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Introduction and Index - The Austin Somerset Coupé
Contents
1. Suspension Description Suspension Dismantling Suspension Parts Examination Suspension Removal I Suspension Replacing Castor Camber and Swivel Pin Incli nation T ES bos STEERING Data Description Maintenance Sect ion Adjusting Track Double Levers Removal Double Levers Refitting Idler Assembling and Dismantling Idler Refitting Idler Removal Swivel Arms 3 4 3 6 3 3 S 5 5 7 7 J l 2 Steering Connections and Idler 5 x SS 2 3 4 4 4 3 5 Steering Gear 5 Adjustment 7 Dismantling 7 Faults 8 Removal 5 K REAR AXLE Section Data Axle Shaft Removal and Replacement ba Axle Unit Removal Bevel Pinion Oil Seal Renewal Carrier Bevel Pinion and Bearing Carrier Replacement Carrier Withdrawal Crown Wheel and Bearings Crown Wheel and Bevel Pinion Gears Differential Wheels and Pinions Ru t Hubs ses x Reassembly ix n ss d Removal T e iae rud Replacement 1 REAR SUSPENSION Section L Springs vd jea Mor 12 Data 2n ts sud Description Jus mw Y Dismantling 2 Replacement 52 Removal 7 2 Shackle Bush Renewal LES Shackle Removal u Y E Shock Absorbers and Anti Roll Bar 3 Description me Refitting Fis ve a 9 Rubber Bushes m E ice Testing ae 3 Topping Up 3 BRAKES Section M Data
2. us 142 Handbrake Principle of System Adjustment and Maintenance Bleeding the System Front Brakes Rear Brakes Replenishment of Fluid Fitting of Shoes Front Brakes Rear Brakes General Advice Master Cylinder Assembly Dismantling TYRES AND JACKING General Jacking Section u AWA ARAA Tyres Care of 3 Misalignment 1 Pressures Refitting T 12 Removal ia T uo Wheel Changing 2 ELECTRICAL Section Data Lubrication and General Maintenance Battery ee Distributor Cleaning Distributor Lubrication Distributor Setting Contact Breaker Dynamo Lubrication en Trafficators Lubrication Wiring Diagram Saloon Wiring Diagram Sports Wiring Diagram Commercial General Information Ammeter Battery Initial Filling and Charging Battery Dry Charged Control Box Description Control Box Regulator Adjustment Control Box Mechanical Setting Cut Out Adjustment 355 Distributor Dynamo Dynamo Brush Gear Dynamo Dismantling Dynamo Reassembly Dynamo Removal and Replacement x Qo OO 4 WO xC wes Ww OS CA CA CA SERVICE MANUAL Fuse Unit Headlamps Bulb Replacement Headlamps Replacing a Unit Headlamp Setting ad High Tension Cables Horn 220 Horn Adjustment Ignition Coil Lighting
3. 0 1 83 Back of Rear Seat folded to Rear Body interior Height js I 3 7 1 10 Doors H 5 1 1 55 Height of Rear Door Opening J 3 1 0 94 Height of Rear Door Opening I 3 1 0 94 Overall Height unladen m K 6 1 1 86 Height over Rear Seat J 3 2 0 96 Body Floor to Ground unladen L 2 5 0 74 Overall Height K 6 1 1 86 Centre of Front Wheel to Bumper M 2 04 0 62 Body Floor to Ground L 2 5 0 74 Wheelbase d N 7 84 2 35 Overall Length T M 3 4 05 Centre of Rear Wheel to Bumper T O 3 6 1 08 Cab Floor to Ground N 2 0 35 Overall Length 13 3 4 05 Back of Rear Seat PANAD to Rear Doors n 2 10 0 86 Overall Width E iis 5 4t 1 64 Overall Width 5 4 1 64 Body Interior Width ids 5 2 1 58 Max Interior Width 5 0 1 52 Width between Wheelarches _ 3 3i 1 00 Width between Wheelarches 3 31 1 00 Width of Rear Door SPD 4 11 1 25 Width of Door Opening 4 I 1 25 Track front 4 11 1 25 Wheelbase 7 8 2 35 Track rear in n cy e 21 1 28 Track front 4 Ik 1 25 Turning Circle e n o 38 0 11 58 Track rear 4 2l 1 28 Ground Clearance jos E T 7 0 19 Turning Circle 223 e 38 0 11 58 Body Capacity se 116 cu ft 3 29 cu m Ground Clearance 74 0 19 Approx Weight less spare wheel tools Approx Weight less spare wheel tools and fuel plus oil and water 18 cwt 23165 924 kg and fuel plus and water 20 19155 1024 kg A40 PICK UP DIMENSIONS English M
4. air cleaner and then thoroughly rinse the louvred end in a shallow dish of petrol After drying the metal gauze mesh should be re oiled with clean engine oil allowing the surplus oil to drain off before refitting the cleaner to the carburetter An oil bath type filter is fitted to cars for the ex port market The oil therein should be checked and the gauze cleaned regularly Fuel System Check the flow of the fuel at the carburetter inlet union and if necessary clean the petrol filters in the pump and in the carburetter inlet union also clean the jets Radiator Flush out the cooling system by opening the drain taps There is one at the bottom of the radiator and another on the right side at the rear of the crankcase Open the heater water cock Water should then be allowed to run through until it comes out clear When refilling and particularly if cold water is used a few minutes must be allowed for air to escape past the thermostat valve before final topping up is effected In winter when flushing the radiator take care to preserve the cooling mixture if anti freeze has been added Speedometer Drive Disconnect the cable from the speedometer end and pull the inner member out of the casing Lubricate by dipping it in fairly thick oil To reassemble thread the oily shafting into the casing giving a twisting movement while threading since this will help to engage it easily at the gearbox end When the engagement is fel
5. detail of the main components Although the A40 Sports manifolds and carburetters differ to those of the above illustration the main construction and servicing operations are identical unless otherwise stated Bt eed io iii SERVICE MANUAL AUSTIN 40 NOOTVS LASUAWOS OtV FHL SERVICE MANUAL AUSTIN 40 514045 OPV JHL SERVICE MANUAL AUSTIN 40 cum s OtV JHL SERVICE MANUAL AUSTIN A40 dfi Old LMD 0 OP V xii AUSTIN 40 YW Examination for Wear Bearings Clutch Shaft Bushes First and Third Motion Shaft Bush Gear Synchronising Cones Laygear Thrust Washers Layshaft and Bushes Third Motion Shaft Sleeve 1 41 4 4 4 41 Gear Change Meclianism Adjustment sug Description Lubrication N MM Removing the Gearbox PROPELLER SHAFT Description Dismantling Examination Lubrication Reassembling Y Removing Complete Assembly Replacing Shaft aen Tests for Wear E Section lad ind KO INK O FRONT HUBS AND INDEPENDENT SUSPENSION Section H Data e S Lis Front Hubs TN 1 Assembly 2 Checking for Wear Dismantling Independent Front Suspension Coi Spring R efitting Coil Spring Removal Suspension Assembly me Suspension Check for Wear
6. kg cm Dimensions Sports No of cylinders 4 Bore 2 578 ins 65 48mm stroke 3 5 ins 89mm R A C rating 10 6 capacity 73 17 cu ins 1 200 B H P 46 46 63 at 5 000 r p m max torque 59 lbs ft 8 15 kgm at 2 400 r p m compression ratio 7 2 to 1 oil pressure 45 to 50 lbs per sq in 3 16 to 3 51 kg cm Valve Timing and Clearances Inlet valve opens 5 B T D C and closes 45 A B D C Exhaust valve opens 40 B B D C and closes 10 A T D C Inlet and exhaust valve clearances 015 ins 38 cm FUEL SYSTEM Carburetter Saloon Make Zenith Type 30 VIG 8 Choke tube 25 Main jet 90 Compensating jet 65 slow running jet 50 Needle and seating 1 5 Pump jet 50 Carburetter Sports Twin S U Carburetters inclined at an angle 20 Needle model EK Fuel Pump Sphinx fuel pump type U normal working pressure 14 to 21 Ibs per sq in 105 to 189 CLUTCH A flexible dry plate Borg and Beck clutch Pedal free movement 3 in 1 9 GEARBOX Four forward speeds and reverse Steering column mounted gear lever synchromesh engagement for second third and top Ratios Ist 3 89 2nd 2 44 3rd 1 54 4th direct reverse 5 39 REAR AXLE Spiral bevel three quarter floating Crown wheel and pinion ratios Saloon 37 7 Sports 36 7 Com mercials 43 7 Overail Gear Ratios Ist 2nd 3rd 4th Rvse Saloon and Coup 20 54 12 88 8 13
7. 0 83 Track front 4 0 1 23 Maximum Interior Height 3 6 1 07 Track rear 4 1 26 Height over Front Seat G 3 1 0 94 Ground clearance 7 0 19 Front Seat Cushion Depth H 1 6 0 46 Turning circle 38 11 58 Front Seat Cushion Width 2 1 9 0 53 Luggage Compartment Height of Opening 1 7 0 50 Steering Wheel to Cushion 4 0 11 Luggage Compartment Width of Opening 3 10 1 17 Front Cushion above Floor K 10 0 27 Luggage Compartment Depth of Platform 2 9 0 84 Rear Cushion above Floor L 1 41 0 43 Luggage Compartment Capacity 13 cu ft 0 37 cu m Minimum Height Floor to Ground M 1 3l 0 39 Approximate Weight wheel 23s Overall Height us T jat N 4 9 1 46 tools and fuel 18 cwt 44 Ibs 934 kg xvi GENERAL SPECIFICATION A40 VAN DIMENSIONS English Metric A40 COUNTRYMAN DIMENSIONS English Metric ft ins metres ft ins metres Pedal to Seat Squab A 3 3 0 99 Steering Wheel to Seat A 7 0 18 Steering Wheel to Seat Squab B 1 3 0 38 Pedal to Seat Squab B 3 4 1 01 Steering Wheel to Seat 55 0 16 Steering Wheel to Seat Squab ja 1 4 0 42 Height of Seat above Floor D 1 11 0 34 Height of Front Seat above Floor D 1 0 0 31 Seat Cushion Depth A E 1 5 0 43 Depth of Front Seat ja T E 1 7 0 48 Height over Seat F J 3 0 99 Height over Front Seat Sya F 3 3 0 99 Cab Floor to Ground unladen G 4 0 40 Height of Rear Seat above Floor ide G 1 4 0 42 Length of Body Floor H 6
8. 5 28 28 46 Sports 20 00 12 52 7 89 5 14 27 68 Commercials 23 89 14 95 9 43 6 14 33 09 STEERING 14 to ratio cam gear steering Toe in 1 l6 in to 1 8 in SUSPENSION Front Independent coil springs Castor angle 2 Camber angle 1 Swivel pin inclination 64 Rear Semi elliptic underslung reverse camber springs BRAKES Girling hydraulic front and rear Front brakes of two leading shoe design Pedal free movement 41 in Handbrake operates mechanically on rear wheels only FRAME Welded pressed steel frame with full length box section side front and rear members The centre part is stiffened by cross bracing Additionally the cross bracing of the Sports chassis is completely boxed in to give the greater torsional and diagonal strength required for a sporting car CAPACITIES Petrol tank 8 gallons 10 5 U S gallons 37 litres Oil sump 7 pints 8 4 U S pints 4 litres in clusive of filter cooling system Saloon 12 pints 14 4 U S pints 6 82 litres Sports 14 pints 16 8 U S pints 7 9 litres Gearbox 3 pints 3 6 U S pints 1 68 litres Rear axle 21 pints 2 7 U S pints 1 26 litres Battery capacity 38 ampere hours at 10 hour discharge rate GENERAL SPECIFICATION LEADING DIMENSIONS A40 SALOON DIMENSIONS English Metric A40 COUP DIMENSIONS English Metric ft ins metres a WIE 1 ft ins metres Pedal to
9. AUSTIN A40 Series GS4 GV4 GP4 GQU4 GD3 605 Workshop UBL ET d A BMG Service Publication AUSTIN A40 MODELS SERIES GS4 GD5 GV4 4 GQU4 DECEMBER 1957 ESE THE AUSTIN MOTOR COMPANY LIMITED BIRMINGHAM ENGLAND SSS Publication No 97H 890E Printed in England World Copyright 29 55 46571 ii AUSTIN A40 SERVICE MANUAL ET This manual has been compiled to assist Austin Distributors and Dealer Organisations in the efficient servicing and maintenance of the A40 Models Each assembly of the major components is described in detail In addition comprehensive instructions are given for complete dismantling assembling adjusting and inspection of these assemblies It is emphasized that only genuine Austin parts should be used as replacements for components found unfit for further service The information given within these pages is authentic and covers the models produced prior to the publication date on page 1 Modifications to later vehicles which may become necessary will be described in subsequent editions of the manual When ordering spares it is imperative that operators use the Spare Parts List of the appropriate model and not refer to the manual AUSTIN A40 SERVICE MANUAL 40 O H V ENGINE LLL PARAL J Im UN n R wai a AN AN 19 4 n J A sectional view of the engine showing the
10. Number Plate Illumination Sidelamps Stop Tail Lamps Starter pst Starter Dismantling i Starter Normal Service Starter Reassembly Starter Removal Starter Switch Starter Testing Trafficators Description Windscreen Wiper Location and Remedy of Faults Charging Circuit Ignition Curcuit Lighting Circuit Starter Motor BODYWORK Secti Care of the Bodywork P Dismantling and Assembly of Parts and cour Apron Bonnet Top Bonnet Surround and Grille Bumpers Fascia and Instrument Board Flitch Plate A Front Wing and Baffles Heater Hood Coup Radio Rear Wings Seating Sliding Roof Valance Panel Windows and Doors Windscreen Dismantling and cem of M Parts Commercials 7 Bonnet Bumpers and Apron Fascia Panel 3 Front Wings and Flitch Plate Heater Unit Rear Wheel Covers Seating Windows and Doors Windscreen Dismantling and of D Parts Sports Bonnet s Boot Lid Bumpers Doors and Windows Fascia Panel Flitch Plate Front Wings Grille Heater Hood Rear Panel Rear Wings Seating Shroud Windscreen on P 1 AUSTIN A40 Page Removing and SUME the Saloon and Coup 11 Removing Refitting the Body Commercials Removing and Renting the Body Sports ux 25 Page SERVICE TOOLS Section Q Engine and Clutch Tools is Fr
11. Seat Squab 2 10 0 86 Pedal to Seat Squab A 3 1 04 1 5 0 43 2 10 0 86 Steering Wheel to Seat Squab B 10 0 25 Steering Whecl to Seat Squab B 1 5 0 43 2 0 36 10 0 25 Distance between Seats C 7 0 18 Maximum Distance between Seats C 11 0 28 Rear Seat Cushion Depth D 1 7 0 50 Rear Seat Cushion Deptb is D 7i 0 50 Height over Rear Seat E 2 10 0 88 Height over Rear Seat E 2 10 0 86 Maximum Interior Height F 3 11 1 19 Maximum Interior Height F 3 11 1 19 Height over Front Seat G 3 04 0 92 Height over Front Seat G 3 Ot 0 92 Minimum Height of Door Opening H 3 7 1 09 Height of Door Opening H 3 4 1 02 Front Seat Cushion Depth I 6i 0 47 Front Seat Cushion Depth I 0 47 Steering Wheel to Seat Cushion J il 0 14 Front Seat Cushion Width LA 1 91 0 54 Front Seat Cushion above Floor K 0 35 Steering Wheel to Cushion 5 0 14 Rear Seat Cushion above Floor L 1 2i 0 37 Front Cushion above Floor L 1 0 35 Overall Height vl M 5 4 1 63 Rear Cushion above Floor M 1 14 0 34 Overall Length N 13 3 4 05 Minimum Hasht Floor to Ground N 1 0 39 Wheelbase 7 8i 2 35 Overall Height O 5 2i 1 59 Overall Width 5 3 1 60 Overall Length P 13 3 4 05 Body Width between Centre Pillars at Waist 4 0 1 22 Overall Width e 5 3 1 60 Front Seat Cushion Width max 1 10 0 56 Scuttle Width at knee height 3 9 1 14 Rear Seat Cushion Width 3 3 1 00 Rear Seat Maximum men 3 31 1 00 Maximum Width over Rear Seat 3 11 19 Wheel
12. TTENTIONS The following additional inspections and adjustments should be carried out periodically by an Austin Dealer at the mileages mentioned These attentions are not usually carried out by normal owner drivers and the tools supplied in the Tool Kit are not sufficient for the work entailed REGULAR EVERY 5 000 MILES 8 000 Km Decarbonising Valve Grinding and Tappet Adjustment This attention may not be needed so frequently on cars used for long journeys As a general rule a falling off in engine power with pinking indicates when de carbonising is due This operation entails such preliminary dismantling of components as the carburetter manifolds cylinder head and push rods The correct valve clearance measured between the rocker arm and the valve stem 15 015 with the engine hot or cold Shock Absorbers All the shock absorbers fitted to the A40 models with the exception of the A40 Sports fronts are of Arm strong manufacture Check the fluid levels and top up if necessary The correct level is just below the filler plug threads Carefully clear away all road dirt and grit from the vicinity of the filler plug before removal Use only Armstrong Super Thin Shock Absorber Oil Girling shock absorbers are fitted to the A40 Sports front suspension They must be removed from the chassis before inspecting the fluid levels or topping up with Girling Piston Type Thin Fluid EVERY 6 000 MILES 9 600 Km External Oil Filte
13. VERY 2 000 MILES 3 200 Km Engine Drain the sump and refill with new oil Capacity Is 7 pints inclusive of filter Gearbox Check the level and top up if necessary For access lift the front carpet and remove the small plate on the side of the gearbox covering The filler plug is then accessible Clean any dirt or grit away from around the plug Remove the plug and fill up to the bottom of the threads This gives the correct level Shock Absorbers Check all shock absorbers for leaks and see that the rubber bushes are undamaged Clutch Pedal With the oil gun lubricate the nipple at the pivot of the lever On left hand drive models the nipple is situated on the underside of the larger diameter tube of the telescopic fitting see Section E page 3 Brakes Examine the brakes and adjust if necessary Apply the oil gun to the balance lever on the rear axle case the handbrake pivot and the pedal pivot nipple Rear Axle Check the level and replenish if necessary The correct oil should be used and injected into the axle casing from underneath using the adaptor on the oil gun First remove the plug which is on the right lower front side of the axle carrier then place the end of the acaptor into the oil hole and inject the oil The plug also serves as an oil level indicator There fore do not replace the plug at once but give time for the superfluous oil to run out if too much has been injected This is most important becau
14. base 7 8i 2 35 Track front at ground a 4 04 1 22 Track front at gr ound 4 0 1 22 Track rear 4 2 1 27 Track rear 2 4 2 1 27 Ground Clearance 7i 0 19 Ground Clearance 7i 0 19 Turning Circle 37 0 11 28 Turning Circle 37 0 11 28 Luggage Compartment Height of Opening 1 8 0 51 Luggage Compartment Height of Opening 8 0 51 Luggage Compartment Width of Opening 2 7 0 80 Luggage Compartment Width of Opening 2 7 0 80 Luggage Compartment Maximum Depth 3 Of 0 93 Luggage Compartment Depth of Platform 3 01 0 93 Luggage Compartment A pprox Capacity 10 cu ft 0 28 cu m Luggage pore ment e 1O0cu ft 0 28 cu m Luggage Carrier Load m cwt 51 kg Luggage Carrier Load cwt 51 kg Approx Weight less spare wheel tools and Approximate Weight less spare wheel tools fuel plus oil and water e 0 wee I9cwt 141bs 971 kg and fuel plus oil and water e wee 194 991 kg A40 SPORTS DIMENSIONS English Metric A40 SPORTS DIMENSIONS English Metric ft ins metres 3 6i 1 08 ft ins metres Pedal to Seat Squab A 3 2 0 97 Overall Length ae vi O 13 3i 4 04 2 0 37 Overall Width ss 5 1 1 55 Steering Wheel to Seat Squab B i 10 at knee tq 2 1520 ody Wi over Front Seat Distance between Seats c 8i 0 22 Rear Seat Maximum Width 3 0 99 Rear Seat Cushion Depth D 5 0 43 Wheelbase ES eus 7 8i 2 35 Height over Rear Seat E 2 8
15. be taken to a local Austin dealer for cleaning in a special machine Clean and dress the plug points and reset to the correct gap of 018 in for the Saloon and 025 in for the Sports Before replacing the plugs check that the copper washers are in a sound condition Never over tighten a plug but ensure that a good joint is made between the plug body the copper washer and the cylinder head Saloon and Commerials use Champion N 8B Long Reach 14 mm plugs Sports use Champion 8 Long Reach 14 mm plugs Distributor Cam and Drive Shaft Bearings Lubricate the distributor camshaft bearings by withdrawing the rotor arm from the top of the distri butor spindle and carefully adding a few drops of thin machine oil round the screw exposed to view Take care to refit the arm correctly by pushing it on to the shaft and turning until the key is properly located REGULAR ATTENTIONS xix Distributor Cam Apply a trace of engine oil to the distributor cam Do not let any oil reach the contact breaker points Distributor Automatic Advance Remove the distributor cap and add a few drops of engine oil through the hole in the contact breaker base through which the cam passes EVERY 5 000 MILES 8 000 Km Air Cleaner Saloon Every 5 000 miles the air cleaner should be removed cleaned and wetted with fresh oil To do this slacken the clamping bolt and release the breather pipe from the valve rocker cover lift off the
16. eering side cross tube nipples 4 Top up the steering idler with oil via the filler plug in the top cap Wheels and Tvres Check the tightness of the wheel nuts also check the Lyre pressures using a tyre gauge and inflate if necessary See that all valves are fitted with valve caps and inspect the tyres for injury Remove any flints or nails from the treads and ensure that there is no oil or grease on the tyre since these substances prove injurious to rubber For recommended pressures see Section N A tyre that loses more than three to four pounds per square inch in a week should be suspected of a puncture but first make sure that the valve is not leaking FIRST 500 MILES 800 Km Engine On new and reconditioned engines the sump should be drained and refilled with new oil after the first 500 miles At the same time as these changes are made the cylinder head nuts should be tested and tightened if it is found necessary With the new engine during the running in and settling down period approximately 1 000 miles a slight falling off of power sometimes develops it is then advisable to lightly grind in the valves and re set the valve clearances On such occasions there is no need to decarbonise the tops of the pistons Gearbox and Rear Axle After 500 miles on new vehicles drain and refill the gearbox and rear axle Always drain the oil after a run since it will flow more easily when warm xviii REGULAR ATTENTIONS E
17. etric A40 PICK UP DIMENSIONS English Metric ft ins metres Pedal to Seat Squab E 01 0 93 ft ins metres Steering Wheel to Seat Squab B 0 33 Centre of Rear Wheel to Bumper N 3 7 1 09 Steering Wheel to Seat 61 0 16 Overall Length O 2 4 4 07 Height of Seat above Floor D 0 33 Overall Length tailboard down ed 14 4 4 3 Seat Cushion Depth E 5 0 43 Overall Width 5 14 1 56 Height over Seat F 3 9 0 97 Track front 4 11 1 25 Cab Floor to Ground G I 4 0 41 Track rear 4 2l 1 28 Length of Body Floor H 5 3 1 61 Interior Body Width 4 3 1 29 Height over Body Sides I 1 5 0 43 Width between Wheelarches 1 00 Body Floor to Ground J 2 4i 0 72 Ground Clearance 7i 0 19 Overall Height K 5 6 1 70 Turning Circle 38 0 11 58 Centre of Front Wheel to Bumper L 2 0 0 61 Approx Weight less spare wheel tools and Wheelbase M 7 8 2 35 fuel plus oil and water id 18 cwt 44 lbs 934 kg AUSTIN 40 SERVICE MANUAL xvii REGULAR ATTENTIONS The following is a convenient list of regular attentions which the car should receive to keep it in good mechanical condition owner or the local garage These instructions should be closely followed whether the attentions are performed by the The attentions under the Daily and Weekly headings are based on the assumption that the maximum mileage per week does not exceed 500 but see After Sales Service as detailed in the handboo
18. k for special attention during the first 1 000 miles Under more arduous conditions such as very dusty or very muddy roads long distances at high speeds or with heavy loads it will be advisable to attend to chassis lubrication more frequently DAILY Engine Check the level of oil in the sump and top up if necessary to the full mark on the dipstick situated on the right hand side of the engine When adding oil through the oil filler at the rear end of the valve rocker cover pour slowly to avoid the oil overflowing If the engine has been running allow a few minutes for the oil to settle before checking the level Radiator Check the level of water in the radiator and top up if necessary Fill to just below the top of the filler plug thread when the engine is cold Fuel Tank Check the quantity of fuel in the tank and add upper cylinder lubricant if desired EVERY 500 MILES 800 Km Shackle Pins These are on the rear ends of the rear road springs and should be given a charge of oi once a week There are two nipples one for each top shackle Front Suspension Apply the oil gun to each of the lower wishbone arm outer bearing nipples Swivel Axles Apply the oil gun on the two nipples on each swivel axle This is best done with the axle jacked up since the oil is then able to penetrate to the thrust side of the bearing Steering Connections Apply the oil gun to the steering centre cross tube nipples 2 and the st
19. ont Suspension and Hub Tools Gearbox Tools xd Oil Gun Axle Tools Steering and Chassis Tools un QN S2 GJ SERVICE MANUAL xiii Page PART NAME ALTERNATIVES SERVICE FACILITIES LUBRICATION Section R Section S Section T xiv AUSTIN 40 GENERAL SPECIFICATIONS manual contains information for vehicles of chassis number 657001 and engine number 700001 onwards Some models prior to this were fitted with series G S 3 engine see manual publication No 441D When ordering parts note engine and chassis numbers quoted on spare parts list The engine number is located on the right hand side of the cylinder block and the chassis number on the chassis adjacent to the engine front mounting bracket on the opposite side of the steering column For quick reference these numbers are stamped on a plate attached to the sun visor on all models except the Sports where it is fixed to the inside of the glovebox lid Except where specifically stated all information given for the Saloon should be regarded as also SERVICE MANUAL appertaining to the Coup and Commercial models ENGINE Dimensions Saloon No of cylinders 4 Bore 2 578 ins 65 48mm stroke 3 5 ins 89mm R A C rating 10 6 capacity 73 17 cu ins 1 200 c c B H P 42 42 58 at 4 500 r p m Max torque 58 lbs ft 8 02 kgm at 2 400 compression ratio 7 2 to 1 oil pressure 45 to 50 Ibs per sq in 3 16 to 3 51
20. r Take off the old filter and replace it with a new unit Use only A C Sphinx type ARIC or Purolator Micronic type MF2001 EVERY 10 000 MILES 16 000 Km Contact Breaker Points Clean the contact breaker points Cleaning of the contacts is made easier if the contact breaker lever which carries the moving contact is removed To do this slacken the nuts on the terminal post and lift off ATTENTIONS xxi the spring which is slotted to facilitate removal Before replacing smear the pivot on which the contact breaker works with clean oil Check the contact breaker setting re setif necessary The correct gap is 014 0161 Starter Commutators Clean also check the freedom of the brushes within the holders Track Adjustment Check the front wheel alignment 1 amp 3in toe in taken along a horizontal line at centre height using the wheel rims as data points Steering Box Check for wear This may be felt when the front wheels can be moved without creating any movement at the steering wheel Clutch Pedal Clearance Check and adjust if necessary The pedal should be depressed approximately in before the clutch springs are felt to be under compression Oil Sump Remove and clean the sump also the oil pump strainer gauze Front and Rear Hub Bearings Check for any signs of wear Details for this operation are given in Sections H and K Ignition Timing Check the setting and adjust if necessary
21. s road spring clips shock absorber retaining bolts and body mounting bolts Examine other parts such as steering connections brake rods etc neglect of any may be followed by an expensive repair and inability to use the car for a lengthy period XX REGULAR ATTENTIONS EVERY 10 000 MILES 16 000 Km Universal Joints Lubricate the universal joints The front joint is best lubricated from above through the hole in the propeller shaft tunnel at a point between the two front seats The rear joint must be lubricated from below Move the car to bring the nipples to the required positions Also test the flange bolts and tighten if these have worked loose the nuts are secured with tab washers Clutch Operating Shaft Lubricate the two nipples sparingly SPORTS Sparking Plugs Renew the sparking plugs Champion N 8B Long Reach for the Saloon and Champion N A 8 Long Reach for the Sports Dynamo Bearings Unscrew the wick type lubricator cover and if the wick is dry refill the cup with high melting point grease Note From engine No 857519 Saloon Coup and Commercials and engine No 817406 Sports the wick type lubricator has been dispensed with Instead a hole has been drilled in the end cap through which a few drops of oil S A E 20 should be forced every 6 000 miles REGULAR ATTENTIONS The following list of attentions 1s of those which cover components or accessories not common to the Saloon All o
22. se if the rear axle is overfilled the lubricant may leak through the brakes and render them ineffective Wipe away the excess oil from the casing Steering Column Lubricate the felt washer at the top of the steering column by adding a few drops of light machine oil through the hole in the steering wheel hub close to the steering column Battery Ascertain the state of charge of the 12 volt battery by taking hydrometer readings The specific gravity readings should be Fully charged 1 280 1 300 Half charged approx 1 201 Discharged below 1 150 These figures are for an assumed electrolyte tem perature of 60 deg F Check that the electrolyte in the cells is just level with the tops of the separators If necessary add a few drops of distilled water Never use tap water as it contains impurities detrimental to the battery Never leave the battery a dis harged condition If the car is to be out of use for any length of time have the battery removed and charged about once a fortnight Brake Supply Tank Inspect and refill to the correct level This tank is situated on the radiator mounting frame of the Saloon and secured to the scuttle of the Sports and Commer cials Use only the recommended fluid EVERY 3 000 MILES 4 800 Km Sparking Plugs Remove the plugs and clean off all carbon deposit from the electrodes insulations and plug threads with a stiff brush dipped in paraffin Alternatively the plugs may
23. t the shafting can be pushed right home so that the top square end stands out from the casing approximately inch Gearbox Drain when the oil is warm after a run and refill to the level of the filler plug with new oil Capacity 3 pints Rear Axle It is wise to drain the rear axle after a run as the oil will flow more freely when warm then refill to the level of the filler plug with new oil Capacity 21 pints Front Road Wheel Hubs Unscrew the hub cap and recharge with grease It is important that the hubs are not given too much grease as it may penetrate to the brake shoes Rear Road Wheel Hubs These are packed with grease upon assembly and do not require greasing attention Fan Belt The fan belt must be sufficiently tight to prevent slip at the dynamo and water pump yet there should be sufficient slackness to move the centre of the belt side ways about one inch To make any necessary adjustment slacken the bolts and raise or lower the dynamo until the desired tension of the belt is obtained Then securely lock the dynamo in position again Steering Box The steering box should be topped up with oil using the special adaptor on the oil gun Take out the hexagon plug on the side of the steering box to inject the oil Make certain that grit does not enter the casing during the operation and wipe away any excess oil afterwards General Check Examine and if necessary tighten all bolts and nuts of such components a
24. ther attentions should be carried out as previously recommended EVERY 2 000 MILES 3 200 Km Air Cleaners The air cleaners should be dismantled and the elements thoroughly cleaned with the aid of compressed air see page C 12 If an element has become contami nated with oil or grease it should be thoroughly washed in petrol and allowed to dry before being replaced Carburetters Remove the knurled cap at the top of each carburet ter and add a few drops of oil to the suction piston chambers EVERY 5 000 MILES 8 000 Km Carburetters The flow of fuel at the carburetter inlet unions to the float chambers should be checked and if necessary the filters in those unions should be cleaned Disconnect the float chamber fuel supply pipes when the filters may be taken out and cleaned slacken the float chamber cap nuts and unscrew their securing bolts The chambers themselves can then be removed for cleaning EVERY 10 000 MILES 16 000 Km Carburetters Clean out the suction assembly by removing the two securing screws and lifting off the body in the same plane to avoid damage to the needle Lift out the hydraulic damper and wash the assem bly in petrol Dry thoroughly refit and replenish the damper with oil When fully re assembled lift the piston to its fullest extent thus expelling the surplus oil through the top cap and at the same time lubricating the rod Air Cleaners Remove the top caps and renew the elements SERVICE A
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