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SECTION
Frame Unit
Propeller Shaft
TR3 Supplement T
Service Instruction A3
Manual
GENERAL DATA
SECTION A
GENERAL DATA
INDEX
Page
Chassis Specification ...... ...... ...... ...... ...... 1
Performance Data ...... ...... ...... ...... ...... 3
Fuel Consumption ...... .....* ...... ...... ...... 3
Car Dimensions ...... ...... ...... ...... .....- 3
Body Dimensions ...... ...... ...... ...... 5&6
Car Weight ...... ...... ...... ...... ...... ...... 7
Tyres ...... ...... ...... ...... ...... ...... 7
Capacities (Petrol. Oil, etc.) ...... ...... ...... ...... 7
Body Specification ...... ...... ...... ...... ...... 7
Spire Speed Nuts ...... ...... ...... ...... ...... 7
Commission Numbers ...... ...... ...... ...... 8
Engine Numbers ...... ..... ...... ...... ...... 8
Gearbox Numbers ...... ...... ...... ...... ...... 8
Rear Axle Numbers ...... .....a...... ...... ...... 8
Recommended Lubricants-British Isles ...... ...... 9
Recommended Lubricants-Overseas ...... ...... 10
Lubrication Chart ...... ...... ...... ...... 11& 12
Nut Tightening Torque Data ...... ...... ...... 13
Standard Measure and Metric Equivalents ...... 16
Page
Fig. I Power Cuwe ...... ...... .....a ...... ...... ...... 4
Fig. 2 Body Dbensioms ...... ...... ...... 58r6
Fig. 3 Spire Speed Nuts ...... ...... ...... ...... ...... ...... a
Fig. 4 Gosnmissisn Numbers ...... ...... ...... ...... ...... 8
Fig. 5 Lub~ca~oaaChart ............ ...... 11&W
GENERAL DATA
Camshaft Bearings ...... Front B-g-cast Capacity of Cooling
iron sleeve ; 2nd, System ...... ...... 13 pints (7.4 litres).
3rd and 4th With Heater ...... 14 pints (8 litces).
direct in crankcase. Thermostat ...... ...... Commences to open
After Engine No. TS at 150°F. (70°C.).
9095E engines will be Fully open at 197°F.
fitted with replace- (92°C.).
able V a n d e r v e l l Frost Precautions ...... With '"Smith's Blue-
shell bearings, See col " anti-fr eeze mix-
T R 3 Supplement sure. Other brandis
Engine Secuon CCB"". as recommended bv
Lubricating System......Wet Sump. Capacity their rnanufacrurex~.
I1 pints* Degrees of Frost
(Fahrenheit) ......
Oil Pump ...... ...... Hobourn Eaton high Proportion ... ......
capacity double ec-
centric rotor. Feed Bimount of " Bluecol "
to main bearings, big (Pints) *..... ...... 1.5 2.5 3
end bearings and all Piston Speed...... ...... 2,850 fiFt./min. at 4,800
camshaft bearings r.p.rn. (This speed
under pressure. is equivalent to 100
m.p.h. in " Normal "
Oil Pressure ......
P
...... 70 lbs. s , in. at 2,000
r.p.m. 4.9 kg.sq.an.) Flywheel ......
top gear.)
...... C a s t Iron with induc-
Oil Cleaner ...... ...... lfutolator by-pass flow tion hardened
system with re- shrunk-on steel
placeable cartridge. starter ring gear.
...... Twin S.U. H.4. Transmission
Standard needles FV.
For high speed Clutch ..-... ...... Borg and Beck 9"
motoring G . C . single dry plate. Hy-
needles. draulically operated.
Ball baring- clutch
Valve Timing ...... With valve rocker throw out.
clearance set at .015" Gearbox ...... ...., Four forward ratias aad
("38mm.) reverse. Spclhro-
Inlet Valve opens at mesh on 2nd, 3rd aad
15' B.T.D.C. tap forward ratios.
Exhaust Valve closes at Silent helical gears,
1 5 O A.T.D.C. Oil filler combined
15" is equivalent to with dipstick.
.081" piston navel or Ratios
1.5" (3.81 cms.), Overdrive
measured round the Rev.
flyevheel adjacent to Top Top 3rd 2nd 1st
Gearbox .a2 1.00 1.325 2.00 3,38 4.28
the starter teeth. Overall 3.03 3.7 4.9 7.4 12.5 15.8
Dims. on fan pulley
=. 72', Rear Axle ...... ...... Hypoid Bwek Gears.
Taper roller bear-
Cooling System ..... Thermostatically con- ings on differential
trolled. and for Hypoid Pin-
Pressurised Radiator Pressure release at ion Shaft. Ball bear-
3 i 4 &lbs. ings for road wheels.
Radiator Temperature Normal d g should Shim adjustment for
not exceed 185°F. Pinion and Crown
(85"C.), Wheel adjustment.
GENERAL DATA
Rear Axle Ratio ...... 3.7. (37T x 10T). Maximum Speeds
Wheels ...... ...... Steel Disc Type with (Touring Trim)
chrome nave plates
(yire wheels op-
honal extra.).
a
To Gear ......
3r Gear ......
2nd Gear ......
110m.p.h.
75
45
1st Gear ...... 25
Suspension ...... ...... Coil springs for in.
dependent front sus- Engine R.P.M.at 10 rn.p.h,
pension with tele- Top Gear ...... 500
scopic dampers 3rd Gear ..... 660
Wide semi-elliptic 2nd Gear ..... 1,000
springs at rear, 1st Gear ...... 1,680
controlled by piston Rev.Gear ...... 2,130
type dampers.
Acceleration Two Up
Brakes ...... ...... Lockheed H draulic Gear Speed Time
1 0 x 2iiH= i
ront. 9"
x l#"rear. ( ~ f i e r Top 9 secs.
Commission No.
TS.5481 10" x 2i" 30-50 M.P.H. 9 secs.
front and rear.) Two (48-80 Km.P.H.)
leading shoe type Through 0-SO M.P.H. 8 secs.
used on front Gears (0-80 3Gn.P.H.)
wheels, leading and 6-40 M.P.H. ' 12 secs.
trailing shoe type on ( 0 - 4 Km.P.H.)
rear wheels. Alloy
cast i r o n brake Fuel Consumption
drums. Foot opera- Petrol ...... ...... 26-32 m.p.g. (10.87
tion hydraulic on all -4.83 litres per 100
four wheels. Hand km.).
operation mechani-
cal on rear wheels Oil ...... ...... ...... 3,000 m.p.g. (1,100
only. km.per htre.)
RECONDITION PLATE
q. CO SSION NU ER (Chassis
Number) factory rebuat engbes have the previous
This number is found on a plate attached to n m b e r erased and the new number
the bulkhead under the bonnet at the right- stamped on a plate whichis aetached to the
hand side (see Fig. $). It has the prefix. same boss (see Fig. 4).
letters '' T S g Y 9 late dso gives S o m a t i o n as to the
NOTE : It is importat &at ~s Bum- the crank pins and journals, also the
ber is quoted when which d ~ eunit was rebuilt.
the Campay cone
car and pardedarly when I6 FRO3>
orderhg spare parts.
ENGINE
Shell X-100 Essolube Duckham's Mobiloil Castrol Energol
WL,,
Summer 30 30 " Thrty A XL S A E 30
REAR AXLE . Shell Spirax Esso Expee Duckham's Mobdube Castrol Energol
STEERING GEARBOX 90 E P Compound 90 Hypoid 90 G X 90 HWOY E P S A E 90
RECOMMENDED LUBRICANTS
OVERSEAS COUNTRIES
HlANDBRAKE CABLES
Duckham's
Keen01
Mobitgrease
M 1'
Castrolease
Brake Cable
Energrease
C3G
Shell
Retinax A
Esso
Spring -
KG16 Grease Grease
THREE OR
FOUR STROKES
WITH O I L GUN
GENERAL DATA
ENGINE
CYLINDER HEAD 4" UNF and UNC Stud 106960 100-105 Tighten nuts wth en- I
106959 gine cold
CONNECTING ROD CAPS &" UNF Bolt 105312 55-69
MAIN BEARING CAPS J" x 13 NC Setscrew 57121 85-93
FLYWHEEL ATTACHMENT T0
CRANKSHAFT 4" x 24 NF Setscrew 102065 42-46
TIMING CHAIN WHEEL T O CAM-
SHAFT -& " x 18 NC Setscrew 56370 24 - 26
MANIFOLD ATTACHMENT $" NC Stud 58688 2244
102475
107055
OIL PUMP ATTACHMENTS 3 x 24 UNF Stud
" HN 2008 12-14
REAR OIL SEAL ATTACHMENT f 4" x 20 UNC Setscrew ; UN0755 840
CLUTCH ATTACHMENT +" 'n 18 UNC Setscrew HLJ0856 20
ATTACHMENT OF END PLATES A " x 18 UNCBolt HU 0856 14-16 Tapped into Aluminium
ATTACHMENT OF OIL FILTERS fg" x 18 x 24 UNC HB.0874
Bolts HB.0882 18-20
Cap Nut DN 3408
Bolt HB 0856
TIMING 'COVER &" x 18and 24 NC HU.0805 14-16
Setscrew HU 0857
SUMP ATTACHMENT A" x 18 NC Setscrew 100749 1618
PULLEY T 0 WATER PUMP SPINDLE A" x 24 UNF TN.3208 16-18
Slmmonds Nyloc Nut
DYNAMO BRACKET T 0 BLOCK I A" x 18 UNC Setscrew HU0856 1 16-18 I
DYNAMO T 0 BRACKET AND PEDES- I%" x 24 UNF 59115 1GI8
TAL Setscrew and Bolt HU.0808
ROCKER PEDESTAL $" NF and NC Stud 108205 24--26
OIL GALLERY PLUGS 6"x 14 UNC 102785 32-36 Tighten on to copper
3" X 16 UNC HU0954 24-26 washer
ATTACHMENT OF STARTER MOTOR #" x 24 NF Bolt NB0915 2628
WATER PUMP ATTACHMENT .it" X 16 UNC Bolt HB 0971 2628
#" x 26 UNC Bolt HB.0968 26-E
PETROL PUMP ATTACHMENT A " NF and NC Stud 3 1ST 12-14
131C056
THERMOSTAT ASSEMBLY T O CYL- A" x 18 UNC Bolt HB0878 16-18
INDER HEAD fk" X 18 UNC Bolt I
HE30866 16-18
INLET T O EXHAUST MANIFOLD 6"x 24 UNF Stud 100419 1244
DYNAMO T O PEDESTAL FRONT fk" x 24 UNF Bolt 59115 16-18
FRONT HUB TO CRANKSHAFT 5/8" x 18 UNF Bolt 108498 140
GENERAL DATA
CE RBOX
FRONT S S,PE S IO
R E R . XLE
Steeri ng box
Drop Arm to Rocker Shaft 5/8 x 18 UNF 62 FNH 80
14
GENERALDATA
TRIUMPH SPORTS T R . 2
ENGINE
TRIUMPH SPORTS T R . 2
ENGINE
TRIUMPH SPORTS T R . 2
GEARBOX
TRIUMPH SPORTS T R . 2
FRONT SUSPENSION
TRIUMPH SPORTS T R . 2
FRONT SUSPENSION
REAR AXLE
ENGINE
SECTION B
ENGINE
INDEX
Page Page
Engine Dimensions ...... ...... ...... 1 Refitting Camshaft ...... ...... ...... ...... 21
General Description ...... ...... ...... 8 To set Valve Clearances ...... ...... ...... 22
The Cylinder Block ...... ...... ...... 8 To set Valve Timing in the absence of
The Cylinder Sleeves ...... ...... ...... 8 Timing Wheel Markings ...... ...... 22
The Connecting Rods ...... ...... ...... 9 Ignition and Distributor timing ............ 24
Aeroflex Compensating Pistons ...... ...... 10 To Decarbonise ...... ...... ...... ...... 25
The Crankshaft ...... ...... ...... ...... 10 ValveGrinding ...... ...... ...... ...... 25
The Valves ...... ...... ...... ...... 10 Removal of Carbon ...... ...... ...... 26
The Camshaft ...... ...... ...... ...... 10 Low Compression Kit ...... ...... ...... 27
The Cooling System ...... ...... ...... 11 The Purolator Oil Filter ...... ...... ...... 27
The Fuel System ...... ...... ...... ...... 11 Removal of Engine and Gearbox ............ 28
The Hobourn Eaton Oil Pump ...... ...... 11 Dismantfing Engine. . . . . . . . . . . . ...... ...... 30
Coil Ignition ...... ...... ...... ...... 11 Re-assembly of Engine ..... ...... ...... 31
The Engine Mountings ...... ...... ...... 11
Notes on Sparking Plugs . . . . . . . . . . ...... 37
The Flywheel ...... ...... ...... ...... 11
List of Champion Spark Plug Co. I.td .
To fit replacement Starter Ring Gear ...... 11 Distributors ..... ...... ..... ...... 42
Crankcase Ventilation ...... ...... ...... 12 Engine Noises ...... ...... ......
Engine Lubrication ...... ...... ...... 13 Main Bearing Knock ...... ......
Description ...... ...... ...... ...... ...... 13 Crankshaft End Float ...... ......
The Oil Pump ...... ...... ...... ...... 13 Big End Bearing Knock ...... ......
To remove the Oil Pump from the Engine 16 Small End Knock ...... ...... ......
To dismantle Oil Pump ...... ...... ...... 16 Piston Knock (Piston Slap) ......
Servicing the Oil Pump ...... ...... ...... 16 Noisy Valve Rockers or Tappets ......
Engagement of Oil Pump and Distributor Ignition Knock (Pinking) ...... ......
Driving Gear ...... ...... ...... ...... 16
Backfiring into Carburettor ......
The Crankshaft and Main Bearings ..... 17
Excessive Oil Consumption ......
Main Bearing Clearance ...... ...... ...... 17
Low Oil Pressure ...... ...... ...... ...... 48
Crankshaft End Float ...... ...... ...... 17
High Oil Pressure ...... ...... ...... ...... 49
Connecting Rod Bearings ...... ...... 18
......
Notation for Fig. 49 (Exploded view of
Piston Assemblies and Cylinder Sleeves ...... 19 Cylinder Block Details) ...... ...... 51
Figure of Eight Joints ...... ...... ..... l9 Notation for Fig. 50 (Exploded view of
Camshaft and Timing Gears ...... ...... 20 Crankshaft Details) ...... ...... ...... 53
To remove Camshid? ...... ...... ...... 20 Fault Location ...... ...... ...... ..... 54
ILLUSTRATIONS
Page Page
Fig. 1 Longitudinal view of Engine ...... 6 Fig. 25 The TR2 Valve Timing Diagram 23
Fig. 2 Cross section view of Engine ...... 7 Fig. 26 Plug Lead Attachment Sequence 25
Fig. 3 Cvlinder Sleeve and Dimensions 8
<
Fig. 27 A " Pocketed " Valve Seating ...... 26
Fig. 4 Figure of Eight Joints ...... ...... 8 Fig. 28 Cylinder Head Nut Tightening
Sequence ...... .... . .,.
Fig. 5 Checking Cylinder Sleeve pro-
jection ...... ...... ..... 9 Fig. 29 The Pwolator Oil Filter ......
Fig. 6 The Piston and Connecting Rod Fig. 30 The front of Car prepared for
Assembly in exploded form 9 Engine and Gearbox Removal
Fig. 7 The Piston and Connecting Rod Fig. 31 The Engine and Gearbox being
Assembly ...... ...... ...... 9 removed from the Chassis ......
Fig. 8 Crankshaft, Bearings and Thrust Fig. 32 Rear Oil Seal for Crankshaft ......
Washers ...... ...... ...... 10 Fig.33 Crankshaft Mandrel for Centring
Fig. 9 Exploded view of Valve Operat- the Rear Oil Seal ...... ......
ing Gear ...... ...... +..... 10 Fig. 34 Fitting the Lower Thrust Washer
Fig. 10 Fitting a Replacement Starter Fig. 35 Sealing Rear Main Bearing Cap
Ring ...... ...... ..,.., ...... 12 Fig. 36 The Rocker Gear Assembly ......
Fig. 11 A diagrammatic view of Crank- Fig. 37 Setting the Starter Dog at '' ten
shaft Ventilation ...... ...... 12 minutes to four " ...... ......
Fig. 12 Longitudmal view of Oil Circula- Fig. 38 Sparking Plugs in a tray ready
tion ...... ...... ...... ...... 14 for comparison ...... +...,,
Fig. 13 Cross section view of Oil Circula- Fig. 39 Oil fouling indicated by a wet
tion ...... ...... ...... ...... 15 Shiny Black Deposit on the
Fig. 14 Exploded view of Oil Pump ...... 16 Insulator ...<. ...... L..+..
Crankshaft
Journal diameter
Big End
Crank Pin Diameter
1
ENGINE-Dimensions and Tolerances
- - - - - -
Small End
I
Bore for Bush 1.ooOO"
.9950M
Press Fit in Con. Rod.
Bush External Diameter 1.0005"
.995"
Internal Diameter of Bush ,8752"
.8748" .0002"
at
Gudgeon Pin Diameter .87510M 68°F.
.87485"
Piston Rings
Compression Ring Width
Groove Width
Groove Width
+
Piston Rings are obtainable in the following oversizes : .010", +.02OV,+.030n, +.040".
Pistons and Cylinder Sleeves
F G H
Bore Diameter 3.2676" 3.2680" 3.2684"
Oil Pump
Outer Rotor Outside Diameter
Depth of Rotor
Housing Depth
Inner Rotor
Major Diameter
Minor Diameter
Rotor Depth
Housing Depth
Valve Springs
Outer Springs
Inlet and Exhaust
Fitted Length 1.560"
Fitted Load 38 lbs.
Free Length, approx. 1.980"
Inner Spring
Pdef
Fitted Length 1.500"
Fitted Load 33 lbs.
Ehaaast
Fitted Length 1 .450M
Fitted Load 36.5 lbs.
Met and Exhaust
Free Length, approx.
A u d a q Inner Spring
Ehaust Valve O d y
Fined Length 1.140"
Fitted Load 10 lbs.
Free Length, approx. 1.540"
Inlet
Exhaust
Fig. 2 Cross section view of Engine. For illustration purposes the sump oil filter has been omitted.
7
ENGINE
I. GENERAL DESCRIPTION These two pairs of flats provide alter-
(Figs. I and 2) native fitting positions to deal with
(a) The Engine has four cylinders and piston slap which normally occurs due
the overhead valves are push rod to wear along the axis of thrust.
operated, the 83 mm. bore and 92 mm. The sleeves are machined all over and
stroke give a capacity of 1,991 cubic ground on their upper faces. The lower
centimetres. The compression is 8.5 portion of each liner is provided
to 1. externally with a reduced diameter,
A low compression kit (see page 27) surmounted by a flanged face for,
is available and reduces the com- spigoting into machined recesses in the
pression ratio to 7.5 to 1. cylinder block and a water seal pro-
(b) The Cylinder Block is an integral vided by a plastic covered steel joint.
casting in cast iron, the abutments for
the cylinder sleeves, the three rear
camshaft bearings and the crankshaft
bearing housings are machined in a
single unit. The main bearing housings
are line bore machined; the bearing
caps are not interchangeable and are
stamped together with the casting to
assist identification.
After Engine No. 9095E four Vander-
vel bi-metal bearings were fitted
to accommodate the camshaft. A
recognition feature of engines so fitted
with these bearings will be that three
setscrews retaining the three rearmost
bearings will clearly be seen on the left- Fig. 4 A Figure of Eight Joint.
hand side of the cylinder block. See
TR3 Supplement Engine Section "B".
The Figure of Eight joint (Fig. 4) is
made of steel and is plastic coated to
provide the necessary sealing pro-
perties. Care must be exercised when
handling or storing these joints and
they should always be examined for
chipping or peeling of the plastic coat
before use.
If doubt exists as to the condition of
the plastic coat the joint should be
discarded. Only in the cases of ex-
treme emergency should they be used
and then with a liberal application of a
sealing compound.
The sleeves are spigot mounted and
held in position by the combustion
Fig. 3 Cylinder Sleeves and Dimensions. head, the initial position of the sleeve
allowing this to stand proud of the
(c) The Cylinder Sleeves (Fig. 3) are of cylinder block .003" minimum to
the wet type, being centrifugally cast .0055" maximum (Fig. 5). The bores
in nickel chrome iron and provided are graded F, G or H, and the ap-
with flanged upper faces, having two propriate symbol is engraved on the
pairs of flats at 90° to one another. upper face of each sleeve. (See page 2.)
8
ENGINE
":'1:,"
," ,4JI!:;
~: ..>: ..
, ",-',
. #. '.
,
~ .... ,
", ~: '.
i "'_~"
o 0 "',', ~l ,' . ,
;
,~~
,
) ~'~!
9 TR2 C
ENGINE
(e) Aeroflex Compensating Pistons be taken when replacing the front
(Fig 6) are employed, which are made and rear oil seals. This operation is
from a special aluminium alloy and described on page 32 and 33.
each provided with two compression (g) The Valves are overhead, push rod
rings and one oil scraper ring. operated. The push rods themselves
The pistons are graded F, G or H are tubular being fitted with a ball at
(dimensions on page 2) and this symbol one end and a cup at the other, both
is stamped on the crowns. The piston being spot welded into position.
skirt has a -1,/' slot on the non-pressure All val ves are made from a chrome
side and is fitted to the connecting rod nickel silicon valve steel stamping,
so that this slot is away from the point the inlet valve having a larger head and
of maximum thrust, Fig. 7 (facing the a smaller stem than the exhaust valve.
camshaft side of the engine). The stems have a hardened tip. The
exhaust valves fitted to engines
after Engine No. TS. 481 E were
made from a high nickel chromium
tungsten valve steel stamping, and the
stem was stellite tipped.
10
ENGINE
these bearings will be that three set- is supplied by an A.C. Type UE Pump
screws retaining the three rearmost to the twin S.U. Type H4 carburettors.
bearings will clearly be seen on the left- Each carburettor has its individual
hand side of the cylinder block. The A.C. air cleaner. The vacuum pipe to
front bearing is pressed into the front the distributor is taken from the front
bearing sleeve. carburettor.
The camshaft operates directly on flat (k) The Hobourn-Eaton Double Rotor
based hollow cylindrical chilled cast Oil Pump (Fig. 14) is of the sub-
iron tappets which in turn engage merged type and is self priming; oil is
hardened spherical-ended push rods, drawn from the engine sump through
the upper extremities of which are a gauze filter. The oil is fed to the oil
hardened and cup-shaped, accommo- gallery and to the Purolator oil filter.
dating hardened ball ended screws,
(I) Coil Ignition is employed and the
which are mounted on the outer ends
distributor (Lucas DM.2 Type V.167)
of the respective rockers. Camshaft has a vacuum and centrifugal auto-
end thrust is taken by the flanged front
matic advance incorporated. It is
bearing, against the timing wheel and a
suppressed for radio and television.
shoulder on the shaft itself. End float
is measured by a feeler gauge between (m) The Engine Mountings are of the
the camshaft chain wheel and the front flexible type, the front bearer being
bearing housing or by a dial indicator. assembled on the rubber blocks on
To reduce the end float a replacement either side of the chassis frame, the
bearing of increased length must be gearbox itself being supported on a
fitted. To increase the end float it will rubber pad secured to a cross member
be necessary to rub the bearing down of the chassis frame.
on a sheet of emery cloth placed on a (n) The Flywheel is manufactured from
surface plate to reduce its length. cast iron and is fitted with a shrunken
The rockers are of case hardened steel starter ring of heat treated steel. It is
and provided with phosphor bronze located on the crankshaft by a dowel
bushes which are lubricated under and secured by four bolts with lock
pressure from the main oil supply. plates. The flywheel is marked by an
The eight rockers themselves are car- arrow which, when aligned with a
ried on a hollow rocker shaft which is scribe line on the cylinder block, sets
in turn mounted on four pedestal Nos. 1 and 4 pistons at T.D .C.
brackets, the oil being fed along the When fitting the flywheel to the
rocker shaft to the various rockers. crankshaft ensure that both compo-
(i) The Cooling System. (see Section nents are free from burrs. After fitting,
"C") is thermostatically controlled and the run-out should be checked by a
pressurised ; an impeller pump is D.T.I. to ensure the run-out does not
utilised to assist the circulation of the exceed .003". Failure to observe this
cooling fluid. point may lead to clutch disorders
A four-bladed 12!,' fan is mounted on and vibration.
rubber bushes and is attached to the There are two dowel holes in the fly-
crankshaft. The fan pulley is drilled wheel 90° removed from one another'
in its outer periphery and aligning this this will enable the flywheel to b~
hole with a pointer welded to the turned 90° should the teeth of the
timing chain cover sets Nos. 1 and 4 starter ring gear become increasingly
pistons at T.D.C. (see Fig. 37). worn and a replacement not be readily
The radiator is attached to the body at available. It must be remembered that
the upper corners and secured to the the timing mark must be obliterated
chassis at its sides. and a second stamped on the flywheel.
(j) !he Fuel System (see Section "P") (0) To Fit Replacement Starter Ring
mcorporates a petrol shut off cock in Gear. When it is necessary to fit a re-
th~ ~ip~ line from the tank to the pump, plac~ment ring gear, certain pre-
this IS sItuated on the left-hand chassis cautIons should be taken to ensure its
member adjacent to the engine. Petrol future life. The installation can be
11
ENGINE
carried out whilst the flywheel is still
cold. T h e ring should be immersed in
boiling water or its temperature raised
by some other means ; a temperature
higher than boiling water is not re-
commended for the heat properties of
the ring may be destroyed. The ring
must be fitted with the leading edges
of the teeth toward the starter motor.
Should a press not be available, fitting
of the ring gear can be carried out
using four "G" clamps and tapping the
ring into position with a brass rod
(Fig. 10).
the cylinder block and a routine check offset from a tooth centre. When the chain
should be made whenever the combustion wheel is fitted at 90" to its initial position,
head is removed. Should the cylinder which location we will identify as position
sleeve(s) be below the specified limits new +
"A", a tooth of adjustment is obtained.
If on the other hand the wheel is turned
figure of eight joints should be fitted.
" back to front" from position "A" a 1
tooth of adjustment is obtained, whilst a
8. CAMSHAFT AND TIMING GEARS 90" movement in the reversed position will
The camshaft is of cast iron, having chilled give 2 of a tooth variation from that given
faces for the cams and journals. With the by position " A."
camshaft a cast iron flanged front bearing is When the timing has been correctly set the
used, the other three journals making direct faces of the two gears are marked with a
contact with the cylinder block. scribed line drawn radially in such a manner
In the near future it is proposed to fit that if the lines were produced outwards on
four Vandervel bi-metal bearings to ac- the respective gears they would pass through
commodate the camshaft A recognition of the centres of the two gears.
an engine so fitted with these bearings will In addition, to avoid any possibility of the
be that three setscrews retaining the three camshaft position being incorrect, a centre
rearmost bearings will be clearly visible on punch mark is made on the end of the cam-
the left-hand side of the cylinder block. The shaft through an unoccupied bolt hole and
front bearing is pressed into the front on the face of the timing gear adjacent to the
bearing sleeve. setscrew hole ; Fig. 21 shows the marking
The camshaft is driven by a double roller of the timing wheels.
silent chain which engages with a sprocket The helical gear for the distributor and
on the crankshaft and one spigotted on the tachometer drive and the cam for operating
the fuel pump are integral parts of the
camshaf?.
End float of the camshaft is taken between
the flange on the front camshaft bearings
and the rear face of the timing wheel.
This end float can be increased by reducing
the length of the front bearing sleeve by
rubbing the rearmost end on a sheet of
emery cloth placed on a surface plate, to
decrease the end float it will be necessary to
re lace the front bearing.
l3.ler grinding pera at ions on the camshaft
have been completed it is degreased,- bon-
derized and whilst still warm immersed in a
solution of " Dag " (colloidal graphite).
This process considerably improves the
bearing surfaces and gives additional wear-
ing properties.
9. TO REMOVE CAMSHAFT
The camshaft may be removed from the
engine while the unit is stdl in the chassis
Fig. 21 Showing Wheel Markings for Valve
and the following procedure is used.
Timing. Note the Keyway in the Crank- (a) Remove the fiont cowl and radiator as
shaft Sprocket pointing downward. described in " Removal of Engine))'
page 28.
end of the camshaft and secured by two (b) Remove the cylinder head as described
bolts. in " Decarbonising " and cc Valve
Four holes are provided in the camshaft Grindmg," page 25. Immediate1
timing gear, which are equally spaced but afta removal of the cylinder h e a l
ENGINE
sleeve retainers (Churchill Tool No. removal. It is considered desirable to
S. 138) should be applied as shown in describe certain operations as follows :-
Fig. 22. (a) When resetting the valve timing, the
In the event of sleeve movement, new engine should be set with Nos. 1 and 4
figure of eight washers should be fitted. pistons at T.D.C. In this position the
Remove push rods and tappets. crankshaft timing wheel keyway is
(c) Disconnect tachometer drive. Remove pointing vertically downwards, as
distributor assembly complete with shown in Fig. 21.
pedestal by removing the two securing Rest the camshaft chainwheel on the
nuts at the crankcase. Do not slacken camshaft spigot and turn the chain-
clamp bolt. Remove distributor and wheel about the camshaft until the
oil pump helical driving gear. identification punch mark on the end
of the camshaft can be seen through
(d) Check that the pztrol has been turned the punch marked hole in the chain-
off, remove petrol pipe and pump. wheel. Secure the chainwheel to the
(See "Fuel" Section P.) camshaft leaving the two bolts finger
(e) Loosen off dynamo and remove fan tight.
and fan assembly by withdrawing four Turn the camshaft chainwheel until
bolts and the extension bolt. the scribe line thereon aligns with the
(f) Remove the timing cover by with- scribe Ldne on the crankshaft sprocket.
drawing the seven setscrews, four Without moving the camshaft re-
bolts and one nut. Note the timing move the camshaft chainwheel and
markings on the gear wheels and cam- when removed fit the timing chain to
shaft; this will assist in the re- this wheel and the one on the crank-
assembly (see Fig. 21). shaft in such a manner that the scribe
( g ) Release the locking plate and with- lines remain aligned. Reposition the
draw the two setscrews. The timing camshaft chainwheel and check by
chain can be Jified off the chain wheel simulating pressure of the chain ten-
and both components moved clear. sioner that the timing marks have
retained their positions and re-adjust
(h) Tlie front camshaft bearing is next if necessary. Tighten bolts to correct
removed by withdrawing the two set- torque loading and turn over tabs of
screws and locking washers. T h e locking plates.
bearing can be lifted away.
(b) When refitting the 011 ump and dis-
(i) The carnshafi can now be drawn
forward out of the cylinder block.
P
tributor driving helica gear, ensure
that No. 1 piston is at T.D.C. on
the compression stroke. In this posi-
ro. REFITTING CAMSHAFT tion the correct engagement of the
Re-assembly is the reverse procedure to the helical gear should allow the Wood-
ruffe key to be positioned towards the
front of the engine, pointing approxi-
mately towards the dipstick (Fig. 16).
It may be found that the oil pump,
shaft will not engage with the pump
for the tongue and slot of these com-
ponents are out of line. The engine
will need to be turned over slowly until
the shaft engages with the pump.
Continue to turn the engine until the
offset slot in the distributor drive boss
attains the position as illustrated in
Fig. 16. Disengage the helical gear
and remove it from the housing. Turn
the engine over until No. 1 piston
Fig. 22 Showing one of the two Cylinder Sleeve attains the T.D.C. position on the
Retainers required to prevent movement. compression stroke and replace the
ENGINE
(2.06 mrn.) piston travel or 1.5" T.R.2. VALVE TIMING DIAGRAM
(3.81 cm.) measured round the fly-
wheel adjacent to the starter teeth.
(d) Offer up the camshaft chainwheel to
the camshaft itself but without moving
this shaft and adjust its engagement
with the chain until a pair of holes in
the chainwheel exactly match a pair in
the shaft. It may be necessary to turn
this wheel back to front to match
these holes.
(e) Having attained the correct position of
the chainwheel relative to the shaft,
encircle the wheel with the timing
chain.
(f) Without moving either crankshaft or
camshaft, position the loop of the chain
round the crankshaft sprocket in such
a manner that the holes in the chain-
wheel match those in the camshaft.
(g) The camshaft chainwheel is now se-
cured to the canaslnaft by two bolts and
Pocking plates, the bolts are not locked
until a final check has been made.
(h) A final check can be made when the I
engine is on a bench by marking the Fig. 25 The TR2 Valve Timing Diagram.
rear of the cylinder block opposite slowly in a c l o c h s e direction. As the
the T.D.C. mark on the flywheel flywheel is turned clochse, insert a
with Nos. ]I and 4 cylinders at T.D.C. .010" feeler gauge bemeen the valve
stem and the rocker of No. 4 eyEnder
idet vdve unta a §fight resistance is
felt, that is when rhe valve begins to
open. At this stage. the movement of
the flywheel should be stopped; with a
pencil mark the flywheel opposite the
mark previously made on the cylinder
b%ock.
Remove the feelerr gauge from eke inlet
valve.
Turn the flywheel c l o c h s e until the
feeler gauge can be inserted between
the valve stem and the rocker of No. 4
cylinder exhaust valve, after w,h.ich the
flyheel is mrned to T.D.C. Proceed
to turn the flywheel slowly clockwise
and at the same time puttmg a slight
p d on the feeler gauge. The m r u g
of the flywheel should be stopped at a
point where the feeler gauge can be
removed and Chis indicates that the
exhaust valve has closed. A second
Fig. 24 The Valve Tappet is at Point of Balance. mark of the pencil is now made on the
flywheel opposite the mask on the cyl-
The flywheel is then moved a inder block. With a rule measure the
4 turn anti-clockwise (viewed from the distance from the T.D.C. mark on the
front of the engine) and then mrned flyheel to each of the pencil marks.
ENGINE
If the timing is correct the two dimen- "interference" of .00SW. It will be
sions will be identical. Having finally necessary to fit shims or packings under
proved the valve timing, thechainwheel the distributor adapter to obtain the
locking tabs may be turned up. correct end float.
(i) The tcming gears are now m&ked with Assuming the first instance to be the
a scribe line as shown in Fig. 21. case, it d l be necessary to add one
(j) Fit the timing chain tensioner and packing of .002" thckness to bring the
secure with plam washer and split pm. end float to top limit. For the second
Replace timing cover. instance it will be first necessary to
, , The rocker clearances are now set to
(k) "zero" the interference, i.e., .005" and
their working clearances of .012" ex- add sufficient packings to obtain the
haust valve and .01OVfor inlet valves correct end float. The packing necessary
(see page 22). When the car is used for in this case is .011" for a middle limit
hgh speed work the valve clearances end float.
for all valves is .013".
.-la
l6. REMOVAL OF CARBON
Remove the spark plugs, clean, set and test
ready for replacement. If for any reason
such as badly burnt or broken electrodes,
and damaged insulation the plug should be
replaced. For normal motoring Champion
LlOS 4" reach ; for high speed motoring
L 11S 4'' reach is recommended and the gap
is to be set at .032". The normal life of a S J W CAUSED BY SEAT WFAR
spark plug is 10,000 miles.
Clean the carbon from the cylinder head,
finally wipe the chambers clean. Scrape the
valve ports clean, exercising great care not
to damage the valve seats. When the head is Fig. 27 A '' Pocketed " Valve Seating.
clean of carbon blow out with a compressed
air line and wipe with a rag moistened with sleeves. Clean the grease from the cylinder
petrol. Ensure that the contact face is bores and remove the cloth stufhggfromthe
perfectly clean and flat. bores and tappet chambers.
Before cleaning the carbon from the tops of The valve springs should be examined for
the pistons, smear a little grease around the damage and their length compared with
top of the two bores and raise the piston new springs. If any doubt exists as to the
almost to the top. Fill the other two bores condition they should be replaced. The
and tappet chambers with non-fluffy cloth ; exhaust valve is fitted with an auxiliary
this will safeguard against any carbon chips inner spring, making three springs in all.
entering the lower extremities of the engine. It should be noted that the close-coiled end
It is suggested that the piston crowns are of these springs is fitted nearest the cylin-
cleaned, utilising a stick of lead solder, der head.
which will not scratch the piston crown, Ensurethat the cylinder block and head faces
in such a manner that the carbon deposit are perfectly flat and clean, it should only be
on the vertical wall of the piston and that necessary then to apply a coating of grease
deposit formed in each cylinder bore to the cylinder gasket. Should it be decided
above the maximum travel point of the top to use a sealing compound, one of the non-
iston ring is not disturbed. This carbon setting type must be used for on future
gelps to insulate the piston rings from the occasions when the head is removed, the
cylinder sleeves may be disturbed because " Corgasyl" gasket ; this may be
of their adherence to the gasket. fitted either side up.
When refitting the cylinder head nuts, (d) Fit the longer push rods and lower
tighten them gradually in the sequence the combustion head into position.
shown in Fig. 28 in order to produce an Omitting the plain washers, tighten
even pressure on the gasket and prevent the combustion head nuts (Fig. 28) to
undue strain in the cylinder block casting. the correct torque (100 to 105 lbs. ft.).
It will be necessary to recheck the nut (e) Screw back the ball pins in the rockers
tightness when cold to 100-105 lbs. ft. and then fit shaft assembly to the com-
Before tightening down the rocker shaft
pedestals, screw back each adjusting screw
and ensure that the ball ends of these
screws engage correctly in the push rods.
Failure to attend to this procedure can
result in damage to the push rods. Smother
the rocker gear with oil, particularly where
the rockers bear on the valves.
Before replacing the rocker cover ensure
that the cork joint is undamaged and
shellaced to the cover, otherwise oil may
leak through the joint. F@
! . 28 Cylinder Head nut tightening sequence
After the first 500 miles the cylinder head bustion head and tighten nuts to 2 4 -
nuts should be checked for tightness with 26 lbs. ft.
the engine hot. Adjust valves for clearance. (See
page 22.)
LOW COMPRESSION KIT- (f) Reconnect fuel ~ i ~ carburettorldis-
e .
PART No. 502227 \ , I I 2
32
either side oft he rear main bearing cap
with the aid of a &" square brass
drift (Fig. 35). Two lengths about 9"
long are necessary. Completely fill the
groove and cut the felt off &" proud of
the cylinder block face. It is suggested
that the felt strip is cut into approxi-
mately 2" lengths for easy insertion.
Check the connecting rods for align-
ment in the Churchill Tool No. 335 or
a similar tool. Press the Clevite bush
into the small end of the connecting rod
and ream out whilst in position using
the Churchill Tool No. 6200A and
reamer ; dimensions are to be found
on page 2. Assemble the piston to the
connecting rods so that the split of the
skirt faces the cap side of the rod
(Fig. 7). It is suggested that the
pistons be first submerged in hot
water for a few moments and the
gudgeon pin should then be a light
push fit. Secure the gudgeon pin
with circlips, one either side. Dry the
piston and rod assemblies thoroughly.
(x) Fit the piston rings to the pistons, the
two compression rings are uppermost
with one oil scraper ring below. Lub-
ricate freely. Move the rings so that
their gaps are f 80" removed from one
pig- 35 Sealing Rear Main Bearing Cap.
another ; failure to observe this point
may lead to increased oil consumption. pair of cylinder sleeves and on the
Wire brush the exterior of the cylinder mating faces in the cylinder block after
liners to ensure that they are free ensuring that all components have
from scale and all loose dirt on their been thoroughly cleaned of all loose
machined surfaces. With the assistance deposits and the machined surfaces in
of a piston ring compressor fit the which the cylinder sleeves spigot are
piston assemblies to the cylinder clean and free from burrs, the sleeves
sleeves bearing the same letter as the with their respective piston assemblies
piston. can now be fitted to the block.
(xi) Arrange the piston and connecting rod (xii) Locate the cylinder sleeves and piston
assemblies now in their cylinder assemblies in the cylinder block so that
sleeves, so that the numbers stamped the cap of the connecting rod is ad-
on the rods and caps run consecutively, iacent to the camshaft side of the
i.e., 1, 2, 3, 4. Turn these assemblies engine. The assembly which bears
upside down in pairs, 1 and 2,3 and 4, the number 1 on its connecting rod is
with the flat of the liner adjacent to fitted to the foremost position. The
one another. The bearing caps are now sleeves should stand .003" to .0055"
all uppermost and must be turned face proud of the cylinder block face (Fig.
c\
one way. Remove the bearing caps and
fit the shell bearings to rods and caps. ( d i ) It is essential that means are em-
Fit one figure of eight packing, using a ployed to prevent the cylinder sleeves
light coating of " Wellseal " jointing from moving in the block. Messrs. V.
compound on the flanged faces of each L. Churchill & Co. Ltd. have manu-
ENGINE
factured special retainers for this pur- (xix) Lubricate the camshaft and feed into
pose (Fig. 22) and it is suggested that the cylinder block and secure the front
these are employed. Until this is done bearing with two setscrews. Check the
the piston assemblies must not be end float as described on page 17.
moved, for any movement will be Rest the camshaft chainwheel on the
transferred to the sleeve and damage camshaft spigot and turn the chain-
the figure of eight washers. If damage wheel about the camshaft until the
is undetected, water leakage will result. identification punch mark on the end
An alternate method is to insert the of the camshaft can be seen through
cylinder sleeves alone into the block, the punch marked hole in the chain-
clamp them with the Churchill sleeve wheel. Secure the chainwheel to the
retainers to ensure no further move- camshaft leaving the two setscrews
ment and then fit the piston assemblies finger tight. If a replacement chain-
similarly as described in paras. (x) and wheel is being fitted, see "12. T o set
(xi). Valve Timing in the Absence of Mark-
ings" (page 22). Check the alignment
(xiv) Having the sleeve retainers in position, of the chainwheel with that of the
the connecting rods may be fitted to sprocket on the crankshaft, taking into
the crankshaft, Nos. 1 and 4 cylinders, consideration the end float of the cam-
followed by 2 and 3 cylinders. The shaft. The alignment can be adjusted
caps are fitted to their respective rods by altering the thickness of the shim
and in such a manner that the tubular between the crankshaft sprocket and
dowel will sink into its recess and their the abutment on the crankshaft.
identification numbers coincide. It
should be noted that the bearing cap, (xx) Turn the camshaft chainwheel until
because of this dowel, can only be the scribe line thereon lines up with
fitted one way round. The cap is the scribe line on the crankshaft
secured by two bolts and a locking sprocket. Without moving the cam-
plate. Tighten the bolts to the correct shaft remove the chainwheel and when
torque loading and turn over the tabs removed fit the timing chain to this
of the locking plates. wheel and the one on the crankshaft.
Reposition the camshaft chainwheel
(xv) Push the oilite bush into the centre of and check by simulating pressure of
the crankshaft at its rear end and tap the chain tensioner that the timing
the flywheel locating dowel into posi- marks have retained their positions
tion in the flange. and re-adjust if necessary. Tighten
bolts to correct torque loading and
(xvi) Fit fl wheel located b$ the dowel so
K
that t e arrow marked on its periphery turn over tabs of loclung plates. Lubri-
cate tappets and place in tappet
lines up with the centre of the cylinder
block with Nos. 1 and 4 pistons at chambers.
T.D.C. Secure flywheel with the four
(xxi) Fit the chain tensioner to its
setscrews and two locking plates, then
turn over the tabs of the locking plates pin
secure with washer and sp ~t pln. and
when the setscrews have been tightened Screw in timing cover support bolt to
to their correct torque loading. the engine plate and fit the oil de-
flector to the crankshaft so that the
(xvii) Utilisjng jointing compound affix the raised edge faces the timing cover.
front plate packing and locating the
engine plate on the two dowels secure (xxii) Press the oil seal with its lip inwards
with the five bolts and locking washers. into the timing cover and fit this cover
Fit the engine mountings secured by with its packing to the engine plate
two nyloc nuts. utilising one nut, eleven bolts with
four nuts.
(xviii) T o the forward end of the crankshaft NOTE- Seethat the short earth bond-
fit the. sprocket locating shims, the ing strip from engine to chassis frame
Woodruffe key and the sprocket wheel. is attached under the head of the bolt
ENGINE
which aligns with L.H. rubber mount- bolt is fitted through the fiont flange
ing attachment nut. of the sump into the sealing block.
(xxiii) The machinedfaces on the combustion The rearmost bolt on the left-hand side
head and the upper flanges of the accommodates the breather pipe clip
cylinder sleeves; which contact the and the bolt in fkont of this accom-
combustion head gasket, should be modates the clutch slave cylinder stay.
lightly coated with " Wellseal " sealing When an aluminium sump is fitted,
compound. A substitute compound, two packings are used, one either side
whch retains its plashcity, may be of the tray.
used if' " Wellseal " is not available. (xrrrr) Fit the breather pipe to the cylinder
This sealing is necessary to ensure a
proper life for the gasket. block and secure the clip to the sump
plate by the bolt, nut and lock washer
(xxiv) Assemble the valves and springs to the with a distance piece between the two
combustion head (see " To De- plates.
carbonise," page 25)and fittheassembly
to the block, tightening the ten nuts (4)
Fit ignition coil to side of cylinder
and washers down as shown in Fig. block with two nuts and lock washers.
28. Fit push rods in the chambers.
(xxv) Assemble the rocker shaft as follows :
To the rocker shaft fit No. 4 rocker
pedestalin such a manner that the oil-
feed holes coincide and secure with
setscrew. To the shorter end of the ,
,
shaft, fit No. 8 rocker, a double coil
spring washer and a collar. Secure the
collar to the shaft with a mills pin. On
the longer end of the shaft feed the
r e m a G g rockers, springs and pedes- i 2 P~'J(STAU I 4I
Fig. 44 The Champion Spark Plug Gap Tool. performance (Fig. 471, namely, paint
splashes, accumulation of grime and
When gaps are badly burned, it is dust ; cracked insulators caused by
indicative the plug is worn to such slipping spanner, or overtightening of
an extent that further use is un- terminals. Examine for cracked in-
warranted and wasteful. When re- sulators at shoulder and terminal post.
setting, bend the side wire only, never Remove grime and dust. Recommend
bend centre electrode as this may split inspection, cleaning and testing every
the insulator tip. 3,000 miles (Fig. 48).
Clean and replace sparking plugs
(i) Ins ect for lezikage after testing, by periodically as necessary. The correct
P
app ying oil around the terminal (Fig. gap for the TR2 plugs should provide
45). Leakage is indicated bv the me-
sence of ai; bubbles, the i6tensiG of
which will serve to show degree of
leakage. Leakage throws the plug out
of its proper heat range, as the hot gas
escaping has a " blow torch " effect on
the plug, causing compression loss,
pre-ignition, rapid electrode destruc-
tion and overheating of the insulator
tip.
New gaskets have been fitted to the
plugs and the general improvement in
appearance is apparent now that the
plugs are ready to be installed in the
engine (Fig. 46). It requires no
imagination to know that improved
engine pRformance better petrol con-
Fig.46 S arlring Plugs ready to fit to Engine.
sumpdon and satisfaction will result. d t e the New Gaskets and the use of the
The use of the stand (as illustrated) is Stand.
4Q
ENGINE
a gap of .032", the Champion ElOS a piece of carborundum stone, so that
4"reach plug being specifiedfor normal when the points are closed they fit
road work, the L l l S for high speed flush against each other. If the points
work. The normal efficient life of a have become seriously worn they
sparking plug is 10,000 miles, after should be replaced by new items. T h e
which, if full efficiency and economy is points should be properly set to pro-
desired, the plugs should be replaced vide a gap of -014" to .016" when fully
by new ones of the type specified. open.
P.O. Box 9,
-
Somalilands Tradinn Com~anv.L ,
Port Louis, Mauritius.
PERSIA
%a Cardinal 6. Massaia N.50. MEXICO Auto-Teheran, S.A
Mogadishu, Somalia. Auto Repuestos, S.A.. Avenue Bargh,
Balderas 36-901, Teheran, Persia.
ITALY Mexico D.F., Mexico
PERU
AD gia Impresa Forniture Industrialiifi, Importadora de Artivulos Para Auto- E. S. DeLaney, SA.,
5 Via Lovanio, moviles, S.A. Avenida Grau 290,
Milan, Italy. Calle Barcelone No. 11, Lima, Peru.
Mexico City, Mexico.
Wilfred Van Singer, PHILIPPINE REPUBLIC
36 Via Barberini, Angel de Caso, Jnr.,
Rome, Italy. Manila Auto Supply,
Ave. Bucareli Num 5, 1054--56, Rial Ave.,
Mexico City, Mexico. Manila, Philippine Islands.
7
Empire Motor Co. Ltd., NEW CALEDONL4 Motor Service Co. Inc.,
2 4 Nihonbashi-Tori Chuo-Ku. Ets. Ballande, Boston St., Port Area,
Tokyo, Japan. Noumea, New Caledonia. Manila, Philippine Islands.
ENGINE
Square Auto Supply Co., S. Cohen Ltd., G. & A. Baker Limited,
625, Juan Luna, P.O. Box 215, Prevuayans Han Tahtakale,
Manila, Philippine Islands. Windhoek, S-W. Africa. Postbox 468,
Istanbul. Turkev
PORTUGAL SPAIN
C Santos Lda., Francisco Flores, UNION O F S O U T H AFRICA
29-41, Avenida da Liberdade, Espinardo, Representative :
Lisbon, Portugal. Murcia, Spain. J B Steele Pr J. D Matson (Pty.) Ltd.,
P.O. Box 130,
Soc. de Comal. C. Santos Lda., Branch at : Bilbao. Kny sna, Cape Province.
160-168, Rua Santa Catarina,
Posto, Portugal. SPANISH GUINEA Branch at : Yorkshire House, Smith
Representative : Street, Durban.
PORTUGUESE E A S T AFRICA Vda. de Jose Penate Medina,
(Mozambique) Leon y Castillo 15, URUGUAY
Auto Sobressalentes, Las Palmas, Canary Islands. Representative :
P.O. Box 693, George Dombey,
Lourenco Marques, P.E.A. SPANISH MOROCCO Avda Corrientes 1373,
Francisco Flores, Buenos Aires, Argentine Republic.
E m ~ o r i u mGrandes Arrnazens da Beira.
p.0: Box 200. Zoco Grande 53,
Tangiers. VENEZUELA
Beira, P.E.A. Sres. Francisco Sapene e Hijo,
Adolfo Matos Ltda., SUDAN Apartado de Correos 1528,
P.O. Box 11, Sudan Mercantile Co. (Motors) Ltd., Caracas, Venezuela
Manpula, P.E.A. P.O. Box 97, RAM-MAC,
Khartoum, Sudan. Apartado de Correos 21,
PORTUGUESE W E S T AFRICA
Branches at: Port Sudan and Wad Medani. Calle 99 (Cornercio) 9-63,
Wngola) Maracaibo, Venezuela.
Robest Hudson & Sons Ltd..
RaIetrux House. SWEDEN
Meadow Lane, VIRGIN ISLANDS
A.B. Amerikanska Motor i nlporten, Virgin Islands Corporation,
Leeds, England. Stockholm 6, Sewden, St. Croix, Virgin Islands.
Branches at : P.O. Box 1210, Branches at : Malrno, Gothcnburg, Hal-
Luanda, Angola singborg, Kristianstad and Auto Sales 8r Parts Co.,
Sodertalje. St. Thomas, Virgin Islands.
P.O. Box 101,
Lobito, Angola. Christiansted Utilities Co.,
SWITZERLAND Christiansted,
P U E R T O RICO S.A.F.I.A.,, St. Croix, Virgin Islands.
Julio T. Rodriguez, Avenue Pictet de Rochemont., 8.,
206, O'Donnel Street, Geneva, Switzerland. WEST AFRICA
San Juan 6, Puerto Rita Branches at : Berne and Zurich Compagnie Francaise de 1'Afrique Oc-
cidentale,
RHODESIA (Northern and Southern) Max Gromann A.G., Royal Liver Building,
Duly & Co. Lt-d., Solothurnerstrasse 60, Liverpool 3, England.
P.O. Box 131, Basle, Switzerland
Bulawayo, Southern Rhodesia. Societe Cornmerciale de l'Ouest Africain,
SYRIA 5 & 7, Hall Street,
Branches at: Salisbu Umtali, Gatooma, Ets. F. A. Kettaneh S.A., Oxford Street,
~ w e l o , F o r tVictoria, Ndola Manchester 2, England.
and Kitwe. P.O. Box 242.
Beyrouth, Lebanon.
Motor Car Equipment (Sby.) Ltd., T H E ABOVE DISTRIBUTORS COVER
P.O. Box 1394, TAHITI (Society Islands) T H E -FOLLOWING TERRITORIES
Salisbury, Southern Rhodesia. Etablissements L)onald, I N WEST AFRICA AND HAVE BRAN-
Papeete, Tahiti. CHES I N THOSE TOWNS SHOWN
SALVADOR I N PARENTHESIS.
Frenkel & Co., Lionel L. Bambridge,
Apartado 63, P.O. Box 88, GAMBIA - (Bathurst).
San Salvador, El Salvador. Papeete, Tahiti. G O L D COAST - (Accra, Kumasi,
Takoradi).
Duran Hennanos, TANGIERS NIGERIA - (Lagos, Kano, Onitsha,
3A, Avenida Norte No. 17, Francisco Flores, P o r t Harcourt, Sokoto, Warri)
San Salvador, El Salvador Zoco Grande 53, SIERRA LEONE - (Freetown).
Ernesto McEntee, Tangiers. CAMEROONS - ( ~ u a l a ) .
Santa Ana, El Salvador. DAHOMEY - (Lome and Cottonou).
THAILAND (Siam) FRENCH EOUATORIAL AFRICA
SAUDI ARABIA Sombat Phanich, FRENCH G~IINEA
F. A. Kettaneh, New Road, FRENCH SENEGAL - (Dakar)
Jeddah, Saudi Arabia. Bangkok, Thailand. FRENCH SUDAN
FRENCH IVORY COAST-(Abijan).
SEYCHELLES TONGA (Friendly Islands) TOGOLAND.
Temooljee & Cb., Morris, Hedstrom Ltd.,
P.O. Box 9, Nukualofa, Tonga. YUGOSLAVIA
Mahe, Seychelles. Progres General Trade Agency
TUNISIA Knez Mihajlova 1,
S O U T H W E S T AFRICA Belgrade, Yugoslavia.
S.I.S.A.A.,
Re resentative :
9. B. Steele & J. D. M m n (Pty.) Ltd.,
P.O. Box 130,
42, Rue Thiers,
Tunis.
Autocentar,
Marticeva U1.8,
Zagreb, Yugoslavia.
Knysna, TURKEY
Cape Province, Union of South Africa. Etablissements Archmidis, S.A.T., Auto Srbija,
S. Gorelick's Garage, Boite Postale 1832, Bulevar Jogisl,
P.O. Box 200, Galata, rue Okcu Musa 39-5 1, Armije 61,
Windhoek, S-W. Aftiu. Istanbul, Turkey. Belgrade, Yugoslavia
ENGINE
23. ENGINE NOISES (ii) Insufficient supply of oil.
(a) Main Bearing Knock (iii)Low oil pressure.
This knock can usually be identified (d) Small End Knocks
by its dully heavy metallic note which As the gudgeon pin used in this model
increases with frequency as the engine is able to float in the piston and the
speed and load rises. A main bearing bearing in the connecting rod, a knock
knock is particularly noticeable when may arise owing to slackness in the
the engine is running very slowly and small end bush or the piston bosses.
consequently unevenly, it is more The knock will make itself audible
pronounced with advanced ignition. under idling conditions or at road
When this bearing knock is experienced speeds between 20-30 m.p.h. (32-
it can be explained by one of the 48 krn.p.h.).
following faults and should be treated T o test for a gudgeon pin knock, cut
accordingly. out each cylinder one at a time by
(i) Unsuitable grade of oil or badly disconnecting the plug leads. The
diluted oil supply. offending gudgeon pin will be identi-
(ii) Low oil pressure. fied by the fact that a double knock is
caused when the disconnection of the
(iii) Insufficient oil in sump. plug lead is made.
(iv) Excessive bearing clearance With complaints of this nature, the
caused by worn journal and/or following possible causes should be
bearings. examined.
(i) A too tight gudgeon pin.
(b) Crankshaft End Float (ii) A gudgeon pin slack in the con-
When a knock is being caused by the necting rod bush or piston boss
development of end float, it will be (see page 2 for gudgeon pin
found most noticeable when the engine clearance).
is running at idling speeds. This (iii) Misalignment of connecting rod
knock can temporarily be eliminated allowing connecting rod bush to
by operating the clutch. foul the piston bosses.
(c) Big End Bearing Knock (e) Piston Knock (Piston Slap)
This will increase with the applicahon
A big end bearing knock is lighter in of load up to 30 m.p.h. (48 km.p.h.1
note than that experienced with a but only in very bad cases will it con-
main bearing. It will be evident at tinue to be audible over that speed. In
idling speeds and will increase with some cases piston knock will only be
engine speed. evident when the engine is started from
The best test for this noise is to detach cold and will disappear as the engine
the lead from each sparking plug in warms. I n such cases it is suggested
turn and reconnecting the lead whilst that the engine is left untouched.
flicking the throttle open. On re- A suggested method of locating the
connection of the lead, a light thud will offending piston is to engage a gear and
be audible where the bearing looseness with the hand brake hard on, just let
or correcting misalignment exists, fur- the clutch in sufficiently to apply a load
ther investigation can be carried out with the engine at a moderate speed.
to that particular rod or rods. By detaching a spark plug lead and
In addition to the knock being caused thus putting a cylinder out of action, it
by excessive bearing clearance it is is possible to cut out the knock and so
sometimes caused by :- determine the offending piston.
(i) Unsuitable grade of oil or badly Faults in the engine components listed
diluted supply. hereafter often contribute to piston
ENGINE
knock (piston slap) and should there- cylinder to be spontaneously ignited,
fore be examined. resulting in this striking the cylinder
(i) Excessive clearance between piston wall with a ringing sound ; this noise
and cylinder sleeve due to fair being familiar to motorists as
usage or to an unsuitable replace- " pinking."
FAULT LOCATION
Lack of 1. Choked silencer and/or tail pipe. Examine the components for
Power. carbon deposits
2. Binding brakes. Check brake mechanism.
3. Slipping clutch. Check adjustment then overhaul
f necessary.
ENGINE
COOLING SYSTEM
SECTION C
COOLING SYSTEM
INDEX
Page
Description ...... ...... ...... ...... ...... ...... ...... 1
To Drain the System ...... ...... ......
...... ......
Fan Belt Adjustment ...... ...... ......
...... ......
The Thermostat ...... ...... ......
......
To remove Thermostat Housing (witht her most at)
To replace Thermostat Housing (with Thermostat)
To remove Thermostat only ...... ...... ......
To replace Thermostat ...... ...... ...... ......
Testing the Thermostat ...... ...... ...... ......
Water Temperature Gauge ...... ...... ......
To test Water Temperature Gauge ...... ......
The Radiator ...... ...... ...... ...... ...... ......
To remove Radiator ...... ...... ...... ...... ......
To replace Radiator ...... ...... ...... ...... ......
Flexible Hose Connections ...... ...... ...... ......
The Water Pump Assembly ...... ...... ...... ......
To remove the Water Pump Bearing Housing ......
To replace the Water Pump Bearing Housing ......
To dismantle the Bearing Housing Assembly ......
To assemble the Bearing Housing Assembly ......
Recutting the Water Pump Sealing Face ...... ......
T o remove the Water Pump Body ...... ...... ......
TOreplace the Water Pump Body ...... ...... ......
The Fan Assembly ...... ...... ......
To remove Fan Assembly fro&'13ngine unit"' ......
To fit Fan Assembly to Engine Unit ...... ......
To assemble the Fan for Balancing ...... ...... ......
Anti-Freeze Precautions ...... ...... ...... ......
Service Diagnosis ...... ...... ...... ..... ......
Page
Fig. 1 Draining the Cooling System ......
...... ...... ...... 1
Fig. 2 The Thermostat ...... ...... ...... 1
Fig. 3 Circulation of Water before'the ~h&mosiathas opened 2
Fig. 4 Circulation of Water after the Thermostat has opened 2
Fig. 5 Exploded Details of Thermostat Housing The Hoses .
are also shown ............ ...... ...... ...... 3
Fig. 6 The " Run " of the Water Temperature ~apillaryTube 4
.
Fig 7 Exploded details of Water Pump Housing Assembly ...... 6
.
Fig 8 Utilising the Churchill Tool No . FTS 127 to remove the.
Water Pump Impeller ...... ...... ...... 7
Fig. 9 Fitting the Water Pump 1mPeller*utilisingthe churchill
.
Tool No FTS 127 ....... ...... 7
.
Fig 10 Showing the correct clearance between dreVVater'Pump
Impeller and Bearing Housing ...... 8
.
Fig 11 Recutting Water Seal Face with ~ ~ U r c ~ i i i ' TNo o o.i
6300 ...... ...... ...... ...... ...... ...... ...., 8
COOLING SYSTEM
I. DESCRIPTION (ii) The bolt attaching the lower por-
The cooling system is pressurised and tion of the front flange to the
thermostatically controlled, with an impel- dynamo fulcrum.
ler pump to ensure efficient circulation of (iii) The bolt securing the upper por-
water at all times. The capacity is 13 pints tion of the flange to the adjusting
or 14 when a heater is fitted. Carehl con- link.
sideration has been given to points where
adequate cooling is necessary, such as (b) By moving the dynamo to or away
sparking plugs and valve guides, etc. from the engine the fan belt is loosened
or tightened respectively. When the
T o assist cooling when the car is stationary
or travelling at low speeds a 124" diameter belt has a" "play" in its longest run
four bladed fan attached to the crankshaft suitable adjustment is provided.
draws air through the radiator. (c) Tighten the adjusting !ink bolt,
RADIATOR CAP
followed by the two lower attachments.
Ref.
No. Description
THERMO
CLOSED >
1 Thermostat Housing.
2 Studs for Top Plate.
3 Studs for Outlet Cover.
4 Thermostat.
5 Outlet Cover.
6 Outlet Cover Joint Washer. Up to
7 Nut for securing Outlet Commission
Cover. >No.TS.1201
8 Lock Washer for Nut
9 Top Plate.
10 Top Cover Joint Washer.
11 Nut for securing Top Plate
12 Lock Washer for Nut.
13 Thermo Housing Joint
Washer.
14 Thermostat Housing.
15 Studs for Outlet Cover.
Fig 3 Circulation of Water before the Ther- 16 Thermostat.
mostat has opened. 17 Outlet Cover.
18 Outlet Cover Joint Washer From
19 Nut for securing Outlet Commission
+
Fig. 5 Exploded details of Thermostat Housings (the housing in the insert is that fitted to current
production cars). Cooling System hoses are also shown.
3
COOLING SYSTEM
(0 The thermostat c q be removed from 9. TESTING THE THERMOSTAT
housing by removlng the remamder of Remove the thermostat from its housing as
the front cover nuts (already loosened described on page 2. It should be tested in
in para. c) but after the removal of the water, at a suitable temperature employing
joint washer. a thermometer to ascertain that the valve
does commence to open at the correct tem-
6. TO REPLACE THERMOSTAT perature 158OF. There is no need to check
HOUSING the temperature at which the valve is fully
The replacement is the reversal of the re- open as this follows automatically.
moval but care should be taken concerning
the following points.
(a) That the contact smfaces of the house-
ing and the cover are perfectly clean
and do not bear traces of the old joint
washer. Failure to observe this point
may lead to water leakages.
(b) The thermostat is fitted to the housing
first and followed next by the joint
washer. Ip no circumstances should
the joint washer be fitted first.
washers to the steady rods, which are in turn T h e smaller diameter curved hose is the by-
secured to the body of the car by jam nuts. pass hose for the thermostat-water pump
The lower attachment is by two pointed housing connection, the larger diameter
shanked bolts with 9" thick composition straight corrugated hose connects the therm-
packings between the radiator brackets and ostat housing to the radiator.
the chassis frame at either side. The two large diameter curved hoses are
The radiator is pressurised, a relief valve assembled to a metal connecting pipe so that
being incorporated in the radiator cap. The their ends are 90" removed from one
spring loaded rubber valve is lifted off its another. This assembly connects the water
seating when the pressure in the cooling pump housing to the radiator outlet.
system exceeds 4 lbs. per sq. inch letting the The overflow pipe is attached to the filler
excess pressure escape through the overflow pipe, clipped at the top right hand upper
pipe. corner of the radiator and again on its nm
T o relieve the vacuum when the system down at a point on the wing valance just
cools a small spring-loaded relief valve is above the chassis frame.
incorporated inthe centre of the pressure
valve unit which will open to admit atmos-
pheric pressure. 16, THE WATER PUMP ASSEMBLY
T h e overflow pipe is a rubber tube and is (Fig* 7)
attached to the filler pipe, clipped at the This assembly is attached to the cylinder
right hand steady attachment, and after block by three bolts of unequal length. The
running downward it is clipped to the lower longer bolt is situated in the upper right
right hand wing valance. hand position and its purpose is two-fold.
In addition to attaching the pump assembly
to the cylinder block it also secures the bear-
ing housing to the pump body. The head
of this bolt is trapped by the belt pulley
13. TO REMOVE RADIATOR and the bolt cannot be removed until this
(a) Remove the front cowling as described pulley is first removed. The two remaining
in the Body Section. bolts are of equal length and are situated in
the lower extremities of the impeller body.
(b) Drain the cooling system as described
on page 1.
17. TO REMOVE THE WATER
(c) Remove top and bottom hoses and PUMP BEARING HOUSING (Fig. 7)
overflow pipe from radiator.
(a) Loosen the two lower dynamo attach-
(d) Remove the nuts and bolts from the ments, remove the upper fixing bolt
two steady rods, one either side at the with the two plain washers and then
top of the radiator. remove the fan belt.
(e) Remove the two bolts and lock washers (b) Loosen the two nuts and the bolt secur-
from the brackets at the sides of the ing the bearing housing to the pump
block. The paclng between bracket body progressively until the bearing
and chassis frame can be removed housing can be lifted away with its
after the radiator has been lifted. joint washer.
COOLING SYSTEM
Fig. 8 Utilising the Churchill Tool No. FTS 117 Fig. 9 Fitting the Impeller, utilising the
to remove the Water Pump Impeller. Churchill Tool No. FTS 127.
7
COOLING SYSTEM
solder run round the end face to ensure protruding end of the pilot feed the
a water-tight joint (Fig. 10). bush S.126, followed by the tool
bearing and knurled nut (Fig. 11).
(c) Turn the knurled nut until the cutter
contacts the seal face and turn the tool
LAYER Of SOlDER
round by the tommy bar, apply firm and
steady pressure.
(d) Tightening the knurled nut slightly
continue to turn the tool until the seal
face is free from score lines and has
attained a polished surface.
(e) Whilst carrying out this operation it
will be necessary to remove the tool and
clean the cutter with a blast from a
compressed air line. Do not remove
more than .030" from the seal surface,
if the score marks are not removed at
Fig. 10 Showing the correct clearance between this figure a replacement bearing
Water Pump Impeller and Bearing housing should be fitted.
Housing.
22. TO REMOVE WATER PUMP BODY
21. RECUTTING THE WATER PUMP (When bearing assembly has been
SEALING FACE removed)
When servicing the water pump it is some- (a) Disconnect the by-pass hose, also the
times necessary to re-cut the water seal heater pipe if the car is so fitted.
abutment face. The Churchill Tool (b) Remove dynamo adjusting link which
No. 6300 and bush S.I~6 is designed for is secured to the pump body by a set-
this operation (Fig. 11) and carried out as screw locked by a tabwasher.
follows :- (c) Remove the remaining two bolts secur-
(a) The bearing housing is dismantled as ing the pump body to the cylinder block.
described on page 7. (d) Remove the body complete with its
joint washer.
23. TO REPLACE WATER PUMP BODY
The replacement is the reversal of the re-
moval, but care should be taken concerning
the following point.
That the contact surfaces of the housing and
the cover are perfectly clean and do not
bear traces of the old joint washer. Failure
to observe this point may lead to water
leakages.
24. THE FAN ASSEMBLY
The fan is built up on a hub and hub ex-
tension, then balanced as a unit. When this
operation has been completed the balancing
plate is drilled right through and the drill
Fig.II Refacing Water Seal Face with Churchill allowed to touch the hub extension.
Tool No. 6300 and Bush S.126.
If,~ for any reason,:the fan is dismantled all
that is necessary on re-assembly is to line up
(b) Feed the pilot shaft of the Churchill the component parts so that the drill holes
Tool No. 6300 in from the seal seating are all in line with the dimple in the hub
of the bearing housing. On to the extension and the re-assembled unit is in
8
COOLING SYSTEM
balance. Only when replacement parts are 26. TO FIT FAN ASSEMBLY TO
fitted will it be necessary to re-balance the ENGINE UNIT
unit. (a) Fit the Woodruffe key to the crank-
The hub extension is attached to the hub, shaft and slide on the hub and hub
the latter being keyed to the crankshaft by extension assembled as described in
six nyloc nuts and bolts and the whole operations a, band c of" To assemble
assembly is secured to the crankshaft by the fan for balancing," hereafter.
extension bolt, the head of which acts as (b) Fit the two shims under the head of the
the starting handle dog and on re-assembly extension bolt and insert through the
it will be necessary to place sufficient centre of hub extension and tighten
shims under the head of the extension bolt until the abutment of the starting dog
to bring it into such a position that when jaws, incorporated in the head of the
the starting handle is in use compression is extension bolt, assume a "10 to 4
felt just after the handle has left B.D.C. as o'clock" position to ensure correct
shown in Fig. 37 in Engine Section. relationship with compression when
the starting handle is in use.
(c) On to one pair of fan securing bolts
feed one lock plate followed by one
25. TO REMOVE THE FAN ASSEMBLY plain washer per bolt.
FROM ENGINE UNIT (d) Offer up the fan assembly in such a
manner that the hole in the web is
(a) Remove the front cowling as described over the dimple in the hub extension
in the Body Section " N". face. Fit the extension bolt locking
(b) Remove the radiator as described on plate with the larger diameter plain
page 5. washer between it and the rubber
bushes. Secure the extension bolt lock-
(c) Scribe a mark on the balancing plate ing plate with the bolts built up as
and fan assembly to ascertain the front described in operation (c above) utilis-
of these components for re-assembly. ing the two tappings opposite those
Cd) Turn back the tabs of the locking with the fz" drill hole.
plates and withdraw the four bolts (e) The remaining pair of bolts are made
together with lock plates, plain washers, up in a similar manner to those al-
the balance plate (if one is fitted) and ready mentioned, but with the balancer
the extension bolt locking plate. The fan fitted. These bolts are assembled to
assembly, together with split rubber the remaining tappings in the hub ex-
bushes, metal sleeves and larger dia- tension. Before tightening, the balan-
meter plain washer can now be re- cer is moved until the hole aligns
moved. with those in the fan assembly; after
(e) Remove the extension bolt and shims tightening the tabs of the locking
from the hub extension. plates are turned over.
(f) Replace the radiator and hoses.
(f) By tapping the front flange of the hub (g) Replace the front cowling as de-
extension remove the hub extension, scribed in the Body Section.
hub and fan belt pulley from the
crankshaft. Collect Woodruffe key.
27. TO ASS E M B L E FAN FOR
(g) By releasing the tabs of the locking BALANCING
plates the nuts and bolts can be re- Check that the four fan blades riveted to
moved. On engines after Engine the fan webs are free from movement. If
No. TS.4145E nyloc nuts and plain for any reason replacement parts have been
washers were fitted in place of lock fitted the fan unit should be re-balanced.
plates and plain nuts. The hub extension The dimple in hub extension face should
can be removed and the hub with- be filled in with solder to avoid confusion
drawn from the pulley pressings. during re-assembly.
9
COOLING SYSTEM
(a) Place the two pulley pressings together, the radiator, and the second tap at the right
the flatter one with the drilled hole hand side of the cylinder block.
uppermost and the second pressing on In severe frosty weather an anti-freeze
top; feed the hub through the pres sings additive to the cooling system is strongly
with its keyway lowermost. It is neces- recommended, for it is possible for the lower
sary that this procedure is followed portion of the radiator to become frozen,
for it ensures a visual check of even when the car is being driven,
setting the engine at T.D.C. on Nos. restricting the circulation of the water as
1 and 4 cylinders. well as causing possible damage to the
(b) Position the six bolts and secure the radiator itself. Before adding the anti-freeze
hub extension with the nyloc nuts. compound thoroughly flush out the radiator
On early production cars, nuts and and cylinder block, and ascertain that all
locking plates were used. hoses and connections are in perfect con-
dition. Check also that the cylinder head
(c) Insert the rubber bushes in the fan nuts are tight, for if due to leaks, any
assembly and locate the metal sleeves anti-freeze solution finds its way into the
through the centres of these bushes. cylinder bores serious damage may result.
(d) Feed the four fan attachment bolts Theanti-freezesolutionitselfdoesnotusually
through the larger diameter plain wash- evaporate, thus apart from leakage, it should
ers and metal sleeves of the fan assem- only be necessary to top up with water as the
bly and secure the latter to the hub level in the radiator head drops.
extension. This Company uses and recommends Smiths
"Bluecol", and for protection from various
(e) Using a jig, ascertain the lighter side degrees of frost the following proportions
of the assembly and fit the balancer are recommended.
to that side. This can be moved to Degrees of Frost
obtain perfect balance. (Fahrenheit) 15 25 35
(f) When the balanced condition is at- Proportion
tained a 352 drill hole should be put
1/ (per cent) 10 15 20
through the thinner edge of the balan- Amount of Bluecol
cer and fan assembly webs until it (pints) 2 3 4
makes a small dimple in the face of the Water capacity 13 pints, 14 pints with heater.
hub extension. Withdraw the four Other reputable anti-freeze compounds are
bolts and remove fan assembly from available and the compound chosen should
hub extension. be used in accordance with the manufac-
turer's instructions.
It is a very wise precaution when using anti-
z8. ANTI-FREEZE PRECAUTIONS freeze in the cooling system to employ some
During frosty weather it is necessary to pro- method of indicating the fact for the enlight-
tect the engine from damage and this can be enment of repairers who may be called upon
effected by draining the cooling system by to carry out adjustments or the replacement
opening the tap at the lowermost portion of of parts.
10
COOLING SYSTEM
SERVICE DIAGNOSIS.
OVERHEATING.
This drfficultymay arise owing to one or more of the causes listed below :-
CAUSE REMEDY
Ignition timing too late or auto advance and Check ignition timing, automatic advance
retard mechanism or suction not operating and retard mechanism and the suction pipe
correctly. for the carburettor.
Fan belt slipping. Adjust to give belt $" play by moving
dynamo outwards along adjusting lirk
Insufficient water in coohg system. Check all joints for leaks including combus-
tion head gasket
Radiator and/or cylinder block restricted by Flush out system with a detergentand r e a
the accumulation of sludge, dirt or other solid using clean, softened or soft water.
matter.
Thermostat not operating correctly. Remove and test as described on page 4.
Weak mixture caused by incorrect carburettor Check carburettor manifold and carburettor
setting or air leaks in induction manifold. joints, ensure tightness of manifold,
Initial tightness after an engine overhaul or If due to the former, run-in engine most
insufficient clearance of replacement parts carefully and overheating should disappear.
during an overhaul. If overheating is caused by the latter it d
not disappear, it can even get worse. The
engine should be examined for badly fitting
parts.
Overheating from bad lubrication, incorrect Check oil level, grade and circulation, flush-
oil level or incorrect grade of oil. The use of ing system and refilling if necessazy. Smiths
certain brands of anti-fi-eezecompound which " Bluecol " has a tendency to raise the boil-
have a lowering effect on the boiling point ing point.
during warm weather.
Service Instruction
Manual
CLUTCH
SECTION D
CLUTCH
INDEX Page
General Data ...... ...... ...... ...... ...... .... - ...... ...... 1
Clutch Operation ...... ...... ...... ...... ...... ...... 1
Twin Bore Master cylinder ...... ...... ...... ...... ...... ...... 1
Clutch Slave Cylinder ...... ...... ...... ...... ...... ...... 1
The Clutch Operating Shaft ...... ...... ...... ...... ...... ...... 2
The Release Bearing ...... ...... ..... ...... ...... ...... ...... 2
The Cover Assembly ...... ...... ...... ...... ...... ...... 2
The Driven Plate ~ s s e g b l...... ~ ...... ...... ...... ...... ...... 3
Maintenance ...... ...... ...... ...... ...... ...... ...... 3
Bleeding the ~ ~ d r a u l i c ' S ~ s t e m ...... ...... ...... ...... 4
Greasing the Clutch Operating shaft "" ...... ...... ...... ...... 4
Adjusting the Clutch ...... ...... ...... ...... ...... ...... ...... 4
Adjusting the Master Cylinder ...... ...... ...... ...... ...... 4
Adjusting the Slave Cylinder ...... ...... ...... ...... ...... ...... 4
To remove the Flexible Hose ...... ...... ...... ...... :..... 5
To fit the Flexible Hose ...... ...... 5
Removing the Slave ~ylinder"(&ithFork ~ & n b l i ) " ...... ...... 5
T o replace the Slave Cylinder ...... ...... ...... ...... ...... 5
Dismantling the Slave Cylinder ...... ...... ...... ...... ...... 6
Assembling the Slave Cylinder ..... ...... ...... 6
Removing the Release Bearing and clutch operating Shaft ............ 6
To replace the Clutch Operating Shaft and Release Bearing ...... 7
Removing Clutch from Flywheel ...... ...... ...... ...... ...... 7
T o replace Clutch to Flywheel ...... 7
Dismantling the Cover Assembly &&sing the 'churchill TA
No . 99A Fixture 7
Assembling the Cover Assembly utiising the ~h&chillNO . 996:
Fixture ...... ...... ...... ...... 9
Dismantling the Cover ~ s s e i b (Alternate
l~ methid) ...... ...... 10
Assembling the Cover Assembly (Alternate method) ...... ...... 10
Inspection of cover Assembly ...... ...... ...... ...... ...... 11
Adjusting the Release Levers ...... ...... ..... ...... ...... I 1
Condition of Clutch Facings ...... ...... ...... ...... ...... ...... 12
Reconditioning the Driven Plate Assembly ...... ...... ...... ...... 13
Service Diagnosis ...... ...... ...... ...... ...... ...... ..... 14
Paee
Fig. 1 Sectional view of Clutch
Fig. 2 Exploded details of ~ 1 u t c h ' ~ s s e m with'klave**~ylind~~
bf~
Fig. 3 The Slave Cylinder and Support Plate ...... ...... ......
Fig. 4 Sectional view of Slave Cylinder ...... ...... ......
Fig . 5 The Clutch Operating Shaft ~ s s e g b l ~ ...... ......
Fig. 6 Showing Constant Pinion Mandrel in ...... ......
Fig. 7 The Churchill Fixture No . 99A ...... ...... ...... a*.
a
(e) The com onents should be washed in
Lockhee Brake Fluid and any compo-
nent that shows excess wear should be
Fig. 5 The Clutch Operating Shaft Assembly.
(d) Place the cover assembly on the base- Pig. 10 Adjusting nuts have been removed, cover
plate so that the release levers are securing bolts being removed.
situated directly above the spacers and
the bolt holes in the rim of the cover (i) Take off cover pressing and remove the
pressing are in line with the tapped nine thrust springs and anti-rattle
holes in the base plate. springs.
CLUTCH
(j) Lift up inner end of release lever and (d) Place the strut into groove in the outer
disengage the strut. Repeat procedure end of the release lever.
for 2nd and 3rd levers.
(k) Gripping the tip of the release lever and ?
(e) Repeat. operations (a to (d) for the
remaining two release evers.
the eye bolt lift out the assembly from (f) Place the pressure plate and the assem-
the pressure plate. Repeat procedure bled release levers, with the latter over
for 2nd and 3rd levers. the spacers, on the base plate of the
Churchill Fixture.
(1) Remove the eye bolts from release
levers and take out pins. Remove the (g) Place the cover pressing over the pres-
struts from pressure plate. sure plate laying on the base allowing
the lugs to protrude through the cover.
Should the holes in the cover pressing
fail to line up with those in the base
27. ASSEMBLY OF COVER PLATE plate the cover and pressure pl-*te must
ASSEMBLY USING THE then be tuned to allow alignment.
CHURCHILL FIXTURE No. ggA Remove the cover pressing without
Before assembling a smear of Lockeed Ex- disturbing the position of the pressure
pander Lubricant or Duckham's Keen01 plate. Fit the anti-rattle springs.
K.O. 12 should be applied to the release (h) Place s~rinns
\ I
on their seats on the Dres-
lever pins, contact faces of the struts, eye- sure pfate,ufollowed by cover pr&sing
bolt seats in the cover pressing, drive lug (Fig. 12).
sides on the pressure plate and the plain end
of the eye bolts.
Assembly is to be made with strict regard to
the markings on certain parts and so ensure
that the unit remains in balance.
(a) Place strut in positionin lug of pressure
plate.
(b) Assemble pin to eye bolt and feed
threaded portion through release lever.
(c) By holding the strut in the pressure
plate to one side, feed the plain end of
the eye bolt (assembled to release
lever) into the pressure plate (Fig. 11).
bolts.
peening
over the collars into the cuts o the eye
(d)
has to be overcome.
Release the pressure of the press slowly
(p) Remove cover assembly from base to prevent the thrust springs from
plate and it is ready to be fitted to the flying out.
flywheel (with the driven plate assem- (e) Remove the cover pressing and collect
bly). the component parts.
IMPORTANT
1. Drag or (a) Oil or grease on the driven plate Fit new facings.
Spin. facings.
(6) Misalignment between the en- Check over and correct the
gine and gearbox shaft. alignment.
(c) Improper pedal adjustment not Correct pedal adjustment.
allowing full movement to release
bearing.
(d) Warped or damaged pressure Renew defective part.
plate or clutch cover.
(e) Driven late hub binding on Clean up splines and lubri-
R
splined s aft. cate with small quantity of
high melting point grease
such as Duckham's Keenol.
(f) Pilot or operating shaft bearings Renew or lubricate bearings.
binding.
(g) ~i?to;ed driven plate due to the Fit new driven plate assy.
weight of the gearbox being using a jack to take the over-
allowed to hang in clutch plate hanging weight of the gear-
during erection. box.
(A) Broken facings of driven plate. Fit new facings.
Cj) Dirt or foreign matter in the Dismantle clutch from fly-
clutch. wheel and clean the unit, see
that all working parts are
free.
Caution. Never use petrol
or paraffin for cleaning out
clutch.
(k) Air in hydraulic line or insuffi- Bleed or replenish.
cient fluid.
2. Fierce- (a) Oil or grease on driven plate Fit new facings and ensure
ness or facings. isolation of clutch from pos-
Snatch. sible ingress of oil or grease.
(b) Misalignment. Check over and correct the
alignment.
(c) Binding of clutch pedal mech- Free and lubricate journals.
anisms.
(d) Worn out driven plate facings. New facings required.
3. Slip. (a) Oil or grease on the driven plate Fit new facings and elim-
facings. inate cause of foreign pre-
sence.
(b) Improper pedal adjustment indi- Correct pedal adjustment
cated by lack of the requisite and/or clearances,
.820" free or unloaded foot pedal
movement-.030" at master cyl-
inder, -079" at slave cylinder.
4. Judder (a) oil, frease or foreign matter on Fit new facings and elimin-
the riven plate facings. ate cause of foreign presence.
(6) Misalignment. Check over and correct
alignment.
CLUTCH
P
(e) Bent splined shaft or buckled Fit new shaft or driven plate
driven plate. assembly.
(f) Unstable or ineffective rubber Replace and ensure elimina-
engine mountings. tion of endwise movement
of power unit.
6. Tick or
Knock.
(a) Hub splines badly worn due to
misalignment.
Check and correct align-
ment, then fit new driven
plate.
I
(b) Worn pilot bearing. Pilot bearing should be re-
newed. I
7. Fracture (a) Misaligment distorts the plate Check and correct alignment
of Driven and causes it to break or tear and introduce new driven
Plate round the hub or at segmentnecks plate.
in the case of Borglite type.
(b) If the gearbox during assembl Fit new driven plate assem-
P
be allowed to hang with the sha t
in the hub, the driven plate niay
bly and ensure satisfactory
re-assembly .
be distorted, leading to drag,
metal fatigue and breakage.
8. Abnormal Usually produced by overloading and In the hands of the operator.
Facing by the excessive slip starting
Wear. associated with overloading.
Service
GEARBOX
SECTION E
GEARBOX
INDEX
Page
Dimensions and Tolerances ...... ...... 1
Notation for Fig. 1 ...... ......
Bearings
Mounting
Oil Capacity ...... ...... ...... ...... ...... ......
ILLUSTRATIONS
Page Page
Fig. 1 Exploded view of Gearbox Casing, Fig. 22 Fitting Bearing on Constant Pin-
Extension housing ...... ...... 4 ion shaft with Churchill Press No.
Fig. 2 Exploded view of Gears ...... 6 S4221 and adapter from set No.
Fig. 3 Sectional view of Gearbox ...... 8 S4615 ......
Fig. 4 Gearbox ready for withdrawal ...... 10 Fig. 23 ~ e a s u r i n i t h gpp'between
e ~aulk
Fig. 5 Aligning Clutch Floating Plate Ring and Cone ......
with mandrel ...... ...... ...... 10 Fig. 24 Inserting Churchill ~ o o l N o20s: .
Fig. 6 Showing the removal of Gearbox 77 rec carat or^ to driving out
extension with Churchill Tool No. needle roller retaining tube ......
20S63 ...... ...... ...... ...... 10 Fig. 25 Fitting extension Ball Bearing and
Fig. 7 Countershaft and Reverse Locat- Thrust Washer with Churchill
ing Screw partially withdrawn ...... Tool No. 20s. 87 :...
Fig. 8 Showing Needle Roller Retainer l1 Fig. 26 Fitting Extension HO;&-I~ 0c
Seal with Churchill Driver Tool
tube Tool No. 20SM. 68 being No. 20s. 87 ...... ......
used to drive out Countershaft ...... l1 Fig. 27 Tightening ~ r i v & ~ l a nSecur- ~e
Fig. 9 Extracting Constant Pinion Shaft ing Nut with torque spanner ......
assembly with Tool No. 20SM. Fig. 28 Fitting front Cover Oil Seal with
66A ...... ...... ...... ...... 11 Tool No. 20SM. 73 .....
Fig. 10 Extraction of Constant Pinion Ball Fig. 29 Assembling Front Cover, utilis&
Race with Churchill Press No. Churchill Tool No. 20SM. 47 to
4221 and adapter from set S4615 11 protect seal face ...... ......
Fig. 11 Driving Mainshaft to rear with Fig. 30 Checking overall float if Main-
Tool No. 20SM. 1 to free centre shaft Bushes with feeler gauge ......
main bearing ...... ...... ...... Showingthe Oil Transfer Hole and
Fig. 12 Removal of Top and Third Syn- method of wiring bolts. The gear-
chro Unit ...... ...... ...... ...... box casing has to be drilled on
Fig. 13 Showing the removal of the Main- early models whereas all present
shafi Circlip with Churchill Tool production are already drilled ......
No. 20SM. 69 ...... ...... ...... 12 Fig. 32 Showing correct location of four
Fig. 14 Removing Mainshaft CentreBear- sp*gs
ing with Churchill Press No. 4221 Fig. 33 F~tung~ i r ' b o td'overd'&e
x
and adapter fiom set No. S4615 13 This operation is shown being
Fig. 15 Fitting Needle Roller Retainer carried out
Rings with Churchill Tool No. Fig. 34 ~ e t h o d osetting
f valve operat&;
20SM. 68 ...... ...... ...... ...... Levers ...... ...... ...... ......
l3 Fig. 35 Setting Solenoid Lever ...... ......
Fig. 16 Fitting Mainshaft Centre Bearing Fig. 36 Showing the position of the Iso-
with Churchill Press No. S4221 lator Switchonthe Gearbox Cover
and adapter from set No. S4615 l4 Fig. 37 Showing the position of the Over-
Fig. 17 Checking Second Mainshaft Con- drive Control
stant Gear for endfloat ...... l4 Fig. 38 Instructions for &ing the ~ e l i i
Fig. 18 Checking Third Gear ~ a i n s h k Switch ...... ......
Constant Gear for endfloat 14 Fig. 39 Overdrive ~ontrol'cira&'
Fig. 19 Checking Mainshaft Gear BUS^ Fig. 40 Ghost view of Top Cover A;
overall float ...... ...... 14 sembly ...... ...... ...... ......
Fig. 20 Fixture which can be readily Fig. 41 To? Cover showing Isolation
manufactured to test axial loading 15 Smtches ......
Fig. 21 Fitting Mainshaft Circlip with Fig. 42 Adjusting the 1soKion ~witche'r
Churchill Tool No. 20SM. 46. ...... 15 Fig. 43 Wiring Diagram ...... ...... ......
Dimensions and Tolerances
PARTS AND DESCRIPTION DIMENSIONS CLEARANCE REMARKS
NEW
Mainshaft
Spigot External Diameter
to
Internal Diameter of Constant .6887" .0017"
Pinion Bush .6880N
-
Mainshaft Bushes
Diameter of Mainshaft
Internal Diameter of
2nd Gear Bush
Internal Diameter of
3rd Gear Bush
Mainshaft Bush Float
Length of 2nd Gear Bush 1.162"
(measured without flange) 1.160" .004' End float of .004" to
to .006" obtained by selec-
Length of 2nd Gear 1.156" .W8" tive assembly.
1.154"
Length of 3rd Gear Bush 1.225'
1.223" .004" End float of .004" to
to .OM" obtained by selec-
Length of 3rd Gear 1.219" .008" tive assembly.
1.217"
Overall Float of .Bushes
Overall Length of 2nd gear bush has
Mainslaaft Bushes .124"-. 122" flange.
Thickness of 2nd Gear
Thrust Washex
Thickness of 3rd Gear
Thrust Washer
Overall Float of Bushes .O0OW End float of .007" to
.015" .012" obtained by selec-
tive assembly.
GEARBOX
Dimensions and Tolerances
PARTS AND DESCRIPTION DIMENSIONS CLEARANCE REMARKS
NEW
Countershaft
External Diameter of
Countershaft
Internal Diameter of
Countershaft Gear
Needle Roller Diameter
Distance Piece
Overall Width of :-
Countershaft Gears and Two
Thrust Washers
Overall Float of Select parts to provide
Countershaft Gears .006"-.010" end float.
8. TO DISMANTLE
(a) Remove eight setscrews from the top
cover assembly and withdraw complete
with selector mechanism. To dismantle I:.?
- -
(i) After removal of the countershaft front Fig. 9 Extracting Constant Pinion Shaft Assem-
bly with Churchill Tool No. 20SM66A.
end cover plate which is secured by
two wired- setscrews, plain washers the mainshaft spigot bush located in
and lead linger drive out the counter- the pinion itself. The further dis-
shaft using a suitable tube as shown in mantling of this assembly necessitates
Fig. 8, to retain the 48 needle rollers in the removal of the small circlip and
position maintaining contact through- thrust washer which fit against the inner
out between the tube and countershaft. ring of the ball race. After extraction of
ball race in the fixture shown in Fig..
10, the oil thrower may be withdraw&
but owing to probable damage to this
thrower during the dismantling opera-
tion a new one may be required when
re-assembling the unit.
Fig. 17 Checking Second Mainshaft Constant Fig. 19 Checking Mainshaft Gear Bush Overall
Gear for End Float. Float.
GEARBOX
(iv) Axial release loading of 2nd speed
synchro unit 25-27 lbs.
(v) Axial release loading of 3rd and
top speed synchro unit 19-21
lbs.
(iv) and (v) can be checked as shown
in Fig. 20. If it is found to be in-
CAUTION. Do not use undue force setting lever and into the casting thus
in tightening the nuts on the long studs. locking the valve operating shaft.
There are two sets of splines in the Actuate the solenoid with a 12 volt battery
overdrive unit and unless these are in and while the plunger is drawn into the
line, it is impossible to tighten the solenoid, tighten the clamping bolt on the
overdrive unit home on to the adapter solenoid lever and at the same time ensure
plate face. that opposite end of the solenoid lever is
against the head of the actuating bolt.
The overdrive valve setting should Repeat the first check and if satisfactory,
now be checked. refit the cover plate.
4. VALVE CHECKING
On the R.H. of the overdriveunit and pinned
to 'the valve operating shaft, is a valve
setting lever with a &" diameter hole. In
the casting adjacent to this lever is another
&" 'diameter hole. Actuate the solenoid
with a 12 volt battery and while the plunger
is drawn into the solenoid and if the valve
adjustment is correct, it should be possible
to insert a ig" diameter pin through the
valve setting lever and into the casting (see
Fig. 34).
If this is not possible then the valve must be
re-adjusted in the following manner.
Fig. 36 Showing the position of the Isolator A wire is connected from " W2 " on the
Switch on the Gearbox Cover. relay to a terminal of the operating switch
on the facia panel. The remaining terminal
7. THE OPERATING SWITCH
L.H. Drive Cars. Two holes are pierced
in the facia panel on the L.H. side of the
speedometer and covered with fabric. The
fabric should be pierced through the ex-
treme L.H. hole and the operating switch
fitted. The remaining hole is used for a
heater switch when fitted.
The Relay. Reference to Fig. 38 shows of the operating switch is connected through
the fitted position of the relay. a snav connecter to a terminal on the
i s o l a switch
~ ~ situated on the gearbox lid.
Wiring. The feed wire to the terminal The remaining terminal of the isolating
marked " W1" on the relay is taken fiom switch is &ed to one of the bolts securing
GEARBOX
RELAY C O N T A C T S
?c- ?
7l
TO A M M E T E R I
CLOSING HOLDING
COl L COIL.
the gearbox lid. A second feed wire is When the solenoid is energised, both coils
connected from the negative side of the are in circuit until the plunger reaches a pin
m e t e r to " C1 " on the relay. which operates the internal switch. This
To complete the wiring, a wire is connected switch switches out the closing coil and
from " C2 " on the relay through a snap allows the holding coil to remain in circuit.
connecter to the solenoid.
The closing current of 15 amperes is of a
Built into the solenoid are two coils, a very short duration. The holding current
closing coil and a holding coil. These two
coils are connected in parallel with an should be less than one ampere. Fig. 39
internal switch connected in series with the shows the theoretical wiring diagram.
closing coil.
GEARBOX
SUPPLEMENTARY INSTRUCTIONS
FOR INCORPORATING OVERDRIVE ON
" SECOND " AND " THIRD " GEARS
(iii) Withdrawing the pivot bolt (3) (f) Remove 1st and 2nd speed selector
to enable the change speed lever shaft retaining screw (6), spring and
assembly to be withdrawn. $" locking ball and slide this selector
shaft rearwards clear of the casting to
Caution. When withdrawing enable the removal of the selector
the change speed lever assembly, fork.
ensure that the anti-rattle spring
and retainer, which is located on (g) Remove " Reverse " selector fork and
shaft (9) carrying out the procedure
the spherical part of the lever, as in (f) above, excepting that the
is retained for re-assembling. shaft is positioned by a plunger,
(d) Remove the three wire locked stop spring, distance piece and retaining
screws (4). screw instead of the ball, spring,
and retaining screw.
(e) Unscrew and remove the three wire (h) Remove 3rd and ' T o p " speed select-
iocked screwed taper pins (5) securing or shaft (7) and fork, carrying out
the forks to the selector shafts. the procedure used in (f) above.
GEARBOX
SUPPLEMENTARY INSTRUCTIONS FOR INCORPORATING
OVERDRIVE ON ccSECOND" AND CcTHIRD" GEARS
(a) Ensure before fitting the centre selector (b) The synchro sleeve begins to cover the
shaft that the interlock pin is positioned dog teeth of the driving gear.
in the end of the shaft. (See 10).
NOTE. Failure to obtain these con-
ditions will result in noisy and difficult
(b) After fitting and moving the centre gear changing.
shaft to the " Neutral " position, feed
the two interlock balls into position To obtain correct switch adjustment pro-
from either side. (See 10). ceed as follows :-
TOP COVER CASTING L ~ N I LEAD
P T NO 3O;lbB
,
P1 NO 5 0 2 4 1 2
(a) Move the gear lever until " Second "
gear is fully engaged.
(b) Wire a bulb in series with the switch
contacts and connect to a battery.
(Fig. 42).
Y
w 1 c M PLUGS M L ~ T O P SwlrCHS E I R T M E D BV (c) Screw the switch into the rear switch
V l I(P 5 1 5 0 5 P l 110 4 2 7 8 1 SECURING BOLT
boss (Fig. 42), until the contacts close.
Fig* 41 Top Cover showing Isolation Switches. (Indicated by the bulb lighting.)
GEARBOX
SUPPLEMENTARY INSTRUCTIONS FOR INCORPORATING
OVERDRIVE ON c6SECOND" AND 'cTHIRD" GEARS
(d) Measure with feeler gauges the gap Wiring. The switches are wired in
between the switch and boss, that is, parallel (Fig. 43) and the necessary link
the amount the switch would have to lead from switch to switch is obtainable
be screwed down to be f d y home. under Part No. 502412.
One of the link wires is connected to earth
(e) From this dimension subtract .040" (Fig. 41). The remaining link wire is
and make up the remainder with connected through a snap connector to one
paper packing washers, Part No. side of the operating switch.
502146.
Example. If the gap measured Top Cover Conversion Pack-Part No.
.090" the subtraction of the .040" 503219. The following is a list of the parts
would leave .05CU. By selection included in the pack to convert the old
(the washers vary in thickness) obtain type cover assembly, part No. 502078 to
a pack which measures .050". 502411.
1 Top Cover Casting 301768
( f ) Disconnect the switch and remove it 1 1st and 2nd Selector Fork 110753
from the top cover. 1 Top and 3rd Selector Fork 110754
2 Welch Plugs 54505
(g) After installing the washer-pack over 1 Isolator Switch 42781
the screwed portion of the switch, 6 Packing Washers 502146
screw the switch securely into the top 1 Link Lead 502412
cover. 3 Welch Plugs 104449
Repeat the procedure with the
c c Third " and " Top " isolator switch. Overdrive Kit-Part No. 501803 for R.H.
Part No. 502104 for L.H.
+
TO AMMETER IF FITTED
BROWN WIRE BATTERY SIDE
RELAY CONTACTS
(b) T o convert cars fitted with the old
type overdrive unit (Serial No. 221
12751-, in which case either :-
COIL
REAR AXLE
SECTION F
REAR AXLE
INDEX
.
Notation for Fig 2 ...... ...... ...... ......
Data ...... ...... ...... ...... ...... ......
General description ...... ...... ......
To remove hubs ...... ...... ...... ......
T o replace hubs ...... ...... ...... ......
To remove hubs 1J Centre lock type ......
T o replace hubs
T o remove axle shah ...... ...... .....
T o replace axle shaft ...... ...... ....
To remove axle ...... ...... ...... ......
To replace axle ...... ...... ...... ......
T o dismantle axle ...... ...... ...... ......
To assemble axle ...... ...... ...... ......
Service Diagnosis ...... ..... ...... ......
ILLUSTRATIONS
Fig. 1 Axle arrangement ...... ...... ...... ...... ......
Fig. 2 Exploded view of axle detail; ...... ...... ..... ......
Fig. 3 Hub removal ...... ...... ......
Fig. 4 The removal of the " knock-on " type h i 6 ...... ......
Fig. 5 The replacing of the " knock-on " type hub ...... ......
Fig . 6 Hub removal. ...... ...... ...... ...... ..... ....
Fig . 7 Removing hub bearings ...... ...... ...... ...... ......
Fig. 8 Replacing hub oil seal ...... ...... ...... ...... ......
Fig. 9 Replacing hub bearings ...... ...... ...... ....
Fig. 10 Axle being removed from car ..... ...... ...... ......
Fig. 11 Removing split pin from hub securing nut ...... .....
Fig. 12 Identification numbers on bearing caps and axle casing.....
Fig . 13 Casing spreader in position .... ..... ..... .....
Fig . 14 Removing split pin from driving flange securing nut ......
Fig . 15 Removal of pinion head bearing . . . . . . . . . . . . ...... ......
Fig. 16 Driving out pinion bearing outer rings ...... ......
Fig. 17 Checking the run-out of the crown wheel mounting flange
Fig. 18 Fitting pinion bearing outer rings ...... ...... ......
.
Fig 19 Pinion setting gauge assembled to axle centre casing ......
Fig . 20 The pinion setting gauge is set to zero ...... ...... ......
Fig . 21 Measuring the shim pack ...... ...... ...... ...... ......
Fig . 22 Shims placed in position on outer ring abutment face ......
Fig. 23 Pressing the pinion head bearing on to the pinion shaft......
Fig. 24 Showing the pinion bearing spacer chamfer pointing
outward...... ...... ...... ...... ......
Fig. 25 Testing the pre-load"of the pinioi'bearings ...... ......
Fig . 26 Fitting pinion housing oil seal ...... ...... ...... ......
.
Fig 27 Fitting differential bearings to the differential casing ......
.
Fig 28 Ascertaining the total end float of the differential unit
without the crown wheel ...... ......
Fig. 29 Location of planet gears for entry into d@eren&l casing
Fig. 30 Ascertaining the depth of engagement between crown
wheel and pinion ...... ...... ...... ...... ......
Fig. 31 Removal of differential bearings ............ ...... ......
Fig. 32 Checking the backlash ...... ...... ...... ......
Fig. 33 Crown wheel tooth marking ...... ......
Fig. 34 The replacing of the disc wheel type hub"' ...... ......
Fig. 35 ccKnock-on" type hub in exploded form ...... ......
:--- - - -- - - - 8·94"- -- - -_ __ __ "'1
FRAME DATU M
SECTlQN -e e~
-
IN SHIM5 OVER BOTH BEARINGS
FOR BRG . NO WHEN SPREADING HOUSING
increased to 125
to 145 Ibso ft .
with special nut
fitted from axle
Noo TS . 8039.
Fig. I
Axle arrangement. (For Notes I and z See page 4).
REAR AXLE
Ref. Ref.
No. Description No. Description
DATA
Crown wheel run out ...... ...... ...... ...... ...... ...... Not more than .003"
Backlash between crown wheel and pinion ...... ...... ...... ...... .004" - .006"
Distance from ground thrust face on pinion to centre of crown wheel ...... ...... 3.4375"
Pinion bearing re-load, measured without oil seal ...... 15 - 18 in. lbs.
Pre-load for A e n t i a l bearings Allowance for .002" to .OOi<himiispread over both bearings
Diameter of differential bearings ...... ...... ...... ...... ...... 2.8446" - 2.8440"
Later production cars 2.8460" - 2.8450"
Pinion nut tightening torque ...... ...... ...... ...... ...... ...... 85 - 100 Ibs. ft.
Hub securing nut tightening tor ue ...... 110 - 125 lbs. fi.
4
125-145 bs. ft. with'ipecial"&t fitted to.'.&le No. TS.8039 onwards.
TO REMOVE AXHX
NOTE : As the axle has to be tilted it may
be desirable to drain off the oil.
(a) Jack up car and remove road wheels.
(b) Detach propeller shaft from pinion
flange by the removal of four bolts
and nyloc nuts.
(c) Disconnect hand brake cable from the
compensator lever.
(d) Drain the hydraulic system and discon-
nect the line at the front end of
the flexible hose. (See Brake Section.)
(e) Remove the brake drums after with-
drawing the two countersunk setscrews.
If wirewheels are fitted the split taper
ring will have to be removed fist, Fig. 10 Axle being removed fiom car.
REAR AXLE
9. TO REPLACE TME AXLE the axle is going to be completely
If a replacement axle is being fitted it will dismantled the hubs can be removed at
be necessary to remove the complete brake a later stage, which means that the
assemblies at the axle ends. half shafts, hubs, brake backing plates,
etc., must be removed as an assembly.
It is not necessary to remove the hubs,
for these can be removed with the half (d) Remove brake shoes and return springs.
shafts and brake backing plates.
The axle must be tilted during the fitting Withdraw the brake backing plates
operations and filling the axle with oil after removal of the eight bolts, spring
should be delayed until the axle has been washers and nyloc nuts, four from
fitted to the car. either back plate. Further dismantling
of the brake backing plates only require
The fitting is the reversal of the removal. the removal of the hydraulic wheel
For the bleeding of the hydraulic system cylinders and anchor blocks, the latter
see " Brakes-Section R." being secured by spring washers and
two nuts, the former can be withdrawn
provided the hydraulic connections,
10. TO DISMANTLE rubber dust sealing boots, etc., have
(a) Drain oil. been removed.
(b) Remove wheel securing cones (wire (f) The half shafts can now be withdrawn
wheel hubs only). This enables the from the axle casing,the bearing hous-
brake drum securing screws to be ings tapped off the bearings and the
removed and the drums withdrawn. bearings withdrawn with a suitable
(c) Remove split pins (as shown in Fig. 11) puller. (As shown ia Fig. 7.)
- - out
The grease seal can then be tapped
of the bearing housings.
NOTE : If the hubs have not been pre-
viously withdrawn due to Bifficulties
in slackening the hub nuts mentioned
in (c) they can now be slackened by
gripping the axle shaft in ,the vice,
and the hubs then pressed off the
axle shafts with a suitable tool or press.
8
REAR AXLE
(g) Remove axle centre casing cover and
joint after withdrawal of eight setscrews.
(h) Remove the differential bearing caps,
noting the markings stamped on the top
of these and the correspondingly abutt-
ing portions of the casing. The existing
relation between the caps and casing
must be retained when re-assembling.
Fig. 12 shows example of markings.
(i) Apply axle casing spreader as shown
in Fig. 13, arrd lift differential assembly
Fig. 16 Driving out pinion bearing outer rings thrust washers, so completing the
utilising Churchill Tool No. 2oSM F T ~ I . dismantling of the rear axle.
Fig. 18 Fitting pinion bearings outer rings utilis- Fig. 20 Utilising the " button ",the Pinion Setting
ing Churchill Tool No. M70. Gauge (Churchill Tool No. M8q) is set to
zero.
(3)Fit the dummy pinion (M.84), the is required under the pinion head bear-
pinion bearing inner cones and install ing outer ring, to bring the pinion into
into the axle centre casing ;tightening its correct datum position mentioned
the flange nut progressively until the earlier. Due to the fact that the
correct pinion pre-load of 15-1 gin. bearing inner cones are a slide fit on the
lbs. is obtained. dummy pinion and a press fit on the
actual pinion to be used, bearing expan-
(iii) Install the pinion setting gauge in sion will undoubtedly take place in the
the axle centre casing (Fig. 19), (after latter case. A pack of shims .002"--
zeroing the dial with a ground button .003"below the gauge reading will be
held firmlyon the gauge plunger, Fig.20) required to allow for this expansion and
and tighten bearing caps. This gauge is thus ensure the pinion is in its correct
used to assess the shim thickness which datum position.
Fig. 19 Pinion setting gauge, Churchill Tool No. Fig. 21 Measuring the shim pack.
Mu assembled to axle centre casing.
REAR AXLE
(iv) Although the packing shims are sup-
plied to nominal thicknesses, the dimen-
sions should be measured with a
micrometer gauge. It is important that
no damaged shims are used and that
they are thoroughly cleaned before
measurement. (Fig. 2 1.)
(v) Remove the pinion setting gauge,
dummy pinion and pinion bearing
outer rings.
(vi) Insert the measured pack of shims on
the pinion head bearing outer ring
abutment face (Fig. 22) and replace
the pinion bearing outer rings, pulling
them into place with the special tool
(vii) Press the pinion head bearing inner Fig. 24 Showing the pinion bearing spacer cham-
cone on to the pinion shaft (Fig. 23). fer pointing outwards, followed by the
previously used shim pack.
(viii) The bearing spacer is fed on to
the pinion shaft with the chamfer out-
wards as shown in Fig. 24. The shims
previously removed when dismantling The driving flange is fitted on the end
the axle are placed in position on the (x)
pinion and the assembly fitted into the of the pinion shafl and firmly secured
axle centre casing. The thickness of with the castellated nut and plain
shims fitted will probably have to be washer to a tightening torque of 85-
adjusted to provide the correct pre-load 100 lbs. fi. THE OIL SEAL IS NOT
figure.
FITTED UNTIL THE BEARING
(ix) The inner cone of the pinion tail PRELOAD HAS BEEN CHECKED
bearing is tapped into position on the
pinion and up against the shims on the AS DESCRIBED IN THE NEXT
distance collar. OPERATION.
REAR AXLE
CAUSE REMEDY
I. Axle Noise
(a) Inadequate or improper lubrication. (a) Drain, flush casing out with flushing
oil and replenish with correct grade
of oil. See "General Data" Section A.
(b) Teeth broken off gears. (b) Replace damaged parts.
(c) Contact of crown wheel and pinion (c) Noise during coasting; move the
not correctly adjusted. pinion away from crown wheel.
Noise during driving ; move the
pinion toward the crown wheel.
Do not move the pinion more than
.004"when making these adjustments.
2. Lubricant Leakage
(a) Leakage in general. (a) Reduce level of oil if overfill. Clean
out breather.
(b) Leakage at hub. (b) Clean out breather. Renew oil seal if
leakage persists.
(c) Leakage at pinion head. (c) Clean out breather. Renew oil seal if
leakage persists.
3. Axle Knock
(a) Splines on axle shafis or in differential (a) Replace worn parts.
gears badly worn.
(b) Splines on hub shell or centre of wire (b) Replace worn parts.
wheel badly worn.
(c) Incorrect shimming of planet gears in (c) Replace present ones in use with
differential unit. thicker ones.
Service
Manua
FRONT SUSPENSION
AND
STEER
FRONT SUSPENSION AND STEERING
FRONT SUSPENSION
INDEX
Page
Front Suspension Data ...... ...... ...... ...... 3
Description ...... ...... ...... ...... ...... ......
Notation for Fig. 2 ...... ...... ...... ......
Maintenance ...... ...... ...... ...... ...... ......
Front Wheel Alignment ...... ...... ......
To adjust Front Wheel Alignment"'". ...... ......
Steering Lock Stops ...... ...... ...... ......
To set Steering Lock Stops ...... ......
To remove Front Hub and Stub Axle ...... ......
To replace Front Hub and Stub Axle ...... ......
To remove Front Shock Absorber ...... ......
To fit Front Shock Absorber ...... ...... ......
To remove Front Road Spring ...... ...... ......
To fit Front Road Spring ............ ...... ......
To remove and dismantle Front Suspension Unit
To assemble and fit Front Suspension Unit ......
STEERING
INDEX
Notation for Fig. 11 ...... ...... ......
Type and Description ...... ...... ......
Maintenance ...... ...... ...... ...... ......
Adjustment of Steering Box
To remove Control Head and stat& ~ u b e "
To fit Control Head and Stator Tube ......
To remove Steering Wheel ...... ......
To fit Steering Wheel ...... ...... ......
To remove Steering Unit . . . . . . . . . . . . ......
To fit Steering Unit ...... ...... ......
To dismantle Steering Unit ...... ......
To assemble Steering Unit ...... ......
To remove and replace Drop Arm ......
To remove Idler Unit .... ...... ......
To fit Idler Unit ...... ...... ...... ......
Steering Column Bracing ............ ......
ILLUSTRATIONS
Page Page
Fig. 1 Front Suspension arrangement 1 Fig. 12 Removing the Steering Wheel,
Fig. 2 'Exploded details of Front Suspen- utilising the Churchill Tool No.
sion Unit ...... ...... ...... ...... 4 2OS.3600 ...... ...... ...... ...... 17
Fig. 3 Outer Tie-rod assembly ......
Fig. 13 Showing the removal of the
Steering Unit from front of car
Fig. 4 Showing use of Wheel Turning Fig. 14 Diagrammatic view showing the
Measure for setting wheel lock. angular position of the Drop Arm
V. L. Churchill Tool No. 121U Fig. 15 The Telescopic (adjustable)
Fig. 5 Section showing Rubber Bushes Steering Unit ...... ...... ......
at lower end of dampers ...... Fig. 16 The Circlip in position on the
Fig. 6 Front Road Springbeing removed, Inner Steering Column...... ......
utilising the Churchill Tool No. Fig. 17 The Idling Lever ...... ......
M50 ...... ...... ...... ...... Fig. 18 The Steering Drop Arm .....
Fig. 7 The Front Suspension Unit Fig. 19 The Steering Lever ...... ......
partially dismantled ...... ...... Fig. 20 The Vertical Link ...... ......
Fig. 8 Section showing Rubber Bushes Fig. 21 The R.H. front and L.H. rear
Inner Fulcrum-Top Wishbone Upper Wishbone...... ...... ......
Fig. 22 The L.H. front and R.H. rear
Fig. 9 Section showing Rubber Bushes Upper Wishbone...... ...... ......
Inner Fulcrum-Lower Wishbone Fig. 23 The R.H. front and L.H. rear
Fig. 10 Section through Outer Shackle Lower Wishbone. The R.H. rear
Pin-Lower Wishbone ...... ...... and L.H. front are symmetrical
Fig. 11 Exploded view of Steering details but opposite handed ...... ......
FRONT SUSPENSION AND STEERING
I. FRONT SUSPENSION DATA washer, bearing on the screwed trunnion on
Track at Ground (Static Laden) 45" the inside and-on the outer side against a
Castor Angle ...... ...... Nil steel washer which is secured by a split
King pin ~nclinatiih pinned castellated nut. During production
(Static Laden) ...... 7" the outer lower ends of the wishbone arms
are assembled to the shackle pin to give an
Wheel Camber (Static Laden) ...... 2" end float of ,004" to .012". The need for
Wheel Camber (Full Bump 3") 4" adjustment should only occur when the
Wheel Camber front suspension units have been disturbed.
(Full Rebound 2.25") ...... lo Road dirt and weather areexcluded from the
Turning Circle ...... ...... ...... 32' grease lubricated bearings by special oil
Back Lock ...... ...... ...... 31" resisting rubber seals.
Front Lock ...... 28.5"
A 20" Back ~ i c givgan
k 18.75" The screwed trunnion at the lower end and
Front Lock. the ball joint at the upper end of the vertical
Front Wheel link provide the bearings for the pivoting of
Alignment Parallel to 3" toe in the road wheels. Road dirt and weather are
Length of Centre Tie Rod ...... 19.44" excluded from these bearings by a rubber
Length of Outer Tie Rod 7.68" gaiter interposed between the vertical link
End Float of Lower Outer ~hacKe and the ball joint assembly at its upper
Pin Assembly ...... .004" to .012" end, at the lower end a circular rubber
seal is fitted between the trunnion and the
link. The thread of the trunnion is sealed
2. DESCRIPTION (Fig. I) off by a disc let into the lower end of the
The two front suspension units are of threaded bore. The steering lock stop
wishbone construction. Road shocks are consists of an eccentric roller bolted to the
absorbed by low periodicity coil springs, upper side of the trunnion and abuts
each of these springs are controlled by a against a machined face on the vertical link.
double acting telescopic shock absorber The vertical link, which couples the upper
fitted inside the coil spring.
-
and lower wishbone arms as previously
The upper wishbones are rubber bushed at described, is a carbon steel stamping and
their inner ends to a fulcrum pin which is carries the stub axle shaft, the brake backing
attached to the spring housing, they are plate and the steering lever.
shaped to form a "U" and the outer ends The stub axle is of manganese molybdenum
are interlaced to accommodate a distance steel, which is mounted as a press taper fit
piece and are secured together by the in the vertical link, is secured by a split pin
screwed shank of a ball joint. This joint is locked castellated nut.
fitted to, and provides the axial movement The brake backing plate, with the brake
for, the upper end of the vertical link. shoesand hydraulic wheel cylindersattached,
The inner ends of the lower wishbone arms is secured to a machined flange on the verti-
are rubber bushed on each side and are cal link by two setscrews with a lock plate
attached to the fulcrum pin mounted on the at the lower two points and two bolts of
upperside of the chassis frame. The fulcrum unequal length at the upper two points.
is steadied at its extremities by two support The longer of these bolts passes through the
brackets. front bore of the brake plate, the vertical
The outer ends of the wishbone arms, link, a distance piece and the steering lever
bushed with a Clevite bearing, are and is secured by a nyloc nut; the shorter
mounted on either end of a shackle pin. bolt is similarly secured and utilises the
The shackle pin is splined centrally to fit lower bore.
transversely into the manganese bronze The front hub is mounted on a pair of
trunnion which is threaded to accommodate opposed taper roller bearings carried on the
the lower end of the vertical link. stub axle shaft. The inner bearing abuts
Each bushed end of the wishbone arms is against a projecting shoulder on the vertical
located sideways on the shackle pin by link and its outer ring against a flange
means of a white metal covered steel thrust machined in the hub. The outer ring of the
Fig. 2 Exploded details of L.H. Front Suspension Unit.
FRONT SUSPENSION AND STEERING
NOTATION FOR FIGURE 2
Ref. Ref.
No. Description No. Description
1. Inner Upper Fulcrum Pin. 41. Oil Seal.
2. L.H. Front Upper Wishbone Arm. 42. L.H. Front Lower Wishbone Arm
3. R.H. Front Upper Wishbone Arm. Assembly.
4. Rubber Bush. 43. R.H. Front Lower Wishbone Arm
5. Plain Washer. Assembly.
6. Castellated Nut. 44. Bush for Wishbone Arm.
7. Split Pin. 45. Grease Nipple.
8. Upper Wishbone Ball Joint Assembly. 46. Spring Pan Studs
9. Grease Nipple. 47. Thrust Washer.
10. Rubber Gaiter. 48. Lock Washer.
11. Upper Wishbone Distance Piece. 49. Grease Seal.
12. Vertical Link. 50. Castellated Nut.
13. Castellated Nut. 51. Split Pin.
14. Plain Washer. 52. Rubber Bush.
15. Steering Lever. 53. Support Bracket.
16. Bolt. 54. Nyloc Nut.
17. Bolt. 55. Bolt.
18. Steering Lever Distance Piece. 56. Nut.
19. Nyloc Nut. 57. Lower Spring Pan Assembly.
20. Setscrew. 58. Bolt.
2 1. Locking Plate. 59. Bump Rubber.
22. Stub Axle. 60. Castellated Nut.
23. Castellated Nut. 61. Cotter Pin.
24. Plain Washer. 62. Front Road Spring.
25. Split Pin. 63. Rubber Washer.
26. Oil Seal. 64. Packing Piece.
27. Front Hub Inner Bearing. 65. Shock Absorber.
28. Front Hub. 66. Lower Rubber Mounting.
29. Wheel Stud. 67. Upper Rubber Mounting.
30. Grease Nipple, fitted up to Commission 68. Metal Sleeve.
No. TS.5348. 69. Washer.
31. Front Hub Outer Bearing. 70. Nut.
32. Castellated Nut. 71. Lock Nut.
33. "D " Washer under nut. 72. Shock Absorber Bracket and Fulcrum
34. Split Pin. Pin.
35. Grease Retaining Cap. 73. Shock Absorber Bracket.
36. Bottom Trunnion. 74. Setscrew.
37. Steering Lock Stop. 75. Tab Washer.
38. Bolt for Steering Lock Stop. 76. Nut.
39. Spring Washer. 77. Rebound Rubber.
40. Grease Nipple.
12. T 0 R E M 0VE FR 0N T R 0AD Fig. 6 Front Road Spring being removed, utilising
SPRING the Churchill Tool No. M.50.
(a) Remove front shock absorber as de-
scribed on page 8. (d) Feed the plate on to the threaded
(b) Withdraw the split pins from the portion of the rod protruding from the
castellated nuts on the underside of the spring pan in such a manner that the
lower wishbones. Remove the centre bearing seat is downwards, ensure too
nut and bolt from the front wishbone that the holes in the block locate on
arm and the burnv rubber assembly the studs of the spring pan.
from the rear wishbone arm. ~ e e d (e) Feed bearing on to threaded rod fol-
two guide pins into the vacant holes. lowed by the fly nut, tighten to com-
(c) Place a small lifting jack under the press spring a small amount.
spring pan, with a suitable packing
between jack and pan to prevent dam- (f) Remove the four remaining nuts secur-
age to the shock absorber attachment ing the spring pan to the wishbone
studs on the latter. arms.
(d) Remove the four remaining nuts secur- (g) By slowly unscrewing the fly nut the
'
ing the spring pan to the wishbone spring pan can be lowered down the
arms and lower jack, easing the guide guide pins.
pins through the wishbone arms. (h) When all tension is released from the
(e) The spring can be withdrawn from its road spring the guide pins and the "6 "
upper abutment together with rubber washer can be removed from the upper
washers and distance piece. end of the shaft.
An alternative method is to utilise the
Churchill Tool, No. M50 in the following (i) Withdraw the Churchill Tool from the
manner :- suspension unit together with the
spring pan, spring, rubber washers and
(a) Carry out operation (a) and (b) as distance piece.
previously described.
(b) Remove the fly nut, bearing and plate 13. TO FIT ROAD SPRING
from the threaded rod of the Churchill (a) Attach the rod of the Churchill Tool
Tool followed by the " C" washer. No. M50 to the spring abutment
(c) Feed the rod, notched end first, bracket of the front suspension unit
through the spring pan and upper and fit the guide pins through the
shock absorber abutment, to the pro- centre holes of the lower wishbone
truding end fit the "C" washer. arms.
FRONT SUSPENSION AND STEERING
(b) Assemble the alloy distance piece two of the four bolts securing the
(spigot downward) on the road spring brake backing plate to the vertical
with a rubber washer interposed be- link, followed by the upper two bolts.
tween, and position a second rubber These bolts pass through the vertical
washer on the spring's lower extremity. link and distance pieces and thence
through the steering lever, on the
(c) The spring and distance piece assembly withdrawal of these bolts it will be
is offered up to the front suspension necessary to hold the steering lever
unit followed by the spring pan, the and collect the bushes. Alternately the
latter located on the guide pins. brake plate can be removed from the
(d) Fit the plate to the threaded rod of the vertical link without draining the
Churchill Tool in such a manner that system. (Fig. 7).
the bearing will seat in its recess and (6)Remove the nyloc nuts from the ends
the studs of the spring pan in their of the lower wishbone fulcrum pin,
recesses. Follow with the bearing and followed by the nuts, bolts and lock
fly nut. washers securing the fulcrum pin sup-
(e) The fly nut of the tool is turned to port brackets to the chassis frame. The
compress the spring. Ensure that, support brackets can now be removed.
when the spring pan closes to the wish- (c) Remove the split pins from the outer
bone arms that it is located on the ends of the lower shackle pins. Remove
attachment studs at the inner ends the castellated nuts, grease seals and
of the wishbone. Secure and lock washers from both ends of the shackle
washers and castellated nuts and fit two
bolts with castellated nuts and lock
washers at the trunnion end of the (d) The wishbone arms can now be re-
wishbone arm. moved and the thrust washer and
grease seal withdrawn from the shackle
(f) When the spring pan is secured to the pin.
wishbone arms the Churchill Tool can
be removed and the guide pins with-
drawn from the wishbone arm.
(g) The spring pan is finally secured to the
wishbone arms by a nut, bolt and lock
washer at the front arm and a bump
rubber assembly at the rear arm.
Lock all six nuts with split pins.
(h) The shock absorber can now be fitted
as described on page 8.
TO REMOVE AND DISMANTLE
FRONT SUSPENSION UNIT
Before dismantling the units, suitably mark
the components so that they can be returned
to their relative positions.
Carry Out h ~ t r u c t i ~asn detailed
~ for "TO Fig. The Front Suspension unit gartially dis-
Remove Front Hub and Stub Axle," page 7, mantled.
and "To remove Front Road Spring," page
9, then proceed as follows :-
(e) Remove the two bolts, nuts, plain and
(a) Drain the hydraulic system and dis-
locking washers, followed by the two
connect the flexible hose as described setscrews and spring washers, from the
in Brakes, Section " R." Remove the upper Mcrurn pin.
grease catcher by removing four nuts
and bolts. Release the tabs of the (f) The front suspension unit can now be
locking plates and withdraw the lower lifted away fiom the car.
FRONT SUSPENSION AND STEERING
(g) Withdraw the split pin from the castel- (ii) Feed the fulcrum pin into the upper
lated nut securing the ball joint as- wishbone arm, press the second rubber
sembly to the upper wishbone arm. bush into the wishbone and fit the large
Remove the castellated nut and with- plain washer followed by the castellated
draw the ball joint assembly from the nut. This nut should be left loose at
wishbone arms, collecting the distance this juncture.
piece as the ball joint is moved. (iii) While similarly fitting the second wish-
bone arm ascertain that the other ends
(h) Withdraw the split pin and remove the of the arm are positioned eorrectly to
nut and plain washer securing the ball
joint assembly to the vertical link and receive the ball pin assembly and dis-
withdraw ball joint. tance piece. With the ball pin assembly
toward the operator the wishbone
(i) Withdraw the split pins from the Pange on the right overlaps the one
castellated nuts at the outer ends of the on the left. This applies to both left
upper inner fulcrum pin. Remove the and right suspension units.
large diameter plain washers and the (iv) Feed through the upper attachment
outer rubber bushes. of the ball joint assembly with the
distance piece between the wishbone
(j) The wishbone arms can now be re- arms and secure with the plain washer
moved and the second rubber bush and castellated nut locked by the split
withdrawn from the fulcrum pin. pin. Tighten castellated nuts of inner
(k) Remove the steering stop screw from upper Mcrum pins and lock with
the lower end of the vertical link and split pins.
detach the bottom trunnion assembly (v) Fit the ball pin taper into the
from the vertical link and collect the oil vertical link with the rubber gaiter in
seal situated between the vertical link position and secure with the plain
and the trunnion assembly. washer and castellated nut. Fit split
pin in nut.
Offer up the inner upper fulcrum pin
15. TO ASSEMBLE AND REPLACE to the chassis frame and secure by bolts
FRONT SUSPENSION UNIT with a plain washer under its head and
Assembly is made with strict regard to the a lock washer with the nut at the points
markings on certain parts to ensure that near the centre line of the car. Set-
they are returned to the same relative screws and lock washers are used for
position. the attachment points nearer the ball
joint assembly.
(i) Fit a rubber bush to each end of the (vii) Ascertain that the shackle pin of the
upper fulcrum pin. bottom trunnion assembly is mounted
centrally. This pin is a press fit in the
RUBBER BUSHES body of the casting and is prevented
from turning by the imbedding of the
splines, it can be centralised by the use
of a press or gentle tapping with a
copper faced mallet.
(viii) Fit the rubber sealing ring to the
lower end of the vertical link followed
by the bottom trunnion assembl ,
which is a screw fit on the vertical
The trunnion is screwed home and
J.
SECTION SHOWING RUBBER BUSHES. then turned back approximately one
INNER FULCRUM -TOP WISHBONE. turn so that the shackle pin lies parallel
to the fore and afl line of the car but
Fig. 8 A section showing the rubber bushes of the between the base of the vertical link
Upper Wishbone Inner Fulcrum. and the chassis frame.
FRONT SUSPENSION AND STEERING
(ix) Feed the locking washer and steering lated nuts to the ends of the shackle pin
lock stop bush on to the steering stop and obtain the necessary end float
securing bolt and attach to the bottom before locking with the split pin.
trunnion assembly. The bolt is left
finger tight at this juncture.
I.
25.
26.
27.
28.
29.
Nut.
Lock Washer.
Trunnion Bracket.
Bolt.
Steering Column Clamp.
TYPE AND DESCRIPTION
The steering gear is of the cam and lever
B.
C.
D.
E.
F.
Plain Washer
Tie Rod
Thick Washers
Lock Washer
Nut i
Fitted in place of
30 after Comm.
No. TS. 1390.
See page 20.
TAPER I IN 8 ON DIA.
Fig. 17 The Idler Lever R.H.S. and L.H.S. are Fig. 19 The Steering Lever R.H. L.H. is symmetrical
identical. but opposite handed.
FRONT SUSPENSION AND STEERING
'.,i f<
G)«>
,·coos·.
. ~9!!!S D," ~""'E: R I 'N
I :' /:1-
" .J
I I
- ')/ '6'D 'A . N C 10 TPI EFFECTIVE DlA .
7044 ' 796"
74 2' TRUNCATE TO :794" OIA .
THREADS MUST BE SMOOTH .
25
FRONT SUSPENSION AND STEERING
5 4'
Fig. 21 R.H. front and L.H. rear upper wishbone. Fig. 22 L.H. front and RH. rear upper wishbone.
10.2~'cas
&I% PtZh54ED IN TO RH FRONT
MATCH HOLE FOR G K A S C R 8.63' I
L H REAC.
Fig. 23 The R.H. front and LH. rear Lower Wishbone. The R.H. rear and L.H. front are symmetrical
but opposite handed.
Service Instruction
Manual
HI
ROAD SPRINGS
AND
SHOCK ABSORBERS
SECTION H
ROAD SPRINGS AND SHOCK ABSORBERS
PMDE X
Front Road Spring Page
Description ...... ...... ...... ...... ...... ...... ...... 2
Maintenance ...... ...... ...... ...... ...... ...... ...... 2
T o Remove or Replace ...... ...... ...... See Section 6
Rear Road Spring
Description ...... ..... ......
Maintenance ...... ..... ......
T o Remove Rear Road Spring
Notation for Figure 3 . . . . . . . . . . .
T o Fit Rear Road Spring ......
Rear Road Spring Overhaul ......
T o Dismantle Rear Road Spring
T o Assemble Rear Road Spring
Front Shock Absorber
Description ...... ...... ...... ...... ...... ...... ...... 6
Maintenance ...... ...... ...... ...... ...... ...... ...... 6
Notation for Figure 4 . . . . . . . . . . . . ...... ...... ...... ...... 6
T o Remove or Replace Front Shock Absorber See Section G
Rear Shock Absorber
Description ...... ...... ...... ...... ......
Notation for Figure 5 . . . . . . . . . . . . ...... ......
Maintenance ...... ...... ...... ...... ......
Valve operation ...... ...... ...... ......
fLLUSTRAa[lONS
Page
Fig . 1 Front Road Spring ...... ...... ...... ...... ...... 1
Fig . 2 Rear Woad Spring . . . . . . . . . . . . ...... ...... ...... ...... 3
Fig . 3 Exploded Rear Suspension Details ...... ...... ...... 4
Fig . 4 The Front Shock Absorber ...... ...... ...... ...... 6
Fig. 5 The Rear Shock Absorber ...... ...... ...... ...... 7
Fig . 6 Sectional View of Rear Shock Absorber Valve ...... 8
ROAD SPRINGS AND SHOCK ABSORBERS
43" f .O~*THICKNESS
ON E K H END
'i
Fig. I Front Road Spring. For illustration purposes only the Competition Spring is shown.
This spring has a left-hand helix.
ROAD SPRINGS AND SHOCK ABSORBERS
FRONT SPRING cleaned, brush the blades at their edges
I. DESCRIPTION with engine oil, this will allow sufficient
oil to penetrate between the leaves and
The low periodicity coil spring used in the provide inter-leaf lubrication.
f b n t suspension of this car is illustrated in Lubrication of spring blades is chiefly
Fig. 1. This illustration also gives the data required at the ends of the leaves where one
of both the normal road spring and the presses upon the next and where the maxi-
competition spring. This competition mum relative motion occurs.
spring can easily be distinguished from the
normal type, for it has a left-hand helix. The clips should be inspected and any loose-
Damping action is provided by a direct ness corrected by pinching the closer
acting telescopic type shock absorber, to the spring. Failure to keep these clips
mounted centrally through the coil spring. tight often causes "knocks" at the rear of
the car.
2. MAINTENANCE
Very little maintenance should be required
during the lifetime of the car. There is no 3. TO REMOVE REAR ROAD SPRING
lubrication required, and the only possible (a) Jack up the body at the rear of the car
maintenance would be to replace the rubber sufficiently to take the weight off the
washers, or to check the spring against the road spring.
data given in Fig. 1.
(b) Remove the rear wing stay situated
behind the rear wheel between the
3 TO REMOVE OR REPLACE chassis and wing itself.
These operations are fully covered in the (c) Holding the hexagon of the shock
"Front Suspension, Section G" of this absorber-link remove the nyloc attach-
manual. ment nut.
(d) Remove the two nuts and lock washers,
REAR ROAD SPRINGS followed by the plate of the shackle
assembly at the rear end of the spring.
I. DESCRIPTION (Fig. 2) Withdraw the plate and pin assembly
Semi-elliptical laminated springs are used and collect the rubber bushes from the
which have their location point with the spring eye and the chassis bracket.
axle below and forward of the centre, so
that the longer end of each spring is fitted (e) Screw a &" x 24 UNF bolt into the
toward the rear of the car. head of the forward fulcrum bolt to a
depth of +".Withdraw the split pin to
The forward fulcrum of the spring has a remove nut and "D" washer. Utilising
silentbloc bush and is mounted on a bolt a lever under the head of the A" UNF
rotruding from the outer side of the chassis bolt, the fulcrum bolt can now be
game. The attachment is completed by a withdrawn from the spring and chassis
"D" washer and split pinned castellated nut. frame.
The rear fulcrum is a shackle assembly
utilising split rubber bushes interposed (f) Supporting the spring by a small jack
between the pins, the spring or the chassis remove the four nyloc nuts of the two
frame. The attachmentis completed by nuts "U" bolts attaching the spring to the
and lock washers situated between the spring axle, remove the "U" bolts and the
and the chassis frame. spring plate from the shock absorber
link.
MAINTENANCE (g) The road spring and the supporting
The only lubrication required is that for the jack is now removed fiom under the car
spring leaves, on no account must the to a bench.
rubber or silentbloc bushes be lubricated. (h) The silentbloc bush can now be re-
Over lubrication of the spring leaves should moved fiom the forward eye of the
be avoided. M e r the springs have been spring.
ROAD SPRINGS AND SHOCK ABSORBERS
Fig. 6. Sectional view of Rebound and Compression 5. TO FIT REAR SHOCK ABSORBER
Valve of Rear Shock Absorber. (a) Remove the connecting link from the
Valve Screw
shock absorber arm.
Valve Screw Washer (b) Offer up the shock absorber to its
Ring Seal bracket on the chassis frame in such
Rebound Valve a manner that the body faces outwards
Compression Valve and the arm points rearwards. Secure
Rebound Valve Spring
Rebound Valve Spring Nut with two bolts and nyloc nuts.
Compression Spring (c) With the spherical knuckle of the con-
Ring Seal necting link lowermost, offer up the link
to the shock absorber arm and spring
plate, the link should be positioned
3. VALVE OPERATION between the road spring and chassis
T o accomplish general damping of the car frame, with the nuts away from the
springs, a small bleed is built into the valve. centre line. Holding the hexagon of
This operates both on compression (axle the lower attachment bolt secure the
moving up) and on rebound (axle moving link to the spring plate with a nyloc
down). As bumps become more severe on nut and plain washer.
compression, pressure builds up in the com- (d) utilising a nut and lock washer secure
pression cylinder and blows the compression the connecting link to the shock
valve off its seat at a pre-determined pres- absorber arm.
sure controlled by the outer spring. (e) Fit road wheel and remove jacks.
Service Instruction
Manual
FRAME UNIT
SECTION J
FR E UNIT
INDEX
Fage
Description ,. -
-... .... -." ...... .. *... ...." .....- 3
The assessment of accidental damage ...... ...... .-" ....a. 3
Preparation of the car ...... ...." ..... ......
v .-.... ... 4
Checking Side Members for "Twist" .., ...... ...... ."." 5
Checking Side Members for "Cra&g" ...... ...- ....- ...." 5
Checking Side Members for "Squareness" --.. ... ...... 6
Checking Side Members for "Bowings' , ...... ...... - 7
ILLUSTRATIONS
Page
Fig' ' Plan view of Frame Unit
Side view of Frame Unit } - ., Folding page 1 & 2
Pig. 2 Preparing the car to assess accidental damage and check-
ing Frame for " C r a w ' ...... ...... ...... .*.... 4
Fig. 3 Generating the 8 points for assessment of accidental
Fig. 4 Checking Frame for " S q ~ e s s " ...... ...- ...... 6
Fig. 5 C h e g Frame for '%0BPingY.., ...... ...." ...... 7
FRAME UNIT
43 78"
Fig. I
Plan view of Frame Unit.
Side view of Frame Unit.
I. DESCRIPTION. Fig. I. Welded in position approximately half-way
A rigid structure is provided, the frame side along the inner side of each side member are
members being formed by opposed steel the jacking brackets. To each cruciform
pressings welded together, giving tubular member is welded an outrigger body sup-
type side members of rectangular section. port bracket, these brackets pass through
and are supported by the side members.
Welded at the front and rear ends of the There are four such brackets.
side members are two tubular cross mem- The complete frame is protected from
bers. The front tube is 1+" diameter and is corrosion by rust proofing.
supported by the steering unit and idler unit
mounting brackets welded to the side
members. The rear tube of la" diameter is
welded between the two side members. A THE ASSESSMENT OF
s a n d tube, just forward of the rear one, ACCIDENTAL DAMAGE
protrudes through the side members and For this purpose reproduction drawings of
to it the rear road spring shackle brackets the chassis frame giving the necessary
are welded. dimensions are given as Fig. 1.
The centre of the frame is braced by channel Even when a car has suffered only superficial
sectioned steel pressings forming a rigid damage it is possible that the frame mem-
cruciform structure and stiffened at its bers have been displaced which will result
centre by heavy gauge plates. This structure in the road wheels failing to track correctly
carries the gearbox and handbrake mount- and it is recommended that the frame is
ing brackets. checked for squareness.
At the h n t end but a little to the rear of the It is possible to check the frame dimension-
tubular cross member, the frame is braced ally to a satisfactory degree of accuracy
by op sed steel pressings welded together
P"
and onning a rigid box section cross
member. This member forms the lower
without first removing the body. For
clarity the chassis frame only is shown in
the illustrations of this section.
points of attachment for the front suspen-
sion and engine mountings. It is built up to Details of checks for "twist, " "cradling, "
(6
form the upper abutments for the front squareness," and Ccbowhg,'' are given in
road springs and this upper structure is this section. By canying out these checks
braced by a detachable tubular crossmember in the order mentioned a great deal of work
and by supports to the two side members. is eliminated.
FRAME UNIT
Fig. 2 The car prepared for the assessment of accidental damage, in particular the assessment of
"cradling" (for clarification purposes only the chassis frame is shown).
3. PREPARATION OF CAR (Fig. 2) (f) From inside the car adjacent to the
front door posts raise the carpet and
(a) Select a clean level floor space and jack remove the most forward body securing
up the car,utilising four screw jacks. It bolts from the forward outrigger body
is suggested that two jacks are placed supports.
near the front box section cross
member and the second two under the (g) Pass the plumb bob cord from below
side members at the rear. through the bolt hole. Mark the floor
Remove all four road wheels. imrnediatelv below the vlumb bob
pointer. he operation is >epeated on
(b) Adjust the rear jacks until the straight the other side and so creates voints C
portion of the rearmost tubular cross and D (Fig. 3).
A
Fig. 3 Illustrating the eight points of the chassis which are generated on the floor below.
4. CHECKING THE SIDE MEMBERS sible to calculate their height above the
FOR TWIST ground.
If, by adjusting the screw jacks under the As an example, when checking the posi-
chassis frame as described in "Preparation tion of one of the front "out rigged"
of Car" page 3 operation a-c, it is found body supports, the dimension given is
to be an impossibility to bring the front 6.94" from the top of the support to the
cross member and the straight portions of datum, therefore if we subtract 6.94"
the rear cross members parallel to the from 20" the result will be 13.06" which
ground, the frame can be considered to be should be the distance between the top
"twisted." of the support and the floor.
(c) Measure the height above the ground
5. CHECKING SIDE MEMBERS FOR at several points and subtract the
CRADLING dimensions obtained from 20". By
comparing the results with the drawing
(a) Having prepared the car as detailed in dimensions, it will be possible to
"Preparation of Car" page 3 operations determine whether the frame is true.
a-c,it is now standingwith the datum
line parallel to the ground and this line (d) (ij When the difference is greater than
is 20" from the ground (Fig. 2). the drawing, the chassis frame is
" bowed " downward.
(b) Referring to Fig. 1 it will be observed
that all dimensions are given from this (ii) When the difference is less that
datum line and by simple subtraction the drawing the chassis frame is
of bese dimensions from 20" it is pos- "bowed " upwards.
FRAME UNIT
Fig* 4 Utilising the eight generated points for the assessment of frame cc squareness."
6. CHECKING SIDE MEMBERS FOR (c) If the chassis frame is square the length
SQUARENESS (Fig. 4) AD will equal BC, CF will equal DE
and EH will equal FG.
(a) It is assumed that the car has been pre- (d) (i) When BC, DE, and FG are of
pared and the eight points generated on greater length than AD, CF and
the floor below. Replace the road wheel EH respectively the left hand (BH)
and rebound rubber bracket. The car side member is forward of the
is now moved so that the position of the right hand (AG) side member.
markings can be examined. (ii) When AD, CF and EH are of
greater length than BC, DE and
(b) Utilising a suitable measure ascertain FG respectively the right hand
the lengths of the diagonals AD, BC, (AG) side member is forward of
CF, DE, EH, and FG. the left hand (BH) side member.
FRAME UNIT
Fig. 5 Utilising the eight generated points for the assessment of "bowing."
7. CHECKING THE SIDE MEMBERS (c) With a suitable straight edge join point
FOR BOWING (Fig. 5) J to point M.
(a) Having gained access to the points (d) (i) If this line passed through points
generated on the floor beneath the car, K and L the side members are
join the points A to B, C to D, E to F correctly aligned.
and G to H. (ii) When the points K and L lay to
the right of the line JM the side
(b) Accurately determine the mid-points members are "bowed" to the right.
of the lines ABj CD, EF and GH. (iii)When the points K and L lay to
Call these points J, K, L and M respec- to the left of the line JM the side
tively. members are "bowed" to the left.
Service Instruction
Manua
PROPELLER SHAFT
SECTION K
PROPELLER SHAFT
INDEX
Page
Type and Description ...... ...... ...... ...... ...... ...... ...... 1
Lubrication and Maintenance Instructions ...... ...... ...... ...... 1
Removal of Propeller Shafi ...... ...... ...... ...... ...... ...... 2
Dismantling Propeller Shaft ...... ...... ...... ...... ...... ...... 2
To Examine and Check for Wear ...... ...... ...... ...... ...... 3
To Fit Propeller Shaft ...... ...... ...... ...... ...... ...... 4
ILLUSTRATIONS
Page
Fig. 1 Propeller Shaft Details ...... ...... ... ...... ...... 1
Fig. 2 Tapping Tube Yoke to Release Bearing Race ...... ...... 2
Fig. 3 Removing Bearing Race by Hand ...... ...... ...... 2
Fig. 4 Removing Bearing Race with Special Punch ...... ...... 2
Fig. 5 Removing Yoke ...... ...... ...... ...... ...... ...... 3
Fig* 6 Fitting New Oil Seals ...... ...... ...... ..... ...... 3
PROPELLER S W T
SECTION L
WHEELS AND TYRES
INDEX
Page
Construction of Tyre ..... ..... ...... ...... ...... ...... ...... 1
Tyre Pressures ...... ...... ...... ...... ...... ...... ...... ...... 2
Valve Cores and Caps ...... ...... ...... ...... ...... ...... ...... 2
Tyre Examination ...... ...... ...... ...... ...... ...... ...... 2
Repair of Injuries ...... ...... ...... ...... ...... ...... ...... 2
Factors affecting Tyre Life and Performance ...... .... ...... 3
Special Types of Irregular Tread Wear ...... ..... ...... 6
Wheel Alignment and its Association with Road Camber ...... ...... 8
Camber, Castor and King Pin Inclination ... .... .....
Tyre and Wheel Balance ...... ...... ... .... ......
Changing Position of Tyres ...... ...... ...... ... ......
Pressed Steel Wheels ...... ...... ...... ...... ...... ......
Wire Wheels ...... ...... ...... ...... ...... ...... ......
To Remove ...... ...... ...... ...... ...... ...... .....*
T o Replace ..... ...... ...... ...... ...... ...... ......
Examination ...... ...... ...... ...... ...... ...... ......
&'heel Building ...... ...... ...... ...... ...... ......
ILLUSTRATIONS
Page
Fig. 1 Tyre Construction ...... ...... ...... ...... ...... ...... 1
Fig . 2 Excessive Tyre Wear due to persistent Under-inflation 3
Fig . 3 Breaking up of Casing due to O v e r - f l e ~ gand Heat
Generation ...... ...... ...... ...... 3
Fig . 4 Running Deflated destroyed';his e&ing ...... ...... ...... 3
Fig . 5 Local excessive wear due to Brake Drum Eccentricity ...... 4
Fig . 6 Diagrammatic ]Illustration of Slip Angles ...... ...... 5
Fig . 7 Severe Impact has fractured this Casing ...... ...... 6
Fig. 8 A Double Fracture ...... ...... ...... ...... ...... ...... 6
Fig . 9 Heel and Toe Wear...... .....* ...... 6
Fig . 10 The effect of Braking and"Rolliig Resigsnce on Tyre
Tread ...... ...... ...... ...... 7
Fig. 11 Spotty Wear due to ';variety of <;uses ...... ...... 7
Fig . 12 Fins and Feathers due to Severe 2k"Lisafignment ...... ...... 8
Fig . 13 Exaggerated Diagram showing effect sf Road Camber on
a Car's Progress ...... 9
Fig . 14 The correct relationship between T h e a i d ~ u d ; " ...... 10
Fig . 15 Dunlop Tyre Balancing Machine ...... ...... ...... 10
Fig . 16 The Churchill 120 Electronic Wheel ~ a l & c e ...... ...... 11
Fig. 17 Dynamic or Couple Unbalance ...... ...... ...... ...... 12
Fig . 18 Wire Wheel and Hub Cap ...... ...... ...... ...... 12
Fig. 19 Wheel Building Dimensions ..... ...... ...... ...... 14
WHEELS AND TYRES
RS
0 EAD
Ct 1
-
me.,
Ntr
EAD W 1 RES
ACTUAL
I
I
I
fl\
I
CENTRE OF TURN
WITH NO S L I P A N G L E
Fig. 6 Diagrammatic Illustration of Slip Angles.
WHEELS AND TYIRES
(g) Impact Fractures fractured by the blow and rhe
In order to provide adequate strength, weakened tyre fails some time later ;
resistance to wear, stability, road grip there is usually no clear evidence on the
and other necessary qualities, a tyre outside of the tyre unless the object
has a certain thickness and stiffness. has been sufficiently sharp to cut it.
Excessive and sudden local distortion This damage is not associated solely
such as might result from striking a with speed and care should be exercised
kerb, a large stone or brick, an up- at all times, particularly when drawing
standing manhole cover, or a deep up to a kerb or parking against one.
pothole may fracture the casing cords.
(Figs. 7 and 8.) 2. SPECIAL TYPES OF IRREGULAR
Impact fractures often puzzle the car TREAD WEAR
owner because the tyre and road spring (a) " Heel and toe " or " saw tooth "
may have absorbed the impact without wear
his being aware of anything unusual ; This is the condition where one end of
only one or two casing cords may be each pattern segment or stud is more
worn than the other (Fig. 9). To
some extent it is latent in any non-skid
0
DIRECTION OF They do not consist of separate un-
supported studs or blocks such as are
shown in the diagram. In normal con-
ditions " heel and toe " wear should be
absent or barely noticeable but any
localised forces such as from eccentric
brake drums, fierce or binding brakes,
incorrect brake balance and severe
front braking will usually cause this
4- type of wear to appear amongst other
SLIP OF ROAD IN B R A K I N G R E L A T I V E TO TYRE
Fig. 10 Showing the effect of braking and rolling
evidence of these troubles. An un-
resistance on Tyre Tread. suitable tyre contact area and distri-
bution of load, resulting from road
camber, wheel camber, or excessive
" heel and toe " wear. If the tyre is deflection, will also produce " heel
assumed to be on a locked wheel and and toe" wear.
sliding forward, the abrasive road Regular interchanging of tyres will
surface may be likened to a file passing prevent or reduce irregular wear (see
across the tread. The manner in which page 11).
the flexible rubber studs will be worn
is clear. There is a similar but less '' Spotty '' Wear
marked effect when the tyre is re- Fig. 11 shows a type of irregular wear
which sometimes develo~son front
tyres and particularly 06 near front
tyres. The causes are difficult to
diagnose although evidence of camber
wear, misalignment, under-inflation, or
braking troubles may be present.
Front tyres are at a disadvantage due
to their fore and aft slip and distortion
being in one direction. Front tyres are
connected to the car through swivelling
stub axles and jointed steering linkage
and they are subjected to complicated
movements resulting from steering,
spring deflection, braking and camber.
Load transference during braking
causes increased loading and pattern
displacement on front tyres, and adds
to the severity of front tyre operation.
Unbalance of the rotating assembly
may also contribute to a special form of
irregular wear with one half of the
tyre's circumference more worn than
the other half. Unbalance alone does
not cause the type of " spotty " wear
illustrated but the unbalance usually
becomes progressively worse as the
irregular or unequal wear develops.
Fig. XI " Spotty " Wear due to a variety The nature of " spotty " wear-the
causes. pattern being much worn and little
WHEELS AND 'I"YRES
worn at irregular spacings round the beanngs, suspension bearings and
circumference-indicates an alternat- steering joints.
ing " slip-grip " phenomenon but it is ( f ) Wheel concentricity at the tyre
seldom possible to associate its origin bead seats. S.M.M. & T. toler-
and development with any single ances provide for a radial throw
cause. not exceeding &", but this may be
It is preferable to check all points affected by Impact or other
which may be contributory factors. damage.
The front tyre and wheel assemblies (g) Balance of wheel and tyre assem-
blies.
(h)
. , Condition of road springs- - and
shock absorbers.
Corrections which may follow a check
of these points will not always effect a
complete cure and it may be necessary
to continue to interchange wheel posi-
tions and reverse directions of rotation
at suitable intervals.
Irregular wear may be inherent in the
local road conditions such as from a
combination of steep camber, abrasive
surfaces, and frequent hills and bends.
Driving methods may also be involved.
Irregular wear is likely to be more
prevalent in summer than in winter,
particularly on new or little worn tyres.
WHEEL ALIGNlMENT AND ITS
ASSOCIATION WITH ROAD CAM-
BER
It is very important that correct wheel
alignment should be maintained. Mis-
alignment causes a tyre tread to be scrubbed
off laterally because the natural direction of
the wheel differs from that of the car.
An upstanding sharp " fin " on the edge of
each pattern rib is a sure sign of rnisalign-
ment and it is ossible to determine from
Fig. 12 Fins and Feathers due to severe mis-
alignment.
?
the position o the " fins " whether the
wheels are toed in or toed out (Fig. 12).
" Fins " on the inside edges of the pattern
may then be interchanged, which will ribs--nearest to the car-and particularly
also reverse their direction of rotation, on the nearside tyre indicate toe in. "Fins"
or better still the front tyres may be on the outside edges, particularly on the
interchanged with the rear tyres. offside tyre, indicate toe out.
Points for checking are :- With minor misalignment the evidence is
(a) Inflation pressures and the con- less noticeable and sharp pattern edges may
sistency with which the pressures be caused by road camber even when wheel
are maintained. alignment is correct. In such cases it is
(b) Brake freedom and balance, shoe better to make sure by checking with an
settings, lining condition, drum alignment gauge.
condition and truth. Road camber affectsthe direction ofthe car by
(c) Wheel alignment. imposing a side thrust and if left to follow
(d) Camber and similarity of camber its natural course the car will drZt towards
of the front wheels. the nearside. This is instinctively corrected
(e) Play in hub bearings, king pin by steering towards the road centre.
WHEELS AND TYRES
mined by noting the positlon of the " fins."
Severe misalignment produces clear evi-
dence on both tyres.
The front wheels on a moving car should be
parallel. Tyre wear can be affected notice-
ably by quite small variations from this
condition. It will be noted from the dia-
gram that even with parallel wheels the car
is still out of line with its direction of move-
ment, but there is less tendency for the
wear to be concentrated on any one tyre.
The near front tyre sometimes persists in
wearing faster and more unevenly than the
other tyres even when the mechanical con-
TOE O U T dition of the car and tyre maintenance are
M O R E W E A R ON satisfactory. The more severe the average
R H. F R O N T road camber the more marked will this
tendency be. This is an additional reason
for the regular interchanging of tyres.
(a) Precautions when measuring
Wheel Alignment
(i) The car should have come to rest
from a forward movement. This
ensures as far as possible that the
wheels are in their natural running
T O E IN
MORE WEAR ON
positions.
L.H. F R O N T (ii) It is preferable for alignment ro be
checked with the car laden.
(iii) With conventional base-bar tyre
alignment gauges measurements
in front of and behind the wheel
centres should be taken at the
same points on the tyres or rim
flanges. This is achieved by
marking the tyres where the first
reading is taken and moving the
car forwards approximately half
W H E E L S PARALLEL
WEAR E Q U A L
a road wheel revolution before
taking the second reading at the
same points. With the Dunlop
Optical Gauge two or three read-
Fig. 13
- CAMBER D O W N
Exaggerated Diagram showing effect of
ings should be taken with the car
moved forwards to different posi-
tions-180" road wheel turn for
road camber on a car's progress. two readings and 120" for three
readings. An average figure
As a result the car runs crab-wise, dia- should then be calculated.
grammatically illustrated in an exaggerated Wheels and tyres vary laterally
form in Fig. 13. The diagram shows why within their manufacturing toler-
nearside tyres are very sensitive to too much ances, or as the result of service,
toe in and offside tyres to toe out. It also and alignment figures obtained
shows why sharp " fins " may appear on one without moving the car are un-
tyre but not on the other and why the reliable.
direction of misalignment can be deter-
WHEELS AND TYRES
CAMBER, CASTOR AND KING PIN tageous to fit the covers so that the
INCLINATION white spots are at the valve position.
These angles normally require no attention Some tyres are slightly outside stan-
unless they have been disturbed by a dard balance limits and are corrected
severe impact or abnormal wear of front end before issue by attaching special loaded
bearings. It is always advisable to check patches to the inside of the covers at
them if steering irregularities develop.
Wheel camber, usually combined with road
camber, causes a wheel to try to turn in the
direction of lean, due to one side of the
tread attempting to make more revolutions
per mile than the other side. The resulting
increased tread shuffle on the road and the
off centre tyre loading tend to cause rapid
and one-sided wear. If wheel camber is
excessive for any reason the rapid and one-
sided tyre wear will be correspondingly
greater. Unequal cambers introduce un-
balanced forces which try to steer the car Fig. 14 The correct relationship between Tyre
one way or the other. This must be and Tube.
countered by steering in the opposite direc-
tion which results in still faster tread wear. the crown. These patches contain no
When tyre wear associated with camber fabric, they do not affect the local
results from road conditions and not from stiffness of the tyre and should not be
car condition little can be done except to mistaken for repair patches. They are
interchange or reverse the tyres. This will embossed " Balance Adjustment
prevent one-sided wear, irregular wear, and Rubber."
fast wear from developing to a maximum The original degree of balance is not
degree on any one tyre, usually the near necessarily maintained and it may be
front tyre. affected by uneven tread wear, by cover
Castor and king pin inclination by them- and tube repairs, by tyre removal and
selves have no direct bearing on tyre wear refitting or by wheel damage and
but their measurement is often useful for
providing a general indication of the con-
dition of the front end geometry and
suspension.
TYRE AND WHEEL BALANCE
(a) Static Balance
In the interests of smooth riding, pTe-
cise steering, and the avoidance of high
speed " tramp " or " wheel hop," all
Dunlop tyres are balance checked to
predetermined limits.
T o ensure the best degree of tyre
balance the covers are marked with
white spots on one bead, and these
indicate the lightest part of the cover.
Tubes are marked on the base with
black spots at the heaviest point. By
fitting the tyre so that the marks on the Fig. 15 Dunlop Tyre Balancing Machine.
cover bead exactly coincide with the
marks on the tube, a high degree of eccentricity. The car may also become
tyre balance is achieved (Fig. 14). more sensitive to unbalance due to
When using tubes which do not have normal wear of moving parts.
the coloured spots it is usually advan- If roughness or high speed steering
WHEELS AND TYRES
troubles develop, and mechanical in- eccentric wheels give the same effect.
vestigation fails to disclose a possible During rotation the offset weight dis-
cause, wheel and tyre balance should tribution sets up a rotating couple
be suspected. which tends to steer the wheel to
A Tyre Balancing Machine is marketed right and left alternately.
by the Dunlop Company to enable Dynamic unbalance of tyre and wheel
Service Stations to deal with such assemblies can be measured on the
cases. This is shown in Fig. 15; a Dunlop Tyre Balancing Machine and
second, marketed by Messrs. V. L. suitable corrections made when cars
Churchill Ltd., in Fig. 16. show sensitivity to this form of un-
balance. Where it is clear that a
(b) Dynamic Balance damaged wheel is the primary cause of
Static unbalance can be measured severe unbalance it is advisable for the
when the tyre and wheel assembly is wheel to be replaced.
stationary. There is another form
known as dynamic unbalance which 6. CHANGING POSITION OF TYRES
can be detected only when the assem- There have been references to irregular
bly is revolving. tread wear and there may be different rates
SPOKES X ; X ~ ~ ~ S ne.
W G
POSITION NV LENGTH BEND DUNLOPNQ
A &B 16 6'r' 30' 94fSP222
CG D 32 4 40' 95/5~222
NOMINAL INSET %
OUTSIDE DISH 3%:vr'
ELECTRICAL EQUIPMENT
MI
SECTION M
ELECTRICAL EQUIPMENT
INDEX
.
BATTERIES Page
Routine Maintenance ...... ...... ...... ...... ...... ...... 1
Service Data ...... ...... ...... ...... ...... .... ...... 1
Specific Gravity of Electrolyte ...... ...... ...... ..... 1
Servicing . . . . . . . . . . . . ...... ...... ...... ..... ...... ...... 2
Recharging from an External Supply . . . . . . . . . . . . ...... ...... 3
Preparing new unfilled, uncharged Batteries for Service ...... 3
Preparing GTZ " Dry-charged " Battkries for Service ...... 4
Battery Cable Connectors ..... ...... ..... ...... ...... 5
Description ......
Routine Maintenance
Performance Data
Servicing ......
T o Dismantle ......
Bench Inspection ......
Testing Field Coils
Bearings ...... ......
T o Assemble ......
INDEX
HEADLAMPS . Page
Description ...... ...... ...... ...... ...... ...... ...... 22
Bulb Replacement ...... ...... ...... ...... ...... ...... 23
Ministry of Transport Lighting Regulations ...... ...... ...... 23
Beam Setting ...... ...... ...... ...... ...... ...... ...... 23
Renewal of Light Unit . . . . . . . . . . . . ...... ...... ...... ...... 23
CONTROL BOX.
Description ...... ...... ......
Operation of Regulator ......
Operation of Cut-Out ...... ......
Servicing ...... ...... ......
Electrical Setting of Regulator
Mechanical Setting of Regulator
Cleaning Regulator Contacts
Electrical Setting of Cut-Out
Mechanical Setting of Cut-Out
Cleaning Contacts of Cut-Out
WINDSCREEN WIPER.
T o detach Cable Rack from Motor and Gearbox ...... ...... 28
Inspection of Commutation ...... ...... ...... ...... ...... 29
Inspection of Brush Gear ...... ...... ...... ...... ...... 29
WINDTONE HORNS .
Method of Operation ...... ...... ...... ...... ...... ...... 29
Adjustment ...... ...... ...... ...... ...... ...... ...... 30
Fault Location ...... ...... ...... ...... ...... ..... ...... 30
ILLUSTRATIONS
Page
Fig . 1 " Topping-up " Battery ...... ...... ...... ...... ...... 2
Fig . 2 Taking Hydrometer Readings ...... ...... ...... ...... 2
Fig . 3 Commutator End Bearing Lubrication ...... ...... ...... 5
Fig. 4 Checking Brush Gear ...... ...... ...... ...... ...- 6
Fig. 5 Testing Brush Spring Tension ...... ...... ...... ...... 7
Fig. 6 Dismantled view of Generator ...... ...... ...... ...... 7
Fig . 7 Showing Commutator Insulation Under-cutting ...... 8
Fig. 8 Method of Under-cutting Comrhutator ...... ...... ...... 8
Fig . 9 Tightening Pole Shoe Retaining Screws ...... ...... 9
Fig. 10 Method of fitting Porous Bronze Bearing Bush ...... 9
Fig. 11 Exploded view of Drive End Bearing ...... ...... ...... 10
Fig. 12 Internal Connections of the Starting Motor ...... ...... 10
Fig . 13 Checking Starting Motor Brush Gear ...... ...... ...... 10
Fig. 14 Testing Brush Spring Tension ...... ...... ...... ...... 11
Fig. 15 Method of measuring Stall Torque and Current ...... 12
Fig . 16 Showing Starting Motor Dismantled ...... ...... ...... 13
Fig. 17 C.E. Bracket Brush Connections ...... ...... ...... 14
Fig. 18 Testing for Open Circuit in the Field Coils ...... ...... 15
Fig . 19 Method of fitting Bearing Bushes ...... ...... ...... 15
Fig . 20 Exploded view of Starter Motor Drive Assembly ...... 17
Fig. 21 Exploded view of Distributor ...... ...... ...... ...... 17
Fig. 22 Fitting H.T. Cables ...... ...... ...... ...... ..... 18
Fig. 23 Headlamp with Front Rim and Dust Excluding Rubber
removed ...... ...... ...... ...... ...... ...... 22
Fig . 24 Replacement of Headlamp Bulb ...... ...... ...... ...... 22
Fig. 25 Diagram showing Headlamp Beam Setting ...... ...... 23
Fig. 26 Light Unit replacement ...... ...... ...... ...... 23
Fig. 27 Control Box with Cover removed ...... ...... ...... 24
Fig . 28 Internal Connections of Control Box ...... ...... ...... 24
Fig . 29 Cut-Out and Regulator Assembly ...... ...... ...... 26
Fig . 30 Mechanical Setting of Regulator ...... ...... ...... ...... 26
Fig . 31 Mechanical Setting of Cut-Out ...... ...... ...... ...... 27
Fig . 32 Sectioned view of Windscreen Wiper Motor ...... ...... 28
Fig . 33 Horn with Cover removed ...... ...... ...... ...... 29
Fig . 34 Wiring Diagram ...... ...... ...... ...... ...... 32
Fig . 35 Automatic Advance Curve ...... ...... ...... ...... 33
Fig. 36 Control Box with Cover removed ...... ...... ...... 33
Fig. 37 Internal Connections of Control BOX ..... ...... ...... 34
Fig . 38 Regulator Air Gap Settings ..... ..... ...... ...... 36
.
Fig 39 Cut-out Air Gap Settings ...... ...... ...... - 37
ELECTRICAL EQUIPMENT
BATT.ERIES Some earlier batteries incorporated correct-
Models GTW7A/2, GTW9A/2, GT9A/2 and acid-level devices for ease of topping up.
GTZ9A/2. These consist of a central plastic tube with
I. ROUTINE MAINTENANCE
a perforated flange-one being located in
Every 1,000 miles, or monthly (weekly in each cell filler hole. The method of topping
hot climates) examine the level of the up is as follows :-
electrolyte in'the cells, and if necessary add Pour distilled water into the perforated
distilled water to bring the level up to the flange not down the central tube of the
top of the separators. A convenient correct-acid-level device until no more
method of adding the distilled water is by water will enter the cell and the water
means of the Lucas Battery Filler, a device begins to rise in the filling hole. This will
which automatically ensures that the correct happen when the electrolyte level reaches
level is attained. The action of resting the the bottom of the central tube and prevents
nozzle of the battery filler on the separators further escape of air displaced by the
opens a valve and allows distilled water to topping-up water. Lift the tube slightly and
flow into the cell, this being indicated by air allow the small amount of visible water in
bubbles rising in the filler. When the the filling hole to drain into the cell.
correct level has been reached air bubbles
cease and the battery filler can then be WARNING : Do not repeat these operations.
withdrawn from the cell. A special non- The acid level will be correct and the rubber
spill nozzle prevents leakage from the filler. plugs can be refitted.
2. SERVICE DATA
(a) Capacity and Charging Rates
GTW7A/2 7 38 43 (Pint) 24 4
GT9A/2
GTw9A'2
GTZ9A/2 I 51 58 1 (Pint) 34 5
Cleanliness
See that the top of the battery is free
from dirt or moisture which might
provide a discharge path. Ensure that
the battery connections are clean and
tight.
\_ lH &
Fig. I Topping up Battery.
1111 READINGS HOLD TUBE
AT EYE LEVEL VERTICALLY
N.B.-Never use a naked l%ht when examin- DO NOT DRAW
ing a battery, as the mixture of I N TOO MUCH
oxygen and hydrogen given off by I \ , ELECTROLYTE
2. ROUTINE MAINTENANCE
6. BATTERY CABLE CONNECTORS (a) Lubrication
When fitting the diecast cable connectors, Every 12,000 miles, inject a few drops
smear the inside of the tapered hole with of Oiline BBB, or any high quality
petroleum jelly and push on the connector medium viscosity (S.A.E.30) engine
by hand. Insert the self-tapping screw and oil into the hole marked " oil " in the
end of the bearing housing.
tighten with medium pressure only ; fill On earlier models, unscrew the cap
in the recess around the screw with more of the lubricator on the side of the
petroleum jelly. bearing housing, lift out the felt pad
and spring and about half-fill the
If the connectors are fitted dry and driven lubricator with high melting point
home on the tapered battery posts too grease (H.M.P. Grease). Replace the
tightly, difficulty may be experienced when spring and felt pad and screw the
it is required to remove them. lubricator cap back into position.
ELECTRICAL EQUIPMENT
(c) Belt Adjustment
Occasionally inspect the generator driv-
ing belt. If necessary, adjust to take up
any undue slackness by turning the
generator on its mounting.
Care should be taken to avoid over-
tightening the belt, which should have
just sufficient tension to drive without
slipping.
See that the machine is properly
aligned, otherwise undue strain will
be thrown on the generator bearings.
3. PERFORMANCE DATA
Cutting-in speed 1.050- 1,200 r.p.m. at 13
generator volts. Maximum output:- 19
Fig. 4 Checking Brush Gear. amps at 1,900-2,150 r.p.m. at 13.5 generator
volts (on resistance load of 0.7 ohm).
(b) Inspection of Brush Gear and Field resistance 6.1 ohms.
Commutator
At the same time, remove the metal 4- SERVICING
band cover to inspect the brushgear (a) Testing in position to locate fault
and commutator. Check that the in charging circuit
brushes move freely in their holders
by holding back the brush springs In the event of a fault in the charging
and pulling gently on the flexible circuit, adopt the following procedure
connectors. If a brush is inclined to locate the cause of the trouble.
to stick, remove it from its holder (i) Inspect the driving belt and adjust
and clean its sides with a petrol- if necessary (see Para. 2 (c)).
moistened cloth. Be careful to replace
brushes in their original positions in (ii) Check that the generator and con-
order to retain the " bedding." trol box are connected correctly.
In service, brush wear takes place and The larger generator terminal
the brushes become shorter. If the must be connected to control box
brushes are permitted to wear down terminal " D " and the smaller
until the embedded ends of the flexible generator terminal to control box
connectors are exposed at the running terminal " F ". Check the earth
surface, serious damage can occur to connection to control box ter-
the commutator. It is therefore minal " E ".
important to measure from time to
time the length of each brush. If this (iii) Switchoff all lights and accessories,
length, measured from the running disconnect the cables from ter-
surface to the top edge of the brush, minals of generator and connect
has decreased 10 $&" the brush (or the two terminals with a short
brushes) should be replaced. length of wire.
The commutator should be clean, (iv) Start the engine and set to run at
free from oil or dirt and should have normal idling speed.
a polished appearence. If it is dirty,
clean it by pressing a fine dry cloth (v) Clip the negative lead of a moving
against it while the engine is slowly coil type voltmeter, calibrated O-
turned over by hand. If the comrnu- 20 volts, to one generator terminal
tator is very dirty, moisten the cloth and the other lead to a good
with petrol. earthing point on the yoke.
ELECTRICAL EQUIPMENT
(vi) Gradually increase the engine this value to fall to 15 oz. before
speed, when the voltmeter reading performance may be affected. Fit
should rise rapidly and without new springs if the tension is low.
fluctuation. Do not allow the If the commutator is blackened
voltmeter reading to reach 20 or dirty, clean it by holding
volts and do not race the engine a petrol-moistened cloth against
in an attempt to increase the it while the engine is turned
voltage. It is sufficient to run slowly by hand cranking. Re-test
the generator up to a speed of the generator as in (vi) ; if there
1,000 r.p.m. is still no reading on the voltmeter,
If there is no reading, check there is an internal fault and the
the brush gear as described in complete unit, if a spare is avail-
(vii) below. If there is a low able, should be replaced. Other-
reading of approximately +--1 wise the unit must be dismantled
volt, the field winding may be (see Para. 4 (b)) for internal exam-
at fault (see Para. 4 (e)). If there ination.
is a reading of approximately (viii) If the generator is in good order,
half the nominal voltage the arm- remove the link from between the
ature winding may be at fault (see terminals and restore the original
Para. 4 (d)). connections, taking care to connect
(vii)Remove the cover band and the larger generator terminal to
examine the brushes and commu- control box terminal "D " and the
tator. Hold back each brush smaller generator terminal to con-
spring and move the brush by trol box terminal " F ".
pulling gently on its flexible con-
nector. If the movement is
sluggish, remove the brush from
its holder and ease the sides
by lightly polishing on a smooth
file. Always replace the brush
in its original position. If a
brush has worn to &" in length
a new brush must be fitted and
bedded to the commutator. Fig. 6 Dismantled View of Generator (Yoke cut
away to show Interior).
(b) To Dismantle
(i) Take off the driving pulley.
(ii) Remove the cover band, hold
back the brush springs and remove
the brushes from their holders.
(iii) Unscrew and withdraw the two
through bolts.
(iv) The commutator end bracket can
Fig. 5 Testing Brush Spring Tension. now be withdrawn from the gener-
ator yoke.
Test the brush spring tension
with a spring scale. The tension (v) The driving end bracket togethcr
of the springs when new is 22-25 with the armature can now be
oz. In service it is permissible for lifted out of the yoke.
ELECTRICAL EQUIPMENT
(vi) The driving end bracket, which (d) Armature
on removal from the yoke has The testing of the armature winding
withdrawn with it the armature requires the use of a volt-drop test
and armature shaft ball-bearing, and growler. If these are not available
need not be separated from the the armature should be checked by
shaft unless the bearing is sus- substitution. No attempt should be
pected and requires examination, made to machine the armature core
or the armature is to be replaced ; or to true up a distorted armature shaft.
in this event the armature should To remove the armature shaft from
be removed from the end bracket the drive end bracket and bearing,
by means of a hand press. support the bearing retaining plate
firmly and press the shaft out of
(c) Commutator the drive end bracket. When fitting
the new armature, support the inner
A commutator in good condition will journal of the ball bearing whilst
be smooth and free from pits or pressing the armature shaft firmly
burned spots. Clean the commutator home.
with a petrol-moistened cloth. If
this is ineffective, carefully polish
with a strip of fine glass paper while (e) Field Coils
rotating the armature. To remedy a Measure the resistance of the field
coils, without removing them from
INSULATOR SEGMENTS INSULATOR the generator yoke, by means of an
ohm meter connected between the
field terminal and yoke. The ohm
meter should read 6.1 ohms approxi-
R I G H T WAY WRONG WAY mately. If an ohm meter is not
Fig. 7 Showing the Correct and Incorrect Ways available, connect a 12 volt D.C.
of undercutting Commutator Insulation. supply with an ammeter in series
between the field terminal and gener-
ator yoke. The ammeter reading
badly worn commutator, mount the should be approximately 2 amperes.
armature, with or without the drive No reading on the ammeter, or an
end bracket, in a lathe, rotate at infinite ohm meter reading, indicates
high speed and take a light cut with an open circuit in the field winding. If
a very sharp tool. Do not remove the current reading is much more than
more metal than is necessary. Polish the 2 amperes, or the ohm meter reading
comm'utator with very fine glass paper. much below 6.1 ohms, it is an indi-
Undercut the insulators between the cation that the insulation of one of
segments to a depth of &" with a hack the field coils has broken down.
saw blade ground down to the thickness In either case, unless a substitute
of the insulator generator is available, the field coils
must be replaced. T o do this, carry
out the procedure outlined below,
using a wheel-operated screwdriver.
SUPPORTING BLOCK
11
ELECTRICAL EQUIPMENT
(b) Bench-testing (iii) Measuring lock torque and
(i) Removing the starting motor lock current
from the engine : WLES FOR YDIA YORE C L A M P W O E FROM
CLAMPING M T S 3' CHANNEL !RON MACHINED
m WIT A N Y PARTICULAR YOKE
Speed, torque and current consumption low. High resistance in brushgear, e.g., faulty
connections, dirty or burned commutator
causing bad brush contact.
Speed and torque low, current consumption Tight or worn bearings, bent shaft, in-
high. sufficient end play, armature fouling a pole
shoe, or cracked spigot on drive end bracket.
Short-circuited armature, earthed armature
or short-circuited field coils.
Speed and current consumption high, torque Short-circuited field coils.
low.
Armature does not rotate, no current con- Open-circuited armature or field coils. If
sumption. the commutator is badly burned there may
be poor contact between brushes and com-
mutator.
Armature does not rotate, high current Earthed field winding. Armature prevented
consumption. mechanically from rotating.
Excessive brush movement causing arcing at Low brush spring tension, worn or out-of-
commutator. round commutator, " Thrown " or high
segment on commutator.
Excessive arcing at the commutator. Defective armature windings.
If any fault is indicated, the motor must be dismantled, see Para. 4 (c) and a fiuther
check made.
Insulation Test :
Connect an ohm meter or a
110-volt a.c. test lamp between
the terminal post and a clean part
of the yoke.
Lighting of the test lamp or a
low ohmic reading indicates that
the field coils are earthed to the
yoke and must be replaced.
Fig. 19 Method of fitting Bearing Bushes.
Replacing the field coils :
Unscrew the four pole-shoe re- Press the bearing bush out of the
taining screws, using a wheel- end bracket.
operated screwdriver. Press the new bearing bush into
Remove the insulation piece which the end bracket, using a should-
is fitted to prevent the inter-coil ered, highly polished mandrel of
connectors from contacting with the same diameter as the shaft
the yoke. Mark the yoke and pole- which is to fir in the bearing.
ELECTKICAL EQUIPMENT
Porous bronze bushes must not The torque through the rubber limits the
be opened out after fitting or the total torque which the drive transmits and
porosity of the bush may be since the rubber is bonded to the inner
impaired. sleeve, under overload conditions slipping
NOTE : Before fitting a new will occur between the rubber bush and the
porous bronze bearing bush it outer sleeve of the coupling. Slipping does
should be completely immersed not take place under normal engagement
for 24 hours in clean, thin conditions, when the rubber acts merely as
engine oil. In cases of extreme a spring with a limiting relative twist on the
urgency this period may be two members of approximately 30".
shortened by heating the oil to Under conditions of unduly severe overload
100°C. for 2 hours, then allow- 'which might cause damage to the drive or
ing to cool before removing the its mounting, the rubber slips in its housing
bearing bush. so that a definite upper limit is set to the
(e) Re-assembly torque transmitted and to the stresses
which may occur.
This is, in the main, a reversal of the
procedure given in Para. q (c) for
dismantling.
2. ROUTINE MAINTENANCE
Commutator end bracket replacement :
The starting motor is designed for If any difficulty is experienced with the
clockwise rotation, indicated by the starting motor not meshing correctly with
arrow on the yoke. Press out the the flywheel, it may be that the drive
through bolt indentations marked cc C " requires cleaning. The pinion should move
on the replacement bracket. freely on the screwed sleeve ; if there is any
Press the locating dowel into the dirt or other foreign matter on the sleeve it
appropriate hole marked cc C." must be washed off with paraffin.
Insert the through bolts into the holes In the event of the pinion becoming jammed
made in the bracket and tighten the in mesh with the flywheel, it can usually be
bracket to the yoke. freed by turning the starter motor armature
by means of a spanner applied to the shafi
STARTING MOTOR DRIVE extension at the commutator end. This is
I. GENERAL accessible by removing the cap which is a
The drive embodies a combination of push fit.
rubber torsion member and fiction clutch
in order to control the torque transmitted 3. CONSTRUCTION
from the starter to the engine flywheel and The construction of the drive will be clear
to dissipate the energy in the rotating from the illustration. The pinion is carried
armature of the starter at the moment when on a barrel type assembly which is mounted
the pinion engages with the flywheel. on a screwed sleeve.
It also embodies an overload release
mechanism which functions in the event of The screwed sleeve is secured to the
extreme stress, such as may occur in the armature shafi by means of a location nut
event of a very heavy backfire, or if the and is also keyed to the inner sleeve of the
starter is inadvertently meshed into a fly- rubber coupling by a centre coupling plate.
wheel, rotating in the reverse direction. A friction washer is fitted between the
When the starter is energised, the torque is coupling plate and rubber assembly and the
transmitted by two paths, one via the outer outer sleeve of the rubber coupling is keyed
sleeve of the rubber coupling and at the armature end of the starter by means
through the friction washer to the screwed of a transmission plate.
sleeve, while the other path is from the A pinion restraining spring is fitted in the
outer to the inner sleeve through the rubber barrel assembly to prevent the pinion
coupling and then directly to the screwed vibrating into mesh when the engine is
sleeve. lxlming.
ELECTRICAL EQUIPMENT
RUBBER RETAINING SLEEVE the centrifugal force imparted by in-
UNIT ASSEMBLY RING
creasing engine speed, the governor weights
swing out against the spring pressure to
advance the contact breaker cam and
thereby the spark, to suit engine con-
ditions at the greater speed.
A built-in vacuum-operated timing control
FRICTION WASHER COUPLING RESTRAINING FRICTION LOCATING LOCATING
PLATE SPRING WASHER NUT RING is also included, designed to give additional
Fig. 20 Exploded view of Starter Motor Drive advance under part-throttle conditions. The
Assembly. inlet manifold of the engine is in direct
communication with one side of a spring-
4. DISMANTLING loaded diaphragm. This diaphragm acts
through a lever mechanism to rotate the
Having removed the armature as described heel of the contact breaker about the cam,
in the section dealing with starting motors, thus advancing the spark for part-throttle
the drive can be dismantled as follows :-
Remove the locating cover (A) and then
..
~
\
withdraw the locating ring (B) from the \
starter shaft at the end of the starter drive. ROTOR @ \ L .TTERMINAL
5. RE-ASSEMBLY
The re-assembly of the drive is a reversal
of the dismantling procedure.
17
operating conditions. There is also a
micrometer adjustment by means of which
fine alterations in timing can be made to
allow for changes in running conditions,
e.g., state of carbonisation, change of fuel,
etc.
A completely sealed metallised paper
capacitor is utilised. This has the property
of being self-healing ; should the capacitor
break down, the metallic film around the
point of rupture is vaporised away by the
heat of the spark, so preventing a per-
manent short circuit. Capacitor failure
will be found to be most infrequent. SCREW SECURING \
CABLE
The H.T. pick-up brush is of a composite Fig. 22 Fitting H.T. Cables.
construction, the top portion consisting of a
resistive compound and the lower of softer
carbon to prevent wear taking place on the bearing. It is not necessary to remove
rotor electrode. The resistive portion of the exposed screw, since it affords a
this carbon brush which is in circuit clearance to permit the passage of oil.
between the coil and the distributor gives a Replace the rotor arm carefully, locat-
measure of radio interference suppression. ing its moulded projection in the
Under no circumstances must a short non- keyway in the spindle and pushing it
resistive brush be used as a replacement for on as far as it will go.
one of these longer resistive brushes.
The Pre-tilted Contact Breaker Unit (b) Cleaning--every 6,000 miles
During 1955 an improved contact breaker Thoroughly clean the moulded dis-
unit was introduced on the DM2P4 distri- tributor cover, inside and out, with a
butor. Important features of this pre-tilted soft dry cloth, paying particular atten-
contact breaker unit are : improved sensi- tion to the spaces between the metal
tivity of vacuum control and elimination of electrodes. Ensure that the carbon
any tendency for the moving contact brush moves freely in its holder.
breaker plate to rock at high cam speeds. Examine the contact breaker. The
Contact adjustment has also been simplified. contacts must be quite free from
grease or oil. If they are burned or
blackened, clean them with very fine
2. ROUTINE MAINTENANCE carborundurn stone or emery cloth,
In general, lubrication and cleaning con- then wipe with a petrol-moistened
stitute normal maintenance procedure. cloth. Cleaning is facilitated by re-
moving the contact breaker lever. T o
.(a) Lubrication--every 3,000 miles do this, remove the nut, washer,
Take great care to prevent oil or insulating piece and connections from
grease from getting on or near the the post to which the end of the contact
contacts. breaker spring is anchored. The contact
Add a few drops of thin machine oil breaker lever may now be removed
through the aperture at the edge of from its pivot. Before refitting the
the contact breaker to lubricate the contact breaker, smear the pivot post
centrifugal timing control. with Ragosine Molybdenised non-creep
oil or Mobilgrease No. 2. After
Smear the cam with Mobilgrease cleaning, check the contact breaker
No. 2. setting. Turn the engine by hand until
Lift off the rotor arm and apply to the the contacts show the maximum open-
spindle a few drops of Ragosine ing. This should measure 0.014" to
Molybdenised ,non-creep oil or thin 0.016". If the measurement is in-
machine oil to lubricate the cam correct, keep the engine in the position
ELECTRICAL EQUIPMENT
giving maximum opening, slacken the 4. SERVICING
screw(s) securing the fixed contact
plate and adjust its position to give the Before starting to test, make sure that the
required gap. Tighten the screw(s). battery is not fully discharged, as this will
Recheck the setting for other positions often produce the same symptoms as a
of the engine giving maximum opening. fault in the ignition circuit.
HEADLAMPS-MODEL F ~ O MK/M O
r. General Description
The lamps incorporate a combined reflector /
Light Unit. They are fitted with a " pre- Fig. 24 Replacement of Headlamp Bulb.
focus " bulb which ensures that the filament
is always positioned correctly with respect thus ensuring the correct positioning
to the focal point of the reflector. of the filament. A bayonet-fitting cap
(a) Light Unit with spring-loaded contacts secures the
The construction of the Light Unit bulb firmly in position and also carries
ensures that the reflector surface is the supply to the bulb contacts.
ELECTRICAL EQUIPMENT
2. BULB REPLACEMENT T o adjust the vertical setting, turn
Slacken the captive securing screw at the the screw at the top of the lamp
bottom of the front rim and remove the clockwise to raise the beam and anti-
front rim and dust-excluding rubber. clockwise to lower the beam. Adjust-
T o remove the Light Unit assembly from ment in the horizontal plane is effected
the three spring-loaded screws, press the by turning the two spring-loaded
Unit inwards, turning it anti-clockwise to screws at the sides of the Light Unit.
disengage the slotted holes in the seating
rim from the setting adjustment screws.
Disengage the bayonet 'fitting cap and
withdraw the defective bulb from the
Light Unit.
Re-assembly of the Light Unit to the lamp
is a reversal of the above procedure.
CENTRE LINE DISTANCE BETWEEN CONCENTRATED
OF VEHICLE CENTRES OF HEADLAMPS AREA OF LIGHT
r I 1 I
i11 I , I) '
HEK;M
FROM
OF CENTRES
OF LAMPS
GROUND
The Regulator
The regulator is set to maintain the
generator terminal voltage between close
limits at all speeds above the regulating
point, the field strength being controlled
by the automatic insertion and withdrawal
of a resistance in the generator field circuit.
When the generator voltage reaches a pre-
determined value, the magnetic flux in the
regulator core due to the shunt or voltage
winding becomes sufficiently strong to
attract the armature to the core. This
causes the contacts to open, thereby in-
serting the resistance in the generator field
circuit. CONTROL BOX
The consequent reduction in the generator Fig. 28 Internal Connections.
field current lowers the generator terminal
voltage and this, in turn, weakens the mag-
netic flux in the regulator core. The shown in Fig. 28, a split series winding is
armature therefore returns to its original used, terminal A being connected to the
position, and the contacts closing allow the battery and terminal A1 to the lighting and
generator voltage to rise again to its ignition switch.
maximum value. This cycle is then re- By means of a temperature compensation
peated and an oscillation of the armature device the voltage characteristic of the
is maintained. generator is caused to conform more closely
As the speed of the generator rises above to that of the battery under all climatic
that at which the regulator comes into conditions. In cold weather the voltage
operation, the periods of contact separation required to charge the battery increases,
increase in length and, as a result, the mean whilst in warm weather the voltage of the
value of the generator voltage undergoes battery is lower. The method of compen-
practically no increase once this regulating sation takes the form of a bi-metallic spring
speed has been attained. located behind the tensioning spring of the
The series or current winding provides a regulator armature. This bi-metallic
compensation on this system of control, for spring, by causing the operating voltage of
if the control were arranged entirely on the the regulator to be increased in cold weather
basis of voltage there would be a risk of and reduced in hot weather, compensates
seriously overloading the generator when for the changing temperature-character-
the battery was in a low state of charge, istics of the battery and prevents undue
particularly if the lamps were simultaneously variation of the charging current which
m use. would otherwise occur.
ELECTRICAL EQUIPMENT
The bi-metallic spring also compensates two windings and partly demagnetise the
for effects due to increases in resistance of electro-magnet. The spring, which is under
the copper windings from cold to working constant tension, then pulls the armature
values. away from the magnet and opens the cir-
cuit. The contacts opening prevent further
The Cut-out discharging of the battery through the
generator.
The cut-out is an electro-magnetically
operated switch connected in the charging Like the regulator, operation of the cut-out
circuit between the generator and the is temperature-controlled by means of a
battery. Its hnction is automatically to con- bi-metallic tensioning spring.
nect the generator with the battery when the
voltage of the generator is sufficient to 2. SETTING DATA
charge the battery, and to disconnect it
when the generator is not running, or when (a) Regulator
its voltage falls below that of the battery, Open-circuit setting at 20°C. and
and so prevent the battery from discharging 1,500 dynamo r.p.m. : 15.6-16.2
through and possibly damaging the genera- volts.
tor windings. Note : For ambient temperatures other
The cut-out consists of an electro-magnet than 20°C., the following allowances
fitted with an armature which operates a should be made to the above setting :
pair of contacts. The electro-magnet em- For every 10°C. (18°F.) above
ploys two windings, a shunt winding of 20°C., subtract 0.3 volt.
many turns of fine wire, and a series For every 10°C. below 20°C.,
winding of a few turns of heavier gauge add 0.3 volt.
wire. The contacts are normally held open
and are closed only when the magnetic pull (b) Cut-out
of the magnet on the armature is sufficient
to overcome the tension of the adjusting Cut-in voltage : 12.7-13.3
spring. Drop-off voltage : 8.5-10.0
The operation of the cut-out is as follows : Reverse current : 3.5-5.0 amp.
The shunt coil is connected across the
generator. When the vehicle is starting, 3. SERVICING
the speed of the engine, and thus the
voltage of the generator, rises until the Testing i n Position to Locate Fault
electro-magnet is sufficiently magnetised to i n Charging Circuit
overcome the spring tension and close the If the generator and battery are in
cut-out contacts. This completes the circuit order, check as follows :-
between the generator and the battery
through the series winding of the cut- (i) Ensure that the wiring between
battery and regulator is in order.
out and the contacts. The effect of the To do this, disconnect the wire
charging current flowing through the cut- from the A terminal of the control
out windings creates a magnetic field in the box and connect the end of the
same direction as that produced by the wire removed to the negative
shunt winding. This increases the mag- terminal of a voltmeter.
netic pull on the armature so that the Connect the positive voltmeter
contacts are firmly closed and cannot be terminal to an earthing point on
separated by vibration. When the vehicle the chassis. If a voltmeter reading
is stopping the speed of the generator is is given, the wiring is in order and
decreased until the generator voltage is the regulator must be examined.
lower than that of the battery. Current then
flows from the battery through the cut-out (ii) If there is no reading, examine the
series winding and generator in a reverse wiring between battery and con-
direction to the charging current. This trol box for defective cables or
reverse current through the cut-out will loose connections.
produce a differential action between the (iii)Re-connect the wire to terminal A.
ELECTRICAL EQUIPMENT
(b) Regulator Adjustment If the voltage at which the reading
The regulator is carefully set during becomes steady occurs outside
manufacture and, in general, it should these limits, the regulator must be
not be necessary to make further adjusted.
adjustment. If, however, the battery
does not keep in a charged condition, ARMATURE
FIXING SCREWS
or if the generator output does not REGULATOR
fall when the battery is fully charged, FRAME 0.020" ,ARMATURE
N BROWN 17 HORNS
18 DIPPER SWITCH
U BLUE 19 HORN PUSH AND DIRECTION INDICATOR
SWITCH
B BLACK 20 HEADLAMP
21 SIDE (PARKING) AND FLASHER LAMP
22 FLASHER UNIT
23 CONTROL BOX
24 SOLENOID STARTER SWITCH
25 STARTER MOTOR
26 12V. BATTERY
27 GENERATOR
28 IGNITION SWITCH
29 STARTER SWITCH
30 AMMETER
31 PANEL LAMP
32 TEMPERATURE GAUGE
33 WI)ffiSCREEN WIPER MOTOR
34 SCREEN WIPER SWITCH
35 IGNITION WARNING LAMP
36 FLASHER WARNING LAMP
37 PANEL LIGHTING SWITCH
38 PANEL LAMP
39 LIGHTING SWITCH
40 FUEL GAUGE
41 FUSE (FITTED U.S.A. ONLY)
42 OIL PRESSURE GAUGB
OVERDRIVE ONLY:
Fig. 44.
43 STEERING COLUMN SWITCH
44 RELAY UNIT
45 TO A ON CONTROL BOX
47 OVERDRIVE SOLBNOID
Fig. 44. \Viring Diagram 48 TO IGNITION VIA A3 ON FUSE UNIT
for Overdrive Unit.
ELECTRICAL EQUIPMENT
BODY
SECTION N
BODY
INDEX
Page
Body Mounting Points...... ...... ...... ...... ...... ...... ...... 1
To remove Body ...... ...... ...... ......
...... ...... ...... 1
To fit Body ...... ...... ...... ...... ......
...... ...... ...... 2
Battery Box Drain ...... ...... ...... ...... ...... ...... ...... 2
T o remove and Dismantle Front Bumper ...... ...... ...... ..... 2
T o fit Front Bumper . . . . . . . . . . . . ...... ...... ...... ...... ...... 3
T o remove Rear Over-Riders and Brackets . . . . . . . . . . . . ...... ...... 3
To fit Rear Over-Riders ...... ...... ...... ...... ...... ...... 3
To remove Front Wing ...... ...... ...... ...... ...... ...... 4
To fit Front Wing ...... ...... ...... ...... ...... ...... ...... 4
T o remove Rear Wing ...... ...... ...... ...... ...... ...... 4
To fit Rear Wing ...... ...... ...... ...... ...... ...... ...... 4
T o remove Bonnet Lid ...... ...... ...... ...... ...... ...... 4
T o fit Bonnet Lid ...... ...... ..... ...... ...... ...... ...... 4
To remove Front Apron ...... ...... ...... ...... ...... ...... 5
T o fit Front Apron ...... ...... ...... ...... ...... ..... ...... 5
Adjustment of Bonnet Locks ...... ...... ...... ...... ...... ...... 5
T o remove Windscreen ...... ...... ...... ...... ...... ...... 5
To fit Windscreen ...... ...... ...... ...... ...... ...... ...... 6
T o fit Aero-Windscreen ...... ...... ...... ...... ...... ...... 6
T o remove Door ...... ...... ...... ...... ...... ...... ...... 6
T o fit Door ...... ...... ...... ...... ...... ...... ...... 6
Front Door sealing ...... ...... ...... ...... ...... ...... ...... 6
To remove Door Lock ...... ...... ...... ...... ...... ...... 6
T o fit Door Lock ...... ...... ...... ...... ...... ...... ...... 6
T o remove Gearbox Tunnel ...... ...... ...... ...... ...... 7
To fit Gearbox Tunnel ...... ...... ...... ...... ...... ...... 8
T o remove Hood and Fittings ...... ...... ...... ...... ...... 8
T o fit Hood and Fittings ...... ...... ...... ...... ...... ...... 8
Water Sealing of Hood Seams ...... ...... ...... ...... ...... 8
Adjustment of Side Curtains . . . . . . . . . . . . ...... ...... ...... ...... 9
T o prepare car for Fibreglass Hard Top Canopy . . . . . . . . . . . . ...... 9
Fitting Fibreglass Hard Top Canopy ...... ...... ...... ...... 10
To remove Fibreglass Hard Top Canopy . . . . . . . . . . . . ...... ...... 11
To remove and Dismantle Luggage Boot Lid ...... ...... ...... 11
To fit Luggage Boot Lid ...... ...... ...... ...... ...... 11
T o remove and Dismantle Spare Wheel id' ...... ...... ...... 11
To assemble Spare Wheel Lid ...... ...... ...... ...... 11
T o fit Smiths Circular Heater CHS 92014 . . . . . . . . . . . . ...... ...... 12
LIST OF ILLUSTRATIONS
Page Page
.
Fig 1 Body mounting points. . . . . . . . . . . . 1 Fig. 9 Assembling water pipe connectors 12
Fig. 2 Battery box drain ...... ...... 3 Fig. 10 Releasing steering support rod ...... 12
Fig. 3 Front door water sealing ...... 7 Fig. 11 Location of heater control switch 13
Fig. 4 Hard top windscreen brackets ...... 9 Fig. 12 The heater unit ready for assembly 13
Fig. 5 Bridge pieces in position ...... 10 Fig. 13 Fitting heater hoses ...... ...... 14
Fig. 6 Protection caps in position ..... 10 Fig. 14 Heater unit in position . . . . . . . . . . . . 14
Fig. 7 Hard top rear attachments ...... 10 Fig.15 Showing position water pipes ...... 14
Fig. 8 Fitting tap extension ...... ...... 12 Fig. 16 Exploded view of heater kit ...... 15
BODY
(g) Front outrigger brackets.
ATTACHMENT DETAILS PACKINGS. Four square pads each side.
WASHFK AND BOLT
(h) Along rear cruciform member.
One strip with hole each side.
(i) Rear outrigger brackets.
Four square pads each side.
WASHERS AND BOLTS
IALUM PKG.
\ u
(j) Rear of rear wheel. Wing valance to
chassis frame.
d - I STRIP
WASHER AND BOLT
e-lPAD
A metal stay secured to wing and
chassis frame bracket by bolts, nuts
and lock washers at each side.
WASHERS
(k) Rear end of chassis frame.
One pad at each side.
Fig. 2 Illustration giving details of Battery Box Drain for modifying cars prior to Commission No. T.S. 3288.
(d) The bumper can now be lifted away head of the lower steering column
from its support brackets and the four trunnion bracket bolt and the other
metal vackin~s and the two centre end under the head of the front
bolts cdlectedu. bumper support bracket bolt.
(b) The four strips of moulding should be
(e) Withdraw two bolts from each pair of placed between the contact edges of
support brackets and chassis frame to the over-riders and the bumper bar.
release the four brackets. The two
brackets on the steering column side 7. TO REMOVE REAR OVER-RIDERS
have a secondary support from the AND BRACKETS
lower steering column trunnion bracket
bolt, and it may be necessary to loosen (a) Release the over-riders by loosening
this bolt before the bumper support the nuts and then slide the o ver-riders
brackets on that side can be removed off.
(b) Hold the head of the lower attachment
bolt under the car and remove the
6. TO FIT FRONT BUMPERS nut, lock and plain washer and bolt.
Whilst it is possible to build the bumper (c) Hold the nut of the upper attachment
assembly on the bench and then fit it to bolt and withdraw bolt through the
the car as a unit, it may be considered distance piece and support bracket.
desirable to fit the support brackets to the Collect the nut and plain washer and
chassis frame and then fit the bumper to remove distance piece from body of
the brackets. car.
The fitting procedure is the reverse of that g. TO FIT REAR OVER-mERS
for dismantling, but the following points (a) Attach the support bracket to the
should be noted. chassis frame first at its bottom point
(a) That an additional support is fitted to by feeding the attachment bolt thrbugh
the brackets on the steering column the chassis frame into the bracket and
side. This is a short plate with holes attaching a plain and lock washer, but
at each end. One end is fitted under the leave the nut loose at this juncture.
BODY
(b) Position the distance piece in the car 11. TO REMOVE REAR WING
body. Feed the bolt through the (a) Disconnect battery.
support bracket and a plain washer and
thence into the distance piece, follow- Remove rear light unit by withdrawing
ing with a second plain washer and two fixing screws and disconnecting the
then secure with a nut. wires at the snap connectors. These
will need identification marks if the
(c) The lower attachment can now be code colours of the harness are not
tightened. distinguishable.
(d) The over-rider attachment bolts are
positioned in the brackets together (c) Jack up the car and remove the
with the plain and lock washers and appropriate road wheel.
nuts. The over-rider has a " key-hole " (d) Withdraw nine bolts from inside the
shaped aperture to accommodate the e g running from the top of the
head of the attachment bolt, the nut W E I ~to the lower front edge.
of which is tightened when the over-
rider is in position. (e) Remove five bolts from inside the rear
luggage compartment.
9. TO REMOVE FRONT WING (f) Release winglchassis stay by removing
(a) Jack up the car and remove the appro- nut, bolt, lock and plain washer.
priate road wheel. (g) Loosen three bolts on fixing flange of
(b) Withdraw the six bolts securing front wing at extreme rear end.
wing to apron and the five bolts, the (h) The wing can now be removed in a
heads of which face the tyre tread. backward direction and the sealing
(c) Remove the six bolts from on top of strip collected.
the wing, these are situated just
beneath the side of the bonnet lid. 12. TO FIT REAR WING
(d) Remove the door by withdrawing the This is the reversal of the removal but care
seven bolts attaching the hinges to the should be taken when replacing the sealing
door post and withdraw the nut and strip and the electrical wires, the latter
bolt from the door check strut. This should be carried out with regard to the
gives access to six bolts at the extreme diagram in the cc Electrical Equipment ",
rear of the wing, these can now be Section M, or to the special identification
removed. markings.
(e) Remove the rubber grommet from
inside the car and withdraw the bolt 130 TO REMOVE THE BONNET LID
from inside the aperture.
*
(a) Release the bonnet locks either side by
(f) Remove the bulkhead sealer plate after cable or by turning the Dzuz fastener
withdrawing the five bolts from under and leave the bonnet resting in this
the wing at rear of arch. Withdraw the lower position.
three bolts situated underneath the
sill and behind the arch opening. (b) Remove the four nuts and washers
(two to each hinge) from under the
(g) Free the lower rear end of the wing by
pulling outward, then lift to disengage dash inside the car.
the flange of the wing abutting the dash (c) With an operator each side of the car
panel. lift the lid squarely upwards.
10. TO FIT FRONT WING
This is the reversal of the removal but care 14. TO FIT THE BONNET LID
should be taken to ensure all joints are The fitting is the reversal of the removal.
watertight and that the door closes correctly. If the locks are cable operated the instruc-
The sealing bead strip between the wing tions on " Adjustment of Bonnet Locks ",
and apron is fitted with its hole uppermost, page 5, should be followed.
BODY
IS. TO REMOVE FRONT APRON apron and the remaining slotted holes
(a) Open the bonnet by releasing the locks are adjacent to the lower holes.
from inside the car, or cars after (b) The electrical wires are connected
Commission No. TS.4229 fitted with with regard to their colour identifica-
Dzuz fasteners at the forward comers tions and the wiring diagram as found
of the bonnet lid by use of the carriage in the "Electrical Equipment", Section
key. Prop the bonnet open and M, or the special identifications if
disconnect battery. the colours are not distinmishable.
(b) Remove four bolts (two each side),
which secure the top apron re- (c) On completion of the fitting the bonnet
enforcement bar to the " U " brackets, lid must be lowered gently to ascertain
situated on top of the front wings. that the lock plungers and locks align
correctly. (See notes below).
(c) Disconnect the electrical wires at their
snap connectors after suitably identtfjr-
ing them if the colours are not dis- 17. ADJUSTMENT TO BONNET LOCKS
tinguishable. On cars prior to Commission No. TS.4229
(d) If the car is earlier than C o ~ s s i o n the bonnet locks were cable operated. It
No. TS.4229, release the cable which is essential when the bonnet lid or front
connects the two locks from its clip. apron have been removed that the bonnet
This clip is fitted at the centre of and locks are checked for alignment and the
forward of the apron re-inforcement operating cables are correctly set.
bar. On cars later than TS.4229 this
instruction can be disregarded. (a) It must be positively determined that
when the bonnet release knob is
(e) Remove the twelve bolts (six each operated the release levers of the
side) which secure the outer edges of locks are pulled clear of the plunger
the apron to the wings. These bolts apertures. This can be ascertained by
are those which are fitted horizontally an operator in the car and an observer
from inside the wheel arches. The at the locks. If the release lever is not
other series of bolts, fitted vertically fully clear the cable must be adjusted.
into the wheel arch, are NOT to be
touched. (b) Plunger centres and apertures must be
identical. Longtitudal positioning of
(f) Remove the chassis frame to apron the plungers can be approximated by
steady stay, at the apron end, by removal positioning on the lock centres. First
of the nut and bolt with lock washer. attempt at closing the bonnet lid
(g) Withdraw the bolt from the starting should be done with gentle pressure
handle guide bracket. There is no and the locking mechanism released.
necessity to remove the bracket itself. Any fouling of the plungers can be
easily felt and adjustments made.
(h) The apron can now be removed by
lifting the lower portion upward and
forward to break the water seal and 18. TO REMOVE WINDSCREEN
then lifting it bodily out of its brackets
on top of the wing. The sealing (a) Release the hood from the top of the
beadings can now be removed. windscreen.
(b) Remove windscreen wiper blades and
16. TO FIT FRONT APRON arms.
The fitting is the reversal of its removal
but care should be taken over the following (c) Turn the windscreen stanchion secur-
points. ing screws 90" anti-clockwise.
Although these screws are spring
(a) The sealing beading is adhered to the loaded it may be necessary to ease the
apron in such a manner that the hole head outwards to ensure that the bolts
is adjacent to the uppermost hole of the are quite free.
BODY
(d) With operators each side of the car 23. FRONT DOOR WATER SEALING
gently ease the windscreen assembly Additional water sealing at the top forward
forward allowing the draught excluder end of the doors was introduced in manu-
to slide over the wiper blade spindles. facture at Commission No. TS.5251. This
The windscreen can be withdrawn and sealing can be fitted to cars prior to this
lifted from the car. number. (Fig. 3)
This additional seal has been effected by
19. TO FIT WINDSCREEN the introduction of a rubber seal (Pt. No.
This is the reversal of the removal but the 603257). This seal is fitted to the underside
following points should be noted. face of the front door post by six clips
(Pt. No. 552901) in i" diameter holes
(a) The stanchion guides should be drilled in this face .19" from the edge.
greased to prevent corrosion. A seventh and similar clip is fitted in the
(b) After fitting the screen ensure that the outward face of the pillar above the top of
draught excluder are in good con- the hinge.
dition and position correctly.
(c) Fit the windscreen wiper arms and 24. TO REMOVE DOOR LOCK
blades and test for correct arcuate (a) Withdraw four screws securing front
movement. side screen retainer bracket, idenufy
the component and its position.
20. TO FIT AERO-WINDSCREEN
(b) Remove upper end of trimmed lock
(a) Remove winsdcreen as described on pull strap by withdrawing screw.
page 5. The steady bracket can also
be removed if desired. (c) Remove rear side screen retainer
(b) Withdraw the two chrome headed bracket and identify.
bolts on each side of the scuttle (d) Remove dome nut from door lever and
panel. Using these bolts attach the withdraw two screws to remove lock
aero windscreen. The toe of the plate.
mounting bracket should point forward.
(e) Withdraw the screws and cup washers
(c) If it is so desired the normal windscreen from edge of door trim and remove
can be replaced with the aero-screens trim.
still in position.
(f) The lock can be detached by re-
21. TO REMOVE DOOR moving the four screws holding the
plate to the door frame.
(a) Withdraw the nut and bolt securing
door check strap to the front door-post (g) The door check can be removed by
first removing the nut and bolt attach-
(b) Withdraw the screws securing the two ing the strap to the door post. Then
hinges to the front door post, four in remove from the door by withdrawing
upper hinge, three in lower hinge. the two attachment screws.
(c) The door can be lifted away.
25. TO FIT DOOR LOCK
22. TO FIT DOOR The fitting of the door lock is the reversal
The fitting of the door is the reversal of of the removal. The following points
its removal but care should be taken to should be noted.
ensure that it hangs correctly and the lock (a) To ensure satisfactory operation of
engages with the dovetail on the rear post.
It is suggested that the two hinges are not the lock it should be greased before
fully tightened and the door is closed fitting.
slowly and gently. Any fouling will be (b) After fitting the lock to the door frame
immediately ascertained and the appropri- it should be set in conjunction with
ate corrective action taken. the striker dovetail.
BODY
Fig. 3 Front Door Water Sealing. For illustration purposes, only the right-hand door is shown.
(c) When fitting the side screen retainer (d) Withdraw the sixteen fixing bolts
brackets the correct position is only around the flange of the tunnel.
obtained by fitting them so that the On early R.H.S. production cars it is
heads of the locking screws face necessary to remove the dipper switch
inwards. Having replaced the and bracket (3 bolts).
brackets it is a wise precaution to (el If the car is fitted with overdrive
check the fitting of the side curtain. disconnect the electric control wires
at their snap connectors and feed
26. REMOVAL OF GEARBOX TUNNEL them through the aperture in the
(a) Lift out seat cushions and remove eight tunnel.
nuts from each seat. Lift out seats. (f) Withdraw the drain pipe from front
(b) Remove front carpets and underfelts. portion of tunnel.
(c) Release hand brake and speedo drive (g) Remove screws from gear lever
draught excluder and slide this up the grommet and- push the rim of the
brake lever. grommet through the aperture.
BODY
(h) The tunnel can now be removed by (a) That the front draught excluder is in
levering up the rear end to break the good condition.
water seal. (b) All canopy fasteners are securely fitted
and operate correctly.
TO FIT THE GEARBOX TUNNEL
The fitting is the reversal of the removal, (c) All seams are fully watertight and if
but the following points should be noted. any new panels fitted or stitching
carried out the stitching should be
(a) It is essential that sufficient compound coated with " Everflex " Stitch Sealing
is used around the periphery of the Lacquer. See below.
tunnel to effect a good water seal.
(b) If the car is fitted with overdrive it
will be necessary to feed the control 30. WATER SEALING OF HOOD SEAMS
wires through the aperture in the When panels have been replaced in the
tunnel before finally bolting the latter hood or tonneau cover it is essential that
in position. These wires must be the stitching should be sealed. Failure to
correctly matched. observe this instruction may cause water
(c) On replacing the carpets an adhesive leaks not only at the seam itself but by the
will be necessary. inner backing material acting as a wick and
(d) The dipper switch will need replacing spreading the water to other parts of the
on early production cars. component.
The sealing compound recommended is
28. TO REMOVE HOOD AND FITTINGS " Everflex " Stitch Sealing Lacquer. This
(a) Remove the hood by lifting the fasteners is obtainable from our Spares Department
around the edge starting at the screen in 4 oz. tins. It should be noted that the
rail. lacquer is highly inflammable and as such
(b) The metal frame can be removed by must comply with the limitations imposed
withdrawing the screws and fastener upon transport and storing of such materials.
pegs and aluminium plate securing the The seams or stitching to be treated should
webbing strap to the rear elbow rail. be first carefully cleaned with a small
(c) Withdraw the two dome headed screws nail brush using soap and water and then
(one each side) securing the frame to the left to dry.
pivot bracket. The bracket can then be The " Everflex " Stitch Sealing Lacquer
detached from the body by the with- must be applied in a warm work shop,
drawal of four countersunk screws to dry material and to both sides of the
(2 each side). seams. In no circumstances must it be
(d) The webbing strap can be removed allowed to come into contact with the
by withdrawing the two screws and transparent plastic windows owing to the
aluminium plate at each attachment solvent effect of this lacquer upon such
point. material.
(e) The frame is a riveted construction The lacquer should be applied by a brush
and unless any servicing is required with light even strokes and as it dries
the frame rivets should not be quickly excessive brushing must be avoided.
disturbed. Two coats are usually sufficient, allowing
(f) The fastener pegs may be withdrawn ten minutes drying time at room temper-
from the body by turning the hexagon ature between each coat.
head. The canopy fasteners can be Immediatelyupon completion of the lacquer-
withdrawn by removal of the nut on ing the component should be heat treated
the inside of the canopy, utilising a to improve the bonding of the coating.
forked tool. Thmy minutes heat treatment at 220" F
is recommended and should not be exceeded.
29. TO FIT HOOD AND FITTINGS The use of an infra red lamp should be
The fitting is the reversal of removal, avoided.
but care should be taken with the following A lower temperature than that recom-
points. mended in the previous paragraph may be
BODY
used, or a hot air blast can be directed to
the lacquer. If neither oven nor hot air
blast is available the component can be
left undisturbed in a warm atmosphere
for 24 hours. Although reasonable sealing
will be obtained by the instructions con-
tained in this paragraph, the proper heat
treatment at the higher temperature will
provide the best possible water proofing.
Fig. 5 Bridge Pieces in position on Elbow Rail Fig. 6 Protection Plates in position on R.H. and
Channel. Centre Cappings.
L SYSTEM
FUEL SYSTEM
INDEX
Page Page
.
Notation For Fig 1...... ...... ...... ...... 1 A.C. Air Cleaners :-
Data and Description ...... ...... ...... 2 Description ...... ...... ..... ...... 10
To remove Petrol Tank ...... ...... ...... 2 To remove Air Cleaners ...... ...... 10
To fit Petrol Tank ...... ...... ...... ...... 3 To fit Air Cleaners ...... ...... ...... 10
Petrol Gauge :- Servicing Air Cleaners ............ ...... 10
Description ...... ...... ...... ...... 3 Disconnection of Throttle controls ...... 11
Precautions when carrying out tests ...... 3 To remove Accelerator Pedal R.H.S. ...... 11
To test Dash Meter ...... ...... ...... 3 To fit Accelerator Pedal R.H.S. ...... 11
To test Tank Unit ...... ...... 3 To remove Accelerator Pedal L.H.S. ...... 11
Fault Location for Petrol Gauge ...... 4 Notation for Fig. 7 ...... ...... 12
To remove Flexible Petrol Feed Pipe ...... 4 To fit Accelerator Pedal L.H.S. ...... 13
To fit Flexible Petrol Feed Pipe ...... 4 To remove Carburettors from Manifold 13
Petrol Stop Tap :- To fit Carburettors from Manifold ...... 13
Description ...... ...... ...... ...... 4
To remove Petrol Stop Tap ...... ...... 4 The S.U. Carburettor :-
To fit Petrol Stop Tap ...... ...... ...... 4 Notation for Fig. 8 ...... ...... ......
Servicing the Petrol Stop Tap ...... ...... 5 Description ...... ...... ...... ......
To dismantle Petrol Stop Tap ...... ...... 5 Construction ......
To assemble Petrol Stop Tap ...... ...... 5 Throttle and &mre "control" Inter-
A.C. Fuel Pump :- connection ...... ...... ......
Description ...... ...... ...... ...... 5 Effect of Altitude and climate extremes
Notation for Fig. 3 ............ ...... ...... 6 on Standard Tuning ...... ......
To clean the Pump Filter ...... ...... 6 Carburettor Jet Needles ...... ...... ......
Petrol Pump Oil Seal ...... ...... ...... 6 To remove Jet Needle ...... ...... ......
Testing while on Engine ...... ...... 7 To fit Jet Needle ...... ......
To remove Petrol Pump from Engine ..... 7 Centralisation of Jet ~ e e h i e ...... ......
To fir Petrol Pump to Engine ...... 7 To assemble Carburettor ...... ......
To dismantle Petrol Pump ...... ...... 7 Notation For Fig. 10 ...... ...... ......
Notation for Figure 5 ...... ...... ...... 8 To adjust Fuel Level ...... ...... ......
To assemble Petrol Pump ...... ...... 9 To tune Carburettors ...... ...... ......
Inspection of Parts ...... ...... ...... 10 Carburation Defects ...... .a ......
LIST OF ILLUSTRATIONS.
Page Page
Fig. Exploded view of Petrol Tank Fig. 8 Sectional view of the S.U. Car-
and Pipe Lines ...... ...... ...... 1 burettor ...... ...... ...... 14
.
~ i g Theoretical Circuit of the Fuel Fig. 8a Sectionalview of carburettor Float
Gauge Tank Unit and Meter ...... 3 Chamber ...... ...... 14
~ i ~ . *Sectional
- view of Petrol Pump ...... 6 Fig. 8b Showing the ~hoi';ler atu urn
of
the Jet Needles ...... ...... 14
Fig. Cleaning the Petrol Pump Filter 7 .
Fig 9 Throttle and Mixture G t r o l
Fig. 'Exploded view of Petrol Pump ...... 8 Interconnection ...... ...... 18
Fig. Fitting the Diaphragm ...... ...... 9 Fig. 10 Exploded view of the S.U.
Fig. Exploded view of Accelerator Carburettor...... ...... 20
Pedal (R.H. and L.H. Steering) ...... 12 Fig. 11 Adjusting the ~uel"iXve1:::::: ...... 23
FUEL SYSTEM
Ref. Ref.
No. Description No. Description
(c) Remove hose from the pump by turn- disconnection of the petrol pipe at the
ing the entire length of the hose. pump without first draining the petrol tank
as the level of the ~ e t r o lin the tank is
above that of the p&p.
g. TO FIT FLEXIBLE PETROL FEED
HOSE
Do not attempt to twist the hose without rr. TO REMOVE PETROL STOP TAP
allowing its entire length to turn. (a) Drain the petrol tank.
(a) Attach the hose to the petrol pump (b) Remove the union of the flexible hose
and secure to make a petrol tight joint. and withdraw from outlet connection
of the tap body.
(b) To the rigid end feed on the union
nut and the olive. (c) Remove the union nut from the lower
extremity of the tap and ease out
(c) Position this rigid end in the petrol the rigid petrol supply pipe.
stop tap so that it reaches the bottom (d) Loosen the jam nut situated on the
of its bore. Secure with union nut, underside of the welded fork bracket.
the tightening of the union nut seat The tap can now be lifted out of
the olive and make a petrol tight the fork.
joint.
(d) Open petrol tap and using hand 12. TO FIT PETROL STOP TAP
primer on the petrol pump prime the (a) To the threaded stem of the tap
system to ensure carburettor float
chambers are full. attach the securing nut and plain
washer. Screw the nut until it is
(e) Start engine and run for a little while approximately #" from the abutment
observing the connections for leaks. shoulder.
FUEL SYSTEM
. Fit
(bl
r
the tap into the fork bracket so
that the fied to the pump is upper-
- TO ASSEMBLE PETROL STOP TAP
15.
(a) Fit the cork seal on to the centre rod
most. The two flats on the tap body and screw the tad into the plunger
will assist in locating its position. head sufficiently to just nip the seal.
Secure the tap to bracket by tightening Attach the lock nut to the centre rod
the jam nut. protruding through the head of the
(c) Position the rigid petrol feed pipe plunger.
from tank into lower portion of tap
and ensure that the olive is seated (b) Smear the cork and the inside of the
before the union nut is attached and tap body with a little oil or grease.
tightened.
(c) Carefully feed the plunger into the
(d) Attach the flexible hose from pump to tap body so that the groove in the
outlet connection of the tap and plunger aligns with the round headed
secure to give a petrol tight joint. screw in the exterior of the body.
(e) Fill petrol tank, open tap and prime (d) Tighten the body screw so that the
pump by hand until the carburettor plunger is located in the tap body
chambers are full. and has freedom of movement.
(0 Start the engine and allow it to run (e) Adjust the interference of the plunger
for a short time while inspecting the to ensure that petrol will not seep
connections for leaks. past the cork seal. This is effected by
turning the centre rod of the plunger
anti-clockwise to increase or clockwise
13. SERVICING THE PETROL STOP to decrease the interference.
TAP
In practice the tap will require little atten- (f) Lock the centre rod with the lock nut
tion apart from a periodical inspection to in the head of the plunger.
ensure that it is leak proof.
The tap has a cork plunger which can be 16. AC FUEL PUMP TYPE " UE "
expanded to increase the interference and
so improve the seal. Description (Fig. 3)
The cork is expanded by loosening the The AC firel pump, type " UE ", is
lock nut at the top of the plunger and the o~eratedmechanically from an eccentric
centre rod in an anti-clockwise direction, (H) on the engine tamshaft (G). The
retighten the locknut. It will be noticed illustration gives a sectional view of the
that increased resistance is felt when the tap pump, the method of operation is as
is operated. follows :-
As the engine camshaft (G) revolves, the
cam (H) lifts pump rocker arm (D) pivoted
14. TO DISMANTLE PETROL STOP TAP at (E) which pulls the pull rod (F) together
(a) Loosen the round headed screw at the with the diaphragm (A) downward against
side of the tap body sufficiently to allow spring pressure (C) thus creating a vacuum
the plunger to be withdrawn. in the pump chamber (M).
Petrol is drawn from the tank and enters
(b) Remove the lock nut in the head of the at (J) into sediment chamber (K) through
plunger. By turning the cork it can be filter gauze (L), suction valve (N) into the
removed together with the centre rod. pump chamber (M). On the return stroke
the spring pressure (C) pushes the dia-
(c) The cork can now be pushed off the phragm (A) upwards, forcing petrol from
centre rod. the pump chamber (M) through the delvery
(d) Clean and inspect all parts and renew valve (0) and outlet (P) to the carburettor
any that are believed to be defective. feed pipe.
FUEL SYSTEM
turns passes into the lower body of the
petrol pump below the diaphragm assembly
and by action of the latter is pumped out
by way of the breather hole.
T o obviate this condition an oil seal is
fitted round the diaphragm assembly push
rod and is prevented from rising with the
action of the push rod by a metal retainer
staked to the lower pump body.
Petrol pumps fitted with this oil seal were
fitted to engines after No. TS.2074E.
Hand priming lever During dismantling this oil seal should not
Section view of Petrol Pump.
be removed unless it is known to be
Fig. 3 defective.
When the carburettor float chambers are full
the float will rise and shut the needle valve,
thus preventing any flow of petrol from the 18. TO CLEAN THE PUMP FILTER
pump chamber (M). This will hold The pump filter should be examined every
diaphragm (A) downward against spring 1,000 miles and cleaned if necessary.
pressure (C), and it will remain in this
position until the carburettors requires Access to the filter is gained by loosening
further petrol and the needle valve opens. the thumb nut situated below the glass
The rocker arm (D) operates the connecting sediment chamber at the side of the petrol
link by making contact at (R) and this pump body and swinging the wire frame to
construction allows idling movement of the one side. The sediment chamber can be
rocker arm when there is no movement of removed followed by the cork gasket and
the fuel pump diaphragm. gauze filter.
Spring (S) keeps the rocker arm (D) in The gauze filter should be cleaned by a
constant contact with cam (H) and elirnin- blast of air or washing it in clean petrol.
ates noise. The cork gasket should be inspected for
condition and replaced if broken or hard.
17. PETROL PUMP OIL SEAL The glass sediment chamber should be
During very fast cornering oil rises up the cleaned and its upper rim inspected for
cylinder block walls and during right-hand chips.
FUEL SYSTEM
(c) Remove the two pump securing nuts
and spring washers. Note the oil
pressure pipe clip is attached to the
rear stud.
(d) The pump can be removed from the
cylinder block, together with the pack-
ing.
2- -- 3
Ref.
No.
1 Upper body.
2
3
4
5*
Gauze filter.
Valve gasket.
Cork seal
Description
,
SHOULD BE IN THIS POSITION.
(b) Fit the diaphragm rod oil seal (15)
and retainer (13) in the lower body
(16) and stake over the wall of the
seal recess. Position the hand primer
\ 1i 1 ENGINE MOUNTING
FLANGE
spring between the lever and the pump SLOT IN LINK AND TURNING I
QUARTER T ~ R NTO RIGHT, TAB II
(e) Push the rod to the left of the car, right it can be freed from the left-
this will eject the accelerator pedal in hand bearing.
to the interior of the car and also (f) The bearings and housings can be
free the shaft from its right-hand removed by withdrawing the eight
bearing. On drawing the shaft to the self tapping screws (four each bearing).
FUEL SYSTEM
(g) The shaft can now be dismantled by and spring situated in the top of each
drifting out the mills pin securing float chamber body.
the lever assembly to the shaft and (c) Withdraw the split pin from the
collecting a double coil washer and clevis pin at the rear end of the
mounting bracket. mixture control link and remove clevis
The split pin locating the bracket on ?in.
the shaft can also be withdrawn. (d) Disconnect the throttle spindle at the
rear folded coupling by loosening the
33. TO FIT ACCELERATOR PEDAL clamping bolt.
L.H.S. (Fig. 7) (e) By removing the two nuts at the
(a) Position- the nylon bearing between mounting flange of the rear carb-
the half housings and secure both to urettor it can be removed from the
the bulkhead with eight self tapping manifold together with an asbestos
screws (four each bearing). insulating washer and two packings.
(b) It will be observed that the shaft is (f) Disconnect the Bowden inner cable
drilled at each end; the single hole from the swivel pin of the jet lever and
end is on the left-hand side and the end the outer cable from the front jet
with two holes is the right-hand end. lever link by loosening a clamp bolt.
(c) Fit the lever assembly to the right- (g) Remove the nut and lock washer of the
hand end, with lever on left-hand short link rod assembly and disconnect
side, and secure with a mills pin to the control linkage from the carb-
the outer or extreme right-hand hole. urettor throttle lever.
(d)
. . Feed on the shaft the double coil (h) Remove the two nuts securing the
spring washer followed by the support carburettor to the manifoid and remove
bracket, mounting holes to the left. carburettor together with the asbestos
Apply pressure tothe support bracket insulating washer and two packings.
to compress the spring and feed split
pin through hole in shaft to position 35. TO FIT CARBURETTORS TO
bracket. MANIFOLD
(e) Feed metal bush on to left-hand end (a) Ensure that the joint washers and
of shaft (larger end first). Feed asbestos insulating washers are in
shaft and bush into the left-hand good order. Fit two joint washers,
bearing already fitted to car. Posi- one to each manifold flange, followed
tion fulcrum of lever assembly in by an asbestos insulating washer and a
the right-hand bearing, it may be second joint washer.
necessary to withdraw the shaft from (b) Offer up and secure the rear carbur-
the left-hand bearing, and secure ettor to its mounting and secure with
mounting bracket to bulkhead, utilising plain washers, lock washers and nuts.
two bolts and lock washers. Secure the (c) Ensure that the folding connection of
bush to the shaft by a mills pin, the throttle spindle connecting rod
supporting bush and shaft with a will not foul the front carburettor
small anvil. when the latter is offered up to its
(f) From inside the car feed the accelerator positiori.
pedal into the bush and similarly (d) Attach and secure front carburettor to
secure with a mills pin. its mounting, utilising plain and lock
(g) Couple up long carburettor link rod washers and nuts.
and secure with nut and lock washer. (e) Connect the outer Bowden cable to the
front jet lever link.
(f) Connect the short link rod assembly to
34. TO REMOVE CARBURETTOR the throttle lever of the front carb
FROM MANIFOLD urettor.
(a) Remove air cleaners as described on (g) The inner cable, the throttle rods and
page 9. jet levers are left disconnected until
(b) Disconnect petrol supply pipe, taking after the carburettors have been tuned.
care not to damage the conical filter See page 23.
FIG. 8 0
The shoulder of the needle should be flush wkh the
under face of the piston. Two types of shoulder are In
use, and the correct datum point for each Is shown.
FIG. 8 FIG. 8A
The mixture is correct when this operation (a) Pistons Sticking. Fig. 8.
causes no change in engine RP.M: When The symptoms are stalling and a
the engine slows down with this operation refusal to m slowly, or lack of power
it indicates the mixture is too weak and it and heavy fuel consumption.
should be enriched by unscrewing the jet The piston (3) is designed to lift the
adjusting nut. An increase of engine speed jet needle (6) by the depression trans-
during this operation indicates that the ferred to the top side from the passage
mixture is too rich and, consequently, it facing the butterfly. This depression
should be weakened off by screwing up the overcomes the weight of the piston and
jet adjusting nut. The mixture setting spring (8). The piston should move
should now give a regular and even exhaust freely over its entire range and rest on
beat, it is irregular with a " splashy" the bridge pieces (28) when the engine
type of misfire and a colourless exhaust, is not running.
the mixture is too weak. A regular or This should be checked by gently
rhythrmcal type of misfire in the exhaust m n g the piston with a small screw-
note, possibly with a blackish exhaust, driver and any tendency for binding
indicates the mixture is too rich. generally indicates one of the following
The jets of both carburettors should be faults :-
held against the adjusting nuts before
replacing the mixture control linkage, which (i) The damper rod may be bent
should be adjusted as necessary, and simi- causing binding and this can be
larly the throttle should be held tight checked by its removal. If the
against their respective idling stops before piston is now free the damper
retightening the folding coupling cl.amp rod should be straightened and
bolt. refitted.
FUEL SYSTEM
(3)The piston is meant to be a There is no remedy other than
fine clearance fit at its outer removing the whole jet assembly after
diameter in the suction chamber disconnecting the operating lever and
and a sliding fit in the central cleaning or replacing the faulty parts.
bush. T h e suction chamber It is very important that all parts are
should be removed, complete replaced in their correct sequence, as
with piston, and the freedom of shown in the illustration, and it must
movement checked after removal be realised that centralisation of the
of the damper rod. The assembly jet and needle and re-tuning will be
should be washed clean and very necessary after this operation.
lightly oiled where this slides in
the bush and then checked for any
tendency of binding. It is per- (e) Dirt in the Carburettor
missible to carefully remove, This should be checked in the normal
with a hand scraper, any high way by examining and cleaning the
spots on the outer wall of the float chamber, but it may be necessary
suction chamber, but no attempt if excessive water or dirt is present to
should be made to increase the strip down and clean all parts of the
clearance by increasing the general carburettor with petrol.
bore of the suction chamber or
decreasing the diameter of the
piston. The fit of the piston in (f) Failure of Fuel Supply to Float
its central bush should be checked Chamber
under both rotational and sliding If the- engine is found to stop under
movement. idling or light running conditions,
notwithstanding the fact that a good
(b) Eccentricity of Jet and Needle supply of fuel is present at the float
Fig. 8. chamber inlet union (observable by
The jet (14) is a loose fit in its recess momentarily disconnecting this), it is
and must always be centred by the possible that the needle has become
needle before locking up the clamping stuck to its seating. This possibility
ring (15). arises in the rare cases where some
gummy substance is -presentin the fuel
(i) The needle should be checked in system. The most probable instance
the piston to see that it is not bent. of this nature is the polymerised gum
It will be realised that it does not which sometimes results from the
matter if it is eccentric as the protracted storage of fuel in the tank.
adjustment of the jet allows for After removal of the float chamber
this, but a bent needle can never lid and float lever, the needle may be
have the correct adjustment. For withdrawn, and its point thoroughly
" Centralisation of Jet ",see page
SPECIALISED TOOLS
SECTION Q
SPECIALISED TOOLS
SPECIALISED TOOLS As the necessity for further tools becomes
POLICY apparent they will be manufactured, and our
agents will receive notice of such items as and
Considerable time and care has been taken when they are introduced.
in the preparation of specialised tools for
servicing our Models, as it is realised that
efficient servicing is not possible without the PARTICULARS OF TOOLS
correct tools and equipment. Brief particulars of approved tools which
Messrs. V. L. Churchill & Co. Ltd. have have been produced are given below. The tool
designed and are manufacturing on our behalf in question should be ordered direct from
and this Company has already circulated inform- Messrs. V. L. Churchill & Co. Ltd:, Great
ation concerning these tools, for many have South West Road, Bedfont, Feltham, Mddlesex.
similar applications on the Vanguard, Renown, Telephone : Feltham (Middx.) 5043.
Mayflower and Eight and Ten H.P. Models. Telegrams : Garaquip, Feltham.
GENERAL
Press and Slave Ring ...... ....- .., S 4221
ENGINE
Cylinder Sleeve Retainers ...... ...... S 138
Sparking Plug Wrench ...... .... w ...... 20SM 99
Connecting Rod Alignment Jig ....- ...... 335
Valve Spring Compressor ...... ...... S137
Stud Extractor ...... ...... ...... ...... 450
COOLING SYSTEM
Universal Puller ...... ...... ...... ...... 6312
Water Pump Refacer ...... ..... ...... S126 and 6300
Water Pump Impeller Remover & Replacer FTS 127*
CLUTCH
Clutch Assembly Fixture ...... ...... ...... 99A
Clutch Plate Centraliser ...... ...... ...... 20S72
GEARBOX
Mainshafi Remover ...... ...... ...... 20SM1
Mainshaft Circlip Installer ...... ...... 20SM 46
Front Oil Seal Protecting Sleeve ...... ...... 20SM 47
Gearbox Extension Remover ...... ...... 20s 63
Constant Pinion Shaft: Remover ...... ...... 20SM 66A
Countershaft Needle Roller
Retainer Ring Driver ...... ...... 20SM 68
Mainshaft Circlip Remover ...... ...... 20SM 69
Countershaft Assembly Pilot ...... ...... 20SM 76
Countershaft Assembly Needle Roller
Retainer ...... ...... ...... ...... 20SM 77
Gearbox Rear Bearing Replacer ...... ...... 20S78
Gearbox Mainshaft Rear Oil Seal Replacer 20s 87A
Constant Pinion and Mainshaft Bearing
Remover and Replacer ...... ...... S 4615t
Two-way Circlip Pliers ...... ...... ...... 7065
Front Cover Oil Seal Replacer ...... ...... 20SM 73A
REAR AXLE
Half Shaft Bearing Remover ...... ......
HalfShaftBearingReplacer ...... ......
Differential Case Spreader ...... ......
Propeller Shaft Flange Wrench ...... ......
Pinion Bearing Outer Ring Remover ......
Pinion Bearing Outer Ring Replacer ......
Pinion Oil Seal Replacer ...... ...... ......
Pinion Head Bearing Remover & Replacer
Differential Bearing Remover ...... ......
Differential Bearing Replacer ...... ......
Pinion Setting Gauge and Dummy Pinion
Pinion Bearing Preload Gauge ...... ......
Rear Hub Extractor (Disc Wheels) ......
Rear Hub Extractor (Knock-on Wheels)
Rear Hub Replacer (both type Wheels) ......
Rear Hub Oil Seal Replacer ...... ......
Backlash Gauges ...... ...... a
...........
BRAKES
SECTION R
BRAKES
INDEX
Page Page
Notation for Figure 1 1 To dismantle 12
Description ...... 2 To assemble 12
Routine maintenance 2 Rear Wheel Hydraulic Cylinders :-
Identification of linings 2 Description 12
Data ...... 3 Notation for Figure 6 13
Brake Adjustment :- To remove 14
Front brake shoes 3 To fit 14
Rear brake shoes ...... 3 To dismantle 14
Handbrake 3 To assemble 14
To bleed the hydraulic system ...... 3 To remove hydraulic pipe line from rear
Leakage from master cylinder ...... 4 axle ...... 15
Brake and clutch pedal adjustment 4 To fit hydraulic pipe line to rear axle 15
Adjusting brake pedal 4 Fitting replacement brake shoes 15
To remove and fit flexible hoses 5 Pedal Assembly :-
Twin Bore Master Cylinder :- To remove 15
Notation for Figure 2 6 To fit 15
Description 7 Notation for Figure 8 16
To remove 7 To dismantle 16
To fit 7 To assemble 16
To dismantle 8 The Handbrake Lever Assembly :-
To assemble 8
Notation for Figure 3 9 To remove 17
To fit 17
Front Wheel Hydraulic Cylinders :- To dismantle 17
Description 10 Notation for Figure 9 18
To remove 10 To assemble 19
Notation for Figure 5 10 To remove handbrake cables 19
To fit 12 To fit handbrake cables ...... 19
ILLUSTRATIONS
Page
Fig. 1 Exploded view of hydraulic pipe lines and connections 1
Fig. 2 Sectional view of the brake master cylinder ...... 6
Fig. 3 Exploded view of twin bore master cylinder 9
Fig. 4 Sectional view of front wheel cylinder ..... . 10
Fig. 5 Exploded view of front brake details 11
Fig. 6 Exploded view of rear brake details 13
Fig. 7 Sectional view of rear wheel cylinder 14
Fig. 8 Exploded view of pedal assembly ..... . 16
Fig. 9 Exploded view of handbrake assembly 18
BRAKES
NOTATION FOR Fig. I.
Ref. Ref.
No. No.
Brake Operation 14 Large shake proof washer
1 Master cylinder t~ front connection pipe 15 Front to rear connection pipe
2 Two-way connectIon 16 Flexible hose
3 Banjo bolt 17 Hose locknut
4 Large copper gasket 18 Large shake proof washer
5 Small copper gasket 19 Copper gasket
6 Right to left-hand front connection pipe 20 Three-way connection
7 Front banjo connection 21 Connection attachment bolt
8 Banjo bolt 22 Right-hand brake pipe
9 Large copper gasket 23 Left-hand brake pipe
10 Small copper gasket 24 Rear axle clips
11 Stop light switch Clutch Operation
12 Flexible hose 25 Master cylinder to frame bracket pipe
13 Hose locknut 26 Flexible hose
Fig. I
Exploded view of Hydraulic Pipe Lines and Connections.
1
BRAKES
I. DESCRIPTION depressed the lever will remain in that
Lockheed Hydraulic Brakes are fitted to all rearward position. To release the handbrake
four wheels. Two leading shoe type are it is only necessary to pull the lever rear-
used on the front wheels and leading and ward sharply and then let it travel forward.
trailing shoe type on the rear wheels.
2. ROUTINE MAINTENANCE
A foot pedal operates the brakes hydraulic-
ally on all four wheels simultaneously, Examine the fluid level in the master
whilst the handbrake operates the rear cylinder periodically and replenish if nec-
brakes only by means of a cable. essary to keep the level t" below the under-
side of the cover plate.
The foot pedal is coupled by a push rod to
the master cylinder bore in which the Do not fill completely. The addition of
hydraulic pressure of the operating fluid fluid should only be necessary at infrequent
is originated. The second bore of the master intervals and a considerable fall in fluid
cylinder is connected to the clutch operating level, indicates a leak at some point in
mechanism. the system, which should be traced and
rectified immediately.
A supply tank, integral with the master
cylinder, provides a fluid reservoir for both ~nsure that the air vent in the filler cap
cylinders, a pipe line consisting of tube, IS not choked, blockage at this point will
flexible hose and unions connect the master cause the brakes to drag.
cylinder bore to the wheel cylinders. Adjust the brakes when the pedal travels to
The pressure created in the master cylinder, within 1" of the toe board before solid
by application of the foot pedal, is trans- resistance is felt. If it is desired, adjustment
mitted with equal force to all wheel cylin- may be carried out before the linings have
ders simultaneously. This moves the piston become worn to this extent.
which in turn forces the brakes shoes
outward and in contact with the brake drum. 3. BRAKE LINING IDENTIFICATIONS
An independent mechanical linkage, actuated To af~o~d maximl!m braking efficiency
by a hand lever, operates the rear brakes by brake lmmgs of an lffiproved material have
mechanical expanders attached to the rear been progressively introduced. To enable
wheel cylinder and acts as a parking brake. identification linings are colour marked at
The handbrake is situated in the centre of their edges.
the car on the right-hand side of the gearbox !he .follo~ing tabulation will give these
tunnel. I t is operated by pulling the grip Identificatlon marks and also the Commision
rearwards and operating the push button on number of the car on which they were
top by the thumb; when the button is first used.
2
BRAKES
4. DATA (d) Insert screwdriver in slot and turn the
Front Brakes 10" X 2!" adjuster until brake shoes contact brake
Rear Brakes 9" x l!" up to Commision drums then turn adjuster cam back
No. TS.5481. Rear Brakes 10" X 21" one notch.
after TS.5481.
(e) Repeat operations (c) and (d) with
Transverse rear brake cable lengths: second wheel.
Right-hand 12.97" ± .06" 12.47"} 10"
Left-hand 26.85" ± .06" 26.35" brakes. (f) Replace road wheels and nave plates
These lengths are measured from pin Lower car to ground and remove jack
centre of each fork end.
(g) Road test car in a quiet thoroughfare.
Front brake shoes are interchangeable with
one another providing they have the same
lining. 7. HAND BRAKE ADJUSTMENT
Rear brake shoes are interchangeable with Adjustment of the brakes shoes already
one another providing they have the same described automatically readjusts the hand-
lining and also interchangeable with front brake mechanism.
brake shoes of the same diameter and lining The cables are correctly set during assembly
type. and only maladjustment will result from
altering the mechanism.
5. FRONT BRAKE SHOE ADJUSTMENT From the compensating linkage to the brake
(a) Apply the brakes hard while the car is levers mounted on the wheel cylinders are
stationary to position the shoes centr- transverse cables which are of a set length
ally in the brake drum, then release when leaving the works. They are however
brake. adjustable at their inner ends and should
(b) Jack up front of car, remove nave these have been tampered with it is necess-
plates and road wheels. ary to check the following:
(c) Rotate hub until hole provided in The cable assembled to the right-hand
brake drum coincides with screw- . cylinder lever is 12.97" ± .06" between
driver slot in micram adjuster. centres.
(d) Insert screwdriver in slot and turn the The left-hand is 26.85" ± .06", this gives
adjuster until brake shoes contact the the correct angle of the compensator lever
drum, then turn adjuster back one as 17°. Only when a complete overhaul
notch. is necessary should the handbrake cables
(e) Repeat operations (c) and (d) with require resetting.
second micram adjuster. To carry out this operation, the brake
(f) Repeat operations (c), (d) and (e) shoes should be locked up in the brake
with second wheel. drums with the hand brake in the "off"
position. Any slackness that is in the cable
(g) Replace wheels and nave plates. Lower from compensator to handbrake lever should
car to ground and remove jacks. be removed at the handbrake lever end.
(h) Road test car in a quiet thoroughfare.
The method detailed hereafter is suitable (b) The breaking up of the filler seal due
only for the braking system; the procedure to foreign matter between it and the
to be adopted when bleeding the clutch rim of the orifice.
is detailed in the " Clutch Section".
(c) Leakage has been traced to jets of
(a) Ensure an adequate supply of Lock- fluid from one of the cylinder recuper-
heed Brake Fluid is in the reservoir ating holes finding its way past a
of the Master Cylinder Unit and keep defective filler cap sealing ring or
the level at least half full throughout via the breather hole.
the operation. Failure to observe this
point may lead to air being drawn into The latter condition can be corrected
the system and the operation of bleed- by removing the cover plate and turn-
0
ing will have to be repeated. ing it 180 so that the filler cap is no
longer directly above the jets.
(b) Clean the bleed nipple on one of the
wheel cylinders and fit a piece of rubber
tubing over it, allowing the free end 10. BRAKE AND CLUTCH PEDAL
of the tube to be submerged in a ADJUSTMENT
glass jar partly filled with clean
Lockheed Brake Fluid. The pedal adjustment is set when the car
is assembled and should not require atten-
(c) Unscrew the bleed nipple one full tion unless the assembly or adjustment has
turn. There is only one bleed nipple been disturbed.
to each brake.
A minimum clearance of .030" is necessary
(d) Depress the brake pedal completely between each push rod and the piston
and let it return without assistance. which it operates, this free movement can
Repeat this operation with a slight be felt at the pedal pad when it is depressed
pause between each depression of the gently by hand.
pedal. Observe the fluid being dis- The movement at the pedal pad will be
charged into the glass jar and when all magnified owing to the length of the lever
air bubbles cease to appear hold the and this movement will become between i"
brake pedal down and securely tighten to i". Should this free movement not be
the bleed nipple. Remove rubber apparent, first check that the pedals are
tubing only when nipple is tightened. free on their shaft and not prevented to
NOTE: Check the level of the fluid in return by some other fault than insufficient
the master cylinder frequently and do clearance between push rod and piston.
not allow the level to fall below half
full. Seven or eight strokes of the brake
pedal will reduce the fluid level from II. ADJUSTING THE BRAKE PEDAL
full to half full. (a) Loosen the jam nut on the shank of
(e) Repeat the operation for the remaining the pedal limit stop screw and screw it
three wheels. anti-clockwise approximately 1" away
from the master cylinder support
(f) Top up master cylinder with Lockheed bracket.
Brake Fluid and road test car.
(b) Push the operating push rod end into
9. LEAKAGE OF FLUID FROM the master cylinder until it just contacts
MASTER CYLINDER the piston. Screw up limit stop screw
Leakage of fluid from the reservoir of the to meet the push rod fork end, but do
master cylinder can be explained as follows: not allow the rod to be pushed further
into the piston. Screw the jam nut so
(a) Overfilling which allows fluid to be that it makes contact with the master
trapped in the filler cap and leak cylinder support bracket.
through the breather hole. The fluid
level should never be higher than 1" (c) Unscrew the pedal limit stop screw
measured from the top of the filler together with the jam nut so that a .030"
orifice or t" measured from the under- feeler gauge will pass between nut
side of the cover plate. and support bracket.
4
BRAKES
(d) Holding the pedal limit stop screw (e) Holding the hexagon of the flexible
turn the jam nut to the support hose at the outside of the bracket,
bracket and tighten. tighten the banjo bolt.
NOTE: The clutch pedal is set in a (f) Screw stop light switch into head of
similar way but it must be remembered banjo bolt, still holding the hexagon of
that adjustment at the slave cylinder the hose.
may also be necessary to obtain the (g) Replenish hydraulic reservoir with
correct free pedal movement. fresh fluid.
(h) Bleed all brakes as described on page 3.
12. TO REMOVE FRONT LEFT -HAND (i) Check the system for fluid leakage by ,
FLEXIBLE HOSE applying firm pressure to the pedal and
(a) Open bonnet and disconnect battery inspect the line and connections.
and wires to stop light switch.
(b) Drain the hydraulic system of fluid. 14· TO REMOVE FRONT RIGHT-HAND
Hold hexagon of hose near its bracket. FLEXIBLE HOSE
(c) Withdraw the banjo bolt from the (a) Drain hydraulic system.
banjo connection. The stop light switch
attached to this bolt need not be (b) Holding the banjo bolt of the two-way
removed. connection with one spanner remove
the Bundy tubing union with a second.
(d) Holding the hexagon on the outside of
the bracket with a spanner, remove the (c) Grip the hexagon of the flexible hose
larger sized locking nut and shake on the outside of the bracket and
proof washer. remove the bolt passing through the
centre of the two-way connection.
(e) The hose can be withdrawn from its
bracket and now removed from the (d) Still gripping the hexagon of the hose
wheel cylinder. Care should be taken remove locknut and shake proof
to ensure that the entire length of washer. The flexible hose may now
hose is turned whilst it is being removed be withdrawn from its bracket.
from the wheel cylinder. (e) Remove the flexible hose from the
wheel cylinder. Care should be taken
to ensure that the entire length of hose
13· TO FIT FRONT LEFT -HAND is turned whilst it is removed from
FLEXIBLE HOSE the wheel cylinder.
Clean all components so that dirt does not
enter system.
15. TO FIT FRONT RIGHT-HAND
(a) Secure hose to wheel cylinder. FLEXIBLE HOSE
(b) Thread end of hose through chassis Clean all parts and ensure no dirt enters the
frame bracket and feed on shake hydraulic system.
proof washer and locknut.
(a) Secure the flexible hose to the wheel
(c) Set hose by holding hexagon with a cylinder.
spanner, tighten locknut to bracket
assembly whilst still holding hexagon (b) Thread end of the hose through chassis
with spanner. frame bracket and feed on shake
proof washer and locknut.
(d) Fit the larger diameter gasket to the
banjo bolt and feed bolt through banjo (c) Set hose by holding hexagon with a
connection, fit smaller diameter gasket spanner, tighten locknut securely to
to bolt. Feed bolt into hose end bracket whilst still holding hexagon
attached to bracket and secure fmger with spanner.
tight. It will be seen that there is (d) Fit the larger diameter gasket to the
a gasket between the head of the banjo banjo bolt and feed bolt through
bolt and the banjo connection and a two-way connection, fit smaller dia-
second gasket between the connection meter gasket to bolt and secure bolt to
and the thread of the hose protruding end of hose protruding through chassis
through the bracket. bracket.
5
BRAKES
(e) Hold the hexagon of the flexible hose (e) Replenish the hydraulic reservoir with
at the outside of the bracket and fluid.
tighten the banjo bolt, at the same
time ensuring that the two-way con- (f) Bleed all four brakes as described on
nection is not allowed to turn. page 3.
(f) Reconnect the Bundy tubing to the
head of the connection bolt. (g) Check the system for fluid leakage by
applying firm pressure to the pedal
(g) Replenish hydraulic reservoir with fluid. and inspect the line and connections.
(h) Bleed all brakes as described on page 3.
(i) Check the system for fluid leakage by 18 17 16
applying firm pressure to the pedal and
inspect the line and connections.
(c) Still holding the hexagon of the hose Fig. 2 Sectional view of Brake Master Cylinder.
To prevent fluid leakage the cover plate is
remove the locknut and shake proof 0
turned 180 (the dotted outline of the filler
washer. The hose can now be removed cap shows this condition) on later
from the bracket. production cars.
(d) Disconnect hose from three way con-
nection on rear axle. Care should be
taken to ensure that the entire length NOTAnON FOR Fig. 2.
of hose is turned whilst it is removed
from the three way connection.
I Valve seat
17. TO FIT REAR FLEXIBLE HOSE 2 Valve body
Clean all parts thoroughly and ensure that 3 Rubber cup
no dirt is allowed to enter the hydraulic 4 Return spring
system. 5 Spring retainer
(a) Position a gasket on the end of the 6 Rubber cup
flexible hose, secure to the three way 7 Piston washer
connection in the rear axle. 8 Secondary cup
(b) Feed foremost end of hose through 9 Piston
bracket welded to chassis frame, 10 Gasket
attach shake proof washer and lock- 11 Boot fixing plate
nut to end of hose, fmger tight.
12 Large boot clip
(c) Holding the hexagon of the hose with 13 Rubber boot
a spanner, set it so that the hose is
free from any obstructions. Still 14 Small boot clip
holding the hexagon secure hose to 15 Push rod
bracket, with the locknut. 16 Cover plate
(d) Continuing to hold the hexagon of the 17 Filler cap
hose attach the Bundy tubing and 18 Gasket
tighten union nut. X Port in cylinder bore
6
BRAKES
18. TWIN BORE MASTER CYLINDER 19. TO REMOVE MASTER CYLINDER
Description (a) Drain hydraulic system of operating
fluid.
This unit consists of a body which has two
identical bores, one connected to the brakes (b) Remove the square panel under the
and the second to the clutch. Each of the dash, which forms the rear wall of the
bores accommodates a piston having a rubber master cylinder pocket from inside the
cup loaded into its head by a return spring; car. Remove also the rubber grommet,
in order that the cup shall not tend to be from the inside wall of the pocket, to
drawn into the holes of the piston head, a facilitate the withdrawal of the rear
piston washer is interposed between these master cylinder attachment bolt.
parts. At the inner end of the bore connected (c) Disconnect the Bundy tubing from the
to the brakes, the return spring also loads a connections at the rear of the master
valve body, containing a rubber cup, against cylinder. Care must be exercised
a valve seat; the purpose of this check when removmg the clutch Bundy
valve is to prevent the return to the master tubing; this is connected first to
cylinder of fluid pumped back into the line an adapter and then to the cylinder
whilst bleeding the brake system, thereby body. It will be necessary to hold
ensuring a charge of fresh fluid being de- the adapter with one spanner, whilst
livered at each stroke of the brake pedal loosening the Bundy tubing nut
and a complete purge of air from the with a second. The connection for
system. the brake operation is made direct to
the master cylinder.
During normal operation, fluid returning (d) Withdraw the clevis pins from the lever
under pressure and assisted by the brake push rod fulcrums by removing the
shoe pull-off springs, lifts the valve off split pins, plain washers and double
its seat, thereby permitting fluid to return coil spring washers.
to the master cylinder and the brake shoes
to the " off" position. (e) Remove the nuts, lock and plain
washers, from the master cylinder
attachment bolts and withdraw the
There is no check valve fitted in the bolts, the rearmost one being passed
bore connected to the clutch, this through the aperture in the wall of the
precludes the risk of residual line pressure pocket into the car.
which would tend to engage the clutch, or
keep the ball release bearing in contact with (f) The master cylinder is now free to be
the release lever~. lifted from its support bracket. Empty
any fl~id that may still be in the
reserVOIr.
The by-pass ports, which break into each
bore, ensure that the systems are maintained
full of fluid at all times and allow full 20. TO FIT MASTER CYLINDER
compensation for expansion and contraction
of fluid due to change of temperature. (a) Ensure that the connection adapter
is secure in the left-hand (clutch)
outlet of the master cylinder.
They also serve to release additional fluid (b) Place the assembly in the master cylinder
drawn into the cylinder through the small support bracket, connections to the
holes in the piston after a brake or clutch rear, and secure at the front end, with
application. If this additional fluid is not the attachment bolt and washers, but
released to the reservoir, due to the by-pass leave the nut finger tight at this
port being covered by the main cup, as a juncture.
result of incorrect pedal adjustment, or
to the hole being choked by foreign matter, (c) The rear attachment bolt is fed in from
pressure will build up in the systems and inside the car, through the aperture
the brakes will drag, or the clutch tend to in the pocket wall. This bolt passes
disengage. through two adjustment brackets, one
7
BRAKES
either side of the support bracket. (d) Detach the boot fixing plate and joint
With the washers in place screw on nut washer.
finger tight. (e) Withdraw pistons and washer.
(d) Connect the Bundy tubing to the
master cylinder connections through (f) By applying low air pressure to the by-
the aperture at the rear of the master pass ports blowout the rubber cups.
cylinder. The clutch operating pipe (g) Tip out the springs and the check
is fitted to the adapter on the left and valve from the brake operating cylinder.
the brake operating pipe, which is on
the right, direct to the master cylinder. (b) Remove the valve seat from the bottom
of the bore.
(e) Attach the piston rod fork ends to the
pedals so that the heads of the clevis (i) Ease the cup out of the valve body and
pins are nearest the centre line of the the secondary cups off the piston.
master cylinder assembly. Secure (j) Remove the adapter from the master
clevis pins with new split pins after cylinder body.
fitting double coil spring and plain
washers.
22. TO ASSEMBLE THE MASTER
(f) Loosen the jam nuts of the adjusting CYLINDER (Fig. 3)
brackets, at both sides of the support Ensure absolute cleanliness during the
bracket, and turn the front nut in a assembly of these components. Assemble
clockwise direction to bring the parts with a generous coating of clean
master cylinder assembly forward to its Lockheed Brake Fluid.
fullest extent.
(a) Fit the secondary cups to the pistons
(g) Secure master cylinder to support so that the lip of the cup faces the head
bracket by tightening nuts of securing of the piston. Gently work the cup
bolts. Lock up jam nuts to the adjust- round the groove with the fmgers to
ing bracket. ensure that it is properly seated.
(b) Adjust pedal clearance as described on (b) Looking at the open piston bores of
page 4. the master cylinder, place a valve seal
(i) Replenish fluid reservoir with clean in the bottom of the left-hand (brake
Lockheed Brake Fluid. Bleed brakes operating) bore.
as described on page 3. Bleed clutch (c) Ease the rubber cup into the valve
as described in "Clutch Section" D. body and fit the body in one end of
(j) Check the system for fluid leaks by a return spring, fit a spring retainer on
applying firm pressure to the foot the other end of the spring and insert
pedals and inspecting the line and the assembly, valve leading, into the
connections for leaks. bore which has the valve seat.
(k) Replace rubber grommet in wall of (d) Fit the second spring retainer on the
master cylinder pocket and the cover at second return spring and insert the
the rear of the pocket. spring,plain end leading, into the right-
hand bore.
(e) Insert the mam cup, lip leading,
21. TO DISMANTLE THE MASTER into each bore taking care not to
CYLINDER (Fig. 3) damage, or turn back the lip of the
(a) Remove the circ1ip and rubber boot cup. Follow with the two piston
from the master cylinder body and washers, ensuring that the curved
withdraw them together with the push washers are toward the rubber cups.
rod fork assembly. (f) Insert the two pistons, exercising care
(b) Remove the circlip and boot from the not to damage the rubber cups.
fork end assembly. (g) Depress the two pistons, and fit the
(c) Remove cover plate and joint washer boot fixing plate, ulitising a new joint
from top of master cylinder body, washer and securing plate with two
also remove filler cap. screws and shake proof washers.
8
BRAKES
3 l--- --.c-
10
20
9
BRAKES
(b) Position the cover plate on the body Each front wheel cylinder consists of a body
in such a manner that the filler cap formed with a blind bore to accommodate a
is nearer the outlet ports. This will piston: a rubber cup, mounted in a cup
ensure the jets of fluid from the filler, is loaded upon the piston by a spring
cylinder will impinge upon the plate which is located in the recess formed in
and so avoid possible leakage through the cup filler.
the filler cap. Ensure that the joint
washer and filler cap sealing ring are
in good order and that the vent hole 24. TO REMOVE FRONT WHEEL
is clear. CYLINDERS
(i) Test the assembly by filling the tank (a) Jack up car, drain off hydraulic fluid,
with Lockheed Hydraulic Brake Fluid remove nave plate, wheel, and brake
to within I" of the filler orifice top. drum.
Then push the piston inward and it (b) Pull one of the brake shoes against the
should return without any assistance; load of the pull-off springs away from
after a few aplications fluid should be its abutment on the wheel cylinders.
ejected from the outlet connections. Slide the micram mask off the piston
cover of the operating piston. On
releasing the tension of the pull-off
springs the opposite brake shoe will
fall away.
(c) Remove the flexible hose as described
on page 5.
(d) Unscrew the bridge pipe tube nuts
from the wheel cylinders and remove
the bridge pipe.
(e) Remove the fixing bolts and lock
washers to withdraw wheel cylinders
from back plate.
11 TR2 Y
BRAKES
25. TO FIT FRONT WHEEL CYLINDERS (a) Fit the smaller end of the coil spring
(a) Mount the wheel cylinders on the over the projection in the cup filler and
back plate and secure each with a insert both parts into the cylinder
bolt and lock washer. body, with the spring leading.
(b) Connect bridge pipe to bottom (b) Follow up with the rubber cup, lip
bore of each wheel cylinder, utilising end foremost, taking care not to damage
the union nuts trapped on the pipe. or tum back this lip.
Ensure that the pipe is located on its
seat before attempting to attach the (c) Feed in piston with cover in position.
nut. Tighten nut sufficiently to give
and oil and air tight joint.
(c) Attach the flexible hose to the upper
bore of the rear cylinder, checking 28. REAR WHEEL CYLINDER
first that the copper gasket is in good Description
order. Fit flexible hose to bracket
on the chassis frame as described on The cylinder, which is fitted in an elongated
page 5. slot in the rear brake plate, is free to slide in
the slot between the tips of the brake shoes
(d) Fit bleed screw to upper bore of which are of the leading and trailing shoe
front wheel cylinder. type. The cylinder has a single piston
operating on the tip of the leading shoe and
(e) Fit brake shoes, taking care to locate this shoe abutts against a fixed anchor
the" micram" adjusters in the slots block at the bottom of the back plate, the
in the leading tip of each shoe, with web of the shoe being free to slide in
the masks in position. a slot in a block. The trailing shoe is
(f) Fit brake drum and bleed hydraulic located in a similar manner between the
system as described on page 3. anchor and the closed end of the cylinder
and is free to slide and therefore self
(g) Adjust brake as described on page 3. centring.
(b) Check the system for fluid leakage by The trailing shoes are operated by move-
applying a firm pressure to the pedal ment of the reaction of the leading shoe
and inspecting the pipe line and against the brake drum. A" micram "
connections. adjuster is located in a slot in the top of
the leading shoe.
(i) Fit road wheel and nave plate. Remove
jacks. The wheel cylinder contains a single piston,
split in two, the inner piston being
26. TO DISMANTLE FRONT WHEEL hydraulically operated while the outer
CYLINDER piston is manually operated by the hand
brake lever. A rubber cup mounted in the
(a) Withdraw the piston complete with cup filler is loaded upon the inner piston
piston cover from cylinder body. by a spring. When operated hydraulically,
(b) Apply low air pressure to the flexible the inner piston abuts against the outer
hose connection, the rubber cup, the piston leaving the handbrake lever undis-
cup filler and spring can readily turbed, and applies a thrust to the tip of the
be removed. leading shoe through the dust cover,
micram adjuster and mask. When operated
manually, an inward movement of the hand
27. TO ASSEMBLE FRONT WHEEL brake lever brings the head of the contact
CYLINDER lever into contact with the outer piston,
Ensure absolute cleanliness during the thrusting it outwards against the leading
assembly of these components. Assemble shoe without disturbing the inner piston.
parts with a generous coating of clean A rubber boot is fitted to exclude water
Lockheed Brake Fluid. and foreign matter.
12
BRAKES
fl
~ / 21
13
BRAKES
29. TO REMOVE REAR WHEEL (e) Bleed the hydraulic system as described
CYLINDER on page 3. Adjust the brake shoes
(a) Jack up rear of car. Remove nave as described on page 3.
plate, road wheel and brake drum.
Slacken off micram adjuster. (f) Check the system for fluid leakage by
applying firm pressure to the pedal
(b) Drain off hydraulic fluid, disconnect and inspecting the line and connections.
handbrake cables and remove banjo
bolt from banjo connection which is (g) Fit road wheel and nave plate. Re-
situated on the inner side of the brake move jacks.
plate.
(c) Pull the trailing shoe against the load 31. TO DISMANTLE REAR WHEEL
of the pull-off springs and away from CYLINDER
its abutment at either end; on releasing
tension of the pull-off springs the lead- (a) Withdraw the piston complete with
ing shoe will fall away. Collect the piston cover from the cylinder body.
micram adjuster and mask. (b) Remove the seal from the piston by
(d) Remove the rubber boot and the hand- easing out of its groove.
brake piston. (c) Drift out the hand brake lever pivot
(e) Swing the hand brake lever until the pin to remove handbrake lever.
shoulder is clear of the back plate and
slide the cylinder casting forward. (d) Apply low air pressure to the
Pivot the cylinder about its forward inlet connection, the rubber cup, the
end and withdraw its rear end from cup filler and spring can readily be
the slot in the back plate. A rearward removed.
movement of the cylinder will now
bring its forward end clear of the back
plate.
14
BRAKES
(b) Follow up with the rubber cup, lip (b) Remove brake shoes and collect pull-
end forward, taking care not to damage off springs and adjusters.
or turn back this lip.
(c) Insert hydraulic piston into body (c) Fit the replacement shoes and new
ensuring that the slot coincides with pull-off springs after ascertaining that
the lever slot in the cylinder body. the brake linings are of the same
(d) Place the handbrake lever in position material (see page 2).
and fit pivot pin. (d) Fit brake drum and adjust brakes as
(e) Stretch the hand brake piston rubber described in page 3.
seal over the hand brake piston and
place with dust cover in cylinder
body, ensuring that the hand lever is 36. TO REMOVE PEDAL ASSEMBLY
engaged in the slot of the piston. (a) Working under the bonnet, drain
The seal is to be twisted on its side so both hydraulic systems and remove
that the edge which tends to protrude clevis pins from piston rods of twin
from the groove enters the bore last. master cylinder and disconnect pipe
33. TO REMOVE HYDRAULIC PIPE lines from rear of master cylinder.
LINE FROM REAR AXLE (b) Remove four nuts and lock washers
(a) Remove rear flexible hose as described from front end of master cylinder
on page 6. support bracket adjacent to pedal
(b) Disconnect the Bundy tubing at the push rods.
brake plate by withdrawing union nut (c) From inside the car withdraw the
from banjo connection at each side. two bolts and lock washers securing
(c) Repeat operation (b) at three-way the side flanges of the pedal shaft
connection. casing to the bulkhead.
(d) Remove Bundy tubing from axle by (d) Remove the two bolts and lock washers
releasing pipe clips at each side. from the front and rear flange of the
(e) The three-way connection can be shaft casing and remove pedal assembly
removed after withdrawing bolt and from bulkhead. The support bracket
lock washer. with master cylinder attached can
also be removed from top of bulkhead.
34· TO FIT HYDRAULIC PIPE LINE TO An alternative method of pedal
REAR AXLE
The fitting of the Bundy tubing is the assembly removal is to omit the drain-
reversal of the removal but the following ing of the hydraulic system and
points should be noted: the disconnection of the pipe lines
mentioned in operation (a), leaving
(a) The olives of the Bundy tubing should the master cylinder and support bracket
be correctly seated before securing the in position.
union nut.
(b) The pipe clips should be attached in
such a manner that the pipe is in no 37. TO FIT PEDAL ASSEMBLY
way squeezed or damaged. (a) Working inside the car, secure the
(c) The flexible hose is fitted as described pedal assembly to the bulkhead,
on page 6. utilising two bolts and lock washers
(d) The connections should be inspected and the front and rear mounting
for leaks by applying firm pressure to flanges.
the foot pedal.
(b) Position the support bracket and
35· FITTING REPLACEMENT BRAKE master cylinder on the four studs
SHOES protruding through the bulkhead shelf
(a) Jack up car and remove wheels, brake in such a manner that the clutch
drums and slacken off all adjustment and brake piston fork ends engage
of micram adjusters. with the two pedal levers.
15
BRAKES
NOTATION FOR Fig. 8
18
BRAKES
43. TO ASSEMBLE HANDBRAKE (c) Release the tension of the sprmg
ASSEMBLY securing the brake cable to the gearbox
(a) Feed the push rod into the lever tunnel. Withdraw the two bolts from
from below so that its shape corres- the cable abutment brackets and re-
ponds with that of the handle. move cable assembly.
(b) Attach the pawl to the push rod so (d) Withdraw the split pins and clevis
that it points rearward. pins attaching the transverse cables
(c) Allow the push rod to protrude through to the levers on the brake backing plate.
the upper portion of the handle and (e) Remove the split pms and clevis
feed on a plain washer and coil spring, pins at their inner ends, taking care
followed by the button. Apply pressure to collect the anti-rattle springs.
to the button to compress spring. Remove cables from car.
(d) Hold the pressure on the button and
feed the ratchet, teeth facing forward, (f) The compensator assembly can be
into the lower portion of the casing, removed from the axle by turning
ensuring that it is positioned well lever and bar assemblies independently
inside the lever. Manipulate the pawl in an anti-clockwise direction.
until its fulcrum hole is aligned with
the hole in the lever and insert the
clevis pin; pressure on the button
can now be released. Secure clevis pin 45. TO FIT HANDBRAKE CABLES
with plain washer and split pin. The fitting is the reversal of the removal
(e) Secure the attachment plate to the but the following points should be noted :--
ratchet, utilising a bolt and nyloc nut. (a) The transverse cables should be of
Tighten the nut sufficiently to allow the correct length. R.H. 12.97" ±.06"
the attachment plate to swing on the L.H. 26.85" ±.06". These measure-
ratchet. Failure to observe this instruc- ments for 10" brakes are 12.47" and
tion will result in imperfect handbrake 26.35" respectively.
operation.
(f) The tape protecting the thread can (b) All cables and fulcrums should be
now be removed and the grip fitted. thoroughly greased before fitting.
44. TO REMOVE HANDBRAKE CABLES (c) The bar assembly is attached to the
(a) Let off the hand brake, lock the rear axle with a new felt seal and then
brakes on by turning the micram turned back one turn. This instruction
also applies to the lever assembly
adjuster. when fitted to the bar assembly.
(b) Withdraw the split pins and clevis
pins at each end of the handbrake (d) The handbrake is adjusted as described
cable assembly. on page 3.
19
Service Instruction
Manual
EXHAUST SYSTEM
s
SECTION S
EXHAUST SYSTEM
INDEX
Page
Notation for Figure 1 ...... ...... ...... ...... ...... 1
Description ...... ...... ...... ...... ...... 2
Maintenance ............ ...... ...... ...... ...... 2
Exhaust System. T o remove and dismantle ...... 2
Notation for Figure 3 . . . . . . . . . . . . ...... ...... ...... 3
Exhaust System. T o fit ...... ...... ...... ...... 4
.
Manifolds To remove ...... ...... ...... ...... 4
Manifolds. T o fit ...... ...... ..... ...... ..... 4
ILLUSTRATIONS
Page
Fig . 1 Exploded view of exhaust system ............ ...... ...... 1
Fig. 2 Fitting the auxiliary silencer ...... ...... ...... ...... 2
Fig. 3 Exploded view of manifolds............ ...... ...... .,.... 3
EXHAUST SYSTEM
Ref. Ref.
No. No.
1 Exhaust flange joint. 10 Clamp plate.
2 Front exhaust pipe. 11 Attachment nut.
3 Prior to Commission No. TS.4310 only : 12 Clamp bolt
A Attachment bolt to chassis. 13 Attachment nut.
B Flexible mounting strip. 14 Attachment bolt to chassis frame.
C Clamp plate. 15 Rubber and steel grommet.
D Attachment nut. 16 Rubber and steel grommet.
E Exhaust pipe clip (Upper half). 17 Attachment nut.
F Clamping bolt. 18 Clamp nut.
G Attachment nut. 19 Clamp plate.
H Rubber and metal grommet. 20 Attachment bolt (Support bracket).
J Clamp plate. 21 Pipe clip.
K Attachment bolt. 22 Pinch bolt.
L Exhaust pipe clip (Lower half). 23 Nut for pinch bolt.
M Rubber washer. 24 Flexible mounting strip.
N Attachment bolt (Lower half clip). 25 Pinch bolt.
P Nut for clamp bolt. 26 Attachment nut.
4 Silencer. 27 Clamp plate.
5 Tail pipe assembly. 28 Attachment bolt to chassis.
6 Tail pipe extension. 29 Pipe clip attachment bolt.
7 Flexible mounting strip. 30 Nut for pinch bolt.
8 Exhaust pipe support bracket. 31 Clamp plate.
9 Attachment bolt to chassis. 32 Clip attachment nut.
EXHAUST SYSTEM
EXHAUST SYSTEM 2. MAINTENANCE
I. DESCRIPTION The exhaust system should be inspected
periodically to ensure its correct function.
The manifolds are attached to one another Attention should be paid to the gaskets at
by studs in the aluminium alloy induction the cylinder head, carburettor and front
manifold and lugs moulded in the cast exhaust pipe flanges to ascertain their
iron exhaust manifold. There is no condition. If signs of " blowing" are
" hot spot " for easy starting. detected then gasket must be replaced as
The exhaust system is situated on the soon as possible. Manifold gaskets should
right-hand side of the engine and passes be replaced as a pair and no gasket should
down to the rear of the car through the ever be used twice.
centre of the cruciform to a position The flexible mounting strips should be
adjacent to the left-hand chassis member. inspected and replaced if any deterioration
The front exhaust pipe is attached to the is apparent.
engine by a flange and is flexiblymounted to The position of the silencer assembly in
the chassis frame at a point forward of relation to the cruciform centre should
the cruciform centre. This attachment also always be such that during any vibrationary
secures the pipe to the outside of the period the exhaust system cannot come
silencer. Cars with Commission No. into contact with the cruciform.
TS.4310 and before has this clip in two
halves as shown in Fig. 1. 3. TO REMOVE AND DISMANTLE
Two types of silencers have been used in EXHAUST SYSTEM
production, the former 18" silencer being (a) Working from the rear of the car
changed for a 24" type at Commission loosen the bolt of the rear pipe clip
No. TS.2532. A modified tail pipe incor- attachment and withdraw exhaust pipe
porating a 12" silencer can be fitted, at the extension.
owner's discretion, to the shorter type
silencer, if the exhaust note is considered (b) Withdraw the lower bolt securing
too loud (see Fig. 2). This modified pipe clip attachment to flexible mount-
tail pipe fits into the main silencer and is ing strip and collect nut and lock
attached with the existing clip. washer.
At the rear the tail pipe is attached to the (c) Loosen the pinch bolt of the pipe
chassis by a flexible mounting strip and the clip attachment at the rear of the
clip secures the chromium plated extension silencer and withdraw tail pipe
piece inside the tail pipe. assembly.
EXISTING INSTALLATI ON
- OR-
PART N O 2 0 2 3 2 0 (24" LONG)
F I T T E D TO LATER C A R 4
THIS PIPE IS CARRIED ON EXISTING
TAIL PlPE MOUNTING.
EXHAUST SILENCER [IZ"LONG)AND TAIL PIPE
PART NQ 2 0 2 2 8 5
REPLACING TAILPIPE PART NQ2 0 2 0 0 9
Fig. t Method of supplementary silencing provided by 18" Silencer, fitted prior to Corn. No. T.S.253~.
EXHAUST SYSTEM
TR3 MODELS
Issnea by the
SERVICE DIVISION, THE STANDARD MOTOR CO. (1959) LTD.
COVENTRY, ENGLAND
FOREWORD
Certain modifications have been incorporated in the
TR3 models and have been made with a view to
enhancing its appearance and performance.
GENERAL DATA
SECTION A
GENERAL DATA
GENERAL DATA TRANSMISSION
The information given in this section should be Ratios
studied in conjunction with that given in the
appropriate pages of the main Manual. O/D Top Top
Gearbox .82 1.00
CAMSHAFT BEARINGS Overall 3.03 3.7
Vandervell shell bearings are fitted to the 2nd,
3rd and rear journals. O/D 2nd 2nd 1st Rev.
Gearbox 1.64 2.00 3.38 4.28
CARBURETTORS Overall 6.07 7.4 12.5 15.8
Two S.U. Type H6 carburettors are fitted.
The early TR3 cars were fitted with carbu-
rettors having " T D " needles, but this needle Engine Speed at
was changed to type " TE " early in normal 10 m.p.h. 10 km.p.h.
production and was, at Engine No. TS. 10037E, O/D Top 410 R.P.M. 245 R.P.M.
superseded by type " SM ". Where replace-
ment needles are required for carburettors TOP 500 ,, 310 ,,
fitted with the early needles, both needles O/D 3rd 540 3, 340 9,
410 ,,
should be replaced by the " SM " needle. 3rd
OID 2nd
2nd
660 3,
820
1,000 3,
..
-< 510 ,,
620 9,
PERFORMANCE DATA 1st 1,680 3, 1,050 ,,
95 B.H.P. at 4,800 R.P.M. Rev. 2,130 ,, 1,325 ,,
GENERAL DATA
ENGINE
I. CYLINDER BLOCK this instruction may. result in the
Vandervell replaceable shell bearings have bearing becoming distorted when the
been introduced for the 2nd, 3rd and rear locating screw is tightened.
camshaft journals. These are manufactured Fit a plain steel washer of &" thickness
to very fine limits, and whilst certain fitting (1.558 rnm.) between the head of each
precautions must be observed, line boring locating screw and the cylinder block.
of the assembled bearings is unnecessary. Refit or replace the camshaft sealing
Removal of the rear bearing will necessitate disc if necessary.
the removal of the sealing disc behind it,
which, in turn, will require the removal of 2. ALUMINIUM PEDESTALS FOR
the gearbox, clutch and flywheel. The tool ROCKER SHAFT
illustrated in Fig. 1 is designed to assist New rocker pedestal brackets of aluminium
in the removal and replacement of the alloy were incorporated in normal produc-
bearings. tion at Engine No. TS.12564E. The new
metal, by reason of its higher degree of
expansion when hot, enables the same
rocker clearances to be used for exhaust
valves as were previously applied only to
the inlets. This reduction in the exhaust
valve clearances has the advantage of
reducing " tappet " noise when the engine
is cold without any sacrifice of performance.
Where it is desired to fit the new pedestal
\'4 / REMOVER a GUIDE GUIDE PIN
brackets, these should be fitted as a
complete set, the part numbers being as
Fig. I. Fitting Intermediate Camshaft Bearing follows :--
using Churchill Multipurpose Tool No. 32 Aluminium Pedestal Bracket (Plain)--
with Adaptors S.32-I. 3 off-Part No. 112546
Aluminium Pedestal Bracket (Drilled)-
(a) Camshaft Bearings 1 off -Part No. 112545
T o remove, proceed as follows :-
(i) Using a suitable tool, drift the 3. PISTONS
sealing disc out of the rear cam- From Engine No. TS.9731E3 the pistons
shaft bearing housing. are fitted with :-
(ii) Unscrew and remove the three 1 Plain ring.
shouldered setscrews and plain 1 Taper ring.
washers which retain the bearings 1 Oil scraper ring.
in position.
(iii)Assemble the extracting tool and 4. COMBUSTION HEAD
adaptors into the cylinder block To further improve performance, " High
as illustrated, and withdraw each Port" type combustion heads where in-
bearing in turn. corporated in production at Engine No.
(b) To Fit New Bearings TS.9350E. In countries where high octane
See Fig. 1 and observe the following: fuel is unobtainable, the compression ratio
The oil feed holes must be correctly may be lowered to 7.511 by the use of a
aligned and when drawing the bearings compression plate, Part No. 200906. This
into position all possible precautions plate must be used in conjunction with a
should be taken to ensure that these steel " Corrojoint " gasket, Part No. 202775
do not turn and so rnisalign the holes. in addition to the normal gasket.
Ensure also that the locating hole in When using this low compression plate it
each bearing is centrally disposed in will also be necessary to use Champion L. 10
the tapped hole which accommodates sparking plugs gapped to 0.025" and special
the locating screw. Failure to observe push rods, Part No. 114048.
ENGINE
ENGINE OIL FILTER
In order to give the maximum protection
to the engine when subjected to high speed
or rally conditions, a new filter of the
" full flow " type has been introduced on
the TR3 models. This type of filter ensures
that all the oil in circulation passes through
the filtration system.
The " full flow " type of filter was intro-
duced into normal manufacture at Engine
No. TS.l2650E., part numbers affected
by this change bemg as follows :-
Oil filter assembly, Part No. 301994, is
replaced by Part No. 20327 1.
The replacement Element, Part No. 101963,
remains the same for both types of filter.
The oil pressure on the " full flow " type
of filter remains at 70 lbs. per sq. in. with
an oil temperature of 70°C. at an engine
speed of 2,000 r.p.m.
The new filter assembly can be fitted if
desired to an engine prior to TS.12650E.
SUMP
A special cast aluminium sump, Part No.
301318, and tray, Part No. 201984, are
available as optional extras.
1 Axle casing assembly. 18 Crown wheel securing bolt. 35 Fibre washer for (34).
2 Bearing cap setscrew. 19 Plain washer for (18). 36 Axle half shaft.
3 Spring washer. 20 Three hole lockplate for (18). 37 Rear hub bearing.
4 Axle case breather. 21 Two hole lockplate for (18). 38 Hub bearing housing.
5 Fibre washer. 22 Pinion head bearing. 39 Oil seal for hub bearing housing.
6 Drain plug. 23 Adjusting shims for (22). 40 Adjusting shims for hub bearing.
7 Differential bearing. 24 Bearing spacer. 41 Lockplate.
8 Adjusting shims for (7). 25 Pinion tail bearing. 42 Setscrew for securing housing.
9 Differential casing. 26 Adjusting shims for (25). 43 Hub.
10 Differential sun gear. 27 Pinion shaft oil seal. 44 Road wheel attachment stud.
11 Thrust washer for (10). 28 Pinion driving flange. 45 Hub driving key.
12 Differential planet gear. 29 Driving flange securing nut. 46 Hub securing nut.
13 Thrust washer for (12). 30 Plain washer for (29). 47 Plain washer for (46).
14 Cross pin. 31 Split pin for (29). 48 Split pin for (46).
15 Thrust block. 32 Rear cover. 49 Cover plate securing screw.
16 Lock pin for securing (14). 33 Joint washer for (32). 50 Spring washer for (49).
17 Crown wheel and pinion. 34 Oil filler plug. 51 Axle tube oil seal.
REAR AXLE
(e) The stud plates can be withdrawn by (b) Fit the back of the seat cushion under
sliding them to the end of each half the spring clip at the rear of the seat
moulding. pan and settle cushion into position.
BODY
XI. TO FIT OCCASIONAL SEATS (e) Position the occasional seat behind the
driver and passenger seats and secure
(a) Slide the driver and passenger seats with four bolts removed during the
forward to their fullest extent. previous operations.
(b) Lift up the carpet at the rear of the
two seats and remove the two bolts
and washers so exposed. 12. TO REMOVE OCCASIONAL SEAT
(a) Withdraw the four attachment bolts
(c) Make two small holes in the carpet to and plain washers.
align with the tappings in the floor
assembly. (b) Remove the seat from the rear of the
passenger compartment.
(d) Withdraw the two chrome headed
bolts and washers from the trim at the (c) Return the bolts and plain washers to
rear of the passenger compartment. their tappings for safe keeping.
BODY
'D'
4. BRIDGE PIECES-TO FIT (b) Over the cappings, extend the markings
previously scribed on the body. Re-
(a) Loosely secure the five bridge pieces move the cappings from the car.
to the angle brackets ,previously fitted Scribe the inside of the cappings
in the rear stiffener rail. (Fig. 4.) exactly in line with the marks on the
(b) Reposition the "Hard Top " to the car outside. (Fig. 1.)
and secure to the three windscreen
attachment brackets. The bridge (c) Using a driU, drill the cappings at
pieces will now be resting on the elbow the positions marked on the insides
rail channel. (Fig. 4.) and ensure that when drilled, the holes
are aligned with those in the bridge
ANGLE BRACKETS pieces.
(d) Attach the millboard to the front of the
petrol tank and secure with P.K.
screws. Refit the cappings over the
bridge pieces and secure.
(e) Select the three narrow protection
c a ~ sand position these on the rear
cabpings, *aligning the centre holes
with the threaded centres of the bridge
pieces. Drill the cappings through the
~rotectioncam and secure with P.K.
klf tapping Bcrews. The two larger
caps are fitted in a similar manner to
the side elbow rails. (Fig. 1.)
(f ) Fit four countersunk screws and chro-
Fig. q Drilling the Elbow Rail and installing Bridge mium washers in the holes previously
Pieces. used to accommodate the hood bracket
NOTE : Drilling should only be necessary on Cars screws. Remove the protecting tape
prior to TS.6824. from the body of the car.
BODY
6. DRIP CHANNELS-TO FIT
(See Figs. 5 and 6 )
". w
Fig. 7 Fitting Rear Window and Waist Rubber.
Fit the rubber moulding around the glass stripdinto position. with thewaid of a
with the filler sectionpositioned towards the " Seelastik gun ",complete the installation
rear of the car. Offer the glass with the by forcing Sealastik compound between the
rubber attached, to the aperture in the cc Hard Top " and the outer lip of the
<(HardTop" and with the help of an assistant glazing rubber to effect water sealing.
FUEL SYSTEM
I. PETROL TANK 7. TO FIT FLEXIBLE FUEL HOSE
The petrol tank has been modified slightly ASSEMBLY
to accommodate the occasional seat, its (a) Position the filter assembly in the rear
capacity is thereby reduced to 12 gallons. carburettor float chamber, spring first.
2. FLEXIBLE FUEL PIPES (b) Feed a fibre washer on to the banjo
A flexible fuel pipe connects the twin bolt, followed by the banjo connection
carburettors and is integral with a short and a second fibre wa&er, and then
feed line which is connected to the Bundy attach to the rear carburettor and leave
tubing at a point adjacent to the thermostat finger tight at this juncture.
housing. (c) Repeat operation (a) and (b) with the
front carburettor.
3. CARBURE'ITORS
S.U. H6 type carburettors are fitted to this (d) Holding the hexagon of the flexible
engine. This carburettor has a four-point hose with a spanner, attach the union
mounting but is similar in other respects nut of the rigid supply pipe and secure
to the H4 used on the TR2, is identical in to give a petrol tight joint.
operation and requires the same main-
tenance. (e) Adjust the position of the banjo con-
Carburettors fitted to early cars were nections on the float chambers of the
equipped with " T D " needles, while with twin carburettors so as to avoid any
later cars " T E " needles were used, this strain, and tighten banjo bolts to give
needle in turn was superseded by a petrol tight joint.
cc SM " at Engine No. TS.10037E. 2;
needles are changed for any reason a pair
(f) Start the engine and observe the he1
pipes for leaks.
of type CC SM " should be fitted.
4. AIR CLEANERS 8. CARBUREl'TOR DETAILS
The air cleaners are similar to those fitted The instructions given for the H4 car-
to the TR2 apart from the off-set mount- burettor as fitted to the TR2 apply to the
ings. H6 type apart from the four-point mount-
ings. The jet needles at present used in
5. INLET MANIFOLD normal manufacture are of the "SM"
This has been modified to accommodate type, although with early releases of the
the four-point fixing H6 carburettor, and TR3 model the " TD " or cC TE " needle
manifolds fitted to engines after TS.9350E was fitted.
have a larger bore to align with the enlarged The " T D " or Cc T E " needles in both
throat area of the high port combustion carburettors should be replaced by type
head. " SM " if damage or wear justifies the
exchange in either unit.
6. TO REMOVE FLEXIBLE FUEL
HOSE ASSEMBLY
(a) Hold the hexagon of the flexible hose 9. AIR CLEANERS
assembly and disconnect the union The air cleaners have off-set mounting and
nut of the rigid pipe adjacent to the must be positioned on the carburettor air
thermostat housing. intake in such a manner that the off-set is
rearward.
(b) Withdraw the banjo bolt from one
carburettor, collecting the gauze filter
and retaining spring. 10. INLET MANIFOW
(c) Repeat operation (b) with the second The inlet manifold is removed and fitted as
carburettor. those fitted to the TR2 engine.
BRAKES
MASTER CYLINDERS
- GREASE NIPPLE
CY
LEVER ONE NOTCH. CABLE AND
WIRE ROPES SHOULD BE JUST TAUT.
f- SET BOLTS
/
/ @-SHAKE PROOF WASHER
LINING SEGMENTS
BLEED
DUST C
Due to the simplicity of these disc brakes In order to fit new segments the pistons
the only normal servicing which will be in the caliper bore should be pushed to
carried out by the owner or garage will be the bottom, and the new segments
the replacement of worn lining segments, placed into position. When the seg-
seals and boots of the hydraulic caliper. ments are positioned correctly, the
retaining plates should be replaced in
(a) Lining Segment Replacement their original position and the setscrews
(Fig. 2) tightened down.
Jack up the front of car and remove The replacement of segments is then
road wheels. On the top of the caliper complete and bleeding is unnecessary,
body are two setscrews which secure the but the foot pedal should be pumped
segment retaining plates. The release until a solid resistance is felt.
of these will enable the retaining plates Jack down the front of the car and
to be raised out of engagement with road test,
the casting and swung through an arc
of 180". The segments are then fully (b) Caliper Cylinder Maintenance
exposed and can be lifted out of the To Replace the Rubber Seals
caliper. In order to replace the rubber " 0 "
Under no circumstances should at- rings or seals it is necessary to remove
tempts be made to reline worn segments the caliper assembly from the vehicle.
and these must be replaced by new The brake segments should be re-
Parts* moved in the manner described above.
BRAKES
Instead of pushing the pistons to the the bore, taking great care not to
bottom of the bore withdraw them damage the polished surface. Push the
from the caliper body, taking great piston right home and then engage the
care not to damage the bores. The outer lip of the rubber boot into the
sealing rings may then be removed by groove of piston.
inserting a blunt tool under the seals The replacement of the lining segments
and prising out, taking care not to as described under the heading " Seg-
damage the locating grooves. Ex- ment Replacement" will retain the
amine the bores and pistons carefully pistons in position.
for any signs of abrasion or "scuffing." Refit the caliper assembly to the sup-
No attempt should be made to remove
the end plug retainer, as this is screwed port bracket by means of the two
in tightly by mechanical means. securing bolts ensuring that the disc
passes between the two lining segments.
It is important that in cleaning the Re-connect the pressure hose and bleed
components no petrol, paraffin, tri- the brake, as described under " Bleed-
chlorethylene or mineral fluid of any ing the System."
kind should be used. Clean with
methylated spirits and allow to vapor-
ise, leaving the component clean and 2. DISCS
dry T o ensure that the brake functions at
After cleaning and examining, lubricate maximum efficiency a check should be
the working surfaces of the bores and made to see that the disc runs truly
piston with clean genuine Girling between the segments. The maximum
Crimson Brake and Clutch Fluid. run-out permissible on the disc is .004".
(For instructions regarding wheel bearing
(c) Assembling settings refer to page 7, Section " G," in
Fit new rubber seals into the grooves the main part of this manual.) If excessive
of caliper cylinder bore. Locate the run-out is present this will cause the
rubber dust cover with the projecting knocking back of the pistons which will
lip into the groove provided which is possibly cause judder.
the outer one of the cylinder bore. If it is found that the discs have been
damaged in any way, which is extremely
Insert the piston, closed end first, into unlikely, it will be necessary to remove the
discs from the car in order for them to be
" trued " up. Under no circumstances
should more than .060" be removed, with
the finish to be 32 micro ins. maximum
measured circumferentially and 50 micro
ins. measured radially.
piston, while the trailing shoe rests in a slot finished bore of a light alloy die cast wheel
formed in the cylinder body. At the cylinder body, whilst a slot, machined in
adjuster end the shoe ends rest in slots in the the opposite end of the body, serves to
adjuster links. The shoes are supported by carry the trailing shoe. The cylinder,
platforms formed in the backplate, these incorporating a bleed screw with rubber
beine held in ~ositionbv two hold-down cap, is attached to the back plate by spring
sprggs fitted on'each shoekith a peg passing clips which allow it to slide laterally. The
through a hole in the backplate. handbrake lever pivots on, and projects at
The adjuster consists of an alloy right angles through the back plate.
housing with studs, which is spigoted and When the brake is applied, the piston under
secured firmly to the inside of the backplate the influence of the hydraulic pressure
by nuts and spring washers. moves the leading shoe and the body reacts
by sliding on the backplate to operate the
The housing carries two opposed steel links, trailing shoe.
the outer end slotted to take the shoes, and
the inclined inner faces bearing on inclined The handbrake lever is pivoted in the
faces of the hardened steel wedge (the axis cylinder body and when operated, the lever
of which is at right angles to the links). tip expands the leading shoe and the pivot
moves the cylinder body and with it the
The wedge has a finely threaded spindle trailing shoe.
with a s uare end which projects on the
9
outside o the backplate. By rotating the
wedge in a clockwise direction the links are (a) Dismantling
forced apart and the fulcrum of the brake If it is found necessary to remove a
shoe expanded. rear wheel cylinder, the following
A piston and seal moves in the highly procedure should be followed :-
BRAKES
(i) Jack up the vehicle, remove the of the slots in the adjuster link and
wheels, and disconnect the rod wheel cylinder piston. Both shoes
from handbrake lever. complete with springs can then
(ii)Remove the brake drum and shoes. be removed. Place a rubber band
Disconnect the pressure pipe round the wheel cylinder to keep
union from the cylinder, and piston in place.
remove the rubber dust cover from (iii) Clean down the backplate, check
rear of backplate. wheel cylinders for leaks and free-
By using a screwdriver, prise the dom of motion.
retaining plate and spring plate (iv) Check adjusters for easy working
apart, then tap the retaining plate and turn back (anti-clockwise) to
from beneath the neck of the full " off" position. Lubricate
wheel cylinder. where necessary with Girling
(iv) Withdraw the handbrake lever White Brake Grease.
from between the backplate and (v) Smear the shoe platforms and the
wheel cylinder. operating and abutment ends of
(v) Remove the spring plate and the new shoes with Girling White
distance piece, and finally the Brake Grease.
wheel cylinder from the backplate.
(vi) Fit the two new shoe return
springs to the new shoes (with
(b) Refitting the Rear Wheel Cylinder the shorter spring at the adjuster
Mount the wheel cylinder on to the end) from shoe to shoe and
backplate with the neck through the between shoe web and backplate.
large slot. Replace the distance piece Locate one shoe in the adjuster
between cylinder neck and backplate, link and wheel cylinder piston
with the open end away from hand- slots, then prise over the opposite
brake lever location. The two cranked shoe into its relative position.
lips must also be away from the Remove rubber band. Insert the
backplate. hold down peg through hole in
Insert the spring plate between the backplate, and replace spring and
distance piece and backplate, also with cupped washers smeared with
open end away from handbrake lever Girling White Brake Grease.
location and the two cranked lips away (vii) Make sure drums are cleaned and
from the backplate. free from grease, etc., then refit.
Replace handbrake lever. Locate the (viii) Adjust brakes.
retaining plate between the distance
piece and spring plate (open end (ix) Refit road wheels and jack down.
towards the handbrake lever), tap into
position until the two cranked tips of
the spring plate locate in the retaining Note.-The first shoe has the lining
plate. positioned towards the heel of
Fit the rubber dust cover. Attach the the shoe and the second shoe
pressure pipe union to the cylinder towards the toe or operating end
and connection to the handbrake lever. in both L.H. and R.H. brake
Replace the shoes, brake drum, and assemblies.
bleed the system. Finally re-fit wheels. Several hard applications of the
pedal should be made to ensure
all the parts are working satis-
(c) Fitting Replacement Shoes factorily and the shoes bedding to
(i) Jack up the car and remove road the drums, then the brakes should
wheels and brake drums. be tested in a quiet road before
(ii)Remove the holding down springs normal running is resumed.
by turning the washer under the
peg head. Lift one of the shoes out Handbrake Setting-refer to F@. 1 .
BRAKES
RUNNING ADJUSTMENTS Release the handbrake and jack up the car.
The front disc brakes are entirely self- Turn the square end of the adjuster on the
adjusting. The rear brakes are adjusted outside of each rear brake backplate in a
for lining wear at the brakes themselves, clockwise direction until a resistance is
and on no account should any alteration be felt, then slacken back two clicks, when the
made to the hand brake cable for this pur- drum should rotate freely.
pose (Fig. l ). Immediately after fitting replacement shoes
One common adjuster is provided for each it is advisable to slacken one further click
brake assembly. Adjustment of both rear to allow for possible lining expansion,
wheels is identical. reverting to normal adjustment afterwards.
BOOT RETAINING BAND
RUBBER BOOT \
INLET PORT
WASHER
BLEED VALVE
I BODY
a DUST COVER PUSH ROD
Essential Precautions
Always Exercise extreme cleanliness when Always Use WAKEFIELD / GIRLING
dealing with any part of the Rubber Grease No. 3 (Red) for
hydraulic system. packing rubber boots, dust covers
Never Handle rubber seals or internal and lubricating parts likely to
hydrauhcs parts with greasy hands contact any rubber components.
or greasy rags. Never Use Girling White Brake Grease"
Always use Girling Crimson Brake and or other grease for this purpose.
Clutch Fluid from sealed quart
tins. Always Replace all seals, hoses and gaskets
Never Use fluid from a container that with new ones if it is suspected
has been cleaned with petrol, that incorrect fluids have been
parafin or trichlorethylene. used or the system contaminated
with mineral oil or grease. Drain
Never Put dirty fluid into the reservoir, off the fluid, thoroughly wash all
nor that which has been bled metal parts and flush out all pi es,
from the system. etc., with alcohol or clean GirYmg
Always Use clean Girling Brake and Crimson Brake and Clutch Fluid
Clutch Fluid or alcohol for clean-
ing internal parts of hydraulic Never Use anydung else for this purpose.
system. Always Use a particular container (re-
Never Allow petrol, paraffin or tri- served for this purpose) for bleed-
chlorethylene to contact these ing the system, and always main-
parts. tain in a clean condition.
Always Examine all seals carefully when Never Use a receptacle which has been
overhauling hydraulics cylinders cleaned with petrol, paraffin or
and replace with genuine Girling trichlorethylene.
spares, any which show the least
sign of wear or damage. Always Remember that your safety and
Always Take care not to scratch the the safety of others may depend
highly finished surfaces of cylinder on the observance of these pre-
bores and pistons. cautions at all times.
EXHAUST SYSTEM
EXHAUST SYSTEM
The exhaust system is unchanged from the
TR2 apart from the new manifold gasket
fitted to the enlarged port combustion
head after engine number TS.9350E.
STANDARD AND TRIUMPH VEHICLES
The modified pressure will be 70 lbs. per sq.in. and this should be
adjusted with the engine oil at normal running temperature, i.e. about 70C, with the
engine running at 2000 r.p.m.
NOTE: These instructions are for information only and do not constitute
an authority to carry out modifications at the expense of The
Standard Motor Company Limited.