No. DO I Y 145

DATE 28 -11-68ISSUE No. I

DRAWING OFFICE INSTRUCTION

MODEL ADO 17/2 AUTOMATIC

SUBJECT FORWARD HM:<NESS SHEET OF 1

- I-

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THEF<E f-iAS BEEN A TENDENCY IN EARLY MODELS FOR THE

PO,RWARD I-IARNESS TO BECOME FF?AYED, AND IN SWviE CASES

TO S/-IDQT OUT, DUE TO CHAFllvG AGA NST Tl-iE GEAR BOX UNiT.TO AVOID TI-II$ OCCURl?ENCE THE I-JAf=2NESS SHOULD BE F2E-FWUTEDAS SHOWN.

BATTEF2Y SUPPOF;T

1. DISCONNECT AND F(EMOVE BATTEQY FJ<OM VEHiCLE.? "!='''OVi= BA"TC"¥ -"Av'-. ,"- .... , vi .... ,i I .... /''< I r, I.

3. ,"'E,'''O\lF THE T,IWO LJ,'-"wE,Q ~"'R;:\I!C: <::'Fr u' 'R'c'c BATTc-Dv ,,-,'OO,'-"OT'"" :VI _ . _ . ~,,_ ... .....,,<-1,- V\"-" ..., ... __ ,.''<.'-/ M I i'J ,-,,,-,,, Vi,i~

A/\JD SLAC,!(EN OFF TVvO UPPEF<. SCiREVv'S.

ON WiNG V,~,LP."i\jC':E BELOiJJ BATTE;J::(Y SUPPO!<.T.

5. ,,<EROUTE Li4!=<NESS THROUGH LEGS 0= BATTEC(Y SUPPOF<T.6. 1<.EPLACE Ai\JD TIGHTEi\} ALL SCf<.E S.

7 ,"FOf Arr=__""'- __ II.- __ '- ~ A.,-TE -v -RAVCi'-',/! ,"<,1, .I.

PE 94

AUTHORISED BY 7'

DRAWING OffiCE INSTRUCTION

MODEL

SUBJECT

2/.W017

TAIL IJl10:PS

No.

DATE

ISSUE

SHEET

Dor-Y/1l.,4

27.11.68

No. 1

1 OF 1

In cases of Customer Complaint of Vlater and Dust entering through the Tail LightAssembly, the following action should be taken:

1. Remove Tail Lamp Assembly from the Body.

2. Remove Rubber Seal

3. Using about 15" of SEY-1 Grey Butyl Sealer (Soft Grade)(Expendite - Secostrip 500) place it around reflector and2 holes locating .!\mber and Red Lens. Tamp dovID well toensure good Seal.

4. Replace Rubber Seal.

5. Replace 'Tail Lamp Assembly to Body.

2i-II-C,8

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DATE

.s lOY-I

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DRAWING OFFICE INSTRUCTION No.

SUBJECT FIN<U DRIVE PINION NUT.

MODEL ADO.17!A l'DO.I0!ADATE 14th

ISSUE No.

SHEET 1

November,

1

OF 1

1968.

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In the event of removal of the Final Drive Pinion Retaining Nut, 27H.9420,

the following should be observed:-

1. Thoroughly degrease threads on the output shaft and on the pinion nut.

2. Apply Loctite Grade I: (Part No. PS132) as required to the relevant areas.

3. Torque the pinion nut up to the specified figure of 150 - 170 ft. lb.

AUTHORISED BYR. WALCOT ..

DATE14.11.68.

PE 94

DRAWING OffiCE INSTRUCTION

MODEL .'l.D017, YDOl0

SUBJECT RADIUS .4Jllvl FOUL ON CAllltIER.

No. DOI-Y/139DATE 7.11.68ISSUE No. 1

SHEET 1 OF 1

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Due·to tolerance build up on various rear suspension componentson the above vehicles, a condition can occur where a machiningLocation Boss on the Rear lladius Arm fouls the rear suspensioncarrier on full rebound. This condition produces a metallicrattle which can be eliminated by relieving the Boss by grindingaway the fo~vard edge as illustrated below.

I

/

~ '\~~Grind away this area to suit

. ~Area Boss Fouls on

PE 94

AUTHORISED BY K. ERIKSEN

rDATE 7/11/68

DRAWING OFFICE INSTRUCTION

MODEL ADO 17/2 YDO 10/2

SUBJECT ROCk.ER SWITCH ES - WIPERS

No. DOiY - 132DATE tG - 10- G8ISSUE No.

SHEET I OF

c:iI­....I

>=I­...

T~E WINDSCREEN WIPER SWITCH BEiNG fiTTED IS A T!-IREE "OSiTION

SWITCI-i WHILST TI-IE WIPER MOTOR IN USE IS A SiN6LE SPEED iYPE:.SU(\!" n 'iT K~ nr=p!~" NEf'f'C<::AroV -1·0 f',IO· ('VOce TU;:: IW,IJ<zen S"PT('U P0J "ITiON,,0\..)'.-v ': J..,i:.. U,-<-iV( ... L/ \....-'--'_, ..... K i ;.,..-_" ,-r-... j, '."_ '-'" _'-_ Y\i1i\.." , -" -,

A ~TOP r-0. D("',c;:.n OC A K <:: r.p DCPCDC·X· ;"~D "'NT 'J"O'".;), ; \,...V ,'-' __ .... v , ,.I....i._. v, .... ,,-,-,,,->, ,-1 \'-"'__ 4.)!-\> i ':-' -"

"'(\, AB'L'TY) SI-iO'!' T' Ole rr=rl!re, I" T'("\c T nN '<:: -,....... 'Vl-, .... J-lo.. ' ;, i • U!-U <..,.1\... :; ... ~,-n<:.... ,-", ,J'! 'z-"v_ , v, - ~, .... ::;"

S\(ETCW, BELO\i\j i USING ADY I OR EGUI t,LE. ES \jE.

i STO ?

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PE 94

AUTHORISED BY K"'~/ •

DRAWING OFFICE INSTRUCTION..2:_== i_... No DOI-Y/109

DA.TE Hay 8th, 19680

MODEL

SUBJECT

ADO.17

CRACKED TRANSNISSION C!:lSE DBA,IN HOLE. 30SS.

ISSUE No.

SHEET 1

1

OF 1

This defect is to be rectified as fol1~ws:-

1. Remove existing drain plug and "rasher and replace with a ~N long, SIgH dia~

IT.N.C. 11 ToP.l. bolt using existing copper washer. Cover tbe bolt hesd neatlyand seal any cracks with Devcon F Aluminium Putty (Geo~ i:I. Sample 6: Co.)

Thorough degreasing with white spirits or similar solvent is essential pr:,or'1:0 application of the sealing compound. Hanufacturers ~ instructions on correctmixing of resin and catalyst must: be fono~\i'ed. A minimtw coating thicl<ness of1/16!r is recommended for the sealer.

J. Tighten plug Ivith n8",r \<rasher to a torque of 15 ft./lb. J'l':§l2f.- Over-tightening\?ill crack the boss.

CAROF

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\

3.. Discard existing copper ~?asher and replace with a collapsible one~ Aye .0094_This must be replaced at every oi 1 change.

4,.. E:emove sufficient metal from sump guard in vicinity of new dn::d.n pluglocation to provide clearance on spanner.

2.. Drill and tap ne~" boss showll below to 5/8H dia. 1.:'.N.C. 11 T••1. to acceptexisting drain plug.

In transmission Cases l>Jhere there is no cracking of the boss" the solid copper~<7asher should also be discarded and replaced with ,,,asher, AYG.009L,l' as above.The same torque of lS fe./lb. max must 1:1'8 adhered to.

l~,-' ":~

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CUTo'VT IN SUMP GUARD/ '\To GivE ACCESS TO / \N£.w DRAIN PLUG / \

(I '\1, \

In \ .-£;<ISFING DRAIN Pi UGlJ'· It )(! l. /" \

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VERTICAL UPWARDPROPOSED DRAIN HOLE.To SUIT EXIST/NG

DRAIN PLuG ON BOTTOM OFCASE

VIEJA!

TRANs..

AUTHORiSED BY R. hTALCOT DATE,/ \_IJ -J.'( /""-J~'-yr .

DRAWING OFFICE INSTRUCTION-=~====~----~-=-=--=--==-= ......_,..-..

MODEL ADO.17

SUBJECT FRONT SEAT Flwrn; REWORK.

Nu DOr Y.107.

DATE May 7th. 1968.

ISSUE No. 1

SHEET 1 OF 2

It has been found that ADO.!7 vehicles with tag nos. between :3323 and 4783(Automatics) and. 26866 and 26967 (Manuals) have been fitted with faulty frontseat hinge mechanisms and are to be rectified by:-

(a) Removing the front seat assemblies and replacing them withnew front seat assemblies.

or(b) Reworking the hinge assemblies with components supplied .by R.M.C.

and carried out as per instructions.

This rework consists of:

The rework is to rectify a squab locking mechanism malfunction caused byfaulty components in seat frame assemblies.

These vehicles are fitted with locally-made front seat frames and can beidentified by any of the following points:-

Local seat assemblies have a 3" gap between each seat squab.English seats have -?in gap.

Local seats are fitted with black enamelled seat slides ­English ones have zinc plated slides.

Local seats have a metal cushion pan - English ones are fittedwith rubber Diaphragm Cushions.

Eemoving seats from vehicles, and removing the squab trim backboards and hinge covers.

Removing the cam, HYA.4760, and pawl, HYA.4761, from seats,and replacing them with reworked ones which have been reducedin thickness from .160 to .157 by surface grinding, and are

.155 .150flat within .005.

Replacing the cross-bar return springs, lIYA.4922, with strongersprings. This is to be done while the cam. and pawl aredismantled in (2) above.

If the opposite side to the handle do~s not disengage afterfitment of stronger springs, the original spring may bere-fitte·d to the end of the cross-shaft which is farthestaway from the handle.

If stiffness of operation is evident after tightening the nuton the pivot pin, HYA.4766, the tension on the nut shou.ld bereduced until satisfactory operation is possible, and thenthe nut staked to the thread with a centre punch or round­nosed chisel to prevent it loosening furtber in service.

Re-lubricate the hinge assembly, replace the squab trim board,and hinge covers, and refit the seat in the vehicle.

(1)

(2)

(1)

(2)

(3)

AUTHORiSED BY DATE 7.5.68.~N~~~JZ-·~

DRAWING OFFICE INSTRUCTIONMODEL ADO.l?

SUBJ EeT FRONT SEAT FRAME llEWORK

No DOl Y.l07

DATE 7.5.68.

ISSUE No. 1

SHE,ET 2 OF2

\-\ Y1\ 4'32:2.

Pl\JOT PIN M'f!~ 4766

AUTHORiSED 8~?c/~~'Z«.j)ATE7.5. 68.

/0,

OF 11SHEET

No DOI/Y-81

DATE 13.7.67

!ssur:: No.

Rear Main B~ar:i.ug Cap s

ADO .17 & ADO;.23

Early mode ls .ADO.17 t S j a"ld fillO. 23' s with ADO.1 7 type CylinierBlocks, were fittet1l. with a Rear Main Bearir,g Cap equippei withlarge corei slots in the bottom of the Gap to ensure rapid Oilclrainage. This i.,YJ. cases have resulted in the Oil Seal rUc':4'1ingdry with hcavy lip wear and. Gr'12:ksh3.ft Seal surface wear.

SUBJECT

MODEL

DRAWING OFFICE INSTRUCTION· ,~==;;:::~=~====-==---=-=======-==="""""'---

I~--------------------------------I

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PROCEDD1l.E :

P'lJTTY:Deveon F Aluminhun Filled Pu".:ty

1 .rhorot1.ghly degrease surfaces beforeapplicat ion of putty.

G-eo. H. Sa'11ple & Sons P/L.,I~, Chippen Street,Chippendale.

from:

On ...'illO.17, the twoi cored slots a..'l'ld on Jl.DO.23, the single coredslot i:'1 the bottom or the l::'ear Main Bearins: Cap should be f incdwith a suitable plastic metal. 4. - +" clia. holes should. alsobe clrilled. as shovm on Drawing Ho. AYH.04.73 sheet 1 & 2.

3. Hardenll1>S time is approx. 3 - 4. hoursat robm temperature.

2. Mix in exact ratio of 1 part Hardenerto 1 part Resin by weight(Pot life 20 - 30 Dins.)

In cases of excessive leakage of oil past the Oil Seal necessitatingremoval of the Seal, or during any major engine overhaul, it isrecommended that the Bearing Gaps be modified to ensure that areservoir of' oil it present; at all t:i..lnes for lubricating the lipsof the seal.

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AUTHORISED DATE

DRAWING OFFICE INSTRUCTIONMODEL

SUBJECT

ADO 17

OIL CONSUl@TION

No D.O.I.-Y/66

DATE 25.11.1966

ISSUE No. 1

SHEET 1 OF 1

Heavy Oil Consumption on the above M:odel will in most cases be reduced

to an acceptable a.m.ount if rectification is carried out as f0110\78:-

1. Discard O.E. Piston Rings.

2. Remove Cylinder Bore JUdges.

3. Deglaze Cylinder Bores.

4. Ensure correct Piston to Cylinder Bore Clearance.

5. Pit:-

AL1..0420 Piston Ring - Top Groove 4 off

AYH.0421 Piston Ring - 2nd & 3rd Groove 8 off

ATII.0423 SegF..£nt for Oil Ring 8 0-1"1".... -.AYE.0424 Expander for Oi.l Ring 4 off

AUTHORISED BY K. :SlUKSEF. DATE 25.11.66

DRAWING OFFICE INSTRUCTION.1)'.

MODEL ADO.17

SUBJ EeT DIFFERENTIAL ASSEnmLY .4.i\fD DRIVE SHAFTS.

No DOI-Y/65

DATE 12.10.66

ISSUE No. 1

SHEET i OF 2

1. DIFFERENTIAL ASSE~ffiLY 22H.753

Some early production vehicles suffered from drive shaft rt clonJctl

which was caused by the differential shafts failing to slide freelywithin the differential gears. This fault is most noticeable wherehigh torque and large suspension movements are involved (i.e. low gearand rough road surface), and can lead to looseness of the inner yokesplines and lor excessive float in the constant velocity joint.

DIFFERENTIAL ASSEBffiLY 22H.I070

SERVICE ACTION.

Should owner complain of drive shaft tlclonk tl the follo,vingaction should be taken:

At engine number 18 AI~/U/H 54627 new differential shafts (part no.BTB 881),differential gears (part no. BTE 883) and distance piece (partno. 22H 980) were introduced under a U.K. modification also iUcteerlded toremove llclonklf

•

The locally introduced sealing block (part no. AYH.3092) was discontinuedat this point, but the grease packed within the differential shaft splineswas retained by welch plugs in the differential gears, and the new differentialshafts were shorter than previously.

DIFFERENTI.~ ASSE~1BLY 22H.9792.

To entirely remove the problem of drive shaft Hclonk!l new slidingspline drive shafts (part no. BTB 950) are to be intrOduced shortly,this necessitating a new differential assembly. This latest design issimilar in operation to the ADO.15/l6 series in which all sliding actiontakes nlace in the drive shafts instead of inside the differential.New differential shafts (part no. 22H 1071) are introduced, whilstdifferential gears revert to the earlier type (part no. BTB 641) withno welch plugs. Distance piece (part no. 22H 980) is retained.

At engine number 18 AMvV/U/H 33776 a locally manufactured sealingblock ("Cart 1\io. AYH 3092) was introduced into the centre of the differential,and ~he differential shaft splines were packed with GB1~/20 grease ( l~ ozs.per assembly). The function of the sealing block was to prevent engine oilfeeding the sliding shafts and washing away the grease.

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Replace differential gears BCE.641 by ErB.883, and differentialshafts BTB.644 by BTB.S8l. Fit distance piece 22H 980 over centrepin with flat faces to the heads of the differential gears. Beforefitting differential shafts pack the cavities in the differentialgears with G~;~/20 molybdenum grease (l~oz. per assembly)

conti•••

AUTHORiSED BY DATE

DRAWING OFFICE INSTRUCTIONL. ~

MODEL ADO.17

5UBJEeT DIFFEP31TTIAL ASSET1IBLY AND DRIVE SHAFTS.

No DOI-Y/65

DATE 12.10.66

ISSUE No. 1

SHEET 2 OF 2

conti•.• 2.

lb. Power units 18AJ:.flN U H 776assembly 22H753 and sealing

differentialAYH3092j

Remove differential shafts mB.644 a.nd repack cavities Yli. thGBM2/20 molybdenum grease. Refit differential shafts.

11..1 ternatively carry out previous instruction la. and removesealing block AYH3092

2. Differential assembly 22E979: Remove and discard differentialshaftsBTB.S81. Fit new differ~ntial shafts ETB.645.

Remove differential shafts BTB.881 a.nd repack cavitieswith GBt~/20 molybdenum grease. Refit differential shafts.

2. Power units l8Al~v;;J/H 54627 onwards having differentialassembly 22H979

j)IFf"ERENTIAL GEAR

-DISTANCE PIECE

CENTRE PIN

DIFFERENTIAL A5SEM8L Y22HI070

Vehicles 3lready in service may be fitted withthe new sliding spline{mB 950)drive sl~ts provided the following mOdifications are made to thedifferential assembly:

1. lli.fferential assembly 22H.753: Remove &.'1.d discard sealir.gblock AYE 3092 (if fitted) and differential shafts BTB644. Pitnew Distance Piec~ 22H.980 and new differential shafts 22H 1071.

,cc. Product EngineeringExperimentalServiceQuali.ty Control

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AUTHORISED BY DATE

DRAWING OFFICE INSTRUCTION~======= == ===!e'! "_.Jr"'i~

MODEL

SUBJECT

ADO 17

FRONT SUS2E1TSION ':rIE RODS

No DOI-Y/55

DATE 16.6.66.

ISSUE No. i

SHEET 1 OF 1=

RELEV1.:bTT DRAWIJ:TGS: All{ 4068

Failure of the front suspension tie rod assemblies (llE 1548) has occurred irr a fevlinstances, the fork ends fractvring across the fixing holes.

A rework of the tie rod assemblies y,as in"croduced at CD1dI 6950, reinforcement strips(A11I 4093) being welded to the fork ends; this has increased the tensile strengthof the component by approx. 70%. E. c. S. 21739 v;'hich introduced the reworJ.:ed tie rodassemblies (ArB 4094), instructed tJ:.l3.t all stocks of llH 1548 from Parts Be Acce.5sorie£Department and the field sho'Uld be returJ.1ed for rev;1ork to AYE 4094.

It is recoIDJnended that a ca...":lpaign cha."1ge on all yerJ.ic1es prior to GUM 6950 sho'Uld becarried out as fo1lows:-

Steps haye be"m t"'ken to procure redesigned tie rod assemblies of increased strength..'1'he8e 'will be identified 0;,/ part l'lwrrbers ;~i1i 40&,S (Aust. supply - E. C.S. 19475) orl~-- , 6?" (_. -r ~ .'" ~ S ~2f"\-1\ - .• - , .... •.L."1 _ ,_ 0 U • .1\.. SUpp..l.;Y - .:::.. ". • c:. VJ. I an;:,. -en...;..!. be use 0_ in produc ",ion insteao. ofrework AYIi 4094 when tr~y become ayailable.

Front suspension tie rod assy.Bolt - tie rOd to lower armFront Suspension tie roel ass;y.

" n "" "

SERVICE~

PA1~TS & ACCESSORIES

2 Off2 off2 offH H

2 off

EXPBRIlvIElIfTiiLPLAl'I1UIIG

only redesigDed tie rod assemblies AY:~ 4068 and llB 1626assemblies, and preferably they should a1w3.3TS be changedNote also that new bolts (sTnI 0165) - tie rod to lower

redesigned tie rOds, to g-JJ:lrantee full thread e'ngagement

tie rod to lower arm.

PRODUCT EIJGD.'fBEP..IIJGQUP.LITY CONTROL

Bolt

It is most imp.ol6ttant thatbe used to replace failedin csr sets (i.e. 2 orr).arm are reauired wi_th thein the nut.

Delete lUI 1548IlH 14·09

~ AYE 4068or llB: 1626

IiTYH 0165

CIRCD"LATION:

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No DOI-7/54

DATE 9. 6.. 66.

ISSUE No. 1

SHEET 1 OF 'I

-[~DRAWING OFFICE INSTRUCTION

SUBJ ECT THROTTLE DAIvIPER

MODEL ADO 17

l3H 3486

l2H 2024

21A 839

AUE480

Tl1rottle Damper Complete

Bracket

Tl~ottle Return Spring

Lever

1. RemOVE: the two lower nuts a..YJ.d v,rashers securing carburettor to manifold.

A

Product EngineeringE1.periments.lPlmmingQuali ty ControlSe!'V"ice

Circulation.:-

5. If degree of damping is inadequate, adjust clearance in st;eps of .Oll!,testi~g car until a suitable setting is found.

3. Discard throttle return spring and anchor tag a..'1;d fit new spring 21A 839.

4. Lightly clamp lever AuE 480 to exposed end of throttle spindle, so thatit will operate on damper spindle.. With engine idling set clearance ll,l\}l

(see sketch) between end of spindle, depressed to i is limt, and leverto .ogtl. This will give a degree of damping on final throttle closingwi thout preventing full closuxe.

2. Bolt tlJ.rottle damper to its bracket, and attach to carburettor fla.Yl.geusing e:x:Lsting nuts and washers.

To fit the damper, proceed as fol1ows:-

A throttle damper has been introduced On the above model to prevent excessivesurge on engine overrun. It rnay be fitted retrospectively to older vehiclesif required.

(

DATE

~D",;;,,;R;.;.,,;A;,;,;;W..;,;,IN...;.,,;G;.,.,.,;;;O;;..;,F..;.F.....IC;;,.;;E-....,;,;,IN.....,;S....T.....R....U.....C_TI_O~MODEL ADO.17

5 UBJ ECT STIFF OOOR WINDOW GlASSES

No Dor!Y-44­DATE 7.3.66

ISSUE No. 1

SHEET 1 OF 3

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Where door glasses are hard to move because of tightness in i;heglass cmenneJs, i;he following procedure is i;o be adopi;ed.

FRONT DOORS.

Remove 10he Door Upper casing and i;he necessary Sealing Tapes.Slacken 1;he Screw holding i;he boi;1;cm of i;he "Glass ChannelFroni;" (S=_ "A" Sheei;2)

Push 1;he chamlel as far forward as i;he elongai;ed sloi; will allowand retigbwn securely.

Wi10h 1;he w.l.ndc:m glass in 1;he "up" posii;ion, insert a suii;able bsrthroogh i;he smaJ.l. access hole in i;he "Inner Door Panel" above10he door lock (Hole "B" Sheei; 2). Bend i;he inner legs onJ.,y of10he "Glass Channel Boi;tan Rear" wI:lich is of mei;a1 section. andi;he "Glass Channel" which is of reinforoed fabric seo'l;ion, fora leng10h of 2", as shown on Sheet 2.

If the Window glass is sUll stiff to move in its channel after~ out operations 1 and 2 as a.bO'w, widen the glasschannel above 10he waist line ai; a:r:rr point where ii; grips 10heglass i;igbtly.

R~lace i;he Sealing Tapes and the Door Upper Casing.

REAR OOORS

Remove 10he Door Upper casing and i;he necessary Seeling Tapes.SlackflJl i;he Screw holding i;he bot1;cm of i;he "c;lass ChannelRear~ (S=ew C - Shee1; 3). Push i;he channel as fer rearwardsas 1;he elongated slot will allow and rei;iglli;flJl securely.

Wi10h 1;he window glass in i;he "up" position, insert a suii;ablebsr 1;hro' 10he lock access hole in the Door Inner Panel (Hole DSheei; 3). Bend rearwards 1/16" bo1;h 1;he Glass Channel mei;a1secUon and i;he reinforoed fabric section over a length of 5"approx., as shown on Sheei; 3.

If the w.l.ndc:m glass is still stiff i;o move in ii;s channel afwr~ 0I1i; operaticms 1 and 2 as above, widen i;he glassohannel ai; 8IJ3' poini; where ii; grips the glass tightly.

Replace 1;he Sealing Tapes and the Door Upper Casing.

I AUTI-JORISED BYI. LOVEGROVE

DATE7.3.66

DRAWING OFFICE INSTRUCTION.~ ~

MODEL

SUBJECT

ADO.17

RATTLE - REAR BRAKE ASSEMBLY

No DOI/Y-40

DATE T. 2.66

ISSUE No. 1

SHEET 1 OF 2

Rattles from the rear brake assembly are generally caused by the

handbrake lever rattling against the backplate and brake shoe.

The noise can be effectively r~oved by the fitting of a tension

spring to hold the handbrake lever against the brake shoe. This

may be achieved by drilling a 5/64-ff diameter hole centrally in

the end of the handbrake lever, and fitting a tension spring

(Part No: 1E5537) as shown on the attached sketch.

(Part No: 1E5537 is a throttle return spring used tb.roughout the

ADO.15/16 range).

CIRC1JLATION :

PRODUCT :ENGINEERING (i)

EXPEEIMFNTAL DEPT. ( 1 )

SERVICE DEPARTMJiNT (2)

QUALITY CONTROL (1)

I ORIGINATED BY: R.F. CLARK AUTHORiSED BY R.F. CLARK DATE 7.2.66//r/jllk:~cJ!?

5 UBJEeT RA'l"l'I:E: - REAR BRAKE ASS~LY

DRAWING OFFICE INSTRUCTION ........ , L~

MODEL ADO.17

No DOI;Y-40

DATE 7. 2.66

ISSUE No. 1

SHEET 2 OF 2

V/£W IN DIRECTiON

0,(:' ARROW

"A ~ .DIA HoLE /S TO 8£ OR/.t.Lcl>

ceNiRA LL Y IN €NC 01=

HANDBRAX£ LEVeR AND

SPRINa PO~/TION£OAS SHOWN,

SP~/NG 1£55.37

R,H. BRAkE ItI..J./,sTRATE"O

AUTHORiSED 8Y

/J-erJzDATE

7-"L -bb

DRAWING OFFICE INSTRUCTIONk. i<~

MODEL

SUBJECT

ADO. 17

No Dor/Y-3'9DATE 2.2-,&0

ISSUE No. 1

SHEET i OF 2

This DOL. supersedes and cancels DOIlY-57

PRODUCTION:

To ensure that over stroking does not occur, the stroke of the Clutch.o Slave Cylinder should be adjusted to .286 rr • If a clean disengagement

~ CaI".;Ilot be achieved, the stroke may be adjusted to a maximum of .36011 in~ increments of one packing washer 1iB.5138.i!-- See Fig. 1Cl

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SERVICE:

Slave Cylinder stroke on new vehicles should be set to .286n - .36011•

After 10000 miles the stroke may be .286 fl- .40011

•

A wear-in dimens:Lon of .14311 must be checked as outlined overleaf.

AUTHORISED

DRAWING OFFICE INSTRUCTION"-==-----........._....------------,~MODEL

SUBJECT

100.17

CI1.1TCH Jill.ruS~jEN'T

No DOIh-39

DATE 2.2.66

ISSUE No. 1

SHEET 2 OF 2

Fit packing washer 11.B.5138 under the Clutch Master Cylinder Mounting

Flange until a Clutch Slave Cylinder stroke crf: .28611 is a.chieved.

f. STROkE

FULL srROKE POSITION

RELAXED POSITION

" /vv"£AR-IN POSITION

r-./43-"2. lA/EAR-IN

-RELAXED POSITION

A wear-in d.imension of: less than .143ft will require attention.

See Technical Information iD .45.. ·

I AUTHORiSED BY DATE

2

1

have been receivec ".'",' ,;<~::'< ,~,\..~~~" ,j". .l.- '-':~-'~

-,-his oe corr ..::;-c":;;ed.

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DHAWING NO. AYE: 3089 REllISED.

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DRAWING OFFICE INSTRUCTION ....:I.... .t~

RELEVANT DRAWINGS :

No Dor!i-}8

DATE 9.11.65

ISSUE· No. 1

SHEET 1 OF 1DIFFICULT 1ST GEAR ENGAGBdENT FROM A srANDSTILLSUBJECT

MODEL.

Complaints have been received. of clifficulty experienced in

engaging 1st gear from a standstill.

This fault will be corrected in production in due course,

but those cars already built can be cured by the fitting

of new synchronizer springs.

In extreme cases, therefore, the transmission should be

dismantled and the 1st and 2nd speed synchronizer assembly

broken apart. The three synchronizer springs (Part No:

22H.827) must be discarded. Reassemble the synchronizer

assembly using three new springs (Part No: AYH.,3089) and

the existing three balls (Part No: BLS.109) •

The assembly can then be built back into the transmission

in the normal. manner.

Engagement of 1st and 2nd gear from a. standstill will be

impr0'VeC4 but the baulldng effect at speeds over 5 m.p.ho

wiJ.l be unchanged.

wI

CIRCUIATICN :

PRODUCT :lliG!J.~G

~TAL

SERVICE

QUALITY CONTROL

...

...•••

•••

(2)

(1 )

(2)

(1 )

I ORIGlliATED BY:F

R.F. CLARK

i=~'~-~

ING 0 ~

180,,17

CIJ.JTCE[ PED1\L IICIGI-IT 5 b.E ET

-------------------------_._--

-<.

;' .PACK//JG P/£CE.5

TT£D ~

T/.... THIS D/MEA!.s 10M

..~

/..5 .ACHleVeD \\\

/

THe HeiGHT /S TO 8£ /vJEASJReD VV/

CARPET AND ;./N.D£R;:t'LT REMOVeD 8t,../T Tf-!

T~E Ct..UTC,H PcDAt- RUB8ER PAl) F/7'T£D.

The Clutol1. Ped.al I-Ieigh:t is to -De adjusted -0:7" Clcidir-€ b.eJ.i' p2.c1:i:r...g pieces1, ~lB .5138 iJetv!een tl'l8 Glutell 11Iaster Cylinder It'lCLJ.ge aYJ.Ct. tl"le bi)Jl~b_Eiac1,,~ It isiID.:pO~t~'J.t that the d.imensions Sb.OVlTI al~8 Iik'1.il'1tail1.ed. so that Cl~1tc;}1c-\r8rstr~o}~.i.n·s

a;.tld. SUDsequen:t damage naj'''' be avoided~ 1:1-18 actjtLstment Sb.OTll3.. lJe cCLrried OlXton engines prior to I'Jo eP 25C'30 UI1~cil fllrthel~ notioe~

- I

DRAWING OFFICE INSTRUCTION.-===~ "'''''_=-=====__~ ....__n\~

MODEL

SUBJECT

ADO.17

OIL LEAKS GEARCHINGE CABLES

No DOI-Y/36

DATE 2.11.65

ISSUE No. 1

SHEET 1 OF 1

Fol1ow:Lng this operation it will be necessary to reset

the gearchaJJge cables in accordance nth drawing B416.

The forward ends o£ the gea.rcbange cables where they

enter the ca.bJ.e change housing (225650) are sea.led

by '0' ri.ng.s. It has been found that the housin.g

bores into wh:i.ch the tot rings fit have in some cases

been badly r.aa.ch:i ned and scored.. this resulting in oil

leakage..

In cases where leakage does occur 8:t this point~the

cables should be removed £rem the cable change housing,

aDd a Sealing Ring (Part No: YS377) fitted to the

spigot end of each cable before re-assembly into the

housing. This nIl effectively prevent further oil

leaks at this point.

PRODUCT BNGINEERING 1

QUALITY CONTROL , • 1

SERVICEDEP~ 3

EXPERIMENTAL DEPr. .. 1

CIRCUIATION:

Ii

ORIGDTATED BY: R..F. CU....RK. AUTi-JORiSED BY R..F. CIABK DATE 2o~:1 .,65

4(21~.

MODEL AUSTIN 180(J MI{ I & MI{ II (ADO. 17)

DRAWING OffiCE INSTRUCTION

SUBJECT SEAT SLIDE FAILlJll.E.

No.

DATE

ISSUE

SHEET

DOI-Y-269

4-5-72

No. II OF I

Instances have been found on a particular version of ssat slide where theforward ends of the Seat Slide Lower traek have failed adjacent to thefixing serew due t.o fatigue.

As tIle failure is of a fatigue type, it probable that most vehicles willeventually become affeeted. Therefore a reinforcement has been producedto prevent the area flexing, but which is also stiff enough to withstandthe seat loads should slide be already broken.

all vehicles are affected.

to the

insertingan,a

the reinforcer~ent Hl1D7738 ever the top of the slide,the narrow end of tile reinfo reemeut between the base ef i>he ell,anxlelthe cress pin. Tap lightly iuto plaee if l1ecessary.

Re:move the Pan Head tlC:I"&WS and washers securing the seatfloo!:" (2 per seat).

The early MI{ I vehicles were fitted with slides which are quite satisfactoX)-,and can be identified by their zinc plated finish, Only the last 1831 LnaJrliualand 2.1&15 Automatie vehicles were fitted wi'th the suspect slides, and can. beidentifhd by th.eir black finish.

In the Mark II range, 'tile first 19,989 vehicles were fitted with the suspeet(blThck) slideSe lifter this figure" the slides 11ere reintorced$ and althoughstill black can be identified by a double thickness of metal at the front edgeof tbe slide. Tbese do not require reinforcement. 7,136 vehicles, thelast of MI{ II produetion, were reinforced in this manner.

hlaterial required: Reinforeement Plate Seat Slide BYB7738 - 4 off per vehicle.

1, Slide both front seats to the r<lar of their adjustment, exposing tile frontfastenings to the vehicle floor.

5. Operate tile seat through its full travel to eusure tbat it slides freel:y~.

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AUTHORISED BY C. W. ROGERS, DATE !J--5-72

PE 94