Chevrolet 10 series 1973 Overhaul Manual Download Page 20

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AIR C O N D IT I O N I N G COM PR ES SO R

1-15

SPECIAL TOOLS

J 8393

Charging S tation

12.

J-5403

No. 21 Snap Ring Pliers

23.

J-9481

J-24095

O il Inducer

13.

J-6453

No. 26 Snap Ring Pliers

2A.

J 9393

Super Heat Switch

14.

J-9396

Compressor H olding

24.

J-8092

Remover

F ixture

25.

J-21352

J-5453

Goggles

15.

J-9397

Compressing F ixture

J-9459

90 Degree Gauge Line

16.

J-9403

Clutch Hub H olding Tool

26.

J-5139

A dapter

17.

J 9399

9 /1 6 " T h in Wall

J-5420

Gauge Line Adapter

Socket

27.

J-9432

J-6084

Leak Detector

18.

J-9401

Hub and Drive Plate

28.

J-9553

J-8433

Puller

Assembly Remover

J-9395

Puller P ilot

19.

J-9480

Hub and Drive Plate

29.

J-21508

J-23595

Refrigerant Can Valve

Assembly Installer

(Side-Tap)

20.

J 9392

Seal Remover

30.

J-22974

10.

J-6271

Refrigerant Can Valve

21.

J-23128

Seal Seat Remover

31.

J-9527

(Top-Tap)

22.

J-9398

Pulley Bearing Remover

32.

J-9402

11.

J-5421

Pocket Therm om eters (2)

Pulley and Bearing

Installer
Handle
Internal Assembly

S u p p o rt Block
Oil Pickup Tube

Remover

Needle Bearing Installer

Seal Seat " 0 ” Ring

Remover

Seal Seat " O " Ring

Installer

Shaft Seal P rotector

Pressure Test Connector
Parts Tray

Fig. 2 8 -A ir C o n d itio n in g Special Tools

OVERHAUL MANUAL

Summary of Contents for 10 series 1973

Page 1: ......

Page 2: ...use of specific service methods that can damage the vehicle or render it unsafe are stated in this service manual It is also important to understand these warnings are not exhaustive Chevrolet could...

Page 3: ...r...

Page 4: ...section Summaries of Special Tools when required are found at the end of major sections while Specifications covering vehicle components are presented at the rear of the manual This manual should be k...

Page 5: ......

Page 6: ...ring Item 39 fig 1 Then remove the hub spacer Inspection If the frictional surface shows signs of damage due to Compressor Rear Head and Internal Mechanism 1 7 Pressure Relief Valve 1 7 Superheat Swit...

Page 7: ...Oil Inlet Tube 0 Ring 38 Spacer 12 Front Head 25 Oil Inlet Tube 39 Clutch Hub Retainer Ring 13 Coil and Housing Assembly 26 Wobble Plate and Mainshaft Assembly 40 Shaft Nut 14 Coil Housing Retainer R...

Page 8: ...and drive plate assembly Use proper tools DO NOT drive or pound on the hub assembly Coil Housing Assembly Removal 1 Remove the hub and drive plate assembly the pulley and bearing assembly and electri...

Page 9: ...of the proper service tools and the condition that an adequate stock of service parts is available Service parts stock should include the following 1 Major interior mechanism assembly ready for insta...

Page 10: ...the shaft the exposed portion of the seal seat and the shaft itself of any dirt or foreign material before removing the seal seat Fig 9 Installing Coil Housing 4 Place Tool J 22974 over the end of the...

Page 11: ...ace and Bearing Pack 41 Oil Inlet Tube 0 Ring 54 Rear Head to Shell Retaining Nuts 15 Front Head to Shell 28 Suction Crossover 42 Oil Inlet Tube 55 Compressor to O Ring Cover 43 Mainshaft Rear Bearing...

Page 12: ...n the new metal sleeve retainer so that its flange face will be against the front end of the sleeve Tool J 9395 may be used to install the retainer Press and tap with a mallet setting the retainer and...

Page 13: ...eeds or damaged seats and replace entire assembly if such is found CAUTION Excessive force during this opera tion may loosen valve reed retainer rivets 8 Carefully lift off the rear suction reed valve...

Page 14: ...ft 4 Remove front head casting front discharge valve plate and suction reed valve from the mechanism Examine parts for damage and replace if necessary Check particularly for damage to the sealing surf...

Page 15: ...hrust washers and bearing and discard all three pieces 11 Examine all surfaces of the wobble plate and if satisfactory reuse If it shows signs of wear replace the shaft and wobble plate as an assembly...

Page 16: ...on pockets The petroleum jelly will hold the balls in place 7 Apply a light smear of petroleum jelly to the cavity Fig 22 Assembling Cylinder Halves of three new ZERO ball seats and place one seat ove...

Page 17: ...efully remove one piston at a time from the wobble plate and the front half of the cylinder Transfer each piston ball and seat to its proper place in the parts tray along with the numbered rear seat c...

Page 18: ...fiber block and mallet to seat the rear half of the cylinder over the locating dowel pins If necessary clamp the cylinder in Fixture J 9397 to complete drawing the cylinder halves together 11 Generous...

Page 19: ...hole and the O ring Rotating the compressor mechanism to line up with the hole in the compressor oil sump baffle install the pickup tube Be sure that the O ring and intake tube are properly seated 13...

Page 20: ...ak Detector 18 J 9401 Hub and Drive Plate 28 J 9553 7 J 8433 Puller Assembly Remover 8 J 9395 Puller Pilot 19 J 9480 Hub and Drive Plate 29 J 21508 9 J 23595 Refrigerant Can Valve Assembly Installer S...

Page 21: ......

Page 22: ...e same position 4 Position Spreader Tool J 5231 01 so the two dowels on tool fit into recesses in carrier install two hold down bolts and install a dial indicator at one end of opening in carrier to i...

Page 23: ...ifferential Bearing Cap 32 D ifferential Carrier 5 Drive Pinion Shims 23 D ifferential Bearing Cone 33 Inner Bearing Cone 6 Inner Bearing Shims 15 D ifferential Pinion 24 D ifferential Bearing Cup 34...

Page 24: ...t 5 Gasket 13 Cone and Roller 20 Shims Differential 27 Thrust Washer 6 Outer Pinion Oil Slinger Inner Pinion Adjusting Pinion 7 and 8 Cone and Roller 14 Ring and Pinion 21 Cone and Roller 28 Pinion Ou...

Page 25: ...reassembly 5 Remove inner pinion cone and roller using Tool J 22912 installed as shown in Figure 6 and press pinion from bearing Inspection 1 Clean all gears and bearings in cleaning solvent and insp...

Page 26: ...indicator reading This will be the total amount of shims needed less preload for setting backlash later during assembly 11 Remove differential from carrier DRIVE PINION Installation and Adjustment of...

Page 27: ...2 5 Press inner pinion bearing cone and roller onto pinion shaft using Installer J 9772 on arbor press as shown in Figure 9 6 7 8 9 Install drive pinion and inner bearing cone and roller assembly in d...

Page 28: ...tial carrier using spreader as shown in Figure 1 2 Install differential bearing cups in their correct locations then install differential case into carrier 3 Install differential bearing caps in the c...

Page 29: ...f the ring gear Decreasing shim thickness will move pinion farther away from centerline of the ring gear HEEL CONTACT DECREASE BA CKLA SH HIGH FACE CONTACT IN C R EA SE P IN IO N SH IM Fig 12 Gear Too...

Page 30: ...and down on the face of the ring gear teeth 0 J 8614 01 J 23476 J 5341 J 8001 J 22912 J 23494 Holder and Remover Companion Flange Installer Companion Flange Gauge Pinion Depth Consists of Parts 1 SE...

Page 31: ......

Page 32: ...section by ring gear size The following chart lists pertinent information needed on Pas senger Car and Series 10 30 Truck axles MODEL SOURCE TIRE CAPACITY RING GEAR SIZE C10 Chevrolet S alisb u ry 375...

Page 33: ...inch For example if the indicator reading was 028 and the pinion code is 1 the required shim would be 028 001 027 inch 8 7 8 Ring Gear Passenger Car 1 Set up the tools as shown in figure 0 3 2 Preload...

Page 34: ...REAR AXLE DIFFERENTIAL CARRIER 4 3 OVERHAUL MANUAL...

Page 35: ...ring P re lo a d 4 13 Pinion D epth and B a c k la s h 4 13 Gear T o o th C o ntact P attern Check 4 13 SHIM AND 1 C om panion Flange 2 D e fle cto r 3 P inion O il Seal 4 P inion Front Bearing 5 Pini...

Page 36: ...n figure 2A to prevent case from falling 6 Place right and left bearing outer races and shims in sets with marked bearing caps so that they can be reinstalled in their original positions Inspection 1...

Page 37: ...t and lock screw It is not necessary to torque lock screw until axle shafts are installed 5 Differential may be installed in carrier now or after service is performed on the drive pinion Installation...

Page 38: ...B C 265 i N J O O O TO MAINTAIN PROPER BACKLASH 005 008 ring gear is moved away from pinion by subtracting 010 shims from ring gear side and adding 010 shims to other side 010 275 004 TO OBTAIN PROPE...

Page 39: ...perly preloaded If any adjustments are required in later procedures make sure that preload remains established as in step 9 If backlash is changed be sure that total thickness of two shim packs does n...

Page 40: ...n it 1 8 of a turn to locked position Remove flange by turning J 8614 3 while holding J 8614 11 as shown in figure 13A 6 To remove the drive pinion first thread the original pinion nut half way on the...

Page 41: ...figure 16A 7 Install the front cup with the large end against the Fig 15A Removing Drive Pinion Rear Bearing Fig 16A Installing Pinion Rear Bearing Cup bore shoulder using Installer J 7137 as shown in...

Page 42: ...l snug and rotate the bearings to make sure they are properly seated See figure 18A for illustration of proper positioning 4 Hold the preload stud stationary with a wrench on the flats and tighten hex...

Page 43: ...ring caps and depth gauging tools from carrier 16 Position the shim selected in step 14 on the pinion shaft against pinion head 17 Lubricate the rear pinion bearing with liberal amounts of hypoid lubr...

Page 44: ...y rotating pinion re set preload to specification CHECKS AND ADJUSTMENTS Four adjustments are essential for proper operation of the differential and its related parts These adjustments are a Pinion Be...

Page 45: ...s are backlash and position of drive pinion in carrier The effects of bearing preloads are not readily apparent on hand loaded teeth pattern tests however these adjustments should be within specificat...

Page 46: ...o increase backlash increase right shim and decrease left shim an equal amount To decrease backlash decrease right shim and increase left shim an equal amount The important thing to note is that the c...

Page 47: ...and A d ju stm en t 4 24 G ear T o o th C o n tac t P attern Check 4 26 Installation and A d ju stm e n t 4 18 1 C om panion Flange 7 D iffe re n tia l Case 13 C o ve r 19 Thrust W asher 2 D e fle c t...

Page 48: ...nd right bearing cups with bearing caps so that they may be reinstalled in original positions Place shims with appropriate cups Inspection 1 Clean all parts in cleaning solvent inspect all bearing cup...

Page 49: ...le shafts are installed 5 Differential may be installed in carrier now or after service is performed on the drive pinion Installation and Adjustment 1 Check condition of bearing bearing cups cup seat...

Page 50: ...r Gauge C 010 240 TO MAINTAIN PROPER BACKLASH 005 008 ring gear is moved away from pinion by subtracting 010 shims from ring gear 010 275 side and adding 010 shims to other side 004 TO OBTAIN PROPER P...

Page 51: ...re properly preloaded If any adjustments are required in later procedures make sure the preload remains as established in step 9 If backlash is changed in later steps be sure the total thickness of th...

Page 52: ...to locked position Remove flange by turning J 8614 3 while holding J 8614 11 as shown in figure 13B 6 To remove the drive pinion first thread the original pinion nut half way on the pinion for thread...

Page 53: ...ing Installer J 0270 14 for Truck models and J 9745 for Passenger Car as shown in figure 16B Fig 15B Removing Drive Pinion Rear Bearing Fig 16B Installing Pinion Rear Bearing Cup 7 Install the front c...

Page 54: ...plate J 21779 36 mounted on preload stud J 21777 43 c For all models insert stud through rear bearing and pilot J 21777 35 and through front bearing and pilot J 21777 42 Install the hex nut until snug...

Page 55: ...nion has no plus or minus number use the indicator reading as the correct shim thickness c If the pinion is stamped with a minus number subtract that many thousandths from the indicator reading For ex...

Page 56: ...t a suitable thick washer or sheet metal plate over the pinion stem Install the original Fig 26B Installing Pinion Oil Seal Truck pinion nut and tighten sufficiently to draw pinion through the front b...

Page 57: ...gear to pinion backlash Gear Tooth Contact Pattern Check Prior to final assembly of the differential a Gear Tooth Contact Pattern Check is necessary to verify the correct relationship between ring ge...

Page 58: ...on head and inner race of rear bearing The shim is used in the differential to compensate for manufacturing tolerances Increasing shim thickness will move the pinion closer to centerline of the ring g...

Page 59: ...ront Bearing 5 Differential Pinion 14 Pinion Bearing Shim Bearing Cup 6 Ring Gear Bolt 15 Pinion Rear Bearing 22 Side Bearing Cup 29 Pinion Front Bearing 7 Differential Case 16 Pinion Rear Bearing 23...

Page 60: ...r spline wear or yoke cracking If equipment is available use magnetic penetrant method to check for minute fractures in yokes or gears Differential Bearing Replacement 1 Place Puller J 22888 over diff...

Page 61: ...ier and carrier caps to make sure they are free from nicks burrs and foreign material 2 Lubricate bearings with axle lubricant Position cups on proper bearings then install differential assembly in ca...

Page 62: ...the service shim is determined by subtracting the thickness of the service spacer from the higher of the two averaged readings obtained in Steps 7 and 8 EXAMPLE Gauge thickness higher reading 254 Serv...

Page 63: ...ndicular to tooth angle and in line with gear rotation 18 If variation in backlash exceeds 003 measure ring gear and case runout as shown in Figure 13C Gear runout should not exceed 003 should runout...

Page 64: ...r scoring Discard all parts that show excessive wear or failure Pinion and or Bearing Replacement 1 If necessary to replace pinion bearings tap old cups out of carrier using a brass drift See Figure 1...

Page 65: ...parts to insure accuracy of measurements 2 Lubricate the front and rear pinion bearings which will be used in final assembly and position them in their respective races in the carrier 3 With cloverlea...

Page 66: ...th a plus number add that many thousandths to the indicator reading For example if indicator reading is 019 and pinion is marked 2 the correct depth shim for installation will be 019 002 021 inch b If...

Page 67: ...Installation and Adjustment Following service to the Differential Case or to the Drive Pinion and Ring Gear a Gear Tooth Contact Pattern Check must be made to verify the accuracy of the work in setti...

Page 68: ...ash and drive pinion adjustments NOTE It may be necessary to adjust both pinion depth and backlash to obtain the correct pattern The position of the drive pinion is adjusted by increasing or decreasin...

Page 69: ...ITS INDEX General Description 4 39 Eaton Positraction 4 39 Disassembly 4 40 Inspection 4 41 Reassembly 4 41 Chevrolet Positraction 4 43 Disassembly 4 43 Inspection 4 43 Reassembly 4 43 Power Lok Diffe...

Page 70: ...by Chevrolet use an optional Eaton Positive Locking differential that is serviced as an assembly only Truck 10 1 2 ring gear axles produced by Dana use only the optional Dana Power Lok shown in figur...

Page 71: ...retainer from the case until enough of the retainer is exposed to permit installation of bar stock and C clamp as shown in Figure 6D Center the bar stock over the axle shaft hole in the spring retaine...

Page 72: ...plates and discs for excessive wear and signs of overheating NOTE Clutch plates and discs are not serviced separately If replacement is re quired clutch pack must be replaced as an assembly 2 Inspect...

Page 73: ...n gears can be performed by reversing the pinion gear removal procedure Fig 12D Spring Pack Compressed for Installation 15 For all except Corvette assemble springs in spring retainer and clamp assembl...

Page 74: ...pring from the case 3 Support an axle shaft in a vise and slide the case into the shaft then turn the case to remove both pinions and thrust washers NOTE The pinion shaft may be partially installed to...

Page 75: ...and side gears into case 12 Mount the case onto the axle shaft locked in a vise Place both pinions and thrust washers into position 180 apart and carefully roll in by turning the case on the shaft NO...

Page 76: ...elleville friction plates on each side of differential side gears transmits drive from differential case to axle shafts Carefully observe the order in which the plates are used since they must be repl...

Page 77: ...case over previously assembled parts with scribe markings on both halves of case in alignment 7 Install differential case bolts but do not tighten at this time 8 Before tightening bolts use axle shaf...

Page 78: ...ion Depth and Backlash 4 52 Gear Tooth Contact Pattern Check 4 52 19 Retainer Screw 20 Bearing Cap 21 Case to Ring Gear Bolt 22 Differential Cover 23 Bearing Cap Bolt 24 Cover Screw 25 Axle Shaft 1 Co...

Page 79: ...om carrier Side Bearing Replacement 1 Install bearing puller J 8107 onto one side bearing with puller screw centered on pilot plug as shown in figure 4E Be sure to install puller fingers into notches...

Page 80: ...side nut using J 24429 as shown in figure 3E until the ring gear contacts the drive pinion Do not force the gears into contact so as to bind them At this point zero lash is obtained 3 Back off the le...

Page 81: ...pon reassembly 4 Thread end of J 8614 3 into small O D end of J 8614 2 Then with J 8614 11 installed as in step 2 insert J 8614 2 into J 8614 11 and turn it 1 8 of a turn to locked position Remove fla...

Page 82: ...using J 24433 3 Install the front and rear pinion bearing cups into the bearing retainer using driver handle J 8092 on J 8608 for the front cup and on J 24432 for the rear cup 4 Install the pinion str...

Page 83: ...PINION 2 ADD 001 ADD 002 ADD 003 ADD 004 1 SUBT 001 ADD 001 ADD 002 ADD 003 0 SUBT 002 SUBT 001 ADD 001 ADD 002 1 SUBT 003 SUBT 002 SUBT 001 ADD 001 2 SUBT 004 SUBT 003 SUBT 002 SUBT 001 Fig 16E Pinio...

Page 84: ...4 Apply load to gears by expanding brake shoes or by wrapping a heavy rag around the companion flange to resist rotation NOTE A test made without loading the gears will not give a satisfactory patter...

Page 85: ...4 54 REAR AXLE DIFFERENTIAL CARRIER OVERHAUL MANUAL...

Page 86: ...inner and outer bearing shim pack The inner shim is used to maintain proper pinion depth The outer shim is used to maintain proper preload on the pinion bearings 2 1 D iffe re n tia l S p id e r 22 D...

Page 87: ...move the differential case fom the carrier Record the dimensions and location of the side bearing shims Remove the spreader tool Disassembly 1 Remove differential side bearings by placing J 22912 unde...

Page 88: ...inner bearing cup Tag shims for reassembly 9 Remove rear pinion bearing using J 22912 and an arbor press Fig 5F Removing Pinion Nut Fig 6F Removing Companion Flange Inspection 1 Clean all gears and b...

Page 89: ...earing Fig 8F Screwdrivers Against Case Pinion Shims Ring gears and pinions are supplied in matched sets only Matching numbers on both pinion and ring gear are etched for verification If a new gear se...

Page 90: ...or Pinion Code Chart remove an equal amount as was added or removed from the inner shim pack 5 Install outer cup in carrier bore using installer J 7818 with Drive Handle J 8092 6 Press rear pinion bea...

Page 91: ...shim just installed on the ring gear side of the case was 172 inch the correct shim dimension would be 329 172 157 006 163 inch 11 Spread the differential carrier as shown in figure 2F 12 Assemble the...

Page 92: ...ange with wrench so that ring gear rotates one full revolution then reverse rotation so that ring gear rotates one revolution in opposite direction Excessive turning of ring gear is not recommended 5...

Page 93: ...4 62 REAR AXLE DIFFERENTIAL CARRIER OVERHAUL MANUAL...

Page 94: ...inion Adjustment 4 66 Backlash and Preload Adjustment 4 66 Ring Gear Thrust Pad Adjustment 4 67 Installation 4 67 1 Universal Joint Yoke 2 Pinion Bearing Oil Seal and Retainer 3 Oil Seal 4 Oil Seal Ga...

Page 95: ...ring outer races are not dropped while removing assemblyfrom carrier 6 Remove the bolts which attach the pinion bearing retainer to the carrier 7 Remove the pinion and bearing assembly from the carrie...

Page 96: ...and nut Torque nut to specifications and install cotter pin without backing off on nut Differential Disassembly 1 Check differential case to make sure that the two halves are marked so they may be rea...

Page 97: ...o bolts Torque all bolts alternately and evenly to specifications Reassembly 1 Place new pinion bearing retainer gasket on the retainer and install pinion assembly in carrier NOTE The pinion assembly...

Page 98: ...NOTE Make sure screw does not turn during locking process This adjustment provides 005 in to 007 in clearance between thrust pad and ring gear face Installation 1 Clean out axle housing and cover and...

Page 99: ...orque Measuring Adapter 4 J 22912 Press Plate 14 J 8608 Drive Pinion Rear Bearing Cup Installer 5 J 8609 Pinion Rear Bearing Installer 15 J 9458 Companion Flange Installer 6 J 6266 Pinion Depth Gauge...

Page 100: ...45 Side Discs 16 J 5853 In Lbs Torque W rench J 21777 29 Gauge Plate 17 J 7137 Pinion Front Bearing C u p Installer J 21777 42 Front Bearing Plug Used w ith J 8092 J 21777 43 Stud 18 J 8 107 4 Differe...

Page 101: ...9 J 7137 J 8608 J 22175 J 22888 J 9774 J 5780 J 8092 J 7079 2 J 8001 J 22779 J 4880 J 5810 J 3289 J 22311 J 1313 J 5853 J 8614 3 21 Pinion Setting Gauge 10 J 6266 28 Barrel Gauge 11 J 6266 31 Sleeves...

Page 102: ...ler 6 J 1364 Pinion Bearing Ring Drive 18 J 24385 Case Spreader Tool 7 J 1488 Differential Side Bearing Replacer 19 J 24430 Side Bearing Installer 8 J 8608 Drive Pinion Rear Bearing Cup Installer 20 J...

Page 103: ...V...

Page 104: ...Dual Diaphragm Delco Moraine 5 9 Power Brake Cylinder Single Diaphragm Bendix 5 19 Power Brake Cylinder Dual Diaphragm Bendix 5 24 Vacuum Booster Single Diaphragm Bendix 5 32 Special Tools 5 37 DELCO...

Page 105: ...port Plate 18 A ir Filters Fig lA Delco Moraine Vacuum Power 3A Place Spanner Wrench J 9504 over studs on rear housing and attach with nuts and washers Draw nuts down tight to eliminate bending or dam...

Page 106: ...Clevis Type Push Rod loosen the clevis locknut and then remove the clevis and locknut 2 Remove the boot from the neck of the power piston Fig 2A Holding Power Cylinder Using Tool J 22805 Fig 3A Separ...

Page 107: ...ept Chevelle 11 Reaction Bumper 3 Floating Control 12 A ir Valve Spring s Valve Cup 13 Reaction Levers 4 Floating Control 14 Reaction Plate Valve Assem bly 15 Reaction Retainer 5 0 Ring 16 0 Ring 6 Di...

Page 108: ...structions Assembly Figs IA 5A and 6A CAUTION Be sure to keep parts clean until reassembly Re wash at reassembly if there is any occasion to doubt cleanliness such as parts dropped or left exposedfor...

Page 109: ...Replace A ir Valve Push Rod Assembly 1 A ir valve scratches dents distortion or corrosion of I D or O D All seats to be smooth and free of nicks and dents 1 Do not repair Replace 2 Push rod must move...

Page 110: ...a padded vise Do Not Clamp Fig 10A 1nstaIIing Air Valve and Retainer Fig llA ln s ta llin g Power Piston to Support Plate 16 Install snap ring in groove of air valve with Snap Ring Pliers J 4880 fig...

Page 111: ...co Silicone Lube 5459912 or equivalent 3 Place the rear housing assembly over the front housing assembly and align the scribe marks of the Fig 13A Installing Retainer Lock Ring two housings so they wi...

Page 112: ...sing lightly with a plastic hammer 4 Remove Tools J 9504 and J 22893 from rear housing tilted mounting bracket type Tool J 9504 on regular type CAUTION Care must be exercised not to damage or loosen s...

Page 113: ...on the primary support will temporarily lock the primary support plate to the primary power piston and permit continued counterclockwise rotation to un screw the primary power piston from the secondar...

Page 114: ...Piston in Tool Fig 5B Locking or Unlocking Primary and J 23101 Large Dia End Up Secondary Power Pistons clockwise to unlock the secondary support plate 7 Remove the secondary diaphragm from the from t...

Page 115: ...primary 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 18 Removal of the air valve push rod...

Page 116: ...ake system in accordance with the Chassis Service Manual Lubricate rubber plastic and metal friction points with Delco Silicone Lube 5459912 or equivalent Front Housing Group 1 Replace vacuum check va...

Page 117: ...r Replace 2 Push rod must move freely in air valve but must not pull out 2 If worn replace air valve push rod assembly 3 Deterioration of rubber or warped valve face in floating control valve 3 Replac...

Page 118: ...mportant In order to maintain correct power brake output the power piston assembly must be gauged for selective fit of Fig 11B Installing Floating Control Valve Retainer with Installer J 23175 reactio...

Page 119: ...avity of the secondary power piston and push the disc down to seat on the reaction piston 10 Unlock the secondary power piston from the primary power piston 11 Assemble the primary diaphragm to the pr...

Page 120: ...sembly of front and rear housings 25 Place the secondary diaphragm support ring on the secondary power piston assembly so that it rests on the edge of the diaphragm 26 Hold the housing divider so that...

Page 121: ...seat in the depression in the face of the secondary power piston Check that the bead on the O D of the secondary diaphragm is positioned between the edges of the housings 7 Assemble front and rear hou...

Page 122: ...Attach base of Holding Fixture J 22805 to front housing with nuts and washers and draw down tight to eliminate bending or damage to studs Clamp base in bench vise with power section up fig 2A CAUTION...

Page 123: ...7 Valve Return Spring 18 M ounting Stud 19 A ir Valve Lock Plate 20 Diaphragm Lip 21 Front Housing 22 Front Housing Seal 23 Piston Rod 9 10 11 12 13 14 15 16 A ir Valve Front Housing Seal Poppet Valve...

Page 124: ...n depress the push rod slightly approximately 1 16 inch and rotate piston so the air valve lock will fall from its location in the diaphragm plate hub Remove the air valve push rod assembly from the d...

Page 125: ...ate and extension to bearing surfaces of air valve and to outer edge of valve poppet Insert air valve and push rod assembly in extension of diaphragm plate NOTE The air valve poppet valve and push rod...

Page 126: ...distortion or corrosion of I D or O D A ll seats to be smooth and free of nicks and dents 1 Do not repair replace 2 Push rod must move freely in air valve but must not pull out 2 If worn replace air...

Page 127: ...Assembly OVERHAUL Disassembly Figs ID and 2D 1 Scribe across the flanges of front and rear housings in line with master cylinder cover to provide a guide mark for reassembly 2 Remove two 2 master cyl...

Page 128: ...es break during straighten ing the housing must be replaced fig 5D 14 Attach base of Holding Fixture J 22805 to front housing with nuts and washers and draw down tight to eliminate bending or damage t...

Page 129: ...ar diaphragm retainer with denatured alcohol and remove the retainer using fingers only 23 Clamp Tool J 22839 in a vise Place the diaphragm and plate assembly on the tool with the tool seated in the h...

Page 130: ...ubber parts for cuts nicks and distortion These rubber parts are the key to control of air flow and should account for the majority of troubles traceable to leakage If there is any question whatever a...

Page 131: ...sing with nuts and washers and draw down tight to eliminate bending or damage to studs 12 Secure front housing and Holding Fixture J 22805 on arbor press plate by a suitable means fig 6D 13 Place Span...

Page 132: ...ents distortion or corrosion of I D or O D All seats to be smooth and free of nicks and dents 1 Do not repair replace 2 Push rod must move freely in air valve but must not pull out 2 If worn replace a...

Page 133: ...E PLUNGER Fig 9D Installing Air Valve Assembly CAUTION The piston rod is designed with a self locking adjustment screw to provide the correct relationship between vacuum piston and master cylinder pis...

Page 134: ...g on front housing as in Figure 11D Top of screw should touch gauge NOTE If piston rod height adjustment gauge is not available the required dimensions for fabrication are given in Figure 12D for Corv...

Page 135: ...ted to the intake manifold or other vacuum source through a vacuum check valve The atmospheric port in the control valve is connected to an air cleaner installed in a location protected from road dirt...

Page 136: ...nch remove piston parts 2 through 12 from push rod 8 off piston end of push rod 2 Slide retainer ring 12 out of groove in piston 10 and separate piston from push rod 8 by removing retainer pin 11 3 Wi...

Page 137: ...s Service Manual Lubricate rubber plastic and metal friction points with Delco Silicone Lube 5459912 or equivalent Piston and Push Rod 1 To install a new push rod seal 13 in push rod 8 place new seal...

Page 138: ...Rod Assembly 1 Valve scratches dents distortion or corrosion of I D or O D All seats to be smooth and free of nicks and dents 1 Do not repair replace 2 Push rod for wear at piston pin 2 If worn repla...

Page 139: ...p piston and cup s in clean brake fluid 6 Align valve body to scribe marks and assemble control valve piston carefully in its bore below hydraulic cylinder bore Secure valve body with four capscrews 1...

Page 140: ...Power C ylin der Seal Installer Seal Installer and Protector bibmihS2E5hiE3 13 9 J 22805 10 J 22839 11 J 22893 12 J 23101 13 J 23175 14 J 23188 15 J 23337 16 J 9504 Pow er C ylin der H old in g Fixtu...

Page 141: ...I...

Page 142: ...t 6 29 Installation 6 29 Camshaft 6 29 Inspection 6 29 Oil Nozzle Replacement In Line 6 29 Camshaft Gear Replacement In Line 6 29 Camshaft Bearings 6 29 Inspection 6 29 Removal 6 29 Installation 6 30...

Page 143: ...hrough hollow push rods feed the individually mounted rocker arms fig 1 V8 ENGINES Cylinders are numbered front to rear 1 3 5 7 on the left bank and 2 4 6 8 on the right bank Firing order is 1 8 4 3 6...

Page 144: ...ENGINE 6 3 OIL PRESSURE SENDING UNIT Fig 1 In Line Engine Lubrication OVERHAUL MANUAL...

Page 145: ...6 4 ENGINE FUEL PUMP PUSH ROD OILING OIL FILTER AND BY PASS VALVE Fig 2 Sm all V8 Engine Lubrication OVERHAUL MANUAL...

Page 146: ...OILED BY OIL THROWN OFF PRESSURE FED CONNECTING ROD BEARINGS OIL FILTER AND DISTRIBUTOR OILING CYLINDER WALL AND CAMSHAFT LOBE OILING FUEL PUMP PUSH ROD OILING CROSS DRILLED MAIN BEARING JOURNALS WITH...

Page 147: ...J 6305 11 32 push connecting rod and piston assemblies out of block NOTE It will be necessary to turn the crankshaft to disconnect and remove some of the connecting rod and piston assemblies 13 Remove...

Page 148: ...and cylinder block will prevent crankshaft from rotating NOTE Align dowel hole in flywheel with dowel hole in crankshaft On vehicles equipped with automatic transmissions in stall flywheel with the c...

Page 149: ...s and connectiong rod caps then lubricate bearings pistons piston rings connecting rod bolts and cylinder walls lightly with engine oil b Install connecting rod guide set Tool J 5239 3 8 or Tool J 630...

Page 150: ...eal in crankcase front cover with ends butting side gaskets d Install oil pan and torque bolts to specifications 8 Install torsional damper as follows CAUTION The inertia weight section of the torsion...

Page 151: ...f rocker arms and balls with MOLYKOTE or its equivalent 11 Install valve rocker arms rocker arm balls and nuts and tighten rocker arm nuts until all push rod end play is taken up 12 On In Line engines...

Page 152: ...ad will cause a direct movement of the indicator stem The indicator stem must contact the side of the valve stem just above the valve guide With the valve head dropped about 1 16 off the valve seat mo...

Page 153: ...rsize stud without reaming stud hole 3 Coat press fit area of stud with hypoid axle lubricant Install new stud using Tool J 6880 as a guide Gauge should bottom on head fig 21 Fig 19 Removing Rocker Ar...

Page 154: ...ring correct relation between the head and stem on a valve refacing mechanism Valve stems which show Fig 22 Reaming Valve Guide excessive wear or valves that are warped excessively should be replaced...

Page 155: ...head of valve 8 Remove valve and check face carefully If all pencil Fig 24 Measuring Valve Seat Concentricity marks have not been removed at the point of contact with the valve seat it will be necessa...

Page 156: ...gainst the cap Operate the vacuum pump and make sure no air leaks past the seal fig 27 5 Check the installed height of the valve springs using a narrow thin scale A cutaway scale will help fig 28 Meas...

Page 157: ...he push rod seat is scuffed or worn inspect the push rod An additive containing EP lube such as EOS should always be added to crankcase oil for run in when any new camshaft or lifters are installed Al...

Page 158: ...ndexing 2 Remove the idler gear and the drive gear and shaft from the pump body 3 Remove the pressure regulator valve retaining pin pressure regulator valve and related parts 4 If the pickup screen an...

Page 159: ...plastic hammer CAUTION Be careful of twisting shearing or Fig 37 Installing Screen S m all V8 12 1 S h a ft Extension 8 Pressu re R e gu la to r 2 S h a ft C o u p lin g V a lv e 3 Pu m p B o d y 9 Pr...

Page 160: ...wax like plastic material which will compress evenly between the bearing and journal surfaces without damaging either surface certain precautions should be observed If the engine is out of the vehicl...

Page 161: ...kshaft to the extreme front position Measure at the front end of the rear main bearing with a feeler guage fig 41 10 Install a new rear main bearing oil seal in the cylinder block and main bearing cap...

Page 162: ...ersize for use with new and used standard size crankshafts anu in 010 and 020 undersize for use with reconditioned crankshafts Inspection and Replacement 1 With oil pan and oil pump removed remove the...

Page 163: ...r deposits from the upper end of the cylinder bore NOTE Before ridge and or deposits are removed turn crankshaft until piston is at the bottom of stroke and place a cloth on top of piston to collect t...

Page 164: ...s 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 Fig 49 Piston Support Tool Rework 4 3 32 and J 22250 4 1 4 are available for this purp...

Page 165: ...must be free of varnish or scuffing when being measured The piston pin should be measured with a micrometer and the piston pin bore should be measured with a dial bore gauge or an inside micrometer If...

Page 166: ...e binding is caused by a distorted ring check a new ring 8 Install piston rings as follows fig 57 NOTE Tools J 8020 3 9 16 J 8021 3 7 8 J 8032 4 J 22249 3 15 16 J 22147 4 3 32 and J 22250 4 1 4 are av...

Page 167: ...TRUCK LPG C 1 3 5 7 LEFT 2 4 6 8 RIGHT 400 CU IN E 1 3 5 7 LEFT 2 4 6 8 RIGHT 454 CU IN D 1 3 5 7 LEFT 2 4 6 8 RIGHT 3 With bearing caps removed install Tool J 5239 3 8 or J 6305 11 32 on connecting r...

Page 168: ...1 Guide the connecting rod into place on the crankshaft journal with Tool J 5239 3 8 or J 6305 11 32 Use a hammer handle and light blows to install the piston into the bore Hold the ring compressor fi...

Page 169: ...o correspond with the new cylinder number CRANKSHAFT The crankshaft can be removed while the engine is disassembled for overhaul as previously outlined or without complete disassembly as outlined belo...

Page 170: ...ic or rubber hammer Camshaft Gear Replacement In Line 1 If the inspection indicated that the camshaft gear or thrust plate should be replaced the gear must be removed from the camshaft This operation...

Page 171: ...haft rear bearing to remove the rear intermediate bearing 6 Assemble remover and installer tool on driver handle and remove camshaft front and rear bearings by driving towards center of cylinder block...

Page 172: ...earing has been pulled into bore remove the remover and installer tool from puller screw and check alignment of oil hole in camshaft bearing fig 67 5 Install remaining bearings in the same manner It w...

Page 173: ...r and bypass valve assembly must be replaced as an Fig 67 Replacing Camshaft Center Bearing assembly Clean valve chamber in cylinder block thoroughly Torque retaining screws to specifications fig 71 D...

Page 174: ...k was suitable for continued use except for out of round or tapered cylinders they can be conditioned by honing or boring If the cylinders were found to have less than 005 taper or wear they can be co...

Page 175: ...5 to 65 degrees included angle The finish marks should be clean but not sharp free from imbedded particles and torn or folded metal fig 73 4 Permanently mark the piston for the cylinder to which it ha...

Page 176: ...ceptable range 2 If used piston is not acceptable check Piston Size Chart fig 75 and determine if a new piston can be selected to fit cylinder bore within the acceptable range 3 If cylinder bore must...

Page 177: ...TIONS C Y L I N D E R H E A D T O R Q U E S E Q U E N C E L6 S M A L L V 8 V MARK IV V 8 I N T A K E M A N I F O L D T O R Q U E S E Q U E N C E F R O N T S M A L L V8 M A R K I V V 8 Fig 76 Torque Sp...

Page 178: ...ool J 22147 4 3 32 24 J 09 7 1 Cam shaft Gear Support J 22250 4 1 4 25 J 2 3 5 2 3 Torsional Dam per Puller 8 J 6994 Piston Pin A sse m b ly Tool 26 J 2 2 1 9 7 Torsional Dam per Installer 9 J 9510 Pi...

Page 179: ......

Page 180: ...idle or is adjusted out of limits specified in the Service Manual decrease in engine braking may result ROCHESTER M AND MV MONOJET INDEX General Description 6M 1 Disassembly 6M 3 Air Horn 6M 3 Float B...

Page 181: ...E SHIFT IDENTIFICATION _ ASSEMBLY PLANT CODE YEAR DAY OF THE YEAR MODEL NO __ SHIFT I IDENTIFICATION ASSEMBLY PLANT CODE YEAR DAY OF YEAR OF YEAR M TYPE 2G TYPE CARBURETOR IDENTIFICATION 4M TYPE Fig M...

Page 182: ...hown Typical DISASSEMBLY OF CARBURETOR C E C Valve Assembly and Idle Stop Solenoid Removal 1 Remove vacuum hose from the C E C valve and ported spark tube from throttle body manual transmission only 2...

Page 183: ...m power piston rod c Rotate drive link from keyhole in actuating lever d Remove actuating lever from pump link by rotating off tang on rod e Remove upper end of pump link by rotating from keyhole in p...

Page 184: ...t of throttle valve in the bore of the throttle body do not remove the valve or shaft Cleaning and Inspection The carburetor should be cleaned in a cold immersion type cleaner 1 Thoroughly clean carbu...

Page 185: ...6M 6 CARBURETORS Fig M6 Monojet See Fig M7 for legend...

Page 186: ...until the idle mixture has been adjusted as specified on the engine NOTE A new red plastic idle mixture needle limiter cap is provided in the carburetor repair kit and also in the idle mixture needle...

Page 187: ...eat 16 Install float needle valve into needle seat 17 Insert straight portion of float hinge pin into float arm Install float and hinge pin into float bowl Float Level Adjustment Fig M8 1 Hold float r...

Page 188: ...with attaching screw Tighten securely 6 Install electrically operated idle stop solenoid into boss on float bowl 7 Install C E C valve into bracket on float bowl Install large retaining nut and tighte...

Page 189: ...to remove the pump plunger assembly from the inner lever Rotate the pump plunger stem out of the hole in the Fig G2 Hot Idle Compensator inner lever to remove If the retaining tang on the inner lever...

Page 190: ...d in the service manual IMPORTANT Before removing idle mixture needle be certain to count number of turns to bottom this old idle mixture needle This is required so that when it is necessary to instal...

Page 191: ...ur turns Do not install plastic limiter cap at this time until proper screw settings have been made After completing assembly of the carburetor and when installed in the vehicle adjust the idle speed...

Page 192: ...t Align position cut out in float toward 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 gask...

Page 193: ...8 Float Drop Adjustm ent Brass Fig G10 Float Drop Adjustm ent Nitrophyl and that it will move freely Raise air horn index power piston with spring and lower it straight down to ensure proper installat...

Page 194: ...nut and remove the solenoid from bracket on carburetor NOTE Do not remove solenoid valve bracket from the float bowl assembly unless replace ment of the bracket is necessary The bracket is locked sec...

Page 195: ...rotate choke rod towards pump lever and remove the choke rod from upper choke lever on choke shaft 8 Remove air horn to bowl attaching screws and choke cable bracket on 2G models Tap air horn lightly...

Page 196: ...from the bottom of the fuel bowl using a pair of needle nosed pliers The pump inlet check ball is aluminum and smaller than the steel pump discharge check ball Do not inter change as failure of the p...

Page 197: ...d solenoids should not be immersed in carburetor cleaner However the air horn which has the pressure relief valve will withstand normal cleaning in carburetor cleaner Make sure the cleaning solution i...

Page 198: ...ely Figure V5 shows the float bowl and throttle body at this stage of assembly 6 Install hot idle compensator assembly and gasket where used and tighten screws evenly Assembly of Air Horn Figure V6 1...

Page 199: ...s by bending tang Fig V8 at the rear of the float hanger Fig V8 Float Drop Adjustm ent Assembly of Air Horn to Float Bowl 1 Place air horn on bowl making certain that accelerator pump plunger is prope...

Page 200: ...or DISASSEMBLY NOTE Place carburetor on proper holding fixture Care should be used so as not to damage the throttle valves as they are a precision fit Removal of the Idle Stop Solenoid Assembly 1 Bend...

Page 201: ...m bowl then remove secondary lockout lever from cast boss on bowl 14 Remove fast idle cam from choke assembly CAUTION Do not place vacuum break assembly in carburetor cleaner 15 Remove intermediate ch...

Page 202: ...g sealing surfaces for damage 6 Inspect holes in levers for excessive wear or out of round condition If levers or rods are worn they should be replaced 7 Examine fast idle cam for excessive wear or da...

Page 203: ...proper holding fixture 3 Install fuel inlet filter spring filter new gasket and inlet nut and tighten nut securely 4 Install fast idle cam on choke shaft with cam pick up lever on underside of cam 5 C...

Page 204: ...countersunk screws in primary venturi area All screws must be tightend evenly and securely Figure Q7 3 Connect pump lever to upper pump rod by rotating Fig Q7 Air Horn Tightening Sequence lever into...

Page 205: ...73 J 9789 S J 1137 J 5197 J 4552 BENDING TOOLS J 8328 J 1137 Choke Rod Bending J 4552 Choke Rod Bending 1 2 bbl J 5197 Unloader Bending J 8328 Carburetor Holding Tool J 9789 Universal Carburetor Kit J...

Page 206: ...ld Coil Test for Ground 6Y 4 DISASSEMBLY Figs IS and 2S 1 Disconnect the field coil connector s from the motor solenoid Terminal 2 Remove through bolts 3 Remove Commutator end frame field frame assemb...

Page 207: ...de two piece thrust collar off end of armature shaft b Slide a standard half inch pipe coupling or other metal cylinder of suitable size an old pinion of suitable size can be used if available onto sh...

Page 208: ...no attempt to undercut the insulation should be made or serious damage may result to the commutator Undercutting reduces the bonding of the molding material which holds the commutator bars and since...

Page 209: ...n flux is used for soldering Acid flux should never be used on electrical connections When inspection shows commutator roughness it should be cleaned as follows SiNtlM Fig 7S Field Coil Ground Test Tu...

Page 210: ...shaft with silicone lubricant CLUTCH SPR IN G COLLAR i PIN O N A N D COLLAR A SSEM BLY SPR IN G ROLLER B U SH IN G S SHELL A N D SLEEVE A SSEM BLY l L O C K WIRE b Slide clutch assembly onto armature...

Page 211: ...for this test 2 Momentarily flash a jumper lead from the solenoid motor terminal to the solenoid frame or ground terminal The pinion will now shift into cranking BATTERY Fig llS Circuit for Checking P...

Page 212: ...om solenoid body 3 Remove nut and washer from battery terminal on end cover and remove battery terminal Remove resistor by pass terminal and contactor 4 Remove motor connector strap terminal and solde...

Page 213: ...se clamping the mounting flange lengthwise 2 Remove the four thru bolts and separate the slip ring end frame and stator assembly from the drive Diode Trio Checks 6Y 10 Rectifier Bridge Check 6Y 11 Vol...

Page 214: ...le removing the nut fig 2C b Double groove pulley place a 15 16 socket with wrench flats on the drive end or use adapter J 21501 and a box wrench on the pulley retaining nut insert a 5 16 alien wrench...

Page 215: ...between each pair of stator leads the windings are open Short Circuit A short in the stator windings is difficult to locate without special test equipment due to the low resistance of the windings Ho...

Page 216: ...low reading Repeat this same test between the grounded heat sink and the other two terminals and between the insulated heat sink and each of the three terminals When this is done all six diodes are c...

Page 217: ...er plate and seal assembly from end frame and then pressing bearing out using suitable tube or pipe on outer race 2 Refill bearing one quarter full with Delco Remy No 1948791 grease or equivalent Do n...

Page 218: ...lead clip to brush holder CAUTION Insulating washer on the screw must be assembled over top of the connector 7 Position stator in end frame Connect stator leads to rectifier bridge terminals and inst...

Page 219: ...L...

Page 220: ...ransmission Model 465 7M 37 Dana Model 20 Transfer Case 7M 50 New Process Model 203 Transfer Case 7M 57 New Process Model 205 Transfer Case 7M 64 Adapter Assemblies 7M 76 Special Tools 7M 81 SINGLE PL...

Page 221: ...ate from clutch cover 2 The clutch diaphragm spring and two pivot rings are riveted to the clutch cover Spring rings and cover should be inspected for excessive wear or damage and if there is a defect...

Page 222: ...CEMENT The clutch pilot bearing is an oil impregnated type bearing pressed into the crankshaft This bearing requires attention when the clutch is removed from the vehicle at which time it should be cl...

Page 223: ...ntil it touches vertical 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 pressure plate and near the strut f...

Page 224: ...lease pressure of spindle and remove cover assembly from press 350 V 8 9 SPRINGS PAINTED ORANGE ADJACENT TO LEVERS 3 SPRINGS UNPAINTED 3 SPRINGS PAINTED LIGHT GRAY 454 V8 9 SPRINGS PAINTED LIGHT BLUE...

Page 225: ...coil spring clutches currently available One step is used for the 10 clutch one step for the 13 clutch while the third step is used for 10 1 2 11 and 12 clutches Each side is identified accordingly w...

Page 226: ...ntergear bore Remove the gear bearings and thrust washers 9 Use a long drift or punch through the front bearing case bore and drive the reverse idler shaft and woodruff key through the rear of the cas...

Page 227: ...27 Thrust W ash e r R e a r 34 Countergear Ring 13 1st Speed Synch Gear and Clip 28 S n ap R in g B e a rin g 35 Counter Shaft 6 2 3 Synch S n ap Ring Snap Ring 20 M ainshaft to Extension 36 Reverse I...

Page 228: ...gears for excessive wear chips or cracks and replace any that are worn or damaged 2 Inspect reverse gear bushing and if worn or damaged replace the entire gear NOTE Reverse gear bushing is not servic...

Page 229: ...identifies the end that must be opposite the fork slot in the sleeve when assembled This groove indicates the end of the hub with a 07 greater recess depth Extension Oil Seal or Bushing If bushing in...

Page 230: ...flange on the mainshaft 6 Install a blocker ring with clutching teeth downward over synchronizing surface of the first speed gear 7 Install the first and reverse synchronizer assembly with fork slot...

Page 231: ...r Bearing 29 2nd Speed Gear 16 Case 30 M ainshaft 17 Drive Gear 31 1st Speed Gear 18 Pilot Bearings 32 1st Speed Blocker Ring 33 1 2 Synchronizer Hub 47 Gasket Assembly 48 2 3 Shift Fork 34 1 2 Synchr...

Page 232: ...le the drive gear mainshaft and extension to case as an assembly 13 CAUTION Be sure the drive gear engages the 14 countergear anti lash plate Install extension to case retaining bolts Install front be...

Page 233: ...and press on rear of mainshaft to remove reverse gear thrust washer and rear bearing from shaft CAUTION When pressing rear bearing be careful to center gear washers and bearing on shaft Countergear A...

Page 234: ...se M agnet 4 2nd 3rd Speed Clutch 11 Vent 17 Countergear 25 Anti Lash Plate A ssy Assy 12 Speedometer Gear W oodruff Key Pass Only 5 2nd Speed and Clip 18 Thrust W asher 26 Thrust W ash e r Synchroniz...

Page 235: ...emoving Rear Extension From Mainshaft 2 Push the hub from the sliding sleeve the keys and the springs may be easily removed 3 Place the three keys and two springs in position one on each side of hub s...

Page 236: ...e is assembled with the fork slot in the sleeve toward the thrust face of the hub The 1st reverse hub and sleeve is assembled with the fork slot in the sleeve opposite the thrust face fig 4G CAUTION B...

Page 237: ...rear bearing groove fig 3G 5 Load the mainshaft pilot bearings 16 into the drive gear cavity and assemble the 3rd speed blocker ring onto the drive gear clutching surface with its teeth toward the ge...

Page 238: ...3rd Detent Cam 59 Side Cover 60 Bolt and Lock W asher 61 T C S Switch and Gasket 62 Lip Seal 1 Bearing Retainer 2 B olt and Lock W asher 3 Gasket 4 Oil Seal 5 Snap Ring Bearing to Main Drive Gear 6 M...

Page 239: ...ear from front of mainshaft figs IX 2 Depress speedometer retaining clip and slide gear from mainshaft 3 Remove rear bearing snap ring from mainshaft groove fig 8X Reverse Idler Gear Bushing 7M 23 Cou...

Page 240: ...2 Speed Synch 21 Mainshaft 30 Rear Bearing 38 1 2 Speed Synch Ring Snap Ring 22 Rear Oil Seal 31 Countergear Roller Sleeve and Reverse 6 4 3 Snych Snap Ring 14 1st Speed Blocker 23 Retainer Oil Seal B...

Page 241: ...oving Drive Gear Bearing J 2 2 2 4 6 COUNTER SHAFT Fig 5X Removing Countershaft Fig 6X Removing Reverse Idler Gear Shaft Fig 3X Removing Clutch Gear and Mainshaft Fig 4X Extension to Rear Bearing Snap...

Page 242: ...ced separately REPAIRS Clutch Keys and Springs NOTE The clutch hubs and sliding sleeves are a selected assembly and should be kept together as originally assembled but the keys and two springs may be...

Page 243: ...h springs fig 1IX The tanged end of eaeh synchronizer spring should be installed into different key cavaties on either side Slide the sleeve Fig 14X Removing Bearing Retainer Oil Seal onto the hub ali...

Page 244: ...d replace with a new seal using Tool J 23096 until seal seats in its bore Fig 15X NOTE Lip of seal must face rear of bearing retainer ASSEMBLY OF MAINSHAFT Fig 16X Turn the front of the mainshaft upwa...

Page 245: ...1st Speed Blocker 48 1 2 Synchronizer 62 Lipseal 7 Drive Gear Gear Ring Sleeve and Reverse 63 Detent Cam Retainer 8 Mainshaft Pilot 21 Countershaft 36 First Speed Gear Gear 64 1 2 Shift Fork Bearings...

Page 246: ...ON Be sure countershaft picks up both thrust washers and that the tangs are aligned with their notches in the case 3 Install reverse idler gear and shaft with its woodruff key from the rear of case 4...

Page 247: ...7 M 28 CLUTCHES AND MANUAL TRANSMISSIONS Fig 19X Loading Countergear Bearings Fig 20X Loading Mainshaft Pilot Bearings...

Page 248: ...fter lever boss fig 4B and pull shifter shaft out about 1 8 This disengages the reverse shift fork from reverse gear 5 Remove six bolts attaching the case extension to the case Tap extension with soft...

Page 249: ...tergear Speed Clutch 11 First Speed Gear 20 Countershaft Bearing Assembly 12 First Speed Gear Roller Spacer 5 Third Speed Sleeve 21 Countershaft Bearing Synchronizing Ring 13 Reverse Gear Roller 6 Thi...

Page 250: ...rse Idler Gear Assembly Front 19 Clutch Key Spring 38 Reverse Idler Gear 20 Clutch Hub Rear 39 Flat Thrust Washer 61 Bearing Rollers 28 40 Reverse Idler Shaft 62 Spacer 41 Reverse Idler Shaft 63 Tange...

Page 251: ...gs 1 Wash the front and rear bearings thoroughly in a cleaning solvent Fig 4B Removing Reverse Shifter Shaft Lock Pin 11 Press main drive gear down from front bearing fig 7B 12 From inside case tap ou...

Page 252: ...into holes in the bores and are bored in place This insures the positive alignment of the bushings and their shafts as well as proper meshing of gears Because of the high degree of accuracy to which t...

Page 253: ...them in place slide the hub into the sleeve NOTE The sleeve with the large square edge opposite the fork groove identifies the 3 4 synchronizer sleeve ASSEMBLY OF MAINSHAFT 1 From the rear of the mai...

Page 254: ...f the gear to the flat surface of the rear bearing retainer Fig 14B ASSEMBLY OF COUNTERGEAR 1 Install roller spacer tube type in countergear 2 Using heavy grease to retain the rollers install a spacer...

Page 255: ...detent position fig 6B 12 Lower the mainshaft assembly into the case making certain the notches on the fourth speed synchroniz ing ring correspond to the keys in the clutch assembly fig 18B CAUTION Be...

Page 256: ...nto second gear detent position 25 Install side cover gasket and carefully position side cover into plate There is a dowel pin in the cover to assure proper alignment with the case Install attaching b...

Page 257: ...Speedometer Drive Gear 20 Output Yoke 2 1 Flange Nut 22 Rear Bearing Retainer Oil Seal 23 Rear Bearing Retainer 24 Mainshaft Rear Bearing 25 Rear Bearing Snap Ring 26 Snap Ring 27 Countershaft 28 Coun...

Page 258: ...Spring 42 Snap Ring 54 Reverse Idler Gear 7 Drive Gear and Pilot 19 Thrust Washer 32 Synchronizer Keys 43 3rd Speed 55 Case Bearings 20 Rear Main Bearing 33 3rd 4th Synchronizer Countergear 56 Fill Pl...

Page 259: ...taining ring 11 Remove drive gear and bearing by tapping gently on bottom side of drive gear shaft and prying directly opposite against the case and bearing snap ring groove at the same time Remove 4t...

Page 260: ...are removed 3 Drive out pin holding reverse shifter head and drive out the shaft CAUTION Exercise extreme care during shaft removal since detent balls are under spring tension in the rear rail boss h...

Page 261: ...aft hole and grease to hold in place Continue pushing this shaft through cover bore and fork until retainer hole in fork lines up with hole in shaft Install retainer pin and move to neutral position 6...

Page 262: ...new oil slinger onto drive gear shaft using Tool J 22872 fig 11Q Slinger should be located flush with bearing shoulder on drive gear See Figure 8Q for direction of slinger installation CAUTION Exercis...

Page 263: ...move snap ring in front of 3rd 4th synchronizer assembly 3 Remove reverse driven gear 4 Press behind second speed gear to remove 3rd 4th synchronizer assembly 3rd speed gear and 2nd speed gear along w...

Page 264: ...ace Check synchronizer springs for looseness or breakage 7 Inspect second gear synchronizing ring for excessive wear 8 Inspect bronze synchronizer cone on 2nd speed gear for excessive wear or damage A...

Page 265: ...ft and against synchronizer hub Index synchronizer key slots with keys in synchro nizer hub 6 Install 3rd speed gear thrust washer onto mainshaft with tang on thrust washer in slot on shaft and agains...

Page 266: ...ng ring Discard snap ring 5 Position assembly on an arbor press and press shaft from 3rd speed countergear Assembly 1 Position 3rd speed countergear and shaft in arbor press and press the gear onto th...

Page 267: ...sition Tool J 22874 5 in clutch gear case opening and engaging front mainshaft fig 23Q Rotate case onto front end NOTE Install 1st speed gear thrust washer on shaft if not previously installed 4 Insta...

Page 268: ...er shaft brake NOTE On models equipped with 4 wheel drive install rear lock nut and washer using Tool J 23070 fig 26Q Torque lock nut to 120 ft lbs and bend washer tangs to fit slots in nut Fig 23Q In...

Page 269: ...remove complete unit from case as shown in Figure 3D NOTE Disassembly of rear output shaft sub assembly is covered later in this section 7 Remove locknut and washer from front output shaft yoke if no...

Page 270: ...Lock Plate Bolt 2 3 Inte rm edia te S haft Lock Plate 2 4 In te rm ed ia te S haft B earing S pac e r 25 In te rm ed ia te S haft 2 6 In te rm ed ia te S haft N e e d le Bearings 27 In te rm ed ia te...

Page 271: ...f lubricant and dirt Remove all trace of gaskets from surfaces where used Inspectiorv Carefully inspect all bearings and rollers for evidence of chipping cracks or worn spots that would render bearing...

Page 272: ...ont Shaft Gear 26 Front Wheel Drive Bearing Cup 53 Direct Drive Gear 1 1 Front Output Gear Shift Rail 41 Speedometer Drive 54 Snap Ring Part of 12 Thrust Washer 27 Tanged Thrust Gear Adapter Assembly...

Page 273: ...her seating the front bearing on the shaft 7 Support yoke assembly in soft jaw vise and install washer and locknut CAUTION Locknut must be torqued to 200 250 ft lbs before installing prop shaft during...

Page 274: ...ck and rear cover Torque bolts to 30 ft lbs Fig 13D lnstalling Front Output Shaft Rear Bearing Fig 12D Installing Rear Output Shaft Rear Seal Fig 14D Installing Front Output Shaft Front Bearing 9 Posi...

Page 275: ...ar output shaft bearing assembly Torque retaining bolts to 30 ft lbs Fig 16D Installing Interm ediate Shaft CAUTION Use care to prevent damage to pilot bearings when engaging input shaft pilot 20 Inst...

Page 276: ...e of cover Assembly of Transfer Case 7M 59 Idler Gear 7M 59 Shift Rail and Fork Assemblies 7M 59 Front Output Shaft Assembly 7M 60 Rear Output Shaft Assembly 7M 60 Miscellaneous 7M 62 and using a piec...

Page 277: ...h e r 24 Snap Ring Cover and Gasket 51 Locknut 9 Roller Bearings 25 Bearing 3 6 Thrust W a s h e r 52 Outp ut Yoke 10 S pacer 2 6 S pee dom e te r Gear 37 Snap Ring 53 Bearing Retainer 1 1 Thrust W a...

Page 278: ...Limits are 000 to 002 inch 3 Install idler gear assembly with dummy shaft into case through front output bore large end first Fig 12C Install idler shaft from large bore side and drive through using...

Page 279: ...ail in the front wheel drive 4 Hi position with the clutch teeth in mesh with the teeth of the front wheel hi gear 4 Line up washer high gear and sliding clutch with Fig 8C Removing Idler Gear Shaft b...

Page 280: ...hift Rail Connector Link 60 Front Output Shaft 12 Bearing 36 Front Wheel Drive Shift Rail 61 Needle Bearings 13 Snap Ring 37 Interlock Pins 62 Spacer 14 Thrust W asher 38 Rear Idler Lock Nut 63 Needle...

Page 281: ...rease and install new bearing in retainer housing using Tool J 23431 Fig 17C 6 Install housing onto output shaft assembly install spacer and speedometer gear then install bearing Fig 18C 7 Install rea...

Page 282: ...ing Idler Shaft COVER FLAT Fig 14C lnstalling Idler Shaft Rear Cover J 22836 Fig 16C Installing Front Output Bearing Retainer Seal J 23431 BEARING Fig 17C lnstalling Rear Output Shaft Housing Bearing...

Page 283: ...r Case 7M 65 Cleaning and Inspection 7M 65 Subassembly Repairs 7 M 67 Differential Carrier Assembly 7M 6g Lockout Clutch Assembly 7M 69 Input Shaft Assembly 7M 69 Range Box Assembly 7M 69 Input Gear B...

Page 284: ...retainer to transfer case Tap on front of shaft or carefully pry retainer away from case Remove retainer from shaft and discard gasket Recover any roller bearings which may fall from rear cover NOTE I...

Page 285: ...Brg Outer Ring 33 Input Shaft 0 Ring 55 Countergear 12 Brg Retaining Ring 34 Input Shaft Pilot Bearings 56 Countergear Spacers and Brgs 13 Thrust Washer Locating Pin 35 Differential Carrier Assembly 5...

Page 286: ...ure 13F for exploded view of subassemblies Differential Carrier Assembly Fig 13F Disassembly 1 Remove bolts from carrier assembly and separate carrier sections 2 Lift the pinion gear and spider assemb...

Page 287: ...mbly Fig 13F Disassembly 1 Remove front side gear from input shaft assembly and remove thrust washer roller bearings 123 and spacers from front side gear bore Note position of spacers to facilitate re...

Page 288: ...a screw driver pry behind open end of large snap ring retaining input bearing in bearing retainer fig 15F and remove ring from retainer Tap bearing from retainer Fig 12F Removing Interm ediate Chain...

Page 289: ...7M 70 CLUTCHES AND MANUAL TRANSMISSIONS Fig 13F Transfer Case Exploded View OVERHAUL MANUAL...

Page 290: ...23 Lockout Shifter Shaft 70 S hift Fork Retaining Pin 24 0 Ring Seal 71 Lockout S hift Fork 25 Lockout Shaft Connector Link 72 Lockout Clutch Spring 26 0 Ring Seal 73 Spring Washer Cup 27 Range Select...

Page 291: ...emove cluster gear thrust washers from case Fig 15F Removing Input Shaft Bearing to Retainer Snap Ring 14 Clean and inspect all components Replace worn and defective parts Assembly Fig 13F Installing...

Page 292: ...r and install using tool J 21359 Fig 16 4 Position bearing retainer and gasket to housing Install attaching bolts and tighten to specifications Rear Output Shaft Housing Assembly Fig 13F Disassembly 1...

Page 293: ...d 2 Support rear cover and press bearing from cover 3 Position new bearing to outside face of cover and using a piece of wood to cover bearing press bearing into cover until flush with opening 4 Posit...

Page 294: ...to assist in positioning chain on the drive sprocket 9 Install the shift fork on the clutch assembly and the shift rail then push the clutch assembly fully into the drive sprocket Install roll pin ret...

Page 295: ...clutch shift rail poppet ball spring and screw plug in case 20 Install poppet plate spring gasket and plug if not installed during reassembly of range box 21 Install shift levers on the range box shif...

Page 296: ...sleeve spline with transmission oil before assembly 2 Coat O D of seal with sealing compound and install seal using Tool J 23504 and Handle J 8092 in a similar manner as shown in Fig 3H Utility Model...

Page 297: ...TRANSMISSIONS All Except Utility Models with Full Time 4 Wheel Drive Units Disassembly of Adapter Fig 4H Fig 4H Autom atic Transmission Adapter Cross Section Except Full Time 4 Wheel Drive Units 1 Us...

Page 298: ...NUAL TRANSMISSIO NS 7M 79 SPECIAL TOOLS 1 J 6456 Height Gauge 2 J 1048 Gauge Plate 3 J 1522 Pilot Bearing Driver 4 J 5824 Clutch Pilot Tool 5 J 1448 Pilot Bearing Puller Fig IST C lutch Special Tools...

Page 299: ...Speedometer Drive Gear Remover and Adapter J 5814 15 7 J 1453 01 Speedometer Drive Gear Press Plates and Press Plate Holder J 358 1 8 J 2228 Rear Bearing Press Plates 9 J 933 Main Drive Gear Wrench 1...

Page 300: ...Adapter 12 J 23070 Mainshaft Rear Bearing Lock Nut Installer 1 J 22832 Countergear Rear Bearing Remover 2 J 8433 1 Bearing Puller 3 J 22872 Clutch Gear Bearing Remover and Installer 4 J 22833 Front B...

Page 301: ...ont Output Shaft Bearing Retainer Seal Installer 6 J 21359 Rear Output Shaft Bearing Retainer Seal Installer 7 J 23431 Rear Output Shaft Housing Bearing Remover and Installer 8 J 7137 Adapter Seal Ins...

Page 302: ...u t Shaft Bearing R etainer Seal 3 J 2 1 3 5 9 In p u t gear Bearing R etainer Seal Installer Installer 4 J 8 6 1 4 1 C om panion Flange Rem over 2 J 2 2 3 8 8 Rear O u tp u t S haft Seal Installer Fi...

Page 303: ...staller 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 Pilo...

Page 304: ...ng any disassembly operation the exterior of the case should be thoroughly cleaned to prevent the possibility of dirt entering the transmission internal mecha nism During disassembly all parts should...

Page 305: ...Cushion Spring Waved 18 Planet Carrier 55 Pinion Thrust Washer 19 Planet Input Sun Gear Thrust Washer 56 Planet Long Pinion 20 Ring Gear 57 Low Sun Gear Needle Thrust Bearing 21 Reverse Piston 58 Low...

Page 306: ...seal ring Transmission Internal Components 9 Rotate the holding fixture until the front of the transmission is pointing up and remove the seven oil pump bolts The bolt holes are offset to facilitate p...

Page 307: ...snap ring past the shoulder on the reverse pack pressure plate a feeler gauge may be used as a guide 16 Install Tool J 9542 through the rear bore of the case with the flat plate on the rear face of th...

Page 308: ...ts indicated by arrows in Figure 11PG and carefully lift out the valve body and gasket disengaging the servo apply tube from the transmission case as the valve body is removed 24 If necessary the TV s...

Page 309: ...amaged the oil pump body should be replaced Fig 12PG Inner Control Levers Parking Pawl and Bracket 6 Inspect converter housing hub O D for nicks or burrs which might damage pump seal or bushing Repair...

Page 310: ...pring 18 Servo Piston Seal Fitting Oil Seal 7 Reverse Clutch Piston Ring 38 Lock Plate Attaching Return Spring 19 Servo Piston Screw Retainer Snap Ring 20 Servo Piston Rod 39 Lock Plate 8 Reverse Clut...

Page 311: ...ings Springs 40 Clutch Flange 6 Pump Oil Seal 17 Pump Priming Valve 31 Clutch Spring Retainer Ring 7 Oil Pump Body 18 Pump Priming Valve Retainer 41 Planet Carrier and 8 Pump to Case Oil Spring 32 Clu...

Page 312: ...Range Selector Detent Roller Spring 1 1 Park Lock Actuator Assembly 12 Range Selector Detent Roller Spring Retainer 13 Park Lock Pawl Shaft 14 Park Lock Pawl 15 Park Lock Pawl Shaft Retaining Ring 16...

Page 313: ...and and struts as outlined under Transmission Assembly NOTE If necessary remove two bolts and Fig 19PG Checking Gear End Clearance use J 6585 pullers and J 6585 3 adapters to remove pump assembly Repl...

Page 314: ...steel ball in the clutch drum that acts as a relief valve Be sure that it is free to move in the hole and that the orifice leading to the front of the drum is open If the clutch relief valve check ba...

Page 315: ...essive wear Fig 22PG Installing Clutch Drum Plates typica Planet Assembly and Input Shaft Inspection 1 Wash planet carrier and input shaft in cleaning solvent blow out all oil passages and air dry CAU...

Page 316: ...the output shaft flange Feed J 4599 into the short planet pinion from the lower end pushing the planet pinion shaft ahead of it until the tool is centered in the pinion and the pinion shaft is remove...

Page 317: ...he lower thrust washer 18 Select the proper pinion shaft as marked in Step 2 lubricate the shaft and install it from the top pushing the assembling tools ahead of it 19 Turn the pinion shaft so that t...

Page 318: ...nt and air dry Check condition of all component parts of the assembly Replace any bent damaged or scored parts Body and hub must be replaced as a unit Assembly 1 Reassemble governor weights and reinst...

Page 319: ...y Check all valves and their bores for burrs or other deformities which could result in valve hang up Assembly 1 Replace valve components in the proper bores reversing the disassembly procedures given...

Page 320: ...s Gasket 10 Low and Drive Valve 21 High Speed Down Shift Timing Valve Stop Pin 22 High Speed Down 32 Detent Valve Shift Timing Valve 33 Throttle Valve Spring Spring Regulator 23 High Speed Down 34 Thr...

Page 321: ...nd press it into place 4 Replace extension rear oil seal using Seal Installer J 5154 Prelubricate between lips of seal with cup grease TRANSMISSION ASSEMBLY NOTE Use only transmission oil or petro leu...

Page 322: ...stalled in the groove at the 7 o clock position in the case Then install the thick pressure plate which has a dimple in one lug to align with the same slot in the case as the notched lugs on the other...

Page 323: ...out of case 22 Place the seal ring in the groove around the oil pump body and the two seal rings on the pump cover extension Install clutch drum selective thrust washer oil pump gasket and oil pump t...

Page 324: ...rque and install protective cap CAUTION The amount of back off is not an approximatefigure it must be exact THROTTLE VALVE ADJUSTMENT No provision is made for checking TV pressures However if operatio...

Page 325: ...pection 7A 48 Assembly 7A48 Low and Reverse Roller Clutch Support 7A 50 Disassembly 7A 50 Inspection 7A 52 Assembly 7A 52 Governor Assembly 7A 52 Disassembly 7A 52 Inspection 7A 52 Governor Gear Repla...

Page 326: ...A C T IO N C ARRIER G O V E R N O R OUTPUT CARRIER ST A T O R IN T ERM ED IA TE M A N U A L SH A FT O V E R R U N SHAFT ROLLER CLUTCH L O W A N D REVERSE CLUTCH S U N O UTPUT G E A R SH A FT INPUT SH...

Page 327: ...re remove torque converter assembly 3 Remove vacuum modulator assembly attaching bolt and retainer 4 Remove vacuum modulator assembly O ring seal and modulator valve from case fig 3M Discard O ring RE...

Page 328: ...etaining clip 6 Remove governor cover retainer with a screwdriver 7 Using a screwdriver and hammer gently tap along governor cover lip fig 6M remove governor cover and O ring seal fig 7M Discard seal...

Page 329: ...r lever Remove detent control valve link from detent actuating lever fig 12M Refer to page 7A 37 for valve body disassembly 3 Remove transfer plate support bolts Remove transfer support plate fig 13M...

Page 330: ...Y SPACER PLATE TO CASE GASKET Fig 12M Removing Manual Control Valve Link Valve Body and Detent Actuating Lever Fig 14M Removing Valve Body Transfer Spacer Plate and Gasket TORQUE WRENCH SPACER SUPPORT...

Page 331: ...r Feed Screen 7 Remove governor feed screen from governor feed hole drive oil in case fig 17M 8 Remove manual shaft to case retainer with screwdriver fig 18M 9 Loosen nut holding range selector inner...

Page 332: ...ing Park Lock Lock Bracket 14 Remove parking pawl shaft retaining plug parking pawl shaft and parking pawl fig 24M if necessary NOTE The parking pawl shafts retaining plug may be removed by using a bo...

Page 333: ...ly from case fig 27M Discard pump gasket Fig 24M Parking Pawl Shaft Retaining Plug Parking Pawl Shaft and Parking Pawl Fig 27M Removing Pump from Case PARK PAWL SHAFT PARKING PAWL SHAFT RETAINING PLUG...

Page 334: ...e intermediate clutch drive plates and steel reaction plates fig 29M 5 Remove intermediate clutch pressure plate fig 30M Fig 31M Removing Intermediate Overrun Brake Band Fig 32M Removing Direct and Fo...

Page 335: ...RING INPUT RING GEAR OUTPUT CARRIER OUTPUT CARRIER Fig 34M Removing Input Ring Gear to Output Shaft Snap Ring 8 Remove input ring gear front thrust washer fig 33M NOTE Washer has 3 tangs 9 Remove inpu...

Page 336: ...TCH PACK Fig 40M Removing Low and Reverse Clutch Pack 15 Remove low and reverse clutch support and race assembly and anti clunk spring 16 Remove low and reverse clutch faced plates and steel reaction...

Page 337: ...gear tanged front thrust washer fig 43M 20 Remove output ring gear to case needle bearing assembly fig 44M OUTPUT RING G E A R AN D OUTPUT SHAFT ASSEMBLY Fig 42M Removing Output Ring Gear and Shaft As...

Page 338: ...r Remove seventeen 17 piston springs from piston fig 46M 23 Remove low and reverse clutch piston assembly by applying compressed air in passage shown on Figure 47M 24 Remove low and reverse clutch pis...

Page 339: ...ntermediate clutch accumulator piston cover and remove retaining ring fig 50M 27 Remove intermediate clutch accumulator piston cover and remove O ring seal from case 28 Remove intermediate clutch accu...

Page 340: ...actuating lever and retaining pin stop spring retainer seat outer spring inner spring washer and detent valve Inspection 1 Inspect all valves for scoring cracks and free movement in their respective...

Page 341: ...HER 29 DETENT VALVE INNER SPRING 30 DETENT VALVE OUTER SPRING 31 DETENT VALVE OUTER SPRING SEAT 32 DETENT VALVE SPRING RETAINER 33 DETENT VALVE STOP 34 DETENT VALVE ACTUATING LEVER BRACKET 35 DETENT V...

Page 342: ...P B O D Y BOLTS 5 IN TE R M E D IA TE CLUTCH S PR IN G SEAT RETAINER NOTE Forward clutch oil seal rings are teflon on Monte Carlo 4f 6 Remove pump cover to direct clutch drum housing selective thrust...

Page 343: ...oil pump body should be replaced 5 Inspect converter housing hub O D for nicks or burrs which might damage pump seal or bushing Repair or replace as necessary 6 If hub lip seal is damaged or is leakin...

Page 344: ...e oil seal rings CAUTION Check pump cover and body oil passages to make sure they are not restricted figs 64M and 65M 6 Install intermediate clutch piston inner seal and outer seal on piston 7 Install...

Page 345: ...h piston 9 Remove direct clutch piston outer seal and inner seal fig 73M 10 Remove direct clutch piston center seal from drum fig 74M Inspection 1 Inspect drive and driven clutch plates for signs of b...

Page 346: ...ng Needle Roller Bearing DIRECT CLUTCH DRUM TO FORWARD CLUTCH HOUSING NEEDLE ROLLER BEARING IN T E R M E D IA T E O V E R R U N LUTCH A SSEM B LY DIRECT CLU TC H D R U M R E TA IN IN G RING PRESSURE P...

Page 347: ...es alternating steel and faced plates 7 Install direct clutch pressure plate and retaining ring 8 Install intermediate overrun roller clutch assembly with four 4 holes toward front of transmission CAU...

Page 348: ...CK 5 5 NONE 6 Remove the forward clutch inner and outer piston seals fig 81M Fig 75M lnstalling Direct Clutch Piston Inspection l Inspect drive and driven clutch plates for signs of 2 Remove face plat...

Page 349: ...H P R E S S U R E P L A T E Fig 77M Forward Clutch Assembly Exploded View Fig 78M Removing Forward Clutch Retaining Ring and Pressure Plate Fig 79M Rem oving Forward Clutch Clutch Pack 5 Inspect inpu...

Page 350: ...seal and outer piston seal 2 Install the forward clutch piston assembly with the aid of a feeler gauge or a piece of 020 piano wire crimped into copper tubing fig 83M 3 Install twenty one 21 clutch r...

Page 351: ...on C SUN GEAR AND SUN GEAR DRIVE SHELL FIG 85M Disassembly 1 Remove sun gear to sun gear drive shell rear retaining ring fig 86M 2 Remove sun gear to drive shell flat rear steel thrust washer fig 87M...

Page 352: ...AUTOMATIC TRANSMISSION 7A 49 Fig 85M Planetary Gear Train Exploded View OVERHAUL MANUAL...

Page 353: ...st Washer LOW AND REVERSE ROLLER CLUTCH SUPPORT FIG 89M Disassembly 1 Remove low and reverse clutch to sun gear shell thrust washer 2 Remove low and reverse overrun clutch inner race from support fig...

Page 354: ...U S T H A V E 4 EQ U AL LY S P A C E D 091 LU BE H O L E S O N THIS S ID E L O W A N D R E V E R S E C L U T C H S U P P O R T TCH R O L L E R C L U A S S E M B L Y Fig 89M Low and Reverse Clutch Ass...

Page 355: ...s follows Disassembly 1 Cut off one end of each governor weight pin and remove pins governor thrust cap governor weights and springs Governor weights are interchangeable from side to side and need not...

Page 356: ...r assembly thoroughly to remove any chips that may have collected Assembly 1 Install governor valve in bore of sleeve large land end first 2 Install governor weights and springs and thrust cap on gove...

Page 357: ...ximately 1 16 below rear face inside gear end fig 99M Sun Gear Bushing With sun gear properly supported remove two 2 sun gear bushing using tool J 23062 3 and drive handle J 8092 with extension J 2146...

Page 358: ...Components 4 1 Install low and reverse clutch piston assembly with notch in piston installed adjacent to parking pawl 2 Install seventeen 17 piston return coil springs 3 Install spring retainer and re...

Page 359: ...ch assembly 19 Install clutch assemblies into case CAUTION Make certain forward clutch face plates are positioned over input ring gear and the tangs on direct clutch housing are installed into slots o...

Page 360: ...ive gear retaining clip into hole in output shaft 2 Heat a new speedometer drive gear using a heat lamp or suitable heat method 3 Align slot in speedometer drive gear with retaining clip and install 4...

Page 361: ...etent control valve wire to detent valve actuating lever then attach lever to valve body 10 Install detent roller and spring assembly to valve body 11 Align lube holes in strainer with those in valve...

Page 362: ...te Roller Service 7A 90 Center Support Service 7A 94 Reaction Carrier Roller Clutch and Output Carrier Assembly 7A 98 Pinion Replacement 7A 99 Output Shaft Rear Internal Gear Sun Gear and Shaft Inspec...

Page 363: ...7A 60 AUTOMATIC TRANSMISSION Fig IT S ide Cross Section Typical OVERHAUL MANUAL...

Page 364: ...ch fig 2T NOTE Do not over torque holding screw This will bind center support 3 Install fixture and transmission into holding Tool Base J 3289 14 with bottom pan facing up fig 2T 4 Remove modulator as...

Page 365: ...case Fig 7T Removing Filter Retainer Bolt Fig 8T Removing Filter Assembly and 0 Ring 3 Remove speedometer driven gear attaching screw and retainer fig 6T 4 Withdraw speedometer driven gear assembly fr...

Page 366: ...e assembly from the pressure switch assembly fig 8T A 2 If necessary remove the pressure switch assembly fig 8T B Fig 9T Removing Detent Roller and Spring Assembly Fig lOT Removing Control Valve Assem...

Page 367: ...y 6 Remove governor pipes from control valve assembly 7 Disconnect solenoid lead wires from connector terminal fig 10T B Removal of Rear Servo Valve Body Spacer Gasket and Front Servo 1 Remove rear se...

Page 368: ...gs should be used d If the gauge surface is between the steps the medium pin identified by 2 rings should be used e If both steps are above the gauge surface the short pin identified by 1ring should b...

Page 369: ...se fig 17T 3 Remove manual shaft and jam nut from case fig 18T Do not lose jam nut as it becomes free from manual shaft NOTE CL Model transmission does not have parking brake components 4 Remove parki...

Page 370: ...rting a screwdriver between the parking pawl shaft and the case rib and prying outwards fig 22T 9 Remove parking pawl shaft and parking pawl fig 22T Removal of Rear Oil Seal and Case Extension 1 If ne...

Page 371: ...p cover and forward clutch housing If more or less washer thickness is required to bring end play within specifications select proper washer from the following chart FRONT END WASHER THICKNESS Thickne...

Page 372: ...ights J 6585 01 into bolt holes in pump body and remove pump assembly from case fig 27T See illustration for location of threaded holes 4 Remove and discard pump to case seal and gasket 5 Remove forwa...

Page 373: ...g 3 lugs that is located between output shaft thrust washer and rear face of transmis sion case If a different washer thickness is required to bring end play within specification it can be selected fr...

Page 374: ...one waved steel plate b CY Model Remove two 2 composition and three 3 steel clutch plates 14 Remove center support to case retaining snap ring fig 35T 15 Remove entire gear unit assembly by lifting wi...

Page 375: ...haft facing down through hole in work bench 18 Remove rear unit selective washer from transmis sion case fig 37T 19 Remove center support to case spacer fig 37T A 20 Remove rear band assembly fig 38T...

Page 376: ...al as illustrated 1 Remove center support assembly fig 39T 2 Remove center support to reaction carrier thrust washer fig 40T 3 Remove center support to sun gear races and thrust bearing Fig 41T Removi...

Page 377: ...snap ring fig 43T 11 Remove output shaft 12 Remove output shaft to rear internal gear thrust bearing and two 2 races 13 Remove rear internal gear and mainshaft fig 44T NOTE Do not drop bearings 14 Rem...

Page 378: ...nstallation Steel Speedometer Drive Gear 1 Install speedometer drive gear remover Tool J 21427 01 and J 9539 bolts with J 8105 or suitable puller on output shaft and remove speedometer drive gear fig...

Page 379: ...ng inspections and replace governor driven gear if necessary Inspection 1 Wash all parts in cleaning solvent air dry and blow out all passages 2 Inspect governor sleeve for nicks burrs scoring or gall...

Page 380: ...lly clean governor sleeve of chips that remain from original gear installation 4 Support governor on 7 64 inch plates installed in exhaust slots of sleeve position new gear in sleeve and with a suitab...

Page 381: ...less the oil seal ring requires replacement For service the oil seal ring is aluminum 1 Inspect servo pin for damage 2 Inspect piston and oil ring for damage 3 Check fit of servo pin in piston and cas...

Page 382: ...F CJ CR CL CM CK CZ and CS Remove retaining pin 1 2 modulator bushing 1 2 regulator valve 1 2 regulator spring 1 2 detent valve and 1 2 shift valve 6 From next bore down remove retaining pin 2 3 shift...

Page 383: ...CR CK and CL Install 1 2 accumula tor valve stem end out into bore Place bore plug into valve bore and install grooved retaining pin from cast surface side of the valve body with the groove entering t...

Page 384: ...til flush with cast surface of the valve body 4 In next bore up install detent spring and spacer Compress spring and secure with small screwdriver fig 56T 5 Install detent regulator valve wide land fi...

Page 385: ...o body attaching bolts 7 Remove pump cover from body 8 Remove retaining pin and bore plug from pressure regulator bore fig 62T 9 Remove hook type oil rings from pump cover 10 Remove pump to forward cl...

Page 386: ...l passages fig 57T 5 Check for damaged cover bolt attaching threads 6 Check for overall flatness of pump body face 7 Check bushing for scores or nicks If replacement is necessary proceed as follows a...

Page 387: ...5 with slide hammer Tool J 2619 and adapter tool J 2619 4 remove bushing d Using Tool J 21465 2 with Driver Handle J 8092 pressor drive replacement bushing into place until tool bottoms 14 Inspect oil...

Page 388: ...ve pump assembly from case bore 13 Install pump to case O ring seal FORWARD CLUTCH DISASSEMBLY INSPECTION AND ASSEMBLY Disassembly 1 Place forward clutch assembly with turbine shaft through hole in be...

Page 389: ...sing fig 72T Inspection 1 Inspect composition faced and steel clutch plates Fig 68T Removing Forward Clutch Hub and Thrust Washers Fig 69T Removing Turbine Shaft from Forward Clutch Housing for signs...

Page 390: ...using lip faces up fig 72T NOTE Apply automatic transmission oil to all seals and clutch plates 3 Place seal protector Tool J 21362 over clutch hub and install outer clutch piston seal Protector J 214...

Page 391: ...MISSION FORWARD CLUTCH ASSEMBLY PLATES 5 THRUST WASHERS Fig 73T Forward Clutch Assembly Exploded View Fig 74T Installing Forward Clutch Piston Fig 75T Installing Forward Clutch Composition and Steel P...

Page 392: ...h U notch NOTE Radially grooved composition clutch plates are installed at the factory only All service composition plates have the smooth surface configuration Fig 77T Air Checking Forward Clutch Ass...

Page 393: ...and remove backing plate to direct clutch housing snap ring fig 80T 4 Remove direct clutch backing plate composition plates steel clutch plates and waved steel plate NOTE No waved steel plate used in...

Page 394: ...direct clutch pistons have identical inside and outside diameters It is possible to reverse the Fig 82T Removing Direct Clutch Piston Assembly pistons during reassembly therefore care should be exerc...

Page 395: ...ter chamfer on the clutch plate end and or a groove in theface at the base of the tower fig 87T Should replacement of the direct clutch housing become necessary extreme care must be taken in obtaining...

Page 396: ...king plate retaining snap ring fig 9IT Fig 90T lnstall Direct Clutch Backing Plate Composition Plates and Steel Plates NOTE Install rollers that may have come out of the roller cage by compressing the...

Page 397: ...ight oil feed hole it will escape from direct clutch passage left oil feed hole This is considered normal Apply air through left oil feed hole to actuate piston and move direct clutch INTERMEDIATE CLU...

Page 398: ...e clutch piston Fig 98TD 6 Remove inner and outer piston seal CAUTION Do not remove three 3 screws retaining roller clutch inner race to center support Fig 97T Center Support and Oil Seal Rings Fig 96...

Page 399: ...Fig 98TC Removing Intermediate Clutch Spring Guide Fig 98TA Removing Spring Retainer INTERMEDIATE CLUTCH RELEASE SPRIN G 3 Fig 98TB Removing Clutch Release Springs CENTER SUPPORT RACE ASSEMBLY INTERME...

Page 400: ...or damage NOTE All service center support oil seal rings are hook type cast iron 4 Air check oil passages to be sure they are not inter connected 5 Inspect piston sealing surfaces for scratches 6 Insp...

Page 401: ...washer surfaces for signs of scoring or wear Fig 102T Installing Intermediate Clutch Piston INTERMEDIATE CLUTCH SPRING GUIDE Fig 102TA Installing Intermediate Clutch Spring Guide 4 Inspect bushing fo...

Page 402: ...or flaking fig 42T Pinion Replacement Procedure 1 Support carrier assembly on its front face 2 Using a 1 2 inch diameter drill remove stake marks from the end of the pinion pin or pins to be replaced...

Page 403: ...ND SHAFT Output Shaft 1 Inspect bushing for wear or galling If replacement is necessary proceed as follows a Thread Tool J 21465 16 into bushing and using Slide Hammer J 2619 remove bushing Fig 107T R...

Page 404: ...marks to be in bushing lubrication grooves b CM Model Using Tool J 8400 19 or J 9640 with Driver Handle J 8092 drive or press replacement bushing into place flush to 010 below oil seal counter bore ar...

Page 405: ...amaged threads rough oil surface or loose lever 6 Inspect inside detent lever for cracks or a loose pin 7 Inspect parking pawl shaft if removed for damaged retainer groove 8 Inspect parking pawl retur...

Page 406: ...Driver Handle J 8092 remove bushing Replace Using tool J 21465 8 adaptor ring J 21465 9 Driver Handle J 8092 and extension J 21465 13 with lube passage facing front of transmission case drive replace...

Page 407: ...l gear as follows and retain with petrolatum a Place large race against internal gear with outer flange facing forward or up fig 117T Fig 114T B Checking Converter End Clearance b Place thrust bearing...

Page 408: ...RACE SNAP RING MAIN SHAFT OUT PUT CARRIER ASSEMBLY BEARING I D FLANGE RACE THRUST WASHER NON METAL BEARING FRONT INTERNAL GEAR RING REACTION CARRIER ASSEMBLY ROLLER SUN GEAR ASSEMBLY SUN GEAR SHAFT I...

Page 409: ...lnstalling Rear Internal Gear to Sun Gear Bearing and Races FLANGED RACE Fig 118T lnstalling Rear Internal Gear to Output Shaft Bearing and Races THRUST BEARING I D FLANGED RACE I D FLANGED RACE THRUS...

Page 410: ...nt internal gear rings with the SERVICE ring 16 Install center support to sun gear thrust races and bearings as follows Retain with petrolatum a Install large race center flange up over sun gear shaft...

Page 411: ...sembly to hold units in place 22 Install output shaft to case thrust washer tabs in pockets fig 126T and retain with petrolatum CASE MODIFICATION CORVETTE NOTE Due to the configuration of the body flo...

Page 412: ...ed on pawl and other end on case 5 Install parking bracket with guides over parking pawl using two attaching bolts torque to 18 ft lbs 6 Install rear band assembly so that two lugs index with two anch...

Page 413: ...stall three 3 steel and three 3 composition clutch plates Start with the waved steel plate and alternate composition and steel clutch plates fig 132T b CY Model Oil and install two 2 steel and three 3...

Page 414: ...t jam nut on manual shaft and tighten to 18 ft lbs fig 135T f Install retaining pin indexing with groove in manual shaft Rotate transmission to vertical position and remove J 21795 REAR END WASHER THI...

Page 415: ...assembly and gasket NOTE If turbine shaft cannot be rotated as pump is being pulled into place forward or direct clutch housing have not been properly installed to index with all clutch plates This c...

Page 416: ...or its actual thickness 24 Install remaining front pump attaching bolt and seal Torque 18 ft lbs REAR EXTENSION ASSEMBLY Fig 142T Location of Check Balls c Push turbine shaft rearward d Push output sh...

Page 417: ...s time 7 Install front servo spring and spring retainer into transmission case 8 Install retainer pins in front servo pin groove and install pin into case so that tapered end contacts band Make certai...

Page 418: ...12 Install detent wire and lead wire to electrical connector fig 10TB TORQUE WRENCH Fig 148T Installing Rear Servo Assembly Installation of Rear Servo Assembly 1 Check rear servo band apply pin Fig 14...

Page 419: ...earest the center of the transmission Fig 150T NOTE If transmission is in vehicle before installing the control valve assembly and governor pipes as outlined in Step 3 below insert the governor screen...

Page 420: ...embly 2 Install filter and intake pipe assembly fig 8T Fig 153T lnstalling Vacuum Modulator and Valve Fig 154T lnstalling Governor Assembly NOTE It is recommended that the filter be replaced rather th...

Page 421: ...METER DRIVEN GEAR ASSEMBLY 1 Install speedometer driven gear assembly fig 155T 2 Install speedometer driven gear retainer and attaching bolt INSTALL CONVERTER ASSEMBLY With the transmission in cradle...

Page 422: ...0 J 5403 Snap Ring Pliers J 6585 21 J 5853 Torque Wrench 8 J 6839 Oil Pum p Seal Driver 22 J 8039 Snap Ring Pliers 9 J 9546 Clutch Drum Bushing Rem over and Installer 23 J 21848 Lo w Band A djusting T...

Page 423: ...taller Both Rear 12 J 23062 1 Case Bushing Remover and Installer 13 J 21424 9 Extension Housing Bushing Remover and Installer Used with J 8092 1 20 14 J 21424 7 Stator Shaft Front Bushing Installer Us...

Page 424: ...n Installer Converter Pressure Check Fixture Seal Protector Forward and Direct Clutch Inner 9 J 21363 10 J 21409 11 J 21664 12 J 4670 13 J 8059 14 J 5586 15 J 5403 16 J 1313 Seal Protector Intermediat...

Page 425: ...ng Tool Set 6 J 5154 Extension Oil Seal Installer 22 J 21465 8 Part of Bushing Tool Set 7 J 6585 Slide Hammer Weights 23 J 21465 13 Part of Bushing Tool Set 8 J 9539 Slide Hammer Bolts 3 8 16 24 J 214...

Page 426: ...acement 9 3 Wormshaft Bearing Race Replacement 9 3 Ball Nut Servicing 9 4 Assembly 9 5 Adjustment on Bench 9 8 OVERHAUL OPERATIONS Disassembly Figs 1 through 4 As with any ball bearing unit the steeri...

Page 427: ...tor does not clear the opening in the housing easily turn Fig 5 Removing Pitman Shaft Assembly Typical the wormshaft by hand until the sector will pass through the opening in the housing 5 Remove the...

Page 428: ...or the steering gear is disassembled 1 If the seals were not removed at disassembly pry out the old seals using a suitable size screw driver CAUTION Before installing new seals check Fig 7 Removing L...

Page 429: ...d endwise off the worm 3 Wash 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 indenta...

Page 430: ...ng of the circuit 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 Fig 1 3 Filling Ball Guides Corvette up...

Page 431: ...rmshaft into the housing bearing c Thread the adjuster into the housing until nearly all end play is removed from the wormshaft 5 Position the lash adjuster with shim in the slotted end of the pitman...

Page 432: ...ash Adjuster End Clearance screw and shim but without side cover into the housing as that the center tooth of the pitman shaft sector enters the center tooth space of the ball nut 9 Pack the remaining...

Page 433: ...e disassembly 1 Remove the pulley retaining nut and remove the pulley using Tool J 21239 1 2 Place the pump in a vise and remove the union and O ring seal assembly CAUTION In clamping pump in vise be...

Page 434: ...n g 27 Mounting Stud Square Ring Seals Flow Control Valve Flow Control Valve Spring Flow Control Valve Square Ring Seal Pump Housing Reservoir 0 Ring Seal Shaft Seal Shaft Fig 17 Power Steering Pump E...

Page 435: ...install a new part This part is serviced as a unit only and is factory calibrated 6 Check drive shaft for worn splines breaks bushing material pickup etc 7 Always replace all rubber seals and O rings...

Page 436: ...ure 21 2 Install both dowel pins in the pump housing and install a new pressure plate O ring lubricated with Power Steering Fluid Fig 27 Correct Vane Assembly CAUTION Do not use a C ring to replace th...

Page 437: ...Lubricate the outside diameter and chamfer of the end plate with Power Steering Fluid to ensure against damaging the O ring and install into the housing using an arbor press as shown in Figure 29 NOT...

Page 438: ...ck piston and worm circuit may escape and lay loose inside the rack piston chamber 3 Remove the rack piston end plug as shown in Figure 33 NOTE To aid in loosening end plug strike end plug with a bras...

Page 439: ...taining Ring Fig 33 Removing End Plug Fig 31 Power Steering Gear Typical INLET OUTLET T O R SIO N W O R M V A LVE BO DY SPO O L VA LVE ADJUSTER PLUG TEFLON SEALS THRUST TEFLON R IN G RACK PISTO N NUT...

Page 440: ...over 24 Housing 40 Retainer Ring 25 Locknut 41 Needle Bearing 26 Attaching Bolts and Washers 42 Oil Seal 27 Side Cover 43 Back Up Washer 28 0 Ring 44 Oil Seal 29 Pitman Shaft 45 Back Up Washer 30 Scre...

Page 441: ...ers for wear pitting or scoring If any of these conditions exist replace the bearing and washers Assembly CAUTION Place a block of wood under the adjuster plug to protect the thrust bearing surface Fi...

Page 442: ...y stub shaft down Fig 41 Installing Adjuster Plug Seal Fig 42 Installing Retainer lightly tap the stub shaft against the bench until the shaft cap is free from the valve body fig 43 b Pull the shaft a...

Page 443: ...the spool valve dampener O ring removed If the valve does not rotate freely without binding the complete valve and shaft assembly will have to be replaced Assembly Fig 45 1 If valve body O rings and t...

Page 444: ...ressed air 2 Inspect the worm and rack piston grooves and all the balls for scoring If either the worm or rack piston needs replacing both must be replaced as a matched assembly 3 Inspect ball return...

Page 445: ...ainst the bolt boss and will back out the bolt drawing the connector from the housing Discard the connector 4 Clean the housing thoroughly to remove any tapping chips 5 Drive the new connector against...

Page 446: ...with Steering Gear in Vehicle fig 53 If upon inspection of the gear it is found that oil leakage exists at the pitman shaft seals the seals may RETAINING RING BACK UP WASHER OUTER SEAL J 6278 1 J 627...

Page 447: ...rn wheel to left and check for leaks 8 Remove tape and reconnect pitman arm CAUTION The pitman arm to steering gear nut is an important attaching part in that it could affect the performance of vital...

Page 448: ...end wrench to thread the rack piston onto the worm while holding Tool J 7539 against the end of the worm e When the rack piston is completely threaded on the worm remove Ball Retainer J 7539 and Seal...

Page 449: ...d as follows a Make sure the over center adjusting screw is backed all the way out and then turned back in one half turn b Install an inch lb torque wrench with a 3 4 12 point socket on the stub shaft...

Page 450: ...he housing fig 65 5 Remove spring reaction spool washer reaction spring spring retainer and seal fig 66 O ring may now be removed from the reaction spool 6 Remove the annulus spacer valve shaft washer...

Page 451: ...9 26 STEERING Fig 66 Removing Valve Parts from Shaft Fig 67 Removing Plug to Sleeve Key Fig 68 Seal with Clamp Attachment Fig 69 Turning Adjuster Plug out of Sleeve OVERHAUL MANUAL...

Page 452: ...ck out the bolt thus drawing the connector seat from the top cover housing fig 70 Discard the connector seat Clean the housing out thoroughly to remove any tapping chips Drive new connector seat again...

Page 453: ...her and adjustment spring Install O ring seal on reaction spool before installing spool on shaft Install the washer with the chamfer up 8 Install the seal on the valve spool lip down then install spoo...

Page 454: ...her direction from center the valve has been properly balanced Correct the valve adjustment if necessary When the valve is properly adjusted grease end of valve and install dust cap POWER CYLINDER COR...

Page 455: ...r 2 End Plug and Lube Fitting 7 Ball Seat 12 Scraper Element 3 0 Ring 8 Ball Stud Seal 13 Piston Rod Scraper 4 Spring 9 Piston Body 14 Snap Ring 5 Spring Seat 10 Piston Rod Seal 15 Piston Rod Fig 76 P...

Page 456: ...9 J 2927 Steering Wheel Puller 25 J 8092 Handle 10 J 21239 Pump Pulley Remover Stamped 26 J 6278 Pitman Shaft Bearing Remover Pulley 27 J 6278 2 Pitman Shaft Seal Installer 11 J 21854 Column Pivot Pin...

Page 457: ......

Page 458: ...tal 26 12 Body and Chassis Electrical 27 13 Radiator and Grille 29 14 Bumpers 30 15 Accessories 32 LIGHT DUTY TRUCK Section Page 1A Heating and Air Conditioning 33 IB Body 34 3 Front Suspension 36 4 R...

Page 459: ......

Page 460: ...oz Corvette Four Season 3 lbs 4 oz 525 Viscosity Compressor Oil All Systems 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 F...

Page 461: ...orber B02 B07 150 90 Upper End All Others 90 Lower End 20 150 Stablilizer Bar Link Nuts 13 13 18 13 18 Bracket Bolts 24 126 Lower Control Arm Shaft to Crossmember Front 70 Rear 95 Anchor Pin Drum Brak...

Page 462: ...tion raising up 3 and repeating the cycle a total of three times b Jostle the rear of the car three times by applying the same procedure to the rear bumper as used on the front in 3a c Repeat the jost...

Page 463: ...d K Height at the following distance rearward of the front wheel or frontward of the rear wheel Front Rear 29 W A G O N BOTTOM OF FRAME TOP OF AXLE I CHEVROLET MONTE CARLO CHEVELLE CPE ONLY CHEVELLE C...

Page 464: ...e 2 VEHICLE ALIGNMENT TOLERANCES t t FIELD USAGE Column 1 Service Checking Column 3 Service Reset C am ber C aster T o e in Camber Side to Side Caster Side to Side 3 4 1 1 8 1 1 1 2 1 2 1 16 1 2 1 2 V...

Page 465: ...r Camber Toe in Total S A I 8 3 4 1 2 1 2 to 1 1 2 1 2 to 1 1 16 to 5 16 Toe in 1 1 2 to 2 1 2 1 1 4 to 1 3 4 1 2 Toe in to 1 4 Toe out 1 2 1 2 1 4 1 2 3 16 1 16 C A M A R O Standard Caster Camber Toe...

Page 466: ...ug 25 20 TORQUE FT LBS Chevrolet Except 116 W B Station Wagon Chevelle Monte Carlo and 116 W B Station Wagon Nova Camaro Corvette Upper Control Arm Front Bushing Nut 115 80 Rear Bushing Nut 80 80 Lowe...

Page 467: ...in lbs Brake Hose to Wheel Cylinder 22 ft lbs 22 ft lbs Brake Line Clip to Frame 100 in lbs 100 in lbs 100 in lbs 100 in lbs 100 in lbs Front Brake Hose Support Bracket 100 in lbs 100 in lbs 100 in lb...

Page 468: ...x 0034 Max 0035 Max PISTON RING C 0 M P R E S s I o N Clear ance Groove Produc tion Top 0012 0027 0012 0032 0012 0032 0012 0027 0017 0032 2nd 0012 0032 0012 0027 0012 0032 Service Hi Limit Production...

Page 469: ...Intake 2217 2600 3000 2235 2590 Exhaust 2217 2733 3070 2411 2590 Journal Diameter 1 8682 1 8692 1 9482 1 9492 Camshaft Runout 0015 Max Camshaft End Play 001 005 In Line Engine VALVE SYSTEM Lifter Hydr...

Page 470: ...nt Valve Replace at 24 000 Miles 12 B Corvette only PSI at Cranking Speed throttle wide open Maximum variation 20 PSI between cylinders Rotate cam lubricator 180 at 12 000 mile intervals Replace at 24...

Page 471: ...ft Distributor Clamp 20 lb ft Flywheel Housing 30 lb ft Manifold Exhaust 20 lb ft Manifold Exhaust to Inlet 30 lb ft Manifold Inlet 30 lb ft Manifold to head 35 lb ft Thermostat Housing 30 lb ft Water...

Page 472: ...e Manual deral Automatic Cali Manual Fornia Automatic A G B F X V X X X 250 L 6 Base L22 1MV 7043017 7043014 X X 307 V 8 L14 2GV 7043101 7043100 X 307 V 8 L14 2GV 7043105 7043120 X X X X 350 V 8 L65 2...

Page 473: ...1 7 16 245 130 325 2GV 7043111 M 19 32 1 9 32 1 7 16 200 140 250 2GV 7043118 A 19 32 1 9 32 1 7 16 245 130 325 2GV N A M 4MV 7043202 A 7 32 13 32 430 1 2 250 450 4MV 7043203 M 7 32 13 32 430 1 2 250...

Page 474: ...specified as footnote 1 See Procedures in Section 6M Service Manual In Neutral 2 L 6 250 C I D 750 700 3 850 V 8 307 C I D L 14 950 900 3 V 8 350 C I D L 65 1000 900 5 V 8 350 C I D L 48 920 1 900 3...

Page 475: ...ated Hot Output Amps Spec Volts Amps 2000 RPM Amps 5000 RPM 1100544 Corvette w AC 4522 4 4 5 55 61 1102353 Corvette with LS 4 w N40 4521 4 4 5 37 42 1100934 All V 8 s exc Corvette B02 B07 4519 4 4 5 3...

Page 476: ...500 10500 1108430 350 400 454 CID V 8 Engines w Auto Trans Except Corvette w 454 V 8 3563 Ultra High 14 9 65 95 7500 10500 1108400 Corvette 454 V 8 w Man Trans 3563 Ultra High 14 9 65 95 7500 10500 11...

Page 477: ...064 0 6 Hg 15 12 Hg 29 31 4 Manual AC R44T 350 Cu In V 8 2 bbl exc B Wgn 1112168 C 4815 0 1000 RPM 2 1300 RPM 10 2600 RPM 20 4200 RPM C 6020 0 4 Hg 14 7 Hg 29 31 8 All AC R44T 350 Cu In V 8 2 Bbl B Wg...

Page 478: ...50 Cu In V 8 RPO L 82 Corvette 1112150 C 4844 0 1200 RPM 2 1460 RPM 12 2200 RPM 20 5000 RPM C 3064 0 6 Hg 15 12 Hg 29 31 8 Automatic AC R44T 400 Cu In V 8 RPO LF 6 1112166 C 4815 0 1000 RPM 2 1300 RPM...

Page 479: ...bs Crossmember Mounting B olts 25 ft lbs Line Pressure Take Off Plug 13 ft lbs Strainer Retainer Bolt 10 ft lbs Oil Cooler Pipe Connectors to Transmission Case or Radiator 12 16 ft lbs Oil Cooler Pipe...

Page 480: ...Gear Overall Gear Overall Chevrolet 15 1 to 13 1 17 2 1 to 15 1 1 Chevelle Monte Carlo 16 1 to 12 4 1 18 6 1 to 15 1 1 Nova 16 1 to 13 1 18 9 1 to 14 7 1 16 1 to o 13 1 14 25 1 to 11 1 Corvette 16 1...

Page 481: ...8 Ibs ft 30 Ibs ft Steering Wheel to Hub Screws Corvette and Cushioned Rim Wheels Shroud Torque 25 lbs in 25 Ibs in Floor Pan Cover Screws 35 lbs in 38 Ibs in 35 Ibs in 20 Ibs in 35 Ibs in Floor Pan C...

Page 482: ...rn Hose Clamp Screw 26 lbs in 15 lbs in Power Steering Pump Gear Hose Fittings 25 lbs ft Power Cylinder to Relay Rod Nut 45 lbs f t t t Power Cylinder to Frame Bracket 23 lbs f t t t Power Cylinder Fr...

Page 483: ...ving 3 For continuous high speed operation over 75 mph increase tire inflation pressure 4 psi above the recommended pressure up to a CAMARO Engine and Body Style Standard Optional All L 6 V 8 Except Z...

Page 484: ...EET METAL SECTION 11 TORQUE SPECIFICATIONS Chevrolet Chevelle Monte Carlo Nova Camaro Corvette Hood Lock Striker 25 ft lbs 25 ft lbs Hood Catch to Hood 18 ft lbs 18 ft lbs Lock Support to Rad Support...

Page 485: ...t Seat Courtesy A ll 6 631 Rear Seat Courtesy Camaro 6 212 Instrument Panel Compartment 2 1895 Camaro with A C 2 194 Heater or AC Control Camaro Chevelle Monte Carlo 0 7 1445 Chevrolet Nova 2 1895 Cor...

Page 486: ...with the vehicle center line a good method is to sight through rear window and align center of rear window molding through mirror bracket or hood center line 3 A vertical line aligned with center lin...

Page 487: ...p Clock Cigar Lighter Courtesy Lamps Deck Lid Lock Anti Theft Alarm Glove Box and Dome Lam ps 20 Amp Tail License Marker Luggage and Parking Lamps 20 Amp IN LINE FUSES Air Conditioning High Blower Spe...

Page 488: ...er Guards 22 Ft Front 30 Ft Rear 30 Ft Front 25 Ft Rear 25 Ft Front 30 Ft Rear Rear 25 Ft Bumper Guard Strip 18 In Front 25 In Rear 18 In Reinforcement to Bumper or Brackets 30 Ft 55 Ft 53 Ft Front or...

Page 489: ...4 ft Corvette All Front Urethane Cover 25 in Impact Bar to Slider Brkt 150 in Impact Bar to End Brkts 52 ft Slider Brkt to Frame Ext 150 in End Brace to Frame Ext 70 ft Impact Bar Lower Reinforcement...

Page 490: ...g height If superlifts are used in this manner for sustained driving periods severe damage may result to the superlifts or the car mounting brackets CRUISE MASTER Solenoid Resistance Solenoid Wire R e...

Page 491: ...rhead G Floor and Motor Home Units 12 0 13 7 Max 3400 Min Compressor Clutch Coil Ohms at 80 F 3 70 Amps at 8 0 F 3 33 12 volts System Capacities Refrigerant 12 C K Four Season System 3 lbs C K G Overh...

Page 492: ...bly 18 ft lb Latch Assembly to End G ate 85 in lb Latch Control Assembly to End Gate 40 in lb Access Cover 18 in lb Handle to Latch Control Assembly 55 in lb Glass Channel Assembly to End Gate 85 in l...

Page 493: ...90 in lb Outside Door Handle 45 in lb Remote Control front latch to D oor 90 in lb Rear Latch to D oor 90 in lb Rear Plate to Door 90 in lb Lower Front Roller and Roller Support Support to Door 24 ft...

Page 494: ...for applicable tolerances See Page 3 15 for the proper method of determining Caster Angle See Page 3 15 Figure 20 for method of determining Dimension A f t K 10 with full time four wheel drive toe in...

Page 495: ...50 Wheel Bearing Preload Zero Zero Zero Zero Wheel Bearing End Movement 001 008 001 008 001 010 001 008 Caliper Mounting Bolt 35 35 35 35 Spring Front Eye Bolt 90 Spring Rear Eye Bolt 50 Spring To Re...

Page 496: ...1 2 5 4 Pints Dana 10 1 2 7 2 Pints 12 1 4 14 0 Pints DIFFERENTIAL 8 7 8 1 0 1 2 Dana 1 0 1 2 Chevrolet 1 2 1 4 Gear Backlash Preferred 005 004 005 005 008 009 008 008 Min and Max 003 004 003 003 010...

Page 497: ...nector or Unions 115 In Lbs Flex Hose to Connector 115 In Lbs Front Brake Hose to Frame N ut 58 In Lbs Front Brake Hose Bracket Bolt 150 In Lbs Brake Hose Bracket to Axle Housing Nut 18 Ft Lbs Brake H...

Page 498: ...005 Max Relief Side 0005 Max 001 Max Service 005 Max PISTON Clearance Production 0005 0015 0026 0036 0012 0018 0007 0013 0018 0028 Service 0025 Max 0045 Max 0032 Max 0027 Max 0035 Max PISTON RING C 0...

Page 499: ...15 2600 2343 Lift 002 X Exhaust 2217 2315 2733 2343 Journal Diameter 1 8682 1 8692 1 9482 1 9492 Camshaft Runout 0015 Max Camshaft End Play 001 005 In Line Engine VALVE SYSTEM Lifter Hydraulic Rocker...

Page 500: ...ckfiring may cause fire in the engine compartment the air cleaner should be installed at all times unless its removal is necessary for repair or maintenance services Paper Element Type First 12 000 mi...

Page 501: ...Pressure Plate 35 lb ft Distributor Clamp 20 lb ft Flywheel Housing 30 lb ft Manifold Exhaust 20 lb ft Manifold Exhaust to Inlet 30 lb ft Manifold Inlet 30 lb ft Manifold to head 35 lb ft Thermostat...

Page 502: ...0 20 10 20 350 V 8 LS9 4QJ 7043203 7043202 F F 10 20 30 350 V 8 LS9 4QJ 7043211 7043210 F F 20 30 20 20 30 350 V 8 LS9 4QJ 7043208 7043208 F F 30M 30 350 V 8 LS9 4QJ 7043215 7043215 F F 10 20 454 M 4...

Page 503: ...30 1 2 215 450 4QJ 7043215 A M 5 16 13 32 430 1 2 215 450 4QJ 7043200 A 1 4 1 3 3 20 430 11 16 250 450 4QJ 7043216 1 4 13 32 430 11 16 250 450 4QJ 7043207 A M 1 4 13 32 430 11 16 250 450 4QJ 7043507 A...

Page 504: ...D 700 3 700 3 1000 L 6 292 C I D L 25 775 H D 675 2 H D Calif 700 3 600 2 3 Calif V 8 307 C I D L 14 950 L D 700 H D 900 3 L D 600 3 H D V 8 350 C I D LS 9 920 1 L D 750 H D 900 3 1 L D 600 H D V 8 4...

Page 505: ...102347 250 CID L 6 Engine W K 76 4522 4 0 4 5 X X X X X X 55 61 1102346 250 CID L 6 Engine W K 79 4521 4 0 4 5 X X X X X X 37 42 1102349 292 CID L 6 Engine Base 4521 4 0 4 5 X X X X X X 37 42 1102350...

Page 506: ...ual Trans P 30 Models 1108430 454 V 8 Except Motor Home 3563 9 65 95 7500 10 500 1108480 250 L 6 w Man or Auto Trans C K P 30 C K P 10 20 w Man Trans 3573 9 50 80 5500 10 500 1108502 350 454 V 8 Motor...

Page 507: ...6 Engine Except NB 2 1110486 C 4809 0 860 2 1140 17 2150 20 4000 C 3991 0 9 Hg 18 31 Hg 31 34 All AC R44T 292 C I D L 6 Engine NB 2 1110518 C 4797 0 930 2 1270 14 2300 14 4100 C 6005 0 10 Hg 10 13 Hg...

Page 508: ...1100 2 1320 6 1800 11 2400 18 4200 C 6001 0 6 Hg 15 14 Hg 29 31 Manual AC R44T 350 C I D V 8 Engine 20 30 Series 1112097 C 4890 0 1100 2 1350 12 2400 21 2900 22 4200 C 6006 0 8 Hg 10 13 Hg 29 31 All...

Page 509: ...ing Bolts 75 ft lbs Crossmember to Mount 40 ft lbs Mount to Transmission 50 ft lbs NEW PROCESS TRANSFER CASE MODEL 205 DANA TRANSFER CASE MODEL 20 Idler Shaft Lock N ut 200 ft lbs Idler Shaft Cover Bo...

Page 510: ...lbs Modulator Retainer to Case 130 in lbs Inner Selector Lever to Shaft 25 ft lbs Detent Valve Actuating Bracket 52 in lbs Converter to Flywheel B olts 35 ft lbs Under Pan to Transmission Case 110 in...

Page 511: ...ft 30 lbs ft Lower Mast Jacket Bearing Adjustment 50 04 1 26 02 Power Steering Belt Tension 125 lbs New 75 lbs Used Pump Pulley Nut 60 lbs ft Pump Pressure 1200 1300 psi G10 20 900 1000 G30 00 1300 p...

Page 512: ...6 9 1 to 20 2 1 C20 30 24 1 29 4 1 to 36 3 1 16 1 to 13 1 17 2 1 to 20 6 1 K 10 20 24 1 24 6 1 to 28 0 1 20 1 to 16 4 1 16 7 1 to 21 5 1 POWER STEERING GEAR Components All C P K and G Steering Gear Ba...

Page 513: ...s in Section 0 and Tire Load and Inflation Pressure tables in Section 10 of this manual SHEET METAL SECTION 11 TORQUE SPECIFICATIONS CK G P Lock Support to Hood Lock Bolt Nut Bumper Bolt Nut Hood Hing...

Page 514: ...Indicator lamp1 1 194 2 CP Generator indicator lamp1 1 194 2 CP Instrument cluster lamps2 6 194 or 1895 2 CP Headlamp beam indicator lamp 1 194 2 CP Lamp assembly tail stop lamp 2 1157 3 32 CP License...

Page 515: ...ted Amperes Location Headlamp and parking lamp circuit 15 AMP Light switch C K P MODELS Fuses located in the Junction Block beneath the dash on the driver s side Heater Generator Warning Lam p Idle St...

Page 516: ...y to aim the headlamps on any truck the following simplified screen method may be used This method involves placing the vehicle on a level floor 25 feet from a screen or light colored wall Four lines...

Page 517: ...racket and Brace 38 ft lbs License Plate Bracket 18 ft lbs Gravel Deflector 85 in lbs Rear Step Bumper to Bracket or Frame 40 ft lbs TORQUE SPECIFICATIONS G Front Face Bar to Bracket 24 ft lbs Bracket...

Page 518: ...28 cubic inches 1 cubic foot 27 cubic feet 1 cubic yard COMMON WEIGHT 16 ounces 1 pound 100 pounds 1 hundred weight cwt 2000 pounds 1 ton COMMON U S A EQUIVALENTS LENGTH 1 inch 25 4001Millim eters 1 m...

Page 519: ...28125 A 34375 359375 3 s 375 390625 J 3 j 2 40625 2 4 421875 A 4375 J 4 453125 5 m 46875 484375 2 5 U4 515625 53125 3H a 546875 9 A 5625 578125 3 2 59375 J 4 609375 V s 625 4l 4 640625 2 fc 65625 4 67...

Page 520: ...0 7 1838 1443 8 1685 1285 9 1532 1144 10 1379 1019 11 1225 0907 12 1072 0808 13 0919 0720 14 0766 0641 15 0689 0571 16 0613 0508 17 0551 0453 18 0490 0403 19 0429 0359 20 0368 0320 21 0337 0265 22 030...

Page 521: ...0 0370 Q 0 332 10 0 1935 37 0 1040 64 0 0360 p 0 323 11 0 1910 38 0 1015 65 0 0350 0 0 316 12 0 1890 39 0 0995 66 0 0330 N 0 302 13 0 1850 40 0 0980 67 0 0320 M 0 295 14 0 1820 41 0 0960 68 0 0310 L...

Page 522: ......

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