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Chevrolet 70 1969 Series, Shop Manual

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TRANSMISSION AND CLUTCH 7-18

1.  Gear  Shift  Lever  Dust 

Cover

2.  Gear  Shift  Lever  Pivot  Pin

3.  Control  Top

4.  Gear  Shift  Lever

5.  Gear  Shift  Lever  Support 

Washer

6.  Support  Spring

7.  Control  Top  Gasket

8.  Shift  Rod  Cover

9.  Shift  Rod  Cover  Gasket 

10.  Shift  Rod  Support  Screw

10.  A  Shift  Rod  Support  Screw 

Lock  Washer

11.  Shift  Rod  Support

12.  1st  and  Reverse  Shift  Fork 

Lockscrew

13.  1st  and  Reverse  Shift  Fork

14.  Shift  Fork  Lock  Pin

15.  4th  and  5th  Shift  Fork 

Assembly-lnc.  Items

16  and  17

16.  Shift  Fork  Bushing

17.  Shift  Fork  Bushing

18.  Shift  Fork  Bushing

19.  Shift  Fork  Bushing

20.  Shift  Fork  Lock  Pin

21.  2nd  and  3rd  Fork 

Assembly-lnc.  Items

18  and  19

22.  2nd  Speed  Overshift 

Spacer

23.  Reverse  Shift  Lug  Lock 

Screw

24.  Reverse  Shift  Lug

25.  4th  and  5th  Shift  Rod

26.  Mesh  Lock  Ball

27.  Interlock  Cross  Pin

28.  2nd  and  3rd  Shift  Rod

29.  1st  and  Reverse  Shift  Rod

30.  Mesh  Lock  Ball

31.  Mesh  Lock  Spring

32.  Reverse  Hatch  Plunger

33.  Reverse  Hatch  Plunger 

Retainer  Washer

34.  Reverse  Hatch  Plunger 

Spring

35.  1st  and  Reverse  Rocker

36.  Reverse  Latch 

Plunger  Nut

37.  Reverse  Latch 

Plunger  Nut  Cotter

38.  Backup  Switch  Hole  Plug

39.  Backup  Switch  Hole  Plug 

Gasket

40.  Welch  Plug

41.  Control  Top  Screw  and 

Lock  Washer

F ig u re   2 N — C o v e r   E x p lo d e

CLEANING  AND  INSPECTION 

Cleaning

Clean  all  parts  thoroughly  using  solvent  type  cleaning 

fluid.  It  is  recommended  that  parts  be  immersed  in  clean­

ing  fluid  and  moved  up  and  down  slowly  until  all  old  lu­

bricant  and  foreign  material  is  dissolved  and  parts  are 

thoroughly  cleaned.

C A U T IO N :   C are  sh ou ld   b e   exercised  to  a vo id  

skin  rashes,  fire  hazards,  a n d   inhalation  of

 v a ­

pors  w h e n   using  solvent  type  cleaners.

Bearings:

Remove  bearings  from  cleaning  fluid  and  strike  against 

a  block  of  wood  to  dislodge  solidified  particles  of  lubri­

cant.  Immerse  again  in  cleaning  fluid  to  flush  out  par­

ticles.  Repeat  above  operation  until  bearings  are  thor­

oughly  clean.  Dry  bearings  using  moisture-free  com ­

pressed  air.  Be  careful  to  direct  air  stream  across  bearing 

to  avoid  spinning.  Do  not  spin  bearings  when  drying. 

Bearings  may  be  rotated  slowly  by  hand  to  facilitate 

drying  process.

Housings:

Clean  interior  and  exterior  of  housings,  bearing  caps,

CHEVROLET SERIES 70-80 HEAVY  DUTY TRUCK SH O P  M A N U A L

Summary of Contents for 70 1969 Series

Page 1: ...CHEVROLET HEAVY DUTY TRUCK SHOP MANUAL...

Page 2: ...on 9 of the Overhaul portion of this manual while Specifications covering vehicle components are presented at the end of each section This manual should be kept in a handy place for ready reference If...

Page 3: ......

Page 4: ...experience This information should serve not only as a reference for the experienced mechanical force but also as a comprehensive text for training purposes In some cases considerable space is devote...

Page 5: ...Aux TV 70 6V 53M 14 F070 F090 F110 17221 19101 17101 19202 5752C MT41C HM 80 401M 478M 13 13 2 14 14 2 F070 F090 F120 17121 18121 17221 18221 19201 541GL 541GD 387V 5752C JM 80 401M 478M 13 13 2 14 1...

Page 6: ...throughout the manual Illustrations are numbered consecutively within each section or within each sub section when the major section is so divided SPECIFICATIONS Service data fits and tolerances are...

Page 7: ...nt door of steel tilt and conventional cab models This label lists all special equipment installed on the vehicle This information is imprinted on the label at the factory and represents only the spec...

Page 8: ...h lubrication point on the series shown under each chart Each point is numbered on the charts and each number is keyed to explanatory text on same or opposite page Each item shown on charts requiring...

Page 9: ...LUBRICATION 0 2 Figure 1 Lubrication Chart Conventional Cab Models CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL...

Page 10: ...19 Brake Camshaft F 2 1 fitting ea apply sparingly c 6 000 20 Clutch and Brake Master Cylinder Fill 1 2 below opening S12 6 000 21 Steering Gear H o usin g To level of filler plug c 6 000 22 Battery T...

Page 11: ...LUBRICATION 0 4 CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL...

Page 12: ...fittings c 6 000 22 Auxiliary Trans Shift Tower 1 1 fitting c 6 000 23 Auxiliary Trans Shift Levers 1 2 fittings c 6 000 24 Transmission Shift Rod U Joints 1 1 fitting each joint c 6 000 25 Hand Brake...

Page 13: ...24 000 5 Brake Camshafts 1 1 fitting each C 6 000t 6 Brake Shoe Roller Pins 1 Apply E 20 000 7 Wheel Bearings Hand pack or use lubricator S2 20 000 t Lubricate every 6 000 miles or 60 days whichever...

Page 14: ...tall 7 Distributor 2 1 2 turn of cam lubricator Breaker pivot 1 drop Rotor felt 4 drops 9 Starter See instructions 10 Power Steering Reservoir 1 To OIL L E V E L mark 11 Tachometer Adapter 1 1 fitting...

Page 15: ...r certain service designations and specification numbers The selection of a reliable supplier with close attention to his oil and filter element change recommendations can provide satisfactory lubri c...

Page 16: ...d change filter every 2 000 miles or every 2 months whichever occurs first NOTE 1 following When operating in variable or intermittent low temperature where use of D G oil has resulted in some sludge...

Page 17: ...se on 6V 53 Diesel models and at left rear on gasoline models fig 8 E L E M E N T TYPE 1 Remove plug in filter shell to drain oil from filter 2 Back out center stud and withdraw shell and stud as an a...

Page 18: ...sandy roads unit should be cleaned every day or at least every 200 miles Air cleaners on vehicles operating in dust storm GASOLINE ENGINE DIESEL ENGINE t 2361 areas should be cleaned immediately afte...

Page 19: ...is cleaned recheck after cleaning or washing as described above and every 3 000 miles thereafter Under normal driv ing conditions element should be checked every 6 000 miles 3 Re assemble and install...

Page 20: ...ng Paper element type air compressor cleaner is used on some models and should be replaced when element shows visible evidence of damage or a dirt clogged condition or is oil saturated Cellulose type...

Page 21: ...LINE ENGINES The crankcase breather is a replaceable paper element type mounted in container at left rear of crankcase and should be inspected at each oil change and serviced if necessary fig 12 This...

Page 22: ...ruck is operated in exceptionally heavy work or at con tinuous high speed the lubricant should be changed every 12 000 miles At specified intervals remove plug at bottom of axle housing also at bottom...

Page 23: ...ricant through fitting in universal joint trunnion fig 15 To insure proper lubrication of all four trunnion bearings it is important that lubricant be added until it appears at all four journal bearin...

Page 24: ...lubricant and dirt is removed Check bearings and cups and replace damaged parts PACKING Some wheel bearings are lubricated from axle differential after the initial lubrication However whenever wheel h...

Page 25: ...nge Pins Door Lock Remote Control Link Cowl Ventilator Linkage Seat Adjuster Slides Door Lock Mechanism Door Dove Tails Window Regulator Channels Window Regulators Hood Hinges Tilt Cab Guide Pin Figur...

Page 26: ...re frequent use of clutch release mechanism and consequently should be serviced at more frequent intervals than a vehicle which is operating in highway service Use extreme caution not to over lubricat...

Page 27: ......

Page 28: ...i p e r s 1 4 N O TE Refer to respective cab section for all other information GENERAL to door weatherstrip and adjacent contact areas on cab will prevent squeaks and freezing of weather Regular peri...

Page 29: ...ng must be slow to avoid changing characteristics of the metal Apply slight heat with torch if necessary to retard cooling DINGING AND FINISHING Paint is quickly scuffed off sharp dents leaving metal...

Page 30: ...ies in body opening c Irregularities in rubber channel GLASS TO OPENING C LE A R A N C E CHECK TILT CAB Before installing new glass check glass open ing for proper clearance using five special spacer...

Page 31: ...ends 4 Position glass to seal and insert hood end of installer tool fig 1 into seal groove Move tool around glass to force outer lip of seal over glass 5 Thread end of rubber insert through handle an...

Page 32: ...ps the wiper circuit closed so wiper can keep operating until the blades reach their predeter mined P A R K position PARKING CIRCUIT When wiper is turned off circuit is broken at the dash switch Howev...

Page 33: ...Underneath the dash remove defroster air outlet tubing if necessary and any other items to allow access to transmission linkage 4 At motor crank arm under dash remove the two nut assemblies which secu...

Page 34: ...at pump 3 Remove three screw assemblies which attach motor assembly to front of cab cowl 4 Pull motor forward from opening then through the opening remove two nuts from arm to link rod ball clamp to s...

Page 35: ...on styrofoam pad on pivot shaft hous ing then locate motor and drive unit to cab panel Attach unit mounting bracket to panel with four cap screws and washers IMPORTANT Make sure a good metal to metal...

Page 36: ...h speed only the lead between wiper terminal and dash switch is open or the dash switch is defective 3 If wiper still fails to operate correctly remove it from cab then remove covering from over drive...

Page 37: ...s AC640 to idler gear shaft pin then install idler gear 4 Install output shaft and gear assembly in motor mounting plate bushing Apply AC640 lubri cant sparingly to gear teeth 5 Operate motor and stop...

Page 38: ...ect electric wiring 4 Reconnect water hoses TROUBLESHOOTING W ASHER PU M P On Vehicle Check Fig 15 1 If washer pumps continuously when wiper is on disconnect wiring from washer pump a If pump shuts of...

Page 39: ...t not draw through intake pipe fig 4 5 Attach a hose individually to each of the small exhaust pipes You should be able to draw but not blow through them If any of the valves allow air to pass in both...

Page 40: ...valve assembly to piston housing Separate valve assembly from piston housing NOTE Observe direction of pipes before re moving pipe assembly from piston housing to as sure proper reassembly 7 To assemb...

Page 41: ...n and reinforce the roof The floor panel also of one piece construction eliminates joints pockets and seams which norm ally act as moisture traps In most cases all paneling pieces are lap jointed and...

Page 42: ...the semi shear type Semi shear type mountings are serviced only as assemblies Compression type mounting is readily replaced by removing one mounting bolt At regular intervals all cab mountings should...

Page 43: ...eat adjusters do not release simultaneously lengthen or shorten adjuster lock rod underneath the seat assembly A stud adjustment nut and wing nut at ends of seat back frame fig 4 provide a means of ch...

Page 44: ...al or installation of shims in serted between door and hinge strap fig 5 The door when properly located in door open ing will have equal clearance around itsperimeter T O POSITION D O O R FORE AND A F...

Page 45: ...NOTE Periodically check tightness of striker bolt Figure 9 Relocating Striker Bolt STRIKER BOLT R E PLA C EM EN T R emoval Refer to Fig 7 1 Mark position of striker bolt spacer or washer on door pill...

Page 46: ...fore and aft adjustment is obtained by use of shim spacers located between the bolt washer and the cab pillar Figure 7 illustrates location of bolt washers and spacer Striker Bolt Fore and Aft Adjustm...

Page 47: ...of adjust ment travel it will then be necessary to add or remove shims at the door hinges After obtaining proper height adjustment pro ceed to make Door Rear Edge In or Out Ad justment Door Rear Edge...

Page 48: ...ainer INSTALLATION 1 Position rubber seal around opening in door 2 Place access panel to seal then with hook end oftool in panel groove of seal move tool around panel to force outer lip of seal over e...

Page 49: ...ves of lock cylinder If one of the retainer legs is not engaged the retainer flange will not be vertical in door slot DOOR INSIDE HANDLES REPLACEMENT N OTE If removing door lock inside handle the hand...

Page 50: ...rods out through access opening in door 7 Separate rods from lock mechanism if de sired To disengage pull rod fastener force lock tab of fastener outward through small hole in lock release lever as s...

Page 51: ...ch Friction mechanism consists primarily of a coil spring mounted on vent window lower pivot which exerts frictional force against mounting lower support If friction mechanism is adjusted too tight it...

Page 52: ...oor structure 5 Adjust the vent opening and closing tension as directed previously under Door Vent Window Tension Adjustment 6 Install door access panel DOOR WINDOW GLASS REPLACEMENT R E M O V A L 1 R...

Page 53: ...me 2 If the glass horizontal seal strips were removed from door press new seal strips into position making sure all strip attaching clips are fully engaged 3 Lower the door window assembly into door f...

Page 54: ...b consists of a chain hoist 3 4 ton minimum capacity a sling having padded hangers and two or more support blocks to rest cab on once the cab is removed from chassis 1 Disconnect the battery 2 Remove...

Page 55: ...plained later at end of the heater section in this group STANDARD AIR FLOW HEATER The standard air flow heater provides heated outside air for heating and defrosting requirements Outside air is drawn...

Page 56: ...CAB AND BODY MOUNTINGS 1 29 AIR HEATER CONTROLS T 2428 Figure 31 Heavy Duty Air Flow Heater CHEVROLET SERIES 70 S0 HEAVY DUTY TRUCK SHOP MANUAL...

Page 57: ...The control on dash marked AIR regulates the flow of outside air which passes through the heater and into cab This control must be posi tioned all the way towards the right in order to obtain heat IMP...

Page 58: ...and check the operation of heater and controls AIR DISTRIBUTOR REPLACEMENT HEAVY DUTY AIR FLOW HEATER Refer to Figure 31 The air distributor can be readily replaced after disconnecting the attaching...

Page 59: ...the old seal and adhesive from seal channel If vent cover fails to close firmly against seal the link rod under dash can be bent slightly as re quired to increase the closing pressure N O TE Do not be...

Page 60: ...nchored to chassis Cab is retain ed in lowered operating position by positive lock ing mechanism located at rear of cab Access for minor engine servicing such as oil and engine coolant is accomplished...

Page 61: ...a single support bracket having two rubber cushions supports cab at rear center Cab tilt hold down mechanism locks cab firmly on cushions CAB TILTING INSTRUCTIONS TO RAISE CAB Refer to Figure 2 IMPORT...

Page 62: ...hen cab is in either the operating or full tilted position Right end of bar is anchored to cab bracket and left end is anchored by lever to frame bracket as shown in figure 4 Bar is unloaded when cab...

Page 63: ...ing rfui Attaching Studs Stud Nuts Accessible front Under Cab Figure S Driver s Seat Mounting and Adjustment CAUTION Do no benzene acetone or any tone solvents These so1 ing agents of u resistance to...

Page 64: ...l hinge cap screw access plug in door inner paneling after making final adjustment 4 Install striker bolt and adjust as directed later under Striker Bolt Adjustment REPOSITION DOOR F O R E OR A F T Fi...

Page 65: ...led or aligned in opening the door should not be closed completely until a visual check is made to deter mine if lock cam in door will engage the striker bolt correctly Center of striker bolt should b...

Page 66: ...4 If necessary raise or lower the loosened striker bolt up or down by tapping on the washer or spacer at base of striker bolt D O N O T TA P ON H EAD O F B O LT Door Rear Edge In or Out Adjustment Th...

Page 67: ...on lock cylinder insert cylinder in door and engage lug over lock mechanism lever 2 While holding cylinder insert legs of re tainer into grooves of lock cylinder body Be cer tain legs of retainer are...

Page 68: ...g door lock handle make sure handle is in position previously marked on door inner panel To install either handle force handle with installed lock spring over spindle until lock spring becomes fully e...

Page 69: ...ial locking type screws which attach lock mechanism to door frame Check operation of door lock and remote control mechanism after install ation As required remote control unit may be shifted slightly...

Page 70: ...er filler Figure 20 Removing Door Window Class 3 Cut new piece of glazing rubber filler to length of glass regulator channel 4 Position glazing rubber filler soapstone side away from glass on bottom e...

Page 71: ...with wind pressure If necessary to change vent friction perform procedures as follows 1 Remove access trim panel attached to door just below vent window with five screws Figure 23 shows access openin...

Page 72: ...hen final tighten lower end of division channel to door inner panel Recheck for binding DOOR VENT GLASS REPLACEMENT N O TE The following procedure covers re placement of vent glass and frame only and...

Page 73: ...Install access panel to inner side of door DOOR GLASS RUN CHANNEL REPLACEMENT 1 Remove door window as explained previ ously under Door Window Glass Replacement 2 Pull down on end of run channel at ven...

Page 74: ...Retighten clamp screw after making adjustment HEATING The heater used on tilt cab models is of the air flow type fig 27 and is serviced in same manner as air flow heater described previously under Co...

Page 75: ...bar in between cab right sup port and cab sill Remove three forward bolts lock washers and nuts from cab right support to sill brackets B fig 29 Use pry bar to assist in removing bolts Disconnect che...

Page 76: ...orsion bar right frame bracket and from support cap left support 4 Remove bolt nut and washers which at tach torsion bar anchor lever to cab mounting left frame bracket Remove arm from bar and bracket...

Page 77: ...ll become unloaded when cab is tilted 45 to 50 degrees N OTE This unloaded angle position will vary slightly on different vehicles IMPORTANT Before continuing check tight ness of screw which clamps ca...

Page 78: ...o clear rivet heads IMPORTANT Do not use spacers to raise sills above rivet heads If body longitudinal sill is of metal it will be necessary to use a one piece full length hardwood strip with holes to...

Page 79: ...ivet heads 6 To prevent mounting clip plate becoming embedded in longitudinal sill install a sheet metal channel on top of sill at each mounting point figs 1 2 and 3 Rabbet grooves along each side of...

Page 80: ...y is not equipped with longitudinal sills attach sills if possible as shown in figure 3 since mounting on cross sills bolsters is not recommended Longitudinal sills can be easily made of dry hardwood...

Page 81: ...o provide com fort by cooling and dehumidifying the air which is force circulated within the cab Briefly the air conditioning system is com prised of the following units and controls Figure 1 shows ty...

Page 82: ...ressure COMPRESSOR HIGH DISCHARGE PRESSURE Check for air in system excess refrigerant restriction in con denser refrigerant tubes or air fins See Note B If ice is blocking evaporator adjust suction th...

Page 83: ...r side of radiator shell T H E COOLING UNITS Consist of 1 An evaporator coil located under right side of dash in an enclosed housing assembly 2 A refrigerant expansion valve also located in above ment...

Page 84: ...ove AIR lever to OU TSID E then operate system as described on following page n o t e The air flow direction from any one of the dash outlets can be controlled by positioning of outlet inner deflector...

Page 85: ...itch lever from left to right positions O F F L O W SPEED M EDIUM SPEED and HIGH SPEED For warm weather ventilation less air condi tioning place AIR C O N D lever D E F R O S T and T E M P control kno...

Page 86: ...DAMENTAL PRINCIPLES OF REFRIGERATION The principle of operation of the refrigeration system is based on a few simple laws of physics which are stated informally as follows 1 Temperature is a measureme...

Page 87: ...lammable and nonexplosive It is noncorrosive to any of the ordinary metals Goggles should be worn whenever there is the slightest possibility of refrigerant coming in con tact with the face or eyes be...

Page 88: ...ing is illus trated in figures 1 and 6 A complete cycle of the refrigerating system is as follows 1 Refrigerant in its gaseous state is drawn into the compressor where it is compressed and discharged...

Page 89: ...y tube is fastened to the low pressure refrigerant pipe coming out of the evaporator so that it communi cates the temperature of the refrigerant at this point to the expansion valve If the superheat a...

Page 90: ...creases allowing the valve adjusting spring to move the needle valve toward its seat closing off the flow of refrigerant past the needle valve If the temperature differential begins to go above 10 6 F...

Page 91: ...evaporator pressure and forces the piston in a closing direction until the predeter mined pressure setting is maintained 23 24p s i g The minimum operating pressure of the suction throttling valve is...

Page 92: ...ar to the ordinary rad iator but is designed to withstand much higher pressures It is made up of tubes which carry the refrigerant and cooling fins which provide rapid transfer of heat The condenser i...

Page 93: ...check to see that the space between the condenser and radiador is also free of this material 2 Inspect compressor drive belt Check and adjust tension to 100 to 105 lbs on belt tension gauge Adjust ne...

Page 94: ...side the hoses and cannot be removed the hose should be replaced 3 Sealing caps should be removed from sub assemblies just prior to making connections for final assembly 4 Use a small amount of clean...

Page 95: ...sor belt for proper tension if below 100 lbs used belt adjust to 100 105 lbs using belt tension gauge 2 Check all refrigeration lines for leaks kinks or other restrictions 3 Check outer surfaces of ra...

Page 96: ...lever at O U T SIDE T E M P lever full leftfor maximum cooling and blower switch at high blower speed 11 Set engine speed at 2000 rpm COMPRESSOR I p TO CONDENSER EVAPORATOR GAUGE HIGH PRESSURE HOSE m...

Page 97: ...cating all refrig erant has escaped close valves on manifold gauge set by turning valve clockwise EVACUATING THE SYSTEM When the refrigeration system is depressur ized and opened for service some air...

Page 98: ...efilled to the proper level with Frig idaire 150 viscosity oil or equivalent 5 Observe low pressure gauge and operate vacuum pump until gauge shows 26 28 vacuum Continue to run pump for ten additional...

Page 99: ...t water if a large drum is used over approximately 100 pounds 3 Place refrigerant drum in pail of water on scales bathroom or commercial preferably com mercial fig 14 CAUTION Do not turn refrigerant d...

Page 100: ...k valve at can opener for a second or two to force air fromtheline Retighten line at center fitting 4 Open valve on No 4 Multi opener or on single can and also low pressure and high pres sure valves o...

Page 101: ...above sea level where this operation is being performed the specifica tions should be lowered by 1 inch Example At 5000 ft elevation only 21 to 23 inches vacuum can normally be obtained 6 If 26 28 inc...

Page 102: ...valve on the J 6271 Fits All valve is fully clockwise and at tach the J 6271 to a one pound can of re frigerant as follows Back off the valve from the top of the retainer slip the valve onto the can...

Page 103: ...sed for checking for leaks in system is a gas operated torch type leak detector using a replaceable cylinder ASSEMBLING AN D LIGHTING THE UNIT 1 Remove dust cap from cylinder 2 Close valve knob on det...

Page 104: ...eak detector for detecting re frigerant leaks is also available Instructions for operation of this type detector are supplied with the unit REPLACING COMPRESSOR The compressor removed must be closed i...

Page 105: ...tion lay them aside on a clean surface as they may be installed on the new compressor 5 After the system is completely depressur ized very slowly loosen screw which retains com pressor fittings assemb...

Page 106: ...e is 25 to 32 inch pounds After short period of time torque may drop off as low as 10 inch pounds Final torque the clamp screw to 20 25 inch pounds 2 Evacuate charge and make performance test CONDENSE...

Page 107: ...t each connection 6 Evacuate complete system 7 Charge complete system 8 Make a performance test EVAPORATOR HEATER CORE ASSEMBLY REPLACEMENT N O TE When refrigeration system components other than the c...

Page 108: ...e compressor must be repaired Inspect oil for foreign material which would indicate internal damage to the compressor If no foreign matter is found in oil compressor can be used Flush entire refrigera...

Page 109: ...hould not remain uncapped longer than necessary to make a connection 4 Precautions should be taken to prevent damage to fittings or connections 5 Use only a cloth dipped in alcohol to remove grease or...

Page 110: ...d on the right rail The illustration fig 1 is used merely to serve as a guide in the selection of checking points M In order to obtain reliable results checking must be done thoroughly and accurately...

Page 111: ...estrictions should be ad hered to completely 1 Frame straightening should be attempted only by experienced personnel 2 Heat may be applied toS A E 950 orS A E 1023 steel only by competent personnel Th...

Page 112: ...are caus ed by overload improper weight distribution or misapplication of the vehicle Excessive bending moment failure will occur at different areas on various types of vehicles therefore for easier u...

Page 113: ...er installation of fifth wheels or bodies is covered in the Body Builder s Book however it should be re emphasized that the use of U bolts for attachment of fifth wheels or bodies is not an approved i...

Page 114: ...a Continuous Fillet Weld This is used to weld a continuous bead along a reinforcement plac ed on the web section of the frame rail or for add ing gussets or plates tocrossmembers Continuous fillet wel...

Page 115: ...ot be readily discernible from the unre paired area of side rail Use a copper spacer be tween the flanges of cracked base rail flanges and reinforcement flanges and repair each flange sep arately as t...

Page 116: ...l and can be full length or alocalized reinforce ment The principle disadvantage of the channel is additional weight and hours of labor required to make an installation Additional difficulty may arise...

Page 117: ...this section how ever the importance of adhering to them cannot be overemphasized 1 Always identify the material of base rail 2 Frame straightening or repair must be at tempted only by highly qualifie...

Page 118: ...i6 x1 4 30 6 0 50 8 0 90 125 1 2 0 1 9 0 1 7 5 240 20 22 2 0 2 2 22 24 22 24 22 24 Trade Name Type N A X Jalten 1 Republic Double Strength Republic 50 Yoloy S Man Ten Medium Manganese Tri Ten E Sourc...

Page 119: ......

Page 120: ...and toe in dimensions are for vehicle at design load with frame level If frame is not level on alignment equipment the frame angle must be considered This is espec ially important when making caster...

Page 121: ...llation and run out 3 Check wheel bearing adjustment 4 Check steering tie rod and drag link ends for looseness 5 Check king pins for looseness CHECKING AND CORRECTING FRONT WHEEL TOE IN Incorrect toe...

Page 122: ...If readings still vary over 1 4 replace steering Figure 2 Method of Checking Frame Angle knuckle bushings and king pins as instructed in F R O N T A X L E SEC 3B 2 Check the wheel run out as instruct...

Page 123: ...ter of vehicle King pins are inclined B fig 1 to decrease friction between tires and road when turning Precision instruments must be used to check king pin inclin ation when axle is installed in vehic...

Page 124: ...On F 070 axle inspect and tighten king pin draw key nuts Loose draw keys will permit king pin to turn in axle center thus enlarging king pin hole If hole becomes too greatly enlarged replacement of ax...

Page 125: ...camber would be wrong R E M O V A L 1 Jack up and support vehicle frame to re lieve load from springs 2 Remove wheels and hubs Disconnect brake lines at axle Disconnect drag link from steering arm 3 W...

Page 126: ...directed in ST E E R ING SYSTEM SEC 9 of this manual 2 Remove steering arm from steering knuckle 3 Remove king pin draw key nut and washer Thread nut on draw key far enough to protect threads Strike n...

Page 127: ...yed to knuckles and retained in place with nuts and cotter pins STEERING KN U C K LE R E M O V A L Fig 3 If desired steering knuckles may be removed from front axle without removing front axle as semb...

Page 128: ...ent is available use this method to inspect steering knuckles and king pins for minute cracks checks or fractures which otherwise would not be visible to the naked eye 2 Thrust Bearing Examine thrust...

Page 129: ...KLE TH RU ST 0 005 0 004 0 012 0 015 Max 0 015 Max 0 015 Max 0 015 Max S P A C IN G W A SH ERS A V A ILA B LE 0 114 0 116 W hite 0 121 0 123 Yellow 0 128 0 130 B lue 0 093 0 125 0 093 0 125 0 093 0 12...

Page 130: ...ipment and during installation and as a locating point when assembling spring to axle After assembly it is strictly the function of the U bolts to hold the spring and axle in align ment and the import...

Page 131: ...Y NUT 30 40 FT LBS TORQUE NUT 16 18 FT LBS TORQUE SPRING SHACKLE TO LUBRICATION ijf BRACKET PIN FITTING BOLT SHACKLE SPRING PIN BOLT WASHER REAR MOUNTING MODELS TM80 T 2977 CONV CAB REAR SHACKLE Figur...

Page 132: ...t and at shackle remove clamp bolts 4 Remove lubrication fittings then remove bolt and pins using adapter and slide hammer as shown in figure 4 Adapter threads into holes tapped for lubrication fittin...

Page 133: ...sened the two leaves will generally separate to permit replace ment of center liner on the locating nib of lower leaf However if necessary a flat tapered pry bar can be used to separate the leaves SPR...

Page 134: ...th holes in bracket Install clamp bolts and fitting FRONT SPRING INSTALLATION Refer to Fig 1 2 Assemble shackle to bracket at rear using pin and clamp on T M and WM 80 models Fitting hole in shackle m...

Page 135: ...ock 3 Dots HV JV 70 JM H M 80 90 110 Front Spring Eye Bolt Nut JV HV 70 JM 80 150 200 Front Bracket to Frame Bolt Nut A l l 50 60 Rear Bracket to Frame Bolt Nut A l l 50 60 Front Spring Front Inner an...

Page 136: ...g adjusting nut to spindle 3 Back off the adjusting nut slightly then us ing a torque wrench retighten adjusting nut to 50 foot pounds torque at the same time turn wheel in both directions until there...

Page 137: ...e i Front Hubs and Bearings With Cast Type Wheels Typical shoulder in hub or against inner bearing cup On type hubs having spring loaded lip type seals seal must be installed with lip pointed inward 5...

Page 138: ...mblies in suitable cleaning solvent Clean bearings with a stiff brush if necessary to remove old lubricant Blow bear ings dry with compressed air directing air stream across bearings Do not spin beari...

Page 139: ...e driving cup in squarely Cups must seat against shoulder in hub Brake Drum Replacement 1 Remove bolts and lock nuts or studs and nuts attaching brake drum to hub 2 Remove brake drum and oil shield or...

Page 140: ...construction provides exact alignment and location of axle as sembly at time of assembly and installation Axle shafts are full floating type Inner end of shaft is splined and engages similar splines...

Page 141: ...completed the ends of the spring come together leaving the original tension on the spring Thus pre load tension holds the axle in either selected gear When the shift button is in L O W range the moto...

Page 142: ...MOUNTING Check for axle misalignment Select a point at one side of vehicle and a corresponding point at opposite side Measure distances between points selected and identical points at each end of axle...

Page 143: ...be found in the shift unit Repeat check for L O position as directed in step 3 following b If the light fails to come on this indicates that the circuit is open between the control switch and the shi...

Page 144: ...nd Insert tube into fitting and seat solidly Slide seal ring do not roll into fitting fig 6 Thread tube nut into fitting and tighten slowly and firmly 5 Repeat leakage test as directed in steps 1 and...

Page 145: ...4B 10 After all installation procedures have been completed check air lines for leaks also test brakes for proper application TANDEM AXLE REPLACEMENT R E M O V A L 1 Jack up rear of vehicle until loa...

Page 146: ...t wiring from shift unit also remove air line from inter axle differential lock shift cylinder on forward axle of tandem units 4 Disconnect propeller shaft from yoke as directed in PROPELLER SHAFTS SE...

Page 147: ...rear bearing and oil seal re tainer remove cap screws and lock washers 3 Tap retainer lightly with soft hammer to loosen retainer from housing bowl 4 As thru shaft and retainer assembly is being pulle...

Page 148: ...ls from studs 3 Remove split tapered dowels from studs In some instances it may be necessary to spread dowels while being removed 4 Grasp axle shaft flange and pull outward to remove Remove and discar...

Page 149: ...tton is in HIGH position and will shift to HIGH when the button is in L O W position PINION OIL SEAL REPLACEMENT Several types of oil seal installations are used on axles covered by this publication O...

Page 150: ...essary to prevent damage to drive nut contact bumper 4 Pull out lever shaft fig 11A Disconnect torsion spring from push rod then remove spring and spring winding lever fig 11B Figure IJ A Shift Unit C...

Page 151: ...ousing opening remove cotter pin nut button shift yoke cap and spring fig 15 Stud is pressed into hous ing and it may be necessary to press out slightly in order to remove shift yoke 1 Through opening...

Page 152: ...10 Turn adjusting screw 1 2 additional turn to center shift fork in sliding clutch groove then tighten adjusting screw lock nut R E M O V A L VACUUM CHAMBER 1 Disconnect vacuum line from chamber 2 Re...

Page 153: ...4 attached to motor fig 22 with two cover nuts 2 Remove grommet 7 1 Motor Cover to Housing Screw with Washer 2 Motor to Cover Nut 3 Motor Cover Cable Clip 4 Motor Cover 5 Motor Cover Gasket 6 Electric...

Page 154: ...to replace one of the parts If necessary to disassemble mount as sembly in vise as shown in figure 24 Turn spring winding lever 24 clockwise and pull to separate DISASSEMBLY OPERATIONS ROCKWELL AXLES...

Page 155: ...assembly is serviced only as an assembly The switch should have clean free mov ing points which close firmly under spring tension DRIVE SCREW The drive screw assembly is serviced only as an assembly...

Page 156: ...ws Tighten nuts firmly 1 Motor Cover to Housing Screw with Washer 2 Motor to Cover Nut 3 Motor Cover Cable Clip 4 Motor Cover 5 Motor Cover Gasket 6 Electric Motor 7 Motor Grommet 8 Shift Unit Housing...

Page 157: ...til positioned as shown in figure 24 8 Dip above assembly in lubricant With drive nut on drive screw assembly in center of screw and fiber contact bumper down toward switch position the slots of windi...

Page 158: ...agm and replace if evidence of wear or deterioration is present 3 Inspect shift rod for excessive wear 4 Inspect chamber body and cover for damage that would effect proper function ASSEMBLY Fig 29 1 I...

Page 159: ...alve disc from bottom of body 3 Push against bottom of valve plunger to remove plunger from top of body Remove plunger spring from body and remove O ringfromplunger CLEANING AND INSPECTION Wash all me...

Page 160: ...R R I E R TO H O U S I N G Eaton 2 1 3 Cap Screw 75 85 5 s 11 Cap Screw 160 175 Ms 18 Stud Nut 220 240 Rockwell 5 4 2 0 Stud Nut 80 105 5 g 1 8 Stud Nut 160 205 O IL S E A L R E T A I N E R A N D P I...

Page 161: ...dius leaf rod failure The radius leaf rods maintain axle alignment and transmit driving and braking forces to the frame On tilt cab models a spacer is used at bottom of spring pile to separate the las...

Page 162: ...d spacer when used or tapered shim when used from axle N O TE When tapered shim is used note posi tion of shim to insure installation in proper posi tion FRONT HANGER BRACKET FRONT AUXILIARY SPRING FR...

Page 163: ...rd bracket having spring eye pin or bolt hole IMPORTANT Tapered shim must be installed on axle in same position that was noted at removal N O TE If auxiliary springs are used place spring assembly and...

Page 164: ...Eye Bushing INSTALLATION Fig 7 1 Install new radius leaf bushing using special tool assembly J 8459 as follows a Assemble large O D of guide J 8459 4 over threaded end of shaft J 8459 1 then lubri ca...

Page 165: ...rive line alignment and stabilize driving and braking forces The basic difference between the RT and RU type suspension is that the RT type embodies a spring top saddle pad that uses bolts in place of...

Page 166: ...op Pad Bolt Nut 11 Pad Set Screw 12 Lock Nut 13 Lock Washer 14 Top Pad Slide 18 15 Top Pad Bolt 16 Top Pad 17 Pin Lock Bolt 18 Spring Pin 19 Spring Eye Bushing 20 Spring 21 Spring Assembly 22 Center B...

Page 167: ...shaft from forward rear axle as explained in P R O P E L L E R SHAFTS SEC 4D 3 Raise vehicle frame to remove load from springs Support frame securely and remove re bound bolt from bottom of spring re...

Page 168: ...3 Figure 10 Hendrickson RS 380 Tandem Suspension 1 Rear Spring Front Pin 2 Spring Eye Bushing 3 Spring Eye 4 Rear Spring Front Bracket 5 Frame Side Rail 6 Spring Pin Lock Bolt T 1001 Figure 11 Tool Ap...

Page 169: ...supports from under axle 8 Lubricate shackle pin at lube fitting NOTE Care should be exercised to prevent axles from rolling and causing injury or damage to parts INSTALLATION RS 380 TY PE Refer to Fi...

Page 170: ...ing and saddle 3 Install top pad to saddle bolts and nuts and tighten snugly Tighten top pad set screws to torque listed in Specifications at end of this section Tighten set screw lock nuts IM PORTANT...

Page 171: ...ced SADDLE INSTALLATION 1 Install the vertical drive bushing caps Tighten nuts to 100 125 foot pounds torque 2 Position load cushions on saddle s 3 Support saddle assembly from underneath to prevent d...

Page 172: ...s section Figure 18 t hows section through mounting 3 Install spring saddle caps to attach beam center bushing to spring saddle Install saddle cap SPRING SADDLE TOP PAD TO SPRING SADDLE U BOLT BOLT NU...

Page 173: ...original drive line alignment 2 Adjust length of adjustable type torque rods to original length recorded prior to removal Do not tighten end clamp bolts at this time 3 Install torque rod with end stu...

Page 174: ...ion 3 Install torque rods to axle bracket N OTE When tightening torque rod stud nuts rap bracket with hammer to drive taper of torque rod stud into bracket Tighten nut to torque listed in Specificatio...

Page 175: ...listed in Specifications at end of this section Remove support from under vehicle frame ROCKER ARM R O C K E R A R M R E M O V A L Fig 18 1 Raise and support frame to remove weight from rocker arms 1...

Page 176: ...n mount bore Slide trunnion mount assembly onto trunnion tube using a rocking motion Rotate assembly until dowel pin engages slot in compres sion tube Install dowel pin 4 Tighten compression cap bolt...

Page 177: ...150 TORQUE SPECIFICATIONS Cont Torque Rod Bracket to Crossmember Bolt Nut 40 50 Rear Torque Rod and Bracket to Crossmember Bolt Nut 90 110 Front Torque Rod and Bracket to Crossmember Bolt Nut 40 50 To...

Page 178: ...bracket attaching bolts and units are tight CAUTION On vehicles equipped with tandem rear suspension block vehicle securely before disconnecting torque rods IMPORTANT Tighten all U bolt nuts to torque...

Page 179: ...AR A X L E S SEC 4A 2 On vehicles using outer oil seal and outer oil seal sleeve remove the seal from axle shaft flange studs 3 Remove bearing lock nut and nut lock 4 While rotating the hub and drum a...

Page 180: ...el T 3018 Figure 2 Rear Hubs and Bearings with Disc Type Wheels HUB BEARING AND OIL SEAL REPLACEMENT R E M O V A L Figs 2 and 3 1 Jack up rear axle and remove tire and rim assembly on vehicles having...

Page 181: ...his section lubricate bearings axle housing tube and inside of hub as described in LUBRICATION SEC 0 of this manual Coat lip of inner oil seal and surface contacted by lip with wheel bearing grease or...

Page 182: ...posite end of hub and driving against inner edge of bearing cup Alternately drive on opposite sides of cup to avoid cocking cup and damaging inside of hub 2 To install new cups position cup in hub and...

Page 183: ...slip joint is at transmis sion end of shaft if two or more shafts are used slip joint is at forward end of rear shaft End of slip yoke is sealed by afeltorcork washer held in place by asteel washer an...

Page 184: ...on Refer to Specifications at end of this section for type of joint used at var ious locations on any vehicle with standard equip ment Refer to Parts Book for universal joint application with optional...

Page 185: ...o support center portion of drive line when two or more propeller shafts are used Bearing is ball type mounted in a rubber cushion which is attached to frame cross member by the center bearing support...

Page 186: ...ust cap and withdraw shaft Remove cork or felt washer steel washer and dust cap from shaft UNIVERSAL JOINT DISASSEMBLY Type 58WB Figs 2 and 3 Remove special cap screws and lock washers attaching beari...

Page 187: ...nner removing journal from other oofce C E N T E R BEARING DISASSEMBLY The following procedure covers disassembly i f center bearing with propeller shaft removed from vehicle Key numbers in text refer...

Page 188: ...s replaced splines should be lubricated carefully before assembly to prevent galling during the initial break in period It is not safe to rely on lubrication after assembly only since some of the spli...

Page 189: ...xiliary transmission mountings and adjustable torque rods at rear axles proper adjustment of the angle of the drive line components must be accomplished by the use of spacers or shims at the frame cro...

Page 190: ...REAR SUSPENSION 4D 51 E CHECKING FORWARD REAR AXLE PINION ANGLE Figure 6 Checking Drive Line Angles CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL...

Page 191: ...ENT IS OBTAINED ROCKWELL SLHD AN D SQHD T 3044 Figure 8 Torque Rods Installed at Frame Cross Member with Shims Installed 6 On rear axles which have a machined sur face on the differential carrier at r...

Page 192: ...ving adjust able torque rods until the resultant angle of the forward axle pinion angle subtracted from the inter axle shaft angle is equal to the resultant angle of the inter axle shaft angle subtrac...

Page 193: ...60 70 32 37 58W B 40 50 40 50 P R O P E L L E R S H A F T F LA N G E BOLT O R S T U D NUTS T O R Q U E FT LBS 7 i6 20 50 60 2 4 35 45 P R O P E L L E R S H A F T E N D Y O K E N UT 400 450 P R O P E...

Page 194: ...es pedal and link age power boosters main cylinders wheel cylin ders lines gauges reserve tanks etc are cover ed under respective headings in this section For illustration of typical system installati...

Page 195: ...drag is relieved then move wrench an additional 7 to 10 degrees toprovide running clear ance 7 to 10 degrees is equal tol to 1 1 2 inches of travel at end of an 8 inch wrench 3 Place wrench on opposit...

Page 196: ...dels Bleeder valves at wheel cylinders are accessible at inner sides of the backing plates Figure 3 Type FR 3 Brake Adjustment It is recommended that brake system be bled in a definite sequence to obt...

Page 197: ...rs in sequence shown in figure 4 After bleeding wheel cylinders repeat bleeding operations at power cylinder where used 5 If after bleeding the pedal feel is not satisfactory it is recommended that th...

Page 198: ...e 4 Remove bolt attaching pedal sleeve to panel to dash brace Remove sleeve from brace at the same time removing brake pedal and bush ings PEDAL INSTALLATION Before installing pedals check bushings in...

Page 199: ...ly from inner side of cab sill twisting each as necessary to allow pedal pin to slide completely through bushing and bushing assembly to slide completely through cab sill 2 Install bolts which fasten...

Page 200: ...ble and clean all parts 2 Swollen primary cup due to the use of wrong fluid overhaul master cylinder drain and flush entire brake system and refill with proper fluid 3 Pedal binding on shaft preventin...

Page 201: ...el cylinders Disassembly Fig 7 Clean all dirt from outside of unit using a non petroleum solvent 2 Remove snap ring from groove in both cyl inder bores 3 Remove piston assembly primary cup return spri...

Page 202: ...lts at taching each cylinder to backing plate then remove cylinders from backing plate c Install primary cup in cylinder bore with lip of cup toward outlet end Make sure end of re turn spring seats in...

Page 203: ...ts are available which contain the parts to be replaced when overhauling wheel cyl inders Refer to Parts Book for repair kit part numbers 2 Inspect cylinder bore for scores scratches or corrosion Ligh...

Page 204: ...frame and secured by atoothedlock washer and nut or by a spring lock Brake tube connector or tee fitting threads into end of hose fitting VACUUM PC All models covered by this manual which have hydrau...

Page 205: ...sitating overhaul of power cylinder HYDRAULIC TEST Stop engine and again destroy all vacuum in system Depress brake pedal and hold foot pres sure on pedal It may be necessary to pump pedal two or thre...

Page 206: ...all hydraulic vacuum and atmos pheric lines and hoses to power cylinder Revised i968 Figure 12 Power Cylinder Air Cleaner Installed Conv Cab 3 Bleed master cylinder and vacuum power cylinder as direc...

Page 207: ...se between gauge and check valve Start engine run at idle for a few seconds and note reading on gauge Stop engine and observe rate of vacuum drop If drop exceeds 1 inch in 15 seconds leakage must be c...

Page 208: ...lo cation in vacuum line and observe readings on test gauge at same specific engine RPM Manufacturer specifications permit a variation of i 1 inch of mercury at 5 inches and 2 inches of mercury at 20...

Page 209: ...inserted through hole in shoe web locate toe in wheel cylinder piston shoe guide and position heel in slot in anchor block 3 Install flat washer and C washer on cam and shoe guide stud Crimp ends of...

Page 210: ...hould be replaced if worn down close to rivet heads Refer to Brake Shoe Relining in this sec tion BRAKE SHOE INSTALLATION 1 Install adjusting screws and wheels in anchor supports dry use no lubricant...

Page 211: ...e discard the worn drum and replace with a new standard drum D O N O T E X C E E D THESE LIMITS THIS IS A SA F E T Y PRECAUTION SPECIFICATIONS F R O N T B R A K E S T R U C K S E R I E S ALL H J AND T...

Page 212: ...Flush refill and bleed system Use recom mended brake fluid 3 Improper lining thickness or location 3 Install specified lining or replace shoe and lining 4 Drums worn too thin 4 Replace drums 5 Master...

Page 213: ...compensating port plugged L Open use air or 015 wire Remove any burr in bore 2 Swollen cup in master cylinder 2 Replace rubber parts flush system Refill with recommended fluid 3 Master cylinder piston...

Page 214: ...ar drums 7 Obstruction in line 7 Clean out or replace 8 Distorted shoe 8 Replace 9 Defective lining 9 Replace with specified lining RE A R BRAKES DRAG PROBABLE CAUSE R E M E D Y 1 Maladjustment 1 Adju...

Page 215: ...Match up tire treads from side to side W E T W E A T H E R BRAKES GRAB OR W O N T H O LD R E M E D Y PROBABLE CAUSE 1 Linings too sensitive to water 1 Reline 2 Dirty brakes 2 Clean out 3 Bent backing...

Page 216: ...rd hydraulic brakes After these possible causes have been eliminated check for cause as outlined below N O TE Make the following test before checking hard pedal for the cause With the engine stopped d...

Page 217: ...ion in power unit 1 Rebuild unit 2 Faulty valve action 2 Rebuild unit 3 Broken return spring 3 Replace spring BRAKES GRABBY R E M E D Y PROBABLE CAUSE 1 Broken valve spring 1 Rebuild unit 2 Sticking v...

Page 218: ...ter type brake systems BRAKE SYSTEM MAINTENANCE Normal operation of braking system necessi tates periodic tests inspection and adjustments to assure safe efficient operation Test inspection and adjust...

Page 219: ...r push rod travel reaches the maximum working stroke Line to Air Gauge Valve Mounting Bolt and Nut in Engine Compartment Lines to Trailer Brakes Hand Control Valve 9 Application Double Check Valve and...

Page 220: ...pecifications at end of this section to determine slack adjuster type used The most efficient brake action with S cam brakes will be obtained when the arm travel of the slack adjuster is held to a min...

Page 221: ...adjuster 2 Remove lock ring or cotter pin and spacer securing slack adjuster on camshaft Slide slack adjuster off end of shaft Adjusting Worm Shaft Lubrication Hole Plug Clevis Pin Slack Adjuster Adj...

Page 222: ...bolts b With brakes fully applied check for leak age through the diaphragm by coating the push rod hole and drain holes in non pressure plate with soap suds No leakage is permissible If leakage is ev...

Page 223: ...a larger tank is used to provide sufficient volume of air for the additional brake chambers All air lines are interconnected in a manner similar to the single axle models Air tank U bolts and support...

Page 224: ...onds Once a year safety valve should be disassembled cleaned with kero sene and reset to blow off at 145 to 155 pounds pressure A DJUSTM ENT Fig 9 1 Loosen lock nut 2 Adjust pressure by turning adjust...

Page 225: ...in delivery port of application valve or air tank line 2 Connect air lines to valve 3 Build up air pressure in system and check for leaks 4 Drain air pressure in system below 65 psi and check to deter...

Page 226: ...pedal bracket and pedal assembly is fastened to the bottom of the application valve by three bolts Pedal assembly contacts valve piston with an upward movement The exhaust port is on the back side of...

Page 227: ...g on the test gauge should be approximately that of full reservoir pressure The reading on the test gauge should fall off to zero when application is released Also check pressures registered on the da...

Page 228: ...y dents or kinks If such condition is found tubing or hose should be replaced 2 Leakage Test With air system fully charged and brake ap plied coat all tubing and hose connections with soap suds to che...

Page 229: ...han 65 pounds while vehicle is in motion vehicle should be stop ped and the cause of air loss corrected Dash gauge should be checked regularly with an accurate test gauge If pressure reading varies 4...

Page 230: ...d That is the farther the handle is moved from off to on the greater the air pressure delivered to the trailer brakes If at any time during such an application a service brake application is also made...

Page 231: ...d is identified by a decal on the panel which is illustrated in figure 14 E M E R G E N C Y C O N TR O L V A LV E R E PLA C EM EN T Removal 1 Drain air pressure from brake system 2 Disconnect air line...

Page 232: ...to the trailer brake service line Check valve is installed in delivery port in brake application valve Air line from trailer brake hand control valve connects to other end of check valve Trailer brak...

Page 233: ...wo way valve in the SLIP PERY R O A D position and apply the truck brakes The test gauge at the limiting quick release valve should read approximately one half the amount shown on the test gauge conne...

Page 234: ...e Inlet Valve Valve Carrier Front Brake Chambers Exhaust Port _Plunger DRY ROAD POSITION Limiting Quick Release Valve Hi Figure 15 Front Brake Limiting and Two Way Control Valve Operation CHEVROLET SE...

Page 235: ...lers against the ramp on the collar to engage them with the push plate shaft When the control port of the inversion valve is vented the inversion valve piston moves for ward and opens the inlet exhaus...

Page 236: ...BRAKES 5B 43 I C O N T R O L PORT INLET VALVE SEAT RESERVOIR ATMOSPHERIC AIR SUPPLY SOURCE Figure 16 Schematic Diagram of 003 Brake Actuator System CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL...

Page 237: ...by opening drain cock then back off the slack adjuster at each rear brake chamber If necessary disconnect slack adjuster from cham ber push rod clevis PREVENTIVE MAINTENANCE DD3 BRAKE ACTUATOR Dependi...

Page 238: ...tor 3 At this point exhaust air from parking reservoir This may be done by opening the drain cock in the reservoir tank or by pulling out the push pull control valve button N O T E OF CAUTION Air will...

Page 239: ...ort PREVENTIVE M AINTENANCE The manufacturer recommends that every year or after 50 000 miles the inversion valve be disassembled cleaned and lubricated Lubricate with a barium base grease or equivale...

Page 240: ...Operation and Emergency Operation CONTROL VALVE REPLACEMENT R E M O V A L 1 Secure vehicle by some means other than air brakes Figure 18 DD3 Control Valve Knob 2 Exhaust air from parking brake system...

Page 241: ...release A 100 psi foot valve brake application will be necessary to complete release of tractor brakes 2 Leakage Test Using soap suds check for leakage both with brakes applied and released If any lea...

Page 242: ...lows 1 Loosen anchor pin lock nuts and turn pins to position punch marks as close together as pos sible as shown in figure 20 2 Rotate cam by turning slack adjuster worm shaft to bring shoe lining int...

Page 243: ...between shoes and cam Flats on end of roller pin fit into notches in shoe webs Tension of brake shoe return spring holds shoe rollers firmly against cam Return spring pins are staked in 8 places so t...

Page 244: ...els equipped with off set slack adjusters the inner spacer is thicker than the outer spacer Whenever camshaft has been removed coat bushing surfaces with S 17 Special Lubricant or equivalent before in...

Page 245: ...tration of an automatic adjuster assembly installed When the plunger as sembly is moved outward to apply the shoe against the drum the plunger guide will slide across the sloping sides of the teeth on...

Page 246: ...henever brake shoes are relined and inspected for the general condition of all moving parts It is advisable to use new plunger seals and gaskets when removing and installing these parts R E M O V A L...

Page 247: ...ake for safe driving Final adjustment is made with the vehicle in motion by pumping the pedal SERVICING STANDARD STOPMASTER BRAKE CHAMBERS It is recommended that all brake chambers be removed disassem...

Page 248: ...ng the spanner nut against lock washer and the spider housing Using a punch drive edge of lock washer into notches provided in spider housing and spanner nut see fig 28 BRAKE SHOES AND LININGS BRAKE S...

Page 249: ...Hold Down Clip 13 Guide Screw 14 Anchor Plunger Solid Brake Shoe Return Spring Dust Shield Lock Washer Bolt Dust Cover Wedge Shaft Roller Roller Retaining Cage 23 Wedge Spring Retainer 24 Wedge Sprin...

Page 250: ...e of automatic adjuster components see procedures under that subject on a previous page of this section The following procedures cover the anchor end components and other ac tuation components R E M O...

Page 251: ...hes or corrosion Light scratches or slightly corroded spots may be polished out with crocus cloth Never use emery cloth or sand paper If scratches or corrosion are too deep to be polished out spider m...

Page 252: ...entional brake chamber Movement of dia phragm plate rod is transmitted to the brake shoes through the mechanical actuating components as described later The outer chamber contains a spring loaded pist...

Page 253: ...er mechanisms SERVICEABILITY TESTS OPERATING TEST 1 Service Brakes Make a brake application and check expansion of brake shoes against drum Shoes should move freely and instantly when brake treadle is...

Page 254: ...ING BRAKE W IL L NOT BE APPLIED 1 With air pressure in parking brake cham ber brake released loosen release bolt spring lock and swing to one side then turn release bolt clockwise as far as it will go...

Page 255: ...o disassemble the cap and spring assembly In the event any part of this assembly is defective the complete assembly must be replaced The component parts are not serviced separately CLEANING AND INSPEC...

Page 256: ...wrench see figures 40 and 41 or by putting pressure housing in vise and using a wrench on hex end of cap 4 Position diaphragm over plate rod then in stall pressure housing and cap assembly N O TE Diap...

Page 257: ...ease foot set screw 4 Unscrew foot from piston 5 Remove piston seal 6 Remove sealing compound located at joint between cap and housing 7 Remove lock ring from housing 8 Separate cap spring and piston...

Page 258: ...embly ASSEM B LY Before assembly clean and inspect all parts Lubricate with recommended grease DO N OT lu bricate cap in the area of the breather assembly D O NOT use solvent on back up or O rings Use...

Page 259: ...ve assembly from fixture 12 Install hex nut and snap ring on release bolt 13 Install back up rings and O ring in groove in housing 14 Assemble cap spring and piston assem bly in housing assembly with...

Page 260: ...out of adjustment 5 Adjust 6 Wrong size brake chambers 6 Replace according to Specifications SLO W BRAKE A PPLICATIO N PR O B A B LE CAUSE R E M E D Y 1 Low brake line pressure 1 Check for leaks etc...

Page 261: ...R OB A B LE CAUSE R E M E D Y 1 Uneven slack adjuster settings 1 Adjust properly 2 Linkage binding at one or more wheels 2 Lubricate as necessary 3 Linings worn uneven 3 Adjust or replace 4 Brake shoe...

Page 262: ...replace 5 Open or leaking reservoir drain cock 5 Close repair or replace BRAKES F U L L Y APPLIED 1 Leaking brake chamber 1 Repair or replace 2 Leaking application valve 2 Repair or replace 3 Leaking...

Page 263: ...piston stuck in cap 4 Fail Safe spring failure 5 Rollers not aligned with plungers or wedge not mated with diaphragm plate rod 6 Brakes out of adjustment R E M E D Y 1 Turn release bolt counterclockw...

Page 264: ...chamber diaphragm 2 Replace diaphragm 3 Improper brake shoe adjustment 3 Adjust brake shoes 4 Improper wedge adjustment 4 Make wedge adjustment 5 Plunger seal failure 5 Replace seal and clean and lubr...

Page 265: ..._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ TM80_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Brake Size 15x7 Brake Shoe Lining Width 7 Thickness Area sq in per axle 440 Brake Chamber Type 30 D...

Page 266: ...tenance on a regular daily monthly and yearly basis will help eliminate on the road failures Follow recommended procedures cover ing testing inspection and adjustment for best results CHEVROLET SERIES...

Page 267: ...ten lock nut on adjusting bolt 5 Adjust end on brake rod so that clevis pin may be freely inserted through operating cams and rod end Install clevis pin and cotter pin then tighten lock nut on rod end...

Page 268: ...peller shaftflange against brake drum or output shaft flange If removed attach propeller shaft center bearing hanger bracket to crossmember Replace all lock washers and nuts and tighten securely 3 Ins...

Page 269: ...ng ends of brake shoes Adjusting wheel should be nearest left shoe Install adjusting screw spring 3 Spread apart cam ends of brake shoes Lift shoes vertically and push into position on support plate I...

Page 270: ...e brake lever in cab isinfully re leased position Adjust clevis on brake cable as necessary to permit installation of clevis pin through clevis and brake lever without changing position of lever Insta...

Page 271: ...ea Sq In 67 5 Drum Drum Band Band Tru Stop lQ V z x 3 UVzxW 16 540GL 541GD 385V 6041 Aux 541GL 387V 7231 A Aux 5652 7041 Aux IOV2 M Vz 16 disc 331 32 36 1215 32 3 S1 3 5 l 6 5 l 6 V 4 99 1 126 0 60 7...

Page 272: ...le to all gasoline engines used in vehicles covered by this manual To adequately accomplish a satisfactory tune up reliable test equipment in the hands of trained personnel is necessary APPLICATION CH...

Page 273: ...bolt then remove bolt housing and filter element as an assembly Remove housing gasket 2 Remove element from housing and discard element Clean housing thoroughly Also clean fil ter bracket N OTE When...

Page 274: ...2 Use a voltmeter to check cranking voltage Disconnect coil primary lead from negative term inal on coil to prevent engine from firing during test 3 With voltmeter connected between coil posi tive te...

Page 275: ...of tune up procedure Oil linkage pivot points if any binding is evident Complete information on throttle linkage is given in ENGINE FUEL SYSTEM SEC 6M in this manual CARBURETOR IDLE SPEED AND IDLE MIX...

Page 276: ...1 Remove rocker arm cover from each cyl inder head 2 Make visual inspection of ventilation valves for accumulation of sludge or other matter at valve inlet fig 7 3 If valves appear to be in good cond...

Page 277: ...r compressor discon nect air lines 10 Disconnect engine ground strap 11 Disconnect exhaust pipes from exhaust manifolds 12 Disconnect accelerator and choke controls from carburetor 13 Disconnect tacho...

Page 278: ...ines from compressor In some cases the air compressor mounting bracket may be detached from engine and compressor may remain with chassis when engine is removed 13 If power steering is used the power...

Page 279: ...25 foot pounds torque 8 Install rocker arm shaft and bracket as sembly and tighten bracket bolts evenly to 20 to 25 foot pounds torque Refer to Valve Operating Mechanism Replace ment for additional in...

Page 280: ...s from carburetor 2 Disconnect throttle and choke controls from carburetor Also disconnect vacuum line and hydraulic governor line when used 3 Disconnect fuel line then remove carbu retor from manifol...

Page 281: ...If available guide pins fig 10 may be temporarily installed in two cylinder head bolt holes to locate head as it is lowered into place 2 Set cylinder head in place on gasket with dowels in block enga...

Page 282: ...f crankshaft R E M O V A L 1 Remove radiator if necessary to provide access to crankshaft pulley 2 Use impact wrench or hold engine flywheel and use conventional wrench to remove pulley re taining bol...

Page 283: ...ig 16 is at top as shown 2 Locate new seal assembly at bore in front cover with seal lip pointing inward then assemble special tool components in manner shown in figure 16 3 Tighten nut against thrust...

Page 284: ...ed under Engine Oil Pan Replacement 2 On engines with hydraulic type governor fig 18 remove governor oil line assembly 3 Remove two special pump mounting bolts then remove engine oil pump with oil inl...

Page 285: ...tion 3 Align tongue on adapter shaft with drive bolt slot then place new gasket at cylinder block and install adapter assembly Connect flexible drive shaft housing to adapter 4 Check tachometer drive...

Page 286: ...enough screws to hold pan in place while rechecking governed speed Be sure to add engine oil to mark on dipstick With oil warmed up re check no load speed 5 When governor performance is satisfac tory...

Page 287: ...s Cylinder Head Bolts 60 65 Intake Manifold Bolts 20 25 Exhaust Manifold Bolts 1 5 2 0 Oil Filter Stud If Used 4 0 5 0 Spark Plugs 25 Rocker Arm Shaft Bracket Bolts 20 25 Damper or Hub to Crankshaft B...

Page 288: ...POSSIBLE CAUSES 1 Distributor points burned or corroded 2 Distributor points out of adjustment 3 Faulty spark plugs 4 Defective wiring 5 Ignition out of time R E M E D Y 1 Change to lighter oil 2 Cha...

Page 289: ...logged 3 Dirt in gas tank 4 Air leaks in gas line 5 Fuel pump not functioning properly 6 Governor malfunction SYM PTOM D EXCESSIVE FU EL FLOODING POSSIBLE CAUSES 1 Choke not fully open 2 Air cleaner r...

Page 290: ...7 Dragging brakes 8 Restricted exhaust system 9 Improper valve clearances 10 Ignition distributor advance inoperative 11 Overloaded vehicle R E M E D Y 1 Adjust or replace belt 2 Replace thermostat 3...

Page 291: ...nce too far for fuel being used 2 Wrong type heat range spark plug 3 Excessive build up of deposits in combustion chambers 4 Restricted coolant passages in cylinder head causing hot spots in combustio...

Page 292: ...D Y 1 Clean and lubricate valve stems 2 Adjust valve lash 3 Determine and correct cause of push rod bend ing Install new push rod 4 Replace worn parts and make sure oil is reach ing valve rocker arms...

Page 293: ...e program Be sure all bracket attaching bolts are kept tight Refer to ENGINE MOUNTINGS SEC 6D for engine mounting information USE ENGINE OIL AS SPECIFIED IN LUBRICATION SEC 0 AND SERVICE CRANKCASE VEN...

Page 294: ...shell and discard element Clean shell assembly and remove gasket from base at engine 4 Install new element in shell place new gas ket at filter base on engine then install shell and element assembly...

Page 295: ...val check all manifold bolts for proper torque and be sure end bolts are locked to prevent loosening FU E L SYSTEM INSPECTION a Inspect all fuel lines both the supply line and return line between engi...

Page 296: ...ine do not turn engine in a left hand direction as the crankshaft bolt will be loosened 3 Loosen the push rod lock nut on one of the valve push rods shown in figure 1 for number 1 cylinder and placing...

Page 297: ...acement of engine components which can be made without removing engine from chassis ENGINE REPLACEMENT R E M OV A L 1 Drain cooling system 2 Disconnect battery 3 Disconnect accelerator control at peda...

Page 298: ...xhaust stack clamps at rear of cab f Remove bolts from both front mountings then raise front of cab high enough topermit rocker arm cover removal CAUTION While raising cab check wiring lines and contr...

Page 299: ...Install rocker arm cover CYLINDER HEAD REPLACEMENT The cylinder head and or gasket at either right hand or left hand cylinder bank may be re placed in manner described below R E M O V A L 1 Drain coo...

Page 300: ...thout disturbing seals and gasket CAUTION Compression gaskets and or seals which are jarred out of their proper location will allow leaks and blow fcy which will result in poor performance and damage...

Page 301: ...lange surfaces 4 Clean the oil pan with a suitable solvent dry the oil pan 5 Inspect the oil pan for large dents or breaks in the metal which may necessitate its repair or replacement Check for misali...

Page 302: ...ator valve a full flow oil filter with a by pass valve an oil cooler and an oil cooler by pass valve The rotor type oil pump is bolted to the back of the engine lower front cover and is driven di rect...

Page 303: ...front cover then to the cylinder block oil galleries The by pass valve opens at approximately 52 psi Stabilized lubricating oil pressure is main tained within the engine at all speeds by means of a re...

Page 304: ...ms with probable causes and remedies References are made to other charts also to various sections in this man ual which list correct remedies and procedures HARD STARTING LOW STARTING R P M IMPROPER L...

Page 305: ...fer to Injector Tests under Fuel Injectors in Fuel System SECTION 6M COOLING SYSTEM TEMPERATURE BELOW NORMAL Refer to Abnormal Engine Coolant Temperatures chart NO FUEL OR INSUFFICIENT FUEL Refer to N...

Page 306: ...OF POWER IMPROPER ENGINE ADJUSTMENTS Check for the following 1 Governor Gap Set Incorrect Perform tune up operations as directed in Section 6M 2 Rack Setting Incorrect Perform tune up operations as di...

Page 307: ...tion 6M 2 Improper Timing of Injectors Time fuel injectors as directed under Injector Timing in Section 6M 3 Faulty Injectors Replace injectors 4 Lugging Engine Correct driving practices IMPROPER GRAD...

Page 308: ...l new restricted fitting FAULTY FUEL PUMP RELIEF VALVE NOT SEALING Make Fuel Pressure and Flow Tests and clean and inspect valve and seat assembly WORN GEARS OR PUMP HOUSNG Replace gear and shaft asse...

Page 309: ...iscosity Chart in Lubrication System section 2 Plugged Oil Cooler Clean oil cooler if oil temperature is abnormally high 3 Fuel Oil Dilution Check for fuel leaks at injector seal ring and fuel jumper...

Page 310: ...DER HEAD GASKET LEAKING Remove and replace head gaskets PISTON AND LINER DAMAGED Remove and replace piston and liner PISTON RINGS WORN OR BROKEN Remove and replace piston rings PISTON PIN RETAINER LOO...

Page 311: ...psed or Disintegrated Replace hoses 3 Thermostat Damaged Replace thermostat 4 Water Pump Impeller Loose on Shaft Replace impeller or shaft 5 Inadequate Water Supply on Suction Side of Pump Caused by a...

Page 312: ...ngine to re place a mount raise engine only to height required to replace the mount If raised beyond this height possible damage to wiring lines and control link age could occur N O TE When replacing...

Page 313: ...positioned properly Refer to applic able illustration N O TE If an alignment dowel is used at mount ing make certain that it engages the locating hole in mating part 2 With cushion components in plac...

Page 314: ...Spacer 5 Mounting Lower Cushion V 6 Lock 7 Nut 8 Frame Bracket 9 Bolt and Lock Washer 10 Mounting Bolt 11 L H Frame Member 12 Flywheel Housing 13 R H Frame Member T l 148 Figure4 EngineRearM ountingfo...

Page 315: ...rt Bracket 11 12 13 14 Flywheel Housing Bolt and Plain Washer 4 at Each Bracket Throttle Cross Shaft Bracket Locating Bosses Figure5 EngineRearM ountingforTM 80M odels 478MEngine Inspect engine front...

Page 316: ...ar of each bank From here it flows upward through transfer holes and into rear of cylinder heads then back to front of heads At this point a portion of coolant flows up and out of the engine water man...

Page 317: ...ooler passages to cylinder block From cylinder block coolant flows up through cylinder heads and forward to thermostat housing at front of each cylinder head If engine is at oper ating temperature coo...

Page 318: ...radiator the thermostats will close even though the engine is warm This action may trap air in cylinder block and head passages The trapped air will leak through the thermostat vents thereby lowering...

Page 319: ...for expansion to avoid any overflow loss during test 4 Attach a length of rubber tube to lower end of overflow tube This connection must be airtight Run engine with transmission in neutral at a safe s...

Page 320: ...ion protection When adding solution due to loss of coolant for any reason or in areas where temperatures lower than 20 F may occur a suf ficient amount of an ethylene glycol base coolant that meets GM...

Page 321: ...n provid ing engine water temperature is not exceeding switch setting and the bulb lights engine unit is internally short circuited and should be replaced Refer to Specifications for switch setting 4...

Page 322: ...permanent type anti freeze solutions may contain inhibitor which will produce a green residue or pre cipitation If this is noted more fre quent element change periods will be necessary and if this fa...

Page 323: ...ompressed air 4 Flush system again with the same type of oil normally circulated through the cooler 5 Test flow of oil through cooler If flow is not restricted reconnect oil cooler lines If flow is re...

Page 324: ...n DRIVE BELT RE PLA C EM EN T On some vehicles several accessories may be driven from multiple groove crankshaft pulley and the replacement of any one inside drive belt will make it necessary to remov...

Page 325: ...e 8 Belt Adjusting Mechanisms I6 V S 3 Engine bracket shown in figure 8 Bearings of fan sup port assembly are lubricated at assembly R E M O V A L Refer to Fig 8 1 Remove six fan bolts and remove fan...

Page 326: ...ion on pulley INSTALLATION 1 Place support and adjustment assembly in its original position on the engine 2 Start four adjusting bracket locking bolts 3 Install drive belts on pulley and install ad ju...

Page 327: ...cles with standard equip ment only Because of some optional equipment whicy may be used such as engine oil cooler air conditioning larger engine water filter in creased cooling etc the capacity of coo...

Page 328: ...KAGE ADJUSTMENT TILT CAB MODELS 4 Block accelerator pedal down firmly against floor mat Adjust length of sliding rod at adjusting NOTE Refer to figure 1 trunnion to obtain free fit into bell crank lev...

Page 329: ...nect pull back spring N O TE Refer to Figvre 3 1 Disconnect linkage pull back spring Dis connect rod assembly at cnrburetor throttle lever 2 Block accelerato pedal down firmly against floor mat Using...

Page 330: ...nt and to be sure return spring returns linkage to idle position 2 Check to see that hand throttle wire hous ing is clamped securely at bracket 3 Push hand throttle completely in then loos en trunnion...

Page 331: ...eMe unfed Fuel Filter cated between fuel pump The element of the filter is contained with located on a frame side replace element turn from fuel pump or fram element and gasket if nec IM PORTANT Afte...

Page 332: ...mounting bolts then move pump away from engine and remove gasket INSTALLATION Before installing fuel pump be sure mounting pad on engine is clean and that any gasket cement and portions of old gasket...

Page 333: ...outer position and tension spring 3 returns throttl3 plates to open position When accelerator pec al is released the throt tle driver assembly 121 engages throttle shaft driver 2 and moves throttle pl...

Page 334: ...eratures the vapor bubbles will collect in the outside channel surrounding the main discharge jets rise and vaporize in the domes of the high speed bleeders thus presenting percolation reaction P O W...

Page 335: ...FAST IDLE STAGE High Speed Bleeder Secondary Vacuum Power Piston Vacuum Channel High Speed Bleeder Primary Venturi Cluster Main Discharge Nozzle Vacuum Piston Spring Main Metering Jet Main Discharge...

Page 336: ...um advance disconnected and plugged 3 Set the engine idle speed by adjusting the idle speed screw fig 9 Idle speed is V6 Engine 401M and 478M 550 Rpm N O TE If necessary back out the fast idle screw t...

Page 337: ...he plunger with a 3 8 inch open end wrench until the face of the plunger hex contacting the carburetor throttle lever results in an idle speed of 550 rpm 6 Adjust the idle mixture screws fig 15 With e...

Page 338: ...rom choke lever Disconnect fast idle link and accelerating pump rod Remove three short screws attaching air horn to main body then re move one long screw at forward side of air horn and one long screw...

Page 339: ...ase Ventilation System Closed Posi tive 2 Controlled Combustion System C C S The first system serves to prevent air pollu tion by re cycling fumes from the crankcase used Figure S VacuumIdle Stop Bend...

Page 340: ...m is reduced and the plunger retracts into the idle stop unit The result is the throttle plate closes to a lower position which is controlled by the idle speed screw At this point the throttle plate i...

Page 341: ...luster No 50 35 Vacuum Spark Hole 2 No 65 2 No 65 Float Needle Valve Seat 113 113 Governor Diaphragm Spring No 389702 389702 Governor Throttle Spring No 389703 389703 Throttle Spring Anchor P osition...

Page 342: ...de open internal stop Figure 1 Accelerator Linkage for6V 53 D iesel Engine Conv Cab M odels 3 Adjust swivel 4 on rear rod assembly 5 to enter freely into hole 6 on lever 3 4 When actuated pedal assemb...

Page 343: ...USE TH E ENGINE TO R U N A W A Y A N D POSSIBLY DESTROY ITSELF A N D O R CAUSE INJURY TO PERSONNEL Connections between air cleaner and intake FUEL Fuel filter elements on Diesel engines should be repl...

Page 344: ...used in primary and secondary filters figs 5 and 6 are of different design the element replacement procedure is the Figure6 Sectional ViewofSecondaryFuel Filter I6V53D ieselEngine Typical same for bot...

Page 345: ...unit fuel injector illustrated in figure 2 is a lightweight compact unit which enables quick easy starting directly on Diesel fuel and per mits the use of a simple open type combustion chamber The sim...

Page 346: ...Injector Body 11 22 Gasket 12 23 Filter Cap 13 14 Figure2 Fuel InjectorSystem STROKE fc UPPER PORT 1 t EFFECTIVE STROKE EFFECTIVE STROKE HALF LOAD If FULL LOAD Fuel Metering From N o Injection To Full...

Page 347: ...ger The relation of the helixes to the two ports changes with the rotation of the plunger As the plunger moves downward under force of the injector rocker arm a portion of that fuel trapped under the...

Page 348: ...to FULL LOAD With the control rack pulled out all the way no injection the upper port is not closed by the helix until after the lower port is uncovered Consequently with the rack in this position al...

Page 349: ...uel control lever in the FU LL FU EL position hold in that position with lightfinger pres sure Turn the inner adjusting screw of No 3L injector rack control down as shown in figure 8 until a step up i...

Page 350: ...rt circuiting a spark plug of a gasoline engine 5 If the cylinder is firing properly repeat the procedure on the other cylinders until the faulty one has been located 6 If misfiring difficulty is attr...

Page 351: ...the injector rack for free move ment Excess torque can cause the injector control rack to stick or bind 3 Move the rocker arm assembly into position and tighten the rocker arm bracket bolts to 50 to 5...

Page 352: ...d in the injector tester thoroughly dry the injector with compressed air Then pump up the tester and maintain a pres Figure 11 Spray Pattern Test sure of 1600 to 2000 psi Inspect for leaks at the inje...

Page 353: ...f satisfactory reinstalled without disassembly extreme care should be taken to avoid reversing the fuel flow When the flow is reversed dirt trapped by the filters located in the injectors is back flus...

Page 354: ...s The pump circulates the excess supply of fuel through the injectors and the unused portion of fuel goes back to the fuel tank by means of a fuel return manifold located in each cylinder head and a f...

Page 355: ...n indicates insufficient sup ply of fuel to the injectors and the fuel level is not low in the supply tank check the fuel flow between the restricted fitting in the fuel return passage in the cylinder...

Page 356: ...ssible from behind right front wheel 2 Disconnect fuel tubes from inlet and outlet openings of the fuel pump 3 Disconnect drain line from fuel pump if used 4 Unscrew three pump attaching bolts and was...

Page 357: ...ger Throughout the intermediate speed range the operator has complete control of the engine because the low speed gap is closed and the low speed weights are against their stops and the high speed wei...

Page 358: ...y result from internal dirt accumulation defective plunger and bushing or a bent injector rack The injector must be re moved and tested as outlined in this section 3 An injector rack may bind as the r...

Page 359: ...th engine running at normal operating temperature turn buffer screw in see fig 21 so that it contacts the differential lever as lightly as possible and still eliminates the engine hunting N O TE Do no...

Page 360: ...ENGINE FUEL SYSTEM 6M 33 Do not intermix the needle valve injectors with the other types of injectors in an engine CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL...

Page 361: ......

Page 362: ...come equipped with either a Bendix Westinghouse compressor or a Midland Ross compressor as specified in the Air Compressor Model Appli cation Chart Offered as optional equipment on 70 and 80 series ve...

Page 363: ...nerally at the engine front cover This arm is attached solidly to the engine with a bolt or a bolt and nut The slotted end of arm is attached with a nut and bolt to an adjusting arm bracket fastened t...

Page 364: ...e is running but the actual compression ofair is controlled by the governor and the unloading mechanism During the downstroke of the piston inlet valve open a slight vacuum is created drawing atmosphe...

Page 365: ...ft air compressor assembly off mounting bracket R E M O V A L GEAR DRIVEN 1 Drain engine cooling system 2 Disconnect water air and oil lines from compressor 3 Remove bolts attaching air compressor to...

Page 366: ...ressors can be replaced without removing compressor from vehicle Since the unloader assemblies differ by manufacturer a separate procedure is given for each BENDIX WESTINGHOUSE Parts are available in...

Page 367: ...on top of plunger guides and make sure top of spring engages spring seat in cylinder block 4 Install new gasket at air inlet and connect air inlet elbow MIDLAND ROSS The following procedure includes...

Page 368: ...xhaust port in both cut in and cut out posi tions In the cut in position check exhaust port for inlet valve leakage by applying a soap solution at the port Leakage could also be past the bottom piston...

Page 369: ...and check for operation and leaks TROUBLESHOOTING COM PRESSOR FAILS TO MAINTAIN SUFFICIENT PRESSURE Dirty intake strainer Restriction in compressor cylinder head in take or discharge cavities or in di...

Page 370: ...es Intake cavity restrictions Defective governor Unloader line or cavity to governor restricted Unloader mechanism binding or stuck AIR COMPRESSOR MODEL APPLICATION CHART Truck Models Compressor Model...

Page 371: ......

Page 372: ...vent diametrically opposite Viewed from above with located in tfae bottQm Qf thg yent w l L DO NOT the vent plugs removed the lower end of the vent OVERFILL since this will cause electrolyte to be we...

Page 373: ...by defective starter or excessive use of accessories 3 Dirt and electrolyte on top of battery caus ing a constant drain 4 Hardened battery plates commonly called sulfation due to battery being in a lo...

Page 374: ...cycle must be finished by the Slow Charge method E M E R G E N C Y BOOST CHARGING In cases where the battery is not sufficiently charged to crank the engine an emergency boost charge may be applied as...

Page 375: ...for at least 15 minutes at a rate high enough to cause vigorous gassing 4 If any cell reads above 1 310 the battery may be returned to service However specific gravities above 1 310 are harmful to the...

Page 376: ...a good battery should be fully charged before being returned to service If batteries are to be fully charged by means of a quick charger the charge rate must be tapered reduced to a safe limit when t...

Page 377: ...n frame Operate starter and note the voltage reading 2 Check voltage drop between ungrounded battery terminal and starter terminal stud with starter operating 3 Check voltage drop between starter hous...

Page 378: ...r the pinion when extreme tooth abutment occurs This limits the clutch travel preventing switch contacts in the solenoid from closing Therefore the armature cannot rotate before pinion is engaged prop...

Page 379: ...lenoid term inals referring to applicable Wiring Diagrams in Section 12 to make sure of proper connections Tighten terminal nuts firmly 3 Connect ground strap to battery negative post STARTER AUTOMATI...

Page 380: ...ion should be 23 64 1 32 inch 3 If clearance is incorrect remove plug and adjust clearance by rotating nut clockwise to de crease clearance or counterclockwise to increase STARTER SOLENOID Starter sol...

Page 381: ...S STANDARD PART NO HM JM TM 80 1107376 HV JV TV 70 1114101 O P T IO N A L HM JM TM 80 1107371 HM JM TM 80 1107586 STARTING MOTOR SPECIFICATIONS STARTER MODEL 1107371 a 1107376 a 1107586 a 1114101 b Ma...

Page 382: ...and cables as directed in B A T T E R Y section 2 Check operation of centrifugal advance mechanism by removing distributor cap and turn ing the rotor in clockwise direction The cam should rotate freel...

Page 383: ...MPORTANT Before attempting to adjust ig nition timing make sure carburetor is properly adjusted Disconnect vacuum line from distributor vacuum advance unit and plug the open end of line N OTE The foll...

Page 384: ...hould not ping or knock excessively under load and full throttle 2 If knock is evident loosen distributor mounting clamp cap screw fig 3 and turn dis tributor housing clockwise to retard spark until k...

Page 385: ...of this section 6 Install rotor then position and secure dis tributor cap to housing SETTING DWELL ANGLE The point opening of new points can be checked with a feeler gauge but the use of a feeler gau...

Page 386: ...iaphragm DISTRIBUTOR REMOVAL 1 Locate No 1 cylinder spark plug wire on distributor cap mark this position on cap and mark distributor housing adjacent to No 1 wire in cap 2 Release distributor cap hol...

Page 387: ...aterial causing direct short between metallic elements of condenser This condition prevents any condenser action Low Insulation Resistance This condition per mits leakage which prevents condenser from...

Page 388: ...the plug operating too Hot such as encountered in sustained periods of high speed operation or under extremely heavy loads especially if not installed correctly Spark plugs with broken insulators sho...

Page 389: ...head and give a false torque reading Spark plugs which are not tightened correctly will result in too high an operating temperature if too loose or distortion of the spark plug body and change in gap...

Page 390: ...7 O P T 61 AMP H M J M 8 0 1100849 1119507 O P T 61 AMP T M 8 0 1100849 1119515 O P T 62 AMP HM JM 80 1117754 1116374 O P T 62 AMP TM 70 TM 80 1117754 1116378 GENERATING SYSTEM GENERAL DESCRIPTION The...

Page 391: ...r by blades attached to both ends of the rotor assembly The alternating current generator consists of two major parts a stator and rotor The stator is composed of a large number of windings assembled...

Page 392: ...tion without this wire Wire is identified on wiring diagrams in Section 12 as 24 BN WS 130 Resistance value of wire is approximately 0 ohms 6 25 watts IM PORTAN T Always locate and correct the cause o...

Page 393: ...h Re placement later in this section Excessive generator noise is usually the re sult of one or more of the following 1 Brush Squeal caused by a hard spot on one of the brushes or rough or dirty slip...

Page 394: ...ENERATOR OUTPUT TEST ON VEHICLE Refer to procedures outlined in Charging System Trouble Analysis Chart later in this sec tion to determine whether something other than a generator defect is indicated...

Page 395: ...temper ature which is the temperature of air at a distance of 1 4 inch from the regulator GENERATING SYSTEM W ITH TWO UNIT TY PE R E G U LA TO R 1 Refer to Figure 7 which shows all test equipment conn...

Page 396: ...nge in voltage read ing The upper set voltage should be 0 1 to 0 4 volts higher than on lower contacts The most desirable method for determining that the regulator is operating on the lower set of con...

Page 397: ...setting turn adjusting plug one notch clockwise then check for an im proved battery condition after a service period of reasonable length NOTE After two notches in each direction there is a positive s...

Page 398: ...generator drive pulley and adjust belt tension as explained under Drive Belt Tension Adjustment previously Tight en flange type lock nuts and mounting bolts to torque recommended in Specifications at...

Page 399: ...NSTALLATION IM PORTAN T Make sure one battery cable is disconnected from battery 1 Place regulator to generator ground wire if used on regulator mounting and install regula tor attaching screws 2 Lift...

Page 400: ...obtain the specified difference in voltage between the upper and lower contacts Instructions for making final setting are explained previously See Regulator Voltage Test On Vehicle Figure 16 Adjusting...

Page 401: ...ged or rectified to D C voltage which appears at the output or B A T terminal on the generator The generator then supplies current to charge the battery and operate vehicle accessories On 62 amp syste...

Page 402: ...fter a service period of reasonable length 8 If the regulator cannot be adjusted to with in limits listed in Specifications at end of this section repair or replace the regulator REGULATOR REPLACEMENT...

Page 403: ...TROUBLE ANALYSIS CHART ENGINE ELECTRICAL 6Y 32 CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL...

Page 404: ...s a If output is checked without a regulator the output should be 5 10 higher than the value given ALTERNATING CURRENT GENERATOR TORQUE SPECIFICATIONS TYPE OF TORQUE ITEM PART FT LBS Generator Pulley...

Page 405: ...er contacts must be 0 1 0 4 Volt lower than on upper contacts FULL TRANSISTOR TYPE VOLTAGE REGULATOR MODEL 1116374 AND 1116373 Make Delco Remy 4 5 6 5 No 2 Delco Remy 2 0 3 0 No 2 Field Relay Closing...

Page 406: ...87V transmission the angularity between the gearshift lever 1 and control island panel 2 after adjust ment should be 98 30 Adjustment is accomplished by rotating the adjustable clevis see Inset fig 1...

Page 407: ...ection of transmission gears ASSEMBLY N OTE Key numbers in following text refer to figure 2 1 Place gearshift lever on shift lever finger 10 and position in control cover Install pivot pin 13 and roll...

Page 408: ...Rod ist and Reverse Poppet Springs Shift Finger i k Transmission J t Shifter Housing I fjl Assembly Plunger Retainer Pin Spring s Plunger Pin T IO i Figure 3 Spicer Remote Control Assembly N E W PROC...

Page 409: ...8 then remove shifter shaft 5 and selector finger 16 from remote control housing 7 2 Remove attaching parts holding shifter shaft collar 4 to shifter shaft 5 then remove shifter shaft collar C l V N e...

Page 410: ...ole in shifter shaft 5 with hole in selector finger 16 4 Install selector finger lock screw 18 Tighten screw to 25 foot pounds torque 5 Install new lock wire through lock screw 18 to retain the positi...

Page 411: ...ol linkage check performance of the engine The trans mission is often blamed for poor operation of the vehicle when the engine is not tuned to deliver peak power Refer to ENGINE SEC 6 in this manual f...

Page 412: ...on and lever A 0 060 inch from stop B adjust the swivels on rod I to provide free entry into levers A and C 4 With carburetor throttle lever C at idle position and TV lever F against rear stop rotated...

Page 413: ...G off rod one turn at a time until the desired shift point is obtained Tighten jam nut against clevis TV LINKAGE ADJUSTM ENT M O D E L TV70 Refer to Fig 10 IM PO R T A N T Prior to adjustment of the T...

Page 414: ...f necessary Anchor cable to bracket at point D N O TE Threaded portion of shift cable extends 0 88 inch above top side of bracket as shown at point D 3 Disconnect clevis G from transmission manual shi...

Page 415: ...ngaged ON posi tion 3 Holding the retarder pedal in the O N position adjust the pedal stop bracket at A Conv Cab Models until it touches the pedal as shown Tighten steering pivot bolt C to 8 10 foot p...

Page 416: ...lt of the transmission therefore me chanics should road test to determine if the driver s complaint of noise is actually in the transmission NOISE ARISING OUTSIDE TRANSMISSION In numerous instances dr...

Page 417: ...ly caused by vibra tions in the power train this could be engine propeller shafts joint angle rear axle differen tials etc a Improved highways permit sustained high speeds The fact that engines and en...

Page 418: ...7 Worn shift rods 8 Worn sprung shifter fork 9 Wrong lubricant especially if extreme pressure type lubricants are added 10 Free running gears seized or galled on either the thrust face or diameters ST...

Page 419: ...on of lubricant will produce red dish brown coating and small etched holes over outer and exposed surfaces of race Corrosive oxides also act as lapping agent FATIGUE All bearings are subject to fatigu...

Page 420: ...nd adjust to carry weight of transmission 14 Remove attaching parts that retain trans mission to transmission rear mount when used 15 Visually inspect to determine if other equipment lines or brackets...

Page 421: ...t propeller shaft to transmission as described in P R O P E L L E R SHAFTS SEC 4D NOTE Proper torque values for the main shaft flange or yoke retaining nut is given under Rear Oil Seal Replacement lat...

Page 422: ...mpanion flange on mainshaft Using flange or yoke holding tool install retaining nut Refer to Torque Specifications for proper torque 4 Install speedometer driven gear then con nect speedometer cable 5...

Page 423: ...aged cotter pins Tighten lock nuts firmly 5 Lubricate control linkage as described in LUBRICATION SEC 0 of this manual Shift Control Tower AUXILIARY TRANSMISSION REPLACEMENT R E M O V A L 1 Drain lubr...

Page 424: ...UNT SPICER 6041 45 55 FT LBS CROSS BEAM L CROSSMEMBER FRONT MOUNTING BRACKET MOUNTING PLATE CUSHION ASSEMBLY i_j 95 105 ft lbs CUSHION ASSEMBLY FRAME FRAME MOUNTING BRACKET MOUNTING PLATE 95 105 FT LB...

Page 425: ...per specifica tions as shown in figures 2 and 3 N OTE For proper torque on frame to rear mounting bracket attaching parts if removed refer to torque specifications 4 Reconnect power take off when used...

Page 426: ...A Fig 2 4 5 16 View F Fig 2 3 7 16 JM80 478M CL401V SP6041 View A Fig 2 4 5 8 View F Fig 2 3 5 16 JV70 6V 53 CL385V SP7041 View C Fig 2 1 3 16 View C Fig 3 1 3 16 JV70 6V 53 CL385V SP7041 View D Fig 2...

Page 427: ......

Page 428: ...od is connected to the clutch release fork or lever When clutch pedal is depressed hydraulic fluid is displaced from the master cylinder into the slave cylinder forcing the slave cylinder piston outwa...

Page 429: ...e Is Felt W edge Adjusting Nut Lock Nut UliTlf Push Rod Force Push Rod To Bottom In Slave Cylinder 1 2 Free Travel Hold W edge Against Lever O r Fork slave cylinder or clutch assembly has been re plac...

Page 430: ...Pedal Upper Section 3 Master Cylinder Push Rod 11 Pedal Lower Section 4 Push Rod Lock Nut 12 Pedal Stop Bumper 5 Lever to Shaft Clamp Bolt 13 Sleeve Attaching Screws 6 Special Spacer 14 Sleeve and Bu...

Page 431: ...arance Checking Tool Figure 10 Checking Push Rod Clearance Using Small End of Tool The following describes adjustment procedure using special tool 1 Disconnect the slave cylinder return spring 2 With...

Page 432: ...slippery 3 Slip end of bleeder drain hose over bleed valve at slave cylinder fig 12 and place the other end in a glass jar containing enough hydraulic fluid to cover end of hose Open bleeder valve wit...

Page 433: ...igure 6 install clutch pedal return spring 8 IMPORTANT Exercise caution when installing spring 8 Make sure that pedal stop 12 is in good condition and is located on pedal shaft as shown CLUTCH MASTER...

Page 434: ...ed by one of the following causes 1 Clogged with dirt remove master cylin der and disassemble and clean all parts Refer to applicable section view of master cylinder when assembling 2 Swollen primary...

Page 435: ...stall components in clutch cylinder bore as follows a Install return spring in cylinder bore large diameter first b Install primary cup in cylinder bore with lip of cup toward outlet end Make sure end...

Page 436: ...emoved by honing or by use of crocus cloth 2 Check piston seals 8 if removed Swelling of seals could be due to use of improper brake fluid 3 Check fit of the piston in the cylinder bore using a feeler...

Page 437: ...ountered when removing the clutch release fork from bsill stud This condition could be the result of insuf ficient clearance between the release fork and housing If the fork cannot be pried from fork...

Page 438: ...e outside groove with a small quantity of high temperature grease IM PORTANT An excessive amount of lu bricant applied to release bearing could spin off the bearing and damage other clutch components...

Page 439: ...ring cap 3 Examine contact buttons on ears of bearing support for worn condition Buttons can be pressed out or into support if necessary 4 Slide release bearing and support assem bly on bearing cap to...

Page 440: ...aced Machining for repair is N O T recommended DRIVEN DISC S Inspect driven disc assembly for worn loose and grease or oil soaked facings Check for broken springs loose rivets or cracks in the driven...

Page 441: ...marks 5 Install cover to flywheel bolts and wash ers Tighten bolts alternately one turn at a time to compress clutch tension springs evenly and prevent possible distortion of cover NOTE Tighten clutch...

Page 442: ...ES CLUTCH BUT PEDAL G R A D U A LLY TRAVELS D O W N W A R D 1 Clutch master cylinder leaks past primary cup 2 External leaks PROBABLE R E M E D Y 1 Adjust slave cylinder travel clearance or if control...

Page 443: ......

Page 444: ...8 larger O D than the hose I D into opposite end of hose from slit 3 Insert nipple end of hose into tank until it strikes bottom 4 With the opposite end of the hose in a suit able container which is p...

Page 445: ...g one with a single lap flare A and the other with a double lap flare B It will be noted that the single lap flare splits the tubing while the double lap flare shown in is a heavy well formed joint i...

Page 446: ...e O N or ACCESSORY position The dash gauge consists of a permanent mag netic armature and spindle assembly to which a pointer is attached Surrounding the magnetic arm ature are two coils wound perpend...

Page 447: ...tank sending unit Itis important that dash gauge and sending units not be interchanged between conventional and tilt cab models If wrong fuel gauge components are installed inaccurate fuel quantity r...

Page 448: ...riate terminals or repair broken wire 9 Open circuit between ground terminal on gauge and ground X Clean and tighten mounting bracket where contact is made between gauge and ground 10 Open circuit bet...

Page 449: ...ed to be non toxic however Diesel exhaust will dis place air and cause various physical discomforts If it is absolutely necessary to operate vehicle while an exhaust leak exists use extreme caution an...

Page 450: ...th local fire and safety regulations Before making adjustments on Fuel System Units be sure Electrical System is functioning properly WARNING CARBON M ONOXIDE Keep cowl vent and heater intakes closed...

Page 451: ......

Page 452: ...have an adjuster as sembly at shaft end of gear housing for adjustment of worm thrust bearing lip type oil seals at steer ing worm and Pitman shaft shims for adjustment of Pitman shaft lash and bushin...

Page 453: ...elative posi tion of linkage and Pitman arm so parts may be reassembled in same relative position Refer to Steering Linkage later in this section for cor rect procedures 2 Loosen lock nut and turn las...

Page 454: ...as described later in this section Adjust worm bearings as follows W O R M BEARING ADJUSTM ENT Type 553 D and 554 D Steering Gear 1 Loosen adjuster lock nut at shaft end of steering gear and turn worm...

Page 455: ...eck wheel pull PITMAN SHAFT LASH ADJUSTM ENT 1 Center steering gear by turning steering wheel from extreme right to extreme leftpositions counting the exact number of turns Turn wheel back exactly hal...

Page 456: ...The drag link assembly shown in View B figure 7 has a replaceable ball stud end assembly The threaded end plug can be removed to replace components within the socket end of the drag link R E M O V A...

Page 457: ...onnected from steering arm locate center of steering gear movement Turn steering wheel gently from extreme right to extreme left counting the exact number of turns Turn steering wheel back exactly hal...

Page 458: ...or wear at bearing surfaces Tie rod end parts are replace able Snap ring and plug can be removed from socket end to permit removal of end stud bearing and seat Tie rod socket ends are self adjusting a...

Page 459: ...ring seat 18 then install spring seat 4 Position seat spring 17 and retaining washer 16 then install lock ring 15 5 Install tie rod socket ends on tube thread ing each end the same number of turns on...

Page 460: ...wheel fig 12 It may be necessary to tap on bolt head of tool with a hammer as it is turned down to loosen a tight steering wheel INSTALLATION N O TE Front wheels must be in straight ahead position an...

Page 461: ...Fig 14 1 Remove steering wheel as described under Steering Wheel Replacement previously 2 Mark clamp yoke or coupling and steering gear worm shaft to insure installation in same relative position fig...

Page 462: ...nstall bolts Tighten bolt nuts to 15 20 foot pounds torque N OTE Check to make sure shoulder of bolt is bottomed against coupling flange 3 If previously removed press lower bearing into mast jacket 4...

Page 463: ...s 4 Install screws which attach steering col umn seal and retainer to cab floor 5 If used position trailer brake hand control valve on steering column and attach with clamp 6 Check alignment mark on l...

Page 464: ...l two bushings 11 and two cork washers 10 fall off the center cross 14 Discard cork washers 5 Remove lubrication fitting 13 from center cross 14 6 Remove two tube yoke snap rings 2 then tap yoke tube...

Page 465: ...g sleeve in column upper bearing INSTALLATION Fig 18 1 Position steering column upper and inter mediate steering shaft steering column seal and seal plate in vehicle 2 Position intermediate shaft clam...

Page 466: ...traight ahead position and steering gear in center position Mark on worm shaft should be in 6 o clock position 2 Position steering gear on frame side mem ber and at the same time slide the worm shaft...

Page 467: ...lamp Bolt Nut Intermediate Shaft to Worm Shaft Clamp Bolt Series TV 70 Nut Except Series TV 70 Nut Steering Upper Shaft to Lower Shaft Clamp Bolt Nut Drag Link to Pitman Arm Stud Nut Drag Link to Stee...

Page 468: ...peration of the control valve which supplies hydraulic fluid to either side of the power cylinder piston as required depending on the position of the valve The pressure used to operate this system is...

Page 469: ...for proper pro cedures for checking front end alignment Im proper tire inflation will also affect operation of the power steering The tires therefore should be checked at regular intervals Because of...

Page 470: ...connect hydraulic pump to steering gear pressure line at pump Connect a 0 to 2000 psi pressure gauge J 22181 to the pump outlet then connect a shut off valve between the pressure gauge and pressure li...

Page 471: ...e spool and valve body lock up into a complete unit that then operates as a mechanical unit The valve shown in figure 5 is an open cen tered rotary type three way valve The spool is held in the neutra...

Page 472: ...upon the road bed conditions weight of the vehicle and pressure relief setting in the pump During normal straight ahead driving the steering wheel effort will be approximately the same as manual effo...

Page 473: ...t replace the valve unless the hiss is extremely objectionable since the replacement valve will also have a slight hissing noise Be 7 On conventional cab models and Series R M RG 7500 connect drag lin...

Page 474: ...njunction with other accessories fig 6 The oil reservoir encases the pump and on some vehicles an additional reservoir is remotely mounted on the radiator front support or on the transmission control...

Page 475: ...LEGEND 10 DISCHARGE OIL 12 SUPERCHARGE OIL HIGH PRESSURE OIL RESERVOIR AND RETURN OIL RING ROTOR LEAKAGE OIL VIEW B P U M P O PERATIO N H IG H SPEED T l 166 Figure 8 Power Steering Hydraulic Pump Ope...

Page 476: ...iven at high speed In this case the flow control valve has opened to allow oil flow in excess of system requirements to by pass into intake chamber of the pump PUMP R EPLACEM EN T Removal 1 Disconnect...

Page 477: ...nnected secure ends in raised position to prevent drainage of oil Install caps at pump fit tings to prevent loss of fluid from pump 3 Remove two cap screws and lock washers which attach pump and mount...

Page 478: ...occur at joints in the system where oil passes through at high velocity such as hose connections or at the drive shaft seal N O TE After each step in attempting to elim inate air the pump should be o...

Page 479: ...mpletion of a turn reduced effort on the steering wheel allows steering geometry of the vehicle to return front wheels to a straight ahead the gauge and steering gear Observe pump pres sure on gauge a...

Page 480: ...d install new cotter pins 3 Turn front wheels from extreme right to left and check to see that the power cylinder does not bottom preventing stops from hitting the axle 4 Reconnect hydraulic hoses to...

Page 481: ...position and set pis ton shaft to dimension applicable to axle being used fig 12 SIDE M O U N T E D CYLINDER No adjustment is required on side mounted cylinders since the distance between ball stud c...

Page 482: ...r or re placement if necessary by disconnecting hoses Figure 14 Oil Cooler Installed Typical and removing screws which attach it to support braces OIL COOLER MAINTENANCE At regular intervals or when o...

Page 483: ...flow control plunger Replace assembly 2 Leaks at top of Reservoir too full Fill to proper level of reservoir Air in the oil Locate source of air leak and correct 3 Leaks at the O Ririg seal cut Repla...

Page 484: ...bricant where needed as described in lubrication Sec 0 of this manual Tires not properly inflated Inflate to recommended pressure Insufficient oil pressure If all of the above checks do not reveal the...

Page 485: ...ing gear Remove kinks Rem ove hoses and remove restricting object or replace hose a Leakage at valve rings valve body to worm seal b Loose fit of spool in valve hody or leaky valve body Remove gear fr...

Page 486: ...PUMP SPECIFICATIONS VANE TYPE PU M P M a k e Saginaw Steering Gear Division Minimum Capacity per Minute 2 35 G P M of Type A automatic transmission fluid at 170 F when operating pump at idle speed aga...

Page 487: ...eering Cylinder Anchor Bracket to Tie Rod U Bolt Nut 35 45 Power Steering Cylinder Ball Stud Socket Clamp Bolt Bolt 50 60 Power Steering Cylinder to R H Idler Arm Stud With F 160 Front Axle Nut 125 15...

Page 488: ...n and free of rust or scale build up if wheels are to be retain ed securely The following tightening sequence will give best results and aid in producing correct wheel nut torque 1 Tighten nuts 1 2 3...

Page 489: ...point B for radial runout out of round This should not exceed 3 32 total indicator reading Wheels that are distorted in excess of these limits should be replaced N OTE Additional instructions on balan...

Page 490: ...e tires The pressure loss check should be made consistently with the same gauge so that any element of inaccuracy in the gauge will be the same for all tires VALVE CORE The valve core is a spring load...

Page 491: ...oreign matter The tires should be in good condition and properly mounted with the balance mark on the tire if any lined up with the valve Bent wheels that have runout over 3 32 should either be replac...

Page 492: ...er nuts 190 210 foot pounds 300 400 foot pounds 450 500 foot pounds 450 500 foot pounds At regular intervals check tightness of all wheel nuts A noticeable noise or vibration may indicate loose wheel...

Page 493: ......

Page 494: ...tter method will require the draining of cooling system and disconnecting of radiator hoses R E M O V A L Refer to Fig 2 1 Raise and support hood side panels 2 Disconnect head lamp wiring harness con...

Page 495: ...s NOTE DO NOT move lower lock nuts or jam nuts on strut rods 6 Remove bolts which attach the radiator shell brackets right and left to the flexible mounting as shown in Figure 4 NOTE On HV and JV 70 m...

Page 496: ...d JV70 models flexible mounting bracket fig 4 is inserted 180 Figure 5 Radiator Shell Strut Rods Figure6 RadiatorShell Supports Conv 70 80 Series J M odels ExceptJV70 7 When removing radiator shell wi...

Page 497: ...Remove bolt spacers Figure 8 RunningBoardReplacem ent 2 Remove four bolts and lock washers which attach running board to frame supports Remove running board INSTALLATION 1 Place running board in posi...

Page 498: ...d assembly which includes the right and left and center panels R E M O V A L Refer to Fig 9 1 Raise both hood side panels and support with attached props 2 At front of hood center panel remove two att...

Page 499: ......

Page 500: ...stic insulation as indi cated on the wiring diagrams Insulation colors assist in tracing circuits and in making proper connections On vehicles equipped with the V 6 gasoline engine a 1 52 ohm resistan...

Page 501: ...n By referring to the wiring diagrams circuits may be tested for continuous circuit or shorts with a conventional test lamp or low reading voltmeter Figure 7 ReplacingBladeTypeConnector Term inals REP...

Page 502: ...d A 15 amp automatic reset type circuit break er is used in the two speed axle shift switch cir cuit and in stop light circuit on vehicles equipped with two speed axle or with special I C C stop light...

Page 503: ...d through the horn mounting Therefore it is necessary that Figure 6 Fuse Block and Circuit Breaker Mounting Tilt Cab Models Typical a good ground connection be maintained between the horn mounting bra...

Page 504: ...eter and tachometer Current from the battery No 1 terminal then flows directly through relay contacts and out No 3 terminal to the horn The relay thus provides a higher voltage to the horn by avoiding...

Page 505: ...s and washers to secure to mounting bracket 2 Position instrument cluster in dash panel far enough to gain access to rear of each gauge and unit 3 Connect drive cable lines and wiring con nectors to e...

Page 506: ...b is a miniature base bulb installed in a plastic holder which locks into the case and makes contact with the printed circuit In the event of a visible break in a printed circuit it can be repaired by...

Page 507: ...l tale 13 Fuel Gauge 8 Hi Beam Indicator 14 Turn Signal Tell tale 9 Engine Temperature Gauge 15 Cluster Retaining Clips 10 Generator No Charge Tell tale 16 Instrument Lights 11 Tachometer 17 Wiring Co...

Page 508: ...ge load it will be carrying during the majority ofits operation Tires should be uniformly inflatedto recommended pressure when adjusting headlight beams Beam adjusting screws are identified in View A...

Page 509: ...and engage in slot in retaining ring as shown in View B 5 Check headlight adjustment as explained under Headlight Beam Adjustment previously SINGLE SEALED BEAM UNIT R E P L A C E M E N T Removal Fig 1...

Page 510: ...remove bulb and socket assem bly then remove two screws attaching lamp as sembly to front grille panel Pull lamp assembly from opening in grille panel On tilt cab models remove two nuts which attach...

Page 511: ...n holder press in ward to lock in place Insert holder in case with lugs on holder entering notches in case then turn clockwise to lock in place DOME LIGHT On conventional cab models dome lamp is mount...

Page 512: ...pressing it firmly into place 4 Check operation of all lights DIMMER SWITCH Foot operated dimmer switch is used to se lect headlight high or low beam Switch is mounted on left side of cab flooring and...

Page 513: ...side of cab To replace the side marker lamp bulb re move two screws which retain the amber marker lens to the light assembly then remove the lens Press inward on bulb and turn clockwise to secure Plac...

Page 514: ...teering shaftupper bearing sleeve 3 Disconnect wiring harness at instrument panel harness connector NOTE On some models it may be necessary to remove control assembly wiring from the wir ing harness c...

Page 515: ...itch to dash panel Pull switch from dashpaneland dis connect wiring harness Install new switch NOTE On models which have an indicator bulb in the switch knob the bulb may be replaced by removing the t...

Page 516: ...2 Parking Lights When Used 67 4 Front Marker Lights 67 4 Instrument and Tell Tale Lights Conv Cab 57 2 Tilt Cab Models 161 1 Directional Signals Double Faced Front Direct Sig 1156 32 Combination Corne...

Page 517: ...ERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL grd engjne T R iN S i l I m o o BL K j l c R iM f 70 z o g o 73 5 l Figure 21 C ab Engine and Chassis Wiring HV JV70 Sheet 1 of 6 CHASSIS ELECTRICAL AND INSTRU...

Page 518: ...CHASSIS ELECTRICAL AND INSTRUMENTS 12 19 CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP M ANUAL F ig u re 21 C a b En g in e a n d C h a ssis W iring HM V70 S h eet 2 o f 6...

Page 519: ...18 G RAY 4 6 GRAY 4 R C 0 d o iJ e l e SPEED O M ETER DiFF lO O tt lOW AiR SW f o T o 8 B L K 6 PURPL E O PKG LP 16 PUppL INSTRUMENT LO TS Q PARK MG L P S RPO T H R P0 C9I j 8 O RAN G E Z lS WHT t X 8...

Page 520: ...70 80 HEAVY DUTY TRUCK SHOP MANUAL MARKER LIGHTS TRAILER CABLE RP0 U85 U87 direct iona l ha za r d a s to p LIGHTS Figure 21 Cob Engine and Chassis W iring HV JV70 Sheet4of6 CHASSIS ELECTRICAL AND IN...

Page 521: ...CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL CIRCUIT IDENTIFICATION Figure 21 Cab Engine and Chassis Wiring HV JV70 Sheet 5 of 6 f CHASSIS ELECTRICAL AND INSTRUMENTS 12 22...

Page 522: ...NEL AT FUEL GA Cr o iA R T0 9 PARKING Lf H A R N b t p ti TAil l P FR T E x T HARN t o r e a r STO P a TAiL LR H A R N R EA R STOP 6 Ta l LR h A RN TC STOP 8 TAIL IP A S M R ELA TE D CIRCUITS STOP 8 T...

Page 523: ...CHEVROLET SERIES 70 80 HEAVY D UTY TRUCK SHOP MANUAL Figure22 Cab Engine andChassis W iring TV70 t Sheet 1of6 f 1 I I I I CHASSIS ELECTRICAL AND INSTRUMENTS 12 24...

Page 524: ...CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL CONTROL SWITCH IN ST R U M EN T S Figure 22 Cab Engine andChassis W iring TV70 Sheet 2of 6 CHASSIS ELECTRICAL AND INSTRUMENTS 12 25...

Page 525: ...CHASSIS ELECTRICAL AND INSTRUMENTS 12 26 CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL F ig u re 22 C a b En g in e a n d C h a ssis W iring TV70 Sh eet 3 o f 6...

Page 526: ...CHASSIS ELECTRICAL AND INSTRUMENTS 12 27 CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL F ig u re 22 C a b En g in e a n d C h a ssis W iring TV Q Sh eet 4 o f 6...

Page 527: ...CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL F ig u re 22 C a b En g in e a n d C h a ssis W iring TV70 Sh eet 5 o f 6...

Page 528: ...P HARN REAR STOP TAlu LPHARN TO STOP TAIL LP ASM ____________AXLE SHIFT SW FEED HARN TO AXLE SHlFTSW H A R N ENG HARN TQ a x l e S h i f t w R CABLE o o CIRCUIT B R E A K E R i i iNE CONfiFC O R o t e...

Page 529: ...s i I8PURPL f WH T S T 9 n 6 PuPPLE 1 y P R E S 5 Sw_ r o MBits 1 N ti T 8aC jP n f l u 6 B L K l8 INK 19 P X N t u T k A L R E a P D T T 20PINK 8C h BLJE l j 8 D k bt Jt l_ 8 Bt A C i _i 20E R E T A...

Page 530: ...CHASSIS ELECTRICAL AND INSTRUMENTS 12 31 CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL F ig u re 23 Cob Engine a n d C h a ssis H D W iring TV70 Sh eet 2 o f 6...

Page 531: ...A L A R M B U ZZER ENGINE Al f X54 HORN LKoHt ING marker lights TRl IC C MKR LP RELAY LISE WITH SEWt TRL BRKE CONTROL R PO J9l TRAILER CA8LE R P 0 U 8 5 U 8 7 Figure 23 Cab Engine and Chassis H D Wiri...

Page 532: ...ES 70 80 HEAVY DUTY TRUCK SHOP MANUAL OiRECTtONAL HAZARD 9 STOP LfGHTS E L E C 2SP D A X LE WHEN U SED BACK UP L PS Figure23 Cab Engine andChassis H D W iring TV70 Sheet4of6 CHASSIS ELECTRICAL AND INS...

Page 533: ...U A L d u a l SPD W S WIPER WASHER i EM ERG ENCY A IR BPKE R P C J 7 H EATER R i B L U fH OffAN t I wefi MTR j i I RADIO J t CIRCUIT IDENTIFICATION Figure 23 Cab Engine and Chassis H D Wiring TV70 Sh...

Page 534: ...H A R N STOP TAIL LP FRTEXT HARN TO REAR S TC P TAi L LP HflRN REAR STOP Tail L HARN TO STOP TAIL LP ASM VOLTMETER WRG HARN TO l STR PNL HARN ENG HARN TO A x l E SHIPT CABLE F U S E 3 CIRCUIT BREAKER...

Page 535: ...0 HEAVY DUTY TRUCK SHOP MANUAL GRD CAB ALL MODELS X0 8 L K 1 ENG N GRD ENGNE FRAME MTD BAT trans iff b i l prame R P0 Figure 24 Cab Engine and Chassis Wiring H M JM 80 Sheet 1 of 6 CHASSIS ELECTRICAL...

Page 536: ...T SERIES 70 80 HEAVY D UTY TRUCK SHOP MANUAL GENERATOR IGMTION GAS MODELS CONTROL SWITCH TEMPERATURE GAUGE Figure 24 Cab Engine and Chassis W iring HM JM80 Sheef2 of 6 CHASSIS ELECTRICAL AND INSTRUMEN...

Page 537: ...GAUGE DUAL FUEL TANK R PO NQ7 GAS MODELS ONLY ENGINE ALARM R P0 X54 DFFERENTIAL LOCK TELl TALE s A l TANDEM AXLE M O DELS LOW AIR ALARM BUZZER LIGHTING Figure 24 Cab Engine and Chassis Wiring H M JM...

Page 538: ...9 V v _ L UE A T i OK G ftK l 1 8 R B LU t SPA RE 1 2q e i P S P tiRN TA i l PS 2 8 S S CG cr t 4 1 _ _ 4 GPN R H DIR LP 8 8LK R H FRT Hi if O V r R h i HlR TT 8 oC H FRT oiR LP 8 DK S 8V X d BLK v p...

Page 539: ...ADAPTER AXLE SHFT MTR 2 9 L K I SM O O T H 1 1 6 YELL 6O R A N G E h e a t e rs l o w e r CONTROL KATFR Sl OWLR MTR r 16 BRH 16 YELL v 1O i i6Y E LL 6 l T s l u e ME D BlOw er c o n t r o l s _ i i l...

Page 540: ...CHASSIS ELECTRICAL AND INSTRUMENTS 12 41 CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL F ig u re 24 C a b En g in e a n d C h a ssis W iring HM JM80 Sh eet 6 o f 6...

Page 541: ...CHASSIS ELECTRICAL AND INSTRUMENTS 12 42 CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL F ig u re 25 C a b En g in e a n d C h a ssis W iring TM 80 Sh eet I o f 6...

Page 542: ...CK SHOP MANUAL tGMTCN CONTROL SWITCH IN ST R U M E N T S LOW AIR A L A R M B U ZZER R P 0 0508 J83 TACHO M ETER R P O 1269 INLINE 6 C YL EN G Figure25 Cob Engine andChassis W iring TM 80 Sheet2of6 CHA...

Page 543: ...X54 R P 0 0 6 0 6 HORN LK3HTNG M ARKER LIGHTS TRL IC C MKR LF RELAY USE W TH S E M 1 TRL BRKE CONTROL R RO 91 R PO 0 5 4 0 TRAILER CABLE R P0 U85 U87 R P 0 I2 0 3 1204 Figure 25 Cob Engine and Chassi...

Page 544: ...CHASSIS ELECTRICAL AND INSTRUMENTS 12 45 CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL F ig u re 25 C a b En g in e a n d C h a ssis W iring TM 80 Sh eet 4 o f 6...

Page 545: ...CHASSIS ELECTRICAL AND INSTRUMENTS 12 46 CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL F ig u re 25 Cob En gin e a n d C h a ssis W iring TM 80 Sh eet 5 o f 6...

Page 546: ...P FR T EX T HA RN TQ RE A R ST O P TAIL l c R EA P STO P TA IL LPH A R N TO S TO P TA IL L P ASM VOLTMET ER WRS HARN TO INSTR V _ H A P N EN G HARN TO A L t S h i f t M q C A 8 L E C D SINGLE L N E C...

Page 547: ...CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL AM M ETER Figure 26 Cab Engine and Chassis Wiring HM80 Sheet 1 of 2 CHASSIS ELECTRICAL AND INSTRUMENTS 12 48...

Page 548: ...E B L O C K F U S E B LO C K P A R T OP IN S T R PANEL HARN ASM BRO KEN L IN ES OENOTE BOQY CiRCl i T WRG 8 PARTS OTHER TnAN STD IN S T R P A N E L H ARN TO TR A N S S H IF T CO N TRO L A SM IN S T R...

Page 549: ......

Page 550: ...tors in HV JV 70 Models are trunnion mounted with strut rod provided at each side to adjust and maintain position of radiator Figure 2 illustrates radiator installation in HV JV 70 Models Figure 1 Rad...

Page 551: ...d adjustment is made hood alignment must be checked as instructed in SHEET METAL SEC 11 of this manual MODELS HV JV 70 Removal Refer to Fig 2 1 Remove radiator shell assembly as de scribed under Radia...

Page 552: ...stall electrical components on radiator and connect throttle linkage to radiator support 8 Fill cooling system and inspect system for leaks PRESSURE RELIEF VALVE Rubber Bushing Mounting Bolt Nut Radia...

Page 553: ...ht SPECIFICATIONS COOLING SYSTEM PRESSURE RELIEF VALVE R C 1 2 9 7 9 to 10 psi Combination Filler Cap and Valve Type Stam ped Opening Pressure COOLING SYSTEM NOTES AND PRECAUTIONS 1 Overheating is not...

Page 554: ...of each major subject within the section A summary of Special Tools will be found following Section 9 while Specifications covering vehicle com ponents are presented at the end of each section This ma...

Page 555: ......

Page 556: ...Tandem O verhaul 4 31 Rockwell SLH D and SQ H D Tandem O verhaul 4 40 This publication contains overhaul information on sin new limits fits tolerances torque readings and other im e reduction spiral...

Page 557: ...tial case Differen tial case is two piece type machined as a matched assem bly and must be replaced as such Thrust washers are used between differential side gears and case also between differential p...

Page 558: ...Housing 3 Replacement of Axle Assembly 4 Replacement of Major Units 5 Replacement of Minor Components 6 Overhaul of Minor Components REMOVAL OF SUBASSEMBLIES Procedures in following paragraphs apply...

Page 559: ...ier 2 At inner end of pinion use brass drift and hammer to drive pinion and cage assembly from differential car rier fig 6 Use caution so as not to let assembly be damaged by dropping 3 Remcve adjusti...

Page 560: ...flat washer 12 under oil seal retainer 5 Lift outer bearing cone 10 from cage 6 When inspection indicates necessity cups 6 and 9 can be removed from cage fig 9 with remover J 3940 7 If necessary pinio...

Page 561: ...Inspect differential case assembly for cracks distortion or damage if case is in good condition thoroughly clean case and cover then assemble case with cap screws and mount in lathe centers or V block...

Page 562: ...en the points Measure and note dimensions of this gap 5 Rotate shafts simultaneously and measure gap at four points 90 degrees apart If gap at any point exceeds original gap by more than 1 16 inchs ax...

Page 563: ...universal set 1 3493 as shown in figure 14 2 Install straight roller bearing 1 on shaft Stake end of shaft using a round nose punch or staking tool 3 If new cups 6 and 9 are to be installed press cup...

Page 564: ...ng surface of bevel gear and flange of dif ferential case Position gear to case with bolt holes in alignment then install special bolt 11 with nut 14 Tighten 1 2 inch nuts to 90 100 foot pounds or 5 8...

Page 565: ...auging operation should be accomplished at this stage of assembly Refer to Gear Back lash and Tooth Contact later in this publica tion If gauge method is net to be used continue with assembly operatio...

Page 566: ...41 is a direct reading micrometer mounted in arbor Adapter discs which fit in differential bores are mounted in sleeves that fit over the arbor Different adapter discs are required for various axle mo...

Page 567: ...RKINGS All other markings on pinion or drive gear should not be confused with N O M IN A L A SSEM B LY D IM E N SIO N or IN D IV ID U A L V A R IA T IO N D IST A N C E markings PINION SETTING PROCEDUR...

Page 568: ...than the initial micrometer reading shim pack thickness equal the difference must be removed As an example Refer to right set of gears on Figure 21 Nominal Assembly Dimension 2 656 inches Individual...

Page 569: ...tooth Correct backlash is obtained by mov ing pinion toward bevel gear A L O W NARROW CONTACT is not desirable If gears are permitted to operate with an adjustment of this type galling noise and groo...

Page 570: ...service for 3 000 miles the unit should be drained and refilled with recommended lu bricant See Section 0 SPECIFICATIONS 17121 and A X LE M O D E L S 18121 19121 M A K E Eaton Eaton RATIO j Refer to...

Page 571: ...Number ol Splines 16 16 TORQUE SPEC IFIC A TIO N S Ft Lbs Pinion Shaft Nut 400 600 500 700 Pinion Cage Bolt 115 125 160 175 Differential Case Bolt 90 105 135 155 Differential Bearing Cap Bolt 300 340...

Page 572: ...red dowels are installed on each stud Inner end of axle shaft is attached to differential side gear by splines DIFFERENTIAL CARRIER Differential carrier is attached to axle housing by cap screws or st...

Page 573: ...orts shift fork Slidi ng clutch gear mounted over REAR AXLE 4 18 left axle shaft is a long sleeve with external gear teeth at inner and outer ends B fig 5 LUBRICATION Lubricant is supplied to pinion b...

Page 574: ...Lock Wire 33 Nut 34 Bearing Cone 35 Bearing Cup 36 Bearing Adjuster 37 Sliding Clutch Gear 38 Adjuster Lock 39 Cap Screw Lock Wire Dowel Gasket Cap Screw 44 Oil Trough 45 Expansion Plug 46 Shift Fork...

Page 575: ...ed from vehi cle when unit is to be completely overhauled Before removing axle assembly from vehicle the axle housing should be checked as instructed in Service portion of this Manual Refer to Service...

Page 576: ...M ark right differential bearing adjuster 8 and cap 7 with punch View C fig 5 for locating purposes at assembly 2 Remove bearing cap bolt lock wires loosen bolts then remove cotter pin and adjuster lo...

Page 577: ...ge on bed of arbor Press pinion 2 downward and out of cage Remove propeller shaft yoke 16 4 Remove bearing adjusting spacer 4 from pinion and tag for reassembly reference N O TE Some axles also use a...

Page 578: ...to the naked eye Proper bearing cleaning is important Bearings should always be cleaned separately from other rear axle parts 1 Soak all bearings in clean kerosene Diesel fuel gaso line or cleaning s...

Page 579: ...ion thoroughly clean case and cover then assemble case with bolts and mount in lathe centers or V block stand If lathe is not avail able install differential side bearings and mount case in differenti...

Page 580: ...fications at end of this publication H O U SIN G CHECK Refer to the Service portion of this M anual for Bent Housing Check which is accomplished before axle is removed from vehicle AFTER REMOVAL After...

Page 581: ...h indicator must be positioned at right angle to its shaft Both indicators must be in alignment with one another There should be a slight gap between the points Measure and note dimensions of this gap...

Page 582: ...n arbor press as shown in Figure 15 3 Press tapered roller bearing cups 6 and 9 into cage until seated against cage shoulders 4 Install pinion and bearing assembly in pinion cage Install same bearing...

Page 583: ...yoke washer and nut Tighten nut to torque recom mended in Specifications at end of this manual Figure 18 Installing Support Case Bearings then check as previously explained Remove yoke after correct...

Page 584: ...re cross threaded will re sult in dam age to carrier and bearing caps Tighten cap bolts snugly then back off only sufficiently to turn adjusters 3 Turn right adjuster in until punch mark on adjuster i...

Page 585: ...PIN IO N PIN Outside D iam eter 1 4945 1 4955 1 748 1 749 SLIDING CLUTCH GEAR Inside D iam eter 2 186 2 192 2 318 2 321 Width of Clutch Fork G roove 0 687 0 694 0 690 0 695 CLUTCH PLATE Pin Hole I D 0...

Page 586: ...rearward axle DIFFERENTIAL ASSEMBLY Differential in each axle is conventional four pinion type with drive gear bolted to flanged half of differential case The two halves of differential case are machi...

Page 587: ...housing Remove cover assembly with oil seal 15 and bearing 14 Remove and discard cover gasket 3 If seal is to be replaced remove with punch other wise do not disturb 4 If inspection indicates bearing...

Page 588: ...ly including input shaft front heli cal side gear and shifting mechanism from differen tial carrier Remove and discard cover to carrier gas ket Figure 3 Removal or Installation of Side Gear and Washer...

Page 589: ...inter axle differential shift cylinder Remove cover Figure 8 Rem oval or Installation of Lock Out Air Cylinder and grommets discard grommets 7 Remove nut flat washer and grommet from push rod fig 7 8...

Page 590: ...hrust washers JL__1I Shift Cylinder fSt immJ Body Push Rod Shift Fork Figure 12 Rem oval or Installation of Inter Axle Differential OUTPUT SHAFT DISASSEMBLY FWD AXLE 1 Using soft hammer drive output s...

Page 591: ...emove bearing adjusting spacer 26 used between bearings and tag for reassembly reference 3 Bearing cups can be removed from pinion cage with remover J 3940 in manner illustrated in Figure 15 when insp...

Page 592: ...on for Eaton rear axle model 17121 PINION AND CAGE ASSEMBLY FWD AXLE 1 Press pinion inner tapered bearing cone onto pinion with wide portion of cone toward pinion teeth until seated against shoulder U...

Page 593: ...time of disassembly provided original parts are being reinstalled Tighten cap screws only finger tight NOTE To determine shim pack thickness install retainer without shims and tighten cap screws fing...

Page 594: ...ASSEMBLY DIMENSION 4 125 DRIVE GEAR Maximum Run Out 0 003 DIFFERENTIAL CASE Maximum Run Out 0 002 Side Gear Contact Surface I D 2 374 2 376 30DS 2 756 2 758 34DS SIDE GEAR Differential Case Contact S...

Page 595: ...ear drives forward axle IDLER GEAR AND SHAFT FORWARD AXLE An idler gear supported by tapered roller bearings is mounted between drive gear mounted in adapter case and drive gear mounted on pinion Enti...

Page 596: ...TIAL COVER DRIVE GEAR ADJUSTING SPACER IDLER PINION ADAPTER CASE PINION DRIVE GEAR ADJUSTING SPACER ADJUSTING SHIMS PINION GEAR DIFFERENTIAL CARRIER BEARING AND OIL SEAL RETAINER DIFFERENTIAL ASSEMBLY...

Page 597: ...HALF BOLTS THRUST BLOCK IDLER GEAR SHAFT A HEAR BEARING REAR BEARING CUP H A R I N G SPACING SLEEVE WASHER IDLER SHAFT NUT COTTER KEY BEARING CUP REAR TAPERED BEARING UPPER DR IVE GEAR FRONT TAPERED...

Page 598: ...inter axle differential assem bly from cover fig 5 Do not damage assembly due to being dropped during pressing operating 4 If original match m arks on two halves of differential case are not clear rem...

Page 599: ...two screws as pullers fig 8 pull bearing cage and cup from adapter 3 Lift gear and bearing cone assembly from adapter fig 9 4 When inspection indicates replacement is necessary bearing cones can be r...

Page 600: ...ation when reassembling 4 Cut lock wire and remove bearing cap screws bearing caps and adjusting rings 5 Straight rod can be used as shown in Figure 14 to assist in removing differential assembly from...

Page 601: ...in arbor press with cage on arbor blocks Press pinion downward and out of cage and gear fig 17 3 Remove bearing adjusting spacer used between bear ings and tag for reassembly reference 4 Bearing cups...

Page 602: ...l carrier and bevel gear shaft bearing cages Apply a thin coating of differential lubricant to all thrust and bearing surfaces to prevent scoring of parts when vehicle is first placed in service Use o...

Page 603: ...all pinion and cage assembly on carrier being sure that oil passage holes are not covered 3 Install cap screws and tighten to recommended tor que Figure 20 Pinion Cage Removal Figure 21 Checking Fit o...

Page 604: ...t washer fig 15 4 Install other half of case over assembly Align mating marks on differential case halves fig 15 Install four bolts holding two halves of case together Draw the two halves together fir...

Page 605: ...th cap screws Install lock wires at locks and bearing caps GEAR TOOTH CONTACT ADJUSTMENT AND BACKLASH Drive pinion is adjusted for tooth contact by means of shims between pinion cage and carrier Drive...

Page 606: ...er Install new gasket to differential carrier 3 Position adapter case assembly to differential carrier and secure with ten cap screws and lock washers Tighten cap screws alternately and evenly to reco...

Page 607: ...ess cage and bearing assembly onto rear end of thru shaft until bearing is seated against shoulder on shaft Press against inner race of bearing 3 Install new oil seal assembly in cage C oat outer sur...

Page 608: ...CKNESS Side Gear and Pinion 0 062o 0 062o CLUTCH SHIFT COLLAR Width of Fork Groove 0 504 0 510 CLUTCH SHIFT FORK Width 0 479 0 484 AXLE SHAFT Number of Splines SLHD 21 Number of Splines SQHD 22 Diamet...

Page 609: ......

Page 610: ...Model Model Type Model Model Type 70 Series Single Rear Axle Conventional C 4035 A Single Diaphragm 70 Series Tandem Rear Axle Conventional 70 Series Tilt Cab C 4036 A C 4058 Tandem Diaphragm Tandem D...

Page 611: ...iaphragm control piston and block vee 25 Remove snap ring retainer and seal ring from hous ing 26 Remove valve cap press fit valve seat valve body and valve spring from housing 27 Remove residual chec...

Page 612: ...ke nut in place 18 Install front diaphragm and plate assembly with pis ton rod through bushing 19 Install snap ring on rear end of piston rod 20 P lace d iaphragm return spring collar and d i aphragm...

Page 613: ...ock Vee 27 Hydraulic Piston Bleeder Screw Washer Seal Ring Check Valve Body Check Valve Seat Check Valve Spring Check Valve Snap Ring Hydraulic Cylinder Body Block Vee Control Valve Piston Diaphragm W...

Page 614: ...ng Bracket 18 Piston 7 7 T A 19 Block Vee 20 Valve Insert 21 Valve Body 22 Snap Ring 32 Valve Seat 23 Washer 33 Seal Ring 24 Snap Ring 34 Retainer 25 Gasket 35 Snap Ring 26 Bushing 36 Valve Cap 27 Pus...

Page 615: ...semble diaphragm retainer diaphragm diaphragm washer control piston and cup seal 4 Install control valve diaphragm assembly in hydraulic cylinder body 5 Place control valve diaphragm return spring in...

Page 616: ...7 Worm Shaft 8 Gear 9 Cover Plate T 2325 alent Before installing this fitting make certain that it is positioned in such a manner as to permit easy access for periodic lubrication if desired when sla...

Page 617: ...pressed 2 Place clamp ring over clamping flange of the non pressure plate aligning m arks made prior to disas sembly 3 Position diaphragm in pressure plate Place pressure plate and diaphragm on the no...

Page 618: ...e the remains of actuator on a smooth surface with the push plate down Connect an air supply shop air line to the locking port By hand press down on the actuator non pressure plate and at the same tim...

Page 619: ...wiped clean Discard felt breather Inspect all parts for excessive wear or deterioration Particular attention should be given to the piston and collar bores in the plate Also the air passage from the l...

Page 620: ...en lock nut and remove stop button 3 Remove three bolts which attach pedal bracket to valve body and remove pedal bracket CAUTION Hold bracket firmly so piston return spring does not cause bracket to...

Page 621: ...ring from valve 10 Disassemble piston assembly a Remove O ring and block vee b Place piston assembly in vise to control pressure of spring c Remove snap ring d Open vise slowly to relieve spring press...

Page 622: ...ve O ring from valve body 7 Remove two bolts which fasten exhaust cover to valve body 8 Remove exhaust cover and remove exhaust check from cover 9 Press inlet and exhaust valve assembly out of valve b...

Page 623: ...ly 5 Remove plunger from plunger seat 6 Remove lower body from body Remove gasket from lower body 7 Remove actuator from body Remove O rings from actuator 8 Remove column from body ASSEMBLY Refer to F...

Page 624: ...then remove piston assem bly 24 and piston spring 4 from body Remove bearing plunger 17 and spacers 18 from piston cup Do not lose spacers 18 Remove O ring 26 and seal 5 from piston 5 Remove cage 3 an...

Page 625: ...spring and seat cup against spacers Measure distance from top of cup flange and bottom edge of snap ring groove as shown in Figure 10 Add or remove spacers 7 as necessary to obtain a dimension of 0 09...

Page 626: ...8 Install piston assembly 24 in valve body small end first Use care not to damage lip of piston seal 5 Small end of piston must enter hole in bottom of valve body as piston is pushed into place Insta...

Page 627: ...valve guide over stem and compress spring d Install exhaust valve on stem 2 Install O ring on insert assembly 3 Install inlet and exhaust valve assembly TC 2 insert in valve body 4 Install piston ret...

Page 628: ...return spring from body ASSEMBLY 1 Position discharge valve return spring in body 2 Install discharge valve assembly in body 3 Compress discharge valve return spring install inlet valve disc assembly...

Page 629: ...cleaning fluid Carefully exam ine small end of plunger which contacts valve if any roughness or damage is evident replace plunger Inspect valve seat in body if seat shows wear or damage replace body R...

Page 630: ...11 10 Cover Screw 11 Lower Body Cover 12 Lower Body O Ring 13 Piston 14 Plunger Nut 15 Plunger Washer 16 Valve Spring 17 Plunger O Ring 18 Plunger 3 Install O ring in valve body 4 Install O rings in l...

Page 631: ...n plunger 8 Using a blunt punch tap the exhaust valve L IG H T 2 Install two O rings on plunger LY from the back of tractor protection valve Plastic 3 Install O ring on check valve seat valve spool sh...

Page 632: ...parts in mineral spirits Dry thoroughly Examine body and end covers for cracks or other signs of damage Inspect plunger surfaces and bores in valve body Remove slight scratches or scores with crocus...

Page 633: ...that order 4 Press the cover and retainer down and with a pair of snap ring pliers and snap the ring into the body groove 5 Install diaphragm and diaphragm washer then secure with cap screw 6 Turn inv...

Page 634: ...on Install piston as sembly in valve body Place two springs in position in valve body Install new O ring on valve cap Place valve cap in position on valve body and secure with two screws CONTROL PORT...

Page 635: ...he time the valve is removed from the vehicle 2 Insert a rod or punch in the plunger pin hole to keep plunger from turning while removing nut at bottom of valve 3 Remove plunger and spring 4 Remove pl...

Page 636: ...rt 7 Cover Screw M 3 8 Piston 1 7 9 Piston Grommet Small iff I D T 5 10 Piston Grommet MMMh Hf IgJ Large 16 lll I P illfflU 11 Nut X 12 Valve Body 15 T SpSp l g a g O 13 Exhaust Port M llj I 14 Seal G...

Page 637: ...th in valve guide Assembly 1 Apply a thin coating of a multi purpose grease N L G I number 1 with a rust inhibitor ingredient to inside of valve guide 2 Place guide and shuttle valve in valve body 3 I...

Page 638: ...d forth in valve guide Assembly 1 Apply a thin coating of a multi purpose grease N L G I number 1 with a rust inhibitor ingredient to inside of valve guide 2 Place valve guide and shuttle valve in val...

Page 639: ...ssion of air Crankshaft is mounted in a ball bearing in front and insert type bearing at the rear Connecting rod bearings are replaceable insert TROUBLESHOOTING CHART This Troubleshooting Chart is to...

Page 640: ...ar 23 14 Bearing Cap Rear 24 15 Crankcase 25 16 Connecting Rod Bearing Cap 26 17 Connecting Rod Bearing Insert 27 18 Crankshaft 28 19 Bearing Cap Gasket Front 29 20 Crankshaft Bearing Front 30 Cranksh...

Page 641: ...ed GOVERNOR OPERATION The air compressor governor consists of two separate units a governor assembly and an unloader valve The un loader valve is mounted directly on cylinder head The governor assembl...

Page 642: ...inder block Water cooled compressor has ten nuts attaching cylinder head to cylin der block Lift head assembly off block Remove cylinder head gasket and discard CYLINDER HEAD DISASSEMBLY Key Numbers R...

Page 643: ...583 Figure 4 Rem oving or Installing Discharge V alve Seats 7 1 4 CU FT COMPRESSOR 1 Remove piston pin lock from inside of piston pin by using 1 16 inch diameter wire then press piston pin out of pist...

Page 644: ...be turned over to use the unworn side If valves have been previously turned over so that both sides are worn or if otherwise damaged re place with new parts If valve seats are pitted or oth erwise dam...

Page 645: ...shaft when tight ening or loosening nuts b Install connecting rod cap and tighten connecting bolt nuts to 8 to 10 foot pounds torque This should flatten Plastigage to 0 002 inch Check measurement on P...

Page 646: ...engine oil to bushing dia phragm and body before assembly 4 Install expander spring around inside of diaphragm then install these two parts in body 5 Install rubber retainer on bushing 6 Place disc i...

Page 647: ...bearing cap ASSEMBLY OF PISTONS AND CONNECTING RODS CRANKSHAFT AND BEARING INSTALLATION 1 Install ball bearing on front of crankshaft Press bear ing on crankshaft until inner race is seated firmly aga...

Page 648: ...g Rod Insert Bearing Connecting Rod Cap Lock Nut Main Bearing Assembly Gasket Front Bearing Cap Nut Stud or Cap Screw Stud Gasket Connecting Rod Insert Bearing Connecting Rod Connecting Rod Bolt Oil R...

Page 649: ...case gasket over studs on top of crankcase Hold cylinder block over crankcase with lower ends of connecting rods extend ing just below top of crankcase then lower cylinder block onto crankcase NOTE Cy...

Page 650: ...y on cylinder head with studs 2 Connect tube assembly to unloader and governor then final tighten governor mounting stud nuts Make sure that tube connections are tight A Inlet Valve Guard V Ii Figure...

Page 651: ...mplete turn of adjuster screw will change cut out pressure 20 psi 3 W hen cut out pressure setting of 100 107 psi is at tained lock adjuster plug with lock nut SPECIFICATIONS VA CU FT U N IT 12 CU FT...

Page 652: ...l Bearing Front Outside Diameter Inside Diameter Crankshaft Main Insert Bearing Rear Inside Diameter i 3792 1 380 Crankcase Bearing Bore 2 8331 2 8338 Discharge Valve Springs Free Length 3i 32 Length...

Page 653: ...ressors the crankshaft is mounted in crankcase on a ball bearing in front and an insert type bearing in rear On gear driven air compres sors crankshaft is mounted on insert type bearings bush ings bot...

Page 654: ...aft Nut 29 Inlet Valve 6 Cylinder Block Gasket 18 Crankshaft Key 30 Discharge Valve Seat 7 Crankcase Rear Bearing Cap 19 Connecting Rod 31 Discharge Valve 8 Bearing Cap Gasket 20 Unloader Piston 32 Di...

Page 655: ...oke discharge valve returns to seat blocking return flow of compressed air to cylinder as cycle is repeated OPERATION WITH UNLOADER VALVES OPEN NOT COMPRESSING Fig 4 When air in system reaches maximum...

Page 656: ...3 Remove two cross recess screws on air strainer cover 4 Remove foam filter element and discard NOTE Refer to Cleaning Inspection and Re pair in this manual for servicing of air strainer components UN...

Page 657: ...let valves from top of cylinder block Figure 23 il lustrates components of cylinder head PISTON AND CONNECTING ROD REMOVAL AND DISASSEMBLY 1 On gear driven models remove screws and lock wash ers attac...

Page 658: ...CLEANING GENERAL Thoroughly wash all parts in a suitable cleaning fluid to remove all traces of dirt oil or grease AIR STRAINER Thoroughly clean all air passages with a suitable clean ing fluid to rem...

Page 659: ...more than 0 004 inches Cylinders must be cleaned thoroughly after honing or boring operation Even slight traces of abrasive material left on the cylinder walls may cause rapid ring and wall wear and e...

Page 660: ...To check fit of bearings on crankshaft install bearing inserts into connecting rod Clean the crankshaft journals Figure 12 Piston Ring Arrangement and Clearances 7 1 4 cu ft Figure 11 Measuring Piston...

Page 661: ...d new seats into head and tighten firmly With new valves discharge valve travel should be from 0 056 inches to 0 070 inches for 12 cu ft mod ASSEMBLY OF NOTE Refer to Figure 15 while assembling air co...

Page 662: ...ainer Cover Washer 38 Wing Nut 39 Air Strainer Manifold Crankshaft Cap Screw 42 Washer 43 Crankcase Gasket Insert Bearing Connecting Rod Cap 19 20 21 24 25 26 27 28 29 30 31 32 33 34 35 36 37 40 41 44...

Page 663: ...d of crankshaft in stall drive hub on shaft and secure with nut and cot ter pin NOTE Crankshaft should rotate freely Place new cylinder block gasket on crankcase Position cylinder block on crankcase a...

Page 664: ...er heads of bolts Refer to Figure 21 8 Install No 2 piston and connecting rod in same m an ner as described in Step 7 9 Install crankcase bottom cover on gear driven m od els using a new gasket with m...

Page 665: ...y and install cylinder head on cylinder block Install cylinder head cap screws and tighten firmly Replace all pipe plugs 4 Install new gasket and replace air inlet elbow C O N N E C T IN G ROD C O N N...

Page 666: ...re enters the governor at one of its reservoir ports and acts on the area of the piston and on top of the inlet and exhaust valve As air pressure builds up the piston moves against resistance of the p...

Page 667: ...ly of governor lubricate governor body bore top of piston piston grooves piston grommets Adjusting Screw Retaining Upper Spring Sea Pressure Setting Spring Cover Lower Spring Seats Grom m ets Adjustin...

Page 668: ...by the dash gauge If the pressure settings of the governor are inaccu rate or it is necessary that they be changed adjust gover nor as described in the following paragraphs ADJUSTMENT 1 Unscrew cover...

Page 669: ...estinghouse Bendix W estinghouse Bendix W estinghouse D 2 243106 244874 243710 244814 244609 243111 243123 103 111 psi 86 90 p si 123 32 D 2 243126 118 126 psi 98 104 psi 1 D 2 243104 123 131 psi 105...

Page 670: ...1 380 1 382 0 001 2 AIR COMPRESSOR SPECIFICATIONS 12 CUBIC FOOT M O D E L NO Capacity A t 1250 R P M Cylinder B o re S tro ke Inlet Valve Seat Worn Groove Not to Exceed Inlet Valve Spring Free H e ig...

Page 671: ...iam eter 1 1242 1 1250 1 1242 1 1250 Main Bearing Journal Diam eter 2 1653 2 1658 Main Bearing Outside Diam eter 3 5427 3 5433 M ain Bearing Inside Diam eter 2 1648 2 1654 Main Bushing Journal Diam e...

Page 672: ...flange is provided at bottom of crankcase skirt for attaching oil pan Both the crankshaft and the camshaft are supported in cylinder block Four camshaft bearings are pressed into bores in block while...

Page 673: ...sion insert type Crankshaft end thrust is taken by a special flanged bearing located at No 3 journal Adjacent cheeks 9 Connecting Rod and Piston Assembly 10 Oil Filter Assembly 11 Oil Pump and Governo...

Page 674: ...steel expansion control band Piston pins are re tained by retainer rings installed in grooves in pin bosses Piston pins are floating fit both in the piston bosses and in the connecting rod bushing Al...

Page 675: ...In most cases special tools are illustrated With engine removed from vehicle a special repair stand should be used to sup port engine when making repairs Engine accessories such as generator carburet...

Page 676: ...old bolts w hich interfere w ith lifter removal CYLINDER HEAD REMOVAL 1 Remove bolts attaching cylinder heads to cylinder block then remove cylinder heads 2 Remove cylinder head gaskets and clean depo...

Page 677: ...counterbore in block FLYWHEEL AND HOUSING REMOVAL NOTE Either of tw o types of flyw heel housings designated as two piece an d apron type for conventional transm issions are used Re m oval of each ty...

Page 678: ...ain holes which return to crankcase the oil which lubricates overhead valve mecha nism and camshaft INSPECTION AND REPAIR OF CYLINDER BLOCK CYLINDER BORE RECONDITIONING Examine cylinder bores for scor...

Page 679: ...1099 13 Front Pilot J 21099 9 Shaft J 21099 11 Drive Button BEARING NO 3 Tool No Tool Name J 21099 6 Adapter J 21099 13 Front Pilot J 21099 9 Shaft J 21099 11 Drive Button BEARING NO 2 Tool No Tool Na...

Page 680: ...removing No 1 bearing except as follows Insert front pilot J 21099 13 into No 1 bearing bore as shown in View B of Figure 12 and use adapter J 21099 5 to drive No 2 bearing out to ward rear 3 Remove...

Page 681: ...se adapter J 21099 7 on rear end of re placer shaft and insert front pilot J 21099 13 in No 1 bearing bore With driving button on front end of shaft drive the bearing in so front edge of bearing is fl...

Page 682: ...s in crank shafts ALIGNM ENT OF BEARING JOURNALS With crankshaft supported at front and rear journals check alignment at adjacent intermediate journals using dial indicator If run out is in opposite d...

Page 683: ...pitting or other imperfections If any damage is evident new bearing halves must be used A complete set of new bearing halves should be used when re placement is made Never use a new bearing half with...

Page 684: ...TO RED HEAT AS METAL STRUCTURE WILL BE CHANGED Install ring gear on flywheel as soon as possible after ring is heated Make certain that chamfered edge of ring gear teeth are installed toward engine s...

Page 685: ...ipping or flaking out of bearing melai if a visual inspection reveals any of these defects replace with new pair of bearing halves Measure each bearing half with accurate reading tube micrometer Take...

Page 686: ...connecting rod and in proper cylinder Refer to Figure 44 for location of numbers on connecting rod and cap PREPARING CYLINDER BORES W HEN R E R IN G IN G PISTONS Inspect top of cylinder bores for ring...

Page 687: ...ate and shoulder on camshaft Correct clearance is 0 0045 to 0 0085 inch 4 Inspect camshaft sprocket or gear for wear and dam age at teeth If gear teeth are not in good condition gear must be replaced...

Page 688: ...elief Valve 7 Outer Rotor 3 Valve Spring 8 Cover 4 Spring Cap 9 Cover Bolt 5 Oil Inlet 10 Pump Body below which is applicable with crankshaft either removed or remaining in the cylinder block NOTE The...

Page 689: ...with tooth pitch line not project beyond either front or rear surface of gear hub 3 Bore bushing to 1 4005 to 1 4015 inch diameter in ENGINE FRONT COVER OIL SEAL AND CRANKSHAFT PULLEY INSPECTION Inspe...

Page 690: ...ody 10 2 Remove inner rotor and shaft assembly 6 from body and remove outer rotor 7 3 Remove relief valve spring cap assembly 4 from pump body then remove spring 3 and valve 2 Cleaning and Inspection...

Page 691: ...nner valve shaft 4 in cover and spin ner valve housing 11 and in cover 6 If excessive clearance is evident replace parts as necessary 8 Inspect thrust washer 8 for wear 9 Clean passages through spinne...

Page 692: ...valve stems Discard valves if not usa ble WARNING All engines have sodium cooled type exhaust valves Sodium cooled valves must not be discarded with other scrap metal If a sodium cooled valve is accid...

Page 693: ...st valve seats is 45 degrees After grinding use dial indicator to check concen tricity of valve seat with pilot hole Seat should be concentric with pilot within 0 002 inch e After grinding seats that...

Page 694: ...der respective headings WATER PUMP FOR 401M AND 478M ENGINES Key numbers in text refer to Figure 35 DISASSEMBLY 1 Support hub 1 on press and press the shaft out of hub 2 Insert spacers between impelle...

Page 695: ...bes then install camshaft and gear assembly in bearings in cylinder block 2 Attach camshaft thrust plate to cylinder block with two screws CRANKSHAFT REAR BEARING OIL SEAL Crankshaft rear bearing oil...

Page 696: ...cylinder block bolts to 130 140 foot pounds 6 Tighten the two 1 2 13 rear bearing cap bolts to 55 to 65 foot pounds with torque wrench Turn crank shaft to check for binding in bearings crankshaft must...

Page 697: ...ar shaft then install timing idler gear with timing marks on idler gear indexed with marks on mating gears as shown in Figure 39 Install idler gear retainer plate and secure with two bolts and lock pl...

Page 698: ...ate cone if used at hub and install retaining washer and bolt Tighten retaining bolt with torque wrench to 200 to 210 foot pounds APRON TYPE HOUSING INSTALLATION On engines equipped with one piece apr...

Page 699: ...small hole for identification is used on odd spaced bolts Refer to Figure 44 Six bolts are used on 401 M and eight bolts on 478M engines 3 Tighten flywheel bolts to 100 to 110 foot pounds 4 Mount dia...

Page 700: ...l toward top of piston 3 Installing Piston and Connecting Rod Assembly a Apply engine oil on piston pin and piston rings Wipe cylinder bores with clean cloth and thor oughly coat cylinder bores with e...

Page 701: ...et attach the oil inlet screen and pipe assembly to oil pump body with bolts finger tight Bolt holes in tube flange are large enough to pern it swinging suction tube to obtain dimension shown in Figur...

Page 702: ...ush rods in place in sockets in lifters 3 Referring to Figure 52 assemble rocker arms 12 springs 7 and brackets 4 on rocker arm shaft 6 then install end brackets 1 Lubricate all moving parts with engi...

Page 703: ...intake and the exhaust valve on No 1 cylinder will then be closed 3 On 401M and 478M engines adjust valve lash on No 1 exhaust valve front valve to exactly 0 054 inch 4 Turn engine clockwise until No...

Page 704: ...n Back Holes 3 Oil From Camshaft Front Bearing 10 Oil Filter 4 Rocker Arm Shaft Front Bracket 11 Oil Pump Inlet Screen 5 Rocker Arm Shafts 12 Oil Pump 6 Rocker Arm Shaft Rear Bracket 13 Piston Pin Spl...

Page 705: ...er to Section 6M DIMENSIONS AND CLEARANCES New Limits NOTE Except as otherwise indicated the di mensions listed are applicable to all engines CYLINDER BLOCK Cylinder Bore Std 4 0 1 M 4 8741 4 8779 4 7...

Page 706: ...8708 2 4 8708 4 8711 3 4 8711 4 8714 4 4 8714 4 8717 5 4 8717 4 8720 6 4 8720 4 8723 7 4 8740 4 8743 478M Engine 1 5 1199 5 1202 2 5 1202 5 1205 3 5 1205 5 1208 4 5 1208 5 1211 5 5 1211 5 1214 6 5 12...

Page 707: ...re in Body 0 6098 0 6108 1 D of Outer Rotor Cavity in Body 2 6300 2 6340 Depth of Rotor Cavity V 6 Engines 1 10H 1 1029 O D of Outer Rotor 2 6240 2 6230 Clearance Between Inner and Outer Rotors 0 0010...

Page 708: ...f corrosion fract ure or weakness Rocker arm spring should always be replaced since it is subject to constant action whenever engine is running 5 Remove stake marks from valve recesses of pump covers...

Page 709: ...pump link 2 Remove three short screws identification tag and choke control bracket then remove the four long screws and separate the carburetor assembly into three basic groups shown in Figure 1 NOTE...

Page 710: ...body and remove gasket Disassembly Key numbers in text refer to Figure 5 Remove diaphragm cover screws and lock washers 22 then remove cover 21 outer diaphragm 20 diaphragm and rod assembly 19 and go...

Page 711: ...ION All parts included in repair kit should be installed re gardless of apparent condition of old parts Experience has proven that these parts generally require replacement when overhauling carburetor...

Page 712: ...of any part is in doubt replace with a new part Bearings 2 fig 6 can be inspected without removing them from throttle body Replacement of throttle shaft bearings and seal in throttle body is covered...

Page 713: ...g screws in lightly against seats then backing each screw out one complete turn 6 Install throttle driver assembly on throttle body Spe cial screw is used at bottom hole and serves as stop for idle sp...

Page 714: ...numbers in text refer to Figure 1 1 Firmly support throttle body in manner to prevent damage to throttle plates Locate gasket 10 at throttle body assembly and gasket 5 at main body assembly Set main b...

Page 715: ...am...

Page 716: ...with sealing com pound used between the flange and field frame A com pression type shift lever return spring is located inside the solenoid case On starting motor shown in figure 2 positive lubricati...

Page 717: ...upling or cylinder butts against edge of retainer fig 5 Tap end of coupling with hammer to drive retainer down toward armature and off snap ring c Remove snap ring from groove in armature shaft If sna...

Page 718: ...armature and off snap ring 6 Remove snap ring from groove in shaft using pliers or other suitable tool If snap ring is distorted during removal it must be discarded and a new one obtained for assembl...

Page 719: ...ator end frame On starting motors shown in figure 1 the commutator end frame must be replaced if the bushing is damaged or worn excessively On all other models the bushing may be replaced 6 Inspect co...

Page 720: ...ush holders are insulated from the end frame and two are grounded Test each insulated brush holder by placing one test prod on insulated brush holder and one on end frame If lamp lights brush holder i...

Page 721: ...g and collar over the sleeve and retain with lock wire The heavy duty type overrunning clutch assembly shown in figure 10 may be disassembled to the extent re quired to replace the pinion or the meshi...

Page 722: ...air of pliers as shown in Figure 11 to force retainer over snap ring 4 Lubricate bushing in drive housing with silicone type grease Make sure thrust collar is against snap ring and retainer then slide...

Page 723: ...asher 5 Insert armature shaft into nose housing and engage shift lever yoke with groove in drive clutch shift col lar 6 Push lever housing into counterbore in nose housing noting alignment marks made...

Page 724: ...posi tion and will remain there until the battery is discon nected 3 Push the pinion back toward the commutator to elim inate slack movement 4 Use a feeler gauge as shown in figure 13 to measure clear...

Page 725: ...imum RPM 3600 6025 3800 Maximum RPM 5100 6000 S T A R T IN G M O T O R M O D E L S 1107586 a 1113659 a 1114101 b 1114121 b No Load Test Volts 10 6 11 0 11 5 Minimum Amps 75 105 90 Maximum Amps 100 155...

Page 726: ...l cause excessive pitting of contact points 5 Inspect shaft and bushings in housing for signs of wear If bushings are worn or damaged replace com plete housing and bushing assembly DISTRIBUTOR ASSEMBL...

Page 727: ...SERIES 70 80 HEAVY DUTY TRUCK SHOP M AN U AL Screws 6 Weight Cover 7 Weight Springs 8 Advance Weights 9 Wick Felt 10 Cam Assy 1 I Main Shaft Assy 12 Roll Pin 13 Drive Gear 14 Pin 15 Washer 16 Cushion...

Page 728: ...bearing eliminates need for periodic lubrication Two slip rings insulated from rotor shaft are contacted by the two spring loaded brushes mounted in brush holder and terminal assembly Brushes and slip...

Page 729: ...any lubricant from end of rotor shaft has come in contact with brushes wipe brushes clean A non toxic solvent may be used if necessary to clean brushes 4 Remove three lead attaching nuts and lock wash...

Page 730: ...hod Connect ohmmeter leads to the two slip rings and note the resistance reading If the resistance is less than 4 6 ohms there is a short cir cuit in rotor winding NOTE If an ohmmeter is not available...

Page 731: ...eat sink Sincc the capacitor rating is only 0 5 microfarads it is impractical to test the capacitance with conventional equipment however when generator is disassembled for overhaul a check should be...

Page 732: ...moved from end frame loosen screw which holds strap fig 14 at brush holder so lower end of strap can be disengaged from junction terminal without bending strap Also disengage negative diode leads from...

Page 733: ...ce diode leads in pairs on the three junction studs NOTE Do not install nuts on studs until stator is being assembled to slip ring end frame Diode Junction Stud and Insulators Diode junction studs and...

Page 734: ...ushes may be replaced as instructed in following steps referring to Figure 14 for key numbers 1 Remove the two brush holder retaining screws 7 and 8 and the brush holder 2 with strap 3 from slip ring...

Page 735: ...sting G e ne rator 1 Place inner spacer 1 fig 8 on forward end of rotor shaft Place drive end frame and bearing assembly on rotor shaft then install outer spacer 6 fig 8 on rotor shaft 2 Place fan on...

Page 736: ...s mounted at slip ring end frame assembly and capacitor lead is attached to insulated heat sink Stator assembly consists of three sets of windings as sembled at inner side of laminated core which is m...

Page 737: ...assembly must be replaced Checking for Open Circuit With Test Lamp or Ohm meter fig 5 Touch the leads from lamp or ohmmeter to End Frame Bat Terminal Field Terminal Capacitor Relay Terminal TPM 9815 1...

Page 738: ...checks 2 Check for grounded stator windings by attaching one lead from ohmmeter or test lamp to stator shell and other lead to any one of the stator winding leads If the test lamp glows or if ohmmete...

Page 739: ...connections to determine state of diode 8 To check the No 3 negative diode place a probe on the No 2 cut stator lead diode end and the other probe on the negative heat sink Reverse these con nections...

Page 740: ...s in end frame 2 Inspect bearing assembly If bearing is in good condi tion it may be re used otherwise install new bearing assembly Do not reuse bearing if there is evidence that bearing has had insuf...

Page 741: ...rs from battery terminal at outer side of stator shell Remove bolt lock washer and special bushing which retains positive heat sink Hold bolt nut with wrench if necessary 4 Remove positive heat sink a...

Page 742: ...ay d am age the good diodes To install a new diode support the flat heat sink sur face underneath the diode hole with a smooth flat surface such as the support tool J 9717 2 and press the new diode in...

Page 743: ...lead to brush holder with terminal bolt nut and lock washer Compress brush spring into brush slot insert brush against spring and wrap brush lead over catcher as shown Insert the two brush holder moun...

Page 744: ...Amps 4 14 4 62 Volts 12 Cold Output at Specified Voltage Specified Volts 14 0 Amps 20 Generator R P M Approx 1100 Amps 55 Generator R P M Approx 2500 Rated Hot Output Amps 62 If generator output is c...

Page 745: ......

Page 746: ...or in stallation of power take off unit Figure 1 N e w Process 5 Sp eed Direct Drive T ransm ission Shift Pattern TRANSMISSION OVERHAUL GENERAL Certain precautions should be observed when over hauling...

Page 747: ...Speed Sliding 28 Countershaft 1st Speed Gear 47 Synchronizer Outer Stop Ring Clutch teeth Front 10 2nd Speed Synchronizer 29 Countershaft 2nd Speed Gear 48 Synchronizer Inner Ring Inner Ring Teeth Fr...

Page 748: ...TRANSMISSION AND CLUTCH 7 3 CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP M ANUAL Figure 3 Transm ission C o m p o n e n ts New Process M o d e l 541G L S h o w n...

Page 749: ...Speed Gear 11 Retaining Ring Split 12 Mainshaft 3rd Speed Gear 13 3rd Speed Outer Stop Ring 14 Lock Pins 15 4th and 5th Speed Shift Fork 16 2nd and 3rd Speed Shift Lug 17 1st Speed Shift Lug 18 Retai...

Page 750: ...ront Bearing 64 Countershaft Front Bearing Retaining Washer 65 Countershaft Front Bearing Retaining Spacer 66 Retaining Washer Bolt 67 Thrust Washer 68 Countershaft Drive Gear 69 Countershaft 4th Spee...

Page 751: ...sion case 2 Remove retainers and gaskets Discard gaskets 46 60 and 75 Record number of gaskets used at each retainer The same number of gaskets must be used at each retainer when transmission is reass...

Page 752: ...sion case on bed of arbor press fig 7 then apply pressure against front end of counter shaft 71 to force countershaft out of front bearing NOTE If interference is noticed between third speed gear teet...

Page 753: ...sh the following procedures Model 540GL Transmission Bushing Type Key Numbers In Text Refer to Figure 7 1 Remove bolt lock washer and lock plate 6 which retain idler gear shaft 4 at rear of transmissi...

Page 754: ...shims 9 removed Same number of shims should be installed when transmission is reassembled 7 Using snap ring pliers remove snap ring 2 from groove in mainshaft 31 Remove clutch gear 3 and 4th speed ge...

Page 755: ...shafts and case for wear If installation of a new bearing does not correct conditions install new shafts or replace the case 12 Make sure synchronizer sliding clutch slides freely on clutch gear Check...

Page 756: ...gear hub toward rear of mainshaft 8 3 Install two piece retaining split ring 11 fig 4 in groove of mainshaft at front of 3rd speed gear 12 4 Lubricate bore of 4th speed gear 13 and install gear on mai...

Page 757: ...shows only 0 060 inch This is less than the required minimum of 0 070 inch Therefore it will be necessary to remove at least 0 010 inch from the end of all six synchronizer inner ring pins 5 and 6 NO...

Page 758: ...insert interlock pin 21 fig 16 in hole in 4th and 5th speed shift rail 35 With poppet ball 25 and spring 26 in place move 4th and 5th speed shift rail 35 into operating position Install lock pin 14 to...

Page 759: ...n retainer washer bolts 66 fig 3 in countershaft and secure with new lock wire fig 17 5 Install countershaft front bearing retainer 36 and new gasket Tighten attaching bolts firmly On Model 541GL Tran...

Page 760: ...ims 9 as shown in Figure 16 as necessary to reduce clearance Remove shims if necessary to increase clearance Shims are available in two thicknesses for this purpose INSTALLATION OF TRANSMISSION CONTRO...

Page 761: ...0 Solid Length Maximum 0 59375 SHIFTING MECHANISM Poppet Ball Springs Lbs Pressure at 15 16 Reverse 1 reqd painted yellow 40 45 lbs 1st thru 5th 3 reqd 18 22 lbs Clearance Between Shift Fork and 1st a...

Page 762: ...sembly Refer to Brakes Section 5 Service portion of this Manual NOTE Lock transmission in two gears before removing brake drum retaining nut fig 4N 2 Remove bolt and lock washer assemblies then re mov...

Page 763: ...peed gear fig 13N 4 Remove 3rd speed gear retainer ring 3rd speed gear and locating washer 5 Remove 2nd and 3rd synchronizer assembly 2nd and 3rd shift hub sleeve retainer ring and hub sleeve fig 13N...

Page 764: ...Rocker 36 Reverse Latch Plunger Nut 37 Reverse Latch Plunger Nut Cotter 38 Backup Switch Hole Plug 39 Backup Switch Hole Plug Gasket 40 Welch Plug 41 Control Top Screw and Lock Washer Figure 2 N C ov...

Page 765: ...TRANSMISSION AND CLUTCH 7 19 Figure 3 N Transm ission A ssem b ly Exploded V ie w CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP M ANU AL...

Page 766: ...aft Rear Bearing Cap Gasket 49 Speedometer Drive Gear 50 Mainshaft Rear Bearing 51 Transmission Case 52 P T O Cover Plate Gasket 53 P T O Cover Plate 54 P T O Cover Plate Screw 55 Mainshaft Rear Beari...

Page 767: ...ely by using moisture free compressed air or soft lintless ab sorbent wiping rags free of abrasive materials such as metal filings contaminated oil or lapping compound The importance of careful and th...

Page 768: ...lintless cloth or paper to protect them until in stalled Oil Seals Gaskets Etc Replacement of spring load oil seals gaskets and snap rings is more economical when unit is disassembled than premature o...

Page 769: ...how Figure 1 6 N R em ovin g 1st an d Reverse Shift Lug Lockscrew spots where ease hardening is worn through or cracked replace with new gear Small nicks may be removed with suitable hone Inspect shaf...

Page 770: ...ring Shift Bar Housing Assembly 1 Install 4th and 5th shift rod through support and into Figure 1 9 N Installing 4th a n d 5th Shift Fork Rod Roll Pin Figure 2 0 N Installing Interlock Balls 4th and...

Page 771: ...ng from Figure 2 3 N Installing 3rd Speed G e a r a n d W ashe r Figure 2 4 N Installing 4th an d 5th Shift H u b Sleeve transmission case 2 Apply a light coat of permatex No 2 on the outer di ameter...

Page 772: ...ot B earing 3 Install 2nd and 3rd shift hub sleeve and sleeve retainer ring 4 Install 2nd and 3rd synchronizer assembly 5 Install 3rd speed gear with clutching teeth down In stall 3rd gear locating wa...

Page 773: ...b sleeve 9 Turn mainshaft assembly over and install 1st and rev erse sliding gear with shift fork slot down REASSEMBLY OF TRANSMISSION 1 Coat countershaft pilot bearing needles with heavy grease to ho...

Page 774: ...e Rocker 15 4th and 5th Shift Fork 36 Reverse Latch Plunger Nut Assembly lnc Items 16 and 17 37 Reverse Latch 16 Shift Fork Bushing Plunger Nut Cotter 17 Shift Fork Bushing 38 Backup Switch Hole Plug...

Page 775: ...he transmission MAINSHAFT REMOVAL 1 Remove parking brake parts if used 2 Remove nut and pull companion flange and brake drum if used from rear end of mainshaft 22 3 Remove speedometer driven gear 29 a...

Page 776: ...tershaft Front Bearing 8 Gearshift Lever Spring 25 Mainshaft Rear Bearing Cap 42 Clutch Release Yoke 9 Spring Seat Washer 26 Speedometer Drive Gear Spacer 43 Release Yoke Cross Shaft 10 Dust Cover 27...

Page 777: ...ure 7 carefully pry the countershaft front bearing 44 out of transmission case DISASSEMBLY OF SUBASSEMBLIES CONTROL TOWER DISASSEMBLY Key numbers in text refer to Figure 7P NOTE On transmissions havin...

Page 778: ...18 5 While holding hand over poppet ball hole in housing rod support to prevent loss of poppet ball and spring remove 2nd and 3rd shift rod 17 lug 18 and fork 8 from housing Remove poppet ball and spr...

Page 779: ...ar rod support 11 Remove lock screw 4 from 1st and reverse rocker lug 11 and from 1st and reverse shift lug 3 12 Remove 1st and reverse shift rod 6 rocker lug 11 and shift lug 3 13 Remove cotter pin f...

Page 780: ...e 11 P unless other wise specified 1 Remove the 4th and 5th speed synchronizer assembly 8 from the mainshaft 43 2 Remove 1st and reverse sliding gear 42 from main shaft then place balance of the assem...

Page 781: ...TRANSMISSION AND CLUTCH 7 35 Figure I I P Transm ission Exploded V ie w CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL...

Page 782: ...7 Remove 3rd speed gear 14 thrust washer 15 and 2nd and 3rd synchronizer assembly 16 8 Remove 2nd speed gear retaining ring 17 washer 18 and 2nd speed constant mesh gear 51 from mainshaft 43 9 Remove...

Page 783: ...ction shows clutch release bearing assembly on support are damaged press bearing off support Re place damaged parts 2 Using a press and suitable sleeve press new bearing on support Clutch Housing Repl...

Page 784: ...ng 17 parallel to retaining washer 18 slip snap ring into snap ring groove in mainshaft 43 c Select variable thickness 2nd speed gear retaining washers 18 until a washer is selected that will assure a...

Page 785: ...rough rear support boss driving installer tool out f Align lock screw hole in shift fork with hole in shift rod then install lock screw 13 tighten screw firmly and secure with new lock wire g Move shi...

Page 786: ...r countershaft rear bearing 32 in rear of case far enough so front of counter shaft can be lowered into position Push countershaft 34 forward into position in front bearing 44 4 Using suitable install...

Page 787: ...n flange on rear end of mainshaft 12 With transmission still locked up in two speeds at the same time install companion flange nut Tighten nut to 250 foot pounds torque and install a new cotter pin SH...

Page 788: ...t and Reverse Gear Number of Teeth Outer 53 Backlash with M ate 0 005 0 010 Number of Splines Inner 6 Hub Width 2 3 32 Mainshaft 2nd Speed Gear Inside Diameter 2 883 2 884 Number of Teeth Outer 45 Bac...

Page 789: ...r Washer Select One at Assembly Thick Inside Diameter 1 809 1 819 Outside Diameter 2 927 2 937 Thickness 0 154 0 156 Splines Inner Number 10 Teeth Outer Number 17 Notches Outer Number 2 Notch Inner Nu...

Page 790: ...te overhaul of the transmission The transmission should be overhauled in sequence described unless only one unit is to be worked on CONTROL TOWER REMOVAL NOTE On transmissions having a convention al g...

Page 791: ...ed Gear 32 Countershaft Rear Bearing 51 4th Speed Gear 14 Shift Bar Housing 33 Countershaft Rear Bearing Retainer Washer 15 Mainshaft 3rd Speed Gear Cap Gasket 52 4th Speed Gear Bushing Sleeve 16 Popp...

Page 792: ...6 from gear pocket or from pilot end of mainshaft 22 9 Remove speedometer drive gear 27 and spacer 26 if used 10 Push mainshaft assembly 22 toward rear of trans mission case far enough so mainshaft re...

Page 793: ...shift Lever 4 Pivot Pins 5 Gearshift Lever Support Spring 6 Control Tower Top shaft rear bearing 32 out of transmission case far enough to remove snap ring from bearing 2 Using a suitable puller remov...

Page 794: ...t pins 4 SHIFTER BAR HOUSING DISASSEMBLY Key numbers in text refer to Figure 9 or 10 1 It is suggested that each shift rod shift fork and shift lug be tagged so they can be properly positioned when th...

Page 795: ...er Arm 11 2nd and 3rd Shift Rod 12 Interlock Balls 13 1st and Reverse Rocker Lug 14 Pivot Pin Late Type 15 Interlock Cross Pin 16 1st and Reverse Shift Lug 17 1st and Reverse Shift Rod 18 Shifter Bar...

Page 796: ...ey 89 from slot in countershaft 52 3 Remove drive gear spacer 84 Remove 4th speed gear 85 and 3rd speed gear 86 in same manner used to remove the drive gear 4 4 Remove two remaining Woodruff keys 89 f...

Page 797: ...3 3 3 4 35 TRANSMISSION AND CLUTCH 7 51 CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP M AN U AL Figure 1 3 Transmission C o m p o ne nts...

Page 798: ...re not recommended replace all damaged parts 10 Inspect all bushings for wear or other damage 11 Check keys and keyways for condition 12 Inspect shift forks for wear distortion or other dam age 13 Che...

Page 799: ...snap ring toward pilot end of gear Support front inner race of bearing and press gear into bearing tight against front face of gear 3 Install bearing retainer nut or snap ring 78 COUNTERSHAFT ASSEMBL...

Page 800: ...place retaining washer 10 on mainshaft 43 and hold down securely a gainst bushing sleeve 12 b While holding snap ring 9 parallel to the re taining washer slip snap ring into snap ring groove in mainsh...

Page 801: ...33 tapered end first through shift fork from rear side to compress poppet spring 27 c Insert 1st and reverse shift bar 37 through opening at rear of housing 33 d Position shift fork 38 and installer t...

Page 802: ...sition main drive gear and bearing assembly 5 into front of case so that drive gear engages and meshes with countershaft drive gear 43 and snap ring on bearing 5 contacts transmission case It may be n...

Page 803: ...s 10 Backlash with Mate 0 005 0 010 2nd Speed Gear Inside Diameter 3 124 3 125 Outside Diameter 7 684 7 694 Number of Teeth Outer 53 Backlash with Mate 0 005 0 009 Number of Teeth Inner 23 Backlash wi...

Page 804: ...1 249 9 1 250 REVERSE IDLER GEAR BEARING SPACER Inside Diameter 1 4715 1 4235 Outside Diameter 1 6875 Width 1 250 SPRINGS 1st and Reverse Latch Plunger Spring Free Length Compressed Length 1 1 4 Under...

Page 805: ...meter 1 2656 Outside Diameter 2 1 4 Thickness 0 1615 0 0635 Material S A E 792 BUSHING SLEEVES Mainshaft 2nd Speed Gear Bushing Sleeve Inside Diameter 2 734 2 735 Outside Diameter 2 9997 3 0002 W idth...

Page 806: ...this section for transmission gear ra tios and for transmission application In a conventional transmission which does not have syn chronizers the absence of gear clashing is dependent entirely on skil...

Page 807: ...TRANSMISSION AND CLUTCH 7 61 CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP M AN U AL Kgure 2 Clark 401 Transmission...

Page 808: ...401V transmis sion has a mainshaft pump that supplies mainshaft gear bushings and bearings with adequate oil at all times The pump does not have gears springs valves and pipes the usual pump elements...

Page 809: ...clutch housing 1 M AIN SH AFT REM OVAL 1 Shifting by hand engage the transmission into two speeds at the same time to lock up the transmission 2 Remove propeller shaft brake parts if transmission is...

Page 810: ...nshaft forward and repeat step b Follow these procedures until bearing puller can be used on the rear bearing 19 9 With snap ring picks J 8461 1 remove mainshaft rear bearing locating ring fig 6 10 Us...

Page 811: ...ion case Remove rev erse idler gear 44 from case 3 Remove two reverse idler gear bearings 42 and 45 and spacer 43 from hub of reverse idler gear 44 COUNTERSHAFT REM OVAL 1 Remove countershaft rear bea...

Page 812: ...to Figure 12 1 It is suggested that each shift rod shift fork and shift lug be tagged so they can be properly positioned when the shift bar housing is reassembled 2 Place housing upside down on work b...

Page 813: ...ring remover plates J 8176 or other sui table puller press the mainshaft pilot bearing 68 from front end of mainshaft fig 13 3 Remove 4th and 5th speed synchronizer assembly 67 from mainshaft 52 4 Usi...

Page 814: ...Figure 17 COUNTERSHAFT DISASSEMBLY NOTE Key num bers in text refer to Figure 21 55 Mainshaft 2nd Speed Gear Bushing Sleeve 56 Mainshaft 2nd Speed Gear and Bushing Assembly 57 2nd Gear Retainer Washer...

Page 815: ...TRANSMISSION AND CLUTCH 7 69 Fig 2 1 C lark 401 T ransm ission C om p on en ts CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP M ANU AL...

Page 816: ...in LU B R IC A T IO N SEC 0 of this m anual then w rap each bearing in clean paper until ready to reinstall in transm is sion 2 Remove all portions of old gaskets from parts using a stiff brush or sc...

Page 817: ...aft then press countershaft drive gear 33 on countershaft 38 with long hub toward the rear 6 Install countershaft drive gear retaining ring 32 in groove of countershaft 38 M AIN SH AFT ASSEMBLY NOTE K...

Page 818: ...5 and install 4th speed gear and bushing assembly 64 over bushing sleeve 63 d Place selected washer 65 in position then in stall snap ring 66 into groove of mainshaft Be sure snap ring is well seated...

Page 819: ...smission Shift Rods Installed 1 1st and Reverse Shift Fork 2 2nd and 3rd Shift Fork 3 2nd and 3rd Shift Rod 4 Lock Wire 5 4th and 5th Shift Fork 6 1st and Reverse Shift Rod 7 4th and 5th Shift Rod 8 S...

Page 820: ...ls and pin by trying to shift into two speeds at the same time Shift rods should not shift into more than one speed at a time j Return shift rods to N eutral position CONTROL TOWER ASSEMBLY NOTE O n t...

Page 821: ...20 then using a suitable installer sleeve and hammer in stall mainshaft rear bearing 19 on rear end of main shaft 52 11 Lock transmission gears into two speeds at the same time and tighten countersha...

Page 822: ...50 MAINSHAFT New Limits D iam eter at Pilot E n d 1 3783 1 3788 D iam eter at 4th Speed G e a r 2 3750 2 3755 D iam eter at 3rd Speed Gear 2 6255 2 6260 D iam eter at 2nd Speed G e a r 3 0000 3 0005 D...

Page 823: ...r 2 Outside Diameter 3 Width 0 095 COUNTERSHAFT DRIVE GEAR SPACER Inside Diameter 2 750 2 760 Outside Diameter 2 640 2 652 Width 1 883 1 887 REVERSE IDLER GEAR Diameter of B o re 1 875 1 876 Outside D...

Page 824: ...hick Inside D iam eter 1 933 1 943 Outside D iam eter 3 142 3 152 Thickness 0 166 0 168 Splines Inner Number Teeth Outer Number Notches Outer Number Notch Inner Number 10 18 2 BUSHING SLEEVES Mainshaf...

Page 825: ...ortant and an absolute must when repairing or overhauling the transmission Be fore attempting overhaul procedures thoroughly clean ex terior of the transmission with steam or cleaning solvent to preve...

Page 826: ...ises are caused by worn chipped rough or cracked gears As gears continue to wear the grinding noise will be noticeable particularly in the gear position that throws the greatest load on the worn gear...

Page 827: ...emote controls are used the mechanic must satisfy himself that the remote units are satisfactory and that transmission is actually at fault One other point that should be noted is whether the unit wal...

Page 828: ...or wear out m anu al synchronizers at relatively low mileage 6 Blocker pin detents of the synchronizer worn excess ively resulting in loss of blocker action and crash shifting 7 Blocker pins loose bro...

Page 829: ...33 Mainshaft Rear Bearing Cap 51 Countershaft 3rd Speed Gear 12 Gearshift Lever Oil Seal 52 Countershaft Gear Keys 13 Mainshaft 4th Speed Gear 34 Companion Flange 53 Countershaft 4th Speed Gear 14 Sn...

Page 830: ...If a bearing is not going to be replaced avoid removal during low mileage rebuild Brinelling caused by improper assembly or removal usually hammering with off center blows Use drivers under an arbor D...

Page 831: ...efully lift shifter housing 7 straight up from the transmission case 56 3 Remove and discard the shifter housing gasket REMOVAL OF MAINSHAFT AND M AIN DRIVE GEAR Key Numbers Refer to Figure 1 1 Remove...

Page 832: ...her 19 End Cover 20 Selection Lever Shaft 21 Shift Finger Screw 22 Reverse Shift Finger Stud 23 Reverse Shift Finger 1 Using remover tool J 6648 as shown in figure 3 re move reverse idler gear shaft 2...

Page 833: ...ol tower 6 on edge in vise 2 Remove gearshift knob 1 and grommet 23 3 Depress compression collar 21 against spring 3 and remove pin 2 4 Remove compression collar spring compression cup 4 and felt ring...

Page 834: ...ure 6 1 Using a magnet remove the three poppet springs 4 and poppet balls 3 from top of shifter housing 7 2 Position shifter housing on edge in a vise 3 Tap 4th and 5th shift fork 12 forward to move 4...

Page 835: ...ntil ready to install in transmission GEARS AND SHAFTS 1 Check operating gear teeth for pitting on tooth faces Gears with pitted teeth should be replaced 2 Check all engaging gear teeth Gears with tee...

Page 836: ...eed gear 4 with key and press gear on the countershaft Install 4th gear snap ring 3 in groove of countershaft 6 Align countershaft drive gear 2 with key and press gear on the countershaft Install coun...

Page 837: ...at interlock in notch of rod 11 Select the shortest shift rod 11 and enter poppet end of rod into upper expansion plug opening Position 4th and 5th shift fork 12 on rod as shown in figure 11 Tap shift...

Page 838: ...is flush with case NOTE Be sure to coat outer edge of b ear ing retainer with sealing cement 2 Lower countershaft assembly into transmission case guiding rear end of shaft 55 out through rear bearing...

Page 839: ...e sleeve top bearing into place The bearing snap ring should be flush with rear of transmission case 7 Press speedometer drive gear 32 or spacer onto the mainshaft and seat against bearing 8 C oat mai...

Page 840: ...ring Bore 3 1496 3 1506 Countershaft Rear Bearing Bore 3 5433 3 5443 Reverse Idler Shaft Bore 1 0005 1 0015 SH A FTS NEW LIMITS M ainshaft Diameter at Pilot Bearing 1 3096 1 3 1 0 1 Diameter at 2nd an...

Page 841: ...0 004 0 007 Hub W idth 1 4 36 l 438 Width of K e y w a y 0 250 0 252 M ainshaft 4th Speed Gear Transm ission M odel 5652 Inside Diam eter 2 1527 2 1532 Num ber Teeth Outer 29 Backlash with M a te 0 0...

Page 842: ...2 0 624 Length 8 032 8 094 POPPET A N D INTERLOCK PA RTS NEW LIMITS Poppet or Interlock Ball Diam eter 0 374 0 376 Poppet Ball Spring Free Length 1 120 1 140 Com pressed Length 1 0 03 l 023 Under 21 t...

Page 843: ...9 from bearing cap then remove bearing 38 from cap M AINSH AFT A N D GEARS 1 M ark shift collars 4 and 8 and clutch gears 5 and 9 so they may be assembled in same positions when rebuilding transmissio...

Page 844: ...shaft Rear Bearing C a p 24 Shims 25 Drain Plug 26 Transmission Case 27 Countershaft PLAN V IEW OF CONTROL COVER 28 Countershaft Gear 29 Woodruff Key 30 Snap Ring 31 Bearing Cup 32 Bearing Cone 33 Mai...

Page 845: ...shaft 3 Press bearing cone on each end of countershaft being sure that cone seats firmly against shoulder on coun tershaft M AIN SH AFT A N D GEARS 1 Lubricate bearing surface on mainshaft with transm...

Page 846: ...ut evidence of binding and without perceptible end play After correct adjustment is obtained remove front bearing cap 42 4 From inside case install main drive gear 36 with bearing 35 into case and sec...

Page 847: ...O D Gear to Countershaft Gear 0 006 0 009 Mainshaft Gears to Sliding Clutches 0 004 0 007 Sliding Clutches to Clutch Gear 0 004 0 007 CLEARANCE BETW EEN Shifting Forks and Shift Collars 0 005 0 016 SH...

Page 848: ...ove countershaft front bearing cup 48 from case 11 Remove power take off covers and filler plug from case DISASSEMBLY OF SUBASSEMBLIES Key numbers in text refer to Figure 1 M A IN DRIVE GEAR A N D BEA...

Page 849: ...t Overdrive Gear 10 Direct and Overdrive Shift 26 Mainshaft Rear Bearing Assy 45 Countershaft Keys Rod 27 Mainshaft Rear Retainer Cap 46 Countershaft Drive Gear 11 Mainshaft Overdrive Gear Assy 47 Tra...

Page 850: ...arbor press and suitable driver press countershaft ov erdrive gear 44 and drive gear 46 into place Refer to marks made at disassembly for correct relative position of each gear Figure 3 C over a n d...

Page 851: ...cap assembly temporarily with new gasket Tighten cap screws evenly and firmly Then slide countershaft 2nd speed gear 41 into place on coun tershaft and install snap ring 40 in groove ahead of 2nd spe...

Page 852: ...Countershaft Rear Bearing Cap Shim Thickness 0 003 0 010 0 030 SHIFT ROD POPPET SPRING Free Length approx 1 53 64 Lbs Pressure 1 1 4 36 40 GEAR BACKLASH Main Drive Gear to Countershaft Drive G e a r 0...

Page 853: ...S DISASSEMBLY Figure 1 1 Remove retaining capscrews lock nuts and lock washers Separate cover 1 from case and gasket 2 Remove the two poppet retainers 2 from side of case and use small magnet to remov...

Page 854: ...Be sure interlock is seated in neutral notch of shift rod 8 Enter 3rd 4th speed shift rod 8 in top shift rod opening 9 With long hub toward the front assemble 3rd 4th Figure 2 T ransm ission A ssem b...

Page 855: ...and wash all parts thoroughly MAINSHAFT 1 Use a suitable puller and remove drive gear pocket bearing 12 from front of mainshaft 2 Remove retaining cap screws with lock washers from mainshaft and coun...

Page 856: ...ss shaft into gear Seat shoulder firmly against gear 3 Support hub of 4th speed overdrive gear 6 with long hub down and chamfer up Set countershaft into position align key with keyway and press shaft...

Page 857: ...rings Add or remove shims 15 behind rear bearing cap to se cure zero end play without preload Shaft should roll free to slight drag of 2 3 pounds pull with cord wrapped ar ound 2nd or 4th speed gear 1...

Page 858: ...nd Yoke or Companion Flange 10 Drive Gear Bearing Cap Gasket 11 Remove mainshaft sub assembly from vise and as semble to case by lowering rear of shaft into case and out through mainshaft rear bearing...

Page 859: ...ted against spacer 4 Coat O D of oil seal 7 with Permatex or equiva lent and assemble to front of bearing cap CAU TIO N Use care to prevent distortion of seal NOTE If slinger 8 has been removed from c...

Page 860: ...21 from rear of mainshaft 23 If underdrive clutch gear 21 is a loose fit on mainshaft splines it may be removed at this time If spline fit is tight leave clutch gear 21 in place to retain mainshaft u...

Page 861: ...haft Underdrive Clutch 34 Collar 35 Mainshaft Underdrive Clutch 36 Gear Mainshaft Rear Bearing Snap 37 Ring 38 Mainshaft Mainshaft Flange Nut 39 Mainshaft Rear Bearing Mainshaft Underdrive Gear 40 Cou...

Page 862: ...very small nicks 5 Snap rings should be replaced with new parts when the transmission is reassembled New gaskets should be used 6 Refer to Specifications at end of this section for fits and tolerances...

Page 863: ...enter support 7 Line up set screw hole of fork with slot in rod and start set screw 7 Tighten the 7 16 20 alloy set screw to 80 85 foot pounds torque Secure set screw with lockwire 9 8 Shift underdriv...

Page 864: ...unds torque Omit two cap screws which hold parking brake cable bracket to case 23 Install drain plug 33 and tighten securely 24 Shift auxiliary sliding clutch collars 10 and 20 into neutral position 2...

Page 865: ...n Drive Gear Bearing Cap 17 Transmission Main Drive Gear 18 Release Fork 19 Release Fork Ball Stud 20 Release Fork Retainer Spring 21 Pressure Spring 22 Clutch Housing Figure 1 Long Clutch 13 Inch Typ...

Page 866: ...ot necessary to remove yokes 12 from levers 7 or to remove levers from the pressure plate unless necessary to replace parts as indicated later under Inspection and Repair INSPECTION AND REPAIR Prior t...

Page 867: ...needle bearing rollers with Lubriplate No 320 or equivalent then insert rollers in lever around pilot pin fig 4 Position release lever yoke over release lever then insert new pin through yoke and bear...

Page 868: ...lutch assembly bolted to a flywheel with spacers 3 8 inch thick between the pressure plate and flywheel fig 6 7 With clutch bolted to flywheel with spacers in place lay a straightedge across clutch co...

Page 869: ...PLATE ASSEMBLY M a k e Long Model Num ber 13CF Long Part N u m b e r C 50 348 3 GM Part Number 2452539 Width of Drive Lugs on Pressure Plate 1 487 1 490 Clearance Between Lugs and Cover Slot 0 008 0...

Page 870: ...n 7 Eyebolt Pin 8 Eyebolt Needle Bearing Assembly 9 Release Lever Eyebolt 10 Adjusting Nut 11 Adjusting Nut Lock Nut 12 Retractor Spring 13 Release Lever 14 Driven Disc Assembly Pressure Plate Side 15...

Page 871: ...Figure 4 4 Slowly release arbor press until pressure of springs is relieved Remove clutch cover 1 from pressure plate 2 Remove pressure springs 20 and insulator wash ers 19 from pressure plate Remove...

Page 872: ...ssively loose if must be replaced 3 Install bearing as follows a Pack clutch pilot bearing with a small quantity of high temperature lubricant specified in L U B R IC A TIO N SEC 0 b With shielded sid...

Page 873: ...s DRIVEN DISCS Inspect driven disc assemblies for w orn loose and grease or oil soaked facings Check for broken springs loose rivets or cracks in driven disc hub Examine splines in hub for wear and ma...

Page 874: ...ures passage of grease to release bearing retainer and balls Figure 1 2 Use of G u id e Bolts to Assem ble Clutch CLUTCH RELEASE MECHANISM REPLACEMENT See Section 7E of Service Section of this manual...

Page 875: ...ed adjust ing nut firmly with special tool J 7816 and tighten lock nut securely IMPORTANT Levers must be in plane within 0 031 7 Place wood blocks between release levers and edge of cover fig 3 or ins...

Page 876: ...SE LEVERS PRESSURE PLATE Diameter 0 3750 0 3755 Lenath 1 488 603 Diameter of Pressure Plate Pin Hole 0 3765 0 3785 Width of Eyebolt Pin S lo t 0 377 0 379 PRESSURE PLATE Original Thickness Face of Pla...

Page 877: ...ear components ALL TYPE STEERING GEARS 1 M ount the steering gear assembly in a vise or holding fixture with worm shaft in horizontal position to keep the ball nut from running down to end of worm sha...

Page 878: ...Remove lock nut from lash adjuster screw 5 On all steering gear assemblies having a back up ad Figure 3 R em ovin g Pitm an A rm Steering G e a r Rem oved Typical juster loosen lock nut then remove ba...

Page 879: ...sing attaching bolts and lock washers then carefully withdraw top cover worm and ball nut assembly as a unit Remove lower worm thrust bearing 3 Remove top cover from worm shaft Remove upper thrust bea...

Page 880: ...and condition of threads in tapped holes Replace housing if damaged 3 On steering gear assemblies having an expansion plug in gear housing check for looseness or signs of grease leakage If apparent r...

Page 881: ...amp 9 Check top cover for cracks or damage to tapped holes TYPE STEERING GEAR SHOWN IN FIGURE 1 1 Measure diameter of side cover and gear housing Figure 8 R em ovin g Side C over B u sh in g bushings...

Page 882: ...h Adjuster C learance in figure 9 Improvised tool can be made if desired 2 Drive bushing into housing as shown in figure 10 with remover and replacer tool J 5529 or sleeve WORM THRUST BEARING CUP REPL...

Page 883: ...and press cup in until it is firm ly and evenly seated Use old cup to press new cup into place 5 Repeat these procedures for top cover bearing cup re placement PITMAN SHAFT BEARING REPLACEMENT Type S...

Page 884: ...t and balls then test as sembly by rotating ball nut on shaft worm Do not rotate ball nut to end of worm threads as this may damage ball guides If motion of worm nut is not free cause of bind must be...

Page 885: ...g careful not to damage bearings or bushings with ser rated end of the shaft 4 Position a new gasket on gear housing side cover opening 5 Apply proper lubricant to side cover bearing or bush ing Place...

Page 886: ...554 D 2 0 84 1 5020 1 5025 1 6280 1 6295 568 D 46 0 990 1 000 1 7495 1 7500 2 1245 2 1255 Side C o v e r 0 990 1 000 1 7495 1 7500 2 1245 2 1255 Steering Gear Adjustments Worm Bearings Pull to keep wh...

Page 887: ...10 Adjuster Plug Assembly 11 Adjuster Plug Lock Nut 12 Stub Shaft 13 Torsion Bar 14 Top Cover 15 Top Cover to Housing Bolt 16 Worm Oil Seal 17 Return Guide Clamp 18 Clamp Screws 19 Bolt Nut 20 Shaft W...

Page 888: ...Adjuster Plug 25 Lock Nut 46 Oil Seal 7 O Ring Seal 26 Steering Gear Housing 47 Needle Bearing 8 Thrust Bearing Inner Race 27 Expansion Plug 48 Lash Adjuster 9 Thrust Bearing 28 Drain Plug 49 Pitman S...

Page 889: ...t reaches end of travel at top 2 Loosen the adjuster plug lock nut with a suitable wrench Remove the lock nut fig 22 3 Using spanner wrench J 7624 remove the adjuster plug assembly fig 3 DISASSEMBLY 1...

Page 890: ...race 8 upper thrust bearing 9 small O D thrust bearing outer race 10 and thrust bearing spacer 11 on the adjuster plug 7 Press new bearing retainer 12 into needle bearing bore using suitable sleeve f...

Page 891: ...n both hands with thumbs on the valve body Tap torsion bar lightly against work bench This will dislodge the cap from the valve body to cap pin The stub shaft torsion bar and valve cap assembly can th...

Page 892: ...PORTANT Make sure the groove and pin are in line before tapping on cap Hold these parts together during balance of the assembly procedures 4 Lubricate valve spool 15 with Type A hydraulic fluid Slide...

Page 893: ...section 2 Remove top cover bolts 35 and carefully withdraw top cover 32 with worm 38 and ball nut 56 as a unit Remove lower worm thrust bearing N O TE Hold the assembly as shown in figure 14 with han...

Page 894: ...r Clean housing out thoroughly to remove any tapping chips d Drive new connector against housing seat using driv er tool J 6217 fig 16 Be careful not to damage either the connector or housing seat STE...

Page 895: ...ly damage the gear mechanism Grease and oil used at as sembly must be free from dirt or foreign matter When handling parts make sure that hands are clean and that clean cloths are used Prelubricate a...

Page 896: ...back off slightly 1 4 turn 4 Attach J 6459 inch pound torque wrench to the stub shaft and measure rotary valve assembly drag fig 21 5 Adjust thrust bearing so that preload is 1 to 3 inch pounds torqu...

Page 897: ...7 from reservoir 6 Remove pressure union outlet seal 18 from control valve cavity in pump housing Discard seal 7 Using a small punch depress end plate retaining ring 9 enough to allow removal from gro...

Page 898: ...th Check valve assembly for free dom of movement in bore of pum p housing 9 Check all oil passages in pump parts for obstructions Use a piece of tag wire to remove obstructions 10 Check bushing in pum...

Page 899: ...g 23 fig 10 NOTE Arrow on outer edge of pump ring points in direction of pump rotation counter clockwise direction when viewed from the rear of pump 13 Install ten rotor vanes 17 in slots of pump roto...

Page 900: ...resulting in pump failure Install two pressure plate springs 12 one on each dowel pin 20 in pump housing fig 13 17 Lubricate outside diameter and chamfered edge of end plate 10 with vaseline to insure...

Page 901: ...stud 3 and pressure fitting 5 21 Install reservoir and tube assembly 6 over pump housing 23 22 Install new inner seal 4 on pressure fitting and ori fice assembly 5 23 Install pressure fitting 5 in pu...

Page 902: ...pump assembly in a vise with soft jaws as shown in figure 1 then using puller J 8646 02 re move pulley and hub assembly from pump shaft 4 Use a center punch to mark pump housing spanner nut and front...

Page 903: ...ng rollers in pump housing and front insert to be sure they are satisfactory for further service Figure 1 R em ovin g Pulley from Pum p Shaft REPAIR 1 The oil seal can be removed from front insert usi...

Page 904: ...cked 6 Install new O ring on front insert then position insert over drive shaft with pin punch marks on insert and body aligned Support inner end of drive shaft while insert is pressed into body 7 Ins...

Page 905: ...Figure 1 DISASSEMBLY Refer to Fig 1 NOTE The two power cylinders covered in the following overhaul procedures are of the same basic design The only difference is in the stroke length which for a ll mo...

Page 906: ...the guide assembly with the U of the cup toward the bottom of opening in guide 2 Install scraper retainer O ring seal 3 Install the scraper retainer in guide with U side pointing out 4 Insert the wipe...

Page 907: ...r 0 5620 0 5630 UPPER THRUST BEARING Separator Assembly Width 0 350 0 365 Inside Diameter 1 215 1 225 Outside Diam eter 1 698 1 748 Number of Balls 14 STEERING GEAR ADJUSTMENTS THRUST BEARING P R E L...

Page 908: ...735 psi pressure Pump Model 235 P 47 Maximum 4 8 5 2 gpm of Type A auto matic transmission fluid at HYDRAULIC PUM P SPECIFICATIONS Cont d temperature when operating pump at 1500 rpm against 50 psi pr...

Page 909: ...u t 95 105 Ft Lbs Slipper Spring Free Length 0 440 Compressed Length 0 323 under 2 2 lbs POWER STEERING POWER CYLINDER M a k e Saginaw Steering Gear Division T y p e Hydraulic Length and Stroke See C...

Page 910: ......

Page 911: ...ding Tool J 9399 Compressor Shaft N ut Socket J 8118 Spring Pin Puller use w J 2619 J 9401 Hub and Drive Plate Assembly Remover J 2619 Slide H am m er J 5403 Internal Snap Ring Pliers J 21058 Remover...

Page 912: ...1 2 Pilot Bearing Remover J 1242 Injector Timing Tool J 8130 Injector Test Oil J 5286 9 Injector Tube Reamer J 8932 01 Fuel Line Nut Wrench J 9787 Injector Tester J 8538 10 Adapter Plate Part of J 978...

Page 913: ......

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