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GMC 1989 Light Duty Truck, Repair Manual, Page: 381 / 998

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GMC 1989 Light Duty Truck Repair Manual Download Page 381

2.5  LITER  L4  ENGINE  6A1-25

B-07970

Figure  45— Applying  RTV  to  the  Timing  Gear  Cover

3.  Bolts  (94).

Tighten

•  Bolts  to  10.0  N-m  (90  in.  lbs.).

•  Remove  J  34995  from  the  tim ing  gear  cover.

CRANKSHAFT  PULLEY  HUB

 

INSTALLATION

-►<-  Install  or  C o nn ect  (Fig ures  5  and  47)

1.  Crankshaft  pulley  and  hub.  Slide  the  hub  on  the 

crankshaft  until  it  bottoms  against  the  crankshaft 
gear.

2.  Bolt  (98)  and  washer  (99).

SI

T ig h ten

Hub  retaining  bolt  to  220  N-m  (160  ft.  lbs.).

PISTON  AND  CONNECTING  ROD

 

INSTALLATION

-n -

Install  or  C o nnect  (Figures  5,  48  and  49)

Tool  Required:

J  8037  Piston  Ring  Compressor

•  Make  sure  the  cylinder  walls  are  clean.  Lubricate 

the  cylinder  wall  lightly  with  engine  oil.

•  Make  sure  the  piston  is  installed  in  the  matching 

cylinder.  Refer  to  “ Piston  and  C onnecting  Rod 
Assem blies”   in  this  section.

1.  Connecting  rod  bearing  inserts  (55).

•  Be  certain  that  the  inserts  are  the  proper  size.

•  Install  the  bearing  inserts  in  the  connecting 

rod  and  connecting  rod  cap.

•  Lubricate  the  bearings  with  engine  oil.

2.  Piston  and  connecting  rod  to  the  proper  bore.

•  With  the  connecting  rod  cap  removed.  Install 

two  sections  of  10  mm  (3/s-inch)  rubber  hose 
over  the  connecting  rod  studs.

•  Locate  the  piston  ring  end  gaps  as  shown  in 

figure  48.  Lubricate  the  piston  and  rings  with 
engine  oil.

•  W ithout  disturbing  the  ring  end  gap  location, 

install  J  8037  over  the  piston.

•  The  piston  must  be  installed  so  that  the  notch 

in  the  piston  faces  the  front  of  the  engine.

•  Place  the  piston  in  its  matching  bore.  Using 

light  blows  with  a  hammer  handle,  tap  the 
piston  down  into  its  bore.  At  the  same  time, 

guide  the  connecting  rod  into  position  on  the 

crankpin.  Hold  the  ring  compressor  against 
the  block  until  all  the  rings  have  entered  the 
cylinder  bore.

CONNECTING  ROD  BEARING  SELECTION

Service  bearings  are  available  in  standard  size  and

0.001-inch  undersize  for  use  with  new  and  used  standard 
sized  crankshafts.  The  2.5  L  engine  is  designed  with  a 
rolled   fille t  on  th e   c ra n k s h a ft  jo u rn a l  to  in c re a s e  
crankshaft  strength.  Do  not  grind  a  crankshaft  with  a 

rolled  fillet.  Undersize  bearings  other  than  0.001-inch 
undersize  are  not  available.

€

M easure

C o n n e c tin g   rod  b e a rin g   c le a ra n c e .  R efer 
GENERAL  ENGINE  MECHANICAL  (SEC.  6A).

to

Summary of Contents for 1989 Light Duty Truck

Page 1: ...vr V Light Duty Truck Unit Repair Manual...

Page 2: ......

Page 3: ...their strength Customary bolts use radial lines for this purpose while most custom ary nuts do not have strength markings Mismatched or incorrect fasteners can result in vehicle damage or malfunction...

Page 4: ...he pur pose Accordingly anyone who intends to use a replacem ent part service procedure or tool which is not recommended by the vehicle manufacturer must first determ ine that neither his safety nor t...

Page 5: ...ring Gear 3B3 Power Steering 4 AXLES 4B Rear Axle 4B1 7 1 2 Inch Ring Gear 4B2 8 1 2 Inch Ring Gear 4B3 9 1 2 Inch Ring Gear 4B4 10 1 2 Inch Ring Gear 4B5 Dana Rear Axles 4B6 12 Inch Ring Gear Rockwel...

Page 6: ...ransmissions to GM Goodwrench Motor Oil that meets or exceeds all specifications for General Motors cars or light trucks And Mr Goodwrench has a complete line of GM chemicals for fine care of your GM...

Page 7: ...ory ALWAYS R EFER TO T H IS IN FO R M A TIO N W H E N O R D E R IN G PARTS VEHICLE IDENTIFICATION NUMBER The VIN is the legal identifier of the vehicle On all models except Forward Control it is locat...

Page 8: ...Payload Rating is reduced if any accessories or other equipment is added to the vehicle after final date of manufacture The weight of these items should be determined and deducted from the Payload Ra...

Page 9: ...ary thread notation differ slightly The difference is shown in figure 14 FASTENER STRENGTH IDENTIFICATION Most commonly used metric fastener strength properly classes are 9 8 and 10 9 with the class i...

Page 10: ...ut threads or the threads of a tapped hole This is accomplished by distorting some of the threads or by using a nylon patch or adhesive figure 16 RECOMMENDATIONS FOR REUSE 1 Clean unrusted prevailing...

Page 11: ...GENERAL INFORMATION OA 5 Figure 8 RV Models...

Page 12: ...TION Figure 9 G and P Models G VAN MODELS CUTAWAY VAN P MODELS VALUE VAN STEP VAN ALUMINUM MOTOR HOME CHASSIS RALLY SPORTVAN MAGNAVAN HI CUBE VAN VALUE VAN STEP VAN STEEL FORWARD CONTROL CHASSIS B 091...

Page 13: ...GENERAL INFORMATION OA 7 Figure 11 ST Models...

Page 14: ...n 6 Nut Strength Iden tificatio n 7 Identification M arks Posidriv Screw Head F 00695 1 C ustom ary B o lt 1 4 20 2 M etric B o lt M6 0x1 A 1 4 inch B 6 mm C 20 Threads Per Inch D 1 Thread Per M illim...

Page 15: ...s 1 Top Lock Type 6 Nylon Strip Or Patch B Inch Sizes 2 C enter Lock 7 Nylon W asher Insert 3 Dry Adhesive C oating 8 Nylon Patch 4 Out Of Round Thread 9 Nylon Insert 5 Deform ed Thread Profile B 0240...

Page 16: ...STRESS Inches of water Pounds sq in 0 249 1 kilopascals kPa 6 895 kilopascals ENERGY OR WORK Inch3 16 387 16 387 0 0164 liters 3 785 4 0 764 6 MASS mm3 Quart 0 946 4 Gallon Yard3 cm3 liters I liters m...

Page 17: ...7 7 32 0 21875 5 55625 23 32 0 71875 18 25625 15 64 0 234375 5 95312 47 64 0 734375 18 65312 1 4 0 250 6 3500 3 4 0 750 19 05000 17 64 0 265625 6 74687 49 64 0 765625 19 44687 9 32 0 28125 7 14375 25...

Page 18: ......

Page 19: ...or into the com pressor parts and system during disassembly or reassem bly Keep tools and work area clean Clean the compressor exterior before disassembly Clean parts with trichloroe thane naptha or S...

Page 20: ...t 24 Sleeve 25 Seal 26 Tube 27 Race 28 Bearing 29 C ylinder Front 30 Sleeve 31 Seal 32 Piston 33 Ring Piston 34 Ball 35 Seal Ball 36 Key 37 Ring Piston 38 Pin 39 Shaft 40 Race 41 Bearing 42 C ylinder...

Page 21: ...the vehicle for servicing drain and measure the am ount of oil remaining in the compressor After servicing add new 525 viscosity refrigerant oil to the compressor CLUTCH PLATE AND HUB ASSEMBLY REPLAC...

Page 22: ...of J 9480 B body while pressing the hub onto the shaft 39 After tightening the body several turns remove J 9480 B and check that the shaft key 36 is properly in place in the keyway Air gap between co...

Page 23: ...r J 9395 for the multi groove pulley Turn the screw on J 8433 to remove the pulley 6 Important W hen using J 24092 the puller arms must extend around to the rear side of the pulley Do not attempt to p...

Page 24: ...Clutch coil assembly 8 Coil housing retaining ring 7 with J 6435 Using a large screwdriver or small pry bar pry the clutch coil away from the front head If n e ce ss ary hand im p act a blow to th e s...

Page 25: ...FT SEAL REPLACEMENT I4 Remove or Disconnect Figures 1 13 14 and 15 Tools Required J 5403 Snap Ring Pliers J 9392 01 Shaft Seal Remover and Installer J 9553 Seal Remover J 2 2 9 7 4 A C o m p re s s o...

Page 26: ...2 Retainer 13 Seat 14 Seal 15 Seal O ring Figure 16 Shaft and Seal Position and Correct Position Gaging Guide Rotate J 33011 to seat the seal 15 Remove J 33011 2 Seal seat 14 figure 15 Coat the seal 1...

Page 27: ...ding or collisions can dam age the shaft seal and the axial plate If the axial plate is out of position the carbon face of the shaft seal may not contact the seal seat To check the position of the axi...

Page 28: ...ng 5 Seal 52 6 Rear discharge valve plate assembly 49 figure 19 Use two small screwdrivers under the reed re tainers to remove the assembly Do not position the screwdrivers between the reeds and the r...

Page 29: ...oss over plate 46 figure 22 Pry with a screwdriver between the casting 29 and the cover 16 Cylinder halves 29 and 42 Num ber the piston and the piston bores with the sam e numbers so the pistons can b...

Page 30: ...harge cross over tubes 26 will have a seal and bushing at the end of the tube Remove these tubes by hand Figure 25 Identifying the Notch at the Front of the Piston GAGING OPERATION Install or Connect...

Page 31: ...d 4 Zero thrust race 27 thrust bearing 28 and zero thrust race 27 to the front end of the shaft 39 figure 28 Lubricate the races 27 and the bearing 28 with petroleum jelly 5 Threaded end of the shaft...

Page 32: ...PROCEDURE Tools Required J 8001 Dial Indicator Set J 9397 Compressing Fixture J 9402 Piston Assembly Tray J 9661 01 Feeler Tension G age Set Two gaging procedures provide the running tolerances The f...

Page 33: ...0180 185 I 8V2 0185 190 19 0190 195 191 2 0195 200 20 0200 205 201 2 0205 210 21 0210 215 21 V2 0215 220 22 0220 THRUST BEARING RACE Part No Identification Dial Indicator Ending In Stamp Reading 000 0...

Page 34: ...kness and one ZER O gage thickness providing a total of 16 sizes The thrust race num ber corresponds to the last three digits of the part number Refer to figure 33 8 Remove the nuts from the top plate...

Page 35: ...m the installer and do not store the guide in the installer because the seal will be stretched and weakened during storage This can cause the seal not to hold the ring installer segm ents tight enough...

Page 36: ...hrough 51 1 Support the front half of the cylinder 29 on J 9397 Shaft and axial plate 39 Place the shaft threaded end down with the front bearing race pack race and bearing into the cylinder if this w...

Page 37: ...plate 19 to the front cylinder half 29 figure 44 Align the dowel pins 20 suction ports oil re turn slot and discharge cross over tube 26 12 Front discharge valve plate 18 figure 45 Align the holes wit...

Page 38: ...sity refrigerant oil Position the shell 9 on the internal assembly Rest the shell 9 on the seal With the flat side of a small screwdriver posi tion the seal 17 in a round circle shape to the inside of...

Page 39: ...r oil pump gar 50 over the shaft 39 Line up the identification marks 23 Outer oil pump gear 51 over the inner gear figure 50 Line up the identification marks Face the compressor oil sump and position...

Page 40: ...the compressor 4 Open the low pressure control high pressure control and refrigerant control on charging station to allow refrigerant vapor to flow into the compressor 5 With J 29547 check for leaks a...

Page 41: ...air the leak Assemble and repeat the test Externally leak test 17 After testing release the air pressure from the high side and remove J 5420 or J 9459 and J 9625 A 18 Remove the oil charge screw and...

Page 42: ...03 J 5453 SPECIAL TOOLS 14 1 5 J 6083 J 6271 01 g i J 9392 01 J 9393 A J 9396 J 9397 J 9398 A J 9399 12 J 9401 A 24 17 f 18 19 20 21 22 J 9432 J 9459 J 9553 01 J 9564 01 J 9625 J 21352 J 22974 A J 231...

Page 43: ...Drive Plate A ssem bly Remover Piston Tray Needle Bearing Installer 90 Elbow Adapter Hub and Drive Plate Installer 17 O ring Remover 18 Feeler Gage Set 6 7 8 9 10 13 14 15 16 19 C om pressor Test Set...

Page 44: ......

Page 45: ...tion no crankcase suction pressure differential and the compres sor will have maximum displacement When the A C capac ity demand is lower and the suction pressure reaches the control point the valve w...

Page 46: ...13 mm Socket J 33027 Clutch Hub Holding Tool J 34992 Compressor Holding Fixture Clamp J 34992 in a vise and attach the compressor to the holding fixture with thumb screws 1 Shaft nut 21 using J 33022...

Page 47: ...C lutch Plate and Hub Assem bly Key Pulley Bearing Retainer 25 Pulley Bearing 26 Pulley 27 C lutch Coil A ssem bly 28 Retainer Seal O ring Bolt Gasket Front Head Shim 35 Bearing 36 Thrust Washer 37 S...

Page 48: ...ap between contact surfaces of the clutch plate and hub assembly 22 and the pulley 26 The gap should be 0 38 0 64 mm 0 015 0 025 inch Remove J 33013 B Shaft nut 21 Inspect Position of the shaft even w...

Page 49: ...otate J 33020 clockwise so the tangs will lock into the segments between the slots figure 10 Hold J 33020 in place and tighten the puller screw against J 33023 A puller pilot to remove the pulley 26 f...

Page 50: ...ng the bearing Position the stake pin after striking The staked metal should not contact the outer race of the bearing to prevent the possibility of bending the outer race Stake 3 places 120 degrees a...

Page 51: ...ternal opening of the clutch coil assembly 27 figure 17 J 8433 with through bolts washers and forcing screw over J 33024 Be sure J 8433 and the clutch coil assembly 27 stay in line during installation...

Page 52: ...nd 4 3 O ring seals 44 from the switch cavities Clean Switch cavity and O ring seal goove I 4 Install or Connect Figures 1 and 3 Tools Required J 5403 Snap Ring Pliers 1 O ring seals 44 to the switch...

Page 53: ...damage and or im proper compressor operation All parts used for servicing the compressor internally are protected by a preservative and packaged in a manner which does not require cleaning washing or...

Page 54: ...all the shaft lip seal on J 23128 A Bottom the shaft lip seal into the compressor neck area using J 23128 A 4 Shaft seal retainer ring using J 5403 figure 21 Install the flat side of the shaft seal re...

Page 55: ...and gaskets Place the rear head on J 35372 with the control valve 5 at the 6 o clock position Cylinder Alignment Rods J 34993 in the mounting holes at the 5 and 11 o clock positions figure 26 A Openi...

Page 56: ...adapters connected to the low and high sides and allow the vapor pressure to release from the com pressor If valve depressor type hoses are used loosen the hose connections at the gage manifold to re...

Page 57: ...9 2Cu In Rotation Clockwise 525 Viscosity Compressor Oil Full C harge 227 g 8 oz TORQUE SPECIFICATIONS Compressor Suction and Discharge Connector B o lt 34 N m 25 ft lbs Shaft N ut 17 N m 12 ft lbs Pr...

Page 58: ...7 J 9481 A Pulley Bearing Installer 8 J 9553 01 O ring Seal Remover 9 J 9625 A Pressure Test Plate 10 J 23128 A Seal Remover and Installer 11 J 21352 A Support Block 12 J 33011 O ring Seal Installer 1...

Page 59: ...IONING COMPRESSOR GENERAL DESCRIPTION The Harrison R 4 compressor is a four cylinder radial opposed type with 10 cubic inch displacement There are two designs of the clutch driver which affect the ove...

Page 60: ...Identification Label DISASSEMBLY OF THE DRIVE COMPONENTS CLUTCH DRIVE HUB Remove or Disconnect Figures 4 5 6 and 7 Tools Required J 9399 Thin Wall Socket J 25008 A Holding Fixture J 33027 Clutch Hub H...

Page 61: ...new bearing 6 POLE CLUTCH ROTOR AND OR BEARING Remove or Disconnect Figures 4 12 and 13 Tools Required J 6083 Snap Ring Pliers J 29886 Driver Handle J 9398 A Rotor Bearing Remover J 33020 Pulley Bear...

Page 62: ...embly POLY GROOVE DRIVE Remove or Disconnect Figure 14 4 Tools Required J 8433 Puller J 24092 Puller Legs J 25031 Guide Clutch coil from the front head using the tools as shown in figure 14 Figure 5 C...

Page 63: ...tion SHAFT SEAL 3 Remove or Disconnect Figures 15 and 16 Tools required J 5403 Snap Ring Pliers J 9553 01 O ring Remover J 23128 A Seal Remover Retainer ring using J 5403 Shaft seal Engage the knurled...

Page 64: ...thrust and belleville washers Note the way the washers are installed Bearing from the head Place the head on two blocks and drive the bearing from the head using J 24896 figure 19 FRONT HEAD AND MAIN...

Page 65: ...s any further than needed The shell should come off by hand once it clears the O rings 3 O rings 4 J 25008 A and install it on the opposite side of the cylinder using the short screws with the metric...

Page 66: ...ing the Bearing from the Front Head C A lternately Tighten the Screws Turn D Tool Step C ontacts the C om pressor Shell 19 Seal 19 J 25008 A F 01467 Figure 23 Replacing the Discharge Plate F 01793 31...

Page 67: ...ap rings are installed FRONT HEAD AND MAIN BEARING Install or Connect Figures 17 18 25 and 26 Tools Required J 24895 Bearing Installer 1 The front head with the neck down on a flat surface figure 25 2...

Page 68: ...7 Tools Required J 5403 Snap Ring Pliers J 23128 A Seal Installer J 33011 O ring Installer J 34614 Seal Protector 1 New O ring seal dipped in 525 refrigerant oil onto J 33011 figure 27 2 O ring comple...

Page 69: ...h coil assembly using J 26271 A and J 29886 figure 29 6 Retaining ring POLY GROOVE DRIVE Install or Connect Figure 30 Tools Required J 26271 A Rotor and Bearing Installer J 29886 Driver Handle 1 The c...

Page 70: ...1 Rotate the assembly on the tool to make sure the staking location is completely supported by the tool 4 Compressor in J 25008 A and clamp it in a vise 5 Pulley rotor and bearing to the front head us...

Page 71: ...eyway 2 Clutch plate and hub assembly on the shaft while aligning the shaft key and keyway NOTICE To avoid internal damage to the com pressor do not drive or pound on the clutch hub or shaft 3 J 9480...

Page 72: ...clutch drive plate on the crankshaft several turns to ensure piston assembly to cylinder wall lubrication 12 Connect the charging station high pressure line or a high pressure gage and J 5420 to J 96...

Page 73: ...131623 3090927 3091278 Displacement 10 cubic inches Rotation Clockwise Clutch Plate to Rotor G a p 0 5 1 0 mm 0 02 0 04 in FASTENERS Oil Drain S c re w 17 N m 13 ft lbs Pressure S w itc h 10 N m 88 in...

Page 74: ...Ring Pliers 23 Internal 10 Pulley Bearing and Pulley Installer 2 Snap Ring Pliers Internal 11 O ring Remover 3 Straight Connector 12 Pressure Plate Connector 4 Snap Ring Pliers 24 Internal 13 Compres...

Page 75: ...7 Bearing Remover 18 Compressor Shell Remover Installer and Holding Fixture 19 Rotor and Bearing Puller with Guide 20 Rotor and Bearing Installer 21 Threaded Driver Handle 22 O ring Installer 23 Beari...

Page 76: ...1B3 18 R 4 AIR CONDITIONING COMPRESSOR N...

Page 77: ...are two clutch driver designs for the HR 6 com pressor The clutch driver without a torque cushion and the clutch driver having a thin torque cushion figures 3 and 4 Note When servicing clutch drivers...

Page 78: ...a vise and attach the compressor to the holding fixture with thumb screws figure 5 Shaft nut 1 using J 33022 figure 5 Hold the clutch plate and hub assembly 2 steady using J 33027 Clutch plate and hu...

Page 79: ...assembly 2 figure 8 Make sure the contact surfaces of the clutch plate 2 and the pulley 5 are clean Remove the forcing screw tip from J 33013 B and reverse the body direction on the center screw Inst...

Page 80: ...C lutch Plate and Hub A ssem bly 5 Pulley Rotor 21 Key 35 Keyway Shaft F 04459 Figure 7 Positioning the Shaft Key Clutch Plate and Hub Assembly L Figure 6 Removing the Clutch Plate and Hub Assembly Fi...

Page 81: ...d pulley bearing 5 allow the staking to remain then file away the old staked metal for proper fit when installing a new bearing 5 in the pulley bore Install or Connect Figures 4 1 3 1 4 1 5 and 16 Too...

Page 82: ...osition the stake pin after striking The staked metal should not contact the outer race of the bearing to prevent the possibility of bending the outer race Stake 3 places 120 degrees apart figure 15 P...

Page 83: ...e com pressor Install J 8433 1 with J 33025 figure 17 T ighten J 8433 1 fo rc in g screw aga in st J 33025 A Inspect Clutch coil assembly 6 Replace as necessary Install or Connect Figures 4 1 8 1 9 an...

Page 84: ...servicing or repairing the compressor always add the proper amount of new 525 viscosity refrigerant oil Refer to Specifications Keep the workbench and work area clean when servicing the compressor and...

Page 85: ...e 25 Insert J 33011 into the compressor neck until the installer bottoms Lower the movable slide of J 33011 releasing the O ring seal into the lower groove Rotate J 33011 to seat the O ring seal and r...

Page 86: ...OR 9 One Piece Seal A J 23128 A Seal Remover and Installer B J 34614 Shaft Seal Protector F 06507 Figure 23 Removing or Installing the Shaft Tip Seal Figure 24 Removing the Shaft Seal Seat O Ring Figu...

Page 87: ...mbly from J 33026 Rear head 28 figure 29 Using a wood block tap around the edge of the rear head 28 to ease removal Mount the compressor on J 33026 front head 11 down figure 30 Head gasket 27 Valve pl...

Page 88: ...27 to prevent the dis charge valve reed retainer on the rear valve plate 26 from hitting the internal segment of the head gasket 27 figure 32 Valve plate 26 Over the guide pins into position figure 3...

Page 89: ...ssembly 6 Cylinder and shaft assembly gut pack Shaded parts shown in figure 3 are not service able A replacement kit gut pack is available for replacement Assemble cylinder and shaft assembly over the...

Page 90: ...ad four of the through bolts 7 into the rear head 28 before removing J 33016 guide pins Install two remaining through bolts 7 finger tight Mount the compressor on J 33026 figure 39 Tighten Six through...

Page 91: ...head gaskets and compressor shaft seal After the leak check shut off the low pressure control and the high pressure control on charging station If an external leak is present perform the necessary co...

Page 92: ...r and repair as necessary Reassemble and repeat the pump up test Following the pressure pump up test release the air pressure from the high side and remove the gage adapters and J 9625 A test plate Ti...

Page 93: ...J 8433 3 J 8389 J 9398 A 10 J 9625 A J21352 A 2 J 6 8 3 3 J 8092 16 8 J 9481 A M l 17 J 9553 01 18 19 J 23500 01 15 J 33011 J 33016 J 33017 20 J 33013 B 26 27 J 33019 28 J 33020 J 23128 A 21 J 33022...

Page 94: ...ing Screw 19 Bearing Staking Tool 6 Pulley Bearing Remover 20 Pulley Puller 7 Rotor Bearing Remover 21 6 Point 13 mm Socket 8 Pulley Bearing Installer 22 Puller Pilot 9 O ring Seal Remover 23 Clutch C...

Page 95: ...NSPECTION LEAK CHECK Before disassembling any compressor components check for leaks in the following areas 1 Feel under the seal area between the clutch and com pressor to check for oil seeping in the...

Page 96: ...rew 15 Cylinder Head 22 Shaft O Ring Seal Hub Assem bly 9 Coil Lead Wire Clamp 16 Cap 23 Shaft Seal Seat 3 Shims 10 Coil 17 Valve Plate Gasket 24 Retainer 4 Snap Rings 11 Cap Screw 18 Valve Plate 25 F...

Page 97: ...s Turn the center bolt to the right with the socket wrench until the front plate is loosened Figure 7 Removing the Rotor Pulley 3 Shaft key 27 by lightly tapping it loose with a slot screw driver and...

Page 98: ...igure 10 Shaft seal seat snap ring Shaft seal seat 23 with J 37793 figure 11 Seal assembly Press J 37794 against the seal spring and twist the tool until it engages the slots of the seal cage figure 1...

Page 99: ...with J 37795 and J 29886 figure 14 4 Snap ring to the rotor 3 Rotor pulley 5 to the front housing hub and align Place J 37795 into the bearing cavity with the outer edge on the rotor bearing outer rac...

Page 100: ...mall hammer and the gasket scraper to tap the outer edge of the head until it is freed from the plate figure 16 Check the gasket for wear Valve plate Position the gasket scraper between the outside ed...

Page 101: ...17 Torque Sequence Figure 16 Loosening the Valve Plate SPECIFICATIONS Sanden SD 709 P N 15573115 Application 7 4L Engine P Truck R otation Clockwise O il 500 Viscosity Suniso 5GS or equivalent Capaci...

Page 102: ...9 J 37794 4 J 29886 10 J 37795 J 36045 11 J 37796 6 J 37791 1 Puller Set 2 O Ring Hook 3 Shaft Protector 4 Driver Handle 5 Front Plate Puller 6 Clutch Plate Spanner Wrench 7 Puller Fingers 8 Seal Seat...

Page 103: ...a low friction drive between them Teeth on the ball nut engage teeth on the pitman shaft sector The teeth on the ball nut are made so that a tighter fit exists between the ball nut and pitman shaft se...

Page 104: ...A S E 11 H O U S I N G S T E E R I N G G E A R 12 S E A L S T E E R I N G S H A F T 13 G A S K E T H O U S IN G 14 B U S H IN G OR N E E D L E B R G P IT M A N S H A F T 15 G E A R P IT M A N S H A F...

Page 105: ...rts as shown PRELOAD ADJUSTER NUT If replacing gasket only do not remove SIDE COVER BOLTS SIDE COVER PRELOAD ADJUSTER SHIM PRELOAD ADJUSTER INSTALL 1 Before installing turn preload adjuster screw coun...

Page 106: ...r out with screwdriver using Tool A 2 Install parts as shown 2 Remove cup using J 29369 1 puller and slide hammer W ORM BEARING ADJUSTER LOWER WORM BEARING CUP LOWER WORM BEARING LOWER BEARING RETAINE...

Page 107: ...in lbs 4 Tighten locknut using punch against edge of slot 7 ADJUST OVER C ENTER PRELOAD B a c k o f f p r e l o a d adjuster until it stops then turn it in one full With gear at center of travel che...

Page 108: ...ft Seal Housing Worm Shaft Seal Side Cover Gasket Pitman Shaft Needle Bearing Pitman Shaft Preload A djuster Preload A djuster Shim Side Cover Preload A djuster Nut Side Cover Bolts Ball Guide Clam p...

Page 109: ...efore installing turn preload adjuster screw counterclockwise until it bottoms then back screw oft one half turn Install parts as shown Checking end clearance If clearance is greater than 05 mm lash a...

Page 110: ...bearing cup from housing only if necessary J 35365 Remove Cup Install Cup 4 DISASSEMBLE AND ASSEMBLE WORM BEARING ADJUSTER DISASSEMBLE Pry lower bearing retainer out with screwdriver Remove cup using...

Page 111: ...e of slot HOUSING ASSEMBLY Inspect for burrs PITMAN SHAFT SEAL NEEDLE BEARING Remove only if it needs replacing Installer J 8092 When tool bottoms on housing bearing is fully installed Install Pitman...

Page 112: ...bs Maximum FASTENER TORQUE SAGINAW MODEL 525 MANUAL STEERING GEAR N m Ft Lbs Gear to Frame B o lts 95 70 Pitman Shaft Nut 251 185 Side Cover B olts 40 30 Pitman Shaft Adjusting Screw Locknut 34 25 Cou...

Page 113: ...rm Bearing Cup Installer f rp 11 h 438 F 05905 J 29369 1 J 6278 J 35469 J 35365 J 8092 1 W orm Bearing A djuster Cup Puller Use w ith J 2619 01 2 Pitman Shaft Bearing Remover 3 Pitman Shaft Bearing In...

Page 114: ......

Page 115: ...r or with an equivalent part if replacem ent becom es necessary Do not use a replacem ent part of lesser quality or substitute design Torque values must be used as specified during reassembly to assur...

Page 116: ...ce is part of the pressure line union The pressure relief valve inside the flow control valve limits the pump pressure SAGINAW INTEGRAL POWER STEERING GEAR RV G P ST M NOTICE Repair the steering gear...

Page 117: ...aring Race Seal A djuster Plug Bearing Seal W asher R etaining Ring Nut Races I Bearing 2 5 2 Worm Shaft ___ Seal 230 Valve Body 250 2 Stub Shaft Valve Spool Seal Pitman Shaft Dust Seal 1989 Interim 2...

Page 118: ...nch 220 Retaining Ring F 01805 Figure 2 Unseating the Retaining Ring Figure 5 Removing the Pitman Shaft Bearing A Screwdriver B Punch 220 Retaining Ring F 01862 Figure 3 Removing the Retaining Ring Fi...

Page 119: ...cap clears the valve body by about 6 mm 1 4 inch Valve spool 252 and seals 230 and 231 figure 11 16 Screws 210 clamp 211 and ball guide 212 Balls 213 CLEANING AND INSPECTION JTJj I Clean All parts wit...

Page 120: ...face of the stub shaft 251 If a cro cus cloth cannot clean the nicks or burrs replace the entire valve assembly Outside diameter of the valve spool and inside diameter of the valve body 250 If a crocu...

Page 121: ...figure 14 9 Seal 242 washer 243 and retaining ring 244 in the adjuster plug 240 Important The retainer projections must not extend beyond the washer 243 when the retainer ring 244 is seated The washer...

Page 122: ...vertical while turning the wrench to the left at an even rate figure 19 If the reading is less than 0 45 N m 4 in lbs or more than 1 15 N m 10 in lbs repeat the adjustment procedure Lubricate the stu...

Page 123: ...damaged inspect all mating parts for burrs cracks scratches or damage Replace or repair as needed In some instances power steering fluid will be speci fied to lubricate parts upon assembly In these ca...

Page 124: ...HAFT 39 SEAL O RING RACK PISTON 22 SEAL STUB SHAFT DUST 40 RING RACK PISTON 23 RING RETAINING 41 SEAL O RING HOUSING END PLUG 24 NUT ADJUSTER PLUG LOCK 42 PLUG HOUSING END 25 BEARING ASM NEEDLE PITMAN...

Page 125: ...SING END PLUG REMOVE 1 Remove parts as shown INSTALL 1 Install parts as shown Open end of retaining ring to be approx 25 mm 1 inch from access hole Retaining ring access hole 3 REMOVE AND INSTALL RACK...

Page 126: ...SM ALL TH RU ST BEARING SPACER BEARING RETAINER RETAINER VALVE BODY RING teflon SPO O L TO BO DY O RING Shaft cap A Loosen shaft cap B Remove and install stub shaft Pull cap out approx 6 mmfVV Screw...

Page 127: ...driver to remove pitman shaft dust seal 3 Remove retaining ring with snap ring pliers J 4245 4 Using screw driver pry seals and washers from bore SEA L BACK U P W ASH ER PITMAN SH AFT DUST SEA L 1 Coa...

Page 128: ...anner wrench J 7624 tighten adjuster plug until thrust bearing is firmly bottomed 27 Newton Metres 22 Ft Lbs C Turn adjuster in until torque to turn stub shaft is 0 6 to 1 2 Newton Metres 6to 10 in Lb...

Page 129: ...875 Figure 28 Power Steering Pump Components Model TC 4 5 6 7 8 9 10 11 12 13 14 15 16 Fitting 23 figure 31 O ring seal 22 Flow control valve 21 Flow control spring 20 Retaining ring 19 figure 32 Use...

Page 130: ...ft 18 Bearing F 01880 Figure 33 Remove and Install Driveshaft Bearing Figure 31 Removing the Fitting Control Valve Spring and Seal Figure 34 Remove and Install Driveshaft Seal Figure 32 Remove and Ins...

Page 131: ...ts Vane 9 tips for scoring or wear Fit of vanes 9 in the rotor 10 The vanes must fit properly in the rotor slots without sticking or excessive play 9 10 11 12 13 Install or Connect Figures 28 39 throu...

Page 132: ...33 Slide the assembly into the housing while rotat ing the driveshaft so that the shaft serrations engage with the rotor 17 Retaining ring 19 Use a suitable pair of snap ring pliers figure 32 Make sur...

Page 133: ...plate 65 Tap lightly on the driveshaft with a rubber mallet Pump ring 64 and vanes 63 Shaft retaining ring 62 pump rotor 61 and thrust plate 56 Driveshaft 50 Seal 51 from the housing 53 Dowel pins 55...

Page 134: ...ring Pump Model P ASSEMBLY 4 Install or Connect Figure 46 Tool Required J 7728 Seal Installer Important Lubricate the O rings 54 pump ring 64 rotor 61 and vanes 63 with power steering fluid Dowel pins...

Page 135: ...r Screw Jam N u t 27 N m 20 in lbs Side Cover Bolts 60 N m 40 ft lbs Pitman Shaft N u t 244 N m 180 ft lbs Ball Return Guide S cre w s 5 N m 4 ft lbs Integral Power Steering Gear CK GMT 400 Pitman Sha...

Page 136: ...J 22407 6 J 7624 13 S r J 7728 7 J 7079 2 1 Snap Ring Pliers 8 Pitman Shaft Bearing Puller 2 Valve C onnector Installer 9 Puller Form erly J 6632 3 Ball Retainer 10 Seal Installer 4 A djuster Plug Be...

Page 137: ...upported by two tapered roller bearings The pinion depth is set by a shim pack located between the gear end of the pinion and the roller bearing that is pressed onto the pinion The pinion bearing prel...

Page 138: ...from the axle housing at the differential window figure 2 10 Bearing outer races 22 shims 21 and spacers 23 Mark the races and the shims as left and right and place them with the bearing caps 11 D if...

Page 139: ...r Pinion Flange Pinion Oil Seal Pinion O uter Bearing Plug 17 C ollapsable Spacer 18 Pinion Inner Bearing 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Shim Pinion and Ring Gear Set Shim D iffere...

Page 140: ...eal from sealing Remove any burrs that are found The bearing cup bores for nicks or burrs Remove any burrs that are found The housing for cracks Replace the housing if any cracks are found The housing...

Page 141: ...e with very loose bearings the ring gear and drive pinion will also require replacement Low mileage bearings may have minute scratches and pits on the rollers and the bearing cups from the initial pre...

Page 142: ...ominal setting If the nominal setting is 0 033 inch and the pinion is marked 2 the correct shim depth would be 0 033 inch 0 002 inch 0 031 inch If the pinion has no plus or minus marked on the pinion...

Page 143: ...increments of 0 101 mm 0 004 inch Be sure that the side bearing surfaces are clean and free of burrs 1 Place the case with the bearing cups installed into the axle housing figure 1 L u b rica te the...

Page 144: ...t before additional drag begins is the correct feeler gage thickness This is the zero setting without pre load 7 Remove the left bearing cap and shim s from the axle housing M easure the shim s using...

Page 145: ...t each point within 0 05 mm 0 002 inch If the backlash varies m ore than 0 05 mm 0 002 inch check for burrs a distorted case flange or uneven bolting conditions 7 Backlash at the minimum lash point me...

Page 146: ...fully clean each tooth of the ring gear figure 18 2 Use gear marking compound 1052351 or equivalent and apply this mixture sparingly to all ring gear teeth using a medium stiff brush When properly use...

Page 147: ...re 19 Gear Tooth Pattern SPECIFICATIONS 71 2 AND 75 s INCH RING GEAR AXLE FASTENER N m FT LBS Ring Gear Bolts 120 90 Bearing Cap Bolts 75 55 Axle Cover B olts 27 20 SPACER AND SHIM SIZES SIZE Differen...

Page 148: ...n Flange Remover 5 Side Bearing Remover 6 Rear Pinion Bearing Cone Installer 7 Pinion Oil Seal Installer 8 D ifferential Side Bearing Installer 9 Rear Pinion Bearing Remover 10 Driver Handle 11 Dial I...

Page 149: ...e These shims are also used to preload the bearings which are pressed onto the differential case Two bearing caps are used to hold the differential into the rear axle housing The differential is used...

Page 150: ...ifferential Side Bearing 28 Axle Shaft Seal 9 Shim Pack including spacer 29 Brake Backing Plate 10 Bearing Cap 30 Bolt 11 Gasket 31 Brake Drum 12 Cover 32 W heel Stud 13 Brake Line Clip 33 Axle Shaft...

Page 151: ...ial side bearings 8 using J 8107 4 and J 22888 figure 3 The jaws of J 22888 must pull from beneath the bearing cone and not the cage Use the slots provided for the puller 12 Ring gear bolts 23 Ring ge...

Page 152: ...ng them with compressed air INSPECTION It is very important to carefully and thoroughly inspect all drive unit parts before reassembly Thorough inspection of the drive parts for wear or stress and sub...

Page 153: ...leage bearings may have minute scratches and pits on the rollers and the bearing cups from the initial preload Do not replace a bearing for this reason Bearing caps for cracks or chips SHIMS Inspect L...

Page 154: ...17 Check the pinion face for a pinion adjustment mark This mark indicates the best running position for the pinion from the nominal setting If the pinion is stamped with a plus number add that many th...

Page 155: ...w 2 3 to 2 8 N m 20 to 25 in lbs on new bearings or 1 1 to 1 7 N m 10 to 15 in lbs for used bearings figure 16 If the preload torque is below the preloads given above continue torquing the nut in smal...

Page 156: ...case 24 Thread two left hand threaded studs into the ring gear on opposite sides figure 17 Place the ring gear onto the case and align the holes in the case with the studs Press the ring gear onto th...

Page 157: ...produced figure 21 Tighten the lock bolt on the side of the tool F 04708 Figure 21 Measuring Side Bearing Shim Requirements Leave the tool in place 6 Install a service spacer 9 and a service shim 9 be...

Page 158: ...the ring gear Backlash at the minimum lash point measured should be between 0 13 and 0 23 mm 0 005 and 0 009 inch for all new gear sets 8 If the backlash is not within specifications move the ring ge...

Page 159: ...he position of the drive pinion is adjusted by increasing or decreasing the distance between the pinion head and the centerline of the ring gear Decreasing the distance will move the pinion closer to...

Page 160: ...PACER AND SHIM SIZES Differential Side Bearing S pacer 0 170 inch Differential Side Bearing Shim K its 0 064 0 070 0 072 0 078 0 080 0 086 0 088 0 094 0 096 0 100 0 052 0 056 0 058 0 063 0 040 0 044 0...

Page 161: ...ver 12 Side Bearing Backlash Gauge 3 Driver Handle 13 Rear Pinion Bearing Cone Installer 4 Dial Indicator Set Not Shown 5 Rear Pinion Bearing Cone Installer J 21777 1 Arbor 6 Pinion Flange Remover J 2...

Page 162: ......

Page 163: ...a threaded differential bearing adjusting nut located between the axle housing and the differential bearing cap Two bearing caps are used to hold the differential into the rear axle housing The diffe...

Page 164: ...nion thrust washer 30 Remove the side gears and the side gear thrust washers 32 Mark the gears and the differential case as left and right 7 Adjusting nut lock bolt 18 8 Adjusting nut lock 16 Loosen t...

Page 165: ...on assembly for looseness by moving it back and fo rth Looseness ind icate s excessive bearing wear 16 Pinion flange nut 6 and washer 7 using J 8614 01 to hold the pinion flange figure 5 17 Pinion fla...

Page 166: ...e outer diameter of the pinion seal from sealing Remove any burrs that are found The bearing cup bores for nicks or burrs Remove any burrs that are found The housing for cracks Replace the housing if...

Page 167: ...777 1 Arbor J 21777 8 Rear Pilot Washer J 21777 42 Front Pilot Washer J 21777 43 Stud Assembly Bolt J 21777 85 Gage Plate J 21777 86 Side Bearing Disc Clean all the gage parts Lubricate the front and...

Page 168: ...3 inch as shown in figure 13 record the dial reading of 0 84 mm 0 033 inch not 1 70 mm 0 067 inch 17 Check the pinion face for a pinion adjustment mark This mark indicates the best running position fo...

Page 169: ...pinion 5 Pinion oil seal 9 using J 22388 and J 22804 01 figure 15 6 The pinion flange 8 to the pinion by tapping it with a rawhide hammer until a few threads show through the pinion flange 7 The pinio...

Page 170: ...the pinion gears line up with the pinion shaft holes 4 Pinion thrust washers 30 Rotate the pinion gears toward the differential opening just enough to slide in the pinion thrust washers Check that the...

Page 171: ...CKLASH ADJUSTMENT 1 Install a dial indicator to the case using a magnetic base 2 Place the indicator stem at the heel end of a tooth Set the dial indicator so that the stem is in line with the gear ro...

Page 172: ...he carrier and carefully clean each tooth of the ring gear figure 23 2 Use gear marking compound 1052351 or equivalent and apply this mixture sparingly to all ring gear teeth using a medium stiff brus...

Page 173: ...T IN C R E A S E B A C K L A S H LO W F L A N K C O N T A C T D E C R E A S E P IN IO N S H IM H IG H FA C E C O N T A C T IN C R E A S E P IN IO N S H IM H E E L C O N T A C T D EC R E A S E B A C K...

Page 174: ...0 nch 5 64 mm 0 222 nch 5 69 mm 0 224 nch 5 74 mm 0 226 nch 5 79 mm 0 228 nch 5 84 mm 0 230 nch 5 89 mm 0 232 nch 5 94 mm 0 234 nch 5 99 mm 0 236 nch 6 05 mm 0 238 nch 6 10 mm 0 240 nch 6 15 mm 0 242...

Page 175: ...Rear Pinion Bearing Cone Installer J 21777 8 Rear Pilot W asher 6 Front Pinion Bearing Cup Installer J 21777 42 Front Pilot W asher 7 Driver Handle J 21777 43 Stud A ssem bly Bolt 8 Dial Indicator J 2...

Page 176: ...4B3 14 91 2 INCH RING GEAR...

Page 177: ...ings The differential and ring gear are located in relationship to the pinion by using two different bearing adjusting nuts These allow the differential to be moved from side to side by adjusting the...

Page 178: ...Pinion flange nut 1 and washer 2 using J 8614 01 to hold the flange figure 5 20 Pinion flange using J 8614 01 figure 6 21 Pinion 14 from the pinion cage 10 Place the cage into an arbor press as shown...

Page 179: ...on Cross Shaft Differential Case Washer Ring Gear Bolt Brake Backing Plate Bolt Axle Shaft Seal Bearing Retaining Ring Bearing Lock Nut Key Retaining Ring 6 Pinion Front Bearing 7 Bolt 8 Washer 9 Brak...

Page 180: ...4B4 4 lO z INCH RING GEAR Figure 2 Removing the Differential Side Bearings Figure 7 Pressing the Drive Pinion from the Cage...

Page 181: ...ng wear is most evident B earing cups for wear cracks brinelling and scoring Bearings and cups are only replaced as sets If the rear axle was operated for an extended period of time with very loose be...

Page 182: ...e preload has been obtained rotate the pinion several times to assure that the bearings have seated Recheck the preload and adjust if necessary 11 Pinion cage 10 to the axle housing Refer to Pinion In...

Page 183: ...riginal locations 3 Differential spider 33 to the differential 4 The case halves Align the scribe marks on the case halves Check that the mating surfaces of the differential case and the ring gear are...

Page 184: ...tely two slots to obtain the initial backlash adjustment 5 Adjusting nut lock 21 and lock bolt 22 to the left nut 6 Do not tighten Tighten the right adjusting nut firmly to force the case into solid c...

Page 185: ...oes until a torque of 40 to 50 ft lbs is required to turn the pinion A test made without loading the gears will not give a satisfactory pattern Turn the pinion flange with a w rench so that the ring g...

Page 186: ...S E B A C K LA S H H IG H FA C E C O N T A C T IN C R E A S E P IN IO N S H IM J I I 1 1 1 1 L M m t A __ f t LO W F L A N K C O N T A C T D EC R E A S E P IN IO N S H IM H E E L C O N T A C T D E C...

Page 187: ...B o lts Adjusting Nut Lock Bolts SPACER AND SHIM SIZES Pinion Bearing Shims N m FT LBS 163 120 183 135 27 20 30 22 SIZE 0006 nch 0 007 nch 0 008 nch 0 009 nch 0 010 nch 0 011 nch 0 012 nch 0 013 nch...

Page 188: ...e Bearing Remover 3 Rear Pinion Bearing Cup Installer 4 Driver Handle 5 Rear Pinion Bearing Cone Installer 6 Side Bearing A djustm ent Spanner 7 Rear Pinion Bearing Cone Remover 8 Pinion Pilot Bearing...

Page 189: ...tapered roller bearings The differential and ring gear are located in relationship to the pinion by using selective shims between the bearings and the differential case To move the ring gear shims are...

Page 190: ...a rawhide hammer Ring gear 2 from the vise Put the differential case in the vise 12 Lock pin 29 from the differential using a hammer and a punch figure 8 13 Pinion shaft 28 using a hammer and a brass...

Page 191: ...t 3 Inner Pinion Bearing 14 Cover 24 Pinion Gear 4 Shim s 16 Plug 25 Side Gear 6 Preload Shim s 17 Bolt 26 Pinion Thrust W asher 7 Bearing 18 Bearing Cap 27 Side Gear Thrust W asher 8 Slinger 19 Bolt...

Page 192: ...4B5 4 DANA REAR AXLES Figure 4 Spreading the Differential Case Figure 7 Removing the Ring Gear...

Page 193: ...DANA REAR AXLES 4B5 5 Figure 9 Removing the Pinion Shaft Figure 10 Removing the Pinion Gears Figure 13 Removing the Pinion Flange...

Page 194: ...r wear Pinion flange splines for wear The fit of the pinion on the pinion flange The sealing surface of the pinion flange for nicks burrs or rough tool marks which would cause damage to the seals insi...

Page 195: ...differential opening just enough to slide in the pinion thrust washers 5 Pinion shaft 28 Align the lock pin holes in the case and the shaft 6 Lock pin 29 figure 18 Peen metal from the case over the lo...

Page 196: ...ack without the bearing preload which will be added later 7 Remove the dial indicator from the axle 8 Remove the differential case from the axle housing Do not remove the master bearings from the diff...

Page 197: ...dicates that the distance between the ring gear centerline and the pinion head must decrease by the number of thousandths marked on the pinion This means that the shim pack will increase by the same n...

Page 198: ...and assure a more accurate reading pinion depth setting Figure 30 Installing the Inner Bearing 9 Pinion depth checking tools D 116 1 D 116 2 D 115 3 and D 115 to the top of the pinion Place the discs...

Page 199: ...decrease the preload ASSEMBLING THE DIFFERENTIAL TO THE AXLE HOUSING Tools Required J 23690 Differential Side Bearing Installer J 8092 Driver Handle J 24385 01 Differential Carrier Spreader 1 Assemble...

Page 200: ...on the differential side bearing hub opposite the ring gear and drive the differential bearinq onto the hub using J 23690 and J 8092 12 Assemble J 24385 01 to the axle housing as shown in figure 38 1...

Page 201: ...propeller shaft to the drive shafts This axle is full floating The axle shaft is supported at the wheel ends by the wheel hubs The bolts that attach the shaft to the hub support the axle at the hub T...

Page 202: ...s 21 Shim s 35 W heel Hub 7 Bearing 22 D ifferential Case 37 Inner Lock Nut 8 Slinger 23 Bolt 38 Lock W asher 9 Pinion Oil Seal 24 Pinion Gear 39 O uter Lock Nut 10 Pinion Flange 25 Side Gear 40 Axle...

Page 203: ...Side Bearing Remover J 29721 70 Side Bearing Adapters J 8107 3 Side Bearing Puller Plug D 166 Differential Case Holding Fixture J 8614 01 Pinion Flange Holder Place the axle in a suitable support 1 T...

Page 204: ...166 Miller tool and put the holding fixture into the vise 12 Lock pin 29 from the differential using a hammer and a punch figure 49 Turn the differential over on D 166 13 Pinion shaft 28 using a hamm...

Page 205: ...ad shims 6 Keep the shims toether on the bench 21 Pinion seal 9 22 Pinion outer bearing 7 and oil slinger 8 23 Bearing cups 3 and 7 from the axle housing using a hammer and a punch figure 56 Work the...

Page 206: ...are found The bearing cup bores for nicks or burrs Remove any burrs that are found The housing for cracks Replace the housing if any cracks are found The housing for foreign material such as metal chi...

Page 207: ...se Place the side gears in place on the same side as removed figure 58 Figure 59 Installing the Lock Pin 3 Pinion gears 24 to the differential without the thrust washers 26 Place the pinion gears onto...

Page 208: ...L DIFFERENTIAL SHIM PACK SIZE HEAVY DUTY MODEL 1 Assemble the differential case 22 to the axle housing The pinion must not be installed 2 Mount a dial indicator having a minimum travel of 0 200 inch w...

Page 209: ...sing 5 Install D 116 1 onto D 120 and against the arbor figure 65 6 Place D 115 onto the height block figure 66 Place the gage on the upper step of the height block Push the gage down on the height bl...

Page 210: ...ncluded in the shim pack figure 68 PINION INSTALLATION 0 Install or Connect Tools Required J 7818 Front Pinion Bearing Cup Installer J 5590 Rear Pinion Bearing Cone Installer C 4204 Cup Installer Mill...

Page 211: ...ed If the indicator reading is within 0 05 mm 0 002 inch of the pinion marking the pinion is correctly set If the pinion depth does not meet 10 11 12 13 14 specifications change the shim pack by the a...

Page 212: ...away from the pinion gear to obtain an indicator reading Repeat this action until a consistant reading is obtained 7 Remove the indicator and the differential case from the carrier 8 Remove the master...

Page 213: ...c h Over spreading the carrier can damage or distort the carrier 14 Spread the carrier w hile exam ining the dial indicator 15 Remove the dial indicator 16 Place the bearing cups 20 onto the bearings...

Page 214: ...ar side and drive the differential bearing onto the hub using J 23690 and J 8092 If installing a new bearing be certain that it is the same width as the old bearing 14 Assemble J 24385 01 to the axle...

Page 215: ...ubricant 80W 90 GL 5 101 2 INCH RING GEAR AXLE FASTENER N m FT LBS Ring Gear Bolts 142 105 Bearing Cap Bolts 115 85 Axle Cover B o lts 47 35 Lubricant 80W 90 GL 5 SHIM SIZES SIZE Differential Bearing...

Page 216: ...cs M iller 10 Rear Pinion Bearing Cup Installer 2 A rbor M iller 11 Driver Handle 3 Pinion H eight B lock M iller 12 Rear Pinion Bearing Cone Installer 4 Scooter Gage M iller 13 Pinion Flange Remover...

Page 217: ...ngs M iller 14 6 M aster Pinion Block M iller 15 7 Cup Installer M iller 16 8 Handle M iller 17 9 Preload Shim Installer M iller 18 D ifferential Side Bearing Remover Plug Driver Handle Front Pinion B...

Page 218: ......

Page 219: ...cated in relationship to the pinion by using two differential bearing adjusting nuts These allow the differential to be moved from side to side by adjusting the nuts in or out The differential side be...

Page 220: ...4B6 2 12 INCH RING GEAR ROCKWELL F 04734 Figure 1 Rear Axle Components...

Page 221: ...der 61 W asher 20 Axle H ousing 41 Pinion Gears 62 Nut 21 Bracket 42 Pinion Thrust Washers 63 Backing Plate F 04734 Figure 2 Rear Axle Components Loosen the jam nut 49 and back off the thrust block ad...

Page 222: ...4B6 4 12 INCH RING GEAR ROCKWELL F 04770 Figure 7 Removing the Differential Figure 10 Removing the Differential Side Bearing...

Page 223: ...25 Pilot bearing 52 from the pinion gear 37 using J 22912 CLEANING Do not steam clean drive parts having ground and polished surfaces such as gears bearings and shafts These parts should be cleaned i...

Page 224: ...sure as possible The large end of the bearing rollers for wear This is where tapered roller bearing wear is most evident Bearing cups for wear cracks brinelling and scorring Bearings and cups are only...

Page 225: ...deflector 59 Pinion flange 60 to the pinion figure 16 Press the flange onto the pinion 12 Figure 18 Removing the Pinion Nut Pinion washer 61 and a new nut 62 using J 3453 to hold the pinion figure 17...

Page 226: ...45 ft lbs Check that the mating surfaces of the differential case and the ring gear are clean and burr free The ring gear must be heated before assembly to the differential case Heat the ring gear in...

Page 227: ...r Tighten the same adjusting nut just enough to have 0 000 inch end play on the indicator Rotate the gear and check for run out If the run out exceeds 0 008 inch remove the differential and determine...

Page 228: ...NG GEAR AXLE ROCKWELL FASTENER Piston Nut Pinion Cage B olts Case Half Bolts Ring Gear Bolts Bearing Cap Bolts SHIM SIZES Drive Pinion Bearing Retainer Shim N m FT LBS 325 240 48 35 61 45 136 100 176...

Page 229: ...12 INCH RING GEAR ROCKWELL 4B6 11 SPECIAL TOOLS Special Tools...

Page 230: ...4B6 12 12 INCH RING...

Page 231: ...te 16 and disc pack 12 as an assembly cam unit 14 Side gear thrust washer 13 CAM UNIT DISASSEMBLY 71 2 AND 8V2 INCH 0 Remove or Disconnect Figures 1 and 3 1 Snap ring 22 2 Clutch plates 3 Guide clips...

Page 232: ...91 2 nch Ring Gear 10 Side Gear 20 G uide C lip 1 D ifferential Case 11 Latching Bracket 21 Side Cam Gear 2 Stop Pin 91 2 Only 12 C lutch Plates 22 Retaining Ring 3 Lock Screw 13 Side Gear Thrust W a...

Page 233: ...ntial is adjusted by using selective thickness thrust washers behind each side gear and a selective thickness thrust block between the side gears It is important to build up the differential properly...

Page 234: ...ch 12 If the backlash is too high use a thicker thrust washer 13 If the backlash is too low use a thinner thrust washer Thrust Block Clearance Adjustment Install or Connect Left thrust washer 13 to th...

Page 235: ...ly from the front of the gear to the back of the thrust sleeve 35 including the side gear washer 36 12 Thrust sleeve 35 using J 22912 01 Press the sleeve from the side gear figure 11 13 Clutch plates...

Page 236: ...F 05915 Figure 9 Differential Components ADJUSTMENT OF THE DIFFERENTIAL If it is necessary to replace the cam gear the right hand side gear or the reaction blocks the entire differential must be adjus...

Page 237: ...sing a set of washers nut and a bolt long enough to hold the cam unit in place figure 13 3 Place the pinion gears and thrust washers on the pinion yoke 4 Install the yoke firmly to the differential ca...

Page 238: ...ack and forth while reading the dial indicator Record the reading Do not unseat the pinion yoke This will make the backlash reading inaccurate Repeat steps 7 10 on the other 2 pinions Record the readi...

Page 239: ...h 1 618 G reen 1 284 nch 1 346 nch 1 622 B lu e B la c k 1 288 nch 1 350 nch 1 626 1 630 91 2 lnch inch nch inch inch inch inch nch nch nch REACTION BLOCK SIZES lOVa INCH 0 675 inch 0 672 inch 0 669 i...

Page 240: ...4B7 10 LOCKING DIFFERENTIALS SPECIAL TOOLS Special Tools...

Page 241: ...ransmit the driving force of the engine to the wheels This gear set transfers this driving force at a 90 degree angle from the propeller shaft to the drive shafts This axle is full floating The shafts...

Page 242: ...2 Roll the pinion gears out of the case with the pinion thrust washers 20 Remove the side gears and the side gear thrust washers 19 Mark the gears and the differential case as left and right 6 Differe...

Page 243: ...35 Pinion Nut 6 Shim 17 Pinion Shaft 36 W asher 7 Ring and Pinion Gear Set 18 Bolt 37 Pinion Flange 8 D ifferential Side Bearing 19 Side Gear Thrust W asher 38 Pinion Seal 9 Shim Pack including space...

Page 244: ...4C1 4 8 1 2 INCH RING GEAR Work the cups out of the housing evenly moving the punch back and forth between one side of the cup and the other 20 Axle seals F 04694 Figure 6 Pinion Flange Removal...

Page 245: ...r Fit of the differential side gears in the differential case Fit of the side gears on the axle shafts Differential case for cracks and scorring Replace all worn parts PINION AND RING GEAR Inspect Pin...

Page 246: ...the bearings 5 and 39 into the pinion bearing cups 4 Install J 21777 35 J 21777 42 J 21777 29 and J 21777 43 to the pinion bore figure 11 5 Hold the stud stationary at the flats of the stud Tighten t...

Page 247: ...staller J 8614 01 Pinion Flange Remover J 5590 Rear Pinion Bearing Cone Installer The bearing cups should have been installed in Pinion Depth Adjustment in this section 1 The pinion inner bearing 5 us...

Page 248: ...he pinion gears onto the side gears so that the holes in the pinion gears are 180 degrees apart Rotate the pinion gears into place and verify that the pinion gears line up with the pinion shaft holes...

Page 249: ...8092 9 Differential case 24 to the axle housing Refer to Side Bearing Preload Adjustment in this section SIDE BEARING PRELOAD ADJUSTMENT Tool Required J 22779 Side Bearing Backlash Gage The differenti...

Page 250: ...ness This is the zero setting without preload 8 Remove the strap J 22779 the service spacer service shim feeler gage and differential case from the axle housing 9 M easure J 22779 in three places usin...

Page 251: ...GEAR TOOTH CONTACT PATTERN CHECK Before final assembly of the differential a gear tooth contact pattern check should be performed It should be noted that a gear tooth contact pattern check is NOT a su...

Page 252: ...both pinion depth and the backlash to obtain the correct pattern The position of the drive pinion is adjusted by increasing or decreasing the shim thickness between the pinion head and the inner race...

Page 253: ...ferential Side Bearing Kits 0 064 0 070 nch 0 040 0 044 nch 0 046 0 050 nch 0 052 0 056 nch 0 058 0 063 nch 0 072 0 078 nch 0 080 0 086 nch 0 088 0 094 nch 0 096 0 100 nch Pinion Bearing Shim Kits 0 0...

Page 254: ...cator Set 5 Rear Pinion Bearing Cone Installer 6 Pinion Flange Remover 7 Differential Side Bearing Remover Plug 8 Rear Pinion Bearing Remover Plug 9 Side Bearing Remover 10 Pinion Oil Seal Instailer 1...

Page 255: ...the pinion gear The ring gear is bolted onto the differential case with left hand thread bolts The differential case is supported in the case by two tapered roller bearings The differential and ring g...

Page 256: ...arrier 1 7 Bearing cups 20 Mark the cups as left and right and place them with the proper bearing caps 8 Differential side bearings 20 using J 29721 and J 29721 70 and J 8107 3 figure 6 Mark the beari...

Page 257: ...nion Bearing 14 Cover 24 Pinion Gear 4 Shims 15 Spacer 25 Side Gear 5 Baffle 16 Plug 26 Pinion Thrust W asher 6 Preload Shim s 17 Bolt 27 Side Gear Thrust Washer 7 Bearing 18 Bearing Cap 28 Pinion Sha...

Page 258: ...4C2 4 93 4 INCH RING GEAR FRONT AXLE F 04756 Figure 4 Spreading the Differential Case Figure 7 Removing the Ring Gear...

Page 259: ...93 4 INCH RING GEAR FRONT AXLE 4C2 5 Figure 10 Removing the Pinion Gears Figure 13 Pinion Flange Removal...

Page 260: ...4C2 6 93 4 INCH RING GEAR FRONT AXLE Figure 16 Removing the Pinion Inner Bearing...

Page 261: ...ers for wear The fit of the differential side gears in the differential case The fit of the side gears on the axle shafts Differential case for cracks and scorring Replace all worn parts PINION AND RI...

Page 262: ...ars line up with the pinion shaft holes 5 New pinion thrust washers 26 Rotate the pinion gears toward the differential opening just enough to slide in the pinion thrust washers 6 Pinion shaft 28 Align...

Page 263: ...sandths that the dial indicator traveled not the reading on the dial This will be the measurement of the shimpack without the bearing preload which will be added later 7 Remove the dial indicator from...

Page 264: ...centerline and the pinion head must increase by the number of thousandths marked on the pinion This means that the shim pack will decrease by the same number of thousandths A negative pinion marking...

Page 265: ...r D 115 Scooter Gage Miller D 163 Seal Installer Miller Place the required amount of shims and baffle if used in the inner bearing bore Drive the inner bearing cup into the axle assembly using D 111 a...

Page 266: ...d If the indicator reading is within 0 05 mm 0 002 inch of the pinion marking the pinion is correctly set If the pinion depth does not meet 10 11 12 13 14 specifications change the shim pack by the am...

Page 267: ...he total shim pack size determined earlier Refer to Determining Total Differential Shim Pack Size in this section subtract the reading found in step 6 from the total reading The reading found in step...

Page 268: ...e points checked 4 High backlash is corrected by moving the ring gear closer to the pinion 5 Low backlash is corrected by moving the ring gear away from the pinion 6 To adjust the backlash the differe...

Page 269: ...over B o lts 47 35 AVAILABLE SHIM SIZES Differential Bearing Adjusting S h im 0 003 inch 0 005 nch 0 010 nch 0 030 nch Outer Pinion Bearing S h im 0 003 nch 0 005 nch 0 010 nch 0 030 nch Inner Pinion...

Page 270: ...r 3 Pinion Height Block Miller 4 Scooter Gage Miller 5 Master Pinion Bearings Miller 6 Master Pinion Block Miller 7 Cup Installer Miller 8 Handle Miller 9 Differential Side Bearing Removal Plug 10 Rea...

Page 271: ...ngine to the wheels This gear set transfers this driving force at a 90 degree angle from the propeller shaft to the drive shafts The pinion gear is supported by two tapered roller bear ing The pinion...

Page 272: ...haft 59 and deflector 2 Pry with a screwdriver between the shaft flange and carrier head while striking the flange with a soft face hammer figure 5 Bolts 58 and cover 57 Left seal 3 Bolts 28 Separate...

Page 273: ...T TRUCK FRONT AXLE 4C3 3 F 05785 Figure 1 Axle Components...

Page 274: ...ing 23 O utput Shaft 38 Shim 53 Thrust W asher 9 Carrier C onnector 24 Washer 39 Bearing 54 Side Gear 10 S hift Cable 25 Plug 40 Spacer 55 T hrust W asher 11 S hift Cable H ousing 26 W asher 41 Bearin...

Page 275: ...1782 Figure 9 Remove the Sleeve Bearing Figure 10 Removing the Pinion Nut Figure 8 Removing the Side Bearing Cup Figure 6 Separating the Carrier Case Halves 29 32 19 18 18 Bolt 29 C arrier Case 19 Loc...

Page 276: ...E F 04696 Figure 12 Removing the Pinion Bearing Figure 13 Removing the Inner Pinion Bearing Cup Figure 15 Replacing the Case Bushings INSTALLATION J 33791 3 J 33791 2 J 33791 1 95 C arrier A ssem bly...

Page 277: ...ing gear teeth for cracking chipping scorring or excessive wear Pinion splines for wear Pinion flanges splines for wear Fit of the pinion on the pinion flange Sealing surface of the pinion flange for...

Page 278: ...ears making sure the hole in both pinion gears line up 3 Thrust washers 55 Rotate the pinion gears toward the opening just enough to permit the sliding in of the thrust washers 4 Shaft 52 and bolt 36...

Page 279: ...rther tightening should be attempted until bearing preload has been checked Measure Pinion bearing preload Use an inch pourd torque wrench figure 22 The correct preload is 1 7 2 8 N m 15 25 in lbs 1 R...

Page 280: ...4C3 10 T TRUCK FRONT AXLE F 05791 A Button Located in Bearing Bore B Button Moved Out of Bearing Bore Figure 19 Measuring Pinion Depth...

Page 281: ...te the pinion several times to seat the bearings 8 Install J 34047 J 25025 1 and J 8001 1 figure 27 9 Place the indicator stem at the heel end of a tooth J 33788 F 01791 Figure 23 Installing the Sleev...

Page 282: ...inion Flange To increase backlash turn the left sleeve in and turn the right sleeve out an identical amount To decrease backlash turn the right sleeve in and turn the left sleeve out an identical amou...

Page 283: ...ll affect the tooth contact pattern These are backlash and the position of the drive pinion pinion depth in the carrier The effects of bearing preloads are not easily seen on hand loaded teeth pattern...

Page 284: ...8 Seal 3 Use J 33893 figure 31 9 Seal 15 Use J 33799 fiuge 32 10 Differential pilot bearing 21 Use J 33842 figure 33 11 Washer 24 to the output shaft 23 12 Output shaft to the carrier assembly 13 Slee...

Page 285: ...l Operation of the shift mechanism Insert J 33798 into the shift fork Turn the axle shaft while engaging and disengaging the shift mechanism with the tool The mechanism should operate smoothly If not...

Page 286: ...t Hand Output Shaft Cover Bolts Carrier Case B o lts Adjusting Sleeve Lock B o lts 8 0 71 Differential Ring Gear Bolts N m Ft Lbs 25 18 25 18 47 35 8 0 80 60 AVAILABLE SHIM SIZES Pinion Shim K its 0 5...

Page 287: ...4 Pinion Bearing Installer 5 O utput Shaft Bearing Installer 6 Differential Side Bearing Installer 7 Side Bearing A djuster Wrench 8 Differential Side Bearing Remover 9 Axle Lock Cable Seal Installer...

Page 288: ...RUCK FRONT AXLE SPECIAL TOOLS J 29307 J 8001 J 33791 J 34037 1 Slide Ham m er 2 Bushing Remover 3 Dial Indicator Set 4 Dial Indicator 5 Dial Indicator Stand Part of J 25025 B 6 Engagem ent Tool J 3379...

Page 289: ...ring Cup Installation 4C4 Pinion Depth Adjustm ent 4C4 Pinion Installation 4C4 Differential Case Assembly 4C4 Adjusting Backlash 4C4 Gear Tooth Contact Pattern Check 4C4 Carrier Case Assem bly 4C4 Axl...

Page 290: ...r to Adjusting Backlash This information can be used to deter mine the cause of the axle problem It will also help when setting up the shim packs for locating and pre loading the differential case 3 I...

Page 291: ...K TRUCK FRONT AXLE 4C4 3 Figure 1 Front Axle Com ponents K 15 25 Models...

Page 292: ...h deflector 43 Use J 8614 01 figure 12 Mount the left carrier case in J 36598 Be sure to use the adapter plate J 36598 6 for K15 25 models 27 Pinion 37 with shim 38 bearing cone 39 and spacer 40 Use J...

Page 293: ...K TRUCK FRONT AXLE 4C4 5 Figure 3 Front Axle Com ponents K35 Models...

Page 294: ...17 Damper Spring 53 Thrust Washer 18 Shift Shaft 54 Side Gear 20 Shim 55 Thrust Washer 21 Differential Pilot 56 Differential Pinion Bearing Gear 22 Sleeve 57 Spacer 23 Output Shaft 58 Bolt 24 Bolt 59...

Page 295: ...ving the Pilot Bearing Figure 10 Turning the Adjuster Plug K35 Models Figure 8 Removing the Left Shaft 61 A djuster Plug 63 Bolt 64 Lock T F 5858 J 36599 F 5857 F 5788 Figure 11 Removing the Pinion Nu...

Page 296: ...XLE F 5859 J 36598 6 F 5861 Figure 12 Removing the Pinion Flange Figure 15 Removing the Outer Pinion Bearing and Seal Figure 14 Removing the Pinion Bearing Figure 17 Removing the Side Bearings 39 Bear...

Page 297: ...e component repair after reassembly AXLE HOUSING Inspect l Carrier bore for nicks or burrs that would prevent the outer diameter of the pinion seal from sealing Remove any burrs that are found Bearing...

Page 298: ...wear scoring and damage to thrust surfaces Replace if needed Sleeve 22 and inner output shaft 23 for damaged splines and teeth Replace if necessary Spring 16 for breakage Solenoid 13 and indicator sw...

Page 299: ...ect Figures 1 through 4 and 11 23 and 24 Tools Required J 35512 Bearing Installer K15 25 Models J 36614 Bearing Installer K35 Models J 8614 01 Pinion Flange Remover J 36333 Seal Installer 1 Shim 38 to...

Page 300: ...ated In Bore Bearing Swung Out of Bore Nut W asher Pilot Flats Bearing Inner Pinion Bearing Outer Pinion J 21777 35 K 15 25 F J 29763 J 21777 8 K35 F_ 5869 J 36601 4 K15 25 J 36601 3 K35 A B C D E F 3...

Page 301: ...e 35 6 Bolts 34 The bolts have left hand threads J 8092 J 22761 K15 25 J 29710 K35 F 5871 Figure 26 Installing the Differential Side Bearing DIFFERENTIAL ASSEMBLY INSTALLATION Important Always install...

Page 302: ...r case half Place the differential assembly into the carrier case half which contains the pinion gear Turn the left sleeve 32 K15 25 models or adjuster plug 61 K35 models in until backlash is felt bet...

Page 303: ...olting conditions or foreign matter between the case and the ring gear Gear backlash should be between 0 08 0 25 mm 0 003 0 010 inch with a preferred F 5875 Figure 32 Measuring Backlash at the Pinion...

Page 304: ...eeth and compare with figure 34 ADJUSTMENTS AFFECTING TOOTH CONTACT Two adjustments can be made which will affect the tooth contact pattern These are backlash and the position of the drive pinion pini...

Page 305: ...Drive into place with a soft faced hammer 4 Shaft 59 with deflector 2 Drive in place with a brass hammer 5 Bearing 21 to the output shaft 23 Use J 33842 figure 35 6 Output shaft 23 to the carrier 7 V...

Page 306: ...els 1 27 mm 1 78 mm 2 29 mm 2 70 mm 3 30 mm 3 81 mm K35 models 1 80 mm 2 30 mm 2 80 mm 3 30 mm 3 80 mm 4 30 mm 4 80 mm Alternate Method Use ONLY if proper tools for calculating the shim size are not a...

Page 307: ...K TRUCK FRONT AXLE 4C4 19 C Measure w ith Axle Shaft Forced O utboard 1 Shaft 5 Tube 9 Carrier C onnector 23 O utput Shaft 29 Carrier Case F 5877 Figure 37 Measuring to Calculate Shim Size...

Page 308: ...Rotate the axle flange while moving the shift fork with the d rift The shift m echanism should work smoothly without bind 5 Solenoid 10 Apply sealer GM part no 1052942 Loctite 518 or equivalent to the...

Page 309: ...T SEAL REPLACEMENT Remove or Disconnect Figures 41 and 44 through 47 Tools Required J 8059 Snap Ring Pliers J 35910 Seal Clamp Tool J 36652 Swage Clamp Tool 1 Large swage ring 9 from the C V joint usi...

Page 310: ...Ring Needle Retainer Tri pot Joint Ball Needle Roller Spacer Ring Swage Ring 10 Tri pot Joint Seal 15 Ball 11 Seal Retaining Clamp 16 C V Joint Inner Race 12 Axle Shaft 17 C V Joint Cage 13 C V Joint...

Page 311: ...shaft 12 until retaining ring 14 is seated in groove on axle shaft Slide large diameter of the seal 13 with the large swage ring 9 in place over the outside of the C V joint race 18 and locate the li...

Page 312: ...and tighten by hand until snug Important Make sure that the seal 13 housing 18 and swage ring 9 all remain in alignment figure 47 Continue to tighten each bolt 180 at a time alternating until both sid...

Page 313: ...clamp 11 from the axle shaft 12 with a side cutter and discard Separate seal 10 from the tri pot housing 1 at the large diameter and slide the seal away from the joint along the axle shaft 12 Tri pot...

Page 314: ...age ring 9 in place over the outside of the tri pot housing 1 and locate the lip of the seal in the housing groove Position the tri pot assembly at the proper vehicle dimension as shown in figure 54 F...

Page 315: ...Bolts 40 30 A ctu a to r 22 16 Front Axle S w itch 5 0 45 Drain and Fill Plugs 33 24 Seal Retaining Clamp 136 100 AVAILABLE SHIM SIZES Pinion Shaft Shims K15 25 Models 0 020 0 024 inch 0 025 0 029 inc...

Page 316: ...5 25 Models 8 Pinion Bearing Remover K35 Models 9 Pinion Flange Remover 10 Case Bushing Replacer 11 Differential Side Bearing Installer K15 25 Models 12 Differential Side Bearing Installer K35 Models...

Page 317: ...ller K35 Models 21 Pinion Seal Installer 22 Axle Seal Installer K15 25 Models 23 Axle Seal Installer K35 Models 24 Holding Fixture and Pinion Service Tool 25 Dial Indicator Adapter 26 Side Bearing Adj...

Page 318: ...C4 30 K TRUCK FBOHT AXLE...

Page 319: ...d follow recommended procedures or personal injury may result Do not apply heat to accumulator Do not attempt to repair an inoperative accumulator always replace with a new accumulator Dispose of an i...

Page 320: ...uired J 26889 Accumulator Compressor J 24551 A Seal Protector J 25083 Seal Protector NOTICE For steps 8 and 9 see N otice on page 5 1 of this section Lubricate all the seals and metal friction points...

Page 321: ...A or J 25083 figure 8 12 Retainer 26 13 Spring 7 O ring 6 and plug 5 figure 3 14 Retainer 4 15 O ring 3 and accumulator 2 by using J 26889 and a C clamp figure 2 Depress the accumulator 2 16 Retainer...

Page 322: ...mall amount of air pressure to the front port 7 Seals 8 and 10 8 Spring retainer 7 and spring 6 5 3 Clean All the metal parts in denatured alcohol All the rubber parts in clean brake fluid Stained or...

Page 323: ...nal injury 5 Secondary piston 28 With the rear port plugged apply a small amount of air pressure to the front port 6 Secondary seals 29 from the secondary piston 28 figure 16 7 Spring retainer 26 and...

Page 324: ...es the year it was built a 5 means 1985 or a 6 means 1986 The last digits indicate the day it was built 271 means the 271st day of the production year NOTICE Do not hone the master cylinder bore When...

Page 325: ...piston return spring 50 CAUTION In the following step if air pressure is used to remove the secondary piston place the open end of the cylinder bore approximately 25 mm 1 inch from a padded workbench...

Page 326: ...brake fluid 1 Secondary spring 48 2 Secondary piston assembly 49 3 Piston return spring 50 26 Spring Retainer 27 Primary Seal 28 Secondary Piston 29 Secondary Seals F 04398 4 Primary piston assembly...

Page 327: ...across the front and rear housings to aid in assembly Use J 23456 to apply force in a counter clockwise direction to unlock the housings figure 21 4 Return spring 9 and power piston group 5 Power pis...

Page 328: ...lip with a thin layer of silicone grease Diaphragm and diaphragm support onto the power piston and pushrod assembly New diaphragm retainer 13 figure 22 Seat the retainer using J 28458 Filter 12 react...

Page 329: ...er 15 8 Primary diaphragm 16 and primary support plate 17 from the housing divider 19 9 Primary diaphragm 16 from the primary support plate 17 10 Secondary diaphragm 20 and secondary support plate 21...

Page 330: ...ir valve spring 26 7 Reaction piston 23 and reaction disc 22 into the reaction body 25 8 Reaction body 25 9 Reaction body retainer 24 Lubricate the inside diameter of the secondary dia phragm 20 lip i...

Page 331: ...rear housings using J 23456 fig ure 21 Stake the housing after locking Stake two tabs 180 degrees apart figure 23 Do not stake a tab that has been previously staked Assembly can be aided by connecting...

Page 332: ...y F 05894 Figure 28 Assembling the Secondary Diaphragm and Support SPECIFICATIONS N m Ft Lbs 30 22 149 110 Hydro Boost Housing to Cover Bolts Hydro Boost N u t 18 Secondary Piston Bearing 19 H ousing...

Page 333: ...e Push Rod H eight Gage 2 Piston Seal P rotector 3 Piston Seal P rotector 4 Power Brake B ooster D isassem bly and Reassem bly Tool 5 A ccum ulator Piston 6 Valve C onnector Seat Installer 7 Power Pis...

Page 334: ......

Page 335: ...er and Out of Round All M odels 6A 2 Cylinder Bore Reconditioning 2 5 L E n g in e s 6A 3 Cylinder Bore Reconditioning 2 8 L E n g in e s 6A 4 Cylinder Bore Reconditioning All Except 2 5 L and 2 8 L E...

Page 336: ...ommon examples are oil pans and rocker arm covers Anaerobic gasket eliminator hardens in the absence of air This sealer is used where two rigid parts such as castings are assembled together When two r...

Page 337: ...cylinder bore for out of round and taper as outlined previously 2 Refer to figure 2 Measure dimension A at 13 mm 1 2 inch below the head gasket surface Measure dimension B at 100 mm 4 inches below th...

Page 338: ...o figure 2 Measure for wear at the top of the bore point A and at the bottom point B Cylinder bores can be measured by setting the cylinder gage dial at zero in the cylinder at the point of desired me...

Page 339: ...ce finish marks in a cross hatch pattern of the specified angle 2 5 L 45 degrees 2 8 L 20 to 32 degrees All others 45 to 65 degrees 5 The finish marks should be clean but not sharp free from imbedded...

Page 340: ...to be reused place them in a rack so they can be installed in their original connecting rod and cap 3 Snap rings Use snap ring pliers 4 Piston pin Slide the pin from the piston 5 Piston from the conn...

Page 341: ...ure Figures 8 and 9 1 Piston pin diameter figure 8 Check against Specifications 2 Piston pin to piston clearance Measure the piston pin hole diameter figure 9 Subtract the piston pin diameter from the...

Page 342: ...led in the proper position 2 5 L Engines The raised notch side of the connecting rod must be opposite the notch in the piston crown 2 8 L E ngines The bevel on the connecting rod should face the outsi...

Page 343: ...he piston and connecting rod assembly from the tool and check the piston for freedom of movement on the piston pin Assembling the Piston and Connecting Rod 6 2 L Engines Assemble Figures 7 14 and 15 T...

Page 344: ...t the ring is free If binding occurs at any point the cause should be determined If binding is caused by the ring groove correct by depressing the groove with a fine cut file If the binding is caused...

Page 345: ...res 7 and 16 Ring end gap as follows 1 Select rings comparable in size to the piston being used 2 Slip the compression ring in the cylinder bore then press the ring down into the cylinder bore about 7...

Page 346: ...against the bearing Hold the puller screw with a wrench Turn the nut with a second wrench to pull the camshaft bearing from its bore R epeat th is procedure to rem ove the remaining inner camshaft be...

Page 347: ...IC LIFTERS Two types of hydraulic lifters are used in engines cov ered by this manual flat type and roller type Service procedures are similar for both types Hydraulic lifters are serviced only as an...

Page 348: ...ainer 225 Check Ball B 05236 230 221 223 225 227 229 djit I fL B Idj 222 224 226 228 221 Lifter Body 226 Plunger 222 Plunger Spring 227 M etering Valve 223 Check Ball Retainer 228 Pushrod Seat 224 Che...

Page 349: ...ical Insert the end of a 3 mm Vs inch drift into the plunger and press down solidly Do not attempt to force or pump the plunger At this point oil holes in the lifter body and plunger assembly will be...

Page 350: ...ors if used The rotators should rotate smoothly without bind JJJ Clean Figures 30 and 31 i Tools Required J 8089 Wire Brush J 8101 Valve Guide Cleaning Tool Carbon from the combustion chambers Use J 8...

Page 351: ...pecifications chart Springs should be replaced if not within 44 N 10 lbs of the specified load Valve spring length figure 34 Replace the spring if the length is not as specified Figure 32 Measuring St...

Page 352: ...ive removal of stock may result in damage to the valve seats 4 8 L small block and 7 4 L engines are equipped with hardened non replaceable valve seat inserts REAMING VALVE GUIDES The valve guides use...

Page 353: ...bearing and journal surfaces without damaging them Proceed as follows Q I Clean All oil from the crankshaft journal and main bearing inserts 0 11 Install or Connect Figure 37 Refer to the proper secti...

Page 354: ...oth upper and lower inserts as a unit 6 A standard or undersize bearing may produce the proper clearance Refer to the proper section for bearing availability If not it will be necessary to re grind th...

Page 355: ...ill be found sticking either to the journal or lower connecting rod bearing insert Do not remove it at this time Measure Figure 40 Gaging plastic at its widest point using the scale at the gaging plas...

Page 356: ...ing Tester 11 Intake O pening Cover 12 0 13 mm 0 005 inch Oversize Valve Guide Reamer 2 5 L Engines 13 Valve G uide Reamer Set All Engines Except 6 2 L and 7 4 L C onsists of J 5830 1 0 08 mm 0 003 in...

Page 357: ...ving Crankshaft 6A1 12 Main Bearing Removal Without Removing the Crankshaft 6A1 13 Camshaft Removal 6A1 13 Cleaning Inspection and Repair 6A1 14 Block 6A1 14 Cylinder B ores 6A1 14 Piston and Connecti...

Page 358: ...ification information refer to GENERAL INFORMATION SEC OA ENGINE LUBRICATION The oil pump is gear driven from the camshaft figure 1 Oil is drawn from the oil pan through a pickup screen and tube A byp...

Page 359: ...2 5 LITER L4 ENGINE 6A1 3 A Oil Pump Drive Gear O iling B Oil Pressure Sending Unit B 07950 Figure 1 Engine Lubrication Diagram...

Page 360: ...operations for which they are intended The use of these tools will also minimize possible damage to engine com ponents CLEANING Remove the engine accessories before cleaning to provide better access t...

Page 361: ...2 5 LITER L4 ENGINE 6A1 5 Figure 3 Cylinder Head Manifolds and Components...

Page 362: ...t Bearing 106 C am shaft Gear Spacing Ring 107 Key 108 C am shaft 109 C am shaft Bearing 110 Bolt 111 C oolant Pump 112 Gasket 113 Oil Pump Shaft Upper Bearing 114 Oil Pump Drive Shaft Gear 115 Oil Pu...

Page 363: ...2 5 LITER L4 ENGINE 6A1 7 F 05715 Figure 5 Block and Components...

Page 364: ...5 LITER L4 ENGINE 37 W asher 38 Bolt 42 Stud 43 Intake M anifold 44 Gasket F 01984 Figure 6 Intake Manifold Components 2 Bolt 3 Stud 5 Exhaust M anifold 7 Gasket F 01985 Figure 7 Exhaust Manifold Com...

Page 365: ...valve train component organizer rack can be made from a piece of wood as shown in figure 10 4 Pushrod cover nuts studs and the cover 50 U nscrew the four nuts from the cover attaching studs reverse tw...

Page 366: ...mponents Figure 13 Cylinder Head Components CYLINDER HEAD REMOVAL Remove or Disconnect Figure 13 1 Bolts 25 and 27 2 Cylinder head 24 Use care when handling the cylinder head to prevent damage to the...

Page 367: ...ING FLANGE OIL PUMP DRIVESHAFT REMOVAL Remove or Disconnect Figures 5 16 and 17 1 Ridge or deposits at the top of the cylinder as follows Turn the crankshaft until one piston is at the bottom of its s...

Page 368: ...the connecting rod and piston from the block being careful not to let the connecting rod contact the cylinder bore Loosely assemble the connecting rod cap 116 onto the connecting rod Take note of or m...

Page 369: ...MOVING THE CRANKSHAFT Remove or Disconnect Tool Required J 8080 Main Bearing Remover Installer 1 Main bearing caps 124 and 126 Check the main bearing caps for location markings Mark the caps if necess...

Page 370: ...perly if parts worn beyond accepta ble limits are reused BLOCK Clean Figure 5 1 Block 119 in solvent 2 Block gasket surfaces 3 Cylinder bores 4 Oil galleries and passages 5 Scale deposits from the coo...

Page 371: ...gures 23 and 24 Cylinder bore diameter using a telescoping bore gage Measure the bore parallel to the crankshaft at the gaging point which is 57 15 mm 2 25 inch from the top of the cylinder bore By me...

Page 372: ...mshaft End Play journals If runout exceeds 0 020 inch the camshaft is excessively bent and should be replaced along with the camshaft bearings Camshaft journal out of round Use a micrometer If the jou...

Page 373: ...the rear camshaft bearing 2 Front and rear bearings 109 using J 33049 Drive the bearings towards the center of the block 3 Center bearing using J 33049 Drive the bearing towards the rear of the engin...

Page 374: ...ket flanges for bending or damage Oil pan for rock damage or cracks Drain plug threads for stripping 77 Pump Body 79 Spring R etaining Pin 80 Spring 81 Cover Screws 82 Cover 83 Cover Gasket 85 Pressur...

Page 375: ...oil pump in a soft jawed vise Apply sealer to the end of the pipe Tap the pickup screen and pipe into place using tool J 21882 and a hammer The pump screen must be parallel with the bottom of the oil...

Page 376: ...HANICAL SEC 6A in this manual Assemble Figures 34 35 and 36 Tools Required J 8062 Valve Spring Compressor J 22330 Valve Stem Seal Checker and Tester 1 New valve stem seals 36 Lubricate the seal in ord...

Page 377: ...ct thermostat application Disassemble Figure 3 1 Bolts 8 and 9 2 Water outlet 10 3 Thermostat 12 4 Gasket 11 13 Inspect Figure 3 Water outlet 10 and housing 13 for cracks or damage Assemble Figure 3 1...

Page 378: ...earance Refer to GENERAL ENGINE MECHANICAL SEC 6A in this manual 3 Engine oil to the lower main bearing inserts 13 Main bearing caps except the rear cap with the selected lower main bering inserts 86...

Page 379: ...gure 40 Measuring Crankshaft End Play Tool Required J 34924 A Seal Installer Crankshaft rear oil seal using J 34924 1 Lubricate the seal inside diameter with engine oil 2 Slide the seal over the mandr...

Page 380: ...ber 1051396 or equivalent Coat the bearing journals with engine oil 1 Camshaft 108 into the block 119 Take care not to damage the camshaft bearings 109 103 Tim ing Marks C rankshaft Gear Thrust Plate...

Page 381: ...nd connecting rod to the proper bore With the connecting rod cap removed Install two sections of 10 mm 3 s inch rubber hose over the connecting rod studs Locate the piston ring end gaps as shown in fi...

Page 382: ...Connecting rod side clearance Use a feeler gage between the connecting rod and the crankshaft The co rre ct clea ra n ce is 0 15 0 60 mm 0 006 0 022 inch ENGINE LEFT ENGINE FRONT ENGINE RIGHT C E A O...

Page 383: ...pump body 2 Bearing 113 3 Plate 118 Apply RTV to the plate as shown in figure 52 4 Bolts 117 Tighten Bolts to 14 N m 120 in lbs CYLINDER HEAD INSTALLATION Install or Connect Figures 3 and 53 Make sure...

Page 384: ...rough 8 1 All head bolts to 25 N m 18 ft lbs in the specified sequence refer to figure 53 2 All head bolts except number 9 to 35 N m 26 ft lbs Number 9 bolt should be tightened to 25 N m 18 ft lbs Tig...

Page 385: ...studs 60 Tighten Studs 60 to 10 0 N m 90 in lbs 4 Pushrod cover 50 Apply a 5mm 3 ie inch bead of RTV sealant to the pushrod cover as shown in figure 56 5 Pushrod cover nuts 6 Pushrods 47 Seat the push...

Page 386: ...figure 60 3 Oxygen sensor wire 4 Thermae heat stove pipe FLYWHEEL INSTALLATION Install or Connect Figure 5 1 Spacer 68 2 Flywheel 67 3 Bolts 66 Tighten Flywheel bolts 66 Automatic transmissions 75 N...

Page 387: ...igure 59 Intake Manifold Installation Tightening Sequence Tighten bolts in num ber sequence as shown Or A group bolts can be tightened first then B group bolts Torque Specifications A G roup Bolts 50...

Page 388: ...ine several times Listen for any unusual noises or evidence that any parts are binding 4 Start the engine and listen for unusual noises Run the engine at about 1000 rpm until the engine is at operatin...

Page 389: ...ximum PISTON Clearance 0 00098 0 0022 PISTON RING C 0 M P R E S S I 0 N Groove Clearance Top 0 002 0 003 Second 0 001 0 003 Gap Top 0 010 0 020 Second 0 010 0 020 0 I L Groove Clearance 0 015 0 0 55 G...

Page 390: ...ournal Clearance 0 0007 0 0027 VALVE SYSTEM Lifter Type Hydraulic Lifter Leak Down Rate 12 90 Seconds with 50 lb load Lifter Body Diameter 0 8420 0 8427 Lifter Bore Diameter 0 8435 0 8445 Lifter Clear...

Page 391: ...to Crankshaft B o lt 220 160 Flywheel Bolts Autom atic 75 55 Flywheel Bolts M a nu al 90 65 Intake Manifold B olts 34 25 Exhaust Manifold Bolts Front and Rear Exhaust Tubes 43 32 Center Exhaust Tube...

Page 392: ...49 1 Piston Ring C om pressor 2 Front C rankshaft Seal Installer 3 Main Bearing Replacer 4 Valve Spring C om pressor 5 Cam Bearing Replacer 6 Oil Pump Pickup Tube Installer 7 Rocker Arm Cover Remover...

Page 393: ...nd Connecting Rod R em o val 6A2 10 Flywheel Rem oval 6A2 11 Crankshaft Removal 6A2 11 Main Bearing Removal Without Removing Crankshaft 6A2 11 Cleaning Inspection and Repair 6A2 12 Block 6A2 12 Piston...

Page 394: ...draulic lifters pushrods and ball type rocker arms The valve guides are integral in the cyl inder head The connecting rods are forged steel with precision in sert type crankpin bearings The piston pin...

Page 395: ...2 8 LITER V 6 6A2 3 Figure 1 Engine Lubrication Diagram...

Page 396: ...6A2 4 2 8 LITER V 6 Figure 2 Engine Lubrication Diagram...

Page 397: ...D Lubrication Ends 154 BTDC E C ylinders 2 4 And 6 F 190 Duration Of Lubrication G Lubrication Ends 134 BTDC H For C ylinders 1 3 And 5 J Views Show ing Interm ittent O iling Of C onnecting Rod Beari...

Page 398: ...ns for which they are intended The use of these tools will also minimize possible damage to engine components Some precision measuring tools are required for inspection of certain critical com ponents...

Page 399: ...rain 0Install or Connect 1 Oil pan drain plug and washer 2 Block drain plugs Tighten Block drain plug to 12 N m 9 ft lbs AIR INJECTION TUBE REMOVAL Remove or Disconnect Figure 5 1 Nut 75 2 Air injecti...

Page 400: ...emoved A stuck lifter can be removed using J 3049 figure 10 or J 9290 01 figure 11 CYLINDER HEAD REMOVAL Remove or Disconnect Figure 8 Rocker Arm Cover Installation 1 Bolts 2 Cylinder heads Use care w...

Page 401: ...oving the Hydraulic Lifter Typical FRONT COVER AND WATER PUMP REMOVAL Remove or Disconnect 1 Water pump 2 Front cover bolts 3 Front cover 4 Gasket OIL PAN REMOVAL Remove or Disconnect 1 Bolts and stud...

Page 402: ...top of the piston Perform the cutting operation with a ridge reamer figure 14 Turn the crankshaft until the piston is at TDC Remove the cloth and cuttings Use a silver pencil or quick drying paint to...

Page 403: ...he cylinder block Lift the crankshaft straight up taking care to avoid damage to the crankshaft journals and thrust flange surfaces A Front 85 Bolt 86 Main Bearing Cap 87 Bearing Insert 88 Oil Seal B...

Page 404: ...regularities may be carefully machined If more than 0 25 mm 0 010 inch must be removed replace the block BLOCK Clean 1 Block in solvent 2 Block gasket surfaces 3 Cylinder bores 4 Oil galleries and pas...

Page 405: ...into the bore top down until the skirt is 12 to 25 mm from the top of the block The feeler gage must be 90 degrees from the piston pin If the piston hangs on the feeler gage and does not fall free th...

Page 406: ...ear a new chain Likewise an excessively worn chain will rapidly wear a new set of sprockets Timing chain for wear If the chain can be pulled out more than 9 5 mm 3 s inch from the damper replace the c...

Page 407: ...indexed 2 Idler gear 188 drive gear 181 and shaft 103 from the pump body 3 Pressure relief valve retaining pin 185 4 Pressure relief valve spring 184 5 Pressure relief valve 183 103 Oil Pump Drive Sha...

Page 408: ...r mating surfaces These surfaces should be smooth and free from scoring or other damage Rocker arm areas which contact the valve stems and the sockets which contact the pushrods These areas should be...

Page 409: ...ker arm studs 90 using a deep socket 2 Pushrod guide 91 Install or Connect 1 Pushrod guide 91 2 Rocker arm studs 90 using a deep socket Tighten Rocker arm studs to 65 N m 48 ft lbs ASSEMBLY Install or...

Page 410: ...ely 0 75 mm 0 03 inch thickness between the spring and cylinder head NEVER shim the spring so as to give an installed height under the specified figure THERMOSTAT AND WATER OUTLET Remove or Disconnect...

Page 411: ...0 026 mm undersize Selective fitting of both rod and main bearing inserts is necessary in production to obtain close tolerances For this reason you may find one half of a standard insert with one half...

Page 412: ...t a time until the tight bearing is located Burrs on the bearing cap foreign matter between the insert and the block or the bearing cap or a faulty insert could cause a lack of clearance at the bearin...

Page 413: ...e dowel hole in the sprocket 4 Bolts 30 Draw the camshaft sprocket onto the camshaft using the mounting bolts Tighten Bolts 30 to 23 N m 17 ft lbs Chain damper 31 Bolts 32 Tighten Bolts 32 to 21 N m 1...

Page 414: ...th new and used standard size crankshafts n Install or Connect Tool Required J 8037 Ring Compressor Lubricate the cylinder walls lightly with engine oil Make sure the piston is installed in the proper...

Page 415: ...Figure 38 NOTICE Before installing the oil pan check that the sealing surfaces on the pan cylinder case and front cover are clean and free of oil Make sure that all RTV is rem oved from blind attachi...

Page 416: ...e new lifters with a narrow flat along the lower 3U of the body length This provides additional oil to the cam lobe and lifter surfaces Important Replace all hydraulic lifters if a new camshaft was in...

Page 417: ...the number four firing position The following valves may be adjusted Exhaust 4 5 6 Intake 2 3 4 INTAKE MANIFOLD INSTALLATION Install or Connect Figure 42 1 RTV to the front and rear sealing surfaces...

Page 418: ...ifold and cylinder head Install or Connect Figure 44 1 Manifold 2 Bolts and studs Tighten Bolts to 34 N m 25 ft lbs Figure 42 Intake Manifold Installation EGR VALVE INSTALLATION Install or Connect Fig...

Page 419: ...ual noises Run the engine at about 1000 RPM until the engine is at operating temperature Listen for improperly adjusted valves or sticking lifters and other unusual noises Check for oil and coolant le...

Page 420: ...PM 205 380 kPa a 2000 R P M 10 psi di 500 R PM 30 55 psi a 2000 R P M CYLINDER BORE Diameter 88 992 89 070 Out Of Round 0 02 Maximum Taper Thrust Side 0 02 Maximum PISTON Clearance 0 017 0 043 PISTON...

Page 421: ...mum Out of Round 0 005 Maximum Rod Bearing Clearance 0 035 0 095 Rod Side Clearance 0 16 0 64 CAMSHAFT Lift Intake 6 65 Exhaust 6 94 Journal Diameter 47 44 47 49 Journal Clearance 0 026 0 101 VALVE SY...

Page 422: ...Pan Bolts Rear Two 25 18 Oil Pan Bolts Studs and N u ts 10 7 Oil Pump B o lt 41 30 Camshaft Sprocket B o lts 23 17 Connecting Rod Cap N u ts 53 39 Oil Filter Adapter 85 63 Main Bearing Cap B o lts 95...

Page 423: ...Sprocket Installer 3 C rankshaft S procket Puller 4 Valve Spring C om pressor 5 Ring C om pressor 6 Main Bearing Rem over Installer 7 Pick up Tube and Screen Installer 8 H ydraulic L ifter Remover Sl...

Page 424: ...6A2 32 2 8 LITER V 6...

Page 425: ...Rear Crankshaft Oil Seal Retainer R em oval 6A3 9 Crankshaft Removal 6A3 9 Main Bearing Removal Without Removing C rankshaft 6A3 10 Cleaning Inspection and Repair 6A3 10 Block 6A3 10 Piston and Conne...

Page 426: ...ted to the valves by hydraulic lifters pushrods and ball type rocker arms The valve guides are integral in the cyl inder head The connecting rods are forged steel with precision in sert type crankpin...

Page 427: ...I 4 3 LITER V 6 6A3 3 Figure 1 Engine Lubrication Diagram B 07857...

Page 428: ...Tinning Chain Showing Main Gallery Oil Filter And Crankshaft Oil Feed F 05526 A Regulator Valve Shown In Open Position B Suction C Oil Pressure Switch D Valve Lifter Gallery E Main Oil Gallery F Bypas...

Page 429: ...essed air supply trays to keep parts and fasteners organized and an adequate set of hand tools An approved engine repair stand will aid the work and help prevent personal injury or damage to engine co...

Page 430: ...OVAL Remove or Disconnect 1 Intake manifold bolts 2 Intake manifold and gaskets VALVE TRAIN COMPONENT REMOVAL Remove or Disconnect Figure 4 1 Rocker arm nuts balls rocker arms and pushrods Important S...

Page 431: ...g cap bolt 2 Oil pump FRONT COVER REMOVAL Remove or Disconnect 1 Front cover bolts and reinforcements 2 Front cover 3 Front cover to block gasket 70 Gasket 71 Reinforcement B 07884 Figure 6 Oil Pan In...

Page 432: ...nd cuttings Mark the cylinder number on all pistons connecting rods and caps Starting at the front the cylinders on the left bank are numbered 1 3 5 and the right bank is numbered 2 4 6 2 Connecting r...

Page 433: ...SHAFT OIL SEAL RETAINER REMOVAL Remove or Disconnect Figure 12 1 Screws 81 2 Seal retainer 82 3 Gasket 84 CRANKSHAFT REMOVAL Remove or Disconnect Check the main bearing clearance before removing the c...

Page 434: ...vent Block gasket surfaces Cylinder bores Oil galleries and passages Scale deposits from the coolant passages Inspect 1 All expansion plugs for lack of fit or leakage 2 Valve lifter bores for deep scr...

Page 435: ...oolant passages of the intake manifold EGR passage of excessive carbon deposits Inspect Figure 14 Manifolds for cracks surface damage broken flanges and gasket Alignment of manifold flanges Use a stra...

Page 436: ...rings lubricant supply and cause premature bearing failure Inspect Water pump shaft for roughness and end play If the shaft does not turn smoothly or if there is excessive end play replace the water p...

Page 437: ...le installing the pump 7 Pickup screen and pipe if removed figure 18 If the pickup screen and pipe assembly was removed it should be replaced with a new part Loss of press fit condition could result i...

Page 438: ...GENERAL ENGINE MECHANICAL SEC 6A and perform the following igi 13 Clean Components as outlined Inspect Components as outlined Measure Valve stem clearance Valve spring tension and free length Other i...

Page 439: ...nch oversize stud figure 23 Coat lower end press fit area of rocker arm stud with hypoid axle lubricant Rocker arm stud Use J 6880 figure 22 Stud is installed to proper depth when the tool bottoms on...

Page 440: ...height under the specified figure THERMOSTAT AND WATER OUTLET Remove or Disconnect Bolts Water outlet Gasket Thermostat Inspect Water outlet for cracks Install or Connect Thermostat New gasket Water...

Page 441: ...e fitted to the proper journals 2 Crankshaft 3 Lower main bearing inserts to the main bearing caps Measure Main bearing clearance Refer to GENERAL ENGINE MECHANICAL SEC 6A Apply engine oil to the main...

Page 442: ...the camshaft lobes and journals with a high quality engine oil supplement GM Engine Oil Supplement or equivalent 1 Two or three 5 ie 18 bolts 100 125 mm 4 5 inches long into the camshaft threaded hol...

Page 443: ...The correct installation procedures w ith the p roper tool m ust be follow ed or m ovem ent of the inertia weight section of the hub will destroy the tuning of the torsional damper 2 Stud item A figur...

Page 444: ...ision insert type and do not use shims for adjustment DO NOT FILE RODS OR ROD CAPS If clearances are excessive install a new bearing Service bearings are available in standard size and 0 0014 mm under...

Page 445: ...ing rod cap nuts to 60 N m 45 ft lbs Measure Connecting rod side clearance figure 36 The proper clearance is 0 006 to 0 014 inch OIL PUMP INSTALLATION Install or Connect 1 Oil pump to the engine Align...

Page 446: ...6A3 22 4 3 LITER V 6 F 04488 A Forward B Sealant 70 Gasket 71 R einforcem ent Figure 37 Oil Pan Installation...

Page 447: ...rk on the torsional damper lines up with the O mark on the timing tab and the engine in the number one firing position This may be determined by placing fingers on the number one valve as the mark on...

Page 448: ...all FLYWHEEL INSTALLATION bolts y EGR VALVE INSTALLATION n Install or Connect 1 New gasket 2 EGR valve 3 Bolts Install or Connect 1 Flywheel 2 Flywheel bolts Bolts to 31 N m 23 ft lbs Tighten Bolts to...

Page 449: ...stand is not available the following procedure can be used after the engine is installed in the vehicle 2 Fill the crankcase with the proper quantity and grade of oil Important If a new camshaft or hy...

Page 450: ...at any parts are binding 5 Start the engine and listen for unusual noises 6 Run the engine at about 1000 rpm until the engine is at operating temperature 7 Listen for improperly adjusted valves or sti...

Page 451: ...4 3 LITER V 6 6A3 27 SPECIFICATIONS ENGINE SPECIFICATIONS F 6344...

Page 452: ...ervice Limit 0 001 Maximum Rod Bearing Clearance Production 0 0013 0 0035 Service Limit 0 0030 Rod Side Clearance 0 006 0 014 CAMSHAFT Lobe Lift 0 002 Intake 0 357 M Exhaust 0 390 Journal Diameter 1 8...

Page 453: ...n N uts 22 6 200 Oil Pan Bolts VI 3 _ 100 Oil Pump Bolt 90 65 Rear Crankshaft Oil Seal Retainer Screws and Nuts 15 3 135 Camshaft Sprocket Bolts 28 21 r Connecting Rod Cap Nuts 60 45 Oil Filter Adapte...

Page 454: ...8 Stud Remover 2 Valve Spring C om pressor 9 Reamer 0 003 inch oversize 3 Crankshaft Seal Installer 10 Reamer 0 013 inch oversize 4 Main Bearing Replacer 11 Stud Installer 5 Piston Ring C om pressor 1...

Page 455: ...kshaft 6A4 12 Camshaft Removal 6A4 13 Cleaning Inspection and Repair 6A4 14 Block 6A4 14 Main Bearing Cap Replacement 6A4 14 Cylinder B ores 6A4 15 Piston and Connecting Rod Assemblies 6A4 15 Intake a...

Page 456: ...screen and pipe figure 2 Pressurized oil is routed to the oil filter In case of excessive backpressure at the oil filter a bypass valve is provided This valve will allow oil flow to the main oil gall...

Page 457: ...4 8 LITER L6 6A4 3 Figure 2 Lubrication Diagram Front View...

Page 458: ...safely accomplish the operations for which they are intended The use of these tools will also minimize possible damage to engine components Some precision measuring tools are required for inspection o...

Page 459: ...4 8 LITER L6 6A4 5 11 12 13 9 15 sT iM V le JsJ 1 1 K V 7 B 07997 Figure 4 Cylinder Head Manifolds and Components...

Page 460: ...6A4 6 4 8 LITER L6 C 1 107 112 fK 108 3 109 165 129 B 05056 Figure 5 Block and Components...

Page 461: ...30 Upper Main Bearing Inserts 131 Drain Plug 132 Upper Seal Half 133 Upper Rear Main Bearing Insert 134 Dowel Pin 135 Lower Seal Half 136 Lower Rear Main Bearing Insert 137 Rear Main Bearing Cap 138 B...

Page 462: ...INJECTION TUBE REMOVAL 0Remove or Disconnect Figures 7 and 8 1 Air manifold 182 Unscrew the fittings Remove the air manifold 2 Air injection tubes 183 The air injection tubes are a push fit If the ai...

Page 463: ...UMP REMOVAL Remove or Disconnect Figures 5 and 11 1 Bolts 170 2 Water pump 171 3 Gasket 169 A B r O r A 22 mm 7 a B 55 mm 2 1 a C 40 mm 1 V2 D 10 mm 3 8 drill 25 mm 1 deep Holes for Pushrods E 22 mm 7...

Page 464: ...move the lifters one at a time and place them in the organizer rack The lifters must be installed in the same bore from which they were removed A stuck lifter can be removed using J 3049 figure 13 or...

Page 465: ...om the block 115 Push on the guide rod item A figure 17 to push the piston and connecting rod out Use the guide rod to prevent the connecting rod from scoring the cylinder bore Loosely assemble the co...

Page 466: ...130 133 136 and 153 If the main bearing inserts are to be reused mark them to insure they are instralled in their original positions before removal 4 Figure 19 Removing the Lower Seal Half CRANKSHAFT...

Page 467: ...pper main bearing inserts 130 Insert J 8080 into the crankshaft 154 oil hole figure 22 Rotate the crankshaft to turn the bearing insert out of the block CAMSHAFT REMOVAL Turn the camshaft 182 until th...

Page 468: ...ain bearing webs Engine mount bosses 4 Main bearing bores and main bearing caps 137 and 152 All main bearing bores should be round and uniform in ID at all bearing supports The area where the main bea...

Page 469: ...Inspect Ring fit INTAKE AND EXHAUST MANIFOLDS Disassemble Figure 4 1 Bolts 39 and washers 40 2 Nuts 32 3 Intake manifold 31 and exhaust manifold 37 4 Gasket 36 i j i Figure 25 Main Bearing Cap Shim L...

Page 470: ...Dial Indicator or equivalent Figure 28 Measuring Camshaft Thrust Plate Clearance Camshaft End Play Camshaft 182 runout figure 26 Mount the camshaft between centers or in V blocks Using J 7872 or equi...

Page 471: ...ge figure 28 The co rre ct clea ra n ce is 0 003 0 008 inch CAMSHAFT BEARINGS Refer to GENERAL ENGINE MECHANICAL SEC 6A Ijjjl Lv 13 TIMING GEAR COVER Clean Old gasket from the gasket surfaces Inspect...

Page 472: ...j Inspect Figure 32 Pump body 209 and cover 205 for cracks or other damage Gears 207 and 208 for wear Drive gear and shaft 208 for looseness in the pump body 209 Inside of the cover 205 for wear that...

Page 473: ...uts onto the rocker arm studs If not it is possible that the nut s could back off during engine operation causing loss of lash and valve train noise Pushrods for bending Roll the pushrod on a flat sur...

Page 474: ...threads or are loose in cylinder heads should be replaced New studs are available in 0 003 inch and 0 013 inch oversize 1 Place tool J 5802 01 over the stud to be removed Install a nut and flat washe...

Page 475: ...not hold a vacuum it may have been damaged or improperly installed A i j i i r i a 3 4 i J A G rind out th is portion B 05248 Figure 40 Scale for Checking Valve Spring Installed Height tp Measure Figu...

Page 476: ...r damage In general the lower inserts except the 1 bearing shows a greater wear and the most distress from fatigue If upon inspection the lower insert is suitable for use it can be assumed that the up...

Page 477: ...ure relief valve Use a screwdriver to pry it from the block Assemble Figure 45 Oil pressure relief valve Use a e inch thin wall deep socket to tap it into place ASSEMBLY OF ENGINE PRIOR TO ASSEMBLY Th...

Page 478: ...the seal mating ends Position the tip of the tool between the crankshaft 154 and the seal seat in the block 115 figure 47 Position the seal half between the crankshaft and tip of the tool Make sure th...

Page 479: ...nd to be excessive a new bearing plus both upper and lower inserts will be required Service main bearings are available in standard size and 0 001 inch 0 002 inch 0 010 inch 0 020 inch and 0 030 inch...

Page 480: ...ap or a faulty insert could cause a lack of clearance at the bearing CAMSHAFT INSTALLATION Install or Connect Figures 5 and 51 C oat the ca m sh aft lobes w ith Engine Oil S upplem ent GM part num ber...

Page 481: ...clearances are found to be excessive a new bearing will be required Service bearings are available in standard size and 0 001 inch and 0 002 inch undersize for use with new and used standard size cran...

Page 482: ...cylinder bore 3 Connecting rod cap 110 with the lower connecting rod bearing insert Measure Connecting rod bearing clearance Refer to GENERAL ENGINE MECHANICAL SEC 6A Then apply engine oil to the conn...

Page 483: ...Timing Marks Typical VALVE TRAIN COMPONENT INSTALLATION Important Replace all hydraulic lifters if a new camshaft was installed Install or Connect Figures 4 and 5 Lubricate the hydraulic lifters 100...

Page 484: ...iming mark on the vibration damper is aligned with the 0 mark on the timing marker 3 Position the dial indicator to m easure lifter movement and set indicator at zero Turn the crankshaft 360 degrees a...

Page 485: ...ion OFF or disconnected crank the engine several times Listen for any unusual noises or evidence that any parts are binding 4 Start the engine and listen for unusual noises Run the engine at about 100...

Page 486: ...Taper Relief Side 0 0005 Maximum Service 0 001 Maximum PISTON Clearance Production 0 0026 0 0036 Service Limit 0 0045 Maximum PISTON RING C o Groove niparanrp Production Top 0 0020 0 0040 M P 2nd R E...

Page 487: ...010 0 0026 Clearance Service Limit 0 0030 Maximum Rod Side Clearance 0 006 0 017 CAMSHAFT Lobe Intake 0 2315 Lift 0 002 Exhaust 0 2315 Journal Diameter 1 8677 1 8697 Camshaft Runout 0 020 Maximum Cams...

Page 488: ...Pump Bracket Nut to Main Bearing Cap Bolt 34 25 Oil Pump Cover Bolts 7 9 70 Oil Pan Bolts to front cover 5 1 45 to block p 4 20 9 0 80 to block 5 i 6 18 18 6 165 Cylinder Head Bolts left front bolt 1...

Page 489: ...ort Plate 4 C rankshaft Seal Installer and C entering Tool 5 Main Bearing Replacer 6 Piston Ring C om pressor 7 G uide Set 8 Vacuum Pump 9 H ydraulic L ifter Remover Slide Ham m er Type 10 H ydraulic...

Page 490: ...Ml...

Page 491: ...ecting Rod R em oval 6A5 9 Flywheel Rem oval 6A5 13 Rear Crankshaft Oil Seal Retainer Removal 5 0 L and 5 7 L Engines 6A5 13 Crankshaft Removal 6A5 13 Cleaning Inspection and Repair 6A5 14 Block 6A5 1...

Page 492: ...ith crankshaft thrust taken at the number five rear bearing The connecting rods are forged steel with precision in sert type crankpin bearings The piston pins are a press fit in the connecting rods Th...

Page 493: ...V8 ENGINE 6A5 3 Figure 1 Lubrication Diagram 5 0L and 5 7L Engines...

Page 494: ...6A5 4 V8 ENGINE Figure 2 Lubrication Diagram 5 0L and 5 7L Engines...

Page 495: ...row n o ff pressure fed connecting rod bearings CYLINDER WALL AND CAMSHAFT LOBE OILING FUEL PUMP PUSH ROD OILING OIL FILTER AND DISTRIBUTOR OILING CRANKCASE AND CRANKSHAFT OILING VALVE MECHANISM OILIN...

Page 496: ...etc should be made before removing accessories CLEANING Remove the engine accessories before cleaning to provide better access to engine exterior surfaces After removing the carburetor distributor fu...

Page 497: ...Exhaust Manifold 7 4L Engines J 9290 01 Valve Lifter Remover Slide Hammer Type 1 Nuts 40 balls 41 rocker arms 42 and pushrods 43 Note that on 7 4 L engines the exhaust valve pushrods are longer than t...

Page 498: ...or Disconnect Figure 14 Tool Required J 23523 E Torsional Damper Puller and Installer 1 Crankshaft pulley Figure 7 Intake Manifold 2 Torsional damper retaining bolt and washer 3 Torsional damper Use J...

Page 499: ...the timing chain should be replaced during assembly 4 Remove or Disconnect Figure 18 1 Bolts 100 2 Camshaft sprocket 101 and timing chain 102 together Remove or Disconnect Figure 19 Camshaft In s ta...

Page 500: ...e 11 Valve Train Component Organizer Turn the crankshaft until one piston is at the bottom of its stroke Place a soft cloth on top of the piston Using the manufacturer s directions install a ridge rea...

Page 501: ...cap at a time Place the piston at the bottom of its stroke Remove the connecting rod cap Install J 5239 onto the studs Use of the specified guide set will prevent the connecting rod from scratching t...

Page 502: ...gure 16 Oil Pan 7 4L Engines Figure 17 Front Cover Figure 18 Timing Chain and Sprockets Use the guide rod to prevent the connecting rod from scoring the cylinder bore Assemble the connecting rod cap o...

Page 503: ...L and 5 7 L ENGINES 4 4 Remove or Disconnect Figure 23 1 Screws and nuts 2 Seal retainer 121 3 Gasket 120 CRANKSHAFT REMOVAL Remove or Disconnect Figures 24 and 25 C heck the m ain b earing caps for l...

Page 504: ...e 24 Crankshaft and Components Typical CLEANING INSPECTION AND REPAIR A solvent tank large enough to hold the larger engine parts will be needed along with various bristle brushes and a gasket scraper...

Page 505: ...el 2 Main bearing cap bolts Tighten Bolts to Specifications Measure Figure 27 Main bearing vertical ID inside diameter Use an inside micrometer This dimension should be the same as the other main bear...

Page 506: ...intake manifold EGR passage if used of excessive carbon deposits I f Inspect Figure 28 Manifolds for cracks broken flanges and gasket surface damage Alignment of exhaust manifold flanges Use a straigh...

Page 507: ...32 i Tools Required J 5590 Crankshaft Sprocket Installer 5 0 L and 5 7 L engines J 22102 Crankshaft Sprocket Installer 7 4 L engines 1 Key if removed 2 Crankshaft sprocket Use J 5590 5 0 L and 5 7 L...

Page 508: ...vidence of coolant leakage the water pump shaft seal is leaking and the water pump should be replaced OIL PAN AND ROCKER ARM COVERS Clean Parts in solvent Remove all sludge and varnish Old gaskets fro...

Page 509: ...L and 5 7 L engines J 22144 Pickup Tube and Screen Installer 7 4L engines 1 Pressure relief valve 183 2 Spring 184 3 Washer 189 7 4 L engines 4 Spring retaining pin 185 5 Drive gear and shaft 181 6 Id...

Page 510: ...y can be returned to their original position at assembly CLEANING AND INSPECTION OF COMPONENTS Refer to GENERAL ENGINE MECHANICAL SEC 6A and perform the following Clean Components as outlined Inspect...

Page 511: ...r Head Gasket Rocker Arm Stud Valve Keepers Cap Rotator Spring with Damper 257 Seal 258 Exhaust Valve 259 Intake Valve 260 Pushrod Guide B 08019 Figure 38 Cylinder Head and Components 7 4L Engines ROC...

Page 512: ...nly 7 O ring seals 252 and valve keepers 251 Figure 39 Compressing the Valve Springs ASSEMBLY 5 0 L AND 5 7 L ENGINES Assemble Figures 37 39 and 43 Tools Required J 8062 Valve Spring Compressor J 2373...

Page 513: ...g seal onto the valve stem The seal is to be installed on the stem s lower groove Make sure the seal is flat and not twisted Apply a small amount of grease to the area of the upper valve stem groove A...

Page 514: ...Water outlet for cracks Thermostat Check 1 Suspend the thermostat and a thermometer in water w ith the th erm om ete r located close to the thermostat The thermostat must be completely submerged and t...

Page 515: ...Grind or replace the crankshaft if necessary Main bearing and connecting rod journals for taper and out of round figure 47 If the journals are tapered or out of round more than 0 001 inch grind or re...

Page 516: ...ssembly lubricant unless specified otherwise during assembly This will provide initial lubrication when the engine is started REAR CRANKSHAFT OIL SEAL INSTALLATION 7 4 L ENGINES An oil seal installati...

Page 517: ...oth upper and lower inserts will be required Service bearings are available in standard size and 0 001 inch 0 002 inch 0 010 inch and 0 020 inch undersize 0 009 inch is available for 5 0L and 5 7L eng...

Page 518: ...p b o lts to specifications 5 0 L and 5 7 L engines 110 N m 80 ft lbs 7 4 L engines 135 N m 100 ft lbs 2 With the crankshaft forced forward measure at the front end of the rear main bearing with a fe...

Page 519: ...the seal on J 35621 Position J 35621 against the crankshaft Thread the attaching screws into the tapped holes in the crankshaft T ighten the screw s se curely w ith a screwdriver This will ensure tha...

Page 520: ...the front seal crankshaft oil with engine oil 1 Gasket 90 2 Front cover 91 3 Timing tab 92 7 4 L engines 4 Bolts 93 Tighten Bolts 93 to specifications 5 0 L and 5 7 L engines 10 8 N m 96 in lbs 7 4 L...

Page 521: ...anufacturing for selective fitting Selective fitting of both rod and main bearing inserts is necessary to obtain close tolerances For this reason you may use for example one half of a standard insert...

Page 522: ...SEC 6A Then apply engine oil to the connecting rod bearing Tighten Connecting rod cap nuts to specifications 5 0 L and 5 7 L engines 60 N m 45 ft lbs 7 0 L engines 66 N m 48 ft lbs 44 Measure Figure 6...

Page 523: ...re 68 Oil Pan 7 4L Engines 4 Oil pan Make sure the gasket and seals stay in place 5 Clips 79 reinforcements 75 and bolts Tighten Bolts to specifications Oil pan to block bolts 18 1 N m 160 in lbs Oil...

Page 524: ...ght B 09572 Figure 70 Cylinder Head Bolt Tightening Sequence 1 5 0L and 5 7L Engines Important Replace all hydraulic lifters if a new camshaft was installed Install or Connect Figure 69 Lubricate the...

Page 525: ...ne 4 Intake manifold bolts Tighten Bolts to 48 N m 35 ft lbs Use the tightening sequence shown in figure 75 Figure 72 Timing Mark 3 With the engine in the number one firing position as determined abov...

Page 526: ...pecification 5 0 L and 5 7 L engines 7 3 N m 65 in lbs 7 4 L engines 13 0 N m 115 in lbs EXHAUST MANIFOLD INSTALLATION Install or Connect Figures 80 and 81 1 Exhaust manifold 1 2 Spark plug wire heat...

Page 527: ...mshaft or hydraulic lifters were installed add Engine Oil Supplement GM part no 1051396 or equivalent to the engine oil Fill the coolant system with the proper coolant With the ignition OFF or disconn...

Page 528: ...ifold Bolt Tightening Sequence 7 4L Engines 30 Nut 31 R einforcem ent 32 Rocker Arm Cover 33 Stud 34 Gasket 35 Clip 36 Bolt 37 W asher TB I E N G IN E S C A R B U R E TE D E N G IN E S F 04496 Figure...

Page 529: ...p Num ber and Location Varies B 08008 Figure 79 Rocker Arm Cover Installation 7 4L Engines C A S T IR O N M A N IF O L D TY P IC A L S T A IN LE S S S TE E L M A N IF O L D 1 Exhaust M anifold 2 W ash...

Page 530: ...6A5 40 V8 ENGINE Figure 81 Exhaust Manifold 7 4L Engines Figure 82 Water Pumps and Components...

Page 531: ...ust Side 0 0005 Maximum Taper Relief Side 0 001 Maximum Service 0 001 Maximum PISTON Clearance Production 0 0007 0 0017 Service Limit 0 0027 Maximum PISTON RING C 0 M Groove Production Top 0 0012 0 00...

Page 532: ...Production 0 00 5 Maximum Service Limit o oc 1 Maximum Rod Bearing Clearance Production 0 013 0 0035 Service Limit o oc 3 Maximum Rod Side Clearance 006 0 014 CAMSHAFT Lobe Lift 0 002 Intake 0 2336 0...

Page 533: ...elief Side 0 001 Maximum Service 0 001 Maximum PISTON Clearance Production 0 003 0 004 Service Limit 0 005 Maximum PISTON RING C 0 M P R E S S 1 0 N Groove Clearance Production Top 0 0017 0 0032 2nd 0...

Page 534: ...Service Limit 0 001 Rod Bearing Production 0 0009 0 0025 Clearance Service Limit 0 003 Maximum Rod Side Clearance 0 0013 0 023 CAMSHAFT Lobe Intake 0 2343 Lift 0 002 Exhaust 0 2530 Journal Diameter 1...

Page 535: ...All O thers 110 80 Oil Pump Cover B o lts 9 0 80 Flywheel Bolts 1 0 0 75 Spark Plugs 30 22 Water Outlet Bolts 28 21 Water Pump Bolts 40 30 Flywheel Housing Bolts 44 32 Oil Pan Drain Plug 28 20 Block D...

Page 536: ...k Up Tube Installer Mark IV Engines 5 Crankshaft Seal Installer 6 Piston Ring Compressor 7 Guide Set 8 Vacuum Pump 9 Hydraulic Lifter Remover Slide Hammer Type 10 Hydraulic Lifter Remover Plier Type 1...

Page 537: ...val 6A7 8 Front Cover Removal 6A7 8 Timing Chain and Sprocket Removal 6A7 8 Camshaft Removal 6A7 9 Oil Pan Removal 6A7 9 Oil Pump Rem oval 6A7 9 Piston and Connecting Rod R em o val 6A7 9 Flywheel R e...

Page 538: ...haft is supported by five plain type bearings and is chain driven Motion from the camshaft is transmit ted to the overhead valves by roller type hydraulic lifters pushrods and shaft mounted rocker arm...

Page 539: ...tools or their equivalents are specially designed to quickly and safely accomplish the operations for which they were intended The use of these tools will also minimize possible damage to engine compo...

Page 540: ...solvent cleaning are some acceptable methods Allow the engine to dry before beginning the work It is important that the engine be as clean as possible to prevent d irt from e ntering c ritic a l areas...

Page 541: ...nozzles Cap the lines and nozzles immediately Do not bend injection lines 3 Injection lines at the pump Cap the lines and pump fittings immediately Tag the lines for installation 4 Injection line brac...

Page 542: ...t Figure 7 3 Figure 6 Thermostat and Water Crossover ROCKER ARM AND PUSHROD REMOVAL Remove or Disconnect Figure 7 Bolts 54 Rocker arm assemblies 55 Mark the assemblies so they can be returned to the o...

Page 543: ...asket 78 Bolt 79 Torsional Damper 80 Bolt 81 W asher 82 W ater Pump 83 Oil F iller Neck 84 Nut 85 G rom m et 86 Bolt G M odels 87 Nut G M odels 88 Bolt Figure 8 Front Cover and Components Remove or Di...

Page 544: ...r bolts 2 Bolts 86 nut 87 and baffle 72 G models 3 Bolts 70 4 Front cover 71 TIMING CHAIN AND SPROCKET REMOVAL Measure Timing chain free play as follows 1 Mount a dial indicator to the front of the bl...

Page 545: ...reamer figure 13 Turn the crankshaft until the piston is at TDC Remove the cloth and cuttings 2 Connecting rod cap Check the connecting rod and cap for identification marks Mark the parts if required...

Page 546: ...TER DIESEL Figure 12 Oil Pan and Oil Pump A Use short pieces of 10 mm 3 s inch hose to protect the crankshaft journal B 08045 Figure 13 Removing the Cylinder Ridge Figure 14 Removing the Piston and Co...

Page 547: ...properly if parts worn beyond accepta ble limits are reused BLOCK 31 Clean Block in solvent Block gasket surfaces Cylinder bores Oil galleries and passages 13 5 Scale deposits from the coolant passag...

Page 548: ...a connecting rod is ever transposed from one block or cylinder to another new connecting rod bearings should be fitted and the connecting rod should be numbered to correspond with the new cylinder num...

Page 549: ...ocess Be sure to fit the correct cam bearing into the bore The cam bearing bores vary in size 1 Rear camshaft bearing Drive the bearing into place using the driver handle and J 6098 12 figure 18 Impor...

Page 550: ...h grease Important If a new front cover is installed the engine must be re timed as outlined later Clean Old gasket from the gasket surfaces on the water pump and water pump plate Important Do not imm...

Page 551: ...which contact the pushrods These areas should be smooth and free of damage and wear 170 Valve K e ep er 171 R otator 172 Shield 173 O Ring Seal 174 Seal 175 Valve Spring and D a m p e r k 175 174 1 7...

Page 552: ...e UNACCEPTABLE CRACK LENGTH OVER 5 mm p ie A Head Gasket Sealing Bead Mark B Fire Slot B 08399 Figure 23 Prechamber Inspection P re cham bers for cracks R eplace any pre chambers with facial cracks lo...

Page 553: ...alve spring using J 8062 figure 21 Compress the spring enough so the lower valve stem groove can be clearly seen Push a new seal onto the valve stem The seal is to be installed on the stem s lower gro...

Page 554: ...used in G models are shorter than nozzles used on C K R V P models They must not be in terchan g ed A ttem p ts to use the incorrect nozzle will damage the nozzle and or cylinder head INJECTION LINES...

Page 555: ...b ea rin gs are availab le in 0 013 mm 0 0005 inch and 0 026 mm 0 001 inch undersizes for select fitting to attain proper main bearing clearance Connecting rod bearings are available in 0 026 mm 0 001...

Page 556: ...ervice bearings are available in standard size and 0 013 mm 0 0005 inch and 0 026 mm 0 001 inch undersizes Selective fitting of both rod and main bearings inserts is necessary to obtain close toleranc...

Page 557: ...ct ends of the seal halves should now be at the four and ten o clock positions or at the eight and two o clock positions This is necessary to align the rear main bearing cap and seal lips NOTICE The m...

Page 558: ...ion insert type and do not use shims for adjustment DO NOT FILE RODS OR ROD CAPS If clearances are excessive install a new bearing Service bearings are available in standard size and 0 026 mm 0 001 in...

Page 559: ...re the right bank The numbers on the connecting rod and bearing cap must be on the same side when installed in the cylinder bore If a connecting rod is ever transposed from one block or cylinder to an...

Page 560: ...to the front face of the block the maximum amount with finger pressure on the outside of the chain 6 The total indicator travel can be noted With used parts the deflection must not exceed 20 3 mm 0 80...

Page 561: ...n the vertical 6 o clock position figure 41 If not remove J 333042 and rotate the engine crankshaft 360 degrees 4 Fasten J 33042 to the injection pump gear and tighten figure 42 5 Install one 10 mm nu...

Page 562: ...r tight until the injection pump timing is adjusted 5 Injection pump gear 106 Align the slot in the injection pump with the locating pin on the injection pump hub 107 Important Align the timinq marks...

Page 563: ...42 N m 32 ft lbs Water pump plate to front cover bolts to 22 N m 16 ft lbs 5 Oil filler neck 83 and nuts 84 HYDRAULIC LIFTER INSTALLATION Important Some engines w ill have both standard and 0 010 inch...

Page 564: ...plate CYLINDER HEAD INSTALLATION Install or Connect Figures 47 and 48 Tool Required J 29664 Manifold Cover Set 1 Head gasket to the block over the dowel pins Important The block gasket surfaces must...

Page 565: ...l the mark on the torsisonal damper aligns with the 0 mark on the timing tab Rotate the engine counterclockwise 88 mm 3 1 2 inches m easured at the torsional damper This measurement can be estimated b...

Page 566: ...nd clamps 47 5 Glow plug inhibit switch wire Figure 50 Applying Sealant to the Rocker Arm Cover DIPSTICK TUBE INSTALLATION Install or Connect 1 New O ring to the dipstick 2 Dipstick to the engine 3 Di...

Page 567: ...n Failure to do so w ill result in damage to the injection nozzle 1 Injection nozzle with gasket using J 29873 Figure 52 Injection Nozzles Tighten Nozzle to 70 N m 50 ft lbs 2 Fuel return hose 3 Fuel...

Page 568: ...to its correct position figure 58 3 Clamp and bolt Tighten Bolt to 42 N m 31 ft lbs 4 Speed sensor wire ENGINE ACCESSORY INSTALLATION Install the engine accessories as directed in the proper Truck Ser...

Page 569: ...Number 4 G Cylinder Number 3 H Cylinder Number 1 B 08131 Listen for sticking lifters and other unusual noises Check for oil and coolant leaks while the engine is running Using the proper Truck Service...

Page 570: ...6A7 34 6 2 LITER DIESEL LE FT SID E V D R IG H T SID E B 08023 Figure 55 Intake Manifold Installation Figure 57 Vacuum Pump...

Page 571: ...6 2 LITER DIESEL 6A7 35 Figure 58 Vacuum Pump Installed...

Page 572: ...nd 8 0 102 0 128 Zollner Pistons Bores 1 through 6 0 112 0 138 Bores 7 and 8 0 125 0 151 PISTON RING Compression Groove Clearance Top 0 076 0 178 2nd 0 039 0 080 Gap Top 0 30 0 55 2nd 0 75 1 00 Oil Gr...

Page 573: ...ntake Exhaust 45 Seat Angle Intake Exhaust 46 Seat Runout Intake Exhaust 0 05 Seat Width Intake 0 89 1 53 Exhaust 1 57 2 36 Stem Clearance Intake 0 026 0 069 Exhaust 0 026 0 069 Valve Spring Pressure...

Page 574: ...p Flange N u ts Oil Pan Drain P lug Block Drain P lu g Torsional Damper B o lt Water Pump Plate to Water Pump Bolts Water Pump to Front Cover B olts Water Pump Plate to Front Cover B o lts Hydraulic L...

Page 575: ...6 2 LITER DIESEL 6A7 39 SPECIAL TOOLS 1 Ring C om pressor 2 Tim ing Fixture 3 Nozzle Socket 4 Seal Installer 5 Torsional Dam per Remover 6 M anifold Cover Set F 05731...

Page 576: ......

Page 577: ...sembly 6C1 7 Cleaning Inspection and Repair 6C1 13 Pump System Check 6C1 14 Vacuum Break Checking Procedure 6C1 14 Idle Stop Solenoid Checking Procedure 6C1 15 Carburetor Reassembly 6C 1 16 Metering R...

Page 578: ...ation Figure 2 Model 1MEF Carburetor Front View F 01477 GENERAL DESCRIPTION Model 1MEF is a single stage single barrel carburetor of the 1 M family Figure 2 Letters following the 1M designate these fe...

Page 579: ...edle E Check Valve 234 Float Needle Seat F Valve C losing Spring F 01479 Figure 3 Float System 282 Je t M a in M etering 286 Idle Tube Assem bly 326 N eedle Idle M ixture 333 P lug Idle M ixture Needl...

Page 580: ...p Main Well A ir Bleed K Main Well to A spirator Bleed k J F 01481 Figure 5 Main Metering System 266 Rod Power Piston 274 Power Valve Piston Assem bly 276 Spring Power Piston 279 M etering Rod and Spr...

Page 581: ...ump Plunger Head B Pump Duration Spring C Pump Discharge Channel D Pump Jet 248 B 06645 Figure 7 Pump System 10 15 20 40 43 Fast Idle Cam Fast Idle Cam Link Choke Shaft Lever and Link Assem bly Choke...

Page 582: ...6C1 6 MODEL 1MEF CARBURETOR Figure 9 Monojet Model 1MEF...

Page 583: ...LY 100 AIR HORN ASSEMBLY 301 GASKET FLOAT BOWL TO THROTTLE BODY 101 GASKET AIR HORN TO FLOAT BOWL 305 SCREW ASSEMBLY FLOAT BOWL TO THROTTLE BODY 105 SCREW ASSEMBLY AIR HORN TO FLOAT BOWL LONG 310 LEVE...

Page 584: ...BRACKET Remove or Disconnect Figures 9 10 Loosen bracket attaching screw 421 bottom Remove bracket a tta c h in g screw s 420 and th ro ttle return spring anchor bracket 415 CHOKE COMPONENTS Vacuum Br...

Page 585: ...am Link Figure 14 Choke Housing Assembly 15 Fast Idle Cam Link 20 Choke Shaft Lever and Link Assem bly 20A Choke Link 35 Choke Housing and Bearing Assem bly F 01485 Figure 16 Air Horn Screw Location a...

Page 586: ...er rod lever 310 pow er rod link 314 and pum p link 317 as follow s A Close th ro ttle 240 Pum p Rod 274 Power Valve Piston A ssem bly 310 Pump and Power Rod Lever 311 Pump Lever A ttaching Screw F 04...

Page 587: ...1498 248 247 246 246 Pump Assem bly 247 Pump Plunger Cup 248 Pump Plunger Spring F 04359 Figure 19 Pump and Power Piston Linkage Figure 21 Pump Plunger Cup and Spring 279 M etering Rod and Spring A ss...

Page 588: ...sembly Remove or Disconnect Figure 24 Idle tube assembly 286 Invert carburetor and catch idle tube Pump Discharge Ball and Spring Remove or Disconnect Figure 24 1 Pump discharge spring guide 256 Use n...

Page 589: ...f flo a t bow l Use 0 375 inch s o ft w ire brush T u rn clockwise th ro u g h fu ll length o f th e pow er piston bore Turn brush several m ore turns to rem ove d irt and varnish M etal carburetor pa...

Page 590: ...2 3 I Fill em pty flo a t cham ber and pum p w ell w ith a clean solvent such as m ineral spirits Seal the pum p discharge passage on to p o f the pum p discharge spring guide w ith a fin g e r Use o...

Page 591: ...volts to the terminal and 12 volts to the solenoid body ELECTRIC CHOKE COVER AND STAT ASSEMBLY REPLACEMENT The electric choke cover and stat assembly may be removed for replacement or to access the c...

Page 592: ...aft lever 40 with hole in housing install choke cover with stat tang under stat lever B Rotate choke cover to line up notch in the cover with the projection on the housing 2 Choke cover retainers 50 a...

Page 593: ...ge spring guide 256 Install flush with casting surface Idle Tube Assembly 4 Install or Connect Figure 24 Idle tube assembly 286 Should be flush with casting surface Main M etering Jet and Float Needle...

Page 594: ...th e end o f th e metering rod hanger and the top of the casting Back out idle stop solenoid and hold th ro ttle valve closed Remove m etering rod from hanger Power Valve Piston A ssem bly Hold Down...

Page 595: ...shaft lever 20 Attach fast idle cam 10 to cam link 15 Unloader tang on cam should face outward Fast idle cam attaching screw 12 Sequence Choke Housing Install or Connect 4 Figure 14 1 2 Connect choke...

Page 596: ...inch plug gage th ro ug h the hole in the lever into hole in the choke housing If gage does not pass freely through both holes bend choke link at p oint shown in Figure 39 to align the holes CHOKE LI...

Page 597: ...ource and apply it again Check the gap once m ore and adjust as needed CHOKE UNLOADER ADJUSTMENT Adjust Figures 43 44 Hold the th ro ttle lever in the w ide open th ro ttle position Hold dow n on the...

Page 598: ...h Choke Link Fast Idle C a m 0 275 inch Vacuum B r e a k 0 200 inch Unloader 0 520 inch Figure 44 Specifications SPECIAL TOOLS 1 J 29030 B or BT 7610B or 1 Idle M ixture Socket Adjusting Tool 2 Hand O...

Page 599: ...e rs and a d d itio n a l application in fo rm a tion Federal indicates usage in all states except C alifornia MODEL MODEL NUMBER APPLICATIONS M4MEF 17085004 Federal Canada w ith Manual Transmission...

Page 600: ...ndary w e ll bleed adjusting screw Figure 5 are also factory set A ny a tte m p t to re a d ju s t th e m c o u ld re s u lt in e n g in e d a m a g e o r increased exhaust emissions IDLE STOP SOLENOI...

Page 601: ...dle M ixture Needle 422 Idle M ixture Needle Plug F 01885 Figure 3 Idle System A Part Throttle A djusting Screw Do Not Turn or Remove B Rich Stop A djusting Bushing Do Not Turn or Remove C Rich Stop A...

Page 602: ...r remove Secondary Well Bleed Adjust Spring Secondary Well Bleed Adjust Plug Secondary Discharge Nozzle Baffle Secondary Metering Rod Holder Secondary Metering Rod Air Horn Baffle Power Valve Piston A...

Page 603: ...idle m ix tu re nee dle p lu g 42 2 The d is ta n c e betw een the cuts depends on the size o f the punch to be used Cut dow n to the plug but not m ore than 1 8 beyond the locator points 3 Place a fl...

Page 604: ...6C2 6 MODEL M4MEF CARBURETOR Figure 9 Model M4MEF...

Page 605: ...ve Lever 360 Lever Secondary Throttle Lockout 67 Retainer Pump Stem Seal 364 Seal Intermediate Choke Shaft 68 Seal Pump Stem 370 Nut Fuel Inlet 200 Float Bowl Assembly 372 Gasket Fuel Inlet Nut 201 Ga...

Page 606: ...m break attaching screws 56 3 Primary side vacuum break assembly 55 and prim ary side vacuum break air valve lever lin k 58 AIR HORN COMPONENTS Secondary Metering Rods Remove or Disconnect Figure 13 1...

Page 607: ...o flo a t bowl countersunk screws 47 2 A ir horn assembly 10 Lift straight up Leave air horn gasket 201 on flo a t bow l NOTICE Use care w hen rem oving air horn to p reven t d am aging tubes pressed...

Page 608: ...ton stem and release it causing th e p o w e r p is to n to snap up against retainer Repeat until free NOTICE Do n o t use pliers on m e te rin g rod holder to rem ove p o w e r valve p iston as the h...

Page 609: ...lacem ent is required 4 Pump Discharge Bail and Pump Well Baffle Remove or Disconnect Figure 18 1 Pump discharge plug retainer 250 2 Pump discharge ball 251 Invert bow l and catch ball 3 Pump w ell b...

Page 610: ...Y F 06385 Figure 25 Choke Housing Assem bly Interm ediate choke lever 354 in v e rt bowl Interm ediate choke shaft seal 364 from flo a t bow l Do not remove bushing from flo a t bow l Disassemble Figu...

Page 611: ...electric choke cover and stat assembly flo a t and flo at b o w l insert pum p plunger seals etc in cleaner as th ey m ay becom e n o n fu n c tio n a l sw ell harden or distort The plastic cam on the...

Page 612: ...nd to push pump assembly down slowly in pump well Pump assembly should not travel to bottom o f w ell Only m ovem ent should be compressing of the duration spring If pump assembly moves down in well t...

Page 613: ...11 26 Tools Required J 9789 118 or BT 3553 Carburetor Holding Stand J 29030 B or BT 7610B Idle Mixture Socket Adjusting tool 1 Place carburetor on J 9789 118 or BT 3553 2 Idle mixture needles 420 and...

Page 614: ...4 LEVER INTERMEDIATE CHOKE 360 LEVER SECONDARY THROTTLE LOCKOUT 362 SEAL CHOKE HOUSING TO FLOAT BOWL HOT AIR CHOKE MODELS ONLY A TOOL J 23417 OR BT 6911 B LOCATING POINT F 01920 4 B Guide intermediate...

Page 615: ...p of float bowl If necessary use a small punch and hammer Pump Assemble Figure 18 Pump assembly 205 with new pump plunger cup 204 and spring 203 Install or Connect Figure 18 1 Pump return spring 206 2...

Page 616: ...mp lever 41 A Pump link in specified hole Specification is in fig ure 51 B Use J 25322 or BT 7523 or small punch to align hole in lever w ith hole in air horn casting C Use screw driver to push pum p...

Page 617: ...Cam Figure 45 Vacuum Break Inform ation Figure 46 Primary Side Vacuum Break Figure 47 A ir Valve Link Figure 48 Unloader Figure 49 Secondary T hrottle Lockout Figure 50 Specifications are in Figure 5...

Page 618: ...T 8427 TO BEND LEVER UP OR DOWN REMOVE BENDING TOOL AND MEASURE REPEATING UNTIL WITHIN SPECIFICATION 6 CHECK FLOAT ALIGNMENT 7 REASSEMBLE CARBURETOR J 34817 1 OR BT 8227 A 1 F 01925 Figure 40 Float Ad...

Page 619: ...ve Return Spring Adjustment 0 If riveted drill out and remove rivets Remove Choke Cover and Stat Assembly J 9789 111 or BT 3006M 2 Place Fast Idle Cam on high step against Cam Follower Lever Push up o...

Page 620: ...01929 0 Attach rubber band to Vacuum Break Lever of Intermediate Choke Shaft 0 Open Throttle to allow Choke Valve to close 0 Set up Angle Gage and set to specification 0 Place Fast Idle Cam on second...

Page 621: ...ber band to Vacuum Break Lever of Intermediate Choke Shaft 2 Open Throttle to allow Choke Valve to close 3 Set up Angle Gage and set to specification 0 Plug Vacuum Break Bleed Holes if applicable Appl...

Page 622: ...934 Figure 48 Air Valve Link Adjustment 0 Attach rubber band to Vacuum Break Lever of Intermediate Choke Shaft 2 Open Throttle to allow Choke Valve to close 3 Set up Angle Gage and set to specificatio...

Page 623: ...n of minimum clearance with Lockout Lever 7 Gage the clearance between Lockout Lever and pin Minimum must be 015 8 Adjust if necessary by filing end of F 01937 Figure 50 Secondary Throttle Lockout Adj...

Page 624: ...J 26701 A or BT 7704 6 J 23738 A or BT 7517 J 9789 111 or BT 3006M 1 Universal C arburetor Gage Set 7 2 C arburetor H olding Stand 8 3 Pump Lever Pin Punch Not Shown 9 4 Needle Seat Tool 10 5 Idle M...

Page 625: ...is stamped verti cally on the throttle body next to the vacuum ports figure 1 Refer to this number when servicing the throttle body If replacing the throttle body transfer the identification num ber t...

Page 626: ...NTROL IAC VALVE NOTICE The IAC valve is an electrical com po nent and must not be soaked in any liquid cleaner or solvent Otherwise damage could result Important All IAC valves on TBI Model 220 units...

Page 627: ...Body Throttle Body Attaching Fuel Meter Body Assembly Gasket Throttle Body to Fuel Meter Body G asket A ir Cleaner O Ring Fuel Return Line Nut Fuel Outlet O Ring Fuel Inlet Line Nut Fuel Inlet Gasket...

Page 628: ...iner Remove or Disconnect Figure 6 1 Long and short fuel meter cover screw assemblies 2 Fuel meter cover assembly 1 IACVAttaching Screw Assembly 2 External IACVO Ring 3 Grime Shield F 6739 NOTICE DO N...

Page 629: ...resence of dirt in fuel lines and fuel tank FUEL METER BODY Remove or Disconnect Figure 9 1 Fuel inlet and outlet nuts and gaskets from the fuel meter body assembly Discard gaskets Important Note loca...

Page 630: ...th automatic transmission fluid and push on nozzle end of injector until it presses against injector fuel filter Steel injector backup washer in counterbore of fuel meter body Lubricate new upper larg...

Page 631: ...er than 28mm 1 10 inches it must be reduced to prevent damage to the valve This may be done electrically using an IAC ISC m otor tester J 37027 or B T 8256K or m anually by exerting firm pressure as s...

Page 632: ...ody to Throttle Body S cre w 4 0 35 Fuel Inlet Nut to Fuel Meter Body 40 0 30 Fuel Outlet Nut to Fuel Meter B o d y 29 0 21 Fuel Meter Cover to Fuel Meter Body S crew s 3 0 28 TPS to Throttle Body S c...

Page 633: ...6C4 6 Pressure Regulator Assem bly 6C4 7 Fuel Injector Assem bly 6C4 7 Specifications 6C4 7 IDENTIFICATION The throttle body identification number is stamped on the fuel meter assembly below the fuel...

Page 634: ...Injector Retainer Idle Stop 9 Retainer Injector 24 Spring Idle Stop Screw 10 Fuel Injector 25 Sensor Throttle Position TPS 11 O Ring Fuel Injector Upper 26 Screw Washer Assembly 12 O Ring Fuel Injecto...

Page 635: ...trical connector on top of the injector and nozzle Also because the fuel injector is an electrical com ponent it should not be im m ersed in any type of liquid solvent or cleaner as damage may occur R...

Page 636: ...s present the whole fuel body casting must be replaced FUEL METER ASSEMBLY Remove or Disconnect Figure 7 1 Two fuel meter body attaching screw and washer assemblies 2 Fuel meter assembly from throttle...

Page 637: ...t Figure 10 1 Tube module assembly attaching screws 2 Tube module assembly 3 Tube module assembly gasket and discard Figure 8 Throttle Position Sensor TPS TBI 700 3 2 1 IACVAttaching Screw Assembly 2...

Page 638: ...ody The ECM then has a reset procedure to set the correct pintle position Proper idle regula tion should result Install or Connect Figure 9 1 Lubricate new O ring with transmission fluid and install o...

Page 639: ...Connect Figure 3 Lubricate new upper and lower O rings with auto matic transmission fluid and place them on injector Make sure upper O ring is in groove and lower one is flush up against filter Inject...

Page 640: ...6C4 8 MODEL 700 THROTTLE BODY...

Page 641: ...closed in a solid mold This unit along with the brush holder assem bly is attached to the slip ring end frame The regulator voltage setting is not adjustable The generator rotor bearings contain enoug...

Page 642: ...terminal on the generator From No 1 terminal the current goes through resistor R1 transistors TR3 and TR1 to ground turning on the indicator lamp Resistor R6 carries some of the indica tor lamp curren...

Page 643: ...e a fully charged battery and a 10 ohm resis tor rated at six watts or more between the gener ator No 1 terminal and the battery 2 Slowly increase the generator speed and observe the voltage 3 If the...

Page 644: ...ut 20 from the rectifier bridge 18 Rectifier bridge BAT terminal 1 and insulator 36 from the end frame Both Models 19 Bearing 31 Support the bearing housing from the inside Press out the bearing using...

Page 645: ...C ollar 16 Regulator 35 Rear C ollar 17 R ectifier Bridge 36 Insulator 18 C apacitor 37 Retainer 19 Nut 38 Brushes 20 BAT Terminal Nut 39 Drive End Frame 22 Pulley Nut 40 Slip Ring End Frame 23 W ashe...

Page 646: ...w 21 R ectifier Bridge Terminal Nut 31 Rear Bearing 22 Pulley Nut 32 Front Bearing 23 Wave W asher 33 Slip Ring 39 Drive End Frame 24 Bolt 34 Front C ollar 40 Slip Ring End Frame 25 Short Bolt 35 Rear...

Page 647: ...If the chipped area is small and the rest of the stator is OK repair the stator with insulating varnish Slip rings for scoring wear or pitting If the rings are dirty clean with a 400 grain or finer p...

Page 648: ...the grounded heat sink and the other two terminals or connec tors and between the insulated heat sink and each of three Figure 12 Rectifier Bridge Check terminals or connectors This makes a total of s...

Page 649: ...ator is inside the generator The regulator shuts off the current to the test lamp when the regulator setting is reached This voltage will vary with tem perature differences ASSEMBLY SLIP RING END FRAM...

Page 650: ...ctifier bridge terminals Three terminal nuts Tighten the nuts securely DRIVE END FRAME Assemble Figures 8 and 9 1 Bearing 32 Support the end frame Position the bearing with the sealed end toward the o...

Page 651: ...01240 12 SI CW 2 4 2 8 4 2 5 0 30 1600 94 6500 94 1101243 12 SI CW 2 4 2 8 4 2 5 0 23 1600 66 6500 66 1101244 12 SI CW 2 4 2 8 4 0 5 0 23 1600 66 6500 66 1101245 12 SI CW 2 4 2 8 4 2 5 0 30 1600 94 65...

Page 652: ...nmm...

Page 653: ...he on off time correct average field current for proper system voltage con trol is obtained At high speeds the on time may be 10 percent and the off time 90 percent At low speeds with high electrical...

Page 654: ...re 5 Press the bearing from the end frame 7 Slip ring end bearing 106 from the rotor using J 28509 A figure 6 DISASSEMBLY DRIVE END FRAME SLIP RING END FRAME Remove or Disconnect Figures 4 5 and 6 Too...

Page 655: ...Holder 229 Pulley 35 Insulated Screw 216 Drive End Frame 230 Fan 76 BAT Terminal 217 Slip Ring End Frame 305 Spring 92 Regulator Connector 220 Stator 306 Fan Collar 106 Slip Ring End Bearing F 07091 F...

Page 656: ...pockets are clean Brushes with a soft dry cloth 2 Brushes for wear If the brushes are worn to one half or less of their original length replace the brush holder assembly Use a retainer pin to hold the...

Page 657: ...lip ring If the lamp fails to light or if the ohmmeter reading is high infinite the winding is open Figure 10 Checking the Rotor Field Windings Grounded Winding Connect a test lamp or ohmmeter from on...

Page 658: ...s a total of six checks with two readings taken for each check Some digital ohmmeters cannot be used to check diodes in the rectifier bridge Consult ohmmeter manufacturers to determine ohmmeter capabi...

Page 659: ...the brush holder is in place After the rotor and drive end frame are installed the pin or toothpick will be pulled out allowing the brushes to contact the slip rings Stator 220 into the end frame ali...

Page 660: ...put AMPS 6500 RPM AMPS RPM Hot Ouput AMPS 1101263 CS 144 CW 1 7 2 1 5 7 7 1 50 120 6500 120 FASTENERS Pulley Nut N m 80 Ft Lbs 60 LUBRICATION For generator bearing lubrication use only Delco Remy Lubr...

Page 661: ...mpound between the flange and the field frame The starter motor bearings are lubricated during motor assembly and do not require service except during motor repair The part number can be found either...

Page 662: ...or terminal to the motor frame and an rpm indicator to measure armature speed Connect the motor and an ammeter in series with a fully charged battery of the specified voltage and a switch in the open...

Page 663: ...fields are suspected replace the field coil assembly and check for improved per formance DISASSEMBLY If the motor does not perform to specifications it may need to be disassembled for further testing...

Page 664: ...op col lar figures 8 and 9 Remove the pinion stop retainer ring from the groove in the armature shaft If the retainer ring is distorted during removal it must be replaced Slide the drive assembly and...

Page 665: ...end cover 67 3 End cover from the solenoid body U Inspect 1 Contact disc for wear Replace if worn INSPECTION AND REPAIR Clean All parts except the drive with mineral spirits Do not clean the parts in...

Page 666: ...hacksaw blade held on the armature parallel to the shaft The steel strip will vibrate on the area of the short circuit Shorts between the commutator bars are some times produced by brush dust or coppe...

Page 667: ...lights the field coils are grounded and m ust be repaired or replaced 14 Field coils for opens Connect a test lamp across the ends of the coils If the test lamp does not light the field coils are ope...

Page 668: ...g and a low reading indicates excessive resistance The windings resistance can be read directly using a digital ohmmeter that can measure tenths of an ohm The coil resistance can be determined by d iv...

Page 669: ...t Stop collar with the retainer ring figure 17 Place a suitable washer over the retainer ring end and squeeze the co lla r and w asher together Remove the washer Thrust collar 39 or pinion stop washer...

Page 670: ...olenoid motor terminal to the solenoid frame This will shift the pinion into cranking position and it will remain so until the battery is disconnected 4 Push the pinion back toward the commutator end...

Page 671: ...700 1114520 1998588 SD 300 70 110 6500 10700 1114563 1998589 SD 300 70 110 6500 10700 1114563 10455016 SD 200 50 75 6500 11900 1114530 10455017 SD 200 50 75 6000 11900 1114530 10455018 SD 200 50 75 65...

Page 672: ......

Page 673: ...e date code are stamped on the outside of the end plate The date code shows the year month and day of month of production DIAGNOSIS OF THE STARTING MOTOR STARTING MOTOR TESTS Before disassembling the...

Page 674: ...d armature or fields Check further after disassembly 3 Failure to operate with high current draw indicates a A direct ground in the terminal or brush assem bly b Seized bearings This should have been...

Page 675: ...t put your fingers between the armature and frame when removing or installing the armature assembly or injury could result 4 Field frame with armature and shield 77 from the drive end 5 Armature 9 fro...

Page 676: ...steel strip will vibrate on the area of the short circuit Shorts between the commutator bars are some times produced by brush dust or copper dust 4 Armature for opens Look for loose connections where...

Page 677: ...s section Note the ampere reading a high reading indi cates a shorted or grounded winding and a low reading indicates excessive resistance ASSEMBLY Install or Connect Figures 3 4 11 through 15 Lift th...

Page 678: ...e housing assembly figure 12 Press the bearing until it is 0 25 to 0 45 mm 0 009 to 0 010 inches below the casting face Add lubricant PN 10497186 or equivalent to the bearing 5 Lubricant PN 10497186 o...

Page 679: ...arts To check pinion clearance perform the following steps figures 16 and 17 1 Disconnect the motor lead connector from the sole noid motor terminal 2 Connect a 12 volt battery from the solenoid switc...

Page 680: ...Test 10 Volts Starter AMPS RPM Solenoid Part No Series Minimum Maximum Minimum Maximum Part No 9000735 PG 200 PMGR 50 90 2300 26600 Drive Speed SOLENOID SWITCHES Switch Pull In Winding Hold ln Winding...

Page 681: ...voltage of up to 35 000 volts is induced in the ignition coil secondary wind ing which is directed through the rotor and secondary leads to fire the spark plugs The capacitor in the distributor is fo...

Page 682: ...tem POLE PIECE AND COIL ASSEMBLY Figure 5 The pole piece and plate assembly often referred to as the pickup coil assembly consists of the following A sta Figure 3 Distributor with Separate Coil and Se...

Page 683: ...ver attaching bolts 32 and the cover 19 from the cap 4 Four attaching bolts from the coil 21 5 Coil wires from the connector housing with needle nose pliers figure 8 6 Coil and wiring from the cap 7 A...

Page 684: ...le figure 12 Check the vacuum advance unit if equipped and the pickup coil Refer to Inspection and Electrical Tests later in this section 18 Screw holding the capacitor to the housing 19 Capacitor 36...

Page 685: ...ch F 04235 DISTRIBUTORS 6D5 5 Figure 10 Removing the Roll Pin 14 M odule 36 C apacitor 37 Ignition C oil C onnector 38 Pickup C oil C onnector 39 Electronic Spark C ontrol C onnector F 04236 Figure 9...

Page 686: ...0 H ousing 31 W asher F 04238 Figure 12 Removing the Pickup Coil Connector Figure 14 Pickup Coil Removed 14 M odule 36 C apacitor 40 W iring Harness C onnector F 04237 41 C ontact Button and Spring 42...

Page 687: ...or damage Measure Tool Required J 24642 F Module Tester 1 Vacuum level of the vacuum advance unit with a vac uum source figure 16 Compare to Specifications at the end of this section The unit must fu...

Page 688: ...olts holding the coil to the cap 4 Cover 19 to the cap 23 with two bolts Figure 19 Checking the Ignition Coil Distributor Components 5 Lubricant into the lube cavity of the housing 30 only if needed R...

Page 689: ...butor cap 23 onto the housing 30 with the tab on the rim of the cap in the notch of the housing 19 Four spring clips on the cap onto the rim of the hous ing 20 Wiring harness connector to the terminal...

Page 690: ...mark on the rotor and on the shaft assembly 8 to help line up the rotor during reassembly 2 Rotor 10 9 3 Two bolts holding the Hall Effect swich if equipped 10 to the housing 11 Lift away the locking...

Page 691: ...ance of the ignition coil with an ohmmeter Connect the ohmmeter as shown in figure 28 step 1 Use the high scale The reading should be infinite If not replace the coil Connect the ohmmeter as shown in...

Page 692: ...ector to the module 7 Thin C washer into the coil 8 Shaft 26 into the housing 9 Tan washer 33 spring retainer 52 spring 51 and driven gear 29 onto the shaft Align the marks on the driven gear housing...

Page 693: ...DISTRIBUTORS 6D5 13 Figure 27 Testing the Pickup Coil Figure 28 Testing the Ignition Coil...

Page 694: ...nterm ediate Distributor RPM Degree Maximum Distributor RPM Degree Vacuum Model 1103717 650 0 3 1200 6 6 2050 11 3 1973682 1103719 700 0 2 1000 2 5 3000 4 8 1973682 VACUUM ADVANCE Start Maximum Max Di...

Page 695: ...A2 1 180C Automatic Transmission 7A3 1 HM 290 Manual Transm ission 7B1 1 HM 117 Manual Transm ission 7B2 1 New Process Manual Transmission 7B3 1 Borg Warner Manual Transm ission 7B4 1 New Process 205...

Page 696: ......

Page 697: ...ear And Output Shaft 7A1 23 Internal Transmission Speed Sensor Rotor 7A1 24 Input Carrier And Sun Gear 7A1 24 Input Clutch Assembly 7A1 25 Check Valve Retainer and Ball Assembly Replacement Procedures...

Page 698: ...7A1 2 700 R4 AUTOMATIC TRANSMISSION Figure 1 Case and External Parts J H 0 0 5 3 7 0 0 R 4 R 2...

Page 699: ...TER 85 CAP GOVERNOR THRUST 25 PISTON 2ND APPLY 86 PLUG CASE SERVO 26 SPRING SERVO CUSHION 88 GASKET SPACER PLATE TO CASE 27 RETAINER SERVO CUSHION SPRING 89 GASKET SPACER PLATE TO VALVE BODY 28 RING R...

Page 700: ...ngth should now be checked If the pin length is too short or too long be certain to inspect the 2 4 band and reverse input drum for damage or wear when disassembled Remove or Disconnect Figures 4 5 6...

Page 701: ...63 and 1 2 accumulator cover and pin assembly 62 7 1 2 accumulator piston 61 and seal 60 8 Spring 59 4 Remove or Disconnect Figures 12 13 14 and 15 1 Bolt 75 and manual detent spring assembly 709 2 El...

Page 702: ...lay Check As a diagnostic aid transmission end play should be checked prior to removing the internal parts If the end play is not within specifications you should watch for possible worn or misassembl...

Page 703: ...773 A end play should be 0 13 0 92 mm 005 036 in Oil Pump Assembly 1 2 3 4 5 Remove or Disconnect Figures 22 and 23 TOOLS REQUIRED J 24773 A Oil Pump Remover O ring seal 618 All oil pump bolts 5 and o...

Page 704: ...X 18 3 7 5 BOLT H E X H E A D M 6 X 1 X 35 3 7 6 BOLT H E X H E A D M 6 X 1 X 45 ______ _______________________________________________ JH 0 064 700R4 R1 Figure 12 Valve Body Bolt Locations 64 LIN K T...

Page 705: ...PER FLASH 91 55A 2 CHECKBALL 3RD CLUTCH ACCUM 55B 12 CHECKBALL FORWARD CLUTCH 55C 6 CHECKBALL DRIVE 3 91 10 CHECKBALL T V EXHAUST 359 CUP PLUG ORIFICE JH 0068 700R 4 ILL NO DESCRIPTION 4 7 A G O V E R...

Page 706: ...J 34627 Snap Ring Remover Installer 1 J 23327 Clutch Spring Compressor Bolts 715 and parking lock bracket 710 Important 3 4 5 6 Due to interference the parking pawl may have to be removed before remo...

Page 707: ...700 R4 AUTOMATIC TRANSMISSION 7A1 11 682 A JH 0 0 7 1 700R4 R2 Figure 20 Transmission Internal Parts...

Page 708: ...E R S E C L U T C H 6 2 5 RING 3RD 4 T H C L U T C H A P PLY 6 8 0 SPRING T R A N S M IS S IO N LO R E V E R S E 6 2 6 SPRING A S S E M B LY 3R D 4 T H C L U T C H C L U T C H S U P P O R T RETAINER...

Page 709: ...porosity damage or burrs pin damage 77 orifice cup plug 81 damaged or plugged Speedometer bore damaged sharp edges porosity All bolt holes for thread damage Heli coil to repair Cooler connectors 12 f...

Page 710: ...RIER 669 WASHER THRUST REACTION SHAFT SHELL 670 SHELL REACTION SUN 673 GEAR REACTION SUN 674 WASHER THRUST RACE REACTION SHELL 675 RACE LO REVERSE ROLLER CLUTCH 676 RING LO REVERSE SUPPORT TO CASE RET...

Page 711: ...h for leakage inside the case 5 If leakage is observed replace the third accumulator retainer and ball assembly Replacement Procedure Third Accumulator Retainer and Ball Assembly Remove or Disconnect...

Page 712: ...RVO Figure 30 Servo Bore A 3 4 ACCUMULATOR BORE 81 PLUG TRANSMISSION CASE ACCUM BLEED Figure 33 Leak Check 3rd A ccum ulator 9 5 mm 3 8 in Diameter Metal Rod A C D 80 3RD ACCUMULATOR BORE CASE INTERIO...

Page 713: ...ainer must line up with oil passage in the servo bore To be certain of correct installation depth scribe a mark at 42 0 mm 1 653 in on the 9 5 mm 3 8 diameter metal rod Use it to seat the third accumu...

Page 714: ...cks burrs or damage Parking pawl return spring 714 for distortion or damage Parking pawl pivot shaft 712 for damage and freeness of fit with the parking pawl 1 2 3 Install or Connect Figure 36 Parking...

Page 715: ...support Reaction carrier 681 onto the thrust bearing Lo and Reverse Clutch Spacer Plate Selection Measure Figure 41 and 42 TOOLS REQUIRED Scale and straight edge 1 To Measure for proper selective spa...

Page 716: ...ON GEAR SUPPORT TO CASE 697 DEFLECTOR O IL HIGH OUTPUT MODELS ONLY JH 0 092 700R 4 Figure 39 Reaction Internal Gear and Carrier Assembly Installation Figure 40 Reaction Internal Gear and C arrier Bear...

Page 717: ...CTIVE PLATE FROM TO IDENTIFICATION PLATE THICKNESS 2 9 5 5 9 m m 1 1 6 4 2 8 8 4 4 m m 1 1 3 6 NONE 1 671 mm 0 6 6 1 8 4 2 m m 0 7 3 2 8 8 4 4 m m 1 1 3 6 28 1 29m m 1 1 0 7 4 2 3 8 6 m m 0 9 4 2 5 5...

Page 718: ...MBLY LO REVERSE CLUTCH 680 SPRING TRANSMISSION LO REVERSE CLUTCH SUPPORT RETAINER JH0095 700R4 Figure 45 Lo and Reverse Clutch S upport Assem bly L9 Inspect Figure 48 Reaction Sun Gear 673 for nicked...

Page 719: ...st W asher Locations Input Internal Gear and Output Shaft Remove or Disconnect Figure 50 4 1 Retainer ring 668 from input internal gear 664 2 Reaction carrier shaft 666 from the input internal gear 1...

Page 720: ...r Connect Figures 50 and 52 1 Reaction shaft 666 into the input internal gear 664 2 Retainer ring 668 into the input internal gear 3 Input internal gear and shaft assembly into the sun gear shell inde...

Page 721: ...Disconnect Figure 55 Reverse input clutch assembly 605 from the input clutch assembly 621 Oil pump to selective washer thrust bearing 615 Selective washer 616 10 CASE TRANSMISSION 658 GEAR INPUT SUN 6...

Page 722: ...tch apply ring 625 and piston 623 inner and outer lip seals 624 from piston 9 Forward clutch to input housing O ring seal 622 10 Four turbine shaft oil seal rings 619 Inspect Figure 60 and 61 1 Input...

Page 723: ...Y 6 3 7 BEARING A S S E M B LY INPUT S U N G E A R 6 3 8 S N A P RING O V E R R U N CL H U B RET 6 3 9 HUB O V E R R U N C L U T C H 641 RETAINER R A C E A S S E M B L Y S P R A G 6 4 2 FO R W A R D S...

Page 724: ...ner and ball assembly Install or Connect Figures 56 and 60 1 Using same tools tap in retainer and ball assembly until shoulder is seated in housing 698 A LUBE PASSAGE 615 BEARING ASSEMBLY STATOR SHAFT...

Page 725: ...or Forward clutch housing to input clutch housing O ring seal 622 as shown lubricate with transmission fluid Inner and outer seals 629 on forward clutch piston seal lips must face away from the piston...

Page 726: ...______________________________________ J H 0 1 13 700R4 Figure 64 Overrun Piston Installed Figure 65 Overrun Clutch Retaining Ring Installed Figure 66 Input Hsg to O utput S haft Lip Seal Composition...

Page 727: ...6 700R 4 Figure 68 Input Sun Gear Thrust Bearing TH E N O T C H E S A B O V E E A C H S P R A G M U S T POINT UP A S S H O W N W H E N A S S E M B L E D INTO THE O U T E R R A C E 6 3 7 BEA RIN G A S...

Page 728: ...C LIPPED EDGE 642 FORWARD SPRAG ASSEMBLY 644 RACE FORWARD C L U T C H O U T E R I ___________________________ I _______________________ J H 0 1 18 700R 4 Figure 72 Check Sprag fo r Proper Operation A...

Page 729: ...the same spline configuration as apply plate 4 The 3 4 boost springs 600 5 The 3 4 clutch backing plate 655 and retainer ring 656 chamfered side up 600 SPRING ASM BOOST 3 4 CLUTCH ____________________...

Page 730: ...B M O DELS S TE P P E D A P P L Y PLATE 3 3 0 m m 130 1 1 FLAT ST E E L C L U T C H P LA T E S 1 97m m 077 1 1 FLAT STEEL C L U T C H PLATE 1 78m m 070 6 5 C O M P O S IT IO N F A C E D C L U T C H PL...

Page 731: ...e input housing Backing plate 613 Clutch plates 612 and belleville steel plate 611 Install J 23327 1 and J 25018 A compress the spring assembly Spring assembly retainer ring 610 and spring assembly 60...

Page 732: ...ETAINER 6 5 3 PLATE 3 R D 4T H CL A P PL Y STEPPED 6 5 4 PLATE A S S E M B L Y 3RD 4 T H C L U T C H 6 5 5 PLATE 3R D 4 T H C L U T C H B A C K IN G SEL 6 5 6 RING 3 R D 4T H C L U T C H B A C K IN G...

Page 733: ...ravel Reverse Input and Input Clutches Assemble Figures 89 and 90 1 Selective thrust washer 616 onto the input housing 2 Bearing assembly 615 inside black race goes toward the oil pump 3 Reverse input...

Page 734: ...VERSE INPUT CLUTCH BACKING PLATE SELECTION ALL MODELS B A C K I N G PLATE T R A V E L 1 PLATE THICKNESS IDENTIFICATION 7 6 0 m m 7 4 5 m m 2 9 9 2 9 3 5 6 9 4 m m 6 7 9 m m 2 7 3 2 6 7 6 P 6 2 8 m m 6...

Page 735: ..._________________________________________ JH 0103 700R 4 Figure 90 Reverse Input and Input Clutches 10 CASE TRANSMISSION 602 BAND ASSEMBLY 2 4 605 HOUSING DRUM ASSEMBLY REVERSE INPUT CLUTCH JH O I3 8...

Page 736: ...p cover 217 and pump body 203 for worn or damaged bushings see Bushing Replacement Procedure foreign material or debris porosity scored or irregular mating faces OIL PUMP ROTOR SELECTION CHART THICKNE...

Page 737: ...ST VALVE 2 2 2 VALVE T V BOOST 2 2 3 BUSHING T V BOO ST 2 2 4 RING OIL PUM P REVERSE BOOST VALVE RETAINING 2 2 5 RING OIL PUM P CONVERTER CLUTCH VALVE RETAINING 2 2 6 VALVE STOP 2 2 7 VALVE CONVERTER...

Page 738: ...18 into the pressure regulator bore 7 Pressure regulator valve spring 219 8 T V boost valve 222 into the T V bushing long land of the valve into the large hole of the bushing retain with petrolatum 9...

Page 739: ...UTCH V A LV E OUTER 229 SPRING CONVERTER CLUTCH V ALV E INNER ______________________________________________________JH 0 1 4 4 700R 4 Figure 98 Pressure Regulator and Converter Clutch Apply Valve Trai...

Page 740: ...should be 0 13 0 92 mm 005 036 in The selective washer which controls end play is located between the input housing and the thrust bearing on the oil pump hub If more or less end play is required sele...

Page 741: ...5 MM CONVERTER A 618 621 SHAFT TURBINE SEAL O RING TURBINE SHAFT SELECTIVE WASHER HOUSING SHAFT ASSEMBLY INPUT JH 0 1 0 9 700R 4 Figure 107 Turbine S h a ft 0 Ring Seal 605 670 A AS INSTALLED THESE TW...

Page 742: ...FXM YDM YMM YUM YELLOW YELLOW MCM PRM YPM YELLOW RED THM TLM OK GREEN LT BLUE YTM YZM YELLOW VIOLET HBM VIOLET YELLOW HDM DK GREEN DK GREEN YNM DK GREEN YELLOW YXM DK GREEN DK GREEN JH0151 700R 4 R 1...

Page 743: ...s for scoring nicks scratches Springs for damaged or distorted coils Auxiliary valve body 377 for porosity damaged machined surfaces Orifice cup plug 359 remove only if damaged 1 Remove or Disconnect...

Page 744: ...y 62 the three legs on the piston must face up toward the case when installed 4 The 1 2 accumulator spring 59 onto the piston 5 The 1 2 accumulator cover and pin assembly 62 onto the case torque to 11...

Page 745: ...700 R4 AUTOMATIC TRANSMISSION 7A1 49...

Page 746: ...O RE PLU G C U P 33 DIA S W IT C H A S M P R E S S U R E 3RD C LU T C H S W IT C H A S M P R E S S U R E 4 3 PULSE S W IT C H A S M P R E S S U R E 4TH C LU T C H S W IT C H A S M P R E S S U R E T C...

Page 747: ...61 3 6 2 3 6 3 3 6 4 3 6 5 3 6 6 3 6 7 3 6 9 3 7 0 371 JH01 54 700R 4 M r f V 340 M ANUAL VALVE 703 INNER DETENT LEVER 705 M AN UAL VALVE LIN K 709 M ANUAL DETENT SPRING ASSEMBLY JH 0 066 700R 4 64 LI...

Page 748: ...E A D M 6 X 1 X 16 3 7 5 BOLT H E X H E A D M 6 X 1 X 35 3 7 6 BOLT H E X H E A D M 6 X 1 X 45 3 7 7 A U X IL IA R Y A C C U M V A LV E B O D Y A S M 7 1 0 BRA C K ET P A R K IN G L O C K 7 1 5 BOLT...

Page 749: ...t cap onto the governor assembly 4 Retaining pins 84 into the thrust cap 85 and governor assembly 5 Stake the retaining pins 84 6 Check for free operation of the valve and weights Install or Connect F...

Page 750: ...river install new seal with J 21426 Speedometer driven gear 44 and assembly 43 or speed sensor 99 Retainer 40 bolt and washer 41 Outside electrical connector manual lever and nut Torque Converter Asse...

Page 751: ...em bly Measure Figure 138 Tool Required J 35138 Torque Converter End Play Checking Tool Install J 35138 and measure end play Omm 5mm 000 020 for 245mm Torque Converters Omm 6mm 000 024 for 298mm Torqu...

Page 752: ...131 Speedom eter Gear 687 SHAFT OUTPUT 688 CLIP SPEEDO DRIVE GEAR 689 GEAR SPEEDO DRIVE 689 JH01 60 700R 4 JH 0162 700R 4 690 SLEEVE OUTPUT SHAFT 691 SEAL OUTPUT SHAFT Figure 132 Speedom eter Gear Ins...

Page 753: ...D O DRIVEN G E A R FITTING BOLT W A S H E R A S S E M B L Y S E A L 0 RING SPEED O FITTING TO C A S E EXTEN SIO N FITTING A S S E M B L Y S P E E D O DRIVEN G E A R G E A R S P E E D O DRIVEN G O V E...

Page 754: ...T TO FORWARD HSG 6 2 4 SEAL 3RD 4TH CL INNER OUTER 6 9 2 6 2 9 SEAL FORW ARD CLUTCH INNER OUTER 6 9 6 631 SEAL OVERRUN CLUTCH INNER OUTER 6 3 7 BEARING ASSEM BLY INPUT SUN GEAR DESCRIPTION BEARING ASS...

Page 755: ...1 25 x 4 0 0 22 N m 18 LB FT D ET EN T SPRING TO VALVE B O D Y 1 M 8 1 75 x 2 0 0 22 N m 18 LB FT P U M P A S S Y TO C A S E 7 M 8 1 25 x 6 0 0 2 2 N m 18 LB FT V A LV E B O D Y TO C A S E 1 5 M 6 1...

Page 756: ...STATOR S H A F T F R O N T 90 BUSHING STATOR S H A F T R E A R 217 COVER PUMP 3 BUSHING O IL PUMP BODY 203 BODY PUMP 603 BUSHING REVERSE INPUT CLUTCH FRONT 605 HOUSING DRUM ASSEMBLY REVERSE INPUT CLUT...

Page 757: ...FT FRONT SHAFT REACTION CARRIER BUSHING REACTION CARRIER SHAFT REAR BUSHING REACTION CARRIER SHAFT FRONT SHAFT REACTION CARRIER BUSHING REACTION CARRIER SHAFT REAR J 34196 1 J 34196 1 BUSHING REACTION...

Page 758: ...OTH AS NECESSARY REMOVE AS SHOWN IN STALL AS SHOWN J 8092 36 EXTENSION CASE 38 BUSHING CASE EXTENSION J 8092 36 EXTENSION CASE 38 BUSHING CASE EXTENSION J 34196 10 J 8092 10 CASE TRANSMISSION 76 BUSHI...

Page 759: ...9 J 22976 1 and the governor bore w ith transmission fluid A fter each ten revolutions remove the reamer and dip in transmission fluid to clean A fter the reamer reaches the end of the bore and botto...

Page 760: ...shing Rem over A J 25019 4 A J 25019 16 End Play Fixture Adaptor Bushing Rem over Bushing Rem over E J 34725 A J 25019 14 Servo C ove r C om pressor _ e 3 _ A J 24036 J 29714 Turbine Shaft Seal Instal...

Page 761: ...it Assembly 7A2 24 Intermediate Clutch Assembly 7A2 24 Direct Clutch Assembly and Front B an d 7A2 25 Forward Clutch Assembly 7A2 25 Turbine Shaft Removal 7A2 26 Oil Pump Assembly 7A2 29 Pump Body 7A2...

Page 762: ...7A2 2 400 475 AUTOMATIC TRANSMISSION Figure 1 Case and External Parts H H 0021 400 R 3...

Page 763: ...T O S P A C E R PLATE 57 PLATE V A LV E B O D Y S P A C E R 58 G A S K E T S P A C E R P LA T E TO C A S E 59 B A LL 2 5 DIA 6 0 PISTON F R O N T S E R V O 61 W A S H E R F R O N T S E R V O 62 PIN F...

Page 764: ...magnet Front and Rear Servo Assemblies Remove or Disconnect Figures 7 and 8 1 Front servo piston assembly 60 62 retainer 63 and spring 64 2 Rear servo bolts 65 cover 66 and gasket 67 3 Rear servo acc...

Page 765: ...Valve Assem bly 2 Governor assembly 22 Internal Transmission Speed Sensor I T S S M odels 3 Retaining bolt 83 4 Speed sensor 81 with o ring 82 Front End Play Check 2 3 4 6 7 Measure Figures 13 and 14...

Page 766: ...____________________________________H H 0027 400 Figure 8 Rear Servo Assem bly Figure 9 Installing Servo Pin Gage J 2 1 3 7 0 1 0 u G A G IN G S T E P S LO C A T E D ON T H REE SIDES OF T O O L J H 0...

Page 767: ...e 20 and 21 1 Nut 703 and pin 704 2 Detent lever 707 and actuator 708 3 Bolts 701 and parking pawl bracket 702 5 Shaft 712 and plug 709 Forward C lutch Assembly Remove or Disconnect Figure 22 Forward...

Page 768: ...IDENTIFICATION NOTCH AND OR NUMERAL 074 078 None 1 082 086 ON SIDE OF 1 TAB 2 090 094 ON SIDE OF 2 TABS 3 098 102 ONE END OF 1 TAB 4 105 110 ON END OF 2 TABS 5 1 14 118 ON END OF 3 TABS 6 H H 0036 400...

Page 769: ...G LOCK 709 PLUG PARKING PAWL SHAFT 710 SPRING PARKING PAWL RETURN 711 RETAINER PARKING PAWL SHAFT 712 SHAFT PARKING PAWL LOCK 713 PAWL PARKING LOCK H H 0102 400 Figure 19 Pump Assembly and Selective T...

Page 770: ...sembly Remove or Disconnect Figures 25 26 27 and 29 Tool Required J 6116 Gear Unit Holding Fixture J 21795 Main Shaft Tool 1 Center support bolt 79 2 Snap ring 645 3 Center support assembly 646 654 an...

Page 771: ...amage Heli coil to repair Air check all oil passages see Diagnosis Section for oil passage identification Front and rear servo bores for damage porosity or burrs Cooler connectors 16 for damage proper...

Page 772: ...LATE 23 BOLT HEX HD 3 8 16 X 1 CASE EXTENSION TO CASE 26 SEAL CASE EXTENSION 27 CASE EXTENSION ASSEMBLY 28 BEARING ASSEMBLY 29 SPACER BEARING 30 BUSHING CASE EXTENSION 31 RING INTERNAL SNAP 32 SEAL CA...

Page 773: ...400 475 AUTOMATIC TRANSMISSION 7A2 13 Figure 29 Internal Parts H H 0 0 4 3 4 0 0 R 2...

Page 774: ...ERMEDIATE CLUTCH 650 PISTON INTERMEDIATE CLUTCH 651 SEAL INTERMEDIATE CLUTCH INNER 652 SEAL INTERMEDIATE CLUTCH OUTER 653 RING OIL SEAL PUMP COVER 654 SUPPORT CENTER 655 BUSHING 656 WASHER THRUST SUPP...

Page 775: ...713 711 705 ILL NO DESCRIPTION 703 NUT HEX 3 8 24 704 PIN INSIDE DETENT LEVER 705 SHAFT MANUAL 706 SEAL ASSEMBLY MANUAL SHAFT 707 LEVER INSIDE DETENT 708 ACTUATOR ASSEMBLY PARKING LOCK 709 PLUG PARKIN...

Page 776: ...damaged teeth cracks Output carrier assembly 675 for damaged lugs pinion gear damage excess pinion washer wear end play should be 009 024 228 610 mm Front internal gear ring 673 for damage cracks SPEE...

Page 777: ...TO SUN GEAR BEARING NEEDLE THRUST RACE THRUST BEARING TO REAR INTERNAL GEAR GEAR REAR INTERNAL RACE THRUST BEARING TO SUN GEAR BEARING NEEDLE THRUST RACE THRUST BEARING TO OUTPUT SHAFT RING SNAP BUSHI...

Page 778: ...379 j fx o 3___4 B M L i i ii c f 676 1 11 rif oil t t H 675 CARRIER ASSEMBLY OUTPUT 676 WASHER PINION THRUST BRONZE 677 WASHER PINION THRUST STEEL 678 ROLLER NEEDLE BEARING OUTPUT CARRIER 679 PINION...

Page 779: ...EXCESSIVE REMOVAL OF MATERIAL WILL WEAKEN CARRIER Pinion pins 671 from carrier 666 Pinion gears 669 thrust washers 667 670 and roller needle bearings 668 Inspect Pinion pocket thrust surfaces for burr...

Page 780: ...t Do not remove three screws holding roller clutch race to center support 654 Figure 46 Center Support and Intermediate Clutch Piston L Inspect Figures 46 and 47 Roller clutch race inside center suppo...

Page 781: ...PORT CENTER HH 0108 400 R1 Figure 4 9 Air Checking Intermediate Clutch Low Roller C lutch Assem bly Install or Connect Figures 50 and 51 1 Thrust washer 656 in recess of center support 654 2 Spacer 65...

Page 782: ...Center piston seal 632 from housing 633 L Inspect Figure 52 Roller assembly 634 for damaged rollers cage or distorted springs or sprag assembly 635 Clutch housing 633 for cracks wear and proper openi...

Page 783: ...INER INTERMEDIATE CLUTCH 638 RING SNAP H H 0062 400 R 2 Figure 54 Installing Direct Clutch Piston Figure 53 Direct Clutch and Intermediate Roller Assembly J 21409 362 ILL NO DESCRIPTION 629 PISTON DIR...

Page 784: ...h plates 642 for wear pitting flaking or cracks in lining Clutch plates 643 for discoloration scoring or cracks Backing plate 641 for burrs and dirt 637 638 633 HOUSING DIRECT CLUTCH 634 ROLLER ASSEMB...

Page 785: ...P HH0061 400 R1 Figure 58 Direct and Intermediate Roller Clutch Assembly Figure 5 9 Air Check Direct Clutch A APPLY AIR HERE 633 HOUSING DIRECT CLUTCH 654 SUPPORT CENTER A H H 0066 400 2 Forward clutc...

Page 786: ...ne S haft Removal 1 Place housing 602 in mechanical press with turbine shaft 601 down 2 Remove turbine shaft 601 by placing 3 8 drive extension on end of shaft and pressing out Forward Clutch Assembly...

Page 787: ...04 and 605 on piston 606 with lips facing away from spring pockets 3 Lubricate center piston seal 603 and groove 4 Center piston seal 603 onto clutch housing 602 with lip facing up 5 J 21409 over clut...

Page 788: ...n Oil Pump Assembly Disassemble Figure 71 NO TICE Regulator spring 214 is tightly compressed Use care when removing bushing 212 Retaining ring 211 Pressure regulator and boost valve assemblies 212 217...

Page 789: ...201 lubricate drive gear 209 and driven gear 210 with automatic transmission fluid 2 Pressure regulator valve 217 into bore 3 Pressure regulator spring spacer s 216 if used 4 Spring retainer washer 21...

Page 790: ...smission case 10 3 Bolts 4 except bolt in 10 o clock position torque to 15 20 lbs ft 20 27 N m Important If turbine shaft cannot be rotated as pump assembly is being pulled into place the forward and...

Page 791: ...6 18 X 1 00 COVER TO BODY 204 BOLT 5 16 18 X 1 50 COVER TO BODY 205 BOLT 5 16 18 X 1 75 COVER TO BODY H H 0078 400 Figure 74 Assembling Pump Body and Pump Cover 4 BOLT HEX HD 5 1 6 18 X 1 406 PUMP TO...

Page 792: ...e and free operation in bore of sleeve 407 Driven gear 409 for damage Springs 403 for distortion or damage THICKNESS INCH COLOR NO 060 064 Yellow 0 071 075 Blue 1 082 086 Red 2 093 097 Brown 3 104 108...

Page 793: ...1 Governor driven gear 409 in sleeve and carrier assembly 407 2 Drill new 1 8 125 hole in sleeve and carrier assembly 407 and governor driven gear 409 90 degrees from original hole 3 Pin 408 in new 1...

Page 794: ...linkage Fasten with two 5 16 18 x 1 screws and torque to 18 lbs ft 24 N m Make sure J 21370 10 moves freely in the tool and pin bore To determine correct pin length apply 25 lbs ft Torque to the nut o...

Page 795: ...rear band apply pin 77 65 BOLT HEX HD 5 16 18 X 62 SERVO COVER TO CASE 66 COVER REAR SERVO 67 GASKET REAR SERVO COVER 68 RING RETAINING SERVO PISTON 69 PISTON ACCUMULATOR REAR SERVO 70 SEAL REVERSE SE...

Page 796: ...g 1 2 3 4 Install or Connect Figures 90 91 and 92 Front servo piston spring 64 and retainer 63 Washer 61 piston pin 62 and piston 60 make certain tapered end contacts band Front servo assembly into ca...

Page 797: ...400 475 AUTOMATIC TRANSMISSION 7A2 37 Figure 93 Control Valve Assem bly...

Page 798: ...bly 1 2 3 4 5 Disassemble Figures 93 94 and 95 J 21885 Piston Installer Install J 21885 on front accumulator piston Retainer 302 and front accumulator piston 303 Accumulator spring 305 Accumulator pi...

Page 799: ...Figure 99 for wear or damage bearings 28 spacer 29 bushings 30 and 33 See Bushing Replacement Install or Connect Figure 28 Tool Required J 214426 Rear seal installer 1 New rear seal 26 with J 214426...

Page 800: ...ASSEMBLY 29 SPACER BEARING 30 BUSHING CASE EXTENSION 31 RING INTERNAL SNAP 32 SEAL CASE EXTENSION TO CASE 33 BUSHING 34 GASKET CASE TO EXTENSION H H 0034 400 R 1 Figure 99 Installing Case Extension 3...

Page 801: ...hould Not Be Replaced The fluid has an odor discolored or no evidence of metal or clutch plate material Drain out as much fluid as possible Replace the oil filter and pan gasket Fill to proper level R...

Page 802: ...ON H H 0106 400 3 BUSHING PUMP BODY 30 BUSHING CASE EXTENSION 33 BUSHING 206 BUSHING STATOR SHAFT REAR 220 BUSHING STATOR SHAFT FRONT 655 BUSHING 663 BUSHING STATOR SHAFT MAIN SHAFT 690 BUSHING OUTPUT...

Page 803: ...400 475 AUTOMATIC TRANSMISSION 7A2 43 Figure 104 Bushing Replacement Procedure...

Page 804: ...WN INSTALL AS SHOWN J 8092 J 21465 6 654 654 SUPPORT CENTER 655 BUSHING J 8092 J 21465 6 655 654 J 2619 J 2619 4 J 21465 1 6 J 8092 J 21465 1 690 BUSHING OUTPUT SHAFT 691 SHAFT OUTPUT _____________ I_...

Page 805: ...400 475 AUTOMATIC TRANSMISSION 7A2 45 BUSHING REPLACEMENT PROCEDURE PROTECT PARTS WITH WOOD BLOCKS OR CLOTH A S NECESSARY I Figure 106 Bushing Replacement Procedure...

Page 806: ...ATOR RETAINER TO CASE SCREW 20 27 15 20 20 27 15 20 SPEEDOMETER DRIVEN GEAR RETAINER TO CASE SCR EW 5 8 4 6 5 8 4 6 OIL PAN TO CASE SCREW 8 14 6 10 4 2 2 3 16 EXTENSION HOUSING TO CASE SCREW 27 34 20...

Page 807: ...lignment Band Transmission Modulator Checking Tool J 6125 B J 21368 J 24466 Dial Indicator Set Band to Apply Pin Gauge Used with J 21370 6 Oil Pump Remover End Play Checking Fixture J 8001 J 21370 10...

Page 808: ...J c I i sal...

Page 809: ...r damage Thrust washer surfaces The thrust washers and bearing surfaces may appear to be polished This is a normal condition and should not be considered damage Snap rings Do not over expand snap ring...

Page 810: ...IPE H 180C 91 Figure 2 Hookup of Solenoid Pipes and Electrical Wires 3 Servo piston snap ring 4 Slowly release servo piston Figure 4 Check Balls and Servo Piston Selector Lever and Electrical Connecto...

Page 811: ...Required J 7004 Slide Hammer J 23129 Converter Housing Seal Remover Bolt and speedometer guide bracket Speedometer driven gear assembly and seal ring Extension housing seal using J 23129 and J 7004 if...

Page 812: ...nverter housing with the oil pump and reverse clutch assembly 6 Selective washer Remove or Disconnect Figure 15 1 Second and third clutch assemblies 2 Separate the second clutch and the third clutch a...

Page 813: ...ING OIL PUMP REVERSE CLUTCH PISTON Figure 14 Removing Converter Housing JjP Inspect Low band for cracks flaking heat damage Reaction sun gear and drum for chipped teeth worn bushing scored drum Figure...

Page 814: ...16 17 and 18 Selector seal if necessary Selector shaft identification groove must be on the outside Spring pin Check the selector lever shaft for free movement Inside selector lever and parking pawl a...

Page 815: ...1 2 Install or Connect Figure 20 Planetary carrier and output shaft assembly Thrust washer and bearing Use petrolatum to hold the thrust washer and bearing in place 1 TH R U ST WASHER 2 BEARING ASSEMB...

Page 816: ...ates for damaged lugs or heat damage Third clutch drum for damage or worn clutch splines Thrust washer and bearing for damage Assemble Figures 26 and 27 Tools Required J 23084 Third Clutch Seal Protec...

Page 817: ...Thrust washer and the bearing Use petrolatum to hold the thrust washer and the bearing in place 1 SPRAG ASSEMBLY 2 T H IR D CLUTCH PLATES 3 BEARING A N D TH R U ST W A S H E R S T A K E D TOG ETHER 4...

Page 818: ...nal position 3 4 1 2 3 4 5 6 7 I Second speed clutch plates Thrust washer Disassemble Figures 32 33 and 34 Tools Required J 23327 Clutch Spring Compressor J 29838 Clutch Spring Compressor Adapter Inst...

Page 819: ...ton Lip Seals 2 Outer piston lip seal with the lip facing down if necessary Lubricate the lip seal with transmission fluid 3 Second clutch piston into the clutch drum Lubricate the lip seals with libe...

Page 820: ...85 on the case flange and against the input shaft 2 Position the inner shaft of J 23085 against the thrust surface of the second speed clutch hub 3 Tighten thumb screw Remove J 23085 4 Measure gap A C...

Page 821: ...8 Figure 3 9 Selective W asher Chart Converter Housing Oil Pump and Reverse Clutch Remove or Disconnect Figures 40 and 41 1 Oil pump to case gasket 2 Oil pump outer square cut gasket 1 2 3 4 5 Disasse...

Page 822: ...ng 2 Piston oil seals 1 2 3 4 5 6 7 1 2 3 4 Assemble Figures 45 and 46 Tools Required J 23327 Clutch Spring Compressor Inner and outer piston oil seals Reverse clutch piston onto the rear face of the...

Page 823: ...E CLUTCH PISTON INNER SEAL REVERSE CLUTCH PISTON OUTER SEAL Figure 4 4 Reverse Clutch Piston Governor Hub Inspect Figures 52 and 53 Seal rings for nicks burrs or damage Governor hub oil screen Governo...

Page 824: ...s H 180C 66 1 GUIDE PINS H 1 Inspect Primary and secondary valves for nicks burrs Oil passages and valve bores for nicks burrs varnish Inspect Figure 54 Primary valve small end first 2 Secondary valve...

Page 825: ...426 Extension Housing Seal Installer 1 Extension housing seal use J 21426 2 Gasket 3 Align the parking pawl actuator rod into the extension housing 4 Extension housing bolts Tighten Extension housing...

Page 826: ...valve sleeve small end first TAB MUST ENGAGE SLOT IN MODULATOR BORE 3 Modulator valve and plunger 4 O ring onto the modulator assembly NOTICE Use of another tool to install the vacuum modulator may r...

Page 827: ...using J 23075 Tap servo piston with a rubber mallet while compressing the return spring to seat the piston ring 4 Retaining ring 5 Remove J 23075 Adjust 1 Torque adjusting bolt to 4 5 N m 40 lbs in 2...

Page 828: ...control valve as shown on a clean surface Remove the valve trains beginning with the upper left hand corner Some of the valves are under pressure cover the bores while removing the retaining pins Remo...

Page 829: ...A L LOW CONTROL V A L V E SPRING 7 16 x 1 5 16 M A N U A L LOW CONTROL V A LV E REVERSE CO NTRO L V A L V E 1 2 SHIFT V A L V E 1 2 SHIFT CONTROL V A L V E SPRING 3 4 x 2 7 16 1 2 SHIFT CONTROL V A L...

Page 830: ...orque to 13 N m 9 lbs ft 2 Bolts reinforcement plate and ground wire torque to 19 N m 14 lbs ft 3 Governor pressure switch torque to 10 N m 7 lbs ft 4 Solenoid tubing solenoid and bolts torque to 19 N...

Page 831: ...erter 1 OIL PAN GASKET H 180C 13 2 OIL PAN 3 VALVE BODY AND TRANSFER PLATE 4 STRAINER 5 MANUAL DETENT SPRING 6 MANUAL VALVE LINK 7 HOLDING FIXTURE 8 SERVO COVER 9 MODULATOR 10 GOVERNOR PRESSURE SWITCH...

Page 832: ...NGS TO RADIATOR 27 20 OIL COOLER HOSE CLAMPS TO COOLER LINES 1 7 SHIFTER ASS Y TO CONSOLE 9 7 NEUTRAL SAFETY SWITCH TO BRACKET 2 1 LOWER COVER TO CONVERTER HOUSING 10 7 FLEXPLATE TO CONVERTER 48 35 TR...

Page 833: ...R R IN G T O N B EARING SUN G EAR TO O UTPUT S H A FT T H R U S T W ASHER T H R U S T W ASHER O U T P U T S H A FT TO R E A C TIO N SUN GEAR 9 10 11 12 13 14 15 16 17 18 19 T O R R IN G T O N BEARING...

Page 834: ...H 180C 99 H 180C 98 J 23130 5 1 OIL PUMP 2 DRIFT PUNCH 3 ARBOR PRESS 4 VIEW OF OIL PUMP OPPOSITE SIDE Figure 76 Removing Oil Pump Bushing Rear Inner Tool Threads Into Bushing Bushing Bearing Must Be D...

Page 835: ...n Housing Bushing J 8092 J 23130 3 H 180C 104 Figure 83 Removing Reaction Sun Gear Drum Bushing Sleeve H 180C 106 Figure 82 Removing or Installing Case Bushing J 8092 J 23130 7 H 180C 105 i 2 180C AUT...

Page 836: ...CH PISTON SPRING COMPRESSOR J 23130 5 OIL PUMP BUSHING REMOVER 3 4 14NPT J 23130 6 2ND CLUTCH DRUM BUSHING REMOVER INSTALLER J 23130 1 OIL PUMP BUSHING INSTALLER J 21424 9 EXTENSION HOUSING BUSHING RE...

Page 837: ...UAL TRANSMISSION 7B 1 SECTION 7B MANUAL TRANSMISSION CONTENTS SUBJECT PAGE HM 290 Manual Transmission 7B1 1 HM 117 Manual Transmission 7B2 1 New Process Transmission 7B3 1 Borg Warner Transm ission 7B...

Page 838: ......

Page 839: ...ocedure 7B1 40 Reverse Transmission Assembly 7B1 41 Idler G ear 7B1 24 2WD Models 7B1 41 Disassembly and Assembly of Front 4WD Models 7B1 45 Housing Assembly 7B1 24 2WD and 4WD 7B1 46 Disassembly and...

Page 840: ......

Page 841: ...E M B LY 5T H SP E E D G E A R N EED LE 31 G E A R A S S E M B LY 5TH SPEED 3 3 BEARING A S S E M B LY O U T P U T S H A F T 3 4 R A C E RO LLER BEARING 35 BEARING ROLLER 3 6 R A C E B A L L BEA RIN G...

Page 842: ......

Page 843: ...4 2 2 5 2 2 6 2 2 7 2 2 8 2 2 9 2 3 0 231 2 3 2 2 3 3 2 3 4 2 3 5 2 3 6 2 3 7 2 3 8 2 4 0 241 2 4 2 2 4 3 2 4 4 2 4 5 2 4 6 2 4 7 2 4 8 2 4 9 2 5 0 251 25 2 3 0 0 301 3 0 7 3 0 8 3 0 9 3 1 3 3 1 4 3 1...

Page 844: ...onto the transmission case J 8763 02 onto J 36824 2 Backup lamp switch assembly 313 Figure 5 3 Bolt 317 and electronic speed sensor assembly 314 2WD models only 4 Detent plug 245 using J 36509 and J...

Page 845: ...to remove Grab on OD edge non machined surface of the inner race 217 and remove with large pliers 14 15 16 17 Important Do not damage bearing cage while removing ball bearing inner race Idler shaft su...

Page 846: ...e force will peen the shift shaft and damage the rear housing shift shaft bearing 309 causing increased shift effort Figure 1 1 Removing Shift Socket Assembly Roll Pin 18 Shift Shaft 116 shift shaft s...

Page 847: ...2WD models only The 4WD section starts with step 30 Steps 30 through 36 are for both 2WD and 4WD models J H 0 1 6 9 H M 2 9 0 Figure 14 Removing and Installing Special Tools Remove or Disconnect Figur...

Page 848: ...iral roll pin remover installer out of the way then drive down Put the black depth locating tang back in place with the rod going through it Turn J 36516 counter clockwise till it stops 31 Snap ring 4...

Page 849: ...gure 22 Second speed gear assembly 18 and second speed gear bearing race 16 using J 36513 and hydraulic press Speed gear bearing assembly 17 Leave the synchronizer ring 2 on the 1 2 synchronizer assem...

Page 850: ...7B1 12 HM 290 MANUAL TRANSMISSION J i t i a x V L...

Page 851: ...H 0086 H M 290 12 J 3 6 5 1 5 J 3 6 5 1 5 Figure 20 Removing Gears and Shift Rails 1 SH A FT INPUT 2 RING S Y N C H R O N IZ E R 3 BEARING PILOT 4 S H A F T A S S E M B LY M A IN 2WD 5 S H A F T A S S...

Page 852: ...P U T 2WD 24 SH A FT O U T P U T 4WD ______________________________________________________ JH Q 025 H M 290 Figure 21 Removing 3 4 Gear Components Figure 22 Removing 2nd Gear Components 15 16 17 18 2...

Page 853: ...2 4 SH A FT O U T P U T 4WD JH 0 023 H M 290 Figure 23 Removing 1st Gear Components 2 3 SH A FT O U T P U T 2WD 24 SH AFT O U T P U T 4WD 3 0 BEARING A S S E M B L Y 5TH SPEED G E A R N EED LE MG5 31...

Page 854: ...E M B LY SP E E D G E A R NEEDLE 23 SH AFT O U T P U T 2WD 24 SH AFT O U T P U T 4WD 2 5 G E A R A S S E M B LY R E V E R S E SPEED 2 6 S Y N C H R O N IZ E R A S S E M B L Y 5 T H R E V E R S E MG5...

Page 855: ...ages and wear 10 Lubricate all bearings and check for rough rotation If scuffed nicked burred scoring or synchronizer ring metal transfer conditions cannot be removed with a soft stone or crocus cloth...

Page 856: ...7B1 18 HM 290 MANUAL TRANSMISSION...

Page 857: ...H R O N IZ E R 21 HUB 1 2 S Y N C H R O N IZ E R 22 G E A R 1ST SPEED 2 3 SH AFT O U T P U T 2WD 2 4 SH AFT O U T P U T 4WD 2 5 G E A R A S S E M B LY R E V E R S E SPEED 26 S Y N C H R O N IZ E R A...

Page 858: ...6133 01 J 36513 and hydraulic press Shoulder down towards reverse gear Roller bearing 35 ball bearing inner race 36 HEATED using J 6133 01 J 36513 and hydraulic press Apply grease to roller bearing SM...

Page 859: ...D S Y N C H R O N IZ E R A S S E M B LY 5 T H R E V E R S E RING S N A P SELECTIVE K H 0057 H M 290 J 6 1 3 3 0 1 3 5 NO TE S M A L L E R D IA M E T E R OF B E A R IN G C A G E UP 23 OR 24 2 3 S H A F...

Page 860: ...and hydraulic press NEW selective snap ring 15 Install the thickest snap ring that will fit in the groove Bearing assembly 14 and 3rd speed gear 13 Figure 33 1 Important When pressing the 3rd 4th sync...

Page 861: ...SH AFT O U T P U T 4WD JH 0 0 6 0 H M 2 9 0 P A R T NO DIM A mm IN 2 3 0 4 9 9 8 6 2 0 0 079 2 3 0 4 9 9 8 7 1 95 077 2 3 0 4 9 9 8 8 1 90 075 2 3 0 4 9 9 8 9 1 85 073 2 3 0 4 9 9 9 0 1 8 0 071 2 RING...

Page 862: ...spots a small shinny spot on the gear teeth mating surface that could cause gear noise Bearing assemblies 50 for roughness of rotation burred or pitted condition and gage damage replace if these condi...

Page 863: ...H A F T 231 PIN SHIFT S H A F T L E V E R 2 3 2 ROLLER C O V R D E T E N T 2 3 3 SLEEVE B IAS SPRING 2 3 4 SPRING B IAS L O A D T O R S IO N A L 2 3 5 SEAT BIAS SPRIN G SL E E V E 2 3 6 BOLT H E X H...

Page 864: ...out pivot 4 Shift shaft rails plugs 221 Use a punch to drive the plugs out 5 Countershaft bearing plug 250 Figure 39 Remove staking Drill hole through plug 250 with 5 16 drill bit Tap using 3 8 16 ta...

Page 865: ...bushings 246 using J 36506 Figure 44 Drive J 36506 till BOTH bushings are removed 12 Two detent plunger bushings 242 using J 36507 Figure 45 Remove ONE bushing at a time 13 Breather assembly 223 DO NO...

Page 866: ...dry Bearing race bore for wear scratches or grooves if countershaft bearing race is worn or damaged the rear housing MUST be replaced Bushings for scores burrs roundness or evidence or overheating Ca...

Page 867: ...stake using J 36798 2 J 36798 1 and J 36190 DO NOT STAKE the tabs on the bushings 3 Clutch fork pivot assembly 219 using J 36510 and J 36190 Figure 48 Grease after installation through lube fitting 2...

Page 868: ...er GM P N 1052943 or equivalent to the outside edge of the plug Stake in three places evenly apart Two 5th reverse detent bushings 246 using J 36506 Figure 51 Install one at a time Install the first b...

Page 869: ...E A D M 6 X 16m m _______________________________________________________ JH 0324 H M 290 Figure 53 Bias Spring Components Install 14 Breather assembly 223 15 Oil fill plug 222 and oil drain plug 225...

Page 870: ...l bearings 308 three using J 36800 and J 23907 Figure 57 Screw J 36800 into the bearing then slide hammer out Rear housing shift shaft bearing 309 using J 23907 with pilot bearing puller or J 36032 Fi...

Page 871: ...using MUST be replaced Bushings for scores burrs roundness or evidence of overheating 2WD output shaft bushing 318 cannot be serviced replace the rear housing 300 no service for bushing Tools Required...

Page 872: ...ing assembly 4 Two dowel pins 321 Drive till flush 5 Slip yoke oil seal 319 using J 36503 Figure 62 2WD models only Fill between the seal lips with chassis grease 6 Plug 322 Apply gasket maker GM P N...

Page 873: ...e 1 2 100 5th reverse 111 shift rail and fork assemblies are serviceable as an assembly only 1 Shafts 101 109 112 and 117 for wear or scoring 2 Forks 105 108 and 114 for wear scoring or distortion The...

Page 874: ...7 into J 29369 2 2 Input shaft bearing retainer oil seal 209 Heat oil seal with J 25070 for a minimum of three minutes Hold clutch release bearing pilot with heat resisting glove or equivalent then sl...

Page 875: ...he third gear part of the countershaft for prying Important Measure off gear tooth Make sure that J 8001 stays on gear tooth while measuring endplay Allow the countershaft to lower to its original pos...

Page 876: ...8 7 2 3 0 0 0 9 1 2 4 0 0 0 9 4 2 5 0 0 0 9 8 2 6 0 0 1 0 2 2 7 0 0 1 0 6 0 4 0 0 0 1 6 0 5 0 0 0 2 0 J 8 0 9 2 J 3 6 7 9 9 J 2 5 0 2 5 OIL PLU G FILL HOLE N O T E O U TER BEA RIN G A S S E M B L Y R...

Page 877: ...same or next smaller size as the difference in measurements DIMENSION C D IA L D EPT H G A U G E 212 C A L C U L A T IO N A H O U SING DEPTH B B E A R IN G WIDTH C SHIM S P A C E DIMENSION B ILL DIM C...

Page 878: ...h Select a shim which is the same or next smaller size as the difference in measurements M E A S U R E BEARING O U T E R R A C E W ID TH M E A S U R E B EARING BO RE DEPTH 3 0 0 O R 301 C A L C U L A...

Page 879: ...NPUT SHAFT Retain with petroleum jelly Input shaft 1 pilot bearing 3 synchronizer ring 2 and mainshaft assembly 4 2WD or 5 4WD into J 36515 J 36515 12 onto countershaft 53 Install the assembly onto J...

Page 880: ...e rings off till BOTH ID SLOTS FOR THE BALL 40 LINE UP Slide the assembled rings over the ball that is retained on the output shaft Slide up the rod on J 36516 turn the black depth locating tang over...

Page 881: ...HM 290 MANUAL TRANSMISSION 7B1 43 Figure 7 3 Locking Up Transmission 100 RAIL ASSEMBLY 1ST 2ND SHIFT 108 FORK 3RD 4TH SHIFT _________________________________________________ JH 0 200 H M 290...

Page 882: ...AL TRANSMISSION K H 0 0 7 6 H M 2 9 0 NOTEH D s l o t s l in e d u p 39 RING THREADED THRUST OUTER 40 BALL 4mm 41 RING THREADED THRUST INNER 42 PIN SPRIL ROLL 43 RING SNAP TANG Figure 74 Threaded Thru...

Page 883: ...lly 17 Important PRESS EACH ROLLER TOWARDS THE RACE TO SECURE THEM FOR EASIER ASSEMBLY 2WD Rear housing assembly 300 Make sure the reverse idler shaft is lined up with the hole in the case Rotate back...

Page 884: ...Refer to page 42 steps 7 through 11 for assembly procedures Install seal protector J 36502 2A onto output shaft 4WD output shaft oil seal 320 using J 36502 Figure 80 Fill between the seal lips with ch...

Page 885: ...O U T P U T S H A F T OIL 4WD K H 0075 H M 29 0 Figure 80 4WD Oil Seal Install All forks MUST be in neutral position Coat balls with petroleum jelly Using a magnetic screwdriver or equivalent insert...

Page 886: ...nt Use a new shift shaft socket assembly 123 or stake the socket as shown in Figure 84 This will prevent the roll pin 122 from walking down and rubbing on the reverse speed gear 25 causing a noise in...

Page 887: ...IT TO THE BEARING RACE Apply gasket maker GM P N 1052943 or equivalent to the inside of the bolt hole pattern of the rear housing 37 Front housing 200 Important Bring housing straight down If resista...

Page 888: ...lace Retain with petroleum jelly 42 Input shaft bearing retainer assembly 205 and six bolts 204 Make sure oil drain back hole is lined up with the hole in the housing Tighten Bolts 204 to 8 5 N m 7 Lb...

Page 889: ...ackup lamp switch assembly 313 Apply pipe sealant with Teflon GM P N 1052080 or equivalent to the threads Tighten Switch 313 to 9 N m 7 Lb Ft Remove J 8763 02 and J 36824 Bolts 312 Figure 91 Tighten B...

Page 890: ...0 46 226 5th Reverse Rail Deflection Bolt 35 27 236 Seat Bias Spring and Sleeve Bolt 8 5 7 249 Spring 5th Reverse Detent Hex Head Plug 60 46 304 306 Retainer Output Shaft Bearing Bolts 22 17 311 Suppo...

Page 891: ...e J 36190 Dial Indicator Set Dial Indicator Stand and Guide Pin Set 4W D Output Shaft Oil Seal Installer and Seal Protector 0 0 0 E 3P J 36502 2A J 36502 V J 8001 J 25025 B Universal Driver Handle J 8...

Page 892: ...7B1 54 HM 290 MANUAL TRANSMISSION Figure 93 Special Tools...

Page 893: ...sing bolts Move the reverse shift fork to partially engage the reverse idler gear Lift off the housing 2 Flange nut 221 Lock up transmission in two gears before re moving nut 3 Brake drum and the flan...

Page 894: ...Thrust Washer Snap Ring Front Counter Gear Bearing Counter Gear Front Cover Pilot Bearing Rollers Clutch Gear Oil Slinger Snap Ring Bearing to Shaft 3rd Speed Gear Bushing Thrust Washer 2nd Speed Gear...

Page 895: ...ar Bearing 239 Pilot Bearing Rollers 208 3rd Speed Gear 225 Snap Ring Bearing to Case 240 Clutch Gear Oil Slinger 209 2nd Speed Gear 226 Snap Ring Bearing to Gear 241 Snap Ring Bearing 210 1st and 2nd...

Page 896: ...Shaft 264 Screw 219 Speedometer Drive Gear 250 Main Shaft 265 Gasket 220 Output Yoke 251 Gasket 2WD 4WD 266 Oil Seal 221 Flange Nut 252 Dowel Pin 267 Screw 222 Oil Seal 253 Screw 268 Shift Cover 223 R...

Page 897: ...HM 117 TRANSMISSION 7B2 5...

Page 898: ...ap ring 241 4 Bearing 278 using J 358 1 and J 22872 figures 8and 9 5 Slinger 240 Clean All parts in a suitable solvent Important Do not spin the bearings dry Inspect 1 Parts for damage and wear 2 Oil...

Page 899: ...The bearing snap ring groove goes away from the gear 3 New bearing to shaft small snap ring 241 4 New bearing to case large snap ring 203 5 Pilot bearings 239 Use chassis grease to hold the bearings i...

Page 900: ...it on the synchronizer hubs and for the hubs a snug fit on the mainshaft splines Synchronizer springs and keys for looseness and damage Brass synchronizer rings for excess wear and damage All gear tee...

Page 901: ...HM 117 TRANSMISSION 7B2 9 B 05180 Figure 17 Installing the 1st and 2nd Synchronizer...

Page 902: ...eed gear 216 13 Thrust washer 217 Figure 20 Installing the 3rd and 4th Speed Synchronizer Hub COUNTERGEAR Disassemble Figure 22 Tools Required J 22832 01 Countergear and Mainshaft Rear Bearing Remover...

Page 903: ...chips and wear Assemble Figure 22 Tools Required J 22873 Mainshaft Bushing Installer J 22830 A Snap Ring Installer A minimum press of 681 kg 1500 lbs is required to move each gear If less pressure is...

Page 904: ...ing a scraper Inspect the retainer for damage 4 Install or Connect Figure 2 Tools Required J 22834 Extension Housing Seal Installer 1 Locking compound on the outside of a new seal 222 2 New seal using...

Page 905: ...re 31 Shift rods and the shift forks 206 215 and 301 Shift rods must be in neutral position before any one rod can be removed Do not lose the detent balls and springs and the interlock balls and pin w...

Page 906: ...n place two interlock balls 306 in the cross bore between the 1st 2nd and 3rd 4th shift rods figure 34B 8 Position the 1st 2nd shift fork 215 and push the rod through the fork and into the front suppo...

Page 907: ...ush the rod through the yoke but not into the front sup port bore 5 Place an interlock shuttle 306 in the cross bore of the front support between the reverse and 3rd 4th shift rods figure34B Then inst...

Page 908: ...3 Figure 33A R V P Shift Rod and Fork Positions 212 213Cl 2 1 2 213 4 206 3rd and 4th Shift Fork 212 1st and 2nd Reverse Detent Spring 213 Detent Pin 214 Reverse Shift Rod 215 1st and 2nd Shift Fork 3...

Page 909: ...gaskets and pipe sealant with Teflon GM P N 1052080 or equivalent on all bolt threads when assembling the transmission Tighten all bolts to specified torque Lubricate all assemblies as they are insta...

Page 910: ...meter gear 219 13 Rear bearing retainer 223 and a new gasket 14 Parking brake assembly 4WD models only Back plate New mainshaft lock nut 256 and a new spring washer using J 35907 15 Brake drum and the...

Page 911: ...ange Plate Bolts 41 30 LUBRICATION Capacity 4 0L 4 2 qts Type Recommended SAE 80W or SAE 80W90 SPECIAL TOOLS B 08763 1 2 3 4 5 6 7 8 9 10 11 12 13 J 22873 Main Shaft Bushing Installer J 22875 3rd Gear...

Page 912: ...20 HM...

Page 913: ...mainshaft and are in constant mesh with the counter gear Key type synchronizers are splined to the mainshaft and engage with the drive gears to turn the mainshaft A ball bearing supports the mainshaft...

Page 914: ...405 Main Drive Gear 417 Vent Plug 429 Countershaft 406 3rd Speed Blocker Ring 418 Main Shaft 430 Counter Gear 407 3rd and Overdrive Synchronizer 419 Retainer 431 Countershaft Spacer 408 Overdrive Bloc...

Page 915: ...Drive the countershaft to the front until it pushes the plug out of the case 5 Countershaft 429 using J 29793 Drive the countershaft out the rear of the case 6 Extension housing screw 439 Turn the hou...

Page 916: ...Housing 435 Screw 447 Nut 417 Vent Plug 436 Bearing Retainer Gasket 448 Spring Washer 418 Mainshaft 437 Transmission Case 449 Screw 422 Reverse Idler Gear 438 Spring Washer 450 Side Cover 423 Reverse...

Page 917: ...NEW PROCESS TRANSMISSION 7B3 5 Figure 4 Removing the Mainshaft Figure 5 Removing the Reverse Idler Shaft...

Page 918: ...1st speed blocker ring off 7 Remove the snap ring and the 1st and 2nd synchronizer 412 Do not let the synchronizer come apart 8 Remove the 2nd speed blocker ring and the 2nd speed gear 410 9 Synchroni...

Page 919: ...onto the hub aligning the marks made during disassembly Important The long side of the hub center A must be to the front 2nd speed gear 410 and the blocker ring Slide the gear on with the cone to the...

Page 920: ...st Washer 431 Countershaft Spacer 428 Countershaft 476 Bearing Spacers Bearings 430 Counter Gear B 08868 ij j i 13 Figure 11 Countergear and Components COUNTERGEAR Disassemble Figure 11 Tool Required...

Page 921: ...of retainer 401 i Inspect 1 Retainer nose for scoring wear or cracks especially at the flange 2 Snap ring groove for damage caused by drive gear bearing movement 3 Replace the retainer if it is worn o...

Page 922: ...thrust washer tabs inthe case slots Align the rear thrust washer tabs with the case slots and slide it in 2 Mainshaft 418 and a new snap ring 454 into the extension housing 416 3 Extension housing 416...

Page 923: ...ver the fork to install the cover Important Be sure the detent ball and the spring are in position 15 Side cover screws 449 and new spring washers Install the locating long shoulder screw finger tight...

Page 924: ...7B3 12 NEW PROCESS TRANSMISSION SPECIAL TOOLS...

Page 925: ...a chined in place A tapered bearing supports the mainshaft in the rear of the case Roller bearings support the mainshaft inde pendently in the main drive gear The main drive gear and mainshaft are eng...

Page 926: ...igure 4 3 Extension housing 613 and the offset lever Important The offset lever is engaged into the extension housing and cannot be removed when the ex tension housing is mounted to the transmis sion...

Page 927: ...BORG WARNER TRANSMISSIONS 7B4 3 Figure 2 77 mm Transmission and Components...

Page 928: ...r 656 Detent Plate 657 Detent Ball 658 Detent Spring 659 Pin 655 Offset Lever 656 Detent Neutral Guide Plate 657 Detent Ball 658 Detent Spring 656 B 08480 Figure 5 Detent Ball and the Spring 615 618 6...

Page 929: ...ack f j j H 19 20 Idler gear Snap ring and the countergear rear bearing spacer 634 Countergear rear bearing 635 Drive the countergear 640 to the rear to re move the bearing figure 15 9 Important 21 22...

Page 930: ...ck Spring 629 5th Speed and Reverse Shift Shaft B 08577 Figure 15 Removing the Countergear Rear Bearing Figure 13 5th Speed and Reverse Shift Shaft B 08356 637 Reverse Idler Shaft 037 639 Pin Figure 1...

Page 931: ...the gear using J 22912 01 figure 19 Do not let the synchronizer come apart Important Do not let the mainshaft fall to the floor Remove the snap ring and the 2nd speed gear thrust washer 666 Remove th...

Page 932: ...ents JjJJJ Clean Figure 18 All parts in a suitable solvent and air dry Important L 5 Do not spin dry bearings Inspect Figure 18 Gears for cracks chipped gear teeth and other damage that could cause ge...

Page 933: ...he antirattle ball and spring 669 in the hub Place the keys into the hub Engage the springs in the same key with the open ends away from each other Slide the sleeve onto the hub aligning the marks mad...

Page 934: ...g 681 Seal B 08615 Figure 25 Extension Housing and Components J 23062 14 Extension Housing Bushing Remover and Installer J 21426 Extension Housing Oil Seal Installer 1 New bushing 680 if needed using...

Page 935: ...Drive the retaining pin out of the selector arm 689 figure 31 3 Remove the shift shaft 685 Shift forks and the plates Selector arm Interlock plate 4 Pry the oil seal 602 out Figure 28 Main Drive Gear...

Page 936: ...e under the 1st and 2nd shift fork plate Push the shift shaft through the fork into the cover front bore 6 Turn the shift shaft until the front fork plate is away from the cover and parallel to it 7 D...

Page 937: ...lever fork is engaged in the idler gear slot 12 New reverse shift lever retaining ring 625 13 Countergear rear bearing spacer 634 and a new snap ring 14 5th speed drive gear 632 15 5th speed and reve...

Page 938: ...hronizers The offset lever to shift shaft pin hole must be up Shift cover screws Install the two locating screws in the holes they were removed from first Speedometer drive gear 609 and the retaining...

Page 939: ...aring Assembly Tool 3 J 29895 Countershaft Rear Bearing Installer 4 J 22912 01 Bearing and Gear Puller 5 J 23096 Front Housing Drive Gear Oil Seal Installer 6 J 21426 Extension Housing Oil Seal Instal...

Page 940: ...i ii iii m i in m i...

Page 941: ...h traction gear reduction or direct drive may be selected The model 205 transfer case is a two speed unit which can be used for either two wheel or four wheel drive Direct drive 1 1 ratio is available...

Page 942: ...and 69 Yoke 68 Shaft assembly 26 from the housing 62 Snap ring 46 using Tool J 23432 Discard the snap ring 7 Thrust washer 81 Washer pin 45 Tanged bronze washer 60 Gear roller bearings 32 per row 41 S...

Page 943: ...is spring clips 37 and clevis pins 38 Shift rail link 13 Upper shift rail 39 figure 7 Lower shift rail 59 Shift forks 77 and 35 Sliding clutch hub 34 Front output high gear 33 Washer 32 3 4 5 6 7 8 9...

Page 944: ...7D1 4 TRANSFER CASE FO 5688 Figure 3 NP205 Transfer Case...

Page 945: ...Hi Lo Range Shiaft Shaft 18 Poppet Ball 60 Thrust Washer 19 Transfer Case 61 Rear Output Shaft 20 Fill Plug Retainer Bearing 21 Shift Rail Interlink Plunger 62 Rear Output Shaft 22 Input Main Drive Ge...

Page 946: ...haft Rear Bearing Retainer FO 1979 Figure 5 Removing the Front Output Shaft Bearing Figure 6 Removing the Shift Fork Roll Pin p 5 9 0 39 b 39 Two Four Wheel Shift Shaft 59 Hi Lo Range Shift Shaft FO 2...

Page 947: ...r corrosion cracks and damage 7 Bolts and threaded holes for wear damage stret ched threads or corrosion ASSEMBLY Figure 9 Installing the Bearing Cup IDLER GEAR Install or Connect Figures 3 4 9 10 11...

Page 948: ...first with the poppet notches up 4 Shift fork 35 Install the shift fork long end forward into the front output drive shift rail 59 Push the rail through to the neutral position 5 Input shaft bearing 1...

Page 949: ...ail 39 in the front wheel drive 4H position with the clutch teeth in mesh with the front output high gear teeth Front output shaft and low gear assembly through the high gear assembly Line up the wash...

Page 950: ...m 0 002 0 027 inch Grease in the pilot bore of the rear output shaft 26 Roller bearings 15 each 25 Thrust washer 24 New snap ring 23 in the bore New bearing 61 in the retainer housing 62 usinq Tool C...

Page 951: ...t Front Bearing Retainer B o lts 40 30 Front Output Rear Bearing Retainer B o lts 40 30 Front Output Yoke Lock N ut 202 150 Retainer Housing Bolts 40 30 Seal Retainer Bolts 40 30 Lubricant Dexron I I...

Page 952: ...7D1 12 TRANSFER CASE...

Page 953: ...ing information If the tag is removed or becomes dislodged during service operations it should be reattached using an adhesive sealant such as Loctite 242 or equivalent POWER FLOW In all drive range p...

Page 954: ...7D2 2 NEW PROCESS 241 TRANSFER CASE 77 76 75 74 70 69 6g 71 v 6g 64 63 F 05386 Figure 1 New Process 241 Transfer Case Components...

Page 955: ...ar 21 Front O utput Shaft 63 S hift Lever Nut Prev Torque 22 Driven Sprocket 64 W asher 23 Retainer Snap Ring 65 S hift Lever 24 Front O utput Rear Bearing 66 W asher Plastic 25 M agnet 67 O Ring Seal...

Page 956: ...t Figures 1 2 3 and 4 1 Rear extension housing bolts 3 and rear extension 4 2 Bearing retainer snap ring 5 from the mainshaft 19 3 Pump retainer housing bolts 7 4 5 Pump retainer housing bolts are sho...

Page 957: ...O utput Flange F 05388 Figure 4 Front View 241 Transfer Case 25 Magnet 45 Front Case Half 54 Mode Fork 55 Sector W ith Shaft 81 Synchronizer A ssem bly F 05391 48 S hift Rail 51 Range Fork 52 Mode For...

Page 958: ...oving the range fork 51 figure 6 8 Shift lever nut 63 washer 64 shift lever 65 plastic washer 66 and the O ring seal 67 from the front case half 45 9 Input bearing retainer bolts 43 and input bearing...

Page 959: ...ed port and channel in order to remove any obstructions or cleaning solvent residue All mating and sealing surfaces Inspect 1 Bearings and thrust washers for wear spalling brin neling or corrosion 2 G...

Page 960: ...rear case half 17 using J 36372 and J 8092 Bearing must be flush with the boss on case housing 3 Bearing 61 to the front case half 45 using J 37371 4 Retainer 60 figures 11 and 12 5 Bearing 6 to the p...

Page 961: ...g with J 36371 Tighten Nut 63 to 27 N m 20 ft lbs 7 Range shift hub 34 and the range shift fork into the front case half 45 It is necessary to rotate the sector to align the range shift fork 8 Synchro...

Page 962: ...housing 8 Apply RTV sealer to the mating surfaces Apply Loctite 242 or equivalent on the extension housing bolts Figure 16 Synchronizer Hub Assembly and Mode Fork Tighten Bolts to 31 N m 23 ft lbs EX...

Page 963: ...NEW PROCESS 241 TRANSFER CASE 7D2 11 Figure 17 Oil Pump Pickup Screen Doweled Case Holes...

Page 964: ...7D2 12 NEW PROCESS 241 TRANSFER CASE Figure 18 NP 241 Transfer Case Cut Away...

Page 965: ...Snap Ring 16 Bolt 61 Front O utput Bearing 17 Rear Case Half 62 A nnulus Gear 18 Oil Pump Pick Up Tube 63 S hift Lever Nut Prev Torque 19 M ainshaft 64 W asher 20 Drive Sprocket 65 S hift Lever 21 Fr...

Page 966: ...n and Fill P lu g s 47 35 Lubricant Dexron I I 4 6 Pints SPECIAL TOOLS 1 5 6 3 4 J 2619 01 J 2619 5 J 8092 J 22912 1 J 29369 1 J 29369 2 7 8 9 10 11 12 1 Slide Ham m er 2 Slide Ham m er 3 Driver Handl...

Page 967: ...formation If the tag is removed or becomes dislodged during service operations it should be reattached using an adhesive sealant such as Loctite 242 or equivalent POWER FLOW In all drive range positio...

Page 968: ...Half EXTERNAL COMPONENTS Clean The transfer case exterior using a solvent and a stiff brush Remove or Disconnect Figure 2 3 and 4 1 Front output yoke nut 77 washer 76 rubber sealing washer 75 and fro...

Page 969: ...s necessary to rotate the sector with shaft 55 to obtain clearance when removing the range fork 51 figure 7 7 Shift lever nut 63 washer 64 shift lever 65 plastic washer 66 and the O ring seal 67 from...

Page 970: ...7D3 4 NEW PROCESS 231 TRANSFER CASE F 05849 L Figure 3 New Process 231 Transfer Case Components...

Page 971: ...ing 42 Input Bearing Retainer Seal 43 Input Retainer Bolt 44 Input Bearing Retainer 45 Front Case Half 46 Indicator Lamp Sw itch 47 O Ring Seal 48 S hift Rail 49 Pads 50 Pads Center 51 Range S hift Fo...

Page 972: ...il Pump Pickup Tube and Screen 25 Magnet 45 Front Case Half 54 Mode Fork 55 Sector W ith Shaft 81 Synchronizer A ssem bly F 05391 65 48 S hift Rail 51 Range Fork 52 M ode Fork Spring 54 M ode Fork 55...

Page 973: ...sive wear 8 Synchronizer hub and sleeve for cracks chips spalling or excessive wear 9 Pads on the mode fork and the range fork for wear distortion 10 Oil pump gears and case halves for wear spalling c...

Page 974: ...ve 29 3 Main drive synchronizer stop ring 28 to the synchronizer sleeve 29 4 Install or Connect Drive sprocket 20 to the mainshaft 19 Planetary input gear assembly 38 into the annulus gear 62 using a...

Page 975: ...to damage the oil pump 12 while installing the rear case half 17 Case bolts 3 into case halves Apply Loctite 242 or equivalent to case bolts Figure 14 Synchronizer Hub Assembly and Mode Fork The two l...

Page 976: ...pet screw to 31 N m 23 ft lbs Indicator lamp switch 46 and O ring 47 to the front case housing Tighten Switch to 24 N m 17 ft lbs Front output flange 74 rubber sealing washer 75 washer 76 and flange n...

Page 977: ...m er 8 Bearing Installer R em over 2 Slide Ham m er 9 Bearing Installer 3 Driver Handle 10 Bearing Installer 4 Bearing Remover 11 Seal Installer 5 Bearing Remover 12 Extension H ousing Seal Installer...

Page 978: ......

Page 979: ...ase 7D4 5 External Components 7D4 5 Internal Com ponents 7D4 5 Synchronizer A ssem bly 7D4 7 Oil Pump Assembly 7D4 7 Cleaning and Inspection 7D4 12 Assembly of the Transfer C a s e 7D4 12 Oil Pump As...

Page 980: ...ged during service operations every attempt should be made to keep the identification tag with the unit POWER FLOW Figure 3 In all drive range positions input torque is transmitted to the transfer cas...

Page 981: ...BORG WARNER 1370 TRANSFER CASE 7D4 3 J...

Page 982: ...iner 18 Drive Gear 72 Pick up Tube 19 Driven Gear 75 Rear Output Yoke Nut 20 Drive Chain 76 Front Output Flange Nut 22 Front Output Bearing 77 Identification Tag 23 Mainshaft 78 Vent 24 Oil Pump Assem...

Page 983: ...Four wheel drive indicator switch 60 from the front case half 31 5 Rear bearing retainer bolts 61 and rear bearing retainer 50 from the rear case half 46 INTERNAL COMPONENTS 4 Remove or Disconnect Fig...

Page 984: ...602 8 Shift Rail Spring 10 Clutch Coil Housing Snap Ring 11 Clutch Coil Housing 23 Mainshaft F6604 Figure 5 Removing the Output Bearing Snap Ring Figure 7 Removing the Clutch Coil Housing Figure 6 Rem...

Page 985: ...ng retainer 50 SYNCHRONIZER HUB ASSEMBLY Disassemble 1 Synchronizer hub snap ring 51 from the synchro nizer hub assembly 12 figure 22 2 Lockup hub 52 compression spring 53 from the lockup collar 54 12...

Page 986: ...7D4 8 BORG WARNER 1370 TRANSFER CASE 16 Front Output Shaft 18 Drive Gear 19 Driven Gear 20 Drive Chain 22 Front Output Bearing F6607 Figure 10 Removing the Drive Chain...

Page 987: ...ulus Gear Snap Ring 31 Front Case 32 Annulus Gear F6610 Figure 11 Removing the Mainshaft and Oil Pump Figure 13 Removing the Annulus Gear Snap Ring 9 Shift Rail 28 Range Fork 29 Shift Hub F6609 31 Fro...

Page 988: ...Sector and Shaft Assembly 25 Carrier Assembly Input Shaft 34 Input Carrier Snap Ring F6617 25 Input Carrier Assembly 35 Power Take Off Drive Gear F6618 43 Front Input Bearing Snap Ring 44 Front Input...

Page 989: ...nshaft and Oil Pump Assembly Snap Ring Oil Pump Spring Oil Pump Retainer Oil Pump Front Cover Pickup Tube Retainer Clip Pickup Tube F6630 68 69 70 71 72 23 26 63 64 66 67 Strainer Oil Pump Retainer Bo...

Page 990: ...mp pickup 26 to the pickup tube 72 Pickup tube 72 oil pump pickup 26 and retainer 71 to the oil pump housing 66 The oil pump front cover 70 with the word TOP fac ing the front of the front case Oil pu...

Page 991: ...ynchronizer assembly to the mainshaft drive gear 18 and the mode fork to the shift rail 9 Synchronizer hub 55 to the synchronizer assembly 12 Clutch coil housing 11 and clutch coil housing snap ring 1...

Page 992: ...7D4 14 BORG WARNER 1370 TRANSFER CASE Figure 26 Installing the Rear Output Yoke...

Page 993: ...BORG WARNER 1370 TRANSFER CASE 7D4 15 Figure 27 BW 1370 Transfer Case...

Page 994: ...Fork 48 Shift Lever 15 Front Output Shaft Snap Ring 49 Detent Roller 16 Front Output Shaft 50 Rear Bearing Retainer 17 Flat W asher 51 Synchronizer Hub Snap Ring 18 Drive Gear 55 Synchronizer Hub 19...

Page 995: ...ear Bearing Retainer Screws 31 23 Four Wheel Drive Indicator Switch 41 30 Vent 14 10 Clutch Coil N u ts 10 7 P T O Cover B o lts 27 20 Flange Nut Front Output 224 165 Yoke Nut Rear O u tp u t 170 125...

Page 996: ...OOLS 1 2 3 4 5 J 22912 01 J 8433 4 J 8059 J 29169 J 33832 6 7 8 J 37668 J 8092 J 5590 1 Bearing and Gear Puller 2 Puller 3 Snap Ring Pliers 4 Bearing Remover Installer 5 Bearing Remover Installer 6 Se...

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Page 998: ...X 8937...

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