Service Memorandum

CONFIDENTIAL W/33l SERVICE MEMORANDUM

13 April 1959

STEERING BOX FLANGE COUPLING NUT SIX-NINETY

On original assembly, the nut retaining the coupling flange is locked in position by slightly damaging the thread with a punch or chisel.

However. as a precaution against. the possibility of the nut working loose: a lockplate, Part No. ACBB926, used in conjunction with a i" UNF nut, Part No. FNZll03 is recommended.

It is important to tighten the nut to a torque figure of 525 to 550 lbs./inches (6.05 to 6.47 kgm.) and the lock plate should be rotated or turned over to obtain the optimum locking position. At the same time the fit of the flange coupling on the worm shaft should be examined and, if necessary, the coupling renewed. CONFIDENTIAL W/31? SERVICE MEMORANDUM

28 Nov. 1958

FLEXIBLE PIPE TO CARBURETTER SIX-NINETY

PW!323 notified the introduction of a rubber pipe, Part No. ACC88?8, with clips, Part No. ACA5l03, at Car No. 8938.

This pipe will continue to be fitted as standard in production but service replacements should be made with a metal-braided pipe, Part No. ACB8725, secured with clips, Part No. ACA5ll9.

PW/3?2 and illustration No. L 79 in the Parts List refer. CONFIDENTIAL

W/320 SERVICE MEMORANDUM

9 January 1959

FITTING VACUUM SWITCH & WARNING LIGHT SIX-NINETY TO BRAKING SYSTEM (Series III)

A vacuum switch and warning light (which will light up if there is a leakage of air into the brake vacuum reservoir) can he fitted if required.

The parts required are listed at the end of this memorandum.

ACH5854 ACe8741 ------_____ Ace 8763

D ACH8979

ACH 5854

Proceed as follows:

1. Remove banjo union ~A' '(Fig.l) from servo unit. Drill and tap 5/16" @ U.N.F. as shown at 'B' (Fig.2). Refit modified union, and fit adaptor (Part No. ACB8741) with fibre washer (Part No~ ACB8764).

P.T.O. - 2 - .. 2. Drill two holes 13/64" (5.16 nun.) diameter in servo bracket flange tc' (Fig.l) according to dimension shown in Fig.3, and fit vacuum switch (Part No. ACB8762) using two pan-head screws (Part No. PMZ0382) spring washers (Part LWZ203) and nuts (Part No. FNZI03). 3. Fit to vacuum switch adaptor (Part No. ACB8741) with fibre washer (Part No. ACB8764).

4. Fit rubber hose (Part No. ACB8763) between adaptor on servo unit and adaptor on vacuum switch, using two hose clips (Part No. ACH5854)~ and secure with rubber strap (Part No. ACH8979) as shown at 'D' (Fig. 1). 5. Attach warning light bracket; (Part No, ADB4667) to underside of facia panel t approx , 18*" (479 nun. ) from centre of car on the driver's side, as shown in Fig. 2 Two holes 'E' must be drilled for self tapping screws (Part No PTZ603) ADB4667 6. A double-wire electric cable will be required. Connect the two wires at one end of the cable to the two terminal blocks in the vacuum switch as shown at 'F' (Fig. 1). Run cable along chassis, securing where necessary. At the 17H550 other end of the cable. connect one wire to terminal 'A 4: on fuse box and the other wire to snap connec'or 'G' on warning light lead under facia panel (Fig. 4). Parts reguired: DescriEtion ~No Quant~ll Vacuum switch ACB8762 I off Adaptor - vacuum switch ACB8741 2 off Washer - adaptor ACB8764 2 off Hose - servo unit ACB8763 1 off Bracket - warning light ADB4667 I off \V'arninglight 17H5508 1 off Hose clip ACH5854 2 off Rubber strap ACH8979 I off Nut FNZI03 2 off Washer LWZ203 2 off Pan-head screw PMZ0322 2 off Self-tapping screw PTZ603 2 off

PRINTED IN ENGIAND CONFIDENTIAL

W/313 SERVICE lVIEMORANDUMcanCelling W/308

3 Nov. 1958

OIL LEAKAGE FROM STEERING GEARBOX SIX-NINETY

This trouble is usually traceable to damage to the sealing ring (A) in assembly.

Such damage can be avoided by the use of a suitable pilot (B) turned to the dimensions shown.

c I • I (3·17mm )-- -n- . ~k- j ~ ~~-.-- -~:--1 I-II~ L__ L_____q-----.J '375" 2'000 (SO'80mm) (9'S2mm)

PRINTED IN ENGLAND CONFIDENTIAL

W/3l2 SERVICE MEMORANDUM

23 October 1958

IMpORTANT WDIFICATION§ Parts List Amendment NOt

Steering - From Car No. 40187 (RHD) - 'Fifteen-Fifty' ) PI'{/375 socket Body No.l9748 (approx) - 'Fifteen Hundred r ) assemblies To improve grease release Grease escape hole drilled in ball socket caps. Fibre washers fitted beneath grease nipples. Socket assemblies interchangeable provided fibre washers specified are also fitted.

Carburetter From Car No. 10985 - 'Six-Ninety' PN/370 connecting To prevent cracking at bend pipe Moulded pipe replaces straight pipe bent to shape. Interchangeable. CONFIDENTIAL

W/308 SERVICE MEMORANDUM

3 Sept. 1958

OIL LEAKAGE FROM STEERING GEARBOX SIX-NINETY

This trouble may usually be traced to damage to the sealing ring (tA' in the accompanying sketch) in assembly,

A stator tube pilot - tBt - Part No. SKI0633, is available for service purposes and should always be used in the fitting of the stator tube.

I!I~ 51<10633 --$-t :f!.375"(9.52....)

2.000" (so.eOmm) CONFIDENTIAL

W/301 SERVICE MEMORANDUM

IMPORTANr MODIFICATIONS 11 June 1958

Parts List Amendment No.

Engine mounting From Car No.10394. - Six-Ninety PV{/338 rubber - front To reduce possibility of shake at high speed Harder mounting rubbers fitted. Interchangeable in pairs only.

Gearbox - From Gearbox No.314.8 RHD ) Six-Ninety ) selector & 7175 LHD ) (standard gearbox) operating 1605 RHD ) Six -Ninety ~ Fn/338 levers & 1072 LHD ) (overdrive gearbox) ) cross-shaft To provide firmer anchorage for levers Levers splined to cross-shafts and retained by screw instead of cotter pin, washer and nut. Interchangeable in sets only.

Front seats From Car No.lOO4.8 - Six-Ninety Fn/34.3 Added comfort Front cushion roll raised to improve support; shape at squab now concave to improve fit. Seat assemblies only interchangeable in pairs.

Rear axle- From Car No.17254. - Fifteen Hundred PN/34.4. case and Improved design rubber buffers Spring seats strengthened. Rubber buffers modified to suit. New axle may be used on earlier cars if modified buffers are also fitted. CONFIDENTIAL W/297

SERVICE MEMORANDUM

24 April 1958 Il\1PORJ'ANT flDDIFICATIONS

Parts List Amendment No.

Gear lever From Car No.9913 - Six-Ninety PW/323 draught excluder To improve dust sealing

Material changed from leather to plastic,

Interchangeable.

Gearbox - From Engine No. 5569 - Six-Ninety PW/326 rear extension oil seal To improve oil sealing

Synthetic rubber oil seal replaces leather type.

Interchangeable.

Automatic From Car No.9660 - Six-Ninety PW/320 transmission - selector rod To increase clearance between selector rod and converter housing

Selector rod re-shaped.

Interchangeable. • CONFIDENTIAL

W/296 SERVICE MEMORANDUM

20 March 1958 IMPORTANT MODIFICATIONS Parts List Amendment No.

Rear door From Car No,9760 - Six-Ninety PW/323 glass & felt To improve sealing Bottom edge of glass re-shaped, and extra felt fitted. Interchangeable together,

Manumatic Commencing Car No. not available - PW/322 clutch -Fifteen-Fifty control unit (with Manumatic clutch) To improve operation Control unit with modified internal mechanism introduced. Interchangeable as an assembly.

Clutch and From Engine No. H.5813 - Fifteen-Fifty PW/326 flywheel (with Manumatic clutch) Improved design Introduction of 8" (203.2 mm , ) diameter clutch. Flywheel modified to suit. Interchangeable together.

Inlet From Engine No. L.13101 -_fifteen-Hundred ) manifold H.6957 )_ F'ftee -Fift ) No L.6631) ~ n y ) change ) H.6413) - Fifteen-Fifty in ) L.4323) (with Manumatic Part No, ) clutch) )

Improved design Thickness of carburetter mounting flange bosses and fillet radius between flange and induction track increased, Interchangeable. .. CONFIDENTIAL

W/296 SERVICE MEMORANDUM

20 March 1958 IMPORTANT MODIFICATIONS Parts List Amendment No.

Rear door From Car No.9760 - Six-Ninety PW/323 glass & felt To improve sealing Bottom edge of glass re-shaped, and extra felt fitted. Interchangeable together.

Manumatic Commencing Car No. not available - IW/322 clutch -Fifteen-Fifty cont rol unit (with Manumatic clutch) To improve operation Control unit with modified internal mechanism introduced. Interchangeable as an assembly.

Clutch and From Engine No. H.5813 - Fifteen-Fifty FW/326 flywheel (with Manumatic clutch) Improved design Introduction of 8" (203.2 mm ,) diameter clutch. Flywheel modified to suit. Interchangeable together.

Inlet From Engine No. L.13l01 - Fifteen~undred ) manifold H.6957 ) ) - Fifteen-Fift~ No 663l ) ) Le change ) Fifteen-Fift~ in H.64l3) - ) L.4323) (with Manumatic Part No. ) clutch) )

Improved design Thickness of carburetter mounting flange bosses and fillet radius between flange and induction track increased. Interchangeable. CONFmENTIAL •

W/295

SERVICE MEMORANDUM CANCELLING W/24.1

6 March 1958 REPLACEMENT OF GEARBOX LEVER RUBBERS SIX-NINETY

Attention is drawn to item No.3 in Service Memorandum No. W/235, 7th July, 1955.

It is desirable that the steel bush, Part No. ACH5897, which was introduced to replace the rubber grommet, Part No. ACH5123, fitted to the shifter and selector levers, should be fitted to all cars prior to No.634.

The sketch shows the method of assembly, 'Ao being the new bush which should be brazed into position, 'Bw a 5/16 in. plain washer, Part No. PWZl05, and IC' anti-rattle washers (2 off), Part No. AWZI05. • CONFIDENTIAL

W/292 SERVICE MEMORANDUM

30 Jan. 1953 li\IPORTANTtlIODIFICATIOnS Parts List Amendment Ho , Rear sprinGs From Car NO,91Gl - Six-Ninety PW/315 - front and To improve suspension rear shock absorbers Lower rate rear springs introduced, Settings of front and rear ahocI;:- absorbers modified to suit, Rear bump rubber brackets on chassis frame also modified (but chassis frame Part No, unchanged).

l.Iodifiedchassis frame will service previous type but other items are not interchangeable.

Windscreen Commencing Car No. not available - .?V/294 wiper and Fifteen Hundred blade To prevent bonnet fouling wipers when in open position

Modified wiper arms and blades introduced,

Interchangeable. CONFIDENTIAL

W/289 SERVICE MEMORANDUM

31 October 1957 SUBJECT: CONTINUOUS HORN CONTACT SIX-NINETY

Investigation has proved that this complaint is due to variations in the taper of the steering wheel boss and its seating on the top tube.

With the addition of a ring, Part No. ACC6143, as shown in Fig.l below these irregularities may be rectified in the majority of cases.

Where the ring fails to provide a cure, it is recommended that .312" (.79 mm , ) should be removed from the top end of the tube, as shown in Fig.2.

Ace 6143

n '312 (·79rnm) I • CONFIDENTIAL W/288 SERVICE MEMORANDUM

10 Oct. 1957. SUBJECT: IMPORTANT I\DDIFICATIONS Parts List Amendment No. SIX-NINETY (Series III)

Gear lever From Car No. 8146 PW/283 gaiter To protect gearchange mechanism. Leather gaiter fitted to end of gear lever beneath floor line.

May be fitted to earlier cars with side gearchange.

Rear axle: From Car No. 35858 PW/284 to Front PW/286 suspension Standardisation

Standard B.M.C. fB' type rear axle introduced.

Front suspension assemblies mOdified to incorporate separate hubs and brake drums.

\Vbeel cylinders and brake pipes modified to suit.

Not interchangeable. CONFIDENTIAL

W/286 SERVICE MEMORANDUM

SUBJECT: 19 sept. 1957 IMPORTANT MODIFICATIONS

Parts List SLX-NINETY (SERIES ~I12 Amendment No.

Cylinder head From Eng1ne No, H.8l77 *) PW/272 & Distributor ~3¢) a) To improve coo.rang oet,ween Nos. 2 and 3 and Nos. 4 and 5 cylinders b) To 1.1'l!prov~performance Exhaust ports redesigned. Lip removed from Gombustion chamber and distributor with modified advance curve introduced.

Interchangeable tOGether. * plus H.8175 ¢ plus L.8037, L.8039, L.8041 and L.8043.

Spare wheel From Car No. 7946 PW/275 carrier - ~~ preven clamp becom1ng loose clamp assembly Int oductton of clamp assembly with UNC threads repla~ing Acme type. Interchangeable as an assembly. Carburetter- From Engine No. H.817~ Nil needle Changed from BV to No.1

FIFTEEN-FIFTY 'Jack From Car No.35202 (plus 35197) PW/273 To lmprove jacl<.ing Circular spigot replaces square spigot. Jack~ng channels on body modified to suit. NOT interchangeable. CONFIDENTIAL

W!285 SERVICE MEMORANDUM

SUBJECT: 15th August 1957 NON-INTERCHANGEABILITY OF OIL FILTER ELEMENTS SIX-NINETY

When replacement of the oil filter element becomes necessary, it is essential that the appropriate make is fitted, There are two types of oil filter assembly - Tecalemit and Vokes - and although these are interchangeable as complete assemblies, the respective elements are not, This is because the Tecalenit filter feeds oil from outside the eleTIent, whereas the Vokes element is fed fron inside If a Tecalemit element is used in a Vokes f:_l.lter) it will balloon and seal tight against 'the wall of the filter bowl, thereby causing oil starvation. Conversely, if a Vokes element is used in a Tecalemit filter, the oil will by-pass the filter and feed unfiltered oil to the engine, Advice as to the type of replacement element to be fitted appears on the filter bowl but it would seem that this is insufficient warning (in the case of the Vokes filter, the transfer becomes indistinct as it ages) and pending some other arrangement it is recommended that cars in service should have their filter bowls clearly labelled. TECALEl\lIT oil filter assembly Part No. lB2897 " " " element Part No. 2II4340 VOKES oil filter assembly Part No. AECGOI " " " element Part No. 7IIl927 CONFIDENTIAL

W/284. SERVICE MEMORANDUM

27th June, 1957. SUBJECT: JNPORTANT MODIFICATIONS Parts List Amendment No.

Connecting From Engine No.H.8151 - Six Ninety ?W/262 rod and pistons Improved design

Connecting rod with fully - floating small end introduced. Pistons and gudgeon pin modified to suit. Interchangeable in engine sets only. Cylinder From Engine No. 7675 - Six Ninety. block To increase rigidity of block

Ribs on block rear face extended and added to both sides of block.

Interchangeable.

NB. Only the low compression cylinder blocks and stripped engines have revised part numbers in respect of this change. The corresponding high compression part numbers are unaffected.

Gasket - From Engine No. H. Zl63 ) - Fifteen - fifty ) No cylinder L. 2394 ) ) change head L. Z74) - Fifteen Hundred ) in Part No. To improve sealing Copper ferrules fitted to the eight holes on right-hand side of gasket, i. e. immediately below sparking plugs.

Interchangeable. CONFIDENTIAL

SERVICE MEMORANDUM

27th June, 1957. SUBJECT: ll1PORTANTMODIFICATIONS Parts List AmendmentNo.

Connecting From Engine No.H.8l5l - Six Ninety ?W/262 rod and pistons Improved design

Ribs on block rear face extended and added to both sides of block.

Interchangeable.

~rn. Only the low compression cylinder blocks and stripped engines have revised part numbers in respect of this change. The corresponding high compression part numbers are unaffected.

Gasket - From Engine No. H. 2763 ) - Fifteen - fifty ) No cylinder L. 2394 ) ) change head L. 274) - Fifteen Hundred ) in Part No. To improve sealing Copper ferrules fitted to the eight holes on right-hand side of gasket, i. e. immediately below sparking plugs.

Interchangeable. CONFIDENTIAL

W/282 SERVICE MEMORANDUM

16th May 1957 SUBJECT: IMPORTANTMODIFICATIONS Parts List SIX-NINETY AmendmentNo.

Gasket - cylinder From Engine No.7967 (plus PW/257 head 7767 to 7818)

To improve sealing

Height of corrugations around the three .40611 (lO.31 nnn) dia. and three .594" (15.09 mm) dia. holes increased from. 01l1'/. 01311 (.2:79/ .330 mm) to .016"/.018" (.406/.457 mm). Similar modifications around the six water assages~~us:

Interchangeable.

Windscreen PH/255 wiper blades To improve llwipe" and prevent ~;3tch1~ Blades of improved design introduced

Interchangeable. CONFIDENTIAL \-[/280 SERVICE MEMORANDUM

7th Harch.195" SUBJECT: IMPORTANT HODIFICATIONS

Parts List Amendment No.

SIX-HIHETY Clutch fork and From Engine No.7704 PH/229 lever; slave lmpr:)ve- d dp.s~gn. cyli nder push -rod l~odified clutch fork and lever introduced necessitating longer slave cylinder push-rod. Parts interchangeable in pairs only. Door locks From Car No. 7506 Pvl/232 ~o provide children t s safety lock Front and rear dQor l~~ks now incorporate safety lo~king device. Door inner oanels modified t~ suit (but no change to door part n imbez-s ) Hew Locks can be fitted to earlier carn by slotting inner door panels. Gearbox dip- From Car Ho. 7578 PH/234 stick cover To improve dust sealing Daps ti ck co-res: now has four fixing holes instead of t~0. New cover can be fitted to earlier cars if additional holes are drilled in tunnel. CONFIDENTIAL ii/275 SERVICE MEMORANDUM

3rd Jan 1957 SUBJECT: n1PORTANT HODIFICATIONS Parts List ~endment No. SIX-NINETY

Steering From Car No.7297 - LHD P\J/ 204 '-box :a reduce steering effort 20:1 ratio steering box replaces 18:1 type

Interchangeable ( See Service Memorandum No.\v/273 re RHD cars) fIFTEEN-FIFTY

Door locks From Car No. 1283b PH/204 To provide childr~r.'s safety lock

Front and rear door locks now incorporate safety locking device. Door inner panels modified to suit (but no change to door part numbers)

Engine mounting From Car Jo,32822 Pt~/204 rubbers - front To prevent gear lever vibration

Harder mounting ruboers introduced

Intercp~geable in pairs. CONFIDENTIAL

W/Z74 SERVICE MEMORANDUM

3rd Jan 1957 SUBJECT: II iPOW~A:rTHODIFICATIOllS Parts List AmendmentNo.

SIX -FIllErY

Carburetter Frot:1Engine Ib.H.7367 Nil - needle Changed f'r-on CR to TB

~.ay be fitted to earlier high conpression eng;nes in pairs.

FIFTElli! -I'TFTV

Cylinder head Fl 00 Engine lb. L.60S Nil -heater H.7ll (No change out.Let in Part Ho.) To reduce restriction in flow from headtO heate'!" outlet pipe Diuneter of outlet increased fron .5" to .625" (12.8 to 15.87 mo).