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Triumph TR2, TR3, TR3A factory service manual

1. For instructions regarding wheel bearing settings refer to page 7 Section in the main part of this manual If excessive run out is present this will cause the knocking back of the pistons which will possibly cause judder If it is found that the discs have been damaged in any way which is extremely unlikely it will be necessary to remove the discs from the car in order for them to be trued up Under no circumstances should more than 060 be removed with the finish to be 32 micro ins maximum measured circumferentially and 50 micro ins measured radially REAR BRAKES Figs 3 and 4 From the illustration it will be seen that they are of the drum type with a wheel cylinder and adjuster affixed to a backplate supporting the two shoes which are held in position by two return springs The shoes which are hydraulically operated by the Girling single acting wheel cylinder in corporating lever handbrake mechanism are not fixed but are allowed to slide and centralize Lining wear is adjusted by a Girling wedge type mechanical adjuster common to both shoes At the cylnder end the leading shoe is located in a slot in the 447 Ri BRAKES or FORWARD Ro AN vox 7 e No o NR TNR SHOE RETURN d SPRING CYLINDER END SHOE RETURN SPRING ADJUSTER END SS ADJUSTER HOUSING SPRING ge 9 Fig 4 piston while the trailing shoe rests in a slot formed in the cylinder body At the
2. Kit No 900771 less side screens contains the following items Detail Description No No off 800840 Drip channel 1 800839 Drip channel L H 1 603328 rubber screen top 1 603116A Seal rubber backlight 1 603116B Seal rubber backlight filler 1 602260 Seal strip waist 1 603089 Seal rubber drip channel 2 553132 Backlight Perspex 1 553742 Hard top Metal 1 Headlining fitted 1 602299 Tapping plate 5 WQ0305 Spring washer 10 502406 Screw drip channel attachment 24 602295 Fixing screw screen bracket 3 602938 Protection plate side cappings 2 500488 Round headed screw protection plate 10 603189 Bracket windscreen fitting 3 602380 Fix washer windscreen fitting 3 602939 Protection plate rear cappings 3 602943 Washer 5 602326 Bridge piece 5 602327 Dome headed screw 5 501434 Screw bracket to screen 6 TR 6503 Round headed screw tapping plate 10 Detail Description No No off 500229 Round headed PK screw drip channel 10 502233 Countersunk screw screen rubber WN 0705 Shake proof washers bracket to screen 6 CD13515 Cup washers 22 When required for TR2 cars sliding side lights must be ordered separately Caution The fitting of Hard Tops to early cars may present some difficulty due to the inconsistencies of body dimensions feature not uncommon with hand made bodies Present manufacturing methods make use of more elaborate assembly jigs which result in the main
3. cleaned with petrol paraffin or trichlorethylene Always Remember that your safety and the safety of others may depend on the observance of these pre cautions at all times 453 EXHAUST SYSTEM EXHAUST SYSTEM The exhaust system is unchanged from the TR2 apart from the new manifold gasket fitted to the enlarged port combustion head after engine number TS 9350E S 455 Notes on the way this file was produced Books on the repair and maintenance of the old Triumphs are becoming more and more difficult to locate many have been out of print for years or even decades and good examples are increasingly hard to find at reasonable prices Then too there are all the people like me who have a copy of a valuable reference book but in rather forlorn condition Mine happened to be sitting in the trunk of an immobile 1957 TR3 for a decade before purchased the car and the manual and thus came to me reeking of gasoline and with a binding which no longer bound the book together but rather produced a crumbly mess any time turned a page So set about to produce an electronic copy of this the Robert Bentley manual for the TR2 and TR3 cars in order to have for myself a copy which could keep in the garage and use without worrying that it might be ruined if it became soaked with gearbox oil could just print anoth er The project took much longer than expected but the results are worth it am pr
4. adjuster end the shoe ends rest in slots in the adjuster links The shoes are supported by platforms formed in the backplate these being held in position by two hold down springs fitted on each shoe with a peg passing through a hole in the backplate The adjuster consists of an alloy housing with studs which is spigoted and secured firmly to the inside of the backplate by nuts and spring washers The housing carries two opposed steel links the outer end slotted to take the shoes and the inclined inner faces bearing on inclined faces of the hardened steel wedge the axis of which is at right angles to the links The wedge has a finely threaded spindle with a square end which projects on the outside of the backplate By rotating the wedge in a clockwise direction the links are forced apart and the fulcrum of the brake shoe expanded A piston and seal moves in the highly 448 m HOLD DOWN PEG CUPPED WASHER DUST COVER CLIP DUST COVER DUST COVER DISTANCE PIECE RETAINING PLATE Details of Rear Brake Assembly finished bore of a light alloy die cast wheel cylinder body whilst a slot machined in the opposite end of the body serves to carry the trailing shoe The cylinder incorporating a bleed screw with rubber cap is attached to the back plate by spring clips which allow it to slide laterally The handbrake lever pivots on and projects at right angles through the back plate When the brake is applied th
5. 2532 A modified tail pipe incor porating a 12 silencer can be fitted at the owner s discretion to the shorter type silencer if the exhaust note is considered too loud see Fig 2 This modified tail pipe fits into the main silencer and is attached with the existing clip At the rear the tail pipe is attached to the chassis by a flexible mounting strip and the clip secures the chromium plated extension piece inside the tail pipe 2 MAINTENANCE The exhaust system should be inspected periodically to ensure its correct function Attention should be paid to the gaskets at the cylinder head carburettor and front exhaust pipe flanges to ascertain their condition If signs of blowing are detected then gasket must be replaced as soon as possible Manifold gaskets should be replaced as a pair and no gasket should ever be used twice The flexible mounting strips should be inspected and replaced if any deterioration is apparent The position of the silencer assembly relation to the cruciform centre should always be such that during any vibrationary period the exhaust system cannot come into contact with the cruciform 3 TO REMOVE AND DISMANTLE EXHAUST SYSTEM a Working from the rear of the car loosen the bolt of the rear pipe clip attachment and withdraw exhaust pipe extension b Withdraw the lower bolt securing pipe clip attachment to flexible mount ing strip and collect nut and lock washer c
6. 6 gigabytes of data It took just over 4 5 hours to distill the pages into PDF files chose the PDF format because it can be opened viewed and printed on many different computing platforms from Windows to Mac to Unix to Linux and think even the Amiga Enjoy
7. HUB BEARINGS The rear hub bearings are each lubricated by a grease nipple located behind the brake backing plate and facing downwards as shown in Fig 2 The nipples should receive a small but regular supply of grease as specified on pages 9 12 Section Six strokes of the hand grease gun every 6 000 miles 10 000 km will normally be sufficient as it is inadvisable to overload with grease AXLE SHAFT WHEEL BEARINGS AND OIL SEALS a To Dismantle The procedure is as follows i Jack up the rear of car remove road wheel unscrew two securing setscrews and detach brake drum from hub Fig 3 Extraction of rear hub ii Withdraw split pin and remove castellated nut from end of half shaft and remove rear hub with extractor as shown in Fig 3 iii Remove six setscrews securing the brake backing plate and bearing housing to the axle sleeve outer flange then detach the bearing housing complete with the bearing outer ring Fig 4 Extracting outer ring of hub bearing from housing Note Removal of a half shaft does not normally require detachment of the brake backing plate but if its removal is necessary then the 427 REAR AXLE Fig 5 Removing hub bearing inner ring Fig 6 Fitting hub bearing inner ring to axle shaft brake fluid pipe and the hand brake attachments must first be disconnected and the backing Fig 7 Fitting oil seal into bearing housing plate sub
8. Hydraulic Fluid f g Bleed and adjust clutch as described in Clutch Section D h Bleed brakes as described on page 3 i Adjust brake shoes as described on page 3 406 16 39 b c 4 e Release the tension of the return spring by withdrawing end from the anchoring tab The spring can now be removed from the pedal Withdraw the two bolts and lock washers from pedal shaft support brackets and remove these brackets Drift out pedal shaft Lift out pedal assemblies from pedal shaft cover TO ASSEMBLE PEDALS During assembly note the marked com ponents and return them to their original positions a Fit the pedals to the shaft cover assembly in such a manner that the wall of the cover pressing is accommo dated in the recess in the revolving collar on each pedal b Feed the pedal shaft through the pivots 40 41 4 e BRAKES Position the support brackets on the shanks of the welded bolts and allow the cut away side to drop into the recess of the revolving collar Slight pressure may be necessary to bed this bracket Secure the bracket to the pedal shaft utilising two bolts and lock washers one each side id Hook the return springs in the shaft of the pedals and anchor the other to the welded tab TO REMOVE HANDBRAKE LEVER a b NI d NA e NA g Chock the wheels jack up the car and release handbrake Rem
9. WHEEL CYLINDER Ensure absolute cleanliness during the assembly of these components Assemble parts with a generous coating of clean Lockheed Brake Fluid 402 12 28 Fit the smaller end of the coil spring over the projection in the cup filler and insert both parts into the cylinder body with the spring leading a b Follow up with the rubber cup lip end foremost taking care not to damage or turn back this lip Feed in piston with cover in position REAR WHEEL CYLINDER Description The cylinder which is fitted in an elongated slot in the rear brake plate is free to slide in the slot between the tips of the brake shoes which are of the leading and trailing shoe type The cylinder has a single piston operating on the tip of the leading shoe and this shoe abutts against a fixed anchor block at the bottom of the back plate the web of the shoe being free to slide in a slot in a block The trailing shoe is located in a similar manner between the anchor and the closed end of the cylinder and is free to slide and therefore self centring The trailing shoes are operated by move ment of the reaction of the leading shoe against the brake drum micram adjuster is located in a slot in the top of the leading shoe The wheel cylinder contains a single piston split in two the inner piston being hydraulically operated while the outer piston is manually operated by the hand brake lever A rubber cup m
10. and wheel cylinder piston slots then prise over the opposite shoe into its relative position Remove rubber band Insert the hold down peg through hole in backplate and replace spring and cupped washers smeared with Girling White Brake Grease vii Make sure drums are cleaned and free from grease etc then refit viii Adjust brakes ix Refit road wheels and jack down Note The first shoe has the lining positioned towards the heel of the shoe and the second shoe towards the toe or operating end in both L H and R H brake assemblies Several hard applications of the pedal should be made to ensure all the parts are working satis factorily and the shoes bedding to the drums then the brakes should be tested in a quiet road before normal running is resumed Handbrake Setting refer to Fig l 449 BRAKES RUNNING ADJUSTMENTS The front disc brakes are entirely self adjusting The rear brakes are adjusted for lining wear at the brakes themselves and on no account should any alteration be made to the hand brake cable for this pur pose Fig 1 One common adjuster is provided for each brake assembly Adjustment of both rear wheels is identical Release the handbrake and jack up the car Turn the square end of the adjuster on the outside of each rear brake backplate in a clockwise direction until a resistance is felt then slacken back two clicks when the drum should rotate freely Immediately a
11. from handbrake lever location and the two cranked lips away from the backplate Replace handbrake lever Locate the retaining plate between the distance piece and spring plate open end towards the handbrake lever tap into position until the two cranked tips of the spring plate locate in the retaining plate Fit the rubber dust cover Attach the pressure pipe union to the cylinder and connection to the handbrake lever Replace the shoes brake drum and bleed the system Finally re fit wheels c Fitting Replacement Shoes 4 Jack up the car and remove road wheels and brake drums ii Remove the holding down springs by turning the washer under the peg head Lift one of the shoes out of the slots in the adjuster link and wheel cylinder piston Both shoes complete with springs can then be removed Place a rubber band round the wheel cylinder to keep piston in place iii Clean down the backplate check wheel cylinders for leaks and free dom of motion iv Check adjusters for easy working and turn back anti clockwise to full off position Lubricate where necessary with Girling White Brake Grease v Smear the shoe platforms and the operating and abutment ends of the new shoes with Girling White Brake Grease vi Fit the two new shoe return springs to the new shoes with the shorter spring at the adjuster end from shoe to shoe and between shoe web and backplate Locate one shoe in the adjuster link
12. rear cappings aligning the centre holes with the threaded centres of the bridge pieces Drill the cappings through the protection caps and secure with P K self tapping screws The two larger caps are fitted in a similar manner to the side elbow rails Fig 1 f Fit four countersunk screws and chro mium washers in the holes previously used to accommodate the hood bracket screws Remove the protecting tape from the body of the car 439 BODY 6 DRIP CHANNELS TO FIT See Figs 5 and 6 DRIP CHANNEL RUBBER MOULDING Fig 7 Fitting Rear Window and Waist Rubber Fig 5 Fitting lower part of Drip Channel After correctly shaping the ends of the drip channels position the channels and draught rubbers C on the Hard as illustrated and secure with the screws A and Fig 6 27 ny Uy en DRIP CHANNEL SHAPED TO FIT SCREEN PILLAR HARD TOP DRIP X CHANNEL Y gt ud NS MOULDING A 2 2 Y ES E dut od MS TURN BACK LIP OF SE X RUBBER MOULDING c CSCREWS A STO FIT B SCREWS SCREWS 8 Fig 8 Fitting Screen Rubber Fig 6 Fitting Drip Channel and Draught Rubber 7 SEALING RUBBERS TO FIT 8 HARD TOP TO FIT Using Seelastik secure the rubber Re position the Hard Top on the body mould Fig 7 to the rear lower and after loosely assembling the attach edge and the rubber section E Fig 8 ment bolts progressiv
13. side of the brake plate Pull the trailing shoe against the load of the pull off springs and away from its abutment at either end on releasing tension of the pull off springs the lead ing shoe will fall away Collect the micram adjuster and mask Remove the rubber boot and the hand brake piston Swing the handbrake lever until the shoulder is clear of the back plate and slide the cylinder casting forward Pivot the cylinder about its forward end and withdraw its rear end from the slot in the back plate A rearward movement of the cylinder will now bring its forward end clear of the back plate b e d e TO a FIT REAR WHEEL CYLINDERS Offer up the rear wheel cylinder to the back plate with the handbrake lever to the slot Engage the forward end of the cylinder in the slot and slide it well forward taking care to position the lever so that the shoulder clears the back plate Engage the rear end of the cylinder in the slot and slide it back to hold it in position Place the rubber boot over the hand brake lever and ease the boot round the wheel cylinder so that it provides maximum weather protection Connect handbrake cable to lever utilising a new split pin for the securing of the clevis pin b Mount the banjo connection with new copper gaskets on the wheel cylinder and secure with banjo bolt d NY Assemble the brake shoes ensuring that the micram adjuster is in the slot in th
14. such a manner that the clutch and brake piston fork ends engage with the two pedal levers 405 b NOTATION FOR Fig 8 Pedal shaft cover assembly Clutch pedal Brake pedal Rubber pad for pedals Pedal pivot bush Pedal shaft Supporting bracket for pedal shaft Lock washer Bolt securing brackets to shaft Pedal return spring Lock washer Bolt securing pedal assembly to bulkhead Master cylinder s upper bracket Bolt securing pedal assembly and master cylinder support bracket to bulkhead Lockwasher Nut securing pedal assembly and master cylinder support bracket to bulkhead Clevis pin Double coil spring washer Plain washer Split pin Jam nut Pedal limit stop Fig 8 Exploded view of Pedal Assembly R H S shown Attach bracket to bulkhead utilising four nuts and plain washers these nuts are left loose at this juncture 38 TO DISMANTLE PEDAL ASSEMBLY a Suitably identify the pedals relative to their positions c d Inside the car the pedal assembly is further secured to the bulkhead by two bolts and lock washers these bolts are fully tightened Under the bonnet tighten the four nuts mentioned in operation b Connect the two pipe lines to their appropriate outlet ports and attach edal levers to master cylinder fork end assemblies utilising clevis pins e Adjust pedal clearances as described on page 4 Replenish reservoir with Lockheed
15. toO REAR AXLE Arrangement of Axle Components Fig 13 431 FRONT SUSPENSION AND STEERING NYLON BEARINGS LOWER INNER WISHBONE ATTACH MENT These bearings supersede the rubber bushes and were introduced into production at car Com mission No TS 9121 They are as follows a Nylon bearing 4 off Pressed into each wishbone arm b Steel bush 4 off Fitted to fulcrum pin Sealing rings 8 off Fitted to outside edge of nylon washers d Nylon washers 8 off Fitted each side of wishbone arms When these bearings are being fitted the following instructions must be observed 1 Fit the rubber sealing rings to the nylon washers ii Press the nylon bushes into the inner ends of the wishbone arms The following four instructions supersede the operations x and xii on page 12 in the main manual Front Suspension Section G i Smear the fulcrum pin situated on the upper face of the chassis frame with grease and feed on the steel bushes ii Smear the outside of the bushes with grease and feed on a pair of nylon washers complete with sealing rings iii Feed the wishbone arms on to the steel bushes on the inner fulcrum pin and on the shackle pins of the vertical link simultaneously followed by a second pair of nylon washers and sealing rings iv Fit the triangular support plates and secure with nyloc nuts but leave finger tight at this juncture Refer to the m
16. 421 LLLUME LL L LLLA LLL m e a H tft LLL LLLA voor 5 STs Mui ma gt Dd a sch aN q S ENGINE CYLINDER BLOCK Vandervell replaceable shell bearings have been introduced for the 2nd 3rd and rear camshaft journals These are manufactured to very fine limits and whilst certain fitting precautions must be observed line boring of the assembled bearings is unnecessary Removal of the rear bearing will necessitate the removal of the sealing disc behind it which in turn will require the removal of the gearbox clutch and flywheel The tool illustrated Fig 1 is designed to assist in the removal and replacement of the bearings 1 REMOVER amp GUIDE GUIDE PIN I Fitting Intermediate Camshaft Bearing using Churchill Multipurpose Tool No 32 with Adaptors S8 32 1 a Camshaft Bearings To remove proceed as follows i Using a suitable tool drift the sealing disc out of the rear cam shaft bearing housing ii Unscrew and remove the three shouldered setscrews and plain washers which retain the bearings in position iii Assemble the extracting tool and adaptors into the cylinder block as illustrated and withdraw each bearing in turn b To Fit New Bearings See Fig 1 and observe the following The oil feed holes must be correctly aligned and when drawing the bearings into position all po
17. BRAKES Fig 5 Exploded view of Front Brake details 401 BRAKES 25 TO FIT FRONT WHEEL CYLINDERS 26 27 a Mount the wheel cylinders on the back plate and secure each with a bolt and lock washer Connect bridge pipe to bottom bore of each wheel cylinder utilising the union nuts trapped on the pipe Ensure that the pipe is located on its seat before attempting to attach the nut Tighten nut sufficiently to give and oil and air tight joint b Attach the flexible hose to the upper bore of the rear cylinder checking first that the copper gasket is in good order Fit flexible hose to bracket on the chassis frame as described on page 5 c d NY Fit bleed screw to upper bore of front wheel cylinder Fit brake shoes taking care to locate the micram adjusters in the slots in the leading tip of each shoe with the masks in position Fit brake drum and bleed hydraulic system as described on page 3 e f g h Adjust brake as described on page 3 Check the system for fluid leakage by applying a firm pressure to the pedal and inspecting the pipe line and connections i Fit road wheel and nave plate Remove jacks TO DISMANTLE FRONT WHEEL CYLINDER a Withdraw the piston complete with piston cover from cylinder body b Apply low air pressure to the flexible hose connection the rubber cup the cup filer and spring can readily be removed TO ASSEMBLE FRONT
18. IT OCCASIONAL SEATS Slide the driver and passenger seats forward to their fullest extent Lift up the carpet at the rear of the two seats and remove the two bolts and washers so exposed Make two small holes in the carpet to align with the tappings in the floor assembly Withdraw the two chrome headed bolts and washers from the trim at the rear of the passenger compartment e Position the occasional seat behind the driver and passenger seats and secure with four bolts removed during the previous operations 12 TO REMOVE OCCASIONAL SEAT a b Withdraw the four attachment bolts and plain washers Remove the seat from the rear of the passenger compartment Return the bolts and plain washers to their tappings for safe keeping BODY TR2 amp 3 HARD INSTALLATION Description The Hard Top is of pressed steel construc tion incorporating channel sections which are spot welded to the main panel These channels considerably stiffen the assembly and also accommodate the front and rear mounting brackets The sides of the main panel are folded to form U section which further strengthens the construction and also serves as a means of securing the drip channels and draught sealing rubbers The Hard is supplied completely trimmed less the rubber sections and the rear window light all of which are included in the kit for fitting at a final stage The Hard Top
19. Loosen the pinch bolt of the pipe clip attachment at the rear of the silencer and withdraw tail pipe assembly EXISTING PART N 108446 AND FITTINGS EXISTING INSTALLATION PART N 201600 18 LONG OR PART 202320 24 LONG FITTED TO LATER CARS PIPE EXTENSION PART 08555 MAY STILL BE FITTED AT R OISCRETION SILENCER amp PIPE LDED TOGETHER THIS PIPE 15 CARRIED ON EXISTING TAIL PIPE MOUNTING EXHAUST SILENCER I2 LONG AND TAIL PIPE PART_N 202285 REPLACING TAILPIPE PART N 202009 Fig 2 414 Method of supplementary silencing provided by 18 Silencer fitted prior to Com No T S 2532 EXHAUST SYSTEM Fig 3 Manifold gasket Inlet manifold Joint washer Insulating washer Exhaust manifold attachment stud Carburettor attachment stud Manifold details Small manifold clamp Si Large manifold clamp Manifold securing nut Exhaust manifold Exhaust pipe attachment stud Flange joint washer 415 EXHAUST SYSTEM d Loosen the pinch bolt or bolts forward of the cruciform centre and withdraw the silencer rearward e Remove the lower bolt attaching flexible mounting strip to chassis frame Remove the nut and bolt collecting the rubber grommet and rubber washer securing the bracket to the chassis frame f The front exhaust is detached from the exhaust manifold by the removal of three nuts w
20. Set screw Ratchet to attachment plate Nyloc nut Set screw Ratchet to attachment plate Tab washer on setscrews Pivot bolt Nyloc nut Cable assembly handbrake to compensating lever Fork end Jam nut Clevis pin Exploded view of Hand Brake Assembly Split pin Plain washer Anti rattle spring Bolt Nut Lock washer Clevis pin Split pin Plain washer Compensator bar assembly Compensator lever assembly Grease nipple Felt seal R H cable assembly 12 97 long L H cable assembly 26 85 long 26 35 Fork end Swivel pin Anti rattle spring Split pin Jam nut Clevis pin Split pin Plain washer 12 47 10 brakes BRAKES 43 TO ASSEMBLE HANDBRAKE ASSEMBLY a Feed the push rod into the lever from below so that its shape corres ponds with that of the handle Attach the pawl to the push rod so that it points rearward Allow the push rod to protrude through the upper portion of the handle and feed on a plain washer and coil spring followed by the button Apply pressure to the button to compress spring Hold the pressure on the button and feed the ratchet teeth facing forward into the lower portion of the casing ensuring that it is positioned well inside the lever Manipulate the pawl until its fulcrum hole is aligned with the hole in the lever and insert the clevis pin pressure on the button can now be released Secure clevis pin with plain w
21. ain section of the manual as mentioned previously for the wish bone arm outer attachments 433 Gl BODY BODY SPECIFICATION Provision is made for the installation of an occasional bench seat in the luggage com partment immediately behind the driver and passenger seats REVEAL MOULDING AND GRILLE A chromium plated moulding is fitted to the front rim of the air intake with a grille mounted immediately behind STAINLESS STEEL WING BEADING The stainless steel wing beadings are positioned between the front and rear wings and the body of the car PASSENGER SEAT A folding squab seat is now fitted to allow easier access to the luggage space behind or to the occasional seat if the car is so fitted OCCASIONAL REAR SEAT These seats are an optional extra on the TR3 models Provision is made for the installation of this seat in each car TO REMOVE REVEAL MOULDING AND GRILLE a Withdraw the self tapping screw from each end of two horizontal grille bars b Ease the upper portion of the grille into the air intake and withdraw the assembly when it is inclined approxi mately 30 c Slide the moulding joint plates to one side to expose the joint in the mould ings d Remove the nuts and lock washers from the stud plates securing the mouldings to the air intake and with draw the two half mouldings Access to these nuts entail working behind the front cowling e The stud plates can be withdrawn by slidin
22. arburettors so as to avoid any strain and tighten banjo bolts to give a petrol tight joint f Start the engine and observe the fuel pipes for leaks CARBURETTOR DETAILS The instructions given for the H4 car burettor as fitted to the TR2 apply to the H6 type apart from the four point mount ings The jet needles at present used in normal manufacture are of the SM type although with early releases of the TR3 model the TD or TE needle was fitted The TD or TE needles in both carburettors should be replaced by type SM if damage or wear justifies the exchange in either unit AIR CLEANERS The air cleaners have off set mounting and must be positioned on the carburettor air intake in such a manner that the off set is rearward INLET MANIFOLD The inlet manifold is removed and fitted as those fitted to the TR2 engine 443 PI BRAKES MASTER CYLINDERS O xe COMPENSATOR Qe Ea Hc WIRE ROPE SLAVE CYLINDER HAND BRAKE RATCHET BEFORE SETTING HAND BRAKE CABLE LOCK THE REAR SHOES UP IN THE DRUMS AND APPLY HAND BRAKE LEVER ONE NOTCH CABLE AND WIRE ROPES SHOULD BE JUST TAUT Fig 1 Brake and Clutch layout GIRLING BRAKES AND HYDRAULIC CLUTCH From Chassis No TS 13101 I DESCRIPTION The brakes on the front wheels are the Girling Disc Brakes and on the rear are Girling HL 3 Drum Brakes All four wheels are hydraulically operated by foot pedal operation di
23. asher and split pin Secure the attachment plate to the ratchet utilising a bolt and nyloc nut Tighten the nut sufficiently to allow the attachment plate to swing on the ratchet Failure to observe this instruc tion will result in imperfect handbrake operation The tape protecting the thread can now be removed and the grip fitted b c d e f TO REMOVE HANDBRAKE CABLES a Let off the handbrake lock the rear brakes on by turning the micram adjuster b Withdraw the split pins and clevis pins at each end of the handbrake cable assembly 19 45 e Release the tension of the spring securing the brake cable to the gearbox tunnel Withdraw the two bolts from the cable abutment brackets and re move cable assembly d Withdraw the split pins and clevis pins attaching the transverse cables to the levers on the brake backing plate e Remove the split pins and clevis pins at their inner ends taking care to collect the anti rattle springs Remove cables from car f The compensator assembly can be removed from the axle by turning lever and bar assemblies independently in an anti clockwise direction TO FIT HANDBRAKE CABLES The fitting is the reversal of the removal but the following points should be noted a The transverse cables should be of the correct length 12 97 1 06 26 85 06 These measure ments for 10 brakes 12 47 and 26 35 respect
24. assembled brackets under the windscreen top rail b A CENTRALISE HARD TOP 2 WINDSCREEN RAIL CLAMPED BETWEEN HARD TOP A AND BRACKETS LJ TEMPORARY SECURE HARD TOP BY TIGHTENING THE SCREW BRACKET MARK POSITION OF HOLES TRANSFER MARKINGS FROM UNDERSIDE TO TOP FACE OF WIND SCREEN TOP RAIL Positioning Hard Top and drilling Screen Rail BODY Centralise the Hard over the windscreen and temporarily secure by tightening the three attachment brackets Fig 3A Mark the position of the attachment bracket holes on the underside of the windscreen top rail Fig 3B Slacken off the brackets then remove the Hard from the car Mark the top side of the screen exactly in line with the markings previously made on the underside Fig 3C Using a No 11 drill carefully drill six holes from the above screen and is from the edge Fig 3D Remove the windscreen attachment brackets from the Hard Top and finally secure to the underside of the windscreen top rail by six chromium plated screws and lock washers Fig 1 BRIDGE PIECES TO FIT a Loosely secure the five bridge pieces to the angle brackets previously fitted in the rear stiffener rail Fig 4 Reposition the Hard to the car and secure to the three windscreen attachment brackets The bridge pieces will now be resting on the elb
25. cks behind both back ing plates will be approximately of equal thickness vii Replace brake drum road wheel and before removing the lifting jack it is essential to grease the hub bearing DIFFERENTIAL AND PINION ASSEMBLIES Except for the addition of a thrust block item 15 Fig 13 the crown wheel and pinion assemblies remain the same as fitted to the previous axle Therefore instruc tions for the servicing and adjustment of these assemblies are unaltered 429 REAR AXLE 5 HIGH SPEED AND COMPETITION WORK a Rear Axle Assembly ratio 4 1 1 A rear axle of the above ratio is available for high speed and com petition work but is only suitable for cars fitted with Overdrive The installation and servicing procedure is the same as for standard ratio axles Crown wheel Part No 202579 41 teeth Pinion 10 teeth Part No 202580 Complete axle as sembly for wire wheels Part No 505179 for disc wheels Part No 503930 b Speedometer Fig 11 Fitting splined hub extension to normal hub The following special ratio speedo meters are necessary when using 4 1 1 axles Speedo Kilo Part No 113632 Speedo Mile Part No 113631 c Centre Lock Adaptors Wire Wheel These splined hub extensions attached to the hubs by shorter studs than normally used for disc wheels Figs 11 and 12 show the extensions being fitted and the existing studs sawn off flush with the outside of the wheel
26. d Clutch Fluid from sealed quart tins Never Use fluid from a container that has been cleaned with petrol paraffin or trichlorethylene Never Put dirty fluid into the reservoir nor that which has been bled from the system Always Use clean Girling Brake and Clutch Fluid or alcohol for clean ing internal parts of hydraulic system Never Allow petrol paraffin or tri chlorethylene to contact these parts Always Examine all seals carefully when overhauling hydraulics cylinders and replace with genuine Girling spares any which show the least sign of wear or damage Always Take not to scratch the highly finished surfaces of cylinder bores and pistons Always Use WAKEFIELD GIRLING Rubber Grease No 3 Red for packing rubber boots dust covers and lubricating parts likely to contact any rubber components Never Use Girling White Brake Grease or other grease for this purpose Always Replace all seals hoses and gaskets with new ones if it is suspected that incorrect fluids have been used or the system contaminated with mineral oil or grease Drain off the fluid thoroughly wash all metal parts and flush out all pipes etc with alcohol or clean Girling Crimson Brake and Clutch Fluid Never Use anything else for this purpose Always Use a particular container re served for this purpose for bleed ing the system and always main tain in a clean condition Never Use a receptacle which has been
27. drained Unscrew the pressure pipe union and remove the bolts from the flange The cylinder can then be removed Remove the rubber cover and piston stop then by using an air line blow out the piston and seal The spring will also be removed Examine all parts especially the seal and replace if worn or damaged b Assembling Place the seal on to the stem of the piston with the back of the seal against the piston replace the spring with small end on stem smear well with Girling Crimson Brake and Clutch Fluid and insert into cylinder Re place the piston stop and stretch rubber dust cover over cylinder Mount the cylinder in steel clip making sure the ush rod enters the hole in the rubber t Secure the cylinder by the two bolts and screw in the pipe union 451 SPRING BLEED VALVE Fig 6 Bleeding Remove the bleed screw dust cap open the bleed screw approximately three quarters turn and attach a tube im mersing the open end into a clean receptacle containing a little Girling Crimson Brake and Clutch Fluid Fill the master cylinder reservoir with genuine Girling Crimson Brake and Clutch Fluid and by using slow full strokes pump the pedal until the fluid entering the container is free from air bubbles On a down stroke of the pedal nip up the bleed screw remove the bleed tube and replace the dust cap After bleeding top up the reservoir to its correct level of approximately three quart
28. e gas tight joints b The manifolds should be attached to the cylinder head before finally tighten ing the inter connection nuts c The carburettors must be synchronised before the car is ready for the road MANUAL TR3 MODELS Issued by the SERVICE DIVISION THE STANDARD MOTOR CO 1959 LTD 1 COVENTRY ENGLAND 417 TR3 Foreword 1976 Edition The TR3 is a result of The Standard Motor Company s attempting to improve the ap pearance and the performance of the TR2 The improvements consist of a more stylish grille a one half gallon reduction in fuel capacity a ten horsepower increase in engine output and the greater potential for the application of the overdrive With the exception of the differences described in this Supplement the specifications for the TR3 are the same as those previously set forth in this Manual for the TR2 The TR3 was introduced in 1956 and was discontinued after 1961 During these years TR3 was the only designation used for the cars by the manufacturer It has since become common to refer to the later models of the TR3 as the or TR3B The custom of ad ding letter suffixes to the TR3 designation deserves some explanation Owing to the larger carburetors and an in creased compression ratio the engine of the TR3 is more powerful than that of the TR2 In the United States the TR3 was always adver tised as having 100 B H P at 5 000 R P M though
29. e in turn was superseded by type SM at Engine No TS 10037E en needles are changed for any reason a pair of type SM should be fitted AIR CLEANERS The air cleaners are similar to those fitted to the TR2 apart from the off set mount ings INLET MANIFOLD This has been modified to accommodate the four point fixing H6 carburettor and manifolds fitted to engines after TS 9350E have a larger bore to align with the enlarged throat area of the high port combustion head TO REMOVE FLEXIBLE FUEL HOSE ASSEMBLY a Hold the hexagon of the flexible hose assembly and disconnect the union nut of the rigid pipe adjacent to the thermostat housing b Withdraw the banjo bolt from one carburettor collecting the gauze filter and retaining spring c Repeat operation b with the second carburettor 7 9 10 TO FIT FLEXIBLE FUEL HOSE ASSEMBLY a Position the filter assembly in the rear carburettor float chamber spring first b Feed a fibre washer on to the banjo bolt followed by the banjo connection and a second fibre washer and then attach to the rear carburettor and leave finger tight at this juncture Repeat operation a and b with the front carburettor d Holding the hexagon of the flexible hose with a spanner attach the union nut of the rigid supply pipe and secure to give a petrol tight joint e Adjust the position of the banjo con nections on the float chambers of the twin c
30. e leading shoe with the mask in position Fit the brake drum 404 14 31 Fig 7 e Bleed the hydraulic system as described on page 3 Adjust the brake shoes as described on page 3 Check the system for fluid leakage by applving firm pressure to the pedal and inspecting the line and connections g Fit road wheel and nave plate Re move jacks TO DISMANTLE REAR WHEEL CYLINDER a Withdraw the piston complete with piston cover from the cylinder body b Remove the seal from the piston by easing out of its groove Drift out the handbrake lever pivot pin to remove handbrake lever c d Apply low air pressure to the inlet connection the rubber cup the cup filler and spring can readily be removed Sectional view of Rear Wheel Cylinder 32 TO ASSEMBLE REAR WHEEL CYLINDER Fig 7 Ensure absolute cleanliness during the assembly of these components Assemble hydraulic parts with a liberal smear of clean Lockheed Brake Fluid a Fit the smaller end of the coil spring over the projection in the cup filler and insert both parts into the cylinder body with spring leading 33 34 35 BRAKES b Follow up with the rubber cup lip end forward taking care not to damage or turn back this lip Insert ensuring that the slot coincides with the lever slot in the cylinder body Place the handbrake lever in position and fit pivot pin Stretch the handbrake pi
31. e piston under the influence of the hydraulic pressure moves the leading shoe and the body reacts by sliding on the backplate to operate the trailing shoe The handbrake lever is pivoted in the cylinder body and when operated the lever tip expands the leading shoe and the pivot moves the cylinder body and with it the trailing shoe a Dismantling If it is found necessary to remove a rear wheel cylinder the following procedure should be followed b NY BRAKES i Jack up the vehicle remove the wheels and disconnect the rod from handbrake lever ii Remove the brake drum and shoes Disconnect the pressure pipe union from the cylinder and remove the rubber dust cover from rear of backplate iii By using a screwdriver prise the retaining plate and spring plate apart then tap the retaining plate from beneath the neck of the wheel cylinder iv Withdraw the handbrake lever from between the backplate and wheel cylinder v Remove the spring plate and distance piece and finally the wheel cylinder from the backplate Refitting the Rear Wheel Cylinder Mount the wheel cylinder on to the backplate with the neck through the large slot Replace the distance piece between cylinder neck and backplate with the open end away from hand brake lever location The two cranked lips must also be away from the backplate Insert the spring plate between the distance piece and backplate also with open end away
32. ely tighten them until to the front top edge of the Hard the Top is finally secured 440 REAR WINDOW LIGHT TO FIT See Fig 7 Fit the rubber moulding around the glass with the filler section positioned towards the rear of the car Offer the glass with the rubber attached to the aperture in the Hard Top and with the help of an assistant BODY manipulate the inner rubber lip into posi tion Using a special tool see Fig 7 finally secure the glass by feeding the filler strip into position With the aid of a Seelastik gun complete the installation by forcing Sealastik compound between the Hard Top and the outer lip of the glazing rubber to effect water sealing 441 NI FUEL SYSTEM PETROL TANK The petrol tank has been modified slightly to accommodate the occasional seat its capacity is thereby reduced to 12 gallons FLEXIBLE FUEL PIPES A flexible fuel pipe connects the twin carburettors and is integral with a short feed line which is connected to the Bundy tubing at a point adjacent to the thermostat housing CARBURETTORS S U H6 type carburettors are fitted to this engine This carburettor has a four point mounting but is similar in other respects to the H4 used on the TR2 is identical in operation and requires the same main tenance Carburettors fitted to early cars were equipped with TD needles while with later cars TE needles were used this needl
33. er as this is screwed in tightly by mechanical means It is important that in cleaning the components no petrol paraffin tri chlorethylene or mineral fluid of any kind should be used Clean with methylated spirits and allow to vapor ise leaving the component clean and dry After cleaning and examining lubricate the working surfaces of the bores and piston with clean genuine Girling Crimson Brake and Clutch Fluid Assembling Fit new rubber seals into the grooves of caliper cylinder bore Locate the rubber dust cover with the projecting lip into the groove provided which is the outer one of the cylinder bore Insert the piston closed end first into Rear Drum Brake Assembly the bore taking great care not to damage the polished surface Push the piston right home and then engage the outer lip of the rubber boot into the groove of piston The replacement of the lining segments as described under the heading Seg ment Replacement will retain the pistons in position Refit the caliper assembly to the sup port bracket by means of the two securing bolts ensuring that the disc passes between the two lining segments Re connect the pressure hose and bleed the brake as described under Bleed ing the System DISCS To ensure that the brake functions at maximum efficiency a check should be made to see that the disc runs truly between the segments The maximum run out permissible on the disc is 004
34. ers full GENERAL MAINTENANCE a Replenishment of Hydraulic Fluid for both Brake and Clutch Systems Inspect the reservoir at regular intervals and maintain at about threequarters full by the addition of Girling Crimson Brake and Clutch Fluid Great care should be exercised when adding brake fluid to prevent dirt or foreign matter entering the system Important Serious consequences may result from the use of incorrect fluids and on no account should any but Girling Crimson Brake and Clutch Fluid be used This fluid has been SEAL b DUST COVER PISTON STOP PISTON 0 6 D 0 PUSH ROD Clutch Slave Cylinder specially prepared and is unaffected by high temperatures or freezing Never top up the system with any other fluid Bleeding the Hydraulic System Bleeding is necessary any time a portion of the hydraulic system has been disconnected or if the level of the brake fluid has been allowed to fan so low that air has entered the master cylinder With all the hydraulic connections secure and the reservoir topped up with fluid remove the rubber cap from the L H rear bleed nipple and fit the bleed tube over the bleed nipple immersing the free end of the tube in a clean jar containing a little Girling Brake and Clutch Fluid Unscrew the bleed nipple about three quarters of a turn and then operate the brake pedal with slow full strokes until the fluid entering the jar is completely
35. ese must be replaced by new parts amp SHAKE PROOF WASHER Ls RETAINING PLATES LINING SEGMENTS DUST COVER SEALING RING ISTO j N END PLUG NN PLUG RETAINER GASKET Exploded arrangement of Disc Brake Caliper Assembly b In order to fit new segments the pistons in the caliper bore should be pushed to the bottom and the new segments placed into position When the seg ments are positioned correctly the retaining plates should be replaced in their original position and the setscrews tightened down The replacement of segments is then complete and bleeding is unnecessary but the foot pedal should be pumped until a solid resistance is felt Jack down the front of the car and road test Caliper Cylinder Maintenance To Replace the Rubber Seals In order to replace the rubber rings or seals it is necessary to remove the caliper assembly from the vehicle The brake segments should be re moved in the manner described above c Fig 3 BRAKES Instead of pushing the pistons to the bottom of the bore withdraw them from the caliper body taking great care not to damage the bores The sealing rings may then be removed by inserting a blunt tool under the seals and prising out taking care not to damage the locating grooves Ex amine the bores and pistons carefully for any signs of abrasion or scuffing No attempt should be made to remove the end plug retain
36. f the cylinder is protected by a rubber dust cover BRAKES b Dismantling Disconnect the pressure and feed pipe unions from the cylinder and remove the securing bolts and clevis pin from jaw end Pull back the rubber dust cover and remove the circlip with a pair of long nosed pliers The push rod and dished washer can then be re moved When the push rod has been removed the plunger with seal at tached will then be exposed Remove the plunger assembly complete The assembly can then be separated by lifting the thimble leaf over the shouldered end of the plunger Ease the pressure seal off the plunger and remove back seal Depress the plunger return spring allowing the valve stem to slide through the elongated hole of the thimble thus releasing tension of J Spring c Remove thimble spring and valve complete Detach the valve spacer taking care of the spacer spring washer which is located under the valve head Remove the seal from the valve head Examine all parts especially the seal for wear or distortion and replace with new parts where necessary Assembling Replace the valve seal so that the flat side is correctly seated on the valve head The spring washer should then be located with dome side against the underside of the valve head and held in position by the valve spacer the legs of which face towards the valve seal Replace the plunger return spring centrally on the spacer insert the thimble i
37. free of air bubbles Then during a down stroke of the brake pedal tighten the bleed screw sufficiently to seat remove bleed tube and replace the bleed nipple dust cap Under no circumstances must ex cessive force be used when tighten ing the bleed screw This process must now be repeated for each bleed screw at each of the three remaining brakes finishing at the BRAKES wheel nearest the master cylinder Always keep a careful check on the reservoir during bleeding since it is most important that a full level is maintained Should air reach the master cylinder from the reservoir the whole operation of bleeding must be repeated After bleeding top up the reservoir to its correct level of approximately three quarters full Never use fluid that has just been bled from a brake system for topping up the reservoir since this fluid may be to some extent aerated Great cleanliness is essential when dealing with any part of the hydraulic system and especially so where the brake fluid is concerned Dirty fluid must never be added to the system GENERAL ADVICE ON HYDRAULIC COMPONENTS The following precautions should be studied carefully and observed punctiliously by all concerned Essential Precautions Always Exercise extreme cleanliness when dealing with any part of the hydraulic system Never Handle rubber seals internal hydraulics parts with greasy hands or greasy rags Always Use Girling Crimson Brake an
38. fter fitting replacement shoes it is advisable to slacken one further click to allow for possible lining expansion reverting to normal adjustment afterwards BOOT RETAINING BAND RUBBER BOOT VALVE SPACER PLUNGER SEAL oppo PLUNGER N 2 SPRING THIMBLE yo 1 END SEAL Fig 5 INLET PORT PILAM D un TH ni e MASTER CYLINDER BODY VALVE SEAL VALVE STEM PS I o9 SPRING WASHER gt SPRING C V Girling Brake and Clutch Master Cylinder CLUTCH HYDRAULIC OPERATING MECHANISM 5 HYDRAULIC CLUTCH OPERATION A slave cylinder mounted on the side of the clutch housing is mechanically connected to the clutch operating mechanism This assembly by reason of its hydraulic con nection is actuated by a Girling C V master cylinder to which the suspended clutch pedal is coupled When pressure on the clutch pedal is applied the piston of the master cylinder displaces the fluid in the cylinder which in turn moves the piston of the slave cylinder pushing against the lever of the clutch thrust race 450 a The CV Master Cylinder For Brake and Clutch Fig 5 This is the Girling CV Type which consists of an alloy body with a polished finished bore The inner assembly is made up of the push rod dished washer circlip plunger and seal plunger seal spring thimble plunger return spring valve spacer spring washer valve stem and valve seal The open end o
39. g them to the end of each half moulding 7 9 REFIT REVEAL AND GRILLE a Slide the joint plates on to the ends of any one moulding MOULDING b Position five stud plates in the upper half of the beading and six in the lower half at intervals to align with the holes in the air intake periphery Attach the two halves of the reveal mouldings to the air intake with nuts and lock washers d NY Slide the joint plates from one mould ing to the other and position in such a manner that the joint is covered e Feed the grille in top side first and settle the extremities of the vertical struts adjacent to the reveal moulding already installed f Secure the grille by four self tapping screws one at each end of two of the horizontal bars TO REMOVE OR FIT WING BEAD ING This is effected by removing or fitting the front and rear wings as described on page 4 of the Body Section in the main portion of the Manual TO REMOVE PASSENGER SEAT SQUAB a Remove the cushion from the seat pan b Remove the two domed nuts at the base of the seat squab c Spring the squab from the seat pan ro TO FIT PASSENGER SEAT SQUAB a Position the seat squab on the seat pan studs and attach with the dome nuts b Fit the back of the seat cushion under the spring clip at the rear of the seat pan and settle cushion into position 435 NI 11 TO a b c d NA 436 BODY F
40. he body d Detach the five cappings from the elbow rail after removing the P K securing screws Remove the two wood blocks from the elbow rail Fig 2 e Remove the millboard from the front of the petrol tank after removing the P K securing screws Fig 2 REMOVE MILLBOARD HOOD WEBBING SECURING PLATE REMOVE WOOD BLOCKS THE BRIDGE PIECE _ HOLES IN THE ELBOW 5 RAIL ARE PRE ORILLED 7 ALL CARS AFTER TS 6824 Fig 2 Showing Cappings removed NOTE The P K screws securing the bottom of the millboard can be removed after lifting the rear of the carpet 438 i Fig 3a b c and d HARD TOP PREPARATION a Loosely assemble the three windscreen attachment brackets on the Hard Top front rail If not already fitted insert the three shorter angle brackets through slots in the stiffener rail at the rear of the Hard Top and a longer angle bracket at each side Using short flat headed screws and lockwashers secure the brackets in position Fig 4 NOTE It will be necessary to neatly cut the trim fabric to allow entry of the brackets into the slots the stiffener channel E WINDSCREEN ATTACHMENT BRACKETS TO FIT CAUTION To guard against the possi bility of damage to paintwork masking tape should be applied to that part of the body which will be in contact with the hard top during fitting operations a Position the hard top on the car and feed the
41. high performance modification has intake ports that are set high in the casting so that there is no water jacket space above them The first TR3 models with the high port head had a compression ratio of 8 5 1 The 1961 model was advertised at least in the United States as having a compression ratio of 9 0 1 the same as that of the 419 GENERAL DATA GENERAL DATA The information given in this section should be studied in conjunction with that given in the appropriate pages of the main Manual CAMSHAFT BEARINGS Vandervell shell bearings are fitted to the 2nd 3rd and rear journals CARBURETTORS Two S U Type H6 carburettors are fitted The early TR3 cars were fitted with carbu rettors having TD needles but this needle was changed to type early in normal production and was at Engine No TS 10037E superseded by type SM Where replace ment needles are required for carburettors fitted with the early needles both needles should be replaced by the SM needle PERFORMANCE DATA 95 B H P at 4 800 R P M TRANSMISSION Ratios O D Top Gearbox 82 1 00 Overall 3 03 3 7 O D 2nd 2nd Gearbox 164 2 00 Overall 6 07 7 4 Engine Speed at 10 m p h O D Top 410 R P M Top 500 O D 3rd 540 3rd 660 O D 2nd 820 2nd 1 000 Ist 1 680 Rev 2 130 Al O D 3rd 3rd 1 08 1 325 402 49 Ist Rev 3 38 4 28 12 5 15 8
42. ith spring washers After the joint is broken the front exhaust pipe is moved clear of the car TO FIT EXHAUST SYSTEM The fitting of the system is the reversal of the removal but the following points should be noted a It is suggested that work is started at the front as each component fits into the one in front b Each mounting should be left loose and finally tightened when the position of the silencer is set The front tube of the silencer assembly which passes through the cruciform centre will need setting to avoid the possibility of it vibrating against thecruciform centre The mountings can be tightened pro gressively from front to rear 416 5 6 c If the tail pipe incorporating the small silencer is being fitted it is attached in a similar manner to the pipe and uses the existing clips Fig 2 TO REMOVE MANIFOLDS a Remove the carburettors as described in the Fuel Section P b Disconnect the exhaust pipe at the flange by removing the three nuts and spring washers c Remove the eight nuts spring washers and six clamps Both manifolds together with the gaskets can be removed from the combustion head d The manifolds can be separated by removing the two nuts and spring washers situated below the carburettor mounting flanges TO FIT MANIFOLDS The fitting is the reversal of the removal but the following points should be noted a New gaskets should be used and so ensur
43. ively b All cables and fulcrums should be thoroughly greased before fitting c The bar assembly is attached to the e with a new felt seal and then turned back one turn This instruction also applies to the lever assembly when fitted to the bar assembly The handbrake is adjusted as described d on page 3 409 RI Service Instruction Manual EXHAUST SYSTEM 91 SECTION 5 411 412 EXHAUST SYSTEM Notation for Figure 1 s us uu uu Description Sl elus en ann Maintenance a 0220022 2 abc ou Exhaust System remove and dismantle 20 2 Notation for ous mw 2 ow Exhaust System Toft rn Manifolds To remove iiss Manifolds Toft ILLUSTRATIONS Fig 1 Exploded view of exhaust system mn Fig 2 Fitting the auxiliary silencer u a a Fig 3 Exploded view of manifolds a am EXHAUST SYSTEM Fig 1 1 Exhaust flange joint 2 Front exhaust pipe l 3 Prior to Commission No TS 4310 only Attachment bolt to chassis Flexible mounting strip Clamp plate Attachment nut Exhaust pipe clip Upper half Clamping bolt Attachment nut Rubber and metal grommet Clamp plate Attachment bolt Exhaust pipe clip Lower half Rubber washer Attachment bolt Lower half clip P Nut for clamp bolt Silencer Tail pipe assembly Tail pipe extension Flexible mounting strip Exhaust pipe su
44. luder on to the lever and secure to floor with plate and three self tapping screws The tape can now be removed from the thread and the bakelite grip screwed into position Lower the car and remove chocks from the wheels No readjustment of the handbrake should be necessary as the lengths of the cables have not been altered TO DISMANTLE HANDBRAKE ASSEMBLY a b c d Remove the bakelite grip and protect thread with tape Detach the attachment plate from the ratchet by removing the bolt and nyloc nut Remove the split pin and plain washer from the clevis pin applying pressure to the press button at the top of the hand withdraw clevis pin This will allow the ratchet to become disengaged from the pawl and enable it to be with drawn Releasing the pressure on the button and allow it to protrude through the lever casing under the influence of the spring Remove button from push rod followed by the spring and plain washer The push rod and pawl can now be withdrawn from the lower end of the lever and the pawl removed from the 407 Fig 9 v 00 10 VIB Wt BRAKES Lever assembly Lever pivot bush Handbrake lever grip Pawl stop mills pin Pawl release push rod Pawl release spring Plain washer between spring and lever Push rod button Pawl Clevis pin pawl to lever Split pin Plain washer between split pin and lever Ratchet Attachment plate
45. nto the spring and depress until the valve stem engages through the elongated hole of the thimble making sure the stem is correctly located in the centre of the thimble Check that the spring is still central on the spacer Refit new plunger seal on to the plunger with flat of seal seated against the face of plunger and a new back seal with lip of seal facing plunger seal Insert the reduced end of plunger into the thimble until the thimble leaf engages under the shoulder plunger Press home the thimble 6 Smear the assembly well with Girling brake and clutch fluid and insert the assembly into the bore of the cylinder valve end first easing the plunger seal lips in the bore Replace the push rod with the dished side of washer under the spherical head into the cylinder followed by the circlip which engages into groove machined m the cylinder body Replace the rubber dust cover refit the cylinder to the chassis and bleed the system THE CLUTCH SLAVE CYLINDER Fig 6 The slave cylinder is of simple construc tion consisting of alloy body piston with seal piston stop spring and bleed screw the open end of the cylinder being protected by a rubber dust cover The cylinder is mounted to the clutch housing by a flange and two bolts a Dismantling Remove the rubber dust cap from the bleed nipple attach a bleed tube open the bleed screw threequarters of a turn and pump the clutch pedal until all the fluid has been
46. nuts Hub Extension LH Part No 202447 R H Part No 202446 Knock off Wheel Nut L H Part No 107949 Fi Reducing length of stud ble wi R H Part No 107948 75 wheels to be fitted 00870 wire NOTATION FOR EXPLODED ARRANGEMENT OF REAR AXLE Fig 13 Ref Description 2 Description Description Axle casing assembly Crown wheel securing bolt Fibre washer for 34 Bearing cap setscrew Plain washer for 18 Axle half shaft Spring washer Three hole lockplate for 18 Rear hub bearing Axle case breather Two hole lockplate for 18 Hub bearing housing Fibre washer Pinion head bearing Oil seal for hub bearing housing Drain plug Adjusting shims for 22 Adjusting shims for hub bearing Differential bearing Bearing spacer Lockplate Adjusting shims for 7 Pinion tail bearing Setscrew for securing housing Differential casing Adjusting shims for 25 Hub Differential sun gear Pinion shaft seal Road wheel attachment stud Thrust washer for 10 Pinion driving flange Hub driving key Differential planet gear Driving flange securing nut Hub securing nut Thrust washer for 12 Plain washer for 29 Plain washer for 46 Cross pin Split pin for 29 Split pin for 46 Thrust block Rear cover Cover plate securing screw Lock pin for securing 14 Joint washer for 32 Spring washer for 49 Crown wheel and pinion Oil filler plug Axle tube oil seal 00 30
47. ounted in the cup filler is loaded upon the inner piston by a spring When operated hydraulically the inner piston abuts against the outer piston leaving the handbrake lever undis turbed and applies a thrust to the tip of the leading shoe through the dust cover micram adjuster and mask When operated manually an inward movement of the hand brake lever brings the head of the contact lever into contact with the outer piston thrusting it outwards against the leading shoe without disturbing the inner piston A rubber boot is fitted to exclude water and foreign matter 1 Rear brake plate 2 Abutment assembly 3 Abutment attachment nut 4 Lock washer 5 Wheel cylinder body 6 Spring in body 7 Cup filler 8 Cup 9 Hydraulic piston 10 Handbrake piston assembly 11 Handbrake lever 12 Handbrake lever pivot pin 13 Rubber boot 14 Banjo connection 15 Small copper gasket 16 Banjo bolt 17 Large copper gasket 18 Bleed nipple 19 Brake shoe assembly 20 Micram adjuster 21 Micram adjuster mask 22 Tension spring 23 Brake shoes pull off spring 24 Rear brake drum 13 403 29 30 BRAKES REMOVE REAR WHEEL CYLINDER a Jack up rear of car Remove nave plate road wheel and brake drum Slacken off micram adjuster Drain oft hydraulic fluid disconnect handbrake cables and remove banjo bolt from banjo connection which is situated on the inner
48. ove the bakelite handle grip and tape the thread for protection Withdraw the three self tapping screws securing the draught excluder plate to floor Remove plate and draw excluder up the handbrake ever Working under the car withdraw the clevis pin from the front fork end of the handbrake cable after first remov ing split pin and washer Release the tabs of the locking plate and withdraw two bolts securing attachment plate Remove the nyloc nut locking pivot bolt to chassis frame Withdraw pivot bolt The handbrake lever can be drawn downward through the floor TO FIT HANDBRAKE LEVER a b c Feed the pivot bolt through first the d assembly and then the mounting plate Working beneath the car feed the lever through the floor assembly and attach lever to chassis by the pivot bolt which is left loose at this juncture Utilising two bolts and a locking plate secure the lever mounting plate to the chassis frame and lock bolts with tabs of locking plate 17 42 d e f g h Tighten the pivot bolt leaving the lever freedom of movement and attach the locking nut to the pivot bolt from inside the cruciform When tightening this nut the head of the pivot bolt must be held to ensure the freedom of movement of the lever Attach the fork end of the cable to the brake lever and secure with clevis pin split pin and plain washer Working inside the car feed the draught exc
49. oviding this document so that others like myself can have a copy of this most valuable book to use in their shop or to keep in their boot and thus preserve their origi nal for some time to come suspect that the publishers of this book might not be terribly happy about the project l ve completed but since they ve had the book out of print for nearly a quarter century don t think I m cutting in to their profits in any way am not realizing any sort of prof it on this myself Nevertheless make the following dis claimer you should really only be using this electronic copy as a backup to a legitimately owned printed copy if you use this electronic copy and don t own the real book you assume all responsibility for any copyright violation which may have occurred That having been said hope that this document pro vides a valuable service to the Triumph community and that you find it useful and helpful in the restoration and care of your own Triumph automobile also hope to con tinue this type of operation with other books and docu ments though my free time is at a premium right now whose isn t And now for some notes on the use of this particular file have not yet gone to the trouble of performing OCR optical character recognition on the book that s more time intensive and indeed computer intensive than can deal with right now The proof reading alone would kill me and why and it would have to proof
50. ow rail channel Fig 4 ANGLE BRACKETS INSERTED INTO STIFFENER RAIL Fig 4 Drilling the Elbow Rail and installing Bridge Pieces NOTE Drilling should only be necessary on Cars prior to TS 6824 c Mark the position of the bridge pieces on the elbow rail and identify them to these positions Release the Hard Top at the windscreen and remove from the car d Using a No 11 drill drill ten holes through the markings on the elbow rail e Remove the bridge pieces from the Hard Top and secureto the elbow rail channel using flat headed screws which screw into tapping plates fed position under the channel Fig 4 REAR CAPPINGS TO FIT a Opposite to the centre of each bridge piece scribe a line with a pencil on the body protection tape Attach the cappings to the body loosely securing with the P K screws Fig 1 b Over the cappings extend the markings previously scribed on the body Re move the cappings from the car Scribe the inside of the cappings exactly in line with the marks on the outside Fig 1 Using a 3 drill drill the cappings at the positions marked on the insides and ensure that when drilled the holes are aligned with those in the bridge pieces d Attach the millboard to the front of the petrol tank and secure with P K screws Refit the cappings over the bridge pieces and secure e Select the three narrow protection caps and position these on the
51. pport bracket Attachment bolt to chassis A B C D E H J K L M N Clamp plate Attachment nut Clamp bolt Attachment nut Attachment bolt to chassis frame Rubber and steel grommet Rubber and steel grommet Attachment nut Clamp nut Clamp plate Attachment bolt Support bracket Pipe clip Pinch bolt Nut for pinch bolt Flexible mounting strip Pinch bolt Attachment nut SI Clamp plate Attachment bolt to chassis Pipe clip attachment bolt Nut for pinch bolt Clamp plate Clip attachment nut 413 EXHAUST SYSTEM EXHAUST SYSTEM DESCRIPTION The manifolds are attached to one another by studs in the aluminium alloy induction manifold and lugs moulded in the cast iron exhaust manifold There is hot spot for easy starting The exhaust system is situated on the right hand side of the engine and passes down to the rear of the car through the centre of the cruciform to a position adjacent to the left hand chassis member The front exhaust pipe is attached to the engine by a flange and 1s flexibly mounted to the chassis frame at a point forward of the cruciform centre This attachment also secures the pipe to the outside of the silencer Cars with Commission No TS 4310 and before has this clip in two halves as shown in Fig 1 Two types of silencers have been used in production the former 18 silencer being changed for a 24 type at Commission No TS
52. read imagine if the software screwed up a torque settings chart for example Right now each and every page except for this one is a large black and white graphic You should be able to print this to just about any sort of printer but you will get the best results on a PostScript capable laser printer that operates at 600 dpi dots per inch or better The printing will be slow however as each page is a rela tively good size about 3 7 MB found that a 600 dpi B amp W scan gave me outstanding results when copying the text and illustrations and also reproduced the photo graphs acceptably well This would not be the case with many documents but given the very high contrast of the pictures in the original manual and the relatively coarse line screen it worked out rather well If you re interested in the details of the production of this file used a G3 upgraded PowerMacintosh 8500 comput er an Agfa SnapScan 1212U scanner a relatively cheap model but of acceptable quality Agfa s own FotoLook scanning software Adobe Photoshop 5 5 for some quick and dirty image retouching and Adobe Acrobat 4 0 to con vert the pages from EPS to PDF Finally because each and every page was a separate document used AppleScript a programming language included with the Macintosh operating system to combine all 455 pages into a single document Each scanned page was 3 7 MB in size and all of the pages together weighed in at over 1
53. rectly coupled to a CV master cylinder in which the hydraulic pressure is originated A supply tank which provides fluid reserve for both brake and clutch systems is installed to allow for fluid replenishment n independent mechanical linkage see Fig 6 actuated by a hand lever control operates the rear brakes by levers attached to the wheel cylinder bodies thus acting as a hand or parking brake 2 FRONT BRAKES Fig 1 Fig 2 Front Disc Brakes Assembly The front brakes are the 11 dia Girling which is made from high quality cast iron Disc Brakes which are extremely simple and cast iron calipers mounted to a support in construction consisting of the 11 disc bracket 445 DUST COVER Fig 2 Due the BRAKES SET BOLTS to the simplicity of these disc brakes only normal servicing which will be carried out by the owner or garage will be the replacement of worn lining segments seals a 446 and boots of the hydraulic caliper Lining Segment Replacement Fig 2 Jack up the front of car and remove road wheels On the top of the caliper body are two setscrews which secure the segment retaining plates The release of these will enable the retaining plates to be raised out of engagement with the casting and swung through an arc of 180 The segments are then fully exposed and can be lifted out of the caliper Under no circumstances should at tempts be made to reline worn segments and th
54. rmance High Port type combustion heads where in corporated in production at Engine No TS 9350E In countries where high octane fuel is unobtainable the compression ratio may be lowered to 7 5 1 by the use of a compression plate Part No 200906 This plate must be used in conjunction with a steel Corrojoint gasket Part No 202775 in addition to the normal gasket When using this low compression plate it will also be necessary to use Champion L 10 sparking plugs gapped to 0 025 and special push rods Part No 114048 423 5 ENGINE ENGINE OIL FILTER In order to give the maximum protection to the engine when subjected to high speed or rally conditions a new filter of the full flow type has been introduced on the TR3 models This type of filter ensures that all the oil in circulation passes through the filtration system The full flow type of filter was intro duced into normal manufacture at Engine No TS 12650E part numbers affected by this change being as follows Oil filter assembly Part No 301994 is replaced by Part No 203271 The replacement Element Part No 101963 remains the same for both types of filter The oil pressure on the full flow type of filter remains at 70 Ibs per sq in with an oil temperature of 70 C at an engine speed of 2 000 r p m The new filter assembly can be fitted if desired to an engine prior to TS 12650E SUMP A special cast al
55. roceed as shown in Fig 8 Oil seal renewal is recommended in all cases of axle overhaul v Replace the original shim pack over the spigoted portion of the axle sleeve followed by the brake backing plate vi Again exercising care in the case of the inner oil seal thread the assembled axle shaft through the seal and into the axle casing After locating the shaft splines in those of the sun wheel secure the bearing housing by inserting and tightening six setscrews with lock plates Checking axle shaft end float Axle Shaft End Float The specified axle shaft end float is 0 004 0 006 0 102 0 152 mm This can be checked by mounting a dial indicator on the backing plate as shown in Fig 9 then moving the hub Fig ro Showing position of differential cross pin in relation to thrust block towards and away from the axle casing The dial indicator will then record the axle shaft end float Adjustment is effected by adding to or subtracting from the shim pack interposed between the axle sleeve flange and the brake backing plate thus increasing or decreasing respec tively the axle shaft end float Important addition to the exis tence of the specified end float it is important that the thrust block which separates the inner ex tremities of the two axle shafts should have a clearance on the cross pin as shown in Fig 10 To ensure centralization of the thrust block with the cross pin the shim pa
56. sequently removed iv Extract the bearing outer ring from the housing as shown in Fig 4 after first tapping out the oil seal which should be renewed during re assembly v Withdraw the axle shaft and inner bearing ring After first removing the driving key the bearing inner ring is then removed by using the extractor as shown in Fig 5 b Inspection Inspect bearing for looseness and roughness the axle shaft for cracks and worn splines the hub for loose wheel studs and worn keyway Re place all parts which are excessively worn or defective in any way Note When inspecting rear axle hub Fig 8 Fitting oil seal into axle sleeve bearings apply as much load as pos sible by hand as this enables noise and roughness to be more readily detected ii Draw the bearing outer ring into the housing by using the same tool c To Re assemble as shown in Fig 4 and install a Continue as follows new oil seal Fig 7 i Using a special tool drive the hub iii Exercising care to avoid damage bearing inner ring on to the axle to the fabric face of the seal shaft as shown in Fig 6 and thread the assembled bearing refit key housing on to the shaft and refit 428 Fig 9 REAR AXLE hub plain washer and castellated nut tightening this to a torque of 125 145 Ibs ft 17 29 19 71 kg metres and securing it with a split pin iv Examine the inner oil seal and if a replacement is necessary p
57. ssible precautions should be taken to ensure that these do not turn and so misalign the holes Ensure also that the locating hole in each bearing is centrally disposed in the tapped hole which accommodates the locating screw Failure to observe this instruction may result in the bearing becoming distorted when the locating screw is tightened Fit a plain steel washer of 7 thickness 1 588 mm between the head of each locating screw and the cylinder block Refit or replace the camshaft sealing disc if necessary ALUMINIUM PEDESTALS ROCKER SHAFT New rocker pedestal brackets of aluminium alloy were incorporated in normal produc tion at Engine No TS 12564E The new metal by reason of its higher degree of expansion when hot enables the same rocker clearances to be used for exhaust valves as were previously applied only to the inlets This reduction in the exhaust valve clearances has the advantage of reducing tappet noise when the engine is cold without any sacrifice of performance Where it is desired to fit the new pedestal brackets these should be fitted as a complete set the part numbers being as follows Aluminium Pedestal Bracket Plain 3 off Part No 112546 Aluminium Pedestal Bracket Drilled 1 off Part No 112545 FOR PISTONS From Engine No TS 9731E the pistons are fitted with Plain ring 1 Taper ring Oil scraper ring COMBUSTION HEAD To further improve perfo
58. ston rubber seal over the handbrake piston and place with dust cover cylinder body ensuring that the hand lever is engaged in the slot of the piston The seal is to be twisted on its side so that the edge which tends to protrude from the groove enters the bore last TO REMOVE HYDRAULIC PIPE LINE FROM REAR AXLE a Remove rear flexible hose as described on page 6 b Disconnect the Bundy tubing at the brake plate by withdrawing union nut from banjo connection at each side Repeat operation b at three way connection Remove Bundy tubing from axle by releasing pipe clips at each side The three way connection can be removed after withdrawing bolt and lock washer TO FIT HYDRAULIC PIPE LINE TO REAR AXLE The fiting of the Bundy tubing is the reversal of the removal but the following points should be noted a The olives of the Bundy tubing should be correctly seated before securing the union nut The pipe clips should be attached in such a manner that the pipe is in no way squeezed or damaged The flexible hose is fitted as described on page 6 The connections should be inspected for leaks by applying firm pressure to the foot pedal FITTING REPLACEMENT BRAKE SHOES a Jack up car and remove wheels brake drums and slacken off all adjustment of micram adjusters d NY c d e b c d Insert hydraulic piston into body 15 36 37 b Remove brake shoes and collec
59. t pull off springs and adjusters c Fit the replacement shoes and new pull off springs after ascertaining that the brake linings are of the same material see page 2 d Fit brake drum and adjust brakes as described in page 3 TO a REMOVE PEDAL ASSEMBLY Working under the bonnet drain both hydraulic systems and remove clevis pins from piston rods of twin master cylinder and disconnect pipe lines from rear of master cylinder Remove four nuts and lock washers from front end of master cylinder support bracket adjacent to pedal push rods From inside the car withdraw the two bolts and lock washers securin the side flanges of the pedal shaft casing to the bulkhead Remove the two bolts and lock washers from the front and rear flange of the shaft casing and remove pedal assembly from bulkhead The support bracket with master cylinder attached can also be removed from top of bulkhead An alternative method of pedal assembly removal is to omit the drain ing of the hydraulic system and the disconnection of the pipe lines mentioned in operation a leaving the master cylinder and support bracket in position b 4 FIT PEDAL ASSEMBLY a Working inside the car secure the pedal assembly to the bulkhead utilising two bolts and lock washers and the front and rear mounting flanges Position the support bracket and master cylinder on the four studs protruding through the bulkhead shelf in
60. tenance of close body tolerances A further cause of a badly fitting Hard may be the result of bent screen pillars which have become displaced by heavy drivers or passengers pulling on the windscreen to remove themselves from the car When fitting the Hard Top must be initially positioned from the screen it should be appre ciated therefore that any misplacement of the screen itself will move the Hard Top out of position at the rear of the car No difficulty should be experienced with cars in normal condition after Commision Number TS 6824 x CAR PREPARATION To prepare the car for the installation of a Hard prepare as follows a Starting at the screen rail remove the hood by lifting the fasteners from around the edge of the body b NA Release the hood webbing at the rear by removing the two flat headed screws and the two hood fastener screws Fig 1 437 BODY 2 WINDSCREEN TOP RAIL WINDSCREEN ATTACHMENT BRACKET PROTECTION PLATE PENCIL MARK TRANSFERED Pe SECURING TO CAPPING N SCREW BRIDGE PIECE x GEBBINES PENCIL MARK RN OPPOSITE CENTRE OF BRIDGE PIECE SS gt N NS lt N lt 3 REMOVE HOOD WEBBING BY REMOVING 2 FLAT HEADED SCREWS AND 2 HOOD FASTENER SCREWS Fig 1 Marking and fitting Rear Cappings Unscrew and remove the four counter sunk screws securing the hood frame to the body and then lift the frame out of t
61. the General Data given in this Supplement list the power as 95 B H P at 4 800 R P M which is the British rating On TR3 cars with overdrive the overdrive can be engaged on the top three gears whereas on the TR2 overdrive is available on top gear only The 1957 TR3 is the earliest model equipped with the disc front brakes the separate brake and clutch master cylinders and the tapered roller bearing rear axle that are described in this Supplement Also introduced on the 1957 models was an optional 4 1 1 ring and pinion gearset for cars equipped with overdrive Road speed and ratio data for cars with the 4 1 1 rear axle can be found in Part 1 of this Manual The 1958 TR3 is the first model commonly referred to as a TR3A or TR3B The only significant differences between this model and the 1957 model are a wider grille external door handles reinforced bumper overriders and redesigned bucket seats The TR3A and TR3B are not different models they are simply different people s designations for wide grille TR3 cars Only one important change was made to the TR3 between 1959 and 1961 During the last several months of manufacture the 1991 cc TR3 engine was fitted with the high port cylinder head that was continued on the subse quent 2138 cc TR4 The TR4 was also available on special order with a 1991 cc engine that had the high port head This cylinder head which offers superior opportunities for
62. uminium sump Part No 301318 and tray Part No 201984 are available as optional extras 424 Fig 2 Oil cleaner full flow type CLUTCH CLUTCH DRIVEN PLATE ASSEMBLY An improved clutch driven plate incorpor ating a Belleville washer friction centre was ed after Engine No TS 7830E TR2 The new driven plate can be recognised by four small tongues or tabs protruding through the spring retaining plates adjacent to the longer side of the splined hub and by the colour of the six cushioning springs white and light green HYDRAULIC OPERATING MECHANISM This is described under Girling Brakes and Hydraulic Clutch in the Brake supplement 425 D d RES SU if FST sal SIS SS Fig 1 Rear axle section inserts indicate axle arrangement for cars up to Commission No T S 1300 426 I REAR AXLE GENERAL A new rear axle assembly Part No 302177 bearing the Serial No 13511 was intro duced at Commission No 13046 and fitted on all subsequent cars xd The major differences incorporated in the new axle include new half shaft and hub assemblies a thrust button mounted on the differential cross pin and adjustable taper roller hub bearings as shown in Fig 1 The sectioned insert views indicate the axle arrangement for cars prior to this change Fig 2 Rear hub lubricator 2 LUBRICATION OF REAR

Triumph TR2, TR3, TR3A factory service manual

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