Chevrolet 1967 CAMARO Overhaul Manual Download Page 200

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Summary of Contents for 1967 CAMARO

Page 1: ......

Page 2: ...n so f ma t e r i a l sc o n t a i n e d h e r e i nh a v eb e e nr e p r i n t e dwi t hp e r mi s s i o n o f Ge n e r a l Mo t o r sC o r p o r a t i o n S e r v i c eOp e r a t i o n s L i c e n s e0 7 1 0 8 9 6 ...

Page 3: ... Ring 6 Piston Drive Ball 7 Ball Seat 8 Piston 9 Front Suction Reed Plate 10 Front Discharge Valve Plate 11 Front Head to Shell O Ring 12 Front Head 13 Coil and Housing Assembly 14 Coil Housing Retainer Ring 15 Pulley and Bearing Assembly 16 Pulley Bearing 17 Pulley Bearing Retainer Ring 18 Pulley and Bearing Retainer Ring 19 Clutch Hub and Drive Plate Assembly 20 Oil Pump Gears 21 Mainshaft Beari...

Page 4: ...he hub and drive plate and the pulley should be replaced Check further for the underlying Fig 2 Removing Shaft Locknut Fig 3 Removing Hub and Drive Plate Assembly cause of the damage i e low coil voltage or binding of the compressor internal mechanism Installation NOTE When hub and drive plate assembly is ready for installation clean its frictional face with a suitable cleaner 1 Insert the square ...

Page 5: ...ctional surfaces of the bearing to be Fig 6 Removing Pulley and Bearing Assembly Retainer Ring used should be cleaned with a suitable solvent before reinstallation Bearing Replacement 1 With the pulley and bearing assembly removed from the compressor use a sharp pointed instrument to remove the wire retainer ring CAUTION If the bearing is to be reused be careful not to slip and damage the seal 2 F...

Page 6: ...ly and the hub and drive plate assembly DO NOT drive or pound on the hub assembly 4 If the compressor is installed in the vehicle connect the electrical connections MAJOR REPAIR PROCEDURES The following service procedures are considered major since the refrigeration system must be completely purged of refrigerant before proceeding and or because major internal operating and sealing components of t...

Page 7: ...54 Compressor to Connector O Rings 7 Main shaft bearings 8 Thrust bearings 9 Compressor shaft and wobble plate 10 Suction reed valves 11 Discharge valve plate front and rear 12 Seal kit service contains all seals and O rings To be used each time a compressor is rebuilt 13 Shaft seal kit 14 Nuts head to shell and shaft 15 Retainer rings all necessary sizes 16 Cylinder locator dowel pins 17 Valve an...

Page 8: ... 2 Coat a new O ring and the interior of the seal cavity shaft and seal with clean refrigeration oil and using Tool J 21508 install the O ring in its groove just above the seal To install the O ring place O ring on tool as shown in Figure 13 insert the tool fully into the front head bore press down the slider twist entire tool to seat O ring and then remove tool 3 Using Tool J 9393 grasp the seal ...

Page 9: ... 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 Valve must be replaced if any damage is evident Installation 1 Carefully replace the suction reed valve and the rear discharge plate over the dowel pins and ports in the cylinder assembly Proper positioning of the reed p...

Page 10: ...ng Fig 17 Removing Suction Crossover Cover 8 Remove mechanism from the cage Disassembly If the mechanism has sustained major damage due possibly to loss of refrigerant and or oil it may be necessary to replace it with a complete service interior mechanism assembly rather than to replace individual parts If further disassembly is considered worthwhile proceed as follows 1 Before disassembling the c...

Page 11: ... and the wobble plate at the tightest place through the 360 rotation of the wobble plate The bronze ball seats are provided in 0005 variations including a basic ZERO seat Fig 19 Separating Cylinder Halves The second gauging operation performed at the rear shaft thrust bearing and race pack is designed to obtain 0005 to 0015 preload between the hub surfaces of the wobble plate and the front and rea...

Page 12: ...k and mallet fig 22 11 Place the cylinder assembly in the checking cage with the front of the compressor shaft pointing up positioning the discharge tube opening between the cage bolts This will provide access for the feeler gauge Assemble the cage and tighten all nuts evenly to 14 16 ft lbs torque 12 Use a leaf type feeler gauge and a suitable spring scale to check clearance between the REAR ball...

Page 13: ...ed under Gauging Procedures the cylinder assembly may be reassembled Be sure to install all new seals and U O rings All are included in the com pressor seal service kit Assembly procedure is as follows 1 Support the front half of the cylinder assembly on Fixture J 9397 and install the shaft and wobble plate threaded end down with its front bearing race pack ZERO race bearing and ZERO race and its ...

Page 14: ...end of the shaft up 2 Assemble the two dowel pins in the front cylinder if they are not already in place NOTE A rod drilled 1 4 deep to the O D of the dowel pins will aid in installing 3 Install the discharge crossover tube front O ring and spacer fig 26 4 Aligning the dowel pin holes discharge crossover and oil return slot assemble the suction reed valve to the front end of the cylinder 5 Assembl...

Page 15: ...e dowel pins into the rear cylinder 14 Install the discharge crossover tube rear O ring and spacer 15 Replace the rear suction reed valve rear discharge valve plate oil pump gears rear head and head nuts as outlined previously under Rear Head and Reed Assemblies Installation Leak Testing the Compressor Whenever service operations are performed on the compressor shaft seal assembly or on the interi...

Page 16: ... 9396 Compressor Holding Fixture 15 J 9397 Compressing Fixture 16 J 9403 Clutch Hub Holding Tool 17 J 9399 9 16 Thin Wall Socket 18 J 9480 Hub and Drive Plate Assembly Installer 19 J 9401 Hub and Drive Plate Assembly Remover 20 J 9392 Seal Remover 21 J 9393 Seal Seat Remover 22 J 9398 Pulley Bearing Remover 23 J 9481 Pulley and Bearing Installer 24 J 8092 Handle 25 J 9521 Internal Assembly Support...

Page 17: ...ring caps to loosen them CAUTION Do not attempt to pry caps off as this may damage machined face of caps Page Ring Gear or Differential Case Replacement 4 4 Installation 4 5 Drive Pinion and Bearing 4 5 Differential Bearing Preload 4 6 Ring Gear and Pinion Adjustment 4 7 Ring Gear and Pinion Contact Pattern 4 8 Using a pry bar as shown in Figure 1 pry differen tial case out of carrier Exercise cau...

Page 18: ...ase Check fit of side gear and axle shaft splines Inspect differential pinion shaft for scoring or evi dence of excessive wear Repairs Pinion and or Bearing Replacement 1 Remove pinion front and rear bearing cups from their positions in the carrier using a brass drift of suitable length Tap alternately on opposite side of cups during removal to prevent cups from cock ing in the carrier 2 Position ...

Page 19: ...n established position gauge plate in carrier so that the large overhanging Fig 7 Measuring Drive Pinion Bearing Simulated Preload Fig 8 Drive Pinion Depth Setting Gauge Plate Installed end is in the up position fig 8 g Position dial indicator Tool J 8001 3 on gauge post of Tool J 6266 28 so that indicator button rests on top of tool plunger h Position Tool J 6266 28 in carrier as shown in Figure ...

Page 20: ...r assembly using Tool J 5590 for light duty axle fig 10 or Tool J 9772 forhea y dutyaxle fig H Press cone against and rear face of pinion Differential Bearing Replacement 1 Itll Tl Fig 11 Drive Pinion Cone and Roller Assembly Installation Install Tool J 7112 and Adapter Plug J 8107 4 making sure puller legs are fitted securely in notches in case and against bearing cone Then tighten puller yoke ag...

Page 21: ...g 1 Position pinion and rear bearing cone and roller as sembly in carrier install a new pinion bearing spacer on pinion shaft and install pinion front bearing cone and roller assembly 2 Pack the cavity between the seal lips of the pinion flange oil seal with a lithium base extreme pressure lubricant position seal in bore then using Tools J 21468 and J 9458 for light duty axle and Tool J 21057 for ...

Page 22: ...e use of cast iron preload shims These shims can not be used when rebuilding the carrier as they may break when tapped into place Therefore as an aid in determining the approximate shim re quirement measure thickness of each cast iron shim Subtract total of two service spacers plus 025 gauging space from total thickness of the cast iron shims removed during carrier disassembly Select two service s...

Page 23: ...tion using a soft faced hammer while rotating differential case with free hand fig 20 DIFFERENTIAL BEARING SHIM IDENTIFICATION Thickness 064 066 068 070 072 074 076 078 080 082 084 086 088 090 092 094 096 098 100 Identification Notches I D Light Duty 0 0 0 0 1 1 1 1 2 2 2 2 3 3 3 3 Heavy Duty 0 0 0 1 1 1 1 1 2 2 2 2 2 3 3 3 3 3 4 O D Light Duty 0 1 2 3 0 1 2 3 0 1 2 3 0 1 2 3 Heavy Duty 2 3 4 0 1 ...

Page 24: ... increasing right shim thickness while decreasing left shim thickness an equal amount If the pattern shows a heel contact C it indi cates too much backlash To correct move the ring gear toward the pinion by increasing left shim thickness while decreasing right shim thickness an equal amount NOTE Make adjustment increasing and de creasing shim thickness by 0 002 at a time check contact with red lea...

Page 25: ...REAR AXLE DIFFERENTIAL CARRIER 4 9 FACE CONTACT FLANK CONTACT Fig 24 Gear Tooth Contact Patterns CHEVROLET CHASSIS OVERHAUL MANUAL ...

Page 26: ...Puller J 8614 2 fig 28 With companion flange removed pinion gear and rear bearing assembly can be removed from carrier Pry companion flange seal out of carrier using screw driver and discard seal Remove pinion front bearing inner race and roller assembly Pry differential side gear yoke seals out of carrier and discard seals Using a piece of 1 3 4 O D pipe of suitable length tap yoke bearings out o...

Page 27: ... use magnetic penetrant method to check for minute fractures in yokes or gears Repairs Pinion and or Bearing Replacement 1 If necessary to replace pinion bearings tap old cups out of carrier using brass drift or long punch fig 29 2 Select front and rear pinion bearings and drive cups into carrier using Drive Handle J 8092 and Cup Installers J 8608 for the rear cup and J 7137 for front cup fig 30 S...

Page 28: ...n gauge post and place pointer on top of plunger fig 35 Swing gauge barrel aside so plunger does not touch gauge plate and set indicator at zero Fig 30 Installing Pinion Bearing Cups 7 8 Swing gauge plunger back across plate and record highest indicator reading All pinion gears are stamped with a code number on the threaded end of the pinion The numerical differ ence between the code number and th...

Page 29: ... bearing inner race and roller assembly from carrier Position pinion shim selected in Step 8 on pinion head and press pinion bearing on pinion using J 9772 Press Plate fig 36 Differential Bearing Replacement 1 Place Puller J 8107 over differential bearing using Adapter Plug J 8107 4 in side gear bore Tighten puller screw to remove bearing fig 37 2 Install new bearing on hub using Installer J 8359 ...

Page 30: ...ring gear bolt and draw ring gear up evenly until gear is seated against flange Fig 40 Installing Side Gear Yoke Bearings 5 Remove guide vins and install remaining ring gear bolts Torque bolts to specifications 6 Install thrust washers and side gears in case if same parts are used replace in original sides Position pinions and thrust washers through loading hole in case 180 degrees apart so that t...

Page 31: ...l companion flange using Holder J 8614 1 and Installer J 5780 fig 44 6 Install companion flange washer and nut holding flange with Holder J 8614 1 Tighten nut until bear ing is pre loaded and a torque of 15 25 in lbs is required to rotate pinion 5 15 in lbs for used bearings Inch pound torque Wrench J 5853 and Adapter J 5810 or Spring Scale J 0544 and Handle J 8614 1 may be used to check pre load ...

Page 32: ...and bearing cup Withdraw shim and reinsert several times to get feel produced by drag of gauge against shim and bearing Rotate differential case while gauging b Progressively insert in increments of 002 larger feeler gauges until there is a noticeable increase in the drag produced on the feeler gauge The gauge thickness used just before additional drag is encountered is the proper thickness NOTE W...

Page 33: ...nd fig 49 Shim Identification Shim 064 066 068 070 072 074 076 078 080 082 084 086 088 090 092 094 096 098 100 Notches I D None None None 1 1 1 1 1 2 2 2 2 2 3 3 3 3 3 4 O D 2 3 4 None 1 2 3 4 None 1 2 3 4 None 1 2 3 4 None Backlash Adjustment 1 Install bearing caps in their original position and tighten but do not torque 2 Mount dial indicator on carrier with pointer set on ring gear tooth and ch...

Page 34: ...sistency to produce a contact pattern 8 Grasp companion flange firmly with a cloth to form a friction brake Rock the ring gear back and forth shifting bolt heads to develop a contact pattern on ring gear teeth fig 51 10 Fig 52 Installing Side Gear Yoke Inspect contact pattern and refer to Ring Gear and Pinion Contact Pattern outlined previously to de termine if further adjustments are required Ins...

Page 35: ...m one pack with those of another pack 5 Pry clutch pack cage out of differential case fig 56 Inspection 1 Clean and inspect side gear thrust surfaces pinion gear thrust surfaces thrust washers and spring cup for excessive wear and replace where necessary 2 Inspect clutch pack for excessive wear or over heating and replace as a unit if necessary 3 If plates and discs are suitable for reinstallation...

Page 36: ...alling Spring Seat to Side Gear Fig 58 lnstalling Clutch Pack 8 Place differential in carrier and adjust bearings and backlash as outlined in this section 9 Check operation of unit as follows a Raise rear of vehicle until rear wheels are off the ground and remove one wheel and tire assembly b Attach Adapter J 5748 to axle shaft flange and install a 1 2 13 bolt into adapter fig 59 c With wheel and ...

Page 37: ...ipped axle Page Inspection 4 23 Reassembly 4 23 are the same as on a conventional axle except for the operations listed below Disassembly 1 Remove ring gear and side bearings following the procedures established for the conventional differ ential unit Fig 60 Positraction Exploded View EATON 1 Ring Gear to Case Bolt 2 Differential Case 3 Side Bearing 4 Pinion Lock Screw and Washer 5 Ring Gear 6 Shi...

Page 38: ... of a 1 4 inch bolt in each of the two front springs Secure each bolt with a nut fig 63 After installing the retaining bolts in Step 6 continue Fig 63 Installing Bolts to Retain Springs to drive spring retainer from the case until enough of the retainer is exposed to permit installation of bar stock and C clamp fig 64 Center the bar stock over the axle shaft hole in the spring retainer then compre...

Page 39: ...nd other defects Fig 67 Removing Clutch Pack 3 Compress springs and determine if they are capable of properly preloading the clutch pack replace springs that are weak or questionable 4 Examine spring retainer for alignment between the retainer halves and for excessive wear at spj ing seats Reassembly 1 Lubricate clutch plates and discs with special p si traction lubricant 2 Alternately position cl...

Page 40: ...sing the pinion gear removal procedure Assemble springs in spring retainer and clamp as sembly in vise Install C clamp and bar stock on spring retainer then install a 1 4 inch bolt and nut in each front spring fig 70 Position spring pack between side gears and remove bar stock and C clamp On Corvette vehicles install Tool J 22311 to com press clutch pack secure pack with 1 4 bolts fig 70 Partially...

Page 41: ...g Installer Light Duty Axle Used with J 7079 2 21 J 8359 Companion Flange Installer Pinion Rear Bearing Cone and Roller Assembly 22 J 5810 Installer Light Duty Axle 23 J 5853 Driven Handle Insert Type 24 J 0270 14 Driver Handle Threaded Type Differential Bearing Remover Used with 25 J 7137 j 8107 4 Adapter Drive Pinion Rear Bearing Installer Heavy 26 J 7817 Duty Axle Pinion Rear Bearing Cone and R...

Page 42: ...2 Drive Pinion Front Bearing Cup Installer Used with J 8092 Drive Pinion Rear Bearing Cup Installer Used with J 8092 Adapter Plug Used with J 6266 and J 7112 11 J 7112 12 J 9774 13 J 5780 14 J 8092 15 J 7079 2 16 J 8001 17 J 0544 18 J 4880 19 J 5810 20 J 3289 21 J 22311 22 J 1313 23 J 5853 24 J 8614 Differential Bearing Remover Used with J 8107 4 Differential Yoke Bearing Seal Installer Companion ...

Page 43: ... lanced locks around shell edges f Turn flat bar wrench clockwise until cut outs on front shell are aligned with locks on rear shell g Unscrew center bolt Shells should begin to separate as load on center bolt is released If shells do not separate check out and lock align ment and then tap shell flange lightly with soft hammer to break bond between diaphragm and shells NOTE Press down firmly on to...

Page 44: ...is any question whatever as to serviceability of any part replace it Assembly The following procedure refers to the power section of the power brake unit only for assembly procedure of the main cylinder refer to applicable portion of Standard Brakes During assembly make sure all parts are free of for eign material before applying lubricant If there is any doubt of cleanliness rewash and air dry Wh...

Page 45: ...ore of power piston 5 Press and twist push rod in order to seal push rod and disc in power piston NOTE If reaction disc is not fully seated it will result in an erroneous push rod height adjustment 6 9 10 11 Fig 5 Adjustment of Push Rod Assemble push rod seal plate side first over end of push rod and press seal into bottom of shell cavity If vacuum check valve and grommet were removed dip new part...

Page 46: ...e assembly should always be used on Chevy II Power brake cylinders whenever removed from the power piston Fig 7 Moraine Vacuum Power Cylinder Typical 1 Front Shell 2 Power Piston Return Spring 3 Reaction Retainer 4 Master Cylinder Piston Rod 5 O Ring 6 Reaction Plate 7 Lock Ring 8 Diaphragm 9 Support Plate 10 Rear Shell 11 Power Piston 12 Reaction Levers 13 Air Valve Spring Two for Chevy II only 1...

Page 47: ...hell is separated from front shell CAUTION Care must be exercised not to damage or loosen studs in shell Also take care that no pressure is brought to bear on plastic power piston extension 3 Lift the power piston assembly and rear housing from the unit 4 Remove power piston and boot from the rear housing 5 Remove the silencer from inside the boot fig 8 6 Remove the power piston return spring from...

Page 48: ...ing retainer Place square shank of Tool J 21524 in a vise and po sition the assembly down on the tool so that the three lugs on the tool fit into the three notches in the power piston Pull the diaphragm edges away from the support plate and grip the steel support plate by hand press down and rotate counter clockwise to separate the plate from the power piston fig 10 Remove the diaphragm from the s...

Page 49: ...ng reas SCRIBE LINE ON TOOL J 21601 sembly that no grease or mineral oil comes in contact with these rubber parts Inspection Wipe cleaning fluid from all parts and carefully inspect each part for damage and wear Inspect rubber parts for cuts nicks and distortion These rubber parts are the key to control of air flow and should account for the ma jority of troubles traceable to leakage If there is a...

Page 50: ...iaphragm will fit into the groove on the power piston Press down and rotate the support plate assembly clockwise until the lugs on the power piston come against the stops on the support plate Place this assembly tube down in a padded vise Do Not Clamp Install snap ring in groove of air valve with Pliers J 4880 fig 11 Install the air valve spring retainer to seat on the snap ring Install the reacti...

Page 51: ...The primary seal and primary seal protector are now assembled over the end of the floating piston opposite the secondary seals so that the flat side of the seal seats against seal protector and the seal protector seats against the flange of the piston which contains the small compensating holes 3 The new secondary seal is now assembled into the groove on the push rod end of the primary piston The ...

Page 52: ...uum Power Cylinder Seal Installer 2 J 21524 Power Piston Remover and Installer 3 J 9504 Vacuum Power Cylinder Spanner Wrench 4 J 7723 01 Push Rod Height Gauge 5 J 9576 1 Vacuum Power Cylinder Holder and Compressor 6 J 4880 Truarc Pliers External Type 7 J 21601 Power Brake Retainer Installer CHEVROLET CHASSIS OVERHAUL MANUAL ...

Page 53: ...using only typical illustrations and procedures except where specific il lustrations and procedures will help clarify the opera tion The similarity of engines engine parts and engine sub assemblies and the resulting similarity of proce dures required to service these units should aid the technician in servicing the many engines Many operations outlined in this section when done as single operation...

Page 54: ...ENGINE 6 2 OIL PRESSURE SENDING UNIT DISTRIBUTOR SHAFT OILING FILTER BY PASS SYSTEM Fig 1 In Line Engine Lubrication CHEVROLET CHASSIS OVERHAUL MANUAL ...

Page 55: ...ENGINE 6 3 1 1 V 7 DISTRIBUTOR SHAFT OILING FUEL PUMP PUSH ROD OILING OIL FILTER AND BY PASS VALVE Fig 2 V8 Engine Lubrication 283 327 and 350 CHEVROLET CHASSIS OVERHAUL MANUAL ...

Page 56: ...ILING RELIEF OCCURS AT THIS POSITION THRU CONNECTING ROD CAP ONCE IN 360 CYLINDER WALL AND CAMSHAFT LOBE OILING FUEL PUMP PUSH ROD OILING CROSS DRILLED MAIN BEARING JOURNALS WITH HIGH PERFORMANCE ENGINE ONLY CRANKCASE AND CRANKSHAFT OILING VALVE MECHANISM OILING Fig 3 V8 Engine Lubrication 396 and 427 CHEVROLET CHASSIS OVERHAUL MANUAL ...

Page 57: ... a light press fit on cam shaft To dislodge tap lightly on lower edge of camshaft sprocket with a plastic hammer Install two 5 16 18 bolts in camshaft sprocket bolt holes and carefully remove camshaft WITH TIMING GEAR In Line Remove camshaft thrust plate screws through holes in camshaft gear then remove camshaft and gear as an assembly 14 Remove the flywheel 15 Remove main bearing caps and lift cr...

Page 58: ...ge bearings fig 6 4 Install connecting rod and piston assemblies as follows a Install connecting rod bearings in connecting rods and connecting rod caps then lubricate bear ings pistons piston rings and cylinder walls lightly with engine oil b Install connecting rod guide set Tool J 5239 3 8 or Tool J 6305 11 32 on connecting rod bolt and using Tool J 8307 to compress the rings install number one ...

Page 59: ...oil then install crankcase front cover aligning tool J 21202 in seal fig 10 b Coat gasket with sealer and place in position on cover then install crankcase front cover on cyl inder block and torque bolts to specifications Remove tool 7 Install the oil pan as follows a Install side gaskets on cylinder block using sealer as a retainer b Install rear oil pan seal in groove in rear main Fig 8 Checking...

Page 60: ...7 cu in 325 HP 350 HP engines with a 7 16 20 retaining bolt use a 7 16 20 x 4 bolt and a 7 l6 20 nut in place of the bolt and nut furnished with Tool J 21058 Install cylinder head s as follows CAUTION The gasket surfaces on both the head and the block must be clean of any foreign matter and free of nicks or heavy scratches Cylinder bolt threads in the block and threads on the cylinder head bolts m...

Page 61: ... 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 install push rod covers 13 Install intake and exhaust manifolds Torque to specifications in the sequence outlined under Engine Torques 14 Install the following sub assemblies if applicable as outlined in the Passenger Chas...

Page 62: ...ds rocker arms and push rod guides 4 Clean valve stems and heads on a buffing wheel 5 Clean carbon deposits from head gasket mating surface Inspection 1 Inspect the cylinder head for cracks in the exhaust ports combustion chambers or external cracks to the water chamber 2 Inspect the valves for burned heads cracked faces or damaged stems NOTE Excessive valve stem to bore clearance will cause exces...

Page 63: ...l J 5802 1 over the stud installing nut and flat washer and removing stud by turning nut fig 19 2 Ream hole for oversize stud using Tool J 5715 for 003 oversize or Tool J 6036 for 013 oversize fig 20 CAUTION Do not attempt to install an over size stud without reaming stud hole 3 Coat press fit area of stud with hypoid axle lubri cant Install new stud using Tool J 6880 as a guide Gauge should botto...

Page 64: ...different types of equipment are available for refacing valves The recommendations of the manufac turer of the equipment being used should be carefully followed to attain proper results 1 If necessary dress the valve refacing machine grinding wheel to make sure it is smooth and true Set chuck at angle specified for valve Refer to specifications and Figure 24 2 Clamp the valve stem in the chuck of ...

Page 65: ...essor tool 3 Install the remaining valves 4 On In Line and 283 327 350 cu in V8 engines check each valve stem oil seal by placing a vacuum cup or similar device over the end of the valve stem and against the cap Operate the vacuum cup and make sure no air leaks past the seal A vacuum cup can be made from a small syringe and a high voltage shield fig 27 5 Check the installed height of the valve spr...

Page 66: ...ove Assembly 1 Place the check ball on small hole in bottom of the plunger 2 Insert check ball spring on seat in ball retainer and place retainer over ball so spring rests on the ball Carefully press the retainer into position in plunger with the blade of a small screw driver fig 32 3 Place the plunger spring over the ball retainer and slide the lifter body over the spring and plunger being carefu...

Page 67: ...d air Blow Out oil holes in lifter body and push rod seat with compressed air In spect push rod seat retainer Inspect lifter for scuffed or worn lifter body or push rod seat If the lifter body wall is scuffed or worn inspect the cylinder block lifter bore If the bottom of the lifter is scuffed or worn inspect the camshaft lobe if the push rod seat is scuffed or worn inspect the push rod All damage...

Page 68: ...rews 10 Pickup Screen and Pipe 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 and pipe assembly need re placing mount the pump in a soft jawed vise and extract pipe from pump CAUTION Do not disturb the pickup screen on the pipe This is serviced as an assemb...

Page 69: ...aring inserts is necessary in production in order to obtain close tol erances For this reason you may find one half of a standard insert with one half of a 001 undersize insert which will decrease the clearance 0005 from using a full standard bearing When a production crankshaft cannot be precision fitted by this method it is then ground 009 undersize on main journals only A 009 undersize bearing ...

Page 70: ...nd the journal is out of round 001 interference between the 6 7 Fig 41 Measuring Gauging Plastic bearing and journal will result in rapid bearing failure If the flattened gauging plastic tapers toward the middle or ends there is a difference in clearance indicating taper low spot or other irregularity of the bearing or journal Be sure to measure the journal with a micrometer if the flattened gaugi...

Page 71: ... to rotate bearing into place The last 1 4 movement may be done by holding just the slinger with the pliers or tap in place with a drift punch 3 All other crankshaft journals In Line and V8 have oil holes Replace the main bearing upper half as follows a Install a main bearing removing and installing tool in oil hole in crankshaft journal NOTE If such a tool is not available a cotter pin may be ben...

Page 72: ...an out of round crankpin be sure to fit to the maximum diameter of the crankpin If the bearing is fitted to the minimum diameter and the crankpin is out of round 001 interference between the bearing and crankpin will result in rapid bearing failure a Place a piece of gauging plastic the full width of the crankpin parallel to the crankshaft fig 44 b Install the bearing in the connecting rod and cap...

Page 73: ...sconnect some of the con necting rod and piston assemblies and push them out of the cylinder Disassembly 1 Remove connecting rods and caps rod bearings from connecting NOTE If connecting rod bearings are being reused place them in a rack so they may be reinstalled in their original rod and cap 2 Remove piston rings by expanding them and sliding them off the pistons Tools J 8020 3 9 16 J 8021 3 7 8...

Page 74: ...nditions Because of this the piston and piston pin are a matched set and not serviced separately Inspect piston pin bores and piston pins for wear Piston pin bores and piston pins 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 clearance is in exc...

Page 75: ... on the upper side of the ring When installing compression rings make sure the marked side is toward the top of the piston PISTON VIEWED FROM TOP Af D E ENGINE PISTON CYLINDER SIDE OF PISTON ALIGNED WITH OILING HOLE 153 CU IN ALL RIGHT 194 CU IN ALL RIGHT 230 CU IN A ALL RIGHT 250 CU IN ALL RIGHT 283 CU IN 1 3 5 7 2 4 6 8 RIGHT LEFT 327 CU IN EXCEPT 325 350 HP 1 3 5 7 2 4 6 8 RIGHT LEFT 327 CU IN ...

Page 76: ...sert anti rotation tang in oil hole b Hold spacer ends butted and install lower steel oil ring rail with gap properly located c Install upper steel oil ring rail with gap properly located d Flex the oil ring assembly to make sure ring is free If binding occurs at any point the cause should be determined and if caused by ring groove removed by dressing groove with a fine cut file If binding is caus...

Page 77: ...d the cylinder bore 5 Remove Tool J 5239 or J 6305 6 Install the bearing caps and torque nuts to specifications NOTE If bearing replacement is required refer to Connecting Rod Bearings NOTE Be sure to install new pistons in the same cylinders for which they were fitted and used pistons in the same cylinder from which they were removed Each connecting rod and bearing cap should be marked beginning ...

Page 78: ...lock and main bearing caps Cleaning and Inspection 1 Wash crankshaft in solvent and dry with compressed air 2 Measure dimensions of main bearing journals and crankpins with a micrometer for out of round taper or undersize see specifications 3 Check crankshaft for run out by supporting at the front and rear main bearings journals in V blocks and check at the front and rear intermediate journals wit...

Page 79: ... be 001 to 005 fig 62 Oil Nozzle Replacement In Line 1 Remove nozzle with pliers fig 63 2 Drive new nozzle in place oil hole in vertical posi tion using a suitable light plastic or rubber hammer Camshaft Gear Replacement In Line 1 If the inspection indicated that the shaft gear or thrust plate should be replaced the gear must be removed from the shaft This operation requires the use of camshaft ge...

Page 80: ...e threads of connecting rod bolts to prevent damage to crankshaft Fasten con necting rods against sides of engine so they will not be in way while replacing camshaft bearings 1 With camshaft and crankshaft removed drive cam shaft rear plug from cylinder block NOTE This procedure is based on removal of the bearings nearest center of the engine first With this method a minimum amount of turns are ne...

Page 81: ... plug NOTE Plug should be installed flush to 1 32 deep and be parallel with rear surface of cylin der block CYLINDER BLOCK Cleaning and Inspection 1 Wash cylinder block thoroughly in cleaning solvent and clean all gasket surfaces 2 Remove oil gallery plugs and clean all oil passages NOTE These plugs may be removed with a sharp punch or they may be drilled and pried put 3 Clean and inspect water pa...

Page 82: ... the bushing bore The thrust washer where used may be replaced at the same time the bushing is replaced The lower bushing will ordinarily require only a clearance or wear check during engine overhaul When distributor shaft to bushing clearance exceeds 0035 Fig 66 Replacing Front Camshaft Bearing Oil Filter Bypass Valve Inspection and Replacement In Line Engines With the oil filter removed check th...

Page 83: ...than 005 taper or wear they should be bored and honed to the smallest oversize that will permit complete resurfacing of all cylinders When pistons are being fitted and honing is not neces sary cylinder bores may be cleaned with a hot water and detergent wash After cleaning the cylinder bores should be swabbed several times with light engine oil and a clean cloth and then wiped with a clean dry clo...

Page 84: ... 2 from top of cylinder bore b Measure the Piston Diameter at skirt across center line of piston pin c Subtract piston diameter from cylinder determine Piston to bore Bore diameter to Clearance d Locate piston to bore clearance on Piston Selec tion Chart fig 72 and determine if piston to bore clearance is in the acceptable range If used piston is not acceptable check Piston Size Chart fig 73 and d...

Page 85: ...5 4 2465 OVERSIZE 001 3 8760 3 8770 3 5635 3 5645 4 0010 4 0020 3 9975 3 9985 4 0930 4 0940 4 2498 4 2508 4 2465 4 2475 020 3 8937 3 8957 3 5812 3 5832 4 0187 4 0207 4 1130 4 1150 4 2678 4 2698 030 3 9037 3 9057 3 5 2 3 5932 4 0287 4 0307 4 0264 4 0284 4 1230 4 1250 4 2778 4 2798 4 2760 4 2780 040 3 9137 3 9157 3 6012 3 6032 0 0 4 306 0 4 30 0 Not Available on the 250 cu in Engine Fig 73 Piston Si...

Page 86: ...INE 6 34 CYLINDER HEAD TORQUE SEQUENCE L6 L4 V8 283 327 350 V8 396 427 INTAKE MANIFOLD TORQUE SEQUENCE FRONT V8 283 327 FRONT o V8 396 427 o Fig 74 Torque Specifications CHEVROLET CHASSIS OVERHAUL AAANUAL ...

Page 87: ...ead Bolt Wrench 16 J 5715 003 Rocker Arm Stud Reamer J 6036 013 17 J 6880 Rocker Arm Stud Installer 18 J 5802 Rocker Arm Stud Remover 19 J 9534 Distributor Lower Bushing Remover 20 J 9535 Distributor Lower Bushing Installer 21 J 22144 Oil Pick up Screen Installer 22 J 8369 Oil Pick up Screen Installer 23 J 6098 Cam Bearing Tool 24 J 0971 Camshaft Gear Support 25 J 6978 Torsional Damper Puller 26 J...

Page 88: ... as shown fig 4 Press shaft and impeller assembly out of pump ap plying pressure on the outer race of the shaft bearing only CAUTION Shaft and bearing assembly must not be pushed out of housing by applying force on shaft or bearings will be damaged Use a 7 8 deep socket or piece of tubing 1 1 8 P P on 283 and 327 cu in engines Use a 1 1 1677 deep socket or a piece of tubing 1 7 16 P P on 396 and 4...

Page 89: ... should be replaced Assembly 1 Install pump shaft and bearing assembly into pump body bearing bore applying pressure to outer race until it is flush with front of pump body fig 8 CAUTION Apply pressure to outer race only 2 Lightly coat O D of new seal with a sealing com pound and press into place with Tool J 5590 applying pressure to the seal outer flange The seal should bottom with the outer flan...

Page 90: ...s it will be necessary to put a bend about 1 2 from end of feeler gauge to enable clearance checking figs 12 and 13 Impeller must be flush to 018 below pump body back plate gasket surface on V8 models On V8 models install pump back plate and gasket with a light coat of gasket sealer and install screws then tighten all six diagonally Fig 10 Installing Fan Hub In Line Fig 11 Installing Fan Hub V 8 C...

Page 91: ...AN HUB LOCATING DIMENSION Engine 153 194 230 250 283 327 350 396 427 Chevrolet _ 3 7 8 5 9 16 5 3 4 Chevelle 4 3 8 4 3 i 5 9 16 5 3 4 Chevy II 3 7 8 3 7 8 3 7 8 5 9 16 Camaro 3 7 8 3 7 8 5 9 16 5 9 16 Corvette 5 9 16 5 3 4 3 1 8 With Air Conditioning CHEVROLET CHASSIS OVERHAUL MANUAL ...

Page 92: ...WATER PUMP 6K 5 SPECIAL TOOLS 1 J 22162 Fan Hub Locating Gauge Fig 14 Water Pump Special Tools 2 J 5855 Impeller Remover 3 J 358 1 Holder 4 J 5590 Seal Installer CHEVROLET CHASSIS OVERHAUL MANUAL ...

Page 93: ...trations showing bench opera tions are used most single operations when not part of a general overhaul should be performed if practical with the carburetor on the engine Typical illustrations and procedures are used except where specific illus trations or procedures are necessary to clarify the operation ROCHESTER BV INDEX Page General Description 6M 1 Repair Procedures 6M 3 Disassembly 6M 3 Clean...

Page 94: ...LTER RELIEF SPRING ASKET FILTER GASKET FLOAT NEEDLE SEAT FLOAT SYSTEM POWER PISTON SPRING POWER PISTON sVACUUM PASSAGE MAIN METERING SYSTEM POWER SYSTEM CHOKE VALVE DIAPHRAGM VACUUM DIAPHRAGM UNIT IDLE VENT LVE DURATION SPRING PUMP PLUNGER PUMP CUP PUMP RETURN SPRING PUMP SYSTEM THERMOSTATIC COIL CHOKE SYSTEM Fig 2R Rochester BV Systems CHEVROLET CHASSIS OVERHAUL MANUAL ...

Page 95: ...pring and ball 9 Remove main well support attaching screw and re move support Lift straight up to prevent damage to main well support tube 10 Lift power piston and spring from air horn 11 Lift gasket from air horn 12 Remove choke shaft lever screw diaphragm side remove two diaphragm bracket screws and remove diaphragm 13 Holding accelerator pump plunger all the way down remove hairpin retainer fro...

Page 96: ...ce of throttle valve fit required and the fact that the idle discharge and spark ad vance holes are drilled in relation to a proper fitting valve 10 Check the choke valve for freedom of operation in air horn 11 Check bronze fuel filter for cleaniness or damage Blow on cone end element should allow air to pass freely Clean element by washing in solvent and blowing out Blowing opposite direction of ...

Page 97: ...using new gasket and install float needle Attach float with hinge pin Adjust Float 1 With the air horn inverted and the gasket in place check height of each float as shown Bend tang 6 8 Fig 8R Float Drop Adjustment which contacts needle until each pontoon is set to specified dimension Align floats to avoid inter ference in bowl fig 7R 2 With the air horn assembly held upright and floats suspended ...

Page 98: ...r With the throttle valve wide open and the choke valve held toward the closed position with a rubber band bend the unloader tang on the throttle lever to obtain specified clearance between the lower edge of the choke valve and the air horn wall fig 10R Adjust Choke Vacuum Break Push the vacuum break diaphragm plunger in until seated Hold the choke valve toward the closed position with a rubber ba...

Page 99: ...antaneous response for maximum efficiency and performance The removable venturi cluster contains the main noz zles idle tubes mixture passages air bleeds and pump jets The main nozzles and idle tubes are suspended in fuel in the main wells of the float bowl which helps in sulate them from engine heat and minimize percolation spill over during hot engine operation fig 14R On vehicles equipped with ...

Page 100: ...ELL INSERT MAIN METERING JET MIXTURE PASSAGE BOOST VENTURI MAIN VENTURI THROTTLE VALVE POWER PISTON POWER PISTON SPRING POWER VALVE POWER RESTRICTION MAIN METERING SYSTEM MAIN WELL POWER SYSTEM CHOKE VALVE PUMP JET VACUUM DIAPHRAGM UNIT DIAPHR PUMP DISCHARGE CHECK BALL PUMP DISCHARGE E RETURN SPRING PUMP SYSTEM CHOKE SYSTEM Fig 14R Rochester 2GV Systems CHEVROLET CHASSIS OVERHAUL MANUAL ...

Page 101: ... 4 Remove fuel filter inlet nut filter spring and two gaskets 8 9 10 11 HMI 12 13 14 15 16 17 18 19 20 Fig 16R Air Horn Exploded View 1 Choke Valve 2 Choke Shaft 3 Choke Kick Lever 4 Vent Shield 5 Vent Valve 6 Air Horn 7 Vacuum Diaphragm 8 Diaphragm Link 9 Choke Lever 10 Pump Outer Lever 11 Pump Inner Lever 12 Accelerator Pump 13 Float 14 Needle and Seat Assembly 15 Float Hinge Pin 16 Filter Sprin...

Page 102: ...rburetor 5 Upend carburetor and remove three large bowl to throttle body attaching screws Throttle body and gasket may now be removed 8 Throttle Body to Bowl Gasket 9 Throttle Body Assembly 10 Pump Discharge Check Assembly 11 Accelerator Pump Spring 12 Fast Idle Cam 13 Idle Mixture Screws 14 Choke Rod 6 Remove idle adjusting needles and springs from throttle body Cleaning and Inspection 1 Thorough...

Page 103: ...choke shaft and choke valve if they were removed 2 Install vacuum diaphragm with bracket screws then install choke lever on end of choke shaft and retain with screw 3 Install vent valve and shield 4 Install fuel inlet filter spring filter gaskets and inlet nut 5 Install pump lever assembly NOTE Lubricate pump shaft bearing surface with lubriplate before installation 6 Install float needle seat and...

Page 104: ... fast GAUGE ACROSS TOP OF AIR HORN RING TO TOP OF ROD OPEN THROTTLE VALVES TO POINT WHERE VENT VALVE JUST CLOSES O N ITS SEAT GAUGE FROM TOP OF AIR HORN RING TO TOP OF PUMP ROD BEND PUMP ROD TO ADJUST THROTTLE VALVES FULLY CLOSED Fig 23R Idle Vent Adjustment idle cam at the other end rotate the rod and install cam on bowl NQTE The rod offset end goes toward fast idle cam 5 Connect vacuum hose at f...

Page 105: ... upper edge of choke valve and air horn wall Adjust to specified dimension by bending tang on choke lever and collar assembly fig 24R Adjust Choke Unloader With the throttle valves held wide open and the choke valve held toward the closed position with a rubber band bend the unloader tang on the throttle lever to obtain specified clearance between the upper edge of the choke valve and air horn wal...

Page 106: ...nifold over the exhaust crossover pas sage is used with 327 cu in 275 HP engines with 350 cu in 295 HP engines with 396 cu in 325 HP engines and with 427 cu in 385 HP Chevrolet engines This is a four barrel two stage carburetor with versatility and principles of operation that make it adaptable for small to large engines without design changes The fuel bowl is centrally located to avoid problems o...

Page 107: ...ALVE MAIN JET VACUUM CHANNEL MAIN METERING SYSTEM ENGINE MANIFOLD VACUUM SECONDARY METERING RODS METERING ORIFICE PLATES SECONDARY THROTTLE VALVE POWER SYSTEM AIR VALVE SHAFT LEVER Q VACUUM BREAK DIAPHRAGM RESTRICTION VACUUM BREAK DIAPHRAGM ASSEMBLY AS PLUNGER MOVES UP FUEL FLOWS PAST CUP INTO PUMP WELL LEVER DURATION SPRING PUMP SPRING DISCHARGE CHECK BALL AIR VALVE DASHPOT OPERATION ACCELERATING...

Page 108: ...short screws two counter sunk screws 5 Remove air horn by lifting straight up Air horn gasket should remain on bowl for removal later CAUTION Care must be taken not to bend two small main well air bleed tubes protruding from air horn These are permanently pressed into casting DO NOT REMOVE Air Horn Disassembly 1 Remove secondary metering rods by holding air valve wide open then tilt and slide rods...

Page 109: ...ry remove clip from vacuum break link at vacuum break lever then remove rod from vacuum break lever Spread the retaining ears on bracket next to vacuum break assembly then remove vacuum break assembly from lever 15 Remove fast idle cam from choke assembly CAUTION Do not place vacuum break assem bly in carburetor cleaner 16 Remove lower choke rod and actuating lever from inside of float bowl well 1...

Page 110: ...owl Assembly 1 Install new throttle body to bowl insulator gasket being certain the gasket is properly installed over two locating dowels on bowl 2 Install throttle body making certain throttle body is properly located over dowels on float bowl then install throttle body to bowl screws and tighten evenly and securely Place carburetor on proper holding fixture 3 Install fuel inlet filter spring fil...

Page 111: ... from toe NOTE Make sure retaining pin is held firmly in place and tang of float is seated on float needle b Bend float up or down for proper adjustment 15 Install power piston spring in power piston well If primary main metering rods were removed from hanger reinstall making sure that tension spring is connected to top of each metering rod Install power piston assembly in well with metering rods ...

Page 112: ...n lower choke lever and retain in upper lever with spring clip Fig 39R Air Horn Tightening Sequence 6 Install idle vent valve engaging actuating rod and tighten attaching screw Pump Rod Adjustment With throttle valves completely closed and pump rod in specified hole of pump lever measure from top of choke valve wall next to vent stack to top of pump stem with adjustable T scale Dimension should be...

Page 113: ...OKE VALVE BEND CHOKE ROD TO ADJUST ROTATE VACUUM BREAK LEVER DOWNWARD CAM FOLLOWER ON SECOND v STEP OF CAM GAUGE BETWEEN AIR HORN WALL AND LOWER EDGE OF CHOKE VALVE PUSH UP LIGHTLY ON VACUUM BREAK LEVER UNTIL TANG CONTACTS Fig 44R Vacuum Break Adjustment break diaphragm stem against its seat so vacuum link is at the end of slot The dimension between the lower edge of choke valve and air horn at ch...

Page 114: ...ustment Holding choke valve and primary throttle valve in wide open position with secondary throttle valve closed the lockout pin should have a minimum of 75 contact on lockout lever To adjust bend lockout lever 48R Secondary Lockout Clearance With choke valve and both throttle valves fully closed 75 MINIMUM CONTACT BEND LEVER TO ADJUST Fig 48R Secondary Lockout Clearance and Opening Adjustment WI...

Page 115: ...d Adjust Metering Rod 6M 26 Page Assemble Air Horn 6M 28 Adjust Float 6M 28 Assemble Air Horn to Bowl 6M 28 Adjust Idle Vent 6M 28 Adjust Choke Rod Fast Idle 6M 28 Adjust Choke Unloader 6M 28 Adjust Vacuum Break 6M 28 GENERAL DESCRIPTION The Carter YF Carburetor with manual choke is used with the L4 engine The Carter YF Carburetor with an automatic choke used in conjection with a temperature sensi...

Page 116: ... connector link 9 Remove diaphragm housing screws and lift out entire pump metering rod and idle vent assembly fig 2C 10 Remove metering rod from metering rod arm then compress upper pump spring s remove retainer spring s metering rod arm and pump lifter link as sembly If necessary remove idle vent screw as sembly from lifter link fig 3C 11 Compress lower spring remove the spring retainer and lowe...

Page 117: ...d Assembly and Adjustments Assemble Bowl and Throttle Body 1 If disassembled install fast idle arm with manual choke over boss on throttle flange and slide shaft into flange 2 Install throttle valve with lettering toward manifold side of flange and part number opposite idle port 3 Install throttle valve screws support the shaft at the screwhead and stake the other end of the screws 4 Install idle ...

Page 118: ...r should just contact the pump lifter link do not compress upper Fig 8C Float Level Adjustment pump spring If necessary to adjust bend pump con nector link at U bend Assemble and Adjust Metering Rod 1 Place metering end through metering jet then bottom rod in casting and with throttle valve closed press down on upper pump spring until pump bottoms out fig 7C Metering rod arm should rest parallel o...

Page 119: ...t Adjustment BEND ROD ALIGN MARK AND TANG AS SPECIFIED SPECIFIED GAUGE BETWEEN CHOKE VALVE AND AIR HORN Fig 12C Choke Unloader Adjustment SPECIFIED GAUGE BETWEEN CHOKE VALVE AND AIR HORN WALL Fig 11C Choke Rod Adjustment Fig 13C Vacuum Break Adjustment CHEVROLET OVERHAUL SHOP MANUAL ...

Page 120: ... Vacuum Break Adjustment With the vacuum break arm held in against its stop and the choke valve held toward the closed position with a rubber band bend the vacuum break link to obtain the specified clearance between the lower edge of the choke valve and the air horn wall fig 13C HOLLEY 2300 AND 2300C INDEX Page General Description 6M 28 Repair Procedures 6M 29 Disassembly 6M 29 Disassembly into su...

Page 121: ... H R A G M j p r f S I HOUSING ASSEMBLY Fig 2H Holley Secondary Carburetor REPAIR PROCEDURES Disassembly Disassemble Into Subassemblies Figs 4H and 5H NOTE Before disassembly loosen the fuel in let fitting fuel bowl sight plugs and needle and seat assembly lock screws 1 Remove primary fuel bowl screws and remove fuel bowl metering body on primary carburetor splash shield and gasket On secondary ca...

Page 122: ...PRIMARY BOOSTER VENTURI DISCHARGE NOZZLE HIGH SPEED AIR BLEED POWER VALVE RESTRICTION DISCHARGE NOZZLE BOOSTER VENTURI MAIN JET MAIN WELL MAIN WELL AIR BLEED MAIN METERING SYSTEM MAIN JET l MAIN WELL MANIFOLD POWER SYSTEM TYPICAL DISCHARGE NOZZLE CHOKE VALVE VACUUM BREAK DIAPHRAGM DISCHARGE CHECK VALVE PUMP DISCHARGE PASSAGE DIAPHRAGM PUMP INLET CHECK BALL CHOKE ROD DIAPHRAGM LINK THERMOSTATIC COI...

Page 123: ...t baffle 2 Remove float hinge screws and remove float from bowl NOTE Primary carburetor uses a brass float and secondary carburetors use a plastic float 3 Loosen inlet needle and seat lock screw then turn 1 Carburetor Body 2 Fuel Bowl Gasket 3 Metering Body Plate 4 Metering Body Gasket 5 Metering Body 6 Fuel Bowl Assembly 7 Diaphragm Housing Assembly 8 Throttle Body Gasket 9 Throttle Body 8 Fig 5H...

Page 124: ...ree movement and damage Damage to ball passage or retainer requires new bowl assembly Disassemble Metering Bodies 1 On primary carburetor fig 8H remove main meter ing jets with a wide blade screw driver to avoid Fig 7H Fuel Bowl Assembly Secondary 1 Float Bowl 5 Sight Plug Gasket 8 Gasket 2 Inlet Nut 3 Inlet Nut Gasket 4 Sight Plug 6 Ftoat 7 Needle and Seat Assembly 9 Adjusting Nut 10 Lockscrew Fi...

Page 125: ... follows 4 File off the staked ends of the throttle plate attach ing screws then remove the screws and throttle plates Slide the throttle shaft out of throttle body MAIN BODY CHOKE VACUUM BREAK LINK CHOK VACUUM BREAK FAST IDLE CAM Fig 11 H Main Body Assembly 5 On primary carburetor remove accelerator pump cam from throttle lever shaft Cleaning and Inspection NOTE The most frequent causes of carbur...

Page 126: ...iaphragm lever on sec ondary carburetor 7 On primary carburetor install fast idle cam lever on vacuum break hose on fitting 8 Install idle speed screw and spring on primary car buretor Turn idle speed screw clockwise until contact with throttle lever is made and turn 1 1 2 additional turns for preliminary adjustment 9 Install accelerator pump actuating lever assembly and assemble screw spring and ...

Page 127: ...n secondary carburetors install throttle operating assembly with new gasket and connect rod to throttle lever 3 On primary carburetor connect vacuum break hose to vacuum break PUMP ARM FULLY DEPRESSED SPECIFIED GAUGE SPECIFIED GAUGE BEND TO ADJUST VAC BREAK ROD FULLY DEPRESSED CHOKE VALVE HELD CLOSER AT LEVER Fig 16H Vacuum Break Adjustment 4 On secondary carburetor install new fuel bowl gas kets ...

Page 128: ...then measure opening between choke valve lower edge and main body see specifications 3 If necessary to adjust bend choke rod at off set bend Recheck after adjusting HOLLEY 4150 AND 4160 INDEX Page General Description 6M 36 Repair Procedures 6M 39 Disassembly 6M 39 Disassemble into Subassemblies 6M 39 Disassemble Fuel Bowls 6M 39 Disassemble Metering Bodies 6M 39 Disassemble Secondary Throttle Oper...

Page 129: ...RIBUTOR CONNECTION CHOKE VALVE FUEL LEVEL SIGHT PLUG CHOKE VACUUM BREAK FUEL TUBE ID MIXTURE OPERATING SCREW LEVER IDLE SPEED SCREW IDLE VENT VALVE SECONDARY THROTTLE OPERATING ASSEMBLY CRANKCASE CHOKE VENTILATION DISTRIBUTOR VACUUM CONNECTION CONNECTION BREAK PRIMARY METERING BODY PRIMARY FUEL BOWL FUEL INLET NUT MODEL 4160 SECONDARY FUEL BOWL CHOKE VALVE IDLE MIXTURE SCREW FUEL TUBE SECONDARY TH...

Page 130: ... MAIN WELL MAIN WELL AIR BLEED MAIN METERING SYSTEM TYPICAL AIR BLEED AIR BLEED SECONDARY g l FUEL BOWL 7 IDLE SECONDARY TRANSFER MAIN JET SLOT SECONDARY THROTTLE PLATE 4150 SECONDARY SYSTEM IDLE LOW SPEED TRANSFER SLOT IDLE DISCHARGE IDLE WELL 4160 SECONDARY SYSTEM RESTRICTION MAIN WELL METERING RESTRICTION IDLE LOW SPEED HIGH SPEED AIR BLEED POWER VALVE RESTRICTION DISCHARGE NOZZLE BOOSTER VENTU...

Page 131: ... 2 If so equipped remove inlet baffle from bowl 3 On center fuel inlet model loosen inlet needle and seat lock screw then turn adjusting nut counter clockwise to remove the needle and seat assembly 4 On center fuel inlet model remove sight plug and gasket 5 Remove inlet fitting fuel filter spring and gaskets 6 PRIMARY BOWL ONLY Remove air vent valve assembly Remove pump diaphragm screws and lift p...

Page 132: ...and gasket then up end the body assembly to remove pump discharge check valve NOTE The choke rod seal will withstand nor mal cleaning in carburetor cleaner therefore further disassembly of the main body is not required for cleaning purposes If part replace ment is required proceed as follows File off the staked ends of shaft screws then remove screws Remove valve from shaft slot and slide shaft fr...

Page 133: ...s should be replaced 5 Inspect floats for bad dents and or possible leaks 6 Inspect pump diaphragm for damage 7 Inspect float needles and seats for burrs and ridges if present replace both the needle and seat Never replace either alone as these are an assembly 8 Inspect edges of primary and secondary throttle valves for gouges and other deformations If these Cleaning and Inspection NOTE The most f...

Page 134: ...s Assemble Throttle Body 1 Install secondary throttle stop screw if removed 2 Install throttle shafts in throttle body NOTE The throttle shafts have plastic bush ings Roll new bushing between thumb and first finger to help shape the bushing on the shaft for easier installation 3 Install the throttle valves on the shaft do not tighten retaining screws 4 Center the throttle valves on the shafts by h...

Page 135: ...ws and make preliminary adjustment of idle mixture screws by turning lightly to seat and back out one turn CAUTION seat Do not turn screw tightly against 2 On 4160 secondarys Install gasket new then meter ing plate over secondary metering body dowel pins Assemble Fuel Bowls 1 PRIMARY AND SECONDARY BOWL On center inlet model install sight plugs with new gaskets Install inlet needle and seats leavin...

Page 136: ...gasket install secondary throttle op erating assembly on main body and tighten securely 3 Lay flange and main body on primary side then install new fuel bowl gasket and secondary metering body assembly onto main body aligning dowel pins and holes On Model 4160 Carburetors install six retaining screws and tighten securely 4 Install secondary fuel bowl and retaining screws with new gaskets under hea...

Page 137: ...ry Throttle Valve Stop Screw Fig 31H 1 Back off on adjustment screw until throttle plates are fully closed 2 Turn adjustment screw until it just touches the throttle lever and turn one half turn more to posi tion the valves Adjust Air Vent Valve Fig 32H 1 Back off idle speed screw until throttle valves are fully closed Choke valve open and throttle arm off idle screw 2 Check clearance between chok...

Page 138: ...s 3 If necessary to adjust bend choke rod at off set bend Recheck after adjusting Adjust Vacuum Break Fig 36H 1 Hold choke valve closed with a rubber band attached to linkage 2 Hold vacuum break in against stop 3 Measure distance between choke valve lower edge and main body 4 Bend vacuum break link to adjust SPECIAL TOOLS k J 7825 J 1137 J 4552 J 5197 J 6058A J 5496i J 6556 uu BENDING TOOLS j_9789...

Page 139: ...eplaced To maintain the close tolerances required for an efficient air pump the rear rotor ring is manufactured as a part of the rotor assembly and the rotor assembly is fitted to the housing with a selective spacer ground to maintain the required clearances therefore the rotor and housing assembly with rear rotor ring are serv iced as an assembly and parts from one assembly must never be intercha...

Page 140: ... the aluminum housing 2 Remove the rear rotor ring attaching screws fig 4 then remove the rear rotor ring and bearing as sembly and rear carbon seal Discard the rear carbon seal 3 Remove the vane assemblies fig 5 4 Remove the vane shoes with tweezers or needle nose pliers fig 6 then remove the shoe springs CAUTION Carbon shoes chip easily Do not use excessive pressure when removing NOTE Unless the...

Page 141: ...indicate rear bearing failure and the bearing and cover as sembly must be replaced Inspect the vane pivot pin This pin has been precision ground Grooves scratches or dis coloration indicate vane bearing failure If bear ings have failed a new vane assembly and cover assembly are required 5 Clean rear rotor ring and bearing assembly in petroleum solvent then dry with compressed air Check the rear be...

Page 142: ...27 350 396 427 PRESSURE RELIEF VALVE mwmmm Fig 11 Assemble Vane Assemblies on Rod dition is normal but chipped or broken shoes must be replaced Rear Bearing Replacement 1 Using J 21058 and J 21844 pull the rear bearing out of rotor ring fig 7 2 Using J 21058 and J 21844 pull the rear bearing into rotor ring until bearing is 1 32 beneath the rotor ring surface fig 7 Pull on lettered end of bearing ...

Page 143: ...Work grease well into bearings then carefully wipe away any excess grease 2 Position vanes on a 3 8 x 4 rod as shown fig 11 3 Position rotor with one vane slot at stripper fig 15 then support the housing in a vise by the drive hub and install the vanes with rod fig 12 4 Install one carbon shoe on each side of every vane fig 13 Shoes must be installed with bearing sur face against vane and with rad...

Page 144: ...E Installation of a new vane set in the Air Injection Pump may result in the vanes chirping or squeaking during initial operation The new vanes require wear in running time to eliminate vane chirping After pump installation the ve hicle should be driven five to ten miles Should slight squeaking s t i l l persist run vehicle through two or three full throttle shift points In most cases the five to ...

Page 145: ...with hammer driving retainer towards armature end of snap ring Page Field Coil Test for Ground 6Y 3 Loose Electrical Connections 6Y 3 Turning the Communtator 6Y 3 Brush Holder Replacement 6Y 4 Assembly 6Y 4 Pinion Clearance 6Y 5 c Remove snap ring from groove in shaft using pliers or other suitable tool If the snap ring is too badly distorted during removal it may be necessary to use a new one whe...

Page 146: ...lvent would dissolve the grease packed in the clutch mechanism and would damage armature and field coil insulation 2 Test overrunning clutch action The pinion should turn freely in the overrunning direction and must not slip in the cranking direction Check pinion teeth to see that they have not been chipped cracked or excessively worn Check the spring for normal ten sion and the drive collar for w...

Page 147: ... armature Armature Test for Ground Place one lead on the armature core or shaft and the other on the commutator fig 5s If the lamp lights the armature is grounded and must be replaced Field Coil Test for Open Circuit Place one lead on the insulated brush and the other to the field connector bar fig 6s If the lamp does not light the field coils are open and will require replace ment CYLINDER RETAIN...

Page 148: ...lders b Assemble insulated and grounded brush holder together with the V spring and position as unit on the support pin Push holders and spring to bottom of support and rotate spring to engage the V in slot in support c Attach ground wire to grounded brush and field lead wire to insulated brush d Repeat for other set of brushes 2 Assemble overrunning clutch assembly to armature shaft a Lubricate d...

Page 149: ...her on armature shaft and slide commutator end frame onto shaft 6 Reconnect the field coil connectors to the motor solenoid terminal Fig 10s Checking Pinion Clearance After reassembly a Free Speed check of the start ing motor may be made if equipment is available To make this check connect a 12 volt battery in series with an ammeter to the starting motor terminal and ground Use a mechanical drive ...

Page 150: ...ove solenoid assembly INSTALLATION 1 With solenoid return spring installed on plunger position solenoid body to drive housing and turn counterclockwise to engage the flange key in the keyway slot 2 Install two screws retaining solenoid housing to end frame SOLENOID BODY TO HOLD IN COIL CONTACT RING CONTACT FINGER TO PULL IN COIL MOTOR CONNECTOR STRAP TERMINAL END _J COVER Fig 11s Exploded View of ...

Page 151: ...d or overhaul operations are encountered separate mention will be made of the two generators DISASSEMBLY Fig 2c 5 5 Delcotron 1 Hold generator in a vise clamping the mounting flange lengthwise 2 Remove 4 thru bolts then break loose the end frames by prying at bolt locations 3 Remove the slip ring end frame and stator as an assembly from drive end and rotor assembly 4 Place a piece of tape over the...

Page 152: ... Adapter J 21501 and a box wrench on retaining nut insert a 5 16 alien wrench through socket and adapter into hex on shaft to hold the shaft while removing the nut Remove rotor and spacers from end frame assembly Remove drive end frame bearing retainer plate and bearing assembly from frame 6 2 Delcotron 1 Hold generator in a vise clamping the drive end mounting flange lengthwise 2 Remove two screw...

Page 153: ...uire rotor assembly replacement 6 Inspect brushes for wear If they are worn halfway replace Inspect brush springs for distortion or weakening If brushes appear satisfactory and move freely in brush holder springs may be reused TESTING ROTOR The rotor may be checked electrically with a 110 volt test lamp or an ohmmeter Grounds Connect test lamp or ohmmeter from either slip ring to the rotor shaft o...

Page 154: ...r Grounds 5 5 STATOR OHMMETER OHMMETER CO 6 STATOR TEST LAMP TEST LAMP TEST LAMP 5 5 DELCOTRON INSULATORS INSULATED HEAT SINK TEST LAMP V CUT GROUNDED STATOR HEAT SINK LEAD 6 DELCOTRON Fig 6c Checking Stator for Grounds or Opens Fig 7c Checking Diodes CHEVROLET CHASSIS OVERHAUL MANUAL ...

Page 155: ...nd press out diode with diode removal Tool J 9717 1 and an arbor press or vise fig 8c CAUTION Do not strike diode as shock may damage other diodes 3 Select diode with proper color marking NOTE Diodes in the heat sink with batt termi nal are positive red markings and those in the heat sink grounded to the case are negative black markings 4 Support outside end of frame around diode hole on a flat sm...

Page 156: ... down onto the slip rings 3 Replace heat sinks to end frame as outlined in Heat Sink Replacement Bearing Replacement Drive End Frame 1 The drive end frame bearing can be removed by detaching the retainer plate bolts and separating retainer plate and seal assembly from end frame and then pressing bearing out using suitable tube or pipe on outer race NOTE 5 5 Delcotron uses staked retainer plate bol...

Page 157: ...ench into opening at end of drive shaft Tighten shaft nut to 40 50 ft lbs fig 12c 5 Assemble slip ring end frame and stator assembly to drive end frame and rotor assembly 6 Install 4 through bolts in the end frame assemblies 6 2 Delcotron 1 Install stator assembly in slip ring end frame and locate diode connectors over the relay diode and stator leads and tighten terminal nuts 2 Install the front ...

Page 158: ...DELCOTRON 6Y 14 SPECIAL TOOLS J 9717 2 SUPPORT TOOL J 9717 1 PRESS TOOL J 9600 2 SHOULDERED INSTALLER J 21501 PULLY ADAPTER Fig 14c Special Tools CHEVROLET CHASSIS OVERHAUL MANUAL ...

Page 159: ...ressure plate and flywheel for scores on the and retracting springs and remove pressure plate contact surfaces Use a straight edge and check for from clutch cover flatness of contact surfaces NOTE When disassembling prick punch edge 3 C h e c k retracting springs for looseness at the clutch of pressure plate and cover These marks must 5 Ver fnd evidence of looseness at pressure plate be aligned in...

Page 160: ...er Clutch Cross Section Typical 3 Pilot Bushing 4 Driven Disc 5 Pressure Plate 6 Diaphragm Spring 7 Cover 8 Throwout Bearing 9 Fork 10 Retracting Spring Fig 3 Retracting Spring Location Typical Fig 4 Clutch Pilot Bearing Removal Typical CHEVROLET CHASSIS OVERHAUL MANUAL ...

Page 161: ... vehicle at which time it should be cleaned and in spected for excessive wear or damage and should be replaced if necessary To remove install Tool J 1448 and remove bearing from crankshaft fig 4 In replacing this bearing use Tool J 1522 Place bearing on pilot of tool with radius in bore of bearing next to shoulder on tool and drive into crankshaft Assembly 1 Install the pressure plate in the cover...

Page 162: ...3A MAINSHAFT Disassembly 1 Using snap ring pliers remove the 2nd and 3rd speed sliding clutch hub snap ring from mainshaft and remove clutch assembly second speed blocker ring and second speed gear from front of mainshaft 2 Remove rear bearing snap ring from mainshaft groove 3 Support reverse gear with press plates and press on rear of mainshaft to remove reverse gear thrust washer spring washer r...

Page 163: ... Gear Thrust Spring Washers 16 Snap Ring Bearing to Mainshaft 17 Extension 18 Vent 19 Speedometer Drive Gear 20 Mainshaft 21 Rear Oil Seal 22 Retainer Oil Seal 23 Snap Ring Bearing to Gear 24 Clutch Gear Bearing 25 Snap Ring Bearing to Case 26 Thrust Washer Front 27 Thrust Washer Rear 28 Snap Ring Bearing to Extension 29 Rear Bearing 30 Countergear Roller Bearings 31 Anti Lash Plate Assembly 32 Ma...

Page 164: ...fferent key cavities on either side Slide the sleeve onto the hub aligning the marks made before disassembly NOTE A groove around the outside of the synchronizer hub 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 rear of extension requires replace...

Page 165: ...d over synchronizing surface of the first speed gear 7 Install the first and reverse synchronizer assembly with fork slot downward press it onto splines on the mainshaft CAUTION Be sure the notches of the blocker ring align with the keys of the synchronizer assembly 8 Install synchronizer hub to mainshaft snap ring 9 Install reverse gear with clutching teeth downward 10 Install reverse gear thrust...

Page 166: ... transmission case rear bore alignment This tool may be made from a new or good used clutch gear which has a good bearing surface on the crankshaft pilot end and at the front main bearing location The splines on the clutch gear shaft and the teeth on the clutch gear should be ground off so the shaft may be rotated in a clutch disc hub without interference when as sembled in the car Weld a piece of...

Page 167: ... 26 2 3 Synchronizer Sleeve 27 Synchronizer Key Spring 28 2 3 Synchronizer Hub Assembly 29 2nd Speed Blocker Ring 30 2nd Speed Gear 31 Mainshaft 32 1st Speed Gear 33 1st Speed Blocker Ring 34 1 2 Synchronizer Hub Assembly 35 1 2 Synchronizer Sleeve 36 Snap Ring Hub to Shaft 37 Reverse Gear 38 Thrust Washer 39 Spring Washer 40 Rear Bearing 41 Snap Ring Bearing to Shaft 42 Speedometer Drive Gear 43 ...

Page 168: ...tch gear and second speed gear Inspect the second and third speed clutch internal clutching teeth If the teeth are worn or tapered even slightly the gears should be replaced Reassemble the transmission 8 Install the transmission assembly to the clutch housing using the correct number of shims at the proper locations as previously determined Shims Fig 9A Checking Case Rear Bore are available by uni...

Page 169: ...onnect wires from solenoid and from governor switch 4 Disconnect speedometer cable from driven gear fitting 5 Remove propeller shaft as outlined in Section 4 Fig 1B Overdrive Cross Section 1 Sun Gear 2 Sun Gear Control Plate 3 Sun Gear Shift Collar 4 Pinion Cage Assembly 5 Output Shaft Ring Gear 6 Pinion 7 Clutch Cam Roller Retainer 8 Cam 9 Output Shaft 10 Speedometer and Governor Drive Gear 11 Ou...

Page 170: ...embly of transmission Fig 4B Removing Output Shaft from Housing 12 Remove gasket from adapter and install one bolt removed from housing to hold the adapter to the transmission case and pinion if not previously Disassembly 1 Remove governor removed 2 Pierce plug in rear bearing snap ring access hole in top of housing and pry plug out of housing 3 Spread rear bearing snap ring with snap ring pliers ...

Page 171: ...ricate new seal between lips with cup grease 5 Install output shaft rear bearing snap ring in slot in housing 6 Install shift rail retractor spring inside housing and insert long 3 8 drift pin through spring to align spring with holes in housing 7 Slide output shaft assembly into housing until rear bearing contacts snap ring Spread snap ring and push shaft in until snap ring engages bearing 8 Inst...

Page 172: ...plate or blocker ring is to be re placed they may be separated by pulling blocker ring off plate 7 Lift sun gear pawl out of adapter Cleaning and Inspection As each part is removed from the rear of the trans Fig 1 OB Removing Solenoid mission wash in cleaning solvent dry and protect from subsequent dirt accumulation 1 Inspect U clips control plate retainer control plate blocker ring and pawl for d...

Page 173: ...f ring facing out then start the assembly over transmission main shaft with ring toward rear Slide the assembly into position with slot in ring toward sun gear pawl fig 12B 2 Km 1 iiiiii j j r L _ Fig 13B Removing Adapter from Transmission Case 3 Slide control plate retainer over mainshaft against control plate and install snap ring in adapter 4 Install solenoid oil seal solenoid and cable bracket...

Page 174: ...am Rollers 21 Cam Roller Cage 22 Roller Cage Retracting Spring 23 Free Wheeling Cam 24 Cam Retaining U Clip Small 25 Shift Rail Retractor Spring 26 Shift Rail Assembly Also see Fig 17B 26a Plunger 27 Sun Gear Solenoid 28 Sun Gear Pawl 29 Sun Gear Pawl Rod Oil Seal 30 Control Cable Bracket 31 Ring Gear 32 Output Shaft 33 Ring Gear Snap Ring 34 Output Shaft Bearing 35 Woodruff Key 36 Speedometer Dri...

Page 175: ... 15B Measuring Blocker Ring Tension Fig 17B Shift Rail Plunger Fork and Spring Assembly 1 Fork 2 Snap Ring 3 Washer 4 Spring 5 Shift Rail 6 Plunger Fig 16B Installation of Cam Roller Retaining Springs CHEVROLET CHASSIS OVERHAUL MANUAL ...

Page 176: ...nd drive the reverse idler shaft and its woodruff key through the rear of the case fig 2C CAUTION Do not damage the roller bearings 4 Rotate the extension counter clockwise to expose 1 2 3 6 7 8 9 10 11 12 13 14 15 16 17 18 19 31 30 29 28 27 26 1 Bearing Retainer 2 Lip Oil Seal 3 Snap Ring and Special Washer 4 Clutch Gear Bearing 5 Clutch Gear 6 3rd Speed B locker Ring 7 2 3 Sliding Clutch Sleeve ...

Page 177: ...th countergear thrust washers reverse idler gear and Fig 4c Removing Mainshaft and Extension from Case 25 roller bearings and both idler gear thrust washers from the case MAINSHAFT Disassembly 1 Using snap ring pliers remove the 2nd and 3rd speed sliding clutch hub snap ring from mainshaft fig 8C and remove clutch assembly second speed blocker ring and second speed gear from front of mainshaft 2 R...

Page 178: ...ompressed air CAUTION Do not allow the bearings to spin turn them slowly by hand Spinning bearings will damage the race and balls 3 Make sure bearings are clean then lubricate with light engine oil and check them for roughness by slowly turning the race by hand Bearing Rollers and Spacers All main drive gear countergear and reverse idler gear bearing rollers should be inspected closely and replace...

Page 179: ...the two springs in position one on each side of hub so all three keys are engaged by both springs fig 13C Place the keys in position and holding them in place slide the sleeve onto the hub aligning the marks made before disassembly Extension Oil Seal or Bushing If bushing in rear of extension requires replacement remove seal and use Tool J 5778 to drive bushing into extension housing fig 14C Using...

Page 180: ...E This snap ring is available in six thick nesses Use thickest snap ring that will as semble with all parts stacked tight endwise 8 Press the speedo drive gear onto the rear of main shaft until centered on the shaft boss fig 17C 9 10 Fig 16c Installing Rear Bearing to Mainshaft Install the second speed gear over the front of the mainshaft with the gear clutching teeth toward the front Install the ...

Page 181: ...at the washer tangs are aligned with their notches in the case Attach a dial indicator as shown in Figure 22C and check end play of the countergear If end play is Fig 19c Clutch Gear Bearing Retainer and Components 1 Retainer 2 Lip Seal 3 Snap Ring 4 Special Washer 5 Snap Ring 6 Clutch Gear Bearing 7 Clutch Gear 8 Mainshaft Pilot Bearings 9 Bearing Spacer Fig 20c Loading Countergear Bearings Using...

Page 182: ...ft and rear bearing Be sure snap ring has started over the ALIGN BLOCKER RING NOTCHES WITH CLUTCH KEYS 9 10 Fig 24c Installing Clutch Gear Bearing Using J 5590 rear bearing then install and tighten extension to case bolts to specified torque fig 5C Use graphite sealer on the two lower attaching bolts CAUTION Care should be taken not to damage the extension bearing or oil seal during installation T...

Page 183: ...ree on their gear cone surfaces 11 Install gaskets and clutch gear bearing retainer and lip seal assembly with oil drain passages at bottom and tighten to specified torque on threads of retainer bolts Use graphite sealer NOTE Install two retainer to case gasket 010 and 015 to replace the one 025 pro duction gasket removed 12 Install the shift forks to the clutch sleeve grooves with the first and r...

Page 184: ...p ring from mainshaft groove fig 10X 3 Support first gear with press plates and press on rear of mainshaft to remove first gear thrust wash er spring washer rear bearing snap ring and finally the speedo drive gear from rear of main shaft figs 11X and 12X Repairs 7 30 Clutch Keys and Springs 7 30 Replacement 7 30 Extension Oil Seal or Bushing 7 31 Clutch Bearing Retainer Oil Seal 7 31 Mainshaft 7 3...

Page 185: ...ar 16 Reverse Gear Thrust and Spring Washers 17 Snap Ring Bearing to Mainshaft 18 Extension 19 Vent 20 Speedometer Drive Gear 21 Mainshaft 22 Rear Oil Seal 23 Retainer Oil Seal 24 Snap Ring Bearing to Gear 25 Clutch Gear Bearing 26 Snap Ring Bearing to Case 27 Thrust Washer Front 28 Thrust Washer Rear 29 Snap Ring Bearing to Extension 30 Rear Bearing 31 Countergear Roller Bearings 32 Anti Lash Pla...

Page 186: ...8 Key Retainer 29 3rd Speed Blocker Ring 30 3rd Speed Gear 31 Needle Bearings 32 Second Speed Gear 33 2nd Speed Blocker Ring 34 Mainshaft 35 1st Speed Blocker Ring 36 First Speed Gear 37 Thrust Washer 38 Wave Washer 39 Rear Bearing 40 Snap Ring Bearing to Shaft 41 Speedo Drive Gear 42 Gasket Extension to Case 43 Snap Ring Extension to Rear Bearing 44 Extension 45 Vent 46 Bushing 47 Oil Seal 48 1 2...

Page 187: ...ushing is not serviced separately Countergear Anti Lash Plate Inspect the plate teeth for wear or other damage The J 22246 COUNTER SHAFT Fig 6X Removing Countershaft Fig 7X Removing Reverse Idler Gear Shaft plate and two damper springs are retained to the counter gear by three rivets Disassembly is not recommended fig 25X Fig 5X Extension to Rear Bearing Snap Ring Fig 8X Third Fourth Synchronizer ...

Page 188: ... the keys and two springs may be replaced if worn or broken Fig 1IX Removing Rear Bearing First Speed Gear Replacement 1 Mark hub and sleeve so they can be matched upon reassembly 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 Fig 10X Rear Bearing to Mainshaft Snap Ring Fig 12X Removing Speedo Drive Gear ...

Page 189: ...shing If bushing in rear of extension requires replacement remove seal and use Tool J 5778 to drive bushing into extension housing fig 16X Using the same tool drive new bushing in from the rear Coat I D of bushing and S L E E V E J0 H U B k SPRING 1 V Fig 15X Three Four Synchronizer Assembly seal with transmission lubricant then install new oil seal using Tool J 5154 fig 17X Clutch Bearing Retaine...

Page 190: ...fig 2IX CAUTION Be sure the notches of the blocker ring align with the keys of the synchronizer assembly 4 Install synchronizer hub to mainshaft snap ring fig 8X Both synchronizer snap rings are identical Turn the rear of the mainshaft upward Install the following components on the mainshaft 5 Install the second speed gear with clutching teeth upward the front face of the gear will butt against th...

Page 191: ...of the synchronizer assembly Fig 23X Installing Rear Bearing 8 Install synchronizer hub to mainshaft snap ring fig 13X 9 Install a blocker ring with notches downward so they align with the keys of the 1 2 synchronizer assembly 10 Install first gear with clutching teeth downward 11 Install first gear thrust washer steel 12 Install first gear spring washer 13 Install rear ball bearing with snap ring...

Page 192: ...ear bearing groove fig 5X 5 Load the mainshaft pilot bearings 14 into the clutch gear cavity and assemble the 4th speed blocker ring 9 10 11 Fig 26X Loading Mainshaft Pilot Bearings onto the clutch gear clutching surface with its clutch ing teeth toward the gear fig 26X Pilot the clutch gear pilot bearings and 4th speed blocker ring assembly over the front of the main shaft assembly Do not assembl...

Page 193: ...W OF REVERSE IDLER GEARS Fig 1M Four Speed Transmission Cross Section Close Ratio Shown 1 Bearing Retainer 2 Main Drive Gear 3 Fourth Speed Synchronizing Ring 4 Third and Fourth Speed Clutch Assembly 5 Third Speed Synchronizing Ring 6 7 8 9 10 Third Speed Gear Second Speed Gear Second Speed Synchronizing Ring First and Second Speed Clutch Assembly First Speed Synchronizing Ring 11 First Speed Gear...

Page 194: ... Extension 34 Extension Bushing 35 Rear Oil Seal 36 Reverse Idler Front Thrust Washer Tanged 37 Reverse Idler Gear Front 38 Reverse Idler Gear Rear 39 Flat Thrust Washer an anti lash Plate Assembly 2 anti lash springs on Reverse Gear 40 Reverse Idler Shaft 41 Reverse Idler Shaft Roll Pin 42 Reverse Shifter Shaft Lock Pin 43 Reverse Shifter Shaft Lip Seal 44 Reverse Shift Fork 45 Reverse Shifter Sh...

Page 195: ...he rear reverse idler gear flat thrust washer shaft and roll spring pin may now be removed Fig 5M Removing Speedometer Gear with J 5814 7 Remove speedometer gear and reverse gear The speedometer gear may be removed using Tool J 5814 as shown in Figure 5M NOTE Slide 3 4 synchronizer clutch sleeve to 4th speed gear position forward before trying to remove mainshaft assembly from case fig 6M 8 Carefu...

Page 196: ...olvent and inspect for cracks Fig 9M Removing Mainshaft Front Snap Ring Inspect the front face which fits against clutch housing for burrs and if any are present dress them off with a fine cut mill file Front and Rear Bearings 1 Wash the front and rear bearings thoroughly in a cleaning solvent 2 Blow out bearings with compressed air CAUTION Do not allow the bearings to spin but turn them slowly by...

Page 197: ...rear Coat I D of bushing with trans V CLUTCH KEY Fig TIM Installing Reverse Shifter Shaft and Detent Ball Fig 12M Installing Synchronizing Ring mission lubricant then install new oil seal using Tool J 5154 Prelubricate seal between lips with cup grease Clutch Keys and Springs Replacement NOTE The clutch hubs and sliding sleeves are a select fit assembly and should be kept together as originally as...

Page 198: ...acer In stall in the other end of the countergear a spacer 28 rollers a spacer 28 more rollers and another spacer fig 15M 3 Insert Tool J 22246 into countergear Transmission Assembly 1 Rest the transmission case on its side with the side cover opening toward the assembler Put counter gear tanged thrust washers in place retaining them with heavy grease making sure the tangs are resting in the notch...

Page 199: ...ronizing ring correspond to the keys in the clutch assembly fig ISM 13 14 15 16 17 18 Fig 18M Installing Mainshaft Assembly CAUTION Be sure main drive gear engages both the countergear and anti lash plate on standard ratio models With the guide pin in rear bearing retainer aligned with hole in rear of case tap rear bearing retainer into position with a soft hammer From the rear of the case insert ...

Page 200: ...stall main drive gear retaining nut on the gear shaft and draw it up tight using Tool J 0933 Be sure bearing fully seats against shoulder on gear Torque retaining nut to 40 ft lbs and lock in place by staking securely into main drive gear shaft hole with a center punch Care must be used to avoid damaging the threads on the shaft Install the main drive gear bearing retainer gasket four attaching bo...

Page 201: ... governor then remove the shaft Page Assembly 7 55 Valve Body 7 57 Removal 7 57 Disassembly 7 57 Inspection 7 57 Assembly 7 57 Installation 7 57 Vacuum Modulator 7 57 Removal 7 57 Inspection and Repairs 7 57 Installation 7 57 Transmission Case 7_57 Inspection 7 57 Repairs 7 57 Rear Bushing Replacement 7 57 Transmission Extension 7 53 Inspection 7 58 Repairs 7 59 Rear Bushing Replacement 7 59 Trans...

Page 202: ... 8 9 10 11 12 13 14 15 16 17 18 19 20 2T 22 23 24 25 26 27 28 29 30 31 32 33 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 54 A 53 52 51 47 45 44 43 Fig 1PG Aluminum Powerglide Typical Sectioned View ...

Page 203: ...eeler 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 the case and turn down the wing nut to compress the rear piston spring retainer and springs then remove the snap ring fig 9PG Tool J 8039 may be used to remove the snap ring if desired Speedometer Drive and Driven Gear Governor Shaft Urethane Washer Governor Shaft Gov...

Page 204: ...dy is removed 24 If necessary the TV shift and parking actuator as sembly levers and the parking pawl and bracket fig 13PG may be removed This completes the entire transmission disassembly procedure Component parts disassembly and repair pro cedures will be found in succeeding pages of this manual OVERHAULING UNIT ASSEMBLIES GONVERTOR AND STATOR The converter is a welded assembly and no internal r...

Page 205: ...ore using Seal Driver J 6839 NOTE Outer diameter of seal should be coated with a non hardening sealer prior to installation On water cooled models so equipped check condition of oil cooler by pass valve and replace if valve leaks excessively For removal an Easy Out or its equivalent may be used For installation tap seat in place with soft hammer or brass drift so it is flush to 010 below the surfa...

Page 206: ...g 12PG Valve Body Removal 5 Place the pump assembly less the rubber seal ring upside down into the pump bore of the case use guide pins if desired Install remaining attaching bolts and torque to specification 6 Remove pump assembly from case bore Replace the clutch drum and input shaft low band and struts as outlined under Transmission Assembly NOTE If necessary remove two bolts and use J 6585 pul...

Page 207: ...ase 14 Servo Piston Return Spring 15 Servo Piston Rod 16 Servo Piston Apply Spring Seat 17 Servo Piston Apply Spring 18 Servo Piston Seal Ring 19 Servo Piston 20 Servo Piston Rod Spring Retainer 21 Servo Cover Seal 22 Servo Cover Gasket 23 Servo Cover 24 Servo Cover Plug 25 Servo Cover Bolts 26 Transmission Case Bushing 27 Gasket 30 Governor Support Bushing 31 Governor Support 32 Governor Support ...

Page 208: ...e Spring Retaining Pin 21 Oil Cooler By Pass Valve Spring 22 Oil Cooler By Pass Valve 23 Oil Cooler By Pass Valve Seat 27 Band Apply Strut 28 Band Anchor Strut 29 Band Anchor Adjusting Screw 30 Band Anchor Adjusting Screw Nut 31 Low Brake Band 32 Clutch Drum 33 Clutch Drum Bushing 34 Clutch Piston Outer and Inner Seals 35 Clutch Piston 36 Clutch Return Springs 37 Clutch Spring Retainer 38 Clutch S...

Page 209: ...d face must be protected whenever it must be brought to bear on a press or tool of any sort 9 Park Lock Pawl Disengaging Spring 10 Range Selector Detent Roller Spring 11 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 Park Lock Pawl Reaction Bracket 17 Park Lock Pawl Reaction Bracket Att...

Page 210: ...age the bushing bore or the machined face on the front of the clutch drum Fig 20PG Checking Gear End Clearance 2 Use the same tool to install the new bushing Press do not hammer the bushing into the clutch drum from the machined face side of clutch drum Press only far enough so that the tool meets the clutch drum Do not force the tool against the clutch drum machined face Assembly 1 Install new pi...

Page 211: ...um Bushing ring When installed the openings in the retainer ring should be adjacent to one of the lands of the clutch drum 9 Check the assembly by turning the clutch hub to be sure it is free to rotate LOW BAND The brake band used in the Aluminum Powerglide transmission has bonded linings which due to the trans mission characteristics and band usage should require very little attention However whe...

Page 212: ... of the Fig 24PG Checking Planet Gear End Clearance planet pinion needle bearings Twenty needie bearings are used in each end and are separated by a bearing spacer in the center 7 By following the procedure as outlined in Steps 4 5 and 6 remove the adjacent long planet pinion that was paired by thrust washers to the short planet pinion now removed NOTE Twenty needle bearings are used in each end o...

Page 213: ...ion shaft in until the lower end is flush with the lower face of the planet carrier 21 Following the same general procedure as outlined in Steps 15 through 20 assemble and install a short planet pinion in the planet carrier adjacent to the long planet pinion now installed NOTE The thrust washers already installed with the long planet pinion also suffice for this short planet pinion as the two pini...

Page 214: ...ove the smaller inner weight retaining snap ring and remove the inner weight and spring 3 If it is considered necessary remove the four body assembly bolts and separate the body hub and gasket Remove the two seal rings Inspection Clean all parts thoroughly in a solvent and air dry Check condition of all component parts of the assembly Replace any bent damaged or scored parts Body and hub must be r...

Page 215: ...ecking Figure 28PG if necessary NOTE Upper and lower valve body gaskets are the same 2 Carefully install the lower valve body and gasket and install 15 1 3 8 attaching bolts Torque to specification Installation Install the valve body onto the transmission as outlined under Transmission Assembly VACUUM MODULATOR The vacuum modulator is mounted on the left rear of the transmission and can be service...

Page 216: ... 23 High Speed Down Shift Timing Valve 24 Upper Valve Body 25 Manual Control Valve 26 Vacuum Modulator Valve Plunger and Spring exc L 4 L 194 27 Throttle Valve 28 Throttle Valve Spring 29 Throttle Valve Spring Seat 30 Throttle Valve Spring Regulator Guide Washer 31 Detent Valve Spring 32 Detent Valve 33 Throttle Valve Spring Regulator 34 Throttle Valvfe Spring Regulator Nut 35 Upper Valve Body Pla...

Page 217: ... and the bracket 5 Insert the outer shift lever into the case being care ful of the shaft seal and pick up the inner shift lever and parking lock assembly and tighten alien head screw Lubricate the shaft and seal with oil 6 Insert outer TV lever and shaft special washer and O ring into case and pick up inner TV lever Tighten alien head nut NOTE To prevent possible binding between throttle and rang...

Page 218: ...s on the planet carrier 18 Remove the rubber seal ring from the oil pump body and using guide studs from J 3387 set install clutch drum selective thrust washer oil pump gasket and oil pump to case Install two pump to case bolts 19 To check for correct thickness of the selective fit thrust washer move transmission so that output shaft points down and proceed as follows a Mount a dial indicator so t...

Page 219: ...tall the guide plate fig 35PG making sure that the inner lever properly picks up the manual valve Install attaching bolts 31 Install the vacuum modulator valve and the vacuum modulator and gasket 32 Install the oil pan using a new gasket and the oil pan attaching bolts 33 Install converter and Safety Holding Strap J 9549 or a suitable substitute LOW BAND ADJUSTMENT Tighten the low servo adjusting ...

Page 220: ...point Smaller pressure adjustments can be made by partial turns of the jam nut The end of TV adjusting screw has an alien head so the screw may be held sta tionary while the jam nut is moved TV ADJUSTMENT ALLEN WRENCH NUT Fig 37PG TV Adjustment Nut NOTE Use care when making this adjustment since no pressure tap is provided to check TV pressure CHEVROLET CHASSIS OVERHAUL MANUAL ...

Page 221: ...ansmission into holding Tool Base J 3289 14 with bottom pan facing up fig 2T 4 Remove modulator assembly attaching screw and retainer fig 3T 5 Remove modulator assembly and O ring seal from case fig 4T 6 Remove modulator valve from transmission case Removal of Governor Speedometer Driven Gear Pan Strainer and Intake Pipe 1 Remove attaching screws governor cover and gasket fig 5T 2 Withdraw governo...

Page 222: ...CLUTCH AND TRANSMISSIONS 7 64 CHEVROLET CHASSIS OVERHAUL MANUAL ...

Page 223: ...from transmission case fig 17T Fig 4T Removing Vacuum Modulator and Valve Removal of Rear Oil Seal and Extension Housing 1 If necessary to replace pry rear oil seal from ex tension housing fig 18T 2 Remove extension housing to case attaching bolts 3 Remove extension housing and extension housing to case gasket fig 19T 4 Make front unit end play check as follows fig 20T Front Unit End Play Checking...

Page 224: ... washer controlling this end play is the phenolic resin washer located between pump 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 c d e f g Thickness 060 064 071 075 082 086 093 097 104 108 115 119 126 130 Color Yellow Blue Red Brown Green Black Purple NOTE An oil soaked washer may...

Page 225: ...g and gasket 5 Remove forward clutch assembly and turbine shaft from transmission fig 23T 6 Remove forward clutch hub to direct clutch housing V REAR SERVO ASSEMBLY Fig 12T Removing Rear Servo Assembly phenolic thrust washer if it did not come out with forward clutch housing assemblyl 7 Remove direct clutch assembly fig 24T NOTE If necessary remove manual linkage as follows a Unthread jam nut hold...

Page 226: ...g Front Servo Piston Washer and Pin extension housing attaching bolt hole fig 34T b Mount a dial indicator on rod and index with end of output shaft c Move output shaft in and out to read end play End play should be from 003 019 Selective washer controlling this end play is a steel washer having 3 lugs that is located between output shaft thrust washer and rear face of transmission case If a diffe...

Page 227: ...olding Fixtures J 6116 with J 21364 adapter 17 Remove rear unit selective washer from transmis sion case fig 38T 18 Remove rear band assembly fig 39T Disassembly of Gear Unit Assembly 1 Remove case center support assembly fig 40T Fig 2IT Removing Front Seal 2 Remove center support to reaction carrier bronze or phenolic thrust washer fig 41T 3 Remove center support to sun gear races and thrust bear...

Page 228: ... Removing Manual Shaft Retaining Pin from Case b Install new speedo drive gear and drive rear side to location 5 43 64 below end of output shaft using J 5590 fig 46T 11 Remove output shaft to rear internal gear thrust bearing and two 2 races 12 Remove rear internal gear and mainshaft fig 47T NOTE Do not drop bearings 13 Remove rear internal gear to sun gear thrust bearing and two 2 races 14 If nec...

Page 229: ...nspect governor valve for nicks burrs scoring or galling 5 Check governor valve for free operation in bore of governor sleeve 6 Inspect governor driven gear for nicks burrs or damage 7 Check governor driven gear for looseness on gover nor sleeve 8 Inspect governor weight springs for distortion or damage 9 Check governor weights for free operation in their retainers 10 Check valve opening at entry ...

Page 230: ...ve and with a suitable socket press gear into sleeve until nearly seated Carefully remove any chips that may have shaved off gear hub and press gear in until it bottoms on shoulder 5 A new pin hole must be drilled through sleeve and gear Locate hole position 90 from existing hole center punch and then while supporting governor in press drill new hole through sleeve and gear using a standard 1 8 in...

Page 231: ... prevent them from falling out 4 Check governor weight assemblies for free operation on pins 5 Check governor valve for free movement in governor sleeve FRONT SERVO PARTS INSPECTION 1 Inspect servo pin for damage 2 Inspect piston for damage D oil ring groove check freedom of ring in groove fig 17T V J 9539 ii y II J 21795 V Fig 37T Removing Case Center Support and Gear Unit from Case 3 Inspect pis...

Page 232: ... CONSTANT BLEED ORIFICE PLUG Fig 41T Removing Center Support Thrust Washer Re Assembly 1 Install spring retainer cup side down spring and washer on band apply pin 2 Install band apply pin retainer spring and washer into bore of servo piston and secure with E ring 3 Install oil seal ring on servo piston if removed 4 Install outer and inner oil rings on accumulator piston if removed and assemble int...

Page 233: ...ng Speedometer Drive Gear modulator bushing 1 2 regulator valve 1 2 regu lator spring 1 2 detent valve and 1 2 shift valve 6 From next bore remove retaining pin 2 3 shift valve spring modulator valve bushing 2 3 modulator valve 3 2 intermediate spring and 2 3 shift valve 7 From next bore remove retaining pin bore plug spring spacer and 3 2 valve 8 At other end of assembly top bore remove retaining...

Page 234: ...for cracks scratches or distortion 3 Inspect body for cracks or scored bores 4 Check all springs for distortion or collapsed coils c Reassembly 1 Install front accumulator spring and piston into valve body 2 Install special Tool J 21885 and compress spring and piston and secure with retaining E ring 3 Install the 1 2 accumulator valve train into the lower left hand bore as follows a Models CB CD a...

Page 235: ...lug compress the spring until the grooved retaining Fig 52T Removing Retaining E Ring from Rear Servo Pin pin can be inserted from the cast surface side of the valve body with the grooves entering the pin hole last Tap the retaining pin with a hammer until it is flush with the cast surface of the valve body Remove the temporary retractor pin 4 In next bore up install detent spring and spacer Compr...

Page 236: ...d install retain ing pin 16 Install the governor oil screen assembly into the governor oil feed hole pinched end first fig 57T NOTE Screen is held in place by the governor feed pipe when installed on the transmission case 17 Install manual valve with detent pin groove to the right OIL PUMP DISASSEMBLY INSPECTION AND RE ASSEMBLY a Disassembly 1 Place oil pump assembly in hole in bench or holding fi...

Page 237: ...e bushing b From front side of pump using J 21465 17 install new bushing flush to 010 below machined sur face for seal 8 Inspect pump attaching bolt seals for damage re place if necessary 9 Inspect pump cover face for overall flatness 10 Check for scores or chips in pressure regulator bore 11 Check that all p a s s a g e s are open and not interconnected 12 Check for scoring or damage at pump gear...

Page 238: ...ded View install both parts into pump cover by compressing bushing against spring 6 Install retaining snap ring 7 Install pressure regulator valve bore plug and re taining pin into opposite end of bore SNAP RING J 5403 REGULATOR BOOST VALVE BUSHING AND VALVE REGULATOR SPRING SPRING RETAINER WASHER PRESSURE REGULATOR SPACER REGULATOR VALVE PUMP ASSEMBLY i n Fig 6IT Removing Pump Regulator Valve Sna...

Page 239: ...in bench or Holding Fixture J 6116 and remove 12 13 14 Fig 66T Checking Pump Body Face to Gear Face Clearance forward clutch housing to direct clutch hub snap ring fig 69T 2 Remove direct clutch hub 3 Remove forward clutch hub and thrust washers fig 70T 4 Remove five 5 radial grooved composition and five 5 steel clutch plates 5 If necessary place forward clutch and turbine shaft in arbor press and...

Page 240: ...ct ground bushing journals for damage d Inspect shaft for cracks or distortion NOTE Turbine shaft and clutch housing are serviced separately Shaft may be removed from FORWARD CLUTCH HUB THRUST WASHEI FORWARD CLUTCH HOUSING TURBINE SHAFT Fig 71T Removing Turbine Shaft from Forward Clutch Housing housing by using a suitable size socket in an arbor press fig 71T c Reassembly NOTE The Turbo Hydra Mati...

Page 241: ...sing lip faces up fig 74T 3 Place seal protector Tool J 21362 over clutch hub FORWARD CLUTCH HOUSING CLUTCH CENTER SEAL Fig 74T Removing Forward Clutch Center Seal and install outer clutch piston seal Protector J 21409 into clutch drum and install piston rotating piston on drum until seated fig 76T 4 Install sixteen 16 clutch release springs green into pockets in piston 5 Place spring retainer and...

Page 242: ...omposition fig 77T t a Ji r e C t C M c h h u b a n d retaining gJ 12 Place forward clutch housing on pump delivery sleeve and air check clutch operation fig 79T COMPOSITION PLATES FORWARD CLUTCH HOUSING FORWARD CLUTCH HOUSING DIRECT CLUTCH HUB Fig 78T lnstalling Forward Clutch Housing to Direct Clutch Hub Snap Ring DIRECT CLUTCH AND INTERMEDIATE SPRAG DISASSEMBLY INSPECTION AND RE ASSEMBLY a Disa...

Page 243: ...ck Plate Snap Ring 6 Remove retainer and sixteen 16 piston release springs 7 Remove direct clutch piston Fig 84T 8 Remove outer seal from piston 9 Remove inner seal from piston 10 Remove center piston seal from direct clutch housing SNAP RING INTERMEDIATE CLUTCH RETAINER INTERMEDIATE CLUTCH OUTER RACE INTERMEDIATE CLUTCH SPRAG ASSEMBLY SPRAG BUSHINGS DIRECT CLUTCH HOUSING AND RACE ASSEMBLY DIRECT ...

Page 244: ...g 85T Direct Clutch Assembly Exploded As shown in Figure 90T the direct clutch piston can be identified by the check ball 1 Install a new inner clutch piston seal on piston with lip facing away from spring pockets fig 86T 2 Install a new outer clutch piston seal with lip facing away from spring pockets fig 87T 3 Install a new center seal on clutch housing with lip of seal facing up fig 88T NOTE Ap...

Page 245: ...OF CASE CENTER SUPPORT a Disassembly 1 Remove four 4 hook type oil seal rings from center support 2 Using clutch compressor J 4670 in arbor press compress spring retainer and remove snap ring fig 97T 3 Remove spring retainer and three 3 clutch release springs CLUTCH CENTER SEAL r J 21362 J 21409 Fig 89T Installing Direct Clutch Piston 4 Remove intermediate clutch piston 5 Remove inner and outer pi...

Page 246: ... INTERMEDIATE CLUTCH SPRAG ASSEMBLY DIRECT HOUSING AND RACE c Assembly 1 Install new inner and outer seals on piston with lip Fig 93T Installing Intermediate Sprag to Direct Clutch of seal facing away from spring pocket fig 99T and 100T Install inner seal protector Tool J 21363 oh center support hub install piston indexing spring pockets of piston into cored areas of the center support fig 101T In...

Page 247: ...move pinions thrust washers and roller needle bearings 4 Inspect pinion pocket thrust faces for burrs and remove if present 5 Install nineteen 19 needle bearings into each pinion using petrolatum to hold bearings in place Use pinion pin as guide fig 107T 6 Place a bronze and steel washer on each side of pinion so steel washer is against pinion hold them in place with petrolatum 7 Place pinion asse...

Page 248: ...T WASHER INTERMEDIATE CLUTCH OUTER SEAL INTERMEDIATE CLUTCH PISTON OIL SEAL INTERMEDIATE CLUTCH RINGS SPRING RETAINER Fig 98T Center Support Assembly Exploded View INTERMEDIATE CLUTCH PISTON INTERMEDIATE CLUTCH PISTON Fig 99T Installing Intermediate Clutch Inner Seal Fig 100T Installing Intermediate Clutch Outer Seal CHEVROLET CHASSIS OVERHAUL MANUAL ...

Page 249: ... necessary to replace proceed as follows Sun Gear Shaft Bushing Front Remove With sun gear shaft properly supported using Tool J 21465 15 with slide hammer and Adapter J 2619 remove bushing Replace Using Tool J 21465 5 with Adapter J 8092 press or drive replacement bushing into place until tool bottoms Sun Gear Shaft Bushing Rear Remove With sun gear shaft properly supported using Tool J 21465 15 ...

Page 250: ... modulator assembly for any signs of bending or distortion fig 109T Fig 107T Plant Pinion Assembly Exploded View 2 Inspect O ring seal seat for damage 3 Apply suction to vacuum tube and check for dia phragm leaks 4 Check modulator bellows modulator plunger is under pressure 16 lbs If bellows is damaged plunger will have very little pressure 5 Inspect modulator valve for nicks or damage 6 Check fre...

Page 251: ...amage 6 Inspect bore for governor assembly for scratches or scoring 7 Inspect modulator valve bore for scoring or damage 8 Inspect cup plug inside case for good staking and sealing 9 Inspect case bushing If necessary to replace proceed as follows CASE BUSHING Remove With case properly supported using Tool J 21465 8 with Handle J 8092 remove bushing Replace Using Tool J 21465 8 Ring Adapter J 21465...

Page 252: ...at pinions mesh with rear internal gear 5 Place above portion of build up through hole in bench so that mainshaft hangs downward 6 Install rear internal gear to output shaft thrust races and bearings as follows and retain with petrolatum fig 117T a Place small diameter race against internal gear with center flange facing up b Place bearing on race c Place second race on bearing with outer flange c...

Page 253: ...m the outer edge fig 122T 17 Install roller clutch assembly fig 123T into re action carrier 18 Install center support to reaction carrier phenolic thrust washer into recess in center support Retain with petrolatum fig 4IT 19 Install case center support into roller clutch in reaction carrier fig 124T NOTE With reaction carrier held case center support should only turn counter clockwise after instal...

Page 254: ...ling Front Internal Gear Ring to Output Carrier ASSEMBLY OF UNITS TO TRANSMISSION CASE NOTE The first three steps can be omitted if the parts involved were not removed on disassembly 1 Install parking pawl tooth toward inside of case and parking pawl shaft fig 126T Fig 1 t8T Installing Output Shaft Fig 120T Installing Reaction Carrier and Roller Assembly CHEVROLET CHASSIS OVERHAUL MANUAL ...

Page 255: ...ed by previous end play check into slots provided inside rear of transmission case 8 Install complete gear unit assembly into case using Tool J 21795 fig 129T 9 Oil and install center support to case retaining snap ring with bevel side up and locating gap adjacent to band anchor pin Make certain ring is properly seated in case fig 130T 10 Install case to center support locating screw part 8623498 ...

Page 256: ...y End play should be from 003 019 The selec Fig 1271 Installing Parking Shaft Retaining Spring Fig 127T Installing Parking Shaft Retaining Spring tive washer controlling this end play is steel washer having 3 lugs that is located between thrust washer and rear face of transmission case If a different washer thickness is required to bring end play within specifications it can be selected from the f...

Page 257: ...ousing to allow sprag outer race to index with clutch drive plates Housing hub will bottom on sun gear shaft fig 136T NOTE First visually line up the intermediate clutch drive lugs one above the other to help engagement of housing hub splines It also may be helpful to remove the direct clutch plates while installing housing 17 Install forward clutch hub to direct clutch housing phenolic thrust was...

Page 258: ...located between pump cover and forward clutch housing If more or less washer thickness is required to bring end play within specifications select proper washer from the chart below Thickness 060 064 071 075 082 086 093 097 104 108 115 119 126 130 Color Yellow Blue Red Brown Green Black Purple Fig 134T lnstalling Manual Shaft to Case NOTE An oil soaked washer may tend to dis color It will be necess...

Page 259: ...ump Seal NOTE Do not tighten bolts at this time 10 Install O ring seal on solenoid connector 11 Lubricate and install case connector with lock tabs facing into case positioning locator tab in notch on side of case fig 145T 12 Install detent connector into case sleeve connector Installation of Rear Servo Assembly NOTE Before installing rear servo assembly check band apply pin using Tool J 21370 5 a...

Page 260: ... be used 1 Install rear accumulator spring into case fig 147T 2 Lubricate and install rear servo assembly into case fig 148T Fig 142T Location of Check Balls 3 Install rear servo gasket and cover fig 149T 4 Install attaching screws Torque bolts to 15 20 ft lbs Installation of Control Valve Assembly and Governor Pipes 1 Install control valve to spacer gasket fig 150T 2 Install governor pipes into v...

Page 261: ...m pan with attaching screws Torque to 12 ft lbs Installation of Modulator Valve and Vacuum Modulator 1 Install modulator valve into case stem end out fig 153T CASE CONNECTOR SLEEVE TORQUE WRENCH J 21370 6 J 21370 5 Fig 146T Checking Rear Band Pin 2 Install O ring seal on vacuum modulator 3 Install vacuum modulator into case 4 Install modulator retainer and attaching bolt Torque bolt 18 ft lbs Inst...

Page 262: ...MBLY Fig 148T Installing Rear Servo Assembly Fig 150T Installing Control Valve Assembly to Spacer Gasket Fig 149T Installing Rear Servo Cover and Gasket Fig 151T Installing Control Valve Assembly and Governor Pipes CHEVROLET CHASSIS OVERHAUL MANUAL ...

Page 263: ...152T Installing Detent Roller and Spring Assembly MODULATOR VALVE Fig 154T Installing Governor Assembly Fig 153T Installing Vacuum Modulator and Valve SPEEDOMETER DRIVEN GEAR ASSEMBLY Fig 155T Installing Speedometer Driven Gear and Sleeve CHEVROLET CHASSIS OVERHAUL MANUAL ...

Page 264: ...CLUTCH AND TRANSMISSIONS 7 106 SPECIAL TOOLS 1 J 1522 Pilot Bearing Driver Fig 156T Clutch Special Tools 2 J 5824 Clutch Pilot Tool 3 J 1448 Pilot Bearing Puller CHEVROLET CHASSIS OVERHAUL MANUAL ...

Page 265: ...2246 Countergear Loading Tool 6 J 5778 Extension Housing Bushing Remover and Installer 7 J 5154 Extension Housing Seal Installer 8 J 58I4 15 Speedometer Drive Gear Remover 9 J l453 01 Speedometer Drive Gear Press Plates J 9771 Press Plates Not Illustrated J 358 1 Press Plate Holder 10 J 4653 Overdrive Governor Wrench 11 J 5590 Clutch Gear Bearing Installer 12 J 7785 Clutch Gear Retainer Lip Seal I...

Page 266: ...J 4599 Planet Pinion Assembly Tool Set 13 J 9542 Reverse Piston Spring Compressor 14 J 9557 Transmission Case Rear Bushing Remover and Installer and Rear Pump Bushing Remover 15 J 7079 16 J 6582 17 J 9543 18 J 5778 19 J 5154 20 J 5403 21 J 5814 22 J 5853 23 J 8039 24 J 21848 J 8001 J 5492 J 6585 J 6585 3 J 9534 Handle Rear Pump Bushing Installer Vacuum Modulator Wrench Extension Bushing Remover an...

Page 267: ...ure 12 J 21370 5 Rear Band Apply Pin 13 J 21795 1 Gear Unit Assembly Holding Tool 14 J 21795 2 Part of Above Holding Tool 15 J 16 J 17 J 18 J 19 J 20 J 21 J 22 J 23 J 24 J 25 J 26 J 27 J 28 J 29 J 5384 21465 01 21465 5 21465 3 21465 2 21465 1 21465 17 21465 8 21465 13 21465 6 21465 15 21465 16 21465 9 21465 10 22182 Converter Holding Strap Bushing Tool Set Part of Bushing Tool Set Part of Bushing ...

Page 268: ... J 21885 Accumulator Piston Installer 7 J 21369 Converter Pressure Check Fixture 8 J 21362 Seal Protector Forward and Direct Clutch Inner 9 J 21363 Seal Protector Intermediate Clutch Inner 10 J 21409 Seal Protector Forward Clutch Outer 11 J 21664 Clutch Spring Compressor Adapter Ring 12 J 4670 Clutch Spring Compressor 13 J 8059 Snap Ring Pliers 14 J 5586 Snap Ring Pliers 15 J 5403 Snap Ring Pliers...

Page 269: ...must be kept free of dirt Clean paper or rags should be spread on the bench before starting disassembly of the steering gear 1 Loosen locknut on end of sector shaft and turn the lash adjuster a few turns counter clockwise This will remove the load from the worm bearings caused by the close meshing of the rack and sector teeth 2 Loosen the locknut on the worm bearing adjuster and turn the adjuster ...

Page 270: ...r locknut and turn lash adjuster screw several turns counter clockwise Re move three cap screws retaining side cover assem bly and pull side cover sector shaft assembly from gear housing fig 5 W HUPP IPi 7 4 L NOTE If the sector does not clear the opening in the housing easily turn the wormshaft by hand until the sector will pass through the opening 2 Remove the worm bearing adjuster adjuster lock...

Page 271: ...ering parts by welding or straightening Repairs Sector Shaft Bushing Replacement 1 Support steering gear housing in an arbor press and press sector shaft bushing 2 bushings for Chevy II and Corvette from housing with Tool J 1614 in serted from lower end of housing as shown fig 7 2 Press new bushing or bushings into position using the same sector shaft bushing driver as used for removal Check posit...

Page 272: ...oved the nut can be pulled 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 indentation Check ball guides for dam age at ends where they deflect or pick up the balls from the helical path Any parts that show signs of damage should be replaced 4 For Chevrolet...

Page 273: ...he other to close up the spaces between the balls and fill the circuit completely and solidly Fig 13 Filling Ball Guides Chevy II and Corvette 6 Assemble the ball guide clamp to the nut being sure to use a lock washer under the clamp screw then tighten the screw securely Check the assembly by rotating the nut on the worm to see that it moves freely Do not rotate the nut to the end of the worm thre...

Page 274: ...er shim unit is available It contains four shims 063 065 067 and 069 thick 4 After lash adjuster and clearance has been adjusted start sector shaft pilot into bushing in side cover Then using a screw driver through the hole in cover turn lash adjuster in a counter clockwise direction to pull sector shaft pilot into its bushing as far as it will go 5 Rotate wormshaft by hand until ball nut is about...

Page 275: ...t the worm bear ing adjuster until the proper preload is obtained See Specifications 4 Turn the steering shaft from one stop all the way to the other counting the number of turns Then turn the shaft back exactly half the number of turns to the center position 5 Turn the sector lash adjuster screw clockwise to remove all lash between rack and sector teeth Tighten the locknut 6 Again use the 11 16 1...

Page 276: ...ds 4 Remove reservoir from housing Remove mounting bolt O rings and union O rings On Chevy II and Corvette remove filter and filter cage discard filter element Remove end plate retaining ring Compress end plate retaining ring by inserting small punch in 1 8 diam eter hole in pump housing When ring is in com pressed position remove with screw driver as shown fig 18 Remove end plate End plate is spr...

Page 277: ...lways present on rotor pressure plate and thrust plate as a result of normal wear Do not confuse this with scoring Make certain vanes were installed with rounded edge toward pump ring and see that they move freely in rotor slots If the flow control plunger is suspected of being faulty install a new part This part is serviced as a unit only and is factory calibrated Check drive shaft for worn splin...

Page 278: ...fer of pressure plate with petroleum jelly to insure against damaging 9 10 11 12 13 14 15 O ring and install on dowel pins with ported face toward the pump ring Seat pressure plate by placing large socket on top of plate and pushing down with hand Pressure plate will travel about 1 16 to seat Install pressure plate spring in center groove of pressure plate fig 28 Install end plate O ring Lubricate...

Page 279: ...t and torque to 60 ft lbs NOTE Always use a new pulley nut Fig 25 Installing Pump Ring 16 Install studs union and drive shaft woodruff key Support the shaft on the opposite side of key when tapping key into place Fig 26 Installing Vanes Fig 28 Installing Pressure Plate Spring CHEVROLET CHASSIS OVERHAUL MANUAL ...

Page 280: ...STEERING 9 12 Fig 30 Installing Flow Control Valve Fig 29 Installing End Plate Retaining Ring CHEVROLET CHASSIS OVERHAUL MANUAL ...

Page 281: ...wer steering gear used on Chevrolet Chevelle and Camaro are of the same design and are overhauled in a like manner The following procedure outlines the disassembly of the gear overhaul of the individual com ponents and assembly of the gear In many cases complete disassembly of the gear will not be necessary since most of the component parts can be removed without complete disassembly OVERHAUL OPER...

Page 282: ...ows a Remove coupling flange attaching bolt and flange b Loosen the adjuster plug locknut with Spanner Wrench J 972 c Remove adjuster plug assembly with Spanner 6 Wrench J 7624 fig 36 Remove and discard the plug O ring 7 Grasp the lower shaft and pull the valve and shaft assembly from the housing bore Separate worm and shaft and remove the lower shaft cap O ring and discard 8 If the worm or lower ...

Page 283: ... Retainer Ring 47 Needle Bearing 48 Oil Seal 49 Back Up Washer 50 Oil Seal 51 Back Up Washer 52 Retaining Ring bearing manufacturer s identification away from the tool and drive bearing into plug until the tool bottoms in the housing fig 40 CAUTION Place block of wood under adjuster plug to protect thrust bearing surface Temporarily install the adjuster plug in the gear housing and place dust seal...

Page 284: ...e the spring from the shaft Be careful not to distort spring To remove the lower shaft assembly from the valve body proceed as follows a While holding the assembly lower shaft down lightly tap the stub shaft against the bench until the shaft cap is free from the valve body fig 43 The spool valve should be held in the valve body while tapping the shaft b Carefully remove the lower shaft assembly so...

Page 285: ...comes cocked carefully realign the spool valve then remove 4 Remove the dampener O ring from the spool valve and discard 5 If the teflon oil rings are to be replaced cut the 3 teflon oil rings and O rings from the valve body and discard Cleaning and Inspection 1 Wash all parts in clean solvent and blow out all oil holes with compressed air BEARING WITH IDENTIFICATION AWAY FROM TOOL urn Fig 40 Inst...

Page 286: ...ngs were re moved install O rings in the oil ring grooves and lubricate with Type A Transmission Fluid 2 Lubricate the 3 teflon oil rings with petroleum and install in grooves over O rings NOTE The teflon rings may appear to be dis torted but the heat of the oil during operation of the gear will straighten them out 3 Assemble the lower shaft assembly in the valve body so the notch in the lower sha...

Page 287: ...ile holding Tool J 7539 tightly against worm so the balls will not fall out of the rack piston When the worm is in place remove Tool J 7539 c Clamp rack piston flanged end of worm up in vise then install the valve and lower shaft as sembly so that the small notch in the valve body engages the drive pin in the worm Locate the over center position of the worm by slowly turn ing the worm and noting t...

Page 288: ...s for wear scoring or burrs Assembly 1 If the teflon oil seal and O ring was removed in stall a new O ring and seal lubricated with Type A Transmission Fluid in the groove of the rack piston 2 Slide the worm all the way into the rack piston It is not necessary to have the thrust bearing assembly on the worm at this time 3 Turn the worm until the worm groove is aligned with the lower ball return gu...

Page 289: ...h Adapter J 6278 2 and continue driving the seals until the retaining ring seats in its groove Refer to Inset Figure 51 then remove the tool adapter Assembly 1 Lubricate the worm lower thrust bearing and the two thrust washers with Type A Transmission WASHER INNER SEAL J 6278 1 J 6278 2 TOP OF TOOL FLUSH WITH HOUSING STUB SHAFT VALVE BODY WORM SHAFT LOWER THRUST BEARING O RING LOWER THRUST BEARING...

Page 290: ... 4 twelve point socket or box 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 Compressor J 8947 5 Install the pitman shaft and side cover as follows a Install a new O ring in the pitman shaft side cover and retain with petrolatum b Turn the lower s...

Page 291: ...l the way out b Install an inch pound torque wrench with a 3 4 12 point socket on the lower shaft splines c Rotate the lower shaft from one stop to the other Count the number of turns and locate the center of travel then check the combined ball and thrust bearing preload by rotating the torque wrench through the center of travel Note the highest reading Fig 59 Locking Preload Adjustment d Tighten ...

Page 292: ...using and spool from adapter 4 Remove spool from housing fig 63 5 Remove spring reaction spool washer reaction spring spring retainer and seal fig 64 O ring may now be removed from the reaction spool Remove the annulus spacer valve shaft washer and 6 10 plug to sleeve key See Figure 65 Remove clamp by removing nut bolt and spacer or if crimped type clamp is used straighten clamp end and pull clamp...

Page 293: ...physically but not functionally interchangeable with the Chevy II spring which is a 30 lb spring The Corvette valve incorporating this spring is identified by an X stamped on the dust cover In case a connector seat becomes damaged proceed as follows To remove connector seat tap threads in center hole using a 5 16 18 tap Thread a bolt with nut and flat washer attached into tapped hole so that the w...

Page 294: ...ool lip down then in stall spool in housing being careful not to jam spool in housing Install housing and spool onto adapter The side ports should be on the same side as the ball stud Bolt the housing to the adapter Depress the valve spool and turn the locknut onto the shaft about four turns with a clean wrench or socket NOTE Always use a new nut Fig 67 Turning Adjuster Plug out of Sleeve the wash...

Page 295: ...n Spool 11 Spring Thrust Washer 12 Valve Spring 13 Spring Retainer 14 Annulus Seal 15 Annulus Spacer 16 Gasket 17 Valve Shaft Washer 18 O Ring Seal 19 Plug to Sleeve Key 20 Ball Adjuster Nut 21 Valve Shaft 22 Ball Seat Spring 23 Ball Seat 24 Ball Seat 25 Sleeve Bearing 26 Adapter Housing 27 Lubrication Fitting 28 Ball Stud 29 Seal 30 Clamp Fig 72 Proper Key Installation Fig 71 Replacing Adjuster P...

Page 296: ...ller 10 J 8524 2 Adjuster Plug Bearing and Seal Remover 11 J 5403 Snap Ring Pliers 12 J 6278 Pitman Shaft Bearing and Seal Remover 13 J 6278 2 Pitman Shaft Bearing and Seal Installer 14 J 6222 Adjuster Plug Seal Protector 15 J 8947 Rack Piston Ring Compressor 16 J 5860 Torque Wrench Adapter 17 J 6217 Connector Seat Installer 18 J 1315 Torque Wrench in lbs 19 J 8433 1 Power Steering Pump Pulley J 8...

Page 297: ...0 amp 30 amp 20 amp 20 amp FRONT SUSPENSION SECTION 3 WHEEL ALIGNMENT SPECIFICATIONS Vehicle at Curb Weight Caster Camber Steering Axis Inclination t Toe in Total Wheel Bearing Adjustment Preload End Movement Chevrolet Pos 3 4 1 2 Pos 1 4 1 2 7 1 2 1 2 l 8 to 1 4 12 ft lbs zero 001 to 008 Chevelle SS and El Camino Neg 1 2 1 2 All others Neg 1 1 2 Pos 1 2 1 2 8 1 4 1 2 1 8 to 1 4 12 ft lbs zero 001...

Page 298: ...r Upper Shaft Nut Lower Attachment Bracket to Spring Tower Stabilizer Bar Frame Bracket Bolts Link Nuts Strut Rod Rod to Arm Nut Adjustment Nut Front Spring Spring Seat to Control Arm Nuts Lower Control Arm Inner Pivot Nuts Upper Control Arm Attaching Nuts Collar Bolts Brake Anchor Pin Drum Brakes Brake Anchor Bolt Disk Brakes Lower Control Arm Cross Shaft Bolts Front Rear Wheel Stud Nuts Chevrole...

Page 299: ...Caps 55 Filler Plug 20 Differential Pinion Lock 20 Type Heavy Duty Axle Light Duty Axle Bolt Torque ft lbs Spring Retainer Control Arm Upper Front Bracket Upper Bushings Lower Bushings Shock Absorber Upper Nut Upper Bracket Lower Nut Spring Shackle Front Rear Tie Rod Attaching Nuts Stud to Axle Bracket Universal Joint Companion Flange Transmission Yoke Wheel Stud Nuts Axle Drive Shaft to Spindle t...

Page 300: ...Install nut to expose hole Corvette then insert cotter pin only Neg 1 2 1 2 1 32 to 3 32 Station Wagon All 4 Link System Plus additional torque necessary to line up cotter pin hole Camber must not vary more than 1 2 degree from side to set side Toe setting must be made after camber is RIDING HEIGHT Body Style 2 Door Sedan 4 Door Sedan 4 Door Sport Sedan Sport Coupe Convertible Station Wagon Sedan ...

Page 301: ...ions Brake Hose to Brake Assembly Connection Parking Brake Equalizer Check Nut Hydraulic Brake Pipe Connections Rear Brake Hose to Rear Brake Line T Connection Caliper Half Retaining Bolts Caliper to Mounting Bracket Retaining Bolts Chevrolet 24 lb ft 14 lb ft 100 lb in Front Line 115 lb in Rear Line 23 lb ft 85 lb in 110 lb in 113 lb in 130 lb ft 130 lb ft Chevelle 60 lb in 24 lb ft 14 lb ft 115 ...

Page 302: ... 300 5000 360 3400 325 5600 355 3600 350 5800 360 3600 350 295 4800 380 3200 4 8 75 1 3 25 10 0 1 11 0 1 3 48 396 325 4800 410 3200 350 5200 415 3400 4 3 32 10 25 427 385 5200 460 3400 390 5400 460 3600 3 L 400 5400 460 3600 4 1 4 76 425 N A N A t N A 435 5800 460 4000 11 0 1 1 8 4 3 6 5 7 2 3 8745 3 8775 3 5620 3 5650 3 8745 3 8775 005 Max 3 9995 4 0025 4 0925 4 0995 4 2495 4 2525 001 Max 002 Max...

Page 303: ...0 425 435 9270 9273 00015 00025 00045 00055 0015 0025 9895 9898 00025 00035 00030 00040 001 Max 0008 0016 Interference All 2 2983 2 2993 1 2 2984 2 2993 2 3 4 2 2983 2 2993 5 2 2978 2 2988 1 2 3 4 2 4483 2 4493 5 2 4478 2 4488 1 2 2 7487 2 7497 3 4 2 7482 2 7492 5 2 7478 2 7488 0002 Max 001 Max 0002 Max 001 Max All 0003 0029 1 0008 0020 2 3 4 0018 0020 5 0010 0036 1 2 3 4 0008 0020 5 0018 0034 1 2...

Page 304: ...90 400 425 435 Hydraulic 1 75 1 1 50 1 Mechanical 1 70 1 One Turn Down From Zero Lash One Turn Down From Zero Lash 022 024 024 028 45 46 002 Max 1 32 1 16 1 16 3 32 0010 0027 0015 0032 0010 0027 0010 0025 0012 0027 Hi Limit Production 001 Intake 002 Exhaust 2 08 78 86 1 66 170 180 1 26 1 92 1 90 54 64 1 66 170 184 1 33 180 192 1 27 1 21 32 2 03 N A N A 1 5 32 2 11 84 96 1 88 210 230 1 46 2 09 94 1...

Page 305: ...9 R3806A 170 300 Use 427 425 Syn 3886091 R3418A 350 450 D 327 325 Syn 3903391 3807 396 350 Auto 3908956 R3836A Syn 3908957 R3837A Four Barrel 4160 327 300 327 350 All 3906631 R3810A 427 390 Syn 3906633 R3811A D 396 350 Auto 3908958 R3838A Syn 3908959 R3839A D 327 300 327 350 All Ii 427 390 All 3906637 R3815A 170 300 Sight Plug Two Prim 427 400 427 435 Syn 3902355 R3660A Barrel Sec 427 400 427 435 ...

Page 306: ...i 1 283 327 210 Syn 8 8 283 327 210 Auto o 283 327 210 Syn i H o CO o 3XD 283 327 210 Auto C M CO O C D 283 327 210 Syn 8 CO o 3 4 1 3 4 1 1 8 1 060 110 120 110 120 110 130 110 130 t 215 1 Rod Diameter 059 060 058 059 058 060 1 9 16 Interference 052 054 052 054 052 054 052 054 1 7 16 327 275 350 295 Auto 8 CM 8 Quadra Jet Four Barrel 4MV 327 275 350 295 Syn CO o CM 8 396 325 427 385 Auto CM 396 32...

Page 307: ... __ 25 ft lb _ _ 20 ft lb 30 ft lb 30 ft lb _ _ _ n 65 ft lb _ _ _ 95 ft lb _ _ _ _ _ _ _ _ Hand Tight 250 80 in 55 in 35 ft _ _ _ 1 283 1 ___Z 80 in 80 in __ ib 1 _ lb lb 10 ft 30 ft 20 ft i T 7 1 I 1 60 ft r n r _ _ _ ____ i 20 ft 20 ft 25 ft I 327 _ lb lb _ _ 65 in _ _ _ _ lb lb _ _ _ _ _ _ lb _ 65 ft 80 ft lb 60 ft 1 _ _ _ lb lb lb V 8 I 350 80 in 80 in 20 ft IE _ _ 35 ft 20 ft 30 ft 30 ft lb ...

Page 308: ...New Using Strand r 5 lbs Used r 75 5 lbs New Using Strand r 28 4 B 4 B 4 B 4 B rensior rensior rensior 32 4 B 4 B 4 B 4 B 3Z 4 B 4 B 4 B 4 B I Gauge l Gaug I Gauge 1 9 2 3 oz 10 B X X X 5 B X 5 B X Hydraulic Hydraulic 500 500 X X 700 600 3 to 700 500 4 1 2 500 600 One Turn One Turn 500 500 700 600 Down From Zero Lash Down From Zero Lash 700 750 500 500 700 500 500 500 700 500 550 550 700 500 550 5...

Page 309: ...r Construction GENERATOR Generator Model Application Field Amp Draw Hot Output Amps Cold Output Volts 1100695 Chevy II Exc V 8 Sta Wgn or AC 2 2 2 6 32 14 1100693 Chevy II w V 8 Camaro Chevelle Chevrolet and Corvette w AC 2 2 2 6 37 14 1100696 Chevy II w AC RPO K 66 2 2 2 6 42 14 1100742 Chevrolet w AC Turbo Hydramatic 2 8 3 2 63 14 1100750 All A C except w RPO M 40 and Chevy II 2 2 2 6 61 14 1117...

Page 310: ...ed Volts Amperes RPM Resistance Test Armature Locked Volts Amperes 1107399 153L 4 194L 6 230L 6 w Manual Trans 230L 6 w Auto Trans 250L 6 All trans 35 10 6 49 87 6200 10700 4 2 290 425 1107400 153L 4 194L 6 w Auto Trans 35 10 6 49 87 6200 10700 4 2 290 425 1107496 283 Cu In V 8 All Trans 35 10 6 49 87 6200 10700 4 2 290 425 1107320 327 Cu In V 8 Auto Trans 35 10 6 65 100 3600 5100 3 5 300 360 1107...

Page 311: ...0 32 3950 0 900 11 1500 26 4100 0 900 10 1500 15 2000 28 4200 0 900 9 1200 15 1500 30 5100 0 900 19 1200 25 1500 40 5100 0 900 9 1200 15 1500 30 5100 0 900 9 1200 15 1500 30 5100 0 900 9 1300 15 1700 26 4700 0 900 8 5 1250 17 2000 32 5 J00 0 900 8 5 1250 17 2000 32 5000 0 900 8 5 1250 17 2000 32 5 5000 0 900 30 3800 0 900 17 1600 28 4600 0 900 8 5 1250 17 2000 32 5000 Vacuum Advance In Crank Degre...

Page 312: ... Primary Resistance Ohms Secondary Resistance Ohms Ignition Resistor Type Ohms L 4 L 6 1 45 1 63 5600 6900 1 8 V 8 Non Transistor 1 24 1 46 6500 9500 Fixed In Wiring Harness 1 8 V 8 Transistor 38 51 8200 12 400 43 68 CHEVROLET CHASSIS OVERHAUL MANUAL ...

Page 313: ...Shaft Nut j 25 ft lbs Lubrication Filler and Drain Plugs j 20 ft lbs Transmission Case to Clutch Housing Bolts 55 ft lbs Crossmember to Frame Nuts 25 ft lbs Crossmember to Mount Bolts 40 ft lbs FOUR SPEED SAGINAW Clutch Gear Retainer to Case Bolts 22 ft lbs Side Cover to Case Bolts 22 ft lbs Extension to Case Bolts except overdrive 45 ft lbs Shift Lever to Shifter Shaft Bolts 20 ft lbs Lubrication...

Page 314: ... Pan to Transmission Case 7 1 2 ft lbs Oil Cooler Pipe Connectors to Transmission Case or Radiator 10 ft lbs Oil Cooler Pipe to Connectors 10 ft lbs Vacuum Modulator to Transmission Case 15 ft lbs Oil Pan Drain Plug 20 ft lbs Converter Drain Plug Taxies 20 ft lbs Parking Brake Lock Range Selector Inner Lever Allen Head Screw 2 1 2 ft lbs TURBO HYDRAMATIC Pump Cover Bolts 18 lb ft Parking Pawl Brac...

Page 315: ... 5 1 21 3 1 17 5 1 20 4 1 870 1000 Recirculating Ball 900 1000 Integ Recirc Ball 17 5 1 17 5 1 870 1000 Recirculating Ball 17 6 1 Only ADJUSTMENT SPECIFICATIONS STANDARD STEERING Adjustment Worm Bearing Preload Sector Lash Adjustment Total Steering Gear Preload Torque to Turn Worm Shaft 5 8 Lb In 4 10 Lb In in excess of above 16 Lb In Maximum ADJUSTMENT SPECIFICATIONS POWER STEERING Ball Drag Thru...

Page 316: ...ng Pump Pulley Power Steering Mounting Bolt Power Steering Mounting Nut Power Cylinder to Relay Rod Nut Power Cylinder to Frame Bracket Control Valve to Pitman Arm Control Valve Clamp Bolt Steering Shaft to Gear Clamp Nut Chevrolet 70 lb ft Chevelle 70 lb ft Chevy II 30 lb ft Camaro 68 lb ft Corvette 30 lb ft 140 lb ft 35 lb ft 1 lb in 1 lb in 18 lb ft 30 lb ft 1 lb in 18 lb ft 30 lb ft 35 lb ft 1...

Page 317: ...ustment would require pressures greater than the maximums stated above 3 Cool tire inflation pressure after vehicle has been inoperative for three 3 hours or more or driven less than one 1 mile Hot tire inflation pressure after vehicle has been driven ten 10 miles or more at 60 70 MPH 4 Station Wagon loads should be distributed as far forward as possible 5 Vehicles with luggage racks do not have a...

Page 318: ...ver 75 MPH increase tire inflation pressures four 4 pounds per square inch over the recommended pressures up to a maximum of 32 pounds per square inch cool for 4 ply rating tires or 40 pounds per square inch for 8 ply rating tires Sustained speeds above 75 MPH are not recommended when the 4 pounds per square inch adjustment would require pressures greater than the maximums stated above 3 Cool tire...

Page 319: ... 5 When towing trailers the allowable passenger and cargo load must be reduced by an amount equal to the trailer tongue load on the trailer hitch CORVETTE Tire Usage and Recommended Tire Inflation Pressures Pounds per Square Inch PSI Cool Models All Models 1 to 2 passengers 150 lbs luggage 450 lbs load Tire Ply 4 Ply Rating 2 Ply Tire Usage 7 75 15 Standard Inflation Pressure for all Loads includi...

Page 320: ...sengers 750 lbs load Front 24 24 Rear 24 24 1 to 5 passengers 750 lbs load Front 22 22 Rear 26 26 1 to 5 passengers 750 lbs load Front 22 Rear 26 1 Tire inflation pressures may increase as much as six 6 pounds per square inch PSI when hot 2 For continuous high speed operation over 75 MPH increase tire inflation pressures four 4 pounds per square inctuover the recommended pressures up to a maximum ...

Page 321: ...Chevelle and Chevy II Hi Beam Indicator Chevrolet Camaro Chevelle and Chevy H Corvette Directional Indicator Chevrolet Camaro Chevelle Chevy H Corvette Cigarette Lighter Lamp Corvette Ignition Lock Lamp Chevrolet Corvette Heater or A C Control Panel Chevrolet Chevelle Chevy n Camaro Corvette Glove Box Lamps Chevrolet Chevelle Chevy II Camaro Corvette Dome and Courtesy Lamps Cartridge Type All Bayo...

Page 322: ... until the cause is found and eliminated Fuses located in the Fuse Panel under the instrument panel are Wiper Chevrolet Chevelle and F Car 3AF AGC 20 Amp Back up Lamp and Gauges 3AG AGC 10 Amp Heater Air Conditioning 3AG AGC 25 Amp Radio 3AG AGC 10 Amp Radio Wiper Chevy II and Corvette 3AG AGC 20 Amp Instrument Lamps 3AG AGC 4 Amp Stop and Tail Lamps 3AG AGC 20 Amp Clock Lighter Courtesy Lamps and...

Page 323: ...d Park Chevrolet Corvette Two Speed Operating Voltage 12 VDC Gear Ratio 3 36 1 Crank Arm Rotation Looking at Crank Arm Clockwise Crank Arm Speed No Load Lo 34 RPM min Hi 65 RPM min Current Draw amperes No load low speed 3 6 Installed in Car dry windshield 4 5 Stall 12 Shunt Field Resistance OHMS 24 WASHER PUMP Number of squirts at full pressure 12 Pressure PSI 11 15 Coil Resistance OHMS 20 CHEVROL...

Page 324: ...me Crossmember Nuts Front Bumper Bracket to Frame Nuts Front Outer Brace Center Brace to Frame Bolts Gas Tank Filler Door to Rear Bumper Nuts Rear Bumper to Frame Crossmember Nuts Rear Bumper to Bumper Bracket Nuts Rear Bumper to Bumper Brace Nuts Chevrolet 30 lb ft 30 lb ft 53 lb ft 53 lb ft 43 lb ft 30 lb ft 30 lb ft Chevelle 24 lb ft 24 lb ft 39 lb ft 53 lb ft 53 lb ft 43 lb ft 30 lb ft 45 lb f...

Page 325: ...er to Bumper Nuts Rear License Plate Bezel to Body Screws Chevrolet 50 lb ft 25 lb ft Chevelle 30 lb ft 45 lb ft for station wagon El Camino 53 lb ft 53 lb ft Chevy II 28 lb ft 28 lb ft Corvette 30 lb ft _ 13 lb in Camaro t j ACCESSORIES SECTION 15 CRUISE MASTER Solenoid Resistance 5 ohms 1 4 ohm Solenoid Wire Resistance 40 ohms Maximum allowable Vacuum Leahage Rate for Servo Unit 5 inches of Vacu...

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Chevrolet 1967 CAMARO, Overhaul Manual

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