September-October 1956 - Pontiac Custom Safari 55 56 & 57
Contents
1. 1 Wash the surface of the unpainted panel with white gasoline or some other suitable solvent prior to painting 2 Mix the entire contents of the one ounce bottle of anti scuff compound 565974 with one half pint 8 fl oz of uncut lacquer of desired color Mix thoroughly 3 Reduce this mixture to spraying viscosity and spray panel with three separate coats allowing each to dry long enough for proper flowout CAUTION Avoid excessive finish thickness as this tends to change the appearance of the grain of the panel 4 Allow to dry a minimum of 6 to 8 hours before installing in car www PontiacSafari com SERVICE CRAFTSMAN NEWS Fig 3 J 6116 Clutch Unit Holding Fixture Modification MODIFICATION OF CLUTCH UNIT HOLDING FIXTURE J 6116 The gear ratio of the 1957 Strato Flight reverse unit has been decreased resulting in a larger re verse sun gear The larger sun gear will not fit through the Clutch Unit Holding Fixture J 6116 when mounting the clutch unit in the fixture for disassembly or assembly To enable proper mounting of the unit it is rec ommended that the hole in the Holding Fixture be enlarged by filing or grinding approximately 1 16 as indicated in Fig 3 USE CORRECT TRIM CEMENT TO PREVENT BLEEDING To prevent Bleeding of trim attaching cement through imitation leather and genuine leather up holstery it is necessary to follow these directions 1 3M Minnesota Mining and2. Reports have been received of interference be tween the air conditioning compressor hoses and the crankcase oil level indicator when the indicator is removed to check engine oil level Continual removal and replacement of the oil level indicator will even tually break the indicator On cars where this condition has occurred the oil level indicator tube assembly may be modified as follows to permit easy removal of the indicator 1 Procure a piece of sheet metal 1 32 thick 1 7 8 long and 5 8 wide 2 Drill two 3 8 holes 1 1 2 apart 3 Remove oil level indicator upper tube assembly from engine attach extension to upper tube as sembly with a nut lock washer and bolt and replace upper tube assembly and extension NOTE This extension may be brazed on to the upper tube assembly extension rather than attaching with a bolt lock washer and nut 4 Replace oil level indicator upper tube assembly SERVICE MANAGER IMPORTANT This News contains important service information on Pontiac cars Each subject should be cross referenced in the space provided at the end of each section in the Shop Manual or its Supplement Be sure and cover every point with your entire organization Each service man should sign in the space below after he has read and understands the information in this issue 60
3. Manufacturing Super Weatherstrip Adhesive Neoprene or its equiva lent should be used when attaching all leather or imitation leather trim 2 3M Trim Cement or its equivalent should be used on all Cloth Trim This is the cement that was previously recommended for use on all trim 58 TWO TYPES OF TWO TONING USED IN 1957 Pontiac will make available two styles of two toning for 1957 models These combinations will be called Starlight and Accent The Starlight Two Tone combination will have the Lower Body Area of one color with the Upper Body Area and Insert of the other color The Accent Two Tone combination will have the Lower and Upper Body Areas of one color with the insert the other color Three code letters will designate the two tone combinations and the paint colors to be used The first letter signifies the color of the lower body the second letter signifies the color of the roof and the third letter signifies the color of the insert Two examples of the coding appear below 1 Starlight AUU will mean Raven Black lower and Sage Blue upper with Sage Blue insert 2 Accent AAU will mean Raven Black lower and upper body with Sage Blue insert Solid Color will be designated by use of a triple letter combination For example AAA will mean a solid Raven Black Pontiac does not furnish a three tone paint com bination NEW CONTROL VALVE ASSEMBLY IMPROVES 2 3 SHIFT Beginning with production trans
4. cases of this nature indicates that the usual cause of the condition is a leak at the carburetor throttle body to bowl gasket The gasket originally used was shaped in such a manner that it could cause a leak between the vacuum passage and one of the secondary throats A new gasket is now being used in production to eliminate the possibility of a leak The new gasket is available under part number 7009762 DO To test for a choke vacuum leak remove the choke housing to manifold pipe and check the vacuum at the choke housing If vacuum is less than 10 inches improper choke action will result and the old gasket should be replaced with the new gasket The time allowance for this operation is 1 2 hours Loading During Warm Up New Rochester 4 GC Carburetor Adjustment March 1956 To prevent loading during warm upof the Roches ter 4 GC carburetor the contour of the choke piston link has been changed This gives increased opening of the choke valve on cold idle With the choke valve closed the piston should protrude approximately 1 16 from the cylinder and the piston pin is one half exposed On all cases of loading the piston link should be bent to achieve the correct choke piston position The checking and setting of the choke piston as described above should be considered in the future as a regular carburetor adjustment and should be per formed as such during carburetor overhauls and ad justments Extreme care should be u
5. is only necessary to tighten the bowl cover attaching screws to eliminate this condition If this does not correct the complaint it may be necessary to install a bushing or standpipe in the vacuum passage between the bowl cover and bowl Installation of this bushing assures a more positive seal and prevents fuel leaking into the vacu um passage on left turns This bushing is released for service under part number 3732788 ROCHESTER 4 JET CARBURETOR Rochester 4 Jet Choke Piston Change Rochester 4 Jet and Carter 4 Barrel Carburetors Modified December 1955 The Rochester 4 Jet choke piston has been modi fied to improve cold engine operation and eliminate engine stalling after a cold start A comparison of the new piston and the earlier type shows that the new piston has only two lands and one hole as com pared to three lands and two holes found on the first type The new piston is released for service under part number 7009710 All Rochester carburetors using the new piston will be identified by the letter F embossed on the carburetor identification tag Stalling During Warm Up Correction of Rochester 4 Jet Vacuum Leak January 1955 Engine stalling during warm up on cars equipped with the Rochester 4 Jet carburetor may be due to a leak in the choke piston vacuum passage A leak in the passage reduces the effect of engine vacuum in opening the choke thereby allowing the engine to load up Investigation of
6. 4 Barrel has been changed from one notch rich to center index If the center index setting does not completely eliminate the com plaint it is permissable to go to a one notch lean setting Carburetor Flooding New Fuel Filter June 1955 A new glass bowl impregnated fiber element precipitation type fuel filter is now being installed on all cars in production To assist in correcting carburetor flooding problems on early production cars the filter has been released as a service package under part number 854345 It can be installed using one 90 elbow part number 504500 or 114920 54 SERVICE CRAFTSMAN NEWS Using Proper Viscosity Oil in Heavy Duty Air Cleaner Heavy Duty Air Cleaner Oil Viscosity July 1956 It is necessary to use only recommended vis cosity oils in oil bath air cleaners The use of an oil lighter than specified will result in oil being drawn into the combustion chamber causing spark plug fouling and poor performance Improper oil will also contribute to exhaust smudging of the bumper face bar at the exhaust outlet The same condition will be experienced if the oil level is too high in the air cleaner If the average outside air temperatures are above 32 F the use of SAE 50 viscosity oil is required in the oil bath air cleaner Average temperatures of below 32 F require the use of SAE 20 W oil CARTER 4 BARREL CARBURETOR Carter 4 Barrel Choke Piston and Vacumefer Spring Changed Ro
7. Hydra Matic Shop Manual is now being used in all 1956 Hydra Matic Transmissions The early type washer is completely interchange able with the new washer and will continue to be used for service until present supplies are exhausted ROCHESTER 4GC SECONDARY THROTTLE VALVE ADJUSTMENT Several cases of rough hot idle on the Rochester 4 GC carburetor have been traced to a sticking action of the secondary throttle valve To eliminate this condition a carburetor adjustment has been released which will ensure a positive closing of the secondary throttle valve on idle This adjustment establishes tension of the secondary lock spring Fig 4 against the secondary throttle operating lever holding the secondary throttle valves closed The adjustment will apply to all 1956 Rochester 4 GC carburetors as outlined below This is an on the car adjustment only Following is the adjustment procedure 1 Adjust carburetor idle speed and mixture Be sure secondary valves are closed during this adjustment 2 Shut off engine and manually close choke valve 3 Position idle speed screw on the second step of the fast idle cam 4 Measure clearance between the secondary lock spring and the secondary throttle operating lever This clearance should be 042 Bend lock spring to adjust 99 e cy fase SECONDARY T SECONDARY LOCK SPRING THROTTLE f OPERATING LEVER r 042 Ei Fig 4 Measuring Clearance Between Secondary
8. Lock Spring and Secondary Throttle Operating Lever It is important that this adjustment be made ac curately 042 clearance ensures the proper amount of tension when car is on hot idle Too much tension less than 042 clearance could interfere with the idle speed adjustment Another possible cause for secondary throttle valve sticking was covered on page 48 of August 1956 Service Craftsman News NEW NEOPRENE WATER PUMP TO CYLINDER HEAD INLET ELBOW HOSE In all cases of power steering pump oil seal leak inspect the hose between the water pump and the left hand cylinder head inlet elbow for oil damage If the hose is damaged replace with the new neoprene hose part No 524631 The neoprene hose is im pervious to hydraulic fluid and therefore will not be damaged by fluid which may spill or leak from the power steering pump It will fit all 1955 and 1956 cars Stock of the former hose can be used on cars without power steering or on the right hand side of cars with power steering www PontiacSafari com HIGH POINT MARK ON UPPER END OF STEERING SHAFT On early 1957 Power Steering equipped cars a few units were used having the high point mark on the upper end of the steering shaft located toward the bottom rather than at the top when the steering is at the high point front wheels in the straight ahead position If it is necessary to locate the high point it must be determined by disconnecting the steering connecting rod a
9. chester 4 Jet and Carter 4 Barrel Carbu retors Modified December 1955 To improve cold engine operation and eliminate engine stalling after a cold start the Carter 4 Barrel Carburetor vacumeter piston spring and choke piston have been changed The new choke piston is the same piston that was used on the 1955 Carter 22685 carburetor and is available for service under part number 7008360 The vacumeter spring is available for service under part number 7009746 All Carter carburetors built with an identification tag of M 5 or later will contain the new type parts In all cases of attempted correction of poor cold engine operation or cold stalling on Carter 4 Barrel carburetors built prior to units with tag number M 5 both the choke piston and the vacumeter spring must be installed Carter Model 2364SA Released Carter 4 Barrel Carburetor Changed March 1956 A new air horn casting and choke housing are now in production on the Carter WCFB 4 Barrel carburetor The new air horn and choke housing are not individually interchangeable with the earlier type Carburetors using the new parts will be known as model 2364SA www PontiacSafari com SERVICE CRAFTSMAN NEWS Cut Out on Left Turn Correction of Carter 4 Barrel Left Turn Cut Out July 1956 The cause of Carter 4 Barrel equipped cars cut ting out on turns is leakage of fuel from the carbu retor bowl to the choke vacuum passage In some instances it
10. f it does the United Motor Service Manual should be consulted for proper testing procedures 06 2 Ya DRILL Sie 18 TAP r 7 9 Fig 1 J 5923 Carburetor Holding Stand Modification MODIFICATION OF CARBURETOR HOLDING STAND J 5923 The new 1957 Rochester two barrel carburetors will have a different throttle body The carburetor holding stand J 5923 must be modified to accom modate usage on off the car repairs The holding stand can be used satisfactorily if it is modified according to the dimensions shown in Fig 1 Two new 1 4 holes must be drilled and tapped with a 5 16 18 tap in the location as shown 15 LB RADIATOR CAP USED IN 1957 AIR CONDITIONED CARS All 1957 air conditioned equipped cars will use 15 lb radiator pressure caps instead of the 13 lb cap used on all other models This part can be or dered under part number 861042 1957 ENGINE IDLE SPEED ADJUSTMENT The hot engine idle speed on 1957 Hydra Matic equipped cars should be set with the transmission in Drive range The idle speed specifications are as follows Idle Speed in Drive All Hydra Matic Except Air Conditioning 430 450 RPM All Air Conditioning 900 520 RPM NOTE Idle speed should be set on Air Con ditioned Cars with Air Conditioning off Synchro Mesh transmission equipped cars will continue to be adjusted 450 470 RPM www PontiacSafari com SERVICE CRAFTSMAN NEWS Fig 2 Cor
11. g Unioader Adjustment Procedure Carburetor Unloader Adjustment Procedure May 1956 www PontiacSafari com 1 Loosen top trunnion nut on intermediate throttle rod and push down rod until it bottoms 2 With rod in this position tighten nut finger tight plus three full turns This ensures maximum ac celerator pedal travel commensurate with proper clearances at toe board 3 Remove carburetor air cleaner assembly 4 Depress accelerator pedal forcibly tofloor This should be done by person sitting in drivers seat of car to simulate actual driving conditions Check to see that accelerator pedal is not hitting hump over transmission Move upper end of pedal to left if necessary by enlarging left hand hole in accelerator pedal bracket and rotating bracket counterclockwise 5 With accelerator pedal depressed as in step 4 bend unloader tang on carburetor to give correct opening between edge of choke valve and air horn Individual specifications vary with carbu retor being used Check shop manual for indi vidual specification 6 Replace air cleaner assembly The above procedure will eliminate variance in linkage floor mat pedal location etc and should ensure correct unloader action Hard Starting of Partially Warmed Up Engine Carburetor Choke Setting Changed March 1956 In order to correct a hard starting condition of a partially warmed up engine the choke setting on Rochester 4 Jetand Carter
12. justments previously published which no longer apply have been left out or replaced with current information If necessary reference may be made to the original articles listed in parentheses below the headings Some of the information con tained in this article is published for the first time It will be marked Not Previously Published in parentheses below the heading 03 CARBURETOR GENERAL Carburetor Icing Stalling Due to Carburetor Icing November 1955 In all cases of carburetor icing check exhaust gas passages in the throttle flange for carbon build up Clean holes in manifold and manifold surface Always use new gasket to ensure against leak Unloading Procedure Carburetor Unloading Procedure January 1956 If an engine fails to start after a reasonable amount of cranking it may be flooded In this case forcibly depress the accelerator to the floor to open the choke Hold firmly in this position while crank ing do not pump accelerator at any time If this procedure does not relieve the flooding it is possible that there is interference between the accelerator pedal and the floor mat at the hump above the transmission Throttle linkage adjustment should be checked to ascertain that the TV lever stop does not interfere with unloading action at the carburetor with the choke fully on A thick floor mat will sometimes prevent full travel of the accelerator pedal thereby interfering with choke unloadin
13. mission P56 199036 a new control valve assembly provides lower 2 3 and 3 4 shift speeds and improved 2 3 shift feel The changes were made by recalibrating several springs in the clutch and shift valve bodies and by removing the 1 8 check ball at the transition valve A service kit part number 8616966 is available for making this modification in the field The kit consists of a new 2 3 shift valve outer spring a new 3 4 shift valve inner spring and a new transition valve spring In addition to changing these springs when modifying valve bodies in the field the tran sition valve check ball 1 8 and the 3 4 shift valve outer spring should be removed and discarded The field modification can be summarized as follows Clutch Valve Body Assembly 1 Remove Transition Valve Spring black and re place with new spring gray www PontiacSafari com SERVICE CRAFTSMAN NEWS 2 Remove Transition Check Ball 1 8 Shift Valve Body Assembly 1 Remove 3 4 Shift Valve Outer Spring and discard 2 Remove 3 4 Shift Valve Inner Spring copper and replace with new spring black 3 Remove 2 3 Shift Valve Spring black and re place with new 2 3 spring black daubed with white paint The time allowance for this operation will be a straight time of 1 6 hours NEW FRONT UNIT DRIVE TORUS SPACING WASHER USED IN PRODUCTION A new Front Unit Drive Torus Spacer Washer referred to as Front Unit Drive Torus Thrust Washer in 1956
14. nd measuring load through the high point with a spring scale The location of the high point can also be checked by turning the steering wheel to its mid position by counting the turns from stop to stop FITTING HARMONIC BALANCER ON CARS EQUIPPED WITH AIR CONDITIONING Whenever it is necessary to replace the harmonic balancer and or key as a result of damage at the key or harmonic balancer keyway the following pro cedure should be used 1 Measure the thickness of the new key with a micrometer If the key measures on the low limit 187 then use a piece of shim stock to build the key thickness up to 1885 or to permit a slip fit in the keyway of the harmonic balancer 2 Add or delete shims as necessary to provide a slip fit 3 If the thickness of the key is such that it does not provide a slit fit 003 Min into the keyway of the harmonic balancer without the use of shims then carefully file the keyway in the balancer file both sides of the keyway to provide a slip fit of the balancer onto the crankshaft and key CAUTION DO NOT FILE THE KEY Since the key must fit in the crank shaft filing the key would provide too loose a fit in the crankshaft NOTE Before attempting any repair or fit of the key to the harmonic balancer keyway be sure the key in the crankshaft is properly positioned SERVICE CRAFTSMAN NEWS Fig 5 Dip Stick Installed DIP STICK MODIFICATION FOR 1956 AIR CONDITIONED CARS
15. rect Installation of Windshield Washer Outlet Hose WINDSHIELD WASHER OUTLET HOSE INCORRECTLY CONNECTED Product Information Reports received recently advise of ruptured vacuum pump diaphragms Our investigation of these cars has shown that the wind shield washer outlet hose has been connected in error to the air intake pipe on the bottom of the windshield wiper motor When the hose is connected in this manner and the windshield wiper is turned on the water in the washer bottle is drawn into the engine combustion chamber by way of the vacuum pump In passing through the pump the water causes a rupture of the vacuum pump diaphragm Hose A Fig 2 should be attached to the spray nozzle connection on the underside of the hood Do not connect it to the air inlet pipe B on the windshield wiper motor FRONT SEAT SIDE PANELS To eliminate the storage and handling of a great number of different colored plastic Front Seat Side Panels all 1957 model service panels will be re leased minus the silicon finish which was used on previous models This will provide a surface which can be painted with Duco lacquer The panels are 9T to be sprayed with a mixture of lacquer which matches the interior colors and an anti scuff com pound to give maximum wear resistance Right hand and left hand panels will be packaged individually along with a bottle of the anti scuff com pound and an instruction sheet for painting Painting Instructions
16. sed to insure that no bind exists in choke system after adjustment Choke Rod Adjustment 1956 and 1957 Rochester 4 GC Carburetor Not Previously Published A change has been made in the adjustment of the choke rod which includes presetting the idle speed screw Presetting this screw insures the proper re lationship between the fast idle cam and the choke valve The adjustment is as follows 1 Back off idle speed screw several turns 2 Hold choke valve fully open 3 Turn idle speed screw in until it just contacts the low speed step of the fast idle cam 4 Turn idle speed screw in one fullturn This gives an idle speed adjustment of approximately 450 R P M 5 Set the idle speed screw on the second step of the fast idle cam and against the shoulder of the high step 6 Be certain that choke trip lever is in contact with the choke counterweight lever www PontiacSafari com SERVICE CRAFTSMAN NEWS 7 For 1957 cars there should be a 1 16 clearance between top edge of choke valve and dividing wall of air horn For 1956 cars there should be a 054 clearance gauge KMO 480 A Bend choke rod at lower angle if necessary to adjust ROCHESTER DUAL 4 JET CARBURETORS Improved Hot Starting of Extra Horsepower Engines Dual 4 Jet Carburetor Changes March 1955 To improve hot starting characteristics of the extra horsepower engine a new throttle body to bowl gasket is now being used in production The new ga
17. sket is released for service under part number 7009256 and should be installed on each carburetor in cases of hard hot starting Engine Stalling After Fast Stop Dual 4 Jet Carburetor Changes March 1956 Engineering tests have shown that engine stalling after a fast stop can be alleviated by removing the air horn assemblies from both carburetors and drilling out one internal vent in each side with a 1 8 drill It is important that only the two vents illustrated in the March News be drilled otherwise excessive fuel spilling may result if car is used for racing This condition has been corrected in production Sag on Acceleration Not Previously Published A new accelerating pump plunger and rod as sembly part number 7010846 has been released for use on Extra Horsepower Engine carburetors This assembly replaces part number 7009129 currently being used Its purpose is to correct complaints of a sag in acceleration from a standing start by re ducing the initial discharge of fuel from the accele rating pump system DELCO DELUXE RADIO CIRCUIT Delco Deluxe Radio 988623 released for late 1956 production utilizes printed circuits Radios containing this circuit started with Serial Number ON 2 The last Serial Number of the wire con nection model 988568 was LN 2897 Dealerships who do radio work should make a special point of checking the serial numbers to as certain whether or not the radio has the printed cir cuit I
18. www PontiacSafari com PUI LEN Service Craftsman News No 9 S 287 September October 1956 TAR REMOVER MAY DAMAGE FINISH USE CARE WHEN CLEANING ACRYLIC LACQUER FINISH When removing road oils and tar from acrylic lacquer finishes care must be exercised to use a cleaner that is not harmful to this finish Ordinary tar and lacquer removers that were developed for Cleaning regular lacquer may be harmful to this new finish Instances have been reported where these commercial cleaners have caused spotting and in some cases dissolving of the acrylic lacquer causing extensive paint damage Any cleaner is satisfactory if it is recommended for use on regular lacquer enamel and acrylic lacquer Number Seven Dissolvo newly developed and marketed by duPont and a new Prepsol mixture or their equivalents can be used safely for removing road oils and tars from acrylic lacquer This same new cleaner is compatible for use on regular line lacquers enamels or acrylic lacquers and any equiv alent product would be as acceptable When purchas ing make sure that instructions on the container specifically state that the contents can safely be used on acrylics and other finishes 1956 CARBURETOR TROUBLE DIAGNOSIS In conformance with many requests a special section follows which contains pertinent 1956 carbu retor information found in the Service Craftsman News since the beginning of the model Any speci fications or ad
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