1925 FORD MODEL T SERVICE MANUAL – PDF DOWNLOAD
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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
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