positioning 1977 A-6 Oil Pump Gears
104
1977 A-6 Shell-To-Front Head 0-Ring Installation
105
Installing 1977 A-6 Rear Head
105
Minor Repair Procedures for the R-4 Compressor
105
1977 R-4 Compressor
106
R-4 Compressor Clutch Plate and Hub Asm.
106
R-4 Compressor Clutch Rotor And/Or Bearing
106
Exploded View of 1977 R-4 Compressor
107
1977 R-4 Compressor Cross Section
108
1977 R-4 in Holding Fixture
108
Removing 1977 R-4 Shaft Nut
109
1977 R-4 Clutch Plate Hub Asm. Removal
109
Installing 1977 R-4 Shaft Key
109
Installing 1977 R-4 Clutch Plate & Hub Asm.
109
Removing 1977 R-4 Rotor & Bearing Asm. Retainer Ring
110
Removing 1977 R-4 Clutch Rotor Asm.
110
Installing 1977 R-4 Rotor & Bearing Puller Guide
110
R-4 Compressor Clutch Coil And/Or Pulley Rim
110
1977 R-4 Rotor & Bearing Asm.
111
Installing 1977 R-4 Clutch Rotor Bearing
111
Installing 1977 R-4 Rotor and Bearing Asm. (on Car)
111
Installing 1977 R-4 Rotor & Bearing Asm. (on Bench)
111
1977 A-4 Clutch Coil Asm.
112
Assembling 1977 R-4 Clutch Coil, Pulley Rim and Rotor & Bearing
112
Major R-4 Compressor Repair Procedures
112
R-4 Compressor Shaft Seal
112
R-4 Compressor Shaft Seal Replacement (on Car)
113
Installing 1977 R-4 Seal (on Car)
114
Installing 1977 R-4 Ceramic Seal Seat (on Car)
114
R-4 Compressor Shaft Seal Replacement (off Car)
114
Removing & Installing 1977 R-4 Seal Seat (off Car)
114
Removing & Installing 1977 R-4 Shaft Seal (off Car)
115
Installing 1977 R-4 Shaft Seal Seat 0-Ring (off Car)
115
R 4 Compressor Pressure Relief Valve
115
R-4 Compressor Front Head And/Or O-Ring
115
Removing 1977 R-4 Front Head Mounting Screws
116
Removing 197 7 R-4 Front Head Asm.
116
R-4 Compressor Thrust and Belleville Washers
116
R-4 Compressor Main Bearing
116
Removing 1977 R-4 Main Bearing
117
Installing 1977 R-4 Main Bearing
117
R-4 Compressor Shell And/Or O-Ring Seals
117
Releasing 1977 R-4 Shell Retaining Strap
117
Removing 1977 R-4 Shell
118
Installing 1977 R-4 Shell
118
R-4 Compressor Discharge Valve Plate And/Or Retainer
118
Replacing 1977 R-4 Valve Plate Retainer
119
Replacing 1977 R-4 Discharge Valve Plate
119
A-6 and R-4 Compressor Leak Testing (External and Internal)
120
Bench-Check Procedure
120
1977 C60 Temperature Cable Adjustment
121
A & G Series Turnbuckle-Type
121
B Series Self-Adjusting Cable
121
F Series Turnbuckle-Type
121
1977 Series A/C Module
122
1977 B Series A/C Interior Service Procedures
125
1977 B Series A/C Exterior Service Procedures
127
1977 A Series (Lemans-Lemans Sport) A/C Interior Proc.
128
1977 A & G Series Exterior Service Procedures
133
1977 F Series A/C Interior Service Procedures
136
1977 F Series A/C Exterior Service Procedures
140
1977 X Series A/C Interior Service Procedures
143
1977 X Series A/C Exterior Service Procedures
147
1977 Astre Series A/C Interior Service Procedures
150
1977 Astre Series A/C Exterior Service Procedures
153
1977 Sunbird Series A/C Interior Service Procedures
156
1977 Sunbird Series A/C Exterior Service Procedures
159
1977 A, B, F, G Series Compressor Wiring
162
1977 X Series Compressor Wiring
163
1977 Astre & Sunbird Compressor Wiring
164
1977 Compressor Mounting No. 1 of 4 (Engine Codes 8-1 4 0 and V-15 1)
165
1977 Compressor Mounting No. 2 of 4 (Engine Codes R-350 and K-403)
165
1977 Compressor Mounting No. 3 of 4 (Engine Codes C-231, U-305 and L-350)
166
1977 Compressor Mounting No. 4 of 4 (Engine Codes Y-301, P-350 and 2-400)
167
1977 A/C Special Tools
168
Automatic Temperature Control
169
A and G Series C65 Control
169
B Series C65 Control
169
C65 Functional Test (B Series)
169
A and G Series Vacuum Diagram
170
On-Car Service Procedure
170
C65 Programmer Temperature Cable Adjustment
170
C65 Programmer "Removal-Replacement-Adjustment" Procedure
170
B Series Vacuum Diagram
171
1977 B Series C65 Programmer-Front View
172
1977 B Series C65 Programmer-Rear View
172
1977 B Series C65 Service Procedures
172
1977 A and G Series C65 Service Procedures
173
1977 A and G Series C65 Service Procedures-View "E"
174
Frame and Body Mounts
175
Frame Identification
175
On Car Service
176
Frame Inspection
176
Underbody Inspection
176
Frame Repair
176
Typical Frame Alignment Checks
177
B Series Frame Dimensions
177
Body Mounts
177
Frame Braces
177
A and G Series Frame Dimensions
178
Frame Body Mounts-A, B and G Series
179
Frame Body Mounts-F and X Series
180
Frame Braces-B Series
181
Frame Braces-F Series
181
Frame Braces-G Series
182
Frame Braces-A Series
183
Front & Rear Bumpers
184
Bumper Energy Absorbing Units
184
Testing Front or Rear Energy Absorber Operation
184
Energy Absorbing Device-Extended
185
Energy Absorbing Device-Collapsed
185
Inspection after Collision
185
Scrapping Energy Absorber
186
Care of Aluminum Bumpers
186
Service Procedures
186
Typical Plastic (Surlyn) Bumper Rub Strip Attachment
186
Exploded Service Procedures-"A" Series-Front Bumper
187
Exploded Service Procedures-"A" Series-Rear Bumper
188
Exploded Service Procedures-"B" Series-Front Bumper
189
Exploded Service Procedures-"B" Series-Rear Bumper (Exc. Wagon)
190
Exploded Service Procedures-"A" Series-Rear Bumper (Wagon Only)
191
Exploded Service Procedures-"G" Series-Front Bumper
192
Exploded Service Procedures-"G" Series-Rear Bumper
193
Exploded Service Procedures-"F" Series-Rear Bumper
194
Exploded Service Procedures-"X" Series-Front Bumper
195
Exploded Service Procedures-"X" Series-Rear Bumper
196
Exploded Service Procedures-"H" Series-Rear Bumper
197
Exploded Service Procedures-"HM" Series-Front Bumper
197
Exploded Service Procedures-"HM07" Rear End & "HM" Series Rear Bumper
198
Front License Plate Mounting Locations
199
Chassis Metal, Plastics, Paint and Repair
200
Hood
200
Adjust
200
Hood Hinge/Spring
201
Hood Latch
201
Hood Release Cable/Rod
201
Front Fender
202
Painting and Repairing Non-Metal Exterior Parts
202
Endura Paint Refinishing Procedures for Urethane, P.V.C. and T.P.R. Surfaces
202
Repairing & Refinishing Urethane Bumpers and Headlamp Mounting Panels
202
Coloring Procedure
203
Painting Primed Service Replacement Urethane Bumpers/Headlamp Mounting Panels & Colored Plastic Bumper Close-Out Panels
203
1977 Non-Metal Exterior Painted Parts
204
Proper Identification and Painting of Interior Plastic Trim
204
Polypropylene, ABS or Vinyl Plastic
204
Painting Interior Plastic Parts
204
1977 Pontiac Exterior Colors
205
"Polypropylene" Plastic Parts
206
"Rigid or Hard ABS" Plastic Parts
206
"Vinyl and Flexible (Soft) ABS" Plastic Parts
206
Exploded Service Procedures-"A" Series-Front End
207
Exploded Service Procedures-"A" Series-Fenders and Hood
208
Exploded Service Procedures-"B" Series-Front End
209
Exploded Service Procedures-"B" Series-Fenders and Hood
210
Exploded Service Procedures-"G" Series-Front End
211
Exploded Service Procedures-"G" Series-Fenders and Hood
212
Exploded Service Procedures-"F" Series-Front End and Front Bumper
213
Exploded Service Procedures-"F" Series-Fenders and Hood
214
Exploded Service Procedures-"X" Series-Front End
215
Exploded Service Procedures-"X" Series-Fenders and Hood
216
Exploded Service Procedures-"H" Series-Front End and Front Bumper
217
Exploded Service Procedures-"HM" Series-Front End
218
"H" Series and "HM" Series-Hoods
219
"A" Series and "B" Series-Woodgrain Molding Attachments
220
A Series and "G" Series-Stripe Decals
221
B Series-Stripe Decals and Moldings
222
"F" Series-Esprit-Stripe Decals and Moldings
223
"F" Series-Formula-Decals
224
"F" Series-Trans Am-Decals
225
"X" Series-Decals and Moldings
226
"H" Series-Astre-Decals
227
"H" Series-Wagon-Decals
228
"HM" Series-Stripe Decals and Moldings
229
Steering, Suspension, Wheels and Tires
230
Car Pulls (Leads)
230
Linkage Diagnosis
232
Manual Steering Gear Diagnosis
232
Power Steering Pump and Gear Diagnosis
232
Hissing Noise in Steering Gear
232
Steering Column Diagnosis
234
All Columns (no Mark)
234
Tilt Column Only
234
Standard Column Only
234
Key Buzzer
236
Checking Buzzer at Chassis Connector
237
Checking Buzzer Circuit at Column Connector
237
Checking Buzzer Switch Pads
237
Buzzer Continues to Operate with Key in the Lock Cylinder with the Driver's Door
237
Column Mounted Dimmer Switch
238
Power Steering Pump & Gear
238
External Leakage Diagnosis
238
Component Replacement Recommendations
238
Power Steering System Test Procedure
239
Shock Absorber Diagnosis
239
On-Car Checks
239
Gear and Pump Leak Diagnosis
240
Bench Checks
241
Spiral Groove Reservoir
241
Tire Diagnosis
241
Irregular And/Or Premature Wear
241
Front Wheel Bearing Diagnosis
242
Tire Wear Diagnosis
244
Tread Wear Indicator
244
Lead
244
Radial Tire Waddle
244
Lead Diagnosis
245
Diagnosis Charts
246
Using the Charts
246
Using the TPD for Radial-Lateral Vibration
246
Substitution Method
250
Front End Alignment
251
Front Alignment
251
Caster
251
Preliminary Checks Prior to Adjusting Front Alignment
251
Caster, Camber and Toe-In
252
Front Alignment Requirements
252
Alignment Adjustments-Except H Series
253
Toe-In
253
Caster and Camber Adjustment
253
Alignment Correction Charts Except H Series
254
Example Use of Correction Chart
254
Alignment Adjustments-H Series
254
Caster and Camber
254
Series Alignment Correction Chart
255
A & G Series Alignment Correction Chart
256
F Series Alignment Correction Chart
257
X Series Alignment Correction Chart (with Power Steering)
258
X Series Alignment Correction Chart (Except Power Steering)
259
Trim Heights-B Series
260
Trim Heights-H Series
261
Alignment Specifications Chart
262
Steering Linkage
263
Description and Operation
263
Suspension and Steering Linkage Check
263
Tie Rods
263
Checking Linkage Wear
264
Disconnecting Linkage Joint
265
Tie Rod Clamp and Adjuster Tube Positioning-Except H Series
265
Intermediate Rod
265
Tie Rod Clamp and Adjuster Tube Positioning-H Series
265
Steering Linkage-A Series (Manual Steering)
266
Steering Linkage-X Series (151 Engine)
266
Tie Rod Adjuster Tube
267
Idler Arm
267
Shock Absorber (Intermediate Rod)
268
Pitman Arm
268
Torque Specifications
269
Manual Steering Gear
270
Manual Gear Assembly
270
Manual Steering Gear (Cross Section)
271
Worm Shaft Seal
271
Disassembly of Gear
271
Installing Worm Shaft Seal
271
Manual Steering Gear (Exploded)
272
Removing Pitman Shaft Assembly
273
Loosening Lock Nut
273
Pitman Shaft Bushing Replacement
273
Side Cover Bushing Replacement
273
Installing Pitman Shaft
274
Wormshaft Bearing Race Replacement
274
Adjuster Plug Race
274
Ball Nut Servicing
274
Assembly
275
Positioning Ball Nut on Worm Shaft
275
Installing Balls in Circuit
275
Checking End Clearance
276
Adjustment Specifications-Manual Steering
276
Recommended Torque Specifications
276
Power Steering Gear and Pump
277
Power Steering Gear
278
Power Steering Pump
279
Pitman Shaft Seals
279
Removal and Installation with Steering Gear in Car
279
Installing Seal (Pitman Shaft in Place)
280
Steering Gear
280
Coupling Shield-X, H Series
280
Coupling Shield-A, B and G Series
280
Coupling Shield-F Series
281
Servicing Individual Units
281
Adjuster Plug Assembly
281
Power Steering Gear (Exploded)
282
Mounting Steering Gear in Vise
282
Removing End Cover
282
Removing Rack Piston Plug
283
Loosening Adjuster Plug Lock Nut
283
Removing Adjuster Plug
283
Valve and Stub Shaft Assembly
283
Removing Thrust Bearing Retainer
284
Cleaning and Inspection
284
Removing Seal and Bearing
284
Installing Bearing
285
Installing Seal
285
Installing Bearing Retainer
285
Valve and Stud Shaft Assembly
285
Removing Stub Shaft Assembly
286
Installing Stub Shaft Assembly
286
Pitman Shaft and Side Cover
286
Rack-Piston
286
Installing Ring on Rack Piston
287
Installing Balls in Rack Piston
287
Steering Gear Hose Connector and Poppet Check Valve
287
Removing Connector Seat
287
Installing Connector Seat
288
Pitman Shaft Needle Bearing and Seals
288
Removing Bearing and Seals
289
Installing Needle Bearings
289
Installing Seals (Gear Disassembled)
289
Gear Assembly and Adjustment
289
Worm Shaft and Valve Body
290
Installing Valve Body
290
Valve Body Properly Seated
290
Installing Adjuster Plug
290
Adjusting Thrust Bearing
291
Marking Gear Housing
291
Measuring for Second Mark
291
Rotating Adjuster (CCW)
291
Tightening Lock Nut
292
Checking Preload
292
Installing Rack Piston
292
Centering Stub Shaft
292
Power Steering Gear Ball Plug
293
Leak Repair
293
Pump Belt
293
Checking
293
Adjustment-All Single Groove Pulleys
294
Adjustment-Two Groove Pulleys
294
Flow Control Valve
294
Pump Pulley
294
Pump Shaft Oil Seal
295
Replacement (Without Disassembling Pump)
295
Removing Pulley
295
Installing Pulley Installer
295
Installing Pulley
296
Cutting Seal
296
Removing Pump Seal
296
Installing Pump Seal
296
Power Steering Pump (Exploded)
297
Power Steering Pump Mounting-140 Engine
297
Power Steering Pump Mounting-151 Engine
298
Power Steering Pump Mounting-231 Engine
299
Power Steering Pump Mounting-301, 350 (Engine Code P) and 400 Engines
300
Power Steering Pump Mounting-350 (Engine Code R) and 403 Engines
301
Bleeding Power Steering System
301
Fluid Level
301
Power Steering Pump Mounting-305 and 350 (Engine Code L) Engines
302
Hose Routing (4 Cyl. Engine)
303
Hose Routing (V6 Engine)
304
Hose Routing-301-350 (P)-400 V8 Engines
306
Hose Routing-350 (R)-403 V8 Engines
307
Hose Routing-305-350 (L) V8 Engines
308
Remove and Replace Reservoir
309
Remove and Replace Control Valve and End Plate
309
Remove and Replace Rotating Group
310
Remove and Replace Seals
310
Remove and Replace Thrust Plate and Rotor
310
Power Steering Gear (605 Model)
311
Remove and Install Pitman Shaft Seals in Car
312
Remove and Install Pitman Shaft and Side Cover
312
Remove and Install Stub Shaft Seals Without Disassembling Gear
312
Remove and Install Lower Bearing and Adjuster
312
Remove and Install Rack Piston and Valve Assembly
313
Remove and Install Valve and Worm Assembly from Rack Piston
313
Remove and Install Valve Assembly from Worm Assembly
313
Disassemble and Assemble Valve
313
Remove and Install Stub Shaft Seals and Bearings
314
Remove and Install Pitman Shaft Seals and Bearing
314
Remove and Install Connectors
314
Adjust Worm Bearing Preload
315
Adjust "Over Center" Preload
315
General Specifications
315
Steering Wheels and Columns
317
Function Locking Columns
317
Steering Column with Dimmer Switch
318
Key Release Columns
318
H Series and X Series W/5 Speed
318
Mechanical Neutral Start System
318
Steering Column (All Series)
319
Column Mounting-B Series
320
Column Mounting-A and G Series
321
Column Mounting-F and X Series
321
Column Bracket-X Series
321
Tilt-Away Column and Key Release in Car Procedures
322
Lock Plate And/Or Cancelling Cam (Tilt-Away)
322
Tilt-Away Key Release Column
322
Tilt-Away Column
323
Cover Attachment
324
Removing Wire Snap Ring
324
Turn Signal Switch (Tilt-Away)
324
Lock Plate and Cancelling Cam
325
Installing Wire Snap Ring
325
Turn Signal Switch Attachment
325
Ignition Lock Assembly (Tilt-Away)
325
Column Mounting a and G Series
326
Shift Indicator Link a and G Series
327
Shift Indicator Needle-B Series
327
Key Warning Buzzer Switch (Tilt-Away)
327
Cover (Tilt-Away)
327
Shift Indicator Cable-X Series
328
Steering Lock Bolt Spring (Tilt-Away)
328
Sector And/Or Lock Bolt (Tilt-Away)
328
Location of Switch for Lock Removal
329
Ignition Lock Removal
329
Installing Ignition Lock
329
Remove Key Warning Buzzer Switch
329
Opening Shield and Lock Spring
330
Removing Lock Bolt Spring
330
Sector Snap Ring
330
Lock Drive Shaft
330
Housing (Tilt-Away)
331
Housing Seat and Race
331
Tilt Spring Retainer
331
Removing Pivot Pins
331
Lock Shoe Attachment
332
Shoe Release Lever
332
Rack And/Or Spring (Tilt-Away)
332
Steering Shaft (Tilt-Away)
332
Lower Shaft Spacer
333
Removing Spherical Joint
333
Spherical Joint
333
Support And/Or Shift Gate (Tilt-Away)
333
Support Attachment
334
Shift Gate Mounting
334
Key Release Lever (Tilt-Away)
334
Aligning "V" in Support
334
Shift Lever Installation
335
Ignition Switch (Tilt-Away)
335
Positioning Switch for ACC Position
335
Actuator Rod (Ignition Switch) Tilt-Away
335
Dimmer Switch Adjustment or Replacement (B Series)
336
Removing Dimmer Switch
336
Adjusting Dimmer Switch
336
Tilt-Away Column with Dimmer Switch
336
Removing Actuator Screw
337
Removing Turn Signal Lever
337
Turn Signal Switch Screws
337
Removing Key Warning Buzzer Switch
338
Removing Cover
338
Removing Cap and Rod Actuator
338
Removing Pivot Pin
339
Removing Dimmer Switch Mounting Screw
339
Removing Dimmer Switch Rod and Support
339
Installing Rod Actuator
339
Installing Actuator Arm
340
Lower Bearing And/Or Adapter (Tilt-Away)
340
Lower Bearing Attachment
341
Out of Car Procedures
341
Bowl And/Or Shift Tube
341
All Except H Series (Tilt-Away)
341
Neutral Start Switch
342
Shift Tube Retainer and Thrust Washer
342
Removing Shift Tube
342
Align Shift Tube in Jacket
342
Lock Plate and Wave Washer
343
Installing Shift Tube
343
Installing Tool J 23073-1
343
Regular Column and Key Release in Car Procedures
344
Lock Plate And/Or Cancelling Cam (Regular)
344
Turn Signal Switch (Regular)
344
Regular Column (Except H Series)
345
Regular Key Release Column-H Series
346
Column Wiring Connectors
348
Ignition Lock Assembly (Regular)
348
Key Warning Buzzer Switch (Regular)
348
Column Mounting-Typical
349
Turn Signal Wire Protectors
350
Installing Turn Signal Switch
350
Ignition Switch (Regular) Exc. X Series
350
Install Key Warning Buzzer Switch
351
Position Switch for Off-Unlock Position
351
Housing (Regular)
351
Housing Attachment-H Series
352
Shroud Attachment-H Series
352
Remove Key Release Lever and Spring
352
Key Release Lever and Spring Position
353
Key Release Wave Washer
353
Shift Gate (Regular) Exc. H Series
353
Shift Gate Mounting (Exc. H Series)
354
Sector (Regular)
354
Lock Bolt And/Or Rack (Regular)
354
Install Sector
354
Rack Spring
355
Bowl (Exc. H Series)
355
Bowl Thrust Cup
355
Lower Bowl Bearing (Regular)
355
Lower Bowl Bearing and Thrust Washer
356
Aligning Lower Bowl Bearing
356
Regular Column with Dimmer Switch
356
Removing Actuator Arm
357
Removing Housing Bolts
358
Removing Cover and Screw
358
Installing Cup
359
Installing Housing
359
Adjusting Dimmer
359
Lower Bearing And/Or Adapter or Bushing Assembly (Regular)
359
Removing Lower Bearing
360
Lower Bearing And/Or Adapter (Regular)
360
H Series W/Manual Steering
360
Removing Lower Bearing and Adapter Series
361
Steering Shaft (Regular)
361
Shift Tube (Regular) Exc. H Series
361
Automatic Transmission
361
Lower Bearing Assembly (Exc. H Series)
362
Shift Tube (Regular) F and X Series
362
Back-Up Switch (Manual Transmission)
362
Intermediate Shaft And/Or Stone Shield Replacement A, B and G Series
362
Lower Bearing (Manual Transmission Column)
363
Shift Tube (Manual Transmission Column)
363
Adjust Shift Levers (Manual Transmission)
364
Intermediate Shaft and Coupling
364
H, X and F Series
364
Disassembly (Except F and X Series)
364
Installing Preload Spring
365
Aligning Intermediate Shaft
365
Coupling Assembly
365
Ignition Lock Assembly
365
Ignition Lock Service Package
366
Depress Brass Pin
366
Position Buzzer Cam for Removal
366
Pre-Cut Tumblers
366
Installing Lock Cylinder into Sleeve
367
Steering Wheel
367
Staking Adapter Stop
367
Steering Wheel-Standard or Luxury Cushion
367
Custom Sport Steering Wheel
368
Formula Steering Wheel
368
Checking Steering Column for Accident Damage
368
Check Capsules in Bracket
369
Proper Bolt Installation
369
Check Jacket for Collapse
369
Check Steering Shaft Injections
369
Check Intermediate Shaft
370
Front Suspension
371
Except H Series
371
H Series
371
Front Suspension (Except H Series)
372
Front Suspension (H Series)
372
Maintenance and Adjustments
373
Front Wheel Bearings
373
Adjusting Front Wheel Bearings
373
Service Procedures Except H Series
373
Wheel Bearing Adjustment
374
Pressing Front Hub Bolts (Typical)
375
Replacement of Bearing Cups
375
Shock Absorber Attachments
375
Stabilizer Bar-Typical
376
Front Spring
376
Removing Spring with Adapter J-23028
376
Ball Joint Service
377
Upper
377
Coil Spring Positioning
377
Pressing Ball Joint from Knuckle (Typical)
378
Lower Ball Joint
378
Removing Lower Ball Joint from L.C.A.
378
Steering Knuckle
379
Wear Indicating Ball Joint
379
Installing Ball Joint to L.C.A.
380
U.C.A. Removal
380
Loosening Upper Control Arm Bolts
380
Shaft/Bushing-Replacement
380
Removing Upper Control Arm Bolts
381
Removing First Upper Control Arm Bushing (Front or Rear)
381
Installing Upper Control Arm Front Bushing First
381
Intalling Upper Control Arm Second Bushing
381
Lower Control Arms (L.C.A.)
382
Rear Bushing Replacement
382
Installing L.C.A. Bushing
382
Front Bushing Replacement
382
Forming Flare
383
L.C.A. Front Bushing Flaring
383
Wheel Hub and Disc
383
Replacement of Bearings
383
Replacement of Wheel Hub Bolts
384
Shock Absorbers
384
Stabilizer Bar
384
Coil Springs
384
Shock Absorber Attachment
385
Front Stabilizer Bar
385
Removing Coil Spring
386
Upper Ball Joint-Removal from Knuckle
386
Installation to Knuckle
386
Lower Ball Joint Inspection
386
Removing Ball Joints from Knuckle
387
Removal from Knuckle
387
Removing Lower Control Arm Ball Joint
388
Installing Lower Control Arm Ball Joint
388
Upper Control Arm (U.C.A.)
389
U.C.A. Ball Joint-Inspection
389
U.C.A. Bushing Replacement
389
U.C.A. Installation
389
Lower Control Arm (L.C.A.)
390
L.C.A. Removal
390
L.C.A. Bushing Replacement
390
L.C.A. Installation
390
Front Suspension Torque Specifications
391
Rear Suspension
392
A, B and G Series
392
Rear Suspension-A, B and G Series
393
F and X Series
393
Rear Suspension-H, F and X Series
394
Rear Suspension Service Operations
394
Upper Control Arms (A, B and G Series)
394
Upper Control Arm Attachment
395
Service Replacement Parts-B Series
395
Torque Arm (H Series)
395
Track Rod (H Series)
395
Torque Arm-H Series (151 Engine)
396
H Series Track Rod
397
Lower Control Arms (Exc. F and X Series)
398
Bushings (Exc. F and X Series)
398
Torque Arm Bushing H Series (Except 151 Engine)
398
Bushing (Differential Carrier)
398
Bushing Removal
399
Coil Springs (Exc. F and X Series)
399
Coil Spring Mounting (Typical)
399
Leaf Spring (F and X Series)
399
Leaf Spring Front Bracket Mounting
400
Leaf Spring Shackles and Bushings
400
Axle Housing
400
Rubber Bumper (Exc. F and X Series)
400
Axle Housing Alignment
401
Rear Stabilizer Shaft
401
Superlift Shock Absorbers
401
Superlift System Leaks Air Pressure
401
Superlifts Noisy When Car
402
Lines and Fittings
402
Leveling Unit
402
Rear Stabilizer Shaft-F and X Series
403
Rear Stabilizer Shaft-H Series
404
Automatic Level Control
404
Compressor Reservoir and Regulator Leak Test
404
Height Control Valve Test-Off Car
404
Superlift Shock Absorbers (Typical)
405
Automatic Level Control Diagnosis
406
Trouble Chart
406
Checking Tank Pressure
406
Checking Vacuum Supply to Compressor
407
Attaching Gage to Compressor-High Pressure Fitting
408
Checking System Operation Without Compressor
409
Checking for Leaks
410
Checking Fittings
410
Inspecting Height Control Valve
411
Checking out Height Control Valve
412
Checking Operation of Height Control Valve
413
Checking Attaching Parts to Height Control Valve
414
Location of Exhaust Check Valve
415
Lines and Fittings Leak Test
415
Compressor Assembly
416
Height Control Valve
416
Superlift Shock Absorber
416
On-Car Service
416
Automatic Level Control Valve and Shocks
417
Tubing
418
Compressor, Reservoir and Regulator Valve Assembly
418
Piston-Diaphragm Assembly
418
First Stage Housing and Valve Mechanism
418
Exploded View of Compressor
419
Automatic Level Control Compressor Installation
420
Removing Diaphragm Retainer
421
Distributor Valve Assembly
421
Second Stage Housing
421
Clean and Inspect Parts
421
Removing Check Valve
422
Positioning Check Valve
422
Installing Distributor Arm
423
Installing Diaphragm Retainer
423
Installing Piston Seal
423
Major Components
423
Coil Spring Suspension (A, B and G Series)
424
Leaf Spring Suspension (F and X Series)
424
Torque Arm Suspension (H Series)
425
Superlift Shock Absorber (A, B and G Series)
425
Automatic Level Control (B Series)
425
Replacement Tires
426
Replacement Wheels
426
Maintenance and Minor Adjustments
427
Inflation of Tires
427
Tire Rotation
427
Cast Aluminum Wheels
427
Tire Rotation Diagram
428
Stowaway Spare Maintenance
428
Wheel and Tire Assembly
428
Tire Mounting and Demounting
428
Tire Repair
429
Balancing Wheels
429
General Balance Precautions
429
Off/On-Car Balancing
429
Static Unbalance Correction
430
Dynamic Unbalance Correction
430
Standard Axle
430
Anti-Spin Axle
431
Vibration
431
Styled Wheel Hub Cap
431
Rally Wheel
431
Cast Aluminum Wheel
432
Removing Cast Aluminum Wheel Cap
433
Installing Cast Aluminum Wheel Cap
433
Recharging CO 2 Inflator Canister
433
Wheel Nut Torque
433
Propeller Shaft-Cross Section
434
Propeller Shaft Trouble Diagnosis
435
Trouble Diagnosis Chart
436
Checking Rear Universal Joint Angle
437
Inclinometer Method
437
Angle at Rear Universal Joint
437
Measuring Angle at Rear Propeller Shaft Bearing Cup
437
Measuring Angle at Companion Flange Yoke Bearing Cup
438
Angle at Front Universal Joint
438
Propeller Shaft Balancing Procedure
438
Hose Clamp Method
438
Universal Joint Angles
439
Measuring Angle at Front Propeller Shaft Bearing Cup
440
Measuring Angle at Front Slip Yoke Bearing Cup
440
Strobe Light-Wheel Balance and Hose Clamp Method
440
Rotating Balance Hose Clamps
440
Reference Marks on Drive Shaft
441
Pick-Up Unit at Differential Pinion Nose
441
Balance Hose Clamps in Place
441
Positioning Hose Clamp to Achieve Best Balance
442
Removal of Propeller Shaft
442
Installation of Propeller Shaft Assembly
442
Disassembly of Propeller Shaft
443
Disassembly of Universal Joint-A, B Series
443
Assembly of Propeller Shaft
443
Disassembly of Universal Joint-H and X Series
443
Pressing out U-Joint Bearing with Guide Installed
444
Installing U-Joint Bearing with Guide in Place
444
Service Universal Joint
444
Installing U-Joint Bearing
445
Seating U-Joint Snap Rings
445
Assemble of Universal Joint-H and X Series
445
Universal Joint Repair Kit-H and X Series
446
Propeller Shaft Specifications
446
Tightening Specifications
446
Standard Differential Description
447
Positive Traction Differential Description
447
Operation-Standard Differential
448
Operation-Positive Traction Differential
448
Exploded View-Typical Standard Differential
449
Exploded View-Typical Positive Traction Differential
450
Pre-Repair Investigation and Trouble Diagnosis
451
Gear Tooth Nomenclature
451
Tooth Contact Pattern Test
451
Effects of Increasing Load on Teeth Contact Pattern
451
Gear Teeth Nomenclature
452
Adjustments Affecting Tooth Contact
452
Effects of Pinion Position on Tooth Pattern
452
Elimination of External Noises
452
Tooth Pattern-Pinion too Close to Ring Gear (Excessive Shim Thickness)
453
Effect on Tooth Pattern as Shim Thickness Is Decreased
453
Rear Axle Noises
453
Body Boom Noise or Vibration
454
Testing Positive Traction Differential
454
Positive Traction Flushing Procedure
454
Correcting Rear Axle Companion Flange Spline Leaks
454
Removal and Installation of Differential Assembly
455
Removal of Rear Axle Assembly
455
Installation of Rear Axle Assembly
455
Remove Axle Shaft Assemblies
455
Pinion Shaft Lock Bolt
456
Axle Shaft "C" Locks
456
Remove and Install Axle Shaft Bearing And/Or Seal
456
Removing Axle Shaft Bearing Retainer Ring
456
Pressing New Retainer Ring against Bearing
457
Remove and Install Rear Wheel Bolt
457
Axle Shaft Bearing and Seal Remover
458
Installing Axle Shaft Bearing
458
Install Axle Shaft Assembly
458
Installing Rear Wheel Bolt
458
Removal and Disassembly of Differential Case Assembly
459
Removal of Differential Case Assembly-Differential in Car
459
Disassemble Standard Differential Case Assembly
459
Disassemble Plate Type Positive Traction Differential Case Assembly
459
Removing Differential Side Bearings
460
Removing Pinion Shaft Retaining Bolt
460
Removal of Pinion and Bearings
460
Removing Preload Thrust Blocks and Springs
460
Assembly and Installation of Differential Case Assembly
461
Install Pinion Bearing Outer Races in Carrier
461
Installing Rear Pinion Bearing Outer Race
461
Set Pinion Depth
461
Installing Front Pinion Bearing Outer Race
462
Pinion Gage Tools
462
Pinion Marking All Axles
463
Installing Rear Pinion Bearing
463
Install Pinion Assembly and Adjust Pinion Preload
463
Installing Pinion Oil Seal on 8 1/2" and 8 3/4 " Axles
463
Installing Pinion Nut
464
Checking Pinion Preload
464
Assemble Standard Differential Case Assembly
464
Assemble Plate Type Positive Traction Differential Case Assembly
464
Installing Differential Side Bearings
465
Install Differential Case and Adjust Side Bearing Preload
465
Checking Side Gear to Pinion Gear Backlash
465
Compressing Preload Springs
465
Installing Differential Adjusting Shims
466
Checking Ring Gear to Pinion Backlash
466
Adjust Differential Backlash
466
Install Axle Shaft Assemblies
466
Install Pinion Oil Seal with Differential Installed in Car
467
Pinion Flange-R & R All-Series
467
Differential Installed in Car
467
Differential Specifications
467
Gear Backlash
468
Axle Shaft End Play
468
Differential Gear Ratios
468
Axle Usage Chart
469
Axle Manufacturer Identification
470
Special Tools
470
Brakes
471
Inspection and Testing Brakes
472
External Conditions that Affect Brake Performance
472
Diagnosis
472
Brake Diagnosis
476
Brake Pedal Mounting-H Series
477
Pedal Travel
477
Stop Light Switch
477
Bleeding and Flushing Brake System
477
On Car Service
477
Brake Pedal Mounting-X Series
478
Manual Bleed
478
Flushing Brake Hydraulic System
478
Brake Pipes
478
Brake Pedal Mounting-A & G Series
479
Brake Pedal Mounting-B Series
479
Bleeding Wheel Cylinder
480
Front Brake Hose
480
Rear Brake Hose
480
Front Brake Pipes-H Series
481
Center Brake Pipes-H Series
481
Rear Brake Pipes-H Series
482
Parking Brake Cables
482
Replace (Except B Series)
482
Front Cable
482
Front Brake Pipes-X Series
483
Center Brake Pipes-X Series
484
Rear Brake Pipes-X Series
484
Front Brake Pipes-A and G Series
485
Parking Brake Adjustment
485
Center Brake Pipes-A and G Series
486
Rear Brake Pipes-A and G Series
486
Front Brake Pipes-B Series
487
Center Brake Pipes-B Series
487
Rear Brake Pipes-B Series
488
Parking Brake Switch
488
Combination Valve
488
Testing Warning Light Switch Portion of Combination Valve
488
Parking Brake Lever and Equalizer-H Series
489
Combination Valve Replacement
489
Filling Brake Master Cylinder
489
Master Cylinder Overhaul
489
Parking Brake Control Assembly-X Series
490
Inspection of Brake Master Cylinder
490
Assembly of Brake Master Cylinder
490
Parking Brake Cable Assembly-A and G Series
491
Installation of Brake Master Cylinder
492
Disc Brakes
492
Caliper Removal and Installation
492
Lining Inspection
492
Parking Brake Rear Cables-X Series
493
Parking Brake Rear Cables-H Series
494
Parking Brake Control Assembly A, B and G Series
495
Caliper Installation
495
Parking Brake Cable Assembly-B Series
496
Completion
496
Distributor Switch to Master Cylinder Mounting-H Series
497
Combination Valve to Master Cylinder Mounting-X Series
497
Brake Lines-Master Cylinder to Combination Valve-A & G Series
498
Brake Lines-Master Cylinder to Combination Valve-B Series
498
Exploded View-Power Brake Master Cylinder A, B, G, F and X Series
499
Exploded View Master Cylinder H Series Manual Brakes
499
Power Brake Master Cylinder Exploded Series
500
Exploded View-Manual Brake Master Cylinder a Series
500
Secondary Piston-Exploded View
501
Master Cylinder Mounting-Typical
501
Single Piston Disc Brake
502
Lining Inspection
502
New and Worn Linings
502
Use of C Clamp
502
Removing Mounting Bolts
503
Sleeve Installation
503
Remove Sleeves
503
Caliper to Knuckle Clearance
503
Inserting Shoe Support Spring
504
Installing Mounting Bolts
504
Installing Outboard Shoe
504
Clinching Outboard Shoe
504
Caliper Removal
505
Removing Mounting Pins
505
Removing or Installing Shoes
505
Mounting Sleeve
505
Caliper Overhaul
506
Removing Piston
506
Rotor Servicing
507
Parallelism Check
507
Rotor Tolerance and Surface Finish
507
Rotor Thickness
507
Wheel Bolt Removal and Installation
508
Drum Brakes
508
Replace or Reline Brake Shoes
508
Relining Brake Shoes
508
Typical Drum Brake Assembly
509
Repair Brake Lining
509
Inspection and Reconditioning Brake Drums
509
Cracked, Scored, or Grooved Drum
509
Out-Of-Round or Tapered Drum
510
Turning Brake Drums
510
Drum Diameters
510
Wheel Cylinder Overhaul
510
Unit Repair
511
Removal and Installation of Power Brake Units
511
Disassembly of Delco Moraine Tandem Power Brake Unit
511
Disassembly of Front Housing Group
512
Unlocking Front and Rear Housings
512
Disassembly of Rear Housing Group
512
Disassembly of Power Piston Group
512
Power Piston Group
513
Tool Rework-J 23101
513
Positioning Secondary Power Piston in Tool J
513
Locking or Unlocking Primary and Secondary Power Pistons
514
Cleaning and Inspection of Delco Moraine Tandem Power Brake Unit
514
Removing Reaction Piston and Reaction Disc
514
Locking or Unlocking Primary Support Plate from Primary Power Piston
514
Inspecting Rubber Parts
515
Inspection Metal Parts
515
Reassembly of Delco Moraine Tandem Power Brake Unit
515
Reassembly of Power Piston Group
515
Seating Floating Control Valve Assembly with Installer J 23175
516
Reassembly of Rear Housing Group
517
Final Assembly
517
Gaging Delco Moraine Tandem Power Brake Unit
517
Gaging Piston Rod
517
Disassembly of Bendix Tandem Power Brake Unit
518
Disassembly of Overall Unit
518
Cleaning and Inspection Bendix Tandem Power Brake Unit
518
Power Section
518
Removing Air Valve Rod
519
Lances in Front Shell
520
Reassembly of Bendix Tandem Power Brake Unit
520
Gaging of Bendix Tandem Power Brake Unit
520
Diaphragm and Plates
521
Disassembly of Delco Moraine Power Brake Unit
521
Removing Rear Seal
522
Rear Bearing and Rear Shell
522
Disassembly of Power Brake Unit-All Except X Car
522
Installing Air Valve Plunger
522
Disassembly of Power Piston Assembly
523
Cleaning and Inspection of Delco Moraine Power
523
Brake Unit
523
Inspection and Replacement of Parts
523
Inspection Table
524
Power Brake Unit-Exploded View
525
Separating Power Brake Unit
525
Power Piston Assembly-Exploded View
526
Removing Lock Ring from Power Piston
526
Removing Reaction Retainer
526
Positioning Support Plate Retainer in Vise
527
Removing Power Piston Snap Ring
527
Positioning Power Piston on Support Plate Remover
527
Removing Support Plate
527
Assembly of Delco Moraine Power Brake Unit
528
Assembly of Front Housing
528
Assembly of Power Piston Group
528
Installing Floating Control Valve Assembly
528
Installing Power Piston into Support Plate
529
Assembly of Rear Housing Group
529
Final Assembly of Power Brake Unit-X Car
529
Gaging of Delco Moraine Power Brake Unit
529
Gaging Master Cylinder Push Rod
530
Engine Identification Codes
531
Engine Code Locations 4 Cycl.
532
Engine Code Locations V6 and V8
533
Engine Performance Diagnosis
535
Engine Mechanical
546
L-4, V6 and V8 Engines
546
General Information on Engine Service
546
Engine Mechanical Diagnosis
547
Engine Knock Diagnosis
548
2.2 Litre 140 Cu.in.engine, Vin Code-B
550
Cylinder Block
550
Cylinder Head
550
Crankshaft and Bearings
550
Oil Filter and Distributor Oiling
551
Pistons and Connecting Rods
551
Hydraulic Valve Lifters
551
Intake Manifold
551
Main Oil Circuit
552
Engine Lubrication
552
Bearing Oil Feeds
553
Engine Front Cover
553
Accessory Drive Pulley
553
Specifications
553
Timing Belt and Water Pump
554
Checking Timing Belt Tension
554
Timing Belt Adjustment
554
Camshaft Timing Sprocket
554
Tension Adapter Locating Hole
555
Adjusting Timing Belt
555
Timing Belt Cover Upper (Camshaft)
555
Lower (Crankshaft)
555
Crankshaft Timing Sprocket
556
Removing Crankshaft Sprocket
556
Oil Pump (Crankcase Front Cover) Seal
556
Oil Pan and Baffle
556
Removing Oil Pan Baffles
557
Oil Pump Screen and Pick-Up Tube
557
Oil Seal (Rear Main)
557
Installing Oil Pickup Tube and Screen
558
Cutting Bearing Cap Rope Seal
558
Applying Bearing Cap Sealant
558
Oil Pump (Crankcase Front Cover)
558
Oil Pump Pressure Regulator
559
Checking Driven Gear-To-Housing Clearance
559
Checking Drive Gear-To-Crescent Clearance
559
Checking Driven Gear-To-Crescent Clearance
559
Checking Gear End Clearance
560
Installing Oil Pump Seal
560
Oil Pump-To-Cylinder Block Installation
560
Camshaft Cover
560
Camshaft Removal Tool Installed
561
Depressing Valve Lifters
561
Replacing Camshaft Bearings
561
Camshaft Bearing Alignment
561
Bearing Replacement
562
Measuring Camshaft End Play
562
Measuring Camshaft Retainer
562
Valve Stem Oil Seal And/Or Valve Spring
562
Installing Tool J 26402
563
Seal Removal
563
Installing New Seal
563
Seating Valve Stem Seal
563
Installing Exhaust Gas Recirculating Tube
564
Exhaust Manifold
564
Exhaust Manifold Bolts
565
Cylinder Head Assembly
565
Cleaning Combustion Chamber
565
Cleaning Valve Guide
565
Measuring Valve Stem Clearance
566
Checking Valve Spring Tension
566
Valve Guide Bores
566
Valve Seats
566
Measuring Valve Seat Concentricity
567
Relation of Valve and Seat Angles
567
Measuring Valve Spring Installed Height
567
Flywheel
568
Engine Mounts
568
Checking Engine Mounts
568
Front/Rear Mount
568
Rear Mount Replacement
569
Connecting Rod and Piston Assemblies
569
Removing Connecting Rod and Piston Assembly
569
Removing Piston Pin
569
Piston Selection
570
Measuring Cylinder Bore
570
Measuring Piston Diameter
570
Piston Size Chart
570
Tool and Support Assembly
571
Installing Piston Pin
571
Piston Rings
571
Measuring Ring Gap
571
Checking Ring in Groove
572
Ring Gap Location
572
Measuring Ring Groove Clearance
572
Piston Alignment Reference
573
Connecting Rod Bearings
573
Installing Connecting Rod
573
Installing Piston Assembly
573
Gauging Plastic on Crankpin
574
Measuring Gauging Plastic
574
Measuring Connecting Rod Side Clearance
574
Main Bearings
574
Measuring Crankshaft End Play
575
Without Crankshaft Removal
575
Crankshaft
575
Oil Filter Bypass Valve
576
Repairs
576
Roughing Operation
576
Polishing Operation
576
Cylinder Case Threads
577
Engine Torques
578
Engine Specifications
579
Engine Special Tools
580
2.5 Litre 151 Cu.in. L4 Engine
581
Camshaft and Drive
582
Camshaft and Crankshaft Gears
583
Piston and Rod Assembly
583
Valve Train
583
Intake and Exhaust Manifolds
583
Combustion Chambers
584
Lubrication System
584
Oil Filter
584
Engine Lubrication (L4)
585
Front Insulators
586
Intake and Exhaust Manifold
586
Engine Insulators-L4 H Series
586
On-Car Service
586
Engine Insulators-L4 X Series
587
Rocker Arm Cover
587
Intake and Exhaust Manifolds
587
Rocker Arm, Push Rod And/Or Rocker Stud
588
Valve Springs, Shield And/Or Seals
588
Push Rod Cover or Gasket
588
Valve Lifter
588
Recondition
589
Removing Push Rod Seat Retainer
589
Removing Stuck Plunger
589
Clean and Inspect
589
Hydraulic Valve Lifters
589
Hydraulic Valve Lifter-Exploded View
590
Test Leak-Down Rate
590
Testing Leak-Down Rate
590
Cylinder Head or Gasket
590
Cylinder Head Gasket 6A2-10
590
Cylinder Head Dowell Pins
591
Head Bolt with Sealer Applied
591
Upper Valve Train Parts
591
Cleaning Valve Guide Bore (Typical)
591
Valve Guide Bore
592
Valves and Seats
592
Crank Pulley Hub And/Or Oil Seal
592
Timing Gear Cover
593
Cutting Pan Gasket
593
Applying Front Cover Sealant
593
Installing Timing Cover
593
Camshaft
593
Removing Camshaft Thrust Plate Screws
594
Removing Camshaft Timing Gear
594
Camshaft Bearings
595
Oil Pan
595
Oil Pump
595
Oil Pump-Exploded View
596
Engine Oil Pump Recondition
596
Connecting Rod Bearing Clearance
596
Rear Main Bearing Oil Seal
596
Plastic Gage on Rod Journal
597
Measuring Plastic Gage
597
Checking Connecting Rod Side Clearance
597
Removing Rear Seal Upper Half
597
Main Bearings
597
Plastic Gage on Journal
598
Main Bearing Clearance
598
Connecting Rod and Piston Assembly
598
Checking Ring Gap
599
Checking Side Clearance (Typical)
599
Piston Pin Replacement
600
Connecting Rod Identification
600
Cylinder Bores
600
Honing or Boring
600
Normal Cylinder Wear Pattern
601
Measuring Cylinder Gage
601
Piston Sizing Points
601
Fit and Replace
601
Measuring Piston
602
Guide Tool Installed
602
Installing Piston
602
Crankshaft with Bearings and Seal
603
Bolt Torque
604
Connecting Rods
604
Pistons and Cylinders
604
Valve Timing (in Crankshaft Degrees)
604
Lubricaton System
605
Special Tools (L4)
606
3.8 Litre 231 Cubic Inch Engine-V.I. Code C
607
Engine Construction
607
Engine Crankshaft and Bearings
607
Hydraulic Valve Lifter
608
Schematic Diagram of Engine Oil Flow
608
Oil Pump and Filter Assembly
609
Front End Lubrication
609
Overhead Lubrication
609
Engine Intake Manifold or Gasket
610
Rocker Arm Assembly
610
Removing Nylon Retainer
611
Service Rocker Arms
611
Position on Service Rocker Arms on Shaft
611
Left Cylinder Head Removal
611
Cylinder Head Installation
612
Cylinder Head Bolt Tightening Sequence 231 Engine
612
Reconditioning Valves and Guides
612
Removing Valve Cap Retainers
612
Reaming Valve Guide
613
Oversize Valve Identification
613
Timing Chain Cover
613
Timing Chain Cover Removal and Installation
614
Locking Flywheel to Torque Harmonic
614
Front Crankshaft Oil Seal Replacement
614
Timing Chain and Sprocket
614
Installation of Timing Chain and Sprocket
615
Camshaft Bearing
615
Bearing Removal
615
Oil Slinger Installation
615
Removing and Installing Camshaft Bearings
616
Camshaft Bearing Service
616
Bearing Installation
616
Oil Pump Pipe and Screen Assembly
616
Testing Oil Pressure
617
Priming the Oil Pump with Tool J 25087
617
Oil Pump and Relief Valve Cleaning
617
Oil Pump Cover and Gears
617
Oil Pump Cover and Pressure-Relief Valve
618
Checking Oil Pump End Clearance
618
Measuring Oil Pump Side Clearance
618
Measuring Gears for Wear
618
Measuring Gear Pocket for Wear
619
Inspection of Connecting Rod Bearings and Crankpin Journals
619
Checking Clearance and Selecting Replacement Bearings
619
Checking Bearing Clearance with Plastic-Type Gage
619
Location of Undersize Mark on Bearing Shel
620
Crankshaft Bearings and Seals
620
Replacement of Crankshaft Bearings
620
Removal and Installation of Crankshaft Bearing Upper Shell
621
Installation of Rear Bearing Oil Seals
621
Installing Rear Bearing Oil Seals
621
Rear Main Bearing Upper Oil Seal Repair
621
Sealer Applied to Split Line
622
Packing Seal into Cylinder Block
622
Packing Short Pieces of Rope Seal into Guide Tool and Cylinder Block
622
Pistons, Rings, and Connecting Rods
623
Piston and Rod Assemblies
623
Connecting Rod Bolt Guides Installed
623
Reboring Cylinder and Fitting New Pistons
624
Fitting New Piston Rings
625
Correctly Fitted New Piston
626
Assembly and Installation of Piston and Connecting Rod Assemblies
626
Left Bank Piston and Rod Assembly
626
Right Bank Piston and Rod Assembly
626
Piston Ring Gap Positioning
627
Installing Piston with Ring Compressor Installed
628
Engine Removal and Installation
628
Automatic Transmission Flywheel
628
Flywheel or Ring Gear on Manual Transmission Engine
629
Automatic Transmission Flywheel Balance
629
Manual Transmission Flywheel Balance
629
Harmonic Balancer
629
Harmonic Balancer-Balance Weight Details
630
Bolt Torque Specifications
630
Lubrication System Specifications
631
Engine Dimensions and Fits
631
Crankshaft Specifications
631
Valve System Specifications
631
5.7 Litre 350 CU.IN. and 6.6 Litre 403 CU.IN. Engines
633
350 (VIN R) and 403 (VIN K) Engines (Exploded View)
634
Cylinder Numbers
634
Engine Lubrication System
634
Oil Filter Base
635
Engine Oil Dipstick and Dipstick Guides
636
Front Engine Mounts (Typical)
637
Rear Engine Mounts (Typical)
637
L.H. and R.H. Exhaust Manifold
638
R.H. and L.H. Exhaust Manifold
638
Valve Cover
638
Rocker Arm Assemblies
638
Intake Manifold Installation
639
Intake Manifold Torque Sequence
640
Replacing Valve Spring (Head on Engine)
640
Checking Rotators
640
Valve Lifters
640
Removing Hot Air Shrouds
641
Applying Sealer on Valve Cover
641
Valve Rotation Pattern
642
Removing Valve Springs
642
Valve Lifter (Cutaway View)
642
Removing Valve Lifter
642
Installing Ball Check Valve
643
Valve Lifter Testing
643
Cylinder Head and Gasket
643
Valves and Spring with Head Removed
643
Cylinder Head-Exploded View
644
Valve Location
644
Valve Seal Identification
644
Reconditioning Valves
644
Cylinder Head Gasket
645
Cylinder Head Torque Sequence
645
Measuring Valve Stem Height
645
Measuring Rotor Height
646
Reaming Procedure
646
Crankshaft Pulley
646
Balancer
646
Removing Balancer
647
Front Cover
647
CID Harmonic Balancer
647
Installing Balancer
647
Dowel Pin with Chamfer
648
Rework Pan Seal
648
Oil Seal
648
Timing Chain and Gears (with Front Cover Removed)
648
Engine Front Cover Bolts
649
Crankshaft Gear Removal
649
Сhecking Valve Timing Without Removing Front Cover
649
Aligning Timing Marks
650
Fuel Pump Eccentric
650
Сamshaft
650
Checking Valve Timing
651
Camshaft Identification
651
Сamshaft Bearings
651
Installing Rear Cam Bearing
651
Checking No. 5 Oil Hole
652
Installing No. 1 Cam Bearing
652
Camshaft and Oil Galley Plugs
652
Engine Support Tool (Typical)
653
Oil Pan Assembly
653
Oil Pump Exploded View
653
Oil Pump Drive Shaft Extension
653
Oil Pump Installation
654
Rod Bearings
654
Connecting Rod Bolt Guide
654
Bearing Tang and Notch
655
Bearing Identification
655
Checking Bearing Clearances
655
Main Bearing Replacement
655
Main Bearing Identification
656
Installing Rear Main Oil Seal
656
Rear Main Bearing Upper Oil Seal
656
Repair
656
Packing Oil Seal
657
Rear Main Lower Oil Seal
657
Rod Assembly
657
Piston Identification
657
Cylinder Bore Marking
658
Checking Cylinder Bore
658
Checking Piston Clearance
658
Cleaning Piston
658
Piston Rings
658
Side Clearance
659
Allowable Side Clearance
659
Ring Identification and Installation
659
Rod and Piston Assembly
659
Connecting Rod Guide Bolt
660
Piston Ring Compressor
660
Connecting Rod Side Clearance
660
Piston Pins
660
Piston Pin Removal and Piston Pin Replace
661
Engine Assembly
661
Engine Lift Fixture
662
Removal (Cylinder Heads On)
662
Crankshaft Removal
662
Removal (Cylinder Heads Removed)
662
Crankshaft Exploded View
663
Installing Rear Main Oil Seal Upper Half
663
Aligning Center Main Bearing Flang
663
Timing Chain
665
Engine Specifications
665
Piston
667
Camshaft
667
Valve-Intake
668
Valve-Exhaust
668
Valve Springs
668
Crankshaft Sprocket
668
5 Litre 301, 5.7 Litre 350, 6.6 Litre 400 V8 Engines
670
Special Tools
670
General Description
670
Cylinder Block
670
V8 Side View-Typical
671
Cylinder Block 301
671
Cylinder Block 350-400
671
Cylinder Head
671
Cylinder Head-Typical
672
Connecting Rod and Piston Assembly Typical
672
Fuel Distribution System
672
Intake Manifold 350-400
673
Engine Lubrication-Typical
673
Engine Mountings
673
Front Mountings
673
Engine Mountings-Typical
674
Rear Mount
674
Right Side Exhaust Manifold or Gasket
674
Left Side Exhaust Manifold or Gasket
674
Engine Lifting Tools Installed-Typical
675
Intake Manifold or Gasket
675
Intake Manifold Gasket and Retainers 301
675
Rocker Arm Cover or Gasket
676
Valve Springs, Shield or Seal
676
Installing Valve Stem Seal
676
Rocker Arm Studs
676
Hydraulic Valve Lifter - Exploded View
678
Cylinder Head Bolt with Sealer Applied
679
Head Bolt Torque Sequence
679
Cylinder Head and Valves Recondition
679
Cleaning Valve Guide Bore-Typical
680
Reaming Valve Guide Bore-Typical
680
Harmonic Balancer or Pulley Hub
681
Timing Chain Cover Seal
681
Timing Chain Cover, Gasket or Fuel Pump Eccentric
681
Fuel Pump Drive
682
Timing Chain and Sprockets
682
Timing Marks Aligned at No. 1 T.D.C.
682
Camshaft And/Or Camshaft Bearing
682
Positioning Index Collar-Typical
683
Removing Camshaft Bearing-Typical
683
Installing Camshaft Bearing
684
Oil Pan And/Or Oil Pan Gasket
684
Front Oil Pan and Gasket
685
Rear Oil Pan Gasket Installation
685
Oil Pump and Oil Pump Drive Shaft
686
Engine Oil Pump
686
Measuring Plastic Gage (Rod Bearings)-Typical
687
Measuring Plastic Gage (Main Bearings)-Typical
687
Upper Rear Main Bearing Seal Tool
687
Forming New Seal in Cap-Typical
688
Connecting Rod with Hose Protectors
688
Installing Piston Assembly-Typical
688
Connecting Rod and Piston
688
Rod Identification
689
Removing Piston Pin-Typical
689
Piston Pin Replacement (Typical)
689
Measuring Cylinder Bore-Typical
690
Measuring Cylinder Bore Gage
690
Measuring Piston-Typical
691
Checking Ring Gap-Typical
691
Checking Side Clearance-Typical
692
Torque Chart
693
5 Litre 305 CU. in and 5.7 Litre 350 CU. in Engine
697
General Description
698
Front Mount Replacement
699
Service Procedures
699
Engine Mounts
699
Intake Manifold
699
Intake Manifold Gasket and Seal Location
701
Manifold Bolt Torque Sequence
701
Choke Stove Installation
701
Exhaust Manifold
701
Rocker Arm Cover
701
Valve Mechanism
702
Valve Adjustment (Typical)
702
Valve Lifters
702
Compressing Valve Spring (Typical)
703
Removing Ball Check Valve Retainer
703
Assembling Hydraulic Lifter
704
Cylinder Head
704
Compressing Valve Spring
705
Cleaning Combustion Chambers
705
Cleaning Valve Guides
705
Measuring Valve Stem Clearance (Typical)
705
Valve Spring Installation
706
Cutaway Scale
706
Measuring Valve Spring Installed Height (Typical)
706
Cylinder Head Bolt Torque Sequence
707
Removing Rocker Arm Stud
707
Reaming Rocker Arm Stud Bore
707
Installing Rocker Arm Stud
707
Valve Guide Bores
707
Valve Seats
707
Removing Torsional Damper
708
Installing Torsional Damper
708
Valves
708
Crankcase Front Cover
709
Oil Seal (Front Cover)
709
Replacement with Cover Installed
709
Measuring Lobe Lift
709
Removing Camshaft
710
Checking Camshaft Alignment
710
Timing Sprocket Alignment Marks
711
Installing Timing Chain
711
Camshaft Bearing Removal
711
Replacing Camshaft Front Bearing
712
Installing Oil Pan
712
Oil Pump 6A6
712
Installing Screen
713
Connecting Rod Bearings
713
Gaging Plastic on Crankpin
714
Measuring Gaging Plastic
714
Main Bearings
714
Checking Clearance
715
Gaging Plastic on Journal
715
Oil Seal Installation Tool
716
Removing Oil Seal (Lower Half)
716
Oil Seal (Rear Main)
716
Removing Oil Seal (Upper Half)
717
Crankshaft Oil Seal (Rear Main)
717
Sealing Bearing Cap
717
Removing Connecting Rod and Piston Assemblies
718
Disassembling Connecting Rod and Piston Assemblies
718
Piston Pins
718
Assembling Connecting Rod and Piston Assemblies
719
Piston Rings
719
Connecting Rods-Installed Position
722
Installing Connecting Rod and Piston Assemblies
722
Sealing Bearing Cap and Block
723
Sprocket or Gear Replacement
723
Engine Cooling
727
Radiator Cap
727
Cross-Flow Radiator
728
Reservoir
729
Pressure-Type Radiator Cap
729
Cross Section of Water Pump Typical V6-V8
729
Cross Section of Water Pump (L-4 Typical)
730
Power Flex Fan
730
Thermostatically Controlled Fluid Clutch Fan
730
Engine Fans (Typical)
730
Fluid Clutch Fan Assembly
731
Pellet-Type Thermostat
731
Cooling System Circulation
731
Fan Clutch Diagnostic Procedure
732
Cooling System Diagnosis Chart
733
Thermostat Diagnosis Chart
736
Cooling System
736
Checking and Filling
736
Cooling System Care
736
Testing Coolant
737
Refractometer Test
737
Cleaning Refractometer
737
Procedure for Collecting Coolant Sample
737
Reading Refractometer
738
Thermostat
738
Water Pump
738
Water Pump Overhaul
739
Radiator
739
Coolant Reservoir
739
Radiator Mountings-B Series Typical
740
Radiator Mountings-G and a Series Typical
740
Radiator Mountings-F Series Typical
741
Radiator Mountings-X Series Typical
741
Radiator Mountings-H Series Typical
742
Radiator Mountings-HM Series Typical
742
Coolant Reservoir Tank Mounting-B Series Typical
743
Coolant Reservoir Tank Mounting-G and a Series Typical
743
Coolant Reservoir Tank Mounting-F Series Typical
744
Belt and Pulley Diagrams-350 & 403 Engine
744
Belt and Pulley Diagrams-305 Engine
745
Belt and Pulley Diagrams-301-350-400 Engines
746
Belt and Pulley Diagrams-231 Engine
747
Belt and Pulley Diagrams-151 L4 Engine
747
Radiator Usage
748
Cooling System Capacity
750
Fuel System
751
Fuel Filter
751
Mechanical Fuel Pump
751
Fuel Tank and Lines
751
Fuel Cap
752
Evaporative Emission Control System (EEC)
752
Model 52'1 0-C Carburetor
758
Fuel Inlet and Float System
758
Main Metering System
759
Accelerating System
759
Electric Choke L4-151 Engine
759
Secondary Power Enrichment System
759
Bowl Vent
760
Vacuum Break
760
Vacuum Break Delay L4-151 Engine
760
Secondary Vacuum Break L4-140 California and High Altitude
760
Electric Choke Assembly
761
Vacuum Break Delay
761
Idle Speed Adjustment-L4-140 and 151 Engines
761
Carburetor Adjustments
762
Carburetor Replacement
762
Adjustment Procedures
763
Solenoid or Solenoid/Dashpot
766
Unit Overhaul
766
Choke Secondary Vacuum Break
767
Float and Power Valve Economizer
767
Bown Vent
767
Choke Housing
767
Choke Water and Thermostat Housing
768
Choke Bi-Metal Coil Removal
768
Choke Housing-Assembled View
768
Throttle Lever, Solenoid or Dashpot, and Hot Idle Compensator
768
Choke Housing-Disassembled
769
Accelerator Pump
769
Carburetor Body
770
Throttle Lever, Solenoid and Hot Idel Compensator
771
Model 2GC-2GE Carburetor
771
2GE Carburetor
772
2GC Carburetor
772
Carburetor Identification
773
Float System (Typical)
773
Electric Choke
773
Idle System 2GE
773
Idle System 2GC Except California
774
Choke Check Procedure
774
Idle Speed Adjustment
774
Idle System 2GC California
775
Main Metering System 2GC
776
Power System 2GE
776
Power System 2GC, 2GE
777
Pump System 2GC, 2GE
777
Fuel Filter Replacement
777
Idle Stop Solenoid Assembly (if Used)
777
Choke System 2GC
778
Electric Choke Assembly 2GE
779
Float Bowl
779
Throttle Body
779
2GC-2GE Adjustment Procedures
780
Flooding
780
Removing Intermediate Choke Rod (Typical)
784
Hesitation
784
Hard Starting-Poor Cold Operation
784
Power Piston
784
Poor Performance-Poor Gas Mileage
785
Rough Idle
785
Carburetor Assembly
785
Air Horn
786
Completion of Carburetor Assembly
786
Model M2MC 200 Carburetor
787
Identification
787
Float System
788
Idle System
788
Carburetor Choke and Hoses
788
Pump System
788
Choke Fresh Air Modulator
789
Secondary Vacuum Break Thermal Vacuum Switch-SVEB-TVS
789
Procedure for Using Carburetor Choke Valve Angle Measuring Gage
789
Choke Valve Angle Gage
790
Functional Check
790
M2MC 200 Adjustment Procedures
791
Solenoid Replacement
793
M2MC 200 Carburetor Removal
794
Air Horn-Removal, Disassembly
794
Choke Lever and Rod
794
Pump Lever Pivot Pin Removal
795
Float Bowl-Disassembly
795
Choke Disassembly
795
Removing Inlet Needle Seat
796
Rear Vacuum Break
796
Throttle Body Attaching Screws
796
Choke Housing to Float Bowl
797
Choke Housing Installation
798
Float Level Adjustment
798
Float Needle Pull Clip Location
798
Air Horn Screw Tightening Sequence
799
Pump Lever Pivot Pin
799
Model M4MC Carburetor
800
M4MC Carb 350 X Series VI Code L
801
M4MC Carburetor Identification
802
M4MC Float System
802
M4MC Idle System Exc. X Series VI Code L
802
Idle Mixture
802
Idle System M4MC X Series VI Code L
803
M4MC Main Metering System
803
M4MC Power System
803
M4MC Pump System
804
M4MC Choke System Exc. X Series VI Code
804
Choke System M4MC X Series VI Code L
804
M4MC Adjustment Procedures
805
Solenoid Removal (if Equipped)
809
Removing Upper Choke Lever
810
Removing Secondary Metering Rods
810
Removing Pump Lever
810
Air Horn Screws
810
Removing Air Horn
811
Removing Front Vacuum Break
811
Float Bowl Disassembly
811
Power Piston and Metering Rods
811
Removing Needle Seat
812
Remove Pump Discharge Retainer and
812
Throttle Body Disassembly
813
Throttle Body Gasket
813
Choke Lever and Housing
814
Pull Clip Location
815
Air Horn Assembly
815
Air Horn to Bowl Installation
815
Air Horn Tightening Sequence
815
Installing Pump Lever
816
Fuel Supply
816
Fuel Pump-Electric
816
Fuel Pump-Mechanical
817
Fuel Pump Inspection and Test
817
Fuel Pump Pressure Test
817
Fuel Pump Flow Test
817
Removal and Installation of Electric Fuel Pump
818
Removal and Installation of Mechanical Fuel Pump
818
Removal and Installation of Fuel Tank or Fuel Gage Tank Unit
818
"A" Series Wagons
818
Fuel Line Repair
819
Cleaning Fuel System-All Series
819
Fuel Tank Filler Cap
819
Accelerator Controls
819
Accelerator Controls B Series
820
Accelerator Controls a and G Series
820
Accelerator Controls F Series
820
Accelerator Controls X Series
820
Accelerator Control Cable 301 Engine VI Code y
821
Accelerator Control Cable 350 Engine VI Code L
821
Accelerator Control Cable 305 Engine VI Code U
821
Accelerator Control Cable 350-400 Engine VI Codes P and Z
822
Accelerator Control Cable 231 Engine VI Code C
822
Accelerator Control Cable 151 Engine VI Code V
822
Accelerator Control Cable 350-403 Engines VI Codes R and K
822
Idle Mixture Specifications
823
Engine Electrical
825
Diagnostic Connector Location
825
Electrical System Diagnosis
829
Conventional Battery
831
Construction
831
Sealed Battery
831
Operation
831
Common Causes of Failure
832
Electrolyte Freezing
832
Carrier and Hold-Down
832
Ratings
832
Test Indicator
833
Visual Inspection
833
Check Charge of Battery
833
Load Test Battery
833
Side Terminal Battery Adapters
834
Load Test Values
834
Charging Procedures
834
Jump Starting in Case of Emergency with Auxiliary (Booster) Battery
834
Battery Charging Rates
835
Negative Jumper Cable Connection
835
Remove and Replace Battery
836
Charging System
837
Noisy Generator
837
10-SI Generator
837
27-SI Generator
838
Regulator in Charging Circuit
838
Faulty Indicator Lamp Operation
838
Undercharged Battery
838
Charging System Diagnosis
839
Charging Circuit-SI System
840
Generator Test Hole
841
Overcharged Battery
841
Generator Mounting: H Series with 151, A/C and Power Steering
841
H and X Series with 151, A/C and Standard Steering
841
H and X Series with 15 1 and no A/C
842
All Series with V6, no A/C
842
All Series with V6, A/C
842
A, F and G Series with "R" and "K" V8'S
842
B and X Series with "R" and "K" V8'S. no A/C
843
Rotor Field Winding Checks
843
Diode Trio Check
843
Rectifier Bridge Check
843
A, B, F and G Series with "P" and "Z" V8'S, Except 80 AMP Generator
844
Series with "R" and "K" V8', 80 AMP Generator
844
Stator Checks
844
Brush Holder and Regulator Replacement
844
X Series with "U" and "L" V8'S
845
H Series with 140 L-4, Standard Steering
845
H Series with 140 L-4, Power Steering
845
Slip Ring Servicing
846
Bearing Replacement and Lubrication
846
Checking Rotor
846
Slip Ring End Frame Assembly
846
Checking Diode Trio
847
Checking Rectifier Bridge
847
Checking Stator
847
Voltage Regulator Tester CTW-1170
847
Drive End Frame Bearing Assembly
848
Reassembly
848
Ignition System
849
H.E.I. Distributor Assembly
849
Ignition Timing
849
H.E.I. Distributor-Exploded View
850
Secondary Wiring
850
Spark Plugs
850
Magnetic Timing Probe Hole
850
Spark Plug-Tapered Seat
851
Vacuum Advance Systems
851
L4-140 Engine
851
Ignition Switch
852
L4-151 Engine
853
V8-350 and 4 0 0 Engine, VIN Code P & Z
853
California Certified Vehicles
853
High Altitude Certified Vehicles
853
Distributor Spark Thermal Vacuum Switches
854
H.E.I. Diagnosis
855
Checking Internal Coil
856
Checking External Coil
856
Checking Pick-Up Coil
856
Distributor Base and Components
856
Remove and Replace
857
Module
857
Pick-Up Coil
857
Vacuum Advance Unit
857
Integral Ignition Coil
858
Distributor Spark Switches
858
All L4-140 Engines
858
V6-231 Engine Except California
858
California V6-231 Engine with Automatic Transmission
859
California V6-231 Engine with Manual Transmission
859
V8-301 Engine with Automatic Transmission and Air Conditioning
859
V8-400 Engine with Manual Transmission and High Altitude V8-350 & 403
859
V8-350 & 4 0 0 Engines, VIN Codes P & 2, with Automatic Transmission
860
Low Altitude V8-350 & 403 Engines, VIN Codes R & K
860
California V8-350 & 403 Engines, VIN Codes R & K
860
Off-Car Check of Thermal Vacuum Switches
861
Spark Plug Wire Routing-140 L-4
861
Spark Plug Wire Routing
862
Fig. 6D-44 Spark Plug Wire Routing-VIN Code "U" and "L" V8'S
863
Cranking System
864
Cranking Circuit
864
Starting Motor
864
Cross Section of Starting Motor
865
No-Load Test Hook-Up
865
No Load Test Values
866
Starter
866
Solenoid
867
Overhaul
867
Removing Retainer from Snap Ring
867
Component Inspection
867
Overrunning Clutch
868
Starter Motor Circuits
868
Testing Field Coils for Ground
869
Testing Field Coils for Open
869
Connections for Checking Solenoid
869
Forcing Snap Ring over Shaft
870
Forcing Retainer over Snap Ring
870
Circuit for Checking Pinion Clearance
870
Checking Pinion Clearance
870
Battery Applications and Specifications
871
Generator Applications
872
Starter Motor Applications and Specifications
872
Emission Control Systems
873
Carburetor Calibration
873
Distributor Calibration
873
Catalytic Converter
873
Engine Specifications
873
Early Fuel Evaporation System (EFE)
874
Exhaust Gas Recirculation System (EGR)
874
Thermostatic Air Cleaner (TAC)
874
Air Injection Reaction Systems
874
E.F.E. Systems
875
PCV System Flow
875
PCV Valve Cutaway View
875
Pulse Air Injection Reaction-Pair
875
Thermostatic Air Cleaner
876
Pulse Air Injection Reaction Systems
876
Vacuum Controls
876
Vacuum Hose Schematics
876
C.I.D. Nationwide
877
C.I.D. California Automatic Transmission Without Air Conditioning
877
6E-8 C.I.D. California Automatic Transmission with Air Conditioning
878
6E-9 C.I.D. Low Altitude Manual Transmission
878
C.I.D. Low Altitude Automatic Transmission with Air Conditioning
879
C.I.D. Low Altitude
879
C.I.D. High Altitude
880
C.I.D. California Manual Transmission
880
C.I.D. California Automatic Transmission
881
C.I.D. Low Altitude Automatic Transmission Without Air Conditioning
882
V8-350 and 400 C.I.D., VIN Codes P and Z
883
V8-400 C.I.D. Low Altitude Manual Transmission
883
V8-350 and 403 C.I.D., VIN Codes R and K, Low Altitude
884
V8-350 and 403 C.I.D. VIN Codes R and K, High Altitude
884
V8-350 and 403 C.I.D., VIN Codes R and K, California
885
Early Fuel Evaporation Systems
886
Valve Controlled EFE
886
Exhaust Gas Recirculation Systems
886
System Functional Test
886
Functional Test of Individual EGR System Component Parts
887
Port Type EGR Valve
887
EGR System-Inspection and Cleaning
888
Positive Crankcase Ventilation System
888
Vacuum Motor Check
888
Sensor Check (Quick Check of System)
888
EGR Port Locations-Typical
889
Snorkel Passage Open and Closed
889
Thermometer Check of Sensor
889
Vacuum Motor
889
Removing TAC Vacuum Motor
890
Sensor
890
T.A.C. System-140 and 151 Engines
890
Pulse Air System Service
890
A.I.R. System Service
891
Drive Belt
891
A.I.R. Belt Tensioning
891
Pump Filter
891
A.I.R. Hoses and Tubes
892
Check Valve
892
Diverter Valve and Silencer Assembly
892
A.I.R. Pump
892
Exhaust System
896
Resonator
896
Hanger
896
Clamp
896
Installation of Exhaust System Clamp
897
Catalyst
897
Installation of Aspirator
897
Threaded Fill Plug Removal
897
Deform & Remove Pressed Plug
898
Vibrator and Catalyst Container
898
Fill Tube Extension
898
Service Fill Plug
899
Bottom Cover
899
Bridge Positioning
899
Torque Fill Plug
899
Bottom Cover Removal
900
Bottom Cover Replacement
900
Retaining Channel Installation
900
Replacement Bottom Cover Installed
900
Еurbo Hydra-Matic (200)
901
Cut Away View-THM 200 Transmission
903
Diagnosis, Maintenance and Adjustments
904
Sequence for Diagnosis
904
Checking and Adding Fluid
904
Fluid Drain Intervals
904
Changing Fluid
905
Adding Fluid to Fill Dry Transmission and Converter
905
Fluid Level and Capacity
905
Possible Points of Oil Leak
906
Converter Stator Operation Diagnosis
906
Stator Assembly Remains Locked up
906
Installing Tool J 21369
907
Installing Tool J 25020
907
Installing Tool J 21371-3
907
Oil Pressure Checks
907
Torque Convener Diagnosis Chart
908
Retaining Converter with Tool J 21366
909
Oil Pressure Chart
910
Oil Flow Chart
911
Hydra-Matic (200) Diagnosis Chart
912
Transmission Problems and Related Causes
912
Clutch Plate Diagnosis
922
Causes of Burned Clutch Plates
922
Engine Coolant in Transmission
923
Governor
923
Intermediate Servo Assembly
923
Pressure Regulator Valve
923
Control Valve Assembly
924
Rear Housing Oil Seal
924
Oil Cooler Pipes
924
T.V. Cable
924
Speedometer Driven Gear
925
Checking Transmission Mount
925
Console Shift Controls
925
T.V. Cable Routing-L-4 Shown
926
General Service Precautions
926
Parts Cleaning and Inspection
926
T.V. Cable Routing at Engine-V8 Shown
927
T.V. Cable Routing at Transmission-V8 Shown
927
Manual Linkage
927
Column Shift Controls-"B" Series Shown
928
Column Shift Controls-"H" Series Shown
929
Console Shift Controls-"X" Series Shown
930
Transmission
930
Transmission Disassembly
931
Teflon Seals
931
Snap Rings
931
Thrust Washer Surfaces
931
Teflon Oil Seal Rings
932
External Parts
932
Removing Oil Screen
932
Removing Throttle Lever and Bracket
932
Removing Control Valve Assembly from Case
933
Removing 1-2 Accumulator Spring
933
Removing Governor Cover Retaining Ring
933
Removing Intermediate Servo Retaining Ring
933
Removing Servo Cover and Seal
934
Removing Intermediate Servo
934
Direct Clutch Accumulator Port
934
Intermediate Band Apply Pin Tools
934
Checking for Proper Intermediate Band Apply Pin
935
Intermediate Band Apply Pin Selector Chart
935
Front Unit Parts
935
Installing Tools on Rear End of Case
935
Front Unit End Play Washer Thickness Chart
936
Removing Pump Assembly
936
Front Gear Parts
936
Removing Intermediate Band Assembly
937
Removing Intermediate Band Anchor Pin
937
Location of Front Selective Washer
937
Checking Rear Unit End Play
937
Rear Unit End Play Washer Thickness Chart
938
Removing Output Shaft to Selective Washer Snap Ring
938
Removing Front Carrier and Roller Bearing Assembly
938
Removing Thrust Bearing Assembly and Front Sun Gear
938
Removing Input Drum and Rear Sun Gear
939
Rear Gear Parts
939
Removing Low and Reverse Housing to Case Snap Ring
939
Removing Low and Reverse Clutch Housing
939
Removing Rear Unit Parts
940
Removing Thrust Washer
940
Removing Rear Oil Seal
940
Manual Shaft and Parking Pawl Parts
940
Manual Shaft and Parking Shaft Parts
941
Removing Manual Shaft
941
Inspection of Case Assembly
941
Removing Manual Shaft from Case
941
Removing Parking Brake Bracket Bolt
942
Removing Parking Brake Pawl Shaft Pin
942
Removing Parking Brake Pawl Shaft from Case
942
Oil Passages-Bottom of Case
942
Oil Passages-Front of Case
943
Installing Rear Oil Seal
943
Manual Shaft and Parking Pawl
943
Output Shaft
943
Installing Manual Shaft Seal into Case
944
Installing Parking Brake Pawl
944
Installing Parking Brake Actuator Assembly
945
Installing Manual Shaft into Case
945
Roller Clutch and Rear Carrier Assembly
945
Installing Rear Internal Gear
945
Roller Clutch and Rear Carrier View
946
Checking Rear Carrier Pinion End Play
946
Installing Thrust Washer into Rear Carrier
946
Installing Roller Clutch into Rear Carrier
946
Installing Roller Clutch Race
947
Installing Thrust Washer
947
Installing Rear Unit Parts
947
Low and Reverse Clutch Housing Assembly
947
Low and Reverse Clutch Housing-Exploded View
948
Removing Low and Reverse Clutch Spring Retaining Snap Ring
948
Removing Wave Release Spring
948
Removing or Installing Clutch Outer/Inner Seal
948
Installing Low and Reverse Clutch Piston
949
Installing Wave Release Spring
949
Installing Clutch Retaining Snap Ring
949
Checking for Correct Selective Spacer
949
Low and Reverse Clutch Selective Spacer Chart
950
Installing Selective Spacer
950
Rear Sun Gear and Input Drum
950
Front Sun Gear
950
Clutch Plate and Apply Ring Usage Chart
951
Installing Case Spacer Ring
951
Installing Low and Reverse Clutch Housing
951
Front Internal Gear and Thrust Washer
951
Installing Input Drum and Rear Sun Gear
952
Front Sun Gear Identification
952
Installing Front Sun Gear
952
Installing Thrust Bearing and Race Assembly
952
Checking Pinion End Play
953
Installing Thrust Bearing Assembly
953
Check Rear Unit End Play
953
Installing Output Shaft to Selective Washer Snap Ring
953
Direct Clutch Housing Assembly
954
Direct Clutch Assembly-Exploded View
955
Removing Direct Clutch Housing Snap Ring
955
Removing Direct Clutch Inner Snap Ring
955
Removing or Installing Direct Clutch Piston Outer Seal
955
Removing and Installing Direct-Clutch Piston Inner Seal
956
Direct Clutch Housing Center Seal
956
Installing Direct Clutch Piston
956
Forward Clutch Housing Assembly
956
Piston Installing Tool
957
Installing Spring Guide to Direct Clutch Piston
957
Installing Direct Clutch Retainer Snap Ring
957
Installing Direct Clutch Plates into Direct Clutch Housing
958
Installing Direct Clutch Housing Outer Snap Ring
958
Forward and Direct Clutch
958
Pump Assembly
958
Forward Clutch Assembly-Exploded View
959
Removing Forward Clutch to Direct Clutch Thrust Washer
959
Pressure Regulator
959
Removing Forward Clutch Release Spring Snap Ring
959
Removing or Installing Piston Inner Seal
960
Forward Clutch Housing
960
Installing Forward Clutch Piston
960
Install Forward Clutch Housing Outer Snap Ring
960
Installing Forward Clutch to Direct Clutch Thrust Washer
961
Properly Seated Forward Clutch Within Direct Clutch Housing
961
Pump Body
961
J 25021 Installed on Direct and Forward
961
Installing Intermediate Band
962
Pump Assembly-Exploded View
962
Removing Pressure Regulator Valve Retaining Ring
962
Removing Pump Drive Gear
962
Pump Driven Gear Identification
963
Pump Body Face
963
Pump Cover
963
Installing Pump Body Oil Seal
963
Pump Cover Face
964
Pump Cover Oil Passages
964
Aligning Pump Cover to Pump Body
964
Installing Pressure Regulator Valve Retaining Ring
964
Installing Thrust Washer on Pump
965
Guide Pins Installed Thru Pump to Case
965
Check Front Unit End Play
965
Output Shaft Support and Sleeve Tools
966
Governor Assembly
966
Installing Governor and Cover Assembly
967
Intermediate Band Anchor Pin
967
Installing Intermediate Band Anchor Pin
967
Intermediate Servo Piston Assembly
967
Intermediate Servo Piston-Exploded View
968
Intermediate Servo Cover and Piston Usage Chart
968
Intermediate Band Apply Pin Chart
969
Compressing Intermediate Servo Piston
969
Installing Intermediate Servo Piston into Cover
970
Installing Servo Assembly into Case
970
Installing Cup Plug and Seal into Case
970
Control Valve Assembly-Exploded View
971
Compressing Shift T.V.spring
972
Removing Shift T.V. Bore Plug
972
Removing Inner Coiled Pin
972
Installing 1-2 Throttle Valve Bushing
973
Installing 2-3 Throttle Valve Bushing
973
Installing 1-2 Accumulator Spring in Case
974
Bushing Service
974
Pump Cover Bushing
974
Front Bushing
974
Valve Body Spacer Plate
975
Installing 5Th Check Ball in Case
975
Rear Bushing
975
Lo and Reverse Clutch Housing Bushing
975
Control Valve Assembly-Case Face
976
Control Valve Spacer Plate to Case Gasket
976
Case Bushing
976
Installing Control Valve Assembly Using Guide Pins
976
Installing Manual Detent Roller and Spring Assembly
977
Install Throttle Lever and Bracket Assembly
977
Throttle Lever and Bracket Assembly
977
Installing Oil Screen
977
Removing Pump Cover Bushing-Rear
978
Installing Pump Cover Bushing-Rear
978
Removing Pump Body Bushing
979
Removing Direct Clutch Housing Bushing-Front and Rear
979
Installing Pump Body Bushing
979
Installing Direct Clutch Housing Bushing-Front and Rear
979
Installing Rear Sun Gear Bushing
980
Installing lo and Reverse Clutch Housing Bushing
980
Installing Front Internal Gear Bushing
980
Removing Rear Sun Gear Bushing
980
Removing Rear Carrier Bushing
981
Installing Rear Carrier Bushing
981
Removing or Installing Case Bushing
981
Transmission Identification
981
Turbo Hydra-Matic 250 Transmission
984
Turbo Hydra-Matic 250 Transmission-Sectional View
985
Fluid Checking Procedures
985
Fluid Leak Diagnosis
985
Determining Source of Fluid Leak
985
Possible Points of Fluid Leak
986
Fluid Pressure Check
986
Pressure Tap Location
986
Vacuum Modulator Diagnosis
986
Transmission Clutch Plates Diagnosis
987
Causes of Burned Clutch Plates or Burned Band
987
Spring Comparison Gage
987
Governor Pressure Check
987
Road Test
988
No Drive in Drive Range
988
High Line Pressure
988
Low Line Pressure
988
Diagnosis Chart
989
First Speed Only-No 1-2 Shift
990
First and Second Speeds Only-No 2-3 Shift
990
No Motion in Reverse or Slips in Reverse
990
Slips in All Ranges or Slips on Start
990
No Engine Braking in L2 Range
991
No Part Throttle Downshift
991
High or Low Shift Points
991
Transmission Noisy
991
Park, Neutral and All Driving Ranges
992
First, Second And/Or Reverse Gear
992
During Acceleration-Any Gear
992
Squeal at Low Vehicle Speed
992
Circuit Schematic-Typical (Drive Range, Third Gear Shown)
993
Transmission Fluid
994
Checking Procedure and Adding Fluid
994
Draining and Refilling Transmission
994
Adding Fluid to Fill Dry Transmission and Converter Assembly
995
Intermediate Band Adjustment
995
Shift Control Cable Adjustment
995
Detent Control Cable Adjustment
995
Detent Control Cable
996
Vacuum Modulator and Modulator
996
Valve Assembly
996
Console Cover
997
Control Shifter Assembly
997
Extension Housing Oil Seal
998
1-2 Accumulator
998
Valve Body Assembly
999
Manual Shaft, Range Selector Inner Lever and Parking Linkage
999
Remove Transmission
999
Removal of Converter and Vacuum Modulator
999
Transmission in Holding Fixture
1000
Removing Vacuum Modulator
1000
Removing Extension Housing Lip Seal
1000
Removing Governor Cover
1000
Governor Cover and "O" Ring Seal
1001
Removing Governor
1001
Removing Transmission Oil Pan
1001
Removal of Valve Body and Linkage
1001
Detent Roller and Spring Assembly
1002
Removal of Oil Pump and Internal Case Components
1002
Removing Transfer Support Plate and Intermediate Servo Return Spring
1002
Removing Valve Body Transfer Plate and Gasket
1002
Check Ball Four Locations
1003
Removing Oil Pump Pressure Screen
1003
Removing Governor Feed Screen
1003
Removing Manual Shaft to Case Retainer
1003
Loosening Nut Holding Selector Lever to Manual Shaft
1004
Removing Manual Shaft to Case Lip Seal
1004
Removing Selector Lever and Actuator Rod
1004
Removing Parking Lock, Lock Bracket
1004
Removing Parking Pawl Disengaging Spring
1005
Oil Pump Attaching Bolts
1005
Parking Pawl Shaft Retaining Plug, Park Pawl Shaft and Park Pawl
1005
Removing Oil Pump from Case
1005
Intermediate Band Anchor Bolt and Nut
1006
Intermediate Band
1006
Removing Direct and Froward Clutch Assemblies
1007
Removing Output Carrier to Output Shaft Snap Ring
1007
Removing Input Ring Gear Front Thrust Washer
1007
Removing Input Ring Gear
1007
Removing Input Ring Gear Rear Thrust Washer
1008
Removing Low and Reverse Clutch Support Retaining Ring
1008
Removing Output Carrier Assembly
1008
Removing Sun Gear Drive Shell
1008
Removing Low and Reverse Clutch Pack
1009
Removing Output Ring Gear Tanged Thrust Washer
1009
Removing Reaction Carrier Assembly
1009
Removing Output Ring Gear and Shaft Assembly
1009
Removing Output Ring Gear to Case Needle Bearing Assembly
1010
Low and Reverse Clutch Piston Springs and Piston
1010
Compressing Low and Reverse Clutch Piston Spring Retainer
1010
Removing Low and Reverse Clutch Piston
1010
Removing Low and Reverse Clutch Piston Outer Seal
1011
Removing Low and Reverse Clutch Piston Center and Inner Seal
1011
Valve Body
1011
Accumulator Assembly-Exploded View
1011
Valve Body-Exploded View
1012
Removing Pump Cover to Body Attaching Bolts
1013
Pump Hub Oil Seal Rings
1013
Removing Pump Cover from Pump Body
1013
Direct Clutch
1013
Removing Oil Pump Hub Lip Seal
1014
Installing Oil Pump Hub Lip Seal
1014
Installing Pump Drive and Driven Gears
1014
Pump Body Oil Passages
1015
Forward Clutch
1015
Sun Gear and Sun Gear Drive Shell
1015
Removing Direct Clutch Pressure Plate
1016
Removing Lined and Steel Clutch Plates
1016
Compressing Direct Clutch Spring Seat
1017
Removing Direct Clutch Outer and Inner Seals
1017
Low and Reverse Clutch Support
1017
Removing Direct Clutch Piston Center Seal
1017
Direct Clutch Drum to Forward Clutch Housing Needle Roller Bearing
1018
Removing Forward Clutch Retaining Ring and Pressure Plate
1018
Governor Driven Gear Replacement
1018
Removing Forward Clutch Pack
1019
Compressing Forward Clutch Spring Return Seat
1019
Removing Forward Clutch Piston Inner & Outer Seals
1019
Forward Clutch Ball Check Exhaust
1019
Determining Correct Forward Clutch Pressure Plate
1020
Bushing Replacement
1020
Extension Housing Bushing
1020
Output Shaft Bushing
1020
Planetary Gear Train-Exploded View
1021
Removing Sun Gear Drive Shell Rear Retaining Ring
1022
Removing Sun Gear to Drive Shell Front Retaining Ring
1022
Removing Sun Gear to Drive Shell Rear Thrust Washer
1022
Low and Reverse Clutch Assembly-Exploded View
1023
Removing Overrun Clutch Inner Race
1023
Removing Roller Clutch Retaining Ring
1023
Removing Roller Clutch Assembly
1024
Governor Assembly-Exploded View
1025
Removing Extension Housing Bushing
1025
Installing Extension Housing Bushing
1025
Removing Output Shaft Bushing
1026
Stator Shaft Front and Rear Bushing
1026
Input Ring Gear Support Bushing
1026
Sun Gear Bushing
1026
Installing Inner and Outer Stator Shaft Rear Bushings
1027
Reaction Carrier Bushing
1027
Direct Clutch Bushing
1027
Transmission Reassembly
1027
Installing Direct Clutch Drum Bushing
1028
Transmission Internal Components
1028
Installing Low and Reverse Clutch Support Assembly
1028
Pump Cover to Direct Clutch Selective Thrust Washer
1028
Checking End Play for Proper Selective Thrust Washer
1029
Speedometer Drive Gear and Extension
1029
Installing Extension Housing Oil Seal
1029
Park Lock Bracket Special Bolt Identification
1030
Valve Body, Oil Pan and Gasket
1030
Installing Manual Shaft to Case Retainer
1030
Location of Four Check Balls
1030
Governor and Vacuum Modulator
1031
Install Transmission
1031
1-2 Accumulator Assembly
1031
Turbo Hydra-Matic 350 Transmission
1034
THM 350 Transmission-Cross Section
1035
Sequence for Turbo Hydra-Matic 350 Transmission Diagnosis
1035
Turbo Hydra-Matic 350 Transmission Oil Checking Procedures
1035
External Oil Leaks
1036
Possible Points of Oil Leaks
1036
Vacuum Modulator Diagnosis Procedure
1036
Modulator Load Comparison Check
1037
Causes of Improper Vacuum at Modulator
1037
Turbo Hydra-Matic 350 Trouble Diagnosis Chart
1038
Valve Body-Oil Passages
1044
Valve Body-Spacer Plate (Typical)
1045
Case Oil Channels-Bottom View
1046
Pump Cover and Stator Shaft Face-Oil Channels
1047
Pump Body Front Face-Oil Channels
1047
Adjust Column Shift Controls
1047
Adjust Console Shift Controls
1047
Adjust Downshift (Detent) Control Cable
1048
Replacing Downshift (Detent) Control Cable
1048
Fluid Recommendations
1048
Turbo Hydra-Matic 350 Towing Instructions
1048
Console Shift Controls (Typical)
1049
Rocking Car
1049
Downshift (Detent) Control Cable (Typical)
1050
Transmission Dipstick
1051
Removal of Speedometer Drive Gear and Governor
1051
Speedometer Drive Gear and Clip
1051
Drive Gear Installed
1051
Removing Governor Assembly
1052
Removal of Oil Pan, Oil Filter and Valve Body
1052
Removing Filter Attaching Screws
1052
Removing Filter and Gasket
1052
Valve Body to Spacer Plate Gasket
1053
Сase Porosity Repair
1053
Removing Spacer Plate and Gasket
1053
Location of Check Balls
1053
Transmission Assembly-Removal and Installation
1054
Converter Holding Tool
1054
Removal of Converter
1054
Removal of Vacuum Modulator
1054
Transmisison in Holding Fixture
1055
Removing Modulator Attaching Bolt
1055
Removal of Extension Housing, Lip Seal and Bushing
1055
Install Extension Housing Bushing and Lip Seal
1055
Removing Extension to Case Bolts
1056
Removal of Oil Pump Screen, Governor, Screens and Check Balls
1056
Collapsing Extension Housing Bushing
1056
Removal of Range Selector Inner Lever
1056
Removal of Lntermediate Servo Piston
1057
Removing Pump Pressure Screen
1057
Cleaning Governor Screen
1057
Removal of Oil Pump Assembly
1057
Removing Manual Shaft Retainer
1058
Removing Manual Shaft Oil Seal
1058
Parking Pawl Assembly
1058
Removal of Direct and Forward Clutch Assemblies
1058
Removing Pump from Case
1059
Removal or Input Ring Gear
1059
Removal of Output Carrier Assembly
1059
Removal of Sun Gear Drive Shell Assembly
1059
Removal of Low and Reverse Clutch Support Assembly
1060
Removal and Reverse Clutch Plates
1060
Removal of Reaction Carrier Assembly
1060
Removal of Output Ring Gear and Shaft Assembly
1060
Removal of Low and Reverse Clutch Piston Seals
1061
Removing Low and Reverse Clutch Plates
1061
Removing Reaction Carrier
1061
Removal of Intermediate Clutch 1-2 Accumulator Piston
1061
Output Ring Gear and Shaft Assembly
1062
Removing Needle Bearing
1062
Installation of Intermediate Clutch 1-2 Accumulator Piston
1062
Disassembly of Oil Pump Assembly
1062
Removing Low and Reverse Clutch Piston Seals
1063
Compressing 1-2 Accumulator Piston Cover
1063
Removing Pump Cover Attaching Bolts
1063
Reassembly of Oil Pump Assembly
1063
Oil Pump Assembly-Exploded View
1064
Intermediate Clutch Piston Seals
1064
Removing Pump Cover from Body
1064
Disassembly and Reassembly of Direct Clutch
1064
Removing Drive and Driven Gears
1065
Removing By-Pass Valve Seat
1065
Disassembly of Direct Clutch
1065
Pump to Case 0-Ring Seal
1066
Removing Pump Body Lip Oil Seal
1066
Installing By-Pass Valve Seat
1066
Location of Pump Cover Hub Lube Holes
1067
Removing Roller Clutch
1067
Removing Clutch Retainer
1067
Removing Overrun Outer Race
1067
Removing Needle Roller Bearing
1068
Removing or Installing Retaining Ring
1068
Reassembly of Direct Clutch
1068
Compressing Spring Retainer
1068
Direct Clutch Piston and Return Springs
1069
Direct Clutch Piston Inner and Outer Seals
1069
Direct Clutch Piston Center Seal
1069
Disassembly of Forward Clutch
1069
Intermediate Overrun Clutch-Exploded View
1070
Removing Retainer Ring
1071
Forward Clutch Plates
1071
Forward Clutch Piston Inner and Outer Seals
1071
Reassembly of Forward Clutch Assembly
1071
Location of Ball Check Exhaust
1072
Disassembly of Sun Gear to Drive Shell
1072
Disassembly of Low and Reverse Roller Clutch Assembly
1072
Reassembly of Low and Reverse Roller Clutch Assembly
1072
Installing Forward-Clutch Piston
1073
Checking Plate Clearance
1073
Pressure Plate Identification
1074
Removing or Installing Front Retaining Ring
1074
Removing or Installing Rear Retaining Ring
1074
Removing or Installing Rear Thrust Washer
1074
Low and Reverse Clutch Support and Overrun Roller Clutch Assembly
1075
Installing Race into Roller Clutch
1075
Installing Roller Clutch into Clutch Support
1075
Installing Clutch Retaining Ring
1076
Disassembly of Valve Body
1076
Valve Body Assembly-Exploded View
1076
Reassembly of Valve Body
1077
Reassembly of Transmission
1077
Installation of Low and Reverse Clutch Piston
1077
Installing Output Shaft and Reaction Carrier
1077
Installing Piston Center and Inner Seals
1078
Installing Low and Reverse Clutch Plates
1078
Compressing Low and Reverse Clutch Piston
1078
Installing Sun Gear Drive Shell Assembly
1078
Installing Needle Thrust Bearing
1079
Lnstalling Output Carrier Assembly
1079
Lnstalling Input Ring Gear
1079
Lnstalling Clutch Support Retainer Ring
1079
Installing Direct and Forward Clutch Assemblies
1080
Installing Intermediate Clutch Overrun Brake Band
1080
Installing Output Carrier Assembly
1080
Installing Oil Pump Assembly
1080
Installing Needle Roller Bearing
1081
Installing Clutch Assemblies
1081
Installing Clutch Pressure Plate
1081
Installing Speedometer Drive Gear
1081
Installing Intermediate Clutch Plates
1082
Installing Clutch Cushion Spring
1082
Installing Extension Housing
1082
Installing Shim and Thrust Bearing on Pump Hub
1083
Installing Pump Assembly
1083
Checking Direct Clutch to Pump Clearance
1083
Installing Square Cut O-Ring Seal
1084
Installing Parking Pawl and Actuating Rod
1084
Installing Manual Shaft and Range Selector Inner Lever
1084
Installing Intermediate Servo Piston, Check Balls
1084
Installing Retainer Plug
1085
Installing Park Lock Bracket
1085
Installing Valve Body, Detent Roller and Spring Assembly and Filter
1085
Installing Shaft Lip Seal
1085
Installing Oil Pan, Governor and Modulator Valve
1086
Converter Replacement
1086
Check Converter for Leaks
1086
Install Converter
1086
Intermediate Servo Assembly-Exploded View
1087
Installing Spacer Plate and Gasket
1088
Installing Pump Pressure Screen
1088
Installing Governor Screens
1088
Installing Support Plate
1089
Installing Detent Spring and Roller
1089
Connecting Manual Control Valve Link
1089
Intalling Filter and Gasket
1089
Governor, Cover and Seal
1090
Air Checking Converter
1090
Installing Modulator Valve and Modulator
1090
Installing Tool J 21371-2
1090
Installing Converter
1091
Transmission Identification Number
1091
Tightening Specifications for Metric External Fasteners
1092
Transmission Model and Clutch Plate Usage
1092
Turbo Hydra-Matic 400 Automatic Transmission
1093
Transmission-Cross Section
1094
Compound Planetary Gear Set
1094
Converter Operation
1095
Planetary Gear Train
1095
Preliminary Checking Procedure
1095
If Line Pressures Are Initially High
1095
Preliminary Checking Procedure Chart
1096
Oil Pressure Gage Installed
1097
Using the Hand Operated Vacuum Device
1097
Checking Transmission Oil Level
1097
Manual Linkage Adjustment
1097
Road Test if Necessary
1098
Causes of Transmission Malfunctions
1099
Improper Vacuum at Modulator
1099
Control Valve Assembly-Governor Line Pressure Check
1099
Preliminary Diagnosis Chart
1099
Spacer-Control Valve Assy. (Typical)
1100
Diagnosis Chart a
1101
Diagnosis Chart B
1102
Diagnosis Chart C
1103
Diagnosis Chart D
1104
Diagnosis Chart E
1105
Diagnosis Chart F
1106
Roller Thrust Bearing and Race
1107
Center Support
1108
Burned Clutch Plates
1108
Oil Leaks
1109
Case Porosity Repair
1109
Periodic Service Recommendations
1112
Downshift Control Switch
1112
Towing
1112
Transmission Fluid
1112
Column Shift Controls
1112
Console Shift Controls
1112
Neutralizer Switch
1112
Column Shift Controls
1113
Steering Column Lock Controls (Typical)
1114
Fluid Capacity
1114
Cooler and Cooler Line
1114
Removing Pressure Regulator Valve
1116
Converter and Modulator
1116
Governor, Speedometer Driven Gear, Pan, Filter and Intake Pipe
1116
Unit Repair
1116
Remove Transmission
1116
Removing Modulator Retainer
1117
Control Valve, Governor Screen, Electrical Connector
1117
Governor Pipes, Detent Spring Assemblies
1117
Removing Filter and Intake Pipe Assembly
1117
Removing Control Valve Assembly
1118
Removing Governor Screen Assembly
1118
Rear Servo, Valve Body Spacer, Gasket and Front Servo
1118
Checking for Correct Rear Band Pin
1118
Removing Detent Solenoid
1119
Removing Electrical Connector and O-Ring Seal
1119
Rear Oil Seal and Case Extension
1119
Removing Front Servo
1119
Case Extension and Gasket
1120
Front End Play Checking Procedure
1120
Checking Front End Play
1120
Removing Front Seal
1120
Oil Pump
1120
Removing Turbine Shaft and Forward Clutch
1121
Removing Direct Clutch Assembly
1121
Location of Manual Shaft Retaining Pin
1121
Removing Jam Nut and Manual Shaft
1122
Removing Parking Bracket
1122
Disassembly of Gear Unit
1122
Removing Parking Pawl Return Spring
1123
Removing Retaining Spring from Parking Pawl Shaft
1123
Removing Parking Pawl and Shaft
1123
Transmission with Nylon Speedometer Drive Gear
1123
Removing Front Band
1124
Transmission with Steel Speedometer Drive Gear
1124
Checking Rear End Play
1124
Removing Center Support Bolt
1124
Removing Support-To-Case Snap Ring
1125
Removing Entire Gear Unit Assembly
1125
Location of Rear Unit Selective Washer
1126
Removing Center Support Assembly
1126
Location of Support-To-Case Spacer
1126
Removing Rear Band
1126
Removing Center Support Thrust Washer
1127
Disengaging Snap Ring from Output Carrier
1127
Removing Sun Gear
1127
Depressing Retaining Clip
1128
Installing Steel Speedometer Drive Gear
1128
Installing Reatining Clip
1128
Removing Steel Speedometer Drive Gear
1128
Overhaul of Major Units
1129
Governor Driven Gear
1129
Governor Assembly
1129
Assemble Governor
1130
Inspect Front Servo
1130
Rear Servo
1130
Checking Feed Port
1131
Checking Exhaust Port
1131
Front Servo-Exploded View
1131
Removing Accumulator Piston from Servo
1131
Rear Servo-Exploded View
1132
Assemble Rear Servo
1132
Compressing Accumulator Piston and Spring
1132
Control Valve Assembly
1132
Front Accumulator Piston-Exploded View
1133
Inspect Control Valve Assembly
1133
Assemble Control Valve Assembly
1133
Installing Detent Regulator Valve and Detent Valve
1134
Removing Snap Ring Front Boost Valve Bushing
1134
Inspect Oil Pump
1134
Removing Oil Seal Rings from Pump Cover
1135
Removing or Installing Pump Gears
1135
Pump Cover-Exploded View
1135
Checking Body Face-To-Gear Face Clearance
1135
Pump Body-Oil Passages
1136
Pump Cover-Oil Passages
1136
Assemble Oil Pump
1136
Forward Clutch
1136
Installation of Teflon Rings
1137
Inspect Forward Clutch
1137
Assemble Forward Clutch
1137
Removing or Installing Clutch Hub Retaining Snap Ring
1138
Removing or Installing Forward Clutch Hub
1138
Direct Clutch and Intermediate Roller
1138
Pressing Turbine Shaft from Clutch Housing
1139
Removing or Installing Spring Retainer Shap Ring
1139
Removing or Installing Clutch Piston Seals
1139
Removing or Installing Clutch Housing Center Seal
1139
Installing Forward Clutch Pack
1140
Removing or Installing Clutch Retainer Snap Ring
1140
Inspect Direct Clutch and Roller
1140
Assemble Direct Clutch and Roller
1140
Direct Clutch Pack-Exploded View
1141
Removing or Installing Clutch Piston Snap Ring
1141
Removing Direct Clutch Piston
1141
Direct Clutch and Intermediate Roller Assembly-Exploded View
1142
Installing Clutch Piston Inner Seal
1142
Installing Clutch Piston Outer Seal
1142
Direct Clutch Housing
1143
Installing Intermediate Roller Assembly
1143
Installing Outer Race
1143
Inspect Center Support
1143
Installing Clutch Retainer
1144
Air Checking Direct Clutch
1144
Assemble Center Support
1144
Center Support Assembly-Exploded View
1145
Removing Intermediate Clutch Piston
1146
Installing Clutch Piston Outer/Inner Seal
1146
Removing Clutch Spring Guide
1146
Installing Intermediate Clutch Piston
1146
Inspection of Major Units
1147
Reaction Carrier, Roller Clutch and Output Carrier Assembly
1147
Checking Reaction Carrier Pinion End Play
1147
Spacer Ring-Reaction Carrier
1147
Checking Output Carrier Pinion End Play
1148
Pinion Replacement Procedure
1148
Planet Pinion-Exploded View
1148
Driving Pinion Pin into Carrier (Reaction Carrier Shown)
1148
Output Shaft
1148
Sun Gear Shaft
1149
Mainshaft
1149
Case Extension
1149
Modulator and Valve
1149
Front and Rear Bands
1149
Vacuum Modulator-Cross Section
1150
Manual and Parking Linkage
1150
Case Assembly
1150
Case Passages-Front & Bottom View
1150
Converter Assembly
1151
Pressurizing Converter
1151
Installing Fixture-J-21371-2
1151
Installing Fixture J-21371-3
1152
Checking Converter End Play
1152
Converter Assembly-Cross Section
1153
Reassembly and Installation of Transmission
1153
Rear Unit
1153
Rear Unit-Exploded View
1154
Assembly of Units into Transmission Case
1154
Installing Mainshaft Snap Ring
1155
Installing Bearing and Races on Rear Internal Gear
1155
Installing Output Shaft
1155
Installing Gear Ring to Output Carrier
1155
Installing Reaction Carrier
1156
Installing Bearing and Races on Sun Gear Shaft
1156
Installing Roller into Roller Clutch
1156
Installing Roller Clutch Assembly
1156
Installing Center Support Assembly
1157
Installing Output-To-Case Thrust Washer
1157
Installing Parking Pawl and Shaft
1157
Installing Retaining Spring Onto Pawl Shaft
1157
Driving Cup Plug into Case
1158
Installing Parking Pawl Return Spring
1158
Proper Location of Support-To-Case Spacer
1158
Install Case Extension Assembly
1158
Installing Complete Gear Unit
1159
Installing Support-To-Case Snap Ring
1159
Installing Center Support Bolt
1159
Installing Intermediate Clutch Pack
1159
Check Balls. Control Valve
1159
Installing Front Band
1160
Positioning Actuator Rod Plunger
1160
Installing Jam Nut Onto Manual Shaft
1160
Installing Direct Clutch Assembly
1160
Installing Forward Clutch Assembly
1161
Installing Front Seal
1161
Location of Check Balls in Case Valve Body Face
1161
Location of Check Balls in Spacer Plate
1162
Installing Detent Solenoid and Gasket
1162
Installing Gasket and Spacer Plate
1162
Installing Front Servo Assembly
1162
Installing Electrical Connector
1163
Connecting Leads to Connector
1163
Rear Servo Assembly
1163
Governor Pipes and Governor Screen Assembly
1163
Control Valve Assembly
1163
Installing Rear Servo Piston
1164
Installing Rear Servo Cover
1164
Installing Governor Screen Assembly
1164
Filter and Intake Pipe
1164
Installing Detent Roller and Spring Assembly
1165
Installing Filter Assembly
1165
Modulator Valve and Vacuum Modulator
1165
Installing Vacuum Modulator
1165
Modulator Valve and ......................................... Governor
1165
Installing Governor
1166
Speedometer Driven Gear
1166
Converter Assembly
1166
Torque
1167
Specifications
1167
Transmission Identification
1167
Manual Transmissions
1170
3-Speed 76 MM Transmission-Cross Section
1171
3-Speed 76 MM Transmission-Exploded View
1172
4-Speed 76 MM Transmission-Cross Section
1173
4-Speed 76 MM Transmission-Exploded View
1174
4-Speed 82Mm Transmission-Cross Section
1176
4-Speed 82 MM Transmission-Exploded View
1177
5-Speed 77Mm Borg-Warner Transmission
1178
5-Speed 77Mm Transmission-Cross Section
1178
5-Speed 77Mm Transmission-Exploded View
1179
5-Speed 77Mm Transmission-Exploded View-Index
1180
Clutch Free Pedal Travel
1180
Clutch Spin down Time
1180
Shift Linkage Adjustment
1181
Transmission Shift Effort Checking Procedures
1181
Shift Effort-Pound Inches
1181
Transmission Internal Problems Related to Shift Effort
1181
Manual Transmission Diagnosis
1182
Shifting Difficulty Diagnosis
1184
Checking Transmission Mounts
1185
Linkage Adjustment
1185
Floor Mounted Shift-F & X Series
1186
Floor Mounted Shift-H Series
1186
Floor Mounted Shift Back Drive Controls
1186
Column Shift Linkage (Typical)
1186
3-Speed Floor Shift Controls (Typical)
1187
3-Speed Floor Shift Back Drive Controls (Typical)
1188
4-Speed Floor Shift Controls (Typical)
1189
4-Speed Floor Shift Back Drive Controls (Typical)
1190
4-Speed Floor Shift Controls
1190
3-Speed 76 MM Lt. Duty Muncie Transmission
1191
Rear Extension Oil Seal-R & R
1191
Rear Extension Bushing-R & R
1191
Case Cover-R & R
1191
Transmission Case Cover-Exploded View
1192
Speedometer Driven Gear-R & R
1192
4-Speed 76 MM Lt. Duty Muncie Transmission
1192
Transmission Case Cover Assembly
1193
Shift Control Assembly-R & R
1193
Shift Control Assembly-Repair
1193
Shift Control Assembly-Exploded View ("H" Series Only)
1194
4-Speed 82 MM Borg-Warner Transmission
1194
Floor Shift Levers
1195
Shift Control Lever-R & R
1195
3-Speed 76Mm Lt. Duty Muncie Transmission
1196
Removal of Transmission
1196
Disassembly of Transmission
1196
Disassembly of Mainshaft
1196
Transmission Case
1197
Front and Rear Bearings
1197
Bearing Rollers
1197
Reverse Idler Gear Bushing
1197
Clutch Keys and Springs
1198
Extension Oil Seal or Bushing
1198
Clutch Bearing Retainer Oil Seal
1198
Assembly of Mainshaft
1199
Assembly of Transmission
1199
Loading Roller Bearings
1199
4-Speed 76Mm Lt. Duty Muncie Transmission
1200
Removing Drive Gear Bearing
1201
Removing Mainshaft Assembly from
1201
Removing Countershaft
1201
Removing Reverse Idler Shaft
1201
Removing Third and Fourth Synchronizer Snap Ring
1202
Removing Rear Bearing Snap Ring
1202
Removing First and Second Synchronizer Snap Ring
1202
Reverse Idler Gear Bushings
1202
Countergear Anti-Lash Plate
1203
Synchronizer Assembly
1203
Removing Extension Bushing
1203
Installing Extension Oil Seal
1203
Removing Bearing Retainer Oil Seal
1204
Installing Bearing Retainer Oil Seal
1204
Mainshaft Assembly-Exploded View
1205
Installing Rear Bearing
1206
Installation of Transmission
1206
Loading Mainshaft Pilot Bearings
1206
4-Speed 82Mm Borg-Warner Transmission
1207
Removing Reverse Shifter Shaft Lock Pin
1207
Speedometer Gear and Snap Rings
1208
Removing Reverse Gear
1208
Removing Main Drive Gear Bearing
1208
Removing Countergear Shaft
1208
Removing 3-4 Clutch Assembly Retainer Ring
1209
Removing Rear Bearing Retainer
1209
Roller Bearings and Spacers
1209
Synchronizer Keys and Springs Replacement
1210
Extension Oil Seal And/Or Bushing Replacement
1210
Drive Gear Bearing Retainer Oil Seal Replacement
1210
Reverse Shifter Shaft And/Or Seal Replacement
1210
Reverse Ldler Shaft Replacement
1211
Transmission Case Cover
1211
Assembly of Countergear
1211
Checking Countergear End Play
1211
Case Cover-Exploded View
1212
Countergear-Cross Section
1212
Installing 1St Gear Sleeve
1212
Installing Front Main Bearing
1213
Extension Bolt to be Sealed
1214
5-Speed 77 MM Borg-Warner Transmission
1214
Removing Plug, Poppet Spring and Plunger
1215
Removing Selector Lever Pivot
1215
Removing Shifter Head Roll Pin
1215
Removing Pin and Rail Selector
1215
Snap Ring and Needle Bearing Identification
1216
Removing First Speed Gear Snap Ring
1217
Removing Synchronizer Hub Snap Ring
1217
Removing First and Reverse Synchronizer, Shift Fork, Rail and Link
1217
Removing Reverse Idler and Reverse Gears
1217
Removing Center Support
1218
Removing Needle Thrust Bearing and Race
1218
Removing Input Shaft from Output Shaft
1218
Needle Bearings
1218
Removing Fifth and Second Speed Gear
1219
Removing Second and Third Gear Synchronizer Assembly
1219
Removing Third Speed Gear
1219
Replacement of Case Bearings and Seal
1219
Synchronizer Assembly (Typical)
1220
Replacement of Center Support Bearings
1220
Removal and Installation of Output Shaft Needle Bearing
1220
Removal and Installation of Countergear Needle Bearing
1220
Installing Countergear Needle Bearing into Case
1221
Driving Seal from Case
1221
Replacement of Extension Housing Bearing
1221
Bushing and Seal
1221
Installing Output Shaft Needle Bearing into Center Support
1222
Assembly and Installation of Transmission
1222
Installing Countergear Needle Bearing into Center Support
1222
Removing Countergear Needle Bearing from Extension Housing
1222
Installing Countergear Needle Bearing into Extension Housing
1223
Removing Oil Seal from Extension Housing
1223
Installing Oil Seal into Extension Housing
1223
Removing or Installing Bushing in Extension Housing
1223
Installing Third Speed Gear
1224
Installing Second and Third Gear Synchronizer Assembly
1224
Installing Fifth Speed Gear Needle Rollers
1224
Installing Fourth and Fifth Gear Synchronizer Assembly
1224
Installing Input Shaft Needle Thrust Bearing
1225
Installing Input Shaft Needle Rollers
1225
Installing Needle Thrust Bearing and Race to Output Shaft
1225
Installing Output Shaft, Mainshaft and Countergear into Center Support
1225
Installing Reverse and Reverse Idler Gears
1226
Shift Forks and Links
1226
Installing First and Reverse Shift Fork to Shift Rail
1226
Installing First and Reverse Shift Fork and Rail
1226
Installing First Speed Gear, Thrust Washer and Snap Ring
1227
Installing Speedometer Gear and Rail Selector
1227
Installing Selector Lever, Shift Rail and Shifter Head
1228
Installing Selector Lever Pivot
1228
Installing Shifter Head Roll Rin
1228
Installing Plunger, Poppet Spring and Plunger
1228
Installing Shift Lever and Cover
1229
Gear Ratios
1229
Lubricant
1229
Special Tools-3 and 4 Speed 76Mm Muncie Transmissions
1230
4-Speed 82 MM Borg Warner Transmission
1231
5-Speed 77 MM Borg Warner Transmission
1231
Special Tools
1231
Clutch
1232
Driving Members
1232
Driven Members
1232
Operating Members
1232
Exploded View of Clutch
1233
Clutch Driven Plate Assembly
1233
Clutch Operation
1233
Diaphragm Spring Clutch-Cross Section
1234
Clutch Adjustment
1234
Linkage Inspection
1234
Clutch Pedal Free Travel
1236
Clutch Mechanism-Adjustment (H Series)
1236
Initial Ball Stud Adjustment
1236
Clutch Cable Attachment & Adjustment (Lower End)
1237
Clutch Pedal Replacement
1237
Clutch Cross Shaft
1237
Clutch Cable Replacement
1237
Clutch Pedal Linkage (a Series)
1238
Clutch Pedal Linkage (F Series)
1238
Clutch Pedal Linkage (X Series)
1239
Clutch Assembly Replacement
1239
Cross Shaft Controls (a Series)
1240
Cross Shaft Controls (Typical-F or X Series)
1240
Clutch Cable Routing (Typical-H Series)
1241
Release Bearing Lubrication
1241
Single Plate Diaphragm Clutch
1241
Retracting Spring Location (Typical)
1242
Pilot Bearing Replacement
1242
Clutch Pilot Bearing Removal
1242
Chassis Electrical
1243
Wiring Harnesses
1243
Engine Wire Harness
1244
Front End Wire Harness
1244
Fusible Link
1244
Fuse Block and Bulkhead Connector
1244
Battery Cables
1244
Redundant Ground
1244
Engine Wire Harness Installation, All Series, V-8
1245
Engine Wire Harness Installation, V-6 and 15 1 L-4, All Series
1246
Engine Wire Harness Installation
1247
Front End Wire Harness Installation, B Series
1248
Front End Wire Harness Installation, a and G Series
1249
Front End Wire Harness Installation, F Series
1250
Front End Wire Harness Installation, X Series
1250
Front End Wire Harness Installation, H Series
1251
Front End Wire Harness Installation, HM Series
1251
Battery Cable Routing, B Series
1252
Battery Cable Routing, a Series V-6
1253
Battery Cable Routing, a and G Series V-8
1254
Battery Cable Routing, F Series
1255
Battery Cable Routing, X Series
1256
Battery Cable Routing, H and HM Series
1257
Battery Cable to Engine Attachment
1257
Redundant Ground Cables
1258
Battery Cable to Engine Attachment-V-6 Positive Cable
1259
Miniaturized Fuse
1259
Fuse Block Identification-All Series Except H, HM and B
1260
Fuse Block Identification-H and HM Series
1261
Fuse Block Identification-B Series
1262
Bulkhead Connector-All Series Except H, HM and B
1263
Bulkhead Connector-H and HM Series
1264
Bulkhead Connector-B Series
1265
Instrument Panel Pad, Cluster, and Attaching Parts
1266
Instrument Panel Pad/Carrier Assembly
1266
B Series Instrument Panel Attaching Parts
1267
B Series Instrument Cluster and Trim Plates
1267
A Series Lnstrument Panel Pad
1268
A Series Lnstrument Panel Attaching Parts
1268
A Series Lnstrument Cluster
1269
G and AG Series Lnstrument Panel Pad
1269
G and AG Series Instrument Panel Attaching Parts
1270
G and AG Series Instrument Cluster
1271
F Series Instrument Panel Pad
1271
F Series Instrument Panel Attaching Parts
1272
F Series Instrument Cluster
1273
Instrument Panel (Speedo) Cluster
1273
X Series Instrument Panel Pad and Cluster Assembly
1274
Printed Circuit
1274
X Series Instrument Panel Attaching Parts
1275
Instrument Panel Wire Harness
1275
G and AG Series
1275
H Series Instrument Panel Pad and Cluster
1276
H and Hm Series Instrument Panel Attaching Parts
1277
"Hush" Panel
1277
HM Series Instrument Panel Pad and Cluster
1278
B Series Printed Circuit Without Rally Gages
1278
B Series Printed Circuit with Rally Gages
1279
A and F Series (Late Cluster) Printed Circuit Without Rally Gages
1279
A Series Printed Circuit with Rally Gages
1279
F Series Printed Circuit Without Rally Gages, Early Cluster
1280
F Series Printed Circuit with Rally Gages
1280
HM Series Printed Circuit Without Rally Gages
1280
G, AG and X Series Printed Circuit
1281
HM Series Printed Circuit with Rally Gages
1281
A Series Instrument Panel Wire Harness
1282
F Series Instrument Panel Wire Harness
1283
G and AG Series Instrument Panel Wire Harness
1284
B Series Instrument Panel Wire Harness
1285
X Series Instrument Panel Wire Harness
1286
H Series Instrument Panel Wire Harness-Standard Cluster
1287
H Series Instrument Panel Wire Harness-GT Cluster
1288
HM Series Instrument Panel Wire Harness
1288
H and HM Series-Steering Column and Fuse Panel
1289
"Hush" Panel, B Series, L.H.
1290
"Hush" Panel, G Series
1290
"Hush" Panel, F Series
1290
"Hush" Panel, H Series
1290
"Hush" Panel, HM Series
1291
"Hush" Panel, B Series, R.H.
1291
"Hush" Panel, Early B Series, LH
1292
Temperature Indicator Lamp
1292
Generator Lamp
1292
Engine Oil Pressure Indicator Lamp
1292
Instruments
1292
Temp/Press Warning Lamp Circuit
1293
Speedometer
1293
Coolant Level Indicator
1293
Low Coolant Level Indicator
1294
Indicator Lamp Reamins on at All Times
1294
Indicator Lamp Flickers on and off
1295
Fuel Gage
1295
Warning Lamps
1295
Speedometer Cable
1295
Speedometer Cable Attachment at Cluster
1296
Speedo Cable Routing-B Series
1296
Speedo Cable and Case Replacement
1296
Speedometer Cable Attachment at Transmission
1297
Speedo Cable Routing-A and G Series
1297
Speedo Cable Routing-F Series
1298
Speedo Cable Routing-X Series
1298
Speedo Cable Routing-H and HM Series
1299
Horn
1299
Horn Mounting
1300
Horn Relay Mounting
1301
Horn Diagnosis
1302
Lamps and Lighting
1303
Back-Up Lamps
1303
Traffic Hazard Flasher
1303
Directional Signal
1303
General Description
1303
Bulb Usage
1304
Neutral Stan and Back-Up Lamp Switch
1305
Cornering Lamps
1305
Side Marker Lamps
1305
Turn Signal System
1305
Diagnosis
1305
Electrical Check
1306
One Headlight Lnoperative or Lntermittent
1306
One or more Headlights Are DIM
1306
All Headlights Inoperative or Lntermittent
1306
High or Low Beam will Not Light or Intermittent
1307
One Lamp Inoperative
1307
Both Lamps Inoperative
1307
Turn Signal and Hazard Warning Lamps
1308
Turn Signal Inoperative-One Side
1308
Turn Signals Inoperative-Both Sides
1308
Hazard Warning Lamps Inoperative
1309
Front or Rear Lamps Inoperative
1309
All Lamm Inoperative
1310
Tail, Park or License Lamps
1310
One Side Inoperative
1310
Both Sides Inoperative
1310
One Lamp Inoperative or Intermittent
1311
Both Lamas Inoperative or Intermittent
1311
Lamps will Not Turn off
1311
Stop Lamps
1311
Seat Belt Warning System
1312
On-Car Service
1312
Remove and Replace
1312
General Description
1312
Diagnosis
1312
Seat Belt Diagnosis
1313
Windshield Washer and Wiper System
1314
Windshield Washer Target Area
1314
Electrical Wire Codes by Category
1315
Electrical Wire Codes by Circuit Number
1317
Wiring Diagram
1319
B Series Wiring Diagram
1323
A Series Wiring Diagram
1324
G & AG Series Wiring Diagram
1333
F Series Wiring Diagram
1334
X Series Wiring Diagram
1343
H Series Wiring Diagram
1344
HM Series Wiring Diagram
1353
Accessories
1354
Cruise Control Systems
1355
Speed Adjustment
1355
Regulator Assembly
1355
Vacuum Checks
1355
General Description
1355
Diagnosis
1355
Cruise Control Diagnosis
1356
Cruise Control Wiring Schematic
1357
Cruise Control Does Not Engage
1357
Cruise Control Does Not Disengage When Brake Is Applied
1358
Cruise Control Re-Engages When Brake Is Released
1358
Carburetor Does Not Return to Normal Idle
1358
Cruise Control Does Not Control at Selected Speed
1358
Cruise Control Controls Speed 3 or more MPH above Selected Speed
1359
Cruise Control Controls Speed 1 or more MPH below Selected Speed
1359
Cruise Control Regulator Test Procedure
1359
On-Car Service
1359
Cruise Control Regulator Mounting-"Y" V8, a and G Series
1360
Cruise Master
1360
Electrical System
1360
Engagement Switch Test
1360
General Description
1360
Diagnosis
1360
Cruise Control Regulator and Servo Mounting
1361
Cruise Control Regulator Servo Mounting
1362
Regulator
1362
On-Car Service
1362
Cruise Control Engagement Switch Wiring-All Series Except B
1363
Cruise Control Under-Dash Wiring-Typical
1364
Cruise Master Wiring Schematic
1365
Cruise Master Diagnosis Chart 1
1366
Cruise Master Diagnosis Chart
1367
Cruise Master Regulator
1368
Servo Unit
1368
Brake Release Switches
1368
Column Mounted Engagement Switch
1368
Cruise Master Regulator & Servo Mounting-V6, B & X Series, Typical
1369
Cruise Master Regulator & Servo Mounting-"R" & "K" V8, B Series
1370
Cruise Master Servo Mounting on Engine-"Y" V8, All Series
1371
Cruise Master Regulator Mounting-"Y" V8, B & X Series
1372
Cruise Master Regulator & Servo Mounting-"Y", "P" and "Z", F Series
1373
Cruise Master Regulator & Servo Mounting-"U" & "L" V8, X Series
1374
Cruise Control System Vacuum Schematics
1375
AM/FM Monaural
1377
Radio Availability
1377
General Description
1377
AM/FM Stereo
1378
AM or AM-FM Stereo/Tape Player
1378
Digital Display Radio
1378
CB Radio
1379
CB Antenna
1379
All Radios
1379
Setup Procedure
1380
Digital Display Set-Up
1380
CB Units
1380
Windshield Radio Antenna
1380
Adjusting Standing Wave Ratio
1381
Radio Diagnosis
1382
Radio Noise Suppression
1384
Minor Adjustments
1386
Antenna Trimmer Adjustment
1386
Windshield Antenna Diagnosis
1386
On-Car Service
1386
Balance Adjustment
1387
Stereo Tape Player
1387
Remove and Replace-Except CB Radios
1387
A Series
1387
AG and G Series
1387
B Series
1387
F Series
1387
Radio Installation-A and G Series
1388
Tape Player Convector Wiring-A and G Series
1389
Stereo Light
1389
Radio Dial Light
1389
Antenna Lead-In
1389
Radio Suppression Equipment
1389
Radio Installation-B Series
1390
Radio Installation-F Series
1391
Stereo Tape Installation-F Series
1392
Radio Installation-X Series
1393
Radio Installation-H Series
1393
Radio Installation-HM Series
1394
Front Speaker Installation-H & HM Series
1394
Remove and Replace-CB Radio
1394
Radio Suppression Equipment-Typical
1395
Bracket Mounted CB Installation, X Series, and CB Antenna Mounting
1395
Bracket Mounted CB Installation-A, B, F & G Series
1396
Microphone Mounting-B, F, G and AG Series
1397
Integral CB Installation, B, G & AG Series
1398
Power Antenna Assembly
1399
General Description
1399
Antenna Wiring Diagram
1400
Problem-Antenna Inoperative (Motor Doesn't Run)
1400
Problem-Antenna Doesn't Move up and down Full Travel
1402
On-Car Service
1402
Power Antenna Mounting
1403
Overhaul Procedure
1403
Mast and Support Tube
1403
Power Antenna Wiring
1404
Extending Mast
1405
Starting Mast Cable
1405
Rally Gauge, Tachometer and Clock
1405
Fuel Economy Indicator
1405
General Description
1405
Tachometer
1406
Digital Clock
1406
Trip Odometer
1407
Oil Pressure Gage
1407
Voltmeter
1407
Water Temperature Gage
1407
Diagnosis
1407
Fuel Economy Gage
1408
On-Car Service
1408
A and G Series
1408
F Series
1408
Series
1408
H and HM Series
1408
Tach Installation-A and G Series
1409
Digital Clock-B Series
1410
Fuel Economy Gage Hose Routing-B Series
1410
Clock Installation-A, G, F and X Series
1411
Fuel Economy Gage Hose Routing
1411
Rally Gage and Tach Installation-F Series
1412
Tach Wiring-X Series
1413
Clock Installation-H and HM Series
1413
Miscellaneous Accessories
1414
Electric Defogger
1414
Trailer Wiring Harness
1414
Controlled Cycle Wiper Systems
1414
Console
1414
Engine Block Heater
1414
Rear Window Defogger
1414
Right Hand Remote Control Rear View Mirror
1414
Console Installation-G and AG Series
1415
Console Installation-A and X Series
1416
Console Installation-F Series
1417
Console Installation-H and HM Series
1418
Luggage Compartment Lamp
1418
Deck Lid Release
1418
Dash Mounted Accessory Switches
1418
Engine Block Heater
1419
Engine Block Heater 150 L-4
1420
Rear Window Defogger-B Series
1420
Rear Window Defogger-A and G Series
1421
Rear Window Defogger-H Series
1422
Rear Window Defogger-HM Series
1422
Rear Window Defogger-F Series
1423
Controlled Cycle Wiper-B Series
1424
Controlled Cycle Wiper-A and G Series
1425
Controlled Cycle Wiper-X Series
1425
Controlled Cycle Wiper-H and HM Series
1426
R.H. Rear View Mirror-B Series
1426
R.H. Rear View Mirror-G Series
1427
R.H. Rear View Mirror-A Series
1427
Luggage Compartment Lamp-Typical
1428
Deck Lid Release-B Series
1428
Deck Lid Release-A, G and F Series
1429
Accessory Switch Mounting-B Series
1430
Accessory Wiring-B Series
1430
Tailgate Release-A Series Wagon
1431
Accessory Switch Mounting-F Series
1431
Roof Rack Installation-B Series
1432
Accessory Wiring Diagram-B Series
1433
Accessory Wiring Diagram-A and G Series
1434
Accessory Wiring Diagram-F Series
1435
Accessory Wiring Diagram-Miscellaneous
1436
Index
1438
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