1967 CHEVROLET CAMARO relay

ENGINE-ELECTRICAL 6Y-J2

Fig.
8c—Ammeter Method Test Connections

10.
Turn off ignition, disconnect battery ground cable,

and remove all test equipment.

11.
li the Delcotron meets the test specifications, the

problem is not in the generator.

12.
Ti the Delcotron fails to meet the test specifications,

remove it and perform bench tests and make repair

needed.

DELCOTRON DIODE AND FIELD TEST (Fig. 9c)

NOTE:
These tests will indicate good,, shorted

or open field or shorted diode but will not indi-

cate a failed open diode. If output was low and

following tests show good, refer to service op-

erations to determine cause and repair.

1.
Disconnect battery ground cable at battery.

2.
Positive diodes (Test A) connect an ohmmeter be-

tween "R" terminal and "BAT" terminal and note

Fig.
9c-Deicotron Diode and Field Test
reading, then reverse the leads at same terminals

and note this reading. Meter should read high re-

sistance in one direction and low in the other.

3.
Negative diodes (Test B) connect ohmmeter between

"R" terminal and "GRD" and note reading, then

reverse the leads and note this reading. Meter

should read high in one direction and low in the

other.

NOTE:
A high or low reading in both directions

indicates a defective diode.

4.
Open Field Check:

a. Connect an ohmmeter from "F" terminal to

"GRD"
terminal stud and note reading on the

lowest range scale. Meter should read 7 to

20 ohms.

b.
If meter reads zero or excessively high resist-

ance, the Delcotron is faulty.

5. If above tests indicate a defective Delcotron, remove

and completely check Delcotron as outlined under

''Service Operations".

INDICATOR LAMP/INITIAL FIELD

EXCITATION CIRCUIT TESTS (Fig. 10c)

On standard models the indicator lamp circuit provides

initial field excitation (causing lamp to glow). The light

is cancelled by closing the field relay which applies bat-

tery voltage to both sides of bulb (bulb goes out).

The indicator light should glow when ignition switch is

"ON"
and go out almost immediately when engine starts.

Ammeter equipped vehicles use the same initial field

excitation and control circuits as the indicator lamp ex-

cept the lamp is omitted. The continuity tests on both

type vehicles can be made as follows:

If Lamp Fails to Glow or Ammeter Fails to

Function the Possible Causes are:

1.
Faulty bulb or bulb socket.

2.
Faulty ammeter.

3.
An open circuit in wiring, regulator, or field.

4.
A shorted positive diode—(may also cause glow with

ignition switch "OFF").

TEST AS FOLLOWS:

1.
Disconnect connector from regulator and turn

ignition switch to "ON". Connect a test lamp from

connector terminal "4" to ground (fig. 10c, Step 1)

and note test lamp.

a. Lamp fails to glow—check for faulty bulb, socket

or open circuit between switch and regulator con-

nector. Repair as needed.

b.
Light goes on—failure is in regulator, Delcotron,

or wire between "F" terminals on regulator and

Delcotron. Go to Step 2.

2.
Disconnect lamp lead at ground end and connect be-

tween connector "F" and "4" terminals (fig. 10c,

Step 2), and note lamp:

a. Test Lamp glows—problem is in regulator. An

open circuit in regulator or relay is stuck dosed.

See "Service Operations" for repair.

b.
Fails to glow—problem is in wire between "F"

terminals on generator and regulator or infield

windings. Go to Step 3.

3.
Disconnect test lamp at connector "F" terminal and

CHEVROLET CHASSIS SERVICE MANUAL

ENGINE-ELECTRICAL 6Y-13

F 2 3 4

f 2 3 4

F 2 3 4

Fig.
10c—Initial Field Excitation Circuit Tests

connect to "F" terminal on Delcotron (fig. 10c,

Step 3), and note lamp:

a. Lamp glows-an open circuit in wire between "F"

terminals—correct as needed.

b.
Fails to glow—Delcotron field has open circuit,

see "Service Operations" to repair %

If Lamp Fails to Go Out, or if Ammeter Shows

Discharge the Possible Causes are:

1.
Loose drive belt—adjust as necessary.

2.
Faulty field relay—(see relay test and adjustment).

3.
Defective Delcotron—(see Delcotron output test).

4.
At normal idle—parallel resistance wire open (see

Resistance test). On ammeter models the initial

field excitation wire to "ACC" terminal is open.

5. Switch off—positive diode shorted (see Diode test).

FIELD CIRCUIT RESISTANCE

WIRE CHECKS

The resistance wire is an integral part of the ignition

harness. However, the resistance wire is not solderable;

it must be spliced with a crimp-type connector. It is

rated at 10 ohms, 6.25 watts minimum.

The check for an open resistor or field excitation wire

(connected to the ignition switch "ACC" terminal) is as

follows:

1.
Connect a test lamp from the wiring harness con-

nector terminal "4" to ground as shown in Figure

10c (Step 1).

2.
Turn the ignition switch to the "ON" position and

note test bulb.

a. Test lamp glows—resistance is O.K.

b.
Test lamp does not glow—the resistor is open

circuited—note also that dash lamp does not glow

during this test because series resistance of the

2 bulbs causes amperage to be too low.
VOLTMETER

3 4

WIRING*
HARNESS

CONNECTOR

Fig.
11c—Testing Field Relay

CHEVROLET CHASSIS SERVICE MANUAL

ENGINE-ELECTRICAL 6Y-14

VOLTMETER

WIRING HARNESS

CONNECTOR

Fig.
12c—Field Relay Closing Voltage Test

FIELD RELAY CHECKS AND ADJUSTMENT

To check for a faulty relay proceed as follows:

1.
Connect a voltmeter into the system at the regulator

No.
2 terminal to ground (fig. lie).

2.
Operate the engine at fast idle (1500 to 2000 rpm) and

observe voltmeter reading.

3.
If voltmeter shows zero voltage at regulator, check

circuit between No. 2 terminal on regulator to "R"

terminal on Delcotron.

4.
If voltage at regulator exceeds closing voltage
Fig.
13c—Adjusting Field Relay Closing Voltage

specification and light remains on, regulator field

relay is faulty (Refer to specifications). Check and

adjust regulator as follows:

CLOSING VOLTAGE ADJUSTMENT

•1.
Make connections as shown in Figure 12c using a 50

ohm variable resistor.

NOTE: This gives us a variable resistance in

series from a hot lead to the relay coil.

2.
Turn resistor to "open" position.

3.
Turn ignition switch off.

4.
Slowly decrease resistance and note closing voltage

of the relay. Adjust by bending heel iron in the man-

ner illustrated in Figure 13c.

OTHER HARNESS CHECKS

Other wires in the charging system harness need be

checked for continuity by use of an ohmmeter or a test

ligjit (12 Volt). Connect the test so the wire in question is

in series in the test circuit.

SERVICE OPERATIONS

Service Procedures described in this section are for

the 5.5" aluminum and 6.2" perforated stator Delcotrons

(fig. 14c). Where important differences are encountered

separate mention will be made of the two generators.

GENERATOR

REMOVAL AND INSTALLATION

1.
Disconnect the battery ground strap at battery to

prevent damaging diodes.

2.
Disconnect wiring leads at Delcotron.

3.
Remove generator brace bolt, (if power steering

equipped, loosen pump brace and mount nuts) then

detach drive belt (belts).

4.
Support the generator and remove generator mount

bolt (6.2" Delcotron uses 2 mount bolts) and remove

from vehicle.
5.
Reverse the removal procedure to install then adjust

drive belt.

PULLEY REPLACEMENT

5.5" Delcotron

Single Groove Pulley

1.
Place 15/16" box wrench on retaining nut and insert

a 5/16" alien wrench into shaft to hold shaft while

removing nut (fig. 15c).

2.
Remove washer and slide pulley from shaft.

3.
Reverse Steps 1 and
2
to install, use a torque wrench

with a crow-foot adapter (instead of box wrench) and

torque the nut to 50 ft. lbs. (fig. 16c).

Double Groove Pulley

1.
Place a 15/16" socket (with wrench flats on the drive

CHEVROLET CHASSIS SERVICE MANUAL

ENGINE-ELECTRICAL 6Y-15

L
RELAY

TERMINAL "F" TERMINAL

"BAT" \ ' /

TERMINAL
/ / /
GRD7
TERMINAL

5.5" SERIES ID DELCOTRON
"BAH"

TERMINAL

^Vs^^^^lijBii^^8C^3^SH|j^^^^^^sH^^Bf- y/

RELAY ^^^"^^^jWwIi^^^^ RELAY

6.2" SERIES 2D, TYPE 150 DELCOTRON

Fig.
14c—Delcotrons - Full View

end or use Adapter J-21501 and a box wrench) on re-

taining nut, insert a 5/16" alien wrench through

socket and adapter into hex on shaft to hold the shaft

while removing the nut.

2.
Remove washer and slide pulley from shaft.

3.
To install, slide pulley and washer on shaft and start

the nut.

4.
Use the socket and adapter with a torque wrench and

tighten-nut to 50 ft. lbs. torque.

BRUSH
REPLACEMENT

6.2"
Delcotron

1.
Remove two nuts retaining the blade connectors and
remove the connectors (fig. 17c). Slide the indicator

light relay wire from the terminal post.

2.
Remove two screws retaining the capacitor and brush

holder to rear end frame, Remove brush holder.

3.
To install brushes, push brushes into holder and

install pin to keep the brushes in holder.

4.
Attach brush assembly and condenser to the end

frame with hex-head stud on the .left side only.

Fig.
15c—Pulley Removal

Fig.
16c—Torqulng Pulley Nut

CHEVROLET CHASSIS SERVICE MANUAL

ENGINE-ELECTRICAL
6Y-16

POINT
OPENINGJL

Fig. 17c-6.2"
Brush
Holder
Assembly

5. Rearrange leads as shown in Figure 18c with right-

hand brush lead connected under the right hand hex-

head stud.

6. Remove pin and attach terminal cover with two

screws, making sure leads are not caught under-

neath the cover.

DOUBLE CONTACT REGULATOR

While most regular adjustments are made on the vehi-

cle as outlined under "Maintenance and Adjustments",

the regulator may be removed for field relay point and

air gap adjustment. However, voltage regulating contacts

should never be cleaned as they are made of special

material that may be destroyed by cleaning with any

abrasive material.

NOTE:
A sooty or discolored condition of the

contacts is normal after a relatively short

period of operation.
Fig. 19c—Checking Field Relay Point Opening

REMOVAL AND INSTALLATION

To remove the regulator assembly, disconnect the bat-

tery ground cable and the wiring harness connector at the

regulator, then remove the screws securing the regulator

to the vehicle.

Electrical settings must be checked and adjusted after

making mechanical adjustments. Before installing regu-

lator cover, make sure the rubber gasket is in place on

the regulator base.

MECHANICAL ADJUSTMENTS

NOTE:
Only an approximate voltage regulator

air gap setting should be made by the "feeler

gauge" method.

BRUSH

LEAD

BRUSH

LEAD
RELAY
^B-/lliLlK
CONDENSER

LEAD
GROUND
LEAD

STUD
AIR GAP

(Check
With
Points

Just
Touching)

Fig.
18c—Lead
Arrangement
after
Assembly
Fig. 20c—Checking Field Relay Air Gap

CHEVROLET CHASSIS SERVICE MANUAL

ENGINE-ELECTRICAL 6Y-17

Field Relay Adjustment touching (fig. 20c). The air gap normally need not be

adjusted. If the point opening and closing voltages

1.
Point Opening: The point opening is checked as il- are within specifications, the relay will operate

lustrated in Figure 19c. If adjustment is necessary, satisfactorily even though the air gap may not be

carefully bend the armature stop. exactly according to specifications. If adjustment is

2.
Air Gap: Check the air gap with the points just necessary, bend the flat contact spring.

CHEVROLET CHASSIS SERVICE MANUAL

CLUTCH AND TRANSMISSIONS 7-9

6. Connect speedometer cable.

7. Install propeller shaft assembly.

8. Fill transmission with lubricant specified in Section

O.

CORVETTE TRANSMISSION REPLACEMENT

, 1. Disconnect battery ground cable.

2.
Pisassemble transmission shift control lever by un-

screwing ball from lever, lifting out
"T"
handle re-

turn spring and "T" handle, then remove the anti-

rattle bushings.

3.
Raise front and rear of vehicle.

4.
Insert a block of wood between the top of the dif-

ferential carrier housing and the underbody (to pre-

vent upward travel of the carrier when the carrier

front support is disconnected).

5. Disconnect the differential carrier front supportfrom

its frame bracket, by removing the nut on the under-

side of the biscuit mount.

6. Pry the carrier downward to relieve load while re-

moving the two center mounting bolts from the car-

rier front support. (To pry carrier downward insert

crowfoot end of a pry bar through the opening in the

carrier front support, hooking end of bar over top of

the center mounting bolt pad cast in the underside of

the carrier.)

7. Pivot carrier support downward for access to prop

shaft "U" joint.

8.
.
Disconnect prop shaft front and then rear "U" bolts.

9. Disconnect parking brake cable from ball socket at

idler lever located near center of underbody.

10.
Remove prop shaft by moving shaft forward.

11.
Remove heat deflectors from the right and left ex-

haust pipe.

12.
Remove left bank exhaust pipe.

13.
Remove right bank exhaust pipe and heat riser.

14.
Disassemble the transmission mount, as follows:

a. Remove the two bolts that attach rear mount

cushion to the rear mount bracket.

b.
Support engine under oil pan and raise engine to

remove load from rear mount cushion.
CAUTION: To avoid damage to oil pan, a suit-

able wide base, heavy wood platform should be

placed between the jack pad and the oil pan.

c. Remove the three transmission mount bracket-

to-
crossm ember bolts and remove mount bracket.

d. Remove the two bolts from mount pad to trans-

mission case and remove rubber mount cushion

and exhaust pipe "yoke".

15.
Disconnect transmission linkage by removing the

shift levers at the transmission side cover.

16.
Disconnect speedo cable at transmission extension.

17.
Remove transmission output shaft slip yoke.

NOTE:
The yoke is removed to avoid tearing

the heat reflecting pad on the underbody, when

the transmission is being removed.

18.
Remove two bolts to disconnect the transmission

gearshift control lever and bracket assembly from

its adapter plate on side of transmission. Lower

transmission assembly from the vehicle, letting the

gearshift lever slide down and through the dust boot

in the console.

19.
Remove transmission-to-clutch housing attaching

bolts.

20.
Slide transmission assembly rearward from clutch

and rotate transmission for access to the three flat

head machine screws in the control lever bracket

adapter plate. Remove adapter plate. Rotate trans-

mission back to the upright position.

21.
To allow room for transmission removal slowly

lower the rear of engine until the tachometer drive

cable at the distributor just clears the horizontal

ledge across the front of dash.

CAUTION: The tachometer cable can be easily

damaged by heavy contact with the dash. Slide

transmission rearward out of the clutch, then

tip front end of transmission downward and

lower the assembly from vehicle.

22.
Reinstall transmission assembly by performing above

steps in reverse order.

TRANSMISSION OVERDRIVE

INDEX

Page

General
Description 7-10

Maintenance
and Adjustments 7—10

Governor
Switch and Pinion .............. 7-10

Sun
Gear Solenoid Oil Seal and Control

Cable
Bracket 7-10

Case
Rear Oil Seal 7-10

Removal
7-10

Installation
. . . . . 7-10

Control
Shaft Lever and Oil Seal 7-10

Speedometer
Driven Gear 7-10

Electrical
Unit Checks 7-11

Overdrive
Relay . 7-11
Page

Air
Gap 7-11

Point
Opening 7-11

Closing
Voltage 7-11

Solenoid
. 7-11

Closing
Coil 7-11

Engaging
Spring . - 7-11

Ignition
Grounding Contact . 7-11

Governor
Switch 7-11

Kickdown
Switch 7-11

Diagnosis
- Overdrive 7-12

Mechanical
. 7-12

Electrical
7-13

CHEVROLET CHASSIS SERVICE MANUAL

CLUTCH AND TRANSMISSIONS 7-10 ,

GENERAL DESCRIPTION

The overdrive unit is essentially a two-speed planetary-

transmission attached to the rear of a conventional three-

speed transmission. In overdrive, engine speed is ap-

proximately 30 per cent slower at a given road speed

since the drive train includes planetary gears which pro-

vide a lower overall gear ratio than that obtained in high

gear with the conventional transmission.

The electrical equipment which controls the automatic

action of the mechanical portion of the overdrive unit

consists of a solenoid, a speed-sensitive governor switch,

a relay and a kickdown switch. The circuit including this

equipment makes it possible to operate in overdrive above

a pre-set cut-in speed, or in .conventional drive at any

speed.

With the overdrive unit engaged, the transmission

should not be left in any forward gear with intent of lock-

ing the drive-line as the overrunning clutch is a free-

wheeling condition.
SERVICING THE OVERDRIVE

With the,overdrive assembly removed from the trans-

mission, service operations on the transmission proper

are the same as for the standard three-speed trans-

mission.

Repairs to the overdrive housing, output shaft, ring

gear assembly, clutch cam, roller retainer, pinion cage,

sun gear, shift rail, sun gear control plate, output shaft

bearing, oil seal, speedometer drive gear, solenoid pawl

and interlock plunger may be performed underneath the

car, if so desired, by removing the overdrive housing

without disturbing the transmission. Refer to Overhaul

Manual for Service Procedure.

If the transmission mainshaft, overdrive adapter or

transmission rear bearing which is retained in adapter

require replacement, the entire transmission and over-

drive assembly should be removed and overhauled on the

bench.

MAINTENANCE AND ADJUSTMENTS

Servicing of the overdrive governor switch and pinion,

the sun gear solenoid, oil seal and cable bracket, the out-

put shaft rear oil seal, the control shaft lever, and the

speedometer driven gear may be accomplished without

removing the overdrive from the vehicle, as discussed

in the following paragraphs:

GOVERNOR SWITCH AND PINION

To remove governor switch, disconnect wires at gover-

nor switch and screw governor
out
of housing, using Tool

J-4653 on the flat hexagonal surface of governor case.

The pinion may be separated from the governor by re-

moving the snap ring on the shaft.

SUN GEAR SOLENOID, OIL SEAL AND

CONTROL CABLE BRACKET

Remove the solenoid by taking out the two mounting

bolts and lock washers, removing
the.
cable bracket with

the lower bolt. Turn the solenoid 1/4 turn and
pull,
sole-

noid plunger out of adapter. The oil seal may be pried

out of the adapter.

CASE REAR OIL SEAL

Removal

1.
Remove propeller shaft as outlined in Section 4.

2.
Using a punch against seal in housing, pry out seal

from housing.

Installation

1.
Prelubricate between sealing lips and coat outside of

new oil seal with a suitable sealant, then start seal

into bore in overdrive housing.

2.
Using Tool J-5154 drive oil seal into counterbore.

3.
Install propeller shaft as outlined in Section 4.

CONTROL SHAFT LEVER AND/OR "O" RING

OIL SEALS

To remove- the control shaft, disconnect the cpntrol
cable, remove tapered pin and pull lever out. Replace

the two "0" ring seals on the control shaft. Insert shaft

and new "O" ring seals into housing and install tapered

pin. Connect control wire to lever.

SPEEDOMETER DRIVEN GEAR

Disconnect speedometer cable, remove lock plate to

housing bolt and lock washer and remove lock plate. In-

sert screw driver in lock plate slot in fitting and pry

fitting, gear and shaft from housing. Pry "O" ring from

groove in guide.

Install new "O" ring in groove in fitting and insert

shaft.

Hold the assembly so slot in fitting is toward lock plate

boss on housing and install in housing. Push fitting into

housing until lock plate can be inserted in groove and

attached to housing.

L
dl

ZAIR GAP

km (CHECK WITH

M*= POINTS BARELY
'A

AoWER
|^

POINT

0 ADJUST

=^ i
SUPPORT

Fig. IB - Checking Relay Air Gap

CHEVROLET CHASSIS SERVICE MANUAL