Starting System Test

Starting System Test

Ignition Switch
Starting Safety Switch
Remote Starter Switch
Solenoid
Voltmeter
Battery

Charging System

Charging System

Battery
Ammeter
Ignition Switch
Voltage Regulator
Alternator

Steering and Suspension System Service

Problem

Hard steering.

Cause

Power steering inoperative. Low or uneven tire pressure. Friction in steering gear. Friction in steering linkage. Friction in ball joints. Excessive positive caster. Body or frame bent or misaligned.

Solution

Inflate tire pressure to correct pressure. Lubricate, adjust or repair steering gear. Lubricate, adjust or repair steering linkage. Lubricate or repair ball joints. Align wheels. Straighten, replace or adjust body or frame bent.

Problem

Excessive play in steering.

Cause

Looseness in steering gear. Looseness in steering linkage. Worn ball joints or steering knuckle parts. Loose wheel bearing.

Solution

Adjust or replace worn parts in steering gear. Adjust or replace steering linkage. Replace ball joints or steering knuckle parts. Adjust wheel bearing.

Problem

Wander drift from one side to other side.

Cause

Mismatched tires or uneven pressure. Linkage binding. Steering gear binding. Excessive toe out. Looseness in linkage. Looseness in steering gear. Looseness in ball joints. Loose leaf spring. Unequal load in vehicle. Stabilizer bar ineffective.

Solution

Correct the mismatch tires or uneven pressure. Adjust, lubricate or replace linkage binding. Adjust, lubricate or replace worn parts in steering gear binding. Align wheels. Adjust or replace in linkage. Adjust or replace worn parts in steering gear. Replace ball joints. Tighten the leaf spring. Adjust load in vehicle. Tighten or replace stabilizer bar.

Problem

Steering pulls to one side.

Cause

Uneven tire pressure. Uneven caster or camber. Tight wheel bearing. Uneven springs such as sagging, broken, loose attachment. Uneven tortion bar adjustment. Brakes dragging.

Solution

Inflate to correct pressure. Align wheels. Adjust or replace wheel bearing. Tighten or replace defective parts on springs. Adjust tortion bar. Adjust or repair brakes.

Rear Wheel Drive Line System Service

Problem

Leak at front slip yoke, an occasional drop of lubricant leaking from splined yoke is normal.

Cause

Rough outside surface on spline yoke. Defective transmission rear oil seal.

Solution

Replace seal if cut by burrs on yoke. Minor burrs can be smoothed by careful use of crocus cloth or honing with a fine stone. Replace yoke if outside surface is very rough or badly burred. Replace rear transmission oil seal. Bring transmission oil up to proper level after correction.

Problem

Knock in drive line, clucking noise when car is operated under floating condition at 10 mph or 16 kph  in high gear or neutral.

Cause

Worn or damaged universal joints. Slide gear hub counter bore in differential worn oversize.

Solution

Replace universal joints. Replace differential case or  side gears as required.

Problem

Ping, snap or click in drive line. Usually occurs on initial load application after transmission has been put in gear either forward or reverse.

Cause

Loose bushing bolts in upper or lower control arm. Loose companion flange.

Solution

Tighten bolts to specified torque. Remove companion flange, turn 180  degrees from its original position lubricate splines and reinstall. Tighten pinion nut to specified torque.

Problem

Roughness at low speed light load at 15 to 35 mph or 24 to 56 kph.

Cause

U bolt clamp nuts excessively tight.

Solution

Check and tighten to specified torque. If torque was excessive or if brinelled pattern on trunnions. Replace U joints.

Problem

Scraping noise.

Cause

Oil slinger, companion flange or end yoke rubbing on rear axle carrier.

Solution

Straighten or replace oil slinger, companion flange or end yoke rubbing on rear axle carrier to remove interference.

Manual Transmission System Service

Problem

Hard shifting into gear. 

Cause

Shift shaft or interlock binding. Clutch cable not adjusted properly. Bent or worn shift fork. Worn shift shaft. Gear or synchronizer sleeve tight on shaft or splines. Worn synchronizer rings or spring.s. Worn or stripped external teeth on gear. Input shaft or pilot bearing binding. Low lubricant level. Improper lubricant used.

Solution

Free shaft or interlock binding. Check adjust or replace clutch cable not adjusted properly. Replace shift fork. Replace shift shaft. Replace worn parts. Replace gear. Replace pilot bearing or input shaft. Fill to proper lubricant level. Drain and refill with specified lubricant.

Problem

Transmission sticks in gear.

Cause

Shift shaft or interlock binding. Shift detent sticking. Clutch not engaging. Synchronizer binding. Low lubricant level.

Solution

Free shaft and interlock binding. Free shift. Repair clutch cable. Replace synchronizer. Fill to proper lubricant level.

Problem

Transmission jumps out of gear.

Cause

Weak detent spring. Worn input or output shaft bearing. Worn pilot bearing. Excessive shaft or gear end play. Worn synchronizer. sleeve. Loose or broken input shaft retainer. Loose transmission or clutch housing. Misaligned transmission.

Solution

Replace detent spring. Replace input or output shaft bearing. Replace pilot bearing. Replace worn thrust washer. Replace synchronizer and gear. Replace input shaft retainer. Tighten attaching bolts. Check transmission alignment.

Problem

Gear clash when shifting.

Cause

Worn synchronizer. Clutch dragging. Pilot bearing or input shaft binding. High engine idle speed. Low lubricant level or improper lubricant.

Solution

Replace synchronizer. Repair clutch. Replace bearing or shaft. Adjust engine speed. Fill with correct lubricant to proper level.

Problem

Transmission noisy in neutral.

Cause

Worn pilot shaft bearing. Broken or worn gear.

Solution

Replace pilot shaft bearing. Replace gear.

Clutch System Service

Problem

Clutch slips while engaged.

Cause

Incorrect clutch linkage adjustment. Broken or weak pressure spring. Binding in clutch linkage. Broken engine mount. Worn friction disc facing. Grease or oil on disc facing. Incorrectly adjusted release levers. Wrapped friction disc.

Solution

Adjust clutch linkage adjustment. Replace pressure plate assembly. Free, adjust and lubricate clutch linkage. Replace engine mount. Replace disc facing. Adjust release levers. Wraped friction disc.

Problem

Clutch chatters or grabs while engaging.

Cause

Binding in clutch linkage. Broken engine mount. Oil or grease on disc facing or glazed or loose facing. Binding on friction disc hub on clutch shaft. Broken disc facing, springs or pressure plate. Warped friction disc.

Solution

Free, adjust and lubricate linkage. Replace engine mount. Replace disc facing. Clean and lubricate splines. Replace defective parts. Replace broken parts of disc facing, springs or pressure plate. Replace friction disc.

Problem

Clutch spins or drags while disengaged.

Cause

Incorrect linkage adjustment or operation. Warped friction disc or pressure plate. Loose friction disc or disc facing. Improper release lever adjustment. Friction disc hub binding on clutch shaft. Broken engine parts. 

Solution

Adjust, repair or replace linkage adjustment. Replace defective parts on friction disc or pressure plate. Replace disc. Adjust release lever adjustment. Clean and lubricates splines. Replace defective parts. Replace engine parts.

Problem

Clutch noisy while engaged.

Cause

Friction disc hub loose on clutch shaft. Friction disc dampener springs broken or weak. Misalignment of engine and transmission.

Solution

Replace worn parts. Replace disc. Align engine and transmission.

Problem

Clutch noisy while disengaged.

Cause

Release bearing worn, binding or out of lubricant. Release levers not properly adjusted. Pilot bearing in crank shaft worn or out of lubricant. Diaphragm spring worn or damaged.

Solution

Replace bearing. Adjust or replace pressure plate assembly. Lubricate or replace crank shaft. Replace pressure plate assembly.

Valve System Service

Problem

Valve sticking.

Cause

Deposits on valve stem. Worn valve guide. Warped valve stem. Insufficient oil. Overheating valves.

Solution

Clean or remove valve stem deposits. Replace valve. Check oil or service lubricating system.

Problem

Valve burning.

Cause

Valve sticking. Distorted valve seat. Valve tappet clearance too small. Spring cocked or weak. Overheated engine. Lean air fuel mixture. Preignition. Detonation. Valve seat leakage

Solution

Check cooling system, tighten cylinder head bolts.  Adjust.  Replace spring.  Check cooling system.  Service fuel system.  Clean carbon from engine, use cooler plugs.  Adjust ignition timing, use higher octane fuel.  Replace valve face and seat.  Replace valve guide.

Problem

Valve breakage.

Cause

Valve burning.  Detonation.  Excessive valve tappet clearance.  Valve sticking.  Scratches on valve system.

Solution

Adjust ignition timing, use higher octane fuel.  Adjust.  Replace valve.

Problem

Valve-face wear

Cause

Excessive valve tappet clearance.  Dirt on face.

Solution

Adjust.  Clean, check air cleaner.

Problem

Valve deposits

Cause

Carbon from rich mixture.  Worn valve guides.  Carbon from poor combustion.  Dirty or wrong oil.

Solution

Service fuel system.  Replace.  Service fuel system, ignition or service engine.  Replace oil.