BillyBob Maintenance Log

WHAT'S NEW is a chronological listing of updates to the BillyBob site.

TRUCK LINKS including vendor sites for old parts, custom parts, and tools as well as sites for classic car and truck organizations

STORE Operating in association with Amazon.com, books, recordings and tools can be purchased.

PLANNING for the restoration including project schedule and cost estimates.

TRAVELS WITH BILLYBOB With apologies to Steinbeck, this area of BillyBob's Garage will be used to log the trips BillyBob and I make together.

WORK-IN-PROGRESS was the restoration of parts of BillyBob that I could accomplish without a garage up until the summer of 2010 when I finally got enough warehouse space to work in. Now, it also includes the continuing work on BillyBob in the shop.

PRE-RESTORATION includes log entries of minor repairs and and adventures between time of purchase and the time when I started restoration, a piece at a time.

JR'S KORNER JR's Korner is the history of BillyBob before I got him authored by my brother, Wm. C. Kephart.

BILLYBOB MAINTENANCE Ever changing detailing, oil change, lube, etc. maintenance routines specifically developed for BillyBob, including required tools, materials and procedures.

PARTS SHOP The Parts Shop is a repository of How-To articles. Things that I have done over and over enough times to have developed a procedure. This gives me a checklist and saves brain cells.

STEALTH SHOP Urban residence design with large integrated shop and separate living quarters for a relative or renter.

Ever changing detailing, oil change, lube, etc. maintenance routines specifically developed for BillyBob, including required tools, materials and procedures.

Detailing Consumables

The table below lists to products I'm currently using in my detailing efforts.

Engine Compartment Detailing Procedures

Degreasing/Washing

1. Gather tools - air compressor, numbered clothespins, goggles, grime blaster, garden hose and water source, one gal 20/80 purple degreaser/water mix, seran quick covers;
2. warm up engine. remove air cleaner, distributor cap and spark plug wires, protect carb throat and distributor from water penetration with quick covers, seal off coil wire hole with tape;
3. spray engine and compartment with 20/80 degreaser/water mix, use brushes on thick build-ups, rinse engine and compartment with water, blow water off with compressed air;
4. dry shift box assembly, horn relay, fuse box with hair dryer;

Component Detailing

1. clean oil filter cannister and hoses with spray cleaner and wipe dry, treat cannister hoses with protectant;
2. unbolt coolant recovery tank (7/16" wrench), clean with damp cloth, treat with chrome polish (including brackets) and replace, treat tank hoses with protectant;
3. clean spark plug wires and distributer cap, treat with protectant and replace;
4. remove coil wires (3/8" wrench), remove coil bracket from engine (1/2" wrench), remove coil from bracket (slot screwdriver);
5. clean coil, bracket and fasteners with spray cleaner and water, wipe dry;
6. touch up coil bracket with detail gray paint, if necessary, clean electrical contacts and re-assemble (use threadlocker on the bracket-to-head cap screws and dielectric grease at the coil-to-distributor wire contact);
7. clean air cleaner exterior with soap and water and wipe dry, replace air cleaner;
8. spray gearshift linkage with Silicone Lubricant, wipe excess off, treat shift box bellows with protectant;

Radiator Area and Inner Fenders

1. gather tools - 3/8", 1/2", 9/16" wrenches and a big phillips screwdriver;
2. remove fender braces, remove hood latch assembly, remove upper radiator baffle bolts as necessary and clean;
3. clean fender braces, clean and polish hood latch assembly, clean baffle and touch-up paint if required, otherwise clean with soap and water, wipe dry;
4. clean radiator and touch-up paint if required;
5. replace fender braces, replace baffle, replace hood latch assembly, replace bolts, protect hood latch assembly with polish;
6. clean hoses and hood bumpers and treat with protectant.

Body Detailing Procedures

Clean Body

1. Gather tools - garden hose and nozzle, wash bucket, scrub brush, scrub mitt, carwash soap;
2. clean the body a section at a time starting at the top and working downward;
3. wet down body section with hose;
4. wash with car wash soap solution;
5. rinse off with hose;
6. touch-up rustoleum paint as required.

Taillights

1. Gather tools - 7/16" wrench, 1/2" wrenches, medium flat blade screwdriver, mini radial bristle brush with embedded 36 grit abrasive in Dremel motor tool, spray cleaner, electronic cleaner/degreaser, chrome polish, protectant;
2. disconnect battery, disconnect wires, remove taillights from brackets (7/16" wrench);
3. clean tallights, boot and brackets with spray cleaner, clean corrosion from contacts with bristle brush in motor tool, treat sockets with electronic cleaner/degreaser;
4. remove brackets (1/2" wrenches), clean brackets with spray cleaner;
5. touch-up brackets with Chassis Black paint, if necessary, remove taillight lens, treat taillight housings with chrome polish, then wax;
6. remount brackets with new or cleaned bolts, washers and nuts;
7. reconnect taillights to brackets, treat boot with protectant, connect wires, connect battery and test lights;
8. treat lens gasket with protectant, assemble taillights, spray bolts with silicone lubricant

Parking Lights

1. Gather tools - medium phillips screwdriver, spray cleaner, electronic cleaner/degreaser, chrome polish, wax, silicone lubricant;
2. disconnect battery, remove lenses and gaskets, remove bulbs, remove housings, disconnect socket;
3. clean lenses and housings with spray cleaner;
4. treat housings front and back with chrome polish, then wax;
5. treat sockets with electronic cleaner/degreaser, treat screws with silicone lubricant;
6. re-assemble housings and sockets, insert bulb and test, re-assemble lenses and gaskets

Headlights

1. Disconnect battery, remove trim ring, remove bucket screws, and gently pry headlight assembly from fender opening to avoid damage to rubber gasket;
2. remove electrical tape and wire connectors from headlight socket at back of bucket assembly, tape off wire connectors with masking tape;
3. wire brush, wash and dry, prime and touch-up fender paint, if required;
4. disassemble trim ring assembly, remove headlamp retainer, headlamp, headlamp cradle, clean trim ring parts, and screws with a tumbler session followed by a tumbler polishing session;
5. wax headlight bucket, wax headlamp cradle and install;
6. polish and wax headlamp retainer ring, wipe clean headlamp with damp cloth, treat retainer screws with WD-40 and install;
7. polish and wax headlamp trim ring, clean trim ring rubber and treat with protectant, re-assemble trim ring assembly, treat trim ring screw with WD-40 and install;

Bumpers

1. gather tools - 3/4" socket and box end wrenches, sissors jack, 1/2", 5/16", 10mm socket wrenches, special license plate allen wrench, blade screwdriver, car wash soap, water, and bucket, scrub brush and wash mitt, shop towels, rubber gloves, SEM Trim Paint, Detail Silver Paint, threadlocker;
2. Remove front bumper, remove bumper brackets and splash apron. collect corroded bolts, nuts and washers for future cleaning and derusting ops;
3. clean bumper brackets and touch-up with black SEM Trim Paint, if necessary;
4. touch-up splash apron paint, if necessary;
5. clean bumper front and back with car wash soap and water, touchup silver detail paint on back, wax front;
6. re-attach brackets, splash apron and bumper with threadlocker on new bolts;
7. Remove rear bumper, remove bumper brackets with 3/4" socket wrench and box end wrench;
8. place jack under spare tire carrier end, unbolt and lower spare tire and carrier to provide access to license plate bracket connectors, remove license plate and license plate bracket assembly with 1/2" socket wrench;
9. remove license plate with special allen wrench and 10mm socket wrench, disassemble license plate bracket assembly with bladed screwdriver and 5/16" socket wrench, clean and touch-up with black SEM Trim Paint, if necessary, collect corroded bolts, nuts and washers for future cleaning and derusting ops;
10. clean bumper brackets and touch-up with black SEM Trim Paint, if necessary;
11. clean license plate front and back with car wash soap and water, wax license plate front and back;
12. clean bumper front and back with car wash soap and water, touchup silver detail paint on back, wax front;
13. reassemble license plate assembly, re-attach license plate, license plate bracket, bumper brackets and bumper with threadlocker on new bolts

Tonneau Cover

1. clean tonneau cover with spray cleaner and water mixture;
2. treat tonneau cover with 303 protectant.

Wheelwells

Clean Wheelwell

1. Gather tools: floor jack, jack stands, plastic glass installer stick, impact wrench with 3/4" socket, degreaser mix, grimeblaster spray gun, hose, bucket, scrubbrush, wrench asortment (1/2",9/16",3/4");
2. jack up and place jackstands, remove hubcap with installer stick, remove wheel;
3. spray wheelwell with 25/75 degreaser/water mix, use brushes on thick build-ups, rinse with water, blow water off with compressed air;
4. remove front shocks (9/16" wrench), remove rear shocks (9/16", 3/4" wrenches), shackles (if necessary). remove rear axle bumpers (1/2" wrenches), place lug nuts, shock fittings, shackle bolts, washers and axle bumper bolts washers and nuts in tumbler for a cleaning session;
5. wire brush, clean, mask threads and other things not to be painted, touch-up with Chassis Black paint;
6. tin-zinc plate fittings (if necessary), place in tumbler for a polishing session;
7. clean shocks and rubber bushings with spray cleaner, treat rubber bushings and axle bumpers with protectant, install axle bumper bolts with threadlocker, wax shocks and reinstall with threadlocker;
8. replace wheels, treat lug nuts with WD-40 and install

Wheels and Tires

1. Gather tools: floor jack, jack stands, plastic glass installer stick, impact wrench with 3/4" socket, degreaser mix, grimeblaster spray gun, hose, bucket, scrubbrush;
2. jack up and place jackstands, remove hubcap with installer stick, remove wheel;
3. wash wheel, clean tire, touch-up wheel paint;
4. mounting: dress tire back, WD-40 spray lug nuts, mount wheel, tighten lugs, dress tire front;
5. hub cap: wash, wax, and install;
6. inner tube valve stems: wipe with Protectant.

Undercarriage

Clean Chassis

1. Gather tools: putty knives, gasket scrapers, wire brush, air compressor, jackstands, floor jack, grime blaster, degreaser, bucket and wash brushes;
2. jack up truck, place on jack stands;
3. Scrape thick buildups with putty knives, gasket scrapers and wire brush;
4. spray chassis with 25/75 degreaser/water mix, use brushes on thick build-ups, rinse with water, blow water off with compressed air

Chassis Front

1. Gather tools: 9/16" deep socket wrench;
2. remove and clean radiator support hex nuts and washers;
3. clean and touchup frame as required with Chassis Black paint;
4. Clean and touchup radiator support as required with Underhood Black paint

Mid-Chassis Component Detailing

1. Gather tools: 9/16" wrenches, 1/2" wrench, 5/8" wrench, terminal puller;
2. remove gearshift linkage at transmission (2 wrenches 9/16" needed), tumbler clean, tin-zinc plate linkage items (if necessary), tumbler polish, re-install;
3. wipe master cylinder with spray cleaner, touchup "spray gray" paint (if required), treat master clyinder rod boot with protectant, replace support bolts if corroded;
4. disconnect and remove battery, spray battery and battery box with battery cleaner/acid neutralizer, rinse with clean water and wipe dry with clean cloth, clean terminals with a terminal brush and re-install battery, replace battery retainer hex nuts and washers if corroded;

Exhaust System

1. Gather tools: two 1/2" wrenches and two 9/16" wrenches;
2. remove both muffler clamps, muffler strap and tail pipe support;
3. clean and touch up clamps, strap and support with Detail Gray paint;
4. clean and touch up exhaust pipe, muffler and tail pipe with exhaust paint;
5. tin-zinc plate connectors (if necessary), tumbler polish, re-install connectors.

Parking Brake Cables

1. Gather tools: two 1/2" wrenches, 5/8" wrench, 11/16" wrench, bent needle-nose pliers, vice-grips;
2. remove clevis, jamb nuts (1/2" wrench), cable clamp bolts (1/2" wrench), washers and nuts, lever bolts (5/8" wrench), washers and nuts (11/16" wrench) and cable boots (mark location of clevis jamb nut before removal for reassembly purposes - use a coffee stirrer as an alignment guage);
3. place small corroded parts in tumbler for cleaning session and immerse threaded cable ends in OxiSolv for fifteen minutes if rusted;
4. after OxiSolve treatment, mask off beginning threads covered by clevis and jamb nut and paint remaining threads with underhood black;
5. reassemble and treat rubber boots and cables with protectant.

Spare Wheel and Carrier

1. Gather tools: sissors jack, wrench with 3/4" socket, hose, bucket, scrubbrush, tire dressing;
2. jack up end of carrier with sissiors jack, remove carrier nut and flat washer with 3/4" socket wrench, lower carrier end with sissors jack, lift and rotate carrier end out from under truck by hand (carefully), lift wheel off carrier (carefully);
3. wash wheel, clean tire, touch-up wheel paint;
4. remove carrier hinge clevis pin and cotter pin, place in tumbler along with flat washer and nut for a cleaning session followed by a polishing session;
5. clean carrier with soap and water, touch up paint;
6. mounting: dress tire front, mount wheel (carefully) so that valve stem will be pointing down and to rear of truck when tire carrier is in place, dress tire back, lift and rotate carrier back in under truck and place end on sissors jack;
7. jack carrier back up into position (carefully), replace flat washer and nut with threadlocker blue;
8. inner tube valve stem: wipe with Protectant.

Interior Detailing Procedures

General Cleaning

1. Gather tools - vacuum cleaner, spray cleaner, bucket, sponge, scrubbrush, clean rags, 11/16" open end wrench, threadlocker, protectant, vinyl cleaner, vinyl conditioner, dishwash soap;
2. vacuum mat, remove seat, gas pedal and mat, vacuum floor pan;
3. wash mat with spray cleaner and water, front and back, rinse and dry in the sun;
4. wash master cylinder access cover with spray cleaner and water, dry and treat with protectant;
5. if starter button needs remedial work, lift boot and loosen starter button rod jamb nut (11/16" wrench), remove button, rod and boot assembly, remove jamb nut then boot;
6. wash boot and treat with protectant inside and out, install boot back on rod, re-install jamb nut;
7. treat bolt threads with threadlocker and reinstall button assembly, tighten jamb nut, then seat boot;
8. wipe headliner, seat, seat back and door panels with damp cloth;
9. clean seat, seat back and door panels with vinyl cleaner, treat with vinyl conditioner, replace seat, reinstall floor mat, reinstall gas pedal;
10. clean dash, gauges, steering wheel, turn signal switch assembly, gearshift assembly, dome light, doors and window rubber with dishwash soap and water;

General Lubrication

1. Gather tools - oil can (with engine oil), white lithium grease aerosol;
2. lube cowl vent pivots with drop of engine oil;
3. note that the choke and throttle cables need some friction to work properly;
4. Check choke cable, remove if necessary, clean and re-lubricate with white lithium grease, re-install and adjust;
5. Check throttle cable, remove if necessary, clean and re-lubricate with white lithium grease, re-install and adjust

Windshield

1. Gather tools - medium blade screwdriver, 1/2" open end wrench, medium philips screwdriver, vacuum cleaner, spray cleaner, glass cleaner, protectant;
2. remove mirror from mirror base with 1/2" wrench, remove mirror base with blade screwdriver, remove defroster trim piece with phillips screwdriver;
3. vacuum defroster channel and clean with spray cleaner, clean windshield with glass cleaner, apply protectant to windshield gasket;
4. replace defroster trim piece, mirror base and mirror.

Steering wheel Assembly

1. Gather tools - medium flat blade screwdriver, 3/4" socket wrench, steering wheel puller, 1/2" wrench, 9/16" wrench;
2. if steering wheel needs remedial work, disconnect battery, remove and wash steering wheel;
3. sand, clean and touch-up paint;
4. if gearshift needs remedial work, remove gearshift assembly, clean and touch-up paint if required, otherwise, wax assembly;
5. clean and touch-up steering column paint if necessary, otherwise, wax column and re-install gearshift assembly
6. WD40 lube mounting splines, re-install wheel;

General Finishing

1. apply chrome polish to turn signal switch assembly, ignition switch, door and window handles, and gauge surrounds;
2. polish and wax horn button;
3. wax steering wheel, gearshift, steering column, and window moldings;
4. treat window rubber, starter button boot with protectant

Glass and Trim

Brightwork

1. Gather tools - nitrile gloves, lacquer thinner, paper towels, Q-tips, clean soft lint-free rags, chrome polish;
2. clean hood emblem, side designation plates, headlight trim rings, parking light enclosures, outside mirror, windshield wiper bezels, windshield trim, outside door handles, door window trim, chrome gas cap, tailgate hooks, taillight housings, bumpers and hub caps with lacquer thinner and paper towels;
3. apply chrome polish to the above cleaned items with paper towels and Q-tips for tight spaces;
4. hand buff polish off with lint-free rags;
5. Items that are corroded beyond a general cleaning and polishing will require disassembly and re-finishing as outlined below and other sections of this detailing procedure

Driver Side Mirror

1. Gather tools - medium flat blade screwdriver, 7/16" wrench, small pliers, threadlocker, anti-seize compound, chrome polish, Q-tip, protectant;
2. remove mirror head, clean and polish mirror head and bracket, apply protectant to bracket gasket with Q-tip, touch-up mounting stud paint, if required;
3. install new adjusting screws, if required, with anti-seize compound;
4. install new mounting stud hex bolts and flat washer, if required, with threadlocker

Exterior Door Handles

1. Gather tools - 1/8" allen wrench, medium flat blade screwdriver, 1/4" clutchead screwdriver, internal snap ring pliers, chrome polish, threadlocker;
2. remove interior door handle (allen wrench), remove window crank (screwdriver), carefully pry door panel off (screwdriver);
3. remove exterior door handle (clutchead screwdriver) and gaskets, if push button needs re-finishing, remove button assembly (snap ring pliers);
4. polish door handle with chrome polish, clean rubber gaskets with soap and water;
5. re-assemble door handle, re-install door handle with threadlocker on fasteners, re-install interior panel and handles with threadlocker on the set screws.

Glass

1. Gather tools - razor scraper, protectant, glass cleaner, Rain-X and Rain-X Anti-Fog, paper towels, Q-tips;
2. scrape faded window decals off;
3. clean glass gaskets and apply protectant;
4. clean windshield, windows, mirrors, headlights, parking lights, and taillights with glass cleaner;
5. apply new window decals;
6. treat windshield, windows outside with Rain-X;
7. treat windshield, windows inside with Rain-X Anti-Fog.

Monthly Maintenance

Check Lights

1. park in front of glass doors or storefront so you can see the reflection of the lights from the driver's seat;
2. check parking lights and turn signals, check headlights high and low beam;
3. turn vehicle around and check taillights, brake lights and turn signals

Check Differential

1. gather tools - creeper, shop rag, SAE 85W-140W Gear Oil, 3/4" open end wrench;
2. remove square nut plug at rear of differential;
3. add gear oil if fluid level is not up to bottom of plug hole, and replace plug

Check Transmission (3 speed manual)

1. gather tools - creeper, shop rag, SAE 75W-140W Synthetic Gear Oil, 1/2" open end wrench;
2. remove square nut plug at passenger side of transmission;
3. add gear oil if fluid level is not up to bottom of plug hole, and replace plug

Check Brake Master Cylinder

1. gather tools - DOT 3 brake fluid, squeeze bulb filler tool, ratchet wrench with 10" extension and 7/8" socket;
2. turn back floor mat on driver's side to expose master cylinder access floor plug and remove plug;
3. remove filler plug from top of master cylinder with wrench carefully (keep dirt out);
4. using filler tool, add brake fluid, if needed, so that level is 1/4" below plug opening (don't overfill), and replace master cylinder plug, access plug and floor mat

Check Battery

1. gather tools - electrolyte, filler tool, volt meter;
2. turn back floor mat on passenger side to expose battery access panel and remove panel;
3. unscrew cell cap(s) carefully (keep dirt out);
4. using filler tool, add electrolyte, if needed, so that level is just touching split-ring filler port extension (about 1/2" above plates), don't overfill, and replace cell cap(s);
5. using volt meter check voltage across battery terminals (should be a little more than 12 volts on a twelve volt system), replace access panel and floor mat
6. during off-season, to avoid sulfation, cables should be disconnected and battery should be charged every thirty days or put it on an automatic float charger

Check Engine Oil

1. gather tools - SValvoline VR1 20W-50 Racing motor oil, filler spout, shop rag;
2. pull out and wipe dipstick, return and pull out again, determine oil level;
3. if necessary, add oil through valve cover cap with oil spout tool

Check Radiator

1. let engine cool first, if hot;
2. remove radiator cap and top off with 50/50 coolant/water mix, if necessary

Check Tires

1. gather tools - air compressor, tire filler attachment, tire pressure gauge;
2. check each tire and bring up to 26/26 PSI front/rear (6.50 x 16 6-ply rated truck tires with inner tubes), 36 PSI for spare and for rear tires too if bed is loaded

Quarterly Maintenance

Lube Chassis (23 zerk fittings)

1. gather tools - floor jack, jackstands, wheel chocks, creeper, shop rags, air compressor, air powered grease gun, chassis grease, MAPP torch;
2. put front of vehicle up on jackstands, lube front suspension and steering linkage fittings, lube clutch pedal shaft fitting, lube drive shaft universal joint fittings and lube rear suspension fittings;
3. if any fittings won't take grease, carefully heat them up with the MAPP torch to liquidify the old grease

Distributor Grease Cup

1. turn distributor grease cup down one turn;
2. When grease cup is screwed down as far as it will go, remove it and refill with chassis grease, start over with grease cup at top of its travel

Check Steering Gear

1. gather tools - GM steering gear lube, 7/16" open end wrench;
2. remove square nut plug top of steering gear box;
3. add steering gear lube, if required, and replace plug

Lube Throttle Linkage

1. lubricate throttle linkage bellcrank shaft with 3-in-1 oil

Oil Change

Change Oil and Filter

1. gather tools and parts - creeper, drain pan, sludge siphon, 7/8" open end wrench, filler spout, shop rags, Valvoline VR1 20W-50 Racing motor oil, Purolator or Fram C4 filter element
2. warm up engine, place drain pan, remove oil pan bolt and drain old oil;
3. wipe and reinstall oil pan bolt, remove old oil filter element and siphon remaining oil out of cannister, check cannister fittings and clean inside of cannister with clean rag, pour one quart fresh oil into cannister and insert new filter element carefully, replace cannister cap;
4. Pour five quarts new oil into valve cover oil filler hole;
5. replace cap, start engine and check oil pressure and for leaks (especially at filter cannister cap);
6. turn off engine, wait for oil to drain down some and check dipstick

Replenish Air Cleaner

1. Remove oil bath air cleaner and drain oil;
2. Clean oil reservoir with clean shop rag and remount on carb;
3. fill oil reservoir with clean oil

Brake Maintenance

Inspect and Adjust Front Brakes

1. gather tools and parts - floor jack, jackstands, creeper, shop rags, screwdrivers, wrenches, drum puller, brake cleaner, brake adjusting spoon;
2. put front end up on jackstands, remove hubcaps, wheels and brake drums;
3. clean brake parts with brake cleaner, inspect lining wear and for leaks at wheel cylinder, inspect wheel bearings;
4. replace brake drums, torque spindle nut to 33 footpounds while rotating wheel, back off one notch and replace cotter pin, replace dust cap, wheel and hubcap;
5. remove rubber plug from adjuster hole on backing plate and expand brake shoes until they drag slightly (move outer end of tool towards center of wheel), retract brake shoes until drag stops (move outer end of tool away from center of wheel);
6. replace rubber plugs, put front end back on ground

Inspect and Adjust Rear Brakes

1. put rear end up on jackstands, remove hubcaps, wheels and brake drums;
2. clean brake parts with brake cleaner, inspect lining wear and for leaks at wheel cylinder, inspect wheel bearings;
3. replace brake drums, wheel and hubcap;
4. remove rubber plug from adjuster hole on backing plate and expand brake shoes until they drag slightly (move outer end of tool towards center of wheel), retract brake shoes until drag stops (move outer end of tool away from center of wheel)
5. replace rubber plugs, put rear end back on ground

Vacuum Bleed Brakes (Mitivac)

1. gather tools and parts - creeper, shop rags, screwdrivers, 7/8" socket and extension, 3/8" six pt deep socket and box end wrenches, Mitivac bleeding system, DOT 3 brake fluid, 2x4 "helper";
2. Put vehicle level on ground for bleeding procedure;
3. Start with wheel farthest away from the master cylinder first (driver side rear);
4. loosen/tighten bleeder valve (3/8" six pt deep socket) and attach mitivac vacuum pump line to valve (after substituting 3/8" six pt box end wrench for socket);
5. top off master cylinder with fresh DOT 3 brake fluid, replace plug (7/8" socket and extension), pump brake pedal and hold down with 2x4 helper;
6. pump mitivac fifteen to twenty times and loosen bleeder valve 1/4 turn (3/8" box end wrench), close bleeder valve when flow slows;
7. top off master cylinder with fresh DOT 3 brake fluid, replace plug, pump brake pedal and hold down with 2x4 helper;
8. repeat steps d,e and f until new fluid runs into mitivac reservoir, tighten bleeder valve;
9. repeat bleeding procedure on passenger side rear wheel next;
10. repeat bleeding procedure on passenger side front wheel next, then driver side front wheel last.

or Pressure Bleed Brakes (Motive Systems)

1. gather tools and parts - creeper, shop rags, screwdrivers, 7/8" socket and extension, 3/8" six pt deep socket and box end wrenches, Motive Systems Power Bleeder, DOT 3 brake fluid;
2. Put vehicle level on ground for bleeding procedure;
3. Start with wheel farthest away from the master cylinder first (driver side rear);
4. loosen/tighten bleeder valve (3/8" six pt deep socket) and attach tubing to valve (after substituting 3/8" six pt box end wrench for socket) with other end of tubing placed in collection reservoir;
5. connect power bleeder to master cylinder (7/8" socket and extension) with "antique car" adapter, pump to 10 psi to test for leaks in connection;
6. release pressure and fill power bleeder with two to three quarts DOT 3 brake fluid, repressurize to 10 psi;
7. loosen bleeder valve 1/4 turn (3/8" box end wrench), close bleeder valve when new fluid runs into reservoir, tighten bleeder valve and check power bleeder pressure, repressureize as required;
8. repeat bleeding procedure on passenger side rear wheel next;
9. repeat bleeding procedure on passenger side front wheel next, then driver side front wheel last.

Engine Tune-Up

Compression

1. Gather tools - 14 mm spark plug wrench socket, ratchet and extension, wood clothespins marked 1 thru 6 to id plug wires, wood block with holes drilled and marked 1 thru 6 to hold plugs, jumper wire, note pad and pen, compression gauge with 14 mm adapter;
2. Warm up engine to operating temperature, Shut engine off;
3. Block throttle open, mark and remove spark plugs, pull coil wire from distributor and ground with a jumper;
4. Check compression on each cylinder with compression gauge and note highest setting (crank engine with starter motor until gauge reaches highest reading - about 8 revs or 4 compression cycles);
5. Compression should be 130 lbs or better and all cylinders should be within 5 or 10 lbs of each other (235 cid inline six).
6. Replace plugs and coil wire; unblock throttle.

Spark Plugs

1. Gather tools - 14 mm spark plug wrench socket, ratchet and extension, wood clothespins marked 1 thru 6 to id plug wires, wood block with holes drilled and marked 1 thru 6 to hold plugs, spark plug gap gauge/tool, replacement plugs (AC 45 for daily driving around town 235 cid inline six, if you can find them, NGK B6S if you can't), anti-seize compound and dielectric grease;
2. Warm up engine to operating temperature, Shut engine off;
3. Mark wires with clothepins and remove spark plugs;
4. Mark new plug boxes 1 thru 6 and put old plugs in boxes for later analyzation and cleaning;
5. Check new plug gaps and adjust if necessary to .035" (235 cid inline six);
6. Install new plugs with anti-seize compound on threads, tighten to 20-25 ft-lbs;
7. Replace plug wires with a dab of dielectric grease in the boots.

Battery

1. Gather tools - Voltmeter (multimeter) and two alligator clip jumpers;
2. using a jumper, connect the positive voltmeter probe to the starting switch termimal;
3. using the other jumper, connect the negative voltmeter probe to a good ground;
4. set the multimeter function to hold the minimum voltage reading, crank the engine (with ignition off) for fifteen seconds;
5. five volts or better (6 volt system) indicates a satisfactory starting circuit (ten volts? or better for a 12 volt system).

Distributor

1. Gather tools - Big ass flat blade screwdriver, small flat blade screwdriver, 14 mm spark plug wrench socket, ratchet and extension, wood clothespins marked 1 thru 6 to id plug wires, wood block with holes drilled and marked 1 thru 6 to hold plugs, feeler gauge, dwell/tach, new distributor cap, rotor, points and condenser, distributor cam lubricant and dielectric grease;
2. one-by-one, tag and remove spark plug wires from distributor cap and plugs and examine terminals for corrosion, check wires for insulation damage and oil soaking, apply dieletric grease to terminal and insert in same location in new cap;
3. remove spark plugs, place in wood block with number holes;
4. remove old distributor cap and rotor, inspect for cracks, burns and pitted contacts;
5. check distributor auto advance by turning distributor cam clockwise as far as possible, release cam and to see if springs return to retarded position;
6. replace points and condenser, crank engine (with ignition off, tranny in neutral) to get points cam follower to rest on the peak of the cam (use big ass screwdriver as lever between firewall and foot starter mechanism to operate starter motor), adjust points gap with feeler guage to .019" (new points), connect dwell/tach and turn engine over with starter to check dwell (33 degrees), check and re-adjust point gap if necessary to achieve desired dwell;
7. check vacuum spark advance by turning distributor body counterclockwise and see that the spring returns it to the retarded position;
8. re-install spark plugs, install new rotor and cap, reconnect plug wires, check coil wires for corrosion and tightness.

Ignition Timing

1. Gather tools - 1/2" box end wrench, timing light;
2. Attach timing light induction clamp to #1 spark plug wire a few inches from the spark plug, attach positive alligator clip to starter hot wire and negative clip to ground (thermostat housing bolt);
3. put tranny in neutral and set parking brake, start engine and run at idle, ain timing light at timing hole and pointer in bellhousing above starter;
4. loosen distributor clamp bolt (1/2" wrench) and rotate distributor body until steel ball in flywheel lines up with pointer;
5. In the old days, you would be finished but modern gas blends require more advance so, move the distributor counter clockwise in small increments until you reach a "sweet spot" where the engine runs smooth without hesitation on acceleration. If you get pinging, you've advanced too far;
6. tighten distributor clamp bolt, turn off engine and remove timing light.

Valve Clearance

1. Gather tools - 14 mm spark plug wrench socket, ratchet and extension, wood clothespins marked 1 thru 6 to id plug wires, wood block with holes drilled and marked 1 thru 6 to hold plugs, 1/2" box end wrench, mechanix gloves, medium blade screwdriver, 5/8" box end wrench, feeler gauge;
2. Give vehicle a warm up run, disconnect the battery, set tranny in neutral and set the parking brake;
3. id spark plug wires with clothspins, remove spark plug wires and distributor cap, remove spark plugs (with 14 mm socket) and place in wood block holder, remove valve cover (screwdriver);
4. loosen alternator/generator mounting bolt (1/2" wrench) and tighten fan belt, put on gloves and rotate engine by hand using fan blades until #1 cylinder is at TDC (Top Dead Center - distributor rotor will point towards front where #1 plug contact is when cap is in place and steel ball in flywheel is opposite timing hole pointer);
5. adjust intake valves to 0.008" and exhaust valves to 0.020" (235 ci engine severe service), adjust following valves from front to back #1 (exhaust),#2 (intake),#3 (intake),#5 (exhaust),#7 (intake) and #9 (exhaust), check valve with feeler gauge first - if blade fits with slight drag, it doesn't need adjusting, for valves that need adjusting, back off locknut (5/8" wrench), adjust (screwdriver) until the feeler gauge blade just lightly fits with a slight drag, hold adjuster screw with screwdriver and tighten locknut;
6. put on gloves and rotate engine by hand using fan blades until #6 cylinder is at TDC (Top Dead Center - distributor rotor will point towards rear where #6 plug contact is when cap is in place and steel ball in flywheel is opposite timing hole pointer);
7. adjust following valves from back to front #12 (exhaust),#11 (intake),#10 (intake),#8 (exhaust),#6 (intake) and #4 (exhaust), make sure all locknuts are tight, reset fan belt to proper tension, replace spark plugs, replace spark plug wires and distributor cap;
8. connect battery, start engine and idle, observe valve train to see if all rockers are receiving oil, turn engine off and replace valve cover.

Front Wheel Bearings

Remove Wheels and Brake Drums

1. Gather parts - wheel bearing seals, cotter pins, bearing grease, parts cleaner (gallon can with dipping bucket);
2. gather tools: floor jack, jack stands, plastic glass installer stick, impact wrench with 3/4" socket, gasket scraper, bent needlenose pliers, 1-1/16" socket wrench, brake spoon, shop rags, seal puller, bearing packing tool, grease gun, bearing seal driver, brass hammer, nitrile gloves, torque wrench;
3. jack up front end and place jackstands, remove hubcaps with installer stick, remove wheels;
4. one wheel at a time - adjust brake shoes away from the drum with the brake spoon, pry off grease cap with gasket scraper, remove rubber plug from adjuster hole on backing plate and retract brake shoes until drum is free (move outer end of brake spoon away from center of wheel), remove spindle cotter key with pliers, remove spindle nut with socket wrench.

Clean and Pack Bearings

1. Pull drum, clean grease from outer race and bearing, sumerge in parts cleaner, remove bearing seal from back of drum with seal puller, clean grease from inner race and bearing, sumerge in parts cleaner, clean other two races in place on drum;
2. with gloves on, fish bearings and races from parts cleaner and dry off with shop rags, check for pits and excessive wear, pack inner bearing with packing tool and grease gun, replace bearing, carefully drive new bearing seal into place with seal driver and brass hammer, pack outer bearing with packing tool and grease gun, replace bearing and put drum on spindle, replace washer and spindle nut.

Replace Wheels and Brake Drums

1. Torque spindle nut to 33 footpounds while rotating wheel, back off one notch and replace cotter pin, replace dust cap, wheel and snug up lug nuts, expand brake shoes with brake spoon until they drag slightly (move outer end of tool towards center of wheel), retract brake shoes until drag stops (move outer end of tool away from center of wheel), replace adjuster hole rubber plug;
2. after both wheels are finished, lower front end, torque lug nuts to 60 footpounds and replace hubcaps.

Gear Oil Change

Transmission (3 speed manual) Oil Change

1. gather tools and parts - creeper, drain pan, 1/2" open end wrench, shop rags, SAE 75W-140W Synthetic Gear Oil;
2. Give vehicle a warm up run, place drain pan, remove transmission drain plug and drain old gear oil;
3. reinstall drain plug, remove fill plug and add gear oil (about 1-1/2 pt) to bottom of fill plug hole, and replace plug

Differential (1/2 Ton) Oil Change

1. gather tools and parts - creeper, drain pan, sludge siphon, 3/4" open end wrench, shop rags, SAE 85W-140W Gear Oil;
2. Give vehicle a warm up run, place drain pan, remove differential fill plug and remove old gear oil using the sludge siphon;
3. add gear oil (about 4 pt) to bottom of fill plug hole, and replace plug

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Issued Saturday June 23, 2001

Updated Tuesday April 24, 2018

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