'75 W300 repair/mod project - Ol' Blue

I think you may have made a common mistake. You installed the timing chain with the marks next to each other, up & down, correct. And then assuming TDC you dropped in the dist at #1, correct?....WRONG, with the timing marks next to each other the dist is 180 deg. off. After installing the timing chain you should always turn the crank 180 deg., THEN drop the dist at #1. Pull the dist., turn the crank 180 deg. and drop your dist back in.
 
best thing you can do at this point is pull the #1 plug, hand turn it over to TDC verify it with a screwdriver down the sparkplug hole , set the dizzy to a neutral location and assume that its pointing at #1, hook it all back up and give it a whirl, if that doesnt work, flip the wiring 180 and try again

if you really want to verify #1 pull the valve cover too, bring it round to TDC but be sure that the valves are CLOSED not open/opening then you KNOW for fact your at #1

even with vac leaks it should fire up..and run rough
 
The broken manual choke is bolted back onto the carb now. I cut out a small piece of cork gasket material and sandwiched it between the choke and the vacuum port. Then I moved the distributor vacuum advance hose from the nipple on the base plate where it was getting manifold vacuum, and moved it up to the metering block to give it a ported vacuum signal. I plugged the now open port in the base plate with a new rubber cap. Still no luck yet.

Without finding any documentation on the manufacturer or markings on the 3-way crank sprocket, I had to set the timing gears based on how there were actually working together. To figure that out I left the timing chain off, set the crank at TDC, then brought the cam sprocket around to where the intake ramp was just about to start bringing the lifter up. That put the dot on the cam sprocket right at the 6 o'clock position, and the stamped number 0 on the crank sprocket at the 12 o'clock position. This was all done before the heads were on, so it was easy to see and measure the cam and piston for verification. Timing chain stretch was evident, but still within specs per the FSM.

If I don't get this thing going soon I may just buy a whole new timing set. That way I'll have the setup documentation and a fresh chain on it. I really hope it doesn't come to that though.
 
From what you say I don't think your cam timing is off. But I'll still bet that the dist is 180 deg. off. :hmmm:
 
Just catching up a little here, and a few thoughts:

If you're in a parts store, and they don't know what "15460" means in terms of a belt's part number, I'd leave and never go back. Jesus H. Christ at a Clambake, that's Parts Guy 101: 15 = 7/16" top width, 460 = 46.0" effective length (it'll measure about 46.5" around the outside). I have yet to encounter an accessory (or equipment) belt whose part number doesn't translate into its actual dimensions. :doh:
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Your blasting-cabinet gloves can likely be repaired with a $2 inner tube patch kit. Hook up a shop vac to the outlet port, as 69.5 suggested, and if you can use some kind of filter on the inlet port (a round paint-mask filter fits mine perfectly). If you want to love it even more, build a cyclone for it. I made a truly-crappy one using a steel 5-gallon solvent pail, my welder, some old exhaust pipe and scrap metal, and a bunch of silicone. It looks like shit but works amazingly well--nothing makes it into the actual shop vac, saving costs on clogged filters. While we're near the subject of silicone, use some on the seams of your blast cabinet. Clean all the dust off the area prior to applying it and you can go ahead and use the cheapest crap caulk you can find at the hardware store.
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Take the #1 spark plug out and hold your thumb over the hole while either bumping the engine with the starter or cranking it (clockwise) with a ratchet on the dampener bolt. When you feel pressure against your thumb, you're coming up on #1 firing. Hand-turn the engine to align the timing mark on the dampener with 0° on the timing tab. Proper alignment on the distributor body is achieved by pointing the vacuum advance nipple at the driver's side shock tower. At that point, the rotor should be pointing exactly at a plug-wire tower. If it's not, pop the distributor out and use a large flat screwdriver to twist the oil-pump drive gear out of mesh with the cam. Rotate the oil-pump driveshaft as necessary to achieve the right rotor alignment--you'll have to check by dropping in the distributor if your eyeball calibration isn't particularly keen. You can literally play God here, because there are a lot of teeth. Reverse your twist on the screwdriver and the driveshaft will suck itself back into place. The oil pump driveshaft will self-align in the pump no matter where you clock it. Once you've got the body and rotor correctly aligned, you can wire your cap so that whichever tower the rotor is pointing at is your #1 cylinder. I shoot for the service manual layout personally. If it doesn't fire up instantly, you have some problem other than ignition timing, period.

It's a lot more complex to write and/or read the above paragraph than it is to actually do. The whole procedure takes literally a couple of minutes. If I can change the oil pump on a 440 in twenty minutes in a Hardee's parking lot without marking any positioning whatsoever on the distributor, you should be able to get just the distributor set up in less than half that. I had to do all of it and change the pump. Hell, I even had to run across the street and buy new oil--in my haste I forgot to reinstall the oil filter, and while priming I pumped four quarts of oil onto the tarmac. :doh: :D Process is the same with a small-block other than rotation direction and the fact that it's a much bigger pain in the ass with the rear-mounted distributor. The vacuum canister should still point at the shock tower, though. In both instances, that leaves ideal adjustment range for when you do your final timing.

When you do get to doing the final timing, there's a bunch of power in running the advance several degrees beyond the very-conservative factory spec. I didn't look it up for your engine, but it's probably not far from zero. I ran my '71-spec 440 at approximately 14°BTDC initial; the factory '71 spec called for 2.5°BTDC. I say "approximately" because I set total timing at 34° and that alone determined my initial timing setting. Obviously if you get any kind of detonation you've gone too far.
 
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Unfortunately, it seems like being a "parts guy" probably isn't listed in the job requirements to get hired on at the two local parts shops. :doh:

I saved a link somewhere to a how-to article on how to make one of those dust collectors using a 5 gal pail, a shop vac and some hose. Just haven't had the time (or motivation) to make one yet. It will get built, but most likely sometime over the winter, when it's too cold to work on anything outside.

I've been pulled off the truck project to help with building a small barn for the last few days. As a result, I haven't been able to do anything to the truck since my last post. :doubt:
 
I went back and replaced the pics on the first half of this thread. I'll get the rest of them fixed later.
 
I went over the initial timing setup again and everything appears to be set where it's supposed to be. With the #1 piston at TDC the intake valve is about to come up, the distributor drive gear has the slot running front to back and the vacuum advance can is pointing to the driver side of the engine while the rotor is pointing directly at the terminal for plug #1. The plug wires have been verified to be in the correct firing order for CCW rotation, and both the two wire distributor plug and the coil wires are secured/connected properly.

I spent quite a bit of time today testing out the ignition system to see if I could find any faulty parts or wiring. So far I've looked at the primary and secondary wiring sections of the harness, as well as the ECU, distributor pickup and ballast resistor. I still need to check the coil and I haven't been able to check it for spark with a wire pulled yet. I'll have to make up a remote start button so I can crank it from the engine bay.

The only part that failed the testing specs in the FSM was the distributor pickup. I found that the pickup was tilted, so the bottom was closer to the reluctor (almost touching it) than it was at the top (.008-.010). I gave the plate holding the pickup a slight twist and was able to get the pickup to run parallel to the reluctor. I set the gap to .008 as per the FSM, however it still wouldn't start when I tried it after reseting the pickup gap.

With the tests on the wiring and components reading within specs, the FSM recommended trying to swap out the ECU and/or the coil next. I had a used/spare ECU and ballast resistor that came with the truck in the glove box, so I swapped out the ECU first. I sanded the fender mounting points under the ECU and put a little dielectric grease on the bare metal to keep it from rusting and maintain conductivity. Tried to start it again, and still was getting nothing but the starter cranking it over. Since that didn't work, I installed the first ECU that was working previously back into the truck. I don't have a spare coil here to swap out, so next I tried the spare (used) ballast resistor. Same result as with the ECU, cranking but no starting.

I need to get another coil to try out next, but if that doesn't work, I'll have to see what the FSM says to check next.:hmmm: For now I had to stop there since my battery voltage was getting pretty low due to all the cranking of the starter. My big battery charger stopped working a few months ago, so I'm having to use a tiny HF slow trickle charger to get by.
 
I went over the initial timing setup again and everything appears to be set where it's supposed to be. With the #1 piston at TDC the intake valve is about to come up, the distributor drive gear has the slot running front to back and the vacuum advance can is pointing to the driver side of the engine while the rotor is pointing directly at the terminal for plug #1. The plug wires have been verified to be in the correct firing order for CCW rotation, and both the two wire distributor plug and the coil wires are secured/connected properly.

I spent quite a bit of time today testing out the ignition system to see if I could find any faulty parts or wiring. So far I've looked at the primary and secondary wiring sections of the harness, as well as the ECU, distributor pickup and ballast resistor. I still need to check the coil and I haven't been able to check it for spark with a wire pulled yet. I'll have to make up a remote start button so I can crank it from the engine bay.

The only part that failed the testing specs in the FSM was the distributor pickup. I found that the pickup was tilted, so the bottom was closer to the reluctor (almost touching it) than it was at the top (.008-.010). I gave the plate holding the pickup a slight twist and was able to get the pickup to run parallel to the reluctor. I set the gap to .008 as per the FSM, however it still wouldn't start when I tried it after reseting the pickup gap.

With the tests on the wiring and components reading within specs, the FSM recommended trying to swap out the ECU and/or the coil next. I had a used/spare ECU and ballast resistor that came with the truck in the glove box, so I swapped out the ECU first. I sanded the fender mounting points under the ECU and put a little dielectric grease on the bare metal to keep it from rusting and maintain conductivity. Tried to start it again, and still was getting nothing but the starter cranking it over. Since that didn't work, I installed the first ECU that was working previously back into the truck. I don't have a spare coil here to swap out, so next I tried the spare (used) ballast resistor. Same result as with the ECU, cranking but no starting.

I need to get another coil to try out next, but if that doesn't work, I'll have to see what the FSM says to check next.:hmmm: For now I had to stop there since my battery voltage was getting pretty low due to all the cranking of the starter. My big battery charger stopped working a few months ago, so I'm having to use a tiny HF slow trickle charger to get by.
 
OK, cam & ignition timing are right on, next, if no spark at a plug move backwards, 12v to ballast resistor? resistor output, both sides? voltage to + coil lead? pickup sensors rarely go bad, but possible, (the technical name is Hall Effect Sensor) ECU's are notoriously evil. I've had bad ones out of the box. They rarely die while in use. They usually die like a light bulb, when you hit the switch.

Remote start switch not needed for Mopars, jump a screwdriver between large terminal on starter relay to smaller terminal.
 
if you would like to test the system WITHOUT runing the starter. grab a spare dizzy, chuck it up in a drill, wrap a ground wire around it or bolt a ground wire to the vacume screw, ground out some plugs, fire up the drill and watch the plugs...this is the ONLY way i know to test the system as a whole

bonus section

you can spin the dizzy by hand and acomplish the same thing as it doesnt need to spin crazy fast, secondly you can just stuff a plug wire on the coil and eliminate the need for cap n rotor to "dumb down" the system and see if the issue is prior to the cap n rotor


this whole method has always been my "goto" on electronic ignition rigs that are being fussy as you can quick test every bit by bit without actualy cranking on the engine..and since mopars...especialy trucks...LOVE to have the stupidest thing happen..the system works perfectly when NOT cranking
 
A friend stopped by today, so I got him to turn the key while I checked for spark. There was a good spark when he was cranking it over, so I started looking elsewhere for the issue(s). I also tried advancing and retarding the distributor while he was cranking it and the most I got from it was a few coughs (backfires) through the carb. I reseated the carb and gaskets on the intake and torqued the four mounting nuts to Holly's recommended specs to make sure there weren't any vacuum leaks there. Next I checked the fuel bowl levels through the sight holes and reset the adjustable needles and seats. They were already close from the baseline setting I had them at, so there wasn't much of a change to either side of the carb. Fuel pressure is reading between 3-5 PSI on the gauge at the carb fuel line.

So, I'm getting spark and I'm most likely getting compression (based on the sound of the coughs/backfires). I'm also getting fuel, but it's smelling way rich at the moment. The carb I have had a number of issues with it when I took it apart to rebuild it. There may be some internal problems I didn't see during the rebuild that popped up after everything was cleaned up. I'm going to see if my neighbor that races has a spare known good 750cc carb I can throw on to test it out. He's at the track this weekend, so I'll have to try to catch up with him on Monday.
 
I've discovered that the FSM now has two confirmed errors on a rather critical topic. The distributor rotation shown in the Engine section (CW vs CCW) and the initial rotor direction at TDC shown in the Electrical section. The way the FSM describes the way it functions, it would seem to be correct with the rotor pointing towards the front of the vehicle at TDC. As a result, I'm even more confused as to why it's almost firing now. I'm not going to argue with it though and I'll try dialing it in to where I can get it to run well enough to tune it.

Yep, turning the dist shaft 180* got it closer to running, even though the FSM said that way wasn't correct. It's now trying to start and actually getting a continuous series of combustion pops out of the collectors. It's not close enough to get up to idle speed yet, but at least it's in the ballpark now. For now, the battery is on the slow charger again. I'll give it another shot once it's charged up.
 
Good news and bad news.

First the good news. With the battery charged up a bit, I got my wife to hop in and crank the engine over so I could adjust the distributor until it would start. It only took a few seconds messing with it until it finally fired up and stayed running. The idle is way low at the moment, hovering around 450-500 RPM right now. I've never had a 440 that could idle that low before.[smilie=2: After I adjusted the clutch rod to get the proper pedal freeplay, I took it once around the block to see how it ran on the default carb settings. Even with it just timed by ear, it's running a lot more like you would expect a 440 truck with 4.88 gears should run. Now it's running waaay better than it did when I first bought it (it was kinda sluggish before).:dance:

Now the bad news. It looks like I have a rear main seal leak to deal with.:doh:
 
I think it's most likely going to be the side seals (molded silicone pieces), but won't know for sure till I drop the pan and check it out. The actual main seal itself is a two piece rubber type.
 
I think it's most likely going to be the side seals (molded silicone pieces), but won't know for sure till I drop the pan and check it out.
That's why I prefer seals made of a fiberous material, they swell up when saturated with oil.

The actual main seal itself is a two piece rubber type.
I've seen instances where they were installed backwards. :hmmm:
 
With the #1 piston at TDC the intake valve is about to come up...
Right there, you should've known you were 180° out. At TDC firing, neither valve should be about to do anything. :doh:

If you'd followed my suggestion, you'd have had it running without all that FSM f__kin' around you did to get nowhere. :naughty: My method takes 5 minutes. The wires don't care which cap tower they occupy--they just need to be above the rotor when it's their cylinder's turn to fire. The position of the vacuum advance canister doesn't really matter either, as long as it's got clearance for making timing adjustments.

When Hughes Engines installed Kev's rear main seal backward (among other major f__k-ups), it shot out of there like nobody's business--destroying the $800 dual-disc clutch they swore he'd need (because they sell 'em) for his stock-stroke, all-stock-iron-manifolded 440. :liar:
 

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