Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
1971
SECTION NAME
SERIES 10-30
POWER BRAKE
CHEVROLET TRUCKS 5 CYLINDER
FOREW O RD
This manual includes procedures involved in disassem b ly
6 ENGINE
and assem b ly of major components of 1971 Chevrolet,
C hevelle, Monte Carlo, Nova, Camaro, Corvette and S eries
10 -3 0 Trucks. Information on maintenance and adjustm ents,
m inor se rv ic e operations, and rem oval and installation for
these components is contained in either the 1971 P assen ger
Car or Truck C hassis Service Manual. 6M CARBURETORS
The Section Index on this page enables the u ser to quickly
locate any d esired section. At the beginning of each section
containing more than one major subject is a Table of Con
tents, which g ives the page number on which each major STARTING MOTOR
subject begins. An index is placed at the beginning of each
major subject within the section.
6Y SOLENOID AND
DELC0TR0N
Sum m aries of Special T ools, when required, are found at
the end of major section s, while Specifications covering
veh icle components are presented at the rear of the manual. TRANSMISSION
T his manual should be kept in a handy place for ready AND CLUTCH,
referen ce. If properly used, it will enable the technician to
better se rv ic e the ow ners of Chevrolet built v eh icles.
7 4-WHEEL DRIVE
All information, illustration s and sp ecification s contained TRANSFER CASE
in this literature are based on the latest product information
available at the tim e of publication approval. The right is STEERING GEAR,
reserv ed to make changes at any tim e without notice.
POWER STEERING
9 PUMP AND CONTROL
VALVE
M inor R epair P ro ced u res................................. ............. 1-1 Compressor R ear Head and Internal Mechanism 1-7
H ub and Drive P late...................................... ............. 1-1 Pressure Relief Valve ................................................. 1-7
Pulley and Bearing Assembly...................... ............. 1-2 R ear Head, Oil Pum p and Valve A ssem blies...... 1-7
Coil Housing Assembly ............................... ............. 1-3 M ajor Internal M echanism ........................................ 1-8
M ajor Repair P ro ced u res................................. ............. 1-4 Leak Testing the Com pressor................................... 1-13
Shaft Seal A ssem b ly ...................................... ............ 1-5 Special T o o ls..................................................................... 1-15
For all practical purposes all vehicles make use of the same excessive heat, the hub and drive plate and the pulley should
air conditioning compressor. A ctual differences between be replaced. Check further for the underlying cause of the
com pressors are found in their m ounting brackets, pulleys, damage, i.e. low coil voltage or binding of the compressor
connector assemblies and com pressor capacities, none of internal mechanism.
which affect the following O verhaul Procedures.
Installation
MINOR REPA IR P R O C ED U R ES
NOTE: When hub and drive plate assembly is ready
The following operations to the H ub and Drive Plate, for installation, clean its frictional face with a suita
Pulley and Bearing, and Coil Housing are covered as "M i ble cleaner.
nor" because they m ay be perform ed w ithout first purging
the system or removing the com pressor from the vehicle. The 1. Insert the square hub and drive plate key into the key
shaft seal assembly may also be serviced w ithout removing way in the drive shaft allowing it to project approxi
the com pressor from the vehicle but this operation is covered mately 3/16" out of the end of the keyway (fig. 4).
later in this section as a "M ajor R epair Procedure" because 2. Line up the key in the shaft with the keyway in the hub.
the system m ust first be purged of refrigerant.
Illustrations used in describing these operations show the 3. Using Tool J-9480 and W asher J-9480 2 (fig. 5), install
com pressor removed from the vehicle to more clearly illus the hub - and drive plate assembly. Pull the assembly
trate the various operations. onto the shaft until there is approxim ately 3/32" space
between the frictional surfaces of the drive plate and
Hub and Drive Plate pulley. (A ZER O thrust race is approximately 3/32"
thick and may be used to roughly gauge this operation.)
Removal
1. If disassembly is being perform ed on a bench, m ount NOTE: Use Tool J-9403 to hold hub and drive plate
Holding Fixture J-9396 in a vise and attach the com if necessary.
pressor to the fixture.
2. Using C lutch H ub Holding Tool J-9403 and Socket 4. Install the hub spacer washer and, using Snap Ring
J-9399, remove the locknut from the shaft (fig. 2). Dis Pliers J-5403, install the retainer ring (Item 37, fig. 1),
card locknut. convex side of ring facing washer.
3. Tool J-9401 may now be used to remove the hub and 5. Use Tools J-9399 and J-9403 to install a new locknut.
drive plate assembly (fig. 3). Tighten the nut to 14-26 ft. lbs. torque. A ir gap between
the frictional faces should now be .022" to .057".
NOTE: Carefully snug tool into place with wrench
to insure engagement with threads. NOTE: The shoulder or circular projection on the
locknut must face towards retainer ring.
4. Use Snap Ring Pliers J-5403 to remove the retainer ring
(Item 37, fig. 1). T hen remove the hub spacer. 6. The pulley should now rotate freely.
1. Rear Head 15. Pulley and Bearing Assem bly 26. T hrust Bearing
2. Rear Head to Shell ” 0 " Ring 16. Pulley Bearing 27. T hrust Race
3. Rear Discharge Valve Plate 17. Pulley Bearing Retainer Ring 28. Com pressor Shell
4. Rear S uction Reed Plate 18. Pulley and Bearing Retainer 29. C ylinder Assem bly
5. Piston Ring Ring 30. S haft Seal
6. Piston Drive Ball 19. Clutch Hub and Drive Plate 31. S haft Seal Seat " 0 " Ring
7. Ball Seat Assem bly 32. S haft Seal Seat
8. Piston 20. Oil Pump Gears 33. Shaft Seal Seat Retainer Ring
9. Front Suction Reed Plate 21. M ainshaft Bearing (Rear) 34. A bso rbe nt Sleeve
10. Front Discharge Valve Plate 22. Oil Inlet Tube " 0 " Ring 35. A bsorbent Sleeve Retainer
11. Front Head to Shell " 0 " Ring 23. Oil Inlet Tube 36. Spacer
12. Front Head 24. W obb le Plate and M ainshaft 37. Clutch Hub Retainer Ring
13. Coil and Housing Assem bly Assem bly 38. S haft Nut
14. Coil H ousing Retainer Ring 25. T hrust Race
Installation
1. Using Tool J-9481, press or drive the pulley and bearing
assembly onto the com pressor neck. The pulley should
now rotate freely.
2. Install retainer ring using Snap Ring Pliers J-6435.
Fig. 3-R em oving Hub and Drive Plate Assem bly Fig. 5— Installing Hub and Drive Plate Assem bly
Fig. 6-R em oving Pulley and Bearing Assem bly Retainer Ring
Installation
1. R otate the coil housing to the correct position as in
Fig. 8-R em oving Coil Housing Retainer Ring
dicated by the scribe m arks and the location of the
electrical term inals and fit into place (fig. 9). ing disassembled and serviced. A clean workbench, prefera
2. Use Snap Ring Pliers J-6435 to install retainer ring. bly covered with a sheet of clean paper, orderliness in the
M A JO R REPA IR P R O C ED U R ES
The following service procedures are considered major
since the refrigeration system m ust be completely purged of
refrigerant before proceeding a n d /o r because m ajor internal
operating and sealing com ponents of the compressor are be-
work area and a place for all parts being removed and re and the shaft itself of any dirt or foreign m aterial before
placed is of great im portance as is the use of the proper, clean removing the seal seat. (This is absolutely necessary to
service tools. A ny attem pt to use make-shift or inadequate prevent any m aterial from getting into the compressor.)
equipm ent m ay result in dam age a n d /o r im proper com pres
sor operation. 4. Place Tool J-22974 over the end of the shaft to prevent
These procedures are based on the use of the proper service chipping the Ceramic seat. Fully engage the knurled
tools and the condition th at an adequate stock of service tangs of Tool J-23128 into the recessed portion of the
parts is available. Service parts stock should include the fol seal seat by turning the handle clockwise. Lift the seat
lowing: from the compressor with a rotary m otion (fig. 11).
1. M ajor interior m echanism assem bly-ready for installa
tion in shell as is. CAUTION: DO NOT tighten the handle with a
2. Service cylinder assem bly-front and rear halves with wrench or pliers; however, the handle must be hand
m ain bearings in place and halves dowel pinned tightened securely to remove the seat.
together.
3. Piston drive balls. 5. W ith Tool J-22974 still over the end of the shaft, engage
4. Ball seats—total of 10 sizes, including the Z ER O seat. the tabs on the seal assembly with the tangs on Tool
5. T hrust ra c e s-to ta l of 14 sizes, including the ZERO J-9392 by twisting the tool clockwise while pressing the
race. tool down. Then lift the seal assembly out.
6. Pistons—low and high compression. 6. Remove the seal seat ”0 ” ring from the compressor
7. Piston rings. neck using Tool J-9553 (fig. 11).
8. M ain shaft bearings. 7. Recheck the shaft and inside of the com pressor neck for
9. T hrust bearings. dirt or foreign m aterial and be sure these areas are
10. C om pressor shaft and wobble plate. perfectly clean before installing new parts.
11. Suction reed valves.
12. D ischarge valve p la te -fro n t and rear. Inspection
13. C om pressor front head.
Seals should not be reused. Always use a new seal kit on
14. C om pressor rear head.
rebuild. Be extremely careful that the face of the seal to be
15. Pulley and pulley bearing.
installed is not scratched or damaged in any way. M ake sure
16. C lutch hub and drive plate assembly.
that the seal seat and seal are free of lint and dirt that could
17. Seal k it-serv ice-co n tain s all seals and "O" rings.(a)
damage the seal surface.
18. Shaft seal kit.(a)
19. N u ts-h e a d to shell, and shaft.(a) A pparent seal leaks are sometimes the result of misposi-
tioning of the wobble plate on the com pressor shaft caused
20. R etainer rin g s-all necessary sizes.
21. Cylinder locator (dowel) pins. by im proper procedures during pulley removal, pounding or
22. Valve and head locator (dowel) pins. dropping on the com pressor shaft or collision impact. Check
23. Service discharge crossover tube kit. as shown in Figure 12. If m easurem ent is greater than shown,
replace the shaft and wobble plate assembly.
(a)To be used each time a compressor is rebuilt.
All parts required for servicing are protected by a preser
vation process and packaged in a m anner which will elimi Installation
nate the necessity o f cleaning, washing or flushing of the 1. Coat the new shaft seal seat ”0 ” ring with clean Frigi-
parts. The parts can be used in the m echanism assembly just
daire 525 viscosity refrigeration oil (or equivalent) and
as they are rem oved from the service package.
install in the com pressor neck groove using Tool J-
I iston ball seats and shaft th ru st races will be identified on 21508 (fig. 13).
the parts themselves to denote their size and dimension.
Shaft Seal Assembly NOTE: Refrigerant oil has been specifically dehydrated
and therefore has a great affinity for the moisture in
W hen replacing the shaft seal assembly, even if the com
the atmosphere. NEVER leave the refrigeration oil bottle
pressor remains on the vehicle during the operation, it will
uncapped for more than a few moments or oil contam
be necessary to purge the system of refrigerant as outlined in
the Chassis Service M anual. ination will result.
2. Coat the ”0 ” ring and seal face of the new shaft seal
Removal assembly with clean refrigeration oil and carefully en
gage the seal assembly onto the locking tangs of Tool
1. A fter first purging the system of refrigerant, remove the J-9392 (fig. 13). Place shaft Seal Protector J-22974 over
clutch hub and drive plate, and the shaft key. the end of the shaft and slide the seal down the shaft,
2. Pry out the sleeve retainer and remove the absorbent turning the tool clockwise and applying light pressure
sleeve. Remove the seal seat retaining ring using Snap until the seal assembly engages the flats on the shaft and
Ring Pliers J-5403. is seated in place. R otate the tool counter-clockwise
3. Thoroughly clean the area of the compressor neck sur slightly (to release it from the seal) and remove Tool
rounding the shaft, the exposed portion of the seal seat, J-9392.
1. S haft Nut 16. S haft Seal Seat 29. Drive Key 43. M ainsha ft Rear
2. Clutch Hub Retainer Retainer Ring 30. Discharge Crossover Bearing
Ring 17. Shaft Seal Seat Tube 44. Discharge Crossover
3. Spacer 18. S haft Seal 31. Piston Ring Tube Rear " 0 " Ring
4. Clutch Hub and Drive 19. S haft Seal Seat " 0 " 32. Piston Front Drive and Spacer
Plate Assem bly Ring Ball 45. Rear Suction Reed
5. Pulley and Bearing 20. Com pressor Front 33. Piston Front Ball Plate
Retainer Ring Head Seat 46. Rear Discharge Valve
6. Pulley Bearing 21. Front Discharge 34. Piston Plate
Retainer Ring Valve Plate 35. Piston Rear Ball Seat 47. Oil Pump Drive Gear
7. Pulley Bearing 22. Front Suction Reed 36. Piston Rear Drive 48. Oil Pump Driven Gear
8. Pulley Valve Ball 49. Rear Head-to-Shell
9. Coil Housing Retainer 23. Discharge Crossover 37. Piston Ring " 0 " Ring
Ring Tube Front " 0 " Ring 38. Drive S haft and 50. S trainer Screen
10. Coil Housing and Spacer W obb le Plate 51. C om pressor Rear
11. Com pressor Shell 24. M ainsha ft Front A ssem bly Head
12. A bso rbe nt Sleeve Bearing 39. Rear T hrust Race and 52. High Pressure Relief
13. A bso rbe nt Sleeve 25. Head Locating Pins Bearing Pack Valve and " 0 " Ring
Retainer 26. Front C ylinder Half 40. Rear C ylinder Half 53. Rear Head-to-Shell
14. Oil Drain Plug and 27. Front T hrust Race 41. Oil Inlet Tube " 0 " Retaining Nuts
Gasket and Bearing Pack Ring 54. C om pressor-to-
15. Front Head-to-Shell 28. Suction Crossover 42. Oil Inlet Tube C o n n e cto r “ 0 ” Rings
" 0 " Ring Cover
3. Coat the seal face of the new seal seat with clean refrig into a cylinder, overlapping the ends, and slipping the
eration oil. G rip the seal seat w ith Tool J-23128 and sleeve into the com pressor neck with the overlap to
push into place with a rotary motion, so as not to dis ward the top of the compressor. W ith a small screw
turb the ”0 ” ring and to also effect a seal with this ”0 ” driver or similar instrum ent, carefully spread the sleeve
ring. Remove Tool J-23128. until the ends of the sleeve b u tt at the top vertical
4. Install the new seal seat retainer ring with Tool J-5403, centerline.
with the flat face against the seal seat. Press on the 7. Position the new metal sleeve retainer so that its flange
retainer ring until it snaps into place. Remove Tool face will be against the front end of the sleeve. Tool
J-22974 from the end of the shaft. J-9395 may be used to install the retainer. Press and tap
5. Leak test the com pressor as described under ’’Leak with a mallet, setting the retainer and sleeve into place
Testing the Com pressor” in this section. C orrect any (retainer recessed approxim ately 1/32” from the face of
leaks found. the com pressor neck).
6. Install the new absorbent sleeve by rolling the material 8. Reinstall the clutch hub and drive plate assembly.
SEAL SEAT
NOTE: Keep the ends of the two oil pump gears
"O " RING matched and replace the same end toward the dis
charge plate upon reassembly.
SEAL ASSEMBLY
6. Remove the rear head-to-shell ” 0 ” ring and discard.
7. W ith two screw drivers, carefully pry up on the rear
discharge valve plate assembly (fig. 14). Check for
broken reeds or damaged seats and replace entire as
sembly if such is found.
8. Carefully lift off the rear suction reed valve. Valve m ust
be replaced if any dam age is evident.
Installation
1. Carefully replace the suction reed valve and the rear
discharge plate over th e dowel pins and ports in the
cylinder assembly. Proper positioning of the reed plate
may be determ ined by lining up the proper opening in
the plate with the discharge crossover tube opening.
2. Position the rear head casting to align with the dowel
pins. The two lower m ounting pads will be in alignment
w ith the oil sum p in the shell. R otate the cylinder as
sembly back and forth by hand, if necessary, to permit
this alignm ent. Remove the rear head from this trial Fig. 15-P rop er Oil Pump Gear P ositioning
assembly.
3. Install the inner oil pum p gear over the ” D ” flat on the Major Internal Mechanism
shaft and place the outer oil pum p gear over the inner
gear. Position the outer gear as follows: The clutch hub and drive plate assembly, drive key, pul
a. Observe the position of the oil sum p in the shell. ley, and coil housing and shaft seal should be removed before
b. Locate the approxim ate centerline of this sump. proceeding with the following com pressor disassembly.
c. Facing the centerline of the sump and viewing from
the sum p side (bottom ) of the compressor, move the Removal from Shell
O U T E R gear tow ard the right (side having the oil
drain fitting) until it is at approxim ately 90 degrees 1. Remove the rear head, discharge plate and suction reed
(3 o’clock position) from the centerline of the oil valve from the compressor as outlined under ’’Rear
sum p (fig. 15). H ead and Reed Valve Assemblies.”
4. Coat the head-to-shell ”0 ” ring with clean refrigeration 2. Remove the oil inlet tube and ”0 ” ring with Tool J-
oil and generously lubricate the area around the outer 5139 as shown in Figure 16.
edge of the valve plate where the ”0 ” ring will be 3. Carefully lay the compressor shell on its side and slide
placed. Oil also the oil pum p gears, valve reeds and the out interior mechanism and front head assembly. DO
area where the head casting web sealing surface will N O T ham m er or use undue force to remove the mech
contact the valve plate. anism; however, gentle taps on the head casting may aid
5. Install the head-to-shell ” 0 ” ring. in removing the assembly.
6. Be sure th at the suction screen is properly positioned in
the rear head, then assemble the rear head to the com CAUTION: DO NOT hammer or tap on the compres
pressor shell being careful not to damage the sealing sor shaft.
surface on head casting webs.
4. Remove front head casting, front discharge valve plate
CAUTION: Be sure head does not bind against oil and suction reed valve from the mechanism. Examine
pump gears when being installed. parts for damage and replace if necessary. Check p ar
ticularly for damage to the sealing surfaces on the front
7. Install new nuts to the threaded shell studs and tighten head casting webs.
to 19-25 ft. lbs. torque. 5. Examine the mechanism for any obvious damage.
8. Leak test the com pressor as outlined under ’’Leak Test 6. Remove the suction crossover cover (fig. 17).
ing the C om pressor” in this section. 7. If desired, the mechanism may be assembled in Check
9. Install com pressor in the vehicle. ing Cage J 9397 and operated on a m otor test stand, or
Fig. 17— Rem oving S u ctio n Crossover Cover Fig. 19 -S e p a ra tin g C ylinder Halves
a notch in the casting web (fig. 20). The piston com Proper selection of thrust races and ball seats is of extreme
partments in Tray J-9402 have a boss at this notch importance.
location to indicate the front. 1. Secure from service parts stock:
Four-ZER O thrust races
6. Remove and inspect all piston rings. Replace all broken Three-ZER O ball seats
or dam aged rings. D am aged pistons m ust also be re Two-New thrust bearings
placed. 2. Assemble a ZER O thrust race, a new needle thrust
7. Examine piston balls. Replace if they show burning or bearing and another Z E R O thrust race, in that order,
excessive wear. to the front end of the shaft. (A dab of clean petroleum
8. Remove the rear com bination of thrust races and bear jelly will hold the bearing-race pack together and in
ing from the shaft and discard all three pieces. place on the shaft.) Lubricate front and rear faces of the
9. Remove the shaft and wobble plate assembly from the wobble plate with clean refrigeration oil.
front half of the cylinder. 3. W ith the front half of the cylinder assembly resting on
10. Remove the front com bination of thrust washers and Tool J- 9397, insert the shaft threaded end through the
bearing and discard all three pieces. front main bearing until the thrust race assembly rests
11. Exam ine all surfaces of the wobble plate and, if satisfac on the front cylinder hub.
tory, reuse. If it shows signs of wear, replace the shaft 4. Assemble a ZER O thrust race, a new needle bearing
and wobble plate as an assembly. Use care not to move and a second ZER O thrust race in that order, to the
wobble plate on the shaft. This is factory set. rear of the shaft.
12. Examine the front and rear cylinder halves and replace 5. Apply a light smear of clean petroleum jelly to the ball
if cylinder bores are deeply scored or damaged. pockets of each of the three pistons.
13. W ash all parts to be reused in a suitable cleaner. Blow 6. Place the balls in the piston pockets. The petroleum
dry all parts. jelly will hold the balls in place.
14. If cylinder main bearings are to be replaced they may 7. Apply a light smear of petroleum jelly to the cavity of
be removed and reinstalled at this time using Tool J- three new ZER O ball seats and place one seat over each
9432. Drive against the lettered end of the bearings and front piston ball. There should now be a ball and seat
from the outside of the cylinder. Bearing m ust be not in the front ball pocket of each piston and a ball only
m ore than 1 /8 ” below surface. in the rear ball pocket.
H o ld in g F ix tu re l
H I J-9396
| Compressing |
Fixture J-9397
Fig. 2 0 -N o tc h Id e n tifyin g Front End of Piston Fig. 2 1 — Installing Piston, Front Ball and Seat and Rear Ball
S pring Scale
Thrust B ea ring
f
"Ot; * ' •*-.
along with the num bered rear seat chosen in Steps 12 faces the inside of the compressor to allow for wob
and 13 above. ble plate clearance.
CAUTION: When the balls and seat are removed 10. W hen all parts are in proper alignment, tap with a fiber
from the piston, be sure that they are placed in the block and mallet to seat the rear half of the cylinder
proper parts tray pocket so as not to lose the rela over the locating dowel pins. If necessary, clamp the
tionship of the balls and seats to the proper end of cylinder in Fixture J-9397 to complete drawing the cyl
the piston. inder halves together.
11. Generously lubricate all moving parts with clean refrig
19. Remove the rear outer (upper) Z E R O thru st race from eration oil and check for free rotation of the parts.
the com pressor shaft and replace it with the num bered
thrust race (determ ined in Step 14 above) from parts NOTE: It may be desirable to clamp the cylinder
tray. assembly in compressing Fixture J-9397 and check
on the motor test stand for proper operation before
NOTE: This ZERO thrust race may be put aside for proceeding further. If any improper operation is ob
reuse in future gauging and/or rebuild operations. served, the mechanism should be regauged to insure
proper operation. Complete the assembly procedure
20. The gauging operations are now complete. when correct operation is obtained.
Assem bly 12. Replace the suction crossover cover as shown in Figure
25. Compress the cover as shown to start it into the slot
After properly perform ing the gauging procedure and and then press it in until flush on both ends.
choosing the correct ball seats and thrust races as outlined
under ’’G auging Procedures,” the cylinder assembly may be Installation Into Shell
reassembled. Be sure to install all new seals and ” 0 ” rings.
All are included in the com pressor seal service kit. 1. Support the cylinder on Fixture J-21352 with the
Assembly procedure is as follows: threaded end of the shaft up.
1. Support the front half o f the cylinder assembly on Fix 2. Assemble the two dowel pins in the front cylinder if
ture J-9397 and install the shaft and wobble plate, they are not already in place.
threaded end down, w ith its front bearing race pack
(ZE R O race, bearing and Z E R O race) and its rear bear NOTE: A rod drilled 1/4 in. deep to the O.D. of the
ing race pack (ZERO race, bearing, num bered race) if dowel pins will aid in installing.
this was not already done at the end of the ’’Gauging
Procedure.”
2. Assemble a piston ring, scraper groove tow ard the cen
ter of the piston, to each end of the three pistons.
3. Apply a light sm ear of petroleum jelly to the num bered
ball seats chosen in the gauging procedure and install
all balls and seats (if rem oved in Step 18 of the gauging
procedure) in their proper place in the piston.
4. R otate the wobble plate so th at the high point is above
cylinder bore No. 1. Carefully assemble piston No. 1,
complete with ball and Z E R O seat on the front and ball
and num bered seat on the rear, over the wobble plate.
H old front thrust bearing pack tight against wobble
plate hub while lifting hub. Compress and enter the
piston ring into the front cylinder half.
5. Repeat this operation for pistons No. 2 and No. 3.
6. Assemble one end of a service discharge crossover tube
into the hole in the front cylinder half.
7. R otate the shaft to position the pistons in a stair-step
arrangem ent, then carefully place the rear cylinder half
over the shaft and start the pistons into the cylinder
bores.
8. Compress the piston ring on each piston to perm it its
entrance into the cylinder.
9. W hen all three pistons and rings are in their respective
cylinders, align the end of the discharge crossover tube
with the hole in the rear half of the cylinder.
NOTE: Be sure the flattened portion of this tube Fig. 2 5 —Installing Suction Crossover Cover
1. Install ” 0 ” rings and Cover Plate J-9527 over the suc 4. H ook up a R efrigerant-12 container and charging line
tion and discharge ports o f the com pressor head. (using A dapter J-5420) to cover plate fitting over the
2. Check and add oil to the com pressor as outlined under suction port, charge the com pressor up to can pressure,
’’Checking Com pressor Oil Charge” in the Chassis Ser and leak test com pressor with a leak detector.
vice M anual. 5. T urn off the refrigerant container valve. Transfer gauge
3. Tem porarily install the shaft nut. W ith the compressor line and adapter to cover plate fitting over the discharge
in the horizontal operating position (oil sum p down), port and repeat the procedure outlined in Step 4.
rotate the com pressor shaft several times in the normal 6. C orrect any leaks present.
direction of rotation.
SPECIAL TOOLS
1. J -8 3 9 3 C harging Station 17. J-9401 Hub and Drive Plate Assem bly
2. J-5 4 5 3 Goggles Remover
3. J-9 4 5 9 9 0 Degree Gauge Line A da pter 18. J-9 4 8 0 Hub and Drive Plate Assem bly
4. J-5 4 2 0 Gauge Line A da pter Installer
5. J-6 0 8 4 Leak Detector 19. J-9 3 9 2 Seal Remover
6. J-8 4 3 3 Puller 20. J-2 3 1 2 8 Seal Seat Remover
7. J-93 95 Puller Pilot 21. J-93 98 Pulley Bearing Remover
8. J -2 3 5 9 5 R efrigerant Can Valve (Side 22. J-9481 Pulley and Bearing Installer
Tap) 23. J-8 0 9 2 Handle
9. J-6271 R efrigerant Can Valve (Top 24. J -2 1 3 5 2 Internal Assembly Support
Tap) Block
10. J-5421 Pocket Therm om eters (2) 25. J-51 39 Oil Pickup Tube Remover
11. J-5403 N o. 21 Snap Ring Pliers 26. J-9 4 3 2 Needle Bearing Installer
12. J-6 4 3 5 No. 26 Snap Ring Pliers 27. J-9 5 5 3 Seal Seat " 0 " Ring Remover
13. J-9 3 9 6 Com pressor Holding Fixture 28. J -2 1 5 0 8 Seal Seat " 0 " Ring Installer
14. J-9 3 9 7 Com pressing Fixture 29. J -2 2 9 7 4 Shaft Seal Protector
15. J-9 4 0 3 Clutch Hub Holding Tool 30. J-9 5 2 7 Pressure Test Connector
16. J-9 3 9 9 9 / 1 6 ” Thin W all Socket 31. J-9 4 0 2 Parts Tray
Front Axle D ifferential................................................... ........ 3-1 Pinion and B e arin g s........................................................ 3-3
R em oval.................................................................................. 3-1 Removal and Disassembly ........................................ 3-3
D isassem bly................................................................... ........ 3-1 Assembly and Installation ........................................ 3-3
A ssem b ly ................................................................................ 3-1 Axle Shaft G uide and Oil Seal Replacement .......... 3-4
Installatio n ..................................................................... ........3-1 Special T o o ls ..................................................................... 3-5
1. Nut 12. D ifferential Bearing Cup 21. D ifferential Bearing A djusting 30. T hrust W asher
2. W asher 13. Bearing Cap Shims 3 1. Ring Gear Bolt
3. Pinion Flange 14. D ifferential Bearing A djusting 22. D ifferential Bearing Cap 32. Oil S linger
4. O uter Bearing Shims Shims 23. D ifferential Bearing Cone 33. D ifferential Carrier
5. Drive Pinion 1 5. D ifferential Pinion 24. D ifferential Bearing Cup 34. Inner Bearing Cone
6. Inner Bearing Shims 1 6. T hrust W asher 25. Cover B olt 35. Inner Bearing Cup
7. Lock Pin 1 7. Cover 26. Gasket 36. O uter Bearing Cup
8. D ifferential Side Gear 1 8. Pinion Cross Shaft 27. Axle Shaft 37. O uter Bearing Cone
9. T hrust W asher 19. Ring Gear 28. Axle Shaft Guide 38. Oil S linger
10. Axle Shaft 20. D ifferential Case 29. Oil Seal 39. Oil Seal
11. D ifferential Bearing Cone
b.Install differential w ithout ring gear and check run not vary more than .002" between positions checked. If
out of differential case flange. If runout is more than backlash is not within these limits, change the differen
.002", the defect is probably due to bearings or dif tial bearing shim pack at both bearings to correct. Total
ferential case. If flange runout is less than .002" the of both shim packs must remain the same.
ring gear was probably at fault. Correct the defect 6. Check ring and pinion tooth contact pattern, using red
before proceeding further. lead and oil as outlined in Section 4.
6. If runout is saftisfactory (less than .002"), remove in 7. Install new gasket on carrier and install cover. Install
dicator and determ ine shim thickness necessary for dif metal ratio tag under one of the cover bolts. Tighten
ferential side bearing preload as follows: bolts evenly and alternately.
a. Insert a pry bar between carrier and bearing on end 8. Install axle shafts as outlined previously. (Refer to
housing half of case to move carrier as far as it will Truck Chassis Service Manual, Section 3).
go-
b. M easure clearance between carrier and bearing at
end housing half of case by inserting long feeler
gauges all the way across outer face of bearing. PINION AND BEA RIN G S
W rite down total feeler gauge thickness (For exam
ple: .054"). Remove feeler gauge.
Removal and Disassem bly
c. Insert pry bar between carrier and bearing on ring
gear flange half of case to move carrier until no 1. Remove pinion flange, oil seal, gasket, and oil slinger.
backlash can be detected between ring gear and pin Use Tool J-8614 to hold flange.
ion. 2. Remove differential as outlined in preceding pages.
d. M easure clearance between carrier and bearing at 3. Tap drive pinion and inner bearing cone out of carrier,
ring gear flange half of case by inserting long feeler using a soft hammer. Tag and save shim pack on splined
gauge all the way across outer face o f bearing. W rite end of pinion (outer bearing shim) for reference during
down feeler gauge thickness. (F or example: .036"). assembly. If ring gear and pinion are to be replaced,
e. Remove differential assembly from carrier and write down the m arkings plus, minus or (0) on face of
remove differential side bearings. pinion for reference during assembly.
f. Install shim packs as follows: 4. Remove pinion outer bearing cone from carrier.
5. If pinion bearings are to be replaced:
NOTE: If old shims are to be reinstalled make sure a. Remove inner bearing cup, using suitable drift, and
nicks in shims caused by bearing puller are placed to driver or slide ham m er to take cup out of carrier.
line up with notches in the case. Tag and save shim pack for inner bearing cup for
reference during assembly.
1. A t ring gear flange end of case, install shim pack b. Remove outer bearing cup from carrier, using a
equal to am ount gauged in Step d, above (example: suitable drift or punch.
.036"). Install bearing tight against shim. c. Press pinion inner bearing cone off pinion using
2. Subtract the am ount of shims installed (example: J-8553 and remove oil slinger from pinion.
.036") from the am ount gauged in Step b, above
(example: .054:). To the result (example: .054"
Assem bly and Installation
.036" .018") add .015" to .020" shims to provide
bearing preload. 1. Install oil slinger and new bearing cone on drive pinion,
3. Install the shim pack determ ined in Step (2) above using J-5590 to seat outer bearing against shoulder.
(example: .018" .015" .033") at end housing half of 2. Install outer bearing cup in carrier, using Tool J-6368
case and install bearing tight against shim. with driver handle J-8092 to seat cup in counterbore.
3. If a new ring gear and pinion are to be installed, note
the "plus" or "minus" markings on the rear face of the
Installing Differential
original pinion. These markings represent the variation
1. Using dial indicator and Tool J-5231-01 again, as when from the nominal pinion depth dimension to obtain the
removing and installing differential, spread carrier not proper tooth contact for individual gear sets.
more than .020". The approxim ate depth setting of the new pinion may be
2. Install differential bearing cups and set differential in made by increasing or decreasing the shim pack next to the
carrier. R otate differential and tap ring gear with a soft pinion inner bearing cup to correspond with the difference in
ham m er to assure bearing seating. markings on old and new pinions.
3. Install differential bearing caps in their correct loca To maintain proper pinion bearing preload, shims must be
tions as indicated by m arks m ade at time of removal. added to or subtracted from the pinion outer bearing shim
Tighten bolt slinger tight. pack to correspond with changes made to the inner bearing
4. Release pressure on spreader tool and remove; tighten shim pack.
bearing cap bolts to 80 ft. lbs. torque. If the difference in the markings on the old and new pin
5. Install dial indicator and check ring gear to pinion ions is in the "plus" direction, shims must be removed from
backlash at four equally spaced points around ring gear. both pinion bearing shim packs. If the difference is in the
Backlash must be between .003" and .006" and must "minus" direction, shims must be added.
Examples of shim selection- than minus .001" to plus .003", the pinion depth is
satisfactory. If not, change pinion bearing shim packs
Markings on to make the two figures correspond within the specified
Pinions D ifference Amount limits.
New Old Between To Change 8. Using a troque wrench calibrated in inch pound and a
Pinion Pinion Markings Each Shim Pack suitable socket, check pinion bearing preload. The
rotating torque of the pinion shaft should be 10 to 20
+8 +5 +3 D ecrease .003" inch pounds. A dd or remove shims behind the outer
+5 +8 -3 Increase .003" bearing cone to bring preload within limits.
-5 -3 -2 Increase .002” 9. W hen pion depth and bearing preload are within limits,
-3 -5 +2 D ecrease .002”
install differential in carrier, adjust differential bearing
+5 -3 +8 D ecrease .008"
-4 +2 -6 Increase .006"
preload and ring gear backlash and complete the axle
assembly as outlined under "D ifferential-Installation."
4. W hen the approxim ate shim packs have been sleeted, 10. Remove flange and install slinger, new oil seal, flange
install inner bearing shim pack in carrier and install and propeller shaft.
cup, using Tool J 9276-2 to seat cup tight against shims.
NOTE: If not completely assembled, refer back to
5. Insert pinion and inner bearing cone in carrier and Step 3, page 3-1 to install differential into carrier
housing.
install outer bearing shim pack on end of pinion. Install
outer bearing cone, using Tool J-5590 to seat bearing
11. Fill unit with recommended lubricant, lower vehicle on
tight against shim pack. D o not install oil seal at this
time. hoist, and road test vehicle.
6. Install pinion flange, w asher and nut, using Tool J-8614
to hold flange while tightening nut to 210 ft. lbs. torque. AXLE SHAFT GUIDE AND OIL SEAL
REPLACEMENT
7. D eterm ine proper pinion depth using Pinion D epth
Gauge, Tool J- 5341, with Tool J-7892 (SE-1065-1, The axle shaft guides and oil seals, located just outboard
(2)-5, (2)-6, (2)-9SS, (1)-10, (l)-58 with 1" microme of the differential bearings, can be replaced only after re
ters). W hen using the m icrom eter gauge, the actual moval of the differential.
pinion depth setting can be determ ined by adding the 1. Remove differential as outlined previously.
m icrom eter gauge reading to the thickness of the step 2. Drive the guides and seals inboard out of carrier.
plate and com paring the result with the nominal dimen 3. Install new guides in tube.
sion of 2.625" plus or m inus the m arking on the face of 4. Lubricate new oil seals and install in tube, with lip of
the pinion. If the difference in the two figures is less seal inboard, with J-8 107-4.
SPECIAL TOOLS
Chevelle, M onte Carlo, 116" W.B. Station Series 20 5500 Lb. Differential (D a n a ) ........................ 4-30
W agons, N ova and 10 Series Trucks ............... 4-1 Positraction Differentials ................................................. 4-35
Chevrolet (Except 116"W.B. Station W agons) and Series 20-30 T ruck 5200-7200-11,000 lb.
C a m a ro ..................................................................... 4-11 D ifferentials................................................................441
C o rv ette............................................................................... 4-20 S pecialT oo ls..................................................................... ...4-51
INDEX
r y ----------- 1 4
15
Fig. 3A ~ D iffere ntial Bearing Removal Fig. 5A -R in g Gear Guide Pins Installed
Drive Pinion
Removal
1. Remove differential as previously outlined.
2. Remove propeller shaft.
3. Install Tool J-8614-1 on pinion flange and remove pin
ion flange nut and w asher (fig. 6A). (Position J-8614-1
on flange so th at the four notches are tow ard flange.)
Discard nut and use a new one upon reassembly.
4. Thread end of Tool J-8614-3 into small O.D. end of
J-8614- 2. Then with J-8614-1 installed as in Step 6,
Fig. 7A~Drive Pinion Flange Removal
insert J-8614-2 into J-8614-1 and turn it 45 degrees to
locked position. Remove flange by turning J-8614-3 chipping or evidence of excessive wear. On pinion bear
while holding J-8614-1 (fig. 7A). ing rollers, inspect large end of rollers for wear. This is
5. Pry old seal out of bore, using a screw driver or a where wear is most evident on tapered roller bearings.
ham m er and chisel.
If deflector requires replacement, remove by tapping
from flange. Clean up stake points. Install new deflec NOTE: The pinion bearings are of the tapered type,
tor, and stake deflector at three new equally spaced and the natural wear pattern is a frosted condition
positions. with occasional slight scratches on races or rollers.
This does not indicate a defective bearing.
NOTE: Staking operation must be performed in
such a manner that the seal operating surface is not 2. Inspect pinion splines and flange splines for evidence of
damaged. excessive wear.
3. Inspect ring gear and pinion teeth for possible scoring,
6. Remove drive pinion by tapping on front end w ith a soft cracking or chipping.
faced ham m er. T hen remove pinion front bearing cone
from carrier bore. D iscard pinion bearing spacer and
use a new one upon reassembly. Pinion and/or Bearing Replacement
1. If necessary to replace pinion bearings, tap old cups out
NOTE: Care must be taken not to damage pinion of carrier using a brass drift. Tap alternately on oppo
bearings while removing pinion from carrier. Inspect site sides of cup to prevent cups from cocking in carrier.
bearings and cups for damage and replace if needed. Inspect cup seats and bore for any nicks or burrs and
Inspection remove as necessary.
2. Position new bearing cup in carrier, thick edge of cup
1. Clean all gears and bearings in cleaning solvent and
inspect all bearing cups, races and rollers for scoring,
Fig. 6A -D rive Pinion Nut Removal Fig. 8A -D rive Pinion Rear Bearing Cup Installation
Fig. 10 A -D rive Pinion Cone and Roller Assem bly Removal Axle)
PLUNGER
j. Slowly swing inner end of tool plunger across gauge
plate until highest indicator reading is obtained. Re
cord this m easurem ent and recheck to see th at it is
correct.
k. All service pinion gears are stam ped with a code
num ber on the threaded end of the pinion. The
num erical difference between the code num ber and
the gauge reading obtained in Step i determines the
required thickness of the pinion locating shim.
EX A M PLE:
Pinion Code N u m b er................................... 45
Fig. 13A --lnstalled V ie w of Pinion Depth Gauge
D ial Indicator R e a d in g ............................... 16
D ifference........................................................ 29
Light-duty axle-position gauge plate with lower surface Proper Shim T h ic k n e ss................................... 029”
(x stam ped near low side) tow ard top of carrier.
Heavy-duty axle-position gauge plate with higher sur
face tow ard top of carrier. NOTE: Shims are available in .001" increments from
d. Insert clam p screw through gauge plate and both of .021" to .037". Each shim has the thickness etched on
the pinion bearings. flat surface for easy identification.
e. Position J-6266-25 on threaded end of clam p screw
and index it in front bearing, install hex nut and
rotate bearings several times to m ake sure th at they 9. Remove Tool J-6266 and pinion bearing cone and roller
are seated. assemblies from carrier.
8. Continue with the following steps for both passenger and 10. Position shim selected in above procedure on pinion
truck. shaft and against pinion head.
f. Tighten hex nut until 20 in lbs. of torque is required 11. Install new cone and roller assembly, using Tool J-5590
to rotate bearings (fig. 14A). for lightduty axle (fig. 16A) or Tool J-9772 for heavy-
g. A fter torque has been established check position of duty axle (fig. 17A). Press cone against shim and rear
gauge plate in carrier (See Steps b and c). face of pinion.
h. Position dial indicator (Tool J-8001-3) on gauge
post of Tool J- 6266-28 so th at indicator button rests
on top of tool plunger.
Fig. 14 A -M e a su rin g Drive Pinion Bearing Rotating Torque Fig. 15 A -M e a su rin g Drive Pinion Shim Requirem ent
J-22804-2
J-9458
Fig. 17 A -D rive Pinion Cone and Roller Assem bly Installation Fig. 19A~Drive Pinion Flange Oil Seal Installation
(Heavy Duty) (Heavy Duty)
Fig. 20A~D rive Pinion Flange Installation 4. Install strap J-22779-6 on left bearing by tightening
bearing bolts alternately and evenly to snug fit.
5. W ith the ring gear tight against the pinion gear (.000"
pull flange on shaft (fig. 20A). Remove J-9458 after to .001" backlash) insert gauging Tool J-22779 between
flange is seated. the left bearing cup and carrier housing (fig. 22A).
5. Pack the cavity between end of pinion splines and pin W hile oscillating tool, turn adjusting nut clockwise un
ion flange w ith a nonhardening sealer (such as Per- til a noticeable drag is produced.
m atex Type A or equivalent) prior to installing washer
and nut on pinion.
DIFFERENTIAL BEARING SHIM IDENTIFICATION
6. Install new self-locking nut on pinion shaft. Tighten nut
to remove end p lay -co n tin u e alternately tightening, in
Identification Notches
small increm ents, and checking preload with Torque Shim
W rench J-5853 and A dapter J-5810 until torque re Heavy Duty Light Duty
Thickness
quired to rotate pinion is 20-25 in. lbs. for new bearings I.D. O.D. I.D. O.D.
and seal, or 5-10 in. lbs. when used parts are reinstalled
.040 0 0 3 4
(fig. 21 A). .042 4 1 4 0
.044 4 2 4 1
NOTE: Rotate torque wrench slowly as torque in .046 4 3 4 2
creases relatively fast. If, however, it happens that .048 4 4 4 3
the torque specification is exceeded back off nut .050 5 0 5 0
and readjust to specifications. .052 5 1 5 1
.054 5 2 5 2
Differential Bearing Preload and Ring Gear .056 5 3 5 3
Adjustment .058 5 4 5 4
1. Check condition of bearing cups, cup seat in carrier and .060 6 0 6 0
carrier caps to m ake sure they are free from nicks, burrs .062 6 1 6 1
and foreign m aterial. .064 0 2 0 0
.066 0 3 0 1
2. Lubricate bearings w ith axle lubricant, position cups on
.068 0 4 0 2
proper bearings then install differential assembly in car .070 1 0 0 3
rier. Install right bearing cap, tightening the bolts to a .072 1 1 1 0
snug fit. .074 1 2 1 1
.076 1 3 1 2
.078 1 4 1 3
.080 2 0 2 0
.082 2 1 2 1
.084 2 2 2 2
.086 2 3 2 3
.088 2 4 3 0
.090 3 0 3 1
.092 3 1 3 2
.094 3 2 3 3
.096 3 3 0 4
.098 3 4 1 4
.100 4 0 2 4
* Additional shims are available for the light-duty axle; these shims,
with a thickness of .052' through .062', are identified by a number
Fig. 21 A--M easuring Drive Pinion Bearing Preload stamped on the shim. This number indicates the shim thickness.
Fig. 2 3 A -M e a su rin g Gauge Plate Thickness Fig. 2 4 A -ln s ta llin g D ifferential Shim
gear and case for deform ation a n d /o r foreign m atter between 5. Inspect the contact pattern produced by the above
case and gear. procedure. (Figure 27A shows the terminology used in
If gear lash is not w ithin limits, correct by decreasing shim analyzing contact patterns). M ake adjustm ents as in
thickness on one side and increasing thickness of the other dicated by the contact pattern (fig. 28A).
shim the same amount. T otal shim thickness m ust be m ain The large end of the tooth is called the "heel" and the
tained to m aintain proper preload. small end the "toe". Also, the top of the tooth, which
EX A M PL E : By decreasing shim on the right side is the part above the pitch line, is called the "face,"
.002" and increasing shim thickness of the left side by while the part below the pitch line is called the "flank".
.002" backlash will decrease by .001". The space between the adjacent meshing teeth is re
ferred to as "backlash".
Figure 28A shows correct and incorrect contact pat
Ring Gear and Pinion Contact Pattern terns. Contact pattern "A" provides the ideal bearing
for quietness and long life. If the pattern shows a toe
1. Thoroughly clean the ring and pinion gear teeth.
contact "B", it indicates not enough backlash. To cor
2. Paint ring gear teeth lightly and evenly with a mixture
rect, move the ring gear away from the pinion by in
of pow dered red lead and oil of a suitable consistency
creasing the right thickness while decreasing left shim
to produce a contact pattern.
thickness an equal amount.
3. Remove the differential pinion shaft, and install axle
If the pattern shows a heel contact "C," it indicates
shafts and d ru m s-in stall wheel bolts to retain drum s on
too m uch backlash. To correct, move the ring gear
axle shaft. Expand brake shoes until a torque of 60 ft.
tow ard the pinion by increasing left shim thickness
lbs. is obtained at pinion nut.
while decreasing right shim thickness an equal amount.
4. R otate pinion through several revolutions in the for
ward and reverse direction until a definite contact pat
tern is developed on the ring gear.
NOTE: Make adjustment increasing and decreasing
shim thickness by 0.002" at a time, check contact
with red lead mixture and continue adjustment until
tooth contact appears as in "A ". Backlash must re
main within limits.
ion in reduces backlash and moving it out increases NOTE: This wheel to axle flange fastener is an im
backlash. portant attaching part in that it could affect the
A fter satisfactory contact pattern is produced as in performance of vital components and systems, and
"A ," clean ring and pinion gear teeth and pour a liberal /or could result in major repair expense. It must be
q u a n tity o f re a r axle lu b ric a n t o n g ears a n d b e a r replaced with one of the same part number or with
ings. T u rn gears to w o rk lu b ric a n t in to all su rfaces. an equivalent part if replacement becomes neces
sary. Do not use a replacement part of lesser quality
6. Install wheel assembles: fill rear axle with proper lubri or substitute design. Torque values must be used as
cant to specifications. specified during reassembly to assure proper reten
tion of this part.
INDEX
Service Inform ation.......................................................... .... 4-11 Install Pinion Assembly and Adjust Pinion
Removal and Disassembly of Differential Case P r e lo a d ..................................................................... .. 4-15
A ssem bly................................................................... .... 4-12 Assemble Standard Differential C ase................. .. 4-17
R em oval.......................................................................... 4-12 Install Case and Adjust Side Bearing
Disassembly o f C a s e ................................................... 4-12 P r e lo a d .................................................................4-17
Rem oval of Pinion B earings................................. .... 4-12 A djust Backlash...........................................................4-18
Assembly and Installation o f Differential C ase........ .... 4-13 G ear Tooth Pattern C h eck ................................... ...4-18
Set Pinion D e p th ................................................................... 4-14
SERVICE INFORMATION
O verhaul procedures for P and M type axles used on located on the front of the right axle tube about three (3)
Chevrolet Models differ slightly from other axles. These axles inches outboard from the differential carrier. For example,
will be stam ped "P" or "M " in the axle identification num H K P 218 DW .
ber. Refer to the third letter in the axle identification num ber
NOTE: The following steps also apply when making Fig. IB -D iffe re n tia l Case Removal
repairs with differential assembly removed from
car. Disassem ble Standard Differential Case
Assem bly
5. Remove bolts securing cover to housing to drain lubri
cant.
6. W hile lubricant is draining, remove rear wheels and 1. If differential side bearings are to be replaced, install
drum s. Tool J-22888 and A dapter Plug J-8 107-4 for P Type
Axles and A dapter Plug J-8 107-2 for all others. (Fig.
7. Remove rear axle shafts as outlined in Chassis Service
2B)
M anual.
2. Remove screw that retains differential pinion shaft.
Remove differential pinions, side gears and thrust
NOTE: Before proceeding with following steps, it is washers from case.
advisable to check the existing ring gear to pinion 3. If ring gear is to be replaced and it is tight on case after
backlash as described under "Adjust Differential removing bolts, tap it off using a soft hammer; do not
Backlash". This will indicate gear or bearing wear or pry between ring gear and case, to do so may damage
an error in backlash or preload setting which will m achined surfaces.
help in determining cause of axle noise. Backlash
should be recorded so that if same gears are reused, Removal of Pinion and Bearings
they may be reinstalled at original lash to avoid
1. Check Pinion bearing preload as described under "In
changing gear tooth contact.
stall Pinion Assembly and A djust Pinion Preload." If
there is no preload reading, check for looseness of pin-
Preload
PROTECTIVE
TUBE OR PIPE
J— 9 7 7 2 OR
J— 6 5 4 7 FOR
PO NTIAC BUILT AXLES
J— 22388
Fig. 12B— Installing Drive Pinion Oil Seal Fig. 14B -M e a su rin g Drive Pinion Bearing Preload
J-8107-4
Fig. 15B -R ing Gear Guide Pins Installed (Typical) Fig. 1 7 B --D iffe re n tia l Bearing In sta lla tio n (E xce p t P-Type A xles)
HEEL
Fig. 23B ~E ffect on Pattern as Shim Thickness is Increased Fig. 25B ~E ffect on T ooth Pattern as Shim Thickness is
Decreased
side and high toe contact on coast side, provided backlash is
within specifications of .007", .008", .009". See Figure 22B.
Moving the pinion closer to centerline of the ring gear by
increasing shim thickness will cause the high heel contact on
drive side to lower and move tow ard the toe; the high toe
contact on coast side will lower and move tow ard the heel.
See Figure 23B.
W hen the pinion is too close to the centerline of the ring
gear, the pattern will be a low toe contact on drive side, and
a low heel contact on coast, provided backlash is within
specifications. See Figure 24B. Moving the pinion farther
away from the ring gear by decreasing shim thickness will
cause low toe contact on drive side to raise and move toward
HEEL
the heel; the low heel contact on coast side will raise and
move tow ard the toe. See Figure 25B.
DRIVE SIDE COAST SIDE
(CONVEX) (CONCAVE)
NOTE: Whenever the rear axle is overhauled to the
point of requiring a new ring gear and pinion set the
Fig. 24B~Tooth P a ttern -P inio n too Close to Ring Gear rear axle should be filled ONLY with the lubricant
(Excessive Shim Thickness) included with the gear set.
CORVETTE
INDEX
Differential Case
R em oval.......................................................................... 4-21 Inspection ............................ ........................................ 4-22
Inspection ...................................................................... 4-21 Pinion a n d /o r Bearing R ep lacem en t...................... 4-23
Bearing Replacem ent ................................................. 4-22 Installation..................................................................... 4-26
Ring G ear or Case R ep lacem en t............................ 4-22 Differential Bearing Preload and Ring G ear
Side G ear Yoke Bearing a n d /o r Seal...................... 4-22 A d ju stm en t............................................................... 4-26
Drive Pinion Ring G ear and Pinion Contact P a tte rn .......... ........... 4-28
R em oval.......................................................................... 4-22
1. Cover B olt 11. D ifferential Pinion 19. Side Bearing Cap 26. Side Gear Yoke
2. Carrier Cover Pin Retainer Bolt Bearing Seal
3. Filler Plug 12. Hypoid Ring Gear 20. Side Bearing Cap 27. Side Gear Yoke
4. Cover Gasket 13. Hypoid Drive Pinion 21. D iffere ntial Side 28. Pinion Front Bearing
5. D ifferential Pinion 14. Pinion Bearing Shim Bearing Cup
6. Ring Gear Bolt 15. Pinion Rear Bearing 22. Side Bearing Cup 29. Pinion Front Bearing
7. D iffere ntial Case 16. Pinion Rear Bearing 23. Side Bearing Shim 30. Pinion Oil Seal
8. Pinion Shaft Cup and Spacer 31. Com panion Flange
9. D ifferential Side Gear 17. Pinion Bearing 24. D ifferential Carrier 32. Pinion W asher
10. Side Gear Thrust Spacer 25. Side Gear Yoke 33. Pinion Nut
W asher 18. Side Gear Yoke Snap Bearing
Ring
4. Inspect side gear driveshaft yokes closely for spline
Differential Case wear or yoke cracking. If equipment is available, use
magnetic penetrant m ethod to check for m inute frac
Removal tures in yokes or gears.
1. Clam p carrier in Holding Fixture J-3289.
2. Remove snap rings securing side gear yokes and pull
yokes out of carrier (fig. 1C).
3. M ark differential bearing caps for reassembly in same
relative location and remove caps.
4. Pull differential assembly out of carrier, taking care not
to damage m achined m ounting surface on carrier (fig.
2C). Remove differential bearing shims and m ark for
future reference.
Disassem bly
Follow procedures outlined in "PO SIT R A C TIO N D IF
F E R E N T IA L CASE" Section.
Inspection
1. Clean all gears and bearings in cleaning solvent and
blow dry.
2. Inspect gears for scoring, pitting or cracks.
3. Inspect bearings for spalling, pitting or scoring. Discard
all parts that show excessive wear or failure. Fig. 2C--Removing D ifferential
J— 8614-2
\
J-8614-1
J-7079-2
2. Select front and rear pinion bearings and drive cups into
carrier using Drive H andle J-8092 and Cup Installers
J-8608 for the rear cup and J-7137 for front cup (fig.
11C). Seat cups securely and squarely against shoulders
in carrier.
Fig. 8C--Removing Com panion Flange Nut Fig. 10C~Removing Pinion Bearing Cup
3. Remove pinion rear bearing inner race and roller as Tighten clamp bolt enough to seat properly and check
sembly using Press Plates J-9771 in H older J-0358-1 gauge plate alignment.
(fig. 12C). Remove and discard shim between bearing 4. Tighten clamp screw until it takes a torque of 20 in. lb.
and gear head. to rotate bearings (fig. 14C).
5. Carefully slide A dapter Rings J-6266-31 over Gauge
Determ ining Pinion Shim Barrel J-6266-28 and place barrel assembly in differen
tial bearing bores (fig. 15C). Plunger on barrel m ust rest
If hypoid gear set, pinion rear bearings or carrier assembly
on lowest step of Gauge Plate J-6266-53.
are to be replaced, thickness of pinion bearing shim will have
6. M ount Dial Indicator J-8001 on gauge post and place
to be determ ined as follows:
pointer on top of plunger (fig. 16C). Swing gauge barrel
1. Lightly lubricate pinion bearings, place in carrier and
aside so plunger does not touch gauge plate and set
rotate several times to seat properly.
indicator at zero.
2. Position Gauge Plate J-6266-53 on rear bearing making
sure it is properly seated and piloted. Loose pilot allows
DIAL INDICATOR
plate to be easily centered in bearing.
3. Insert clam p screw through gauge plate, both bearings
and Clam p Plate J-8 107-4 on front bearing (fig. 13C).
J-6266-31
ADAPTOR
J-6266-53
REAR
P IN IO N
BEARING
FRONT
PINION
BEARING
J -8 107-4
Fig. 12C-Rem oving Pinion Rear Bearing Fig. 13C--Gauge and Clamp Plates Installed
PROTECTIVE
TUBE OR PIPE
EX A M PLE: #1 #2 #3
J-6266-3 Pinion Code N um ber 40 45 50
Dial Indicator Reading 19 16 14
Difference 21 29 36
Proper Shim Thickness .021” .029” .036’'
Fig. 16C -G auging Pinion Depth Fig. 18C —Insta llin g P in ion Seal
5. W ith the ring gear tight against the pinion gear (.000"
to .001" backlash), insert gauging Tool J-22779 be
tween the left bearing cup and carrier housing (fig.
22C). T urn adjusting nut clockwise while oscillating
Fig. 20C--M easuring Drive Pinion Bearing Preload tool until a noticeable drag is produced.
Shim Identification
Shim
Notches
Thickness
I.D. O.D.
.040 0 0
.042 4 1
.044 4 2
.046 4 3
.048 4 4
.050 5 0
.052 5 1
.054 5 2
.056 5 3
.058 5 4
.060 6 0
.062 6 1
.064 0 2
.066 0 3
.068 0 4
.070 1 0 Fig. 23C--M easuring Gauge Plate Thickness
.072 1 1
.074 1 2 higher of the two averaged readings obtained in Steps
.076 1 3 7 a n d 8.
.078 1 4
EX A M PLE:
.080 2 0
.082 2 G a u g e th ick n ess (h ig h er re a d in g ) ................254"
1
.084 2 2 Service s p a c e r...................................................... 170"
.086 2 3 Service shim size (left s id e ) ............................084"
.088 2 4 10. Install the selected shim between the service spacer and
.090 3 0 bearing. Remove strap J-22779-6 and install left bearing
.092 3 1 cap. Torque bearing cap bolts to specifications.
.094 3 2 11. Remove right-hand bearing cap and install Tool J-
.096 3 3 22779 between right bearing cup and carrier housing.
.098 3 4
12. Turn adjusting nut clockwise while oscillating tool until
.100 4 0
a noticeable drag is produced (bearing outer race ro
tates with tool). Remove tool and m easure the thickness
6. Tighten lock bolt on side of the tool then remove tool.
of the gauging plate in a minimurh of three places.
7. Using a microm eter, m easure the thickness of the gaug
Average these readings and record results.
ing plates in a m inim um of three places (fig. 23C).
13. Turn ring gear 90 degrees and repeat Steps 11 and 12.
Average these readings and record result.
8. T urn ring gear 90 degrees and repeat Steps 5, 6 and 7.
14. The thickness of the service shim is determined as in
9. The thickness of the service shim is determ ined by sub
Step 9, however, an additional .008" must be added to
tracting the thickness of the service spacer from the
obtain proper side bearing preload.
EX A M PLE:
G a u g e thick n ess (hig her re a d in g )................226"
Service sp acer u s e d ......................... m in u s .170"
D iffe re n c e .................................................... 056"
P r e lo a d ..................................................... plus .008"
Service shim s iz e ................................................ 064"
NOTE: Service shims are available in increments of
.002 in.-if the shim measurement falls between the
available shims, select a shim thinner by $01 in-
15. Install the selected shim between the service spacer and
bearing using a soft face ham m er (fig. 24C).
16. Install right bearing cap and torque both bearing caps
to specifications.
17. M ount a dial indicator on the carrier and check back
lash between the ring gear and pinion (fig. 25C). Back
lash should be within the range of .003" to .010" with
a reading of .005" to .008" preferred. Check reading at
four equally spaced positions around the ring gear.
Fig. 22C ~M easuring D ifferential Shim Requirem ent Variation in reading should not exceed .002".
NOTE: Position the dial indicator so that indicator 2. Paint ring gear teeth lightly and evenly with a mixture
button is perpendicular to tooth angle and in line of powdered red lead and oil of a suitable consistency
with gear rotation. to produce a contact pattern.
SNAP
RING
GENERAL DESCRIPTION
The D ana Spicer axle, is sim ilar in design to other Salis differential case the carrier m ust be spread.
bury type axles with the following exceptions: 2. The pinion assembly incorporates an inner and outer
1. The differential side bearing shims are located between bearing shim. The inner shim is used to m aintain proper
the side bearing cone and roller assembly and the differ pinion depth. W hile the outer shim is used to m aintain
ential case (fig. ID ). These bearings are of the tapered proper preload on the pinion bearing.
roller design and are preloaded. In order to remove the
D IFFER EN TIA L C A S E 8. Remove dial indicator and with the use of a pry bar
remove differential case from carrier. Remove spreader.
Removal
Disassem bly
1. Place vehicle on hoist with rear axle hanging free.
2. Remove wheel and tire assemblies. 1. Remove differential bearing cups and identify with a
3. Remove axles shafts as follows: tag for reassembly.
a. 10 S eries-T he axle shaft on the 10 Series are the 2. Place differential in vise and drive out pinion shaft lock
semi floating type. O uter end of shaft is supported pin.
by a tapered roller bearing. 3. Remove differential bearing cone and roller using
1. Remove brake drum . Puller J-22888, with Plug J-8 107-3, Figure 3D. Tag
2. Remove four bolts holding wheel bearing flange cone and rollers for assembly.
plate to axle shaft flange.
3. Install Puller J-2 1579 w ith Slide H am m er J- NOTE: If ring gear and pinion are to be reassembled,
2619 and remove axle shafts. note position of shims and replace accordingly.
b. The axle shafts are full-floating type with flanged
outer end of shaft attached to wheel hub by studs 4. Remove spacer, pinion shaft, pinions, side gears and
and nuts. Wheel is supported by tapered roller bear thrust washers from differential case.
ings at outer end of axle housing. 5. Remove screws attaching ring gear to differential case.
1. Remove axle shaft to hub attaching nuts. Remove gear.
2. R ap on axle shaft to loosen shaft from hub and
remove shafts.
4. Remove plug in carrier and drain lubricant.
D RIVE PINION
5. Remove cap screws and lock washers attaching cover
to carrier. Remove cover and gasket.
Removal
6. M ark one side of carrier and m atching cap for reassem 1. Separate rear universal joint, tape trunnion bearings to
bly. Rem ove cap screws attaching bearing caps to car joint, position propeller shaft to one side and tie propel
rier. ler shaft to frame side rail.
7. Using spreader Tool J-5231-01 and dial indicator as 2. Using Holding Bar J-8614-1, attached to pinion shaft
shown in Figure 2D , spread carrier a m aximum of flange, remove self-locking nut and washer from pinion
.020 ". shaft.
3. Install Tool J-8614-2, and 3 into holding bar as shown
NOTE: Do not exceed this dimension as carrier may in Figure 4 D and remove flange from drive pinion.
be permanently damaged. Remove drive pinion from carrier.
4. W ith a long drift, tap on inner race of outer pinion
bearing to remove pinion oil seal, slinger, gasket, outer
pinion cone and roller and shim pack. Tag shim pack
for reassembly.
5. Should inspection indicate necessity, pinion bearing
cups can be removed from carrier using a long drift and
hammer. Remove shims and oil slinger which are
J 22888
Fig. 2D--Spreader J-52 3 1-01 M ounted on Carrier Fig. 3D--Removing D ifferential Side Bearings
D IFFER EN TIA L C A S E
Reassem bly
1. Position differential side gears and new thrust washers
in differential case.
2. Position differential pinions and new thrust washers in
differential case. Align pinions with holes in differential
case.
Fig. 4D--Removing Pinion Flange 3. Install pinion shaft in differential case. Align hole in
shaft with hole in case, then install lock pin. Peen hole
located behind the inner bearing cup. Tag shims for to prevent pin dropping out of case.
reassembly. 4. Position ring gear to case, then install cap screws.
6. Remove inner pinion cone and roller using Tool J- Tighten cap screws evenly and alternately to specifica
22912, installed as shown in Figure 5D, and press pin tions (See Specification Section).
ion from bearing. 5. W ith an arbor press, press differential side bearings
onto case using Tool J-2 1051. D o not install shims at
IN SPECTIO N OF CO M PO N EN TS this time.
6. Place differential case in carrier and install bearing
1. Clean all gears and bearings in cleaning solvent and caps. Care should be taken to install caps in original
inspect all bearing cups, races and rollers for scoring, position. Use m ark placed on caps and carrier at re
chipping or evidence of excessive wear. On pinion bear moval. Tighten caps just enough to keep bearing caps
ing rollers, inspect large end of rollers for wear. This is in place.
where wear is most evident on tapered roller bearings. 7. Install dial indicator on carrier with indicator button
contacting back of ring gear (Fig. 6D). R otate differen
NOTE: The pinion bearings are of the tapered type, tial case and check for runout. If runout is greater than
and the natural wear pattern is a frosted condition .002", the assembly should be removed and the ring
with occasional slight scratches on races or rollers. gear removed from the case. Again install differential
This does not indicate a defective bearing. case and check runout at differential case flange.
8. Should runout of case flange be greater than .002", the
2. Inspect pinion splines and flange splines for evidence of defect is probably due to bearings or differential case,
excessive wear. and should be corrected before proceeding further.
Fig. 5D--Removing Inner Pinion Bearing Cone and Roller Fig. 6D ~Checking Runout
D RIVE PINION
In s ta lla tio n an d A d ju s tm e n t
If inspection indicates th at either the drive pinion or ring
gear m ust be replaced, they m ust be installed in pairs, as these
parts are m atched and lapped at tim e of m anufacture, to
obtain the correct gear tooth contact.
1. W henever it is necessary to install a new drive pinion
and ring gear, observe plus or m inus m arks on end of
old pinion, Figure 7D. If m arking on the new pinion is
the same as those on the old pinion, do not change the
shim packs. If m arking is different proceed as follows:
a. M easure the shim pack removed at disassembly.
Fig. 8D— Installing O uter Pinion Bearing Cup
The plus or minus figure on the pinion indicates the
variation from the nom inal distance between the
front of the pinion and the center line of the carrier. this shim pack as was added or removed from the inner
b. If a pinion m arked plus 2 was originally installed shim pack.
w ith a shim pack o f .035" and the new pinion is
m arked m inus 1, the shim pack should be increased 4. Install outer cup in carrier bore. Drive outer bearing
.003" to bring the new pinion to its correct position cup into position using Installer J-7818 with Drive
and the new shim pack would be .038". H andle J-8092 as shown in Figure 8D.
2. Install shim pack and oil slinger in inner cup bore and 6. Install drive pinion and inner bearing cone and roller
drive inner cup into position using Tool J-21059 used assembly in differential carrier.
with J-8092.
7. Install shims and outer pinion cone and roller on pinion
3. M easure shim pack, remove from outer bearing cone
shaft using Tool J-5590 and com panion flange to press
and roller seat. A dd or remove an equal am ount from
bearing onto pinion (Fig. 10D).
8. Install flange holding b ar and install washer and nut on 13. Install flange, washer and nut. Torque nut to specifica
pinion shaft. Torque nut to 255 ft. lbs. tions.
9. Remove holding b ar and with an inch pound torque
w rench m easure rotating torque. Rotating torque
should be 10 to 20 in. lbs. with original bearings or 20
D IFFER EN TIA L C A S E
to 40 in.lb. with new bearings.
Preload and Adjustm ent
NOTE: Torque reading to start shaft turning must
be disregarded. 1. Install differential bearing cups and place differential
assembly in carrier.
10. A dd shims to reduce rotating torque. Delete Shims to 2. Install differential bearing caps and secure temporarily
increase preload. with cap screws.
11. Remove nut, washer and flange from pinion shaft. 3. W ith shim pack determined in Step 9 "Differential Case
12. Install oil slinger, gasket and using Tool J-22804 install Reassembly", place shims between cups and carrier.
oil seal. Force shims in on both sides of carrier, use total am ount
of shims in pack, and set ring and pinion with zero
backlash.
4. Remove bearing caps and case from carrier.
5. Remove differential side bearing cone and rollers from
differential case.
6. Install shims as indicated in Step 3, adding .015" addi
tional shims to the ring gear side of case (this will give
the proper am ount of bearing preload and ring gear
backlash) and install side bearing.
Installation
1. Spread differential carrier, using spreader as shown in
Figure 2D.
2. Install differential bearing cups in their correct loca
tions then install differential case into carrier.
3. Install differential bearing caps in the correct location
as indicated by m arks made at disassembly. Install cap
screws finger tight. R otate differential assembly and rap
on case with a soft faced ham m er to ensure proper
seating of case in carrier.
4. Remove spreader and torque cap bolts to specifications.
5. Install dial indicator and check ring gear backlash at
four equally spaced points around the ring gear. Back
lash m ust be held to .004" to .009" and m ust not vary
Fig. 10D— Installing Pinion Flange m ore than .002" between positions checked.
6. W henever backlash is not within limits, differential 10. Install axles into carrier and axle flange over hub studs.
bearing shim pack should be corrected to bring back Torque hub stud nuts to specifications.
lash within limits.
7. Check gear tooth contact, using red lead method, as 11. Fill differential with lubricant.
described in "R ear Axle A djustm ent G ear Tooth Con
12. Install wheel and tire assembly.
tact (R ed Lead M ethod)".
8. Using a new gasket, install housing cover and torque
bolts to specifications.
9. Reinstall the rear universal joint, and torque "U" bolt NOTE: This wheel to axle flange fastener is an im
nuts to specifications. portant attaching part in that it could affect the
performance of vital components and systems, and
NOTE: This propeller to pinion flange fastener is an /or could result in major repair expense. It must be
important attaching part in that it could affect the replaced with one of the same part number or with
performance of vital components and systems, and an equivalent part if replacement becomes neces
/or could result in major repair expense. It must be sary. Do not use a replacement part of lesser quality
replaced with one of the same part number or with or substitute design. Torque values must be used as
an equivalent part if replacement becomes neces specified during reassembly to assure proper reten
sary. Do not use a replacement part of lesser quality tion of this part.
or substitute design. Torque values must be used as
specified during reassembly to assure proper reten
tion of this part.
GENERAL DESCRIPTION
There are three optional Positraction differential units, tial side bearings and must be replaced with an Eaton Posi
namely Eaton, Borg W arner and D ana Power-Lok. The traction differential unit, if service is necessary. (Fig. IE).
D ana Pow er-Lok (Fig. 16E) is used only on T ruck models Overhaul procedures for Positraction equipped axles are
and has its own repair procedure. the same as on a conventional axle except for the operations
The Borg W arner unit is not repairable except for differen- listed herein.
1. Ring Gear-to-Case 4. Pinion Lock Screw 7. Clutch Pack Guide 11. Spring Retainer
Bolt and W asher 8. Clutch Disc 12. Pinion T hrust w asher
2. D iffere ntial Case 5. Ring Gear 9. Clutch Plates 13. Pinion Gear
3. Side Bearing 6. Shim 10. Side Gear 14. Pinion Shaft
15. Preload Spring
Inspection
1. Check clutch plates and discs for excessive wear and
Fig. 5E--Removing Preload Spring Pack (Corvette) signs of overheating.
AXLE
SHAFT
Fig. 6E-- C-Clamp and Bar S tock Installed fo r Spring Removal Fig. 8E--Removing D ifferential Pinion Gears
Fig. 9E~Removing Side Gear Fig. 1 1 E--Measuring Pinion Gear Tooth Clearance
16. Position spring pack between side gears and remove bar
stock and "C" clamp.
Fig. 13E— Installing Spring Pack Com pression Tool (Corvette) Fig. 15E -M e asu ring P ositraction Rotating Torque
1. D ifferential Case Bolt 4. Friction P late-Tabbed 6. Friction P late-Tabbed 8. Side Gear Ring
2. D ifferential (Belleville) (Flat) 9. Side Gear
Case-Plain Half 5. Friction D isc-T oothed 7. Friction D isc-T oothed 10. Pinion Gears
3. D ifferential (Belleville) (Flat) 11. Cross Shafts
Case-Flanged Half
8. Before tightening bolts, use axle shafts and align splines be repeated with the opposite wheels on the dry and slippery
of the side gear and side gear ring, on each side. Tighten surfaces.
bolts evenly and alternately. Remove axle shafts.
The above testing procedure is a rough test that can be
9. Observe if Power-Lok com ponents have been assem made by the owner of the vehicle. However, if it is suspected
bled properly. Each pinion cross shaft can be tight on that the unit is not operating properly, it can be checked by
its ram p or if there is clearance it should be only a few the following procedure.
thousandths, and it should be equal at all four cross
shaft ends. Be sure the transm ission is in neutral. Raise one wheel off
the floor and place a block in the front and rear of the
opposite wheel. Remove the hub cap and install a special tool
Testing Procedure across two wheel studs. Apply a torque wrench to special
tool. D isregard breakaway torque and observe only the
The Pow er-Lok can be effectively tested for correct oper torque required to continously turn the wheel smoothly.
ation by placing one rear wheel on good dry pavement and
the other on ice, snow, mud, gravel, grease, etc. If the torque reading is less than 40 foot-pounds or more
It can easily be determ ined w hether or not the non-slipping than 200 ft. lb., the unit should be disassembled and the
wheel is providing pulling power. The procedure should then necessary repairs made.
1. Universal J o in t Yoke 7. Pinion Bearing Shim 12. D ifferential Pinion 16. D iffere ntial Bearing
2. Pinion Bearing and (exc. 11 ,000 lb. axle) (Spider) Gear 17. D iffere ntial Bearing
Oil Seal Retainer 8. Rear Pinion Bearing 13. D iffere ntial Side Gear A d ju stin g Nut
3. Oil Seal 9. Ring Gear T hrust Pad 14. D iffere ntial C ase-Left 18. A d ju stin g Nut Lock
4. Gasket 10. Ring Gear Half 19. D iffere ntial
5. Front Pinion Bearing 11. D ifferential Spider 15. Axle S haft C a se-R ight Half
6. Drive Pinion
Removal
1. D rain lubricant from differential, remove axle shaft as
outlined in T ruck Service M anual. See "Axle Shaft Re
moval".
2. Remove two trunnion bearing "U " bolts from the rear
yoke and split the rear universal joint.
9. On all axles except the 11,000 lb., the pinion rear bear
ing outer race and roller assembly is pressed into the
carrier. Remove assembly by driving it from its seat
using a soft drift or punch (fig. 3F). Fig. 4 F -P in ion Rear Bearing Removal (1 1 ,0 0 0 Lb. Axle)
LOCK RING
DRIVER
Differential Inspection
1. W ash all parts thoroughly in cleaning solvent.
2. Inspect ring gear for chipped, scored or worn teeth.
3. Check radial clearance between differential side gears
and differential case, also fit of differential pinions on
spider.
4. Inspect spider arm s for wear and distortion.
5. Inspect splines and teeth of differential side gears and
pinions for chipping or excessive wear.
6 . Check th ru st washers for wear and replace if even slight
wear is indicated.
7. Check differential side bearings and cups for broken
Fig. 9 F -P in ion Front Bearing Installation races, discoloration or roughness.
8 . Inspect differential case for cracks or distortion.
NOTE: The opposed tapered bearing assembly is
serviced as a unit and consists of one double outer
race, two inner race and roller assemblies and one Ring Gear Replacement
spacer. These parts should always be installed as a
group as the spacer is preselected to give proper 1. Remove ring gear from case by tapping the back of the
pinion bearing adjustment. gear with a soft faced hammer.
2. Inspect ring gear pilot case flange and back of ring gear
6. Slide oil seal retainer on pinion shaft, then tap drive for dirt or burrs.
flange onto pinion splines. 3. Install two guide pins (made from cap screws with
7. Clam p drive flange in a bench vise and install flange heads cut off and ends slotted) to new gear diam etri
washer and nut. Torque nut to specifications and install cally opposite each other.
cotter pin w ithout backing off on nut. 4. Start guide pins through case flange and tap ring gear
on case.
Differential Dissem bly
1. Check differential case to m ake sure th at the two halves
Differential Bearing Replacement
are m arked so they m ay be reassembled in same relation
(fig. 10F). 1. Install Tool J-8107 m aking sure puller legs are fitted
securely in notches in case and tighten retaining yoke
2. Rem ove bolts holding case and cover together. (fig. 11F).
2. Tighten puller screw to remove bearing.
NOTE: Ring gear is mounted on the case. 3. Place new bearing on hub with thick side of inner race
tow ard case and install bearing using appropriate tool
3. Separate cover from case and remove differential side as shown in Figure 12F.
gears and thrust washers, pinion gears w ith thrust a. J-2226-5200 and 7200 lb. axles.
washers and differential spider. b. J-1 4 8 8 -1 1,000 lb. axle.
Fig. 1 0 F -D iffe re n tia l Case Line-Up M arks Fig. 11 F -D iffe re n tia l Bearing Removal
Reassem bly
To facilitate adjusting o f pinion depth in the ring gear,
there are five shims available for service use. They are .012",
.015", .018", .021" and .024".
Installation
The optionally available N O -SPIN differential unit (fig. 2. Check spider, center cam, holdout ring and driven
1G) is installed in a conventional 5200 or 7200 lb. rear axle clutch teeth for excessive chipping or burring. M inor
housing and the only difference in service procedures are the chips or burrs may be stoned smooth.
Disassembly, Assembly and A djustm ent procedures outlined
below.
Disassem bly (Fig. 1G) NOTE: Replace holdout rings or cams in pairs only.
SLOT IN HOLD O U T
SPIDER RING
SPECIAL TOOLS
Fig. 1T--Special T ools— A ll Salisbury T ype A xles (In c lu d in g 1 1 6 ” W.B. S ta tio n Wagons)
E xcep t C h evro let and Cam aro
1. J-62 66 Pinion S etting Gauge Consists o f: 17. J-2 1 4 6 8 Drive Pinion O il Seal In sta lle r— L ig h t
J-62 66 -28 Barrel A d a p te r D u ty A x le (Used w ith J-9 4 5 8 )
J-62 66 -25 Plug 18. J -2 1 0 5 7 Drive P inion O il Seal In s ta lle r -
2. J-62 66 -52 Pinion S etting Gauge Plate Heavy D u ty A xle
Passenger and T ru c k L ig h t D u ty 19. J-83 59 D iffe re n tia l Bearing In sta lle r— Heavy
and T ru c k Heavy D u ty A xles D u ty A x le (Used w ith J-8 0 9 2 )
3. J-6266-53 P inion S etting Gauge Plate— 20. J-5853 0 -5 0 In. Lbs. T orqu e W rench
Passenger Heavy D u ty A xle 21. J-02 70 -14 P inion Rear Bearing Cup I n s ta lle r -
4. J-22 80 4 P inion Seal Gauge Plate L ig h t D u ty A xle (Used w ith J-80 92 )
5. J-6266-31 P inion S e ttin g Gauge 22. J-7 1 3 7 P inion F ro n t Bearing Cup I n s ta lle r -
Sleeves— Heavy D u ty A xle Heavy D u ty A x le (Used w ith J-8 0 9 2 )
6. J-2 2 7 7 9 Side Bearing Shim 23. J-78 17 P inion F ro n t Bearing Cup I n s ta lle r -
Gauge— Includes J-2 2 7 7 9 Strap L ig h t D u ty A x le (Used w ith J-8 0 9 2 )
7. J-9 5 3 7 D iffe re n tia l Bearing In sta lle r— L ig h t 24. J-81 07 -4 D iffe re n tia l Bearing Rem over— Installer
D u ty A x le — (Used w ith J-7079-2) A d a p te r (Used w ith J-95 37 and
8. J-9 4 5 8 C om panion Flange Installer J-22 77 9)
9. J-5 5 9 0 P inion Rear Bearing Cone and R o lle r 25. J-5231-01 Spreader
A ssem bly In sta lle r— L ig h t D u ty A x le 26. J-86 14 C o m panion Flange H o lde r and
10. J-70 79 -2 D river Handle (In se rt T yp e ) Remover
11. J-80 92 D rive r Handle (Threaded T yp e ) 27. J-21051 Seal Installer
12. J-2 2 8 8 8 D iffe re n tia l Bearing Rem over— 28. J-22 91 2 Press Plate
(Used w ith J-81 07 -4 A d a p te r) 29. J -21 57 9 A x le S h a ft Remover
13. J-97 72 Drive Pinion Rear Bearing 30. J-21 05 9 Bearing Cup Installer
In sta lle r— Heavy D u ty A xle 31. J -86 08 Pinion Rear Bearing Cup In s ta lle r -
14. J-8001 Dial In d ic a to r Set Heavy D u ty A x le (Used w ith J-8 0 9 2 )
15. J-5748 P ositra ction T orqu e Measuring 32. J-26 19 Slide Ham m er
A d a p te r
16. J-13 13 0 -1 5 0 F t. Lbs. T o rq u e W rench
t- ' ; . • *® *A
1. J-2 2 8 8 8 D iffe re n tia l Side Bearing Rem over J-8092 Drive Handle
Use w ith J-81 07 -4 A d a p te r Plug on 10. J-62 66 Pinion D epth S etting Gauge Consists o f:
P&M T ype A xle s and J-81 07 -2 fo r J-6266-31 Ring A dapters (F o r P Type
all others A xle s) J-62 66 -54 Gauge Plate
2 . J-81 07 -4 A d a p te r Plugs— P and M T ype Axles J-62 66 -25 F ro n t Pinion Bearing Bore
3. J-81 07 -2 A d a p te r Plug K ,G ,B ,0 T ype A xles Plug Used w ith J-8001 In d ic a to r
4. J -8 6 1 4 C om panion Flange Remover Consists o f: 11 . J-8001 Dial In d ic a to r
J-86 14 -10 H o lde r 12 . J-65 47 Drive Pinion Rear Pinion Bearing
J-8614-1 N u t (P T ype A x le )
J-8614-2 Screw 13. J-9772 Drive Pinion Bearing In sta lle r K ,G ,B ,0
5. J-2 2 9 1 2 Press Plate T ype A xles
6. J-7 1 3 7 Drive Pinion F ro n t Bearing Cup Installer 14. J-22 38 8 Drive P inion O il Seal Installer
Use w ith J-8 0 9 2 D river Handle 15. J-94 58 C om panion Flange Installer
7. J-9 7 4 5 Drive P inion Rear Bearing Cup Installer 16. J-5853 In. Lb. T orqu e Wrench
K ,G ,B ,0 T ype Axles Use w ith J-80 92 17. J-22 17 5 D iffe re n tia l Side Bearing Installer
D river Handle P T ype A x le
8. J-86 0 Drive Pinion Rear Bearing Cup Installer 18. J-22761 D iffe re n tia l Side Bearing Installer
P T ype A x le Use w ith J-8 0 9 2 D river K ,G ,B ,0 Type Axles
Handle
20
1. J-6266 Pinion Setting Gauge-Consists of J-6266- 11. J-22888 Differential Bearing Remover (Used with
28 Barrel Gauge, J-6266-31 Gauge Sleeves and J- J-8107-4)
6266-53 Gauge Plate 12. J-9774 Differential Yoke Bearing Seal Installer
2. J-0358-1 Press Plate Holder 13. J-5780 Companion Flange Installer
3. J-9771 Drive Pinion Bearing Cone and Roller 14. J-8092 Driver Handle (Threaded Type)
Assembly Remover (Used with J-0358-1) 15. J-7079-2 Driver Handle (Insert Type)
4. J-21058 Drive Pinion Oil Seal Installer 16. J-8001 Dial Indicator Set
5. J-9772 Drive Pinion Rear Bearing Cone and 17. J-22779 Side Bearing Shim Gauge-Includes J-
Roller Assembly Installer 22779 Strap
6. J-9773 Differential Yoke Bearing Install (Used 18. J-4880 Snap Ring Pliers
with J-7079-2) 19. J-5810 Torque Wrench Adapter (3 /4 " male to
7. J-8359 Differential Bearing Installer (Used with 3 /8 " female)
J-8092) 20. J-3289 Differential Carrier Holding Fixture
8. J-7137 Drive Pinion Front Bearing Cup Installer 21. J-22311 Positraction Clutch Pack Remover and
(Used with J-8092) Installer
9. J-8608 Drive Pinion Rear Bearing Cup Installer 22. J-1313 0-150 ft. lbs. Torque Wrench
(Used with J-8092) 23. J-5853 0-15 in. lbs. Torque Wrench
10. J-22804-1 Pinion Seal Gauge Plate 24. J-8614 Companion Flange Holder and Remover
1. J-0358 Press Plate Holder 10. J-2225 Pinion Front Bearing Remover Plate
2. J-1453 Pinion Bearing Press Plate 11. J-6203 Pinion Front Bearing Remover Plate
3. J-8107 Differential Bearing Puller Set 12. J-8092 Drive Handle
4. J-1364 Pinion Bearing Ring Drive 13. J-22281 Pinion Flange Oil Seal Installer
5. J-2226 Differential Side Bearing Replacer 14. J-8001 Dial Indicator Set
6. J-22300 Bearing Installer 15. J-0972 Differential Adjusting Nut Wrench
7. J-1488 Differential Side Bearing Replacer Not Illustrated:
8. J-22301 Bearing Installer J-2224 Pinion Front Bearing Remover Plate
9. J-6171 Pinion Front Bearing Remover Plate J-1439 Pinion Front Bearing Remover Plate
Power Brake Cylinder Single D iaphragm (Delco Power Brake Cylinder Single Diaphragm (Bendix) 5-16
M o ra in e )................................................................... 5-1 Power Brake Cylinder D ual Diaphragm (Bendix) .. 5-21
Power Brake Cylinder D ual D iaphragm (Delco Vacuum Booster, Single D iaphragm (Bendix).......... ...5-27
M o ra in e )................................................................... 5-7 Special T o o ls .........................................................................5-31
OVERHAUL OPERATIONS
1' 2 3 4 5
Fig. 2A ~M oraine Power Unit Fig. 3A--Power Piston and Com ponents
22. Push the main cylinder piston rod from the reaction
retainer and remove the "O" ring from the rod.
C A U T IO N :
NOTE: A new floating control valve should always
D O N O T C L A M P TIGHT
O N POWER PISTON. be used whenever it is removed from the power pis
ton.
Cleaning
Fig. 7 A -ln s ta llin g A ir Valve and Retainer Fig. 8 A ~ ln sta llin g Power Piston to S upport Plate
7. Install a new "O" ring on the air valve in the second 19. Install the air valve spring retainer to seat on the snap
groove from the push rod end. ring.
8. Coat the new floating control valve rubber and the air 20. Install the reaction bum per into the groove in the end
valve "O" ring w ith a thin film of lubricant. of the air valve.
9. Press the air valve assembly (air valve first) to its seat 21. Position the air valve return spring, (large end down)
in the power piston tube. on the spring retainer.
10. Install a new floating control valve retainer over the 22. Install the 3 reaction levers into the slots of the power
push rod, (flat side tow ard the floating control valve.). piston with the small end resting on the air valve return
spring.
11. Start the floating control valve and retainer into the 23. Install main cylinder piston rod through the reaction
power piston tube. retainer with round end out tube side.
12. Seat retainer in the power piston tube by pressing it in 24. Center reaction plate on the reaction levers (numbered
place w ith Tool J -2 1601. (Scribe line on tool should line side up), and place reaction retainer down on power
up w ith top edge to power piston tube, Fig. 7A). piston. (M ake sure small end of push rod engages in
13. Install the push rod lim iter washer over the push rod center hole of reaction plate), (fig. 9A).
25. Push reaction retainer down and line up the lugs with
and then the air filter element.
the notches in the power piston.
14. Install the power piston diaphragm on the support plate
26. Secure w ith lock ring making sure ends of lock ring are
(opposite side of locking tang).
set in place on the large divided lug of the power piston,
(one end on each side of lug), (fig. 10A).
NOTE: Make sure the support plate is in the groove
27. Install a new power piston bearing in the center of the
in the center flange of the diaphragm.
rear housing (large flange of bearing on stud side of
housing). Lubricate the inside of the bearing.
15. H olding the suport plate assembly over the tube of the
power piston (Fig. 8A).
NOTE: Make sure flange on rear housing is engaged
in groove of power piston bearing.
NOTE: The flange of the diaphragm will fit into the
groove on the power piston.
28. Install air silencer over the holes on the power piston
16. Press down and rotate the support plate assembly tube and lubricate tube.
clockwise, until the lugs on the power piston come 29. Install power piston tube through rear housing, (from
against the stops on the support plate. side opposite of studs).
17. Place this assembly tube dow n in a padded vise, (Do Not 30. A ttach base of Tool J-22805 to front shell with nuts and
Clamp). washers and draw down tight to eliminate bending or
18. Install snap ring in groove of air valve with Pliers J- damaging of studs. Place power piston return spring
4880 (fig. 5A). over the insert in the front housing.
31. Lubricate the I.D . of the support plate seal and the
reaction retainer tube. Talcum powder the beaded edge
of the diaphragm .
32. Place the rear housing assembly over the front housing
assembly and align with scribe m arks of the two hous
ings so they will m atch when in locked position.
33. Position Tool J-22893 inside tilted m ounting bracket.
Place spanner wrench Tool J-9504 on top of J-22893
and tighten nuts and washers to bolts provided, secur
ing spanner wrench or place spanner wrench J-9504
over studs on rear shell and attach with nuts and
w ashers-draw nuts down tight to eliminate bending or
damaging of studs. Press down on spanner wrench and
INDEX
Removal from Vehicle 2. Connect power brake push rod to brake pedal.
3. Connect vacuum hose to vacuum check valve.
1. D isconnect the brake lines from the two m aster cylin 4. Connect brake lines to main cylinder outlets.
der hydraulic outlets. Cover brake line fittings to pre 5. Bleed brakes as necessary and fill fluid reservoirs to
vent dust and dirt from entering brake lines. within 1/4" of top of the reservoirs.
3. If th e b ra k e p e d al travels to w ithin o ne in c h o f th e
NOTE: All brake attachments are important attach to e -b o a rd , th e b ra k e shoes re q u ire a d ju s tm e n t o r
ing parts in that they could affect the performance relining.
of vital components and systems, and/or could re
sult in major repair expense. They must be replaced 4. Start engine. W ith transm ission in Park or N eutral,
with parts of the same part numbers or with equiva open throttle to m edium speed. Close throttle and tu rn
lent parts if replacement becomes necessary. Do not off engine. This evacuates the housing chambers. W ait
use replacement parts of lesser quality or substitute no less than 90 seconds, then try brake action. If not
design. Torque values must be used as specified dur vacuum assisted for two or more applications, vacuum
ing reassembly to assure proper retention of these check valve is faulty or there is a leak in the vacuum
parts. system.
OVERHAUL OPERATIONS
Disassembly (Fig. 1-HI and 2-H) 2. Remove the power piston group from the rear housing
and remove the prim ary power piston bearing from the
center opening of the rear housing.
NOTE: Scribe a mark on the top center of the front
and rear housings in line with master cylinder reser
P o w e r P is to n G roup
voir cover to facilitate reassembly.
1. Lift the bead on the O.D. of the secondary diaphragm
1. Remove the two locknuts which hold the m aster cylin and remove the diaphragm support ring (Fig. 3-H).
der to the front housing, and remove the m aster cylin 2. If not already disengaged, remove the retainer plate
ders from the m ounting studs. Remove the front from the secondary piston. Remove the piston rod re
housing seal from the front housing. tainer and piston rod from the secondary piston.
2. M ount tool J-22805 to power booster and install two 3. M ount double-ended tool J-23101 (with large diameter
nuts. end up) in a vise. Position the secondary power piston
3. Position housing unlock tool J-9504 over the rear hous so th at the two radial slots in the piston fit over the ears
ing m ounting studs. Secure w ith nuts. Install tool J- (tangs) of the tool (Fig. 4- H).
9504 w ith power booster in a bench vise. Applying 4. Fold back prim ary diaphragm from the O.D. of the
dow nw ard pressure, rotate rear housing counter-clock prim ary support plate. G rip the edge of the support
wise to unlock the housings. It is norm al for this operat plate and rotate counter clockwise to unscrew the pri
ion to require heavy pressure to unlock the housings. m ary power piston from the secondary power piston.
11. Fold back prim ary diaphragm from the support plate. 16. Using T ruarc No. 2 pliers (J-4880), remove the retain
G rip the edge o f the support plate and rotate in a coun ing ring from the air valve (Fig. 10-H).
ter-clockwise direction to unlock the prim ary support
plate from the prim ary power piston (Fig. 9-H).
17. Remove the air valve-push rod assembly from the tube
end of the prim ary power piston. The following removal
12. Remove the prim ary diaphragm from the prim ary sup m ethod is recommended:
port plate. Place the prim ary power piston in an arbor press, and
press the air valve push rod assembly out the bottom of the
power piston tube with a rod not exceeding 1/ 2 " in diameter.
13. Remove the air filter and push rod lim iter washer from
the tubular section of the prim ary power piston.
18. Removal of the air valve push rod assembly will disas
semble the control valve retainer.
14. Remove the power head silencer from the neck of the
power piston tube.
19. Remove the "O" ring seal from the air valve.
15. Remove the rubber reaction bum per from the end of the
air valve.
Fig. 4 -H -P ositio nin g Secondary Power Piston in Tool J-23101 Fig 5-H -Locking or U nlocking Primary and S econdary Power
(Large Dia. End Up) Pistons
P RIM ARY
POW ER
P IS TO N
J-23101
Fig. 6-H -L o ckin g or U nlocking Secondary S upport Plate and Fig. 8 -H -P ositio nin g Prim ary Power Piston in Tool J-23 10 1
Secondary Power Piston (Small Dia. End Up)
PRIMARY
SUPPORT
PLATE
J-23101
Fig. 7-H -Rem oving Reaction Piston and Reaction Disc From Fig. 9-H~Locking o r U nlocking Prim ary S up po rt Plate From
S econdary Power Piston Prim ary Power Piston
Assem bly
If the grom m et was rem oved for replacem ent, insert the
new grom m et in the front housing and press the vacuum
check valve through the gromm et. Fig. 10-H~Removing Retaining Ring From A ir Valve
J -2 3 1 7 5
3. Place the air valve end of the air valve push rod assem
bly into the tube of the prim ary power piston. M anually
PRIMARY
press the air valve push rod assembly so th at the float
POW ER.
ing control valve bottom s on the tube section of the PIS TO N
prim ary power piston. Installer tool J-23175 can be
used to m anually press the floating control valve to its
seat.
J-23101
o f the large cavity, with the two levels of the center 18. Apply silicone lubricant to the O.D. of the prim ary
section of the gage w ithin the smaller reaction pis power piston tube.
ton cavity. 19. Remove the prim ary piston assembly from tool J-23101
e. M ove the gage to the left or right of the "nose" of and lay it aside.
the reaction piston. The reaction piston is the cor 20. Assemble the secondary diaphragm to the secondary
rect length if the "nose" of the piston "hits" the support plate from the side of the support plate opposite
lower level of the gage and clears the higher level of the locking tangs. Press the raised flange on the I.D . of
the gage, while perm itting the outer edges of the the diaphragm through the center hole of the support
gage to rem ain seated on the larger cavity of the plate. Be sure that the edge of the support plate center
secondary power piston. hole fits into the groove in the raised flange of the
f. If the reaction piston is too long, the higher level of diaphragm . Apply a thin coat of silicone lubricant to
the gage will not clear the "nose" w ithout moving the I.D . of the secondary diaphragm and the raised
the outer edges of the gage off the seat in the large surface of the flange (that fits into a groove in the
cavity of the secondary power piston. If the reaction secondary power piston).
piston is too short, both levels of the gage will clear 21. M ount tool J-23101 (with large diam eter end up) in a
the "nose" of the reaction piston. If either condition vise. Position the secondary power piston so that the
exists, a separate kit of three selective reaction pis radial slots in the piston fit over the ears (tangs) of the
tons (differing in length and color) m ust be obtained tool. Apply a light coat of silicone lubricant to the tube
to perm it use of piston to meet correct size require of the secondary power piston (Fig. 4-H).
ments of step (e) above. 22. Fold the secondary diaphragm away from the O.D. of
the secondary plate.
23. Holding the edges of the support plate with the locking
NOTE: Care must be taken to insure that the gage tangs down, place the secondary diaphragm and sup
is n o t" cocked." port plate assembly over the tube of the secondary
power piston. The flange on the I.D . of the secondary
diaphragm will fit into the groove in the secondary
9. A fter determ ination of the correct reaction piston, ap piston.
ply a light film of silicone lubricant to the O.D. of the 24. G rip the edges of the secondary support plate, press
rubber reaction disc. down, and rotate counter-clockwise until the tabs on
10. Place the rubber reaction disc in the large cavity of the the secondary power piston contact the stops on the
secondary power piston and push the disc down to seat support plate. Fold the secondary diaphragm back into
on the reaction piston. position on the secondary support plate. Leave the sec
11. U nlock the secondary pow er piston from the prim ary ondary power piston assembly on tool J-23101 in the
power piston. vise (Fig. 6 -H).
12. Assemble the prim ary diaphragm to the prim ary sup 25. Apply a light coat of talcum powder or silicone lubri
port plate from the side of the support plate opposite the cant to the bead on the O.D. of the secondary dia
locking tangs. Press the raised flange on the I.D . of the phragm. This will facilitate reassembly of front and rear
diaphragm through the center hole of the support plate. housings.
Be sure th at the edge o f the support plate center hole 26. Place the secondary diaphragm support ring on the
fits into the groove in the raised flange of the dia secondary power piston assembly so that it rests on the
phragm . Lubricate the diaphragm I.D . and the raised edge of the diaphragm.
surface of the flange (that fits into a groove in the 27. Hold the housing divider so that the formed over flange
prim ary power piston) w ith a light coat of silicone lubri (that holds the prim ary diaphragm ) of the divider faces
cant. down. Place the secondary bearing in the I.D. of the
13. M ount tool J-23101 (small diam eter end up) in a vise. divider so that the extended lip of the bearing faces up.
Position the prim ary power piston so th at the two radial 28. Lubricate the I.D. of the secondary bearing with sili
slots in the piston fit over the ears (tangs) of the tool cone lubricant.
(Fig. 8-H). 29. Position secondary bearing protector tool J-23188 on
14. Fold the prim ary diaphragm away from the O.D. of the the threaded end of the secondary power piston (Fig.
prim ary support plate. 14H).
15. Holding the edges of the support plate, w ith the locking 30. H old the housing divider with the form ed flange (that
tangs down, place the prim ary support plate and dia holds the prim ary diaphragm ) facing up. Press the di
phragm assembly over the tube of the prim ary power vider down over the tool and onto the secondary power
piston. The flange on the I.D . of the prim ary diaphragm piston tube where it will rest against the diaphragm
will fit into a groove in the prim ary power piston. support ring. Remove tool J-23188 from secondary
16. G rip the edges o f the prim ary support plate, press power piston; however, do not remove the secondary
down, and rotate clockwise until the tabs on the pri power piston sub-assembly from tool J-23101.
m ary pow er piston contact the stops on the support 31. Pick up the prim ary power piston assembly and posi
plate (Fig. 9-H). tion the small end of the air valve return spring on the
17. Place the power head silencer on the tube of the pri air valve so that it contacts the air valve retaining ring.
m ary power piston so th at the holes at the base of the 32. Fold the prim ary diaphragm away from the O.D. of the
tube are covered. prim ary support plate.
FORMED FLANGE
Final Assem bly
OVERHAUL OPERATIONS
Passenger car and light duty trucks use the power brake Removal from Vehicle
cylinders covered in this section. A noticeable difference is in
the valve rod. Passenger cars use a screw-on clevis with an 1. Disconnect push rod at brake pedal arm.
eye where light duty trucks use a straight rod w ith an eye to 2. Remove vacuum hose from check valve.
attach to the brake pedal. 3. D isconnect hydraulic lines at main cylinder.
4. Remove four nuts and lock washers securing power
unit to fire wall, and remove power unit from engine
com partm ent.
1 2 3 4 5 6
7 8 9 10 11 12 13 14
1. Clevis 9. Diaphragm Plate 6. Scribe alignment m ark across surface at front and rear
2. Rubber Boot 10. Reaction Disc
shells.
3. Foam and Felt A ir 1 1. H ydraulic Push Rod
7. Position bar wrench (Tool J-9504) over studs of the rear
Filter-Silencers 12. Power Piston Return
4. Rear Shell
shell and tighten nuts (Fig. 4B).
Spring
5. Bearing Seal 13. Front Shell
6. Rolling Diaphragm 14. Push Rod Seal
7.
NOTE: Tilt mounting bracket. Place Tool J-22893
A ir Valve Push Rod 15. G rom m et
Assem bly 16. Check Valve
inside tilted mounting bracket. Place spanner
8. A ir Valve Lock wrench Tool J-9504 on top of J-22893 and tighten
nuts and washers to bolts securing spanner wrench
Disassem bly (Fig. I B and 2B) (Fig. 5B).
Inspection
Carefully inspect each part for damage and wear, inspect
rubber parts for cuts, nicks and distortion. These rubber
parts are the key to control of air flow and should account
for the majority of trouble traceable to leakage. If there is any
question whatever as to serviceability of any part, replace it.
Assem bly
D uring assembly, make sure all parts are free of foreign
Fig. 6 B -B e n d ix Power C ylinder Com ponents (Typical)
m aterial before applying lubricant. If there is any doubt of
cleanliness, rewash and air dry. W hen applying lubricant as
1. Spring 5. A ir Valve Lock
2. H ydraulic Push Rod 6. A ir Valve Push Rod
specified in assembly procedure, use an approved lubricant
3. Reaction Disc Assem bly of known quality and composition that will not be harmful
4. Diaphragm Plate 7. Diaphragm to rubber and plastic materials.
Corvette and light duty trucks use the power brake cylin light duty trucks use a straight rod with an eye to attach to
ders covered in this section. A noticeable difference is in the the brake pedal.
valve rod. Corvette uses a screw-on clevis with an eye where
OVERHAUL OPERATIONS
Removal from Vehicle 2. Remove vacuum hose from check valve.
3. Disconnect hydraulic line at main cylinder.
1. Disconnect push rod at brake pedal arm. 4. Remove m ain cylinder attaching nuts, lock-washers,
rubber seal and metal retainer and set aside.
NOTE: It may be necessary to remove the clevis Remove four nuts and lock washers securing power
from the push rod on Corvette models. Note approxi unit to fire wall, and remove power unit from engine
mate location of clevis on the rod. com partm ent.
REAR SHELL
VACUUM
CHECK
V ALVE
R E AC TIO N DISC
V ALVE RETURN S PR IN G
CHECK V A LV E PLUNGER
V ALVE V A LV E POPPET
GROM M ET
POPPET S PR IN G
VA LV E ROD
FRO N T V A C U U M
SEAL
D IA P H R A G M
RETURN
S PR IN G
REAR D IA P H R A G M
FR O N T D IA P H R A G M
PLATE
FR O N T D IA P H R A G M REAR D IA P H R A G M PLATE
CENTER PLATE
Disassembly (Fig. 1C and 2C) 5. Place assembly in bench vise with rear shell up using
holding fixture Tool J-22805 and tighten vise jaws se
1. Scribe across the flanges of both power section shells in curely.
line w ith m ain cylinder cover to provide a guide m ark
for re-assembly. D o not remove vacuum check valve
(Step 2) unless a new valve is to be installed. 6. Using a thin-bladed screw driver carefully pry silencer
retainer off hub of rear diaphragm plate, being careful
2. Remove vacuum check valve from front shell by pulling not to chip plastic.
straight out on valve. T hen remove rubber grommet
from front shell.
7. Place a block of wood 3 inches long on rear shell, (Fig.
3C). Insert a heavy round shanked screw driver into eye
3. U nseat dust boot from flange of rear shell and remove
of valve rod or wrench as shown and pry out valve rod,
boot.
air silencer and air filter. D o not pry with strokes or
rear plate may be damaged. A considerable force will
4. Use an ice pick to remove two valve silencers and air be required.
filter from diaphragm plate hub. Position power section
with valve operating rod up and squirt alcohol down rod to
wet rubber grommet in valve plunger at ball end of rod.
REAR DIAPHRAGM
PLATE
\ VALVE
\ RETURN
DIAPHRAGM RETAINER
SPRING
VACUUM CHECK
VALVE
CHECK VALVE
GROMMET
VALVE OPERATING
ROD
VACUUM SEAL
DUST
BOOT
FRONT SHELL
REACTION DISC
FRONT DIAPHRAGM
CENTER PLATE
J-22805 8. Slide air filter and air silencer from ball end of valve
rod.
9. Remove valve rod spring, poppet retainer and valve
Fig. 3C -R em oving Valve Rod, A ir Silencer and F ilter poppet from hub of rear diaphragm plate (Fig. 5C).
16. Remove three nuts and washers from bar and remove
rear shell.
17. Remove holding fixture Tool J-22805 from front shell.
Fig. 4C-Holding and separating Fixture using Tools
J-22805 and J-9504 in Arbor Press 18. W ith rim of front diaphragm disengaged from scallops
in rear shell, align any lug on center plate with any
groove on rear shell. This may be done by sighting
10. Remove assembly from vise. between shell and center plate. Using finger pressure
11. Remove front vacuum seal and hydraulic push rod
and screw driver, as little as possible, separate assembly
from power head by pulling push rod straight out. from rear shell.
19. Examine rear bearing vacuum seal in rear shell and
NOTE: It will be necessary to straighten the c u t
remove only if defective. If necessary, place on work
lanced, areas (around the outside of the can) flush
bench with studs up and drive out seal with punch or
with the shell. If the tangs break, replace that half chisel and hammer.
of the shell. 20. Clam p front holding fixture J-22839 in a vise and posi
tion front diaphragm plate on it (fig. 6 C).
s
12. Place power unit w ith holding fixture Tool J-22805 in
an arbor press with rear shell up and secure to plate of
press by a suitable m eans of holding Tool J-22805 (fig.
4C). By using a 1-1/2" open end wrench on Tool J-
22805 and allowing unit to turn against back of arbor
press will hold it from turning.
Assem bly
Be sure all parts are clean before assembling unit. D o not
let grease or m ineral oil come in contact with any rubber
parts. Lubricate rubber parts of power piston group with
special lubricant included in service kit.
1. W et valve poppet in alcohol and insert poppet in hub
or rear diaphragm plate, small end first.
2. W et poppet retainer in alcohol and insert hub with
flange side up. Press against poppet retainer to make
certain shoulder of retainer is positioned inside poppet.
3. Assemble air silencer and air filter over ball end and
shoulder of valve rod.
4. Install valve rod spring over ball end of valve rod, with
small diam eter of spring against shoulder of valve rod.
5. G uide valve rod spring, air silencer, air filter and valve
rod into hub of rear diaphragm plate.
6 . A pply a light coat of silicone lubricant to front and rear
bearing surfaces of valve plunger.
Fig. 7C~Removing D iaphragm s, Plates, Retainer and Plunger 7. W et rubber grom m et in valve plunger w ith alcohol.
P our out any excess alcohol from valve plunger.
8 . Secure valve rod in vise. Place valve plunger and a
hard-w ood block no wider than threaded bore of rear
1. Diaphragm Retainer 6. Seal plate over it. While holding rear plate down with hand,
2. Rear Diaphragm 7. Center Plate tap wood with plastic headed ham m er to secure valve
3. Rear D iaphragm Plate 8. Front Diaphragm rod to valve plunger.
4. Valve Plunger 9. Front Diaphragm Plate
9. Remove rear plate from vise.
5. Valve Return Spring 10. Reaction Disc
10. Install silencer retainer on hub of rear diaphragm plate
being careful not to chip plastic.
11. Secure F ront Plate Holding Fixture J-22839 in a vise
23. Twist rear plate counter-clockwise using hand leverage and position front plate on it (fig. 6 C).
only at outer edge of plate or atm ospheric pressure 12. Install front diaphragm on front diaphragm plate.
channel and unscrew rear plate from hub of front dia 13. Apply a light coat of silicone lubricant to outside sur
phragm plate. face of front diaphragm plate hub and apply liberal coat
to seal in center plate bore.
NOTE: Vacuum seal may stay in front or rear dia 14. Install Seal Protector J-22733 on front plate hub and
phragm plate. If seal assembly is defective, center install center plate and seal assembly, seal side first on
plate and seal assembly must be replaced as an as hub (fig. 6 C). Remove Seal Protector J-22733.
sembly. 15. Place square-cut vacuum seal firmly against shoulder of
front diaphragm plate hub.
24. Rem ove front diaphragm and front diaphragm plate. 16. Install valve return spring in recess of hub on front
25. Rem ove front diaphragm plate from F ront Plate H old diaphragm plate.
ing Fixture Tool J-22839. 17. Screw rear diaphragm plate over front diaphragm plate
26. Use a screw driver through center bore of front dia and hand tighten. Valve return spring may cock when
phragm plate to push out reaction disc. tightening. Be sure assembly is tight but do not over
tighten.
18. Install rear diaphragm on rear diaphragm plate over lip
Cleaning
of center plate.
A fter disassembly, all m etal parts should be cleaned in 19. W et diaphragm retainer with silicone and press retainer
metal parts cleaner. Plastic parts and rubber parts should be onto center plate until it fully seats against shoulder of
cleaned O N L Y in alcohol. Care should be taken to prevent center plate.
chipping or cracking plastic parts. Replace all rubber parts,
except power diaphragm s. A fter parts have been cleaned,
wash them thoroughly w ith alcohol and use clean, dry com
pressed air to blow dirt and fluid out of recesses and internal NOTE: Retainer must seat on center plate to prop
passages. Use all parts furnished in the repair kit. erly assemble front and rear shell.
Inspection
Inspect all parts for dam age or excessive wear. The power NOTE: use Bearing Seal Installer J-22677, to press
diaphragm s m ust be free o f kinks, cracks and tears. Replace new seal into rear shell until flat rubber is about
any damaged, worn or chipped parts. 5 /1 6 " below flat inside surface of shell (fig. 8C).
35. Remove three nuts and lock washers securing rear shell
to spanner wrench.
36. Remove H olding Fixture J-22805 from front shell by
removing two nuts and washers.
37. D ip check valve grom m et in alcohol and install into
front shell, beveled side first.
38. Dip end of vacuum check valve in alcohol and install
valve through grommet.
39. Apply liberal coat of silicone lubricant to entire surface
of reaction disc and to piston end of hydraulic push rod;
apply a light coat of silicone lubricant to push rod stem.
Keep lubricant away from adjusting screw end of push
rod.
40. Insert reaction disc and push rod in opening of front
shell and into bore of front diaphragm plate hub. Twist
Fig. 8C ~lnstalling Rear Bushing Vacuum Seal
push rod to make certain reaction disc is seated in bore
and there are no air pockets between disc and end of
push rod.
41. Install front vacuum seal, metal support plate side first,
21. Apply talcum powder to inside of rear shell. A pply light over adjustm ent screw end of push rod, pressing seal
coat of silicone lubricant to outside surface of rear dia until it bottom s in recess of front shell.
phragm plate hub and liberal coat to bearing vacuum 42. Assemble main cylinder to front shell and securely
seal in rear shell. tighten retaining nuts.
22. G uide rear shell over assembly so as not to dam age rear 43. Install backing plate on rear shell and thread clip nut
bearing vacuum seal. on stud m arked during disassembly.
23. Align any lug on center plate and seal assembly with
any groove in rear shell. Press down on rear shell evenly
to slide lances on rear shell past center plate.
NOTE: The push rod is designed with a self-locking
24. Assemble air silencer inside dust guard and install a adjustment screw to provide the correcting relation
valve rod with dust guard over scallops on rear shell
ship between vacuum piston and main cylinder pis
hub.
ton. The adjustment is important as it provides for
25. Remove assembly from F ro n t Plate Holding Fixture
the compensating port being kept open while unit is
J-22839.
in released position. Adjustment screw is set to the
26. Secure front shell to H olding Fixture J-22805. correct height when assembled, and under normal
27. Secure Holding Fixture J-22805 on arbor press plate by
service, will not require further adjustment. After
a suitable means (fig. 4C). unit has been disassembled however, the height
28. Place Spanner W rench Tool J-9504 over studs on rear
should be checked as follows.
shell. Use three washers and nuts to attach wrench to
shell. Using a suitable piece of pipe approxim ately 2
inches I.D . and approxim ately three inches in length,
place over plastic diaphragm plate hub. Place a piece of
flat stock steel over end o f pipe.
29. Line up scribe m arks on front shell so th at front shell
is slightly counter-clockwise of scribe m ark on rear
Hydraulic Push Rod Adjustment
shell.
30. Install diaphragm return spring so th at small end of If adjustm ent is necessary, grasp push rod with pliers at
serrated end and turn adjusting screw either in or out as
spring is against front shell.
31. Lubricate outer rim o f front diaphragm with silicone required.
1. Place top of Push R od H eight Gauge J-7723-01 (truck)
lubricant and w ork rim so it is under each of the retain
or J- 21183 (Corvette) over push rod w ith legs of gauge
ing lances of rear shell.
resting on front of rear shell Figure 9C. Top of screw
32. A pply liberal coat of silicone lubricant to cut-out trim
surface of front shell th at will engage front diaphragm. should touch gauge.
# 1 5 OR **16
U.S.S. GAUGE
SH EET STEE L
BENDIX
SINGLE DIAPHRAGM TYPE HYDROVAC
INDEX
Fig. 1 D—Bendix Single Diaphragm Hydrovac Fig. 2D~Removal of Control Tube, Clamp Band, Rear Shell and
Diaphragm
1. A vacuum power chamber which consists of a power ^ H ydraulic C ylinder 6. Rear Shell
diaphragm and a push rod th at connects the power 2. C ontrol Tube Seal 7. Nut
diaphragm to the hydraulic piston. 3. Control Tube Nut 8. Clamp Band
2. A hydraulic (slave) cylinder which contains a hydraulic 4. Vacuum Hose 9. Clamp Bolt
piston with a drilled passage to perm it the filling of the 5 Rear Shell Control Tube
hydraulic cylinder and return of the fluid to the m aster
cylinder upon release of the brakes.
Cleaning and Inspection CAUTION: Make sure snap ring is seated all the
way around its groove before releasing pressure
Thoroughly clean all m etal parts in Bendix M etalclene or
against return spring. Failure to seat snap ring se
equivalent. A fter cleaning, rewash all hydraulic system parts
curely can result in parts damage and personal in
in clean isopropyl alcohol or equivalent before reassembly.
jury.
Inspect all parts for excessive w ear or damage. Replace worn
or dam aged parts. Inspect control valve body atm ospheric
valve seat. If damaged, replace housing. Always use the cor
rect repair kit when overhauling unit. Assem bly of Control Valve (Fig. 5D)
1. Assemble cup (4) facing up on control valve piston (5),
Assembly (Fig. 4D) as shown. If two cups are used, install them on piston
back to back. Then assemble piston, washer ( 6 ) and
Piston and Push Rod diaphragm (7) and seat inner bead of diaphragm in
piston groove.
1. To install a new push rod seal (13) in push rod ( 8), place 2. Lay piston and diaphragm assembly aside. Assemble
new seal (R ubber side down) on a clean block of wood. poppet return spring ( 11), vacuum poppet ( 10) and at
m ospheric poppet (14) in valve body ( 12) from opppsite
2. H old push rod vertically (threaded end up) with drilled sides, as shown.
end of rod resting on shaft end of seal and then strike 3. Snap poppet retainer (15) over end of vacuum poppet
threaded end of push rod with soft ham m er to seat seal stem. (Set valve body with vacuum poppet down on 1"
w ith its shoulder firm ly against end of push rod. wooden cube and tap retainer with soft ham m er until
3. D ip cup (9) in brake fluid and assemble cup on piston it snaps onto stem of vacuum poppet).
( 10) with lip of cup as shown. 4. Assemble cover (16) securely in groove of valve body.
4. Install piston parts (2 through 12) on push rod from Assemble spring retainer washer ( 8) and spring (9) on
seal end of push rod in order shown. end of control valve piston, from end shown. Insert
5. Slide snap ring (7), stop washer (6 ), bearing (4) with control valve piston, diaphragm and spring assembly in
"O" ring (5) installed in bearing groove, push rod seal valve body with spring around bosses.
cup (3), seal retainer (2), retainer ring (12) and piston 5. Press outer bead of diaphragm into valve body groove
assembly ( 1) on push rod. and, while holding spring compressed, dip piston and
6 . Assemble retainer pin (11) through holes in piston and cup(s) in clean brake fluid.
rod. Secure pin in place with retainer ring (12), making 6. Align valve body to scribe m arks and assemble control
certain ring is seated in groove on piston. valve piston carefully in its bore below hydraulic cylin
der bore. Secure valve body with four capscrews (13).
Front Shell Assem bly to Piston (Fig. 3-D)
7. Tighten screws to 40-60 in. lbs. Install check valve (A),
1. Place new gasket (3) in groove on flange of hydraulic spring (B), retainer (C) and snap ring (D) in end fitting
cylinder ( 1). (1). Install fitting and gasket (2) on end of hydraulic
2. Assemble front shell (4) to cylinder, aligning cutout in cylinder and tighten fitting to 50-85 ft. lbs. If removed,
shell with porting in cylinder flange. install bleed screw(s), tighten to 10-15ft. lbs.
3. Assemble capscrew tighten to 130-230in. lbs.
4. If diaphragm ,plate and return spring were disassem
bled, install nut (7) (if n u t is undercut, install undercut,
Assem bly of Rear Shell,Control Tube, Hose
side first) and tighten to 160-200in. lbs., then washer
(Fig. 2D)
(9), diaphragm plate (10), concave side first, on
threaded end of push rod. 1. C oat bead of diaphragm or flanges of front and rear
5. Install diaphragm (11), washer (12) and nut (13) on shells with talcum pow der or equivalent and place rear
push rod, as shown, and securely tighten nuts (7 and 13) shell ( 6 ) on diaphragm .
to 160-200 in. lbs. 2. Align scribe m arks on both shells. M ake certain bead
6 . Coat hydraulic cylinder bore with clean brake fluid. of diaphragm is seated in outer flanges of both shells
Dip hydraulic piston and bearing parts in clean brake and hold rear shell in position while assembling clamp
fluid. Slide diaphragm return spring ( 8 ) onto push rod band ( 8) over flanges of shells and bead of diaphragm .
large diam eter of spring first, over hydraulic piston end. Position opening in band 45 degrees off vertical center
7. Seat spring against concave surface of diaphragm plate
line of Hydrovac on side away from m ounting bracket.
( 10) and align entire assembly with hydraulic cylinder
3. Squeeze ends of band together and assemble bolt (9)
bore. and nut (7). Tap band lightly with soft ham m er while
8 . Carefully insert hydraulic piston assembly, retainer,
tightening bolt to seat band securely on shells. After
seal and bearing in cylinder bore. Press against dia
tapping, re-tighten to 40-60 in. lbs.
phragm and plate to com press return spring and seat
4. Place new seal (2) on control tube (3), as shown, and
stop washer against bearing inside bore and then, using
assemble hose (4) to tube (5) of rear shell and to control
snap ring pliers, install snap ring ( 2 ) securely in groove
tube. A ttach tube and nut (3) to control valve body
in cylinder bore. port. Securely tighten to 7-10 ft. lbs.
Special Tools
9 10
ENGINE
INDEX
SU BJECT PA G E SUBJECT PA G E
INTRODUCTION
This section, convering all gasoline engines, has been M any operations outlined in this section, when done as
condensed using only typical illustrations and procedures single operations and not p art of a general overhaul, should
(except where specific illustrations and procedures will help be performed with the engine in the vehicle.
clarify the operation). The sim ilatity of engines, engine parts In order to avoid repetition and to identify the engines
and engine sub-assemblies and the resulting similarity of involved in a particular procedure, the 307-, 3 50-, and 400-
procedures required to service these units should aid the cu. in. V 8 engines are identified as "Small V 8 ’s". The 402-
technician in servicing the m any engines. and 454- cu. in. V 8 engines are identified as "M ark IV V 8’s".
GENERAL DESCRIPTION
REPAIR PROCEDURES
OIL PRESSURE
SENDING UNIT
TO OIL COOLER
(HI-PERFORMANCE ONLY)
NOTE: For further disassembly, cleaning and in Fig. 4--Sealing Bearing Cap and Block
spection refer to the part or sub-assembly to be ser
viced.
2. Install flywheel and torque to specifications. A wood
block placed between the crankshaft and cylinder block
will prevent crankshaft from rotating.
Assem bly
NOTE: Align dowel hole in flywheel with dowel hole
NOTE: For inspection, repair, assembly or replace in crankshaft. On vehicles equipped with automatic
ment of any engine part or sub-assembly refer to transmissions, install flywheel with the converter
this section under the part or sub assembly being attaching pads towards transmission.
serviced. Use new gaskets and seals on engine as
sembly. 3. Install the camshaft as follows:
1. Install the crankshaft as follows: NOTE: Whenever a new camshaft or new lifters are
a. Install rear main bearing oil seal in cylinder block installed, lubricate camshaft lobes and foot of lifters
and rear main bearing cap grooves. Install with lip with “ Molykote” or its equivalent.
of seal tow ard front of engine. W here seal has two
lips install lip with helix tow ards front of engine. W IT H T IM IN G C H A IN (V 8)
b. Lubricate lips of seal with engine oil. Keep oil off a. Install two 5/16-18 bolts in camshaft bolt holes,
parting line surface. then lubricate cam shaft journals with engine oil and
c. Install main bearings in cylinder block and main install camshaft, being careful not to damage bear
bearing caps then lubricate bearing surface with en ings (fig. 5). Remove the two 5/16- 18 bolts.
gine oil.
d. Install crankshaft, being careful not to damage
bearing surfaces.
e. Apply a thin coat of brush-on type oil sealing com
pound to block m ating surface and corresponding
surface of cap only (fig. 4). Do not allow sealer on
crankshaft or seal lip.
f. Install main bearing caps with arrow s pointing to
w ard front of engine.
g. Torque all except rear main bearing cap bolts to
specifications. T orque rear main bearing cap bolts
to 10-12 ft. lbs. then tap end of crankshaft, first
rearw ard then forw ard with a lead ham m er. This
will line up rear m ain bearing and crankshaft thrust
surfaces. R etorque all main bearing cap bolts to
specifications.
h. M easure crankshaft end play with a feeler gauge.
Force crankshaft forw ard and m easure clearance
between the front of the rear main bearing and the
crankshaft thrust surface. Refer to Figure 42.
W IT H T IM IN G G E A R (In Line)
b. Check cam shaft and crankshaft gear run out with a a. Install connecting rod bearings in connecting rods
dial indicator (fig 8 ). The cam shaft gear run out and connectiong rod caps then lubricate bearings,
should not exceed .004", and the crankshaft gear pistons, piston rings, connecting rod bolts and cylin
run out should not exceed .003". der walls lightly with engine oil.
b. Install connecting rod guide set J-5239 (3 /8 ") or
c. Check the backlash between the tim ing gear teeth Tool J-6305 (11/32") on connecting rod bolt and
with a dial indicator (fig. 9). The backlash should be using Tool J-8037 to compress the rings, install
not less than .004" nor more than .006". num ber one connecting rod and piston assembly in
V 8 E N G IN E S
a. Place crankcase front cover gasket in position over
dowel pins on cylinder block. Fig. 1 1--Installing Torsional Damper (Drive on Type)
10. Install valve lifters and push rods. Install in the same
location from which removed during engine disassem
bly.
Fig. 12—Installing Torsional Damper (Pull on Type) 11. In sta ll valve ro c k e r arm s, ro c k e r a rm b alls a n d
n u ts a n d tig h te n ro c k e r arm n u ts u n til all p u sh
r o d e n d p la y is ta k e n up.
c. Position dam per on crankshaft and drive into posi 12. On In-Line engines, install push rod covers.
tion using J-5590 until it bottom s against crankshaft 13. Install intake and exhaust manifolds. Torque to specifi
gear or sprocket (fig. 11). Remove installer tool. cations in the sequence outlined under "Torque Specifi
cations" Figure 77.
P U L L O N T Y P E (W ith Retaining Bolt) 14. Install the following sub-assemblies (if applicable) as
a. Coat front cover seal contact area (on dam per) with outlined in the applicable "Chassis Service M anual".
engine oil. • Oil D ip Stick Tube and Oil Dip Stick
b. Place dam per in position over key on crankshaft. • G round Strap
c. Using Tool J-23523 pull dam per onto crankshaft • Clutch Pressure Plate and Disc
(fig. 12). • Starter
• Oil Filter (new)
CAUTION: Install bolt in crankshaft with sufficient • C arburetor and Fuel Lines
thread engagement (min. 1/2"). • D istributor Cap (with spark plug wires)
• Fuel Pum p (and fuel pump push rod on V 8
d. Rem ove tool from crankshaft. engines)
e. Install dam per retaining bolt and torque to specifi • W ater Pum p (and by pass hose)
cations. • Accessory Drive Pulley(s) (and belts)
9. Install cylinder head(s) as follows: • D elcotron (with brackets)
• A ir Injection R eactor System (with brackets)
CAUTION: The gasket surfaces on both the head 15. A djust all belts as necessary.
and the block must be clean of any foreign matter 16. A djust valves as outlined under Valve M echanism, In
and free of nicks or heavy scratches. Cylinder bolt stallation and A djustm ent in the applicable "Chassis
threads in the block and threads on the cylinder Service M anual".
head bolts must be cleaned. (Dirt will effect bolt 17. A ttach engine lift at appropriate cylinder head bolt
torque). location or at engine lift brackets.
a. O n engines using a STEEL gasket, coat both sides
o f gasket with sealer, spread the sealer thin and C YLIN D ER HEAD A S S E M B L IES
even. Too m uch sealer may hold the beads of the
gasket away from the head or block. One m ethod of Disassem bly
applying the sealer th at will assure the proper coat
is w ith the use of a paint roller. 1. W ith cylinder head removed, remove valve rocker arm
nuts, balls and rocker arms (if not previously done).
CAUTION: Use no sealer on engines using a compo 2. Using Tool J-8062, compress the valve springs (fig. 13)
sition STEEL ASBESTOS gasket. and remove valve keys. Release the compressor tool and
remove spring caps, spring shields (if so equipped)
b. Place the gasket in position over the dowel pins, springs and spring dam per, then remove oil seals and
with the bead up. valve spring shims.
Fig. 14-C leaning Com bustion Chambers Fig. 16 -M ea surin g Valve Stem Clearance
Fig. 2 1 -ln s ta llin g R ocker A rm Stud (In -L in e and “ Small V 8 ” ) Measure valve seat concentricity (fig. 24).
/
250 & 292 LIQUID PETROLEUM
GAS TRUCK ENGINES HAVE
ALLOY CAST INLET AND
EXHAUST VALVE SEAT INSERTS
nW W W XW W ^ PARALLEL
INLET & EXHAUST VALVES 250 & 292
LPG TRUCK ENGINES
INTERFERENCE
INLET & EXHAUST VALVES 350
LPG TRUCK ENGINES Fig. 2 4 -M e a su rin g Valve Seat C o nce ntricity
VALVES
Valves th at are pitted can be refaced to the proper angle, NOTE: Only the extreme end of the valve stem is
insuring correct relation between the head and stem on a hardened to resist wear. Do not grind end of stem
valve refacing mechanism. Valve stems which show excessive excessively.
ENGINE 6-14
9. G rind and check the rem aining valves in the same m an
ner.
Assem bly
1. Insert a valve in the proper port. Fig. 26--E xhaust Valve Spring In s ta lla tio n (“ M ark IV V 8 ” )
Fig. 25--Valve S pring In sta lla tio n (In -L in e and “ Sm all V 8 ” ) Fig. 27--Vacuum Cup
,
-G- ^R I N D O U T THI S P O R T I O N
■|i 1111|1111111111111|111111111
: 1 4 'I 6
V A LV E L IFT E R S (H Y D R A U L IC )
Disassem bly
3. Place the plunger spring over the ball retainer and slide
the lifter body over the spring and plunger, being care Yit" DRIFT
PIN
ful to line up the oil feed holes in the lifter body and
plunger.
4. Fill the assembly w ith SAE 10 oil, then insert the end
of a 1/ 8 " drift pin into the plunger and press down
solid. A t this point oil holes in the lifter body and
plunger assembly will be aligned (fig. 33). Fig. 3 3 -A sse m b lin g H ydraulic L ifter
NOTE: On lifter “ B” (fig. 30) the drift pin must not NOTE: Before installing lifter, coat the bottom of
extend inside the plunger. the lifter w ith “ Molykote” or its equivalent.
V A LV E LIFT ER S (M ECHANICAL)
2. Remove the idler gear and the drive gear and shaft from
the pum p body.
3. Remove the pressure regulator valve retaining pin,
pressure regulator valve and related parts.
4. If the pickup screen and pipe assembly need replacing,
m ount the pum p in a soft-jawed vise and extract pipe
from pump.
Inspection
In general, the lower half of the bearing (except No. 1
bearing) shows a greater wear and the most distress from
fatigue. If upon inspection the lower half is suitable for use,
it can be assumed that the upper half is also satisfactory. If
the lower half shows evidence of wear or damage, both upper
and lower halves should be replaced. Never replace one half
w ithout replacing the other half.
Checking Clearance
To obtain the most accurate results with "Plastigage", (or
its equivalent) a wax-like plastic m aterial which will com
press evenly between the bearing and journal surfaces w ith
out damaging either surface, certain precautions should be
observed. If the engine is out of the vehicle and upside down,
the crankshaft will rest on the upper bearings and the total
Fig. 39 --ln sta llin g Screen (“ M ark IV V 8 " ) clearance can be measured between the lower bearing and
journal. If the engine is to remain in the vehicle, the crank
CAUTION: Be careful of twisting, shearing or col shaft should be supported both front and rear (dam per and
lapsing pipe while installing in pump. Pickup screen flywheel) to remove the clearance from the upper bearing.
on In-Line engines must be parallel to bottom of oil The total clearance can then be measured between the lower
pan when oil pump is installed. bearing and journal.
NOTE: To assure the proper seating of the crank
2. Install the pressure regulator valve and related parts. shaft all bearing cap bolts should be at their speci
3. Install the drive gear and shaft in the pum p body. fied torque. In addition, preparatory to checking fit
4. Install the idler gear in the pum p body with the smooth of bearings, the surface of the crankshaft journal
side of gear tow ards pum p cover opening. and bearing should be wiped clean of oil.
5. Install the pum p cover (with new gasket on In-Line
engines) and torque attaching screws to specifications. 1. W ith the oil pan and oil pum p removed, and starting
6. T urn drive shaft by hand to check for sm ooth operat with the rear main bearing, remove bearing cap and
ion. wipe oil from journal and bearing cap.
2. Place a piece of gauging plastic the full width of the
bearing (parallel to the crankshaft) on the journal (fig.
MAIN BEA R IN G S 40).
M ain bearings are of the precision insert type and do not
utilize shim for adjustm ent. If clearances are found to be
excessive a new bearing, both upper and lower halves will be
required. Bearings are available in standard size and .001",
.002", .009", .010",.020" and .030" undersize.
Selective fitting of both rod and main bearing inserts is
necessary in production in order to obtain close tolerances.
F or this reason you m ay find one half of a standard insert
with one half of a .00 1 " undersize insert which will decrease
the clearance .0005" from using a full standard bearing.
W hen a production crankshaft cannot be precision fitted
by this m ethod, it is then ground .009" undersize on main
journals only. A .009"undersize bearing and .OIO"undersize bear
ing may be used for percision fitting in the same manner as
previously described. Any engine fitted with a .009"undersize
crankshaft will be identified by the following markings.
• “ .009” will be s ta m p e d on th e c ra n k s h a ft c o u n te r
w eig h t fo rw a rd o f th e c e n te r m a in jo u rn a l.
• A figure “ 9 ” w ill be sta m p e d o n th e b lo ck at th e left
fro n t oil p a n rail.
CAUTION: Do not rotate the crankshaft while the NOTE: If a new bearing cap is being installed and
gauging plastic is between the bearing and journal. clearance is less than .001'' inspect for burrs or
nicks; if none are found then install shims as re
quired.
3. Install the bearing cap and evenly torque the retaining
bolts to specifications. 7. A standard, .001" or .002" undersize bearing may pro
4. Remove bearing cap. The flattened gauging plastic will duce the proper clearance. If not, it will be necessary to
be found adhering to either the bearing shell or journal. regrind the crankshaft journal for use with the next
5. On the edge of gauging plastic envelope there is a gra undersize bearing.
duated scale which is correlated in thousandths of an 8 . Proceed to the next bearing. After all bearings have
inch. W ithout removing the gauging plastic, measure its been checked rotate the crankshaft to see that there is
compressed w idth (at the widest point) with the gradua no excessive drag.
tions on the gauging plastic envelope (fig. 41). 9. M easure crankshaft end play (see specifications) by
forcing the crankshaft to the extreme front position.
M easure at the front end of the rear main bearing with
NOTE: Normally, main bearing journals wear evenly a feeler guage (fig. 42).
and are not out-of- round. However, if a bearing is 10. Install a new rear main bearing oil seal in the cylinder
being fitted to an out-of-round journal (.001 ' max.), be block and main bearing cap.
sure to fit to the maximum diameter of the journal:
If the bearing is fitted to the minimum diameter and
Replacement
the journal is out-of-round .001',' interference be
tween the bearing and journal will result in rapid
bearing failure. If the flattened gauging plastic ta NOTE: Main bearings may be replaced with or with
pers toward the middle or ends, there is a difference out removing the crankshaft.
in clearance indicating taper, low spot or other ir
regularity of the bearing or journal. Be sure to meas
ure the journal with a micrometer if the flattened
W IT H C R A N K S H A F T REM OVAL
gauging plastic indicates more than .001 'difference.
1. Remove and inspect the crankshaft.
2. Remove the main bearings from the cylinder block and
main bearing caps.
6. If the bearing clearance is within specifications, the
3. Coat bearing surfaces of new, correct size, main bear
bearing insert is satisfactory. If the clearance is not
ings with oil and install in the cylinder block and main
within specifications, replace the insert. Always replace
bearing caps.
both upper and lower insert as a unit.
4. Install the crankshaft.
Fig. 4 5 -M e a su rin g Gauging Plastic Fig. 4 7 -M e a su rin g C onnecting Rod Side Clearance (V8)
Fig. 48--Removing C onnecting Rod and Piston Assem blies 2. Remove piston rings by expanding and sliding them off
the pistons. Tools J-8020 (3-9/16"), J-8021 (3 7/8"),
J-8032 (4"), J- 22249 (3-15/16"), J-22147 (4-3/32"),
NOTE: It will be necessary to turn the crankshaft and J-22250 (4-1/4") are available for this purpose.
slightly to disconnect some of the connecting rod 3. Using Tool J-9510 for In-Line and "Small V 8 " (fig. 51)
and piston assemblies and push them put of the cyl or Tool J-6994 for "M ark IV V 8 " (fig. 52), place con
inder. necting rod and piston assembly in an arbor press with
piston on Support then using Remover, press piston pin
out of connecting rod and piston.
Disassem bly
PIST O N SU PPO R T TO O L
If bosses on pistons (fig. 49) do not allow piston support
Tool J-9510-1 to seat squarely on the piston for press operat
ions, m odifications to the tool are necessary. To allow ade
quate clearance for these bosses, turn or grind the upper
portion of the tool to the dimensions shown in Figure 50.
BOSSES
C O N N E C T IN G RO D S
W ash connecting rods in cleaning solvent and dry with
compressed air.
Check for twisted or bent rods and inspect for nicks or
Fig. 53--Piston Pin and T o o l L a y o u t (In -L in e and “ Small V 8 ” )
cracks. Replace connecting rods th at are damaged.
PISTONS Assem bly
Clean varnish from piston skirts and pins with a cleaning
1. Lubricate piston pin holes in piston and connecting rod
solvent. D O N O T W IR E BRU SH A N Y PA R T O F T H E
to facilitate installation of pin.
PISTON . Clean the ring grooves with a groove cleaner and
2. Using Tool J-9510 for In-Line and "Small V 8 " (fig. 53)
make sure oil ring holes and slots are clean.
or Tool J-6994 for "M ark IV V 8 " (fig. 54) place Sup
Inspect the piston for cracked ring lands, skirts or pin
port with spring and pilot in place on an arbor press.
bosses, wavy or worn ring lands, scuffed or dam aged skirts,
3. Position piston on connecting rod with appropriate side
eroded areas at top of the piston. Replace pistons that are
of piston (fig. 55) and connecting rod bearing tangs
damaged or show signs of excessive wear.
aligned (fig. 53 or 54).
Inspect the grooves for nicks or burrs th at might cause the
4. Place piston on support, indexing pilot through piston
rings to hang up.
and rod.
M easure piston skirt (across center line of piston pin) and
5. Place Installer on piston pin, start piston pin into piston
check clearance as outlined under "Piston Selection".
and press on installer until pilot bottom s in support.
PISTO N PIN S
6 . Remove installer from connecting rod and piston as
The piston pin clearance is designed to m aintain adequate
sembly and check piston for freedom of movement on
clearance under all engine operating conditions. Because of
piston pin.
this, the piston and piston pin are a m atched set and not
serviced separately.
Inspect piston pin bores and piston pins for wear. Piston Piston Flings
pin bores and piston pins m ust be free of varnish or scuffing
All compression rings are m arked on the upper side of the
when being measured. The piston pin should be measured
ring. W hen installing compression rings, make sure the
with a m icrom eter and the piston pin bore should be mea
m arked side is tow ard the top of the piston. The top ring is
sured with a dial bore gauge or an inside m icrometer. If
chrome faced, or treated with m olybdenum for maximum
clearance is in excess of the .0 0 1 " wear limit, the piston and
piston pin assembly should be replaced. life.
REMOVER
A N D INSTALLER 5. Fit each compression ring to the cylinder in which it is
going to be used.
C O N N E C T IN G ROD
BEARING T A N G SLOTS
PISTO N
PIN
7. Slip the outer surface of the top and second com pres
sion ring into the respective piston ring groove and roll
the ring entirely around the groove (fig. 57) to make
sure that the ring is free. If binding occurs at any point
the cause should be determ ined, and if caused by ring
groove, remove by dressing with a fine cut file. If the
binding is caused by a distorted ring, check a new ring.
PILOT
G R IN D TO O L
NOTE: Tools J-8020 (3-9/16"), J-8021 (3-7/8"), J-8032
FOR CLEARANCE (4 ") J-22249 (3-15/16"), J-22147 (4-3/32"), and
J-22250 (4-1/4") are available for this purpose.
SPRING
2. Slip the compression ring in the cylinder bore; then f. Install top compression ring with gap properly
press the ring down into the cylinder bore about 1/4 located.
inch (above ring travel). Be sure ring is square with
cylinder wall.
9. Proper clearance of the piston ring in its piston ring
groove is very im portant to provide proper ring action
and reduce wear. Therefore, when fitting new rings, the
3. M easure the space or gap between the ends of the ring clearances between the surfaces of the ring and groove
w ith a feeler gauge (fig. 56). should be measured (fig. 59). (See Specifications.)
Installation
C O N N E C T IN G ROD
B EA R IN G T A N G
SLOTS INSTALLED
OPPOSITE
CA M S H A FT
SLOT
SLOT
Fig. 6 0 -C o n n e ctin g Rods--lnstalled Position V8 Fig. 6 2 — Installing C onnecting Rod and Piston Assemblies
1. W ith the engine removed from the vehicle and the • O n In -L in e e n g in e s, re m o v e c ra n k s h a ft g e a r u sin g
transm ission a n d /o r clutch housing removed from the T o o l J-8105, in sta ll using T o o l J-5590.
engine, m ount engine in overhaul stand and clamp se • O n “ Sm all V 8 ” engines, rem ove c ra n k sh a ft sp ro c k et
curely. u sin g T o o l J-5825, install using T o o l J-5590.
• O n M ark IV V 8 engines, rem ove c ra n k sh a ft sp rocket
2. Remove the oil dip stick and oil dip stick tube, (if
u sin g T o o l J-1619, install using T o o l J-21058.
applicable).
3. Check crankshaft for run-out by supporting at the front 1. If the inspection indicated that the camshaft, gear or
and rear main bearings journals in "V" blocks and thrust plate should be replaced, the gear m ust be
check at the front and rear interm ediate journals with removed from the camshaft. This operation requires the
a dial indicator. (See Specifications.) use of camshaft gear remover J-971.
REMOVAL INSTALLATION
IN LIN E
J-8105 J-5590
SM ALL
V -8’ *
J-5825 !J-5590
MARK IV V-8
J-1619 WASHER
J-21058
BEARING JOURNALS
Fig. 6 5 -M e a su rin g Cam shaft End Play Fig. 67-R em oving Cam shaft Gear
C A M SH A FT B EA R IN G S
Inspection
W ith the cam shaft removed, inspect the bearings for evi
dence of wear or damage. (Bearings showing the above
should be replaced.)
Removal
Cam shaft bearings can be replaced while engine is disas
sembled for overhaul, or w ithout complete disassembly of the
engine. To replace bearings w ithout complete disassembly
remove the camshaft and crankshaft leaving cylinder heads
attached and pistons in place. Before removing crankshaft,
tape threads of connecting rod bolts to prevent damage to
crankshaft. Fasten connecting rods against sides of engine so
they will not be in the way while replacing camshaft bearings.
1. W ith cam shaft and crankshaft removed, drive camshaft
rear plug from cylinder block.
IN -L IN E E N G IN E S
W ith the oil filter removed, check the spring and fibre
valve for operation. Inspect for a cracked or broken valve. If
replacement is necessary, remove valve by prying it out with
a screw driver. Install and seat a new valve by tapping it in
place, using a 9 /16 thin-wall deep socket (fig. 71).
V 8 E N G IN E S
W ith the oil filter removed, check the spring and fibre
4. Using two wrenches, hold puller screw while tu rn
valve for operation. Inspect for a cracked or broken valve. If
ing nut. A fter bearing has been pulled into bore,
replacement is necessary, the oil filter adapter and bypass
remove the rem over and installer tool from puller
valve assembly must be replaced as an assembly. Clean valve
screw and check alignm ent of oil hole in camshaft
cham ber in cylinder block thoroughly. Torque retaining
bearing (fig. 68 ).
screws to specifications (fig. 72).
5. Install remaining bearings in the same manner. It
will be necessary to index pilot in the camshaft rear
bearing to install the rear interm ediate bearing.
6. Install a new cam shaft rear plug.
C YLIN D ER B LO CK
Repairs
C Y L IN D E R C O N D IT IO N IN G
The performance of the following operation is contingent
upon engine condition at time of repair.
If the cylinder block inspection indicated th at the block
was suitable for continued use except for out-of-round or
tapered cylinders, they can be conditioned by honing or bor
ing.
If the cylinders were found to have less than .005" taper
or wear they can be conditioned with a hone and fitted with
the high limit standard size piston. A cylinder bore of less
then .005" wear or taper may not entirely clean up when
fitted to a high limit piston. If it is desired to entirely clean
Fig. 7 2 -O il Filter By-Pass Valve (V8) up the bore in these cases, it will be necessary to rebore for
an oversize piston. If m ore than .005" taper or wear, they 3. W hen finish honing a cylinder bore to fit a piston, the
should be bored and honed to the smallest oversize that will hone should be moved up and down at a sufficient speed
perm it complete resurfacing of all cylinders. to obtain very fine uniform surface finish m arks in a
W hen pistons are being fitted and honing is not necessary, cross-hatch pattern of approximately 45° to 65° in
cylinder bores may be cleaned with a hot water and detergent cluded angle. The finish m arks should be clean but not
wash. A fter cleaning, the cylinder bores should be swabbed sharp, free from imbedded particles and torn or folded
several times with light engine oil and a clean cloth and then m etal (fig. 74).
wiped with a clean dry cloth.
1. Before using any type boring bar, the top of the cylinder
block should be filed off to remove any dirt or burrs.
This is very im portant. Otherwise, the boring bar may CAUTION: Handle the pistons with care and do not
be tilted which would result in the rebored cylinder wall attempt to force them through the cylinder until the
not being at right angles to the crankshaft. cylinder has been honed to correct size as this type
piston can be distorted through careless handling.
C Y L IN D E R H O N IN G
1. W hen cylinders are to be honed follow the hone m anu PISTO N SELEC TIO N
facturer’s recom m endations for the use of the hone and
cleaning and lubrication during honing.
1. Check U SED piston to cylinder bore clearance as fol
lows:
2. Occasionally during the honing operation, the cylinder a. M easure the "Cylinder Bore Diam eter" with a tele
bore should be thoroughly cleaned and the piston se scope guage ( 2 - 1/ 2 " from top of cylinder bore).
lected for the individual cylinder checked for correct fit.
307 PASSENGER
----- 307 TRUCK
350 (330 HP)
nin o >o o
o o o
io o
o o
,o, i O, , , ,o. i O, , , ,o.
Measure piston skirt 2 W from top of piston. Measure cylinder bore 2 '/i" from top of bore.
2. If used piston is not acceptable, check Piston Size C hart hone cylinder bore to correct clearance (preferable
(fig. 76) and determ ine if a new piston can be selected range).
to fit cylinder bore within the acceptable range. 4. M ark the piston to identify the cylinder for which it was
3. If cylinder bore m ust be reconditioned, measure new fitted.
piston diam eter (across center line of piston pin) then
PISTONS A V A IL A B L E
ENGINE
OVERSIZE
(D ISPLAC EM ENT) STD.
.0 0 1 " .0 2 0 " .030" .040
3.8750 3.8760 3.8935 3.9035
250 & 307
3.8760 3.8770 3.8955 3.9055
3.8730 3.8740 3.8938 3.9038 3.9138
292
3.8740 3.8750 3.8962 3.9062 3.9162
3.9998 4.0008 4.0183 4.0283
350 (245, 255 & 270 HP) -
4.0008 4.0018 4.0203 4.0303
3.9953 3.9963 4.0138 4.0252
350 (330 HP) -
3.9963 3.9973 4.0158 4.0272
4.1241 4.1251 4.1426 4.1526
400 (265 HP) -
4.1251 4.1261 4.1446 4.1546
4.1237 4.1247 4.1450 4.1550
402 (300 HP) -
4.1247 4.1257 4.1470 4.1570
4.2481 4.2491 4.2675 4.2775
454 (365 HP) -
4.2491 4.2501 4.2695 4.2795
4.2465 4.2475 4.2657 4.2757
454 (425 HP) -
4.2475 4.2485 4.2677 4.2777
C Y L I N D E R HE A D T ORQUE S EQ U E N C E
IN T A K E M A N IF O L D T O R Q U E S E Q U E N C E
FRONT
FRONT
SPECIAL TOOLS
20. J-95 35 D istrib u to r Lower Bushing 28. J-58 25 C rankshaft Sprocket Puller
Installer 29. J -81 05 C rankshaft Gear Puller
21. J-2 2 1 4 4 Oil Pick-up Screen Installer 30. J-5 5 9 0 C rankshaft Sprocket or Gear
22. J-8 3 6 9 Oil Pick-up Screen Installer Installer
23. J-6 0 9 8 Cam Bearing Tool 31. J -2 3 0 4 2 Crankcase Cover Centering
24. J-097 1 Cam shaft Gear Support Gauge
25. J-2 3 5 2 3 Torsional Damper Puller 32. J -2 2 1 0 2 Crankcase Cover and Seal
26. J-2 2 1 9 7 Torsional Damper Installer Installer
27. J-1 6 1 9 C rankshaft S procket Puller
INTRODUCTION
(SEE R O C H E S T E R C A R B U R E T O R S ID E N T IFIC A T IO N , FIG. M1;
H O L L E Y C A R B U R E T O R S ID E N T IFIC A T IO N , FIG. S2)
Various carburetors, designed to meet the particular re a general overhaul, should be performed (if practical) with
quirem ents of engines, transm ission and vehicles, are used on the carburetor on the engine. Typical illustrations and proce
passenger vehicles and although carburetors may look alike dures are used except where specific illustrations or proce
they are not always interchangeable. Refer to carburetor part dures are necessary to clarify the operation.
num ber a n d /o r specifications.
This section, divided into sub-sections by carburetor
CAUTION: If the C.E.C. solenoid on the carburetor
model, covers the repair procedures for the various carburet
is used to set engine idle or is adjusted out of limits
ors, assembly and disassembly procedures and internal car
specified in the Service Manual, decrease in engine
buretor adjustm ent. A lthough illustrations showing bench
braking may result.
operations are used, most single operations, when not part of
GENERAL DESCRIPTION
The model MV (Fig. M2) carburetor used on the Chev enrichm ent system is used to provide good performance dur
rolet, 6 cylinder engine is a single bore, down draft unit using ing moderate to heavy acceleration and at higher engine
a triple venturi in conjunction with a plain tube nozzle. The speeds.
main venturi is 1 5/16" in diam eter and the throttle bore is
1 11/16". The idle system incorporates a ho. idle com pensator to
Fuel flow through the main m etering system is controlled m aintain smooth engine idle during periods of extreme hot
by a main well air bleed and a variable orifice jet. A power engine operation.
I— A
Or
ASSEMBLY
— MODEL NO. PLANT CODE
OF YEAR
MODEL NO. _
I SHIFT
SHIFT I— IDENTIFICATION
IDENTIFICATION ASSEMBLY
PLANT CODE
ASSEMBLY
YEAR
PLANT CODE
YEAR
DAY OF YEAR
DAY OF THE YEAR
The model MV carburetor has an autom atic choke system. screw will be pre-set at the factory and capped, and no fur
The vacuum diaphragm unit is an integral part of the air ther adjustm ent should be required except during the clean
horn. The choke coil is m ounted on the manifold and is ing &nd overhaul.
connected to the choke valve shaft by a rod. An overhaul idle m ixture adjustm ent procedure will be
An internal fuel inlet filter is m ounted in the fuel bowl provided, should the idle m ixture needle need replacement or
behind the fuel inlet nut to give m aximum filtration of incom the m ixture channels cleaned during the overhaul process. A
ing fuel. new idle m ixture needle limiter cap will be provided in the
O ther features of the model MV include an alum inum overhaul kit.
throttle body and a thick throttle body to bowl insulator
gasket. The carburetor has internally balanced venting
through a vent hole in the air horn which leads from the float
DISASSEMBLY OF CARBURETOR
bowl into the bore beneath the air cleaner. The float bowl is
Removal of C.E.C. Valve Assembly
externally vented through a pressure relief valve system
which allows vapors to be vented during hot engine operat 1. Remove vacuum hose from the C.E.C. valve and timed
ion. spark tube.
The carburetor part num ber is stam ped on a vertical sec 2. Bend back retaining tabs on lock washer; then remove
tion of the float bowl, next to the fuel inlet nut. W hen replac large C.E.C. valve nut and remove valve from bracket.
ing the float bowl assembly, follow the m anufacturer’s
instructions contained in the service package so that the part
num ber can be transferred to the new float bowl. NOTE: Do not remove C.E.C. valve bracket from the
float bowl assembly unless replacement of the
The idle stop solenoid has been replaced by a combination bracket is necessary. Complete replacement in
emission control valve (C.E.C. valve). The valve, when ener structions are included in the replacement bracket
gized through the transmission, acts as a throttle stop by
kit.
increasing idle speed during high gear operation of the engine
which helps in controlling overrun hydrocarbons during de
CAUTION: Do not immerse the C.E.C. valve assem
celeration. The C.E.C. valve also provides full spark vacuum
bly in any type of carburetor cleaner.
advance during high gear operation and is de-energized in the
lower gears and at idle, for retarded spark timing during this
period. N orm al idle speed setting will be made with the idle Air Horn Removal
stop screw.
The idle m ixture screw will have a lim iter cap installed and 1. Remove the fast idle cam attaching screw. Then remove
no adjustm ent will be provided on the vehicle. The mixture the fast idle cam from choke rod at lower end by rotat-
C.E.C. SOLENOID
VACUUM TUBE
FUEL INLET
AND FILTER
FUEL BOWL
PUMP LEVER
THERMAC
C.E.C. SOLENOID (VALVE)
TUBE
IDLE CHANNEL
RESTRICTION
AIR INLET
IDLE TUBE
BI-METAL
STRIP ~~
VALVE -
GASKET-
HOT IDLE
COMPENSATOR
THROTTLE VALVE
MAIN DISCHARGE
NOZZLE
METERING
ROD
CHOKE VALVE
PUMP LEVER
VACUUM BREAK
DIAPHRAGM
DURATION SPRING
PUMP CUP
PUMP RETURN SPRING
PUMP
DISCHARGE
BALL
t
PUMP
ACTUATING
LINK
THERMOSTATIC
COIL — LINKAGE
PUMP CUP
PUMP SYSTEM o p e ra tio n
ing over squirt on rod and from upper lever by rotating 4. Remove fuel inlet nut, gasket, paper filter element and
rod out of slot in lever. N ote position of rod and cam pressure relief spring.
for ease in reassembly. 5. Using long nosed pliers, remove "T" pum p discharge
2. Rem ove six air horn to float bowl attaching screws. spring retainer. Pum p discharge spring and ball may be
3. Remove air horn by lifting straight up. Invert air horn removed by inverting bowl.
and place on clean bench. A ir horn to bowl gasket can 6. The idle tube can be removed at same time by inverting
rem ain on bowl for removal later. bowl.
7. To remove accelerating pump plunger and metering
rod -p o w er piston drive assemblies, perform following
Air Horn Disassembly operation:
1. Remove two vacuum break diaphragm cover screws. a. Remove actuating lever on throttle shaft by remov
Then carefully remove diaphragm cover. ing attaching screw at end of shaft.
2. To remove vacuum break diaphragm and plunger rod, b. Remove upper end of drive link from power piston
hold choke valve wide open. Then push upw ard on rod.
eyelet on choke valve at a 45 degree angle until the c. R otate drive link from keyhole in actuating lever.
looped end of rod slides off wire lever attached to the d. Remove actuating lever from pum p link by rotating
choke valve. Then remove diaphragm and plunger rod off tang on rod.
assembly through the hole in air horn. (Figure M4). e. Remove upper end of pum p link by rotating from
3. If desired, the choke valve, vacuum break lever, and keyhole in pump slide.
choke shaft can be removed from air horn by first 8. The power piston—metering rod assembly and drive rod
removing the therm ostatic coil lever from the end of can now be lifted from float bowl.
choke shaft, by removing the attaching screw. After 9. Remove power piston spring from power piston cavity.
removing the therm ostatic coil lever, remove the two
choke valve attaching screws; then remove the choke 10. Remove pum p plunger assembly from float bowl.
valve and choke shaft from air horn. 11. Remove pum p return spring from pum p well.
12. Remove main metering jet from bottom of fuel bowl.
NOTE: The choke valve screws are held in place by 13. Remove two screws from idle com pensator cover. Then
lock-tite so it will be necessary to re-stake after as remove cover, hot idle com pensator and gasket from
sembly. recess in bowl beneath compensator.
14. Idle adjustm ent screw and fast idle cam can be removed
at this time if desired. No further disassembly of the
float bowl is required.
Float Bowl Disassembly
1. Remove air horn to float bowl gasket. G asket is slit next Throttle Body Removal and Disassembly
to m etering rod hanger so that it can be easily removed.
1. Invert carburetor bowl on bench and remove two th ro t
2. Remove float assembly from float bowl by lifting up tle body to bowl attaching screws. Throttle body and
ward on float hinge pin. Remove hinge pin from float insulator gasket may now be removed from float bowl.
arm.
3. Remove float needle, float needle seat and gasket. Use NOTE: Do not tamper with the idle mixture needle
caution in removing needle seat to prevent damage. with a limiter cap unless performing an overhaul or
due to needle damage. This has been set to test re 8. Check throttle and choke levers and valves for binds
quirements by the manufacturer. and other damage.
9. Replace filter element.
10. Check all springs for distortion or loss in tension, re
place as necessary.
2. N o fu rth e r disassem bly o f the th ro ttle b o d y is nec
e ssa ry u n le ss th e id le m ix tu re n e e d le is d a m a g e d
o r th e id le ch a n n e ls n eed cleaning. I f n e cessary to CARBURETOR ASSEMBLY
re m o v e th e idle m ix tu re needle, d e stro y plastic
Throttle Body Assembly
lim ite r c a p as a n ew o n e is p ro v id e d in th e o v e r
haul kit. New Part Replacement
If a new throttle body is being replaced, install and bottom
the new idle m ixture needle and back off four turns. Do not
IMPORTANT: If CO Reading equipment is not avail install plastic lim iter cap at this time until proper screw
able, before removing idle mixture needle, be certain settings have been made.
to count number of turns to bottom the old idle mix A fter completing assembly of the carburetor, and when
ture needle. This is required so that when it is neces installed in the vehicle, adjust the mixture screw to achieve
sary to install a new needle, you may bottom the the required percent of "CO" in the exhaust gas (see Service
new needle and then back off the same number of M anual under, "A dditional External Settings and A djust
turns it took to bottom the old needle. m ents") -which is the recommended method; however, if
equipment for a "CO" reading is not available, you may set
3. R em o v e th e idle m ix tu re n eed le a n d spring, if the idle speed and idle m ixture settings as outlined also under
req u ired . "A dditional External Settings and A djustm ents".
1. If removed, install idle m ixture needle and spring until
lightly seated. Back out four turns as a prelim inary idle
adjustment.
2. Install idle adjustm ent screw, if removed. 15. Install float needle seat and gasket. Tighten securely
3. Install gasket into recess in idle com pensator cavity in and carefully to avoid damage to seat.
float bowl, then install idle com pensator assembly. 16. Install float needle valve into needle seat.
4. Install idle com pensator cover, with (2) attaching 17. Insert straight portion of float hinge pin into float arm.
screws. Tighten securely. Install float and hinge pin into float bowl.
5. Install pum p return spring into pum p well. Make sure
spring is properly seated in bottom of well.
6. Install pump plunger assembly into pum p well with Float Level Adjustment (Fig. M5)
slide protruding through bottom of bowl casting. Push 1. Hold float retainer firmly in place and push down on
dow nw ard on pum p slide and install pum p drive link float arm at outer end.
into hole in lower end of shaft. Ends of drive link point 2. W ith adjustable T -scale, measure distance from top of
tow ards carburetor bore. Tang on upper end of link float at index point on toe, to float bowl gasket surface
retains link to pum p slide. (gasket removed).
Install power piston and pum p actuating lever to lower 3. Bend float pontoon up or down at float arm junction to
end of link. Projection on this lever points downward. adjust.
Install power piston spring into power piston cavity.
Install end of power piston actuating rod into groove on
side of power piston. Then install power piston m eter Metering Rod Adjustment (Fig. M6)
ing rod assembly and actuating rod into float bowl. End 1. To check adjustm ent back out idle adjusting screw to
of metering rod must enter jet orifice. ensure closed throttle valve. R otate fast idle cam so that
10. Install drive link into keyhole in actuating lever. fast idle cam follower is not contacting steps on cam.
11. Hold complete assembly dow nard in bowl, then install 2. W ith throttle valve completely closed, apply pressure to
upper end of power piston drive link into hole in lower hanger directly above power piston and hold piston
end of power piston actuating rod. Align "D" hole in down against its stop.
actuating lever with flats on throttle shaft and install 3. Holding downward pressure on power piston, swing
lever on end of throttle shaft. Install retaining screw in metering rod holder over flat surface of bowl casting
end of throttle shaft and tighten securely. until metering rod rests lightly against inside edge of
bowl.
NOTE: Before installing air horn, check operation of 4. Use specified plug gauge and insert between bowl cast
entire drive mechanism, metering rod and accelera ing and lower surface of metering rod holder against
tor pump to ensure free operation from closed to metering rod. Gauge should have a slide fit between
wide open throttle. both surfaces, as shown.
5. To adjust, carefully bend metering rod holder up or
12. Install idle tube into cavity in float bowl. down at point shown.
13. Install pump discharge ball, spring and spring retainer.
M ake sure spring retainer is flush with top of bowl
casting.
14. Install fuel filter relief spring, fuel inlet filter, filter nut
and gasket. Tighten securely. Open end of filter should
face hole in fuel inlet nut.
BEND HERE
GAUGE FROM TOP OF
CASTING TO TOP OF SEE
INDEX POINT AT TOE SPECIFICATIONS
OF FLOAT
Fig. M 7~T ightening Sequence--Air Horn NOTE: Refer to the adjustment chart for the remain
ing adjustments; adjustments must be performed in
the sequence shown. Slow and fast idle RPM
6. Install air horn gasket on float bowl by carefully sliding specifications are also shown on the chart.
slit portion of gasket over metering rod holder. Then
align gasket with dowels provided on top of bowl cast
ing and press gasket firmly in place.
GENERAL DESCRIPTION
The Rochester Models 2G and 2GV carburetors (fig. G1 These are two barrel carburetors with two venturi and a
and G2) are used in conjunction with a tem perature sensing separate fuel feed for each. All fuel metering is centerally
choke coil (m ounted on the intake manifold over the exhaust located so that each system will give instantaneous response
crossover passage). for maximum efficiency and performance.
The removable venturi cluster contains the main nozzles, On air conditioned passenger cars and trucks with auto
idle tubes, m ixture passages, air bleeds and pum p jets. The matic transmission the carburetor contains a hot idle com
main nozzles and idle tubes are suspended in the main wells pensator (fig. G3). The hot idle com pensator consisting of a
of the float bowl which helps insulate them from engine heat bi-metal strip, a valve and a m ounting bracket located in a
and to minimize percolation spill over during hot engine cavity at the rear of the carburetor bowl is a therm ostatically
operation (fig. G4 and G5). controlled air bleed, which supplies additional air to the idle
m ixture during prolonged hot idle periods.
C H O K E V A C U U M BREAK
PUMP LEVER
PUMP R O D
C .E.C. S O L E N O ID
(VALVE)
DISTRIBUTOR
SCREW
THERMAC TUBE
FAST IDLE C A M
IDLE MIXTURE LIM ITER C A P A N D NEEDLE
THROTTLE LEVER
PUMP R O D
DISTRIBUTOR
IDLE SPEED VACUUM
SC R E W
TH E R M A C
TUBE
ID L E AIR B L E E D S F IL T E R IM TCDM A,
G A S K E T S F |L T E R R E L IE F J mt L
ID L E
R E S T R IC T IO N
O F F ID LE
D ISC H A R G E P O R T S
FLO A T N E E D LE
FLO A T
N EED LE
ID LE D ISC H A R G E H O LE
PISTON VACUUM
CHAM BER
M IX T U R E PA SSA G E
MAIN NOZZLE POWER PISTON
BO O ST VEN TURI
MAIN VENTURI
MAIN W E L L T U B E POW ER PISTON
S PRIN G
MAIN W E LL IN S E R T ■THROTTLE VALVE
POW ER VALVE
MAIN METERING
JE T
POWER R ES T R IC T IO N S
M A I N M E TE R IN G S Y S TE M
MAIN W E LL
PO W ER S Y S T E M
CHOKE VALVE
VACUUM
DIAPHRAGM UNIT
DIAPHRAGM
PUMP DISCHARGE
CHECK B A L L
PUMP DISCHARGE
PA SSA G E
PUMP
R ETU R N SPRING
CHOKE
PUMP S Y S T E M SYSTEM
ID LE
ESTRICTION
ID LE
PASSAGE -
IDLE
TUBE ""
MAIN _
M ETERING
JET S
IDLE
M IXTURE
N E E D LE
FLOAT SYSTEM
IDLE SYSTEM
M ANIFOLD
PISTON VACUUM .VACUUM
CHAMBER VACUUM R E L I E F
PA SSAG E
POWER PISTON
POWER PISTON
SPRING
POWER VALVE
POWER RESTRICTIONS
RETAINER 8 SPRING
PUMP DISCHARGE
CHECK B A LL
PUMP DISCHARGE
PASSAGE
PUMP
R ETU RN SPRING
PUMP SY S T E M
TO VACUUM
ADVANCE ON
DISTRIBUTOR
ELECTRICAL
CONNECTIONS
C.E.C. VALVE
COMBINED EMISSION CONTROL VALVE
9. Using a wide bladed screwdriver, remove the float nee NOTE: The center cluster screw has a fiber washer
dle seat and gasket. and the two outer screws have lock washers. Also,
10. Remove air horn to float bowl gasket. the center screw is not threaded the full length of
11. Remove power piston by depressing shaft and allowing the body. The smaller diameter is required for pump
spring to snap sharply -thus forcing piston from casting. jet discharge.
12. Remove retaining screw from the inner pum p lever and
remove outer pum p lever and plastic washer from air
horn. Place plunger in gasoline or kerosene to prevent 4. Using a pair of long nose pliers, remove the pum p dis
rubber from drying out. charge spring retainer. Then remove the spring and
13. If the choke shaft or valve need replacement, remove check ball from the pump discharge cavity.
two choke valve screws, then remove choke valve and 5. Invert carburetor and remove three large throttle body
slide shaft and lever from air horn. to bowl attaching screws. T hrottle body and gasket may
now be removed.
NOTE: The two choke valve screws are staked in
place, remove the staking before removing screws NOTE: Do not tamper with the idle mixture needles
with limiter caps unless performing an overhaul or
due to needle damage. This has been set to test re
quirements by the manufacturer.
Disassemble Bowl and Throttle Body
6. F urther disassembly of the throttle body is not recom
(Figure G8)
mended. If parts are damaged, replace the throttle body
1. Remove pump plunger return spring from pump well. assembly. The idle mixture needles have plastic limiter
caps installed. They should not be removed unless it is
2. Remove main m etering jets and power valve and gas necessary to replace the m ixture needles or clean the
kets. idle m ixture channels. If removal is necessary, new li
3. Remove three screws on top of cluster; then remove the m iter caps are provided in the repair kits. They should
cluster and gasket from the float bowl. not be installed until after the idle m ixture has been
adjusted on the engine per instructions provided in the CAUTION: Do not force the idle mixture needle
service manual. against the seat or damage will result.
A S S E M B L Y AND A D JU S T M EN TS
4. Install main well inserts, gasket and cluster assembly, 6. Install power piston into vacuum cavity. M ake sure
tighten screws evenly and securely. M ake certain that that piston travels freely in cavity. Lightly stake re
the center screw is fitted with fiber gasket. tainer in place.
5. Install main m etering jets, power valve gasket and 7. Install the float needle seat and gasket into air horn
power valve. Figure G9 shows the bowl and throttle casting. Tighten securely with a wide blade screw
body at the stage of assembly. Install pum p return driver. Place the float needle into needle seat.
spring, apply pressure with finger to center it in pump 8. Install air horn to float bowl gasket. Align position
well and to m ake sure th at is properly seated. cut-out in float tow ard power piston and align float
hanger with holes in the links on air horn casting; then
install retaining pin.
9. Install fuel filter spring, fuel filter, filter gasket, fuel
Assemble Air Horn (Figure G10) inlet nut gasket and fuel inlet nut. Torque inlet nut
1. Install choke kick lever on choke shaft with tang on sufficiently to seat gasket. Install vacuum break dia
kick lever tow ards lever on shaft. phragm assembly on to air horn with the part number
2. Install choke shaft into air horn--insert shaft left to on bracket facing outward. Install two attaching screws
right. and tighten securely. Insert off-set and vacuum break
3. Center choke valve on choke shaft with letters "R P" diaphragm rod into plunger on vacuum break dia
facing upward. Install choke valve screws. Before tight phragm. Then install other end of rod to hole in choke
ening the choke valve screws, make sure th at there is coil lever. Install choke coil lever on to end of choke
.0 2 0 " clearance between the choke kick lever on the air shaft aligining flats on lever with flats on shaft. Install
horn casting. Then tighten the choke valve screw se retaining screw into the end of choke shaft and tighen
curely and stake in place to eliminate any possibility of securely. Part num ber on choke coil lever face outward
their coming loose. when installed correctly.
4. Install accelerator pum p plunger and rod to the inner
pum p lever - end of pum p plunger rod points inward Installation of the Combined Emission
tow ards air horn bore.
5. Install outer accelerator pum p lever with plastic washer Control Valve on Float Bowl.
partially through air horn and align flats on lever with
inner lever. Then install and secure levers with retaining 1. Install C.E.C. valve into bracket on float bowl. Install
screw. lock washer, large retaining nut and tighten securely.
Then, bend retaining ears on lock washer over flats of
nut so that nut is locked securely in place.
2. Install vacuum hose on tube located between the idle
m ixture needles and the throttle body and to the outer
tube on the C.E.C. valve. (Figure G 6 ).
Adjust Float
Brass-Type
1. W ith air horn inverted and air horn gasket installed
measure the distance from the air horn gasket to the
lower edge (sharp edge) of the float seam at the outer
end of the float pontoon. To adjust, bend the float arm
at rear, as shown in inset (Fig. G il) .
2. W ith the air horn assembly held upright and float sus
pended freely, measure dimension from air horn gasket
to bottom of float pontoon at toe, adjust to specified
dimension by bending tang which contacts seat at rear
of float arm (fig. G 12).
Nitrophyl-Type
1. W ith air horn inverted, gasket in place and needle
seated measure distance from lip at toe of float to air
horn gasket. Adjust float to specifications by bending
Figure G 1 0 -A ir Horn A ssem bly-P arts Location tang (fig. G13).
2. W ith air horn right side up so that float can hang free,
Fig. G1 1 -F lo at Level A djustm en t (Brass) measure distance from lip at toe of float to air horn
gasket. Adjust float to specifications by bending tang
(Fig. G14).
TO V A C U U M
ADVANCE ON
D IS T R IB U T O R
E LE C TR IC A L
C O N N E C T IO N S
C.E.C. VALVE
COMBINED EMISSION CONTROL VALVE
Disassemble Air Horn (Figure V2) 7. Place choke valve in wide open position, rotate choke
rod towards pum p lever and remove the choke rod from
1. On 2GV models, remove choke coil lever retaining upper choke lever on choke shaft.
screw from end of choke shaft and remove choke coil 8. Remove air horn to bowl attaching screws and choke
lever from choke vacuum diaphragm rod. cable bracket on 2G models. Tap air horn lightly to
2. Remove the choke vacuum break diaphragm rod from loosen from bowl and lift air horn from float bowl.
the vacuum diaphragm plunger by rotating off-set end 9. Place air horn top-down on a flat surface and remove
of rod out of slot in diaphragm plunger. float hinge pin, float, air horn gasket, splash shield and
3. Remove choke vacuum diaphragm supply hose from float needle.
tube on throttle body, then remove vacuum diaphragm 10. Using a wide bladed screwdriver, remove the float nee
assembly by removing two retaining screws. dle seat and gasket.
4. Place carburetor on a proper holding fixture being care 11. Remove power piston by depressing shaft and allowing
ful not to damage the throttle valve or components. spring to snap sharply thus forcing piston from casting.
Then remove the fuel inlet filter nut, filter, spring, and 12. Remove screw retaining pump inner lever to outer lever
filter nut gasket. and withdraw lever and plastic washer from air horn.
Place plunger in gasoline or kerosene to prevent rubber
NOTE: The paper fuel inlet filter has its own sealing from drying out.
gasket so there is no extra gasket required between 13. If choke shaft or valve needs replacement, remove two
the filter element and fuel inlet nut. choke valve screws:
a. On 2GV Models, remove choke valve, and slide
5. Remove pump rod retaining clip from throttle lever end shaft and kick lever from air horn.
o f rod, and remove rod from throttle lever, depress b. On 2G Models, disconnect choke spring from lever,
pum p and rotate the pum p rod out of upper pum p lever. and remove shaft and lever assembly from air horn.
6. Using a wide bladed screwdriver, remove the fast idle c. On 2G Models, remove retaining ring from annular
cam attaching screw-rotate cam and remove cam from groove in casting, then remove choke lever and
rod. swivel and spring.
Disassembly of Float Bowl and Throttle NOTE: Do not tamper with the idle mixture needle
with a limiter cap unless performing an overhaul or
Body (Figure V3)
due to needle damage. This has been set to test re
1. Remove the pum p plunger return spring from pump quirements by the manufacturer.
well.
2. Remove main metering jets and power valve and gas 7. F urther disassembly of the throttle body is not recom
ket. mended. If the idle mixture needles are damaged, or
3. Remove three screws on top of cluster after which clus need replacement or the idle mixture channels have to
ter and gasket may be removed. be cleaned, the plastic limiter cap should be broken
away from m ixture screws as new ones are provided in
NOTE: The cluster center screw has two fiber wash
the repair kit.
ers and a baffle located just above the main well air
bleeds. The two outer screws have lock washers.
IMPORTANT: If CO Reading equipment is not avail
Also, the center screw is not threaded the full length
able, before removing idle mixture needle, be certain
of the body -- smaller diameter is required for pump
to count number of turns to bottom this old idle mix
jet discharge. The high speed bleed baffle must be
ture needle. This is required so that when it is neces
installed between the two fiber gaskets underneath
sary to install a new needle, you may bottom the
the head of center cluster screw.
new needle and then back off the same number of
4. Using a pair of long nose pliers, remove the pum p dis turns it took to bottom the old needle.
charge spring retainer (Figure V4). Then the pump dis
charge spring and check ball may also be removed. 8. Remove idle mixture needle and spring, if required.
8. Check throttle and choke levers and valves or binds and 3. D rop steel pum p discharge ball into pum p discharge
other damage. cavity. Ball is 3/16" diam eter steel. Install pump dis
9. Replace filter element. charge spring and retainer.
10. Check all springs for distortion or loss in tension, re
place as necessary. NOTE: The top of retainer should be flush with top
of float bowl casting beneath venturi cluster.
2. Invert the float bowl, and place new throttle body gas
ket in position over locating dowels and attach throttle
body to bowl with three attaching screws. Tighten
screws evenly and securely. Fig. V 5~Bow l A ssem bly-P arts Location
TO V A C U U M
ADVANCE ON
D IS T R IB U T O R
E LE C T R IC A L
C O N N E C T IO N S
ROCHESTER 4 MV (QUADRAJET)
INDEX
GENERAL DESCRIPTION
The Rochester 4M V C arburetor (fig. Q l), used in con The model 4MV for Chevrolet has the following major
junction w ith a tem perature sensing choke coil (m ounted on changes for 1971:
the intake manifold), is used w ith 350 cu. in. and larger 1. Calibration for 1971 engines.
displacem ent engines.
2. New accelerator pum p for greater capacity on 350"
This is a four barrel, two stage carburetor with versatility
truck engines.
and principles of operation th at m ake it adaptable for small
3. Vacuum break diaphragm restriction increased to .020"
to larger engines w ithout design changes. for faster choke valve opening on cold starts.
The fuel bowl is centrally located to avoid problems of fuel 4. Heavier choke closing assist spring for improved engine
slosh, causing engine tu rn cut-out, and delayed fuel flow to starting.
the carburetor bores. 5. The choke unloader mechanism is changed in that the
The prim ary side has small bores and a triple venturi for separate wide open kick lever is removed. A tang has
fine fuel control in the idle and economy ranges. The second
ary side has larger bores and an air valve for high air capacity
(fig. Q2).
PUMP FAST
PLU N GER IDLE
CAM
IDLE SPEED
SCREW
C.E.C.
S O L E N O ID
(VALVE)
FUEL INLET
NUT A N D
FILTER
CHOKE VACUUM
BREAK
S E C O N D A R Y THROTTLE TH E R M AC
PUMP R O D L O C K O U T LEVER TUBE
A N D LEVER
IDLE M IXTURE LIMITER
C A P A N D NEEDLE THROTTLE LEVER
PULL CLIP
■FLOAT NEEDLE
FLOAT NEEDLE
•SEAT , , INTERNAL VENTS
THROTTLE
IDLE SVALVE
DISCHARGE HOLE
POWER PISTON
SPRING
ENGINE "SECONDARY
MANIFOLC THROTTLE VALVE
VACUUM
y
VACUUM CHANNEL POWER SYSTEM
MAIN METERING MA|N METER|NQ SYSTEM
AS PLUNGER MOVES UP
FUEL FLOWS PAST CUP
INTO PUMP WELL.
PUMP JETS
DISCHARGE PASSAGE
PUMP ROD.
PUMP RETURN
SPRING
been added to the faster idle lever. This contacts a tang DISASSEMBLY
on the fast idle cam and through the interm ediate choke
shaft forces the choke valve slightly open to adm it more
air to the carburetor bores and intake m anifold should NOTE: Place carburetor on proper holding fixture.
the engine become flooded or loaded during starting. Care should be used so as not to damage the throttle
Except for certain truck applications, a combination valves as they are a precision fit.
Emission Control Valve (C.E.C. Valve) is used. The valve,
when energized through the transmission, acts as a throttle
stop by increasing idle speed during high grear operation of
the engine which helps in controlling overrun hydrocarbons Removal of the Combination Emission
during deceleration. The C.E.C. Valve also provides full
spark vacuum advance during high gear operation but is Control (C.E.C.) Valve Assembly
de-energized in the lower gears and at idle for retarded spark
tim ing during this period. N orm al idle speed setting is made 1. Remove vacuum hose or hose assembly from vacuum
with the idle stop screw. Idle speed settings should be made tube on float bowl. Then remove the hose from the
following vehicle emission control inform ation on the label outer tube on C.E.C. valve assembly. (Fig. Q3)
located in the engine com partm ent. 2. Bend back retaining tabs on lock washer; then remove
The idle m ixture screws on all 4MV models except for larger C.E.C. valve nut and remove valve from bracket.
some truck applications, will have a plastic lim iter cap in
stalled to prevent idle fuel over-enrichm ent. N o adjustm ent NOTE: Do not remove C.E.C. valve bracket from the
will be provided on the vehicle. The idle m ixture screw will air horn unless replacement of the bracket is neces
be pre-set at the factory and capped, and no further adjust sary. Complete replacement instructions are in
ment should be required except during cleaning and over cluded in the replacement bracket kit.
haul. If the lim iter cap, idle needle and spring are removed
for cleaning and inspection, follow the specifications for idle
m ixture adjustm ent.
In conjunction with the use of idle needle limiters in 1971, CAUTION: Do not immerse the C.E.C. valve assem
the throttle body casting has been revised to provide stop lugs bly in any type of carburetor cleaner.
for the lim iter caps.
Air Horn Disassembly (Figure Q4) NOTE: The power pistong assembly is held in place
for ease in assembly of the air horn, by a plastic
retainer at top of power piston bore.
NOTE: Further disassembly of the air horn is not
required for cleaning purposes.
Remove metering rods from power piston by discon
necting tension spring from top of each rod then rotat
ing rod to remove from hanger.
7. Remove float assembly by pulling up slightly on retain
NOTE: If part replacement is required, proceed as
ing pin until pin can be removed by sliding toward
follows:
pum p well. After pin is removed, slide float assembly
tow ard front of bowl to disengage needle pull clip being
1. Remove choke valve attaching screws, then remove
careful not to distort pull clip.
choke valve and shaft (Figure Q4).
Remove pull clip and fuel inlet needle.
REmove fuel inlet needle seat with wide blade screw
CAUTION: Air valves and air valve shaft are cali driver. Remove needle seat gasket and discard.
brated and should not be removed. 10. Remove prim ary metering jets. No attem pt should be
made to remove secondary metering discs.
There is an air valve shaft spring repair kit which includes 11. Remove pum p discharge check ball retainer and check
the plastic cam, torsion spring, spring and retaining screw. If ball.
replacem ent is necessary, instructions are provided in kit. 12. Remove baffle from secondary side of bowl.
13. Remove retaining screw from choke assembly and
remove assembly from float bowl then remove second
Float Bowl Disassembly (Fig. Q5) ary lock out line from bowl.
1. Remove pum p plunger from pum p well. 14. Remove fast idle cam from choke assembly.
2. Remove air horn gasket from dowels on secondary side
of bowl, then remove gasket from around power piston CAUTION: Do not place vacuum break assembly in
and prim ary metering rods. carburetor cleaner.
1. Fuel Inlet Nut 10. Secondary T hrottle 18. Power Piston Spring 26. Float Needle Pull
2. Gasket Lockout 19. Primary M etering Clip
3. Fuel Filter 11. T hrottle Body-to-Bowl Rods 27. Float Needle
4. Fuel F ilter Spring Gasket 20. Power Piston 28. Float Needle Seat
5. Vacuum Break Hose 12. Float Bowl Assem bly 21. M etering Rod 29. Needle Seat Gasket
6. Vacuum Diaphragm 13. Idle Speed Screw Retainer 30. Discharge Ball
7. A ir Valve Dashpot 14. Primary Jets 22. Float Retainer
8. Choke Control 15. Pump Discharge Ball 23. Secondary A ir Baffle 31. Choke Rod
Bracket 16. Pump Return Spring 24. Float Bowl Insert 32. Choke Lever
9. Fast Idle Cam 17. A ccelerato r Pump 25. Float Hinge Pin
15. Remove interm ediate choke rod and actuating lever m ixture needles, destroy plastic limiter caps as new
from inside of float bowl well. ones are provided in the overhaul kit.
16. Remove fuel inlet filter nut gasket, filter and spring.
17. Remove throttle body by removing throttle body to IMPORTANT: If CO Reading equipment is not avail
bowl attaching screws. able before removing idle mixture needle, be certain
18. Remove throttle body to bowl instulator gaskets. to count number of turns to bottom this old idle mix
ture needle. This is required so that when it is neces
sary to install a new needle, you may bottom the
Throttle Body Disassembly (Figure Q6) new needle and then back off the same number of
turns it took to bottom the old needle.
NOTE: Do not tamper with the idle mixture needle
Remove idle m ixture needle and spring, if required.
with a limiter cap unless performing an overhaul or
due to needle damage. This has been set to test re
quirements by the manufacturer. NOTE: No further disassembly of the throttle body
is required.
1. Remove pum p rod from throttle lever by rotating rod
out of prim ary lever.
2. No further disassembly of the throttle body is necessary
unless the idle m ixture needles are damaged or the idle CAUTION: Extreme care must be taken to avoid
channels need cleaning. If necessary to remove the idle damaging secondary throttle valves.
A S S E M B L Y AND A D JU STM EN TS
Cleaning and Inspection NOTE: Do not install the new plastic limiter caps
until the idle mixture has been set with the carbu
CAUTION: Do not immerse the C.E.C. valve in any retor installed on the engine. Instructions for adjust
type of carburetor cleaner or solvent. ment are included in the service manual.
4. Connect choke rod into lower choke lever in float bowl IM PO RTANT: After carburetor overhaul, throttle
cavity and retain in upper lever with retaining clip.
body part replacem ent, m ixture needle part
5. Install air valve to dashpot rod into air valve shaft lever
and into the hole in the dashpot plunger; then position replacement, or limiter cap and needle rem oval,
dashpot into retaining bracket and connect choke assist the procedures in Section 6M , 1971 Chassis
spring and finally the choke vacuum hose.
6. Install secondary metering rod and hanger. Rod should Service M anual, under “ A d d ition al External
be positioned with upper ends through hanger holes and Settings and Adjustm ents,” must be followed.
tow ards each other. (Figure Q10). Install hanger re
tainer screw and tighten securely.
HOLLEY 4150
INDEX
General D e sc rip tio n ........................................................ 6M-35 Cleaning and In sp ectio n .......................................... 6M-40
Repair Procedures............................................................ 6M-35 Assembly and A d ju stm e n t................................... .. 6M-41
D isassem bly............................................................... 6M-35 Assemble T hrottle B o d y ................................. 6M-41
Disassemble into Sub-assemblies................. 6M-35 Assemble M ain Body ................................... .. 6M-41
Disassemble Fuel Bowls ............................... 6M-35 Assemble Secondary Throttle Operating
Disassembly M etering B odies...................... 6M-38 Assem bly........................................................... .. 6M-41
Disassemble Secondary T hrottle Assemble M etering Bodies .......................... ..6M-41
Operating A ssem bly............................................... 6M-39 Assemble Fuel Bowls ................................... ..6M-41
Disassemble M ain Body ............................... 6M-39 A djust Floats (Preliminary) ........................ ..6M-42
Disassemble T hrottle B o d y .......................... 6M-40 Assemble Subassemblies ................................. 6M-42
GENERAL DESCRIPTION
The Holley 4150 center inlet carburetor fig. SI is used a n d se c o n d a ry fu el bow ls, p rim a ry a n d se c o n d a ry
on 350 and 454 cu. in. engines. See C arburetor identification, m e te rin g b o d ie s a n d th e se c o n d a ry th ro ttle o p e ra tin g
fig. S2. This carburetor is used in conjunction with a tem per assem bly. T h e se c o n d a ry m eterin g bo d y o n th e M odel
ature sensing choke coil m ounted on the intake manifold over 4150 C a rb u re to r is sim ilar to the p rim a ry m ete rin g
the exhaust crossover passage. bo d y . T h e se c o n d a ry th ro ttle o p e ra tin g a sse m b ly is
T h is fo u r b a rre l c a rb u re to r co n sists o f seven sub- v acu u m o p e ra te d (Fig. S3).
assem b lies; th e th ro ttle b o d y , th e m a in b o d y , p rim a ry
3. Remove prim ary fuel bowl screw (4) and remove fuel
DISASSEMBLY
bowl, metering body, baffle and gaskets.
4. Remove secondary fuel bowl screws (4) then remove
Disassemble Into Subassemblies (Fig. bowl and metering body and gasket.
S4) 5. Disconnect secondary throttle operating rod at throttle
lever.
NOTE: Before disassembly, loosen the fuel inlet fit 6. Remove secondary throttle operating diaphragm as
ting, fuel bowl sight plugs and needle and seat as sembly and gasket from main body.
sembly lock screws. 7. Remove secondary diaphragm rod retaining clip.
8. Remove throttle body to main body screws, then
1. Remove vacuum hose from the C.E.C valve and timed remove throttle body and gasket.
spark tube.
2. Bend back retaining tabs on lock washer; then remove
large C.E.C. valve nut and remove valve from bracket.
Disassemble-Fuel Bowls (Fig. S5)
NOTE: Do not remove C.E.C. valve bracket from the 1• Loosen inlet needle and seat lock screw, then turn ad
float bowl assembly unless replacement of the justing nut counter-clockwise to remove the needle and
bracket is necessary. seat assembly.
Remove float hinge pin retainer and slide float from
Com plete replacem ent instructions are included in the bowl; note position and remove spring and hinge pin
replacem ent bracket kit. from float assembly. Remove bowl filler from primary
bowl after float is removed.
CAUTION: Do not immerse the C.E.C. valve assem- 3. Remove sight plug and gasket.
bly in any type of carburetor cleaner. 4. Remove inlet fitting, fuel filter, spring and gaskets.
DIAPHRAGM
SECONDARY
FILTER DIAPHRAGM THROTTLE
SPRING INLET ROD
PLATE
VALVE
FUEL INLET SYSTEM (END INLET)
SECONDARY THROTTLE OPERATING SYSTEM
DISCHARGE
PASSAGE IDLE TRANSFER
IDLE AIR BLEEDf AIR BLEED
DIAPHRAGM ^ — ^DIAPHRAGM IDLE TRANSFER
RESTRICTION PUMP INLET RETURN FEED RESTRICTION!
CHECK BALL SPRING
PUMP SYSTEM
DISCHARGE
NOZZLE
BOOSTER
VENTURI
SECONDARY SECONDARY
IDLE ADJUSTING/
FUEL BOWL THROTTLE
N EEDLE jU ^ in 'OLE
IDLE T R A N S F E R ^ L y S p ^ DISCHARGE
POWER VALVE
RESTRICTION
IDLE PLATE
SECONDARY TRANSFER
PASSAGE > C _Jr PASSAGE MAIN JET SLOT
IDLE TRANSFER IDLE DISCHARGE
SLOT HOLE
SECONDARY SYSTEM (IDLE & LOW SPEED)
IDLE SYSTEM
M AIN JET
MAIN WELL { f lN J j X D
POWER SYSTEM
6M-38 CARBURETOR
M A IN BODY
FUEL
METERING BOW L
BODY
Fig. S4--Subassemblies
5. P R IM A R Y BOW L ONLY--
• R e m o v e p u m p d ia p h ra g m screw s a n d lift p u m p
housing, d ia p h rag m an d spring fro m fuel bow l.
• C h eck p u m p in let b all for free m o v e m e n t a n d d a m
ag e. D a m a g e to ball, p a ssa g e o r r e ta in e r r e q u ir e s
new bow l assem bly.
fl
Disassemble Metering Bodies (Fig. S6)
1. On prim ary metering body remove the metering body
filler block.
2. Remove main metering jets with a jet wrench or a wide
blade screw driver (a small screw driver will damage the
jets). Remove the power valves using a 1" 12pt. socket.
Remove Idle mixture screws and seals (prim ary side
Fig. S5~Fuel Bowl Assem bly o n ly ).
y*~— 8
• F ile o ff th e sta k e d en d s o f sh a ft screw s th e n rem o v e 4. Remove cotter key and disconnect throttle connecting
screws. link (secondary lockout) from shaft levers.
• R em ove choke ro d (u p w ard th ro u g h p lastic seal) an d 5. File off the staked ends of the throttle plate attaching
rem o v e seal fro m m a in body. screws, then remove the screws and throttle plates.
• R e m o v e v a lv e fro m sh a ft slo t a n d slid e s h a ft fro m 6. Remove burrs from throttle shaft and slide the shafts
m ain body. out of flange.
7. Remove accelerator pump cam from throttle lever.
8. Remove vacuum break hose from fitting.
Disassemble Throttle Body (Fig. S9)
NOTE: Ordinarily the throttle body need not be dis Cleaning and Inspection
assembled for cleaning and inspection purposes.
The carburetor should be cleaned in a cold immersion
type cleaner.
NOTE: If necessary, diassemble for part replace
ment as follows: NOTE: The most frequent causes of carburetor mal
function are gum, carbon, and water. Carefully
1. Remove pum p operating lever assembly. Disassemble clean and inspect all parts and castings as the car
spring, bolt and nut if needed. buretor is being serviced as follows:
2. Remove idle speed screw and spring.
3. Remove diaphragm lever from secondary thorttle shaft 1. Thoroughly clean carburetor castings and metal parts
and fast idle cam lever from prim ary throttle shaft. in an approved carburetor cleaner.
CAUTION: Any rubber parts, plastic parts, dia 6. Install the throttle connecting link (secondary lockout)
phragms, pump plungers, electric parts, including to the throttle shaft levers.
solenoids, should not be immersed in carburetor 7. Install fast idle cam lever on prim ary throttle shaft and
cleaner. However the air horn which has the pres diaphragm lever on secondary throttle shaft.
sure relief valve will withstand normal cleaning in 8. Install idle speed screw and spring. T urn idle speed
carburetor cleaner. Make sure the cleaning solution screw clockwise until contact with throttle lever is
is thoroughly removed from pressure relief valve made and turn 1 1/ 2 " additional turns for preliminary
area. adjustm ent.
9. Install accelerator pum p cam on throttle lever.
10. Assemble and install pum p operating lever assembly.
11. Install vacuum break hose on fitting.
NOTE: Secondary throttle shaft bushings and accel
erator pump cam are plastic. Assemble Main Body
1. Install pum p discharge valve.
2. Install pum p discharge nozzle. Use new gaskets.
2. Check secondary throttle operating diaphragm for free 3. Install choke rod seal and choke rod in main body.
operation and leakage by moving diaphragm rod to the 4. Install choke shaft in main body and connect upper end
up position then covering vacuum passage opening in of choke rod.
housing with thum b. The diaphragm should hold up 5. Install choke valve on choke shaft (do not tighten re
ward. Remove thum b from vacuum passage and dia taining screws).
phragm rod should move down readily. 6. Center choke valve on shaft by holding valve closed
3. Blow out all passages in castings with compressed air. while tightening screws.
D o not pass - drills through jets or passages. 7. Stake screw ends with pliers.
4. Inspect idle m ixture needle for damage.
5. Exam ine flaot needle and seat assembly for wear. Install NOTE: The choke valve is offset and should fall
a new factory m atched set if worn. freely to wide open position from its own weight.
6. Inspect upper and lower casting sealing surfaces for
damage. 8. Install choke lever and fast idle cam; then retainer.
7. Inspect holes in levers for excessive wear or out of 9. Connect vacuum break link to choke lever, then install
round condition. If levers or rods are worn they should vacuum break with two retaining screws.
be replaced.
8. Exam ine fast idle cam for excessive wear or damage. Assemble Secondary Throttle Operating
9. Check throttle and choke levers and valves for binds
and other damage. Assembly
10. Replace filter element.
11. Check all springs for distortion or loss in tension re 1. Install diaphragm assembly and spring in housing.
place as necessary. 2. Install diaphragm cover and tighten securely.
3. Install the throttle valves on the shaft (do not tighten CAUTION: Do not turn screw tightly against seal.
retaining screws).
4. C enter the throttle valves on the shafts by holding the 2. On prim ary metering body install filler block.
valves closed while tightening the screws.
NOTE: The throttle valves are installed with identifi Assemble Fuel Bowls
cation numbers down (to manifold side).
1. P R IM A R Y A N D SEC O N D A R Y BOW L
5. Support the throttle shafts and stake the throttle valve • O n p rim a ry bow l install bow l filler before float
screws. in stallatio n (Fig. S10).
Assemble Subassemblies
A d ju s t F lo a ts (Fig. S 1 1)
1. Invert the main body, align new throttle body to main
1. M ake a prelim inary float adjustm ent by inverting pri body gasket, then position throttle flange assembly and
m ary fuel bowl and turning adjustable needle-seat until install the screws and tighten securely. (Fig. S I2).
top of float is specified distance from top of fuel bowl.
2. Using a new gasket, install secondary throttle operating
2. R ep e a t Stop one fo r seco n d ary float. assembly on main body and tighten securely.
3. Lay flange and main body on prim ary side then install
NOTE: Final adjustment of the float is made on the new fuel bowl gasket and secondary m etering body as
vehicle. Refer to Section 6M of the Chassis Service sembly onto main body algining dowel pins and holes.
Manual. 4. Install secondary fuel bowl and retaining screws with
new gaskets under heads.
5. Lay assembly on secondary bowl then install prim ary
metering body and gasket on main body.
6. Install splash shield, new gasket and prim ary fuel bowl.
CENTER IN BOWL
SPECIAL TOOLS
V
SECTION 6Y
ENGINE ELECTRICAL
CONTENTS OF SECTION
STARTING MOTOR
INDEX
CONTACT SOLENOID
FINGER PLUNGER RETURN SPRING
SHIFT
LEVER
GROMMET
SPIRAL
BUSHING SPLINES
BUSHING
PINION
STOP
OVERRUNNING
BRUSH INSULATED BRUSH HOLDER FIELD COIL ASSIST CLUTCH
BRUSH SPRING ARMATURE SPRING
GROUNDED BRUSH HOLDER
1. Drive Housing 7. Solenoid Case 15. O verrunning Clutch 22. G rounded Brush
2. S hift Lever B olt 8. Screw and Lock Assem bly Holders
3. S hift Lever Nut and W asher 16. A rm ature 23. Brushes
Lock W asher 9. Grom met 17. Braking W asher 24. Screws
4. Pin 10. Field Frame 18. Com m utator End 25. Field Coils
5. S hift Lever 11. Through Bolts Frame 26. Insulators
6. Solenoid Plunger 12. T hrust Collar 19. Brush Springs 27. Pole Shoes
6A. Solenoid Return 13. Snap Ring 20. W asher 28. Screws
Spring 14. Retainer 21. Insulated Brush
Holders
1. D isconnect the field coil connector(s) from the m otor a. Slide two piece thrust collar off end of arm ature
solenoid Terminal. shaft.
2. Remove through bolts. b. Slide a standard half-inch pipe coupling or other
metal cylinder of suitable size (an old pinion of
3. Remove C om m utator end frame, field frame assembly
suitable size can be used if available) onto shaft so
and arm ature assembly from drive housing.
end of coupling or cylinder butts against edge of
4. Remove overrunning clutch from arm ature shaft as fol retainer (fig. 3S). Tap end of coupling with hammer,
lows: driving retainer towards arm ature end of snap ring.
Field Coil Test For Open Circuit Fig. 6S--Field Coil Open C ircu it Test
Place one lead on the insulated brush and the other to the
field connector bar (fig. 6 S). If the lamp does not light, the
field coils are open and will require replacement.
Loose Electrical Connections
W hen an open soldered connection of the arm ature to
com m utator leads is found during inspection, it may be resol
dered provided resin flux is used for soldering.
Field Coil Test For Ground
Place one lead on the connector bar and the other on the CAUTION: Acid flux must never be used on electri
grounded brush (fig. 7S). If the lamp lights, the field coils are cal connections.
grounded.
Overrunning Clutch
d. Repeat for other set of brushes.
The overrunning clutch (roll clutch design) used in the 2. Assemble overrunning clutch assembly to arm ature
various starting m otors is (fig. 8 S) designed to be serviced as shaft.
a complete unit. a. Lubricate drive end of arm ature shaft with silicone
lubricant.
b. Slide clutch assembly onto arm ature shaft with pin
A SSEM BLY ion outward.
c. Slide retainer onto shaft with cupped suraface facing
A fter all parts have been thoroughly tested and inspected end of shaft (away from pinion).
and worn or damaged parts replaced, the starter should be d. Stand arm ature on end of wood surface with com
reassembled. m utator down. Position snap ring on upper end of
1. Assemble brush rigging to field frame. shaft and hold in place with block of wood.
a. Assemble brushes to brush holders. end of shaft (fig. 9S). Slide snap ring down into groove.
b. Assemble insulated and grounded brush holder
together with the "V" spring and position as unit on
the support pin. Push holders and spring to bottom
of support and rotate spring to engage the "V" in
slot in support.
c. A ttach ground wire to grounded brush and field
lead wire to insulated brush.
Fig. 8 S— RolI Type Clutch Cross-Section Fig. 10S--Forcing Snap Ring Into Retainer
5. Lubricate the bushing in the com m utator end frame 3. Push the pinion back towards the com m utator end to
with a silicone lubricant. Place leather brake washer on eliminate slack movement.
arm ature shaft and slide com m utator end frame onto
shaft.
STARTING SOLENOID
INDEX
Removal Installation
1. Remove the outer screw and washer from the m otor 1. W ith solenoid return spring installed on plunger, posi
connector strap terminal. tion solenoid body to drive housing and turn counter
2. Remove the two screws retaining solenoid housing to clockwise to engage the flange key in the keyway slot.
end frame assembly. 2. Install two screws retaining solenoid housing to end
3. Twist solenoid clockwise to remove flange key from frame.
keyway slot in housing; then remove solenoid assembly. 3. Install outer screw and washer securing m otor connec
tor strap terminal.
4. Install starter m otor as previously described.
Replacement of Contacts (fig. 13S)
1. W ith solenoid removed from m otor, remove nuts and
washers from switch and m otor connector strap term i
nals. S O LEN O ID
BO D Y TO HOLD-IN
2. Remove the two solenoid end cover retaining screws C O IL C O N TA C T C O N TA C T
R IN G S FINGER
and washers and remove end cover from solenoid body. SW ITCH
TERMINAL
3. Remove nut and washer from battery terminal on end FIBER
W ASHER
cover and remove battery terminal. Remove resistor
by-pass term inal and contactor.
4. Remove m otor connector strap term inal and solder new BATTERY
TERMINAL
term inal in position.
TO PULL-IN
5. Using a new battery term inal, install term inal washer C O IL PLUNGER
and retaining nut to end cover. Install by-pass terminal
and contactor. M OTOR C O N N E C T O R
STRAP TERMINAL
6. Position end cover over switch and m otor terminals and
install end cover retaining screws. Also install washers
and nuts on the solenoid switch and starting m otor
terminals.
7. Bench test solenoid for proper operation. Fig. 13S--Exploded V iew of Solenoid
CHARGING SYSTEMS
5.5" Series ID D e lc o tro n ............................................... 6 Y -8 10-SI Series Type 100 D elco tro n ................................. 6Y-11
fi Y 8
D isassem bly........................................................................ Test Lam p M e th o d ........................................................ 6Y-10
Cleaning and In sp ectio n ................................................. 6Y-9 O hm m eter M e th o d ........................................................ 6Y-10
Testing R otor ................................................................... 6Y-9 R epairs................................................................................. 6Y-11
G ro u n d s............................................................................ 6Y-9 Diode R eplacem ent........................................................ 6Y-11
Open C ir c u it................................................................... 6Y-9 Heat Sink Replacement ............................................... 6Y-11
Short C irc u it................................................................... 6 Y ‘9 Brush R eplacem ent........................................................ 6Y-11
Testing Stator ................................................................... 6Y-10 End Fram e Replacement ............................................ 6 Y -11
G ro u n d s............................................................................ 6Y-10 Drive End Fram e ........................................................ 6Y-11
Open C ir c u it................................................................... 6Y-10 Slip Ring End F r a m e ................................................. 6Y-12
Short C irc u it................................................................... 6Y-10 A ssem bly............................................................................ 6Y-12
Testing Diodes................................................................... 6Y-10
R E LA Y T E R M IN A L F” T E R M IN A L
SLIP RING DRIVE END
END FRAME FRAME
SLIP RINGS
BEARING
PULLEY
DIODES FAN
ROTOR STATOR
ASSEMBLY
4. Place a piece of tape over the slip ring end frame bearing (CHECK FOR GROUNDS)
to prevent entry of dirt or other foreign m atter. OHMMETER
Open Circuit
Connect one test lamp or ohm m eter lead to each slip ring.
If the lamp fails to light or if the ohm m eter reading is high,
the windings are open.
Short Circuit
The windings are checked for shorts by connecting a
12-volt battery and an am m eter in series with the two slip
rings. Note the am m eter reading. An am m eter reading above
the specified field amperage draw indicates shorted windings.
Fig. 2C~Pulley Removal Refer to Specifications at the end of this manual.
OHMMETER
OHMMETER OHMMETER
TEST LAMP TEST LAMP
(Check for Opens) (Check for Grounds)
Grounds
Diode in Heat Sink
Connect a 110-volt test lamp or an ohm m eter from any
stator lead to the stator frame. If test lamp lights or if ohm m W ith the stator previously disconnected connect one of
eter reads low, the windings are grounded. the lamp leads to the heat sink and other lead to the light in
only one of the test directions. If lamp lights in both direc
tions or fails to light at all, the diode is defective.
Open Circuit
If lamp fails to light of if ohm m eter reads high when
successively connected between each pair of stator leads, the Diode in the End Frame
windings are open.
Connect one lamp lead to the end frame and the other
lamp lead to the diode lead, and observe lamp condition.
Short Circuit Reverse the lamp lead connections and observe the lamp
A short in the stator windings is difficult to locate without condition. A good diode will allow lamp to light in only one
special test equipm ent due to the low resistance of the wind direction. If lamp lights in both directions or fails to light at
ings. However, if all other electrical checks are norm al and all, the diode is defective.
the generator fails to supply rated output, shorted stator
windings are indicated. Also, look for heat discoloration on
the windings.
Ohmmeter Method
TESTIN G DIO D ES (Fig. 5C) Use an ohm m eter with a 1-1/2 volt cell and use the lowest
range scale.
Two m ethods may be used to check diodes for shorts or Connect the ohm m eter leads at each diode as previously
opens, a test lam p of not more than 12 volts or an ohmmeter. described using a test lamp first in one direction and then the
other. N ote the readings. If both readings are identical (very
CAUTION: Do not use a 110-volt test lamp to test high or very low), the diode is defective. A good diode will
diodes. give one high and one low reading.
D IS A S S EM B LY (fig. 10C) NOTE: A scribe mark will help locate the parts in the
same position during assembly.
1. Hold generator in a vise, clamping the m ounting flange
lengthwise.
2. Remove the four thru-bolts and separate te slip ring end
frame and stator assembly from the drive end and rotor 3. Place a piece of tape over the slip ring end frame bearing
assembly by prying apart with a screwdriver at the to prevent entry of dirt and other foreign material, and
stator slot. also a piece of tape over the shaft at the slip ring end.
Open Circuit
W ith generator completely disassembled the com ponents
should be cleaned and inspected. Be sure testing equipment Connect one test lamp or ohm m eter lead to each slip ring.
is in good working order before attem pting to check the If the lamp fails to light or if the ohm m eter reading is high,
generator. the windings are open.
1. W ash all metal parts except stator and rotor assemblies.
Short Circuit
2. Clean bearings and inspect for sealing, pitting or rough
ness. The windings are checked for shorts by connecting a 12
3. Inspect rotor slip rings, they may be cleaned with 400 volt battery and an ammeter in series with the two slip rings.
grain polishing clot. R otate rotor for this operation to Note the am m eter reading. An am m eter reading above the
prevent creating flat spots on slip rings. specified field amperage draw indicates shorted windings.
4. Slip rings which are out of round may be trued in a lathe Refer to Specifications at the end of this manual.
to .001" maximum indicator reading. Remove only
enough m aterial to m ake the rings sm ooth and concen
tric. Finish with 400 grain polishing clot and blow dry.
Stator Checks (fig. 12C)
Grounds
5. Slip rings are not replaceable-excessive damage will
require rotor assembly replacement. Connect a 110-volt test lamp or an ohm m eter from any
6. Inspect brushes for wear. If they are worn halfway, stator lead to the stator frame. If test lamp lights or if ohm m
replace. Inspect brush springs for distortion or weaken eter reads low, the windings are grounded.
ing. If brushes appear satisfactory and move freely in
brush holder, springs may be reused.
Open Circuit
If lamp fails to light or if ohm m eter reads high when
TESTIN G successively connected between each pair of stator leads, the
windings are open.
BRUSH
HOLDER REGULATOR
SINGLE CONNECTOR
INSULATED
Fig. 13C--Diode Trio Checks
HEAT SINK INSULATING
WASHER
GROUNDED
Diode Trio (fig. 13C) HEAT SINK
W ith the diode trio unit remove from the end frame, OHMMETER
connect an ohm m eter to the single connect and to one of the
three connectors. Observe the reading, then reverse the
ohm m eter leads to the same connectors. A good diode trio Fig. 14C--Rectifier Bridge Checks
will give one high and one low reading. If both readings are
the same, replace the diode trio. Repeat this test between the and between the insulated heat sink and each of the three
single connector and each of the other two connectors. terminals. W hen this is done all six diodes are checked with
two readings taken for each diode.
NOTE: There are two diode trio units differing in
appearance used in the generator but they are com
pletely interchangeable.
NOTE: The diodes are not replaced individually. The
The diode trio may also be checked for a grounded brush entire rectifier ridge is replaced if one or more diodes
lead while still installed in the end frame. Connect an ohm m are defective.
eter from the brush lead clip to the end frame as shown in
Step 2, Figure 15C, then reverse the lead connection. If both CAUTION: Do not use high voltage to check the
readings are zero, check for a grounded brush lead clip rectifier bridge, such as a 110 volt test lamp.
caused by omission of the insulating washer, of the insulating
sleeve over the screw, or dam aged insulating sleeve. Remove
the screw to inspect the sleeve. If sleeve or screw are not
grounded, replace regulator. Voltage Reg./Brush Lead Clip Check
Bearing Replacem ent-Slip Ring End NOTE: The two screws retaining the brush clips
have insulating washers over the top of the brush
Frame clips and special insulating sleeves over the screw
body above the threads. If the third screw does not
1. Replace the bearing if the grease supply is exhausted. have an insulating sleeve, it must not be inter
M ake no attem pt to re-lubricate and reuse the bearing. changed with either of the other two screws.
2. Press out from outside of housing, using suitable tool
over outer race of bearing.
3. To install, place a flat plate over the bearing and press 5. Position rectifier bridge to end frame. Install attaching
in from outside of housing until bearing is flush with the screw and the "BAT" term inal screw. Connect capaci
outside of the end frame. Support inside of end frame tor lead to bridge.
around bearing bore with a suitable tool to prevent 6. Position diode trio on rectifier bridge term inal and in
distortion. Use extreme care to avoid misalignment. stall screw attaching brush lead clip to brush holder.
4. Install new seal whenever bearing is replaced. Lightly
coat the seal lip with oil and press seal into the end
frame with the seal lip tow ard the inside of the end
frame. CAUTION: Insulating washer on the screw must be
assembled over top of the connector.
R E A S S E M B LY
1. Install rotor in drive end frame and attach spacer, fan, 7. Position stator in end frame. Connect stator leads to
pulley, washer, and nut. rectifier bridge term inals and install attaching nuts.
2. Using adapter J-2 1501, insert an alien wrench into hex 8. Position slip ring end frame to drive end frame and
shaped hole at end of shaft and torque the shaft nut to install four thru bolts.
40-50 ft. lbs. (fig. 9C).
3. Install capacitor and retaining screw in slip ring end
frame. NOTE: Remove tooth pick from brush holder at
4. Position brush holder and regulator assemblies in end opening in slip ring end frame before operating ma
fram e and install two retaining screws. chine on vehicle.
SPECIAL TOOLS
J 9 7 1 7 -2 J 9 7 1 7 -1 J-9 6 0 0 -2 J - 2 1 501
SUPPORT PRESS SHOULDERED PULLY
TO O L TO O L INSTALLER ADAPTER
Single Plate D iaphragm Spring C lu tc h ...................... 7- 1 4-Speed New Process Transmission (Model 435).... 7- 49
D ual Plate D iaphragm Spring C lu tc h ........................ 7 -3 D ana Model 20 Transfer C a se ...................................... 7- 60
Single Plate Coil Spring C lu tc h ................................... 7- 4 New Process M odel 205 Transfer C ase...................... 7-66
3-Speed Saginaw T ransm ission...................................... 7 -8 A dapter Assemblies ........................................................ 7-74
3-Speed M uncie Transm ission ...................................... 7-14 A lum inum Powerglide ................................................... 7-77
4-Speed Saginaw T ransm ission...................................... 7-20 Turbo H ydra-M atic.......................................................... 7-99
4-Speed M uncie Transm ission (Passenger C ar)........ 7-29 Special T o o ls..................................................................... 7-192
4-Speed M uncie Transm ission (M odel 465) ............. 7-37
INDEX
NOTE: When disassembling, mark edge of pressure 1. Remove three drive-strap to pressure plate bolts and
plate and cover. These marks must be aligned in retracting springs and remove pressure plate from
assembly to maintain balance. clutch cover.
2. The clutch diaphragm spring and two pivot rings are
riveted to the clutch cover. Spring, rings and cover
Disassembly (Fig. 3) should be inspected for excessive wear or damage and
if there is a defect, it is necessary to replace the complete
cover assembly.
6. Exam ine splines in hub and m ake sure they slide freely
on splines of transm ission clutch shaft. If splines are
worn, the clutch disc or clutch gear should be replaced
as necessary.
7. Inspect clutch fork ball socket and fingers for wear and
ball retaining spring for damage. Spring should hold
fork tightly to ball stud.
Assembly
1. Install the pressure plate in the cover assembly, lining
up the punch m arks on the edge of the pressure plate
with the punch m arks on the edge of the cover. Fig. 4 -C lu tch Pilot Bearing Removal (Typical)
2. Install pressure plate retracting springs and drivestrap
to pressure plate bolts and lock washers and tighten to tion when the clutch is removed from the vehicle, at which
11 ft. lbs. torque. The clutch is now ready to be in time it should be cleaned and inspected for excessive wear or
stalled. damage and should be replaced if necessary.
To remove, install Tool J-1448 and remove bearing from
Pilot Bearing Replacement crankshaft (fig. 4). In replacing this bearing, use Tool J-1522.
Place bearing on pilot of tool with radius in bore of bearing
T he clutch pilot bearing is an oil im pregnated type bear next to shoulder on tool and drive into crankshaft. Lubricate
ing pressed into the crankshaft. This bearing requires atten- with several drops of machine oil.
Disassembly (Fig. 5)
CAUTION: Assembly should be handled with pres- 2. Remove front pressure plate and rear driven disc from
sure plate face up to prevent movement of the plate the cover assembly.
and distortion of the retracting spring. 3. The rear pressure plate, clutch diaphragm spring, and
pivot rings are riveted to the clutch cover. These items
1. W ith assembly resting on flywheel side of cover, remove and the front pressure plate should be inspected for
drive strap-to-front pressure plate bolts and washers. wear or damage and if there is any defect, it is necessary
Care should be taken to support the front pressure plate to replace the complete cover and pressure plates as
to prevent bending o f the drive straps. sembly.
Assembly
1. Install clutch disc and front pressure plate in the cover
assembly, aligning the reference " 0 " m ark on the edge
of the pressure plate with the " 0 " m ark on the edge of
the cover.
2. Install lock washers and bolts retaining front pressure
plate to the cover. Torque bolts to 18 ft. lbs.
INDEX
Disassembly
1. Place the cover assembly on the bed of an arbor or drill
press with a block under the pressure plate so arranged
that the cover is left free to move down.
2. Place a block or bar across the top of the cover with the
spindle. H old compressed while the adjusting nuts are
removed as shown in Figure 2E, then slowly release
pressure to prevent springs flying out.
3. Lift off cover and all parts will be available for inspec
tion. N ote carefully the location of all parts including
Fig. 1 E -C oil Spring C lutch Cross-Section (Single Plate) arrangem ent of springs, see (fig. 3E).
1. Release Lever
2. Eyebolt 8. Pressure Plate
4. To remove levers grasp lever and eyebolt between
3. S trut 9. A nti-R attle Spring thum b and fingers as shown in Figure 4E, so that inner
4. Cover 10. T h ro w o u t Bearing end of lever and upper end of eyebolt are close together,
6. Coil Spring 1 1. Flywheel keeping eyebolt pin seated in its socket in lever.
1. Release Lever
2. Eyebolt
Fig. 2E--Compressing Clutch 3. Strut
1. Release Lever NOTE: If there are spaces for more springs than
2. Eyebolt
specified for the particular assembly, or if two differ
3. S trut
ent colors of springs are used. Figure 8E shows the
5. Lift stru t over ridge on end of lever, (fig. 5E). proper sequence. It is very important that each
group be arranged in like sequence.
6. Lift lever and eyebolt off pressure plate.
7. Assemble anti-rattle springs in cover as shown in Fig
NOTE: It is important to replace all parts which ure 9E. The spring to the left is in operating position.
show wear. 8 . Lower the cover on top of the assembled parts, (fig.
10E) being sure that the anti-rattle springs are in correct
Assembly position and also th at the punch m arks m ade before
dism antling are m atched to insure retaining the original
1. Lay the pressure plate on the block in the press and coat balance.
the lugs with a thin film of approved lubricant such as 9. Place a bar across the cover and slowly compress, guid
lubriplate as shown in Figure 6 E. ing the holes in the cover over the pressure plate lugs
2 . Assemble lever, eyebolt and pin, holding eyebolt and and all springs into their spring seats in the cover.
lever as close together as possible and with the other 10. Assemble adjusting nuts on the eyebolts and screw
hand grasp strut as shown in figure 7E. them down until their tops are flush with the tops of the
3. Insert Strut in the slots in the pressure plate lug, drop eyebolts. Slowly release pressure of spindle and remove
slightly and tilt the lower edge until it touches vertical cover assembly from press.
milled surface of lug.
4. Insert lower end of eyebolt in hole in pressure plate. The
short end of the lever will then be under the hook of the Adjusting Levers
pressure plate and near the strut, (fig. 5E).
W hile no wear adjustm ent is needed because of the coil
5. Slide the stru t upw ard in the slots of the lug, lifting it
spring design, it is imperative that the clutch release levers
over the ridge on the short end of the lever and drop it
are each set to exactly the same height at the time of m anu
into the groove in the lever, (fig. 4E).
facture or rebuild to insure uniform clutch application. To
6. Assemble the pressure springs, on the small bosses of
obtain exactly the same adjustm ent at each release lever, use
the pressure plate in accordance with Figure 8 E in or
gauge plate J-1048 and release lever height gauge J-6456 as
der to retain original balance.
follows:
6 S P R IN G S
3 SPRINGS P A IN T E D
UNPAINTED B LA C K
A D JAC E N T
T O LEVERS
6 S P R IN G S
9 SPRINGS U N P A IN T E D
PAINTED
3 9 6 -V 8
ORANGE
3 5 0 V -8 ADJACENT
TO LEVERS
Fig. 10E -A ssem bling Cover and Pressure Plate Fig. 1 2E-D epressing Lever
J-6456
ADJUSTING
NUT
SUBJECT PAGE
30 31 32 33 34 35 36 37 38 39 40
4. Case 12. 1st Speed Synch. 18. V en t 26. Thrust W a sh e r-F ro n t 35. C ounter S haft
5. 3 rd Speed B locker Hub 19. Speedom eter Drive 27. Thrust W asher-R ear 36. Reverse Id le r S haft
Ring 13. 1st Speed Synch. Gear and Clip 28. Snap R ing-B earing 37. 1st Speed Synch.
OVERHAUL MANUAL
Transmission Case
1. W ash the transmission thoroughly inside and outside
with cleaning solvent, then inspect the case for cracks.
2. Check the front and rear faces for burrs, and if present,
dress them off with a fine mill file.
Gears
1. Inspect all gears for excessive wear, chips or cracks and
replace any th at are worn or damaged.
2. Inspect reverse gear bushing and if worn or damaged
replace the entire gear.
1. Clutch Gear 6. 2-3 Synchronizer 11. 1st Speed Blocker 15. Reverse Gear Thrust
2. Clutch Gear Bearing Assem bly Ring W asher
3. 3rd Speed B locker 7. 2nd Speed blocker 12. 1st Speed 16. Spring W asher
Ring Ring Synchronizer 17. Rear Bearing
4. M ainsha ft Pilot 8. 2nd Speed Gear Assem bly 18. Snap Ring
Bearings (14) 9. S houlder (Part of 13. Snap Ring 19. Speedo Drive Gear
5. Snap Ring M ain Shaft) 14. Reverse Gear and Clip
10. 1st Speed Gear 20. M ainshaft
1. T hrust W asher - Front 19. 3rd Speed Blocker 33. 1-2 S ynchronizer Hub 47. Gasket
2. Bearing W asher Ring Assem bly 48. 2-3 S hift Fork
3. Needle Bearings 20. "E " Ring 34. 1-2 S ynchronizer 49. 1st and Reverse S hift
4. C ountergear 21. Reverse Idler Gear Sleeve Fork
5. Needle Bearings 22. Reverse Idler Shaft 35. Snap Ring - Hub to 50. 2-3 S hifter Shaft
6. Bearing W ahser 23. W o o d ru ff Key Shaft Assem bly
7. T hrust W asher - Rear 24. Snap Ring - Hub to 36. Reverse Gear 51. 1st and Reverse
8. Counter Shaft Shaft 37. T hrust W asher S hifter Shaft
9. W o o d ru ff Key 25. 2-3 Synchronizer 38. Spring W asher Assem bly
10. Bearing Retainer Sleeve 39. Rear Bearing 52. " 0 " Ring Seal
1 1. Gasket 26. Synchronizer Key 40. Snap Ring - Bearing 53. "E " Ring
12. Oil Seal Spring to Shaft 54. Spring
13. Snap Ring - Bearing 27. 2-3 Synchronizer Hub 41. Speedom eter Drive 55. 2nd and 3rd Detent
to Case A ssem bly Gear Cam
14. Snap Ring - Bearing 28. 2nd Speed Blocker 42. Retaining Clip 56. 1st and Reverse
to Gear Ring 43. Gasket Detent Cam
15. Clutch Gear Bearing 29. 2nd Speed Gear 44. Snap Ring - Rear 57. Side Cover
16. Case 30. M ainshaft Bearing to Extension 58, TCS S w itch and
17. Clutch Gear 31. 1st Speed Gear 45. Extension Gasket
18. Pilot Bearings 32. 1st Speed Blocker 46. Oil Seal 59. Lip Seal
Ring
12. Install rear ball bearing w ith snap ring slot downward; 6. Pilot the clutch gear, pilot bearings and 3rd speed
press onto m ainshaft. blocker ring assembly over the front of the mainshaft
13. Install rear bearing to m ainshaft snap ring. assembly. D o not assemble bearing to gear yet.
14. Install speedom eter drive gear and retaining clip.
CAUTION: Be sure the notches in the blocker ring
align with the keys in the 2-3 synchronizer assem
bly.
A S S E M B L Y OF TRA N SM ISSIO N
1. Using Tool J-22246 load a row of roller bearings (27) 7. Place extension to case gasket at rear of case holding in
and a bearing th ru st w asher at each end o f the counter place with grease and, from the rear of case, assemble
gear. Use heavy grease to hold them in place (fig. 6 A). the clutch gear, m ainshaft and extension to case as an
2. Place countergear assembly through case rear opening assembly.
along w ith a tanged th ru st washer (tang away from
gear) at each end and install countergear shaft and CAUTION: Be sure the clutch gear engages the
w oodruff key from rear of case. countergear anti-lash plate.
SUBJECT PA G E
D IS A S S E M B L Y OF TRA N SM ISSIO N 3. Remove clutch gear bearing to gear stem snap ring,
then remove clutch gear bearing by pulling outw ard on
(Fig. 1G) clutch gear until a screw driver or other suitable tool
can be inserted between bearing, large snap ring and
1. Remove side cover attaching bolts, side cover assembly, case to complete removal. The clutch gear bearing is a
slip fit on the gear and into the case bore. (This provides
gasket and shift forks.
2. Remove clutch gear bearing retainer bolts, retainer and clearance for removal of clutch gear and mainshaft as
gasket. sembly.)
1. C lutch Gear 8. 1st Speed 15. Rear Bearing-to-S haft 21. Reverse Idler Shaft
2. C lutch Gear Bearing Synchronizer Ring Snap Ring 22. C ountergear
Retainer 9. 1st Reverse Clutch 16. Rear Bearings
3. 3rd Speed Assy. Bearing-to-Extension 23. C ountergear
S ynchronizer Ring
CHEVROLET
S ynchronizer Ring 13. Rear Extension Seal 19. Reverse Idler S haft 27. Clutch Gear Bearing
6. 2nd Speed Gear 14. Rear Extension W o o d ru ff Key 28. Snap Ring
7. 1st Speed Gear 20. Reverse Idle r Gear 29. C lutch Gear Retainer
Lip Seal
CLUTCHES AND TRANSMISSIONS 7-16
D IS A S S E M B L Y OF M A IN SH AFT (Fig.
4G)
1. Depress speedom eter gear retaining clip and slide gear
from m ainshaft.
2. Remove rear bearing snap ring from m ainshaft groove.
Fig. 3G~Removing Rear Extension From M ainshaft
3. Support reverse gear w ith press plates and press on rear
of m ainshaft to remove reverse gear, thrust washer and
rear bearing from shaft. 7. Support 2nd speed gear with press plates and press on
front of mainshaft to remove clutch assembly, second
speed blocker ring and second speed gear from shaft.
CAUTION: When pressing rear bearing be careful to This completes the disassembly of mainshaft.
center gear, washers, and bearing on shaft.
Bearing Rollers
All clutch gear and countergear bearing rollers should be
inspected closely and replaced if they show wear. Inspect
counter shaft and reverse idler shaft at the same time, replace
Fig. 2G--Removing Reverse Idler Shaft if necessary. Replace all worn washers.
1. Clutch Gear 7. Retaining Clip 14. Snap Ring 18. S ho ulder (Part o f
2. Snap Ring 8. M ainsha ft 15. 1st Speed M ain sh a ft)
3. Clutch Gear Bearing 9. Speedo Drive Gear Synchronizer 19. 2nd Speed Gear
4. Oil Slinger 10. Snap Ring Assem bly 20. 2nd Speed B lo cker
5. 3rd Speed Blocker 11. Rear Bearing 16. 1st Speed B locker Ring
Ring 12. Reverse Gear T hrust Ring 21. 2-3 S yn ch ro n ize r
6. M ainshaft Pilot W asher 17. 1st Speed Gear Assem bly
Bearings (16) 13. Reverse Gear 22. Snap Ring
T urn the front of the m ainshaft upward. Install the follow 8. Install synchronizer hub to m ainshaft snap ring.
ing com ponents on the m ainshaft: 9. Install reverse gear with clutching teeth downward.
1. Install the second speed gear with clutching teeth up 10. Install reverse gear steel thrust washer (align flats).
ward; the rear face of the gear will b u tt against the 11. Install rear ball bearing with snap ring slot downward;
flange on the mainshaft. press onto mainshaft.
2. Install a blocking ring with clutching teeth downward 12. Install rear bearing to mainshaft snap ring.
over the synchronizing surface of the second speed gear. 13. Install speedometer drive gear and retaining clip.
All three blocker rings used in this transm ission are This completes the assembly of the mainshaft.
identifcal.
3. Install the second and third synchronizer assembly with
the fork slot downward; press it onto splines on the A S S E M B L Y OF TRA N SM ISSIO N (Fig.
m ainshaft until it bottom s out. Both synchronizer as
semblies are identical but assembled differently. The
6G)
2 nd-3rd speed hub and sleeve is assembled with the fork 1. Load a double row of roller bearings (29) and the bear
slot in the sleeve tow ard the thru st face of the hub. The ing thrust washers in the countergear (Fig. 6 g). Use
1st- reverse hub and sleeve is assembled with the fork heavy grease to hold them in place.
slot in the sleeve opposite the thrust face (fig. 4G). 2. Place countergear assembly through case rear opening
along with a tanged thrust washer (tang away from
CAUTION: Be sure the notches of the blocker ring gear) at each end and install countergear shaft and
align with the keys of the syncrhonizer assembly.
w oodruff key from rear of case. End of shaft m ust be
4. Install synchronizer hub to m ainshaft snap ring. Both flush with case.
synchronizer snap rings are identical.
T urn the rear of the m ainshaft upward. Install the follow CAUTION: Be sure countershaft picks up both
ing com ponents on the mainshaft: thrust washers and that the tangs are aligned with
5. Install the first speed gear with clutching teeth upward; their notches in the case.
the front face o f the gear will butt against the flange on
the m ainshaft. 3. Position reverse idler gear in case.
6 . Install a blocker ring with clutching teeth downward 4. Using snap ring pliers, expand the snap ring in the
over synchronizing surface of the first speed gear. extension and assemble extension over rear of m ain
7. Install the first and reverse synchronizer assembly with shaft and onto rear bearing. Seat snap ring in rear bear
fork slot up; press it onto splines on the mainshaft. ing groove (fig. 3G).
5. Load the mainshaft pilot bearings (16) into the clutch
gear cavity and assemble the 3rd speed blocker ring
onto the clutch gear clutching surface with its teeth
CAUTION: Be sure the notches of the blocker ring tow ard the gear.
align with the keys of the synchronizer assembly 6. Pilot the clutch gear, pilot bearings and 3rd speed
and that both synchronizer sleeves face the front of blocker ring assembly over the front of the m ainshaft
the mainshaft. assembly. D o not assemble bearing to gear yet.
CAUTION: Be sure the notches in the blocker ring 10. Install front bearing outer snap ring to bearing and
align with the keys in the 2-3 synchronizer assem install bearing on stem of clutch gear and into front case
bly. bore.
11. Install snap ring to clutch gear stem, and clutch gear
7. Place extension to case gasket on extension holding it bearing retainer and gasket to case.
in place with grease and, from the rear of case, assemble
the clutch gear, m ainshaft and extension to case as an NOTE: The retainer oil return hole should be at the
assembly. bottom.
CAUTION: Be sure the clutch gear engages the 12. Shift synchronizer sleeves to neutral positions and in
teeth of the countergear anti-lash plate and that the stall cover, gasket and fork assembly to case. Be sure
oil slinger is in place on the clutch gear. forks align with their synchronizer sleeve grooves.
13. Tighten all bolts to specified torque.
8. R otate extension and install reverse idler shaft and
woodruff key. NOTE: Apply sealer to all through bolts.
9. Install extension to case retaining bolts.
14. R otate clutch gear and shift transmission through gears
NOTE: Apply sealer to all through bolts. to check free rotation of gears.
SUBJECT PA G E
D IS A S S E M B L Y OF TRA N SM ISSIO N 6. Using snap ring pliers, expand the snap ring in the
extension which retains the m ainshaft rear bearing (fig.
(Figs. 1X and 2X) 5X) and remove the extension.
1. Remove side cover attaching screws and remove side 7. Using J-22246 at the front of the countershaft, drive the
cover assembly and shift forks. shaft and its woodruff key out the rear of the case. Tool
J-22246 will now hold the roller bearings in position
within the countergear bore. Remove the gear and bear
2. Remove clutch gear bearing retainer.
ings (fig. 6 X).
4. Case Hub Gear and Clip Extension 37. Reverse Idler S haft
5. 4th Speed B locker 13. 1-2 Speed Synch. 21. M a in sh a ft 30. Rear Bearing 38. 1-2 Speed Synch.
Ring Snap Ring 22. Rear Oil Seal 31. C ountergear Roller Sleeve and Reverse
6. 4-3 Snych. Snap Ring 14. 1st Speed B locker 23. R etainer Oil Seal Bearings Gear
7. 4-3 Synch. Hub Ring 24. Snap Ring-Bearing to 32. Anti-Lash Plate 39. Reverse Idler Gear
8. 3rd Speed B locker 15. First Gear Gear Assem bly (S liding)
Ring 16. Reverse Gear T hrust 25. C lutch Gear Bearing 33. Magnet 40. C lutch Key
9. 3rd Speed Gear and S pring W ashers 26. Snap R ing-Bearing to 34. 4-3 Snych. Sleeve 41. W o o d ru ff Key
10. 2nd Speed Gear 17. Snap R ing-Bearing to Case
M a in sh a ft
CLUTCHES AND TRANSMISSIONS 7-22
Fig. 2X ~ T ransm ission -E xplo de d V ie w
1. Bearing Retainer 15. T hrust W asher-Front 29. 3rd Speed Blocker 42. Gasket-Extension to 55. D etent Spring
2. G asket-Retainer to Gear Ring Case 56. 3-4 D etent Cam
Case 16. Needle Retainer 30. 3rd Speed Gear 43. Snap Ring-Extension 57. 1-2 D etent Cam
3. Oil Seal W asher 31. Needle Bearings to Rear Bearing 58. 3-4 S h ifte r Shaft
4. Snap R ing-Bearing to 17. Needle Bearings 32. Second Speed Gear 44. Extension 59. G asket-Cover to Case
Shaft 18. C o untergear 33. 2nd Speed B locker 45. Vent 60. Cover
5. Snap R ing-Bearing to 19. Needle Retainer Ring 46. Bushing 61. TCS S w itch and
Case W asher 34. M a in sh a ft 47. Oil Seal Gasket
6. C lutch Gear Bearing 20. T hrust W asher-Rear 35. 1st Speed B locker 48. 1-2 S ynchronizer 62. Lipseal
7. C lutch Gear Gear Ring Sleeve and Reverse 63. Detent Cam Retainer
8. M a in sh a ft P ilot 21. C o un te rshaft 36. First Speed Gear Gear 64. 1-2 S h ift Fork
Bearings 22. W o o d ru ff Key 37. T hrust W asher 49. Key Retainer 65. " 0 " Ring
9. 4th Speed B locker 23. Synchronizer Sleeve 38. W ave W asher 50. 1-2 Synchronizer Hub 66. 1-2 S h ift S haft
Ring 24. Snap Ring-Hub to 39. Rear Bearing 51. Clutch Keys 67. S pring
10. Case S haft 40. Snap R ing-Bearing to 52. Key Retainer 68. Ball
1 1. Filler Plug 25. Key Retainer Shaft 53. Snap Ring-Hub to 69. " 0 " Ring
12. Reverse Idle r Gear 26. 3-4 S ynchronizer Hub 41. Speedo Drive Gear Shaft 70. Reverse S h ifte r S haft
13. Reverse Idler S haft 27. C lutch Keys and C lip 54. 3-4 S hift Fork and Fork
14. W o o d ru ff Key 28. Key Retainer
CLUTCHES AND TRANSMISSIONS 7-28
J . 22246 COUNTER
SHAFT
PULL MAIN
DRIVE GEAR
FORWARD
Fig. 3X -R em oving Clutch Gear Bearing
Fig. 9X~Rem oving 3-4 S ynchronizer and T hird Speed Gear Fig. 1 1X--Removing Rear Bearing and First Speed Gear
5. Remove the 1st and second sliding clutch hub snap ring
from the m ainshaft and remove the clutch assembly,
2 nd speed blocker ring and second speed gear from the
rear of the m ainshaft (figs. 12X and 13X). This com
pletes the disassembly of the mainshaft.
Fig. lO X -R e ar Bearing to M ainsha ft Snap Ring Fig. 12X~First and Second Synchronizer Snap Ring
R EP A IR S
Bearing Rollers
All clutch gear and countergear bearing rollers should be
inspected closely and replaced if they show wear. Inspect
counter shaft and reverse idler shaft at the same time, replace
if necessary. Replace all w orn washers.
Gears
1. Inspect all gears for excessive wear, chips or cracks and
replace any th at are worn or damaged.
2. Check both clutch sleeves to see that they slide freely
on their hubs. Fig. 1 4X -T hree-F our Synchronizer Assem bly
SCREWDRIVER
sion housing (fig. 15X). Using the same tool, drive new bush
Fig. 1 5X -E xtension Bushing Replacement ing in from the rear. Coat I.D . of bushing and seal with
transmission lubricant, then install new oil seal using Tool
J-5154 (fig. 16X).
NOTE: A groove around the outside of the synchro
nizer hub identifies the end that must be opposite
the fork slot in the sleeve when assembled. This Clutch Gear Bearing Retainer Oil Seal
groove indicates the end of the hub with a .07"
greater recess depth. If the lip seal in the retainer needs replacement; pry the
oil seal out and replace with a new seal using Tool J-23096
Extension Oil Seal or Bushing until seal seats in its bore (figs. 17X and 18X).
J-23096
Fig. 16 X -ln s ta llin g Extension Oil Seal Fig. 1 8X —Installing Bearing Retainer Oil Seal
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 14 15 15 14 15 14
3. Install reverse idler gear and shaft with its woodruff key
from the rear of case.
4. Using snap ring pliers, expand the snap ring in the
extension and assembly extension over rear of m ain
shaft and onto rear bearing. Seat snap ring in rear bear
ing groove (fig. 5X).
5. Load the mainshaft pilot bearings (14) into the clutch
gear cavity and assemble the 4th speed blocker ring
onto the clutch gear clutching surface with its clutching
teeth tow ard the gear (fig. 24X).
6. Pilot the clutch gear, pilot bearings and 4th speed
blocker ring assembly over the front of the mainshaft
assembly. Do not assemble bearing to gear yet.
Fig. 22 X --lnsta llin g Rear Bearing CAUTION: Be sure the notches in the blocker ring
align with the keys in the 3-4 synchronizer assem
15. Install speedometer drive gear and clip. bly.
This completes the assembly of the mainshaft.
Fig. 23X ~Loading Countergear Bearings Fig. 24X--Loading M ainshaft Pilot Bearings
9. Install front bearing outer snap ring to bearing and 11. Shift synchronizer sleeves to neutral positions and in
position bearing over stem of clutch gear and into front stall cover, gasket and fork assembly to case. Be sure
case bore. forks align with their synchronizer sleeve grooves.
10. Install snap ring to clutch gear stem, and clutch gear
bearing retainer and gasket to case. 12. Tighten all bolts to specified torque.
FOUR-SPEED
MUNCIE TRANSMISSION (PA SS. CAR)
INDEX
SU BJECT PA G E
4. W ith transm ission gears in neutral, drive lock pin from 11. Press main drive gear down from front bearing (fig.
reverse shifter lever boss, (fig. 4B) and pull shifter shaft 7B).
out about 1/8". This disengages the reverse shift fork
from reverse gear.
12. From inside case, tap out front bearing and snap ring.
1 2 3 4 5 6 7 8 9 10 11 12 13
64
I
CLUTCHES AND TRANSMISSIONS 7-33
Fig. 8B--Removing C ountershaft W ith J-2 2 2 4 6 Fig. 10B~Removing Rear Bearing Retainer
A
CLUTCHES AND TRANSMISSIONS 7-34
R EP A IR S 1. Push the hub from the sliding sleeve. The keys will fall
Reverse Shifter Sh aft and Seal free and the springs may be easily removed.
2. Place the two springs in position (one on each side of
Replacement the hub), so all three keys are engaged by both springs.
Place the keys in position and, holding them in place,
1. W ith case extension rem oved from transm ission the slide the hub into the sleeve.
reverse shifter shaft lock pin will already be removed.
(See Step 4 under Disassembly). NOTE: The sleeve with the large square edge oppo
2. Remove shift fork. site the fork groove identifies the 3-4 synchronizer
3. Carefully drive shifter shaft into case extension, allowing sleeve.
ball detent to drop into case.
4. Place ball detent spring into detent spring hole and from
inside extension install shifter shaft fully into its opening
A S S E M B L Y OF M AIN SH AFT
until the detent plate is butted against inside of extension 1. From the rear of the m ainshaft, assemble the secon
housing. speed gear (with hub of gear tow ard rear of shaft).
5. Place detent ball on spring (fig. 1 IB) and, holding ball 2. Install 1-2 synchronizer clutch assembly to mainshaft
down with your thum b or a suitable tool push the (sliding clutch sleeve taper tow ard the rear, hub to the
shifter shaft back in away from case until it is directly front); together with a synchronizing ring on either side
over the ball and tu rn until the ball drops into detent of clutch assembly so their keyways line up with the
on the shaft detent plate. clutch keys (fig. 12B).
6 . Install shift fork. 3. Press the 1st gear sleeve onto the m ainshaft using a 1
3/4" I.D. pipe cut to a convenient length or other suita
NOTE: Do not drive the shifter shaft lock pin into ble tool.
place until the extension has been installed on the 4. Install the first speed gear (with hub tow ard front) and
transmission case. using 1 5/8" I.D . pipe cut to a suitable length, press on
the rear bearing (fig. 13B).
Extension Oil Seal Or Bushing 5. Choose the correct selective fit snap ring (.087", .090",
.093", or .096") and install it in the groove in mainshaft
If bushing in rear of extension requires replacement,
behind the rear bearing. W ith proper ring, maximum
remove oil seal and use Tool J-5778 to drive bushing into case
distance between snap ring and rear face of bearing will
extension. Using the same tool, drive new bushing in from the
be from zero to .005".
rear. Coat I.D . of bushing with transmission lubricant, then
install new oil seal using Tool J-5154. Prelubricate seal be
tween lips with cup grease. NOTE: Always use new snap rings when reassem
bling transmission and do not expand the snap ring
Clutch Keys and Springs Replacement further than is necessary for assembly.
CLUTCH
mm ■i
Fig. 1 1 B—Installing Reverse S hifter Shaft and Detent Ball Fig. 1 2B— Installing S ynchronizing Ring
I.D. PIPE
SNAP RING
GROOVE
Fig. 13 B -ln s ta llin g Rear Bearing Fjg. 15B--Loading Countergear Bearings Using J -2 2 2 4 6
ALIGNMENT
PIN
BOTTOM
OF CASE
NOTCH IN 0
SYNCHRONIZING
I RING MM
12. Lower the m ainshaft assembly into the case making NOTE: Roll pin should be in a vertical position.
certain the notches on the fourth speed synchronizing
ring correspond to the keys in the clutch assembly (fig. 18. Pull reverse shifter shaft to left side of extension and
18B). rotate shaft to bring reverse shift fork forward in exten
sion (reverse detent position). Start the extension onto
the transmission case (fig. 19B), while slowly pushing
in on the shifter shaft to engage the shift fork with the
reverse gear shift collar. Then pilot the reverse idler
shaft into the extension housing perm itting the exten
sion to slide onto the transmission case.
19. Install 6 extension and retainer-to-case attaching bolts.
Torque upper 3 bolts and lower 3 bolts to specification.
20. Push or pull reverse shifter shaft to line up groove in the
shaft with the holes in the boss and drive in the lock pin.
Install shifter lever.
21. Press bearing onto main drive gear (snap ring groove to
front) and into case until several main drive gear retain
ing nut threads are exposed.
22. Lock transmission up by shifting into two gears. Install
main drive gear retaining nut on the gear shaft and
draw it up tight using Tool J-0933. Be su~e bearing fully
S3 seats against shoulder on gear. Torque retaining nut to
Fig. 17B--Checking Countergear End Play 40 ft. lbs. and lock in place by staking securely into
SU BJECT PA G E
Disassembly of T ran sm issio n ............................................ 7-37 Clutch G ear Bearing R etainer Oil S eal................... ..... 7 4 3
Subassembly O p e ra tio n s................................................. .... 7 4 0 M ainshaft............................................................................... 7 4 3
Transm ission Cover............................................................ 7 4 0 D isassem bly................................................................... ..... 7 4 3
D isassem bly................................................................... .... 7 4 0 Inspection ..................................................................... ..... 7 4 5
A ssem b ly ............................................................................ 741 A ssem bly............................................................................. 7 4 5
Clutch G e a r.......................................................................... 7 4 2 C ountershaft ................................................................... ..... 7 4 6
D isassem bly................................................................... .... 7 4 2 D isassem bly................................................................... ..... 7 4 6
Inspection ..................................................................... .... 7 4 2 A ssem bly............................................................................. 7 4 7
A ssem b ly ....................................................................... .... 7 4 2 Assembly of T ran sm issio n ............................................ ..... 7 4 7
K” MODELS
40 < 1
1. Main Drive Clutch 11. Reverse Driven Gear 24. M ainshaft Rear 37. T hrust W asher
Gear 12. Poppet Spring Bearing 38. Snap Ring
2. Drive Gear Bearing 13. Poppet Ball 25. Rear Bearing Snap 39. Front C ountershaft
Retainer 14. S hift Rail Ring Bearing
3. Snap Ring-Outer 15. 1st and 2nd Shift 26. Snap Ring 40. C ountergear Front
4. 3rd and 4th Fork 27. C ountershaft Cover
Synchronizer Ring 16. 1st Speed Gear 28. C ountershaft Rear 41. Pilot Bearing Rollers
5. 3rd and 4th 17. T hrust W asher Bearing 42. Clutch Gear Oil
Synchronizer C ollar 18. Bearing Snap Ring 29. Bearing Snap Ring S linger
6. 3rd and 4th S hift 19. Speedom eter Drive 30. Reverse Idler Gear 43. Snap Ring
Fork Gear 31. Reverse Idler Shaft 44. 3rd Speed Gear
7. 3rd and 4th Speed 20. O utput Yoke 32. Case M agnet Bushing
Synchronizer Ring 21. Flange Nut 33. Snap Ring 45. T hrust W asher
8. 3rd Speed Gear 22. Rear Bearing 34. Snap Ring 46. 2nd Speed Gear
9. 2nd Speed Gear Retainer Oil Seal 35. Damper Assembly Bushing
10. 1st and 2nd 23. Rear Bearing 36. C ountergear 47. 1st Speed Gear
Synchronizer Retainer Bushing
Assem bly
CAUTION: Make sure Tool J-22832 engages full 15. To remove reverse idler gear, drive reverse idler gear
circumference of groove in bearing to prevent tool shaft out of case from front to rear using a drift.
damage. Remove reverse idler gear from case.
11. Remove clutch gear and bearing by tapping gently on Transmission Cover
bottom side of clutch gear shaft and prying directly
opposite against the *case and bearing snap ring groove Disassem bly (Fig. 5Q)
at the same time. Rem ove 4th gear synchronizer ring.
1. Using a small punch drive out pins retaining lst-2nd
and 3rd-4th shifter forks to shifter shafts and also drive
out expansion plugs.
CAUTION: Index cut out section of clutch gear in
down position with countergear to obtain clearance
for removing clutch gear. J-8433-1
14. Slide reverse idler gear rearw ard and move countergear
rearw ard until front end is free of case, then lift to
remove from case.
REVERSE
3RD/4TH f
1ST/2ND
NOTE: The pin retaining the third and fourth shifter Assem bly (Fig. 6Q)
fork to the shaft must be removed, and the shifter
fork removed from the cover before the reverse 1. In reassembling the transmission cover, care m ust be
shifter head pin can be removed. used in installing the shifter shafts. They should be
installed in the order shown in Fig. 7Q, namely, reverse
2. W ith shifter shafts in neutral position, drive shafts out 3rd-4th, and lst-2nd.
of cover and shifter forks. 2. Place fork detent ball springs and balls in position in
holes in cover.
CAUTION: Exercise care so shaft detent balls, 3. Start shifter shafts into cover; depress yoke detent balls
springs and innerlock pin located in the cover are with small punch and push shafts on over balls. Starting
not lost as the shifter shafts are removed. with reverse shifter shaft, hold fork in position and push
shaft through yoke. Install split pin in fork and shaft,
3. Drive out pin holding reverse shifter head and drive out then position fork in neutral position.
the shaft. 4. Push 3rd and 4th shaft through to the neutral position
and line up retaining hole in the fork with the hole in
the shaft. Install retaining pin.
CAUTION: Exercise extreme care during shaft re
moval since detent balls are under spring tension in NOTE: Detent balls should line up with detents in
the rear rail boss holes. shaft.
Inspection
1. W ash all parts in cleaning solvent.
2. Inspect roller bearings for pits or galling.
Fig. 7Q --Shifter S haft Installation 3. Inspect bearing diam eter in shaft recess for galling.
4. Inspect gear teeth for excessive wear.
5. A fter 1st and 2nd fork is installed, place two innerlock 5. Inspect clutch shaft pilot for excessive wear.
balls between the low speed shifter shaft and the high 6. Re-oil bearing, then rotate clutch gear bearing slowly
speed shifter shaft in the crossbore of the front support by hand and check for roughness.
boss. Install the innerlock pin in the high speed (center
position) shifter shaft hole and grease to hold in place.
Continue pushing this shaft through cover bore and Assem bly
fork until retainer hole in fork lines up with hole in 1. Press bearing and new oil slinger onto clutch gear shaft
shaft. Install retainer pin and move to neutral position. using Tool J-22872 (fig. 1 IQ). Slinger should be located
flush with bearing shoulder on clutch gear. See Figure
6. Place two innerlock balls in crossbore in front support
8Q for direction of slinger installation.
boss between reverse, and 3rd and 4th shifter shaft.
Then push rem aining shaft through fork and cover
bore, keeping both balls in position between shafts until CAUTION: Extercise care to prevent distortion of
retaining holes line up in fork and shaft. Install retain the oil slinger.
ing pin.
2. Install snap ring to secure bearing on clutch gear shaft.
7. Install new shifter shaft hole expansion plugs and ex 3. Install bearing retainer ring in groove on O.D. of bear
pand in place. ing.
O IL S L IN G E R
R E T A IN E R R IN G
SNAP R IN G
M ainshaft Assembly
Disassem bly (Fig. 14Q)
Replacement
1. Remove retainer and oil seal assembly and gasket.
2. Pry oil seal out of retainer. Fig. 1 1Q -R eplacing Clutch Gear Bearing
Fig. 12Q ~Roller Bearing Retainer Fig. 13Q --lnstalling Bearing Retainer Oil Seal
1. 1st Speed Gear 5. 2nd Speed Blocker 10. 3rd Speed Blocker 13. 4th Speed Blocker
2. Reverse Driven Gear Ring Ring Ring
3. 1 st Gear Bushing 6. 2nd Speed Gear 11. 3rd-4th Speed 14. Snap Ring
4. 1st-2nd Gear 7. T hrust W asher Synchronizer Hub 15. M ainshaft
Synchronizer Hub 8. 3rd Speed Bushing Assem bly 16. 2nd Speed Gear
Assem bly 9. 3rd Speed Gear 12. 3rd-4th Speed Bushing
Synchronizer Sleeve
Assem bly
Fig. 1 5Q--Disassembly of M ainshaft
1. Using Tool J-22873 press 2nd speed bushing onto m ain
1. Remove first speed gear. shaft until it bottom s against shoulder (fig. 16Q).
2. Remove snap ring in front of 3rd-4th synchronizer as
sembly. NOTE: Lubricate bushing with E.P. oil before press
3. Remove reverse driven gear. ing.
4. Press behind second speed gear to remove 3rd-4th syn
chronizer assembly, 3rd speed gear and 2nd speed gear
along with 3rd speed gear bushing and thrust washer CAUTION: 1st, 2nd and 3rd speed gear bushings are
(fig. 15 Q). sintered iron, exercise care when installing.
5. Remove 2nd speed synchronizer ring.
6. Remove 2nd speed synchronizer keys. 2. Press 1st and 2nd speed synchronizer hub onto m ain
7. Supporting 2nd speed synchronizer hub at front face, shaft until it bottom s against shoulder with annulus
press m ainshaft through removing 1st speed gear bush tow ard rear of shaft.
ing and 2 nd speed synchronizer hub.
8. Split 2nd speed gear bushing with chisel and remove
bushing from shaft.
Inspection
1. W ash all parts in cleaning solvent.
2. Inspect m ainshaft for scoring or excessive wear at
th ru st surfaces or splines.
3. Inspect clutch hub and clutch sleeve for excessive wear
and m ake sure sleeve slides freely on clutch hub. Also
check fit of clutch hub on m ainshaft splines.
Countershaft Assembly
NOTE: The 30-60 series trucks with transmission
mounted parking brake incorporate a spacer instead
of the damper plate. The clutch countergear and
spacer are pressed on using the same procedures
utilized for the clutch countergear with the damper
plate.
Disassem bly
1. Remove front countergear retaining ring and thrust
washer. Discard snap ring.
1ST GEAR
BUSHINGl
Assem bly
1. Position 3rd speed countergear and shaft in arbor press
and press the gear onto the shaft.
2. Install Tool J-22832 on countershaft, open side to CAUTION: Do not over stress snap ring. Ring should
dam per, (fig. 20Q); support assembly in an arbor press be tight in groove without side play.
and press countershaft out of clutch countergear assem
bly. TRA N SM ISSIO N A S S E M B L Y
1. Lower the countergear into the case until it rests on
bottom s of case.
DAMPER
Fig. 23Q --lnstalling M ainsha ft Rear Bearing Fig. 24Q --C ountergear Front S up po rt Tool
J-23070
Fig. 2 6 Q ~ ln sta llin g M ainsha ft Rear Bearing Lock Nut (4-W heel
Drive Only)
10. Tap countergear front bearing assembly into case. 15. Lock transm ission in two gears at once. Install univer
11. Install countergear front bearing cap and new gasket. sal joint flange locknut and tighten to 90-120 ft. lbs.
T orque cap screws to 20-30 in. lbs. 16. Move all transm ission gears to neutral except the re
12. Slide speedometer drive gear over m ainshaft to bearing. verse idler gear which should be engaged approximately
13. Install rear bearing retainer with new gasket. Be sure 3/8 of an inch (leading edge of reverse idler gear taper
snap ring ends are in lube slot and cut out in bearing lines up with the front edge of the 1st speed gear).
retainer. Install bolts and tighten to 15-18 ft. lbs. Install Install cover assembly with new gasket to transmission
brake backing plate assembly on models equipped with case. Shifting forks m ust slide into their proper posi
propeller shaft brake. tions on clutch sleeves and reverse idler gear. Forks
m ust be positioned as in removal.
NOTE: On models equipped with 4-wheel drive, in
stall rear lock nut and washer using Tool J-23070 17 Install cover attaching bolts and torque to 20-25 ft. lbs.
(fig. 26Q). Torque lock nut to 120 ft. lbs. and bend 18. Using Tool J-8109, replace gearshift lever and check
washer tangs to fit slots in nut. operation of transmission.
Disassembly of T ran sm issio n ........................................ 7-51 C ountershaft Bearing R ep lac em en t.......................... ....... 7-56
Cleaning and In sp ectio n ................................................. 7-52 Reverse Idler G e a r ............................................................... 7-56
Subassembly O p e ra tio n s................................................. 7-52 D isassem bly................................................................... ....... 7-56
Transm ission Cover........................................................ 7-52 A ssem bly............................................................................... 7-56
D isassem bly................................................................... 7-52 Assembly of T ra n sm issio n ............................................ ....... 7-57
A ssem b ly........................................................................ 7-54 Countershaft ................................................................... .......7-57
M ain Drive G ear............................................................ 7-54 Reverse Idler G ear and Shaft..................................... .......7-57
D isassem bly................................................................... 7-54 M ainshaft.................................................................................7-57
A ssem b ly........................................................................ 7-54 M ain Drive G ear............................................................ .......7-57
M ain Drive G ear Bearing Retainer Oil S eal.......... 7-55 R ear Bearing Retaining and Parking Brake .......... .......7-58
M ainshaft.......................................................................... 7-55 Transmission Cover...............................................................7-59
D isassem bly................................................................... 7-55 Rem ote Control A ssem b ly .................................................7-59
A ssem b ly ........................................................................ 7-55 Miscellaneous ........................................................................7-59
M ainshaft R ear Bearing R etainer Oil Seal ............ 7-55
5. Remove speedometer drive gear from rear end of m ain NOTE: After cleaning and inspecting bearings as
shaft. directed, lubricate bearings generously with lubri
6. Using a suitable puller over snap ring on bearing cant recommended in LUBRICATION (SEC. 0) of
remove m ainshaft rear bearing. this supplement; then wrap each bearing in clean
7. Remove four self-locking, self-sealing screws and paper until ready to reinstall in transmission.
remove main drive gear retainer and gasket. Discard
gasket. 2. Remove all portions of old gaskets from parts, using a
8. R otate m ain drive gear assembly so part of gear with stiff brush or scraper.
missing clutch teeth is on the bottom . Pull drive gear
assembly straight out o f transmission.
9. Lift 3rd and 4th speed synchronizer parts out of case Inspection
(fig. 11K). 1. Inspect all parts for discoloration or warpage due to
heat.
NOTE: On light duty models remove the roller type 2. Examine all gear teeth and splines for chipped, worn,
thrust bearing on the mainshaft then slide synchro broken, or nicked teeth or splines. Small nicks or burrs
nizer parts from mainshaft. may be removed with a fine abrasive stone.
3. Inspect the breather assembly to see that is open and
10. Lift m ainshaft and gears assembly from transmission
not damaged.
case.
4. Check all threaded parts for damaged, stripped or
11. Remove screw and lock plate retaining reverse idler
crossed threads.
shaft.
5. Replace all gaskets, oil seals, and snap rings.
12. Using a suitable puller, pull reverse idler shaft from
6. Examine housing, retainers, and covers for cracks or
case. Remove idler gear from inside case.
other damage. Since repairs by welding, brazing, etc.,
13. Remove four screws and lock washers, then remove
are not recommended, replace damaged parts.
countershaft rear bearing retainer and gasket. Discard
7. Check keys and keyways for condition and fit.
gasket.
8. Inspect shift forks for wear, distortion, or other dam
14. Remove countershaft rear thrust bearing and race.
age.
15. Lift countershaft gear out of transm ission case.
9. Check detent ball springs for distortion or collapsed
16. If so equipped, remove power take off cover attaching
coils.
screws and lock washers. Remove cover and gasket.
10. Inspect thrust washers, stop rings, and spacers for wear
Discard gasket.
or damage.
11. Check fit of bearing on their respective shafts and in
CLEAN IN G AND IN SPECTIO N their bores. Inspect bearings, shafts, and case for wear.
If installation of a new bearing does not correct condi
(Refer to Figure 2K) tions, install new shafts or replace the case.
12. M ake sure synchronizer sliding clutch slides freely on
Cleaning clutch gear. Check pins on synchronizer outer stop
rings for straightness and tightness.
D uring overhaul procedures all com ponents of the trans
13. Inspect all bearing rollers for pitting or galling.
mission (except bearing assemblies) should be thoroughly
14. Examine detent balls for corrosion or brinneling. If shift
cleaned w ith cleaning solvent and dried with air pressure
lever shaft detents show signs of wear, replace them.
prior to inspection and reassembly of the transmission.
15. Replace all worn or damaged parts. W hen reassembling
1. Clean the bearing assemblies as follows:
the transmission, coat all moving parts with lubricant
a. Careful and proper cleaning of bearings is of utm ost
recommended in L U B R IC A T IO N (SEC.O) of the ap
importance. Bearings should always be cleaned
propriate Chevrolet Service M anual.
separately from other parts.
b. Soak all bearing assemblies in C L E A N cleaning sol S U B A S S E M B L Y O PERA TIO N S
vent. G asoline is not recommended. Bearings
should never be cleaned in hot solution tank. Transmission Cover
c. Slush bearings in solvent until all old lubricant is
loosened. H old bearing races so bearings will not Disassem bly (Fig. 4K)
rotate; then brush bearings with a soft bristled brush 1. Using a No. 2 easy out as shown in Figure 4K, remove
until A L L D IR T has been removed. Remove loose roll pin retaining 3rd and 4th shift fork to 3rd and 4th
particles of dirt by striking bearing flat against a shift rail.
block of wood. 2. Remove 3rd and 4th shift rail and shift fork driving
d. Rinse bearings in clean solvent; then blow bearings shift rail out through welch plug opening in cover forc
dry with air pressure. D O N O T SPIN B E A R IN G S ing out welch plug.
W H IL E D R Y IN G . 3. Remove detent ball and spring.
e. R otate each bearing slowly while examining balls or 4. Using a No. 2 easy out, remove roll pin from 1st and
rollers for roughness, damage, or excessive wear. 2 nd shift lug.
Replace all bearings th at are not in first class condi 5. W ith a No. 2 easy out remove roll pin from 1st and 2nd
tion. shift fork.
F R O N T B E A R IN G
B E A R IN G SNAP R IN G
O IL S LIN G E R
DRIVE G E A R SHAFT
S N A P R IN G
M IS S IN G
(SELECTIVE)
C LU TC H TEETH
M A IN DRIVE G E A R
Main Drive Gear Bearing Retainer Oil 2. Place m ainshaft 2nd speed gear over spring and ring.
3. Install retaining snap ring, when tangs of snap ring
Seal pointing out.
4. Position 2nd speed gear and synchronizer assembly on
Replacem ent
mainshaft.
1. Remove bearing retainer oil seal from main drive gear 5. Install m ainshaft 2nd speed gear split ring in groove of
bearing retainer. m ainshaft making sure ends of ring are securely lock
2. Using a suitable sleeve, press or drive new oil seal into together (fig. 8 K).
bore of bearing retainer.
NOTE: Lubricate parts. Parts should turn freely.
NOTE: Lip of oil seal should point toward gasket
surface of retainer. 6. Position m ainshaft 3rd speed gear on mainshaft and
lubricate freely. G ear should turn easily.
M ainshaft 7. Install 3rd and 4th synchronizer sliding clutch gear on
mainshaft.
Disassem bly 8. Using snap ring pliers, install mainshaft clutch gear
snap ring in groove of mainshaft.
1. Remove m ainshaft rear spacer from rear of mainshaft.
NOTE: Install the thickest snap ring possible in
2. Remove m ainshaft 1st speed sliding gear from m ain groove of shaft. Snap rings are available in four dif
shaft. ferent thicknesses as shown in the following table:
3. Remove synchronizer clutch gear snap ring, then
remove synchronizer clutch gear.
4. Remove m ainshaft 3rd speed gear and synchronizer T h in .......................................................... 0.086” - 0.088”
adjusting shims if used. M ed iu m .................................................... 0.089” - 0.091”
5. Remove m ainshaft 2nd speed gear split ring. T h ic k .........................................................0.091” -0 .0 9 4 ”
6. Remove m ainshaft 2nd speed gear and synchronizer Extra T h ic k ............................................ . 0.095” - 0.097”
assembly from m ainshaft. 9. Position m ainshaft 1st speed sliding gear (51) on m ain
7. Remove 2nd speed synchronizer retaining ring from shaft.
synchronizer pins. Remove synchronizer spring assem
bly and synchronizer spring from 2 nd speed gear.
M ainshaft Rear Bearing Retainer Oil
Assem bly Seal
1. Position 2nd speed gear and synchronizer inner stop Replacement (Fig. 2K)
ring and pin assembly on bench. Place synchronizer
spring in stop ring (fig. 7K).
1. Press or drive bearing retainer oil seal out of retainer.
BEARING CONE
OIL SEAL
GASKETS
BEARING RETAINER
M A IN S H A F T
SYNCHRONIZER
CLUTCH GEAR
TORRINGTON BRG.
M O D EL C A -C L U T C H GEAR W ITH TAPERED ROLLER BEARING
RETAINER
BEARING
RING
ROLLERS (14)
2. Prelubricate between lips of seal before installing and Clean and inspect retainer, if not previously accom
using a suitable sleeve, press or drive new oil seal into plished.
bore of retainer. Press oil seal into bore of retainer until
it bottoms. 2. Using a heavy grease to hold rollers in place, position
needle rollers in bore of bearing retainers.
NOTE: Coat outer diameter of oil seal with a light
coat of sealing cement. Wipe off excess cement. Lip Reverse Idler Gear Assembly
of seal goes toward front of retainer.
Two different design reverse idler gears are used in the
4-speed New Process transmission models on Chevrolet
Countershaft Bearings
trucks. All models use a bushing in the gear except for Tilt
Replacement (Front or Rear) Cab models (6.69 ratio) which use a reverse idler gear incor
porating a heavy duty needle roller bearing assembly. Nei
1. If inspection shows countershaft bearing needle rollers ther the bushing or roller bearing is serviced separately and
are worn or damaged, remove rollers from retainer. the gear and bearing must be replaced as an assembly.
SYNCHRONIZER BEARING
SPRING BEARING
2ND SPEED BEARING RACE
RETAINER
GEAR
REAR BEARING
SNAP
RING
INNER STOP
AND CLUTCH PIN
RING ASSEMBLY
M ainshaft
Installation
1. Position the m ainshaft assembly in transmission case,
using a block of wood at front end of mainshaft to help
m aintain its position.
2. Install m ainshaft rear spacer on rear end of m ainshaft.
3. W ith block of wood still positioned in transm ission case
as described in Step 1, use a suitable sleeve and ham m er
and drive m ainshaft rear bearing onto m ainshaft (fig.
10K). Remove block of wood.
4. Install 3rd and 4th speed synchronizer parts on front
end of m ainshaft, (fig. 11K) then move mainshaft as
Fig. 8 K -ln s ta llin g M ainsha ft 2nd Speed Gear Ring sembly forward into position in transmission case.
WOOD BLOCK
MAINSHAFT ASSEMBLY
, SPACER f
REAR BEARING
SLEEVE
NOTE: On transmission having a tapered front main 2. Install rear bearing retainer and new gasket. Using seal
bearing, install roller bearing thrust washer. ing cement on the four screw and lock washer assem
blies. Tighten screws firmly.
Rear Bearing Retainer and Parking
Brake
Installation NOTE: When installing output yoke, shift transmis
sion into two speeds at one time. Torque on yoke
1. Position speedometer drive gear on rear end of m ain
attaching nuts is 110 foot-pounds.
shaft.
SYNCHRONIZER
SLIDING CLUTCH
SYNCHRONIZER
CLUTCH GEAR
OUTER
STOP RING
Transmission Cover
4. Install four self-sealing, self-locking screws attaching
drive gear bearing retainer to transm ission case.
Tighten screws firmly (25-35 lb. ft.). Installation
1. Place all transm ission and cover parts in "N eutral"
5. Using a dial indicator, check end play of the input gear position.
(fig. 12K). If end play is not .007 to .017", remove or 2. Using a new gasket, install transmission cover and gas
add shims as required. ket. Tighten the eight attaching screws firmly.
6. Using feeler gauges, check float in 3rd and 4th speed Remote Control Assembly
synchronizer assembly. Insert feeler gauges between
m ainshaft 3rd speed gear and 3rd and 4th speed syn
Installation
chronizer outer stop ring (fig. 13K). Float should be
0.050"-0.070". If necessary, disassemble the unit and 1. On transm ission having remote controls, position
add or subtract synchronizer adjusting shims as neces remove control assembly and new gasket on transm is
sary to bring float within limits. sion cover.
2. Install four attaching screws and lock washers. Tighten
screws firmly.
3. Secure bell crank to stud in boss of transm ission cover
with retaining clip.
SUBJECT PA G E
Disassembly of Transfer Case Remove front washer, front bearing, gear washer, and
output gear from case as they clear shaft. This proce
1. Remove cover from bottom of transfer case. dure will also remove the rear bearing cup.
2. Remove poppet hole cap screws from the outside of the
front bearing retainer.
3. Remove the interm ediate gear shaft lockplate at the NOTE: Remove front bearing cup as required, using
rear side of the transfer case. a suitable puller or driver.
4. Using dum m y shaft J-23419, drive interm ediate shaft
out of rear of case as shown in Figure 2D. 11. Loosen dog set screw from the front wheel drive shift
5. Remove interm ediate gear and thrust washers from fork. Swing fork and gear tow ard cover opening and lift
case. out gear. R otate shift rail to preload poppet ball and
6 . Remove bolts attaching rear output shaft subassembly pull rail out of the retainer. Remove fork as it clears the
to transfer case and remove complete unit from case as shift rail and remove poppet ball and spring from re
shown in Figure 3D. tainer.
12. Support inner race of rear bearing and press bearing
from shaft as shown in Figure 5D.
NOTE: Disassembly of rear output shaft sub-assem- 13. Remove front output shaft bearing retainer and gasket.
bly is covered later in this section. 14. Remove shift rail lip seals with a suitable puller or pry
tool.
7. Remove locknut and washer from front output shaft 15. Remove the front bearing retainer seal using a suitable
yoke, if not removed during unit removal from vehicle, puller or pry tool.
and slide yoke from output shaft.
8. Loosen dog set screw from rear wheel drive shift fork.
R otate shift rail to preload poppet ball and pull rail out Cleaning and Inspection
of the housing. Remove shift fork and clutch gear from
case. Remove poppet ball and spring from retainer. B earings-Place all bearings and rollers in cleaning solu
9. Remove front output shaft rear cover and shims. Tie tion and allow to remain long enough to loosen all ac
shims together before laying aside. cum ulated lubricant. Bearings should be sloshed up and
10. Tap on front end of front output shaft, removing shaft down and turned slowly below surface of solution to remove
from the rear of the case as shown in Figure 4D. as much lubricant as pollible. Remove bearings and blow out
1. Inp ut Shaft 13. Rear O utput Shaft 24. Interm ediate Shaft 34. Drain Plug
2. Transfer Case Rear Bearing Cup Bearing Spacer 35. Front O utput Shaft
3. Input Gear 14. Rear O utput S haft 25. Interm ediate Shaft Drive Gear
4. Snap Ring Rear Bearing 26. Interm ediate Shaft 36. Spacer
5. S liding Clutch Gear 15. Rear O utput Shaft Needle Bearings 37. Front O utput Shaft
6. Rear Input Shaft Yoke 27. Interm ediate Shaft Front Bearing
Needle Bearing 16. Rear O utpu t Shaft Tanged T hrust 38. Front O utpu t Shaft
7. Rear O utput Shaft Locknut W asher Front Bearing Cup
Front Bearing 17. W asher 28. Interm ediate Gear 39. Spacer
8. Rear O utput Shaft 18. Rear O utput Shaft 29. Front O utput Shaft 40. Front O utput Shaft
Front Bearing Cup 19. Rear O utput Shaft Rear Cover Seal
9. Rear O utput Shaft Seal 30. Front O utput Shaft 41. Front O utput Shaft
Housing Gasket 20. Shims Rear Bearing Bearing
10. Rear O utput Shaft 21. Speedom eter Drive 31. Front O utput Shaft 42. Front O utput Shaft
Housing Breather Gear Rear Cover Shim Yoke
11. Speedom eter Driven 22. Interm ediate Shaft Pack 43. Rubber "O " Ring
Gear Lock Plate Bolt 32. Front O utput Shaft 44. W asher
12. Rear O utput Shaft 23. Interm ediate Shaft Rear Bearing Cup 45. Front O utput Shaft
Housing Lock Plate 33. Front O utput S haft Locknut
S liding Clutch Gear
with com pressed air, being careful to direct air across bearing 2. Support yoke assembly in a soft jaw vise and remove
so that bearings do not spin. yoke locknut and washer.
Shafts and G ears-C lean all shafts in cleaning solution to 3. Remove assembly from vise and using a soft hammer,
remove all accum ulations. D ry with compressed air. tap yoke from shaft.
Case, Cover and Bearing C ups-T ransfer case, cover, and
bearing cups m ust be thoroughly cleaned in solution to 4. Support rear face of retainer and press output shaft
remove all accum ulations of lubricant and dirt. Remove all from the retainer.
trace of gaskets from surfaces where used. 5. Pry seal from housing bore.
Inspection-C arefully inspect all bearings and rollers for 6. Remove the tapered bearing and, using a drift, drive the
evidence o f chipping, cracks, or worn spots that would render bearing cup from the housing rear bore.
bearing unfit for further service. Bearings are non-adjustable
and if worn or damaged, m ust be replaced with new parts. 7. Using a brass drift, remove the bearing cup from the
Inspect shaft splines and gears. If any indication of failure, housing front bore.
such as chipped teeth or excessive wear is indicated, those 8. Remove shims and speedometer gear from the shaft.
parts should be replaced with new parts. Tie shims together before laying aside.
Disassembly of Rear Output Shaft 9. Using press plates J-8331, remove front bearing from
Sub-Assembly the shaft as shown in Figure 7D.
1. Remove speedom eter driven gear lockplate and gear 10. Collapse and remove pilot bearing from output shaft
from rear retainer. pilot bore.
Fig. 2D~Removing Interm ediate Gear S haft Fig. 4D--Removing Front O utput Shaft
Fig. 3D -R em oving Rear O utpu t Shaft Sub-Assembly Fig. 5D--Removing Front O utput Shaft Rear Bearing
1. Cover Bolts (4) 15. Spacer 30. Interm ediate Gears 44. Rear O utput Bearing
2. Front O utput Shaft 16. Front O utput Bearing 31. Tanged T hrust Retainer
Rear Cover Retainer Gasket W asher 45. Rear Retainer Bolts
3. Front O utput Rear 17. Front O utput Bearing 32. Interm ediate Shaft (10)
Cover Shims Retainer 33. Transfer Case 46. Rear O utput Rear
J 4. Front O utput Rear 18. Seal 34. Interm ediate S hift Bearing Cup
Bearing Cup 19. O utput Yoke Lockplate and B olt 47. Rear O utput Rear
5. Front O utput Rear Assem bly 35. Rear W heel Drive Bearing
Bearing 20. ” 0 " Ring S hift Fork 48. Rear O utput Retainer
6. Front O utput S haft 21. W asher 36. Rear W heel S liding Seal
7. Bottom Cover Gasket 22. Locknut Gear 49. Rear O utpu t Yoke
8. Bottom Cover and 23. S hifter Rail Seals 37. Pilot Bearing A ssem bly
Bolts 24. Poppet Ball, Spring 38. Rear O utput Shaft 50. Spacer
9. Front W heel Drive and Cap Screw 39. Rear O utput Front 51. Locknut
S hift Fork 25. Rear W heel Drive Bearing 52. Snap Ring (Input
10. Front O utpu t S liding S hift Rail 40. Rear O utput Front Shaft)
Gear 26. Front W heel Drive Bearing Cup 53. Direct Drive Gear
11. Front O utput Gear S hift Rail 41. Speedom eter Drive 54. Snap Ring (Part of
12. T hrust W asher 27. Tanged Thrust Gear A dapter Assem bly)
13. Front O utput Bearing W asher 42. Rear O utpu t Shaft 55. Bearing (Part of
14. Front O utput Bearing 28. Spacer Shims Adapter Assembly)
Cup 29. Needle Bearings 43. Rear Retainer Gasket 56. Input Shaft
Sub-Assembly
3. Install the front bearing cup in the front housing bore
using Tool J-23423 as shown in Figure 10D until cup
1. Press new pilot bearing in bore of rear output shaft with seats in housing.
bearing identification facing out using Tool J-23420 as
shown in Figure 8 D.
4. Install the rear bearing and cup in the rear housing bore
using Tool J-23423 as shown in Figure 11D until cup
seats in housing.
CAUTION: Bearing identification must face out. Op
posite end of bearing is soft and must not be used to 5. Install the seal in the housing rear bore using Tool
install bearing in bore or damage to the bearing may J-22833 as shown in Figure 12D until seal bottom s in
result. housing.
J-23422
BEARING CUP
J -2 3 4 2 3
Fig. 8D --lnstalling Rear O utput Shaft Pilot Bearing Fig. 1 1 D— Installing Rear O utput Shaft Rear Bearing Cup
J-5590
Fig. 9 D--Installing Rear O utpu t S haft Front Bearing Fig. 12 D--I nsta 11i n g Rear O utput S haft Rear Seal
Fig. 1 3 D—Installing Front O utput S haft Rear Bearing 16. Install front output shaft yoke, washer and locknut.
A L IN E S H A F T S L O T
W IT H B O LT H O LE
Fig. 1 5D --lnstalling Front O utput S haft Seal Fig. 16D --lnstalling Interm ediate Shaft
CAUTION: Locknut must be torqued to 250 ft. lbs. CAUTION: Rear yoke locknut must be torqued to
before installing prop shaft during unit installation. 200-250 ft. lbs. before checking end play and before
installing the rear prop shaft.
SUBJECT PA G E
Disassembly of Transfer Case .......................................... 7-68 Assembly of Transfer C ase............................................ ... 7-70
Rear O utput Shaft A sse m b ly ................................... 7-68 Idler G ear .................................................................... 7-70
F ro n t O utput Shaft Assembly ............................ .... 7-68 Shift Rail and Fork A ssem blies.......................... ... 7-70
Shift Rail and Fork A ssem blies.......................... .... 7-69 F ront O utput Shaft Assembly ................................ 7-70
Idler G ear ................................................................. .... 7-69 R ear O utput Shaft A ssem b ly .................................. 7-72
Cleaning and Insp ectio n ................................................. .... 7-69 M iscellaneous............................................................ ... 7-73
Fig. 1C— New Process Transfer Case Cross Section (See Legend on Page 7-68)
1. Input S haft 18. Rear Bearing 32. IdlerG ear S haft Bearing 43. S liding Clutch
2. " 0 " Ring Retainer Cup 44. Front W heel Hi-Gear
3. Snap Ring 19. Rear Yoke Assem bly 33. Idler S haft Bearing 45. Spacer
4. Bearing 20. Locknut Cone 46. Bearing
5. Snap Ring 21. W asher 34. Idler S haft Cover 47. Snap Ring
6. Input S haft Gear 22. Rear O utput Shaft Bolts and 48. Seal
7. S liding Clutch 23. Bearing Retainer Lockwasher 49. Front O utpu t Shaft
8. Tanged Bronze T hrust Seal 35. Idler S haft Gear 50. W asher
W asher 24. Snap Ring Cover and Gasket 51. Locknut
9. Roller Bearings 25. Bearing 36. T hrust W asher 52. O utput Yoke
10. Spacer 26. Speedom eter Gear 37. Snap Ring 53. Bearing Retainer
11. T hrust W asher 27. Pilot Bearings 38. T hrust W asher Pin 54. Idler Gear
12. T hrust W asher Pin 28. Rear O utput Shaft 39. Rear Bearing 55. Idler Gear Spacer
13. Snap Ring Front Bearing Retainer and O utput 56. Idler S haft
14. B olt and Lockwasher 29. W asher Shaft Cover 57. Locknut
15. Needle Bearings 30. Bearing Retainer 40. Front W heel Drive 58. W asher
16. Spacer 31. Rear W heel Drive Low Gear 59. Bearing Cone
17. Rear O utput S haft Low Gear 41. Roller Bearings 60. Bearing Cup
Housing 42. Spacer
Disassembly of Transfer Case (Fig. 1C) Front Output Shaft Assembly (fig. 3C)
Rear Output Shaft and Yoke Assembly 1. Remove lock nut, washer and yoke.
2. Remove front bearing retainer attaching bolts and re
(Fig. 2C) tainer.
3. Remove front output shaft rear bearing retainer attach
1. Loosen rear output shaft yoke nut.
ing bolts.
2. Remove rear output shaft housing bolts and remove
4. Tap on output shaft with a soft ham m er (Fig. 4C) and
housing and retainer assembly from case.
remove shaft, gear assembly, and rear bearing retainer
3. Remove retaining n ut and yoke from shaft, then remove from case.
shaft assembly from housing.
4. Remove snap ring using Tool J-23432 and discard. NOTE: Remove the sliding clutch from output high
5. Remove thrust washer and washer pin. gear, washer, and bearing which will have remained
in the case.
6. Remove tanged bronze washer. Remove gear needle
bearings (32 per row), spacer and second row of needle 5. Using large snap ring picks, such as J-23432-1, remove
bearings. the gear retaining ring from the shaft (Fig. 5C) and
7. Remove tanged bronze thru st washer from shaft. discard.
8. Remove pilot rollers (15), retainer ring and washer. 6. Remove thrust washer and pin from shaft.
9. Remove oil seal retainer, ball bearing, speedometer gear 7. Remove gear, needle bearings (32 per row) and spacer.
and spacer. D iscard all gaskets. Press out bearing as 8. If necessary to replace front output shaft rear bearing,
required. replace bearing and retainer assembly. Do not attem pt
10. Remove oil seal from the retainer. to press new bearings into old retainer.
POPPET NUTS
SHIFT RAIL
LINK
REAR OUTPUT
ASSEMBLY
Fig. 2C -R ear V iew of Transfer Case Fig. 3C~Front V iew of Transfer Case
“ T” HANDLE W / # 2 EASY
OUT WELDED O N END
FRONT—
OUTPUT SHAFT
REAR BEARING
RETAINER
Shift Rail and Fork Assemblies Fig. 6C--Removing S hift Fork Pins
1. Remove the two poppet nuts on top of case, two poppet 9. Tip case on P.T.O. and remove two interlock pins from
springs, and using a m agnet, remove the poppet balls. inside of case.
2. Remove cup plugs on top of case using a 1/4 inch Idler Gear
punch.
3. Position both shift rails in neutral and remove shift fork 1. Remove idler gear shaft nut.
pins (Fig. 6 C) using a long handle screw extractor. 2. Remove idler shaft rear cover.
4. Remove clevis pins and shift rail link. 3. Remove idler gear shaft using a soft ham m er and tool
5. Remove shift rails (Fig. 7C), upper (range) rail first, J-23429 (Fig. 8C).
then lower (4-wheel) rail. 4. Roll idler gear to front output shaft hole and remove
6. Remove shift forks and sliding clutch from case. from case.
7. Remove the front output high gear, washer, and bear 5. Remove bearing cups (2) as required from idler gear.
ing from the case. Remove the shift rail cup plugs from
the case. Cleaning and Inspection
Input Shaft Assembly Bearings-Place all bearings and rollers in cleaning solu
tion and allow to remain long enough to loosen all ac-
8. Remove snap ring in front of bearing. Using a soft
ham m er, tap shaft out rear of case. Tap bearing out
front of case.
SNAP RING
Fig. 5C~Removing Gear Retaining Ring Fig. 7 C—S hift Rail Removal
5. Install washer and new locknut. Check for end play and
free rotation. Torque nut to 150 ft. lbs.
1. Press the two rail seals into the case. Seals should be
TOOL J-23429
installed with metal lip outward.
3. Start front output drive shift rail into case from back,
Fig. 8C~Removing Idler Gear Shaft slotted end first, with poppet notches up.
cum ulated lubricant. Bearings should be sloshed up and
4. Install shift fork (long end inward) into rail, push rail
down and turned slowly below surface of solution to remove through to neutral position.
as m uch lubricant as possible. Remove bearings and blow out
with com pressed air, being careful to direct air across bearing 5. Install input shaft bearing and shaft into case.
so that bearings do not spin.
6. Start range rail into case from front, poppet notches up.
Shafts and G ears-C lean all shafts in cleaning solution to
remove all accum ulations. D ry with compressed air. 7. Install sliding clutch onto fork, place over input shaft
in case. Position to receive range rail and push rail
Case, Cover and Bearing C ups-T ransfer case, cover, and through to neutral position.
bearing cups m ust be thoroughly cleaned in solution to
remove all accum ulation of lubricant and dirt. Remove all 8. Install new lock pins through holes at top of case and
trace of gaskets from surfaces where used. drive them into the forks (Fig. 15C).
Inspection-C arefully inspect all bearings and rollers for
evidence o f chipping, cracks, or worn spots that would render NOTE: Tip case on P.T.O. opening when installing
bearing unfit for further service. Bearings are non-adjustable range rail lock pin.
and if w orn or damaged, m ust be replaced with new parts.
Front Output Shaft and Gear Assembly
Inspect shaft splines and gears. If any indication of failure,
such as chipped teeth or excessive wear, is indicated, those
parts should be replaced w ith new parts. 1. Install two rows of needle bearings (32 each) separated
by a spacer in the front low output gear and retain with
a sufficient am ount of grease.
Assembly of Transfer Case (Fig. 9C)
2. Place front output shaft in soft jaw ed vise, spline end
down. Install front low gear over shaft with clutch gear
Idler Gear facing down and install thrust washer pin, thrust
washer and new snap ring using Tool J-23432.
1. Press the two bearing cups in the idler gear (if previ
ously removed) using Tool J-9276-2 and H andle J-8092
NOTE: Position the snap ring so that the opening is
(Fig. 10C).
opposite the pin.
2. Assemble the two bearing cones, spacer, shims and idler
gear on dum m y shaft J-23429 with bore up. Check end 3. Position front wheel hi-gear and washer in case. Install
play (Fig. 11C). Lim its are .000 to .002 inch. sliding clutch in the shift fork, then put fork and rail in
the front wheel drive (4-Hi) position with the clutch
3. Install idler gear assembly with dumm y shaft into case teeth in mesh with the teeth of the front wheel hi-gear.
through front output bore, large end first (Fig. 12C).
4. Line up washer, high gear, and sliding clutch with bear
Install idler shaft from large bore side and drive through ing bore. Insert front output shaft and low gear assem
using a soft ham m er (Fig. 13C). bly through the high gear assembly.
FRONT OUTPUT
BORE
J-8092
J-9276-2
Fig. 10C--I nsta 11i ng New Bearing Cups Fig. 1 2C --lnstalling Idler Gear
5. Install new seal in bearing retainer using Tool J-22836 2 Install thrust washer onto rear output shaft, tang down
(Fig. 16C) and install the front output bearing and in clutch gear groove. Install output low gear onto shaft
retainer in the case. with clutch teeth facing down.
6. Clean and grease rollers in front output rear bearing
retainer. Install onto case using one gasket. Dip bolts 3 Install thrust washer over gear with tab pointing up and
into sealant. Install bolts and torque to 30 ft. lbs. away from gear. Install washer pin and also large thrust
7. Install front output yoke, washer and lock nut. Torque washer over shaft and pin. R otate washer until tab fits
nut to 150 ft. lbs. into slot approximately 90 degrees away from pin. Fi
Rear Output Shaft Assembly nally, install snap ring using Tool J- 23423 and J-23423-
1 and check end play which should be withing .002 -
1. Install two rows of needle bearings (32 each) separated
.027 inch.
by a spacer into the output low gear.
NOTE: Use sufficient grease to retain needles. 4 Grease pilot bore or rear output shaft and install needle
bearings (15). Install thrust washer and new snap ring
in bore.
Fig. 1 1C--Checking Idler Gear End Play Fig. 13C --lnstalling Idler Shaft
10. Position range rail in ’high’ and install output shaft and
retainer assembly on transfer case. Torque housing
bolts to 30 ft. lbs.
J-23431
BEARING
Fig. 1 5 C--I nsta 11i ng S h ift Rail Lock Pins Fig. 1 7 C--I nsta 11ing Rear O utput S haft Housing Bearing
SPEEDO M ETER
-G E A R
S P A C ER
J-21359
O UTPUT
LO W G E A R
C LU T C H G E A R
SEAL
Fig. 1 8C—Installing Rear O utput S haft Spacer and
Speedom eter Gear
4. Install shift rail cross link, clevis pins and lock pins. Fig. 19C—Installing Rear Bearing Retainer Seal
ADAPTER ASSEMBLIES
INDEX
SUBJECT PAGE
M ANUAL TR A N SM ISSIO N S 3. Using a suitable tool or piece of pipe with a diam eter
Except Blazer Models comparable to splined sleeve, tap sleeve from adapter.
D isassem bly of Adapter (Figs. 1H and 2H)
4. Using a brass drift, punch out the oil seals from the
1. Using a brass drift or other suitable tool, tap sleeve from
adapter bore.
adapter.
2. Using a brass drift, punch out oil seal from adapter
bore. 5. If required, support bearing and press input shaft from
bearing.
Inspection
Inspect the sleeve for any indication of failure. If the sleeve
has chipped teeth or excessive wear, it should be replaced.
Check internal snap ring in sleeve. Replace if bent or broken.
Blazer Models
D isassem bly of Adapter (Fig. 2H)
1. Remove snap ring retainer drive gear to input shaft and
slide gear from shaft.
Assem bly of Adapter 1. Remove small snap ring on sleeve retaining bearing to
sleeve.
i
1. If removed during disassem bly, press new bearing onto
2. Remove snap ring retaining bearing to adapter.
input shaft.
2. Using Tool J-7137 and H andle J-8092, install new seals
in the adapter bore as shown in Figure 3H. 3. Using a soft ham m er, tap sleeve and bearing through
3. Insert splined sleeve through seals into adapter bore. seals and out of adapter.
4. Insert input shaft and bearing into adapter and install
bearing retaining ring.
4. Using a suitable punch or drift, drive seals from
5. Slide drive gear onto input shaft and install retaining
adapter.
ring.
All Models 1. Support sleeve and press bearing onto sleeve using Tool
J- 22875 as shown in Figure 5H.
Disassem bly of Adapter (Fig. 4H)
2. Install new seals in adapter using Tool J-7137 and J-
1 2 3 4 8092 as shown in Figure 3H.
SU BJECT PA G E
NOTE: Cleanliness is an important factor in the 3. If replacement is necessary, remove speedometer driven
overhaul of the transmission. Before attempting any gear. Loosen capscrew and retainer clip holding speed
disassembly operation, the exterior of the case ometer driven gear in extension and remove gear.
should be thoroughly cleaned to prevent the possi
bility of dirt entering the transmission internal
4. Remove transmission extension by removing five bolts
mechanism. During disassembly, all parts should be
retaining extension to case. Note seal ring on governor
thoroughly cleaned in cleaning fluid and then air
support. (Pilot on Torque Drive.).
dried. Wiping cloths or rags should not be used to
dry parts as lint may be deposited on the parts
which may cause later trouble. 5. Remove the speedometer drive gear from output shaft
as shown on Figure 3PG.
Fig. 2P G -Tranm ission M ounted in Fixture Fig. 3PG -Rem oving Speedom eter Drive Gear
11. Release the tension on the low band adjustm ent, then, NOTE: If difficulty is experienced in getting the
with transm ission horizontal, grasp the transm ission snap ring past the shoulder on the reverse pack pres
input shaft and carefully w ork it and the clutch assem sure plate, a feeler gauge may be used as a guide.
bly out of the case (fig. 7PG). Use care so as not to lose
the low sun gear (splined) bushing from the input shaft.
The low sun gear th ru st w asher will probably rem ain in 16. Install Tool J-9542 through the rear bore of the case
the planet carrier. w ith the flat plate on the rear face of the case and turn
down the wing nut to compress the rear piston spring
retainer and springs, then remove the snap ring (fig.
CAUTION: Use care so as not to damage the ma 8PG). Tool J-8039 may be used to remove the snap ring
chined face on the front of the clutch drum. if desired.
17. Remove Tool J-9542, the reverse piston spring retainer
12. The low brake band and struts may now be removed. and the 17 piston return springs.
Fig. 6PG~Removing Oil Pump Fig. 8PG--Removing Rear Piston Spring Retainer Snap Ring
18. Remove the rear piston by applying air to the reverse 21. Remove the vacuum m odulator and gasket, and the
port in the rear of the transm ission case as shown in vacuum m odulator plunger, dampening spring (except
Figure 9PG. Remove the inner and outer seals. L-4 model) and valve (fig. 10PG).
19. Remove the three servo cover bolts, servo cover, piston 22. Remove the two bolts attaching the detent guide plate
and spring. to the valve body and the transmission case. Remove
the guide plate and the range selector detent roller
Oil Pan and Valve Body spring.
NOTE: The oil pan and valve body may be serviced 23. Remove the rem aining valve body-to-transmission case
without the necessity of removing the extension attaching bolts (indicated by arrows in Figure 11PG)
and internal components covered in the preceding and carefully lift out the valve body and gasket, disen-
steps.
20. R otate the holding fixture until the transm ission is up
side down and the oil pan is at the top. Remove the oil
pan attaching bolts, oil pan and gasket. Remove screen:
replace at assembly using new transm ission case screen.
Fig. 7PG~Removing Clutch Drum and Inp ut Shaft Fig. 9 P G -A p plyin g A ir to Remove Rear Piston
SPRING
L-153)
MODULATOR
PLUNGER M A N U A L VALVE LEVER PARKING
GASKET PAWL
BRACKET
TV LEVER
PARKING
PAWL
Fig. 10PG~Vacuum M od ula tor, Dam pening S pring, Plunger ACTUATOR
and V alve -P o w e rg lid e
gaging the servo apply tube from the transm ission case
as the valve body is removed. PARKING
PAWL
24. If necessary, the TV, shift and parking actuator assem
bly levers, and the parking pawl and bracket (fig. 12PG)
m ay be removed. Fig. 12P G -lnner C ontrol Levers, Parking Pawl and Bracket
This completes the entire transm ission disassembly proce
dure. Com ponent parts disassembly and repair procedures Oil Pump
will be found in succeeding pages of this manual.
Seal Replacem ent
O VERH AULIN G UNIT A S S E M B L IE S If the pum p seal requires replacement, remove the pump
from the transmission, pry out and replace the seal. (Drive
Convertor and Stator new seal into place, fully seated in counterbore using J-6839).
The converter is a welded assembly and no internal re Then, if no further work is required on the pump, reinstall
pairs are possible. Check the seams for stress or breaks and it in the case.
replace converter if necessary.
NOTE: Outer diameter of the seal should be coated
with non-hardening sealer prior to installation.
Disassem bly
1. Remove bolts attaching pum p cover to body and
remove the cover.
2. Remove pum p gears from body.
SPRING
43 4 2 41 39 38 37
1. Reverse Ring Gear 13. Transm ission Case 31. G overnor Support
2. Reverse Clutch Pack 13A. Transm ission Case 32. G overnor Support to
Snap Ring Screen Case A ttaching Bolts
3. Reverse Clutch 14. Servo Piston Return 33. G overnor Assem bly
Pressure Plate Spring 34. Speedom eter Drive
4. Reverse Clutch 15. Servo Piston Rod Gear and Clip
Reaction Plates 16. Servo Piston A pply 35. Seal
5. Reverse Clutch Drive S pring Seat 36. Speedom eter Shaft
Plates 17. Servo Piston A pply F itting
6. Reverse Clutch Spring 37. Speedom eter Shaft
Cushion Spring 18. Servo Piston Seal F ittin g Oil Seal
7. Reverse Clutch Piston Ring 38. Lock Plate A ttaching
Return Spring 19. Servo Piston Screw
Retainer Snap Ring 20. Servo Piston Rod 39. Lock Plate
8. Reverse Clutch Piston Spring Retainer 40. Speedom eter Driven
Return Spring 21. Servo Cover Seal Gear
Retainer 22. Servo Cover Gasket 41. Transm ission
9. Reverse Clutch Piston 23. Servo Cover Extension
Return Springs 24. Servo Cover Plug 42. Extension Bushing
10. Reverse Clutch Piston 25. Servo Cover Bolts 43. Extension Oil Seal
Inner Seal 26. Transm ission Case 44. Extension to Case
11. Reverse Clutch Piston Bushing A tta chin g Screws
12. Reverse Clutch Piston 27. Gasket
O uter Seal 30. G overnor Support
Bushing
49
/ 47
1. Converter Assem bly 13. Oil Pump Cover and 27. Band A pp ly Strut 40. Clutch Hub
2. Input S haft C onverter S tator 28. Band A nchor Strut 41. Clutch Driven Plates
3. Inp ut Shaft Oil Seals S haft 29. Band A nchor (Flat)
4. Oil Pump to Case 14. Oil Pump Gasket A d ju stin g Screw 42. Clutch Cushion
A tta chin g Bolts and 15. Clutch Drum T hrust 30. Band A nchor Spring (Waved)
Sealing W ashers W asher (Selective Fit) A d ju stin g Screw Nut 43. Clutch Drive Plates
5. Low Sun Gear 16. High Clutch Seal 31. Low Brake Band (Waved)
Bushing Rings 32. Clutch Drum 44. Clutch Hub Drive
6. Pump Oil Seal 17. Pump Prim ing Valve 33. Clutch Drum Bushing T hrust W asher
7. Oil Pump Body 18. Pump Prim ing Valve 34. Clutch Piston Outer 45. Low Sun Gear and
8. Pump to Case Oil Spring and Inner Seals Clutch Flange
Seal 20. Pump Prim ing Valve 35. Clutch Piston Assem bly
9. Oil Pump Drive Gear Spring Retaining Pin 36. Clutch Return 46. Clutch Flange
10. Oil Pump Driven Gear 21. Oil Cooler By-Pass Springs Retainer Ring
11. D o w nsh ift T im ing Valve Spring(1) 37. Clutch Spring 47. Planet Carrier and
Valve 22. Oil Cooler By-Pass Retainer O utput S haft
12. Oil Pump Cover to Valve(1) 38. Clutch Spring Assem bly
Pump Body A tta chin g 23. Oil Cooler By-Pass Retainer Snap Ring 49. O utput S haft T hrust
Screws Valve Seat(1) 39. Clutch Hub Front Bearing
T hrust W asher
1. Park Lock and Range 7. Park Lock and Range 13. Park Lock Pawl Shaft
Selector O uter Lever Selector Inner Lever 14. Park Lock Pawl
and Shaft 8. Park Lock and Range 15. Park Lock Pawl Shaft
2. T h ro ttle Valve Control Selector Inner Lever Retaining Ring
S haft Oil Seal A tta chin g Screw and 16. Park Lock Pawl
3. T h ro ttle Valve Control Nut Reaction Bracket
S haft W asher 9. Park Lock Pawl 17. Park Lock Pawl
4. T h ro ttle Valve Control D isengaging Spring Reaction Bracket
Lever and Shaft 10. Range Selector A tta chin g Bolts
5. T h ro ttle Valve Control Detent Roller Spring 18. Park Lock A ctuator
Inner Lever to Control 1 1. Park Lock A ctua to r to Park Lock and
Shaft A tta chin g A ssem bly Range Selector Inner
Screw and Nut 12. Range Selector Lever Retaining Clip
6. T h ro ttle Valve Control Detent Roller Spring
Inner Lever Retainer
excessively. F o r removal, an "Easy O ut" or its equiva c. G ear end clearance (fig. 19PG) should be .0005"-
lent may be used. .0015".
F or installation tap seat in place with soft ham m er or
Assem bly
brass drift so it is flush to .0 1 0 " below the surface.
9. W ith parts clean and dry, install pum p gears and check: W ith the transmission facing up, proceed as follows:
1.Remove the input shaft, clutch drum , low band and
a. Clearance between O.D. of driven gear and body struts as outlined uner "Transm ission Disassembly."
should be .0035 "-.0065" (fig. 17PG). 2. Install the downshift timing valve, conical end out, into
b. Clearance between I.D . of driven gear and crescent place in the pum p cover to a height of 17/32" measured
should be .003 "-.009" (fig. 18PG). from the shoulder of the valve assembly to face of pump
cover.
4. Carefully set the pum p cover in place over the body and
loosely install 2 attaching bolts. face must be protected whenever it must be brought
5. Place the pum p assembly, less the rubber seal ring, to bear on a press or tool of any sort.
upside down into the pum p bore of the case (use guide
pins if desired). Install remaining attaching bolts and 1. Remove retainer ring and low sun gear and clutch
torque to specification. flange assembly from the clutch drum.
6. Remove pum p assembly from case bore. Replace the 2. Remove the hub rear thrust washer.
clutch drum and input shaft, low band and struts as 3. Lift out the clutch hub, then remove the clutch pack
outlined under "Transm ission Assembly." and the hub front washer.
4. Remove the spring retainer using J-9542 as shown in
NOTE: If necessary, remove two bolts and use J- Figure 20PG, or if using an arbor press, use J-5133 and
6585 pullers and J 6585-3 adapters to remove pump J-7782 adapter ring. Compress the springs far enough
assembly. Replace and retorque bolts. to allow removal of the retainer snap ring; then, releas
ing pressure on the springs, remove the retainer and the
7. Replace rubber seal ring in its groove in the pum p body springs.
and install the pum p assembly properly in place in the
case bore, using a new gasket, being sure that the selec NOTE: When using J-9542, place a piece of cloth or
tive fit thrust washer is in place. cardboard between the tool and the front side of the
8. Install the attaching bolts, using new bolt sealing wash clutch drum as protection for the machined face.
ers if necessary.
5. Lift up on the piston with a twisting m otion to remove
Governor Support Bushing Replacement from the drum , then remove the inner and outer seals.
placem ent or restaking of the ball should not be at measure this stack height. Now refer to chart and
tempted. select the proper selective driven plate and install it
4. Check fit of clutch flange in drum slots. There should into clutch drum on top of the cushion spring.
be no appreciable radial play between these two parts.
Also check low sun gear for nicks or burrs and bushing 7. Install the steel reaction plates and faced drive plates
for wear. alternately, beginning with a steel reaction plate (fig.
5. Check clutch plates for burning and wear. 22PG). See clutch chart.
8. Install the rear hub thrust washer w ith its flange toward
B u s h in g R e p la c e m e n t (Fig. 2 1 PG) the low sun gear, then install the low sun gear and
flange assembly and secure with retainer ring. When
1. Remove the old bushing w ith Tool J-9546 using care installed, the openings in the retainer ring should be
not to damage the bushing bore or the m achined face adjacent to one of the lands of the clutch drum .
on the front of the clutch drum . 9. Check the assembly by turning the clutch hub to be sure
2. Use the same tool to install the new bushing. Press (do it is free to rotate.
not ham m er) the bushing into the clutch drum from the
m achined face side of clutch drum . Press only far
LOW BAND
enough so th at the tool meets the clutch drum . D o not The brake band used in the alum inum Powerglide trans
force the tool against the clutch drum m achined face. mission has bonded linings which, due to the transmission
characteristics and band usage, should require very little a t
A s s e m b ly tention. However, whenever a transm ission is disassembled
the band should be cleaned of metal particles and inspected.
1. Install new piston inner seal in hub of clutch drum with
1. Check lining for evidence of scoring or burning.
seal lip dow nw ard (tow ard front of transmission).
2. Check band and lining for cracks.
2. Install a new piston seal in clutch piston. Seal lips must
3. Check all band linkage for excessive wear.
be pointed tow ard the clutch drum (front of transm is
sion). Lubricate seals generously and install piston in
clutch drum with a twisting motion. PLA N ET A S S E M B L Y AND INPUT
3. Place the springs in position on the piston, then place
the retainer in place on the springs. SH A FT
4. Using Tools J-5133 and J-7782 and a press, or J-9542
as a hand operation, depress the retainer plate and In s p e c tio n
springs far enough to allow installation of the spring
1. W ash planet carrier and input shaft in cleaning solvent,
retainer snap ring in its groove on the clutch drum hub.
blow out all oil passages and air dry.
5. Install the hub front w asher with its lip tow ard the the
clutch drum , then install the clutch hub.
6. Install (wave) cushion spring wherever used, see chart. CAUTION: Do not use rags to dry parts.
REACTION PLATES
DRIVE PLATES
(W A V E ) SPRING
/HEREVER USED; SEE CHART)
Fig. 21 PG-Rem oving and Installing Clutch Drum Bushing Fig. 22P G ~lnstalling Clutch Drum Plates (typical)
307 V-8;
250 L-6 Taxi
230 L-6 T ru ck;
L-4 & & Hvy. Duty
250 L-6
230 L-6 Chassis; 350 V-8
Exc. Taxi & Hvy.
Pass. Cars 350 V-8
Duty Chassis
Truck
292 L-6 T ruck
Drive Plate 3 4 5 5
Driven Plate 4 5 6 6
Cushion Spring 1 1 None 1
TORQUE DR IVE
L-4, L-6
Drive Plate 5
Driven Plate 6
Fig. 23P G -C hecking Planet Gear End Clearance
Cushion Spring 1
2. Inspect planet pinions for nicks or other tooth damage. 1. Place the planet carrier assembly in a fixture or vise so
that the front (parking lock gear, end) of the assembly
faces up.
3. Check end clearance o f planet gears. This clearance
should be .006" - .030" (fig. 23PG)
2. Using prick punches or other similar means, m ark each
pinion shaft and also the planet carrier assembly (fig.
4. Check input sun gear for tooth damage, also check
25PG), so th at reassembling, each pinion shaft will be
input sun gear rear th ru st washer for damage.
reinstalled in the same location from which it was
removed.
5. Inspect output shaft bearing surface for nicks or scoring
and inspect input pilot bushing.
NOTE: The pinion shafts are not selectively fit but
it is good practice to reinstall them in their original
6. Inspect input shaft splines for nicks or damage and locations.
check fit in clutch hub and input sun gear. Also check
fit o f splines in turbine hub.
NOTE: Planet pinion remover and replacer Tool J- 5. Remove the short planet pinion from the assembly.
4599, comes in two pieces, both alike. Only one is
used when removing the planet pinion; two, how 6. Remove J-4599, needle bearings and needle bearing
ever, must be used when reassembling. spacers (3) from short planet pinion.
10. Remove low sun gear needle th rust bearing, input sun
Fig. 25PG~Suggested Pinion S haft M arkings gear and input sun gear thrust washer.
11. W ash all parts in cleaning solvent and air dry. 24. Check end clearance of planet gears. This clearance
12. Recheck the planet pinion gears and input sun gear for should be .005" - .030" (fig. 23PG).
nicks or other tooth damage; also check the planet pin 25. Place the pinion shaft lock plate in position, then with
ion thru st washer and input sun gear thrust washer. the extended portions of the lock plate aligned with
Check low sun gear needle th ru st bearing for spalled slots in the planet pinion shafts, rotate the lock plate
needles. Replace w orn or dam aged parts. clockwise until the three attaching screw holes are ac
13. Inspect the planet pinion needle bearings closely and if cessible.
there is indication of excessive wear, all the needle bear 26. Install the pinion shaft lock plate attaching screws and
ings m ust be replaced. Also inspect pinion shafts closely tighten to specification.
and, if worn, replace the worn shafts.
14. Inspect the input shaft bushing installed in the base of GOVERN OR--POW ERGLIDE
the output shaft. If damaged, it m ay be removed by
threading Tool J 9534 into the bushing and pulling the The governor assembly is a factory balanced unit. If body
bushing out using Slide H am m er J-6585. New bearing replacem ent is necessary, the two sections m ust be replaced
can be installed by pressing in flush or below thrust as a unit. Remove the governor as outlined under "Transm is
surface with the pilot end of input shaft as press tool. sion- Disassembly".
15. Using J-4599, assemble needle bearing spacer and nee
dle bearings (20 in each path) in one of the long planet Disassem bly
pinions (fig. 24PG). Use petroleum jelly to aid in assem
bling and holding the needle bearings in position. NOTE: The governor valve and shaft were already
16. Position the long planet pinion with J-4599, centered in disassembled from the assembly during the removal
the pinion assembly and with thru st washers at each procedures.
end, in the planet carrier. Oil grooves on thrust washers
m ust be tow ard gears. 1. Remove the outer weight assembly by sliding tow ard
center of body.
NOTE: The long planet pinions are located opposite 2. Remove the sm aller inner weight retaining snap ring
and remove the inner weight and spring.
the ciosed portions of the carrier, while the short
planet pinions are located in the openings. 3. If it is considered necessary, remove the four body as
sembly bolts and separate the body, hub and gasket.
Remove the two seal rings.
17. Feed the second J-4599 in from the top picking up the
upper th ru st w asher and the planet pinion and pushing Inspection
the already installed Tool J-4599 out the lower end. As
the first tool is pushed down, check th at it picks up the Clean all parts thoroughly in a solvent and air dry. Check
lower th ru st washer. condition of all com ponent parts of the assembly. Replace
18. Select the proper pinion shaft, as m arked in Step 2, any bent, dam aged or scored parts. Body and hub m ust be
lubricate the shaft and install it from the top, pushing replaced as a unit.
the assembling tools ahead of it.
Assem bly
19. T urn the pinion shaft so th at the slot or groove at the
upper end faces the center of the assembly. 1. Reassemble governor weights and reinstall in body
20. W ith a brass or soft steel drift, drive the pinion shaft in bore. Replace seal rings on hub.
until the lower end is flush w ith the lower face of the 2. Slide hub into place on output shaft and lock into place
planet carrier. with the drive screw. Install gasket and governor body
21. Following the same general procedure as outlined in over output shaft, install governor shaft, line up prop
Steps 15 through 20, assemble and install a short planet erly with output shaft and install body attaching bolts.
pinion in the planet carrier adjacent to the long planet Torque to specification.
pinion now installed.
NOTE: Place transmission selector lever in PARK to
keep shaft from turning while tightening these
NOTE: The thrust washers already installed with
the long planet pinion also suffice for this short pla bolts.
net pinion as the two pinions are paired together on 3. Check the governor weight for free fit in body after the
one set of thrust washers. four attaching bolts are torqued. If the weight sticks or
binds, loosen the bolts and retorque.
22. Install the input sun gear th ru st washer, the input sun
gear and low sun gear needle thrust bearing. V A LV E BODY
23. Assemble and install the rem aining planet pinions, in Removal
pairs, by first installing the long planet pinion and then Remove valve body as described under "Transmission-
the adjacent short planet pinion. -Disassembly." If perform ing the operation on the vehicle,
the vacuum m odulator and valve, oil pan and gasket, guide the valve body, then remove the detent valve assem
detent plate and range selector detent roller spring m ust be bly and throttle valve spring. Tilt the valve body to
removed in order to remove the valve body from the trans allow the throttle valve to fall out. If necessary,
mission. remove the "C" clip and disassemble the detent
valve assembly.
Disassem bly
CAUTION: Do not disturb the setting of the adjust
1. Remove the m anual valve, suction screen and gasket. ment hex nut on the detent valve assembly. This is
2. Remove valve body bolts and carefully remove lower a factory adjustment and should not normally be
valve body and transfer plate from upper valve body. changed. However, some adjustment is possible if
D iscard gaskets. desired. See” Throttle Valve Adjustment."
3. F rom the upper valve body, remove TV and detent
valves and the downshift tim ing valve as follows: b. Downshift Timing V alve-D rive out the roll pin,
a. TV and D etent V alve-R em ove the retaining pin by remove the valve spring and the downshift timing
wedging a thin screw driver between its head and valve.
4. From the lower valve body, remove the low drive shift and continually low transm ission oil. No vacuum m odulator
valve and the pressure regulator valve as follows: repairs are possible; replace as an assembly.
a. Low-Drive Shift V alve-R em ove the snap ring and
tilt the valve body to remove the low-drive regulator
Installation
valve sleeve and valve assembly, valve springs and
the shifter valve-Pow erglide and Torque Drive. 1. Install vacuum m odulator valve, dam pening spring (ex
b. Pressure R egulator V alve-R em ove the snap ring, cept L- 4 model) and plunger in bore of transmission.
then tilt valve body to remove the hydraulic
m odulator valve sleeve and valve, pressure regulator 2. Place a new gasket on vacuum m odulator. The gasket
valve spring retainer, spring and pressure regulator has centering tabs to hold it centered during installa
valve assembly. tion.
3. Install vacuum m odulator, tighten firmly, and install
Inspection vacuum line as follows (fig. 10PG): R ubber tubing "A"
Since most valve failures are caused initially by dirt or should bottom against m odulator can. Pipe assembly
other foreign m aterial preventing a valve from functioning "B" should bottom against the m odulator extension.
properly, a thorough cleaning of all parts in clean solvent is
m andatory. Check all valves and their bores for burrs or TRA N SM ISSIO N C A S E
other deformities which could result in valve hang-up.
Inspection
Assem bly
1. W ash case thoroughly with cleaning solvent, air dry
1. Replace valve com ponents in the proper bores, revers and blow out all oil passages.
ing the disassembly procedures given above and check
ing Figure 27PG, if necessary. CAUTION: Do not use rags to dry parts.
2. Carefully install the lower valve body and gasket and NOTE: This is a precision bushing and if damaged or
install 15 1-3/8" attaching bolts. Torque to specifica worn excessively must be replaced.
tion.
4. Check shifter shaft seal. If it shows signs of damage or
leaking, pry it out and install a new seal. The new seal
Installation
m ust be firmly seated in case counterbore.
Install the valve body onto the transm ission as outlined
under T ransm ission-A ssem bly. Repairs
Check the vacuum m odulator plunger and valve for nicks Inspection
and burrs. If such cannot be repaired with a slip stone, re
place the part. 1. W ash extension thoroughly with cleaning solvent and
The vacuum m odulator can be checked with a vacuum air dry.
source for leakage. However, leakage norm ally results in
transm ission oil pull-over and results in oil smoky exhaust CAUTION: Do not use rags to dry parts.
1. Snap Ring 11. Low and Drive Valve 22. High Speed Down 32. Detent Valve
2. H ydraulic M o d u la to r Inner Spring S hift T im ing Valve 33. T h ro ttle Valve Spring
Valve Sleeve 12. Low and Drive Valve Spring R egulator
3. H ydraulic M o d u la to r O uter Spring 23. High Speed Down 34. T h ro ttle Valve Spring
Valve 13. Low and Drive S hift T im ing Valve R egulator Nut
4. Pressure R egulator Regulator Valve 24. U pper Valve Body 35. U pper Valve Body
S pring Retainer 14. Low and Drive 25. M anual Control Valve Plate Gasket
5. Pressure R egulator Regulator Valve 26. Vacuum M od ula tor 36. U pper Valve Body
Spring Sleeve and Cap Valve, Plunger and Plate
6. Pressure R egulator 15. Snap Ring S pring (exc. L-4) 37. Detent Valve and
S pring Seat 16. Transfer Plate to 27. T h rottle Valve Spring Retaining
7. Pressure R egulator Low er Valve Body 28. T h ro ttle Valve Spring Stud
Valve Gasket 29. T h ro ttle Valve Spring 38. Range Selector
8. Lower Valve Body 17. T ransfer Plate Seat Detent Lever
9. Suction Screen, 18. T ransfer Plate to 30. T h ro ttle Valve Spring 39. Snap Ring
G asket and A tta chin g Upper Valve Body R egulator Guide 40. U pper Valve Body
Screws Gasket W asher Plate to U pper Valve
10. Low and Drive Valve 21. High Speed Down 31. Detent Valve Spring Body A tta chin g Bolts
S hift T im ing Valve and W ashers
Stop Pin
T R A N S M IS S IO N -A S S E M B LY
NOTE: Use only transmission oil or petroleum jelly
as lubricants to retain bearings or races during as
sembly. Lubricate all bearings, seal rings and clutch
plates prior to assembly.
20. Install the servo piston, piston ring, and spring into the
servo bore. Then, using a new gasket and "O" ring,
install the servo cover. See th at gasket is properly SERVO
aligned with the three bolt holes and the drain back APPLY
passage in the case.
21. Remove the oil pum p and the selective fit washer from
the case, and install the low brake band, anchor and
apply struts into the case. Tighten the low band adjust
ing screw enough to prevent struts from falling out of
case.
22. Place the seal ring in the groove around the oil pump
Fig. 33PG ~lnstalling Valve Body
body and the two seal rings on the pum p cover exten
sion. Install clutch drum selective th ru st washer, oil
pum p gasket and oil pum p to case. Remove guide pins servo apply line into its boss in the case as the valve
and install all pum p bolts, replacing any damaged bolt body is set into place (fig. 33PG). Install six m ounting
sealing washers necessary and torque bolts to specifica bolts and range selector detent roller spring shown in
tion. Figure 1 IPG .
23. T urn transm ission so th at shaft points upward. 30. Install new suction screen and gasket.
25. Install governor over output shaft (See "Governor- 32. Install the vacuum m odulator valve and the vacuum
-Assembly" for body to hub installation.) Install gover m odulator and gasket.
nor shaft and valve, urethane washer, and retaining "C"
clips. Center shaft in output shaft bore and tighten
governor hub drive screw.
26. Using Tool J-5 8 14, install speedom eter gear into output
shaft.
33. Install the oil pan, using a new gasket, and the oil pan TH RO TTLE V A LV E A D JU STM EN T
attaching bolts.
psi, backoff the jam nut one (1) full turn. This increases the
dimension from the jam nut to the throttle valve assembly
Tighten the low servo adjusting screw to 70 inch lbs. using stop. Conversely, tightening the jam nut one (1) full turn
torque wrench, J-5853 and a 7/32" hex head driver (fig. lowers TV pressure 3 psi. A difference of 3 psi on TV pressure
35PG) or J- 21848. The input and output shaft m ust be will cause a change of approxim ately 2 to 3 M PH in the wide
rotated sim ultaneously to properly center the low band on open throttle upshift point. Smaller pressure adjustm ents can
the clutch drum . Then back off four (4) complete turns for be made by partial turns of the jam nut. The end of TV,
a band which has been in use for 6,000 miles or more, or 3 adjusting screw has an alien head so the screw may be held
turns for one in use less than 6,000 miles. Tighten the locknut stationary while the jam nut is moved.
to specified torque.
CAUTION: The amount of back-off is not an approxi- NOTE: Use care when making this adjustment since
mate figure, it must be exact. no pressure tap is provided to check TV pressure.
INDEX
SU BJECT PA G E
Transm ission Disassembly and Reassembly ............... 7-101 Extension Housing B u sh in g ..................................... ...7-130
D isassem bly........................................................................ 7-101 R em oval........................................................................... 7-130
Removal of Extension, Speedometer Installation................................................................... ... 7-130
D riven G ear,O il Pan and S train er........................ ..7-101 O utput Shaft B ushing.................................................... 7-130
Removal of Valve Body and Linkage ................... .. 7-104 R em oval........................................................................... 7-130
Removal o f Oil Pum p and Internal Installation................................................................... ...7-130
Case Com ponents ........................................................7-108 Case B ushing....................................................................7-130
Valve Body ................................................................... .. 7-114 R em oval...........................................................................7-130
D isassem bly................................................................. ..7-115 Installation................................................................... ...7-131
Inspection........................................................................7-115 Stator Shaft B ushing................................................... ...7-131
Reassembly ................................................................. ..7-115 Removal ( F r o n t) ...........................................................7-131
Oil Pum p Installation................................................................... ...7-131
D isassem bly................................................................. ..7-116 Removal (R e a r).............................................................7-131
Inspection........................................................................7-118 Installation................................................................... ...7-131
Reassembly ................................................................. ..7-119 Input Ring G ear Support B ushing.......................... ...7-131
D irect C lutch R em oval...........................................................................7-131
D isassem bly................................................................. .. 7-120 Installation................................................................... ...7-132
Inspection........................................................................7-122 Sun G ear B ushing...........................................................7-132
Reassembly ................................................................. ..7-122 R em oval...........................................................................7-132
F orw ard C lu tch ............................................................ .. 7-123 Installation................................................................... ...7-132
D isassem bly................................................................. ..7-123 Reaction C arrier B ushing.......................................... ...7-132
Inspection........................................................................7-124 R em oval...........................................................................7-132
Reassembly ................................................................. ..7-125 Installation................................................................... ...7-132
Sun G ear and Sun G ear D rive S h e ll........................7-126 D irect Clutch Bushing ..................................................7-132
D isassem bly................................................................. ..7-126 R em oval...........................................................................7-132
Inspection........................................................................7-126 Installation................................................................... ...7-133
Reassembly ................................................................. 7-126 Reassembly ..................................................................... ...7-133
Low and Reverse Clutch .......................................... ..7-127 Transmission Internal C om p o n en ts........................ ...7-133
D isassem bly................................................................. 7-127 Pum p to D irect C lutch Thrust
Inspection..................................................................... ..7-127 W asher Selection P ro ce d u re ................................... ...7-134
Reassembly ...................................................................7-129 Speedometer Drive G ear and E x te n sio n ..................7-135
G overnor Assembly........................................................7-129 M anual Linkage .............................................................7-135
D isassem bly................................................................. ...7-129 Interm ediate Servo Piston,
Inspection..................................................................... .. 7-129 Valve Body, Oil Pan and G a sk e t.......................... ...7-136
G overnor G ear R e p la c e m e n t................................. .. 7-129 G overnor and Vacuum M odulator.......................... ...7-136
Reassembly ................................................................. .. 7-130 Intermediate Clutch A ccum ulator.............................. ..7-136
Bushing R ep lacem en t................................................... .. 7-130
Sectioned V iew
350
Hydra-Matic
Fig. 1M~Turbo
j-8763-01
4. Remove vacuum m odulator assembly, "O" ring seal,
and m odulator valve from case (fig. 4M). D iscard "O"
ring.
VACUUM MODULATOR
O-RING-SEAL
Fig. 3M --Transm ission in H olding Fixture Fig. 4M -R em oving Vacuum M od ula tor Assem bly
E XT ENSI ON H O U S I N G
LIP SEAL
Y OK E SEAL
J-23103
Fig. 5M ~Removing Extension Housing Seal Fig. 7M ~Rem oving O utput S haft Yoke Seal
2. Remove extension housing from case and remove Remove extension housing bushing using screwdriver
square cut "O" ring seal from extension housing. to collapse bushing (fig. 6 M) if necessary to replace.
3. Remove extension housing lip seal using screw driver 5. Remove speedometer drive gear and retaining clip from
(fig. 5M). output shaft.
Fig. 6M ~Rem oving Extension Housing Bushing Fig. 8M -R em oving G overnor Cover
GOVERNOR COVER
TO C A S E " O ” RING
SEAL
CAUTION: Do not attempt to pry the screwdriver NOTE: Check governor bore and governor sleeve for
between the case and governor cover as this could scoring.
cause damage to the case.
9. Remove oil pan attaching screws (fig. 11M), oil pan, and
gasket. D iscard gasket.
10. Remove oil pum p suction screen (strainer) to valve
8. W ithdraw governor assembly from case (fig. 10M). body attaching screws (fig. 12M).
Fig. 10M ~Removing G overnor from Case Fig. 12M ~Removing Oil Pump Strainer from Valve Body
V ALVE B O D Y
A SSEM B LY
VALVE BODY
SPACER PLATE
DETENT S P R I N G A N D Q
R OLLER A SSE M B LY
VALVE BODY T O ^ ^ f c *
SPACER PLATE GASKET
VALVE BODY ASSEMBLY 4. Remove transfer support plate bolts. Remove transfer
support plate (fig. 16M).
TORQUE
WRENCH
mm |DETENT®
I f v jih
^ i
.Jig > j S S l i c O N TR O L l f
m M wA aN ^ .UaA. L^S^ V A L V E WIRE
CONTROL®
VALVE LINK SPACER SUPPORT PLATE
Fig. 14M ~Rem oving M anual C ontroi Valve Link, Valve Body Fig. 1 6M--Removing Transfer (Spacer) S up po rt Plate
and Detent A ctua tin g Lever
VALVE
V A L V E B O D Y SP A CER PLATE
TO C A S E G A S K E T
Fig. 17 M -R em oving T ransfer (Spacer) Plate and Gasket Fig. 19M--Removing Oil Pump Pressure Screen
5. Remove valve body transfer plate and valve body trans- 7. Remove oil pum p pressure screen from oil pum p pres
fer plate to case gasket (fig. 17M). sure hole in case (fig. 19M).
6. Remove four (4) check balls from correct passages in 8. Remove governor feed screen from governor feed hole
case face (fig. 18M). (drive oil) in case (fig. 20M).
CHECK BALLS
** B1MI
GOVERNOR
SCREEN
GOVERNOR
FEED HOLE
Fig. 18M ~Check Ball (4) Locations Fig. 20 M -R em o ving G overnor Feed Screen
RANGE SELECTOR
INNER LEVER
MANUAL SHAFT TO
CASE RETAINER
SCREWDRIVER
MANUAL SHAFT
PARKING PAWL
ACTUATING ROD
9. Remove m anual shaft to case retainer with screwdriver 11. Remove range selector inner lever from m anual shaft.
(fig. 21M). Remove m anual shaft from case. Remove inner lever
and parking pawl actuator rod from case. Disassemble
10. Loosen n ut holding range selector inner lever to m anual
inner lever from parking pawl actuator rod (fig. 23M).
shaft (fig. 22M).
12. Remove m anual shaft to case lip seal (fig. 24M).
SCREW DRIVER
PARK PAWL
A C T U A T IN G ROD SHAFT
Fig. 25M ~R em oving Park Lock, Lock Bracket Fig. 27M --Parking Pawl S haft and Retaining Plug
13. Remove parking lock bracket (fig. 25M). (Special NOTE: The parking pawl shafts retaining plug may
Bolts). be removed by using a bolt extractor.
14. Rem ove parking pawl disengaging spring (fig. 26M). 16. Remove interm ediate servo piston and seal ring.
Remove washer, spring seat and apply pin (fig. 28M).
15. Remove parking pawl shaft retaining plug, parking
pawl shaft, and parking pawl (fig. 27M) if necessary.
PARKING PAWL
PARKING PAWL
D ISEN G A G IN G SPRING
Fig. 2 6 M -R em o ving Parking Pawl Disengaging Spring Fig. 2 8 M ~ lnterm ed iate Servo Piston and Related Parts
Fig. 29M --Rem oving Pump A tta chin g Bolts Fig. 31 M--Removing Interm ediate Clutch Cushion Spring
FACED PLATES
TIGHTEN JAM NUTS STEEL PLATES til
Fig. 30M ~R em oving Pump from Case Fig. 32M ~R em oving Interm ediate Clutch Plates
Removal of oil pump and internal case pum p assembly from case (fig. 30M). Discard pum p
components gasket.
Refer to pages 7 -1 1 6 and 7-1 1 9 for disassembly and
1. Remove eight ( 8) pum p attaching bolts w ith washer of the oil pump.
type seals (fig. 29M). 3 Remove interm ediate clutch cushion spring (fig. 31M).
4. Remove interm ediate clutch faced plates and steel reac
2. Install two (2) threaded slide ham m ers J-9539 (weights tion plates (fig. 32M).
J-6585) into threaded holes in pum p body and remove 5 Remove interm ediate clutch pressure plate (fig. 33M).
Fig. 33M ~R em oving Interm ediate Clutch Pressure Plate Fig. 35 M -R em o ving D irect and Forward Clutch Assemblies
Fig. 3 4 M -R em o ving Interm ediate Overrun Band Fig. 36M ~R em oving Inp ut Ring Gear Front T hrust W asher
OUTPUT SHAFT
SNAP RING
Fig. 37M --Rem oving O utpu t C arrier to O utput S haft Snap Ring Fig. 3 9 M -R em o ving Input Ring Gear Rear T hrust W asher
NOTE: Washer has 3 tangs. 10. Remove input ring gear (fig. 38M).
9. Remove output carrier to output shaft snap ring (fig. 11. Remove input ring gear rear (output carrier) thrust
37M). washer (fig. 39M).
NOTE: Use new snap ring at assembly. 12. Remove output carrier assembly (fig. 40M).
------- 1 ^ —’ 'V
OUTPUT CARRIER ASSEMBLY
INPUT R IN G G E A R
Fig. 38 M -R em o ving Inp ut Ring Gear Fig. 4 0 M -R em o ving O utput C arrier Assem bly
— - — - — —
WKKmmtm m 1 - ! >Wm ■
S U N G E A R DRIVE
SHELL ASSEMBLY
LO W A N D REVERSE
CLUTCH PACK
Fig. 4 1 M -R em o ving Sun Gear Drive Shell Fig. 43 M -R em o ving Low and Reverse Clutch Pack
13. Remove sun gear drive shell assembly (fig. 41M). 16. Remove low and reverse clutch faced plates and steel
reaction plates (fig. 43M).
14. Remove low and reverse roller clutch support to case
retaining ring (fig. 42M).
17. Remove reaction carrier assembly from output ring
15. Remove low and reverse clutch support and race assem gear and shaft assembly (fig. 44M).
bly and anti-clunk spring.
REACTION CARRIER
ASSEMBLY
18. Remove output ring gear and shaft assembly from case 20. Remove output ring gear to case needle bearing assem
(fig. 45M). bly (fig. 47M).
21. Compress low and reverse clutch piston spring retainer
19. Remove reaction carrier to output ring gear tanged using tool J-23327 and remove piston retaining ring and
(front) thru st washer (fig. 46M). spring retainer (fig. 48M).
OUTPUT
RING
GEAR
OUTPUT RING
GEAR TO CASE
OUTPUT RING GEAR ^ NEEDLE B E A R IN G
AND OUTPUT S H A F Tt !e* i
ASSEMBLY
Fig. 4 5 M -R em o ving O utpu t Ring Gear and S haft Assem bly Fig- 4 7 M “ Rem oving O utput Ring Gear to Case Needle Bearing
Assem bly
Fig. 4 6 M -R em o ving O utput Ring Gear T hrust W asher Fig. 48M --Com pressing Low and Reverse Clutch Springs
Retainer
REVERSE
LUTCH
PISTON
f
LOW AND REVERSE
CLUTCH PISTON
Fig. 49M --Low and Reverse Clutch Springs and Piston Fig. 5 1 M--Removing Low and Reverse Clutch Piston Oil Seals
22. Remove seventeen (17) piston springs from piston (fig. 24. Remove low and reverse clutch piston outer seal (fig.
49M). 51M).
23. Remove low and reverse clutch piston assembly by ap 25. Remove low and reverse clutch piston center and inner
plying compressed air in passage shown on Figure 50M. seal (fig. 52M).
; : I
W
WW"”*
J-23069
Fig. 53M --Rem oving 1-2 A ccum u lato r Piston Cover Fig. 54 M ~lnterm ed iate Clutch A ccum u lato r Components
26. Install tool J-23069 to compress interm ediate clutch Remove interm ediate clutch accum ulator piston assem
accum ulator piston cover and remove retaining ring bly. See Figure 54M.
(fig. 53M).
27. Remove interm ediate clutch accum ulator piston cover. Also, remove inner and outer hook type oil seal rings if
Remove "O" ring seal from case. required.
® -S H
40 ' 39 m-m p nrrcrrm ©
23 24 25 ^
«=3S>= imrnro i$s 1
19 20 21 22
f r 3°231&LUaA
• 33 30
AAAJ wvm
29
i
28
5335£!^ teS-'j u iS i
fA^YYYYVOsfesfe
Valve Body Disassembly, Inspection, and 9. Remove direct clutch accum ulator piston, and metal oil
Reassembly (fig. 55M) seal ring, and spring.
10. From the next bore down from the direct clutch ac
Disassembly cum ulator, remove the detent actuating lever bracket
bolt, bracket, actuating lever and retaining pin, stop,
spring retainer, seat, outer spring, inner spring, washer
1. Position valve body assembly with cored face up and
and detent valve.
direct clutch accum ulator piston pocket positioned as
shown in Figure 55M.
Inspection
2. Remove m anual valve from lower left hand bore.
5. In the next bore up, install 2-3 shift control valve, shift
control valve spring, 2-3 shift control valve, shift con
trol valve spring, shift control valve sleeve and retaining
pin.
6. In the next bore up, install the 1-2 shift valve, 1-2 shift
control valve, control valve spring, control valve sleeve
and retaining pin.
DIRECTCLUTCH TO PUMP
-DRIVE GEAR HUB HOOK TYPE OIL
SEAL RINGS (3)
PUMP BODY ASSEMBLY
INTERMEDIATE CLUTCH
PUMP COVER AND STATOR
RETURN SPRINGS (30)
SHAFT ASSEMBLY
PUMP COVER TO PUMP BODY
ATTACHING BOLTS (5)
Disassembly
1. Place pum p cover and stator shaft assembly through 3. Remove interm ediate clutch spring seat retainer, thirty
hole in bench. (30) interm ediate clutch return springs and the inter
2. Remove pum p cover to body attaching bolts 5/16 x m ediate clutch piston assembly (fig. 59M).
18-1 1/2 (fig. 58M).
IN T E R M E D I A T E RETURN
CLUTCH S P R I N G S P RIN G S (30)
SEAT R E T A I N E R
IN T E R M E D IA T E
CLUTCH P IS T O N
SPRING
PU M P B O D Y BOLTS (5) RETAINER
Fig. 58M --Removing Interm ediate Clutch Spring Seat Retainer Fig. 5 9 M -ln te rm e d ia te Clutch Spring and Retainer
PUMP C O V E R A N D
S TA TO R S H A F T
ASSEMBLY
PUMP B O D Y
SCREWDRIVER
PUMP COVER TO DIRECT CLUTCH
SELECTIVE THRUST WASHER
WOOD BLOCKS
Fig. 61 M -P um p Hub Oil Seal Rings Fig. 63M -R em o ving Pump to Converter Hub Seal
COOLER
BY-PASS
BOLT EXTRACTOR VALVE SEAT
Fig. 66M --Checking Pump Body to Gear Face Clearance
Fig. 64M -R em o ving Cooler By-Pass Valve 2. Inspect pum p gears for nicks or damage.
NOTE: Place pump on wood blocks so surface finish 3. Inspect body and cover faces for nicks or scoring. In
is not damaged. spect cover hub O.D. for nicks or burrs which might
11. Remove oil pum p prim ing valve and spring. damage clutch drum bushing journal.
12. Remove cooler by-pass valve seat, check ball, and 4. Check for free operation of the priming valve and re
spring (fig. 64M). place if necessary.
PRIM ING V A LV E LO C A T IO N
EXH A U ST
E X H A U ST
PUMP
INTERM EDIATE
PRESSURE
CLU TCH
R EV E R SE CO O LER
B Y -P A S S
V A LV E
C O O L E R OUT
( FROM R A D IA T O R
C O O L E R IN
R EV E R SE ( TO R A D IA T O R |
D IR E C T C LU T C H
O UTER)
E X H A U ST
C O N V E R T E R FEED
PUMP LIP S E A L D RA IN
F O R W A R D C LU T C ..
D IR E C T C LU T C H EXHAU ST
PUMP B O D Y
Fig. 6 7 M ~ ln sta llin g Pump Drive and Driven Oil Pump Gears Fig. 68M ~Pum p Body Oil Passages
Reassembly
1. Install pum p drive gear and driven gear (fig. 67M).
EXH A U ST INTERM EDIA TE CLUTCH
2. Install direct clutch drum housing to pump cover selec
D IRECT C L U T ^
tive thrust washer over pum p cover delivery sleeve. FO RW A RD CLUTCH C O O L E R IN
( TO R A D IA TO R |
3. Install three (3) direct clutch to pum p hub hook type C O N V E R T E R FEED
oil seal rings. Install two (2) forw ard clutch to pump
hub hook type oil seal rings. SU C TIO N
C O O L E R OUT
FROM R A D IA T O R )
PUMP
PRESSU RE
Fig. 70M --lnterm ediate Overrun Clutch Assem bly-E xploded V iew
INTERMEDIATE OVERRUN
R CLUTCH ASSEMBLY
OVERRUN
RETAINING RIN
DIRECT
CLUTCH
DRUM
STEEL
PLATES
- D IR E C T C L U T C H DRUM
STEEL SEPARATO R
F A C E D PLA TE -
D IR E C T C L U T C H P R E S S U R E P L A T E '
R E T A IN IN G R IN G '
LINED PLATES
Fig. 73M ~ D irect Clutch Assem bly-E xploded V iew Fig. 7 5 M -R em o ving Direct Clutch, Clutch Pack
R E T A IN IN G RING
PRESSURE PLATE
IRECT CL UTCH D R U M
Fig. 7 4 M -R em o ving D irect Clutch Pressure Plate Fig. 76 M -C om p ressin g D irect Clutch Spring Retaining Seat
OUTER SEAL
.020" PIANO WIRE CRIMPED
INTO COPPER TUBING
DIRECT CLUTCH
'PISTON
PISTON
INNER SEAL
Fig. 77M --Removing D irect Clutch O uter and Inner Seal Fig. 79 M --lnstalling Direct Clutch Piston
Reassembly
1. Install the direct clutch piston outer seal and inner seal.
2. Install direct clutch piston center seal on drum with lip
facing upward.
3. Install the direct clutch piston (fig. 79M).
CLUTCH ASSEMBLIES
DRIVE D RIV EN C U S H IO N
C LU TC H PLATE PLATES S P R IN G
FORWARD
L-6, 307 V-8 4 4 1
350 V-8, 400 2-bbl. 5 5 1
TAXI AND TRUCK
INTERMEDIATE
L-6, 307 V-8 2 2 1
350 V-8, 400 2-bbl. 3 3 1
TAXI AND TRUCK
DIRECT
L-6, 307 V-8 3 3 NONE
350 V-8, 400 2-bbl. 4 4 NONE
TAXI AND TRUCK
REVERSE
L-6, 307 V-8 4 4 NONE
350 V-8, 400 2-bbl. 5 5 NONE
TAXI AND TRUCK
Disassembly
10. Install interm ediate overrun clutch retainer and re 2. Remove forward clutch pressure plate (fig. 83M).
tainer ring as shown on Figure 76M.
3. Remove face plates, steel reaction plates and cushion
Forward Clutch Disassembly, Inspection,
spring (fig. 84M).
and Overhaul (Fig. 8 1 M)
- iinr u i o n Ar i
P IS TO N RETURN S EA T '
F A C E D PLATES
R E TA IN IN G RING
F O R W A R D C L U T C H PRESSURE P LA T E '
Fig. 82M ~C om pressing Forward Clutch Spring Retaining Seat Fig. 84M ~R em oving Forward Clutch, Clutch Pack
-m | . ^
RETAINING FORWARD CLUTCH OUTER SEAL
m
RING ASSEM BLY
FORWARD
CLUTCH
PISTON
IN N E R SEAL
FORWARD CLUTCH
PRESSURE PLATE
Fig. 8 3 M -R em o ving Forward Clutch Retaining Ring and Fig. 8 5 M -R em o ving Forward Clutch Piston Inner and Outer
Pressure Plate Seals
4. Remove forward clutch piston return spring seat retain 7. If required, remove input shaft from forward clutch
ing ring and spring seat and twenty-one ( 21 ) clutch housing with ram press or arbor press.
return coil springs. Inspection
5. Remove forw ard clutch piston assembly.
6. Remove the forw ard clutch inner and outer piston seals 1. Inspect drive and driven clutch plates for signs of burn
(fig. 85M). ing, scoring or wear.
SUN G EA R
RETA IN IN G
RING
Disassembly
Fig. 91 M~Removing Sun Gear to Drive Shell Rear Steel T hrust 4. Remove low and reverse roller clutch assembly (fig.
W asher 96M).
L O W A N D REVERSE
CLUTCH SUPPORT
RO LLERCLUTCH
ASSEM BLY
SNAP RING
IN N E R RACE
THRUST W A S H E R
C A G E M U ST H A V E (4) EQ U A LLY SPACED
.091 LUBE H O LE S O N THIS SIDE IF ROLLER FALLS O U T , IN S T A L L ROLLER
FROM "O U T S ID E I N ” AS S H O W N TO
A V O ID B E N D IN G SPRINGS
Fig. 93M ~Low and Reverse Clutch A ssem bly-E xploded V iew
Fig. 94M ~R em oving Overrun Clutch Inner Race Fig. 9 5 M -R em o ving Overrun Roller Clutch Retaining Ring
LO W & R EV ER SE RO LLER
CLUTCH A S S E M B LY
~ -l — —— ..." W ’’”
Fig. 9 6 M -R em o ving Overrun Roller Clutch Assem bly Fig. 9 7 M -G o ve rn o r Assem bly-E xploded V iew T ypical
Reassembly
Fig. 9 8 M ~ ln s ta llin g Extension Housing Bushing
1. Install governor valve in bore of sleeve, large land end
first.
2. Install governor weights and springs, and thrust cap on
Installation
governor sleeve. 1. Using tool J-2 1424-7 and Drive handle J-8092 install
3. Align pin holes in th ru st cap, governor weight assem output shaft bushing.
blies and governor sleeve, and install new pins. Crimp
both ends of pins to prevent them from falling out.
4. Check governor weight assemblies for free operation on
pins.
Case Bushing
5. Check governor valve for free movement in governor
sleeve.
Removal
1. W ith case properly supported, remove case bushing.
Turbo Hydra-matic 350
Bushing Replacement
Installation
1. Using tool J-23062-1 and drive handle J-8092 with ex
tension J-21465-13, install case bushing from interior of
case to 3/16" from front surface. Split in the bushing
should be located at governor pilot upper bore wall
J-8092
area. DRIVE
HANDLE
Stator Shaft Bushing J-21424-7
PUMP C O V E R
Removal (Front) PUMP
A N D STATOR DY
1. W ith stator shaft properly supported, remove front SHAFT ASSEMBLY
bushing using tool J-2 1465-15 with slide ham m er J-
2619 and adapter J-2619- 4 (fig. 100M).
Installation
1. Using tool J - 2 1424-7 and drive handle J-8092 install
front stator shaft bushing (fig. 101M) to .250" from
front face.
Removal (Rear)
1. W ith stator shaft properly supported, remove front Fig. 101 M -ln s ta llin g Front Stator Shaft Bushing
bushing as previously described. Place tool J-2 1424-7
extension J-21465-13 and drive handle J-8092, through
front of the stator shaft and drive out rear ( 2) bushings. Input Ring Gear Support Bushing
Removal
Installation 1. W ith input ring gear support properly supported,
1. Using tool J-23062-2 and extension J-21465-13, install remove bushing.
center bushing to approxim ately 1 5/32" below front
face and rear bushing 3/32" below front face (fig.
102M).
J - 21465-15
J - 2619-4
ADAPTER
J-23062-2
s 'BODY PUMP
PUMP COVER
AND STATOR
SHAFT ASSEMBLY
Fig. 10O M -R em oving S tator S haft Front Bushing Fig. 10 2 M --ln sta llin g Rear and Center S tator Shaft Bushings
Removal
J-8092 1. W ith sun gear properly supported, remove sun gear
bushings (fig. 104M).
Installation
1. Using tool J-23062-3 and drive handle J-8092 install
sun gear bushings to .0 1 0 " below surface at either end
J-23062-5 (fig. 105M).
Installation
Fig. 10 3 M -ln s ta llin g Inp ut Ring Gear S upport Bushing J Using tool J .23062-3 and drive handle J-8092 install
reaction carrier bushing to flush or .0 1 0 " below inside
face.
Removal
1. W ith direct clutch drum properly supported, remove
PLASTIC bushing (fig. 106M).
MALLET
CAPE CHISEL
S UN G E A R
SUN
BUSHING GEAR
DRIVE J-8092
SUN GEAR SHELL
DRIVE SHELL
75-190
J-23062-3
Fig. 10 4 M -R e m o vin g Sun Gear Bushings
Installation S U N GEAR
ASSEM BLY
L O W A N D REVERSE
CLUTCH SUPPORT
Installation L O W A N D REVERSE
CLUTCH SUPPORT
1. Using tool J-23329 and drive handle J-8092, install di
rect clutch bushing (fig. 107M). RETAINER SPRING
TRA N SM ISSIO N R E A S S E M B LY
10. Install low and reverse roller clutch inner race to sun
gear shell thrust washer.
11. Install low and reverse clutch support to case snap ring
with anti-clunk spring between gap.
12. Install rear th ru st w asher and sun gear drive shell as
sembly.
13. Install output carrier assembly.
14. Install input ring gear rear thru st washer.
15. Install input ring gear.
16. Install input ring gear to output shaft snap ring.
Fig. 1 1 1M --Installing O utput Shaft Yoke Seal Fig. 1 13M~Park Lock Bracket Special Bolt Ide ntification
9. Install m anual shaft through case and range selector 9. Connect detent control valve wire to detent valve ac
inner lever. tuating lever, then attach lever to valve body.
3. Install four (4) check balls into transm ission case pock
ets (fig. 18M).
Governor and Vacuum Modulator
Transm ission Disassembly and Reassembly ............ 7-137 Sun G ear Shaft B ushing-Front.................................... 7-174
Disassembly of M ajor U n its........................................ 7-137 Sun G ear Shaft Bushing-Rear .................................... 7-174
G overnor, Speedometer Driven Gear, Pan, Filter M ain Shaft Inspection................................................... ... 7-174
and Intake Pipe ...................................................... 7-137 F ront and R ear Bands In sp e c tio n ............................ ... 7-174
Control Valve Assembly, Solenoid Connector, Case Extension .............................................................. ... 7-174
G overnor Pipes and D etent S p rin g................... 7-139 M odulator V alv e ............................................................ ... 7-175
R ear Servo, Valve Body Spacer, Gasket and M anual and Parking Linkage Inspection................. ... 7-175
F ront Servo............................................................... 7-141 Case Assembly Inspection .......................................... ...7-176
Band Apply Pin Selection........................................ 7-142 Case Assembly Bushing ............................................ ... 7-176
R ear Oil Seal and Extension H o u sin g ................... 7-143 Converter Inspection..................................................... ... 7-176
F ront U nit End Play Checking Procedure ........ 7-143 Converter End Clearance C h e c k ............................ ... 7-176
Oil Pum p and Internal Case C om ponents............ 7-144 Assembly of R ear U n it....................................................7-177
Rear End Play Checking Procedure ...................... 7-147 Case M odification-Corvette ...........................................7-181
G ear U nit A ssem bly................................................... 7-148 Assembly of U nits to Transmission Case ............... ...7-181
Speedometer Drive G ear............................................ 7-150 Install M anual Linkage............................................ ...7-184
G overnor Assembly ...................................................... 7-152 Rear Extension A ssem bly.............................................7-186
D isassem b ly I n s p e c tio n ......................................... 7-152 Check Balls, F ront Servo, Spacer and
Driven G ear Replacem ent ...................................... 7-152 S olenoid...........................................................................7-186
F ront Servo Parts In sp e c tio n ................................... 7-153 R ear Servo A ssem b ly ....................................................7-187
R ear Servo Parts Service .......................................... 7-154 Control Valve Assembly and G overnor Pipes.........7-188
Control Valve Service................................................... 7-155 Filter and Intake Pipe....................................................7-190
Oil Pum p Service .......................................................... 7-158 M odulator Valve and Valve and Vacuum
Forw ard Clutch S erv ice............................................... 7-162 M o d u la to r......................................................................7-190
Direct Clutch and Interm ediate Spag Service........ 7-165 G o v e rn o r...........................................................................7-190
Center Support S ervice................................................. 7-170 Speedometer Driven G ear.............................................7-191
Reaction Carrier, Low Roller and O utput Converter Assembly-Installation ............................ ...7-191
C arrier Assembly.......................................................... 7-172
Pinion Replacem ent ................................................... 7-173
O utput Shaft, Rear Internal Gear, Sun G ear
and S h a ft........................................................................ 7-174
1. W ith transm ission in cradle on portable jack, remove 5. Remove m odulator assembly and "O" ring seal from
converter assembly by pulling straight out. case (fig. 4T). Discard "O" ring.
NOTE: Converter contains a large amount of oil. 6. Remove m odulator valve from transmission case.
NOTE: Do not over-torque holding screw. This will 1. Remove attaching screws, governor cover and gasket
bind center support. (fig. 5T). Discard gasket.
3. Install fixture and transm ission into holding Tool Base 3. Remove speedometer driven gear attaching screw and
J- 3289-14 with bottom pan facing up (fig. 2T). retainer (fig. 6 T).
Cross S e c tio n -T y p ic a l
Fig. 1T-Side
MODULATOR VALVE
RETAINER
Fig. 3T~Removing M od ula tor Retainer 8. Remove intake pipe to case "O" ring seal from intake
pipe or case and discard.
4. W ithdraw speedom eter driven gear assembly from case.
Removal of Pressure Sw itch Assembly,
5. Remove bottom pan attaching screws, bottom pan and Control Valve Assembly, Solenoid
bottom pan gasket. D iscard gasket.
Connector, Governor Pipes, Governor
Screen Assembly, and Detent Spring
6. Remove the filter retainer bolt (fig. 7T).
Assembly
7. Remove filter and intake pipe assembly from case (fig. NOTE: CM Model transmission does not have Pres
8T) and discard filter. sure Switch (TCS).
F ig . 8 T — R e m o v in g F ilt e r A s s e m b ly a n d “ O ” R in g
ELECTRIC WIRE)
CLIP_______ I
PRESSURE SWITCH
ASM. ____ _
2. If necessary, remove the pressure switch assembly (fig. CAUTION: If transmission is in the vehicle, the front
8T- B). servo parts may drop out as the control valve assem
bly is removed.
3. Remove control valve body attaching screws and detent
roller and spring assembly (fig. 9T). 4. Remove control valve body assembly and governor
pipes (fig. 10T).
NOTE: Do not remove solenoid attaching screws. CAUTION: Do not drop manual valve.
(PRESSURE SWITCH
ASM.______________
GOVERNOR SCREEN
ASSY.
GOVERNOR FEED
PIPE HOLE
5. Remove governor screen assembly from governor feed 1. Remove rear servo cover attaching screws, servo cover
pipe hole in the case or from end of governor feed pipe and gasket. Discard gasket (fig. 1IT).
(fig. 10T-A). Clean governor screen in clean solvent and
air dry.
2. Remove rear servo assembly from case (fig. 12T).
7. Disconnect solenoid lead from connector term inal (fig. 4. M ake band apply pin selection check to determine poss
10-A). ible cause of m alfunction (fig. 13T).
REAR SERVO
ASSEMBLY
370-6
o,
SERVO PISTON
RETAINER RING
GASKET
SERVO PIN
SERVO SPRING SERVO PISTON
RETAINER SPRING___ S
Fig. 14T-R em oving Detent Solenoid and Gasket Fig. 16T~Removing Front Servo Piston, Retainer Ring, and Pin
Thickness Color
.060 - .064 Yellow
.071 - .075 Blue
.082 - .086 Red
.093 - .097 Brown
.104 - .108 Green
.115 - .119 Black
.126 - .130 Purple
NOTE: If necessary, remove manual linkage as fol d. Remove parking actuator rod and detent lever as
lows: sembly.
a. U nthread jam nut holding detent lever to m anual e. Remove attaching screws and parking bracket (fig.
shaft. 26T).
b. Rem ove m anual shaft retaining pin from case (fig.
24T). f. Remove parking pawl return spring (fig. 27T).
RETAINING
SPRING
SHAFT
Fig. 25T~Rem oving Detent Lever and Jam Nut from Manual
h. Remove parking pawl shaft cup plug by inserting a
S haft
screwdriver, between the parking pawl shaft and the
case rib, and prying outw ards (fig. 29T).
RETURN SPRING
g. Remove parking pawl shaft retainer (fig. 28T). Fig. 29T~Rem oving Parking Brake Pawl, S haft and Cup Plug
DIAL INDICATOR
J-9539
12. Remove interm ediate clutch backing plate, three (3) 16. Place gear unit assembly, with output shaft facing down
composition, and three (3) steel clutch plates (fig. 34T). through hole in work bench or Holding Fixtures J-6116
with J-21364 adapter.
13. Remove center support to case retaining snap ring (fig.
35T). 17. Remove rear unit selective washer from transmissions
case (fig. 37T).
14. Remove entire gear unit assembly by lifting with gear
assembly installing and removing Tool J-21795 with 18. Remove support to case spacer (fig. 129T-A).
J-9539 slide ham m er (fig. 36T).
19. Remove rear band assembly (fig. 38T).
15. Remove output shaft to case thru st washer from rear of
output shaft or inside case.
Disassembly of Gear Unit Assembly
t 1. Remove center support assembly (fig. 39T).
BACKING PLATE
..
\ H
COMPOSITION PLATES (3)
STEEL PLATES (3)
Fig. 36T -R em oving Center S upport and Gear U nit from Case
Fig. 35T-R em oving Center S upport to Case Snap Ring Fig. 37T-R em oving Selective W asher
CENTER SUPPORT
T O CASE SPACER ROLLER
CLUTCH
/ LOCATE SPACER G A P
ADJACENT TO
1 B A N D A N C H O R PIN
F ig . 3 7 T A — R e m o v in g S u p p o r t t o Case S pacer
THRUST WASHER
ROLLER CLUTCH
SNAP RING
ASSEMBLY
REACTION
CARRIER
SUN
GEAR
PLASTIC GEAR
RING
SPEEDOMETER DRIVE
GEAR CLIP
Fig. 45T-A--Removing Speedom eter Drive Gear (steel) Fig. 46T--Removing Rear Internal Gear and M ainshaft
Inspection
1. W ash all parts in cleaning solvent, air dry and blow out
all passages.
2. Inspect governor sleeve for nicks, burrs, scoring or gall
ing.
Ring
3. Check governor sleeve for free operation in bore of
transm ission case.
Transmissions With Steel 4. Inspect governor valve for nicks, burrs, scoring or gall
Speedometer Drive Gear ing.
a. Install speedom eter drive gear rem oving Tool J- 5. Check governor valve for free operation in bore of gov
21427-01 and J-9539 bolts with J-8105 or suitable ernor sleeve.
puller on output shaft, and remove speedometer 6. Inspect governor driven gear for nicks, burrs, or dam
drive gear (fig. 45T-A). age.
b. Install new steel speedometer drive gear and drive 7. Check governor driven gear for looseness or governor
to location (5 43/64" below end of output shaft for sleeve.
all models except "CA" and "C R ") (11 29/64 below 8. Inspect governor weight springs for distortion or dam
end o f output shaft for models "CA" and "C R ") age.
using J-5590 (fig. 45T-B). 9. Check governor weights for free operation in their re
tainers.
10. Check valve opening at entry (.020" minim um ) with a
GOVERN OR A S S E M B L Y
feeler gage, holding governor as shown with governor
All com ponents of governor assembly, with exception of weights extended completely outw ard (fig. 48T-A).
driven gear, are a select fit and each assembly is calibrated. 11. Check valve opening at exhaust (.020" minim um ) with
The governor, including the driven gear, is serviced as a a feeler gauge, holding governor as shown with gover
complete assembly. However, the driven gear can also be nor weights completely inward (fig. 48T-B).
serviced separately.
It is necessary to disassemble governor assembly in order Governor Driven Gear Replacement
to replace driven gear. Disassembly may also be necessary
To facilitate governor repair in the field, a governor driven
due to foreign m aterial causing im proper operation. In such
gear and replacement pins are available for service use. The
cases, proceed as follows:
service package contains a nylon driven gear, two governor
weight retaining pins and one governor gear retainer split
Disassem bly
pin. Replacem ent of gear must be perform ed with care in the
1. Cut off one end of each governor weight pin and remove following manner:
pins, governor thrust cap, governor weights, and 1. Drive out governor gear retaining split pin using small
springs. Governor weights are interchangeable from punch (fig. 49T).
side to side and need not be identified, (fig. 48T). 2. Support governor on 7/64 inch plates installed in ex
2. Remove governor valve from governor sleeve. Be care haust slots of governor sleeve, place in arbor press, and
ful not to damage valve. with a long punch, press gear out of sleeve.
CLUTCHES AND TRANSMISSIONS 7-153
Fig. 48T-A~Checking Valve O pening W ith W eig hts O utward Fig. 49T--Rem oving G overnor Gear Retaining Pin
3. Carefully clean governor sleeve of chips that remain new pin hole m ust be drilled through sleeve and gear. Lo
from original gear installation. cate hole position 90 degrees from existing hole, center
punch and then, while supporting governor in press,
4. Support governor on 7 /6 4 inch plates installed in ex
drill new hole through sleeve and gear using a standard
haust slots of sleeve, position new gear in sleeve and,
( 1 /8 inch) drill.
w ith a suitable socket, press gear into sleeve until nearly
6 . Install split retaining pin.
seated. Carefully remove any chips th at may have
7. W ash governor assembly thoroughly to remove any
shaved off gear hub and press gear in until it bottom s
chips th at may have collected.
on shoulder.
Assem bly
1. Install governor valve in bore of governor sleeve, large
end first.
2. Install governor weights and springs, and thrust cap on
governor sleeve.
3. Align pin holes in thrust cap, governor weight assem
blies and governor sleeve, and install new pins. Crim p
both end of pins to prevent them from falling out.
4. Check governor weight assemblies for free operation on
pins.
5. Check governor valve for free movement in governor
sleeve.
1. Inspect servo pin for damage. 2. Remove "E" ring retaining rear servo piston to band
and apply servo pin (fig. 5 IT).
2. Inspect piston and oil ring for damage.
3. Remove rear servo piston and seal from band and apply
3. Check fit of servo pin in piston and case bore. servo pin (fig. 52T). (Exploded view).
“ E” RING
Fig. 50T-A-R em oving Rear A ccum u lato r Piston from Rear Fig. 5 1 T — Rem oving Retaining “ E ” Ring fro m
Servo Assem bly Rear Servo Pin
RETAINING
"E ” RING
SERVO PISTON \
SERVO PIN
Fig. 52T~Rear Servo and A ccum u lato r A ssem bly-E xploded V iew
2. Inspect fit of band apply pin in servo piston in case bore. 4. Remove front accum ulator piston and spring (fig. 54T).
3. Inspect band apply servo pin for scores or cracks.
4. Inspect accum ulator and servo pistons for scoring, NOTE: No front accumulator spring used in CY
cracks or porosity. model.
5. On the right side adjacent to the m anual valve, remove
Reassem bly the 1-2 valve train as follows:
1. Install spring retainer cup side down, spring and washer
on band apply pin.
2. Install band apply servo pin, retainer, spring and
washer, into bore of servo piston and secure with "E"
ring.
3. Install oil seal ring on servo piston, if removed.
4. Install outer and inner oil rings on accum ulator piston,
if removed, and assemble into bore of servo piston.
CO N TRO L V A LV E, D IS A S S E M B LY ,
IN SPECTIO N AND RE A S S E M B L Y (Fig.
55T)
Passenger Cars
Disassem bly
1. Position control valve assembly with cored face up and
accum ulator pocket nearest operator.
2. Remove m anual valve from upper bore.
3. Install Special Tool J-2 18 85, on accum ulator piston and Fig. 5 3 T -ln s ta llin g Com pressor Tool to Front A ccum ulator
remove retaining ring (fig. 53T). Piston
1. Manual Valve 10. 1-2 Regulator Valve 17. 1-2 Primary 26. 3-2 Valve Spring
2. Retaining Pin Spring A ccum u lato r Spring 27. Bore Plug
3. Bore Plug 10a. 1-2 M od ula tor Valve 18. 2-3 S hift Valve 28. Retaining Pin
4. Detent Valve Spring 19. 3-2 Interm ediate 29. 1-2 A ccum ulator
5. Detent Regulator 1 1. 1-2 Regulator Valve Spring Valve Sec. Spring
Valve 12. 1-2 M od ula tor 20. 2-3 M od ula tor Valve 30. 1-2 A ccum ulator
6. Spacer Bushing 21. 2-3 S hift Valve Valve
7. Detent Regulator 13. Retaining Pin Spring 31. 1-2 A ccum ulator
Valve Spring 14. Retaining Pin 22. 2-3 M od ula tor Valve Bushing
8. 1-2 S h ift Valve 15. Bore Plug Bushing 32. 1-2 A ccum ulator
9. 1-2 Detent Valve 16. 1-2 A ccum ulator 23. Retaining Pin Primary Valve
9a. 1-2 M od ula tor Valve Valve 24. 3-2 Valve 33. 1-2 A ccum ulator
25. Spacer Prim ary Valve Spring
VENT
CONVERTER
DRIVE M ODULATOR OR
INTERMEDIATE
REVERSE
COOLER
RETURN EXHAUST
TO
COOLER
TO
COOLER INTAKE
COOLER
RETURN
BREATHER
HOLE
INTAKE
REVERSE CONVERTER
Fig. 57T~Pum p Body Oil Passages Fig. 58T~Pump Cover Oil Passages
Oil Pump Disassembly, Inspection and 10. Remove pum p to forward clutch housing selective
washer.
Reassembly
11. M ark drive and driven gears for reassembly in same
position and remove from the pum p body.
Disassem bly
2. Com press regulator boost valve bushing against pres NOTE: The 1971 solid type pressure regulator valve
does not contain oil holes and an orifice cup plug like
sure regulator spring and remove snap ring, using J-
5403 pliers (fig. 60T). the previous pressure regulator valve. The solid
style valve must only be used in the pump cover with
the squared pressure regulator boss. (Pressure
3. Remove regulator boost valve bushing and valve. boost bushing end.) See figure 64T. The previous
pressure regulator valve with the oil holes and ori
fice cup plug may be used to service either type
4. Remove pressure regulator spring. pump cover.
5. Remove regulator valve, spring retainer and spacer(s), 1. Inspect drive and driven gear pocket and crescent for
if present (fig. 6 IT). scoring, galling or other damage.
8. Remove retaining pin and bore plug from pressure 4. Check oil passages (fig. 57T).
regulator bore (fig. 62T.
5. Check for damaged cover bolt attaching threads.
9. Remove hook type oil rings from pum p cover. 6. Check for overall flatness of pum p body face.
RETAINING PIN
BORE PLUG
REGULATOR SPRING
PUMP ASSEMBLY
Fig. 60T~Removing Pump R egulator Valve Snap Ring Fig. 61T-R em oving Pressure Regulator Valve
RETAINING
PIN
PUMP C O V ER
BORE PLUG
PUMP COVER
FOR ID E N T IF IC A T IO N -
SQ U A R ED O FF PRESSURE
REG. BO SS.
7. Check bushing for scores or nicks. If replacem ent is 8. Inspect pum p attaching bolt seals for damage, replace
necessary proceed as follows: if necessary.
a. Using Tool J-21465-17 and driver H andle J-8092 9. Inspect pum p cover face for overall flatness.
remove bushing. 10. Check for scores or chips in pressure regulator bore.
b. F rom front side of pum p, using J-21465-17 and 11. Check th at all passages are open and not interconnected
driver H andle J 8092 install new bushing flush to (fig. 58T).
.0 1 0 " below gear pocket face. 12. Check for scoring or damage at pum p gear face.
13. Inspect stator shaft for damaged splines, or scored
bushings. If replacem ent of bushing is necessary pro
ceed as follows:
Front
a. W ith pum p cover and stator shaft properly sup
PUMP DRIVE GEAR
(TA N G S UP)
ported, using Tool J-21465-15, with slide ham m er
PUMP
PUMP DRIVEN
BODY
Fig. 63T--lnstalling Pump Drive Gear Fig. 65T~C hecking Pump Body Face to Gear Face Clearance
Rear
15. Inspect selective w asher th ru st face for wear or damage. Fig. 6 6 T ~ ln sta llin g Pump Cover to Pump Body
16. Inspect pressure regulator and boost valve for free oper
ation in their respective bores. NOTE: Leave bolts one turn loose at this time.
17. Inspect pum p cover for open 1/8" breather hole (fig. 11. To align the pum p body and cover, place the pump
58T). assembly, less rubber seal ring, upside down into the
pum p bore of the case (fig. 66 T).
5. Install boost valve into bushing, stem end out, and in
stall both parts into pum p cover by compressing bush
ing against spring.
10. Assemble pum p cover to pum p body with attaching Fig. 67T-R em oving Forward Clutch Housing to D irect Clutch
bolts. Hub Snap Ring
FORWARD
CLUTCH HUB
THRUST
WASHERS
FORWARD CLUTCH
HOUSING
1. Place forw ard clutch assembly with turbine shaft 5. If necessary place forward clutch and turbine shaft in
through hole in bench or Holding Fixture J-6 116, and arbor press and remove turbine shaft (fig. 69T).
remove forward clutch housing to direct clutch hub 6. Using J-4670 clutch spring com pressor in arbor press
snap ring (fig. 67T). with A dapter J-2 1664, compress spring retainer and
2. Remove direct clutch hub. remove snap ring (fig. 70T).
3. Remove forw ard clutch hub and thru st washers (fig. 7. Remove spring retainer and sixteen (16) clutch release
68 T). springs.
4. Remove five (5) radial grooved composition and five (5)
steel clutch plates. NOTE: Keep springs separate from direct clutch re
lease springs.
TURBINE SHAFT
Reassem bly
CLUTCH CENTER SEAL
NOTE: The Turbo Hydra-Matic forward and direct
Fig. 72T~Rem oving Forw ard Clutch Center Seal clutch pistons have identical inside and outside
diameters. It is possible to reverse the pistons dur
10. Remove center piston seal from forw ard clutch housing ing reasembly, therefore, care should be exercised
(fig. 72T). to make certain the proper piston be installed in the
clutch assemblies. As shown in Figure 89T, the di
Inspection rect clutch piston can be identified by the check ball.
FORWARD CLUTCH
ASSEMBLY
WAVED
STEEL
PLATE
COMPOSITION
PLATES (5) THRUST
WASHERS
J-21362
Fig. 7 4 T -ln s ta llin g Forward Clutch Piston Fig. 7 5 T ~ ln sta llin g Forward Clutch Com position and Steel
Plates
2. Place a new center seal on clutch housing, lip faces up CAUTION: Do not confuse the flat steel clutch plate
(fig. 72T). (plate with “ V" notch) with the waved steel clutch
plate (plate with "U" notch). (See Fig. 76T).
3. Place seal protector Tool J-2 1362, over clutch hub and 11. Install direct clutch hub and retaining snap ring (fig.
install outer clutch piston seal Protector J-2 1409, into 77T).
clutch drum and install piston, rotating piston on drum
until seated (fig. 74T).
10. Oil and install five (5) radial grooved composition and
four (4) flat steel and one (1) waved steel clutch plate
(plate with "U" notches) starting with waved steel and
alternating composition and steel clutch plates (fig. Fig. 76T--Forw ard Clutch Plate Id e n tifica tio n
75T).
SNAP RING
CLUTCH RETAINER
SNAP RING
Disassem bly
Fig. 77T--lnstalling Forward Clutch Housing to Direct Clutch
Hub Snap Ring 1. Remove interm ediate sprag retainer snap ring and re
tainer (fig. 79T).
12. Place forw ard clutch housing on pum p delivery sleeve 2. Remove sprag outer race, bushings and sprag assembly.
and air check clutch operation (fig. 78T). 3. T urn unit over and remove backing plate to direct
clutch housing snap ring (fig. 80T).
D IR EC T CLU TCH AND IN TERM ED IA TE 4. Remove direct clutch backing plate (five) 5 composi
tion, and (five) 5 steel clutch plates.
SP R A G D IS A S S E M B L Y , IN SPECTIO N
AND RE A S S E M B L Y NOTE: Models CF, CR, CS, and CY, have six (6) com
position and six (6) steel clutch plates. No waved
steel plate used in model CY.
V
FORWARD CLUTCH ASSEMBLY DIRECT CLUTCH BAC KIN G PLATE
PUMP ASSEMBLY
DIRECT CLUTCH
H O U S IN G
Fig. 78T--Air Checking Forward Clutch Assem bly Fig. 80T~Removing Direct Clutch Backing Plate Snap Ring
SNAP RING
SPRAG BUSHINGS
5. Using clutch com pressor Tool J-4670 and J-21664, 8. Remove outer seal from piston.
compress spring retainer in arbor press and remove 9. Remove inner seal from piston.
snap ring (fig. 82T). 10. Remove center piston seal from direct clutch housing.
DIRECT
CLUTCH
HOUSING
Fig. 82 T -R em o ving or Installing Direct Clutch Snap Ring Fig. 83T-R em oving Direct Clutch Piston Assem bly
Fig. 8 4 T ~ D ire ct Clutch A ssem bly Exploded to make certain the proper piston be installed in the
clutch assemblies. As shown in Figure 89T, the di
4. Inspect clutch housing for cracks, wear, proper opening rect clutch piston can be identified by the check ball.
of oil passages or wear on clutch plate drive lugs. On CY model, the direct clutch piston has 2 check
balls.
5. Inspect composition-faces and steel clutch plates for
sign of wear or burning. *• Install a new inner clutch piston seal on piston with lip
facing away from spring pockets (fig. 85T).
6. Inspect backing plate for scratches or other damage.
2 Install a new outer clutch piston seal with lip facing
7. Inspect clutch piston for cracks and free operation of
away from spring pockets (fig. 86 T).
ball check.
NOTE: The Turbo Hydra-Matic forward and direct NOTE: Apply automatic transmission oil to all seals
clutch pistons have identical inside and outside and clutch plates.
diameters. It is possible to reverse the pistons dur
ing reassembly, therefore, care should be exercised
CAUTION: The direct clutch housing for the CF, CR,
CS, and CY models use the 6 plate clutch assembly.
CLUTCH
CENTER SEAL
Fig. 8 5T— I nsta 11i ng D irect Clutch Inner Seal Fig. 8 7 T ~ ln sta llin g Direct Clutch Center Seal
CHECK BALL
DIRECT CLUTCH
HO U SIN G
Fig. 9 2 T -ln s ta llin g Interm ediate Sprag to D irect Clutch Fig. 94 T ~ ln sta llin g Interm ediate Clutch Retainer
9. Install clutch backing plate. 14. Install sprag bushing over sprag, cup side down.
10. Install backing plate retaining snap ring (fig. 9 IT).
15. Install sprag retainer and snap ring (fig. 94T and 95T).
11. T urn unit over and install one sprag bushing, cup side
up, over inner race. 16. Place direct clutch assembly over center support and air
12. Install sprag assembly into outer race. check operation of direct clutch (fig. 97T).
D IS A S S E M B L Y , IN SPECTIO N AND
RE A S S E M B L Y OF CEN TER SU PPO RT
Disassem bly
1. Remove three (3) hook type cast iron oil seal rings from
the center support. D o not remove the teflon oil seal
ring unless replacem ent is required. All service center
support oil seal rings are hook type cast iron (fig. 96T).
Fig. 1 0 1T— Installing Interm ediate Clutch O uter Seal Fig. 10 3 T —Installing Interm ediate Clutch Piston Snap Ring
J-21363
CENTER
SUPPORT
Fig. 102T --lnstalling Interm ediate Clutch Piston Fig. 1 0 4 T -A ir Checking Interm ediate Clutch Piston
P IN IO N PIN
B R O N ZE W A S H ER
14. Inspect front internal gear ring for flaking (fig. 41).
9. Inspect front internal gear (output carrier) for damaged 7. Place a bronze and steel washer on each side of pinion
teeth. so steel washer is against pinion, hold them in place
with petrolatum .
10. Inspect output carrier pinions for damage, rough bear
ings or excessive tilt.
8. Place pinion assembly in position in carrier and install
11. Check pinion end play. Pinion end play should be a pilot shaft through rear face of assembly to hold parts
.009 "-.024" (fig. 106T). in place.
Remove
W ith sun gear shaft properly supported, using Tool J-
21465-15, with slide ham m er and A dapter J-2619, remove
bushing.
IN SPECTIO N OF C A S E A S S E M B L Y
GOVERNOR
{FIGS. 112T AND 113T) 7A C C U M U LA fO R
[INTERMEDIATE
CLUTCH
IN SPECTIO N OF CO N VERTER
1.
Check converter for leaks as follows (fig. 114T):
a. Install Tool J-21369 and tighten.
b. Apply 80 psi air pressure to tool.
c. Submerge in w ater and check for leaks.
2. Check converter hub surfaces for signs of scoring or
wear.
A S S E M B L Y OF REA R UNIT
Fig. 1 14T--Air Checking Converter
1. Install rear internal gear on end of mainshaft.
5. Loosen hex nut while holding cap n u t stationary. W ith 2. Install internal gear retaining snap ring (fig. 116T).
the hex nut loosened and holding Tool J-21371-3 firmly
against the converter hub, the reading obtained on the 3. Install sun gear to internal gear thrust races and bear
dial indicator will be the converter end clearance. End ings against innner face of rear internal gear as follows,
clearance should be less than .050". If the end clearance and retain with petrolatum .
is .050" or greater, the converter m ust be replaced. a. Place large race against internal gear with outer
flange facing forward or up (fig. 117T).
b. Place thrust bearing against race.
c. Place small race against bearing with inner flange
facing into bearing or down.
I.D . FLANIGE
RACE
O' R IN G
M A IN SHAFT
FRO NT IN TE R N A L
RE A C TIO N G EAR R|N G
CARRIER
A SSEMBLY
10. T urn assembly over and support so th at output shaft 11 Install reaction carrier to output carrier thrust washer
hangs downward. with tabs facing down in pockets of output carrier and
retain with petrolatum .
12. Install sun gear I.D . splines with cham fer down.
INTERNAL GEAR
Fig. 116T --lnstalling Rear Internal Gear to M ain S haft Snap Fig. 1 17 T -ln s ta llin g Rear Internal Gear to Sun Gear Bearing
Ring and Races
THRUST
BEARING
I.D. FLANGED
RACE
14. Install sun gear shaft w ith long splined end down.
15. Install reaction carrier (fig. 12IT ).
Fig. 1 19T— Installing O utput S haft Fig. 1 2 I T — Installing Reaction C arrier and R o lle r Assem bly
ROLLER CLUTCH
ASSEMBLY
17. Install rollers that may have .come out of the roller
clutch cage, by compressing the energizing spring with
forefinger and inserting roller from the outer edge (fig.
Fig. 122 T — Installing Center S upport to Sun Gear T hrust 123T).
Bearing and Races
18. Install roller clutch assembly (fig. 124T) into reaction
carrier.
gear ring prevents assembly of the carriers, replace
the front internal gear ring with the SERVICE ring. 19. Install center support to reaction carrier thrust washer
into recess in center support. Retain with petrolatum
(fig. 40T).
16. Install center support to sun gear th ru st races and bear
ings as follows: (R etain with petrolatum .) 20. Install center support into roller clutch in reaction car
a. Install large race, center flange up over sun gear rier (fig. 125T).
shaft.
b. Install thrust bearing against race. NOTE: With reaction carrier held, center support
c. Install second race, center flange up (fig. 122T). should only turn counter-clockwise after installa
tion.
Fig. 12 3 T -ln s ta llin g Roller into Roller Cage Fig. 12 5 T -ln s ta llin g Center S upport to Reaction Carrier
THRUST WASHER
3. Install parking pawl shaft cup plug and drive into the
case, using a 3 /8 dia. rod, until the parking pawl shaft
bottom s on the case rib (fig. 127T).
u CENTER S U P P O R fi
RETAINING
SPRING
f I t o CASE SPACER U
Fig. 1 2 8 T -ln s ta llin g Parking S haft Retaining Spring Fig. 12 9 T -A -ln s ta llin g Support to Case Spacer
X* ' !
REAR
BAND
Fig. 1 2 9 T ~ ln sta llin g Rear Band Fig. 13 0 T -ln s ta llin g Center S upport and Gear U nit
SNAP RING
BACKING PLATE
Identification
Thickness Notches a n d /o r Numerals
.074-.078 N one ............................1
.082-.086 1 Tab Side ................ 2
.090-.094 2 Tabs Side ...............3
.098-. 102 1 T ab O .D ...................4
.106-.110 2 T abs O .D .................5
Fig. 131T-A— Installing Center S upport Bolt .1 14-.118 3 T abs O .D ................. 6
16. Install front band with anchor hole placed over band
anchor pin and apply lug facing servo hole (fig. 133T).
SHAFT DETENT
LEVER
FRONT SEAL
Fig. 136T--Installing D irect Clutch Assem bly Fig. 13 8 T ~ ln sta llin g Pump Seal
20. Install front pum p assembly and gasket. 23. Check front unit end play as follows (fig. 139T).
DIAL
IN D IC A T O R
24. Install rem aining front pum p attaching bolt and seal.
Torque 18 ft. lbs.
NOTE: If transmission is in the vehicle, install check
balls into ball seat pockets on spacer plate (Fig.
142T-A.
Rear Extension Assem bly
3. Install control valve spacer plate-to-case gasket (gasket
1. Install new extension housing to case gasket on exten with extension for detent solenoid). Fig. 143T.
sion housing.
2. A ttach extension housing to case using attaching bolts. 4. Install control valve spacer plate.
Torque bolts to 20-25 ft. lbs.
5. Install detent solenoid gasket.
3. If necessary, install a new seal as follows:
a. A ll models except " C M " - Use a non-hardening 6. Install detent solenoid assembly with connector facing
sealer on outside of seal body; and using Tool outer edge of case (fig. 144T). Do not tighten bolts at
J-21359, drive seal in place (fig. HOT). this time.
b. M odel " C M " - Use a non-hardening sealer on
outside of seal body; and using Tool J-2 1464, drive 7. Install front servo spring and spring retainer into trans
seal in place (fig. HOT). mission case.
SPACER PLATE
Fig. 143T —Installing Control Valve Assem bly Spacer Plate and
Fig. 142T--Location of Check Balls Gasket
Fig. 1 4 4 T -ln s ta llin g Detent Solenoid and Gasket Fig. 145T— Installing Electrical Connector
and “ O ” Ring
Selecting proper length pin is equivalent to adjusting
band. The band lug end of each selective apply pin bears
identification in the form of one, two or three rings.
There are three selective pins identified as follows:
c. If both steps are below the gauge surface, the long 3. Install rear servo gasket and cover (fig. 149T).
pin, identified by 3 rings, should be used.
4. Install attaching screws. Torque bolts to 15-20 ft. lbs.
d. If the gauge surface is between the steps, the
m edium pin, identified by 2 rings, should be used.
IN STALLATION OF CON TRO L V A LV E
e. If both steps are above the gauge surface, the short
pin, identified by 1 ring, should be used.
A S S E M B L Y , GOVERNOR P IP ES AND
GOVERNOR SCR EEN A S S E M B L Y
1. Install rear accum ulator spring into case (fig. 147T).
1. Install governor pipes on control valve assembly. Gov
2. Lubricate and install rear servo assembly into case (fig. ernor pipes are interchangeable.
148T).
REAR
SERVO
GASKET
Fig. 1 4 7 T -ln s ta llin g Rear A ccum u lato r Spring Fig. 14 9 T ~ ln sta llin g Rear Servo Cover and Gasket
2. Install governor screen assembly, open end first, into NOTE: Check manual valve to make sure it is in
governor feed pipe hole in case (hole nearest the center dexed properly with pin on detent lever and check
of the transmission). Fig. 150 governor pipes to make certain they are properly
seated in case holes.
NOTE: If transmission is in vehicle, before installing
the control valve assembly and governor pipes as
4.Start control valve assembly attaching bolts and make
outlined in Step 3 below, insert the governor screen,
certain lead wire assembly clip is installed.
closed end first, into governor feed pipe. (This pipe
locates in the governor feed pipe hole in the case
nearest the center of the transmission). SEE figure
NOTE: If transmission is in the vehicle, remove
150T.
feeler stock before tightening any control valve
bolts.
REAR SERVO
ASSEMBLY X
GOVERNOR SCREEN
ASSY.
GOVERNOR FEED
PIPE HOLE
Fig. 1 4 8 T -ln s ta llin g Rear Servo Assem bly Fig. 15 0 T -ln s ta llin g Governor Screen Assem bly
MODULATOR VALVE
GUIDE PINS
Fig. 1 5 2 T -ln s ta llin g Detent Roller and Spring Assem bly Fig. 154 T —Installing Governor Assem bly
SPECIAL TOOLS
Fig. 2ST-3-Speed and 4-Speed Passenger and 10-30 Series Truck Manual Transmissions
1. J-1126 Transmission Guide Pins 9. J-1453-01 Speedometer Drive Gear Press Plates
2. J-8059 Retainer Snap Ring Pliers Press Plate Holder J-358-1
3. J-5589 Countergear Loading Tool 10. J-2228 Rear Bearing Press Plates
4. J-21629 Countergear Loading Tool 11. J-0433 Main Drive Gear Wrench
5. J-22246 Countergear Loading Tool 12. J-5590 Clutch Gear Bearing Installer
6. J-5778 Extension Bushing Remover and Installer 13. J-9772 Clutch Gear Bearing Installer
7. J-5154 Extension Seal Installer 14. J-23096 Clutch Gear Retainer Seal Installer
8. J-5814-01 Speedometer Drive Gear Remover 15. J-5752 Transmission Holding Fixture
and Adapter J-5814-15
1. J-2680 Reverse Idler Gear Bushing Staking Tool 10. J-1453 Clutch Gear Bearing Replacer
2. J-1619 Transm ission M ainshaft Bearing Puller 11. J-2228 Clutch Gear Bearing Remover Plate
3. J-8109 (K -353)— Gear S hift Lever Remover and Replacer 12. J-8106 (K 342) Clutch Gear Bearing Replacer
4. J-8107 (TR-278-R)— C ountershaft Rear Bearing Remover 13. J-1614 Reverse Idler Gear Bushing Remover and Replacer
5. J-1126 Transm ission Guide Pin Set (2) 14. J-1488 Rear Bearing Retainer Oil Seal Driver
6. J-2671 Third Speed Gear Bushing Installer 15. J-4869 Speedom eter Gear Replacer
7. J-7785 Oil Seal Installer 16. J-0358 (J-358-1)— Press Plate Holder
•8. J-2667 M ainshaft and Bearing Assem bly R em overand Replacer 17. J-6416 Rear Bearing Retainer Seal Installer
9. J-6382 Reverse Idler S haft Remover
1. J-8092 Handle.
2. J-8331 Rear Output Shaft Front Bearing Remover.
3. J-23422 Rear Output Shaft Front Bearing Cup Installer.
4. J-23423 Rear Output Shaft Rear Bearing Cup Installer.
5. J-5590 Bearing Installer.
6. J-23419 Intermediate Shaft Remove and Installer.
7. J-22833 Output Shaft Housing Seal Installer.
8. J-23420 Pilot Bearing Installer.
9. J-7137 Adapter Seal Installer.
10. J-6219 Front Output Shaft Bearing Installer.
1. J-8 7 6 3 T ransm ission Holding Fixture 15. J - 2 1424-7 S tator Shaft Front Bushing
(M od ified fo r THM 350) Installer
2. J-3289-1 4 T ransm ission Holding Fixture 16. J-2 3 0 6 2 -5 Inp ut Ring Gear Bushing
Base Installer
3. J -2 3 1 0 3 P ropeller S haft Yoke Seal 17. J-5 1 5 4 or Extension Housing Seal
Remover and Installer J-21426 Installer
4. J-8 0 9 2 Driver Handle 18. J - 2 1359 Pump Seal Installer
5. J-2 1465-13 Driver Handle Extension 19. J-6 5 8 5 Slide Hammer W eights
6. J-2 3 0 6 2 -3 Sun Gear and Reaction Carrier 19a. J-9 5 3 9 Slide Hammer Screw
Bushing 20. J - 2 1885 2-3 A ccum u lato r Piston
7. J -2 3 0 6 2 -7 O utpu t S haft Bushing Installer Com pressing Tool
8. J - 2 1465-15 S tator S haft Front Bushing 21. J-23071 Interm ediate Band A p p ly Pin
Remover Gauge
9. J -2 3 3 2 9 D irect Clutch Bushing Installer 22. J-2 3 0 6 9 1-2 A ccum ulator Cover
10. J-9534-01 O utput S haft Bushing Remover Remover and Installer
1 1. J -2 3 3 2 7 Clutch Spring Com pressor 23. J-2 6 1 9 Slide Hammer (Used w ith
12. J-2 3 0 6 2 -2 S tator S haft Rear Bushing J-26 19 -4 A dapter and
Installer J-21465-15 Stator Shaft Front
13. J-23 06 2-1 Case Bushing Installer Bushing Remover
14. J - 2 1424-9 Extension Housing Bushing
Installer
1. J-8 7 6 3 Transm ission H olding Fixture 9. J - 2 1363 Seal P rotector - Interm ediate
2. J -3 2 8 9 -1 4 H olding Fixture Base Clutch - Inner
3. J - 2 1427-1 Speedo Gear Remover 10. J - 2 1409 Seal P rotector - Forward Clutch
4. J -9 5 3 9 Slide Hammer Bolts ( 3 /8 " - 16 - Outer
Threads) 11. J -2 1664 Clutch Spring Com pressor
5. J-81 05 Speedo Gear Remover Puller A da pter Ring
6. J - 2 1885 A ccum u lato r Piston Installer 12. J -4 6 7 0 Clutch Spring Com pressor
7. J - 2 1369 Converter Pressure Check 13. J-8 0 5 9 Snap Ring Pliers
Fixture 14. J -5 5 8 6 Snap Ring Pliers
8. J -2 1362 Seal Protector - Forward and 15. J-5 4 0 3 Snap Ring Pliers
D irect Clutch - Inner 16. J -1 3 1 3 Torque W rench 0 -1 4 0 Ft. Lbs.
17 18 19 20 21 22
STEERING
CONTENTS OF THIS SECTION
OVERHAUL OPERATIONS
As with any ball bearing unit the steering gear parts must CAUTION: Use care that the ball nut does not run
be kept free of dirt. Clean paper or rags should be spread on down to either end of the worm. Damage will be
the workbench before starting disassembly of the steering done to the ends of the ball guides if the nut is al
gear. lowed to rotate until stopped at the end of the worm.
1. Place the steering gear in a vise, clamping onto one of
the m ounting tabs. The w orm shaft should be in a hori
zontal position. 7. All Except Corvette-Remove the upper bearing from the
2. R otate the w orm shaft from stop to stop, counting the wormshaft.
total num ber of turns. Then tu rn back exactly half way, Corvette- Remove lower bearing from inside the gear
placing the gear on center (the w orm shaft flat should be housing.
at the 12 o’clock position). 8. All except Corvette-Using a suitable size screw driver,
3. Place a pan under the assembly to catch the lubricant pry the lower bearing retainer from the adjuster plug
and remove the three self locking bolts attaching the housing and remove the bearing (fig. 7).
side cover to the housing.
9. Remove the locknut from the lash adjuster screw in the
4. Tap lightly on the end of the pitm an shaft with a plastic
side cover. Remove the lash adjuster screw from the
ham m er and lift the side cover and pitm an shaft assem
side cover by turning the screw clockwise. Slide the
bly from the gear housing (fig. 5).
adjuster screw and shim out of the slot in the end of the
pitm an shaft.
NOTE: If the pitman shaft sector does not clear the 10. Pry out and discard both the pitm an shaft and worm
opening in the housing easily, turn the wormshaft shaft seals.
by hand until the sector will pass through the open
ing in the housing. Inspection
W ith the steering gear completely disassembled, wash all
parts in cleaning solvent. D ry them thoroughly with air.
5. Remove the adjuster plug and locknut assembly (incor W ith a magnifying glass inspect the bearings and bearing
porates the lower w orm shaft bearing and race on all races for signs of indentation. Also check for any signs of
except C orvette - upper worm shaft bearing race on C or chipping or breakdown of the surface. A ny parts that show
vette). signs of damage should be replaced
6. D ra w th e w o rm s h a ft a n d b all n u t a sse m b ly fro m Inspect all seals. Any seal that is worn or has been removed
the h o u sin g (fig. 6 ). should be replaced.
W O R M BEAR IN G LOCKNUT
(UPPER)
ADJUSTER
PLUG
SEAL
BEARING
CUP
Fig. 3 -S te e rin g G ear-C orvette Fig. 4--Steering Gear (Corvette and G 10-30 Series Trucks)
Inspect the fit of the pitm an shaft in its bushing in the side CAUTION: Before installing new seals, check the
cover. If this bushing is worn, a new side cover and bushing con d itio n of the p itm a n s h a ft b u s h in g ( s ) an d the
assembly should be installed. upper w orm shaft bearing race.
Check steering gear w orm shaft assembly for being bent or
dam aged in any way. Never attem pt to salvage steering parts 2. A su ita b le size socket, p ressin g o n th e o u te r
by welding or straightening. d ia m e te r o f th e seal, m ay be u se d to in s ta ll new
seals.
HOLD ASSEMBLY
J0r
w'
WORM
Adjuster Plug Races BEARING RACE
1. All Except Corvette- Remove the w orm shaft bearing
race using Tool J-5822 and Slide H am m er J-2619 as Fig. 10— Installing W orm sha ft Bearing Race in Housing Using
shown in Figure 9. Tool J-5755--Typical
Corvette- Using a ham m er and punch, drive the bear
ing race out of the adjuster plug. to deform it inward and secure it in the housing. Make
2. Press the new bearing race into position using Tool sure the plug is tight or lubricant leakage could result.
J-5755.
Ball Nut Servicing
Housing Races
As a rule, disassembly of the ball bearing nut will not be
1. Corvette only- Using a drift or punch (inserted into the
necessary if it is perfectly free with no indication of binding
housing from the adjuster plug end) drive the sheet
or tightness when rotated on the worm. However, if there is
metal expansion plug out of the lower end of the hous
any indication of binding or tightness, the unit should be
ing.
disassembled, cleaned and inspected as follows:
2. Using a drift or punch, drive the bearing race out of the
1. Remove screws and clamp retaining the ball guides in
housing.
nut. Draw guides out of nut.
3. Press the new bearing race into position using Tool
2. T urn the nut upside down and rotate the wormshaft
J-5755 (fig. 10).
back and forth until all the balls have dropped out of
4. Corvette only- Install a new expansion plug into the the nut into a clean pan. W ith the balls removed, the nut
lower end of the housing. Press on the center of the plug can be pulled endwise off the worm.
3. W ash all parts in cleaning solvent and dry them
thoroughly with air. Using a magnifying glass inspect
the worm and nut grooves and the surface of all balls
for signs of indentation. Check ball guides for damage
at ends where they deflect or pick up the balls from the
helical path. Any parts that show signs of damage
should be replaced.
4. All Except Corvette (fig. 11):
a. Place the worm shaft flat on the bench and slip the
nut over the worm with the ball guide holes up and
the shallow end of the ball nut teeth to the left from
the steering wheel position. Align the grooves in the
worm and nut by sighting through the ball guide
holes.
b. Place two ball guide halves together and insert them
into the upper circuit in the ball nut. Place the
remaining two guides together and insert them in
the lower circuit.
c. Count 24 balls into a suitable container. This is the
proper num ber of balls for one circuit.
Fig. 9--Removing A djuster Plug Bearing Race Using Tools d. Load the balls into one of the guide holes while
J -5 8 2 2 and J-2 6 1 9 turning the wormshaft gradually away from that
hole. W hen all of the balls have been installed, the d. Close this half of guide with the other half. Hold the
circuit is complete. two halves together and plug each open end with
e. Fill the rem aining ball circuit in the same m anner petroleum jelly so that balls will not drop out while
as described for the first circuit in Steps c and d installing the guide.
above. e. Push the guide into the guide holes of the nut. This
5. Corvette only (figs. 12 and 13): completes one circuit of balls. If the guide does not
a. Place the worm shaft flat on the bench and slip the push all the way down easily, tap it lightly into place
nut over the worm with the ball guide holes up and with the wooden handle of a screw driver.
the shallow end of the rack teeth to the left from the f. Fill the second ball circuit in the same manner. Con
steering wheel position. Align the grooves in the tinue until the ball circuit is full from the bottom of
w orm and nut by sighting through the ball guide one guide hole to the bottom of the other or until
holes. stopped by reaching the end of the worm.
b. C ount 27 balls into a suitable container. This is the
proper num ber of balls for half the circuit. Place NOTE: In cases where the balls are stopped by the
these balls into one of the guide holes while turning end of the worm, hold down those balls already
the worm gradually away from th at hole. dropped into the nu;t with the blunt end of a clean
c. Lay one-half of the ball guide, groove up, on the rod or punch (fig. 12) and turn the worm in the re
bench and place the rem aining balls from the count verse direction a few turns. The filling of the circuit
container in it. can then be continued. It may be necessary to work
the worm back and forth, holding the balls down
first in one hole and then the other, to close up the
spaces between the balls and fill the circuit com
pletely and solidly.
1. W orm Bearing A djuster 9. Upper W orm Bearing Race 16. Lash A d ju ste r
Locknut 10. Pitman S haft Seal 17. Lash A d ju ste r Shim
2. W orm Bearing A djuster 11. Housing 18. Housing Side Cover and
3. Lower W orm Bearing Race 12. W o rm sh a ft Seal Bushing Assem bly
4. Low er Ball Bearing 13. Side Cover Gasket 19. Lash A d ju ste r Locknut
5. Low er Bearing Retainer 14. Pitman S haft Bushing (2 20. Side Cover Bolts
6. Ball Nut Bushings on G 10-30 Series 21. Ball Guide Clamp Screws
7. W o rm sh a ft Trucks) 22. Ball Guide Clamp
8, U pper Ball Bearing 15. Pitman Shaft 23. Ball Guides
24. Balls
1. Place the steering gear housing in a vise w ith the w orm 4. Corvette-
shaft bore horizontal and the side cover opening up. a. Place a w orm shaft bearing in the housing race. Slide
2. W ith the pitm an shaft and worm shaft seals, pitm an the other bearing and the adjuster plug assembly
shaft bushings and w orm shaft bearing races installed, over the upper end of the wormshaft.
and the ball n u t installed on the worm shaft, proceed to b. Insert the wormshaft, nut and adjuster assembly
Step 3 or 4. into the housing, guiding the lower end of the
3. All Except Corvette-- worm shaft into the housing bearing.
a. Slip the upper ball bearing over the w orm shaft and c. Thread the adjuster into the housing until nearly all
insert the w orm shaft and nut assembly into the end play is removed from the wormshaft.
housing, feeding the end of the shaft through the 5. Position the lash adjuster (with shim) in the slotted end
upper ball bearing race and seal. of the pitm an shaft. Check the end clearance, which
b. Place a ball bearing in the adjuster race and press should not be greater than .002" (fig. 16). If clearance
the stam ped retainer into place with a suitable is greater than .0 0 2 ", a steering gear lash adjuster shim
socket. unit is available. It contains four shim s-.063", .065",
c. Install the adjuster and locknut into the lower end .067" and .069" thick,
of the housing (being careful to guide the end of the 6 . Lubricate the steering gear with 11 oz. of lubricant
w orm shaft into the bearing) until nearly all end play meeting G M Specification G M 4673 (or equivalent).
has been removed from the wormshaft. R otate the worm sahft until the ball nut is at the end of
1. Side Cover Screws 9. Expansion Plug 17. W orm Bearing R ace-U pper
2. Lash A d ju ste r Locknut 10. Steering Gear Housing 18. A d ju ste r Plug
3. Side Cover and Bushing 1 1. Pitman S haft Seal 19. W orm sha ft Seal
4. Lash A d ju ste r Shim 12. W orm Bearing R ace-Low er 20. A d ju ste r Plug Locknut
5. Lash A d ju ste r Screw 13. W orm B ea rin g -L o w e r 21. Clamp Screw
6. Side Cover Gasket 14. Ball Nut 22. Ball Guide Clamp
7. Pitman Shaft 15. W orm sha ft 23. Balls
8. Pitman S haft Bushings 16. W orm B ea rin g -U p p e r 24. Ball Guides
its travel and then pack as m uch new lubricant into the 7. R otate the w orm shaft until the ball nut is about in the
housing as possible w ithout losing it out the pitm an center of travel. This is to make sure th at the pitm an
shaft opening. R otate the w orm shaft until the ball nut shaft sector and ball nut will engage properly, with the
is at the other end of its travel and pack as m uch lubri center tooth of the sector entering the center tooth
cant into the opposite end as possible. space in the ball nut.
8. Insert the pitm an shaft assembly (with lash adjuster
screw and shim but w ithout side cover) into the housing
as that the center tooth of the pitm an shaft sector enters
the center tooth space of the ball nut.
9. Pack the remaining portion of lubricant into the hous
ing.
11. Install the side cover onto the pitm an shaft by reaching
through the side cover with a screwdriver and turning
the lash adjuster screw counterclockwise until the screw
bottoms; back the screw off one half turn. Loosely in
stall a new locknut onto the adjuster screw.
12. Install and tighten the side cover bolts to specifications.
18 19 20
■&u 6
1 2 3 4 6 7 8 9 10 1 1 12 13 14 15 16 17 21 22 23 24 25 26 27
OVERHAUL OPERATIONS
Disassembly (Fig. 17) 10. Separate the parts removed in Step 9 above. If inspec
tion shows the shaft to be defective, separate it from the
Clean the outside of the pum p in a Nontoxic Solvent rotor by removing the retainer snap ring. D iscard the
before disassembly. snap ring.
1. Remove the pulley retaining nut and remove the pulley 11. Remove the end plate and pressure plate "O" rings
using Tool J-2 1239-1. from the pum p housing and discard "O" rings.
2. Place the pum p in a vise and remove the union and "O" 12. Remove the dowel pins.
ring seal assembly. 13. Remove the flow control valve and spring assembly.
14. Pry the shaft seal out of the pump housing being careful
CAUTION: In clamping pump in vise, be careful not not to damage the housing bore, discard the shaft seal.
to exert excessive force on the pump front hub as
this may distort the shaft bushing.
Inspection
3. Remove the pum p reservoir retaining studs. Clean all metal parts in a nontoxic solvent and inspect as
4. Remove the reservoir from the pum p housing by tap follows:
ping lightly on the outer edge of the reservoir with a soft 1. Flow control valve m ust slide freely in housing bore. If
ham m er. Remove the "O" ring seal from the pump sticking is observed, check for dirt and burrs.
housing and discard seal. 2. Check cap screw in the end of the flow control valve for
5. Remove the m ounting stud square ring seals and the looseness; if loose, tighten, being careful not to damage
flow control valve square ring seal and discard. machined surfaces.
6 . On Corvette, remove filter and filter cage; discard filter 3. Be sure that pressure plate and pum p plate surfaces are
element. flat and parallel with pum p ring. Check all of these
7. Remove the end plate retaining ring. Compress the end parts for cracks and scoring.
plate retaining ring by inserting a small punch in the
1/8" diam eter hole in the pum p housing. W hen the ring NOTE: A high polish is always present on rotor pres
is in compressed position, remove with a screw driver sure plate and thrust plate as a result of normal
as shown in Figure 18. wear. Do not confuse this with scoring.
8 . Remove the end plate. The end plate is spring loaded
and will generally sit above the housing level. If sticking 4. M ake certain vanes were installed with rounded edge
should occur, a slight rocking action or light tapping tow ard pum p ring and see that they move freely in rotor
w ith a soft ham m er will free the plate. Remove the end slots.
plate spring. 5. If the flow control plunger is determ ined to be faulty,
9. W ith the pum p still in a vise, remove the shaft w oodruff install a new part. This part is serviced as a unit only
key and tap end of shaft gently with a soft ham m er until and is factory calibrated.
the shaft, pressure plate, pum p ring, rotor assembly and 6. Check drive shaft for worn splines, breaks, bushing
th ru st plate can be removed as a unit (fig. 19). material pickup, etc.
Fig. 18-R em oving End Plate Ring Fig. 1 9 -Im p e lle r U nit Removal
Fig. 2 3 ~ ln sta llin g Shaft Snap Ring Fig. 2 6— 1nsta 11i ng Vanes
7. Install the pum p ring onto the dowel pins with the
direction of rotation arrow to the rear of the housing
(fig. 25). Rotation is clockwise as viewed from the pul
ley end of the shaft.
8. Install the vanes into the rotor slots with the radius edge
tow ards the pum p ring and the square edge towards the
rotor as shown in Figures 26 and 27.
9. Lubricate the outside diam eter and cham fer of the pres
sure plate with Power Steering Fluid, to ensure against
damaging the pressure plate "O" ring, and install the
pressure plate onto the dowel pins with the ported face
towards the pump ring. Seat the pressure plate by plac
ing a large socket on top of the plate and pressing down
PUMP
ROTOR
PUMP
VANES
Fig. 2 5--I nsta 11i ng Pump Ring Fig. 2 7 -C o rre c t Vane Assem bly
Fig. 2 8 ~ ln sta llin g Pressure Plate Spring Fig. 3 0 — 1nsta 11ing Flow Control Valve
by hand (pressure plate will travel approxim ately 1/16" maging the "O" ring, and install into the housing using
to seat). an arbor press as shown in Figure 29.
10. Install the pressure plate spring in the center groove of
the pressure plate (fig. 28). NOTE: Place the end of the ring so that it is near the
11. Lubricate a new end plate "O" ring with Power Steering valve bore in the housing.
Fluid and install in housing groove.
12. Lubricate the outside diam eter and cham fer of the end 13. Install the flow control spring and flow control plunger.
plate w ith Power Steering Fluid, to ensure against da Be sure the hex head screw goes into the bore first (fig.
30).
14. On Corvette, install cage and a new filter.
VALVE BORE 15. Install new m ounting stud and union square ring seals.
INDEX
OVERHAUL OPERATIONS
NOTE: In the following te x t Power Steering Fluid is piston just forces end cover out of housing. Remove
noted for use in lubricating components upon reas cover and discard "O" ring.
sembly. If Power Steering Fluid is not available,
Transmission Fluid bearing the mark DEXRON may
be used as a substitute. CAUTION: DO NOT turn the stub shaft any further
than absolutely necessary to remove the end plug,
or balls from rack-piston and worm circuit may es
Disassembly (Fig. 31) cape and lay loose inside the rack-piston chamber.
In m any cases, complete disassembly of the gear will not 3. Remove the rack-piston end plug as shown in Figure
be necessary since most of the com ponents can be removed 33.
w ithout complete disassembly.
NOTE: To aid in loosening end plug, tap end plug
with a brass drift.
NOTE: Disassembly of the major components
within the gear must be performed on a clean work
bench. The work area, tools and parts must be kept 4. Remove the pitm an shaft and side cover as follows:
clean at all times. a. Loosen the over-center adjusting screw locknut and
remove the 4 side cover attaching bolts and lock
washers.
b. R otate the side cover until the rack-piston and pit
1. R otate end cover retainer ring so that one end of the
man shaft teeth are visible, then turn the stub shaft
ring is over the hole in the side of the housing. Force
until the pitm an shaft teeth are centered in the hous
the end of the ring from its groove and remove ring (fig.
ing opening. Tap the pitm an shaft with a soft ham
32).
m er and remove the pitm an shaft and side cover
from the housing. Remove the side cover "O" ring
2. T urn the stub shaft counter-clockwise until the rack- and discard.
INLET OUTLET
STUB SHAFT
•TORSION BAR
SEAL
Fig. 3 2 -R e m o vin g End Cover Retaining Ring Fig. 33~Removing End Plug
5. Remove the rack-piston as follows: b. Remove the rack-piston with Ball Retainer Tool
a. Insert Ball R etainer Tool J-7539 into the rack-pis J-7539 from gear housing.
ton bore with pilot of tool seated in the end of the
worm (fig. 35). T urn the stub shaft counter-clock 6. Remove the adjuster plug as follows:
wise while holding tool tightly against worm. The a. Loosen the adjuster plug locknut and remove.
rack-piston will be forced onto the tool. b. Remove adjuster plug assembly with Spanner
RETAINER
SEAL
s ■>;r*»*
.. ______ Li______
Fig. 39--Removing Bearing and Seal Fig. 4 1— Installing A d ju ste r Plug Seal
4. W ash all parts in clean solvent and dry parts with com drive the bearing into the adjuster plug until the tool
pressed air. bottom s in the housing (fig. 40).
5. Inspect thru st bearing spacer for wear or cracks. R e 2. Place dust seal and a new oil seal on Tool J-8524-1 (lip
place if damaged. of seal away from tool). Lubricate seal with Power
6. Inspect thrust bearing rollers and washers for wear, Steering Fluid and drive or press seals into adjuster plug
pitting or scoring. If any of these conditions exist, re until seated (fig. 41).
place the bearing and washers. 3. Install retaining ring with Internal Pliers J-4245.
Assem bly 4. Lubricate the thrust bearing assembly with Power
Steering Fluid. Place the large thrust bearing washer on
CAUTION: Place a block of wood under the adjuster the adjuster plug hub, then install the upper thrust
plug to protect the thrust bearing surface. bearing, small bearing washer and spacer (grooves of
spacer away from bearing washer).
1. If the needle bearing was removed, place new needle 5. Install a new bearing retainer on the adjuster plug by
bearing over Tool J-8524-1 and J-7079-2, with the bear carefully tapping on the flat surface of the retainer (fig.
ing m anufacturer’s identification tow ard the tool, and 42).
BEARING W ITH
ID E N TIFIC ATIO N
TO W ARD TO O L
Disassem bly
1. Remove and discard the "O" ring in the shaft cap end
of the valve assembly.
2. To remove the lower shaft assembly from the valve
body, proceed as follows:
a. W hile holding the assembly (stub shaft down),
lightly tap the stub shaft against the bench until t he
shaft cap is free from the valve body (fig. 43).
b. Pull the shaft assembly out of the spool valve until Fig. 44-R em oving Spool Valve
the shaft cap clears the valve body approximately
1/4".
3. If there is evidence of leakage between the torsion bar
and the stub shaft, or scores, nicks, or burrs on the
CAUTION: Do not pull the shaft assembly out too
ground surface of the stub shaft that cannot be cleaned
far or the spool valve may become cocked in the
up with crocus cloth, the entire valve and shaft assem
valve body.
bly m ust be replaced.
4. Check the outside diam eter of the spool valve and the
c. Carefully disengage the shaft pin from the valve
inside diam eter of the valve body for nicks, burrs, or
spool and remove the shaft assembly (fig. 43).
bad wear spots. If the irregularities cannot be cleaned
3. Push the spool valve out of the flush end of the valve
up by the use of crocus cloth, the complete valve and
body until the dam pener "O" ring is exposed, then
shaft assembly will have to be replaced.
carefully pull the spool from the valve body, while
5. If the small notch in the skirt of the valve body is
rotating the valve (fig. 44). If the spool valve becomes
excessively worn, the complete valve and shaft assem
cocked, carefully realign the spool valve, then remove.
bly will have to be replaced.
4. Remove the dam pener "O" ring from the spool valve 6. Lubricate the spool valve with Power Steering Fluid
and discard. and check the fit of the spool valve in the valve body
5. If the teflon oil rings are to be replaced, cut the 3 teflon (with the spool valve dam pener "O" ring removed). If
oil rings and "O" rings from the valve body and discard. the valve does not rotate freely w ithout binding, the
Cleaning and Inspection complete valve and shaft assembly will have to be re
placed.
1. W ash all parts in clean solvent and blow out all oil holes
with compressed air. Assem bly (Fig. 45)
2. If the drive pin in the stub shaft or valve body is
cracked, excessively worn or broken, replace the com 1. If valve body "O" rings and teflon rings were removed,
plete valve and shaft assembly. install new "O" rings in the oil ring grooves and lubri
cate with Power Steering Fluid.
2. Lubricate the 3 new teflon oil rings with Power Steering
Fluid and install in grooves over "O" rings.
" O " RING 3. Check the sealing and bearing surfaces of the pitm an
SPO O L VALVE shaft for roughness, nicks, etc. If m inor irregularities in
TEFLON RINGS (3) surface cannot be cleaned by use of crocus cloth, replace
" O ” RINGS (3) the pitm an shaft.
INSTALLED UNDER 4. Replace pitm an shaft assembly if teeth are damaged or
TEFLON RINGS if the bearing surfaces are pitted or scored.
5. Check pitm an shaft lash adjusting screw. It must be free
to turn with no perceptible end play. If adjusting screw
V ALVE BODY is loose replace the pitm an shaft assembly.
Rack-Piston
6. Align the notch in the shaft cap with the pin in the valve
body and press the spool valve and shaft assembly into Disassem bly
the valve body (fig. 46).
1. Remove tool J-7539 from the rack-piston.
CAUTION: Make sure that the shaft cap notch is 2. Remove the ball return guide clamp, ball guide and
mated with the valve body pin before installing balls.
valve body into the gear assembly. 3. If necessary to replace the teflon oil seal and "O" ring,
remove at this time.
7. Lubricate a new "O" ring with Pow er Steering Fluid
and install it in the shaft cap end of the valve body
Cleaning and Inspection
assembly.
1. W ash all parts in clean solvent and dry with com
pressed air.
Pitman Shaft and Side Cover 2. Inspect the worm and rack-piston grooves and all the
Disassem bly balls for scoring. If either the worm or rack-piston
needs replacing, both m ust be replaced as a matched
Remove the locknut and unscrew the side cover from the assembly.
adjusting screw. Do not attem pt to disassemble pitm an shaft. 3. Inspect ball return guide halves, making sure that the
D iscard locknut. ends where the balls enter and leave the guides are not
damaged.
4. Inspect lower thrust bearing and washers for scores or
Cleaning and Inspection
excessive wear. If any of these conditions are found,
1. W ash all parts in clean solvent and dry parts with com replace the thrust bearing and washers.
pressed air. 5. Inspect rack-piston teeth for scoring or excessive wear.
2. Check pitm an shaft bearing surface in the side cover for Inspect the external ground surfaces for wear, scoring
scoring. If badly worn or scored, replace the side cover. Or burrs.
N O T C H IN END C AP MU ST FULLY
E N G A G E PIN PR O JEC TIN G IN T O
VALVE BODY
BACK-UP
O -R IN G MUST
BE INSTALLED
RACK-PISTON
UNDER PISTON
NUT
R ING
Fig. 4 6 — 1nsta llin g S tub S ha ft Assem bly Fig. 4 7 --Installing Ring on Rack-Piston
Assem bly CAUTION: Do not tap the threads too deep in the
pressure hose connector seat as the tap will bottom
1. If the teflon oil seal and "O" ring were removed, lubri the poppet valve against the housing and damage it.
cate a new "O" ring and seal with Power Steering Fluid It is necessary to tap only two or three threads deep.
and install in groove on rack-piston. The teflon ring
may be slightly loose after assembly, but will tighten up 2. Thread a 5/16-18 bolt, with a nut and flat washer at
when subjected to the hot oil in the system (fig. 47). tached, into the tapped hole so that the washer rides
2. Slide the worm all the way into the rack-piston. It is not against the face of the port boss and the nut rides
necessary to have the thrust bearing assembly on the against the washer.
worm at this time. 3. Hold the bolt from rotating while turning the nut off
3. T urn the worm until the worm groove is aligned with the bolt. This will force the washer against the bolt boss
the lower ball return guide hole (fig. 48). and will back out the bolt, drawing the connector from
4. Lubricate the balls with Pow er Steering Fluid, then feed the housing. Discard the connector.
17 balls into the rack-piston, while slowly rotating the 4. Clean the housing thoroughly to remove any tapping
worm counter- clockwise. chips.
5. Drive the new connector against the housing seat using
IMPORTANT: The black balls are .0005" smaller Tool J-6217, being careful not to dam age either the
than the silver balls. The black and silver balls must connector or housing seat (fig. 49).
be installed alternately into the rack- piston and re
turn guide. Pitman Shaft Needle Bearing and Seals
5. A lternately install 7 balls into the return guide and Removal
retain with chassis lubricant at each end of guide. In
stall the return guide assembly onto the rack-piston. 1. If pitm an shaft seals ONLY are to be replaced, remove
Install the return guide clam p and tighten the 2 clamp the seal retaining ring with Internal Pliers J-4245 and
screws to 10 ft. lbs. remove outer steel washer. Pry out the outer seal.
6. Insert Bearing R etainer Tool J-7539 into the rack-pis Remove the inner steel washer, then pry out the inner
ton, then while holding tool tightly against end of seal (fig. 50). Discard seals.
worm, thread worm out of the rack-piston.
CAUTION: When prying out seals, be extremely
Hose Connector Inverted Flares careful not to score the housing bore.
If the brass inverted flare connectors show need of re 2. If pitm an shaft needle bearing replacement is necessary,
placement, proceed as follows: remove with Tool J-6278. Since this bearing is shoul
1. Tap threads into the center hole of the connector with dered, it must be pressed out the pitm an shaft end of the
a 5/16-18 tap. housing.
Installation
WORM
FLANGE 1. If the pitm an shaft needle bearing was removed, place
bearing Installer Tool J-22407 onto H andle J-8092.
Place needle bearing (shouldered end first) on to Tool
J-22407. Press bearing into gear housing until Tool bot
toms on housing. The bearing is now correctly posi
tioned (fig. 51).
INSTALL BALLS
WHILE ROTATING W O R M
COUNTER C LOCKW ISE
GUIDE
HALVES
WASHER
INNER OUTER
•# t ^ i SEAL SEAL
J-6278-1
- <
J-6278-2
TOP OF TOOL
FLUSH WITH
H O USIN G
Fig. 50--Pitman S haft Bearing and Seals Fig. 5 2--I nsta 11i ng Pitman S haft Seals (Bench Overhaul)
1. Housing 5. Oil Seal (Double Lip) c. Remove the tool and adapter, then install the outer
2. Bearing 6. Steel W asher steel washer and seal retaining ring. The retaining
3. Oil Seal 7. Retaining Ring ring will not seat in the groove at this time.
4. Steel W asher d. Reinsert Tool J-6278 with A daper J-6278-2 and
continue driving the seals until the retaining ring
seats in its groove (Refer to Inset, Figure 52), then
CAUTION: Do not drive the bearing further into the
remove the tool and adapter.
housing after removing Tool J-22407, since damage
to the bearing would result.
Removal and Installation of Pitman
2. Lubricate the lips of the oil seals with Power Steering
Fluid. Shaft Seals w ith Steering Gear in
3. Install the pitm an shaft oil seals as follows:
a. Place A dapter J-6278-2 over Tool J-6278, then in Vehicle (fig. 53)
stall the outer seal (double lip), inner steel washer,
and inner seal with the lips of the seals facing away If upon inspection of the gear, it is found that oil leakage
from the adapter. exists at the pitm an shaft seals, the seals may often be re
b. Drive the seals into the housing until the top of placed w ithout removing the gear assembly from the vehicle
A dapter J-6278-2 is flush with the housing (fig. 52). as follows:
DO NOT
BOTTOM BEARING
IN HO U SIN G
J-8092
J -6 2 1 9
Fig. 5 1-In s ta llin g Pitman Shaft Bearing Fig. 5 3--I n sta 11i n g Pitman Shaft Seals
“ O ” RING
NOTE: Only one layer of tape should be used; an
excessive amount of tape will not allow the seals to
pass over it, due to the close tolerance between the
seals and the pitman shaft.
LOWER THRUST
BEARING WASHERS
NOTE: The valve body is properly seated when the c. W ith Ball Retainer J-7539 in place in the rack-pis
oil return hole in the housing is entirely uncovered ton, push the rack-piston (with teeth tow ard pitm an
(fig. 57). shaft opening), into the housing until Tool J-7539
contacts the center of worm (fig. 59).
d. T urn the stub shaft clockwise with a 3/4" twelve
3. Lubricate a new adjuster plug "O" ring with Power point socket or box end wrench to thread the rack-
Steering Fluid and install in groove on adjuster plug. piston onto the worm while holding Tool J-7539
Place Seal Protector J-6222 over the stub shaft, then against the end of the worm.
install the adjuster plug assembly in the housing until e. W hen the rack-piston is completely threaded on the
it seats against the valve body (fig. 58). Remove Seal worm, remove Ball Retainer J-7539 and Seal Com
Protector. Do not adjust the thru st bearing preload at pressor J-8947 (Cars) or J-7576 (Trucks).
this time. 5. Install the pitm an shaft and side cover as follows:
a. Install a new "O" ring in the pitm an shaft side cover
and retain with chassis lubricant.
4. Install the rack-piston as follows: b. T urn the stub shaft until the rack-piston teeth are
a. Lubricate the rack-piston teflon seal with Power centered in the pitm an shaft opening, then install
Steering Fluid. the pitm an shaft and side cover so that the center
b. Position Seal Com pressor J-8947 (Passenger Cars) tooth of the pitm an shaft engages the center groove
J-7576 (Trucks) against the shoulder in the housing. of the rack-piston.
OVERHAUL OPERATIONS
Fig. 63-R e m o vin g Spool from Housing Fig. 65~Rem oving Plug-to-Sleeve Key
Disassem bly 9. Remove the adapter from the vise and invert, perm it
ting the spring and one of the two ball seats to fall free.
1. Place the valve in a vise as shown and remove dust
10. Remove the ball stud and the other ball seat and the
cover (fig. 61).
sleeve will fall free.
2. Remove adjusting nut (fig. 62).
3. Remove valve to adapter bolts and remove valve hous Inspection
ing and spool from adapter.
1. W ash all metal parts in nontoxic solvent and blow dry
4. Remove spool from the housing (fig. 63).
with compressed air.
5. Remove spring, reaction spool, washer reaction spring, 2. Inspect all parts for scratches, burrs, distortion, evi
spring retainer, and seal (fig. 64). "O" ring may now be dence of wear and replace all worn or damaged parts,
removed from the reaction spool. including mating parts when necessary.
6. Remove the annulus spacer valve shaft washer and plug 3. Replace all seals, gaskets, covers with approved service
to sleeve key (See Figure 65). parts.
7. Remove clam p by removing nut, bolt and spacer or, if
Repairs
crim ped type clamp is used, straighten clamp end and
pull clamp and seal off end of stud (fig. 66 ). NOTE: The Corvette valve incorporates a 55 lb. cen
tering spring. The Corvette valve incorporating this
8 . Carefully, so as not to nick the top surface, turn ad
spring is identified by an "X " stamped on the dust
juster plug out of sleeve (fig. 67).
cover.
Fig. 64-R em oving Valve Parts from Shaft Fig. 66--Seal w ith Clamp A ttachm ent
Fig. 6 7 -T u rn in g A d ju ste r Plug out of Sleeve Fig. 6 9 —1nsta11 ing Connector Seat
In case a connector seat becomes damaged, proceed as 2. Clam p the adapter in vise, put the shaft through the seat
follows: in the adjuster plug and screw adjuster plug in sleeve
To remove connector seat, tap threads in center hole using (fig. 70).
a 5/16- 18 tap. Thread a bolt with nut and flat washer a t
3. T urn the plug in until it is tight, then back it off until
tached into tapped hole so that the washer rides against the
the slot lines up with notches in the sleeve.
face of the port boss and the nut rides against the washer.
Hold the bolt from rotating while turning the nut off the bolt. 4. Install new seal and clamp over stud so lips on seal mate
This will force the washer against the port boss face and will with clamp. (A nut and bolt attachm ent type clamp
back out the bolt thus drawing the connector seat from the replaces the crimped type for service fig. 66 ).
top cover housing (fig. 68 ). D iscard the connector seat. Clean 5. Center the ball stud, seal and clamp at opening in
the housing out thoroughly to remove any tapping chips. adapter housing, then install spacer, bolt and nut.
Drive new connector seat against housing seat, using Tool
6. Insert the key, making sure that the small tangs on the
J 6217, being careful not to dam age either the connector seat
ends of the key fit into the notches in the sleeve (fig. 72).
or the housing seat (fig. 69).
7. Install the valve shaft washer, annulus spacer, and the
Assem bly (Fig. 71) reaction seal (lip up), spring retainer, reaction spring
1. Replace the sleeve and ball seat in the adapter, then the and spool, washer and adjustm ent spring. (Install "O"
ball stud, and finally the other ball seat and the spring, ring seal on reaction spool before installing spool on
small coil down. shaft.) Install the washer with the cham fer "up".
Fig. 68 -R em oving Connector Seat Fig. 70 -R e p la cin g A djuster Plug and Shaft
INDEX
OVERHAUL OPERATIONS
Disassem bly (Fig. 74) 6. Remove the "O" ring seal from the top lip of the power
cylinder ball stud opening.
1. To remove the piston rod seal, remove the snap ring; 7. If the ball seat is to be replaced, it m ust be pressed out
then pull out on rod, being careful not to spray oil. using Tool J-8937.
2. Remove the piston rod scraper and scraper element,
back up washer and piston rod seal from the rod.
Assem bly
3. A t the ball stud end of the cylinder, remove the ball
stud seal. 1. Reassemble the piston rod seal components by revers
4. Remove the snap ring retaining the end plug and lube ing the disassembly procedure. Apply power steering
fitting. fluid, or transmission fluid bearing the m ark DEX-
5. Push on the end of the ball stud and remove the end RO N , on the inner surfaces of the seal and scraper
plug, spring, spring seat and ball stud. before assembly.
2. Reverse the disassembly procedure when reassembling NOTE: Be sure to use new seals and"0"rings when
the ball stud. re-assembling cylinder.
3. In each case be sure th at the snap ring is securely seated
in the ring groove.
SPECIAL TOOLS
Fig. 75--M anual and Power Steering Special T ools-P assenger Car
20 21 23 24 25 26 28
PASSENGER CAR
HEATER
Amps RPM
V olts (Cold) (Cold)
Blower Motor................... 13.5 6.25 Max. 2550 Min.
2950 Max.
Fuses
Fuse B l o c k .................................................................... 25 Amp.
FRONT SUSPENSION
SECTION 3
BOLT TORQUES
Chevrolet C hevelle and Nova Camaro Corvette
Monte Carlo
B all Joint Stud Nut
Upper Stud *50 ft. lbs. *50 ft. lbs. *50 ft. lbs. *50 ft. lbs. *50 ft. lb s.
Lower Stud *90 ft. lbs. *90 ft. lbs. *90 ft. lbs. *90 ft. lbs. *90 ft. lbs.
Joint to Upper Arm
(Service Replacem ent) 25 ft. lb s. 25 ft. lb s. 25 ft. lbs. 25 ft. lb s. 25 ft. lbs.
Steering Arm Nuts - 70 ft. lbs. 70 ft. lb s. - 70 ft. lbs.
Control Arm P ivot to
Fram e
Upper 85 ft. lb s. 55 ft. lb s. 55 ft. lb s. 85 ft. lb s. 55 ft. lbs.
Lower 90 ft. lbs. 90 ft. lb s. 90 ft. lb s. 90 ft. lb s. See Below
Upper Control Arm Shaft
N u ts/B olts 60 ft. lbs. 40 ft. lbs. 40 ft. lbs. 60 ft. lb s. 60 ft. lbs.
Shock A bsorber
Upper End 100 in. lb. 100 in. lbs. 100 in. lbs. 100 in. lbs. 100 in. lb s.
Lower End 20 ft. lbs. 20 ft. lbs. 20 ft. lbs. 20 ft. lb s. 150 in. lb s.
Stabilizer Bar
Link Nuts 15 ft. lb s. 150 in. lbs. 20 ft. lb s. 150 in. lbs. 20 ft. lbs.
Bracket Bolts 24 ft. lbs. 24 ft. lbs. 24 ft. lbs. 24 ft. lb s. 120 in. lb s.
Lower Control Arm
Shaft to C ross m em ber
Front 70 ft. lbs.
Rear - — — — 95 ft. lbs.
Anchor Pin Drum 130 ft. lb s. 130 ft. lbs. - -
-
Brakes
Mounting Bolts D isc 35 ft. lb s. 35 ft. lbs. 35 ft. lbs. 35 ft. lb s. 120 ft. lb s.
Brake Caliper
Wheel Stud Nuts 70 ft. lb s. 70 ft. lb s. 70 ft. lb s. 70 ft. lb s. 75 ft. lb s.
Wheel Bearing Adjustm ent 12 ft. lb s. 12 ft. lbs. 12 ft. lbs. 12 ft. lbs. 12 ft. lbs.
Preload Zero Zero Zero Zero Zero
End Movement .001 to .008 .001 to .008 .001 to .008 .001 to .008 .001 to .008
* P lu s additional torque to align cotter pin hole. NEVER back off to align cotter pin.
C a m b e r ..................................................................................................................................... ± 3 /4 ° ± 1 /2 °
C a s t e r ........................................................................................................................................ ± 1° ± 1/2°
T oe-in ..................................................................................................................................... ± 1/8" ± 1/16"
Camber (Side to S i d e ) ...................................................................................................... 1° 1 /2 °
C aster (Side to S id e ) .......................................................................................................... 1° 1 /2 °
Specification For
Specification For
Diagnosis for W arranty Specifications For
Periodic Motor
Repair or Customer Resetting Alignment
Vehicle Inspection
Paid Service
CHEVROLET
(except 116" W .B. Wagon)
Caster *- 2 ° to 0 ° -3° to +1° @ -1 ° ± 1/ 2°
Camber * 0 ° to + 1 ° -1 ° to +2 ° @ + 1/ 2 ° ± 1/ 2 °
Toe-In (total) 1/16" to 5/16" 1/ 2 " toe-in to 1/4 " toe-out $ 1/8" to 1/4"
S.A.I. 10 ° ± 1/ 2 °
NOVA
Caster *- 1/ 2 ° to + 1 -1/ 2 ° -1 -1/ 2 ° to +2 -1/ 2 ° @ + 1/ 2 ° ± 1/ 2 °
Camber *- 1/ 2 ° to + 1 ° -1-1/4° to +1-3/4° @ +1/4° ± 1/2°
Toe-in (total) 1/16" to 5/16" 1/ 2 " toe-in to 1/4" toe-out $ 1/8" to 1/4"
S.A.I. 8-3/4° ± 1/2°
CAMARO (standard)
Caster *- 1 ° to + 1 ° -2 ° to +2 ° @ 0 ° ± 1/ 2 °
Camber *+1/4° to +1-3/4° -1/ 2 ° to +2 -1/ 2 ° @ +1 ° ± 1/ 2 °
Toe-in (total) 1/16" to 5/16" 1/ 2 " toe-in to 1/4" toe-out $ 1/8 " to 1/4"
S.A.I. 9-1/2° ± 1/2°
Z-28
Caster *-2 ° to 0 ° -3° to +1° @ -1 ° ± 1/ 2 °
Camber * 0 ° to + 1 -1/ 2 ° -3/4° to +2-1/4° @ +3/4° ± 1/2°
Toe-in (total) 1/16" to 5/16" 1/ 2 " toe-in to 1/4" toe-out $ 1/8" to 1/4"
S.A.I. 9-3/4° ± 1/2°
CORVETTE
Caster-Manual strg. * 0 ° to +2 ° -1° to +3° @ + 1 ° ± 1/ 2 °
Caster-Power strg. *+1-1/4° to +3-1/4° + 1/4° to ±4-1/4° @ +2-1/4° ± 1/2°
Front Camber * 0 ° to + 1 -1/ 2 ° -3/4° to +2-1/4° @ +3/4° ± 1/2°
Front toe-in (total) 3/16" to 5/16" 5/8" toe-in to 1/ 8" toe-out $ 3/16" to 5/16"
S.A.I. 7° ± 1/2°
R ear Camber -7/8° ± 1/4°
Rear toe-in (per wheel) $ 1/16" ± 1/32"
TRIM HEIGHTS
The following procedure should be followed before NOTE: Follow the same pattern as stated above
making any trim height measurement. for the “ Z ” dimension when measuring the “ D "
1. “ Z ” Dimension dimension except: lift and push on the rear
a. Lift vehicle up approximately 1-1/2" at the front bumper.
bumper and gently remove hands allowing vehicle 3. “ J ” & “ K” Dimensions
to settle on its own. Repeat this lifting operation a. Jostle the front of the car up and down three
three tim es. Measure the “ Z ” height in the set tim es by lifting the vehicle up approximately
tled position after the third lift. 1-1/ 2" at the front bumper and im mediately push
b. Push vehicle down approximately 1-1/2" at the vehicle down approximately 3" from the raised
front bumper and gently remove hands allowing position, raising up 3" and repeating the cycle
vehicle to settle on its own. Repeat this pushing three tim es.
down operation three tim es. Measure the “ Z ” b. Jostle the rear of the car three times by applying
height in the settled position after the third push the same procedure to the rear bumper as used
down. on the front in (3 a.).
c. The true " Z " height is the average of (a) and (b) c. Repeat the jostling of front a second time.
for each side. d. Measure the “ J ” and “ K ” dimensions in the set
2. “ D ” Dimension tled position.
Z J K D
CHEVROLET MODELS
Coupes - Sedans and F-78 9.62 9.57
Convertibles with V -8 G-78 3.13 9.78 9.91 6.24
Engines (Exc. 116” W .B. Wag.) H-78 10.06 10.03
CHEVELLE MODELS
E-78 9.98 9.96
Sedan 2.10 5.07
F-78 10.20 10.20
E-78 10.06 9.79
Coupe and Convertible 2.30 4.80
F-78 10.27 9.97
CH EVELLE MODELS
w/F-40 Suspension
E-78 9.95 10.18
Sedan 1.94 5.40
F-78 10.17 10.42
Z J K D
Tires
Curb Curb Curb Curb
CAMARO MODELS
Base A ll 1.82 5.83 8.07 7.63
Z-28 A ll 2.69 6.97 9.16 8.84
NOVA MODELS
A ll Except "SS" A ll 9.70 9.69
2.18 5.55
"SS" A ll 9.38 9.39
CORVETTE MODELS
Coupe w/C-60 2.29 7.79 7.77 1.99
A ll
w o/C -60 2.65 8.16 8.03 2.18
CENTER O F LOW ER B O TT O M
C O N TR O L A R M BOLT END OF FRAME
REAR SUSPENSION
SECTION 4
Chevrolet Chevelle
Except Monte Carlo
Chevy Nova Cam aro Corvette
116" W.B. and 116" W.B.
Station Wagon Station Wagon
Upper Control A rm
Front Bushing Nut 115 80
Rear Bushing Nut 80 80
Lower Control A rm
Front Bushing 115 80 50
R ear Bushing 115 80
Shock Absorber
Upper 12 12 18 18 50
Lower 65 65 45* 8 35
Leaf Spring
Front Eye Bolt Nut 80 75 75
R ear Shackle Bolt Nut 115 50 50
Leaf Spring Front Mounting
Bracket 30 30
Leaf Spring Retainer
(Anchor Plate) 40 40 40 70
RIDING HEIGHTS
See "Riding Heights" in Front Suspension Specification Section.
BRAKES
SECTION 5
TORQUE SPECIFICATIONS
Chevelle
Chevrolet and 116"
and 125" W.B. Wagons Camaro Nova Corvette
W.B. Wagons and Monte
Carlo
Main Cylinder to D ash ............................................. 24 ft. lbs. 24 ft. lbs. 24 ft. lbs. 24 ft. lbs. 24 ft. lbs.
Main Cylinder to B o o s te r ...................................... 24 ft. lbs. 24 ft. lbs. 24 ft. lbs. 24 ft. lbs. 24 ft. lbs.
Vacuum Cylinder to D a s h ...................................... 25 ft. lbs. 25 in. lbs. 25 ft. lbs. 25 ft. lbs. 22 ft. lbs.
Push Rod to C l e v i s ................................................. 14 in. lbs. — 14 ft. lbs. 14 ft. lbs.
P rim ary Brake Pipe N u t ...................................... 150 in. lbs. 150 in. lbs. 150 in. lbs. 150 in. lbs. 150 in. lbs.
Secondary Brake Pipe N u t...................................... 150 in. lbs. 150 in. lbs. 150 in. lbs. 150 in. lbs. 150 in. lbs.
Brake Line to Fram e S c r e w ............................... 100 in. lbs. 100 ft. lbs. 100 in. lbs. 100 in. lbs. 100 in. lbs.
Brake Shoe Anchor P i n .......................................... 120 ft. lbs. 120 ft. lbs. 120 ft. lbs. 120 ft. lbs. __
Wheel Cylinder to Backing P l a t e ........................ 50 in. lbs. 50 in. lbs. 50 in. lbs. 50 in. lbs. —
Parking Brake E q u a l i z e r ...................................... 60 in. lbs. 90 in. lbs. 90 in. lbs. 90 in. lbs. 70 ill. lbs.
Parking Brake Assem bly A tta ch m e nt................. 150 in. lbs. 100 in. lbs. 100 in. lbs. 100 in. lbs. 100 in. lbs.
Flex Hose to Wheel C y l in d e r ............................... 22 ft. lbs. — 22 ft. lbs. __
Tubing to Flex H o s e ................................................. 120 in. lbs. 120 in. lbs. 120 in. lbs. 120 in. lbs. 120 in. lbs.
Caliper Mounting B o l t ............................................. 35 ft. lbs. 35 ft. lbs. 35 ft. lbs. 35 ft. lbs. 70 ft. lbs.
C aliper Housing B o l t ............................................. — — — — 130 ft. lbs.
Flex Hose to C a l i p e r ............................................. 22 ft. lbs. 22 ft. lbs. 22 ft. lbs. 22 ft. lbs. 22 ft. lbs.
Support Plate to Steering Knuckle (Upper Bolt) 140 in. lbs. 140 ft. lbs. 140 in. lbs. 140 ft. lbs. —
Shield to Steering Knuckle Nuts (Hold Bolt) . . 70 ft. lbs. — 70 ft. lbs. __
Shield to Steering Knuckle Bolt (Hold Nut) . . 95 ft. lbs. — 95 ft. lbs. __
Combination Valve M ou nting................................... 150 ft. lbs. 100 in. lbs. 150 in. lbs. 150 in. lbs. -
ENGINE
SECTION 6
GENERAL DATA:
In Line V-8
TyPe
Displacement (cu. in.) 250 307 350 TOO" ~m r
145 200 245 270 330 255 300 365 425
Horsepower @ rpm @ @ @ @ @ @
4200 4600 4800 4800 5600 4400 4800 4800 5600
230 300 350 360 360 390 400 465 475
Torque @ rpm @ @ @ @ @ @ @ @ @
1600 2400 2800 3200 4000 2400 3200 3200 4000
Bore 3 7/8 4 1/8 4 1/4
Stroke 3.53 3.25 3.48 3.75 3.76
Compression Ratio 8.5:1 9.0:1 8.5:1 9.0:1
Firing Order 1-5-3-6-2-4 f 1-8-4-3-6-5-7-2
CYLINDER BORE:
Diameter 3.8745-3.8775 3.9995-4.0025 4.1246-4.1274 4.2495-4.2525
Out of Production .0005 Max. .001 Max.
Round Service .002 Max.
Thrust
.0005 Max.
Produc Side
Taper tion Relief .001 Max.
.0005 Max.
Side
Service .005 Max.
PISTON:
.0005 .0005 .0036 .0014 .0018 .0024 .0040
Production .0007-.0013
Clearance .0015 .0011 .0042 .0020 .0026 .0034 .0050
.0034 .0035 .0049 .0065
Service .0025 Max. .0027 Max. .0061 Max.
Max. Max. Max. Max.
PISTON RING:
Clear Produc Top .0012-.0027 . 001 2 - .0012-.0032 .0012-.0027
.0017-.0032
ance tion 2nd .0012-.0032 .0032 .0012-.0027 .0012-.0032
Groove Service Hi Limit Production + .001
.010
Top . 0 10-.020 .010-.020 . 010-.020
Produc .020
Gap tion .013
2nd . 010-.020 .013-.025 .010-.020
.023
Service Hi Limit Production + .01
Groove Production .005 Max. |.002-.007l~ .005 Max. .0005-.0065
Clearance Service Hi Limit Production + .001
Production .015-.055
Gap
Service Hi Limit Production + .01
PISTON PIN:
Diameter .9270-.9273 .9895-.9898
.00045 .00015
Production .00015-.00025 .00025-.00035
Clearance .00025
.00055
Service .001 Max.
Fit in Rod .0008-. 0016 Interference
CRANKSHAFT:
Auto. Man. #1-2 #1
#i #l-2-3-4 2.7487 2.7485
#l-2-3-4 #l-2-3-4
2.7475 2.7481
2.6484 2.7481
#l-2-3-4 2.7496 2.7494
2.4484-2.4493 2.7484 2.7490 #3-4 #2-3-4
All 2.6493 2.7490
#2-3-4 #5 2.7481 2.7481
2.2983
Diameter 2.7481 2.7473
2.7490 2.7490
2.2993 #5 #5
2.7490 2.7483 #5 #5
Main #5 2.6479 2.7478
#5 2.7473 2.7478
Journal 2.4479-2.4488
2.7473
2.6488 2.7488
2.7483 2.7488
2.7483
Produc
.0002 Max.
Taper tion
Service .001 Max.
Produc .0002 Max.
Out of
tion
Round .001 Max.
Service
ENGINE TUNE UP
E Type L -6 V8
N
G Displacement 250 307 350 400 402 454
I
N
E Horsepower 145 200 245 270 330 255 300 365 425
K 0 Gap .035"
Idle Synchro. 550 600 600 600 700 600 600 600 700
rpm
© Auto. 500 550 550 550 700 550 600 600 700
3 1/2 to 5 to
Fuel Pressure 7 to 8 1/2 @ 3600 rpm
4 1/2 6 1/2
Pump
Volume One Pint in 30-45 Seconds @ Cranking Speed
©
Crankcase Vent Replace at 24,000 Miles
ENGINE TORQUES
------------------------
In Line Sm all V -8 Mark IV-V -8
Size Usage
250 307 350 402 454
CARBURETOR
SECTION 6 M
IDENTIFICATION
Also refer to Rochester and Holley Carburetor Identification Illustrations in the 1971 Overhaul Shop Manual.
B arrel
D isplace
(Bbl.)
Chevrolet
RPO
Corvette
Chevelle
Option and
Type
Monte
Type
Nova
ADJUSTMENTS
Rochester Carburetors
M NUMBER
O Fast
(A) Automatic Float Float Metering Pump Choke A ir Valve Vacuum
D Idle Unloader
Trans. Level Drop Rod Rod (Bench) Rod Dashpot Break
E
L (M) Manual Trar LS.
MV 7041014 (A) 1/4 - .080 _ .100 .160 - .200 .350
MV 7041017 (M) 1/4 - .080 - .100 .180 - .230 .350
MV 7041023 (M) 1/16 - - - .110 .120 - .200 .350
2GV 7041024 (A) 1/16 - - - .110 .080 - .140 .350
2GV 7041101 (M) 13/16 1 3/4 - 1 3/64 - .075 - .110 .215
2GV 7041110 (A) 13/16 1 3/4 - 1 3/64 - .040 - .080 .215
2GV 7041102 (A) 25/32 1 3/8 - 1 5/32 - .100 - .170 .325
2GV 7041114 (A) 25/32 1 3/8 - 1 5/32 - .100 - .170 .325
2GV 7041113 (M) 23/32 1 3/8 - 1 5/32 - .100 - .180 .325
2GV 7041127 (M) 23/32 1 3/8 - 1 5/32 - .100 - .180 .325
2GV 7041117 (M) 23/32 1 3/8 - 1 5/32 - .100 - .170 .325
2GV 7041118 (A) 23/32 1 3/8 _ 1 5/32 - .100 - .170 .325
2GV 7041181 (M) 5/8 1 3/4 - 1 3/8 - .080 - .120 .180
2GV 7041182 (A) 5/8 1 3/4 _ 1 3/8 - .080 - .120 .180
4MV 7041200 (A) 1/4 _ _ - .100 .020 .260 -
Holley Carburetors
FLOAT LEV EL
(Bowl Inverted)
P rim ary Float Centered in Bowl.
Secondary Float Centered in Bowl.
WET FUEL LE V EL
(On Engine)
P rim ary Fuel Level with Bottom of Sight Plug Hole.
Secondary Fuel Level with Bottom of Sight Plug Hole.
FAST ID LE
Mechanical (Hi-Step) .025 .025 .025 .025
Running (R .P.M .) (Hi-Step) 2200 2200 2200 2200
MAIN M ETERING JE T
P rim ary #70 #70 #70 #70
Secondary #76 #76 #76 #76
THROTTLE BORE
P rim ary 1 11/16" 1 11/16" 1 11/16” 1 11/16”
Secondary 1 11/16” 1 11/16” 1 11/16” 1 11/16”
OTHER ADJUSTMENTS
Initial Idle Speed Final Idle Speed % "C O " CEC Valve Engine Speed
Transm ission Engine
(RPM) (RPM) @ Idle **(RPM )
* These engines incorporate A .I.R . and do not have "M ixture Screw L im ite r" caps. Idle adjustment is 1/4 turn
rich from lean ro ll on mixture screws (See Tune-Up Sticker).
** CAUTION: If the C .E .C . Valve (solenoid) on the carburetor is used to set engine idle or is adjusted out of
lim its specified in the Service Manual, decrease in engine braking may result."
ENGINE ELECTRICAL
SECTION 6Y
BATTERIES
GENERATORS
VOLTAGE REGULATOR
Field Relay Voltage Regulator
Model
Application Voltage
No. A ir Gap Point Opening Closing Voltage A ir Gap Point Opening Setting
STARTING MOTOR
DISTRIBUTORS
C-4797 C-3990
250 Cu. In. L -6 1110489 0 @ 930 R PM 0 @ 8" Hg 31° - 34° 4° @ 500 R PM Manual AC-46TS
(145 HP) Nova, 2° @ 1270 R PM 23° @ 16” Hg
Chevelle and 14° @ 2300 R PM
Chevrolet 24° @ 4100 R PM 4° @ 550 RPM Automatic
C-4815 C-3954
307 Cu. In. V -8 1112039 0 @ 680 R PM 0 @ 8” Hg 29° - 31° 8 ° @ 550 R PM Automatic AC-R45TS
(200 HP) Nova, 2° @ 1320 R PM 20° @ 17” Hg
Chevelle and 20° @ 4200 R PM
Cam aro
C-4753 C-3954
307 Cu. In. V -8 1112005 0 @ 800 R PM 0 @ 8” Hg 29° - 31° 4° @ 600 R PM Manual AC-R45TS
(200 HP) Nova, 2° @ 1200 R PM 20° @ 17” Hg
Chevelle and 12° @ 2200 R PM
Cam aro 24° @ 4300 R PM
C-4816 C-3954
350 Cu. In. V -8 1112042 0 @ 880 R PM 0 @ 8” Hg 29° - 31° 2° @ 600 R PM Manual AC-R45TS
(250 HP) Base and 2° @ 1120 RPM 20° @ 17” Hg
R PO L-65 Chevrolet, 10° @ 1600 R PM
Chevelle, Nova, 15° @ 2200 R PM
Cam aro and Monte 28° @ 4300 R PM
Carlo
C-4573 C-3954
350 Cu. In. V -8 1112005 0 @ 800 R PM 0 @ 8” Hg 29° - 31° 6 ° @ 550 RPM Automatic AC-R45TS
(250 HP) Base and .2° @ 1200 R PM 20° @ 17” Hg
R PO L-65 Chevrolet, 12° @ 2200 R PM
Chevelle, Nova, 24° @ 4300 R PM
Cam aro and Monte
Carlo
C-4817 C-3036
350 Cu. In. V -8 1112044 0 @ 840 RPM- 0 @ 8” Hg 29° - 31° 4° @ 600 R PM Manual AC-R44TS
RPO L-48 Chevelle 2° @ 1160 R PM 15° @15.5”Hg
and Monte Carlo 10° @ 1800 R PM
15° @ 2400 R PM
22° @ 4200 R PM
C-4818 C-3036
350 Cu. In. V -8 1112045 0 @ 865 R PM 0 @ 8” Hg 29° - 31° 8 ° @ 550 RPM Automatic AC-R45TS
R PO L-48 Chevelle, 2° @ 1335 R PM 15° @15.5”Hg
Camaro, Nova and 11° @ 2400 R PM
Monte C arlo 18° @ 4200 R PM
DISTRIBUTORS (CONT’D)
C-4827 C-3036
350 Cu. In. V -8 1112049 0 @ 1070 RPM 0 @ 8” Hg 29° - 31° 8 ° @ 700 R PM Manual AC-R44TS
RPO Z28. 2° @ 1330 R PM 15° @15.5"Hg
Camaro 16° @ 2250 R PM
24° @ 5000 R PM
C-4844 C-3036
350 Cu. In. V -8 1112074 0 @ 1034 R PM 0 @ 8” Hg 29° - 31° 12° @ 700 R PM Automatic AC-R44TS
R PO Z28 2° @ 1366 RPM 15° @15.5"Hg
12° @ 2200 RPM
20° @ 5000 R PM
C-4829 C-3993
400 Cu. In. V -8 1112056 0 @ 930 RPM 0 @ 10” Hg 29° - 31° 8 ° @ 550 R PM Automatic AC-R44TS
RPO L F -6 2° @ 1270 R PM 18° @ 17” Hg
Chevrolet 14° @ 2300 R PM
24° @ 4500 R PM
C-4830 C-3954
402 Cu. In. V -8 1112057 0 @ 930 RPM 0 @ 8” Hg 29° - 31° 8 ° @ 600 R PM A ll AC-R44TS
RPO LS-3 2° @ 1260 RPM 20° @ 17” Hg
Chevrolet, Chevelle, 16° @ 2400 R PM
Monte C arlo and 30° @ 4400 R PM
Camaro
C-4823 C-3954
454 Cu. In. V- 8, 1112052 0 @ 857 R PM 0 @ 8” Hg 29° - 31° 8 ° @ 600 R PM A ll AC-R43TS
RPO LS-5. 2° @ 1143 R PM 20° @ 17” Hg
Chevrolet, Chevelle 14° @ 2000 R PM
and Monte C arlo 22° @ 3900 R PM
C-4831 C-3955
454 Cu. In. V- 8, 1112054 0 @ 1090 RPM 0 @ 7” Hg 29° - 31° 12° @ 700 R PM Automatic AC-R43TS
R PO LS- 6. 2° @ 1310 RPM 12° @ 12” Hg
Chevelle and 21° @ 2350 R PM
Monte Carlo 28° @ 5000 R PM
C-4845 C-3955
454 Cu. In. V- 8, 1112075 0 @ 1300 RPM 0 @ 7” Hg 29° - 31° 8 ° @ 700 R PM Manual AC-R43TS
RPO LS-6. 5° @ 1500 RPM 12° @ 12” Hg
Chevelle and 12° @ 2400 RPM
Monte Carlo 16° @ 5000 R PM
DISTRIBUTORS (CONT’D)
C-4818 C-3036
350 Cu. In. V- 8, 1112050 0 @ 865 RPM 0 @ 8” Hg 29° - 31° 4° @ 600 R PM Manual AC-R44TS
Base Corvette 2° @ 1335 R PM 12° @15.5"Hg
(RPO L-48) 11° @ 2400 R PM
18° @ 4200 R PM 8 ° @ 550 R PM Automatic
C-4842 C-3036
350 Cu. In. V- 8, 1112038 0 @ 1060 R PM 0 @ 8" Hg -- 8 ° @ 700 R PM Manual AC-R44TS
RPO LT-1 (T ransis 2° @ 1340 R PM 15° @15.5"Hg
Corvette tor Ign.) 17° @ 2400 R PM
24° @ 4800 R PM 12° @ 700 R PM Automatic
C-4823 C-3954
454 Cu. In. V- 8, 1112051 0 @ 857 R PM 0 @ 8" Hg 29° - 31° 8 ° @ 600 R PM A ll AC-R43TS
R PO LS-5 2° @ 1143 R PM 20° @ 17" Hg
Corvette 14° @ 2000 R PM
22° @ 3900 R PM
C-4846 C-3955
454 Cu. In. V- 8, 1112076 0 @1100 R PM 0 @ 7" Hg - - 8 ° @ 700 R PM Manual AC-R43TS
RPO LS- 6, (T ran sis 3° @ 1300 R PM 12° @ 12" Hg
Corvette tor Ign.) 10.8°@1590 R PM
25° @ 2350 R PM
32° @ 5000 RPM
C-4843 C-3955
454 Cu. In. V- 8, 1112053 0 @ 1090 R PM 0 @ 7" Hg - - 12° @ 700 R PM Automatic AC-R43TS
RPO LS -6 (T ransis 2° @ 1310 R PM 12° @ 12" Hg
Corvette tor Ign.) 22° @ 2400 R PM
28° @ 5450 R PM
IGNITION COIL
SECTION 7
TURBO HYDRA-MATIC—350
TURBO HIYDRA-MATIC—400
STEERING
SECTION 9
STANDARD STEERING
Except “ SS”
A ll A ll Road Fast
“ SS” Models
Steering
Ratio Gear 24:1 24:1 24:1 24:1 16:1 16:1
Gear
O verall 30.7:1 28.7:1 27.3:1 21.4:1 20. 2:1 17.6:1
Type P a ra lle l Relay Rod
Linkage Location Rear Front Rear
Tie Rods 2
POWER STEERING-GEAR
16:1 19.3:1
Chevrolet - - - - to to - -
12.4:1 15.5:1
16:1 18.6:1
Chevelle & to
- - - - to - -
Monte Carlo 14.5:1
12.4:1
125” W.B.
17.5:1 21. 2:1 - - - - - -
Sta. Wgn.
116" W.B.
17.5:1 21. 6:1 - - - - - -
Sta. Wgn.
16:1 18.9:1 16:1 14.25:1
Nova - - - - to to to to
12.4:1 14.7:1 12.4:1 11:1
Corvette - - 16:1 17.6:1 - - - -
*On Center
Chevrolet, Chevelle, Station Wagon, Monte Carlo, Cam aro and Nova
Ball Drag 3 In. Lb. Max.
Thrust Bearing Preload 1 / 2 - 2 In. Lb. in excess of valve assy, drag
Over Center Preload 3 - 6 In. Lb. in excess of above
Total Steering Gear Preload 14 In. Lb. Max.
Corvette
W orm Bearing Preload 4 to 7 In. Lb.
Sector Lash Adjustment 4 to 10 In. Lb. excess of above
Total Steering Gear Preload 14 In. Lb. Max.
TORQUE CHART
Steering Gear Mounting Bolts 70 ft. lb. 70 ft. lb. 68 ft. lb. 70 ft. lb. 70 ft. lb.
Pitm an Shaft Nut 180 ft. lb. 140 ft. lb. 180 ft. lb.
Pitm an A rm to Relay Rod
50 ft. lb.*
Stud Nut
Idler A rm to Relay Rod
50 ft. lb.*
Stud Nut
Idler A rm to Fram e Nuts 45 ft. lb. | 35 ft. lb.
Tie Rod End Stud Nuts 35 ft. lb.**
Tie Rod Clam p Nuts 22 ft. lb. | 150 in. lb. | 22 ft. lb.
Steering Coupling to Shaft
20 ft. lb.
Flange Nuts
Steering Coupling Clam p Bolts 30 ft. lb.
Steering Wheel Nut 30 ft. lb.
Steering Wheel to Hub
Screws (Corvette and 25 in. lb. 25 in. lb. - 25 in. lb. 25 in. lb.
Cushioned R im Wheels)
Floor Pan Cover Screws 35 in. lb.
Floor Pan Cover Clamp
35 in. lb.
Screws
Floor Pan Bracket Nuts — — — 120 in. lb. -
Dash Panel Bracket to
15 ft. lb. 15 ft. lb. 15 ft. lb. - 15 ft. lb.
Column Screws
Dash Panel Bracket to
20 ft. lb. 20 ft. lb. 20 ft. lb. 15 ft. lb. 20 ft. lb.
Dash Nuts
Ignition Switch Screws 35 in. lb.
Turn Signal Switch Screws 35 in. lb.
Column Lock Plate Cover
20 in. lb.
Screws
Turn Signal Housing Screws 45 in. lb.
Lock Bolt Spring Screw
35 in. lb. 35 in. lb. - 35 in. lb.
(Tilt a Tilt-Telescope)
Bearing Housing Support
60 in. lb. 60 in. lb. - 60 in. lb.
Screws (Tilt & Tilt^Tele)
Trans. Control Lock Tube
Hsg. Ext. Screws - - - 40 in. lb. -
(Tilt-Telescope)
Power Steering Pump
58 ft. lb.
Pulley Nut
Power Steering Pump
20 ft. lb.
Mounting Bolts
Power Steering Pump
25 ft. lb.
Mounting Stud Nut
Power Steering Pump Return
26 in. lb. 26 in. lb. 26 in. lb. 15 in. lb. 26 in. lb.
Hose Clam p Screw
Power Steering Pum p &
25 ft. lb.
Gear Hose Fittings
Power Cylinder to Relay
- - — 45 ft. lb .* -
Rod Nut
Power Cylinder to Frame
- - - 23 ft. lb .* -
Bracket
Power Cylinder Fram e
- - - 17 ft. lb. -
Bracket to Fram e Nuts
Control Valve to Pitm an
- - - 45 ft. lb .* -
A rm
Control Valve Clam p Bolt - - - 25 ft. lb. —
* Plus additional torque required to align castellation with cotter pin hole in stud (not to exceed 60 ft. lb. maximum)
** Plus additional torque required to align castellation with cotter pin hole in stud (not to exceed 50 ft. lb. maximum)
★ Plus additional torque required to align castellation with cotter pin hole.
350 V -8 (4 bbl.) A ll
400 V -8 (2 bbl.) Biscayne and Bel A ir
H78 x 15;
Base V -8 G78 x 15
White Stripe
350 V -8 (4 bbl.) Im pala
400 V -8 (2 bbl.) Caprice
402 V -8
A ll H78 x 15
454 V -8
Chevelle
L -6 Sedans, Coupes, Convertible E78 x 14 F78 x 14; White Stripe
E78 x 14
Except SS Models E78 x 14; or F78 x 14; White Stripe
F78 x 14
V -8
F60 x 15
SS Models
White Letters
E78 x 14
E l Camino Except
A ll or E78 x 14; or F78 x 14; White Stripe
SS Models
F78 x 14
F60 x 14
SS Models
White Letters
Camaro
Engine and Body Style Standard Optional
F70 x 14
A ll E78 x 14 White Stripe or
White Letters
F70 x 14
SS Models
White Letters
F60 x 15
Z-28
White Letters
Monte Carlo
A ll A ll Exc. SS 454 G78 x 15
G70 x 15 White Stripe
SS454 G70 x 15
Nova
A ll except SS Models E78 x 14 E70 x 14 White Stripe
A ll
E70 x 14
SS Models -
White Stripe
Standard and Optional Tires are Load Range B unless otherwise specified.
Tire inflation pressure may increase as much as 6 pounds per square inch (psi) when hot. For continuous high
speed operation (over 75 mph) increase tire inflation pressure 4 pounds per square inch over the recommended
pressures up to a maximum of 32 pounds per square inch cold for load range B tires. Sustained speeds above
75 mph are not recommended when the 4 pounds per square inch adjustment would require pressures great than the
m axim um stated above.
Cold tire inflation pressure: after vehicle has been inoperative for 3 hours or more, or driven less than 1 m ile.
Hot tire inflation pressure: after vehicle has been driven 10 m iles at speeds of more than 60 m iles per hour.
Station wagon loads should be distributed as far forward as possible. Vehicles with luggage racks do not have a
vehicle load lim it greater than specified. When towing tra ile rs, the allowable passenger and cargo load must be
reduced by an amount equal to the tra ile r tongue load on the tra ile r hitch.
CANDLE
BULB
LAM P USAGE POW ER
NUMBER
(OR WATTS)
Headlamp Unit
Chevrolet, & Corvette
37 1/2 Watts
4002
55 Watts
37 1/2 Watts 4001
Nova, Camaro, Monte Carlo, Chevelle
60 Watts
6014
50 Watts
3-32 1157NA
3-32 1157
32 1156
Instrum ent Illum ination Lamps
2 194
2 1895
3 168
Console Instrum ent Cluster (N o v a )............................................................................ 2.5 1816
2 194
2 194
2 194
Hi-Beam Indicator
2 194
2 1895
Directional Indicator
2 194
2 1895
Cigar Lighter Lamp
1 1445
Warning Lamps
Corvette - Door A j a r .................................................................................................... 2 1895
Headlamps U p ............................................................................................. 2 1895
Seat B e l t s .................................................................................................... 2 194
Chevrolet - Low F u e l .................................................................................................... 2 194
2 194
Seat B e l t .................................................................................................... 2 194
Nova - Low Fuel ............................................................................ .............................. 2 194
Heater or A /C Control Panel
Chevelle, Monte C arlo, Cam aro ................................................................................ 1 1445
Chevrolet & N o v a ........................................................................................................... 2 1895
Corvette ............................................................................................................................ 2.5 1816
Glove Box Lamps
Camaro, Chevrolet, without A /C , Nova & C o r v e tte ............................................. 2 1895
Camaro, Chevelle, Monte Carlo & Chevrolet with A /C ................................... 2 1893
Dome and Courtesy Lamps
Cartridge Type ( A l l ) ........................................................................................................ 12 211
Bayonet Type ..................................................................................................................... 6 631
Seat Separator - Courtesy Lamp ................................................................................... 6 212
Side M arker - Front (Except Chevelle, Chevrolet) ................................................ 2 194
Chevelle, C h e v r o le t ....................................................... ' .............................................. 2 194A
Side M arker - Rear ........................................................................................................... 2 194
Side M arker - Corvette Only .................................. ....................................................... 3 168
License Plate Lamp (Except C o r v e t t e ) ................. ....................................................... 4 67
Corvette ..................................................................... ....................................................... 4 97
Radio D ial Lamp
AM Only Radios ( N o v a ) ................................................................................................ 2 293
Tape Players and FM Radios, Corvette, Nova .................................................... 2 1893
A ll Except Corvette, N o v a ............................... ....................................................... 3 1816
CANDLE
BULB
LAM P USAGE (Cont’d.) POW ER
NUMBER
(OR WATTS)
A circuit breaker in the light control switch protects separate 15 amp in-line fuse. Where current load is too
the headlamp circuit, thus elim inating one fuse. A sep heavy, the circuit breaker rapidly opens and closes, p ro
arate 30 amp circuit breaker mounted on the firew all tecting the circuit until the cause is found and eliminated.
protects the power window, seat and top circuits. The Fuses located in the Fuse Panel under the instrument
under hood and spot lamp circuit is also protected by a panel are:
Radio, Transm ission Control Spark System, Rear Defogger, Power Window,
3 Speed A /T Downshift, Glove Box L a m p ..................................................................... 10 Amp.
W ip e r /W a s h e r................................................................................................................................ 25 Amp.
Stop Lamps, Hazard F la s h e r .................................................................................................... 20 Amp.
Heater and A ir C o n d itio n in g .................................................................................................... 25 Amp.
D irectional Signals, Back-Up Lamp, Cruise Master, Blocking Relay ( A C ) .............. 20 Amp.
Instrum ent and Dome Lamps, Anti-Diesel and Blocking Relays ( C a m a r o ) .............. 2 Amp.
Instrum ent Lamps - C h e v ro le t................................................................................................. 3 Amp.
Instrum ent Lamps (incl. A /T Quadrant Illum ination) Nova, Chevelle, Monte Carlo 4 Amp.
Instrument Lamps - C o r v e t t e ................................................................................................. 5 Amp.
Gauges and Tell-Tale Warning Lamps ................................................................................ 10 Amp.
Clock, Cigar Lighter, Courtesy Lamps, Anti-Diesel Control, Deck Lid, Lock,
Anti-Theft A larm , Glove Box and Dome Lamps ....................................................... 25 Amp.
Tail, License, M arker, Luggage and Parking L a m p s ....................................................... 20 Amp.
In-Line Fuses:
A ir Conditioning High Blower Speed Fuse located in wire running from horn relay to A /C Relay
Comfortron and Four S e a s o n ...................................................................................................................... SAE 30 Amp.
Fusible Links:
P ig tail lead at battery positive cable (except C o r v e tt e ) ............................................................... 14 gauge brown wire
Molded splice at Solenoid "B a t" term inal (Corvette o n ly ) ....................................................... .... 14 gauge brown wire
Molded splice Located at the horn r e l a y ........................................................................................... 16 gauge black wire
Molded splice in Voltage Regulator #3 term inal w i r e .............................................................. .... 20 gauge orange wire
Molded splice in A m m eter c irc u it (Both sides of m e t e r ) ....................................................... .... 20 gauge orange wire
WINDSHIELD WIPERS
Depressed Park Two Speed Washer Pump
Operation Test Voltage (Bench or Battery). . 12 VDC Number of "sq u irts" at full p r e s s u r e ................. 10
Gear R a t i o ........................................................... 51:1
Current Draw (Amps) No Load (no linkage) Pressure ( p s i ) .............................................................. 11-15
Low S p e e d ........................................................ 6 Max.
H i Speed ........................................................4.5 Max. Coil Resistance (ohm s).................................................9 ± 1
S t a l l ......................................................................... 18 Max.
Shunt F ield Resistance (ohms)........................ 5-6
Crank A rm Speed (rpm's)-No Load
L o w ......................................................................... 35-50
Hi ......................................................................... 70-95
SEC TIO N 13
Fan Shroud 50 In. 50 In. 50 In. 150 In. 50 In. 20 Ft. (Upr. Grille)
150 In. (Lwr. Grille)
BUMPERS
SECTION 14
30 Ft. (Otr.)
Front Bumper Bracket & Brace 55 Ft. 70 Ft. 70 Ft. 70 Ft. 24 Ft. 55 Ft. (Otr.)
25 Ft. (Upr.)
R ear Bumper to Outer Bracket 30 Ft. 40 Ft. (Lwr.) 55 Ft. 30 Ft. 17 Ft. 30 Ft.
55 Ft.
Rear Bumper to Body Fram e (Wag. Only) 55 Ft. 38 Ft.
70 Ft.
Rear Bumper Outer Bracket & Brace 55 Ft. (Wag..) 55 Ft. 38 Ft. 25 Ft. 24 Ft. 70 Ft.
ACCESSORIES
SECTION 15
CRUISE MASTER
AIR CONDITIONING
Compressor
M ake......................................................................... Frigidaire
T y p e .............................................................. 6 Cylinder Axial
Displacement
Four-Season (Except Corvette)
and C om fortron.......................................... 12.6 Cu. In.
Corvette Four-Season................................... 10.8 Cu. In.
Rotation ............................................................... Clockwise
Torque Specifications
Com pressor Suction and Discharge
Connector B o l t ................................................. 25 ft. lbs.
Rear Head to Shell Stud N u t s ............................ 23 ft. lbs.
Shaft Mounting N u t ............................................. 15 ft. lbs.
Belt T e n s io n ...................................... See Tune-Up Chart
System Capacities
Refrigerant 12
Four-Season (Except Corvette) and
Comfortron S y s te m s ............................ 3 lbs., 12 oz.
Corvette F o u r - S e a s o n ............................... 3 lbs., 4 oz.
525 Viscosity Compressor O il
A ll S y s te m s ....................................................11 Fluid oz.
Amps RPM
Blower Motor Volts (Cold) (Cold)
Four-Season and
Comfortron . . . . . . . 12 16.5 Max. 3700 Min.
Fuse In
Fuses Block Line
Four-Season............................................. 25 amp 30 amp
C o m fo r tr o n ............................................. 25 amp 30 amp
IB BODY
SPECIFICATIONS
DOORS
Window Regulator to Door Panel .............................................................................. ....................................................... 40 in. lb.
Door Lock to Door P a n e l ........................................................................................... ....................................................... 75 in. lb.
Lock Striker to Body P i l l a r ..................................................................................... .......................................................... 25 ft. lb.
Rear Door Lock S t r ik e r ..............................................................................................
Outside Door H a n d le ...................................................................................................
Rear Door A rm C h e c k ...................... .........................................................................
Hinge to Door and Body
A ll Except Rear D o o r s ...........................................................................................
Rear D o o rs .................................................................................................................
Rear Door B u m p e r s ...................................................................................................
Rear Door Latch C o n t r o l...........................................................................................
Rear Door L a tc h . . . . < ..............................................................................................
LIFTGATE
Hinge B o l t s ....................................................................................................................
Liftgate S u p p o r t......................... .. ...............................................................................
H a n d le ............................................................................................................................
S t r ik e r ............................................................................................................................
T ru n n io n ..........................................................................................................................
ENDGATE (SUBURBAN)
SEATS
............................................................. 25 ft. lb.
Front Seat
Bench Type
Adjuster-to-Seat................................................................................................... ............................................................. 150 in. lb.
Adjuster-to-Floor....................................................... ......................................... ............................................................. 150 in. lb.
Bucket Type
Adjuster-to-Seat...................................................................................................
Adjuster-to-Floor....................................................... ......................................... ............................................................. 18 ft. lb.
Center and Rear Seat (Bench Type)
Leg-to-Seat.................................................................. ......................................... ............................................................. 17 ft. lb.
Leg-to-Floor......................................................................................................... ............................................................. 50 ft. lb.
Rear Mounting Bracket
to S e a t................................................................................................................. ............................................................. 18 ft. lb.
to F lo o r ..................................................................... ......................................... ............................................................. 30 ft. lb.
Body Mounts A ll Except Rear # 2 ............................................................................. ............................................................. 20 ft. lb.
Rear # 2 ....................................................................................................................... ............................................................. 50 ft. lb.
Seat B e l t ................................................................................ ......................................... ............................................................. 40 ft. lb.
FRONT SUSPENSION
SECTION 3
/
ALIG NM ENT SPECIFICATIONS
C-10
Camber #*
Caster #*
Toe-In (Total) $ 1/16" to 5/16” $ 1/8" to 1/4"
C-20-30 m #*
Camber m #*
Caster
Toe-In (Total) $ 1/16” to 5/16" $ 1/8" to 1/4"
P-10
Camber #@ #*
Caster #*
Toe-In (Total) $ 1/16" to 5/16" $ 1/8" to 1/4"
P-20-30
Camber m #*
Caster m #*
Toe-In (Total) $ 1/16" to 5/16" $ 1/8" to 1/4"
K-10-20 * * —
Camber * * * —
Caster
Toe-rn (Total) $ 1/16" to 5/16" $ 1/8" to 1/4"
* Plus additional torque to align cotter pin. Not to exceed 90 ft. lbs. maximum.
** Plus additional torque to align cotter pin. Not to exceed 130 ft. lbs. maximum.
***P lu s additional torque to align cotter pin.
# Back nut off to align cotter pin at nearest slot.
REAR SUSPENSION
SECTION 4
** Back-off nut and retighten to 35 Ft. Lbs. then, back-off nut 1/4 turn.
* With wheel rotating.
DIFFERENTIAL SPECIFICATJONS
Lb. Capacity
Lb. Capacity
5500# (Dana)
Lb. Capacity
5500# (Dana)
Lb. Capacity
3300-3600
5200-7200
3300-3600
5200-7200
11,000
Gear Backlash
F ille r Plugs 18 10 18 10
Preferred .005” - .004” - .005” - .005” - Differential Pinion
.008”
20 — — —
.009” .008” .008” Lock
.003” - .004” - .003” - .003” - Drive Pinion Nut — 255 220 220
Min. and Max.
.010 ” .009” .012 ” .012 ”
Differential C a rrie r
— — 45 85
Pinion Bearing to Axle Housing
Preload (In. Lbs.)
Differential Bearing
— — 15 15
New 20-25 20-40 Adjusting Lock
o
r-H o
< o CO
<N 1
ft o 1 o o
O
rH
< < < <
U O W ft O
Axle to Control A rm
145 145 - - -
U Bolts
Spring to Axle U
- 120 120 150 120
Bolts Nuts
Control A rm Front
145 145 - - -
Attaching Bolts
Shock Absorber
75 75 65 65 -
Attaching Bolts
Propshaft Bearing
Support Hanger
20 # - 35 35
Rear Stabilizer - - - 25 -
TORQUE SPECIFICATIONS
___________________
SPECIFICATIONS 40
ENGINE
SECTION 6
TUNE-UP CHART
E
Type In Line V8
N
G
Displacement 250 292 307 350 402
I
N
Horsepower 145 165 200 215 250 300
E
COMPRESSION (D 130 psi 150 psi
Gap .035"
D
Point Dwell
1
CO
CO
I
S
T Point Gap .016" (Used) .019" (New)
R
I Arm Spring Tension 19-23 ounces
B
U Condenser .18-.23 microfarad
T
O Timing Syn. 4°B 4°B 4°B 4°B 4°B 8°B
R
© Auto. 4°B 4°B 8°B 8°B
<D 4°B 8°B
DRIVE Fan and P/S 50 lb. Min. 75 ± 5 lbs. (Used) 125 ± 5 lbs. (New) Using Strand Tension Gauge
BELT
A/C Compressor 65 lb. Min. 95 ± 5 lbs. (Used) 140 ± 5 lbs. (New) Using Strand Tension Gauge
(T) PSI at Cranking Speed, throttle wide open - Maximum variation, 20 PSI between cylinders.
(2) 6 Cylinder engine - Rotate cam lubricator 180° at 12,000 mile intervals - Replace at 24,000 mile intervals.
8 Cylinder engine - Change cam lubricator end for end at 12,000 mile intervals - Replace at 24,000 mile intervals.
(3) At idle speed with vacuum advance line disconnected and plugged. On Step Van vehicles, use number two cylinder
and timing tab on bottom of cover. B - B.T.D.C.
(4) CAUTION: In addition to its function of filtering air drawn into the engine through the carburetor, the air cleaner
also acts as a flame arrestor in the event the engine backfires. Because backfiring may cause fire in the engine
compartment, the air cleaner should be installed at all times unless its removal is necessary for repair or main
tenance services.
Paper Element Type - First 12,000 miles, inspect element for dust leaks, holes, or other damage and replace if
necessary. If satisfactory, rotate element 180° from original installation position. Replace element at 24,000
miles. Element must not be washed, oiled, tapped, or cleaned with an air hose. If so equipped, replace P.C.V.
breather filter every 24,000 miles (do not attempt to clean). If so equipped, clean wire mesh frame arrestor every
12,000 miles
Oil Bath Type - The oil level in the oil bath air cleaner reservoir should be checked every 12,000 miles and suf
ficient S.A.E. 50 oil added when temperature is above freezing or S.A.E. 20 oil added when temperature is below
freezing. Adding oil and servicing the cleaner will vary greatly, depending upon operating conditions.
Oil Wetted Paper Element With Polyurethane Wrap - This dual element air cleaner has extremely long life and
will not require replacement for 50,000 to 100,000 miles under normal operating conditions. Cleaning and oiling
of the polyurethane wrap should be done at 24,000 miles under normal highway or city-type operation. Service
under off-the-road or extremely dusty operations should be performed at 12,000 miles or less depending upon
severity of operating conditions
ENGINE TORQUES
CARBURETOR
SEC TIO N 6M
IDENTIFICATION
Also refer to Rochester Carburetor Identification
Illustration in the 1971 Overhaul Shop Manual.
T5fPE
Displacement
RPO HP BBL. SYNCH. AUTOMATIC
and type
C K P G
* Start of Production
# Interim Release
SPECIFICATIONS 44
ADJUSTMENTS
Rochester Carburetors
M
0 NUMBER
DASHPOT
D (A) Automatic Trans.
E (M) Manual Trans.
(bench)
BREAK
L
ROD
LE V EL
DROP
ROD
UNLOADER
AIR VALVE
ROD
METERING
FAST IDLE
VACUUM
FLOAT
FLOAT
CHOKE
PUMP
MV 7041021 (A)(M) 1/4 — .080 — .100 .180 — .230 .350
MV 7021022 (A)(M) 1/4 — .070 — .100 .300 — .350 .350
MV 7041025 (A)(M) 1/4 — .070 — .100 .180 — .260 .350
MV 7041026 (A)(M) 1/4 — .070 — .100 .275 — .350 .350
2GV 7041105 (M) 21/32 1-3/4 — 1-3/64 — .040 — .080 .215
2GV 7041125 (A) 21/32 1-3/4 — 1-3/64 — .040 — .080 .215
2GV 7041111 (M) 21/32 1-3/4 — 1-3/64 — .040 — .080 .215
2GV 7041126 (A) 21/32 1-3/4 — 1-3/64 — .040 — .080 .215
2GV 7041138 (A) 23/32 1-1/4 — 1-5/32 — .100 — .170 .325
2GV 7041139 (M) 23/32 1-1/4 — 1-5/32 — .100 — .180 .325
4MV 7041206 (M) 1/4 — — — — .100 .020 .260 —
4MV 7041208 (A)(M) 1/4 — — — — .100 .020 .260 —
4MV 7041209 (A)(M) 11/32 — — — — .100 .020 .260 —
4MV 7041211 (A)(M) 1/4 — — — — .100 .020 .260 —
'-w —r~
SPECIFICATIONS 45
OTHER ADJUSTMENTS
Refer to “Additional External Settings and Adjustments’Yor
“C.E.C. Valve Adjustment”, as applicable, in Section 6M
(Service), under carburetors before using the following charts.
Manual L -6 250
C.I.D .
580 550 1000
L -6 292
C.I.D . (L-25)
V -8 307
700 600 1000
C.I.D .
V -8 350
675 600 900
C .I.D . (LS-9)
MK IV 402
675 600 850
C .I.D . (L-47)
Automatic L -6 250
C .I.D .
530 500 750
L -6 292
C .I.D . (L-25)
V -8 307
C.I.D .
580 550 650
V -8 350
C.I.D . (LS-9)
MK IV 402
630 600 650
C.I.D . (L-47)
** CAUTION: If the C .E .C . valve (solenoid) on the carburetor is used to set engine idle or is adjusted out of lim its
specified in the Service Manual, decrease in engine braking may result.
ENGINE ELECTRICAL
SECTION 6Y
BATTERY
1980141 (Y- 86) 250 L -6 & 307 V-8 , GS & GE 10-20-30 54 2300 45
% .
GENERATORS
COLD OUTPUT*
FIELD
MODEL D ELCO REM Y RATED HOT
APPLICATION CURRENT AMPS AMPS
NO. SPEC. NO. SPEC OUTPUT** AMPS
AMPS (80 °F) @ 2000 @ 5000
VOLTS
RPM RPM
VOLTAGE REGULATOR
STARTING M O TO R
1108365
1108367 3573 35 9 50-80* 5500-10500
1108368
1108338
2438 35 9 55-80* 3500-6000
1108360
* Includes Solenoid
DISTRIBUTORS
Centrifugal
Engine Ignition Vacuum Ignition O riginal
Advance Point
Description D istributor Advance Tim ing Equipment
(Crank Dwell Trans.
and (Product (In Crank BTDC at Spark
Degrees @ Setting
A vailability Part No.) Degrees) Engine Idle* Plug
Engine RPM)
250 Cu. In. L -6 1110489 C-4977 C-3990 31°-34° 4° @ 550 RPM Manual AC-R46TS
(145 HP) 0° @ 930 RPM 0° @ 8" Hg 4° @ 500 RPM Automatic
2° @ 1270 RPM 23° @ 16" Hg
14° @ 2300 RPM
24° @ 4100 RPM
292 Cu. In. L -6 1110486 C-4809 C-3991 31°- 34° 4° @ 550 RPM Manual AC-R44T
(165) HP) RPO L-25 0 0 @ 860 RPM 0° @ 8" Hg 4° @ 500 RPM Automatic
2° @ 1140 RPM 18° @ 16" Hg
17° @ 2150 RPM
28° @ 4000 RPM
307 Cu. In. V -8 (200 1112040 C-4815 C-3954 31° - 34° 8 ° @ 550 R PM Automatic AC-R45TS
HP) 10 Series 0° @ 680 RPM 0° @ 8" Hg
2° @ 1320 RPM 20° @ 17" Hg
20 ° @ 4200 RPM
307 Cu. In. V -8 1112041 C-4753 C-3954 31°- 34° 4° @ 600 RPM Manual AC-R45TS
(200 HP) 10 Series 0 0 @ 800 RPM 0° @ 8" Hg
2° @ 1200 RPM 20° @ 17" Hg
12° @ 2200 RPM
24° @ 4300 RPM
307 Cu. In. V -8 (215 1112043 C-4824 C-3036 31°- 34° 4° @ 600 RPM Manual AC-R45TS
HP) 20-30 Series 0° @ 800 RPM 0° @ 8" Hg 8 ° @ 550 RPM Automatic
2° @ 1200 RPM 15° @ 15.5" Hg
11° @ 2100 RPM
20 ° @ 4200 RPM
350 Cu. In. V -8 (250- 1112047 C-4818 C-3036 31°- 34° 8 ° @ 550 RPM Automatic AC-R44TS
255 HP), RPO LS-9 0° © 865 RPM 0° @ 8" Hg
2° @ 1335 RPM 15° @ 15.5" Hg
11° @ 2400 RPM
18° @ 4200 RPM
350 Cu. In. V -8 (250- 1112046 C-4753 C-3036 31°- 34° 4° @ 600 RPM Manual AC-R44TS
255 HP), RPO LS-9 0° @ 800 RPM 0° @ 8" Hg
2° @ 1200 RPM 15° @ 15.5" Hg
12° @ 2200 RPM
24° @ 4300 RPM
402 Cu. In. V -8 (300 1112064 C-4830 C-3954 31°- 34° 8 ° @ 600 RPM All AC-R44TS
HP) RPO L-47 0° @ 930 RPM 0° @ 8" Hg
2° @ 1260 RPM 20° @ 17" Hg
16° @ 2400 RPM
30 0 @ 4400 RPM
IG N ITIO N COIL
P RIM A R Y RESISTANCE IGNITION RESISTOR
SECONDARY RESISTANCE
@ 75°F.
APPLICATION
- OHMS - - OHMS - TYPE OHMS
STEERING
SECTION 9
—
Tie Rod Ball Joint
Nut 30 ft. lbs. 50 ft. lbs. 45 ft. lbs. 50 ft. lbs.
Steering Connecting
Rod Nut - - - 50 ft. lbs. -
Power Steering
125 lb. New --- 75 lb. Used
Belt Tension
SECTION 9 (C O N T’D)
- 4 to 6 4 to 6 4 to 6 9 to 12
Worm Bearing Preload
in. lbs. in. lbs. in. lbs. in. lbs.
Worm Bearing Lock Nut - 85 ft. lb. 85 ft. lb. 85 ft. lb. 85 ft. lb.
- 4 to 10 .j. 4 to 10 ^ 4 to 10x 9 to 13 ,
Sector Lash Adjustment
in. lbs. in. lbs. in. lbs. in. lbs.
Sector Lash Lock Nut - 30 ft. lb. 30 ft. lb. 30 ft. lb. 30 ft. lb.
Total Steering Gear - 14 in. lbs. 14 in. lbs. 14 in. lbs. 25 in. lbs.
Preload Max. Max. Max. Max.
Steering Gear 3 in. lbs. 3 in. lbs. 3 in. lbs. 3 in. lbs.
- Max. Max.
Ball Drag Max. Max.
Thrust Bearing 1/2 to 2 1/2 to 2 1/2 to 2 1/2 to 2
-
Preload in. lbs.* in. lbs.* in. lbs.* in. lbs.*
Adjuster Plug
- 80 ft. lbs. 80 ft. lbs. 80 ft. lbs. 80 ft. lbs.
Lock nut
Over-Center 3-6** 3-6** 3-6** 3-6**
-
Preload in. lbs. in. lbs. in. lbs. in. lbs.
Over-Center
- 25 ft. lbs. 25 ft. lbs. 25 ft. lbs. 25 ft. lbs.
Adjusting Screw
Locknut
Total Steering 14 in. lbs. 14 in. lbs. 14 in. lbs. 14 in. lbs.
-
Gear Preload Max. Max. Max. Max.
WHEELS
Wheel Nut Torques - 10-30 Series
TIRES
SHEET METAL
SECTION 11
LAMP USAGE
* CP - Candle Power
W - Watts
A ir Conditioning 25 3AG/AGC
WASHER____________________________________________________
Number of "sq u irts” at full p r e s s u r e ............................ 10 Heater Motor 15 3AG/AGC
Pressure ( P S I) ................................................................ 11-15
Coil Resistance (ohms)..................................................... 6±1 Backup Lamps Fuse block 10 3AG/AGC
in driver's
Tail, Stop, Dome compartment
License Lamps
M arker Lights 20 SAE/SFE
Spotlamp, Park
Lamps
In-Line Part
of Gen. & fwd. 3AG/AGC
Ammeter 4
lamp harness
(2 reqd.)
TORQUE SPECIFICATIONS
G r i l l e .............................................................150 in. lbs. outer
10 ft. lbs. inner
G rille B r a c k e t....................................................... 20 ft. lbs.
Fan S h r o u d ............................................................. 45 in. lbs.
BUMPERS
SECTION 14
TORQUE SPECIFICATIONS
Front B u m p e r ......................................... 35 ft. lbs.
Front Bumper Bracket and Brace . . . 40 ft. lbs.
Rear Bumper to Outer B r a c k e t ........... 35 ft. lbs.
Rear Bumper Outer Bracket and Brace 45 ft. lbs.
ACCESSORIES
SECTION 1 5
CRUISE-M ASTER
Solenoid R esistance....................................................................................................................................................... 5 ohms ±1/ 4 ohm
Solenoid W ire R e sista n c e ............................................................................................................................................................. 40 ohms
Maximum allowable Vacuum Leakage rate for Servo u n i t ..........................................................5 inches of Vacuum Per Minute
Not Greater than 1 inch of Vacuum per 10 seconds
Operational Test S p e e d .................................................................................................................................................................. 60 MPH
16 ounces......................................... = 1 pound
1/12 foot (ft.)................................ = 1 inch (in.)
100 pounds................ = 1 hundred weight (cwt.)
12 in ch e s............................................ = 1 foot
2000 pounds......................................... = 1 ton
3 fe e t....................................... = 1 yard (ly d .)
144 square inches...................... = 1 square foot 1 in ch .............................. = 2 5.4 001 m illim eters
1 y a rd .................................. = 9 .9 1 4 4 0 2 meters
1/16 pint (pt.). ........ = 1 ounce (oz.)
1 m e te r.................................. =1.093611 yards
1 pint .......... ............ = 1 6 ounces
1 m ile ............................. =1.60 93 47 kilom eters
2 pints......... 1 quart (qt.) = 32 ounces
1 kilom eter............................. =0.62 13 70 miles
4 qu arts....... ___ = 1 gallon (gal.)
DRY MEASURE
1 qu art..................................... = 0 .9 4 6 3 3 liters