Original Labor Time Manual - Bricklin Parts of Virginia

LAEIEFT TIIV|EMANt.!AL

F

BFIIG]<Lll\lStandard Labor Operations

1974 and 1975Effective February 10, 1975

The following pages provide the labor operation descriptions and times to be used as a

guide in preparing warranty claims for the 1974 and 1975 Bricklin SV-1. These pagescom-pletely replace the previous issue.

Revisions to this Manual will be distributed on a periodic basis to update the content matterand to provide broader coverage.

FOREWORD

Understanding The Manual

This Manual is divided into groups covering separate areas of the car. The groups range from1000 (Engine) to 25000 (Glass - Channels - Seals).

Labor Operations

There are two tvpes of operations listed throughout the manual. They are "Rasic" and"Combination" operations. A Basic operation is a complete single operation and is identi-fied with a number which is correlated to the group number of the part or assembly beingrepaired or replaced.

A Combination operation is an additional repair which is performed in conjunction to theBasic operation and is related to the basic components. These Combinations are never usedsingly, They must be used in conjunction with a Basic repair operation. They are identifiedwith a letter (A, B, C, etc.) and always follow the Basic operation to which they are ap-plicable. An example would be:

OPERATIONNUMBER

RADIATOR_R&R(Combinations to be used with Basic if applicable)Radiator- Replace

Fan Blades-Reolace

Radiator Hose-Reolace o.2

2000 1.0

0.3

o.2

c

Definition Of Terms Used

R&R (Remove and Reinstall)

R&R is the removal and reinstallation of an originaltion, all necessary adjustments and lubrication. unless

assembly or part. lt includes inspec-otherwise noted.

Replace

This is to remove a part or assembly and replace it with a new part or assembly. This in-cludes clean, adjust, lubricate and transfer parts if necessary, unless otherwise noted.

Overhaul

This is to completely disassemble a unit, clean, inspect all parts and reassemble the unitwith the necessary new parts. lt also includes lubrication and necessary adjustments.

| | Inspect

This is to examine a part, component or system to determine correct function or condition.

Check

This is to verify that a system, component or measurement is within specification.

Adjust

This is to bring a part, component or system into required specification in relation todimension, measurement, pressure etc.

It is recommended that all personnel using this manual be thoroughly familiar with theterms and procedures outlined in the Warranty Policy Administration Manual.

OPERATIONNUMBER

1 000

c

1010

1012

1014

1020

GROUP lOOO _ ENGINE

OPERATION DESCRIPTION

ENGINE ASSEMBLY_R&RWith transmission attached remove assemblythrough hood opening - Includes R&R hood,radiator. rear crossmember, and adjust trans-mission throttle valve linkage.

Short Engine Assembly-Replace-As supplied forservice, consisting of cylinder block, pistons androd assemblies, crankshaft, camshaft, timing gearsand chain.

Includes uncrate engine and transfer of componentparts, clean carbon, torque cylinder head, set igni-tion timing, adjust carburetor idle and clean-up. ......

NOTE: Does not include overhaul of individualunits. Refer to and use only combination timelisted under Malor Operations when overhaul ofindividual components or assemblies is required.

Crankshaft- Replace ..........

Engine Front Support Cushions- Replace ...................

VALVE COVE R GASKET-R EPLACEOne

Both ............

VALVE COVER_REPLACEIncludes new gasket and paint cover.....,.....

POSITIVE CRANKCASE VENTILATION VALVEAND/O R HOSE- R EPLAC E- I ncludes test .......,......

COMPRESSION TEST_WET AND DRY ....................

5.94.3

3.8

0.2

o.7

0.5

ENGI NEAPPLICATION

360351

360351

1-1

MODEL YEAR AND TIME74 75 76

4.64.6

360351

360351

360

351360J5 l

360351

360351

360351

0.4

0.40.6

0.6

2.9

0.2

o.7

o.4

o.4

0.5

EFFECTIVE FEBRUARY 10, 1975

1-2

OPERATIONNUMBE R

1 030

GROUP 1OOO _ ENGINE


CYLINDER HEAD-R&R- Includes clean carbon,replace gasket, and adjust throttle valve linkage.

Left Head Only ............

Right Head Only ............

Both Heads


3.71.9

3.71.9

5.83.0

0.5o.4

0.4o.4

t.ot.b

2.92.5

0.1u. l

o.70.5

n?

0.4

0.8o.t

0.30.3

o.2o.2

0.30.3

o.20.2

0.6

1.0u.o

t.u

ENGINEAPPLICATION

A

G

Valves-Refacestem oil seals

One cylinder

or Replace-lncludes replace valveor deflectors-no mach ining.

JbU

Jr)U

360JCI

JTJU?tr1

360351360

JOU

360351

360J5 I

360351

360?61

360J5 I

JOU351360!tr1

Atl

Each additional cylinder (not to exceed time for allcylinders per head)

One head

Both heads

Valve Guide-One Cvlinder-Ream Oversize-Both

Cylinder Head-Replace

Both

Install Valve Stem Oil Seals-lncludes machine topguides-Perfect circle seats .............

Hydraulic Valve Tappets-Replace-All ... ......................

Cylinder Head Water Jacket Core Plug-Replace

Valve Seats-Recondition-(Use when required withcombination A).One cylinder

Each additional cylinder (not to exceed time for allcylinders per head)

One head

Both heads

JOU351360

JbU

JOU?ql

EFFECTIVE FEBRUARY 10. 1975

OPERATIONNUMBER

1 050

B

c

1052

B

1060

A

B

1062

A

B

c

1070

GROUP 1OOO _ ENGINE

OPERATION DESCR IPTIONVALVE SPRINGS-ONE CYLINDER_R&R_

Head not removed

Valve Spring(s), Def lector(s) or Seal(s)-One CylinderReplace-No machining

One Cylinder-Opposite head

Each Additional Cvlinder

VALVE SPRINGS_REPLACE_FU LL SETCylinder Head(s) Not Removeo

Valve Stem Deflectors or Seals-Reolace-All

Valve Stem OilSeals (Skinner Tvpe)-Full Set-lnstall ......

PUSH ROD-ONE REPLACE

Cylinder Head Cover Gasket- Replace

Two or More Push Rods ............

PUSH ROD{S)_ONE CYLINDER_REPLACE

Cylinder Head Cover Gasket- Replace ........,......

One Cylinder On Opposite Head

Each Additional Cylinder

REFACE VALVESIncludes R&R head(s). recondition seats, remove carbon,replace valve stem oil seals, perform leak test. and adjusttransmission throttle valve linkage.

1-3

MODEL YEAR AND TIMEr+ I3 t6

0.80.6

9.07.O

ENGI NEAPPLICATION

360351

Anl

0.1

0.6u.o

o.20.2

2.32.6

o.2

360351

360351

360351

360351

JOUJ5 l

36035i

360

360

Ao.2

0.80.6

0.5U. Z+

nlu. l

0.10.1

0.50.4

0.1nlu. l

n2o.4

0.10.1

360351

360JCI

360

360351

360aRl

360351

Continued


"t-4

OPERATIONNUMBE R

1070Continued

A

1 080

1092

A

B

c

D

E

1 100

GROUP 1OOO _ ENGINE


Cylinder Head-ReplaceOne head......

Both heads

Cylinder Head Water Jacket Core Plug-Replace

Hydraul ic Valve Tappets- Replace

NOTE: Refer to Operations 112O,1i30 and 1140 forcombi ned engine repairs.

HYDRAU LIC VALVE TAPPETS_ALL_R&Rlncludes cleaning all push-rod passages, and adjusttransmission throttle valve linl<age

ROCKER ARM(S)-ONE CYLINDE R_REPLACE

One Cylinder-Opposite Head ............

Each Additional Cylinder

Rocker Arm Stud-Replace ..........

Push Rod(s)-Replace

Valve Cover Gasket- Rep1ace ...............

OIL PAN-R&R-lncludes replace gasket, seals andnecessary steps to raise engine.

Connecting Rod Bearings-Replace One-lncludes plasti-gage all bearings

Each Additional Connecting Rod Bearing-Replace-Add

All-lncludes plastigage all bearings

ENGI NEAPPLICATION


0.30.3

o.40.4

o.2o.2

0.30.3

360J3 l

JOU

36035',1

360351

360JCI

360

360J3 l

360

360J5 I

JOUJ5 l

360351

0,90.8

0.10.1

t.o1.5

360351

Jr)U351

360351

JCIUJbl

A

??2.6

0.50.4

U.JU.J

0.10.1

0.10.1

0.10.1

0.10.1

1.9l.t


Continued

OPERATIONNUMBE R

1100Continued

B

F

1102

1104

1110

1120

GROUP 1OOO _ ENGINE


Crankshaft Main Bearings-Replace-lncludes rear mainbearing oil seal with rear main bearing replacement,plastigage all bearings.

Front or intermediate

Atl

Rear Main Bearing Oil Seal-Replace-lncludes upper andtower ...........

Oil Pump-Replace ............

Oil Pump-Overhaul ..........

Engine Front Support Cushions- Replace ..........

OIL FILTER_REPLACEIncludes check engine oil level

ENGINE OIL DIP STICK TUBE_ REPLACE

OIL PUMP COVER_R&R OR REPLACEIncludes check gear clearance-replace parts as required..,

PISTONS-REPLACE-ALL- lncludes adjust transmissionthrottle valve linkage

Connecting Rod Bearings- Replace

Crankshaft Main Bearings-Replace-lncludes rear mainbearing oil seal with rear main bearing replacement,plastigage all bearings

Front or Intermediate

1-5


0.90.9

1.11.1

1.5t_c

nav.zu.z

0.2

0.2

ntu.z

o.40.4

1.10.6

U.TJ

0.6

10.5

0.3

0.90.8

1.11.2

t.c1.4

ENGI NEAPPLICATION

360

360

360

c

D

360

360

360

360J5 l

JbU351360

JOUJ5 l

o.2

o.2

360351

360351

360JCI

12.O

0.3

360

360351

A


1-6

OPERATIONNUMBE R

1120Conti nued

c

G

1130

GROUP 1OOO _ ENGINE


Rear Main Bearing Oil Seal-Replace-lncludes upper andrower ...........

Reface Valves ..........

Valve Tappets-Replace

Cylinder Bores-Remove ridge at top of cylinders

Cylinder Bores-Surface hone all cylinders to remove glaze.

PISTON-ON E-R EPLACE- | ncl udes de-carbonizing,installing new rings, and adjust transmission throttle valveI i n kage.

Left.............

Rinht

First Additional Piston Opposite Bank- Replace ................

Each Additional Piston-Rep1ace ..........

Not to exceed Operation 1 120.

Connecting Rod Beari ng-One- Replace

Each Additional Connecting Rod Bearing-ReplaceNot to exceed Combination E.

All Connecting Rod Bearings .................

ENGI N EAPPLICATION


o.2u.z

2.72.5

0.3U.J

0.60.6

t.z1.2

D

7.06.5

A66.0

u.20.2

0.10.1

0.30.3

t.r)

A

D

360JCI

360351

JC}U

351

360

360

JbUJ3 l

360J3 l

360J5 l

360351

360JCI

360351

360351

F Crankshaft Main Bearings-Replace-lncludes rear mainbearing oil seal with rear main bearing replacement,plastigage all bearings.

Front or Intermediate

Rear .............

Ail ...............

JbU351JOU351360JCI

0.9

1.1

1.5

0.9

1.2

1.5


Conti nued

OPERATIONNUMBE R

1130Continued

G

J

1140

GROUP 1OOO _ ENGINE


Rear Main Bearing OilSeal-Replace-lncludes upper andlower ...........

Reface Valves ..........

Hydraul ic Valve Tappets-Replace

PISTON RINGS_REPLACEIncludes adjust transmission throttle valve linkage .........

Connecting Rod*One-Replace .........,

Connecting Rod Bearings- Replace

Crankshaft Main Bearings-Replace-lncludes rear maanbearing oil seal with rear main bearing replacement,plastlgage all bearings-Front or Intermediate

R ea r .. . .... ... ...

Ail...............

Rear Main Bearing OilSeal-Replace-lncludes upper andtower ...........

Re face Valves

Hydraul ic Valve Tappets- Replace

Cylinder Bores-Remove ridge at top of cylinders

Cylinder Bores-Surface hone all cylinders to remove glaze

ENGINEAPPLICATION

360

360JCI

360J5 l

't-7

MODEL YEAR AND TIIVIE74 75 76

JOUJ5 l

360J5 I

360351

0.2o.2

2.12.5

0.30.3

10.5

o.2

0.2

11.1

o.2

o.2B

c

U.Z

2.5

0.3

0.6

t.z

o.2

z.t

U.J

0.6

360J5 I

360

JbU351

360JCI

360

360J5 l

JbUJCI

360?R1

0.9

1.10.9

1.0

1.4

D

t.z

EFFECTIVE FFBRUARY 10, 1975

1-8

OPERATIONNUMBE R

1150

A

E

1152

1160

1 161

1162

1166

GROUP 1OOO _ ENGINE


CRAN KSHAFT VIBRATION DAMPER_R&R

Timing Chain Cover Oil Seal-ReplaceI ncl udes Gaskets

Timing Chain Cover- Replacelncludes Gaskets and Seal lf Required

Ti ming Chai n and Sprockets- Replace ..........

Timing Chain Cover Gaskets- ReplaceIncludes Seal lf Required ...............

Crankshaft Vibration Damper-Replace ..............

PU LLEY-ACCESSORY DR IVE-REPLACE ...................

CAMSHAFT-REPLACE- | ncludes adjust transmissionthrottle valve linkage

CAMSHAFT BEAR I NGS_R EPLACEIncludes adiust transmission throttle valve linkage ..........

CAMSHAFT REAR BEARING PLUG AND/ORGALLEY PLUGS_REPLACEIncludes adjust transmission throttle valve linkageManual transmissionAutomatic transmission

CAMSHAFT LOBE LIFT AND/OR VALVE TIMING_CHECK_lncludes valve cover R&R ............

ENGINEAPPLICATION

JOU

360J5 l


o.70.8

3.2J. Z+

7.08.0

2.52.2

2.2

0.50.5

J. l

3.3

0.40.4

?nJ. l

0.1u. l

0.50.5

360351

360J:) l

360351

360JCI

360351

360360351

360351

5.86.7

360351

360J5 l


OPERATIONNUMBER

1170

c

1 180

1 190

1200

12',1O

0.2

0.3

JOU

JOU

360

360351

360?61

A

B

GROUP 1OOO _ ENGINE


FLYWHEEL_R&RFour Speed

Automatic

Crankshaft Pilot Bushing- Replace

Flywheel-Replace ............

Flywheel Ring Gear-Rep1ace ..........

WATER JACKET CORE HOLE PLUG_REPLACEIncludes ad just transmission throttle valveli nkage when necessary.

Block-Front or Center-lncludes engine cushion R&R ..

Block-Left- Rear .............

Block- Right- Rear- | ncludes starter R&R .....................

Head-Side-l ncludes man ifold assembly R&R ...............

Head- Rear- Includes head R& R where required ............

Head-Front-Left .............

Head-Front-R ight ...........

ENGINE SUPPORT CROSSMEMBER-REPLACEFront..........

Rear............

ENGINE FRONT SUPPORT CUSHION_REPLACEOne

Both

ENGINE REAR SUPPORT CUSHION_REPLACE

ENGI NEAPPL I CATI ON

1-9

IVIODEL YEAR AND TIME74 75 76

a4z. I

2.52.5

n)

o.2.

0.3

1.01.0

0.5ntr

0.60.6

4.9

3.72.6

0.80.8

u.t0.9

0.5

360351JbUJCI360351360

JOU

0.7

0.9

o.4

351360

360351

360

360351

36035i360351

36035i

1a0.8

0.50.5

0.8

0.9

EFFECTIVE FEBRUARY 10. i975

GROUP 2OOO - COOLING


RADTATOR-R&R ...........

With Automatic Transmission-Add

Radiator-Replace ............

Fan Blades-Reolace ..........

Radiator Hose- Replace -....,............

FAN SHROUD-REPLACE-lncludes R&R fan blades ......

BOTTLE. COOLANT RECOVERY_R&R

Bottle- Replace ................

THERMOSTAT OR GASKET_REPLACE

TH ERMOSTAT HOUSI NG_REPLACE

RADIATOR BY-PASS HOSE-REPLACE-lncludes addingcoolant, checking anti-freeze content. and pressure check-ing system for leaks.

RADIATOR HOSE-REPLACE-lncludes adding coolant,checking anti-freeze content, and pressure checking sys-tem for leaks.

Upper..........Lower ..........

HOSE CLAMP_REPLACEOne .............

Each Additional ...............

HOSE, COOLANT RECOVERY BOTTLE-REPLACE .....

PRESSURE TEST COOLING SYSTEM AND CAP

Replace Cap .......,......

WATER PUMP OR GASKET_REPLACE

FAN BLADES, FAN SPACER AND/OR FAN PULLEY_REPLACE

FAN AND ALTERNATOR DRIVE BELT_REPLACE_(Use Belt Tension Gauge)

ENGI NE ACCESSORY DRIVE BELTS_ADJUST(Use Belt Tension Gauge)

One belt

ENGI NEAPPLICATION

ALL

2-1

AND TIMEto

OPERATIONNUMBER

2000

A

B

c

2002

2006

A

2010

2012

2015

MODEL YEAR74 75

1.0 1.0

0.1 0.1

0.3 0.3

o.2 0.2

o.2 0.2

0.7 0.7

o.2 0.2

0.1 0.1

0.5 0.5

o.7 0.7

o.4o.4

2020

2022

2024

2030

A

2040

2060

2070

2072

0.5 0.5

0.6 0.6

o.4 0.4

0.'t 0.1

0.3 0.3

0.3 0.3

o.2

t.o

o.7

0.6

t.o

o.7

0.3

0.6

0.3

0.6

PRINTED IN U.S.A.

OPERATIONNUMBE R

3020

3030

3060

3078

3080

3090

A

B

0.60.6

0.3n?

0.50.3

o.4

3050

0.5

o.2o.2

0.80.6

o.2o.2

0.60.6

0.60.6

0.60.6

0.50.5

0.4o.7

o.2o.2

o.71.3

D

GROUP 3OOO _


SPARK PLUGS_CLEAN AND ADJUST OR

ELECTRICAL

ENGI NEAPPLICATION

3-1


REPLACE

ALTERNATOR VOLTAGE REGULATOR_REPLACE ...

ALTERNATOR_BRUSH ASSEMBLY-REPLACE ..........

ALTERNATOR_R&R

Alternator-Replace- | ncludes pulley and fan R& R ...........

Alternator Overhaul

Overhaul includes-disassemble, clean, test all parts,assemble with original or new parts and make all nec-essary adjustments.

Mounting Bracket- Replace ..............

Alternator Diode Trio-Replace ..........

Alternator Diode Trio Solder Connection-Repair

ALTERNATOR BRACKET_REPLACE

ALTERNATOR DRIVE BELT_REPLACE

STARTER MOTOR_R&R

Replace

Overhaul

Overhaul includes-disassemble, clean, test all parts andassemble with original or new parts. Includes bushingreplacement and all necessary adjustments.

360351

360351

360351

360351

360351

360351

JOU

360351

360351

360351

360351

JOU351

?AN

360J5 l

Continued


3-2

OPERATIONNUMBE R

3090Continued

D

3102

3106

3110

3112

3120

3122

3123

3124

3125

3126

3127

31 30

A

GROUP 3OOO _ ELECTRICAL


lf commutator is turned-Add

lf f ield coils are replaced-Add

Drive Assembly- Replace

Armature Shaf t Spacer- Replace

STARTER MOTOR RELAY_REPLACE ..........

FUSIBLE LINK_STARTER SOLENOID BATTERYTERMINAL TO AMMETER-REPLACE(Dark Brown Wire) ...........

NEUTRAL SAFETY STARTER SWITCH AND BACK.UPLIGHT SWITCH-REPLACE

NEUTRAL SAFETY STARTER SWITCH AND/ORBACK.UP LIGHT SWITCH_ADJUST ...........

CONSOLE OUADRANT ILLUMINATION BULB_AUTOMATIC TRANSMISSION_REPLACE

AMBI ENT TEMPERATURE OVERRIDE SWITCH-"TCS"- R EPLACE ..........

TEMPERATURE SWITCH_AI R CLEANER-REPLACE..

so L E NO I D VA LV E-"TCS"- R E pLACE............... "..........

3-WAY SOLENOI D VALVE_REPLACE

BODY HAR N ESS_"TCS''_R EPLACE

LATCHING RELAY_REPLACE .........,

DISTRI BUTOR-R&R-l ncludes Set Timing

Distributor-Reolace ..........

ENGI NEAPPLICATION 15 76

0.3

MODEL YEAR AND TIME74

0.3

0.30.3

o.2o.2

o.4o.4

0.50.5

360351360351

360J5 l

360J5 l

360351

360J5 l

360351

360J5 l

360351

0.50.5

o.7o.7

o.4o.4

o.4o.4

360

351

360

0.3

0.3

0.3

0.3

0.3

o.4

0.4o.4

o.2o.2

351

360

351

360351

360351


Continued

OPERATIONNUMBE R

31 30Continued

B

F

31 40

3145

3150

3152

3154

31 60

31 80

A

31 85

31 90

A



Check Points and Condensor (replace if necessary) setto specification and check mechanical and vacuumaova nce

Distributor Vacuum Advance Assembly- Replace ..............

Main Shaft Assembly-Replace ..........

Distributor Driven Gear- Replace

Check Rotor and Cap-Replace if necessary .......................

DISTRIBUTOR CAP_REPLACE ..........

ROTOR_REPLACE

DISTR I BUTOR VACUUM ADVANCE ASSEMBLY_REPLACE-l ncludes check dwel I and 1imin9 ..................

DECE LE RATION VALVE_R EPLACE

DECELERATION VALVE-ADJUST (On Car)Includes testing

tGNtTtoN cot L-REpLACE ............

BATTERY TEST-lncludes clean, tighten terminals andadd f luid if necessary.

Replace Battery

BATTERY HOLD DOWN STRAP_REPLACE ..................

BATTERY-R&R-l ncl udes cleaning terminals

3-3


0.30.3

0.30.3

0.30.3

0.30.3

0.30.3


ENGINEAPPI-ICATION

o.2

o.20.2

o.2o.2

o.2o.2

u-zo.2

0.4o.4

0.30.3

D

360

360

360

360351

360

360JCI

360?tr1

360351

360351

360351

360351

0.50.5

0.30.3

o.40.4

o.4o.4

360351

JOU351

360J5 l

360351

360351

Replace

3-4

OPERATIONNUMBE R

3200

3210

A

3220

3222

3232

3246

3248

3250

3260



BATTE RY CABLES_R EPLACEPositive

N egative

HORNOne

Two

-R&R

Replace

HORN RELAY-REPLACE

HORN FUSIBLE LINK-REPLACE-(Orange Wire) ..........

HORN CONTACT PLATE AND DIRECTIONALSIGNAL CAM-REPLACE-l ncludes steering wheel R&Rand lubricate horn contact

HORN OPERATING MECHANISM_REPLACE

IGNITION KEY ALARM SWITCH-REPLACE

IGN ITION LOCK-(Column Lock Assembly)-R&R .........

Replace

lgnition Switch Actuator and/or Rack-Replace ................

IGNlTION SWITCH_R&R

HEADLAMP SWTTCH-R&R .................

Replace

Rheostat-Replace .........-..

ENGI NEAPPLICATION

351

JOU351

360351

360351

360


0.90.9

0.30.3

0.30.3

0.5

0.6

0.4

0.6

n?

o.7

o.4

0.4

0.6

U.J

o.7

360

JbUJCI

0.6

360351

360

360

3234

360J5 l

360351

360351

360J5 l

360351

J5 I

360351

360351

360351

0.5

o.20.2

0.30.3

0.6u.o

0.6

o.4

A

o.4

0.30.3

u-zo.2

o.2o.2


OPERATIONNUMBER

3262

3270

3290

3300

3332

3333

3334

3340

3345

3347

3348

3349

3365



HEADLAMP AND/OR IGNITION KEY WARNINGBUZZER_REPLACE

COURTESY LIGHT PILLAR SWITCH_REPLACE

FUSE PANEL-REPLACE

DIMMER SWITCH_REPLACE

I NSTRUMENT PANEL HARNESS_REPLACE

I NSTRUMENT CLUSTER HARNESS_R EPLACE

ENGINE COMPARTMENT HARNESS_REPLACE ..........

BODY WI RE HARNESS_FRONT_REPLACE

BODY WIRE HARNESS_REAR_REPLACE ...................

DOOR WIRE HARNESS_REPLACE ...............

DOOR SWITCHING CIRCUIT FUSIBLE LINK_REPLACE(Orange "Loop" Wire) ...........

DOOR SOLENOID_REPLACE

IGNITION Wl RES-REPLACE-l ncludes test al I wiresOne .............

Complete set ...............

HEADLIGHT HARNESS-REPLACE

ENG I NEAPPLICATION

3-5


0.3360351

360351

360351

360

0.3

0.4o.4

o.4o.4

o.4351

360351

360351

360351

360

1.4

1.0

1.5

2.0

0.4

1.4

1.0

1.5

360JCI

JOU351

JOU351

360JCI

360351360J3 l

360351

0.60.6

0.50.5

2.0

2.O2.0

1.01.0

0.30.3

0.50.5

1.01.0

3360


3-6

OPERATIONNUMBE R

3368

3370

3371

3372

A

B

c

3390

A

3412

3413

3414

3428



HEADLAMP ACTUATOR_R EPLACEOne .,...........

8oth............

HEADLAMP BULB-REPLACE ............

Aim Bulb

H EADLAMP MECHAN ISM_ REPLACEOne .............

Both ............

HEADLAMP DOOR_R EPLACE ..........

Mechanism-Rep|ace ..........

Aim Bulb-One side

Aim Bulb-Other Side

AIM HEADLAMPS_

PARKING LAMP LENS_REPLACE

Parking Lamp Assembly- Replace

TAIL LAMP BODY_REPLACE ,.........

TAIL LAMP LENS_REPLACE ...........

TAIL LAMP SOCKET AND WIRE ASSEMBLY_REPLACE

DIRECTIONAL SIGNAL SWITCH LEVER_REPLACE ...

ENGI NEAPPLICATION

360J3 I

360J3 l

360JCI

36035i

360351360JCI

360351

360351

?AN

351

360351

360J5 l

360

360351

360

MODEL YEAR AND TIME74 15 t6

1.0

1.8

0.3

0.1A

1.0

1.8

0.3

0.1

1.5

2.7

0.3

1.5

0.1

0.1

2.7

0.3

1.5

0.1

0.1

3400

0.30.3

0.3

0.1

0.5

0.3

0.1

351

360351

360351

360J5 l

0.5

0.30.3

o.40.4

o.4o.4


3440

OPERATIONNUMBE R

3430

3431

3432

3450

3490

E

F

3495

3520



DI RECTIONAL SIGNAL SWITCH ASSEMBLY_REPLACE

DTRECTIONAL SIGNAL FLASHER UNIT_REPLACE ...

FOUR-WAY HAZARD WARNING LIGHT SWITCH_REPLACE

LICENSE PLATE LAMP ASSEMBLY AND/OR BULB_REPLACE

STOP LIGHT SWITCH_ R EPLACE

I NSTRUMENT CLUSTE R ASSEMBLY-R&R- | ncludesd isconnect battery when necessary ................

Fuel I ndicator-Replace

Temperature I ndicator- Replace ............

Speedometer Assembly- | ncl udes setti ng odometer-Replace

Ammeter-Replace ............

Oil Pressure Gauge-Replace ................

Tachometer- Replace

INSTRUMENT OR WARNING LIGHT CLUSTERI LLUMINATION BULB AND/OR SOCKET_REPLACE

ENGINE OIL PRESSURE SENDING UNIT-REPLACE ...

ENGINE TEMPERATURE SENDING UNIT_REPLACE-Without draining cooling system

ENGI NEAPPLICATION

3-7


0.40.4

o.4o.4

o.7o.7

0.4o.4

360

360

360

0.30.3

o.4o.4

0.60.6

o.2u.z

0.2o.2

360

360

360351

360351

360351

360J3 l

360351

360J5 l

360J5 l

360351

360J5 l

0.30.3

o.2o.2

0.30.3

0.30.3

o.7o.7

o.4o.4

360351

3530


3-8

OPERATIONNUMBE R

3540

3550

3560

3570

3580

3582

3584

3586

3587

3671

3672

3673

3674

3694

3800

GROUP 3OOO - ELECTRICAL


SPEEDOMETE R CORE_R EPLACEIncludes cutting to length and crimping

SPEEDOMETER CABLE AND CORE_REPLACE

SPEEDOMETER DRIVEN GEAR AND/OR SEAL RING_REPLACE

COU RTESY LIGHT ASSEMBLY-REPLACE

RADIO_R&R

RADIO SPEAKER-REPLACE

ANTENNA_REPLACE

RADIO DIAL ILLUMINATION BULB-REPLACEIncludes radio R&R

EMERGENCY START RELAY_SEAT BELT INTER-LOCK SYSTEM_REPLACE

SEAT BELT WARNING INTERLOCK MODULE-REPLACE

SEAT BELT WARNING SYSTEM SENSING SWITCH_REPLACE

SEAT BELT WARNING TIMER ASSEMBLY 4 TO 8SECOND DELAY_REPLACE

SEAT BELTWARNING SYSTEM BUZZER OR RELAY_REPLACE

REAR WINDOW DEFOGGER SYSTEM SWITCH_REPLACE

PARK/DIRECTIONAL SIGNAL LAMP ILLUMINATIONBULB_REPLACE ............

ENGI N EAPPLICATION

360351

aAn

360


0.90.9

0.80.8

360J5 l

360JCt

o.4

0.3

0.7

AA

n?

0.7

o.40.4

0.60.6

35i

360351

360351

0.8

U.J

0.8

0.3

360d5 l

360J5 l

360351

360351

360351

360J5 l

n?0.3

0.60.6

0.30.3

0.30.3

0.30.3

0.3

360351

0.3360351


OPERATIONNUMBE R

3802

3804

3806

3812

3826



TAIL/STOP LAMP ILLUMINATION BULB_REPLACE..

BACK-UP LAMP ILLUMINATION BULB_REPLACE,.....

FENDER SIDE LAMP ILLUMINATION BULB-REPLACE

HIGH BEAM INDICATOR BULB_REPLACE

HEADLAMP SWITCH I DENTI FICATION BULB_REPLACE- Includes R&R switch

WIPER SWITCH I DENTIFICATION BULB_REPLACE_lncludes R&R switch

HEATED REAR WINDOW DEFOGGER SYSTEMI DENTI FICATION BU LB_REPLACE

DOME LAMP AND/OR DOME LAMP BULB-REPLACE

DIRECTIONAL SIGNAL INDICATOR BULB_REPLACE

3-9


0.30.3

0.30.3

0.30.3

o.7o.7

o.4o.4

o.40.4

o.7o.7

0.3

o.7

ENGI NEAPPLICATION

360351

360351

360351

360351

360351

3828

3834

3842

3852

0.3

o.7

360J5 l

360351

360351

360351


OPE RATIONNUMBER

4000

A

4004

4005

4006

A

4008

401 0

4020

GROUP 4OOO _ FUEL _ CARBURETION


FUEL PUMP_R&R

Fuel Pump-Replace

FUEL PUMP FITTING_REPLACE

FUEL PUMP ECCENTRIC_REPLACE

FUEL LINE-REPLACE-(Pump to Carburetor or Filter)

Pump Inlet Line .............

IN.LINE FUEL FI LTER_REPLACE

FUEL PUMP TEST- On the CarIncludes pressure. volume and vacuum check

CARBURETOR-R&R-lncludes replace flange gasket andadjust transmission throttle valve linkage if required. .......

Carburetor-Replace-lncludes adjust idle speed anomtvf I tra

Install Minor Repair or Gasket Kit-lncludes necessarydisassembly, adjustments and cleaning fuel meteringpassages with compressed air.....................

Overhaul Carburetor-l ncludes disassemble completely,clean with solvent, install major repair kit and performall adjustments (Bench and on Car). ............

Carburetor Manifold Adapter andlor Lower AdapterGasket-Replace-lncludes adjust idle speed and mixture

FUEL INLET NEEDLE AND SEAT ASSEMBLY AND/OR AUXI LIARY VALVE_REPLACEIncludes check f loat or f uel level, adjust transmissionthrottle valve linkage, idle speed and mixture if required...

- EXHAUST

ENGI NEAPPLICATION

360351

360

4-1


0.60.5

0.30.3

0.4o.4

0.60.6

0.30.3

0.50.5

U.J

0.3

0.3

0.3

0.50.5

o.2o.2

0.80.8

l-zt.z

0.4o.4

0.8u.o

J5 l

360351

360

360351

36035',1

JOU351

A

360351

360351

360351

JOU351

JOU?61

360J3 l

360351

D

4030


4-2

OPERATIONNUMBER

4040

4080

4090

4092

4100

41 09

4110

4116

4140

4142

4144

GROUP 4OOO _ FUEL - CARBURETION _ EXHAUST

OPERATION DESCRIPTIONENGI N E

APPLICATION

ADJUST CARBURETOR FUEL OR FLOAT LEVELIncludes adlust idle speed, mixture and adjust transmissionthrottle valve linkage

MAIN JET(S)_REPLACEModel 4300

POWER VALVE (ECONOMI ZER )_REPLACEIncludes adjust transmission throttle valve linkage .......... 360

351

ACCE LE RATOR PUMP_R EPLACEModel 4300

CHECK CARBUR ETOR ADJUSTMENT_Includes check fuel pump pressure, perform all externaladjustments and adjust transmission throttle valve linkage

360

[/ODEL YEAR AND TIME74 75 76

o.70.5

0.5o.7

0.50.5

o.40.4

o.7o.7

0.3

0.30.3

0.4o.4

0.4o.4

Q.40.4

o.4Q.4

4054

4060

360351

JOUJCI

ACCE LE RATOR PUMP STROKE_ADJUSTModel 4300

Model 2100

CHOKE-ADJUST-lncludes removing choke cover to freeup choke mechanism

INITIAL CHOKE VALVE CLEARANCE_ADJUSTIncludes fast idle cam linkage and fast idle speed adjust-men1 ............

DASH POT-REPLACE- Includes adiustment

THROTTLE RETURN SPRING_REPLACEIncludes adjust curb idle speed and adjust transmissionthrottle-valve I i nkage

AIR CLEANER ASSEMBLY_REPLACE

THERMOSTATIC AIR CLEANER DUCT AND VALVEASSEMBLY-REPLACE- | ncludes testino

THERMOSTATIC AIR CLEANER EXHAUST SHROUDASSEMBLY_REPLACE

360JCI

360

351

JOU351

0.3

360351

360351

360351

360351

360351

360351

0.60.6

0.50.5



ENG I NEAPPLICATION

JOU351

360351

360351

JOUJ5 l

360351

360

360?tr1

360

360JCI

360351360

4-3


0.30.3

0.80.8

0.2o.2

0.2o.2

0.50.5

0.6

o.7

o.4

u-o

o.l

0.4

0.3

t.J

1.5

2.5

0.3

0.6

o.7

OPE RATI ONNUM BE R

4146

41 50

A

B

c

4152

4154

4155

41 60

A

4162

4182

41 85


CHARCOAL CAN ISTER-REPLACE

FUEL TANK-R&R-lncludes transfer tank qauqe unit....

Drain and Refill

Fuel Tank*Replace

Fuel Tank-Clean

FUEL TANK UPPER FILLER NECK_REPLACE

FUEL TANK SENDING UNIT_REPLACEIncludes 0.2 hrs. for tank drain and fill ...............

CONNECTOR_FUEL TANK FILLER NECK TO TANK_REPLACE

INTAKE MANIFOLD-R&R-lncludes replace gasket andadjust idle speed. mixture and adjust transmission throttlevalve linkage

I ntake Manifold- Replace

CHOKE HEAT TUBE (IN MANI FOLD)-REPLACEModel 4300Model 2100

EXHAUST MANI FOLD_R EPLACE_Left side

R ight side

Both

EXHAUST MANIFOLD HEAT SHROUD_REPLACE .....

11

1.6

o.40.5

360J5 l

360J3 l

J5 l

360

360351

1.1

0.50.5

EFFECTIVE FEBRUARY,l O, 1975

4-4

OPE RATI ONNUMBE R

41 90

A

B

4200

GROUP 4OOO _ FUEL _ CARBURETIOIJ _ EXHAUST

ENGI N E

OPERATION DESCRIPTION APPLICATIONMODEL YEAR74 75

AND TIIV]Et6

4210

A

4220

4250

4252

EXHAUST PIPE FLANGE GASKET_REPLACE :

One Side

Both Sides

EXHAUST MANIFOLD HEAT VALVE (DAMPER}_REPLACE

EXHAUST PIPE_REPLACEFront and/or intermediate

Muff ler- Rep1ace ..............

MUFFLER-REPLACEIncludes installing extensions

Intermediate Exhaust Pipe- Replace

EXHAUST ALIGNMENT-Adjust and tighten all connec-tions and align exhaust pipes and muffler for properctearance.

SU PPORT_MU F F LE R_ R EPLACEAny one

Each additional-Add

AI R PUMP-"AI R-GUARD'' SYSTEM_R&RAI R PUMP_"TH ERMACTOR" SYSTEM R&R .............Includes adlust belt-tension ...........

Air Pump-Replace ............

Mounting Bracket(s)-Replace ..........

360

360351

360

360351

360351

360JCI

360A

o.4o.4

NK0.5

0.4

o.7

0.3

4240

0.3

0.5

o.4

o.7

0.3

0.3

ntr

o.40.4

0.10.1

JOUJ3 I

360351

360J5 l

A

0.80.4

o.20.3

0.2nav.z

JbU

360351

360JCt

0.4o.4

EFFECTIVE FEBRUARY 10,'1975

Conti nued


ENGI NEAPPLICATION

4_5

MODEL YEAR AND TIME7A -7R

o.4

0.1

o.2

1.01.0

o.70.7

0.2o.2

0.3

na0.3

0.4

0.4

OPERATIONNUMBE R

4252Continued

c

D

4254

4255

4256

A

4257

4258

4270

4271

4400

4408


Air Pump Relief Valve-Replace

Centrifugal F i lter- Replace ................

HOSE_"AIR.GUARD" OR "THERMACTOR" SYSTEM-REPLACEAny one

All hoses-Add ..................

AIR PUMP RELIEF VALVE_REPLACE

AI R DISTRIBUTION MANI FOLD_R&RRight Side

Left Side

Air Distribution Man ifold- Replace

ANTI-BACKFI RE VALVE_REPLACE .

BY-PASS VALVE_ "AIR-GUARD" OR,,THE RMACTOR'' SYSTEM_REPLACE

EXHAUST GAS RECIRCULATION VALVE "AIRGUARD" SYSTEM_REPLACE

EXHAUST GAS CHECK VALVE "THERMACTOR"SYSTEM_REPLACE

ACCE LERATOR PEDAL-REPLACE

ACCELERATOR CONTROL CABLE-REPLACE

360351

360

u-zo.2

o.2o.2

0.4

0.1

0.2

360351JOUJ5 l

360

360351360351

360351

0.4

0.4

0.4

o.4360

351

360351

360

360


OPERATIONNUMBER

5000

5006

5010

501 1

5012

501 5

5020

A

B

c

D

E

F

G

H

5030

A

5031

5032

GROUP 5OOO _ CLUTCH


ADJUST PEDAL FREE PLAY.

CLUTCH PEDAL ANDiOR BRAKE PEDAL_REPLACE_Includes lubrication and stop light switch adjustment as

requ i red

CLUTCH PEDAL OVERCENTER SPRING_REPLACE ,..

CLUTCH PEDAL BUSHING (NYLON)_REPLACEA nrr nne

Atl

Pl LOT BUSHING-lncludes installinq new oilwick

CLUTCH THROWOUT SLEEVE AND BEARING_REPLACE-lncludes transmission R&R and adjustnpr'lel frpc nlarr

CLUTCH COVER ASSEMBLY AND/OR DRIVEN PLATE-REPLACE-lncludes R&R transmission, R&R clutchhousing, adjust clutch pedal free play and R&R exhaustpipes............

Adjust Clutch Lever Height-Use Gauge J-1048

Clutch Throwout Sleeve and Bearing-Replace

Clutch Throwout Lever and/or Ball Bearing Pivot-Replace

Crankshaft Pilot Bushing- Replace

Flywheel-Rep1ace ............

Clutch Housing-Replace-lncludes check and correctalign ment

Flywheel Ring Gear-Replace ..........

Pilot Bushing-lncludes install new oil wick

CLUTCH BE LLCRAN K ASSEMBLY_R&R_Includes adjust pedal free play and lubrication ...............

Replace

CLUTCH THROWOUT LEVER_REPLACE ....................

CLUTCH TH ROWOUT LEVER BOOT-R EPLACE ..........

ENGI N E

APPLICATION

JOU

5-1

MODEL YEAR AND TIMEt4 15 76

0.3

0.2

0.1

0.1

0.1

0.2

0.8

0.3

o.2

o.7

o.2

1.5

0.5

JOU

360360

0.9

0.5

0.51.)

l.fi

1.3

2.2

360

360

360

360

JOU

360

JOU

360

360

360

360

360


OPERATIONNUMBE R

6000

A

B

c

D

601 0

6012

6014

601 6

6020

6030


TRANSMISSION_FOUR SPEED MANUAL_R&R_Includes adjust and align shift levers, and R&Rexhaust pipes. ........... 360 1.2

Transmission Assembly-Replace .......... 360 O.2

Transmission Front Oil Seal-Replace 360 0.3

Clutch Housing-Check and correct alignment with dialindicator 360 0.8

360 2.8

360 0.6

-Transmission not removed.................. 360 0.9

SPEEDOMETE R DR IVE GEAR-REPLACE-Transmissionnot removecl ..

GROUP 6000 _ TRANSMISSION _ MANUAL

Transmission Assemblv-Overhau I

TRANSMISSION REAR OI L SEAL_REPLACE-Transmission not removed

TRANSMISSION EXTENSION HOUSING BUSHING_REPLACE- Includes housing R&R and seal replacement

Manual

SWITCH SOLENOID CONTROL_"TCS'' (AT TRANS.MISSION)_R EPLACE

TRANSMISSION COVER AND SHIFT FORK ASSEM-BLY GASKET- R EPLACE-"4-Speed"

TRANSMISSION COVER AND SHIFT FORK ASSEM.BLY-OVERHAUL-lncludes checking interlock sleeve

6-1

ENGINE MODEL YEAR AND TIMEAPPLICATION 74 75 76

360 0.8

360 0.4

360 0.9

360 1.1cr eara nce-


OPERATIONNUMBER

7000

7022

7050

A

B

7051

7052

7056

7060

GROUP TOOO - SHIFT MECHANISM

OPERATION DESCR IPTION

SHI FT LINKAGE ADJUSTMENT"4-Speed"

"Console Shift"-Automatic ...........

GEAR SHIFT LEVER KNOB, HANDLE AND/ORBUTTON_REPLACE_"Console" Shift-Automatic ..............

Hurst Floor Shift-Manual ...................

SHIFT MECHANISM_R&R_"Console" Shift-Automatic ..............

Hurst Floor Shift-Manual ...................

Overhaul Automatic Shift Mechanism ...............

Overhaul-Hurst Floor Shift Mechanism-"4-Soeed" .........

ADAPTER, GEAR SHIFT MECHANISI\4 TO TRANS.M ISSION-R EP LACE-"4-Speed"

BEZEL AND/OR BOOT-R EPLACE ............

GEAR SHIFT LEVER AND/OR RETAINER_REPLACE"4.-Q noor'1"

"Console" Shift-Automatic ..............

CONSOLE GEAR SELECTOR COVER (lncludingindicator)-R EPLACE

GEAR SHIFT RODS_REPLACE_Includes adjust shift linkage and lubrication"4-Speed"

ENG I NEAPPLICATION

360351360

7-1


0.30.3

U.J

0.30.3

0.2

o.7o.7

t.u

u.zo.2

u.o

o.4

0.4

0.4

0.3

360

360

360

360

360351

360

360

360Qq't

360351360

JOUJ3 l

0.5

0.4

o.4

0.3

1.0360

7090


GROUP SOOO _ BRAKES _ WHEELS - HUBS - DRUMS

ENGI NEAPPLICATION

ALL

8-1


OPE RATI ONNUM BE R

8020

8040


BRAKE SHOES_TWO WHEELS_REAR_REPLACE-lncludes adjust parking brake

NOTE: Refer to the appropriate combination operationslisted for 8050 as they also apply.

BRAKE SUPPORT PLATE-ONE-REAR_R EPLACE_Includes bleed rear hydraulic system and adjust parkingbrake ...........

NOTE: Refer to the appropriate combination operationlisted for 8050 as they also apply.

DISC BRAKES

BRAKE SHOES (FRICTION PADS AND REAR SHOES)_FOUR WHEELS_REPLACEIncludes adlust parking brake

Disc Assembly-Replace-lncludes new seal, repackand adjust bearings.

0.80.8

f .i1.1

8050

A

an2_O

Both

Drum Assembly ( | ncludes Hub)-One- Replace .................

Overhaul Caliper Assembly or Replace if Required-One ...

Caliper Mounting Bracket and/or Front Splash Shield-Replace-lncludes A.

One .............Both............

Rear Wheel Cyl inder-ReplaceOneBoth

Rear Wheel Cylinder-ReconditionOne .............Both ............

Rear Support Plate-Replace-lncludes F.

One .............Both ............

Rear Wheel Inner and Outer Grease Seals-Replace-lncludesrepacking or replacing bearing, check axle shaft end play-adjust as required.

Left SideR ight SideBoth Sides

Bleed Hydraulic System

0.30.5

o.4

ntr

0.30.5

o.4

D

0.5 0.50.9 0.9

o.2n?

0.5 0.50.9 0.9

o.20.3

0.3 0.3n6 n6

u.t1.01.3

0.3

o.71.0t.J

0.3

EFFECTIVE FEBRUARY 10. 19]5

8.2 GROUP SOOO _ BRAKES _ WHEELS _ HUBS _ DRUI\4S

OPERATON ENGINE MODEL YEAR AND TIMENUMBER OPERATION DESCRIPTION APPLICATION 74 75 76

8060 FRICTION PADS_REPLACE_FRONTNOTE: Refer to the appropriate combination operationslisted for 8050 as they would also apply.

One WheelTwo Wheels

8O7O ROTOR DISC_REPLACEIncludes new seals, repack bearings and adjust.

One.............Both ...........'

A Dust Shield andlor Mounting Bracket- Replace

One.............Both ..'..'......

8075 CALIPER ASSEMBLY_REMOVE AND INSTALL ORREPLACE

One """"""'Both ............

8075 A CALIPER ASSEMBLY_OVERHAULOne .""""""Both ............

HYDRAULIC SYSTEM

NOTE: R&R of pressure differential switch plunger is

I ncluded when required.

8O8O BLEED BRAKE HYDRAULIC SYSTEM

8086 BRAKE PRESSURE DIFFERENTIAL WARNINGLIGHT SWITCH-REPLACE

8090 MASTER CYLINDER-R&R-Includes bleed system.

A Overhaul Master Cylinder-CAUTION: Only clean brakefluid should be used for cleaning cylinder

B Replace..........

81OO WHEEL CYLINDER-RECONDITION OR REPLACE_Includes bleed svstem(s) involved.

A One-Rear

B 8o1h..............

ALL 0.8 0.81.3 1.3

0.8 0.81.3 1.3

0.3 0.30.4 0.4

o.7 0.70.9 0.9

0.6 0.61.0 1.0

0.5 0.5

0.4 0.4

0.5 0.5

o.2 0.2

o.7 0.7

1.2 1.2

BRAKE HOSE AND TUBES

8110 BRAKE HOSE_REPLACE_Any one hose, includes bleed system 0.6 0.6


GROUP SOOO - BRAKES - WHEELS _ HUBS _ DRUMS B-3OPERATION ENGINE MODEL YEAR AND TIMENUMBER OPERATION DESCRIPTION APPLICATION 74 15 76

8136 BRAKE TUBE-(DISC)_REPLACE_Master cvlinder to combination valve-lncludesbleed system(s).

Either one ALL 0.8 0.8Both ............ 1.5 1 .5

8142 BRAKE TUBE-FRONT (DISC)-REPLACE_Combination valve to right f ront hose-lncludes bleedf ront system. 0.6 0.6

8144 BRAKE TUBE_FRONT (DISC)_REPLACE_Combination valve to left front hose-lncludes bleedfront svstem 1.3 1.3

8150 BRAKE TUBE_REAR_REPLACECombination valve to junction block, includes bleed rearsystem 0.8 0.8

8154 BRAKE TUBE_REAR_REPLACE_Junction block to rear hose-lncludes bleed rear svstem . O.7 O.7

8156 VALVE_COMBINATION, DIFFERENTIAL ANDPROPORTIONING_R&RDisc Brakes-lncludes bleed svstem 0.8 0.8

- A Reolace 0.3 0.3

B Tube, valve to junction block-Rep|ace................ 0.3 0.3

8160 BRAKE TUBE-REPLACE-Over Rear Axle-lncludes bleedrear svstem 0.7 0.7

8164 BRAKE PEDAL (AUTOMATIC TRANSMISSION)_REPLACE-lncludes lubrication and stop light switchadjustment (Operation 5006-Manual Transmission) ....... 0.5 0.5

PARKING BRAKE

8170 PARKING BRAKE-ADJUST............ 0.4 0.4

8180 PARKING BRAKE CABLE_EOUNIIZEN TO REARSHOES-REPLACE-lncludes adjust parking brake ........ O.4 O.4

One Side 0.8 0.8Both Sides 1.4 1.4

8190 PARKING BRAKE ASSEMBLY_REPLACE_Includes adjust parking brake 1.0 1.0


8-4

OPERATIONNUM BE R

8220

A

B

c

D

8230

8240

8300

8310

8324

A

8324

8324 A

8505

GROUP SOOO _ BRAKES _ WHEELS _ HUBS - DRUMS

OPERATION DESCR IPTION

POWER BRAKE

POWER BRAKE UNIT_R&BMaster Cylinder lines not disconnected

Power Brake Unit-Complete Overhaul

Power Brake Unit Linkage-Replace or Overhaul

Vacuum Check Valve-Replace

Vacuum Hose-Replace ..................

VACUUM CHECK VALVE-REPLACE

VACUUM HOSE_REPLACE ............

REAR BRAKE DRUM_R&ROne .....,.......Both ............

Drum and Flub Replace-lncludes adjust park brakeOne .............Both ............

FRONT WHEEL BEAR INGS_ADJUSTBoth Sides

FRONT WHEEL BEARINGS_REPACK OR REPLACE_Both sides-Remove, wash, inspect, replace, install newseals and adjust ..........

Disc-One- Replace ..........

FRONT WHEEL BEARINGS_REPACK OR REPLACE_WITH DISC BRAKES-Both sides-Remove, wash,inspect, repack, install new seals and adjust ..........

Disc- ReplaceOne.............Both ............

Wheel Bearing Cup- ReplaceOne lnnerOne Outer

REAR WHEEL BEARING-REPLACEOne .............Both ............

POWER BRAKE REACTION DISC_REPLACEIncludes master cylinder R&R-Lines not disconnected

ENGINEAPPLICATION


AL L 0.6 0.6

0.8 0.8

n2 n2

0.1 0.1

u.t u.l

o.4 0.4

0.4 0.4

0.3 0.3o.4 0.4

ntr0.9

0.50.9

0.40.4

1.1 1.1

0.1 0.1

1.1 1.1

0.1 0.1o.2 0.2

0.1 0.10.i 0.1

0.8 0.8t.J t.J


0.4 0.4

GROUP SOOO _ BRAKES - WHEELS _ HUBS _ DRUMS

OPERATION ENGINE MODEL YEAR AND TIMENUMBE R APPLICATION 74 75 76

- 8510 WHEEL ASSEMBLY_REPLACEI ncludes transfer tireOne............. ALL 0.5 0.5Each Additional ............... O.4 O.4

B51O A WHEEL AND TIRE ASSEMBLY_ROTATE FRONT TOREAR -lncludes all four wheels and tires 0.6 0'6

B-5


GROUP 9OOO -


REAR AXLE-PROPELLER SHAFT

AXLE SHAFT AND/OR BEARING_REPLACEIncludes new inner and outer seals, check axle shaftend play, adjust as required, bleed rear brake systemand adjust parking brakeLeft SideR ight SideBoth Sides

ADJUST AXLE SHAFT END PLAYIncludes bleed rear svstem

AXLE SHAFT SEALS_INNER AND OUTER_REPLACEIncludes clean and pack bearing, check axle shaft end play,adjust as required, bleed rear brake system, and adjustparki ng brake.

Left SideR inh+ Qido

So-tf' Sia.,

AXLE SHAFT SEAL-OUTER-REPLACE-lncludesadjust parking brake.

1 0" Brake

Brake Shoes-Two Rear Wheels- Reolace ...............

REAR AXLE ASSEMBLY-REPLACE_WITHASSEMBLY AS SUPPLIED FOR SERVICE

Axle Shafts and/or Bearings- Replace

REAR AXLE_DISASSEMBLE. CLEAN, INSPECT ANDASSEMBLE-lncludes propeller and axle shafts R&R,check case run-out, adjust side bearing pre-load, back-lash, drive pinion depth and pre-load, replace pinion oilseal, rear cover gasket and axle shaft inner and outergrease seals. Road test to verify work............

NOTE: The appropriate combination operations are to beused where required.

Drive Gear and Pinion Set and/or Drive Pinion Bearings-Replace

Differential Side Bearings-Replace

Differential Side Gears, Pinions, Thrust Washers, Shaft(Non-Twin Grip) and/or Case-Rep|ace ...........................

9-1

OPERATIONNUMBE R

9000

9002

9006

A

9030


ALL 1.51.82.1

1.4

t.51.82.1

1.4

9004

l.:) 1.51.8 1.82.1 2.1

0.6

0.4

o.2

0.6

o.4

3.2

o.2

9020

A

5.1E1

0.30.3

0.30.3

0.5

1.2

0.5

1.2D Housing-Replace ..................

Continued


9-2

OPERATIONNUMBE R

E

F

9040

A

9042

9050

9060

9062

9072

A

9074

GROUP 9OOO _ REAR AXLE _ PROPELLER SHAFT

ENGINEOPERATION DESCRIPTION APPLICATION

Axle Shafts and/or Bearinqs- Replace .............. ALL

Twin Grip Differential-Overhaul

DI FFERENTIAL CASE ASSEMBLY_REPLACE OROVERHAUL

Axle Shafts and/or Bearings- Replace ..............

SWAY STABI LI ZER_R EPLACE

REAR AXLE HOUSING COVER OR GASKET_REPLACE

PINION OIL SEAL OR REAR YOKE_REPLACEIncludes propeller shaft R&R

PINION PRELOAD_RESET .........,.

REAR SUSPENSION CONTROL ARM_REPLACEUpper ..........

Replace upper control arm axle housing bushing

REAR SUSPENSION UPPER CONTROL ARM AXLEHOUSING BUSH I NGS_R EPLACEOne .............8oth............

REAR SPRING_REPLACEOne SideBoth Sides

REAR SPRING FRONT EYE BUSHINGS-REPLACEOne SideBoth Sides

REAR SPRI NG SHACKLE-R&R- | nstall bushinq and/orshack I e.

One SideBoth Sides

REAR SHOCK ABSORBER_REPLACEOne SideBoth Sides

Reolace Both Front Shock Absorbers ..............

MODEL YEAR AND TIN4E74 75 76

0.3 0.3

o.7 0.7

3.0 3.0

0.3 0.3

0.5 0.5

ntr ntr

0.3 0.3

0.50.5

0.91.4

1.0 1.0

0.6 0.6

o.4 0.40.6 0.6

o.4 0.4

o.71.2

0.71.2

0.9t.+

o.71.2

91 00

9120

91 30

9140

0.8 0.81.4 1.4

o.71.2



PROPELLER SHAFT_R&R .................

Spider Assembly- ReplaceFront...........Rear .............

Transmission Extension Housing Oil Seal-Replace ............

Propel ler Shaft- Replace ................

UNIVERSAL JOINT ANGLE INSPECTION

Correct Rear Universal Joint Angle

Correct Front Universal Joint Angle-lncludes adjustmentof shift linkage

9-3


0.3 0.3 0.3

0.4 0.40.3 0.3

0.3 0.3

o.2 0.2

0.3 0.3

GROUP 9OOO _ REAR AXLE _ PROPELLER SHAFT

OPERATIONNUMBE R

9152

A

B

c

9154

A

B

ENGINEAPPLICATION

ALL

0.30.3

o.4 o.4


GROUP lOOO _ FRONT SUSPENSION AND STEERING

ENGI N EAPPLICATION

10-1

MODEL YEAR AND TIME74

OPE RATIONNUM BE R

1 0000

10010

1 0020

1 0030

1 0040

1 0062

A

1 0070

A

B

10080

10090

1 0092


NOTE: Caster, camber and toe-in adjustments arenot included in operations except where noted.

CHECK CASTER, CAMBER AND TOE-IN

CHECK TOE.IN

ADJUST CASTER, CAMBER, AND TOE-IN- Includescheck alignment, tighten front suspension and controlarm bolts, nuts, and bushings, align steering wheel spoke,check wheel bearings and wheel run-out

ADJUST TOE-lN ONLY-lncludes check toe-in andsteering wheel spoke alignment

STEERING KNUCKLE SPIN DLE-REPLACERequires Operation 10010 or 10020.

STEERING KNUCKLE PIN_ONE_REPLACERequires Operation 10000 or 10020.

Steering Arm-Replace ..................

LOWER CONTROL ARM_ONE SIDE_REPLACE_.........Requires Operation 10000 or 10020.

Steeri ng Arm- Replace- Requ i res Operation 1 0030

Steering Knuckle Spindle-Rep1ace ..............

STRUT ROD-REPLACE-Requires Operation 10000 or1 0020.

Left SideRinh+ Qido

Both Sides

STRUT ROD BRACKET ASSEMBLY_REPLACERequires Operation 10000 or 10020.

Left sideR ight SideBoth Sides

STRUT ROD BRACKET BUSHING_REPLACERequires Operation 10000 or 10020.

Left SideR ight SideBoth Sides

ALL n6

o.4

u.5

0.4

0.5 0.5

0.9 0.9

0.1

1.0

0.1

0.1

1.21.2

1.2 1.2

0.1

1.0

0.1

0.1

0.60.50.9

0.80.7t.J

u.o0.5nq

0.8o.71.2

0.8o.71.2

0.8o.lt.J


10-2

OPERATIONNUM BE R

10100

101 10

10120

A

10141

10142

10144

10146

10148

10150

10160

10170

A

B

10180

10190

1 0191

GROUP lOOOO _ FRONT SUSPENSION


STEERING ARM-REPLACE-l ncludes adjust toe-inOne SideBoth Sides

COIL SPRING_REPLACE_One Side

SHOCK ABSORBER-F RONT- REPLACEOne SideBoth Sides

Replace Both Rear Shock Absorbers ..............

LOWER CONTROL ARM_REPLACE ............

UPPER CONTROL ARM_REPLACE ............Requires Operation 10000 or 10020.

UPPER CONTROL ARM PIVOT BUSHINGS_REPLACE

UPPER CONTROL ARM BALL JOINT CLEARANCE_INSPECT

UPPER CONTROL ARM BALL JOINT_REPLACERequires Operation 10000 or 10020-lncludes crearancei nsoection

One SideBoth Sides

STEERING LI NKAGE_COMPLETE_REPLACEIncludes adjust toe-in

PITMAN ARM_REP1ACE ............Requires Operation 'l 0010 or 10030

I DLE R ARM-R EPLACE- | ncludes ad iust toe-ir. ..............

ldler Arm Bracket-Replace ..............

ldler Arm Bushing-Replace ..............

TIE ROD, TIE ROD END, ANDiOR ADJUSTING TUBE_R EPLACE-lncludes adiust toe-in.

One SideBoth Sides

SWAY STABI LIZER BAR-REPLACE ...............

SWAY STABLIZER BAR CUSHION_REPLACE

AND STEERING

ENG I NEAPPLICATION

ALL

I\4ODEL YEAR AND TIME74' 75 76

t.J2.1

0.8

1.32.1

0.8

o.4 0.4n6 ntr

0.5 0.5

0.8 0.8

0.9

1.'l

0.9

1.1

0.30.3

0.9 0.91.4 1.4

1.2 1.2

u.o u.o

0.8 0.8

0.1 0.1

0.1 0.1

0.91.4

0.8

0.3

0.91.4

0.8


0.3

GROUP lOOOO _ FRONT SUSPENSION AND STEERING

ENGI N EAPPLICATION

ALL

10-3


1.0 1.0

o.2 0.2

0.7 0.7

o.4 0.4

0.6 0.6

1.3 't.3

OPERATIONNUM BE R

10210

A

B

10220

10222

10230


STEERING GEAR-R&RIncludes steering column alignment

Steering Gear Assembly- Replace

Steering Gear Assembly-Overhaul

ADJUST STEERING GEAR ONLY-Assembly in Car.......

CENTER STEERING SHAFT AND/OR FLEXIBLECOUPLI NG_REPLACE

STEERING COLUMN ASSEMBLY_R&RI ncludes Linkage Adjustment

Replace- | ncludes painting

Overhaul-lncludes C, D, E, F, G, H, J, "Tilt" Column

NOTE: Any combinations of the following are not toexceed the overhaul time allowance.

Steering Shaft-Rep1ace ...,..............

Shift Tube-Rep1ace ..........

Directional Signal Housing or Cover-Replace-lncludespa i nti ng

Shift Bowl or Housing- Replace- I ncludes Paintin9............

Steering Jacket Tube-Replace-lncludes painting

Lower Steering Shaft Beari ng- Replace ..............

Actuator-Steering Wheel-Replace-lncludes painting ......

STEERING LINKAGE CENTER CROSS LINK_REPLACE-l ncludes adiust toe-in

A

B

0.6

0.6

0.6 0.6

1.4 1.4

0.8 0.8

1.1 1.1

c

D

E

F

G

10240

o.2

1.0

H

J

1.1

o.2

1.0

1.1

1.01.0


10-4

OPERATIONNUMBE R

1 0250

c

D

E

*

1 0290

1 0300

10310

c

D

10320

A

B

c


A

B


STEERING WHEEL_R&R_With Center Horn Button

Replace

Directional Signal Housing or Cover-Replace-lncludes^^;-+i-^Pdilrtilrq

Steering Shaft Lock Plate- Replace ..................

Steering Lock Bolt-Replace ..........

Steering Lock Gate- Replace ..........

DI R ECTI ONAL SIGNAL SWITCH_ASSEMBLY_REPLACE- *(Operation No. 3430)

POWER STEERING

POWE R STEERI NG GEAR_ADJUSTIncludes R&R pitman arm and perform pitman shaft

over-center adjustment. -(Gear on car)

PITMAN SHAFT SEALS-REPLACE-Gear on car ...........

POWER STEERING GEAR_R&RI ncludes steering column alignment

Power Steering Gear Assembly-Replace

Power Steering Gear-Overhaul-lncludes complete unitdisassembly, assembly and perform all adjustments .........

NOTE: Overhaul Power Steering Gear lndividual Unitslisted as operations, C and D-lncludes adjustments (Donot combine with operation B. Use only as spearateoperailonl.

Adjuster Plug -Rep|ace,..................

Valve Body Assembly -Replace

POWER STEERING PUMP_R&R

Pump Assembly-Replace

Pump Assembly-Overhaul

Pump Bracket-Replace

ENGINEAPPLICATION

ALL


0.3

nt

u.o

n.)

0.6

o.7

i.1

0.2

t.J

AA

u./

ia

0.3

0.5

t.J

0.3

0.5

o.2

0.3

o.2

o.4

o.7

u.o

o.2

0.6

0.7

A

B1.3

U.J

0.5

11

0.3

0.5

u.z


Continued


ENG I NEAPPLICATION

10_5


U.J U.J

o.2 0.2

o.2 0.2

o.4 0.4

o.4 0.40.6 0.6

0.5 0.5

0.3 0.3

0.5 0.5

OPE RATIONNUMBE R

10320Continued

D

E

F

10322

10323

1 0330

1 0350

1 0360

1 0370

10371


Pump Drive Shaft OilSeal-Replace ALL

Oil Reservoir to Pump "O" Rings-Replace ..........

Pump Control Valve Retaining Plug Seal-Replace .............

POWER STEERING PUMP PU LLEY_REPLACE

POWER STEERING PUMP BRACKET-REPLACE ..........

FLOW CONTROL AND RELIEF VALVE ASSEMBLYAND/OR PLUG SEAL_REPLACE

POWER STEERING HOSE_REPLACEOne .............8oth............

POWER STEERING PUMP DRIVE BELT_REPLACE .....

POWER STEERING OIL PRESSURE CHECK

POWER STEERING CHECK VALVE KIT_INSTALL ......

o.4

0.9

0.4

0.9


OPERATIONNUMBE R

1 2000

A

12001

12002

12020

1 2030

12040

12048

1 2050

12051

12070

1 2090

12160

12237

A

12162

12238

12240

12250

GROUP 12OOO _ HOOD _ FENDERS _ BUMPERS

ENGINEOPERATION DESCR IPTION APPLICATION

HOOD_R&R ALL

Hood-Replace ..................Includes transfer of individual components and adjust-ment.

APPLY ADHESIVE TO HOOD INNER PANEL

HOOD I NSU LATION_REPLACE

HOOD BRACE_REPLACE ..........

BRICKLIN MEDALLION REAR_REPLACE ...................

HOOD HINGE_REPLACEOne .............Both ............

HOOD LOCK RELEASE CABLE_REPLACE

HOOD LOCK-REPLACE ............One or Both-lncludes adiustment

ADJUST HOOD LOCK AND RUBBER BUMPERS

FRONT FENDER_REPLACERi9ht...........Left . . . . .. ...... .

FRONT FENDER SIDE MOULDINGS_REPLACEOne .............

BRICKLIN NAME PLATE FRONT_REPLACE................

EN ERGY ABSORBE R ASSEMBLY_REPLACEIncludes bumper R&R.

FrontOne .............Both............

RearOne .............Both ............

FENDER REFLECTOR OR WINK LIGHTS_REPLACEASSEMBLY OR COMPON ENT(S)

ENERGY ABSORBING BUMPER OPERATION_Check-on-car

FRONT BUMPER ASSEMBLY_COMPLETE- REPLACE.Includes R&R parking lamp assemblies.

REAR BUMPER ASSEMBLY_COMPLETE_R&R

12-1


0.5 0.5

0.3 0.3

0.30.3

0.3 0.3

0.3 0.3

0.3 0.4

o.li0.6

0.3

U.J0.4

0.3

t.J1.0

0.40.6

0.3

0.3o.4

0.3

t.J1.0

0.3 0.3

0.3 0.3

1.41.7

no1.4

0.3

'1.0

0.3 0.3

1.41.7

0.91.4

0.3

1.0

1.0 1.0


GROUP 13OOO _ AIR CONDITIONING 13-1


OPERATIONNUMBER

13002

1 3004

13006

13010

130',12

1 3020

1 3030

13040

A

B

13042

1 3080

13082

1 3084

13086

13088

1 3090


NOTE: Air Conditioning Operations-Time allowancefor discharge, evacuate, leak test and charge system ts

not included in the individual operations. As applicableuse only one of the following operations-13086 or 13088.

CONTROL ASSEMBLY_R EPLACE

CONTROL CABLE-REPLACE- | ncludes adjustEach additional control cable-Add

CONTROL CABLE(S)-ADJUST-One or all ....................

BLOWER SWITCH_REPLACE

BLOWER MOTOR RESISTOR_ REPLACE

HEATER CONTROL VALVE_R EPLACE

HEATER HOSE-REPLACE-OneAil ...............

HEATER CORE AND BLOWER HOUSING ASSEMBLY_R&R-lncludes drain coolant, disconnect and connectcontrols, and adjust

Housing- Replace ..............

Heater Core-Replace

BLOWER MOTOR AND/OR BLOWER WHEEL_REPLACE

DE FROSTER DUCT_REPLACERight or Left .............

DEFROSTER BEZEL_REPLACE ........,.

ADD PARTIAL CHARGE-lncludes leak test-To be usedonly when system is low on ref rigerant with no evidenceof further leakage. Systems equipped with sight glass......

EVACUATE. LEAK TEST AND CHARGE SYSTEM .......To be used only once in conjunction with the R&R orreplacing of ref rigerant charge components

DISCHARGE, EVACUATE. LEAK TEST, CHARGE ANDTEST FOR PROPER OPERATION

AIR CONDITIONING DISCHARGE DUCT_REPLACE ...

ENGINEAPPLICATION

ALL t.c

0.80.5

0.5

0.8

0.3

0.5

0.50.8

1.5

0.80.5

0.5

0.8

0.3

ntr

0.50.8

0.4o.4

t.J t.J

o.2 0.2

o.2 0.2

0.9 0.9

o.4 0.4

0.5

0.9

|.5 r.c

0.6 0.6

0.5

no


13-2

OPERATIONNUMBE R

13100

A

B

131 10

13112

13116

13120

A

13130

A

B

c

13140

A

B

13150

A

B

13160

GROUP 13OOO _ AIR CONDITIONING

ENGINEOPERATION DESCRIPTION APPLICATION

EVAPORATOR AND HOUSING ASSEMBLY_R&R ....... ALL

Evaporator Housing-Replace ..............

Evaporator-Replace-Does not include charge system-Use Operation 13086

TEMPERATURE CONTROL THERMOSTAT_REPLACE

TEMPERATURE CONTROL TH ERMOSTAT CAP.ILLARY TUBE_INSPECT FOR CORRECT IN.STALLATION, RE-POSITION IF NECESSARYAND MAKE CONFIRMING ROAD TEST UPONwoRK coMPLETION. ................

AI R CONDITIONING TEMPERATURE OVERRI DESWITCH_REPLACE

EXPANSION VALVE_R&R_Does not include charge system-Use Operation 13088..

Replace

AIR CONDITIONING DRIVE BELT_ADJUST ........,.......

Crankshaft to ldler or Power Steering Pump Belt-Replace

ldler or Power Steering Pump to Crankshaft Belt- Replace

-lncludes A .................

Crankshaft to Compressor Belt- Replace ................

AIR CONDITIONING IDLER PULLEY_R&R .................

Air Conditioning ldler Pulley Bearing-Replace

Air Conditioning ldler Pulley-Rep1ace ................

COMPRESSOR AND CLUTCH ASSEMBLY-R&R_System not discharged. Includes Mounting Bracket R&R ........

Compressor-Replace-Does not include charge system-Use Operation 13086

Compressor Mounting Bracket-R&R or Replace

COMPRESSOR FRONT BEARING AND SEAL PLATEAND SEAL RING_REPLACE_Does not include charge system-Use Operation 13086...

Shaft Seal- Reolace ..........


3.8 3.8

o.2 0.2

0.6 0.6

0.8

0.3

0.9

o.2

o.2

0.1

0.4

0.1

0.6

o.2

0.1

0.5

0.3

0.9

o.2

0.2

0.1

0.4

0.1

0.6

o.2

0.1

0.5

0.6 0.6

0.1 0.1

2.4 2.4

U.J U.5A


GROUP 13OOO _ AIR CONDITIONING 13.3

OPERATION ENGINE MODEL YEAR AND TIMENUMBER OPERATION DESCRIPTION APPLICATION 74 75 76

- 13170 COMPRESSOR BOTTOM PLATE GASKET_REPLACE- Does not include charging system-UseOperation 13086 .......... ALL 2.5 2.5

13180 COMPRESSOR REAR BEARING PLATE GASKET_REPLACE- Does not include charging system-UseOperation 13086 ......... 2.4 2.4

13190 COMPRESSOB VALVE PLATE_REPLACE_(On the car)-Does not include charging system-UseOperation 13086 .......... 1.2 1.2

132OO COMPRESSOR CLUTCH PULLEY_R&R OR REPLACE.. 0.3 0.3

A Coil- RePlace o.2 o'2

13210 AIR CONDITIONING HOSE_HIGH PRESSURE ORSUCTION-REPLACE-Does not include charging system-Use Operation 13086 0.9 0.9

A Each Additional Hose o'2 o'2

13216 COMPRESSOR SERVICE VALVE_SUCTION ORDISCHARGE-REPLACE-l ncludes discharge, evacuate,leak test and charge system

one or 8oth............ 1.2 1.2

13220 CONDENSER-R&R-System not discharged-lncludesradiator R&R ............ 1.0 1.0

A Condenser and/or Receiver Replace-Does not includecharging system-Use Operation 13086 .......... 0.2 0.2

B Check Valve Overhaul- Does not include charging system-Use Operation 13086 O.2 O.2

C Receiver Pressure Relief Valve-Replace O.2 0.2

13300 ROAD TEST TO VERIFY OPERATION AND COOLINGEFFTCTENCY 0.3 0.3


OPERATIONNUM BE R

1 6200

A

B

c

D

E

F

G

H

J

K

M

N

P

o

R

S

T

U

W

X

Y

GROUP 1600 - AUTOMATIC TRANSI\4ISSION


AUTOMATIC TRANSMISSION

,,TORQUE COMMAND" TRANSMISSION_R&R_Includes adjust throttle valve linkage

Converter drive plate-Rep1ace ..........

Converter- Replace ..........

Transmission- Replace

Front pump seal- Replace

Transmission-Disassemble, clean, inspect and assemble ....

Front pump-Overhaul or Replace

Front clutch-Overhaul

Rear clutch-Overhaul

Planetary gear assembly-Overhaul

Overrunning clutch-Overhau1 ...............

Overrunning clutch cam-Replace (lncludes U if necessary)

Extension housing-Overhaul ............

Valve body-Overhaul-lncludes throttle and regulatorpressure adjustment

Valve body-Replace-lncludes throttle and regulatorpressure adjustment

Front servo-Overhaul

Rear servo-Overhaul

Case-Replace-lncludes front and rear servo-Overhaul ....

Output Shaft Support- Replace

Governor-Overhaul ..........

Converter-Clean ..............

Air Pressure Test .............

NOTE: F. G, H, J, K, M, N, P, O, R, S. T, U, W, X, andY can only be used with E which includes maximum partsand special tool supplemental times.

ENGI NEAPPLICATION

360

360

360

360

JOU

360

360

360

360

360

JOU

JOU

360

360

JOU

360

360

JbU

JOU

360

360

360

16-1

MODEL YEAR AND TIME74. 75 76

2.3

0.2

o.2

0.2

0.3

1.7

0.4

0.5

0.2

0.4

0.3

1.0

0.1

0.3

n?

o.4

0.1

o.2

0.3

o.2

n6

0.1


16-2

OPERATIONNUMBE R

16200 A

A1

A2

A3

A4

A5

A6

A7

A8

A9

16220

A

B

c

D

E

H

J

K

M

GROUP 16000 _ AUTOI\4ATIC TRANSMISSION


,,FMX'' AUTOMATIC TRANSMISSION_R&R

Front or Rear Bands-Replace ..........

Transmission Assembly-Overhaul

Converter Assembly-Clean and check ...........

Front Pump-Overhaul.or clean (lncluded in 42) ..............

Front Oil Seal-Front Pump-Rep1ace ................

Parking Paw-Replace

Flywheel and Ring Gear Assembly-Replace

Transmission Case-Rep1ace ..................

Transmission Oil Cooler and Cooler Lines-Flush

orL PAN-R&R OR REPLACE ...............

Oil Filter-Replace ............

Low and Reverse Band-Adjust

Valve Body-R&R,...........

Valve Body-Replace (lncludes A and K)

Valve Body-Overhaul (lncludes disassemble, clean, inspect,f ree all valves and combinations A and K)

Throttle Valve Lever Shaft Seal-Replace ..........

Kick-Down Servo-Overhaul or Replace-lncludes adjust-ment ............

Accumulator Piston-Overhaul or Replace .........................

Low and Reverse Servo-Overhaul or Replace-lncludes B .

Adiust Throttle Valve and Regulator Valve ..'........

Adlust Throttle Valve Linkage ..................

NOTE: D, E, F, G, H, J, K to be used with C whichincludes adjust throttle valve linkage.

360

Jr)U

360

360

360

ENGINEAPPLICATION

JCI

J5 l

351

J3 I

351

J5 l

351

351

J3 l

360

360

360

360

360


2.5

t-o

5.7

1a

0.3

u. l

1.6

0.3

3.0

o.2

0.6

u-l

u. I

0.3

0.3

o.4

0.1

0.3

o.2

0.1

360

360

1.0

0.1


OPERATIONNUIVIBE R

16220 A

A3

A4

A5

o.7

0.5

LJJ5 l

A1

A2

GROUP 16000 _ AUTOMATIC TRANSMISSION


OIL PAN OR GASKET-REMOVE AND INSTALLoR REPLACE ..................

Main Control Valve Body-Replace

ENGI N EAPPLICATION

?61

351

16_3


Maln Control Valve Bodv-CleanIncludes road test. Not to be used with A1 .

Oil Pressure Regulator-Replace ..........

Oil Pressure Regulator-Clean .............

Seals and/or Levers-Throttle and Manual-Replace-Doesnot include road test. Includes main control valve removaland installation ................-.

Parking Pawl-Replace ..................

Front Servo-Overhaul

Rear Servo-Overhaul

EXTENSTON HOUSTNG-R&R ..............

Extension Housing-Replace ..............

Rear Oil Seal-Replace

Extension Housing Bushing-Replace(lncludes B) ........,...

Output Shaft Bearing-R&R or Replace

Governor Assembly-Overhau | ( | ncludes D). .............

Parking Brake Sprag- Replace

Parking Gear/Governor Support-Replace (lncludes D) .....

EXTENSION HOUSING OR GASKET_REPLACE ..........

Oi I Seal or Bushing-Transmission- Rear-Replace .............

EXTENSION HOUSING OI L SEAL_REPLACE

SPEEDOMETER DR IVE GEAR_REPLACE ....................

OIL FILLER TUBE AND/OR SEAL RING_REPLACE ....

351

351

o.2

AA

0.'r

o.2

0.1

o.4

0.1

0.5

0.2o.2

o.4

A6

A7

A8

16230

A

B

c

D

E

F

G

16230 A

A1

16240

16245

1 6250

0.6

'1.1

0.6

0.5

0.9

n?

JCI

J5 l

J5 l

360

360

360

.iou

360

JOU

360

360

351

J5 l

JOU

i.6

0.5

0.5

360

360

EFFECTIVE FEBRUARY 1C, 19]5

16-4

OPERATIONNUMBER

16251

16252

16253

16253 A

16260

GROUP 16000 _ AUTOMATIC TRANSMISSION


FRONT SE RVO-OVERHAU L-l ncludes adjustband............

REAR SERVO-OVERHAUL-l ncludes adiust bano .........

VACUUM DIAPHRAGM UN IT_REPLACE,...,.........,......

VACUUM DIAPHRAGM UNIT_ADJUST ....,..............,....

OIL COOLER TUBES_REPLACE

Both

AUTOMATIC TRANSMISSION MANUAL LINKAGE_ADJUST

THROTTLE VALVE LINKAGE BELLCRANK_REPLACEIncludes adjust throttle valve linkage

Throttle Valve Linkage Rod-Replace-At carburetor ........

Throttle Valve Linkage Rod-Replace-At transmission .....

THROTTLE VALVE LINKAGE ROD_REPLACE_ATTRANSMISSION-lncludes adjust throttle valve linkage

Throttle Valve Linkage Rod-Replace-At carburetor ........

THROTTLE VALVE LINKAGE ROD_REPLACE_ATCARBURETOR-lncludes adjust throttle valve linkage ..

FRONT BAND-ADJUST ...............

REAR BAND_ADJUST

KI CK-DOWN BAND_ADJUST ...............

TH ROTTLE VALVE LI N KAGE_ADJUSTIncludes check linkage for bind.

Shift Linkage-Adjust

Kick-Down Band-Adjust

Li n kage PirTots- D isassemble a nd c1ean ............

Adiust ldle Speed

ENGIN EAPPLICATION

JOU

360

360

360

351

360

360

360

360

360

360


0.40.5

n?o.2

u.o

0.5

0.3

0.5

351

351

351

JOU360

16265

16270

A

B

16280

A

16290

16295

16299

1 6300

16310

A

B

c

D

360

360

JbU

0.4

0.1

0.5

0.1

0.1

o.4

o.7

0.3

0.1

0.3

0.2

0.1

0.4

n?


OPERATIONNUMBER OPERATION DESCRIPTION

16320 TRANSMISSION PRESSURE TEST

GROUP 16000 _ AUTOMATIC TRANSMISSION 16-5

ENGINE MODEL YEAR AND TIMEAPPLICATION 74, 75 76

360 0.7351 0.7

16325 AUTOMATIC TRANSMISSION DIAGNOSIS COMBINA-TION-lncludes pressure test, stall and road test, adjustidle speed, dashpot, vacuum diaphragm, manual andthrottle linkage. To be used in combination with over-haul, valve body replacement or governor repairoperation on|y............. 360 0.9

351 0.9


GROUP 22OOO _ WINDSHIELD WIPER _ INSTRUMENT PANEL

ENGINE MODELAPPLICATION 74

ALL 1.0

0.3

0.7

22-1

YEAR AND TIIVIE75 76

1.0

u./

OPERATIONNUMBE R

22000

A

22Q10

22013

22015

22020

22022

22024

22034

22078

22084

22102


WINDSHI ELD WIPER LINKAGE ASSEMBLY_REPLACE

Motor-Replace ................

wt NDSHtELD WrPER MOTOR-R&R .................

ELECTRIC WINDSHIELD WIPER MOTOR DRIVENGEAR, PARK PLATE, THRUST WASHER_REPLACE-One or all ................

ELECTRIC WINDSHIELD WIPER MOTOR CONTACTPLATE AND SWITCH_REPLACE

WINDSHIELD WIPER ARM AND/OR BLADE_REPLACE

WINDSHI ELD WASHER HOSE_REPLACE .....................

WINDSHIELD WASHER MOTOR AND/OR RESERVOIR-REPLACE

WINDSHIELD WIPER CONTROL SWITCH_REPLACE ..

I NSTRUMENT PAN EL_R EPLACE_lncludes R&R all instruments and controls

TNSTRUMENT PANEL OVERLAY PAD_R&R

INSTRUMENT CLUSTER BEZEL_REPLACE_Includes cluster R&R where necessarv

0.5

0.5

0.3

0.3

0.6

0.5

'1 tr

1.0

NE

0.5

0.3

0.3

0.6

0.5

1.5

1.0

0.7o.1


GROUP 23OOO _ DOORS _ INTERIOR TRIM & PANELS _ SEATS _ BODY PANELS 23.1

OPERATIONNUM BE R

23000

A

23020

23030

23036

23080

A

23100

23110

23120

23180

23215

23220

23225

23230

23240

A

B


DOOR_R&R

Door-Replace-lncludes transfer of individual components

DOOR OUTER PANEL_REPLACE ..........

DOOR HINGE-REPLACE-lncludes adjust door.Ono

Qa+h

ADJUST FRONT DOOR HINGE ON DOORAny one hinge ...........Each additional-Add

DOOR LOCK STRI KER_REPLACEIncludes adjustment

DOOR SEAL_RUBBER-REPLACE_EACH DOORInner ............Outer ...........Rnth

DOOR KEY LOCK-REPLACE

File New Cylinder to Existing Key and Assemble

DOOR INTERIOR REMOTE CONTROL HANDLE-REPLACE

WINDOW REGULATOR HANDLE_REPLACE

WI NDOW R EGU LATOR_REPLACE

DOOR LATCH_REPLACE ..........

HATCH ASSEMBLY_REPLACE

REAR HATCH ADJUSTMENT AT HINGES AND LOCKSTRIKER

HATCH SPRING_REPLACE

REAR HATCH LATCH_REPLACE

HATCH KEY LOCK_R&R ...........

Key Lock Cylinder-Replace ............

File New Cylinder to Existing Key ..............

ENGINE MODEL YEAR AND TIMEAPPLICATION ]4 75 76

ALL 0.6 0.6

2.O 2.O

2.O 2.O

1.0 1.01.5 1.5

0.3 0.30.3 0.30.5 0.5

0.6 0.6

0.3 0.3

0.6 0.6

0.3 0.3

0.6 0.6

0.3 0.3

0.5 0.5

0.5 0.5

0.3 0.3

0.3 0.3

0.3 0.3

0.2 0.2

0.5 0.5o.4 0.4

23040

23050

0.4o.4

o.2o.2


23-2

OPE RATI ONNUM BE R

23262

23270

23275

23276

23277

23278

23275

23280

23281

23282

23283

23284

GROUP 23OOO _ DOORS - INTERIOR TRIM & PANELS _ SEATS - BODY PANELS


REAR HATCH HINGE ASSEMBLY_REPLACE

HATCH LATCH STRIKER_REPLACE

ROOF PANEL_REPLACE

HOOD EXTENSION _REPLACE

VALANCE ASSEMBLY _R EPLACE

SPOI LER _REPLACE

OUARTER PANEL_(OUTER) -REPLACE ..................,..

HATCH SEALER RUBBER_REPLACE

OUARTER PANEL_(REAR LOWER) -REPLACE...........

LOWER BACK PANEL_REPLACE

ROCKER PANEL_REPLACE ..........

DOOR LOWER TRIM PANEL _REPLACERisht...........Left .. . . ... ..... .

Both ............

OUARTER TRIM LOWER FRONT PANEL_REPLACERight...........Left .. . .. . . . .. . . .

OUARTER TRIM PANEL _REPLACE

REAR END TRIM PANEL_REPLACE

ARM REST. PARKING BRAKE COVER ASSEMBLY_REPLACE

SHIFT BEZEL_REPLACEAutomatic"4-Speed"

CARPET ASSEMBLY, REAR FLOOR_REPLACE ..........

CARPET. FRONT FACE REAR FLOOR_REPLACE ......

CARPET, UNDE RSEAT_REPLACE


ALL 1.1 1.1

0.3 0.3

3.8 3.8

|.z l.z

0.6 0.6

0.3 0.3

2.6 2.6

o.7 0.7

0.3 0.3

2.9 2.9

o.4 0.4

0.3 0.30.3 0.3

U.J U.J0.3 0.30.5 0.5

23285

23286

23287

23288

23289

23290

23291

23292

0.5 0.50.5 0.5

0.3 0.3

o.4o.4

0.4 0.40.3

1.5 1.5

0.5 0.5

1.0 1.0

EFFECTIVE FEBRUARY 10, 19/5

GROUP 23OOO _ DOORS _ INTERIOR TRIM &


CARPET, FRONT FLOOR_REPLACERiqht........... ALLLeft .............Both ............

REAR HATCH_R&R

Hatch-Replace-lncludes transfer of individual components

SEAT ASSEMBLY-COMPLETE_REPLACE ....................

SEAT ADJUSTER TRACK ASSEMBLY_REPLACERight...........Left .............Both ............

,,A'' PILLER TRIM PANEL_REPLACERi9ht..........Left .............Both ............

SUN VISOR ASSEMBLY_REPLACERight ...........Left .............Both ............

PANEL, SILL PLATE (SCUFF PLATE)_REPLACERi9ht...........Left ... . ... . .. .. .

Both ............

COWL INTERIOR TRIM PANEL_REPLACERi9ht...........Left ... ..... .... .

Both ............

HEADLINER, ROOF_REPLACE ....,.....

HEADLINER, DOOR UPPER_REPLACE ..........

PAD ASSEMBLY, INSTRUMENT PANEL CRASH-REPLACE

BEZEL, A/C AND HEATER_REPLACE

SEAT BE LT ASSEMBLY-REPLACE

PANELS _ SEATS _ BODY PANELS 23-3


OPERATIONNUMBE R

23293

23310

A

23312

23313

23314

23315

23316

23317

23318

23319

23320

23321

23322

0.4 0.40.4 0.40.6 0.6

0.6 0.6

1.0 '1.0

0.3 0.2

0.3 0.30.3 0.30.5 0.5

0.3 0.30.3 0.30.5 0.5

0.30.30.5

0.30.3ntr

0.30.30.5

0.4

0.3

o.4

n?

0.5

0.30.30.5

0.4

0.3

0.30.30.5

0.30.30.5

o.4

n?

0.5


OPERATIONNUMBER

- 25000

25052

25100

25102

25120

25122

25400

25410

25415

25420

25425

25430

25435

25440

GROUP 25OOO - GLASS _ CHANNELS _ SEALS

ENG IN EOPERATION DESCRIPTION APPLICATION

DOOR GLASS_REPLACE...,...... ALL

DOOR GLASS WEATHER STRIP-REPLACE-lnner-lncludes trim panel R&R ............

REAR OUARTER SIDE WINDOW GLASS. RUBBERCHANNEL. OR REVEAL MOULDING_REPLACE ......

RESEAL REAR OUARTER SIDE WINDOW

REAR WINDOW HATCH GLASS_REPLACEIncludes sealing

GR lD REPAI R-Rear Window Defogger System..............

WATER TEST(Can be used only once for each problem) ......................

WINDSHIELD_REPLACEI ncludes seals.

SEAL, REAR HATCH-REPLACE ..........

SEAL ASSEMBLY-HOOD_REAR_R EPLACE

SEAL. WIPER MOTOR MOUNTING PLATE_REPLACE

SEAL. WHEEL HOUSE_REPLACE

SEAL, BATTERY COMPARTMENT ACCESS DOOR_REPLACE

SEAL. TOOL COMPARTMENT ACCESS DOOR_REPLACE

25-'l

MODEL YEAR AND TIME14 75

0.7 0.7

o.7

0.8

o.4

0.7

0.8

o.4

1.2

o.4

1.2

o.4

0.80.8

ntr nE

0.8 0.8

0.3 0.3

0.3 0.3

0.3 0.3

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Original Labor Time Manual - Bricklin Parts of Virginia

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Transcript of Original Labor Time Manual - Bricklin Parts of Virginia