Section A - ENGINE - PETROL MODELS

INDEX

Camshaft

Page

Removal Fitment Camshaft bearings Removal Firment Camshaft chain wheel Removal Fitment Connecting rod Removal Fitment Connecting rod bearings Removal Firment Crankshaft Removal Fitment Crankshaft bearings Removal Fitment Crankshaft chain wheel Removal Fitment .... Cylinder head Removal Fitment Data ....

A-4 A-5 A-4 A-5 ..... A-IO A-4 A-6 A-4 A-6 A-4 A-5 A-4 A-S
A-lO A-3

Ignition timing

Page

Liner fitrnent ..
Oil fil ter=-exrernal Removal Firment Pistons and piston rings Removal Firment Push-rod Removal Fitment Reboring Rocker gear, exhaust Removal Fitment Rocker gear, inlet Removal Fitment Tappet adjustment Timing chain Removal-e-engine removed Fitment--engine removed Renewal-engine installed Timing chain tensioner Removal Fitment Valves Removal Fitment Valn guides Removal Fitment Valve timing Vibration damper

A-12 A-7 A-14 A-J4 A-4 A-6 A·3 A-9 A-7 A-4 A-9 A-3
A-9

A-IO A-3 A-lO A-14 A-3 A·lO A-4 A-9 A-S and 9 A-B and 9
A-tO .... A·1l

A-3 A-3 A-9

Decarbonising

Defect location Engine removal from chassis Engine dismantling procedure Engine assembly procedure Fan belt adjustment Flywheel Gudgeon pins Removal Fitment

A-I3 A-I5 A-2 A-2 A-5 A-12 A-4 and 8 A-4 A-7

A-16.

.

LIST Fig.

OF Page

ILLUSTRATIONS Fig. Page

A·I A-2 A-3 A-4 A-5 A-6 A-7 A-a A-9 A-IO A·ll A-12 A-I3 A-14

Oil pressure relief valve Timing chain and tensioner Clip for timing chain teasiener Removing camshaft chainwheel ... Exhaust rocker shafts and distributor housing location bolts .... Camshaft bearing location bolts Removing gudgeon pin Checking main bearing Checking crankshaft end- oat Guide in position on cylinder block (oil seals) Checking big-end bearing nip Checking piston clearance .... Checking piston ring gap Fitting gudgeon pin

,

A·2 A·3 A-3 A-3
A-4

niN.

A-4 A-4 A-5 A-5 A-5 A-6 A-6 A-7 A-7

A-I5 A-16 A-17 A-IS A-19 A-ZO A-21 A-22 A-23 A-24 A-25 A-26 A-27 A-28 A-29

Reboting, jig block Fitting cylinder liner Checking flywheel run-out Fitting exhaust valve guide Removing exhaust valve seat Fitting exhaust valve seat .... Early and late type valve seals Drilling oil feed holes, inlet rockers ..-. Tightening cylinder head bolts .... Tappet adjustment .... Exhaust valve fully open position Timing chain and te.nsioner Checking vibration damper run-out Balancing vibration damper Oil pressure relief valve A-30 Order of tightening cylinder head bolts

A-7 A-7 A-8 A-8 A-8 A-9 A-9 A-lO A-lO A-lO A-U A-ll A-ll A-13
19

A-8 A-9

A-2 ENGINE REMOVAL PROCEDURE Removing eDgine

ENGINE-PETROL AND DISMANTLING Operation

MODELS that the speedometer cable and all wires, etc., are clear, then hoist tho engine gendy from the vehicle. 21. Drain the oil from sump. 22. Bolt the engine to a suitable stand. DISMANTLING ENGINE

AI"

1. If fitted, remove the spare wheel from bonnet

panel.

2. Remove the bonnet panel. 3. Disconnect the battery leads. 4. Disc:onnect the air intake pipe from the carburetter and remove air cleaner. 5. Drain the coolant from system (oDe tap at bottom L.H. side of radiator and one tap at L.H. side of cylinder block). 6. Disconnect the side lamp leads at snap connectors at each side of the grille panel assembly and the froDt lamp harness from the junction box at R.H. side of scuttle, then pull the wiring clear to &oat of engine. 7.

Detach the top hose at radiator header tank and
the bottom hose from water pump inlet.

8•. Remove the fan blades .. 9. Remove the bolts securing the grille panel to the front cross member and front wings. 10. Lift the radiator. grille ~ and headlamps assembly upward. then forward to clear the vehicle. II. Discottnect

Externals Operation A/4 1. Disconnect the accelerator linkage <at a ball joint), distributor vacuum pipe and remove carburetter. Detach sparking plug covers and leads, remove locating screw and withdraw the distributor. Remove sparking plugs. 2. If fitted, disconnect the heater pipe and flow control tap from cylinder head. 3. Remove the exhaust rocker cover. 4. Remove the dynamo and starter motor. 5. Remove the exhaust and inlet manifolds. 6. Remove the external full flow oil filter complete. 7. Disconnect the oil feed pipe-gallery to cylinder head. 8. Remove the dipstick and tube. then drain and remove sump. Oil _pump Ope-ratioD A/6 1. SJackeu the locknut securing oil pressure adjusting screw. then remove screw, washer, spring, plunger and ball (which may remain in the pump and can be removed when the pump complete is withdrawn). 2. Remove the pump locating screw. 3. Withdraw the pumP. leaving the drive shaft in position. 4. If necessary, withdraw the oil pump drive shaft. Operation AIlS. Note: See Section AO for details of oil pump strip and assembly.

manifold.

the

cmaust

pipe from. exhaust

v

12. DiscODnect the beater pjpes (if fitted) at the mgin.e side of scuttle.

13. DiscoDDtct the petrOl pipe at carburetter. 14. Disconnect the throttIc return spring, throttle Iiukage (at a ball joint) and the cold start control cable at carburetter and clamp. If fitted, discoimeCt the engine governor operating rod. Section T.

15. Disconnect:

from switch ; oil pressure switch wire; miDure
control switch wire (at rear of cylinder bead).

Dynamo wiring;

ignition coi1leads;

starter lead

16. Secure a sling to the engine and with suitable lifting tackle just tab du: strain. 17. Remove the front floor and gurbox cover.

18. Support the gearbox assembly with a
packing blocks.

jack

or Fia'.
A-l--Oil pre ... ", relief valve

19.

Remove the rem@ning natll and washers securing the gearbox to the flywheel housing.

20 'RemoVe the bolts from engine frout support

bracha and allow the engine to move forward aDd thUi clear the gearbcD:input abaft. Busure

A-LocImut B-Loc:atiDg screw--oil pump C-BaU
D-,Plunpr

B-Spriq
F-Washer G-Lcx:b.ut
H-AdjUlfiq aemr-oil

~

20

ENGINE-PETROL
Vibration damper Operation AIS L Remove the starter dog, using spanner Part No 263055 or 530102. 2. Withdraw the vibration damper complete. 3. Remove the plate, shims (if fitted), rubber disc, driving flange and second disc from the damper flywheeL Six set screws. 4. If necessary, remove the flywheel bush.

MODELS

A-3

Fig, A·3--Clip for timing chain tensioner

Water pump and front cover Operation A/IO 1. Remove the thermostat housing from the cylinder head complete with thermostat, outlet pipe, inlet elbow and joint washer. 2. Remove the copper tube and rubber joint ring from either the bottom face of the thermostat housing or the top face of the water pump casing. 3. Remove the water pump complete with joint washer and inlet pipe; as the pump casing is splgoted in the block, it will be necessary to oscillate it slightly as it is removed. To strip water pump completely for overhauling purposes, refer to Section L. 4. Remove the front cover. securing bolts and remove the

666a

3. Remove the jockey pulley; remove the driving chain. 4. Withdraw the jockey pulley arm and tensioner, 5. Carefully remove the special clip and part the: tensioner spring, piston, cylinder and, if necessary I extract the ball and the two retaining springs from the cylinder. 6. If necessary, extract the pawl pivot pin (5/16 in. 8.~.F. tapped hole); remove the pawl and pawl sprmg. 7. Remove the camshaft chainwheel, using extractor, Part No. 262750, or Part No. 507231.

Timing chain
-

tensioner and chain wheels
Operation

A/12

1. Remove the crankshaft oil thrower. 2. Release the pawl from the ratchet, compress the tensioner spring by lifting the jockey pulley arm as far as possible, and fit clip, Part No. 26274B, over the tensioner,

Fig. A-4-Removing

camshaft chainwheel

B. If necessary, remove: the crankshaft chainwheel,
using a claw extractor. 9. Wash and dry all rensioner renew any worn part. Cylinder components and

Operation AJI4 1. Remove the inlet rocker cover.

head and inlet rocker gear

Fig. A-2-Timing chain and tcnsioner
A~Camshaft chainwheel B-Crank:lbaft chainwheel C-Jockq< pulley D-Hydraulic tensioner E-Pawl F-Ralchel G-- Timing chain (driving side) H-Jockey pulley arm

2. Remove the rocker shaft complete with all components. Note: The 3':8 in. (spanner size) nuts have 7/16 in. threads. 3. Remove 'the components and layout in the folIowing order: Rear bracket (located hy set screws); spring; R.H. rocker: bracket; L.H. rocker; two brackets: spring; R.H. rocker; bracket; L.H. rocker; spring; front bracket. 4. Withdraw the push rods and insert them in a piece of cardboard pre-pierced and marked. 5. Loosen the securing bolts evenly and lift the cylinder head dear, 21

The bearing halves must ·be preserved in pairs. washer. 4. A-6-Camshaft bearing location bolts A-Location bolts 4. Pistons and connecting rods Operation Aj24 I. Note: Mark all components in sets. Remove the camshaft and front bearing. 2. remove the piston. 4.H. remove the valve assemblies. 278668. Remove the flywheel housing. Withdraw the rear shaft using extractor. Remove the location bolts i two for the rocker shafts and a hollow bolt for the distributor housing. Withdraw the distributor housing. Part No. 3. bearings and bolts. then the flywheel securing bolts and withdraw the flywheel. Part No. The valves should be inserted in a piece of cardboard pre-pierced and marked. Remove the rear bearing. Remove the camshaft thrust plate. Same order applies to both rocker shafts. Using a valve spring compressmg tool. Lift out the crankshaft and remaining bearing halves. Split the front bearing and remove. main bearing and rear bearing oil seal Operation' Aj26 1. Ensure that the thrust washers are retained in original housings if used 'again. Remove the connecting rod caps. 2. washer. spring. Part No. Camshaft bearing removal Operation Aj20 1. 2. Repeat for the front shaft. Exhaust valves Operation AI16 1. 262749. and camshaft Fig. 2. Push each connecting rod up and turn. remove the bolt and lock washer from the rear bearing. they are selected to ensure an interference fit. 2. The lower half of the rear main oil seal may be removed complete with rear main bearing cap. Remove the bolt and lock washers locating each of the three front bearings.H. L. If necessary. Exhaust rocker shafts and distributor housing Operation A/IS 1. Lower each connecting rod. Remove the main bearing caps and shells. and remove oil pump drive shaft. Fig.A-4 ENGINE-PETROL MODELS 6. in order to engage the slots at the bottom of the cylinder bore. 3. Layout the components in order s-« Spring. preserve all bearings in their respective pairs. The valves should be inserted in a piece of cardboard pre-pierced and marked. cam follower. Remove the plug and fibre washer from the flywheel end of the cylinder block. The primary pinion bush may be extracted if necessary. A-1-Removing gudgeon pin 3. Remove the dutch assembly. Slacken the tappet adjusting screws right back. Part No. rocker. Remove the circlips: withdraw the gudgeon pin. Set each rocker on the back of its cam. 276102. and using a valve spring compressing tool. they are selected to ensure an interference fit. 3. housing A-Distributor B-Exhaust housing location bolt. Remove the rear camshaft cover. Retain the springs in pairs. Withdraw the camshaft until the third bearing is clear of No. R. A-5-Exhaust rocker shaft and distributor location bolts rocker shaft location bolts. Retain the springs in pairs. Remove the piston rings. using extractor.H. turning the crankshaft as necessary to effect withdrawal. rocker. Crankshaft. Fig. 276102. split the bearings and lay aside. 5. 2 bearing housing. Flywheel Operation A/22 1. remove the valve assemblies. 22 . R.

07 mm): to ensure that the crankshaft remains centralised. bottom half shells and crankshaft 7.006 in.002 to .8-Checking main bearing nip 2. first assemble the caps without bearing shells to the crankcase. main bearing and seals Operation A/30 1. these are available in slightly varying· thicknesses.07 mm) to . Tighten both securing bolts for each cap. obtained in Item 5.. A-9-Checking crankshaft end-float 6.Guide in pO~'''''': "I': . A-IO. make sure that they can be dismantled and assembled without difficulty. and push the shaft into position. The camshaft should have .~ Fig.05 to 0. (0. . Remove the bearing caps and fit the bearing shells. is placed between anyone bearing shell and crankshaft journal. 8. as illustrated in Fig. 2. Tighten the caps down and slacken off one bolt of each pair.006 in. (0. Adjust by selective assembly of bearing shells. and on the rear face fit the lower half of crankshaft rear bearing seal. A-9).004 to . Checking bearing clearance on camshaft./' / //. and before replacing the set bolts.Clck 23 . 4.to 0./. 3. (O. A-8. Fig.12 mm) end-float.06 mm) thick. When the bearing nip has been check ed. Position a standard-size thrust bearing at each side of centre bearing shell-top half.003 in. The nip can be corrected by selective assembly of bearing shells. MODELS A·S 3. =rJinde. 5. Check the crankshaft end-float with a feeler gauge (Fig. The variation. of thrust bearing thickness at each side must not exceed . they must always be renewed in paired halves and the numbers stamped on one of the end faces of each of the bearing halves must be adjacent. squirt oil down the holes to lubricate the bearings until oil pressure is built up. To check that the bearing caps have not been filed. Check the bearing Rip.ENGINE-PETROL ENGINE ASSEMBLY Operation A/28 Camshaft Note: The bearings must be fitted dry and must be a hand push fit in the cylinder blocks. if new bearings are fitted. A.15 mm). There should be no clearance at the joint face. Insect the camshaft partly into the cylinder block. fit suitable oversize thrust bearings. adjust at centre bearing by selective assembly of thrust washers to give . assemble the bearings on to the shaft with the locating holes in line with the holes in the housing. Remove [he bearing caps. A 6. If the crankshaft end-float reading. ensuring that they are correctly located by means of the dowels. and fit the crankshaft. Lubricate bearing face with Silicone MS4 Compound. The rear bearing is provided with four lateral holes. (0. Tighten the securing bolts evenly and check each bearing in turn for correct clearance. See Fig.0025 in. " . Replace set bolts. (0. ensuring that the clearance does not exceed . Refit the bearing shell bottom halves and bearing caps. 1. Crankshaft. The crankshaft should resist rotation when a feeler paper. Fit the camshaft thrust plate and chain wheel. measured between the chain wheel and the thrust plate. e. locatiug by means of the tags. Fig. (O.15 mm) end-float. Fit the top half of crankshaft rear bearing oil seal to the crankcase. was not within the limits... remove the caps and bearing shell bottom halves. ).005 in. and turn freely by hand when the feeler paper is removed. then slacken one bolt of each pair right off. 4.10. 9. Line up the locating holes in the bearings and housings.003 in. To the rear main bearing cap fit neoprene seals in recess at each side.

(0. When fitting pistons. To check thai the connecting roo has not been 'filed:~ . Pistons Operation A/l4 1.A-6 ENGINE-PETROL Lubricate the cra!lkshaftjournaJs. The gudgeon pin. then check for correct end-float.05 to 0." on one face. to a suitable test rig and check for twist and mal-alignment.e. when cold and dry. re-check that the It will be foundadvantageous to cut a slight lead bottom edges of the side seals. \ 2. Fig. A-12-Checking piston clearance !!G19. Stepped scraper rings. will be facilitated by U$ing a lead tool (Part No. support the ring in the cylinder bore with an old piston. Check the bearing nipas foJlows:Fit the bearing shells and tighten both securing nuts-slacken one nut as before and check the nip with a feeler gauge.0025 in. will align when. when: USed.00.and the crankpin shoulder. Reatn the bush when fitted to connecting rod to allow a . a long feeler . the block must be honed to suit the selected pistons.002 to . and the piston located crown downward. the bush is pressed into position.OO9 to . End-float should be. 0. 270304) fitted to the sump studs adjacent to rear bearing cap aperture. should be an easy sliding fit in the connecting rod and should have a slight interference fit in both piston bores. In the-absence of suitably accurate measuring instruments.0(>05 in. 'ensuring that the bearing shells are' kept with the rods to which they were htted. 3.· Fit each connecting rod. this should be . If the bearing nip is too great. i. big-end bearing nip . (0. 3.012 mm) gudgeon pin' clearance. Fitment of the rear main bearing cap with side seals in position. main bearing shells and thrust bearings. bearing-nip.10 mm). MODELS 5. When reboring. Select the correct cap for 'each connecting rod. must befitted with the larger diameter at the top. so that it can he pressed in by hand.001 to . The oil hole in gudgeon pin bush is pre-drilled and care must be taken to ensure that the oil holes' of bush and connecting rod. as denoted by the number stamped near the joint faces.05 mm) interference fit in connecting rods. Smear seals with Silicone MS4 Compound when fitting. Tighten the securing nuts. The gudgeon pin bushes should be a . and re-check the connecting rod has NOT been filed (see Item 3). . as this will prevent them from folding under the cap duriiig fitmentvthus Causing an oil leak due to the cap not seating properly. (0. This fit is selected to give the smallest possible clearance consistent 'with a smooth revolving action. 7. .013 in. The piston should become a tight fit when the tOP of the skirt (immediately below the bottom scraper ring) enters the bore. Assemble the big-end of each connecting rod to its respective crankpin.0Q()3 to .06 mm) thick may be inserted against the thrust side of the bore as illustrated in Fig. decrease by rubbing down the joint faces of the bearings on fine emery cloth . A-12. with corresponding numbers together. (0. select another pair of bearings. 6.1 Piston ring fitting Check gap and side clearance. Smear bearing face of crankshaft rear bearing oil seal withSiliconeMS4 compound. A-ll-Chec:kio. If the bearing nip is still small. standard or oversize.02 to 0. To check gap. the cylinder bore clearanceshould be in accordance with the dimensions laid· down in the data section. 872!:1 4.33 mm). but will not fall out under its own weight. Ensure that correct alignment is maintained while reamering.007 to 0. on to the Connecting rods Operation A/32 1. Compression rings are marked "T" or "Top. Thisnumbtr also indicates the crankpin to which it must be fitted. by inserting a feeler gauge between the end face of therod.4 in.002 in. less shell bearings. if the bearing nip is too small. then refit crankshaft. then slacken one of them right off and check that there is no clearance at the joint face.23 to. Assemble the connecting rods. Remove the connecting rods from the crankshaft. 1 Fig. (0.

/38 1. 4 cylinders are at B. in the connecting rod.001 (82. . Cylinder Iiners 1. Squirt oil on to the journal. Fit the gudgeon pin. (0. Machine the cylinder block bores as follows: 1948-51 1.bor'ng jig block Fig. A·I s----RI!'.. Blend to the shape of the cylinder block. Acl4--Fitting gudgeon pip. 2. If the cylinder block has already been bored out to maximum size. Re-horingconforms to normal practice.5 mKg) on 1954-58 models and then turn on to the next split pin hole. Tum the crankshaft until the crank journals relative to numbers 1.003 to .60 mm 0. + . 262864. A·I6-Fitting cylinder liner 2S . until the top edge is level with the bottom of thee:dlaust Valve pocket. . 4. (74.0 litre .42 mm + 0.OO~ . cylinder liners may be fitted.025) or Re-boring Operation A!40 1. Prior to pressing in the liner.nuts to 301b/ft. ensuring that the oil hob: in the connecting rod is on the oppcsite side to the camshaft. (0.jig block. using press block Part No. S. note the following points:2. It should also be noted that on early engines the upper portion of the bores is chromium plated. 272103.937 in. I 3.0 litre enginecan only be: bored out to suit standard . and. with the flat top of the piston in line with the oil hole. To facilitate re-alignment should the liner not be positioned correctly at the' first attempt. Enter the connecting rod.to align piston and connecting rrod. Bore to suit the' selected pistons.245 in. (4 mgg) on 1948-53 models and to 40 lb/ft.. Press in the liner. 18:8 in. 261287 r to enable standard equipment to be: used. Liners for the 2. refit appropriate bearings to cap and connecting rod.using thimble Part No'. the chromium is too hard for standard cutters. Part No. Lock the pin in position with circlips. 2.010 in. Enter the skirt of the piston into the top ofthe bore. (5 moi) clockwise.040 in. Fit split pin. + + + (80i97 rnm~+ 0. (5.C. (1. 2. up into the cylinder bore and engage in the cylinder block slots. so that the first cut" starting from the top of the bore. scribe lines down the sides of' the liner' from the two peaks and make corresponding marks on the cylinder block.25 mill) oversize pistons.ENGINE-PETROL MODELS Fig. Operations A/40 and A/34. Piston and connecting rod to cylinder block and crankshaft Operation A.6 litre . Liners for the 1. It is necessary to employ j. This gives an interference fit of .00 mm). A-l3-Checking piston riog gap liS'tons to connecring rods Operation A/lfJ 1. .6 litre engine can be bored out to a maximum of .10 mm).(25) 1952-542.. Fitting conforms Operation A/42 to standard practice. The 'connecting rod bolts are a tight fit in the rod and must be tapped into place with a 'Z' shaped bat. Fig.D. 3. 1955-58 2.004 in. without bolts.0 litre 3. 2. Fig. 'must be sufficiently deep to cut behind the plating. .025) 3.075 to 0. pull the rod down to the journal and fit cap. Tighten the .001 . allowance must be made for twist up to 3/16 in.

A-19-R~moving exhaust valve seat 8.. '. To fit new guides 5. - . 26 .3448 in. fit the spring assemblies. 4. The run-out must not exceed . Remove the guide with a drift. 2.. Break the insert by means of a chisel applied through the hole in the plate. Wash each paraffin.012) 7. ~:. Exhaust valves L Grind the seats to 45° equipment. 263051. over the appropriate cylinder bore.. using tool Part No. bolts Fig. A-l7. using Operation A/46 'Vibro-centric' o valves to 45"-1 and lap into their seats. 262752. 2. then secure the flywheel housing to cylinder block. Face the respective + I. the securing .. (0.8 mKg). Locate each valve into their respective guides and.005 in. Pull in the new guide.. A-I7-Checking run-out on flywhe~1 face 10.:>--. It is not necessary to heat the block or freeze the insert.. caps and split cones.. Part No. Check the run-out on the flywheel face as illustrated by Fig. 9. but light taps on the tool may be required to ensure that the insert enters smoothly. I L Clean the seat recess and pull the new insert into position.-:>. port and guide in 3. Part No.12 mrn] at outer edge of face. 276102.OOO5 (8. seat. Ensure that the rear main bearing oil seal is in good condition. 263051. Secure protection plate. ~_. 263050.-Special attention is needed to prevent possible injury from flying fragments when the insert is broken ._i. valve..A-S Flywheel housing and flywheel ENGINE-PETROL MODELS Operation A/44 1. using compressor Part No. .:.-. Fig. Anew '0' ring seal must be fitted to each guide. and cover the opening below the insert with a heavy pad of rag. A·:ro-Fitting exhaust valve seat . Part No. using tool Part No. Fig. Fit the flywheel and tighten to 70 Ib/ft (9. . ~ To fit new seats Note. A-1SFitting exhaust valve guide 3.757 mrn-----O. Remove the valve guide by means of a piloted drift. . 262753. Repeat items I to 4 inclusive. 6.--' ~/ Fig. and ream to .

ENGINE-PETROL 12. Continue precautions against fragmentation for a few minutes, as the insert may shatter a short time after fitting. 13. Pull in the new valve guide, using tool Part No. 262753. 14. Repeat Exhaust items 1 to 4 inclusive. rocker shafts assembly

MODELS

A-9

To fit new guides 5. Remove the guide with a drjft, Part No. 263051. 6. Press in the new guide, and ream to .3448 in..0005 (8,757 mm-D,012). 7. Repeat items 1-4, noting that the seat must he ground in the event of a new guide being fitted. Cylinder head and rocker gear

Operation A/48 Note.-When fitting a replacement rocker or camfollower, it is essential that the component be fitted with the special protective coating of grease still adhering. 1. Fit new bushes in the rockers and followers as necessary and drill through the 1/16 in. (1,58 mm) oil feed hole. The bush must be a light drive fit in the rocker or follower and a sliding fit on the shaft. Ream in position to .593 in. +.001 (15,081 mm +0,025). 2. Replace shafts by inserting front shaft through the locating hole and assembling component parts in the following order: spring; R.H. rocker, washer; R.H. cam-follower; L.H. camfollower; washer; L.H. rocker; spring. 3. Repeat for rear shaft, ensuring that, with both shafts in position, the oil feed holes in the rocker shafts are facing towards the cylinder block. The front of each shaft is marked 'F'. 4. Fit the plugs and fibre adjustment see Operation washer; A/54. . for tappet

Operation A/52
L Smear the joint face of cylinder block and cylinder head gasket with engine oil, then fit the gasket and cylinder head to cylinder block. 2. Locate head and gasket with the securing bolts, fitting all bolts except those which also secure the rocker shaft pedestals, but do not tighten at this stage. 3. Insert the push-rods into their original position, through cylinder head and locate in the earnfollowers. 4. Fit new bushes in the rockers as necessary. The bush must be a light drive fit in the rocker and a sliding fit on the shaft. Press a new bush, in with its shoulder on the same sideas the rocker pad; drill through the oil feed holes7/64 in. (2,77 mm) to the push-rod and 1/16 in. (1,58 mm) in the top of the rocker. Ream in position to .005 in+.OOI (12,7 mm+ 0,025).

Fig. A-22-

DrHling oil feed holes Inlet valves Operation A/50 1. Cut the valve seats (in cylinder head) to 300-H only when necessary; normally they require cutting only at every second or third decarbonising operation. 2. Face the valves to 3Oo-l and lap into their respective sea ts, 3. Wash each valve, seat, port and guide in paraffin, 4. Locate each valve into their respective guides and, using compressor Part No. 276102, fit the spring assemblies, caps and split cones. A new '0' ring seal must be fitted to each guide.

5. Fit the component parts to the rocker shafts in the following order: Rear bracket (located by set screw); spring; R.H. rocker; bracket; L.H. rocker; two brackets; spring; R.B. rocker; bracket; L.R. rocker; spring; front bracket. 6. Fit the rocker shaft to the cylinder head. When in position. the oil feed holes in the rocker shaft must face the push-rods. Tighten all the bolts down in the manner illustrated by Fig. A-a: in. bolts to 50 Ib/ft. (7 mKg); i in. bolts to 30Ib/ft. (4 mKg). '.' ,"

*

e
B652

12

e

6

@

4

«)

Z

49)

8

e

10

Later seal

Fig. A-21

Early seal

Order

Fig. A-2:3of tightening cylinder head bolts. Tbose marked X also secure the rocker shaft.

21

A-lO Tappet adjustment

ENGINE-PETROL
Operation A/54

MODELS

The exhaust tappets may be set with the engine hot or cold. The inlet tappets should be set with the engine at running temperature.

I. Set the valve receiving attention fully open by
engaging the starting handle and turning the engine. then rotate the engine one complete revolution, to bring the tappet on the back of the cam.

8.671

Fig. A·25-Checking exhaust valve fully open position

Fig. A-24-Tappet
A- Tappet adjusting

adjustment B-Locknut

screw C-Feeler gauge

2. Slacker. the tappet locknut and using a feeler gauge, rotate the adjusting screw to give the correct clearance .010 in. (1),25rom) inlet and .012 in. (0,30 mm) exhaust. bearing down on the screw to take up all tbe clearance at the push-rod ends. Tighten the locknut. 3. Repeat for the remaining tappets. Chain wheels, timing and valve timing chain, adjuster. Operation

(b) Note the reading on dial test indicator. then continue to turn the chain wheel slowly in direction of rotation until the needle has again reached the same position. (c) Mark the chain wheel at a point opposite to the mark On timing case and make a third mark on the chain wheel, exactly midway between those made previously. (d) Turn the camshaft against direction of rotation until the third mark is in line with that on timing casing, whereon the valve should be fully open. Fit the timing chain with "no slack" on the driving side. It may be neces;;ary to remove a~d re-position the camshaft cham wheel to obtain this "no slack" condition on the driving side when the flywheel and camshaft are correctly positioned. . The camshaft chain wheel is provided With three Irregularly spaced keyways to facilitate accurate timing.

A/56

1. Fit the crankshaft chain wheel on to shaft and key. 2. Turn the crankshaft in direction of rotation until the E.P. mark on the flywheel is in line with the timing pointer. 3. Replace the camshaft chainwheel and key (do not secure at this stage), rotate the camshaft and set No. 1 exhaust tappet at .010 in. (0.254 mm). 4. If removed, refit the pawl pivot pin. pawl and spring. 5. Fit dial test indicator and bracket, Part No. 262751, so that the "fully open" position of No. 1 exhaust valve can be ascertained in the following manner:(0) Turn the camshaft in direction of rotation

until the lobe of cam has nearly opened the valve fully, then stop rotation and mark the chain wheel and timing case to record the position.

F,ig. A-26-Timing A-Camshaft chainwheel B-Crankshaft chain wheel C- JockeypuUey D-Hydraulic tensioner

chain and tensioner E-Pawl F-Ratchet G- Timing chain (drivingside) H- Jockeypulleyarm

28

ENGINE-PETROL MODELS
6. Fit the jockey pulley arm to its locating spindle. 7. Assemble the hydraulic tensioner, compress and retain the spring with dip, Part No. 262748 , and fit complete assembly to its locating spindle. Position the ball-end in its seat on the pulley arm, holding the ratchet pawl clear, and push arm upwards to the extent of its travel. Remove the special clip and fit jockey wheel. 8. Release the pulley arm and allow jockey wheel to take up slack in the timing chain. 9. Check the timing by rotating the engine and correct if necessary. by moving the camshaft chain wheel to one of the other key-ways. 10. Finally, secure the tensioner with a split pin and plain washer, secure the jockey wheel with a circlip and secure the camshaft chainwheel by locating the lock washer in one of the vacant keyways and bending over the tag. Fit the oil thrower to the crankshaft noting that, correctly located, it CUI'Vesaway from the chain.
Fig. A-27-Checking

A-ll

vibration damper run-out

4. Balance statically, using putty or similar material. Weigh the putty and drill balancing holes in the flywheel. Nate: A hole i in. (9,52 mm) dia. x i in. (6,35 mm) deep represents Iigrams.

Water pump and front cover Operation A/58 1. Renew the joint washer and smear with a light grease. 2. Fit front cover to block (two locating dowels) and secure with bolts. 3. For details "of assembly procedure pump, refer to Section L. for water
Fig. A-28-Balancing vibration damper A-Putty B-BaIancing hole

5. Refit damper on crankshaft,

4. Fit new joint washer, smear with light grease and offer assembly to cylinder block, complete with copper tube and rubber joint ring in recess on top of water pump. S. Locate securing bolts and tighten. 6. Fit thermostat housing complete with thermostat, outlet pipe, inlet elbow and joint washer, to cylinder head, taking care not to dislodge the copper and rubber washer.

securing with a lock washer and starting dog. Tighten the starting dog, using spanner Part No. 263055.

Oil pump

Operation A/62 1. For details of assembly procedure for oil pump, refer to Section AO. offer the pump up to the engine.

2. With the gauze oil strainer secured in position.

Vibration

damper

Operation

Aj60

1. If stripped, examine the flywheel bush. Renew if necessary, noting that it should be a press fit in the flywheel and an easy fit on the driving flange. 2. When reassembling the damper, discard any shims which may have been previously fitted. These have been found to be unnecessary. Tighten the screws fully. 3. Mount the unit on a suitable mandrel, using a slave location key and rotate on centres. Adjust the run-out on the front face by tightening the screws at the point where a dial test indicator gives a minus reading. Secure the screws by staking.
Fig. A·29-Oil pressure relief valve A--~ut, E--Spring B-Locating screw-s-oilpump F-Washer C-Ball G-Lockllut D-Plunger H--Adjusting sceew=-oil
pressure

29

and coolant. drive shaft so that when fully e~d in oil pump. and joint washers. or for fine adjustments.A-12 ENGINE-PETROL. 3 exhaust port and vacuum unit facing forward when the distributor is located. (0. 5. 10 mark (1954-58 models) on the flywheel is in line with the pointer. Rotate the distributor spindle until the rotor is at the firing point for No. 4. 4. I cylinder closed.5 litres). Fit the carburetter. the broad segment of drivmg spigot will be nearest to No. gallery to cylinder head. ~ MODELS (b) Rotate the distributor. 1 cylinder. to refit 1. Engine. Adjust as required by slackening the pinch bolt and turning the distributor bodily.A. connect fuel feed pipe from pump. refit heater pipes. side of the calibrated slide is against the face of distributor body casting.H. Slacken the pinch bolt at the base of the distributor body. 9. 6. 11. 3. The crankshaft may have to be rotated slightly to allow engagement of driving shaft in oil pump. and connect vacuum pipe between carburetter and distributor.016 in. Fit the dipstick and tube. packing strip and three distance pieces at rear. etc. by means of the vernier screw. covers and rubber sealing rings.75 litres). 30 . 3. noting rubber seal. item 1 must be repeated.. then fit distributor drive shaft. Fit the oil filter complete and joint washer. 1. Rotate the engine in running direction until the F. Check for oil and coolant necessary. Locate a cork washer in recess in top of distributor housing. retighten the pinch bolt. Distributor and ignition timing Operation Externals AIM 0 1. Check the distributor contact breaker clearance and adjust if necessary.014 to . 6. rotate the distributor bodily in the opposite direction to the arrow on the rotor arm. Mount distributor housing. Fit the oil sump. Fit the relief valve assembly. 8. 2. Reverse removal procedure-fit Operation A/66 8. until the contact breaker points are just opening with the fibre cam follower on the leading side of the Cant. with both valves on No. (12 to 19 tom) when pressed by thumb between the crankshaft and water pump pulleys. 2. the bulb will glow exactly when the points begin to open. . Connect the accelerator linkage to the carburetter. Fit the inlet rocker cover and joint washer. The broad side of the driving spigot should be towards No. Fit the pump locating screw and locknut.3 exhaust port. Do not tighten 5. adjust the dynamo belt tension to allow the belt to move ! to 1 in. 2. 3. Checking with 12 volt timing lamp (a} Connect a lead between the distributor new mounting rubbers if necessary. Fit the exhaust and inlet manifolds. leaks-rectify as L. 10 imperial pints (5. Fit the sparking plugs. .35 to 0. Refill with lubricating oil•. T. 3. ~~the oil pump. the locknut at this stage. If removed. 150 mark (1948-53 models) or the F_A. Fit the exhaust rocker cover and joint washer. See Section M for details of carburetter adjustments. 5. to cylinder head. 17 imperial pints (9. 4. Fit the oil feed pipe. Secure the distributor housing in position with the hollow oil feed bolt.40 mm). Set the octane selector so that the fourth line from the L. 7. 10. Fit the dynamo and starter motor. 9. 4. terminal and the centre pole of the bulb j earth the bulb body. Refer to Section AO for details of oil pressure adjustment. and when this is necessary. and secure to distributor 7. and connect plug leads to distributor. See Section AD for details of oil pressure adjustment.

Remove the bonnet panel.30 mm) and inlet .010 in.ENGINE-PETROL MAINTENANCE PROCEDURE MODELS 5. the battery leads. 3. 12 and 13.T. Pull down the cylinder head bolts evenly to the correct tension in the order shown in Fig.T.25 mm). Remove the distributor butor cap. It is not necessary to remove the oil pump drive shaft. 15. Reverse removal procedure and set tappet clearance as directed in Operation A/54. Opera- Removing cylinder head Operation A(68 1. Remove the valves. Exhaust (0. Renew valve guides or Operations Af46 and A/50. 2. 12. Remove the air cleaner. Decarbonising. Remove the rocker covers. If necessary. 3. 6. remove the engine governor.012 in. Pull off the plug covers and detach the distriRemove the sparking plugs. 5. 7.25 mm). 10.012 in. Check and clean the sparking plugs. 3. see: Operation AJ68. 9. and Tappet adjustment Operation A/74 Fitting cylinder head Operation 1. Operation A/64. Reverse the removal procedure. A/70 1. (0. e 14 e 8652 e X e 0 e I 4 @ 3 e X 8 (9) e 13 Operation A/76 2. Note: The ! in. Run the engine for a few minutes and check for leaks. lapping valve grinding and Operation AJ72 5. remove the spare wheel from the bonnet panel. (0. Note. Carry out ignition timing. Operation A/64. Section M.010 in.30 mm) and inlet . (0. 13. II. which should be preserved. Operations A/14 (inlet). (0. Disconnect drain off coolant. To remove the exhaust rocker gear. Exhaust . Disconnect vacuum pipe. 3. 11. 14. 2. Remove the carbon from the cylinder head face and ports. Section T. 8. L. I. throttle linkage (at a ball joint). threads. Remove the inlet rocker cover. Engage the starting handle and set the tappet clearance by the method described in Operation A/54. 10. exhaust ports and piston tops. Grind in the valves. the top water hose at the radiator.012 in. If fitted. 4. mixture control switch wire (at rear of cylinder head). Adjust the tappet clearances=-exhaust . see Operation A/IB. 2. items I. A-13 . Operation Aj70. 4. Disconnect the throttle return spring. 8. Operation AJ68._ Lift out the push rods. together with the rubber seal between the water pump thermostat housing. Remove the distributor complete with clamp. seats as necessary. To remove the inlet rocker gear. Do not use a wire brush or sharp tools. A/16 (exhaust). 31 IZ ee 2 e bolts 10 fig. petrol pipe at the carburetter . Remove the cylinder head complete. (0.30 mrn) and inlet . Remove the radiator cap 4.the distributor. Adjust the tappet clearances. Run the engine for a few minutes and check for leaks. tion A/54. Renew all joint washers. using a blunt scraper. 6. (0. H.. Rocker gear removal 1. Release the dipstick 7. A-29. 9. j 6.010 in.25 mrn). A·30-0rder of tightening cylinder head Those marked X also secure the rocker shaft. 2. wire from the coil. . (0.010 in. Operation Af54. Refit the cylinder head. Carry out ignition timing. using a blunt scraper. Remove the inlet rocker shaft complete. The inlet valves should be set with the engine at running temperature.25 mm). On no account must the cylinder head be sandblasted. Exhaust . Disconnect: Oil feed pipe from the cylinder head. Rocker gear fitment Operation AJ78 1. Remove the carbon from the cylinder block combustion chambers. 2.30 mm) and inlet . The exhaust tappets may be set either hot or cold. Remove the cylinder head and inlet rocker shaft. wire from. nuts (spanner size) have '1-/16 in.012 in. tube bracket. Remove the rocker covers. Clean out the small water holes on the righthand side of the cylinder block and head faces. the mixture control (at the carburetter and clamp) and hand throttle control (if fitted) at the lever and clamp.

2. Reverse the removal procedure. bearings and bolts. Remove the circlips: withdraw the gudgeon pin. 3. chain and discard. and that the container is correctly located in the top cover. by reversing the oil filter. Remove the radiator. 3. turning the crankshaft as necessary to effect withdrawal. fit the new element and rubber sealing ring. Fit the pulley arm and jockey wheel and check that the exhaust valve of No. Run the engine for five minutes and rectify any oil leaks. Unscrew the bolt at base of container. remove the piston.P. Discard the old element and the large rubber sealing ring from filter head. fit the new chain with "no slack" on the driving side. Fit a new gasket between the filter head and cylinder block. 6_ Release the pawl from the ratchet. Check the engine oil level and top up as necessary. the gudgeon pin should be an UlSy sliding fit in the connecting rod and should have a slight interference fit in both piston bores. (5. Place a drip tray under the filter. compress the tensioner spring by lifting the jockey pulley arm as far as possible. Fit the new filter by reversing this procedure. 3.A.5 mKg) on 1954-58 models. 9. Remove the front cover and mark the camshaft and crankshaft chain wheels. Remove bonnet top. Drain the oil from the sump. Remove the securing filter complete. 1955-58 modelsrenewal Operation A/go 1. Fit the connecting rods with the oil spray hole on the opposite side to the camshaft. then fit clip. 262748. 1955-58 models-fitment Operation A/S8 1. and inspect 5. the Section L.1 cylinder is fully open when the timing pointer is in lIne with the E. 4. External bolts and withdraw the 8. With the marks on chain wheels and casing aligned. Complete the assembly removal procedure. then reverse removal procedure. Tighten securingbolts in base of container.ft. over the tensioner. External oil filter. 7. ENGINE-PETROL Operation A/SO MODELS 2.-14 Timing chain renewal 1. 1. Slacken the four set bolts securing the filter mounting bracket and clip to the cylinder block. 10. External oil filter element. 4. Remove the jockey pulley. Operation A/82 Operation A/68. and refill the engine with one of the recommended lubricants. Push each connecting rod up and turn to engage the slots at the bottom of the cylinder bore. Pivot the dynamo belt: 4. 1955-58 models-removal 5. Remove sump carefully to avoid damage to the joint washer. 32 . then remove the element and container complete. Refit sump and joint washer. 263052. Lower each connecting rod. Refit the cylinder 2. Unscrew damper. withdraw and discard the filter. 4. Operation A/84 using tool Part No. SO that it can be pressed in by hand but will not fall out under its own weight. 2. ensure that all the sealing washers are in position. Tighten the nuts to 30 lb. to renew. Piston and connecting rod removal. 2. then mark the casing opposite these marks. Refill with oil. and remove the fan and remove the inwards starting dog 4. remove the driving Operation A/86 L Jack the front end of vehicle up and position suitable stands beneath the side members. Jack the front end of vehicle up. See Item 1 of Operation A/86. 3. head.e. Operation A/70. using extractor Part No. 1948-54 models L Disconnect filter. i. noting that when cold and dry. 2. Wash the container thoroughly in paraffin or petrol. Remove cylinder head. mark on the flywheel. the inlet and outlet pipes from the Piston and connecting rod-fitment 1. (4 m Kg) on 1948-53 models and to 40 lbift. and position suitable stands beneath the chassis side members. See Operation A/56. Remove the connecti-ng rod caps. External oil filter. 3. 5. 263053 to refit the gudgeon pins. Part No.

EXCflSllivearbon deposit-lHcarDonise.-RecUfy. 4. 3. Sticking valw. 2. Sticking valve-Rectify. Low oil level-Rephllish. Incorrect carburetter setting-Section 2. Faulty coil or condenset-Renlw. 6. 4. 2. VALVE MECHANISM Excessive tappet clearance-Adjust. Incorrect tappet clearance-Adjust. Incorrect tappet clearance-Adjust. 5. Damaged exhaust system-RfCtlfy or renew. 10. E-ENGINE STARTS. Badly seating valves-Rectify or renew. Defective fuel pump-Section M. Starter pinion not tngaging-Cleon drive sleeve and pinion with paraffin. Distributor advance mechanism faulty-Rectify. 6. 6. Loose bearing caps-Tighten. 3. Ignition defect-Section P. Loose timing chain-Rectifp tensiOnet. Thin 'or diluted oil-Refill with correct oil. Defective starter motot-Section P. 4. Incorrect. 6. KNOCKS B-ENGINE STALLS. Weak valve springs-Renew. Incorrect carburetter setting-Section M. Faulty ignition system-Section P. 4. Faulty electrical connectiOl1ll-Rectify low tension ciralit. 5. 4.!. crank- N-LOW OIL PRESSURE F-ENGINE FAILS TO IDLE I. 4.ats-Re-cut.. Leab or restrictions in fuel sys~-Section M. 10. Faulty exhaust silencer-Renew. Worn pistons or bearings-Renew. Faulty coil or condenser-Renew. 13. Low idling speed-Section M. c K-BURNED VAL YES l. 6.s-Rectify. 2. 11. Weak valve springs-Renew. (Page A-16) the piston. 2. 5. 1. . L Low oil pressure-See N. Unsuitable fuel-AdjllSt octane seiector. Defective sparking plugs-Rectify or renew. 5. D-ENGINE RUNS ERRATICALLY 1. Faulty sparking plugs-Rectify. 6. Faulty cylinder head gasket-Renew. 7. Loose or restricted oilline-RectiJy· 33 . 2. Distorted valves-Renew. Clutch sJip-Sl(. 4.yli1!dm iJldicaus a f(lUrty cylilllkT mad gasket. M-MAIN BEARING RATUE . Starter pinion jammed in flywheel-Rowte starter shaft with spanner to free pinwn. 3. Section P. 7-12. Faulty fuel pump-Section M.tion B. Low pressure in adj(Jining (. Incerreet starting procedure-See I1I3!nzction Manual. 4. Faulty valve mechanism-Renew WOTn parts. 3.ENGINE-PETROL DEFECT (Symptom. Weak valve springs-Renew. 3. 4. 5. 8. Faulty electrical COWlections-RfCtify. A-ENGINE FAILS TO START MODELS A-IS LOCATION G--ENGINE MISFIRES ON ACCELERATION StCtion P. L-NOISY 1. 3. 9. 9. condenser or battery-Sectillll P. 7. Faulty fud pump-Section M.. 2. 2. Defective sparking plugs-Rectify. Excessive bearing clearance-RmelCl shaft.rinD. Incorrect tappet clearance-Adjrut.tge-RecharB' oottery. Faulty carburttter-Section M. 2. 9.m P. 3. 1-4. . Incorrect ignition timing-Rectify. Water or dirt ill fuel system-Section M. 2. 3. Excessive carbon deposit-. Brakes binding-Section H. Incorrect ignition timing-Rectify. Cause and Remedy) I. Choked pump intake filter--Clean. Excessive deposit on valve se. 3. Ignition tinung advaneed-Adjust.Decarbonise. Faulty fuel pump-Section M. 8. J-ENGINE BACKFIRES C-LACK OF POWER I.zalve timing-Adjust. 5. Insufficient tappet clearance-MjllS!. 7. Defective distributot-Rectify. rings or valveS are faulty. See defect D. H-ENGINE 1. Carburetter floociLng-SectiQlI M. tions. Low battery cm.' beanJlf. 1. Poor compression-If the compression IS appreciably leJ' than tM correct figure. Incorrect tappet clearance-Adjust. I. Burnt-out bearings-Renew. Carburetter defect-Section M. Sticking valves-Rectify. Faulty sparking plug-Recti/po 4. 4. Worn valve guides or valves-Renew. Incorrect mixture-Adjust carbuTetter. 9. Excessive carbon deposit-D«arbonise. Secti. Badly seating valves-Rectify or renew. Section P. Section M. Foreign matter in fuel system-Section M. 3. Faulty distributor points-Rect(fy or renew. 2. I. S. 7. l. Faulty release valve-Rectify. M. Faulty sparking plugs-Rectify. 4. Defective valve springs-Renew. 5. 7. 4. Excessive bearing c1earance-RICCify. 8. Excessively worn valve stems and guide:s-PRIIflW. 9. Starter motor speed too low-Check ~ttery and connec3. I. 10. Sticking valves-Rectify or TeIJBlII. 5. BUT STOPS IMMEDIATELY. 'Distributor points incorrectly set. 2. Incorrect valve: liming-Adjust. 7. 3. Foreign matter ill fuel s}'3tem-Seuion M. Excessive camshaft bearing clearance-Rectify. Foreign matter in fuel sYlltem-Sectwn M. 12. Faulty coil. 2. Set defect D. 6. Low fuel level in t=k-RepJenish. 3. 8.

9 cu. with engine hot and carburerter butterfly fully open) 125 lb/sq.204 in.997 cc (121. 10°.025 to 0.001 to . " . 1.003 to ...025 to 0.. (47. 97 Thickness at pressure Primary pinion bush Fit in flywheel .m. Minimum thickness after grinding: 88 models.P.187 mm-O.006 (0.8 mm (3.. (.002 in. 1. (11 mKg) at 2.. Flywheel Number of teeth .047 in.. (50..80 rum) Crankpin diameter 1..) 77.0003 to . . 002 to ..0127 mm) clearance Crankshaft Journal diameter 2.23 to 0.736 in.020 in.595 cc (97.075 to 0. ..005 in. 52 at 4.003 to .. 1948-56 Markings: T.. 300 r.p.. i..001 to .. (0.500 r. rods Bearing fit on crankpin E.D.A-16 ENGINE-PETROL MODELS GENERAL Capacity (piston displacement) 1948-51 models Capacity (piston displacement) 1952-58 models Number of cylinders Bore.8755 in.001 to . .p.ft.005 in.003 in.C.05 to 0. 1952-58 models Stroke Compression B.005 in.... 1 cylinder When opposite pointer.134 in..D.030 in.075 to 0. indicates firing point of No.. 1954-58 models pointer. 1. (0.0003 in.9-1 ...5 mm) Connecting ...10 mm) End-float at big-end .075 mm) interference Internal diameterreamed in position .855 in.5 mm (2. (0...3 mm) Fit of shaft in bush .34 cu.0127 mm) clearance Main bearings Clearance on crankshaft journal . 8.004 in. 1 exhaust 0 When opposite pointer. 4 69. 1956-58 . 114 before T.33 mm) Gudgeon pin bush fit in small end ...in.. (0..A.004 in. Other models.063 in. valve should be fully open.878 in.050 mm) interference Gudgeon pin bushinternal diameterreamed in position ..000 r.-. .) .52 mm) End-float .12 mm) .025 to O. . ... (zero to 0._ Zero to ...p.05mm) 34 . Firing order 1-3--4-2 Compression pressure (at starter motor cranking speed..rn.002 in..... Crankpin dia. 1. 1 cylinder. No..0005 in.) DATA Maximum models Maximum models torque.5 mm) 1..960_in.. (0.12mm) Maximum permissible run-out on flywheel face Maximum refacing depth .0075 to 0.OOl 1. 1.75 rum) Camshaft bearings Type Internal diameter Split Mazak die casting .970 in.. . 1.063 mm) Bearing nip . When 1 piston is at top centre opposite opposite pointer.-.980 in..) .013 in.10 mm) clearance Gudgeon pin Fit in piston (selective assembly) ..C .040 in.. . torque. 001 to ..050 mm) End-float .030 in.H.. (0.. . 105 mm (4. 1948-53 models F.874 in.. dead .A.002 to .0025 in.025 to 0..e.. (0. (0.15 mm) Regrind sizes: Undersize Journal dia.990 in. F. 1948-51 models Bore.865 in. 1...0003 to ..002 in.. (26. 1948-51 . (30.. 15°.in. When No....0127) Fit of gudgeon pin in bush . 6.-.0075 mm) interference Fit in connecting rod bush (selective assembly) . 1952-58 1.m. .. ratio 1.p.025 to 0. ..in.876 in... .845 in.. (O. 1.8 kg/em' DETAIL DATA Camshaft Journal diameter .P. 009 to .OOO5 Clearance in bearing .875 in. 101Ib/ft.(14mKg) 1. (0..0005 in. 001 to . indicates firing point of No.rn.) .010 in.... (22.0075 to 0.. 80 lb. (0.835 in.000 r.05 to 0.0005 (22. (0.

.. 50 tb/ft..7 mm -1·0..-..002 (2....S.17 mm) interference Fit of inlet and exhaust valves in guides ... .4 Cylinder head bolts: 7/16 in.012 to 0.025) (15... 30"+1 (12.012 to 0.+ .12 to 0.0005 to . (0.. Endless roller.05 to 0..017 in. (0.3 to 0...F... late models . 3448 in. (0.-. 012 in.025) Clearance on shaft. to . steel backed. (0.OOI rom) Clearance in groove .7 mKg) Valves Inlet valve Diameter (stern) ...05 mm) Scraper ring (lower) Type Slotted.80 Kg/em') Thrust bearings.016 . .757 35 . 4.. 15i Jb±! (7 Kg±!) Hydraulic chain tensioner Inlet valve lifts at .. (4 mKg) Main bearing bolts 80 lbjft.05 min) Rocker gear .5 mKg) Clearance in groove ..075 rom) Tappet clearance Type Removable insert Angle 45"+1 Fit in cylinder block . 343 in... .. H section Gap in bore 012 to .002 in..36 mm -0.0005 to .OOI .•. 2.. Length in position 1. 0025 in. prestretched Diameter of rollers 1in...593 in.ENGINE-PETROL Pistons MODELS Timing chain tensioner Driving chain Type ..05 mm) Scraper ring (upper) Early models only Type . measured at bottom of skirt at right angles to gudgeon pin .30 mm) Inlet.005 in..012 to 0.0022 to ... Type Thickness . .002 to . B. (0. (0.(Xl02 Chain tensioner spring Free length .002 in.. (6.25 mm) (8.in..-. 0075 in.3 to 0...08 mm) clearance Valve guides Length-inlet Length--exhaust Reamed bore 1.016 ..005 in.. Integral Rockers and cam followers: Reamed bore Inlet .055 to 0. (0. 701b/ft..968 in. tin plated . +..003 in. ...0005 to .S..002 in..068 mm) Gudgeon pin bore.8747 in. (7 mKg) 3/8 in. 30Ib/ft.001 Valve seat-inlet Type Angle Valve seat--exhaust .200 in..0027 in.38 to 0.001 Exhaust ..025 to (0. .00I to . Gudgeon pin bore.020 in.030 to 0. (0...45 mm+O.21 mm+O.... .. Stepped Gap in bore . and .003 in.050 mm) 0.043 mm) Clearance in bore.025 to 0. Oversizes (17...F...4 rom) Face angle Exhaust valve Diameter Face angle 300_! Clearance in groove . 4 to 12 Ib/sq. +.35 mm) A-17 Type .30 to 0.-.. (0. measured at top of skirt at right angles to gudgeon pin ...012 to . Taper periphery . B. 500 io...." 45°-1 .. (0. (11 mKg) Flywheel securing bolts .50mm) Torque loadings Connecting rod bolts 40 th/ft...002 in. (9..0002 in.+ .. early models .-. (5... (0. Load in position . (0. + .081 rom +0...250 in.. . Light alloy.007 in. engine hot or cold .005) Piston rings Compression (2) Type Gap in bore crankshaft Semi-circular..0017 in.001 to .015 to .010 in.093 in. (0.937 in.012) Exhaust. engine at running temperature ... tin plated Clearance in bore. 0lD in..05) .6872 in. 0012 to ..017 in. 343 in.OO5) (22.. (0..0005 mm+O.

5 kg+H Vibration daDnper Fit of bush in fiywheel .. outer .. valve open.2 mm) Pressure. ...817 in..D..±l (14.C...D.B.T.10 mm) interference Clearance of bush or driving flange .8 Ib. 1. (46. (41.....T.1 kg±l) oveer .. inner . (0.B...D. inner Pressure..002 to . 16 A.A-IS Valve springs Free length.17mm) Run-out on front face .12 to 0. (0. outer Compressed length...D.12 mm) maximum Permissible out-ofbalance _. 32. (0. 0 0 0 0 Pressure.005 to .007 in.D..". outer ..0 mm) . 10 lb. . (46. (36.B.469 in.0 Ibs...3 mm) Compressed length. ..C..C. valve closed.in. 17.±1 (8.C. inner Free length..625 .8 kg±l) Pressure.±l (4.4r B.004 in. . . 1.005 in.C.B. 83 B.. 3 grams 36 .C. . valve closed.05 to 0.+l (33.845 in.91b.8 mm) 1. 9· B. 66 A.." 74.. 45 A.5 kg±-1-) . inner ENGINE-PETRO~L MODELS Valve timing Inlet opens closes peak Exhaust opens closes peak __ 1. valve open.D.

c..ENGINE .. Checking exhaust valve "fully-open" position . Timing diagram... Outer camshaft bearing removal Inner camshaft bearing removal Fitting camshaft bearings Reamering camshaft bearings Checking main bearing nip Checking crankshaft end-float Fitting rear bearing cap and seal assembly Checking cylinder liner extension Checking big-end bearing nip Checking piston clearance Checking piston ring gap Checking ring Clearance in groove . Decarbonising Defect location Engine removal from chassis Engine dismantling procedure Engine assembly procedure Fan belt adjustment Flywheel Fuel lift pump Removal Fitment Fuel injection pump Removal Fitment INDEX Fuel injection nozzles Removal Fitment Gudgeon pins Removal Firment Liner.. Fitment Timing chain Removal-engine removed Fitment-engine removed Renewal-engine installed Timing chain tensioner Removal Fitment Valves Removal Fitment Valve guides Removal Fitment Valve timing Page A-38 A-40 A-45 A-40 A-40 A-39 A-45 A-39 A-43 A-39 A-51 A-39 A-44 A-39 A-43 A-53 A-38 A-50 A-39 A-44 A-39 A-46 A-39 A-46 A-39 A-46 A-48 A-39 A-43 A-40 A-42 A-40 A-42 A-39 A-47 A-39 A-46 A-55 A-52 A-54 A-38 A-38 A-4L\ A-51 A-45 A-38 A-51 A-38 A-50 A-45 A-39 A-47 A-52 A-39 A-47 A-39 A-46 A-39 A-45 ."l A -48 A-407 A-422 A-423 A-425 A-426 A-427 A-428 A-439 A-424 A-408 A-410 A-409 A-411 A-412 A-413 A-414 A-415 A-4l6 A-417 A-43 A-44 A-44 A-44 A-45 A-45 A-45 A-46 Adjusting tappets A-48 Checking vibration damper run-out A-49 Sectioned view of vibration damper A-49 Driving gear in correct timing position A-50 Distributor pump timing marks Timing gear arrangement... A-48 A-430 A-431 Position of injection nozzle washers A-51 Order of tightening cylinder head bolts A-52 correctly aligned A-50 37 .. A-401 A-404 Page Removing vertical drive shaft gear . Compressing valve springs .. Order of tightening cylinder head bolts Timing pointer.... Page A-46 A-402 A-403 A-405 A·406 A-4Q A-40 A-42 A-42 A-43 A-43 A-41 A-41 A-39 A-420 A-421 A-46 A-47 A-47 A -4........_... Fitment Lubricating oil filter-external Lubricating oil pump and filter Removal Firment Pistons and piston rings Removal Fitment Push-rod Removal Fitment Push-rod tubes Removal Fitment Rocker gear Removal Fitment Tappet adjustment Tappets. cylinder Removal ... guides and rollers Removal .. A-418 A-419 Correct position of push-rod tubes in relation to hot plugs .Section A.. Checking run-out on flywheel face Checking camshaft end-float Tappet guide and roller Fitting valve guides Fig. A-47 LIST OF ILLUSTRATIONS Fig.. : .DIESEL MODELS Page Camshaft Removal Firment Camshaft bearings Removal Firment and reamering Camshaft chain wheel Removal Firment Connecting rod Removal Fitment Connecting rod bearings Removal Firment Crankshaft Removal Fitment Crankshaft bearings Removal Fitment Crankshaft chain wheel Removal Fitment Cylinder head Removal Fitment Data .... .

grille' panel and headlamps. 2. A new plug must be fitted if the old one has been removed. The rearmost tappet chamber cover and fuel lift pump may be removed as one unit. S. 4. 8. the foremost "tappet chamber COVerand oil filler pipe may also be removed together. Ensure that Operation A/flO 1. DISMANTLING Removing engine I. 1. dynamo. 20. 2.H. Unscrew the securing nut and remove the filter gauze assembly. 16. then disconnect the three pipes joined at scuttle.. after removing the locating screw from the external filter adaptor joint face. Vibration damper 21. side of cylinder block). Drain the coolant from system (one tap at bottom L.R. 18. disconnect the wiring. Remove the fan blades. then pull the wiring clear to front of engine. ENGINE 5. oil pressure warning switch and glowplug lead at resistance on bulkhead. 15. 22. thermostat to water pump casing. If fitted remove the spare wheel from bonnet. Detach the top hose at radiator header tank and the bottom hose from water pump inlet. 3. etc. Disconnect the wiring from starter motor. Disconnect the battery leads and remove the LH. 23. 10. 7. Disconnect the fuel inlet and outlet pipes from fuel lift pump and injection pump. Remove the inlet and exhaust manifolds. 4. 11. Remove the front floor and gearbox cover. 2. 12. then the starter. Lift the radiator. Remove the remaining nuts and washers securing the gearbox to the flywheel housing. Disconnect the hose from inlet manifold. Remove the L. with a pair of snipe-nosed pliers. then withdraw the injectors and seating washers. Remove the securing bolts and withdraw the pump assembly. allow the engine to move forward and thus clear the gearbox input shaft. 9. Make sure the small steel washer is also removed from out of the orifice in the: cylinder head.H. Remove the accelerator control rod. 9. Remove the starting nut and tab washer. then withdraw the vibration damper assembly from crankshaft. Externals Operation A/404 1. side of scuttle. 7. side. front of engine. Remove the securing straps. 13. Remove the bolts from engine front support brackets. Withdraw the driving shaft from the pump upper casing. 38 . Disconnect the heater pipes (if fitted) at the engine side of bulkhead. then forward to clear the vehicle. 5. Release the accelerator pull-off spring and remove the injection pump. Disconnect the oil feed pipe-gallery to cylinder head and' the hose.H. Lift the drive shaft gear and external bush assembly clear. Fit the engine sling to the support brackets at front and rear of cylinder head and with suitable lifting tackle just take the strain. side of radiator and one tap at L.-'see Section AO for oil pump strip and assembly. unscrew the securing wing nut and lift the air cleaner and hose clear. The split bush may be removed by tapping to release the dowels. Bolt the engine to a suitable stand. Remove the fuel filter from mounting bracket at R. 3. 17. Disconnect the bonnet support stay and remove the bonnet. assembly upward. Disconnect the heater pipes and water tap from cylinder head if fitted. Remove the bolts securing the grille panel to front cross member and front wings. Drain oil from sump. Disconnect the side lamp leads at each side of the grille panel assembly and the front lamp harness from the junction box at R.H. Vertical drive shaft gear Operation A/408 1. battery support. then the cut-off control cable from the steady bracket on engine and from the lever on injection pump. Loosen the bolts securing the intermediate to front exhaust pipe and disconnect the exhaust pipe from exhaust manifold. then remove heater plugs carefully to avoid damage to element. fan belt and dynamo. 6. Note. 3. lower R. 19. Support the gearbox assembly with a jack or packing blocks. then hoist the engine gently from the vehicle. Oil pump Operation A/406 14. Remove the external full-flow oil filter complete with oil pressure warning switch. and all wires are clear. Donat remove the aluminium plug in the gear unless absolutely necessary. Disconnect the fuel spill gallery pipe from injectors and remove the fuel feed pipes-injection pump to injectors.H. 6.A-38 ENGINE ENGINE-DIESEL REMOVAL AND DISMANTLING PROCEDURE Operation A/402 MODELS the speedometer cable. battery. Drain the oil and remove the sump. Remove the clutch slave cylinder bracket from the flywheel housing and pull back the complete assembly as far as possible.

39 Rocket' gear and cylinder head Operation Aj4l6 1. Part No. 3. The push rod tubes may also be removed if necessary by drifting them out. then withdraw the piston and connecting rod assemblies from the top of cylinder block. Drift the valve guides from the cylinder head using tool. The rollers have a chamfer on their front face inside diameter. Remove the camshaft front thrust plate.ENGINE-DIESEL MODELS A-39 3. if necessary remove the small end bushes from connecting rods. 7. then tap evenly and gently around the inside of hot plug. withdraw the back plate. Flywheel Operation A/422 1. roller and tappet Operation A/4l8 1. then remove the tappet guide. gud~eon pin retaining circlips 'and press out the gudgeon ~jn:. 4. then withdraw the camshaft. Remove the component parts from the rocker shafts but retain the items in their correct relative positions. preferably taped together on the crankpins from which they were removed. 2. Using a valve spring compressing tool. Avoid using a hammer if possible and thus minimise the possibility of damage. Extract the bushes from flywheel and back plate if necessary.H. Remove and scrap the seals. 6. then lift out the thermostat. until ready for inspection. Operation A/424 1. Remove the piston rings. 274401 (exhaust) and 274400 (inlet). Part No. roller and tappet are marked to ensure correct refitment. The bushes in idler wheel and ratchet arm should also be removed if worn beyond reasonable limits. remove the valve assemblies. Retain the bearing shells in pairs.. 4. Turn the crankshaft until the pistons of numbers 1 and 4 cylinders are at B. using tool Part No. Timing chain tensioner and chain wheels Operation A/4 . and lift the rocker gear assembly complete from the cylinder head. The guide. Camshaft removal Operation A/420 1. Lift off the timing chain and remove the chain wheels. Compress the chain tensioner spring and unscrew the lower fixing bolts and remove the chain tensioner assembly. Fig.D. The screwed plug and ball may be removed from the piston if necessary and the piston pressed from its housing if unduly worn. Remove the rocker gear covert unscrew the bolts securing the rocker shaft support brackets. 274399. Remove the clutch assembly. Unscrew the rocker covet securing studs from the centre: and end support brackets and the locating set bolts from the intermediate support brackets. connecting rods and liners . Remove the locating bolts from R. With a piece of bent wire remove the rollers . H necessary remove the hot plugs by inserting a copper drift through the injector aperture. Pistons. Remove the big end bolt securing nuts of numbers 1 and 4 connecting rods. see Section L.. Remove the front cover and water pump assembly. 2.C. .. Remove the cover and joint washer. A·40I-Removing the vertical drive shaft gears 2. side of cylinder block and lift out the brass tappets. Unscrew the set bolts securing the back plate to flywheel. Remove the ratchet securing bolt and withdraw the ratchet and spring. Water pump and front covel' Operation A/412 1. 1. For overhaul of water pump. Tappet guide. rubber discs and shims. Repeat for numbers 2 and 3 assemblies. 5. 8. then the flywheel securing bolts and withdraw the flywheel. The tensioner cylinder and bush must be renewed complete if the bush is unduly worn. Withdraw the push rods and insert them in a piece of cardboard pte-pierced and marked. The primary pinion bush may be extracted if necessary. 276102. Loosen the securing bolts evenly and lift the cylinder head clear.

) long stud from the joint face at front of cylinder block. removing using the removing 2. Part No. Fig. Retain the shell bearings in flairs adjacent to the journal from which they were removed. then slide a spacer. then withdraw the bearing from the chamber aperture... This is [0 differentiate between Diesel camshafts which are similar in all respects other than the positioning of the cam lobes. Remove the main bearing caps. but it must be collapsed before withdrawing from the drive aperture as illustrated by Fig. Part No. lift the crankshaft clear and place in a suitable stand. Crankshaft. 1.Innercamsbaft bearing removal ENGINE ASSEMBLY Camshaft bearings Operation Aj428 When replacing camshafts it should be noted that 21 litre petrol engine camshafts are marked "Petrol" between No. the liners may be withdrawn by hand and the sealing rings removed from the crankcase end of cylinder block bores. Position a new bearing on to the handle end of bearing fitting bar. After marking the top with a scriber to ensure correct refitrnent. then insert three end cover set bolts loosely for location purposes. 274388. on to the fitting bar and engage the locating shoulder Note: The inner bearing should be positioned at the innermost lower side of the chamber. 2. Part No. The front intermediate bearing is removed by drifting it into the fuel injection pump drive chamber. Note: When new camshaft bearings are to be fitted. 274382. the front and front intermediate bearings must be removed and new ones fitted before removing the rear bearings. Unscrew the 31 in. 2 cam lobes. two old rearmost bearings with the part of flange marked "TOP" uppermost. Fit a guide tool. using the same tool.. 2. A·403. Fit new front and front intermediate Items 1 to 5 Operation A/428. same tools and method employed when the foremost bearings. before inserting a suitable bar which should then be tapped lightly against the bearing.9 mm. Part No. Note: Ensure that the component parts are retained in their correct relative positions. Drift the front camshaft bearing in to the foremost tappet chamber using toot. Insert the bearing fitting bar into the front bearing housing and feed the spigot on to the bat. Place a new bearing on spigot. 274384. See Items 1 to 5 of Operation A/428 for bearing fitment. into the Fig.A-40 ENGINE-DIESEL MODELS 4. Part No. before the rear bearings by drifting them. 274383. A"402-Outer camshaft bearing removal B-Drift. 274385. 3. Camshaft bearing removal Operation A/427 Note: When new c~haft bearings are to be fitted. withdraw the spigot handle. bearings. the front and front intermediate bearings must be removed and new ones fitted before removing the two rearmost bearings. A-403. main bearings fear bearing seal and Operation A}426 1. The rear bearing seal halves may be removed from the cylinder block and bearing cap. 2. See Items 2 to 4 inclusive of Operation A/420 for bearing removal procedure. A-Cylindtrblock. 1 and No. and position it inside the foremost tappet chamber with the bearing nearest the front intermediate housing.. Turn the 40 . and locate by means of the peg and semi-circular cut-out. (88. Care must be taken to avoid damage to the machined faces in the chamber.

A-404-Fitting camshaft front bearings A-Cylinder block. bearings in the same manner as for front bearing fitment. turning it in the same direction as for cutting. 274386. Do not tighten these screws until the reamer. then drive the bearings into position· with a hide-faced hammer. Remove the reamer handle and carefully remove the reamer. best results are obtained when the bearings are cut dry. B-Bearing fitting bar. Remove the plugs from the ends of oil gallery passage and clean the gallery and oil feed passages to camshaft and crankshaft beatings. 3. turning as necessary to engage the bar slot with the peg in guide tube. 41 . This precaution is to ensure correct alignment of the reamer. remove the guide plug Part No. Refit the plugs flush with the face of the cylinder block and lock in position. A-40'i-Reamering camshaft bearing•.ENGINE-DIESEL MODELS A-41 Fig. but remove the spacer from fitting bar and use guide tool. Engine must be in vertical position. in order that the weight of the reamer will assist in the cutting operation. Part No. P-Guide tube. blows away the white metal cuttings. before cutting the foremost bearing. D-Spigot. Remove the bearing fitting tools and check the oil holes for alignment. 4. ensure that all locating points are properly engaged. Fit new camshaft rear 5.e. After the rear most and the two intermediate bearings have been cut. which is firstto be cut. then press the fitting bar inward. As each bearing is cut the reamer should be held steady by the operator whilst an assistant. Operation Aj420. spigot to engage the locating shoulder in the spacer. Part No. u~g the end-plate screws. before allowing the reamer to enter the next bearing. Care must be taken to prevent the reamer damaging the foremost bearing as the reamer is removed. i. front end facing downwards. E-New bearings. in the front new camshaft bearing and locate. 274389. using a high pressure air line. Before commencing the rearnering operation it is necessary to turn the engine block to a vertical position. C-Spacer. 274394. isput into position and the guide collar immediately in frontofthe cutter is entered into the rearmost bearing. using compressed air. instead of the guide tube used when fitting front bearings. Locate a guide plug. Fig. When the fitting bar has been pressed in as far as possible by hand. Remove the two rearrnost bearings-Item 4. 274394. Note: No lubricant is necessary for the reamering operation. Part No.

Lubricate with Silicone MS4 Compound. (0. Check the bearing nip. bearing face 8.0025 in. and on the rear face fit the lower half of crankshaft rear bearing seal. The crankshaft should resist rotation when a feeler paper. then refit crankshaft. 2. Fitment of the rear main bearing cap. Refit the bearing shell bottom halves and bearing caps.07 mm) to ensure that the crankshaft remains centralised. these are available in slightly varying thicknesses. Fig. ensuring that the clearance does not exceed . See Fig.050 to 0. locating by means of the tags. Fit the top half of crankshaft rear bearing oil seal to the crankcase. 9.15 mm).06 mm) thick. 1. fit suitable oversize thrust bearings. (0.15 mm). as illustrated in Fig.006 in. therefore. Check the main bearing nip as follows Remove the bearing caps and fit the bearing shells. first assemble the caps without bearing shells to the crankcase. Lubricate the crankshaft journals. Adjust by selective assembly of bearing shells. then check and note tlle crankshaft end-float reading which should be . with side seals in position. remove the caps and bearing shell bottom halves. Remove the bearing caps. main bearing shells and thrust bearings. main bearings and seal Operation A/430 Note: Crankshafts considered unserviceable because of wear on the journals must not under any circumstances be reconditioned. To check that the bearing caps have not been 5. A-408. Position a standard size thrust bearing at each side of centre bearing shell-top half. Tighten both securing bolts for each cap.004 to . (0. There should be no clearance at the joint face. is placed between anyone bearing shell and crankshaft journal.003 in. If the crankshaft end-float reading. Lubricate seals with Silicone MS4 Compound. Mount a dial test indicator. A-406--Checking main bearing nip 7. The nip can be corrected by selective assembly of bearing shells. and damaged to ensure that it cannot be subsequently reconditioned. was not within the limits. and turn freely by hand when the feeler paper is removed. Note: It will be found advantageous to carry out Items 5. A new crankshaft of the latest type must be fitted.10 to 0. 6 and 7 of Operation A/434 relating to connecting rods at this stage. It is most important. (0. When the bearing nip has been checked. To the rear main bearing cap 6t neoprene seals in recess at each side. Tighten the caps down and slacken off one bolt of each pair. filed. It will be found advantageous to cut a slight lead on to the bottom edges of side seals as this will prevent them from folding under the cap during fitment. 42 . The variation of thrust bearing thickness at each side must not exceed . that when a 6.A-42 ENGINE-DIESEL MODELS 4.A-406. will be facilitated by using a lead tool (Part No. Tighten the securing bolts evenly and check each bearing in tum for correct clearance. .002 to . and fit the crankshaft. obtained in Item 4. Crankshaft. 3.006 in. then slacken one bolt of each pair right off. A-407-Cbeckiug craukshaft end-float Fig. bottom half shells and crankshaft. Diesel crankshaft becomes unserviceable it should be scrapped out. and no undersize main bearings are supplied. ensuring that they are correctly located by means of the dowels. Smear bearing face of crankshaft rear bearing oil seal with Silicone MS4 Compound. thus causing an oil leak due to the cap not seating properly. 270304) fitted to the sump studs adjacent to rear bearing cap aperture.

Press the liners into their respective bores by hand and align the marks made whilst dismantling. A-408-Fitting rear bearing cap and seal assembly A-Bearing cap. with Silicone MS4 Compound. Connecting rods Operation A/434 1. (0.0003 to . Shim washers are available . less shell bearings.10 mm).002 in. This number also indicates the crankpin to which it must be fitted. Fit each connecting rod to a suitable test rig and check for twist and mal-alignment. (0. 3.50 mm) and . Ensure that correct. A-41QChecking the big-end bearing nip Fig. but a minimum drying time of ten minutes must be allowed.002 in.050 to O. Adjust if necessary by removing liner and adding a suitable shim washer under the flange.10 mm) thick.ENGINE-----DIESEL Cylinder liners and seals Operation A/432 1.0076 to 0. The oil hole in gudgeon pin bash is pre-drilled and care must be taken to ensure that the oil holes of bush and connecting rod will align when the bush is pressed into position. The gudgeon pin bushes should be a . Fig. A"41O.002 to .lO nun) above the cylinder head joint face.050 mm) interference fit in connecting rods Ream the bush when fitted to connecting rod to allow a . Mount a dial test indicator (d) The nip assembly available Do not can be corrected by selective of the bearing shells. file the rod or cap. Check bearing nip as follows:(c) Fit the bearing shells and tighten both securing bolts-slacken one bolt as before and check the nip with a feeler gauge.004 in. these are in slightly varying thickness. (0.004 in. (b) Tighten the securing bol ts. and the liner sealing rings. (0. 2. Fig. as denoted by the number stamped near the joint faces. Clamp and re-check liner as described above. A small hole is drilled through the cylinder block into the middle groove to provide evidence of coolant leakage past the top sealing ring.050 to 0. then fit a ring to the upper and lower grooves of each bore. Clamp each liner in turn in the manner illustrated and tighten the securing bolts to 65Ib/ft.025 to 0. MODELS A-43 and check that the outer edge of the cylinder liner is from. then slacken one of them right off and check that there is no clearance at the joint face. (0.OO2 to . The coated joint faces may be allowed to dry thoroughly before assembly if desired. C-Lead tool. B-Seal.0127 mm) gudgeon pin clearance. To check that the connecting rod and cap have not been filed:(a) Select the correct cap for each connecting rod. Assemble the: connecting rods. Smear the sealing ring grooves at the crankcase end of cylinder block bores. this should be . This fit is selected to give the smallest possible clearance consistent with a smooth revolving action. See Fig. 43 .004 in.9 KgJm) torque. 2. using a fairly stiff brush for application. (8.001 to . A-409-Checking cylinder liner extension 3. with corresponding numbers together.0005 in. alignment is maintained while reamering. Lightly coat the underside of the liner flange and the mating recess in the cylinder block with Hylomar SQ 32 M sealing compound. (0.

using an old piston as illustrated in Fig.0025 in.011 in.004 in. C-Liner retainer. A-411. Pistons Operation A/436 1. 274411) to joint face of cylinder block. then move freely by hand when the shim paper is removed.001 to . 5. Note: It will be seen that provision is made for the fitment of two oil scraper rings.0635 mm) shim paper is fitted between the crankpin and one-half of big-end bearing shell.007 to . Lock the gudgeon pin in position with eirclips. the top chromium plated compression and the oil scraper ring bas a square friction edge and may be fitted either way. A-41l-Checking ring clearance in groove 2. Fit the connecting rod to the piston with the oil spray hole of rod on the same side as the swirl-inducing recess in piston crown. (0. or the slight interference fit may be lost. and the piston located crown downward. The second groove is for service purposes only. as illustrated in Fig.10 mm) thick. Assemble the big-end of each connecting rod to its' respective crankpin.ap piston. Piston and connecting rod to cylinder block and crankshaft Operation A/438 Note: See Items 1 to 6 of Operation A/434 inclusive for gudgeon pin bearing fitment and big-end shell bearing selection. 6. Check the connecting rod end-float on crankpin by inserting a feeler gauge between the end face of rod and the crankpm shoulder. C-Feeler gauge. should be a slight interference fit in both bores of the piston-see Data. See Data Section.A-44 ENGINE-DIESEL MODELS 3.063 mm). Fig.0025 in. Remove the connecting rods from crankshaft. Fit liner retainers (Part No. then check for correct clearance. the clearance in liner bore should be in accordance with the dimensions laid down in the Data Section. 0. The gudgeon pin. Fig. 4. When fitting pistons. The second and third compression rings arebevel edged and must be fitted with the side marked "T" uppermost. then rotate assembly in the stand to bring crankshaft uppermost.177 to 0. A-412. Lubricate the gudgeon pin when the correct size has been selected for a particular piston. B-Piston. to keep the rings square in the bore.025 to 0. 44 Pistons to connecting rods 4. Adjust by selective assembly of bearing shells. In the absence of suitably accurate measuring instruments. ensuring that the bearing shells are kept with the rods to which they were fitted. . Bearing clearance should be . A·tI2-Checking a piston ring gap A-5c. It must be fitted by hand pressure but must not be able to fallout of either bore under its own weight. The connecting rod should resist rotation when a . Check the piston ring gaps in the liner bores. (0. a long feeler. A-til-Checking piston clearance A-Feeler gauge. (0. EndBoat should be . The piston should become a tight fit when the bottom of skirt enters the bore. Fig.279 mm). but do not fit and remove the pin from piston unnecessarily thereafter. Fit the piston rings and check the clearance in ring groove. may be inserted in the thrust side of the liner bore. when cold and dry. 7. . ~Piston ring.

063 to 0. (0.w. as it is easily damaged.002 in. 2. The tappet rs marked " Front" and must be facing the front of the guide. Fit the tappet locating screws and washers.C. A-415 and ensure that the reading is within . Check the camshaft end-float with a dial test indicator as illustrated by Fig. Tappet assembly and fitment Operation A/444 1. -' Flywheel housing and flywheel Operation A/440 I. 3. using tool Part No. then secure the Bywhee1 housing to cylinder in block. MODELS A-45 ~) Ib ~-~ ~'5'+' Fig. Check the run-out on flywheel face as illustrated by Fig. Ensure that the oil seal is good condition. with the oil spray hole in connecting rod and turbulence recess in piston towards the R.g. Fit tappet guides into the cylinder block.chain wheel but do not bend up the locking tab for securing bolt at this stage. Fit tappet into hole. The tappet guides must not be too tight in the block or they may be damaged by insertion of the locating screw in cases when they are not properly aligned. with the chamfer to the front. using new nuts and tightening to 35 Ib/ft. remove and investigate reason. ~ock t~e locating screws in pairs.9 Kgs/m) torque. B-Tappet guide bolt location Valve gear. 2. thoroughly dean all parts and check that the tappet will move freely in the tappet guide when held in the hand and shaken up and down.D.3 Kgs/m). Insert the connecting rods and pistons for these cylinders from the top of cylinder block.H. the guide and C-Roller with chamfer to front. Locate an "0" ring seal in each inlet and exhaust valve guide after the valves have been ground and lapped in. 45 . iron wire. Before fitting the tappet assembly into the block. (4. 2. (0. The run-out on flywheel face must not exceed . hot plugs and thermostat to Fig.050 mm). Fit the flywheel and tighten the securing bolts to 50 Ibs/ft. S. A-414-Checldug run-out on flywheel face I. 3. using 20 s. Adjust by selective assembly of the front thrust plate. Do not drop the roller. the locating screws must be screwed up with the fingers and then tightened. Repeat Item 1 for numbers 2 and 3 cylinders. Fit the front thrust plate and secure the camshaft . A-416-Tappetguide 4. Tum the crankshaft until the crankpins relative to numbers 1 and 4 cylinders are at B. (6. A-414.139 mm).ENGINE-DIESEL 1. locate on to the roller. side of engine-toward the camshaft.0025 to . Gentlyinsertthe roller into the guide. Camshaft fitment Operation A/442 Note: For replacement and line boring of camshaft bearing. Secure the big ends to crankpins. ensuring thatthe 10 ca tin g hole lines up with the hole in the cylinder block. Pull th~ inlet and exhaust valve guides into position. and roller A-Btass tappet slide marked "front". 6. A-4iS-Checking camshaft end-float cylinder head Operation A/446 I. D988 Fig.0055 in. if they are not free. 274406. 2. see Items 1 to 5 of Operation A!428 inclusive. Insert the camshaft-keyed end to extend at front of engine.

002 in. Cylinder head and valves assembly to cylinder block Operation A/448 When fitting the cylinder head. these must now be replaced by tapping gently into position with a hide. 1. The reamer and rocker assembly must be held in such a manner as to ensure the correct alignment of the reamed hole. It is strongly recommended that the head should be fitted before fitment of the rocker shaft assembly. smeared with Silicone M.02 mm) to obtain the correct clearance. Push ~ods 3. by immersingin hot water. 274402. Ensure that the chamfers on tube and in cylinder head are in full contact and that the "fiat" of tube is at right angles to a line drawn between the centre of push rod tube and centre of hot plug. 3. using tool Part No. should be pulled into position. new tubes complete with new sealing rings. A-418. (0. The fitment of wooden plugs in· the injector nozzle apertures will be found advantageous at this stage. Locate head and gasket with the securing bolts. Fig. 2.050 mm) and are not recessed below the level of the cylinder head face more than .4+0. as illustrated by Fig.53O in. U. Rocker shaft assembly Operation A/450 1. B-Hot plug.. x 5 in. through cylinder head and locate in the tappets. Test the thermostaf before fitment to cylinder head. Insert the thermostat in the housing in cylinder head with rubber '0' ring and fit the joint washer and cover. springs. ensuring that the components are retained in their original sets and positions. then fit the gasket and cylinder head assembly to cylinder block.N.S. If the hot plug and peg assemblies have been removed.A-46 ENGINE-DIESEL MODELS Fig. 5. C-Cylinder head inverted.001 (13.faced hammer. 2. but do not tighten at this stage.4 Compound. Insert the push rods into their original positions.:F. Reamer the bush to.025 mm). dummy studs (! in. otherwise damage to the push rod seats may occur. Smear the joint face of cylinder block and cylinder head gasket with engine oil. A-418-Correct position of push-rod tubes in relation to hot plugs A-Push rod tubes. If necessary. A-4I!il-Compressing valve springs. 46 . A-417-Fitting valve guides 2. 6. cups and split cotters. long) must be used to locate the gasket. 4. The oil holes in the rocker bushes are predrilled and care must be taken to ensure that the oil holes of bush and rocker will align when pressed into position. (0. When fitted they must be checked with a dock gauge to ensure that they do not protrude above the level of the cylinder head face more than . press new bushes into the rockers. fitting all bolts except those which also secure the rocker shaft pedestals. Co Fig.001 in. using the two studs to facilitate alignment. If the push rod tubes were removed. +. Fit the valves. Expansion should commence between 164°F and 173°F and be complete at 193°P.

adjuster and valve timing Operation A/4S2 I. A-421Timing pointer .F. 4. including those that also secure the rocker brackets must be pulled down to 75 Ib/ft. (120. timing chain. It is important before rotating the camshaft to adjust all the tappets which are slack. then continue to tum the chain wheel slowly in direction of rotation until the needle has again reached the same position. and slide a support bracket on to each shaft. 4. A-420. (10.P. U. locate the cylinder assembly and compress the spring. Slacken off all tappet adjusting screws and offer the rocker assembly to cylinder head. (b) Note the reading on dial test indicator. mark on flywheel is in line with the timing pointer. When all excessive clearance has been eliminated adjust the tappets to the correct clearance. ensure that the fits and clearances are in accordance with those laid down in the Data Section.F. then stop rotation and mark the chain wheel and timing casing to record the position. bolts securing the rocker brackets only are pulled down to 12-13lb/ft. whereon the valve should be fully open. exactly between those made previously. Fit the bracket securing bolts. MODELS A-47 Chain wheels. Fit the compression spring over piston. with the bored ends together. studs to the 5. A-422-Checking exhaust position valve "fully open" (a) Turn the camshaft in direction of rotation Fig. but do not tighten. 3.N. (c) Mark the chain wheel at a point opposite to the mark on timing casing and make a third mark on the chain wheel.7 Kg/m).6-1. 5_ Fit new bushes to the chain tensioner components as necessary. Assemble the remaining components with the plugged end of the shafts in the end brackets and the bored end of both shafts located in the centre bracket. bolts. and then secured with a locating screw and spring washer. A-42G-Order of tighteuing cylinder head bolts 8. Turn the crankshaft in direction of rotation until the E. 6. 7. until the lobe of cam has nearly opened the valve fully. o " 0 10 0 6 0 o o 14 0 '" Fig. Fit the rocker cover securing rocker brackets. Place the idler wheel on 47 Fig. Rotate the camshaft a quarter revolution at a time and after each movement adjust any tappets which are slack.65 rom) from the plugged end. The ! in. Fit the timing chain with "no slack" on the driving side.75 in. The locating hole in each bracket must be positioned immediately above the chamfered hole in shaft. 2. Tighten down the cylinder head bolts in the order indicated by Fig.3 Kg/m) whilst the 5/16 in.N. Position the ball in chain tensioner piston and secure with the retaining clip. Align the lubricated rocker shafts. Fit the crankshaft chain wheel on to shaft and key. Fit a dial test indicator so that the "fullyopen" position of the valve can be ascertained in the following manner:- 4.ENGINE-DIESEL 3. It may be necessary to remove and re-position the camshaft chain wheel to obtain this "no slack" condition on the driving side when the flywheel and camshaft are correctly positioned. (d) Tum the camshaft against direction of rotation until the third mark is in line with that on timing casing. (1. U.

Timing diagram X-Injection point is 17· 6. checking that the exhaust valve reaches the "fully open" position. the first necessitates revolving the crankshaft 16 times approximately. This arrangement allows a variation ofZo between each position. then finally secure with two set bolts. In this position the tappet for number 1 valve is on the dwell of its cam and the tappet clearance may be set with a . 90° then slowly in direction of rotation. Fig. until number 8 valve (counting from front end of engine) is fully open.25 mm) feeler inserted between the rocker and valve stem. Adjust if necessary by means of the six irregularly spaced keyways in the timing chain wheel. Method 2 Fig. locating by means of the dowels. two revolutions only. (0. Re-check clearance after tightening Repeat for each valve in turn." mark on flywheel is in line with the pointer on flywheel housing. and the second. as indicated by the dial Fig.010 in.25 mm) with a feeler inserted between the rocker and valve stem. locknut. Screw the stepped bolt with ratchet and spring in posicion into cylinder block. A-424-Timing gear arraagement. Recheck the clearance after tightening the locknut. Turn the flywheel against direction of rotation approx. exactly when the "E. " 7. Lock the set bolt securing camshaft chain wheel when timing has been set satisfactorily. (0.P. 1. Turn the crankshaft in direction of rotation 48 . Method I Turn the crankshaft in direction of rotation until the selected valve is fully open and then continue for a further revolution whereon the tappet concerned will be resting on the cam dwelL Adjust the tappet clearance to _010 in.A-48 ENGINE-DIESEL MODELS test indicator. A-425-Adjusting tappets 2. Tappet adjustment Operation A/454 Two methods of setting the tappet clearance may be used. A-42l-. . bearing arm and offer the assembly to the cylinder block. Secure the timing chain vibration damper to the front of cylinder block.

valve fuUy open. Locate the vibration damper on crankshaft and key. necessary. 3. Check the run-out with a (i) Early. unmodified engines. valve fully open.5 Set No. as these have been found to be unnecessary. valve fully open. Vibration damper Operation Aj458 1. In order to time these engines correctly.127 mm) by means of the securing bolts. Position new joint washers and fit the front cover and water pump assembly to cylinder block. then fit the set bolts and locking tabs. and reamer the bushes (ensuring that the bore is axially concentric) to allow a clearance fit on driving flange of .2 following order: valve fully open.1 cylinder closed. mount the flywheel and backplate.4 tappet with No.i. Examine the crankshaft oil seal and replace if and fitment Operation Aj460 1. A-427-SOI:ctioned view of vibration damper A-Flywhed and pulley.004 in. 49 .005 in. 3. with both valves on No.ENGINE-DIESEL The tappets should be set in the Set No.7 Set No.3 tappet with No. 2. Fig. Finally bend up the locking tabs to secure the set bolts. valve fully open.076mm).5 tappet with No. to cylinder Front cover block 2.8 tappet with No. Discard any shims which may have been previously fitted. Vertical gear assembly Operation A/462 1.003 in.8 Set No. MODELS A-49 dial test indicator and adjust to within . 4. A-426---ChOl:ck. (0. vibration damper run-out Fig.025 to O.6 tappet with No.7 tappet with No. See "Coolant System" for water pump assembly. Ds--Shims. 6. Drift the plug into the gear until it abuts on the circlip. Mount the unit on a suitable mandrel and rotate between centres.2 tappet with No. drive shaft Water pump assembly and fitment to front cover Operation A/456 I. valve fully open. Injection pump timing Operation A/464 1. Fit the circlip to groove dividing the upper and lower internal splining and enter the tapered splined plug in the end furthest from gear teeth. small end first. 3. Remove the securing bolts and withdraw the backplate from flywheel. B-Bushes. E-Driving flange C-Rubbe~ discs. Fit a rubber disc to each side of the driving Bange. Bolt the flywheel and backplate together. Lubricate the split bush and fit it to the gear with the reduced diameter nearest the teeth •.3 Set No. If necessary renew the bushes in flywheel and backplate with an interference fit of . A-Early engines. (0. with the arrows on backplate and Range ali~ned. until the timing pointer is exactly in line with the SI mark.05 mm) to . valve fully open.6 Set No.ring bolts and tighten fully. 2. Fit the water pump pulley to hub. then locate and secure the pump to front cover. then secure with the starting dog and tab washer. assembly 2. turn the crankshaft in the direction of rotation. Renew the joint washer.1 Set No. (0.4 Set No.001 to . valve fully open. I tappet with No. On early engines the flywheel is marked 51.ng 5. (0. Fit the secu.002 in.10 mm).

(i) Late engines with latest type pistons and earlf type hot plugs. In this way any slight error is magnified by the 2: 1 ratio of camshaft to crankshaft and the large diameter of the Bywheel. The injection pump timing for these engines must be altered to 17 B.C.1 cylinder closed. Replace inspection COveron pump and Bywheel housing. offer the pump to engb e. Note: Engines fitted with late type hot plugs are identified by a splash of red paint on the cylinder head. The timing must be checked by turning the engine until the timing marks on the pump are dead in line and then checking the timing marks on the flywheel.5 mm) past the 51 mark on the flywheel. 3. Offer the pump to engine with the fuel inlet connection forward and engage in the splined drive. With the inlet port rearward. with both valves on No.T. cylinder closed.1 B.C. Turn the crankshaft in the direction of rotation. and the splined upper end of 'driving shaft aligned to the vertical drive gear. the master spline is approx. The correct timing for these engines is 17° B. This type of engine must be timed at 16° Observe the markings through inspection aperture in injection pump side and make any final necessary adjustment by turning the pump body to align the timing marks. Two or three degrees advance can cause excessive black smoke at low speed. On late engines the flywheel is marked 16° and 18°. Two or three degrees retardation can cause excessive white smoke when starting from cold and running at light load. Late engines. Fig. An error of a given width on the pump markings will be 12 times that width if transferred to the flywheel. (iii) Early engines with latest type pistons and hot plugs. full load.1 cylinder closed.T.T. Note 2: It is very important that the injection pump is timed as accurately as possible. with both valves on No.D. Lock the driving gear assembly in position with a grub screw. until the timing pointer is .D. 20" from the centre line of engine (measured from front end) and the locating holes are correctly Oil pump Operation Af466 1.A-50 (ii) Early engines with ENGINE-DIESEL latest type pistons and early type hot plugs. Note 1: It will be found advisable to use a mirror when checking markings. and secure in position.C. on the flywheel. Turn the crankshaft until the timing pointer is exactly in line with the 16° mark on the flywheel. timing for these engines 1S Turn the crankshaft in rotation. 0 MODELS aligned. Tighten pump down and re-check setting. The correct 16~B. the direction of pointer is .D.C..T. 50 . Tum the crankshaft in the direction of rotation. (ii) Late engines Fig. Insert the longer splined end of driving shaft into the pump and locate in the driving gear.1 in. 4. Insert the driving gear assembly for injection and oil pumps complete with split bushes. A-428-Driving gear in ccrrect timing position 2. A--429-Distributor timing marks correctly aligned with latest type pistons and hot plugs. (2. 5. until the timing (5 rnm) past the SI mark with both valves on No. 2.D. then mesh with camshaft gear so that when fully engaged. B.1 cylinder closed. Remove the inspection cover from injection pump and rotate the spindle in direction of rotation until the line marked "A" on driving plate aligns with mark on timing ring. It is very important that the backlash in the vertical drive shaft is taken into account when timing the injection.2 in. with both valves on No. until the timing pointer is exactly between the 16° and 18° mark on the flywheel.

A-43Q. then pressing the extreme end pedestals towards the centre of rocker shaft. see Section M. Screw the unit into the pump inlet port and position the filter square with sump bottom. Remove the bolts securing filter to support bracket at engine. 2. Tum the injectors to align with the pipes and connect.75 Iitres). for method of priming injection pump. 8. 51 . If adjustments are made with the engine running and the oil bath cleaner balanced on top of the engine. should the cleaner tip to one side. (8 to 11 mm) when pressed by thumb between the camshaft and water pump pulleys. See Fig. 11 pints (6 litres) and coolant. 3. Engine. 10. 3. lift the complete rocker assembly clear. where if will act as a fuel and cause the engine to overspeed out of control and serious damage may result.ust be removed completely to prevent distortion. 2. 8. Open the tap at base of radiator and drain the coolant from this point only. ensure that the rubber insulators are left fitted to the main harness and thus avoid the danger of "shorting". 12. Do not overtighten the clamping strap. Connect the oil feed pipe and pressure gauge assembly between cylinder head and cylinder block rear end. 10. to refit Operation A/468 1. lock in position. Note: At all times when the diesel engine is running. Note: Ensure that the bottom steel washer (corrugated) is replaced correctly. Should it be necessary to run the engine with the air cleaner out of the normal position. Fuel Section. e)-C Fig. Remove the pin securing stay to bonnet and lift 4. Check for oil and water leaks-rectify as necessary. Externals 1. Secure the coolant pipe to thermostat and water pump casings. Fit the dynamo driving belt and adjust the tension to allow the belt to move -& to !!r in. Connect the injector pipes to the injector pump. Secure the breather pipe and oil filler assembly over the forward tappet chamber aperture. 7. the bonnet clear of vehicle. Remove the rocker pedestal securing bolts. Refill with lubricating oil. Disconnect the hom leads at the snap connectors adjacent to horn. Disconnect the pipes from main fuel filttr. it is necessary to ensure that the oil bath air cleaner is fastened securely in the vertical position. Insert a new corrugated sealing washer into each injector nozzle recess in cylinder head. and steady bracket to top of cylinder block. then Section Q for resetting controls and slow-running adjustment procedure. II. Withdraw the push rods but ensure that they are retained in correct order for refitment. Note: No provision is made for oil pressure adjustment. the pipe-"filter to injection pump"-rr. Reverse removal procedure-fit new mounting rubbers if necessary. 4. 17 pints (9. 6. A-430-Posi!ioll of injection no. 6. 5. Fit the oil sump. Smear new injector copper joint washers with grease and fit one to each injector. See Section M. 9. the MAINTENANCE PROCEDURE Removing cylinder head Operation Aj470 1. when refitting injectors. Position joint washer and fit the rocker and valve gear cover. for oil to be drawn into the intake manifold and hence into the engine. then locate the injector nozeles: do not tighten the clamping straps fully at this stage. with the raised portion upward. MODELS A-51 13. Remove the air cleaner and flexible air intake pipe Complete. Mount and secure the fuel lift pump and cover plate assembly over the rear tappet chamber aperture. 2. Fit a tab locking washer and seal to the filter gaw:e and nut assembly. Fit the starter motor. Unscrew the dome nuts securing rocker cover and lift the cover clear.ENGINE-DIESEL 3. Disconnect the fuel "bleed back" pipe from injection nozzle and from union nut on main fuel return pipe. detach the heater plug earth lead and withdraw the filter. S. the rubber hose should be disconnected from the inlet manifold and the whole oil bath removed from the vehicle. Fit the heater plugs to cylinder head and tighten. 3. Fit the lubricating oil filter assembly and joint washer. Note: For injector assembly and check.z::t!e w"Qe~s A-Nozzle B-Copper washer C-5teel washer 7. 9. . Mount and secure the fuel oil filter assembly. it is possible.

Disconnect the leads and remove the heater plugs. 2. 4. 2. using a blunt scraper. 6. (0. Examine the valves and valve and renew as necessary. Unscrew the starting nut and withdraw the vibration damper. 4.A-431. and pons.. Replace the cover and rubber hose. 5.010 in. If this procedure is not adopted there is danger of the gasket being nipped on the liner spigot. Inner and outer valve springs ace a selected interference fit and must not be interchanged. part number 274406. See Section M. U. A-417 5. When fitting the cylinder head. then from the piston crown and swirl-controlling recess. 18. Pull down the cylinder head bolts evenly to the correct tension in the order shown in Fig. Fit a new rubber seal to each guide.F. Fitting cylinder head Operation Ai472 1.A-52 ENGINE -DIESEL MODELS Position each valve with its springs and collets together and chalk mark the bench to ensure refitment to the guide from which they were removed. Remove the rocker gear cover. Remove the radiator-Section L. (0. Page A-48.ation A/470. Remove the fuel pipes-injection pump to injection nozzle.6 to 1. side-and the front exhaust pipe from exhaust manifold. Refit the valves. Remove the carbon from the cylinder head. then pour paraffin into each port and check the valve seats for tightness.25 mm)Operation A-454.010 in. 16.N. valve springs and retaining collets. bolts 10 12 to 13 Ib/ft. 2. Loosen the cylinder head bolts evenly. Deearbonising. guides for wear guides may be number 274400 new ones fitted See Fig. See Items 2 to 6 of Operation A/470. (10.only when necessary and then remove the minimum amount of metal. Remove the cylinder head-Oper. to the fuel lift pump outlet. Make sure the injector washers are fitted correctly. Disconnect the rubber air intake hose from the induction manifold and from air cleaner. 8. A/478 o o I o • 0 0 1 Fig.25 mm) as directed under "1 appet adjustment". Remove the top coolant hose and the thermostat by-pass hose. 0 11. 14. The drifted out using tools.11radiator. 15. It is important that the cylinder head bolts are retightened to the torque figures above after 30 minutes' running. x 5 in. then remove them completely and lift the head clear. remove the valves. Engage the starting handle and set the tappet clearance to . i in. Reface the valves to 45°-1 and lap them into their seats. 52 Rocker gear fitment Operation A/480 L Reverse removal procedure and set tappet clearance to . Pivot the dynamo inwards and remove the fan belt. Renew all joint washers. 13. long) must be used to locate the gasket. A-HI-Order of tightening cylinder head bolts. Wash the valves. Rocker gear removal Operation 1. Remove the front cover and water pump assembly. and with tool. 4.. A-430. 3. bolts to 75Ib/ft. l.In. 3. Using valve spring compressing tool. to fuel return pipe union and to the injection nozzle inlet and outlet unions. 17. part inlet and 274401 exhaust. face. Timing chain renewal Operation A/482 1. seats and ports thoroughly with paraffin and wipe dry with a non-furry rag. See Fig. 2.3 Kg/m). 5. 3. Reverse the removal procedure. -Page A-46. springs and collets. .010 in. Prime the fuel system. 7. Adjust tappet clearances to . Run the engine and check for leaks. Refi. Use the valve seat re-cutting tools (part number 274413 inlet and 274414 exhaust) .7 Kg/m). valve grinding and lapping Operation Aj474 1. Remove the inlet and exhaust manifolds if necessary. 4. (1. 12. part number 276102. dummy studs (t in. Remove the injection nozzle securing straps and withdraw the nozzle assemblies. 7. Fit aluminium caps to the injection pump outlet unions. 3.H. 6. (0.25 mm) by either of the methods described under "Tappet adjustment" on Page A-48. Tappet adjustment Operation A/476 1. Lift off bonneftop-Items 2 and 3 of Operation A/470. Disconnect the oil-feed pipe from rear of cylinder head-R.

Remove and discard the two sealing rings from the grooves at lower bore. 1.1 cylinder is fully open when the timing pointer is in line with the E. Refill radiator-I7 Piston and connecting pints (10. 2.ENGINE-DIESEL 6.0 litres). 6. Apply a small amount of Silicone Compound M.C. Refill with oil-e-l l pints (6 litres). immediately surrounding the lower liner bore. Remove the cylinder head-Operation 2. Fit a new gasket between [he filter bead and cylinder block then reverse removal procedure. Smear the top and bottom grooves and two new sealing rings with Silicone Compound M. vibration damper. mark on the flywheel. Cover the oil hole in crankpin with masking tape or some similar material to prevent the entry of foreign matter to the crankshaft oilways. oil filter-removal Operation A/494 1. Jack the front end of vehicle up and position suitable stands beneath the side members.C.' (4.P. side of cylinder block into the middle groove. External rod-removal Operation A/488 1. 2. A/472. Discard the old element and the large rubber sealing ring from filter head. Remove' the cylinder head-Operation A/470. Jack the front end of vehicle up and position suitable stands beneath the chassis side- members. 4. Drain the oil from sump. Place a drip tray under the filter.8 Kgs/m) torque. See Item 1 of Operation Aj494. The timing should be checked to ensure that the exhaust valve of No. 7. is clear.. Remove the sump carefully to avoid damage to the joint washer. then remove the element and container complete.SA. 53 . Check the liner extension above cylinder block joint face in tbe manner instructed by Items 2 and 3 of Operation A/432. External oil filter element-renewal Operation A/498 1. Disconnect the lead at oil pressure switch on filter head. Mark the camshaft and crankshaft chainwheels and mark the casing opposite these marks. Piston and connecting rod fitment Operation A/490 1. 7. Unscrew the bolt at base of container. With the crankpin at B. Replace the cylinder head--Operation 5. 9. 8. 8. 2. Remove piston and connecting rod-Operation Aj488. then replace the container. fit the new element and rubber sealing ring. 4. 4.. and fit liner retainers. 2. Part No. Discard the old chain. 9. 5.fft. 3. radiator and bonnet top by reversing removal procedure. then remove the connecting rod cap and push the rod and piston upward to remove. Cylinder liner replacement Operation A/492 A/470. 4. 3. 3. Wash the container thoroughly in paraffin. side of engine (nearest the External oil fitter-fitment Operation A/496 camshaft). 10. 274411. wipe the grooves clean and ensure that the small hole drilled through the L. Refit the sump and joint washer. Refit the front covet.4 to the outer walls of liner and refit to cylinder block. 11. Remove the securing bolts and withdraw the filter complete. MODELS A-53 3. With the marks on chain wheels and casing aligned. Clean the liner bore spigot at top of cylinder block and the area inside the block. fan belt. 5.D.S. then fit the rings to the top arid bottom grooves.D. Fit new connecting rod cap nuts and tighten to 3S lh. Refit the piston and connecting rod-Operation A/49fJ. Press the liner upward and then withdraw it from the top of cylinder bore. 3. Turn the crankshaft to bring the connecting rod concerned to B.H. Refit the chain tensioner. 1. fit the new chain with no "slack" on the driving side. insert the connetting rod and piston assembly from the top of cylinder block with the oil spray hole in connecting rod and turbulence recess in piston towards the R. then remove the timing chain tensioner and timing chain.H.

valve springs. starting procedure-See Instrueliorl Marlual. Heater plug circuit broken-Section P. 5. Defective Section 4. Restricted fuel supply-Section M. Incorrectly timed injection pump-Check and adjust.A-54 ENGINE-DIESEL MODELS DEFECT LOCATION (Symptom. Incorrect injection M. cylinder head for lightness. llUufficient compression-See item 70/ "An above. 2. 54 . 3. G-WHITE 1. Slow-running incorrectly . D-ENGINE 1. Defective lubrication Seaion AO. 2. 2. Burnt valve-Renew. Supply of fuel 10 injection nozzles restricted-Section M. Defective L. 7. Defective Servi{:e-Section M. 4.. 1. Injection nozzles setting incorrect-Reset-Section M. Starter motor unserviceable-Section P. F-BLACK SMOKE ISSUES fuel injection FROM EXHAUST C-REDUCED POWER AND ROUGH RUNNING. 2.zle-Secti<1n M.jU$t. Broken valve spring-Reruw. reset tappet clearance and tighten injection nozzles. 3. coolant system-See "Defect Lccation"-Secrion "Defect "Defect 1. 5. Fuel pumps not delivering properly-Section M Note:-Do not confuse with the issue of vapour immediately after starting and caused by condensation in the exhaust pipe •. Incorrect 2. injection pump timing-Chec/( Qnd ad. Insufficient compres!l1Qn--CMck Cappet clearance. 4. 9. pistons. Injection nozzle auxiliary spray hole blocked-CleanSection M. VAPOUR leaking into ISSUES FROM EXHAUST. E-LOW OIL PRESSURE. piston rings and liner« [or wear. Broken piston rings-Renew damaged parts as necesmry. 3. 4. 6. B---ENGINE STALLS. system-See nozzles-See Location"Lccation"- 3. 5. Injection nozzles burnt-nozzle valve seating badly- nO"'.-See Section Q. 5. system-See "Defect Locatioll"- l. 1.tdjusted. Compression uneven-See Item 7 of "A" above. OVERHEATING. Incorrect tappet clearance-Adjust. Injection pump incorrectly timed-Check and adjrm. 1. cylinder head gasket. 7. Cause and Remedy) A-ENGINE FAILS TO START. valve seats. Injection nozzle auxiliary spray hole blocked-CleanSection M. Injection nozzle setting incorrect-Reset-Seclion M. Injection nozzles improperly tightened-Check sealing combustion chamber-Ascertain washer and re-tighten. Coolant cause. S. 6. 9. Foreign matter in fuel s}llitem-Section M. Incorrect tappet clearance-Reset. S. Fuel supply restricted--Clean filters-Section M. Defective lubrication Section AO. 10. Batteries in low state of chatge-RemovJl and charge.

.002 to .M. +.5 mm) Markings T.. 3.OOI (63...126 in.001 to ... 1 piston is at top dead centre . When opposite pointer.00 Kg/m) at 2..002 in.843 in..3 .02) End-float (controlled by centre bearing) thrust washers at . (0.... (7..in.02 to 0. B...725 mm-O..OOI (26.5 to 1 .4 .330 in. (0. (33.0025 to .842 in.. .012) Connecting rods Bearing fit on crankpin . (0. 17~ or 16°. 007 to . 1.011 in.02 to 0.001 to .0035 in..1875 in.08 mm) clearance Gudgeon pin Fit in piston..001 to .39) . .-. (0. See Pages A-49 and start of injection is 50 for details indicated.5 in. Piston .279 in.040 ft-lmin. +.000 RP.06 mm) clearance Bearing nip .. .05 to 0.02 to 0.2 3.9 mm) .002 in.05 to 0.012) Minimum thickness after grinding .P. (0....237 mm +0.262 in. 002 to .M. 1. (7.05 mm) interference Gudgeon pin bush internal diameter1...500 R. .005 mm) interference rod .. No. No.87 mm+O.0005 in. ... white metal lined Maximum permissible run-out on flywheel ..-. 105 lbs/sq..002 (22.. (85.0002 in.OI2) Fit of gudgeon pin in bush . 030 in.002 in.P. (0..M. DETAIL DATA Camshaft Journal diameter Flywheel Number of teeth Thickness face at pressure 100 1. (0.02 to 0..D. 2... ..015 (85. (0. 52 at 3.OOl (54 mm-Q.000 R.02) Clearance in bearing. (12..382 Kg/ cm") at 2.004 in.....0005 (46. 2. (0. (88. (0.65 mm) Cam lift-exhaust . .007 mm to 0.725 mm) .M. ..P. +.P...70 nun-o. . 3.0003 to . 4 ..14 rom) Cam lift-inlet . 87 lbs/ft. (0. 2..5 in..10 mm) End-float at big end .P.006 in.SI2 mm+O.0055 in. When opposite pointer.M.375 in..05 mm) End-float ..06 to 0.500 R.. 22.02 to 0.003 in... . Zero to . 2..875 in.C. 1 exhaust valve should be fully open E. Maximum torque Firing order . 1 .ENGINE-DIESEL MODELS A-55 GENERAL DATA Capacity (piston displacement) ..-.021) . (0.052 cc..083 mm) interference Primary pinion bush Fit in flywheel Internal diameter-reamed in position .127 mm) clearance 55 clearance Crankshaft Journal diameter Crankpin diameter .0510) Fit of shaft in bush .0005 reamed in position (31.076 to 0. speed at ..H...0005 in..10 mm) bearings Split-steel backed. When opposite pointer.. (0. Number of cylinders Bore Stroke Compression ratio B.280 mm) Gudgeon pin bush fit in small end . Fit in connecting bush .177 to 0.05 mm) face Maximum refacing depth .E. (6....76 mm) Camshaft Type Internal diameter (line reamed in position) 1.0025 in.5 mm-O.-.375 in..P ..001 to .15 mm) .. (0.0003 to ... sr..001 to .

(0. . 0. 2.... (0.15 mm) Type and 3 2 Push rod tubes Fit in cylinder head .. 4 Type to 0. . Gudgeon pin bore Liners lnter~diarneter ¥it in cylinder block Top-upper . . ..010 in. 010 to . 010 to .005 in.38 mm) Clearance in groove .. (0.A-56 Injection pump Type ENGINE-DIESEL MODELS Clearance in liner bore. 50 to 60 lbs/sq.003 (0. Zero to . +. 0005 to .25 to 0. SI..V.0025 in.(xn to ...OO4 to .20 mm) . Distributor.. 002 to .063 to 0. clearance engine 2.02 to 0.001 in. (52.. in" Main bearings Clearance on crankshaft journal ...38 mm) clearance Top-lower .0025 to ...... See pages A-49 and 50 for details Injector Type .006 in. warm at R.. (0..53 Kg) 2.• 0005 to .063 to 0.000 Relief valve spring .ckergear Bush internal diameter position) Shaft End-float of gears (reamed in Radial clearance of gears ...002 in.005 in..003 in.02 to 0. 17° or 16~. measured at bottom of skirt at right angles to gudgeon . ....0025 to .07 to Fit of busb whed 0.515 to Kgs/cm') Ro. (O. 005 to . . 010 to . (0.13 to 0..005 mm) interference pin . (0..93 mm) Length in position under a load of 10 lbs.. BDNO/SP6209 . double landed Oil pump Type Drive assembly Spur gear Gap in liner bore . . .003 to . Square friction edgechromium plated Gap in liner bore ...375 in.02 to 0..25 mm) hot or cold + rocker bush clearance Bacldash of gears Oil pressure. (0.. Bevelled friction edge.005 in.OOI (85.187 in. (13. (3.. (0.220 Timing chain tenDoner Fit of bush in cylinder . (61...015 in..0035 in..05) Piston rings Compression No. . {O. (0.05 mm) .089 mm) By splined shaft from camshaft gear .45 in.. (0.051 mm) interference on large diameter. Slotted.. Full contact fit at chamfered edges of tube and cylinder head...57 mm+O.. (0...38 mm) Clearance in groove .02 mm) in ..001 to . .0035 in...725 mm +0..015 in.08 mm) clearance .25 to 0..01 to 0.M Tappet.. .".001 in..02) 1..001 to .. 3.001 to ...002 (47.04 mm) ... (0....+.01 .089 mm) Scraper No.... (0. Marked 'T' on upper side.008 in. (0.02 to 0..004 to ...0025 to . .001 to .530 .P. (0.06 rom) Bearing nip.IO to 0. (0.IO to 0. with recess in crown Fit of idler wheel on stub shaft .....012 to 0.0002 in....07 mm) clearance Fit of piston in cylinder bush .015 in..0035 in.063 to 0.. (4.... .4 + 0. I Type .. square friction edge.07 mm) interference Free length .23 mm) Pistons Type Light alloy.• 003 in.10 to 0.12 mm) interference in idler .. self-governmg Injection takes place ..002 in. (0...003 in.38 mm) Clearance in groove ..02 mm) clearance 56 .840 in... Pintaux Size' ...25 to 0.08 mm) clearance .02 to 0. 001 to .. Gap in liner bore .in.......12 mm) Fit of gudgeon pin in piston.. (0. (0.....02 to 0.02 to Bottom "... C.015 in..004 to .089 mm) Compression-Nos.0005 to . (0.002 in..12 mm) .A.

362 mm-o..D.12 mm) Outer ......C... (0.02) . (0.... (10. (21... 001 to . crankshaft Type . 1. Rocker shaft support bracket bolts (5/16 in.89 mm) Length under 17.B. (0..07 mm) clearance Fit of gear in bush Fit of inlet and exhaust valves in guides .18 mm) .. .D.. 16" A. (1. (0.F. T.02) ".. tin plated on friction surface MODELS A-57 Standard size.5 lbs..768 in.01 to 0. (0.91 Kg/m) Valves Inlet valve Diameter (stem) Face angle Exhaust valve Diameter (stem) Face angle .. (8..." .005 in. Exhaust closes Exhaust peak ". 13" B. (38.9 mm) Length under 18..07 mm) clearance Valve seat Seat angle (inlet and exhaust) .7 Kg/m) Flywheel securing bolts 50Ib/ft.06 mm) .F.05 mm) 57 . 45°-t .) Main bearing bolts (9/16 in... . .311 in.917 in.5 Ibs..T..37 Kgs) load 1.. 1. U..9 mm) Length under 481bs ..05) Oversizes . Semi-circular. (40.254 mm) of .6 to 1.010 in..90 mm) Length under 461hs.02) . 006 to .92 m:m-{).. (44.093 in.) ...003 in.00 in.12 mm) •0075 in.B.001 (47. (44.-... (0. steel back.".002 in.n.". +.508 in. (4.D. Length-free 1. (7.75 Kg/m) Valve timing Inlet opens Inlet closes Inlet peak ". (40. + . total thickness..343 in.07 mm) clearance Maximum permissible run-out of flywheel .O..... .. 1.. 106 B. ..001 to ..4mm+O.T.010 in..OOI (8.C. . V.) .3 Kg/m) 851b/ft.0005 to . (0. 45" A. (38..004 in..C.497 in..768 in.05 to 0. (21 Kgs) load .70 mm + 0. (0.02 to 0. ...C. 45° 1 Vibration damper Fit of bushes in flywheel and back plate .0 mm) 351b/ft.003 in...F. 0 12 to 13 Ib/ft.N.02 to 0..372 in.9 Kgs) load 1.. (34. .C.84 j..ENGINE-DIESEL Thrust bearings.(g/m) 751h/ft. l.. Valve springs-exhaust Inner Length-free ...02) + Valve springs-inlet Inner Length-free 1..OOI (7..8 mm) Outer Length-free "" 1.1524 to 0.OO2 (2.-.76 Kgs) load 1.71 mm-O. . Exhaust opens . U. (0.61 in.T.001 (25.. (35.. 1060 A.N.383 in. . (0.D.25 mm) Torque loadings Connecting rod bolts Cylinder head (! in.002 to .0025 in. 45°-i Vertical drive shaft gear Backlash Internal hush diameter .30 mm) Fit of bushes on driving flange ....C..10 mm) Internal diameter bushes (reamed position) of in ..-. (11. (6. 48° B.N.61 in.OO3in.

.

2. Fig. Remove the oil pump cover and lift out the gears. 0. 2. Withdraw the pump. Refit by reversing removal procedure. To overhaul and refit 1. 9_ Adjust the oil pressure.-"-.OOI (14. Note: On engines numbered 860001 to 16102271 and 16131648 a cylindrical oil pump filter was fitted into the side of the sump. 8.15 mm aluminium gear) of the gears. Diesel models Oil pump.006 in. 5_ If necessary. Remove the oil strainer Operation AO!4 from the pump.float Checking Diesel models of the Engine oil filters.02 to O. 3.20 to 0. The bush should be a light drive fit in the pump body.005 in. press a new bush into the body and ream in position to .5625 in.. press out the idler gear bush and drive out the bush in the pump body.. Check the radial clearance (.. leaving the drive shaft in position.012 in. Slacken the locknut securing oil pressure adjusting screw.>ilpump 59 .28 rnm-> 0.ENGINE LUBRICATION INDEX Approved 1ubricants: Page AO-3 AO-3 AO-7 AO-7 LIST Fig. 3_ Remove the idler gear spindle. AO-l AO-2 AO-3 AO-4 AO-s Oil pressure relief valve.13 mm steel gear. -enew parts as necessary. Petrol models Oil pressure adjustment.004 to . Petrol models Checking clearance of oil pump gears. Petrol models Exploded view of oil pump and driving gear. E-Spring F-washer G-Locknut H-Adjusting screw-s-oil pressure 6. late Petrol models OF Page AO-l AO-l AO·2 AO-8 AO-4 AO-4 AO-9 Filter-external. Petrol models. AO·6 AO-6 Checking for radial clearance. examine for wear and renew as necessary. oil flow would be insufficient. If removed. and . Operation AO/6. 4. spring. If necessary. Filter-s-external.30 mm) and end-float (. backlash (. washer. ensuring correct alignment with the bore at the bottom end of the pump body.008 to .. withdraw the oil pump drive shaft.Section AO . 1948-54 models Engine oil filters. Petrol models Oil pump.075 to 0.10 to 0. models end. all models Page AO-4 AO·6 AO-l AO-4 AO-4 Oil pump. Petrol models ILLUSTRATIONS Fig.001 to . AO-I-Oil A-Locknut B-Locating C-Ball D-Plllrtger pressure relief valve. 0. AO-2-Checking durance of oil pump gears. screw--<. all models Defect location.025).004 in.003 to . 4. Clean parts. then remove screw. Fig. 5. Diesel models Page view of oil pump and AO-s Diesel AO-6 gears. Petrol models To remove Operation AO/2 1. plunger and ball (which may remain in the pump and can be removed when the pump complete is withdrawn). Petrol models Diesel models Petrol models Diesel models Data. AO-6 AO-7 Exploded driving gear. 0.to mm). 0. 7: Complete the assembly. Remove the pump locating screw. If incorrect. Drain the oil and remove sump. Diesel models Relief valve adjustment.

locating distributor housing 32 33 Locker for bolt .]3 14 15-16 17 60 Oil pump body assembly Bush for drive shaft Oil pump shield Oil pump gear.AO-2 ENGINE LUBRICATION -21 -20 Fi. AO-3-E:zploded view of oil pump and driving pal'... driver Oil pump cover assembly Dowel locating body Spindle for idler wheel Self-locking nut (1") fixing spindle Stud for oil strainer Oil pump gear idler assembly Bush for idler gear Fixings-cover to body Oil strainer for pump Fixings-cil strainer to pump Distributor housing assembly 18 Bush for drive shaft 19 Cork washer for housing 20 Oil pump drive shaft 21 Drive shaft for distributor 22 Oil pump.g. fixing gear to shaft 24 Steel ball 25 Plunger 26 Spring For oil pressure 27 Adjusting screw release valve 28 Washer 29 Locknut pump to cylinder block 30-31 Fixin~i1 Oil feed bolt. 1 2 3 4 5 6 7 8 9 10 11 12. driving gear 23 Taper pin. Petrol models..

&so Muhipurpe . Oil 20 ENGINE Bsoolube H020 I Mobil<>i! Atctit: I RoteU.al conditions vary between approximately IOQFand 90°F...l!. trol Hypoy Uttivonal Thubm90 REAR POWER TAU-OPP. NOL EP!IO Esso Exp •• Compound 9() Mobilube GX90 Spirax 90EP C..A-E. 1 !lnrin. 2 NOTE 1: -2O"F . NOLTwcnty r ENGINE ESSO BuoB.B. These recommendations apply to temperate climates. mde. .t:!l LB 10 G. Energol SASlOW DUCKHAM'S Dutkham . 9O"F . LM Marfak MultlPu"".O'C..... UK NOTE 2. .. O'P ~ -I'1"e.. A Castro! ."t. NOTE 3: InformatiM on oil reoomme. PULLEY VNIT AND CAPSTAN WINCH LUBRICATION NIPPLES - Energr'use L-2 Duckbam.ted abo •• are ncommmdod for the hiaher 1"On8' of S. where operation..32·C.tn lOW/3D MOBIL MobilcU Arctic SHELL Sh. S.. 2O/lOW DIESEL ENGINE AND AIR CLEANER lOW Bno~l Oi_11 D OW HOL Di .-12·C. 20W B. oils Ii.J UK under at~m-e conditions can be obtair.y are aI50 approved for winter or tropic:.. 2O/20W CastrO' CR20 i RPMDdco Spoow20 ALL MODELS GEARBOX AND TRANSFER BOX DIFFERENTiALS AND SWIVEL PIN HOUSINGS STEERING STEERING (SEALED) AND RELAY UNIT BOX !IOBP Enml':P Ducldwn'..ENGINE LUBRICATION AO-3 The chart below covers all currently recommended lubricants for use in engines and all other units..UXIOO SAElO/20W WAKEFIELD Caslmlite REGENT Havalin.A.P.ru1atiOD~ Technical ~co ~.. AIR CLEANER AND GOVERNOR S.. lhal Ibey cover. for UN undilJ' under Ih.A. 61 . shown in tho cbarr: U. PETROL COMPONENTS ENGINE..-28'C.ed &on1 The Roftt' Co. 10'P . The multi-~. Ltd..rtm.tin . ·number . Gr_H Mobilgr_ MP R. 32"P .

in.4 Oil pressure relief valve.ust=~nt 1948-54 models A-Adjusting screw. 3. Petrol ENGINE models AOj6 LUBRICATION 2. (1. Warm the engine to running temperature and adjust the pressure by means of the valve to 55-65 Ib. 2. to renew L Disconnect the inlet and outlet pipes from the filter.) in top gear. 1948-54 models. withdraw and discard the filter. 62 2. spring and ball from the filter head. using the new large rubber sealing washer supplied with element. Remove the securing bolts and withdraw pump assembly.8-4. AO-4--0il pressure ad. Reverse dismantling procedure and refit the assembly to the cylinder block with a new joint washer interposed. 2. the engine and check for oil leaks at the filter and then add more oil as necessary. Refit the warning light switch and lead. AO-S-Engine A-COntainer B-Element C-Gasket oil filters.5 Kg/em') at 30 rn. run To adjust Operation 1. then unscrew the bolt at the base of the filter container.5 litre) for filter. Withdtaw the driving shaft from pump upper casing. 4. Fig. Fit the new filter by reversing this procedure. 1955-58 Petrol models Element to renew Operation AO/8 1.in./sq. If necessary.p. 3. Position a suitable drip-tray beneath the filter. Oil pump.p. Check the engine oil level and top up as necessary. Ensure that the sealing washers are in position and intact and that the container is correctly located. AOJI2 and refill the engine with one of the recommended lubricants.4 kg/emt) oil pressure. 5. Withdraw the container complete with element and large rubber sealing washer. Discard the element and wash the container thoroughly in petrol./sq. Operation AOjB. Fig. (3.h. Unscrew the container bolt and renew element. Fit a slave oil pressure gauge in place of the warning light switch. Diesel models To remove Operation 1. Place a new filter element in the container and reassemble the unit. then wash these parts thoroughly in petrol: 4. run the engine and ensure that there is at least 20 Ib. Run the engine for five minutes and inspect and rectify any oil leaks. B-Locknut. 3. Remove the bolts securing the filter head to the adaptor. Fill crankcase sump with clean cil+-Ll pints (6 litres)-to the "high" mark on dipstick. Slacken the four set bolts securing the filter mounting bracket and clip to the cylinder block.. Drain the oil and remove sump. renew the release valve spring. then withdraw complete unit.h. late Petrol models n-Qil pump E-Filter gauze F-Caste1lated nut External oil filter. . 3. Remove the relief valve. 4. (50 k.AO. 2. Figure for capacity includes 1 pint (0. Unscrew the securing nut and remove filter gauze assembly. External oil filter. Filter-to remove and clean Operation AO/tO 1. Tighten the screw to increase pressure and vice versa. 3.

01 mm) will exist between the gears and housing. Check the external diameter of the gears and the internal diameter of the gear housings. 3. The idler gear spindle may be removed if necessary. 63 To overhaul and refit Operation AO/14 1.127 nun). thus allowing a m. plunger and ball.0508 to 0.003 in. .0005 in.u:imum radial clearance of .08 mm) thickness between the gear perimeter and gear housing. Lay a straight edge across the joint fac~of pump body and check the end-float with a feeler gauge. inserting the splined end first.08 mm) between the gear and housing. Unscrew the relief valve plug and remove the spring. 276095 and 276094 respectively. stepped end of idler spindle into the pump body and fit the cast iron idler wheel. 2.05 mm) thickness between the gear perimeter and ring gauge. AO-6-ExplGded view of oil pump and driving gear. With the gauges an exact fit in the bore of the housing. 6.002 and . a radial clearance of . Mesh the steel gear with the idler gear.ENGINE LUBRICATION AO-5 Fig. 1 Lower casing Driving gear Driven gear Relief valve ball 5 Relief valve plunger 6 Relief valve spring 7 Washer 8 Plug 9 Upper casing 10 Set bolt for casings 2 3 4 11 Spring washer for bolt 12 14 Filter gauze assembly Tab washer 13 Oilsea1 15 Driving shaft 16 Driving shaft gear 17 18 19 20 Circlip Bush-drive shaft gear Locating screw Securing bolt 5. tap them gently apart and withdraw the gears. (0. (0.003 in.002 in. (0. Diesel models. This should be between . (0. (0. or a feeler strip of more than . and on the outer diameter of the gears. Remove the bolts securing the upper casing to lower body. using a ring gauge and plug gauge. It should not be possible to interpose -a feeler strip of more than . Part Nos. Press the short.005 in.

then wash these parts thoroughly in petrol. Fig. Figure for capacity includes 2 pints (1 litre) for filter. and the splined upper end of driving shaft aligned to the drive gear. Reverse dismantling procedure and refit the assembly to the cylinder block with a new ioint washer interposed. offer the pump to engine and secure in position. A-Container B-E1ement C-Gasket D-Oil pump F-Nut for filler gaU%e E-Filter gauze G-Locker for nut Filter-to remove and clean the leads from Operation AO/18 the oil pressure 1. 6. bolt and renew element. 7. run the engine and check for oil leaks and then add more oil as necessary. Refit the crankcase sump and refill with oil13 pints (7 Iitres)-to the "high" mark on dipstick. Smear the. Diesel models.end-float 1)f the para. then bolt together.AO·6 ENGINE LUBRICATION External oil filter. is made for oil pressure adjustment. Screw the unit into the pump inlet ports and position the filter square with sump bottom. AO-7-Checlting for radial clearance. plunger and spring. fit a new dement. Figures for capacity includes 2 pints (1 litre) for filter. Fill crankcase sump with clean oil (13 pints (7 lit res» to the "high" mark on dipstick. Unscrew the container Operation AO/16. Fig. lock in position. Note: No provWQi:!. then unscrew the bolt at base of the filter container. Diesel modela 2. 3. Wash the container thoroughly in petrol. 4. Position a suitable drip-tray beneath the filter. 8. new inner and outer top sealing rings. Remove the pressure switch. With the inlet port rearward. 5. AO-8-Checking . Insert the longer splined end of driving shaft into the pump and locate in the driving gear. Fig. joint faces of pump body and cover lightly with suitable jointing compound. 5. Diesel models A-Plug gauge B-!-Ringgauge 4. Secure with plug and washer. Diesel models Element-to renew Operation AO/16 1. Withdraw the container complete with the clement. I~ 3.then withdraw the complete filter assembly. AO-9-Engine oil filters. Fit a tab locking washer and seal to the filter gauze and nut assembly. Disconnect switch. which must be discarded. Insert the relief valve ball. then replace the container. Remove the bolts securing the filter head to cylinderblock. 64 . run the engine and check for oil leaks at the sump joint face. also the relief valve spring and ball from the filter bead. 9. 2. then add more oil as necessary.

005 in. (0. A-WARNING LIGHT REMAINS "ON"-ENGINE RUNNING 1. (3.004 to . 2. Refill with clean oil. engine warm At 2.B to 4. 1.53 Kg. 3.10 to 0.20 to O.. B-LOW OlL PRESSURE Ascertained by gauge fitted in place of switch and with sump oil I~d correct.54 mm) Oil pressure.. etc. Electrical fault-Check circuit. Excessively worn bearings-main.B9 Kg) load 1./sq.45 in. camshaft.000 R.990 in. Relief valve plunger sticking-RemoVll and ascertain cause. (0. (77.002 to . in.20mm) .001 to .lOmm) ..5 Kg/cm") Oil pressure relief valve Type. Dirty gaun filter on pump-RemoVll sump.30mm) Type Drive End-float of gears Radial Steel gear of gears: gear models Spur gear Splined shaft from camshaft .13 mm) . Pump body joints loose-Tighten.050 mm) 0. (3. 0. C----WARNING LIGHT FAILS TO GLOWWhen engine is stopped and ignition (petrol engines) or auxiliary services (Diesel) switch is "on".008 in. Free length . 3.93 mm) Compressed length at 10 lb. Electrical fault-Check circuit. 2. Gears excessively worn-Su Operotirms AO/4 and AO/14 8.P. (0.in. Bulb filament broken-Renew bulb.M. Incorrectly adjusted relief valve (2 litre Petrol only)AdjllSt to 55 to 65 Ib/sq..15 mm) . DATA Oil pump-Petrol Type Drive End-doat models Oil pump-Diesel Gear Skew gear from camshaft . . 2.050 in.47 mm) Compressed length at l3lb.8 to 4.02 to O. 55 to 65 Ib. 3.002 in.) .ENGINE LUBRICATION DEFECT Symptom..012 to.006 in. connecting rod big-end.840 in. (61. 50 to 60 lb. (5. Oil pressure switch unserviceable-Renew.515 to 4.10 to 0. to .. Foreign matter on pump ball valve seat-Remove and clean. AO-7 LOCATION Cause and Remedy 4. (52. remove filter gauze and dean in pttrol with a stiff brush. S.005 in. (50. 6.004 in.220 Kg/em') Oil pressure relief valve Type .008.004 to .12 mm) Backlash of gears to . (3.in.0005 Backlash of gears Oil pressure.. 2. . Section Q..5 Kg/em') 7. 1. Non-adjustable Relief valve spring. 2 Oil pressure switch unserviceable-Ren~w. (0.003 to .075 to 0. Adjustable Relief valve spring: Free length 3. (0.. (0. (0.jsq. load (4.012 in.M.-Arcerraill whkh bearings and rectify.025 to Aluminium Radial gears clearance of gears clearance of 0.P. engine warm At 2.23 mm) 65 . Low oil pressure-See item B. Weak relief valve spring-Renew.000 R.

.

..... OF ILLUSTRATIONS Page Fig.. Measuring mainshaft C-23 C 24 C-24 C-24 shaft ... gear shaft output .... C-14 C-15 C-16 C-6 C-B Tightening Page n~ transfer drive gear securing 2nd speed gear stop bolt. Main gear change lever Fourwheel drive Freewheel Front output shaft housing Reverse stop T I'3nsfer box: . Cross-section Adjusting of reverse stop C-12 Measuring mainshaft bush end-float C-13 Fitting synchronising clutch assembly C·25 C-25 C-25 reverse stop 89 ... C-32 C-32 C-33 gear end-float........ C-lS « 33 C-13 &:: 30 C-B C-30 C-J6 & 33 C-26 UST Fig.Section C GEARBOX UNIT ALL MODELS INDEX Page Data Defect location Gearbox and transfer assembly Gearbox unit mounting Main gearbox: .. Page C-35 C-34 C-17« 22 C-22 C-23 rubbers . C·22 C-23 outer C-22 C-29 C-lO C-31 reverse gear stop bolt Setting the link pin Setting transfer and dog clutch selector ColO C-1I Removing layshaft rear bearing race .. shaft shaft C-28 shaft C-28 COl C-2 C-3 C-4 Layout Layout of the gearbox unit: casings unit: shafts C-2 C-4 of the gearbox and gears C~ C-26 C-27 Adjusting Layout of the gearbox unit: front output shaft housing and controls Layout of the gearbox unit: main gear change lever and selectors '" Cross-section tion of gearbox Wlit: elevaplan Removing intermediate Fitting transfer protection cap box C-17 C-IS C-19 C-20 C-2I C-27 C-S C-6 ColO C-lI C-12 Removing transfer box output front bearing outer race Removing transfer box output front bearing inner race Adjusting transfer end-float Adjusting Cross-section of gearbox unit: Cross-section C-7 C-g C-9 of gearbox unit: controls rubbers drive gear box output shaft Gearbox unit mounting Removing securing the nut transfer ....

Fig......C·2 GEARBOX UNIT-ALL MODELS . C-I-Layol1t or the gearbox uait casings 90 .

D. short. top and bottom Jointwasher for plug Oil level plug Rear mounting foot L. rear mainshaft bearing 19 Bush for housing 20 Retaining plate. Rear mounting foot R.H. bottom. outer 23 Circlip fixing bearing 24 Joint washer for bearing housing 25-26 fixings for housing 27 28 29-30 31 32 33-34 35 36 37-38 39 40 41 42 43 44 45 46 Cover plate for P.H. short. selector Joint washer for cover plate Fixings for cover plate Cover plate for transfer gear change Joint washer for cover plate Fixings for plate Cover plate. short 4 Stud for mainshaft housing 5 Stud for top cover plate 6 Stud. for transfer box Joint washer for bottom cover Fixings for cover Plug.T. transfer box to gearbox Fixings for transfer box Fixings for transfer box 47-48 49 50-52 53-55 91 . for transfer casing 4 Stud for bell housing 5 Dowel locating top cover 6 Dowel locating transfer casing 7 Top cover for gearbox 8-9 Fixings for top cover 10 Inspection cover plate for selectors 11 Set screw fixing cover plate 12 Oil filler cap 13 Joint washer for cap 14 Plug for retaining spring 15 Retaining spring for cap Fixings for spring Oil level dipstick Drain plug for gearbox Washer for plug Bell·housing assembly Stud for withdrawal race housing 23 Dowe1locating gearbox 24 Joint washer bell housing to gearbox. Adjuster for mounting foot Plain washer }For adjuster Self-locking nut Fixings for feet Joint washer. inner 21 Bearing for mainshaft 22 Retaining plate. 25-26 Fixings for gearbox casing 27 Top cover for bell housing 28 Rubber seal for top cover 29 Centre for dust cover 30 Grommet for bell housing hole 31 Grommet for bell housing shaft 16-17 18 19 20 21 22 1 Transfer box casing assembly 2 Stud for intermediate shaft 3 Stud for speedometer housing. for transfer shaft housing 7 Stud for engine mounting 8 Stud for bottom cover 9 Dowel locating speedometer housing 10 Bush for shaft guide 11 Housing assembly for speedometer pinion 12 Insert for pinion 13 Stud for transmission brake 14 Mudshield for housing 15 Shim for speedometer pinion housing 16-17 Fixings for housing 18 Housing assembly.GEARBOX UNIT-ALL MODELS Key to Fig C·l 1 Gearbox casing assembly 2 Stud for top cover and gear change plate 3 Stud.

C-4 -:. 'C-2-Layout .:. ~_g '" "ts' shafts 0f the lear bOI:.. 92 . UDa • and g~ar. '" '" ~~-'" &-::l Fig.

GEARBOX UNIT-ALL MODELS c-s :.::/ 93 .

transfer gear controls and front output shaft aDd housing 94 . C-3-Layout of the gearbox unit: front wheel drive.C-6 GEARBOX UNITS-ALL MODELS Fig.

13-14 15 16 Joint washer for retainer Fixings for retainer Locking dog.GEARBOX UNIT-ALL MODELS C-7 Key to Fig. gear change to pivot shaft 17 18-20 21 22 23-25 26-27 28 47 Locknut for knob and clevis 48 49 Spring for transfer gear change lever 50 Knob for gear change lever 51 Locknut for knob 52 Bracket for gear change lever 53 54-56 Distance piece for bracket Fixings for bracket Fixings for gear lever 95 29 Spring for plunger 30 Plug 57-58 . four wheel drive Clevis complete for rod Split pin for clevis Spring for selector rod Control knob for rod Transfer gear change lever complete 2 Selector fork complete. fout wheel drive 3 Bush fOr selector fork 4 32-33 Fixings for link 35 36 38 39-40 41 Spring for selector fork Block for selector shaft Fixings for block Selector shaft. four wheel drive Flange for transfer shaft 2 Stud for oil seal retainer 3 Front output shaft assembly 4 Bush for shaft 5 Oil thrower for output shaft 17 Mudshield for flange 18-20 Fixings for flange 21 Joint washer for transfer housing 22-23 Fixings for housing 24 6-7 Fixings for oil thrower 8 Bearing for front output shaft 9 Oil seal for shaft 10 Retainer for oil seal 11 Dust cover plate for selector shafts Mudshield for retainer 25-26 Fixings for dust cover 1 Selector shaft. lever to housing Sealing ring. fout wheel drive Bush for lever Special bolt. four wheel drive lever 11 Selector fork. C-3 1 Output shaft housing assembly 12 . transfer gear change 12 Set bolt fixing fork 13 Distance tube for transfer selector shaft 14 42 43 44 Locating bush for selector shaft spring Spring for gear change selector shaft Block for selector shaft Fixings for block Pivot shaft for selector shafts Coupling. four wht~ drive 31 34 Link tor selector shaft Lever assembly. selector shafts to pivot Fixings for coupling Fixings for pivot shaft Plunger for transfer selector shaft 15 45 Special bush for spring 46 16 Connector. four wheel drive locking pin Fixings for locking pin Selector rod. transfer gear change Sealing ring for transfer gear change shaft 5 6-8 9 10 37 Locking pin.

C-8 GEARBOX UNIT-ALL MODELS o W@-9 s ~18 Fig. C-f-Layout of the 8'eal'boxunit: main gear change lever and selectors 96 .

1st and 2nd speed Shaft assembly for fork. 19 Rubber grommet 20-21 22 13-14 FWngs for mounting plate 15 Reverse stop 1·". 18 Retaining plate RH. C·4 1 Sdector fork. 1st and 2nd speed Interlocking pin 6 Peg fixing interlocking pin 7 Selector fork. reverse 9 Set bolt fixing forks to shafts 10 11-12 Stop for 2nd speed Fixings for stop 13 Interlocking plunger 14 Steel ball for selectors 15 Selector spring.H. forward 16 Selector spring. 3rd and 4th speed Selector fork. reverse 8 Shaft for fork. reverse 17 Retaining plate L. side selectee hinge complete For binge 16 Adjusting screw } 17 Locknut Fixings for retaining plates Seal for selector shafts 18 Bracket for reverse stop spring 19 Spring for reverse stop 20-22 Fixinp for hinge and bracket 23 Cork seal for reverse shaft 24 25-26 27 28 Retaining plate for sealing ring Fixings for retaining plate Set bolt Locknut } In cover for 2nd sear stop 29 30 Adjustable stop for reverse selector shaft Locknut for stop 97 . 3rd and 4th speed 2 3 4 5 1 Gear change lever 2 Housing for lever 3 Locating pin for lever balI 4 Spherical seat for gear lever 5 Retaining spring for lever 6 Retaining plate for spring 7 Circlip fixing retaining plate 8 Knob for lever 9 Locknut for knob 10 Mounting plate for gear cbaoge 11-12 Fixings for housing Shaft for fork. J springs.GEARBOX UNIT-ALL MODELS C-9 Key to Fig.

C-5--Cross-scction of gearbox unit: elevation 98 .C-IO GEARBOX UNIT-ALL MODELS •I Fig.

C-6-Cro5s-seetion of gearbo:l[ unit with dog clutch controlling front-wheel drive plan.GEARBOX UNIT-ALL MODELS C-lI Fig. 99 .

100 C-7-Crolll-aectioD of gearbox unit: cODtroll. .C-12 GEARBOX UNIT-ALL MODELS Fic.

9. Slacken the rear engine and gearbox unit mounting bolts. Withdraw the split pin and remove the clevis pin connecting the operating rod to the lever on the clutch cross-shaft. Prior to fitting the freewheel housing. Remove the plug and joint washer from the lefthand side of the output shaft housing and withdraw the transfer selector spring and ball. floorboard. 10. forward and down below the chassis. 12. Re-assemble by reversing the sequence of oper- ations detailed for removal. 101 . Remove the special nut and shakeproof washer securing the transfer control link [0 the selector shaft. 1948w~B models 6. R~move the dust cover from the front of the output housing by removing the three nuts. avoiding damage to the oil seal. . control pivot and eyebolt complete from the output shaft housing. Slacken the locknut and remove the freewheel Four-wheel position) To remove (Gearboxes onwards) drive mechanism (gearbox in numbered Operation C/4 16102314 and 16131688 7. 3.D. models only. 13. gearboxes numbered 860001 to 861988. 5. shaft housing. 8. complete with joint washer.H. 4. R. 19. Check the operation of the transfer and freewheel controls. Withdraw the split pin and remove the joint pin and two washers securing the cross-shaft to the connecting tube on the clutch shaft. securing the transfer control link to the selector shaft and slide the link up the transfer gear change lever. 20. 5. Place the transfer gear change lever in the low 4. 18. it is essential that the locking dog remains in the output shaft housing. transfer lever. Remove the transfer box drain plug and drain off the oil into a suitable receptacle. chassis and remove the housing. Position the vehicle over a pit or raise it as high MODELS C-l3 (gearbox in position) Operation C/2 prior to 16102314 and 15. 11. from the front end first.-/ 16. R. to the rear. Note: On. paying attention to the following points:- as possible with a high-lift jack. Remove the yellow knob. Slide the cross-shaft through the bushes as far as possible towards the chassis side member. Remove the clutch return spring. 2.D. Refill the transfer box with oil of the correct grade. Withdraw the split pin and remove the clevis pin connecting the operating rod to the lever on the clutch cross-shaft.e. ensure that the freewheel operating shaft. Remove the seven nuts and spring washers securing the output shaft housing and carefully remove the housing. Remove the front propeller shaft (see Section D). place a suitable guide thimble over the end of the transfer selector shaft. Remove the seven nuts and spring washers securing the freewheel housing to the transfer casing. Draw out the freewheel operating rod. Position the vehicle over a pit or raise it as high as possible with a high-lift jack. Withdraw the split pin and remove the castle nut and plain washer securing the front axle driving flange. Lever the gearbox unit slightly upwards to allow the bottom freewheel housing boss to clear the 8.H. guide and spring work freely in the transfer casing. locknut. avoiding damage to the oil seal. the two upper nuts can be conveniently reached through the seat box centre panel aperture. Remove the red knob and locknut from the 7.GEARBOX UNIT-ALL 1948-53 models Freewheel components To renew (Gearboxes numbered 16131688) 1. otherwise it will prevent the unit clearing on removal. carefully remove the flange. Remove the front propeller shaft (see Section D).H. Prior to replacing the output off the oil into a suitable receptacle. from the front end first.. Remove the clutch return spring. freewheel components as required and rebuild the unit. Remove the R. Remove the. Slide the cross-shaft through the bushes as far as possible towards the chassis side member. complete with joint washer. 6. bush from the front-wheel drive control rod. 14. to prevent damage to the oil seal. remove the split pin and spring-loaded clevis pin and remove the transfer lever. 2. position. Withdraw the split pin and remove the castle nut and plain washer securing the front axle driving flange. in a similar manner to the output shaft housing. spring and 9. 3. Withdraw the split pin and remove the joint pin and two washers Securing the cross-shaft to the connecting tube on the dutch shaft. 10.. i. Remove the special nut and shakeproof washer 1. carefully remove the flange complete with dust seal. spring washers and distance pieces. Remove the transfer box drain plug and drain 17. models only.

If removed. The bush must be reamed in position to . bearing and housing as 2. (98.640 in.22 mm) giving . Remove the split pin. front-wheel drive dog dutch. Remove the seven nuts and spring washers securing the output housing to the transfer box (ibis action also releases an earth lead). Withdraw the output housing complete with output shaft. castle nut and special screw from the transfer selector shaft and remove the block. remove the two bushes from the Free length: 7. 14. remove the: oil seal from the retainer.156 in. 1948-53 models the gearbox mountings and lift under the lefthand support.002 (0. Check the transfer selector shaft spring in accordance with the following data and renew as necessarye-« (b) Spring.8 kg) Rate: 7. "remove the spigot bush from the rear end of the output shaft. (10. fit a new oil seal in the retainer with its knife edge inwards.875 in. 20. The bearing must be a push fit on the shaft and a light drive fit in the housing. (182. Replace the block on the selector shaft and secure by means of the special screw. 5. replace the output shaft front bearing in the output housing. Remove the six nuts and spring washers securing the oil seal retainer to the front face ofthe output housing and remove the retainer complete with oil seal and joint washer. (5. (2. 8. If removed. to . withdraw the output shaft front bearing from the output housing. If necessary. Leave the transfer selector shaft and link in position protruding from the transfer box.5 mm) Solid length: .8 kg) Rate: 61th. Fit the two springs and selector fork (crank to the rear) over the dog clutch selector shaft.750 in. castle nut and special screw from the dog clutch selector shaft and remove the block.7 mm) Length in position: 3. If necessary. Detach the link from the link pin by removing the special screw. to . Check the two dog clutch selector springs in accordance with the following data and renew as necessary:Free length: 2.02 mm to 0. Note: The connector should not be removed from the link pin unless absolutely necessary. renew the two oilite bushes in the dog clutch selector fork boss.875 in. Replace the oil seal retainer on the output housing and secure with six nuts and spring washers.001 in.jin. necessary. clear of the chasis crossmember. If removed. 23. Four-wheel position) To replace (Gearboxes onwards) drive mechanism (gearbox Operation in C/6 numbered 16102314 and 16131688 13. 18. (69. castle nut and split pin. Remove the housing. hold in low transfer and remove the output housing upwards through the floorboard aperture. (e) Spring. (d) Distance tube.4 mm) Load in position: 24tb. link pin and connector assembly. 1.C-14 GEARBOX UNIT-ALL MODELS 11. If necessary. Slide the following parts from the transfer selector shaft:(a) Link. 21. 12.2 kg). Remove the front-wheel drive control lever assembly by withdrawing the special pivot screw. Slacken 22. (16 mm) Maximum load: 131h. as difficulty will be experienced in effecting correct alignment on re-assembly. 3. Remove the split pin. 4. output shaft from the output 17. If necessary. (3. Slide the two springs and selector fork from the 19. locating bush. Withdraw the dog clutch selector shaft and dog clutch from the rear of the housing.001 in. replace the spigot bush in the rear end of the output shaft.002 clearance on the selector shaft. If necessary. the bushes must be pressed in flush with the end faces of the boss and must have . (22.jin. 7. Renew the shaft. 16.311b. casrle nut and split pin. selector fork boss. pressing it in Bush with the face of the shaft. the dog dutch selector shaft and fork and a joint washer.05) clearance on the transfer box output shaft.7 kg) 6. 9. Remove the top cover plate from the transfer box. dog clutch selector shaft. 102 . 15.

Fit the dog clutch over the splines on the transfer box output shaft. Fit the plunger and spring. block selector shaft and secure with the castle nut split pin. complete with the shim plates. Cd) Compress and the the and and 13. 12. Remove the left-hand (see Section R). 7. remove the knobs and locknuts from the main and transfer gear change levers. 2. If the connector has been detached from the link MODELS C-15 pin. Remove . Renew any worn components. The overhaul operations differ extensively between the two patterns. Secure with the seven nuts and spring washers. it may be necessary to adjust the thickness of shim plates. spring retainer plate and shim plates. anti-rattle springs and nuts securing the ball retainers to the lever and remove the upper (small) and lower (large) ball retainers. 19. Complete the assembly by sequence of removal operations. together with the shim plates. 11. spring washers and nuts securing the reverse stop housing to the gearbox cover and remove the housing. It may be necessary. tighten the connector on the link pin. Fit the complete gear change lever to the gearbox cover panel. (e) Spring. Remove the freewheel control ring or front 'wheel drive control knob.128 in. spring washers and nuts. and . The threaded end of the screw must be downwards and the shorter end of the link towards the transfer selector. Replace the complete gearbox cover panel in the vehicle and check 'the operation of the gear change lever and reverse stop. and . select two-wheel drive in high transfer gear (through the transfer box) and fit the output shaft over the transfer box shaft and through the housing. detent ball and spring in the reverse stop housing and hold them in position with the retainer plate. the plates are available . Place the housing Over the selector shafts (from the top). Remove the detent ball spring. Check the whole assembly for correct operation. and right-hand toe plates 103 . but does not "bottom" in the gearbox selectors. 3. thick. the main gear change lever is bolted to the gearbox cover panel. complete with shim plates. by means of the two bolts. thick.036 in. Remove the knob and locknut from the lever. which should be preserved. 1948-53 models Main gear change To overhaul lever Operation CJ8 On vehicles numbered 860001 to 861500. Adjust the front-wheel drive rod to ensure efficient extraction and replacement of the locking peg. 4. Remove the gearbox cover panel. Secure the link to the link pin by means of the special screw. 2. which should be preserved. Vehicles numbered 860001 to 861500 1. adjust the shims as necessary. Fit the dog clutch selector shaft assembly into the bush in the transfer box. Fit the special screw from bottom. 6. through the coupling jaw. picking up the earth lead under one of the nuts. 17. anti-rattle springs and nuts.the lever selector makes good contact. Remove the two bolts. castle nut and split pin. spring washers and nuts. to adjust the thickness of shim plates to allow ease of operation of the reverse stop unit. it is important to avoid the spring becoming coilbound as under such conditions the operation appears correct. the plates are available . ensuring that the link engages the screw correctly. detent plunger and spring from the housing. 10. with the longer arm of the jaw at the opposite end to the rear. 12. spring washers and nuts securing the gear change lever to the cover and lift off the lever. . with its the spring and fit the link connector assembly until the block is over hole in the shaft. 4. 14. Replace the locknut and knob on the lever. but the peg is not extracted sufficiently to engage four-wheel drive. After fitting the unit in the vehicle. !>rake pedal rod and pad (see 18. ensure that the connector is square with the pin and secure lightly with the nut and sh ikeproof washer.the Section H). ball. Remove the clutch pedal and pad (see Section B). 16. (b) Spring locating bush diameter to the front. at a later stage. 9. from the vehicle. reversing the 8. Slide the following parts shaft:- ~n the transfer selector smaller (al Distance tube. complete with the gear change lever and reverse stop. replace it with the hole for the locking peg vertical and the cutaway on the link pin underneath.128 in. Fit the output housing joint washer. Secure the housing and retainer to the cover plate. and secure it by means of the five bolts. Remove the five bolts. to ensure that . II. Remove the five bolts.GEARBOX UNIT-ALL lO. while on later vehicles it is secured directly to the gearbox unit. 5.036 in. 15. If necessary. Before pushing the housing home. Vehicles numbered 861501 onwards 1. 3. locknut and spring. Fit the upper and lower ball retainers to the gear change lever and secure tham with the five bolts.

.5 mm) below the handle flange. Replace the lever ball locating pin in the housing (if removed on stripping) and secure it by "staking". remove the plate. hand side of the gearbox cover on vehicles fitted with a freewheel control ring. II. locknut and spring. discard the original dipstick and rebuild the gearbox with a new dipstick. 14. 1948-S3 models Transfer box (lower oil level) To modify Operation Cfl4 All 1948 to mid·1950 transfer boxes have an oil capacity of 6 pints (3. remove the lever pin from the housing. 4. and (b) appreciable resistance is felt on moving the gear lever to the reverse gear position. of two spring washers and top cover and two set bolts at the bell housing aperture.cover. the spherical seat. 3. Fit the housing to the mounting plate and secure it by means of four lockers and set bolts. 8. Replace the freewheel control ring or front wheel drive control knob. 20. 16. Remove draw out spherical housing. before the gearbox cover is fitted. Replace the two reverse stop springs. withdraw the gear lever from If necessary.C·16 5. 2. Early transfer boxes should be modified at overhaul as follows:L The oil level should be lowered by tin. replace washer To modify Operation Cjl2 All main gearboxes numbered prior to 16102100 and 16131500 have an oil capacity of 4 pints (2. 2. replace the locknuts and knobs on the main and transfer gear change levers. clutch and right-hand pedal rod and toe plates pad (see below.5 litres). 15. spring seat. Renew the circlip from the lever housing the spring retaining washer. Replace the gearbox cover. 19. Fit a suitable 1 in. spring and retaining and secure the whole with a circlip. (12.5 litres) to counteract the tendency for oil to pass from the transfer box to the main gearbox. 18. Whit. (S7 mm) below the centre of the stud. Replace the brake pedal rod and pad (see Section H). obliterate 2.e. Remove the gearbox . 21. Clean out all swarf from the transfer box.7 mm) below the existing mark. locating 10. Early gearboxes should be so modified at overhaul as follows:. 104 . and and the ball 3. 7. Fit the gear change lever in the housing. Prise up the locking tabs and remove the two set bolts.5 litres) on later gearboxes to counteract the possibility of oil passing along the primary pinion and giving rise to clutch slip.. 9. remove the mounting plate and gear change lever complete. Fit the mounting secure it by means nuts at the gearbox and spring washers plate :0 the gearbox unit.948-53 Gearbox dipstick (lower models oil level) any worn components. spring washers and distance pieces securing the gear change lever mounting plate to the bell housing and the two nuts and spring washers securing the plate to the gearbox top cover. remove the reverse stop hinge (complete with adjusting screw and locknut) and the spring bracket. (148. Replace the Section B). Whit. It can also be carried out at any time after: (a) detaching the access panel from the right. 5it in. the oil capacity is reduced on later gearboxes to 41 pints (2. one lockplate and two set bolts (the plain washers should be fitted under the lockplate). Detach the two springs from the reverse stop hinge. 12.5 Htres). The screw and locknut on the reverse stop hinge should be adjusted so that: (a) the hinge rides easily up the gear lever when reverse gear is selected. (22 mm). Adjust the reverse stop as described 17. This adjustment should be carried out on any gearbox removed for attention. Make a new "H" mark on the dipstick i in. Alternatively. Part No. lockplate and two plain washers securing the reverse stop to the reverse selector. 1. Remove the two set bolts. Reverse stop To adjust Operation CliO 1. 13. or (b) selecting reverse gear and sliding the access panel up the front wheel drive control rod. (S mm) hole at this point and tap i in. Fit the reverse stop binge and spring bracket to the reverse selector and secure them by means of two plain washers. (13 mm) long) and fibre washer to act as a plug. Replace the left-hand (see Section R). i. Drill a --h in. GEARBOX UNIT-ALL MODELS 1948·53 models 6. the oil capacity is reduced to 21 pints (1. set bolt (I in. Prise up the locking tabs and remove the four set bolts and lockers securing the gear change lever housing to the mounting plate. Mark of!"the new position for the level plug on the rear face of the transfer box by scribing a line vertically downwards from the centre of the lower right-hand stud securing the centre power take-off cover plate. the original mark. Mark off a point 21 in. 235242.

13. box complete. Remove the seat. 8. from the front end first. The nip on the pads is adjusted by the addition or removal of shims on the top of the central distance tube. the bearer rubbers. Remove the clutch return spring. Remove the freewheel control ring or the front wheel drive control knob. Remove the petrol tank and tool locker lids. The correct setting is with the top shim approximately -&. Ensure that an oil flinger is fitted in front of the transfer drive gear on the rear of the gearbox mainshaft (see Fig..) 6.D. Withdraw a split pin and washer and tap out the joint pia connecting the crossshaft to the connecting tube. have been disturbed. 15. 3. at the gearbox end in both cases. Remove the clutch return spring. etc. 16. 10. Remove the six set bolts. Should the engine and gearbox unit mounting rubbers. 19. . spring washers and nuts 1. Refill the main gearbox and transfer box with oil of the correct grade. Remove the brake pedal rod and pad (see Section H). towards the chassis side member. Disconnect the front me propeller shaft and rear power take-off propeller shaft (if fined). spring washers and nuts securing the hinges to the back rest panel. On early 1952 models onwards. washers and shims may normally be left in position in the vehicle. the main gear change lever assembly will be removed with the cover. the rear mounting brackets are adjustable laterally. Place a suitable sling round the gearbox unit.in. 9. CoS. 17. spring washers and nuts 22. Withdraw the split pin and remove the clevis pin securing the clutch operating rod to the clutch shaft lever. Withdraw the split pin and remove the clevis pili securing the clutch operating rod to the crossshaft lever. 2. Remove the left-hand and right-hand toe plates (see Section R). 23. end either by removing the bolt. models only. remove the knobs and locknuts from the main and transfer gear change levers.GEARBOX UNIT-ALL 5.5 mm) below the top face of the upper rubber pad. 105 14. L. Remove the gearbox cover. 3. spring washer and nut securing the cable to the pinion bush on the drive housing or by detaching the retaining plate arid three set bolts and spring washers securing the cable to the drive housing. Replacement of the gearbox unit is .D. Remove the hood or hard top. C-2). securing the floor sills to the dash. Note: It may be necessary to remove the righthand bearer from the transfer casing. by detaching the eight bolts. "models only. Disconnect the battery. Place a jack under the rear end of the engine and raise it approximately ~ in. Remove the clutch pedal rod and pad (see Section B). 21. Remove the five bolts. raise it upwards and to the rear and remove the unit from the vehicle. Remove the rear axle propeller shaft (see Section D). Remove the two bolts. 20. Remove the hand brake lever and linkage (see Section H). Remove the thirteen nuts and plain washers securing the bell housing to the engine flywheel housing. 4. Remove the centre inspection panel from the seat box. locknut and spring. to facilitate alignment with the mounting rubbers. this will enable the bell housing flange to clear the chassis cross-member and also prevent any strain being taken on the primary pinion shaft. they should be fitted as shown at Fig. 12. 11. from the front end first. as in some cases it will not clear the hand brake bell crank lever. Remove the self-locking nuts from the two rear engine and gearbox unit bearer bolts and withdraw the bolts. for convenience in MODELS C~17 18. 5. R. it should be checked on replacement and adjusted as necessary. 2.H. (1. (Transfer lever knob only on vehicles numbered 860001 to 861500. Adiust the transmission brake' as described in Section H.effected by reversing the sequence of operations detailed for removal. 7. 4. 1948-53 models securing the top fixing angle on the seat box to the back rest panel. 1948-S3 models Gearbox only To remove 1. (12 mm) above its normal position. Disconnect the speedometer cable at the gearbox Operation Cjl6 working. Slide the crossshaft clear of the bell housing. On vehicles numbered 860001 to 861500. withdraw the cable clear of the gearbox. spring and plain Gearbox only To replace Operation CJ 18 washers securing the side fixing angles to the seat box.H.

Remove the two bolts. distance brackette bracket. 25. Remove the return spring for the freewheel lever. Remove left-hand withdraw ball. If necessary. Remove the freewhee1locking dog. Remove the seven nuts and spring washers securing the freewheel housing to the transfer casing and withdraw the housing complete with joint washer. Remove the circlip securing the rear bearing to the output shaft and withdraw the bearing. 18. Gearboxes numbered 861501 onwards. Gearboxes numbered 860001 to 861988. Strip the assembly. 19. Remove the circlip retaining the output shaft rear bearing in the freewheel housing. this is secured either by four set screws or four set bolts and spring washers. transfer gear change lever to the bracket on the bell housing. If necessary. Remove the reverse stop hinge unit.housing and the transfer shaft selector spring and 11. Prise up the tab washers and remove the six set bolts and two locking plates securing the freewheel outer member to the output shaft. Withdraw the bearing from the shaft. 4. 5. To 12. Gearboxes numbered 861989 onwards. If necessary. Remove the controls as follows: 3.C-18 1948-53 models GEARBOX UNIT -ALL MODELS Gearbox unit strip Operation Cj20 Operation C/20 details the. shaft hush 106 . 16. Remove the distance washer. Mount the gearbox unit on a suitable stand. Withdraw the spring guide and freewheel operating spring from the transfer casing. Remove the transfer gear change cover plate and joint washer from the transfer casing. the seven nuts and spring washers securing the output shaft housing to the freewheel housing and withdraw the housing cornplete with joint washer. Remove the spring ring and retaining plate securing the inner member to the outer member. Withdraw the freewheel output shaft housing. The output shaft front bearing will remain on the output shah protruding from the freewheel housing. Remove the freewheel lever guide by removing the two set bolts and spring washers securing it to the output shaft housing. locking dog and distance piece from the output shaft in the freewheel housing. cover plate and rubber seal at the bell housing and lift off the main gear change lever assembly. 23. 7. operating rod from the 14. Gearboxes numbered 860001 to 861500. three free cam roller shoes and three shoe springs. Remove the inner member complete with the fixed cam roller shoes (which can be removed if necessary by removing the securing set screws). 2. withdraw the bearing from the shaft.' Remove the special screw. remove the operating from the freewheel housing. Gearboxes numbered 860001 to 861988. The front portion of the output shaft ("transfer shaft") will be retained in the output shaft housing. 10. Remove the special screw and distance piece securing the freewheel lever to the output shaft housing and remove the lever complete with the operating wire or rod. remove the spring anchor from the output shaft housing by withdrawing the set bolt. spring washers. Remove the circlip retaining the front bearing in the housing and drive out the transfer shaft and bearing from the housing. Remove Gearboxes numbered prior to 16102314 and 16131688 1. remove the lever complete with 9. 13. Remove the pinch bolt securing the freewheel operating fork to the operating shaft and remove the fork and shaft. Remove the drain plugs (and joint washers) from the bottom of the main gearbox casing and transfer casing and drain off the oil into a suitable receptacle. the plug and joint washer from the side of the output shaft. remove the bush from the front bore of the output shaft. Remove the freewheel unit as follows: 17. Remove the special nut and shakeproof washer securing the transfer selector link to the front of the selector shaft. drive out the output shaft and freewheel assembly from the housing. Remove the two nuts. castle nut and plain washer. spring washers and distance pieces (or cover plate and rubber seal) securing the bell housing inspection cover and remove the cover. 24. remove the pivot and eyebolt (complete ~with locknut). Remove two spring washers and nuts at the main gearbox top cover and two set bolts. pieces and nuts securing the transfer lever the bell housing and remove the 21. 15. 22. spring washer and distance piece. 6. Remove the split pin and clevis pin securing the link. by removing the split pin. remove the output shaft and selector shaft oil seals from the housing. spring washers. See following pages for main gearbox and transfer box strip and reassembly.differences which will be found on 1948-53 gearboxes. Remove the pilot bearing from the outer member. nine graded rollers. 8. Remove the front axle drive flange and dust shield from the output shaft. ~ 20. spring washer and nut securing the freewheel control pivot to the eyebolt in the front of the output shaft housing.

Leave the transfer selector shaft and link in position protruding from the transfer box. Remove the output shaft. . spring washers and distance pieces. Fit the toothed retaining plate in the outer member and secure it with a circlip. cover plate and rubber seal at the bell housing and lift off the main gear change lever assembly. Fit the inner member. If necessary. Fit the freewheel outer member to the front output shaft and secure it with two lockplates and six set bolts. avoiding damage to the' oil seal. (d) Distance tube. Remove the split pin. 'with the spring to the front. remove the oil seal from the retainer. dog clutch selector shaft. Fit the output shaft rear bearing into the freewheel housing and secure it with a circlip . 35. Mount the gearbox unit on a suitable stand. Remove the seven nuts and spring washers securing the output housing to the transfer box (this action also releases an earth lead). 31. 29. 37. Place the inner member pilot bearing in the outer member. 33. press a new operating shaft bush into the freewheel housing and ream it to . Gearboxes numbered prior to 16102314 and 16131688 Assemble the freewheel unit as follows: 1. 5.GEARBOX UNIT-ALL Gearboxes numbered 16102314 and 16131688 onwards 26. Disconnect the operating rod . Withdraw the split pin and remove the castle nut 44. castle nut and split pin. 8. Remove the special nut and shakeproof washer securing the transfer control link to the selector shaft. The bush is a drive fit in the shaft. Remove the split pin and plain washer securing the locking peg to the lever. The shaft must be a light press fit in the bearing. 46. 30. Fit the freewheel selector fork on the shaft and secure it with the pinch bolt. 4. Remove the drain plugs (and joint washers) from the bottom of the main gearbox casing and transfer casing and drain off the oil into a suitable receptacle. spring washers. front wheel drive dog clutch. 40. castle nut and special screw from the transfer selector shaft and remove the block. If necessary. 39. in the bearing. Slide the following parts from the transfer selector shaft:(a) Link. as difficulty will be experienced in effecting correct alignment on reassembly. 45. 3. complete with three fixed cam roller shoes. If necessary. Remove the front wheel drive control lever assembly by withdrawing the special pivot screw. Remove the dust cover from the front of the output housing. Slide the two springs and selector fork from the Note: The connector should not be removed joint washer from the transfer casing (four set bolts and spring washers). from the selector fork boss. remove the two bushes. Fit the freewheel assembly into the freewheel housing and press the output shaft through the bearing. If necessary. 32. place the nine graded rollers in position and fit the free cam roller shoes and springs. and plain washer securing the front axle driving flange. Secure the shaft with a circlip. link pin and connector assembly. press out the bush from the lever. Remove two spring washers and nuts at the main gearbox top cover and two set bolts.from the lever (spring-loaded clevis). Remove the plug and joint washer from the top of the transfer casing and withdraw the transfer shaft selector spring and plunger. renew the ollite bush in the front bore of the output shaft. 1£ necessary. 36. The bearing must be a push fit in the housing. If necessary. remove the split pin and spring-loaded clevis pin and remove the transfer lever. (e) Spring locating bush. 107 34. Push the freewheel operating shaft tluough the bush in the freewheel housing. Gearboxes numbered 860001 to 861988. Strip the assembly. the dog clutch selector shaft and fork and a joint washer. 9. 2. castle' nut and special screw from the dog clutch selector shaft and remove the block. Remove the six nuts and spring washers securing the oil seal retainer to the front face of the output housing and remove the retainer complete with oil seal and joint washer. withdraw the output shaft front bearing from the output housing. remove the spigot bush from the rear end of the output shaft. 7. split pin. 27. 38. Remove the reverse stop hinge unit. 41. the front (transfer) shaft should be an easy fit in the bush bore. If necessary. Withdraw the output housing complete with output shaft. 6. Remove the controls as follows: 28. 42. (b) Spring. Remove the.. Remove the transfer gear change cover plate' and MODELS C-19 from the link pin unless absolutely necessary. carefully remove the flange complete with dust seal. 43. Detach the link from the link pin by removing the special screw.625 in. dog clutch selector shaft and dog clutch from the output housing. by removing the three nuts.

The shaft must be a drive fit in the bearing. with the distance piece between the anchor and the housing. 23. cover plate and rubber seal to the gearbox unit. 19. Fit the flange and dust shield to the output shaft and secure it with a plain washer. The freewheel operating rod should be retained in the free position by means of the lever. the distance piece should be placed between the lever and the housing. Fit the bell housing inspection cover and secure it and the cover plate and rubber seal with two . Assemble the main gear change lever. 21. Drive the output shaft front bearing on to the output shaft until it abuts the shoulder. Fit the complete output shaft housing. the rod should move forward to set the freewheel in the fixed position. Release the operating' spring by removing the peg from the guide and check the freewheel unit for ease of operation.spring washers and nuts. Secure the link to the selector shaft with a special nut and shakeproof washer. Insert the freewheel operating rod through the seal in the housing and enter it into the operating shaft. high transfer gear is engaged and the freewheel operating rod is pushed to the rear. to the freewheel housing. 29. 28. Gearboxes numbered 860001 to 861500. 25. 26.. renew the output shaft and selector shaft oil seals in the output shaft housing. low transfer gear is engaged. spring washers and nuts. Replace the lever guide and secure it to the top of the housing with two set bolts and spring washers. the transfer box should he in neutral. castle nut and split pin. 27. securing them by means of two set bolts and spring washers at the bell housing and two nuts and spring washers at the gearbox top cover. Fit the transfer lever bracket to the bell housing. Examine the outer diameter of the front axle drive flange for -damage which may have caused failure of. the freewheel is "free". Fit the pivot to the eyebolt by means of a special screw. the freewheel should remain free. secure with seven nuts and spring washers. Check the operation of tbe transfer gear change and freewheel controls. Replace the transfer selector link on the transfer gear change lever. Drive the transfer shaft through the bearing until it abuts the shoulder. 13. spring washer and nut. 34. adjusting the eyebolt and pivot as necessary. 17. together with a joint washer. (b) With the transfer change lever pulled halfway back. Remove the thimble. Screw the pivot eyebolt. The bearing must be a drive fit on the shaft.hand side of the output shaft housing and secure them with a plug and joint washer. Replace the transfer change selector ball and spring in the boss on the left. into the tapping in the front face of the output shaft housing. Replace the distance piece. together with a joint washer. locating it on two dowels. When the control wire is pulled or the knob is depressed. 16. the freewheel rod should be forced to the free position as at paragraph (a). Ensure that the splines on the inner member and locking dog are in alignment. 108 24. 20. Gearboxes numbered 860001 to 861988. In this position the freewheel lever should engage the slot in the operating rod. 33. Assemble the controls as follows: 22. so that: (a) With the transfer change lever right forward. 18. Fit the lever assembly. Fit the complete freewheel. Fit a suitable protection thimble over the end of the transfer operating shaft. 30. pieces between the bracket and beU housing. locate the dowel and secure with seven nuts and spring washers. If necessary. (d) On returning to high transfer gear. complete the assembly as follows: secure it by means of either four set screws or four set bolts and spring washers.C-20 GEARBOX U~IT -ALL MODELS 10. (e) With the transfer change lever right back.e. complete with locknut. 31. securing it by means of two bolts. i. Fit the transfer shaft bearing in the output shaft housing and secure it with a circlip. Gearboxes numbered 861501 onwards. Fit the link over the end of the selector shaft and secure the lever to the bracket by means of a clevis pin and split pin. The bearing must be a drive fit in the housing. 32. Slide the freewheel operating spring over the operating shaft guide and fit the guide into the bushes in the transfer casing.the original oil seal and rectify or renew the flange as necessary. Replace the lever return spring. 11. If necessary. renew the bush and operating wire in the freewheel operating lever and fit the complete lever to the output shaft housing by means of the special screw. Gearboxes numbered 861989 onwards. so disengaging the lever from the operating rod. Secure the lever return spring anchor to the housing by means of a set bolt and spring washer. 14. so that the freewheel is in the "fixed" position. 15. Compress the spring and secure it by means of a small peg pushed through the hole in the guide. 12. with the distance. When the controls have been adjusted correctly. to the transfer casing. Replace the transfer gear change cover plate and . Place the locking dog in mesh with the fork and slide the shaft along. locking dog and distance washer on the output shaft protruding from the freewheel housing. Fit and adjust the reverse stop hinge.

Load in position: 24 lb. 43. Tighten the connector securing nut and . special nut and shakeproofwasher. If necessary. castle nut and split pin. Rate: 7. Check the transfer selector shaft spring in accordance with the following data and renew as necessary:Free length: 7. the position of the connector and link should now be adjusted as follows:52. Place the dummy housing over the selector shafts and locate the link pin by means of a suitable peg. Replace the dust cover and secure by means of three nuts. Fit the special screw from the bottom. 38./in. pressing it in flush with the face of the shaft. 42. 54. 46. (a) The most efficient method of carrying out this operation is to use a dummy output housing with a large aperture in the side through which the connector securing nut can be tightened. Slide the follo'Wing parts on to the transfer selector shaft:(a) Distance tube. If they have been separated. Rate : 61Ib. nec:essary:Free length: 2. Fit the dog clutch over the splines on the transfer box output shaft. The bush must be reamed in position to . Renew the shaft. (d) Compress the spring and fit the link and connector assembly until the block is over the hole in the shaft. 109 . replace the output shaft front bearing in the output housing.875 in. and a light drive fit in the housing.loaded clevis pin and split pin. bearing and housing as necessary.3llb/in. (b) Spring locating bush with its smaller diameter to the front. If removed.156 in. The bearing must be a push fit on the shaft. replace it with the hole for the locking peg vertical and the cutaway on the link pin underneath. 40. By this method. Solid length: . with the longer arm of the jaw at the opposite end to the rear. Gearboxes numbered 16102314 and 16131688 onwards Assemble the controls as follows: 36.002 in. through the coupling jaw. to enable the output housing to dear the bell housing. 49.750 in. fit a new oil seal in the retainer with its knife: edge inwards. 58. 53. spring washers and distance: pieces. replace the spigot bush in the rear end of the output shaft. Replace the block on the selector shaft and secure by means of the special screw. ensure that the connector is square with the pin and secure lightly with the nut and shakeproof washer. (b) Ifa dummy housing is not available. 41. 39. Fit the output shaft in its housing and slide the housing over the selector shafts. clearance on the selector shaft. 51. 55. If -removed. 37. The gearbox unit is now ready for installation in the vehicle. Secure the _link pin by means of the special screw. a fact which will only appear when the assembly is complete.640 in. ensuring that the link engages the screw correctly. for this reason the use of a dummy housing is to be preferred. MODELS C·21 48. 56. 45. 47. castle nut and 'Split pin. Check the two dog dutch selector springs in accordance with the following data and renew as .. Secure the lever to the selector shaft by means of the control link. 50. Fit the dog clutch selector shaft assembly into the bush on the transfer box. If the connector has been detached from the link pin. renew the bush in the front wheel drive control.GEARBOX UNIT-ALL 35.875 in. the locking peg hole in the link pin is not necessarily vertical. (c) Spring. . 44. 57. Fit the output housing joint washer. secure with the seven nuts and spring washers. Maximum-load: nib. the bushes must be:pressed in flush with the end faces of the boss and must have . Replace the oil seal retainer on the output housing and secure with six nuts and spring washers.001 to .remove the housing. block and selector shaft and secure with the castle nut and split pin. Length in position: 3. the actual output housing can be used to align the selectors by sliding it over the shafts back to front. (Note: The transfer casing must be detached from the main gearbox. If necessary. Replace the transfer lever and secure with the spring. Select twowheel drive in high transfer gear (through the aperture in the transfer casing) and push the housing home. Replace the control lever assembly and secure with the pivot screw. Connect the operating rod to the lever and secure the locking peg by means of the plain washer and split pin. The threaded end of the screw must be downwards and the shorter end of the link towards the transfer selector. Fill the: main gearbox and transfer casing with oil of a suitable: grade.) Tighten the connector nut with the link in alignment with the two selector shafts. Fit th~ two springs and selector fork (crank to the rear) over the dog clutch selector shaft. renew the two oilite bushes in the: dog clutch selector fork boss. Replace the transfer shaft selector spring and plunger and secure with the plug and joint washer. If removed.

Adjusr the four-wheel drive control rod. 3. at the gearbox end.D. 4~ pints (2. Place a jack under the rear end of the engine i this prevents any strain being taken on the primary pinion shaft. Fit the flange and dust shield to the output shaft and secure it with a plain . Remove the hand brake: lever and linkage. 7.5 litres) and transfer box. Section H. R. Remove the gearbox unit bearer bolts. 5. -8 5. L. models only. To refit Operation C/24 1. 4. Fit and adjust the reverse stop hinge. L. Remove the hood. shims and distance tubes.5 litres) with oil.5 mm) below the top face of. Operation C/4B. as under such conditions the operation appears correct. 12. 63.H. to facilitate alignment with the mounting rubbers. Adjust the front wheel drive control rod to ensure efficient extraction and replacement of the locking peg.l--. hard top or cab. Place a suitable sling around the gearbox unit. Fit the lever assembly. The gearbox unit is now ready for installation in the vehicle. Fill the main gearbox and transfer casing with oil of a sqitable grade.D. Slide the universal jointsleeve together with the rubber dust cover along the cross-shaft and remove the cross-shaft complete with universal joint sleeve and rubber dust cover. A-Plain washer (upper) B-Rubber washer C-Distance tube D-Shim E-Top rubber F-Bottom rubber G-Plain washer(lower) H-Front bolt J-Rear bolt K-Spring washer L-Self-locking nut . Section H. Remove the front wheel drive control knob. 1954-58 2. Remove the clutch cross-shaft rod from the connecting tubes. locknut and spring. C-8-Gearbox unit mounting bolts and pads. for convenience in working. models only.H. Reverse the removal procedure. models Gearbox and transfer box assembly To remove Operation C/22 l. 13. 9. remove the knob and locknut from the transfer gear change lever.. (1. Disconnect the speedometer cable at the gearbox and withdraw the cable dear of the gearbox. top bearer rubbers. If necessary. Remove the seat box complete. Note: The rear mounting brackets are adjustable laterally.washer. The nip on the gearbox unit mounting rubber pads is adjusted by the addition or removal of shims on the top of the central distance tube.H. models only. Remove the hand brake rod and the expander rod from the relay lever. 60. 2i pints (1. 110 CV-. The correct setting is with the top shim approximately 1/16 in. 14.H. rear axle propeller shaft and rear power take-off propeller shaft (if fitted). B. 11. Assemble the main gear change lever. refill the main gearbox. 61. ~r---:-=n $-F~~ ~'-E_ models only. Check the transfer gear change and dog clutch controls for correct operation and adjust as necessary. Replace the transfer gear change-cover plate and secure it by means of four set bolts and spring washers.C-22 GEARBOX UNIT:"'__ALL MODELS 10. raise it approximately 1 inch (25 mm). Section R.D. cover plate and rubber seal to the gearbox unit.® G Fig. 4. Withdraw the gearbox unit and remove it from the vehicle. castle nut and split pin. it is important to avoid the spring becoming coilbound. 3. Disconnect the earth lead at the transfer box.D. securing them by means of two set bolts and spring washers at the bell housing and two nuts and spring washers at the gearbox top cover. Examine the outer diameter of the front axle drive flange for damage which may have caused failure of the original oil seal and rectify or renew the flange as necessary. R. Remove the floor board assembly and gearbox cover. when the gearbox is installed in the vehicle.the upper rubber pad. Section R. but the peg is not extracted sufficiently to engage four-wheel drive. 2. Adjust the transmission brake. 62. washers. 6. Disconnect the universal joint sleeve from the clutch relay shaft and the cross-shaft from the connecting tube. Disconnect the front axle propeller shaft. 59.

select top and 2nd speeds simultaneously. Remove the castle nut from the front of the Iayshaft. 6. Remove the cirdip retaining the mainshaft rear bearing housing to the rear face of the gearbox casing. press out the Iayshaft front bearing. Move the 1st/2nd speed selector to the neutral position and remove it. the gearbox casing must be warmed to facilitate this operation. the rubber grommets and the 3rd/4th and reverse selector springs. 10. Remove the plug retaining the 1st/2nd speed selector spring in the top cover and withdraw spring. Remove the reverse 19. 22. and C/22. Remove the nut securing the primary pinion bearing. 8. 23. Remove the synchronising clutch unit from the mainshaft and then withdraw the layshaft complete from the gearbox and strip it as follows: 25. Remove the two selector. 2. Operation C/SO. Remove the peg locating the distance sleeve and withdraw the located 2nd speed gear thrust washer. To 1. Remove the layshaft bearing plate. Press out the primary pinion and bearing from the bell housing. Tap out the peg-located bearing housing complete from the rear. Remove the distance sleeve and 2nd speed gear. so that it remains in the gearbox. Remove the dust-proofing grommets from the bell housing apertures. press the bearing and shield off the pinion shaft. Remove the split ring retaining the 2nd speed gear. Remove the selector cover plate from the gearbox top cover. Remove the 2nd speed stop from the end of the 1st/2nd selector shaft. {The nut has a left.shaft.hand thread. balls and locking plunger from the gearbox and the 1st/2nd speed selector ball from the top cover. with the top cover removed. 11. C-!JRemoving the traWifer drive gear securing nut. Press off the rear bearing and Ist speed gear.) 24. Remove the transfer box and front output shaft housing complete. 4. Fig. Remove the needle roller bearing from the front end of the mainshaft. pack tl!e hole with grease. Ncte : To prevent the selector ball falling into the gearbox. Drain off the gearbox and transfer box oil. Remove the oil seal from the housing. 14. Remove the retaining plates for the side selector springs. 29. remove the 3rd speed gear thrust washer and gear. 15. 20. Dismantle the main gearbox as follows: 5. Drive out the reverse gear shaft from inside the gearbox. Remove the 3rd and 2nd speed gears. Remove the main gear change lever assembly. 7. strip Operation ellS Mount the gearbox on a suitable stand. Remove the distance sleeve. 18. Remove the Lower selector end cover. Remove the selector shaft end cover securing set bolts. Remove the layshaft front bearing retaining plate.) III . tapping the layshaft out of the front bearing. Remove the Ist speed gear. remove the pinion bearing retaining plate. Disconnect the connecting tube from the clutch cross. Section B. remove the 3rd/4th selector. then the reverse stop hinge. together with the upper selector end cover. Withdraw the gear and distance piece and oil flinger from the mainshaft. Remove the oil filler cap and joint washer from the gearbox top cover. Remove the circlip retaining the bearing in the housing and press out the bearing. Prise out the spring ring inside the 3rd speed gear cone and discard it. 12. Remove the filler cap retaining clip. Remove the bell housing complete with joint washer. Remove the gearbox top cover. 26. rubber sealing ring from the shaft. Drive out the mainshaft complete and strip it as foUows: from the rear 9. Operation Cj34. Withdraw the 3rd/4th selector fork . 28. (To lock the shaft for nnt removal.GEARBOX UNIT-ALL All models Main gearbox Operation see Operations C/26 C/16 MODELS C-23 To remove L For removal procedure. Remove the constant gear and conical distance piece from the bell housing. Remove the nut at the rear of the mainshaft retaining the transfer drive gear. Remove the 2nd gear stop from the top cover. Withdraw the reverse selector fork and the sealing ring from the shaft. Select 1st gear (centre selector to rear) j remove the reverse gear selector by lifting and turning the selector shaft one quarter of a turn to the left. 13. 16. 17. 3. Remove and strip the clutch withdrawal unit from the bell housing. and the 27. Withdraw the selector fork and the sealing ring from the shaft. 21.

Hi . Place the reverse gear (with the smaller wheel to the rear) on its shaft and drive the shaft into the gearbox casing.812 in. renew the reverse gear bush. Check all the bearings 3. A casing may also be scrap as a result of excessive wear in a bearing bore. It may be necessary to warm the casing to assist in this operation.&' housing and push the complete housing into the gearbox casing from the inside. Slide on the mainshaft bush with the large locating slot to the rear. until the housing flange abuts the casing. 4_ Examine the casing for signs of damage or cracks and renew it as necessary. and secure with the second thrust washer and the old spring ring.007 in. The shaft must be a drive fit in the casing. spring rings and joint washers. measured between the gear and. A-Plunger. with the knife edge inwards. Secure the housing with a circlip at the rear face of the casing. Place the third speed gear on the bush with the gear wheel against the shoulder. all other gears may be replaced singly. if necessary. 2nd and 3rd speed gears are only supplied hi mated pairs. It must be a drive fit. Do not fit the large bush locating peg at this stage. synchromesh cone to the rear. such wear will be obvious during the course of assembly. 2. C-IORemoving layshaft real' bearing outer race. together with the second speed gear. To remove the outer race of the layshaft rear gearbox casing. Check for wear and damage. Fit the location peg in the bearin.10-0. 13. It must be a drive fit. Smear the outer diameter of the oil seal with jointing compound and press it into the other end of the housing. 7. (43. the end-float of the second speed gear. 5.C-24 gear and. Wash all the component parts thoroughly and lay them out for inspection. The housing must be a push fit in the casing. It may be necessary to warm the casing to assist in this operation. Press the rnainshaft rear bearing into the bearing housing until it abuts the flange in the housing bore. Fig. insert the plunger and tap it down sharply. The third speed gear end-float should be the same. Press the layshaft rear bearing outer race into the gearbox casing with the lipped edge to the rear. to just fit into the outer race.. 30. 1948-53 models If necessary. (20. B. the bush shoulder. 1948-53 models _ oa 'Press the layshaft rear bearing outer race inter the gearbox casing with the lipped edge to the rear. bearing from follows: the GEARBOX UNIT-ALL press out the bush from MODELS press fit in the gear. renew the reverse gear bush and ream it in position to . 6_ If necessary. It may be necessary to warm the casing to assist in this operation. (0. Stand the gearbox casing on end and fill the race housing with thick oil. i. The housing must be a push fit in the casing.17 mm).812 in. C-ll-Measurillg maioshait gear end-float. In most cases the oil will force the outer ring upwards out of the casing. To assemble Operation C/30 I. If removed.e. While pressing the third speed gear hard against the bush shoulder. secure the housing with a circlip. replace the rear thrust washer. if necessary. It will be necessary to warm the casing to assist in this operation. The constant. 9. bell out its extremities and ream it in position to . 1948-53 models Fit the location peg in the bearing housing and push the complete housing into the gearbox casing from the inside. The shaft must be a drive fit in the casing. Renew all lockwashers.63 mm). split pins. proceed as Make a plunger (preferably from hardwood) about 12 in. should be . measured with the second speed gear pressed hard against the bush shoulder. (300 mm) long and approximately I-H.. (20 mm). and renew them as necessary. the gearbox casing may be warmed to facilitate removal of the race. 11. The bush should be a Fig.004 to . Place the reverse gear (with the smaller wheel to the rear) in position in the gearbox and drive the shaft through the gearbox casing and the gear.in. the bearing must be a press fit in the housing_Secure the bearing with a circlip.50 mm) in diameter. Mainshaft 10. the gear. until the housing flange: abuts the casing. all the gears for damage marks and rectify or renew them as necessary. 12.

(Fig. D-l D-2 D-3 Page 0-3 D-3 D-1 Construction of propeller shaft Removing a yoke bearing. the complete shaft should be removed from the vehicle and rectified as described. The top bearing should then begin to emerge Fig. Stage 2 D-I D-2 D-2 Fig. Disconnect the propeller shaft from the differential input flange. To strip Operation D/6 1. Propeller To remove shaft (rear power take-off drive) Operation D/4 See Section T. Hold the joint in the left hand with one of the splined sleeve: (or shaft) yoke lugs uppermost and tap the radius of the yoke lightly with a soft-nosed hammer. 3. D-l-Construction A-Splined shaft B-Splined sleeve G-Dust cap D-Flange yoke E-Jouroal spider of' propC!llershaft.) 2. Dismantle each universal joint as follows: 2. If any of these defects are apparent. Disconnect the propeller shaft from the transfer box output flange. 4. Clean the enamel and dirt from the four cirdips and the tops of the bearing races. roller bearing assembly G-Circlip securing bearing H-Lubrication nipple fox splined joint J---Qil nipple for univeral )Oint 125 . or is neglected.ALL MODELS INDEX Page Data. To remove Operation D/2 1.PROPELLER SHAFTS . Any circumferential movement of the shaft relative to the flange yokes indicates wear in the roller bearings or the splined joint. Lubricant may seep from the bearings after a lengthy period of service. D-2 D-2 Propeller shaft (front and rear axle drives) Wear on the thrust faces of the bearings can be located by testing the lift in the joint. 0-2. D-4 D·5 Page Removing the splined sleeve or shaft Removing the flange yoke . F-Needk. general Defect location Propeller shafts LIST OF ILLUSTRATIONS Fig. If an oil leak is severe.". from the yoke.Section D . Stage 1 Removing a yoke bearing. owing to failure of the bearing seals. Remove the circlips. Withdraw the propeller shaft complete. Unscrew the dust cap and withdraw the sliding joint from the:splined shaft. failure of the needle roller bearings may result. either by hand or with the aid of a length of wood suitably pivoted. 3.

D-3. 6. (0. The splined sleeve (or shaft) yoke can now be removed (Fig. 2. It may be necessary to tap the bearing race from the inside with a small drift. About half fill the races with oil (5. Replacement journal assemblies comprise a spider complete with cork oil seals and four bearings. races be a light In the event of wear taking place in any of the eight yoke cross holes. if necessary using a smear of vaseline to retain them in place.0-2 PROPELLER SHAFTS-ALL MODELS Fig. 126 . Turn the joint over and withdraw (Fig. Repeat the operation for the other three bearings comprising the universal joint. load markings or distortion be observed. D-2-Removiog a yoke beariog.A. Fig. 4. Stage 2. to avoid dropping the needle rollers. If wear beyond this limit has taken place. Assemble the needle rollers in the bearing races. and assemble the other joint similarly. 7. firmly located the Fig.) the bearing. Insert the journal in the Bange yoke holes and. should not be exceeded. a new propeller shaft complete must be fitted. Always remove a bearing downwards.8. a new propeller shaft complete must be: fitted. 8. as oversize journals or bearing races are not supplied. care should be taken to prevent damage to the bearing race. Should looseness in the fit of these parts. To assemble Operation DIS The parts most likely to show signs of wear after long usage are the bearing races and the spider journals. they must be renewed complete. FiC. If the joint appears to bind. Wash all the parts and lay them out for inspection. Repeat these operations for the opposite bearing. drive fit in the yoke trunnions. D-4). D·SRemoving the Oange yoke. in such cases.004 in.) circumferential movement.bearing 3. Replace circlips snd ensure that they are in their grooves. Rest the flange yoke on a short piece of tubing of suitable diameter (slightly larger than the bearing race) and drive out the two remaining bearings. rendering them oval. using a brass drift slightly smaller in diameter than the hole in the: yoke. It is essential that the . 9. measured on the outside diameter of the splines. 0-4-Removinll the Rplined sleeve or shaft. 1. 140). The other parts likely to show signs of wear are the splined sleeve yoke and splined shaft. 5. 0-5).1 mm. tap the ears slightly with a soft-nosed hammer. A total of . Stage I. D-l-Removing a yoke bearing. lightly tap the first bearing into position. using a brass drift Fig.

.) Rear axle drive . 3. (SO... Tighten the nuts evenly...812 in. shaft (rear power take-off Operation drive) D/16 DEFECT Symptom. 3.) Overall length (face to face in neutral position)Front axle drive 23. Liberally smear the splines of the sliding joint and splined shaft with oil and replace the joint on the shaft. (2. 2 in. 3. Press the centre ball bearing and dust plate off register engages and that the joint faces bed down correctly all round.087 m. (50...4 mm. 4. evenly.. D-I). 2. the complete housing must be renewed. sleeve end. (654 mm. 3. Worn bearings or worn spline-RellfW.. Insert the bolts securing the front and fear propeller shafts together.. To assemble Operation D/12 L Reverse the stripping procedure.PROPELLER SHAFTS-ALL MODELS D-3 5. Hardy Spicer needle bearing . (1. 21.812 in..II~. 6. before fitting the flange on the splined shaft. Hold the centre bearing housing firmly in a vice and drift the shaft. Replace the propeller shaft and ensure that the 2. Lack of lubricalion-Lubricatt 2. Tighten the nuts the shaft. The centre ball hearing must be a press fit in the housing. 5.. Wipe the faces of the transfer box and differential flanges clean. 23. GENERAL DATA Type: 86 and 88 in.) i27 . if a new bearing is loose on the shaft. Drift off the flange from the splined shaft. The centre ball bearing must be a light drive fit on the shaft. Securing nuts 100iSIl~ Tightell. (2. See Section T. Shaft out of balance-Tighten tire securing IIUU.the splined sluve yoke and shaft. Remove the two Woodruff keys from the shaft. A-VIBRATING PROPELLER SHAFT LOCATION Cause and Remedy B-UNIVERSAL JOINTS NOISY 01'" 1. Centre bearing To strip shaft. to the transfer box output flange. 2..) Tubular shaftdiameter wall thickness . 2 in. Worn splinu-Remw. Propeller To refit 1. Hardy Spicer needle bearing . re1IftI' the sho.812 in.) .fr if still out of balanc«. reMII! beatings.4 mm. from the housing. 4. in the rear flange. Secure the propeller shaft to the differential input flange (with the nuts behind the input flange). 1.) Rear axle drive 42. if a new bearing is loose in the housing. complete with the bearing and dust plate.. Balance marks out of a1ignment-Ch«k alignment of balance marks on. Remove the rear driving flange from the front 1. Wash all the parts and lay them out for inspection.. (554 mm. Screw up the dust cap as far as possible by hand.) . assembly drive-I09 (rear power take-off only) Operation D/IO 3.8 mm. the complete shaft must be renewed. Secure the propeller shaft.8 mm. in... Propeller To refit shaft (front and rear axle drives) D/14 Operation 1.. / 4. (654 mm. 2.) h Type: 107 and 109 in. Tubular shaftdiameter wall thickn~ Overall length (face to face in neutral position)Front axle drive .812 in. making sure that the arrows marked on the splined sleeve yoke and shaft are in line (Fig..

.

129 . Depress the brake pedal and wedge it in that . The road wheel studs are peened over in the axle shaft flange and the peening should be filed before withdrawing a faulty stud. the brake anchor plate and the distance washer. Part No. fully floating shafts Data. using the special annular press block.Section E .section of rear hub E·5 Fig.. Remove the collar. E-4 Checking hub end-float. 3. Remove the oil seal and sleeve. fully floating shafts . The bearing should be a light press fit in the bore of the hub and on the axle shaft. Remove the ball bearing from the housing and the oil seal from the sleeve. details and ilfustrations Page B-1 B-3 E-2 E·3 concerning the differential assembly will be found in Section F Axle shaft Semi-floating type assembly To remove Operation Ef2 1. E·4 E-5 Cross.. and it may be necessary to assist the operation with sharp blows on the bearing housing. Remove the road wheel and the brake drum. rear Page E-5 E-5 E-4 LIST OF ILLUSTRATIONS Page Fig. Drain off the rear axle oil. chamfer side down. Examine the bearing for excessive side play or roughness . Layout of rear axle. E-l B-2 Stripping and assembling half-shaft . E-l-Stripping and assembling half-shaft. To strip Operation Ef4 1. the bearing and housing.. Jack up the rear of the vehicle under the chassis frame. position. 4. semi -floating shafts Layout of-rear axle. To assemble Operation E/6 1. Renew the road wheel studs as necessary.ALL MODELS INDEX Page Axle shaft assembly Axle complete Data. 3.REAR AXLE . sn. using a brass drift. 6. 3.. and oil retaining ring (if necessary). 5. general Data.· 2. detail E-1 E-6 E-7 E-7 Differential assembly Differential pinion oil seal Hub.. Section H.. Replace the distance washer. Remove the brake components. 242415 (Fig. 4. A pressure of up to 20 tons will be required. 2. Stand the axle shaft on its splined end and press down squarely on the brake anchor plate and bearing housing flange. detach the brake pipe at the whee brake unit. 2. Withdraw the shaft assembly complete with anchor plate. Fig.

H. L. pinion end Bearing for bevel pinion. E-2-Layout of naT axle.H. semi-floating shafts. 1 Rear axle casing Bolts fixing differential Dowel locating differential 5 Breather 6-7 Oil drain plug 8 Crownwheel and bevel pinion 9 Differential casing 10-11 Fixings. for crownwheel 12 Differential wheel 13 Differential pinion 14 Spindle for pinions 15-16 Fixings for spindle 17 Thrust washer for differential 18 Bevel pinion housing 19 Bolt fixing bearing cap 20 Roller bearings for differential 2-3 4 28 Washer for bearing 29 Retainer for oil seal 30 Mudshield for retainer 31 Joint washer for retainer 32 Oil seal for pinion 33-34 37 3B-40 41-42 Fixings for retainer Dust shield for driving flange Fixings for driving flange Oil filler plug and washer Joint washer for differential Fixings for differential Axle shaft.E·2 REAR AXLE-ALL MODELS Fig. Stud for road wheel Housing for hub bearing Distance washer Bearing for hub Sleeve for oil seal Oil seal for hub Retaining collar Fixings for bearing housing 35 Driving flange 43 44-45 46 47 48 49 50 51 52 21 22 Serrated nut} Lock tab For bearing adjustment 23 Split pin 24 Bearing for bevel pinion. flange end 53 54 55-57 130 . R. Mde shaft. pinion end 25 26 27 Shims for bearing adjustment. flange end Shims for bearing adjustment.

flange end 27 28 29 Shims for bearing adjustment.H. L.H. pinion end 26 Bearing for bevel pinion. E·3-Layout of rear axle. Washer for bearing Retainer for oil seal Mudshield for retainer flange end 57 58 59 60 61-62 63-65 30 66 J oint washer for retainer Oil seal for pinion Fixings for retainer Driving flange Dust shield for driving flange Fixings for driving flange Oil filler plug and washer Joint washer for differential Fixings for differential Axle shaft. outer Fixings-for hub bearing Driving member for rear hub Joint washer for driving member Filler plug for hub driving member Joint washer for filler plug Oil seal for rear axle shaft Fixings-driving member to rear hub Fixings-axle shaft to driving member Hub cap.REAR AXLE-ALL MODELS E-3 Fig. Axle shaft. rear 131 . inner Oil seal for inner bearing Hub bearing. fully floating shafts. R. 1 Rear axle casing 2-3 Bolts fixing differential 4 Dowel locating differential 5 Breather 6-7 Oil drain plug 8 Crownwheel and bevel pinion 9 Differential casing 10-11 Fixings for crownwheel 12 Differential wheel 13 Differential pinion 14 Spindle f'ir pinions 15-16 Fixings for spindle 17 Thrust washer for differential 18 Bevel pinion housing 19 Bolt fixing bearing cap 20 Roller bearings for differential 21 Serrated nut } 22 Lock tab For bearing adjustment . 23 Split pin 31 32 33-34 35 36 37-39 40-41 42 43-44 45 46 47 48 49 50 51 52 53-55 56 24 Bearing for bevel pinion. pinion end 25 Shims for bearing adjustment. Rear hub bearing sleeve Rear hub assembly Stud for road wheel Hub bearing.

Remove the hubcap member. Renew the oil seal as necessary and fit it in the sleeve with the lip away from the axle shaft flange • . 2. LReplace thenle shaft in the axle casing. Withdi'. bend over two tabs of the locking washer.. as a suitable-collar. inner bearing until the oil seal face 1.float.E-4 REJ\R AXLE-ALL MODELS 4. complete with anchor plate. with an interference fit of . Remove the. on which the oil seal runs. 262757) is illustrated at Fig.07 mm) on the shaft. and wedge it in that position. for signs of damage or roughness. (0. spring washers and nuts. 4. seal. Mol safeguard. Bleed the brake system. E-. from the flange. 8. (Section. the locknut. Adjust the end-float of the hub bearing by adiusting the hub idnet 'nut. Remove the.OQ28in. 5. A suitable press block (Part No. . To assemble hub Operation E/16 1. Remove the thrust washer and hub complete with the outer roller bearing~Removebrake anchor plate. pull the hub outwards and again take the indicator reading. Press the oil seal and sleeve over the securing collar into the bearing housing. 2.004. Depress the brake pedal fully. Examine the two hub bearings and renew them as necessary.!iw the shaft and hub assembly. press the seal into the hub with the knife edge towards the. Both bearings should bean easy fit on the rear hub bearing sleeve and a press fit in the hub. the end-float should be checked once more after locking the nuts.15 mm).10 mm to 0. 5. 4. Jack up the rear of the vehicle under the chassis frame. fuUy-floating axle To adjust Operation EIIO 3. Renew as necessary. 132 . Section H. 3~. . before pressing them into the hub. Examine the oil seal and renew as necessary. Place the securing collar over the axle shaft with the chamfer towards the splined end and press it on until it abuts the bearing. drivingmember from the axle shaft and the hub. and fit the bearing in the housing: replace the assembly and brake. examine the outside diameter of the inner bearing distance piece. fully floa ti nit' shafts. 2. lock washer and adjusting nut from the rear bearing sleeve. the hub itself should be renewed. To r¢fit Operation Ej8 am.axle centre. 5. Before assembling the hub. in. To strip 1. 6. . If new bearings are slack in the hub. Rear hub aseembly. by removing the six securing bolts. tightening the locknut and checking the end-Boat by means of a dial test indicator mounted on to one of the wheel studs (see Fig. 1. entering the splined end into the differential. Connect the brake pipe to the wheel cylinder. To remove Operation E/12 2. note the indicator reading. using a wheelbearing lubricator. Pack the beariagswith grease. 4. B-1. . Take the reading by pushing the hub as far as possibletowardsthe . Renew the bearing or bearing housing as necessary. brake components.3.4-:--Checking ··hubend. Withdraw the ail seal and bearings from the hub if necessary. detach the brake pipes ·at the wheel brake unit. must be chosen by selective assembly. E-4). Drain off the rear axle oil. 7. the total hub movement so measured shouldbe .· Replace the brake components.) 6. 3 Remove the road wheel and brake drum. Lower the vehicle off the jack arid refill the differential with oil. required for this operation. . Fig. (0. Operation E/14 (pres~ fit) Oil the driving and joint washer Remove oil 6. A pressure of at least 2~ tons will be. The distance piece should be a press fit on the rear hub bearing sleeve. anchor plate on the axle shaft. to . H. Refit the brake drum and road wheel. When the correct end-float has been obtained. Section H. Any clearance between these two parts will allow oil to leak past on to the brake linings. Prise up the lockingtabs and remove.006 in.

Disconnect the propeller shaft at the differential input flange. Differential assembly Semi-floating type axle To r ernove Operation 1. 2. Operation E/IO. 5. 4. (Section H). Operation Fj2. (150 mm) from the axle casing. Withdraw the shafts complete with driving member about 6 in. Operation EjlS pinion oil seal Operation E!20 Proceed as detailed under Section F. Replace brake components brake pipes. through the oil filler plug in the driving member. Replace oil seal and secure the axle shaft to the driving member by using the slotted nut. Tap the hub cap into place. Remove the road wheels and brake drums. 6. lock washer and locknut. 4. Fill the hub with one-third of a pint (0. H. Place a joint washer on to the driving member. 7.REAR AXLE-ALL MODELS E·5 Fig. so allowing oilto leak past and on to the brake linings. securing it to the hub with the six set bolts and washers.190 litres) of oil. If the seal is pressed too far in.75 litres) of oil. 1. 6. the element will fail to register on the rear hub bearing sleeve distance piece. adjusting nut. plain washer and split pin. Slide the axle shaft through the fear hub bearing sleeve until it locates in the splines of the differential unit. Depress the brake pedal and wedge it in that position: detach the brake pipes at the wheel brake units. Jack up the rear of the vehicle. Replace the filler plug and joint washer. is flush with the rear face of the hub. Bolt the rear hub bearing sleeve and brake anchor plate into position and then slide the complete hub on to the rear hub bearing sleeve. Adjust the hub end-float. Section 5. E-5-Cross-sl'ction of fully floating rear hub. Remove the wheel brake components. bleed and and reconnect the adjust the brakes Differential To renew To assemble complete unit. Fit the keyed thrust washer. E/22 2. Take care not to overtighten. Refill the rear axle with 3 pints (1. 1. 133 . then slide the member on to the spline at the end of the axle shaft.· 3. 3. Drain off the axle oil.

5. it is only necessary to remove the hub caps and six bolts securing the driving member. To strip. Remove the differential assembly from the axle casing. proceed as follows:1. 4. Remove the self-locking nuts and shackle bolts from the rear end of the springs. Jack up the rear of the vehicle. 2. 2.E-6 REAR AXLE-ALL MODELS 7. Refill the axle with oil. Push the axle shafts into the splines of the differential. Replace the axle assembly by reversing the removal procedure (Method I or II). Lower the springs still on the jacks. Disconnect the propeller shaft at the differential input flange. To refit Operation examine An alternative method for removal eliminates removal of the shackle pins. Drain off the axle oil. Replace the brake drums and road wheels. detach the brake pipes at the wheel brake units. Note: If any difficulty is anticipated when adjusting the differential. H. Lower the vehicle to the ground. Operations F/6. 4. 7. 3 pints (1. 3. For data see Section F. and axle to the ground. 9. Disconnect one end of each shock absorber. 3. Section 6. Fit the differential assembly in the axle casing. 3 pints (1. 4. 7. 9. Jack up each of the road springs under the shock absorber plate and remove the U-boIt nuts. Remove the axle casing by manoeuvring it past the road springs and check straps. Lower the vehicle on to suitable stands placed under the chassis. 6. Depress the brake pedal and wedge it in that position. Section H. Fully-floating type axle To remove the differential on the fully-floating type axle. and secure in position. 134 . so 5. 11. 3. it is recommended that the unit be replaced by a new assembly (obtainable from our Spares Department) and the old one returned for reconditioning. Connect the propeller shaft to the input flange. Remove the wheel brake components. Depress the brake pedal and wedge it in that position. Refill the differential with oil.75 litres). To refit Operation E/32 1. 2.75Iitres) and lower the vehicle off the jacking stands. To remove. E/26 1. 5. Z. Lower the springs so that they are relaxed but still on the jacks. lower the jacks. Method II Operation E/30 8. 12.. Disconnect the propeller shaft at the differential input flange. Axle complete To remove. 10. 6. Disconnect the flexible brake pipe at the Teepiece on the differential casing. Jack up the rear of the vehicle. 8. 3. Bleed the brake system. Section H. FI8 and F/IO . Jack up each of the road springs under the shock absorber plate and remove the U-bolt nuts. Remove the road wheels and brake drums. that they are relaxed but 13. 8. and assemble Operation E/24 Proceed as detailed under Section F. Withdraw the shaft and hub assemblies complete from the axle casing. The axle shafts can then be removed. Method I Operation E/28 1. Remove the differential assembly from the axle casing. Replace the wheel brake components. Section H. Remove both road wheels. and remove the axle. Lower the vehicle on to suitable stands placed under the chassis. Disconnect one extremity of each check strap. springs. Connect the brake pipes to the wheel brake units and bleed the brake system. 8. Disconnect the flexible brake pipe at the Tee-piece on the differential casing.

.88 and 107 basic uncdels.025· to 0.001 to . axles numbered 861320 onwards ... 3 pints (1.. Spical bevel ..... Oil capacity Final drive "" .7 to 1 GENERAL DATA: Fully floating Oil capacity lfpe .010 to 0.....75litres) Pre-packed .' 4.. they are also available as Ratio.. 86. (0.88 to 1 Ratio...005 to 0..190 litres) Initial assembly only Hub bearing lubrication Final drive RatiO .. .75 litres) 1/3rd pint (0..04 to ... 4.. 4. Spiral bevel with gre~ Hub bearing lubrication fr-om 131701306...7 to 1 Semi-floating type in- DETAIL DATA: Fit of retaining !lh~ft collar on ... (0. axles numbered 860001 to 861319 .. 3 pints (1. 109 models up to 121704761 and 107 Station Wagon up to 131701305.REAR AXLE-ALL MODELS B-7 GENERAL DATA: Semi-floating type Fitted to all 80.0028 in... (0.• 0002 to ..003 in.16 mm) Clearance of hub bearing' in rear hub bearing sleeve . hub ..033 mm) Fit of hub bearing in . (0.....". 0.. .07 min) terference assembly) (selective DETAIL DATA: Fully floating type Rear hubasscmbly: Rear hub end-float .006 in.075 mm) interference 135 .. Note: Fully floating axlesbafts are fitted to 109 models from 121704770.OO13io... 107 Station Wagon art optional extra on the 88 models.

.

Slide the rubber washer over the bottom of the control tube. Position the felt bush at the top of the tube and the two rubber bushes at equal intervals down the tube.. To replace Reverse the removal wheel from the steering Operation procedure... 7. Checking rocker shaft end-float Layout of steering column and linkage Sectional view of steering column top Relative position of cam.(): Slide the rubber to the clamp. bearings and main nut Sectioned view of rocker shaft and steering box G-3 G-3 G-4 G-9 G-lO G-9 G-9 G-IO G-IO G-6 G-' G-8 G-ll G-12 Alternative method of compressing . GIS 157 . 4. Section P. Fig.. fit the clamp and joint washer on the' bottom cover plate. Remove the steering inner column.STEERING UNIT AND LINKAGE . G-8 Relay unit Compressing Assembling assembly steering relay spring steering relay shaft Page G-8 G-1 G-2 G-3 G-4 Adjusting bearing steering column thrust G-2 G-5 G-6 G-' Replacing main nut in steering box" . Remove the steering wheel Operation control tube... 2. Section P. Page G-8 G-2 G-2 G-6 G-I G-ll G-II OF ILLUSTRATIONS Page Fig. worm and nut type Track rod Wheel alignment . Release the clip securing WIring. relay shaft assembly Replacing steering relay bushes in housing shaft and WORM AND NUT TYPE STEERING UNIT Steering control tube To remove Operation G/2 1. grommet over the wiring up ' 2. Position the control unit with the dipper switch at the bottom and secure the tube in the clamp. • 5. G-lO G-2 G-8 Relay unit Steering column thrust bearing Steering control tube Steering unit. Insert the complete assembly into the steering column and pull the wiring clear at the bottom. the wiring to the steering box and slide the rubber grommet (a!l"~st the bottom of the steering box) off the 3. Defect location Drag link Drop arm Longitudinal steering arm LIST Section G G-ll G-12 G-12 ._. Steering To remove I.ALL MODELS INDEX Page Ball joints Data . G/6 Operation G/2_ 2. 4. horn button and dipper switch unit and control tube bushel! as found necessary. 3. Remove the hom button and dipper switch unit from the control tube and disconnect the wiring from the unit as necessary. Disconnect the steering column wiring from the junction box on the dash panel. Renew the wiring. and secure the wiring to the steering box with a clip. To refit Operation G(4 1. Pull the control tube and wiring up through the steering column and remove. 5.. pull the conical rubber washer in the covet plate off the wiring.. . Remove the control tube clamp and joint washer from the control tube. recirculating balt type Steering unit. Reconnect the steering column wiring to the junction box on the dash panel.

Remove the steering box: from its support 10. Reconnect G/lO MODELS the ball joint to the drop arm. dust Operation cover and G/14 2. Remove the rocker shaft cork sealing washer and retainer from the steering box. 2. 4710 series and early 5710 series. Set the road wheels straight ahead steering unit in the midway position fu1llock in each direction. 8. renew as necessary. unscrew the locking (upper) nut and screw down the adjusting (lower) nut until there is 7 to 9 Ib. 6. G-l) j remove the eighteen 7/32in. To strip L Remove the bottom joint washer./in. 6. taking care not to damage either of its bushes. 3. To remove any end-float in the inner column. 7. This avoids damage to the splines and the' side cover plate.08 to 0. late 5710 series onwards. Examine the inner column and main nut for wear.10 mKg) pre-load on the thrust ball race. 263099 (Fig. Withdraw the front wing. Remove G/10. so that it lines up with the ball-joint pin. Withdraw the outer the inner column. Drop wheel and control tube. Remove the steering column support bracket. Part No. Drive or press out the two rocker shaft bushes. the steering control 4. Remove sprmg. Remove the rocker shaft rubber sealing washer and retainer from the steering box. Remove the air cleaner. Operation G/6. the steering wheel. plate. 5. Remove the locking nut and adjusting nut from arm the top of the inner column. tube. Examine the thrust race components if badly worn. 8. 4. Remove 6. Steering unit To remove L Disconnect the battery. the main 4. in practice this means that the end-float just disappears. 5. Remove the steering column rubber grommet. the rocker shaft. Operation G/16 cover plate complete with plate complete with 2. Fig. Withdraw the drop arm. 3. the steering wheel. Fit the drop arm on the rocker shaft. the steering unit from under 3. using the special spanners. Rotate the inner column to unscrew nut and withdraw the nut. The control tube and steering wheel need only be withdrawn as far as necesssary for the adjustment to be made. Operation GJ22. Section M. column upwards through To renew Operation G/12 1. 3. which will give rise to excessive play between the: two parts. selecting a suitable position on the splines. Vehicles Chassis No. Note: A suitable wedge-shaped tool must be used to open the slot in the drop arm when removing and replacing it on the splined end of [he rocker shaft.5 mm) steel baits forming the thrust race. Withdraw the drop arm from the rocker shaft. Tighten the locking nut. (0. if necessary. To assemble Operation GIIS I. (5. 2. 2. G-I-Adju$ting steering column thrust bearing. Operation Section P.G-2 Steering To adjust column STEERING UNIT AND LINKAGE-ALL thrust bearing Operation 5. 4. if necessary. and renew IS8 . Pull the spring and dust cover clear of the thrust adjustment. Replace the steering Operation G/S. Remove the steering column dip and rubber strip from the support bracket on the dash. using the special spanner. 1. Remove the longitudinal steering rod ball joint from the drop arm. Operation G/6. Renew the drop arm and the between Vehir:lts Chassis No. Fill the steering box with clean oil. Remove the side cover joint washer. Part No. 9. Withdraw 263099. Note: If the baLLjoint pin is tight in the drop arm.. the longitudinal steering tube and drop arm should be removed together.

Fit the drop arm to one ball joint. Longitudinal steering tube Operation G/22 To renew 1. as the rocker shaft must not have any end-float with the side cover plate in position. G-l-- Cbeclting ro<:ker . Fig. so that the relay Lever 15 not disturbed."'ig. Adjust the thrust race. turning the tube to increase or decrease its effective length. Fill the steering box with oil (see Instruction Manual). threaded portion firs t. Set the road wheels in the straight ahead position and the steering wheel in the midway position between full lock in each direction. 3. 5. Assemble the unit by reversing the stripping procedure. (e) Replace the drop arm by using a wedgeshaped tool to slightly open the slot in the drop arm while replacing it on the rocker shaft. Fit the ball joints to the tube. 13. Raise the upper relay lever slightly to allow the ball joint pin to clear the lever and remove the longitudinal tube ball joint from the lever.) (One 6.) Renew the tube if necessary. Fit the front ball joint to the upper relay lever.-ALL MODELS To refit G-3 Operation Gj20 3. 2. thick) by means of a straight edge. 2. replace the rubber covers if damaged. 5. (.. selecting a suitable position on the splines so that it is approximately vertical. Disconnect the ball joint from the drop arm. 159 . Withdraw the longitudinal tube and drop arm together towards the front of the vehicle under [he radiator grille panel. Unscrew the ball joints from the tube. Tighten the ball joint clips. leaving the clips slack at this stage. Operation G/20. G-2-Replacing main nut in steering box. 1!17t7.. Press in the new rocker shaft bushes if the original parts were removed. Withdraw the drop arm from the rocker shaft splines. particular attention being paid to the following points:(a) Replace the nut in the steering box. Ball joints are supplied as complete units. 14. Reverse the removal procedure. left-hand and one right-hand thread. The thrust race should be packed with grease on assembly. 9. Fig. Operation G/LO. Examine the ball joints for wear in the body and pin. Before connecting the drop arm to the rocker shaft.haft end-float. set the road wheels straight ahead and the steering inner column in the midway position between full lock in each direction.010 in. Replace the tube and drop arm under the radiator grille panel. Top up the steering unit.. Check that the road wheels reach full lock (as determined by the limit stops on the swivel pin housings) in each direction. 4. in order to eliminate any possibility of damage to the side cover plate. 7. only the rubber cover and retaining rings can be obtained separately. 4. 1. 12. G-l.STEERING UNIT AND LINKAGB. The b~hes should be a light drive fit in the steering box and reamed in position to the dimension given in die data. (b) Ensure that the top face qf the rocker shaft is almost flush with the top face of the side cover plate joint washer (available .020 in. and .. 3. Fit the drop arm to the steering rocker shaft. 8. and renew the complete units as necessary. 11. 10.

i .0 . 71 a-I 1T IZ ~.G-4 STEERING UNlT AND LINKAGE-ALL MODELS -. G-4-Layout of steering column and linkage.I Fig. 160 .

mbly-R. brael..att 7 Dis..". plote 15 Stud for comret mile clomp 16 Pi..li"lf wash ."'8 . 85 push to junction box 86 L.oint Spring ring.. 63 ~4 86 and 107 model' 100 BoU 101 102 Hom bu lion an dipper switch complete } 86 and 107 mod.t }Piaing hord 84 ~. to st •• box cover 99 Nut 76 65 66 67 68 69 70 71 72 73 14 75 Rubber .cko.10 &5stmbly Ball ioint mbly R.are Ojl ~uininj' wuhu-bottom 'IS Gl'Of'IHnet for control tube wins 96 Cbmp lor control wbe 97 Joint wasber for damp 98 ~prinl"ash.pla... upper Fixinp for lever Fi1dq.il\ll out er 34 Spring ....1 ball 19 Adju..... y 2 Shaft for sturin.R.'r ~rell~jn.' '=~'!f.t shIeld } 86 and 107 modeb S teering wheel Bol! }pixing sreering 86. G-4 Steering Unit.. cover plato her } For sld..nc. grooved Sturin..3 .. tbua<! j Rubbc!:r cover tor ball . mbly fo.. calumn 36 Bush for inner column 37 Oil .d.. hot column 35 Inn. 38 Spring ~r CCNe. I J models ~~t~~~~n:. 1 End pl . 88..1 plug 22 Air re le.:r for retaihtt '''''It ~ 35-37 38 3~ ~1 42 $4 13 I~ 15 16-18 19-21 22 23-2-4 2S 26-2tI 11-12 ~ 44 ~ ~ 47 ~~nr:/~fl ~~ner Joint washu fc. lower Steenng track rod assembly B.. cover body '0 ~?:e~i"i \Cov.!'.. ..::ng washer push br.~.J.H.t< 9 J oinl washer 10 Solt for cover IJhte 11 Bottom cover plate 12 Join! . } 86 ""d 107 mod. d 109 E·n. 161 . 1 38 Main nut ..l joint Pixings for ball joint clips St •• ring d 1". ~~1r"1 brack. fot Nil joint clip.lumn 88 Dip switch for dip .ls Locii .. for boll race 21 Oilliller and lev. thrud lI.. ~~ ~&' ..:r:"w 109 Clip for st•• ri.. eover to bill Fl"ng" for ball join .H. ~::J:Ii Plain wasber washer Boll w:. cov . retainer main nu] I 2 box .t«ring tulle aosembly BiU jciru OlRImlbly R.·..ongltudinol .e ~9 Oil &11 plug •• 60 Sprci..nce pic<:e for shalt !:I Oil sui for obaft 9 Rrwner for oil.. It Spring wash.tobl.aJJ joint assembly R. al fOorseal Satw Special was her ~~ni washer Cover ) 86. brackot 80 Yok .Il oin! . push. mbly L.in.l.. column and nul ~ Roc-kEt shaft for s:teerinl box 6 S. for ball joint Spring ring..o.b bracltt' 79 Clip IQr hom push brack<..r Bolt Plain .~n:1.0 109 modd..for levu 86...nl.r. plug Rtlay lewr. SUpper! bracko..0 Fizi~ support bracket d. 101 and 109 mo<I. ~if:. 7 Re'aim"g washer 8 Side rover "l.. ower to body Fi:Ki.r.. and 1011model..oket lOS Plain washer 106 ~J:nl washer to dash 107 108 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 tCpot1 clamp tub... mbly ~ ~bo.... Nil race StuItullJ . 88.ass~mbly 29 Suoh fo. 29 )0 31 32 :13 ~I 52-53 54 55 56 57 58 59 60 61-63 64 M-66 48-!10 Spring rlUi and R.riDI: c:n.. thread Rubller cave. ID7 and 109 mod". rocker shaft 30 Outer column 31 ~int hot-sttel 32 in hel"'--11"per 33 II } P". 3 Solit buoh fer housing \9oaheT for opri".. thread. ball Retainer ..H. ashor washer l~t~::t buck.. . 81 SOf·bolt for brackel 8l Horn push 88 .H..t mode.. Hom bu lIOn <>ttIy 77 Steeri"& wheel centre COVIE r 18 Hom pu..1 nut 61 Lockwashor 62 Drop urn oinl washU-p1per ~7nJ ~~nr wash. buab 93 Rubber rubo-inlermedi.t. 107 ""d 109 mOO. 9() lLad-dip switch to j.ad-born 87 Cable clll!:3t on ste..¥" column Rubbu :!lui p fQr' Support bradot for s...s Rock er oluft 46 Adju'l« screw Wash.Jtf!'....r.STEERING UNIT AND LINKAGE-ALL MODELS G-5 Key to Fig. ~. plat~8 Relay Unit and Steeri1lg Arms 1 Hau.her } Fo....r for Ilt. . '0 ball Fixings for boil ioints to levers Cli!? ror b. dlaHi& frmK ""1 j 5t_iDS box to clus$i. •• rinll calumn dip 86.. b..::"'t!lb!u..n~g.D.. for oil .t-Jted 103 bracbt on}dash 1011 Support b. """or to body Spri(13 ring }cov •• t. 5 So""i for bushos 6 Tbrust """"'.aft-illnt.. rOt ... . thread Ball joint mbly L. to 49 50 51 52 ~3 '54 5S :~ ~:.. Bush for rocker Sh.1l joint P.........88. for plUI 2-4 Speeial bolt 2:5 C3sUe nut 26 Split pin 1:1 Droparm 28 Steering bolt . 83 Spe~i..."ddu.s for nouslng Fl<Inp plate for relay nlounlin(j: Fixings for !lange plate Rday lever..1 ~ ~~ii~~·!J } For .table Nil race 20 Locknu...r S. Adju. be.. "lUI 23 W.. 101 and 109 JtlOdel. relay lev . complete 92 Fd... Iteh 89 Drnr. Bll..r Nut ConI".H. Wheel and Drop Arm 3 Bush r or rocker !!hafl~I<l..1s ~~n washer wheel J ''''''w '0 =- ~ tCUmP nnll Spring wash.m. sa.. f r····"'."her J6 101 modelo Brackol to 86. her 13 Soh } For bollOIo 14 Spring wash. 88. "lain • Inne.~~ Spring ring. 107 .al 10 Joint washr.«I ball race 17 BoUr= ring 18 5t.ncticn boo 91 Control tub.Fixinll" for boll joint dips l.

8. 6. 9. Lift off the main nut. 10. support brackets and seal must now be removed from the dash.The ball transfer tube may be removed from the main nut. Mount the steering unit less drop ann. RH. G-s--seetioDed view of 1turill8 eo1uDlD top. disconnect the support and lift the bonnet cleat. then remove the assembly complete with leads. 7. Refit the hom switch and bracket assembly. If oil leakage and bearing wear is excessive. 2. using special tool (Part No. Replace the steering wheel with one series of spokes pointing forward and secure. 7. 5. scuttle and wing valance.D. shims. With the front wheels poeitioned "straight ahead" and the steering wheel in the intermediate position. Tum the inner steering column lock to lock and select the intermediate position. 1. Withdraw the steering unit complete with support plate. roller. Make provision for catching the balls. 10. 2. . 3. 5. 6. oil seal and press out the bush from steering box.Remove the name plate and withdraw the radiator grille. Withdraw the box and inner column complete. Loosen the bolt securing the upper relay lever to the relay unit and prise the lever clear. ball race and any balls that may have dropped into the steering box.G-6 STEERING RECIRCULATING STEERING UNIT AND LINKAGE-ALL MODELS BALL TYPE UNIT Operation G/24 Steering unit-to dismantle Operation GI28 1. 'Remove the spare wheel if mounted on bonnet. 3. . drop arm and ball joint from under the front wing. The dust cover at the top of steering column will be freed by this last operation and care must be taken to ensure that this or balls from the steering box are not inadvertently lost. 2. and withdraw the rocker shaft. and with a hide-faced hammer. Steering unit-to assemble Operation G(30 Steering unit----:to remove L Unscrew the clamp holt and withdraw the steering wheel. 6. Screw the ball joint into the longitudinal arm and lock in the original position. 4. Check the steering. Refit the support plate to chassis side-member. 11. remove the retaining washer. lock to lock. The support clip. 262776) •• 12. Unscrew the castellated nut and remove the ball joint from drop ann by tapping the side adjacent to taper smartly with a hammer. A-CoJumn outer tube C-&al 8-Tufnol bush D-Dust cover B-Inncr shaft 2. Locate the rocker shaft seal and retaining washer. Remove the bush and seal from top of outer column. Remove the side cover and drain off the oil. With the outer column held in a vice. for correct functioning. gently tap the box away from the inner column sufficiently to . 8. If· removed fit' the ro£ker shaft bush to the steering box. Remove the end cover. The longitudinal arm may require adjusting slightly to align the splines of drop arm and steering rocker shaft. Press the Tufnol bush with oil Seal into the top outer steering column tube. 3. Note: The main nut should be positioned approximately midway on the cam during this operation. B Fir. then secure at dash and support plate. Fit the longitudinal arm complete with upper relay lever to the drop arm and insert the assembly ~long the top of chassis side-member. 5. 9. 8.remove the outer ball race. Disconnect the clamp securing the hom switch and support bracket to the steering outer 'column. Remove the main nut assembly. 162 I. Tum the inner column to unscrew the main nut assembly and withdraw the column completely from the steering box. Remove the securing screw and extract the drop arm. 4. then slacken the clamping bolt nearest the drop arm and unscrew the longitudinal arm complete with relay lever. Turn the steering wheel to allow the longitudinal steering arm to move fully forward. Connect the upper relay lever to relay unit. 4. Adjust if necessary by alterillg the length of the longitudinal arm. ' 3. mode1sonly-Remove the air cleaner. if excessively worn. Steering unit-to refit Operation 0/26 seuttle and wing valance. fit the drop arm to the rocker shaft. unscrew the nuts holding the steering box and tap the inner column at the steering wheel end with a hide-faced hammer to partially remove the box. 7. Remove the bolts securing the steering support bracket to chassis side-member. rubber strip.

_ ----. (Filler plug towards the outer column. Grease any thickness shim and two paper wallhers each side of the shim. Note: The inner shaft should have DO endfloat. Drop arm To remove Operation G{34 1. 9. The steering unit may now be elevated into a horizontal position._.STEERING UNIT AND LINKAGE-ALL MODELS G-7 Fie. sufficient shims must first be fitted to allow an end-Boat reading and then shims equivalent in thickness to this reading.-:<>----_. joint washer and cover._. replacing balls as necessary and retain them in position with grease. To refit See Operation G/26.. 6. and i \! l-r-- . Unscrew the clamping bolt at hub and withdraw the wheel. ensuring it is free to rotate. Assemble the main nut. to the flange on the outer column. 11. shims. Fit the main nut.. The complete steering unit must be removed before the drop arm can be extracted-see Operation G/24.-. C344.) 8. With the main nut at mid-position on cam. Locate the assembly in steering box and lower on to the cam end of the inner column._. tighten a further tenth of a turn and lock the adjusting screw. F-Shims G--Ball transfer tube and relainer H-Roller J-Rocker shaft 4. and the steering box is up the correct way. Refit the dust cover to top end of steering column. r ----'j A-Inner column cam B-Bal1s . \ __ L. Lift the inner column a little.. then mount the outer column in a vertical position in a vice (Tufnol bush downwards). ensuring that the roller is correctly located in the cover slot. Carefully rotate the inner column. tighten the adjusting screw on side cover by hand until resistance is felt as it contacts the rocker shaft. over the inner column and slide the inner column into the outer column and Tufnol bush. ensuring that none of the balls are dislodged. less ball bearings. G/32 1. ensuring that the ball bearings in the main nut are not dislodged. then carefully tighten. G·6-Relative positions of cam. ensuring that none fall down the inside of the outer column.. Steering wheel To remove Operation.. . replace the rocker shaft. . bearings main nut. be removed. C-U pper ball race D-Lower baU race E-Main nut . Locate the outer ball race. joint washer and end cover. Place one of the ball races. ._ t \ . Grease the lower ball race and stick ten balls in position. grease the ball race and load with ten ball bearings. but to ensure that the bearings are not over-stressed.. 7. J' ~. roller. 10. 5. 163 .

ensuring that the longitudinal arm is screwed back on to exactly the former position. remove the front apron panel. loosen the clamping bolt nearest to drop arm and unscrew the longitudinal arm complete with relay lever. It will now be possible to move the radiator assembly slightly to assist in the removal of the relay unit. an8 Fig. 3.-R. vehicles 164 . but care must be taken to prevent damage to the coolant hoses. .D. Reverse the removal procedure. Remove the bolts securing the grille panel to the chassis frame. then with a solid metallic object on one side of the drop arm adjacent to the_taper. To replace Operation G/38 1. Longitudinal steering To remove arm Operation G/36 1. 3. unit. Remove the bolts securing the radiator grille panel to the front wings. 2. 2. Steering relay unit To remove Operation G/40 1. vehicles B. Unscrew the castellated nut securing the ball joint to the drop arm.Transfer Tube Fig. Section P. when the bolts are clear. Withdraw the assembly from the front of vehicle. tap the other side with a hammer to loosen the ball joint.H. loosen the clamping bolt securing the upper relay lever and prise the lever off the relay unit. Tum the steering wheel to allow the longitudinal steering arm to move fully forward. 2.D. G-8-Relay A. the rubber packing pieces between the panel and frame may also be withdrawn.H. Remove the air cleaner and battery. Remove the radiator grille. Turn the steering wheel to move the drop arm rearwards and remove the ball joint.-L. 4.G-8 STEERING UNIT AND LINKAGE-ALL MODELS A-Rocket shaft B--Adjusting C-Locknut screw-s-rocker shaft D-Rocker shaft bush E-Rocker shaft seal F-Seal retainer G-Main nut H-Main nut baIlS J. Check the "lock to lock" 'movement and alter if necessary by adjusting the length of the longitudinal arm. G-1-Sectioned view of rocker shaft and steenng box.

Fie· G-IO-ASlentbliog steering relay shaft assembly. top end first. securing it with a hose clip as for the first one (Fig. 262769) over each side of the spring. it should need a force of at least 12 lb. Check the spring in accordance with given data. Fit the top end plate and joint washer to the housing. 3. into the housing. slide the lower brass thrust washer over the top end of the shaft and carefully enter the assembly. (76 mm) in a vice.5 kg) to turn the relay lever and shaft. renew them as necessary. Slide a second washer over the shaft and fit the second split qush to the shaft. as shown at Fig. hose clip (Part No. 4. Examine the oil seals in the end caps and renew them if damaged. disconnect the longitudinal tube ball joint from the upper relay lever. so leaving the first hose clip free. 165 . Renew the spring if necessary. Remove the bottom plate complete with oil seal and joint washer. Fit the upper relay lever. Fill the housing with oil. Place a suitable clip (part No. Note: The spring is compressed to over 100 lb. 8. Drain off as much oil as possible by removing Fig. To assemble Operation G/44 I. . and fit the filler and bleed plugs and joint washers. Remove the clips retaining the spring. 5. G-9Method of compressing steering relay spring. and will cause serious damage if care is not exercised. push the shaft into the housing. 7. Remove the clip and push the shaft home. Examine the distance pieces on the shaft (which form tracks for the oil seals) for damage which may have caused failure of the seals. G-lO). Slide a washer over the shaft and fit the spring to the shaft so that it abuts the washer and bush.be shaft and fit the end cap and joint washer. up towards the bleed plug end. if necessary. To strip I. G-9. 9. 11. 3. (5.the split Tufnol bushes if worm or damaged. Release the vice and remove the spring and clips complete. Secure a sack over the bottom half of the relay box and mount relay in a vice with the bottom pointing downwards into the sack. 50320). Remove the bottom end plate and brass thrust washer. 2. 6. 262768) over each end of the spring and compress it to a length of 3 in. The flange plate can be left in position on the underside of the chassis cross-member. Renew. Remove the upper relay lever. Tufnol bushes and spring into the sack. 13. Remove the relay unit upwards. 6. If the assembly is in order. Fit one split bush to the taper on the shaft and secure tightly with a suitable 2 in. Fit a thrust washer to the bottom end of. Detach the lower relay lever from the relay unit shaft. Raise the upper relay lever slightly to allow the ball joint pin to clear the lever. 2. 12. CAREFULLY tap out the shaft. Hold a suitable bar (Part No. 4. Operation Gj42 the oil filler and bleed plugs.STEERING UNIT AND LINKAGE-ALL MODELS G-9 4. with the bars central and vertical. 10. using a spring balance in the relay lever boss. 5. release the second hose clip. tapping gently with a hide-faced hammer. (45 kg) when in position.

3. Examine all parts and renew as necessary. 13. If the unit is in order. replace the rubber covers if damaged. Fit the top end plate and joint washer to the housing. G-IJlteeno. Unscrew the ball joints from the drag link tube (one left-hand and one right-hand thread). remove the clip completely from the shaft. Fit one split bush to the ta~r on the bottom end of the shaft. (5. 3. Ball joints are supplied as complete units. hose dip (Part No. Fit the bleed and filler plugs. 2. Remove the drag link complete. Place a steel washer on to the shaft. Remove the special tool (part No. 10. 50323).haft aDd bwlha ill R~laciq Fi.) Renew the tube if necessary. 0·1. 5. 12. 510309). Place a brass thrust washer on the top end of the shaft. To renew Operation G/48 1. it should require a force of at least 121b. Examine the ball joints for wear in the body and pin and renew the complete units as necessary. 4. using a spring balance in the relay lever boss. 5. The spring can now be wound down the tool until the steel Washer and the split Tufnol bush can be secured to the taper on the other end of the shaft with a hose clip. lubricate the shaft and insert into the housing. replace the bottom end thrust washer. Secure one end of the drag link to the lower relay lever. 7.G-IO STEERING UNIT AND LINKAGE-ALL MODELS 9. 4. joint washer. The lower relay lever must be fitted as illustrated at Fig. Place the spring over the shaft and insert the special tool (Part No.. leaving the clips sIack at this stage. 11. To refit OperatioD Gj46 Reverse the removal procedure. G-ll-Alternative mtthod of ~mpresaing IIteerina relay spring houRnl· Alternative method to assemble relay unit 1.5 kg) to tum the relay shaft. 6. next to the inner side of the T ufnol bush. (Fig. Fit the ball joints to the tube. Disconnect the drag link ball joints from the lower relay lever and steering arm. Filf. 166 Drag link. 510309) through the coils of the spring and right through the lubrication cross-drilling in the shaft. Fit the upper relay lever. . fill the unit with oil.G-8. and secure nghtly with a suitable 2 in. end cover and tighten the retaining bolts. only tbe rubber cover and retaining rings can be obtained separately. Continue to tap the shaft into the housing until the second clip is freed and the shaft abuts the top end cover. 8. relay . With a plastic hammer gently tap the shaft into the housing until the first hose clip slides off the Tufnol bush. 2.

Track rod ball joints To renew Operation G/50 1. 7. Measure the toe-in with the aid of a tracking stick or suitable proprietary equipment.4 mm). No adjustment is provided for castor. Examine tbe ball joints for wear in the body and pin. 2. 4. 2. this applies only if the rubber boot remains in position on the joint. in order to allow full unrestricted movement of the steering linkage. in order . 5. replace the rubber covers if damaged. to 3/32 in. Operation G/50_ Wheel alignment To check and adjust Operation 0/52 1. Set the road wheels straight ahead and the steering wheel in the midway position between full lock in each direction. (1. 3. ensure that the ball joints are aligned with each other. and renew the complete units as necessary. 3. ensure that the ball joint body is parallel with respective steering arms. Reassemble. 4. and spring 8. it should be 3/64 in. Ball joints are supplied as complete units. Thoroughly clean all parts. S. Remove the ball end from the drop arm lever by tapping smartly around the eye of the pin. Tighten the hall joint clips. 5. Place the castle nut upside down on the pin and screw on a few threads. Set the vehicle on level ground with the road wheels in the straight-ahead position. to allow full movement. Should any of the rubber boots be dislodged. 9. proceed as follows: 3. Remove the rubber boot. G-l). 4. The steering ball joints have been designed in such a way as to retain the initial filling of grease for the normal life of the ball iointj however. 6. MODELS G-ll 7. 6. remove the track rod complete.one right-hand thread). until the toe-in is correct. Unscrew the ball joints from the track rod tube (one left-hand and . proceed all follows:- 2. Disconnect the track rod ball joints from the steering arms. and push it forward a short distance. renew the tube if necessary. When refitting longitudinal steering arm and drag link. Secure the other end of the drag link to the steering arm. 167 . Fit the ball joints to the tube. turning the tube to increase or decrease its effective length.2 mm to 2. leaving the clips slack at this stage.STEERING UNIT AND LINKAGE-ALL 6. the toe-in. Secure the ball joints to the steering arms and adjust the toe-in. Steering To check 8. The toe-in is adjustable. Apply grease around the taper. Tighten the ball joint clips. then place the ball joint under a press or between the jaws of a vice and carefully force the pin and ball down against the spring. In this position the interior of the baIl joint can be cleaned and lubricated. camber or swivel pin inclination. only the rubber cover and retaining rings can be obtained separately (Fig. slacken the clips securing the ball joints to the track rod and turn the rod to decrease or increase its effective length as necessary. If correction is required to. so that the relay lever and steering arm are not disturbed. and fill the rubber boot. When refitting track rod and ball joints to the drop arms. using new rubbers rings as required.000 miles (5:000 km) to ensure that they have not become dislodged or the joint damaged. The rubber boots should be checked every 3. Operation G/54 I.

12 mm) ALL MODELS Spring: Number of working coils 10 Free length 71 in.. Loose or worn front wheel bearings-Section S. Worm and nut ni\T A RECIRCULATING BALL TYPE STEERING UNIT Type .. Low or unequal lyre pressures-Section S.. Relay shaft clearances in bushes .8: 1 Inner column end-float Nil Rocker shaft end-float .6: 1 Fulllock .08 to 0....10 mKg) pre-load on bearing at top of column Number of turns of steering wheel from lock to lock . Steering box securing bolts Joose-Tighun. 23. 4.. 2.S. 003 to . E-VEHICLE WANDERS B-TIGHT STEERING I..F....". I. 3. 3. Swivel pin inclination Toe-in ... B.08 to 0. Steering rocket shaft incorrectly adjusted or badly Adjust or rmm'..4 mm) 0 . (47 Kg) Wheel alignment Wheel camber . (l84 mm) Fitted length 3 in. F-WHEEL SHIMMY 1. (4 Kgm) Steering relay unit Bushes Type 168 T ufnol cones 110 3 7" 3/64 to 3/32 in.0045 (0. Steering linkage loose or worn-Rectify or renew. Nil Number of turns of steering wheel from lock to lock .. GENERAL WORM AND NUT TYPE STEERING UNIT ." Non-adjustable.. Steering box oil level low-Replenish. (1. A-EXCESSIVE LOOSENESS OR BACKLASH IN THE STEERING I. 2.. Swivel pins and bearings loose or worn-Section WOtn- LOCA nON Cause and Remedy C-RATTLE IN STEERING COLUMN I.2 mm) Load at fitted length 104 lb.2 mm to 2." Wheel castor . F. Steering rocker shaft adjusted too tightly-Adjust... 2. (0.. 7/16 in. Steering rocker shaft incorrectly 3djusted or badly wornAdjwrt or fflIeIV.4 DET AIL DATA.G-12 STEERING UNIT AND LINKAGE-ALL MODELS DEFECT Symptom.3 Type Ratio Thrust adjustment 15: 1 7-9 lb/in. (72. Longitudinal Ball joints Type steering tube . 3. F.. thread Tightening torque 30 Ib/ft... Section F. D-VEHICLE PULLS TO ONE SIDE 1. Section F. Section F. Recirculating ball Ratio Straight ahead 15.

57 mm) or 2 (upper) x .__ .45 mm) 6 (upper) x .16 mm) and 3 x .SUSPENSION INDEX Page Bump rubber Data . (4.304 kg/m) Free camber 3! in.76 mm) Static load 617 lb.5 mm) 152 lb.649 kg/m) 4 in.5 mm) 86 and Druier 10 10 Passenger 2~ in. 1948-53 Front road spring._" Front spring Page Hydraulic damper Rear axle check strap Rear spring J·7 1·1 . (5.189 kg/m) 4.39 in.74 kg/m) ____ 6.5 mm) top plate x 11/64 in. 1954-58 Layout of suspension Rear road spring 88) (Land-Rover 80 and J·5 Fig.187 in. (1. J-7 J-7 J-6 J-6 LIST OF ILLUSTRATIONS Fig.2 mm) 524 lb. (342 kg) Flat 230 lb. (5./in. (63.203 in. J-5 Rear road spring 88) (Land-Rover 86 and 107 and Page J-l J-2 J-3 J-2 J-2 J·3 J-5 J-5 J-6 J-4 Rear road spring (Land-Rover 109) SUSPENSION Front road springs Land-Rover DATA 80.57 mm) 610 lb. 1948-53 Type 2 862115 to 06113529 8670001 to 06200419 8680001 to 06300030 9 Iiin.".218 in.180 in. (277 kg) 21 in. (4. (44. Width of leaves Thickness of leaves 9 2~ in. (1. (4./in.16 mm) and 3 x . (63.57 mm) 508 lb.57 mm) or 3 (upper) x ./in.875 in.180 in. 1 Fitted to vehicles numbered Prior to 862115 Type 3 06113530 06200420 and 06300031 onwards 9 Ii in.36 rnrrn and 9 x 9(64 in. (63. (63. (165 mm) 2~ in. (89 mm) Land-Rover Number of leaves Width of leaves Thickness of leaves . Static load Camber under static load Rate Free camber Number of leaves .45 mm) 6 (upper) x . (3. (280 kg) Camber under static load Flat Rate 200 lb.5 mm) 9 x ./in.56 mm) and 6 x ..63 in. (2. (230 kg) 2~ in.5 mm) top plate x 11/64 in.jin.165 in.. (102. (4. (4. (44.74 kg/m) 5. (2. (102 mm) 88.56 mm) and 6 x .. 1954-58 Type. (27 mm) 190 lb. (3. (2.5 in.36 mrn) and 9 x 9/64 in.S mm) 152 lb. Page Front road spring. (5.203 in. (63. (4.76 mm) 755 lb. (4. (149 mm) 187 .Section J . (237 kg) 1.218 in.187 in. (5.

(63. (5 x 51. (288. (921 mm) in.7 mm) III in. (Land-Rover 80 and 86. (142. (4.5 nun) in. (46.19 kgJm) 6. (340 kg) (69. (18. (57.2 mm) 636Jb. (247. (340 kg) (69.85 mm) 190 lb. (467 mm) (Except Type 1) B755 Fig.. (286 mm) }Alletnative 11i in. (921mm) G-5 in. (460. (254 mm) 10 in. (Land-Rover A-m 86 and 88. 1954-58 9 2! in.2 E-8t in.5 kg/em) 5nn.1 rom) in. (63. 1948-53) 8-36t in. (4Q3 mm) 1 and 2) and 5 x 21 in. (-4..85 mm) 260 lb.3 mm) 750 lb. (340 kg) 21 in.18 mm) 2i in. (254 mm) 2. 21 in./in.4 mm) E-. 188 . (254 mm) 107 and 1(}9 model 8.19 kg/m) 6. (394 mm) D-86 and 88 model 10 in.5 mm) 9 x .3 mm) (Types D-15i in. 57200469 11· 2~ in. (63. From Chassis No. Width of leaves Thickness of leaves Static load (vehicle unladen) Camber under static load Rate Free camber SUSPENSION 107 and 109.. (460 mm) H-5 x 21 in.720 in.28 mm) 8-18 C-15 F-86 and 88 model 107 and 109 model G---86 and 88 model 107 and 109 model H-86 and as model 107 and 109 model 91 10 in.1 mm) 260 lb. (170.5 mm) 9 x . J-2-Dimeosions with apring flat. (63. Width of leaves Thickness of leaves Static load Camber under static load Rate Free camber .85 mm 190 lb.08 in. (4. (279.jin. (288 kg) (69. 57200470 onwards o AA Fig... ]-I-Dimensiolls with spring flat.in. (130mm) Up to Chassis No.5 mm) 11 x 11/64 in. (19.5 rom) } Alternative 11 in. (222 mm) 10i in.J-2 Land-Rover Number of leaves .165 in.8 mm) J-18i in.9 mm) in. (54 mm) 21 !D.3 mm) 750 lb. (54 mm) }Alternative 21'0.5 kg/em) 5& in. (154. (121 rom) C-181.2 mm) Driver Passenger 9 750 lb. 2~ in. (4. (57. (263.43 mm) 11 2~ in. Number of leaves .5 mm) 11 x 11/64 in.165 in. (5 x 60./in. in. (2. (222 mm) rom) fType 3} F-25/32 in. 1954-58-DIiver and Passenger side) } Altemative m. (286 nun) Hi in.jin. (2.9 mm) 21 in.7'0 in. (46.

ront spring Bush in chassis frame. front Shackle: pin. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29-32 33 34-36 Chassis frame Front bumper Rear draw bar Road spring complete. tapped For Shackle plate. plain front springs Shackle plate.SUSPENSION J-3 Fig.ain leaf }For front 2nd leaf spring Bush for front spring Dowelfor front spring Bolt }For spring Nut clip Road spring complete. front Shackle pin. rear. R. R. tapped For Shackle plate. rear 49 Rubber bush for shock absorbers 50-52 Fixings for shock absorbers 53 Lifting handle. Rubber grommet for brake pipe Clip for grommet 40 Check strap for rear axle 41 Plate for check strap 42-43 Fixings for check strap 44 Rubber buffer for axles. top 68 Rubber washer Fixing engine unit 69 Distance tube 70 Top rubber to chassis frame 71 Bottom rubber at front and rear 72 Plain washer bottom 73 Shim 74 Special nut 37 38 39 189 . front and. rear 45-46 Fixings for buffers ' 47 Shock absorber. plain rear springs Bush in chassis frame. front 48 Shock absorber. rear Self-locking nut. driver's M. RH. front. top 60 Wing nut for clamp 61 Rubber strip for battery 62 Battery cover 63 Battery fixing rod 64 Wing nut fixing battery 65 Suspension rubber for engine. side 59 Air cleaner clamp. rear Bottom plate for front spring. Fixings for front springs Bottom plate for rear spring. rear Shackle pin. rear Shackle pin. driver's Main leaf }For rear 2nd leaf spring Bush for rear spring Dowel for rear spring Bolt leFor Nut spring clip Shack e plate. front 66 Bolt. rear 67 Plain washer. springs to frame.H. front Self-locking nut. Fixings for rear springs 1 Shield for brake pipe. J-3-Layol1t of suspension. rear 54-56 Fixings for handles 57 Battery casing and air cleaner support complete 58 Air cleaner clamp. springs to frame.H.

5 mm) 2~ in./in. (4.15 kg/m) 360 Ib. (4.5 mm) 166 Ib.38 in. (1. (165 kg) 2. (4.0 in.5 mm) top plate x i in.218 in.. (44. (4.0151b.5 mm) 180 lb/in.18 mm) interference 1 All 107 basic models and 109 models up to vehicles numbered 121601061. (525 kg) 2.187 in.. 7 x 3/16 in. (50 mm) Initial rate 160 Ib. (7..5 in.J-4 Rear road springs SUSPENSION Land-Rover 80.187 in. (6. (63. 1954-58 Passenger Driver 11 11 2! in. 1948-53 Number of leaves .218 in. (63.90 kgfm) Rate Free camber 6.76 mm) and 4 x 5/16 in.56 mm) and 2 x ..76 mm) and 2 x (4. (4.93 mm) 5/16 in.(2.. (263 kg) Static load Camber under static load 2. (6.0075 in.0075 in. and 107 Station Wagon up to 87060061 Land-Rover 109 and 107 Station Wagon Driller Number Pa!senger 11 Width of leaves Thickness of leaves .67 in.187 in. (206 kg) 2.074 kg/m) 4i in. (184 mm) 6* in..15 kg/m) Free camber.5 in. (7.35 mm)..jin.35 mm) and top plate x i in. (4. .0025 to . 2.88 kg/m) 250 lb.16 mm) or 7 x . (2. (51.0075 in: (0./in.45 mm) 10 x ./in.074 kgfm) 4 in.. (182.56 mm) and 2 x .35 mm). (50 mm) 160 lb. (0.5 mm) top plate x t in.158. 7 x 3/16 in. (166./in. (152 mm) Fit of bushes in spring and chassis bores . (4. top plate x 1in.0 in..065 to 0.76 mm) 690 lb.18 mm) interference of leaves .jin. (4. (5.. (326 kg) 2.45 mm) 10 x . (63.35 mm). (5. (63. (7. (5. top plate x tin. (50 mm) 2.76 mm) and 2 x 5/16 in.35 mm) and 10 x 3/16 in.0025 to .. 6 x 3f16 in. (63. (1. Land-Rover Number of leaves Width of leaves Thickness of leaves 86 and 88.88 kg/m) 11 in.76 mm) and 4 x 5/16 in.. (63. (114 mm) Passenger (44../in./in.203 in..76 mm) 365 lb.76 mm) 455 lb. (460 kg) Camber under static load 2..5 mm) 2! in. 10 Driver 107 and 109 10 Pa!senger Static load Camber under static load Initial rate Final rate Free camber Fit of bushes in spring and chassis bores 2~in. . 6 x 3/16 in.0 in. in.38 in.51b. (1. (63.35 mm).93 mm) 1.90 kg/m) 166lb. (184 kg/m) 11 From vehicles numbered: 109 models 121601602 up to 121700416 107 Station Wagon 87060062 up to 131700042 190 . 2! in.. (381 kg) 720 lb. (154 mm) 6 in. (7. (2. (5.16 mm) or 7 x .93 mm) 840 lb. (6. (6.67 kgjm) 250 Ib.. (50 mm) 145lb. (6.. Width of leaves Thickness of leaves . (102 mm) 9 or 10 I!in. (0.5 mm) ISO Ibfin.5 mm) . (4.0 in. (2.. (6. (1. (184 kgjm) Final rate 360 Ib..5 mm) top plate x 1in.065 to 0.0025 to .54 mm) 6500 in.6 mm) .93 rum) Static load 1..18 mm) interference Land-Rover Number of leaves .203 in... (51. (313 kg) 580 lb..76 mm) 10 x 3f16 in. ./in. (165 mm) Fit of bushes in spring and chassis bores .065 to 0./in.5 mm) 2. 7. (63.. Static load Camber under static load Rate Free camber Driver 9 or 10 If in.67 kg/m) 145Ib. Width of leaves Thickness of leaves .

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