WHAT THE SHOP MANUAL WON'T TELL YOU
Table of Contents
INTRODUCTION
MY INTENDED READERS
ACKNOWLEDGMENTS
SOME ADVICE BEFORE YOU START
A BASIC ASSUMPTION
A WORD ABOUT VENDORS
ALMOST THE LAST WORD BEFORE YOU BEGIN
GUARANTEE AND DISCLAIMER
BRAKES
FRONT BRAKES
Friction Pad
Caliper Unit
Hub and Disc Assembly
Disc Brake Conversions
REAR BRAKES
Brake Shoes
Wheel Cylinders
Brake Hoses
Brake lines
Brake Drums
POWER BRAKE AND MASTER CYLINDER ASSEMBLY
Power Unit
Master Cylinder
BLEEDING AND FLUSHING THE HYDRAULIC SYSTEM
BRAKE PEDAL
Stop Light Switch
PARKING BRAKE
Front Control Cable
Rear Brake Cable
CLUTCH
HOUSING ALIGNMENT
CLUTCH RELEASE BEARING
CLUTCH LINKAGE
COOLING SYSTEM
MAINTENANCE
FAN BELT
THERMOSTAT
WATER PUMP
HEAT INDICATOR/TESTING
REPAIRING THE RADIATOR RESERVOIR TANK
RADIATOR
Installation
Recoring
Painting
The Radiator Support
THE UPPER RADIATOR HOSE AND CLAMPS
ELECTRICAL SYSTEM
STARTER MOTOR
IGNITION CIRCUIT
Basic Engine Diagnosis
Ballast Resistor
Distributor
Spark Plugs and Cables
ALTERNATOR
VOLTAGE REGULATOR
AMMETER
HORNS
LIGHTS
Headlamps
Parking Lights
Tail and Stop Lights
Signal Lights Flasher
Directional Signal Switch
Directional Signal Tell-Tale Lights
Back-Up Lights
Red Bulbs for the Instruments
Trunk Light and Trunk Light Switch
Current Bulb Numbers
FUSES
MISCELLANEOUS
Three Shorts Waiting to Happen
Critical Grounds
ENGINE
REMOVAL
DISASSEMBLY AND CLEANING THE ENGINE
REBUILDING THE ENGINE COMPONENTS
The Oilinf System
Vibration Damper (A.K.A. Harmonic Balancer)
Timing Gear Cover
Camshaft and Bearinga
Rocker Arm Assembly
Valve Lifters
Valves, Guides, and Seals
The Cylinder Block
PUTTING THE ENGINE BACK TOGETHER
ENGINE SUPPORTS
INSTALLING THE EXHAUST SYSTEM
FRAMES
BODY-OFF RESTORATION?
MISCELLANEOUS
FRONT SUSPENSION AND STEERING
FRONT SPRINGS
FRONT SHOCK ABSORBERS
LOWER AND UPPER CONTROL ARMS
Inner Pivot Shafts and Bushings
Outer Pivot Pins and Bushings
STEERING KNUCKLE AND KING PIN ASSEMBLY
STEERING GEAR
STEERING LINKAGE
Steering Bell Crank Assembly
Tie Rods
STEERING WHEEL
STEERING SHAFT JACKET ASSEMBLY
Lower Support Bearing
Interior Steering Column Collar
Directional Signal Switch
WHEEL ALIGNMENT
POWER STEERING
Reconditioning the System
Converting to Power Steering
GASOLINE SYSTEM
WHY DO YOU SMELL GAS FUMES?
FUEL LINES
FUEL TANK
Removal
Repair
Installation
AN EVAPORATIVE FUEL CONTROL SYSTEM FOR AN AVANTI
FUEL PUMP
CARBURETOR
New Replacement or Major Rebuild?
Cleaning
Do your Own Minor Rebbuild
Fuel Economy, Metering Rods, and Jets
Linkage
The Accelerator Pump
The Choke
The Throtttle Kicker
THE SUPERCHARGER
Normal Operation
Changing Oil
Removing/Installing Supercharger Belts
REAR SUSPENSION AND REAR AXLE
REAR SUSPENSION
Torque Arms, A.K.A. Traction Bars
Rear Springs
Rear AXLE
Hub and Drum Assemply
Rear Axle Shaft
Now for a Little Heresy?
What's That Little Hole For?
POWER-SHIFT AUTOMATIC TRANSMISSION
REBUILD IT YOURSELF
1ST GEAR START IN DRIVE?
NEUTRAL BLOCKING PAWL
MAINTENANCE AND ADJUSTMENTS
Fluid
Band Adjustments
Replacing Leaking Rear Oil Seal
REMOVAL AND INSTALLATION OF THE TRANSMISSION
Removal
Installation
TORQUE CONVERTER
Performance or Standard Model
Ring Gear
Pilot Busning
Alignment
WHEELS AND TIRES
TIRES
Radials?
Size?
Inflation?
RIMS
Disk Brake Rims
Substitutes
Check for these Potential Problems
Correct Rim Color
BODY
SPECIAL PAINTS AND FINISHES
EXTERIOR
Fiberglass Repairs
Paint
Stainless Steel Trim
Glass
Weatherstripping and Keeping the Interior Dry
Hood
Door Assembly
Windshield Wipers
Bumpers
Rear View Mirrors
Radio Antenna
INTERIOR
Removing Door and Window Handles
Sun Visors
Rear View Mirror
Interior Rear Quarter Trim Piece
Cables and Conduits
Dash
Instrument Panel
Headlining
CLIMATIZER AND VENTILATING SYSTEM
AIR CONDITIONING?
CABLES AND CONDUITS
WATER CONTROL VALVE
VENTILATING SYSTEM
Air Outles Screen
Air Control Valve
Avoiding a Flood
APPENDICES:
APPENDIX I MECHANICAL STOP LIGHT SWITCH
APPENDIX II SOLID STATE VOLTAGE REGULATOR
APPENDIX III ARROW SIZE/SHAPE FOR TELL-TALE DIRECTIONAL SIGNAL LENS
APPENDIX IV TEMPLATE FOR THROTTLE KICKER BRACKET
APPENDIX V TEMPLATE FOR TRACTION BAR BRACKET
APPENDIX VI HALOGEN BACK-UP LIGHTS
APPENDIX VII EVAPORATIVE FUEL CONTROL SYSTEM
APPENDIX VIII PARKING LIGHT RECEPTACLE MALE MOLD
APPENDIX IX LOCATIONS FOR LABELS AND DECALS
APPENDIX X 1963 R-2 ENGINE COMPARTMENT
APPENDIX XI STEREO RADIO AND R-3307
APPENDIX XII COPIES OF INSTRUCTIONS FOR ACCESSORIES
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