"MOTOR TRADER" Service Data No. 369 MORRIS MINI-MINOR Manufacturers : B.M.C., Ltd., Cowley, Oxford
All rights reserved. This Service Data Sheet is compiled by the technical staff of MOTOR TRADER, and is checked by the vehicle manufacturers. It is the copyright of this journal, and may not be reproduced, in whole or part, without permission.
OMPLETELY revolutionary in design concept, this car was first introduced in July 1959. Since this time, various modificationsC have taken place which affect the service procedures to a greater or lesser degree and it is for this reason that we have delayed producing an article in our service data series for this model. The body design of the car is a two-door, four-seater saloon, and due to the adoption of a completely new suspension layout coupled with a complete revision of the mechanical disp'Osition of the major components is actu ally capable of containing more within it than its compact dimensions would otherwise sug gest. Chief points of interest, from a mech anical standpoint are centred around the combined engine/ transmission unit which is DISTINGUISHING FEATURES. Instantly recognizable from any standpoint, the arranged to drive the front wheels and the four-wheel independent suspension layout, car is a two-door saloon. In the accepted sense, it is also a '' four-light,'' but in which uses rubber as the suspensory medium. fact the slender screen and door pillars give all-round vision. Briefly, the four-cylindered engine is of unit construction with one reverse gear and four forward gears assembled into a combined ENGINE Removal transmission casing and oil sump below the Engine/ transmission unit are best removed engine crankcase. The whole unit is trans Mounting from the vehicle, complete with sub-frame, versely and flexibly mounted, with the main Engine/ transmission unit is mounted on a from beneath. The engine may be removed shaft in constant mesh with the differential sub-frame, which is in turn bolted up to abut from the car through the bonnet aper gear which is mounted on the transmission ments on body front section at either side by ture provided facilities exist for work to be casing side. Drive from the engine is taken two b9lts and nuts (each side of bulkhead carried out beneath the front of the vehicle. back to the gearbox through a single dry plate cross member); four setscrews securing rear To remove unit with sub-frame, unscrew hydraulically operated clutch, and thence by end of sub-frame to front floor panel and two hexagon plug and remove anti-rattle spring an idler and constant mesh gears to the differ screws securing front of frame to bottom of and plunger from gear change extension ential unit of the final drive assembly. Drive grille panel. Rubber mounting blocks are casing. Remove two set screws securing to the front road wheels is effected by uni bolted up to abutment brackets either side of change speed lever retaining plate to casing versally jointed drive shafts, which are splined unit and to sub frame side members and body and pull lever out of casing from inside car. at their inner ends for axial movement, from mounting points respectively. Disconnect earth lead from battery1 bonnet the differential side gears. Right-hand mounting is located with from hinges and remove bonnet. Disconnect clutch cover, and should be removed with all pipes, wires and controls to unit and re Cup and cone type suspension units are cover when dismantling. Remove three set move carburettor. Unscrew sleeve nut and used at the front and rear of the car, and a screws to release mounting from cover. release speedometer drive cable from back of feature of this layout is that little periodic Tighten all bolts and nuts fully on reassembly. attention is required for correct maintenance. instrument. Disconnect hydraulic brake Steering is by direct acting rack and pinion. Identification of vehicles is by chassis and engine serials and these follow the usual B.M.C. pattern and practice, consisting of a serial number with prefix letters. The first letter indicates make i.e. M =Morris; 2nd letter, the model (c.c. capacity) A=800-900 c.c.; 3rd letter the body type, 2S=2-door saloon; 4th prefix the series of model, 4 =4th series; and the 5th prefix is used to denote differences from standard right-hand drive, i.e., L=left-hand drive. In addition to the above, engines are also serial numbered and a breakdown of the coding together with the 'significance of the letters and symbols is to be found on p. ii. Engine serials are to be found stamped on a plate which is secured to the right-hand side of the cylinder block, above the oil filter. Chassis numbers are to be found stamped on a plate secured between the radiator and the wing valance. It is important that all these serial letters and numbers are quoted when INSTRUMENTS, CONTROLS, GEAR POSITIONS AND BONNET LOCK ordering spare parts or when corresponding 1. Speedometer 8. Clutch pedal 15, Ignition switch with the makers. 2. Main beam warning lamp 9. Starter switch 16. Screen wiper switch Special tools for speeding up certain repair 3. Ignition warning lamp 10. Handbrake 17. Heater switch operations are available from the makers or 4. Fuel cauge 11. Headlamp dip switch 18. Direction indicator warninr 5. Oil pressure warninc lamp 12. Gearlever lamp their agents and a list of those considered the 6. Accelerator 13. Choke control 19. Direction indicator. more essential is to be found on p. ii. 7. Brake pedal 14. Lighting switch 20. Horn push. Threads and hexagons are in the main of Inset upper left shows sltinc of steering column mounted controls, and below is shown detail of the bonnet safety the Unified thread series pattern and form. catch and method ol external release. ii MoRRrs Mrnr-MINoll. Supplement to "Motor Trader," 28 June 1961
supply pipe at three-way union on engine bulkhead and plug union with clean ¾in UNF GENERAL DATA screw. ENGINE DATA Remove exhaust system and support body Wheelbase 611 8in with suitable slings underneath each front General Track: front 311 11,',-in wing. Remove two setscrews securing slave Type 8 MB rear 3ft 9iin cylinder to flywheel housing, release lever No. of cylinders ... 4 Turnlnc circle 29ft 6in Bore x stroke: mm 62.94 X 68.26 Ground clearance 6iin tension spring and extract push-rod from in 2.478 X 2.687 slave cylinder securing cylinder against Tyre size: lront 5.2�10 Capacity: c.c. B48 rear } engine bulkhead. CU in ; �1.7 Overall length 1011 0¾in Disconnect steering rack ball ends from R.A.C. rated h.p. . .. 9.8 Overall width 4ft T½in steering levers and remove telescopic dampers. Max. b.m.e.p. at r.p.m. 128 lb/sq in@@ Overall height 4ft &in �900 Weicht (dry) ... 1,3301b Release engine tie rod from bracket on rear Max. torque at r.p.m. 44 lb/It of cylinder block. Support engine beneath 2900 transm:ssion casing, undo Jock plate tabs and Compression ratio .. 8.3 : 1 withdraw four body/sub-frame bolts, two each SPECIAL TOOLS side of bulkhead cross member. Take out four screws securing rear of sub-frame to Part No. front floor and two screws securing front CRANKSHAFT AND CON. RODS frame to bottom of grille panel. Main Bearings Crankpins ENQlNE Arrange lifting tackle and lift body clear of ValvTseat cutter handle ... 18G27 Valve seat cutter pilot ... 18G167D engine, and withdraw engine/sub-frame unit. Diameter 1.7505-1.751in 1.6254• 18G167 Care should be taken during removal to see 1.6259in Valve seat finishing cutter ... r Valve seat glaze breaker .. . 18G167A that damage to radiator and cowling and also Len th ... 1.187in Valve seat narrowinc cutter (lop) ... 18G167B ! to steering rack rubber gaiters is avoided Running clearance: main bearings Valve seat narrowing cutter (bottom) 18G167C during lifting process. .0005-.002in Crankshaft gear and pulley remover 18G2 big ends .001-.0025in Crankshaft gear and pulley replacer 18G138 End float: main bearings .. . .002-.003in Bearing and oil seal rep lacer ... 18G134 To Remove Engine from sub-frame big ends ... .008-.012in Crankshaft primary cear oil seal re• Undersizes (max.) ...... 040in placer adaptor ...... 18G134BC Drain oil from transmission casing and dis Con. rod centres .. . • . . . .. 5.750in Timing case oil seal replacer adaptor 18G134BD connect drive shafts at inner ends. With sub No. of teeth on starter ring gear/ Oil pump release valve grindinc-in frame supported under both side members, pinion ... tool ...... 18G69 take weight of engine unit with lifting tackle Shock spanner ...... 18G98 and remove two screws securing each engine c ,------,----PISTONS AND RINGS --, Flywheel and clutch remover adaptor 18G304L mounting to sub-frame, and lift engine up I Camshaft liner remover and replae, (basic tool) ...... 18G124A and clear of frame. Note: paper gaskets are Clearance (skirt): bottom ... .0006-.0012in Camshaft liner remover adaptor ... 18G124K fitted between engine mountings, sub-frame top ... .0026-.0032in Camshaft liner reamer (basic tool) .. . 18G123A and clutch cover on engines up to Eng. No. Oversizes ... .010, .020, Camshaft liner reamer pilot-centre 18G12JAH 4354. It is essential that new gaskets are .030, .040 Camshaft liner reamer pilot-rear .. . 18G123AJ refilled similarly to all engines up to this serial Gudgeon pin: diameter .. .624in Camshaft liner reamer cutter ... 18G123AN number. fit in piston hand push Flywheel and lront hub oil seal re• fit in con. rod bolt clamped placer (ada�tor) ...... 18G134BH Refitting is a reversal of previous pro Crankshall primary gear oil seal pro• cedure, but care should be taken to ensure Compression Oil Control tector sleeve ..• •.. . .. 188570 that electric lead to rear of car is not trapped TRANSMISSION between body and sub-frame. Tighten steer No. of rings .. . 3 1 Laygear needle roller bearrn� replace, 188194 ing arm ball joints to 251b. ft. Gap ...... 007-.012in .007-.012in Impulse extractor-basic tool ... 188284 Side clearance in First motion shaft remover adaptor 18G284B It is most important to ensure that when grooves .. . .0015•.0035in .0015-.0035in Dummy layshalt ...... 18G471 exhaust system is assembled to car, pipe/ Width of rincs ... .069-.070in .124•.125in First motion shall bearing circlip manifold clamp is slack to allow movement rauge ...... 18G569 and then to wedge engine to line up hole Synchromesh unit assembly ring .. . 188572 in tie rod with threaded hole in cylinder ,------,------CAMSHAFT ---- Change speed shall oil seal reface, .. . 188573 block; moving sub-frame attachment bolts as Differential bearin replace, ... 188578 in situ, Front Centre Rear First and third mof ion shaft bearing necessary. With unit sufficient slip replacer ...... 18G579 packings to fill gap between transmission Bear.Inc Journal: Front suspension and idler cear needle casing Jug and pipe support stay should be diameier ... 1.6655• 1.622- 1.372• bearing remover ...... 188581 inserted and bolt tightened. If hole in lug 1.666in 1.623in 1.37Jin First motion shall spigot bearing re• is threaded, it should be drilled out for 5/16in mover adaptor ...... 18G581B bolt to replace setscrew. Exhaust pipe/ Bearing clearance: First motion shall spigot bearing re• Front ...... 001-.0021n placer . .• ...... 18G589 manifold clamp should be tightened, also Centre and rear .00125-.00275in Front suspension and Idler gear bear- pipe and tail pipe support clips and wedge End float .003·.007in in replacer ...... • •• 18G582 · removed from bulkhead. Timingi chain: Finaf drrve gear nut spanner ... 18G586 t!��f iinks ::: iin FRONT AND REAR SUSPENSION 52 Hub bearing outer race remover (basic Crankshaft tool) ...... 18G260 Three main bearings, thin wall steel-backed, Front hub drive flange bearing outer white metal-lined located by tabs. End float VALVES race remover adaptor ...... 18G260H controlled by split thrust washers recessed Suspension rubber spring compressor 188574 Inlet Exhaust Front and rear hub remover (basic either side of centre main bearing and re ... tained by tabs in cap. Fit with oil grooves I tool) ...... • ... 18G304 Head diameter ... 1.093-1.098in 1.00-1.006in Front and rear hub remover bolt to crankshaft, no hand filling permissible. . .. 45' I stem diameter .2793•2798in .2788-.s,ain" adaptor ..• ...... • .. 18G304F Main bearings cannot be changed with Face-angle 45' '\. Rear radius arm brush remover ... 188583 engine in place1 nor may thrust washers, etc., Rear radius arm brush replacer ... 188584 be changed, wahout removal of engine and SprinJ lenrth: Rear radius arm brush reamer ... 188588 transmission to achieve access to crankshaft. free ... 1.750in Pressure at load·,·... ,.. Flywheel, with shrunk-on starter ring gear, valve open a5 1Ji� spigoted on rear flange of crankshaft and valve closed 52.5 lb retained by four equally spaced setscrews. No. of ...working. .. 4½ NUT TIGHTENING TORQUE DATA Oil-impregnated spigot bearing bush pressed coils lb/It into end of shaft. Timing sprocket and pulley hub, with oil POWER UNIT SERIAL.NUMBER CODING ...... thrower between lip to front, pressed on (Up to Engine No. 8MB25000J ENGINE AND TRANSMISSION... Cylinder head stud nuts . .. 40 front end of crankshaft, sharing special flat 1st PREFIX1st Prefix GROUP-Cubic number: 8-850 capacity, c.c. make and type Con. rod big-end bolts ...... 35 Woodruff key, and retained by hexagon headed 1st Prefix letter: M-Morris Main bearin& setscrews ...... 60 2nd Preftx letter: B-Variation of engine ...... setscrew. Sprocket fits with longer boss to type Flywheel centre bolt ... 110/115 rear, with shims behind for alignment. Pulley Gudgeon pin clamp screws ...... 25 Crankshaft pulley nut ...... 70 hub passes through felt sealing ring in timing U-Centre gear change gearbox . 1st rotation shall nut 90 cover. 2nd PREFIX GROUP-Gearbox and ancillaries 3rd motion shaft nut ...... 20 H-High compression and serial number of unit. e ng boltsJand stud nuts 18 3rd GROUP-Compression and serial number �\�t ����� ...... Connecting Rods Driver gear./diff. cage ...... 60 Big ends thin wall, steel-backed, lead (From Engine No. 8AM25001) Drive shaft flangenub ... 60 bronze or copper lead shells, tin-plated sur Diff. housing end bolts ...... 18 face, located by tabs. No hand fitting per 1st PREFIX1st Preftx GROUP-Cu�ic number: 8--850capacity, c.c. make, and type SUSPENSION AND STEERING ... missible. Rods split diagonally, cap and rod Jst Prefix letwrs: AM-Morris steerinc lever/ hub bolts 35 stamped on same side and shouldered for steerlnr lever/ball Joint ... 6025 U-Ccnt.re gear change gearbox Front hub nut (drive shaft) ::: location with caps. 2nd PREFIX GROUP-Gearbox and ancillaries Big ends are offset. Fit Nos. I and 3 Rear suspension stub axle nut ... 60 H-High compression and serial number of unit Front suspension upper arm pivot nut 26-28 I with larger boss to rear, 2 and 4 to front. Oil 3rd GROUP-Compression and serial number - Supplement to "Motor Trader," 28 June 1961 MORRIS MINI-MINOR iii bleed hole on longer side of big end must go Initiong from the flywheel end of the crankshaft, to side away from camshaft. Vacuum and centrifugal advance distribu through an idler gear to the constant mesh Gudgeon pins cotter-clamped in small ends, tor spigot mounted on engine crankcase (to pinion on the gearbox mainshaft. A helical clamp towards camshaft. Fit of pins in pis gear on gearbox output shaft drives the main tons is, to some extent, selective. Gudgeon front ot vehicle). To check timing, remove clutch pit inspec differential gear (which replaces the crown pins must be thumb-push fit for three-quarters wheel in conventional layout). This, in turn, of their travel and tapped home with rawhide tion cover and with aid of a mirror, the TDC ¼ and timing marks will be visible on rotation . is bolted up to the differential gear and drive mallet; pistons and pms cold. of the engine. Timing is correct when, with· is taken from this unit via short shafts to piston at TDC No. 1 compression ¼ mark road wheels. Pistons on flywheel is in line with pointer on clutch Aluminium alloy, T-slot, aluininited finish, cover, or that in a similar• engine position To Remove Transmission with dished crown. dimples on crankshaft and camshaft timing Remove engine as detailed in engine sec- Top compression ring plain, second and gears are lined up.' Slot of spindle ,drive dog tion. Take off eight setscrews and remove third rings taper faced and must be fitted is offset an? when. cc_,l'tectly assembled will clutch cover plate and extract flywheel and with sides marked "TOP" upwards. Engine/ as�ume 1 o clock pos1fion,, large segment 11{., clutch (see clutch section above). Remove transmission unit must be removed from car dnve dog uppermost. See data tables p. V!f. starter motor, flywheel housing and withdraw for removal of pistons. for further data and figures performance ,:}�� .12 _setscrews from transmission case flange, Big ends will pass through bores, but notes at foot of Tune-UP Data rega�, • nop.ng lengths and positions fitted. Lift pistons will not pass crank throws. Remove static ignition timing. • , ' � engin�, and part engine and assemble through top. from transmission • �,case. C l g s Camshaft �:�: f!! ::: thermosyphon thern1�stat. ,. � Reassemb el Transmission Single-row roller endless chain drive. Cam located in water o\itlet port of cylinder q.e�. · Refitting is a reversal of dismantling pro- shaft sprocket spigoted on camshaft, keyed Owing to the lateral dispositio!l, of '/:,_ne; !rds, note following points: Renew all with Woodruff key and retained by nut. No engine/transmission unit, and ind'e!se� air ·gaskets, etc., clean off joint faces. If new alternative fitting for valve timing. Crank flow caused by suction resulting frorn fadihg gear train is fitted, check idler gear endfloat shaft and camshaft sprockets must be the matrix in the nearside front wi a�c'ii, before transmission case is refitted. When removed and assembled together. a blower fan is fitted and care should b� ken refitting housings tighten evenly, to ensure Dot-punched timing marks on sprockets to see that this ·is replaced correctly. . good jointing and correct location of crank- must be together when chain is fitted, with Pump. has carbort seal and should not be. shaft primary gear, roller gear and first No. 1 piston at T.D.C. on compression stroke. over lubrkate Parts �f unit sh Diagram showing order of tightening rela cylinder head stud nuts. See also _ table of '' Nut Tightening Torque Data." 'PPlement t o " Moto r .,..,..r a der ," 2 '8 J'l'li tz e 196/ . I d trans :>n1 mission Ponents assem bly. Jn 1 f vi MORRIS MINI-MINOR Supplement to "Motor Trader," 28 June 1961 - strainer bracket screw, lockplate, withdraw setscrews in cover evenly. Fit left-hand final strainer assembly. Release locknut and slacken drive cover withQut joint washer. Tighten off 3rd/ 4th gear selector fork locating set setscrews so that cover register nips bearing CHASSIS DATA I screw. Withdraw rod and remove fork from outer race; check evenness of tightening with ...... casing, followed by reverse gear shaft, gear feeler gauges. If feelers cannot be inserted, Clutch .,. Make ...... BMC and selector fork. Extract detent spring and shims must be added between cover flange Tfpe ...... •·· s.d.p. plunger. Release. circlip from reverse gear and housing shims, up to .008in thick, be Diameter ...... 7tin shifter lever pivot pin and take out lever. tween outer race and register on end cover. Material No...... wound yarn Compressed thickness of cover joint washer Pressure lp;iiics: ...... 6 To Dismantle 3rd Motion Shaft is .007in. Bearing pre-load is .001-.002in. colour...... red spot Damper springs Nil Withdraw top/3rd gear synchro. hub froni Any deviation from these tolerances must be front end of shaft (plain side of hub to rear made up with shims. With tolerances GEARBOX of gearbox). Remove front thrust washer by established remove end cover, refit joint ... depressing spring loaded locating plunger and washer and tighten up cover screws. Tighten Type ...... 4synchromesh diff. housing nuts, refit driving flanges to diff. No. of forward speeds...... rotating washer until splines register with Final ratios: 1st ...... ··• 13. 657 : 1 those on shaft. Take out plunger and spring, gear shafts securing with slotted nuts and ... split pins. Ensure equal freedom of drive 2nd 8.176: 1 followed by 3rd gear bush and interlocking 3rd ...... 5.137: 1 ring. Draw off 2nd speed gear and bush. shafts. Fit operating lever to splined end of 4th ...... 3.765: 1 Remove rear thrust washer, 1st speed gear gear change operating shaft and align recess Rev. 13.657: 1 and hub. If 2nd/3rd or 4th speed striking with drilling in boss. Refit remote controls and replace bottom cover plate. DRIVE SHAFTS dogs and hubs and cones are parted, pre ...... •·· ... serve three balls and springs located in each Finally, refit transmission casing complete ... . . to engine assembly. This is a reversal of Make . Hardy Spicer hub. Reassembly is reversal of dismantling Type f Hemispherical procedure, noting that end float of 2nd and removal procedure detailed earlier in this joint 3rd speed gear when assembled on shaft must section; ensuring that all gaskets, etc., are be .0035-.00SSin. renewed and that tolerances quoted earlier FINAL DRIVE are adhered to...... To Reassemble Transmission Unit Differential ratio I 3.76& : 1 Drive Shafts Press reverse gear shifter lever pivot pin BRAKES ...... into its drilling in casing and fit lever, secur Hardy-Spicer-Birfield constant velocity joints. Hemispherical interior of driven shaft Typ, Lockheed ing it to pivot with circlip. Place reverse ...... hydraulic gear and fork in position to engage reverse and exterior of driving shaft have six grooves Drum diameter ... , .. . .. 71n shifter lever and push reverse gear shaft machined axially, and a ball cage carrying Lining: length ...... 6.25in through centre web of casing into gear; plain six steel balls interposed between each. Ball width ... •·· 1.25in- end foremost, slotted end exposed. Insert re bearings engage grooves of each member and thickness...... verse selector rod interlock spring and key them together, also allowing free hingeing Material M32 plunger, also reverse selector rod in casing between each part. SPRINGS from front to pick up fork on rod insertion. Rubber boot coverings should be examined Similarly fit 3rd/4th gear selector rods and periodically for wear and replaced if this is Front Rear forks, fitting fork setscrews and lock up with evident. No provision for adjustment; com ...... - wire. plete drive shaft must be removed to fit new Type Rubber cone sering Replace oil pick-up strainer in casing, refit boot. Toe in - .,n Camber ... - 10 pos screws leaving nuts slack. Smear sealing Radius arm bushes ring with grease to facilitate suction pipe (reamed bore) .8125-.8130in insertion. Refit 3rd motion shaft in casing, CHASSIS slotted end first, through centre web, so that Brakes 1st and 2nd synchro hubs engage selec tor forks. Place ball bearing on mainshaft, Lockheed hydraulic, with pressure-limiting SHOCK ABSORBERS insert assembly into casing. Position 3rd valve in circuit. Two leading shoe front ...... brakes with separate cylinder for each shoe. Type Tubular Teles- motion shaft bearing in centre web of casing, ...... lining up 1st and 3rd motion shafts. Drift Leading and trailing rear brake layout, with copic both bearings into position (Tool No. lSG- lever operation of shoe expanders for hand Service Replacement. 579 together with distance collar) so that brake operation by cables. outer race will be driven into casing and Square ended adjusters on each brake back STEERING BOX inner 'race on to 3rd motion shaft simul plate. Turn adjuster clockwise until brake ...... taneously. drum is locked and back off one " click," or Type I Rack & pinion Refit 1 st and 2nd speed selector forks and until drum is just free to rotate. Handbrake adjustment usually compen Adjustments: ...... , rod, retaining screw and locknut. Refit is pinion end float ...... Shims 1st/2nd and 3rd top selector rod detent plun sated by adjustments as above. As additional rack backlash I Damper pad gers and springs also sealing washers under check, set handbrake pawl to 5th notch on head of screwed retaining plugs. Replace ratchet, raise car on jack and adjust nuts at drive pinion, lock washers and nut on front handbrake lever until rear wheels are just FRONT-END SERVICE DATA I ...... 3' of 3rd motion shaft and 1st motion shaft free to rotate. ° ° Castor ...... 1 pos-3 gear. Fit pegs of lock washer to holes in ° Rear Suspension Camber ...... pos gear. Refit laygear, thrust washer at each end King pin inciinatio·•· ...... 9 30' and slotted shaft end to front. End float of Independent, cup and cone type units, Toe-out , ...... i'rin2- laygear should be .002-.006in with washers rubber used as suspensory medium. Suspen No. of turns lock to lock ... fitted. Revolve layshaft so that slotted end Adjustments: castor Nil sion is mounted on a sub-frame, and this camber ...... Nil lines up with similar slot on reverse shaft should be removed for work involving this end, so that locating plate may be refitted. toe-in Screwed lit part of the car. Removal effected after dis rod ends Replace 3rd motion shaft bearing retainer connecting eight mounting bolts of frame and shims as necessary, secure with lock unit and taking off hydraulic pipe lines, pres plates and setscrews. Remove front screw of sure-limiting valve, exhaust pipe/manifold filter bracket, insert suction pipe, replace gas clamp and exhaust assembly from car. after taking off road wheel and dismantling as kets, blanking plate and casing; tighten set Gill panels, etc., should be removed and follows: disconnect ball end from steering screws. Replace strainer bracket screw, lock rear dampers disconnected from inside luggage lever and drive shaft at inner flexible joint, plate and tighten up screws and lock tab boot. Hand-brake cables should be discon removing four outer nuts from coupling "U" washers. Refit selector interlock arms and nected from lever trunnion block and body bolts. Mark drive flange and universal joint front cover and gasket. Refit speedo drive for correct replacement. Slacken off brake gear and cover plate. Examine (and replace supported while suspension unit is removed from car. Radius arms may be removed hose at frame union and remove from brake if necessary) pinion shaft housing -seal. Re backplate. Release upper suspension arm place housing and secure with one setscrew. without removal of rear sub-frame, but this involves removal of fuel tank. from swivel hub ball pin. Remove nut Insert gear change operating shaft in casing and spring washer from rear end of lower with Woodruff key fitted to lower half of Front Suspension pivot arm and push pin forward to release shaft. Position selector lever inside casing arm. Withdraw swivel hub complete with with end engaged in interlock arm and Independent, upper and lower suspension drive shaft. push shaft through lever boss, insert and arms are located in side members of front Maintenance of this suspension is confined tighten setscrew. Refit gear change operating sub-frame. Outer ends are attached to swivel to lubrication as detailed on p. viii. shaft reverse detent plunger. spring and hubs by ball joints. Rubber cone spring plug. Refit differential as follows (note idler units are mounted in sub-frame towers, gear end float is .003-.008in, with housing tubular struts interposed between springs and Steering Gear nuts tight). suspension upper support arms. Telescopic Rack and pinion. Tie rods operate steering Place diff. assembly in transmission casing dampers are mounted on upper support arms and are attached to either end of rack with slight bias towards flywheel end of unit. arms, and top spigots of these units are by gaitered ball joints. Pinion end play is Refit diff. housing with nuts slack to allow anchored to wing valance. adjusted by shims beneath pinion tail bearing right-hand end cover to be fitted. Ensure Hubs run on ball bearings and are splined retaining plate. A damper pad beneath rack setscrew holes are lined up and tighten up for drjve shaft flanges. Removal effected assembly controls backlash. ,pplement to "Motor Trader," 28 June 1961 MORRIS MINI-MINOR vii ------TUNE-UP DATA LUCAS EQUIPMENT 'iring ord� ...... 1-3-4-2 ' I Settings: Choke ... !¼in ·appet clearance runnin&' ... • 012in Main Jet ... .090in tBATTERY liming ... • 019in std. needle ...... EB Model GLT7A aIve timing: rich needle ... · ° ... M inlet opens ...... 5 BTDC weak needle .. . ° ... GG inlet closes ... 45 ABDC Air cleaner: type ...... paper ele- tGENERATOR exhaust opens 40° BBDC ment Model C40 .. . I Part No. 22704 ° exhaust closes ...... 10 ATDC Fuel pump: make ...... s.u. electric tandard ignition timing ... TDC• type ...... PD CONTROL BOX ocalion ol timin&' mark ...... Flywheel pressure ...... 2·3Ib/sq in Model RB106-2 ... I Part No. 37290 and pointer . lugs: make Champion fuel of 90 octane and below alternative type ... N5 *For tSTARTING MOTOR 14mm distributor is fitted; identified by letters Fa. Static Model M35G .. • I Part No. 25075 Size ... timing lor engines up to serial No. 14824 with this gap ... .025in 0 Drive: "SB" Inboard ...... distributor unit is 3½ BTDC. For engines subse- arburettor: make s.u. 0 ...... quent to this, set to 2½ BTDC• type ... HS2 tDISTRIBUTOR Model DM2 ...... I Part No. 40707 (Low Compression) Max. centricufal advance (crank degrees) 26° at 6,000 r.p.m. No advance BULB below 850 r.p.m. Centrifugal advance springs .. . I Part No. Lamps Model Part No. Lucas No. Wattage Cap 544 127 14 I I Max. vacuum advance (crank I ° ° ead R.H.D. dip left (Home) ...... F700P 58388 989 (side) 6 M.c.c. degrees) ... 14 -18 with 15 {414 (main) 50/40 B.P,F. in Hg • R.H.D, dip left (Export) ... F700 51336 414 50/40 No advance below 3 in Hg. L.H.D. dip right ...... F700 51337 355 42/36 Export Europe (except France and } IGNITION COIL Sweden) ...... F700 58230 410 45/40 Unified Model LA12 ... I Part No. 45113 France ...... F700 58231 411 45/40 European (45111 when re Sweden ...... F700 58456 410 45/40 cap ordering) U.S,A...... F700 58497 - } Primary resistance ...... I 3.0-3,4 ohms de/flasher (Export) ...... 594 52338 380 6/21 s.B.c. Running current at 1,000 r.p.m. 1.5 amp • ront Flasher (Home) ...... 594 52337 382 21 s.c.c. Stop tail L.H. 647 ...... 53797 380 (S,T.) 6/21 S.B.C. WINDSCREEN WIPER and } } Rear flasher R.H...... 647 53798 382 (F.) 21 S.C.l'. Model DR2 I Part No. 75385 Number plate ...... 467-2 53101 222 4 M.C.C. Number plate (de luxe) ...... 467-2 53093 } HORN averse ...... Model HF1849 ...... I Part No. 70141 1nel li ht Bulb holder ... - 554734 987 2.2 M.E.S. i { ... Type: High frequency ucel s ell Current consumption I 2½·3½ amp. nition warning bulb holder ...... - 863511 987 2.2 M.E.S. ain bearm warning bulb holder - ... 554734 987 2.2 M.E.S. FLASHER UNIT I warnin& bulb holder ...... - 863511 987 2.2 M.E.S. Model FL5 I Part No. 35020 top Tail and Rear Flasher L.H. I 647 53799 380 (8.T.) 6/21 s.B.c. orth America) } R.H. ... I 647 53800 } 382 (F.) 21 s.c.c. FUSE UNIT Model 4FJ imber Plate (later) ...... 467 53837 222 4 M.C.C. Fuse ratings: 35 amp (de Luxe) (later) ...... 467 53836 } I t See p. viii far further electrical data l<;t.lHION W,f1Ah11,.G ' ' LtGttl ruse uN1T ltH, SfOP Lil.MP ,-c>'•�•-..-..--,,. - RH PAAC[l SH(Lt LAMP IGNITION L H. STOP LAMP SWll(H ...... ,__<=>---''="'"'-'-'-- i. -i lN P.LAC[L \H[LI' LAMP rut1. U.HII, UN!f IGNITION COIL � 1.:c_,...,:,••,m�""---=•.,,_a __j=�-----j I• �IAOL 80111 OIL PRCSSultC WARi,11N'3 UGHr &. s,otCH • ---i,- H [AT(l'l MOTOR U...---"-"----t.}----11' 'l�----�--•-•--�-.ar-�- )PANLL llGNl .. ,;:.: :: SWITCH ::::: · LH 11[A0L4MP MA,H t,u,, RH COMPloh'TON POCKtt LAMP &. \WITCH a (DC•LUX[ ONLY) . .-...� ��-i+' . .." . r------,rh-j,. sw,rCH RH HC•OL,l"IP OIP 8C•M L H COMPANl01'1 f>Oc,u:r LAMP 4 SWITCH (OC·LVX[ ONLTf f"LASHCA . SHAP CONNCCfORS' '------�v�,- w.iRNING L•GHf lCRMtJfAL lhOCKS OR JUNCTION aox [AATtt .:o,o,i((.ftONS M.AOC 11'1 ... , ...at.c $10[t.AMP NUM8,(R Pi.Al[ l-'MP ---!!•· ON tkPOAT. t.!OOCLS ft '¥°IA fllBNG 101.rs SIOCLAMPS Ne. f(O a I· .. . ·•r-----=, -----j1, FAOM T£RMIN"I. 7 ...__..__--''---"<"'---- _ --' '---...... --->=�-----i•· Wiring diagram by permu,ion of Joseph Lucas Ltd, viii MORRIS MINI-MINOR Supplement to "Mo1or Trader," 28 June 1961 9 3 5 4 KEY TO MAINTENANCE DIAGRAM FILL-UP DATA DAILY EVERY 6,000 MILES Pints Litres 1. Engine and transmission-check oil level I►. Distrlbutor--0il auto ndvance mechanism, and top up l:ihaft bearing and spindle, s1near cam with Engine sump and trans 2. Radiator-check and top llP grease, also contact breaker pivot mission (including filler) 8½5½ galls 4.83 EVERY 1,000 MILES ttl0. Oil filter element-wash bowl io petrol, and Cooling system .. , 5¼6 galls 3 3. Steering Joint nipples fit new eJen1ent Fuel tank: saloon 25 4. Rear suspension radius arm } 01 -1 g 1 111 11. Water pump-remove plug from pump body van ... 27.3 5. Handbrake cable guide channels-grease and lubricate unit sparingly with S.A.E. HO oil traveller 6½ gall, 29.6 gun 1:2. Rear Hubs-remove ea.eh wheel disc, anclre• Tyre pressures: 6. Carburettor-remove c11,p from suction cham taincr cap, relill with grease (see chart below) front and rear (fully ber :tnd add a teaspoon oi oil (S.A.E. 20) EVERY 12,000 MILES IGaded) 1.7 Kg/ EVERY 3,000 MILES 12. Dynamo-oil commutator end l.Jearing cm• 7. Engine and transmission--d.ra.in and refill * Not shown on diagram front normal 1.7 Kg/ •M. Body-lubricate door hinges, bonnet lock and tt N.B. Disconnect battery cable from terminal on cm• opera.ting mechanism starter before working on filter u11it rear normal 1.6 Kg/ cm• I LUCAS SWITCHES t LUCAS COMPONENT Model Part No. MGdel Part No. I II - Battery (later fltment) 8177 A lgnitiGn/starter 67SA845 3178831899 Generator (alternative) ... C40-1 22700 Starter 37SAST18 76438 (Part Nos. and performance as for 22704) Lighting ... 21SA starling Motor (alternative)... M35H 25071 Direction indicatGr HL2 31945 Armature (25075) ...... - 54250096 Dip ... 57SA 31800 ,, (25071) ...... - 1 6250822 Stop light 3R 31802 Field Coils (25075 ) ...... - 251089 Wiper 31780 ., ., (25071) . .. . . - 54250820251935 Heater 78339 Left: the radiator matrix drain point. �1l .. . CommutatorDr\!!OJ�cii�a �t�End Bracket Right: cylinder block drain tap. I ------(25075 and 25071) ... 5425032 (Performance of 25075 and 25071 as !or (25022)° JACKING POINTS Distributor (L.C.) ...... I DM2 I 40648 When lifting complete vehicle, Max. Centrilugal Advance (Crank Degrees) 30 -34" with weight off road wheels, place at 4400 r.p.m. No advance Below 500 r.p.m.° ° Centrifugal Advance Springs. Part No. 54410984. supports in positions arrowed in Max. Vacuum Advance (Crank Degrees] 8 -12 drawings. Left: front of car. Right: with 18in Hg. No Advance BelGW 4½ In. Hg. rear of car. RECOMMENDED LUBRICANTS I I I ° Castro! I Esso B.P. Duckbam's Mobil Shell Filtrate Sternol ° Above 32 F. Cn.strol XL E1Lergol N.O.L. Mobiloil A X-100 30 Medimn WW30 (0 °C.) ° Extra SAE. 30 Thirty Filtrate 80 and ° ° Motor Oil w Engine 32 to 10 F. Castrolite 20\V/30 Energol NOL Mobiloil X-100 20/20 Zero Filtrate WW20 mission (0 C. to -12 C.) SA.:;J 20\V Twenty Arctic 20 tranis- ° NOL Below IO'F. Castro! Z Motor Oil 10 Energol Mobiloil l0W X-100 10\V Sub. Zero WWlO (-12genrC.) SAE lOW Ten Filtrate l0W Gear 140 Steering and Castro! Expee Energol EP NOL Mobilube SpiraxEP 140 EP Filt,rate Ambroleum water pump Hipress Compound 140 SAE 140 L.B.EP 140 GX 140 EP140 Wheel hubs and Castrolease Multi-purpose Energroase 10 G,ease Mobilgrcasc Ret,inax A Super Lithium Ambroline Distributor Oil can WW20 lubricationt nipples LM .onGrease H L2 NOL }IP Filtrate Grease LH1' Grease Castrolite Extra Motor Energol Arcl-ic X-100 Zero Filtrate SU. carb. dashpot 201wso SAE 20W Twenty 20/20\V 20 lubrication Upper Cylinder CastroUo Upper Cylinder ' Energol UCL Adcoid Liquid Upperlube UCL Petroyle Magikoyl I Lubricant Pnnied England b� Cornwall Press Ltd., Paris Garden, London, in S.E.1