1925 FORD MODEL T SERVICE MANUAL1925 FORD MODEL T SERVICE MANUAL
DESCRIPTION:
1925 FORD MODEL T SERVICE MANUAL – PDF DOWNLOAD
The performance of high grade service work is a vital factor in the development of a successful repair business, in fact it is the only safe foundation on which business of this character can be established. High grade service advertises the business standards of the dealer. It inspires confidence in customers, and customer satisfaction is the forerunner of business growth.
The elements of high grade service are: A sincere desire on the part of the automobile dealer or service station to serve car owners so efficiently that they will derive the maximum satisfaction from their investment. Prompt, courteous and intelligent attention to customers’ wants. Skilled mechanics; men who are specialists in promptly diagnosing and correcting car troubles.
A clean, well laid out repair shop, provided with modern service equipment. A well arranged parts department carrying a complete stock of parts and supervised by a parts salesman who knows stock and appreciates the value of courtesy and salesmanship. Too much importance cannot be attached to the employment of competent mechanics, as the quality of their workmanship governs the satisfaction of the customer to a large extent.
A clean, well laid out repair shop provided with modern service equipment is essential to the performance of good service. Modern service equipment not only saves time in performing the various repair operations, but it improves the accuracy of the work. New tools and measuring devices which are now available permit the mechanic to work to limits which practically approach manufacturing standards.
In Fig. 1 is shown an ideal shop layout for the average size dealer. The equipment is conveniently grouped and so arranged that as the work progresses through the shop each repair operation is performed in its regular order.
A feature of this layout is the comparatively small amount of floor space used, the entire layout requiring only 23 x 40′, thus making it adaptable for practically any type of building. The procedure followed when a car is brought in for major repair work is to first assign the car to a section of the shop set aside for repair jobs. The assembly to be overhauled is then removed from the car and by means of chain falls and an overhead track it is delivered to the wash tank for cleaning.
After the cleaning operation it is transferred to the stand or repair bench on which the work is to be performed. When the overhaul work is completed the assembly is returned by means of the overhead track to the car from. which it, was removed. It is then installed in the car and the job is completed.
TABLE OF CONTENTS:
1925 FORD MODEL T SERVICE MANUAL – PDF DOWNLOAD
Front Cover............................................................................................................................ 1
Price Page............................................................................................................................. 2
Table of Contents...................................................................................................................... 3
Index..................................................................................................................................307
Essentials of Good Service............................................................................................................. 7
Essential Shop Equipment............................................................................................................... 9
The Parts Department................................................................................................................... 11
Chapter I - Disassembling the Car...................................................................................................... 19
1 - Describe each step............................................................................................................. 19
2 - Install car covers............................................................................................................. 19
3 - Box for small parts............................................................................................................ 19
4 - Disconnect starting motor to switch cable...................................................................................... 19
Disassembling the Car.............................................................................................................. 19
5 - Remove rear fenders........................................................................................................ 19
6 - Remove running boards...................................................................................................... 20
7 - Remove headlamps........................................................................................................... 20
8 - Release four hood clamps and lift off hood................................................................................. 20
9 - Disconnect headlamp wires.................................................................................................. 20
10 - Remove hood blocks from frame............................................................................................. 20
11 - Remove front fenders...................................................................................................... 21
12 - Remove body from chassis.................................................................................................. 21
13 - Remove running board shields.............................................................................................. 22
14 - Remove radiator........................................................................................................... 24
15 - Remove radiator apron..................................................................................................... 24
16 - Remove fan................................................................................................................ 25
17 - Remove crankcase front bearing cap........................................................................................ 25
18 - Remove commutator pull rod................................................................................................ 25
19 - Disconnect ammeter to cutout wire at cutout............................................................................... 25
20 - Remove commutator case.................................................................................................... 25
21 - Remove horn............................................................................................................... 26
22 - Remove spark plug wires................................................................................................... 26
23 - Remove engine pan left.................................................................................................... 26
24 - Remove engine pan right................................................................................................... 26
25 - Remove carburetor pull rod................................................................................................ 26
26 - Remove carburetor adjusting rod........................................................................................... 26
27 - Remove priming wire....................................................................................................... 26
28 - Shut off gasoline......................................................................................................... 27
29 - Disconnect feed pipe from carburetor...................................................................................... 27
30 - Disconnect exhaust pipe from manifold..................................................................................... 27
31 - Disconnect magneto terminal wire.......................................................................................... 27
32 - Remove crankcase arm blocks............................................................................................... 27
33 - Remove crankcase arm bolts top............................................................................................ 27
34 - Disconnect axle from transmission......................................................................................... 28
35 - Remove steering gear asembly.............................................................................................. 28
36 - Disconnect starting motor to switch cable................................................................................. 30
37 Remove radius rod ball cap and springs...................................................................................... 30
38 - Remove spark plugs........................................................................................................ 30
39 - Remove engine from chassis................................................................................................ 30
40 - Remove coil box........................................................................................................... 30
41 - Remove lighting wire loom terminals....................................................................................... 30
42 - Remove commutator loom and case........................................................................................... 30
43 - Disconnect tail lamp wire................................................................................................. 31
44 - Remove battery, battery cable, battery box, battery box support, ground connector, and battery to switch cable support.... 31
45 - Remove feed pipe.......................................................................................................... 32
46 - Remove gasoline tank...................................................................................................... 32
47 - Remove terminal block..................................................................................................... 32
48 - Remove dash............................................................................................................... 32
49 - Remove the two dash brackets.............................................................................................. 33
50 - Remove radiator studs, nuts, and storage.................................................................................. 33
51 - Remove front fender irons................................................................................................. 33
52 - Remove starting switch.................................................................................................... 33
53 - Remove tail lamp and license bracket...................................................................................... 33
54 - Remove exhaust pipe and muffler........................................................................................... 33
55 - Remove spare rim carrier.................................................................................................. 34
56 - Remove brake rods from control shaft...................................................................................... 34
57 - Remove rear axle.......................................................................................................... 34
58 - Remove rear spring, handers, and perches.................................................................................. 35
59 - Remove control shaft...................................................................................................... 36
60 - Remove front axle assembly................................................................................................ 36
61 - Remove front axle assembly completing disassembly of car.................................................................. 36
Wiring Diagram (Starter Car)....................................................................................................... 37
Chapter II - Assembling the Car........................................................................................................ 39
62 - Install Spring Pad............................................................................................................ 39
63 - Connect Frame to Front Axle Assembly.......................................................................................... 39
64 - Install crankcase front bearing and clip assembly............................................................................. 39
65 - Install license bracket over ends of spring clip.............................................................................. 40
66 - Install front wheel........................................................................................................... 40
67 - Install control shaft and pipe feed clamp..................................................................................... 40
68 - Install rear spring........................................................................................................... 40
69 - Install rear spring clips..................................................................................................... 40
70 - Install spring clip bars...................................................................................................... 40
71 - Install rear spring hangers and perches....................................................................................... 41
72 - Install rear axle assembly.................................................................................................... 41
73 - Install brake shoes........................................................................................................... 42
74 - Install rear wheel............................................................................................................ 42
75 - Connect brake rods to control shaft and adjust brakes......................................................................... 43
76 - Install rear hub caps......................................................................................................... 44
77 - Install spare rim carrier..................................................................................................... 44
78 - Install tail light wire bushing............................................................................................... 44
79 - Install tail lamp and license bracket......................................................................................... 44
80 - Install starting switch....................................................................................................... 44
81 - Install battery bracket assembly and ground connector......................................................................... 44
82 - Install muffler and exhaust pipe assembly..................................................................................... 45
83 - Install gasoline tank......................................................................................................... 45
84 - Install feed pipe............................................................................................................. 45
85 - Install dash brackets......................................................................................................... 45
86 - Install dash.................................................................................................................. 46
87 - Install loom support bolt and support......................................................................................... 46
88 - Install terminal block "E" on dash............................................................................................ 46
89 - Install coil box.............................................................................................................. 46
90 - Install lighting wire loom on dash............................................................................................ 46
91 - Install battery box and battery............................................................................................... 46
92 - Install battery to switch cable support....................................................................................... 47
93 - Connect motor cable, battery wire, and switch cable........................................................................... 47
94 - Install battery box cover..................................................................................................... 48
95 - Connect tail lamp wire to tail lamp........................................................................................... 48
96 - Mount engine in frame......................................................................................................... 48
97 - Enter universal joint into drive plate assembly............................................................................... 48
98 - Install crankcase arm bolts - top............................................................................................. 48
99 - Install crankcase arm blocks.................................................................................................. 48
100 - Install crankcase arm bolts - side........................................................................................... 48
101 - Connect axle to transmission................................................................................................. 49
102 - Connect magneto terminal wire to post........................................................................................ 49
103 - Connect exhaust pipe to manifold............................................................................................. 49
104 - Connect front radius rod to crankcase........................................................................................ 49
105 - Install crankcase front bearing.............................................................................................. 50
106 - Assemble engine pan - right to engine........................................................................................ 50
107 - Assemble engine pan - left to engine......................................................................................... 50
108 - Install front fender iron bolts, radiator springs, studs, and washer nuts.................................................... 50
109 - Install radiator apron....................................................................................................... 50
110 - Install front fender irons................................................................................................... 51
111 - Connect feed pipe to carburetor.............................................................................................. 51
112 - Turn on gasoline............................................................................................................. 51
113 - Install carburetor hot air pipe.............................................................................................. 51
114 - Connect carburetor pull rod to throttle lever................................................................................ 51
115 - Install carburetor adjusting rod............................................................................................. 51
116 - Install Priming Wire......................................................................................................... 52
117 - Install commutator loom...................................................................................................... 52
118 - Connect headlamp and cutout to ammeter wires................................................................................. 52
119 - Install commutator case...................................................................................................... 53
120 - Install steering gear assembly............................................................................................... 53
121 - Install steering gear bracket block.......................................................................................... 53
122 - Connect carburetor pull rod to throttle rod lever............................................................................ 54
123 - Install steering gear ball arm key........................................................................................... 54
124 - Install ball arm............................................................................................................. 54
125 - Connect steering gear tube flange to dash.................................................................................... 54
126 - Install commutator pull rod.................................................................................................. 55
127 - Install fan and fan belt..................................................................................................... 55
128 - Install radiator and horn.................................................................................................... 56
129 - Install carburetor priming rod............................................................................................... 57
130 Install spark plugs............................................................................................................ 57
131 - Install running boards and shields........................................................................................... 57
132 - Install front fenders........................................................................................................ 58
133 - Install hood blocks.......................................................................................................... 59
134 - Install headlamps............................................................................................................ 60
135 - Assemble body to chassis..................................................................................................... 61
136 - Install priming rod.......................................................................................................... 61
137 - Connect switch loom wires.................................................................................................... 61
138 - Connect horn wire to horn.................................................................................................... 61
139 - Connect starting switch to motor cable....................................................................................... 61
140 - Install steering post bracket cap............................................................................................ 61
141 - Install steering wheel....................................................................................................... 62
142 - Install rear fenders......................................................................................................... 62
143 - Install spare rim on carrier................................................................................................. 63
144 - Check oil and fuel levels.................................................................................................... 63
145 - Install hood on car.......................................................................................................... 63
Alignment of Front Axle and Wheels................................................................................................. 63
146 - Check front axle pitch and alignment..................................................................................... 63
147 - Set axle pitch........................................................................................................... 63
148 - Tilt axle for pitch...................................................................................................... 63
Alignment of Front Wheels.......................................................................................................... 64
149 - Check front wheel camber and gather...................................................................................... 64
150 - Gather measurement....................................................................................................... 64
151 - Check gather............................................................................................................. 64
152 - Camber is non adjust..................................................................................................... 65
153 - Check camber............................................................................................................. 65
154 - Using automatic wheel aligner............................................................................................ 65
Alignment and Focus of Headlamps................................................................................................... 66
155 - Check headlamp alignment and focus....................................................................................... 66
Focusing headlamps................................................................................................................. 66
156 - Focusing headlamps....................................................................................................... 66
Alignment of Headlamps............................................................................................................. 67
157 - Align headlamps by bending headlamp brackets............................................................................. 67
158 - Check headlight alignment................................................................................................ 67
Chapter III - Major Repair Operations.................................................................................................. 68
159 - Overhauling principal repair operations...................................................................................... 68
160 - Do not use unnecessary force................................................................................................. 68
161 - Use new gaskets.............................................................................................................. 68
162 - Clean and lubricate.......................................................................................................... 68
Complete Engine and Transmission Overhaul.......................................................................................... 68
163 - Drain water from radiator................................................................................................ 68
164 - SHut off gasoline at sediment bulb....................................................................................... 68
165 - Break wire and run out universal ball cap cap screws..................................................................... 68
166 - Break wire and run off radius rod ball cap stud nuts..................................................................... 68
167 - Run off nuts on engine pan bolts......................................................................................... 68
168 - Lift off hood............................................................................................................ 68
169 - Disconnect carburetor priming rod........................................................................................ 68
170 - Disconnect bell crank priming wire....................................................................................... 68
171 - Disconnect carburetor pull rod........................................................................................... 68
172 - Remove carburetor pull rod............................................................................................... 68
173 - Disconnect feed pipe..................................................................................................... 68
174 - Run out cylinder head outlet connection screws........................................................................... 68
175 - Loosen radiator rod nut.................................................................................................. 69
176 - Disconnect horn wires at horn............................................................................................ 69
177 - Disconnect switch to starting motor cable................................................................................ 69
178 - Disconnect spark plug wires.............................................................................................. 69
179 - Remove radiator apron.................................................................................................... 69
180 - Remove fan and fan belt.................................................................................................. 69
181 - Run out two crankcase front bearing cap screws........................................................................... 69
182 - Disconnect carburetor pull rod........................................................................................... 69
183 - Loosen commutator case spring bolt....................................................................................... 69
184 - Connect ammeter to cutout wire at cutout................................................................................. 69
185 - Disconnect headlamp wires................................................................................................ 69
186 - Lift off hood blocks..................................................................................................... 69
187 - Loosen the four bolts and one cap screw holding engine pans.............................................................. 69
188 - Run off nut on end of steering gear post................................................................................. 69
189 - Run off nuts and withdraw steering gear bracket.......................................................................... 69
190 - Run off nuts and remove the four steering gear tube flange bolts......................................................... 69
191 - Swing steering gear bracket caps......................................................................................... 69
192 - Steering gear is drawn back through dash................................................................................. 69
193 - Lift out mat and floor boards............................................................................................ 69
194 - Disconnect exhaust pipe.................................................................................................. 69
195 - Disconnect magneto terminal wire......................................................................................... 69
196 - Run off nuts of the two universal call cap bolts......................................................................... 69
197 - Run off nuts and withdraw crankcase arm bolts (side)..................................................................... 70
198 - Run off nuts and withdraw two crankcase.................................................................................. 70
199 - Engine can now be lifted off frame....................................................................................... 70
Disassembling the Engine....................................................................................................... 70
200 - Remove exhaust and intake manifolds.................................................................................. 70
201 - Remove four inlet and exhaust clamp studs............................................................................ 70
202 - Remove Generator..................................................................................................... 71
203 - Remove transmission cover door....................................................................................... 71
204 - Remove crankcase and transmission cover.............................................................................. 71
205 - Disconnect transmission from engine.................................................................................. 71
206 - Remove oil pipe...................................................................................................... 71
207 - Remove valve cover, cylinder head and valves......................................................................... 72
208 - Remove valve springs................................................................................................. 73
209 - Remove camshaft...................................................................................................... 73
210 - Remove main bearing caps............................................................................................. 74
211 - Remove crankshaft.................................................................................................... 74
Inspecting the Cylinder Block, Valves and Push Rods............................................................................ 74
212 - Clean parts before reassembly........................................................................................ 74
213 - Check cylinder roundness............................................................................................. 74
214 - Check cylinder with gauge............................................................................................ 75
215 - Hone cylinder........................................................................................................ 75
216 - Check cylinder hone type............................................................................................. 75
217 - Check valves......................................................................................................... 76
218 - Check pushrod stems.................................................................................................. 76
219 - Check valve stem guides.............................................................................................. 76
220 - Check push rod guides................................................................................................ 76
221 - Reseat valves........................................................................................................ 76
222 - Fixing stripped threads.............................................................................................. 76
Rebabbitting the Cylinder Block................................................................................................ 77
223 - Check babbitt bearings............................................................................................... 77
224 - Cutout old babbitt................................................................................................... 77
225 - Pouring quality babbitt.............................................................................................. 77
226 - Melting babbitt...................................................................................................... 77
227 - Babbitt forming equipment............................................................................................ 77
228 - Keeping babbitt clear of oil holes................................................................................... 78
229 - Pouring into cold blocks............................................................................................. 78
230 - Ladeling babbitt..................................................................................................... 78
231 - Cutoff slag babbitt.................................................................................................. 78
232 - Peening babbitt...................................................................................................... 79
233 - Prepping babbitt for line reaming.................................................................................... 79
234 - Babbitt oil hole alignment tool...................................................................................... 79
235 - Cleaning block....................................................................................................... 80
236 - Dress up babbitt..................................................................................................... 80
237 - Drilling out babbitt oil holes....................................................................................... 80
238 - Check bearing alignment with Prussian blue........................................................................... 82
239 - Reasons for bearing disalignment..................................................................................... 82
240 - After babbitting clean off excess babbitt............................................................................ 82
Inspect Crankshaft and Small Time Gear......................................................................................... 82
241 - Inspect crankshaft and small timing gear............................................................................. 82
242 - Check all bearings for out of roundness.............................................................................. 83
243 - Press time gear on shaft............................................................................................. 83
Installing Crankshaft and Bearing Caps......................................................................................... 84
244 - Install crankshaft................................................................................................... 84
245 - Setting main bearing clearance....................................................................................... 85
246 - Install new bearings for crankshaft.................................................................................. 85
247 - Obtaining 65 percent bearing coverage................................................................................ 86
Running in Crankshaft.......................................................................................................... 86
248 - Running in crank shaft............................................................................................... 86
249 - After running in..................................................................................................... 86
250 - Getting 95 percent bearing surface................................................................................... 87
251 - Setting clearance.................................................................................................... 87
Inspecting and Assembling Pistons and Push Rods................................................................................ 87
252 - Inspecting piston assemblies......................................................................................... 87
253 - Oil push rods........................................................................................................ 87
Inspecting and Installing Camshaft, Camshaft Bearings and Large Time Gear...................................................... 87
254 - Remove bearings from camshaft........................................................................................ 87
255 - Inspect timing gear.................................................................................................. 87
256 - Camshaft bearing clearances.......................................................................................... 88
257 - Camshaft bearing clearance .0005 - .003.............................................................................. 88
Inspecting and Installing Valve Springs and Seats.............................................................................. 88
258 - Checking vavle springs............................................................................................... 88
259 - Assemble valve springs............................................................................................... 88
260 - Replacing valve springs.............................................................................................. 88
Valve Timing................................................................................................................... 89
261 - Adjusting valves using piston timing................................................................................. 89
262 - If too long - grind stems............................................................................................ 89
263 - Timing valves........................................................................................................ 89
264 - Determining when valves are open..................................................................................... 89
265 - Replace cylinder head................................................................................................ 90
Disassembling the Transmission................................................................................................. 90
266 - Disassembling the transmission....................................................................................... 90
267 - Break wire and run out siz drive plate cap screws.................................................................... 91
268 - Remove clutch disks.................................................................................................. 91
269 - Run out clutch disk drum set screw................................................................................... 91
270 - Remove clutch disk drum with ouller.................................................................................. 92
271 - Check drum key and washers........................................................................................... 92
272 - Drums and driven gear removed........................................................................................ 92
273 - Remove transmission gear shaft....................................................................................... 92
274 - Check triple gear shafts............................................................................................. 93
275 - Set triple gear clearance to .002.................................................................................... 93
Testing the Strength of the Magnets............................................................................................ 94
276 - Check magnet strength................................................................................................ 94
277 - Replace bad magnets.................................................................................................. 94
278 - Inspect ring gear.................................................................................................... 94
279 - Install new triple gear shafts....................................................................................... 94
280 - Remove magnets and reinstall......................................................................................... 94
Removing and Installing Magnets................................................................................................ 95
281 - Removing old magnets................................................................................................. 95
282 - Remove old triple gear shafts........................................................................................ 95
283 - Assemble new magnets observing polarity.............................................................................. 95
284 - Magnet shipping board................................................................................................ 96
285 - Assemble magnets on flywheel......................................................................................... 96
286 - Double check polarity................................................................................................ 96
287 - Tighten magnet brass screws.......................................................................................... 96
Removing and Installing Triple Gear Shafts..................................................................................... 97
288 - Remove triple gear shafts............................................................................................ 97
289 - Drive out triple gear shafts from inside of flywheel................................................................. 97
Assembling Transmission........................................................................................................ 97
290 - Wash all parts in kerosene........................................................................................... 97
291 - Examine triple gears................................................................................................. 97
292 - Check triple gears for .005 clearance................................................................................ 97
293 - Examine gear shaft................................................................................................... 98
294 - Examine brake drums.................................................................................................. 98
295 - Check brake drume and shaft clearance................................................................................ 98
296 - Examine low and reverse drums........................................................................................ 99
297 - Check reverse, low, and brake drums.................................................................................. 99
298 - Oil shafts and reassemble triple gear................................................................................ 99
299 - Clean keyways and insert keys........................................................................................ 99
300 - Check driven gear teeth.............................................................................................. 99
301 - Ensure drums turn freely............................................................................................. 99
302 - Position gear shaft on flywheel...................................................................................... 99
303 - Place drums on bench................................................................................................. 99
304 - Mesh triple gears with driven gear...................................................................................100
305 - Drums and gears revolve freely on shafts.............................................................................100
306 - Examine gear sleeve washers for wear.................................................................................100
307 - Install transmission clutch disks....................................................................................100
308 - Run down clutch disc drum set screw..................................................................................101
309 - Inspect clutch discs for wear........................................................................................101
310 - Inspect clutch disc push ring........................................................................................101
311 - Insert driving plate.................................................................................................101
312 - Run in 6 cap screws on driving plate.................................................................................101
313 - Insert clutch shift spring...........................................................................................101
314 - Compress clutch spring and insert pin................................................................................101
315 - Adjust clutch fingers................................................................................................101
Alignment of Magnet Clamps.....................................................................................................102
316 - Check magnet height..................................................................................................102
317 - Use gap gauge to check height........................................................................................102
318 - Clean oil tube.......................................................................................................103
319 - Adjust magneto clearance to .025 - .040..............................................................................103
320 - Use of gap gauge.....................................................................................................104
321 - Shiming magneto gap..................................................................................................104
Assembling Transmission to Engine..............................................................................................104
322 - Clean crankshaft flange..............................................................................................104
323 - Check magnet clearance .025-.040.....................................................................................104
324 - Examine transmission band linings....................................................................................104
325 - Position transmission bands..........................................................................................104
Inspecting and Installing Crankcase............................................................................................104
326 - Clean crankcase thoroughly...........................................................................................104
327 - Check crankcase alignment............................................................................................104
328 - Install new crankcase gaskets........................................................................................105
329 - Install crankcase bolts..............................................................................................105
330 - Install transmission cover gaskets and cover.........................................................................106
331 - Install the ball cap.................................................................................................106
Completing the Assembly........................................................................................................106
332 - Install four manifold clamps.........................................................................................106
333 - Pour 1 gallon oil through crankcase breather.........................................................................106
334 - Place engine in running in stand ....................................................................................106
335 - Engine now ready for installation....................................................................................106
Installing Engine in Car.......................................................................................................107
336 - Install engine in car................................................................................................107
337 - Install radiator apron...............................................................................................107
338 - Install steering gear................................................................................................107
339 - Connect steering flange to dash......................................................................................107
340 - Install commutator case and cutout...................................................................................107
341 - Install steering gear ball arm.......................................................................................107
342 - Connect commutator pull rod to case..................................................................................107
343 - Install carburetor pull rod..........................................................................................107
344 - Install carburetor hot air pipe......................................................................................107
345 - Install carburetor priming wire......................................................................................107
346 - Connect carburetor adjusting rod.....................................................................................107
347 - Connect feed pipe to carburetor......................................................................................107
348 - Install fan, fan belt, radiator and horn.............................................................................107
349 - Position hood blocks on frame........................................................................................107
350 - Connect headlamp plugs...............................................................................................108
351 - Install spark plugs..................................................................................................108
352 - Connect switch to starting motor cable...............................................................................108
353 - Insert horn wires through dash.......................................................................................108
354 - Install steering post bracket cap....................................................................................108
355 - Install floor boards and mat.........................................................................................108
356 - Turn on gasoline at sediment bulb....................................................................................108
357 - Install hood.........................................................................................................108
358 - Close radiator drain cock and fill...................................................................................108
Time Study - Engine and Transmission Overhaul..................................................................................108
359 - Time study on engine and transmission overhaul.......................................................................108
Chapter IV - Clean Carbon and Grind Valves.............................................................................................109
Grinding Valves....................................................................................................................110
369 - Removing valves..........................................................................................................110
370 - Examine valve seats......................................................................................................111
371 - Setting ideal valve seat.................................................................................................111
372 - Grind valves and check clearances........................................................................................113
373 - Replace cylinder head....................................................................................................113
374 - Install horn.............................................................................................................113
375 - Insert cylinder head outlet gasket and outlet............................................................................113
376 - Screw in spark plugs.....................................................................................................113
377 - Replace cylinder vavle cover.............................................................................................113
378 - Install carburetor pull rod..............................................................................................113
379 - Install hood.............................................................................................................113
380 - Close radiator drain plug and fill with water............................................................................113
Time Study - Clean Carbon and Grind Valves.........................................................................................114
381 - Time Study - Clean carbon and grind valves...............................................................................114
360 - Drain water from radiator....................................................................................................109
361 - Lift off hood................................................................................................................109
362 - Remove carburetor pull rod...................................................................................................109
363 - Remove cylinder valve cover..................................................................................................109
364 - Remove spark plugs...........................................................................................................109
365 - Run out the two cylinder head outlet screws..................................................................................109
366 - Remove carbon from pistons and block.........................................................................................109
367 - Use air blower to clean out carbon...........................................................................................109
368 - Removing carbon with wire brush and drill....................................................................................110
Chapter V - Taking up connecting rod bearings..........................................................................................115
Time Study - Taking Up Connect.....................................................................................................119
Taking Up Connecting Rod Bearings..................................................................................................115
382 - Removing crankcase lower cover...........................................................................................115
383 - Remove connecting rod bearing caps.......................................................................................115
384 - Check crankshaft journals for out-of-roundness...........................................................................116
385 - Dress down cap with a file...............................................................................................116
386 - Fitting the rod to journal...............................................................................................117
387 - Adjust No.4 and No.1 then No.2 and No.3..................................................................................117
388 - Replace crankcase inspection cover.......................................................................................117
389 - Check babbitt............................................................................................................117
390 - Before installing rods - check alignment.................................................................................117
391 - Align rod on jig.........................................................................................................118
392 - Connecting rod straightening jig.........................................................................................118
393 - Adjust by removing shims.................................................................................................118
394 - Scrape bearings..........................................................................................................118
395 - Oil and assemble rods....................................................................................................118
396 - Time Study - Taking up connecting Rods...................................................................................119
Chapter VI - Installing new Pistons and Rings..........................................................................................120
Installing New Pistons and Rings...................................................................................................120
397 - Theory...................................................................................................................120
398 - Piston dimensions........................................................................................................120
399 - Preparing to remove pistons..............................................................................................120
400 - Inspect cylinder bores for out-of-roundness..............................................................................121
401 - Inspect pistons for defects..............................................................................................121
402 - Check pistons for leaks..................................................................................................121
403 - Check pistons for wear...................................................................................................121
404 - New piston clearance is .003-.004........................................................................................121
405 - Select pistons of the same weight........................................................................................121
406 - Check old piston pins and rods for wear..................................................................................121
407 - Pin clearance is .001....................................................................................................121
408 - Pins are fitted as in Par. 415 and 418...................................................................................121
409 - Check rods for twisting and cracked babbitt..............................................................................122
410 - Inspect pin and bushing for excessive clearance..........................................................................122
411 - Piston play instructions.................................................................................................122
412 - If .002 clearance in piston pin to bushing - replace.....................................................................122
413 - Piston pin removal.......................................................................................................122
414 - Piston clamp.............................................................................................................123
415 - Fitting piston pins......................................................................................................123
416 - Removing bushings with arbor press.......................................................................................123
417 - Press in new piston pin bushing..........................................................................................123
418 - Press in piston pin......................................................................................................123
419 - Check pin fit............................................................................................................124
420 - Check alignment of piston and rod........................................................................................124
421 - Piston rings can now be installed........................................................................................124
Installing Piston Rings............................................................................................................124
422 - Installing piston rings and definition...................................................................................124
423 - Piston ring composition..................................................................................................125
424 - Renew every 10,000 miles.................................................................................................125
425 - Removing rings with ring extractor.......................................................................................125
426 - Check ring gap...........................................................................................................125
427 - If too small - file......................................................................................................125
428 - Check ring on surface plate..............................................................................................126
429 - How the ring to ring groove fits.........................................................................................126
430 - Set ring gaps 120 degrees apart..........................................................................................127
431 - Oil rings before installing..............................................................................................127
432 - Oil connecting rods and assemble.........................................................................................127
433 - Install cylinder headgasket, cylinder head, and horn.....................................................................127
434 - Install hood and fill radiator...........................................................................................127
Time Study - Fitting New Pistons...................................................................................................127
435 - Time study - Fitting New Pistons.........................................................................................127
Changing Piston Rings..............................................................................................................127
436 - Changing Piston Rings....................................................................................................127
Chapter VII - Taking up Main Bearings..................................................................................................128
Taking Up Main Bearings............................................................................................................128
437 - Intro....................................................................................................................128
438 - To take up main bearings.................................................................................................128
439 - Remove hood..............................................................................................................128
440 - Remove carburetor pull rod...............................................................................................128
441 - Remove valve cover.......................................................................................................128
442 - Remove Crankcase lower cover.............................................................................................128
443 - Remove rear main bearing cap.............................................................................................129
444 - Adjust center bearing....................................................................................................130
445 - Check for tightness......................................................................................................130
Time Study - Taking up Main Bearings - Present Type Crankcase......................................................................131
446 - Time Study - Taking up Main Bearings -- Present Type Crankcase...........................................................131
Chapter VIII - Correcting noisy Time Gears.............................................................................................132
Correcting Noisy Time Gears........................................................................................................132
447 - Noisy time gears - identify..............................................................................................132
448 - Disconnect ammeter wire and remove generator.............................................................................132
449 - Generator gear mesh clearance is .002-.004...............................................................................132
450 - Replace generator bracket................................................................................................133
451 - If gears still noisy look elsewhere......................................................................................133
452 - Replace large timing gear................................................................................................133
453 - Expose timing gears by removing radiator.................................................................................133
454 - Remove commutator........................................................................................................133
455 - Take off gear cover plate................................................................................................133
456 - Check timing gear back-lash..............................................................................................134
457 - New time gears .0005 - .003 back lash....................................................................................134
Removing and Installing Small Time Gear........................................................................................136
458 - Removing and installing small time gear..............................................................................136
459 - Examine felt gasket..................................................................................................137
460 - Lower engine into crankcase..........................................................................................137
461 - Install fan pulley on crankshaft.....................................................................................137
462 - Replace starting crank...............................................................................................137
463 - Replace universal joint ball cap.....................................................................................137
464 - Connect exhaust manifold to exhaust pipe.............................................................................138
465 - Replace generator....................................................................................................138
466 - Grease felt in place.................................................................................................138
467 - Line up camshaft cover and timer.....................................................................................138
468 - Use cover gauge to align camshaft cover..............................................................................138
469 - Install commutator...................................................................................................138
470 - Check gear mesh before installing radiator...........................................................................139
Time Study - Noisy Time Gears..............................................................................................139
471 - Time Study - Noisy Time Gears....................................................................................139
Chapter IX - Installing New Camshaft Bearings..........................................................................................140
Installing New Camshaft Bearings...................................................................................................140
472 - Installing new Camshaft Bearings.........................................................................................140
473 - Remove radiator and fan..................................................................................................140
474 - Run out camshaft bearing set screws......................................................................................140
475 - Fix push rods from falling down..........................................................................................140
476 - Withdraw camshaft........................................................................................................141
477 - Remove bearings from camshaft............................................................................................141
478 - Check camshaft for wear..................................................................................................141
479 - Check camshaft alignment.................................................................................................141
480 - Check camshaft bearing style.............................................................................................142
481 - Bearing clearances.......................................................................................................143
482 - Assemble bearings........................................................................................................143
483 - Replace large gear.......................................................................................................144
484 - Withdraw pins from push rods.............................................................................................144
485 - Replace valve cover......................................................................................................144
486 - Install hot air pipe.....................................................................................................144
487 - Install cylinder front cover.............................................................................................144
Time Study - Installing New Camshaft Bearings......................................................................................145
488 - Time Study - Installing New Camshaft Bearings............................................................................145
Chapter X - Cleaning the Oil Line......................................................................................................146
Cleaning the Oil Line..............................................................................................................146
489 - Lift off hood and remove radiator........................................................................................146
490 - Place air hose nozzle in end of pipe and blow compressed air.............................................................146
491 - Check oil flow by cranking rapidly.......................................................................................146
492 - Drain oil from crankcase.................................................................................................146
493 - Replace time gear, fill radiator.........................................................................................146
Time Study - Cleaning Oil Line.....................................................................................................146
494 - Time Study - Cleaning Oil Line...........................................................................................146
Chapter XI - Stopping Oil Leak at Front End of Crankshaft..............................................................................147
Stopping Oil Leak at Front of Crankshaft...........................................................................................147
495 - How it starts............................................................................................................147
496 - Locate trouble...........................................................................................................147
497 - Remove and install new gaskets...........................................................................................147
498 - Solder front wall........................................................................................................148
Time Study - Oil Leak at Front End of Crankshaft...................................................................................148
499 - Time Study - Oil Leak at Front End of Crankshaft.........................................................................148
Time Study - Oil Leak at Crankcase Front Wall......................................................................................148
500 - Time Study - Oil leak at Crankcase Front Wall............................................................................148
Chapter XII - Replacing transmission bands (old design)................................................................................149
Replacing Transmission Bands (Old Design)..........................................................................................149
501 - Describe problem.........................................................................................................149
502 - To install new bands.....................................................................................................149
503 - Lift off hood............................................................................................................149
504 - Disconnect starting motor cable..........................................................................................149
505 - Run out motor mounting screws............................................................................................149
506 - Remove mat and floorboards...............................................................................................149
507 - Disconnect exhause pipe..................................................................................................149
508 - Disconnect magneto wire..................................................................................................149
509 - Run out universal joint bolts............................................................................................149
510 - Run out transmission cover to crankcase bolts............................................................................149
511 - Loosen transmission band adjusting screw.................................................................................149
512 - Remove transmission cover................................................................................................149
513 - Remove starting motor....................................................................................................149
514 - Lift off transmission cover..............................................................................................150
515 - Install new transmission band linings....................................................................................150
516 - Rivet band linings.......................................................................................................150
517 - Install transmission cover...............................................................................................151
518 - Compress transmission band springs.......................................................................................152
519 - Prevent loosing small parts..............................................................................................152
520 - Connect magneto terminal wire............................................................................................152
521 - Run up exhaust pipe pack net.............................................................................................152
522 - Insert two bolts in universal joint......................................................................................152
523 - remove transmission cover door...........................................................................................152
524 - Adjust low speed band....................................................................................................152
525 - Adjust brake and reverse bands...........................................................................................152
526 - After adjusting examine bands for drag...................................................................................152
527 - Install transmission door................................................................................................153
528 - Install floor boards and mat.............................................................................................153
529 - Connect switch to starting motor.........................................................................................153
530 - Install hood.............................................................................................................153
Time Study - Changing Bands (Old Design)...........................................................................................153
531 - Time Study - Changing Bands (old design).................................................................................153
Chapter XIII - Installing New Type Transmission Bands..................................................................................154
Installing New Type Transmission Bands.............................................................................................154
532 - Show detachable ear band.................................................................................................154
533 - Lug removed from band....................................................................................................154
534 - How to remove lug........................................................................................................154
535 - remove new type bands....................................................................................................154
536 - Don't drop parts in transmission.........................................................................................154
537 - Remove pedals............................................................................................................154
538 - Replace bands............................................................................................................154
539 - Replace reverse band first...............................................................................................155
540 - Use of band tool.........................................................................................................155
541 - Adjust bands.............................................................................................................155
542 - Assemble with lock washer nub in nut groove..............................................................................155
543 - Installing new style band in older Model T's.............................................................................155
544 - Make new low speed adjuster..............................................................................................156
545 - Make tool for bands......................................................................................................156
Time Study - Changing Bands (New Design)...........................................................................................156
546 - Time Study - Changing Bands (New Style)..................................................................................156
Chapter XIV - Replacing Transmission Clutch Spring.....................................................................................157
Replacing Transmission Clutch Spring...............................................................................................157
547 - Lift up car rear end.....................................................................................................157
548 - Remove read spring hangers...............................................................................................157
549 - Break wire and run out universal joint bolts.............................................................................157
550 - Disconnect axle from transmission........................................................................................157
551 - Run out (6) transmission cover screws....................................................................................157
552 - Withdraw ball cap from drive shaft.......................................................................................157
553 - Compress clutch spring...................................................................................................157
554 - Install new clutch spring................................................................................................157
555 - Replace transmission cover door..........................................................................................158
556 - Install ball cap.........................................................................................................158
557 - Insert universal joint...................................................................................................158
558 - Run in ball cap bolts....................................................................................................158
559 - Connect rear spring to perches...........................................................................................158
560 - Connect brake rods to control shaft......................................................................................158
561 - Install floorboards and mat..............................................................................................158
Time Study - Changing Clutch Spring................................................................................................158
562 - Time Study - Changing Clutch Spring......................................................................................158
Chapter XV - Overhauling Rear Axle.....................................................................................................159
Overhauling Rear Axle..............................................................................................................159
563 - Remove rear axle.........................................................................................................159
564 - Place axle on axle stand.................................................................................................159
565 - Removehub key............................................................................................................159
566 - Remove drive shaft.......................................................................................................159
567 - Run off 7 rear-end bolts.................................................................................................159
568 - Withdraw axle............................................................................................................160
569 - Remove roller bearings...................................................................................................161
570 - Break wire and run out (10) differential cap screws......................................................................161
571 - Remove differential drive gear from case.................................................................................161
572 - Remove inner and outer sleevess..........................................................................................161
573 - Disconnect brake rod.....................................................................................................162
574 - Install gear on new axle.................................................................................................162
Disassembling Drive Shaft..........................................................................................................162
575 - Run out grease cup.......................................................................................................162
576 - Replace universal joint..................................................................................................162
577 - Withdraw drive shaft from torque tube....................................................................................163
578 - Withdraw pinion gear.....................................................................................................164
579 - Withdraw roller bearing..................................................................................................164
580 - Remove bearing sleeve....................................................................................................164
581 - Remove drive shaft front bushing.........................................................................................164
Assembling the Drive Shaft.....................................................................................................165
582 - Clean and examine all parts for reassembly...........................................................................165
583 - Install drive shaft bushing..........................................................................................165
584 - Inspect drive shaft..................................................................................................166
585 - Install drive shaft bushing..........................................................................................166
586 - Install drive shaft pinion gear......................................................................................166
587 - Inspect drive shaft roller for cracks and assemble...................................................................167
588 - Inspect bearing housing for cracks...................................................................................167
589 - Inspect differential gear for cracks and chipped teeth...............................................................167
590 - Examine pinion gear..................................................................................................167
591 - Examine universal joint..............................................................................................167
592 - Insert joint housing plugs...........................................................................................168
593 - Insert grease cup....................................................................................................168
Assembling the Differential....................................................................................................168
594 - Wash all parts.......................................................................................................168
595 - Examine axle shaft...................................................................................................168
596 - Examine differential gear teeth......................................................................................168
597 - Examine differential case............................................................................................168
598 - Check spider for wear................................................................................................168
599 - Install differential drive gear......................................................................................168
600 - Examine differential pinions for wear................................................................................169
601 - Insert axle in right housing.........................................................................................169
602 - Insert axle in left housing..........................................................................................169
603 - Place washers on axles...............................................................................................169
604 - Position spider "B" together.........................................................................................169
605 - Mesh differential pinions............................................................................................169
606 - Insert 3 differential case bolts.....................................................................................169
607 - Test for freely rotating differential................................................................................169
608 - Inspect axle housings for cracks.....................................................................................169
609 - Examine bearing sleeves for wear.....................................................................................169
610 - Examine radius rods for cracks.......................................................................................169
611 - Install radius rods..................................................................................................169
612 - Connect brake rod to cam shaft lever.................................................................................169
613 - Examine differential thrust plates and washers for wear..............................................................170
614 - Insert thrust washers................................................................................................170
615 - Position thrush washer over dowel pins...............................................................................170
616 - Inspect roller bearings for cracks...................................................................................170
617 - Assemble housings....................................................................................................170
618 - Insert roller bearings in each housin................................................................................171
619 - Insert bolts in housings.............................................................................................171
620 - Check for freely revolving axle assembly.............................................................................171
621 - Assemble drive shaft to housings.....................................................................................171
622 - Install outer bearings...............................................................................................172
623 - Place 1 1/2 lbs of high grade gear compound into differential........................................................172
Connecting Rear Axle Assembly to Car...........................................................................................172
624 - Lift read end with hoist.............................................................................................172
625 - Position axle under car..............................................................................................172
626 - Insert universal joint into transmission drive plate.................................................................172
627 - Run in the two bolts that connect axle to transmission...............................................................172
628 - Connect perches to axle..............................................................................................172
629 - Lower car and remove hooks...........................................................................................172
Time Study - Rear Axle Overhaul................................................................................................172
630 - Time Study - Rear Axle Overhaul......................................................................................172
Chapter XVI - Stopping Oil Leak at Rear Wheel..........................................................................................173
Stopping Oil Leak at Rear Wheel....................................................................................................173
631 Jack up rear end and remove rear wheels....................................................................................173
632 - Remove old felt retainer.................................................................................................173
633 - Withdraw outer roller bearing............................................................................................173
634 Withdraw outer roller bearing sleeve.......................................................................................173
635 - Place new retainer over end of axle......................................................................................173
636 - Install correct sleeve in correct housing................................................................................173
637 - Insert bearings..........................................................................................................174
638 - Insert felt retainer.....................................................................................................175
639 - Insert hub key...........................................................................................................175
640 - Install wheel............................................................................................................175
Time Study - Oil Leak at Rear Wheel................................................................................................175
641 - Time Study - Oil Leak at Rear Wheel......................................................................................175
Chapter XVII - Changing Rear Radius Rods...............................................................................................176
Removing Radius Rods...............................................................................................................176
642 - Loosen radius rod lock nuts..............................................................................................176
643 - Remove cotter pin and run off nuts.......................................................................................176
644 - Remove rear wheel........................................................................................................176
645 - Remove brake rod.........................................................................................................176
646 - Run off nut on brake rod support.........................................................................................176
647 - Run off nutson ends of radius rods.......................................................................................177
648 - Turn hub camshaft lever to remove forked end of radius rod...............................................................177
Installing Rear Radius Rod.........................................................................................................177
649 - Run lock nuts on radius rod ends.........................................................................................177
650 - Insert 2 radius rod bolts and tighten up.................................................................................177
651 - Turn hub camshaft lever to verticle......................................................................................178
652 - Run down radius rod nut clearing cotter pin hole.........................................................................178
653 - Install new brake rod support............................................................................................178
654 - Position forked end of radius rod........................................................................................178
655 - Install rear wheel.......................................................................................................178
Time Study - Changing Rear Radius Rod..............................................................................................178
656 - Time Study - Changing Rear Radius Rods...................................................................................178
Chapter XVIII - Changing a rear spring.................................................................................................179
Removing Rear Spring from Car......................................................................................................179
657 - Lift up rear of car......................................................................................................179
658 - Run off 4 spring hanger nuts.............................................................................................179
659 - Drive hangers out of spring and perches..................................................................................179
660 - Remove spring............................................................................................................179
Installing Rear Spring.............................................................................................................180
661 - Insert spring into cross member..........................................................................................180
662 - Insert two spring clip bars..............................................................................................180
663 Connect rear spring to perchesusing hanger.................................................................................180
664 - Use block of wood to line up perches.....................................................................................180
665 - Remove blocks, lower car, and remove lifting hooks.......................................................................180
Time Study - Changing Rear Spring..................................................................................................180
666 - Time Study - Changing Rear Spring........................................................................................180
Chapter XIX - Front Axle Assembly Overhaul.............................................................................................181
Removing Front Axle Assembly from Car..............................................................................................181
667 - Break wire and run off radius rod nuts...................................................................................181
668 - Run off steering gear post nut...........................................................................................181
669 - Raise front end of car...................................................................................................181
670 - Run off spring clip nuts.................................................................................................181
671 - Axle can now be removed..................................................................................................181
Disassembling Axle.................................................................................................................181
672 - Remove radius rod........................................................................................................181
673 - Remove spring hanger bars................................................................................................181
674 - Remove steering gear arm.................................................................................................181
675 - Remove steering gear connecting rod......................................................................................181
676 - Remove spindle connecting rod............................................................................................182
677 - Remove spindles..........................................................................................................182
Inspecting and Assembling Axle.....................................................................................................182
678 - Clean and examine parts..................................................................................................182
679 - Examine spring for broken leaves.........................................................................................182
680 - Polish and graphite leaves...............................................................................................182
681 - Assemble spring leaves...................................................................................................182
682 - Examine bushings for wear................................................................................................182
683 - Line up oil holes in spring and perch bushings...........................................................................183
684 - Examine spring hangers for wear..........................................................................................183
685 - Assemble spring to perches...............................................................................................183
686 - Examine spindles and spindle arms........................................................................................184
687 - Replace worn parts.......................................................................................................184
688 - Examine spindle bolts for defects........................................................................................185
689 - Insert spindle bolt through spindle......................................................................................185
690 - Examine steering gear....................................................................................................185
691 - Examine spindle connecting rod bolts - replace if over .003..............................................................185
692 - Assemble spindle connecting rods.........................................................................................185
693 - Grease ball sockets and assemble caps....................................................................................185
694 - Check for loose sockets..................................................................................................186
695 - Replace broken oilers....................................................................................................186
Installing Axle Assembly in Car....................................................................................................187
696 - Place axle on jacks......................................................................................................187
697 - Examine steering post key................................................................................................187
698 - Lover car and remove lifting hooks.......................................................................................187
699 - Check front axle and wheels for alignment................................................................................187
Time Study - Front Axle Overhaul...................................................................................................187
700 - Time Study - Front Axle Overhal..........................................................................................187
Chapter XX - Changing Front Spring.....................................................................................................188
Removing Front Spring from Car.....................................................................................................188
701 - Raise front end and run off hanger nuts..................................................................................188
702 - Run off crank case front bearing nuts....................................................................................188
Installing Front Spring............................................................................................................188
703 - Place spring pad over tie bolt...........................................................................................188
704 - Insert clip bar and license bracket......................................................................................188
705 - Insert spring hangers over hangers.......................................................................................188
706 - Position hanger bars over hangers and tighten nuts.......................................................................188
707 - Remove wood blocks.......................................................................................................188
708 - Lower car................................................................................................................188
709 - Check axle alignment.....................................................................................................188
Time Study - Changing Front Spring.................................................................................................189
710 - Time Study - Changing Front Spring.......................................................................................189
Chapter XXI - Rebushing Front Spring and Perches.......................................................................................190
Rebushing Front Spring and Perches.................................................................................................190
711 - Lift front end and remove hanger bars....................................................................................190
712 - Drive spring perch bushings out of spring and perches....................................................................190
713 - Insert new bushings and drive in place with bushing driver...............................................................190
714 - Install spring hangers...................................................................................................190
715 - Lower car................................................................................................................190
716 - Rear springs and perches are rebushed in similar manner..................................................................190
717 - Check alignment..........................................................................................................190
Time Study - Rebushing Front Spring and Perches....................................................................................190
718 - Time Study - Rebushing front Spring and Perches..........................................................................190
Chapter XXII - Changing Front Radius Rods..............................................................................................191
719 - Break wire and run off rod ball cap nuts.....................................................................................191
720 - Run off perch nuts and remove radius rod.....................................................................................191
721 - To install reverse procedure.................................................................................................191
722 - Check alignment..............................................................................................................191
723 - Time Study - Changing Front Radius Rod.......................................................................................191
Chapter XXIII - Changing Front Axle....................................................................................................192
Removing Axle from Car.............................................................................................................192
724 - Raise front end..........................................................................................................192
725 - Run off perch nuts.......................................................................................................192
Installing Front Axle..............................................................................................................192
726 - Support axle on horses and lower car onto it.............................................................................192
727 - Insert radius rod ends...................................................................................................192
728 - Insert spindle bolt through axle and spindle.............................................................................192
729 - Check alignment of axle..................................................................................................192
Time Study - Changing Front Axle...................................................................................................192
730 - Time Study - Changing Front Axle.........................................................................................192
Chapter XXIV - Replacing Front Hub Bearing Cup and Bearing.............................................................................193
Replacing Front Hub Bearing Cup and Bearing........................................................................................193
731 - Jack up car and remove front wheel.......................................................................................193
732 - Remove dust cap and bearing cups.........................................................................................193
733 - Install new cups and bearings............................................................................................193
734 - Install dust cap.........................................................................................................194
735 - Pack wheel hub with grease...............................................................................................194
Time Study - Changing Front Hub Bearing Cups.......................................................................................194
736 - Time Study - Changing Front Hub Bearing Cups.............................................................................194
Chapter XXV - Steering Gear Overhaul...................................................................................................195
Remove Steering Gear from Car......................................................................................................195
737 - Run off steering gear post nut...........................................................................................195
746 - Withdraw steering gear through dash......................................................................................195
738 - Drive off steering gear ball arm.........................................................................................195
739 - Lift off hood............................................................................................................195
740 - Disconnect carburetor pull rod...........................................................................................195
741 - Remove cotter key and disconnect commutator pull rod.....................................................................195
742 - Drive out lead rod driver pin............................................................................................195
743 - Disconnect horn wires at horn and terminal block.........................................................................195
744 - Remove steering gear bracket bolts.......................................................................................195
745 - Run off steering flange screws...........................................................................................195
Disassembling the Steering Gear....................................................................................................195
747 - Run off steering wheel nut...............................................................................................195
748 - Remove steering gear pinion key..........................................................................................195
749 - Run out steering gear cover..............................................................................................196
750 - Withdraw steering gear post..............................................................................................196
751 - Remove throttle rod lever................................................................................................196
752 - Remove lead and throttle guide...........................................................................................196
753 - Remove lead and throttle rod springs.....................................................................................196
754 - Drive out internal gear case pins........................................................................................197
755 - Withdraw internal gear case and rods from steering gear tubing...........................................................197
756 - Spread ends of guides to remove gear case................................................................................197
757 - Steering gear is now completely disassembled.............................................................................197
Assembling Steering Gear...........................................................................................................197
758 - Inspect gear tube for cracks.............................................................................................197
759 - Check gear case for excessive clearance (.006+)..........................................................................197
760 - Examine rods for cracks at pin holes.....................................................................................197
761 - Replace pins with No. 2 taper pins.......................................................................................197
762 - Insert rods and springs..................................................................................................197
763 - Insert throttle pins.....................................................................................................197
764 - Position rod guides......................................................................................................198
765 - Rivet rod lever to rod...................................................................................................198
766 - Inspect steering post for wear...........................................................................................198
767 - Install post in gear case................................................................................................198
768 - Inspect for wear.........................................................................................................198
769 - Insert pinions over pinion pins..........................................................................................199
770 -Pack case with grease.....................................................................................................199
771 - Insert steering gear pinion key and fit..................................................................................199
New Design Steering Gear Ratio.....................................................................................................199
772 - New 5 to 1 steering gear.................................................................................................199
773 - Old and new not interchangable...........................................................................................199
774 - Mix of old and new steering gear could cause accident....................................................................199
775 - Interchangable steering parts............................................................................................200
776 - 5 to 1 gear part numbers.................................................................................................200
777 - Teeth layout of gears....................................................................................................200
778 - Picture of both gear sets................................................................................................200
Installing Steering Gear in Car....................................................................................................200
779 - Insert steering gear through hole in dash................................................................................200
780 - Install rods.............................................................................................................200
781 - Connect steering gear flange.............................................................................................200
782 - Insert horn wires........................................................................................................200
783 - Install steering gear bracket cap........................................................................................201
784 - Connect carburetor pull rod..............................................................................................201
785 - Connect commutator pull rod..............................................................................................201
786 - Install hood.............................................................................................................201
Time Study - Steering Gear Overhaul................................................................................................201
787 - Time Study - Steering Gear Overhaul......................................................................................201
Chapter XXVI - Repairing the Radiator..................................................................................................202
The Solder.........................................................................................................................202
789 - Solder - What is available...............................................................................................202
The Iron...........................................................................................................................202
790 - The iron.................................................................................................................202
791 - Work squarely............................................................................................................202
792 - "Tin" iron...............................................................................................................202
793 - Solder oxidizes..........................................................................................................203
The Torch..........................................................................................................................203
794 - The torch................................................................................................................203
The Acid...........................................................................................................................203
795 - The acid.................................................................................................................203
796 - Keep soldering acid clean................................................................................................204
797 - Store in corked bottle...................................................................................................204
Miscellaneous......................................................................................................................204
798 - Apply acid with small horsehair brush....................................................................................204
799 - Fiber brushfor acid cleanup..............................................................................................204
800 - Use oven for heating irons...............................................................................................204
801 - Wear canvas gloves.......................................................................................................204
Soldering..........................................................................................................................204
802 - Clean metal before soldering.............................................................................................204
803 - Fit pieces together......................................................................................................204
804 - Always solder in direction of flame flow.................................................................................205
805 - For removing parts use torch.............................................................................................205
Equipment..........................................................................................................................206
806 - Equipment needed.........................................................................................................206
807 - Ensure check valves are used with acetylene..............................................................................206
808 - 5 - 8 lbs of air for pressure testing....................................................................................206
809 - Tools required...........................................................................................................206
Removing the Radiator..............................................................................................................209
810 - Removing radiator........................................................................................................209
Removing and Installing Filler Neck................................................................................................209
811 - Remove filler neck.......................................................................................................209
812 - Before positioning neck - dip in acid....................................................................................209
Removing Bottom Tank...............................................................................................................209
814 - Heat and brush solder from all seams.....................................................................................210
813 - Remove bottom tank.......................................................................................................209
Replacing Bottom Tank..............................................................................................................210
815 - Heat inside of header....................................................................................................210
816 - Light blue flame is best for soldering...................................................................................210
817 - In replacing lower tank - fit as close as possible.......................................................................210
818 - First solder ends and work around........................................................................................211
819 - Solder reinforcement.....................................................................................................211
Removing Bottom Header.............................................................................................................212
820 - Removing bottom header...................................................................................................212
Replacing Bottom Header............................................................................................................212
821 - Replacing bottom header..................................................................................................212
822 - Straighten rods with tube regulator......................................................................................212
823 - Solder in new header.....................................................................................................213
Removing Rear Wall.................................................................................................................213
824 - Removing rear wall.......................................................................................................213
825 - Heat water inlet and drive out rivets....................................................................................213
Replacing Rear Wall................................................................................................................213
826 - Replacing rear wall......................................................................................................213
827 - Excessive heat warps metal...............................................................................................213
828 - Close large openings.....................................................................................................213
Removing Front Wall................................................................................................................214
829 - Removing front wall......................................................................................................214
Replacing Front Wall...............................................................................................................214
830 - Replacing front wall.....................................................................................................214
831 - Take care in soldering top tank..........................................................................................215
832 - How to solder top tank...................................................................................................215
Removing Top Tank..................................................................................................................215
833 - Removing top tank top....................................................................................................215
First Method...................................................................................................................215
834 - First method.........................................................................................................215
835 - Remove splash plate..................................................................................................215
Second Method..................................................................................................................216
836 - Second method........................................................................................................216
837 - Attach overflow pipe.................................................................................................216
Replacing Top Tank Top.............................................................................................................216
First Method...................................................................................................................216
838 - Replace top tank - method 1..........................................................................................216
839 - Brush solder from joints.............................................................................................216
840 - Tack bits before full soldering......................................................................................216
841 - Flow tight solder....................................................................................................217
Second Method..................................................................................................................217
842 - Replace top tank - method 2..........................................................................................217
Removing Overflow Pipe.............................................................................................................217
843 - Remove overflow pipe.....................................................................................................217
Replacing Overflow Pipe............................................................................................................218
844 - Fit and replace overflow pipe............................................................................................218
845 - Assemble overflow pipe with washer.......................................................................................218
Removing Top Header................................................................................................................218
846 - Remove top header........................................................................................................218
Replacing Top Header...............................................................................................................218
847 - Replace top header.......................................................................................................218
848 - Another way to replace top header........................................................................................218
Changing the Core..................................................................................................................219
849 - Remove top tank and supports.............................................................................................219
850 - Assemble bottom tank to new core.........................................................................................219
Repairing a Broken Tube............................................................................................................219
851 - Repair broken tube.......................................................................................................219
852 - Bending fins to get at break.............................................................................................219
853 - Soldering breaks.........................................................................................................220
854 - Replace if large number of bad tubes.....................................................................................220
855 - Fixing broken center tubes...............................................................................................221
856 - Fixing broken tubes near lower header....................................................................................221
Cleaning the Tubes.................................................................................................................221
857 - Cleaning tubes...........................................................................................................221
858 - Flush radiator with water................................................................................................221
859 - Test radiator before reinstalling........................................................................................221
Replacing Radiator Suppport........................................................................................................221
860 - Replace radiator support.................................................................................................221
Testing Radiators..................................................................................................................222
861 - Test radiator submerged with 5-8 lbs of air..............................................................................222
Touching Up a Repaired Radiator....................................................................................................222
862 - Touch up a repaired radiator.............................................................................................222
863 - Get rid of excess solder.................................................................................................222
Removing Dents from Top and Bottom Tanks...........................................................................................222
864 - Removing dents from radiator.............................................................................................222
Installing Radiator in Car.........................................................................................................223
865 - Installing radiator in car...............................................................................................223
Time Study - Repairing the Radiator................................................................................................223
866 - Time Study - Repairing the Radiator......................................................................................223
788 - Read before starting job.....................................................................................................202
Chapter XXVII - Carburetor Overhaul....................................................................................................224
Removing Carburetor from Car.......................................................................................................224
867 - Lift off hood............................................................................................................224
868 - Disconnect carburetor pull rod...........................................................................................224
869 - Disconnect two priming wires at carburetor...............................................................................224
870 - Shut off gasoline at sediment bulb.......................................................................................224
871 - Disconnect feed pipe at carburetor.......................................................................................224
872 - Loosen manifold stud nut and remove hot air pipe.........................................................................224
873 - Run off carburetor flange bolt nuts......................................................................................224
874 - Lift out carburetor and place in vise....................................................................................224
Overhauling the Carburetor.........................................................................................................224
875 - Remove spray needle......................................................................................................224
876 - Remove drain valve plug assembly.........................................................................................225
877 - Remove float.............................................................................................................225
878 - Withdraw gasoline inlet..................................................................................................225
879 - Run out spray nozzle.....................................................................................................225
880 - Run out inlet seat.......................................................................................................225
881 - Before assembling carburetor.............................................................................................225
882 - Assemble carburetor position spray nozzle gasket.........................................................................226
883 - Insert inlet seat and gasket into mixing chamber.........................................................................226
884 - Insert inlet needle into inlet seat......................................................................................226
885 - Place float on mixing chamber............................................................................................226
886 - Install float chamber to carburetor body.................................................................................227
887 - Install spray needle assembly............................................................................................227
888 - Test needle seat.........................................................................................................228
Install Carburetor in Car..........................................................................................................228
889 - Install carburetor in car................................................................................................228
Time Study - Carburetor Overhaul...................................................................................................229
890 - Time Study - Carburetor Overhaul.........................................................................................229
Chapter XXVIII - Installing new Bendix Shaft or Spring.................................................................................230
Removing Bendix from Car...........................................................................................................230
891 - Lift off hood............................................................................................................230
892 - Disconnect switch to starting motor cable................................................................................230
893 - Remove mat and floor boards..............................................................................................230
894 - Remove bendix cover......................................................................................................230
Time Study - Changing Bendix or Spring.............................................................................................232
903 - Time Study - Changing Bendix or Spring...................................................................................232
Installing new Shaft of Springs....................................................................................................230
895 - If spring broken pry out.................................................................................................230
896 - If spring OK remove bendix head..........................................................................................230
897 - Remove bendix key........................................................................................................231
898 Assemble bendix............................................................................................................231
Installing Bendix in Car...........................................................................................................231
899 - Check bendix for turning freely..........................................................................................231
900 - Install bendix on starter shaft..........................................................................................232
901 - Install bendix gasket and cover..........................................................................................232
902 - Replace floor boards and mat.............................................................................................232
Chapter XXIX - Generator Overhaul......................................................................................................233
Generator Overhaul.................................................................................................................233
904 - Remove generator from car................................................................................................233
905 - Place generator on bench plate and raise brushes.........................................................................233
906 - Run out 6 head to yoke screws............................................................................................233
907 - Withdraw armature........................................................................................................233
908 - Drive out pinion pin.....................................................................................................234
909 - Use puller to remove pinion gear from generator..........................................................................234
910 - Lift out Woodruff key....................................................................................................234
911 - Remove head from generator shaft.........................................................................................234
912 - Remove large and small bearings..........................................................................................234
913 - Remove brush end.........................................................................................................234
914 - Lift generator terminal bolt out.........................................................................................235
915 - Remove brush holder assembly.............................................................................................235
916 - Remove third brush holder................................................................................................236
917 - Check field coils for grounds............................................................................................236
918 - Tighten screws for field coils with pole driver..........................................................................236
919 - Withdraw four pole pieces................................................................................................236
Assembling Generator...............................................................................................................236
920 - Before reassembly clean thoroughly.......................................................................................236
921 - Examine pole pieces for burrs............................................................................................236
922 - Insert field coils and pole pieces into yoke.............................................................................237
923 - Use pole spreader to align pole pieces...................................................................................237
924 - Tighten pole screws with pole screw driver...............................................................................237
925 - Check coils for shorts...................................................................................................238
926 - Insert retainer ring and position third brush holder into slot...........................................................238
927 - Check ring assembly for shorts...........................................................................................239
928 - Install brush ring assy into brush end bracket...........................................................................239
929 - Check insulators for breaks..............................................................................................239
930 - Cross leads..............................................................................................................239
931 - Install brush end bracket on yoke........................................................................................240
932 - Line up screw holes with brush ends......................................................................................240
933 - Before installing armature test for shorts...............................................................................240
934 - Test for ground..........................................................................................................240
935 - Test for short circuit by using growler..................................................................................240
936 - Wash bearings in gasoline................................................................................................241
937 - Seat large bearing.......................................................................................................241
938 - Insert generator shaft in bearing........................................................................................241
939 - Position generator head..................................................................................................241
940 - Examine gear teeth.......................................................................................................241
941 - Inspect small bearing for wear...........................................................................................242
942 - Oil small bearing and fit to generator shaft.............................................................................242
943 - Insert armature assy into yoke...........................................................................................242
944 - Run in 6 yoke screws.....................................................................................................242
945 - Seat 2 brushes and leave 3rd brush open..................................................................................242
946 - Setting generator brushes................................................................................................242
Setting Generator Brushes on Test Stand............................................................................................242
947 - Test generator on test stand.............................................................................................242
948 - Shift brush ring.........................................................................................................243
949 - Adjust output to 10-12 amps..............................................................................................243
950 - Install generater in car.................................................................................................243
Setting Generator Brushes with Generator Installed in Car..........................................................................243
951 - Set generator brushes with generator installed in car....................................................................243
Time Study - Generator Overhaul....................................................................................................244
952 - Time Study - Generator Overhaul..........................................................................................244
Chapter XXX - Starting Motor Overhaul..................................................................................................245
Removing Starter Motor from Car....................................................................................................245
953 - Remove starting motor from car...........................................................................................245
Disassembling Starting Motor.......................................................................................................245
954 - Remove cover band........................................................................................................245
955 - Raise four brushes.......................................................................................................245
956 - Run out bracket bolts....................................................................................................245
957 - Withdraw armature........................................................................................................246
958 - Run out 4 brush brackets to yoke screws..................................................................................246
959 - Remove brush end bracket.................................................................................................246
960 - Remove four pole screws..................................................................................................246
961 - Loosen terminal net......................................................................................................246
962 - If shaft bushing worn - replace..........................................................................................246
Assembling the Starting Motor......................................................................................................247
963 - Before reassembly clean thoroughly in gasoline...........................................................................247
964 - Install new shaft bushing................................................................................................247
965 - line ream bushing........................................................................................................247
966 - Inspect pole pieces......................................................................................................247
967 - Insert pole pieces in field coils........................................................................................247
968 - Spread poles.............................................................................................................247
969 - Test using lamp..........................................................................................................247
970 - Check motor brush ring for ground........................................................................................247
971 - Install brush end bracket on end of yoke.................................................................................248
972 - Test armature in growler.................................................................................................248
973 - If commutator rough - dress down.........................................................................................248
974 - Insert armature into yoke................................................................................................248
975 - Replace dust cover.......................................................................................................248
Installing Starting Motor in Car...................................................................................................248
976 - Install starting motor...................................................................................................248
977 - Install bendix and bendix cover..........................................................................................248
Time Study - Starting Motor Overhaul...............................................................................................248
978 - Time Study - Starting Motor Overhaul.....................................................................................248
Chapter XXXI - Tracing Car Troubles....................................................................................................249
979 - Asset to repairman...........................................................................................................249
980 - Use systematic methods.......................................................................................................249
981 - Methods for tracing car troubles discussed...................................................................................249
Engine Fails to Start..............................................................................................................249
Cars Equipped with Starters....................................................................................................249
982 - Engine fails to start................................................................................................249
983 - If equipped with starter.............................................................................................249
984 - Turn off ignition and rock car.......................................................................................249
985 - Remove bendix........................................................................................................249
986 - Sprung armature shaft................................................................................................249
987 - Whirring noise.......................................................................................................250
988 - No spark.............................................................................................................250
989 - If engine turns freely but does not start............................................................................250
990 - Remove commutator....................................................................................................250
Wiring diagram (Starter)...................................................................................................251
Cars Not Equipped with Starter.................................................................................................252
991 - Not equipped with starter............................................................................................252
992 - Check crankshaft endplay.............................................................................................252
993 - Check magnet strength................................................................................................252
994 - If car starts - magneto is weak or dead..............................................................................252
995 - Check for 7 volts....................................................................................................253
Locating a Grounded or Shorted Coil............................................................................................253
996 - Locate grounded or shorted coil......................................................................................253
997 - Check for spark......................................................................................................254
998 - If not shorted or grounded- weak magnets.............................................................................254
Chapter XXXII - Misfiring..............................................................................................................255
Misfiring Caused by Trouble in Ignition System or Valves...........................................................................255
1014 - Check gas and adjust carb needle........................................................................................258
1015 - Open drain cock in carb and check gas flow..............................................................................259
1016 - Check sediment bulb for gas flow........................................................................................259
1017 - Check screen............................................................................................................259
1018 - Clean sediment bulb.....................................................................................................259
1019 - Check intake manifold...................................................................................................259
1020 - Check water leaks.......................................................................................................259
Misfiring, or Engine Fails to Start, Caused by Trouble in the Fuel System..........................................................258
1000 - Misfiring (missing) may result from fuel system, ignition system, or valves.............................................255
1001 - Short plugs with screwdriver............................................................................................255
1002 - Check wires.............................................................................................................255
1003 - Check for spark at coilbox terminal.....................................................................................255
1004 - Bad coil................................................................................................................256
Testing and Adjusting the Coil Units...............................................................................................257
1005 - Check points on coil....................................................................................................257
1006 - Maintain .005 clearance.................................................................................................257
1007 - Adjust gap to 1/32 inch.................................................................................................257
1008 - Test coil in coil tester................................................................................................257
1009 - Properly adjusted coil sparks at each 16 points around ring.............................................................257
1010 - If weak spark or no spark - dress points or install new points..........................................................258
1011 - Clean points............................................................................................................258
Inspecting the Valves..............................................................................................................258
1012 - if not in ignition system - Check valves................................................................................258
1013 - Check that valves are not sticking in guides............................................................................258
Chapter XXXII - Back Firing............................................................................................................260
Back Firing........................................................................................................................260
1021 - Back firing defined.....................................................................................................260
1022 - Three causes of backfiring..............................................................................................260
1023 - Slow-burning worn engine parts or carburetor............................................................................260
1024 - Back firing due to ignition is grounded wire............................................................................260
1025 - Pre-ignition............................................................................................................260
1026 - Check fuel line.........................................................................................................260
1027 - Determine cause of backfire.............................................................................................260
1028 - Short and check plug wires..............................................................................................261
1029 - Check for gasket leakage................................................................................................261
1030 - Check valves............................................................................................................261
1031 - Check compression.......................................................................................................261
1032 - If necessary to short cyls 1 and 2 or 3 and 4 - check inletmanifold gasket..............................................261
1033 - If cannot locate backfire - check carburetor............................................................................261
1034 - Check for continual coil buzzing........................................................................................261
1035 - If coils vibrates constantly - bad commutator wire......................................................................261
Chapter XXXIV - Engine knocks..........................................................................................................262
Engine Knocks......................................................................................................................262
1047 - Light rapping may be camshaft bearings..................................................................................263
1036 - Various knocks..........................................................................................................262
1037 - Carbon knock............................................................................................................262
1038 - Loose piston knock......................................................................................................262
1039 - Connecting rod knock....................................................................................................262
1040 - Main bearing knock......................................................................................................262
1041 - Piston pin knock........................................................................................................262
1042 - With the exception of a carbon knock, all knocks can be found by shorting plugs.........................................262
1043 - If No. 1 plug shorted and knock disappears - front main or piston.......................................................262
1044 - If shorting No. 2 plug and knock disappears - #2 cylinger holds the knock. Same with No. 3.............................263
1045 - Sounds are deceiving....................................................................................................263
1046 - Noisy valves............................................................................................................263
Conditions Which Sometimes Cause Knocks............................................................................................263
1048 - Loose flywheel on crankshaft............................................................................................263
1049 - Loose pulley............................................................................................................263
1050 - Timing gear loose on camshaft...........................................................................................263
1051 - Excessive thrust on camshaft bearing....................................................................................263
1052 - Ignition timed incorrectly..............................................................................................263
1053 - Pistons striking cylinder head..........................................................................................263
1054 - Excessive play in crankshaft............................................................................................263
1055 - Magnets striking field coils............................................................................................263
1056 - Generator bearings tight or broken......................................................................................263
1057 - Loose fan bushing.......................................................................................................263
1058 - Crankcase loose in front bearing........................................................................................263
Chapter XXXV - Clutch Troubles.........................................................................................................264
Slipping Clutch....................................................................................................................264
1059 - If engine races but no speed pickup - adjust clutch.....................................................................264
1060 - Adjust clutch...........................................................................................................264
1061 - Adjust clutch fingers...................................................................................................264
Car Creeps Forward with Hand Brake Applied.........................................................................................265
1062 - Car creeps when warm....................................................................................................265
1063 - Adjust clutch bolt......................................................................................................265
1064 - If still creeps - Clutch or low band too tight..........................................................................266
1065 - Cold weather starting...................................................................................................266
Clutch Pedal Sticks in Low Gear....................................................................................................266
1066 - Clutch pedal sticks in low gear.........................................................................................266
Chapter XXXVI - Tracing Trouble in the Generator.......................................................................................267
Tracing Trouble in the Generatpr...................................................................................................267
1067 - Ammeter registers no charge.............................................................................................267
1068 - If singing noise - flash generator......................................................................................267
1069 - Dirty or oily commutator................................................................................................267
1070 - Clean generator commutator..............................................................................................267
1071 - Faults due to carbon and dirt...........................................................................................267
1072 - Test generator..........................................................................................................268
1073 - Other possibilities.....................................................................................................268
1074 - Inspect generator for broken or worn parts..............................................................................268
1075 - If ammeter flutters - check for shorts..................................................................................268
1076 - Check for ground in terminal............................................................................................268
1077 - Check for tight bearing.................................................................................................268
1078 - If less than 2 amps - check for broken wires............................................................................269
1079 - Loose or worn bearings..................................................................................................269
1080 - Properly running generator - 3-5 amps...................................................................................269
1081 - Check for broken parts..................................................................................................269
1082 - Sand brushes............................................................................................................269
1083 - Brushes sticking........................................................................................................269
1084 - Cheaper to install brush holder.........................................................................................269
1085 - Arcing brushes..........................................................................................................269
1086 - Test for grounds in field coils without disassembling generator.........................................................270
1087 - After locating problem - reassemble generator...........................................................................270
Chapter XXXVII - Tracing Trouble in Starting Motor.....................................................................................271
Tracing Trouble in the Starting Motor..............................................................................................271
1090 - If high reading and armature turns slow - grounded armature.............................................................271
1088 - If switch pressed and motor fails to turn over..........................................................................271
1089 - Conect battery - 50-75 amps - starter OK................................................................................271
1090 - If high reading and slowly turning armature - grounded armature.........................................................271
1091 - Jerky and slow turning armature - shorted armature......................................................................271
1092 - High reading and no rotation of armature - grounded field coils or brush holder.........................................271
1093 - Cannot rotate and 100-200 amps - bent shaft.............................................................................271
1094 - If shaft binding - replace bushing......................................................................................271
Chapter XXXVIII - Tracing Trouble in Lighting System...................................................................................272
Tracing Trouble in the Lighting System.............................................................................................272
Tail Lamp or One Headlamp Fail to Light........................................................................................273
1099 - Tail lamp fails.....................................................................................................273
1100 - If tail lamps still fail - check ignition switch....................................................................273
1101 - Check ignition switch...............................................................................................273
1095 - Lamps fail on "Dim" or "Bright".........................................................................................272
All Lamps Fail to Light........................................................................................................272
1096 - All lamps fail to light.............................................................................................272
1097 - No ammeter discharge - Check battery wire on terminal block.........................................................272
1098 - If all lamps burned out checkcharging circuit.......................................................................273
Chapter XXXIX - Tracing Trouble in Charging Circuit....................................................................................274
Short Circuits.....................................................................................................................274
1104 - Tracing a short.........................................................................................................274
1105 - Ammeter delicate instrument.............................................................................................274
1106 - Disconnect terminal block to starting switch............................................................................274
1102 - The charging circuit........................................................................................................274
1103 - Functioning circuit indicated by ammeter....................................................................................274
Open Circuits......................................................................................................................274
1107 - Open Circuits...........................................................................................................274
1108 - Never burn lights with an open circuit..................................................................................275
1109 - How to locate an open in the charging circuit...........................................................................275
Chapter XL - Horn Fails to Sound.......................................................................................................276
1110 - Failure of horn to sound....................................................................................................276
1111 - Examine horn parts for wear.................................................................................................276
1112 - If horn button OK look at wires.............................................................................................276
1113 - Check plunger and diaphram..................................................................................................276
1114 - Check adjustments...........................................................................................................277
Chapter XLI - Battery Care.............................................................................................................278
1115 - Battery maintenance.........................................................................................................278
1116 - Check battery connections...................................................................................................278
1117 - Clean battery ends with weak ammonia........................................................................................279
1118 - Leak causing battery to run down............................................................................................279
1119 - Check brightness of lights..................................................................................................279
1120 - Detailed procedures for serviceing batteriesare xontained elsewhere.........................................................279
Chapter XLII - Servicing the Improved Car..............................................................................................280
Servicing the Improved Car.........................................................................................................280
1122 - Replacing parts.........................................................................................................280
1121 - Numerous improvements in the 1925 car...................................................................................280
Replacing New Type Fenders.........................................................................................................280
1123 - Wider and heavier construction of fenders...............................................................................280
1124 - New type fender bolts...................................................................................................280
Removing the Front Fender..........................................................................................................281
1125 - Remove radiator.........................................................................................................281
1126 - Drain radiator and lift off hood........................................................................................281
1127 - Loosen outlet hose......................................................................................................281
1128 - Runoff radiator nuts....................................................................................................281
1129 - Pry up 3 loom clips.....................................................................................................281
1130 - Remove radiator rod.....................................................................................................281
1131 - Lift radiator off studs.................................................................................................281
1132 - Remove starting crank ratchet...........................................................................................281
1133 - Withdraw crank..........................................................................................................282
1134 - Run off engine pan nuts.................................................................................................282
1135 - Disconnect headlamp plug................................................................................................283
1136 - Run off headlamp bracket bolts..........................................................................................283
1137 - Run off nuts on front fender............................................................................................283
1138 - Run off front fender to dust shield nuts................................................................................283
1139 - Lift off fenders........................................................................................................283
Installing Front Fender............................................................................................................283
1140 - Install new front fender................................................................................................283
1141 - Insert bolts through dust shield........................................................................................283
1142 - Install fender to running board bolts...................................................................................283
1143 - Install headlamp wire through hood blocks...............................................................................283
1144 - Insert hood blocks and bolts............................................................................................284
1145 - Tighten fender bolts....................................................................................................284
Installing the Radiator............................................................................................................284
1146 - Install radiator apron..................................................................................................284
1147 - Position radiator springs...............................................................................................284
1148 - Attach outlet hose to radiator..........................................................................................284
1149 - Insert headlamp bolts...................................................................................................284
1150 - Connect headlamp plug...................................................................................................284
1151 - Insert lighting wire loom...............................................................................................284
1152 - Connect carburetor priming rod..........................................................................................284
1153 - Replace hood............................................................................................................284
1154 - Align and focus headlamps...............................................................................................284
Focusing and Aligning the Headlamps................................................................................................284
1155 - Focus and align improved car headlamps..................................................................................284
1156 - Align and focus headlamps at 25 feet....................................................................................284
1157 - Focus headlamps.........................................................................................................285
1158 - Headlamp alignment tool.................................................................................................285
1159 - Checking proper alignment...............................................................................................286
Replacing Rear Fenders.............................................................................................................286
1160 - Remove new design rear fender...........................................................................................286
1161 - Unbolt rear taillamp and license bracket................................................................................287
Installing Rear Fender.........................................................................................................287
1162 - Install new design fender...........................................................................................287
1163 - Install bolts.......................................................................................................287
1164 - Tighten bolts.......................................................................................................287
1165 - Draw down and tighten fendor nuts and bolts.........................................................................287
Replacing the New Design Running Boards............................................................................................287
Removing.......................................................................................................................287
1166 - Installing new running boards.......................................................................................287
1167 - Remove by running out 8 bolts.......................................................................................287
1169 - Withdraw bolts......................................................................................................287
1170 - Run off nuts on running board ends..................................................................................287
Installing.....................................................................................................................287
1171 - Place wood blocks on support and set running boards on and bolt up..................................................287
1172 - Add bolts and run up nuts...........................................................................................287
1173 - Insert rear running board bolts.....................................................................................287
1174 - Insert two front fender to running board bolts......................................................................288
1175 - Draw down tightly on rear running board nuts........................................................................288
Replacing the New Dust Shield......................................................................................................288
Removing.......................................................................................................................288
1176 - Removing new design dust shield.....................................................................................288
1177 - Run out wood screws affixing dust shield to body....................................................................288
1178 - Withdraw hood clip..................................................................................................288
1179 - Run off hood block bolt.............................................................................................288
1180 - Run off front fender to dust shield bolts...........................................................................288
1181 - Withdraw bolts......................................................................................................288
1182 - Slide off dust shield...............................................................................................289
Installing.....................................................................................................................289
1183 - Install dust shield.................................................................................................289
1184 - Position hood block support.........................................................................................289
1185 - Draw dust shield forward............................................................................................289
1186 - Insert hood block bolt..............................................................................................289
1187 - Insert hood clip....................................................................................................289
1188 - Insert all dust shield nuts nd bolts................................................................................289
1189 - Draw up bolts.......................................................................................................289
1190 - Tighten nuts on ends of hood block bolt.............................................................................289
1191 - Run down two dust shield body screws................................................................................289
1192 - Dust shields now installed..........................................................................................289
The New Type Coil Box..............................................................................................................290
1193 - New style coil box......................................................................................................290
1194 - New coil box location...................................................................................................290
1195 - Note heavy latches......................................................................................................290
1196 - Remove coil box.........................................................................................................290
1197 - Run off ignition wire nuts..............................................................................................290
1198 - Run out 3 cylinder head bolts holding coilbox...........................................................................290
1199 - To install reverse procedure............................................................................................290
New Design Fan Bracket.............................................................................................................291
1200 - New design fan bracket..................................................................................................291
Adjusting Fan Belt.................................................................................................................291
1201 - Adjusting fan belt......................................................................................................291
Replacing Fan Belt.................................................................................................................291
Installing.....................................................................................................................291
1203 - Install new fan belt................................................................................................291
1202 - Replacing fan belt......................................................................................................291
Replacing Fan......................................................................................................................291
1204 - Run off fan shaft nut...................................................................................................291
1205 - To install - reverse the procedure......................................................................................291
New Design Transmission Brake Band.................................................................................................292
1206 - New transmission brake band.............................................................................................292
1207 - All bands come with detachable ears.....................................................................................292
1208 - Chapter XIII apply to present design bands..............................................................................292
Transmission Brake Drum............................................................................................................292
1209 - Transmission brake drum increased surface...............................................................................292
1210 - Hardened shoes fitted over six lugs.....................................................................................292
1211 - Shoes easily replaced...................................................................................................292
1212 - Rebushing brake drum....................................................................................................293
The Transmission Cover.............................................................................................................293
1213 - New transmission cover..................................................................................................293
1214 - Line up ball cap on reassembly..........................................................................................293
1215 - Alignment of transmission cover.........................................................................................294
1216 - Fit ball cap............................................................................................................294
1217 - Recheck.................................................................................................................294
1218 - Count shims on transmission cover.......................................................................................294
Replacing the Hub Brake Shoe.......................................................................................................295
1219 - New brake hub shoe......................................................................................................295
1220 - no more steel to steel faceoffs.........................................................................................295
1221 - Braking surface increased from 8 inch diameter to 11 inches.............................................................295
1222 - New brakes assembled with a large clip..................................................................................295
1223 - Removal of brake shoes..................................................................................................296
Removing.......................................................................................................................296
1224 - Disconnect using special tool.......................................................................................296
Installing.....................................................................................................................296
1225 - Installing new brake shoe...........................................................................................296
1226 - Using special tool..................................................................................................296
1227 - Rear wheel replaced.................................................................................................296
Removing and Installing the Gas Tank...............................................................................................297
1228 - New location of fuel tank...............................................................................................297
1229 - New location of sediment bulb...........................................................................................297
1230 - Tank filled from outside of car.........................................................................................297
Removing.......................................................................................................................297
1231 - Removing tank.......................................................................................................297
1232 - Drain tank and remove overflow......................................................................................297
1233 - Remove overflow pipe set screw......................................................................................298
1234 - Remove carburetor adjusting rod.....................................................................................298
1235 - Run off gas tank strap nuts.........................................................................................298
1236 - Run out ignition screws.............................................................................................298
1237 - Withdraw ignition switch............................................................................................298
1238 - Disconnect battery..................................................................................................298
1239 - Lift out mat and floor boards.......................................................................................298
1240 - Run out transmission door springs...................................................................................298
1241 - Loosen pedals.......................................................................................................298
1242 - Withdraw gas tank straps............................................................................................298
1243 - Force pedals as far forward as they will go.........................................................................298
1244 - Move tank back and forth until sediment bulb clears frame...........................................................298
Installing.....................................................................................................................299
1245 - Position tank in car................................................................................................299
1246 - Bend straps over tank...............................................................................................299
1247 - Insert overflow pipe................................................................................................299
1248 - Position overflow pipe running down clamp...........................................................................299
1249 - Screw sediment bulb into connection.................................................................................299
1250 - Insert feed pipe....................................................................................................299
1251 - Insert feed pipe....................................................................................................299
1252 - Insert carburetor adjusting rod.....................................................................................299
1253 - Position ignition switch in dash....................................................................................299
1254 - Remove transmission cover and adjust pedals.........................................................................299
1255 - Replace floor boards and mat........................................................................................299
1256 - Withdraw rubber tubing..............................................................................................299
1257 - Install hood and fill gas tank......................................................................................299
More Room for Driver...............................................................................................................300
1258 - How to adjust coupe seat................................................................................................300
Adjusting the Coupe Seat...........................................................................................................300
1259 - How to move the seat back...............................................................................................300
1260 - Lift out cushion........................................................................................................300
1261 - Run off nuts of three seatback strainer bolts...........................................................................300
1262 - Raise seat 2" and release clip..........................................................................................301
1263 - Run off spacer board nuts...............................................................................................301
1264 - By tipping up spacer board, it can be removed...........................................................................301
1265 - Move seat back 2".......................................................................................................301
1266 - Additional bolts needed.................................................................................................301
1267 - Cut down spacer board the same amount as seat was moved.................................................................302
1268 - Cut board...............................................................................................................302
1269 - Remove spacer block.....................................................................................................302
1270 - Withdraw tacks and mark section to be cut...............................................................................302
1271 - Do not cut spacer board nore than 3"....................................................................................302
1272 - Keep several spacer boards onhand.......................................................................................303
1273 - Drill new spacer block holes............................................................................................303
1274 - Assemble spacer block to spacer board...................................................................................303
1275 - Install spacer board....................................................................................................303
1276 - Position seat in car and tighten bolts..................................................................................303
1277 - Replace seat cushions...................................................................................................303
Different adjustment methods used on Coupes Equipped with Former Type Seat bar brackets............................................303
1278 - First run of improved coupe had different bar...........................................................................303
1279 - Bolt on small metal bracket.............................................................................................303
Moving Back the Seats in the Improved Tudor........................................................................................304
1280 - Set back 1 1/2".........................................................................................................304
1281 - Lift out cushion........................................................................................................304
1282 - Run off seat leg nuts...................................................................................................304
1283 - Insert seat legs into forward holes.....................................................................................304
1284 - Place washer and lockwasherover the end of each seat leg................................................................304
1285 - Replace the seat cushion................................................................................................304
1286 - The rear seat can be movedback by sliding back the cushion..............................................................304
Starter Wiring Diagram.................................................................................................................305
Non-Starter Wiring Diagram.............................................................................................................306
Index..................................................................................................................................307
A..................................................................................................................................307
B..................................................................................................................................308
C..................................................................................................................................308
D..................................................................................................................................309
E..................................................................................................................................309
F..................................................................................................................................310
G .................................................................................................................................310
H..................................................................................................................................311
I..................................................................................................................................311
J..................................................................................................................................311
K..................................................................................................................................311
L..................................................................................................................................311
M..................................................................................................................................311
N..................................................................................................................................312
O..................................................................................................................................312
P..................................................................................................................................312
Q..................................................................................................................................312
R..................................................................................................................................312
S..................................................................................................................................313
T..................................................................................................................................313
U..................................................................................................................................314
V..................................................................................................................................314
W..................................................................................................................................314
XYZ................................................................................................................................314
PLEASE NOTE:
This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer
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