ABU/Zebco Cardinal 3 Tutorial

[Midway Tommy]

You'll never get yelled at for activating an old thread, that's what they're here for, to help people through their restoration or service processes.

From your description it sounds like your bail has been bent or twisted out of alignment, but it's hard to tell without photos.

Assuming the bail is bent or twisted as described you can manually realign it by removing the wire from the bail arm and bail plate and checking to make sure that they both turn freely with good spring on their bail screws. Once you know they are not hanging up on anything you can start to adjust the formation of the bail by slightly bending it into alignment so that it lines up perfectly with the bail arm and bail plate in their closed position. Once you get to that point you can reattach the the bail and see if it closes properly. If the bail isn't aligned perfectly it will cause a bind and the bail will hang up while closing. You may have to take it loose multiple times to adjust/tweak it to get line up perfectly.

This can all be done with the rotor attached to the body but I have found that it is much easier and quicker to have the rotor loose and separate from the body. Then you don't have to maneuver around body constrictions. You might want to go back to the early part of the tutorial where the rotor hasn't yet been attached to the body and review some of those steps.

Hope that helps and good luck.

[jgp12000]

Tom,
I always reuse the same e-clips when I service my Cardinals and just was curious if you Happen to know the sizes for the Zebco Cardinal 3 & 4 for the spindle,connecting link,& AR button.I saw a HF set that may include them?

https://www.harborfreight.com/300-piece-e-clip-assortment-67653.html?utm_source=google&utm_medium=cpc&utm_campaign=12169520316&campaignid=12169520316&utm_content=120871697270&adsetid=120871697270&product=67653&store=706&gclid=EAIaIQobChMI2KH1h-C-ggMVoyzUAR1GLA5KEAQYAiABEgL8iPD_BwE

[Midway Tommy]

James, no I don't know the size. A few years ago I bought 100 each of about 10 different sizes from McMaster Carr so I would have just about everything covered for all the different vintage reels I work on. If I need one I just grab the one closest to the size I need.

[nortryder]

Hey Tom,
I did like you suggested. Went back over everything and checked out the bail components for alignment. The spring on the bail plate was knackered and I replaced it. It was actually quite a bugger to get positioned correctly. It took about a half dozen tries to get it seated so it didn't bind up when I tightened the screw. Finally got it and now it works as it should. My pal Donny would be happy. To bad he's not around.
Thanks again.

[Nstd]

tommy did you add this washer? i don't see it in the schematics and my reel. i wonder if this is why i have uneven line lay.

[jgp12000]

I think it's on all the Cardinal 3s I have,maybe protects the drag clicker plastic? Not sure,just a guess.

[Midway Tommy]

tommy did you add this washer? i don't see it in the schematics and my reel. i wonder if this is why i have uneven line lay.

No, I did not add that washer, but they were assembly line installed. It is not shown on any of ABU's or Zebco's Card 3 schematics. It is part #11135 (Card 3) or part #8669 (Card 4,6 & 7). It is shown on most 4, 6 & 7 schematics but on those it's shown between the block & e-clip. It should be positioned in front of the block to help keep the spline ribs from wearing into the block.

There could be a couple of reasons why you aren't getting even line lay and that could very well be one of them. Another could be that the bail trip lever is bent outside the rotor where the bail arm rests on it. Also, check to make sure there is not a space between the line guide washer and the bail arm that the line can get caught in. Usually, though, it has to do with excessive main shaft movement. If there is too much main shaft-block/arm movement due to wear an additional washer can be added behind the block to take up some of the space.

[Nstd]

tommy did you add this washer? i don't see it in the schematics and my reel. i wonder if this is why i have uneven line lay.

No, I did not add that washer, but they were assembly line installed. It is not shown on any of ABU's or Zebco's Card 3 schematics. It is part #11135 (Card 3) or part #8669 (Card 4,6 & 7). It is shown on most 4, 6 & 7 schematics but on those it's shown between the block & e-clip. It should be positioned in front of the block to help keep the spline ribs from wearing into the block.

There could be a couple of reasons why you aren't getting even line lay and that could very well be one of them. Another could be that the bail trip lever is bent outside the rotor where the bail arm rests on it. Also, check to make sure there is not a space between the line guide washer and the bail arm that the line can get caught in. Usually, though, it has to do with excessive main shaft movement. If there is too much main shaft-block/arm movement due to wear an additional washer can be added behind the block to take up some of the space.

thanks tommy there is movement in the shaft. do you know where i can get more washers?

[OhReely]

Regarding the washer you and Tommy are discussing. You don't have it in your reel but did it get put in the drag stack by mistake. Wouldn't that in effect shim the spool further forward resulting in line stacking at the bottom of the spool.

[Midway Tommy]

thanks tommy there is movement in the shaft. do you know where i can get more washers?

You can usually find them on eBay, but if not I've made spring washers like those from thin bronze or brass sheet stock.

The connecting link block behind the splined area of the main shaft should never make it far enough forward to hit the brake arm.

[Nstd]

tommy did you add this washer? i don't see it in the schematics and my reel. i wonder if this is why i have uneven line lay.

No, I did not add that washer, but they were assembly line installed. It is not shown on any of ABU's or Zebco's Card 3 schematics. It is part #11135 (Card 3) or part #8669 (Card 4,6 & 7). It is shown on most 4, 6 & 7 schematics but on those it's shown between the block & e-clip. It should be positioned in front of the block to help keep the spline ribs from wearing into the block.

There could be a couple of reasons why you aren't getting even line lay and that could very well be one of them. Another could be that the bail trip lever is bent outside the rotor where the bail arm rests on it. Also, check to make sure there is not a space between the line guide washer and the bail arm that the line can get caught in. Usually, though, it has to do with excessive main shaft movement. If there is too much main shaft-block/arm movement due to wear an additional washer can be added behind the block to take up some of the space.

where is behind the block? between the clip and the block? (C) do you think adding a washer at "A" would help too?

[Midway Tommy]

where is behind the block? between the clip and the block? (C) do you think adding a washer at "A" would help too?

The block I'm referencing is between B & C. The e-clip is at the rear of the main shaft under C. The washer should go in front of the block but if you have excessive play you can also put a washer behind the block between it and the e-clip.

There should be a spring washer (#11135 or 8669) between the connecting link arm and the main gear at A. The 8669 washers are a little bigger than the 11135s but they will suffice since the 11135s are a real tough find. That washer is shown on the tan & black reel photo you posted.

BTW, here are some of those washers on eBay.