🏷️ Basic Information

Make:

Austin

Model:

Gipsy

Model Code:

G4M15

Production Years Covered:

1958-1967

👋 Introduction

Vehicle Type:

The Austin Gipsy was a British multi-purpose 4x4 military and civilian vehicle produced from 1958 to 1968. It was designed to compete with the Land Rover and offered a robust, utilitarian platform.

Competitors:

Primarily the Land Rover Series II/IIA during its production lifespan.

Vehicle Features:

4-wheel drive, independent front suspension, leaf-sprung rear suspension, robust construction, available in various body styles (e.g., canvas top, hardtop, chassis-cab).

📋 Manual Details

Engine:

Included

Transmission:

Included

Drivetrain:

Included

Suspension:

Included

Brakes:

Included

Steering:

Included

Electrical System:

Included

Fuel System:

Included

Cooling System:

Included

Body And Chassis:

Included

Body Electrical:

Included

Troubleshooting:

Included

Maintenance Schedule:

Included

Wiring Diagrams:

Included

Estimated Pages:

Comprehensive (Exact page count not specified, but described as 'comprehensive')

Type:

Factory Service Repair Manual

Additional Manual Types Indicated:

Troubleshooting manual guide, service manual pdf download, shop repair manual, maintenance schedule, workshop manual.

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Detailed information on engine assembly, disassembly, cylinder head, piston, connecting rods, crankshaft, camshaft, valve train, and timing. Includes specifications and procedures.

Engine Fuel System:

Covers fuel pumps, carburetors (likely Solex or Zenith), fuel lines, and filters. Troubleshooting and adjustment procedures.

Engine Cooling System:

Information on radiator, water pump, thermostat, hoses, and coolant specifications. Maintenance and repair.

Engine Lubrication System:

Details on oil pump, oil filter, oil pan, and lubrication points. Oil type and capacity specifications.

Transmission:

Covers manual transmission operation, disassembly, assembly, and adjustment. Includes gear ratios and fluid specifications.

Drivetrain Transfer Case:

Information on the transfer case (likely a 2-speed unit for 4WD), including lubrication and maintenance.

Drivetrain Axles And Differentials:

Front and rear axle assemblies, including differential maintenance, lubrication, and repair procedures.

Suspension Front:

Details on the independent front suspension system (trailing arms, coil springs, shock absorbers), including component identification, removal, and installation.

Suspension Rear:

Information on the rigid rear axle, leaf springs, and shock absorbers, including maintenance and replacement procedures.

Brakes:

Covers hydraulic braking system, including master cylinder, wheel cylinders, brake shoes, drums, and brake fluid specifications. Maintenance and bleeding procedures.

Steering:

Details on the steering box, steering column, linkages, and kingpins. Lubrication and adjustment procedures.

Electrical System Ignition:

Covers ignition system components: distributor, ignition coil, spark plugs, and ignition timing. Troubleshooting and adjustment.

Electrical System Charging:

Details on the generator (dynamo), voltage regulator, and battery charging circuit. Maintenance and testing.

Electrical System Lighting:

Headlights, taillights, brake lights, turn signals, and interior lighting. Bulb specifications and wiring diagrams.

Electrical System Accessories:

Horn, wipers, heater (if fitted), and dashboard instruments. Troubleshooting and wiring.

Bodywork And Chassis:

Frame construction, body panels, doors, windows, seats, and trim. Repair and adjustment procedures.

Body Electrical And Accessories:

Wiring for accessories, dashboard illumination, and control switches.

Routine Maintenance:

Oil changes, filter replacements, lubrication points, fluid checks and top-offs, and general inspections.

Engine Overhaul:

Step-by-step instructions for complete engine disassembly, inspection, component replacement, and reassembly.

Transmission Rebuild:

Detailed procedures for disassembling, inspecting, replacing parts, and reassembling the manual transmission.

Brake System Repair:

Drum and shoe replacement, wheel cylinder and master cylinder service, brake fluid bleeding, and system adjustment.

Suspension Component Replacement:

Replacement of shock absorbers, coil springs, leaf springs, bushings, and ball joints.

Steering System Adjustment:

Adjustment of steering box and tie rod ends, replacement of steering components.

Electrical Troubleshooting:

Systematic diagnostic procedures for electrical faults, guided by wiring diagrams.

Ignition Timing Adjustment:

Procedures for setting and adjusting ignition timing for optimal performance.

Carburetor Adjustment And Rebuilding:

Detailed instructions for tuning and overhauling the carburetor for proper fuel delivery.

Body Panel Repair And Replacement:

Guidelines for minor bodywork repairs and replacement of body panels.

Diagnostic Procedures:

Troubleshooting flowcharts and diagnostic tips for common problems across all major systems.

Depth:

Comprehensive factory-level service and repair information, suitable for both professional mechanics and experienced DIY enthusiasts. Covers diagnostics, adjustments, overhauls, and component replacement.

Scope:

Covers everything needed for repair or service, implying detailed procedures and specifications for maintenance and component replacement. The description 'comprehensive' suggests a high level of detail.

📊 Manual Specifications

Format:

PDF

Software Requirements:

Adobe PDF Reader

Compatibility:

Windows and Mac compatible

Searchability:

PDF format typically allows for text searching, enhancing ease of finding specific information.

Quality:

High-resolution scans of original factory documentation, ensuring clarity of text and diagrams.

Binding:

Digital download (not a physical book)

Paper:

Not applicable (digital format)

⚙️ Engine Specifications

Engine Type:

Austin 'BMC' C-Series OHV Inline-4 petrol engine

Engine Displacement:

2199 cc (2.2 Litre)

Engine Bore X Stroke:

83.3 mm x 101.6 mm

Engine Compression Ratio:

Approximately 7.2:1

Horsepower:

Approximately 62 hp (46 kW) at 3500 rpm

Torque:

Approximately 106 lb-ft (144 Nm) at 2000 rpm

Carburetor:

Single Zenith or Solex downdraught carburetor

Fuel Type:

Regular Unleaded Petrol (Octane rating of ~91 RON)

Engine Code Example:

Likely variants of the BMC '2.2' engine designation.

🔧 Transmission

Transmission Type:

4-speed manual synchromesh gearbox

Transfer Case:

2-speed transfer case with selectable 4WD

Gear Ratios Typical:

1st: ~3.13, 2nd: ~1.91, 3rd: ~1.35, 4th: 1.00, Reverse: ~3.34 (Specific ratios may vary)

📐 Dimensions

Wheelbase:

Approximately 90 inches (2286 mm) for standard models, longer wheelbase options may exist.

Length:

Varies by body style, typically around 130-140 inches (3302-3556 mm).

Width:

Approximately 65-70 inches (1651-1778 mm).

Height:

Varies by body style, approximately 70-75 inches (1778-1905 mm) for canvas top models.

Curb Weight:

Approximately 2800-3200 lbs (1270-1450 kg).

Payload Capacity:

Typically around 1000-1500 lbs (450-680 kg).

🛡️ Safety Features

Safety Standards:

As a vehicle from the late 1950s to late 1960s, it predates modern standardized crash test ratings (e.g., NHTSA, Euro NCAP). Safety features are basic.

Active Safety:

Four-wheel drive capability for enhanced traction, effective hydraulic drum brakes.

Passive Safety:

Basic body structure, lap belts (if fitted originally, often added later), robust chassis.

💡 Technology Features

Infotainment System:

Basic dashboard instruments (speedometer, fuel gauge, temperature gauge, oil pressure light), no complex infotainment systems as per the era.

Driver Assistance Features:

None beyond the inherent 4WD capability and basic vehicle controls.

Connectivity Options:

Not applicable for this vehicle era.

🔧 Maintenance

Oil Change Interval:

Typically every 3,000 miles or 6 months, whichever comes first. Manual will specify.

Grease Points:

Regular lubrication of chassis points (e.g., suspension kingpins, steering joints, prop shafts) is crucial, often every 500-1000 miles. Manual will detail locations and frequency.

Engine Tune Up:

Spark plug replacement, points gap adjustment, ignition timing, carburetor adjustments typically every 6,000-12,000 miles.

Engine Oil Type:

API SC/SD service classification, SAE 20W/50 or 10W/30 depending on climate. Manual will specify exact grades.

Transmission Oil Type:

GL-4 rated gear oil, SAE 90 or 80W-90. Manual will specify exact specification.

Axle Differential Oil Type:

API GL-5 rated hypoid gear oil, SAE 90 or 80W-90. Manual will specify.

Brake Fluid Type:

DOT 3 Heavy Duty Hydraulic Brake Fluid.

Coolant Type:

Ethylene Glycol based antifreeze mixed with water (50/50 ratio). Manual will specify concentration and type.

Common Wear Items:

Kingpins and bushes (independent front suspension), U-joints in propshafts, carburetor wear, distributor points and condensers, brake shoe adjustment and wear.

Rust Prone Areas:

Wheel arches, sills, floor pans, chassis outriggers, door bottoms are common areas for rust on vehicles of this era.

📚 Vehicle History

Manufacturer Origin:

Austin Motor Company, UK. Known for a range of cars and commercial vehicles.

Development:

Developed as a competitor to the successful Land Rover, aiming for slightly more comfort and car-like features in its early stages, while maintaining ruggedness for off-road use.

Production Period:

1958-1967

Manufacturing Location:

Longbridge, Birmingham, UK