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1956 Hudson Tech Service Manual Spplement

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5. TECHNICAL 5 1 1 4 i i FOREWORD The following product information will provide H udson Service Information for the 1956 Special V 8 Series when used in conjunction with the Electrical Section of the 1956 Rambler Technical Service Manual and the 1956 Technical Service Manual Supplement This product information should be kept in a convenient location together with the Service Manuals so that complete information will be available for prompt model and series reference AMERICAN MOTORS CORPORATION Automotive T echnical Service 3280 South Clement Avenue Milwaukee 7 Wisconsin 56 1695 1 56 7500 LITHOGRAPHED IN U S A TECHNICAL SERVICE MANUAL SUPPLEMENT 1956 Table of Coutents Subject Page ENGINE 8 3 COOLING saa ELECIRICAL CARBURETION 23 CLOUGH ao ou y o Y ox Subject Page TRANSMISSION AND OVERDRIVE 4 HYDRA MATIC TRANSMISSION 25 BRAKES AND WHEELS 108 REAR AXLE 109 LUBRICATION 115 SUBJECT ENGINE IDENTIFICATION CYLINDER HEAD AND GASKET ROCKER ARM AND SHAFT ASSEMBLY VALVES Valve Springs Valve Stem to Guide Clearance Valve Refacing Tappets and Push Rods Valve Timing TIMING CHAIN COVER CAMSHAFT AND BEARINGS PISTONS PISTON PINS PISTO
6. 1625 1825 UNDER 1625 Normal Poor engine performance Tune up etc MAXIMUM FULL CLOSED THROTTLE THROTTLE KICKDOWN DOWNSHIFT 67 63 13 9 22 18 10 6 4 2 MAXIMUM FULL CLOSED THROTTLE THROTTLE KICKDOWN DOWNSHIFT 22 18 10 6 4 2 MAXIMUM FULL CLOSED THROTTLE THROTTLE KICKDOWN DOWNSHIFT 42 38 4 2 ENGINE R P M OVER 1825 Transmission slipping Or excessiver coupling slippage Do not hold throttle open HYDRA MATIC TRANSMISSION 103 power input is from the rear wheels The free wheeling of the front unit is eliminated in D 3 by the use of the overrun clutch in order to provide engine braking on hills or when desirable In L range the low band applies to prevent free wheeling of the rear sprag and provide further engine braking DIAGNOSIS GUIDE Malfunctions Slips in Ist and 3rd Slips in or misses Possible Causes Al A2 2nd and 4th B1 B2 B3 B4 NI K2 K5 Slips in all D Ranges DI D2 D3 NI Slips in Ist and 2nd El E2 Slips in 3rd or 4th Fl Slips in 3rd in D 3 on Coast Cl C2 K5 Slips in 1st and 2nd in L Range on Coast Gl G2 G3 G4 No Drive in D Range A2 A3 B3 M3 E2 4 1 No Upshifts 13 K5 Misses 2nd K3 K4 K5 Misses 3rd K4 K5 Locks Up in 2nd and 4th A2 Locks Up in 3rd and 4th E2 Rough 2 3 P2 P3 P5 P6 Upshifts High J2 3 M2 K5 Upshifts Low J3 MI K5 No Reverse Slips H1 N1 MI M4 Selector Lever Won t Go into R J3 L1 Reverse
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8. 1 EQ P CRANKCASE check levall sees A 37 RE a paa RAE 20 Nd Abere lO F SAE TOW T Belom soo AE Drain ond reF every 2 000 miles Teanamissign y p shek check laval Ces ral Arma 2 sings on each side King Pin an mach Tra cav ER CE Eee Dreg Hitting om cL Steering Arm np ck Mot on poser ering models TRANSMISSION creck bevel Syrchrsengsh ord Overdrive i Abus 43227 nomo mom on on 1 SAE 0 22 F NEUES arriti annaa i Drain ard refill avery 70 000 miles hd Overdrive and refilled through A separate pligi avery 25 000 miles t Wheel Bectings Frani avery 10 00 let Rear wher dismantled aar tarare regen Fil 1 DFFEREMTIAL check level SAE 90 Creve end refill every 10 000 milos i PRESSURE COLD Front and lager 14 Lbs
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10. Jul i E ca ALL SEASCM AIR CONDITIONING SYSTEM laa chock csl level in CAPACITIES system if necesitar a eae 3 TRANSMISSION E COOLING 5YSTEM MEASURE CRANKCASE Flashawey Synchromesh wit GAS STSTEM Hyda Overdriva TANK US A 5 23 225 35 3 5 EE EN i 12 7 1 2 18 3 17 5 16 2 mme ol
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12. 28 TECHNICAL SERVICE MANUAL it up for maximum output When pressure becomes high the pressure regulator valve is forced outward directing oil pressure above the slide to push it down and decrease the output When the slide is up it delivers maximum output When the slide is centered output is zero The torus check valve is held against the pump slide by spring pressure When the slide moves down oil will pass through the torus check valve and into the cooler passage from the cooler to the torus feed passage If the cooler should become inoperative oil from the torus check valve will unseat a ball check held in position by spring pressure and flow into the torus feed passage REAR PUMP The rear pump is of the fixed displacement gear type and is driven by the output shaft therefore rear pump capacity will vary with car speed At idle the rear pump is not supplying oil to the transmission and all oil pressure will be supplied by the front pump As the speed of the car increases the oil from the rear pump will flow together with the front pump oil through a passage in the case Much of the oil pressure requirements of the transmission will be taken over by the rear pump and the front pump will compensate by reducing its output The basic requirements of a need for a rear pump was the necessity for oil pressure to supply the transmission in the event of a need for a push to start the vehicle ACCUMULATOR To effect a s
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14. 1 4 REDUCE LINE PRESSURE FOURTH SPEED 2 a DISCHARGE SUCTION PIPE HOLE OVERRUN CLUTCH APPLY FRONT COUPLING FILL REAR CLUTCH APPLY MEVTRAL CLUTCH APPLY FRONT COUPLING SIGNAL FIGURE 24 Front Pump Body Passages LIME FIGURE 25 Pump Cover Passage EXTENSION 5 1 PRESSURE Hoi EE PUMP SUCTION PRESSURE MAIN UNE bed PRESSURE REVERSE APPLY FIGURE 26 Pump Body Passages PFE HOLE VENT PASSAGE ONE OF Six EVENLY SPACED HOLES FIGURE 28 Rear Clutch Cylinder Passages REMOVING THE TRANSMISSION The transmission flywheel housing torus cover torus mem bers and flywheel are removed as an assembly Raise the car sufficiently on car stands supporting the rear of the car at side sills Support rear axle with hydraulic jack TECHNICAL SERVICE MANUAL Drain Hydra Matic fluid from transmission and torus cover Remove oil filler tube from oil pan Disconnect oil cooler tubes at right side of trans mission Disconnect hand brake cable at bell crank brake cable housing at the bell crank bracket Remove brake hose bracket from floor pan to pre vent damage to hose Disconnect speedometer cable and housing at transmission adapter Disconnect throttle rod assembly from throttle le ver at transmission and bell crank at bell housing Disconnect control rod from transmission shift le ver
15. 340 HOLM _OVvads TP Llc 54 puooos uoissiuisue 1 ISOP pue 801145 51656 3uojoq 10 B NGIA 0 0 YSNOAY 6 111019 191 01 IY 01 SUISSIIg 69 puooos 3 5 02 9 5 LNALAA 6 46 55 mor majag rg paads panty joapo7 3300 14 oo alia 143139 3 ATYA JILLOSHL oo JONY 3 5 518059394 16 YIONNTd A 71 faena JAIVA 2 JH deeree mu a Sawa AA NYA 314943 ONINdNOD LINN INOX H21n Twulnar 440 43v33 d aang H210129 56 UI par pue 3510 1 161666 SUL Teas uns yun UOT ploy o3 yom
16. Disconnect the torque tube from the rear bearing retainer then move the rear axle and torque tube assembly to the rear and separate by sliding the uni versal joint to the rear off the splines of the output shaft Support the rear of the engine to remove the weight from the rear engine support cross member Remove plate from flywheel housing and remove the six nuts that retain the flywheel and torus assembly to the engine flex plate Place a hydraulic jack with Tool J 6130 under transmission Disconnect the flywheel housing to engine attaching bolts Disconnect the crossmember from the rear engine sup ports and from the body side sills With jack handle toward the rear of the car raise the jack slightly to remove the strain or bind from the six bolts that were fastened to the flex plate Move complete transmission assembly to the rear and lower assembly after the six bolts have been withdrawn from the engine flex plate CLEANING AND INSPECTION OF PARTS Care should be exercised during and after a complete disas sembly of any hydraulically operated unit Cleanliness is of the utmost importance All metal parts should be washed in a clean solvent and dried with compressed air Each oil passage should be blown out and checked to make sure that they are not obstructed Small oil passages should be probed with a tag wire to insure against an obstruction A thorough inspection of all parts should be made to determine which parts are t
17. Fig 18 FIGURE 18 Checking Connecting Rod Side Clearance Connecting Rod Alignment Whenever new rings are installed or new piston pins are replaced it is necessary to align the connecting rods and pistons as assemblies to insure true operation in the cylinder FIGURE 19 Piston and Connecting Rod Assembly bore Misaligned rods will cause uneven piston and ring wear which will result in oil consumption The connecting rod should be inspected for a twisted or bent condition Connecting Rod Bearings The connecting rod bearings are the steel backed babbitt lined precision type They are installed as pairs in the connecting rod and cap CAUTION Never file a connecting rod or cap to adjust bearing clearance To determine the amount of bearing clearance use a piece of Plastigage in the bearing cap Then tighten the cap to torque specifications to compress the gauge Remove the bearing cap and calibrate the width of the Plastigage with the scale furnished TECHNICAL SERVICE MANUAL If the bearing clearance is excessive the correct undersize bearing insert pair should be installed in the connecting rod The correct connecting rod bearing clearance is 0007 to 0028 The crankpin diameter is 2 2483 to 2 2490 It is important that the connecting rod bearing cap bolt nuts be drawn up to 52 to 56 foot pounds torque Connecting rod bearings are serviced in 001 002 010 012 undersize CRANKSHA
18. MEASURE DISTANCE PATS WILL BE FORCED Th IM THIS DIRECTION FRONT UNIT SUN GEAR FRONT GEAR MC 1 120707 SELECTIVE SPACES WASHER INSTALLED FO MAKING MEASUREMENT 1 Special Tool J 6127 SPACER SPACER FIGURE 36 Collar of Tool J 6127 DIM A IDENTIFICATION DIM A IDENTIFICATION Installed on Shaft ne Oat O47 094 103 048 045 i 104 MEASURING FRONT UNIT 056 083 3 T 15 END CLEARANCE 64 07 120 127 072 079 128 135 Feeler Gauge Method FIGURE 38 Front Unit Selective Spacer Chart Rotate transmission to vertical position with main shaft up Install a No 1 070 selective spacer washer over Install front unit sun gear and install steel and bronze thrust washers over intermediate shaft against sun gear Install drive torus Truarc snap ring in groove on interme diate shaft nearest to bronze thrust washer Push intermediate shaft and sun gear firmly to rear of transmission to make sure all end play is taken up Push snap ring down against bottom of groove and with feeler gauges very carefully measure clearance between snap ring and bronze thrust washer Fig 39 pee T 1 dc FIGURE 37 Measuring Main Shaft End Play the front unit driven torus hub in place of the washer re moved The No 1 washer must be installed for gauging purposes Fig 38 Install front unit internal gear over front unit driven torus shaft against spacer washe
19. A 1 loa UN jid ou 440 1013 97945 i njeueocg opio g INI 3303913 re 1 1 5 AOD 42 1 113 SONIJAOO d INGOJ TWALNIN 1 1 TK DNI1ENOD 301911934 34056344 JA TV A TTO UU ad A TVA 11123 97045 ae e rt Fi pe ae UN 1 WO 0334 JA IVA MO 17103 cCNITdInO2 LINN WO Es 1 3 aona 4115009 VONMIAOD S 5390155389 110 1O 1vNOIS 52 8 PITY YIANOJ 10 5 oj dn spring sinssoid 01 osessed oui SINO 31 JUSH IY 0 IYI UST 8 puru uorssrusueJ pue JsUTese 94 II YIYS F E 94 03 UY 51 1U939 T JUSH
20. Closed JET 1086 Position 018 024 24 CLUTCH SECTION This series with standard or overdrive transmission incorporates a 10 clutch plate assembly A beam type clutch release linkage is also used CLUTCH SPRING SPECIFICATIONS No of Springs 9 Compressed Length 155 Lbs 5 11 6 CLUTCH COVER LEVER HEIGHT Levers are adjusted flush with the hub Use gauge plate J 1507 or J 5490 CLUTCH PEDAL FREE PLAY Maintain 1 2 to 3 4 pedal play by varying the length of beam to throw out lever rod CLUTCH PEDAL TO BEAM ROD ADJUSTMENT The clutch pedal to beam rod adjustment adjusted in production is made to provide proper leverage The outer rear edge of the beam lever should be located 3 8 forward of the rear edge of the beam bracket with the clutch pedal against the floor panel The pedal to beam rod should not be disturbed at time of service TRANSMISSION AND OVERDRIVE The standard and overdrive to the units installed on the 1956 transmissions 60 Series incorporated on this series are identical Refer to the 1955 Technical Service Manual for service procedures HYDRA MATIC TRANSMISSION Cross Section View of the 1956 Series Flashaway Hydra Matic Transmission SUBJECT PAGE GENERAL DESCRIPTION 26 HOW TO OPERATE THE FLASHAWAY HYDRA MATIC 28 POWER FLOW 31 HYDRAULIC OIL CIRCUITS 27 REMOVING THE TRANSMISSION 63 CLEANING AND INSPECTION OF PARTS 64 DISASSEMBLY OF UNITS FROM CASE 64 DIS
21. Clutch Drive Plate PA Rear Unit Sun Gear Thrust Washer IGURE 80 Installing Rear Clutch Hub Thrust Washer FIGURE 78 Installing Rear Unit Clutch Plates FIGURE 79 WNotches in Rear Unit Clutch Driven Plates Assemble rear unit clutch hub to rear end of intermediate shaft if it was removed Open side of hub goes toward front of shaft The end with longest spline and longest machined surface is rear Install two bronze thrust washers on rear unit clutch hub one on each side and retain with petrolatum Fig 80 Install intermediate shaft and rear clutch hub and thrust washers into rear drum Fig 81 NOTE Pick up clutch drive plates by rotating intermediate shaft Do not drive or force rear unit FIGURE 81 ZJnstalling Intermediate Shaft and clutch hub into rear unit drum Clutch Hub into Plates 80 TECHNICAL SERVICE MANUAL Assemble rear clutch piston into rear clutch cylinder as follows Install new inner seal on hub of clutch cylinder with lip down Fig 821 FIGURE 82 Seal Installed on Hub of Rear Clutch Cylinder Install new outer seal on piston with lip facing away from spring bore side Install piston into cylinder using flat edge of screw driver to start seal into cylinder Fig 83 FIGURE 83 Rear Clutch Piston into Cylinder Install eight clutch release springs into bores in piston Place spring retainer on springs with tangs facing up Compress springs using tool J 4670 and J 612
22. Drive in N H3 Legend for Diagnosis Guide A Front Sprag Clutch 1 Clutch Slipping 2 Clutch Broken 3 Clutch Incorrectly Installed B Front Unit Torus Cover 1 Cover Seals Leaking 2 Cover Exhaust Valves Sticking or Missing 3 Cover Feed Restriction or Leak 4 Cover Signal Restriction or Leak C Overrun Clutch 1 Clutch Slipping or Burned 2 Clutch Apply Restricted or Leaking D Neutral Clutch 1 Clutch Slipping or Burned 2 Clutch Apply Restricted or Leaking 3 Incorrect Number of Clutch Plates E Rear Sprag Clutch 1 Clutch Slipping 2 Clutch Broken 3 Clutch Incorrectly Installed F Rear Unit 1 Clutch Slipping or Burned 2 Clutch Apply Restricted or Leaking 3 Incorrect Number of Clutch Plates G Low Servo 1 Low Servo Apply Restricted or Leaking 2 Low Band Not Anchored to Case or Broken 3 Low Servo Piston and Rod Bind in Case or Servo and Accumulator Body 4 Band Facing Worn or Loose H Reverse Unit 1 Reverse Piston Apply Restricted or Leaking 2 Stationary Cone Key Missing 3 Stationary Cone Sticking J Governor 1 Governor Valves Sticking 2 Leaking or Restricted Main Line Feed to Governor 3 Broken Governor Rings K Control Valve Assembly 1 Limit Valve Sticking 2 Coupling Valve Sticking 3 G 5 Valve Sticking 4 Transition Valve Sticking 5 Sticking Valves or Dirt in Valve Body L Reverse Blocker Assembly 1 Reverse Blocker Piston Stuck M Linkage 1 Throttle Linkage Adjusted
23. FI SU OUTPUT SHAFT FIGURE 6 Power Flow Third Speed FRONT UNIT REDUCTION NEUTRAL CLUTCH REAR UNIT DIRECT DRIVE Sprag On Sprag Off Coupling Empty Rear Clutch On THIRD SPEED In third speed the front unit is in reduction and the rear unit is in direct drive The transmission gear ratio is 1 55 to 1 Power flows mechanically from the flywheel to the torus cover and to the internal gear attached to the torus cover At the internal gear mechanical power divides Part of the mechanical power is directed into the front unit coupling However in third speed the front coupling is empty and no power is transmitted to the front unit driven member Power is also directed from the internal gear to the planet carrier assembly of the front unit where it divides and is directed to the rear unit in two ways Fluid The sun gear of the front unit is held by the front sprag clutch assembly so that the pinions of the carrier walk around the sun gear at a slower rate or in reduction The front unit carrier is attached to the drive torus member and will through oil drive the driven torus member In turn the driven torus member drives the connected main shaft and rear unit sun gear which will drive the pinions of the rear unit carrier Mechanical Power is directed mechanically from the carrier of the front unit to the rear unit through the intermediate shaft which is splined to the drive torus member The intermediate sha
24. IOJDOTOS BY 61 351343 POLIO 61 1 43342018 ISYIAI dwnd 93150089 1 JATVA 31 De INO 21012 3583438 31413 ONITNOD LINN INOX 340 4401 ING 430 21112 wad 9vads D fun Ovads ED 62 TECHNICAL SERVICE MANUAL LOCATION OF OIL HOLE PASSAGES Figures 20 to 28 inclusive illustrate the location of oil passages should be blown out with compressed oil passages After thoroughly cleaning each part all alr WENT HOLE COUPLING FILL CLUTCH APPLY FROM FRONT PUMP COUPLING SIGNAL PEAR CLUTCH AFPLY TE REVERSE PRESSURE TO PRESSURE REGULATOR SERVO APPLY SERVO PISTON STEM HOLE 34 OIL PRESSURE REGULATOR REAR CLUTCH APPLY TEM NEUTRAL CLUTCH B APPLY 2 AIR VENT DRAIN BACK FROM FEAR PUMP REAR EXTENSION HOUSING SUCTION FIGURE 20 Transmission Case Oil Passages COUPLING PASSAGE PASSAGE Figure 21 Case Center Support Passages Figure 22 Front Pump Cover Passeges HYDRA MATIC TRANSMISSION 63 COUPLING SIGNAL COUPLING FILL FIGURE 23 Front Pump Cover Passages PRESSURE TOP Of SLIDE
25. Laer EFTENDEL LENGTA 4 a Dis BALL L LBI4 OPERATING LENGTH Lar n dd Line por TOMO 2 TIS 6e m E 3 PLUNGER CAP we Seg e UNGER 3 FIGURE A Sectional View of Hydraulic Tappet Assembly 2 apr The tappet operates in a guide bore which has an oil passage drilled into the adjoining main oil galleries When the tappet is on the heel of the cam lobe the plunger return spring indexes an oil hole undercut in the plunger with the oil supply admitted through the tappet body Oil under pressure flows into the body through the check valve assembly maintaining the tappet fully charged This cycle of operation occurs when tappet leaks off some oil during the normal valve opening events Opening move ment of the cam lobe causes tappet body movement closing the check valve and transmitting zero lash movement of the push rod to open the cylinder valve TECHNICAL SERVICE MANUAL The valve tappets should be cleaned and serviced at time of engine overhaul or whenever excessive noise exists FIGURE 5 Valve Push Rod and Tappet Assembly When removing the tappets they must be kept in an order that will insure replacement in their respective operating bores in the engine because they are select fitted to that bore Keep each tappet component group by itself as all deta
26. are an interference fit in their bores in the cylinder head and can be replaced by driving out the old guides and driving in the new The new guides are driven to a depth to permit 3 4 or 1 44 to remain exposed above the cylinder head Measure from top of the guide to flat machined surface for lower valve spring retainer New valve stem to guide clearance is as follows Intake 0013 0028 Exhaust 0018 0033 Valve guides are reamed to 3430 3440 inside diame ter after installation Rubber valve stem oil deflectors are provided on the valve guides to aid in preventing oil consumption between the valve stem and guide Valve Refacing The intake valves are faced to a 29 angle and the exhaust valves to a 44 angle Valves may be refaced until remaining margin is down to 1 32 then the valve must be replaced The valve stem tip when worn can be resurfaced and rechamfered However never remove more than 010 Valve Seat Refacing Grind the valve seats to the following specifications seat Angle Intake Valve 30 Exhaust Valve 45 Seat Width Intake Valve 078 093 Exhaust Valve 093 104 Narrowing stones should be used to obtain the proper seat widths when required Control seat runout to a maximum of 002 Valve Tappets and Push Rods The hydraulic valve tappet consists of a body plunger plunger return spring check valve assembly push rod sock et and lock ring Fig 4 F 1 L
27. as slipping a conventional clutch with the difference that in the Hydra Matic the fluid coupling does the slipping without injury to the mechanism if done for only limited periods of time For longer periods or on steep hills this practice is not recommended PUSHING TO START ENGINE If it should become necessary to start the engine by pushing the car this can be done in a manner equivalent to that used in a car with 3 speed transmission Push car in Neutral until a speed of 20 M P H or more is reached turn on the ignition then move selector lever to a D range not to L Under these conditions the engine will be engaged in fourth gear and ordinarily will start within a few seconds It is better to push than to tow the car to avoid the possibility of sudden acceleration after the engine starts causing a collision with the car ahead CAUTION If it becomes necessary to tow or push the car for distances greater than necessary to start a normally operating engine a speed between 15 and 25 M P H should be maintained Towing or pushing under these conditions will be satisfactory assuming the Hydra Matic transmission has been operating satisfactorily AND assuming the car mileage is in excess of 1000 If transmission has not been operating properly the car should be towed ONLY with rear wheels lifted off the ground TOWING THE CAR Disconnect the torque tube and propeller shaft at the trans mission or raise the rear wheels
28. center bearing and separate the movable breaker plate from the support plate Take care that the small side spring is not dislodged from its recess in the edge of the center hole in the support plate This spring helps to prevent any side play in the breaker plate assembly and also contributes to the over all tension of the assembly Reassembly is the reverse of disassembly After reassembly of this unit two checks are required The stabilizing spring tension Fig 3 18 measured with the breaker plate assembly right side up horizontal position Apply a spring scale either push type or a pull type with a C hook at the stabilizing spring post and note the force required to start vertical movement of the post This force should be not less than 18 ounces or more than 24 ounces If necessary the stabilizing spring force can be increased by carefully stretching the spring or re placing it It is also necessary to check the friction between the plates With the breaker plate assembly right side up in the horizontal position rotate the movable breaker plate to the fully retarded position Measure the force required to rotate the movable breaker plate from the fully retarded position measure at the bearing to which the vacuum control units are normally connected The pull required to rotate the movable breaker plate should not exceed 15 ounces Read ings in excess of 15 ounces may be caused by insufficient lubrication cupped or distort
29. control lever in park THRUST WASHER SPECIFICATIONS Outside Location Diameter Reverse Internal Gear to Rear Pump Body Thrust Washer 2 13 Front Sun Gear to Carrier Thrust Backing Washer 2 04 Rear Unit Clutch Drum to Clutch Hub Thrust Washer 2 94 Rear Unit Sun Gear Thrust Washer One Each Side 2 347 Front Sprag Overrun Clutch Inner Race Thrust Washer 1 783 1 788 Front Unit Drive Torus Thrust Backing Washer 1 990 1 995 Front Unit Drive Torus Thrust Washer 1 990 1 995 Front Unit Coupling to Flywheel Rear Housing Bushing 2 880 2 886 Front Internal Gear Hub Thrust Washer 2 204 2 210 Front Internal Gear Hub Thrust Backing Washer 2 182 2 192 Front Sun Gear to Carrier Thrust Washer 2 02 Inside Diameter 2 165 2 175 1 255 1 263 2 115 221222 1 44 1 41 1 675 1 685 1 675 1 685 2 42 1 675 1 685 1 675 1 685 1 253 1 263 Thicknes S 087 091 049 051 087 091 087 091 087 091 049 051 087 091 060 064 087 091 060 064 087 091 105 Material Bronze Steel Bronze Bronze Bronze Steel Bronze Steel Bronze Steel Bronze TECHNICAL SERVICE MANUAL Rear Unit Planet Carrier to Reverse Drive Flange Selective Thrust Washer No 1 No 2 No 3 No 4 No 5 Name Front Pump Inner Priming Spring Outer Pump Priming Spring Check Valve Spring Torus Feed Valve Spring Rear Clutch Release Servo and Accumulator Assembly Accumulato
30. dowels and install overrun clutch piston into front pump cavity compressing piston ring with fingers Fig 105 FIGURE 105 ZJnstalling Overrun Clutch Piston in Front Pump TECHNICAL SERVICE MANUAL Do not force clutch piston into cavity If it does not fit freely the dowels and holes are not in proper alignment After piston is installed check to see that it 18 properly engaged with dowels by attempting to rotate it Install sprag assembly into rear of pump with shoulder up rotating sprag counterclockwise while installing it Fig 106 FIGURE 106 ZJnstalling Front Sprag in Hub of Pump Body Install sprag inner race into sprag with lug side up Inner race should rotate counterclockwise from top Secure sprag assembly with spiral snap ring Fig 107 FIGURE 107 ZJnstalling Front Sprag Retaining Snap Ring Before installing the overrun clutch plate thrust washer and release spring coat one side of each with petrolatum to hold them in place during installation of unit into case Install the overrun clutch plate on top of piston indexing drive lugs with sprag inner race Install the bronze thrust washer on sprag inner race with drive lugs down indexing with sprag inner race Install the clutch release spring on top of piston Fig 108 3 Front Sprag Inner Race 4 Bronze Thrust Washer 1 Release Spring 2 Overrun Clutch Plate FIGURE 108 Overrun Clutch Parts Installed in Front Pump DISA
31. gear was originally removed Position gear against clutch back ing plate Slight tapping with soft hammer may be necessary Fig 76 FIGURE 76 Installing Rear Unit Internal Gear Install output shaft and reverse drive flange asembly into rear unit drum and secure with large snap ring Fig 77 ian 5 FIGURE 77 Installing Output Shaft and Reverse Drive Flange Snap Ring Set rear unit assembly into holding fixture J 6116 with shaft end down As unit is lowered into fixture lift up on drum and remove drive flange retainer J 6120 CAUTION Do not lift on output shaft after J 6120 is removed Position thrust washer in counterbore of output shaft and retain with petrolatum Fig 78 Apply Hydra Matic oil to faces of the seven drive and seven driven plates and alternately install them in rear unit drum Start with drive composition and finish with driven steel Install all drive plates with same side up Assemble driven plates with lugs in rear unit drum slots so that notches in lugs are all in line Fig 79 NOTE Indexing the notches nests the plates to gether so that the waves are all in the same direction no gaps between plates Install main shaft and sun gear assembly into output shaft in rear unit meshing sun gear with planet pinions of output shaft HYDRA MATIC TRANSMISSION 79 1 Rear Unit Clutch Hub 3 Rear Clutch Hub Thrust 2 Intermediate Shaft Washer 1 Rear
32. of body Remove detent valve and spring clean and inspect parts Fig 119 NOTE Jt is not necessary to remove T V plug and from T V bore V Lever Stop V Plunger Guide 3 2 T V Plunge T T 4 Manual Valve 5 Manual Vavle Body 6 T V Spring install the detent valve with large land end out Install T V lever stop with two attaching screws and install manual valve DISASSEMBLY OF PRESSURE REGULATOR Remove pressure regulator valve stop pin Remove reverse booster plug Remove valve spring and pressure regulator valve Remove 0 ring seal from pressure regulator plug and discard Fig 120 ASSEMBLY OF PRESSURE REGULATOR Apply a small amount of petrolatum in bore of pressure regulator plug and in bore of reverse booster plug Install booster plug in pressure regulator plug bore Install pressure regulator valve stop pin in reverse booster plug DISASSEMBLY AND ASSEMBLY OF TORUS CHECK VALVE FROM DRIVEN TORUS Hold finger on cloth over torus check valve bore and 7 Detent Valve 8 Throttle Valve 9 Detent Valve Spring 10 T V Plug In Body Figure 119 Manual Valve Body ASSEMBLY OF MANUAL VALVE BODY Install throttle valve in middle bore with long land first and install T V spring Install T V plunger guide and T V plunger as a unit in middle bore of body long stem out Short land of plunger guide does not enter valve body Insert detent spring in bore lining up spring to a
33. off the ground to prevent possible damage to the transmission If the torque tube and propeller shaft are disconnected for towing make certain that oil does not leak from the rear bearing retainer HYDRA MATIC TRANSMISSION 31 TORUS COVER FLY HEEL DRIVE TORUS FRONT UNIT COUPLING FRONT UNIT T PLANET SAR INTERMEDIATE NEUTRAL CLUTCH REAR CLUTCH SHAFT N G REAR 51 EAR FIGURE 3 Power Flow Neutral Engine Running FRONT UNIT REDUCTION Sprag On Front Coupling Empty NEUTRAL CLUTCH REAR UNIT NEUTRAL Released Sprag Off Rear Clutch Off NEUTRAL ENGINE RUNNING In neutral with engine running the front unit is in reduction and the rear unit is in neutral Power flows mechanically from the flywheel to the torus cover and to the internal gear which is attached to the torus cover At the internal gear mechanical power divides Part of the power is directed into the front unit coupling However in neutral the front unit coupling is empty and no power is transmitted to the front unit driven member Power is also directed from the internal gear to the carrier assembly of the front unit where it divides and is directed to the rear unit in two ways Fluid Since the front unit is in reduction the front unit carrier will be rotating at a slower rate The carrier is at tached to the drive torus member which through oil will drive the driven torus mem
34. piece type two oil control wiper rails with a spacer of segmented steel between them Roll the ring around the groove in which it 1 to operate It must fit freely at all points Checking Ring Gap Clearance Piston ring gap or joint clearance is measured in the bottom of the cylinder near the end of the ring travel area To square the ring in the bore for checking joint clearance place the ring in the bore Then with an inverted piston push the ring down near the lower end of the ring travel area When other than standard ring sizes are used rings should be individually fitted to their respective bores for a gap clearance of No 1 010 020 No 2 010 0201 No 3 015 055 Gap of Rail FIGURE 16 Connecting Rod Squirt Hole Location ENGINE V 8 H Assemble connecting rod to piston with notch in piston and connecting rod identification mark to front of engine Cyl inder numbers should be toward the outside of bank in which they are installed IDENTIFICATION WARK FACES FRONT ENGINE CYLINDER ON AND ASSEMBLED TOWARO OT BOARD OF ENGINE pU FIGURE 17 Connecting Rod Identification Mark The cylinders are numbered 1 3 5 7 in the left bank of engine from front to rear and even numbers 2 4 6 8 in the right bank front to rear as viewed from driver s seat Two connecting rods are mounted side by side on each crankpin The side clearance is 004 to 012
35. rear pump locating screw and attaching screw Fig 52 Rear Pump Attaching Screw 2 Rear Pump Locating Screw FIGURE 52 Rear Pump Attaching and Locating Screws Remove rear pump gasket and reverse piston as an assembly over output shaft discard gasket NOTE f necessary remove two pump cover attaching screws and insert two slide hammers J 6125 and pull pump over shaft Remove thrust washer from reverse internal gear Re move reverse piston release spring Remove internal gear and the reverse clutch release spring Fig 53 1 1 Reverse Internal Gear 2 Reverse Clutch Release Spring FIGURE 53 Removing Reverse Internal Gear Remove reverse planet carrier snap ring Remove reverse stationary cone and planet carrier by pulling the reverse planet carrier assembly out of transmis sion Remove reverse stationary cone key if it did not fall out of transmission case when stationary cone was removed If key sticks it can be tapped out through hole in bottom of case Remove center support to case snap ring at front of case using screw driver Fig 54 Remove case support locking screw on pressure regula tor plug side of transmission case Fig 55 Remove rear unit neutral clutch and case center support assembly by sliding complete assembly out the front of transmission case NOTE f assembly is tight in case use J 6125 slide hammer assemblies with J 6134 adapters Fig 56 Install complete ass
36. rear unit and the clutch hub thrust washer from sun gear NOTE Main shaft and rear unit sun gear may be disassembled if parts replacement is necessary Remove the seven steel clutch plates and seven compo sition plates Remove bronze thrust washer from rear unit carrier Remove rear unit drum and output shaft assembly from holding fixture J 6116 and set on bench with output shaft end up Remove large snap ring holding reverse drive flange to rear unit drum Lift output shaft and reverse drive flange assembly out of rear unit drum Fig 67 FIGURE 67 Removing Snap Ring from Rear Unit Drum If parts replacement is necessary mark internal gear so it can be replaced with same side up Then remove internal gear and rear unit clutch backing plate from rear unit drum assembly together by tapping backing plate with soft ham mer Remove reverse planet carrier locating snap ring from output shaft Remove reverse drive flange and sun gear assembly from output shaft and remove selective washer from reverse drive flange assembly or output shaft Fig 68 Remove spiral snap ring from rear unit sprag inner race Using a small needle nose pliers or small screwdriver insert 76 TECHNICAL SERVICE MANUAL 1 Selective Thrust Washer FIGURE 68 Removing Output Shaft from Reverse Drive Flange small tool into small elongated hole in end of spiral ring and pull upward Fig 69 y oa lt lt FIGURE
37. reduce line pressure in fourth speed when in D 4 position In D 3 position line pressure remains at 90 100 P S I in fourth speed To check pressure in reverse stop car and set hand brake firmly Then place selector lever in R range and apply foot brake and open accelerator to half throttle Pressure should increase to 145 190 P S I Diagnosis of malfunctions can frequently be aided by noting oil pressure under all operating conditions while driving on the road ROAD TEST A road test can be made using the shift speed chart in Figure 146 It will be observed however that the closed throttle downshifts in D 4 and the 3 2 downshift in D 3 cannot be distinguished The reason is that in D 4 the sprags in both 102 TECHNICAL SERVICE MANUAL HYDRAMATIC SHIFT POINTS IN M P H LIGHT SHIFT THROTTLE 1 2 5 9 2 3 11 15 3 4 18 22 4 3 32 2 1 LIGHT SHIFT THROTTLE 12 5 9 2 3 11 15 3 4 3 5 9 1 5 OL 12 7 9 23 3 4 4 3 32 21 TESTING CONDITION FLASHAWAY TRANSMISSION With engine at operating tem pretures set control lever in D 4 range Fully applie hand brake and foot brake and ac celerate engine to wide open throttle DRIVE 4 RANGE MAXIMUM PART FULL THROTTLE THROTTLE KICKDOWN 21 25 41 45 71 65 34 31 DRIVE 3 RANGE MAXIMUM PART FULL THROTTLE THROTTLE KICKDOWN 21 25 41 45 70 74 L RANGE MAXIMUM PART FULL THROTTLE THROTTLE KICKDOWN 35 49 70 74 STALL TEST EINGINE R P M ENGINE
38. rings on the cover arld the snap ring groove in the drive torus with petrolatum Fig 93 FIGURE 93 Lubricate 0 Rings Install springs and exhaust valves in cover and retain with tools J 6122 1 Place cover on drive torus with pencil scribe marks aligned The notches in the cover must be aligned with the locating pins in the drive torus Push the cover as far as possible into the coupling and tap into place with a composition hammer until the snap ring can be installed Fig 94 gt PENCIL MARKS 27 FIGURE 94 Jnstalling Coupling Cover 83 NOTE Tap on alternate sides of cover on puller bolt hole bosses to prevent binding of cover Inspect snap ring groove If part of 0 ring is visible the cover will have to be removed and new 0 rings installed Install large snap ring and remove exhaust valve retain ing tools DISASSEMBLY OF FRONT PUMP Remove the two remaining pump cover bolts and lift the cover from the pump body CAUTION If cover sticks or hangs up on dowels tap with soft hammer to remove Do not pry be tween cover and body Remove retaining pin retainer spring and torus feed valve Fig 95 FIGURE 95 Removing Torus Feed Valve Remove cooler check valve pin spring and ball Fig 96 FIGURE 96 Removing Cooler Check Valve 84 TECHNICAL SERVICE MANUAL Remove front pump rotor and top vane ring Then remove the seven vane
39. support The connecting rod is automatically centered on the pin Figs 13 and 14 CAUTION The pin must be a tight press fit in the connecting rod The piston pin should be a palm press fit in piston boss at room temperature With parts dry and free of oil the pin must support its weight in a vertical position over its entire length in either of the two piston pin bosses FIGURE 11 Removing Piston Pin FIGURE 14 Jnstalling Piston Pin PISTON RINGS A three ring piston is used The two compression and one oil control rings are located above the piston pin boss Before assembling the rings to the piston carbon must be cleaned from all ring grooves The oil drain holes in the oil ring grooves and pin boss must be cleared with the proper size drill Care must be exercised not to remove metal from TECHNICAL SERVICE MANUAL the grooves since that will change their depth nor from the Piston Ring Installation lands since that will change the ring groove clearance and destroy ring to land seating Removal of glaze from the cylinder wall for quicker ring seating can be accomplished by various methods Where an expanding type hone is used do not use more than ten strokes each stroke down and return to recondition a cylin der wall Successful ring installation depends upon cleanliness in handling parts and while honing the cylinder walls The engine bearings and lubrication system must be protected from abrasives R
40. the crankshaft may be required to accom modate the nearest undersize bearings when cleaning up a scored bearing surface Crankshaft End Play The crankshaft end thrust of 003 to 007 is taken at the front or No 1 bearing insert which is flanged for this purpose To check this clearance attach a dial indicator to the crankcase and pry the shaft fore and aft with a screw driver Fig 21 FIGURE 21 Checking Crankshaft End Thrust REAR MAIN BEARING OIL SEALS The rear main bearing oil seal is composed of two hemp packings one in the block the other in the cap The packing is driven into place with Tool J 3048 A Fig 22 Excess packing is cut off flush with the cap FIGURE 22 JInstalling Hemp Packing Oil Seal in Rear Main Bearing Cap VIBRATION DAMPER The vibration damper is balanced independently and then rebalanced as part of the complete crankshaft assembly Service replacement dampers may be installed without attempt to duplicate balance holes present in original damper TECHNICAL SERVICE MANUAL Figure 23 illustrates a vibration damper puller which may be fabricated locally 2 mp 5 LONE THAD BALL 2H 1 a a DATA ANO IAE FIGURE 23 Suggested Damper Puller In the event of engine noises it is time saving to inspect the vibration damper assembly before engine
41. 08 to 012 and can be checked by placing the plates on a flat surface Inspect springs for distortion or collapsed coils Slight wear bright spot on the sides of the springs is permissable DISASSEMBLY OF UNITS FROM CASE SUBJECT PAGE CHECKING MAIN SHAFT END PLAY 66 MEASURING FRONT UNIT END CLEARANCE 67 REMOVAL OF Front Unit Coupling Pressure Regulator and Cooler Adapter 68 Mark flywheel and torus cover so flywheel can easily be reinstalled in the same position Remove torus cover so fly SUBJECT PAGE Oil Pan Oil Screen and Intake Pipe 69 Control Valve Servo and Accumulator 69 Front Pump and Overrun Clutch 69 Case Support Neutral Clutch and Rear Unit Assembly 70 Inside Detent and Throttle Lever 72 Parking Pawl and Linkage 73 cover to flywheel attaching nuts and remove flywheel assembly Fig 29 HYDRA MATIC TRANSMISSION 65 1 Driven Torus Rear Snap Ring FIGURE 29 Removing Torus Cover to Flywheel 2 Drive Torus Snap Ring Attaching Nuts FIGURE 31 Removing Driven Torus Remove large 0 ring seal from back of flywheel torus Rear Snap Ring cover to flywheel seal Remove driven torus Truarc snap ring from main shaft Fig 30 CAUTION Do not attempt to remove torus cover and drive torus together Remove bronze thrust washer and steel backing washer from sun gear to torus hub Fig 32 re FIGURE 30 Removing Driven Torus Front Snap Ring 1 Thrust Washers 2 Front Unit Su
42. 1 passage where it is regu lated at the G 1 valve G 1 booster pressure is directed through the transition valve to one end of the coupling valve When G 1 booster pressure on the end of the coupling valve becomes high enough depending on car speed to overcome the spring force and T V pressure on the other end of the coupling valve it will move the valve for the 1 2 upshift TECHNICAL SERVICE MANUAL 40 81 80 08 pue Teal UO 81 3215 pue Adua sr Sur dnoo yrun 99 Sur dnoo Jo puo pue Suir dnoo pu YSNOIY st ounssoud ATCA JO puo 01 Inssad 1 5004 1 0 195004 J N JO puo 01 81 ounssoud J N jo junoure y sr ounssoJud 1 0 enu ue pue e 16 100 08 ur Surids IOUIDAOS ST SY Tennu uoissruisueJ ou uonoung ou DALY spue Sur dnoo uo Sainssoaid ro ou Sur dnoo y uo pue 1241016 908 os ounssoud Sur dnoo uo pur 6 o3essed e 0 Apuoror
43. 10 Volts Maximum Advance 20 Engine Degrees GENERATOR SPECIFICATIONS Make Delco Remy Delco Remy Without Air Conditioning With Air Conditioning Model 1100324 1103011 Brush Spring Tension 28 Oz 28 Oz Cold Output 25 Amperes 14 0 Volts 2780 R P M 1 5 1 62 Amperes 12 Volts 80 F Field Current Draw 30 Amperes 14 0 Volts 2150 R P M 1 48 1 62 Amperes 12 Volts 80 F VOLTAGE AND CURRENT REGULATOR SPECIFICATIONS Make Delco Remy Delco Remy Without Air Conditioning With Air Conditioning Model 1119122 1119003 Cut Out Relay Air Gap 020 020 Cut Out Relay Point Opening 020 020 Cut Out Relay Closing Voltage 11 8 13 5 11 8 13 5 Voltage Regulator Air Gap 075 075 Voltage Regulator Normal Range 13 8 14 8 Volts 13 8 14 8 Volts Current Regulator Air Gap 075 075 Current Regulator Allowable Limits 23 27 Amperes 27 33 Amperes 22 CARBURETION CARBURETION CARBURETOR SPECIFICATIONS CARTER MODEL WGD 2352 S DIMENSIONS METERING ROD Flange Size Primary Venturi Secondary Venturi Main Venturi FLOAT LEVEL VENTS 1 1 4 Dual Four Bolt 1 1 32 21 32 1 3 16 7 32 T 109 106 Outside None Inside Balance Vent Tube After Accelerator Pump Adjustment Rods Must Bottom in Jet Well With Tight Closed Throttle Valves While Vacumeter Link Contacts Metering Rod Above Choke Valve GASOLINE INTAKE Size 34 Drill i 44 ACCELERATING LOW SPEED JET Plunger Type TUBE Mechanically Operated Jet Size No 66 Dr
44. 3 Removing Pressure Regulator Spring and Valve OIL PAN OIL SCREEN AND INTAKE PIPE REMOVAL Remove oil pan attaching screws oil pan and gasket from transmission discard gasket Remove screw holding front pump intake pipe clamp Remove front pump intake pipe and clamp from pump and screen Remove 0 ring from pump Remove oil screen and rear pump intake pipe and 0 ring Fig 44 1 Rear Pump Intake Pipe 2 Oil Screen 3 Clamp and Bolt 4 Front Intake Pipe FIGURE 44 Transmission with Oil Pan Removed CONTROL VALVE SERVO AND ACCUMULATOR REMOVAL Remove three attaching screws holding servo and accu mulator assembly to case NOTE Servo piston is spring loaded FIGURE 45 Removing Servo and Accumulator Assembly Remove servo and accumulator assembly and servo spring Fig 45 Remove remaining control valve assembly to case at taching screws Remove control valve assembly from transmission case Use care not to drop manual valve Fig 46 FIGURE 46 Removing Valve Control Assembly FRONT PUMP AND OVERRUN CLUTCH RE MOVAL Remove front pump locking screw and lock washer located under control valve assembly Fig 47 70 TECHNICAL SERVICE MANUAL FIGURE 47 Removing Front Pump Locking Screw Remove the three 9 16 front pump attaching screws Then remove two opposite front pump cover to body screws using 1 2 socket Install two slide hammers J 6125 into the two opposite
45. 3 shift valve from the shift valve body Remove the regulator body cover and clean and inspect parts Fig 117 1 Governor Valve Body End Plate 2 2 3 Governor Valve 3 3 4 Governor Valve 4 Shift Valve Body 5 3 4 Shift Valve 6 3 4 Valve Springs 7 Regulator Valve Body 8 Regulator Body Cover 9 3 4 Regulator Valve 10 Regulator Body Plate DISASSEMBLY OF REVERSE BLOCKER ASSEMBLY Remove two reverse blocker body to manual valve body attaching screws and remove reverse blocker assembly Remove hairpin detent plunger retainer and remove detent plunger and spring 11 Governor Booster Valve 12 2 3 Shift Valve 13 2 3 Shift Valve Springs 14 2 3 Regulator Valve FIGURE 117 Shift Valve Body Assembly ASSEMBLY OF SHIFT VALVE BODY Install the 2 3 shift valve with spring stem end out Install inner and outer 2 3 shift valve and regulator springs Install 3 4 shift valve with spring stem out install the inner and outer 3 4 shift and regulator valve springs with large coil end of outer spring out to seat against regulator body Install regulator body cover to regulator body Install 3 4 regulator valve into regulator body with spring stem end in first Install 2 3 regulator valve with spring stem end first Attach regulator body and plate to the shift valve body by inserting two of the attaching screws in the regulator body plate and position on the regulator body Then install the regulator body and plate ass
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47. 69 Removing Spiral Snap Ring from Inner Race Remove outer race sprag and retainer by rotating clock wise and pulling upward Fig 70 1 Rear Sprag Outer Race 3 Rear Sprag Inner Race 2 Sprag Assembly FIGURE 70 Removing Rear Unit Sprag Assembly CAUTION Do not attempt to disassemble sprag assembly Remove rear unit sprag retainer and sprag Disassemble rear unit clutch piston assembly by placing cylinder and piston assembly over tool J 6129 with spring end up Set spring compressor tool J 4670 on top of spring retainer and start nut on stud of tool J 6129 NOTE On special tool J 4670 without hole in mid dle drill a 7 16 hole so tool 1 6129 can be inserted through it Compress clutch springs until snap ring is free and remove snap ring Fig 71 1 Tool J 4670 2 Tool J 6129 FIGURE 71 Removing Rear Unit Clutch Spring Snap Ring HYDRA MATIC TRANSMISSION 77 Remove compressor tool retainer and clutch release springs Remove rear clutch piston from cylinder by tapping piston on wood block Remove seals from piston and hub ASSEMBLY OF REAR UNIT NEUTRAL CLUTCH AND CASE SUPPORT Hold the reverse drive flange and sun gear with the drive flange up Install proper selective thrust washer as deter mined by mainshaft end play check in recess of drive flange with locating lugs indexed in flange Use petrolatum to hold washer in place Fig 72 FIGURE 72 Installing Selective Washer in Reverse D
48. 9 Install snap ring which holds release spring retainer and remove compressor tools Fig 84 Install rear unit sprag assembly in rear unit outer race with shoulder side of sprag on counterbored side of outer race Fig 85 Install sprag and outer race on rear unit inner race Push sprag part way down through outer race then rotate sprag counterclockwise to assemble Fig 86 1 Tool J 4670 2 Tool J 6129 FIGURE 84 Installing Rear Clutch Release Spring Retainer Snap Ring FIGURE 85 Jnstall Rear Unit Sprag in Outer Race Install rear unit sprag retainer in rear unit outer race with large outside diameter up Push retainer down to expose snap ring groove Install spiral snap ring on rear unit clutch hub Fig 87 Install rear unit cylinder and sprag assembly into rear clutch drum with sprag side up Secure cylinder and sprag assembly to rear clutch drum with large snap ring Install neutral clutch drum on rear unit with driven clutch plate lug slots up Fig 88 Apply Hydra Matic oil to five clutch drive plates composition and four driven plates steel Install plates HYDRA MATIC TRANSMISSION 81 1 Rear Sprag Outer Race 3 Rear Sprag Inner Race 2 Sprag Assembly FIGURE 86 Jnstall Sprag and Outer Race on Inner Race FIGURE 87 Installing Rear Unit Sprag Retainer Snap Ring alternately using a release spring between steel plates Start with composition plate and release spring the
49. ASSEMBLY AND ASSEMBLY OF INDIVIDUAL UNITS 74 ASSEMBLY OF UNITS INTO CASE 92 REPLACING THE TRANSMISSION 99 TRANSMISSION FLUID DRAINING AND FILLING 99 THROTTLE AND SELECTOR LEVER LINKAGE ADJUSTMENTS 99 TESTING AND DIAGNOSIS 101 SPECIFICATIONS 105 26 TECHNICAL SERVICE MANUAL GENERAL DESCRIPTION The Flashaway Hydra Matic drive consists of a fluid cou pling combined with a hydraulically controlled automatic transmission having four speeds forward and one reverse Three planetary gear sets are used one each for the front rear and reverse units The combination of the two gear sets for the front and rear units in either direct drive or reduction will give four speeds forward and the reverse unit will give one speed in reverse Gear changing is accomplished automatically by the transmission in accordance with the performance demands or road conditions encountered Reduction and direct drive is achieved in the planetary gear set in the following manner HOW REDUCTION IS ACCOMPLISHED To obtain reduction in a planetary gear set it is necessary to hold one member of the gear set from rotating This is accomplished in this transmission by the use of a one way clutch called a sprag assembly For example in the front unit the center gear is held from rotating counterclockwise by the sprag assembly Power input will enter clockwise through the internal gear driving the pinions of the carrier assembly clockwise The p
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51. FT The crankshaft is a drop forged steel shaft counterweighted and balanced independently There are five main bearings and four crankpins It is provided with an oil slinger at reat 1 Oil Passage Oil Filter Supply 2 Upper and Lower Rear Main Oil Seal with an oil slinger at rear journal inboard of the rear oil seal The component parts of the crankshaft assembly are indi vidually balanced and then the complete assembly is bal anced as a unit Replacement of crankshaft flywheel or vibration damper can be accomplished without rebalancing the complete assembly Main Bearing Journals Main bearing journals can be measured without removing the crankshaft from the engine block Various gauges are available for this purpose Always check both ends of the journal to note the taper Then rotate the shaft 90 and measure for out of round li 5 3 Rear Oil Seal Side Grooves FIGURE 20 Bearing Arrangement ENGINE V 8 The main bearing diameter is 2 4983 to 2 4990 and should not taper or be out of round more than 002 Crankshaft Main Bearings Main bearings are of the precision type having a steel back with a babbitt lining The bearings are not adjustable Shims should never be used and the bearing caps should never be filed Service bearings are supplied in 001 002 010 and 012 undersize When either half of a bearing requires replacement a comple
52. I pu 10je nuinoo 16501638 ro A dde o1inssoud JO osu ou ounssoud 1110141 pue Surids 181688 uojsid 1 pue po1oourp 81 A dde 1921 43145 E Z 941 SULING 21112 seids soseo o1 yoinjo SurA dd sor dde 31 UN IEI 0 IO 1 pue suodo 1118 c c 981 11148 c c 991 uo 11158914 poie pue 922310 Surids AJLA 11148 c c 991 Jo ISI uo o1inssoJd 7 0 pue c c 991 uo 1 H 5 89 11889 14 10019108 Z O pu H ujoq 8 puooos our poods SY HONVA aury je 71 ANNO 47 ro m TULONHL A 1 1315008 1 4 b E mE 4 2 1 5 WONHIAOD 514 153144 wo gt LINN INO 10112 3v3s H21n 2 Tv41n3m 1440 9wads HOLD Ovads 48 Uononpoi OU JIM 1898 UI SI UOISSIUISUEJ
53. Long 2 Throttle Linkage Adjusted Short 3 Manual Linkage Incorrectly Adjusted 4 Manual Valve Not Engaged with Drive Pin N Oil Pressure 1 Low Oil Pressure P Accumulator 1 Trimmer Valve Stuck 2 Accumulator Piston Stuck 3 Accumulator Gasket Broken or Leaking 4 Restricted or Leaking Oil Passages 5 Broken Accumulator Spring 6 Broken or Leaking Piston Oil Seal Rings TECHNICAL SERVICE MANUAL Occurs Under Following Conditions R lst and 3rd lst and 2nd Possible Causes Front Unit Planetary Gears Rear Unit Planetary Gears All Ranges Especially Cold Idle Front Pump All Ranges Loaded Only in R Reverse Planetary Gears Any Time Car Is in Motion Rear Pump OIL LEAKS Possible Points of Oil Leaks Oil around inside of bell housing and in line with torus drain plug Oil on inside of bell housing in line with torus cover seal Oil on torus cover and inside of bell housing Oil between bell housing and transmission case Oil between rear pump and case Oil between rear extension housing and rear pump Oil at U joint slip yoke Oil left side of transmission case in line with throttle and manual lever shafts Center support bolt Bottom pan gasket Drain plug Pressure regulator plug Cooler connectors Possible Causes Torus drain plug in flywheel Torus cover to flywheel bolts not torqued to specifi cation Damaged torus cover to flywheel seal ring Front oil
54. N ASSEMBLY maintained to insure efficient operation of the cooling and electrical systems Too much tension will cause An X type fan is attached to a hub on the water pump excessive wear on the fan and generator bearings 20 ELECTRICAL The twelve volt electrical system is outlined in the 1956 Series Technical Service Manual Supplement Delco Remy electrical unit maintenance and adjustment proce dures are outlined in the 1956 Rambler Series Technical Service Manual Specifications follow DISTRIBUTOR The distributor Delco Remy Model 1110863 Fig 1 is a 12 volt au SPRING i WICK wtiGHT ME SPRING WEIGHT P AND SHAFT Ci a LEVER Mi TERMINAL HOUSING BUSHING CONDENSER CONTACT Jm SUPPORT GEAR 4 CONTROL FIGURE 1 Distributor Assembly A center bearing type of vacuum advance breaker plate assem bly is used in this distributor The vacuum advance breaker plate assembly consists of a movable breaker plate a support plate and a lubricating felt between the two plates These parts are held together by means of retainer washers on a hub and bearing washer spiral stabilizing spring and retainer on the stabilizing spring post The movable breaker plate is supported by three moulded buttons which ride on the support plate A vacuum control unit is mounte
55. N RINGS ENGINE SECTION ri V 8 Engine Assembly CONTENTS OF THIS SECTION PAGE CONNECTING RODS CRANKSHAFT Main Bearings End Play VIBRATION DAMPER Oil Pump Relief Valve CO A A SPECIFICATIONS Main Bearing Journals Main Bearing Clearance REAR MAIN BEARING OIL SEALS FLYWHEEL AND STARTER RING GEAR ASSEMBLY LUBRICATION SYSTEM Lubrication Circuit PAGE 10 T2 12 42 13 13 13 14 14 14 25 15 15 4 TECHNICAL SERVICE MANUAL ENGINE IDENTIFICATION The engine number is stamped vertically on the lower right front corner of the cylinder block above the oil pan flange For service reference the number will be duplicated on a stainless steel plate welded to the valve tappet compartment cover CYLINDER HEAD AND GASKET After thoroughly cleaning the top surface of the block and the bottom surface of the cylinder head inspect each for smooth and flat surfaces with a straight edge The cylinder block surface has two locating dowels to assist in lining up and holding position of cylinder head and gasket during installation or removal Coat the gasket with non hardening gasket paste The A M and TOP markings on the gasket are located to the top when installing After installing the push rods rocker arm assembly and cylinder head cap screws tighten them evenly Then retighten to 60 65 foot pounds with torque wre
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57. RE The first requirement of a hydraulic control system is a source of oil pressure Oil pressure for the Hydra Matic transmission is supplied by two oil pumps One is at the front of the transmission driven by the engine the other at the rear driven by the transmission output shaft The front pump operates whenever the car is in forward motion The front pump is of the vane type and consists of seven vanes rotated within a movable slide by a rotor Variable output is achieved through the movable slide A priming spring holds the slide up to deliver maximum output to quickly attain regulated pressure in the control system when the engine 1s started The pressure regulator will then adjust the position of the slide so that only the amount of oil required is pumped Main line pressure operates on the end of the pressure regulator and tends to move it downward When the pressure regulator is in the upward position oil is directed to hold the slide up for maximum output Oil is directed to the opposite side of the slide when the pressure regulator is forced down and the volume output of the pump will be decreased to the amount required to maintain regu lated pressure The torus feed valve controls the flow of oil to the fluid coupling the valve is held against the slide by the spring The valve closes the oil passage to the fluid coupling until oil pressure moves the slide toward the priming springs The valve follows the slide and opens to dire
58. REAR AXLE 109 REAR AXLE The rear axle assembly Spicer type disassembly and as sembly procedures are similar to those outlined in the 1955 Technical Service Manual Variations in procedures and adjustments are outlined as follows DIFFERENTIAL ASSEMBLY AND DRIVE PINION REMOVAL Place axle assembly in suitable stands to facilitate overhaul Thoroughly clean assembly removing all dirt and accumu lated grease Note metal tag denoting axle ratio under one of the cover screws This tag should be reinstalled after assembly is overhauled An axle flushing solution can be used in the axle to degrease the parts before the actual disassembly is started This practice will save time during disassembly as the parts will be free from lubricant and may be handled and in spected easily Remove carrier cover and gasket Before further disassembly check the ring gear back face for runout Mount a dial indicator as shown in Figure and slowly turn the rear axle drive pinion Total indicator read ing in excess of 006 might indicate loose ring gear sprung case or nicks and burrs between ring gear and flange FIGURE 1 Check Ring Gear Runout A 003 feeler should not enter between differential bear ing cap and cup If the feeler does enter it could denote the differential bearing cup had turned in the carrier Remove differential bearing caps Note matching marks on carrier flange and differential bearing caps Fig 1 NOTE Both
59. SSEMBLY OF REAR PUMP Remove reverse piston from bore of rear pump assembly by lifting out Fig 109 Aix N k gt 2 Hub Ring 1 Reverse Piston Ring FIGURE 109 Removing Reverse Piston from Rear Pump Remove rear pump cover to body attaching screws Remove rear cover by holding cover and tapping body with composition hammer Mark both drive and driven gears so they can be re placed with same side up Fig 110 CAUTION Do not scratch gears Remove governor drive key and drive and driven gears Remove rear bearing snap ring and slide bearing out of the pump cover HYDRA MATIC TRANSMISSION 87 1 Indexing Mark on Gears 3 Driven Gear 2 Drive Gear FIGURE 110 Rear Pump Drive and Driven Gears ASSEMBLY OF REAR PUMP Install rear pump drive and driven gears indexing marks which were made for identification during disassembly Install governor drive key into driven gear making sure key is properly seated Use petrolatum to hold key in place Install cover on pump body indexing dowels in cover with dowel holes in body Then secure cover with eight attaching screws Fig 11 1 pagi v Snap Ring 2 Rear Bearing 3 Governor Drive Key 4 Rear Pump Cover 5 Driven Gear 6 Drive Gear 7 Rear Pump Body 8 Oil Rings 9 Reverse Piston FIGURE 111 Exploded View Rear Oil Pump Turn pump over and install reverse piston in cavity in rear pum
60. This pressure cannot move the plunger without assistance from the accelerator linkage Throttle valve pressure is directed to the 2 3 and 3 4 regulator valves where it is modulated Throttle valve pres sure acts against the end of these valves and due to their design the pressure of the oil passing the valves is reduced It is therefore called modulated throttle valve pressure This pressure assists the 2 3 and 3 4 shift valve springs in opposing governor pressures Throttle valve pressure is directed to one end of the overrun clutch valve to position it to the right and to the coupling valve plug to assist the coupling valve spring in opposing G 1 booster pressure Throttle valve pressure is directed to the transition valve when in detent position for a 3 2 downshift to prevent a 3 1 2 downshift by properly timing the front and rear unit change Throttle pressure is directed to the accumulator to absorb the shock of the rear clutch apply oil pressure GOVERNOR PRESSURE A centrifugal governor driven by the rear pump supplies two governor pressures G 1 is supplied from the governor valve having the large weight G 2 is HYDRA MATIC TRANSMISSON 39 supplied from the governor valve having no weight These two pressures vary with car speed However G 1 increases at a faster rate than G 2 pressure because of the large weight The G 1 valve also has a spring to assist in opening the valve to give an initial 1 1 pressure when the eng
61. ace accordingly Ring Gear Removal Remove the cap screws that attach the ring gear to the 110 differential case Use a brass drift tap the ring gear from the case Do not nick the ring gear face of the differential case or drop the ring gear Differential Pinion Gears and Shaft Removal Use a suitable punch to drive out lock pin that holds differ ential pinion shaft in place The pinion shaft can then be driven out and the thrust block can be dropped out through the differential side gear Roll the differential pinion gears around on the side gears until they can be lifted out through the holes in the case Then lift out the side gears and their thrust washers Pinion Gear and Shaft Removal Inspect the rear axle companion flange for face run out using a dial indicator Fig 3 The runout should not exceed 002 1 iF FIGURE 3 Inspect Rear Axle Companion Flange Face Runout Remove the pinion shaft nut while holding the pinion shaft flange The flange can be held by installing two of the flange bolts and holding with a large screw driver blade pry bar or with a suitable spanner type wrench Use extreme care to avoid damage to the flange surfaces Remove the companion flange This is a press fit use flange puller J 2984 Fig 4 Do not drive the flange off the shaft The oil seal and retainer may now be removed Remove the pinion shaft oil slinger Tap the end of the pinion shaft with a fibre hammer to free t
62. atio is 2 55 to 1 Power flows mechanically from the flywheel to the torus cover and to the internal gear attached to the torus cover At the internal gear mechanical power divides Part of the mechanical power is directed into the front unit coupling The front unit member will drive through oil the front unit driven torus member which is attached to the front unit sun gear Thus we have two members of the front unit gear set internal gear and sun gear locked together through oil which will give direct drive These two members drive the front unit planet carrier at engine speed The planet carrier attached to the drive torus member will drive through oil the driven torus member In turn the driven torus member drives the connected main shaft and rear unit sun gear The rear unit sun gear drives the pinions of the rear unit planet carrier at a reduced speed or reduction around the rear unit internal gear for the internal gear is being held by the rear unit sprag assembly The carrier of the rear unit 1s attached to the output shaft Therefore power will be directed from the carrier through the output shaft 34 FLYWHEEL TORUS COVER DRIVE TORUS DRIVEN TORUS INTERNAL GEAR FRONT UNIT SUN GEAR V INTERMEDIATE Wee SHAFT 4 FRONT UNIT COUPLING CARRIER CLUTCH TECHNICAL SERVICE MANUAL REAR CLUTCH HUS REAR LIMIT PLANET GEARS REAR UNIT FRONT SPRAG f
63. ause of dirt A general tappet noise is in most cases due to a lack of oil volume or pressure The normal tappet plunger operating range is 143 Valve Timing The correct valve timing is established by the relation be tween the sprocket on the camshaft and the sprocket on the crankshaft To obtain the correct valve timing index the 0 marks on camshaft and crankshaft sprockets on a line drawn vertically through the center line of each shaft Fig 6 To check the assembly rotate the crankshaft until the timing mark on camshaft sprocket is on a horizontal line at either the 3 or 9 o clock position Count the number of links or pins on the timing chain between timing marks You should have 10 links and or 20 pins between timing marks Each link con tains two pins Fig 7 To make an external check of valve timing remove the cylinder head covers and spark plugs Crank the engine until ENGINE V 8 No 6 cylinder piston in right bank is T D C compres sion stroke This places No 1 cylinder piston on T D C on the exhaust stroke valve overlap position Rotate the crank shaft counterclockwise 90 Install a dial indicator on the number one intake valve rocker arm push rod end Fig 8 Crank the engine slowly in direction of rotation clockwise until the dial indicator indicates push rod movement The hydraulic lifter should be fully charged for this check At the time the dial indicator moves the ignition timing poi
64. ber In turn the driven member drives the connected main shaft and rear unit sun gear At this point power stops for the rear unit is in neutral because the neutral clutch is released Mechanical Power is directed mechanically back from the front unit carrier to the rear unit through the intermediate shaft which is splined to the drive torus member The intermediate shaft is also splined to the rear clutch hub in the rear unit Here power stops because the rear clutch plates are released and the rear unit is in neutral 32 FLYWHEEL TORUS COVER DRIVE TORUS DRIVEN TORUS IMTERMAL GEAR TECHNICAL SERVICE MANUAL MEUTRAL CLUTCH REAR SPRAG CLUTCH REAR INTERNAL GEAR FRONT UNIT COUPLING FRONT UNIT SUM GEAR CLUTCH AND PLANET GEARS FRONT SPRAG REAR PLANET CARRIER REAR UNI SUM GEA OUTPUT SHAFT 4 MAIN SHAFT FIGURE 4 Power Flow First Speed FRONT UNIT REDUCTION NEUTRAL CLUTCH REAR UNIT NEUTRAL Sprag On On Sprag On Coupling Empty Rear Clutch Off FIRST SPEED In first speed the front and rear planetary units are in reduction The transmission gear ratio is 3 96 to 1 Power flows mechanically from the flywheel to the torus cover and to the internal gear attached to the torus cover At the internal gear mechanical power divides Part of the power is directed into the front unit coupling however in first speed the front coupling is empty and no power is transmitted t
65. caps and each side of housing are stamped with an identifying number or letter On one side the markings will be parallel with each other on the opposite side they will be vertical to each other Install axle housing spreader J 5231 in place on housing making sure tool hold down clamp screws are tight Mount dial indicator as shown in Figure 2 FIGURE 2 Spread Housing to Remove Differential Carrier Assembly The axle assembly must be free in stands or holding fixture when housing is being spread Spread housing 020 maximum indicator reading Do not exceed this limit as it will result in permanent damage It is necessary to spread the housing for removal or installation of the differential as the differential bearings have an initial preload of from 005 to 009 Remove indicator fixture Remove the differential assem bly by prying upward and outward with two large screw drivers or pry bars Remove bearing cups from side bearing if cups or cones are not damaged or excessively worn be sure mating parts are kept together for proper reassembly Differential Side Bearing Removal Bearing puller J 2497 is used to remove side bearing cones from the differential case When using this tool be sure it pulls on the bearing cone in such a manner that the rollers are free Recesses are cast in the carrier case to allow the tool to bear on the cone NOTE 11 ring gear and pinion are to be reassembled note position of shims and repl
66. cover to body screw holes in front pump and remove front pump assembly from case Fig 48 NOTE Front sprag inner race may stick in pump Be careful not to drop it on floor if it is in pump as removed Remove front sprag inner race if it did not come out with pump FIGURE 48 Removing Front Pump Remove overrun clutch thrush washer release spring and overrun clutch plate Fig 49 Install case support holding tool J 6135 set screw end toward front and lock securely Fig 50 7 1 Overrun Clutch Plate 3 Thrust Washer 2 Release Spring FIGURE 49 Removing Overrun Clutch Thrust Washer Spring and Plate 1 Special Tool J 6135 FIGURE 50 Case Support Holding Tool in Position CASE SUPPORT NEUTRAL CLUTCH AND REAR UNIT ASSEMBLY REMOVAL Remove speedometer driven gear from rear extension hous ing If rear oil seal is to be replaced remove seal using tool J 2623 and slide hammer J 2619B Remove rear extension housing and gasket and discard gasket It may be necessary to tap housing to rear to loosen HYDRA MATIC TRANSMISSION 7l Remove governor assembly by pulling governor out of rear pump housing Fig 51 FIGURE 51 Removing Governor from Rear Pump Assembly Governor drive key may or may not stay with governor Remove breather pipe clamp screw from rear of trans mission case and carefully pry breather pipe out of rear pump body Remove rear bearing snap ring from output shaft Remove
67. ct oil through the oil cooler in the radiator lower tank through the fluid coupling and lubrication system A ball check is provided to by pass the cooler in the event the cooler becomes plugged The limit valve in the front clutch valve body protects the system against excessive pressures The rear pump is a gear type Both pumps deliver oil at regulated pressure controlled by the pressure regulator valve through the front pump when the car is driven forward THROTTLE PRESSURE Throttle valve pressure originates at the throttle valve and varies according to carburetor throttle opening by means of linkage from the accelerator pedal As the accelerator pedal is depressed linkage to a lever on the side of the transmis sion moves the throttle valve plunger Plunger movement opens the throttle valve through spring force and oil from the pump then flows through an opening at the throttle valve This oil under pressure acts on the end of the throttle valve to oppose the throttle valve spring force which opened the valve In this manner the throttle valve comes a balanced valve balanced between spring force and throttle pressure As a result of this action throttle pressure varies with accel erator pedal position from zero pressure at closed throttle to full line pressure at full throttle Throttle pressure is directed to a land on the throttle valve plunger to assist in moving the plunger which gives a lighter feel to the accelerator pedal
68. ctly adjusted pinions marked 0 On a pinion marked 2 the reading should be 002 less than this figure and with a pinion marked 3 the reading should be 003 greater If the micrometer reading shows the pinion setting 18 incorrect by more than 002 plus or minus from the given figures shims equal to that difference must either be added to or removed from the shim pack between the rear bearing cup or housing When changing shim packs it is advisable to check each shim separately to avoid unnecessary removal and in stallation of pinion and depth gauge Preloading Pinion Bearings After the correct pinion setting is accomplished remove front pinion bearing cone and rollers Install preload shims on shaft and install front pinion bearing cones and rollers Install oil slinger companion flange and nut Tighten pin ion nut to 200 220 foot pounds A T handle wrench socket and spring scale can be REAR AXLE 113 used to determine the amount of pinion bearing preload The spring scale is attached to the T handle at a distance of six inches from the center of the pinion shaft Pull on the spring scale and note the reading in pounds on the scale as the pinion starts to move and multiply by six To eliminate the effect of gravity turn the assembly so that the pulling effort is on a horizontal plane The specified preload is twenty five to thirty five inch pounds Five pound pull at six inches would indicate thirty inch pounds of
69. d on the outside of the distributor housing The vacuum control unit consists of an enclosed spring loaded diaphragm linked mechanically to the movable breaker plate inside the distributor The airtight side of the diaphragm is connected to the intake manifold side of the carburetor Under part throttle operation the intake manifold vacuum is sufficient to actu ate the diaphragm and cause the movable breaker plate to move thus advancing the spark and increasing fuel economy During acceleration or when the engine is pulling heavily the vacuum is not sufficient to actuate the diaphragm and the movable SECTION RETAINER STABILIZING 4 87 SPRING MOVABLE BREAKER PLATE LUBRICATING FELT SUPPORT PLATE CC BEARING quo WASHER RETAINER c Ii Posr SIDE PRESSURE SPRING FIGURE 2 Distributor Vacuum Advance Breaker Plate Assembly breaker plate is held in the retarded position by a calibrated return spring which bears against the vacuum diaphragm The centrifugal advance mechanism consists of an auto matic cam actuated by two centrifugal weights controlled by springs As the speed of the distributor shaft increases with engine speed the weights are thrown outward against the pull of the springs This advances the cam assembly and rotor to make ignition occur earlier in relation to piston position If centrifugal advance mechanism requires attention rem
70. d rotor wiring breaker points and timing IGNITION RESISTOR A Delco Remy resistor Model 1927809 is used in the 22 TECHNICAL SERVICE MANUAL ignition primary circuit to increase coil efficiency for starting and permits a smaller size coil for operation It has a resistance value of 1 40 to 1 62 ohms IGNITION TIMING The distributor can be rotated in its mounting to obtain ignition timing Correct timing is 5 B T D C at idle speed Firing order is 1 8 4 3 6 5 7 2 SPARK PLUGS Type AL 7 Auto Lite Torque 30 Ft Lbs Gap 0227 Thread Reach 7 16 DISTRIBUTOR SPECIFICATIONS Model 1110863 BATTERY SPECIFICATIONS Rotation Left Hand c c Rotor End Make Auto Lite Point Opening 016 Model Cam Angle 28 35 With Air Conditioning 11 HS 60 Breaker Lever Tension 19 23 075 Without Air Conditioning 11 HS 50 Condenser Capacity 18 23 Microfarads Rating Centrifugal Advance With Air Conditioning 60 Ampere Hours Without Air Conditioning 50 Ampere Hours Engine Engine No of Plates Each Cell 11 R P M Degrees Start 700 1 5 Intermediate 800 4 8 Make Delco Remy Intermediate 1600 14 18 Model 1107648 Maximum 2250 22 26 Brush Spring Tension 35 Oz Minimum Free Speed No Load Volts 10 3 VACUUM CONTROL Amperes 75 R P M 6900 Model 1116095 Inches of Mercury Dee Orme to Start Advance 5 7 Model 1119760 Inches of Mercury Hold in Winding 18 20 Amperes at 10 Volts for Full Advance 11 11 5 Both Windings 72 76 Amperes at
71. d to fourth Direct Drive will occur depending on the amount the accelerator pedal 1s depressed CAUTION Do not coast with the selector lever in N Neutral position It is unlawful in some states and some times is harmful to the transmission FORCED DOWNSHIFT To obtain extra power or acceleration when driving in D 4 D 3 or L range depress accelerator pedal completely When in D 4 Range and with a car speed of less than 60 M P H transmission will shift down to third speed When in D 3 range and with car speed of less than 20 M P H transmission will shift down to second speed STOPPING THE CAR Leave the selector lever in the driving position selected and release accelerator pedal The engine is then left in gear which helps to slow down the car For further stopping effort apply the brakes in the conventional manner CAUTION When the driver leaves the car with the engine running the selector lever should always be placed in the P Park position This precaution prevents movement of the car should the accelerator pedal be accidentally depressed by a passenger and will also keep the car from rolling on a down grade or incline OPERATING IN L RANGE Low Range prevents the transmission from shifting above 2nd speed unless the car exceeds approxi 30 TECHNICAL SERVICE MANUAL mately 35 M P H Low range is provided for pulling through deep sand or snow and ascending or descending steep grades when traffic
72. e bores of the differential case Install thrust washers behind the differential pinion gears and mesh the gears with the side gears so the holes are opposite and in line with each other REAR AXLE Roll the gears around until the gear holes are aligned with the differential pinion shaft hole in the case The pinion gear shaft is installed with the lock pin hole in line with the lock pin hole in the differential case Install the thrust block through a side gear aligning the hole in the block with the differential pinion shaft Press differential pinion shaft in place and measure the clearance between the differential side gear and case This clearance should not exceed 008 However the side gears should not fit tight enough to require more than eight foot pounds torque to turn the differential gears This may be checked by installing an axle shaft and using a torque wrench to turn the shaft Then drive the lock pin into place and upset pin Ring Gear Installation Place the ring gear on the differential case Bolt the ring gear to the differential case with cap screws In some cases two of the cap screws installed in opposite holes may be used as guides to pull the gear into position Tighten the cap screws to 50 55 foot pounds torque Be certain the ring gear is being pulled down evenly and that there are no nicks or burrs to prevent the gear from being installed evenly all the way around Adjusting Side Bearings Install
73. e lines At the same time the regulated governor pressure exerts force on the plungers to move them toward the center Therefore we have governor to exhaust any pressure not required to balance centrifugal force pressures that will vary with vehicle or output shaft speed G 1 pressure rises faster than G 2 pressure as the speed increases because the G 1 unit has greater weight than the G 2 unit therefore G 1 pressure will reach main line pres sure before G 2 The G 1 weight has a one pound spring holding the weight in the open position to produce an initial G 1 pressure of five pounds per square inch G 1 pressure is directed to the G 5 valve to the 2 3 governor valve to the 3 4 shift valve and the reverse blocker G 2 pressure 1s directed to the 2 3 shift valve and to the 3 4 governor valve FRONT PUMP The front pump is a variable output vane type pump which automatically regulates the output according to the need of the transmission It consists of the pump body cover slide rotor seven vanes two guide rings and two priming springs Output of the pump is controlled by the position of the slide The slide is held up by the priming spring for maxi mum output when the pump is started When the pump is operating the position of the slide is controlled by the pressure regulator valve When the output pressure is low the pressure regulator valve is pushed deep into its bore in the pump directing pressure below the slide to hold
74. e speedometer cable and manual and T V linkage Connect oil cooler tubes and replace oil filler tube Connect brake hose bracket Install lower flywheel housing to engine cover Re move engine support and recheck T V and manual con trol linkage adjustment Fill transmission to proper level by following proce dure outlined under Transmission Fluid Draining and Filling TRANSMISSION FLUID DRAINING AND REFILLING TRANSMISSION FLUID Fluid level should be checked every 1000 miles at the time chassis lubrication is performed In order to make an accurate check transmission should be at normal operating tempera ture engine should be idling at 425 R P M selector lever should be in P Park position and car should be on level floor With engine idling remove the fluid level indicator and wipe clean reinsert it and remove the indicator and note reading When refilling or adding fluid use only Automatic Trans mission Fluid Type A from containers bearing Armour Institute qualification number Transmission oil should be changed every 25 000 miles at which time it is recommended that the oil pan be removed and the oil screen cleaned The torus drain plug is located in the fly wheel TRANSMISSION FILLING PROCEDURE Pour in eight quarts of Hydra Matic fluid Operate engine with transmission in neutral for about 11 2 minutes to fill fluid coupling Add 21 2 quarts Hydra Matic fluid Warm up engine thorou
75. ears and the walls of the gear cavity opposite point of gear mesh NOTE The pump cover should be installed with pump out of engine and pump checked for freedom of operation before installation ENGINE V 8 I5 1 Oil Pump Drive Shaft 8 Driven Gear 2 Key 9 Cover to Body Gasket 3 Pump Mounting Gasket 10 Cover 4 Body 11 0 Seal Ring 5 Relief Valve Plunger 6 Relief Valve Spring 7 Drive Gear 12 Inlet Tube and Screen Assembly FIGURE 25 Oil Pump Assembly Oil Pressure Relief Valve The oil pressure relief valve is not adjustable A setting of 55 60 pounds pressure is built into the tension of the spring On the released position the valve permits oil to by pass through ports and a passage in the pump cover to the inlet side of the pump Lubrication Circuit Oil drawn through the inlet screen and tube assembly is displaced into the pressure discharge side of pump to a port indexing with a vertical oil gallery up into the cylinder block where it indexes with a horizontal passage leading to the lower oil filter mounting adapter Figs 20 and 26 Oil is returned from the oil filter to the timing chain compartment All camshaft and main crank shaft bearings are lubricated from the center longitudinal oil gallery Holes drilled in the crankshaft throws afford lubrication to the connecting rod bearings Low speed cylinder wall lubrica tion is obtained through small holes or channels in the parting surface
76. ecess in front unit drive torus shell Fig 137 mo TU in PME T ja FIGURE 137 Installing Steel Thrust Washer Position flywheel housing bushing and seal protector J 6119 over intermediate shaft Install flywheel housing to case 0 ring seal on flywheel housing Fig 138 and flywheel housing on case Attach with six screws tightening to 45 foot pounds torque Then remove bushing and seal protector p ME 2 pg D 221 e E P ae cta Lhe Bp 4 FIGURE 138 Jnstalling 0 Ring Install proper selective washer on drive shaft of front unit as determined when checking front unit end clearance Fig 139 Install torus cover Push cover on evenly without rocking to prevent damage to seal and bushing Install internal gear assembly into cover indexing with torus cover and front unit drive torus hub Install bronze thrust washer then steel backing washer in internal gear Steel backing washer must 98 TECHNICAL SERVICE MANUAL FIGURE 139 lJnstalling Proper Selective Washer be indexed with splines of front unit driven torus shaft Install sun gear over front unit driven torus shaft cham fered side first Install steel backing washer and bronze thrust washer against sun gear Install drive torus member on intermediate shaft index ing front unit planet carrier with sun gear and inte
77. ed upper or lower plate or dirt between the plates Whenever a complete breaker plate assembly is rein stalled in the distributor care must be taken when attaching the vacuum control linkage The linkage must be fitted to the connector bearing on the movable breaker plate so that there is no upward or downward thrust on the plate when the vacuum control operates Also check the clearance of the linkage through full travel to be sure that the condenser or condenser lead does not interfere with the operation of the assembly Replacing Distributor Contact Points When replacing distributor contact points particular care 1 With C Hook on Top of Post Note Scale Reading at Start of Post Movement FIGURE 3 Checking Breaker Plate Stabilizing Spring Tension should be given to Assembly of contact support Assembly of breaker lever and breaker spring Lubrication The hinge cap oiler should be filled with light engine oil at each vehicle lubrication period Every 5000 miles add a trace of Delco Remy Cam and Ball Bearing Lubricant or equiva lent to the breaker cam place three to four drops of light engine oil on the wick in the cam shaft under the rotor one to two drops on the breaker lever pivot and three to four drops to the felt wick between the plates of the vacuum advance assembly Wipe off any excess oil appearing on the breaker plate In addition to lubrication the distributor requires periodic inspection of the cap an
78. el economy When driving in this range at a car speed of less than 65 M P H extra performance can be obtained by depressing the accelerator pedal This will cause the trans mission to downshift into third speed The car speed deter mines the amount the accelerator pedal must be depressed to cause this shift At a speed of 35 M P H or less the acceler ator pedal need only be partially depressed to cause the shift and at speeds of 35 M P H to 65 M P H it is necessary to completely depress the pedal The transmission will auto matically return to fourth speed as car speed 15 increased or the accelerator pedal is released Drive 3 is provided for improved performance at medium car speeds and is very useful when driving in congested traffic In this range the transmission is prevented from shifting into fourth speed except at very high car speeds In effect it becomes a three speed transmission in Drive 3 Range It is also effective when ascending or descending long mountain grades When driving the car in either Drive Range at a car speed of less than 24 M P H an extra burst of speed can be obtained by completely depressing the accelerator pedal This will cause the transmission to shift down to second speed The transmission will automatically return to third or fourth speed depending on the Drive Range being used as the car speed increases or pedal is released Variable shifting events from first to second second to third thir
79. embly After torus feed valve assembly is installed make sure that free movement of the valve can be obtained by moving the slide Install oil cooler ball into oil cooler passage which is nearest to dowel Then install the spring and spring retainer pin Fig 103 FIGURE 103 Jnstalling Cooler Check Valve Assembly Install bottom vane ring into front pump cavity locating it in the center of the slide Then install the rotor with drive slots up Install the seven vanes with proper side against vane rings The vanes will have polished areas where they contact the vane rings Install top vane ring on rotor and check to see that rotor rotates freely Fig 104 The total clearance between vanes and slide with the vane rings installed should be 000 003 FIGURE 104 Jnstalling Vanes Rotor Check with feeler gauge between each vane and inside diameter of slide to make certain that clearance does not exceed 003 NOTE With vanes contacting slide on one side clearance should not exceed 003 on opposite side If clearance is excessive pump must be replaced Install front cover to pump body with four attaching screws using short screw in hole nearest top of pump opposite intake pipe hole Turn pump over and make sure oil rings are in place on overrun clutch piston and hub in front pump body Put location marks on front body and overrun clutch piston opposite dowel so piston can be aligned with dowels Align piston with
80. embly into clutch unit holding fix ture J 6116 positioning output shaft down or drill 2 hole in bench to hold assembly Fig 57 72 TECHNICAL SERVICE MANUAL FIGURE 54 Removing Case Center Support Snap Ring FIGURE 55 Removing Case Support Locking Screw Remove neutral clutch key from case If key is tight it can be tapped out through hole in bottom of case Remove low band from transmission case as follows Unhook band end from case anchor located inside of case With band unhooked rotate band to horizontal position in transmission case Turn band so that band ends are facing rear of transmis sion case and pull out through front of case Fig 58 FIGURE 56 Using Slide Hammer and Adapter to Pull Units FIGURE 57 Clutch Unit Installed in Holding Fixture INSIDE DETENT AND THROTTLE LEVER REMOVAL NOTE Normally these parts should not be re moved unless they are to be replaced Remove outer shift lever from detent lever shaft Remove snap ring from detent lever shaft Fig 59 Rotate detent lever to position which would engage parking pawl so that detent lever will clear the parking bracket assembly Then remove detent lever throttle lever HYDRA MATIC TRANSMISSION 73 assembly and inner steel washer from case by sliding toward center of case Remove steel washer and 0 ring from case PARKING PAWL AND LINKAGE REMOVAL NOTE These parts should not be removed unless they are t
81. embly on the shift valve body assembly and start the two screws Install the remaining two screws and tighten all four mak ing sure that all springs are correctly aligned Install the 3 4 and 2 3 governor valves and governor booster valve in the shift valve body Then fasten the gover nor valve end plate to the shift valve body with the four attaching screws Remove reverse blocker piston retaining pin spring and piston Fig 118 5 Reverse Blocker Piston 2 Detent Plunger Spring Spring 1 Reverse Blocker Body 3 Detent Plunger Retainer 6 Detent Plunger 4 Reverse Blocker Piston FIGURE 118 Reverse Blocker Assembly HYDRA MATIC TRANSMISSION 91 ASSEMBLY REVERSE BLOCKER ASSEMBLY Install reverse blocker piston and spring install retaining pin from counter sunk side of hole Install detent plunger spring and detent plunger into bore in body with spring stern down and compress plunger and install retaining hairpin on end of plunger DISASSEMBLY OF MANUAL VALVE BODY Remove manual valve body by removing the six screws Then remove the manual valve Remove the two screws that retain the T V lever stop to manual body and remove stop CAUTION Do not attempt to adjust or remove T V stop pin retained in lever by fluster head screw This is a factory setting and should not be disturbed Remove T V plunger and guide from center bore of body and separate Remove T V spring and throttle valve from center bore
82. er to Body 6 8 Rear Pump and Case Control Valve to Case 6 8 Front Pump Assembly to Rear Pump Body to Case 10 12 Center Support Case to Front Pump Body 25 Flywheel Housing to Case Front Pump Cover to Body 15 18 Case to Center Support Rear Pump Cover to Body 15 18 Oil Pan Drain Screw Cooler Adapter to Case 15 18 Pressure Regulator Plug Oil Pan to Case 10 13 TECHNICAL SERVICE LETTER REFERENCE Date Letter No Subject Changes Information on Page No 107 22 39 26 58 33 50 34 Torque Lb Ft 25 25 25 25 23 45 25 40 108 BRAKES AND WHEELS HUBS AND DRUMS The brake system incorporated in this series 15 the Bendix Servo type identical to the system used on the 1956 40 Series BRAKE SPECIFICATIONS Type of Mechanism Make Total Foot Braking Area Lining Size Width x Length Primary Front Rear Secondary Front Rear Pedal Free Play Without Power Brakes Drum Diameter Inches Front Wheel Cylinder Bore Diameter Rear Wheel Cylinder Bore Diameter Master Cylinder Bore Diameter Piston Clearance Inches Wheel and Master Cylinder Master Cylinder Piston Rod Diameter Inches Power Brake Treadle Vac WHEELS AND TIRES Wheel Size Tire Size Tire Pressure Cold Front and Rear Wheels Lockheed Hydraulic Bendix Servo 165 Sq In 2 x 8 7 8 1 3 4 x 8 7 16 2 1 2 x 10 31 32 1 3 4 x 10 25 32 1 4 to 1 2 10 1 1 2 7 8 1 001 to 003 21 325 15 6 70 x 15 24 Lbs
83. essary to remove and disassemble the clutch unit so that the correct selective thrust washer can be installed between the rear unit planet carrier and the reverse drive flange Remove end play checking tool 96 TECHNICAL SERVICE MANUAL Align rings so they will be upward when governor sleeve is installed in rear pump cover Compress each ring by hand and work into governor bore Then rock governor back and forth to engage drive key Test to see that governor turns when output shaft is turned Install new rear extension housing gasket on rear pump with petrolatum and install rear extension housing on case with eight attaching screws and washers Install speedometer gear in rear extension housing Insert vent pipe into hole in top of rear pump and clamp pipe to case If rear oil seal was removed coat new seal with perma tex and drive into housing until seal bottoms Tool J 4485 or J 5154A will facilitate installation of the seal NOTE Felt portion of seal must be toward rear INSTALLATION OF FRONT PUMP AND OVERRUN CLUTCH Install front pump and overrun clutch plate assembly over intermediate shaft At the same time align the intake pipe holes in the front pump and case Fig 134 FIGURE 134 Jnstalling Front Pump and Overrun Clutch Install and tighten three front pump to case center screws then back them off one turn Install front pump locking screw through case into pump and tighten securely Fig 135 Then tighten
84. et Oil Supply Gallery 5 Left Hand Tappet Oil Supply Gallery 6 Engine Front Cover Locating Dowl FIGURE 27 Front of Engine Block Crankshaft End Play 003 007 Engine Idle R P M Connecting Rod Bearing Standard and Overdrive Diameter 2 2483 2 2490 Hydra Matic In 550 Connecting Rod Bearing Neutral 425 Clearance 0007 0028 With Connecting Rod Torque 52 56 Ft Lbs Conditioning 450 Connecting Rod Side NOTE When equipped with air conditioning adjust idle Clearance 004 012 with air conditioning unit ON Ignition Timing 5 B T D C eae Distributor Point Gap 016 Camshaft End Play 003 006 Dwell or Cam Angle 28 35 Camshaft Bearing Clearance 001 003 Breaker Point Tension 19 Oz 23 Oz TUNE UP DATA Rotor Rotation Left Hand Rotor End Spark Plugs Auto Lite AL 7 Compression Pressure Gap 035 Cranking Speed Torque 30 Ft Lbs Throttle Wide Open 140 315 R P M Cylinder Head Torque 60 65 Ft Lbs 18 COOLING SYSTEM WATER PUMP The water pump is a centrifugal type utilizing a non adjust able packless type seal The impeller housing is cast inte grally with the water distribution manifold and the engine front cover A separate cylinder head water outlet manifold which houses the thermostat is mounted to the impeller housing at the by pass port and sealed by means of a rubber 0 ring seal Fig 1 4 Water Pump Housing 5 Outlet Manifold By pass 3 Water Pump Seal 1 Thermostat Ho
85. figure will be found on the end of the drive pinion which shows a plus or minus sign Fig 6 FIGURE 6 Matched Gear Set Numbers and Pinion Setting Number 112 This indicates the position of the pinion in relation to the center line of the axle If there are no figures showing a plus or minus sign it denotes a zero pinion setting and a 0 will be shown The gear is marked Plus or Minus the number of thousandths that the gear varies above or below standard Thus Plus means the pinion gear is closer to the cen ter line of the axle than standard and the Minus means farther from the center line When installing a new ring and pinion set or a new rear bearing use new adjusting shims Adjusting shims are available in 003 005 and 010 shims to obtain various thickness combinations Use bearing replacing tool J 2995 press the rear pinion bearing cone tight against the rear face of the gear The large diameter of the bearing should be toward the gear Install rear pinion bearing cup with bearing replacer tool J 2531 placing shims between cup and housing The amount of shims used is determined by the amount of shims removed at disassembly and by the plus or minus figure etched on the pinion For example if the original pinion was marked 2 and had a shim pack of 035 behind the rear bearing cup and the new pinion to be installed is marked 1 the shim pack must be increased by 003 to bring the new pinio
86. front pump to case support attaching screws NOTE Locking screw must be tightened up first to draw pump tightly against case and eliminate the possibility of excessive oil leaks between pump and case FIGURE 135 Jnstalling Front Pump Locking Screw INSTALLATION OF OIL COOLER ADAPTER PRES SURE REGULATOR AND FRONT UNIT COUPLING Install seals on ends of oil cooler sleeves and insert sleeves in case with seal end first Place oil cooler adapter with gasket on case over oil cooler sleeves install two attaching screws with copper washers and tighten securely With spring in place on pressure regulator valve install valve and spring into case Install pressure regulator plug assembly and tighten to five foot pounds torque Fig 136 CAUTION Do not over torque as pressure regulator may push pump away from case and cause an internal oil leak HYDRA MATIC TRANSMISSION 97 Rotate transmission to vertical position with front pump up First install front unit coupling assembly cover into transmission Then rock drive torus shell to make sure that the drive hub engages front pump and rotor and rock driven torus shaft to make sure lugs on shaft engage front unit sprag inner race Driven torus shaft should turn clockwise freely and not turn counterclockwise NOTE For measurement of front unit end clearance refer to Figures 29 and 30 INSTALLATION OF CONTROL VALVE ASSEMBLY AND SERVO AND ACCUMULATOR ASSEMBLY Rotate transmi
87. ft is splined to the rear clutch hub which transmits power through the clutch plates drum and rear internal gear The carrier of the rear unit is attached to the output shaft Therefore power will be directed through the output shaft HYDRA MATIC TRANSMISSION 35 FLY WHEEL TORUS COVER DRIVE TORUS HEAR aia ah HUB Mb i A e PLANET GEARS DRIVEN TORUS INTERNAL GEAR REAR UNIT CARRIER E di FRONT UNIT 27 COUPLING FRONT UNIT SUM GEAR INTERMEDIATE DRIVE TORUS SHAFT OUTPUT SHAFT FIGURE 7 Power Flow Fourth Speed FRONT UNIT DIRECT DRIVE Sprag Off Coupling Full NEUTRAL CLUTCH REAR UNIT DIRECT DRIVE Sprag Off Rear Clutch On FOURTH SPEED In fourth speed the front and rear units are in direct drive Therefore the transmission operates as a solid coupling between the engine and rear axle Power flows mechanically from the flywheel to the torus cover and to the internal gear attached to the torus cover At the internal gear mechanical power divides Part of the mechanical power is directed into the front unit coupling The front unit drive member will drive through oil the front unit driven torus member which is attached to the front unit sun gear The internal gear and sun gear members of the front unit gear set are locked through oil which will give direct drive These two members drive the front unit planet carrier at engine speed Powe
88. g brake lever Position parking brake lever spring in bracket with long end toward rear Slide bracket and spring assembly onto pivot shaft with end of spring under parking lever Hook other end of spring over pin at front of bracket Fig 123 HYDRA MATIC TRANSMISSION 93 1 Spacer FIGURE 122 Parking Pivot Shaft Spacer in Place Parking Pawl Parking Brake Lever Parking Brake Bracket Spring Inside Throttle Control Lever Spacer Washer Inside Detent Control Lever gt WN KR FIGURE 123 Parking Brake Lever Assembly INSTALLATION OF INSIDE DETENT AND THROTTLE LEVERS With throttle and detent levers assembled place spacer washer over detent shaft against detent lever Insert lever and shaft assembly through hole in case from inside with parking brake tang below pin in parking brake bracket Install 0 seal and special washer which fits into bore of case over detent lever shaft Install snap ring to retain seal and washer as shown in Figure 59 INSTALLATION OF LOW BAND Install low band through front end of transmission case with the band ends facing rearward in a horizontal position anchor sup port hole should face right hand side Fig 124 FIGURE 124 Installing Low Band When band is approximately half way through transmission case with band still horizontal rotate band so that ends are in cavity in case above anchor pin and rotate band into position until anchor su
89. ghly oil will expand as it is heated and oil level indicator is calibrated for oil at normal operating temperature Place selector lever in P Park position and recheck fluid level indicator and add oil as necessary to bring level to full mark on indicator NOTE DO NOT OVERFILL TRANSMISSION AT ANY TIME THROTTLE AND SELECTOR LEVER LINAGE ADJUSTMENTS THROTTLE LINKAGE ADJUSTMENT Check the adjustment of the T V lever at the transmission by disconnecting the lower T V rod from the lever Disconnect the vent pipe at the lower left rear of the tranmisson case While holding the T V lever all the way back against the stop the measurement should be 5966 from the machined surface at the rear of the case to the center of the pin on the T V lever Bend lever to conform to this measurement Fig 144 FIGURE 144 Lever Measurement With the carburetor set off of fast idle adjust the upper T V rod at the carburetor throttle rod bracket to engage the hole in the bracket freely Then remove TECHNICAL SERVICE MANUAL move the rod from the bracket and turn the adjusting end of the T V rod to the left one lull turn this lengthens the rod Replace and fasten the T V rod to the carburetor throttle rod bracket Tighten the hexagon nut to secure the adjusting end of the T V rod Fig 145 SELECTOR LEVER LINKAGE ADJUSTMENT Place selector lever in the D 3 position and set the operating lever against the stop on the s
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91. gnment of Rear Drum and Neutral Clutch Drum Pie FIGURE 127 Installing Rear Unit Neutral FIGURE 129 Installing Reverse Clutch Clutch and Case Support Release Spring HYDRA MATIC TRANSMISSION Install thrust washer on reverse internal gear Install gasket on rear pump and retain with petrolatum Install the rear pump assembly on transmission case Install locating screw and attaching screw Fig 130 1 Attaching Screw 2 Locating Screw FIGURE 130 Rear Pump Attaching Screws Remove case support tool J 6135 from intermediate shaft Place rear bearing over output shaft and into pump cover Use tool J 2995 to complete installation of the bearing Install rear bearing to pump cover and output shaft to bearing snap rings Fig 131 1 1001 J 2995 FIGURE 131 Jnstalling Rear Bearing 95 CHECKING MAIN SHAFT END PLAY Remove collar from special tool J 6127 and install on main shaft securing collar with Truarc snap ring Fig 132 FIGURE 132 Main Shaft End Play Tool J 6127 Attach fixture to collar of tool by threading collar into fixture Install dial indicator support tool J 6126 and dial indicator Fig 133 FIGURE 133 Checking Main Shaft End Play Move main shaft back and forth to check end play of main shaft Be sure to get free main shaft end play Forcing main shaft will give inaccurate reading The actual main shaft end play should be 004 018 If outside these limits it will be nec
92. he driven torus which is held stationary by the transmission being in first speed and brakes locked The engine will speed up until the friction created between the torus members equals the power output of the engine Engine speed will denote efficiency and should compare to specifications outlined in Figure 146 If engine R P M is less than the low limit the engine is in need of a tune up If engine continues to speed up to approximately 200 to 350 R P M above the high limit 1t indicates that clutch sprags are not holding properly or that there is slippage in fluid coupling damaged torus members or defective front pump CAUTION Extreme care must be used in making this test DO NOT HOLD THROTTLE OPEN MORE THAN ONE MINUTE If engine speeds up to 350 R P M over specifications close throttle immediately to avoid possible damage to trans mission sometimes it is desirable to know which unit is slipping After making test with selector lever in D position place lever in R position and test again If slippage still occurs fault is with front unit or both If slippage does not occur then all slippage is in the rear unit Since this transmission starts in Ist speed in L range the stall speed should be exactly the same in L range as it is in Drive and Reverse Check Cause for Slipping Under Stall Test Set hand brake lever tightly Start engine and run at a speed equivalent to 20 M P H for approximately 11 2 minutes T
93. he front bearing cone from the pinion shaft and remove the bearing The shim pack located between the bearing and a shoulder TECHNICAL SERVICE MANUAL mmm FIGURE 4 Remove the Rear Axle Pinion Flange with Tool 2984 on the pinion shaft controls the pinion bearing preload Therefore tag to identify it at time of reassembly The pinion gear and rear bearing may now be removed from the rear of the housing Pinion Bearing Cups Recesses are located behind each pinion bearing cup to provide a means of driving the cup from the housing The cups should be driven out of the housing using a brass punch CAUTION Keep the cups square in the bore to prevent damaging the cup bores Remove shims used to adjust the pinion depth in the housing from behind rear bearing cup Check thickness of each shim record total thickness and tie shims together for reinstallation Pinion Rear Bearing Removal The pinion bearing is a press fit on the pinion shaft Attach pinion bearing remover J 2245 A in holder J 358 1 and use an arbor press to remove the pinion bearing DIFFERENTIAL AND DRIVE PINION ASSEMBLY AND ADJUSTMENTS To insure a uniform method of adjusting rear axles all specifications for correct adjustment are established on the basis of dry parts New thrust washers and oil seals should be installed at time of assembly Assembling the Differential Gears Install thrust washers on the side gears and install the gears in th
94. he planet carrier HOW DIRECT DRIVE IS ACCOMPLISHED To effect direct drive it 15 necessary to lock together two members of a planetary gear set Direct drive in the Flasha way Hydra Matic is produced in two ways Front Unit Fluid Direct drive in the front unit is obtained by the use of a fluid coupling The fluid coupling consists of a small engine driven front unit drive torus member which is splined to the internal gear of the front unit gear set The front unit driven torus member is splined to the sun gear of the front unit planetary gear set and to the inner race of the sprag assembly Thus when the small coupling is filled the internal and sun gear are locked together through oil giving direct drive in the front unit In direct drive the front unit sun gear is allowed to turn clockwise by the sprag The oil used to feed the front unit coupling is controlled hydraulically in the control valve assembly The coupling is filled in second and fourth gear for direct drive and empty in first and third gear HYDRA MATIC TRANSMISSION 2 Rear Unit Clutch To obtain direct drive in the rear unit a multiple disc clutch will lock the internal gear mechanically The application of the rear clutch is controlled hydraulically REVERSE UNIT The reverse unit consists of a reverse planetary gear set with a cone clutch which holds the reverse internal gear The reverse cone clutch is engaged by a piston which is oil applied and spri
95. hen with engine IDLING selector lever in N range check the fluid level in the transmission See that fluid 1s at the Full mark on the indicator After level has been checked shut off engine and wait 10 minutes If the fluid level in the transmission has not raised more than 1 2 the driven torus check valve is operating satisfactorily If check valve is operating satisfactorily road test car using Diagnosis Guide OIL PRESSURE TEST Connect oil pressure gauge j 2540 to take off hole at bottom of rear pump using hose and fitting Start engine and operate for several minutes to warm transmission oil to normal operating temperature approx 175 F When transmission is thoroughly warm check pres sure in all ranges Pressure should be 50 158 minimum in P N D 4 D 3 and L ranges with a maximum variation of 10 lbs between ranges The pressure however may be higher in reverse Check pressure in D 3 position at approximately 25 M P H while driving car Pressure should be 90 100 5 1 NOTE Pressure at any speed is constant re gardless of throttle position T V pressure is not used to modulate line pressure While driving at 25 M P H move selector lever back to D 4 position so transmission will shift into fourth speed Oil pressure should drop to 60 70 P S I in fourth speed NOTE To reduce the amount of work done by the front pump pressure is directed from the 3 4 shift valve to the pressure regulator to
96. hen the coupling valve moves to the left it cuts off main line pressure to the signal oil and feed oil passages The exhaust valves in the front unit coupling will open and oil will be thrown from the front unit coupling by centrifugal force OVERRUN CLUTCH VALVE The overrun clutch valve is positioned to the right by throttle pressure in D 4 and reverse In drive range the overrun front clutch apply passage is open to exhaust through the reverse passage at the manual valve In reverse oil is directed from the manual valve to the overrun front clutch piston to apply the clutch In D 3 and L range pump pressure is directed from the manual valve through the coupling valve in first and third to the right end of the overrun clutch valve Pump pressure moves the overrun clutch valve to the left against throttle pressure and slowly opens the passage to the overrun front clutch to delay application of the clutch In second and fourth speeds the coupling valve cuts off the pump pressure to the overrun clutch valve and throttle pres sure moves the valve to the right The overrun clutch apply pressure then exhausts through the reverse passage and the overrun clutch is released by spring force This delay in applying the overrun clutch is to allow the front unit cou pling to empty and front sprag clutch to engage resulting in a smooth 4 3 downshift when moving the selector lever from D 4 to D 3 range TRANSITION VALVE The transiti
97. igid type hones are not to be used to remove cylinder glaze as there is always a slight amount of taper in cylinder walls after the engine has been in service Rings must be installed on the pistons with a ring install ing tool to prevent distortion and ring breakage For service ring replacement follow the detailed instruc tions enclosed in the ring package Prior to installing the piston and connecting rod assem bly into engine the piston ring gaps are to be arranged so that the gap for the oil ring is toward the inside of the block The gaps on the compression rings are 120 apart Do not locate a ring gap over the piston pin boss CONNECTING RODS FIGURE 15 Piston Ring Location Connecting rods are the I beam drop forged steel type The connecting rods are stamped with the cylinder numbers in Checking Ring Groove Clearance which they are assembled The numbers are opposite the Side clearance between land and piston ring should be squirt holes and toward the outside of the banks in which No 1 ring groove they are located No 2 ac bid 002 004 The squirt holes from connecting rods in one bank lubri No 3 ring groove 001 0079 22 cate the cylinders in the opposite bank Piston ring width is cet dish No 1 chrome plated 0775 0780 wide The oles are located the parting No 2 plain 0770 0780 wide surface of the bearing cap Fig 16 No 3 oil control ring is a three
98. il components are select fitted to one another in manu facturing Only complete tappet assemblies are supplied for service replacement The tappet assembly should be cleaned in a solvent to remove all varnish or leaded deposits After cleaning the tappet must be leak down tested to insure its zero lash operating ability Kerosene should be used for this test Test the tappet by filling the body with kerosene and then install the plunger return spring plunger assembly and push rod socket Leave out snap ring for test Insert the push rod in tappet socket and check it for leak down by pushing down ward on rod If the tappet leaks down rapidly or collapses immediately it must be rechecked and or replaced with a complete new tappet assembly The normal tappet will take approximately 10 45 seconds to leak down with kerosene with a 50 Ib load travel of 125 After testing tappets they should be pre lubricated and assembled in the engine without an oil charge They will normally charge themselves in 3 to 8 minutes of engine operation Tappet Noise A loud clicking noise is usually the result of the plunger stuck down below its operating position or a check valve held open A light clicking noise is usually the result of excessive leak down caused by wear or slight leakage at the check valve and its seat An intermittent noise at tappet is the result of dirt or chips stopping the check valve or a lack of oil flow into the body bec
99. ill Discharge Jet Twin By pass No 54 Drill Size No 72 Drill Air Bleed No 54 Drill Intake Ball Check in Economizer No 56 Drill Plunger Shaft IDLE PORT Discharge Needle Seat Upper Port Slot Type 160 x 030 Size No 50 Drill IDLE PORT ACCELERATING is 09 10 PUMP ADJUSTMENT Pump Arm Boss Parallel 115 Above Top Edge to Dust Cover with an om Tight Closed Throttle Valves Adjust by LOWER PORT For Bending Upper End of Idle Adjusting Screw 065 to 069 Diameter IDLE SCREW Link ADJUSTMENT 1 2 to 11 2 Turns Out CHOKE Carter Climatic For Richer Mixture Turn Screw Out CHOKE SETTING Index IDLE SPEED MINIMUM R P M HEAT SUCTION Standard and HOLE Size No 42 Drill Overdrive 550 Hydra Matic In FAST IDLE Neutral 425 ADJUSTMENT 023 Between Throttle 450 Valve and Bore Side NOTE When equ tioning ad with air condie with air K just idle unit ON conditioning an ully Close NOTE When equuipped with air cond UNLOADER tioning adjust idle with air conditioning ADJUSTMENT 3 16 Between Upper it ON Edge of Choke Valve MAIN NOZZLE Installed Permanently and Side of Air Horn Do Not Remove With Throttle Wide Open ANTI PERCOLATOR No 71 Drill VACUUM SPARK METERING ROD Vacumeter Type PORT St 0605 d Location of Bottom 040 x 130 Tapers to 056 of Port Above Top Power Step 040 Edge of Throttle METERING ROD Valve in
100. ine is running This is to provide a higher G 1 pressure at low car speeds The G 1 valve is a balanced valve balanced between G 1 pressure and centrifugal force assisted by spring force The G 2 valve is a balanced valve balanced between G 2 pres sure and centrifugal force Pump pressure is the supply for G 1 pressure and G 1 pressure is the supply for G 2 pres sure 1 1 pressure is used to open the 1 1 booster valve and is also used to assist G 2 pressure in opening the 2 3 and 3 4 shift valves G 2 pressure is used on the transition valve to help control the 2 3 shift G 1 BOOSTER VALVE PRESSURE G 1 booster pressure originates at the G 1 booster valve G 1 pressure working on the larger diameter end of the valve moves it to the right allowing main line pressure to feed into the center area of the valve As G 1 booster pressure builds up in the center of the valve it moves the valve back to the closed position cutting off the main line pressure Since the G 1 booster pressure must force the valve closed against 1 1 pressure and it has less area of the valve to work on booster pressure will be higher than G 1 The G 1 booster valve is a balanced valve balanced between G 1 and G 1 booster pressure G 1 booster pressure increases with car speed until it reaches main line pressure As car speed decreases G 1 booster pressure forces the valve further to the left against G 1 pressure and allows G 1 booster pressure to enter the 1
101. ing system capacity is 22 quarts including heater and oil cooler Radiator Filler Cap The cooling system radiator filler cap is an atmospheric vented cap The atmospheric vent valve closes only if there is a coolant vapor flow through the vent valve of 4 to 7 cubic feet per minute When the vent valve closes the system will become pressurized 61 4 to 73 4 pounds per square inch Pressurizing the cooling system increases the boiling point of the coolant On models equipped with air conditioning the pressure cap pressurizes the cooling system 12 to 15 pounds per square inch THERMOSTAT A thermostat is located in the cylinder head water outlet manifold to insure proper engine operating temperatures for maximum economy and engine life A restricted passage permits the coolant to circulate through the water pump and cylinder block when the thermostat is closed thus by passing the radiator core COOLING 19 shaft When equipped with air conditioning a five blade fan is used FAN BELT The cooling system fan generator and water pump are driven by a V type fan belt from a pulley on the vibration damper The fan belt is adjusted by moving the generator on its mounting bracket to obtain a deflection of approximately 1 2 inward at a point midway between the water pump uem and generator pulleys FIGURE 3 Cross Section Radiator Filler Cap It is important that the proper tension of the fan belt be prop FA
102. inions will tend to drive the center gear in the opposite or counterclockwise direction However this movement is prevented by the one way sprag assembly The pinions and carrier assembly can then travel in only one direction clockwise and in reduction around the center gear which is held stationary The Sprag Assembly The sprag assembly consists of inner race outer race and sprags Fig 1 The outer race is anchored to the transmission case The inner race is attached to the planetary gear set As the driving member of the gear set turns clockwise the sprags will fall free and let the inner race and driving member turn clockwise However if the driving member attempts to turn counterclockwise it is prevented from doing so by the sprag assembly in the following manner When a counterclockwise rotation is imparted to the inner race of the sprag assembly the sprags or wedges will be forced against the outer race by action of the inner race This locking or wedging action is due to the force expended by the driving members forcing the sprags or wedges into an area which is too limited to accommodate them The sprag assembly will then keep one member of a planetary gear set from rotating counterclockwise FIGURE 1 Sprag and Race Assembly In the front unit gear set the sun gear is splined to the inner race of the sprag assembly In reduction the sun gear is held The power input is to the internal gear and the output is from t
103. installation of the camshaft All camshaft bearings are lubricated under pressure The oil lubrication is supplied through connecting drilled passages from the central main oil gallery Camshaft cam heels should not run out over 001 on base circle when gauged between two adjacent camshaft bear ings Camshaft oil clearance is 001 to 003 Camshaft End Play The camshaft end thrust is controlled by the front surface of the camshaft bearing and the rear surface of the thrust plate and the rear hub surface of the camshaft sprocket and the front surface of the thrust plate The end play tolerance is 003 to 006 Camshaft Removal Remove cylinder head covers ignition plug wires rocker arm assemblies intake manifold and carburetor Remove upper oil breather and tappet assembly cover Remove inner oil baffle cover Remove push rods keeping them in their relative operational positions Remove hydraulic tappets and keep in relative operational positions Remove fuel pump vibration damper and timing chain cover Remove water pump and cylinder head water distribu tion manifold Crank engine until timing marks line up on a vertical line with shaft centers Fig 6 Remove fuel pump eccentric crankshaft sprocket cam shaft sprocket and timing chain assembly Timing sprock ets can be pried off with ease Remove the camshaft retainer thrust plate and the end thrust spacer Fig 11 1 Oil Channels for Connecting Oil Gallerie
104. lator body is used to apply the low range band when the selector lever is moved to the L range position Oil is directed from the manual valve to the servo to apply the low range band which holds the rear unit internal gear and prevents the vehicle from overrunning the rear sprag clutch when L range is being used for engine braking HOW TO OPERATE THE FLASHAWAY HYDRA MATIC The Flashaway Hydra Matic drive is convenient to operate by placing the selector lever in the desired speed range These positions are shown on the indicator which is illumi nated when the instrument lights are on Fig 2 FIGURE 2 Selector Lever Indicator The speed range positions are designated as follows P Parking and starting Neutral and starting D 4 For all normal forward driving D 3 For faster acceleration and driving in congested t raffic L controlled power For reverse NOTE Selector lever must be raised to engage parking and reverse position ENGINE STARTING The safety starter switch is mounted on the starter switch HYDRA MATIC TRANSMISSION 29 bracket located at the lower end of the steering gear jacket tube Contact can only be made in the P Park or N Neutral positions Press the foot accelerator pedal part way to the floor board once and release in order to set the Automatic Choke on fast idle Turn the ignition switch ON and lift the selector knob toward the steering wheel to engage the starte
105. les Sheerng Geor plua 3 90 EPL Sear Shik Central Lever GL 1956 HORN Lubricate madela Throttle Linkage Pelr wk andol ponts Cocfral Anra F nings oo each side Thich Reno Leser e Hydia Matic models Tie Rad i LEFT ME MCN Pison Arm ating Power steering medals anly Clutch aed Broke Pegal Shofi 2 fringi 2 CL models 1 fitingl Banke Master Cylinder chick level _ _ Accessible hiewgh kale in floor Power Broke Air Cleaner Clove avery 10 000 miles ATE EPL MOL HEF H L We Bil LUARICANT SYMBOLS Autamalic Tiansmisaion Muid Type AG ATF Chow Lubeicant Presume Gear Lubroort Mineral Char Lubricgnt Broke Flud Lockheed 212 SA 708 1 Ceo Lubrconi Suitable Enging Whoel Booimg ET SPECIAL V 8 Lubrication Service Chart at each arrow point every 1 000 miles except as noted ENGINE COMPARTMENT Filter qvery 2 000 milik 7 and AIR CLEANER Clean ned resol et drain DH Eih 1 Pini 5ummerssSAE 54 20 Wee Spray wiht cranblcose grade od
106. mooth apply of the rear clutch 2 3 oil being directed to the rear clutch apply piston is also directed to an accumulator The accumulator contains a piston with heavy springs holding the piston in the down position which is opposing 2 3 oil directed to the other side of the piston Oil from the 2 3 shift valve will move the accumulator piston against spring and oil pressure and also apply the rear clutch Since the flow of oil to the accumulator and clutch apply piston is restricted the accumulator is capable of collecting any oil that does flow through the restriction at the pressure valve which is required to move it This maintains the pressure acting on the clutch piston at a value below line pressure until the accumulator is full At that time the pressure rises to line pressure The engagement of the clutch must be completed before the accumulator is full to produce smooth shifts at the lower apply pressures Clutch apply requirements will vary with throttle and load conditions The accumulator is a factor in rear clutch en gagement its operation is varied accordingly by directing pressure to assist the spring in resisting 2 3 oil pressure This T V pressure to the accumulator is regulated by a trimmer valve located in the accumulator body held in the open position by spring and closed by T V pressure thereby regulating T V pressure to the accumulator as the need requires LOW SERVO The low servo located in the accumu
107. n Piston at Room Temperature TECHNICAL SERVICE MANUAL 1 Main Center Horizontal Oil Gallery Plug 3 Right Tappet Supply Oil Gallery Plug 4 Camshaft Rear Bearing Hole Plug 2 Left Tappet Supply Oil Gallery Plug 5 Oil Filter Supply Passage Boss FIGURE 26 Rear of Engine Block VALVES AND SPRINGS Valve Lift Intake Valve Stem Standard Diameter 3412 3417 Intake Valve Face Angle 295 Intake Valve Seat Angle 30 Intake Valve Seat Width 078 093 Intake Valve Spring Tension Valve Closed 85 91 Lbs 113 16 Valve Open 150 160 Lbs 17 16 Intake Valve Stem to Guide Clearance Valve Guide I D Exhaust Valve Stem Standard Diameter Exhaust Valve Face Angle Exhaust Valve Seat Angle Exhaust Valve Seat Width 0013 0028 03430 03440 3407 3412 44 45 093 104 Exhaust Valve Spring Tension Valve Closed 85 91 Lbs 113 6 Valve Open 150 160 Lbs 17 16 Exhaust Valve Stem to Guide Clearance 0018 0033 Exhaust Guide I D 03430 03440 Oil Pump Type Gear Normal Oil Pressure 10 Lbs Min 600 R P M Oil Pressure Release 55 60 Lbs Engine Oil Refill Capacity 5 Qts CRANKSHAFT AND BEARINGS Main Bearing Diameter 2 4983 2 4990 Main Bearing Clearance 0006 0032 Main Bearing Cap Torque 80 85 Ft Lbs ENGINE V 8 1 Cylinder Block Water Supply Hole 2 Cylinder Head Locating Dowel 3 Main Center Longitudinal Oil Gallery 4 Right Hand Tapp
108. n Gear Remove driven torus member from main shaft by sliding forward If member sticks tap end of main shaft with soft FIGURE 32 Removing Sun Gear to Torus Hub hammer and at the same time pull out torus member Thrust Washers Remove driven torus member rear Truarc snap ring from main shaft Fig 31 Remove front unit sun gear from front unit driven torus Remove drive torus member Truarc snap ring from inter shaft mediate shaft Remove front unit internal gear with steel backing and Remove drive torus member bronze thrust washer by pulling it out of the TECHNICAL SERVICE MANUAL torus cover assembly Remove torus cover assembly by working hub of torus cover back through oil seal Carefully pull torus cover out with even pressure to prevent damage to oil seal Remove selective spacer washer from front unit driven torus hub Spacer may have remained in internal gear Figure 33 FIGURE 33 Removing Front Unit Selective Spacer Install front seal protector J 6119 over intermediate shaft to protect the front oil seal and bushing when removing the flywheel housing Fig 34 Emo 1 Front Seal Protector J 6119 FIGURE 34 Front Seal Protector in Position Remove bolts and washers holding flywheel housing assembly to front end of transmission case Remove fly wheel housing assembly gently over front seal protector NOTE f front unit coupling steel thrust washer adheres to bushing in ho
109. n steel plate end with composition plate and spring Install oil ring on neutral clutch piston and make sure that the lower ring is in place in the case center support hub Install neutral clutch piston into case center support com pressing piston ring with fingers NOTE Index dowel pins in case center support with dowel pin holes in neutral clutch piston Indexing 1 Neutral Clutch Drive Plate 2 Neutral Clutch Drum FIGURE 88 nstalling Neutral Clutch Plates clutch piston Indexing can be facilitated by mark ing dowel location on side of drum and piston Install two oil rings in ring grooves of case support hub Center rings around hub and install case support assembly into neutral clutch drum in rear unit using care not to damage bushing when lowering support over intermediate shaft If properly centered oil rings on hub of case support will be compressed by taper on hub of rear clutch cylinder Install hook type oil seal ring on intermediate shaft Fig 89 Install case support holding tool J 6135 with screw end up apply pressure to compress clutch springs and tighten lock bolt on J 6135 Fig 90 DISASSEMBLY OF FRONT UNIT COUPLING Remove large snap ring that retains cover to drive torus Install tool J 6122 1 to retain the two exhaust valves Then install tool J 6121 to front unit coupling cover and tighten the four studs securely Place the assembly in holding fixture tool J 6116 and tighten center nut Tigh
110. n the front unit coupling fills It also acts as a pressure relief valve to protect the system from excessive pressure Pump pressure on the large diameter of the valve will move the valve to the right and open the passage to the coupling valve feed oil passage The larger spring serves as the pres sure relief COUPLING VALVE The coupling valve 18 in the oil circuit to control the filling and emptying of the front unit coupling It is held in the closed position in the forward speeds by spring pressure and T V pressure and in reverse position by spring pressure T V pressure and reverse oil pressure The coupling valve opens when G 1 booster pressure builds up high enough to overcome the combined spring pressure and throttle pres sure The valve will not open in reverse When the valve opens main line pressure is directed into the signal oil passage to close the two exhaust valves in the front unit coupling Main line pressure through the limit valve is also directed into the feed passage to fill the front unit coupling The T V passage to the end of the valve is also cut off and the pressure on the plug is allowed to exhaust out the reverse passage This prevents throttle downshift D 3 range oil is directed through the valve to apply the overrun front clutch in third and first speeds D 3 range and L range The coupling valve closes the D 3 range oil passage to the overrun front clutch in second and fourth D 3 range and L range W
111. n to its correct position The new shim pack will therefore be 038 thick Install the drive pinion front bearing cup with replacer J 2534 or J 5367 Insert the drive pinion in position and install the front bearing cone and rollers Clean differential bearing bores in housing are necessary to make the following check Mount discs J 2499 2 on gauge arbor J 6482 1 or discs J 5223 5 on gauge arbor J 5223 Install gauge seated squarely in housing bores Fig 7 Place bearing caps in position and tighten bolts finger tight The gauge block J 5223 16 is held in position against the end of the drive pinion by clamp bar and screw J 5223 6 and J 5223 14 Loosen the thumb screw in end of gauge block and move plunger out of block until head contacts gauge arbor as shown in Figure 7 Lock plunger by tighten ing thumb screw Be certain not to disturb plunger position Loosen screw in clamp holding gauge block against pin ion and remove gauge block Measure the distance from end of anvil to top of plunger head with a two to three inch micrometer Fig 8 This measurement represents the distance from the rear face of the drive pinion to the center line of the rear axle and should be 2 625 TECHNICAL SERVICE MANUAL FIGURE 7 Checking Pinion Depth Adjustment with Pinion Setting Gauge FIGURE 8 Measuring Gauge Block to Determine Distance from Rear Face of Pinion Gear to Rear Axle Center Line This measurement applies only to corre
112. nch following the se quence outlined in Figure 1 FIGURE 1 Tightening Sequence Fifteen cap screws retain the cylinder head and rocker arm ooogey m rocker arm assembly to the cylinder block on each bank They are of various lengths and design Four medium 315 16 two short 3 two with special tapped heads to accommodate the retaining screws that hold the cylinder head cover 41 4 three long plain cap screws to retain rocker arm assembly and cylin der head 63 4 long and one special bolt to index with oil holes for rocker arm lubrication and retain rocker arm shaft and cylinder head 63 8 long This special drilled bolt is part of the lubrication system and must be installed in the rear position to index with oil passages in the tappet area ROCKER ARM AND SHAFT ASSEMBLY The rocker arm shaft assembly is secured to the cylinder head with four long cylinder head and rocker arm shaft retaining cap screws 6 3 8 The rocker arm shafts are hollow plugged at each end serving as oil galleries for rocker arm push rod end and valve stem lubrication The oil pressure supply for each rocker arm assembly is taken from the valve tappet main oil gallery The oil under pressure through connecting passages in cylinder block and cylinder head enters through the special drilled rear bolt around the undercut stem area of the rear rocker arm shaft mounting cap screw upward into the rocker arm shaft Two different r
113. ng released Located in the reverse carrier assembly is a parking pawl sprocket This sprocket has external teeth which receive a parking pawl and provide a positive lock when the selector lever is in the P Park position In the park position it will be possible to start the engine or leave the car on an incline when the engine is running NEUTRAL CLUTCH The sprag assemblies keep the drive line from rotating counterclockwise However for neutral and reverse the rear unit must rotate in a counterclockwise direction This is accomplished by means of a neutral clutch The neutral clutch operates as a connection between the outer race of the rear sprag assembly and the transmission case through the multiple disc clutch When the plates are applied there is a solid connection between the race and the case When the clutch plates are released reverse and neutral the connection is broken between the sprag clutch and case The sprag clutch is non effective allowing the rear unit to rotate counterclockwise for neutral and reverse OVERRUN CLUTCH Reduction is obtained by holding one member of the front and rear planetary gear sets from rotating counterclockwise only This is accomplished by the use of a sprag one way clutch The held member is then free to rotate clockwise even though the gear set is in reduction A condition might exist where the rear wheels would drive the engine Zero throttle downhill In this case the power flow w
114. nter on the front cover should align with a point approxi mately 25 32 before T D C position on the vibration damp er If more than 1 2 variance in either direction is evident remove the timing chain cover and inspect timing chain installation Replace timing chain if over 1 2 chain deflec tion exists FIGURE 8 Jnstallation of Dial Indicator for External Valve Timing Check JE SO 30 TOF DEAD CENTER OF CRANKSHAFT FRONT CLOSES FIGURE 7 Link Count Position FIGURE 9 Valve Timing Diagram TECHNICAL SERVICE MANUAL TIMING CHAIN COVER The timing chain cover is a casting incorporating an oil seal at the vibration damper hub To remove the timing chain cover first remove water pump fuel pump assembly and vibration damper 1 Oil Seal FIGURE 10 Timing Chain Cover To prevent damage to the oil seal it is important that the cover be properly aligned when installing the vibration damper This is accomplished by locating dowels in the cylinder block and by leaving the cover to block screws loose until the vibration damper has been partially installed Then tighten the cover screws CAMSHAFT AND BEARINGS The camshaft is supported by five steel shelled babbitt lined bearings which have been pressed into the block and line reamed The camshaft bearings are step bored being larger at the front bearing than at the rear to permit easy removal and
115. o be replaced Inspect linkage and pivot points for excessive wear Bearing and thrust surfaces of all parts should he checked for excessive wear and scoring Check for broken seal rings damaged ring lands and damaged threads Check the neutral clutch outer oil ring gap Tolerance should be 002 to 007 Mating surfaces of castings and end plates should be checked for burrs and irregularities If a good seal is not apparent burrs and irregularities may be removed by lap ping the surface with crocus cloth the crocus cloth should be held on a flat surface such as a piece of glass Castings should be checked for cracks and sand holes Gear teeth should be checked for chipping scoring and excessive wear A wear pattern may be apparent on the drive and driven lugs however this is to be considered normal and the amount of clearance between the drive and driven lugs will not affect operation of the units Valves should be free of burrs The shoulders of the valves must be square Any burrs or irregularities may be removed by honing Valves should be free to slide in their respective bores Inspect composition clutch plates for damaged surfaces and loose facings If flakes of facing material can be re moved with the thumb nail the plates should be replaced Composition plate discoloration is not an indication of fail ure Inspect steel clutch plates for scored surfaces and dam aged lugs The six equally spaced waves must be 0
116. o be replaced Thread a 3 8 cap screw into the parking pawl pivot shaft then use the screw to work or slide the pivot shaft out of the case Fig 60 Remove cap screw from pivot shaft ELI he FIGURE 58 Removing Low Band from Case FIGURE 60 Removing Parking Pawl Pivot Shaft Unhook parking pawl spring slide bracket and spring from shaft Remove washer from shaft 1 Snap Ring Rotate pawl upward and slide pawl and linkage from shaft FIGURE 59 Detent Lever Retaining Snap Ring Remove parking pawl spacer washer from case SUBJECT PAGE SUBJECT PAGE DISASSEMBLY OF Case Support Neutral Clutch and Rear Unit 74 ASSEMBLY OF Front Unit Coupling 81 Rear Unit Neutral Clutch and Case Support 71 Front Pump 83 Front Unit Coupling 92 Rear Pump 86 Front Pump 94 Servo and Accumulator 87 Rear Pump 87 Governor 88 Servo and Accumulator 87 Control Valve 88 Governor 99 Overrun Clutch Valve Body 88 Overrun Clutch Valve Body 89 Shift Valve Body 89 Shift Valve Body 90 Reverse Blocker Assembly 90 Reverse Blocker Assembly 91 Manual Valve Body 91 Manual Valve Body 91 91 Pressure Regulator 91 Pressure Regulator Torus Check Valve from Driven Torus 91 Torus Check Valve in Driven Torus 91 TECHNICAL SERVICE MANUAL DISASSEMBLY OF CASE SUPPORT NEUTRAL CLUTCH AND REAR UNIT Remove case support holding tool J 6135 backing off set screw far enough to prevent damage to machined surface at front of intermediate shaft Rem
117. o the front unit driven member Power is also directed from the front unit internal gear to the planet carrier assembly of the front unit The sun gear is held by the front unit sprag clutch assembly so that the pinions of the carrier walk around the sun gear at a slower rate or reduction The front unit carrier is attached to the drive torus member and will through oil drive the driven torus member In turn the driven torus member drives the connected main shaft and rear unit sun gear The rear unit sun gear drives the pinions of the rear unit planet carrier at a reduced speed or reduction around the rear unit internal gear for the internal gear is being held by the rear unit sprag clutch assembly The planet carrier of the rear unit is attached to the output shaft Therefore power will be directed from the planet carrier through the output shaft HYDRA MATIC TRANSMISSION 33 FLYWHEEL f TORUS COVER DRIVE TORUS DRIVEN TORUS DRIVE TORUS FRONT UNIT PLANET CARRIER FRONT UNIT COUPLINC DRIVEN TORUS REAR SPRAG CLUTCH i REAR PLANET GEARS REAR INTERNAL GEAR REAR UNII SUM GEAR MAIN SHAFT FIGURE 5 Power Flow Second Speed FRONT UNIT DIRECT DRIVE NEUTRAL CLUTCH REAR UNIT REDUCTION Sprag Sprag On Coupling Full Rear Clutch Off SECOND SPEED In second speed the front unit is in direct drive and the rear unit is in reduction The transmission gear r
118. ocker arms are used to accommodate the angle from the rocker arm shaft support to the valve stems However the rocker arm shaft assemblies are interchangeable from cylin der bank to cylinder bank Fig 2 The rocker arm shafts are 858 8585 outside diameter and the rocker arms are 860 861 inside diameter Oil clearance is 002 a e FAR ndetooo 1 Drilled Bole Right Bank Shown FIGURE 2 Valve Rocker Arm Assembly ENGINE V 8 2 Intake Valves 1 Exhaust Valves FIGURE 3 Valve Arrangement Valve Springs Whenever valve springs are removed they should be tested according to the specifications listed below Use valve spring tester and replace all springs not within specifica tions Intake or Exhaust Valve Springs Valve Closed Valve Open 85 91 Lbs 113 16 150 160 Lbs 17 16 Valve springs are installed with the inactive closed coils against the cylinder head The valve spring retainer serves the purpose of holding the valve and spring together The seal 1s mounted onto the valve guide At valve service periods the valve stem oil seals should be replaced to insure good oil control at this point The half conical shaped valve locks can be removed after compressing the spring Valve springs are 2 20 long free length They are 938 953 inside diameter Valve Stem to Guide Clearance The valve stem to guide clearance is maintained through replacement of valve guides The valve guides
119. of the connecting rod and bearing caps Throw off oil from the connecting rods lubricates cam shaft lobes and cylinder walls at higher speeds Passages at the front of the engine Fig 27 and in the camshaft thrust plate Fig 11 connect the main center oil gallery with the two left and right oil galleries to the hydraulic valve tappets At the rear section of each tappet oil gallery a passage connects upward to the rear rocker arm shaft support retain ing bolt hole These bolts are drilled to permit oil flow to the rocker arm shafts rocker arms push rods valve stems and valve guides Two drain holes in the lower corners of the cylinder head casting return the oil to the oil pan ENGINE SPECIFICATIONS Bore 3 1 2 stroke 3 1 4 Displacement 250 Cu In Compression Ratio carburetor Brake Horsepower 8 0 1 WGD Twin Throat 190 4900 R P M Torque 240 Ft Lbs 2000 3000 R P M Taxable Horsepower 39 2 Piston Displacement 250 Cu In Valve Timing Intake Opens 12 30 B T D C 244 Closes 51 30 A B D C Duration PISTONS AND RINGS Piston to Bore Clearance Top Land 020 024 Skirt Top 001 0015 Skirt Bottom 0009 0015 Piston Ring Gap Clearance Top 010 020 Center 010 020 Bottom Steel Rail 015 055 Piston Ring Side Clearance Top 002 0035 Center 002 004 Bottom 001 0079 Piston Pin to Connecting Rod Press Fit Piston Pin to Piston Palm Press Fit i
120. on small end of accumulator piston with lip toward large end Make sure oil ring is in place on large end Install outer and inner accumulator springs in piston Install accumulator cover and gasket on special tool J 6124 Install springs and piston in accumulator body and place special tool cover and gasket against piston and thread tool studs into body Then tighten center screw until cover is pressed against accumulator body NOTE Make sure that piston is centered when entering bore of body when compressing springs The oil ring will be compressed by taper in bore of body 88 TECHNICAL SERVICE MANUAL FIGURE 113 Exploded View of Servo and Accumulator Install three cover screws and lockwashers and remove special tool and install the remaining screws and lockwash ers Install servo apply piston with oil ring in place in servo body DISASSEMBLY OF GOVERNOR ASSEMBLY Remove three cover attaching screws and washers and remove cover Remove G 2 valve retainer plate attaching screws and remove G 2 valve and sleeve Fig 114 4 G 2 Valve 5 G 2 Sleeve 6 G 2 Retainer Plate 1 Governor Rings 2 G 1 Valve 3 Governor Cover FIGURE 114 Exploded View of Governor ASSEMBLY OF GOVERNOR Install G 2 valve in sleeve then install the G 2 valve and sleeve assembly in the governor with locating notches aligned in the sleeve and body Install cover and retainer plates with attaching screws and washers aligning
121. on valve controls the front unit on the 2 3 upshif t When the 2 3 shift valve opens 2 3 oil pressure is directed to one end of the transition valve which moves it to the right against combined G 2 pressure and spring force Movement of the valve cuts off G 1 booster pressure to the coupling valve and exhausts it through the 3 4 valve The orifice in the 2 3 passage to the transition valve is to aid in timing the front unit with the rear unit during the 2 3 shift DETENT VALVE Main line pressure from the manual valve is directed through the detent valve to the 3 4 governor valve This pressure has no action on the detent valve and the passage to the 3 4 governor valve is closed when the detent valve has been pushed to the left D 3 range oil is directed through the detent valve to the 3 4 shift valve to hold the transmission in third speed The detent valve is mechanically opened by linkage It is re turned to the closed position by spring force on the end of the valve The valve is in the circuit to make the 4 3 and 3 2 detent downshifts When the accelerator pedal has been depressed all the way the valve will be positioned to the left T V pressure at the detent valve will then be directed to the 2 3 and 3 4 shift valves At car speeds 38 TRANSMISSION AND OVERDRIVE below 65 M P H the 4 3 shift valve will close for a 4 3 downshift and at speeds below 20 M P H the 2 3 shift valve will close for a 3 2 downshift PUMP PRESSU
122. ould be from the rear wheels to the output shaft into the rear unit Power flows from the rear unit through the intermediate shaft to the drive torus The carrier of the front unit is attached to the torus and thus becomes the drive member of the front planetary gear set The power flow in the front gear set would be reversed with the input on the carrier the internal gear held by the engine and the sun gear free to rotate clockwise at a faster rate or overrun This in effect would put the front unit gear set in neutral condition To prevent the center gear from overrunning a simple disc called an overrun clutch is used which operates when overrun braking is needed Drive 3 Range Zero throttle The overrun clutch disc is splined to the driven torus member in the front unit which is also splined to the center gear of the front unit The overrun clutch is actuated by an oil applied piston and will compress the overrun clutch against spring pres sure locking the center gear to the case This will retain the front unit center gear from rotating counterclockwise or overrunning GOVERNOR The governor is located in the rear pump housing and is driven by the rear pump driven gear which fits into the governor tower When the vehicle is started in motion the governor starts revolving Centrifugal force causes the governor plungers to move away from the center This opens a passage allowing oil to flow into the regulated governor pressur
123. ove distributor cam centrifugal advance weights and springs from distributor weight base Cleaning and Inspection When inspecting the distributor parts keep in mind the results of the pre disassembly test on the distributor tester as this will indicate certain parts which probably are defec tive Before inspection clean all parts in cleaning solvent except cap rotor condenser breaker plate assembly and vacuum control unit Degreasing compounds may damage insulation of the parts listed or in the case of the breaker plate assembly will saturate the felt between the plates and impair its lubricating ability Servicing of Breaker Plate Assembly The movable breaker plate and support plate are not ser viced separately It is necessary to replace the breaker plate assembly if either part becomes seriously damaged or worn ELECTRICAL 21 However this assembly requires very little maintenance other than lubrication at regular intervals Disassembly of this unit should be attempted only when removed from the distributor Otherwise parts will drop into the distributor bowl when the stabilizing spring post assembly is released necessitating removal and disassem bly of the entire distributor To disassemble the breaker plate assembly release the C shaped retainer washer and the spiral stabilizing spring from the post The stabilizing post and bearing washer can then be removed from the support plate Remove the retainer washer from the
124. ove hook type oil ring from intermediate shaft by pushing one end toward the center of shaft and other away from shaft to unhook the oil ring Fig 61 FIGURE 61 Removing Oil Seal Ring Remove case support and neutral clutch piston assembly Fig 62 FIGURE 62 Removing Case Support and Clutch Piston Assembly Remove two oil rings from case support hub and remove neutral clutch piston Turn case support over and bump on bench to remove piston NOTE Leave rings in place on piston and case hub support Remove neutral clutch drum assembly which contains five composition clutch plates four steel clutch plates and five release springs Fig 63 111 1 Io FIGURE 63 Removing Neutral Clutch Drum Remove large snap ring from rear drum assembly with screw driver Fig 64 FIGURE 64 Removing Snap Ring from Rear Drum HYDRA MATIC TRANSMISSION 75 Remove rear clutch cylinder and sprag assembly by lifting over intermediate shaft Fig 65 FIGURE 65 Removing Rear Clutch Cylinder and Sprag Assembly Remove intermediate shaft and clutch hub together with neutral clutch hub washer from rear unit assembly Fig 66 FIGURE 66 Removing Intermediate Shaft and Clutch Hub NOTE Intermediate shaft and clutch hub may be disassembled if parts replacement is necessary Remove clutch hub front thrust washer from clutch hub Remove the main shaft assembly and rear unit sun gear from
125. p Make sure oil rings are installed on reverse piston and hub in pump and that ring on hub is centered Place piston into cavity indexing it with dowels Compress outer ring with fingers and push piston into cavity CAUTION Inner ring must be centered on hub in order for taper of piston to compress ring NOTE Rear bearing and snap ring will be in stalled in rear pump after rear pump is attached to transmission case DISASSEMBLY OF SERVO AND ACCUMULATOR Remove servo piston from accumulator body Remove two Opposite screws from accumulator cover and install special tool J 6124 Turn screw down against accumulator cover and remove remaining cover screws Back off screw of tool to remove tension on accumulator springs and remove tool and cover Fig 112 1 Accumulator Cover 2 Special Tool J 6124 FIGURE 112 Removing Accumulator Cover Remove accumulator piston inner and outer springs and cover gasket Remove seal from small end of accumulator piston Remove trimmer valve retainer plug pin from accumulator body using a small punch or nail Then remove the plug trimmer valve and spring NOTE The hole in which pin enters is tapered so pin will be retained by cover and not fall out of opposite end Fig 113 ASSEMBLY OF SERVO AND ACCUMULATOR Install trimmer valve spring trimmer valve retainer plug and pin Compress plug against the spring tension so that pin will enter groove of plug Install new neoprene seal
126. pport hole in band fits on pin INSTALLATION OF REAR UNIT NEUTRAL CLUTCH AND CASE SUPPORT Install neutral clutch key in case using petrolatum to hold it in place Position rounded side toward front to provide lead for guiding neutral clutch drum over key Fig 125 Position case support lock bolt hole with center of clutch plate drive lugs and mark rear drum with a pencil so that machined slot in neutral clutch drum can be guided into case to align with key and case support lock bolt Fig 126 Install assembly into case aligning pencil marks with neutral clutch key and push complete assembly into case and install large snap ring If case support fits tight into case it may be necessary to tap into place Fig 12 7 Install case support lock bolt and torque 25 30 ft Ibs INSTALLATION OF REVERSE ASSEMBLY AND REAR PUMP Install reverse planet carrier on the output shaft aligning splines 94 TECHNICAL SERVICE MANUAL and pinions Install snap ring on output shaft Fig 128 FIGURE 128 Installing Reverse Planet Carrier Snap Ring Install reverse stationary cone lock key in case and retain with petrolatum Install reverse stationary cone in the case Make sure cone seats on shoulder in case Install reverse clutch release spring on carrier with tangs pointing out Install wave release spring and reverse internal gear on carrier Fig 129 n 1 Pencil Marks 2 Case Support Lock Bolt Hole FIGURE 126 Correct Ali
127. preload If the reading varies more than the specified preload add shims to those previously placed in drive pinion to reduce turning torque If torque reading is low remove shims Shims are available in the following thicknesses 003 005 010 and 030 When the proper preload is set remove the pinion nut washer and companion flange Install oil seal and retainer Reinstall companion flange washer and nut torque to 200 220 foot pounds Preloading the Differential Side Bearings and Adjusting Backlash Install differential assembly in housing Replace bearing caps in their proper position according to markings and tighten bolts finger tight Insert two screw drivers between bearing cup and housing on the side opposite the ring gear and move the differential assembly and ring gear away from the pinion until the opposite bearing cup is seated firmly against the housing Move the screw drivers to the ring gear side and move the assembly over until the ring gear teeth contact the pinion teeth Refer to the shim requirements established by indicator reading outlined in Adjusting Side Bearings and install shims between bearing cups and housing Divide the total amount of shims between sides in such a manner that all ring gear and pinion backlash is eliminated Remove bearing caps and take out differential assembly Keep each shim pack separate Remove the side bearings from differential with bearing remover tool J 2497 and in
128. r Install bronze thrust washer and steel backing washer in front unit internal gear steel washer has splines which FIGURE 39 Measuring Front Unit End Clearance engage splines of driven torus shaft with Feeler Gauge TECHNICAL SERVICE MANUAL CAUTION The feeler gauge must be flat against the thrust washer to obtain an accurate reading Compare measurement found with feeler gauge with the chart in Figure 38 to determine the correct selective spacer washer to use For example if measurement is found to be 067 a number 6 selective spacer washer should be used when transmission is reassembled Check the number on the original spacer which was removed from the transmission It should be the same as the number found on the chart If not a new spacer must be used for reassem bly The identi fication number of the required spacer should be recorded so that it can be obtained for assembly Remove Truarc snap ring sun gear with bronze and steel thrust washers internal gear with steel and bronze thrust washers and 070 selective spacer washer Special Tool Method Assemble parts as outlined in the first five paragraphs listed under Feeler Gauge Method Place front unit end play checking gauge J 6282 over intermediate shaft with splined end of inner sleeve facing down The outer sleeve of tool will rest on front unit sun gear bronze thrust washer and the splines of the inner sleeve will rest against the bottom edge of the groove f
129. r NOTE Do not start a cold engine with throttle wide open accelerator pedal fully depressed This overrules the auto matic choke and prevents the engine from breathing in a mixture rich enough to start If engine should flood because of attempting to start with ignition off or because of pumping accelerator operate engine starter with accelerator pedal fully depressed Press accelerator down slowly to reduce tendency for more raw gasoline to be pumped into the manifold Opening throttle wide overrules choke mechanism and opens choke valve thereby admitting more air so that starting becomes possible In cold weather O F or colder the engine must idle with the selector lever in P Park or N Neutral position until engine and transmission are warmed up This can more safely be done in the P Park position as the transmission will then keep the car from rolling on a grade or incline When the engine is cold and running on fast idle the car will tend to creep when the selector lever is moved to a driving position A slight application of the foot brake or hand brake will hold the car until motion 15 desired OPERATING IN D RANGE D Range has two positions Drive 4 and Drive 3 The selector lever can be moved at will from one position to the other at any car speed on dry roads where traction is good Drive 4 is provided for all normal forward driving it reduces engine speed provides better driving comfort and improves fu
130. r Trimmer Valve Accumulator Inner Spring Accumulator Outer Spring Servo Release Pressure Regulator Spring Front Coupling Exhaust Valve Torus Check Valve Control Valve Assembly Coupling Valve Detent Plunger Detent Valve Limit Valve Inner Limit Valve Outer 2 94 2 94 2 04 2 94 2 94 2 94 2 94 2 94 2 94 SPRING SPECIFICATIONS Free Length Approx 523 862 54 627 157 97 5 54 461 2 50 2 19 12 69 192 2 04 80 2 03 2 79 2 12 2 12 2 12 2 12 2 12 2 12 2 12 2 12 2 12 055 059 060 064 065 069 070 074 075 079 080 084 085 089 090 094 095 099 No Coils 9 1 2 35 1 2 17 11 14 1 4 14 21 19 8 1 2 23 1 2 19 Bronze Bronze Bronze Bronze Bronze Bronze Bronze Bronze Bronze Diameter 440 604 245 310 44 41 790 1 10 1 625 59 34 187 43 035 35 35 59 HYDRA MATIC TRANSMISSION Reverse Blocker 127 16 Throttle Valve 1 680 17 Transition Valve 1 69 30 2 3 Shift Valve Outer 1 30 9 2 3 Shift Valve Inner 1 36 17 3 4 Shift Valve Outer 1 76 12 3 4 Shift Valve Inner 1 23 17 1 2 TORQUE TIGHTNESS Torque Location Lb Ft Location Control Valve Assembly Screws 2 3 Torus Cover to Flywheel Nut Flywheel Drain Plug 6 7 Servo to Case Rear Pump Oil Pressure Take Off 6 7 Rear Pump Assembly to Case Cover to Accumulator Body 12 15 Rear Extension Housing to Governor Cov
131. r is also directed from the internal gear to the carrier assembly of the front unit where it divides and is directed to the rear unit in two ways Fluid Since the front unit is in direct drive the front unit carrier will be rotating at engine speed The carrier is attached to the drive torus member which through oil will drive the driven torus member In turn the driven torus member drives the connected main shaft and rear unit sun gear The rear sun gear will drive the pinions of the rear unit carrier Mechanical Power is directly mechanically from the carrier of the front unit back to the rear unit through the intermediate shaft which is splined to the drive torus member The intermediate shaft is splined to the rear clutch hub which transmits power through the clutch plates drum and rear internal gear The carrier of the rear unit is attached to the output shaft Therefore power will be directed from the carrier through the output shaft 36 TECHNICAL SERVICE MANUAL FLY WHEEL FRONT SPRAG CLUTCH FRONT UNIT SUN GEAR AMD PLANET CARRIER BEAR SPRAG CLUTCH REAR INTERNAL GEAR REWERSE CONE CLUTCH FRONT UNIT COUPLING REVERSE CARRIER pa n n Tm Wr d i RE ARSE SUN GEAR MAIN SHAFT REAR OUTPUT SHAFT SUM FIGURE 8 Power Flow Reverse FRONT UNIT REDUCTION REVERSE UNIT NEUTRAL CLUTCH REAR UNIT NEUTRAL Sprag On REDUCTION Off Sprag Off Coupling Emp
132. rive Flange Insert output shaft through drive flange and sun gear until carrier bottoms on selective thrust washer Fig 73 Hold the drive flange and sun gear tightly against carrier to keep selective washer from moving and set output shaft and carrier on table on carrier end Install reverse planet carrier front snap ring on output shaft Insert reverse drive flange retainer J 6120 between snap ring and sun gear to prevent selective washer from dropping out of position Fig 74 NOTE When the selective washer used between the reverse drive flange and rear unit planet car rier is at or near the upper limit of thickness retainer tool 1 6120 cannot be inserted between snap ring and flange In this case it is not neces sary to use the retainer since there is not enough clearance to allow the thrust washer to drop out of place Set rear unit drum on bench with long undercuts on lugs 1 Selective Wahers FIGURE 73 Assembling Reverse Drive Flange to Output Shaft _ AY MU IGURE 74 Reverse Drive Flange Retainer J 6120 in Position 78 TECHNICAL SERVICE MANUAL up or with internal gear up if it was not removed Install clutch backing plate with flat surface down if it was removed It may be necessary to tap plate into place with soft hammer Fig 75 1 Rear Clutch Drum 2 Clutch Backing Plate FIGURE 75 Installing Rear Unit Clutch Backing Plate Install rear unit internal gear with mark up if the
133. rnal gear Secure drive torus to intermediate shaft with Truarc snap ring Fig 140 m 5 or g Fi uM FIGURE 140 J nstalling Drive Torus Snap Ring Install driven torus rear Truarc snap ring on main shaft Install driven torus on main shaft Fig 141 FIGURE 141 Jnstalling Driven Torus Install driven torus front Truarc snap ring on main shaft to secure torus member Install flywheel 0 ring seal on flywheel Position flywheel against torus cover indexing with dowels Flywheel can be installed in only one position since the dowels are of different sizes Install and tighten to 25 foot pounds torque 18 flywheel to torus cover nuts leaving six of the nuts off the bolts Fig 142 These six bolts will be used for attaching the flywheel and torus cover to the engine flex plate 1 Flex Plate Attaching Bolts FIGURE 142 lJnstalling Flywheel HYDRA MATIC TRANSMISSION 99 FIGURE 143 Exploded View of Torus Assembly REPLACING THE FLASHAWAY HYDRA MATIC TRANSMISSION Line up crankshaft flex plate in relation to the six bolts on transmission torus cover Lift transmission into place with a hydraulic floor jack and align transmission to engage the six bolts into the flex plate Install the six nuts and torque tighten to 25 to 30 foot pounds Install flywheel housing to engine bolts Install cross member and connect torque tube to rear trans mission housing Replac
134. rom which the clearance is measured Fig 40 It will be noted that the inner sleeve now projects above the outer sleeve Place the front unit selective spacer washer which was removed from the transmission over the inner sleeve of gauge J 6282 When the washer lies flat on the outer sleeve the top of it should be flush with the top of the inner sleeve If it 1s not flush select a washer which 18 flush and install the new washer when the transmission is assembled Fig 40 1 Selective Spacer 2 Special Tool J 6282 FIGURE 40 Measuring Front Unit End Clearance with Tool J 6282 Remove gauge sun gear with bronze and steel thrust washers internal gear with steel and bronze thrust washers and 070 selective spacer washer FRONT UNIT COUPLING PRESSURE REGULATOR AND COOLER ADAPTER REMOVAL Rotate transmission to horizontal position with oil pan up Remove front unit coupling assembly from transmission case and remove oil cooler adapter attaching screws and adapter with gasket from side of transmission case Remove two oil cooler sleeves and seals by pulling from case Fig 41 1 Front Unit Coupling FIGURE 41 Removing Front Unit Coupling Assembly Remove pressure regulator plug assembly from side of transmission case Fig 42 FIGURE 42 Removing Pressure Regulator Plug Assembly HYDRA MATIC TRANSMISSION 69 Remove pressure regulator spring and pressure regulator valve Fig 43 FIGURE 4
135. s FIGURE 11 Camshaft Thrust Plate PISTONS Slipper type tapered skirt cam ground pistons are used They are of aluminum alloy steel reinforced for controlled expansion The ring belt area provides for three piston rings two compression and one oil control ring above the piston pin The pistons are removed from the top of cylinder bore after removing ring ridge ENGINE V 8 The piston pin boss is offset from the piston center line to place it nearer the thrust side of the cylinder To insure proper installation of the piston in the bore a notch is cast in the piston top and letters F cast in the pin boss struc ture at the front Fig 12 1 Notch and F Letter to Front of Engine FIGURE 12 Correct Piston Position The piston to bore clearances are 020 to 024 at top land 001 to 0015 top of skirt and 0009 to 0015 bottom of skirt PISTON PINS The piston pins are a press fit into the connecting rod thus requiring no locking device The piston pin is removed with piston pin remover j 6360 and an arbor press The piston is placed on the remover support so that the pin will enter the support when pressed out with the piloted driver To install the piston pin place the piston pin pilot in the support and insert in piston and connecting rod This aligns the piston and connecting rod piston pin bores Press the piston pin into the connecting rod and piston assembly until the lower pilot bottoms in the
136. s and bottom vane ring Remove front pump slide and priming springs by push ing slide toward priming springs Then lift out of body at opposite end Fig 97 deb RC 5 e e a Pes Ar ror aru MN i Sat a Eos 5 ob act o Lh ee Le FIGURE 97 Removing Front Pump Slide and Priming Springs Turn pump over and remove front sprag spiral retaining ring using small screw driver or needle nose pliers Fig 98 FIGURE 98 Removing Front Sprag Retaining Ring Remove sprag assembly from front pump Do not at tempt to disassemble sprag assembly if the assembly is damaged a new one must be installed Fig 99 Remove overrun clutch piston from its bore by gently tapping on outer diameter of piston side of pump with soft hammer Fig 100 ASSEMBLY OF FRONT PUMP Install inner and outer priming springs in recess of front pump body Position slide into front pump body toward FIGURE 100 Overrun Clutch Piston Removed priming springs and compress slide against springs so slide will drop into pocket of pump Then work slide up and down to make sure that springs are properly seated Fig 101 FIGURE 101 Installing Front Pump Priming Springs and Slide HYDRA MATIC TRANSMISSION 85 Install torus feed valve into large bore on side of pump opposite priming springs with long land entering first Fig 102 lt FIGURE 102 nstalling Torus Feed Valve Ass
137. seal Faulty torus hub weld Rear extension housing to transmission bolts not properly torqued Damaged 0 ring between bell housing and case Rear extension housing to transmission bolts not properly torqued Damaged rear extension housing to rear pump gas ket Rear extension housing to case bolts not properly torqued Damaged rear extension housing to rear pump gas ket Rear seal 0 ring seal between inner T V shaft and inner manual lever shaft seal between inner manual lever shaft and transmission case Not torqued to specifications Damaged gasket Attaching bolts not properly torqued Damaged gasket Not torqued to specifications Damaged gasket Not torqued to specifications Damaged gasket Attaching bolts not torqued to specifications HYDRA MATIC TRANSMISSION GENERAL SPECIFICATIONS Rear Unit End Play Mainshaft End Play Minus 004 018 Rear Unit Sun Gear to Mainshaft End Play Front Unit End Play 024 031 Neutral Clutch Ring Gap When Installed in Piston 002 007 Bore of Case Support Fluid Type Hydra Matic Fluid or Automatic Transmission Fluid Type A Bearing Armour Institute Qualification No AQ ATF Capacity Drain and Refill Approx 10 1 2 Qts Refill after Overhaul Approx 12 Qts Change Transmission Oil Every 25 000 Miles NOTE Correct amount of fluid should always be determined by indication on oil level indicator with transmisson warm car level and engine idling with
138. signs call for placing the transmis sion in first or second gears keep below 35 M P H to avoid a 2 3 shift The control lever can be moved from D to L Range at any car speed This shift into low will not occur at a car speed above 43 M P H Release the accelerator pedal when moving the selector from either of the two D positions to CAUTION The change from either of the two D posi tions to L should only be made on dry roads when traction is good It is not recommended to change to L on Slippery roads since this change could induce a skid On slippery roads safety demands that the car speed be reduced by judicious use of your brakes Release the accelerator pedal when moving the selector lever from either of the two D positions to L REVERSE To engage reverse raise the selector lever and move it to the R position Moving the lever between L and R while applying light accelerator pedal pressure permits rocking the car when required to get out of deep snow mud or sand Avoid engaging reverse at speeds above 5 M P H PARKING For additional safety when parking turn off ignition key and move selector lever to R position When parking on an incline hold car with foot brake a few seconds to permit full engagement of transmission HOLDING CAR ON HILLS It is possible to hold the car stationary on slight upgrades by depressing accelerator pedal slightly with selector lever in a D range The effect is the same
139. ssion to horizontal position Attach control valve assembly to transmission with five attaching screws leaving out screws which will position front pump intake pipe retainer The four outer screws have star washers and the center two have flat washers NOTE Position detent lever so it will engage detent plunger and manual valve Install new front pump 0 ring in intake pipe hole at front of case Install servo and accumulator assembly and servo spring Install front pump intake pipe into case and secure with clip and valve body attaching screw Install new rear pump 0 ring on rear pump intake pipe Install oil screen on front pump intake pipe Install rear pump intake pipe into screen and case Install oil pan with new gasket and tighten attaching screws securely REPLACEMENT OF FLYWHEEL HOUSING SEAL If seal is to be replaced clean up staking and remove front oil seal from front side of housing CAUTION Do not damage torus cover hub bushing while removing seal Replace seal by starting seal into bore in flywheel housing with lip facing toward bushing Drive seal into place using tool J 6118 NOTE Do not use sealer Stake housing against seal in three places INSTALLATION OF FLYWHEEL HOUSING AND TORUS ASSEMBLY Remove transmission with holding fixture J 6115 from bench collet and position on jack adapter J 6130 or bench in horizontal position with pan down Remove holding fixture Install steel thrust washer in r
140. ssure that spring is fully positioned in the bottom of the bore and remove cotter pin retainer Turn torus member over and tap lightly to work valve and spring out At time of assembly install spring and torus check valve into torus member making sure valve fully seats in bore Push valve down against the spring and retain with cotter pin Fig 121 92 TECHNICAL SERVICE MANUAL 4 eee FIGURE 120 Pressure Regulator Assembly SUBJECT INSTALLATION OF Parking Brake Assembly Inside Detent and Throttle Levers Low Band Rear Unit Neutral Clutch and Case Support Reverse Assembly and Rear Pump Checking Main Shaft End Play INSTALLATION OF PARKING BRAKE ASSEMBLY Place parking pawl pivot shaft spacer in recess of case Fig 122 Position parking brake pawl and lever assembly in case with upper lever on pivot in case Locate parking pawl at pivot shaft hole and insert pivot shaft through case then through pawl and spacer until end FIGURE 121 ZJnstalling Torus Check Valve ASSEMBLY OF UNITS INTO CASE PAGE 92 93 93 93 93 95 SUBJECT PAGE Front Pump and Overrun Clutch 96 Oil Cooler Adapter Pressure Regulator and Front Unit Coupling 96 Control Valve Assembly and Servo and Accumulator Assembly 97 Flywheel Housing Seal 97 Flywheel Housing and Torus Assembly 97 of shaft 1s flush with rear of case Slide spacer washer onto pivot shaft against parkin
141. stall shim packs on their respective hubs Install an addi tional 015 thickness of shims behind the differential bear ing on the tooth side of the ring gear to provide the proper backlash between the gear and pinion and proper bearing preload Install bearing with bearing replacer tool J 2646 or J 2104 Place axle housing spreader J 5231 in position Mount the dial indicator and spread housing 020 maximum to permit installation of the differential assembly Install the bearing caps and use sealing compound on the bolt threads Be certain the identifying marks on caps and housing are aligned Remove housing spreader Torque bearing cap screws to 70 90 foot pounds Install the dial indicator on housing with contact button resting against edge of gear tooth and check the backlash between ring gear and pinion Backlash tolerance is 002 to 006 and should not vary more than 002 between positions checked check at four different locations on ring gear Fig 9 FIGURE 9 Checking Ring Gear and Pinion Backlash Install the inspection cover using a new gasket Replace the ratio tag under one of the cap screws TORQUE CHART Recommended Torque Description to Ft Lb All Parts Clean and Dry Ring Gear to Case Screw 50 55 Differential Bearing Cap Screw 70 90 Drive Pinion Nut 200 220 Propeller Shaft Coupling Flange Screw Nut 30 35 Wheel to Hub Nut 70 80 Rear Wheel Hub to Shaft Nut 180 190 Rear Brake Support Plate Scre
142. tarter switch bracket Remove clevis pin from the gear shift control rod at side of transmission case and remove clevis from shift lever Place the transmission outer shift lever in the D 3 range posi tion Adjust clevis so that clevis pin passes freely through hole in lever with the operating lever against the stop on the starter switch bracket Then remove clevis and lengthen the control rod two full turns and replace clevis and clevis pin NOTE This adjustment will insure proper detent location in the transmission with a full reverse en gagement 1 Upper T V Rod 2 Bellcrank 4 T V lever 3 Lower T V Rod FIGURE 145 T V Linkage HYDRA MATIC TRANSMISSION 101 TESTING AND DIAGNOSIS STALL OR TORQUE TEST A Stall or Torque test may be made to determine engine and transmission performance This test must be used with moderation because considerable strain is exerted on the drive line differential gears and axles To perform Stall test proceed as follows Start engine and warm up to operating temperature Connect electric tachometer Set hand brake lever tightly and apply foot brake firmly Place selector lever in D position Depress accelerator pedal to floor Action has placed transmission in first speed Brakes are applied therefore the car cannot move Opening the throttle and speeding up the engine is comparable to slipping a mechanical clutch as the driving torus is turning and trying to turn t
143. te set should be installed To replace the upper half of a bearing remove the bearing cap of the bearing to be replaced Then loosen all of the other bearing caps and insert a small pin about 1 2 long in the crankshaft oil hole The head of this pin should be large enough so that it will not fall into the oil hole yet thinner than the thick ness of the bearing With the pin in place rotate the shaft so that the upper half of the bearing will rotate in the direction of the locating tongue on the bearing Crankshaft Main Bearing Clearance The standard clearance of 0006 to 0032 can be accu rately checked by the use of Plastigage NOTE When checking bearing clearance with the engine in such a position that the bearing caps support the weight of the crankshaft and flywheel keep all main bearings tight except the one being checked Support the weight of the crankshaft with a jack Remove the bearing cap and wipe the oil from the bearing insert Place a piece of Plastigage across the full width of the bearing insert Reinstall the bearing cap and tighten 80 to 85 foot pounds torque Then remove the bearing cap and with the graduated scale which is printed on the Plastigage enve lope measure the width of the flattened Plastigage at its widest point The number within the graduation indicates the clearance in thousandths of an inch Install the proper size bearing liners inserts to bring the clearance to stan dard Grinding of
144. tear down Incorrect assembly of the cushions and rubbers will permit a noise similar to bearing noises Engine support cushions also are a source of misdiag nosed engine bearing rap FLYWHEEL AND STARTER RING GEAR ASSEMBLY The flywheel plate is balanced as a component of the fluid coupling on Hydra Matic transmission equipped cars The flywheel ring gear is part of the torus cover assembly On standard and overdrive transmission equipped cars the flywheel is balanced as an individual component and also as part of the crankshaft assembly Service replacement flywheels may be installed without attempt to duplicate balance holes present in original as sembly LUBRICATION SYSTEM The lubrication system is the full pressure type Pressure is supplied by a gear type positive pressure pump mounted on the rear main bearing cap AW mM 4 Hub 5 Friction Disc 1 Pulley 2 Rubber Cushion 3 Rubber Friction Washer FIGURE 24 Vibration Damper Pulley Oil Pump The oil pump is driven by the distributor drive shaft Oil pump removal or replacement will not affect distribu tor timing as the distributor drive gear remains in mesh with the camshaft gear Upon disassembly of the oil pump locate a straight edge across the pump body and gears in their operational cavity and check the gear to cover clearance which should not exceed 004 A clearance of 008 maximum should exist between the g
145. ten the four nuts alternately to pull the cover out of the drive torus evenly When removing the cover the two square O rings will sheer when passing the 82 TECHNICAL SERVICE MANUAL FIGURE 89 Hook Type Oil Seal Ring on Intermediate Shaft 1 Front Unit Removing Tool J 6121 2 Coupling Valve Retainers J 6122 1 3 Pencil Scribe Mark FIGURE 91 Removing Front Unit Cover tools J 6122 1 that retain the exhaust valves Remove the driven torus bronze and steel thrust wash ers and clean and inspect all parts Fig 92 1 Drive Torus 5 O Rings 2 Steel Thrust Washer 6 Cover 3 Bronze Thrust Washer 7 Exhaust Valve and Spring FIGURE 90 Case Support Holding Tool J 6135 Driven Tors FIGURE 92 Front Unit Coupling snap ring groove After the cover is partially removed pencil scribe both cover and drive torus Fig 91 Remove the four nuts and studs from tool J 6121 after the cover is free and lift unit from holding fixture and Place the drive torus in the holding fixture and install the remove center nut Then remove the cover and the two special steel thrust washer in the counterbore on the vane side of the ASSEMBLY OF FRONT UNIT COUPLING HYDRA MATIC TRANSMISSION drive torus Then install the bronze thrust washer Install driven torus into the drive torus Install new rings on the front unit coupling cover sure that the 0 rings are not twisted in the groove Lubricate the 0
146. the G 2 retaining plate dowel in gov ernor body DISASSEMBLY OF CONTROL VALVE ASSEMBLY The complete control valve assembly consists of four indi vidual assemblies overrun clutch body shift valve body reverse blocker manual valve body and two spacer plates connected to a channel body Fig 115 Each valve body should be disassembled cleaned in spected and assembled individually This should be done to avoid confusion of parts The individual valve bodies are outlined separately in the following operational procedures DISASSEMBLY OF OVERRUN CLUTCH VALVE BODY Remove the two overrun clutch valve body attaching screws but do not remove body After the screws are removed hold body in place turning complete assembly over to avoid losing the 1 4 check ball from the overrun clutch valve body Remove the 1 4 check ball Then remove the four front plate attaching screws and plate Fig 116 Remove overrun clutch valve coupling valve and spring and transition valve and spring HYDRA MATIC TRANSMISSION 89 While holding pressure on the rear plate to keep the limit valve springs compressed remove the two screws and plate Then remove the two springs and washer limit valve and coupling valve plug clean and inspect parts ASSEMBLY OF OVERRUN CLUTCH VALVE BODY Install limit valve into bore with spring stem facing out Install limit valve inner spring washer and outer spring Inner spring seats on limit valve and o
147. the differential bearing cones on the differential case hubs without installing shims using side bearing replacer tool j 2646 or J 2104 Install differential bearing Cups Clean bearing bores in housing and install the differential assembly Install the bearing caps Be sure identification marks on cap Fig 1 are in same position as identification marks on housing Tighten bolts finger tight Mount a dial indicator with the button against the back face of the ring gear Fig 5 Insert two screw drivers between the bearing cup and housing Force the differential assembly to one side as far as possible Set dial indicator to zero and shift differential as far as possible to opposite side note and record reading This reading denotes the shim requirements to be installed later between the differential assembly and the bearing cones Shims are available in 003 005 010 and 030 thicknesses Remove the side bearing caps and remove the differential assembly FIGURE 5 Determining Shim Pack for Side Bearing Adjustment Pinion Depth Adjustment To compensate for machining tolerances the pinion and ring gears are factory tested for tooth contact and quietness This test is conducted at a standard cone setting and varied to obtain correct tooth contact and quietness Note the figures etched on the rear end of the drive pinion One set will be found identical on both the ring gear and pinion This denotes a matched set Another
148. ty Clutch On Clutch Off REVERSE In reverse the front unit and reverse unit are in reduction and the rear unit is in neutral The transmission gear ratio is 4 30 to 1 Power flows mechanically from the flywheel to the torus cover and to the internal gear attached to the torus cover At the internal gear mechanical power divides Part of the mechanical power is directed into the front unit coupling However in reverse the front coupling is empty and no power is transmitted to the front unit driven torus member Power is also directed from the internal gear to the planet carrier assembly of the front unit The sun gear is held by the front sprag clutch assembly so that the pinions of the carrier walk around athe sun gear at a slower rate or reduction The front unit planet carrier is attached to the drive torus member and will through oil drive the driven torus member In turn the driven torus member drives the connecting main shaft and rear unit sun gear Since the rear sprag clutch is released the sun gear of the rear unit will drive the rear internal gear counterclockwise or reverse The internal gear through a flange will drive the sun gear of the reverse unit counterclockwise Power then travels through the reverse planetary carrier to the output shaft in reduction because the internal gear is held by the reverse cone clutch HYDRAULIC OIL CIRCUITS 37 LIMIT VALVE The limit valve prevents a sudden drop in line pressure whe
149. using 2 Water Outlet Manifold FIGURE 1 Water Pump and Manifold Assemblies The water pump discharges coolant into the distribution manifold where dual outlets supply a balanced flow of coolant into both cylinder banks The coolant flows through the block and back through the cylinder head to the radiator inlet RADIATOR The radiator is a conventional vertical flow type with the expansion tank located on top of the tube section Although the capacities remain essentially the same radiators with increased fin area are used on models equipped with air conditioning On models equipped with Hydra Matic trans mission an oil cooler is incorporated in the bottom of the radiator core to facilitate cooling Hydra Matic oil Water or anti freeze solution should whenever possible FIGURE 2 Cross Sectional View of Water Pump be added to the radiator only when the system is cool Cool ant should be added to barely cover the tubes of the core This precaution will prevent constant loss of coolant due to expan sion when heated The Weather Eye valve should be fully open when refilling or flushing the system The engine must be idling during the refilling operation to prevent trapped air interfering with the circulation or Weather Eye operation A drain cock is provided on the lower tank of the radiator as well as two drain cocks located approximately in the center of the side of each cylinder bank Cooling System Capacity The cool
150. using it should be re moved to prevent it from dropping out and being damaged Remove front seal protector and housing to case 0 ring seal from rear side of housing Install transmission holding fixture J 6115 to transmission case Position so that supporting arm of stand is over trans mission Use flywheel rear housing attaching screws threaded through small holes in fixture Fig 35 FIGURE 35 Transmission Mounted in Holding Stand Install transmission into bench collet CAUTION Use care to prevent front unit from sliding out of transmission and falling on floor Position transmission horizontally with oil pan up and install lock handle in bench collet CHECKING MAIN SHAFT END PLAY To check main shaft end play install collar of end play checking fixture J 6127 on main shaft and secure it in position by installing Truarc snap ring Fig 36 Attach fixture J 6127 to collar by threading collar se curely into fixture Install dial indicator support J 6126 and dial indicator Fig 37 Move main shaft back and forth to check end play of main shaft End play should be 004 to 018 Be sure to get free main shaft end play Forcing main shaft will give inaccurate reading NOTE Record amount of end play Remove dial indicator support and end play checking fixture HYDRA MATIC TRANSMISSION 67 INSTALL DRIVE TORUS MAKE MEASUR TRUARC SMAP RING IN FRONT OF ARE THIS GROOVE AND FACING UPWARD 50 THESE
151. uter spring seats on washer Coat coupling valve plug with petrolatum and insert in valve body bore and install rear plate and attaching screws Install the overrun clutch valve in body then insert coupling valve into coupling valve spring and install in body Install transition valve spring transition valve front plate and attaching screws DISASSEMBLY OF SHIFT VALVE BODY Remove four attaching screws and shift valve body from channel body Remove separator plate and check ball and spring from 1 Overrun Clutch Body 6 1 4 Check Ball and Spring channel body Remove governor valve end plate and remove 3 4 gov 3 Reverse Blocker 8 By pass Check Valve 1 4 1 4 Check Ball In Body ernor valve 2 3 governor valve and governor booster valve 5 Channel Plate to 9 Channel Plate to Case Remove the regulator body and plate holding pressure Valve Body 10 Manual Valve Body against plate when removing the four attaching screws 1 Front Plate 5 Coupling Valve Spring 9 Inner Limit Valve 11 Rear Plate 2 Coupling Valve 6 Valve Body Spring 12 Overrun Clutch Valve 3 Transition Valve 7 Limit Valve 10 Outer Limit Valve 13 Coupling Valve Plug 4 Transition Valve Spring 8 Limit Valve Spring Washer Spring FIGURE 115 Control Valve Assembly TECHNICAL SERVICE MANUAL Remove the 3 4 regulator valve 2 3 regulator valve 3 4 shift and regulator valve springs 2 3 shift and regulator valve springs 3 4 shift valve and 2
152. w Nut 50 55 SPECIFICATIONS 2 g Drive Gear Type Ring Gear and Pinion d Backlash 002 006 Axle Shaft End Play Adjust 001 004 on Right Hand Side Only 114 Pinion Shaft Bearing Tension TECHNICAL SERVICE MANUAL 25 35 Inch Pounds Pinion Bearing Adjustment Shims Differential Side Bearing Preload 005 009 Lubrication Capacity 3 1 2 Pts Type of Lubricant SAE 90 HYPOID Rear Axle Ratio Standard 4 1 1 11 45 Rear Axle Ratio With Overdrive 4 5 1 11 50 Rear Axle Ratio With Hydra Matic 3 5 1 13 46 NOTE HYPOID REAR AXLE LUBRICANT IS TO BE USED IN ALL NEW ASSEMBLIES OR FOLLOWING THE INSTALLATION OF REPLACEMENT PARTS After the rear axle has been runin or at the recommended drain and refill period an SAE No 90 All Purpose MultiPurpose or other brand designation lubricant may be used as long as it is suitable for Hypoid Rear Axle Service Naturally the results of such use are the responsibility of the lubricant supplier or servicing dealer Date TECHNICAL SERVICE LETTER REFERENCE Changes Information on Page No Oil Filtee Replacn dement every 2000 miles Power Shee ring Reperecli Check loved Fil 3a 14 Tram tap Shalt ey ee CI Wiek SAE 10 2000 miles Lom eal every 5 000 mies PH Pived SAC 10 every 5D miles Wick between of vezuum advance auembly SAE 18 avery 5 00 mi

1956 Hudson Tech Service Manual Spplement

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