GMC 1975 ZEO 6083 Maintenance Manual Download

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Summary of Contents for 1975 ZEO 6083

Page 1: ... System TRANS MODES Engine Fuel System 6M Emission 6T ZEO 6083 Control Systems Engine 6Y ZEO 6583 Electrical Transmission 7 Fuel Tank 8 and Exhaust Steering System 9 0MC Wheels and Tires 10 Chassis Electrical 12 TRUCK COACH DIVISION Radiator and Coolant 13 GENERAL MOTORS CORPORATION Recovery System RONTIAC MICHIGAN 48053 Bumpers 14 eneral Motors Corporation 1975 Printed in U S A Miscellaneous GMC ...

Page 2: ...GE NO Vehicle Identification 0 1 Component Identification 0 2 Hoisting Instructions 0 3 Jack Usage Instructions 0 3 Towing Vehicle 0 4 Engine Chassis and Body Maintenance Schedule 0 6 Explanation of Maintenance Schedule 0 7 Recommended Fluids and Lubricants 0 11 Lubrication Details 0 12 Winterization and Vehicle Storage 0 16 The Vehicle Identification and Weight Rating tified as to manufacturer en...

Page 3: ...hole as shown in Figure 5 Date Code The code letter is for the month and the number s are for actual date Ratio Code T 3 07 1 EXAMPLE T A12 3 07 1 built January 12 J 9th month I is not used A twin post hoist of sufficient capacity and with proper adapters and or fittings must be used Front hoisting position is the front engine cross member HOISTING INSTRUCTIONS Figure 4 Transmission Serial Number ...

Page 4: ...w jacking instructions in order to reduce the possibility of serious personal injury 2 The jack is designed for use only when chang ing wheels 3 Never get beneath the vehicle when using jack 4 Do not start or run engine while vehicle is on jack Figure 7 Jacking at Front of Vehicle GENERAL INFORMATION 0 3 FRONT ENGINE REAR SUSPENSION CROSSMEMBER BRACKETS DENOTES APPROVED LIFTING POINTS A 1941 Figur...

Page 5: ...uctions of the towing equipment manufacturer A separate safety chain system must be used For such towing the steering must be unlocked transmission in neutral and the parking brake released Attachments must be to en gine front crossmember Do not attach to bumpers or associated brackets Remember that power brakes and power steering assists will not be available when engine is inoperative When towin...

Page 6: ...em ber A wood spacer block assembly should be placed under the front crossmember See figure 10 to re lieve some of the load from the energy absorbers and bumper This spacer block assembly should be di mensioned constructed of hardwood and bolted together with three thru bolts as shown in Figure 11 Raising front of vehicle so front wheels are four inches off the ground will provide about five inch ...

Page 7: ...r Wheel Bearings Clean Repack 11 Final Drive Boots Output Shaft Seals Check Every 6 months or 6 000 miles 12 Owner Safety Checks 13 Tires and Wheels Inspection 14 Exhaust System Check 15 Engine Drive Belts Check 16 Suspension and Steering Check 17 Brake and Power Steering Check Every 12 months or 12 000 miles 18 Drum Brakes and Parking Brake Check 19 Throttle Linkage Check 20 Underbody Flush and C...

Page 8: ...cator that the disc brake pads need replacing 4 AIR CONDITIONING Check condition of air con ditioning system hoses and refrigerant charge at sight glass Replace hoses and or refrigerant if need is indicated 5 AIR COMPRESSOR Filter should be washed with soap and water solution or replaced 6 TIRES To equalize wear rotate tires as illus trated in Section 10 and adjust tire pressures as shown on tire ...

Page 9: ...cracks fraying wear and tension Adjust or replace as necessary It is recommended that belts be replaced every 24 months or 24 000 miles whichever occurs first 16 SUSPENSION AND STEERING Check for da maged loose or missing parts or parts showing visi ble signs of excessive wear or lack of lubrication in front and rear suspension and steering system Ques tionable parts noted should be replaced by a ...

Page 10: ... Check for proper operation A malfunctioning switch must be replaced Check hoses for proper connection cracking abrasion or deterioration and replace as necessary GENERAL INFORMATION 0 9 28 CARBURETOR FUEL FILTER Replace filter at 12 month 12 000 mile intervals or more frequently if clogged 29 POSITIVE CRANKCASE VENTILATION SYSTEM PCV Check system for satisfactory operation at 12 month or 12 000 m...

Page 11: ...replace as necessary 42 POSITIVE CRANKCASE VENTILATION SYSTEM PCV Check the PCV system for satisfactory operat ion at 12 000 mile intervals and clean filter located in rocker cover Replace the PCV valve at 24 000 mile intervals and blow out PCV valve hose with compressed air Replace deteriorated hoses 43 AIR CLEANER ELEMENT Replace the engine air cleaner element under normal operating conditions e...

Page 12: ... cylinder Delco Supreme 11 or DOT 3 fluid or equivalent Transmission shift linkage Engine oil Chassis lubrication Chassis grease meeting requirements of GM 6031 M Transmission DEXRON I I automatic transmission 4 Qts fluid Parking brake cables Chassis grease Front wheel bearings High melting point lubricant Part No 1051344 Rear wheel bearings Chassis grease meeting requirements of GM 6031 M Body do...

Page 13: ...e seated Figure 12 Engine Oil Viscosity Chart NOTE Non detergent and other low quality oils are specifically not recommended Only the use of SE engine oils and proper oil and filter change intervals assure of continued proper lubrication of the vehicle s engine RECOMMENDED SAE VISCOSITY FIGURE 12 Single grade oils are preferred however multi grades such as SAE 1OW 30 or 1OW 40 are also acceptable ...

Page 14: ... only automatic transmission fluids identified with the mark DEXRON II These fluids have been specially formulated and tested for use in the automatic transmission and are available from the GMC Motor Home service outlet or local service station Check the fluid level at each engine oil change period To make an accurate fluid level check 1 Drive vehicle several miles making frequent starts and stop...

Page 15: ... drain as bolts are loosened 2 Remove cover and allow lubricant to drain Discard old gasket 3 Using a new cover gasket install cover Torque attaching bolts to 24 foot pounds Shield to be bent over breather hole 4 Add four pints of recommended lubricant through fill plug hole or fill until lubricant level is at the plug hole STEERING SYSTEM POWER STEERING SYSTEM FIGURE 19 Check the fluid level in t...

Page 16: ... VEHICLE DRAG LINK ASSY 2 FITTINGS L H TIE ROD 2 FITTINGS FRONT SUSPENSION UPPER AND LOWER BALL JOINTS 2 FITTINGS RIGHT AND LEFT SIDE OF VEHICLE R H TIE ROD 2 FITTINGS STEERING COLUMN TO GEAR SHAFT ASSY 2 FITTINGS STEERING RELAY LEVER 1 FITTING A 1953 ...

Page 17: ...master cylinder reservoir could be an indicator that the disc brake pads need replacing The fluid level must be maintained at 1 4 inch below the top of each reservoir with Delco Supreme No 11 or DOT 3 Brake Fluid or equivalent When replacing the cap be sure to fasten the retainer securely taking care not to let dirt enter the reservoirs Figure 21 Checking Brake Master Cylinder BLEEDING BRAKES The ...

Page 18: ...hicle Each key has a different cross section so that it can be inserted only in certain locks The key with a square head is for the ignition switch only The key with an oval head fits the side entrance door lock the glove box and the external utilities compartment All models have ignition and glove compartment lock cylinders incorporating coded keyways and keys The code letter is located on the ke...

Page 19: ... is sometimes more desirable to have a small stain than an enlarged stain as a result of at tempted cleaning CAUTION When cleaning interior do not use volatile cleaning solvents such as ace tone lacquer thinners enamel reducers nail polish removers or such cleaning materials as laundry soaps bleaches or reducing agents except as noted in the instructions EXTERIOR MAINTENANCE INTERIOR MAINTENANCE t...

Page 20: ... water under pressure against vehicle while assistant inside marks points of leakage if any exist If location of leak has been determined to be around windshield or rear glass dry surface and ap DUST AND WATER LEAKS BODY 1 3 clean lightly with fabric cleaning fluid Soap and water is not recommended as it might set the stain CATSUP Wipe with cloth soaked in cool wa ter If further cleaning is necess...

Page 21: ...called wash primer preferably by spraying to a uniform PAINTING Water which shows up at a certain place inside vehicle may actually be entering at a point other than where water is found Back track path of water to point of entry Apply body sealing compound over all leak points If leakage occurs at door opening check weatherstrip Seal with rubber cement or re place if necessary If door does not fi...

Page 22: ...eld opening will continue to crack or break the newly installed windshield especially when the strain on the glass caused by the obstruc tion is increased by such conditions as wind pres sures extremes of temperature motion of the vehicle etc REMOVAL If cracks in glass extend to outer edge of glass mark body with chalk at these points so that wea therstrip flange opening can be examined later for ...

Page 23: ... Rubber Insert Figure 3 Seating Rubber Insert Into Groove using channel spreader hook of Glass Installing Tool J 2189 02 2 Install Inserter J 2189 4 of Glass Installing Tool J 2189 02 into handle of tool Feed the rubber insert locking strip and insert into the channel and draw the tool through the channel feeding the rub ber insert into position as shown in Figure 2 Use a hitching movement oftool ...

Page 24: ...ssembly 5 Remove filler seal from sash assembly Installation 1 Apply a new filler seal to the sash assembly 2 Install sash assembly Position spacers as shown in Figure 6 NOTE Late model vehicles are not equipped with spacers figure 6 A 3 16 inch gap should be maintained between sill and sash 3 Install retainers 4 Install panels if removed and install trim mouldings GLASS Removal 1 Remove sash asse...

Page 25: ...ype living area side window is now in production on 1975 GMC MotorHomes and Trans Modes The window assembly is identified by its one piece sash and center latch and handle The fiber glass screen the vent sliding glass and the station ary glass are serviced with the window assembly in the vehicle as follows SCREEN AND VENT ASSEMBLY Removal 1 Remove top screen track using reasonably stiff wire shape...

Page 26: ... Figure 1 1 Removing Vent Figure 13 Seating Vent Track BODY 1 9 frame assembly Pull bottom of vent forward and remove vent as shown in Figure 11 NOTE Observe that screen track is wider than and sits in front of vent track 1 The screen and vent are installed by reversing removal procedure Move vent to closed position 2 Place vent track in groove and push against adjacent top vent track Figure 12 Us...

Page 27: ...14 Pull gasket back about six in ches 2 Dislodge mullion center bar with block and hammer Figure 15 Pull mullion to side and lift it out of window frame 3 Using a screwdriver remove stationary gasket or glazing bead completely from assembly 4 From inside vehicle pry stationary glass from butyl sealer using a scraper as shown in Figure 16 An assistant standing outside vehicle should sup port glass ...

Page 28: ... stationary gasket by pushing it into place and locking grooves into window frame Figure 18 NOTE Push stationary gasket back while install ing it to avoid being left with an extra length of gasket It may be useful to soften gasket in hot water 150 F 65 6 C before installation Av oid leaving corner installation to last After in stallation if lumps or uneven seams appear gasket is improperly seated ...

Page 29: ...erator assembly is secured to the window sash by the attaching screw shown in Figure 20 A nylon cord travels around the five operator assembly pulleys behind the cord tension guides and is then secured to a small hook on the window glass Should nylon cord require replacement procure locally Removal 1 Remove screw securing hook to window glass 2 Remove screws securing cord tension guides to window ...

Page 30: ...ass reverse removal procedure REAR WINDOW REPLACEMENT The rear window is retained in the opening by a molded rubber weatherstrip with an insert type rub ber seal When replacing a cracked window it is very im portant that the cause of the glass breakage be deter mined and the condition corrected before a new glass is installed Otherwise it is highly possible that a small obstruction or high spot so...

Page 31: ...cur originating at a point adja cent to end of flange build up NOTE If desired sealing cement can be applied between lip of seal and glass and seal and open ing flange 1 Assemble the rubber weatherstrip to the win dow opening flanges Insert end of glass into its chan nel in the weatherstrip and seat into position using channel spreader hook of Glass Installing Tool J 2189 02 Move tool around glass...

Page 32: ...d and insert pin into aligned holes at wiper arm spline shaft Remove wiper arms from pivot shafts by removing wiper arm retaining nuts See figure 24 2 Remove linkage from wiper motor crank arm by sliding back clip s away from motor figure 25 3 Remove three bolts from transmission pivot shaft mounting bracket as shown in Figure 26 Remove assembly Figure 23 Windshield Wiper Nozzle Alignment INSTALLA...

Page 33: ...shield wiper motor is serviced as an assembly Do not attempt to repair the motor REMOVAL 1 Disconnect hoses 2 at motor and tape end to prevent loss of fluid and entrance of dirt or water into system 2 Loosen cable retaining screw at bottom of mo tor and remove pin from arm on motor assembly See Figure 24 3 Remove connector arms by sliding back clips and disconnecting arms from the motor assembly 4...

Page 34: ...f filter 5 Torque filter to 25 ft lbs using a 5 8 18 nut 6 Reconnect hose to filter ADJUSTMENT BODY 1 17 1 8 A 3931 The door maybe adjusted vertically by loosening the bolts at both hinges as shown in Figure 29 Horizontal adjustment may be made by shim ming or removing metal at the shaded area of the hinges as shown in Figure 30 2 Remove door DOOR SEAL The entrance door seal is replaceable Clean o...

Page 35: ...in Figure 32 and removing all other screws Use care when removing panel to avoid damaging door handle mechanism 5 Remove cotter pin from handle control rod Slide rod out of lever at lock mechanism 6 Remove actuator lever pin and lock button rod clip See Figure 33 7 Remove 2 screws from latch assembly at door frame Remove this portion from the door 8 Remove four 4 nuts and lock tumbler clip Remove ...

Page 36: ...op rivets 3 Install T pin ACCESS DOORS BODY 1 19 5 Install lock button rod clip and actuator lever pin as shown in Figure 33 6 Install inner panel and handle assembly At the same time guide handle rod into lever at lock mech anism 7 Install cotter pin to secure rod to lever 8 Secure upper trim panel with screws 9 Install lower door trim panel and window moulding REMOVAL 1 Remove entrance door Refe...

Page 37: ...actors and anchors for damage that could materially lessen the effectiveness of the belt installation and repair or GENERAL INFORMATION The floor of the vehicle is made of 3 4 plywood sections The plywood sections are bonded and pop LAP BELT MAINTENANCE FLOOR Figure 35 External Utilities Compartment Door LP GAS OR STORAGE DOOR REPLACEMENT Both LP gas door and the storage or motor gen erator door a...

Page 38: ...d passenger seat and is secured by a lip in the front and two screw attachments at each rear corner Housings and Floor BODY 1 2 1 The front wheel houses are made of plastic po lyethylene while the rear wheel houses are fiber glass The front housings are repairable or replaceable if damaged The rear housings are repairable of da maged The entire underfloor area has been sprayed with a rust preventa...

Page 39: ...l on TransMode vehicles The insulation con sists of rigid polyurethane foam panels bonded to an aluminum protective skin and in turn bonded to the sub structure and plywood floor Care should be used in repairing plywood floor so as not to damage the insulation package The insulation panels are re placeable if damaged CAUTION Urethane foam is a flammable material Welding near insulation may re sult...

Page 40: ...7 Areas which must remain accessible for servicing have not been coated with insulation These areas include electrical harnesses structure flanges in terior component mounting surfaces and pre insulated areas CAUTION Urethane foam is a flammable material Welding near insulation may re sult in damage to insulation and or vehicle As previously discussed polyurethane foam pan els insulate the floor a...

Page 41: ...e a sander with a vacuum attachment for dust control whenever possible 4 Resin mixtures may produce toxic fumes and Figure 38 Side and Roof Frame should be used in well vantilated areas 5 Be careful not to get any resin material on clothing 6 Use the proper materials for the job 7 Keep materials utensils and work area clean and dry These repairs involve chemical reactions and dirt or moisture may ...

Page 42: ...as a unit with pedestal assembly SEAT REMOVAL 1 Swivel chair to a 45 position SEATS the following address General Motors Service Information P O Box 7124 Detroit Michigan 48202 SHEET METAL REPAIR BODY 1 2 5 Materials for repairing damaged fiberglass pan els are available in kit form through GM Dealer ships or equivalent kits can be purchased locally A replacement panel should be fitted after the r...

Page 43: ...ll by replacing these four bolts 2 Remove twelve nuts and bolts from base of pedestal Access to nuts can be made through the engine access cover 3 Remove pedestal INSTALLATION 1 Position pedestal over mounting holes 2 Install nuts and bolts to retain pedestal 3 Install seat as described previously in this sec tion DUAL PASSENGER SEAT REPLACEMENT The dual passenger seat is removed in the same manne...

Page 44: ...e with studs through body 2 Install six nuts and washers to retain grille in proper position Figure 42 Disconnecting Wire to License Plate Lamp END CAP swing visor to side Visor can now be removed by loosening hex head bolt at end of visor shaft INSTALLATION Position visor and install threaded end of visor arm into its mounting bracket Tighten hex head bolt and position visor in support clip Figur...

Page 45: ...figure 43 4 Remove end cap from body SPECIAL TOOLS J 2189 02 INSTALLATION 1 Check seal to make sure it is still intact Re place seal if necessary 2 Position end cap in place and install 32 retain ing screws NOTE The seven lower screws are self tapping screws while the 25 screws on the sides and top of the end cap are hi low screws 3 Install screws retaining interior trim to end cap 4 Reconnect lic...

Page 46: ...operation and ambient air will be warmed to the desired level in the same manner The dash outlets are rectangular in design and HEAT We all know what air conditioning does for use but very few understand how or why it works An air conditioner is functionally very similar to a refrigera tor A refrigerator is a simple mechanism which surprisingly enough works quite a bit like a teakettle boiling on ...

Page 47: ...hough heat is intangible it can be mea sured by quantity as well as intensity Thermometers indicate only the intensity of heat The unit for mea suring quantity of heat is specified as that amount necessary to make 1 pound of water 1 degree warmer figure 3 We call this quantity of heat a British Thermal Unit Oftentimes it is abbreviated to B T U Perhaps we can get a better idea of these two charact...

Page 48: ...r attract heat because heat will not flow from one warm object to another equally warm object Since we no longer can draw Figure 4 Melting ice Remains at 32 F 0 C AIR CONDITIONING SYSTEM 1 31 heat out of the foods we no longer are cooling them Now let s see what happens when we put ice instead of cold water into the icebox This time we ll set the thermometer on top of the ice figure 4 When we firs...

Page 49: ...em cooler The latent heat ofvaporization can be even better because it will soak up even more heat Whenever we think of anything boiling we think of it being pretty hot but that s not true in every case Just because water boils at 212 F 100 C doesn t mean that all other substances will boil at the same temperature Some would have to be put into a blast furnace to make them bubble and give off vapo...

Page 50: ...into the Atmosphere If there Figure 7 A Simple R 12 Refrigerator Figure 8 Reusing Refrigerant was some way to remove the heat from the vapor and change it back into a liquid it could be returned to the flask and used over again figure 8 That is where we find the biggest difference be tween the old icebox and the modern refrigerator We used to put in new ice to replace that lost by melting Now we u...

Page 51: ...igure 9 Basic Refrigerant Circuit vacuum A perfect vacuum or region of no pressure has never been mechanically produced Gauge pressure is used in refrigeration work Gauges are calibrated in pounds psi ofpressure and inches of Mercury for vacuum At sea level O lbs gauge pressure is equivalent to 14 7 lbs atmospheric pressure Pressure greater than atmospheric is mea sured in pounds psi and pressure ...

Page 52: ...When the surface level of the refrigerant liquid reaches a desired height the float will have risen far enough to close the valve and stop the flow of refrigerant liquid We have described the float and valve action as being in a sort of definite wide open or tight shut condition Actually the liquid level falls rather slowly as the refrigerant boils away The float goes down gradually and gradually ...

Page 53: ...tion will evaporate more slowly consequently less heat is carried away from our body From the standpoint of comfort air conditioning should control the relative humidity of the air as well as its temperature By reducing the humidity we oftentimes can be just as cool in a higher room temperature than otherwise would be comfortable Laboratory tests have shown that the average person will feel just a...

Page 54: ...compressor it is still a vapor although it is now quite hot and ready to give up the heat that it absorbed in the evaporator One of the easiest ways to help refrigerant vapor dis charge its heat is to send it through a radiator like component known as a condenser The condenser really is a very simple device hav ing no moving parts It does exactly the same job as the familiar radiator in a typical ...

Page 55: ...for ward face of the assembly 1 Rear Head 20 Oil Pump Gears 2 Rear Head to Shell O ring 21 Mainshaft Bearing Rear 3 Rear Discharge Valve Plate 22 Oil Inlet Tube O ring 4 Rear Suction Reed Plate 23 oil Inlet Tube 5 Piston Ring Teflon 24 Axial Plate and Mainshaft Assembly 6 Piston Drive Ball 25 Thrust Race 7 Shoe Disc 26 Thrust Bearing 8 Piston 27 Thrust Race 9 Front Suction Reed Plate 28 Compressor...

Page 56: ...mately 042 inch to the RIGHTofthe cavity centerline A small diam eter hole is drilled in the head between the two The unit number is stamped on a plate attached to the counterclockwise rotation head and a decal arrow indicates the direction of rotation Mainshaft The central mainshaft driven by the clutch pul ley when the coil is energized extends through the front head to the rear head and oil pum...

Page 57: ... the top of the cylinder and the under side of the suction and discharge valve plates The REAR end combination of bearing and races is se lected to obtain 0005 inch low limit to 0015 inch high limit running clearance between the hub sur faces of the axial plate and the front and rear hubs 1 O Ring 21 Front Discharge Valve Plate 39 Rear Suction Reed 2 Front Head Assembly 40 Rear Discharge Valve Pla...

Page 58: ... the high pressure vapor to pass from the front to the rear head Should the cylinder halves be separated during service operations a service type discharge tube bushings and O rings must be substituted Suction Reed Valves A separate three reed suction valve disc is assem bled to both front and rear heads These reeds open when the piston is on the intake portion of the stroke to allow the low press...

Page 59: ...wn too tightly or damage to the O rings may result Figure 13 Condenser and Receiver Dehydrator Type 1 Flexible refrigerant hoses should not be permit ted to contact the hot engine manifold nor should they be bent into a radius of less than 10 times their diameter FAN SLIP CLUTCH A special engine fan is used It is a seven bladed fan limited by means of a viscous clutch to a max imum speed of 3200 r...

Page 60: ...re 15 Evaporator Housing Components Type 1 AIR CONDITIONING SYSTEM 1 43 of liquid refrigerant to the expansion valve at all times Since the entering liquid refrigerant may have some gas in it the tank acts as a separator The gas will tend to rise and the liquid will drop to the bot tom This is why the pick up tube extends to the bottom of the tank insuring gas free liquid R 12 to the expansion val...

Page 61: ...nected in the system high pressure liquid refrigerant enters the valve through the screen from the receiver dehydrator or con denser and passes on to the seat and orifice Upon passing through the orifice the high pressure liquid becomes low pressure liquid The low pressure liquid leaves the valve and flows into the evaporator core where it absorbs heat from the evaporator core and changes to a low...

Page 62: ...the puncture EVAPORATOR The function of the evaporator figures 15 and 16 is to cool and dehumidify the air flow before it enters the passenger compartment The evaporator assembly consists of an aluminum core enclosed in a sheet metal housing located in the front ofthe vehicle chassis Two water drain holes are located in the bottom of the housing Two refrigerant lines are con nected to the sides of...

Page 63: ...e 19 is simply a device for mov Figure 19 Blower Location Typical ing air The blower used in this vehicle is a centrifu gal type fan which forces air across the evaporator and or heat cores to the vehicle interior THERMOSTATIC SWITCH The thermostatic switch figures 15 and 16 is basically a bimetal switch which is controlled by a sensing tube across the outlet of the evaporator core As the evaporat...

Page 64: ...AIR CONDITIONING SYSTEM 1 47 Figure 21 Vacuum Ducts and Controls ...

Page 65: ...n increase in temperature causes an increase in pressure This accelerates chemical instability in clean systems Other results are brittle hoses O ring gaskets and by pass valve diaphragms with possible decomposition broken compressor dis charge reeds and seized compressor bearings A fundamental law of nature accounts for the fact that when a substance such as a refrigerant is increased in temperat...

Page 66: ...ier screens roughen bearing surfaces or hasten fatiguing of discharge reeds This can result in high temperature and pressure decomposition or leaks In any event this means a damaged compressor From this we can see the vicious circle that can be produced in a refrigerating system to cause its failure Corrosion can be the indirect cause of leaks and leaks can be the direct cause of corrosion We can ...

Page 67: ...CONTROLS FIGURES 23 AND 24 Combined air conditioning and heating system controls are located on the instrument panel in the upper right hand corner There are three separate controls FAN lever to control speed of blower OFF A C VENT HEATER DEF lever to control direction of air flow and which sys tem is to be operated RECIRC COLD HOT lever to control the temperature of the air The three levers may b...

Page 68: ...ished procedures and practices that have been developed after many years of experience In addition occupa tional hazards may be present that require the obser vation of certain precautions or use of special tools and equipment Observing the procedures practices and precautions of servicing refrigeration equipment will greatly reduce the possibilities of damage to the customers equipment as well as...

Page 69: ...ediate and future treatment PRECAUTIONS IN HANDLING REFRIGERANT LINES CAUTION The following precautions should be observed when handling refriger ant lines 1 All metal tubing lines should be free of kinks because of the restriction that kinks will offer to the flow of refrigerant The refrigeration capacity of the entire system can be greatly reduced by a single kink 2 The flexible hose lines shoul...

Page 70: ...r than is necessary 5 Finally after the operation has been completed and the system sealed again air and moisture should be evacuated from the system before recharging CHARGING STATION J 24410 This portable air conditioner service station fig ure 26 features the new J 24364 High Capacity Vacuum Pump Utilization of J 24364 enables the J 24410 service station to out perform all competi tive stations...

Page 71: ... To change oil simply unscrew hex nut located on back side of pump tilt backward and drain out oil Recharge with 8 ounces of vacuum pump oil Frigi daire 150 or equivalent If you desire to flush out the pump use this same type clean oil Do not use sol vent Improper lubrication will shorten pump life 4 If this pump is subjected to extreme or pro longed cold allow it to remain indoors until oil has r...

Page 72: ...rigerant leak in the high pressure side of the system may be more easily detected if the system is operated for a few minutes then shut off and checked immediately before system pressures equalize A leak on the low pressure side maybe more easily detected after the engine has been shut off for several minutes system pressures equalized this applies particularly to the front seal AVAILABILITY OF RE...

Page 73: ...il charge is satisfactory ion NOTE A slight amount of oil leakage at the compressor front seal is considered normal 7 Check the system controls fpr proper operat 6000 MILE INSPECTION 1 Check unit for any indication of a refrigerant leak COMPRESSOR SERIAL NUMBER The compressor serial number is located on the serial number plate on top of the compressor The serial number consists of a series of numb...

Page 74: ...HE SYSTEM FITTINGS RATHER THAN THE GAUGE LINES FROM THE ADAPTER 7 The system is now ready for purging or per formance testing PURGING THE SYSTEM In replacing any of the air conditioning compo nents the system must be completely purged or drained of refrigerant The purpose is to lower the pressure inside the system so that a component part can be safely removed 1 With the engine stopped install hig...

Page 75: ... has to be added the level of the oil in the bottle should decrease 1 1 2 ounces to add 1 oz to the system CAUTION When removing the gauge lines from the fittings be sure to remove the adapters from the system fittings rather than the gauge lines from the adapter b Turn on vacuum pump and open vacuum control valve slowly open high pressure side of manifold gauge set to avoid forcing oil out of ref...

Page 76: ...G SYSTEM OPERATION 1 Operate system for a maximum offive minutes at maximum cooling high blower speed and with engine operating at 2000 RPM exhaust should be vented if inside 2 When system is stabilized the pressure gauges on the charging station should read pressures corre sponding to values listed under PERFORMANCE DATA 3 When correct system pressures are observed check system charge as describe...

Page 77: ... LBS ENGINE RPM 2000 RPM HEAD PRESSURE EVAP IN CHARGE PORT SUCTION PRESSURE EVAPORATOR OUT CHARGE PORT DISCHARGE AIR TEMP AT RIGHT UPPER OUTLET Just prior to compressor clutch disengagement Temp of Air Entering Condensor 70 F 80 F 90 F 100 F 110 F Relative Humidity 21 1 C 26 7 C 32 2 C 37 8 C 43 3 C 230 270 30 245 285 190 237 283 40 205 252 298 157 202 242 60 172 217 257 127 167 210 80 142 182 225...

Page 78: ... with the drain plug downward Remove the drain plug and tipping the compressor back and forth and rotating the compressor shaft drain the oil into a clean container measure and discard the oil 3 Add new refrigeration oil to the compressor as follows a If the quantity drained was 4 fluid oz or more add the same amount of new refrigeration oil to the replacement compressor b If the quantity drained ...

Page 79: ...rwise damaged threads No bubbles Sight glass clear System is either fully charged or empty Feel high and low pressure pipes at compressor High pressure pipe should be warm low pressure pipe should be cold Temperature differential noted at compressor Even though a differential is noted there exists a possibility of overcharge An overfilled system will result in poor cooling during low speed operati...

Page 80: ...e pressures and poor cooling On bulbs located outside the evaporator case insulation must be properly in stalled Indications of expansion valve trouble provided by the Performance Test are as follows VALVE STUCK OPEN Noisy Compressor No Cooling Freeze Up VALVE STUCK CLOSED PLUGGED SCREEN OR BROKEN POWER ELEMENT Very Low Suction Pressure No Cooling POORLY LOCATED POWER ELEMENT BULB Normal Pressure ...

Page 81: ...ect the expansion tube or inlet screen of the expansion valve for the presence of metal chips or other foreign material If the tube or screen is plugged replace it Reconnect the line to the evaporator core or expansion valve 5 Install the replacement compressor 6 Add the necessary quantity of oil to the sys tem Remember to add the one ounce for the new receiver dehydrator 7 Evacuate charge and che...

Page 82: ...pect the O ring and the fitting and re place if damaged in any way Coat the new O ring with clean refrigeration oil and install carefully 4 Retorque the fitting using a backing wrench 5 Evacuate charge and check the system LEAKS AT HOSE CLAMP CONNECTION 1 Check the tightness of the clamp itself and tighten if necessary Recheck for leak 2 If leak has not been corrected discharge the system and loos...

Page 83: ...allation 7 Remove the nuts and bolts attaching the com pressor brackets to the mounting bracket 8 Remove compressor and attaching brackets and shield by sliding rearward and dropping out bot tom Be sure compressor is removed with attaching brackets as shown in Figure 29 9 Before beginning any compressor disassembly drain and measure oil in the compressor Check for evidence of contamination to dete...

Page 84: ...ped with an air condi tioning unit is involved in a collision or wreck it AIR CONDITIONING SYSTEM 1 67 should be inspected as soon as possible The extent or damage to any of all of the component parts and the length of time the system has been exposed to the atmosphere will determine the replacement of parts and processing that will be required The greater the length of time of exposure to the atm...

Page 85: ...re 11 Leak test all fittings and connections and give particular attention to a leak test at the compressor shaft seal if compressor has not been leak tested on the bench 12 Complete system processing and charge sys tem CONDENSER REPLACEMENT 1 Disconnect battery ground cables 2 Purge the system of refrigerant 3 Remove grill assembly 4 Disconnect the condenser inlet and outlet lines Cap or plug all...

Page 86: ...E 37 REPLACEMENT 1 Disconnect the battery ground cables 2 Disconnect the blower motor lead and ground wires 3 Disconnect the blower motor cooling tube 4 Remove the blower to case attaching screws and remove the blower assembly Pry the blower flange away from the case carefully if the sealer acts as an adhesive 5 Remove the nut attaching the blower wheel to the motor shaft and separate the assembli...

Page 87: ...to remove the cover retaining clip 4 Remove evaporator inlet and outlet hoses 5 Carefully remove thermostatic switch probe from front ofevaporator held by plastic clips Do not bend this tube excessively 6 Remove four attaching screws and gently pull out evaporator core 7 When core and expansion valve are removed the expansion valve may easily be removed without damaging the sensing tube 8 To insta...

Page 88: ...n the junction block protects the entire air conditioning system except for the blower when operating at HI BLOWER MOTOR RELAY The blower motor relay is located on the firewall on the blower side of the blower evaporator case figure 20 REPLACEMENT 1 Disconnect battery ground cables and the wir ing harness at the relay AIR CONDITIONING SYSTEM 1 7 1 2 Remove the relay to case attaching screws and re...

Page 89: ...r 6 Seal Seat Retainer Ring 25 O Ring 43 O Ring 7 Absorbent Sleeve 26 Front Cylinder Half 44 Rear Head 8 Seal Retainer 27 Thrust Races 45 Lock Nut 9 Clutch Coil Retainer Ring 28 Thrust Bearing 46 O Rings 10 Oil Drain Plug 29 Discharge Crossover Tube 47 Pressure Relief Valve 11 Compressor Shell 30 Teflon Piston Ring 48 O Ring 12 Clutch Coil and Housing Assy 31 Teflon Ring Type Piston 49 Suction Scr...

Page 90: ...y the necessary components that preliminary diagnosis in A 3941 1 Rear Head 20 Oil Pump Gears 2 Rear Head to Shell O ring 21 Mainshaft Bearing Rear 3 Rear Discharge Valve Plate 22 Oil Inlet Tube O ring 4 Rear Suction Reed Plate 23 Oil Inlet Tube 5 Piston Ring Teflon 24 Axial Plate and Mainshaft Assembly 6 Piston Drive Ball 25 Thrust Race 7 Shoe Disc 26 Thrust Bearing 8 Piston 27 Thrust Race 9 Fron...

Page 91: ...erant oil added to the compressor See figure 41 COMPRESSOR CLUTCH PLATE AND HUB ASSEMBLY REMOVE 1 Place Holding Fixture J 9396 in a vise and clamp the compressor in the Holding Fixture UNIT ADD OIL CONDENSOR 1 OUNCE EVAPORATOR 3 OUNCES COMPRESSOR AMOUNT OF OIL DRAINED AMOUNT OF OIL CONDITION FROM COMPRESSOR TO INSTALL REPLACING COMPRESSOR WITH MORE THAN 4 OZ DRAIN NEW COMPRESSOR REFILL A NEW COMPR...

Page 92: ...ove hub spacer figure 44 6 Inspect driven plate for cracks or stresses in the drive surface Do not replace driven plate for a scor ing condition figure 45 If the frictional surface shows signs of damage due to excessive heat the clutch plate and hub and pulley and bearing should be replaced Check further for the underlying cause of the damage i e low coil voltage coil should draw 3 2 amps at 12 vo...

Page 93: ...and Clutch Hub Holder J 25030 or J 9403 to install a new shaft lock nut with shoulder or circular projection on the locknut fac Figure 46 Aligning Drive Plate Key Figure 45 Clutch Driven Plate and Drive Plate ing towards retainer ring Tighten the nut to 14 26 lb ft torque Air gap between the frictional faces should now be 002 to 057 figure 48 If not check for mispositioned key or shaft 7 The pulle...

Page 94: ...uller J 8433 figure 50 INSPECTION Check the appearance of the pulley and bearing assembly See Figure 45 The frictional surfaces of the pulley and bearing assembly should be cleaned with suitable solvent before reinstallation REPLACE 1 If original pulley and bearing assembly is to be reinstalled wipe frictional surface of pulley clean If frictional surface of pulley shows any indication of damage d...

Page 95: ...move pulley and bearing assembly as de scribed in Compressor Pulley and Bearing Assem bly Removal procedure 3 Remove pulley bearing retainer ring with a small screwdriver or pointed tool figure 52 4 Place pulley and bearing assembly on inverted Support Block J 21352 and using Pulley Bearing Remover J 9398 with Universal Handle J 8092 drive Bearing assembly out of pulley figure 53 REPLACE 1 Install...

Page 96: ...bly as de scribed in Compressor Clutch Plate and Hub As sembly Removal procedure 2 Remove pulley and bearing assembly as de scribed in Compressor Pulley and Bearing Assem bly Removal procedure NOTE Position of terminals on coil housing and scribe location on compressor front head cast ing 3 Remove coil housing retaining ring using Snap Ring Pliers J 6435 figure 55 4 Lift Coil and Housing assembly ...

Page 97: ...r on the parts themselves for reference to determine their size and dimension See figure 80 COMPRESSOR SHAFT SEAL SEAL LEAK DETECTION A SHAFT SEAL SHOULD NOT BE CHANGED BECAUSE OF AN OIL LINE ON THE HOOD INSULATOR The seal is designed to seep some oil for lubrication purposes Only change a shaft seal when a leak is detected by the following procedure When refrigerant system components other than t...

Page 98: ...See figure 58 7 Recheck the shaft and inside ofthe compressor neck for dirt or neck foreign material and be sure these areas are perfectly clean before installing new parts INSPECTION SEALS SHOULD NOT BE REUSED ALWAYS USE A NEW SEAL KIT ON REBUILD Be extremely careful that the face of the seal to be installed is not scratched or damaged in any way Make sure that the seal seat and seal are free of ...

Page 99: ...til the ends of the sleeve butt at the top vertical centerline 9 Position the new metal sleeve retainer so that its flange face will be against the front end of the sleeve Pulley Puller Pilot J 9395 See figure 50 may be used to install the retainer Press and tap with a mallet setting the retainer and sleeve into place re tainer should be recessed approximately 1 32 from the face of the compressor ...

Page 100: ... oil in compressor should be drained and measured Assist draining by positioning compressor with oil drain plug down Record the amount of oil drained from the compressor 3 Invert compressor and Holding Fixture J 9396 with front end of compressor shaft facing downward figure 63 Additional oil may leak from compressor at this time All oil must be drained into a container so that TOTAL amount can be ...

Page 101: ... 14 Loosen compressor from Holding Fixture J 9396 place Internal Assembly Support Block J 21352 over oil pump end of shaft and holding Support Block in position with one hand lift com pressor from Holding Fixture with other hand In vert compressor and position on bench with Internal Assembly Support Block resisting on bench 15 Lift front head and compressor shell assem bly up leaving internal mech...

Page 102: ...inder half in like manner so that pistons can be replaced in their original locations 3 Separate cylinder halves using a wood block and mallet figure 70 Make certain that discharge cross over tube does not contact axial plate when separating cylinder halves a new Service discharge cross over tube will be installed later CAUTION UNDER NO CIRCUM STANCES SHOULD SHAFT BE STRUCK AT EITHER END in an eff...

Page 103: ...earings on shaft 14 Remove discharge cross over tube from cylin der half using self clamping pliers This is necessary only on original factory equipment as ends of the tube are swedged into cylinder halves The discharge cross over tube in internal mechanism assemblies that have been previously serviced have an O ring and bushing at EACH END of the tubee and can be easily removed by hand See figure...

Page 104: ...nd bearing assembly to rest on hub of cylinder 5 Now install a ZERO thrust race on rear end of compressor shaft figure 75 so that it rests on hub of axial plate Then install thrust bearing and a sec ond ZERO thrust race Lubricate races and bearing with petrolatum 6 Lubricate ball pockets ofthe No 1 Piston with 525 viscosity refrigerant oil and place a ball in each socket Use balls previously remov...

Page 105: ...roper size shoe discs to provide at each piston a 0016 to 0024 total preload between the seats and the axial plate at the tightest place through the 360 degree rotation of the axial plate at the tightest plate The bronze shoe discs are provided in 0005 variations including a basic ZERO shoe The second performed at the rear shaft thrust bearing and race pack is designed to obtain 0025 to 0030 prelo...

Page 106: ... which corresponds to the last three digits of the piece part number See Shoe Disc size Chart in figure 80 above Once a proper selection of the shoe has been made THE MATCHED COMBINATION OF SHOE DISC TO REAR BALL AND SPHERICAL CAVITY IN PISTON MUST BE KEPT IN PROPER RELATIONSHIP during disassembly after gaging operation and during final assembly of internal mechanism 19 Repeat in detail the same g...

Page 107: ...enter of Parts Tray J 9402 Fifteen 15 thrust races are provided in incre ments of 0005 one half thounsandths thickness and one ZERO gage thickness providing a total of 16 sizes available for field service Thrust races are identified on the part by their thickness in thou sandths in excess of the thickness of the ZERO thrust race This number also corresponds to the last three digits of the piece pa...

Page 108: ... the piston ring groove figure 86 If the Te flon ring is slightly off position in the ring groove it can be positioned into place by fingernail or blunt edged tool that will not damage the piston The Ring Installer J 24608 5 will retain the In staller Guide J 24608 2 internally when the Teflon ring is installed on the piston Remove the Installer Guide from the Ring Installer and DO NOT STORE THE I...

Page 109: ... piston with 525 viscosity refrigerant oil before inserting the pis ton into the cylinder bore CAUTION Reasonable care should be exer cised in installing thepiston into the cylin der bore to prevent damage to the Teflon ring ASSEMBLY After properly performing the Gaging Proce dure choosing the correct shoe discs and thrust races and installing any needed Teflon Piston Rings the cylinder assembly m...

Page 110: ...flattened portion of this tube faces the inside of the compressor to allow for axial plate clearance figure 93 6 Now rotate the shaft to position the pistons in a stair step arrangement then carefullyplace the rear Mr O Ring Discharge Bushing Crossover Tube Figure 92 Service Type Discharge Cross Over Tube AIR CONDITIONING SYSTEM 1 93 Figure 93 Installing Discharge Cross Over Tube cylinder half ove...

Page 111: ...21352 with rear end of shaft in block hole 2 Now install new O ring and bushing on front end of discharge cross over tube figure 96 The O ring and bushing are Service parts only for internal mechanisms that have been disassembled in the field See figure 92 Install front suction reed plate on front cylinder half Align with dowel pins suction ports oil return slot and discharge cross over tube figur...

Page 112: ...gerant oil and install new O ring into groove figure 101 9 Coat inside machined surfaces of compressor Rear Discharge Front Discharge Valve Plate Valve Plate Figure 99 Front and Rear Discharge Valve Plate AIR CONDITIONING SYSTEM 1 9 5 Figure 100 Installing Front Head Casting shell with 525 viscosity refrigerant oil and position shell on internal mechanism resting on O ring seal 10 Using flat side ...

Page 113: ...on figure 104 20 Generously oil rear discharge valve plate as sembly with 525 viscosity refrigerant oil around outer edge where large diameter O ring will be placed Oil the valve reeds pump gears and area where sealing surface will contact rear discharge valve plate 21 Using the 525 oil lubricate new head to shell O ring and install on rear discharge valve plate in contact with shell figure 105 22...

Page 114: ...EM 1 97 SLIGHTLY ROTATE FRONT HEAD IF NECESSARY TO LINE UP LOCATOR PINS AND HOLES Figure 106 Installing Rear Head COMPRESSOR LEAK TESTING EXTERNAL AND INTERNAL COMPRESSOR BENCH CHECK PROCEDURE 1 Install Test Plate J 9625 on rear head of com pressor 2 Attach center hose of gage manifold set on Charging Station to a refrigerant drum standing in an upright position and open valve on drum 3 Connect Ch...

Page 115: ...frigerant component will evidence if a defect occurs ture J 9396 and clamp the fixture in a vise so that the compressor can be manually turned with a wrench 15 Using a wrench rotate the compressor crank shaft or drive plate hub 10 complete revolutions at a speed of approximately one revolution per second NOTE Turning the compressor at less than one revolution per second can result in a lower pump ...

Page 116: ...o may be corrected by replacing the valve inlet screen and by properly installing the power element bulb Attachment of the expansion valve bulb to the evaporator outlet line is very critical The bulb must be attached tightly to the line and must make good contact with the line along the entire length of the bulb A loose bulb will result in high low side pres sures and poor cooling Indications of e...

Page 117: ...e replace Check for proper ground and good clean electrical contact at terminals Check for proper air gap Correct if necessary 022 057 Check and correct belt tension REFRIGERATION CHARGE HIGH TORQUE COMPRESSOR IS DEPLETED SEIZED SYSTEM HAS SOME REFRIGERANT LEAKS FREON DOES NOT LEAK FREON Check for refrigerant lines touching metal parts Isolate and re evaluate noise Remove compressor belt to determ...

Page 118: ...enser is OK check for air in system To check observe outlet air temperature and compressor discharge pressure while slowly discharging system at receiver inlet connection CHECK FOR BLOWN FUSE DEFECTIVE BLOWER SWITCH BROKEN WIRE LOOSE CONNECTIONS LOOSE BLOWER MOTOR GROUND WIRE OR INOPERATIVE BLOWER MOTOR OUTLET AIR TEMPERATURE DROPS AS COMPRESSOR DISCHARGE PRESSURE DROPS LEAK TEST SYSTEM REPAIR AS ...

Page 119: ...ck wire connector on blower relay with 12 volt test light LAMP LIGHTS Replace resistor Replace TEST LIGHT DOES NOT LIGHT ON ALL TERMINALS Replace resistor LAMP LIGHTS IN ALL POSITIONS Connect 12 volt test light at wire terminal on blower relay wire from resistor to blower relay LAMP LIGHTS blower relay Repair open in wire from resistor to blower relay BLOWER MOTOR INOPERATIVE CERTAIN SPEEDS EXCEPT...

Page 120: ...ion and refer to the vacuum diagrams and operational charts for proper AIR CONDITIONING SYSTEM 1 103 airflow air door functioning and vacuum circuits If airflow is not out of the proper outlets at each selec tor lever position then proceed as follows 1 Check for good hose connection at the vacuum actuators control head valve reservoir tees etc 2 Check the vacuum source circuit as follows Install v...

Page 121: ......

Page 122: ... Test Connector J 5420 Gauge Adapter J 9553 01 0 Ring Remover J 6084 Leak Detector J 9564 01 Feeler Tension Gauge Set J 6435 Snap Ring Pliers J 9625 Compressor Leak Test Fixture J 8001 3 Dial Indicator Set J 9661 01 Feeler Gauge Set J 8092 Handle J 21303 Shaft Seal Protector J 8433 Pulley Puller J 21352 Internal Assembly Support Block J 9392 Seal Remover J 21508 Seal Seat O Ring Installer J 9395 P...

Page 123: ...he lever in the OFF position the system is off With the lever in the VENT position 100 outside air enters the driver s compartment The air enters through the dash mounted outlets and Figure 1 Heating System Controls Type 1 through the heater outlets Temperature of incoming air may be controlled by moving the RECIRC COLD HOT temperature lever to desired po sition Any one of the three blower speeds ...

Page 124: ...is sec tion AIR CONDITIONING SYSTEM 1 107 HEATER CORE Replacement procedures for the heater core is the same as for models equipped with air conditioning See Evaporator and Heater Core Replacement in air conditioning portion of this section VACUUM CONTROLS Before replacing any vacuum control compo nents check system for proper operation Controls are the same as air conditioned models except for th...

Page 125: ...ehicle should not be sup SECTION 2 FRAME Contents of this section are listed below SUBJECT PAGE N0 General 2 1 Frame Alignment 2 2 Frame Material 2 2 Replacing Frame Extension 2 2 Body Mounting 2 4 GENERAL Figure 1 Frame Components FRAME 2 1 ported at the extreme ends of the frame or at the center of a frame rail Refer to Section 0 for hoisting and jacking instructions In the event the vehicle is ...

Page 126: ...ent therefore straighetning of this unit may not be successful Figure 2 Frame Alignment It is possible that the ordinary straightening methods will suffice for minor damage to the front suspension crossme ber however in case of serious damage or fracture the entire front suspension cross member or front frame extension must be replaced Before the member is replaced it is essential that the frame a...

Page 127: ...r 11 Transmission shift cable at transmission 12 Oil filler tube at front end 13 Vacuum line at vacuum tank mounted on the side of the heater 14 Brake lines at master cylinder 15 Hydraulic lines to windshield wiper motor 16 Air lines Remove 1 Remove Engine Transmission and Final Drive Assembly 2 Remove mufflers and Y pipe FRAME 2 3 3 Remove torsion bars and rear torsion bar sup port 4 Take steerin...

Page 128: ...m retain ing clamp on rear crossmember 9 Remove motor generator assembly if so equipped 10 Remove 8 nuts and bolts securing rear frame extension to side rails 11 Slide out rear frame extension REAR FRAME EXTENSION INSTALLATION Installation of the rear frame extension is accom plished by reversing the removal procedures NOTE The rear frame extension to frame assem bly retaining nuts should be tight...

Page 129: ...FRAME 2 5 Figure 4 Body Mountings ...

Page 130: ...his part NOTE Never attempt to heat quench or straighten any front suspension compo nent Replace it with a new part Contents of this section are listed below SUBJECT PAGE NO Trouble Diagnosis 3A 2 Theory and Operation 3A 5 General Description 3A 6 Disc Hub Assembly 3A 6 Disc 3A 11 Knuckle Seal 3A 11 Knuckle 3A 11 Upper Control Arm 3A 13 Upper Control Arm Bushing 3A 13 Lower Control Arm 3A 14 Lower...

Page 131: ...lls to One 1 Low or uneven tire 1 Inflate tires to the proper Side No Braking Action pressure recommended pressure 2 Broken or sagging 2 Replace torsion bar torsion bar 3 Incorrect front wheel 3 Check and align front suspension alignment Camber Poor Directional 1 Ball joints and 1 Lubricate at proper intervals Stability steering linkage need lubrication 2 Low or uneven front or 2 Inflate tires to ...

Page 132: ... round 3 Blister or bump on tire 3 Replace tire 4 Improper shock absorber 4 Replace shock absorber action Excessive or Uneven 1 Underinflated or 1 Inflate tire to proper overinflated tires recommended pressure 2 Improper toe in 2 Adjust toe in 3 Wheels out of balance 3 Balance wheels 4 Hard Driving 4 Instruct driver 5 Over loaded vehicle 5 Instruct driver Scuffed Tires 1 Toe in incorrect 1 Adjust ...

Page 133: ...sion approximately 2 to 1 It is mandatory that right and left shocks feel comparable If in doubt about condition compare with a known good shock Shock Absorber Noisy 1 Loose mounting 1 Check all shock mounting torques bolt and or nut 2 Faulty shock absorber 2 Observe hoisting instructions and instructions for removal of front shock absorbers Clamp shock upside down Clamp vise on top mount with sho...

Page 134: ...ure 1 Caster Camber and Toe In FRONT SUSPENSION 3A 5 Camber is the tilting of the front wheels from the vertical When thewheels tilt outward at the top the camber is said to be positive When the wheels tilt inward at the top the camber is said to be nega tive The amount of tilt is measured in degrees from the vertical and this measurement is called the camber angle Caster is the tilting of the fro...

Page 135: ...lling of the front wheels Excessive toe adjust ment will cause tire wear Toe adjustment also serves to offset the small deflections of the wheel support system which occurs when the vehicle is rolling forward In other words even when the wheels are set to toe in or toe out slightly when the vehicle is standing still they tend to roll parallel on the road when the vehicle is moving TOE IN DIMENSION...

Page 136: ...FRONT SUSPENSION 3A 7 Figure 4 Front Suspension ...

Page 137: ...eat of knuckle where rust or dirt may fall during removal 2 The outer race of the bearing is a snug fit into the knuckle Light tapping on the hubs outer surface not the disc will aid assembly Care must be used when installing hub assembly over drive axle splines so that splines are in correct alignment 3 Install three bolts attaching bearing retainer to knuckle Torque to 35 ft lbs 4 Install drive ...

Page 138: ...ON on Page 3A 1 of this section Figure 6 Disc and Hub Assembly 1 Position retainer over hub FRONT SUSPENSION 3A 9 RETAINER TO KNUCKLE BOLT HUB CAP RETAINER WHEEL STUD BEARING ASSEMBLY 2 Lubricate seal lips with Special Seal Lubricant No 1050169 or equivalent then position seal over hub with metal end toward retainer 3 Install bearing as shown in Figure 11 4 Install disc hub assembly Refer to DISC ...

Page 139: ...ure 7 Retainer Bolt Removal Figure 8 Hub and Disc Removal WASHER SCREW J 22214 4 J 22214 6 BEARING HUBS J 8433 1 TO BE ASSEMBLED AFTER C CLAMP 15 TIGHTENED SECURELY J 23345 1 RETAINER SEAL C CLAMP A 4128 Figure 9 Bearing Removal ...

Page 140: ...fer DISC and HUB ASSEMBLY Installation REMOVAL KNUCKLE SEAL 1 Remove disc and hub See DISC AND HUB REMOVAL Section 3A 2 Pry seal from knuckle INSTALLATION 1 Place knuckle seal on Tool J 26485 Insert tool Figure 1 0 Disc Removal FRONT SUSPENSION 3A 11 Figure 1 1 Installing Bearing as far as possible into knuckle and then drive it in with a hammer until it bottoms figure 12 Remove tool 2 Install dis...

Page 141: ...9 remove lower ball joint from knuckle figure 15 9 Remove knuckle Pry seal from knuckle INSTALLATION See CAUTION on Page 3A 1 of this section 1 Using Tool J 23115 install seal into knuckle 2 Install lower ball joint stud into knuckle and attach nut Do not torque 3 Install tie rod end stud into knuckle and attach nut Do not torque 4 Install upper ball joint stud into knuckle and attach brake line h...

Page 142: ... stud into knuckle 4 Install brake hose clip on ball joint stud 5 Install ball joint nut See specifications for torque value and procedure NOTE Do not back off nut to install NEW cot ter pin 8 Lower hoist REMOVAL INSTALLATION FRONT SUSPENSION 3A 1 3 CAUTION Cotter pin must be crimped to ward upper control arm to prevent interfer ence with outer C Y joint seal 6 Install upper shock attaching bolt a...

Page 143: ...d remove ball joint stud from knuckle figure 15 10 Remove bolts from lower control arm to frame and remove torsion bar 11 Push inboard on drive axle and pull outward on knuckle to gain clearance then remove lower control arm from knuckle INSTALLATION See CAUTION on Page 3A 1 of this section 1 Install lower control arm making certain shock absorber is guided onto lower control arm shock absorber mo...

Page 144: ...gure 19 Removing Upper Control Arm Bushing FRONT SUSPENSION 3A 1 5 Figure 20 Installing Upper Control Arm Bushing 2 Remove stabilizer link bolt grommets spacer and attaching hardware Discard bolt 3 Place floor stands under frame horn and un der points where frame sections are bolted Lower front lift to floor 4 Install Tool J 22517 02 Method for attaching refer to TORSION BAR REMOVAL Item 2 through...

Page 145: ...ION BAR INSTALLATION item 10 through 13 4 Raise front lift and remove floor stands 5 Using a new bolt with grommets spacer and attaching hardware attach stabilizer link bolt to lower control arm Torque nut to 15 ft lbs Cut bolt off 1 4 below nut Figure 23 Installing Lower Control Arm Front Bushing CP1 Figure 24 Installing Lower Control Arm Rear Bushing 6 Lower and torque lower control arm bushing ...

Page 146: ...t 3 Drive out rivets with hammer and punch 4 Drill center rivet using 5 8 drill bit just deep enough to remove rivet head 5 Using hammer and punch drive center rivet of joint out of control arm REMOVAL FRONT SUSPENSION 3A 1 7 Figure 27 Drilling Ball Joint Rivets INSTALLATION See CAUTION on Page 3A 1 of this section 1 Install service ball joint into control arm and torque bolts and nut as shown in ...

Page 147: ...ust be bent up to prevent interference with outer C V Joint Seal 4 Install wheel and lower hoist REMOVAL STABILIZER BAR 1 Remove link bolts nuts grommets spacers and retainers from lower control arm Discard bolts 2 Remove two bolts attaching dust shield to frame both sides 3 Remove bracket to frame attaching bolts and remove stabilizer bar from front of vehicle INSTALLATION See CAUTION on Page 3A ...

Page 148: ...ne end with an R for right or an L for left side Apply a liberal amount of chassis grease to both ends 2 Install crossmember insulators on the cross members 3 Install crossmember and position approxi mately two inches rearward of its normal position 4 Raise torsion bars and align with hole in cross member Move crossmember forward so torsion bars rest on edge of hole 5 Insert torsion bar adjusting ...

Page 149: ... aligned into hole in crossmember Seat center screw in dim ple of torsion bar adjusting arm 2 If vehicle must be raised turn tool until proper adjustment level is reached then turn the adjusting bolt until it makes contact with the adjusting arm Remove tool 3 If vehicle is to be lowered raise adjusting arm from contact with adjusting bolt Lower bolt then lower arm with tool until proper ride heigh...

Page 150: ...ent Figure 32 1 Loosen the clamp bolts at each end of the FRONT SUSPENSION 3A 21 BOLTS MIST BE INSTALLED IN DIRECTION SHOWN ROTATE BOTH INNER AND OUTER TIE ROD HOUSINGS REARWARD TO THE LIMIT OF BALL JOINT TRAVEL BEFORE TIGHTENING CLAWS WITH THIS SAME REARWARD ROTATION ALL BOLT CENTERLINES MIST BE BETWEEN ANGLES SHOWN AFTER TIGHTENING CLAWS A 0885 Figure 32 Positioning Tie Rod Clamp steering tie ro...

Page 151: ...ll ball joints must be kept sufficiently free of lubricant to prevent excessive pull in mating tapered holes NOTE After reaching minimum torque required nut must always be tight ened to insert cotter pin Never back nut off J 2619 J 8433 1 J 9745 J 214 7 4 3 4 5 J 22214 4 6 J 23345 J 22269 J 22517 02 J 231 15 J 24319 J 247 17 J 26485 TORQUE SPECIFICIATIONS SPECIAL TOOLS Slide Hammer Bearing Puller ...

Page 152: ...ossible Cause Correction Clicking noise in turns Excessive wear or broken Inspect and replace outboard joint outboard joint if necessary Coast to drive clunk 1 Loose inboard joint 1 Tighten to specified flange bolts torque 2 Inoperative rubber 2 Replace RH shaft and damper damper RH side assembly and inboard and outboard seals use seal service kits 3 Loose spline 3 Same as 2 above RH damper to sha...

Page 153: ...complete flexibility only CAUTION Whenever any operations call for disconnecting removal or installation ofthe drive axles care must be exercised to pre vent damage to constant velocityjoint seals Seals may be wrapped with floormat rubber or old innertube etc Make sure any rubber protective covers that are used are removed before vehicle is started or driven Figure 1 Drive Axle Assembly DRIVE AXLE...

Page 154: ...ut shaft into final drive and attach support bolts to engine IMPORTANT When attaching the right hand output shaft to the engine bracket do not let the shaft hang Referring to Figure 3 assemble bracket bolts loosely and by moving the flange end of the shaft up and down and back and forth find the center location Hold the shaft in this position and then torque the bolts to 55 ft lbs on support 4 Mov...

Page 155: ...TION on Page 1 of this section 1 Carefully guide L H Drive axle assembly onto lower control arm 2 Insert lower control ball joint stud into knuckle and attach nut Do not torque Figure 6 Removing Lower Ball Joint 3 Center L H drive axle assembly in opening of knuckle and insert upper ball joint stud 4 Place brake hose clip over upper ball joint stud and install nut Do not torque 5 Insert tie rod en...

Page 156: ...nd discard 8 Remove excess grease from C V joint 9 Insert C V joint in vise clamping on shank Figure 7 Cutting Seal Clamp DRIVE AXLES 3B 5 Figure 8 Spreading Retaining Ring Figure 9 Tapping on Inner Race NOTE Use jaw blocks to prevent damage to the joint shank 10 Carefully place a brass drift against one of the lobes of the inner race and tap gently as shown in Figure 9 Tip the race far enough to ...

Page 157: ...rinelling of the window flats Some wear and slight brinelling from ball contact is normal 4 Inspect inner race for excessive wear scores or breaks 5 Inspect retaining ring for breaks NOTE If any of the above defects except Item 5 are found the C V joint assembly will have to be replaced as a unit Retaining ring may be replaced separately ASSEMBLY 1 Insert short land of inner race through bore of c...

Page 158: ...UTER RACE CLAMP AXLE GROOVE IDO NOT USE Figure 14 Positioning Seal DRIVE AXLES 3131 7 Figure 15 Assembly of J 22716 to Band 10 Insert axle shaft into splines of outer C V joint until retaining ring secures shaft in second snap ring groove 11 Position seal in groove of outer race figure 12 Position small end of seal in nearest joint groove on axle shaft figure 14 NOTE After seal is in position on a...

Page 159: ...Band Figure 19 Bending Lock Tangs bend band over lock tangs of clamp do not let band slip back through tool as this will decrease clamping force Refer to figure 17 g Back tool offjust enough to permit tapping band with a hammer until it lies flat across top of retainer Unwind the excess strap and cut it off close to retainer as shown in Figure 18 Tap the tabs down until they retain strap Tap light...

Page 160: ...axle assembly in vise Clamp on mid portion of axle shaft Protect against jaw marks 4 Using Tool J 5586 remove retaining ring from end of axle shaft 23 5 Slide spider assembly from axle shaft figure 6 Remove retaining ring inner from axle shaft using Tool J 5586 figure 24 7 Remove small seal clamp 8 Slide boot seal off axle shaft and discard seal DRIVE AXLES 313 9 Figure 23 Removing Spider Assembly...

Page 161: ... pattern is suspected to be the cause of a noisy or vibrating C V joint then the housing should be replaced 1 Inspect housing for excessive wear brinneling cracks or chips in housing bore 2 Inspect retaining rings for cracks or bends 3 Inspect balls three for excessive wear cracks nicks scores or breaks 4 Inspect needle bearings for wear breaks or bends 5 Inspect spider for excessive wear chips or...

Page 162: ...from spider assembly 12 Position spider assembly in line with housing assembly and push into housing until bottomed fig ure 22 13 Fill housing with lubricant 1050802 or equivalent 14 Lubricate inside of boot seal retainer and housing outer groove O ring with 1050802 lubri cant or equivalent CAUTION Be careful that seal retainer is positioned so that O ring is not cut 15 With housing positioned as ...

Page 163: ...ver Installer J 22716 C V Joint Boot Clamp Tool J 24319 Pitman Arm Idler Arm Ball Joint Puller 2 Assemble outer C V joint Refer to Outer C V 3 Install drive assembly Refer to DRIVE AXLE ASSEMBLY RIGHT OR LEFT INSTAL LATION Application Ft Lbs R H Output Shaft Support to Engine Bolts 55 Drive Axle to Output Shaft Bolts 75 Drive Axle Nut at Wheel Hub 200 Tie Rod End to Knuckle Nut 40 Ball Joint Stud ...

Page 164: ...ble unless some abnormal noise is present To make a systematic check for final drive noise under standard conditions observe the following 1 Select a level tarvia or asphalt road to reduce tire noise and body drumming 2 Check final drive lubricant to assure correct level then drive car far enough to thoroughly warm up the lubricant 3 Note speed at which noise occurs Then stop vehicle and with auto...

Page 165: ... FINAL DRIVE SHIM PINION PRE LOAD SEALSy OUTER LI P OUT INNER LIP IN Figure 1 Final Drive Pinion Assembly SHIM BEARING CASE ASSY SIDE SEAL L H OUTPUT SHIM SHAFT L H A 0914 Figure 2 Final Drive Case Assembly ...

Page 166: ...t output shaft bolts to The two side bearings are the same and the pre load shims are identical for the right and left side The left output shaft retainer bolt goes through the shaft to the side gear The right output shaft has a vent hole in the flange 2 Hoist vehicle Figure 3 Final Drive Case Assembly Exploded View FINAL DRIVE 3C 3 CAUTION When removing or installing the right drive axle be sure ...

Page 167: ...6 INSTALLATION See CAUTION on Page 3C 1 of this section Figure 5 Removing R H Output Shaft Seal Figure 6 Removing R H Output Shaft Bearing 1 If output shaft bearing was removed assemble parts as shown in Figure 7 2 Position assembly in a press and install bearing until seated as shown in Figure 8 3 Pack area between bearing and retainer with wheel bearing grease then install slinger as shown in Fi...

Page 168: ...ear 6 Install support to engine and brace figure 4 NOTE When attaching the right hand output shaft to the engine do not let the shaft hang Assemble support bolts loosely and by moving the flange end of the shaft up and down and back and forth find the center location Hold the shaft in this position and then torque the bolts to 55 ft lbs on support Figure 11 7 Move drive axle forward until it align...

Page 169: ...ut shaft figure 12 If output shaft seal is to be replaced insert Tool J 23129 into seal and drive out with a hammer fig ure 13 INSTALLATION See CAUTION on Page 3C 1 of this section 1 If output shaft seal was removed install new seal as shown in Figure 14 NOTE Left output shaft seal is installed with vent hole toward top of final drivehousing in the in vehicle Position Figure 12 Final Drive Attachm...

Page 170: ...le 3 Remove bolts A B and C Figure 12 FINAL DRIVE 3C 7 Figure 15 Disconnecting Final Drive From Engine 4 Disconnect right and left drive axles from the output shafts 5 Move R H Drive axle rearward until R H output shaft is clear to be removed from final drive 6 Disconnect R H output shaft support from engine figure 4 and remove from final drive 7 Remove bolt X and Y and loosen Z figure 15 8 Remove...

Page 171: ...s E F and G and nut H figure 12 Install bolts A B and C figure 12 Torque all final drive to transmission bolts to 30 ft lbs Torque nut to an approximate 30 ft lbs 7 Install bolt X and torque to 110 ft lbs Tighten and torque bolts Y and Z to 55 ft lbs figure 15 8 Loosen and remove lift from final drive 9 Position a new cover gasket on the final drive then install cover Torque cover bolts to 30 ft l...

Page 172: ...seal protector 4 Apply Special Seal Lubricant No 1050169 or equivalent to right output shaft seal 5 Install final drive Refer td FINAL DRIVE INSTALLATION steps 3 17 FINAL DRIVE REMOVED FROM VEHICLE Figure 17 Final Drive Holding Fixture DISASSEMBLY FINAL DRIVE 3C 9 Figure 18 Checking Pinion and Side Bearing Pre Load 1 Install adapter J 22296 1 on Differential Hold ing Fixture J 3289 Mount final dri...

Page 173: ...sponding caps 6 Install spreader on housing as shown in Figure NOTE Spreader must be modified with Tools J 22196 7 8 7 Turn the spreader screw to expand spreader until the spacer and shim s can be removed from between the right side bearing and the housing Re tain spacers and shims for reassembly NOTE Spread housing only enough to relieve tension on the spacer and shims The shims may be removed wi...

Page 174: ...ve the output shaft oil seals as shown in Figures 5 and 13 15 Remove the two oil seals from the pinion bearing housing as shown in Figure 27 16 If necessary to remove the pinion rear outer race it can be removed as shown in Figure 28 Figure 24 Removing Pinion And Bearing Housing FINAL DRIVE 3C 1 1 Figure 25 Removing Vent Pin And Seal Figure 26 Removing Pinion Front Bearing Outer Race Figure 27 Rem...

Page 175: ...removed as shown in Figures 31 and 32 Figure 29 Removing Pinion Front Bearing Figure 30 Removing Pinion Rear Bearing 2 Mark ring gear and case then remove all but two of the case to ring gear bolts Leave two of the bolts 180 apart loose NOTE Ring gear must be removed to remove pinion and side gears 3 Position case as shown in Figure 33 and tap lightly on a bench to separate the case from ring gear...

Page 176: ...ashers and shims for wear and replace as necessary NOTE The left side gear has the threaded re tainer that retains the short left output shaft Figure 33 Separating Ring Gear From Case CLEANING AND INSPECTION FINAL DRIVE 3C 1 3 Figure 34 Removing Lock Pin From Pinion Shaft If threaded retainer is to be removed use a brass drift and hammer to remove from left side gear 1 Clean all bearings throughly...

Page 177: ...9 on final drive housing and retain Figure 36 Pre Loading Pinion Front Bearing Figure 37 Pinion Depth Gauge Tool Installation with two bolts Thread screw J 21777 13 into J 21579 until tip of screw engages Tool J 21777 10 Torque screw J 21777 13 to 20 in lbs to pre load bearing figure 36 4 Remove dial indicator post from Tool J 21777 1 and install Discs J 21777 22 as shown in Figure 37 Reinstall di...

Page 178: ...EASED by the amount painted on the ring gear figure 38 Ring gear painted minus the shim thick ness indicated by the dial indicator on the pinion setting gauge must be DECREASED by the amount painted on the ring gear figure 38 Figure 39 Installing Pinion Rear Bearing FINAL DRIVE 3C 1 5 Figure 40 Installing Pinion Front Bearing And Shim 11 Remove pinion depth checking tools and front bearing from ho...

Page 179: ...move Tool J 22587 1 4 With dial indicator J 8001 and extension J 7057 attach existing dial indicator post to Tool J 22587 2 figure 42 While holding contact studs three of Tool J 22587 2 firmly against shoulder of bearing housing position dial indicator as shown in Figure 42 and rotate dial to ZERO 5 Carefully lift dial indicator assembly over flange of bearing housing and position assembly as show...

Page 180: ...r inner seal lip will fold between seal case and pinion shaft resulting in a leak 11 Reinstall Tool J 22208 1 2 and recheck pin ion pre load Must be two to five in lbs for used bearings two to 15 in lbs for new bearings figure 23 FINAL DRIVE 3C 1 7 Figure 46 Installing Bearing Housing Into Final Drive Housing CASE ASSEMBLY Side Bearing Installation 1 Install the side bearings as shown in Figures 4...

Page 181: ... pinions back toward loading opening just enough to permit sliding in pin ion gear shims 4 Install pinion shaft Drive pinion shaft retain ing lock pin into position figure 49 1 After making certain that mating surfaces of case and ring gear are clean and free of burrs install three 7 16 20 x 1 3 4 in bolts as shown in Figure 50 to correctly position ring gear 2 Install Tool J 22822 into a vise and...

Page 182: ...4 Install Spreader J 22196 on housing and spread housing just enough so that shim can be in serted between the spacer and the housing figure 52 5 Release tension on spreader tool install side bearing caps and torque cap bolts to 75 ft lbs then check pre load as shown in Figure 53 Pre load should be 10 to 15 in lbs for new bearings 5 to 7 Figure 52 Spreading Housing For Shim Installation Figure 53 ...

Page 183: ...him 002 and DECREASE thickness of left 002 To increase backlash 002 DECREASE thickness of right shim 004 and INCREASE thickness of left shim 004 5 When backlash is correctly adjusted remove spreader Install the bearing caps and bolts Torquer to 75 ft lbs 6 Install new output shaft seals as shown in Fig ure 10 and 14 NOTE Left output shaft seal in installed with vent hole toward top offinal drive h...

Page 184: ...J 2281 1 J 22812 J 22822 J 22828 J 23129 J 26485 SPECIAL TOOLS Slide Hammer Holding Fixture Slide Hammer Pinion Bearing Cup Remover Pinion Bearing Cup Remover Side Bearing Shim Inst Extension Dial Indicator Driver Handle Puller Race Installer Companion Flange Holder Timing Case Cover Seal Installer Race Installer Pinion Rear Bearing Remover Front Pinion Bearing Installer Pinion Setting Tools Housi...

Page 185: ...eight Control Valve Overhaul 4 21 Component Installation 4 26 On Vehicle Adjustments 4 32 Periodic Maintenance 4 34 Rear Suspension Torque Specifications 4 35 GENERAL DESCRIPTION The rear suspension system figure 1 on the vehi tem operates automatically as load varies to retain cle consists mainly of air bellows height control frame at proper ride height valves control arms and shock absorbers The...

Page 186: ...ool and the water vapor can condense Drain reser voir monthly AIR BELLOWS The air bellows serve as a flexible connection between the two control arms on each side of suspen sion bracket The flexing ofthe air bellows allows the control arms to move up and down in relation to the frame This action absorbs road shocks in the same manner as an inflated rubber tire cushions shock caused by road roughne...

Page 187: ... returning to normal ride height valve arm and shaft return to a neutral posi tion Inlet valve lever also moves away from inlet valve core and inlet valve closes This stops the flow Figure 4 Operation of Height Control Valve of the air into bellows The exhaust valve remains closed Since the exhaust valve is closed and the check valve in the inlet adapter prevents compressed air from returning to a...

Page 188: ...o leakage is permissible Leakage at air line connections can sometimes be stopped by tightening connection If this does not stop the leak replace the affected fittings 1 Cut end of hose tube off square 2 Place brass insert into end of tube and put appropriate fitting over it figure 5 3 Crimp fitting in place with Special Tool J 25520 This tool is designed so that crimp must be completed before too...

Page 189: ...hat check valve unit is defective and must be re placed 6 If bubbles appear at the exhaust port it is an indication the exhaust valve assembly is defective and must be replaced 7 If bubbles appear around edge of valve cover plate the cover plate gasket must be replaced 8 If no leaks are detected remove valve assembly from water then with air pressure still connected to bellows port actuate valve a...

Page 190: ...air leaks heavily at rings 4 Pressure switch con 4 Replace pressure switch tacts are pitted causing improper compressor action 5 Pressure switch not 5 Adjust pressure switch settings properly adjusted to operate at the 100 120 psi range Air pressure in tank 1 Air leak in system 1 Eliminate air leaks in system as unit operating described earlier in this section erratically pump takes too long to pr...

Page 191: ...ompressor from vehicle Figure 8 Pressure Switch Installed REAR SUSPENSION 4 7 AIR COMPRESSOR DANA DOUBLE PISTON 1 Disconnect electrical wires at back of compres sor motor figure 3 2 Release pressure in air reservoir through Schrader valve 3 Disconnect air lines at back of compressor and at head of one piston 4 Remove three bolts that secure compressor to mounting bracket and remove compressor AIR ...

Page 192: ...ink Pull lever downward and hold several seconds to overcome time delay feature This will release compressed air from bellows 2 Referring to Figure 10 disconnect air supply line and bellows air line from height control valve Tape ends of lines to prevent foreign material from entering 3 Remove two nuts attaching height control valve to wheel well and remove valve assembly AIR BELLOWS REMOVAL 1 Sup...

Page 193: ... air bellows as shown in Figure 13 Figure 14 Disconnecting Brake Line REAR SUSPENSION 4 9 Figure 15 Disconnecting Parking Brake Cable 5 Disconnect shock absorbers from control arm mounting 6 Referring to Figure 14 disconnect brake line at center mounting bracket and at each brake back ing plate Remove brake lines from control arms by unbolting all mounting points 7 Disconnect parking brake cable a...

Page 194: ...8 Removing Hub and Drum Figure 19 Removing Brake Backing Plate and Brake Shoe Assembly 9 Referring to Figure 19 remove four bolts and nuts retaining brake backing plate to control arm Repeat procedure on opposite wheel 10 Support mounting bracket with floor jack Referring to Figure 20 remove two bolts holding mounting bracket to crossmember Remove four bolts holding mounting bracket to frame rail ...

Page 195: ... arms Figure 22 Removing Mounting Bracket Nuts REAR SUSPENSION 4 1 1 Figure 23 Location of Retainer 14 Apply penetrating oil to wheel spindle and suspension arm mating surfaces Position screw pad J 25265 6 as shown in Figure 24 15 Install spindle removing tool as shown in Figure 25 16 Tighten tool through bolts and then reaction set screw as shown in Figures 25 and 26 17 Press out spindle by turni...

Page 196: ...hock from mounting bracket Figure 26 Spindle Removal Figure 27 Positioning Wood Block Under Control Arm POWER LEVEL VALVE REMOVAL 1 Bleed air from reservoir tank and place valve in lower position 2 Remove four screws on mounting panel 3 Remove control knobs by removing Allen head screw in center of knobs See figure 29 4 Remove two screws holding each valve to mounting panel 5 Disconnect three fitt...

Page 197: ...replaced also Figure 29 Power Level Control Panel Figure30 Power Level Valves and Fittings COMPRESSOR OVERHAUL BROWN SINGLE PISTON FIGURE 31 REAR SUSPENSION 4 1 3 1 Remove compressor from vehicle 2 Remove four screws from piston dome as shown in Figure 32 Remove piston dome and its gasket Remove valve plate and its gasket ...

Page 198: ... 7 Install piston dome and new gasket and retain in position with four screws Figure 32 Removing Screws From Piston Dome Figure 33 Compressor Components 1 Elbow 8 Screw 15 Piston and Rod 21 Fan Guard 28 Screw 2 Dome 9 Gasket Assembly 22 Lock Washer 29 Eccentric 3 Gasket 10 Sleeve 16 Screw 23 Washer 30 Screen 4 Screw 11 Expander 17 Washer 24 Nut 31 Filter 5 Valve 12 Ring 18 Screw 25 Motor 32 Retain...

Page 199: ...sket Figure 34 Removing Retaining Screw From Exhaust Valve INSTALLATION 3 Remove piston sleeve 4 Remove air filter REAR SUSPENSION 4 1 5 Figure 35 Loosening Allen Screw on Eccentric 3 Remove retaining screw from exhaust valve and remove valve as shown in Figure 34 4 Remove O ring under valve 1 Install O ring by first applying a small amount of silicone rubber cement or equivalent in recess for O r...

Page 200: ...me and its gasket Remove valve plate and its gasket 3 Remove piston sleeve 4 Remove air filter 5 Rotate eccentric until it is at the bottom of its stroke 6 Referring to Figure 35 loosen Allen Head set screw which is at top of eccentric 7 Remove eccentric from motor output shaft and remove piston assembly through air filter open ing as shown in Figure 36 8 Remove two nuts holding on fan blade guard...

Page 201: ...place intake assembly following section COMPRESSOR OVERHAUL The Brown compressor has a thermal overload protector switch mounted in the top of the compres sor body The switch is designed to turn the compres sor off in the event that its temperature reaches a level where the motor can be damaged When the temperature drops to a safe level the switch allows the compressor to operate DANA DOUBLE PISTO...

Page 202: ...12 Plug 13 Tee 14 Head 15 Exhaust Valve 16 Head Plate 17 O Ring 18 Piston and Rod Assembly 19 Tubing 20 Filter Retainer 21 Intake 22 Filter 23 O Ring 24 Crank Pin 25 Crank 26 Thrust Washer 2 7 Housing Assembly 28 Thrust Washer 29 Retaining Ring 30 Pulley 31 Belt 32 Belt Guard 33 Screw A 4183 Figure 3 7 Dana Compressor Exploded View ...

Page 203: ...ALLATION 1 Install motor on bracket and secure with two hex head nuts 2 Slide pulley on motor shaft and secure with two headless set screws 3 Install belt guard and timing belt REAR SUSPENSION 4 19 Figure 40 Replacing Timing Belt Figure 41 Back of Compressor Figure 39 Timing Position Figure 42 Air Filter Removal ...

Page 204: ...re 45 Valve Components 3 Lift the O ring seal out of recess on top of housing assembly 4 Remove the round red silicone rubber intake valve on top of piston by working it off the center rivet INSTALLATION 1 To install round red silicone rubber intake valve put a slight amount of engine oil on the center rivet of piston The valve will rotate freely when it is completely installed 2 Replace O ring se...

Page 205: ...driver to wedge the crank inside the crankcase and unscrew the shaft and pulley as sembly figure 48 7 Slide pulley and shaft assembly out ofhousing INSTALLATION 1 Install pulley and shaft assembly in housing with two black plastic hex thrust washers in respec tive recesses inside and outside the housing 2 Put piston and rod assembly through top of housing assembly Bearing in lower end of connect i...

Page 206: ...T CONTROL VALVE ADJUSTMENTS GENERAL To properly adjust the height control valve it is ESSENTIAL that the following procedures be fol lowed and in the sequence mentioned Three main adjustments are required 1 Overtravel lever center position adjustment 2 Air intake and exhaust valve lever gap adjust ments Figure 49 Height Control Valve 3 Time delay check NOTE The height control valve assembly must b...

Page 207: ...WITH TOP OF BORE without overtraveling po sition C figure 52 Relocate indicator push rod to just contact 1 3 8 inch mark on control body and reset indicator dial to zero at this point position C figure 42 9 Move overtravel lever to full air intake position without overtraveling position A figure 52 delay piston at bottom ofbore Take indicator read ing which may vary from 0 160 to 0 190 10 Repeat S...

Page 208: ...ever to where air intake valve just begins to open Listen for escaping air Note reading on dial at this point Reading should be 0 025 to 0 027 from lever center position Bend lever to correct setting Refer to Figure 53 5 Return overtravel lever to center position Slowly move lever to exhaust side find at same time note the vacuum gauge reading When vacuum just begins to fall off the exhaust valve ...

Page 209: ...ommended Also valves should close from full open position within 4 seconds 1 Pour 5 5 cc 0 25 cc of Silicone fluid 3 000 Centistokes viscosity at 25 C into delay piston bore With valve body tilted slightly as shown in Figure 54 carefully operate overtravel lever fore and aft to vent air from fluid When all air has been expelled from piston pin cavity check fluid level figure 55 VALVE BODY TILTED U...

Page 210: ...n valve assembly b Connect air pressure supply hose to bel lows port figure 50 c Move overtravel lever downward quickly approximately two inches and simultaneously start counting the seconds before air starts to escape from the exhaust port A delay of ten to fifty seconds should exist IMPORTANT A time delay over fifty seconds could mean too large a valve lever gap adjust ment and a time delay unde...

Page 211: ... line connector nuts firmly 3 Connect height control valve overtravel lever to valve link and tighten to 60 90 ft lbs Build up air pressure in system and test for leaks Check ride height dimension and adjust if necessary as described later in this section AIR BELLOWS INSTALLATION 1 Place air bellows piston on floor cone section pointing up Place air bellows in piston with open end pointing up REAR...

Page 212: ...mbly new bolts washers and nuts as shown in Figure 62 Torque bolts 35 45 ft lbs 9 Referring to Figure 21 position unit on vehicle and install four bolts from mounting bracket to frame rail Install two bolts from mounting bracket to frame crossmember See figure 20 10 Referring to Figure 20 install brake backing plate by installing four bolts and nuts that secure plate to control arm 11 Referring to...

Page 213: ...ecure with nut POWER LEVEL VALVE INSTALLATION 1 Wrap threads on air line fittings with teflon tape 2 Install lines to back of valves referring to Fig ure 66 On the right valve red line goes to the port marked MAN blue line goes to the port marked OUT and yellow lines goes to the port marked AUTO On left valve red line goes to the port marked MAN gray line goes to the port marked OUT purple line go...

Page 214: ...4 30 REAR SUSPENSION AIR RESERVOIR AIR COMPRESSOR HEIGHT CONTROL VALVE HEIGHT CONTROL VALVE AIR BELLOWS AIRLINE COLOR RED YELLOW A 4308 Figure 6 4 Standard Rear Suspension Schematic ...

Page 215: ...AIR BELLOWS L HEIGHT CONTROL VALVE HEIGHT CONTROL VALVE AIR BELLOWS AIR LINE COLOR A 4309 Figure 6 5 Rear Suspension Schematic With Power Level REAR SUSPENSION 4 31 ...

Page 216: ...ed with teflon tape or equivalent to avoid leakage 1 Cut nylon tube to required length and be sure components are free of nicks or scratches 2 Position nut and sleeve over tube 3 Push tube insert into tube then push tube and insert into fitting until firmly seated 4 Seat sleeve into fitting then tighten nut se curely 5 Install fitting at other end of nylon tube using the above procedure then check...

Page 217: ...sults in irregular wear of tires at outer shoulder Negative or reverse camber causes wear at inner shoulders Camber is adjusted by shimming as shown in Figure 68 Following the same shimming procedure as that used before to set toe in AIR COMPRESSOR PRESSURE SWITCH ADJUSTMENT The switch is designed to maintain air pressure in the air reservoir between 100 and 120 psi If the pressure in the reservoi...

Page 218: ...ut causing any valve action If amount of adjust ment required falls within these limits adjust lever the required amount However frame will not raise or lower until load is increased or decreased to actu ate height control valve If any one of the height control valves does not function properly with the lever correctly adjusted AIR COMPRESSOR FILTER REPLACEMENT BROWN SINGLE PISTON The air filter o...

Page 219: ... mounting bolts and brackets should be checked at regular intervals for looseness Tighten if necessary Air reservoir may be cleaned inside using steam or hot water If corrosion or other damage has weakened tank it must be replaced LUBRICATION Details on lubrication of rear suspension compo nents are covered in Section 0 at the beginning ofthis manual Air Line Crimp Tool LOCATION TYPE OF PART TORQU...

Page 220: ...ever adjuster lever return spring override spring and override pivot When the brake pedal is depressed the piston in the master cylinder forces fluid under pressure to a wheel cylinder at each wheel which in turn pushes the brake shoes against the brake drum As the shoes contact the drum the friction between the shoes and the rotating drum moves the primary shoe down ward against the adjusting scr...

Page 221: ...gainst the disc surfaces with increased force bring the vehicle to a stop In actual practice the application and release of the brake pressure causes a very slight movement of the piston and caliper Upon release of the braking effort the piston and caliper merely relax into a released position In the released position the shoes do not retract any appreciable distance from the disc surfaces As the ...

Page 222: ...able runs from the hand lever along the underbody to the front equalizer The intermediate cable then runs to outside of each frame rail and back to an intermediate equalizer From this point a cable runs to each of the four brake drums Each of these cables connects to the free lower end of a brake shoe lever These levers one in each rear brake shoe assembly pivot on the secondary shoes Struts are m...

Page 223: ...linders If ex ternal leak is not found remove master cylinder disassemble and inspect parts Leaks will usually be past primary piston cup due to porous or damaged cup or cylinder bore Remedy Remove air by bleeding check compensating port for clearance of cup to provide full open port Adjust brakes Replace See ALL BRAKES DRAG Flush and bleed system using GM Hydraulic Brake Fluid Supreme No 11 or eq...

Page 224: ... Adjust or correct cause Adjust parking brake cables and lubricate Replace defective brake shoe springs and lubricate brake shoe ledges and shoe contact at anchor pin with brake lubricant No 1050110 or equivalent Readjust brakes Replace inoperative or damaged parts Look for evidence of dirt in hydraulic system which could cause damage to the cylinders or cups See first item under ALL BRAKES DRAG O...

Page 225: ...ffects on the drums and on each other Each wheel must have similar linings The primary and secon dary linings must not be interchanged Use only factory specified linings Inflate tires to specified pressures Rearrange tires so that a pair with non skid tread surfaces of similar design and equal wear will be installed on front wheels and pairs with like tread will be installed on rear wheels Sand su...

Page 226: ...e Cause 1 Maladjustment 2 Parking brake cables frozen Remedy Adjust brakes Install factory specified shoes Install factory specified shoes Correct cause and replace linings if necessary Replace Check wheel cylinder piston and boot for damage Install link Check pedal linkage stop light switch adjustment Lubricate with Delco Brake Lube 5450032 or equivalent Sand surface of linings Replace or resurfa...

Page 227: ...system thoroughly with a good grade of clean brake fluid and replace all internal rubber parts in brake system Lubricate pedal linkage and make certain no bind exists See that stop light switch is not defec tive incorrectly adjusted or that switch plunger is not binding on pedal due to lack of lubrication The compensating port in master cylinder must be completely clear when pedal is in released p...

Page 228: ...OO SEVERE Cause Remedy Brake adjustment not correct Adjust brakes Loose support assembly Tighten rear backing plates Adjust brakes Small amount of grease or fluid Correct cause and replace linings on linings Charred linings or scored drums Sand surfaces of linings and drums Clean loose dust from brake In severe cases replace shoes Warn owner regarding abuse of brakes Remove all particles that have...

Page 229: ... noises lubrication will remedy Cause Cause Remedy PEDAL SQUEAK Remedy Grease anchor pins where shoes bear Cause I Remedy Dry pedal bushings or stop light Lubricate switch rubbing pedal I CLICKS DURING HIGH RATE STOPS USUALLY ONCE PER WHEEL REVOLUTION IN ONE WHEEL ONLY Cause Remedy Threaded drum Cross sand CHATTER AT HIGH SPEED Cause Remedy Drum out of round with two or Turn drum more distinct hig...

Page 230: ...orrection BRAKES 5 1 1 Inflate evenly on both sides to the recommended pressures Check and align to specifications Tires with approximately the same amount of tread should be used on the same axle Check for soft hoses and damaged lines Replace with new hoses and new double walled steel brake tubing Check for stuck or sluggish pistons proper lubrication Install new shoe and lining in complete axle ...

Page 231: ...place in axle sets Remove caliper and rebuild or replace Remove and replace with original equipment lining Correction Check both front and rear system for a failure and repair Also check warning light It should have indicated a failure Fill reservoirs with approved brake fluid for leaks Check warning light Bleed system Adjust rear brakes and repair adjusters Replace axle set of shoe and lining Cor...

Page 232: ...r Defective master cylinder seals Cracked master cylinder casting Leaks at front disc brake calipers or rear wheel cylinders in pipes or connections Air in hydraulic system Inspect and repair or replace as necessary Check for proper lubrication of air valve O ring Replace Replace Repair or replace as necessary Inspect and replace as necessary Check for Faulty vacuum check valve or grommet replace ...

Page 233: ...enter the system whenever any part of hydraulic system is disconnected It may be necessary to bleed the hydraulic system at all six wheels if air has been introduced through low fluid level or by disconnecting brake lines at master cylinder If the brake line is disconnected at any wheel cylinder then only that wheel cylinder Figure 1 Brake Bleeding Sequence Figure 2 Brake Bleeder Wrench and Hose n...

Page 234: ...certain the valves on the pressure tank lines are not defective allowing air to be sucked in when fluid BRAKES 5 1 5 passes through the lines 4 Pressure tank should be kept at least 1 3 full of fluid to avoid air bubbles forming 5 If pressure tank is full of air bubbles release air pressure and those bubbles will increase in size be forced to top of fluid and escape It is recommended that pressure...

Page 235: ...crease or decrease the tension on the cable figure 4 If the tension on the cable cannot be adjusted at the lever it should be adjusted at the intermediate equalizer 1 Turn the adjusting knob on top of parking brake lever counterclockwise until it comes up against stop 2 Apply and release parking brake lever 3 Jack up rear wheels 4 Loosen lock nut at intermediate cable equal izer as shown in Figure...

Page 236: ...int indicates tight parking brake cables 3 Install adjusting hole cover in brake backing plate when adjustment is completed 4 Check parking brake adjustment as described earlier in this section COMPONENT REMOVAL BRAKE DRUM REMOVAL 1 Hoist rear wheels off ground NOTE It may be necessary to back off the brake shoe adjustment before the brake drum can be removed To back off brake shoe adjustment refe...

Page 237: ...Figure 10 Removing Hub and Drum 6 Remove the rubber bushing from the grooves in each of the four caliper ears figure 12 COMBINATION VALVE REMOVAL FIGURE 13 No attempt should be made to disassemble or repair the valve If any failure should occur the complete valve should be replaced 1 Disconnect all brake lines at valve Plug lines to prevent loss of fluid and entrance of dirt 2 Disconnect warning s...

Page 238: ...ir of the master cylinder Discard fluid NOTE Do not empty front reservoir or it will be necessary to bleed the brake system 2 Hoist vehicle and remove wheel 3 Remove cotter pin and drive axle nut and washer Figure 1 1 Brake Assembly Rear BRAKES 5 1 9 4 Position Tool J 22269 on caliper as shown in Figure 16 5 Tighten screw of tool until caliper moves out board far enough to push piston to bottom of...

Page 239: ...e hammer and tool No J 24717 12 Assemble tool No J 23345 to tool No J 8433 1 Figure 13 Combination Valve Mounting Figure 14 Hydraulic Lines at Master Cylinder 13 Position tool assembly as shown in Figure 19 CAUTION The gripping or pulling edge of the tool must be under the innerrace Ifthe toolslips up to the bearing cage the bearing will be seriously damaged and need to be replaced 14 With tool No...

Page 240: ...igure 20 3 Remove clevis pin from brake pedal Refer to figure 21 4 Remove master cylinder see Master Cylinder Removal earlier in this section 5 Remove master cylinder bracket by removing two bolts from top of bracket 6 Remove vacuum line to power brake booster 7 Remove four nuts retaining booster assembly to firewall as shown in Figure 22 8 Remove booster assembly through left front access door PA...

Page 241: ...5 2 2 BRAKES j 8433 1 TO BE ASSEMBLED AFTER C CLAMP IS TIGHTENED SECURELY e A 4128 Figure 19 Bearing Removal Figure 20 Power Level Panel Removed Figure 21 Clevis Pin Location ...

Page 242: ... Assembly Retaining Nuts Figure 24 Removing Cable Retaining Bracket FRONT PARKING BRAKE CABLE 4 Remove retaining pin in parking brake lever REMOVAL 0 Remove cable 1 Raise vehicle with suitable lifting device 2 Remove lock nut and adjusting nut from front INTERMEDIATE PARKING BRAKE CABLE REMOVAL 1 Hoist vehicle INTERMEDIATE CABLE FRONT CABLE EQUALIZER ADJUSTING NUT LOCK NUT TORSION BAR ...

Page 243: ...onnect cable from guides at points where cable passes through frame rails as shown in Figure 27 6 Remove cable Figure 27 Cable Guide on Frame Rail Figure 28 Clip on Frame Rail Retaining Bracket REAR PARKING BRAKE CABLE REMOVAL 1 Disconnect intermediate equalizer by remov ing locking and adjusting nuts figure 5 2 Pull wire clips at retainers on frame rails See figure 28 3 Remove ends of cables from...

Page 244: ...ert is damaged 6 Remove brake pedal assembly COMPONENT OVERHAUL BRAKES 5 25 Figure 31 Brake Pedal Assembly Right Side 2 Remove stop light switch from top of brake pedal If equipped with cruise control remove the switch next to the stop light switch figure 30 3 Remove cotter pin from pin retaining power booster clevis to brake pedal Remove clevis pin fig ure 21 4 Remove bolts from each end of pedal...

Page 245: ...ber parts and carefully inspect each rubber part for cuts nicks or other dam age These parts are the key to the control of fluid or air flow If the unit is in for overhaul or if there is any question as to the serviceability of rubber parts REPLACE them Inspect in accordance with the following table The table is organized by power brake unit groups Badly damaged items or those which would take ext...

Page 246: ...oove should have its lips facing toward the end of the secondary piston which contains the small com pensating holes 2 Assemble a new primary seal and primary seal protector over the end of the secondary piston oppo site the secondary seals so that the flat side of the seal seats against the flange of the piston which con tains the small compensating holes 3 In order to insure correct assembly of ...

Page 247: ...IPER OVERHAUL DISASSEMBLY Before beginning disassembly thoroughly clean the exterior of the caliper using clean Declene or equivalent Place the caliper on a clean work surface Remove the brake hose from the caliper discard ing the copper gasket Check the hose for worn spots cracks or other signs of deterioration Discard the hose if damaged replace with a new hose at reas sembly Drain brake fluid f...

Page 248: ...ot use emery cloth or any other form of abrasive Thoroughly clean the caliper after the use of crocus cloth If the bore can not be cleaned up in this manner replace the caliper ASSEMBLY Lubricate the bore in the caliper and the new piston seal with clean brake fluid Position the seal in the caliper bore groove Lubricate the piston with clean brake fluid and assemble a new boot into the groove in t...

Page 249: ... front shell return spring retainer plate and piston rod retainer 7 Remove assembly from tool and remove tool from vise 8 Remove the dust boot retainer and boot from the rear housing and push rod Remove the felt si lencer from inside the boot View of Power Piston 9 Remove the power piston assembly from the rear shell and remove the primary power piston bear ing from the center opening of the rear ...

Page 250: ... piston 13 Remove the housing divider from the second Figure 39 Unlocking Power Piston BRAKES 5 3 1 Figure 40 Removing Secondary Diaphragm ary power piston Remove the secondary power pis ton bearing from the housing divider 14 The secondary power piston should still be positioned on Tool J 23101 Fold back secondary diaphragm from O D of secondary support plate Grip the edges of the support plate a...

Page 251: ...n a counterclockwise direction to unlock the primary support plate from the primary power pis ton figure 43 20 Remove the primary diaphragm from the pri mary support plate 21 Remove the air filter and push rod limiter washer from the tubular section of the primary power piston 22 Remove the power head silencer from the neck of the power piston tube 23 Remove the rubber reaction bumper from the end...

Page 252: ... ASSEMBLY NOTE During assembly when a lubricant is specified use either the lubricant furnished with the repair kit or Seal Lubricant No 1050169 or equivalent 1 Lubricate the O ring seal Figure 37 and place on the air valve Figure 46 Installing Retainer Ring BRAKES 5 33 2 Wipe a thin film of lubricant on the large and small O D of the floating control valve 3 Ifthe floating control valve needs rep...

Page 253: ...the O D of the primary power piston tube 17 Remove the primary piston assembly from Tool J 23101 18 Assemble the secondary diaphragm to the secondary support plate from the side of the support plate opposite the locking tangs Press the raised flange on the I D of the diaphragm through the center hole ofthe support plate Be sure that the edge of the support plate center hole fits into the groove in...

Page 254: ...ion of the secondary power piston mak ing sure that the air valve return spring seats down over the raised center section of the secondary pis ton 32 Grip the edge of the primary support plate press down and start the threads on the secondary power piston into the threaded portion of the pri mary power piston by rotating in a clockwise direc tion figure 39 Figure 48 Installing Secondary Bearing BR...

Page 255: ...E RUBBER REACTION DISC PISTON ROD RETAINER AIR VALVE SPRING FOR GAGING REACTION PISTON TOO SNORT REACTION PISTON TOO LONG AIR VALVE PUSH ROD ASSEMBLY Figure 51 Gauging Piston Rod the front shell facing up Insert the master cylinder piston rod flat end first into the piston rod retainer 46 Press down on the master cylinder piston rod to be sure it is properly seated NOTE To assure that no vacuum is...

Page 256: ...ually falls away under foot pressure hydraulic system is leaking internally or externally 4 If brake pedal travels to within one inch of toeboard brake shoes are not adjusting or require relining 5 Start engine with brakes off and transmission in neutral Run engine to medium speed and turn off ignition Immediately close throttle This builds up vacuum Wait no less than 90 seconds then try brake act...

Page 257: ... of the disc braking surface will normally occur during brake application turning is not required unless they are Figure 53 Boot Installation severely scored It is not necessary to remove all score marks when turning Precision equipment must be used when turning discs and the following specifications must be carefully observed DO NOT reduce total thickness of the braking surface any more than the ...

Page 258: ...make it difficult if not impossible to obtain efficient brake performance OUT OF ROUND OR TAPERED DRUM An out of round drum makes accurate brake shoe adjustment impossible and is likely to cause excessive wear of other parts of brake mechanism due to its eccentric action An out of round drum can also cause severe and irregular tire tread wear as well as a pulsating brake pedal When the braking sur...

Page 259: ...actuating link with the override pivot Then position the adjuster lever and return spring on the secondary shoe Position sleeve in the hole in secondary shoe and fasten to backing plate with hold down spring assembly and pin 7 Install the remaining primary hold down spring washer and pin 8 Install the primary and secondary brake shoe return springs 9 Adjust brake shoes as outlined under BRAKE SHOE...

Page 260: ...new brake fluid No 5464831 or equivalent to within 1 4 oftop of reservoir Figure 57 Installing Outboard Shoe BRAKES 5 41 8 Depress brake pedal to seat linings against rotor 9 Clinch upper ears of outboard shoe by posi tioning channel lock pliers with one jaw on top of upper ear and one jaw in notch on bottom of shoe opposite upper ear 10 After clinching ears must be flat against caliper housing wi...

Page 261: ...three bolts attaching bearing retainer to knuckle Torque to 35 ft lbs 6 Install drive axle washer and nut Torque nut Figure 58 Hub to Disc Bolts to 110 ft lbs If necessary to align cotter pin slot tighten nut and install NEW cotter pin and crimp Torque not to exceed 280 ft lbs NOTE Do not back off nut to install cotter pin POWER BRAKE BOOSTER INSTALLATION 1 Position booster assembly on firewall an...

Page 262: ... connect the ball to the lever Make sure the locking fingers are fully expanded on the backing plate figure 29 2 Install hubs and drums as described under Brake Drum Installation 3 Feed ends of cables through brackets on frame rails and install clips figure 28 4 Connect ends of cables and install intermediate equalizer with intermediate cable on top of rear ca ble figure 25 5 Adjust parking brake ...

Page 263: ... TUBING BE CAUSE COPPER IS SUBJECT TO FATIGUE CRACKING WHICH WOULD RESULT IN BRAKE FAILURE Steel tubing must be double lap flared at the ends in order to produce a strong leakproof joint Special tools are available from tool companies for making double lap flares Do not attempt to flare steel tubing without proper tools Figure 60 shows a single and a double lap flare note the split in the single l...

Page 264: ...Figure 61 Brake Line Routing BRAKES 5 45 ...

Page 265: ...unting Bracket to Frame Rail Screw Torque 72 in lb min Fully Driven not Stripped Power Cylinder to Firewall Nut Torque 12 16 ft lbs Master Cylinder Bracket to Firewall Bolt Torque 15 20 ft lbs Brake Lever Pivot Bolt Bolt Torque 30 35 ft lbs Brake Lever Pivot Bracket to Firewall Nut Torque 25 30 ft lbs Power Cylinder to Master Cylinder Nut Torque 28 ft lbs Hub to Drum Bolt Torque 70 85 ft lbs Drum ...

Page 266: ...d 6A 38 Valve Guide Bores 6A 40 Replacing Valve Spring Head on Engine 6A 41 Oil Pan 6A 42 Oil Pump 6A 42 Connecting Rod and Piston Assembly 6A 44 Rod Bearings 6A 44 Piston 6A 45 Checking Cylinder Bore 6A 47 Rings 6A 47 Rod and Piston Assembly 6A 48 Piston Pins 6A 48 Crankshaft Pulley 6A 48 Belt Tension 6A 49 Harmonic Balancer 6A 49 Front Cover Oil Seal 6A 50 Front Cover 6A 50 Timing Chain and Gear...

Page 267: ...G FEED 8 ROD BEARING FEED GENERAL INFORMATION Figure 1 Engine Lubrication ENGINE LUBRICATION SYSTEM FIGURE 1 The engine oil pan forms a reservoir for engine oil to provide lubrication and also hydraulic fluid to operate the valve lifters Oil pressure for lubrication is furnished by a gear type oil pump that is bolted to the rear main bearing cap and driven by the camshaft gear through a hexagonal ...

Page 268: ... rods The connecting rod bearings are oiled by con stant oil flow from passages drilled through the crankshaft connecting the main journals to the rod journals A groove around each main bearing fur nished oil to the drilled crankshaft passages Oil returns to the oil pan reservoir from the rocker arms through passages at each end of the cylinder heads Oil from the valve lifter compart ment returns ...

Page 269: ...ow Oil Pressure 6A 16 High Oil Pressure 6A 17 No Oil Pressure While Idling 6A 17 No Oil Pressure While Accelerating 6A 17 No Oil Pressure 6A 17 Burned Sticking or Broke Valves 6A 17 Excessive Oil Consumption 6A 18 Engine Noisy 6A 19 A Noisy Main Bearings 6A 19 B Noisy Rod Bearings 6A 20 C Noisy Timing Gears 6A 20 D Noisy Timing Chain 6A 20 E Noisy Pistons 6A 21 F Noisy Valve Mechanism 6A 21 G Nois...

Page 270: ...ngs rings pistons etc IGNITION Engine timing and dwell ENGINE WILL NOT TURN OVER See Battery Diagnosis Charts STARTER See Starter Diagnosis Charts MECHANICAL Seized bearings rings and or pistons ENGINE TURNS OVER SLOWLY BUT DOES NOT START GENERAL BATTERY See Battery Diagnosis Charts STARTER See Starter Diagnosis Charts NOTE Most conditions under Does Not Start may also cause hard starting when col...

Page 271: ...tricted Air intake restricted Carburetor icing 5 Engine timing and dwell MECHANICAL Throttle linkage defective or improperly adjusted Valve train faulty Valve lifter or valve clearance Low compression Choke valve faulty stuck or binding 3 Head cracked or gasket leaking Excessive engine friction FUEL Vapor lock Flooding 4 Accelerator pump 8 Carburetor faulty Fuel pump faulty Fuel restricted IGNITIO...

Page 272: ...rimary coil winding grounded Broken or loose ignition wire or faulty switch MECHANICAL Choke binding sticking or improper adjustment Low or erratic compression Check valve train mechanism rings blown head gasket etc FAULTY SECONDARY 6 Corroded spark plug cable terminals Chafed or cracked cable insulation Ignition coil weak or inoperative Moisture on ignition coil terminals dis tributor cover spark...

Page 273: ...w IGNITION 6 Improper plug or plug gap Faulty plugs Improper point setting worn or damaged Defective condenser and toil Faulty rotor or cap Loose wiring Damaged or corroded coil wiring or spark plug cables Moisture on wiring or in distributor cap Cracked distributor cap ROUGH ENGINE IDLE 1 MECHANICAL Linkage improperly adjusted or damaged Throttle linkage improperly adjusted or faulty FUEL Engine ...

Page 274: ... Low compression Fuel quality poor Air cleaner dirty MECHANICAL Leaky or incorrect valve Worn or leaky valve guide Worn timing chain gears sprocket or camshaft lobe Dirt in hydraulic lifter MECHANICAL Throttle shaft accelerator pedal and or throttle linkage sticking or binding Timing chain or gears and or camshaft lobes worn Burned warped pitted leaky or sticking valves Inoperative choke Sticking ...

Page 275: ...lugs Fouled spark plug or broken porcelain Faulty spark plug cables Clean gap and or replace spark plugs as necessary Too hot spark plugs change to colder type but note that a hot plug may be due to loose installation or lack of plug gasket if gasket is called for Ignition point gap much too wide or pitted Breaker arm binding or sticking Breaker arm weak Weak spark coil or condenser Improper ignit...

Page 276: ... improperly aligned FUEL Fuel pump faulty Carburetor faulty plug wire ENGINE RUNS BUT MISSES ON DIFFERENT CYLINDERS IGNITION 2 Dirty or incorrectly set points Worn dirty or gap set too wide in spark plugs Worn distributor shaft Cam worn or burned distributor rotor Faulty coil or condenser Insufficient spring tension on points MECHANICAL Valve train faulty Valve train defective Stuck hydraulic lift...

Page 277: ...ns of pre ignition when operated at sea level IGNITION 2 ENGINE SURGES 1 Ignition timing or dwell incorrect Centrifugal governor advance not operating properly Vacuum advance not operating properly Ignition points burned pitted sticking or bouncing Due to weak breaker arm spring Faulty spark plugs Faulty ignition cables Faulty ignition coil or condenser Worn or burned distributor rotor Worn distri...

Page 278: ...n cylinder head gasket Burned warped or pitted valves COOLING Defective thermostat stuck open Faulty temperature sending unit or dash unit NOTE Coolant is used to cool the engine and air is used to cool the coolant Anything which prevents the coolant air system from working properly will cause engine to overheat Air oil or grease in the coolant will reduce the ability of the coolant to absorb heat...

Page 279: ...d too high 1 High engine temperature Poor grade fuel octane too low Improper timing and dwell Quick shut down of hot engine MECHANICAL Improper valve timing NOTE Hot spot in combustion chamber ignites fuel before spark occurs May not be noticed unless severe GENERAL Overheated engine Carbon deposits Spark plugs not tight Spark plugs with wrong heat range Timing and dwell improperly set PRE IGNITIO...

Page 280: ...e or improperly set Fuel filter plugged Dirt in carburetor jets BACKFIRES POPPING BACK OR SPITBACK THROUGH CARBURETOR SUBDUED EXPLOSION IN INTAKE MANIFOLD FUEL Lean mixture Dirt or water in fuel Faulty accelerator pump MECHANICAL Leaky or sticky intake valve Weak or broken intake valve Faulty heat valve Plugged heat crossover passage Improper camshaft timing Improper valve lash AFTER BURNING OR MU...

Page 281: ...d weather Viscosity too light grade Oil has foam from water condensation or leaking head gasket Overheating SMOKE LOW OIL PRESSURE BLUE Or Bluish White Excessive oil consumption See Excessive Oil Consumption FUEL Excessive fuel pump pressure Float level high 4 Faulty carburetor Leakage or loose fittings Idle speed settings incorrect Accelerator pump improperly adjusted MECHANICAL Faulty valves or ...

Page 282: ...xhaust back pressure Improper ignition timing HIGH OIL PRESSURE NO OIL PRESSURE MECHANICAL Faulty gauge Oil pressure relief valve adjustment too heavy Relief valve spring too stiff Oil pressure passage clogged NO OIL PRESSURE WHILE IDLING MECHANICAL Oil pump not functioning properly Valve stuck by foreign material Excessive clearance at bearings camshaft rod or main NO OIL PRESSURE WHILE ACCELERAT...

Page 283: ...ing chain cover gasket Worn timing chain cover oil seal Worn or improperly seated rear main bearing oil seal Loose oil line plugs Rear camshaft bearing drain hole plugged Loose rocker arm cover gasket broken or cover distorted or bent Rear main bearing side seal improperly installed INTERNAL LEAKAGE Carbon in oil ring slot Rings fitted too tight in grooves Leaky piston rings due to wear scuffs or ...

Page 284: ...formation can therefore be used only as a general guide to noise diagnosis There is no substitute for experience NOTE A loose main bearing is indicated by a powerful but dull thud or knock when the engine is pulling If all main bearings are loose a noticeable clatter will be audible The thud occurs regularly every other revolution The noise is loudest when the engine is lugging or under heavy load...

Page 285: ...bearing noise GENERAL Gears misaligned Excessive backlash Chipped tooth usually camshaft gear GENERAL Chain loose due to wear Sprocket teeth worn Sprockets misaligned Loose vibration damper or drive pulley C NOISY TIMING GEARS Misaligned rod Connecting rod bolts not tightened cor rectly Should connecting rod misalignment be suspected check for a diagonal wear pattern on the piston skirt and for ex...

Page 286: ...he knock becomes more noticeable at 25 to 35 mph on the rod GENERAL F NOISY VALVE MECHANISM MECHANICAL Sticking or warped valves Bent push rods Dirty worn or scored parts Broken or weak springs Damaged valve lifter and or camshaft lobes Insufficient or poor oil to valve mecha nism Thin foaming or diluted Excessive valve stem to guide clearance Valve lifter incorrectly fitted to bore size Pulled or...

Page 287: ...fer to Generator Diagnosis Charts GENERAL I NOISY FAN J NOISY FUEL PUMP MECHANICAL Loose mounts Belt too tight GENERAL MECHANICAL Fan blades bent Fan blades loose on clutch Fan out of balance when made Fan blades strike shroud Fan shaft end play excessive NOTE Diagnosis of fuel pumps suspected as noisy requires that some form of sounding device be used Judgment by ear alone is not sufficient other...

Page 288: ...ation not seated properly or not torqued to specifications K NOISY FAN BELT MECHANICAL Belt too tight Squeaks Belt pulleys misaligned Belt loose squeaks when engine is accelerated L MISCELLANEOUS NOISE Rattles squeaks etc from loosely mounted accessories generator horn oil pan etc ENGINE VIBRATION Unequal compression in cylinders Missing at high speed Unbalances fan or loose fan blade Incorrect ad...

Page 289: ...of the above procedures will prevent a recurrence of the icing condition The most effective way to prevent icing is to add an anti icing additive to the fuel 6 SPARK INTENSITY CHECK Disconnect a spark plug wire and install a termi nal adapter in the terminal of the wire to be checked Hold the adapter approximately 1 8 away from the exhaust manifold and crank the engine The spark should jump the ga...

Page 290: ...xistence of a fuel consumption problem While making the fuel consumption test the vehicle odometer should be checked over a measured mile for proper calibra tion ENGINE 6A 25 If the results of the fuel consumption test indicate that a fuel consumption problem does exist the diag nostic procedures outlined in this manual under Excessive Fuel Consumption in Carburetor and or Ignition Diagnosis chart...

Page 291: ...Loosen oil cooler line fittings from the adapter and slide lines forward approximately one inch ENGINE OIL PRESSURE TEST 1 ENGINE AT OPERATING TEMPERATURE 2 TRANSMISSION IN NEUTRAL POSITION 3 OIL PRESSURE IiOULD BE AT SLOW IDLE 7 PSI MIN 1500 3000 R PM 35 PSI MIN Figure 3 Checking Engine Oil Pressure 5 Remove oil filter extension fitting and adaptor 6 Remove three 3 bolts securing base to engine b...

Page 292: ...Figure 5 Attaching Engine Removal Tool ENGINE 6A 27 ...

Page 293: ...nch hoise as in Figure 5 3 Remove bolts A and B Remove nuts C and D as shown in Figure 6 Figure 6 Front Engine Lift Location 4 Adjust tool No J 24603 01 so that the front of the egine is raised just enough to enable removal of support cushion 5 Remove engine support cushion INSTALLATION 1 Install new studs into engine support cushion and torque to 30 ft lbs 2 Install engine support cushion into pl...

Page 294: ...ate model vehicles placement of the transmission mount is the reverse shown in Figure 9 Tab fits into the opposite slot Ob serve placement of mount before removal and assemble mount with tab positioned as required by hole pattern 5 Remove tool No J 24603 01 connect coil bracket replace air cleaner install engine cover 4 Remove both upper venturi ring braces on vehicles with air conditioning as sho...

Page 295: ...may be left connected to the coil if desired 14 Remove intake manifold bolts then remove manifold with carburetor attached 15 Clean machined surfaces of cylinder head and intake manifold with a putty knife Use care not to gouge or scratch machined surfaces INSTALLATION 1 Coat both sides of gasket sealing surface that seal the intake manifold to the head with 1050026 sealer or equivalent and positi...

Page 296: ...gure 12 12 Install oil fill tube and flexible elbow Figure 13 Location for Disconnecting Vacuum Hoses and Throttle Cable ENGINE 6A 3 1 ies Figure 14 Distributor and Transmission Vacuum Lines Typical 13 Install generator mounting bracket if removed See Figure 11 14 Adjust belt tension Refer to Belt Tension later in this section 15 Install venturi ring brace s See Figure 10 16 Connect upper radiator...

Page 297: ...olts No 2 and 5 4 Connect exhaust pipe and tighten pipe to manifold bolts until they bottom on spacer 4 Remove power steering or generator brackets as required 5 Lower vehicle 3 Hoist vehicle 5 Disconnect exhaust pipe 6 Remove exhaust manifold INSTALLATION Figure 16 Intake Manifold and Gasket 1 Position exhaust manifold on engine and in 1 Hoist vehicle stall bolts No 3 and 4 finger tight See figur...

Page 298: ... the air con ditioning compressor up for support after removing its bracket See Figure 12 NOTE Freon lines do not have to be discon nected from the compressor 5 Remove vJve cover to cylinder head attaching screws as shown in Figure 16 6 Clean gasket surfaces on cylinder head and valve cover INSTALLATION 1 Thoroughly clean the head and valve cover gasket surface Then apply 1051435 R T V Room Temper...

Page 299: ... the hardened flanged bolts and tighten alternately Torque bolts to 25 ft lbs VALVE LIFTERS OPERATION Oil is supplied to the lifter through a hole in the side of the lifter body which indexes with a groove SPRINGS BODY COIL SPRING VALVE SPRING VALVE ROTATOR FLAT WASHER EXHAUST VALVE A X737 Figure 21 Cylinder Head Exploded View and hole in the lifter plunger Oil is then metered past the oil meterin...

Page 300: ...e Full mark allows crankshaft counterweights to churn the oil into foam When foam is pumped into the lifters they will become noisy since a solid column of oil is required for proper operation Correction Drain oil until proper level is ob tained See Section O in the beginning of this manual b Low oil level Oil level below the Add mark allows the pump to pump air at high speeds which results in noi...

Page 301: ...nd down a certain amount with rocker arm held against valve Valve lash indicates one of the following 1 Worn push rod 2 Worn rocker arm Figure 25 Rocker Arm Wear 3 Lifter plunger stuck in down position due to dirt or varnish 4 Defective lifter Checking of the above four items 1 Observe upper end ofpush rod Excessive wear ofthe spherical surface indicates one of the following conditions a Improper ...

Page 302: ...are removed check the lifter foot for abnormal wear as follows 1 Place a straight edge across the lifter foot NOTE Lifter foot must be clean and dry 2 While holding the lifter at eye level check for light between the straight edge and lifter foot 3 Iflight indicates a flat or concave surface ofthe lifter foot the lifter should be replaced and the cam shaft inspected for wear Wear at the CENTER of ...

Page 303: ... be clean ofany foreign matter and free ofnicks or heavy scratches The cylinder head bolt threads in the block and threads on cylinder head bolt must be cleaned Dirt will affect bolt torque Figure 28 Cylinder Head Torque Sequence INSTALLATION 1 Use a new head gasket and coat both sides with part No 1050026 sealer or equivalent Install gasket with bead facing cylinder 2 Clean and dip cylinder head ...

Page 304: ...sure they are properly seated 6 Set spark plug gap Lubricate plug threads with one drop of engine oil and re install plugs Torque to 35 ft lbs for vehicles equipped with breaker point ignition systems and 25 ft lbs for high energy ignition systems Reconditioning Valves When reconditioning valves and valve seats clean carbon from cylinder heads and valves using care not of gouge or scratch machined...

Page 305: ...ween valve rotator and gauge Failure to maintain this clearance will cause rocker arm and valve rotator interference Example Valve Rotator to Gauge Clearance 038 Minus Valve Stem to Gauge Clearance 035 003 This is less than 005 and a new valve should be installed VALVE GUIDE BORES As previously stated if the valve guide bores are worn excessively they can be reamed oversize The following reamers a...

Page 306: ...its seat See figure 35 4 Install Tool J 5892 1 See Figure 35 Compress CHECKING ROTATORS Figure 36 Valve Stem Wear ENGINE 6A 4 1 Figure 35 Removing Valve Spring the valve spring until valve keys are accessible then remove keys valve rotators and springs NOTE If valve spring does not compress tap tool with a hammer to break bind at rotator and keys The rotators cannot be disassembled and require rep...

Page 307: ...lts 9 Raise front of engine enough so the oil pan can be removed approximately one inch 10 Clean gasket surfaces on the engine block and the oil pan INSTALLATION OIL PAN 1 Apply sealer 1050026 or equivalent to both sides of gaskets Position all gaskets on engine block See Figure 37 2 Position oil pan on engine Start all bolts and install until finger tight Torque oil pan bolts to 10 ft lbs 3 Repla...

Page 308: ...lator valve valve spring and bore for damage Proper valve to bore clearance is 0025 to 0050 ASSEMBLY 1 Install the drive gear into the pump with the hex ID of the drive shaft toward the oil pump mount ing pad then install the idler gear Figure 38 Oil Pump Exploded View INSTALLATION Figure 40 Oil Pump Installation ENGINE 6A 43 Figure 39 Oil Pump Shaft Extension 2 Position a new gasket on the pump b...

Page 309: ...emblies in the same manner ROD BEARINGS The connecting rod bearings are designed to have Figure 41 Connecting Rod Bolt Guide a slight projection above the rod and cap faces to insure a positive contact Connecting rod bearings can be replaced without removing the rod and piston assembly from the en gine REMOVAL 1 Remove oil pan Refer to Oil Pan earlier in this section NOTE It may be necessary to re...

Page 310: ...ning connecting rod bearings All rods must be connected to their journals when rotating the crankshaft to prevent engine damage NOTE Bearings are identified as shown in Fig ure 38 9 Spread rods with screwdriver and measure the rod side clearance as shown in Figure 39 Clearance should be 006 to 020 NOTE If a rod is twisted or bent a new rod must be installed NO ATTEMPT SHOULD BE MADE TO STRAIGHTEN ...

Page 311: ...bore Figure 47 Checking Piston Clearance Each piston should be fitted to its individual cyl inder and marked for that cylinder CLEANING PISTON PISTON INFORMATION CHART Clean the pistons by scraping carbon off the top of the piston Deposits in the ring grooves should be removed with a suitable ring groove cleaning tool It is important that the ring grooves be completely free of deposits BORE DIAMET...

Page 312: ...e rings two compression rings and one oil ring The oil ring consists of two rails and an expander RING TOLERANCES When installing new rings ring gap and side clearance should be checked as follows Figure 48 Piston Rings Figure 49 Measuring Piston Ring Gap PISTON RING AND RAIL GAP ENGINE 6A 47 Each ring and rail gap must be measured with the ring or rail positioned squarely and at the bottom of the...

Page 313: ...nstallation of re maining piston assemblies The clearance between the adjacent rods when checked with a feeler gauge on each crankpin should be from 006 to 020 Refer to Figure 44 5 Torque rod bolt nuts to 42 ft lbs REMOVAL PISTON PINS The correct piston pin fit in the piston is 0003 to 0005 loose If the pin to piston clearance is to the high limit 0005 the pin can be inserted in the piston with ve...

Page 314: ...d remove pulley 7 Remove harmonic balancer hub bolt and washer 8 Using balancer puller remove balancer as shown in Figure 47 CAUTION Use ofany other type puller such as a universal claw type which pulls on the outside ofthe hub can destroy the balancer The outside ring of the balancer is bonded in rubber to the hub by pulling on the out side rather than the hub it is possible to break the bond The...

Page 315: ...to Crankshaft Pulley and Har monic Balancer earlier in this section Figure 54 Installing Harmonic Balancer 4 Pry seal out of cover from the front with a large screwdriver being careful not to damage the surface on the crankshaft INSTALLATION 1 Apply 1050026 sealer or equivalent to outside diameter of seal 2 Using Tool J 5154 01 install oil seal as shown in Figure 55 Tighten until 005 feeler gauge ...

Page 316: ...lley and Harmonic Ba lancer earlier in this section 10 Remove oil pan Refer to Oil Pan earlier in this section 11 Remove front cover to block attaching bolts and remove front cover timing indicator and water pump assembly See figure 56 INSTALLATION 1 Install new cover gasket Apply 1050026 or equivalent sealer to gasket around water holes and place gasket on block 2 Install front cover timing indic...

Page 317: ...ront cover See Front Cover earlier in this section Figure 58 Crankshaft Gear Removal 3 Remove fuel pump eccentric 4 Remove oil slinger camshaft and timing chain 5 Remove key then crankshaft gear NOTE Gear to crankshaft fit tolerances may be such that a puller is necessary See figure 58 CAUTION Remove crankshaft key ifpossi ble before usingpulley ifnot align puller so that it does not overlap end o...

Page 318: ...oved with or without the transmission and final drive attached NOTE It is recommended to remove the trans ENGINE REPLACEMENT ENGINE 6A 5 3 MEASURING NO 4 CYL AT T D C DIFFERENCE 134 9 64 MEASURING NO 4 CYL WITH NO 1 CYL AT T D C A 1468 Figure 61 Checking Valve Timing 5 Slowly turn engine 1 1 2 revolutions until ro tor approaches No 1 spark plug wire position Con tinue to turn engine until timing m...

Page 319: ...engine removal Tool No J 24603 01 to the engine Adjust lift mechanism until all slack is removed from the cable See figure 5 Figure 62 Flywheel Cover Removal NOTE To properly position engine removal tool remove seat belt plate and anchor bolt as sembly Attach load adjustor chain to front and rear engine lift locations as shown in Figures 6 and 7 Then install support braces and chain fall as shown ...

Page 320: ...if so equipped from engine and position on top of intake manifold Dis connect wire from the negative coil terminal 26 Disconnect heater hoses 27 Disconnect wire from brake combination valve 28 Disconnect engine harness 29 Remove engine oil filler upper tube 30 Remove engine oil dipstick tube 31 Disconnect upper radiator hose from engine 32 Disconnect air conditioning compressor if equipped from br...

Page 321: ...nd forth find the center loca tion Hold the shaft in this position and then torque the bolts to 55 ft lbs on support 10 Install lower R H venturi ring bracket Torque nut on engine stud to 45 ft lbs Torque nut at venturi ring attachment to 20 ft lbs 11 Position R H drive axle and torque NEW attaching bolts to 65 ft lbs 12 Connect transmission cooler lines and tighten fittings to 20 foot pounds and ...

Page 322: ...is section 39 Connect vacuum lines to the brake booster and heater controls to the intake manifold Connect the vacuum line from the carbon canister to the front of the carburetor 40 Add engine oil and transmission fluid as re quired Add engine coolant Refer to Engine Cool ing later in this manual Refer to SECTION 7 for details on Checking and Adding Transmission Fluid 41 Connect battery negative g...

Page 323: ...ew cup plug in rear of No 5 bearing bore and seal with a permanent type sealer NOTE To aid aligning bearings with oil pas sages place each bearing in the front bore with tapered edge toward block and align the oil hole in the bearing with the center of the oil slot in the bore Mark top of bearing When installing the bearings the mark will act as a guide 2 Drive No 5 camshaft bearing into place and...

Page 324: ...bolts in pan rails to align rods with rubber bands as shown in Figure 67 Align rods so that the inner thread protectors of adjacent rods overlap approximately one inch as shown Alignment can be adjusted by increasing ten sion on rubber bands with additional turns around the pan bolts or thread protectors 2 Position upper half of main bearings in block and lubricate with engine oil 3 Install a new ...

Page 325: ...s tigauge Figure 69 Checking Bearing Clearance 5 Reinstall bearing capand bearing Place Lubri cant No 1050125 or equivalent on cap bolts and install Torque to 120 ft lbs cap bolts 6 Remove bearing cap and determine bearing clearance by comparing the width of the flattened plastigauge at its widest point with graduation on the plastigauge container The number within the graduation on the envelope i...

Page 326: ...th locating tang in correct position and rotate shaft to turn it into place using cotter pin or roll out pin as during removal 7 Place new bearing shell in bearing cap 8 No 5 bearing Install new asbestos oil seal in the rear main bearing cap as described later in this section Install sealer on cap as shown 9 Install bearing caps lubricate bolt threads with No 1050125 Lubricant or equivalent and in...

Page 327: ...ock between seal and crankshaft to protect bearing surface before trimming 7 Form a new rope seal in the rear main bearing cap Refer to Rear Main Lower Oil Seal next in this section 8 Assemble the cap to the block and torque to 120 ft lbs REPLACEMENT 1 Remove crankshaft Refer to Crankshaft earlier in this section 2 Remove upper oil seal 3 Install a new rear main bearing upper seal Use tool J 26484...

Page 328: ...to tool 4 Apply sealer on shaded areas of Figure 71 5 Clean bearing insert and install in bearing cap ENGINE SPECIFICATIONS ENGINE 6A 63 Figure 76 Installing Rear Main Seal Lower Half 6 Clean crankshaft bearing journal and seal con tact Install sealer on cap as shown 7 Install bearing caps lubricate bolt threads with No 1050125 Lubricant or equivalent and install Torque bearing cap bolts to 120 ft...

Page 329: ... 2 980 Pin to Piston Clearance 0003 0005 Pin to Rod Fit 0008 0018 Press PISTON RINGS No of Compression Rings per piston 2 Width of Compression Rings top bottom 0770 0780 Gap Clearance Compression Rings 010 023 Clearance in Groove Compression Rings Upper 0020 0040 Lower 0020 0040 No of Oil Rings per piston 1 Gap Clearance Oil Ring 015 055 CAMSHAFT Bearing Journal Diameters No 1 2 0365 2 0357 No 2 2...

Page 330: ...of Teeth 18 TIMING CHAIN Width Morse 627 Linkbelt 720 750 No of Links 48 Pitch 500 FLYWHEEL No of Teeth on Starter Gear 166 No of Teeth on Starter Pinion 9 LUBRICATION SYSTEM Crankcase Capacity Drain and Refill 5 Qts Drain Refill with Filter Change 6 Qts Oil Pump Clearance Pressure Relief Valve in Bore 0025 0050 End Clearance Gear 0025 0065 TORQUE SPECIFICATIONS Specified torque is for installatio...

Page 331: ...n Rear Mount to Crossmember 55 Transmission Rear Mount to Support 50 Starter to Cylinder Block Bolts 35 Distributor Clamp to Cylinder Block Bolt 17 Spark Plugs High Energy Ignition 25 Spark Plugs Breaker Point Ignition 35 Coil to Intake Manifold Bolt 15 Cylinder Head Bolts 85 Connecting Rod Nuts 42 Clean and dip entire bolt in engine oil before tightening to obtain a correct torque reading SPECIAL...

Page 332: ...und pressure cap used raises the coolant boiling point approximately 22 F 5 5 C The pressure type radiator filler cap contains a blow off or pressure valve and a vacuum or atmos pheric valve The pressure valve is held against its seat by a spring of predetermined strength which protects the radiator by relieving the pressure if the pressure should exceed that for which the radiator is designed The...

Page 333: ...ch is Figure 3 Coolant Recovery Reservoir Type II mounted on the bearing shaft with the vanes facing forward Coolant flows through the inlet passage to the low pressure area at the center where it then flows radially through six openings in the impeller Vanes on the rotating impeller cause the coolant to flow rearward through two discharge passages cast in the engine block These passages deliver a...

Page 334: ...this section Radiator fins obstructed Clean away bugs leaves etc Flush system add fresh coolant Cooling system passages Flush system add fresh coolant blocked by rust or scale Reservoir hose pinched or Relieve kinks by re routing kinked especially at Replace if permanently kinked radiator filler neck Lower radiator hose Check for hose spring position by collapses squeezing lower end of hose Replac...

Page 335: ...r portion of the engine cooling system DRAINING FLUSHING AND REFILLING COOLING SYSTEM Before draining the cooling system inspect the system and perform any necessary service to insure that it is clean does not leak and is in proper working order CAUTION To avoid the danger of being burned andpreventloss ofcoolant do not remove the radiator cap while the engine and radiator are still hot because th...

Page 336: ...l radiator to filler neck with coolant meeting GM Specification 1899 M for ease and speed of filling use a 20 inch length of rubber hose and funnel to add coolant at radiator cap to provide the re quired freezing and corrosion protection at least a 50 percent solution for 34 F 36 C Install radiator cap Make certain arrow on cap lines up with over flow tube See Figure 5 7 Fill reservoir to COLD lev...

Page 337: ...enturi ring 8 Install venturi ring seal strap 9 Connect lower radiator hose to water pump 10 Lower motor home 11 Secure clamp on bypass hose and install heater hose to water pump 12 Tension belts Refer to Belt Tension later in this section 13 Refill radiator If new coolant is used refer to Section 0 coolant has a smooth unobstructed flow through the thermostat and water outlet See Figure 7 When th...

Page 338: ...T IS NOT IN PROPER BALANCE COULD FAIL AND FLY APART DURING SUBSEQUENT USE CREATING AN EXTREMELY DANGEROUS CONDITION Figure 8 Thermostat Installation INSTALLATION 1 Install fan and fan clutch separately into the area in the shroud between the water pump and the radiator Be careful not to damage the radiator core 2 Install four 4 attaching bolts that secure the fan to the fan clutch and torque to 20...

Page 339: ...ces the shearing action Thus less torque is transmitted to the clutch body and the speed of the fan decreases The temperature at which the automatic fan clutch engages and disengages is controlled by the setting of the bimetallic coil This setting is tailored to satisfy the cooling requirement of the vehicle Trans Mode fan clutch not shown is similar to the MotorHome fan clutch but provides a grea...

Page 340: ... 9 engagement of the fan clutch This will be indicated by an increase or roar in fan air noise and by a drop in the thermometer reading of approximately 5 15 degrees F If the clutch did not engage between 150 190 F 65 6 87 8 C the unit should be replaced NOTE Be sure fan clutch was disengaged at be ginning of test If no sharp increase in fan noise or temperature drop was observed and the fan noise...

Page 341: ...s driven by one primary belt and is used as an idler for a second belt driving some other auxiliary a Follow same checking and adjusting proce dure for the primary power steering pump drive belt as for 1 above Figure 12 Generator Mounting b Recheck and adjust as necessary the pump belt tension after adjusting tension on belt driving the auxiliary 3 To adjust generator or air conditioning com press...

Page 342: ...elt on pulley and move generator away from engine until required ten sion is measured 2 Tighten generator adjusting arm bolts and pi vot bolt to specified torque figure 12 NOTE Removal and installation of air condi tioning compressor belt is accomplished in the ENGINE COOLING 6K 1 1 Figure 13 Air Conditioning Compressor Mounting same manner as described above Refer to Fig ure 13 for specified torq...

Page 343: ...ty increases and thereby controls the air fuel mixture in the secondary bores This mixture combines with the fuel mixture in the primary side Using the air valve principle fuel is metered in direct proportion to the air passing through the secondary bores The fuel reservoir is centrally located and uses a single float pontoon A pleated paper fuel filter is mounted in the fuel inlet casting of the ...

Page 344: ...cleaner Therefore a balanced air fuel mixture ratio can be maintained during part throttle and power operation because the same pres sure acting upon the fuel in the float bowl will be balanced with the air flow through the carburetor bores The internal vent tubes allow the escape of fuel vapors in the float bowl during hot engine operation This prevents fuel vaporization from causing rich mixture...

Page 345: ...ottle valves causes low pressure at the lower idle air bleeds As a result fuel begins to discharge from the lower idle air bleed hole and continues to do so from part throttle to wide open throttle MAIN METERING SYSTEM FIGURE 4 The main metering system consists of main me tering jets vacuum operated metering rods main fuel well main well air bleeds fuel discharge nozzles and triple venturi The sys...

Page 346: ...ot supply sufficient air and fuel requirements the secondary side of the carburetor is used The secondary throttle valves are actuated by a connecting linkage to the primary throttle lever With the throttle valves opened a low pressure vacuum is created beneath the air valve Atmos pheric pressure on top of the offset spring loaded air valve forces the valve open allowing the required air to flow t...

Page 347: ... rated by a pump lever on the air horn which is con nected directly to the throttle lever by a pump rod As the throttle is returned from an open to a closed position the pump return spring pushes the pump plunger upward against the pump lever As the pump begins to move up the discharge check ball immediately seats in the pump discharge passage so that no air will be drawn into the passage which co...

Page 348: ...R THERMOSTATIC COIL INSIDE CUP BAFFLE AIR BLEED FILTER SCREEN BLEED CHECK VALVE CHECK VAL VACUUM BREAK ROD FAST IDLE ADJUSTING SCREW DELAYED VACUUM BREAK DIAPHRAGM UNIT A 1692 Figure 8 Choke System throttle is opened This gives the engine sufficient fast idle speed and correct fuel mixture for running until the engine begins to warm up and heat the thermostatic coil in the choke housing Engine vac...

Page 349: ...t oil choke linkage If parts are replaced check adjustments Vacuum leaks in carburetor base Check all manifold vacuum hoses for proper con or intake manifold nection and location Check manifold and carburet or base gaskets for leaks Tighten or replace as necessary Torque carburetor to manifold bolts to 15 ft lbs No fuel in carburetor 1 Remove fuel line at carburetor Connect hose to fuel line and r...

Page 350: ...buretor unit Disassemble and clean 4 Check float needle and seat for proper seal If a needle and seat tester is not available apply mouth suction needle seat with needle installed If needle and seat is defective replace with factory matched set 5 Check for fuel leaks into float bent float arm or binds in the float hanger Free up or replace parts as necessary NOTE A solid float can be checked for f...

Page 351: ...ne flooded Page 8 2 If carburetor still floods remove air horn and check float needle and seat for proper seal If a needle seat tester is not available mouth suction can be applied to the needle seat with needle installed If needle seat leaks replace with a factory matched set 3 Check for fuel leaks into float bent float arms or binds in float hanger NOTE A solid float can be checked for fuel abso...

Page 352: ...seat are defective replace with factory matched set 3 Check float for fuel leaks bent float arm or binding float hanger NOTE A solid float can be checked for fuel absorp tion by lightly squeezing between fingers If wet ness appears on surface or float feels heavy check with known good float replace float assembly Dirt in idle channels If excessive dirt is found in carburetor or idle channels clean...

Page 353: ...Corrective Action Carburetor throttle valve not Adjust throttle linkage to obtain wide open throttle going wide open Check by in carburetor pushing accelerator pedal to floor Dirty or plugged fuel filter Replace as necessary Air valves not unlocking after Free up and adjust air valve lockout engine warms up Air valves binding stuck 1 Free up air valve shaft and align air valves closed or open 2 To...

Page 354: ...heck for binding choke valve and or linkage pletely Clean and or replace as necessary Do not oil choke linkage 2 Check and adjust choke thermostatic coil Engine flooded carburetor See procedure under Engine cranks will not flooding start engine flooded No fuel in carburetor 1 Check fuel pump Run pressure and volume test 2 Check float needle for sticking in seat or binding float 3 Check and adjust ...

Page 355: ...onnected correctly Choke valve not fully opening 1 Clean choke and free up linkage 2 Check choke coil for proper adjustment Fuel leaks Check fuel tank fuel lines and fuel pump for any fuel leakage High fuel level in carburetor or 1 Check for dirt in the needle and seat Test carburetor flooding using suction by mouth or needle seat tester 2 Check for loaded float 3 Re set carburetor float 4 If exce...

Page 356: ...ur 3 Connect choke housing pipe 4 Install air cleaner stud 5 Connect throttle cable Connect cruise control rod if removed 6 Connect vacuum lines Connect fuel inlet line Hold fuel inlet nut while connecting fuel line to avoid damaging inlet nut nylon gasket 7 Install air cleaner 8 Install engine cover CARBURETOR OVERHAUL NOTE Before performing any service on the car buretor it is essential that the...

Page 357: ...ing screws two attaching screws are located next to the primary venturi Two long screws five short screws two countersunk screws See Figure 12 6 The air horn assembly may now be removed from the float bowl by opening the throttle valve wide open and lifting up on the air horn and turning sideways until the pump rod disengages from the upper pump lever as shown in Figure 15 CAUTION Care must be tak...

Page 358: ... Remove float needle seat and gasket figure 16 TENSION SPRING RETAINER PRIMARY 1106 APLASTICI METER ING POWER PISTON PRIMARY METER ING ROD A 1701 Figure 15 Power Piston and Metering Rod Figure 16 Float Assembly 8 Remove primary metering jets No attempt should be made to remove secondary metering plates figure 18 9 Remove pump discharge check ball retainer and check ball 10 Remove baffle from secon...

Page 359: ...g screw at end of shaft inside the choke housing figure 20 Then remove thermostatic coil lever from flats on intermediate choke shaft Remove intermediate choke shaft from the choke housing by sliding out ward The fast idle cam can now be removed from the intermediate choke shaft See Figure 21 CAUTION Remove the cup seal from inside choke housing shaft hole ifthe housing is to be immersed in carbur...

Page 360: ...ody Attaching Screws Figure 24 Throttle Body Gasket CAUTION Rubber parts plastic parts and pump plungers should not be immersed in carburetor cleaner However the delrin cam on the air valve shaft and the throttle valve shafts will withstand normal cleaning in carburetor cleaner 2 Blow out all passages in castings with com pressed air CAUTION Do not pass drills throughjets or passages 3 Examine flo...

Page 361: ...to flats on inter mediate choke shaft Inside thermostatic choke coil level is properly aligned when both inside and out side levers face towards fuel inlet Install inside lever retaining screw into end of intermediate choke shaft Tighten securely 5 Install lower choke rod lever into cavity in float bowl Install plastic tube seal into cavity on choke housing before assembling choke housing to bowl ...

Page 362: ...et Do not force the air horn assem bly onto the bowl but rather lightly lower in place 2 Install two long air horn screws five short screws and two countersunk screws into primary venturi area All screws must be tightened evenly and securely See Figure 26 Figure 26 Air Horn Tightening Sequence 3 Install vacuum break diaphragm combination rod into the slot in lever on the end of the air valve shaft...

Page 363: ...OW IDLE SCREW ADJUSTED TO OBTAIN 030 CLEARANCE AT PRIMARY THROTTLE BORE 3 PUMP ROD IN INNER HOLE G GAUGE FROM TOP OF CHOKE VALVE WALL NEXT TO VENT STACK TO TOP OF PUMP STEM 5 TO ADJUST BEND PUMP LEVER AS SHOWN USING TOOL J 5197 PUMP ADJUSTMENT O GAUGE BETWEEN LOWER EDGE OF CHOKE VALVE B INSIDE AIR HORN WALL FAST IDLE CAM ADJUSTMENT Figure 27 Carburetor Adjustments ENGINE FUEL SYSTEM 6M 21 IDENTIFI...

Page 364: ...nrn TANU ON OI islUI I IVER LyISt r r oNTAfrS VAr I rNl HRIAK Rr10 VACUUM BREAK ADJUSTMENT AIR VALVE DASHPOT ADJUSTMENT T J y OGAUGE BETWEEN AIR HORN WALL AND LOWER EDGE OF CHOKE VALVE ET AT INDEX ROTATE COVER AND t COIL ASSEMBLY COUNTERCLOCKWISE UNTIL CHOKE VALVE V _ JUST CLOSES y D HOLD PRIMARY CHOKE 0PLACECAM FOLLOWER ON THROTTLE VALVES WIDE OPEN BEND TANG TOADJUST COIL ADJUSTMENT HIGHES STEP O...

Page 365: ...T DISTRIBUTOR AND PLUG 6 WITH DWELL AND TIMING PROPERLY ADJUSTED PLACE CAM FOLLOWER ON LOW STOP AND AGAINST SHOULDER OF NEXT HIGHER STEP ADJUST FAST IDLE SCREW TO OBTAIN 1100 RPM TRANS IN PARKX T UNPLUG DISTRIBUTOR VACUUM HOSE ANDRECONNECTTO DISTRIOUTOR UNPLUG VACUUM FITTING AT INTAKE MANIFOLD AND RECONNECTAIR CLEANER HOSE CONNECT CARBURETOR HOSE 10 CANISTER INSTALL AIR CLEANER AND RECHECK IDLE RP...

Page 366: ...ETOR TO CANISTER HOSE AND DISTRIBUTOR VACUUM ADVANCE HOSE INSTALL AIR CLEANER AND CONNECT VACUUM HOSE NOTE CO METER MUST BE CAPABLE OF LOW LEVEL ACCURATE READINGS METERS SHOULD BE ACCURATE WITHIN 1 CO IN THE SETTING RANGE SPECIFIED THE METER SCALE SHOULD HAVE DIVISIONS OF 2 CO OR LESS Figure 30 Carburetor Adjustments IF ACCURATE CO METER IS NOT AVAILABLE I WITH ENGINE AT NORMAL OPERATING TEMPERATU...

Page 367: ...ING LEVER AS SHOWN IN 3 4 GAUGE BETWEEN ROD AND END OF SLOT AS 4 _ SHOWN IN 4 SEE SPECIFICATION ABOVE 1 5 TO ADJUST OPEN THROTTLE SLIGHTLY AND BEND TANG WITH J 5197 AS SHOWN SECONDARY CLOSING ADJUSTMENT ON VEHICLE 16 ACCELERATOR CABLE DOWNSHIFT SWITCH 0 J 4 n SWITCH ADJUSTMENT PROCEDURE _ AFTER INSTALLING SWITCH PRESS PLUNGER AS FAR FORWARD AS POSSIBLE THIS PRESETS SWITCH FOR ADJUSTMENT SWITCH WIL...

Page 368: ...the fuel cham ber until the diaphragm spring is again compressed The diaphragm will then remain stationary until more fuel is required by the carburetor INSPECTION AND TEST There are three tests that can be preformed to evaluate the fuel pump without removing the pump from the engine It is important that the pump per forms properly using all three tests ACCELERATOR LINKAGE FUEL PUMP Fuel Flow Test...

Page 369: ...uretor bowl and note reading on pressure gauge REMOVAL 1 Remove engine cover 2 Remove wing nut on top of air cleaner 3 Disconnect P C V pipe from the air cleaner housing See Figure 33 4 Lift air cleaner housing off carburetor high enough to reach underneath it and disconnect the vacuum hose from the intake manifold See Figure 33 5 Remove air cleaner housing 6 Inspect air cleaner housing gasket on ...

Page 370: ...aner housing 4 Install wing nut and tighten 5 Install engine cover AIR CLEANER ELEMENT The air cleaner element should be replaced regu larly according to the maintenance information in Section 0 of this manual The element is accessible by removing the wing nut and the air cleaner cover Federal California 1974 7043254 7045554 1975 7045254 7045554 1976 7045254 7045554 ...

Page 371: ...on 6T 3 Purpose 6T 3 Operation 6T 4 Diagnosis 6T 4 Vacuum Motor Replacement 6T 5 Sensor Replacement 6T 5 Exhaust Manifold Shroud 6T 6 Evaporation Control System E C S 6T 6 Thermal Vacuum Switch T V S Description 6T 6 Operation 6T 6 Vacuum Hose Routing 6T 7 Functional Check 6T 7 Throttle Return Control T R C 6T 7 POSITIVE CRANKCASE VENTILATION P C V At high road speeds or heavy acceleration the eng...

Page 372: ...and observe the color Be sure the adapter is firmly sealed against the valve there are no leaks and hose is not kinked Figure 1 Positivie Crankcase Ventilation System 6 An all GREEN window reading indicates valve is OK Any YELLOW showing indicates the valve needs replacing INSTRUCTIONS FOR TESTING COMPLETE SYSTEM 1 Remove oil dipstick and plug hole with dip stick hole plug CT 12 part of CT 3 teste...

Page 373: ...gine warm up and eliminates tendency for ice to form in the carburetor WINDOW READING PROBABLE CAUSE CORRECTION GREEN System satisfactory Check Valve Vent valve partially plugged Blow by close to capacity of valve YELLOW Tester hose kinked or Reposition or clean hose blocked Crankcase not sealed Check tester plugs and other seal properly off points Tester selector knob Check setting set incorrectl...

Page 374: ... pipe is closed off allowing only outside air to enter the air cleaner DIAGNOSIS VACUUM MOTOR AND DAMPER ASSEMBLY 1 With the engine off remove air cleaner cover and tape thermometer J 5421 in air cleaner next to sensor See figure 5 NOTE If temperature is below 79 degrees F 26 1 C continue to Step 2 If temperature is above 79 degrees F 26 1 C remove air cleaner and allow to cool to at least 72 degr...

Page 375: ...VACUUM MOTOR REPLACEMENT REMOVAL 1 Remove air cleaner 2 Disconnect vacuum hose from motor 3 Drill out the two spot welds initially with a 1 16 drill then enlarge as required to remove the EMISSION CONTROL SYSTEMS 6T 5 retaining strap Do not damage the snorkel tube See figure 6 4 Remove motor retaining strap 5 Lift up motor cocking it to one side to unhook the motor linkage at the control damper as...

Page 376: ...ng the engine is equipped with a thermostatic vacuum switch T V S The temperature sensitive switch and valve assembly is mounted in the engine cooling jacket Figure 8 Hot Air Shroud 2 Press retainer clip on hose connectors 3 Connect vacuum hoses and install air cleaner on engine EXHAUST MANIFOLD SHROUD Exhaust manifold hot air shroud is shown in Fig ure 8 Refer to Section 6A for replacement proce ...

Page 377: ...TLE LEVER ACTUATOR The Throttle Lever Actuator is mounted as part of the carburetor assembly This device controls the position of the primary throttle plates a preset EMISSION CONTROL SYSTEMS 6T 7 Figure 10 Thermostatic Vacuum Switch tributor vacuum hose at port D of the T V S switch see Figure 10 connect a vacuum gauge and check for vacuum with the engine idling at normal operating temperature If...

Page 378: ...cuum control valve TRC SYSTEM DIAGNOSIS CONTROL VALVE CHECKING PROCEDURE 1 Disconnect valve to carburetor hose at the Figure 1 1 Throttle Return Control System carburetor and connect to an external vacuum source equipped with a vacuum gauge 2 Disconnect the valve to actuator hose at the actuator and connect to a vacuum gauge figure 12 3 Place finger firmly over the end of the bleed fitting the foa...

Page 379: ...d should return to within 50 RPM of the idle speed noted in step 3b If it does not the plunger may be binding due to dirt corrosion var nish etc If the problem cannot be corrected the actuator must be replaced CONTROL VALVE ADJUSTING PROCEDURE REFER TO FIGURE 13 1 Disconnect valve to carburetor hose at the carburetor and connect to an external vacuum source equipped with a vacuum gauge 2 Disconnec...

Page 380: ...the actuator Manually open the throttle to allow the choke to set top step on fast idle cam The choke will set only if the engine is cold If the engine is too warm and choke won t set it can be set by hand 5 Loosen stem nut Adjust actuator by rotating until plunger tip contacts throttle lever 6 Tighten stem nut remove vacuum pump and complete hose connections Figure 13 Control Valve Adjustment Fig...

Page 381: ...ion are listed below BATTERIES ENGINE ELECTRICAL 6Y 1 SUBJECT PAGE NO Batteries 6Y 1 Battery Specifications 6Y 16 Generating System 6Y 17 Generator Specifications 6Y 29 Breaker Point Ignition System 6Y 29 Breaker Point Ignition System Specifications 6Y 45 High Energy Ignition System 6Y 46 High Energy Ignition System Specifications 6Y 59 Starting System 6Y 60 Starter Specifications 6Y 68 has separa...

Page 382: ...e and testing procedures ap plicable to the particular type battery being serviced Figure 2 TransMode Main and Auxiliary Batteries Figure 3 TransMode Motor Generator Cranking Battery Optional BATTERY DESCRIPTION BATTERIES WITH FLAME ARRESTOR VENT CAPS Batteries with flame arrestor type filler vent caps are identified by the small grey disc in the cap as shown in Figure 4 This centered carbide sect...

Page 383: ...not as likely to reach or remain on the vertical sides where the terminals are located This greatly de creases the cause of terminal corrosion Also con struction of the terminals is such that the mating cable connector seals the junction and provides a permanently tight and clean connection Power rob bing resistance in the form of corrosion is thereby eliminated at these maintenance free connectio...

Page 384: ...in the battery react chemi cally to produce a flow of direct current whenever lights radio cranking motor or other current con suming devices are connected to the battery terminal posts This current is produced by chemical reaction between the active materials of the PLATES and sulfuric acid of the ELECTROLYTE The battery performs three functions in automo tive applications 1 It supplies electrica...

Page 385: ...ries a bat tery of cells is formed which produces six times as Figure 10 Battery Element Compound ENGINE ELECTRICAL 6Y 5 Figure 1 1 Typical 12 Volt Battery Cell Arrangement much electrical pressure as a simple cell or a total of 12 volts figure 11 If the battery continuously supplies current it becomes run down or discharged This is where the generator gets into the act The generator restores the ...

Page 386: ...ne whether the battery is 1 good and usable 2 re quires recharging or 3 should be replaced Refer to test procedures applicable to the battery in this vehi cle BATTERIES WITH FLAME ARRESTOR VENT CAPS Visual Inspection The first step in testing the battery should be a visual inspection which very often will save time and expense in determining battery condition Check the outside of the battery for a...

Page 387: ...Y LOAD TEST Charge Battery If Necessary Until All Cells Are At Least 1 200 Specific Gravity Same As Or Greater Than Voltage On Chart 1 No Obvious Damage Check Electrolyte Level Electrolyte Level Above Top Of Plates In All Cells Proceed To Step 2 Less Than 50 Points Variation Between Highest And Lowest Cell For temperature correction refer to Specific Gravity Readings earlier in this section Specif...

Page 388: ...pera ture before taking reading 4 Hold hydrometer vertically and draw in just enough liquid from battery cell so that float is free floating Hold hydrometer at eye level so that float is vertical and free of outer tube then take reading at surface of liquid Disregard the curvature where the liquid rises against float stem due to surface ten sion 5 Avoid dropping battery fluid on vehicle or clothin...

Page 389: ...e later in this section Once battery is charged proceed to Step 3 NOTE Battery should be charged until green dot appears but not more than 60 ampere hours for example 15 amperes for four hours Some ENGINE ELECTRICAL 6Y 9 chargers are constant current chargers but if a constant voltage charger is used to get the green dot to appear after prolonged charging may re quire tipping the battery slightly ...

Page 390: ... 12 volt and NEGATIVELY GROUNDED like the batter ies in THIS vehicle Check the other vehicle s ow ner s manual to see if it is Thebatteries in THIS vehicle must be equipped with FLAME ARRESTOR TYPE FILLER VENT CAPS on ALL filler openings as was the original equipment Delco batteries or it must be a sealed type battery which does not have filler openings or caps such as the Maintenance Free batteri...

Page 391: ...losions CHARGING PROCEDURES Before charging batteries equipped with flame arrestor type filler vent caps the electrolyte level must be checked and adjusted if need If charging maintenance free battery do not charge more than 60 ampere hours for example 15 amperes for four hours Some chargers are constant current chargers but if a constant voltage charger is used to get the green dot to appear on t...

Page 392: ...ormance however it may con tinue to provide additional service if it has performed satisfactorily in the past An emergency boost charge consisting of a high charging rate for a short period of time may be applied as a temporary expedient in order to crank an engine However this procedure usually supplies insufficient battery reserve to crank a second and third time Therefore the emergency boost ch...

Page 393: ...thout recharging may become so badly damaged by the growth of lead sulfate crystals sulfation in the plates that it can never be restored to a normal charged condition An battery in this condition not only loses its capacity but also is subject to changes in its charging charac teristics These changes due to self discharge are often serious enough to prevent satisfactory perform ance in a vehicle ...

Page 394: ... Area Battery CAUTION During service only water should be added to the Battery not electrolyte The liquid level in the cells should never be al lowed to drop below the top of the plates as the portion of the plates exposed to air may be perma nently damaged with a resulting loss in performance To service MotorHome auxiliary living area battery located in motor generator compartment use a 1 2 inch ...

Page 395: ...the point where the Battery case or cover will be placed under a severe strain Cleaning The external condition of the battery should be checked periodically for damage such as cracked cover case and vent plugs or for the presence of dirt and corrosion The battery should be kept clean An accumulation of acid film and dirt may permit cur rent to flow between the terminals which will slowly discharge...

Page 396: ...CIFICATIONS the battery has ample capacity to cope with these conditions A battery of greater capacity should be consid ered if the electrical load has been increased through the addition of accessories or if driving conditions are such that the generator cannot keep the battery in a charged condition On applications where heavy electrical loads are encountered a higher output generator that will ...

Page 397: ... RING DRIVE END FRAME END FRAME Figure 22 80 Amp Integral Type AC Generator VOLTAGE AND TEMPERATURE CHART Electrolyte Temperature 80 F 70 F 60 F 50 F 40 F 30 F 20 F 10 F 0 F 26 7 C 21 1 C 15 6 C 10 C 4 4 C 1 1 C 6 7 C 12 2 C 17 8 C Voltage Minimum 9 6 9 6 9 5 9 4 9 3 9 1 8 9 8 7 8 5 Make Model No Catalog No Volts Delco Remy Freedom Battery R89 5 12 Delco Remy Freedom Battery R85 5 12 Watt Rating 0...

Page 398: ...rated in the stator windings and the stator sup plies D C field current through the diode trio the field TR1 and then through the grounded diodes in the rectifier bridge back to the stator The six diodes in the rectifier bridge change the stator A C voltages to a D C voltage which appears between ground and generator BAT terminal As generator speed in creases current is provided for charging the b...

Page 399: ...ceed to UNDERCHARGED BATTERY above If ampere output is within 10 amps of rated output as stamped on generator frame generator is not defective recheck Steps 1 through 5 If test hole is accessible ground the field winding by inserting a screw driver into the test hole CAUTION Tab is within 3 4 inch of casting surface Do not force screw driver deeper than 1 inch into end frame Operate engine at mode...

Page 400: ...n or pulley 3 A defective diode or stator resulting in an elec trical unbalance STATIC CHECK Before making any electrical checks visually in spect all connections including slip on connectors to make sure they are clean and tight Inspect all wiring for cracked frayed or broken insulation Be sure generator mounting bolts are tight and unit is properly grounded Check for loose fan belt PRECAUTIONS O...

Page 401: ... above or by an open in the circuit To determine where an open exists proceed as follows ENGINE ELECTRICAL 6Y 2 1 a Check for a blown fuse a burned out bulb defective bulb socket or an open in No 1 lead circuit between generator and ignition switch b If no defects have been found proceed to Undercharged Battery section 3 Switch On Lamp On Engine Running Check for a blown fuse where used between in...

Page 402: ...ield winding as covered in GENERA TOR REPAIR section and test regulator with an approved regulator tester k If output is not within 10 amperes of rated output check the field winding diode trio rectifier bridge and stator as covered in GENERATOR REPAIR section 1 If test hole is not accessible disassemble generator and make tests listed in GENERATOR REPAIR section OVERCHARGED BATTERY 1 To determine...

Page 403: ...ace rectifier b If tester light remains off faulty tester or no voltage to tester broken or faulty connection ok ENGINE ELECTRICAL 6Y 2 3 Figure 27 SI Delcotron Tester Tool J 26290 Engine at Fast Idle 1000 RPM or More 4 If tester light remains off Delcotron system is 5 If tester light remains on remove and check the Delcotron 6 If the tester light flashes remove Delcotron and check regulator rotor...

Page 404: ... Outside 2 Bearing Roller Slip Ring End 10 Rotor 18 Frame Drive End 3 Seal 11 Capacitor 19 Washer Grease Slinger 4 Bolt Thru 12 Diode Trio 20 Bearing Drive End 5 Frame Slip Ring End 13 Bridge Rectifier 21 Drive Shaft Collar Inside 6 Regulator 14 Drive Shaft Nut 22 Retainer Plate 7 Brush Holder 15 Pulley 23 Stator 8 Resistor 16 Fan ...

Page 405: ...eading and refer to Generator Specifications An ammeter reading above the speci fied value indicates shorted windings a reading be low the specified value indicates excessive resistance An alternate method is to check the resistance of the field by connecting an ohmmeter to the two slip rings ENGINE ELECTRICAL 6Y 2 5 figure 28 If the resistance reading is below the specified value the winding is s...

Page 406: ... windings are grounded NOTE Delta windings on 80 amp generator cannot be checked for opens A short circuit in the stator windings is difficult to locate without laboratory test equipment due to the low resistance of the windings However if all other electrical checks are normal and the generator fails to supply rated output shorted stator windings or an open delta winding on 80 amp generator is in...

Page 407: ...ded that a new seal be installed whenever the bearing is replaced Press the seal in with the lip of the seal toward the rotor when assembled that is away from the bearing Ligh tly coat the seal lip with oil to facilitate assembly of the shaft into the bearing GENERATOR BENCH OUTPUT TEST To check the generator in a test stand proceed as follows 1 Make connections as shown in Figure 31 ex cept leave...

Page 408: ...and load capacity of rotor used with A C generators PROPER BELT TENSION MUST BE MAINTAINED All generators are pivot base mounted with the belt tension adjustment arm at the top or bottom using belt tension Tool BT 33 73F Burroughs Tool or other suitable tool to check tension on each in dividual belt If tension is not within 70 801bs used belts or 110 140 lbs new belts loosen adjustment arm clamp b...

Page 409: ...6Y 29 vacuum advance mechanisms and 3 direct high voltage surges through distributor rotor cap and high tension wiring to the spark plugs The distributor houses the contact points that make and break the primary circuit and also directs high voltage and current in proper sequence to the spark plugs The contact point set is replaced as a complete assembly The breaker lever spring tension and point ...

Page 410: ...switch closed current flows through the primary circuit that is from the battery through the primary winding of the ignition coil and closed distributor contacts to ground and then back to the battery A cam mounted on the rotating distributor shaft causes the distributor contacts to open and close When the contacts open the current decreases very rapidly in the ignition coil primary winding and a ...

Page 411: ... must be reached ENGINE ELECTRICAL 6Y 31 while the piston is between 10 degrees and 20 degrees past top dead center At 1 000 engine rpm the crank shaft travels through 18 degrees in 003 of a second at 2 000 rpm the crankshaft travels through 36 de grees Since maximum pressure point is fixed it is easy to see why the spark must be delivered into the cylinder earlier in the cycle in order to deliver...

Page 412: ... time the contacts are closed In order to store the max imum amount of energy obtainable or the coil and consequently obtain sufficient energy to fire the plug it is necessary to design a breaker lever assembly that will operate properly at high speeds The distributor is equipped with a special high rate of break cam and a special high speed breaker lever which is capa ble of following the cam sha...

Page 413: ...s to reduce radio and television interference from the ignition system as well as to reduce spark plug electrode erosion caused by excessively long sparking We have been talking of the high voltage surge from the ignition ENGINE ELECTRICAL 6Y 33 coil secondary as though it were a single powerful surge that almost instantly caused the spark to jump across the spark plug gap Acutally the action is m...

Page 414: ...ed in the ignition running circuit to reduce the voltage to the ignition coil The resistor wire is bypassed when the engine is being started The purpose of this is to compensate for the drop in voltage which occurs as the result of the heavy drain on the battery during starting and to provide a hot ter spark for starting All ignition switches have five terminals which are connected in different co...

Page 415: ...erminal Place a screw driver blade across coil tower to engine block and crank engine a If strong spark is seen remove jumper wire and check wiring connections and switches between battery plus terminal and coil terminal Opens high resistance or intermittent contact will require repair or replacement ENGINE ELECTRICAL 6Y 3 5 b If no spark or intermittent spark is seen remove jumper wire and procee...

Page 416: ...n and Grounded Circuits Before using a coil test instrument the coil should be tested for open and grounded circuits us ing a 110 volt test lamp and test points 1 Apply test points to both primary terminals of coil If test lamp does not light the primary circuit is open 2 Apply one test point to the high tension termi nal and the other test point to one of the primary terminals If secondary circui...

Page 417: ...se build up of metal on the breaker arm positive ENGINE ELECTRICAL 6Y 3 7 point A condenser having excessive capacity will cause build up of metal on the contact support nega tive point In exceptional cases pitting and metal buildup on contact points may be experienced even when condenser capacity is within the specified limits In such cases the life of contact points will be improved by installin...

Page 418: ...of the electric spark on the elec trodes The same type of spark plug used in two different engines of the same make and model may frequently show wide variation in appearance The cause of such differences lies in the condition of the engine its piston rings carburetor setting kind of fuel used and under what conditions the engine is operated namely sustained high speeds or heavy loads or continual...

Page 419: ...ld vacuum actuates the vacuum control diaphragm thus advancing the WINDOW CENTR I FUGAL ADVANCE MECHANISM ONTACT SET ASSEMBLY A 1866 Figure 34 Distributor Components ENGINE ELECTRICAL 6Y 39 spark and increasing fuel economy During fast ac celeration or when the engine is pulling heavily vacuum is not sufficient to actuate the diaphragm therefore the movable breaker plate is held so that the igniti...

Page 420: ... be installed and screws tightened securely Snap lock push in terminal contact points have sufficient clearance between the shield and wire terminals to prevent acciden tal short circuiting Screw terminal contact point sets may not have sufficient clearance Wire ter minals must be firmly pushed in and bent slightly toward cam to prevent them from touching the shield 1 Install contact points on bre...

Page 421: ...ing the rotor The mechanical ad vance plate is assembled to the breaker cam In order to remove the breaker cam and advance plate follow the procedure for DISTRIBUTOR DISASSEM BLY and ASSEMBLY 1 Remove the distributor cap shield and the two vacuum advance attaching screws figure 42 2 Turn the breaker plate clockwise and push the rod end of the vacuum advance down so that it will disengage and clear...

Page 422: ...he harmonic balancer indexes with the 0 degree timing mark on the engine front cover If both valves of the No 1 cylinder are closed the piston will be on top dead center in either the firing or exhaust stroke Install distributor so that the rotor is pointing to No 1 spark plug terminal in the cap when the distributor is fully seated Install clamp and bolt start engine If engine fails to start or r...

Page 423: ...on the upper housing 4 Slide the distributor shaft through housing bushings 5 Push the driven gear onto the distributor shaft with the holes aligned 6 Install the roll pin 7 Check and adjust dwell angle vacuum advance and the mechanical advance Refer to SPECIFICA TIONS Distributor ADJUSTING DISTRIBUTOR DWELL ANGLE 1 With distributor mounted in distributor testing machine connect the dwell meter to...

Page 424: ...or body slightly until points just open and tighten distributor clamp bolt 6 Place distributor cap in position and check to see that rotor lines up with terminal for No 1 spark plug 7 Install cap check all high tension wire connec tions and connect spark plug wires if they have been removed 8 Connect vacuum line to distributor and dis tributor primary wire to coil terminal 9 Start engine and set t...

Page 425: ...motor solenoid for cranking The ignition switch has five positions OFF LOCK ACCESSORY RUN and START OFF is the center position of the key lock cylinder and lock is the next position to the left ACCES SORY is located one more detent to the left of LOCK Turning the key to the right of the OFF position until spring pressure is felt will put the igni tion in the RUN position and when turned fully to t...

Page 426: ...or controlled inductive discharge ignition system The magnetic pick up assembly located in side the distributor contains a permanent magnet a pole piece with internal teeth and a pick up coil When the teeth of the timer core rotating inside the pole piece line up with teeth of the pole piece an induced voltage in the pick up coil signals the all electronic module to open the coil primary circuit T...

Page 427: ...ctronic module The electronic module is con nected to the primary windings in the coil As the distributor shaft turns the timer core teeth out of alignment with the teeth of the pole piece a voltage is created in the magnetic field of the pick up coil The pick up coil sends this voltage signal to the electronic module which determines from RPM when to start current building in the primary wind ing...

Page 428: ...per operation of the vehicle Spark Plug Wires Figure 50 Because of the higher voltage the HEI system has larger diameter 8 millimeter spark plug wires with silicone insulation The silicone wire is gray in color more heat resistant than standard black wire and less vulnerable to deterioration Silicone insult aion is soft however and must not be mishandled The spark plug wire boots seal more tightly...

Page 429: ...1 Rotor 12 Shaft Assembly 13 Springs 23 14 Weights 15 Bracket Attaching Screw 25 16 Capacitator Bracket 26 17 Capacitator 18 Wiring Harness 19 Module Attaching Screw 2 20 Electronic Module 21 Retainer Thin C Washer 22 Pole Piece and Plate Assembly Pick up Coil 27 23 Vacuum Advance Attaching Screw 2 24 Vacuum Advance Control 25 Felt Washer 26 Plastic Seal 27 Housing 28 Gear 29 29 Pin A 4001 Figure ...

Page 430: ...ks on engines equipped with HEI disconnect the ignition switch connector at the battery terminal of the distributor figure 52 Tachometer Connections The tachometer terminal is next to the ignition switch connector on the distributor cap figure 52 Most tachometers can be used however be sure the equipment is compatible with the HEI system The tachometers without a relay cannot be used If there is a...

Page 431: ...on in neutral 4 With the use of a timing light set timing to 8 BTDC by loosening the distributor clamp bolt and rotating the distributor until the specification is ob tained NOTE The indicator has four V slots each representing 4 5 Tighten the distributor clamp bolt and recheck timing to make sure distributor was not moved dur ing tightening of bolt NOTE If a tuned engine detonates with this set t...

Page 432: ...all any good spark plug with 080 gap in lead and lay on engine block while cranking en gine 6 If sparking occurs trouble is not ignition dis tributor Check fuel system and spark plugs Check timing Distributor may have shifted 7 If no spark make Test No 1 with Module Tester J 24642 or equivalent as follows NOTE Use Test No 1 only in an engine no start situation a Disconnect module harness connector...

Page 433: ...TTERY LEAD CONNECTOR CONNECTED TO BATTERY TERMINALS ENGINE ELECTRICAL 6Y 53 Figure 57 Test No 2 Using Tool J 24642 okay so the pick up coil is defective If the red light stays on the module is defective NOTE If necessary to replace pick up coil remove distributor from engine drive pin from gear remove rotor and shaft assembly from housing and remove thin C washer to replace pick up coil as describ...

Page 434: ...ld not be infinite c If reading is infinite check cap and rotor button for arced or burned condition If necessary replace cap If cap and carbon button do not appear defective replace ignition coil 9 If trouble has not been located proceed with Test No 2 using J 24642 step 8 a thru c DISTRIBUTOR COMPONENT REPLACEMENT Following is the complete distributor disassem bly of which part or all can be use...

Page 435: ...ing distributor shifted B 5 Check centrifugal advance on engine B 6 Twist boots to loosen remove all spark plugs and check for usual defects proper gap fouling cracked insulators in side and out etc Check sec ondary wiring B 7 If no defects are found follow procedure under Component Checks C 11 If no defects have been found remove connector and two at taching screws and replace module C COMPONENT ...

Page 436: ...rankshaft pulley to 0 on engine timing indicator 5 Turn rotor to point between No 1 and No 8 spark plug towers on distributor 6 Install distributor and connect feed wire 7 Install distributor cap and spark plug wires 8 Check engine timing DISTRIBUTOR DISASSEMBLY FIGURE 49 1 Remove distributor from engine as described above 2 Remove rotor figure 60 from distributor shaft by removing two screws 3 Be...

Page 437: ...d with new modules 13 Remove capacitor attaching screw and dis connect wiring lead Remove capacitor and bracket from housing 14 Remove wiring harness connector from dis tributor 15 Remove felt washer and plastic seal NOTE No attempt should be made to secure the shaft bushings in the housing 16 Inspect and replace parts as required ENGINE ELECTRICAL 6Y 5 7 VACUUM UNIT ATTACHING SCREWS Figure 61 Top...

Page 438: ...eeth to provide even clearance Tighten three screws figure 62 11 Install washers between gear and housing if distributor is so equipped Slide gear onto shaft in same position as marked when removed 12 Install roll pin into gear and shaft NOTE To prevent damage to the permanent magnet in the pole piece and plate assembly support the driven gear when installing the roll pin 13 If removed carefully r...

Page 439: ...al Typical Federal California DISTRIBUTOR Make Delco Remy Delco Remy Model No 1112893 1112945 Rotation Viewed at Rotor Clockwise Clockwise Dwell Electronic Electronic Centrifugal Advance Start Distributor Degrees 0 0 RPM 900 900 Intermediate Distributor Degrees 9 9 RPM 2000 2000 Maximum Advance Degrees 16 16 RPM 3400 3400 Firing Order 1 8 4 3 6 5 7 2 1 8 4 3 6 5 7 2 DISTRIBUTOR VACUUM CONTROL Mode...

Page 440: ...ssembly passed during cranking The resistor is by passed at the R terminal or ignition terminal See figure 78 on the starting motor With high energy ignition there is no resistor so there is no resistor by pass wire from the starter motor Since there is no longer any requirement for the electrical lead from the starter solenoid to the ignition coil the R terminal or ignition terminal of the starte...

Page 441: ...nion should be checked for freedom of operation by turning it on the screw shaft The arma ture should be checked for freedom of rotation by prying the pinion with a screwdriver Tight bearings a bent armature shaft or a loose pole shoe screw will cause the armature to not turn freely If the armature does not turn freely the motor should be disassem bled immediately However if the armature does ro t...

Page 442: ... switch 2 STARTER STOPS SOLENOID CLICKS ONCE OR TWICE BUT STARTER DOES NOT TURN OR TURNS TOO SLOW CONNECTIONS GOOD Check condition and state of charge of battery BATTERY GOOD Check for proper weight oil Connect red voltmeter lead to positive cable at battery black lead to battery cable terminal of starter Crank engine and observe voltage LESS THAN 0 5 VOLTS 1 Connect voltmeter black lead to batter...

Page 443: ...e components Normally the cranking motor should be disassembled only so far as is necessary to make repair or replacement of the defective parts As a precaution it is suggested that safety glasses be worn when disassembling or assembling the cranking motor Following are gen eral instructions for disassembling a typical overrun ing clutch drive cranking motor ENGINE ELECTRICAL 6Y 63 A 1880 Figure 6...

Page 444: ...move shift lever and or plunger remove shift lever pivot bolt figure 72 c Disassemble shift lever from plunger CLEANING INSPECTION AND TESTS 1 Clean all starting motor parts I ut DO NOT USE GREASE DISSOLVING SOLVENTS FOR PIVOT PIN A 1883 Figure70 Brush Installation CLEANING THE OVERRUNNING CLUTCH ARMATURE AND FIELD COILS since such solvent would dissolve the grease packed in the clutch mechanism a...

Page 445: ...nd will require repair or replacement c Using a test lamp place one lead on the series coil terminal and the other lead on the in sulated brush figure 74 If the lamp fails to light the series coil is open and will require repair or re placement NOTE This test should be made from each in sulated brush to check brush and lead con tinuity d Using a test lamp place one lead on the grounded brush holde...

Page 446: ...gure 76 Checking Solenoid Wiring a Assemble shift lever and plunger b Position shift lever and plunger assembly in drive gear housing and install lever pivot bolt figure 72 c Install solenoid assembly to drive gear housing figure 71 2 If the overrunning clutch was removed from the armature shaft assemble as follows a Lubricate drive end of armature shaft with lubricant 1960954 or equivalent b Slid...

Page 447: ...lar during crank ing To check connect a voltage source of approxi mately 6 volts between the solenoid switch terminal and ground figure 78 SOLENOID BODY SOLENOID SWITCH TERMINAL FLANGE A 1891 Figure 78 Solenoid Terminals and Sealing ENGINE ELECTRICAL 6Y 67 NOTE If a 6 volt battery is not available a 12 volt battery may be used PROVIDING ONLY THREE CELLS ARE CONNECTED IN SE RIES TO PREVENT MOTORING...

Page 448: ...IFICATIONS STARTER MODEL 1108761 1108522 Make Delco Remy Delco Remy Series 10MT 10MT Type 100 100 Rotation Viewed at Drive End CW CW No Load Test Volts 9 9 Minimum Amps 65 65 Maximum Amps 95 95 Minimum RPM 7 500 7 500 Maximum RPM 10 500 10 500 Pinion Clearance 010 140 010 140 Includes Solenoid STARTER SOLENOID Model 1114356 1114356 Rated Voltage 12 12 Current Consumption Pull In Winding Amps 13 0 ...

Page 449: ...rbine half is in effect connected to the transmission The torque converter couples the engine to the planetary gear set through the use of a drive sprocket a link assembly and a driven sprocket Clockwise engine torque turns the drive sprocket clockwise which in turn drives the driven sprocket in a clockwise direction This in effect is a reverse in the direction of engine torque due to the side mou...

Page 450: ...tor is used to sense engine torque input to the transmission automatically The DETENT SOLENOID PUMP Figure 1 Turbo Hydra matic Transmission LINK ASSEMBLY FORWARD CLUTCH FORWARD CLUTCH HUB DRIVEN SPROCKET DRIVEN SPROCKET SUPPORT HOUSING vacuum modulator transmits this signal to the pres sure regulator which controls line pressure so that all torque requirements of the transmission are met and prope...

Page 451: ...g by depressing the accelera tor pedal S Super adds performance for congested traffic or engine braking in hilly terrain The Super range has the same starting gear ratio as Drive but pre vents the transmission from shifting above second speed to retain acceleration when extra performance is desired L Lo range permits operation at a lower gear ratio and should be used where maximum engine braking i...

Page 452: ...Manual Valve Establishes the range of transmission operation PARK R N D S or L as selected by the vehicle operator through the manual selector lever Governor Assembly Generates a speed sensitive oil pressure that in creases with output shaft or vehicle speed Governor pressure is used to control the shift points and modulator pressure regulation Vacuum Modulator Valve Provides modulator pressure th...

Page 453: ...AL LUBRICATION 6 PUMP COVER PLATE PASSAGE TO CASE PASSAGE NOTE THE NUMBERS 1N THE CROSS SECTION 7 CASE PASSAGE TO PRESSURE REGULATOR VALVE INDICATE THAT THERE ARE ADDITIONAL 8 PRESSURE REGULATOR VALVE TO CASE PASSAGE LUBRICATION HOLES IN THIS AREA THAT 9 CASE PASSAGE TO PUMP COVER PLATE PASSAGE ARE NOT SHOWN IN THE CROSS SECTION 10 PUMP COVER PLATE PASSAGE TO CONVERTER 17 FRONT SEAL DRAIN BACK HOL...

Page 454: ...control engagement of the intermediate clutch Figure 5 Case Oil Passages Bottom Detent Valve Shifts when line oil is exhausted at the end of the valve when the detent solenoid is energized This directs detent oil to the 1 2 and 2 3 modulator valves and allows the detent regulator valve to regulate PIN LOBE FROM COOLER CONVERTER RETURN TO COOLER LINE INTAKE ONVERTER FEED VOID VENT REVERSE MODULATOR...

Page 455: ...ENT MODULATOR INTERMEDIATE CLUTCH VOID SERVO DRIVE INTERMEDIATE DIRECT GOVERNOR INTERMEDIATE CLUTCH CLUTCH REV LO LINE EXHAUST 2 ACCUMULATOR LO VOID VOID VOID DRIVE GOVERNOR VOID REV LO DETENT MODULATOR A 4325 ...

Page 456: ...7 8 TRANSMISSION Figure 8 Spacer to Control Valve Assembly VENT PUMP INTAKE DRIVE DRAINBACK HOLE CONVERTER FEED LINE LUBE CONVERTER RETURN A 2088 Figure 9 Pump Cover Oil Passages ...

Page 457: ... CLUTCH CLUTCH BAND CLUTCH SPRAG CLUTCH BAND PARK NEUT OFF OFF OFF OFF OFF OFF OFF DRIVE 1 ON OFF OFF OFF OFF ON OFF LEFT 2 ON OFF OFF ON ON OFF OFF 3 ON ON OFF ON OFF OFF OFF DRIVE 1 ON OFF OFF OFF OFF ON OFF RIGHT 2 ON OFF ON ON ON OFF OFF LO 1 ON OFF OFF OFF OFF ON ON 2 ON OFF ON ON ON OFF OFF REV OFF ON OFF OFF OFF OFF ON ...

Page 458: ...5 Make sure that mating surfaces of castings are flat and smooth free of deep scratches chips and burrs 6 Torque bolts to proper torque To prevent the apply of the front band in Neu tral Drive and Reverse ranges oil is directed from the manual valve to the release side of the servo piston In Drive the servo release oil from the manual valve is used to charge the servo in preparation for the apply ...

Page 459: ...improperly installed 7 Manual shaft O ring damaged or improperly installed chined 8 Vacuum modulator damaged 12 Bottom pan gasket damaged 16 Vent pipe a Transmission over filled b Water in oil h Hole in intake pipe TRANSMISSION 7 11 9 Vacuum modulator retainer screw loose Tighten to 18 foot pounds 10 Vacuum modulator diaphragm damaged not an external oil leak NOTE A ruptured diaphragm would allow ...

Page 460: ...ings The shift points will vary with the throttle opening As the vehicle decreases in speed to 0 mph the 3 2 and 2 1 shifts should occur SUPER RANGE Position the selector lever in SUPER RANGE and accelerate the vehicle from 0 mph A 1 2 shift should occur at all throttle openings No 2 3 shift can be obtained in this range The 1 2 shiftpoint will vary with throttle opening As the vehicle decreases i...

Page 461: ...BRAKE IN DRIVE RANGE 2 Engine 2000 RPM 3 CLOSE THROTTLE FOOT ENGINE 2000 1200 RPM OFF ACCELERATOR AND TAKE PRESSURE READING NOTE WITH CLOSED THROTTLE AND DRIVING WHEELS OFF THE GROUND ENGINE RPM WILL DROP RAPIDLY PRESSURE READING MUST BE TAKEN WITHIN RPM S INDICATED AND WITH CLOSED THROTTLE CHECK OIL PRESSURES IN FOLLOWING MANNER RANGE OIL PRESSURE NORMAL P S I DRIVE BRAKES APPLIED ENGINE AT 1000 ...

Page 462: ... RPM OIL OIL OIL OIL OIL OIL WHEELS FREE PRESSURE PRESSURE PRESSURE PRESSURE PRESSURE PRESSURE TO MOVE NORMAL NORMAL NORMAL NORMAL NORMAL NORMAL DROP MALFUNCTION IN CONTROL VALVE ASSY MALFUNCTION IN NORMAL NORMAL NORMAL NORMAL NORMAL NORMAL NO DROP GOVERNOR OR NO 1 2 UPSHIFT _ GOVERNOR FEED AND OR DELAYED SYSTEM UPSHIFT HIGH NORMAL NORMAL NORMAL HIGH MALFUNCTION IN DETENT SYSTEM MALFUNCTION IN HIG...

Page 463: ... CONTROL VALVE ASSEMBLY CHECK PROCEDURE DISCONNECT ELECT PLUG FROM TRANS AND TEST NORMAL UPSHIFT OCCURS CHECK AND CORRECT DETENT SWITCH OR WIRING CHECK FOR SOLENOID CLICK ROAD TEST CHECK TRANS OIL LEVEL 90 150 PSI WITH BRAKES APPLIED CHECK LINE PRESSURE IN NEUT AT 1000 RPM 1 CHECK SOLENOID FOR FUNCTION OR DAMAGE CHECK MOD FOR LEAKING DIAPHRAGM OR BENT NECK CHECK CASE FOR DAMAGE OR POROSITY AT MOD ...

Page 464: ...t Complaint CHECK VACUUM SYSTEM FOR RESPONSE AT MODULATOR VAC SHOULD VARY AND RESPOND RAPIDLY TO QUICK CHANGES IN THROTTLE OPENINGS CHECK 1 2 ACCUM VALVE SYSTEM CHECK FRONT ACCUM PISTON B OIL RINGS CHECK CENTER SUPPORT BOLT TORQUE AND OK SUPPORT LOOSENESS AIR FOR LEAKAGE AT SEALS CHECK INT CLUTCH EXCESSIVE NORMAL REMOVE TRANS T INSPECT INT CLUTCH IF BURNED CHECK REMOVE AND INSPECT INT CLUTCH AND C...

Page 465: ...GASKET RESTRICTED EXHAUST SYSTEM VEHICLEON LIFT IGNITION ON ENGINE NOT OPERATING DISCONNECT ELECT PLUG FROM TRANS CONNECT TEST LIGHT TO DETENT TERMINAL OF DISCONNECTED WIRE HARNESS SEE ILLUSTRATION BELOW DEPRESS ACCELERATOR FULLY DETENT 2 3 Shift 1st 2nd Speeds No Detent SOFT SHIFT SLIPS OR EXTENDED TIME DURING SHIFT WITH END BU WITH BRAKES APPLIED CHECK LINE PRESSURE IN DRIVE AT 1000 RPM CHECK FO...

Page 466: ... Braking Or Slips In Overrun Braking Lo Range Refer To Shop Manual For Pin Selection 3 Defective Rear Servo Piston or Bore NO DRIVE IN DRIVE RANGE CHECK TRANS OIL LEVEL CHECK OUTSIDE MANUAL LINKAGE CORRECT WITH BRAKES APPLIED CHECK LINE PRESSURE IN DRIVE AT 1000 R P M CHECK TRANS OIL LEVEL No Drive No Reverse NO REVERSE OR SLIPS IN REVERSE CHECK OUTSIDE MANUAL LINKAGE CORRECT WITH BRAKES APPLIED C...

Page 467: ...NT BAND BROKEN BURNED CHECK FOR CAUSE NOT ENGAGED ON ANCHOR PIN AND OR SERVO PIN NO ENGINE BRAKING LO RANGE 1 ST GEAR CASE ASSEMBLY LO REVERSE CHECK BALL MISPOSITIONED OR MISSING CASE DAMAGED AT LO REVERSE CHECK BALL AREA REAR SERVO OIL SEAL RING BORE OR PISTON DAMAGED REAR BAND APPLY PIN SHORT IMPROPERLY ASSEMBLED REAR BAND BROKEN BURNED CHECK FOR CAUSE NOT ENGAGED ON ANCHOR PINS AND OR SERVO PIN...

Page 468: ...NG GEAR ASSEMBLED BACKWARDS CRESCENT INTERFERENCE BUZZING NOISE ORIFICE CUP PLUG IN PRESSURE REGULATOR DAMAGED OR MISSING SEAL RINGS DAMAGED OR WORN CONVERTER LOOSE BOLTS CONVERTER TO FLYWHEEL CONVERTER DAMAGE CRACKED OR BROKEN FLEX PLATE TRANSMISSION NOISY FIRST SECOND AND OR REVERSE PLANETARY GEAR SET GEARS OR THRUST BEARINGS DAMAGED FRONT INTERNAL GEAR RING DAMAGED Transmission Noisy DURING ACC...

Page 469: ...eck stator shaft bushings for damage 1 Check center support oil seal rings 2 Check direct clutch outer seal for dam 6 Case Assembly 1 Vacuum Leak c Improper engine vacuum 2 Damaged Modulator a Stuck valve b Water in modulator c Not operating properly 3 Detent System b Detent wiring shorted TRANSMISSION 7 2 1 3 Check rear servo and front accumula tor pistons and rings for damage or missing a Porosi...

Page 470: ... cold CONTROL VALVE ASSEMBLY GOVERNOR LINE PRESSURE CHECK 3 With vehicle on hoist front wheels off ground foot off brake in drive check line pressure at 1000 rpm 4 Slowly increase engine rpm to 3000 rpm and determine if a line drop occurs 7 psi or more 5 If pressure drop occurs disassemble clean and inspect control valve assembly 4 Check governor valve entry and ex haust 020 min 1 Check screen in ...

Page 471: ...se valve body face not flat or porosity between channels wards TRANSMISSION 7 2 3 j Intermediate sprag clutch installed back k 3 2 valve 3 2 spring or 3 2 spacer pin in stalled in wrong location in 3 2 valve bore 1 Incorrect combination of front servo and accumulator parts m Replace intermediate clutch piston seals NOTE If direct clutch plates and front band are burned check manual linkage VACUUM ...

Page 472: ...age to wide open position One click should be heard from transmission 3 Allow throttle to return to closed position One click should be heard from transmission 4 If system performed as described above down shift circuit is operating properly If system does not perform as described above proceed to step 5 5 Use test light to check orange wire at connec tor on side of transmission case Test light sh...

Page 473: ...ontainer providing a passage for oil to flow from the inlet to the outlet Clean solvent can be flushed through the cooler with air pressure An engine desludge gun may be used The cooler should be back flushed first through the return line to remove all foreign material possible Then flush through the inlet line and finish by flushing through the return line Clean remaining solvent from cooler with...

Page 474: ...7 26 TRANSMISSION Figure 14 Transmission Manual Linkage i ...

Page 475: ...rature 190 200 F 88 93 C Automatic transmissions are frequently overfilled because fluid level is checked when the fluid is cold and dipstick indicates fluid should be added However the low reading is normal as proper fluid level at low operating temperature will be below the ADD mark on the dipstick as shown in Figure 15 and proper fluid level at higher operating temperatures will rise above the ...

Page 476: ...e and filter assembly 7 Install new gasket on bottom pan and install bottom pan Tighten bottom pan attaching screws to 12 foot pounds 8 Lower vehicle and add five quarts of transmis sion fluid through filler tube when replacing intake Figure 15 Transmission Oil Level pipe and filter assembly When draining bottom pan only add four quarts of transmission fluid 9 Operate engine at 800 rpm for approxi...

Page 477: ...sition engine removal tool Remove seat belt plate and anchor bolt assembly Attach load adjuster chain to front and rear engine Lift locations as shown in Fig ures 17 and 18 Then install support braces and chain hoist as in Figure 16 4 Raise vehicle 5 Disconnect starting motor wires 6 Remove starting motor TRANSMISSION 7 2 9 1 Oil pan and pan to case gasket 2 Pressure regulator valve assembly 3 Val...

Page 478: ...7 30 TRANSMISSION Figure 16 Attaching Engine Removal Tool ...

Page 479: ...e 18 Rear Engine Lift Location 6 Install remaining converter housing to engine bolts Torque six 6 bolts to 30 ft lbs 7 Shift transmission to neutral to align weld nuts to the flywheel Rotate the crankshaft to install three 3 attaching bolts and torque to 30 ft lbs Note Weld nuts must be flush to flywheel 8 Remove safety chain and jack from transmis sion 9 Install three 3 rear support bracket to tr...

Page 480: ...ansmission with fluid as described un der CHECKING AND ADDING FLUID in this SECTION 26 Check manual linkage and adjust if neces sary TRANSMISSION OVERHAUL CAUTION Converter with oil weighs ap proximately SO pounds Be careful not to drop or damage converter when removing it ARRANGE TRANSMISSION FOR OVERHAUL 1 Install two 3 8 x 8 bolts with nuts into the case to engine mounting face figure 20 2 Remo...

Page 481: ...m transmission case Remove and discard O ring from vacuum modulator Figure 24 Figure 22 Governor Removal TRANSMISSION 7 3 3 Figure 23 Arrangement of Transmission on Bench 3 Remove modulator valve from transmission case NOTE Modulator bushing is a snug fit in trans mission case and should not be removed forcibly unless it is damaged scored or otherwise de formed REMOVE INTAKE PIPE AND FILTER ASSEMB...

Page 482: ...resent REMOVE CONTROL VALVE ASSEMBLY GOVERNOR PIPES DETENT SPRING ROLLER ASSEMBLY CHECK BALLS AND ELECTRICAL CONNECTOR NOTE Units may be removed with transmission in vehicle after removing bottom pan 1 Remove attaching screw and remove detent roller and spring assembly 2 Disconnect detent solenoid from electrical connector 3 Remove governor feed pipe from transmission case and valve body by liftin...

Page 483: ...rear servo assembly from transmis sion case Figure 28 3 Remove rear servo accumulator spring 4 Make band apply pin selection check to deter mine proper size pin to use at time rear servo is assembled Proceed as described in the following BAND APPLY PIN SELECTION CHECK FIGURE 29 NOTE Check may be made with transmission in vehicle Remove bottom pan control valve as sembly and rear servo 1 Position A...

Page 484: ...emoved with transmission in vehicle after removing bottom pan and detent roller and spring assembly from control valve assembly 1 Remove pin securing manual shaft to case by pulling straight out Be careful not to damage the case or pin 2 Loosen locknut securing detent lever to manual shaft 3 Pry or work detent lever loose from ground flats on manual shaft 4 Remove manual shaft from case bore and r...

Page 485: ...ot pry on the guide links or the aluminum case Pry only on the sprockets Figure 33 Figure 32 Removing Sprocket Link Assembly TRANSMISSION 7 37 Figure 33 Removing Tight Sprockets 5 Remove link assembly from drive and driven sprockets 6 Remove teflon oil seal ring from turbine shaft only if the ring requires replacement For service the ring is hook type cast iron 7 Inspect drive and driven sprocket ...

Page 486: ...ear 8 Inspect turbine shaft oil seal ring for damage Do not remove unless replacement of ring is re quired The service ring is hook type cast iron 9 Inspect the turbine shaft for cracks or distor tion 10 Inspect the link assembly for damage or loose links NOTE Check the guide links Guide links are the wide outside links on each side of the link assembly INSPECT DRIVEN SPROCKET AND INPUT SHAFT 1 In...

Page 487: ...slide hammer bolt and index indicator to register with the Front Unit End Play Checking Tool J 22241 Figure 36 and push tool down to remove slack Figure 36 Checking Front Unit End Play TRANSMISSION 7 39 4 Push and hold output flange upward Place a screw driver in case opening at parking pawl area and push upward on output carrier 5 Place another screw driver between the metal lip of the end play t...

Page 488: ... a plastic mallet vigorously strike the stator shaft of the drive sprocket support Figure 38 and the hub of the driven sprocket support until they are removed from their pump cover plate bores CAUTION When driving the housings out of the pump cover plate avoid damaging or Figure 38 Removing Drive Sprocket Support c Remove and discard housing to pump cover plate gaskets 39 distorting the stator sha...

Page 489: ...installing Front End Play Checking Tool J 22241 into forward clutch and lifting forward clutch straight out Figure 40 Installing Drive Sprocket Support TRANSMISSION 7 4 1 Figure 41 Installing Teflon Oil Seal Rings 2 Remove forward clutch hub to direct clutch housing thrust washer if it did not come out with forward clutch assembly 3 Remove direct clutch and intermediate sprag assembly by lifting s...

Page 490: ... the following chart The tabs will show identification notches numerals or both 6 Remove Dial Indicator J 8001 and Bolt J 21797 from transmission and rotate transmission so that rear end of transmission is up REMOVE REMAINING COMPONENTS 1 Remove center support bolt from transmission case Figure 44 using a 3 8 inch 12 point thin wall deep socket Figure 43 Checking Rear Unit End Play 2 Remove interm...

Page 491: ... case Figure 46 Center Support Snap Ring TRANSMISSION 7 43 Figure 47 Gear Unit Removal spacer is removed from the old case and rein stalled in the new case Also remove the name plate from the old case and reinstall it onto the new case using the truss head nameplate attach ing screw that is serviced with the case 1 Inspect case assembly for cracks porosity or interconnected passages Figure 5 2 Che...

Page 492: ... thrust bearing from sun gear NOTE One of the races may have stuck to back of center support 5 Remove front internal gear ring from output carrier assembly Figure 50 bly 6 Remove sun gear from output carrier assem 7 Remove reaction carrier to output carrier plas tic thrust washer from output carrier NOTE The service thrust washer is metal 8 Invert gear unit and place in Rear Unit Hold ing Fixture ...

Page 493: ...ure 51 Check Pinion End Play TRANSMISSION 7 45 4 Inspect parking gear lugs for cracks or dam age 5 Inspect output flange locating splines for dam age 6 Inspect front internal gear ring for flaking or cracks INSPECT REACTION CARRIER 1 Inspect band surface on reaction carrier for signs of burning or scoring 2 Inspect roller clutch outer cam for scoring or wear 3 Inspect thrust washer surfaces for si...

Page 494: ...ngs in place Use a pinion pin as a guide 7 Place a bronze and steel thrust washer on each side of pinion gear with steel washers against gear Figure 53 Hold washers in place with petrolatum Figure 53 Planet Pinion Components Figure 54 Staking Pinion Pin 8 Place pinion gear assembly in position in car rier and install a pilot shaft through rear face of assembly to hold parts in place 9 Drive a new ...

Page 495: ...on gears in output carrier with transmission fluid and install output carrier on main shaft so that pinion gears mesh with rear internal gear 4 Place the above portion of the build up through hole in bench so that the mainshaft hangs downward 5 Install the rear internal gear to output flange thrust races and bearings as follows Retain with petrolatum figure 57 a Place the small diameter race again...

Page 496: ...nd install reaction carrier on output carrier so that pinion gears mesh with front internal gear NOTE When a new output carrier and or reac tion carrier is being installed and if the front internal gear ring prevents assembly of the carri ers replace the front internal gear ring with the service ring The front internal gear ring is a selective fit at the factory but not in service 14 Install the c...

Page 497: ...SMISSION 7 49 Figure 61 Removing Intermediate Clutch Retaining Snap Ring 3 Using Clutch Spring Compressor J 4670 and Rear Clutch Spring Compressor J 6129 Figure 61 compress spring retainer and remove snap ring with Snap Ring Pliers J 8059 or J 5586 4 Remove spring retainer six intermediate clutch release springs and spring guide Figure 62 5 Remove intermediate clutch piston from cen ter support 6 ...

Page 498: ...Clutch Inner Seal Protec tor J 21363 over center support hub and install in termediate clutch piston Figure 66 3 Install plastic spring guide Figure 67 4 Install six clutch release springs equally spaced into spring holes in spring guide 8 Inspect springs for collapsed coils or signs of distortion 5 Place spring retainer and snap ring over springs 9 Inspect oil seal rings for damage 6 Using Clutch...

Page 499: ... or J 5586 Remove tools 7 If necessary install four oil seal rings on the center NOTE If teflon rings are being used make sure slit ends are assembled in same relation as cut Figure 68 Also make sure oil seal rings are scated in ring grooves to prevent damage to rings during reassembly of mating parts over rings 8 Air check operation of intermediate clutch and piston Apply air through center oil f...

Page 500: ...25 and Speedometer Puller Bolt J 21797 tighten bolt on tool to secure tool on shaft and pre vent movement of the roller clutch during installa tion of the gear unit assembly Figure 47 INSTALL REAR BAND AND COMPLETE GEAR UNIT ASSEMBLY 1 Inspect rear band for cracks or distortion and band ends for damage to anchor lugs and apply lug Also inspect lining for cracks flaking burning and looseness 2 Inst...

Page 501: ...ure 47 8 Lubricate center support to case snap ring with transmission fluid and install snap ring in transmis sion case with beveled side up flat side against cen ter support locating gap adjacent to front band anchor pin Make certain ring is properly seated in groove 9 Install case to center support bolt TRANSMISSION 7 53 REAR UNIT SELECTIVE THRUST WASHER Figure 73 Removing and Installing Rear Un...

Page 502: ...ure 77 Installing Intermediate Clutch 14 Air check operation of intermediate clutch piston Apply air through center oil feed hole to actuate clutch piston 15 Recheck rear unit end play as described previ ously DIRECT CLUTCH AND INTERMEDIATE SPRAG ASSEMBLY FIGURE 78 DISASSEMBLY 1 Remove sprag retainer snap ring and remove clutch retainer 2 Remove sprag outer race and bushings and remove sprag assem...

Page 503: ...he production built direct clutch piston will be aluminum or stamped steel Figure 79 Removing Direct Clutch Snap Ring Figure 78 Direct Clutch and Piston TRANSMISSION 7 55 8 Remove inner and outer seals from clutch pis ton 9 Remove center piston seal from direct clutch housing INSPECTION 1 Inspect sprag assembly for popped or loose sprags 2 Inspect sprag bushing for wear or distortion 3 Inspect inn...

Page 504: ...ton inside Forward and Direct Clutch Pis ton Installer J 21409 insert assembly in direct Figure 80 Direct Clutch Housing Figure 81 Installing Direct Clutch Piston clutch housing Figure 81 and install clutch piston by rotating it slightly in a clockwise direction 4 Install 14 clutch release springs into spring pockets in clutch piston leaving two pockets directly opposite with no springs 5 Place sp...

Page 505: ... to rotate clutch hous ing to allow sprag outer race to index with inter mediate composition clutch plates Removal of direct clutch composition faced and steel plates may be helpful and applying air pressure through the center support screw to apply the intermediate clutch plates may facilitate assem bly 4 Check operation of direct clutch by applying air pressure through direct clutch passage next...

Page 506: ...d and steel clutch plates for signs of burning scoring or wear 2 Inspect release springs for collapsed coils or signs of distortion 3 Inspect clutch hubs for worn splines proper lubrication holes and thrust faces 4 Inspect piston or cracks 5 Inspect clutch housing for wear scoring cracks and open oil passages Figure 84 Forward Clutch Components ASSEMBLY FIGURE 86 1 Lubricate new inner and outer cl...

Page 507: ...ckwise direction until seated 4 Install sixteen clutch release springs into spring pockets in clutch piston 5 Using Clutch Spring Compressor J 4670 and Adapter J 21664 compress spring retainer with ar bor press being careful that retainer does not catch in snap ring groove and install snap ring using Snap Clutch Piston Components Ring Pliers J 8059 or J 5586 See Figure 85 Remove tools CAUTION Make...

Page 508: ... clutch NOTE If the forward clutch housing cannot be rotated as the pump cover plate is being pulled into place the forward or direct clutch housings have not been properly installed to index with all the clutch plates This condition must be cor rected before the pump cover plate is pulled fully into place 4 Torque all bolts to 20 foot pounds 5 Repeat front unit end play check as described 6 Insta...

Page 509: ...o place Use a non hardening sealer on outside of seal before installing into pump Figure 90 2 Install new pump to case square cut O ring seal 3 Install driven gear into pump body with align ment mark up 4 Install drive gear into pump body with drive tangs up Figure 91 NOTE Drive gear should always be installed with counterbore down INSTALLATION 1 Rotate transmission in holding fixture base so that...

Page 510: ...G LINKAGE 1 Inspect parking actuator rod for cracks or broken spring retainer lugs 2 Inspect actuator spring for damage 3 Inspect actuator for a free fit on actuator rod 4 Inspect parking pawl for cracks or wear 5 Inspect manual shaft for damaged threads 6 Inspect inside detent lever for cracks or a loose pin 7 Inspect parking pawl return spring for de formed coils or ends 8 Inspect parking bracke...

Page 511: ...ston grooves NOTE Do not remove the teflon oil seal rings from the rear accumulator piston unless the oil seal rings require replacement If the teflon inner oil seal ring small diameter re quires replacement for service use the aluminum oil seal ring The rear accumulator piston large diameter ring groove depth is machined shallower to take the large teflon oil seal ring if this requires replacemen...

Page 512: ...VO PISTON O FRONT ACCUMULATOR ISTON CAN ENTER BORE Figure 95 Spacer Plate Holding Bracket TEFLON OIL SEAL RING Figure 96 Front Servo Components 2 Position rear servo assembly in transmission case bore 3 Press down on rear servo assembly making certain oil seal ring is properly seated in case bore INSPECT FRONT SERVO NOTE See Figure 96 Do not remove the teflon oil seal ring from the front accumulat...

Page 513: ...MULATOR SPRING 5 OIL RING 6 ACCUMULATOR PISTON 7 E RING 8 3 2 VALVE PIN 9 3 2 VALVE SPRING 31 19 0 21 22 23 25 26 27 jr 4 NRrjP 32 9 1 2 VALVE 20 1 2 DETENT VALVE 21 1 2 SPRING REGULATOR 22 1 2 REGULATOR VALVE 23 1 2 MODULATOR BUSHING 24 RETAINER PIN 25 DETENT REGULATOR PIN 26 DETENT REGULATOR SPRING 27 DETENT REGULATOR VALVE 17 18 24 10 3 2 VALVE 33 28 DETENT VALVE 11 3 2 BORE PLUG 29 VALVE BORE ...

Page 514: ...e of 2 3 modulator bushing 8 Using pin punch remove retaining pin from lower center left bore pressing on pin from outer side of valve body Remove 1 2 modulator bushing 1 2 regulator spring 1 2 detent valve and 1 2 regulator valve from lower left center bore OTHER COMPONENTS OUT OF BORE 10 Remove bore plug detent valve detent regulator valve spacer and detent regulator valve spring from upper left...

Page 515: ... spring install bore plug hole end out and secure with grooved retaining pin from cored side of valve body 9 Insert spacer inside of detent regulator valve spring and install spring and spacer into upper left center bore making certain spring seats in bottom of bore 10 Compress detent regulator valve spring and hold with a small screwdriver placed between end of spring and wall on cored side of va...

Page 516: ... cover 25 Install two governor screen assemblies with open end up into case Figure 101 INSTALL CONTROL VALVE ASSEMBLY AND GOVERNOR FEED PIPE 1 Using two guide pins install control valve as sembly and governor pipe on transmission Make certain gaskets and spacer do not become misposi tioned Figure 102 Control Valve Bolts Figure 101 Installing Governor Screens DETENT ROLLER i AND SPRING ASM GOVERNOR...

Page 517: ...gulator valve first into pressure regulator valve bore being careful not to drop parts during installation 5 Using a screwdriver or steel rod compress regulator boost valve bushing against pressure regulator spring until it is beyond snap ring groove and install snap ring using Snap Ring Pliers J 5403 x 21 Figure 25 out NOTE To facilitate installation of snap ring en circle it around screwdriver o...

Page 518: ...dam age 10 Check governor weights for free operation in their retainers 11 Check valve opening at entry and exhaust 020 minimum GOVERNOR DRIVEN GEAR REPLACEMENT To facilitate governor repair in the field gover nor driven gear and replacement pins are available for service use The service package contains a nylon driven gear and one governor gear retainer split pin Replacement of gear must be perfo...

Page 519: ... for damaged teeth or shaft 2 Inspect sleeve for scores damaged threads or cracks INSTALL SPEEDOMETER DRIVEN GEAR 1 Install new O ring seal on speedometer driven gear assembly Figure 106 Installing Speedometer Driven Gear a Drain oil out of converter TRANSMISSION 7 7 1 2 Lubricate housing lip with a thin coat of Dex ron transmission fluid 3 Install speedometer housing and seal assembly and white n...

Page 520: ...lance weight is off or pilot is broken replace the converter 4 Check converter end play as follows Figure 1 10 Converter Assembly Cross Section Figure 109 Checking Converter End Play a Fully release collet end of Fixture J 21371 8 by turning its cap nut clockwise b Install collet end of Fixture J 21371 8 into converter hub until it bottoms then tighten its cap nut to 5 lb ft Figure 108 c Install F...

Page 521: ...tion but not turn or should be very difficult to turn in the counterclockwise directions IMPORTANT Do not use such items as the pump cover or stator shaft to turn the race as the re sults may be misleading 8 Check for stripped converter bolt holes If found stripped inspect for cause such as damaged TRANSMISSION 7 73 bolt threads heli coil the damaged bolt holes and install new bolt s INSTALL TORQU...

Page 522: ...er End Play Checking Fixture Forward Direct Clutch Outer Seal Protector Speedometer Drive Gear Remover Bolts Clutch Compressor Adapter Gear Unit Holding Tool Gear Assembly Remover and Installer Adapter Speedometer Drive Gear Removal Bolt Forward Clutch End Play Checking Tool Control Valve Direct Clutch Accumulator Piston Compressor Material Number Application Thread Size Foot Pounds 280M Transmiss...

Page 523: ...which normally escape from the fuel tank Vapor arrest is accomplished through the use of a charcoal canister s which ad sorbs the fuel vapors and stores them until they can be removed to be burned in the engine Removal of vapors from the canister s to the engine is accom plished by a calibrated purge orifice in the carbu retor In addition to the carburetor modifications FUEL TANK AND EXHAUST 8 1 a...

Page 524: ... or loss of Leak in fuel line s Replace line or hose fuel rough idle or hose s Purge hose improperly Route hose correctly routed Disconnected purge hose Connect hose to proper fitting Plugged canister filter Replace filter High volatility fuel Change brand of fuel Collapsed tank or pres Plugged or pinched vent Remove obstruction or replace line sure in tank line s Defective canister Replace canist...

Page 525: ... canister If vehicle is equipped with two canisters the filter is in the lower canister 3 Remove filter INSTALLATION 1 Install filter See Figure 2 2 Install canister Refer to Canister Installa tion earlier in this section SERVICING E C S Conventional steel tubing vapor resistant hose and hose clamps are used to connect the various components of the system It is extremely important that all pipes a...

Page 526: ...OSIVE PROOF CONTAINER The fuel tanks incorporate a drain plug in the left front corner of the tanks See figure 5 To drain the tank remove the drain plug in the tank with the correct size Allen wrench Always drain gasoline from complete fuel system including carburetor fuel pump all fuel lines and INSTALLATION 1 Connect hoses to proper ports 2 Install separator and tighten nuts fuel tank if the veh...

Page 527: ...FUEL TANK AND EXHAUST 8 5 WE A M C o 0 FUEL TANK STRAPS FUEL FILLER NECK FUEL TANK STRAP BOLT FUEL TANK VENT LINE GASKET U FILL TUBE LOCKING CAM TEE A 333 Figure 3 Type 1 Fuel Tanks and Lines ...

Page 528: ...8 6 FUEL TANK AND EXHAUST FUEL TANK STRAP BOLT FUEL TANK VENT LINE FUEL FILL TUBE A 3698 Figure 4 Type 2 Fuel Tanks and Lines ...

Page 529: ...filter is contaminated a new filter should be installed upon reassembly 6 Complete draining of tank by rocking it and allowing fuel to run out of tank unit hole 7 Purge fuel tank with steam or running hot water for at least five minutes Pour water out of tank unit hole Rock tank to assure complete removal of water IMPORTANT This procedure will not remove fuel vapor Do not attempt any repair on tan...

Page 530: ...ifying agent water mixture refer to the emulsifying agent manufacturer s specifications Use an available emulsifying agent such as Product Sol No 913 or equivalent 5 Fill tank with water to capacity and agitate again 6 Empty contents 7 When empty refill to overflowing with water to completely flush out remaining mixture and then empty tank 8 If any vapor is present repeat Steps 4 thru 8 Repeat as ...

Page 531: ...ring installation of a new exhaust pipe muf fler or tail pipe care should be taken to properly position components in relation to each other On all joints except exhaust manifold apply sealer GM 9985020 or equivalent to prevent possi ble leaks FUEL TANK AND EXHAUST 8 9 On all exhaust and tail pipe clamp installations locate centerline of clamp to end of slot in pipe as shown CENTERLINE OF CLAMP A ...

Page 532: ...8 10 FUEL TANK AND EXHAUST Figure 9 Exhaust Pipe Clamp Installation ...

Page 533: ...nents and systems and or could resultin majorrepairexpense Theymust be replaced with oneofthesame part number or with an equivalent part ifreplacement becomes necessary Do not use a replacement part oflesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention ofthese parts STEERING LINKAGE GENERAL INFORMATION Figure 1 Steering Linkage S...

Page 534: ...essive vertical lash in idler support 1 Seal damage and leak age resulting in loss of lubricant corrosion and excessive wear 1 Replace damaged parts as necessary C Hard Steering Excessive Effort Re quired at Steering Wheel D Poor Returnability 1 Low or uneven tire pressure 2 Steering linkage or ball joints need lubrication 3 Tight or frozen inter mediate rod tie rod or idler socket 4 Steering gear...

Page 535: ...d smooth The ball stud must have no nicks on the taper NOTE If threads are not clean and smooth ball studs may turn in tie rod ends when attempting to tighten nut 3 Install ball studs in steering arms and inter mediate rod 4 Install ball stud nuts and torque See specifica tions for torque value and procedure STEERING 9 3 5 Lubricate linkage sockets 6 Lower vehicle 7 Adjust toe in See section 3A of...

Page 536: ...ecuring idler arm to frame INSTALLATION 1 Secure idler arm to frame using bolt and lock nut Torque nut to 85 to 110 foot pounds 2 Connect idler arm ball stud to intermediate rod Install ball stud nut making sure threads are clean and torque See specifications for torque value and procedures 3 Lubricate all steering linkage sockets as de scribed in SECTION 0 of this manual 4 Lower vehicle POWER STE...

Page 537: ...ven from the crankshaft The rotor is loosely splined to the drive shaft and secured with a retain ing ring It is located centrally within the ring and between the thrust and pressure plates The ten vanes are mounted in radial slots in the rotor figure 3 The mode of operation of the power steering pump is based upon the demand of the power steer ing gear The various major modes of operation are slo...

Page 538: ...ylinder When this flow exceeds the predetermined system requirements oil is bypassed within the pump This is accomplished by the pressure drop which occurs across the flow con trol orifice 2 The pressure is reduced at the bottom of the flow control valve 9 because the orifice 11 is connected by 8 to the bottom of valve 9 The pressure unbalance of the valve is sufficient to overcome the force of th...

Page 539: ...UBLE DIAGNOSIS STEERING 9 7 sure drop and resulting lower pressure on the bottom end of the control valve 9 The pressure unbalance then causes the valve to compress the spring 10 allowing the major portion of the oil to bypass into the intake chamber from 3 to 6 in the same manner as is accomplished by flow controlling Relief pressures are usually between 750 and 1450 psi depending on the vehicle ...

Page 540: ...compartment through the steering column Rattle or chuckle noise 1 Gear loose on frame 1 Check gear to frame mounting in steering gear screws Tighten screws to 70 foot pounds 2 Steering linkage loose 2 Check linkage pivot points for ness wear Replace if necessary 3 Pressure hose touching 3 Adjust hose position Do not other parts of vehicle bend tubing by hand 4 Loose pitman shaft 4 Adjust to specif...

Page 541: ... noise in steering 1 Vanes not installed 1 Install properly pump properly 2 Vanes sticking in rotor 2 Free up by removing burrs slots varnish or dirt Swish noise in steering 1 Defective flow control 1 Replace part pump valve Whine noise in steering 1 Pump shaft bearing 1 Replace housing and shaft Flush pump scored system Poor return of steering 1 Lack of lubrication in 1 Lube linkage and ball join...

Page 542: ... Sticky or plugged 11 Remove and clean or replace valve spool valve 12 Steering gear adjust 12 Check adjustment with gear out ments over specifications of vehicle Adjust as required Vehicle wanders 1 Front end mis 1 Adjust to specifications Keep in mind road con aligned dition and wind Test vehicle on flat road go ing in both directions 2 Unbalanced steering 2 Replace valve gear valve NOTE If this...

Page 543: ...ring gear flexible 3 Tighten flange pinch bolts to coupling loose on shaft 30 foot pounds if serrations are or rubber disc mounting not damaged Tighten upper flange screws loose to coupling nuts to specified torque 4 Steering linkage joints 4 Replace loose pivots worn enough to be loose 5 Worn poppet valve 5 Replace poppet valve Gear 6 Loose thrust bearing 6 Adjust to specification with preload ad...

Page 544: ...250 1350 psi and the range of readings are within 50 psi the pump is functioning within specs b If the pressures recorded are high but do not repeat within 50 psi the flow controlling valve is sticking Remove the valve clean it and remove any burrs using crocus cloth or fine hone If the system contains some dirt flush it If it is exceptionally dirty both the pump and the gear must be completely di...

Page 545: ...oximately five minutes Check power steering fluid level and add if required 3 Record flow and pressure at idle with gate valve fully open If flow is below 2gpm the pump appears to be in need of repair but continue diagnosis If pressure is above 200 psi check hoses for restrictions and check steering gear for poppet valve functions 4 Partially close gate valve to build 700 psi Observe and record fl...

Page 546: ...remely cold tem fluid level and possible ternal pump leakage peratures will cause system aeria low pressure causing overflow tion should the oil level be low If oil level is correct and pump still foams remove pump from vehi cle and separate reservoir from housing Check welsh plug and hous ing for cracks If plug is loose or housing is cracked replace housing Low pressure due to 1 Flow control valv...

Page 547: ...ASSEMBLY Before disassembly of pump remove reservoir filler cap and drain oil from reservoir by inverting the pump so oil may drain out the filler hole After oil is drained from reservoir cap should be replaced and the entire pump assembly washed in a non toxic solvent to remove all dirt and prevent any foreign matter from contaminating pump compo nents CAUTION Examine exposed part of drive shaft ...

Page 548: ...serting a screwdriver under the ring and twisting the screwdriver figure 12 6 Remove end plate and end plate O ring End plate is spring loaded and will generally sit above the housing level for ease of removal If sticking should occur a slight rocking action of the end plate should be used to free it figure 12 7 Remove pump from vise and invert Flow con trol valve and valve spring will fall free f...

Page 549: ...Shaft to Unseat Pressure Plate STEERING 9 1 7 Figure 15 Removal of Shaft Pressure Plate Pump Ring Vanes and Rotor 1 Inspect flow control valve assembly for score marks wear burrs or other damage 2 Inspect castings for cracks or other visual evi dences of damage Check machined surfaces espe cially mating surfaces on O ring seats for scratches or burrs that might permit leaks Examine Figure 16 Remov...

Page 550: ...ump shaft seal using seal protec tor J 22616 and seal installer J 7728 or a 1 inch socket with an arbor press or hammer figure 17 CAUTION DO not use any more force than necessary to seat the seal 2 Lubricate new pressure plate O ring with Power Steering Fluid and install in third groove from rear of housing 3 Clamp end hub of housing in vise in same position as before and insert both dowel pins fi...

Page 551: ...g Fluid and install in second groove from rear of housing Figure 20 Replacement of Pump Vanes STEERING 9 1 9 Figure 21 Installing Pressure Plate 11 Install end plate spring in groove provided in pressure plate figure 12 12 Lubricate end plate with Power Steering Fluid to protect O ring and press into housing with an arbor press figure 22 Depress only far enough to enable retaining ring to seat pro...

Page 552: ...oximately 2 1 2 inches long into a cylindrical shape then push the shim stock past seal until it bottoms in pump body CAUTION The use ofshim stock around the pump shaft will prevent damage to the ma chined surfaces ofthe shaft when removing seal 2 Cut metal body of seal with a small chisel 3 Tear metal body approximately 1 inch with diagonals Force an awl between the pump body and the OD of seal t...

Page 553: ... wheels turned all the way to the left add power steering fluid to Cold mark on dipstick b Start engine run at fast idle and recheck fluid level Add fluid if necessary to Cold mark on dipstick c Bleed system by turning wheels from side to side without hitting stops Maintain fluid level just above internal pump casting Fluid with air in it will have a cloudy appearance This air must be elimi nated ...

Page 554: ...justing tension on belt driving the auxiliary OIL LINE FILTER The steering gear oil is circulated by the pump through the steering gear and the windshield wiper motor before it returns to the pump In the line at the windshield wiper motor is an oil filter In the event that the oil pump is overhauled or replaced this filter should be replaced For filter replacement proce dure refer to Windshield Wi...

Page 555: ...ward to apply turning effort to the pitman shaft The oil in the chamber at the lower end of the rack piston is forced out through the valve body and spool valve to the pump reservoir Figure 24 Power Steering Gear STEERING 9 23 TROUBLE DIAGNOSIS For complete power steering trouble diagnosis see TROUBLE DIAGNOSIS under POWER STEERING PUMP earlier in this section STEERING GEAR REMOVAL 1 Disconnect th...

Page 556: ...Plug 22 Thrust Bearing 37 Plug 7 O_ Ring 23 Thrust Washer 38 O Ring 8 Thrust Washer Large 24 Housing 39 Housing End Cover 9 Thrust Bearing 25 Locknut 40 Retainer Ring 10 Thrust Washer Small 26 Attaching Bolts and 41 Needle Bearing 11 Spacer Washers 42 Oil Seal 12 Retainer 27 Side Cover 43 Back Up Washer 13 O Ring 28 O Ring 44 Oil Seal 14 Spool Valve 29 Pitman Shaft 45 Back Up Washer 15 Teflon Oil ...

Page 557: ... 25 Figure 27 Removing Rack Piston End Plug NOTE To aid in loosening the aluminum end plug female square drive strike sharply using 1 or larger diameter brass drift and hammer 4 Remove the pitman shaft and side cover as follows a Loosen the over center adjusting screw locknut and remove the four side cover attaching bolts b Rotate the side cover until the rack piston and pitman shaft teeth are vis...

Page 558: ... dis card 1 Retaining Ring 2 Dust Seal 3 Stub Shaft Seal 4 Needle Bearing 5 Adjusting Ring 6 O Ring 2 3 4 5 6 7 Thrust Washer Large 8 Thrust Bearing 9 Thrust Washer Smalh 10 Spacer 11 Retainer 7 8 9 10 11 A 4630 Figure 30 Adjuster Plug Exploded View Figure 29 Removing Adjuster Plug 8 If the worm or the lower thrust bearing and race remained in the gear housing remove them at this time ...

Page 559: ...g is to be replaced remove the retaining ring using Internal Pliers J 4245 Remove thrust bearing as outlined in Step 2 above Drive needle bearing dust seal and oil seal from adjuster plug using Bearing Remover J 8524 2 and Driver J 7079 2 as shown in Figure 32 Discard the seals 4 Wash all parts in clean solvent and dry parts with compressed air 5 Inspect thrust bearing spacer for wear or cracks Re...

Page 560: ... bearing race flanged edge up and spacer grooves of spacer away from bearing washer 5 Install bearing retainer on the adjuster plug by carefully tapping on the flat surface of the retainer figure 35 CAUTION The projections must not extend beyond the spacer when the retainer is seated to prevent interference with valve body The spacer must be free to rotate Disassembly Figure 35 Install Retainer VA...

Page 561: ... the complete valve and shaft assembly 3 If there is evidence of leakage between the torsion bar and the stub shaft or scores nicks or burrs on the ground surface of the stub shaft that cannot be cleaned up with crocus cloth the entire valve assembly must be replaced STEERING 9 29 _ TEFLON RINGS 3 O RINGS 3 INSTALLED UNDER TEFLON RINGS Figure 38 Valve Body and Shaft Assembly 4 Check the outside di...

Page 562: ...ssed air 2 Check pitman shaft bearing surface in the side cover for scoring If badly worn or scored replace the side cover assembly 3 Check the sealing and bearing surfaces of the pitman shaft for roughness nicks etc If minor ir regularities in surface cannot be cleaned by use of crocus cloth replace the pitman shaft 4 Replace pitman shaft assembly if teeth are da maged or if the bearing surfaces ...

Page 563: ...h end of guide Install the return guide clamp and tighten the two clamp screws to six foot pounds STEERING GEAR HOSE CONNECTOR AND POPPET CHECK VALVE REPLACEMENT The following procedure can be performed on vehicle as well as on bench 1 Disconnect pressure and return line hoses at steering gear and secure hose ends in a raised posi tion to prevent loss of fluid 2 To prevent metal chips from becomin...

Page 564: ...Con nector Seat Installer J 6217 figure 43 11 Check operation of valve by pushing lightly against valve with a small punch or small rod Valve should reseat itself against connector seat when pres sure is removed from spring 12 Connect pressure and return line hoses on steering gear Tighten hose fittings to 30 foot pounds 13 Check fluid level in pump reservoir and add if necessary Figure 43 Install...

Page 565: ... 46 Installing Pitman Shaft Bearing STEERING 9 33 Figure 47 Installing Pitman Shaft Seals c Remove the tool and adapter then install the back up washer and seal retaining ring The re taining ring will not seat in the groove at this time d Reinsert Tool J 6278 with Adapter J 6278 2 and continue driving the seals until the retaining ring seats in its groove Refer to inset figure 47 then remove the t...

Page 566: ...far enough to provide clearance for the retaining ring Install retaining ring 8 Fill pump reservoir to proper level with Power Steering Fluid Start engine and allow engine to idle for at least three minutes without turning steering wheel Turn wheel to left and check for leaks Add Power Steering Fluid as required 9 Remove tape and reconnect pitman arm Figure 48 Installing Pitman Shaft Seals STUB VA...

Page 567: ...a new adjuster plug O ring with Power Steering Fluid and install in groove on ad juster plug Place Seal Protector J 6222 over stub shaft then install the adjuster plug assembly in the housing until it seats against the valve body figure 53 Remove Seal Protector a Using spanner wrench J 7624 turn ad juster plug in clockwise until the plug and thrust bearing are firmly bottomed approximately 20 ft l...

Page 568: ...til the rack piston teeth are centered in the pitman shaft opening then install the pitman shaft and side cover so that the center tooth of thepitman shaft engages the center groove of the rack piston c Install the side cover bolts and tighten to 45 foot pounds 7 Install the rack piston plug in the rack piston and torque to 75 foot pounds 8 Install a new housing end cover O ring and lubricate it w...

Page 569: ...it is better to take the extra time and make the adjustment correctly the first time Since a handling stability complaint can be caused by improperly adjusted worm thrust bearings as well as an improper gear over center adjustment it is necessary that the steering gear assembly be Figure 56 Loosening Adjuster Plug Nut STEERING 9 37 Figure 57 Removing Adjuster Plug Nut removed from the vehicle and ...

Page 570: ...tment procedure listed Figure 59 Housing Marks Figure 60 Marking Rotation Distance PITMAN SHAFT OVER CENTER SECTOR ADJUSTMENT 1 Using an in lb torque wrench turn the stub shaft to the right stop then back 1 4 turn Measure the torque Reading should be taken with beam of torque wrench near verticle while turning counter clockwise at an even rate figure 63 2 Turn the stub shaft from stop to stop coun...

Page 571: ...ment the total number of turns This is the center of the gear The flat on the stub shaft is normally up and parallel with the side cover when the gear is on center figure 64 and the block tooth on the pitman shaft is in line with the over center preload adjuster figure 65 Figure 65 Over Center Alignment ...

Page 572: ...o remain in the power steering fluid system noisy and unsatisfactory operation of the system will result Bleed air from the hydraulic system as fol lows NOTE Add only new power steering fluid GM 1050017 or equivalent to power steering sys tem 1 Fill oil reservoir to proper level and let oil remain undisturbed for at least two minutes 2 Start engine and run momentarily 3 Add oil if necessary 4 Repe...

Page 573: ...teering shaft assembly with a universal joint between them A support assembly is held to the STEERING COLUMN STEERING 9 41 mast jacket by a lock plate and a hearing housing assembly is positioned over the upper steering shaft and secured to the support by two pivot pins Two lock shoes are pinned to the housing assembly and engage a pin in the support assembly When the release lever is pulled up an...

Page 574: ...r rod as bowl and rack coupling required I Ignition switch stuck I Replace ignition switch J Acutator rod re J Readjust stricted High effort A Lock cylinder defective A Replace lock cylinder B Ignition switch de B Replace ignition switch fective C Rack preload spring C Replace preload spring broken or deformed D Burrs on sector rack D Remove burr housing support or acuator rod coupling E Bent sect...

Page 575: ...ce or defective C Defective wiring C Repair or replace D Defective ignition D Replace ignition switch switch E Ignition switch not E Readjust adjusted properly Switch will not actuate A Defective ignition A Replace mechanically switch Switch can not be set A Switch actuator rod A Repair or replace correctly deformed B Sector to rack en B Engage correctly in wrong tooth Condition Possible Cause Cor...

Page 576: ...eering wheel is moved High steering shaft A Column assembly mis A Realign effort aligned B Improperly installed B Install new seal or deformed dust seal C Defective upper or C Replace lower bearing D Flash on I D of D Replace shift tube shift tube from plastic joint E Tight steering uni E Repair or replace versal joint High shift effort A Column not aligned A Realign correctly in vehicle B Wave wa...

Page 577: ...ot pounds jacket bolts loose Housing scraping on A Bowl bent or not con A Replace bowl owl centric with hub Steering wheel loose A Excessive clearance A Replace either or both between holes in support or housing and pivot pin diameters B Defective or missing B Add spring or replace both anti lash spring in spheres C Upper bearing not C Replace both seating in bearing D Upper bearing inner D Instal...

Page 578: ...s 25 in lbs B Switch or anchor B Replace switch bosses broken C Broken missing or out C Reposition or replace springs as of position detent return required or cancelling spring D Uneven or incorrect D Adjust switch position cancelling cam to cancel 1 If interference is correct ling spring interference and switch will still not cancel 120 side replace switch 2 If interference cannot be cor rected b...

Page 579: ... function of hazard switch replace turn signal switch Hazard switch will not A Loose switch mounting A Tighten mounting screws stay on or difficult to screws 25 in lbs turn off B Interference with B Remove interference other components C Foreign material C Remove foreign material D None of the above D Replace switch No turn signal lights A Defective or blown A Replace fuse fuse B Inoperative turn ...

Page 580: ...ir defective nection to ground at bulb connection socket C Loose chassis to column C Connect securely connector D Disconnect column to D Replace turn signal switch chassis connector Connect new switch into system and operate switch by hand If turn signal lights are now on and flash turn signal switch is inoper ative E If vehicle lights do E Repair chassis wiring as required not operate check chass...

Page 581: ...ection E Disconnect column to E Replace signal switch chassis connector Connect new switch into system without removing old Operate switch by hand If flashing occurs at normal rate the signal switch is defective F If the flashing rate F Locate and repair as required still extremely slow Use manual as guide check chassis wiring harness from the connector to light sockets for grounds high resistance...

Page 582: ... repair as required D Door jamb switch D Readjust or replace as required misadjusted or in operative E Short in chassis E Check by separating chassis to wiring column connector Connect E black and F black w pink stripe female contacts on the chassis side figure 67 Bent paper clip will work if buzzer sound continue diagnosis If not locate and repair chassis wiring use manual as guide NOTE 1 If the ...

Page 583: ...the signal switch and drive the three screws Check the function as in Note I uzzer does not sound F Short or fault in sig F Connect male E and F con with key fully inserted nal switch wiring tacts of connector with jumper n lock cylinder with figure 69 Check buzzer switch he entrance door open pads with continuity meter If contact is made function is normal If not replace signal switch NOTE 3 If t...

Page 584: ... not made replace buzzer switch L Buzzer switch contact L Reset contact gap gap too large NOTE 4 Setting the contact gap Press a 030 wire type spark plug gap wire with flat piece of stock on the actuator pad figure 74 If contact is not made adjust switch as shown in Figure 75 until positive contact is made Use continuity meter With positive contact at 030 use a 025 plug gap wire beneath the flat s...

Page 585: ...place lock cylinder operate with key out start position if buz ut stops when door zer stops in run posi is closed tion or when turned past run towards start the problem is a sticky lock cylinder actuator B Chips foreign material B Remove reassemble and recheck in lock cylinder bore function C Sticky lock cylinder C Replace lock cylinder actuator tip D Damaged or broken buz D Replace buzzer switch ...

Page 586: ...injections which maintain column rigidity Figure 76 Checking Contact Gap Figure 77 Adjusting Buzzer Switch 1 Disconnect column from lower steering shaft at cinch clamp 2 Disconnect the shift linkage from the shift lever 3 Remove screws securing toe pan cover to fire wall and loosen cover 4 Remove bolts securing bracket to instrument panel and disconnect PARK RNDSL pointer on the automatic shift co...

Page 587: ...ic transmis sion column Remove neutral start switch 8 Depress lock plate with finger and pry retain ing ring out of groove with screwdriver figure 81 Tool J 23653 can be used figure 80 but the full load Figure 79 Connector and Wires Taped STEERING 9 5 5 Figure 80 Removing Retaining Ring of the upper bearing spring should not be relieved as then the retaining ring will turn easily making re moval m...

Page 588: ...ure 84 A flat spring wedges the switch toward the lock cylinder figure 85 Figure 83 Removing Lock Figure 84 Removing Buzzer Switch 14 Remove three housing cover screws and remove housing cover 15 Reinstall tilt release lever and place column in full tilt up position Remove tilt spring retainer using screwdriver blade that just fits into slot open ing Insert screwdriver in slot press in approxi mat...

Page 589: ...semble steering shaft assembly by removing center spheres and anti lash spring 21 Remove four support screws and remove sup port assembly 22 Remove shift tube retaining ring with screw driver Remove thrust washer If service is required on upper end only steps 1 thru 22 may be performed in the vehicle It is neces sary to remove the mounting bracket and loosen toe plate to prevent bending of jacket ...

Page 590: ...all punch lightly tap drive shaft from sector figure 91 Remove drive shaft Remove rack and rack spring also shim if there is one Remove sector and bolt 31 Remove tilt release lever pin with pin punch and hammer Remove lever and release lever spring To relieve load on release lever hold shoes inward and wedge block between top ofshoes over slots and bearing housing figure 92 32 Remove lock shoe pin...

Page 591: ...clock position and under jacket opening Slide lock plate into not ches in jacket Figure 93 Installing Shift Tube STEERING 9 5 9 10 Carefully install shift tube in lower end of jacket Align key in tube with keyway in bowl and use Tool No J 23073 to pull shift tube into bowl figure 93 CAUTION DO NOT PUSH OR TAP ON END OF SHIFT TUBE Install thrust washer and retaining ring by pulling bowl up to compr...

Page 592: ... and lower steering shaft flange or intermediate shaft assembly Tighten pinch bolt to specified torque 24 Install hazard warning knob and pull knob out Install bearing inner race seat bearing preload spring cancelling cam and lock plate Figure 95 Installing Retaining Spring 25 Depress lock plate and install new retaining ring using Tool J 23653 figure 95 26 Reinstall tilt release lever signal swit...

Page 593: ...s 33 Install steering wheel Torque steering wheel nut to 30 foot pounds Make sure this procedure is followed in exactly this order 1 Reconnect all electrical connections 2 Install column into position and loosely attach mounting bracket to instrument panel with two mounting bolts CAUTION Do not use longer bolts or over torque bolts The correct bolts and torque are necessary to insure the breakaway...

Page 594: ...Nuts 20 Return Guide Clamp Screws 5 Rack Piston Plug 75 Pitman Shaft Nut 160 210 Coupling Flange Bolt 30 Torque Part Location Ft Lbs Nut Steering Arm to Tie Rod End 40 50 Nut Tie Rod Clamp Nuts 19 24 Nut Tie Rod to Intermediate Rod 40 50 Nut Idler Arm To Intermediate Rod 40 50 Nut Idler Arm To Frame 85 110 Nut Relay Lever To Intermediate Rod 40 60 Bolt Relay Lever To Frame 250 300 Nut Drag Link To...

Page 595: ...2 Seal Driver J 7576 Rack Piston Seal Compressor J 7624 Spanner Wrench J 7728 Seal Installer J 7754 Torque Wrench J 7786 Gauge Adapter J 8058 Torque Wrench J 8092 Handle J 8524 1 Adjuster Plug Bearing Installer J 8524 2 Adjuster Plug Bearing Remover J 21552 Ball Retainer J 21854 01 Pivot Pin Remover J 22407 Pitman Shaft Bearing Installer J 22616 Pump Shaft Seal Protector J 23063 Spring Remover J 2...

Page 596: ... wheels should be equiva lent to those removed in diameter rim width and off set TIRE TRACTION A decrease in driving cornering and braking traction occurs when water snow ice gravel or other material is on the road surface Driving prac tices and vehicle speed should be adjusted to the road conditions When driving on wet or slushy roads it is possi ble for a wedge of water to build up between the t...

Page 597: ... the stud and nut assembly can reach a point where removal of cap nuts is dif ficult If this is a persistent problem the threads of the stud and the threads of the inner cap nut should be cleaned with a wire brush WHEEL MAINTENANCE Thoroughly remove rust dirt and other foreign materials from all surfaces Hand or electric wire MAINTENANCE TREAD WEAR FIGURE 1 The original equipment tires incorporate...

Page 598: ... SCRIBED AMOUNT OF AIR Unless the correct air pressure is consistently maintained the tires will not function as they should consistently safe economical operation of vehicle will be materially affected An under inflated tire runs sluggishly heats up quickly because of the greater flexing and is sub jected to more frequent bruising On the other hand over inflation may weaken the tire causing a blo...

Page 599: ... bead may bind on the rim and refuse to seat Allowing pressure to continue to build up within the assembly in an attempt to seat the tire bead is a DANGEROUS PRACTICE which can result in a broken tire bead and serious injury to the DYNAMIC BALANCE TIRE REPLACEMENT Dynamic balance sometimes called running bal ance means that the wheel must be in static balance and also run smoothly at all speeds on...

Page 600: ...ot seated by the time pressure reaches 80 pounds assembly should be deflated repositioned on rim relu bricated and re inflated 4 Make sure valve core is inserted in valve stem prior to inflating 5 Use an extension gauge with clip on chuck so air pressure build up can be closely watched and so that you can stand well back from the assembly dur ing the bead seating process to avoid possibility of pe...

Page 601: ...10 6 WHEELS AND TIRES Figure 8 Inserting Tire Iron to Lift Bead Figure 10 Inserting Tire Iron in Second Bead Figure 9 Lifting Bead Over Rim Figure 1 1 Prying Second Bead from Rim ...

Page 602: ...d because it occurs WHEELS AND TIRES 10 7 DEMOUNTING 1 Remove valve core to completely deflate tire With tire lying flat on floor loosen beads from rim seats by walking around on tire with heels at points close to rim With wide side of rim down apply tire lubricant to top bead With stops toward rim insert spoon ends of two tire irons about 10 apart While standing on tire to hold bead in gutter pul...

Page 603: ...the front than they are in the rear When toe in is excessive the tire wear shows feathered edges on inside edge of the skid design Toe Out The wheels on the same axle are closer together in the rear than they are in the front Tire wear shows feathered edges on outside edge of the skid design Camber This designates the tilt of the wheel Positive camber is when wheels are closer together at point of...

Page 604: ... shiny worn surface on wheel face indicating that loose wheels were moving against each other If the stud holes are out of shape oval or egg shaped and where a build up of metal is around them these wheels must be replaced CRACKED DISC WHEELS FIGURE 14 Cracks running from hand hole to stud hole or bolt hole to center hole or hand hole to hand hole or hand hole to rim or stud hole to stud hole are ...

Page 605: ...ked Disc Wheels SPECIFICATIONS Inflation Pressure Cold 60 PSI For Sustained Speeds Over 65 MPH 70 PSI Tires Size 8 75 16 5 Load Range D Construction Bias Ply Steel Belted Wheels Diameter 16 5 Width 6 0 Off Set 4 67 Bolt Circle Diameter 6 50 Number of Studs 8 ...

Page 606: ...8 Dimmer Switch 12 28 Horn 12 28 Horn Diagnosis 12 29 Component Replacement 12 29 Radio and Tape Player 12 29 Radio and Tape Diagnosis 12 31 Servicing 12 31 Mobile Radio Transmitters 12 36 Cruise Control 12 36 General Description 12 36 Component Operation 12 36 Diagnosis 12 40 Servicing 12 40 Brake Release Switches 12 40 Engagement Switch 12 42 Servo 12 42 Transducer 12 42 Electrical System Check ...

Page 607: ...ter other than maintaining clean tight electrical connections re placing defective parts and keeping the speedometer cable properly lubricated Figure 2 shows instrument panel component installation COMPONENT REPLACEMENT INSTRUMENT PANEL BEZEL REPLACEMENT 1 Remove the radio knobs and control rings Figure 1 Instrument Panel 2 Remove the headlight switch knob as de scribed under HEADLIGHT SWITCH RE P...

Page 608: ...taining clip down and pull cable away from speedometer head 6 Disconnect 4 wire electrical connector from the back of the speedometer head 7 Pull the speedometer head out and disconnect the transmission gear indicator cable CIGAR LIGHTER HOUSING INSTRUMENT PANEL HEATER CONTROL SPEEDOMETER HEADLIGHT SWITCH KNOB Figure 2 Instrument Panel Components CHASSIS ELECTRICAL 12 3 CIGAR LIGHTER SOCKET RADIO ...

Page 609: ... 5 3 Pull switch out as far as possible and discon nect the connector from the switch 4 To install switch reverse steps 1 3 FUEL SELECTOR SWITCH REPLACEMENT FUEL SWITCH BATTERY SWITCH CIGAR LIGHTER HOUSING INSTRUMENT PANEL Figure 5 Battery and Fuel Switch Installation 2 Remove the 2 switch retaining screws shown in Figure 5 3 Pull switch out as far as possible and discon nect the connector from th...

Page 610: ...to remove lower portions of cable from transmis sion end of conduit 4 Lubricate cable with lubricant then push cable into conduit Connect upper end of cable to speed ometer head and road test vehicle NOTE Speedometer cable should be lubricated with AC Speedometer Cable lube ST 700 Part No 6478535 or equivalent N CHASSIS ELECTRICAL 12 5 CIRCUIT BREAKERS FUSES AND FUSIBLE LINKS GENERAL DESCRIPTION A...

Page 611: ... wiring faulty connections or mechani cal failure in a component such as a switch or circuit breaker Short circuits are usually caused by wires from different components of the circuit contacting one another or by a wire or component grounding to the metal of the body due to a screw driven through the wires insulation cut through by a sharp metal edge etc The following information may aid in locat...

Page 612: ...LIGHTS HAZARD WARNING LIGHTS TURN SIGNAL LIGHTS SIDE MARKER LIGHTS I D CLEARANCE LIGHTS TAIL LIGHTS DOME LIGHTS LICENSE LIGHT TRANSMISSION CONTROL PARKING BRAKE LIGHT GAUGES A 4076 NOTE Use of fuses or circuit breakers having other than the specified amperage may result in damage to the circuit Figure 12 TransMode Electrical Component Mounting Plate ...

Page 613: ...Blower Relay Built into line at right 30 amp fuse or fusible link access door near heater blower relay Warning and signal In clip behind instru GM No 673499 flasher ment panel Figure 28 Vehicle trouble light In line behind access 10 amp fuse door near light Horn power feed In line behind access Fusible link circuit door near horn relay Figure 11 Auxiliary Battery Engine compartment 50 amp circuit ...

Page 614: ...ut use terminals 7513 and 41 e Low Fuel 1 With the tell tale panel removed connect the test light probes between 929 and 150H if test light lights circuit is good if it does not follow the same procedures explained under DOOR AJAR tell tale f Set Power Lever To Travel SPEEDOMETER CIRCUIT CHASSIS ELECTRICAL 12 9 A 4136 Figure 14 Tell Tale Printed Circuit 1 Follow the same procedure outlined for DOO...

Page 615: ...ty has been used If a condition is present where the vehicle is run in the MAIN position and allowed to deplete fuel supply on gauge then switching to AUX does not provide the reserve 7 to 9 gallon amount it is possi ble the wiring connector figure 17 near the frame rail and tanks has the wires crossed in connection The wires in this connection should be color to color from each side of the connec...

Page 616: ...ition ignition switch in ON DO NOT START ENGINE 1 With tester knob set at Continuity lamp should glow 2 With tester knob set at 0 dash unit should indicate EMPTY 3 With tester knob set at 90 dash unit should indicate FULL If any one of 1 2 or 3 are not OK inspect wiring from ignition switch to the rear wiring con nector including grounds Re pair as necessary to insure good electrical connections a...

Page 617: ...6 Circuit within dash gauge grounded x Install new dash fuel gauge 7 Circuit grounded between battery and x Insulate grounded circuit dash gauge 8 Open circuit between ignition switch x Clean and tighten appropriate and dash gauge terminals or repair broken wire 9 Open circuit between ground terminal x Clean and tighten mounting bracket on gauge and ground where contact is made between dash gauge ...

Page 618: ...ire from the 7 wire connector on the gauge head GRAY DBL BLACK STR 3 Gauge should now read FULL If the gauge continues to read EMPTY replace the dash unit Gauge Now Registers Full 1 Connect a spare tank unit to the tank feed wire at the body harness connector and ground unit at flange to chassis with a jumper wire 2 Raise and lower float arm assembly while ob serving the dash unit a If dash unit s...

Page 619: ...e if the lamp changes intensity A satisfactory unit will change the lamp intensity with changes in engine oil pressure DO NOT USE A LAMP OF OVER 2 candle power 3 Connect the wire and check wiring for open circuit between unit and connector at the back of gauge head 4 Check for continuity in printed circuit trace 5 If no defective wiring or connections exist and sending unit checks out satisfactory...

Page 620: ...re 4 If 1 2 and 3 above are OK clean sender terminal to insure good electrical contact with wire and make sure sender unit is ground ing to engine 5 If pressure gauge system is still not functioning properly after com pleting Step 4 replace sender unit DO NOT START ENGINE AC GG3 TESTER 6 If any one of 1 2 and 3 are not OK check wiring and all connections including grounds 7 If any one of 1 2 and 3...

Page 621: ...the windshield washer pump for pumping of washer sol vent onto the windshield Switch Replacement 1 With a flat blade screwdriver engage the switch ring with the screwdriver blade while holding the back side of the switch See figure 2 2 Remove the retaining ring from the switch and bring the switch down to a more accesible position 3 Disconnect the wiring harness connector from the switch 4 Remove ...

Page 622: ... fusible link later models Both the fuse or the fusible link are installed as part of the heater wiring harness The heater blower relay is mounted above the horn relay on the electrical component mounting plate refer to Figure 42 Diagnosis and component replacement are discussed in Section 1 Body Heat ing and Air Conditioning Disconnect Coolant Level Probe Sensor at Radiator Ignition switch in RUN...

Page 623: ...vel indicator the indicator module is located to the lower left of the dash panel as shown in Figure 22 The indicator light is designed to glow when a cooling system low water condition occurs in the radiator of the vehicle See servicing details before refilling coolant as discussed in Section 13 RADIA TOR AND COOLANT RECOVERY SYSTEM If Coolant Level indicator system malfunctions re fer to Coolant...

Page 624: ...front L H corner ofthe instrument panel Rear lighting circuits can be checked for con tinuity through the female portion of this connector Figure 24 shows the 10 way multiple connector and the appropriate wire position in the connector body Refer to the vehicle wiring diagram for wire size and code used in the rear end wiring FRONT WIRING Dome lights headlamps and front clearance lights are fed th...

Page 625: ... Mono Radio Connector Figure 28 Instrument Panel Wiring Typical STEERING COLUMN WIRING Connections for directional signals ignition switch neutral safety switch back up lamps and power leveler warning are shown in Figure 30 These connectors are located on the steering column Refer to vehicle wiring diagram for applicable wire size and color REAR BODY WIRING Wiring for rear identification and clear...

Page 626: ...re 30 Steering Column Wiring CHASSIS ELECTRICAL 12 21 BODY SIDE HARNESS REAR END WIRING CONNECTOR REAR BUMPER TO REAR MARKER DENT LIGHTS SPEAKERS A 5196 Figure 31 Rear Body Wiring BODY SIDE HARNESS FRONT TRAILER WIRING HARNESS REAR END WIRING REAR SPEAKER CONNECTION A 1801 Figure 32 Trailer Wiring ...

Page 627: ...mination Proper aiming should be checked whenever a sealed beam unit is replaced or after any repair of the headlamp socket assembly Regardless of the method used for checking head lamp aim the vehicle must be at normal ride height that is with gas water and passenger weight most frequently traveled with NOTE Some states have special headlamp aim ing requirements which must be known and fol lowed ...

Page 628: ... or Intermittent Check Wiring Connections to Terminals Check Voltage at Upper and Lower Beam Terminals Check Ground Connection of Sealed Unit Con nector to Body Filament Glows Dim Check for Wrong Sealed Beam Replace Sealed Beam Will Not Aim Properly Check for Open Check for Chipped Ground Connection or Broken Aiming Pad on Lens Check for Proper Calibration and Floor Compensation of Mechanical Aime...

Page 629: ...section for bulb No 3 Install lens and retaining screws SIDE MARKER LAMP BULB FRONT AND REAR REPLACEMENT FIGURES 34 and 36 1 Remove 2 marker lamp retaining screws and remove lens 2 Replace bulb and check operation See Specifi cations at the end of this section for bulb No 3 Install lens and retaining screws TAIL STOP BACK UP AND DIRECTIONAL SIGNAL BULB REPLACEMENT FIGURE 36 1 Remove 4 lens retaini...

Page 630: ...LB REPLACEMENT 1 Remove the 2 lens retaining screws and then remove lens 2 Replace bulb and check operation 3 Install lens and retaining screws FIBER OPTIC RIBBON Lighting for windshield wiper control main light switch and washer switch is transmitted through a fiber optic ribbon from a main source bulb located on the L H side of the lower instrument panel cover The ribbon should remain with the i...

Page 631: ... good light switch immediately before circuit breaker blade burns Refer to service manual to repair ground in circuit between light switch and headlights Install good light switch after repair Disconnect good light switch immediately before circuit breaker blade burns Refer to service manual to repair short or ground in circuit between light switch and headlights Install good light switch after re...

Page 632: ...oltage at Light Switch Red Wire Terminal With 12 Volt Test Light Switch to Battery Bulb If Bulb Fails to Light Repair Open Red Wire Circuit to Battery Possible Open Fusible Link Circuit Shorted to Ground If After a Few Minutes Operation Headlights Flicker On and Off and or a Thumping Noise Can be Heard From the Light Switch Cir cuit Breaker Opening and Closing Repair ShorttoGround in Circuit Betwe...

Page 633: ...nosis of hazard warning and directional signal systems refer to STEERING SECTION 9 of this manual Two air tone S type vibrating electric horns figure 43 are mounted behind the left front access door The electric air tone S type horn is carefully adjusted and inspected during manufacture and should operate indefinitely without attention The horn assembly should not be adjusted or repaired HORN Figu...

Page 634: ...he radio 44 RADIO AND TAPE PLAYER CHASSIS ELECTRICAL 12 29 Figure 44 Horn Relay Buzzer Installation 2 Remove the horn mounting bolts and remove horns See figure 43 3 Reverse steps to install horns and check oper ation HORN RELAY BUZZER 1 Disconnect battery ground cables 2 Remove horn relay buzzer connector figure 3 Remove mounting bolt which attaches relay buzzer to panel 4 Install buzzer by rever...

Page 635: ...Lead To Black Wire Terminal In Directional Signal Switch Connector INOPERATIVE LAMP ON Remove Horn Button And Touch Test Light Lead To Horn Contact Assembly LAMP ON LAMP ON Check For Broken Ground Strap OKAY Repair Ground At Wire From Horn Contact RELAY DOES NOT CLICK Ground One Lead of a 12 Volt Test Light and Touch Other Lead To Black Wire No 2 Terminal On Horn Relay Touch Test Light Lead To Two...

Page 636: ... FM or stereo station giving a total of 10 preset favorite stations To preset push buttons proceed as follows Select the desired band AM or FM and manu ally tune a favorite station until maximum signal is received Pull push button out and then push all the way in to relatch Ten favorite stations 5 AM and 5 FM can be obtained in this manner CHASSIS ELECTRICAL 12 31 CAUTION Do not move the AM FM sli...

Page 637: ...ENGINE CHECK SHIELD OVER IGNITION POINTS TIGHTEN IF LOOSE REPLACE IF MISSING 3 CHECK GROUND STRAPS FOR CLEAN AND TIGHT CONNECTIONS 4 CHECK ANTENNA LEAD IN CONNECTOR AT RADIO 5 HAVE HELPER SIT IN VEHICLE TO EVALUATE NOISE USE A LARGE RAT TAIL FILE AND BRIDGE ACROSS FROM FRAME TO VARIOUS SECTIONS OF EXHAUST SYSTEM DO THE SAME WITH FUEL TANK ENGINE FRONT FENDERS EEC WHEN HELPER RADIO NOISY STATIC REP...

Page 638: ...ayer ok LOOSE MTG MOUNTING LOOSE OR DEFECTIVE CONNECTIONS TAPE PLAYER OK CONNECTIONS 0 K OR SPEAKERS RemoveRemove tape player Replace or for repair Correct as required Remove tape correct as I player for re required pair TAPE PLAYER NOISY TAPE PLAYER TAPE PLAYER DEAD SPEEDINCORRECT SET ALL CONTROLS 1 Turn ignition switch SET ALL CONTROLS TO MID POSITION to Acc Position TO MID POSITION INSERT TEST ...

Page 639: ...tereo effect The only positive method to tell if the balance control needs adjustment is to tune in a non stereo program and make a critical evalua tion A 181 7 Figure 48 Antenna Trimmer Adjustment STEREO TAPE PLAYER MAST NUT ASM MOUNTING NUT WASHER GASKET SEAL BODY COLLAR LEAD IN ASM Figure 49 Antenna Mast Installation If adjustment is needed proceed as follows 1 Turn radio on Switch to AM band A...

Page 640: ...t light probe to blue wire juniper to yellow wire Figure 50 Convector Installation CHASSIS ELECTRICAL 12 3 5 BLUE WIRE YELLOW WIRE YELLOW WHITE BLUE WHITE STRIPE WIRE STRIPE WIRE A 1820 Figure 51 Convector Connector 5 Touch test light probe to blue white stripe wire jumper to yellow white stripe wire 6 If test light lights in either of the above tests remove the convector for repair If the test li...

Page 641: ...ge door openers will not adversely affect vehicle operation In the event any other type of mobile radio transmitter is to be installed further instructions are required so that vehicle operation will not be adversely affected Contact GMC Truck Coach Division General Motors Corporation Tech nical Service Department Pontiac Michigan 48053 or in Canada contact General Motors of Canada Limited Product...

Page 642: ...t The transducer is then disengaged and requires engagement switch operat SERVO UNIT TRANSDUCER Figure 53 Servo Unit Installation CHASSIS ELECTRICAL 12 37 ion to return it to operation A vacuum release switch operates simultaneously with the electric re lease switch whenever the brake pedal is depressed This switch opens a port to atmospheric pressure which rapidly bleeds down the vacuum in the se...

Page 643: ... the Tee fitting and is im posed upon the servo unit to maintain and on speed cruise condition Figure 56 Transducer Cross Section CONTROLLED VACUUM SUPPLY FROM TRANSDUCER VACUUM CHAMBER Figure 55 Servo Unit An additional function of the transducer is to drive the speedometer Since the vehicle speed is sensed by a speedometer like mechanism within the unit the speedometer cable from the transmissio...

Page 644: ...he drum Now any change in vehicle speed will rotate the drum and move the U clip CHASSIS ELECTRICAL 12 39 just as a speedometer moves its needle The top of the U clip is attached to the air bleed valve The clip moves a sleeve which slides on the orifice tube thereby covering and uncovering air ports in the wall of the tube the tube inner end is plugged whenever vehicle speed changes from the speed...

Page 645: ...s the vacuum port to atmospheric pressure within the transducer thereby bleeding down the servo toward the relaxed position As the driver releases the en gagement switch pull in and hold in of the so lenoid occurs respectively The system is now engaged to maintain the vehicle speed at the time of engagement switch release 9 Driver desires lower cruising speed presses engagement switch fully waits ...

Page 646: ...d or casing assemblies Defective transducer Replace transducer System Does Not Disengage Brake and or Vacuum switch misadjusted Adjust or replace as required Refer to With Brake Pedal or defective Servo and Vacuum System Check Out and Electrical Check Out Wires which should be connected to the Reroute wires to stop light switch pedal switch es connected tothefuseblock System Steadily accelerates o...

Page 647: ...h slack into turn signal lever slot at base of II CRUISE DISENGAGE SWITCH AND BRAKE LIGHT SWITCH A 1825 Figure 57 Brake Release Switches lever attachment end This will force switch out of the other end of the lever 6 With a small soldering iron unsolder the wires and resolder them to the correct terminal of the re placement switch Use only rosin core solder INSTALLATION 1 Once a new switch is inst...

Page 648: ...k electric brake switch as follows Unplug connector at switch Connect ohmmeter at points A and B on brake switch The ohmmeter must indicate infinity when the pedal is depressed and continuity when pedal is released The cruise release brake switch electric is adjusted as is the standard stop light brake switch Replace electric brake switch if needed 3 Check engagement switch and connecting wir ing ...

Page 649: ...To utilize engine as vacuum source proceed as follows 1 DISCONNECT SERVO CHAIN and hose from servo then connect engine vacuum directly to the servo fitting 1 TO 2 closed closed open measure the resistance of the brown white stripe wire from point C to D It should measure 40 ohms 2 ohms If a resistance either above or below the value indicated is shown the main wiring harness should be replaced Not...

Page 650: ... 1 74 Power Level Tell Tale 2 74 High Beam Indicator 1 161 Turn Signal Indicator 2 168 Instrument Cluster Light 2 194 Speedo Cluster Light 2 194 Dome Lights 2 211 9422525 Radio Dial AM FM Stereo Tape 1 566 Radio Dial exc AM FM Stereo Tape 1 1893 Heater Control 1 1895 Clearance and LD 10 67 142450 License 1 67 Side Markers 4 194 9421330 Back Up Lights 2 1 156 Parking and Turn Sig 2 1 157 9428902 St...

Page 651: ...coolant level fall below the cold level line additional coolant other than for draining and refill should be added through the coolant recovery reservoir MAINTENANCE At regular intervals cooling system components should be inspected to determine if service is re quired Regular systematic checks will reveal faulty condition of various units and indicate necessity of servicing or replacement of such...

Page 652: ...ce 7 Check radiator filler cap seals for evidence of cracking or separation Replace as required 8 When coolant loss is evident or engine over heating occurs the damaged or clogged radiator should be serviced by a radiator specialist or replaced with a new one Efficient repair of radiators requires the use of special tools and equipment as well as provisions for making proper tests If radiator core...

Page 653: ...SURE CAP AND VALVE A pressure relief valve assembly integral with the radiator filler cap incorporates a pressure valve and a vacuum valve See figure 2 When pressure in system reaches valve setting See Specification at end of this section pressure valve opens and liquid is allowed to escape As liquid in the system cools it contracts this allows pressure valve to close and also creates a partial va...

Page 654: ...adings made at various temperatures Disregard ing temperatures of solution may cause an error as large as 30 F Read and be guided by instructions furnished by the tester manufacturer In the event coolant freezes solid in extreme cold weather place vehicle in warm building or improvise some means of thawing coolant before starting en gine Under no circumstance should engine be ope rated when coolan...

Page 655: ...ESSURE TORQUE SPECIFICATIONS RELIEF VALVE RADIATOR AND COOLANT RECOVERY SYSTEM 13 5 Radiator Support Mounting Bracket to Radiator Support Attaching Bolts 25 30 ft lb Valve Opening Models Stamped PSI 230 23 260 26 RC32 9 ...

Page 656: ...LEAKAGE A trace of oil on the piston tube is normal due to grease packed in the seal area during manufacturing If oil is dripping from the unit it should be replaced DAMAGE DIAGNOSIS BUMPERS 14 1 Inspect the bumper bracket frame bracket piston tube and cylinder tube for evidence of visible distor tion Scuff marks on the piston tube are normal If there is obvious damage to the unit it should be rep...

Page 657: ...UBE ASSEMBLY ORIFICE A 1910 Figure 2 Energy Absorber Collapsed Position GAS FILLED PISTON TUBE ASSEMBLY STOP RING SEAL HYDRAULIC FLUID FILLED FLOATING PISTON ORIFICE CYLINDER TUBE ASSEMBLY FRAME BRACKET PISTON SEAL METERING PIN MOUNTING STUD A 1911 Figure 3 Energy Absorber Extended Position ...

Page 658: ...n the energy absor ber s will require replacing WARNING BE SAFEI PROTECT YOUR EYES WEAR APPROVED SAFETY GLASSES 1 Stand clear of the bumper Figure 4 Relieving Pressure from Energy Absorber FRONT REPLACEMENT BUMPERS 14 3 2 Provide positive restraint such as a chain or cable 3 Relieve the pressure by drilling a 1 8 inch hole in the piston tube near the bumper bracket See fig ure 4 4 Remove the unit ...

Page 659: ...res are the same for front and rear Also due to the fact that both front and rear bumper face bars are two piece assemblies in some cases it may only be necessary to replace half of the face bar REPLACEMENT 1 Remove face bars by removing both bumper bracket thru bolts See figure 5 BUMPER FACE BARS Figure 6 Removing Rear Bumper Bracket Thru Bolts 2 Remove brackets and hardware from old face bar s a...

Page 660: ...E NO 24A Periodic Maintenance and Lubrication 24A 1 24B Living Area Electrical 24B 1 24C Motor Generator 24C 1 24D Refrigerator 24D 1 24E Roof Mounted Air Conditioner 24E 1 24F LP Gas System 24F 1 24G Furnace 24G 1 24H Range Oven 24H 1 24J Living Area Water System 24J 1 24K Toilet 24K 1 24L Holding Tank and Drainage System 24L 1 24N Cabinets and Furniture 24N 1 24P Exhaust Vents 24P 1 24Q Other Eq...

Page 661: ... Check Oil Level 4000 6000 Watt Change Crankcase Oil 1 4000 6000 Watt Clean Air Cleaner 1 4000 6000 Watt Check Spark Plugs 4000 6000 Watt Fuel Filter Check 1 4000 6000 Watt Check Breaker Points 2 4000 6000 Watt Check Governor Linkage 4000 6000 Watt Clean Cooling Fins 1 4000 6000 Watt Change Oil Filter 1 4000 6000 Watt Replace Breaker Points 4000 6000 Watt Replace Air Cleaner 1 4000 6000 Watt Watt ...

Page 662: ...RAGE WATER TANK FILTER The water tank filter which is located in the water compartment is transparent and should be checked periodically and cleaned annually A helpful sign that filter is dirty is when the transparent filter has become discolored See Living Area Water Sys tem Section 24J for filter replacement procedure WINTERIZATION When traveling in winter it is recommended that the water tank n...

Page 663: ... C in Canada PERIODIC MAINTENANCE AND LUBRICATION 24A 3 d Change engine oil as shown on the recom mended S A E Viscosity Chart to aid cold weather starting e Park MotorHome as level as possible end for end and side to side f Wash MotorHome If exposed to road salts the exterior and underside should be thoroughly washed and flushed g Drain moisture from suspension air reservoir For additional instru...

Page 664: ... Model has an oil capacity of 3 quarts 3 1 2 quarts if replacing oil filter The 6KW Model has an oil capacity of 4 quarts 4 1 2 quarts if replacing oil filter Do not mix brands or grades of motor oil Use a LUBRICATION more than 30 days the following steps should be taken to protect the unit 1 Run the unit until thoroughly warm 2 Disconnect fuel supply and run until unit stops 3 Drain oil from cran...

Page 665: ...he preparation list will aid in providing con venience and proper operation of the vehicle SPRING AND OR SUMMER TRIP PREPARATION EXTERIOR a Fill LP gas tank voir b Sanitize and fill water tank c Empty and deodorize holding tank d Check that all exterior vents are unob structed e Drain moisture from suspension air reser f Check operation of the following lights Headlights Parking and turn signals T...

Page 666: ...r includes information on re quired fluids and lubricants for your vehicle FALL AND OR WINTER TRIP PREPARATION EXTERIOR d Check that all exterior vents are unob structed voir level a Fill LP gas tank Add methyl alcohol b Fill water tank c Empty and deodorize holding tank e Drain moisture from suspension air reser f Check operation of the following lights Headlights Parking and turn signals Tail an...

Page 667: ...eeze Motor generator Interior electrical system Toilet Recirculating toilet charged with Windows recreational vehicle anti freeze solution Vacuum carpets c Add recreational vehicle anti freeze ap prox 1 2 cup to the following P traps PERIODIC MAINTENANCE AND LUBRICATION 24A 7 e Clean the following Upholstery 12 Volt Counter tops 120 Volt Cabinetry b Check operation of following if water sys tem is...

Page 668: ...ircuit the cause should be corrected and a new fuse of the same capacity installed For explanation of 12 volt fuse block number code refer to Figure 2 or the Specifications at the end of this section GENERAL INFORMATION LIVING AREA ELECTRICAL 24B 1 12 volt components through a power converter and charge the living area battery If the MotorHome is equipped with a motor gen erator the vehicle will b...

Page 669: ...suspect that the unit is not functioning properly test it in the following manner 1 Check the motor generator frequency setting It should be 63 cycles at 120 volts no load The converter is sensitive to frequency and will not func tion properly below 60 cycles If you plan to bench test the unit make sure the wall socket is producing 60 cycles This can also be checked with your fre quency meter 2 Di...

Page 670: ... FRONT ROOF VENT FAN 3 50A GALLEY LIGHT 2 88A REAR ROOF VENT FAN 3 50A TOTAL 12 76 AMP SYSTEMS MONITOR MOTOR GENERATOR START AND MONITOR PORCH LIGHT WATER PUMP SWITCH W RUN LIGHT GALLEY LIGHT SWITCH FLOOR LIGHT SWITCH PORCH LIGHT SWITCH R H FRONT LIGHT FRONT ROOF VENT FAN BATH VENT FAN REFRIGERATOR RANGE HOOD BATH LIGHTS HALL LIGHT R H READING LIGHT REAR ROOF VENT FAN LPG COMPARTMENT LIGHT L H REA...

Page 671: ...e plug In this event use the op tional motor generator CAUTION If the available power supply is other than 120 240 volt 60 cycle rating or All the lighting throughout the MotorHome is on the 12 volt system and is powered by either the living area battery the power converter when the vehicle is connected to an external power source or when the motor generator is running if the vehicle is so equippe...

Page 672: ... user from the hazards of line to ground electric shock The exterior receptacle is located on the right side of the vehicle beside the refrigerator grille as shown in Figure 7 The exterior ground fault circuit interruptiong receptacle is designed to protect people using appli ances that are plugged into this receptacle LIVING AREA ELECTRICAL 2413 5 For light bulb specifications or for current draw...

Page 673: ...ERTER S 0 REAR OF BEDROOM RECEPTACLE LOCATED ON SIDE OF PANEL BOX i GENERATOR ITEM PART NAME NO 1 MAIN PANEL BOX 2 8 4 WIRE CORD TYPE 50 W PLUG 3 WIRE 12 2 W GROUND WIRE CIRCUIT BREAKER PANEL 4 SINGLE RECEPTACLE CIRCUIT 1 CIRCUIT 2 CIRCUIT 3 CIRCUIT 4 CIRCUIT 5 5 OUTLET BOX _FRONT AIR WATER HEATER HALL OVER VACUUM _REAR AIR 6 DUPLEX RECEPTACLE COND RECEPT RECEPT RECEPT RECEPT COND RECEPT 7 OUTLET ...

Page 674: ...rocedures refer to ENGINE ELECTRICAL Sec tion 6Y WATER TANK This gauge is designed to indicate the amount of water remaining in the living area water tank HOLDING TANK This is designed to indi cate content level in the holding tank Never allow this gauge to reach the FULL mark If theholding tank is overfilled the overflow will back up through the bathroom shower drain LIVING AREA ELECTRICAL 2413 7...

Page 675: ...ircuit the time sending unit and tank 2 Open circuit between 2 Clean contact between gauge and ground terminal on gauge ground and ground 3 Needle rubbing on face 3 Reposition needle of gauge 4 Tank float hang up 4 Free binding float or install new tank unit Gauge reads F all 1 Open circuit between 1 Clean terminals or repair wires the time sending unit and tank 2 Open circuit between 2 Install ne...

Page 676: ...EM FUSES The following are located in the fuse block in the living area electrical com partment near the hall closet Do not use fuses of higher amperage rating than those specified below or damage may result Number on Fuse Usage Fuse Block Type L H Front Light Front Roof Vent Fan No 1 AGC 15 Galley Light Rear Roof Vent Fan Range Hood Vent Fan and Lights Bath Vent Fan No 2 AGC 15 Rear L H Reading L...

Page 677: ...Porch Light 1 44 Amp Bath Room Lights 8 64 Amps Range Hood Vent Fan and Lights 6 70 Amps Furnace Blower 6 8 Amp Water Pump 3 6 Amp Recirculating Toilet 7 0 Amp Monitor Panel 2 5 Amp Front Vent Fan 3 50 Amp Rear Vent Fan 3 50 Amp Bath Vent Fan 3 50 Amp Refrigerator 6 0 Amp Number on Fuse Usage Fuse Block Type Furnace Furnace Auxiliary Blower No 7 AGC 15 Oven Light Motor Generator Compartment Light ...

Page 678: ...y of the Motor Home located in the compartment with the genera tor or motor generator cranking battery located in the compartment with the generator of the Trans Mode A permanent magnet flywheel alternator and solid state voltage regulator rectifier See figure 1 are used to charge the battery Lubrication is provided by a pressure oil system A spin on type oil filter See figure 2 is utilized The mo...

Page 679: ...ne runs for 3 or 4 seconds then stops on two relays K2 and K3 are removable DO NOT attempt to adjust the contacts on these relays they are precision set at the factory The D Low battery low charge rate only maintenance required on these relays is blowing out sand and dirt with a low pressure compressed air source To correct a problem answer the question ofthe step either YES or NO Then refer to th...

Page 680: ...hed 613 713 613 K2 contacts are defective Replace printed circuit board 713 Fuel solenoid K4 must be open during starting and running Remove fuel line from carburetor Does fuel pulsate from line when start switch is pushed 11B 813 WARNING Use extreme care for tests 7B and 8B Direct the fuel flow into a suitable container and make sure area is well ventilated to prevent accumulation of gasoline fum...

Page 681: ... Remote control leads may be shorted or grounded D LOW BATTERY LOW CHARGE RATE YES NO 1D With engine cranking measure voltage at terminal 8 to BAT terminal of K1 start solenoid Is 6 volts present 2D 3D 2D Check battery connections They must be clean and tight 3D Check flywheel alternator G1 output Disconnect AC lead that connects to voltage regulator VR1 and connect voltmeter to this lead and BAT ...

Page 682: ...YST ENGINE TROUBLE DIAGNOSIS Motor Generator Engine Troubleshooting Guide ONAN MOTOR GENERATOR 24C 5 Linkage Out of Adjustment Linkage Worn or Disconnected Governor Spring Sensitivity Too Great Linkage Binding ...

Page 683: ...ower needles at 1 turn open After engine starts and runs set for optimum performance 3 Nozzle boss gasket 3 Remove fuel bowl and replace leaks Engine runs with gasket Tighten bowl retainer power needle seated securely 4 Air bleeds in carbu 4 Remove fuel bowl idle power retor plugged needles Clean thoroughly with compressed air Engine runs lean 1 Improper adjustment 1 Set idle power needles at 1 tu...

Page 684: ...hile assembling throttle valve Make certain valve does not bind in throttle bore when opening and closing throttle Lean carburetion 2 Adjust carburetor Problem Possible Cause Correction No AC output voltage 1 Blown fuse or cir 1 Replace fuse or reset breaker cuit breaker and look for cause 2 Disconnected wire or 2 Reconnect wire or wires lead on brushes bridge rectifier or reactor assembly 3 Brush...

Page 685: ...ove part of load 3 Shorted or grounded 3 Test with series test lamp or circuit in field or arma ohmmeter and replace if defective ture winding 4 Engine not running 4 Refer to Engine Troubleshooting properly causing generator guide to slow down Noisy generator 1 Defective bearing in 1 Replace bearing end bell Generator overheats 1 Generator overloaded 1 Remove part of load 2 Windings and parts 2 Cl...

Page 686: ...removing generator and control box tag all wires according to their respective The following steps serve only as a guide when locations overhauling the engine Specific details on individual engine components 5 Remove flywheel using a puller or pry bar method 6 Remove flywheel alternator stator 1 Drain crankcase oil 7 Remove the gear cover being careful to pro tect the oil seal from keyway damage 2...

Page 687: ...shaft and gear Install valve assemblies etc Figure 5 Valve System 7 Install oil pump oil base and cylinder heads 8 Install breaker box 9 Install fuel pump oil filter starter generator carburetor fuel lines spark plugs etc 10 Install crank gear aligning crank gear mark with camshaft 11 Install gear cover and oil seal 12 Install flywheel alternator stator 13 Install flywheel 14 Install all housings ...

Page 688: ...ONG SEAT A 1595 Figure 6 Valve Interference Angle ONAN MOTOR GENERATOR 24C 1 1 parts and place each valve in its proper location Make pencil marks at intervals across the valve face and observe if the marks rub off uniformly when the valve is rotated part of a turn against the seat TAPPET ADJUSTMENT FIGURE 7 The engine is equipped with adjustable valve tap pets The valve tappet clearance should be...

Page 689: ...mounting screw and washer and pull the flywheel off the shaft Take care not to drop the wheel A bent or broken fin will destroy the balance Always use a steel key for mounting the flywheel FLYWHEEL ALTERNATOR STATOR After disconnecting stator terminal wires remove the three screws securing stator to gear cover and pull off GEAR COVER FIGURE 9 After removing the mounting screws tap the gear cover g...

Page 690: ...shaft gear or the camshaft gear becomes necessary always install both gears new To remove the crankshaft gear first remove the snap ring and retainer washer then attach the gear pulling ring using two No 10 32 screws figure 11 Tighten the screws alternately until both are tight Attach a gear puller to the puller ring and proceed to remove the gear The camshaft and gear must be replaced as an assem...

Page 691: ...cratch ing the crankpin and cylinder wall when removing the piston and rod Figure 12 Removing Ridge From The Cylinder Removal and Installation NOTE Mark each piston and rod assembly so they can be returned to their respective cylinders after overhaul Keep connecting rod bearing caps with their respective rods 5 Remove the piston rings from the piston with a piston ring spreader as shown in Figure ...

Page 692: ...s signs of fractures scored bores or bores out of round more than 0 002 b Use a new piston pin to check connecting rod for wear A push fit clearance is required and varies from engine to engine If a new piston pin falls through a dry rod pin bore as a result of its own weight replace the rod REPAIR 1 Fitting Pistons a Proper piston tolerances must be main tained for satisfactory operation b Measur...

Page 693: ...elsh plugs for a tight even fit and fins for breakage 3 Check the cylinder bore for taper out of round and wear with a cylinder bore gauge telescope gauge or inside micrometer figure 18 These meas urements should be taken at four places the top and bottom of piston ring travel 4 Record measurements taken lengthwise at the top and bottom of the piston travel as follows a Lengthwise of the block mea...

Page 694: ...ap water and clean rags A clean white rag should not be soiled on the wall after cleaning is complete Do not use a solvent or gasoline since they wash the oil from the walls but leave the metal particles 7 Dry the crankcase and coat it with oil CRANKSHAFT Inspect the bearing journals If they are scored and cannot be smoothed out by dressing down re place the crankshaft BEARINGS Removal Installatio...

Page 695: ...ores without oil holes install with bearing groove at the top Be sure to start the bearing straight Press the front bearing in flush with the outside end of the bearing bore Press the rear bearing in flush with the bottom of counterbore which received the expansion plug CRANKSHAFT ENDPLAY After the rear bearing end plate has been tight ened using the torque recommended in Torque ALIGN BEARING OIL ...

Page 696: ...ut fiom the inside Before installing the seals fill the space between lips with a multi purpose grease This will improve sealing When installing the gear cover oil seal tap the seal inward until it is 31 32 from the mounting face of the cover When installing the bearing plate oil seal tap the seal into the bearing plate bore to bottom against the shoulder in the plate bore Use a seal expander or p...

Page 697: ... the camshaft or bottom side of engine See Figure 28 4 Tap the piston down into the bore with the handle end of a hammer until the connecting rod is seated on the journal figure 27 Install the bearing cap on the rod with the witness marks and stamped reference numbers matching the marks on the rod Install and tighten the bolts to the specified torques The bearing cap must be tapped several times t...

Page 698: ... oil every 100 operating hours and only when engine is warm EXCEPTION Drain initial oil fill at 25 operat ing hours To drain remove the 1 2 inch cap screw requir ing 3 4 socket on oil pan After oil drains replace the cap screw and refill crankcase with a good qual ity detergent oil Refer to Section 24A for specific details on oil for the Onan Motor Generator OIL FILTER Change the crankcase oil fil...

Page 699: ...d If the crankcase becomes pressu rized as evidenced by oil leaks at the seals clean baffle and valve in a suitable solvent Crankcase breather disassembly requires removal of exhaust manifold See Figure 31 REMOVAL CARBURETOR REPAIR FIGURE 32 1 Disconnect fuel inlet hose and crankcase breather hose FUEL SYSTEM A 1621 Figure 31 Crankcase Breather 2 Remove air cleaner assembly 3 Disconnect governor t...

Page 700: ...zzle for dam age If float is loaded with fuel or damaged replace it The float should fit freely on its pin without bind ing Check the choke and throttle shafts for excessive side play and replace if necessary CARBURETOR FLOAT ADJUSTMENT 1 Invert float and casting 2 With the float resting lightly against the needle and seat there should be 3 32 inch clearance be tween base of float and carburetor c...

Page 701: ...RBURETOR ADJUSTMENTS FIGURE 37 The carburetor has a main fuel power adjust ment and an idle fuel adjustment The main adjust ment affects operation under heavy load conditions The idle adjustment affects operation under light or no load conditions Under normal circumstances adjustments should not be disturbed If adjustments have been disturbed turn main fuel jet 1 1 4 turn off its seat and idle fue...

Page 702: ...If governor is com pletely out of adjustment make a preliminary adjustment at no load to first attain a safe voltage operating range Engine speed determines the output voltage and current frequency of the generator By increasing the engine speed generator voltage and frequency are increased and by decreasing the engine speed gener ator voltage and frequency are decreased An accu rate voltmeter or ...

Page 703: ...on the governor spring the stop on the carburetor throttle lever just contacts the stop This setting allows immediate control by the governor after starting It also synchronizes travel of the governor arm and the throttle shaft SPEED ADJUSTMENT With the warmed up unit operating at no load adjust the tension of the governor spring See figure 38 Turn the speed adjusting nut to obtain a voltage and s...

Page 704: ...BTC mark aligns with hole Turn another 1 4 turn 90 to ensure points are fully open 8 Using a screwdriver inserted in notch D on the right side of points turn points until gap m s ures 025 016 on 6KW with a flat thic ss gauge Be sure feeler is clean Tighten mounting screw and recheck gap Timing is automatically set ONAN MOTOR GENERATOR 24C 27 sure it is not stuck open or closed Voltage at choke sho...

Page 705: ...OCEDURE ENGINE NOT RUNNING COLD SETTING 4 AND 6 KW 1 Connect a continuity test lamp set across the ignition breaker points Touch one test prod to the breaker box terminal to which the coil lead is con nected and touch the other test prod to a good ground on the engine 2 Turn crankshaft against rotation counter clockwise until the points close Then slowly turn the crankshaft with rotation clockwise...

Page 706: ...ep thebattery terminals clean and tight After making connections coat the terminals with a light application of petroleum jelly or grease to retard corrosion NOTE For complete discussion of battery ser vice and maintenance refer to SECTION 6Y ENGINE ELECTRICAL FLYWHEEL ALTERNATOR FIGURE 44 This unit is equipped with a permanent magnet flywheel alternator and solid state voltage regulator rectifier...

Page 707: ... Be sure cable con tight NOTE Charging system tests require a fully charged battery ture The lever spring compresses holding the pinion gear against the flywheel gear As soon as the arma ture rotates and the gear teeth line up the gears will mesh STARTER REMOVAL 1 Disconnect the ground cables at terminals of both automotive and living area batteries Basic Test Procedure Test Values 1 Battery Batte...

Page 708: ...ct the wires from the motor generator 3 Remove the slide out door by removing the six starter motor solenoid Sec figure 46 attaching bolts See figure 47 Figure 46 Disconnecting Wires from Starter Motor Figure 47 Removing Attaching Bolts from Slide Out Solenoid Duo ...

Page 709: ...ntering hole in the center bolt See figure 50 Figure 49 Removing Flywheel Center Bolt Figure 50 Pulling Flywheel with Straight Bar Puller 8 Pull the flywheel straight of being careful not to contact the alternator stator See figure 51 9 Remove the rear muffler mounting bracket by removing the four attaching bolts See figure 52 10 Remove the right hand air shroud to expose the starter motor by remo...

Page 710: ...ttaches the solenoid mo Figure 53 Removing Right Hand Air Shroud ONAN MOTOR GENERATOR 24C 3 3 Figure 54 Removing Starter Motor Attaching Bolts for terminal to the field coil connector lead and take off the connector lead figure 58 2 Loosen the retaining screws and remove the solenoid from the front bracket Simultaneously the fiber washers the return spring and the solenoid plunger will be removed ...

Page 711: ...er 4 KW Figure 58 Removing Connector Lead 6 If it is necessary to remove overrunning clutch first put a metal cylinder of suitable size over the end of armature shaft so it rests on the stop ring Then tap the cylinder lightly with a hammer the stop ring towards armature and lock ring Remove ring from groove in shaft so the overrunning clutch and the stop ring will be removed from the armature shaf...

Page 712: ...pring holder will be removed 7 To remove the overrunning clutch put a metal cylinder of suitable size over the end of armature shaft so it rests on the stop ring Tap cylinder lightly with hammer the stop ring sliding toward armature and off ring Remove the ring from groove in shaft and then slide the overrunning clutch and the stop ring from the armature shaft CAUTION Do not immerseparts in cleani...

Page 713: ...in steel blade hacksaw blade parallel to the core and just above it while slowly rotating armature in growler Figure 64 Testing for Grounded Armature Figure 63 Starter 6KW A shorted armature will cause blade to vibrate and be attracted to the core Figure 65 Testing for a Short Circuit ...

Page 714: ...g for a grounded field coil First Figure 67 Testing Field Coil ONAN MOTOR GENERATOR 24C 37 Figure 68 Brush Replacement disconnect the grounded end of shunt coil as shown in Figure 67 Then connect one probe of test lamp to yoke and the other probe to field coil connector lead If lamp lights field coil is grounded BRUSH REPLACEMENT Brushes that are worn out to the wear limit line should be replaced ...

Page 715: ...the shift lever is not properly positioned the pinion gear travel will be restricted causing a locking in the clutch mechanism 4 Place the thrust washer on the drive end of the shaft Slide the armature with the lever into the front bracket figure 72 Figure 71 Installing Shift Lever Figure 72 Installing Front Bracket 5 Place the lever spring and the spring holder into the front bracket with the dir...

Page 716: ...r is pulled manually 12 Install the solenoid IMPORTANT The return spring in this case should be straight in the proper position between the bore of the solenoid and the bore of the plunger ASSEMBLY 6KW 1 Lubricate armature shaft splines with a very light grade oil A medium or heavy oil and grease may cause the overrunning clutch assembly faulty operation in cold weather 2 Install the overrunning c...

Page 717: ...n the yoke to the front bracket Be sure that the yoke is properly indexed to the front bracket SWITCH Figure 80 No Load Test Figure 79 Spring Holder 7 Position the brush holder assembly indexing the cuts of the brush plate to the holes of the front bracket 8 Install the brushes in their brush holders Be sure to center the brush springs on the brushes 9 Place the thrust washers on the commutator en...

Page 718: ...e plastic end bell screens Measure brush wear as shown in Figure 81 AC GENERATOR ONAN MOTOR GENERATOR 24C 41 the starter is reassembled the pinion clearance must be adjusted to give sufficient clearance between the end of the pinion and the stop ring when the pinion is in mesh with the ring gear of the engine 1 Connect a battery of the proper voltage be tween the Switch terminal of the solenoid an...

Page 719: ...emove frame field assembly being careful not to let it rest or drag on the armature CAUTION Four seals are used between frame field assembly and engine togener Figure 81 Brush Wear Limits ator adapter These seals must be installed when reassembling generator or the genera tor will overheat 8 Using a square 3 8 inch drive insert into 12 point internal wrenching armature hold down nut and remove 9 W...

Page 720: ...84 Use a 120 volt series test lamp set for this test Place one prod on each collector ring The test lamp should light If lamp does not light armature is open and must be replaced TESTING FIELD WINDINGS FOR GROUNDS FIGURE 85 To test the field assembly for grounds disconnect all field leads and use a 120 volt series test lamp set Touch one prod to Fl and the other prod to the frame Lamp should not l...

Page 721: ...er proceed as fol lows 1 Loosen No 8 32 screw to remove bridge rec tifier assembly See figure 86 for location 2 Disconnect the nylon connector from bridge rectifier assembly noting the polarity marking of bridge rectifier assembly and connector 3 Pull out from end bell and remove bridge rec tifier from its case CAUTION Note that connector can only be mounted in one direction 4 Use an ohmmeter to t...

Page 722: ...REACTOR TORQUE TO 40 70 INCH LBS LOAD WIRES BRUSH BLOCK ASSEMBLY 40 70 IN LB TORQUE A 1663 normal operation Do not attempt to maintain a bright newly machined appearing surface Ordinary cleaning with a dry lint free cloth is usually suffi cient Very fine sandpaper 240 may be used to remove slight roughness Use only light pressure on the sandpaper while the plant is running Do not use emery or carb...

Page 723: ...overhaul WITH ONE AMPERE INPUT THE VOLTAGE SHOULD READ VOLTAGE Figure 88 Testing Compounding Reactor Figure 89 AC Generator Schematic COMPOUNDING REACTOR If output voltage is high with no electrical load connected to the generator with generator running at 1800 rpm then the compounding reactor is proba bly defective Test as shown in Figure 88 using a Variac ...

Page 724: ... K2 maintains ignition To stop engine push the stop switch which shorts out K3 Relay K3 drops out to remove power from the fuel pump fuel solenoid and ignition coil Resis tor R2 absorbs the power that was supplied to K3 during the period the stop switch is held close as the engine slows to a stop GENERATOR VALUES FOR 4KW GENERATOR VALUES FOR 6KW CONTROLS ONAN MOTOR GENERATOR 24C 47 LOW OIL PRESSUR...

Page 725: ...igger CR8 CR8 turns on to de energize K3 relay K2 contacts open as the engine stops and CR8 turns off EMERGENCY START STOP OPERATION In an emergency situation the control board ei ther normal or defective can be bypassed to start or stop the unit To completely bypass all control board functions connect a jumper from terminals 9 to 11 This energizes the ignition and fuel pump Then tem porarily jump...

Page 726: ...NS Spark Plug Gap 020 Breaker Point Gap Full Separation Engine Cold 025 Ignition Timing Engine Not Running Cold Setting 26 BTC Ignition Timing Engine Running Hot 21 BTC Tappet Adjustment Engine Cold Intake 003 Exhaust 010 ITEM SYMBOL DESCRIPTION 1 Printed Circuit Board 2 Terminal 3 R2 Resistor 150u 1 2W 10 4 R3 Resistor 470K s1 1 2W 10 5 Q1 Transistor Unijunction 2N6027 6 R6 Resistor 16K u 1 2W 5 ...

Page 727: ...ng Armature Four Pole 1800 rpm 60 Hertz Recreational Vehicle Rating 6000 Watts 6KW Voltage 120 Volts Current Rating 50 Amperes Phase Single Wire Two TUNE UP SPECIFICATIONS Spark Plug Gap 020 inch Breaker Point Gap Full Separation 016 inch Ignition Timing Engine Running or Static 20 BTC Tappet Adjustment Engine Cold Intake 003 inch Exhaust 012 inch STARTER Engaging System Solenoid operated Overrunn...

Page 728: ...ash 002 005 TAPPET AND VALVES Tappet to Cylinder Block Clearance 0015 0030 Valve Seat Width 1 32 1 8 Valve Stem to Guide Intake 0010 0025 Valve Stem to Guide Exhaust 0025 Valve Face Angle 44 Valve Seat Angle 45 Valve Tappet Clearance Intake Exhaust Valve Stem in Guide Intake Valve Stem in Guide Exhaust 0 001 1 0 0025 0 003 0 012 0 0025 0 004 Valve Spring Length Free Length 1 662 Compressed Length ...

Page 729: ...g 0 0025 0 0038 Crankshaft End Play 0 005 0 009 Camshaft Bearing 0 0015 0 0030 Camshaft End Play 003 Camshaft Lift 300 Camshaft Bearing Diameter 1 3760 1 3770 Camshaft Journal Diameter 1 3740 1 3745 Rod Bearing Forged Rod 0 0005 0 0023 Connecting Rod End Play Ductile Iron 0 002 0 016 Timing Gear Backlash 0 002 0 003 Oil Pump Gear Backlash 0 002 0 005 Piston to Cylinder Strut Type Measured below oi...

Page 730: ...Oil Pan Screws 18 8 12 Starter Mounting Bolts 18 20 Spark Plugs 15 20 GENERATOR 4KW and 6KW FT LBS Generator Through Studs 4 15 18 Armature Hold Down Nut 12 Point 45 50 Compounding Reactor Studs 4 6 Brush Block Assembly Studs 4 6 ...

Page 731: ...below the refrigerator door When the circuit breaker opens a small light will come on be side the breaker The circuit breaker is reset by push ing IN on the red button next to the light The swing motor type compressor operates on A C voltage only An inverter transformer assembly inverts 12 volts D C to 11 volts A C and then transforms this voltage to 23 volts A C This is then supplied to the swing...

Page 732: ...main tain sufficient cooling even with a setting of 5 b Dust may have collected on condenser restricting air flow and must be removed 4 Excess frost build up 4 A frost build up of over one in freezer compartment quarter inch should be avoided Defrost refrigerator 5 Freon overcharge or 5 Can be determined by testing undercharge compressor amperage In either case the entire cooling system must be re...

Page 733: ...r reading should be 22 to 24 volts REFRIGERATOR 2413 3 Figure 3 Checking Thermostat at Inverter If the voltage at the compressor is not adequate the voltage source should be checked D C OPERATION Using a standard A C voltmeter the voltmeter reading should be 31 5 to 33 5 volts COMPRESSOR AMPERAGE One method of determining whether or not the Figure 2 Checking Compressor Amperage Figure 4 Jumper Wir...

Page 734: ...AT The thermostat may be tested by two different methods The first method is gain access to the inverter assembly Pull this assembly from the bottom of the refrigerator and disconnect the gray thermostat mo tor leads Connect an ohmeter to the thermostat leads figure 3 and turn the thermostat to 5 There should be continuity If not replace thermostat Anothermethodis to remove thermostat assem bly fr...

Page 735: ...freezer door out and lift door of hinge figure 8 4 Install kick plate 5 Install door s COMPONENT REMOVAL REFRIGERATOR 2413 5 Figure 7 Removing Top Door Hinge Figure 9 Removing Center Hinge Pin 3 Top of hinge pin is slotted to accept a screw driver Remove this hinge pin figure 9 4 Tilt lower door out at its top and lift offbottom hinge pin Figure 8 Removing Door Figure 10 Removing Thermostat ...

Page 736: ...nd bolts COOLING UNIT REMOVAL 1 Remove refrigerator from vehicle Figure 12 Removing Thermostat Sensing Tube Figure 13 Removing Sheet Metal Plate 2 Remove eight screws from upper and lower evaporator plates four screws in each figure 11 3 Remove thermostat sensing element from lower evaporator plate by removing two screws fig ure 12 4 Disconnect electrical leads to the compressor CAUTION Care must ...

Page 737: ...m compressor 9 Remove blind cover by performing the follow a Wrap the end of a 3 foot wood 1 x 6 with a rag Then firmly tap on blind cover as shown in Figure 14 to loosen caulking type seal Figure 16 Removing Inverter Assembly REFRIGERATOR 24D 7 Figure 17 Disconnecting Wiring b Then carefully remove blind cover See fig ure 15 10 Pull evaporator plates through opening and remove cooling unit as an ...

Page 738: ...NG UNIT INSTALLATION push door to its normal position 1 Through opening in back of refrigerator posi 4 Install top hinge pin and secure travel lock tion evaporator plates in cabinet THERMOSTAT INSTALLATION 2 Install mounting screws in compressor 3 Install blind cover in rear opening See figure 15 Tape in place 1 Install face plate to thermostat with two nuts and bolts 4 Install sheet metal plate o...

Page 739: ...s back on refrigerator Model 7 5 Cubic Ft Power 60 Watts Compressor Amps Required 2 6 Amps Compressor Volts Required A C Operation 22 to 24 Volts A C Compressor Volts Required D C Operation 31 5 to 33 5 Volts A C Compressor Motor Resistance 2 3 Ohms Compressor Motor Speed 60 Strokes Sec Inverter Output 11 Volts A C Transformer Output 23 Volts A C Input Voltage 12 Volts D C or 120 Volts A C Refrige...

Page 740: ...rk IV unit figure 1 with a 13 500 BTU rating 2 a Duo Therm figure 2 with a 13 500 BTU rating The two unit system has a Duo Therm with a 13 500 BTU rating forward mounted and another Figure 1 Mark IV Air Conditioner Shroud Removed GENERAL INFORMATION ROOF MOUNTED AIR CONDITIONER 24E 1 Duo Therm unit with a 11 000 BTU rating rear mounted The refrigerant system consists of four major components The c...

Page 741: ...liquid refrigerant into low pres sure liquid refrigerant It is a long thin copper tube from the evaporator to the condenser The refriger ant charge is critical Precise charging of an exact amount is required Excess refrigerant will cause unit Figure 4 Capillary Tube Typical to frost back on the low or suction side during off cycle EVAPORATOR FIGURE 2 Refrigerant 22 will boil at low temperature whe...

Page 742: ...ctor is con nected in series with compressor and all power to the compressor passes through the protector The pro tector is designed to carry normal starting and oper ating currents The bi metal disc is affected by both current and shell temperatures and will disconnect the compressor if either becomes excessive FAN MOTOR RUN CAPACITOR Is designed for con tinuous duty It increases motor efficiency...

Page 743: ...3 350 1 0 6 33 58 8 21 1 70 121 4 41 7 107 216 9 62 2 144 354 5 1 1 34 60 1 21 7 71 122 5 42 2 108 220 0 62 8 145 358 9 1 7 35 61 5 22 2 72 125 7 42 8 109 223 2 63 3 146 363 4 2 2 36 62 8 22 8 73 127 8 43 3 110 226 4 63 9 147 367 8 2 8 37 64 2 23 3 74 130 0 43 9 111 229 6 64 4 148 372 4 3 3 38 65 6 23 9 75 132 2 44 4 112 232 8 65 0 149 376 9 3 9 39 67 1 24 4 76 134 5 45 0 113 236 1 65 6 150 381 5 ...

Page 744: ...ITH HEAT AND COULD CAUSE AN EXPLO SION THE PROCESS TUBE MAY BE SILVER SOLDERED AFTER BEING CRIMPED NEAR THE END SAFETY WARNINGS ROOF MOUNTED AIR CONDITIONER 24E 5 11a t Figure 9 Mark IV Air Conditioner Exploded View WARNING REFRIGERANT 22 IN THE PRES ENCE OF AN OPEN FLAME PRODUCES PHOS GENE GAS A TOXIC LUNG IRRITANT DO NOT BREATH IT VENTILATE SERVICE AREA IMMEDIATELY WHEN R 22 IS DISCHARGED WARNIN...

Page 745: ...CT WITH THE SKIN THE IN JURY SHOULD BE TREATED THE SAME AS THOUGH THE SKIN HAD BEEN FROSTBITTEN OR FROZEN WARNING KEEP OUT OF REACH OF CHIL DREN INTENTIONALLY INHALING VAPORS TO PRODUCE INTOXICATION IS HARMFUL AND WARNING THIS IS A 120 VOLT SYSTEM NALS OF A CAPACITOR WITHOUT DISCHARG WHERE POSSIBLE TURN POWER OFF AND ING IT FIRST TO AVOID POSSIBLE PERSONAL USE CONTINUITY CHECKS IN PLACE OF INJURY ...

Page 746: ...d probe at the terminal being tested a Overload switch or circuit a Check for power to and from the overload breaker If there is no power from the overload but power is okay to the overload the overload is open Wait 15 minutes for the overload to cool If it doesn t reset replace it b Time delay relay b If the time delay relay has power in there figure 11 should be power out within three minutes Cl...

Page 747: ...eter or self powered test light For a positive continuity check of the thermostat put the sensing probe in warm water 100 F 37 8 C and check for a closed circuit Then check for an open circuit at all dial settings with the tube in cold water 50 F 10 C Problem Remedy 4 Fan Motor figures 1 and 2 4 Disconnect the leads to the fan motor at the box and check for continuity from the white wire through e...

Page 748: ... the compressor 5 Shorted compressor 5 Use a precision ohmmeter with a 0 to 5 and windings 0 to 25 ohm scale Check each winding resistance and combined resistance against specifications Low resistance indicates a shorted winding and the compressor should be replaced 6 Motor generator 6 If the unit works when connected to an external power source but not from the generator the prob lem may be poor ...

Page 749: ...1 Compressor starts and runs 1 If the compressor starts and runs then the problem is in the refrigeration system and more checks can be made If the compressor fails to start and or run steadily check the electrical system 2 Temperature check 2 Place a good refrigeration thermometer close to the center on both the return and blower sides of the evaporator If the temperature difference is from 18 to...

Page 750: ... tube and tip so that it will measure the line temper ature Let the system run 10 to 15 minutes with the shroud in place then read the temperature and pressure Compare with the temperature pressure chart for R 22 found earlier in this section Superheat is the difference between actual and chart temperature It should be from 15 to 25 F 8 to 14 C High superheat indicates an under charge charge the s...

Page 751: ...he flame for a color change With an electronic detector J 23400 01 figure 16 listen for the signal Refrigerant is heavier than air so it may not be detectable directly above a leak but only beneath it 8 Burnout check 8 During a compressor replacement check the oil for evidence of an electrical burnout WARNING DO NOT GET OIL ON YOUR HANDS IF ACID HAS FORMED SEVERE BURNS CAN RE SULT A dark oil with ...

Page 752: ...COMPONENTS 1 When you locate a leak shut off the refrigerant and attach a discharge hose to the center manifold Route the hose into an exhaust hose or shop exhaust system ROOF MOUNTED AIR CONDITIONER 24E 1 3 tioner outside of the vehicle If dirt leaves or other material is lodged inside it will effect the operation of the unit Clean such debris away Make sure noth ing is blocking the moving parts ...

Page 753: ...urned compressor capillary tube and drier While the system is open flush it in reverse of normal flow pattern with either a pound of refrigerant 22 or use Purge or equiva lent followed by a brief flush of 22 If the system has been contaminated to the extent that solids have been formed it is a good idea to tie a cloth over one of the open ends to catch the material blown out This will give you a v...

Page 754: ... place of the pump Purge the line briefly at the gauge port then admit the specified charge CAUTION Be sure to measure the charge accurately The specification is critical with thecapillary tube metering system Each air conditioning unit has an identification tag that specifies the exact charge for that unit 5 If necessary during charging start the com pressor and run it until the charge enters Whe...

Page 755: ...tween near normal pressure 11 inches of water pressure and a much lower pressure which will not allow the appliances to operate The LP liquid petroleum gas system supplies fuel for the range oven and furnace as shown in Figure 1 The LP gas tank which stores the fuel is located in the compartment at the right rear of the vehicle The LP gastank is 42 long and holds 62 lbs of LP gas The tank is equip...

Page 756: ...fficient gas supply Vapor POL valve not open Open valve completely Refer to completely Regulator out ON VEHICLE ADJUSTMENTS of adjustment for regulator pressure specifications Leak in LP gas system Make up a soap solution Apply to all fittings If bubbles occur a leak is present Inspect fitting for damage or cracks Replace fitting if necessary Use only A G A American Gas Approved fittings Otherwise...

Page 757: ...ITHOUT A MANOMETER CHECK EXCESSIVE LINE PRESSURE COULD RESULT IN AN LP GAS LEAK WHICH IS FLAMABLE AND POTENTIALLY DANGEROUS TO VEHICLE AND PERSONNEL LP GAS SYSTEM 24F 3 Correction Empty LP gas tank Refer to LP GAS TANK REMOVAL later in this section for proper procedure of emptying tank Refill tank correctly see WARNING at beginning of this section In freezing weather add 1 pint of suitable tank an...

Page 758: ... Turn one range top burner all the way on with gas burning Figure 4 Setting Manometer Scale Figure 5 Removing Burner From Stove WARNING MAKE SURE THAT RUBBER HOSE IS PLACED CAREFULLY AWAY FROM OPERAT ING RANGE TOP BURNER 4 Turn on burner control connected to manome ter Read the high to low difference on the manome ter If the difference is not 11 inches the regulator needs adjusting Adjust the regu...

Page 759: ...les will ap pear wherever a leak occurs Tighten fittings or re place components as necessary If any fittings require replacement use AGA American Gas As sociation approved components It is recommended that pipe sealant not be used unless necessary to seal a leaking connection if necessary use pipe sealant GM Part No 704133 or equivalent WARNING NEVER CHECK FOR AN LP GAS LEAK WITH A MATCH AN LP GAS...

Page 760: ... and securing screw 3 Fill tank The regulator is adjustable Refer to On Vehicle Adjustment Regulator earlier in this section REMOVAL REGULATOR 1 Turn off gas at the tank See figure 9 2 Remove hose assembly from regulator 3 Remove regulator from POL valve IMPORTANT The connector attaching the regulator to the vapor POL valve is left hand threaded See figure 9 INSTALLATION Figure 9 Regulator Attachm...

Page 761: ... tighten four retaining screws 3 Connect wire to sight dial 4 Fill tank When filling the tank refer to IMPORTANT at beginning of this section REMOVAL Figure 1 1 L P Gas Lines LP GAS SYSTEM 24F 7 LP GAS TANK 1 Empty tank Refer to WARNING at begin ning of this section 2 Disconnect hose assembly from regulator and position out of the way 3 Disconnect wire from sight dial 4 Remove four nuts and bolts ...

Page 762: ...nections under the vehicle The lines are replaceable or repairable A damaged portion of the copper tub ing line may be cut out and a brass approved union used to connect a new section of tube to the line Be sure that the gas is turned offat the tank Remember there may always be some residual gas in the system that will escape when a fitting is loosened therefore work in a well ventilated area WARN...

Page 763: ...he furnace in the GMC MotorHome is a 30 000 B T U Sol Aire furnace The furnace is located in the compartment under the kitchen sink The iden SECTION 24G FURNACE GENERAL INFORMATION COLD AIR DUCT FURNACE ELECTRICAL CONNECTOR IDENTIFICATION PLATE PLENUM A 4030 Figure 1 Furnace Installed FURNACE 24G 1 tification plate is located at the right side of the casing as shown in Figure 1 The furnace has no ...

Page 764: ...cated in the closet module See figure 32 If warm air duct is located on wall below bathroom sink the auxiliary furnace blower is installed be hind the kitchen range oven See figure 33 The furnace operates on 12 volts D C and its wiring diagram is shown in Figure 2 FURNACE COMPONENTS CONTROL BOX The control box contains three control relays thermal relay with manual reset and fuse and Figure 2 Furn...

Page 765: ...upplied through a high tension lead to the spark electrode whenever the thermostat contacts are closed calling for heat BURNER ASSEMBLY FIGURE 4 The burner assembly contains LP gas spray noz zle the spark electrode and a air adjustment feature See Primary Air Adjustment later in this section The spark electrode will supply a constant wiring to ground through the burner assembly whenever volt age i...

Page 766: ...rminal 1 on the con trol box 2 When the blower reaches minimum operating speed approximately 2 3 seconds the blower Figure 7 Furnace Thermostat switch contacts close providing power to the gas so lenoid valve BURNER IGNITES START CYCLE 1 Approximately 10 15 seconds after ignition the flame rod switch contacts close de energizing the thermal relay heater TH 1 through control relay 3CR The furnace w...

Page 767: ...thermostat No Spark 3 e Hold spark electrode approx 1 z from the burner and check for sparking 2 a Replace the spark electrode Turn Gas Present Primary air adjustment too the locking nut on finger tight lean b Turn on L P G c Turn on the thermostat d Sniff for L P fumes at the right No Gas Present 7 hand exterior furnace vent 3 a Check to make sure the ignition Ground wire not connected Loose grou...

Page 768: ...across the thermostat wires 0 volts Defective control box d Check the voltage at the 11 terminal on the control box No Check to Make Results Go To Problem 1 a All thermal relay to completely Less than 35 seconds Defective thermal relay in cool 3 5 minutes control box Replace control box b Press the reset button c Turn the thermostat on d Check the length of time before the 35 45 seconds 2 furnace ...

Page 769: ...reset button Furnace does not turn on 2 2 a Check the 10 amp fuse in the Fuse OK 3 furnace Fuse blown 5 3 a Short across the two thermostat Furnace starts Defective thermostat or leads at the control box on furnace broken wire Furnace does not start 4 4 a Remove Furnace from vehicle Blower runs Defective control circuit b Connect a 12V source across the Blower does not run Defective blower asm 11 ...

Page 770: ...L 1 Be sure LP gas is turned off at LP tank and furnace fuse is removed from fuse block in living area electrical compartment 2 Disconnect furnace electrical connector See figure 1 3 Disconnect LP gas supply line from furnace manual valve See figure 5 4 Disconnect furnace ducts from right side of furnace a If vehicle is equipped with davo raise seat and then disconnect ducts from right side of fur...

Page 771: ...lame Switch 2 Limit Switch FURNACE 24G 9 Figure 10 Location of Upper Furnace Mounting Screws INSTALLATION 1 Slide furnace into sink module 2 Install two mounting bolts at right side of fur nace See figure 8 3 Install two mounting bolts at left side of fur nace See figure 9 Connect ducts at left side of fur nace Install lower shelf in cabinet to left of furnace 4 Install four upper furnace mounting...

Page 772: ...ess to right side of furnace Remove access cover figure 11 2 Disconnect two wires from flame rod See fig ure 12 3 Using 11 16 inch wrench unscrew flame rod from heat exchanger INSTALLATION 1 Install flame rod in combustion chamber open ing Tighten securely 2 Connect two wires to flame rod figure 12 3 Install access cover figure 12 Figure 1 1 Removing Furnace Access Cover Figure 12 Location of Furn...

Page 773: ...ark electrode See Spark Electrode Removal earlier in this section 2 Disconnect gas line at burner assembly See figure 14 3 Remove four screws retaining burner assembly to heat exchanger See figure 15 Figure 14 Disconnecting Gas Line from Burner Assembly FURNACE 24G 1 1 Figure 15 Removing Screws from Burner Assembly NOTE Referring to Figure 15 check which screws have ground connections attached so ...

Page 774: ...to avoid losing screws 5 Remove limit switch Figure 17 Location of Limit Switch INSTALLATION 1 Carefully position limit switch in combustion chamber opening 2 Install two screws retaining limit switch to combustion chamber See figure 17 3 Connect two wires to limit switch 4 Install wiring access cover 5 Connect furnace electrical connector at left side of furnace GAS VALVE REPLACEMENT REMOVAL 1 Re...

Page 775: ...placement earlier in this section IGNITION PAK REPLACEMENT REMOVAL 1 Remove furnace from vehicle Refer to Fur nace Replacement earlier in this section 19 2 Remove wiring access cover See figure 18 3 Remove furnace from outer casing See figure 4 Disconnect hi tension cable from spark elec trode 5 Disconnect two electrical wires from ignition pak See figure 21 Be sure to note which terminal each wir...

Page 776: ...ct all external electrical wires from control box Note the number identification on wires to aid in correct installation later 1 5 Remove two control box mounting screws See figure 23 6 Remove control box INSTALLATION 1 Position control box as shown in Figure 23 Install two control box mounting screws Figure 22 Control Box Cover Removed Figure 23 Removing Control Box 2 Connect electrical wires to ...

Page 777: ...7 Disconnect combustion air tube from blower assembly See figure 27 8 Disconnect flue tube from combustion cham ber See figure 28 Remove flue tube 9 Remove six retaining screws holding blower assembly to combustion chamber See figure 29 10 Remove blower assembly figure 30 FURNACE 24G 1 5 Figure 27 Disconnecting Combustion Air Tube from Blower Assembly Figure 28 Disconnecting Flue Tube from Combust...

Page 778: ...TE To gain access to right side of furnace if vehicle is equipped with a davo squeeze levers located under center of davo seat and raise seat 1 Loosen hex lock nut slightly until burner ad justing rod can be turned with a screwdriver See figure 31 2 Start furnace and watch burner through sight glass view port in plenum See figure 5 Decrease primary air to give a slightly yellow flame with green co...

Page 779: ...a If blower is located in closet module open upper door beside closet Remove rear panel in com partment See figure 32 Figure 32 Auxiliary Furnace Blower Located in Closet Module FURNACE 24G 1 7 b If blower is located behind range oven See figure 33 remove range oven To remove ran ge oven refer to Section 24H for detailed procedures 3 Disconnect electrical lead and ducts from from blower 4 Remove m...

Page 780: ...the Figure 1 Range Oven SECTION 24H RANGE OVEN GENERAL INFORMATION RANGE OVEN 24H 1 power range hood fan should be operating to help ensure proper ventilation In order to operate the range oven the gas supply must be turned on at the L P gas tank Pilots CAUTION The Range Oven should not be used when the vehicle is moving and the LP gas should be turned offat the LPgas tank The burners or pilot lig...

Page 781: ...pilot is non adjustable The range pilot adjustment screw is located behind the range pilot shut off valve Figure 3 Lighting Range Pilot Figure 4 Lighting Oven Pilot Range 1 Be sure power range hood fan is operating 2 Push control knob in and turn gas on counter clockwise all the way to get gas to the burner 3 As soon as the burner lights flame may be reduced to the desired height 4 To turn off the...

Page 782: ...supply is on 2 Pilot outage 2 Check to see that pilot is lit Also pilot may be improperly adjusted 3 Burner ports are 3 Make sure burner ports are not clogged clogged 4 Burner control valve 4 Replace burner valve faulty Pilot outage 1 Gas supply 1 Be sure main gas valve s are open and there is fuel in the tank 2 Air in the gas lines 2 Bleed lines by holding match to burner and turning gas to that ...

Page 783: ...Broiler Pan Insert 20 Door Spring 21 Side Trim Right 22 Oven Door Spring Hook 23 Spring Hinge Arm 24 Door Hinge 25 Front Glass 26 Glass Door Frame 27 Door Handle 28 Inner Door Glass 29 Oven Door Liner 30 Oven Rack 31 Oven Bottom 32 Oven Pilot 33 Oven Burner 34 Safety Valve 35 Broiler Pan Stop 36 Side Trim Left 37 Nameplate 38 Burner Control Knobs 39 Thermostat Knob 40 Indicator Button 41 Manifold ...

Page 784: ...ve door 4 To reinstall reverse procedure RANGE OVEN 24H 5 RANGE OVEN COMPONENT DISASSEMBLY PROCEDURES 2 Lift door as if to close and disengage hinges at door See figure 7 OVEN THERMOSTAT CONTROL REPLACEMENT 1 Remove oven door 2 Remove cook top and grates See figure 8 Figure 7 Disengaging Door Hinge Problem Possible Cause Correction Oven burner ignites as 1 Oven Safety Valve 1 Replace Oven Safety V...

Page 785: ...oven thermostat to manifold figure 11 7 Replace oven thermostat control and reassem ble by reversing procedure Figure 9 Disconnecting Gas Lines From Rear Of Thermostat Figure 10 Location of Thermal Sensing Element in Oven RANGE BURNER CONTROL VALVE REPLACEMENT 1 Close LP control valve on LP gas tank 2 Remove cook top and grates figure 8 3 Pull control knobs off 4 Disconnect gas lines from manifold...

Page 786: ...ved 9 Replace burner control valve s and reassem ble by reversing procedure TOP BURNER REPLACEMENT Should it become necessary to remove the top burners to clean or replace them perform the follow ing Figure 13 Disconnecting Range Pilot Gas Tube RANGE OVEN 24H 7 Figure 14 Disconnecting Flash Tubes 1 Remove cook top and grates figure 8 2 Unhook flash tube from burner figure 14 3 Remove single screw ...

Page 787: ...bly figure 18 5 Carefully remove capillary tube from oven pi lot figure 19 Figure 17 Disconnecting Gas Line From Oven Pilot Figure 18 Removing Oven Pilot Assembly NOTE Capillary tube is attached to the oven safety valve Use care when handling to avoid damage to capillary tube 6 Remove main burner retaining screw figure 20 Then separate the main burner from safety valve Also remove main burner supp...

Page 788: ...unting screws located inside side trim at bottom of oven door figure 23 5 Remove the upper mounting screws that hold unit to the cabinet top figure 24 Figure 21 Disconncting Gas Line from Safety Valve RANGE OVEN 24H 9 Figure 22 Removing Safety Valve Retaining Screws Figure 23 Removing Lower Range Oven Mounting Screws 6 Move the range oven forward far enough to reach behind unit and disconnect the ...

Page 789: ...ight yellow tip The CARE AND CLEANING 4 To install reverse above procedure OVEN DOOR GLASS REPLACEMENT 1 Remove oven door from range oven unit See Oven Door Replacement 2 Referring to Figure 5 carefully disassemble door 3 With oven door disassembled replace glass Items 25 or 28 figure 5 4 Install oven door glass by reversing the above procedure OVEN Clean as soon as possible after use and when the...

Page 790: ...g screw figure Figure 25 Adjusting Range Pilot RANGE OVEN 24H 1 1 2 Rotate air deflector as necessary to supply more or less air to main burner 3 Turn on oven and check burner flame The main burner flame should burn with a blue flame having yellow tips 4 Readjust position of air deflector if necessary after noting CAUTION at the beginning of Oven Main Burner Adjustment Figure 26 Location for Main ...

Page 791: ... flow A pressure switch is located at the water pump to maintain line pressure between 15 psi and 30 psi IMPORTANT Do not attempt to increase water pressure with high pressure air Be sure the wa ter pump is turned OFF when the water tank is empty A 40 gallon water tank stores water to be drawn out by the water pump The tank can be filled only through its own fill tube connection located either ins...

Page 792: ...WATER FILL VALVE RECIRCULATING TOILET HAND HELD SHOWER HEAD WATER HEATER WATER HEATER DRAIN COCK COLD WATER HOT WATER DRAIN COCK HOSE CONNECTION CITY WATER INLET WATER FILL DRAIN COCK A 4639 Figure 1 Living Area Water System Schematic ...

Page 793: ...Pump motor burned out 7 Replace motor 8 Pump is not priming 8 Remove pump dismantle and in itself or doesn t build spect check valve assemblies Refer up enough pressure to to Water Pump Disassembly shut off later in this section No or not enough hot 1 Water Heater Switch 1 Turn on switch water not on 2 Tank has overheated 2 Push reset button 3 Low voltage 3 Check source and correct as necessary 4 ...

Page 794: ...t bowl 8 Allow system to drain 9 Turn off water pump 10 Disconnect intake and outlet hoses on water pump 11 With the recirculating toilet open the toilet water line fill valve and press the flush button Figure 2 Water Heater Type 1 12 Open shower head shut off valve and turn the shower on at the bathroom faucet Extend shower head toward sink to allow the shower head and flexi ble hose to drain 13 ...

Page 795: ...Figure 4 Access to Water Pump and Controls Figure 6 External Water Connection LIVING AREA WATER SYSTEM 24J 5 Figure 5 External Water Connection Drain Valve ...

Page 796: ...e 12 3 To remove seat pull up and out 4 The water tank is enclosed by two wood pan els one along the top the other along the side The two panels are joined and can be removed together Remove screws along the back of the top panel and at the floor side of the other panel Remove wood panels ON VEHICLE ADJUSTMENT 5 Turn water pump switch to OFF position WATER TANK Figure 7 Water Pump Belt Tension The...

Page 797: ...not repairable Polypropylene resists all common adhesives that may be used in patching or plugging However on small punctures a Well Nut may be used Enlarge the hole enough to insert the Well Nut and tighten enough to close up the hole to make it waterproof 1 Install tank 7 Close drain valve INSTALLATION 2 Connect drain hose to valve or tee Connect suction hose to water pump Tighten clamps se cure...

Page 798: ...en a faucet to check for voltage with pump running WATER PUMP ASSEMBLY OF WATER FILTER 1 Place filter screen into filter 2 Assemble filter together with screws ASSEMBLY OF WATER TANK FILTER TO WATER LINES 1 Attach filter to water line hose connections 2 Tighten hose clamps 3 Refill water tank WATER TANK SENDING UNIT FIGURE 9 INSTALLATION 1 Install sending unit tighten nuts securely 2 Connect sendi...

Page 799: ...SYSTEM 24J 9 4 Replace fuse Figure 12 Removing Seat WATER PUMP INSTALLATION 1 Place pump in mounting position and secure with four hold down screws If Type 2 pump is used do not depress rubber feet with mounting screws 2 Connect wires to the pressure switch 3 Connect hoses to water pump 5 Close tank drain valve and fill tank 6 Replace top panel and secure with screws 7 Replace seat and secure with...

Page 800: ...24J 10 LIVING AREA WATER SYSTEM IP CONNECTING ROD SWITCH CAP INLET VALVE SWITCH PLATE PULSATION DAMPENER A 4651 Figure 1 4 Type 1 Water Pump Exploded View ...

Page 801: ...r valve with small hole is UP on intake and rubber valve without the small hole is DOWN on discharge NOTE Do not use valve with small hole in rubber on discharge side of pump 7 When reassembling adjust belt tension to 1 8 play DIAPHRAGM 1 Turn off power to pump 2 If system is filled with water open a faucet to Figure 1 5 Opening Water Pump LIVING AREA WATER SYSTEM 24 1 11 Figure 16 Water Pump Valv...

Page 802: ...n on diaphragm and significantly shorten its life Ad just belt tension to 1 8 play PULSATION DAMPENER REPLACEMENT 1 Turn off power to pump 2 If system is filled with water open a faucet to relieve pressure Close intake and discharge lines near pump 3 Remove pump from vehicle 4 Remove nine screws from bottom of base and bottom plate figure 20 5 Pull out rubber pulsation dampener from base 6 Inspect...

Page 803: ...The pressure switch mounted on the type 1 wa ter pump is non adjustable If the switch fails to operate properly replace it The pump should oper ate between 15 psi and 30 psi NOTE If the pump is equipped with an earlier adjustable pressure switch it should be replaced when it fails or falls out of adjustment For pump models 1000 and above no conversion kit is necessary Pumps below 1000 require a se...

Page 804: ...22 Piston Top Inlet Outlet Valve Assembly Check Valve Assembly Valve Assembly UPPER HOUSING 31 Screw 32 Screw 33 Retainer Ring 34 Check Valve 35 Valve Stem 36 Spring 37 Retainer Ring 38 Seal Washer 39 Valve Plate 40 Seal Washer 41 Poppet 42 Spring 43 Seal Washer 44 Diaphragm 45 Plunger 46 Spring 47 Bridge Ring 48 Switch 49 Switch Cap 50 Screw 43 Retainer Ring 24 1 let Valve 25 Valve Chamber 26 Out...

Page 805: ... entire water system must be winterized thoroughly for winter storage See Section 24A TYPE 2 WATER PUMP OVERHAUL FIGURE 23 DISASSEMBLY FIGURE 24 1 Hold switch cap securely figure 25 while removing two screws because spring inside has Figure 24 Type 2 Water Pump LIVING AREA WATER SYSTEM 24J 1 5 Figure 25 Removing Switch Cap enough tension to throw the cap Pressure switch will drop out of cap after ...

Page 806: ...phragm and piston bottoms then position on lower housing fig ure 35 2 Lubricate steel ball and place on bushing Place bushing with ball into lower housing Flat on bushing shaft matches flat in housing hole figure 33 3 Grease bearings with GM 1051344 or equiva lent Assemble to drive coupling with mylar shim and bearing covers Place assembled parts on wobble plate figure 34 4 Place wobble plate in p...

Page 807: ...Removing Inlet Outlet Valves LIVING AREA WATER SYSTEM 24J 17 Figure 31 Removing Support Plate Figure 30 Removing Rubber Bushing from Motor Figure 32 Removing Wobble Plate with Bearings Coupling and Drive Coupling ...

Page 808: ...Steel Ball and Bushing Figure 34 Removing Coupling and Bearings from Wobble Plate Figure 36 Support Plate Drive Coupling and Wobble Plate Assembled in Lower Housing Figure 35 Removing Pistons from Diaphragm Figure 3 7 Putting Micro Switch in Switch Cap ...

Page 809: ...re at the radiator cap Disconnect hoses and plug ends 7 Disconnect wires and armored cable from junction box on wall INSTALLATION 8 Remove inlet cold water line 9 Disconnect outlet hot water line and reposi tion out of the way 10 Remove banding straps 11 While supporting heater disconnect heater support bracket and position upward and outward 12 Toilet seat may have to be raised or removed in orde...

Page 810: ...24J 20 LIVING AREA WATER SYSTEM PREHEAT ASSEMBLY w TEMPERATURE PRESSURE RELIEF VALVE THERMOSTAT CONTROL HIGH TEMPERATURE CONTROL 0 op A 4713 Figure 38 Type 1 Water Heater Exploded View ...

Page 811: ...eater Element LIVING AREA WATER SYSTEM 24J 21 REMOVAL Figure 41 Installing Heater Element 14 Turn on heater switch and check for hot wa ter after approximately 15 minutes Be sure vehicle is connected to 120 volt AC source by running Mo tor Generator or external power connection TYPE 2 WATER HEATER FIGURE 42 1 Turn off water heater switch and water pump switch 2 Open drain valve and allow water hea...

Page 812: ...relief valve ASSEMBLY FIGURE 43 1 Replace pressure temperature relief valve 2 Secure control assembly with two bolts and attach two wires to assembly 3 Secure heating element with four bolts Con nect two electrical wires to element 1 Turn off water pump at wall switch Open faucet to reduce line pressure Figure 43 Type 2 Water Heater Controls INSTALLATION BATHROOM SINK FAUCET REMOVAL 1 Install wate...

Page 813: ...LIVING AREA WATER SYSTEM 24J 23 O RING WASHER DNERTER SCREW SCREW FAUCET HANDLE GLAND NUT FAUCET STEM WASHER SEAT FAUCET BODY LOCK NUTS A 4717 Figure 44 Bathroom Sink Faucet Assembly ...

Page 814: ... for excessive roughness Replace if necessary SHOWER HEAD AND HOSE REMOVAL INSTALLATION 1 Turn off water pump at wall switch Open 1 Install shower head to connector faucet to reduce line pressure 2 Install hose to shower head connector 2 Remove shower head hose from wall connec tion See figures 45 and 46 3 Connect hose to wall connection 3 Remove hose from shower head connector 4 Turn on water pum...

Page 815: ...ove sink retaining clips See figure 47 4 Disconnect drain lines 5 Lift sink out INSTALLATION 1 Position sink into place and secure with clips figure 47 2 Connect all water lines and drain lines 3 Turn on water pump at wall switch Operate faucet and water purifier if equipped and check for leaks GALLEY SINK LIVING AREA WATER SYSTEM 24J 25 Figure 46 Type 2 Shower Head Figure 47 Sink Retaining Clips ...

Page 816: ... off 5 Pry retainer off with screwdriver 6 Grasp cartridge stem with pliers and pull stem out of body ASSEMBLY 1 Push cartridge stem into body 2 Insert retainer clip 3 Replace spout and grooved sleeve and secure with retainer Tighten snugly 4 Press cartridge stem down Holding handle up hook ring in handle housing into groove on sleeve Swing handle back and forth until it drops down into place 5 Re...

Page 817: ... tridge Place cartridge in pail or other water tight Figure 49 Water Purifier Cartridges WATER PURIFIER LIVING AREA WATER SYSTEM 24J 27 container to prevent spillage Keep a towel handy to clean up spillage inside cabinet 4 Install new cartridge in same position as dis carded cartridge with arrow on label pointing to out let end of unit Then secure in place with strap assembly Open water supply val...

Page 818: ...oset Carpet is stapled in place Remove the staples from the carpet 3 Remove city water access panel screws and remove panel 4 Disconnect water line from city water valve 5 At the external utilities compartment outside the vehicle remove four outer screws and nuts from city water valve and remove valve figure 6 The living area water system plumbing consists of 3 8 inch 1 2 inch and 5 8 inch polybut...

Page 819: ...g Tool mak ing a flare on the end of the line figure 54 4 Assemble the flare insert and coupling to the line so that the repaired line appears the same as that in Figure 55 Figure 53 Flaring Plumbing Line PLUMBING LINE TORQUES Size Torque 3 8 inch 55 60 in lbs 1 2 inch 55 60 in lbs 5 8 inch 90 100 in lbs SPECIAL TOOLS J 26227 Flaring Tool LIVING AREA WATER SYSTEM 24J 29 Figure 54 Plumbing Line Rea...

Page 820: ...the end of a coat hanger or into the bowl of the bowl is not closing similar object into the sealing completely which in turn groove and remove the foreign keeps the water control material Avoid damaging the valve partially open The rubber seal while cleaning groove into which the blade seats when com pletely closed is clogged with foreign material Toilet leaks There is Specify the symptom De wate...

Page 821: ...m breaker figure 1 Remove seat and cover assembly as explained in last paragraph Then turn the toilet up side down To remove water lines from vacuum breaker base pinch hose clamps with a pair of pliers and slide them up the water line Water lines may be pulled off Remove the two vacuum breaker attachment screws Complaint Possible Cause Correction Contd from previous d Closet flange base d Leaks at...

Page 822: ...ift up mechanism to gain access to water line hose clamps Pinch hose clamps with a pair of pliers and slide them up the water line Pull water lines off of mechanism Figure 1 Standard Toilet Components TOILET 24K 3 3 Removal of the mechanism assembly figure 4 Service and replacement of hopper assembly Hopper assembly may be serviced or replaced by removing the above 3 assemblies ...

Page 823: ... TOILET ELECTRA MAGIC GENERAL INFORMATION chemical additive The advantage is that water is conserved when flushing and also not adding to the volumn of the holding tank The toilet operates on 12 volt DC RECIRCULATING TOILET TROUBLE DIAGNOSIS Complaint Possible Cause Correction 1 Toilet will not flush a Blown living area fuse a Replace blown fuse in living area electrical compartment b Blown toilet...

Page 824: ...MENT TOILET 24K 5 1 Disconnect lead wires from power source fig ure 3 2 Remove two cover mounting screws and mo tor cover figure 1 3 Disconnect leads from pump assembly motor figure 3 4 Remove two timer bracket mounting screws and timer assembly 5 Install by reversing steps 1 4 PUMP REPLACEMENT 1 Disconnect lead wires from power source 2 Remove two cover mounting screws and mo tor cover 3 Disconne...

Page 825: ...24K 6 TOILET TIMER MOTOR COVER MOUNTING BOLTS A 1907 Figure 3 Recirculating Toilet Components ...

Page 826: ...Be sure handle on dump valve is pushed in 2 Open fill valve filling toilet to the charge level as indicated by the letter C on prism This will be approximately 3 gallons Close the fill valve NOTE Details on winterizing the recirculating 3 Add recirculating toilet chemical as recom toilet are covered in Section 24A of this manual mended by manufacturer of chemical ...

Page 827: ...24L 1 SECTION 24L HOLDING TANK AND DRAINAGE SYSTEM The contents of this section are listed below SUBJECT PAGE N0 General Description 24L 1 Trouble Diagnosis 24L 2 Holding Tank 24L 3 Drain Pipe and Fittings 24L 6 GENERAL DESCRIPTION A tube assembly bolted to the holding tank and a detachable sewer hose are provided for dumping the contents of the holding tank ROOF VENTS I HOLDING TANK N N SHOWER TR...

Page 828: ...h opening 2 Sediment has accumul 2 Use a plumbers flexible probe ated enough to block to break accumulation open fullway valve opening CAUTION Use a hand turned The recommended use probe not a power driven probe of bio degradable The power driven probe may damage should prevent this the plumbing lines NOTE Once unplugged the contents will quickly drain so be prepared and have dump hose aimed in th...

Page 829: ... retaining nuts from each of the two mounting brackets See figure 2 9 Holding tank can now be lowered to floor Figure 2 Holding Tank Mounting HOLDING TANK AND DRAINAGE SYSTEM 24L 3 HOLDING TANK REPAIR Except for small clean punctures the holding tank is not repairable Polypropylene plastic used to manufacture the tank resists all common adhesives The contents of the tank will quickly corrode any s...

Page 830: ...mp tube at cap Remove the fullway valve and the dump tube assem bly Figure 4 Dump Tube and Valve Assembly INSTALLATION 1 At dump tube assembly apply a film of grease to valve where O ring seats against valve This will hold the new O ring in position while installing valve 2 Position valve at holding tank and assemble enough to loosely install the strap figure 4 Tighten fullway valve to tank screws...

Page 831: ...er SEWER HOSE ASSEMBLY FIGURE 6 REMOVAL 1 Open the storage tube cap 7 and remove the sewer hose assembly 4 5 and 6 Figure 6 Sewer Hose Storage Tube Exploded View 2 Loosen hose clamp 5 and separate waste dis posal tube 4 from sewer hose fitting 6 3 Remove two upper outside nuts 10 and wash ers 11 that secure tube mounting brackets 3 to spare tire carrier 2 Remove hose storage tube 1 with tube mount...

Page 832: ...ndation for preparing the pipe and fittings for assembly P traps are easily removed for cleaning if they become clogged To remove a P trap loosen com pression fitting on either end of the trap as shown in Figure 7 Clean trap position in vehicle and tighten compression fitting by hand VENT LINE ROOF CAPS There are three vent lines Each vent line has a roof mounted cap to help prevent anything from ...

Page 833: ...ts or stains should be removed as soon as possible GM Cleaners CABINETS AND FURNITURE 24N 1 SECTION 24N CABINETS AND FURNITURE GENERAL INFORMATION ment points and before removing the last fastener support the weight of the unit to avoid possible dam age IMPORTANT Seat belt anchor bolts must be tightened to 35 45 foot pounds torque Some types of stains or soilage such as lipsticks some inks certain...

Page 834: ...rial with a clean DULL knife or scraper USE VERY LITTLE CLEANER light pressure and clean cloths preferably cheese cloth Cleaning action should be from outside of stain FEATHERING towards center of stain and con stantly changing to a clean section of cloth When stain is cleaned from fabric immediately dry area with an air hose heat dryer or heat lamp to help prevent a cleaning ring use caution with...

Page 835: ...ions no other measure should be tried CABINETS AND FURNITURE 24N 3 LIPSTICK Difficult to remove Cleaning fluid works on some brands If stain remains after re peated applications do not try other measures MUSTARD Damp sponge with warm water then rub detergent on dampened stain and work into fab ric Rinse with clean damp cloth Repeat several times Some discoloration may remain BLOOD Wipe with clean ...

Page 836: ...S The vents are crank operated from inside the MotorHome In rainy weather it is possible to leave the ceiling vents open slightly for ventilation without entry of water into the MotorHome depending upon the magnitude and direction of rain NOTE All windows and roof vents must be tightly closed when operating the air conditioner or furnace to obtain maximum cooling or heat ing Power fans are availab...

Page 837: ... Position exhaust hood bottom assembly to bot tom of exhaust hood and secure with retaining nuts at switches RANGE OVEN VENT FILTER SEE FIGURE 1 It is important that the power range hood filter be inspected frequently and cleaned as needed To clean filter remove retaining nuts at power hood switches remove filter and wash in hot soapy water Rinse thoroughly and reinstall INSTALLATION 1 Install fan...

Page 838: ...ent cover by removing retaining screws from slide mechanism 2 Remove vent screen six screws 3 Carefully with the aid of a knife or other suita NOTE Use lukewarm water and mild soap solu ble tool remove gasket from vent cover tion if necessary to clean vent screen 4 Using suitable cement secure gasket to vent cover 5 Reinstall cover on slide mechanism Tighten retaining screws securely 2 Install ven...

Page 839: ...s switch nut 6 Remove two screws at each motor mount 7 Remove the two nuts at motor mounting 8 Carefully remove the motor mount brackets 9 Remove spring clip assemblies 10 Disconnect wires and remove motor Pull fan from motor INSTALLATION 1 Position motor with fan in housing and con nect wires 2 Position spring clip assemblies to motor studs 3 Position motor mount brackets on motor studs and secur...

Page 840: ...ift vacuum inlet hinge cap just under the storage cabinet and insert the proper end of the flex hose figure 2 At this point the vacuum system will be operating and is used in the same manner as any household vacuum cleaner BAG AND FILTER REPLACEMENT The vacuum cleaner contains two filters the bag itself which catches the dirt and a secondary filter to keep any residual dirt out of the motor 1 To r...

Page 841: ...ich the trouble should be examined 1 Check first that the Motor Home is receiving 120 volt power to the external power cord Next check the circuit breakers in the living area electrical compartment Finally make sure the vacuum cleaner is securely plugged into the receptacle under the re frigerator module CORD MOTOR DUCT INLET TUBE A 1905 FILTER BAG SECONDARY FILTER FILTER BAG DOOR Figure 3 Vacuum ...

Page 842: ... operation of the power unit 4 Exhaust line may be clogged Make a visual inspection of exterior opening Check for lint clog ging if a guard screen is being used Clear exhaust with a probe while unit is running The optional battery operated wall clock is located above the kitchen range BATTERY REPLACEMENT Remove clock from wall by raising approxi OTHER EQUIPMENT 24Q 3 5 Something may be clogging th...

Page 843: ...start clock simply move the START STOP lever to the left Ifnecessary to stop clock move lever to the right TIME REGULATION Figure 5 Backside of Clock If clock is not maintaining proper time it may be necessary to adjust position of regulating screw Note the time movement cover is marked and If the clock runs fast turn screw towards If the clock runs slow turn screw towards A movement through one s...

Page 844: ...kage 7 25 City Water Connection 24J 28 Washer Arm 1 16 Clearance and Identification Lights 12 24 Washer Nozzle 1 15 Clock 24Q 3 Air Cleaner 6M 27 Compressor Air Compressor Air Conditioning 1 37 Automotive Air Conditioning 1 37 Brown 4 13 Brown Single Piston 4 13 Dana 4 17 Dana Double Piston 4 17 Condensor 1 42 Pressure Switch Alignment 4 33 Constant Velocity Joint 3B 5 Air Conditioner Roof Mounted...

Page 845: ...Heating System Without Air Evaporation Control System ECS 8 1 Conditioning 1 106 Evaporator 1 45 Height Control Valve Exhaust Vents 24P 1 Adjustments 4 22 Exterior Maintenance 1 2 Air Leakage Check 4 5 Exterior Receptacle 24B 5 Hoisting Instructions 0 2 External Power 24B 4 Horn 12 28 F Horn Relay Buzzer 12 29 Fabric Cleaning 24N 2 Hub Bearing 3A 8 Face Bars Bumpers 14 4 I Fan Fan Clutch 6K 7 Iden...

Page 846: ... Lower Control Arm 3A 14 Fluid 0 14 9 21 Low Fuel Indicator 12 14 Pump 9 4 Lubrication 0 12 Test Procedure 9 12 Pressure Relief Valve 13 5 M Pressure Switch Water Pump 24J 6 Maintenance 0 7 Printed Circuits 12 8 Manifold Engine 6A 29 Pump Master Cylinder Brake 5 18 Living Area Water 24J 8 Mirrors and Sun Visor 1 26 Power Steering 9 4 Mobile Radio Transmitter 12 36 Purging Monitor Panel 2413 7 Auto...

Page 847: ...2 16 High Energy Ignition 6Y 51 Turn Signal 9 46 SUBJECT Bulb Removal Convector Tape Player Trouble Diagnosis 12 32 PAGE NO 12 35 12 35 12 34 12 33 SUBJECT PAGE NO Motor Generator 24C 28 Speaker Radio 12 25 12 31 Specifications Batteries 6Y 16 Range Oven 24P 1 Brakes 5 46 Rear Suspension 4 1 Breaker Point Ignition 6Y 45 Air Leaks 4 4 Drive Axles 3B 12 Trouble Diagnosis 4 4 Engine 6A 63 Rear Wheel ...

Page 848: ...rator 24C 27 Steering Column 9 42 Tires 10 1 Steering Gear and Pump 9 8 Balance 10 4 Steering Linkage 9 2 Replacement 10 4 Tape Player 12 33 Rotation 10 3 Transmission 7 10 Wear Patterns 10 4 Turn Signal Switch 9 46 Toilet 24K 1 Vacuum Cleaner 24Q 2 Recirculating 24K 1 Water System Living Area 24J 3 Standard 24K 4 Torsion Bar 3A 19 V Towing Vehicle 0 4 Vacuum Advance Distributor 6Y 41 6Y 47 Traile...

Page 849: ... Washer Switch 12 16 Tank Filter 24J 7 Wiper 1 14 Tank Sending Unit 24J 8 Winterization Vehicle 0 16 Temperature Gauge Engine 12 13 Winterization Water Purifier 24J 28 Wheelhousings 1 21 Wiper Blade Replacement 1 15 Wheel Cylinder Brake 5 27 Wiring Windows Chassis 12 18 A 1 13 Instrument Panel 12 20 GMC Side Windows 1 6 ...

Page 850: ...1975 12v DC 1975 1976 120v AC Effective with TZE165V100893 November 1975 1975 1976 12v DC Effective with TZE165V100893 November 1975 Engine Area 1975 with Breaker Points 1975 with HEI 1975 Transmode with Breaker Points 1975 Transmode with HEI ...

Page 851: ...ng purposes References are made to special tools in the various sections of this manual These tools or their equivalent are necessary and are recommended to readily and efficiently accomplish certain service operations The tools however are not supplied by General Motors Corporation Information regarding the availability of these tools can be obtained from the Zone Office or from the Service Depar...

Page 852: ......

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